CN105634430B - 铝制音叉加工工艺 - Google Patents
铝制音叉加工工艺 Download PDFInfo
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- H—ELECTRICITY
- H03—ELECTRONIC CIRCUITRY
- H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
- H03H3/00—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators
- H03H3/007—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks
- H03H3/02—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks for the manufacture of piezoelectric or electrostrictive resonators or networks
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- H—ELECTRICITY
- H03—ELECTRONIC CIRCUITRY
- H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
- H03H3/00—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators
- H03H3/007—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks
- H03H3/02—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks for the manufacture of piezoelectric or electrostrictive resonators or networks
- H03H3/04—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks for the manufacture of piezoelectric or electrostrictive resonators or networks for obtaining desired frequency or temperature coefficient
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- H—ELECTRICITY
- H03—ELECTRONIC CIRCUITRY
- H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
- H03H3/00—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators
- H03H3/007—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks
- H03H3/02—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks for the manufacture of piezoelectric or electrostrictive resonators or networks
- H03H2003/026—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks for the manufacture of piezoelectric or electrostrictive resonators or networks the resonators or networks being of the tuning fork type
-
- H—ELECTRICITY
- H03—ELECTRONIC CIRCUITRY
- H03H—IMPEDANCE NETWORKS, e.g. RESONANT CIRCUITS; RESONATORS
- H03H3/00—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators
- H03H3/007—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks
- H03H3/02—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks for the manufacture of piezoelectric or electrostrictive resonators or networks
- H03H3/04—Apparatus or processes specially adapted for the manufacture of impedance networks, resonating circuits, resonators for the manufacture of electromechanical resonators or networks for the manufacture of piezoelectric or electrostrictive resonators or networks for obtaining desired frequency or temperature coefficient
- H03H2003/0414—Resonance frequency
- H03H2003/0492—Resonance frequency during the manufacture of a tuning-fork
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Abstract
本发明公开了一种铝制音叉加工工艺,包括浇注毛坯,用融化的铝水浇注出长条形的铝制毛坯;冷拉拔,将铝制毛坯从拉拔模的模孔中拉出,将铝制毛坯的厚度拉至与音叉厚度相近;落料,将铝制毛坯切断至长度与音叉接近;铣叉股,将铝制毛坯的一端固定在铣床上,对另一端的中部铣槽,加工出音叉的两个叉股;车叉柄,将两个叉股固定在车床上,对另一端进行车削,加工出叉柄;研磨;对音叉毛坯进行研磨,将音叉表面的粗糙度保持在Ra0.8~1.6,旨在提供一种生产效率高、成本低的铝制音叉。
Description
技术领域
本发明涉及音叉的加工工艺,更具体地说,它涉及一种铝制音叉加工工艺。
背景技术
音叉(tuning fork)是呈“Y”形的钢质或铝合金发声器,各种音叉可因其质量和叉臂长短、粗细不同而在振动时发出不同频率的纯音,在教学中,音叉可以用来演示共振。
目前市场上的音叉普遍是钢材经锻打之后再经研磨等步骤制成,而在申请号为CN201010617322.2的中国发明专利中公开了一种石英音叉的加工方法,其特征在于,加工步骤如下:A)原料片研磨,将原料片研磨至规定厚度;B)抛光,原料片表面抛光处理,使其成为镜面;C)涂胶光刻,在原料片上涂上光刻胶,利用光刻技术使光刻胶形成音叉形状;D)腐蚀,将光刻后的原料片放入腐蚀液中;E)清洗,洗去表面残留的光刻胶。完成后的音叉尺寸为长度:3170~3185μm,宽度:495~515μm,厚度:125~145μm。
上述两种加工音叉的方法都普遍存在几个问题:一是加工周期长,锻打、研磨的加工用时过长,生产效率低;二是加工成本大,钢材成本高,高温锻打耗能大、石英音叉加工工具磨损大,频繁更换工装导致生产加工成本上升。
发明内容
针对现有技术存在的不足,本发明的目的在于提供一种加工效率高、生产成本低的铝制音叉加工工艺。
一种铝制音叉加工工艺,包括以下步骤:S1、浇注毛坯,用融化的铝水浇注出长条形的铝制毛坯;S2、冷拉拔,将铝制毛坯从拉拔模的模孔中拉出,将铝制毛坯的厚度拉至与音叉厚度相近;S3、落料,将铝制毛坯切断至长度与音叉接近;S4、铣叉股,将铝制毛坯的一端固定在铣床上,对另一端的中部铣槽,加工出音叉的两个叉股;S5、车叉柄,将两个叉股固定在车床上,对另一端进行车削,加工出叉柄;S6、研磨;对音叉毛坯进行研磨,将音叉表面的粗糙度保持在Ra0.8~1.6。
进一步的,S2中的拉拔模为合金钢模。
进一步的,在S2中,铝制毛坯先经过挥发油浸泡,再通过拉拔模拉拔。
通过采用上述技术方案,利用特殊铝合金的拉拔成型的新技术代替的原本的钢材锻打成型工艺,生产加工效率显著提高,而且材料成本、加工成本大大降低,加工出品的音叉具有良好的防锈抗腐蚀性能。
本发明还进一步设置为:S1中的铝制毛坯在浇注成型后,放置在150℃~200℃的温度下并保持30~50小时。
通过采用上述技术方案,在人工时效处理作用下,去除铝制毛坯中的残余应力、防止变形及开裂。稳定组织以稳定零件形状及尺寸。
本发明还进一步设置为:在S1的浇注过程中按每1000重量份的铝液中加入合金助剂,该合金助剂由100重量份的聚乙烯醇,0.5重量份的锌粉,0.5重量份的铜粉,0.5重量份的镁粉,3重量份的氟铝酸钾,3重量份的有机酸组成。
通过采用上述技术方案,利用铝浇注时的高温条件,使得合金助剂与铝液产生渗透反应形成固溶体,从而取得更高的硬度,令加工出的铝制毛坯在后续加工中可以更好的被切削而不至于产生变形。
具体实施方式
实施例一:一种铝制音叉加工工艺,包括以下步骤:第一步:浇注毛坯,浇注温度在690℃~740℃为宜,在浇注模具中用融化的铝水浇注出长条形的铝制毛坯;第二步;冷拉拔,将铝制毛坯从拉拔模的模孔中拉出,将铝制毛坯的厚度拉至与音叉厚度相近,冷拉拔成形工艺是指常温时,将管材或棒材在外加拉力的作用下迫使金属坯料通过固定在设备上的拉拔模具,并产生一定的塑性变形,从而获得与模孔截面形状尺寸相一致的产品的加工方法,此步骤中的拉拔模采用合金钢模,铝材在拉拔过程中形变量大,相对的产生的热量也大,而合金钢的红硬性好,保证在高温下尺寸的稳定、精确。鉴于铝的冷拉拔工艺已经较为成熟,在本实施例中就不做赘述。第三步:落料,将铝制毛坯切断至长度与成品音叉接近,裁出的毛坯长度优选大于成品音叉长度约10mm~20mm,作为后续加工的余量,另外优选采用较大吨位的冲床进行裁切落料,如20t或40t的冲床,避免冲裁毛刺产生;第四步:铣叉股,将铝制毛坯的一端固定在铣床上(该端作为叉柄端),从另一端(叉股端)端面的中部开始向固定端进行纵向铣槽,加工出音叉的两个叉股,为防止毛坯在铣槽时震动影响铣槽效果,所以优选在固定叉柄端后,继续用夹具固定叉股端的两侧;第五步:车叉柄,将两个叉股固定在车床上,对另一端进行旋转车削,加工出叉柄;需注意的是,将车叉股放在叉柄之后,可以避免先加工完叉柄再加工叉股时,因叉柄较细导致其固定不稳影响加工精度,同时也避免加固固定叉柄时夹上叉柄。第六步:研磨,对音叉毛坯进行研磨,将音叉表面的粗糙度保持在Ra0.8~1.6。
实施例二:与实施例一的区别仅在于在第二步中,铝制毛坯先经过挥发油浸泡,再通过拉拔模拉拔。利用挥发油的挥发带走铝材变形时产生的热量,从而进一步保证铝材拉拔过程中尺寸的稳定。
实施例三:与实施例一的区别仅在于在第一步铝制毛坯的浇注过程中,按每1000重量份的铝液中加入合金助剂。方案一:该合金助剂是在常温状态下由100重量份的聚乙烯醇,0.5重量份的锌粉,0.5重量份的铜粉,0.5重量份的镁粉,3重量份的氟铝酸钾,3重量份的有机酸均匀混合而成。方案二:该合金助剂是在常温状态下由100重量份的聚乙烯醇,0.5重量份的锌粉,0.5重量份的铜粉,0.5重量份的镁粉,3重量份的氟铝酸钾均匀混合而成。方案三:该合金助剂是在常温状态下由100重量份的聚乙烯醇,0.5重量份的锌粉,0.5重量份的铜粉,0.5重量份的镁粉,3重量份的有机酸均匀混合而成。
经检测浇注成型后铝制毛坯的硬度(布式硬度HB):
方案一:102~110,方案二:53~60;方案三:55~61,。可见利用方案一产出的铝制毛坯的硬度得到了显著提升。在本合金助剂中,聚乙烯醇用于均匀分散各个组分,锌粉、铜粉、镁粉则与铝渗透反应形成合金,从而获得铝—锌—镁—铜系超硬铝合金,其中的氟铝酸钾则能使得各合金元素更好的结合,氟铝酸钾是焊助剂的主要成分,能够在熔融状态下,消除位于金属表面的氧化膜,能够使得浇注过程中,铜、锌、镁、铝在没有氧化膜的干扰下,能够起到更好的结合。利用浇注铝时690℃~740℃的温度,令有机酸能够在该高温下持续除去在金属表面产生的氧化膜,能够进一步保证了不同金属间的结合,同时因其较小的离子污染残留物和到高的表面抗绝缘性,被认为是最好的助焊剂。有机酸系非离子表面活性剂的加入主要是为了能够消除熔融浇注过程中产生的气泡,而离子型的表面活性剂往往会对金属有进一步腐蚀作用,非离子型着不会有这样的问题,进一步保护了金属材料。同时有机酸系的表面活性剂,往往与有机酸的结构相近,两者相容性较好,能够充分分散,同时在部分表面活性剂发生分解后,依然能够作为有机酸对整个浇注过程起到去除氧化膜的效果。
以上所述的实施例仅仅是对本发明的优选实施方式进行描述,并非对本发明的范围进行限定,再不脱离本发明设计精神的前提下,本领与普通技术人员对本发明的技术方案做出的各种变形、改进等同替换均应落入本发明权利要求书确定的保护范围之内。
Claims (4)
1.一种铝制音叉加工工艺,包括以下步骤:
S1、浇注毛坯,用融化的铝水浇注出长条形的铝制毛坯,浇注过程中按每1000重量份的铝液中加入合金助剂,该合金助剂由100重量份的聚乙烯醇,0.5重量份的锌粉,0.5重量份的铜粉,0.5重量份的镁粉,3重量份的氟铝酸钾,3重量份的有机酸组成;
S2、冷拉拔,将铝制毛坯从拉拔模的模孔中拉出,将铝制毛坯的厚度拉至与音叉厚度相近;
S3、落料,将铝制毛坯切断至长度与音叉接近;
S4、铣叉股,将铝制毛坯的一端固定在铣床上,对另一端的中部铣槽,加工出音叉的两个叉股;
S5、车叉柄,将两个叉股固定在车床上,对另一端进行车削,加工出叉柄;
S6、研磨;对音叉毛坯进行研磨,将音叉表面的粗糙度保持在Ra0.8~1.6。
2.根据权利要求1所述的一种铝制音叉加工工艺,其特征在于:S2中的拉拔模为合金钢模。
3.根据权利要求1或2所述的一种铝制音叉加工工艺,其特征在于:在S2中,铝制毛坯先经过挥发油浸泡,再通过拉拔模拉拔。
4.根据权利要求1所述的一种铝制音叉加工工艺,其特征在于:S1中的铝制毛坯在浇注成型后,放置在150℃~200℃的温度下并保持30~50小时。
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