Machining clamp and machining process for new energy automobile water channel base plate type thin-wall part

Abstract

The invention discloses a machining fixture and a machining process of a new energy automobile water channel base plate type thin-wall part, a hydraulic fixture is designed according to the machining process requirement, it is guaranteed that the clamping and positioning precision of each time is reliable, and through reliable positioning, a 4mm turbulent flow cylindrical surface and an A reference water channel surface which are designed in a hollow mode are subjected to rough machining and finish machining procedures. The rough machining procedure is mainly used for removing the allowance of the A reference water channel surface and the turbulent flow cylindrical surface and effectively controlling the machining allowance of the finish machining procedure, and due to the fact that the middle of the 4-mm turbulent flow cylindrical surface is hollow and is not supported, the overall design rigidity is poor, and if the finish machining allowance is not well controlled when the surface is machined, the machining allowance can be effectively controlled. After the A reference water channel surface for supporting and positioning is processed, the clamp deforms in a loose state. According to the machining allowance design of the finish machining procedure, reliable positioning is achieved through a clamp, it is guaranteed that the machining allowance of the A datum plane water channel face and the turbulent flow cylindrical face is within 0.1 mm to 0.15 mm, and machining deformation of the water channel face is stably and reliably guaranteed.

Description

Technical Field

[0001] The present invention belongs to the technical field of CNC machining technology, and specifically relates to a machining fixture and a machining process for thin-walled parts such as waterway substrates of new energy vehicles, which solves the problem of machining deformation of thin-walled parts such as waterway substrates of new energy vehicles. Background Art

[0002] Since the spoiler cylinder of the waterway substrate of new energy vehicles plays a role in water transportation and cooling, the water flow needs to be strictly controlled, so machining is required. The spoiler cylinder is designed to have a wall thickness of only 4MM, and the overall design rigidity is insufficient. The existing traditional machining process is completed by two CNC machine tools and two sets of fixtures. The OP10 process first processes the A reference waterway surface, BC reference hole and other hole systems; the OP20 process uses the A reference and BC reference processed by OP10 as precise positioning to process the spoiler cylinder and the remaining hole systems. However, the defects caused by this processing technology are: due to the insufficient overall rigidity of the spoiler cylinder, the spoiler cylinder has a processing allowance of about 0.8 that needs to be removed. When processing this surface under tightening, there is a processing stress that cannot be completely released. After the spoiler cylinder is processed, when the fixture is loosened, the entire A reference waterway surface will be bent and deformed, which will affect the sealing of the waterway surface and the remaining dimensional accuracy requirements of the entire product.

[0003] The adverse effects caused by the existing processing technology are mainly reflected in the following aspects: 1. Due to the deformation of product processing, the A reference waterway surface is severely deformed, the CPK stability is only -0.59, and the first-time pass rate of mass-produced products is less than 30%, which is difficult to meet customer order requirements. Based on the processing, casting and labor costs of each piece of 5 yuan / piece, and the monthly output of 10,000 pieces, the monthly direct economic loss is 35,000 yuan / month, and the annual direct economic loss is 420,000 yuan / year. 2. Due to the lack of product rigidity, the blank needs to be subjected to T5 heat treatment to increase product rigidity during each production. Although the pass rate can be increased to more than 80%, the production cost is high, and the cost of each piece increases by 2 yuan. Based on the monthly output of 10,000 pieces, the monthly cost increases by 20,000 yuan / month, and the annual cost increases by at least 240,000 yuan / year. In addition, a new heat treatment equipment of 200,000 yuan is required, and the total cost increases by 440,000 yuan / year. 3. The processing efficiency and cycle time cannot meet the design requirements. Since the processing of the spoiler cylinder will deform the A reference positioning surface, in order to reduce the processing deformation caused by the large cutting force, the processing allowance of 0.8 for the processing of the spoiler cylinder needs to be produced by 6 cuts. The processing cycle is twice the cycle designed in the quotation. The processing efficiency is extremely low. According to this processing cycle, two CNC machine tools, two sets of fixtures and two sets of tools need to be reinvested, and the processing cost will increase by at least 800,000 yuan / year. In summary, the existing processing technology will bring at least 1.66 million yuan / year of direct economic losses, and will also bring serious product quality problems and vehicle safety problems. Summary of the invention

[0004] Purpose of the invention: In view of the problems existing in the above-mentioned existing processing technology, the present invention provides a processing fixture and processing technology of thin-walled parts such as waterway substrates of new energy vehicles. The specific CNC processing technology scheme is: 1. Two CNC machine tools are also used to process this waterway substrate; 2. The existing machining process and the existing machining fixture are improved.

[0005] Technical solution: A processing fixture for thin-walled parts such as waterway substrates of new energy vehicles, wherein the processing fixture is composed of two independent left-station fixtures and right-station fixtures, which are combined into a set of fixtures with left and right double stations through a set of 650*413mm fixture bottom plates;

[0006] The fixture bottom plate is used to support and fix all components on the fixture. By fixing the hard support base, the product can be reliably positioned each time it is clamped, ensuring that the deformation amount after each clamp is tightened and relaxed can be stably controlled;

[0007] The left station fixture is mainly composed of the following accessories: 3 vertical hard support bases, 3 auxiliary supports, four pressure plates and 3 horizontal side positioning surfaces;

[0008] The three vertical hard support bases are used to support the three blank reinforcement surfaces and serve as the three blank positioning reference surfaces for positioning the product;

[0009] The three auxiliary supports are used to increase the local rigidity of the reference waterway surface of product A. The product will be subjected to cutting force during the cutting process, eliminating the risk of insufficient local rigidity of the product due to the cutting force;

[0010] The four pressing plates are used to press the product, so that the product is reliably positioned and is not subject to vibration caused by cutting force during processing, thus ensuring that the roughing and deformation of the A reference waterway surface is reliable;

[0011] The three horizontal side positioning surfaces are used for horizontal limiting, and three gas detection holes are opened on the side. When the product is not clamped in place, gas leakage occurs in the gas detection holes, and the equipment will generate an alarm, which plays a role in ensuring the reliable positioning of the product each time;

[0012] The right station fixture is mainly composed of the following accessories: 10 hard support-like positioning bases, 6 auxiliary supports, four main clamping plates and 2 precision positioning pin seats;

[0013] The 10 similar hard support positioning surface bases enable the product to be reliably positioned on the A reference waterway surface each time it is clamped, ensuring that the deformation amount after each clamp is tightened and relaxed can be stably controlled;

[0014] The six similar auxiliary supports are used to increase the local rigidity of the spoiler cylinder of the product. The product will be subjected to cutting force during the cutting process, eliminating the risk of insufficient local rigidity of the product due to the cutting force.

[0015] The four similar main clamping plates are used to clamp the product, so that the product is reliably positioned and does not vibrate due to cutting force during processing, thus ensuring reliable roughing and deformation of the spoiler cylinder surface;

[0016] The two precision positioning pin seats are used for precise positioning in the horizontal direction. The center distance requirements of the positioning pin seats are 201.15+ / -0.015mm and 185.87+ / -0.015mm. They are used for precise positioning of the BC holes after product processing and for processing the remaining required size and position requirements.

[0017] As an optimization: the processing fixture is applied to the rough processing and finishing processes in the processing technology of thin-walled parts such as waterway substrates of new energy vehicles.

[0018] As an optimization: the fixture positioning method of the finishing process is exactly the same as the fixture positioning method of the roughing process, and is also divided into left-station fixtures and right-station fixtures.

[0019] As an optimization: the positioning of all components of the left station fixture of the finishing process is the same as the positioning of all components of the left station fixture of the fixture of the roughing process.

[0020] As an optimization: the positioning of all components of the right station fixture of the finishing process is the same as the positioning of all components of the right station fixture of the fixture of the roughing process.

[0021] A processing technology for thin-walled parts of a waterway substrate of a new energy vehicle, the processing technology consists of two main processing steps: a rough processing step and a fine processing step. Through precise fixture positioning, the processing allowance of the rough processing step and the fine processing step is guaranteed, thereby ensuring reliable processing deformation of a hollow spoiler cylinder, and finally ensuring stable deformation of an A reference positioning waterway surface used for positioning and processing the spoiler cylinder;

[0022] A. The rough machining process is composed of two stations: the left station and the right station:

[0023] The left station is mainly used for positioning the three blank reinforcement rib positioning surfaces and the three-point positioning of the blank side, completing the roughing of the A reference waterway surface and the processing of B and C holes, releasing the processing deformation stress after the roughing of the A reference waterway surface, and leaving a 0.15mm processing allowance for the finishing process;

[0024] The right station mainly completes the rough processing of the spoiler cylinder surface by positioning the rough-cut A reference waterway surface and BC hole, and also releases the processing deformation stress of the hollow-designed 4mm spoiler cylinder surface, leaving a 0.15mm processing allowance for the finishing process;

[0025] B. The finishing process described above consists of two stations: the left station and the right station:

[0026] The left station of the finishing process removes 0.15mm machining allowance of the A reference waterway surface by finishing to ensure reliable finishing deformation, and uses the B and C reference holes as subsequent fine positioning reference holes;

[0027] The right station of the finishing process uses the finished A reference surface waterway surface as the positioning reference surface, the BC reference hole as the positioning hole, and finishes the machining allowance of the 0.15mm spoiler cylinder surface to ensure reliable finishing deformation.

[0028] As an optimization: the left workstation in the rough machining process removes 0.6mm machining allowance of the A reference waterway surface through rough machining, releases the machining deformation stress, leaves 0.15mm finishing allowance for fine machining to ensure the finishing deformation amount, and uses the B and C reference holes as subsequent fine positioning reference holes.

[0029] As an optimization: the right station in the rough machining process uses the rough-cut A reference surface as the positioning reference surface, the BC reference hole as the positioning hole, and rough-cuts the spoiler cylinder with a 0.6mm machining allowance to release the machining deformation stress, leaving a 0.15mm machining allowance for fine machining to ensure the fine machining deformation amount.

[0030] Beneficial effects: The present invention discloses a processing technology for thin-walled parts of waterway substrates of new energy vehicles, and the specific beneficial effects are as follows:

[0031] 1. As the processing technology separates the roughing and finishing steps to remove the processing deformation stress, the processing deformation amount is stably guaranteed. After the A reference waterway surface is processed, the CPK stability is improved to 2.74, and the first-time qualified rate of mass-produced products is 100%, saving economic losses of 420,000 yuan per year.

[0032] 2. This process can save the blank T5 heat treatment process, reduce the investment in heat treatment equipment, and save economic losses of 440,000 yuan per year.

[0033] 3. This process is divided into rough machining and fine machining steps. The processing of the spoiler cylinder is changed from the original 6-cut processing to 1-cut rough and fine processing, which improves the efficiency to 1 times the original, reduces the investment in CNC equipment, and saves economic losses of 800,000 yuan.

[0034] In summary: the changed processing technology can save 1.66 million yuan in losses per year. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a schematic diagram of clamping a product at the left workstation and a schematic diagram of clamping a product at the right workstation of the present invention;

[0036] Figure 2 It is a product clamping and fixture positioning diagram for the rough machining process and the fine machining process of the present invention;

[0037] Figure 3 It is a schematic diagram of the processing of the A reference waterway surface and the BC reference hole of the present invention;

[0038] Figure 4 It is a schematic diagram of the processing of the spoiler cylinder of the present invention.

[0039] Figure 5 The A reference waterway substrate surface CPK stability chart of the present invention; DETAILED DESCRIPTION

[0040] The technical solutions in the embodiments of the present invention will be described clearly and completely below so that those skilled in the art can better understand the advantages and features of the present invention, thereby making a clearer definition of the protection scope of the present invention. The embodiments described in the present invention are only a part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in the field without creative work are within the scope of protection of the present invention.

[0041] Example

[0042] like Figure 1-4 As shown, a processing fixture for thin-walled parts such as waterway substrates of new energy vehicles is a processing fixture. The processing fixture is composed of two independent left-station fixtures and right-station fixtures, which are combined into a set of left and right double-station fixtures through a set of 650*413mm fixture bottom plates. The fixture bottom plate 1 is used to support and fix all components on the fixture. By fixing the hard support bases 2, 3, and 20, the product can be reliably clamped and positioned each time, ensuring that the deformation amount after each clamp is tightened and relaxed can be stably controlled.

[0043] The left station fixture is mainly composed of the following accessories: three vertical hard support bases 2, 3, 20, three auxiliary supports 19, 22, 26, four pressure plates 9, 10, 11, 12 and three horizontal side positioning surfaces 6, 7, 8. The three vertical hard support bases 2, 3, 20 are used to support the three blank reinforcement surfaces, which are used as the three blank positioning reference surfaces for positioning the product. The three auxiliary supports 22, 19, 26 are used to auxiliary support to increase the local rigidity of the product A reference waterway surface. The product will be subjected to cutting force during the cutting process, eliminating the risk of insufficient local rigidity of the product due to the cutting force. The four pressure plates 9, 10, 11, 12 are used to press the product so that the product is reliably positioned and is not subject to vibration caused by the cutting force during processing, ensuring that the A reference waterway surface is reliably roughened and deformed. The three horizontal side positioning surfaces 6, 7, and 8 are used for horizontal limiting. Three gas detection holes are opened on the side. When the product is not clamped in place, gas leakage occurs in the gas detection holes and the equipment will generate an alarm, which plays a role in ensuring reliable clamping and positioning of the product each time.

[0044] The right workstation fixture is mainly composed of the following accessories: 10 hard support positioning bases 28, 6 auxiliary supports 19, four main clamping plates 38 and 2 precision positioning pin seats 31, 32. The 10 hard support positioning surface bases 28 can reliably position the A reference waterway surface each time the product is clamped, ensuring that the deformation after each clamp clamping and relaxation can be stably controlled. The 6 auxiliary supports 19 are used to assist in increasing the local rigidity of the spoiler cylinder of the product. The product will be subjected to cutting force during the cutting process, eliminating the risk of insufficient local rigidity of the product due to the cutting force. The 4 main clamping plates 38 are used to clamp the product, so that the product is reliably positioned and is not subject to vibration caused by the cutting force during processing, ensuring that the roughing and deformation of the spoiler cylinder is reliable. The two precision positioning pin seats 31 and 32 are used for precise positioning in the horizontal direction. The center distance size requirements of the positioning pin seats are 201.15+ / -0.015mm and 185.87+ / -0.015mm. They are used for precise positioning of the BC holes after product processing and for processing the remaining required size and position requirements.

[0045] In this embodiment, the processing fixture is applied to the rough processing process and the fine processing process in the processing technology of thin-walled parts such as waterway substrates of new energy vehicles. The fixture positioning method of the fine processing process is exactly the same as the fixture positioning method of the rough processing process, and is also divided into a left station fixture and a right station fixture. The positioning of all components of the left station fixture of the fine processing process is the same as the positioning of all components of the left station fixture of the fixture of the rough processing process. The positioning of all components of the right station fixture of the fine processing process is the same as the positioning of all components of the right station fixture of the fixture of the rough processing process.

[0046] A processing technology for thin-walled parts such as waterway substrates of new energy vehicles, the processing technology consists of two main processing steps: a rough processing step and a fine processing step. Through precise fixture positioning, the processing allowances of the rough processing step and the fine processing step are guaranteed, thereby ensuring reliable processing deformation of a hollow spoiler cylinder, and finally ensuring stable deformation of an A reference positioning waterway surface used for positioning and processing the spoiler cylinder.

[0047] A. The rough machining process is composed of two stations: the left station and the right station:

[0048] The left station is mainly used for positioning the three blank reinforcement rib positioning surfaces and the three-point positioning of the blank side, completing the roughing of the A reference waterway surface and the processing of B and C holes, releasing the processing deformation stress after the roughing of the A reference waterway surface, and leaving a 0.15mm processing allowance for the finishing process;

[0049] The right workstation mainly completes the rough processing of the spoiler cylinder by positioning the A reference waterway surface and BC holes after rough processing, and also releases the processing deformation stress of the 4mm spoiler cylinder with a hollow design, leaving a 0.15mm processing allowance for the finishing process.

[0050] B. The finishing process described above consists of two stations: the left station and the right station:

[0051] The left station of the finishing process removes 0.15mm machining allowance of the A reference waterway surface by finishing to ensure reliable finishing deformation, and uses the B and C reference holes as subsequent fine positioning reference holes;

[0052] The right station of the finishing process uses the finished A reference surface waterway surface as the positioning reference surface, the BC reference hole as the positioning hole, and finishes the machining allowance of the 0.15mm spoiler cylinder surface to ensure reliable finishing deformation.

[0053] In this embodiment, the left workstation in the rough machining process removes 0.6mm machining allowance of the A reference waterway surface through rough machining, releases the machining deformation stress, and leaves 0.15mm finishing allowance for fine machining to ensure the finishing deformation amount, and uses the B and C reference holes as subsequent fine positioning reference holes.

[0054] The right station in the rough machining process uses the rough-cut A reference surface as the positioning reference surface, the BC reference hole as the positioning hole, and rough-cuts the spoiler cylinder with a 0.6mm machining allowance to release the machining deformation stress, leaving a 0.15mm machining allowance for fine machining to ensure the fine machining deformation amount.

[0055] like Figure 5As shown, the processing technology of the present invention can effectively solve the problem that the hollow spoiler cylinder surface is not rigid enough, which leads to the deformation of the reference waterway surface after processing, and can be mass-produced. The split processing steps can ensure that the deformation trend of the product processing remains stable.

Claims

1. A processing fixture for thin-walled parts such as waterway substrates of new energy vehicles, characterized by: The processing fixture is composed of two independent left-station fixtures and right-station fixtures, which are combined into a set of fixtures with left and right double stations through a set of 650*413mm fixture base plates (1); The clamp bottom plate (1) is used to support and fix all components on the clamp. By fixing the hard support base (2, 3, 20), the product can be reliably positioned each time it is clamped, ensuring that the deformation amount after each clamp is tightened and relaxed can be stably controlled. The left work station fixture is mainly composed of the following accessories: three vertical hard support bases (2, 3, 20), three auxiliary supports (19, 22, 26), four pressing plates (9, 10, 11, 12) and three horizontal side positioning surfaces (6, 7, 8); The three vertical hard support bases (2, 3, 20) are used to support three blank reinforcement surfaces and serve as three blank positioning reference surfaces for positioning products; The three auxiliary supports (22, 19, 26) are used to auxiliary support and increase the local rigidity of the reference waterway surface of product A. The product will be subjected to cutting force during the cutting process, eliminating the risk of insufficient local rigidity of the product due to the cutting force; The four pressing plates (9, 10, 11, 12) are used to press the product, so that the product is reliably positioned and is not subject to vibration caused by cutting force during processing, thereby ensuring that the roughing and deformation of the A reference waterway surface is reliable; The three horizontal side positioning surfaces (6, 7, 8) are used for horizontal limiting, and three gas detection holes are opened on the side. When the product is not clamped in place, gas leakage occurs in the gas detection holes, and the equipment generates an alarm, which plays a role in ensuring reliable clamping and positioning of the product each time; The right work station fixture is mainly composed of the following accessories: 10 hard support positioning bases (28), 6 auxiliary supports (19), four main clamping plates (38) and 2 precision positioning pin seats (31, 32); The 10 similar hard support positioning surface bases (28) enable the product to be reliably positioned on the A reference waterway surface each time it is clamped, ensuring that the deformation amount after each clamp is tightened and relaxed can be stably controlled; The six similar auxiliary supports (19) are used to assist in increasing the local rigidity of the spoiler cylinder of the product. The product will be subjected to cutting force during the cutting process, eliminating the risk of insufficient local rigidity of the product due to the cutting force. The four similar main clamping plates (38) are used to clamp the product, so that the product is reliably positioned and does not vibrate due to cutting force during processing, thus ensuring reliable roughing and deformation of the spoiler cylinder surface; The two precise positioning pin seats (31, 32) are used for precise positioning in the horizontal direction. The center distance of the positioning pin seats is required to be 201.15+ / -0.015mm and 185.87+ / -0.015mm, and is used for precise positioning of the BC holes after product processing and processing the remaining required size and position requirements.

2. The processing fixture for thin-walled parts of waterway substrates of new energy vehicles according to claim 1 is characterized in that: The processing fixture is applied to the rough processing process and the fine processing process in the processing technology of thin-walled parts such as waterway substrates of new energy vehicles.

3. The processing fixture for thin-walled parts of waterway substrates of new energy vehicles according to claim 2 is characterized in that: The fixture positioning method of the finishing process is exactly the same as the fixture positioning method of the roughing process, and is also divided into a left-station fixture and a right-station fixture.

4. The processing fixture for thin-walled parts of waterway substrates of new energy vehicles according to claim 3 is characterized by: The positioning of all components of the left station fixture of the finishing process is the same as the positioning of all components of the left station fixture of the fixture of the roughing process.

5. The processing fixture for thin-walled parts of waterway substrates of new energy vehicles according to claim 3 is characterized by: The positioning of all components of the right station fixture of the finishing process is the same as the positioning of all components of the right station fixture of the fixture of the roughing process.

6. A processing technology for thin-walled parts of waterway substrates of new energy vehicles, characterized by: The processing technology is composed of two main processing steps: a rough processing step and a fine processing step. Through accurate fixture positioning, the processing allowance of the rough processing step and the fine processing step is guaranteed, thereby ensuring reliable processing deformation of the hollow spoiler cylinder, and finally ensuring the stability of deformation of the A reference positioning waterway surface used for positioning the processing spoiler cylinder; A. The rough machining process is composed of two stations: the left station and the right station: The left station is mainly used for positioning the three blank reinforcement rib positioning surfaces and the three-point positioning of the blank side, completing the roughing of the A reference waterway surface and the processing of B and C holes, releasing the processing deformation stress after the roughing of the A reference waterway surface, and leaving a 0.15mm processing allowance for the finishing process; The right station mainly completes the rough processing of the spoiler cylinder surface by positioning the rough-cut A reference waterway surface and BC hole, and also releases the processing deformation stress of the hollow-designed 4mm spoiler cylinder surface, leaving a 0.15mm processing allowance for the finishing process; B. The finishing process described above consists of two stations: the left station and the right station: The left station of the finishing process removes 0.15mm machining allowance of the A reference waterway surface by finishing to ensure reliable finishing deformation, and uses the B and C reference holes as subsequent fine positioning reference holes; The right station of the finishing process uses the finished A reference surface waterway surface as the positioning reference surface, the BC reference hole as the positioning hole, and finishes the machining allowance of the 0.15mm spoiler cylinder surface to ensure reliable finishing deformation.

7. The processing technology of thin-walled parts of waterway substrates of new energy vehicles according to claim 6 is characterized by: The left workstation in the rough machining process removes 0.6mm machining allowance of the A reference waterway surface through rough machining, releases machining deformation stress, and leaves 0.15mm finishing allowance for fine machining to ensure the finishing deformation amount, and uses the B and C reference holes as subsequent fine positioning reference holes.

8. The processing technology of thin-walled parts of waterway substrates of new energy vehicles according to claim 6 is characterized by: The right station in the rough machining process uses the rough-cut A reference surface as the positioning reference surface, the BC reference hole as the positioning hole, and rough-cuts the spoiler cylinder with a 0.6mm machining allowance to release the machining deformation stress, leaving a 0.15mm machining allowance for fine machining to ensure the fine machining deformation amount.

Images