Special equipment for machining chip groove through manual file

Abstract

The invention discloses special equipment for machining a chip groove through a manual file, belongs to the technical field of manual file machining, and aims to solve the problems that no special machining equipment is provided for a diamond chip groove of an existing manual file, and the machining efficiency is low. The equipment comprises a rack, a power device, a cuboid clamp body, a workpiece bearing and reciprocating motion mechanism, a numerical control index plate, a control box and a lifting system. The rack provides a mounting reference, the power device drives the grinding head to rotate through a motor and belt transmission, and the grinding head can adapt to different chip groove distances by replacing a round pad; the workpiece bearing and reciprocating motion mechanism drives a working plate to conduct reciprocating feeding through an air cylinder, a dovetail guide rail and a linear guide rail guarantee the motion precision, and a numerical control index plate achieves accurate adjustment of the angle of a workpiece. The lifting system is matched with a ball screw through a servo motor, so that the cutting amount is accurately adjusted; a PLC in the control box cooperates with a travel switch, a servo motor and a numerical control index plate, and full-process automatic control is achieved. The diamond chip groove can be accurately machined, and the machining efficiency is high.

Description

Technical Field

[0001] This invention relates to the field of hand file processing technology, and in particular to a special device for processing chip removal grooves with hand files. Background Technology

[0002] Files are common hand tools widely used in machining, mold making, and other fields. However, conventional files on the market generally have poor applicability when processing soft metals (such as aluminum and zinc alloys). Specifically, metal shavings generated during processing tend to adhere to the file surface and the workpiece, which not only reduces processing efficiency but also causes scratches on the workpiece surface, affecting the surface finish and failing to meet the high-precision processing requirements of soft metals.

[0003] To address the aforementioned issues, the industry has developed a specialized hand file for soft metals with a surface featuring diamond-shaped cross-grooves for chip removal. This file rapidly collects and removes soft metal chips generated during processing through its high-smoothness diamond-shaped grooves, effectively reducing chip residue between the file and the workpiece, minimizing workpiece scratches, and significantly improving the surface finish. The file demonstrates excellent performance. However, a processing challenge exists in the finished product: due to the high surface finish of the chip removal grooves, grinding is the only option after heat treatment. Currently, there are no other processing methods available, and suitable grinding machines are unavailable.

[0004] Currently, the unidirectional straight / oblique tooth chip grooves of conventional files are generally processed by stamping using a tooth-cutting machine. This processing method has become a mature technology system for the mass production of ordinary unidirectional toothed files. However, for the diamond-shaped cross chip grooves of the aforementioned soft metal-specific hand files, existing tooth-cutting machines and conventional processing equipment have the following inherent technical defects that cannot be overcome: 1. The processing principle has inherent limitations and cannot adapt to the requirements of diamond groove forming: The existing tooth chopping machine adopts the forming method of stamping and breaking teeth, which can only partially punch and break the pre-formed file teeth to form chip removal grooves. It cannot directly process complete diamond grooves with high surface finish. When processing the second direction cross groove, the punching action will impact and compress the already processed first direction tooth shape, which cannot guarantee the dimensional accuracy and cross angle consistency of the diamond groove shape, and cannot meet the high precision requirements of file tooth shape for soft metal processing.

[0005] 2. The forming quality of the groove is extremely poor, completely violating the original design intention of soft metal chip removal: The chip removal groove formed by the tooth chopper punching will have irregular broken tooth roots remaining in the groove, and the groove wall is a metal tear cross surface with extremely poor surface finish; this kind of groove with protruding tooth roots and rough tear surface is very easy to jam and stick soft metal chips when processing soft metals such as aluminum and zinc alloys. Not only will it fail to achieve smooth chip removal, but it will also aggravate the problem of chip accumulation and workpiece scratches, and completely fail to achieve the design function of the diamond chip removal groove.

[0006] 3. Insufficient control over cutting depth and indexing accuracy, resulting in low product qualification rate: The existing tooth chopper has low indexing mechanism and low stamping depth control accuracy, making it impossible to accurately control the intersection angle and groove depth of the diamond chip removal groove. The processed grooves are uneven in depth and have large angle deviations, resulting in an extremely low product qualification rate and making it unsuitable for the mass production needs of soft metal special files.

[0007] 4. Lack of suitable specialized processing equipment: Existing tooth-cutting machines are all designed for processing the chip grooves of ordinary steel files. Their stamping and tooth-breaking processing principle cannot fundamentally meet the core requirements of the smoothness of the inner wall of the chip groove for soft metal files. At present, there is no specialized grinding processing equipment in the industry for this type of diamond-shaped chip groove, which makes it impossible to achieve stable and efficient mass production of compliant soft metal files.

[0008] Therefore, there is an urgent need to develop a special equipment for grinding the diamond-shaped cross-chip grooves of hand files, in order to solve the above-mentioned defects of the existing technology and meet the mass production needs of new files for soft metals. Summary of the Invention

[0009] To address the problem of low processing efficiency due to the lack of dedicated equipment for processing chip removal grooves on hand files, this invention provides a dedicated device for processing chip removal grooves on hand files, enabling precise and automated processing of diamond-shaped chip removal grooves on the file surface, while improving processing efficiency and product qualification rate.

[0010] To achieve the above objectives, this invention provides a special equipment for manually filing chip removal grooves, comprising a frame, a power unit, a cuboid clamping body, a workpiece bearing and reciprocating motion mechanism, a CNC indexing plate, a control box, and a lifting system; the specific structure and connection relationship of each component are as follows: (a) Frame structure The frame includes a base plate, a fixed upright plate, and a top plate. The fixed upright plate is fixed to the upper part of the base plate with four M16 bolts, and the top plate is fixed to the top of the fixed upright plate, forming a stable frame support structure and providing an installation reference for each functional component.

[0011] (ii) Power unit The power unit includes a motor, a driven shaft, and a grinding head, providing the grinding power required for chip removal groove machining. The motor is fixed to the top plate, and the driven shaft is fixed to the top plate via bearings. A pad is provided under the bearings to adjust the horizontal level of the driven shaft. A drive pulley is mounted on the motor shaft, and a driven pulley is mounted on the driven shaft. The drive pulley and the driven pulley are connected by a belt to achieve a transmission connection between the motor and the driven shaft. The grinding head is mounted on the driven shaft and secured with a nut to ensure that the grinding head does not loosen during high-speed rotation. The grinding head consists of grinding discs and circular pads spaced between the grinding discs. The thickness of the circular pads is adapted to the chip removal groove spacing. By replacing the circular pads with different thicknesses, chip removal grooves with different spacing requirements can be machined, improving the versatility of the equipment.

[0012] (III) Workpiece bearing and reciprocating motion mechanism The front side of the fixed upright plate is provided with a dovetail guide rail, on which a worktable is slidably connected. The dovetail guide rail ensures the straightness and stability of the worktable's movement. A platform is fixed on the worktable, and two parallel slide rails are fixed on the platform. A slider is slidably connected to the slide rails, and a work plate is fixed on the slider. Through the cooperation of the slide rails and the slider, the smooth reciprocating movement of the work plate is achieved.

[0013] The work plate is fixed with a CNC indexing plate, and a cuboid clamping body is provided on the CNC indexing plate, which is fixed to the CNC indexing plate with T-bolts. A cylinder fixing plate is fixed to one side of the platform, and a cylinder is fixed on the cylinder fixing plate. The push rod of the cylinder is connected to a vertical plate fixed to one end of the work plate. Through the extension and retraction of the cylinder, the work plate is driven to reciprocate linearly along the slide rail, providing feed motion for the grinding of the chip removal groove.

[0014] (iv) Lifting system The lifting system includes a servo motor, a ball screw, a lead screw nut, and a U-shaped frame, used to drive the worktable to rise and fall, thereby adjusting the cutting amount. The U-shaped frame is fixed to the underside of the worktable, the lead screw nut is fixed to the bottom of the U-shaped frame, and the ball screw is threadedly connected to the lead screw nut. The lower end of the ball screw is fixed to the output shaft of the servo motor via a flat key, key sleeve, and set screw, ensuring that the power of the servo motor can be stably transmitted to the ball screw. The forward and reverse rotation of the servo motor drives the ball screw to rotate, and then, through the threaded engagement between the ball screw and the lead screw nut, the rotational motion is converted into linear motion, driving the U-shaped frame and the worktable to rise and fall along the dovetail guide rail. The servo motor is fixed to the base plate.

[0015] (v) Control system and testing organization A control box is fixed to the base plate on the rear side of the fixed upright plate. The control box contains a PLC controller, a driver, and other control components, providing the control core for the automated operation of the equipment. A left limit switch and a right limit switch are provided on the outer side of the platform. The front control arms of the left limit switch and the right limit switch are fixed to the work plate and used to control the reciprocating stroke position of the work plate.

[0016] (vi) Core Automation Control Logic The PLC controller inside the control box receives trigger signals from the left and right limit switches to accurately identify the completion status of the worktable's reciprocating stroke. When the worktable moves to the right under the drive of the cylinder, it triggers the right limit switch, which sends a signal to the PLC controller. Upon receiving the signal, the PLC controller controls the cylinder to reverse its movement, driving the worktable to move to the left. When the worktable moves, it triggers the left limit switch, which sends a signal to the PLC controller. At this point, the worktable has completed one left-right reciprocating stroke. After the worktable completes one left-right reciprocating stroke, the PLC controller automatically sends a control command to the servo motor, driving it to rotate a set angle. This rotation, through the transmission between the ball screw and nut, moves the worktable upward a set distance. The set distance is determined based on the target chip removal groove depth. This parameter is preset and stored by the PLC controller. When the limit switches are triggered, the PLC controller recalls the parameter to drive the servo motor. This distance is the precise cutting amount for the next stroke, achieving automated and precise adjustment of the cutting height.

[0017] (vii) Optimized technical features 1. The length of the grinding head is adapted to the length of the hand file to be processed. The work plate can complete the grinding of all unidirectional chip grooves of the hand file in one stroke, without the need for multiple longitudinal movements of the workpiece, which significantly improves the processing efficiency.

[0018] 2. The top surface of the cuboid clamp is provided with a contouring recess. The shape of the contouring recess is adapted to the hand file to be processed. The depth of the contouring recess is 1 / 2 to 2 / 3 of the thickness of the hand file. This depth setting can take into account the positioning stability, machinability and workpiece loading and unloading convenience. It can prevent the hand file from shifting during processing and facilitate the quick removal of the workpiece after processing.

[0019] 3. The fixing method of the fixed upright plate to the bottom plate and the top plate is bolt fixing or welding fixing; the cylinder and the cylinder fixing plate are fixed by bolts, the cylinder push rod and the upright plate are threaded connection and fixed with anti-loosening nuts.

[0020] 4. The pad is height-adjustable, and the height can be adjusted by increasing or decreasing the number of pads or replacing them with pads of different thicknesses. The pads are preferably made of stainless steel to improve wear resistance and service life and ensure the installation accuracy of the driven shaft. The round pad is detachable, and round pads of different thicknesses can be replaced according to the chip groove spacing requirements to improve the versatility of the equipment. The slide rail is a linear guide rail, and the clearance between the slider and the slide rail does not exceed 0.005mm, which can effectively reduce the shaking during the movement of the work plate and ensure machining accuracy.

[0021] 5. The transmission accuracy of the ball screw is not less than 0.01mm / revolution; the servo motor is an AC servo motor with a power of 0.75-1.5kW, which can precisely control the rotation angle, thereby precisely controlling the rising distance of the worktable and ensuring the consistency of grinding amount per stroke.

[0022] 6. A control panel is fixed horizontally on the front side of the workbench for setting various parameters and operation buttons.

[0023] Compared with the prior art, the present invention has the following beneficial effects: 1. Adaptable to soft metal processing needs: This equipment precisely processes diamond-shaped chip removal grooves, which can effectively improve the chip removal capacity of the file, avoid chip adhesion when processing soft metals such as aluminum and zinc alloys, reduce the degree of workpiece scratches, improve the surface finish of the processed surface, and successfully solve the problem that existing files are not suitable for processing soft metals.

[0024] 2. High processing efficiency: The length of the grinding head is adapted to the length of the hand file, and the grinding process of the unidirectional chip removal groove of the hand file can be completed in one reciprocating stroke of the work plate; there is no need to move the workpiece longitudinally multiple times. With the full-process automated control, there is no need for frequent manual intervention, which significantly improves the processing efficiency.

[0025] 3. Precise positioning and flexible angle adjustment: The contouring groove on the cuboid fixture can achieve stable positioning of the workpiece and prevent the workpiece from shifting during processing; the CNC indexing plate can achieve precise angle adjustment, which can adapt to the processing needs of different specifications of diamond chip removal grooves, greatly improving the versatility of the equipment.

[0026] 4. Automated and Precise Control of Grinding Amount: This equipment adopts an automated control architecture that coordinates a PLC controller, limit switches, and servo motors, enabling precise closed-loop control of the cutting amount. The PLC controller monitors the reciprocating stroke status of the worktable in real time through limit switches. After each reciprocating stroke, it automatically triggers the servo motor to drive the worktable upward to the corresponding cutting height, eliminating the need for manual adjustment. Combined with a lifting system consisting of ball screws and AC servo motors, the transmission accuracy is high, significantly improving the product qualification rate while greatly reducing the intensity of manual operation, achieving fully automated grinding. Attached Figure Description

[0027] Appendix Figure 1 This is a front three-dimensional structural diagram of the present invention, used to show the overall assembly relationship of the various components; Appendix Figure 2 This is a three-dimensional structural diagram of the rear side of the present invention, used to show the installation position of the control box and the assembly relationship of the equipment at the rear side; Appendix Figure 3 This is a schematic diagram of the connection structure between the dovetail guide rail and the worktable of the present invention, used to illustrate the sliding fit relationship between the two and the surrounding components; Appendix Figure 4 This is a schematic diagram of the structure of the hand file to be processed by the equipment of the present invention, used to show the structural form of the hand file and the chip removal groove.

[0028] In the attached diagram: 1. Base plate; 2. Servo motor; 3. Dovetail guide rail; 4. Set screw; 5. Ball screw; 6. Nut; 7. U-shaped frame; 8. Cylinder; 9. Cylinder fixing plate; 10. Vertical plate; 11. Top plate; 12. Motor; 12-1 drive pulley; 13. Belt; 14. Grinding head; 15. Nut; 16. Driven shaft; 17. Work plate; 18. Slide rail; 19. Platform; 20. Worktable; 21. Flat key; 22. Key sleeve; 23. CNC indexing plate; 24. Cuboid fixture; 25. Hand file; 26. T-bolt; 27. Fixed vertical plate; 28. Slider; 29. ​​Left limit switch; 30. Right limit switch; 31. Control panel; 32. Bearing; 33. Pad; 34. Driven pulley; 35. Control box; 36. Chip removal groove. Detailed Implementation

[0029] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment takes a hand file for processing soft metal with a processing length of 200mm and a thickness of 5mm as an example to describe the equipment structure, processing flow and operation process in detail, to ensure that the parameters of each component are clear, the structural description is complete, and the use of all part numbers is covered.

[0030] The special equipment for processing chip removal grooves by hand filing in this embodiment includes a frame, a power unit, a cuboid clamping body 24, a workpiece bearing and reciprocating motion mechanism, a CNC indexing plate 23, a control box 35, and a lifting system. The materials, specifications, and connection relationships of each component are as follows: The frame is constructed from Q235 steel plates, with the base plate 1 measuring 800mm × 600mm × 20mm, the fixed upright plate 27 measuring 800mm × 400mm × 30mm, and the top plate 11 measuring 800mm × 500mm × 15mm. The fixed upright plate 27 is securely connected to the upper side of the base plate 1 using four M16 × 80 high-strength bolts. Flat washers and spring washers are added at the bolt connections to prevent loosening. The top plate 11 is fully welded to the fixed upright plate 27, and high-temperature aging treatment is performed after welding to eliminate welding stress and ensure that the overall flatness error of the frame does not exceed 0.02mm, providing a stable installation benchmark for all functional components.

[0031] The power unit includes a motor 12, a driven shaft 16, a grinding head 14, a drive pulley 12-1, a driven pulley 34, a belt 13, bearings 32, spacers 33, and nuts 15. The motor 12 is a 2.2kW three-phase asynchronous motor with an adjustable speed range of 0-2800r / min. It is fixed to the center of the upper surface of the top plate 11 via a motor mount, secured with four M12 bolts. The driven shaft 16 is made of 45# steel, with a diameter of 50mm and a length of 600mm. It is fixed to the upper surface of the top plate 11 via two deep groove ball bearings 32. Stainless steel spacers 33 are provided under the bearings 32. The spacers 33 come in three thicknesses: 2mm, 3mm, and 5mm, which can be combined according to installation requirements to ensure that the horizontal error of the driven shaft 16 does not exceed 0.01mm. A drive pulley 12-1 is mounted on the output shaft of motor 12, and a driven pulley 34 is mounted on the upper end of driven shaft 16. The two are connected by a V-belt 13 with a transmission ratio set to 1:1.2 to ensure that the grinding head 14 rotates at a stable speed of 3360 r / min, meeting the grinding requirements of the chip groove. The grinding head 14 is composed of diamond grinding discs and round pads. The grinding discs are 150 mm in diameter and 2 mm thick, and the round pads are made of 45 steel with a thickness of 10 mm. The grinding discs and round pads are alternately fitted on the driven shaft 16 and secured by M24 locking nuts 15 and flat washers to ensure that the grinding head 14 does not loosen or become eccentric during high-speed rotation. The overall length of the grinding head 14 is set to 200 mm to match the length of the hand file 25 to be processed.

[0032] The workpiece bearing and reciprocating motion mechanism consists of a dovetail guide rail 3, a worktable 20, a platform 19, a slide rail 18, a slider 28, a work plate 17, a CNC indexing plate 23, a cuboid fixture 24, T-bolts 26, a cylinder fixing plate 9, a cylinder 8, and a vertical plate 10. The dovetail guide rail 3 is a high-precision, heavy-duty type with a width of 80mm and a clearance controlled between 0.005-0.01mm. It is bolted to the front of the fixed vertical plate 27. The bottom of the worktable 20 has a dovetail groove adapted to the dovetail guide rail 3, which slides onto the dovetail guide rail 3, allowing for smooth up-and-down movement along the guide rail. The worktable 20 is made of cast iron and measures 500mm×400mm×50mm. It undergoes aging treatment to eliminate internal stress. A cast iron platform 19 is fixed to the upper surface of the platform 19. Two parallel linear guide rails (slide rails 18) are bolted to the upper surface of the platform 19. Four matching sliders 28 are slidably connected to the slide rails 18. The clearance between the sliders 28 and the slide rails 18 is controlled at 0.003-0.005mm. The work plate 17 is fixed to the upper surface of the sliders 28. Through the cooperation of the slide rails 18 and the sliders 28, the work plate 17 can move smoothly back and forth in the horizontal direction. The CNC indexing plate 23 is fixed in the center of the upper surface of the work plate 17 with an indexing accuracy of 0.01°. The worktable of the CNC indexing plate 23 is fixed to the cuboid fixture 24 by two M16 T-bolts 26. The cuboid fixture 24 is made of 45 steel and has a size of 220mm×80mm×50mm. The top surface has a contouring pit adapted to the hand file 25. The depth of the contouring pit is set to 3.5mm (corresponding to 2 / 3 of the 5mm thickness of the hand file 25) to ensure that the hand file 25 is stably positioned and easy to pick up and put down. The right side of the platform 19 is fixed with a cylinder fixing plate 9. The standard cylinder 8 is fixed on the cylinder fixing plate 9 by four M8 bolts. The working pressure of the cylinder 8 is 0.4-0.6MPa. The end of the push rod is connected to the vertical plate 10 fixed to the right end of the work plate 17 by an M16 thread and locked with double anti-loosening nuts. Through the extension and retraction of the cylinder 8, the work plate 17 is driven to reciprocate linearly along the slide rail 18, providing stable feed for the grinding of the chip removal groove 36. At the same time, the end point of the stroke of the work plate 17 is precisely controlled by the left limit switch 29 and the right limit switch 30.

[0033] Lifting system: It includes a servo motor 2, a ball screw 5, a nut 6, a U-shaped frame 7, a flat key 21, a key sleeve 22 and a set screw 4. The servo motor 2 is an AC servo motor with a power of 1.1 kW and a positioning accuracy of ±0.001 mm. It is fixed on the upper surface of the bottom plate 1 through a motor bracket, and the motor output shaft faces upward. The ball screw 5 is of a high-precision model, with a lead of 5 mm, a transmission accuracy of 0.008 mm / revolution, and a length of 400 mm. The lower end is fixed to the output shaft of the servo motor 2 through a common flat key 21, a 45# steel key sleeve 22 and an M8 hexagon socket set screw 4 to ensure stable power transmission; the nut 6 is used in conjunction with the ball screw 5 and is fixed to the bottom of the U-shaped frame 7. The U-shaped frame 7 is made of welded steel plates, and the top is firmly connected to the bottom of the workbench 20 through bolts. By the forward and reverse rotation of the servo motor 2, the ball screw 5 is driven to rotate. With the threaded fit between the ball screw 5 and the nut 6, the rotational motion is converted into a linear motion, driving the U-shaped frame 7 and the workbench 20 to move up and down along the燕尾导轨3 (swing guide rail 3) to achieve precise adjustment of the cutting amount.

[0034] Control system and detection mechanism: The control box 35 is fixed on the bottom plate 1 behind the fixed vertical plate 27, with dimensions of 300 mm × 200 mm × 400 mm. Inside, there are a PLC controller, a servo driver supporting the servo motor 2, and electrical components such as an air switch and a relay, providing a control core for the automatic operation of the equipment. On the left and right outer sides of the platform 19, a mechanical left travel switch 29 and a right travel switch 30 are respectively fixed. The front control arms of the two travel switches are fixed to the work plate 17 through brackets, used to precisely control the end points of the reciprocating stroke of the work plate 17, and the stroke error can be controlled within ±0.02 mm. On the front side of the workbench 20 in the horizontal direction, a 7-inch touch screen (control screen 31) is fixed, connected to the PLC controller through a communication line, which can display the operation status of the equipment in real time (such as the rotation speed of the motor 12, the stroke of the work plate 17, the cutting amount, etc.), and supports manual setting of processing parameters, including the depth of the chip removal groove 36, the rotation angle of the CNC indexing table 23, the reciprocating speed of the cylinder 8, etc., with convenient operation. The PLC controller in the control box 35 can receive the trigger signals of the left travel switch 29 and the right travel switch 30, and synchronously control the actions of the cylinder 8, the servo motor 2 and the CNC indexing table 23 to form a closed-loop control, providing a stable guarantee for the subsequent automatic processing process.

[0035] The specific processing flow and operation steps of this embodiment are as follows: Step 1: Workpiece clamping and parameter setting. Place the hand file 25 to be processed into the contouring groove of the cuboid fixture 24, ensuring that the axis of the hand file 25 is parallel to the axis of the grinding head 14, with a positioning deviation not exceeding 0.02mm, and complete the workpiece clamping; set the processing parameters through the control panel 31, set the depth of the chip removal groove 36 to 1mm (to be completed in 5 grinding passes, with a cutting amount of 0.2mm each time), set the rotation angle of the CNC indexing plate 23 to 60° (to match the cross angle of the diamond-shaped chip removal groove 36), and set the reciprocating speed of the cylinder 8 to 50mm / s. After setting the parameters, save and start the equipment.

[0036] Step 2: Unidirectional chip removal groove grinding. After the equipment is started, the motor 12 drives the driving pulley 12-1, the driven pulley 34, and the driven shaft 16 to rotate via the belt 13, thereby driving the grinding head 14 to rotate at high speed. The grinding head 14 is composed of diamond grinding discs and round pads spaced apart, and is fastened to the driven shaft 16 by nuts 15 to ensure grinding stability; in the initial state, the working plate 17 is located on the slide rail 18. At the right end, the cylinder 8 push rod extends, driving the work plate 17 to move to the left along the slide rail 18. The grinding head 14 performs the first grinding process on the upper surface of the hand file 25. When the work plate 17 moves to the left end, it triggers the left limit switch 29. The PLC controller synchronously controls the cylinder 8 push rod to retract, driving the work plate 17 to move to the right and triggering the right limit switch 30. After completing one reciprocating stroke, the PLC controller drives the servo motor 2 to move, which drives the ball screw 5 to rotate through the flat key 21 and key sleeve 22, causing the worktable 20 to move upward 0.2mm along the dovetail guide rail 3, completing one grinding cycle. The set screw 4 can ensure the connection stability between the servo motor 2 and the ball screw 5 and avoid transmission deviation. The above grinding cycle is repeated 4 times until the machining of the inclined chip removal groove 36 on the front of the hand file 25 is completed (the depth reaches 1mm).

[0037] Step 3: Turn over and process the chip removal grooves in the same direction. After the chip removal grooves in one direction on the front of the hand file 25 are processed, turn off the power of the equipment, manually turn the hand file 25 over, place it with the unprocessed side facing up into the contouring pit of the cuboid clamp 24, and reposition and tighten it; start the equipment and, following the grinding process in step 2, complete the processing of the oblique chip removal grooves 36 in the same direction on the other side of the hand file 25.

[0038] Step 4: Angle Adjustment and Machining of Cross Chip Removal Grooves. After the chip removal grooves on both sides of the hand file 25 are machined in the same direction, a command is sent through the control panel 31 to start the CNC indexing plate 23, which drives the cuboid fixture 24 and the hand file 25 to rotate 60° and lock in position, ensuring that the cross angle is accurate. Then, the operation process of steps 2 and 3 is repeated to machine the oblique chip removal grooves 36 on the other side of the two sides of the hand file 25 in turn, and finally the overall machining of the cross diamond chip removal grooves 36 on both sides of the hand file 25 is completed. Throughout the process, the bearing 32 and the pad block 33 cooperate to ensure the levelness of the driven shaft 16 and the grinding head 14, and the high-precision cooperation between the slide rail 18 and the slider 28 ensures that the work plate 17 moves smoothly. The coordinated work of all components further improves the machining accuracy of the chip removal grooves 36.

[0039] Testing revealed that the chip removal grooves of the hand file processed in this embodiment had a spacing error of ±0.02mm, a depth error of ±0.01mm, and a surface finish Ra≤0.8μm. Processing one hand file takes only 8 minutes, representing an efficiency improvement of more than 8 times compared to manual processing, with a product qualification rate exceeding 99%. These results fully validate the stability and precision of this equipment, demonstrating its stable adaptability to the mass production needs of hand files for soft metal processing.

Claims

1. A special device for processing chip removal grooves with a hand file, characterized in that, It includes a frame, a power unit, a cuboid clamping body, a workpiece carrying and reciprocating motion mechanism, a CNC indexing plate, a control box, and a lifting system; the frame provides an installation reference for each component, the power unit provides grinding power, the workpiece carrying and reciprocating motion mechanism realizes the reciprocating feed of the workpiece, the CNC indexing plate adjusts the workpiece angle, the lifting system adjusts the cutting amount, and the control box realizes automated control.

2. The special equipment for processing chip removal grooves by hand filing according to claim 1, characterized in that, The frame includes a base plate, a fixed upright plate, and a top plate. The fixed upright plate is fixed to the upper part of the base plate with four M16 bolts, and the top plate is fixed to the top of the fixed upright plate to form a frame support structure. The fixed upright plate can be fixed to the base plate or the top plate by bolting or welding.

3. The special equipment for processing chip removal grooves by hand filing according to claim 1, characterized in that, The power unit includes a motor, a driven shaft, and a grinding head. The motor is fixed to the top plate, and the driven shaft is fixed to the top plate by a bearing. A height-adjustable pad is provided on the lower side of the bearing. A drive pulley is provided on the motor shaft, and a driven pulley is provided on the driven shaft. The two are connected by belt drive. The grinding head is installed on the driven shaft and fixed by a nut. The grinding head consists of grinding discs and spaced round pads. The thickness of the round pads is adapted to the chip removal groove spacing and they are removable and replaceable.

4. The special equipment for processing chip removal grooves by hand filing according to claim 3, characterized in that, The pads are made of stainless steel, and their height can be adjusted by increasing or decreasing their quantity or changing their thickness, thereby improving wear resistance and service life and ensuring the installation accuracy of the driven shaft. The length of the grinding head is adapted to the length of the hand file to be processed, and the work plate can complete the grinding of all unidirectional chip removal grooves of the hand file in one left and right stroke, which significantly improves processing efficiency.

5. The special equipment for processing chip removal grooves by hand filing according to claim 1, characterized in that, The workpiece bearing and reciprocating motion mechanism includes a dovetail guide rail, a worktable, a platform, a slide rail, a slider, a work plate, a cylinder fixing plate, and a cylinder. The dovetail guide rail is located on the front side of the fixed vertical plate. The worktable is slidably connected to the dovetail guide rail. The platform is fixed on the worktable. Two parallel slide rails are fixed on the platform. The slider is slidably connected to the slide rail. The work plate is fixed on the slider. The cylinder fixing plate is fixed on one side of the platform. The cylinder is fixed on the cylinder fixing plate. The cylinder push rod is threadedly connected to the vertical plate at one end of the work plate and fixed by an anti-loosening nut.

6. The special equipment for processing chip conveying grooves by hand filing according to claim 5, characterized in that, The slide rail is a linear guide rail, and the clearance between the slider and the slide rail does not exceed 0.005mm; the CNC indexing plate is fixed on the work plate, and the cuboid clamp is fixed to the CNC indexing plate by two M16 T bolts.

7. The special equipment for processing chip removal grooves by hand filing according to claim 6, characterized in that, The top surface of the cuboid clamp has a contouring recess, the shape of which is adapted to the hand file to be processed, and the depth of the contouring recess is 1 / 2 to 2 / 3 of the thickness of the hand file.

8. The special equipment for processing chip removal grooves by hand filing according to claim 1, characterized in that, The lifting system includes a servo motor, a ball screw, a nut, and a U-shaped frame. The U-shaped frame is fixed to the underside of the worktable, the nut is fixed to the bottom of the U-shaped frame, the ball screw is threadedly connected to the nut, and the lower end of the ball screw is fixed to the output shaft of the servo motor via a flat key, a key sleeve, and a set screw. The transmission accuracy of the ball screw is not less than 0.008 mm / revolution. The servo motor is an AC servo motor with a power of 0.75-1.5 kW and is fixed to the base plate.

9. The special equipment for processing chip conveying grooves by hand filing according to claim 1, characterized in that, The control box is fixed to the base plate behind the fixed upright plate and contains a PLC controller and a driver; the outer side of the platform is equipped with a left limit switch and a right limit switch, and the front control arms of both are fixed to the work plate; the front side of the workbench is equipped with a control screen for setting parameters and operation.

10. A special equipment for processing chip conveying grooves by hand filing according to claim 9, characterized in that, The automated control logic is as follows: The PLC controller receives the limit switch trigger signal, controls the cylinder to drive the work plate to reciprocate. After completing one reciprocating stroke, the PLC controller controls the servo motor to move the worktable upward to set the cutting amount. The set distance is preset according to the target chip removal groove depth and stored in the PLC controller.

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