Method and apparatus for carburizing, quenching and tempering

Abstract: Method and apparatus for carburizing, quenching and tempering workpieces, by which the step of carburizing can be incorporated into a machining and manufacturing process to be performed by an on-line machining and manufacturing system as one stage thereof, and by which high-quality treatment or processing can be achieved without occurrences of variation in quality among heat-treated products. In this apparatus, a preheating chamber (2), six carburizing chambers (5a to 5f), a cooling chamber (6), a reheating chamber (7), a quenching chamber (8) are placed around an intermediate chamber (4) having a transport device (12). Further, a high-frequency induction heating technique is used for heating each of major ones of the treatment or processing chambers. Moreover, a plasma carburizing method is performed in the carburizing chambers. Furthermore, workpieces, which are successively carried into this apparatus through a machining and manufacturing line, are assigned and distributed to the chambers, respectively, and are then treated or processed therein. Thus, the process of carburizing, quenching and tempering can be performed without stagnation.

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention generally relates to an apparatus for carburizing, quenching and tempering, and, furthermore, to a method for carburizing, quenching and tempering, by means of such an apparatus by which a step of carburizing can be incorporated into a machining and manufacturing process to be performed by an on-line machining and manufacturing system as one stage thereof. 2. Description of the Related Art Hitherto, continuous gas carburize/quench furnaces of the tray pusher type or of the roller hearth type have been used as apparatuses for carburizing and quenching, so as to carry out the mass production of (steel) products. The continuous gas carburize/quench furnace of any of such types usually provides around-the-clock operation in what is called a heat-treating shop, which is away from a machining shop, by being made to be offline from a machining (process) apparatus. Further, the furnace has employed a producing method by which a heat treatment is performed according to a batch system that is adapted to set up a large number of workpieces (such as parts), which are to be processed, on trays, respectively. Meanwhile, the process to be performed by such a conventional continuous gas carburize/quench furnace is composed of steps illustrated in FIG. 4. Namely, the cutting of the workpieces are first performed in the machining shop. Subsequently, the cut workpiece is transported from the machining shop to the heat-treating shop which is made to be offline and is away therefrom. When the workpieces arrive at the heat-treating shop, the set-up step of setting up the workpiece on a tray is performed by jigs. After cleaning, the workpieces are loaded into the continuous gas carburize/quench furnace. Thence, the steps of carburizing and quenching are performed in the continuous gas carburize/quench furnace. Subsequently, the workpieces are cleaned and tempered. Upon completion of a sequence of heat-treating steps, a step of taking the workpiece out of the tray and further disassembling the workpiece is performed. The disassembled workpiece is transported to the machining shop which is made to be offline and is away from the heat-treating shop. Thereafter, in the marching shop, the grinding of the workpiece is performed. The aforementioned process of FIG. 4 which is to be performed in the conventional continuous gas carburize/quench furnace, has the following problems. i) Because the machining shop is placed apart from the heat-treating shop, a transport system and personnel therefor are needed. Moreover, it is necessary to stock workpieces, which are to be processed (or treated), for a time period having a predetermined length. ii) There is the necessity of the set-up step of setting a workpiece on a tray by using a jig so as to charge the workpiece into the furnace. Moreover, the disassembling step of taking out the workpiece, which has been set on the tray, therefrom is needed upon completion of the heat-treating step. iii) It takes time to raise and lower the temperature of the workpiece. The lead time of the heat treatment is long. Thus, the process from the step of inserting or charging the workpiece into the furnace to the step of extracting thereof from the furnace is time-consuming. iv) When starting up the furnace, it takes long time to perform seasoning for regulating (or controlling) the furnace atmosphere. v) Batch processing results in variation in quality among the heat-treated workpieces. From US-A-4,790,750 there is known an automated flexible installation for a rapid thermochemical treatment of parts, notably for the mechanical industry. In particular, said automated installation comprises a transfer lock for the parts under a controlled atmosphere, a plurality of treatment modules of the parts, all of said modules being connected to said transfer lock; a loading lock; an unloading lock; and a handling robot for the parts disposed in said transfer lock in order to provide for successive transfers of parts between the various modules. The steps of preheating, carburizing and quenching of said workpieces are performed by providing treatment means in the amount necessary for performing each of the steps without stopping the flow of said workpieces. In essential, the features as comprised in the preamble portion of the independent apparatus claim of the present invention are known from said US-A-4,790,750. The present invention is accomplished to solve the aforementioned problems. Accordingly, an object of the present invention is to provide an apparatus for carburizing, quenching and tempering workpieces, by which the step of carburizing can be incorporated into a machining and manufacturing process to be performed by an on-line machining and manufacturing system as one stage thereof, and by which high-quality treatment or processing can be achieved without occurrences of variation in quality among heat-treated products. Further, another object of the present invention is to provide a method of carburizing, quenching and tempering workpieces by means of such an apparatus. SUMMARY OF THE INVENTION The above objects of the present invention are achieved in terms of an apparatus by the subject matter of claim 1 and are achieved in terms of a method by the subject matter of claim 8. Preferred embodiments and further improvements are defined in the depending subclaims. According to a preferred embodiment, the number Z of the aforesaid carburizing devices is set in such a manner as to meet the condition given by the following inequality: Z≥X/Y where X denotes a time period taken for performing the aforesaid carburizing step; and Y the time interval between the supplies of the workpieces in the units of treatment through the aforesaid machining and manufacturing line. According to another preferred embodiment, the aforesaid cooling device and the aforesaid reheating device are provided in such a manner as to meet conditions given by the following inequalities: C≥M/Y, H≥N/Y where M designates a time taken to accomplish the aforesaid cooling step of cooling the workpiece to a temperature which is not higher than the aforesaid A1 transformation temperature; N a time taken to accomplish the aforesaid reheating step of reheating the workpiece, which has been cooled in the aforesaid cooling step, to the quenching temperature; Y the time interval between the supplies of the workpieces in the units of treatment through the aforesaid machining and manufacturing line; C the number of the aforesaid cooling devices for performing the aforesaid cooling step; and H the number of the aforesaid reheating devices for performing the aforesaid reheating step. BRIEF DESCRIPTION OF THE DRAWINGS Other features, objects and advantages of the present invention will become apparent from the following description of preferred embodiments with reference to the drawings in which like reference characters designate like or corresponding parts throughout several views, and in which: FIG. 1 is a schematic longitudinal sectional view of the apparatus for carburizing, quenching and tempering workpieces, of the present invention; FIG. 2 is a schematic plan view of this apparatus for carburizing, quenching and tempering workpieces; FIG. 3 is a time chart illustrating another method for carburizing, quenching and tempering workpieces in this apparatus embodying the present invention; and FIG. 4 is a block diagram illustrating the steps of a conventional method for carburizing, quenching and tempering workpieces. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Hereinafter, methods of carburizing, quenching and tempering workpieces according to the present invention, and apparatuses for carburizing, quenching and tempering workpieces according to the present invention, will be described in detail by referring to the accompanying drawings. FIG. 1 illustrates a schematic longitudinal sectional view of an apparatus for carburizing, quenching and tempering workpieces, which is an embodiment of the present invention. FIG. 2 is a schematic plan view of this apparatus. In this apparatus, the treatment chambers are arranged as a plurality of stages placed in a vertical (namely, upward or downward) direction. The apparatus for carburizing, quenching and tempering workpieces, which is this embodiment of the present invention, is provided with a preheating chamber 22, an intermediate chamber 24, carburizing chambers 27a to 27f, a quenching chamber 211 and a tempering chamber 214. In the vicinity of the preheating chamber 22, there is provided an entrance door 21 through which workpieces to be treated (or processed) are carried into the preheating chamber 22. Further, an intermediate door 25 is provided in a coupling portion between the preheating chamber 22 and the intermediate chamber 24. Further, each of intermediate doors 26a to 26f is provided in a coupling (or joint) portion between the preheating chamber 24 and a corresponding one of carburizing chambers 27a to 27f placed therearound. Moreover, intermediate doors 210 and 213 are provided in a coupling portion between the intermediate chamber 24 and the quenching chamber 211 provided thereunder, and a coupling portion between the quenching chamber 211 and the tempering chamber 214, respectively. Furthermore, an exit door 215, through which workpieces are carried out of the tempering chamber 214, is provided therein. In addition, although an induction heating coil for performing high-frequency induction heating is provided in each of the preheating chamber 22, the carburizing chambers 27a to 27f, and the tempering chamber 214, only the induction heating coils 23, 28a and 214a, which are provided in the preheating chamber 22, the carburizing chamber 27a and the tempering chamber 214, respectively, are shown in FIG. 1 and the illustration of the other induction heating coils is omitted therein, for simplicity of drawing. Besides, transport units 217 and 219, which further serve as supporting bases each for supporting workpieces, are provided in the preheating chamber 22 and the quenching chamber 211, respectively. Although a supporting base for supporting the workpiece in upwardly and downwardly movable manner is provided in each of the carburizing chambers 27a to 27f and the tempering chamber 214, only a supporting base 29a provided in the carburizing chamber 27a and another supporting base 221 provided in the tempering chamber 214 are shown in FIG. 1 and the illustration of the other supporting bases is omitted. Further, a transport fork 216 for carrying workpieces into the preheating chamber 22 through the entrance door 21 is provided in the vicinity of the preheating chamber 22. Further, transport forks 218a to 218f, each of which is used for taking in workpieces to and taking out workpieces from a corresponding one of transport units 217 and 219 in the intermediate chamber 24, are provided in the carburizing chambers 27a to 27f. Moreover, a transport fork 220 for transporting workpieces to the tempering chamber 214 is provided with the quenching chamber 211. Furthermore, a transport fork 222 for carrying out workpieces from the tempering chamber 214 is provided in the proximity of the exit door 215. Incidentally, the drawing of a vacuum pumping system, a gas injection (or introduction) system and a power supply system is omitted. The preheating chamber 22 is a vacuum-sealable chamber used to receive workpieces, which have been machined by a machining apparatus (not shown) and transported by the transport fork 216, through the entrance door 21 and to rapidly heat the received workpieces to the carburizing temperature. Further, the preheating chamber 22 has a double wall structure for the water-cooling of the walls thereof and is provided with the transport unit 217 for supporting and transporting workpieces to the intermediate chamber 24, and the induction heating coil 23 for preheating the workpiece are provided therein. As will be described later, the preheated workpiece is conveyed to the intermediate chamber 24 through the intermediate door 25. The intermediate chamber 24 is a vacuum-sealable chamber that is needed as a relay chamber when transporting workpieces from the preheating chamber 22 to the carburizing chambers 27a to 27f or when each of the carburizing chambers to the quenching chamber 211. Further, the intermediate chamber 24 receives the preheated workpieces through the intermediate door 25 and serially transports the workpieces to the carburizing chambers 27a to 27f through the intermediate doors 26a to 26f by putting the workpieces on the transport forks 218a and so on (incidentally, the drawing of the transport forks corresponding to the carburizing chambers 27b to 27f), respectively. As will be described later, the intermediate chamber 24 receives the workpieces, which are conveyed from the carburizing chambers 27a to 27f through the intermediate doors 26a to 26f, respectively, and have been carburized. Further, the intermediate chamber 24 is adapted to put the workpieces on the transport unit 219 and carry the workpieces into the quenching chamber 211 through the intermediate door 210. The carburizing chambers 27a to 27f are vacuum-sealable chambers for carburizing the workpieces transported thereto by the transport fork 218a and so forth, respectively. Further, these carburizing chambers have double wall structures for the water-cooling of the walls thereof. Moreover, each of the carburizing chambers is provided with a corresponding one of the supporting bases 29a and so forth, which is adapted to support the workpieces in an upwardly and downwardly movable manner (incidentally, in FIG. 1, the drawing of the supporting bases corresponding to the carburizing chambers 27b to 27f is omitted), and a corresponding one of the induction heating coils 28a and so on (incidentally, the drawing of induction heating coils corresponding to the carburizing chambers 27b to 27f is omitted in FIG. 1) for maintaining the temperature of the workpiece at the carburizing temperature. Upon completion of the carburization, the workpieces are loaded onto the transport forks and are further transported from the carburizing chambers 27a to 27f to the intermediate camber 24 through the intermediate doors 26a to 26f, respectively. Incidentally, the supporting bases of the carburizing chambers 27a to 27f are electrically insulated from the chamber walls of the aforesaid carburizing chambers 27a to 27f, respectively. The quenching chamber 211 is a vacuum sealable chamber for quenching the workpiece, which is transported by the transport fork 219 that is provided therein and further serves as a supporting base for supporting the workpiece. Further, the quenching chamber 8 has a nozzle 212 for cooling the workpiece therein. Upon completion of the quenching, the workpiece is loaded onto the transport fork 220 and is then transported to the tempering chamber 214 from the quenching chamber 211 through the intermediate door 213. The tempering chamber 214 is a vacuum sealable chamber for tempering the workpiece transported by the transport fork 220 and is provided with a supporting base 221 for supporting a workpiece in an upwardly and downwardly movable manner, and with an induction heating coil 214a for heating the workpiece. Upon completion of the tempering, the workpiece is loaded onto the transport unit 222 and is further transported to the machining shop for performing the next step through the exit door 215. Thus, the aforementioned apparatus for carburizing, quenching and tempering according to this embodiment of the present invention has the configuration, wherein the preheating chamber 22, the carburizing chambers 27a to 27f, the quenching chamber 211 and the tempering chamber 214, which are vacuum sealable chambers, are connected through the intermediate doors 25, 26a to 26f, 210 and 213 with one another, and wherein the intermediate chamber 24 is placed just under the preheating chamber 21 and further, the quenching chamber 211 is placed just under the intermediate chamber 24. Moreover, the six carburizing chambers 27a to 27f are placed around the intermediate chamber 24 substantially at a same height as of the intermediate chamber 24. Furthermore, the tempering chamber 214 is placed nearly at a same height as of the quenching chamber 211. Hereinafter, an operation of the apparatus for carburizing, quenching and tempering the workpieces, which has such a configuration, will be described in detail by referring to a time chart of FIG. 3. In the case of the time chart of FIG. 3, it is assumed that the machining time per workpiece is 3 minutes and that the carburizing time at a temperature of 950 degrees centigrade is 15 minutes, on the supposition that the effective case depth required of each workpiece is 0.3 to 0.5 mm. First, after machining oil having adhered to workpieces, which are machined by the machining apparatus, is cleaned, the workpieces are carried into the preheating chamber 22 through the entrance door 21 by the transport fork 216 (at time 0). The workpiece carried thereinto is set at the transport unit 217 that further serves as a supporting base. Then, this workpiece is raised (or elevated) by the transport unit 217 up to a predetermined position where the workpiece is preheated. Subsequently, the entrance door 21 is closed. Further, air and gases are removed from the preheating chamber 22 by vacuum-pumping till the internal pressure of the preheating chamber 22 becomes 1 Pa or so (namely, reaches a pressure which is small to the extent that the workpiece does not undergo oxidation). Then, the workpiece is quickly heated by an induction (magnetic) field which is caused by passing a high-frequency electric current, whose frequency is equal to or higher than 0.5 kHz but is equal to or less than 3 kHz, through the induction heating coil 23. When the temperature of the workpiece reaches the carburizing temperature which is not lower than the A1 transformation point (or temperature), the workpiece is maintained at this carburizing temperature until the processing to be performed in the next step is commenced. If the intermediate chamber 24 and the carburizing chamber (namely, one of the chambers 27a to 27f) are empty, the passage of the high-frequency electric current is stopped. Then, the transport unit 217 is lowered. Thus, the workpiece is transported to the intermediate chamber 24 through the intermediate door 25. From the intermediate chamber 24, air and gases are exhausted until the (internal) pressure thereof becomes 1 Pa or so (namely, reaches a pressure which is small to the extent that the workpiece does not undergo oxidation). The workpieces transported from the preheating chamber 22 are carried into the corresponding one of the carburizing chambers 27a to 27f by the transport forks 218a to 218f through the corresponding one of the intermediate doors 26a to 26f. Here, it is assumed that the workpiece is charged into the carburizing chamber 27a (at time 3 (min.)). At that time, another workpiece having been machined by the machining apparatus is simultaneously carried into the preheating chamber 22 through the entrance door 21 after cleaned. In this way, the workpieces are carried into the preheating chamber 22 from the machining apparatus with no waiting (or wait) time (namely, a waiting time is 0) by controlling the carrying timing according to the machining time. From the carburizing chamber 27a, air and gases are exhausted until the (internal) pressure thereof becomes 1 Pa or so (namely, reaches a pressure which is small to the extent that the workpiece does not undergo oxidation). The workpiece transported from the intermediate chamber 24 is set on the supporting base 29a. Then, the workpiece is raised by the supporting base 29a to the predetermined position where the workpiece is carburized. Subsequently, the workpiece is maintained at the carburizing temperature by an induction (magnetic) field by passing a high-frequency electric current, whose frequency is equal to or higher than 0.5 kHz but is equal to or less than 3 kHz, through the induction heating coil 28a. Simultaneously with this, the intermediate door 26a is closed. At that time, a carrier gas is introduced into the carburizing chamber 27a through a gas manifold (not shown). Here, note that the carrier gas is a carbon containing gas, for instance, a single-substance gas of hydrocarbon, such as C 3 H 8 , alternatively, a mixed gas containing gaseous hydrocarbon and one or two kinds of inert gases, such as Ar, and gaseous hydrogen (H 2 ). The carrier gas is injected into the carburizing chamber 27a at a predetermined flow rate. Thereafter, when the (internal) pressure of the carburizing chamber 27a reaches the predetermined pressure (approximately in the 1 × 10 1 - to 2.6 × 10 3 -Pa range) by controlling amounts of air and gases exhausted therefrom), a d.c. current or a pulse d.c. current is passed therethrough by employing the wall of the carburizing chamber 27a as an anode, and employing the supporting base 29a as a cathode. Further, a voltage, by which a glow discharge can be caused, is applied thereacross. Upon completion of the carburization, the introduction of the carrier gas, the passage of the glow-discharge electric current and the passage of the high-frequency current through the induction heating coil (not shown) are stopped. Then, air and gasses are exhausted from the carburizing chamber 27a by vacuum-pumping until the internal pressure of the carburizing chamber is reduced to 1-Pa or so, which is a preset pressure. Subsequently, the intermediate door 26a is opened. Further, the passage of the high-frequency current to the induction heating coil 28a is stopped. Then, the supporting base 29a is lowered. Thus, the workpiece is transported by the transport fork 218a into the intermediate chamber 24 through the intermediate door 26a. From the intermediate chamber 24, air and gases are exhausted by vacuum-pumping until the (internal) pressure thereof becomes 1 Pa or so (namely, reaches the pressure which is small to the extent that the workpiece does not undergo oxidation). The workpiece transported from the carburizing chamber 27a is put on the transport unit 219 having been raised from the quenching chamber 211. As a result of lowering the transport unit 219, the workpiece put thereon is carried into the quenching chamber 211 through the intermediate door 210. From the quenching chamber 211, air and gases are exhausted by vacuum-pumping until the (internal) pressure thereof becomes 1 Pa or so (namely, reaches the pressure which is small to the extent that the workpiece does not undergo oxidation at the quenching temperature). When the workpiece put on the transport unit 219, which further serves as a supporting base, is rapidly cooled by a refrigerant sprayed by the nozzle 212 placed in such a manner as to uniformly envelope the workpiece. Thereby, the workpiece is quenched. At that time, the quenching of the workpiece is performed in atmospheres of inert gases such as N 2 gas under a reduced pressure or under an atmospheric pressure. Further, one of oil, water and gasses (including a liquefied gas) is employed as the refrigerant. After the quenching of the workpiece is finished, the supporting base 219 descends and the workpiece is put on the transport fork 220. Then, the workpiece is transported to the tempering chamber 214 through the intermediate door 213. When reaching the tempering chamber 214, the workpiece is set on the supporting base 221. Subsequently, the supporting base 221 is raised to the predetermined position where the workpiece is heated. Then, the tempering of the workpiece is performed. At that time, the tempering thereof is performed by quickly heating the workpiece up to a preset tempering temperature (150 to 250 degrees centigrade) by the use of an induction heating coil 214a (incidentally, a direct energization heating (method) or a far infrared radiation heating (method) may be employed, instead of this coil) under a reduced pressure or under an atmospheric pressure and by further maintaining the workpiece at the tempering temperature for a time period having a predetermined length. Thereafter, upon completion of the tempering of the workpiece, the supporting base 221, on which the workpiece is put, moves down. Then, the workpiece is put on the transport fork 222 and is subsequently transported through the exit door 215 to the machining apparatus for carrying out processing to be performed in the next step. As described above, the transport unit is provided correspondingly to almost all of the chambers, respectively, so that a quick transport can be achieved. Therefore, the treating (or processing) tact time can be short. Although the preferred embodiments of the present invention have been described above, it should be understood that the present invention is not limited thereto and that other modifications will be apparent to those skilled in the art without departing from the scope of the claims. For example, in the case of the aforementioned embodiment of the present invention, the carburizing process is performed by inserting (or loading) into the carburizing chamber one by one. However, the carburizing process may be performed by simultaneously inserting a small number of workpieces into the carburizing chamber. Furthermore, although the aforementioned embodiment of the present invention is provided with six carburizing chambers, one quenching chamber, one reheating chamber and one tempering chamber, the number of the chambers of such kinds may be determined optionally or arbitrarily by taking into account the machining time required to machine a single workpiece. The scope of the present invention, therefore, should be determined solely by the appended claims.

Claims: An apparatus for carburizing, quenching and tempering workpieces, comprising: one or more preheating devices each for preheating a workpiece to a carburizing temperature; one or more carburizing devices each for carburizing the workpiece at the carburizing temperature after preheating the workpieces; one or more quenching devices for quenching the workpiece after carburizing the workpiece; one or more tempering devices each for tempering the workpiece after quenching the workpiece, said various treating devices being arranged in a plurality of stages in vertical direction; and a plurality of transport devices each for performing an operation of setting one workpiece or a set of two workpieces or more as a unit of treatment, for carrying the workpieces into each of said devices and for performing an operation of carrying out the workpieces thereform, said apparatus for carburizing, quenching and tempering workpieces being placed in a machining and manufacturing line for machining and manufacturing products, wherein each of a set of said preheating devices, a set of said carburizing devices, a set of said quenching devices and a set of said tempering devices, has said corresponding devices of the number which are necessary for performing a corresponding one of said steps substantially without stopping a flow of the workpieces on a machining and manufacturing line, correspondingly to a time period which is necessary for performing the corresponding one of said steps, and wherein a distributing unit for distributing workpieces, which are subsequently supplied in the units of treatment from a preceding step, is provided corresponding to each of said corresponding devices so that the workpieces are sequentially supplied to such devices, respectively, characterized in that said various treating devices (22, 27a through 27d, 212, 213) are arranged in a plurality of stages in vertical direction and that a plurality of transport devices (216, 218, 220, 222) is provided for simultaneously transferring a plurality of workpieces from chamber to chamber through the various stages. The apparatus for carburizing, quenching and tempering workpieces, according to claim 1, wherein said preheating device is provided with a high frequency induction heating device and the number of the one or more preheating devices is 1, wherein said carburizing devices is provided in such a manner that the number thereof meets a condition given by the following inequality: Z ≥ X/Y where X denotes a time period taken for performing said carburizing step; Y a time interval between supplies of the workpieces in the units of treatment through said machining and manufacturing line; and Z the number of said carburizing devices. The apparatus for carburizing, quenching and tempering workpieces, according to claim 1 or 2, wherein said carburizing device comprises: a vacuum carburizing chamber; a plasma carburizing unit for performing plasma carburizing by causing a glow discharge between said carburizing means and the workpiece; and a heating unit for maintaining the temperature of the workpiece at a carburizing temperature. The apparatus for carburizing, quenching and tempering workpieces, according to claim 3, wherein said heating unit for maintaining the temperature of the workpiece at the carburizing temperature is a high frequency induction heating unit. The apparatus for carburizing, quenching and tempering workpieces, as in one of claims 1 to 4, which further comprises: one or more cooling devices each for performing a cooling step of cooling the workpieces to a temperature, which is not higher than A1 transformation temperature; and one or more reheating devices each for reheating the workpiece, which has been cooled by this cooling device, to a quenching temperature. The apparatus for carburizing, quenching and tempering workpieces, according to claim 5, wherein said cooling device and said reheating device are provided in such a manner as to meet conditions given by the following inequalities: C≥M/Y, H≥N/Y where M designates a time taken to accomplish said cooling step of cooling the workpiece to a temperature which is not higher than said A1 transformation temperature; N a time taken to accomplish said reheating step of reheating the workpiece, which has been cooled in said cooling step, to the quenching temperature; Y the time interval between the supplies of the workpieces in the units of treatment through said machining and manufacturing line; C the number of said cooling devices for performing said cooling step; and H the number of said reheating devices for performing said reheating step. The apparatus for carburizing, quenching and tempering workpieces, as in one of claims 1 to 6, wherein said tempering devices for performing a tempering step are provided in such a manner as to meet a condition given by the following inequality: W ≥ L / Y where L denotes a time period taken for performing said tempering step; Y the time interval between the supplies of the workpieces in the units of treatment through said machining and manufacturing line; and W the number of said tempering devices for performing said tempering step. A method of carburizing, quenching and tempering workpieces by means of an apparatus as defined in claim 1, comprising: a preheating step of preheating a workpiece, which is to be treated, to a carburizing temperature; a carburizing step of carburizing said workpiece at the carburizing temperature after preheating said workpiece; a quenching step of quenching said workpiece after carburizing said workpiece; and a tempering step for tempering said workpiece after quenching said workpiece, wherein said workpieces are supplied onto a machining and manufacturing line for machining and manufacturing a product, and wherein each of said steps is performed by providing treatment means of the number, which are necessary for performing each of said steps without substantially stopping a flow of said workpieces on said machining and manufacturing line, in accordance with a supplying speed, at which said workpieces are supplied onto said machining and manufacturing line, and by setting one workpiece or a set of two workpieces or more as a unit of treatment, as needed, and then distributing and supplying said workpieces in the units of treatment in sequence to said treatment means, and wherein one or a plurality of transport means for transporting said workpieces between each of said steps are used. The method of carburizing, quenching and tempering workpieces, according to claim 8, wherein preheating means for performing said preheating step is configured separately from carburizing means for performing said carburizing step, wherein said preheating means employs a high frequency induction heating process to thereby establish a preheating time period in such a manner as to be sufficiently shorter than a time interval between supplies of the workpieces in the units of treatment through said machining and manufacturing line, wherein the number of said preheating means is set at one, and wherein the number of said carburizing means is set in such a manner as to meet the condition given by the following inequality: Z ≥ X / Y where X denotes a time period taken for performing said carburizing step; Y the time interval between the supplies of the workpieces in the units of treatment through said machining and manufacturing line; and Z the number of said carburizing means for performing said carburizing step. The method of carburizing, quenching and tempering workpieces, according to claim 9, wherein said carburizing means for performing said carburizing step comprises: means for carburizing by a plasma carburizing method to be performed by causing a glow discharge between said carburizing means and the workpiece while maintaining the temperature of the workpiece at the carburizing temperature, to thereby reduce a starting time, which is taken to start performing said method of carburizing, quenching and tempering the workpieces, in such a manner as to become close to a start-up time, which is taken to cause said machining and manufacturing line to start working, so that performance of said method of carburizing, quenching and tempering the workpieces is started substantially in synchronization with the starting of an operation of said machining and manufacturing line and that the performance of said method of carburizing, quenching and tempering the workpieces is stopped near to the stopping of the operation of said machining and manufacturing line. The method of carburizing, quenching and tempering workpieces, according to claim 10, wherein a high-frequency induction heating process is used as a process of maintaining the temperature of the workpiece at the carburizing temperature. The method of carburizing, quenching and tempering workpieces, according to claim 9, 10 or 11, wherein a high frequency used in said high-frequency induction heating process is set in such a way as to range from 0.5 kHz to 3 kHz. The method of carburizing, quenching and tempering workpieces, as in one of claims 8 to 12, wherein said carburizing step is performed at a temperature, which is not lower than 950 degrees centigrade and is not higher than 1200 degrees centigrade, so as to reduce a length of time period taken to accomplish said carburizing step, wherein a cooling step of cooling the workpieces to a temperature, which is not higher than A1 transformation temperature, and a reheating step of reheating the workpiece, which has been cooled in this cooling step, to a quenching temperature are added between said carburizing step and said quenching step. The method of carburizing, quenching and tempering workpieces, according to claim 13, wherein said cooling means and said reheating means are provided in such a manner as to meet conditions given by the following inequalities: C ≥ M / Y, H ≥ N / Y where M designates a time taken to accomplish said cooling step of cooling the workpiece to a temperature which is not higher than said A1 transformation temperature; N a time taken to accomplish said reheating step of reheating the workpiece, which has been cooled in said cooling step, to the quenching temperature; Y the time interval between supplies of the workpieces in the units of treatment through said machining and manufacturing line; C the number of said cooling means for performing said cooling step; and H the number of said reheating means for performing said reheating step.

Inventors: ABUKAWA FUMITAKA, INOUE HIDEKI, JURYOSAWA HIDETOSHI, TAKAHASHI JUN, TAKEMOTO SHINICHI, YOKOSE KEIJI, ABUKAWA, FUMITAKA, INOUE, HIDEKI, JURYOSAWA, HIDETOSHI, TAKAHASHI, JUN, TAKEMOTO, SHINICHI, YOKOSE, KEIJI
Applicants: DOWA MINING CO, DOWA MINING CO., LTD.
Application year: 1997
Main classification: C21D9
IPC codes: C21D9, C21D1, F27B9, C23C8