High-precision hard machining method for signal wheel

Abstract

The application discloses a high-precision signal wheel hard machining method, which sequentially comprises the following steps: rough machining, contour whole machining, residual material machining, surface cutting machining and projection machining; wherein the rough machining adopts electrode discharge machining and milling rough machining; the contour whole machining performs semi-finishing machining on the workpiece; the residual material machining performs machining on the gear groove; the surface cutting machining removes residual material at the R corner in orientation; and the projection machining is divided into two parts and is processed by using two knives. The projection machining divides the knife path into two parts, finely processes the knife path, improves the die surface roughness, selects two CBN knives for final shaping, reduces the knife wear, and guarantees the shape precision; and through data analysis, the size manufacturing precision is effectively improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of mechanical gear hard machining method, in particular to a high-precision signal wheel hard machining method. BACKGROUND

[0002] As shown in the prior art high-precision signal gear machining method specifically includes the following steps: Figure 4

[0003] 1) rough machining;

[0004] 2) side wall machining;

[0005] 3) plane machining;

[0006] 4) residual material machining;

[0007] Among them, the rough machining step usually adopts four-blade structure cutter for machining, but the amount of residual material at the root after machining is very large, which brings trouble for subsequent machining.

[0008] Side wall machining adopts ball cutter milling, which leads to poor chip removal and is not suitable for groove machining; and plane machining will lead to sparse tool path at R arc, and there is tool path intersection with the plane, leaving tool marks on the mold surface.

[0009] And the residual material machining is that the amount of residual material is large and uneven, which leads to serious tool wear, and the tool is easy to break during machining.

[0010] In summary, the existing high-precision signal wheel usually has the following shortcomings:

[0011] 1) large amount of mold machining, uneven excess, and tool easy to break;

[0012] 2) high-precision signal wheel is mostly used for automotive interior parts, so the precision requirement is high, and the existing machining method cannot guarantee the precision.

[0013] Therefore, in order to solve the above problems, it is necessary to provide a signal wheel hard machining method with reasonable machining method and high machining precision. SUMMARY

[0014] The purpose of the present application is to solve the problems existing in the prior art, and to provide a high-precision signal wheel hard machining method; the technical scheme is as follows:

[0015] A high-precision signal wheel hard machining method, comprising the following steps in sequence: rough machining, contour machining, residual material machining, face cutting machining and projection machining;

[0016] ​The rough machining adopts electrode discharge machining and milling rough machining; the contour whole machining performs semi-finishing machining on the workpiece; the residual material machining performs machining on the gear groove; the surface cutting machining directionally removes the residual material at the R corner; and the projection machining divides the whole tool path into two parts and uses two tools to perform machining.

[0017] Further, the rough machining step is performed by electrode, and after machining, milling is performed, the milling amount is reduced, and when milling, a ball cutter with a cutter diameter D of 1mm and a blade R angle of 0.5mm is used to perform rough milling, and the rotating speed is set to 30000 revolutions / MIN, the feeding speed is 1500MM / MIN, and the feeding amount is 0.05mm.

[0018] Further, the contour whole machining refers to semi-finishing machining on the workpiece, the whole tool path is divided into two parts for machining, and the machining is repeated once to ensure the allowance.

[0019] Further, the diameter D of the cutter used in the contour whole machining is 1mm, the blade R angle is 0.5mm, the rotating speed is set to 30000 revolutions / MIN, the feeding speed is 1500MM / MIN, and the feeding amount is 0.02mm.

[0020] Further, the residual material machining uses a ball cutter with a cutter diameter of 0.6mm and a blade R angle of 0.3mm to clean the R corner, so that there is no residual material at the gear groove; and the cutter rotating speed is set to 40000 revolutions / MIN, the feeding speed is set to 1000MM / MIN, and the feeding amount is set to 0.02mm.

[0021] Further, in the residual material machining, the machining number is at least twice, and the groove is independently machined with a tool path, an R0.2 ball cutter is used, and the R arc is machined in place.

[0022] Further, the surface cutting machining directionally removes the residual material at the R corner, and the diameter of the cutter used in the surface cutting machining is 0.4mm, the blade R angle is 0.2mm, the rotating speed is 40000 revolutions / MIN, the feeding speed is 720MM / MIN, and the feeding amount is 0.02mm.

[0023] Further, the projection machining divides the tool path into two parts, the tool path is refined, the mold surface roughness is improved, and the projection machining step selects two CBN tools to perform projection shaping, the cutter diameter is set to 0.4mm, the blade R angle is set to 0.2mm, the rotating speed is set to 40000 revolutions / MIN, the feeding speed is 650MM / MIN, and the feeding amount is 0.01mm.

[0024] Beneficial effects: The present application has the following beneficial effects:

[0025] 1) The present application adopts the steps of rough machining, contour whole machining, residual material machining, surface cutting machining and projection machining, compared with the traditional technology, the steps of contour whole machining, surface cutting machining and projection machining are added, which can effectively improve the machining quality and machining efficiency;

[0026] 2) The electrode is used for rough machining in the present application, and then milling is carried out, so that the processing amount of milling is reduced, and the corner can be machined by selecting ball cutter processing, so that the uniform allowance is ensured;

[0027] 3) The contour whole machining is used for fine machining in the present application, so that the surface is free of tool marks and the allowance is uniform; R0.2 ball cutter is used for directional removal of R corner residual material;

[0028] 4) The projection machining divides the tool path into two parts, the tool path is refined, the mold surface roughness is improved, two CBN cutters are selected for final shaping, the cutter wear is reduced, and the shape precision is ensured; and the size manufacturing precision is effectively improved through data analysis. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 It is a structure diagram of the high-precision signal wheel mold of the present application;

[0030] Figure 2 It is a tooth body structure diagram in the high-precision signal wheel mold of the present application;

[0031] Figure 3 It is Figure 2 the enlarged view of A in the figure;

[0032] Figure 4 It is a process flow chart of the prior art;

[0033] Figure 5 It is a process flow chart of the present application;

[0034] Figure 6 It is a rough machining tool path diagram;

[0035] Figure 7 It is a rough machining entity display diagram.

[0036] Figure 8 It is a contour whole machining tool path diagram;

[0037] Figure 9 It is a contour whole machining entity display diagram;

[0038] Figure 10 It is a residual material machining tool path diagram;

[0039] Figure 11 It is a residual material cleaning schematic diagram;

[0040] Figure 12It is a projection processing schematic diagram in the present application.

[0041] Figure 13 It is a projection processing schematic diagram in the present application. DETAILED DESCRIPTION

[0042] The present application will be further illustrated below in combination with the drawings and specific embodiments. The embodiments are implemented on the premise of the technical scheme of the present application, and it should be understood that the embodiments are only used for illustrating the present application and not for limiting the scope of the present application.

[0043] As shown in Figure 1 , Figure 2 , Figure 3 and Figure 5 , a high-precision signal wheel hard machining method comprises the following steps in sequence: rough machining, contour whole machining, residual material machining, surface cutting machining and projection machining;

[0044] The rough machining adopts electrode discharge machining and milling rough machining; the contour whole machining performs semi-finishing machining on the workpiece; the residual material machining performs machining on the gear groove; the surface cutting machining removes residual material at the R corner; the projection machining is divided into two parts and uses two tools for machining.

[0045] As shown in Figure 6 and Figure 7 , the rough machining step is processed by electrode, and after processing, milling is performed to reduce the milling processing amount, and a ball cutter with a cutter diameter D of 1 mm and a blade R angle of 0.5 mm is used for rough milling, and the rotation speed is set to 30000 revolutions / MIN, the feed speed is 1500 MM / MIN, and the feed amount is 0.05 mm.

[0046] As shown in Figure 8 and Figure 9 , the contour whole machining refers to semi-finishing machining on the workpiece, and the whole tool path is divided into two parts for machining, and the machining is repeated once to ensure uniform allowance.

[0047] The diameter D of the cutter used in the contour whole machining is 1 mm, the blade R angle is 0.5 mm, and the rotation speed is set to 30000 revolutions / MIN, the feed speed is 1500 MM / MIN, and the feed amount is 0.02 mm.

[0048] As shown in Figure 10 and Figure 11 , the residual material machining uses a ball cutter with a cutter diameter of 0.6 mm and a blade R angle of 0.3 mm to clean the R corner, so that there is no residual material at the gear groove; and the cutter rotation speed is set to 40000 revolutions / MIN, the feed speed is set to 1000 MM / MIN, and the feed amount is set to 0.02 mm.

[0049] In the residual material processing, the processing times are at least twice, and the groove is independently processed by setting the tool path, using R0.2 ball cutter tool, and R arc processing is in place.

[0050] The R angle residual material is removed by surface cutting processing, and the diameter of the cutter used in the surface cutting processing is 0.4 mm, the blade R angle is 0.2 mm, the rotating speed is 40000 revolutions / MIN, the feeding speed is 720 MM / MIN, and the feeding amount is 0.02 mm.

[0051] As shown in Figure 12 and Figure 13 The projection processing divides the tool path into two parts, the fine and dense tool path, and improves the mold surface roughness, and the projection processing step selects two CBN tools for projection shaping, and the cutter diameter is set to 0.4 mm, the blade R angle is set to 0.2 mm, the rotating speed is set to 40000 revolutions / MIN, the feeding speed is 650 MM / MIN, and the feeding amount is 0.01 mm

[0052] Compared with the traditional technology, the steps of contour processing, surface cutting processing and projection processing are added, which can effectively improve the processing quality and processing efficiency.

[0053] The rough machining in the application uses an electrode for rough machining, and then milling, which reduces the processing amount of milling, and selects a ball cutter for processing, which can process the corner and ensure uniform allowance.

[0054] The finish machining in the application uses contour processing for finish machining, which ensures that the surface is free of tool marks and the allowance is uniform; and R0.2 ball cutter is used for directional removal of R angle residual material.

[0055] The projection processing in the application divides the tool path into two parts, the fine and dense tool path, and improves the mold surface roughness, and selects two CBN tools for final shaping, which reduces tool wear and ensures shape accuracy; and through data analysis, the size manufacturing precision is effectively improved.

[0056] The above specific embodiments are only a preferred embodiment of the application, and are not intended to limit the implementation and scope of claims of the application, and any equivalent changes and modifications made according to the scope of the application patent protection shall be included in the scope of the application patent application.

Claims

1. A method for hard machining a high-precision signal wheel, characterized in that: The steps are as follows: Rough machining, contour line machining, residual material machining, surface cutting machining, and projection machining; The roughing process employs electrode discharge machining and milling roughing; the contour line machining performs semi-finishing on the workpiece; the residual material machining processes the gear grooves; the face cutting process removes residual material at the radius corners; and the projection machining divides the overall toolpath into two parts, using two tools for machining. The roughing step is performed by electrodes, followed by milling to reduce the amount of milling work. During milling, a ball end mill with a tool diameter D of 1 mm and a cutting edge R angle of 0.5 mm is used for rough milling, with the rotation speed set to 30,000 rpm, the feed rate to 1,500 mm / min, and the feed amount to 0.05 mm. The tool used for machining the entire contour line has a diameter D of 1mm, a cutting edge R angle of 0.5mm, a rotation speed of 30,000 rpm, a feed rate of 1,500 mm / min, and a feed amount of 0.02mm. The residual material processing uses a ball end mill with a cutting edge radius of 0.3mm and a cutting edge radius of 0.6mm to clean the radius of radius, so that there is no residual material in the gear groove; and the cutting speed is set to 40,000 rpm, the feed rate is set to 1,000 mm / min, and the feed amount is set to 0.02mm. The aforementioned face cutting process is used to remove residual material at the radius (R) corner. The diameter of the tool used in the face cutting process is 0.4 mm, the radius (R) corner of the cutting edge is 0.2 mm, the rotation speed is 40,000 rpm, the feed rate is 720 mm / min, and the feed amount is 0.02 mm. The projection machining process divides the toolpath into two parts, refines the toolpath, and improves the surface roughness of the mold. The projection machining step uses two CBN tools for projection shaping, with the tool diameter set to 0.4mm, the cutting edge radius set to 0.2mm, the rotation speed set to 40,000 rpm, the feed rate set to 650mm / min, and the feed amount set to 0.01mm.

2. The high-precision signal wheel hard machining method according to claim 1, characterized in that: The aforementioned contour line machining refers to semi-finishing the workpiece by dividing the overall toolpath into two parts for machining and repeating the machining once to ensure uniform allowance.

3. The high-precision signal wheel hard machining method according to claim 1, characterized in that: In the aforementioned residual material processing, the processing times are at least two, and the groove is set as an independent processing toolpath, using an R0.2 ball end mill, and the R arc is processed to the desired position.

Images