Elastic shaft machining process

Abstract

The invention relates to an elastic shaft machining process, which belongs to the technical field of elastic shaft machining, and comprises the following steps: S1, forging a blank; step S2, hardening and tempering; s3, turning for the first time; clamping an outer circle, turning the left end face, drilling a center hole, and requiring the outer circle run-out to be less than or equal to 0.1 mm; s4, ultrasonic flaw detection; step S5, drilling; step S6, quenching; step S7, secondary turning is carried out; jacking and turning the left end excircle; step S8, turning for the third time; trimming a center hole, wherein the jumping of the outer circle to the center hole is less than or equal to 0.05 mm; step S9, turning for the fourth time; machining an outer circle, wherein the jump of the outer circle relative to the center hole is less than or equal to 0.2 mm; step S10, turning for the fifth time; step S11, turning for six times; step S12, primary external grinding; the grinding surface run-out is less than or equal to 0.02 mm; s13, primary bench work is carried out; step S14, performing primary inspection; the taper coloring and the groove bottom fillet of the processed elastic shaft are qualified, the taper coloring area reaches 95%-100%, and the requirement for 500,000 times of tests with the turning load and the torsion angle of + / -9 degrees is met.

Description

Technical Field

[0001] The invention relates to an elastic shaft processing technology, belonging to the technical field of elastic shaft processing. Background Art

[0002] Elastic shafts are often used in engines. Splines are mainly used to connect mechanical transmission with private service motors, playing the role of elastic recoil and torque transmission. During use, the elastic shaft also plays an overload protection function. Once the engine is overloaded during operation, the elastic shaft will break instantly to protect the engine from damage.

[0003] The overall structural precision of the elastic shaft is a non-conventional part, one end of which is a spline and the other end is a cone. The elastic shaft needs to be subjected to a torsion test after processing. The elastic shaft is required to be tested 500,000 times under the requirements of changing direction load and torsion angle of ±9°. If any elastic shaft is broken during the test, double the test pieces in the original batch will be taken for retesting. If one piece is still broken, the entire batch of parts will be scrapped. The elastic shafts produced by the existing conventional processing technology will break after about 10,000 torsion tests on the torsion testing machine, which makes it difficult to meet product requirements. The main reason is that the taper coloring and the groove bottom fillet are unqualified.

[0004] Therefore, there is a need for a flexible shaft processing technology to improve the torsional resistance of the flexible shaft and ensure product quality. Summary of the invention

[0005] The technical problem to be solved by the present invention is: in order to overcome the deficiencies of the prior art, to provide an elastic shaft processing technology which can improve the torsional resistance of the elastic shaft and ensure the product quality.

[0006] The technical solution adopted by the present invention to solve the above problem is: a flexible shaft processing process, comprising the following steps:

[0007] Step S1, forging a blank;

[0008] Step S2, conditioning;

[0009] Step S3, one-time turning;

[0010] Clamp the left end face of the external circle lathe and drill the center hole. The external circle runout is required to be ≤0.1mm;

[0011] Step S4, ultrasonic flaw detection;

[0012] Step S5, drilling;

[0013] Step S6, quenching;

[0014] Step S7, secondary turning;

[0015] The outer circle of the left end of the top car;

[0016] Step S8, three times turning;

[0017] Repair the center hole, the outer circle to the center hole runout ≤ 0.05mm;

[0018] Step S9, four times turning;

[0019] When machining the outer circle, the outer circle runout to the center hole is ≤0.2mm;

[0020] Step S10, five times of turning;

[0021] The outer circle runout to the center hole is ≤0.2mm, the machine tool spindle speed is ≥500r / min, the turning tool feed rate is 0.1~0.3mm / r, and stable tempering is carried out within 2 hours after the qualified processing, and the oil tank is tempered at low temperature to relieve stress according to KA / JSZY22;

[0022] Step S11, six times turning;

[0023] After machining, the outer circle runout to the center hole is ≤0.08mm, the machine tool spindle speed is ≥500r / min, the turning tool feed rate is 0.1-0.3mm / r, and stable tempering is carried out within 2 hours after the machining is qualified, and the oil tank is tempered at low temperature to relieve stress, according to KA / JSZY22;

[0024] Step S12, primary external grinding;

[0025] Grinding surface runout ≤ 0.02mm;

[0026] Step S13, primary bench work;

[0027] The external circle runout is ≤0.02mm before and after processing, the machine tool running speed is ≥1000r / min, the feed rate is 10mm / min, and stable tempering is carried out within 2 hours after the processing is qualified, and the oil tank is tempered at low temperature to relieve stress according to KA / JSZY22;

[0028] Step S14, one-time inspection;

[0029] Carry out appearance inspection and external circle runout inspection;

[0030] Step S15, gear hobbing;

[0031] The spline is machined on the right end, and the external circle runout is corrected before and after machining ≤0.02mm;

[0032] Step S16, secondary fitter;

[0033] The periphery of both ends of the spline is rounded to R0.1~0.3, and the rest is deburred;

[0034] Step S17, marking;

[0035] Step S18, secondary external grinding;

[0036] Ensure that the grinding surface runout is ≤0.01mm, the machine tool running line speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, the grinding wheel particle size is 60#, and stable tempering is carried out within 2 hours after the processing is qualified, and the oil tank is tempered at low temperature to relieve stress, according to KA / JSZY22;

[0037] Step S19, secondary inspection;

[0038] Carry out appearance inspection and external circle runout inspection;

[0039] Step S20, external grinding three times;

[0040] Ensure that the grinding surface runout is ≤0.01mm, the machine tool running speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, and the grinding wheel particle size is 60#;

[0041] Step S21, shot peening once;

[0042] According to STA100-84-09 standard: shot peening type: SAE110 MIL-S-13165C, shot peening intensity: 0.2~0.24, coverage: 200%, center hole runout after shot peening ≤0.08mm;

[0043] Step S22, three tests;

[0044] Check the outer circle runout. For over-tolerance deformation, use the knocking method to knock the yield point of the part. After correction, perform stable tempering within 2 hours. Temper at low temperature in the oil tank to relieve stress. Perform according to KA / JSZY22. After tempering, check the outer circle runout of the part;

[0045] Step S23, grinding splines;

[0046] The external circle runout is ≤0.01mm before and after processing. After the first piece is qualified, the remaining products are processed. The machine tool running line speed is ≥35m / s, the feed rate is 0.005mm / min, and the grinding wheel particle size is 80#;

[0047] Step S24, three times of benchwork;

[0048] The periphery of both ends of the spline is rounded to R0.1~0.3, and the rest is deburred;

[0049] Step S22, secondary shot peening;

[0050] According to STA100-84-09 standard: shot peening type: G110 MIL-S-13165C, shot peening intensity: 0.2~0.24, coverage: 200%;

[0051] Step S23, four tests;

[0052] Carry out appearance inspection and use the deflection instrument to check the spline pitch circle runout;

[0053] Step S24, external grinding for four times;

[0054] Ensure that the grinding surface runout is ≤0.008mm, the machine tool running line speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, and the grinding wheel particle size is 80#;

[0055] Step S25, thread grinding;

[0056] Ensure that the thread outer circle runout is ≤0.01mm before grinding; ensure that the thread runout is ≤0.04mm after grinding;

[0057] Step S26, four times of benchwork;

[0058] Sharp angles are chamfered to R0.1~0.2, and the flange burrs are removed;

[0059] Step S27, cadmium plating;

[0060] Surface gloss: cadmium plating depth 0.005~0.008 passivation, after plating, use thread ring gauge to check thread diameter;

[0061] Step S28, external grinding five times;

[0062] Ensure that the grinding surface runout is ≤0.008mm, the machine tool running line speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, and the grinding wheel particle size is 80#;

[0063] Step S29, finished product inspection;

[0064] Carry out surface finish, chamfering, fillet, sharp edge rounding and inspection for defects such as bumps and pulls. The end thread runout to the center line is ≤0.05mm, and the spline gear ring runout is ≤0.05mm;

[0065] Hardness inspection: Check the quenching surface hardness of the sample HRC43-48;

[0066] Step S30, torsion test;

[0067] Conduct mechanical strength inspection of test bars according to NS001-64 standard;

[0068] Technical requirements: For each batch of more than 10 pieces, 2 pieces shall be selected for torsion test, with a torsion angle of ±9° and a total number of test cycles of 5,000,000. If there is a broken elastic shaft during the test, double the test pieces shall be taken from the batch for retesting. If there is still one broken piece, the whole batch shall be scrapped. The tested elastic shaft cannot be installed and used on the motor;

[0069] Parts clamping is carried out according to the torsion test clamping diagram;

[0070] Technical requirements: Before the test, the torsion test parts and tooling are first inspected for cone coloring. If they are unqualified, they are ground with 200-mesh grinding paste and cleaned with diesel after meeting the coloring requirements. If two parts are tested, two toolings are required;

[0071] Step S31, magnetic particle inspection;

[0072] The torsion test pieces are 100% magnetic particle inspected;

[0073] Step S32, cleaning the oil seal and storing it;

[0074] Among them, the outer circle runout detection is carried out by using an outer circle runout detection device, and the torsion test is carried out by using an elastic shaft torsion test device.

[0075] Preferably, the outer circle runout detection device comprises a detection seat, a mounting seat is slidably connected to the detection seat, the mounting seat and the detection seat are slidably connected along the left and right directions, the mounting seat is used to install a micrometer, and a support mechanism is provided on the detection seat;

[0076] The support mechanism includes a drive shaft and a plurality of support components, the plurality of support components are distributed along the left-right direction, the drive shaft is parallel to the left-right direction, the drive shaft is connected to a drive system, and the drive system is used to realize the self-rotation of the drive shaft;

[0077] The support assembly includes a support seat, on which a connection unit and two support units are arranged symmetrically front to back, and the two support units are connected by the connection unit, and one of the two support units is connected to the drive shaft;

[0078] The support unit comprises a support rod, the support rod is arranged obliquely, one end of the support rod is hinged to the support seat through a pin shaft, the pin shaft is parallel to the left and right directions, two support wheels are rotatably connected to the support rod, the two support wheels are distributed along the length direction of the support rod, the rotation center of the support wheels is parallel to the left and right directions, one of the support wheels is installed on the driving shaft, the pin shaft is connected to the connecting unit, and the connecting unit is used to drive the pin shaft to rotate;

[0079] The two support rods in the same support assembly are in an inverted eight-shaped shape.

[0080] Preferably, the support wheel is provided with anti-slip grooves.

[0081] Preferably, the connecting unit includes a guide rod, which is arranged vertically, and the two support rods are symmetrical about the guide rod front and back, a connecting plate is fixedly provided at the bottom end of the guide rod, the connecting plate is fixedly provided on the support seat, the top of the guide rod is fixedly provided on the limit block, and a slider is movably connected to the guide rod, the slider is connected to two first connecting rods, and the two first connecting rods correspond to the two support rods one by one, the slider at one end of the first connecting rod is hinged, and the other end of the first connecting rod is connected to the pin shaft through the second connecting rod, the second connecting rod is arranged obliquely, one end of the second connecting rod is fixedly provided on the pin shaft, and the other end of the second connecting rod is hinged to the first connecting rod, the slider abuts against the limit block, and a spring is sleeved on the guide rod, the spring is located between the connecting plate and the slider, and the two ends of the spring are respectively fixedly connected to the connecting plate and.

[0082] Preferably, a slot is provided at one end of the pin shaft, one end of the second connecting rod is inserted into the slot, and the second connecting rod is detachably fixedly connected to the pin shaft via a locking screw.

[0083] Preferably, a first slide groove is provided on the top of the detection seat, the first slide groove is parallel to the left and right direction, the bottom of the support seat is inserted into the first slide groove, and the support seat is slidably connected to the first slide groove along the left and right direction.

[0084] Preferably, the elastic shaft torsion test device comprises a base, on which a test mechanism and a protection mechanism are arranged, and the test mechanism is used to implement a torsion test of the elastic shaft;

[0085] The protection mechanism includes a protection cover, an opening is provided on the protection cover, a cover is provided at the opening, an air pipe is provided on the protection cover, the air pipe is connected to the air supply system, and air with a certain humidity and temperature is transported from the air pipe to the protection cover through the air supply system, and air holes are provided on the protection cover.

[0086] Preferably, the air holes are provided in two groups, and the two groups of air holes are respectively located on the left and right sides of the protective cover.

[0087] Preferably, a collecting pipe is provided at the bottom of the protective cover, the collecting pipe is arranged vertically, and a sealing plug is connected to the bottom end of the collecting pipe.

[0088] Preferably, the test mechanism comprises two support frames, the two support frames are arranged on the base at intervals along the left-right direction, a first connecting tool and a second connecting tool are arranged between the two support frames, the first connecting tool and the second connecting tool are distributed at intervals along the left-right direction, the first connecting tool is fixedly connected to the support frame on the left side through a first flange, a test motor is arranged on the support frame on the right side, an output end of the test motor is connected to the second connecting tool through a second flange, and the test motor and the second flange are both located on the right side of the second connecting tool;

[0089] The protective cover and the cover form a cylindrical structure parallel to the left and right directions. The first connecting tool is fixedly passed through one end of the protective cover, and the second connecting tool is movably passed through the other end of the protective cover.

[0090] Compared with the prior art, the advantages of the present invention are:

[0091] The invention discloses a processing technology for an elastic shaft. The processed elastic shaft has qualified taper coloring and groove bottom fillet, the taper coloring area reaches 95% to 100%, and meets the requirements of 500,000 times of tests with a variable load and a torsion angle of ±9°. BRIEF DESCRIPTION OF THE DRAWINGS

[0092] Figure 1 is a schematic diagram of the structure of the elastic shaft;

[0093] Figure 2 It is a three-dimensional diagram of the outer circle runout detection device;

[0094] Figure 3 for Figure 2 The main view;

[0095] Figure 4 for Figure 2 A top view of

[0096] Figure 5 for Figure 2 Left view of

[0097] Figure 6 is a schematic diagram of the structure of the support assembly;

[0098] Figure 7 is a structural schematic diagram of a connection unit;

[0099] Figure 8 Schematic diagram of the connection structure between the pin and the support rod;

[0100] Fig. 9 is a schematic diagram of the structure of the mounting base;

[0101] Fig.10 is a three-dimensional diagram of an elastic shaft torsion test device;

[0102] Fig.11 for Fig.10 The main view;

[0103] Fig.12 for Fig.10 A top view of

[0104] Fig.13 for Fig.10 Left view of

[0105] Fig.14 A three-dimensional diagram of the test mechanism;

[0106] Fig.15 for Fig.14 The main view of

[0107] Fig.16 for Fig.14 A top view of

[0108] Fig.17 for Fig.14 Left view of;

[0109] Fig.18 A three-dimensional diagram of the protective mechanism;

[0110] Fig.19 for Fig.18 The main view of

[0111] Fig. 20 for Fig.18 A top view of

[0112] Fig.21 for Fig.18 Left view of;

[0113] Fig. 22 for Fig.18 A cross-sectional view of

[0114] Fig.23 A schematic diagram of the structure of the protective cover.

[0115] in:

[0116] Detection seat 10, mounting seat 11, support mechanism 12, first slide slot 13, second slide slot 14, connecting strip 15;

[0117] A driving shaft 121, a supporting assembly 122;

[0118] Support base 1221, connecting unit 1222, supporting unit 1223;

[0119] Guide rod 12221, connecting plate 12222, limit block 12223, slide block 12224, first connecting rod 12225, second connecting rod 12226, spring 12227, slot 12228, locking screw 12229;

[0120] Support rod 12231, pin shaft 12232, support wheel 12233;

[0121] Base 20, testing mechanism 21, protection mechanism 22;

[0122] Support frame 211, first connecting fixture 212, second connecting fixture 213, first flange 214, test motor 215, second flange 216, spacer 217, first screw 218;

[0123] Protective cover 221 , opening 222 , cover 223 , air pipe 224 , air hole 225 , collecting pipe 226 , sealing plug 227 , lifting rod 228 , conduit 229 , second screw 220 . DETAILED DESCRIPTION

[0124] like Figure 1-23 As shown, a flexible shaft processing process in this embodiment includes the following steps:

[0125] Step S1, forging a blank;

[0126] The raw material electric slag furnace smelting round steel is in accordance with the standard GB702-72, and the rest is in accordance with the standard GB / T3077-2015 without hairline;

[0127] The macrostructure and defects of the bulk sample inspection shall be in accordance with GB / T226-2015 standard, and the average grain size of the metal shall be inspected in accordance with GB / T6394-2017 standard;

[0128] Step S2, conditioning;

[0129] Quenched and tempered hardness HB220~240;

[0130] Step S3, one-time turning;

[0131] Clamp the left end face of the external circle turning machine to start and end, drill the center hole, and require the external circle runout ≤0.1mm;

[0132] Step S4, ultrasonic flaw detection;

[0133] Ultrasonic flaw detection is carried out according to HB / Z 59-1997;

[0134] Step S5, drilling;

[0135] Fixed outer circle drilling, hole opening deburring;

[0136] Step S6, quenching;

[0137] The overall quenching hardness is HRC44-48, with external cylindrical supports at both ends. Check that the external cylindrical runout is ≤3mm. Correction after quenching is not allowed. Re-quenching after annealing correction is allowed. The following items are tested: surface core hardness, metallographic structure, busbar bending ≤3mm, and mechanical strength inspection according to HB5024-89;

[0138] Step S7, secondary turning;

[0139] The outer circle of the left end of the top car;

[0140] Step S8, three times turning;

[0141] Repair the center hole, the outer circle to the center hole runout ≤ 0.05mm;

[0142] Step S9, four times turning;

[0143] When machining the outer circle, the outer circle runout to the center hole is ≤0.2mm;

[0144] Step S10, five times of turning;

[0145] The outer circle runout to the center hole is ≤0.2mm, the machine tool spindle speed is ≥500r / min, the turning tool feed rate is 0.1~0.3mm / r, and stable tempering is carried out within 2 hours after the qualified processing, and the oil tank is tempered at low temperature to relieve stress according to KA / JSZY22;

[0146] Step S11, six times turning;

[0147] After machining, the outer circle runout to the center hole is ≤0.08mm, the machine tool spindle speed is ≥500r / min, the turning tool feed rate is 0.1-0.3mm / r, and stable tempering is carried out within 2 hours after the machining is qualified, and the oil tank is tempered at low temperature to relieve stress, according to KA / JSZY22;

[0148] Step S12, primary external grinding;

[0149] Grinding surface runout ≤ 0.02mm;

[0150] Step S13, primary benchwork;

[0151] The external circle runout is ≤0.02mm before and after processing, the machine tool running speed is ≥1000r / min, the feed rate is 10mm / min, and stable tempering is carried out within 2 hours after the processing is qualified, and the oil tank is tempered at low temperature to relieve stress according to KA / JSZY22;

[0152] Step S14, one-time inspection;

[0153] Carry out appearance inspection and external circle runout inspection;

[0154] Step S15, gear hobbing;

[0155] The spline is machined on the right end, and the external circle runout is corrected before and after machining ≤0.02mm;

[0156] Step S16, secondary fitter;

[0157] The periphery of both ends of the spline is rounded to R0.1~0.3, and the rest is deburred;

[0158] Step S17, marking;

[0159] Step S18, secondary external grinding;

[0160] Ensure that the grinding surface runout is ≤0.01mm, the machine tool running line speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, the grinding wheel particle size is 60#, and stable tempering is carried out within 2 hours after the processing is qualified, and the oil tank is tempered at low temperature to relieve stress, according to KA / JSZY22;

[0161] Step S19, secondary inspection;

[0162] Carry out appearance inspection and external circle runout inspection;

[0163] Step S20, external grinding three times;

[0164] Ensure that the grinding surface runout is ≤0.01mm, the machine tool running speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, and the grinding wheel particle size is 60#;

[0165] Step S21, shot peening once;

[0166] According to STA100-84-09 standard: shot peening type: SAE110 MIL-S-13165C (HRC44-48), shot peening intensity: 0.2~0.24, coverage: 200%, center hole runout after shot peening ≤0.08mm (before shot peening ≤0.03mm);

[0167] Step S22, three tests;

[0168] Check the outer circle runout. For over-tolerance deformation, use the tapping method to tap the yield point of the part (the yield point is the lowest point of the shaft diameter deformation to ensure the runout requirements). After correction, perform stable tempering within 2 hours, and perform low-temperature tempering in the oil tank to relieve stress. Perform according to KA / JSZY22. After tempering, check the outer circle runout of the part;

[0169] Step S23, grinding splines;

[0170] The outer circle runout is ≤0.01mm before and after processing. After the first piece is qualified (including pitch circle runout), the remaining products are processed. The machine tool running line speed is ≥35m / s, the feed rate is 0.005mm / min, and the grinding wheel particle size is 80#;

[0171] Step S24, three times of benchwork;

[0172] The periphery of both ends of the spline is rounded to R0.1~0.3, and the rest is deburred;

[0173] Step S22, secondary shot peening;

[0174] According to STA100-84-09 standard: shot peening type: G110 MIL-S-13165C, shot peening intensity: 0.2~0.24, coverage: 200%;

[0175] Step S23, four tests;

[0176] Carry out appearance inspection and use the deflection instrument to check the spline pitch circle runout;

[0177] Step S24, external grinding for four times;

[0178] Ensure that the grinding surface runout is ≤0.008mm, the machine tool running line speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, and the grinding wheel particle size is 80#;

[0179] Step S25, thread grinding;

[0180] Ensure that the thread outer circle runout is ≤0.01mm before grinding; ensure that the thread runout is ≤0.04mm after grinding;

[0181] Step S26, four times of benchwork;

[0182] Sharp angles are chamfered to R0.1~0.2, and the flange burrs are removed;

[0183] Step S27, cadmium plating;

[0184] Surface gloss: cadmium plating depth 0.005~0.008 passivation, after plating, use thread ring gauge to check thread diameter;

[0185] Step S28, external grinding five times;

[0186] Ensure that the grinding surface runout is ≤0.008mm, the machine tool running line speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, and the grinding wheel particle size is 80#;

[0187] Step S29, finished product inspection;

[0188] Carry out surface finish, chamfering, fillet, sharp edge rounding and inspection for defects such as bumps and pulls. The end thread runout to the center line is ≤0.05mm, and the spline gear ring runout is ≤0.05mm;

[0189] Hardness inspection: Check the quenching surface hardness of the sample HRC43-48;

[0190] Step S30, torsion test;

[0191] Conduct mechanical strength inspection of test bars according to NS001-64 standard;

[0192] Technical requirements: For each batch of more than 10 pieces, 2 pieces shall be selected for torsion test, with a torsion angle of ±9° and a total number of test cycles of 5,000,000. If there is a broken elastic shaft during the test, double the test pieces shall be taken from the batch for retesting. If there is still one broken piece, the whole batch shall be scrapped. The tested elastic shaft cannot be installed and used on the motor;

[0193] Parts clamping is carried out according to the torsion test clamping diagram;

[0194] Technical requirements: Before the test, the torsion test parts and tooling are first inspected for cone coloring (coloring ≥ 85%). If unqualified, they are ground with 200-mesh grinding paste and cleaned with diesel after meeting the coloring requirements. If two parts are tested, two toolings are required;

[0195] Step S31, magnetic particle inspection;

[0196] The torsion test pieces are 100% magnetic particle inspected;

[0197] Step S32, cleaning the oil seal and storing it;

[0198] Use 120# gasoline to clean parts:

[0199] Use a brush to clean the entire outer surface of the part, paying special attention to cleaning the shaft shoulders and fillets on the outer surface of the part to ensure that there is no dirt;

[0200] Wash the spline parts separately, and brush the tooth root, tooth surface and tooth top separately in the cut direction. The brushing direction cannot be changed at will during the brushing process to ensure that there is no dirt on the spline surface;

[0201] Drain: Let dry naturally;

[0202] It is allowed to use kerosene (heat to 110℃ and keep warm for half an hour, then cool to 40℃ for cleaning);

[0203] Rust prevention: Use 20# thin layer of anti-rust oil. Heat the anti-rust oil to 110℃, dehydrate and keep warm for half an hour, then cool to 50℃ for use. The anti-rust oil must be used on the same day.

[0204] Packaging: Pack with oil-sealed paper, add protective sponge, and finally pack in a sealed bag, put moisture-proof sand inside, and finally remove the air;

[0205] Warehousing: Warehousing after inspection and packaging;

[0206] The elastic shaft processed in this way has qualified taper coloring and groove bottom fillet, among which the taper coloring area reaches 95% to 100%, and meets the requirements of 500,000 tests with variable load and torsion angle of ±9°;

[0207] Among them, the outer circle runout detection is carried out by using an outer circle runout detection device, and the torsion test is carried out by using an elastic shaft torsion test device;

[0208] The outer circle runout detection device includes a detection seat 10, a mounting seat 11 is slidably connected to the detection seat 10, the mounting seat 11 is slidably connected to the detection seat 10 along the left-right direction, the mounting seat 11 is used to install a micrometer, and a support mechanism 12 is provided on the detection seat 10, the support mechanism 12 is used to realize the rotation support of the elastic shaft, and the support assembly 122 is used to realize the self-rotation of the elastic shaft;

[0209] The support mechanism 12 includes a drive shaft 121 and a plurality of support components 122, the plurality of support components 122 are distributed along the left-right direction, and the specific number of the support components 122 is three. The drive shaft 121 is parallel to the left-right direction, and a drive system is connected to the drive shaft 121, and the drive system is used to realize the self-rotation of the drive shaft 121;

[0210] The support assembly 122 includes a support base 1221, on which a connection unit 1222 and two support units 1223 are disposed, the two support units 1223 are symmetrically arranged front to back, the two support units 1223 are connected by the connection unit 1222, and one of the two support units 1223 is connected to the drive shaft 121;

[0211] The support unit 1223 includes a support rod 12231, the support rod 12231 is arranged obliquely, one end of the support rod 12231 is hinged to the support seat 1221 through a pin shaft 12232, the pin shaft 12232 is parallel to the left and right directions, and two support wheels 12233 are rotatably connected to the support rod 12231, the two support wheels 12233 are distributed along the length direction of the support rod 12231, and the rotation center of the support wheel 12233 is parallel to the left and right directions, one of the support wheels 12233 is installed on the driving shaft 121, and the pin shaft 12232 is connected to the connecting unit 1222, and the connecting unit 1222 is used to drive the pin shaft 12232 to rotate;

[0212] The two support rods 12231 in the same support assembly 122 are in an inverted figure eight shape;

[0213] Before testing the outer circle runout of the elastic shaft, place the elastic shaft parallel to the left and right directions, and install the micrometer on the mounting seat 11;

[0214] When the elastic shaft is supported for rotation by the support assembly 122, the elastic shaft moves downward, and the elastic shaft pushes the two upper support wheels 12233 to move away from each other in the front and rear directions, that is, the support rod 12231 is driven to rotate, thereby realizing the self-rotation of the pin shaft 12232. When the elastic shaft is separated from the upper support wheel 12233, the pin shaft 12232 is driven to rotate in the opposite direction through the connecting unit 1222, so that the four support wheels 12233 clamp and fix the elastic shaft. When the outer circle runout of the elastic shaft is detected, the drive shaft 121 is driven by the drive system. Rotate, so that one of the support wheels 12233 rotates, and the rotation of this support wheel 12233 drives the elastic shaft to rotate by friction force, and the rotation of the elastic shaft also drives the other support wheels 12233 to rotate by friction force. Then, the test needle of the micrometer is pressed against the outer peripheral wall of the elastic shaft. As the elastic shaft rotates, the micrometer detects the outer circle runout of the elastic shaft. At the same time, the mounting seat 11 is moved in the left and right direction, that is, the outer circle runout detection can be realized at each position in the length direction of the elastic shaft. After the detection is completed, the elastic shaft can be pulled out upwards.

[0215] The driving system may be a driving source such as a motor, or a manual driving device such as a rocking wheel, and the rotation of the driving shaft 121 is achieved through the motor and the rocking wheel;

[0216] Here, when fixing the elastic shaft, no complicated operation is required, which improves the convenience of the outer circle runout detection, that is, improves the efficiency of the outer circle runout detection;

[0217] The support wheel 12233 is provided with anti-skid grooves, which improve the friction between the support wheel 12233 and the elastic shaft, thereby improving the reliability of the support wheel 12233 driving the elastic shaft to rotate.

[0218] The connecting unit 1222 includes a guide rod 12221, which is arranged vertically. Two support rods 12231 are symmetrical about the guide rod 12221. A connecting plate 12222 is fixedly provided at the bottom end of the guide rod 12221. The connecting plate 12222 is fixedly provided on the support seat 1221. The top end of the guide rod 12221 is fixedly provided on the limit block 12223. A slider 12224 is movably connected to the guide rod 12221. The slider 12224 is connected to two first connecting rods 12225. The two first connecting rods 12225 correspond to the two support rods 12231 one by one. The end slider 12224 is hinged, the other end of the first connecting rod 12225 is connected to the pin 12232 through the second connecting rod 12226, the second connecting rod 12226 is arranged obliquely, one end of the second connecting rod 12226 is fixedly set on the pin 12232, the other end of the second connecting rod 12226 is hinged to the first connecting rod 12225, the slider 12224 abuts against the limit block 12223, the guide rod 12221 is sleeved with a spring 12227, the spring 12227 is located between the connecting plate 12222 and the slider 12224, and the two ends of the spring 12227 are respectively fixedly connected to the connecting plate 12222 and the slider;

[0219] When the elastic shaft pushes the two upper supporting wheels 12233 to move away, the two pin shafts 12232 rotate at the same time, and the two pin shafts 12232 rotate in opposite directions. The rotation of the pin shaft 12232 drives the slider 12224 to descend on the guide rod 12221 through the second connecting rod 12226 and the first connecting rod 12225 in turn, and causes the spring 12227 to deform. When the elastic shaft is separated from the upper supporting wheel 12233, the slider 12224 is raised by the elastic action of the spring 12227. The rise of the slider 12224 drives the pin shaft 12232 to rotate in the opposite direction through the first connecting rod 12225 and the second connecting rod 12226 in turn, that is, the four supporting wheels 12233 can clamp and fix the elastic shaft. In addition, because the two first connecting rods 12225 are hinged to the slider 12224 at the same time, the two supporting rods 12231 can rotate at the same time and always maintain symmetry.

[0220] One end of the pin shaft 12232 is provided with a slot 12228, one end of the second connecting rod 12226 is inserted into the slot 12228, and the second connecting rod 12226 is detachably fixedly connected to the pin shaft 12232 via a locking screw 12229;

[0221] The top of the detection seat 10 is provided with a first slide groove 13, the first slide groove 13 is parallel to the left and right direction, the bottom of the support seat 1221 is inserted into the first slide groove 13, the support seat 1221 is slidably connected with the first slide groove 13 along the left and right direction, and the first slide groove 13 is a dovetail groove;

[0222] Two second slide grooves 14 are arranged on the top of the detection seat 10, and the two second slide grooves 14 are distributed along the front-to-back direction, and the second slide grooves 14 are parallel to the left-to-right direction. Two connecting strips 15 are arranged on the bottom of the mounting seat 11, and the two connecting strips 15 correspond to and match the two second slide grooves 14 one by one, and the connecting strips 15 are inserted into the second slide grooves 14;

[0223] The elastic shaft torsion test device comprises a base 20, on which a test mechanism 21 and a protection mechanism 22 are arranged. The test mechanism 21 is used to implement the torsion test of the elastic shaft, and the protection mechanism 22 is used to improve safety and prevent splashing debris generated when the elastic shaft breaks from injuring people.

[0224] The test mechanism 21 includes two support frames 211, which are arranged on the base 20 at intervals along the left-right direction, and a first connecting fixture 212 and a second connecting fixture 213 are arranged between the two support frames 211, and the first connecting fixture 212 and the second connecting fixture 213 are distributed at intervals along the left-right direction, and the first connecting fixture 212 is fixedly connected to the support frame 211 on the left side through a first flange 214, and a test motor 215 is arranged on the support frame 211 on the right side, and the output end of the test motor 215 is connected to the second connecting fixture 213 through a second flange 216, and the test motor 215 and the second flange 216 are both located on the right side of the second connecting fixture 213;

[0225] During the test, the conical end of the elastic shaft is fixedly connected to the first connecting fixture 212, and the spline end of the elastic shaft is fixedly connected to the second connecting fixture 213. Then, the test motor 215 is started, so that the second flange 216 drives the first connecting fixture 212 to rotate back and forth, that is, drives the spline end of the elastic shaft to rotate back and forth, so as to achieve the torsion of the elastic shaft, and the torsion angle is ±9°.

[0226] The protection mechanism 22 includes a protection cover 221, an opening 222 is provided on the protection cover 221, a cover 223 is provided at the opening 222, an air pipe 224 is provided on the protection cover 221, the air pipe 224 is connected to the air supply system, and air with a certain humidity and temperature is transported from the air pipe 224 to the protection cover 221 through the air supply system, and air holes 225 are provided on the protection cover 221, and the air holes 225 are provided in two groups, and the two groups of air holes 225 are respectively located on the left and right sides of the protection cover 221;

[0227] The protective cover 221 and the cover 223 form a cylindrical structure parallel to the left and right directions, the first connecting tool 212 is fixed through one end of the protective cover 221, and the second connecting tool 213 is movable through the other end of the protective cover 221;

[0228] A collecting pipe 226 is disposed at the bottom of the protective cover 221. The collecting pipe 226 is disposed vertically, and a sealing plug 227 is connected to the bottom end of the collecting pipe 226.

[0229] When installing the elastic shaft, open the cover 223, and then cover the cover 223 after the installation is completed. When the elastic shaft is twisted, air with a certain humidity and temperature is transported from the air pipe 224 to the protective cover 221, and the air in the protective cover 221 is discharged from the air holes 225. Here, because the two groups of air holes 225 are respectively located on the left and right sides of the protective cover 221, the air can be evenly distributed in the protective cover 221, thereby improving the uniformity of the temperature and humidity distribution in the protective cover 221, so that the elastic shaft can be subjected to a torsion test under a certain temperature and humidity environment, thereby improving the accuracy of the test. When the elastic shaft breaks and generates flying debris, the debris is blocked by the protective cover 221 to avoid the debris from hurting people, thereby improving safety. Moreover, after the debris falls into the protective cover 221, it moves to the collecting pipe 226 under the action of the airflow to realize the collection of the debris. When it is necessary to remove the debris in the collecting pipe 226, the sealing plug 227 is removed and the debris is taken out.

[0230] A cushion block 217 is provided between the support frame 211 and the base 20. The support frame 211 is fixed to the base 20 by a first screw 218. When the height of the first connecting fixture 212 and the second connecting fixture 213 needs to be adjusted, the cushion block 217 of different thicknesses can be replaced.

[0231] The protective cover 221 is provided with a support member, and two support members are provided, and the two support members are distributed along the left and right directions;

[0232] The support member is located between the base 20 and the protective cover 221, and the support member includes a lifting rod 228 and a guide tube 229. The guide tube 229 is arranged vertically, and the guide tube 229 is fixedly set on the base 20. The lifting rod 228 is coaxially inserted into the guide tube 229, and the lifting rod 228 is slidably connected with the guide tube 229. The lifting rod 228 is fixedly set on the protective cover 221, and the lifting rod 228 and the guide tube 229 are fixed by the second screw 220. The connection between the lifting rod 228 and the guide tube 229 plays an effect of supporting the protective cover 221. When the first connecting tool 212 and the second connecting tool 213 need to adjust the height, the second screw 220 is loosened, and the protective cover 221 is lifted and lowered during the lifting and lowering of the first connecting tool 212 and the second connecting tool 213, that is, the lifting rod 228 is driven to adjust the height on the guide tube 229. After the adjustment is completed, the second screw 220 can be tightened;

[0233] In addition to the above embodiments, the present invention also includes other implementation modes. Any technical solutions formed by equivalent transformation or equivalent replacement should fall within the protection scope of the claims of the present invention.

Claims

1. A process for processing an elastic shaft, characterized in that: The steps include: Step S1, forging a blank; Step S2, conditioning; Step S3, one-time turning; Clamp the left end face of the external circle lathe and drill the center hole. The external circle runout is required to be ≤0.1mm; Step S4, ultrasonic flaw detection; Step S5, drilling; Step S6, quenching; Step S7, secondary turning; The outer circle of the left end of the top car; Step S8, three times turning; Repair the center hole, the outer circle to the center hole runout ≤ 0.05mm; Step S9, four times turning; When machining the outer circle, the outer circle runout to the center hole is ≤0.2mm; Step S10, five times of turning; The outer circle runout to the center hole is ≤0.2mm, the machine tool spindle speed is ≥500r / min, the turning tool feed rate is 0.1~0.3mm / r, and stable tempering is carried out within 2 hours after the qualified processing, and the oil tank is tempered at low temperature to relieve stress according to KA / JSZY22; Step S11, six times turning; After machining, the outer circle runout to the center hole is ≤0.08mm, the machine tool spindle speed is ≥500r / min, the turning tool feed rate is 0.1-0.3mm / r, and stable tempering is carried out within 2 hours after the machining is qualified, and the oil tank is tempered at low temperature to relieve stress, according to KA / JSZY22; Step S12, primary external grinding; Grinding surface runout ≤ 0.02mm; Step S13, primary benchwork; The external circle runout is ≤0.02mm before and after processing, the machine tool running speed is ≥1000r / min, the feed rate is 10mm / min, and stable tempering is carried out within 2 hours after the processing is qualified, and the oil tank is tempered at low temperature to relieve stress according to KA / JSZY22; Step S14, one-time inspection; Carry out appearance inspection and external circle runout inspection; Step S15, gear hobbing; The spline is machined on the right end, and the external circle runout is corrected before and after machining ≤0.02mm; Step S16, secondary fitter; The periphery of both ends of the spline is rounded to R0.1~0.3, and the rest is deburred; Step S17, marking; Step S18, secondary external grinding; Ensure that the grinding surface runout is ≤0.01mm, the machine tool running line speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, the grinding wheel particle size is 60#, and stable tempering is carried out within 2 hours after the processing is qualified, and the oil tank is tempered at low temperature to relieve stress, according to KA / JSZY22; Step S19, secondary inspection; Carry out appearance inspection and external circle runout inspection; Step S20, external grinding three times; Ensure that the grinding surface runout is ≤0.01mm, the machine tool running speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, and the grinding wheel particle size is 60#; Step S21, shot peening once; According to STA100-84-09 standard: shot peening type: SAE110 MIL-S-13165C, shot peening intensity: 0.2~0.24, coverage: 200%, center hole runout after shot peening ≤0.08mm; Step S22, three tests; Check the outer circle runout. For over-tolerance deformation, use the knocking method to knock the yield point of the part. After correction, perform stable tempering within 2 hours. Temper at low temperature in the oil tank to relieve stress. Perform according to KA / JSZY22. After tempering, check the outer circle runout of the part; Step S23, grinding splines; The external circle runout is ≤0.01mm before and after processing. After the first piece is qualified, the remaining products are processed. The machine tool running speed is ≥35m / s, the feed rate is 0.005mm / min, and the grinding wheel particle size is 80#; Step S24, three times of benchwork; The periphery of both ends of the spline is rounded to R0.1~0.3, and the rest is deburred; Step S22, secondary shot peening; According to STA100-84-09 standard: shot peening type: G110 MIL-S-13165C, shot peening intensity: 0.2~0.24, coverage: 200%; Step S23, four tests; Carry out appearance inspection and use the deflection instrument to check the spline pitch circle runout; Step S24, external grinding for four times; Ensure that the grinding surface runout is ≤0.008mm, the machine tool running line speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, and the grinding wheel particle size is 80#; Step S25, thread grinding; Ensure that the thread outer circle runout is ≤0.01mm before grinding; ensure that the thread runout is ≤0.04mm after grinding; Step S26, four times of benchwork; Sharp angles are chamfered to R0.1~0.2, and the flange burrs are removed; Step S27, cadmium plating; Surface gloss: cadmium plating depth 0.005~0.008 passivation, after plating, use thread ring gauge to check thread diameter; Step S28, external grinding five times; Ensure that the grinding surface runout is ≤0.008mm, the machine tool running line speed is ≥35m / s, the feed rate is 0.1~0.3mm / min, and the grinding wheel particle size is 80#; Step S29, finished product inspection; Carry out surface finish, chamfering, fillet, sharp edge rounding and inspection for defects such as bumps and pulls. The end thread runout to the center line is ≤0.05mm, and the spline gear ring runout is ≤0.05mm; Hardness inspection: Check the quenching surface hardness of the sample HRC43-48; Step S30, torsion test; Conduct mechanical strength inspection of test bars according to NS001-64 standard; Technical requirements: For each batch of more than 10 pieces, 2 pieces shall be selected for torsion test, with a torsion angle of ±9° and a total number of test cycles of 5,000,000. If there is a broken elastic shaft during the test, double the test pieces shall be taken from the batch for retesting. If there is still one broken piece, the whole batch shall be scrapped. The tested elastic shaft cannot be installed and used on the motor; Parts clamping is carried out according to the torsion test clamping diagram; Technical requirements: Before the test, the torsion test parts and tooling are first inspected for cone coloring (coloring ≥ 85%). If unqualified, they are ground with 200-mesh grinding paste and cleaned with diesel after meeting the coloring requirements. If two parts are tested, two toolings are required; Step S31, magnetic particle inspection; The torsion test pieces are 100% magnetic particle inspected; Step S32, cleaning the oil seal and storing it; Among them, the outer circle runout detection is carried out by using an outer circle runout detection device, and the torsion test is carried out by using an elastic shaft torsion test device.

2. The elastic shaft processing process according to claim 1, characterized in that: The outer circle runout detection device comprises a detection seat (10), a mounting seat (11) is slidably connected to the detection seat (10), the mounting seat (11) is slidably connected to the detection seat (10) along the left-right direction, the mounting seat (11) is used to install a micrometer, and a support mechanism (12) is arranged on the detection seat (10); The support mechanism (12) comprises a drive shaft (121) and a plurality of support components (122), wherein the plurality of support components (122) are distributed along the left-right direction, the drive shaft (121) is parallel to the left-right direction, and a drive system is connected to the drive shaft (121), wherein the drive system is used to realize the self-rotation of the drive shaft (121); The support assembly (122) comprises a support seat (1221), a connection unit (1222) and two support units (1223) are arranged on the support seat (1221), the two support units (1223) are symmetrically arranged front to back, the two support units (1223) are connected via the connection unit (1222), and one of the two support units (1223) is connected to the drive shaft (121); The support unit (1223) comprises a support rod (12231), the support rod (12231) is arranged obliquely, one end of the support rod (12231) is hinged to the support seat (1221) via a pin shaft (12232), the pin shaft (12232) is parallel to the left and right directions, two support wheels (12233) are rotatably connected to the support rod (12231), the two support wheels (12233) are distributed along the length direction of the support rod (12231), the rotation center of the support wheel (12233) is parallel to the left and right directions, one of the support wheels (12233) is mounted on the driving shaft (121), the pin shaft (12232) is connected to the connecting unit (1222), and the connecting unit (1222) is used to drive the pin shaft (12232) to rotate; The two support rods (12231) in the same support assembly (122) are in an inverted figure eight shape.

3. The elastic shaft processing process according to claim 2, characterized in that: The support wheel (12233) is provided with anti-slip grooves.

4. The elastic shaft processing technology according to claim 2, characterized in that: The connecting unit (1222) comprises a guide rod (12221), the guide rod (12221) is arranged vertically, the two support rods (12231) are symmetrical about the guide rod (12221), a connecting plate (12222) is fixedly arranged at the bottom end of the guide rod (12221), the connecting plate (12222) is fixedly arranged on the support seat (1221), the top end of the guide rod (12221) is fixedly arranged on the limit block (12223), the guide rod (12221) is movably connected with a slider (12224), the slider (12224) is connected to two first connecting rods (12225), the two first connecting rods (12225) correspond to the two support rods (12231) one by one, and one of the first connecting rods (12225) is connected to the guide rod (12221). The end slider (12224) is hinged, the other end of the first connecting rod (12225) is connected to the pin shaft (12232) through the second connecting rod (12226), the second connecting rod (12226) is arranged obliquely, one end of the second connecting rod (12226) is fixedly set on the pin shaft (12232), the other end of the second connecting rod (12226) is hinged to the first connecting rod (12225), the slider (12224) is abutted against the limit block (12223), the guide rod (12221) is provided with a spring (12227), the spring (12227) is located between the connecting plate (12222) and the slider (12224), and the two ends of the spring (12227) are respectively fixedly connected to the connecting plate (12222) and.

5. The elastic shaft processing technology according to claim 2, characterized in that: One end of the pin shaft (12232) is provided with a slot (12228), one end of the second connecting rod (12226) is inserted into the slot (12228), and the second connecting rod (12226) is detachably fixedly connected to the pin shaft (12232) via a locking screw (12229).

6. The elastic shaft processing technology according to claim 2, characterized in that: A first slide groove (13) is provided on the top of the detection seat (10), and the first slide groove (13) is parallel to the left-right direction. The bottom of the support seat (1221) is inserted into the first slide groove (13), and the support seat (1221) is slidably connected with the first slide groove (13) along the left-right direction.

7. The elastic shaft processing technology according to claim 1, characterized in that: The elastic shaft torsion test device comprises a base (20), on which a test mechanism (21) and a protection mechanism (22) are arranged, and the test mechanism (21) is used to implement a torsion test of the elastic shaft; The protection mechanism (22) comprises a protection cover (221), the protection cover (221) is provided with an opening (222), a cover (223) is provided at the opening (222), an air pipe (224) is provided on the protection cover (221), the air pipe (224) is connected to an air supply system, and air with a certain humidity and temperature is transported from the air pipe (224) to the protection cover (221) through the air supply system, and an air hole (225) is provided on the protection cover (221).

8. The elastic shaft processing technology according to claim 7, characterized in that: The air holes (225) are provided in two groups, and the two groups of air holes (225) are respectively located on the left and right sides of the protective cover (221).

9. The elastic shaft processing technology according to claim 7, characterized in that: A collecting pipe (226) is provided at the bottom of the protective cover (221); the collecting pipe (226) is arranged vertically, and a sealing plug (227) is connected to the bottom end of the collecting pipe (226).

10. The elastic shaft processing technology according to claim 7, characterized in that: The test mechanism (21) comprises two support frames (211), the two support frames (211) are arranged on the base (20) at intervals along the left-right direction, a first connecting tool (212) and a second connecting tool (213) are arranged between the two support frames (211), the first connecting tool (212) and the second connecting tool (213) are arranged at intervals along the left-right direction, the first connecting tool (212) is fixedly connected to the support frame (211) on the left side through a first flange (214), a test motor (215) is arranged on the support frame (211) on the right side, an output end of the test motor (215) is connected to the second connecting tool (213) through a second flange (216), and the test motor (215) and the second flange (216) are both located on the right side of the second connecting tool (213); The protective cover (221) and the cover (223) form a cylindrical structure parallel to the left-right direction; the first connecting tool (212) is fixedly passed through one end of the protective cover (221); and the second connecting tool (213) is movably passed through the other end of the protective cover (221).

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