A processing method of 170 supercharger ZB axial bearing

Abstract

This invention relates to the field of turbocharger manufacturing technology, specifically to a machining method for a ZB axial bearing of a 170 turbocharger. The method involves a fitter marking the workpiece's center line and aligning it accordingly, followed by milling oil grooves and drilling. The machined inner hole is used to position the ZB axial bearing workpiece, and milling and drilling are performed again, followed by deburring. A three-jaw chuck is used to hold the large outer diameter of the ZB axial bearing workpiece, and a first finishing turn is performed, finishing the two semi-finished end faces. A second finishing turn is performed, clamping the two end faces from the first finishing turn, aligning them, and then finishing the outline of the part's large shape. The workpiece is then aligned, followed by a third finishing turn. After milling the inclined grooves and drilling, an additional finishing turn is added, requiring the positioning and clamping surfaces of the finishing tool to have a parallelism within 0.004mm, effectively solving the deformation problem caused by milling and drilling on the positioning and clamping surfaces.

Description

Technical Field

[0001] This invention relates to the field of turbocharger manufacturing technology, and in particular to a method for machining a ZB axial bearing for a 170 turbocharger. Background Technology

[0002] The 170 turbocharger is an internally supported, sliding bearing, radial-flow turbocharger. The ZB axial bearing is a crucial component of this type of turbocharger, possessing several key characteristics. It supports the turbine shaft rotor assembly, protects the rotating support components, and transmits loads. It also plays a vital role in the overall system's operational stability. The ZB axial bearing is located between the compressor impeller and the bearing housing. Parts that mate with it include: the compressor housing, the sealing bushing (an important component), the support bearing (an important component), and the bearing housing (an important component). The ZB axial bearing passes through the turbine shaft and mates with the outer diameter of the sealing bushing. The pin hole on the bearing body connects and is fixed to the pin hole on the bearing housing via a locating pin. Its inner hole mates with the outer diameter of the support bearing, and the end face of the ZB axial bearing is flush with the end face of the bearing housing. The machining process for the ZB axial bearing involves rough turning to remove excess material from the bar stock, milling the slanted groove, turning the outer locating surface, drilling and milling the groove, finish turning the outer shape, finish turning the groove and bottom, and drilling and milling the oil wedge. Chemical composition analysis of the ZB axial bearing material CuZn40Al2 reveals the following: copper content is 57%-60%, indicating good ductility and deformation resistance superior to aluminum but significantly lower than steel and iron; aluminum content is 2.5%-3.5%, enhancing the strength, hardness, and corrosion resistance of the copper alloy; nickel content is 2%-3%, providing good ductility; it also contains less than 0.5% iron, less than 0.1% lead, less than 0.9% impurities, and the remainder is zinc, which also exhibits good ductility. In summary, this ZB axial bearing material possesses good ductility and relatively high hardness among copper alloys, but significantly lower than that of steel-based materials.

[0003] The large end face is used for positioning, and the small end face is used for clamping. Because the parallelism between the large and small end faces is poor, and because runout is required for alignment, the small end face is pressed firmly, causing plastic deformation. Therefore, during finish machining, the small end face is used as the starting point for machining. Axial dimension (machined to intermediate tolerances). Measured under clamping condition on the machine tool. The dimensions were inspected and found to be acceptable.

[0004] However, in the aforementioned prior art, during the final machining process, after removing the tooling pressure plate, the dimensional deviation will be out of tolerance when measured again. Furthermore, since the dimensional boundary is two planes, there is still an unstable deviation after measuring multiple points. Summary of the Invention

[0005] The purpose of this invention is to provide a machining method for the ZB axial bearing of a 170 turbocharger, which solves the problem in the prior art that when the tooling pressure plate is removed during the final precision machining process, the dimensions will be out of tolerance when measured again, and the problem that the dimensional boundary is two planes, and the measurement of multiple points will still result in unstable out-of-tolerance conditions.

[0006] To achieve the above objectives, the present invention provides a method for machining the ZB axial bearing of a 170 turbocharger, comprising the following steps:

[0007] Rough turning is performed on the ZB axial bearing workpiece to remove most of the allowance;

[0008] The ZB axial bearing workpiece is subjected to two and a half precision turning processes to produce two end faces.

[0009] The ZB axial bearing workpiece is machined with a slanted groove.

[0010] The fitter marks the center line of the workpiece, aligns it according to the center line, and then performs milling of oil grooves and drilling.

[0011] The machined inner hole is used to position the ZB axial bearing workpiece, and milling and drilling are performed again, followed by removal of milling burrs;

[0012] The outer diameter of the ZB axial bearing workpiece is held by a three-jaw chuck, and then the workpiece is subjected to the first precision turning. The two end faces that were semi-finished are then precision turned.

[0013] A second precision turning process is performed, where the two end faces from the first precision turning are clamped, aligned, and then the outline of the part's overall shape is precision turned.

[0014] The workpiece is aligned, and then a third precision turning process is performed.

[0015] Five-axis machining equipment is used to perform drilling and milling of oil wedges, followed by deburring and cleaning of the workpiece;

[0016] The workpiece is inspected for surface cracks. The workpiece is removed from the fixture, the clamping force is released, the dimensions are checked, and the inspection is qualified.

[0017] In the rough turning of the ZB axial bearing workpiece:

[0018] First, clamp the outer diameter and use a CA6140 conventional lathe to remove most of the excess material. The spindle speed is 400 r / min and the feed is 2 mm.

[0019] Then, a standard CA6140 lathe was used to drill and turn through holes, turn the outer diameter and stepped holes, and then cut off the holes. The spindle speed was 400 r / min and the feed was 2 mm.

[0020] In the ZB axial bearing workpiece, two and a half precision turning processes are performed:

[0021] First, a QTN200 CNC lathe is used to machine the inner holes and end faces. For the inner holes with high tolerance requirements and the end faces with high form and position requirements, allowances are left. The inner holes are left with a 0.5mm allowance and the end faces are left with a 0.2mm allowance. The speed is 800r / min and the feed rate is 0.1~0.2mm. A 55° cutting tool is used for machining.

[0022] Then, a QTN200 CNC lathe was used to machine the two end faces and the inner hole. The inner hole was machined to the required depth, and a 0.2mm allowance was left on the two end faces. The speed was 800r / min, the feed rate was 0.1~0.2mm, and a 55° cutting tool was used for machining.

[0023] In the milling of inclined grooves on ZB axial bearing workpieces:

[0024] Using a five-axis machining center C42U, three 45° oblique notches were machined by milling the oblique groove at a speed of 1000 r / min and a depth of cut of 5 mm. A Φ10 end mill was used to remove the large allowance, and then a Φ6 ball end mill was used to mill the root R3 shape.

[0025] In the process of the fitter marking the workpiece's center line, aligning the workpiece according to the center line, and then performing milling of the oil groove and drilling:

[0026] The fitter uses a scribing tool to draw the center line of the workpiece for subsequent alignment; a five-axis machining center C42U is used to mill notches, drill and ream holes, and mill oil grooves to the drawing requirements (milling oil grooves of the shape shown in the drawing with dimensions R2, R3, R1, 1.5, R0.4, 1.5, 6°, and R1.5), with a milling depth of 3mm and a spindle speed of 1000r / min. Φ4.1 and Φ4.8 drill bits are used to machine the bottom hole, and a 5H7 reamer is used to ream the Φ5 hole for subsequent positioning;

[0027] Using a bench drill, model Z3032, drill a radial Φ2.4 hole with a depth of cut of 2mm, and drill a Φ2.85 hole with a depth of cut of 2mm;

[0028] Remove the burrs at the intersection of the Φ4 and Φ2.4 holes, then clean the parts to remove oil and impurities. Finally, use a steel ball pressing tool (model 170Q-05) to press the Φ3 steel ball into the Φ2.85 hole.

[0029] In the process of positioning the ZB axial bearing workpiece using the machined inner hole, performing milling and drilling again, and then removing milling burrs:

[0030] Using the aforementioned Φ5 hole for positioning, a 170X-08 milling tool is used to machine a 6mm wide and 7.7mm deep groove with a Φ6 end mill, a feed rate of 3mm, and a speed of 600r / min. Then, the milling burrs are removed.

[0031] In the process of using a three-jaw chuck to hold the outer diameter of the ZB axial bearing workpiece, and then performing the first finish turning of the workpiece, the two end faces that have undergone semi-finish turning are then finished:

[0032] Using a QTN200 CNC lathe, the two end faces with a size of 6.3mm in the semi-finish turning process are machined by 0.05mm to ensure that the parallelism between the two machined surfaces is within 0.004. 55° finish turning inserts are used, and the spindle speed is 800r / min.

[0033] In the second finishing process, the two end faces from the first finishing process are clamped, aligned, and then the overall outline of the part is finished.

[0034] The CNC lathe model is QTN200, the workpiece loading tool is 170C-15, the two end faces machined in the first precision turning are clamped, and after alignment, the outline of the workpiece is precision turned. A 55° cutting tool is used and the spindle speed is 800 r / min.

[0035] In the process of aligning the workpiece and then performing the third precision turning:

[0036] The CNC lathe model is QTN200, and the workpiece loading tool is 170C-16. After the end face of the alignment fixture has runout, place the workpiece and press the end face pressure plate. When the outer circle of the aligned workpiece runs out, press the outer pressure plate again and remove the end face pressure plate. Perform precision machining as required, and machine each end face to the required dimensions.

[0037] In the process of using a five-axis machining center to perform drilling and milling of oil wedges, followed by deburring and cleaning of the workpiece:

[0038] The five-axis machining equipment C42U was used to re-drill a Φ5 hole to Φ6, with a depth of cut of 2mm and a speed of 1000r / min. The oil wedge was milled using a milling cutter at a speed of 1200r / min.

[0039] Perform chamfering R1 and clean the parts.

[0040] This invention discloses a machining method for a ZB axial bearing in a 170 turbocharger. The method involves rough turning the ZB axial bearing workpiece to remove most of the excess material; performing two semi-finish turning operations to machine two end faces; milling inclined grooves on the ZB axial bearing workpiece; marking the workpiece's center line by a fitter, and simultaneously aligning the workpiece according to the center line, followed by milling oil grooves and drilling; using the machined inner hole to position the ZB axial bearing workpiece, and then performing milling and drilling again, followed by removing milling burrs; using a three-jaw chuck to hold the large outer diameter of the ZB axial bearing workpiece, and then performing the first finish turning operation on the two semi-finish turned end faces. The process involves: precision turning; a second precision turning, where the two ends of the first precision turning are clamped and aligned to create the outline of the part; workpiece alignment followed by a third precision turning; drilling and milling of oil wedges using a five-axis machining center, followed by deburring and cleaning; surface crack inspection of the workpiece, removal of the workpiece from the fixture, release of clamping force, dimensional inspection, and acceptance of the workpiece. After milling the inclined groove and drilling, an additional precision turning process is added, where the positioning and clamping surfaces of the precision turning tool are required to have a parallelism of less than 0.004, effectively solving the deformation problem caused by milling the inclined groove and drilling to the positioning and clamping surfaces. Attached Figure Description

[0041] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0042] Figure 1 This is a flowchart of the processing method for the ZB axial bearing of the 170 turbocharger of the present invention.

[0043] Figure 2 This is a schematic diagram of the structure of 170C-15 of the present invention.

[0044] Figure 3 This is a schematic diagram of the structure of 170C-16 of the present invention.

[0045] 1-ZB axial bearing workpiece, 2-170C-15, 3-170C-16, 4-quick release washer, 5-tooling pressure plate. Detailed Implementation

[0046] The embodiments of the present invention are described in detail below. Examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, but should not be construed as limiting the present invention.

[0047] Please see Figures 1 to 3 This invention provides a method for machining the ZB axial bearing of a 170 turbocharger, comprising the following steps:

[0048] S1: Rough turn ZB axial bearing workpiece 1 to remove most of the allowance;

[0049] S2: Perform two semi-finish turning operations on ZB axial bearing workpiece 1 to machine two end faces;

[0050] S3: Perform milling of inclined grooves on ZB axial bearing workpiece 1;

[0051] S4: The fitter marks the center line of the workpiece, aligns it according to the center line, and then performs milling of oil grooves and drilling.

[0052] S5: Use the machined inner hole to position the ZB axial bearing workpiece 1, and then perform milling and drilling again, and remove the milling burrs.

[0053] S6: Use a three-jaw chuck to hold the outer diameter of the ZB axial bearing workpiece 1, and then perform the first precision turning of the workpiece, and perform precision turning on the two end faces that have been semi-finished.

[0054] S7: Perform a second precision turning process. Clamp the two ends of the first precision turning process, align them, and then precision turn out the outline of the large shape of the part.

[0055] S8: Align the workpiece and then perform a third precision turning.

[0056] S9: Use a five-axis machining center to perform drilling and milling of oil wedges, then remove burrs and clean the workpiece;

[0057] S10: Inspect the surface cracks of the workpiece, remove the workpiece from the fixture, release the clamping force, check the dimensions, and the inspection is qualified.

[0058] When using the machining method of the ZB axial bearing of the 170 turbocharger in this embodiment, the ZB axial bearing workpiece 1 is rough machined to remove most of the allowance.

[0059] The ZB axial bearing workpiece 1 is subjected to two and a half precision turning operations to produce two end faces;

[0060] The ZB axial bearing workpiece 1 is machined with a slanted groove.

[0061] The fitter marks the center line of the workpiece, aligns it according to the center line at the same time, and then processes the oil groove milling and drilling; locates the ZB axial bearing workpiece 1 by using the machined inner hole, and processes the groove milling and drilling again, and then removes the milling burrs; uses a three-jaw chuck to hold the large outer circle of the ZB axial bearing workpiece 1, and then performs the first precision turning process on the workpiece, and performs precision turning on the two end faces of the semi-precision turning process; performs the second precision turning process, holds the two end faces of the first precision turning process, and after alignment, precision turns the contour of the large outer shape of the part; performs alignment of the workpiece, and then performs the third precision turning process; uses a five-axis machining equipment to perform drilling and oil wedge milling, and then removes the burrs and cleans the workpiece; performs surface crack inspection on the workpiece, removes the workpiece from the fixture, cancels the clamping force, inspects the dimensions, and the inspection is qualified;

[0062] After the inclined groove milling and drilling are completed, an additional precision turning process is added to precision turn the positioning and clamping surfaces required by the tool. The requirement is that the parallelism between the two surfaces is within 0.004, effectively solving the deformation problem of the positioning and clamping surfaces caused by the inclined groove milling and drilling; in the second precision turning process, the parallelism between the positioning surface and the clamping surface is within 0.004, and the clamping force is evenly distributed on the contact surface. After the precision turning is completed, when the quick-release washer 4 is removed, the influence of the clamping surface's springback on the large and small end faces is tiny, ensuring that the parallelism between the large and small end faces is relatively good. In the third precision turning process, due to the relatively good parallelism between the large and small end faces, the clamping force is evenly distributed on the small end face and the large end face, and the force on each surface and at each place is uniform, making the influence of the clamping surface's springback on the large and small end faces tiny, and the influence on the dimensions is tiny. After aligning the small end face and the outer circle, precision turn according to the attached drawing. After the processing is completed, remove the part from the fixture, cancel the clamping force, and inspect the dimensions The inspection is qualified.

[0063] The above disclosure is only one or more preferred embodiments of the present application, and cannot be used to limit the scope of rights of the present application. Those of ordinary skill in the art can understand the entire or partial processes of implementing the above embodiments, and the equivalent changes made according to the claims of the present application still fall within the scope covered by the present application.

Claims

1. A method for machining the ZB axial bearing of a 170 turbocharger, characterized in that, Includes the following steps: Rough turning is performed on the ZB axial bearing workpiece to remove most of the excess material; The ZB axial bearing workpiece is subjected to two and a half precision turning processes to produce two end faces. The ZB axial bearing workpiece is machined with a slanted groove. The fitter marks the center line of the ZB axial bearing workpiece, aligns it according to the center line, and then performs milling of the oil groove and drilling. The ZB axial bearing workpiece is positioned by using the machined holes, and the oil groove is milled and drilled again, and then the milling burrs are removed. The outer diameter of the ZB axial bearing workpiece is held by a three-jaw chuck, and then the first precision turning of the ZB axial bearing workpiece is performed. The two end faces that were semi-finished are then precision turned. A second precision turning process is performed, where the two end faces from the first precision turning are clamped, aligned, and then the outline of the large outer shape of the part is precision turned. Align the ZB axial bearing workpiece and then perform a third precision turning. Five-axis machining equipment is used to perform drilling and milling of oil wedges, then deburring and cleaning of ZB axial bearing workpieces; The ZB axial bearing workpiece was inspected for surface cracks. The ZB axial bearing workpiece was removed from the tooling, the clamping force was released, the dimensions were inspected, and the inspection was qualified.

2. The machining method of the ZB axial bearing for the 170 turbocharger as described in claim 1, characterized in that, During rough turning of ZB axial bearing workpiece: First, clamp the outer diameter and remove most of the excess material using a CA6140 conventional lathe with a spindle speed of 400 r / min and a feed rate of 2 mm. Then, using a CA6140 conventional lathe, the outer diameter and stepped hole are machined, and then cut off. The spindle speed is 400 r / min and the feed is 2 mm.

3. The machining method of the ZB axial bearing for the 170 turbocharger as described in claim 2, characterized in that, In the two-and-a-half finishing process of the ZB axial bearing workpiece: First, a QTN200 CNC lathe is used to machine the inner holes and end faces. For the inner holes with high tolerance requirements and the end faces with high form and position requirements, allowances are left. The inner holes are left with a 0.5mm allowance and the end faces are left with a 0.2mm allowance. The speed is 800r / min and the feed rate is 0.1~0.2mm. A 55° cutting tool is used for machining. Then, a QTN200 CNC lathe was used to machine the two end faces and the inner hole. The inner hole was machined to the required depth, and the two end faces were left with a allowance of 0.2mm. The speed was 800r / min, the feed rate was 0.1~0.2mm, and a 55° cutting tool was used for machining.

4. The machining method of the ZB axial bearing for the 170 turbocharger as described in claim 3, characterized in that, In the milling of inclined grooves on ZB axial bearing workpieces: Using a five-axis machining center C42U, three 45° oblique notches were machined by milling the oblique groove at a speed of 1000 r / min and a depth of cut of 5 mm. A Φ10 mm end mill was used to remove the large allowance, and then a Φ6 mm ball end mill was used to mill the root R3 mm shape.

5. The machining method of the ZB axial bearing of the 170 turbocharger as described in claim 4, characterized in that, In the steps of the fitter marking the center line of the ZB axial bearing workpiece, aligning it according to the center line, and then performing milling of the oil groove and drilling: The fitter used a scribing tool to draw the center line of the ZB axial bearing workpiece for subsequent alignment; a five-axis machining center C42U was used to mill notches, drill and ream holes, and mill oil grooves to the drawing requirements. Oil grooves of the shape shown in the drawing were milled with dimensions R2mm, R3mm, R1mm, a first 1.5mm straight groove section, R0.4mm, a second 1.5mm straight groove section, a 6° inclined surface, and R1.5mm. The milling depth was 3mm, and the speed was 1000r / min. The bottom hole was machined using Φ4.1mm and Φ4.8mm drill bits, and the Φ5mm H7 reamer was used to ream the Φ5mm hole for subsequent positioning. Using a bench drill, drill a radial Φ2.4mm hole with a depth of cut of 2mm, and drill a Φ2.85mm hole with a depth of cut of 2mm; Remove burrs from the intersection of the Φ4mm and Φ2.4mm holes, then clean the parts to remove oil and impurities. Finally, use a steel ball pressing tool (model 170Q-05) to press a Φ3mm steel ball into the Φ2.85mm hole.

6. The machining method of the ZB axial bearing of the 170 turbocharger as described in claim 5, characterized in that, In the steps of positioning the ZB axial bearing workpiece using the machined drill holes, and then performing milling of the oil groove and drilling again, followed by deburring: Using the aforementioned Φ5mm hole for positioning, a 170X-08 milling tool is used to machine a 6mm wide and 7.7mm deep groove with a Φ6mm end mill, a feed rate of 3mm, and a spindle speed of 600r / min. Then, the milling burrs are removed.

7. The machining method of the ZB axial bearing for the 170 turbocharger as described in claim 6, characterized in that, In the process of using a three-jaw chuck to hold the large outer diameter of the ZB axial bearing workpiece, and then performing the first finish turning of the ZB axial bearing workpiece, the two end faces that have been semi-finish turned are then finish turned: Using a QTN200 CNC lathe, the two end faces with a size of 6.3mm in the semi-finish turning process are machined by 0.05mm to ensure that the parallelism between the two machined surfaces is within 0.

004. 55° finish turning inserts are used, and the spindle speed is 800r / min.

8. The machining method of the ZB axial bearing of the 170 turbocharger as described in claim 7, characterized in that, In the second finishing process, the two end faces from the first finishing process are clamped, aligned, and then the overall outline of the part is finished. The CNC lathe model is QTN200, and the tool for mounting the ZB axial bearing workpiece is 170C-15. The two end faces machined in the first precision turning are clamped and aligned. The overall outline of the ZB axial bearing workpiece is then precision turned using a 55° cutting tool and a spindle speed of 800 r / min.

9. The machining method of the ZB axial bearing for the 170 turbocharger as described in claim 8, characterized in that, In the process of aligning the ZB axial bearing workpiece and then performing the third precision turning: The CNC lathe model is QTN200, and the workpiece tool for the ZB axial bearing is 170C-16. After aligning the end face runout of the tooling, the ZB axial bearing workpiece is placed, and the end face pressure plate is pressed down. When the outer circle of the ZB axial bearing workpiece is aligned and runout is corrected, the outer pressure plate is pressed down again. The end face pressure plate is then removed, and the workpiece is precision machined as required. Each end face is machined to the required dimensions. The two end faces after the first precision machining are machined from 6.2mm to 5.9mm, with the machining allowances for both end faces being the same. The end face dimensions are machined to 4.1mm and 3.9mm, and the inner hole is machined to Φ60mm.

10. The machining method of the ZB axial bearing of the 170 turbocharger as described in claim 9, characterized in that, In the steps of drilling and milling oil wedges using a five-axis machining center, followed by deburring and cleaning of the ZB axial bearing workpiece: The five-axis machining equipment C42U was used to re-drill a Φ5mm hole to Φ6mm, with a depth of cut of 2mm and a speed of 1000r / min. The oil wedge was milled using a milling cutter at a speed of 1200r / min. Chamfer the surface by R1mm and clean the parts.

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