Shaft double key groove machining method and key groove machining device

Abstract

The invention discloses a shaft double-key-groove machining method and a key groove machining device, and the shaft double-key-groove machining method comprises the steps that an auxiliary tool is manufactured, a through hole, a first through groove and a second through groove which communicate with one another are formed in the auxiliary tool, and the first through groove and the second through groove are symmetrically formed in the radial direction of the through hole; floating rust polishing is conducted on the main shaft; the positions of a first key groove and a second key groove to be machined are determined according to the positions of original key grooves in the main shaft; the auxiliary tool is arranged on the main shaft in a sleeving mode, so that the first through groove and the second through groove are aligned with the first key groove to be machined and the second key groove to be machined respectively; and the position of a cutter of the key groove machining device is adjusted, so that the cutter is aligned with the first through groove or the second through groove, the cutter penetrates through the first through groove or the second through groove to machine the main shaft, and a first key groove and a second key groove are formed. In the application, through the first key groove and the second key groove formed by the machining method, online machining of the double key grooves is achieved, the accuracy of the positions of the double key grooves is guaranteed, and the operation stability and safety of equipment are improved.

Description

Technical Field

[0001] This application relates to the field of machining technology, specifically to a method and apparatus for machining double keyways on shafts. Background Technology

[0002] In the metallurgical industry, the KR (Kambara Reactor) desulfurization station is a key facility for molten iron treatment. It relies on a rotating agitator to stir the molten iron to achieve a full reaction between lime and sulfur, generating calcium sulfide, which is insoluble in the molten iron and floats to the surface to form a slag layer. The agitator and its connecting flange (coupling) are core components, and the fit between the keyway of the drive shaft and the keyway and key of the connecting flange directly affects the safe operation of the equipment. Design specifications require the keyway and key to adopt an interference fit, but in actual operation, frequent wear leads to an expansion of the fit clearance, resulting in an unexpected clearance fit. If the shaking amplitude continues to increase, it will cause the agitator to accidentally fall off, causing the entire desulfurization station to shut down.

[0003] The current production site faces a shortage of critical spare parts such as drive shafts and bearings, and the manufacturing and supply cycle for new spare parts is lengthy, failing to meet continuous production demands. To maintain the normal operation of the desulfurization station, online machining of the drive shaft keyway is necessary. However, existing machining technologies lack precise online machining solutions for double keyways on shafts, making it difficult to ensure the coordinated accuracy of the double keyway position and dimensions. This results in excessive equipment vibration and insufficient operational stability after installation, severely restricting desulfurization efficiency and equipment lifespan. Summary of the Invention

[0004] The purpose of this application is to provide a method and apparatus for machining double keyways on shafts, which solves the problems of spindles being unable to be machined online and low precision in keyway machining.

[0005] To achieve the objectives of this application, the following technical solution is provided:

[0006] In a first aspect, this application provides a method for machining double keyways on shafts, including:

[0007] An auxiliary tooling is fabricated to form a through hole, a first through groove, and a second through groove, which are connected to each other. The first through groove and the second through groove are symmetrically arranged in the radial direction of the through hole.

[0008] Remove surface rust from the spindle;

[0009] The positions of the first and second keyways to be machined are determined based on the existing keyway positions on the spindle.

[0010] The auxiliary tooling is fitted onto the spindle so that the first through groove and the second through groove are aligned with the first keyway and the second keyway to be machined, respectively.

[0011] Adjust the tool position of the keyway machining device to align the tool with the first through slot or the second through slot, so that the tool passes through the first through slot or the second through slot to machine the spindle, thereby forming the first keyway and the second keyway.

[0012] In one embodiment, determining the positions of the first and second keyways to be machined based on the existing keyway positions on the spindle includes:

[0013] Using the original keyway position on the spindle, draw the center line of the original keyway on the spindle, and determine the center lines of the first keyway and the second keyway based on the center line of the original keyway.

[0014] In one embodiment, determining the center lines of the first keyway and the second keyway based on the center line of the existing keyway includes:

[0015] The centerline positions of the first keyway and the second keyway are determined at a 90-degree circumferential position along the main shaft, using the centerline of the original two keyways.

[0016] In one embodiment, the manufacturing auxiliary tooling includes:

[0017] The dimensions of the first through groove and the second through groove on the auxiliary tooling are greater than or equal to the dimensions of the first keyway and the second keyway to be processed.

[0018] In one embodiment, after the surface rust is removed from the spindle and before determining the positions of the first and second keyways to be machined based on the original keyway positions on the spindle, the method further includes:

[0019] The spindle was cooled to below 40 degrees Celsius for ultrasonic testing, and multiple sets of diameter data of the spindle were detected.

[0020] In one embodiment, fitting the auxiliary tooling onto the spindle includes:

[0021] The auxiliary tooling is fitted onto the unworn shaft diameter of the main shaft;

[0022] Perform a feeler gauge check to ensure that the clearance between the auxiliary tooling and the spindle is uniform;

[0023] Detect the perpendicularity of the auxiliary tooling to the spindle;

[0024] The auxiliary tooling is fixed to the main shaft by bolts.

[0025] In one embodiment, detecting the perpendicularity of the auxiliary tooling to the spindle includes:

[0026] Place a right-angle ruler on the upper surface of the auxiliary fixture, ensuring that there is no gap between the right-angle ruler and the upper surface of the auxiliary fixture and the surface of the spindle.

[0027] In one embodiment, the step of machining the spindle by passing the cutting tool through the first through groove or the second through groove to form the first keyway and the second keyway includes:

[0028] Align the cutting tool with the first through groove, and machine the spindle to form the first keyway;

[0029] The cutting tool is then aligned with the second through groove, and the spindle is machined to form the second keyway.

[0030] Secondly, this application also provides a keyway machining apparatus, applied to the shaft double keyway machining method according to any one of the various embodiments of the first aspect, the keyway machining apparatus comprising:

[0031] Support frame;

[0032] The cutting tool is mounted on the support frame. The cutting tool includes a drive unit and a cutting head. The drive unit is used to drive the cutting head to rotate.

[0033] In one embodiment, the support frame includes a base and a bracket, the bracket being detachably connected to the base. The cutter also includes a mounting base and a handwheel, the mounting base being vertically and vertically mounted on the bracket, and the handwheel being rotated to adjust the height of the cutter head.

[0034] Compared with the prior art, this application has at least the following beneficial effects:

[0035] 1. In this application, by manufacturing a high-precision auxiliary tooling and aligning the first through groove and the second through groove on the auxiliary tooling with the first keyway and the second keyway to be machined, a stable machining guide is provided for the tool of the keyway machining device, reducing machining deviations caused by human operation errors or inaccurate workpiece positioning, thereby significantly improving the machining accuracy of the keyway, ensuring that the dimensional and positional accuracy of the keyway meets the design requirements, and improving the assembly quality and performance of shaft parts.

[0036] 2. In this application, the use of auxiliary tooling enables the tool to be quickly and accurately aligned with the machining position, reducing the time required for tool adjustment and trial cutting. Simultaneously, it allows for online machining of the original spindle without disassembling it, significantly shortening the machining cycle, improving production efficiency, and reducing production costs.

[0037] 3. In this application, the machining method achieves relatively accurate positioning and machining guidance through auxiliary tooling. Operators only need to follow the prescribed steps to complete the machining of the original spindle double keyway. It does not require highly skilled operation skills and rich experience, thus reducing the dependence on the skill level of the operator.

[0038] 4. In this application, the first keyway and the second keyway formed by this processing method effectively solve the problem of equipment vibration caused by insufficient online processing accuracy in the prior art. It improves the processing accuracy of the keyway, ensures the accuracy of the double keyway position, effectively reduces vibration during equipment operation, and enhances the operational stability and safety of the equipment. Attached Figure Description

[0039] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0040] Figure 1 This is a flowchart illustrating a method for machining a double keyway in a shaft according to one embodiment of this application.

[0041] Figure 2 This is a perspective view of a spindle, auxiliary tooling, and keyway machining apparatus according to one embodiment of this application;

[0042] Figure 3 This is a perspective view of an auxiliary tooling according to one embodiment of this application;

[0043] Figure 4 This is an exploded view of a keyway machining apparatus according to one embodiment of this application.

[0044] Explanation of reference numerals in the attached figures:

[0045] 100. Spindle; 200. Auxiliary tooling; 210. Through hole; 220. First through slot; 230. Second through slot; 300. Keyway machining device; 310. Support frame; 311. Base; 312. Bracket; 320. Cutting tool; 321. Drive component; 322. Cutting head; 323. Mounting base; 324. Handwheel. Detailed Implementation

[0046] The following are specific embodiments of this application, which are described in conjunction with the accompanying drawings to further illustrate the technical solutions of this application. However, this application is not limited to these embodiments.

[0047] During on-site operations at the KR desulfurization station in the steel plant, the keyway of the drive shaft was found to be worn, causing periodic shaking of the agitator during rotation. On-site inspection confirmed a clearance between the connecting flange and the drive shaft. Due to a lack of inventory of critical spare parts such as the drive shaft and bearings, and the inability of the spare parts preparation cycle to meet production needs, online repair of the drive shaft was required without interrupting production at the desulfurization station.

[0048] If the clearance fit problem caused by keyway wear is not resolved, the agitator's swaying amplitude will continue to increase with prolonged operation, exacerbating stress concentration between the connecting flange and the drive shaft. Repeated dynamic loads may cause the agitator to completely detach, leading to unplanned shutdowns of the desulfurization station. Furthermore, a detached agitator can cause structural damage and process interruptions, severely impacting the continuity and safety of the hot metal desulfurization process, and ultimately causing a chain reaction of technical failures in the production system.

[0049] refer to Figure 1 , Figure 2 and Figure 3 This application proposes a method for machining double keyways on shafts, including:

[0050] S100. Fabricate an auxiliary tooling 200, so that a through hole 210, a first through groove 220 and a second through groove 230 are formed on the auxiliary tooling 200. The first through groove 220 and the second through groove 230 are symmetrically arranged in the radial direction of the through hole 210.

[0051] S200, Polish the surface rust off the spindle 100;

[0052] S300. Determine the positions of the first and second keyways to be machined based on the existing keyway positions on the spindle 100.

[0053] S400, The auxiliary tooling 200 is fitted onto the spindle 100, so that the first through groove 220 and the second through groove 230 are respectively aligned with the first keyway and the second keyway to be processed;

[0054] S500, adjust the position of the tool 320 of the keyway machining device 300 to align the tool 320 with the first through groove 220 or the second through groove 230, so that the tool 320 passes through the first through groove 220 or the second through groove 230 to machine the spindle 100 to form the first keyway and the second keyway.

[0055] In step S100, the auxiliary tooling 200 is fabricated to form a fixture structure with a through hole 210, a first through groove 220, and a second through groove 230. The first through groove 220 and the second through groove 230 are symmetrically arranged radially on the through hole 210, providing a stable guide reference for the tool 320 during the machining of shaft parts. Further, in step S300, the positions of the first and second keyways to be machined are determined based on the existing keyway positions on the spindle 100, and the coordinates of the new keyways are set with the existing keyways as a reference. Specifically, the geometric parameters of the existing keyways can be directly obtained using measuring instruments, and the positions of the new keyways can be calculated. For example, the keyway depth can be measured using a dial indicator and then the offset angle can be determined using an angle gauge. Alternatively, a coordinate measuring machine can be used to scan the keyway contour to generate a digital model for positioning. This is mainly to establish a reference point that meets the machining requirements even when there is wear on the surface of the spindle 100. Therefore, in step S500, the position of the tool 320 of the keyway machining device 300 is adjusted to align the tool 320 with the first through groove 220 or the second through groove 230, so that the tool 320 passes through the through groove to machine the spindle 100, thereby forming the first keyway and the second keyway to be machined.

[0056] This application, by combining a specially designed auxiliary tooling 200 with the existing keyway positioning reference, enables online machining of double keyways on shafts without specialized equipment. This effectively solves the problem of accurately machining double keyways on drive shafts to ensure installation accuracy when there are no spare parts available on site, thereby preventing the risk of shaking and falling of rotating equipment caused by clearance fit due to keyway wear.

[0057] Specifically, an auxiliary tooling 200 is fabricated, on which interconnected through holes 210, a first through groove 220, and a second through groove 230 are formed. The first through groove 220 and the second through groove 230 are symmetrically arranged radially in the through hole 210. This design utilizes the through hole 210 to accommodate the spindle 100 and the symmetrical first through groove 220 and second through groove 230 to ensure the geometric symmetry of the machining of the first keyway and the second keyway, avoiding rotational imbalance caused by the asymmetry of the first keyway and the second keyway. Through step S200, the surface rust of the spindle 100 is ground away, providing a clean and flat reference surface, ensuring the accuracy of subsequent positioning and machining. The positions of the first keyway and the second keyway to be machined are determined based on the original keyway positions on the spindle 100. The new keyway coordinates are established using the original keyway as a reliable reference point, avoiding the accumulation of errors from re-measuring on the worn shaft. Especially in emergency situations where spare parts are scarce, a machining reference that meets system compatibility can be quickly established. In step S400, the auxiliary fixture 200 is fitted onto the spindle 100, aligning the first through groove 220 and the second through groove 230 with the first and second keyways to be machined, respectively. The rigid structure of the auxiliary fixture 200 ensures precise matching between the first through groove 220 and the second through groove 230 and the first and second keyways to be machined, reducing manual operation errors. In step S500, the position of the tool 320 of the keyway machining device 300 is adjusted so that the tool 320 is aligned with either the first through groove 220 or the second through groove 230. The tool 320 passes through the through groove to machine the spindle 100, forming the first and second keyways. The first and second through grooves 220 and 230 serve as physical templates to guide the path of the tool 320, ensuring precise forming of the dimensions and positions of the first and second keyways, thereby restoring the interference fit requirements.

[0058] In one specific implementation, the through hole 210 of the auxiliary tooling 200 has a diameter of 338 mm, and the first through groove 220 and the second through groove 230 have a width of 80 mm and a length of 359 mm, and are symmetrically distributed radially in the through hole 210. Surface rust on the spindle 100 is removed by an electric grinder. The original keyway centerline is marked with a scribing tool, and the centerlines of the first and second keyways to be machined are set at a 90-degree circumferential offset. The auxiliary tooling 200 is fitted onto the unworn area of ​​the spindle 100, and the first through groove 220 and the second through groove 230 are precisely aligned with the machining position using an alignment tool. The cutting tool 320 is adjusted to align with the first through groove 220 to machine the spindle 100 to form the first keyway, and then aligned with the second through groove 230 to form the second keyway.

[0059] The double keyway machining method of this application solves the problem of accurately machining the double keyway of the main shaft 100 online to ensure installation accuracy when there are no spare parts available on site. Through the symmetrical design of the auxiliary tooling 200, the use of the original keyway positioning reference, and the machining mechanism guided by the through groove, the shaking phenomenon caused by the clearance fit due to keyway wear of the agitator is prevented, the safety risk of the agitator falling off is eliminated, and the stable operation of the rotating equipment is ensured.

[0060] Further, step S300 includes step S310: using the original keyway position on the spindle 100, draw the center line of the original keyway on the spindle 100, and determine the center lines of the first keyway and the second keyway based on the center line of the original keyway.

[0061] The process of drawing the center line of the original keyway is to determine the axis of symmetry of the original keyway. This can be achieved using a scribing tool or an optical projector. The purpose is to transform the geometric features of the keyway into a visual baseline, eliminating interference caused by wear or surface irregularities at the edge of the original keyway. Determining the center lines of the first and second keyways can be understood as a geometric derivation based on the baseline of the original keyway. This can be achieved using an angle measuring instrument or template alignment. The purpose is to ensure that the first and second keyways maintain the relative positional relationship with the original keyway as required by the design, avoiding the influence of accumulated errors in the measuring tools.

[0062] As a preferred embodiment, the solution of this application is implemented as follows: The operator uses a scriber and ruler to mark the center line of the original keyway on the surface of the main shaft 100; subsequently, using an angle gauge as a reference, the center line positions of the first and second keyways are determined at designated positions circumferentially on the main shaft 100. This effectively reduces keyway position deviation, improves the fitting accuracy of the keyway and key, thereby suppressing the shaking phenomenon during the rotation of the agitator and ensuring the safe operation of the equipment.

[0063] Step S310 further includes step S311, which involves determining the centerline positions of the first keyway and the second keyway at a 90-degree circumferential position along the spindle 100 on the original centerline of the two keyways.

[0064] The 90-degree circumferential position of the spindle 100 is a precise 90-degree offset from the original keyway centerline along the circumference of the spindle 100. This positioning can be achieved using an indexing head, angle gauge, or rotary encoder. The purpose is to ensure that the first and second keyways are orthogonally distributed with the original keyways, optimizing the stress state of the shaft. The centerline position of the first and second keyways is the centerline of the newly machined keyway, which can be determined by scribing or laser marking at the 90-degree position. This ensures the uniform symmetry of the double keyways in the circumferential direction, thereby achieving a strict interference fit. The fixed angular offset between the first and second keyways and the original keyways guarantees their uniform symmetry in the circumferential direction, enabling the machined first and second keyways to achieve a strict interference fit, replacing the original clearance fit, and effectively suppressing the shaking during the rotation of the agitator.

[0065] Step S100 includes: making the dimensions of the first through groove 220 and the second through groove 230 on the auxiliary tooling 200 greater than or equal to the dimensions of the first keyway and the second keyway to be processed.

[0066] Specifically, the dimensions of the first through groove 220 and the second through groove 230 are the geometric parameters of the groove opening on the auxiliary tooling 200. They can be achieved by setting the dimensions of the first keyway and the second keyway to be machined to be greater than or equal to the dimensions of the keyway. Specifically, the width and depth of the through groove can be controlled within the tolerance range of the keyway through precision machining. The purpose is to provide sufficient operating space for the tool 320, ensuring that the tool 320 can completely cover the entire area to be machined when cutting along the axial direction, avoiding the restriction of the tool 320 movement by the edge of the tooling, thereby accurately forming the keyway profile that meets the design requirements.

[0067] In some of the embodiments described above in this application, the keyway position is directly determined after the spindle 100 is polished to remove surface rust. However, during its implementation, the high temperature of the spindle 100 may lead to inaccurate dimensional measurements, and the lack of internal defect detection results in insufficient machining accuracy and structural safety hazards.

[0068] In this regard, this application further proposes that after the spindle 100 is polished to remove surface rust, and before determining the positions of the first keyway and the second keyway to be processed based on the original keyway positions on the spindle 100, the application also includes: cooling the spindle 100 to below 40 degrees Celsius for ultrasonic testing, and detecting multiple sets of diameter data of the spindle 100.

[0069] In practical applications, cooling the spindle 100 to below 40 degrees Celsius is to control the temperature of the spindle 100 to below a specified threshold. This can be achieved through natural cooling, forced air cooling, or circulating water cooling, with the aim of eliminating the interference of thermal expansion on dimensional measurement and flaw detection results. Ultrasonic flaw detection utilizes ultrasonic energy to detect internal defects in the spindle 100. This can be achieved using a portable ultrasonic flaw detector or a fixed flaw detection workstation, with the aim of identifying potential structural defects such as cracks and porosity, ensuring the material integrity of the spindle 100. Specifically, detecting multiple sets of diameter data for the spindle 100 involves collecting diameter measurements at multiple points along the spindle 100's axial direction. This can be achieved using tools such as digital calipers, laser diameter gauges, or optical measurement systems, with the aim of obtaining comprehensive data on the overall wear condition of the spindle 100, avoiding measurement deviations caused by local deformation, and thus ensuring the accuracy and safety of subsequent keyway machining.

[0070] In this application, step S400 includes:

[0071] S410. Fit the auxiliary tooling 200 onto the unworn shaft diameter of the main spindle 100.

[0072] S420. Perform a feeler gauge check to ensure that the gap between the auxiliary tooling 200 and the spindle 100 is uniform.

[0073] S430, Detect the perpendicularity of the auxiliary tooling 200 to the spindle 100;

[0074] S440. Fix the auxiliary tooling 200 to the spindle 100 with bolts.

[0075] In step S410, the auxiliary fixture 200 is fitted onto the unworn shaft diameter of the spindle 100. This involves selecting an area of ​​the spindle 100 surface with no or minimal wear as the installation reference surface. This can be determined by visual inspection combined with a surface roughness tester. The purpose is to avoid the influence of dimensional inaccuracies in worn areas and provide a stable and reliable reference for fixture positioning. Step S420 involves checking the gap distribution between the auxiliary fixture 200 and the spindle 100 using standard feeler gauges. Feeler gauges of different specifications can be inserted at multiple points along the circumference of the fixture for inspection. The purpose is to ensure consistent contact between the fixture and the spindle 100 surface and prevent localized gaps. The tilting and offset caused by stress concentration; Step S430 detects the perpendicularity of the auxiliary tooling 200 and the spindle 100 to verify the orthogonal relationship between the tooling mounting surface and the axis of the spindle 100. A laser level or electronic angle gauge can be used instead of traditional measuring tools. The purpose is to maintain the axial perpendicularity accuracy of the keyway machining and avoid the misalignment of the keyway position due to angular deviation; Step S440 fixes the auxiliary tooling 200 and the spindle 100 with bolts to achieve a rigid connection between the tooling and the spindle 100 using bolts. High-strength bolts can be used with anti-loosening washers for fastening. The purpose is to eliminate the risk of relative displacement during the machining process and ensure the stability of the tooling under dynamic load.

[0076] Specifically, firstly, the unworn shaft diameter on the spindle 100 is selected as the installation reference, providing a dimensionally stable positioning surface for the auxiliary tooling 200, thereby avoiding interference from the wear area on the reference accuracy. Based on this, a feeler gauge is used to check the dynamic adjustment of the clearance uniformity, ensuring full contact between the tooling and the surface of the spindle 100, preventing stress concentration and tilting caused by local clearance differences. Subsequently, the perpendicularity is checked to verify the orthogonality between the tooling mounting surface and the axis of the spindle 100, ensuring the accuracy of the keyway machining direction. Finally, bolts are used for rigid fixing, locking the aforementioned adjustment results, thereby eliminating the combined effects of uneven clearance, perpendicularity deviation, and insecure fixing on the keyway machining accuracy, ensuring the stability of the machining process and the precision of the keyway position.

[0077] In some of the embodiments described above in this application, the perpendicularity of the auxiliary tooling 200 to the main spindle 100 is proposed to ensure the accuracy of the installation of the auxiliary tooling 200. However, in its implementation, due to the lack of a clear perpendicularity detection method, there may be a slight tilt or uneven gap between the auxiliary tooling 200 and the main spindle 100, which may cause the keyway machining position to deviate, resulting in the keyway not being perpendicular to the axis of the main spindle 100, thereby aggravating the shaking of the equipment during operation and increasing the safety risk of the stirring paddle falling off.

[0078] In this regard, this application further proposes that S430 includes:

[0079] S431. Place the right-angle ruler on the upper surface of the auxiliary fixture 200, so that there is no gap between the right-angle ruler and the upper surface of the auxiliary fixture 200 and the surface of the main shaft 100.

[0080] Among them, the right-angle ruler is a measuring tool with precise right-angle geometric characteristics. It can be made of metal or cast iron and aims to provide an intuitive and stable vertical reference. To ensure that there are no gaps between the right-angle ruler and the upper surface of the auxiliary fixture 200 and the surface of the spindle 100, the two working surfaces of the right-angle ruler form a tight physical contact with the upper surface of the auxiliary fixture 200 and the surface of the spindle 100, respectively. The purpose is to verify the vertical consistency in three-dimensional space by eliminating local gaps and avoid the cumulative effect of small tilts on machining positioning.

[0081] Specifically, the solution of this application uses a right-angle ruler as a reference tool, placed on the upper surface of the auxiliary fixture 200. Utilizing its inherent right-angle geometry, it establishes an intuitive basis for judging the horizontal state of the auxiliary fixture 200. Simultaneously, the right-angle ruler is tightly fitted to the surface of the spindle 100, forming a dual verification mechanism. This mechanism can quickly confirm the vertical relationship without relying on complex instruments, ensuring that the auxiliary fixture 200 and the spindle 100 maintain spatial vertical consistency during installation. This provides precise positioning assurance for subsequent keyway machining and effectively eliminates the keyway position offset problem caused by reference deviation.

[0082] In this embodiment of the application, step S500 includes:

[0083] S510. Align the tool 320 with the first through groove 220 and machine the spindle 100 to form the first keyway;

[0084] S520. Align the tool 320 with the second through groove 230 and machine the spindle 100 to form the second keyway.

[0085] In step S510, aligning the tool 320 with the first through groove 220 ensures that the center line of the tool 320 precisely coincides with the center line of the first through groove 220. This can be achieved through real-time monitoring and adjustment using a laser calibrator or mechanical positioning pins, aiming to ensure the accuracy of the initial positioning of the tool 320. Machining the spindle 100 to form the first keyway can be understood as forming a keyway structure on the surface of the spindle 100 through milling or broaching processes. Specifically, a standard keyway tool 320 can be used in conjunction with a feed mechanism to establish the reference position of the first keyway. Step S520, aligning the tool 320 with the second through groove 230, is a positioning operation performed immediately after the machining of the first keyway. This can be achieved by using the scale markings on the surface of the auxiliary tooling 200 or an optical alignment device to quickly reset, aiming to maintain the relative positional relationship between the first through groove 220, the second through groove 230, and the spindle 100, avoiding reference offset due to external interference, and ultimately achieving precise symmetry of the first keyway and the second keyway in the circumferential position of the spindle 100.

[0086] The specific implementation of this application is as follows: After the operator completes the setting and alignment of the auxiliary tooling 200, the tool 320 of the keyway machining device 300 is first moved horizontally to a position completely overlapping with the center line of the first through groove 220. The drive unit 321 is started to drive the cutter head 322 to rotate, and the surface of the spindle 100 is milled to form the first keyway. After the first keyway is machined, the auxiliary tooling 200 and the spindle 100 are kept in a fixed state, and the horizontal displacement of the tool 320 is directly adjusted to align it with the center line of the second through groove 230. The milling process is then continued to form the second keyway.

[0087] In actual operation, the original connecting flange (coupling) on ​​the spindle 100 must first be removed and cut from the original keyway position to avoid damaging the spindle 100. The inner diameter of the connecting flange (coupling) is determined based on the measured diameter data of the spindle 100, and the inner hole is machined at the factory. Since the old spindle 100 may have wear, after removing the old flange, the diameter of the old spindle 100 is measured to obtain the final actual diameter. A 2mm machining allowance is reserved for the inner diameter of the arriving connecting flange. The inner hole of the flange is then machined according to the actual diameter of the spindle 100 to ensure an interference fit between the spindle 100 and the flange diameter.

[0088] refer to Figure 2 and Figure 4 This application also provides a keyway machining device 300, which is applied to a shaft double keyway machining method. The keyway machining device 300 includes a support frame 310 and a cutting tool 320. The cutting tool 320 is mounted on the support frame 310 and includes a driving member 321 and a cutting head 322. The driving member 321 is used to drive the cutting head 322 to rotate.

[0089] Among them, the support frame 310 serves as the basic structure of the keyway machining device 300, providing stable support in the absence of a fixed workshop environment, thus preventing the tool 320 from shifting due to the shaking of the spindle 100. At the same time, the integrated configuration of the drive component 321 and the cutter head 322 maintains the continuity and consistency of the cutting process, suppresses the keyway size deviation caused by power fluctuations, and ultimately achieves high-precision synchronous machining of the double keyways, meeting the timeliness and safety requirements of emergency maintenance at the desulfurization station.

[0090] Furthermore, the support frame 310 includes a base 311 and a bracket 312, with the bracket 312 detachably connected to the base 311. The tool 320 also includes a mounting base 323 and a handwheel 324. The mounting base 323 is vertically mounted on the bracket 312, and the handwheel 324 is rotated to adjust the height of the tool head 322. The detachable connection between the bracket 312 and the base 311 can be achieved using bolts, snap-fit ​​structures, or slide rails, facilitating quick installation or disassembly according to site conditions and adapting to different spindle 100 sizes and machining environments. Mounting base 323 is vertically adjustable on bracket 312, allowing for adjustable vertical displacement. This can be achieved using a screw drive mechanism, guide rail slider system, or hydraulic lifting device. The purpose is to enable continuous fine-tuning of the cutter head 322 height, ensuring machining accuracy. Handwheel 324 is a manually operated rotating component, which can be implemented using a gear and rack mechanism, worm gear drive, or thread adjustment mechanism. Its purpose is to convert rotational motion into vertical displacement of mounting base 323, enabling precise alignment of cutter head 322 according to the actual diameter data of spindle 100 and keyway position requirements. This ensures that the cutter 320 accurately passes through the first through slot 220 and second through slot 230 of auxiliary tooling 200, achieving precise matching of keyway depth and position, so as to form the first and second keyways extending axially on spindle 100.

[0091] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in the embodiments of this application are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0092] Furthermore, the use of terms such as "first," "second," and "a" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0093] In this application, unless otherwise expressly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0094] Furthermore, the technical solutions of the various embodiments of this application can be combined with each other, but only if they are based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this application.

Claims

1. A method for machining double keyways on shafts, characterized in that, include: An auxiliary tooling is fabricated to form a through hole, a first through groove, and a second through groove, which are connected to each other. The first through groove and the second through groove are symmetrically arranged in the radial direction of the through hole. Remove surface rust from the spindle; The positions of the first and second keyways to be machined are determined based on the existing keyway positions on the spindle. The auxiliary tooling is fitted onto the spindle so that the first through groove and the second through groove are aligned with the first keyway and the second keyway to be machined, respectively. Adjust the tool position of the keyway machining device to align the tool with the first through slot or the second through slot, so that the tool passes through the first through slot or the second through slot to machine the spindle, thereby forming the first keyway and the second keyway.

2. The method for machining double keyways on shafts according to claim 1, characterized in that, Determining the positions of the first and second keyways to be machined based on the original keyway positions on the spindle includes: Using the original keyway position on the spindle, draw the center line of the original keyway on the spindle, and determine the center lines of the first keyway and the second keyway based on the center line of the original keyway.

3. The method for machining double keyways on shafts according to claim 2, characterized in that, Determining the center lines of the first keyway and the second keyway based on the center line of the original keyway includes: The centerline positions of the first keyway and the second keyway are determined at a 90-degree circumferential position along the main shaft, using the centerline of the original two keyways.

4. The method for machining double keyways on shafts according to claim 1, characterized in that, The manufacturing auxiliary tooling includes: The dimensions of the first through groove and the second through groove on the auxiliary tooling are greater than or equal to the dimensions of the first keyway and the second keyway to be processed.

5. The method for machining double keyways on shafts according to claim 1, characterized in that, After the surface rust is removed from the spindle, and before determining the positions of the first and second keyways to be machined based on the original keyway positions on the spindle, the process further includes: The spindle was cooled to below 40 degrees Celsius for ultrasonic testing, and multiple sets of diameter data of the spindle were detected.

6. The method for machining double keyways on shafts according to claim 1, characterized in that, The step of fitting the auxiliary tooling onto the spindle includes: The auxiliary tooling is fitted onto the unworn shaft diameter of the main shaft; Perform a feeler gauge check to ensure that the clearance between the auxiliary tooling and the spindle is uniform; Detect the perpendicularity of the auxiliary tooling to the spindle; The auxiliary tooling is fixed to the main shaft by bolts.

7. The method for machining double keyways on shafts according to claim 6, characterized in that, The detection of the perpendicularity between the auxiliary tooling and the spindle includes: Place a right-angle ruler on the upper surface of the auxiliary fixture, ensuring that there is no gap between the right-angle ruler and the upper surface of the auxiliary fixture and the surface of the spindle.

8. The method for machining double keyways on shafts according to claim 1, characterized in that, The step of machining the spindle by passing the cutting tool through the first through slot or the second through slot to form the first keyway and the second keyway includes: Align the cutting tool with the first through groove, and machine the spindle to form the first keyway; The cutting tool is then aligned with the second through groove, and the spindle is machined to form the second keyway.

9. A keyway machining apparatus, characterized in that, The keyway machining apparatus, applicable to the shaft double keyway machining method as described in any one of claims 1 to 8, comprises: Support frame; The cutting tool is mounted on the support frame. The cutting tool includes a drive unit and a cutting head. The drive unit is used to drive the cutting head to rotate.

10. The keyway processing apparatus according to claim 9, characterized in that, The support frame includes a base and a bracket, the bracket being detachably connected to the base. The cutter also includes a mounting base and a handwheel, the mounting base being vertically and vertically mounted on the bracket, and the handwheel being rotated to adjust the height of the cutter head.

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