CN102886639A - 一体铸造的控制体的加工方法 - Google Patents

一体铸造的控制体的加工方法 Download PDF

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CN102886639A
CN102886639A CN2012102536993A CN201210253699A CN102886639A CN 102886639 A CN102886639 A CN 102886639A CN 2012102536993 A CN2012102536993 A CN 2012102536993A CN 201210253699 A CN201210253699 A CN 201210253699A CN 102886639 A CN102886639 A CN 102886639A
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CN102886639B (zh
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迈克尔·J·哈贝尔
德里克·金奇
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Ford Global Technologies LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B23C3/02—Milling surfaces of revolution
    • B23C3/05—Finishing valves or valve seats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B23C3/28—Grooving workpieces
    • B23C3/34—Milling grooves of other forms, e.g. circumferential
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C5/00—Milling-cutters
    • B23C5/28—Features relating to lubricating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P13/00—Making metal objects by operations essentially involving machining but not covered by a single other subclass
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16K—VALVES; TAPS; COCKS; ACTUATING-FLOATS; DEVICES FOR VENTING OR AERATING
    • F16K27/00—Construction of housing; Use of materials therefor
    • F16K27/04—Construction of housing; Use of materials therefor of sliding valves
    • F16K27/041—Construction of housing; Use of materials therefor of sliding valves cylindrical slide valves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2222/00—Materials of tools or workpieces composed of metals, alloys or metal matrices
    • B23C2222/04—Aluminium
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49405—Valve or choke making
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49405—Valve or choke making
    • Y10T29/49409—Valve seat forming
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49405—Valve or choke making
    • Y10T29/49412—Valve or choke making with assembly, disassembly or composite article making
    • Y10T29/49416—Valve or choke making with assembly, disassembly or composite article making with material shaping or cutting
    • Y10T29/49419—Valve or choke making with assembly, disassembly or composite article making with material shaping or cutting including machining or drilling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49405—Valve or choke making
    • Y10T29/49426—Valve or choke making including metal shaping and diverse operation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T408/00—Cutting by use of rotating axially moving tool
    • Y10T408/03—Processes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T409/00—Gear cutting, milling, or planing
    • Y10T409/30—Milling
    • Y10T409/303752—Process
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/02—Other than completely through work thickness
    • Y10T83/0304—Grooving
    • Y10T83/0311—By use of plural independent rotary blades
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/384—By tool inside hollow work
    • Y10T83/395—One tool having only rectilinear motion[s]
    • Y10T83/398—Internal tool is an active cutter
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T83/00—Cutting
    • Y10T83/929—Tool or tool with support
    • Y10T83/9372—Rotatable type
    • Y10T83/9408—Spaced cut forming tool

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Abstract

一种用于形成阀门的方法，包括形成阀体，通过将具有刀口的工具沿轴线穿入阀体加工孔，通过绕圆周旋转工具在孔中轴向间距位置加工凹槽和表面，所述圆周的中心与孔对齐，以及在通过工具的气流中向刀口提供润滑剂。

Description

一体铸造的控制体的加工方法
技术领域
本发明总体上涉及一种用于制造调节阀的方法，所述调节阀由位于用于自动变速箱的经过机械加工的主控制铸件中的直动式螺线管控制。
背景技术
自动变速箱包括用于调节液压的液压系统和流动在连接到变速箱组件的各种线路中的液压液体。该系统包括封装在主控制铸件中的调节器短管阀，所述主控制铸件在变速箱生产厂机械加工。所述铸件，优选为铝合金，通常称为阀体。所述系统的组件装配在阀体中。
螺线管驱动的换挡油阀控制着由阀门向离合器或制动器传递的压力，离合器或制动器的啮合和解离状态决定变速箱中齿轮的运转。但是，大多数阀体铸件叠加的尺寸公差过大，不能允许实用的集成式电磁体的使用以及实现所需的流量和压力调节精度。
具有直动式螺线管的变速箱需要一种方法来向离合器和制动器提供用于高扭矩操作条件的液压，使得压力能够独立于适于换档控制的控制压力范围传递。
业内需要一种用于在阀体中加工阀门的方法，使得阀门的一些特征的规格和相关公差超精密。关键的特征，比如槽和表面，最好在单个操作中用采用最低量润滑加工工艺的处理设备同时加工。
发明内容
一种用于形成阀门的方法，包括形成阀体，通过将具有刀口的工具沿轴线穿入阀体加工孔，通过绕圆周旋转工具在孔中轴向间距位置加工凹槽和表面，所述圆周的中心与孔对齐，以及在通过工具的气流中向刀口提供润滑剂。
所述方法使用环形内插法加工工艺，同时机械加工多个关键性功能特征。
所有需要精确的相对位置的边缘在单一的操作中切割，以改进公差和生产效率。计量边缘48，49精密加工，而非铸造，用于改善边缘质量、定位精度和无锥度。高精确度公差能够使液压液体泄漏和压力调节精度严密控制。
优选实施例的适用范围将通过以下详细说明、权利要求和附图变得显而易见。应该理解，所述说明书和具体实例尽管表明了本发明的优选实施例，但仅通过示例的方式给出。对于本技术领域的技术人员来说，所述实施例和实例的各种变化和修改是显而易见的。
附图说明
结合附图参照以下说明会更容易理解本发明，其中：
图1是通过成型于阀体中的一体铸造的直动式螺线管阀门径面的截面图；
图2是用于加工如图1所示阀门的工具的俯视图和端视图的示意图；以及
图3是如图2所示工具的俯视图。
具体实施方式
如图1所示的一体铸造的直动式螺线管液压阀门10成型于由铸造金属形成的阀体12中，所述铸造金属优选为铝合金。所述阀门10包括具有槽脊16-19的阀槽14；调节器22；穿过调节器延伸并接触阀槽14的电枢销24；电磁螺线管26，当螺线管26通电时驱动销24向左运动，而当螺线管螺管断电时允许阀槽轴向移动。
阀体12具有控制端口30、42，通过该端口控制压力与含有阀槽14的室32相通；管道压力端口34，通过该端口管道压力与室相通；液箱端口36，通过该端口液压液体从室流向低压液箱；以及排出端口38、40，通过该端口室32与低压源相通。
调节器22持续地保持与安装基准面接触，即，参考表面46形成于液箱端口36中。由弹性扣板产生、固定到密封螺线管螺管26的壳体的外表面的弹力维持调节器22与表面46接触并建立螺线管模块50的正确的轴向位置。所述螺线管模块50包括调节器22、螺线管螺管26、壳体45以及弹簧28。
如图1所示，控制槽脊17、18、19的直径与槽脊16的直径大体上相同但稍大。槽脊16-19在孔70中加工。槽脊16的直径形成大直径的阀槽末端阻尼器60用于增加稳定性，允许使用较大直径的防污染的阻尼器端口。阻尼器60在反馈通路64的外面形成，用于最小化反馈延迟和改进稳定性。相对于槽脊16和17的直径之差，阻尼器60的直径较大。
由于与基准表面46接触，调节器22的轴向表面64定位在室32中，以致当螺线管26断电而阀槽14在室中向右移动时，槽脊19在电枢销24接触螺线管的止动表面之前接触表面64。通过这种方式，阀槽末端特征提供前挡块用于螺线管模块50的强制超程保护。
如图2和图3所示，单一切割工具68在阀体12的孔70中加工凹槽72，阀体12与孔70的轴线同心。工具68同时在阀体12中加工（i）在控制端口30的计量边缘48、49二者，(ii)连接边缘48、49的径向凹槽72以及(iii)液箱端口36上的安装基准面或参考表面46。表面74定位在槽底72的径向外侧。
所有需要精确的相对位置的边缘在单一操作中切割，以改进公差和生产效率。计量边缘48、49精确加工，而非铸造，用于改善边缘质量、定位精度和无锥度。高精确度公差能够使液压液体泄漏和压力调节精度严密控制。紧公差能够利用短行程磁性部分50进行流动控制。
切割工具68具有精确的轴向定向的柄76。第一支承刀口78由柄76径向延伸，并且包括用于在阀体12中形成凹槽72的刀口80，所述凹槽通过在控制端口30上的内部计量边缘48和外部计量边缘49限定。第二支承刀口82与支承刀口78轴向隔开并且由柄76径向延伸，包括用于形成参考表面46的刀口84，该参考表面形成于液箱端口34上。
所有精确孔的直径和鞋面以及阀门10的其他特征在使用切割工具68之前都是用现有标准切割工具半加工的，或者可以在完整的孔70完成加工之后完成。
径向端口30、34、36、38、40和42随后用其他切割工具形成。
切割工具68运行时需要润滑剂，润滑剂置于沿着柄76的轴向通路86和沿着支承刀口78、82到刀口80、84的径向通路88、90中。气流，优选为压缩气流，带着润滑剂通过通路86、88、90到达刀口80、84，优选气流流量在每小时10-200ml范围内。通路88、90的大小应该实现从每个出口的流量稳定和等量。
优选润滑剂是CareCutTM ES1NA，一种可从嘉实多（Castrol）购买到的不含氯和重金属的清洁切削油。
在孔70半完成或完成加工之后，通过使切割工具68的轴92沿着圆周94旋转在孔中加工设定边缘48、49的径向槽72以及安装基准面或参考表面46，所述圆周的中心与孔70的轴对齐，其半径与计量边缘48、49和支承刀口80的外径之间的径向距离实质相等。
在先前或后续的处理步骤中，控制体铸件的精确直径和表面使用工业化标准钻孔器完成加工。
依照专利法的规定，优选实施方式已经阐述如上。但是，应该注意到的是，不同于已详细阐述和说明的其他可替代实施方式同样能够实施。

Claims (6)

1.一种用于形成阀门的方法，其特征在于，包含：
（a）形成阀体；
（b）通过将具有刀口的工具沿轴线穿入阀体加工孔；
（c）在铸件端口中通过绕圆周旋转工具在孔中轴向间距位置加工凹槽和表面，所述圆周的中心与孔对齐；
（d）在通过工具的气流中向刀口提供润滑剂。
2.如权利要求1所述的方法，其特征在于，步骤（a）中进一步包含形成铸造金属的阀体。
3.如权利要求1所述的方法，其特征在于，步骤（b）进一步包含：
在使用工具在阀体中加工凹槽和表面之前，使用第二切割工具将孔表面加工成半成品。
4.如权利要求1所述的方法，其特征在于，步骤（b）进一步包含：
在使用所述工具在阀体中加工凹槽和表面之后，使用钻孔器完成阀门加工。
5.如权利要求1所述的方法，其特征在于，步骤（c）进一步包含：
当工具旋转时，绕圆周旋转所述工具，该圆周中心与孔对齐，其半径与凹槽半径和加工凹槽的工具的刀口外径之间的径向距离实质上相等。
6.如权利要求1所述的方法，其特征在于，步骤（d）进一步包含：
在通过工具中的通路的加压气流中提供润滑剂，所述通路将气流中的润滑油带到工具的刀口。
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