A method for cutting and blanking a thin-walled material

Abstract

The application relates to the field of aviation thin-wall part machining, and particularly discloses a thin-wall material cutting and blanking method, which comprises the following steps: S1: fixing a workpiece to be machined; supporting the inner wall of the workpiece to be machined, and tightly clamping the workpiece to be machined on a machine tool; S2: transverse groove machining; setting an X axis parallel to the width direction of the workpiece to be machined and a Y axis perpendicular to the width direction of the workpiece to be machined, cutting from one side of the workpiece to be machined along the X direction, and processing a first layer of transverse groove type through a back-and-forth reciprocating machining path with a 2mm feeding each time, wherein the machining allowance of each layer is 0.2mm, thus the transverse groove type penetrating through the wall thickness of the workpiece to be machined is completed, and the distance between the transverse groove type and a transverse cutting point is 2-3mm; and S3: cutting the material; the remaining part of the transverse cutting point is directly cut off by using a machining cutter, and the required part is obtained. The scheme can solve the problems that the existing thin-wall part is deformed and the cutter is easily broken when small materials are cut.

Description

Technical Field

[0001] This invention relates to the field of aerospace thin-walled parts processing, specifically to a method for cutting and blanking thin-walled materials. Background Technology

[0002] Aerospace thin-walled parts refer to aerospace components with a wall thickness of less than 3mm. In aerospace component manufacturing, various single-piece thin-walled parts are cut from integral thin-walled parts. In existing technology, the cutting and separation of parts is usually completed during rough machining using turning. During turning, the cutting tool cuts the material with the entire diameter, meaning the depth of cut reaches its maximum. When the cutting tool directly grooves, after penetrating 4mm in one go, due to the excessive depth, the metal chips at the bottom of the groove cannot be discharged and are squeezed together inside the groove. This results in insufficient clearance after the tool feeds, causing excessive runout of the thin-walled part and tool breakage. If the entire single-piece thin-walled part is cut off in one go, it will cause creases at the cut and large deformation. Therefore, a new cutting method is urgently needed to minimize part deformation during cutting and to prevent the cutting tool from getting stuck or breaking in the middle of the part. Summary of the Invention

[0003] The present invention provides a method for cutting thin-walled materials to solve the problem that existing thin-walled parts are prone to deformation and chipping when cutting small pieces.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: a method for cutting and blanking thin-walled materials, comprising the following steps:

[0005] S1: Fix the workpiece to be processed; support the inner wall of the workpiece to be processed, and clamp the workpiece to be processed onto the machine tool with tension;

[0006] S2: Transverse groove machining; Let the width direction parallel to the workpiece be the X-axis and the width direction perpendicular to the workpiece be the Y-axis. Start from one side of the workpiece and cut downwards along the X-axis. Machining the first layer of transverse groove by feeding 2mm and retracting the tool each time, with a machining allowance of 0.2mm for each layer. This process completes the transverse groove that penetrates the wall thickness of the workpiece. Leave a 2-3mm gap between the transverse groove and the transverse cutting point.

[0007] S3: Cutting the material; using a machining tool to directly cut off the remaining part at the transverse cutting point to obtain the required part.

[0008] The basic principle of this solution is as follows: a transverse groove is first formed at the cutting point by reciprocating feed. Since the transverse groove is formed by step-by-step feeding and layer-by-layer forming, no creases will be formed at the cutting point of the workpiece. After most of the material at the break point is milled out, only a small amount of material remains. The amount of material cut is small, resulting in small deformation of the thin-walled part, which leads to no creases on the surface of the part after cutting.

[0009] The beneficial effects of this solution are as follows: Existing methods for cutting blanks, especially thin-walled parts of approximately 3mm, result in excessive deformation of the cut edge when cut directly. While wire cutting with a grooving cutter without retraction can lead to chipping as the feed rate increases, the inability of metal chips to escape from the gap causes the cutter head to be squeezed against the thin-walled titanium alloy part. This solution employs a pre-grooving method, first cutting out most of the boundary of the cut surface. The pre-grooving cutter head uses a small forward and backward reciprocating motion to ensure that metal chips can be discharged from the workpiece, preventing chipping and jamming in the middle of the transverse groove. This effectively avoids the thin-walled part from jumping, resulting in a smaller deformation of the cut surface of the finished part.

[0010] Furthermore, the width of the transverse groove is 4mm.

[0011] Furthermore, the machining tool in S3 is a grooving tool. The tool feeds multiple times along the X-axis within the transverse groove, machining multiple layers along the thickness of the workpiece to completely remove the remaining portion of the transverse groove. After the transverse groove is machined, the final remaining portion needs to be removed. This is done by using the grooving tool in the opposite direction of the transverse groove formation, further reducing shearing deformation and ensuring cutting accuracy.

[0012] Furthermore, the machining tool in S3 is an external circular cutter. The external circular cutter feeds along the X direction once within the transverse groove, completely removing the remaining portion of the transverse groove in one pass. By using the external circular cutter to cut away the last remaining part in a direction perpendicular to the workpiece surface, heat can be evenly distributed across the entire length of the remaining portion through wire cutting, reducing tool wear and improving machining efficiency.

[0013] Furthermore, the cutting width of the external circular cutter is 5-6 mm. The width of the external circular cutter covers the entire length of the remaining material, allowing the entire remaining portion to be cut off in a single feed.

[0014] Another method for cutting and blanking thin-walled materials is also proposed, including the following steps:

[0015] S1: Fix the workpiece to be processed; support the inner wall of the workpiece to be processed, and clamp the workpiece to be processed onto the machine tool with tension;

[0016] S2: Transverse groove machining; Let the width direction parallel to the workpiece be the X-axis and the width direction perpendicular to the workpiece be the Y-axis. Start from one side of the workpiece and cut downwards along the X-axis. Machining the first layer of transverse groove by feeding 2mm and retracting the tool each time, with a machining allowance of 0.2mm for each layer. This process completes the transverse groove that penetrates the wall thickness of the workpiece. Leave a 2-3mm gap between the transverse groove and the transverse cutting point.

[0017] S3: Vertical cut; cut along the Y-axis towards the direction close to the horizontal groove, with a cutter diameter of 3mm, and cut off the remaining part at the cutting point.

[0018] Compared to the previous cutting method, the advantages of this method are as follows: The previous cutting method cuts directly along the cutting line on the remaining part of the cut surface. If the two cuts are not aligned very precisely, the height of the two cuts will be uneven, which will result in some traces of secondary cutting remaining at the interface. This solution uses a vertical cutting method to cut the material from the width direction, resulting in a more regular cross-section with no obvious cutting marks compared to the previous method.

[0019] Furthermore, the diameter of the cutter head in S3 is greater than the length of the remaining portion.

[0020] The entire remaining portion is cut off using a single vertical cut. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of Embodiment 1 of the present invention;

[0022] Figure 2 This is a schematic diagram of Embodiment 2 of the present invention;

[0023] Figure 3 This is a schematic diagram of Embodiment 3 of the present invention. Detailed Implementation

[0024] The following detailed description illustrates the specific implementation method:

[0025] The reference numerals in the accompanying drawings include: 1. transverse groove; 2. remaining portion; 3. grooving tool; 4. machining tool; 5. annular housing; 51. spring; 52. protrusion; 6. thin-walled material; 7. workpiece to be machined.

[0026] Example 1:

[0027] Example 1 is basically as shown in the appendix. Figure 1 As shown:

[0028] A method for cutting and blanking thin-walled materials, wherein the thin-walled material obtained by cutting is ring-shaped and has a wall thickness of 3mm, and the specific processing method includes the following steps:

[0029] S1: Fix the workpiece to be processed; In this embodiment, the workpiece to be processed is cylindrical with the cylinder axis vertical, supporting the inner wall of the workpiece to be processed, and clamping the workpiece to be processed onto the machine tool.

[0030] S2: Transverse Groove Machining; Let the X-axis be parallel to the diameter of the workpiece, and the Y-axis be perpendicular to the diameter of the workpiece and parallel to the cylinder axis. Starting from the outside of the workpiece, cut downwards along the X-axis, following a 2mm feed and retraction path to machine the first layer of transverse grooves. Each layer has a machining allowance of 0.2mm. This process completes the transverse grooves covering the wall thickness of the workpiece. The total width of the transverse grooves is 4mm. Leave a 2-3mm margin between the transverse groove and the transverse cut-off point, i.e., a 2-3mm distance from the inner wall of the cylinder.

[0031] S3: Cut the material; use the machining tool 4 to directly cut off the transverse cutting residue 2 to obtain the required part.

[0032] The machining tool 4 in S3 can be either a grooving tool 3 or an external turning tool. When the machining tool 4 is a grooving tool 3, the machining tool 4 feeds multiple times along the X direction in the transverse groove and performs multi-layer machining along the thickness of the workpiece to be machined, completely removing the remaining part 2 of the transverse groove.

[0033] When the machining tool 4 is an external circular cutter, the cutting width of the external circular cutter is 5-6 mm, which is greater than the width of the remaining part 2. This allows the external circular cutter to feed along the X direction once on the other side of the transverse groove, completely removing the remaining part 2 of the transverse groove in one go.

[0034] Example 2:

[0035] The basic implementation examples are as follows: Figure 2 As shown:

[0036] A method for cutting and blanking thin-walled materials, wherein the thin-walled material obtained by cutting is ring-shaped and has a wall thickness of 3mm, and the specific processing method includes the following steps:

[0037] S1: Fix the workpiece to be processed; In this embodiment, the workpiece to be processed is cylindrical with the cylinder axis vertical, supporting the inner wall of the workpiece to be processed, and clamping the workpiece to be processed onto the machine tool.

[0038] S2: Transverse groove machining; Let the X-axis be parallel to the diameter direction of the workpiece and the Y-axis be perpendicular to the diameter direction of the workpiece and parallel to the cylinder axis. Start from the outside of the workpiece and cut downwards along the X-axis. Machining the first layer of transverse grooves by feeding 2mm and retracting the tool each time. The machining allowance for each layer is 0.2mm. In this way, a transverse groove that penetrates the wall thickness of the workpiece is completed. Leave 2-3mm between the transverse groove and the transverse cutting point.

[0039] S3: Vertical cut; cut along the Y-axis towards the direction close to the horizontal groove, with a cutter diameter of 3mm. The cutter diameter is greater than the length of the remaining part 2, and the remaining part 2 at the cutting point is cut off.

[0040] Example 3:

[0041] The basic implementation examples are as follows: Figure 3 As shown:

[0042] A method for cutting thin-walled material 6, wherein the thin-walled material 6 obtained by cutting is annular and has a wall thickness of 3mm, and the specific method includes the following steps;

[0043] S1: Fix the workpiece 7 to be processed; In this embodiment, the workpiece 7 to be processed is columnar with the axis of the column being vertical. The bottom end of the workpiece 7 to be processed is fixedly clamped on the machine tool, and an annular fixing sleeve is provided on the outer edge of the column.

[0044] S2: Transverse groove machining; Let the direction parallel to the diameter of the workpiece 7 be the X-axis, and the direction perpendicular to the diameter of the workpiece 7 and parallel to the cylinder axis be the Y-axis. Start from the outer side of the workpiece 7 and cut downwards along the X-axis. Machining the first layer of transverse grooves by feeding 2mm and retracting the tool each time. The machining allowance for each layer is 0.2mm, that is, feed 2mm and retract 1.8mm. In this way, a transverse groove through the wall thickness of the workpiece 7 is completed. The distance between the transverse groove and the transverse cutting point is reserved by 2-3mm.

[0045] S3: Fix the outer wall of the thin-walled component; inflate the annular fixing sleeve with air so that the protrusion 52 inside the annular fixing sleeve that contacts the outer wall of the thin-walled component tightly holds the outer wall of the thin-walled component.

[0046] Specifically, the structure of the annular fixing sleeve is as follows: Figure 3 As shown, the inner diameter of the fixing sleeve is the same as the outer diameter of the column. The fixing sleeve is an annular shell 5. Several through holes are spaced circumferentially on the inner wall of the fixing sleeve. A protrusion 52 is slidably connected in each through hole. A spring 51 is connected between the side wall of the protrusion 52 inside the annular shell 5 and the inner wall of the annular shell 5. The spring 51 is a tension spring. The annular shell 5 is connected to an external air source through a pipe. By controlling the switch of the air source, air can be injected into the inner cavity of the annular shell 5. When the annular shell 5 is full of air, the protrusions 52 slide out of the through holes under the action of air pressure. Multiple protrusions 52 move radially towards the center of the annular shell 5, thereby clamping the outer wall of the column.

[0047] The annular fixing sleeve is fixed on the externally mounted robotic arm, whose position can be freely controlled. The height of the annular fixing sleeve is controlled by the robotic arm to be outside the thin-walled part, thereby fixing the outside of the thin-walled part and preventing it from popping out after cutting, thus starting the next step of vertical cutting.

[0048] S4: Vertical cut; cut along the Y-axis towards the direction close to the horizontal groove, with a cutter diameter of 3mm. The cutter diameter is greater than the length of the remaining part 2, and the remaining part 2 at the cutting point is cut off.

[0049] S5: Obtain thin-walled material 6; release the air from the annular fixing sleeve, reduce the air pressure inside the annular shell 5, and under the action of spring 51, the protrusion 52 retracts into the annular shell 5, the external positioning of the thin-walled material 6 is eliminated, and the cut annular thin-walled material 6 can be removed.

[0050] This embodiment uses solid cylindrical raw materials, which provides better stability during cutting. After the horizontal groove is cut, the outer wall of the annular thin-walled material 6 is pressed tightly by the annular shell 5. This ensures a flat cut surface for the thin-walled part and prevents the annular thin-walled material 6 from shifting during vertical cutting, or even flying out of the processing position at the moment of cutting. The above description is only an embodiment of the present invention, and common knowledge such as specific structures and characteristics in the solution are not described in detail here. It should be noted that for those skilled in the art, several modifications and improvements can be made without departing from the structure of the present invention, and these should also be considered within the scope of protection of the present invention. These will not affect the effect of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application shall be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A method for cutting and blanking thin-walled materials, characterized in that: Includes the following steps: S1: Fix the workpiece to be processed; support the inner wall of the workpiece to be processed, and clamp the workpiece to be processed onto the machine tool with tension. The workpiece to be processed is cylindrical. S2: Transverse groove machining; Let the X-axis be parallel to the diameter direction of the workpiece and the Y-axis be parallel to the cylinder axis. Start from one side of the workpiece and cut downwards along the X-axis. Machining a transverse groove is done by feeding 2mm and retracting the tool each time. The machining allowance for each layer is 0.2mm, that is, 2mm feed and 1.8mm retraction. Leave 2~3mm between the transverse groove and the transverse cutting point. S3: Vertical cutting; cut along the Y-axis towards the direction close to the transverse groove, with a cutter diameter of 3mm, and cut off the remaining part at the transverse cutting point to obtain an annular thin-walled material.

2. A method for cutting and blanking thin-walled materials, characterized in that: Includes the following steps: S1: Fix the workpiece to be processed; support the bottom of the workpiece to be processed, and vertically clamp the workpiece to be processed on the machine tool. The workpiece to be processed is cylindrical. S2: Transverse groove machining; Let the X-axis be parallel to the diameter direction of the workpiece and the Y-axis be parallel to the cylinder axis. Start from one side of the workpiece and cut downwards along the X-axis. Machining a transverse groove is done by feeding 2mm and retracting the tool each time. The machining allowance for each layer is 0.2mm, that is, 2mm feed and 1.8mm retraction. Leave 2~3mm between the transverse groove and the transverse cutting point. S3: Fix the outer wall of the thin-walled part; move the annular fixing sleeve to the outer peripheral wall of the thin-walled material, inflate the annular fixing sleeve, and the annular fixing sleeve clamps the outer peripheral wall of the thin-walled material. S4: Vertical cutting; cut along the Y-axis in a direction close to the transverse groove, with a cutter diameter of 3mm, and cut off the remaining part at the transverse cutting point to obtain a ring-shaped thin-walled material.

3. The method for cutting and blanking thin-walled materials according to claim 2, characterized in that: The annular fixing sleeve is an annular shell shape. Several through holes are provided at intervals on the inner peripheral wall of the annular fixing sleeve. A protrusion is slidably connected in each through hole. A spring is provided between the protrusion and the inner side wall of the annular fixing sleeve. The annular fixing sleeve is connected to an external air source through a pipe.

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