Clamping and jacking tool clamp for machining complete sphere and machining method

Abstract

The invention discloses a top clamping tool clamp for machining a complete sphere, which comprises an alignment template, a cutter bar device and a tool sleeve, and the tool sleeve is divided into a front-end tool sleeve and a rear-end tool sleeve; the longitudinal spherical shape of the alignment template is asymmetrical in the front-back direction, a wide step is arranged on the surface of the hemisphere on the rear side, and a wide outer cylindrical surface machined through tool setting according to the wide step is matched with the first inner cylindrical surface in the front-end tool sleeve. The invention further discloses a machining method of the complete ball, and on a center lathe, the clamping and jacking tool clamp for machining the complete ball is utilized, and the machining method comprises the steps that the position of the alignment sample plate is determined; clamping the cylindrical blank; rough machining twice; adjusting the positions of a tailstock and a middle sliding plate; installing and adjusting the height position of the blade; two times of finish machining; and the two tip chucks are removed, and a workpiece of a finished product sphere is obtained. The invention belongs to the technical field of mechanical equipment manufacturing, and solves the problems that a clamp in the prior art is unreasonable in structure, and a center lathe is difficult to accurately machine a whole ball.

Description

Technical Field

[0001] The present invention belongs to the technical field of mechanical equipment manufacturing, and relates to a clamping and supporting tool for machining a complete sphere, and the present invention also relates to a machining method for a complete sphere. Background Art

[0002] The turning motion of a spherical workpiece can be decomposed into a rotational motion of the workpiece centered on the spindle axis and a circular motion of the tool centered on a point on the spindle axis.

[0003] Currently, there is no special clamping and supporting tool for machining a complete sphere (front-end clamping and rear-end supporting). During the process of machining a spherical workpiece on a lathe, it is difficult to machine the entire sphere without a suitable tool, including a numerical control lathe. Conventional methods can only machine part of the sphere, either with a chuck or a flat surface. During the machining process, deformation or vibration is likely to occur due to the cutting force, and the overall rigidity of the workpiece to be machined is insufficient; the contact design of the inner conical surface of the tool cannot withstand high loads, and low-speed and high-precision machining cannot be achieved, and the appearance quality of the finished sphere is difficult to guarantee. Summary of the Invention

[0004] The purpose of the present invention is to provide a clamping and supporting tool for machining a complete sphere, which solves the problems that the fixture structure in the prior art is unreasonable and it is difficult for a lathe to achieve high-quality machining of the entire sphere.

[0005] Another purpose of the present invention is to provide a machining method for a complete sphere, which solves the problems that the clamping method in the prior art is unreasonable, low-speed and high-precision machining cannot be achieved, and it affects the rapid and accurate machining of the entire sphere by the lathe.

[0006] The technical solution adopted by the present invention is that a clamping and supporting tool for machining a complete sphere includes a alignment template, a tool bar device and a tooling sleeve. The tooling sleeve is divided into a front-end tooling sleeve and a rear-end tooling sleeve; The longitudinal spherical shape of the alignment template is asymmetric before and after, and a wide step is provided on the rear hemisphere surface. The wide outer cylindrical surface machined according to the wide step is matched with the inner cylindrical surface I in the front-end tooling sleeve.

[0007] Another technical solution adopted by the present invention is that for the machining method of a complete sphere, on an ordinary lathe, using the above-mentioned clamping and supporting tool for machining a complete sphere, the steps are as follows: Step 1: Determine the position of the alignment template; Step 2: Clamp the cylindrical blank; Step 3: Perform the first rough machining to obtain workpiece A; Step 4: Reinstall workpiece A; Step 5: Readjust workpiece A; Step 6: Perform the second rough machining to obtain workpiece B; Step 7: Adjust the positions of the tailstock and the cross slide; Step 8: Install and adjust the height position of the blade, and install workpiece B; Step 9: Obtain workpiece C through the first finish machining; Step 10: Obtain workpiece D through the second finish machining; Step 11: Remove the two center chucks on workpiece D to obtain the finished spherical workpiece.

[0008] The beneficial effects of the present invention are that the tooling structure is simple, easy to use and maintain, the method is easy to operate, and the requirements for supporting equipment are low, which can fully ensure the surface machining quality of the complete sphere. Brief Description of the Drawings

[0009] Figure 1 is a schematic structural diagram of the alignment template adopted in the method of the present invention; Figure 2 is a schematic structural diagram of the tool shank device adopted in the method of the present invention; Figure 3 is a schematic structural diagram of the front-end tooling sleeve adopted in the method of the present invention; Figure 4 is a schematic structural diagram of the rear-end tooling sleeve adopted in the method of the present invention; Figure 5 is a schematic diagram of the remaining hemisphere contour surface of the wide outer cylindrical surface machined according to the alignment sample during the machining process of the method of the present invention; Figure 6 is a schematic diagram of the remaining hemisphere contour surface of the other side machined according to the sample during the machining process of the method of the present invention; Figure 7 is a schematic diagram of machining one side of the spherical surface by assembling the tool shank device and removing the turntable fixing screw during the machining process of the method of the present invention; Figure 8 is a schematic diagram of machining the other side of the spherical surface during the machining process of the method of the present invention; Figure 9 is a schematic diagram of preparing to cut the two center chucks during the machining process of the method of the present invention; Figure 10 is a schematic diagram of obtaining the spherical finished product after cutting the two center chucks in the method of the present invention; Figure 11 is a schematic diagram of withdrawing the tool shank device after completing the machining of the spherical finished product in the method of the present invention.

[0010] In the figure, 1. alignment template, 2. tool bar device, 3. front-end tooling sleeve, 4. rear-end tooling sleeve, 5. workpiece, 6. live center, 7. square tool post, 8. four-jaw chuck, 9. compound rest, 10. compound rest handle, 11. cross slide, 12. cross slide handle, 13. turntable, 14. fastening bolt, 15. tailstock, 16. carriage; 101. wide step, 201. blade, 202. tool bar, 203. flange, 204. screw, 205. screw hole, 206. external threaded rod, 207. fixing nut, 208. through hole for clamping, 209. first set of adjusting shims, 301. first positioning end face, 302. first inner cylindrical surface, 303. first inner conical surface, 401. second positioning end face, 402. second inner cylindrical surface, 403. second inner conical surface, 501. wide outer cylindrical surface, 502. maximum outer diameter, 503. spherical positioning end face, 504. center chuck, 601. third positioning end face, 602. outer diameter of live center outer sleeve, 701. cut-off tool, 702. second set of adjusting shims. Detailed implementation mode

[0011] The present invention will be described in detail below in conjunction with the accompanying drawings and the detailed implementation mode.

[0012] Refer to Figures 5 - 10 , the tooling fixture of the present invention is applicable to a common lathe, and the common lathe should have the following basic settings: including the clamping front end, clamping rear end and cutting mechanism of the lathe; The clamping front end is equipped with a four-jaw chuck 8 (a three-jaw chuck can also be used); the clamping rear end is provided with a tailstock 15, and a live center 6 is installed on the inner end face of the tailstock 15. The outer circumferential surface of the main body of the live center 6 is called the outer diameter 602 of the live center outer sleeve. A raised third positioning end face 601 is provided at the end (outer edge) of the outer diameter 602 of the live center outer sleeve; The cutting mechanism includes a square tool post 7 and its movement control components. The movement control components include a carriage 16. A cross slide 11 is slidably arranged on the upper surface of the carriage 16. A first driving unit of the cross slide 11 is equipped with a cross slide handle 12. A turntable 13 is installed on the upper surface of the cross slide 11. A fastening bolt 14 is arranged between the turntable 13 and the cross slide 11 (the turntable 13 and the cross slide 11 are fixed and immovable. After removing the fastening bolt 14, the turntable 13 can rotate relative to the upper surface of the cross slide 11). A compound rest 9 is slidably arranged on the upper surface of the turntable 13. A second driving unit of the compound rest 9 is equipped with a compound rest handle 10; a square tool post 7 is installed on the upper surface of the compound rest 9. A cut-off tool 701 is installed on the square tool post 7. An installation surface of the cut-off tool 701 is provided with a second set of adjusting shims 702. The second set of adjusting shims 702 is used to adjust the installation height of the cut-off tool 701; By rotating the cross slide handle 12 and the compound rest handle 10 as needed, the transverse and longitudinal feeding of the square tool post 7 can be coordinated and driven.

[0013] The structure of the tooling fixture of the present invention includes an alignment template 1, a tool bar device 2, and a tooling sleeve, which is divided into a front tooling sleeve 3 and a rear tooling sleeve 4. The specific structure is described as follows: Refer to Figure 1 , Figure 1 The left - right direction shown in it is the longitudinal direction of the feed, and the up - down direction is the transverse direction of the feed. The alignment template 1 is drawn and printed using drafting tools. Its function is the tool setting reference for the rough - machining allowance outer contour. The longitudinal spherical shape of the alignment template 1 is asymmetric front - to - back. There is a wide step 101 on the rear hemispherical surface. The wide outer cylindrical surface 501 machined according to this wide step 101 is used in cooperation with the inner cylindrical surface 302 in the front tooling sleeve 3. The longitudinal feed is given according to the width of the cut - off tool 701, and the longitudinal feed is less than or equal to the cutting width, which is an integer multiple of the longitudinal movement of the tool rest when the small slide handle 10 turns one grid, ensuring that the longitudinal movement of the tool rest is basically accurate during the rough - machining process.

[0014] Refer to Figure 2 , the structure of the tool bar device 2 includes a tool bar 202 and a flange 203. The tool bar 202 is larger at the bottom than at the top. There is a screw hole 205 for assembling the cutting blade 201 on the top step surface of the tool bar 202. The cutting blade 201 is fixed on the top step surface through this screw hole 205 using a fixing screw, and the installation position of the upper cutting blade 201 is inclined outward; an external threaded rod 206 is fixed on the lower end surface of the tool bar 202. The flange 203 has a main bolt hole and three clamping clearance holes 208. The external threaded rod 206 passes through the main bolt hole and is screwed and fitted with a fixing nut 207 to fix the tool bar 202 on the flange 203.

[0015] Before finish - machining, use the screw 204 to fix the assembled tool bar device 2 at the position of the upper part of the small slide 9 where the square tool rest 7 is installed (first disassemble the square tool rest 7, and then install the tool bar device 2, see Figure 7 ); during the finish - machining process, the cutting blade 201 in the tool bar device 2 makes a circular motion with the center of the sphere as the center. The position of the cutting blade 201 at the upper end of the tool bar 202 is set outward, avoiding the possible interference phenomenon during machining while ensuring the rigidity of the tool bar 202.

[0016] Refer to Figure 3 , the main body of the front tooling sleeve 3 is in the shape of a thick - walled cylinder. The outer end of the front tooling sleeve 3 ( Figure 3 the left end in it) is clamped by the jaws 8, and the inner end of the front tooling sleeve 3 ( Figure 3 the right end in it) is used to clamp the workpiece 5, which is called the first positioning end face 301. The inner surface of the edge of the first positioning end face 301 is set as the first inner conical surface 303. The first inner conical surface 303 is closely adjacent inward to the first inner cylindrical surface 302. The arc dimension of the first inner conical surface 303 matches the surface of the semi - finished sphere to be machined.

[0017] Refer toFigure 4 The main body of the rear end tooling sleeve 4 is also in the shape of a thick-walled cylinder, and the outer end of the rear end tooling sleeve 4 ( Figure 4 The right end in the middle) is connected with the live center 6 on the tailstock 15, and the outer end of the rear end tooling sleeve 4 is called the positioning end face 2 401. The inner surface of the port where the positioning end face 2 401 is located is provided with a stepped inner cylindrical surface 1 402. The inner cylindrical surface 1 402 matches the outer circle 602 of the live center jacket of the live center 6. The size of the inner cylindrical surface 1 402 must refer to the size of the outer circle 602 of the live center jacket to ensure the transition between the two; the inner end of the positioning end face 2 401 ( Figure 4 The left end in the middle is provided with an inner conical surface 403 at the mouth edge, and the arc surface size of the inner conical surface 403 also matches the surface size of the semi-finished sphere.

[0018] The method for processing a complete sphere of the present invention utilizes the above-mentioned fixture for processing a complete sphere, and then completes the clamping through the basic setting of an ordinary lathe, and is implemented according to the following steps: Preparatory steps: make alignment template 1, tool rod device 2, front tool sleeve 3, and rear tool sleeve 4, and make them accordingly according to the size of the sphere to be processed, the thickness of the blade, and the top of the movable sleeve. The alignment template 1 is prepared for rough processing, and the diameter allowance is 1.5+0.5mm to ensure no interference and easy adjustment during later use.

[0019] Step 1: Determine the position of the alignment sample 1. Place the alignment template 1 flat and fix it on the large support plate 16 of the ordinary lathe, and place the side with the wide step 101 on one end of the tailstock 15. The magnetic base with a dial indicator is fixed on the side of the small slide 9. Slowly turn the middle slide handle 12 and the small slide handle 10, gently move the middle slide 11 and the small slide 9, and use the dial indicator to find the cross center line of the alignment template 1. The dial indicator contact is aligned with the cross center line. Since the relative position of the square tool holder 7 and the dial indicator remains unchanged, the track of the dial indicator on the alignment template 1 is the tool path of the cutting tool 701, see Figure 5 As shown; Step 2: Clamp the cylindrical blank of workpiece 5, The outer end of the cylindrical blank for making the workpiece 5 is clamped with four claws 8, and the inner end surface of the cylindrical blank is flattened and then a center hole is drilled; a live center 6 is installed on the tailstock 15, and a cutting knife 701 is installed on the square tool holder 7. The height of the cutting knife 701 is adjusted by adjusting the shim set 2 702 to ensure that the tip of the cutting knife 701 and the live center 6 are at the same height, and then the live center 6 is used to support the center hole of the inner end surface of the cylindrical blank. Figure 5 ; Step 3: Carry out the first roughing process. Set the tool according to the alignment template 1. Coordinate the rotation of the cross-slide handle 12 and the compound rest handle 10 to drive the transverse and longitudinal feed of the cut-off tool 701, and complete the machining of the right outer contour of the stock sphere, including machining a section of the maximum outer diameter 502 and leaving a wide outer cylindrical surface 501 on the hemispherical surface. The dimensions and roughness of the wide outer cylindrical surface 501 have requirements, and it has a transition fit with the inner cylindrical surface 302 of the previously fabricated front-end tooling sleeve 3 to obtain the workpiece A after the first rough machining, as shown in Figure 5 the workpiece shown in the lower right corner; Step 4: Reinstall the workpiece A after the first rough machining, After reversing the alignment template 1 left and right, fix it on the carriage 16 of the lathe again as a reference for aligning the other-end stock spherical surface. Place the side with the wide step 101 of the workpiece A after the first rough machining on the left end, clamp the maximum outer diameter 502 with the four-jaw chuck 8, and the wide outer cylindrical surface 501 and the rough spherical surface are in the space within the four-jaw chuck 8. Slowly rotate the cross-slide handle 12 and the compound rest handle 10, gently move the cross-slide 11 and the compound rest 9, and use the dial indicator to align the cross center line on the alignment template 1, as shown in Figure 6 ; Step 5: Readjust the workpiece A after the first rough machining, Clamp the workpiece A after the first rough machining reliably with the four-jaw chuck 8, align it according to the machined surface for machining the other outer end face, drill a center hole after ensuring that it is equal in total length to the alignment template 1, and tighten the workpiece A, as shown in Figure 6 ; Step 6: Perform the second rough machining, Set the tool according to the alignment template 1, ensure that the contact point of the dial indicator is aligned with the outer contour line of the alignment template 1. Since the relative position between the square tool post 7 and the dial indicator remains unchanged, the trajectory of the dial indicator on the alignment template 1 is the feed trajectory of the cut-off tool 701. Slowly rotate the cross-slide handle 12 and the compound rest handle 10, gently move the cross-slide 11 and the compound rest 9, and drive the transverse and longitudinal feed of the cut-off tool 701 to complete the machining of the outer contour of the other side of the stock sphere, obtaining the workpiece B after the second rough machining (i.e., the semi-finished spherical body of workpiece 5). At this time, the outer contour of the stock spherical surface of the workpiece B has been machined, as shown in Figure 6 ; Move the tailstock 15 backward, unload the workpiece B after two rough machinings, and record the diameter value at the maximum outer diameter 502 of the workpiece B.

[0020] Step 7: Adjust the positions of the tailstock 15 and the cross-slide 11, Remove the square tool holder 7 on the lathe; remove the fastening bolts 14 on the turntable 13 of the lathe so that the small slide 9 of the lathe can rotate freely; fix the magnetic base of the dial indicator on the small slide 9, move the middle slide 11, rotate the small slide 9, and hit the meter at the horizontal generatrix of the top cylindrical surface of the tailstock 15 to ensure that the center of the turntable 13 coincides with the center of the lathe spindle in the horizontal direction, fix the horizontal position of the middle slide 11, see Figure 7 ; Step 8: Install and adjust the height of the blade 201, and install the workpiece B. The tool bar device 2 of the present invention is assembled at the installation position of the square tool holder 7, and the blade 201 is adjusted by adjusting the shim set 1 209 to ensure that the tip of the blade 201 is at the same height as the live center 6; Use four claws 8 to clamp the end of the front tooling sleeve 3 and align it, and then load the workpiece B processed in step 6. At this time, the inner cylindrical surface 1 302 of the front tooling sleeve 3 cooperates with the wide outer cylindrical surface 501 of the workpiece B, and the positioning end surface 1 301 is axially positioned with the spherical positioning end surface 503 of the workpiece B; the other end of the workpiece B is pressed tightly against the live center 6, as shown in FIG. Figure 7 ; Step 9: Carry out the first finishing process. Move the small slide 9, use the table to align, and ensure that the tip of the blade 201 is facing the center of the sphere of the workpiece B; move the small slide 9, and perform multiple feeds according to the diameter size of the maximum outer circle 502 and the diameter size of the sphere drawing. Multiple feeds can ensure the processing quality. During the processing, only the small slide 9 needs to be rotated to process the workpiece C (that is, most of the smooth sphere), and a suitable first top chuck 504 is retained on the sphere of the workpiece C; Move the small slide 9 and the tailstock 15 backwards, and take out the workpiece C after the first fine machining. Figure 7 ; Step 10: Perform the second finishing process. The workpiece C that has been finely machined for the first time is turned around and reconnected with the front end tooling sleeve 3. At this time, the inner conical surface 303 of the front end tooling sleeve 3 is linearly matched with the machined workpiece C on a spherical surface; the other end of the workpiece C is supported by a live center 6; the small slide plate 9 is moved and rotated, and the table is pulled for alignment to ensure that the tip of the blade 201 is aligned with the center of the workpiece C at this time; the small slide plate 9 is moved, and the cutting is performed multiple times according to the diameter size of the sphere to be machined. Multiple cutting can ensure the machining quality. During the machining process, the workpiece D can be machined by simply rotating the small slide plate 9, and the second center chuck 504 is also retained; Move the small slide plate 9 and the tailstock 15 backward, and take out the workpiece D with a top chuck 504 at both ends of the axis line of the second fine processing. Figure 8 ; Step 11: Remove the two top chucks 504 to obtain the finished spherical workpiece 5. Assemble the rear-end tooling sleeve 4 with the outer sleeve of the live center 6. The positioning end face three 601 of the live center 6 is axially sleeved and positioned with the positioning end face two 401 of the rear-end tooling sleeve 4. Move the tailstock 15 forward to ensure clamping the workpiece D after the second finish machining. Place the two remaining center chucks 504 at the same longitudinal position, that is, the two center chucks 504 are located on the same circumference vertically. At this time, the inner conical surface one 303 of the front-end tooling sleeve 3 and the inner conical surface two 403 of the rear-end tooling sleeve 4 both achieve spherical linear fit with the workpiece D after the second finish machining. Move and rotate the compound rest 9, use a dial indicator to align, and ensure that the tip position of the cutting blade 201 is exactly opposite to the center of the workpiece D at this time. Move the compound rest 9 and perform multiple small feed rate machining according to the sphere diameter dimension on the drawing (Note: The two center chucks 504 are obvious protrusions. With multiple small feed rates, the machining will not cause impact damage to the cutting blade 201 at this time). Multiple small feed rates can ensure the machining quality. During the machining process, only rotate the compound rest 9. After cutting off the two center chucks 504, the finished sphere workpiece 5 is obtained, as shown in Figure 9 and Figure 10 ; Move the compound rest 9 and the tailstock 15 backward, take out the spherical finished product of the workpiece 5, and it is completed, as shown in Figure 11 .

[0021] Embodiment 1 In this Embodiment 1, according to the aforementioned complete sphere machining method, on the basis of the basic settings of an ordinary lathe, using the aforementioned clamping and centering tooling fixture for machining a complete sphere, a sphere with a diameter of φ100mm is machined, and the process parameters are as follows: 1. Rough machining alignment template 1, leave a minimum allowance of 1.5mm according to the minimum diameter. The width of each frustum is 2.3mm. The diameter of the wide step 101 is made according to φ81mm and the width is made according to 2.3mm X 4 = 9.2mm.

[0022] 2. The taper of the inner conical surface one 303 in the front-end tooling sleeve 3 is made at 30°, and the surface roughness is controlled according to Ra1.6; the diameter of the inner cylindrical surface one 302 is made according to φ82H7 (hole depth 6mm), and the surface roughness is controlled according to Ra1.6.

[0023] 3. The taper of the inner conical surface two 403 in the rear-end tooling sleeve 4 is made at 60°, and the surface roughness is controlled according to Ra1.6; the diameter of the inner cylindrical surface two 402 is made according to φ45H7 (hole depth 30mm), ensuring a transition fit with the outer diameter of the live center outer sleeve 602, with a clearance not greater than 0.01mm, and the surface roughness is controlled according to Ra1.6, and it is trial-fitted with the live center 6.

[0024] 4. The outer diameter dimension of the wide outer cylindrical surface 501 of part A for rough machining of the vehicle repair is processed as φ82k6 for φ81mm, ensuring a transition fit with the inner cylindrical surface 302 of the previously fabricated front tooling sleeve 3, with a clearance not greater than 0.01mm, the roughness controlled according to Ra1.6, and a trial fit with the front tooling sleeve 3.

[0025] The diameter dimension of the complete sphere machined in this Example 1 can be controlled within φ100±0.03, and the roughness is not greater than Ra1.6.

[0026] Example 2 In this Example 2, according to the processing method of the complete sphere described above, on the basis of the basic settings of an ordinary lathe, using the clamping and supporting tooling fixture for machining the complete sphere described above, a sphere with a diameter of φ95mm is machined, and the process parameters are as follows: 1. Rough machine the alignment template 1, leaving a minimum allowance of 1.5mm in diameter, with a frustum width of 2.3mm, and the diameter of the wide step 101 is made as φ77mm and the width 2.3mm×4 = 9.2mm.

[0027] 2. The taper of the inner conical surface 303 in the front tooling sleeve 3 is made as 30°, and the roughness is controlled according to Ra1.6; the diameter of the inner cylindrical surface 302 is made as φ78H7 (hole depth 6mm), and the roughness is controlled according to Ra1.6.

[0028] 3. The taper of the inner conical surface 403 in the rear tooling sleeve 4 is made as 60°, and the roughness is controlled according to Ra1.6; the diameter of the inner cylindrical surface 402 is made as φ45H7 (hole depth 30mm), ensuring a transition fit with the outer circle 602 of the live center sleeve, with a clearance not greater than 0.01mm, the roughness is controlled according to Ra1.6, and a trial fit with the live center 6 (the tooling sleeve parameters are the same as those for machining a sphere with a diameter of φ100mm).

[0029] 4. The outer diameter dimension of the wide outer cylindrical surface 501 of part A for rough machining of the vehicle repair is φ77mm, processed as φ78k6, ensuring a transition fit with the inner cylindrical surface 302 of the previously fabricated front tooling sleeve 3, with a clearance not greater than 0.01mm, the roughness is controlled according to Ra1.6, and a trial fit with the front tooling sleeve 3.

[0030] The diameter dimension of the complete sphere machined in this Example 2 can be controlled within φ95±0.03, and the roughness is not greater than Ra1.6.

[0031] Example 3 In this Example 3, according to the processing method of the complete sphere described above, on the basis of the basic settings of an ordinary lathe, using the clamping and supporting tooling fixture for machining the complete sphere described above, a sphere with a diameter of φ90mm is machined, and the process parameters are as follows: 1. The rough machining alignment template 1 is made with a minimum diameter allowance of 1.5 mm, a frustum width of 2.3 mm, and the width step 101 has a diameter of φ72 mm and a width of 2.3 mm X 4 = 9.2 mm.

[0032] 2. In the front-end tooling sleeve 3, the inner conical surface - 303 taper is made at 30°, and the roughness is controlled at Ra1.6; the inner cylindrical surface - 302 has a diameter of φ73H7 (hole depth 6 mm) and the roughness is controlled at Ra1.6.

[0033] 3. In the rear-end tooling sleeve 4, the inner conical surface - 403 taper is made at 60°, and the roughness is controlled at Ra1.6; the inner cylindrical surface - 402 has a diameter of φ45H7 (hole depth 30 mm), ensuring an interference fit with the outer diameter of the live center sleeve 602, with a clearance not exceeding 0.01 mm, the roughness is controlled at Ra1.6, and it is trial-fitted with the live center 6 (the tooling sleeve parameters are the same as those for machining a sphere with a diameter of φ100 mm).

[0034] 4. The outer diameter of the wide outer cylindrical surface 501 of the part A for rough machining of the lathe is φ72 mm, and it is machined to φ73k6, ensuring an interference fit with the inner cylindrical surface - 302 of the previously made front-end tooling sleeve 3, with a clearance not exceeding 0.01 mm, the roughness is controlled at Ra1.6, and it is trial-fitted with the front-end tooling sleeve 3.

[0035] The complete sphere machined in this Example 3 has a diameter dimension controllable within φ90 ± 0.03, and the roughness is not greater than Ra1.6.

[0036] Example 4 In this Example 4, following the machining method of the complete sphere described above, on the basis of the basic settings of an ordinary lathe, using the clamping and centering tooling fixture for machining the complete sphere described above, a sphere with a diameter of φ105 mm is machined, and the process parameters are as follows: 1. The rough machining alignment template 1 is made with a minimum diameter allowance of 1.5 mm, a frustum width of 2.3 mm, and the width step 101 has a diameter of φ85 mm and a width of 2.3 mm X 4 = 9.2 mm.

[0037] 2. In the front-end tooling sleeve 3, the inner conical surface - 303 taper is made at 30°, and the roughness is controlled at Ra1.6; the inner cylindrical surface - 302 has a diameter of φ86H7 (hole depth 6 mm) and the roughness is controlled at Ra1.6.

[0038] 3. In the rear-end tooling sleeve 4, the inner conical surface - 403 taper is made at 60°, and the roughness is controlled at Ra1.6; the inner cylindrical surface - 402 has a diameter of φ45H7 (hole depth 30 mm), ensuring an interference fit with the outer diameter of the live center sleeve 602, with a clearance not exceeding 0.01 mm, the roughness is controlled at Ra1.6, and it is trial-fitted with the live center 6 (the tooling sleeve parameters are the same as those for machining a sphere with a diameter of φ100 mm).

[0039] 4. The outer diameter dimension of the wide outer cylindrical surface 501 of part A for rough machining of the vehicle repair is φ85mm, which is machined according to φ86k6, ensuring a transition fit with the inner cylindrical surface -302 of the previously fabricated front-end tooling sleeve 3, with a clearance not greater than 0.01mm, the roughness controlled according to Ra1.6, and a trial fit with the front-end tooling sleeve 3.

[0040] For the complete sphere machined in Example 4, the diameter dimension can be controlled within ±0.03, and the roughness is not greater than Ra1.6.

[0041] Example 5 In Example 5, according to the machining method of the complete sphere described above, on the basis of the basic settings of a common lathe, using the clamping and supporting tooling fixture for machining the complete sphere described above, a sphere with a diameter of φ110mm is machined, and the process parameters are as follows: 1. For the rough machining alignment template 1, the minimum diameter allowance is 1.5mm, the width of the frustum is 2.3mm, and the diameter of the wide step 101 is made according to φ89mm and the width 2.3mm×4 = 9.2mm.

[0042] 2. In the front-end tooling sleeve 3, the taper of the inner conical surface -303 is made according to 30°, and the roughness is controlled according to Ra1.6; the diameter of the inner cylindrical surface -302 is made according to φ90H7 (hole depth 6mm), and the roughness is controlled according to Ra1.6.

[0043] 3. In the rear-end tooling sleeve 4, the taper of the inner conical surface two 403 is made according to 60°, and the roughness is controlled according to Ra1.6; the diameter of the inner cylindrical surface two 402 is made according to φ45H7 (hole depth 30mm), ensuring a transition fit with the outer circle 602 of the live center sleeve, with a clearance not greater than 0.01mm, the roughness is controlled according to Ra1.6, and a trial fit with the live center 6 (the tooling sleeve parameters are the same as those for machining a sphere with a diameter of φ100mm).

[0044] 4. The outer diameter dimension of the wide outer cylindrical surface 501 of part A for rough machining of the vehicle repair is φ89mm, which is machined according to φ90k6, ensuring a transition fit with the inner cylindrical surface -302 of the previously fabricated front-end tooling sleeve 3, with a clearance not greater than 0.01mm, the roughness is controlled according to Ra1.6, and a trial fit with the front-end tooling sleeve 3.

[0045] For the complete sphere machined in Example 5, the diameter dimension can be controlled within φ95±0.03, and the roughness is not greater than Ra1.6.

[0046] Example 6 In Example 6, according to the machining method of the complete sphere described above, on the basis of the basic settings of a common lathe, using the clamping and supporting tooling fixture for machining the complete sphere described above, a sphere with a diameter of φ115mm is machined, and the process parameters are as follows: 1. For the rough machining alignment template 1, leave a machining allowance of 1.5 mm at the minimum diameter, with a frustum width of 2.3 mm. The wide step 101 has a diameter of φ93 mm and a width of 2.3 mm × 4 = 9.2 mm.

[0047] 2. In the front-end tooling sleeve 3, the inner conical surface - 303 taper is made at 30°, and the surface roughness is controlled at Ra1.6; the inner cylindrical surface - 302 has a diameter of φ94H7 (hole depth 6 mm), and the surface roughness is controlled at Ra1.6.

[0048] 3. In the rear-end tooling sleeve 4, the inner conical surface two - 403 taper is made at 60°, and the surface roughness is controlled at Ra1.6; the inner cylindrical surface two - 402 has a diameter of φ45H7 (hole depth 30 mm), ensuring a transition fit with the outer diameter of the live center outer sleeve 602, with a clearance not greater than 0.01 mm, and the surface roughness is controlled at Ra1.6. Then, it is trial-fitted with the live center 6 (the parameters are the same as those of the tooling sleeve for machining a sphere with a diameter of φ100 mm).

[0049] 4. For the outer diameter of the wide outer cylindrical surface 501 of part A in rough machining for repair, it is machined to φ94k6 with a diameter of φ93 mm, ensuring a transition fit with the inner cylindrical surface - 302 of the pre-made front-end tooling sleeve 3, with a clearance not greater than 0.01 mm, and the surface roughness is controlled at Ra1.6. Then, it is trial-fitted with the front-end tooling sleeve 3.

[0050] For the complete sphere machined in this embodiment 6, the diameter dimension can be controlled within φ95 ± 0.03, and the surface roughness is not greater than Ra1.6.

Claims

1. The clamping and topping tooling fixture for machining a complete sphere, characterized in that: It includes an alignment template (1), a tool shank device (2), and a tooling sleeve. The tooling sleeve is divided into a front-end tooling sleeve (3) and a rear-end tooling sleeve (4). The longitudinal spherical shape of the alignment template (1) is asymmetric before and after. A wide step (101) is provided on the rear hemispherical surface. The wide outer cylindrical surface (501) machined according to the wide step (101) cooperates with the inner cylindrical surface I (302) in the front-end tooling sleeve (3).

2. The clamping and topping tooling fixture for machining a complete sphere according to claim 1, wherein The structure of the tool shank device (2) is as follows: it includes a tool shank (202) and a flange (203). The tool shank (202) is smaller at the top and larger at the bottom. A screw hole (205) for assembling the cutting blade (201) is provided on the top step surface of the tool shank (202). The cutting blade (201) is fixed on the top step surface by a fixing screw through the screw hole (205). The installation position of the upper cutting blade (201) is inclined outward; an external threaded rod (206) is fixed on the lower end surface of the tool shank (202). The flange (203) is provided with a main bolt hole and three fitting clearance holes (208). The external threaded rod (206) passes through the main bolt hole and is tightly fitted with a fixing nut (207) to fix the tool shank (202) on the flange (203).

3. The clamping and topping tooling fixture for machining a complete sphere according to claim 1, characterized in that, The main body of the front-end tooling sleeve (3) is in the shape of a thick-walled cylinder. The outer end of the front-end tooling sleeve (3) is clamped by a claw (8). The inner end of the front-end tooling sleeve (3) is used to clamp the workpiece (5) and is called the first positioning end surface (301). The inner surface of the edge of the first positioning end surface (301) is set as the first inner conical surface (303). The first inner conical surface (303) is closely adjacent to the inner cylindrical surface I (302) inward. The arc size of the first inner conical surface (303) matches the surface of the semi-finished sphere to be machined.

4. The clamping and holding tooling fixture for machining a complete sphere according to claim 1, characterized in that, The main body of the rear-end tooling sleeve (4) is also in the shape of a thick-walled cylinder. The outer end of the rear-end tooling sleeve (4) is sleeved with a live center (6) on the tailstock (15). The outer edge of the rear-end tooling sleeve (4) is called the second positioning end surface (401). The inner circular surface of the port where the second positioning end surface (401) is located is provided with a stepped inner cylindrical surface I (402). The inner cylindrical surface I (402) cooperates with the outer circle of the live center outer sleeve (602) of the live center (6). The size of the inner cylindrical surface I (402) must refer to the size of the outer circle of the live center outer sleeve (602) to ensure an interference fit between the two; the inner edge of the inner port of the second positioning end surface (401) is provided with a second inner conical surface (403). The arc size of the second inner conical surface (403) also matches the surface size of the semi-finished sphere.

5. Method for machining a complete sphere. On an ordinary lathe, by using the clamping and supporting fixture for machining a complete sphere as described in claim 1, it is characterized in that The steps are as follows: Step 1: Determine the position of the alignment template (1). Step 2: Clamp the cylindrical blank. Step 3: Obtain workpiece A through the first rough machining. Step 4: Reinstall workpiece A. Step 5: Readjust workpiece A. Step 6: Obtain workpiece B through the second rough machining. Step 7: Adjust the positions of the tailstock (15) and the middle slide plate (11). Step 8: Install and adjust the height position of the cutting blade (201), and install workpiece B. Step 9: Obtain workpiece C through the first finish machining. Step 10: Obtain workpiece D through the second finish machining. Step 11: Remove the two center chucks (504) from the workpiece D to obtain the finished spherical workpiece (5).

6. The processing method of the complete sphere according to claim 5, characterized in that, Before Step 1, there is also a preparatory step: fabricate an alignment template (1), a tool shank device (2), a front-end tooling sleeve (3), and a rear-end tooling sleeve (4), and fabricate them correspondingly with reference to the dimensions of the sphere to be machined, the thickness of the cutting blade, and the movable outer sleeve center. The diameter allowance of the alignment template (1) is 1.5 + 0.5 mm.

7. The processing method of the complete sphere according to claim 5, characterized in that, In Step 1, the specific process is as follows: Lay and fix the alignment template (1) on the carriage (16) of an ordinary lathe, place the side with the wide step (101) at one end of the tailstock (15), fix the magnetic base with a dial indicator on the side of the compound rest (9), slowly rotate the cross-slide handle (12) and the compound rest handle (10), gently move the cross-slide (11) and the compound rest (9), and align the cross center line of the alignment template (1) with the dial indicator. Align the dial indicator contact with the cross center line.

8. The processing method of the complete sphere according to claim 5, characterized in that, In Steps 3 and 6, The specific process of the first rough machining is as follows: Set the tool according to the alignment template (1), coordinate the rotation of the cross-slide handle (12) and the compound rest handle (10) to drive the transverse and longitudinal feeding of the cut-off tool (701), and complete the machining of the outer contour of the right side of the sphere with machining allowance, including machining a section of the maximum outer diameter (502) and leaving a section of wide outer cylindrical surface (501) on the hemispherical surface. The dimensions and roughness of the wide outer cylindrical surface (501) have requirements, and it has a transitional fit with the inner cylindrical surface I (302) of the fabricated front-end tooling sleeve (3) to obtain workpiece A; The specific process of the second rough machining is as follows: Set the tool according to the alignment template (1), ensure that the dial indicator contact is aligned with the outer contour line of the alignment template (1), and the trajectory of the dial indicator on the alignment template (1) is the feeding trajectory of the cut-off tool (701); slowly rotate the cross-slide handle (12) and the compound rest handle (10), gently move the cross-slide (11) and the compound rest (9), drive the transverse and longitudinal feeding of the cut-off tool (701), and complete the machining of the outer contour of the other side of the sphere with machining allowance to obtain workpiece B; at this time, the outer contour of the sphere of workpiece B with allowance has been machined; Move the tailstock (15) backward, remove workpiece B that has completed two rough machinings, and record the diameter value at the maximum outer diameter (502) of workpiece B.

9. The processing method of the complete sphere according to claim 5, characterized in that, In Steps 9 and 10, The specific process of the first finish machining is as follows: Move the compound rest (9), perform alignment by pulling the dial indicator, and ensure that the tip position of the cutting blade (201) is directly opposite to the center of the sphere of workpiece B; move the compound rest (9), and perform multiple feedings according to the diameter dimension of the maximum outer diameter (502) and the diameter dimension of the sphere on the drawing. During the machining process, only rotate the compound rest (9) to machine workpiece C, and retain a suitable first center chuck (504) on the sphere of workpiece C; move the compound rest (9) and the tailstock (15) backward, and take out workpiece C after the first finish machining; The specific process of the second finish machining is as follows: Turn the workpiece C after the first finish machining around, and reconnect it with the front tooling sleeve (3). At this time, the inner conical surface I (303) of the front tooling sleeve (3) is in spherical linear fit with the workpiece C; the other end of the workpiece C is supported by a live center (6); move and rotate the compound rest (9), use a dial indicator to align, and ensure that the tip position of the cutting blade (201) is exactly opposite to the center of the workpiece C at this time; move the compound rest (9), and feed multiple times according to the diameter dimension of the sphere drawing to be machined. During the machining process, only rotate the compound rest (9) to machine the workpiece D, and also retain a suitable second center chuck (504); move the compound rest (9) and the tailstock (15) backward, and take out the workpiece D with a center chuck (504) at both ends of the axis after the second finish machining.

10. The processing method of the complete sphere according to claim 5, characterized in that, In step 11, the specific process is as follows: Assemble the rear tooling sleeve (4) with the outer sleeve of the live center (6). The positioning end face III (601) of the live center (6) is axially sleeved and positioned with the positioning end face II (401) of the rear tooling sleeve (4). Move the tailstock (15) forward to ensure clamping of the workpiece D, and place the two retained center chucks (504) at the same longitudinal position; at this time, both the inner conical surface I (303) of the front tooling sleeve (3) and the inner conical surface II (403) of the rear tooling sleeve (4) are in spherical linear fit with the workpiece D; move and rotate the compound rest (9), use a dial indicator to align, and ensure that the tip position of the cutting blade (201) is exactly opposite to the center of the workpiece D at this time; move the compound rest (9), and perform multiple small feed rate machining according to the sphere diameter dimension on the drawing. After cutting off the two center chucks (504), the finished spherical workpiece (5) is obtained; move the compound rest (9) and the tailstock (15) backward, and take out the spherical finished product of the workpiece (5), and it is completed.

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