Machining method suitable for speed reducer shell with friction welding aluminum alloy

Abstract

The invention discloses a machining method suitable for a friction welding aluminum alloy speed reducer shell, which is divided into single machining before friction welding and combined machining after welding, so that the situation that the size is out of tolerance due to workpiece deformation caused by friction welding is avoided; rough machining and finish machining are conducted in sequence, the rough machining sequence is used for machining threaded holes and the like with the requirement for the position degree being 0.2 or above, the beat can be effectively balanced, and efficiency is improved. According to the method, multi-angle machining contents are sequenced, and a drawing design reference is used as a positioning reference to ensure the sequenced position degree, so that a five-axis machine tool can be replaced by a four-axis horizontal machining tool, and the use cost of the machine tool is reduced.

Description

Technical Field

[0001] The invention belongs to the technical field of die-cast aluminum alloy machining, and mainly relates to a machining method suitable for a friction-welded aluminum alloy reducer housing. Background Art

[0002] The reducer is a commonly used transmission device in industrial machinery. Its housing, as an important part of the reducer, plays a supporting and protective role. There are many installation contents on the housing, and many processing angles are required, and the precision requirements are high. The housing needs to be processed separately and in combination if it has welding requirements. It usually requires a four-axis + five-axis machining center to process, and the five-axis processing content is more, and the beat is unbalanced. Summary of the invention

[0003] The purpose of the present invention is to solve the above problems and provide a machining method suitable for a friction welded aluminum alloy reducer housing.

[0004] The purpose of the present invention is achieved through the following technical solutions: A machining method for a friction welded aluminum alloy reducer housing comprises the following steps: A. Pre-welding single body processing, using three-axis vertical machining center and A-axis rotary table: a1. Use a milling cutter with a diameter of φ32mm to mill three process platforms, with an internal control flatness of 0.1mm, which will be used as the positioning surface for steps BCD; a2. Use a step drill and PCD reamer to finish two process holes with a nominal diameter of 7mm and a hole tolerance of 0.015mm, which are used as positioning holes for steps BCD; a3. Rough milling friction welding area, face distance tolerance ±0.05mm, step depth 4.45~4.55mm; B. Use three process platforms and two process holes to position and weld the cover plate at the friction welding surface; C. After welding, three process platforms and two process holes are used for positioning and clamping, and the first and second assembly surfaces and hole systems are rough-machined. The equipment used is a three-axis vertical machining and an A-axis rotary table: c1. Use a φ80mm diameter disc milling cutter to rough mill the first and second box surfaces, leaving a 0.3mm margin for fine milling; c2. Use a step drill to process the first bolt hole on the surface. The nominal diameter of the hole is 9 mm, the hole diameter tolerance is 0.22 mm, and the position tolerance is 0.4 mm. c3. Use a step drill and tap to process two first M8 threaded holes, with thread specification of M8*1.25-6H; c4. Use a rough boring tool to rough bore the first bearing hole and outer circle, leaving a 0.1mm margin on the hole wall for fine machining; c5. Use a step drill and tap to process 22 second M8 threaded holes, with thread specification M8*1.25-6H; c6. Use a step drill to process 7 second bolt holes. The nominal diameter of the bolt holes is 11mm and the hole diameter tolerance is 0.2mm. c7. Use a step drill and tap to process three M6 threaded holes, with thread specifications of M6*1-6H; c8. Use a rough boring tool to rough bore the second bearing hole, the third bearing hole and the fourth bearing hole, leaving a 0.1mm margin on the hole wall for subsequent fine machining; D. Use three process platforms and two process holes for positioning and clamping, and finish the first and second box surfaces and high-precision holes. The equipment used is a four-axis horizontal machining center; d1. Use a D80 disc milling cutter to fine-mill the first and second box-joining surfaces and the small end surface. The flatness requirement is 0.05mm, and the face distance tolerance is ±0.05mm. The box-joining surface is used as the precision positioning surface in step E. d2. Use a step drill and PCD reamer to process two pin holes on the motor surface. The nominal diameter of the pin holes is 8mm and the hole diameter tolerance is 0.015mm. d3. Use a non-standard fine boring tool to fine bore the first bearing hole and outer circle. The nominal diameter of the bearing hole is 58mm, the hole diameter tolerance is 0.046mm, the outer circle nominal diameter is 74.5mm, and the hole diameter tolerance is 0.1mm; d4. Use a step drill and PCD reamer to process three installation positioning holes. The nominal diameter of the positioning holes is 12mm, and the hole diameter tolerance is 0.018mm. d5. Use a step drill, tap and PCD reamer to process a M8 threaded hole with a countersunk head. The thread specification is M8*1.25-6H, the nominal diameter of the countersunk hole is 10mm, and the hole diameter tolerance is 0.015mm; d6. Use a step drill and PCD reamer to process the pin hole on the box surface. The nominal diameter of the pin hole is 8mm, and the hole diameter tolerance is 0.015mm. The pin hole is used as the precision positioning hole in step E. d7. Use a non-standard guide boring tool to fine bore the second bearing hole, the third bearing hole and the fourth bearing hole. The second bearing hole and the third bearing hole have a nominal diameter of 90mm and a hole diameter tolerance of 0.022mm. The fourth bearing hole is a step hole. The first step hole has a nominal diameter of 100mm and a hole diameter tolerance of 0.022mm. The second step hole has a nominal diameter of 69mm and a hole diameter tolerance of 0.046mm. d8. Use a step drill and PCD reamer to process the manipulator positioning hole on the side. The nominal diameter of the positioning hole is 10mm and the hole diameter tolerance is 0.015mm. d9. Use a deep hole drill to drill an inclined oil channel hole with a hole diameter of 6mm±0.1mm and an angle of 50°±5°; E. Position and clamp the second box surface and the pin holes processed in step D, and process the friction welding surface and the surrounding hole system. The equipment used is a three-axis vertical machining and an A-axis rotary table: e1. Use a φ50 diameter disc milling cutter to finely mill the friction welding surface, with a face distance tolerance of ±0.05mm; e2. Use a φ8 diameter milling cutter to mill the end face of the water pipe hole, and the face distance requirement is ±0.1mm; e3. Use a step drill and tap to process 4 M5 threaded holes, with thread specification of M5*0.8-6H; e4. Use a step drill and PCD reamer to process two water pipe holes. The nominal diameter of the water pipe holes is 20mm, the hole diameter tolerance is 0.033mm, and the position tolerance is 0.1mm; e5. Use a step drill to drill two water pipe installation positioning holes, the hole diameter is required to be 3.5mm±0.1mm; e6. Use a step drill and tap to process a third M8 threaded hole with thread specification M8*1.25-6H; e7. Use a step drill and PCD reamer to process two pin holes. The nominal diameter of the pin holes is 10mm, the hole diameter tolerance is 0.015mm, and the position tolerance is 0.1mm. e8. Use a step drill, PCD reamer and reverse hook cutter to process the filter plug hole. The nominal diameter of the filter plug hole is 13.7mm, and the hole diameter tolerance is 0.027mm. The nominal diameter of the reverse hook hole is 15mm, and the hole diameter tolerance is 0.2mm.

[0005] Compared with the prior art, the present invention has the following advantages: The invention is divided into step A of single body processing before friction welding and steps C, D and E of combined processing after welding. Step B is a friction welding process, which can avoid deformation of workpieces caused by friction welding and dimensional deviation.

[0006] Rough and fine machining are divided into step C and step D. The rough machining process requires the position tolerance of threaded holes to be above 0.2mm, which can effectively balance the beat and improve efficiency.

[0007] The present invention divides the multi-angle processing content into step D and step E. Step E uses the design reference in the drawing as the positioning reference to ensure the position accuracy of the sequence, so that a four-axis horizontal machining center can replace a five-axis machine tool, thereby reducing the cost of using the machine tool. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 Processing main body view for shell monomer; Figures 2 to 4 Process the main body view for the shell assembly; Figure 5 It is the main view of the monomer; Figure 6 For the shell Figure 5 The main view after rotating 90°; Figure 7 This is the main view of the shell combination rough and fine machining; Figure 8 For the shell Figure 7 The main view after rotating 180°; Fig. 9 For the shell Figure 7 The main view after rotating 90°; Fig.10 This is the main view after the shell is rotated -90°; Fig.11 It is a top view of the side processing of the shell assembly; Fig.12 It is a partial cross-sectional view; Fig.13 For the shell Fig.11 Top view after rotation 178°; Numbers in the figure: 1-process boss, 2-process hole, 3-friction welding surface, 4-first box surface, 5-second box surface, 6-first bolt through hole, 7-first M8 threaded hole, 8-first bearing hole, 9-second M8 threaded hole, 10-second bolt through hole, 11-M6 threaded hole, 12-second bearing hole, 13-third bearing hole, 14-fourth bearing hole, 16-pin hole, 17-installation positioning hole, 18-countersunk M8 threaded hole 19-box surface pin hole, 20-manipulator positioning hole, 21-inclined oil channel hole, 22-water pipe hole end face, 23-M5 threaded hole, 24-water pipe hole, 25-water pipe installation positioning hole, 26-third M8 threaded hole, 27-pin hole, 28-filter plug hole. DETAILED DESCRIPTION

[0009] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of the embodiments. The elements and features described in one embodiment of the present invention may be combined with the elements and features shown in one or more other embodiments. It should be noted that for the purpose of clarity, the representation and description of components and processes that are not related to the present invention and are known to those of ordinary skill in the art are omitted in the description. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative work are within the scope of protection of the present invention.

[0010] The present invention is further described below in conjunction with the accompanying drawings: A machining method suitable for friction welded aluminum alloy reducer housing, A. Pre-welding single body processing: A. Pre-welding single body processing, using three-axis vertical machining center and A-axis rotary table: a1. Use a milling cutter with a diameter of φ32mm to mill three process platforms 1, with an internal control flatness of 0.1mm, which will be used as the positioning surface for steps BCD; a2. Use a step drill and PCD reamer to finish two process holes 2. The nominal diameter of the process holes is 7mm and the hole diameter tolerance is 0.015mm. They are used as positioning holes for steps BCD. a3, rough milling friction welding area 3, face distance tolerance ±0.05mm, step depth 4.45~4.55mm; B. Positioning with three process platforms 1 and two process holes 2, welding the cover plate at the friction welding surface 3; C. After welding, three process platforms 1 and two process holes 2 are used for positioning and clamping, and the first and second assembly surfaces 4 and 5 as well as the hole system are rough-machined. The equipment used is a three-axis vertical machining and an A-axis rotary table: c1. Use a φ80mm diameter disc milling cutter to rough mill the first box surface 4 and the second box surface 5, leaving a 0.3mm margin for fine milling; c2. Use a step drill to process the first bolt hole 6 on the surface. The nominal diameter of the hole is 9 mm, the hole diameter tolerance is 0.22 mm, and the position tolerance is 0.4 mm. c3. Use a step drill and a tap to process two first M8 threaded holes 7, with thread specifications of M8*1.25-6H; c4. Use a rough boring tool to rough bore the first bearing hole 8 and the outer circle, leaving a 0.1mm margin on the hole wall for fine machining; c5. Use a step drill and tap to process 22 second M8 threaded holes 9, with thread specification M8*1.25-6H; c6. Use a step drill to process 7 second bolt holes 10, the nominal diameter of the bolt holes is 11mm, and the hole diameter tolerance is 0.2mm; c7. Use a step drill and tap to process three M6 threaded holes 11, with thread specification M6*1-6H; c8. Rough bore the second bearing hole 12, the third bearing hole 13 and the fourth bearing hole 14 with a rough boring tool, leaving a 0.1mm margin on the hole wall for subsequent fine machining; D. Use three process platforms 1 and two process holes 2 for positioning and clamping, and finish machining the first box surface 4 and the second box surface 5 and high-precision holes. The equipment used is a four-axis horizontal machining center; d1. Use a D80 disc milling cutter to fine-mill the first box-joining surface 4, the second box-joining surface 5 and the small end surface. The flatness requirement is 0.05mm, and the face distance tolerance is ±0.05mm. The box-joining surface 5 is used as the precision positioning surface in step E. d2. Use a step drill and PCD reamer to process two pin holes 16 on the motor surface. The nominal diameter of the pin holes is 8 mm, and the hole diameter tolerance is 0.015 mm. d3. Use a non-standard fine boring tool to fine bore the first bearing hole 8 and the outer circle. The nominal diameter of the bearing hole is 58mm, the hole diameter tolerance is 0.046mm, the outer circle nominal diameter is 74.5mm, and the hole diameter tolerance is 0.1mm; d4. Use a step drill and PCD reamer to process three installation positioning holes 17. The nominal diameter of the positioning holes is 12 mm, and the hole diameter tolerance is 0.018 mm. d5. Use a step drill, tap and PCD reamer to process a countersunk M8 threaded hole 18, with a thread specification of M8*1.25-6H, a nominal countersunk hole diameter of 10mm, and a hole diameter tolerance of 0.015mm; d6. Use a step drill and PCD reamer to process the pin hole 19 on the box surface. The nominal diameter of the pin hole is 8mm, and the hole diameter tolerance is 0.015mm. The pin hole 19 is used as the precision positioning hole in step E. d7. Use a non-standard guide boring tool to fine bore the second bearing hole 12, the third bearing hole 13 and the fourth bearing hole 14. The second bearing hole 12 and the third bearing hole 13 have a nominal diameter of 90 mm and a hole diameter tolerance of 0.022 mm. The fourth bearing hole 14 is a step hole. The first step hole has a nominal diameter of 100 mm and a hole diameter tolerance of 0.022 mm. The second step hole has a nominal diameter of 69 mm and a hole diameter tolerance of 0.046 mm. d8. Use a step drill and PCD reamer to process the manipulator positioning hole 20 on the side. The nominal diameter of the positioning hole is 10 mm, and the hole diameter tolerance is 0.015 mm. d9. Use a deep hole drill to drill an inclined oil channel hole 21, the hole diameter is required to be 6mm±0.1mm, and the angle is required to be 50°±5°; E. Position and clamp the second box-joining surface 5 and the box-joining surface pin hole 19 processed in step D, and process the friction welding surface and the surrounding hole system. The equipment used is a three-axis vertical machining and an A-axis rotary table: e1. Use a φ50 diameter disc milling cutter to finely mill the friction welding surface 3, with a face distance tolerance of ±0.05mm; e2. Use a φ8 diameter milling cutter to mill the end face 22 of the water pipe hole, and the face distance requirement is ±0.1mm; e3. Use a step drill and tap to process four M5 threaded holes 23, with thread specification M5*0.8-6H; e4. Use a step drill and a PCD reamer to process two water pipe holes 24. The nominal diameter of the water pipe holes is 20 mm, the hole diameter tolerance is 0.033 mm, and the position tolerance is 0.1 mm; e5. Use a step drill to drill two water pipe installation positioning holes 25, the hole diameter is required to be 3.5mm±0.1mm; e6. Use a step drill and a tap to process a third M8 threaded hole 26, with thread specification M8*1.25-6H; e7. Use a step drill and PCD reamer to process two pin holes 27, with a nominal diameter of 10 mm, a hole diameter tolerance of 0.015 mm, and a position tolerance of 0.1 mm; e8. Use a step drill, PCD reamer and reverse hook cutter to process the filter plug hole 28. The nominal diameter of the filter plug hole is 13.7mm, and the hole diameter tolerance is 0.027mm. The nominal diameter of the reverse hook hole is 15mm, and the hole diameter tolerance is 0.2mm.

[0011] The present invention is divided into single processing before friction welding and combined processing after welding to avoid deformation of workpieces caused by friction welding and resulting in dimensional deviation. Rough and fine processing are divided into sequences, and the rough processing process requires the position accuracy of threaded holes above 0.2mm, etc., which can effectively balance the beat and improve efficiency. The present invention divides the multi-angle processing content into sequences, and uses the design reference of the drawing as the positioning reference to ensure the position accuracy of the sequence, so that the four-axis horizontal machining can replace the five-axis machine tool, reducing the cost of machine tool use.

[0012] Finally, it should be noted that although the present invention and its advantages have been described in detail above, it should be understood that various changes, substitutions and transformations can be made without exceeding the spirit and scope of the present invention as defined by the appended claims. Moreover, the scope of the present invention is not limited to the specific embodiments of the processes, devices, means, methods and steps described in the specification. It will be readily understood by those skilled in the art from the disclosure of the present invention that existing and future processes, devices, means, methods or steps that perform substantially the same functions as the corresponding embodiments described herein or obtain substantially the same results as the corresponding embodiments described herein can be used according to the present invention. Therefore, the appended claims are intended to include such processes, devices, means, methods or steps within their scope.

Claims

1. A machining method suitable for a friction welded aluminum alloy reducer housing, characterized in that: A. Pre-welding single body processing, using three-axis vertical machining center and A-axis rotary table: a1. Use a milling cutter with a diameter of φ32mm to mill three process platforms (1), with an internal control flatness of 0.1mm, which will be used as the positioning surface for steps BCD; a2. Use a step drill and PCD reamer to finish two process holes (2). The nominal diameter of the process holes is 7 mm and the hole diameter tolerance is 0.015 mm. They are used as positioning holes for steps BCD. a3, rough milling friction welding area (3), face distance tolerance ± 0.05mm, step depth 4.45 ~ 4.55mm; B. Using three process platforms (1) and two process holes (2) for positioning, welding the cover plate at the friction welding surface (3); C. After welding, three process platforms (1) and two process holes (2) are used for positioning and clamping, and the first box surface (4) and the second box surface (5) and the hole system are rough-machined. The equipment used is a three-axis vertical machining and an A-axis rotary table: c1. Rough milling the first box surface (4) and the second box surface (5) with a disc milling cutter with a diameter of φ80 mm, leaving a 0.3 mm margin for fine milling; c2. Use a step drill to machine the first bolt hole (6) on the surface. The nominal diameter of the hole is 9 mm, the hole diameter tolerance is 0.22 mm, and the position tolerance is 0.4 mm. c3. Use a step drill and tap to process two first M8 threaded holes (7), with thread specification of M8*1.25-6H; c4. Rough bore the first bearing hole (8) and the outer circle with a rough boring tool, leaving a 0.1mm margin on the hole wall for fine machining; c5. Use a step drill and tap to process 22 second M8 threaded holes (9), with thread specification M8*1.25-6H; c6. Use a step drill to process seven second bolt holes (10). The nominal diameter of the bolt holes is 11 mm and the hole diameter tolerance is 0.2 mm. c7. Use a step drill and tap to process three M6 threaded holes (11), with thread specification M6*1-6H; c8. Rough boring the second bearing hole (12), the third bearing hole (13) and the fourth bearing hole (14) with a rough boring tool, leaving a 0.1 mm margin on the hole wall for subsequent fine machining; D. Using three process platforms (1) and two process holes (2) for positioning and clamping, the first box surface (4) and the second box surface (5) and high-precision holes are finely processed using a four-axis horizontal machining center; d1. Use a D80 disc milling cutter to fine-mill the first box-joining surface (4), the second box-joining surface (5) and the small end surface. The flatness requirement is 0.05 mm, and the face distance tolerance is ±0.05 mm. The box-joining surface (5) serves as the precision positioning surface in step E. d2. Use a step drill and PCD reamer to process two pin holes (16) on the motor surface. The nominal diameter of the pin holes is 8 mm, and the hole diameter tolerance is 0.015 mm. d3. Use a non-standard boring tool to fine bore the first bearing hole (8) and the outer circle. The nominal diameter of the bearing hole is 58 mm, the hole diameter tolerance is 0.046 mm, the outer circle nominal diameter is 74.5 mm, and the hole diameter tolerance is 0.1 mm. d4. Use a step drill and PCD reamer to process three installation positioning holes (17). The nominal diameter of the positioning holes is 12 mm, and the hole diameter tolerance is 0.018 mm. d5. Use a step drill, tap and PCD reamer to process a M8 threaded hole (18) with a countersunk head. The thread specification is M8*1.25-6H, the nominal diameter of the countersunk hole is 10mm, and the hole diameter tolerance is 0.015mm. d6. Use a step drill and a PCD reamer to process the pin hole (19) on the box surface. The nominal diameter of the pin hole is 8 mm, and the hole diameter tolerance is 0.015 mm. The pin hole (19) serves as the precision positioning hole in step E. d7. Use a non-standard guide boring tool to fine bore the second bearing hole (12), the third bearing hole (13) and the fourth bearing hole (14). The second bearing hole (12) and the third bearing hole (13) have a nominal diameter of 90 mm and a hole diameter tolerance of 0.022 mm. The fourth bearing hole (14) is a stepped hole. The first stepped hole has a nominal diameter of 100 mm and a hole diameter tolerance of 0.022 mm. The second stepped hole has a nominal diameter of 69 mm and a hole diameter tolerance of 0.046 mm. d8. Use a step drill and PCD reamer to process the manipulator positioning hole (20) on the side. The nominal diameter of the positioning hole is 10 mm, and the hole diameter tolerance is 0.015 mm. d9. Use a deep hole drill to drill an inclined oil channel hole (21). The hole diameter should be 6 mm ± 0.1 mm and the angle should be 50° ± 5°. E. Position and clamp the second box surface (5) and the box surface pin hole (19) processed in step D, and process the friction welding surface and the surrounding hole system using a three-axis vertical machining and an A-axis rotary table: e1. Use a φ50 diameter disc milling cutter to finely mill the friction welding surface (3), with a face distance tolerance of ±0.05mm; e2. Use a φ8 diameter milling cutter to mill the end face of the water pipe hole (22), and the face distance requirement is ±0.1mm; e3. Use a step drill and tap to process four M5 threaded holes (23), with thread specification of M5*0.8-6H; e4. Use a step drill and a PCD reamer to process two water pipe holes (24). The nominal diameter of the water pipe holes is 20 mm, the hole diameter tolerance is 0.033 mm, and the position tolerance is 0.1 mm. e5. Use a step drill to drill two water pipe installation positioning holes (25), the hole diameter is required to be 3.5mm±0.1mm; e6. Use a step drill and tap to make a third M8 threaded hole (26), with thread specification M8*1.25-6H; e7. Use a step drill and PCD reamer to process two pin holes (27). The nominal diameter of the pin holes is 10 mm, the hole diameter tolerance is 0.015 mm, and the position tolerance is 0.1 mm. e8. Use a step drill, PCD reamer and reverse hook cutter to process the filter plug hole (28). The nominal diameter of the filter plug hole is 13.7 mm, and the hole diameter tolerance is 0.027 mm. The nominal diameter of the reverse hook hole is 15 mm, and the hole diameter tolerance is 0.2 mm.

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