Processing and optimization of copper-based powder metallurgy synchronizing ring for double cone synchronizer
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摘要: 以-200目电解铜粉和雾化细黄铜粉为原料, 利用喷撒烧结设备、拉伸成锥设备及模具, 研究了铜基粉末冶金双锥同步器同步环的撒粉烧结和拉伸成锥工艺。结果表明, 铜基粉末冶金摩擦材料的孔隙率保持在30%左右, 且孔隙呈细微和均匀分布; 摩擦材料层的平均动摩擦系数为0.081, 静摩擦系数为0.146, 磨耗率为8.70×10-9 cm3/J; 该材料在随钢芯板冷拉伸成锥形时不掉渣, 厚薄均匀, 锥度、圆度及尺寸变化很小, 其原料配方和拉伸成锥工艺可适用与大批量生产。Abstract: The copper-based powder metallurgy synchronizing ring for double cone synchronizer was prepared by using-200 mesh electrolytic copper powder and atomized fine brass powder as raw material, the processes of dusting powder, sintering, and stretching of copper based powder metallurgy synchronous ring were investigated by spraying sintering equipment, stretching equipment, and cone mould. The results show that, the porosity of copper based powder metallurgy friction material is maintained at about 30%, the fine pores are in uniform distribution. The average friction coefficient of friction material layer is 0.081, the static friction coefficient is 0.146, and the wear rate is 8.70 × 10-9 cm3/J. The copper based powder metallurgy friction material is tapered without dregs in cold drawing with steel core plate, the thickness is uniform, and the taper, roundness, and dimensions are steady. The composition of raw material and the stretching technology are suitable for the mass production.
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图 1 铜基粉末冶金双锥同步器同步环示意图
Figure 1. Schematic diagram of copper-based powder metallurgy synchronizing ring for double cone synchronizer
图 2 铜基粉末冶金摩擦片生产工艺路线示意图
Figure 2. Production process route of copper base powder metallurgy friction plate
图 3 采用-300目雾化细黄铜粉的1-3号配方试样显微组织形貌(×200)
Figure 3. Microstructure morphology of sample No.1-3 prepared by-300 mesh atomization brass powders (×200)
图 4 各工序图形: (a)芯板展开; (b)喷撒烧结; (c) 13°锥角成形; (d) 9°锥角成形; (e)油槽成形; (f)高频淬火; (g)精整(成品)
Figure 4. Graphics for each working procedure: (a) core; (b) spraying sintering; (c) forming in 13°taper angle; (d) forming in 9°taper angle; (e) forming of oil groove; (f) high-frequency quenching; (g) finishing
表 1 非金属组元质量分数与拉伸工艺性能表
Table 1. Non-metallic element content by mass and drawing performance
配方编号 黄铜基体（Sn7Zn10Cu）质量分数/ % 非金属组元质量分数/ % 拉深后状态 石墨 硅酸锆 总量 1 余量 5.5 5.5 11 摩擦层沿锥面母线方向开裂较严重，肉眼观察其表面分布着较密的细小裂纹，外锥表面边缘摩擦层局部有脱落。 2 余量 5.0 5.0 10 摩擦层沿锥面母线方向开裂，肉眼观察其表面分布着较密的细小裂纹，外锥表面边缘摩擦层无脱落。 3 余量 4.5 4.5 9 肉眼观察其表面无裂纹，显微镜下观察有少许微裂纹。 4 余量 4.0 4.0 8 显微镜下观察无裂纹。 5 余量 3.5 3.5 7 显微镜下观察无裂纹。 6 余量 3.0 3.0 6 显微镜下观察无裂纹。 
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表 2 密度和孔隙率试验原料配方(质量分数)
Table 2. Composition of raw material for the density and porosity test
% 电解铜（-200目） CuZn20（-300目） 锡粉（-200目） 石墨粉（-299目） 硅酸锆（-200目） 43.62 43.62 7.00 4.00 4.00
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表 3 铜基粉末冶金摩擦材料试样密度和孔隙率
Table 3. Density and porosity of copper based powder metallurgy friction material
试样编号 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 工艺密度/ (g·cm-3) 4.8 5.0 5.2 5.4 5.6 5.8 6.0 6.2 理论孔率/ % 36.0 33.3 30.6 28.0 25.3 22.6 20.0 17.3
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表 4 基体研究材料配方(质量分数)和工艺密度表
Table 4. Composition of raw material and the density of copper based powder metallurgy friction material
配方编号 材料配方质量分数/ % 工艺密度/ (g·cm-3) 理论孔隙率/ % 电解铜粉
（-200目）CuZn20
（-200目）CuZn20
（-300目）锌粉
（-200目）铝粉
（-200目）锡粉
（-200目）石墨粉
（-299目）石墨粉
（-199目）硅酸锆
（-200目）1-1 77.00 0 0 8 0 7 0 4 4 6.0 20 1-2 43.62 41.38 0 0 0 7 0 4 4 6.0 20 1-3 43.62 0 41.38 0 0 7 4 0 4 6.0 20 1-4 77.00 0 0 0 8 7 0 4 4 6.0 20 1-5 77.00 0 0 8 0 7 4 0 4 6.0 20
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