The application of composite cutters is restricted by factors such as machining process, tool life and part structure. However, under the influence of various factors, it is an advanced processing method in the current machining and manufacturing.
The compound processing technology is to effectively combine a plurality of single processes in the machining process, and concentrate on the change of the structure of the machining tool, that is, the so-called composite tool replaces the ordinary single tool, and completes in one tool change process. The contents of the process are realized to improve the production efficiency, ensure the position accuracy of the parts, and improve the cutting of the tools.
Flexible production is a kind of machining method widely used by automobile manufacturers. By combining the high rigidity, high efficiency and flexibility of the machining center, the flexible production line has obtained shorter and less equipment than the combined machine tool production line. More concentrated advantages, in order to better balance the production cycle, composite processing technology has been applied in the machining center, and with the continuous improvement of composite processing technology, many combination machine tools have begun to adopt this technology.
Increase productivity and ensure the accuracy of the drawings in <br> <br> double overhead camshaft (DOHC) engine, the cylinder head is generally manufactured by casting, and the cooling water jacket is arranged in the feed space is limited on the exhaust Airway, so the structure of the cylinder head is very complicated. The key parts of the machining are: the camshaft hole with high coaxiality requirement and the tappet hole required for cylindricity; the 90° sealing band of the race and the conduit of φ6mm The hole is the most difficult to process, and the quality of the processing will directly affect the sealing of the valve.
In the whole process of the ring and the conduit hole from roughing to finishing, if the ordinary single tool is used, not only the efficiency is low, but also the error of the tool center does not coincide due to multiple clamping, which affects the subsequent machining accuracy. , must choose the composite processing technology.
(1) Using the composite tool to complete the bottom hole of the intake seat, the bottom hole of the rough drill pipe φ10.5mm and the roughing of the throat of the knife inlet.
Since the center of the conduit hole is arranged at an oblique angle to the center of the inlet port, it is difficult to ensure the straightness of the bottom hole of the conduit due to the uneven load of the two cutting edges of the drill when the bottom hole of the conduit is drilled, so it is usually processed first on the inlet slope. A φ13mm process platform is perpendicular to the centerline of the conduit hole; the main function of the intake throat above the valve seat is to reduce the air intake resistance, so the design space when casting the throat must be guaranteed to remove the sand and mud core The displacement caused by the extra aluminum tumor. Considering the above two factors, when the bottom hole is installed in the roughing seat, the composite tool is used to complete the processing of the three processes with a tool, which not only ensures the relative position, but also improves the processing efficiency.
(2) The finishing of the race mounting hole and the φ11mm conduit bottom hole is completed at one time by using the composite cutter.
The φ11mm conduit bottom hole requires the cylindricity and straightness of the hole to be 0.01mm. The center of the mounting hole of the raceway requires φ0.2mm for the coaxiality of the center of the conduit hole. In order to ensure the accuracy, the composite tool is used for finishing. In the design of the tool, in order to avoid the machining interference between the fine φ11mm hole and the subsequent fine seat ring hole, the front end tool is used to carry out the fine boring process of the φ11mm hole, and then the latter two tools respectively complete the thickness of the seat mounting hole. Finishing not only reduces the cutting load of the cutting edge during fine grinding, but also prolongs the service life of the tool.
(3) Finished car seat ring hole 60°, 90°, 120° sealing band and fine hinge φ6mm pipe hole.
In the process, the drawing requires that the center of the 90° seal belt has a runout error of ≤615mm at the center of the φ6mm conduit hole. Therefore, the front end of the composite cutter is a φ6mm gun reamer, and after the φ6mm conduit hole is refined, the hydraulic cylinder controls the reamer. The knife sleeve is returned, and then the three turning tools of 120° circumference are respectively processed by 60°, 90° and 120° cones to ensure the uniform width of the sealing strip and the radial runout of the 90° sealing strip to the center of the conduit hole. Claim.
Machining the main bearing side <br> <br> profile at both sides of the main bearing profile machining, a machining tool is used in a composite, i.e. a multi-blade cutter plate 3 is mounted on the machine tool spindle, the feed may be a In the middle, the processing of the two side planes of the multi-speed main bearing hole is completed.
Improved cutting tool load <br> <br> roughing head 16-φ30.4mm tappet hole, since the margin is greater than the blank unilateral 4mm, the original design was completed in one pass all the cutting, but cutting tool Will withstand large cutting resistance, prone to boring, damage to the tool and damage to the workpiece surface. If the machining is used twice, the tool change process will be added, making it difficult to guarantee the machining cycle. After comprehensive consideration, the composite tool with step structure is finally used to distribute the cutting allowance on the front and rear teeth, thus meeting the process requirements.
Conclusion <br> <br> With the progress of modern machining methods, composite processing technology has been more and more applications, its advantages are constantly emerging. However, any technology has its strong and weak aspects. In the processing of box parts such as cylinders and cylinder heads, the advantages of composite machining technology can be effectively utilized due to the complex structure and large production volume of such parts. In contrast, for components with simple structure, single-piece, small-volume production, the machining process should be arranged on a general-purpose machine tool as much as possible, using general-purpose tool processing, mainly because the composite machining technology uses a combined tool. Class tools are complex in design and have limited demand. They are close to single-piece production, and the cost of tools is several times higher than that of general-purpose tools, even dozens of times.
The application of composite machining technology is also often limited by machining conditions, tool life, tool manufacturing processability, and part structure. For a set of processes such as drilling, chamfering, and scraping, if a composite tool is used, not only is the tool structure complicated, but also the process is not reasonable. The drilling is first contacted with the blank surface of the workpiece. Due to the unequal cutting force of the cutting edges on both sides of the drill during drilling, the drill bit is easily deflected, and the diameter of the scraping plane tool is too different from the diameter of the drill bit, which is easy to cause the drill bit and the scraper during the machining process. The joint is broken.
Composite processing technology is a widely used process in machining today. As long as the processing technology, the structural rationality of the tool and the production cost are fully considered, it is an advanced processing method.
The compound processing technology is to effectively combine a plurality of single processes in the machining process, and concentrate on the change of the structure of the machining tool, that is, the so-called composite tool replaces the ordinary single tool, and completes in one tool change process. The contents of the process are realized to improve the production efficiency, ensure the position accuracy of the parts, and improve the cutting of the tools.
Flexible production is a kind of machining method widely used by automobile manufacturers. By combining the high rigidity, high efficiency and flexibility of the machining center, the flexible production line has obtained shorter and less equipment than the combined machine tool production line. More concentrated advantages, in order to better balance the production cycle, composite processing technology has been applied in the machining center, and with the continuous improvement of composite processing technology, many combination machine tools have begun to adopt this technology.
Increase productivity and ensure the accuracy of the drawings in <br> <br> double overhead camshaft (DOHC) engine, the cylinder head is generally manufactured by casting, and the cooling water jacket is arranged in the feed space is limited on the exhaust Airway, so the structure of the cylinder head is very complicated. The key parts of the machining are: the camshaft hole with high coaxiality requirement and the tappet hole required for cylindricity; the 90° sealing band of the race and the conduit of φ6mm The hole is the most difficult to process, and the quality of the processing will directly affect the sealing of the valve.
In the whole process of the ring and the conduit hole from roughing to finishing, if the ordinary single tool is used, not only the efficiency is low, but also the error of the tool center does not coincide due to multiple clamping, which affects the subsequent machining accuracy. , must choose the composite processing technology.
(1) Using the composite tool to complete the bottom hole of the intake seat, the bottom hole of the rough drill pipe φ10.5mm and the roughing of the throat of the knife inlet.
Since the center of the conduit hole is arranged at an oblique angle to the center of the inlet port, it is difficult to ensure the straightness of the bottom hole of the conduit due to the uneven load of the two cutting edges of the drill when the bottom hole of the conduit is drilled, so it is usually processed first on the inlet slope. A φ13mm process platform is perpendicular to the centerline of the conduit hole; the main function of the intake throat above the valve seat is to reduce the air intake resistance, so the design space when casting the throat must be guaranteed to remove the sand and mud core The displacement caused by the extra aluminum tumor. Considering the above two factors, when the bottom hole is installed in the roughing seat, the composite tool is used to complete the processing of the three processes with a tool, which not only ensures the relative position, but also improves the processing efficiency.
(2) The finishing of the race mounting hole and the φ11mm conduit bottom hole is completed at one time by using the composite cutter.
The φ11mm conduit bottom hole requires the cylindricity and straightness of the hole to be 0.01mm. The center of the mounting hole of the raceway requires φ0.2mm for the coaxiality of the center of the conduit hole. In order to ensure the accuracy, the composite tool is used for finishing. In the design of the tool, in order to avoid the machining interference between the fine φ11mm hole and the subsequent fine seat ring hole, the front end tool is used to carry out the fine boring process of the φ11mm hole, and then the latter two tools respectively complete the thickness of the seat mounting hole. Finishing not only reduces the cutting load of the cutting edge during fine grinding, but also prolongs the service life of the tool.
(3) Finished car seat ring hole 60°, 90°, 120° sealing band and fine hinge φ6mm pipe hole.
In the process, the drawing requires that the center of the 90° seal belt has a runout error of ≤615mm at the center of the φ6mm conduit hole. Therefore, the front end of the composite cutter is a φ6mm gun reamer, and after the φ6mm conduit hole is refined, the hydraulic cylinder controls the reamer. The knife sleeve is returned, and then the three turning tools of 120° circumference are respectively processed by 60°, 90° and 120° cones to ensure the uniform width of the sealing strip and the radial runout of the 90° sealing strip to the center of the conduit hole. Claim.
Machining the main bearing side <br> <br> profile at both sides of the main bearing profile machining, a machining tool is used in a composite, i.e. a multi-blade cutter plate 3 is mounted on the machine tool spindle, the feed may be a In the middle, the processing of the two side planes of the multi-speed main bearing hole is completed.
Improved cutting tool load <br> <br> roughing head 16-φ30.4mm tappet hole, since the margin is greater than the blank unilateral 4mm, the original design was completed in one pass all the cutting, but cutting tool Will withstand large cutting resistance, prone to boring, damage to the tool and damage to the workpiece surface. If the machining is used twice, the tool change process will be added, making it difficult to guarantee the machining cycle. After comprehensive consideration, the composite tool with step structure is finally used to distribute the cutting allowance on the front and rear teeth, thus meeting the process requirements.
Conclusion <br> <br> With the progress of modern machining methods, composite processing technology has been more and more applications, its advantages are constantly emerging. However, any technology has its strong and weak aspects. In the processing of box parts such as cylinders and cylinder heads, the advantages of composite machining technology can be effectively utilized due to the complex structure and large production volume of such parts. In contrast, for components with simple structure, single-piece, small-volume production, the machining process should be arranged on a general-purpose machine tool as much as possible, using general-purpose tool processing, mainly because the composite machining technology uses a combined tool. Class tools are complex in design and have limited demand. They are close to single-piece production, and the cost of tools is several times higher than that of general-purpose tools, even dozens of times.
The application of composite machining technology is also often limited by machining conditions, tool life, tool manufacturing processability, and part structure. For a set of processes such as drilling, chamfering, and scraping, if a composite tool is used, not only is the tool structure complicated, but also the process is not reasonable. The drilling is first contacted with the blank surface of the workpiece. Due to the unequal cutting force of the cutting edges on both sides of the drill during drilling, the drill bit is easily deflected, and the diameter of the scraping plane tool is too different from the diameter of the drill bit, which is easy to cause the drill bit and the scraper during the machining process. The joint is broken.
Composite processing technology is a widely used process in machining today. As long as the processing technology, the structural rationality of the tool and the production cost are fully considered, it is an advanced processing method.
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