A method for saving material in processing graphite valve plate

Abstract

The application relates to a material-saving processing method of graphite valve clappers, which comprises the following steps: vertically placing a plate-shaped material on a platform and making the side edge abut against a trapezoidal baffle, pushing the plate-shaped material to move along the trapezoidal baffle until one side end of the plate-shaped material abuts against a fixed-distance baffle, making a saw blade of a trapezoidal cutting die cut and move along an avoiding groove to obtain a first semi-finished product; turning the first semi-finished product by 180 DEG with the side edge abutting against the trapezoidal baffle as the rotating center to pass through the trapezoidal cutting die again to obtain a trapezoidal long strip material; cutting the trapezoidal long strip material into a quadrangular pyramid material through the trapezoidal cutting die; clamping the quadrangular pyramid material on a lathe to perform turning processing to obtain a circular table-shaped material, evenly divide the circular table-shaped material into four parts to cut open to obtain four valve clappers. The material utilization rate of each quadrangular pyramid material processed into the circular table-shaped material is 78.3%, the waste material rate is 21.7%, the material is greatly saved, the material utilization rate is improved, the waste material is reduced, the waste material rate is reduced, and therefore the production cost is reduced.

Description

Technical Field

[0001] This application relates to the field of graphite product processing technology, and in particular to a material-saving processing method for graphite card segments. Background Technology

[0002] With the rapid development of the photovoltaic industry, the demand for graphite clamps, a major consumable in polysilicon material production equipment, has also increased significantly. Graphite clamps are one of the important components of the reduction furnace in polysilicon material production equipment, and their main function is to fix the silicon core and conduct electricity during production. Each set of graphite clamps consists of clamping segments and clamping caps.

[0003] During the silicon core mounting process, one clamping cap and four clamping segments are required to form a graphite clamp. The clamping segments and the clamping cap are detachably connected by clamping or threaded connections, facilitating later disassembly and separation, and enabling the clamping cap to be reused. In applications where the clamping segments clamp the bottom end of the silicon core, after polycrystalline silicon growth, the bottom end of the silicon core becomes fused with the clamping segments and cannot be separated. The clamping segments must be separated from the clamping cap, and the clamping cap can be reused. However, for the next batch of polycrystalline silicon growth, four new clamping segments are needed to clamp the silicon core, resulting in significant consumption of the clamping segments.

[0004] Currently, the processing of graphite fixtures required in polysilicon production mainly uses cylindrical or square blanks. A material removal method (such as the material removal method disclosed in Chinese Invention Patent 201510118129.7, "A Processing Method and Special Tool for Graphite Caps and Splinters for Polysilicon Production") is used to process one cap and four splinters at a time, achieving full utilization of raw materials. However, after the splinters are used, multiple splinters need to be supplied separately. It is understood that for polysilicon manufacturers, if one cap is reused four times, 4*4 splinters are needed to match it, meaning an additional 3*4=12 splinters need to be supplied separately. The production of individual splinters cannot be carried out using the aforementioned material removal method.

[0005] In the existing technology, only cylindrical or square blanks can be used to process the card segments. First, the cylindrical or square blank needs to be turned into a frustum shape, and then it needs to be precision machined and cut into 4 card segments. In the process of turning the cylindrical or square blank into a frustum shape, there are problems of extremely low raw material utilization and high cost. Summary of the Invention

[0006] Therefore, it is necessary to address the problems of extremely low raw material utilization and high cost in the current process of machining graphite card segments from cylindrical or square blanks into frustum shapes. A material-saving machining method for graphite card segments is provided, which enables a raw material utilization rate of 78.3% and a scrap rate of 21.7% for each frustum shape machined from a square blank. This significantly saves material, improves raw material utilization, reduces waste, and lowers the scrap rate, thereby reducing production costs.

[0007] A material-saving processing method for graphite card segments includes the following steps:

[0008] S10. Cut the graphite block into sheet material using a wire EDM saw;

[0009] S20. Place the plate material upright on the platform of the trapezoidal cutting mold, and make the side of the plate material abut against the trapezoidal stop of the trapezoidal cutting mold. Push the plate material along the trapezoidal stop until one side of the plate material abuts against the fixed-distance stop of the trapezoidal cutting mold. Start the trapezoidal cutting mold and make the saw blade of the trapezoidal cutting mold move along the clearance groove to cut and obtain the first semi-finished product.

[0010] S30. The first semi-finished material is rotated 180° with the side of the trapezoidal stop as the rotation center and then cut again through the trapezoidal cutting mold to obtain a trapezoidal strip. The cross-sectional shape of the trapezoidal strip is an isosceles trapezoid.

[0011] S40. The trapezoidal strip is cut into a frustum shape using the trapezoidal cutting die;

[0012] S50. The frustum material is clamped on a lathe and machined to obtain a frustum-shaped material. The frustum-shaped material is then cut into four equal parts along its radial direction to obtain four clips.

[0013] Preferably, in the above-mentioned material-saving processing method for graphite card segments, the trapezoidal cutting mold includes a platform, a trapezoidal side, a fixed-distance side, and a saw blade. The trapezoidal side and the fixed-distance side are both disposed on the platform. The platform has an avoidance groove that extends along the straight line where the top edge of the trapezoidal side is located. The saw blade moves along the avoidance groove. There is a preset distance between the fixed-distance side and the top edge of the trapezoidal side, and the preset distance is adjustable.

[0014] Preferably, in the above-mentioned method for saving material in the processing of graphite card segments, step S30 specifically includes the following steps:

[0015] The first semi-finished material is rotated 180° and placed upright on the platform with its side abutting the trapezoidal stop as the rotation center. The side of the first semi-finished material abuts the trapezoidal stop, and the first semi-finished material is pushed to move along the trapezoidal stop until the side of the first semi-finished material that was cut in step S20 abuts the fixed-distance stop. The trapezoidal cutting mold is then activated, and the saw blade moves along the clearance groove to cut and obtain the trapezoidal strip material.

[0016] Preferably, in the above-mentioned method for saving material in the processing of graphite card segments, step S40 specifically includes the following steps:

[0017] S41. Place the trapezoidal strip on the platform and make the bottom edge of the trapezoidal strip abut against the trapezoidal stop. Push the trapezoidal strip along the trapezoidal stop until one end of the trapezoidal strip abuts against the fixed-distance stop. Start the trapezoidal cutting mold and make the saw blade cut along the clearance groove to obtain the second semi-finished product.

[0018] S42. The second semi-finished material is rotated 180° with the bottom edge of the trapezoidal stop as the rotation center and then cut again through the trapezoidal cutting mold to obtain the frustum material.

[0019] Preferably, in the above-mentioned method for saving material in the processing of graphite card segments, step S42 specifically includes the following steps:

[0020] The second semi-finished material is rotated 180° onto the platform with its bottom edge abutting against the trapezoidal stop as the rotation center, and its top edge abutting against the trapezoidal stop. The second semi-finished material is pushed to move along the trapezoidal stop until the side of the second semi-finished material that was cut in step S41 abuts against the fixed-distance stop. The trapezoidal cutting mold is then activated, and the saw blade moves along the clearance groove to cut and obtain the frustum material.

[0021] Preferably, in the above-mentioned material-saving processing method for graphite truncated cones, the lathe includes a special fixture for truncated cone materials and a center. The special fixture for truncated cone materials includes a four-jaw chuck and four trapezoidal jaws. The four trapezoidal jaws are disposed on the four-jaw chuck. When the special fixture for truncated cone materials clamps the truncated cone material, the four trapezoidal jaws abut against the four oblique sides of the truncated cone material one by one to achieve clamping. The center is positioned on the end face of the truncated cone material.

[0022] Preferably, in the above-mentioned method for saving material in the processing of graphite card segments, step S50 specifically includes the following steps:

[0023] S51. The frustum material is clamped in the frustum material special fixture, the four trapezoidal jaws abut against the four oblique sides of the frustum material one by one, and the center is positioned on the end face of the frustum material. The machine tool is started.

[0024] S52. One end of the frustum material is machined to form a circular bottom;

[0025] S53. Remove the frustum material from the special jig for the frustum material, remove the special jig for the frustum material from the machine tool, and replace it with a three-jaw chuck for clamping the column.

[0026] S54. Clamp the circular bottom of the frustum material into the three-jaw chuck, start the machine tool, turn and machine the conical side to obtain a frustum-shaped material, and cut the frustum-shaped material into four equal parts along the radial direction to obtain four clamping parts.

[0027] The technical solution adopted in this application can achieve the following beneficial effects:

[0028] In a material-saving processing method for graphite card segments disclosed in this application, frustum-shaped material is processed from a square frustum blank to achieve material saving. Compared with processing frustum-shaped material from a square blank, the method disclosed in this application can increase the yield by 28.6%. The raw material utilization rate of each square blank processed into a frustum-shaped material is 45.8%, and the waste rate is 54.2%, while the raw material utilization rate of each square frustum blank processed into a frustum-shaped material is 78.3%, and the waste rate is 21.7%. Similarly, the raw material utilization rate of a plate material processed from a square blank is 45.8%, and the waste rate is also 54.2%; while the raw material utilization rate of the same plate material processed from a square frustum blank is 58.9%, and the waste rate is also 41.1%. Meanwhile, compared to processing frustum-shaped materials from cylindrical blanks, the method disclosed in this application can increase the yield by 1.7%. The raw material utilization rate of each cylindrical blank processed into a frustum-shaped material is 58.3%, and the scrap rate is 41.7%. The raw material utilization rate of each square frustum-shaped material processed into a frustum-shaped material is 78.3%, and the scrap rate is 21.7%. For materials of the same volume, the raw material utilization rate is 57.9% and the scrap rate is 42.1% when using cylindrical blanks, and the raw material utilization rate is 58.9% and the scrap rate is 41.1% when using square frustum-shaped materials.

[0029] In summary, the processing method disclosed in this application can greatly save materials, improve the utilization rate of raw materials, reduce waste, and lower the waste rate, thereby reducing production costs. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the trapezoidal cutting mold disclosed in the embodiments of this application;

[0031] Figure 2 This is a schematic diagram of the special fixture for square frustum material disclosed in the embodiments of this application;

[0032] Figure 3 This is a schematic diagram of the frustum-shaped material disclosed in the embodiments of this application;

[0033] Figure 4 This is a schematic diagram of the frustum-shaped material disclosed in the embodiments of this application;

[0034] Figure 5 This is a schematic flowchart of a material-saving processing method for graphite card segments disclosed in an embodiment of this application;

[0035] Figure 6 This is a flowchart illustrating steps S20 and S30 as disclosed in the embodiments of this application;

[0036] Figure 7 This is a flowchart illustrating steps S41 and S42 as disclosed in the embodiments of this application;

[0037] Figure 8 This is a schematic diagram showing the cutting process from a square billet to a trapezoidal strip.

[0038] Figure 9 This is a schematic diagram showing the cutting process from trapezoidal strip to truncated pyramid.

[0039] Among them: trapezoidal cutting mold 100, platform 110, clearance groove 111, trapezoidal side guard 120, fixed distance side guard 130, saw blade 140, special clamp for four-sided frustum material 200, four-jaw chuck 210, trapezoidal jaw 220. Implementation

[0040] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings. Preferred embodiments of this application are shown in the drawings. However, this application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this application.

[0041] It should be noted that when an element is referred to as being "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," "top," "bottom," "end," "top," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0042] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0043] Please refer to Figure 1 , Figure 6 , Figure 7 , Figure 8 and Figure 9 This application discloses a trapezoidal cutting mold 100 for cutting sheet material into trapezoidal strips, and then cutting the trapezoidal strips into frustum-shaped pieces to achieve material saving. The trapezoidal cutting mold 100 disclosed in this application includes a platform 110, a trapezoidal side guard 120, a fixed-distance side guard 130, and a saw blade 140, wherein:

[0044] Please refer to this again. Figure 1 Both the trapezoidal guard 120 and the fixed-distance guard 130 are set on the platform 110. The platform 110 has a clearance groove 111, which extends along the straight line where the top edge of the trapezoidal guard 120 is located. The saw blade 140 moves along the clearance groove 111 to cut. There is a preset distance between the fixed-distance guard 130 and the top edge of the trapezoidal guard 120, and the preset distance is adjustable.

[0045] Please refer to this again. Figure 6 In the specific processing of cutting sheet material into trapezoidal strips, firstly, the preset distance between the fixed-distance retaining edge 130 and the top edge of the trapezoidal retaining edge 120 is adjusted. After the adjustment is appropriate (specifically, reduced), the sheet material is placed upright on the platform 110, that is, the sheet material is placed vertically on the platform 110, and the side of the sheet material abuts against the trapezoidal retaining edge 120. The sheet material is pushed along the trapezoidal retaining edge 120 until one end of the sheet material abuts against the fixed-distance retaining edge 130. The trapezoidal cutting mold 100 is then activated, causing the saw blade 140 to move along the clearance groove 111 to cut and obtain the first semi-finished product. Then, the fixed distance is adjusted... After adjusting the preset distance between the top edge of the retaining edge 130 and the trapezoidal retaining edge 120 (specifically, increasing it), the first semi-finished material is rotated 180° and placed upright on the platform 110 with the side of the first semi-finished material abutting against the trapezoidal retaining edge 120 as the rotation center. The side of the first semi-finished material is then pushed along the trapezoidal retaining edge 120 until the end of the first semi-finished material that was cut in the previous step (the tip of the inclined side) abuts against the fixed-distance retaining edge 130. The trapezoidal cutting mold 100 is then activated, and the saw blade 140 moves along the clearance groove 111 to cut and obtain a trapezoidal strip.

[0046] Please refer to this again. Figure 7In the specific processing of cutting a trapezoidal strip into a frustum, firstly, the preset distance between the fixed-distance stop 130 and the top edge of the trapezoidal stop 120 is adjusted. After the adjustment is appropriate (specifically, reduced), the trapezoidal strip is placed on the platform 110, with the bottom edge of the trapezoidal strip abutting against the trapezoidal stop 120. The trapezoidal strip is then pushed along the trapezoidal stop 120 until one end of the trapezoidal strip abuts against the fixed-distance stop 130. The trapezoidal cutting mold 100 is then activated, causing the saw blade 140 to move along the clearance groove 111 to cut and obtain the second semi-finished product. Then, the fixed distance is adjusted... After adjusting the preset distance between the top edge of the retaining edge 130 and the trapezoidal retaining edge 120 (specifically, increasing it), the second semi-finished material is rotated 180° and placed on the platform 110 with its bottom edge abutting against the trapezoidal retaining edge 120 as the rotation center. The top edge of the second semi-finished material is then placed against the trapezoidal retaining edge 120. The second semi-finished material is pushed along the trapezoidal retaining edge 120 until the side of the second semi-finished material that was cut in the previous step abuts against the fixed-distance retaining edge 130. The trapezoidal cutting mold 100 is then activated, causing the saw blade 140 to cut and move along the clearance groove 111 to obtain a truncated pyramid material.

[0047] In the process of processing individual card segments, they first need to be processed into a frustum shape (frustum-shaped material mentioned later). Please refer to [reference needed]. Figure 8 and Figure 9 Suppose there are two sheet materials of the same size. One sheet material, processed using existing methods for individual frustum shapes, first needs to be transversely cut into strips, resulting in 7 strips. Each strip is then vertically cut into square blanks, resulting in 7 square blanks, totaling 7*7=49 square blanks, which can be processed into 49 frustum shapes. However, when cutting the other sheet material using the trapezoidal cutting mold 100 disclosed in this application, the sheet material is first cut into trapezoidal strips, which can be cut into 9 trapezoidal strips. Each trapezoidal strip is then cut into truncated pyramids, resulting in 7 truncated pyramids (this is because to ensure the taper direction of the truncated pyramids is the same, and that both the top and bottom surfaces are square, it is impossible to cut them in the same direction). Figure 8 The cutting method described above only allows for the removal of the middle portion (to reduce waste of the removed portion, it can be done according to...). Figure 9 The cut is made along a triangular path, resulting in a triangular portion with minimal waste. This sacrifices material for the next frustum cut. If the trapezoidal strip is cut according to... Figure 8If the material is cut in the manner shown in the image (the even-numbered pieces are not frustums, and their top and bottom faces are not squares), a total of 9*7=63 frustums can be processed into 63 frustum-shaped pieces. That is, a sheet of the same size, cut using the existing method, can produce 49 frustum-shaped pieces, while a sheet of the same size, cut using the frustum method, can produce 63 frustum-shaped pieces, a significant increase in quantity (a squared increase trend), and a 28.6% increase in yield. If the sheet is larger, the yield will be even higher, exceeding 28.6%. It should be noted that frustum-shaped pieces (frustum-shaped pieces as discussed later) can be processed from frustums.

[0048] In the processing of individual card segments, in the existing technology, when turning a square blank into a frustum shape, most of the material is wasted during turning, especially at the top of the frustum shape, where the most material is wasted, resulting in extremely low raw material utilization. However, by using a square frustum material, the material wasted at the oblique side of the square frustum material can be reduced when turning at the top of the frustum shape, thereby saving material and increasing the yield by 28.6%. This improves the raw material utilization rate in the processing of individual card segments and helps to reduce production costs.

[0049] Please refer to Figure 2 and Figure 3 This application discloses a special fixture 200 for clamping frustum materials, used to clamp frustum materials. After the frustum materials are clamped in the special fixture 200, they are machined on a lathe. The special fixture 200 for frustum materials disclosed in this application includes a four-jaw chuck 210 and four trapezoidal jaws 220, wherein:

[0050] Please refer to this again. Figure 2 Four trapezoidal jaws 220 are set on the four-jaw chuck 210. When the four-sided frustum material is clamped by the special clamp 200 for the four-sided frustum material, the four trapezoidal jaws 220 abut against the four oblique sides of the four-sided frustum material one by one to achieve clamping, and the top point is set on the end face of the four-sided frustum material.

[0051] During the specific clamping process, the four inclined sides of the frustum material correspond to the four trapezoidal jaws 220. That is, the four trapezoidal jaws 220 clamp the four inclined sides of the frustum material, thereby achieving the clamping of the frustum material. The special fixture 200 for frustum material is used on a lathe. In other words, the lathe includes the special fixture 200 for frustum material. The lathe clamps the frustum material using the special fixture 200 for frustum material and then performs turning machining.

[0052] To prevent the oblique side of the truncated pyramid material from sliding out of the special fixture 200 due to clamping force, after the lathe clamps the truncated pyramid material through the special fixture 200, the lathe's center presses against the end face of the truncated pyramid material. The center restricts the truncated pyramid material from sliding out of the special fixture 200, thereby avoiding unstable clamping and improving the stability and reliability of the machining process.

[0053] Please refer to Figures 1 to 9 This application discloses a material-saving processing method for graphite card segments, including the following steps:

[0054] S10. Cut the graphite block into sheet material using a wire EDM saw;

[0055] S20. Place the sheet material upright on the platform 110 of the trapezoidal cutting mold 100, and make the side of the sheet material abut against the trapezoidal stop 120 of the trapezoidal cutting mold 100. Push the sheet material along the trapezoidal stop 120 until one side of the sheet material abuts against the fixed stop 130 of the trapezoidal cutting mold 100. Start the trapezoidal cutting mold 100, and make the saw blade 140 of the trapezoidal cutting mold 100 cut and move along the clearance groove 111 to obtain the first semi-finished product.

[0056] Furthermore, the following steps are included before step S20:

[0057] S10-20. Adjust the preset distance so that in step S20, when one end of the sheet material abuts against the fixed-distance retaining edge 130, the projection plane of the portion of the sheet material end that extends beyond the clearance groove 111 is triangular. The portion of the sheet material end that extends beyond the clearance groove 111 is cut off and becomes waste. Therefore, minimizing the portion of the sheet material end that extends beyond the clearance groove 111 can reduce waste and achieve the purpose of saving material. The placement position with the minimum portion of the sheet material end that extends beyond the clearance groove 111 is the placement position when the projection plane of the portion of the sheet material end that extends beyond the clearance groove 111 is triangular. Therefore, this method can minimize waste and achieve the purpose of saving material.

[0058] In the specific processing, firstly, the preset distance between the fixed-distance stop 130 and the top edge of the trapezoidal stop 120 is adjusted. After the adjustment is appropriate (specifically, the projection surface of the part of the plate material that extends beyond the relief groove 111 is triangular), the plate material is placed upright on the platform 110, that is, the plate material is placed vertically on the platform 110, and the side of the plate material abuts against the trapezoidal stop 120. The plate material is pushed to move along the trapezoidal stop 120 until one end of the plate material abuts against the fixed-distance stop 130. The trapezoidal cutting mold 100 is started, and the saw blade 140 moves along the relief groove 111 to cut and obtain the first semi-finished product.

[0059] S30. The first semi-finished material is rotated 180° with the side of the trapezoidal stop 120 as the rotation center and then cut again through the trapezoidal cutting mold 100 to obtain a trapezoidal strip. The cross-sectional shape of the trapezoidal strip is an isosceles trapezoid.

[0060] Specifically, step S30 includes the following steps:

[0061] The first semi-finished material is rotated 180° and placed upright on the platform 110 with its side abutting against the trapezoidal stop 120 as the rotation center. The side of the first semi-finished material is then pressed against the trapezoidal stop 120. The first semi-finished material is pushed along the trapezoidal stop 120 until the side of the first semi-finished material that was cut in step S20 abuts against the fixed-distance stop 130. The trapezoidal cutting mold 100 is then activated, and the saw blade 140 moves along the clearance groove 111 to cut and obtain a trapezoidal strip.

[0062] Furthermore, the following steps are included before step S30:

[0063] S20-30. Adjust the preset distance so that in step S30, when the side of the first semi-finished material cut in step S20 abuts against the fixed-distance retaining edge 130, the projection surface of the part of the first semi-finished material that extends beyond the clearance groove 111 is an isosceles trapezoid, and meets the dimensional requirements for turning the frustum-shaped material in step S50.

[0064] Before step S30, the preset distance is adjusted so that the trapezoidal strip material obtained by the final cutting meets the size requirements for turning the frustum-shaped material in step S50. This avoids the size being too small to meet the size requirements for turning the frustum-shaped material, and also avoids the size being too large, which would result in a lot of waste material during the turning of the frustum-shaped material.

[0065] In the specific processing, firstly, the preset distance between the fixed-distance stop 130 and the top edge of the trapezoidal stop 120 is adjusted. After the adjustment is appropriate (specifically, the projection surface of the part of the first semi-finished material that extends beyond the relief groove 111 is an isosceles trapezoid, and meets the size requirements for turning the frustum-shaped material in step S50), the first semi-finished material is rotated 180° and placed upright on the platform 110 with the side of the trapezoidal stop 120 as the rotation center, and the side of the first semi-finished material is pressed against the trapezoidal stop 120. The first semi-finished material is pushed to move along the trapezoidal stop 120 until the end of the first semi-finished material (the tip of the inclined side) that was cut in step S20 is pressed against the fixed-distance stop 130. The trapezoidal cutting mold 100 is started, and the saw blade 140 moves along the relief groove 111 to cut and obtain a trapezoidal strip.

[0066] S40. Cut the trapezoidal strip into a frustum using the trapezoidal cutting die 100;

[0067] Specifically, step S40 includes the following steps:

[0068] S41. Place the trapezoidal strip on the platform 110 and make the bottom edge of the trapezoidal strip abut against the trapezoidal stop 120. Push the trapezoidal strip along the trapezoidal stop 120 until one end of the trapezoidal strip abuts against the fixed-distance stop 130. Start the trapezoidal cutting mold 100 and make the saw blade 140 cut along the clearance groove 111 to obtain the second semi-finished product.

[0069] Furthermore, the following steps are included before step S410:

[0070] S30-41. Adjust the preset distance so that in step S41, when one end of the trapezoidal strip abuts against the fixed-distance retaining edge 130, the projection surface of the portion of the trapezoidal strip end that extends beyond the clearance groove 111 is triangular, and the portion of the trapezoidal strip end that extends beyond the clearance groove 111 is cut off and becomes waste. Therefore, minimizing the portion of the trapezoidal strip end that extends beyond the clearance groove 111 can reduce waste and achieve the purpose of saving material. The placement position with the minimum portion of the trapezoidal strip end that extends beyond the clearance groove 111 is the placement position when the projection surface of the portion of the trapezoidal strip end that extends beyond the clearance groove 111 is triangular. Therefore, this method can minimize waste and achieve the purpose of saving material.

[0071] In the specific processing, firstly, the preset distance between the fixed-distance stop 130 and the top edge of the trapezoidal stop 120 is adjusted. After the adjustment is appropriate (specifically, the projection surface of the part of the trapezoidal strip that extends beyond the clearance groove 111 is triangular), the trapezoidal strip is placed on the platform 110, and the bottom edge of the trapezoidal strip abuts against the trapezoidal stop 120. The trapezoidal strip is pushed to move along the trapezoidal stop 120 until one end of the trapezoidal strip abuts against the fixed-distance stop 130. The trapezoidal cutting mold 100 is then started, and the saw blade 140 moves along the clearance groove 111 to cut and obtain the second semi-finished product.

[0072] S42. The second semi-finished material is rotated 180° with the bottom edge of the trapezoidal stop 120 as the rotation center and then cut again through the trapezoidal cutting mold 100 to obtain a truncated square material.

[0073] Specifically, step S42 includes the following steps:

[0074] The second semi-finished material is rotated 180° with its bottom edge abutting against the trapezoidal stop 120 as the rotation center and placed on the platform 110. The top edge of the second semi-finished material abuts against the trapezoidal stop 120. The second semi-finished material is pushed along the trapezoidal stop 120 until the side of the second semi-finished material that was cut in step S41 abuts against the fixed-distance stop 130. The trapezoidal cutting mold 100 is activated, and the saw blade 140 moves along the clearance groove 111 to cut and obtain a truncated pyramid material.

[0075] Furthermore, the following steps are included before step S42:

[0076] S41-42. Adjust the preset distance so that in step S42, when the side of the second semi-finished material cut in step S41 abuts against the fixed-distance retaining edge 130, the projection surface of the part of the second semi-finished material that extends beyond the clearance groove 111 is an isosceles trapezoid, and meets the dimensional requirements for turning the frustum-shaped material in step S50.

[0077] Before step S42, the preset distance is adjusted so that the final cut frustum material meets the size requirements for turning the frustum material in step S50. This avoids the material being too small to meet the size requirements for turning the frustum material, and also avoids the material being too large, which would result in a lot of waste during the turning process.

[0078] In the specific processing, firstly, the preset distance between the fixed-distance stop 130 and the top edge of the trapezoidal stop 120 is adjusted. After the adjustment is appropriate (specifically, the projection surface of the part of the second semi-finished material that extends beyond the relief groove 111 is an isosceles trapezoid, and meets the size requirements for turning the frustum-shaped material in step S50), the second semi-finished material is rotated 180° with the bottom edge of the trapezoidal stop 120 as the rotation center and placed on the platform 110, and the top edge of the second semi-finished material is made to abut against the trapezoidal stop 120. The second semi-finished material is pushed to move along the trapezoidal stop 120 until the side of the second semi-finished material that was cut in step S41 (the tip of the inclined side) abuts against the fixed-distance stop 130. The trapezoidal cutting mold 100 is started, and the saw blade 140 moves along the relief groove 111 to cut and obtain the frustum material.

[0079] S50. The frustum material is clamped on a lathe and machined to obtain a frustum-shaped material. The frustum-shaped material is then cut into four equal parts along its radial direction to obtain four clips.

[0080] The clamping of the frustum material can be achieved using the frustum material special fixture 200 disclosed above, so that the frustum material special fixture 200 can stably clamp the frustum material, thereby improving the stability and reliability of the processing.

[0081] Specifically, step S50 includes the following steps:

[0082] S51. Clamp the frustum material in the frustum material special fixture 200. The four trapezoidal jaws 220 abut against the four oblique sides of the frustum material one by one, and the center is set on the end face of the frustum material. Start the machine tool.

[0083] S52. Turn one end of the frustum material to produce a round bottom;

[0084] S53. Remove the frustum material from the frustum material special fixture 200, remove the frustum material special fixture 200 from the machine tool, and replace it with a three-jaw chuck for clamping the column.

[0085] Alternatively, first remove the truncated pyramid material from the machine tool along with the truncated pyramid material using the special fixture 200, and then remove the truncated pyramid material from the special fixture 200.

[0086] S54. Clamp the circular bottom of the frustum material in a three-jaw chuck, start the machine tool, turn and machine the conical side to obtain a frustum-shaped material, and cut it into four equal parts along the radial direction of the frustum-shaped material to obtain four clamping parts.

[0087] It should be noted that the cutting method for cutting sheet material into trapezoidal strips follows... Figure 8 As shown, the cutting method for cutting trapezoidal strips into frustum-shaped pieces follows... Figure 9 As shown.

[0088] In a material-saving processing method for graphite card segments disclosed in this application, frustum-shaped material is processed from a square frustum blank to achieve material saving. Compared with processing frustum-shaped material from a square blank, the method disclosed in this application can increase the yield by 28.6%. The raw material utilization rate of each square blank processed into a frustum-shaped material is 45.8%, and the waste rate is 54.2%, while the raw material utilization rate of each square frustum blank processed into a frustum-shaped material is 78.3%, and the waste rate is 21.7%. Similarly, the raw material utilization rate of a plate material processed from a square blank is 45.8%, and the waste rate is also 54.2%; while the raw material utilization rate of the same plate material processed from a square frustum blank is 58.9%, and the waste rate is also 41.1%. Meanwhile, compared to processing frustum-shaped materials from cylindrical blanks, the method disclosed in this application can increase the yield by 1.7%. The raw material utilization rate of each cylindrical blank processed into a frustum-shaped material is 58.3%, and the scrap rate is 41.7%. The raw material utilization rate of each square frustum-shaped material processed into a frustum-shaped material is 78.3%, and the scrap rate is 21.7%. For materials of the same volume, the raw material utilization rate is 57.9% and the scrap rate is 42.1% when using cylindrical blanks, and the raw material utilization rate is 58.9% and the scrap rate is 41.1% when using square frustum-shaped materials.

[0089] In summary, the processing method disclosed in this application can greatly save materials, improve the utilization rate of raw materials, reduce waste, and lower the waste rate, thereby reducing production costs.

[0090] To further illustrate the effects of the method disclosed in this application, the applicant provides the following embodiments:

[0091] Regardless of whether the blank is cylindrical, square, or truncated pyramidal, the process always begins by machining a truncated pyramidal shape, followed by machining the flaps. The machining of flaps from a truncated pyramidal shape follows the same method, and this process is identical. Therefore, the following examples illustrate the waste or material savings during the machining of truncated pyramidal shapes from cylindrical, square, and truncated pyramidal blanks. It should be noted that all length units mentioned below are in centimeters, and all volume units are in cubic centimeters.

[0092] Suppose we need to process a frustum-shaped material with a base diameter of 4, a top diameter of 2, and a height of 4. We need a 4*4*4 square blank; a cylindrical blank with a base diameter of 4 and a height of 4; and a quadrangular frustum with a top side length of 2, a bottom side length of 4, and a height of 4.

[0093] Example 1: Take a sheet of material with a length of 28, a width of 28, and a height of 4, and cut it into square blanks (4*4*4). First, the sheet of material needs to be cut horizontally into strips, resulting in 7 strips. Each strip is then cut vertically into square blanks, resulting in 7 square blanks. A total of 7*7=49 square blanks can be produced, which can be processed into 49 frustum-shaped blanks. The waste is calculated as follows (pi is taken as 3.14):

[0094] The volume of each frustum-shaped piece is approximately 29.3, so the volume of 49 frustum-shaped pieces is 49 * 29.3 = 1435.7.

[0095] The volume of each square billet is equal to 64, and the volume of 49 square billets (i.e., the volume of the sheet material) is equal to 3136.

[0096] The waste material from processing each square billet into a frustum shape is 64 - 29.3 = 34.7. Therefore, the total waste material from processing 49 square billets (i.e., plate-shaped materials) is 34.7 * 49 = 1700.3, or 3136 - 1435.7 = 1700.3.

[0097] The raw material utilization rate for processing each square blank into a frustum shape is 45.8%, and the scrap rate is 54.2%.

[0098] This sheet material can be processed into a maximum of 49 frustum-shaped pieces. The raw material utilization rate of this sheet material is 45.8%, and the scrap rate is 54.2%.

[0099] Example 2: Take a plate-shaped material with a length of 28 mm, a width of 28 mm, and a height of 4 mm, and cut it according to the method disclosed in this application. First, cut the plate-shaped material into trapezoidal strips, which can be cut into 9 trapezoidal strips. Each trapezoidal strip is then cut into a frustum, resulting in 7 frustum pieces (see reference). Figure 8 and Figure 9With an upper base length of 2 and a lower base length of 4, a total of 9*7=63 square frustum pieces can be processed into 63 frustum-shaped pieces. The waste material is calculated as follows (pi is taken as 3.14):

[0100] The volume of each frustum-shaped piece is approximately 29.3, so the volume of 63 frustum-shaped pieces is 63 * 29.3 = 1845.9.

[0101] The volume of each frustum is 37.4, the volume of 63 frustums is 2356.2, the volume of the plate is 3136, and the waste material here is 3136-2356.2=779.8.

[0102] The waste material from processing each truncated pyramid into a frustum shape is 37.4 - 29.3 = 8.1. Therefore, the total waste material from 63 truncated pyramids is 8.1 * 63 = 510.3, or 3136 - 1845.9 - 779.8 = 510.3. The total waste material from the plate shape is 779.8 + 510.3 = 1290.1.

[0103] The raw material utilization rate for processing each truncated square piece into a frustum shape is 78.3%, and the scrap rate is 21.7%.

[0104] The raw material utilization rate of processing the sheet material into 63 frustum-shaped pieces was 58.9%, and the scrap rate was 41.1%.

[0105] From Examples 1 and 2, we can obtain:

[0106] (1) A plate of the same size can only be processed into 49 frustums by using the square blank method, while it can be processed into 63 frustums by using the square frustum method of this application, increasing the yield by 28.6%. If the length of the strip is longer, the yield will be even greater, exceeding 28.6%.

[0107] (2) When processing a single frustum, the raw material utilization rate of each square blank processed into a frustum is 45.8%, and the scrap rate is 54.2%; while the raw material utilization rate of each square frustum is 78.3%, and the scrap rate is 21.7%. The raw material utilization rate is improved, thereby achieving the purpose of saving materials. Improving the raw material utilization rate in the processing of individual card segments is beneficial to reducing production costs.

[0108] (3) The raw material utilization rate of a sheet of the same size is 45.8% and the waste rate is 54.2% when it is made into a square blank; while the raw material utilization rate of a sheet of the same size is 58.9% and the waste rate is 41.1% when it is made into a frustum. From the perspective of a sheet of the same size, the raw material utilization rate can also be improved.

[0109] In conclusion, when producing card segments, it is advisable to directly purchase frustum material instead of buying graphite blocks or plates and then processing them into frustum material. This would increase the raw material utilization rate from 58.9% to 78.3%.

[0110] Example 3: Take a cylindrical blank with a base diameter of 4 and a height of 4, and machine it into a frustum-shaped piece with a base diameter of 4, a top diameter of 2, and a height of 4. Calculate the waste material as follows (pi is taken as 3.14):

[0111] The volume of each frustum-shaped blank is approximately 29.3, and the volume of each cylindrical blank is 50.24. The waste material from processing each cylindrical blank into a frustum-shaped blank is 50.24 - 29.3 = 20.94. The raw material utilization rate from processing each cylindrical blank into a frustum-shaped blank is 58.3%, and the waste rate is 41.7%.

[0112] Through Examples 2 and 3, we can obtain:

[0113] When processing a single frustum-shaped piece, the raw material utilization rate of each cylindrical blank into a frustum-shaped piece is 58.3%, and the scrap rate is 41.7%; while the raw material utilization rate of each quadrangular frustum piece into a frustum-shaped piece is 78.3%, and the scrap rate is 21.7%. The improved raw material utilization rate achieves the goal of saving materials. Improving the raw material utilization rate in the processing of individual card segments is beneficial to reducing production costs.

[0114] Based on Example 3, the total volume of the material was calculated to be 3136, resulting in 62 frustum-shaped pieces of waste material.

[0115] In Example 2, the overall volume of the material is 3136. Based on this volume, a cylindrical material with a base diameter of 4 and a length of 249.7 can be obtained. Cutting this cylindrical material yields a maximum of 62 (249.7 / 4 = 62.425) cylindrical blanks with a base diameter of 4 and a height of 4. The waste is calculated as follows (pi is taken as 3.14):

[0116] The volume of each frustum-shaped piece is approximately 29.3, so the volume of 62 frustum-shaped pieces is 62 * 29.3 = 1816.6.

[0117] The volume of each cylindrical billet is 50.24, and the volume of 62 cylindrical billets is 62 * 50.24 = 3114.88. The total waste here is 3136 - 3114.88 = 21.12.

[0118] The waste material from processing each cylindrical billet into a frustum shape is 50.24 - 29.3 = 20.94. Therefore, the total waste material from 62 cylindrical billets is 20.94 * 62 = 1298.28, or 3136 - 21.12 - 1816.6 = 1298.28, and the total waste material is 1298.28 + 21.12 = 1319.4.

[0119] The raw material utilization rate for processing each cylindrical blank into a frustum shape was 58.3%, and the scrap rate was 41.7%.

[0120] The raw material utilization rate of the material with a volume of 3136 was 57.9% when it was processed into 62 frustum-shaped pieces, and the scrap rate was 42.1%.

[0121] Therefore, it can be seen that:

[0122] (1) For the same volume of material (volume is 3136), 62 frustum-shaped pieces can be processed from cylindrical blanks, while 63 frustum-shaped pieces can be processed from plate-shaped pieces to square frustum-shaped pieces, increasing the yield by 1.7%. If the length of the strip is longer, the yield will be even greater, exceeding 1.7%.

[0123] (2) When processing a single frustum, the raw material utilization rate of each cylindrical blank to frustum is 58.3% and the scrap rate is 41.7%; while the raw material utilization rate of each quadrangular frustum to frustum is 78.3% and the scrap rate is 21.7%. The raw material utilization rate is improved, thereby achieving the purpose of saving materials. Improving the raw material utilization rate in the processing of individual card segments is beneficial to reducing production costs.

[0124] (3) For materials of the same volume (volume is 3136), the raw material utilization rate is 57.9% and the waste rate is 42.1% when using cylindrical blanks; while for materials of the same volume using truncated square blanks, the raw material utilization rate is 58.9% and the waste rate is 41.1%; from the perspective of materials of the same volume, the raw material utilization rate can also be improved.

[0125] In conclusion, when producing card segments, it's advisable to directly purchase frustum-shaped material instead of cylindrical blanks. This would increase the raw material utilization rate from 58.3% to 78.3%. Similarly, when producing card segments, it's advisable to directly purchase frustum-shaped material instead of cylindrical blanks of the same volume and weight. This would also increase the raw material utilization rate from 57.9% to 78.3%.

[0126] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0127] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A material-saving processing method for graphite card segments, characterized in that, Includes the following steps: S10. Cut the graphite block into sheet material using a wire EDM saw; S20. The plate material is placed upright on the platform (110) of the trapezoidal cutting mold (100), and the side of the plate material is made to abut against the trapezoidal stop (120) of the trapezoidal cutting mold (100). The plate material is pushed to move along the trapezoidal stop (120) until one side of the plate material abuts against the fixed-distance stop (130) of the trapezoidal cutting mold (100). The trapezoidal cutting mold (100) is started, and the saw blade (140) of the trapezoidal cutting mold (100) moves along the clearance groove (111) to cut and obtain the first semi-finished product. S30. The first semi-finished material is rotated 180° with the side of the trapezoidal stop (120) as the rotation center and then cut again through the trapezoidal cutting mold (100) to obtain a trapezoidal strip. The cross-sectional shape of the trapezoidal strip is an isosceles trapezoid. S40. The trapezoidal strip is cut into a frustum shape using the trapezoidal cutting die (100); S50. The frustum material is clamped on a lathe and machined to obtain a frustum-shaped material. The frustum-shaped material is then cut into four equal parts along its radial direction to obtain four clips. The trapezoidal cutting mold (100) includes a platform (110), a trapezoidal side (120), a fixed-distance side (130), and a saw blade (140). The trapezoidal side (120) and the fixed-distance side (130) are both disposed on the platform (110). The platform (110) has a clearance groove (111). The clearance groove (111) extends along the straight line where the top edge of the trapezoidal side (120) is located. The saw blade (140) moves along the clearance groove (111) for cutting. There is a preset distance between the fixed-distance side (130) and the top edge of the trapezoidal side (120), and the preset distance is adjustable. The S40 step specifically includes the following steps: S41. Place the trapezoidal strip on the platform (110) and make the bottom edge of the trapezoidal strip abut against the trapezoidal stop (120), push the trapezoidal strip along the trapezoidal stop (120) until one end of the trapezoidal strip abuts against the fixed-distance stop (130), start the trapezoidal cutting mold (100), and make the saw blade (140) cut along the clearance groove (111) to obtain the second semi-finished product; S42. Rotate the second semi-finished product 180° with the bottom edge abutting against the trapezoidal stop (120) as the rotation center and cut it again through the trapezoidal cutting mold (100) to obtain the truncated pyramid material.

2. The material-saving processing method for graphite card segments according to claim 1, characterized in that, Step S30 specifically includes the following steps: The first semi-finished material is rotated 180° and placed upright on the platform (110) with the side of the first semi-finished material abutting against the trapezoidal stop (120) as the rotation center. The side of the first semi-finished material abuts against the trapezoidal stop (120), and the first semi-finished material is pushed to move along the trapezoidal stop (120) until the side of the first semi-finished material that was cut in step S20 abuts against the fixed-distance stop (130). The trapezoidal cutting mold (100) is activated, and the saw blade (140) moves along the clearance groove (111) to cut and obtain the trapezoidal strip material.

3. The material-saving processing method for graphite card segments according to claim 2, characterized in that, Step S42 specifically includes the following steps: The second semi-finished material is rotated 180° onto the platform (110) with its bottom edge abutting against the trapezoidal stop (120) as the rotation center, and the top edge of the second semi-finished material abutting against the trapezoidal stop (120). The second semi-finished material is pushed to move along the trapezoidal stop (120) until the side of the second semi-finished material that was cut in step S41 abuts against the fixed-distance stop (130). The trapezoidal cutting mold (100) is activated, and the saw blade (140) moves along the clearance groove (111) to cut and obtain the frustum material.

4. The material-saving processing method for graphite card segments according to claim 1, characterized in that, The lathe includes a special fixture (200) for truncated pyramidal materials and a center. The special fixture (200) for truncated pyramidal materials includes a four-jaw chuck (210) and four trapezoidal jaws (220). The four trapezoidal jaws (220) are disposed on the four-jaw chuck (210). When the special fixture (200) clamps the truncated pyramidal material, the four trapezoidal jaws (220) abut against the four oblique sides of the truncated pyramidal material one by one to achieve clamping. The center is abutted on the end face of the truncated pyramidal material.

5. The material-saving processing method for graphite card segments according to claim 4, characterized in that, The S50 step specifically includes the following steps: S51. The frustum material is clamped in the frustum material special fixture (200), the four trapezoidal jaws (220) are in contact with the four oblique sides of the frustum material one by one, and the center is placed on the end face of the frustum material. Start the machine tool. S52. One end of the frustum material is machined to form a circular bottom; S53. Remove the frustum from the frustum material special fixture (200), remove the frustum material special fixture (200) from the machine tool, and replace it with a three-jaw chuck for clamping the column. S54. Clamp the circular bottom of the frustum material into the three-jaw chuck, start the machine tool, turn and machine the conical side to obtain a frustum-shaped material, and cut the frustum-shaped material into four equal parts along the radial direction to obtain four clamping parts.

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