{"id":2322,"date":"2026-06-24T02:50:11","date_gmt":"2026-06-24T02:50:11","guid":{"rendered":"https:\/\/helicalcutgears.top\/?p=2322"},"modified":"2026-06-24T02:50:11","modified_gmt":"2026-06-24T02:50:11","slug":"helical-gear-heat-treatment-guide","status":"publish","type":"post","link":"https:\/\/helicalcutgears.top\/sk\/helical-gear-heat-treatment-guide\/","title":{"rendered":"Tepeln\u00e9 hodnotenie \u0161pir\u00e1lov\u00e9ho ozuben\u00e9ho kolesa \u2013 v\u00fdpo\u010det straty v\u00fdkonu, po\u017eiadavky na v\u00fdrobu tepla a chladenie"},"content":{"rendered":"
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Tepeln\u00e9 spracovanie ozuben\u00fdch kolies so \u0161pir\u00e1lovou hlavou \u2013 porovnanie cement\u00e1cie, induk\u010dn\u00e9ho kalenia, nitrid\u00e1cie a kvantitat\u00edvneho spracovania<\/h1>\n

Tepeln\u00e9 spracovanie aplikovan\u00e9 na \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koleso<\/strong> \u0160pir\u00e1lov\u00e9 ozuben\u00e9 koleso ur\u010duje jeho povrchov\u00fa tvrdos\u0165, \u00fanavov\u00fa \u017eivotnos\u0165, deform\u00e1ciu po \u00faprave a to, \u010di je potrebn\u00e9 dodato\u010dn\u00e9 br\u00fasenie. V\u00fdber nespr\u00e1vneho procesu \u2013 cement\u00e1cia ozuben\u00e9ho kolesa, ktor\u00e9 by malo by\u0165 nitridovan\u00e9, alebo kalenie QT ozuben\u00e9ho kolesa, ktor\u00e9 potrebuje cement\u00e1ciu \u2013 m\u00f4\u017ee vies\u0165 k ozuben\u00e9mu kolesu so spr\u00e1vnym vzh\u013eadom, ale \u00faplne nespr\u00e1vnym v\u00fdkonom pri \u00fanave. T\u00e1to pr\u00edru\u010dka pokr\u00fdva v\u0161etky praktick\u00e9 mo\u017enosti tepeln\u00e9ho spracovania s procesn\u00fdmi parametrami, dosiahnute\u013enou tvrdos\u0165ou, \u03c3_H lim a \u0161pecifik\u00e1ciou v\u00fdkresu.<\/p>\n

Potvr\u010fte tepeln\u00e9 spracovanie v\u00e1\u0161ho zariadenia \u2192<\/a><\/p>\n<\/div>\n<\/div>\n

\u0160tyri procesy tepeln\u00e9ho spracovania pre \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koles\u00e1 \u2013 porovnanie ved\u013ea seba<\/h2>\n
\n\n\n\n\n\n\n\n\n
Proces<\/th>\nTvrdos\u0165 povrchu<\/th>\nTvrdos\u0165 jadra<\/th>\nH\u013abka pr\u00edpadu<\/th>\n\u03c3_H limit (MPa)<\/th>\nSkreslenie<\/th>\nBr\u00fasenie po HT<\/th>\nRelat\u00edvne n\u00e1klady<\/th>\n<\/tr>\n<\/thead>\n
QT (kalenie a pop\u00fa\u0161\u0165anie)<\/td>\nHB 220\u2013350<\/td>\nRovnak\u00fd prierez<\/td>\n\u017diadny pr\u00edpad \u2013 cez kalen\u00e9<\/td>\n490 \u2013 680<\/td>\nMinim\u00e1lne<\/td>\nVolite\u013en\u00e9 (vhodn\u00e9 pre odva\u013eovanie)<\/td>\n1,0\u00d7<\/td>\n<\/tr>\n
Induk\u010dn\u00e9 kalenie<\/td>\nHRC 50\u201358<\/td>\nHRC 28\u201338 (jadro QT)<\/td>\n0,5\u20135 mm (frekven\u010dne riaden\u00e9)<\/td>\n820 \u2013 1050<\/td>\nMierne \u2013 lok\u00e1lne tepeln\u00e9 nam\u00e1hanie<\/td>\nPo\u017eadovan\u00e9 pre DIN triedu 5\u20136<\/td>\n1,4\u20131,8\u00d7<\/td>\n<\/tr>\n
Plynov\u00e1 cement\u00e1cia + Q + T<\/td>\nHRC 58 \u2013 62<\/td>\nHRC 30\u201338<\/td>\n0,5\u20133,0 mm (\u010dasovo riaden\u00e9)<\/td>\n1500 \u2013 1800<\/td>\nVysok\u00e1 \u2014 pln\u00fd cyklus pece<\/td>\nPovinn\u00e9 pre triedy DIN 5\u20137<\/td>\n2,0\u20132,8\u00d7<\/td>\n<\/tr>\n
Plynov\u00e1 nitrid\u00e1cia<\/td>\nHV 700\u20131050 (HRC 62+)<\/td>\nHRC 28\u201338 (QT pred HT)<\/td>\n0,1\u20130,6 mm (plytk\u00e9)<\/td>\n1100 \u2013 1450<\/td>\nVe\u013emi n\u00edzka (max. 520 \u00b0C)<\/td>\nZvy\u010dajne sa nevy\u017eaduje<\/td>\n2,2\u20132,8\u00d7<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Proces 1: Kalenie a pop\u00fa\u0161\u0165anie (QT) \u2013 z\u00e1kladn\u00e1 l\u00ednia m\u00e4kk\u00e9ho boku zuba<\/h2>\n

QT (kalenie a pop\u00fa\u0161\u0165anie) je najjednoduch\u0161ie tepeln\u00e9 spracovanie pre \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koleso<\/strong> triedy ocele: kovan\u00fd alebo ty\u010dov\u00fd polotovar sa austenitizuje pri teplote 820 \u2013 880 \u00b0C, kal\u00ed sa v oleji alebo vode a potom sa pop\u00fa\u0161\u0165a pri teplote 550 \u2013 680 \u00b0C na cie\u013eov\u00fa tvrdos\u0165. V\u00fdsledkom je rovnomerne kalen\u00fd, h\u00fa\u017eevnat\u00fd prierez bez povrchov\u00e9ho obalu. Povrchov\u00e1 tvrdos\u0165 je obmedzen\u00e1 teplotou pop\u00fa\u0161\u0165ania \u2013 HB 220 zodpoved\u00e1 teplote pribli\u017ene 630 \u00b0C; HB 320 teplote pribli\u017ene 560 \u00b0C.<\/p>\n

QT \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koles\u00e1<\/strong> sa re\u017e\u00fa po cykle QT \u2013 zuby ozuben\u00e9ho kolesa sa odva\u013euj\u00fa alebo tvaruj\u00fa v kone\u010dnom kalenom stave (HB 220\u2013350 je \u013eahko kompatibiln\u00e1 s \u00e1zijsk\u00fdm trhom). Po rezan\u00ed zubov sa neaplikuje \u017eiadne tepeln\u00e9 spracovanie, tak\u017ee nie je potrebn\u00e1 \u017eiadna n\u00e1prava deform\u00e1cie a priamym odva\u013eovan\u00edm je mo\u017en\u00e9 dosiahnu\u0165 presnos\u0165 triedy DIN 7\u20139. QT je spr\u00e1vna \u0161pecifik\u00e1cia, ke\u010f: aplikovan\u00e9 za\u0165a\u017eenie je v rozsahu \u03c3_H lim 490\u2013680 MPa; br\u00fasenie sa nepl\u00e1nuje; a ozuben\u00e9 koleso je v nekritickom v\u0161eobecnom priemyselnom pohone s r\u00fdchlos\u0165ou na \u010diare st\u00fapania pod 15 m\/s.<\/p>\n

Proces 2: Cement\u00e1cia v plyne \u2013 \u0161tandard pre pr\u00e9miov\u00e9 \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koles\u00e1<\/h2>\n

\"cementovan\u00e9<\/p>\n

Nauhli\u010den\u00e9 \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koleso<\/strong> \u2014 povrch s tvrdos\u0165ou HRC 58\u201362, typicky s efekt\u00edvnou h\u013abkou puzdra 0,8\u20132,0 mm (do HV 550), poskytuje \u03c3_H lim 1500\u20131800 MPa a je zodpovedn\u00fd za v\u00e4\u010d\u0161inu presn\u00fdch obr\u00e1ban\u00ed v automobilovom priemysle, elektromobiloch, CNC, n\u00e1mornom priemysle a \u0165a\u017ekom priemysle \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koleso<\/strong> celosvetov\u00e1 produkcia<\/p>\n

Cyklus cement\u00e1cie \u2013 parametre procesu<\/h3>\n

Plynov\u00e1 cement\u00e1cia obohacuje povrch zuba \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koleso<\/strong> n\u00edzkouhl\u00edkovej legovanej ocele (typicky 20CrMnTi alebo 17CrNiMo6) s uhl\u00edkom vystaven\u00edm atmosf\u00e9re endotermick\u00e9ho plynu + obohacovacieho plynu (prop\u00e1nu alebo zemn\u00e9ho plynu) pri teplote 880 \u2013 940 \u00b0C. Uhl\u00edk difunduje dovn\u00fatra od povrchu, \u010d\u00edm vytv\u00e1ra gradient koncentr\u00e1cie uhl\u00edka, ktor\u00fd po kalen\u00ed a pop\u00fa\u0161\u0165an\u00ed vytv\u00e1ra tvrd\u00fd martenzitick\u00fd povrch nad h\u00fa\u017eevnat\u00fdm jadrom s ni\u017e\u0161\u00edm obsahom uhl\u00edka:<\/p>\n

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Austenitiza\u010dn\u00e1 teplota<\/strong><\/p>\n

880 \u2013 940 \u00b0C. Vy\u0161\u0161ia teplota zvy\u0161uje r\u00fdchlos\u0165 dif\u00fazie uhl\u00edka, ale v niektor\u00fdch oceliach predstavuje riziko rastu z\u0155n. 17CrNiMo6 toleruje 940 \u00b0C bez rastu z\u0155n; 20CrMnTi je obmedzen\u00fd na maxim\u00e1lne 920 \u00b0C.<\/p>\n<\/div>\n

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Kontrola uhl\u00edkov\u00e9ho potenci\u00e1lu<\/strong><\/p>\n

Atmosf\u00e9rick\u00fd uhl\u00edkov\u00fd potenci\u00e1l C_P = 0,75 \u2013 0,851 TP3T po\u010das cement\u00e1cie; zn\u00ed\u017een\u00fd na 0,65 \u2013 0,701 TP3T po\u010das dif\u00faznej f\u00e1zy pre splo\u0161tenie profilu n\u00e1teru. Monitorovan\u00e9 sondou CO\u2082 alebo O\u2082 v peci.<\/p>\n<\/div>\n

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Kontrola h\u013abky puzdra<\/strong><\/p>\n

Efekt\u00edvna h\u013abka puzdra (do HV 550) \u2248 0,18 \u00d7 \u221a\u010das pri teplote [hodiny]. Cie\u013e 0,8 mm: celkov\u00fd cyklus pribli\u017ene 20 hod\u00edn. Cie\u013e 1,5 mm: pribli\u017ene 70 hod\u00edn. \u010cas predstavuj\u00fa n\u00e1klady na proces.<\/p>\n<\/div>\n

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Uhasi\u0165 a zmierni\u0165<\/strong><\/p>\n

Kalenie v oleji z 820 \u2013 840 \u00b0C na okolit\u00fa teplotu. Pop\u00fa\u0161\u0165anie pri 150 \u2013 200 \u00b0C po\u010das 2 hod\u00edn \u2013 zni\u017euje zvy\u0161kov\u00e9 nap\u00e4tie a krehkos\u0165 pri zachovan\u00ed HRC 58 \u2013 62. Vy\u0161\u0161ie teploty pop\u00fa\u0161\u0165ania zni\u017euj\u00fa tvrdos\u0165 povrchu pod \u0161pecifik\u00e1ciu.<\/p>\n<\/div>\n<\/div>\n

Pre\u010do je br\u00fasenie po cement\u00e1cii povinn\u00e9:<\/strong> Cyklus pece pri teplote 880 \u2013 940 \u00b0C sp\u00f4sobuje tepeln\u00e9 a transforma\u010dn\u00e9 skreslenie profilu zuba a st\u00fapania 0,05 \u2013 0,3 mm \u2013 \u010do v\u00fdrazne presahuje toleran\u010dn\u00e9 p\u00e1sma triedy presnosti DIN 5 \u2013 7. Skreslen\u00e9 ozuben\u00e9 koleso sa mus\u00ed po cement\u00e1cii br\u00fasi\u0165, aby sa obnovila trieda presnosti. Preto sa pou\u017e\u00edva cementovan\u00e9 ozuben\u00e9 koleso triedy 5 pod\u013ea DIN. \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koleso<\/strong> je v\u017edy cementovan\u00e9 A br\u00fasen\u00e9 ozuben\u00e9 koleso \u2013 samotn\u00e9 cementovanie vytv\u00e1ra triedu DIN 10\u201312 a br\u00fasenie obnovuje presnos\u0165.<\/div>\n

Proces 3: Induk\u010dn\u00e9 kalenie \u2013 Selekt\u00edvne povrchov\u00e9 kalenie ve\u013ek\u00fdch ozuben\u00fdch kolies<\/h2>\n

Induk\u010dn\u00e9 kalenie vyu\u017e\u00edva elektromagnetick\u00fa indukciu na ohrev \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koleso<\/strong> povrch zuba r\u00fdchlo (zvy\u010dajne v priebehu 1 \u2013 10 sek\u00fand na zub alebo na jeden skenovac\u00ed prechod) na austenitiza\u010dn\u00fa teplotu, po ktorej nasleduje okam\u017eit\u00e9 kalenie. Zahrieva sa a kal\u00ed sa iba povrch v h\u013abke elektromagnetick\u00e9ho prieniku \u2013 jadro zost\u00e1va na svojej predinduk\u010dnej tvrdosti (zvy\u010dajne QT HB 280 \u2013 320 pre 42CrMo). V\u00fdsledok: tvrd\u00fd povrch, h\u00fa\u017eevnat\u00e9 jadro s hranicou medzi pl\u00e1\u0161\u0165om a jadrom umiestnenou v kontrolovanej h\u013abke ur\u010denej frekvenciou induktora:<\/p>\n

\n\n\n\n\n\n\n\n
Frekvencia induktora<\/th>\nH\u013abka prieniku<\/th>\nVhodn\u00fd prevodov\u00fd modul<\/th>\nVzor kalenia<\/th>\n<\/tr>\n<\/thead>\n
450 kHz (VF)<\/td>\n0,3\u20130,8 mm<\/td>\nM2\u2013M5<\/td>\nLen povrch; sledovanie kont\u00fary profilu zuba<\/td>\n<\/tr>\n
10\u201330 kHz (skr\u00e1tene)<\/td>\n1,0\u20132,5 mm<\/td>\nM5\u2013M16<\/td>\n\u010ciasto\u010dn\u00fd pr\u00edpad kop\u00edruj\u00faci obrys zuba; priechodn\u00fd zub pre men\u0161ie moduly<\/td>\n<\/tr>\n
1\u20133 kHz (n\u00edzky frekvencia)<\/td>\n3\u20136 mm<\/td>\nM16\u2013M40+<\/td>\nKalenie cez zub pre ve\u013ek\u00e9 moduly; hranica medzi pl\u00e1\u0161\u0165om a jadrom pod kore\u0148om<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Induk\u010dn\u00e9 kalenie je vhodn\u00e9 najm\u00e4 pre ve\u013ekomodulov\u00e9 \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koles\u00e1<\/strong> (M16\u2013M50) pre ban\u00edctvo, cement\u00e1rne a valcovne, kde by plynov\u00e1 cement\u00e1cia vy\u017eadovala neprakticky dlh\u00e9 cykly pece (70\u2013200 hod\u00edn pre h\u013abku 2\u20135 mm) a sp\u00f4sobovala by nezvl\u00e1dnute\u013en\u00fa deform\u00e1ciu polotovarov s ve\u013ek\u00fdm prierezom. Induk\u010dn\u00e9 kalenie lok\u00e1lne zahrieva a kal\u00ed, \u010d\u00edm vytv\u00e1ra men\u0161iu celkov\u00fa deform\u00e1ciu ako pln\u00fd cyklus pece \u2013 hoci komplexn\u00fd tepeln\u00fd gradient st\u00e1le vy\u017eaduje dodato\u010dn\u00e9 br\u00fasenie pre triedu DIN 5\u20137.<\/p>\n

Proces 4: Nitrid\u00e1cia plynom \u2013 rozmerov\u00e1 stabilita ozuben\u00fdch kolies obr\u00e1bac\u00edch strojov<\/h2>\n

Plynov\u00e1 nitrid\u00e1cia difunduje dus\u00edk do povrchu pre-QT \u0161pir\u00e1lov\u00e9 ozuben\u00e9 koleso<\/strong> oce\u013e (zvy\u010dajne 38CrMoAl, ale aj 42CrMo a 40Cr pre priemyseln\u00e9 ozuben\u00e9 koles\u00e1) pri teplote 490 \u2013 530 \u00b0C \u2013 \u010do je v\u00fdrazne pod teplotou transform\u00e1cie. Dus\u00edk sa sp\u00e1ja s leguj\u00facimi prvkami (Cr, Mo, Al) a vytv\u00e1ra extr\u00e9mne tvrd\u00e9 nitridov\u00e9 zrazeniny, \u010d\u00edm sa dosahuje povrchov\u00e1 tvrdos\u0165 HV 700 \u2013 1050 bez akejko\u013evek f\u00e1zovej transform\u00e1cie. Absencia transform\u00e1cie znamen\u00e1:<\/p>\n