Flexible on-line machining method and system for large diameter-thickness ratio thin-walled disc parts

Abstract

The present application provides a kind of flexible on-line processing method and system of large diameter-thickness ratio thin-walled disc parts, comprising: step one, according to product size characteristics, make compatible adsorption surface mould;Step two, process inner concave surface datum at product blank;Step three, install small lithium battery and pressure alarm function vacuum pump and integral support assembly on machine tool table;Step four, install adsorption surface mould to integral support assembly upper end, use pipeline to connect vacuum pump and adsorption surface mould with gas circuit;Step five, according to the size of on-line processing adsorption surface to theoretical size;Step six, use sealing washer to set sealing area, place the part on adsorption surface mould, open vacuum pump to fix the part;Step seven, install auxiliary pressing plate on the outside of the part for finishing, complete all processing.The present application can be used in combination according to different size products to make compatible adsorption surface mould clamp, and its use range and strain capacity become higher.

Description

Technical Field

[0001] This invention relates to the field of machining technology, specifically to a flexible online machining method and system for thin-walled disk parts with a large diameter-to-thickness ratio. Background Technology

[0002] Large-diameter-to-thickness thin-walled disk-shaped components are crucial parts in rocket fuel storage systems, primarily responsible for storing and supplying fuel to the propulsion system during rocket launch. The design requirements necessitate sufficient strength while minimizing weight, resulting in a high diameter-to-thickness ratio, often exceeding 500:1. To ensure reliability and safety, the design specifications impose high precision dimensional control requirements on the thickness dimension, for example: The ability to effectively control the thickness and machining accuracy of these parts directly affects their performance indicators. Therefore, the machining quality requirements for the precision dimensions of these parts are of paramount importance.

[0003] Large-diameter-to-thickness thin-walled disk-type parts are common in various types of launch vehicles. Many components utilize this type of part, varying in function, technical specifications, and characteristics. Currently, similar parts exhibit both typical and differentiated features. The thickness of these parts presents a significant machining challenge, and to improve machining flexibility and convenience across different parts, a convenient and high-precision control method is lacking in the manufacturing process.

[0004] There are currently two ways to improve this problem: (1) change the machining method to die casting for production; (2) use filler material for auxiliary support to enhance the rigidity of the parts themselves for production.

[0005] Problems with die casting production: (1) Depending on the size of different parts, it is necessary to customize the corresponding stamping molds. In single-piece and small-batch processing, the processing cost will increase dramatically and the production method has low generalization ability; (2) The processing method has low precision control ability and it is difficult to meet the thickness control requirements.

[0006] Problems with using filler material to enhance the rigidity of parts during production: (1) This method has low control over machining accuracy and is cumbersome and inefficient; (2) During machining, the filler material is easily deformed by cutting heat, which can lead to separation from the parts, resulting in low reliability of the machining method.

[0007] Therefore, a completely new processing method is urgently needed to solve the manufacturing problem of thin-walled disc-shaped parts with a large diameter-to-thickness ratio. Summary of the Invention

[0008] To address the shortcomings of existing technologies, the purpose of this invention is to provide a flexible online machining method and system for thin-walled disk parts with a large diameter-to-thickness ratio.

[0009] The flexible online machining method for large diameter-to-thickness thin-walled disk parts provided by the present invention includes:

[0010] Step 1: Create a suitable adsorption surface mold based on the product's size characteristics;

[0011] Step 2: Machin a concave reference surface on the product blank;

[0012] Step 3: Install the small vacuum pump with lithium battery and pressure alarm function and the integrated support assembly to the center of the vertical lathe table, and use the positioning key, positioning pin, pressure plate and bolts to align and fix it;

[0013] Step 4: Install the adsorption surface mold onto the upper part of the integral support assembly, adjust its position using positioning pins, fix it with countersunk bolts and washers, and connect the vacuum pump to the adsorption surface mold using an air pipe.

[0014] Step 5: Machine the adsorption surface online to the theoretical size according to the part dimensions;

[0015] Step 6: Use sealing gaskets to set the sealing area, place the part on the adsorption surface mold, and turn on the vacuum pump to fix the part;

[0016] Step 7: Install the auxiliary pressure plate at the process foot on the outside of the part using a dial indicator to complete all machining.

[0017] Preferably, step 1 includes:

[0018] The radius of the arc of the adsorption surface mold is R1755mm, the thickness is 2mm-4mm, the envelope diameter is Φ1420mm, and the thickness ratio of the thickness to the envelope diameter is 0.0014-0.0028.

[0019] Use CNC gantry milling to process the adsorption surface mold, ensuring that the size of the adsorption surface exceeds the part size by 105-108%, and that its sealing area is 10mm-12mm smaller than the part's envelope diameter.

[0020] The sealing grooves are distributed in a cross-shaped and circular structure, with a threaded connection hole near the middle position, and a 0.1mm-0.15mm allowance is reserved before machining.

[0021] Preferably, step 2 includes: fixing the blank with process feet, performing multiple layer-by-layer machining on a vertical lathe until the entire concave surface is polished, machining the inner surface to a preset size for use as a reference for subsequent machining, using machining parameters of lathe table speed of 10r / min-15r / min, cutting depth of 0.2mm-1mm, machining speed of 2mm / min-5mm / min, and using air cooling for machining.

[0022] Preferably, step 5 includes: machining the adsorption surface online to the theoretical size R1755mm according to the part size, ensuring that the size of the adsorption surface is consistent with the dynamic movement size of the machine tool, improving the machining accuracy of the machine tool and the adsorption surface mold to the theoretical state, using machining parameters such as lathe table speed of 10r / min-15r / min, cutting depth of 0.2mm-1mm, and processing speed of 2mm / min-5mm / min, and using a low-pressure air pipe to blow air to cool the cutting position of the tool.

[0023] Preferably, step 6 includes:

[0024] Use sealing strips to set the sealing area in the outermost sealing groove, and place the parts on the adsorption surface mold.

[0025] The vacuum pump negative pressure value is set to -60KPA to 80KPA, and is set to a warning state when the pressure and power are less than 20%.

[0026] Install the part onto the surface of the adsorption mold, use a magnetic holder to fix the dial indicator to the machine tool spindle, and move it to the concave end face of the part through the machine tool control handwheel. After the pointer contacts the end face, the pointer position jump range is controlled within 0-1mm. Align the part position by adjusting the reference of the lower end face of the part, and turn on the vacuum pump to fix it.

[0027] The flexible online machining system for large diameter-to-thickness thin-walled disk parts provided by the present invention includes:

[0028] Module M1: Creates an adsorption surface mold that is compatible with the product's size characteristics;

[0029] Module M2: A concave surface reference is machined on the product blank;

[0030] Module M3: Install the small vacuum pump with lithium battery and pressure alarm function and the integrated support assembly to the center of the vertical lathe table, and use positioning keys, positioning pins, pressure plates and bolts for alignment and fixation;

[0031] Module M4: Install the adsorption surface mold onto the upper part of the integral support assembly, correct its position using positioning pins, fix it with countersunk bolts and washers, and connect the vacuum pump to the adsorption surface mold using an air pipe.

[0032] Module M5: Online machining of the adsorption surface to the theoretical size based on the part dimensions;

[0033] Module M6: Use sealing gaskets to set the sealing area, place the part on the adsorption surface mold, and turn on the vacuum pump to fix the part;

[0034] Module M7: Install the auxiliary pressure plate at the process foot on the outside of the part to complete all machining.

[0035] Preferably, the module M1 includes:

[0036] The radius of the arc of the adsorption surface mold is R1755mm, the thickness is 2mm-4mm, the envelope diameter is Φ1420mm, and the thickness ratio of the thickness to the envelope diameter is 0.0014-0.0028.

[0037] Use CNC gantry milling to process the adsorption surface mold, ensuring that the size of the adsorption surface exceeds the part size by 105-108%, and that its sealing area is 10mm-12mm smaller than the part's envelope diameter.

[0038] The sealing grooves are distributed in a cross-shaped and circular structure, with a threaded connection hole near the middle position, and a 0.1mm-0.15mm allowance is reserved before machining.

[0039] Preferably, the module M2 includes: fixing with process feet at the blank, performing multiple layer-by-layer machining on a vertical lathe until the entire concave surface is polished, machining the inner surface to a preset size for use as a reference for subsequent machining, using machining parameters of lathe table speed of 10r / min-15r / min, cutting depth of 0.2mm-1mm, machining speed of 2mm / min-5mm / min, and using air cooling for machining.

[0040] Preferably, module M5 includes: online machining of the adsorption surface to the theoretical size R1755mm according to the part size, ensuring that the size of the adsorption surface is consistent with the dynamic motion size of the machine tool, improving the machining accuracy of the machine tool and the adsorption surface mold to the theoretical state, using machining parameters such as lathe table speed of 10r / min-15r / min, cutting depth of 0.2mm-1mm, and processing speed of 2mm / min-5mm / min, and using a low-pressure air pipe to blow air to cool the cutting position of the tool.

[0041] Preferably, the module M6 includes:

[0042] Use sealing strips to set the sealing area in the outermost sealing groove, and place the parts on the adsorption surface mold.

[0043] The vacuum pump negative pressure value is set to -60KPA to 80KPA, and is set to a warning state when the pressure and power are less than 20%.

[0044] Install the part onto the surface of the adsorption mold, use a magnetic holder to fix the dial indicator to the machine tool spindle, and move it to the concave end face of the part through the machine tool control handwheel. After the pointer contacts the end face, the pointer position jump range is controlled within 0-1mm. Align the part position by adjusting the reference of the lower end face of the part, and turn on the vacuum pump to fix it.

[0045] Compared with the prior art, the present invention has the following beneficial effects:

[0046] The solution provided by this invention can be used to create compatible adsorption surface mold clamps for products of different sizes, thus increasing its application range and adaptability. By performing online precision machining of the adsorption surface, the dynamic machining accuracy of the machine tool and the dimensional accuracy of the adsorption surface can be improved to near the theoretical state. Combined with vacuum adsorption technology, better machining accuracy and surface roughness quality can be obtained after processing. By using this invention, a flexible and high-precision machining method can be realized. Attached Figure Description

[0047] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0048] Figure 1 This is a schematic diagram of the tooling fixture structure for the adsorption surface;

[0049] Figure 2 This is a schematic diagram showing the features and dimensions of the part;

[0050] Figure 3 This is a schematic diagram of the adsorption surface mold;

[0051] Figure 4 A schematic diagram of machining the concave surface reference for the product blank;

[0052] Figure 5 A schematic diagram of the vacuum pump installation;

[0053] Figure 6 This is a schematic diagram of the integrated support component structure;

[0054] Figure 7 This is a schematic diagram of the installation of the integrated support assembly;

[0055] Figure 8 This is a schematic diagram of the installation of the adsorption surface mold;

[0056] Figure 9 This is a schematic diagram of the pipeline connection;

[0057] Figure 10 This is a schematic diagram of the installation of the adsorption fixture for precision machining.

[0058] Figure 11 A diagram showing the product calibration and installation;

[0059] Figure 12 This is a schematic diagram for installing the auxiliary pressure plate.

[0060] In the figure, 1-machine tool table, 2-integral support assembly, 3-adsorption surface mold, 4-part product, 5-vacuum pump, 6-fastening components, 7-positioning pin, 8-countersunk screw and washer, 9-rubber sealing ring, 10-pipe connector, 11-air pipe;

[0061] 20-Auxiliary pressure plate assembly, 21-Support base plate, 22-Support column, 23-Locking key, 24-Bolt, 25-First nut, 26-First washer, 27-Step positioning key;

[0062] 31-Adsorption surface, 32-Pipe thread connection hole, 33-Sealing groove, 34-Stepped hole;

[0063] 51-Pressure gauge, 52-Power indicator;

[0064] 61-Second nut, 62-Screw, 63-Washer, 64-T-block. Detailed Implementation

[0065] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0066] Example

[0067] This invention provides a flexible online machining method for thin-walled disk parts with a large diameter-to-thickness ratio, comprising the following steps:

[0068] Step 1: Make an adsorption surface mold that matches the product's size characteristics.

[0069] refer to Figure 1 , Figure 2 and Figure 3 The adsorption surface mold is designed and processed, with the adsorption surface 31 transitioning with an arc of R20; a pipe thread connection hole 32, a sealing groove 33, and a fixed step hole 34 are machined in the middle; the diameter of the two positioning pin holes in the middle is Φ12±0.01, the diameter of the distribution circle is Φ800±0.01, and the depth is 20mm.

[0070] The adsorption surface 31 has an envelope diameter of Φ1500mm and an R1755mm.

[0071] The pipe thread connection hole 32 is Φ10 adapter 3 / 8”, with an effective thread length of 50mm;

[0072] The dimensions of the sealing groove 33 are: maximum outer ring size Φ1400mm, width 6mm, and depth 5mm;

[0073] The stepped hole 34 is Φ17 through hole with Φ35, and the minimum depth of the stepped hole is greater than 32mm.

[0074] Using a CNC gantry milling machine, the R1755 dimension in the adsorption surface 31 is machined to R1755.15, and the sealing groove depth is machined to 5.15mm, leaving a 0.15mm allowance.

[0075] Step 2: Machin a concave reference surface on the product blank;

[0076] refer to Figure 4 The blank is fixed using process feet, and the concave surface R1755mm is machined into place. The machining parameters used are lathe table speed 12r / min, cutting depth 0.5mm, and machining speed 3mm / min. Air cooling is used for machining and is used as a reference for subsequent machining.

[0077] Step 3: Install a small vacuum pump with a lithium battery and pressure alarm function and an integrated support assembly on the machine tool table 1;

[0078] refer to Figure 5 Install the small vacuum pump 5 with lithium battery and pressure alarm function onto the center of the table 1 of the vertical lathe, and fix it on the left and right sides using fastening components 6. The fastening components 6 include: second nut 61, bolt 62, second washer 63, and T-block 64.

[0079] refer to Figure 6 and Figure 7 The integral support assembly 2 consists of a support base plate 21 and a support column 22. It is positioned and installed with the machine tool table 1 through a positioning key 23 and a stepped positioning key 27, and is fixed with bolts 24, a first washer 26 and a first nut 25, so that the center of the positioning hole of the integral support assembly 2 is consistent with the rotation center of the machine tool table 1.

[0080] The width of the positioning key 23 is 12 ± 0.005.

[0081] The step positioning key 27 has a size of 12±0.005, which is converted to 16±0.005.

[0082] Step 4: Install the adsorption surface mold onto the upper part of the integrated support assembly, and use pipelines to connect the vacuum pump to the adsorption fixture for gas supply.

[0083] refer to Figure 8 Using the positioning pin 7 and positioning hole, the position of the adsorption surface mold 3 is quickly corrected so that the center of the adsorption surface mold 3 is consistent with the rotation center of the machine tool table 1. The adsorption surface mold 3 and the integral support component 2 are fixedly installed using countersunk screws and washers 8.

[0084] The locating pin 7 has a size of Φ12±0.005.

[0085] refer to Figure 9 By using the manufactured pipe thread, install the pipe connector 10, and use the air pipe 11 to connect the small vacuum pump 5 with lithium battery and pressure alarm function to the adsorption surface mold 3.

[0086] Step 5: Machine the adsorption surface online to the theoretical size according to the part dimensions;

[0087] refer to Figure 10 The 0.15mm allowance reserved in the CNC gantry machining is precision machined to make the adsorption surface of the adsorption mold 3 online to the theoretical R1755 size, so that the machining accuracy of the machine tool and the adsorption surface is improved to the theoretical state. The machining parameters used are: lathe table speed 15r / min, cutting depth 0.3mm, cutting speed 3mm / min, and air cooling is used for machining.

[0088] Step 6: Use a sealing gasket to set the sealing area, place the part on the adsorption surface mold, and turn on the vacuum pump to fix the part.

[0089] Install the outermost sealing ring of the tooling using a Φ6.5 diameter rubber sealing strip, set the vacuum pump negative pressure value to -60-80KPA, and set it to a warning state where the pressure and power are less than 20%; then place the product on the adsorption surface mold.

[0090] refer to Figure 11 Use a dial indicator to calibrate the part to a position close to the machine tool's rotation plane, and then turn on the vacuum pump to fix the part in place.

[0091] Step 7: Install the auxiliary pressure plate on the outside of the part and perform turning to complete all machining.

[0092] refer to Figure 12 Install the auxiliary pressure plate assembly 20 at the process foot on the outside of the part. Check the pressure gauge 51 and the power indicator 52 to ensure they are working properly before proceeding with machining. The machining parameters used are: lathe table speed 12 r / min, cutting depth 0.5 mm, machining speed 3 mm / min, and air cooling.

[0093] Ultimately, all processing was completed by cutting the process feet.

[0094] The advantages of this invention include: providing a flexible and high-precision machining method for processing thin-walled disc-shaped parts with a large diameter-to-thickness ratio. The product can be manufactured using a suitable adsorption surface mold and combined with an integral support assembly. This method is flexible, convenient, and cost-effective. During the product dimensional control stage, online precision machining of the adsorption surface allows for the achievement of dimensional accuracy closest to the theoretical machining accuracy. Combined with the application of vacuum adsorption technology, the precision control capability of the parts is significantly improved. Simultaneously, as the thickness of the part gradually decreases with cutting, its own strength weakens, thus resulting in a closer fit to the adsorption surface. For thin-walled disc-shaped parts with a large diameter-to-thickness ratio, the thickness dimensional control effect is also better at the finished machining stage.

[0095] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0096] Those skilled in the art will understand that, in addition to implementing the system, apparatus, and their modules provided by this invention in purely computer-readable program code, the same program can be implemented in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers, and embedded microcontrollers by logically programming the method steps. Therefore, the system, apparatus, and their modules provided by this invention can be considered a hardware component, and the modules included therein for implementing various programs can also be considered structures within the hardware component; alternatively, modules for implementing various functions can be considered both software programs implementing the method and structures within the hardware component.

[0097] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A flexible online machining method for thin-walled disk parts with a large diameter-to-thickness ratio, characterized in that, include: Step 1: Create a suitable adsorption surface mold based on the product's size characteristics; Step 2: Machin a concave reference surface on the product blank; Step 3: Install the vacuum pump with small lithium battery and pressure alarm function and the integrated support assembly to the center of the vertical lathe table, and use the positioning key, positioning pin, pressure plate and bolts to align and fix it; Step 4: Install the adsorption surface mold onto the upper part of the integral support assembly, adjust its position using positioning pins, fix it with countersunk bolts and washers, and connect the vacuum pump to the adsorption surface mold using an air pipe. Step 5: Machine the adsorption surface online to the theoretical size according to the part dimensions; Step 6: Use sealing gaskets to set the sealing area, place the part on the adsorption surface mold, and turn on the vacuum pump to fix the part; Step 7: Install the auxiliary pressure plate at the process foot on the outside of the part using a dial indicator to complete all machining. Step 1 includes: The radius of the arc of the adsorption surface mold is R1755mm, the thickness is 2mm-4mm, the envelope diameter is Φ1420mm, and the thickness ratio of the thickness to the envelope diameter is 0.0014-0.0028. Use CNC gantry milling to process the adsorption surface mold, ensuring that the size of the adsorption surface exceeds the part size by 105-108%, and that its sealing area is 10mm-12mm smaller than the part's envelope diameter. The sealing grooves are distributed in a cross-shaped and circular structure, with a threaded connection hole near the middle position, and a 0.1mm-0.15mm allowance is reserved before machining. Step 2 includes: fixing the blank with process feet, performing multiple layer-by-layer machining on a vertical lathe until the entire concave surface is polished, machining the inner surface to a preset size to serve as a reference for subsequent machining, using machining parameters of lathe table speed of 10r / min-15r / min, cutting depth of 0.2mm-1mm, machining speed of 2mm / min-5mm / min, and using air cooling for machining.

2. The flexible online machining method for large diameter-to-thickness thin-walled disk parts according to claim 1, characterized in that, Step 5 includes: machining the adsorption surface online to the theoretical size R1755mm according to the part size, ensuring that the size of the adsorption surface is consistent with the dynamic movement size of the machine tool, and improving the machining accuracy of the machine tool and the adsorption surface mold to the theoretical state. The machining parameters used are: lathe table speed 10r / min-15r / min, cutting depth 0.2mm-1mm, and speed 2mm / min-5mm / min. Low-pressure air blowing pipe is used to blow air to the cutting position of the tool for cooling.

3. The flexible online machining method for large diameter-to-thickness thin-walled disk parts according to claim 1, characterized in that, Step 6 includes: Use sealing strips to set the sealing area in the outermost sealing groove, and place the parts on the adsorption surface mold. The vacuum pump negative pressure value is set to -60KPA~80KPA, and it is set to alert users when the pressure and power are less than 20%. Install the part onto the surface of the adsorption mold, use a magnetic holder to fix the dial indicator to the machine tool spindle, and move it to the concave end face of the part through the machine tool control handwheel. After the pointer contacts the end face, the pointer position jump range is controlled within 0-1mm. Align the part position by adjusting the reference of the lower end face of the part, and turn on the vacuum pump to fix it.

Images