Slip ring high-precision V-shaped groove machining method

Abstract

The invention discloses a high-precision V-shaped groove machining method for a slip ring, and relates to the field of part machining. Comprising the steps that an assembly is axially pressed through a spore clamp and a shaft sleeve; a scribing trace is machined at the position, calculated theoretically, of each V-shaped groove by grinding and repairing a V-shaped blade; the actual distance between the scribing trace of each V-shaped groove and the conducting ring is observed through the electronic magnifying lens, and the error compensation amount is fed back; the machining position of each V-shaped groove is adjusted according to the error compensation amount, and then turning is conducted; and carrying out surface polishing on the turned V-shaped groove. The problems that an existing machining scheme cannot adapt to the assembling error condition of all conducting ring intervals, and the Ra0.2 roughness of a V-shaped groove is difficult to guarantee only through turning machining are solved.

Description

Technical Field

[0001] This application relates to the field of parts processing technology, and in particular to a method for machining high-precision V-grooves in slip rings. Background Technology

[0002] As a high-precision component of slip rings, the main difficulty in machining the shaft assembly lies in processing evenly spaced V-grooves with a surface roughness of Ra0.2 on 44 adhesive conductive rings. This is a high-precision, small shaft component, making machining challenging and requiring high precision equipment and advanced machining methods. The main challenges are:

[0003] (1) It is difficult to guarantee Ra0.2 of V-groove: Since the conductive ring material that needs to be processed for V-groove is H62 GB / T 4423-2007 round copper rod, the material is relatively soft and is prone to build-up edge and burrs, which affects the surface roughness and makes it difficult to meet the processing requirements.

[0004] (2) It is difficult to guarantee the V-groove spacing of 0.35: Due to the cumulative error in the assembly spacing of the 44 conductive rings of the shaft assembly, the V-groove width of the conductive rings is small, making it difficult to adjust the center spacing of the V-groove through visual observation and feedback to meet the processing requirements.

[0005] (3) Coaxiality of 0.01 is difficult to guarantee during machining: Since the components of the shaft assembly are fixed by glue, during the turning process, the spacer between the conductive rings is easily loosened due to insufficient glue strength, resulting in the overall machining of the assembly having excessive coaxiality.

[0006] The conventional machining scheme for this type of part is to calculate the theoretical machining positions of 44 V-grooves based on the design drawings, considering the process dimension chain and cumulative error tolerance. The part is then machined in one setup on a high-precision CNC lathe. However, this method is prone to errors due to the spacing error of the conductive ring assembly exceeding the theoretical tolerance range. Furthermore, it is difficult to achieve the Ra0.2 requirement for V-grooves by turning alone, which leads to the scrapping of the part. Summary of the Invention

[0007] The purpose of this application is to provide a high-precision V-groove machining method for slip rings, which solves the problem that existing machining schemes cannot adapt to the assembly error of all conductive ring spacings, and that the Ra0.2 roughness of the V-groove is difficult to guarantee by turning alone.

[0008] To achieve the above objectives, this application adopts the following technical solution:

[0009] This application provides a method for machining high-precision V-grooves in slip rings, including:

[0010] The assembly is axially compressed using a twin clamp and bushing;

[0011] At each V-groove location calculated theoretically, the engraving marks are machined using a ground V-shaped cutting tool;

[0012] The actual distance between the engraving marks of each V-groove and the conductive ring is observed using an electronic magnifying glass to provide feedback on the error compensation amount.

[0013] After adjusting the machining position of each V-groove according to the aforementioned error compensation amount, turning is then performed.

[0014] The surface of the V-groove after turning is polished.

[0015] Optionally, the axial clamping of the assembly using the ferrule clamp and bushing tooling includes:

[0016] First, use the twin clamp to clamp and fix the component on one end face;

[0017] The other end face of the component is processed;

[0018] The other end face of the component, which has already been machined, is axially pressed using a bushing tool.

[0019] Optionally, the clamping and fixing of the component on one end face using the twin clamp includes:

[0020] During the clamping process, the Φ28 outer circle is clamped using a ferrule, and the runout of the Φ17 outer circle is aligned to be no greater than 0.005.

[0021] Optionally, before machining the engraving marks with a grinding tool at each theoretically calculated V-groove location, the method further includes:

[0022] Based on the assembly relationship of the 44 conductive rings, the theoretical center positions of the 43 V-grooves are calculated.

[0023] Optionally, the step of calculating the theoretical center positions of the 43 V-grooves based on the assembly relationship of the 44 conductive rings includes:

[0024] The theoretical center position of each V-groove is calculated based on the center position of the lower conductive ring assembly installed in the V-groove, the dimensional tolerance of the conductive ring assembly, and the assembly sequence.

[0025] Optionally, the step of calculating the theoretical center position of each V-groove based on the center position of the lower conductive ring assembly into which the V-groove is installed, the dimensional tolerances of the conductive ring assembly, and the assembly sequence includes:

[0026] Calculated using the following formula:

[0027]

[0028] Among them, Z t(N)Z0 represents the theoretical center position of the Nth V-groove, where N is the number of V-grooves, Z0 is the center position of the lower conductive ring assembly, and T is the tolerance zone of the conductive ring.

[0029] Optionally, the step of adjusting the machining position of each V-groove according to the error compensation amount before performing turning includes:

[0030] The V-groove machining position is compensated using the following formula:

[0031] Z f =Z t(N) +Δz

[0032] Among them, Z f The position of the V-groove after compensation is Δz, which is the feedback compensation adjustment amount.

[0033] Optionally, the tip radius of the ground V-shaped blade is 35°-40°.

[0034] Optionally, the adjustment radius of the blade tip of the grinding V-shaped blade is 0.02-0.05.

[0035] Optionally, the surface polishing of the V-groove after turning includes:

[0036] The V-groove after turning is polished by using a silk cloth to form a linear coating with green paste.

[0037] Based on the above technical solution, this application can achieve the following technical effects:

[0038] This application presents a technical study on the high-precision multi-V-groove machining of a certain slip ring-type shaft assembly, overcoming the cumulative error in conductive ring assembly and ensuring the design requirements of the V-groove for this type of part. The main advantages are:

[0039] 1) By combining theoretical calculations of process dimensions with feedback and compensation adjustments from electron microscopy, the cumulative error in the assembly of the conductive ring assembly is effectively overcome, ensuring the requirement of a uniform spacing of 0.35.

[0040] 2) The V-groove was machined by turning with a grinding tool and then polished to ensure a surface roughness of Ra0.2.

[0041] 3) The use of ferrule clamping and bushing tooling for axial clamping effectively avoids the loosening of the adhesive on the parts during the V-groove machining process, which could lead to out-of-tolerance coaxiality of the parts.

[0042] Through the technical research of the above methods, the problem of high-precision machining of slip ring multi-V grooves was successfully solved, and the first-time machining pass rate reached 84.6%, effectively verifying the feasibility of the method. Attached Figure Description

[0043] Figure 1 This is a schematic flowchart of a high-precision V-groove machining method for slip rings provided in an embodiment of this application;

[0044] Figure 2 This is a flowchart of the V-groove machining process for a shaft assembly according to an embodiment of this application;

[0045] Figure 3 This is a 20-step drawing provided in an embodiment of this application;

[0046] Figure 4 This is a 30-step drawing provided in an embodiment of this application;

[0047] Figure 5 This is a simplified diagram of the V-groove machining process for a shaft assembly according to an embodiment of this application;

[0048] Figure 6 This is a physical image of a V-groove machining process provided in one embodiment of this application;

[0049] Figure 7 This is a simplified diagram illustrating the theoretical calculation approach for V-groove machining according to an embodiment of this application.

[0050] Figure 8 This is a physical diagram of the cutting tool trajectory provided in one embodiment of this application;

[0051] Figure 9 This is a physical image of a V-groove machining process provided in one embodiment of this application. Detailed Implementation

[0052] The present application will be further described in detail below with reference to the accompanying drawings and specific embodiments. The advantages and features of the present application will become clearer from the following description and claims. It should be noted that the drawings are all in a very simplified form and are not to scale, and are only used to facilitate and clarify the illustration of the embodiments of the present application.

[0053] It should be noted that, in order to clearly illustrate the content of this application, several embodiments are provided to further explain the different implementations of this application. These embodiments are enumerated rather than exhaustive. Furthermore, for the sake of brevity, content mentioned in the preceding embodiments is often omitted in the following embodiments. Therefore, content not mentioned in the following embodiments can be referred to in the preceding embodiments.

[0054] Example 1

[0055] like Figure 1 The diagram shown is a flowchart illustrating a high-precision V-groove machining method for slip rings provided in this embodiment. It includes:

[0056] Step 101: Use the ferrule clamp and bushing to axially compress the assembly;

[0057] In one embodiment, axial clamping of the assembly using a ferrule clamp and a bushing tooling includes:

[0058] First, use the twin clamp to clamp and fix the component on one end face;

[0059] The other end face of the component is processed;

[0060] The other end face of the component, which has already been machined, is axially pressed using a bushing tool.

[0061] In one embodiment, clamping and securing the component to one end face using a twin clamp includes:

[0062] During the clamping process, the Φ28 outer circle is clamped using a ferrule, and the runout of the Φ17 outer circle is aligned to be no greater than 0.005.

[0063] Step 102: At each V-groove location calculated theoretically, the engraving marks are machined using a ground V-shaped cutting tool;

[0064] In one embodiment, prior to machining the engraving marks with a grinding blade at each theoretically calculated V-groove location, the method further includes:

[0065] Based on the assembly relationship of the 44 conductive rings, the theoretical center positions of the 43 V-grooves are calculated.

[0066] In one embodiment, calculating the theoretical center positions of the 43 V-grooves based on the assembly relationship of the 44 conductive rings includes:

[0067] The theoretical center position of each V-groove is calculated based on the center position of the lower conductive ring assembly installed in the V-groove, the dimensional tolerance of the conductive ring assembly, and the assembly sequence.

[0068] In one embodiment, calculating the theoretical center position of each V-groove based on the center position of the lower conductive ring assembly into which the V-groove is installed, the dimensional tolerances of the conductive ring assembly, and the assembly sequence includes:

[0069] Calculated using the following formula:

[0070]

[0071] Among them, Z t(N) Z0 represents the theoretical center position of the Nth V-groove, where N is the number of V-grooves, Z0 is the center position of the lower conductive ring assembly, and T is the tolerance zone of the conductive ring (actually 0.005).

[0072] In one embodiment, the tip radius of the V-shaped blade is 35°-40°.

[0073] In one embodiment, the adjustment radius of the blade tip for grinding the V-shaped blade is 0.02-0.05.

[0074] Step 103: Observe the scribing marks of each V-groove and the actual distance between the conductive ring using an electronic magnifying glass, and provide feedback on the error compensation amount;

[0075] Step 104: After adjusting the machining position of each V-groove according to the error compensation amount, perform turning machining;

[0076] In one embodiment, the step of adjusting the machining position of each V-groove according to the error compensation amount and then performing turning includes:

[0077] The V-groove machining position is compensated using the following formula:

[0078] Z f =Z t(N) +Δz

[0079] Among them, Z f The position of the V-groove after compensation is Δz, which is the feedback compensation adjustment amount.

[0080] Step 105: Polish the surface of the V-groove after turning.

[0081] In one embodiment, the surface polishing of the V-groove after turning includes:

[0082] The V-groove after turning is polished by using a silk cloth to form a linear coating with green paste.

[0083] In one specific embodiment, steps 101-105 can be implemented as follows:

[0084] In this embodiment, the high-precision V-groove machining process of the slip ring is mainly completed by four processes: 10 machining operations, 20 machining operations, 30 machining operations, and 40 inspection operations. Figure 2 As shown. Among them, lathe operator 10 mainly checks the quantity and appearance quality of parts, and performs oil sealing and surface protection on the component parts; lathe operator 20 mainly completes the main machining work of the component (machining completed in one clamping), including clamping, turning the end face and outer diameter, turning threads, turning chamfers, and turning and polishing V-grooves, etc. Figure 3 As shown; the 30-year-old lathe operator mainly completes the length dimension requirements of the components, including clamping and machining the end faces, such as... Figure 4 As shown; the final 40 inspection processes complete the inspection of all dimensions of the parts.

[0085] The machining of V-grooves mainly focuses on 20-inch lathes. The simplified process diagram and actual product image are shown below. Figure 5 and Figure 6As shown, the clamping and fixing are mainly achieved by the ferrule clamp, the center distance of the V-groove is observed by the electronic magnifying glass, and the axial pressing of the end face of the part is achieved by the bushing.

[0086] To ensure the V-groove design requirements are met in a single machining operation, high precision and stability are required for the CNC lathe spindle. Roughing, semi-finishing, and finishing of the part are all performed using the Spinner GB-42 lathe, with a machine tool positioning accuracy of 0.003 and a repeatability of 0.0015, which meets the machining requirements for this part. The main tasks of the 20-step turning operation include clamping, roughing, semi-finishing, and finishing. During clamping, the Φ28 outer diameter is clamped using a ferrule, and the runout of the Φ17 outer diameter is aligned to be no greater than 0.005. A single clamping and turning operation ensures a coaxiality of 0.01. In the roughing and semi-finishing processes, the right end face, outer diameter, and threads of the component part are machined first.

[0087] In calculating the theoretical centers of the 44 V-grooves, the assembly relationship (orientation and position) of the 44 conductive rings was primarily used to ensure consistency between the process dimensional datum and the design datum. This allowed for the calculation of the theoretical center positions of the 43 V-grooves. Figure 7 As shown. In calculating the 43 V-grooves, the theoretical position Z is adjusted based on the center position Z0 of the installed lower conductive ring assembly, the dimensional tolerances of the conductive ring assembly, and the assembly sequence. t(N) The theoretical position of the center of the Nth V-groove is given by the following formula.

[0088]

[0089] During the finishing process of V-grooves, the relevant parameters need to be controlled from the following aspects:

[0090] First, axial clamping is achieved on the right end face of the pre-machined component using a bushing tool to avoid loosening of the adhesive during the V-groove machining process, which could lead to dimensional deviations in the parts.

[0091] Secondly, by grinding the tip R of the V-shaped cutting tool (35°~40°) and adjusting the tip R range to 0.02-0.05, the surface roughness after cutting the conductive ring part can be improved.

[0092] Thirdly, to ensure the uniform distribution of the V-groove spacing to 0.35, during the processing of each V-groove, etched lines were first machined according to the theoretically calculated 44 V-grooves (for easy observation, not to the final size). Then, an electronic magnifying glass was used to project the magnification onto a mobile phone to observe the actual distance between the etched lines of each V-groove and the conductive ring. Based on visual feedback, the final V-groove processing position was compensated to obtain the final processing position Z. f This ensures the uniform distribution of the 43 V-grooves, as shown in the following formula:

[0093] Z f=Z t(N) +Δz

[0094] Wherein, Δz is the electronic detection feedback compensation adjustment amount, which generally ranges from 0.002 to 0.01.

[0095] Fourth, the machining of V-grooves mainly involves roughing, semi-finishing, and finishing. The relevant dimensional requirements of the V-grooves are achieved through a tool path method, with some tool paths as follows: Figure 8 As shown.

[0096] Fifth, after the V-groove is finished by turning, a silk cloth is used to apply green paste to the surface of the V-groove to ensure that the roughness requirement of Ra0.2 is met.

[0097] In this embodiment, the V-groove of the part needs to be matched with appropriate cutting parameters during roughing, semi-finishing, and finishing to ensure that the dimensional and surface roughness requirements of the V-groove are met after machining. The turning process is mainly based on centerless machining, and the corresponding cutting parameters are shown in Table 1.

[0098] Table 1. Cutting parameters for V-groove machining

[0099]

[0100] This embodiment further provides actual machining verification results. Machining verification was performed based on the RHD-44-01 slip ring-type shaft assembly parts from Xiewai. The machining results are shown in Table 2. A total of 13 parts were machined, with 2 parts scrapped during trial machining, and 11 parts passed the machining test, meeting the design requirements, achieving a pass rate of 84.6%. Specific results are as follows: Figure 9 As shown.

[0101] Table 2 Verification of V-groove Machining

[0102]

[0103]

[0104] In summary, this method has been used to conduct technical research on the high-precision multi-V-groove machining of a certain slip ring-type shaft assembly. It overcomes the cumulative errors in conductive ring assembly and ensures the design requirements of the V-groove for this type of part. The main advantages are:

[0105] 1) By combining theoretical calculations of process dimensions with feedback and compensation adjustments from electron microscopy, the cumulative error in the assembly of the conductive ring assembly is effectively overcome, ensuring the requirement of a uniform spacing of 0.35.

[0106] 2) The V-groove was machined by turning with a grinding tool and then polished to ensure a surface roughness of Ra0.2.

[0107] 3) The use of ferrule clamping and bushing tooling for axial clamping effectively avoids the loosening of the adhesive on the parts during the V-groove machining process, which could lead to out-of-tolerance coaxiality of the parts.

[0108] Through the technical research of the above methods, the problem of high-precision machining of slip ring multi-V grooves was successfully solved, and the first-time machining pass rate reached 84.6%, effectively verifying the feasibility of the method.

[0109] The above description is merely an embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of this application should be included within the scope of the claims of this application.

Claims

1. A method for machining a high-precision V-groove on a slip ring, characterized in that, include: The assembly is axially compressed using a twin clamp and bushing; At each V-groove location calculated theoretically, the engraving marks are machined using a ground V-shaped cutting tool; The actual distance between the engraving marks of each V-groove and the conductive ring is observed using an electronic magnifying glass to provide feedback on the error compensation amount. After adjusting the machining position of each V-groove according to the aforementioned error compensation amount, turning is then performed. The surface of the V-groove after turning is polished.

2. The method according to claim 1, characterized in that, The axial clamping of the assembly using a ferrule clamp and bushing tooling includes: First, use the twin clamp to clamp and fix the component on one end face; The other end face of the component is processed; The other end face of the component, which has already been machined, is axially pressed using a bushing tool.

3. The method according to claim 2, characterized in that, The method of clamping and fixing the component on one end face using a twin clamp includes: During the clamping process, the Φ28 outer circle is clamped using a ferrule, and the runout of the Φ17 outer circle is aligned to be no greater than 0.

005.

4. The method according to claim 1, characterized in that, Before machining the engraving marks with a grinding tool at each theoretically calculated V-groove location, the process further includes: Based on the assembly relationship of the 44 conductive rings, the theoretical center positions of the 43 V-grooves are calculated.

5. The method according to claim 4, characterized in that, The calculation of the theoretical center positions of the 43 V-grooves based on the assembly relationship of the 44 conductive rings includes: The theoretical center position of each V-groove is calculated based on the center position of the lower conductive ring assembly installed in the V-groove, the dimensional tolerance of the conductive ring assembly, and the assembly sequence.

6. The method according to claim 5, characterized in that, The calculation of the theoretical center position of each V-groove based on the center position of the lower conductive ring assembly installed in the V-groove, the dimensional tolerances of the conductive ring assembly, and the assembly sequence includes: Calculated using the following formula: Among them, Z t(N) Z0 represents the theoretical center position of the Nth V-groove, where N is the number of V-grooves, Z0 is the center position of the lower conductive ring assembly, and T is the tolerance zone of the conductive ring.

7. The method according to claim 6, characterized in that, The step of adjusting the machining position of each V-groove according to the error compensation amount and then performing turning includes: The V-groove machining position is compensated using the following formula: With f =Z t(N) +Δz Among them, Z f The position of the V-groove after compensation is Δz, which is the feedback compensation adjustment amount.

8. The method according to claim 1, characterized in that, The tip radius of the V-shaped blade being ground is 35°-40°.

9. The method according to claim 8, characterized in that, The adjustment radius of the blade tip of the V-shaped blade is 0.02-0.

05.

10. The method according to claim 1, characterized in that, The surface polishing of the V-groove after turning includes: The V-groove after turning is polished by using a silk cloth to form a linear coating with green paste.

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