A machining method for a shaftless rotor cast aluminum mold

Abstract

The application discloses a processing method of an axis-free rotor cast aluminum mold, which comprises processing of a lower mold, a pressing plate and an upper mold of the axis-free rotor mold. The application firstly proposes a concept of integrally manufacturing the lower mold, the pressing plate and the upper mold, and processes outer circle dimensions of the lower mold, the pressing plate and the upper mold on a bar to ensure that the axis centers of the lower mold, the pressing plate and the upper mold are consistent. Then, the application finds positioning points suitable for the three parts, that is, taking the center of a lower mold plug hole as the positioning, and through penetrating the lower mold, the pressing plate and the upper mold with pre-plug holes, corresponding cavities are formed according to the positions of the pre-plug holes, so that the matching of the cavity concentricity of the three parts after installation is ensured, and the product qualified rate of the axis-free rotor is improved. The application can increase the integrated processing procedure at the front end of the existing production line of the lower mold, the pressing plate and the upper mold, and the enterprise can operate relying on the conventional production equipment, and the production line has the advantages of low transformation cost, simple operation and strong practicability.

Description

Technical Field

[0001] This invention belongs to the field of mold manufacturing, and specifically relates to a processing method for a shaftless rotor aluminum casting mold. Background Technology

[0002] Shaftless rotors are components of most small and medium-sized three-phase asynchronous motors, primarily formed by casting rotor laminations and aluminum using a pressure casting machine. The formation of shaftless rotors relies on aluminum casting molds. Commonly used pressure casting molds mainly consist of an upper mold pad, upper mold, middle mold, dummy shaft, lower mold, lower mold plug, and pressure plate, etc. Figure 1 As shown. Therefore, the quality of the aluminum casting mold directly affects the quality of the shaftless rotor. Currently, the components of the aluminum casting mold are manufactured separately, which often leads to improper installation, thus reducing the product qualification rate of the shaftless rotor. Existing research on aluminum casting molds includes application number 201410530732.1, invention title: A method for processing a rotor die-casting aluminum mold. The process is as follows: a) Rough turning of H13 steel according to the mold drawings, with a radial allowance of 0.4 mm and an axial allowance of 0.3 mm. Then, threaded holes and locating pin holes are machined according to the drawings; b) Stress relief treatment is applied to the rough-machined mold at 520–540℃ for 3–4 hours; c) The stress-relieved mold is quenched, first at 650℃ for 1.5 hours, then at 850℃ for 1.5 hours, then heated to 1020℃ for 2.5 hours, followed by air cooling for 1 hour; d) Tempering treatment is applied to the quenched mold at 580℃; e) Finish machining is performed on the heat-treated mold, followed by mirror polishing of the cavity. This invention ensures the surface quality of subsequent processing and saves on tooling costs; it prevents significant deformation during subsequent quenching; it reduces mold hardness and increases mold toughness to prevent excessive hardness from reducing mold life; it effectively improves product surface quality and reduces the possibility of mold sticking; and it improves the wear resistance of the mold surface, further extending mold life. However, this invention does not propose a solution to the problem of improper installation of cast aluminum mold components. Summary of the Invention

[0003] The purpose of this invention is to solve the above-mentioned technical problems and provide a simple and practical method for processing shaftless rotor aluminum casting molds. This invention can ensure that the lower mold, pressure plate and upper mold are aligned, and at the same time, it can ensure that the concentricity of the cavities after the three parts are installed is matched, thereby improving the product qualification rate of shaftless rotors.

[0004] To achieve the above objectives, the technical solution of the present invention is as follows: A method for machining a shaftless rotor aluminum casting mold, comprising machining the lower mold, pressure plate, and upper mold of the shaftless rotor mold, with the following steps: (1) Blanking: The blank is a cylindrical bar. (2) Turn the outer circle of the bar stock with the diameter of the pressure plate as the radial dimension, and at the same time leave a radial machining allowance of 5mm on the bar stock; the sum of the thickness of the lower die, the pressure plate and the upper die is the thickness dimension of the bar stock. Cut the bar stock in a direction perpendicular to the axis, and leave a thickness machining allowance of 5mm to obtain the preliminary workpiece. Grind the two circular end faces of the workpiece flat. (3) Take the circular end face of the workpiece as the reference surface, and take the two diameters of the small base plate and the large base plate of the lower die as the radial dimensions, respectively turn the outer circle of the workpiece; control the cutting distance of the cutting tool in the thickness direction with the thickness of the small base plate and the large base plate respectively, and then obtain the outer shape structure of the lower die on the workpiece at this end; (4) Using the other circular end face of the workpiece as the reference surface, the diameter of the upper die is used as the radial dimension to turn the outer circle of the workpiece. The thickness of the upper die is used to control the cutting distance of the cutting tool in the thickness direction. Then, the outer shape structure of the upper die is obtained on the workpiece at this end. After this step, the workpiece is finally formed by the coaxial combination of the lower die, the pressure plate and the upper die. (5) According to the design requirements of the aluminum casting mold drawing, find the center point of the lower mold plug hole on the lower mold end face of the processed part obtained in step (4) and draw the line, and then make a sample punch; (6) The workpiece punched in step (5) is clamped on a four-jaw chuck, and a pre-plug hole with a diameter lower than that of the lower die plug hole is machined at the punch position. The pre-plug hole penetrates the two end faces of the workpiece. (7) Using a wire cutting device, the workpiece obtained in step (6) is cut into three parts in a direction perpendicular to the axis of the workpiece, to obtain the lower die preparation part, the pressure plate preparation part and the upper die preparation part respectively; (8) The lower mold preparation, pressure plate preparation and upper mold preparation are clamped by a four-jaw chuck respectively, and processed according to the design requirements of the lower mold, pressure plate and upper mold drawings, so as to finally obtain the lower mold, pressure plate and upper mold with consistent size and concentricity.

[0005] As a further technical solution, in step (7) above, the cutting positions of the workpiece include: a. Using the end face of the workpiece closest to the lower die as the reference plane, and the thickness of the lower die as the cutting distance; b. Use the end face of the workpiece closest to the upper mold as the reference surface, and the thickness of the upper mold as the cutting distance.

[0006] As a further technical solution, the processing method of the lower mold in step (8) above is as follows: clamp the lower mold preparation part on a lathe with a four-jaw chuck, use the outer circle of the small base as the clamping point, use a dial indicator to measure the runout of the diameter of the first pre-plug hole of the lower mold preparation part until the runout of the diameter of the first pre-plug hole is zero, lock the four-jaw chuck, and process the first cavity with the axis of the first pre-plug hole as the center according to the design requirements of the lower mold drawing. After the first cavity is processed, loosen the four-jaw chuck; rotate the lower mold preparation part, use a dial indicator to measure the runout of the diameter of the second pre-plug hole until the runout of the diameter of the second pre-plug hole is zero, lock the four-jaw chuck, process the second cavity, and so on, until all the lower mold cavities are processed. Remove the lower mold preparation part, place it on a drilling machine, and drill all the balance holes in each cavity in sequence to obtain the finished lower mold.

[0007] As a further technical solution, the processing method of the pressure plate in step (8) above is as follows: a. Clamp the pressure plate pre-piece on a lathe with a four-jaw chuck, using the outer circle of the pressure plate pre-piece as the clamping point, and use a dial indicator to measure the runout of the diameter of the pressure plate pre-piece until the runout is zero. Then lock the four-jaw chuck and machine out the limit opening. The diameter and depth of the limit opening shall be in accordance with the specifications of the pressure plate standard part. b. Loosen the chuck and use a dial indicator to measure the runout of the first pre-plugging hole diameter on the pressure plate pre-workpiece until the runout is zero. Lock the four-jaw chuck and, according to the design requirements of the pressure plate drawing, machine the first cavity with the axis of the first pre-plugging hole on the pressure plate pre-workpiece as the center. After the first cavity is machined, loosen the four-jaw chuck, rotate the pressure plate pre-workpiece, and use a dial indicator to measure the runout of the second pre-plugging hole diameter until the runout is zero. Lock the four-jaw chuck and machine the second cavity with the axis of the second pre-plugging hole as the center. Repeat this process until all the pressure plate cavities are machined, thus obtaining the finished pressure plate.

[0008] As a further technical solution, the processing method of the upper mold in step (8) above is as follows: clamp the upper mold preparation part on a lathe with a four-jaw chuck, take the outer circle of the upper mold preparation part as the clamping point, use a dial indicator to measure the runout of the diameter of the first pre-plug hole of the upper mold preparation part until the runout of the diameter of the first pre-plug hole is zero, lock the four-jaw chuck, and process the first cavity with the axis of the first pre-plug hole on the upper mold preparation part as the center according to the design requirements of the upper mold drawing. After the first cavity is processed, loosen the four-jaw chuck, rotate the upper mold preparation part, use a dial indicator to measure the runout of the diameter of the second pre-plug hole until the runout of the diameter of the second pre-plug hole is zero, lock the four-jaw chuck, process the second cavity, and so on, until all the upper mold cavities are processed, and the upper mold finished product is obtained. Place it on a drilling machine and drill all the balance holes and threaded holes in sequence.

[0009] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. By Figure 1 As can be seen, the cavities on the upper mold, lower mold, and pressure plate in the aluminum casting mold are arranged in a ring. This requires ensuring the concentricity of each cavity during assembly, which places extremely high demands on the production of the upper mold, lower mold, and pressure plate. Currently, most companies use methods such as scribing and punching to process the lower mold, pressure plate, and upper mold separately. This method cannot truly guarantee the concentricity of the three, which may cause concentricity deviations in their cavities. This can affect the installation and fit of the lower mold, pressure plate, and upper mold, resulting in the unqualified shaftless rotor produced from a certain cavity, thus reducing the product qualification rate. This invention first proposes the concept of manufacturing the lower die, pressure plate, and upper die as a whole. The outer diameters of the lower die, pressure plate, and upper die are machined coaxially on a single bar stock to ensure the alignment of their axes. Next, this invention finds a positioning point applicable to all three parts, namely, the center of the lower die plug hole. By pre-plugging holes through the lower die, pressure plate, and upper die, and opening corresponding cavities according to the position of the pre-plugging holes, the concentricity of the cavities after the three parts are installed is ensured, thereby improving the product qualification rate of shaftless rotors.

[0010] 2. This invention can add an integrated processing step to the front end of the existing production line of lower mold, pressure plate and upper mold. Enterprises can operate it by relying on conventional production equipment. The production line transformation cost is low, the operation is simple and the practicality is strong. Attached Figure Description

[0011] Figure 1 A cross-sectional view of a shaftless rotor aluminum casting mold; Figure 2 Here is a schematic diagram of the pallet structure; (a) front view, (b) sectional view; Figure 3 Here is a schematic diagram of the lower mold structure; (a) front view, (b) sectional view; Figure 4 Here is a schematic diagram of the intermediate mold; (a) front view, (b) sectional view; Figure 5 Here is a schematic diagram of the pressure plate structure; (a) front view, (b) sectional view; Figure 6 Here is a schematic diagram of the upper mold structure; (a) front view, (b) sectional view; Figure 7 Here is a schematic diagram of the upper pad; (a) front view, (b) sectional view; Figure 8 Here is a schematic diagram of the lower mold plug; (a) front view, (b) top view; Figure 9 A schematic diagram of the dummy axis structure; (a) front view, (b) top view; Figure 10 Here is a schematic diagram of the rotor lamination structure; (a) front view, (b) sectional view; Figure 11 This is a schematic diagram of the structure of the processed part obtained after step (2) of Embodiment 1 of the present invention; (a) front view, (b) bottom view; Figure 12 This is a schematic diagram of the structure of the processed part obtained after step (4) of Embodiment 1 of the present invention; (a) front view, (b) bottom view; Figure 13 This is a schematic diagram of the structure of the processed part obtained after step (6) of Embodiment 1 of the present invention; (a) front view, (b) sectional view; Figure 14 This is a schematic diagram of the structure of the lower mold preparation part after step (7) in Embodiment 1 of the present invention; (a) front view, (b) sectional view; Figure 15 This is a schematic diagram of the structure of the pressure plate preparator after step (7) in Embodiment 1 of the present invention; (a) front view, (b) sectional view; Figure 16 This is a schematic diagram of the upper mold preparation part after step (7) of Embodiment 1 of the present invention; (a) front view, (b) sectional view; Figure 17 This is a schematic diagram of the structure of the finished product after step (8) of Embodiment 1 of the present invention; (a) front view, (b) sectional view; Figure 18 This is a schematic diagram of the structure of the finished pressure plate after step (8) of Embodiment 1 of the present invention; (a) front view, (b) sectional view; Figure 19 This is a schematic diagram of the structure of the finished product after step (8) of Embodiment 1 of the present invention; (a) front view, (b) sectional view.

[0012] Figure label:

[0013] 1-Die casting machine motorized mold base, 2-Bolt, 3-Nut, 4-Die casting machine stop block, 5-Pressure plate, 6-Support plate, 7-Die casting machine fixed mold base, 8-Molten aluminum, 9-Lower mold plug, 10-Plug hole, 11-Lower mold, 1101-Large chassis, 1102-Small chassis, 12-Rotor lamination, 13-Dummy shaft, 14-Middle mold, 15-Upper mold, 16-Upper pad, 17-Machined part, 18-Lower mold preparation part, 1801-Lower mold cavity, 1802-Lower mold balance hole, 19-Pressure plate preparation part, 1901-Limit opening, 1902-Pressure plate cavity, 20-Upper mold preparation part, 2001-Upper mold cavity, 2002-Upper mold balance hole, 2003-Threaded hole, 21-Pre-plug hole.

[0014] Lower mold: D1 - Diameter of the large base of the lower mold, D2 - Diameter of the small base of the lower mold, D3 - Diameter of the plug hole, D4 ​​- The distance between the centers of the two lower mold cavities passing through the lower mold axis on the same plane, D10 - Diameter of the lower mold balance hole, L1 - Total thickness of the lower mold, L2 - Thickness of the small base; Pressure plate: D5 - pressure plate diameter, D6 - the distance between the centers of the two pressure plate cavities passing through the axis of the pressure plate in the same plane, D13 - the diameter of the limiting opening, L3 - the thickness of the pressure plate; Upper mold: D7 - upper mold diameter, D8 - distance between the centers of the two upper mold cavities passing through the upper mold axis on the same plane, D11 - upper mold balance hole diameter, D12 - threaded hole diameter, L4 - upper mold thickness; D9 - Diameter of the pre-plugging hole. Detailed Implementation

[0015] The present invention will be further described in detail below with reference to the embodiments, but the implementation of the present invention is not limited to the scope shown in the embodiments.

[0016] Example 1:

[0017] like Figure 1 The commonly used pressure casting aluminum mold includes assembly parts such as the die casting machine mold base 1, die casting machine stop block 4, pressure plate 5, support plate 6, die casting machine fixed mold base 7, lower mold plug 9, lower mold 11, rotor lamination 12, dummy shaft 13, middle mold 14, upper mold 15, upper pad 16, etc.

[0018] like Figure 2 The tray 6 shown has a round hole in the middle for placing the lower mold 11; like Figure 3 The lower mold 11 shown is composed of two coaxial cylindrical large base plates 1101 and a small base plate 1102, arranged vertically. The small base plate 1102 is fitted into a circular hole in the center of the support plate 6, while the large base plate 1101 is mounted on the edge of the circular hole in the support plate 6, providing stable support. Four lower mold cavities 1801 are formed on the large base plate 1101 and extend through to the small base plate 1102. The four lower mold cavities 1801 are arranged in a ring around the axis of the lower mold 11. A plug hole 10 is provided at the center of the lower part of each lower mold cavity 1801, and an instrument is installed in the plug hole 10. Figure 8 The lower mold plug 9; a lower mold balance hole 1802 is also provided in the lower mold cavity 1801; like Figure 4 The middle mold 14 shown is installed in the lower mold cavity 1801.

[0019] like Figure 9 and Figure 10 As shown, the rotor lamination 12 passes through the dummy shaft 13 to form a rotor core with the dummy shaft 13, and the four rotor cores with the dummy shaft 13 are placed in the middle mold 14. like Figure 5The pressure plate 5 shown primarily passes through the upper part of the intermediate mold 14, providing stable pressure on the outer edge of the intermediate mold 14. Therefore, the pressure plate 5 has four holes that facilitate the passage of the intermediate mold 14 and can press it down. The shape of the holes is described in this invention by the limiting opening 1901 and the pressure plate cavity 1902, and is also a conventional structural design in this field. An L-shaped die-casting machine stop 4 is provided on the outer periphery of the pressure plate 5 to prevent displacement of the pressure plate 5. The die-casting machine stop 4 is fixedly mounted on the die-casting machine fixed mold base 7.

[0020] like Figure 6 The upper mold 15 shown is installed on the upper part of the middle mold 14. Therefore, the upper mold 15 has four upper mold cavities 2001 corresponding to the positions of the lower mold cavity 1801. The shape of the upper mold cavity 2001 corresponds to the shape of the combined middle mold 14 and the dummy shaft 13, which is a conventional setting in the field. The upper mold cavity 2001 also has corresponding upper mold balancing holes 2002. The upper mold 15 also has threaded holes 2003 for connecting with the upper pad plate 16 in a ring shape.

[0021] like Figure 7 The upper backing plate 16 shown is installed above the upper mold 15. The upper mold 15 and the upper backing plate 16 are installed in the die-casting motor mold base 1 using T-bolts 2.

[0022] During casting, pour the high-temperature molten aluminum 8 into the melting cup of the die-casting machine's fixed mold base 7, press the push button, and move the assembled mold to the position of the melting cup of the die-casting machine's fixed mold base 7. Press the injection button to complete the die casting.

[0023] From an assembly structure perspective, the concentricity of the cavities of the upper mold 15, lower mold 11, and pressure plate 5 must be consistent to produce qualified products. Specifically, under the same plane, the axial distance D4 between the two lower mold cavities 1801 passing through the axis of the lower mold 11, the axial distance D6 between the two pressure plate cavities 1902 passing through the axis of the pressure plate 5, and the axial distance D8 between the two upper mold cavities 2001 passing through the axis of the upper mold 15 must be the same to ensure concentricity. Based on this theory, this invention proposes a processing method for a shaftless rotor aluminum casting mold, including the processing of the lower mold 11, pressure plate 5, and upper mold 15 of the shaftless rotor mold. Before processing, the dimensions of the corresponding parts are designed, as shown in Table 1. Table 1

[0024] According to the dimensions in Table 1, the processing steps are as follows: (1) Blanking: The blank is a cylindrical bar. (2) such as Figure 11As shown, the outer circle of the bar stock is machined with a radial dimension of 420mm for the diameter of the pressure plate 5, while leaving a radial machining allowance of 5mm on the bar stock; the thickness of the bar stock is determined by the sum of the thicknesses of the lower die 11, the pressure plate 5, and the upper die 15, which is 48mm, and the bar stock is cut off in a direction perpendicular to the axis, leaving a thickness machining allowance of 5mm; the preliminarily obtained workpiece 17 is obtained, and the two circular end faces of workpiece 17 are ground flat; (3) such as Figure 12 As shown, taking the circular end face of the workpiece 17 as the reference surface, and using the small base plate 1102 and the large base plate 1101 of the lower mold 11 with diameters of 280mm and 320mm as radial dimensions, the outer circle of the workpiece 17 is turned sequentially. The transverse cutting distance of the cutting tool is controlled by the thickness of the small base plate 1102 and the large base plate 1101, which are 5mm and 10mm respectively, and then the outer shape structure of the lower mold 11 is obtained on this end workpiece. The turning process is carried out by setting parameters and operating according to the existing lathe, so that the lower mold size defined in this embodiment can be finally produced.

[0025] (4) such as Figure 12 As shown, the other circular end face of the workpiece 17 is used as the reference surface, and the outer circle of the workpiece 17 is machined with the diameter of the upper die 15 (320 mm) as the radial dimension. The cutting distance of the cutting tool in the thickness direction is controlled by the thickness of the upper die 15 (15 mm), and then the outer shape structure of the upper die 15 is obtained on the workpiece 17 at this end. After this step, the workpiece 17 is finally formed by the coaxial combination of the lower die 11, the pressure plate 5, and the upper die 15. (5) According to the design requirements of the aluminum casting mold drawing in Table 1, it is known that the distance between the four lower mold cavities passing through the lower mold axis is 170mm. Draw a line on the end face of the lower mold base plate 1102 of the workpiece obtained in step (4). Find the center point of the lower mold plug hole 10 on the end face of the base plate 1102 and draw a line (at the same time, find the cavity axis position of the pressure plate 5 and the upper mold 15). Then make a sample punch. There are many methods for determining the line position in this field. In this embodiment, the indexing chuck is used to assist in the line drawing. The line drawing steps are: install the workpiece 17 obtained in step (4) on the indexing chuck, measure the maximum size of the workpiece 17 installed on the indexing chuck with a height gauge, calculate the center size of the workpiece 17 based on the maximum diameter of the workpiece 17, and set the height gauge to the maximum diameter of the workpiece 17. Adjust the measuring tape to the center dimension of the workpiece 17, draw a horizontal line with a height gauge, rotate the indexing chuck 90 degrees, and draw another horizontal line. The intersection of the two lines is the midpoint of the workpiece 17. Calculate the height according to the dimensions of the pre-filled hole 21 in the lower die drawing, adjust the height gauge to the height of the pre-filled hole 21, and draw two horizontal lines, one upper and one lower, intersecting the previously drawn lines. The intersection point is the position for the future sample punch. Rotate the indexing chuck 90 degrees again, calculate the height according to the dimensions of the pre-filled hole 21 in the lower die drawing, adjust the height gauge to the height of the pre-filled hole 21, and draw two horizontal lines, one upper and one lower, intersecting the previously drawn lines. The intersection point is the position for the future sample punch. This completes the formation of four intersection points. This is a standard marking procedure; any unclear points should be understood using the standard method.

[0026] (6) For example Figure 13 As shown, the workpiece 17 punched in step (5) is clamped on a four-jaw chuck, and a pre-filled hole 21 with a diameter of 14mm is machined at the punch position. The pre-filled hole 21 penetrates the two end faces of the workpiece. (7) Using a wire cutting machine, the workpiece obtained in step (6) is cut into three parts in a direction perpendicular to the axis of the workpiece 17, resulting in a lower die preparation part 18, a pressure plate preparation part 19, and an upper die preparation part 20, as shown below. Figure 14-16 As shown; the cutting positions of the processed parts include: a. Using the end face of the workpiece 17 closest to the lower mold 11 as the reference surface, and the cutting distance of the lower mold total thickness of 15mm; b. Using the end face of the workpiece 17 closest to the upper mold 15 as the reference surface, and the cutting distance of the upper mold thickness 15mm.

[0027] (8) The lower mold preparation part 18, the pressure plate preparation part 19 and the upper mold preparation part 20 are clamped by a four-jaw chuck respectively. The lower mold 11, the pressure plate 5 and the upper mold 15 are processed according to the design requirements of the drawings (as shown in Table 1) to finally obtain the lower mold 11, the pressure plate 5 and the upper mold 15 with consistent dimensions and concentricity.

[0028] like Figure 17 As shown, the machining method of the lower mold 11 is as follows: The lower mold preparation part 18 is clamped on a lathe with a four-jaw chuck. The outer circle of the small base plate 1102 is used as the clamping point. The runout of the diameter of the first pre-plug hole 21 of the lower mold preparation part 18 is measured with a dial indicator until the runout of the diameter of the first pre-plug hole 21 is zero. The four-jaw chuck is then locked. According to the design requirements of the lower mold 11 drawing, the first cavity is machined with the axis of the first pre-plug hole 21 as the center. After the first cavity is machined, the four-jaw chuck is released. The lower mold preparation part 18 is rotated, and the runout of the diameter of the second pre-plug hole 21 is measured with a dial indicator until the runout of the diameter of the second pre-plug hole 21 is zero. The four-jaw chuck is then locked, and the second cavity is machined. This process is repeated until all the lower mold cavities 1801 are machined. The lower mold preparation part 18 is then removed and placed on a drilling machine. All the balance holes are drilled in each cavity in sequence to obtain the finished lower mold 11.

[0029] like Figure 18 As shown, the processing method of pressure plate 5 is as follows: a. Clamp the pressure plate preparation part 19 on a lathe with a four-jaw chuck, using the outer circle of the pressure plate preparation part 19 as the clamping point, and use a dial indicator to measure the runout of the diameter of the pressure plate preparation part 19 until the runout is zero. Then lock the four-jaw chuck and machine out the limit opening 1901. The diameter and depth of the limit opening 1901 shall be in accordance with the specifications of the pressure plate 5 standard part. b. Loosen the chuck and use a dial indicator to measure the runout of the diameter of the first pre-plugging hole 21 on the pressure plate preparation part 19 until the runout of the diameter of the first pre-plugging hole 21 is zero. Lock the four-jaw chuck and, according to the design requirements of the pressure plate 5 drawing, machine the first cavity with the axis of the first pre-plugging hole 21 on the pressure plate preparation part 19 as the center. After the first cavity is machined, loosen the four-jaw chuck, rotate the pressure plate preparation part 19, and use a dial indicator to measure the runout of the diameter of the second pre-plugging hole 21 until the runout of the diameter of the second pre-plugging hole 21 is zero. Lock the four-jaw chuck and machine the second cavity with the axis of the second pre-plugging hole 21 as the center. Continue in this manner until all the pressure plate cavities 1902 are machined, thus obtaining the finished pressure plate 5.

[0030] like Figure 19As shown, the machining method of the upper mold 15 is as follows: The upper mold preparation part 20 is clamped on a lathe with a four-jaw chuck. The outer circle of the upper mold preparation part 20 is used as the clamping point. The runout of the diameter of the first pre-plug hole 21 of the upper mold preparation part 20 is measured with a dial indicator until the runout of the diameter of the first pre-plug hole 21 is zero. The four-jaw chuck is then locked. According to the design requirements of the upper mold 15 drawing, the first cavity is machined with the axis of the first pre-plug hole 21 on the upper mold preparation part 20 as the center. After the first cavity is machined, the four-jaw chuck is released, the upper mold preparation part 20 is rotated, and the runout of the diameter of the second pre-plug hole 21 is measured with a dial indicator until the runout of the diameter of the second pre-plug hole 21 is zero. The four-jaw chuck is then locked, and the second cavity is machined. This process is repeated until all the upper mold cavities 2001 are machined, thus obtaining the finished upper mold 15. The finished product is then placed on a drilling machine, and all the balance holes and threaded holes 2003 are drilled in sequence.

[0031] The cavity dimensions described above are processed according to the requirements of the actual processing plant. The operation steps are conventional and are not within the scope of protection of this invention, so they will not be described in detail.

[0032] The cavities of the lower mold 11, pressure plate 5 and upper mold 15 obtained by the processing method of the present invention are consistent, thereby improving the product qualification rate of shaftless rotors.

[0033] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "front," "rear," "left," "right," "head," "tail," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of this invention. It should also be noted that, unless otherwise explicitly specified and limited, terms such as "connected" and "linked" should be interpreted broadly. For example, it can refer to a fixed connection; a detachable connection; a point connection; a direct connection; or an indirect connection through an intermediate medium, allowing communication between the internal parts of two elements. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Device connection methods not described in detail in this invention are understood according to conventional connection methods in the art.

[0034] The above embodiments are merely specific examples to further illustrate the purpose, technical solution, and beneficial effects of the present invention, and the present invention is not limited thereto. Any modifications, equivalent substitutions, improvements, etc., made within the scope of the disclosure of the present invention are included within the protection scope of the present invention.

Claims

1. A method for processing a shaftless rotor aluminum casting mold, characterized in that, The machining steps for the shaftless rotor mold, including the lower mold, pressure plate, and upper mold, are as follows: (1) Blanking: The blank is a cylindrical bar. (2) Turn the outer circle of the bar stock with the diameter of the pressure plate as the radial dimension, and at the same time leave a radial machining allowance of 5mm on the bar stock; the sum of the thickness of the lower die, the pressure plate and the upper die is the thickness dimension of the bar stock. Cut the bar stock in a direction perpendicular to the axis, and leave a thickness machining allowance of 5mm to obtain the preliminary workpiece. Grind the two circular end faces of the workpiece flat. (3) Take the circular end face of the workpiece as the reference surface, and take the two diameters of the small base plate and the large base plate of the lower die as the radial dimensions, respectively turn the outer circle of the workpiece; control the cutting distance of the cutting tool in the thickness direction with the thickness of the small base plate and the large base plate respectively, and then obtain the outer shape structure of the lower die on the workpiece at this end; (4) Using the other circular end face of the workpiece as the reference surface, the diameter of the upper die is used as the radial dimension to turn the outer circle of the workpiece. The thickness of the upper die is used to control the cutting distance of the cutting tool in the thickness direction. Then, the outer shape structure of the upper die is obtained on the workpiece at this end. After this step, the workpiece is finally formed by the coaxial combination of the lower die, the pressure plate and the upper die. (5) According to the design requirements of the aluminum casting mold drawing, find the center point of the lower mold plug hole on the lower mold end face of the processed part obtained in step (4) and draw the line, and then make a sample punch; (6) The workpiece punched in step (5) is clamped on a four-jaw chuck, and a pre-plug hole with a diameter lower than that of the lower die plug hole is machined at the punch position. The pre-plug hole penetrates the two end faces of the workpiece. (7) Using a wire cutting device, the workpiece obtained in step (6) is cut into three parts in a direction perpendicular to the axis of the workpiece, to obtain the lower die preparation part, the pressure plate preparation part and the upper die preparation part respectively; (8) The lower mold preparation, pressure plate preparation and upper mold preparation are clamped by a four-jaw chuck respectively, and processed according to the design requirements of the lower mold, pressure plate and upper mold drawings, so as to finally obtain the lower mold, pressure plate and upper mold with consistent size and concentricity. The machining method for the lower mold is as follows: Clamp the lower mold pre-piece on a lathe with a four-jaw chuck, using the outer circle of the small base as the clamping point. Use a dial indicator to measure the runout of the diameter of the first pre-plugging hole in the lower mold pre-piece until the runout is zero. Lock the four-jaw chuck. According to the design requirements of the lower mold drawing, machine the first cavity with the axis of the first pre-plugging hole as the center. After the first cavity is machined, release the four-jaw chuck. Rotate the lower mold pre-piece and use a dial indicator to measure the runout of the diameter of the second pre-plugging hole until the runout is zero. Lock the four-jaw chuck and machine the second cavity. Repeat this process until all lower mold cavities are machined. Remove the lower mold pre-piece and place it on a drilling machine. Drill all the balance holes in each cavity sequentially to obtain the finished lower mold.

2. The processing method of a shaftless rotor aluminum casting mold according to claim 1, characterized in that: In step (7), the cutting positions of the workpiece include: a. Using the end face of the workpiece closest to the lower die as the reference plane, and the thickness of the lower die as the cutting distance; b. Use the end face of the workpiece closest to the upper mold as the reference surface, and the thickness of the upper mold as the cutting distance.

3. The processing method of a shaftless rotor aluminum casting mold according to claim 1, characterized in that: The processing method for the pressure plate in step (8) is as follows: a. Clamp the pressure plate pre-piece on a lathe with a four-jaw chuck, using the outer circle of the pressure plate pre-piece as the clamping point, and use a dial indicator to measure the runout of the diameter of the pressure plate pre-piece until the runout is zero. Then lock the four-jaw chuck and machine out the limit opening. The diameter and depth of the limit opening shall be in accordance with the specifications of the pressure plate standard part. b. Loosen the chuck and use a dial indicator to measure the runout of the first pre-plugging hole diameter on the pressure plate pre-workpiece until the runout is zero. Lock the four-jaw chuck and, according to the design requirements of the pressure plate drawing, machine the first cavity with the axis of the first pre-plugging hole on the pressure plate pre-workpiece as the center. After the first cavity is machined, loosen the four-jaw chuck, rotate the pressure plate pre-workpiece, and use a dial indicator to measure the runout of the second pre-plugging hole diameter until the runout is zero. Lock the four-jaw chuck and machine the second cavity with the axis of the second pre-plugging hole as the center. Repeat this process until all the pressure plate cavities are machined, thus obtaining the finished pressure plate.

4. The processing method of a shaftless rotor aluminum casting mold according to claim 1, characterized in that: The machining method of the upper mold in step (8) is as follows: clamp the upper mold preparation part on a lathe with a four-jaw chuck, use the outer circle of the upper mold preparation part as the clamping point, use a dial indicator to measure the runout of the diameter of the first pre-plug hole of the upper mold preparation part until the runout of the diameter of the first pre-plug hole is zero, lock the four-jaw chuck, and machine the first cavity with the axis of the first pre-plug hole on the upper mold preparation part as the center according to the design requirements of the upper mold drawing. After the first cavity is machined, loosen the four-jaw chuck, rotate the upper mold preparation part, use a dial indicator to measure the runout of the diameter of the second pre-plug hole until the runout of the diameter of the second pre-plug hole is zero, lock the four-jaw chuck, machine the second cavity, and so on, until all the upper mold cavities are machined, and the upper mold finished product is obtained. Place it on a drilling machine and drill all the balance holes and threaded holes in sequence.

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