Machining device and technology of aluminum clamping shell coupler for bilge water pump

Abstract

The invention discloses a machining process of an aluminum clamping shell coupling for a bilge water pump, the clamping shell coupling is composed of two semi-cylindrical clamping shells with the same size, and torque transmission is achieved through keys and key grooves; the tool fixture is characterized in that the tool fixture during machining comprises a four-axis rotary table, a directional supporting plate, a tool frame supporting plate, a fine boring cutter, a workpiece positioning shaft and a bottom plate locking nut; the four-axis rotary table is connected with the directional supporting plate, the work frame supporting plate is connected with the directional supporting plate, and the workpiece positioning shaft is connected with the work frame supporting plate through the bottom plate locking nut. The clamping shell coupler comprises a key groove side clamping shell coupler and a keyless clamping shell coupler. According to the aluminum clamping shell coupling, the rotational inertia and the overall mass are remarkably reduced, so that the power density of a power unit is optimized, and the balance weight burden of ship equipment is relieved.

Description

Technical Field

[0001] This invention relates to the field of coupling processing technology, and in particular to a processing device and process for an aluminum clamp coupling for a bilge pump. Background Technology

[0002] As a core subsystem ensuring safe navigation, the bilge water system directly impacts a ship's survivability and overall resilience. The bilge pump, the power source of this system, plays a crucial role in promptly removing floodwater from the bilge, preventing equipment immersion failure, and maintaining hull stability. Under these demanding conditions, the performance of the power transmission components is paramount. Aluminum clamp couplings, with their unique material and structural advantages, play an indispensable role in the power transmission of the bilge pump.

[0003] In the machining of aluminum clamp couplings, the low hardness and high plasticity of the material make it prone to tool sticking and work hardening during cutting, which in turn affects the form and position tolerances and surface finish of the inner hole of the clamp. Furthermore, the positional accuracy of the keyway centers at both ends is easily affected by the parallelism and straightness of the left and right sides of the keyway during machining. During keyway milling, the elastic deformation of the material itself can easily lead to taper angles between the planes. Simultaneously, during precision boring of the inner hole, the release of residual stress may cause elastic deformation, causing the coaxiality and parallelism positional tolerances of the holes on both sides to exceed the specified range, thus affecting the overall quality of the product. Therefore, traditional machining methods are insufficient to meet the product's precision requirements.

[0004] Therefore, it is necessary to provide a processing device and process for an aluminum clamp coupling for bilge pumps to solve the above-mentioned technical problems. Summary of the Invention

[0005] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0006] In view of the aforementioned existing problems, the present invention is proposed.

[0007] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a processing device for an aluminum clamp coupling for a bilge pump, wherein the clamp coupling is composed of two semi-cylindrical clamps of the same size, and torque transmission is achieved through a key and a keyway; characterized in that the tooling fixture for processing includes a four-axis rotary table, a directional support plate, a tool holder support plate, a precision boring tool, a workpiece positioning shaft, and a base plate locking nut; the four-axis rotary table is connected to the directional support plate, the tool holder support plate is connected to the directional support plate, and the workpiece positioning shaft is connected to the tool holder support plate through the base plate locking nut; the clamp coupling includes a keyway-side clamp coupling and a keyless clamp coupling.

[0008] As a preferred embodiment of the processing device for the aluminum clamp coupling for the bilge pump described in this invention, the workpiece positioning shafts are configured as a pair and mounted on the workpiece support plate.

[0009] As a preferred embodiment of the processing device for the aluminum clamp coupling for the bilge pump described in this invention, the keyway-side clamp coupling is fixedly connected by a flange nut.

[0010] As a preferred embodiment of the processing device for the aluminum clamp coupling for the bilge pump described in this invention, the clamp coupling is placed on a flat elastic washer and fixed by tightening a brass flange nut.

[0011] As a preferred embodiment of the processing device for the aluminum clamp coupling for the bilge pump described in this invention, a positioning straight cylindrical nut and a locking round nut are respectively installed on the workpiece positioning shaft.

[0012] As a preferred embodiment of the machining device for the aluminum clamp coupling for the bilge pump described in this invention, a precision boring tool is installed on the other side of the four-axis rotary table, and a tooling rotation positioning device is installed below the precision boring tool.

[0013] As a preferred embodiment of the processing device for the aluminum clamp coupling for the bilge pump described in this invention, the four-axis rotary table is capable of rotating at multiple angles.

[0014] A preferred embodiment of the processing technology for the aluminum clamp coupling described in this invention includes the following steps:

[0015] Step 1: Rough machining. The aluminum round bar is cut into blanks. The inner hole and outer circle contour of the product are preliminarily machined using a lathe, leaving a machining allowance of 1.5mm.

[0016] Step 2, sawing: Place the rough-processed product horizontally or vertically on the worktable of the saw and cut it in half equally.

[0017] Step 3, Aging treatment: A low-temperature tempering heat treatment process is used to heat the product to a range of 190°C to 230°C, hold it at that temperature for 3 to 4 hours, and then allow it to cool naturally.

[0018] Step 4, Semi-finishing 1, Four-axis machining center for coupling Torque transmission input end and The output end hole is rough bored, the keyway is rough milled, and a 0.3mm fine boring and fine milling allowance is retained;

[0019] Step 5, Semi-finishing 2: Based on the product dimensions after the semi-finishing 1 process, make a corresponding special model mandrel (14), place it between the two halves of the product, and tighten the screws to fix it.

[0020] Step 6: Keep the product at a constant temperature. After the product has completed the two semi-finishing processes, loosen the fastening screws. The two halves of the product will then undergo elastic deformation.

[0021] Step 7, Finishing 1: Install the tooling fixture for this process on the A-axis rotary table of the four-axis machining center, and then rotate the tooling 180 degrees.

[0022] Step 8, Finishing 2: Place the product on a special tooling and first perform finish milling on the keyway. Set the spindle speed to 1500 r / min and the cutting speed to 170 m / min.

[0023] Step 9: Product processing dimension inspection. According to the drawing requirements, use a customized inspection tool or a coordinate measuring machine to conduct a comprehensive measurement and detailed inspection of the product's dimensions and spatial position.

[0024] As a preferred embodiment of the processing technology of the aluminum clamp coupling described in this invention, the constant temperature standing in step 6 requires placing the product in a constant temperature environment of 20°C to 25°C for 8 to 10 hours.

[0025] As a preferred embodiment of the machining process of the aluminum clamping coupling described in this invention, after the finishing process 2 in step 8 is completed, the A-axis is rotated 90 degrees to align and fix the two halves of the clamping coupling with the tooling. Then, the holes on both sides are precision bored, the spindle speed is increased to 2000 r / min, and the cutting speed is 200 m / min.

[0026] The beneficial effects of this invention are as follows: Compared with traditional cast iron or steel couplings, aluminum clamp couplings achieve a significant reduction in rotational inertia and overall mass, thereby optimizing the power density of the power unit and reducing the counterweight burden on marine equipment. Furthermore, the elastic modulus of aluminum provides the coupling with appropriate flexibility, effectively mitigating transient shocks and high-frequency vibrations caused by pump start-up and shutdown, load fluctuations, or hull vibrations, thus reducing the risk of bearing wear and shaft fatigue failure. Attached Figure Description

[0027] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] in:

[0029] Figure 1 A schematic diagram of the overall structure of the aluminum clamp coupling for a bilge pump, provided as an embodiment of the present invention, showing the processing device and process for the aluminum clamp coupling.

[0030] Figure 2 A schematic diagram of the mandrel used in the processing apparatus and process for the aluminum clamp coupling for the bilge pump according to an embodiment of the present invention;

[0031] Figure 3 A schematic diagram of the tooling fixtures for processing the aluminum clamp coupling for the bilge pump according to an embodiment of the present invention;

[0032] Figure 4 A schematic diagram showing the specific placement of workpieces during the milling of the keyway in a processing device and process for an aluminum clamp coupling for a bilge pump according to an embodiment of the present invention.

[0033] Figure 5 A schematic diagram showing the alignment of the shaft centerlines in the XY direction of the processing apparatus and process for the aluminum clamp coupling for the bilge pump according to an embodiment of the present invention.

[0034] Figure 6 A schematic diagram showing the influence of the processing device and process of the aluminum clamp coupling for the bilge pump as described in one embodiment of the present invention on the bore diameter factors on both sides of the aluminum clamp coupling;

[0035] Figure 7 A schematic diagram of the processing procedure for the aluminum clamp coupling for bilge pumps according to an embodiment of the present invention. Detailed Implementation

[0036] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0037] Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without inventive effort should fall within the scope of protection of this invention.

[0038] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0039] Example 1

[0040] Reference Figures 1-7 According to an embodiment of the present invention, a processing device for an aluminum clamp coupling for a bilge pump is provided. The clamp coupling consists of two semi-cylindrical clamps of the same size, and torque transmission is achieved through a key and a keyway. The device is characterized in that the tooling fixture used during processing includes a four-axis rotary table 1, a directional support plate 2, a tool holder support plate 3, a precision boring tool 11, a workpiece positioning shaft 5, and a base plate locking nut 4. The four-axis rotary table 1 is connected to the directional support plate 2, the tool holder support plate 3 is connected to the directional support plate 2, and the workpiece positioning shaft 5 is connected to the tool holder support plate 3 via the base plate locking nut 4. The clamp coupling includes a keyway-side clamp coupling 6 and a keyless clamp coupling 10. Specifically, the tooling design of the present invention has wide applicability and can be adapted to various models of four-axis rotary tables. Its structure is connected to the four-axis rotary table 1 via the directional support plate 2, and the tool holder support plate 3 is embedded in the surface of the directional support plate 2. The workpiece positioning shaft 5 is connected to the tool support plate 3 via the base plate locking nut 4, achieving precise positioning of the clamp coupling 6 with the keyway on one side. The clamp coupling 6 is placed on the flat elastic washer 7 and fixed by tightening the brass flange nut 8. The keyway is precision milled. After the keyway is precision milled, the brass flange nut 8 is removed and replaced with a positioning straight cylindrical nut 9 to smoothly install the clamp coupling 10 without the keyway on the other side. Subsequently, the workpiece is locked with the convenient locking round nut 13 to ensure the concentricity and perpendicularity of the holes on both sides of the coupling.

[0041] After the precision boring of one side of the hole is completed, the four-axis rotary table 1 rotates 180°, and the precision boring tool 11 moves to the fixture's unidirectional rotation positioning device 12 to align the XY axis of the clamping coupling. After alignment, the precision boring of the other side of the hole begins. Once both sides of the hole are machined, the convenient locking round nut 13 and the positioning straight cylindrical nut 9 are loosened and removed to allow for the clamping of the next pair of workpieces. The ease of use of this fixture structure design solves, to the greatest extent possible, the high spatial requirements of the product during processing and the problem of dimensional deviations caused by deformation.

[0042] Example 2

[0043] Reference Figure 7 The difference between this embodiment and the previous embodiment is that this embodiment provides a processing technology for an aluminum clamp coupling, wherein the processing technology for the aluminum clamp coupling includes the following steps:

[0044] Step 1, Rough Machining Stage: The aluminum round bar is cut into blanks. The inner hole and outer circle contour dimensions of the product are preliminarily machined using a lathe, leaving a machining allowance of 1.5mm.

[0045] Step 2, Sawing: Place the rough-processed product horizontally or vertically on the worktable of the saw and cut it in half equally.

[0046] Step 3, Aging Treatment: Use a low-temperature tempering heat treatment process to heat the product to a range of 190° to 230°, hold it at that temperature for 3 to 4 hours, and then let it cool naturally.

[0047] Step 4, Semi-finishing 1: Four-axis machining center for coupling Torque transmission input end and The output end bore is rough bored, and the keyway is rough milled, leaving a 0.3mm allowance for fine boring and fine milling. Except for the outer diameter, all other dimensions are machined strictly according to the drawing requirements.

[0048] Step 5, Semi-finishing 2: Based on the product dimensions after semi-finishing 1, fabricate a corresponding special-type mandrel 14, place it between the two halves of the product, and tighten the screws to secure it. Then, place the assembly on a lathe for finishing of the outer diameter.

[0049] Step 6, Constant Temperature Resting: After completing the two semi-finishing steps, loosen the fastening screws. The two halves of the product will exhibit elastic deformation. Therefore, the product needs to be placed in a constant temperature environment of 20℃ to 25℃ for 8 to 10 hours to allow the product's elastic deformation peak to reach its maximum value.

[0050] Step 7, Finishing 1: Install the tooling fixture specifically designed for this process onto the A-axis rotary table of the four-axis machining center, and then rotate the fixture 180 degrees. Use a dial indicator to meticulously measure multiple angular factors such as flatness, perpendicularity, and parallelism, ensuring that the errors of these factors are controlled within 0.02mm to effectively reduce the occurrence of angular errors.

[0051] Step 8, Finishing 2: Place the product on a dedicated fixture. First, perform finish milling on the keyway, setting the spindle speed to 1500 r / min and the cutting speed to 170 m / min. After completion, rotate the A-axis 90 degrees, align and fix the two halves of the clamping coupling with the fixture, and then perform finish boring on both sides of the hole, increasing the spindle speed to 2000 r / min and the cutting speed to 200 m / min. It is particularly important to ensure that there is no backlash in the tool holder before starting the finish boring process to guarantee machining accuracy.

[0052] Step 9: Product processing dimension inspection: According to the drawing requirements, use a customized inspection tool or a coordinate measuring machine to conduct a comprehensive measurement and detailed inspection of the product's dimensions and spatial position.

[0053] In summary, the superiority of this process has been verified through practice. With the optimized processing technology, the product accuracy fully meets the requirements of the drawings, and the processing efficiency has been significantly improved.

[0054] It is important to note that the constructions and arrangements of this application shown in several different exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those who consult this disclosure will readily understand that many modifications are possible (e.g., changes in the size, dimensions, structure, shape, and proportions of various elements, as well as parameter values ​​(e.g., temperature, pressure, etc.), mounting arrangements, use of materials, color, orientation, etc.) without substantially departing from the novel teachings and advantages of the subject matter described in this application). For example, an element shown as integrally formed may be composed of multiple parts or elements, the position of elements may be inverted or otherwise altered, and the nature or number or position of discrete elements may be changed or altered. Therefore, all such modifications are intended to be included within the scope of the invention. The order or sequence of any process or method steps may be changed or rearranged according to alternative embodiments. In the claims, any "device plus function" clause is intended to cover the structure described herein that performs the function, and not only structurally equivalent but also equivalent in structure. Other substitutions, modifications, alterations, and omissions may be made in the design, operation, and arrangement of the exemplary embodiments without departing from the scope of the invention. Therefore, the present invention is not limited to the specific embodiments, but extends to various modifications that still fall within the scope of the appended claims.

[0055] Furthermore, in order to provide a concise description of exemplary embodiments, not all features of actual embodiments (i.e., those features that are not relevant to the currently considered best mode for carrying out the invention, or those features that are not relevant to implementing the invention) may be omitted.

[0056] It should be understood that numerous specific implementation decisions can be made during the development of any practical implementation, such as in any engineering or design project. Such development efforts may be complex and time-consuming, but for those skilled in the art who benefit from this disclosure, the development effort will be a routine work of design, manufacturing, and production without requiring much experimentation.

[0057] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A processing apparatus for an aluminum clamp coupling for a bilge pump, wherein the clamp coupling consists of two semi-cylindrical clamps of the same size, and torque transmission is achieved through a key and a keyway; characterized in that, The tooling fixtures used in machining include a four-axis rotary table (1), a directional support plate (2), a tool holder support plate (3), a precision boring tool (11), a workpiece positioning shaft (5), and a base plate locking nut (4); the four-axis rotary table (1) is connected to the directional support plate (2), the tool holder support plate (3) is connected to the directional support plate (2), and the workpiece positioning shaft (5) is connected to the tool holder support plate (3) through the base plate locking nut (4); the clamping coupling includes a keyway-side clamping coupling (6) and a keyless clamping coupling (10).

2. The processing apparatus for the aluminum clamp coupling for the bilge pump according to claim 1, characterized in that, The workpiece positioning shafts (5) are configured as a pair and installed on the workpiece support plate (3).

3. The processing apparatus for the aluminum clamp coupling for the bilge pump according to claim 1, characterized in that, The clamp coupling (6) is fixedly connected by a flange nut (8).

4. The processing apparatus for the aluminum clamp coupling for the bilge pump according to claim 1, characterized in that, The clamp coupling (6) is placed on a flat elastic washer (7) and fixed by tightening the brass flange nut (8).

5. The processing apparatus for the aluminum clamp coupling for the bilge pump according to claim 2, characterized in that, The positioning shaft (5) of the workpiece is respectively equipped with a positioning straight tube nut (9) and a locking round nut (13).

6. The processing apparatus for the aluminum clamp coupling for the bilge pump according to claim 2, characterized in that, A precision boring tool (11) is installed on the other side of the four-axis rotary table (1), and a positioning device (12) is installed below the precision boring tool (11).

7. The processing apparatus for the aluminum clamp coupling for the bilge pump according to claim 2, characterized in that, The four-axis turntable (1) can rotate at multiple angles.

8. A processing technology for an aluminum clamp coupling, characterized in that, The processing apparatus for the aluminum clamp coupling for the bilge pump according to any one of claims 1-7 is characterized by comprising the following steps: Step 1: Rough machining. The aluminum round bar is cut into blanks. The inner hole and outer circle contour of the product are preliminarily machined using a lathe, leaving a machining allowance of 1.5mm. Step 2, sawing: Place the rough-processed product horizontally or vertically on the worktable of the saw and cut it in half equally. Step 3, Aging treatment: A low-temperature tempering heat treatment process is used to heat the product to a range of 190°C to 230°C, hold it at that temperature for 3 to 4 hours, and then allow it to cool naturally. Step 4, Semi-finishing 1, Four-axis machining center for coupling Torque transmission input end and The output end hole is rough bored, the keyway is rough milled, and a 0.3mm fine boring and fine milling allowance is retained; Step 5, Semi-finishing 2: Based on the product dimensions after the semi-finishing 1 process, make a corresponding special model mandrel (14), place it between the two halves of the product, and tighten the screws to fix it. Step 6: Keep the product at a constant temperature. After the product has completed the two semi-finishing processes, loosen the fastening screws. The two halves of the product will then undergo elastic deformation. Step 7, Finishing 1: Install the tooling fixture for this process on the A-axis rotary table of the four-axis machining center, and then rotate the tooling 180 degrees. Step 8, Finishing 2: Place the product on a special tooling and first perform finish milling on the keyway. Set the spindle speed to 1500 r / min and the cutting speed to 170 m / min. Step 9: Product processing dimension inspection. According to the drawing requirements, use a customized inspection tool or a coordinate measuring machine to conduct a comprehensive measurement and detailed inspection of the product's dimensions and spatial position.

9. The processing technology of the aluminum clamp coupling according to claim 8, characterized in that, In step 6, the product needs to be placed in a constant temperature environment of 20°C to 25°C for 8 to 10 hours.

10. The processing technology of the aluminum clamp coupling according to claim 8, characterized in that, After finishing step 8, rotate axis A by 90 degrees, align and fix the two halves of the clamping coupling with the tooling, and then perform precision boring on the two side holes. The spindle speed is increased to 2000 r / min and the cutting speed is 200 m / min.

Images