标题: new era kepsar, 0.1mm [打印本页] 作者: joxrsnvoz 时间: 2013-8-14 16:12 标题: new era kepsar, 0.1mm Spherical differential case Turney and tool design
differential spherical shell processing more difficult. According to the differential use of performance requirements, dimensions and location of the housing in order to ensure the degree of precision, the structure was designed using tipped drill and countersink the inner spherical surface aids (countersink certain extent within the sphere Arbor device). However, the spherical countersink drill manufacturing and sharpening more difficult,new era kepsar, and after tool wear once for each tooth grinding, tooth points on the surface to be machined with the positional relationship between corresponding points have changed, and thus directly affect within the sphere processing quality, because the spherical countersink drill sharpening post processing parts position error is often greater than f 0.2mm, it is difficult to fully meet the processing requirements.
machine folder indexable turning heads turning arbor groove geometry design known parameters : Blade France backward angle anb = 7 °, blade edge inclination lsb = 0 °; turning independent perspective kr = 62.5 °, ls = 4 °, pre-clearance angle ao = 4 °; Arbor tank main angle krg = kr = 62.5 °, shank groove edge inclination lsg = ls = -4 °. The rake angle gog Arbor tank can be calculated as: tangog = (tananb-a0/cosls) / 1 + tananbtanao / cosls) coslsg = 0.052364957 available aog = 2.9975528 °, taking aog = 3 °. After checking the turning angle ao: arctan (tananb-tanaogcoslsg) cosls / (1 + tananbgogcoslsg) = 0.06992572 available ao = 3.99 °, with a preselected angle ao = 4 ° after the close, indicating that the preselection value after a reasonable angle.
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tool clamping structure using threaded pin, screw clamp the blade through the blade sink hole, simple structure, fewer parts, high precision, high repeatability indexable cutting edges, large chip space. Be processed according to material characteristics, and consider the process of cutting edge wear, using TiC + Al2O3 + TiN composite coating blade. The blades can reduce the friction of the chip and the tool,new era snapback, the cutting temperature can still maintain high hardness and good oxidation resistance, thereby improving tool life, reduce the surface roughness of parts. In addition, the use of heat treatment company developed new technology to add on TiC based cemented carbide TiN, can significantly improve the thermal conductivity of the blade and chipping resistance in micro-machining and surface machining high precision can give full play to TiC based alloy performance advantages.
differential housing fracture CAE computational analysis
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1. Machine tool design ideas and features folder indexable turning tools is to have a reasonable geometry and cutting edges of the finished indexable by mechanical clamping means mounted on the arbor, when a cutting work added to the blade wear can not be reused, it can be replaced quickly by a new indexable cutting edges.
determine indexable turning toolholder shank and coupling means : Depending on the machine type and center height, to increase the intensity Arbor, Arbor section size ranging cross-section is designed to , loaded folders and Arbor knife self-locking coupling through the wedge surface,casquettes new era, the tool allows loading and unloading fast, accurate and reliable. The machine design indexable turning head clamp shown in Figure 2. Used machine folder indexable turning method instead of the original spherical countersink processing method, without making special fixture, a fixture on the CNC machine can be completed within a spherical differential case processing. Due to reduced working hours and other auxiliary tool to improve the efficiency of CNC machining, tool without sharpening, improve durability, so that the production efficiency by 2-fold, 75% reduction in tool costs. As a result of processing methods to avoid the original tool regrinding machining errors caused by the product quality has been effectively guaranteed.
roll groove CNC Turning 3D dynamic simulation of
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In addition, within the spherical countersink higher processing methods on the fixture, you need to configure certain extent device to control the tool feed, so that the fixture design and manufacturing complex. To solve this problem, we plan based on product characteristics of the process were repeated research, decided to use the S1-325 CNC Turning on the method of using a differential supplement countersink alternative processing methods to achieve within a spherical shell spherical differential processing, and Design a dedicated machine folder indexable turning tools.
non-standard tool design handbook
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folder using the machine for processing indexable turning tool has the following features : cutting tool geometry and stability , high positioning accuracy and repeatability , the edge position can be changed to ensure the accuracy of the workpiece and the machining accuracy of the allowable range of consistency. insert clamping reliable , in the cutting force shock, vibration and thermal effect of cutting is not easy to loose. long tool life , no sharpening, simple operation, and other auxiliary tool can shorten stopping work. Arbor translocation convenient, fast, and can be used repeatedly, long life, can reduce inventory and simplify tool management. Machine folder indexable turning tools designed rake angle g = -4 °, blade angle l = -4 °, the cutting edge has sufficient strength to withstand the impact of a large cutting forces, to avoid chipping tip. Indexable inserts used car GB Universal diamond blade cutting process ensures automatic volume curve machining debris and smooth, and easy to implement tool standardization, serialization, suitable for automated production profile turning.
cutting: cutting speed vc = 2m / s, feed rate f = 0.4mm / r, cutting depth ap = 3mm. Machine tools: S1-325 CNC machine tools. Tool design steps are as follows: According to the parts to be machined materials and processing requirements, blade carbide substrate material selection YG6 new composite coating (TiC + Al2O3 + TiN) blade. According to characteristics of parts to be machined and the cutting parameters, the blade is designed to form the fastening screw pin is press-hole structure. Indexable type chosen diamond GB Universal blades, knives sharp is 55 °, France backward angle of 7 °, one side has a V-type chipbreaker, blade thickness S = 3.97, nose radius re = 0.4 ± ; 0.1mm; according to machining accuracy, precision blade used M-Class. OK indexable model DCMT11T304-V1. Blade cutting edge length Sa = ap / sinkrcosl = 3/sin62.5 ° cos-4 ° = 3.39mm; roughing cutting edge length should satisfy L ≥ 1.5Sa = 5.086mm, the selected main cutting edge blade edge length L ≈ 11.6mm, can meet the cutting requirements.
2. Cutter design methods to be processed within the sphere of the differential housing sizes are S = f138.5mm, f124mm, f161mm. Workpiece material: Ductile iron GH45-33-15 (core hardness HB150 ~ 190). Machining accuracy: position relative to the reference tolerance of f0.03mm, surface roughness Ra1.6μm.
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