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Automobile Drum Brake Gear MIM Parts

Name: Automobile Drum Brake Gear MIM Parts Manufacturers Suppliers Factory
Brand: Zhongwei
SKU: 191017407

The design parameters of gears include number of teeth, modulus, pressure angle, addendum coefficient and helix angle, etc. The evaluation parameters in the gear manufacturing process include span distance MDK, radial runout FR and gear precision measurement report.

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Introduction of MIM automobile drum brake gear parts

Automobile drum brake gear MIM parts
Item	Material	Production Process		Sintering Temperature		Mold	Custom
Drum brake gear	20crmnti	Metal Injection Molding		1550℃		To be customized	Yes
Chemical Composition	C: 0.17～0.23 Si: 0.17～0.37 Manganese Mn: 0.80～1.10 Chromium Cr: 1.00～1.30 Sulfur S: allowable residual content ≤ 0.035 Phosphorus P: allowable residual content ≤ 0.035 Nickel Ni: allowable residual content ≤ 0.030 Copper Cu: allowable residual content ≤ 0.030 Titanium Ti: 0.04～0.10
Available Materials	Low carbon stainless steel, titanium alloy (Ti, TC4), copper alloy, tungsten alloy, cemented carbide, high temperature alloy (718, 713)
Finish	Dimensional Accuracy		Product Density		Appearance Treatment			Appropriate Weight
Roughness 1～5μm	（±0.1%～±0.5%）		95～100%		Mirror Reflection			0.03g～400g）

What metal material is good for car gears?

Zhongwei Precision and Central South University tested and compared 5 different metal materials, selected appropriate evaluation indicators for heat treatment indicators, dimensional deformation and production smoothness, and carried out under the same manufacturing process (the machining process and heat treatment process are exactly the same) In the experiment, the advantages and disadvantages of 5 kinds of automobile transmission gear materials in the manufacturing process were analyzed, which provided the basis for the selection of automobile transmission materials.

1. Introduction of common materials for Automobile drum brake gear MIM parts

Gear materials for automobile transmissions should not only have good strength, toughness, and wear resistance, but also require small deformation and high machining accuracy. In the heat treatment process of gears, in addition to general quenching and tempering, various surface hardening processes such as carburizing and quenching, nitriding treatment, and high-frequency quenching are also used. The technical requirements for gear materials are:

1) Sufficient core hardenability, surface hardness and deep depth, and ensure that there is no supercooled austenite decomposition product in the carburized layer and core during carburizing and quenching of gears;

2) The dimensional deformation of the gear after carburizing and quenching is small and uniform, which is convenient for subsequent finishing.

Commonly used domestic materials for automobile gears are 20CrMnTi, 20CrMo, 20MnCr5, 25CrMnS4, etc. This paper compares the above four domestic materials and German imported materials (model TL4521) under the same manufacturing process (the machining process and heat treatment process are exactly the same) The performance of The pros and cons of the material.

2. Introduction of evaluation parameters of automobile gear manufacturing process

The precision measurement report of the gear mainly evaluates the gear tooth surface modification error (the deviation between the actual shape and the designed non-theoretical involute tooth profile) and the indexing error (circular pitch error), and the tooth surface modification error includes the tooth profile angle. Deviation, tooth shape error, tooth drum amount, tooth angle deviation, tooth shape error and tooth drum amount, etc. The indexing error includes single pitch error, accumulated pitch error, etc. These parameters determine the gear The machining accuracy level of the machine affects the vibration and noise of the gearbox.

3. Experimental design

Selection of evaluation indicators: In order to compare the performance of the above five materials in the process of manufacturing automobile gearbox gears, this paper selects key indicators as evaluation indicators, and the dimensions in the table are all the core of the gear parts manufacturing process. size. The selection of evaluation dimensions is not the more the better. It is best to use fewer and more precise dimensions to accurately reflect the overall performance of the part.

Determination of the scoring principle: In order to systematically evaluate the performance of the above five materials in the gear processing and manufacturing process, quantitative evaluation indicators are used for the size (fluctuation and deformation) of dimensional deformation. The influence of materials and different rounds of experiments, an evaluation index of "material performance consistency" is added, which is calculated by subtracting the minimum value from the maximum value of the average deformation of each dimension index in multiple rounds of experiments, and then dividing by the tolerance of the size. Evaluate.

Overall design of the experimental scheme: The experiment uses an ECM vacuum heat treatment furnace, using 8 types of gear parts (4 types of pinions, 1 type of large ring gear, 2 types of shafts, and 1 type of synchronizer). According to the form of finishing, it can be divided into 3 types of grinding parts and 4 types of shaving parts. Since the final product size of shaving parts is guaranteed by heat treatment deformation, 5 rounds of experiments are carried out on shaving parts and 3 rounds of experiments on grinding parts to ensure the accuracy of the experimental results. In each round of experiments, 9 test pieces of 5 materials were processed and placed side by side in 8 corners and centers of the heat treatment trays (ie, the heat treatment nine-point experiment).

4. Data analysis

Analysis of heat treatment index: It can be seen from the experimental results of 5 kinds of gear parts:

1) Materials TL4521, 20MnCr5, 20CrMnTi (J9=37~40), 20CrMnTi (J9=35~38) are all qualified in terms of core hardness, surface hardness and layer depth;

2) Materials 20CrMo and 20CrMnTi (J9=32~35) have insufficient hardenability, resulting in insufficient core hardness under the same process conditions. The heat treatment indexes of the first gear shift gear parts corresponding to 20CrMo material are as follows: As shown in Figure 1;

3) The material 25CrMnS4 has only been tested on the shaft parts, and the conclusion is that the heat treatment indicators are all qualified.

Dimensional deformation analysis of Automobile drum brake gear MIM parts:

1) The cumulative total score of 5 kinds of parts, TL4521 is the highest, followed by 20CrMo and 20CrMnTi (J9=35~38);

2) In terms of the single lowest score, 20MnCr5, 20CrMnTi (J9=37~40) and 20CrMnTi (J9=32~35) all have 0 points, that is, the deformation exceeds the tolerance range;

3) The material 25CrMnS4 is only tested on the shaft parts, and the total score is TL4521, 25CrMnS4, 20CrMo, 20MnCr5, 20CrMnTi in descending order.

In the process of dimensional deformation evaluation, abnormal data points have been analyzed and eliminated to avoid differences in analysis results due to abnormal data.

Production smoothness: During the experiment, 4 kinds of domestic materials (20CrMnTi, 20CrMo, 20MnCr5, 25CrMnS4) had different degrees of chip entanglement in the turning process, as shown in Figure 2(a). The first-gear shift gear corresponding to 20CrMnTi material had material sticking phenomenon in the gear shaping process, resulting in pressure injury on the end face of the finished part, which is an appearance defect, as shown in Figure 2(b). Improving the hardness of domestic blank materials can reduce the phenomenon of chip wrapping in the turning process and material sticking in the gear shaping process. For example, the hardness of the 20CrMnTi material is increased from the original 167~192 HB to 180~200 HB. Combined with the optimization of the equipment parameters of the lathe and the gear shaper, these processing defects can be completely eliminated and the requirements of production smoothness can be met.

5.In conclusion:

In this paper, five different metal materials (TL4521, 20CrMnTi, 20CrMo, 20MnCr5, 25CrMnS4) are compared, starting from three aspects: heat treatment index, dimensional deformation and production smoothness, by selecting appropriate evaluation index, under the same manufacturing process premise (The machining process and heat treatment process are exactly the same) to carry out experiments, and analyze the advantages and disadvantages of 5 kinds of automobile transmission gear materials in the manufacturing process.

In terms of heat treatment indicators, TL4521, 20MnCr5, 20CrMnTi (J9=37~40), 20CrMnTi (J9=35~38) can ensure that the experimental data are all within the qualified range; in terms of dimensional deformation, quantitative evaluation methods are used, gear and synchronization The order of the size deformation of the device parts is TL4521, 20CrMo, 20CrMnTi, 20MnCr5, and the order of the size deformation of the shaft parts is TL4521, 25CrMnS4, 20CrMo, 20MnCr5, 20CrMnTi; in terms of production smoothness, 4 kinds of domestic materials Different degrees of chip entanglement occurred in the turning process, and the material 20CrMnTi appeared material sticking in the gear shaping process. By adjusting the hardness of the blank and optimizing the processing parameters of the equipment, the defects can be completely eliminated.

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Evaluate according to drawings or products, calculate the price, and submit it to the buyer for confirmation

On sale

The production process of all products is supported by the production system and delivered according to the mutually agreed time. (If the size of the drawing needs to be changed in the middle, the buyer is responsible for the inconsistency with the original drawing. If we fail to meet customer requirements during the modification process, a full refund will be given)

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After handing over the product, we will seal all the buyer's molds for safekeeping.

(Problem solving) If there is a second or third revision in the production process, we will reply within 1 hour at the earliest, and we will solve customer problems within 8 hours at the latest depending on the situation of products that need to be evaluated.

Why Choose US?

Our R&D team	Zhongwei Precision Co., Ltd. and Central South University have a R&D team of 10 people. They develop more than 400 products each year, which is more than 68% higher than the same industry, and have obtained more than 20 patent certificates.
Our technical team	Zhongwei Precision has 5 professional engineers in the field of metal injection molding, and 15 technicians responsible for workshop management.
Our philosophy on quality management	1. Focus on the customer Organizations depend on customers, so organizations should understand customers' current and future needs in order to meet customer requirements and exceed their expectations. 2. Leadership Organizers unify the purpose, direction and internal environment of the organization and create an environment in which employees can fully participate in the achievement of organizational goals. 80% of quality problems are related to management and 20% are related to employees. 3. Full participation Employees at all levels are the foundation of the organization's survival and development, and only with their full participation can they bring benefits to the organization. Job responsibilities include all staff (from general manager to grassroots staff). 4. Process Approach Manage related resources and activities as a process to achieve desired results more efficiently. Flowchart method. 5. A systematic approach to management Identifying, understanding, and managing a system of interrelated processes against set objectives contributes to the effectiveness and efficiency of an organization. The principle of the hoarding of the wooden bucket. 6. Continuous Improvement It is an eternal development goal of the organization. PDCA cycle. 7. A fact-based approach to decision-making: Logical analysis or judgment of data and information is the basis for effective decision-making. Speak with data and facts. 8. Mutually beneficial supplier relationships Enhance the ability of the organization and its suppliers to create value through mutually beneficial relationships.
Device resources	The company has 10 MIM production lines, CNC and intelligent automated production workshops for production lines, which can guarantee the production of millions of MIM parts per day.
System Certification	ISO9001, ISO14001, IATF16949 certification
Port	It is 200 kilometers away from Tianjin Port, and goods can arrive at the port within 24 hours.

Process After Sintering

1. Heat treatment: annealing, carbonization, tempering, quenching, normalizing, surface tempering

2. Processing equipment: CNC, WEDM, lathe, milling machine, drilling machine, grinder, etc.;

3. Surface treatment: anodizing, powder spraying, chrome plating, painting, sandblasting, nickel plating, galvanizing, blackening, polishing, bluing, etc.

Moulds and Inspection Fixtures

1. Mold service life: usually semi-permanent. (except for lost foam)

2. Mold delivery time: 10-25 days, (according to product structure and product size).

3. Tooling and mold maintenance: Zhongwei is responsible for precision parts.

Quality Control

1. Quality control: the defective rate is less than 0.1%.

2. Samples and trial run will be 100% inspected during production and before shipment, sample inspection for mass production according to ISDO standards or customer requirements.

3. Testing equipment: flaw detection, spectrum analyzer, golden image analyzer, three-coordinate measuring machine, hardness testing equipment, tensile testing machine.