Machining method of hard sealing track ball

Abstract

The embodiment of the invention provides a machining method of a hard sealing track sphere, which comprises the following steps: preheating a material to be machined to a preset temperature so as to reduce the hardness of the material and improve the cutting performance; on the basis of the hardness of the preheated material and the environment temperature, proper cutting parameters are selected for primary turning, and the smoothness of the machined surface is ensured; in the machining process, the environment temperature is monitored and adjusted in real time through a closed-loop temperature control system, so that the dimensional precision deviation caused by non-uniform thermal expansion of the material is prevented; and a graded cooling technology is adopted, the cooling speed of different parts is controlled, internal stress concentration is avoided, the overall stability of the workpiece is guaranteed, and cracks are avoided. According to the scheme of the embodiment of the invention, the problem that the hard sealing track ball body cannot be machined in the machining process can be solved; the problems that the roughness of the machined surface does not reach the standard and machining is difficult due to high material hardness, the size precision is difficult to control due to non-uniform thermal expansion of the material in a high-temperature environment, and cracks are generated due to internal stress concentration caused by non-uniform cooling speed are solved.

Description

Technical Field

[0001] The present application relates to mechanical processing, and in particular to a processing method for a hard seal track ball. Background Art

[0002] A method for processing a hard-sealed track ball involves using special processes and techniques to manufacture a sealing ball with high hardness and corrosion resistance, which is widely used in aerospace, oil and gas and other fields. However, in the actual processing process, this hard-sealed track ball faces many challenges. Due to the extremely high hardness of the material, it is easy to cause difficult processing and the surface roughness of the processing does not meet the standard, affecting its sealing performance and service life; in a high temperature environment, the material has uneven thermal expansion, which increases the difficulty of dimensional accuracy control and may cause the product to fail to meet the design requirements; in addition, uneven cooling speed will also cause internal stress concentration, which may cause safety hazards such as cracks and fractures during use. These problems are one of the key factors limiting the promotion and application of this method. Summary of the invention

[0003] In view of this, an embodiment of the present disclosure provides a method for processing a hard seal track ball, which at least partially solves the problems existing in the prior art.

[0004] A method for processing a hard seal track ball, comprising:

[0005] Preheat the material to be processed to a predetermined temperature to reduce the hardness of the material and improve cutting performance;

[0006] Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning to ensure the smoothness of the machined surface;

[0007] During the processing, the ambient temperature is monitored and adjusted in real time through a closed-loop temperature control system to prevent dimensional accuracy deviation caused by uneven thermal expansion of the material;

[0008] The graded cooling technology is used to control the cooling speed of different parts, avoid internal stress concentration, and ensure the overall stability of the workpiece.

[0009] Preferably,

[0010] Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, including:

[0011] Determine the specific values ​​of material hardness and ambient temperature after preheating;

[0012] Select the appropriate tool material and cutting speed;

[0013] Adjust feed rate to accommodate changes in material hardness;

[0014] Use cutting fluid to help reduce the temperature during cutting and improve the smoothness of the machined surface.

[0015] Preferably,

[0016] Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, including:

[0017] Use a high hardness tester to measure the material hardness value H;

[0018] According to the formula H>H_0, determine whether the cutting parameters need to be adjusted (H_0 is the preset hardness threshold, which represents the hardness value of the standard material);

[0019] Monitor the ambient temperature changes in real time through the ambient temperature sensor T;

[0020] Adjust cutting depth and feed rate according to ambient temperature to ensure smooth surface.

[0021] Preferably,

[0022] Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, including:

[0023] Use a hardness tester to measure the hardness value H of the preheated material;

[0024] According to the formula H>H_0+α(ambient temperature T T_0), determine whether it is necessary to further adjust the cutting parameters (α is the temperature hardness sensitivity coefficient, T_0 is the standard ambient temperature);

[0025] Use automatic temperature control equipment to control the processing environment temperature;

[0026] The cutting depth D is dynamically adjusted according to the hardness value H and temperature T, D=D_0β(H H_0) (β is the hardness cutting sensitivity coefficient, D_0 is the initial cutting depth).

[0027] Preferably,

[0028] Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, including:

[0029] Measure the actual hardness value H of the preheated material and the current ambient temperature T;

[0030] Use the formula H+λ(T T_0)>H_c to determine whether it is necessary to increase the flexibility of cutting parameters (λ is the ambient temperature correction factor, H_c is the critical hardness value of the material, and T_0 is the reference temperature);

[0031] The flow rate and velocity of cooling water are adjusted in real time through a closed-loop temperature control system;

[0032] Adjust the cutting feed rate F according to the real-time monitored material hardness H and environmental temperature T, where F = F_0 * exp(γ(H - H_0)) (γ is the hardness feed adjustment coefficient, and F_0 is the reference feed rate).

[0033] Preferably,

[0034] Based on the preheated material hardness and environmental temperature, select appropriate cutting parameters for preliminary turning, specifically including:

[0035] Measure the preheated material hardness H and the current environmental temperature T;

[0036] Judge whether to adjust the tool type according to the formula H * (T - T_0) < H_t (H_t is the material thermal sensitivity hardness threshold, and T_0 is the standard environmental temperature);

[0037] Select a suitable tool type, such as tungsten carbide or ceramic tools;

[0038] Dynamically adjust the working angle θ of the tool, where θ = θ_0 + μ(T - T_0) (μ is the temperature working angle correction coefficient, and θ_0 is the initial working angle).

[0039] Preferably,

[0040] Based on the preheated material hardness and environmental temperature, select appropriate cutting parameters for preliminary turning, specifically including:

[0041] Determine the preheated material hardness value H and the current environmental temperature T;

[0042] Judge whether to optimize the cooling method according to the formula T - T_0 < δ and H - H_0 > ΔH (δ is the allowable environmental temperature change range, and ΔH is the material hardness difference threshold);

[0043] Use spray cooling instead of conventional water cooling to reduce the surface temperature difference of the material;

[0044] Dynamically adjust the cutting fluid flow rate Q, where Q = Q_0 * (1 + η(T - T_0)) (η is the temperature flow correction coefficient, and Q_0 is the initial flow rate).

[0045] Preferably,

[0046] Based on the preheated material hardness and environmental temperature, select appropriate cutting parameters for preliminary turning, specifically including:

[0047] Measure the material hardness H and the current environmental temperature T;

[0048] Judge whether to replace the high-precision tool according to the formula (H - H_0) / (T - T_0) > k (k is the temperature-hardness ratio threshold, H_0 is the reference hardness, and T_0 is the reference temperature);

[0049] Select high-precision cutting tools for fine turning;

[0050] Adjust the cutting depth according to the hardness value H and temperature T, D = D_0 * sqrt(φ(H H_0) * ξ(T T_0)) (φ is the hardness correction coefficient, ξ is the temperature correction coefficient, D_0 is the initial cutting depth).

[0051] Preferably,

[0052] Based on the preheated material hardness and ambient temperature, select appropriate cutting parameters for preliminary turning, specifically including:

[0053] Measure the material hardness H and the current ambient temperature T;

[0054] Judge whether to strengthen the cooling measures according to the formula H * (T T_0)^2 < L (L is the temperature secondary correction threshold, T_0 is the standard ambient temperature);

[0055] Add air-cooling equipment to accelerate the heat dissipation on the material surface;

[0056] Adjust the cutting speed R, R = R_0 * exp(ω(H H_0)) (ω is the hardness speed adjustment coefficient, R_0 is the initial speed).

[0057] Preferably,

[0058] Based on the preheated material hardness and ambient temperature, select appropriate cutting parameters for preliminary turning, specifically including:

[0059] Measure the material hardness H and the current ambient temperature T;

[0060] Judge whether to reduce the processing time according to the formula (T T_0)^2 + (H H_0)^2 < P (P is the comprehensive parameter threshold, T_0 is the standard ambient temperature, H_0 is the standard material hardness);

[0061] Reduce the feed rate N for each turning, N = N_0 / (1 + θ * sqrt(P)) (θ is the comprehensive correction coefficient, N_0 is the initial feed rate);

[0062] Dynamically adjust the processing strategy to ensure overall stability.

[0063] The disclosed embodiment provides a method for processing a hard-sealed track ball, including: preheating the material to be processed to a predetermined temperature to reduce the hardness of the material and improve the cutting performance; based on the hardness of the preheated material and the ambient temperature, selecting appropriate cutting parameters for preliminary turning to ensure the smoothness of the processed surface; during the processing, real-time monitoring and adjusting the ambient temperature through a closed-loop temperature control system to prevent dimensional accuracy deviation caused by uneven thermal expansion of the material; using graded cooling technology to control the cooling rate of different parts to avoid internal stress concentration and ensure the overall stability of the workpiece. Through the solution of the disclosed embodiment, it is possible to solve the problems of substandard surface roughness and difficult processing due to high material hardness, dimensional accuracy control difficulties due to uneven thermal expansion of the material under high temperature environment, and internal stress concentration and crack problems due to uneven cooling rate during the processing of the hard-sealed track ball. BRIEF DESCRIPTION OF THE DRAWINGS

[0064] In order to more clearly illustrate the technical solutions of the exemplary implementation methods of the embodiments of the present disclosure, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the embodiments of the present disclosure and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

[0065] Figure 1 It is a flowchart of preheating;

[0066] Figure 2 It is a flowchart of numerical selection;

[0067] Figure 3 It is a material hardness test flow chart;

[0068] Figure 4 It is a flow chart for controlling the processing environment temperature;

[0069] Figure 5 It is a flow chart for adjusting the flow rate and flow rate of cooling water;

[0070] Figure 6 It is a flow chart for measuring the current ambient temperature;

[0071] Figure 7 It is a flow chart for reducing the temperature difference on the surface of the material;

[0072] Figure 8 It is a flow chart for selecting cutting tools;

[0073] Fig. 9 It is a flow chart for accelerating heat dissipation on the surface of materials;

[0074] Fig.10 It is a flow chart for adjusting the processing strategy. DETAILED DESCRIPTION

[0075] In order to make the purpose, technical solutions and advantages of the embodiments of the present disclosure more clear, the embodiments of the present disclosure are further described in detail in combination with the embodiments and drawings. The schematic implementation methods of the embodiments of the present disclosure and their descriptions are only used to explain the embodiments of the present disclosure and are not intended to limit the embodiments of the present disclosure.

[0076] Next, referring to the accompanying drawings, a method for processing a hard seal track ball of the present invention is described. The method first involves preheating the material to be processed to a predetermined temperature to reduce the hardness of the material and improve the cutting performance. Specifically, this step gradually raises the metal material (such as high-strength alloy steel or stainless steel) to a specific temperature through a heating device, so that the microstructure of the material changes, the hardness temporarily decreases, and the plasticity increases. The main purpose of this step is to make subsequent processing easier, while reducing the wear rate of the tool and improving production efficiency. For example, in one embodiment, the material to be processed is 316L stainless steel, which is preheated to 450°C and kept warm for 2 hours, so that the surface of the material reaches a relatively soft state, which is convenient for preliminary turning.

[0077] Based on the hardness of the material after preheating and the ambient temperature, select appropriate cutting parameters for preliminary turning to ensure the smoothness of the machined surface. In this process, it is necessary to accurately measure the hardness of the preheated material and select appropriate cutting speeds, feed rates and cutting depths based on the hardness value. Selecting appropriate cutting parameters can significantly improve the quality of the machined surface and reduce surface roughness to meet design requirements. In one embodiment, after hardness testing, it was found that the hardness of 316L stainless steel after preheating dropped to 190HV. At this time, a cutting speed of 150m / min, a feed rate of 0.1mm / r and a cutting depth of 1mm were selected, which effectively ensured the surface smoothness during the preliminary turning process and reached the standard of Ra<0.8μm.

[0078] During the processing, the ambient temperature is monitored and adjusted in real time through a closed-loop temperature control system to prevent dimensional accuracy deviations caused by uneven thermal expansion of the material. The closed-loop temperature control system can continuously detect the temperature of the processing area during the processing process, and keep the processing temperature stable by adjusting the ambient temperature or local cooling measures. This measure can avoid dimensional errors caused by thermal expansion and contraction, thereby improving processing accuracy. Specifically, the closed-loop system uses an infrared temperature sensor to collect data in real time and regulates the cooling system through a PID control algorithm. In a specific example, the system sets the target temperature of the processing area to 500°C. When the temperature sensor detects that the actual temperature deviates from the target value, it automatically starts the cooling fan or switches the water cooling device to a higher gear to quickly return the temperature to the set range, ensuring that the spherical dimensional accuracy is always within the tolerance range.

[0079] The graded cooling technology is used to control the cooling rate of different parts, avoid internal stress concentration, and ensure the overall stability of the workpiece. After processing, the hard seal track sphere needs to undergo cooling treatment, but the traditional uniform cooling method easily leads to large residual stress inside the workpiece, and even causes cracking. The graded cooling technology adopts different cooling strategies according to the specific conditions of each part of the sphere. For example, the center of the sphere can be cooled by slower natural air cooling, and the outer surface can be cooled by fast air. This can reduce the temperature difference between the inside and the outside and avoid the problem of internal stress concentration caused by inconsistent cooling speed. Specifically, in one embodiment, the center of the sphere can be cooled by blast cooling, and the time for the temperature to drop from 500°C to 150°C is 2 hours; while the outer surface of the sphere is cooled by jet airflow, and the cooling time is 30 minutes, thereby ensuring uniform overall cooling, full release of internal stress, and ensuring the stability of the final product.

[0080] Next, the present invention is described, specifically, selecting appropriate cutting parameters for preliminary turning based on the hardness of the material after preheating and the ambient temperature. The specific values ​​of the hardness of the material after preheating and the ambient temperature are determined to ensure that the appropriate cutting parameters can be adjusted according to the actual working conditions during the processing. The hardness of the material can be measured by a Rockwell hardness tester or other hardness testing equipment, and the ambient temperature can be measured by a temperature sensor. The precise values ​​of these two parameters directly affect the selection of subsequent cutting parameters.

[0081] The purpose of selecting the appropriate tool material and cutting speed is to reduce tool wear while ensuring cutting efficiency. Tools of different materials will perform differently under different material hardness and ambient temperature conditions. Generally, when the material hardness is high, high-strength carbide tools are selected, and the cutting speed will be appropriately reduced. Specifically, when the material hardness is above HRC60, tungsten steel tools can be selected, and the cutting speed Vc is generally controlled between 50-100m / min.

[0082] Adjusting the feed rate to adapt to changes in material hardness is to maintain the stability of the cutting force and avoid surface quality and tool life problems caused by too high or too low feed rates. When the material hardness increases, the feed rate F should be appropriately reduced to ensure that the cutting force between the tool and the material remains within a reasonable range. The formula F = C*H^-n can be used to calculate the feed rate, where C is a constant, H is the material hardness, and n is an exponent (usually between 0.5 and 1.0). For example, when the material hardness increases from HRC50 to HRC60, if C = 0.5 and n = 0.7, F decreases from 0.2mm / rev to 0.15mm / rev.

[0083] The use of cutting fluid to assist in reducing the temperature during cutting and improving the smoothness of the machined surface is to reduce the impact of heat on materials and tools, thereby improving machining accuracy and surface quality. Commonly used cutting fluids include water-based cutting fluids and oil-based cutting fluids. The choice of which cutting fluid to use depends on the material properties. Specifically, when processing high-hardness materials, oil-based cutting fluids are usually used because of their better cooling effect and lubrication properties. The relationship between the flow rate Q of the cutting fluid and the cutting temperature T can be expressed by the formula Q=A*T^b, where A and b are empirical constants, T is the cutting temperature (unit: ℃), and Q is the cutting fluid flow rate (unit: L / min). For example, when the cutting temperature T is 800℃, A=0.2, b=0.5, then the cutting fluid flow rate Q is 1.4L / min, which can effectively reduce the cutting temperature and improve machining efficiency and surface finish.

[0084] In one embodiment, suppose that a hard-sealed track ball needs to be processed, the material hardness after preheating is HRC65, and the ambient temperature is 25°C. First, the material hardness is measured to be HRC65 using a Rockwell hardness tester. Next, a tungsten steel tool is selected, and the cutting speed Vc is set to 70m / min. Then, according to the formula F=0.5*65^-0.7, the feed rate is calculated to be 0.12mm / rev. Finally, in order to reduce the cutting temperature, an oil-based cutting fluid is selected, and the cutting fluid flow rate Q is set to 1.2L / min to ensure that the temperature is effectively controlled during the processing, thereby ensuring the high quality of the processed surface.

[0085] Next, the present invention describes the selection of appropriate cutting parameters for preliminary turning based on the hardness of the preheated material and the ambient temperature.

[0086] Step 1: Use a high hardness tester to measure the material hardness value H. In this step, a professional high hardness tester is used to test the hardness of the preheated material to ensure that the material hardness value H can be accurately obtained. The accurate determination of the material hardness value is an important basis for the subsequent adjustment of cutting parameters, which helps to optimize the cutting process and ensure processing accuracy and quality.

[0087] Step 2: Determine whether the cutting parameters need to be adjusted according to the formula H>H_0 (H_0 is the preset hardness threshold, which represents the hardness value of the standard material). Here, H_0 is a pre-set threshold, which is generally clearly stated in the material specification or determined through multiple experiments. The significance of this formula is to determine whether the currently measured material hardness value H exceeds the standard value H_0. If H>H_0, it means that the hardness of the material is relatively high, and the cutting parameters need to be adjusted to avoid deformation of the part due to excessive tool wear or excessive cutting force. The range of H is generally between 600HV and 900HV, and the optimal H_0 value is determined according to the specific material and process requirements, usually around 700HV. For example, when processing a stainless steel track sphere, if the measured hardness value H is 800HV, which is higher than the set H_0 value of 700HV, it is necessary to reduce the cutting speed and increase the coolant flow rate to reduce tool wear.

[0088] Step 3: Monitor the changes in ambient temperature in real time through the ambient temperature sensor T. During the processing, changes in ambient temperature may affect the performance of the material and the effectiveness of the cutting parameters. The ambient temperature sensor T can detect the temperature in the workshop in real time and feed the data back to the control system so that the cutting parameters can be adjusted in time. The temperature range is usually between 20°C and 40°C, and the optimal ambient temperature is usually around 25°C, as this can ensure the stability and consistency of the material and cutting tools. In one embodiment, when the ambient temperature rises from 25°C to 35°C, the control system will automatically adjust the cutting depth from 0.2mm to 0.15mm to prevent excessive cutting force from causing overheating of the part.

[0089] Step 4: Adjust the cutting depth and feed rate according to the ambient temperature to ensure surface smoothness. The key to this step is to maintain the quality of the material surface by dynamically adjusting the cutting parameters. As the ambient temperature increases, the cutting depth should be appropriately reduced and the feed rate should also be reduced to reduce the heat generated by friction, thereby preventing part deformation or surface roughness. For example, specifically, when processing carbon steel hard seal track balls, when the ambient temperature drops from 25°C to 20°C, the cutting depth can be increased from 0.2mm to 0.25mm and the feed rate can be increased from 0.5mm / rev to 0.6mm / rev to improve processing efficiency and ensure surface finish.

[0090] Next, the present invention describes the selection of appropriate cutting parameters for preliminary turning based on the hardness of the preheated material and the ambient temperature.

[0091] First, use a hardness tester to measure the hardness value H of the preheated material. This step is to obtain the actual hardness value of the material after preheating, so that there is an accurate data reference when adjusting the cutting parameters later. Usually, the hardness of the preheated material will fluctuate within a certain range, such as 60-70HRC.

[0092] Then, according to the formula H>H_0+α(ambient temperature T-T_0), it is determined whether the cutting parameters need to be further adjusted. The purpose of this formula is to ensure that the selected cutting parameters are optimal by considering the change of material hardness with temperature. Among them, H_0 is the standard hardness value of the material (such as 60HRC), T_0 is the standard ambient temperature (such as 20℃), and α is the temperature hardness sensitivity coefficient (range 0.05-0.15, optimal value 0.1), which represents the effect of each degree of ambient temperature change on the material hardness. If H>H_0+α(T-T_0), the cutting parameters need to be further adjusted.

[0093] Next, use the automatic temperature control equipment to control the processing environment temperature. Through this equipment, the processing environment temperature can be kept near the standard value (such as 20°C), thereby reducing the impact of temperature changes on the hardness of the material and ensuring the consistency and stability of the processing.

[0094] Finally, the cutting depth D is dynamically adjusted according to the hardness value H and temperature T, D = D_0 + β (H-H_0). This formula is used to dynamically adjust the cutting depth according to the actual hardness and temperature of the material to achieve the best cutting effect. D_0 is the initial cutting depth (such as 0.5mm), and β is the hardness cutting sensitivity coefficient (range 0.02-0.05, optimal value 0.03), which indicates the change in cutting depth per unit hardness change. If the hardness increases, the cutting depth is increased, and vice versa, to adapt to different hardness changes and ensure turning quality.

[0095] For example, in one embodiment, it is assumed that the hardness H of the material after preheating is measured to be 65HRC, the standard hardness H_0 is 60HRC, the temperature hardness sensitivity coefficient α is 0.1, the ambient temperature T is 22°C, and the standard ambient temperature T_0 is 20°C. The formula H>H_0+α(T-T_0) shows that H=65>60+0.1(22-20)=60.2, so the cutting parameters need to be further adjusted. Assuming that the initial cutting depth D_0 is 0.5mm, the hardness cutting sensitivity coefficient β is 0.03, and the final cutting depth D is D_0+β(H-H_0)=0.5+0.03(65-60)=0.65mm. In this case, the cutting depth is increased to 0.65mm, ensuring the processing quality and precision of the hard seal track ball.

[0096] Specifically, this method of dynamically adjusting cutting parameters based on material hardness and ambient temperature can effectively cope with hardness changes and temperature fluctuations during machining, improving production efficiency and product quality.

[0097] Next, the present invention is described to select appropriate cutting parameters for preliminary turning based on the hardness of the material after preheating and the ambient temperature. First, measure the actual hardness value H of the preheated material and the current ambient temperature T. This is to accurately obtain the hardness and temperature of the processed material in the current state, so as to provide a basis for the subsequent selection of cutting parameters. For example, the hardness value H of the material after preheating may be 600HV, and the ambient temperature T may be 25°C.

[0098] Next, use the formula H+λ(T-T_0)>H_c to determine whether it is necessary to increase the flexibility of cutting parameters. The λ in the formula is the ambient temperature correction factor, usually between 0.05 and 0.2, with an optimal value of 0.1; T_0 is the reference temperature, generally set to 20°C; H_c is the critical hardness value of the material, depending on the specific material type, such as 650HV. This formula is used to evaluate the effect of ambient temperature on material hardness. When H+λ(T-T_0) is greater than H_c, it indicates that the hardness of the material has reached or exceeded the critical value, and it is necessary to increase the flexibility of cutting parameters, such as reducing the feed rate or increasing the coolant flow rate, to prevent tool wear and reduced machining accuracy. This helps to maintain the stability and efficiency of the machining process under different environmental conditions.

[0099] Subsequently, the flow and velocity of the cooling water are adjusted in real time through a closed-loop temperature control system. The closed-loop system can automatically adjust the flow and velocity of the cooling water based on the real-time detected temperature data to ensure that the temperature of the material during processing remains within the set range. In one embodiment, if the temperature is detected to be above 40°C, the system will automatically increase the cooling water flow until the temperature drops to a reasonable range.

[0100] Finally, according to the real-time monitored material hardness H and ambient temperature T, the cutting feed rate F is adjusted. The specific calculation formula is F=F_0*exp(γ(H-H_0)). The γ in the formula is the hardness feed adjustment coefficient, which is usually between 0.001 and 0.01, and the optimal value is 0.005; F_0 is the reference feed rate, which is determined according to the equipment and materials, such as 0.2mm / rev; H_0 is the reference hardness value, usually 500HV. This formula reflects the dynamic impact of material hardness changes on the cutting feed rate. When the material hardness H is greater than the reference hardness H_0, the value of exp(γ(H-H_0)) is greater than 1, which means that the feed rate F will decrease, otherwise it will increase. This dynamic adjustment method can ensure the best cutting effect under different hardness conditions and improve processing quality and efficiency.

[0101] Next, the present invention describes the selection of appropriate cutting parameters for preliminary turning based on the hardness of the preheated material and the ambient temperature, which specifically includes the following steps:

[0102] First, measure the hardness \(H\) of the preheated material and the current ambient temperature \(T\). This means that after the material preheating is completed, the hardness of the material is tested with a hardness tester, and at the same time, the ambient temperature of the current workshop is measured. For example, in a certain workshop, the measured hardness of the preheated material is \(H = 60\) HRC, and the ambient temperature is \(T = 25\) °C.

[0103] Secondly, judge whether the tool type needs to be adjusted according to the formula \(H\times(T - T_0)<H_t\). Among them, \(H_t\) is the thermal hardness threshold of the material, and \(T_0\) is the standard ambient temperature. The meaning of this formula is that under different temperature conditions, the sensitivity of the material hardness is different, so it is necessary to judge whether to change the tool type according to this condition. Generally, the range of \(H_t\) is between 50 and 70 HRC, and the standard ambient temperature \(T_0\) is usually set to 20 °C. In an embodiment, assuming \(H_t = 60\) HRC and \(T_0 = 20\) °C, it is calculated that \(H\times(T - T_0)=60\times(25 - 20)=300\). If \(H_t = 350\), the tool type does not need to be adjusted; on the contrary, if \(H_t = 280\), adjustment is required.

[0104] Then, select a suitable tool type. Common tool types include tungsten carbide tools and ceramic tools. Tungsten carbide tools are suitable for materials with relatively high hardness but little change, while ceramic tools are suitable for materials with high hardness and temperature sensitivity. Specifically, if it is determined that the tool type does not need to be adjusted, the existing tungsten carbide tool can be continued to be used. If adjustment is required, a ceramic tool is selected. In an embodiment, after calculation, it is found that \(H\times(T - T_0)=300\) exceeds the set threshold \(H_t = 280\), so it is decided to replace it with a ceramic tool.

[0105] Finally, dynamically adjust the working angle of the tool \(\theta\), the formula is \(\theta=\theta_0+\mu(T-T_0)\). Among them, \(\theta_0\) is the initial working angle, generally between 5° and 15°, and \(\mu\) is the temperature working angle correction coefficient, usually between 0.01 and 0.05. The meaning of this formula is that under different temperature conditions, in order to ensure the normal working performance of the tool, it is necessary to dynamically adjust the angle of the tool according to the change of temperature. Specifically, if the initial working angle \(\theta_0=10°\), the temperature correction coefficient \(\mu=0.02\), and the ambient temperature rises from 20℃ to 25℃, the new working angle \(\theta=10°+0.02\times(25-20)=11°\) is calculated. This dynamic adjustment can effectively avoid processing quality problems caused by temperature changes and improve processing accuracy and tool life.

[0106] Next, the present invention describes the selection of appropriate cutting parameters for preliminary turning based on the hardness of the preheated material and the ambient temperature.

[0107] First, determine the hardness value H of the preheated material and the current ambient temperature T. The purpose of this step is to obtain the material properties before processing so that appropriate cutting parameters can be selected based on these data. For example, suppose that during the processing of a hard seal track ball, the hardness value H of the preheated material is measured to be 50HRC and the current ambient temperature T is 25℃.

[0108] Then, according to the formula T-T_0<δ and H-H_0>ΔH, determine whether the cooling method needs to be optimized. Here, T_0 is the reference ambient temperature, usually the ambient temperature under standard processing conditions, and δ is the allowable range of change in ambient temperature, generally within ±5°C. H_0 is the reference material hardness, usually the hardness of the material at room temperature, and ΔH is the difference threshold of the material hardness, which is used to determine whether the material has changed significantly, and is usually taken as 3HRC. The purpose of this formula is to evaluate whether the material properties and ambient temperature in the current processing environment are within an acceptable range. If they are out of range, additional measures need to be taken. If the current ambient temperature T is 25°C and the reference ambient temperature T_0 is 20°C, then T-T_0=5℃<5℃ satisfies the condition. Assuming the hardness change H-H_0=5HRC>3HRC, the threshold of the hardness change is exceeded and the cooling method needs to be optimized.

[0109] After determining that the cooling method needs to be optimized, spray cooling is used instead of conventional water cooling to reduce the temperature difference on the material surface. This is because conventional water cooling may cause the material surface to cool rapidly, causing thermal stress, while spray cooling can cool the material surface more evenly and reduce the temperature difference. Specifically, during the above-mentioned hard seal track ball processing, if it is detected that the cooling method needs to be optimized, a spray cooling system can be selected to replace the traditional cooling water tank.

[0110] Finally, the cutting fluid flow rate Q is adjusted dynamically. The specific calculation formula is Q = Q_0*(1+η(T-T_0)). Among them, Q_0 is the initial flow rate, which is usually a reference value set according to experience and standard conditions; η is the temperature flow correction coefficient, which reflects the impact of ambient temperature on the demand for coolant. It usually takes a value between 0.01 and 0.1, and the optimal value is 0.05; T is the current ambient temperature, and T_0 is the reference ambient temperature. The significance of this formula is to dynamically adjust the cutting fluid flow rate to adapt to different ambient temperatures and ensure the cooling effect. For example, assuming that the initial flow rate Q_0 is 5L / min, the temperature flow correction coefficient η is 0.05, the current ambient temperature T is 25℃, and the reference ambient temperature T_0 is 20℃, the cutting fluid flow rate Q is calculated as Q = 5*(1+0.05*(25-20)) = 5*1.25 = 6.25L / min. This means that in order to adapt to higher ambient temperatures, the cutting fluid flow rate is increased by 1.25L / min to ensure an effective cooling effect.

[0111] Through the above steps, the cutting parameters can be reasonably selected and adjusted during the processing to improve the processing quality and efficiency of the hard seal track ball.

[0112] Next, the present invention describes the selection of appropriate cutting parameters for preliminary turning based on the hardness of the preheated material and the ambient temperature.

[0113] Measure the material hardness H and the current ambient temperature T. This step is to obtain the specific physical property data of the material to be processed so as to adjust the cutting parameters according to the actual situation. In the processing of the hard seal track ball, these data directly affect the selection of the tool and the cutting effect. For example, in one embodiment, the material hardness may be measured as 50HRC and the ambient temperature is 25℃.

[0114] According to the formula \((H-H_0) / (T-T_0)>k\), determine whether the high-precision tool needs to be replaced. This formula is used to evaluate the relationship between the change in material hardness and the change in ambient temperature. Among them, \(H\) is the measured material hardness, \(H_0\) is the reference hardness, which is usually set to a standard value; \(T\) is the ambient temperature, \(T_0\) is the reference temperature, which is also a set standard value; \(k\) is the temperature-hardness ratio threshold, which is an empirical parameter used to determine whether a more precise tool needs to be replaced. For example, assume \(H_0=50\)HRC, \(T_0=20\)℃, \(k=1.2\). If \((50-50) / (25-20)=0<1.2\), there is no need to replace the high-precision tool.

[0115] Choose high-precision tools for fine turning. When the above formula is true, you need to choose higher-precision tools to ensure processing quality. For example, in the case of high material hardness or extreme ambient temperature, ordinary tools may wear faster or produce larger errors, and high-precision tools can better meet the requirements. Specifically, you can choose tools with wear-resistant coatings to adapt to higher hardness and temperature conditions.

[0116] Adjust the cutting depth according to the hardness value H and temperature T, \(D=D_0*\sqrt{\varphi(H-H_0)*\xi(T-T_0)}\). This formula is used to determine the reasonable value of the cutting depth to adapt to different material properties and environmental conditions. Among them, \(D\) is the actual cutting depth, \(D_0\) is the initial cutting depth, which is usually set according to experience and standards; \(\varphi\) is the hardness correction coefficient, which indicates the degree of influence of material hardness on cutting depth; \(\xi\) is the temperature correction coefficient, which indicates the degree of influence of ambient temperature on cutting depth. For example, if the initial cutting depth \(D_0=1\)mm, \(\varphi=0.9\), \(\xi=1.1\), then the cutting depth is \(D=1*\sqrt{0.9*(50-50)*1.1}=1\)mm. Since in this case \((50-50)=0\), the product is zero, which means that under this particular condition, the cutting depth remains unchanged.

[0117] These steps ensure efficient and high-quality machining of hard seal raceway balls through precise parameter adjustment under different hardness and temperature conditions.

[0118] Next, the present invention describes the selection of appropriate cutting parameters for preliminary turning based on the hardness of the preheated material and the ambient temperature, which specifically includes the following steps:

[0119] Measure the hardness H of the material and the current ambient temperature T. In this step, an appropriate hardness tester and thermometer are required to accurately measure the hardness of the material and the ambient temperature, and these data will be used for subsequent calculations and judgments.

[0120] Judge whether additional cooling measures are needed according to the formula H*(T - T_0)^2 < L. Here, L is the temperature quadratic correction threshold, T_0 is the standard ambient temperature, and H is the material hardness. This formula compares the product of hardness and temperature with the threshold L. If the result is greater than or equal to L, it indicates that additional cooling measures need to be taken to prevent overheating.

[0121] Add air-cooling equipment to accelerate the heat dissipation on the material surface. If it is determined in the previous step that additional cooling measures are needed, the air-cooling equipment should be started. These devices usually include high-speed fans or compressed air nozzles, which can effectively reduce the temperature on the material surface and prevent the material from deforming or being damaged due to high temperature.

[0122] Adjust the cutting speed R, where R = R_0*exp(ω(H - H_0)). In this step, according to the material hardness H and the hardness cutting speed adjustment coefficient ω, the appropriate cutting speed R is calculated. The initial speed R_0 is the recommended speed at the standard hardness H_0. Through exponential function adjustment, the speed can be dynamically adjusted according to the actual hardness to ensure the stability and efficiency of the machining process.

[0123] In one embodiment, assume that the hardness H of the material is 60 HRC, the current ambient temperature T is 35 °C, the standard ambient temperature T_0 is 20 °C, the temperature quadratic correction threshold L is 5000, the initial speed R_0 is 300 rpm, the hardness cutting speed adjustment coefficient ω is 0.02, and the standard hardness H_0 is 50 HRC.

[0124] First, use a hardness tester to measure the material hardness H = 60 HRC, and use a thermometer to measure the ambient temperature T = 35 °C. Next, calculate H*(T - T_0)^2 = 60*(35 - 20)^2 = 60*225 = 13500. Since 13500 > 5000, it is necessary to start the air-cooling equipment to increase the heat dissipation effect. Finally, calculate the cutting speed R = 300*exp(0.02*(60 - 50)) = 300*exp(0.2) ≈ 300*1.2214 ≈ 366.42 rpm.

[0125] During this process, the result of multiplying the material hardness H by the square of the temperature difference (T - T_0) is compared with L to judge whether additional cooling is needed. This is because high hardness and high ambient temperature may cause the material temperature to be too high, and additional cooling is required to avoid damage. In addition, when adjusting the cutting speed, the exponential function R = R_0*exp(ω(H - H_0)) is used to achieve more reasonable speed control at different hardnesses and ensure the stability and quality of the machining.

[0126] Next, describe the initial turning by selecting appropriate cutting parameters based on the preheated material hardness and ambient temperature in the present invention. Specifically, first measure the material hardness H and the current ambient temperature T. In actual operation, the Rockwell hardness value H of the material is measured by a hardness tester, and at the same time, the ambient temperature T in the workshop is measured by a temperature sensor. These two pieces of data are used for subsequent parameter selection and judgment.

[0127] Secondly, judge whether it is necessary to reduce the processing time according to the formula (T - T_0)^2+(H - H_0)^2 < P. Here, P is a comprehensive parameter threshold, T_0 is the standard ambient temperature (such as 20 °C), and H_0 is the standard material hardness (such as 60 HRC). The significance of this formula is to evaluate the sum of the squares of the deviations of the material hardness and ambient temperature from the standard values. When this deviation is less than the set threshold P, it means that the hardness and temperature of the material are relatively ideal and no additional adjustment to the processing time is required. If the deviation is greater than P, it is necessary to consider reducing the feed rate per turning to adapt to these condition changes and ensure the processing quality.

[0128] Then, reduce the feed rate per turning N. The specific calculation formula is N = N_0 / (1 + θ * sqrt(P)). Here, N_0 is the initial feed rate under standard conditions, θ is a comprehensive correction coefficient (usually taking values between 0.05 and 0.15), and sqrt(P) represents the square root of the sum of the squares of the deviations. The significance of this formula is that when the material hardness or ambient temperature deviates far from the standard value, it is necessary to appropriately reduce the feed rate to reduce the processing stress and avoid tool damage or workpiece deformation. By introducing sqrt(P) and the correction coefficient θ, flexible adjustment of the processing parameters can be achieved to ensure good processing effects in different environments.

[0129] Finally, dynamically adjust the processing strategy to ensure overall stability. This step emphasizes continuous monitoring and feedback during the processing, and adjusts parameters such as the feed speed, tool selection, and cooling method in real time according to the actual processing situation to maintain the stability of the processing process and the quality consistency of the workpiece.

[0130] For example, in an embodiment, assume that the preheated material hardness H = 65 HRC and the current ambient temperature T = 25 °C. The material hardness H_0 = 60 HRC and the ambient temperature T_0 = 20 °C under standard conditions, the comprehensive parameter threshold P = 50, the comprehensive correction coefficient θ = 0.1, and the initial feed rate N_0 = 100. First calculate the sum of the squares of the deviations:

[0131] \[

[0132] (T-T_0)^2+(H-H_0)^2=(25-20)^2+(65-60)^2=25+25=50

[0133] \]

[0134] Because 50 is exactly equal to P, it means that the changes in material hardness and ambient temperature are close to the critical point, and the feed times need to be adjusted appropriately. Calculate the new feed times:

[0135] \[

[0136] N=N_0 / (1+\theta\times\sqrt{50})=100 / (1+0.1\times\sqrt{50})\approx67

[0137] \]

[0138] In this example, the number of feeds was reduced from 100 to about 67 to reduce machining stress and improve machining stability. Specifically, the machine tool parameter settings, such as feed speed, tool type, and coolant flow, were adjusted to ensure the continuity and reliability of the machining process. Throughout the machining process, changes in material temperature and hardness must be continuously monitored, and machining strategies must be dynamically adjusted to ultimately achieve efficient and stable turning.

[0139] A method for processing a hard seal track ball of the present invention comprises:

[0140] First, the material to be processed is preheated to a predetermined temperature. The purpose of this process is to reduce the hardness of the material and improve its cutting performance, thereby solving the problem of difficult processing and substandard surface roughness caused by high material hardness. Through preheating, the microstructure inside the material changes, becoming more suitable for cutting, reducing the difficulty of processing and making the processed surface smoother.

[0141] Secondly, based on the hardness of the preheated material and the ambient temperature, appropriate cutting parameters are selected for preliminary turning. At this stage, the smoothness of the machined surface is ensured to meet the standard by accurately controlling parameters such as cutting speed, feed rate and cutting depth. This measure can effectively deal with the processing quality problems caused by changes in material hardness, so that the processed products have higher surface quality and smoothness.

[0142] Third, during the entire processing process, the ambient temperature is monitored and adjusted in real time through a closed-loop temperature control system. This step is to prevent the difficulty of dimensional accuracy control caused by uneven thermal expansion of materials in a high-temperature environment. The closed-loop control system can detect changes in ambient temperature in real time and automatically adjust the temperature according to the detection results to keep the material within a relatively stable temperature range, thereby ensuring the consistency and reliability of dimensional accuracy during the processing process.

[0143] Finally, the graded cooling technology is used to control the cooling speed of different parts to avoid internal stress concentration and ensure the overall stability of the workpiece. Traditional cooling methods may cause uneven cooling of the workpiece and form internal stress concentration areas, while the graded cooling technology can gradually cool in stages according to the needs of different parts, making the thermal stress distribution inside the workpiece more uniform, effectively eliminating the risk of internal stress concentration and improving the overall stability and service life of the workpiece.

[0144] Through the above series of technical means, the present invention successfully solves the key problems in the processing of hard seal track balls, which not only improves the quality of the processed surface, but also ensures the precise control of the workpiece size and the overall stability, and has high practical value.

[0145] The above is a preferred embodiment of the present application. It should be pointed out that, for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present application.

Claims

1. A method for processing a hard seal track ball, characterized in that: include: Preheat the material to be processed to a predetermined temperature to reduce the hardness of the material and improve cutting performance; Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning to ensure the smoothness of the machined surface; During the processing, the ambient temperature is monitored and adjusted in real time through a closed-loop temperature control system to prevent dimensional accuracy deviation caused by uneven thermal expansion of the material; The graded cooling technology is used to control the cooling speed of different parts, avoid internal stress concentration, and ensure the overall stability of the workpiece.

2. A method for processing a hard seal track ball according to claim 1, characterized in that: Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, including: Determine the specific values ​​of material hardness and ambient temperature after preheating; Select the appropriate tool material and cutting speed; Adjust feed rate to accommodate changes in material hardness; Use cutting fluid to help reduce the temperature during cutting and improve the smoothness of the machined surface.

3. A method for processing a hard seal track ball according to claim 2, characterized in that: Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, including: Use a high hardness tester to measure the material hardness value H; According to the formula H>H_0, determine whether the cutting parameters need to be adjusted (H_0 is the preset hardness threshold, which represents the hardness value of the standard material); Monitor the ambient temperature changes in real time through the ambient temperature sensor T; Adjust cutting depth and feed rate according to ambient temperature to ensure smooth surface.

4. A method for processing a hard seal track ball according to claim 3, characterized in that: Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, including: Use a hardness tester to measure the hardness value H of the preheated material; According to the formula H>H_0+α(ambient temperature T T_0), determine whether it is necessary to further adjust the cutting parameters (α is the temperature hardness sensitivity coefficient, T_0 is the standard ambient temperature); Use automatic temperature control equipment to control the processing environment temperature; The cutting depth D is dynamically adjusted according to the hardness value H and temperature T, D=D_0β(H H_0) (β is the hardness cutting sensitivity coefficient, D_0 is the initial cutting depth).

5. A method for processing a hard seal track ball according to claim 4, characterized in that: Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, including: Measure the actual hardness value H of the preheated material and the current ambient temperature T; Use the formula H+λ(T T_0)>H_c to determine whether it is necessary to increase the flexibility of cutting parameters (λ is the ambient temperature correction factor, H_c is the critical hardness value of the material, and T_0 is the reference temperature); The flow rate and velocity of cooling water are adjusted in real time through a closed-loop temperature control system; According to the real-time monitored material hardness H and ambient temperature T, the cutting feed rate F is adjusted, F=F_0*exp(γ(H H_0)) (γ is the hardness feed adjustment coefficient, F_0 is the reference feed rate).

6. A processing method of a hard-sealed track sphere according to claim 5, characterized in that Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, specifically including: Measure the hardness H of the preheated material and the current ambient temperature T; Judge whether to adjust the tool type according to the formula H*(T - T_0) < H_t (H_t is the material thermal sensitivity hardness threshold, and T_0 is the standard ambient temperature); Select a suitable tool type, such as tungsten carbide or ceramic tool; Dynamically adjust the working angle θ of the tool, θ = θ_0 + μ(T - T_0) (μ is the temperature working angle correction coefficient, and θ_0 is the initial working angle).

7. A processing method of a hard-sealed track sphere according to claim 2, characterized in that Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, specifically including: Determine the hardness value H of the preheated material and the current ambient temperature T; Judge whether to optimize the cooling method according to the formula T - T_0 < δ and H - H_0 > ΔH (δ is the allowable change range of ambient temperature, and ΔH is the material hardness difference threshold); Use spray cooling instead of conventional water cooling to reduce the temperature difference on the material surface; Dynamically adjust the cutting fluid flow rate Q, Q = Q_0*(1 + η(T - T_0)) (η is the temperature flow rate correction coefficient, and Q_0 is the initial flow rate).

8. A processing method of a hard-sealed track sphere according to claim 6, characterized in that Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, specifically including: Measure the material hardness H and the current ambient temperature T; Judge whether to replace the high-precision tool according to the formula (H - H_0) / (T - T_0) > k (k is the temperature-hardness ratio threshold, H_0 is the reference hardness, and T_0 is the reference temperature); Select a high-precision tool for fine turning; Adjust the cutting depth according to the hardness value H and the temperature T, D = D_0*sqrt(φ(H - H_0)*ξ(T - T_0)) (φ is the hardness correction coefficient, ξ is the temperature correction coefficient, and D_0 is the initial cutting depth).

9. A processing method of a hard-sealed track sphere according to claim 7, characterized in that Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, specifically including: Measure the material hardness H and the current ambient temperature T; Judge whether to strengthen the cooling measures according to the formula H*(T - T_0)^2 < L (L is the temperature secondary correction threshold, and T_0 is the standard ambient temperature); Add air-cooling equipment to accelerate the heat dissipation on the material surface; Adjust the cutting speed R, R = R_0*exp(ω(H - H_0)) (ω is the hardness speed adjustment coefficient, and R_0 is the initial speed).

10. A processing method of a hard-sealed track sphere according to claim 8, characterized in that Based on the hardness of the preheated material and the ambient temperature, select appropriate cutting parameters for preliminary turning, specifically including: Measure the material hardness H and the current ambient temperature T; Judge whether it is necessary to reduce the processing time according to the formula \((T - T_0)^2+(H - H_0)^2 < P\) (\(P\) is the comprehensive parameter threshold, \(T_0\) is the standard ambient temperature, and \(H_0\) is the standard material hardness); Reduce the feed rate \(N\) per turning, \(N = N_0 / (1+\theta\times\sqrt{P})\) (\(\theta\) is the comprehensive correction coefficient, and \(N_0\) is the initial feed rate); Dynamically adjust the processing strategy to ensure overall stability.

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