A roller for continuous processing and its installation mechanism and processing method

Abstract

The present invention relates to the technical field of grinding processing, and discloses a roller for continuous processing, its installation mechanism and processing method, wherein the roller comprises a roller body; the roller body is a cylindrical body formed by tool steel; a connection hole for connecting a tool handle is provided at the center of the roller body; no chip groove is provided on the roller body; and a forming surface formed by turning a forming turning tool is provided on the outer circumference of the roller body. The present invention can achieve higher roller forming quality and forming efficiency, is easy to process, has low processing cost and good economic efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of grinding processing, and in particular to a roller used for continuous processing, a mounting mechanism thereof and a processing method thereof. Background Art

[0002] Grinding is generally used as the final process of workpiece processing, and its task is to ensure that the product parts can achieve the accuracy and surface quality required on the drawings. Forming grinding is a high-precision grinding process in grinding, which is used to process workpiece surfaces with complex geometric shapes, such as curved surfaces, contours, grooves, etc. This grinding method is widely used in aerospace, automobile, mold manufacturing and other fields, and can achieve high-precision and high-surface quality processing. The basic principle of form grinding is to use a grinding wheel with a specific shape to process the surface of the workpiece to achieve the required geometry and surface quality. The shape of the grinding wheel is usually pre-made according to the final shape of the workpiece. Through precise control and adjustment, the relative movement between the grinding wheel and the workpiece is ensured to achieve high-precision grinding. In form grinding, the quality of the grinding wheel and the grinding wheel dressing technology are the two major difficulties that affect its processing quality. The device directly related to these two difficulties is the roller.

[0003] The roller for dressing the profiled grinding wheel, also known as a grinding wheel dresser or a grinding wheel dresser, is an important tool for dressing the grinding wheel on machine tools. Its main functions include shaping the grinding wheel and, after using the grinding wheel for a period of time, dressing the grinding wheel surface into a specified shape through the dresser to ensure the accuracy and efficiency of machining. Common types of rollers for dressing profiled grinding wheels include diamond rollers. Diamond rollers are widely used in mass profiled grinding due to their high efficiency, long life and low cost. Diamond rollers are installed on the dressing device of the grinder to dress ordinary ceramic grinding wheels or CBN grinding wheels to ensure that the grinding wheel is formed before grinding the part, thereby replicating its shape contour, accuracy and size to the surface of the processed part.

[0004] However, the existing diamond roller is generally an inner diamond-plated forming roller. When producing such a forming roller, it is necessary to first process the mold of the required forming teeth and then process the roller based on the mold. This method is theoretically more accurate, but the actual processing of the roller's forming tooth shape is quite different from the requirements (the reasons are that the mold itself may have manufacturing errors or wear, and when diamond particles are subsequently plated on the tooth shape, the uniformity and bonding force of the diamond particle coating are difficult to ensure, etc.), and it cannot meet the requirements of high-precision forming surfaces. There is also a more advanced diamond pen profiling finishing technology, which uses a diamond pen to trim the roller according to a predetermined shape and size to achieve the required shape and accuracy. Although the finishing effect of this method is better than the former, the efficiency is extremely low. And diamond is a very expensive substrate, the material cost is extremely high and the manufacturing process of the diamond pen is complicated, requiring high-precision processing equipment and technology. For example, the tip of the diamond pen needs to be precisely ground and polished to ensure the high accuracy of its shape and size. In actual use, it is more necessary to trim the pen shape frequently, and the overall processing cost is even higher. Summary of the invention

[0005] The present invention aims to provide a roller for continuous processing, a mounting mechanism thereof and a processing method thereof. The roller has high molding quality and molding efficiency, is easy to process, has low processing cost and good economy.

[0006] To achieve the above objectives, the present invention provides the following basic solutions.

[0007] Solution 1

[0008] A roller for continuous processing comprises a roller body; the roller body is a cylinder formed of tool steel; a connecting hole for connecting a tool handle is provided at the center of the roller body; no chip groove is provided on the roller body; and a forming surface formed by turning a forming turning tool is provided on the outer circumferential surface of the roller body.

[0009] Furthermore, the tool steel is a tool steel that has been subjected to quenching and tempering treatment, and the hardness of the material after the quenching and tempering treatment is HRC60-64.

[0010] Furthermore, the connecting hole is a straight hole.

[0011] Furthermore, bosses are respectively provided on the front side and the rear side of the roller body.

[0012] Furthermore, the outer diameter of the boss is 2:3 with respect to the outer diameter of the roller body, and the thickness of the boss is 0.8-1.2 mm.

[0013] Furthermore, in the continuous processing, the roller body is processed by the forming turning tool, and then the grinding wheel is processed by the roller body.

[0014] Solution 2

[0015] A mounting mechanism for a roller for continuous processing, used for mounting a roller for continuous processing as described in Scheme 1; comprising a tool holder bracket for stabilizing the tool holder and a roller motor for driving the roller to rotate; the roller motor comprises an electric spindle; when mounting the roller, the roller is mounted on the tool holder through a connecting hole; one end of the tool holder is placed on the tool holder bracket; the other end of the tool holder is connected to the electric spindle, and the tool holder is driven to rotate by the electric spindle.

[0016] Option 3

[0017] A method for processing a roller for continuous processing, used for processing a roller for continuous processing as described in scheme 1; comprising the following steps:

[0018] Step 1, selecting a tool steel substrate as a roller blank;

[0019] Step 2, heat treatment and surface treatment of the tool steel substrate;

[0020] Step 3, grinding the tool steel substrate to a target size and a target surface roughness;

[0021] Step 4: Use a forming turning tool to turn the forming surface of the roller.

[0022] Furthermore, the forming turning tool includes a blade base and a blade edge; the blade base is made of a cemented carbide material, and the blade edge is made of a CBN material; the blade edge is provided with a tooth shape matching the roller forming surface, and the side clearance angle of the tooth shape is set to 1°.

[0023] Further, in step 4, when the forming turning tool is turning, the spindle speed in the turning parameters is set to 210 r / min, and the feed rate in the turning parameters is set to 0.01 mm / r.

[0024] The working principle and advantages of the present invention are:

[0025] The present invention provides a roller for continuous processing, an installation mechanism and a processing method thereof, which has high roller forming quality and forming efficiency, is easy to process, has low processing cost and good economic efficiency. The key point is -

[0026] For options 1 and 3:

[0027] The present invention breaks through the conventional roller processing stereotype, and specially selects tool steel as the roller body substrate, and uses turning to process the roller forming surface, which fundamentally reduces the production cost and can greatly improve the production efficiency. First of all, although tool steel is a commonly used industrial substrate, in the existing roller processing, tool steel is often not selected as the roller substrate, because the hardness of tool steel is low for grinding scenarios and the wear rate is high. However, this solution goes the other way, and specially selects tool steel as the roller substrate, and on this basis, uses the tempering process to improve the material hardness and wear resistance of tool steel to meet its high-intensity use requirements as a grinding tool. Secondly, on the basis of selecting tool steel as the substrate, turning and forming processing of the roller is possible. The present invention no longer uses the existing diamond pen method or diamond particle internal plating method, but instead uses a turning processing technology. Compared with existing methods, firstly, turning processing does not require the use of diamond materials, and there is no high material cost; secondly, the molded surface obtained by turning processing does not have the risk of falling off / peeling off similar to coating materials, and is more stable and has higher surface accuracy; thirdly, the equipment for turning processing is highly versatile and easy to operate, the processing cost is low, and the process details are easy to control.

[0028] As for the technical difficulties in turning processing - the risk of tool damage when processing high-hardness materials and the difficulty in controlling the forming error, the present invention has achieved the overcoming of the difficulties by optimizing the design of the tool material and the turning process. First, this solution uses a tool with a specific material combination, a CBN blade and a carbide tool body, which has a hardness basis for the roller body with a processing hardness of HRC60-64, and the side back angle of the tool tooth shape is set to 1°, which can further enhance the strength and rigidity of the blade part, has the ability of high-intensity cutting, can successfully form and turn the required tooth shape, and ensure that the forming accuracy meets the standard (the shape error is kept within 0.003mm); secondly, in view of the problem of large-scale wear and chipping when turning hard materials, the turning parameters are set to a set of specific preferred values. By controlling the cutting state, the cutting force can be kept in a suitable range to reduce the risk of wear and chipping.

[0029] Second, the present invention can be applied to continuous processing, and realize continuous processing of the roller body processed by the forming turning tool, the grinding wheel processed by the roller body, and the workpiece processed by the grinding wheel. It can also realize integrated continuous processing by integrating the turning assembly, the roller assembly and the grinding wheel assembly. The existing process scheme is difficult to achieve such continuous processing operations (because the diamond pen needs to use a professional dressing machine, and the diamond internal plating method often adopts the hand-planting method, which cannot support continuous processing). Moreover, this form of continuous processing can greatly improve the overall grinding efficiency. In addition, since the forming surface of the roller can be uniformly and efficiently trimmed by the forming turning tool, the roller tooth shape can achieve a high consistency, and then the grinding wheel tooth shape can maintain a high consistency, which can help improve the shape retention of the grinding wheel and help improve the grinding quality.

[0030] Third, the roller body of the present invention does not have a chip groove, which can improve the stability and processing efficiency of the roller during the dressing process. In the conventional design logic of the tool, the tool needs to be provided with a chip groove to accommodate and discharge the debris generated during the processing, so as to prevent the debris from accumulating between the tool and the workpiece, thereby affecting the surface quality. Figure 2 As shown in the figure, the chip groove is marked at A), and the chip groove is actually retained according to the existing ideas. However, in actual applications, we found that the shape accuracy of the processed product is low, and the service life of the roller itself and the processing object of the roller-the grinding wheel are both short; after various tests and verifications, we have made a breakthrough discovery that in the grinding scenario, the setting of the chip groove is more disadvantageous than beneficial. Since the grinding process is an extrusion and dressing process, the setting of the chip groove will reduce the stability of the roller body structure, making the roller body extremely susceptible to vibration and deformation during extrusion and dressing, thereby affecting the molding accuracy of the roller, and aggravating the misaligned extrusion between the roller and the grinding wheel, which will reduce the service life of both. Based on this discovery, the present invention chooses not to set the chip groove, which can avoid the above-mentioned problems from the root, and improve the smoothness of the grinding wheel extrusion and dressing process; improve the grinding wheel extrusion and dressing efficiency.

[0031] Fourth, the roller body of the present invention adopts a straight hole type connection hole, which can be adapted to a standard tool handle, is easy to disassemble and can be adapted to most machine tools, and has strong versatility; and the standard disassembly and assembly form is easier to ensure the clamping accuracy and reduce the clamping error. In addition, a boss is provided on the roller body, which can better clamp and fix the tool handle and ensure installation stability.

[0032] Regarding Solution 2: The present invention is equipped with a modular roller installation mechanism, which has a simple structure, can stably install the roller, and makes it easy to process the grinding wheel and cooperate with turning processing. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1It is a schematic diagram of the structure of the roller body when the forming surface is not processed in Embodiment 1 of a roller for continuous processing and its installation mechanism and processing method of the present invention;

[0034] Figure 2 This is a schematic diagram of the roller body structure in the initial version;

[0035] Figure 3 A bearing view of the mounting mechanism of the first embodiment of a roller for continuous processing and its mounting mechanism and processing method of the present invention;

[0036] Figure 4 A top view of the mounting mechanism of a roller for continuous processing and a mounting mechanism and a processing method thereof in Embodiment 1 of the present invention;

[0037] Figure 5 It is a structural schematic diagram of a forming turning tool of Embodiment 1 of a roller for continuous processing and its mounting mechanism and processing method of the present invention;

[0038] Figure 6 The present invention is a schematic diagram of the structure of a roller body after the forming surface is processed in Embodiment 1 of a roller for continuous processing and its installation mechanism and processing method. DETAILED DESCRIPTION

[0039] The following is a further detailed description through specific implementation methods:

[0040] The symbols in the drawings of the specification include: roller body 1, connecting hole 2, boss 3, forming surface 4, tool handle bracket 5, roller motor 6, electric spindle 61, tool handle 7, base 8, threaded hole 81.

[0041] Embodiment 1

[0042] The embodiment is basically as shown in the attached Figure 1 and Figure 6 As shown: A roller for continuous processing, comprising a roller body 1; the roller body 1 is a cylinder formed of tool steel; a connecting hole 2 for connecting a tool handle 7 is provided at the center of the roller body 1; no chip groove is provided on the roller body 1; a forming surface 4 formed by turning by a forming turning tool is provided on the outer circumferential surface of the roller body 1.

[0043] The tool steel is a tool steel that has been subjected to quenching and tempering treatment, and the hardness of the material after quenching and tempering treatment is HRC60-64; in this embodiment, it is specifically HRC63; it has high material hardness and strong wear resistance, and can meet its high-intensity use requirements as a mold.

[0044] The connecting hole 2 is a straight hole; it can be adapted to a standard tool handle 7, is easy to disassemble and assemble, and can be adapted to most machine tools, and has strong versatility. The front side and rear side of the roller body 1 are respectively provided with bosses 3; they can better clamp and fix the tool handle 7 to ensure installation stability.

[0045] The thickness of the boss 3 is 0.8-1.2 mm, and in this embodiment, it is set to 1 mm. With this structure, the boss 3 can help improve the rigidity of the roller body 1.

[0046] The outer diameter of the boss is 2:3 with the outer diameter of the roller body, which can effectively disperse the load borne by the roller body 1 during operation, reduce stress concentration, and thus improve the stability and load-bearing capacity of the overall structure; and this proportional design achieves the required strength requirements with less material usage, and has a lightweight effect. In addition, the proportional design of the boss 3 and the roller body 1 can affect the running stability of the roller. The proportional setting here helps to maintain appropriate contact pressure between the roller and the grinding wheel in subsequent applications, reduce unnecessary friction and wear, and thus extend the service life of the roller body 1.

[0047] In the continuous processing, the roller body 1 is processed by the profile turning tool, and then the grinding wheel is processed by the roller body 1. Preferably, the continuous processing of roller-grinding wheel-workpiece integration can be realized by integrating the turning assembly, the roller assembly and the grinding wheel assembly.

[0048] In addition, this solution can also realize continuous processing of the roller body 1. After the turning process of one roller body 1 is completed, the roller can be disassembled and assembled by replacing the tool handle 7 through the connecting hole 2, and the next roller body 1 to be processed can be replaced for turning process, and the above process can be repeated to realize continuous processing.

[0049] like Figure 3 As shown, this embodiment also provides a mounting mechanism for a roller for continuous processing, which is used to mount a roller for continuous processing as described above; it includes a base 8, a tool handle bracket 5 for stabilizing the tool handle 7, and a roller motor 6 for driving the roller to rotate.

[0050] like Figure 4As shown, the base 8 is provided with multiple threaded holes 81, and the tool handle bracket 5 and the roller motor 6 are both installed on the base 8 through the threaded holes 81. The roller motor 6 includes an electric spindle 61; when the roller is installed, the roller is installed on the tool handle 7 through the connecting hole 2; one end of the tool handle 7 is mounted on the tool handle bracket 5; the other end of the tool handle 7 is connected to the electric spindle 61, and the tool handle 7 is driven to rotate by the electric spindle 61. Specifically, a pair (2) of auxiliary wheels are provided on the tool handle bracket 5, the axis of the auxiliary wheels is parallel to the axis of the tool handle 7, and the two auxiliary wheels are rotatably connected to the tool handle bracket 5 through a rotating shaft. The tool handle 7 is mounted on the outer surface of the two auxiliary wheels. With this structure, when the tool handle 7 rotates, the tool handle bracket 5 can stably support it to rotate. In specific applications, the base 8 can also be fixed to the processing platform of the machine tool through the threaded hole 81, so as to participate in turning processing or participate in dressing the grinding wheel.

[0051] This embodiment also provides a method for processing a roller for continuous processing, which is used to process the roller for continuous processing as described above; the method comprises the following steps:

[0052] Step 1: Select a tool steel substrate as a roller blank.

[0053] Step 2, heat treatment and surface treatment are performed on the tool steel substrate. The heat treatment is tempering; the surface treatment is carburizing, nitriding and hard chrome electroplating.

[0054] Step 3: Grind the tool steel substrate to a target size and a target surface roughness. In this embodiment, the target surface roughness is Ra0.8.

[0055] Step 4, using a forming turning tool to turn the forming surface 4 of the roller, such as Figure 6 shown.

[0056] Step 5: Processing quality verification: Use a hardness measuring device (such as a Brinell hardness tester or a Vickers hardness tester) and a dimension measuring device to check the hardness, size, shape and surface quality of the roller to ensure that the processed roller meets the technical requirements.

[0057] like Figure 5 As shown, the forming turning tool includes a blade base and a blade edge; the blade base is made of cemented carbide material, and the blade edge is made of CBN material; the blade edge is provided with a tooth shape matching the roller forming surface 4, and the side clearance angle of the tooth shape is set to 1°, which can further enhance the strength and rigidity of the blade part and have the ability of high-intensity cutting.

[0058] In this step, when the forming turning tool is turning, the spindle speed in its turning parameters is set to 210r / min, and the feed rate in its turning parameters is set to 0.01mm / r. This setting can achieve the optimal turning state, effectively control the cutting state between the forming turning tool and the roller body 1, and ensure that the cutting force is within a reasonable range to reduce damage to the forming turning tool and improve the cutting surface quality. In actual processing, the spindle speed and feed rate can be slightly adjusted. While increasing the spindle speed, the feed rate can be appropriately increased to keep the cutting force within a reasonable range. When reducing the spindle speed, the feed rate should be appropriately reduced to avoid excessive cutting force.

[0059] As shown in Table 1, the turning processing conditions under different turning parameters are displayed. It can be seen from this table that the turning parameters set in this scheme are the optimal parameters, there is no risk of chipping, the processing can be completed more efficiently, and the surface quality obtained by processing can meet the requirements.

[0060] Table 1 Parameter comparison table

[0061]

[0062] The application of this processing method can greatly improve the forming efficiency of the roller and can achieve a forming accuracy comparable to that of diamond dressing and other methods at a lower cost. As shown in Table 2, the comparison of the associated processing parameters and processing costs of this scheme and the existing process method when processing the same number of rollers with the same tooth shape and size is shown. It can be seen from the data in the table that the processing efficiency of this scheme is significantly improved compared with the existing technology (the processing time is significantly shortened), and the processing cost is significantly reduced compared with the existing technology.

[0063] Table 2 Process comparison table

[0064]

[0065] The present embodiment provides a roller for continuous processing, a mounting mechanism thereof, and a processing method thereof. The roller has high molding quality and molding efficiency, is easy to process, has low processing cost, and has good economy.

[0066] Embodiment 2

[0067] A method for processing a roller for continuous processing, based on the first embodiment, further comprises step 6, using the roller body 1 to process a grinding wheel.

[0068] In specific applications, existing grinding machines can be used to perform this step.

[0069] Install the grinding wheel to be processed on the processing position of the grinding machine, install the roller body 1 on the tool seat of the grinding machine, and ensure that it is aligned with the grinding wheel surface.

[0070] The working parameters of the grinder are set according to the preset processing parameters, and the roller is controlled to feed at a stable speed until the required tooth shape is trimmed on the grinding wheel.

[0071] In this embodiment, the preset processing parameters include: the feed depth of the roller body 1 - 0.01mm~0.05mm; the feed speed of the roller body 1 - 0.1mm / min~0.5mm / min; the cutting pressure applied by the roller body 1 on the grinding wheel - 0.5kg / cm²~2.0kg / cm².

[0072] In specific applications, the specific values ​​in the above range depend on the hardness, material and size of the grinding wheel. Among them, a smaller feed speed can reduce the impact on the grinding wheel, thereby avoiding damage to the grinding wheel surface. Excessive cutting pressure may cause the grinding wheel to break, while too little cutting pressure may not be able to effectively dress the grinding wheel. By balancing the above processing parameters, this solution can achieve precise dressing of the grinding wheel and avoid damage to the roller body 1.

[0073] This embodiment provides a method for processing a roller for continuous processing. Based on the first embodiment, it further provides a method for processing a roller body 1 when processing a grinding wheel in continuous processing. By controlling relevant processing parameters, even if there is no chip groove, the roller body 1 designed in this scheme can still effectively dress the grinding wheel.

[0074] The above is only an embodiment of the present invention. The common sense such as the known specific structure and characteristics in the scheme is not described in detail here. The ordinary technicians in the relevant field are aware of all the common technical knowledge in the technical field of the invention before the application date or priority date, can obtain all the existing technologies in the field, and have the ability to apply the conventional experimental means before that date. The ordinary technicians in the relevant field can improve and implement the scheme in combination with their own abilities under the enlightenment given by this application. Some typical known structures or known methods should not become obstacles for the ordinary technicians in the relevant field to implement this application. It should be pointed out that for the technicians in this field, without departing from the structure of the present invention, several deformations and improvements can be made, which should also be regarded as the protection scope of the present invention, and these will not affect the effect of the implementation of the present invention and the practicality of the patent.

Claims

1. A roller for continuous processing, characterized in that: It comprises a roller body; the roller body is a cylinder formed by tool steel; a connecting hole for connecting a tool handle is provided at the center of the roller body; no chip groove is provided on the roller body; a forming surface formed by turning by a forming turning tool is provided on the outer circumference of the roller body; in continuous processing, the roller body is processed by the forming turning tool, and then the grinding wheel is processed by the roller body.

2. A roller for continuous processing according to claim 1, characterized in that: The tool steel is a tool steel that has been subjected to quenching and tempering treatment, and the hardness of the material after the quenching and tempering treatment is HRC60-64.

3. A roller for continuous processing according to claim 1, characterized in that: The connecting hole is a straight hole.

4. A roller for continuous processing according to claim 1, characterized in that: Bosses are respectively arranged on the front side surface and the rear side surface of the roller body.

5. A roller for continuous processing according to claim 4, characterized in that: The outer diameter of the boss is 2:3 with respect to the outer diameter of the roller body; and the thickness of the boss is 0.8-1.2 mm.

6. A method for processing a roller for continuous processing, characterized in that: Used for processing a roller for continuous processing as described in any one of claims 1 to 5; comprising the following steps: Step 1, selecting a tool steel substrate as a roller blank; Step 2, heat treatment and surface treatment of the tool steel substrate; Step 3, grinding the tool steel substrate to a target size and a target surface roughness; Step 4, using a forming turning tool to turn the forming surface of the roller; The forming turning tool comprises a blade substrate and a blade edge; the blade substrate is made of a cemented carbide material, and the blade edge is made of a CBN material; the blade edge is provided with a tooth shape matching the roller forming surface, and the side clearance angle of the tooth shape is set to 1°.

7. A method for processing a roller for continuous processing according to claim 6, characterized in that: In step 4, when the forming turning tool is turning, the spindle speed in the turning parameters is set to 210 r / min, and the feed rate in the turning parameters is set to 0.01 mm / r.

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