A method for machining complex grooves of parts using standard tools

Abstract

The present invention relates to a method for machining complex grooves of parts using standard cutting tools, comprising the following steps: using a standard grooving tool, firstly rough machining with the grooving tool to obtain the preliminary outline of the complex groove and leave a margin; then fine machining, by profiling, to complete the final size of the groove. The invention discloses a method for machining complex grooves of parts using standard cutting tools, which reduces the tool cost by more than 95%. When using a standard grooving tool, if the tool is worn, only the grooving blade needs to be replaced, and there is no need to repeat positioning and alignment. The blade can be replaced to continue processing, which greatly improves the processing efficiency and reduces the scrap rate of parts.

Description

Technical Field

[0001] The invention relates to the technical field of mechanical processing, and in particular to a method for processing a complex groove of a part by using a standard tool. Background Art

[0002] Complex grooves refer to grooves with small size and high precision, with multiple arcs and multiple inclined surfaces, which are often designed on various mechanical parts. At present, when machining parts, the first idea is to customize non-standard forming tools when encountering complex grooves. In the machining of gearbox parts, complex annular grooves that are difficult to machine are often encountered. For example, it is necessary to machine complex annular grooves distributed in a circle on the upper and lower end faces of a friction plate with a diameter of Φ300 and a thickness of 8.3mm. The friction plate material is 42CrMoA, and the heat treatment hardness is 47-50HRC. In the later assembly, the grooves between several friction plates are interlocked to increase friction. Therefore, the design accuracy of the grooves is very high, the groove size tolerance is small, the groove spacing tolerance is small, and the runout requirements are high.

[0003] Friction plates are important components in gear reducers. In the design of the entire gear reducer, all friction plates have a total of 6 complex groove types. In the early trial production stage, we designed a non-standard forming tool to process one of the complex grooves. However, due to the high hardness of the friction plate, a non-standard tool can often only process one part, or a friction plate cannot be processed, so the tool needs to be replaced. The tool cannot be re-aligned, resulting in the scrapping of parts, high scrap rate, and low processing efficiency; and non-standard customized tools have a long delivery cycle, a large minimum order quantity, and are expensive. In addition, the non-standard tool cannot be re-grinded due to the complex groove type of the corresponding processing, and the processing cost is also high. Another groove type corresponds to a non-standard tool. There are 6 existing groove types, and 6 non-standard tools need to be designed. The number of parts is large and the operation is not convenient. The above-mentioned solution of using non-standard forming tools to process complex grooves greatly increases the production cost of the enterprise and extends the delivery cycle of parts. Summary of the invention

[0004] In order to solve the above technical problems, the purpose of the present invention is to provide a method for machining complex grooves of parts using standard tools. This method improves the problem of complex groove machining, reduces tool costs, reduces scrap rates, improves machining efficiency, and shortens parts delivery cycles.

[0005] In order to achieve the above-mentioned object of the invention, the present invention adopts the following technical solutions:

[0006] A method for machining a complex groove of a part using a standard tool, which is used to machine a plurality of annular complex grooves distributed on the end face of the part, comprises the following steps:

[0007] a. Use a standard grooving knife, the tip radius of the grooving knife blade is 0.2-0.6mm;

[0008] b. First, rough machining is performed. The CNC machine tool carries the grooving cutter from the starting position of the complex groove to be machined, cuts into the corresponding depth and then withdraws. Then, it moves in the width direction of the groove once, cuts into the corresponding depth and then withdraws. Then, it moves in the width direction of the groove, continues to cut in and then withdraws. This process is repeated 6 times in total until it reaches the other end of the groove. Then, by copying the shape, the arc of the first layer of the two ends of the groove is cut to complete the first layer cutting of the groove.

[0009] c. The CNC machine tool moves the grooving cutter to the center of the groove, cuts into the second layer depth and then retracts the cutter, then moves to the first layer arc, follows the oblique line to machine the inclined surface and then retracts the cutter, moves to the other end arc, follows the oblique line to machine the inclined surface and then retracts the cutter, completing the second layer cutting of the groove;

[0010] d. The CNC machine tool moves with the slotting cutter to the center of the slot, cuts into the third layer depth and then retracts the cutter, then moves to the second layer oblique line, performs profiling to the third layer depth and then retracts the cutter, moves to the other end oblique line, performs profiling to the third layer depth and then retracts the cutter, completing the third layer cutting of the slot. After three layers of cutting, the preliminary outline of the complex slot is obtained, and the inner wall of the slot is left with allowances, completing the rough processing of the complex slot;

[0011] e. The CNC machine tool is equipped with a grooving cutter for finishing. The grooving cutter moves from the end of the groove to the bottom of the groove, removes the excess and then retracts the cutter. Then, the grooving cutter moves from the other end of the groove to the bottom of the groove, removes the excess and then retracts the cutter to complete the finishing of the complex groove. If there are multiple annular complex grooves, repeat the above steps.

[0012] As a preferred solution: the grooving tool adopts Sandvik standard grooving tool bar QS-SMALL2525X3HP, the blade adopts Sandvik MAPL30801025, and the blade tip radius is 0.4mm.

[0013] As a preferred solution: the cross-sectional shape of the annular complex groove includes top arcs on both sides, middle oblique lines on both sides and a U-shaped line at the bottom.

[0014] As a preferred solution: the groove width of the annular complex groove is 0.8mm-4mm, the groove depth is 1mm-3.8mm, the circumferential size of the annular complex groove is Φ100mm-Φ350mm, and the heat treatment hardness of the part material is ≤HRC50.

[0015] As a preferred solution: multiple annular complex grooves are processed multiple times by a standard grooving tool.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] The present invention uses a method for processing complex grooves of parts using standard tools, and uses a standard grooving tool and grooving blade to complete the processing of multiple and various complex grooves of parts, perfectly replacing the 6 non-standard tools that were originally required. Since this type of non-standard forming tool needs to process corresponding complex grooves, the tool manufacturer needs to grind the grooves, so the minimum order quantity is 10. Six complex grooves need to be ordered in an amount of more than 60. Now, a standard tool can be used for processing to replace it, and the tool cost is reduced by more than 95%. During the processing, if a non-standard forming tool is used, if the tool is worn out and the part has not been processed, due to the small tolerance of the groove size, it cannot be re-positioned and aligned after the tool is changed, and the part is scrapped. Now a standard grooving tool is used. If the tool is worn out, only the grooving blade needs to be replaced, and there is no need to repeat the positioning and alignment. The blade can be replaced to continue processing, which greatly improves the processing efficiency and reduces the scrap rate of parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The drawings in the specification, which constitute a part of the present application, are used to provide a further understanding of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute a limitation on the present application.

[0019] Figure 1 A schematic diagram of the groove type to be processed on a part in the method of the present invention;

[0020] Figure 2 A schematic diagram of the tool path for machining the first layer of rough grooving and a schematic diagram of the groove shape change of the part in the method of the present invention;

[0021] Figure 3 A schematic diagram of the tool path for machining the second layer of rough grooving and a schematic diagram of the groove shape change of the part in the method of the present invention;

[0022] Figure 4 A schematic diagram of the tool path for machining the third layer of rough grooving and a schematic diagram of the groove shape change of the part in the method of the present invention;

[0023] Figure 5 The figure is a schematic diagram of the tool path for machining a precision-turned groove and a schematic diagram of the change in the groove shape of a part in the method of the present invention. DETAILED DESCRIPTION

[0024] It should be noted that the following detailed descriptions are illustrative and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present application belongs.

[0025] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0026] In addition, in the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0027] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "plurality" means two or more, unless otherwise clearly specified.

[0028] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0029] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0030] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0031] like Figures 1 to 5 As shown, a method for machining a complex groove of a part using a standard tool is used to machine a plurality of annular complex grooves 11 distributed on the end face of a part 1, comprising the following steps:

[0032] a. Use a standard grooving knife 2, the tip radius of the grooving knife blade is 0.2-0.6mm;

[0033] b. First, rough machining is performed. The CNC machine tool carries the grooving cutter from the starting position of the complex groove to be machined, cuts into the corresponding depth and then withdraws. Then, it moves in the width direction of the groove once, cuts into the corresponding depth and then withdraws. Then, it moves in the width direction of the groove, continues to cut in and then withdraws. This process is repeated 6 times in total until it reaches the other end of the groove. Then, by copying the shape, the arc of the first layer of the two ends of the groove is cut to complete the first layer cutting of the groove.

[0034] c. The CNC machine tool moves the grooving cutter to the center of the groove, cuts into the second layer depth and then retracts the cutter, then moves to the first layer arc, follows the oblique line to machine the inclined surface and then retracts the cutter, moves to the other end arc, follows the oblique line to machine the inclined surface and then retracts the cutter, completing the second layer cutting of the groove;

[0035] d. The CNC machine tool moves with the slotting cutter to the center of the slot, cuts into the third layer depth and then retracts the cutter, then moves to the second layer oblique line, performs profiling to the third layer depth and then retracts the cutter, moves to the other end oblique line, performs profiling to the third layer depth and then retracts the cutter, completing the third layer cutting of the slot. After three layers of cutting, the preliminary outline of the complex slot is obtained, and the inner wall of the slot is left with allowances, completing the rough processing of the complex slot;

[0036] e. The CNC machine tool is equipped with a grooving cutter for finishing. The grooving cutter moves from the end of the groove to the bottom of the groove, removes the excess and then retracts the cutter. Then, the grooving cutter moves from the other end of the groove to the bottom of the groove, removes the excess and then retracts the cutter to complete the finishing of the complex groove. If there are multiple annular complex grooves, repeat the above steps.

[0037] The grooving tool adopts Sandvik standard grooving tool bar QS-SMALL2525X3HP, and the blade adopts Sandvik MAPL30801025, and the blade tip radius is 0.4mm. Multiple annular complex grooves are processed multiple times by a standard grooving tool.

[0038] The cross-sectional figure of the annular complex groove includes top arcs on both sides, middle oblique lines on both sides and a U-shaped line at the bottom. The groove width of the annular complex groove is 0.8mm-4mm, the groove depth is 1mm-3.8mm, the circumference size of the annular complex groove is Φ100mm-Φ350mm, and the heat treatment hardness of the part material is ≤HRC50.

[0039] Below we will Figure 1 Take the processing of the specific groove type shown as an example. Figure 1 This is a friction plate actually processed in an embodiment of the present invention. The material is 42CrMoA, the heat treatment hardness is HRC47-50, and there are a total of 10 complex grooves distributed from the end surface Φ200-Φ280. It can be seen that the structure of the groove is complex, the dimensional tolerance is small, the tolerance of the distance between the two grooves is tight, and the groove runout requirement is high.

[0040] According to the previous processing thinking, we used non-standard forming cutters for processing, but found that the processing was difficult, the cutters wore out quickly, and many parts were scrapped.

[0041] In order to improve these problems, a method of using standard grooving tools to process complex grooves of parts was invented. The processing method is as follows:

[0042] First, the CNC machine tool starts rough machining with a slotting cutter and cuts into the groove 0.11mm (such as Figure 2 After the tool is retracted in the middle tool path 1), it moves 0.18mm in the width direction of the slot and cuts in 0.39mm ( Figure 2 After the tool is retracted in the middle tool path 2), it moves 0.39mm in the slot width direction again and cuts in 0.39mm ( Figure 2 After the tool is retracted in the middle tool path 3), it moves 0.40mm in the slot width direction again and cuts in 0.39mm ( Figure 2 After the tool is retracted in the middle tool path 4), it moves 0.18mm in the slot width direction again and cuts in 0.11mm ( Figure 2 After the tool is retracted in the middle tool path 5), it moves 0.28mm in the slot width direction again, and the machine tool is used to perform profiling at the slot end, cutting into an arc of 0.39mm to cut out the first layer depth of the slot ( Figure 2 After the tool is retracted from position 1 to position 2), it moves to another port, performs profiling, and cuts out an arc of the first depth of the groove ( Figure 2 Middle tool path 7, from position 1 to position 2) and then retract to complete the first layer of slot cutting;

[0043] The grooving knife moves to the position of the cutting path 3 and cuts into 2.14mm ( Figure 3 After the tool is moved to the first arc, the tool is moved to the inclined line to produce the inclined surface ( Figure 3 Tool path 9, from position 1 to position 2), then retract the tool and move to the other end of the arc to machine the inclined surface ( Figure 3 Tool path 10, from position 1 to position 2) and then retract to complete the second layer cutting of the groove;

[0044] The grooving knife moves to the position of the cutting path 3 and cuts into the third depth ( Figure 4After the tool path 11), the tool is retracted to complete the third layer of cutting of the groove; after three layers of cutting, the preliminary outline of the complex groove is obtained, and the inner wall of the groove is left with an allowance, completing the rough processing of the complex groove (see the groove type Figure 4 );

[0045] Finishing: Profiling from the end of the groove to the bottom of the groove, removing the excess and then retracting the tool, then profiling from the other end of the groove to the bottom of the groove, removing the excess and then retracting the tool to complete the finishing of the complex groove ( Figure 5 ). The remaining annular grooves can be processed by repeating the above steps.

[0046] In order to improve processing efficiency and reduce processing costs, the present invention designs a new complex groove processing method: using a standard grooving tool, firstly rough processing is performed with the grooving tool to obtain the preliminary outline of the complex groove and leave a margin; then fine processing is performed to complete the final size of the groove by profiling.

[0047] The above can be processed with a grooving cutter. Compared with non-standard tools, this processing method greatly reduces the processing cost. One tool can replace 6 non-standard tools. When the tool is worn, only the blade needs to be replaced, and there is no need to repeatedly align it. The processing efficiency is high and the part yield rate is high.

[0048] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0049] Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limiting the present invention. Ordinary technicians in the field can change, modify, replace and modify the above embodiments within the scope of the present invention without departing from the principles and purpose of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A method for machining complex grooves of parts using standard tools, characterized in that: It is used to process multiple annular complex grooves distributed on the end face of the part, including the following steps: a. Use a standard grooving knife, the tip radius of the grooving knife blade is 0.2-0.6mm; b. First, rough machining is performed. The CNC machine tool carries the grooving cutter from the starting position of the complex groove to be machined, cuts into the corresponding depth and then withdraws. Then, it moves in the width direction of the groove once, cuts into the corresponding depth and then withdraws. Then, it moves in the width direction of the groove, continues to cut in and then withdraws. This process is repeated 6 times in total until it reaches the other end of the groove. Then, by copying the shape, the arc of the first layer of the two ends of the groove is cut to complete the first layer cutting of the groove. c. The CNC machine tool moves the grooving cutter to the center of the groove, cuts into the second layer depth and then retracts the cutter, then moves to the first layer arc, follows the oblique line to machine the inclined surface and then retracts the cutter, moves to the other end arc, follows the oblique line to machine the inclined surface and then retracts the cutter, completing the second layer cutting of the groove; d. The CNC machine tool moves with the slotting cutter to the center of the slot, cuts into the third layer depth and then retracts the cutter, then moves to the second layer oblique line, performs profiling to the third layer depth and then retracts the cutter, moves to the other end oblique line, performs profiling to the third layer depth and then retracts the cutter, completing the third layer cutting of the slot. After three layers of cutting, the preliminary outline of the complex slot is obtained, and the inner wall of the slot is left with allowances, completing the rough processing of the complex slot; e. The CNC machine tool carries out finishing processing with a slotting cutter. The slotting cutter moves from the slot end to the slot bottom, removes the excess and then retracts the cutter. Then, it moves from the other end of the slot to the slot bottom, removes the excess and then retracts the cutter to complete the finishing of the complex slot. If there are multiple annular complex slots, repeat the above steps; The cross-sectional shape of the annular complex groove includes top arcs on both sides, middle oblique lines on both sides and a U-shaped line at the bottom; Multiple annular complex grooves are machined multiple times using a standard grooving tool.

2. A method for machining a complex groove of a part using a standard tool according to claim 1, characterized in that: The grooving cutter adopts Sandvik standard grooving cutter bar QS-SMALL2525X3HP, and the blade adopts Sandvik MAPL30801025, and the tip radius of the blade is 0.4mm.

3. The method for machining a complex groove of a part using a standard tool according to claim 1, characterized in that: The groove width of the annular complex groove is 0.8mm-4mm, the groove depth is 1mm-3.8mm, the circumferential size of the annular complex groove is Φ100mm-Φ350mm, and the heat treatment hardness of the part material is ≤HRC50.

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