A kind of manufacturing process and positioning mould for preventing deformation of barrel

Abstract

The application provides a kind of for deformation prevention manufacturing process and positioning mould of cylinder piece, comprising the following steps: step one, determine blank size, adopt split type blanking scheme, after blanking, each single piece arc segment is respectively carried out roll forming processing;Step two, design and manufacture deformation prevention positioning mould;The arc segment after segmented roll forming is assembled one by one in the deformation prevention positioning mould for positioning and spot welding fixation, welding is realized in the welding process by the whole turnover mould to realize the welding of both sides weld;Step three, make special bottom mould platform, a plurality of special platforms for placing shock-absorbing support are designed on the bottom mould platform;Matched production detachable shock-absorbing support;Step four, adopt vertical lathe processing mode, find the welding completed cylinder blank on the vertical lathe workbench;In turn, rough machining and finishing are carried out.The stability of machining precision and surface quality caused by the insufficient rigidity of thin-walled cylinder piece in traditional process is solved.

Description

Technical Field

[0001] This invention belongs to the field of cylindrical component processing technology, specifically relating to a manufacturing process and positioning fixture for preventing deformation of cylindrical components. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] In the manufacturing of large-diameter thin-walled cylindrical components, deformation control during production remains a core technical challenge due to the structural characteristics of large diameter and thin wall thickness. Traditional manufacturing processes typically employ segmented welding to form the cylinder, which generates significant welding deformation, causing the initial shape and dimensions of the component to deviate severely from design requirements. To compensate for deformation and meet final dimensional tolerances, a conservative design strategy of increasing wall thickness is often forced upon the manufacturer. This approach not only directly results in a large waste of raw materials but also drastically increases the time and cost of subsequent machining due to the increased machining allowance, impacting overall production economics.

[0004] In the machining process, thin-walled cylindrical parts suffer from local and overall deformation due to clamping force during clamping due to insufficient rigidity; in the hoisting and transportation process, they suffer from gravity deformation due to their own weight; and in the cutting process, the low system rigidity easily induces chatter and tool vibration, which affects the stable achievement of machining accuracy and surface quality. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a manufacturing process and positioning fixture for preventing deformation of cylindrical components, which solves the problem of inconsistent machining accuracy and surface quality caused by insufficient rigidity of thin-walled cylindrical components in traditional processes.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: In a first aspect, the present invention provides a manufacturing process for preventing deformation of cylindrical components, comprising the following steps: Step 1: Determine the blank size based on the finished product size and the processing and welding shrinkage allowance. Use a segmented blanking scheme to divide the cylinder into multiple arc segments, with at least one arc segment having an additional welding shrinkage allowance on the basis of equal length. After blanking, each individual arc segment is rolled into a circle, and the roundness of the cylinder arc segment is checked in real time using an arc template. Step 2: Design and manufacture anti-deformation positioning jigs; assemble the segmented rolled arc segments one by one into the anti-deformation positioning jigs for positioning and spot welding, using a double-sided V-shaped bevel form, and complete the welding through a symmetrical welding process, and achieve the welding of the two sides by flipping the positioning jigs as a whole during the welding process. Step 3: Fabricate a dedicated base platform, on which multiple anti-vibration supports are designed. The anti-vibration supports are adjusted according to the processing steps: when machining the outer diameter, the anti-vibration supports are installed on the base platform inside the workpiece to support the cylinder from the inside; when machining the inner hole, the anti-vibration supports are installed on the base platform outside the workpiece to support the cylinder from the outside. Step 4: Using a vertical lathe, the welded cylindrical blank is securely connected to the base platform, and the entire piece is placed on the worktable of the vertical lathe for alignment. Roughing and finishing are performed sequentially. After machining, the upper jig is installed and rotated 180 degrees to remove the workpiece from the base platform. The lower jig is fixed on the vertical lathe, and the stop groove is machined based on the measured outer diameter. The cylindrical body is inserted into the stop groove and fixed. The anti-vibration support is installed and adjusted. The process threaded hole is removed, and the final dimensions are finished. Step 5: Dimensionally inspect the completed cylinder. If it passes inspection, remove the parts, repair them, clean them, and perform rust prevention treatment.

[0007] As a further implementation, in step one, the blank size parameters are: outer diameter Φ5770mm, inner diameter Φ5710mm, and height 700mm; the segmented blanking scheme specifically involves dividing the cylinder into 8 equally divided arc segments according to the circumference, of which 7 are equally long arc segments, and 1 arc segment has an additional welding shrinkage allowance on the basis of the equally divided length.

[0008] As a further implementation, in step two, the special anti-deformation positioning fixture includes a base platform, an upper plate, and a lower plate, which are used to provide support during the lifting and turning of the cylinder, and can be precisely matched with subsequent machining fixtures to achieve a unified benchmark for welding and processing.

[0009] As a further implementation method, in step two, the welding process is as follows: the arc segment is positioned and installed on the base platform, and the positioning is adjusted and fixed by spot welding after using the positioning and shock-absorbing support; after completing the welding on one side, the positioning and shock-absorbing support installed inside the cylinder is flipped over as a whole and then installed outside the cylinder to weld the weld on the other side.

[0010] As a further implementation, in step three, the base platform is designed with eight shock-absorbing supports. The main body of the shock-absorbing supports is made of steel, and the support parts that contact the workpiece are made of hard rubber.

[0011] As a further implementation method, in step four, the cylinder blank and the clamping base are fastened together with hexagonal screws, and the whole is placed on the vertical lathe workbench and the allowance is evenly distributed for alignment.

[0012] As a further implementation method, in step four, after the allowance is aligned, the top surface of the cylinder is first machined flat, and then the outer circle and inner hole are rough machined, leaving a allowance for finishing; then the inner and outer circles of the cylinder are finished to the finished size, and the actual size of the outer circle is recorded.

[0013] As a further implementation, in step four, after roughing and finishing, the workpiece is removed, the base is rotated 180 degrees and re-fixed to the vertical lathe, and the outer diameter of the positioning groove is machined to a tolerance of 0 to -0.1 mm, based on the recorded outer circle dimension.

[0014] Secondly, the present invention also provides a positioning fixture for the manufacturing process, comprising a base platform, an upper fixture plate, and a lower fixture plate; the base platform is used to accommodate and position segmented arc segments during the assembly welding process, and the base platform is provided with shock-absorbing support; the upper and lower fixture plates are used to cooperate during the welding process to achieve overall rotation and welding of both sides of the cylinder; the upper fixture plate has the function of providing effective support during the lifting and rotation of the cylinder, and can be precisely matched with subsequent machining tooling to achieve a unified reference.

[0015] As a further implementation, the upper tire plate is provided with lifting rings for hoisting.

[0016] Compared with the prior art, the advantages and positive effects of this invention are: This invention achieves precise deformation control throughout the entire process of large-diameter thin-walled cylindrical parts by employing segmented blanking to compensate for shrinkage, symmetrical welding to control thermal deformation, and combining specialized jigs and a shock-absorbing support system for clamping and cutting control. This solution successfully solves the persistent deformation problem of such parts, ensuring that the deformation after welding is stable at ≤2mm, the coaxiality after machining is ≤0.1mm, and the ellipticity in the free state is ≤2mm, fully meeting stringent technical specifications. Based on this systematic process assurance, the product qualification rate is significantly improved.

[0017] This invention changes the traditional method of compensating for deformation by "increasing wall thickness." While ensuring controlled deformation, production can be carried out directly according to the designed wall thickness, thus significantly reducing material consumption. Simultaneously, process optimization reduces repetitive processing and finishing steps, effectively saving processing time and costs. Furthermore, specialized tooling integrating hoisting, flipping, and positioning functions simplifies the process and reduces the number of tooling changes; while the introduction of anti-vibration supports not only improves processing stability and efficiency but also enhances the safety of hoisting and transportation, achieving a dual improvement in production efficiency and operational safety.

[0018] The injection molding production system of this invention includes an automatic raw material drying and conveying unit connected to a central control system, a skeleton placement robot, an injection molding machine, and a conveying and unloading line. It enables fully automated and digitalized control of the entire process from raw materials to finished products, shifting the reliance on process stability from human experience to equipment and system precision. It significantly reduces human intervention and operational errors, ensuring a high degree of consistency in product quality across different batches and shifts. Simultaneously, all process data is traceable, providing a data foundation for quality analysis and optimization. Attached Figure Description

[0019] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0020] Figure 1 This is a schematic diagram of the welding base fixture of the present invention.

[0021] Figure 2 This is a schematic diagram of the upper and lower tire plates of the present invention.

[0022] Figure 3 This is a schematic diagram of the shockproof support of the present invention.

[0023] In the diagram: 1. Base platform; 2. Shock-absorbing support; 3. Upper tire plate; 4. Lower tire plate; 5. Lifting ring; 6. Cylinder; 7. Support frame; 8. Ball-head threaded rod; 9. Support head base; 10. Positioning fixture. Detailed Implementation

[0024] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0025] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof. Example 1 This embodiment provides a manufacturing process for preventing deformation of cylindrical components, including the following steps: Step 1: Determine the blank size based on the finished product dimensions and machining / welding shrinkage allowance. Use a segmented cutting method to divide the cylinder into multiple arc segments, such as... Figure 1As shown, at least one arc segment has an additional welding shrinkage allowance on the basis of equal length division; after blanking, each single arc segment is rolled into a circle using a rolling machine, and the roundness of the 6 arc segments of the cylinder is checked in real time using an arc template to ensure that the curvature of each single arc segment meets the design requirements. Step 2: Design and manufacture an anti-deformation jig with hoisting and flipping support and machining reference functions; assemble the segmented rolled arc segments one by one into the anti-deformation jig for positioning and spot welding, using a double-sided V-shaped bevel, which ensures weld penetration and improves welding strength; complete the welding through a symmetrical welding process, reduce welding thermal deformation by evenly distributing welding heat, and achieve welding of both sides of the weld by flipping the jig as a whole during the welding process; Step 3: Fabricate a dedicated base platform, which is designed with multiple anti-vibration supports. These supports are adjusted according to the machining process: when machining the outer diameter, the anti-vibration supports are installed on the base platform inside the workpiece to support the cylinder from the inside; when machining the inner hole, the anti-vibration supports are installed on the base platform outside the workpiece to support the cylinder from the outside. The base platform is made of cast iron, with a soft material protective layer at the contact points with the workpiece. Multiple dedicated platforms for placing the anti-vibration supports are designed on the base platform. Detachable anti-vibration supports are also fabricated; the main body of the anti-vibration support is made of steel, and the support parts in contact with the workpiece are made of hard rubber. Step 4: Using a vertical lathe, the welded cylinder 6 blank is securely connected to the base platform and placed on the vertical lathe workbench for alignment. Roughing and finishing are performed sequentially. After machining, the upper jig is installed and rotated 180 degrees to remove the workpiece from the base platform. The lower jig is fixed on the vertical lathe, and the stop groove is machined based on the measured outer diameter. The cylinder 6 is then inserted into the stop groove using copper casting and secured with hammering. The anti-vibration support is installed and adjusted using dial indicator to ensure accurate support position. The threaded hole portion is removed, and the final dimensions are finished. The anti-vibration support is finely adjusted according to the machining status. The finishing operations of the inner hole and outer diameter are completed respectively. Step 5: Perform dimensional inspection on the completed cylinder 6. After passing the inspection, remove the parts, repair them, clean them, and perform rust prevention treatment.

[0026] As a further implementation, in step one, the blank size parameters are: outer diameter Φ5770mm, inner diameter Φ5710mm, and height 700mm; the segmented blanking scheme specifically involves dividing the cylinder 6 into 8 equally divided arc segments according to the circumference, of which 7 are equally long arc segments, and 1 arc segment has an additional welding shrinkage allowance on the basis of the equally divided length.

[0027] As a further implementation, in step two, such as Figure 2As shown, the special anti-deformation manufacturing jig includes a base platform, an upper jig plate, and a lower jig plate, which are used to provide support during the hoisting and turning of the cylinder, and can be precisely matched with subsequent machining tooling to achieve a unified benchmark for welding and processing.

[0028] As a further implementation method, in step two, the welding process is as follows: the arc segment is positioned and installed on the base platform, and the positioning is adjusted and fixed by spot welding after using the positioning and shock-absorbing support; after completing the welding on one side, the positioning and shock-absorbing support installed inside the cylinder is flipped over as a whole and then installed outside the cylinder to weld the weld on the other side.

[0029] As a further implementation, in step three, the base platform is designed with eight dedicated platforms for placing anti-vibration supports; the anti-vibration supports are adjusted according to the processing steps: when processing the outer circle, the anti-vibration supports are installed on the base platform inside the workpiece to support the cylinder 6 from the inside; when processing the inner hole, the anti-vibration supports are installed on the base platform outside the workpiece to support the cylinder 6 from the outside.

[0030] As a further implementation method, in step four, the blank of cylinder 6 is fastened to the clamping base with hexagonal screws, and the whole is placed on the vertical lathe workbench and the allowance is evenly distributed for alignment.

[0031] As a further implementation method, in step four, after the allowance is aligned, the top surface of the cylinder 6 is first machined flat, and then the outer circle and inner hole are rough machined, leaving a allowance for finishing; then the inner and outer circles of the cylinder 6 are finished to the finished size, and the actual size of the outer circle is recorded.

[0032] As a further implementation, in step four, after roughing and finishing, the workpiece is removed, the base is rotated 180 degrees and re-fixed to the vertical lathe, and the outer diameter of the positioning groove is machined to a tolerance of 0 to -0.1 mm, based on the recorded outer circle dimension.

[0033] Example 2 This embodiment provides a manufacturing jig for the aforementioned manufacturing process, including a base platform 1, an upper jig plate 3, and a lower jig plate 4. The base platform 1 is used to accommodate and position segmented arc sections during the assembly welding process, and the base platform 1 is equipped with anti-vibration supports 2. The upper jig plate 3 and the lower jig plate 4 are used to cooperate during the welding process to achieve the overall flipping and side welding of the cylinder 6. The manufacturing jig has the function of providing effective support during the lifting and flipping of the cylinder 6, and can accurately cooperate with subsequent machining tooling to achieve a unified reference. Figure 3 As shown, the shockproof support 2 includes a support frame 7, on which a ball-head threaded rod is installed. The ball-head threaded rod is connected to the support frame 7 by a thread. The ball end of the ball-head threaded rod is provided with a support head base 8 ball-head threaded rod 9, which is used to abut against the cylinder 6.

[0034] As a further implementation, the upper tire plate 3 is provided with lifting rings 5 ​​for lifting, which are used to flip the cylinder 6 by lifting equipment.

[0035] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A manufacturing process for preventing deformation of cylindrical components, characterized in that, Includes the following steps: Step 1: Determine the blank size based on the finished product size and the processing and welding shrinkage allowance. Use a segmented blanking scheme to divide the cylinder into multiple arc segments, with at least one arc segment having an additional welding shrinkage allowance on the basis of equal length. After blanking, each individual arc segment is rolled into a circle, and the roundness of the cylinder arc segment is checked in real time using an arc template. Step 2: Design and manufacture a deformation-resistant jig; assemble the segmented, rolled arc segments one by one into the deformation-resistant jig for positioning and spot welding, using a double-sided V-groove form, and complete the welding through a symmetrical welding process, and achieve the welding of the two sides by flipping the positioning jig as a whole during the welding process. Step 3: Fabricate a dedicated base platform, on which multiple anti-vibration supports are designed. The anti-vibration supports are adjusted according to the processing steps: when machining the outer diameter, the anti-vibration supports are installed on the base platform inside the workpiece to support the cylinder from the inside; when machining the inner hole, the anti-vibration supports are installed on the base platform outside the workpiece to support the cylinder from the outside. Step 4: Using a vertical lathe, the welded cylindrical blank is securely connected to the base platform, and the entire piece is placed on the worktable of the vertical lathe for alignment. Roughing and finishing are performed sequentially. After machining, the upper jig is installed and rotated 180 degrees to remove the workpiece from the base platform. The lower jig is fixed on the vertical lathe, and the stop groove is machined based on the measured outer diameter. The cylindrical body is inserted into the stop groove and fixed. The anti-vibration support is installed and adjusted. The process threaded hole is removed, and the final dimensions are finished. Step 5: Dimensionally inspect the completed cylinder. If it passes inspection, remove the parts, repair them, clean them, and perform rust prevention treatment.

2. The manufacturing process for preventing deformation of cylindrical components as described in claim 1, characterized in that, In step one, the blank dimensions are: outer diameter Φ5770mm, inner diameter Φ5710mm, and height 700mm. The segmented blanking scheme specifically involves dividing the cylinder into 8 equally divided arc segments along its circumference, of which 7 are equally long arc segments and 1 arc segment has an additional welding shrinkage allowance on the basis of the equally divided length.

3. The manufacturing process for preventing deformation of cylindrical components as described in claim 1, characterized in that, In step two, the special anti-deformation manufacturing jig includes a base platform, an upper jig plate, and a lower jig plate, which are used to provide support during the hoisting and turning of the cylinder, and can be precisely matched with subsequent machining tooling to achieve a unified benchmark for welding and processing.

4. The manufacturing process for preventing deformation of cylindrical components as described in claim 1, characterized in that, In step two, the welding process is as follows: the arc segment is positioned and installed on the base platform, and the positioning is adjusted and fixed by spot welding after using the positioning and shock-absorbing support; after completing the welding on one side, the positioning and shock-absorbing support installed inside the cylinder is flipped over as a whole and then installed outside the cylinder to weld the other side.

5. The manufacturing process for preventing deformation of cylindrical components as described in claim 1, characterized in that, In step three, the base platform is designed with eight shock-absorbing supports. The main body of the shock-absorbing supports is made of steel, and the support parts that contact the workpiece are made of hard rubber.

6. The manufacturing process for preventing deformation of cylindrical components as described in claim 1, characterized in that, In step four, the cylinder blank and the clamping base are fastened together with hexagonal screws, and the whole thing is placed on the vertical lathe workbench and the allowance is evenly distributed for alignment.

7. A manufacturing process for preventing deformation of cylindrical components as described in claim 6, characterized in that, In step four, after the allowance is aligned, the top surface of the cylinder is first machined flat, followed by rough machining of the outer circle and inner hole, leaving allowance for finishing; then the inner and outer circles of the cylinder are finished to the finished size, and the actual size of the outer circle is recorded.

8. The manufacturing process for preventing deformation of cylindrical components as described in claim 7, characterized in that, In step four, after roughing and finishing, the workpiece is removed, the base is rotated 180 degrees and re-fixed on the vertical lathe, and the outer diameter of the positioning groove is machined to a tolerance of 0 to -0.1 mm, using the recorded outer diameter as a reference.

9. A jig for manufacturing a cylindrical component anti-deformation manufacturing process as described in any one of claims 1-8, characterized in that, It includes a base platform, an upper jig plate, and a lower jig plate; the base platform is used to accommodate and position the segmented arc segments during the assembly welding process, and the base platform is equipped with anti-vibration support; the upper jig plate and the lower jig plate are used to cooperate during the welding process to realize the overall flipping of the cylinder and welding on both sides; the upper jig plate has the function of providing effective support during the lifting and flipping of the cylinder, and can be precisely cooperated with subsequent machining tooling to achieve a unified reference.

10. The die-making tool according to claim 9, characterized in that, The upper jig plate is equipped with lifting rings for hoisting.

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