Synchronizer Sleeve Induction Heating Press Hardening Integrated Machine Design

With the rapid development of automobile industry, the automobile parts industry as thedownstream industry also appears to the good development momentum. The design andmanufacture technology of synchronizer as the main part of automobile transmission are alsomature gradually,but the heat treatment deformation amount of synchronizer gear sleeves as thethin-walled parts are very big and the product quality is not stable. The heat treatmentdeformation of gear sleeves are controlled by induction heating and pressure quenching in themost of automobile enterprises. Based on the development situation of domestic and foreigninduction heating and quenching machine, the possibility and necessity of the pressure quenchingmachine transformed into integration device are proposed so as to improve the productionefficiency and save cost.First of all, the processing technology of gear sleeves based on the design requirements andstructural features of gear sleeves are maked. The deformation mechanism of gear sleeves arediscussed from the angle of the materials, size structure, internal original organization and so onof gear sleeves. The overall design scheme of integration in the paper is proposed through thereasons analysis of gear sleeves deformation. The optimal program is determined through thecontrast of every system scheme.Secondly, the principle of electromagnetic heating are introduced. The current frequency andpower parameters of induction equipment in the integration device are determined in the paper.The materials, cross section shape and induction coil turns of new sensor are determined bycomparing the sensor of original heating machine. The structure of mobile sensor are designedbased on the basic principles of the sensor design. The diameter, height, width and spacing of thesensor are determined. The structure model of mobile induction device is designed. The lengthparameter selection of the sensor bar are discussed on the basis of design theory and fieldexperiment.Again, the original pressure quenching machine are mapping in the enterprise field. Thetransformation design of pressure quenching machine are completed through Solidworks software.The mould lifting mechanism and the mould pushing mechanism characteristics of pressurequenching machine are analyzed. The parameters of spindle with key parts are to theoreticalderivation.Finally, the bed structure of integration device are designed based on the design of theoverall structure. The main component model and parameter of the transmission system, coolingsystem, hydraulic system and electrical control system and so on of integration device arepreliminary determined, through the overall structure characteristics analysis of device design. The integration function of induction heating and pressure quenching are realized in theory.