花键的生产过程一般包括以下主要步骤：
设计与工艺规划
• 根据花键的使用要求，如传递扭矩、精度要求等，进行详细的设计，确定花键的尺寸、形状、公差等参数。
• 依据设计要求制定工艺路线，包括选择合适的加工方法、确定加工顺序以及所需的工装夹具等。
原材料准备
• 选择合适的材料，如中碳钢、中碳合金钢等，需保证材料的强度、韧性和加工性能满足花键的使用要求。
• 对原材料进行检验，包括化学成分分析、硬度检测、金相组织检查等，确保材料质量符合标准。
• 将检验合格的原材料加工成所需的毛坯，常用的方法有锻造、轧制等，以改善材料的内部组织，提高力学性能。
切削加工
• 齿形加工：常用的方法有滚齿、插齿等。滚齿是利用滚刀与工件之间的相对运动来切削出花键齿形，生产效率较高，适用于加工各种模数的花键。插齿则适用于加工内花键或多联齿轮等复杂形状的花键。
• 键槽加工：对于一些特殊的花键，可能还需要进行键槽加工。可采用铣削或拉削的方法，铣削加工灵活性较高，适用于单件小批量生产；拉削加工则生产效率高、精度高，适用于大批量生产。
热处理
• 对加工后的花键进行淬火、回火等热处理，提高花键的硬度、强度和耐磨性。
• 控制热处理过程中的加热速度、保温时间和冷却速度等参数，以获得良好的金相组织和力学性能，同时要注意防止变形和开裂。
表面处理
• 为了提高花键的耐腐蚀性、耐磨性和润滑性，通常会进行表面处理。常见的表面处理方法有镀硬铬、氮化、磷化等。镀硬铬可以提高花键表面的硬度和光洁度，氮化能在花键表面形成一层硬度高、耐磨性好的氮化层，磷化则可以提高花键的润滑性能和耐腐蚀性。
质量检验
• 采用量具如卡尺、千分尺、花键量规等对花键的尺寸精度进行测量，检查齿形、齿向、键槽宽度等参数是否符合设计要求。
• 通过肉眼或使用光学显微镜等设备，检查花键表面是否有裂纹、砂眼、气孔等缺陷。
• 采用硬度计对花键不同部位进行硬度测试，确保硬度符合热处理后的要求。
装配与包装
• 将检验合格的花键与其他相关零部件进行装配，装配过程中要注意保证花键与配合件的配合精度和装配间隙。
• 对装配好的产品进行清洗、防锈处理后，进行包装，选择合适的包装材料，如塑料袋、纸盒等，以防止在运输和储存过程中受到损坏。
The production process of splines generally includes the following main steps:
Design and process planning
• According to the use requirements of splines, such as transmission torque and precision requirements, detailed design is carried out to determine the size, shape, tolerance and other parameters of splines.
• According to the design requirements, the process route is formulated, including selecting appropriate processing methods, determining the processing sequence and the required fixtures, etc.
Raw material preparation
• Select appropriate materials, such as medium carbon steel, medium carbon alloy steel, etc., to ensure that the strength, toughness and processing performance of the materials meet the use requirements of splines.
• Inspect the raw materials, including chemical composition analysis, hardness testing, metallographic structure inspection, etc., to ensure that the material quality meets the standards.
• Process the qualified raw materials into the required blanks. Common methods include forging and rolling to improve the internal structure of the material and improve the mechanical properties.
Cutting processing
• Tooth shape processing: Common methods include hobbing and gear shaping. Hobbing is to use the relative movement between the hob and the workpiece to cut the spline tooth shape. It has high production efficiency and is suitable for processing splines of various moduli. Gear shaping is suitable for processing splines with complex shapes such as internal splines or multi-gear gears.
• Keyway processing: For some special splines, keyway processing may also be required. Milling or broaching can be used. Milling has high flexibility and is suitable for single-piece small-batch production; broaching has high production efficiency and high precision and is suitable for large-scale production.
Heat treatment
• The processed splines are subjected to heat treatment such as quenching and tempering to improve the hardness, strength and wear resistance of the splines.
• Control parameters such as heating rate, holding time and cooling rate during heat treatment to obtain good metallographic structure and mechanical properties, and pay attention to preventing deformation and cracking.
Surface treatment
• In order to improve the corrosion resistance, wear resistance and lubricity of splines, surface treatment is usually performed. Common surface treatment methods include hard chrome plating, nitriding, phosphating, etc. Hard chrome plating can improve the hardness and finish of the spline surface, nitriding can form a nitride layer with high hardness and good wear resistance on the spline surface, and phosphating can improve the lubrication performance and corrosion resistance of the spline.
Quality Inspection
• Use measuring tools such as calipers, micrometers, spline gauges, etc. to measure the dimensional accuracy of the spline, and check whether the parameters such as tooth shape, tooth direction, keyway width, etc. meet the design requirements.
• Check whether there are defects such as cracks, sand holes, pores, etc. on the spline surface by naked eyes or using optical microscopes and other equipment.
• Use a hardness tester to test the hardness of different parts of the spline to ensure that the hardness meets the requirements after heat treatment.
Assembly and Packaging
• Assemble the qualified splines with other related parts. During the assembly process, pay attention to ensure the matching accuracy and assembly clearance between the splines and the mating parts.
• After cleaning and rust-proofing the assembled products, package them and choose appropriate packaging materials, such as plastic bags, paper boxes, etc., to prevent damage during transportation and storage.