A precision fixed-angle spline machining device and machining method

Abstract

The present invention relates to a precision fixed-angle spline machining device and a machining method, including a machining device base plate, a mandrel, a fork part, a spline dummy, a positioning template, a circumferential adjustment assembly, and a radial adjustment assembly; the fork part is a standard fork part, the base plate is fixed on the turntable of a universal gear shaper, the mandrel is fixed at the center position of the base plate, and its center coincides with the center of the turntable of the universal gear shaper; the spline dummy has an external spline that perfectly matches the fork part; one end of the positioning template is provided with an internal spline of the positioning template that matches the external spline of the spline dummy, and the other end is provided with a positioning hole, and the position of the positioning hole relative to the internal spline of the positioning template is the same as that of the fork part; the radial adjustment assembly is arranged on the circumferential adjustment assembly, and a through hole that matches the positioning hole is also provided on the radial adjustment assembly; the radial adjustment assembly and the circumferential adjustment assembly are adjusted to ensure that the through hole and the positioning hole are coaxial and perpendicular to the plane where the base plate is located.

Description

Technical Field

[0001] The present invention belongs to the field of machining, and particularly relates to the precision spline machining with angular requirements for parts in the shaping machine machining. Background Art

[0002] The fork part is an important part in machining, with the material of 35Cr2Ni4MoA, Class II forgings, a hardness as high as HRC40 - 45, and a complex shape with high precision requirements. The external spline of the 12 teeth on the part has extremely high requirements for the position tolerance and symmetry tolerance, and there is a requirement for the angle of 90° ± 0.1° between the starting position of the spline and the Φ6H7 through hole on the long arm. Currently, this part belongs to the category of small - batch production, and the annual output is extremely limited.

[0003] On this part The external spline has a short length of only 13 mm, with a relief groove at the lower part. Generally, a customized special shaping cutter is selected to machine the spline by the generation method on the shaping machine. The position tolerance, symmetry and uniformity of the spline are controlled by the precision of the shaping machine and the shaping cutter. However, when the shaping cutter is installed on the shaping machine, its initial position is random. Therefore, the starting position of the machined spline cannot meet the requirement of the angle of 90° ± 0.1°. Usually, the method of scribing on the part and aligning the scribed line on the part and the tip of the shaping cutter by the naked eye is used for machining, but this method has a large error and cannot ensure the angular requirement of 90° ± 0.1° for the starting position of the spline of the fork part. Summary of the Invention

[0004] The purpose of the present invention: Use a tooling fixture to machine the external spline on the fork on a general shaping machine, meet the drawing dimensions and geometric tolerances, ensure the requirement of the angle of 90° ± 0.1° between the starting position of the external spline and the Φ6H7 through hole on the long arm, so that when the fork part is assembled, the angular position is fixed without jamming.

[0005] Technical Solution: The present invention on the one hand provides a precision angular - fixed spline machining device. The machining device includes: a base plate, a mandrel, a fork part, a spline dummy, a positioning template, a circumferential adjustment component, and a radial adjustment component; the fork part is a standard fork part, the base plate is fixed on the turntable of the general shaping machine, the mandrel is fixed at the center position of the base plate, and its center coincides with the center of the turntable of the general shaping machine; the spline dummy has an external spline that perfectly matches the fork part; one end of the positioning template is provided with an internal spline of the positioning template that matches the external spline of the spline dummy, and the other end is provided with a positioning hole, and the position of the positioning hole relative to the internal spline of the positioning template is the same as that of the fork part; the radial adjustment component is arranged on the circumferential adjustment component, and a through - hole that matches the positioning hole is also opened on the radial adjustment component; adjust the radial adjustment component and the circumferential adjustment component to ensure that the through - hole and the positioning hole are coaxial and perpendicular to the plane where the base plate is located.

[0006] Furthermore, the processing device further includes a positioning pin for coaxially fixing the through hole on the radial adjustment component and the positioning hole on the positioning template.

[0007] Furthermore, the positioning pin has a variable diameter structure, with a small diameter at the lower end and a large diameter at the upper end.

[0008] Furthermore, the processing device further includes a taper bushing and a lock nut, which are used in combination; the taper bushing is used for centering, and the lock nut is used for pressing and locking.

[0009] Furthermore, one end of the positioning template has a large round hole structure, and the other end has a small round hole structure.

[0010] Furthermore, the radial adjustment component is a Z-shaped plate member, with a through hole on the side of the upper section and a waist-shaped hole for easy adjustment on the lower flat section.

[0011] Furthermore, the base plate is a disc structure, with a positioning hole for installing the core shaft at the center, and an arc groove is provided at a certain radius position along the center for adjusting the position of the circumferential adjustment component on the base plate.

[0012] On the other hand, the present invention also proposes a processing method for precision angular splines. The processing method uses the above-mentioned processing device, and specifically includes the following steps:

[0013] Step S1: Install the base plate and the core shaft at the center of the turntable of the universal gear shaper, and fix the base plate; install the radial adjustment component and the circumferential adjustment component on the base plate; install the spline dummy, center it with the taper bushing, and tighten it with the lock nut; adjust the universal gear shaper, complete the machining of the external spline that matches the standard fork part on the spline dummy, and reset the machine tool.

[0014] Step S2: Put the spline positioning template on the spline dummy, adjust the circumferential adjustment component and the radial adjustment component so that the positioning pin can be smoothly inserted into the through holes of the spline positioning template and the radial adjustment component at the same time; then fix the circumferential adjustment component and the radial adjustment component.

[0015] Step S3: Remove the spline positioning template and the positioning pin, loosen the lock nut, remove the taper bushing and the spline dummy, and keep the remaining parts in a fixed position on the universal gear shaper.

[0016] Step S4: Put the fork to be gear-shaped on the core shaft, rotate the fork so that the positioning pin can be smoothly inserted into the through holes of the fork and the radial adjustment component at the same time, install the taper bushing for centering, and tighten it with the lock nut; start the gear shaper and start gear shaping using the machining parameters for the spline dummy, and reset the machine tool after machining.

[0017] After a fork is processed, the spline positioning template is sleeved on the fork, and a positioning pin is inserted into the through holes of the positioning template and the fork. If it can be inserted smoothly, it proves that the spline size and angular machining of the fork are qualified. Then, another fork part can be disassembled and installed for repeated spline machining to complete batch processing.

[0018] Beneficial technical effects: Using the processing device and method designed by the present invention to process the fork spline can ensure the angular requirements of the spline. After the tooling is installed in place once, the subsequent machining and installation of parts are convenient, the positioning is reliable, and the alignment is fast. Moreover, the spline size and angular requirements of each batch of parts have high consistency. It is convenient to operate during use, has low requirements for the skills of operators, can ensure quality, and has a high qualified rate of part machining, which not only significantly improves production efficiency but also greatly saves production costs. Description of the Drawings

[0019] Figure 1 is the plane of the fork part,

[0020] Figure 1 The dimensions marked in are only related to the external spline;

[0021] Figure 2 is the three-dimensional sketch of the fork part;

[0022] Figure 3 is the schematic diagram of the processing and installation of the spline dummy. This assembly is installed on the gear shaper for gear hobbing of the spline dummy;

[0023] Figure 4 is the schematic diagram of the spline positioning template,

[0024] Figure 4 The internal spline in and the position of the Φ6H7 hole are consistent with those of the fork part;

[0025] Figure 5 is the schematic diagram of the fixed-angle adjustment and positioning, which is used for the positioning and fixing of the circumferential adjustment component and the radial adjustment component;

[0026] Figure 6 is the schematic diagram of the fixed-angle installation of the fork part, which is mainly composed of the fork part, the circumferential adjustment component, and the radial adjustment component;

[0027] Figure 7 is the schematic diagram of the base plate;

[0028] Figure 8 is the schematic diagram of the installation mandrel;

[0029] Figure 9 is the schematic diagram of the spline dummy;

[0030] Figure 10 is the schematic diagram of the taper sleeve;

[0031] Figure 11 It is a schematic diagram of a locking nut;

[0032] Figure 12 It is a schematic diagram of a positioning pin;

[0033] Figure 13 It is a schematic diagram of a radial adjustment component;

[0034] Figure 14 It is a schematic diagram of a circumferential adjustment component;

[0035] Among them, 1. Base plate, 2. Mounting mandrel, 3. Spline dummy, 4. Taper sleeve, 5. Locking nut, 6. Radial adjustment component, 7. Circumferential adjustment component, 8. Positioning template, 9. Positioning pin, 10. Fork part, 8a. Internal spline of the positioning template, 8b. Positioning hole. Specific implementation mode

[0036] The technical solution of the present invention will be clearly and completely described below in conjunction with the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of them. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0037] The fork is an important part with a complex shape and high precision in a certain task production. It is not easy to install and align during processing, and it is difficult to control the dimensions and geometric tolerances. Especially, the accuracy and angular position of the spline are required strictly, which requires high precision of the machine tool and skills of the operator. This method avoids the fixed angular requirement of the gear shaper, only uses the precise indexing function of the machine tool, uses a special gear shaper cutter, installs the part on a set of fixed angular workpieces adjusted well. Each time the part is installed, the part is sleeved on the mounting mandrel, and the part is rotated to make the Φ6 positioning pin smoothly inserted into the Φ6 through holes of the fork part and the radial adjustment component, realizing the fixed angular installation of the fork part. After the locking nut presses the part tightly, the work of cutting the spline teeth is completed. This method can quickly realize the installation, alignment, clamping and processing of the fork part through a set of simple workpieces, meet the requirements of each dimension and geometric tolerance of the spline teeth of the part, and enable ordinary operators to complete the high-precision angular processing of the fork part.

[0038] Based on the above design concept, the processing device specifically designed by the present invention is as Figure 3-14As shown in the figure, a precision fixed-angle spline machining device includes: a base plate 1, a mandrel 2, a fork part 10, a spline dummy 3, a positioning template 8, a circumferential adjustment component 7, a radial adjustment component 6, a taper sleeve 4, and a locking nut 5; the fork part 10 is a standard fork part, the base plate 1 is fixed on the turntable of a universal gear shaper, the mandrel 2 is fixed at the center position of the base plate 1, and its center coincides with the center of the turntable of the universal gear shaper; the spline dummy 3 has an external spline that perfectly matches the fork part; one end of the positioning template 8 is provided with an internal spline 8a of the positioning template that matches the external spline of the spline dummy, and the other end is provided with a positioning hole 8b, and the position of the positioning hole 8b relative to the internal spline 8a of the positioning template is the same as that of the fork part; the radial adjustment component 6 is arranged on the circumferential adjustment component 6, and a through hole that matches the positioning hole is also opened on the radial adjustment component; adjust the radial adjustment component and the circumferential adjustment component to ensure that the through hole is coaxial with the positioning hole and perpendicular to the plane where the base plate is located. The taper sleeve 4 and the locking nut 5 are used for centering and fixing the spline dummy 3 or the fork part 10 on the mandrel 2.

[0039] The precision fixed-angle spline machining method is completed by using the machining device designed above, and the specific operation steps are as follows:

[0040] See the appendix Figure 3 、 4 First step, install the base plate 1 and the installed mandrel 2 at the center of the turntable of the universal gear shaper, and fix the base plate. Install the radial adjustment component 6 and the circumferential adjustment component 7 on the base plate 1. Install the spline dummy 3, center it with the taper sleeve 4, and tighten it with the locking nut 5. Adjust the gear shaper and complete the external spline machining on the spline dummy 3, and reset the machine tool;

[0041] Second step, put the spline positioning template 8 on the spline dummy 3, adjust the circumferential adjustment component 7 and the radial adjustment component 6 so that the positioning pin 9 can be smoothly inserted into the Φ6H7 through holes of both the spline positioning template 8 and the radial adjustment component 6 at the same time. Then fix the circumferential adjustment component 7 and the radial adjustment component 6;

[0042] Third step, remove the spline positioning template 8 and the positioning pin 9, loosen the locking nut 5, remove the taper sleeve 4 and the spline dummy 3, and keep the remaining parts fixed on the machine tool;

[0043] Fourth step, put the fork 10 to be gear-shaped on the installed mandrel 2, rotate the fork 10 so that the positioning pin 9 can be smoothly inserted into the Φ6H7 through holes of both the fork 10 and the radial adjustment component 6 at the same time, install the taper sleeve 4 for centering, and tighten it with the locking nut 5. Start the gear shaper and start gear shaping using the machining parameters for machining the spline dummy, and reset the machine tool after machining.

[0044] In the design of the present invention, the spline positioning template 8 can also be used as an inspection template to further detect the machined fork and determine its qualification. When the spline positioning template 8 is sleeved on the fork 10 and the positioning pin 9 is inserted into the Φ6H7 through holes of the positioning template 8 and the fork 10, if it can be inserted smoothly, it proves that the spline size and angular orientation (90°±0.1°) of the fork 10 are qualified in machining. Then, it can be disassembled and another fork part can be installed to perform repeated spline machining, and so on to complete batch machining in a cycle.

[0045] In the implementation of the present invention, in the design structure of the spline positioning template 8, the core design point lies in the internal spline and the position of the Φ6H7 hole being consistent with that of the fork part. Of course, for different special-shaped structures, the spline positioning template 8 can also be adaptively changed. Using the design concept of converting standard parts, essentially, it is to achieve the mutual conversion of spatial positions to ensure the unity of the conversion reference, thereby reliably guaranteeing the machining accuracy. While improving the accuracy, the machining efficiency is significantly improved.

[0046] The above specific implementation manners or cases are only used to explain the technical solutions of the present invention and do not limit this application. The parts not described in detail are regarded as conventional technical means or common general knowledge in the art. Those of ordinary skill in the art should understand that based on the design concept of this application, the technical solutions recorded in the foregoing implementation manners should be adaptively modified, or some or all of the technical features should be equivalently replaced. These modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A precision fixed-angle spline machining device, characterized in that, the machining device includes: a base plate, a mandrel, a fork part, a spline dummy, a positioning template, a circumferential adjustment component, and a radial adjustment component; the fork part is a standard fork part, the base plate is fixed on the turntable of a universal gear shaper, the mandrel is fixed at the center position of the base plate, and its center coincides with the center of the turntable of the universal gear shaper; the spline dummy has an external spline that perfectly matches the fork part; one end of the positioning template is provided with an internal spline of the positioning template that matches the external spline of the spline dummy, and the other end is provided with a positioning hole, and the position of the positioning hole relative to the internal spline of the positioning template is the same as that of the fork part; the radial adjustment component is arranged on the circumferential adjustment component, and a through hole that matches the positioning hole is also opened on the radial adjustment component; adjust the radial adjustment component and the circumferential adjustment component to ensure that the through hole and the positioning hole are coaxial and perpendicular to the plane where the base plate is located.

2. The precision fixed-angle spline machining device according to claim 1, characterized in that, the machining device further includes a positioning pin for coaxially fixing the through hole on the radial adjustment component and the positioning hole on the positioning template.

3. The precision fixed-angle spline machining device according to claim 2, characterized in that, the positioning pin has a variable diameter structure, with a small diameter end at the lower end and a large diameter end at the upper end.

4. The precision fixed-angle spline machining device according to claim 1, characterized in that, the machining device further includes a taper sleeve and a locking nut, which are used in combination; the taper sleeve is used for centering, and the locking nut is used for pressing and locking.

5. The precision fixed-angle spline machining device according to claim 1, characterized in that, one end of the positioning template is a large round hole structure, and the other end is a small round hole structure.

6. The precision fixed-angle spline machining device according to claim 1, characterized in that, the radial adjustment component is a Z-shaped plate member, with a through hole opened on the side of the upper section and a waist-shaped hole convenient for adjustment opened on the lower flat section.

7. The precision fixed-angle spline machining device according to claim 1, characterized in that, the base plate is a disc structure, with a positioning hole for installing the mandrel opened at the center, and an arc groove opened at a certain radius position along the center for adjusting the position of the circumferential adjustment component on the base plate.

8. A method for machining a precision fixed-angle spline, the machining method using the machining device according to any one of claims 1-7, characterized in that, the machining method includes the following steps: Step S1: Install the base plate and the installed mandrel at the center of the turntable of the universal gear shaper and fix the base plate; install the radial adjustment component and the circumferential adjustment component on the base plate; install the spline dummy, center it with the taper sleeve, and tighten it with the locking nut; adjust the universal gear shaper to complete the machining of the external spline on the spline dummy that matches the standard fork part, and reset the machine tool; Step S2: Put the spline positioning template on the spline dummy, adjust the circumferential adjustment component and the radial adjustment component so that the positioning pin can be smoothly inserted into the through holes of the spline positioning template and the radial adjustment component at the same time; then fix the circumferential adjustment component and the radial adjustment component; Step S3: Remove the spline positioning template and positioning pin, loosen the locking nut, remove the tapered sleeve and spline dummy, and keep the remaining parts in fixed positions on the universal gear shaper. Step S4: Place the fork to be gear-shaped on the mounting mandrel, rotate the fork so that the positioning pin can be smoothly inserted into the through holes of both the fork and the radial adjustment assembly at the same time, install the tapered sleeve for centering, and tighten with the locking nut; start the gear shaper and begin gear shaping using the machining parameters for the spline dummy. After machining, reset the machine tool.

9. A method for machining a precision fixed-angle spline as claimed in claim 8, characterized in that, After one fork is machined, place the spline positioning template on the fork and insert the positioning pin into the through holes of the positioning template and the fork. If it can be smoothly inserted, it proves that the spline dimensions and angular machining of the fork are qualified. Then, the fork part can be disassembled and another one installed, and the spline machining can be repeated to complete batch machining.

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