Hook-headed wedge key machining method

Abstract

The invention relates to the technical field of key machining, in particular to a hook-headed wedge key machining method which comprises the following steps: manufacturing a hook-headed wedge key, and reserving excessive allowance in the height direction of the hook-headed wedge key; the hook-headed wedge key is inserted into a key groove between a hub and a shaft, so that the hook-headed wedge key enters the key groove by a set length; the hook-headed wedge key is taken down, a high contact pressure area of the hook-headed wedge key is determined, directional grinding is conducted on the top face, with the set length, of the hook-headed wedge key to form a grinding top face, and the contact area of the grinding top face and the key groove top face meets the design requirement; by taking the ground top surface as a reference, milling the bottom surface of the hook-headed wedge key to remove part of reserved excessive allowance; and the top face of the hook-headed wedge key is subjected to micron-order accurate grinding, and the remaining excessive allowance is eliminated. The machining error can be accurately controlled, the machining efficiency and precision can be guaranteed, and the service life is prolonged.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of key processing, and in particular to a hook head wedge key processing method. BACKGROUND

[0002] In the field of heavy machinery (such as hot die forging press), the hook head wedge key is the core structure for transmitting large torque. The assembly accuracy of the hook head wedge key directly determines the reliability and service life of the equipment. In the traditional process, the hook head wedge key is processed by reserving a fixed grinding allowance (such as 0.3mm) according to the theoretical size of the keyway. After the hub is installed on the shaft, the hook head wedge key is ground by hand to make the contact area with the keyway reach more than 85%, and at the same time, the gap between the hook head end face of the hook head wedge key and the shaft end is controlled to be 10mm. However, the following problems exist in actual application:

[0003] 1. Uncontrollable processing error: due to angle deviation, left and right depth unevenness and other problems during keyway processing, the theoretical reserved grinding allowance cannot be adapted to the actual keyway size. If the reserved amount is too small, the wedge key may fail due to insufficient contact area after grinding; if the reserved amount is too much, the grinding time is too long, and the efficiency is low.

[0004] 2. Assembly failure risk: the traditional method relies on the experience of operators to repeatedly try and error, and during the operation of the equipment, the hook head end face of the wedge key may come into contact with the shaft end too early (no gap, which means failure), which requires reprocessing, resulting in high cost.

[0005] Therefore, a hook head wedge key processing method is needed to solve the above problems. SUMMARY

[0006] The purpose of the present application is to provide a hook head wedge key processing method, which can accurately control the processing error, ensure the processing efficiency and precision, and prolong the service life.

[0007] To achieve this purpose, the present application adopts the following technical solutions:

[0008] The hook head wedge key processing method comprises the following steps:

[0009] S1, manufacturing a hook head wedge key, and reserving an excess allowance in the direction of the height of the hook head wedge key;

[0010] S2, inserting the hook head wedge key into the keyway between the hub and the shaft, and tightening the hook head wedge key so that the hook head wedge key enters the keyway by a set length;

[0011] S3, taking down the hook head wedge key, determining the high contact pressure area of the hook head wedge key, and directionally grinding the top surface of the set length of the hook head wedge key to form a ground top surface, so that the contact area between the ground top surface and the top surface of the keyway meets the design requirements;

[0012] S4. Using the grinding top surface as a reference, the bottom surface of the hook wedge key is milled to remove the excess allowance, and the amount removed from the high contact pressure area is greater than the amount removed from the rest.

[0013] S5. Perform micron-level fine grinding on the top surface of the hook wedge key to eliminate the remaining excess material, while controlling the distance between the end face of the hook wedge key and the end face of the shaft to a set distance.

[0014] In some embodiments, in step S2, the set length is 1 / 3 of the length of the hook wedge key.

[0015] In some embodiments, in step S2, the surface of the hook wedge key is colored using a mixed medium.

[0016] In some embodiments, the mixing medium is prepared in a ratio of red lead to engine oil of 3:1.

[0017] In some embodiments, in step S3, the contact area between the grinding top surface and the keyway top surface accounts for more than or equal to 85%.

[0018] In some embodiments, in step S3, an angle grinder is used to perform directional grinding on the hook wedge key.

[0019] In some embodiments, in step S4, the tilt angle of the clamp holding the hook wedge key is adjusted according to the depth difference on both sides of the keyway.

[0020] In some embodiments, in step S5, a pneumatic grinding tool is used to grind the top surface of the hook wedge key.

[0021] In some embodiments, in step S5, the set distance between the end face of the hook wedge key and the end face of the shaft is 10mm.

[0022] In some embodiments, in step S5, after the hook wedge key is installed into the keyway, the ratio of the area of ​​the upper end face of the hook wedge key in contact with the upper end face of the keyway to the area of ​​the upper end face of the hook wedge key located in the keyway is greater than or equal to 85%.

[0023] The beneficial effects of this invention are:

[0024] This invention provides a method for manufacturing a hook-head wedge key. The method involves manufacturing the hook-head wedge key with an excess allowance in its height direction. The hook-head wedge key is inserted into the keyway between the hub and shaft, and tightened until it reaches a predetermined length within the keyway. The hook-head wedge key is then removed, and its high contact pressure area is identified. The top surface of the hook-head wedge key at the predetermined length is then directionally ground to form a ground top surface. Using this ground top surface as a reference, the bottom surface of the hook-head wedge key is milled to remove some of the excess allowance, with the removal amount in the high contact pressure area being greater than the removal amount in the rest of the keyway. Finally, the top surface of the hook-head wedge key undergoes micron-level precision grinding to eliminate any remaining excess allowance. During the tightening process, the wedge key experiences higher contact pressure at its lower height position within the keyway, thus identifying the high contact pressure area. In subsequent milling, the removal amount in the high contact pressure area is greater than the removal amount in the rest of the keyway. Finally, the top surface of the hook-head wedge key undergoes micron-level precision grinding to adapt to the shape of the keyway. By using the above methods, processing errors can be accurately controlled, processing efficiency and precision can be guaranteed, and service life can be extended. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the content of the embodiments of the present invention and these drawings without creative effort.

[0026] Fig. 1 This is a schematic diagram of the installation of the hook wedge key in a processing method of the hook wedge key of the present invention;

[0027] Fig. 2 This is a schematic diagram of the keyway in a method for processing a hook wedge key according to the present invention.

[0028] In the picture:

[0029] 1. Hook wedge key; 2. Shaft; 3. Hub; 4. Keyway. Detailed Implementation

[0030] Before explaining any implementation of this application in detail, it should be understood that this application is not limited to its application to the structural details and component arrangements set forth in the following description or shown in the above drawings.

[0031] In this application, the terms "comprising," "including," "having," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0032] In this application, the terms "connection," "combination," "coupling," and "installation" can refer to direct connection, combination, coupling, or installation, or indirect connection, combination, coupling, or installation. For example, a direct connection refers to two parts or components being connected together without the need for an intermediary, while an indirect connection refers to two parts or components each being connected to at least one intermediary, with the connection achieved through the intermediary. Furthermore, "connection" and "coupling" are not limited to physical or mechanical connections or couplings, but can also include electrical connections or couplings.

[0033] In this application, those skilled in the art will understand that the function performed by a component can be performed by one component, multiple components, one part, or multiple parts. Similarly, the function performed by a part can also be performed by one part, one component, or a combination of multiple parts.

[0034] In this application, the directional terms "upper," "lower," "left," "right," "front," and "rear" are used to describe the orientation and positional relationships shown in the accompanying drawings and should not be construed as limiting the embodiments of this application. Furthermore, in the context, it should be understood that when an element is mentioned as being connected "upper" or "lower" to another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected through an intermediate element. It should also be understood that directional terms such as upper side, lower side, left side, right side, front side, and rear side not only represent positive orientation but can also be understood as lateral orientation. For example, "below" can include directly below, lower left, lower right, lower front, and lower rear.

[0035] In heavy machinery applications (such as hot forging presses), hook-head wedge keys are core structures for transmitting high torque in shaft-hub connections. The assembly precision of the hook-head wedge key directly determines the reliability and lifespan of the equipment. During the manufacturing process of hook-head wedge keys, in order to accurately control machining errors, ensure machining efficiency and precision, and extend service life, such as… Figs. 1-2 As shown, the present invention provides a method for machining a hook-head wedge key. The machining method for a hook-head wedge key includes the following steps:

[0036] S1. Manufacture hook wedge key 1, and reserve an excess allowance in the height direction of hook wedge key 1;

[0037] S2. Insert the hook wedge key 1 into the keyway 4 between the hub 3 and the shaft 2, and tighten the hook wedge key 1 so that the hook wedge key 1 enters the keyway 4 to a set length.

[0038] S3. Remove the hook wedge key 1, determine the high contact pressure area of ​​the hook wedge key 1, and perform directional grinding on the top surface of the hook wedge key 1 at a set length to form a grinding top surface, so that the contact area between the grinding top surface and the top surface of the keyway 4 meets the design requirements.

[0039] S4. Using the grinding top surface as a reference, mill the bottom surface of the hook wedge key 1 to remove the excess allowance, and remove more material in the high contact pressure area than in the rest.

[0040] S5. Perform micron-level fine grinding on the top surface of the hook wedge key 1 to eliminate the remaining excess material, while controlling the distance between the end face of the hook wedge key 1 and the end face of the shaft 2 to a set distance.

[0041] During the tightening of the hook wedge key 1, the contact pressure is higher at the lower position of the wedge key in the keyway 4. Therefore, the high contact pressure area of ​​the hook wedge key 1 can be identified. In the subsequent milling process, the amount of material removed from the high contact pressure area is greater than that removed from the rest. Finally, after micron-level precision grinding of the top surface of the hook wedge key 1, it can adapt to the shape of the keyway 4. Through the above method, machining errors can be accurately controlled, machining efficiency and accuracy can be guaranteed, and service life can be extended.

[0042] In some embodiments, in step S2, the length is set to 1 / 3 of the length of the hook wedge key 1. By driving the groove wedge key into the keyway 4 at 1 / 3 of its length, the high contact pressure area of ​​the hook wedge key 1 can be determined, thereby facilitating subsequent processing.

[0043] In some embodiments, in step S2, the surface of the hook wedge key 1 is colored using a mixed medium. After coloring with the mixed medium, the hook wedge key is driven into the keyway 4. The color change visually reflects the high contact pressure area of ​​the hook wedge key 1. After the hook wedge key 1 is removed from the keyway 4, the high contact pressure area displays dark red spots. The machining operator can easily identify the high contact pressure area through visual observation, facilitating subsequent targeted grinding.

[0044] In some embodiments, the mixing medium is prepared according to a 3:1 ratio of red lead to machine oil. Preparing the mixing medium in the manner described above facilitates coating the hook wedge key 1 and ensures effective color development after the hook wedge key 1 is removed from the keyway 4.

[0045] In some embodiments, in step S3, the contact area between the grinding top surface and the top surface of the keyway 4 is greater than or equal to 85%. This limitation ensures a tight fit between the grinding top surface and the top surface of the keyway 4 after grinding, thereby guaranteeing the accuracy of using the grinding top surface as a reference surface and ensuring that the quality of subsequent machining of the hook wedge key 1 meets the requirements.

[0046] In some embodiments, in step S3, an angle grinder is used to perform directional grinding of the hook wedge key 1. Angle grinders, as a widely used power tool in industrial production and daily life, exhibit many advantages in grinding operations. The following are some of the main advantages of using an angle grinder for grinding: 1. High efficiency and durability: Brushless angle grinders utilize advanced brushless DC motor technology, which has higher efficiency and a longer service life compared to traditional brushed motors. Since brushless motors use magnetic force to drive the rotor, there is no problem with carbon brush wear, thus enabling continuous and efficient operation and ensuring grinding efficiency. 2. Low noise: Brushless motors operate more smoothly and with lower noise, without producing noticeable brush friction sounds, making the working environment quieter and reducing noise pollution. 3. High torque: Brushless motors have high torque performance, providing greater torque output, making them more suitable for processing harder materials in industrial grinding and effectively grinding the hook wedge key 1. 4. Easy maintenance: Brushless angle grinders do not require carbon brush replacement, reducing the complexity and frequency of maintenance. In addition, because its rotor is made of solid silicon steel sheets without metal coils, it is more durable and reduces maintenance costs.

[0047] In some embodiments, in step S4, the tilt angle of the clamp holding the hook wedge key 1 is adjusted according to the depth difference on both sides of the keyway 4. Specifically, for the deeper areas of the keyway 4, the hook wedge key 1 needs to remove less material, and for the shallower areas of the keyway 4, the hook wedge key 1 needs to remove more material. This ensures that after milling the keyway 4, the hook wedge key 1 and the keyway 4 have a large contact area. Furthermore, by using a tilted clamping method, it is easier to process the keyway key using a milling machine.

[0048] In some embodiments, in step S5, a pneumatic grinding tool is used to grind the top surface of the hook wedge key 1. Pneumatic grinding tools, as commonly used handheld grinding devices in industrial fields, are widely used in metal processing, shipbuilding, and automotive repair due to their pneumatic drive characteristics and structural design advantages. Because the body of pneumatic grinding tools is mostly made of aluminum alloy or engineering plastics, their weight is typically only 1kg-3kg, making them suitable for prolonged handheld operation, reducing hand fatigue, and facilitating operation by the grinding personnel, thereby ensuring grinding accuracy.

[0049] In some embodiments, in step S5, the distance between the end face of the hook wedge key 1 and the end face of the shaft 2 is set to 10mm. By reserving 10mm, the portion of the end face of the hook wedge key 1 that is between the end face of the hook wedge key 1 and the end face of the shaft 2 can continue to extend into the keyway 4 after the hook wedge key 1 wears out, ensuring a stable connection and extending the service life of the hook wedge key 1.

[0050] In some embodiments, in step S5, after the hook wedge key 1 is installed into the keyway 4, the ratio of the area of ​​the upper end face of the hook wedge key 1 in contact with the upper end face of the keyway 4 to the area of ​​the upper end face of the hook wedge key 1 in the keyway 4 is greater than or equal to 85%. This limitation ensures that the hook wedge key 1 and the keyway 4 have sufficient contact area, thereby ensuring that the hook wedge key 1 effectively connects the hub 3 and the shaft 2.

[0051] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method for machining a hook-shaped wedge key, characterized in that, Includes the following steps: S1. Manufacture the hook wedge key (1) and reserve an excess allowance in the direction of the height of the hook wedge key (1); S2. Insert the hook wedge key (1) into the keyway (4) between the hub (3) and the shaft (2), and tighten the hook wedge key (1) so that the hook wedge key (1) enters the keyway (4) by a set length; S3. Remove the hook wedge key (1), determine the high contact pressure area of ​​the hook wedge key (1), and perform directional grinding on the top surface of the hook wedge key (1) at a set length to form a grinding top surface, so that the contact area between the grinding top surface and the top surface of the keyway (4) meets the design requirements. S4. Using the grinding top surface as a reference, the bottom surface of the hook wedge key (1) is milled to remove the excess allowance, and the amount removed from the high contact pressure area is greater than the amount removed from the rest. S5. Perform micron-level fine grinding on the top surface of the hook wedge key (1) to eliminate the remaining excess material, and at the same time control the distance between the end face of the hook wedge key (1) and the end face of the shaft (2) to a set distance.

2. The processing method of the hook wedge key according to claim 1, characterized in that, In step S2, the set length is 1 / 3 of the length of the hook wedge key (1).

3. The processing method of the hook wedge key according to claim 1, characterized in that, In step S2, the surface of the hook wedge key (1) is colored using a mixed medium.

4. The processing method of the hook wedge key according to claim 3, characterized in that, The mixing medium is prepared according to a ratio of red lead to engine oil of 3:

1.

5. The method for processing the hook-head wedge key according to claim 1, characterized in that, In step S3, the contact area between the grinding top surface and the top surface of the keyway (4) is greater than or equal to 85%.

6. The method for processing a hook-shaped wedge key according to claim 1, characterized in that, In step S3, the hook wedge key (1) is oriented and ground using an angle grinder.

7. The method for processing a hook-shaped wedge key according to claim 1, characterized in that, In step S4, the tilt angle of the clamp holding the hook wedge key (1) is adjusted according to the depth difference on both sides of the keyway (4).

8. The method for processing a hook-shaped wedge key according to claim 1, characterized in that, In step S5, a pneumatic grinding tool is used to grind the top surface of the hook wedge key (1).

9. The method for processing a hook-shaped wedge key according to claim 1, characterized in that, In step S5, the set distance between the end face of the hook wedge key (1) and the end face of the shaft (2) is 10mm.

10. The method for processing a hook-head wedge key according to claim 1, characterized in that, In step S5, after the hook wedge key (1) is installed into the keyway (4), the area of ​​the area where the upper end face of the hook wedge key (1) contacts the upper end face of the keyway (4) is greater than or equal to 85% of the area of ​​the upper end face of the hook wedge key (1) located in the keyway (4).

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