CN110076536B

CN110076536B - Step-by-step processing method of overlong turnout switch rail

Info

Publication number: CN110076536B
Application number: CN201910490467.1A
Authority: CN
Inventors: 王永波
Original assignee: Xintie Deou Turnout Co ltd
Current assignee: Xintie Deou Turnout Co ltd
Priority date: 2019-06-06
Filing date: 2019-06-06
Publication date: 2020-10-13
Anticipated expiration: 2039-06-06
Also published as: CN110076536A

Abstract

The invention provides a step-by-step processing method of an ultra-long turnout switch rail, which utilizes the existing short-stroke machine tool to perform step-by-step processing on the ultra-long turnout switch rail, realizes complete continuation of drilling and milling by moving a workpiece and accurately positioning the workpiece, and greatly reduces the equipment investment cost or the switch rail inlet cost.

Description

Step-by-step processing method of overlong turnout switch rail

Technical Field

The invention relates to the technical field of steel rail processing, in particular to a step-by-step processing method of an overlong turnout switch rail.

Background

With the rapid development of the passenger high-speed railway in China, the application of large turnouts is more and more extensive, such as 42#, 50#, 62# and the like. The large turnout has the characteristics of high passing speed and comfortable riding of the locomotive.

The overlength switch tongue is one of the main parts widely used in high-speed railway switches, and has the characteristics of large length specification, strong bearing capacity and high precision requirement. The ultra-long turnout switch rail is machined by one-step clamping, the required machine tool has a long stroke, and the machine tool is directly imported into finished products or developed long-stroke machining equipment.

Disclosure of Invention

Aiming at the problems, the invention provides a step-by-step processing method of an overlong turnout switch rail, which utilizes the existing short-stroke numerical control machine to carry out step-by-step processing on the overlong turnout switch rail, thereby greatly reducing the equipment investment cost or the switch rail import cost.

A step-by-step processing method of an ultra-long turnout switch rail comprises the following steps:

1. placing one end of the steel rail, which contains a reference end face, in a machine tool stroke range, and machining bolt holes in the machine tool stroke range by aligning the steel rail reference end face (a tip or a heel);

the length limit deviation control of the high-speed turnout switch rail is relatively loose relative to the machining precision requirement of a bolt hole, so that in the step-by-step drilling process, in order to ensure the precision, the respective end heads in a machining area cannot be completely used as tool setting references for machining;

2. and moving the workpiece, moving the adjacent unprocessed hole section and the last bolt hole processed in the previous time into the stroke range of the machine tool, calculating the zero point coordinate of the actual reference end surface by using the existing coordinate value and the positioning size of the last bolt hole processed in the previous time, and processing the bolt hole of the section.

3. If an unprocessed hole section exists after the step 2 is finished, continuously moving the workpiece, and processing the bolt hole of the next section until all the bolt hole cutters are connected;

4. moving a workpiece, moving the tip of the switch rail and the front variable cross-section area to a machine tool stroke range, taking the end face of the tip as a reference, firstly milling while not working, then carrying out rough milling and finish milling while working, and finally finishing rail bottom milling;

5. moving a workpiece, moving the end surface of the heel end of the switch rail and part of the working side milling tail end to the stroke range of a machine tool, taking the end surface of the heel end of the switch rail as a processing reference, slowly entering and slightly cutting the switch rail in a range of 2-3m away from the working side milling tail end by adopting a travelling face milling cutter, and covering the forming size of the working side milling cutter for subsequent milling; the straightness requirements of the working edge and the rail top of the high-speed switch point rail are high, and the straightness is qualified only by milling the part where the working edge of the rail head is connected with the running surface and slowly entering and slightly cutting the rear cutter along the forming size of the front cutter in a long distance during step-by-step processing;

when a first piece is manufactured, the height and the working edge side of a cutter are respectively reserved for more than 1mm upwards, the feed is gradually adjusted according to the machining amount of 0.2-0.5mm per cutter until the section size measurement meets the requirement of a drawing, the flat ruler lapped working edge and the driving surface meet the requirement of straightness, and the machining is finished;

the limit deviation of the height of the steel rail at the high-speed switch point rail processing section is +/-1.0 mm, in actual production, the height of the steel rail with a series of sections and the width of the top end which is descended by 16mm (the tolerance is usually +/-0.5 mm) are usually taken as measuring elements, and because the size change of the working edge of the switch rail is relatively slow, the shape precision requirement can be met by using the end head in the stroke range of a machine tool as the tool setting reference during step milling.

When the milling and clamping sections in the step 4 and the step 5 are sequentially overlapped with the drilling and clamping sections in the step 1-3, drilling and milling can be completed simultaneously, and the clamping times are reduced.

Further, when the first hole in the step 1 is machined, lightly scratching the surface of the corresponding steel rail by using a cutter, measuring the distance between the cutter and the reference end surface, and correcting the coordinates of the machine tool according to the distance; and 2, when the first hole is machined in the step 2, lightly scratching the surface of the corresponding steel rail by using a cutter, measuring the distance between the cutter and the last bolt hole machined in the previous time, and correcting the coordinate.

Further, the last bolt hole selected in step 1 should be at a relatively close distance from the adjacent unmachined bolt hole.

Further, the existing coordinate value of the last bolt hole machined in the previous time is adopted in the step 2 for determining, the cutter bar consists of an operation end part and a fixed tail part, the aperture of the operation end part is smaller than that of the last bolt hole machined in the previous time by 0.2mm, and the fixed tail part is used for being fixedly connected with a standard cutter handle; when the bolt is used, the coordinates are manually adjusted, so that the operation end part extends into the last bolt hole machined in the previous time.

The invention has the beneficial effects that: the existing short-stroke machine tool is used for processing the ultra-long turnout switch rail step by step, so that the equipment investment cost or the switch rail import cost is greatly reduced.

Drawings

FIG. 1 is a schematic structural diagram of a turnout ultra-long tongue;

FIG. 2 is a schematic view of the processing content of the CN42# switch blade;

FIG. 3 is a schematic diagram of a triple chucking using a 28 meter stroke machine tool for machining a CN42# switch point;

FIG. 4 is a schematic view of a one-time card-mounting heel end fixture;

FIG. 5 is a schematic view of the front end fixation of the one-time chucking;

FIG. 6 is a schematic view of secondary clip rail attachment;

FIG. 7 is a schematic view of three times of rail attachment.

Detailed Description

The technical solutions in the embodiments of the present invention are clearly and completely described below with reference to the accompanying drawings, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments that can be derived by one of ordinary skill in the art from the embodiments given herein are intended to be within the scope of the present invention.

Example 1

The high-speed turnout overlength switch rail is manufactured by rolling a special AT rail into a standard rail shape through a heel end. The front part is cut and processed, and the section is changed slowly; the rear part is a relatively complete AT rail and a standard rail section, and is processed linearly by a driving surface (a rail top and a working side). As the cross-sectional dimension gradually widens and increases, the contact point gradually shifts from the stock rail to the point rail as the wheel passes. The structure of the switch overlength tongue is schematically shown in figure 1.

The typical location and prevailing manner of machining for an ultra-long switch point will now be described by way of example with respect to the CN42# switch point, and the body structure of other switch point models will be similar. The processing contents of the CN42# turnout switch rail mainly comprise rail bottom surface milling, rail bottom hole drilling and reaming, rail waist drilling, non-working side rail head milling, working side rail head rough milling and finish milling, traveling surface milling and rail bottom milling, and the processing schematic diagram is shown in figure 2.

The invention utilizes a short-stroke numerical control machine tool to finish the processing production of the overlong turnout switch rail step by moving a workpiece and installing a clamping cutter for multiple times, and the embodiment provides the step-by-step processing method for processing the CN42 turnout switch rail by utilizing a 28-meter stroke machine tool for processing the CN18 turnout switch rail.

The basic dimensions of the CN42# switch blade are shown in Table 1, and the long workpiece is clamped once to finish machining, and a long-stroke machine tool is required. In the embodiment, the 28-meter stroke machine tool for machining the CN18# switch blade is used for machining the CN42# switch blade, so that the investment cost of equipment or the cost of blade import is greatly reduced.

TABLE 1

Note: the 1:40 row face data did not contain overlap with the working edge during processing.

The specific steps are as follows (as shown in fig. 3-7, the addition and subtraction of the X coordinate values in the expression, taking the left switch rail direction as an example, and the right switch rail as the corresponding inverse operation):

1. the primary clamping is carried out, the trailing end (rolling section) is arranged at the electromagnet position at the most end of the machine tool, and the distance between the switch rail and the overhanging electromagnet body of the trailing end is as follows: the oil cylinder at the forefront part of the extending end of the left switch rail 160 and the right switch rail 200 is not tightly propped, other oil cylinders are tightly propped, and the manual tightening device is not required to be tightly propped;

the coordinate of the heel end face to the X axis is used, the coordinate value is added with the radius of the cutter and then input into a workpiece coordinate system for drilling, and a numerical control machine is used for programming and milling a rail bottom plane with 1-5 holes and drilling and reaming the 1 st-5 th holes; before machining, marking a line at the first hole, observing whether the cutter accords with a corresponding line or not in the machining process, and observing the measurement of the first hole.

2. And (3) secondary clamping, moving the workpiece, enabling the tip end to fall within the clamping distance of the straight section of the machine tool, enabling the end face of the tip end of the steel rail to be flush with the side guide magnetic block at the foremost end correspondingly, enabling the oil cylinders at the two outermost sides of the machine tool not to be tightly jacked during clamping, enabling all other oil cylinders to be tightly jacked, and enabling all the manual jacking devices to be tightly jacked.

Firstly, taking a tool setting rod to adjust a coordinate to extend into a 21543 hole (a 5 th hole) of a rail bottom to adjust an X-axis coordinate, and paying attention to that gaps are reserved between the head of the tool setting rod and the edge of the hole in each direction when the tool setting is carried out, so that the tool setting rod cannot be forced to enter by the force of a machine tool; subtracting 21543 from the X-axis tool setting value, and inputting the subtracted value into a workpiece coordinate system for drilling (namely, the origin of the coordinate system for drilling is the point heel end), wherein the X value in the coordinate system for milling is the sum of the X value in the workpiece coordinate system for drilling and the full length 47248 of the point (namely, the origin of the coordinate system for milling is the point tip end);

before processing, draw the processing lines of the 6 th hole (120 from the 5 th hole), the first rail base plane (from the tip 22505) and the starting points of the working edge and the non-working edge (from the tips 21522 and 26039).

Secondly, programming and processing a rail bottom plane by using a numerical control machine (observing whether the first rail bottom plane processed at this time is in line with a corresponding line or not), then drilling and reaming the rest phi 32 holes, and when drilling, paying attention to the measurement of the distance between the 5 th hole and the 6 th hole as 120 and paying attention to the measurement of the diameter of the first hole;

and thirdly, the non-working edge is milled by two cutters through the programming of a numerical control machine tool, and the starting point line is controlled to be not more than the marking point (causing the over-tolerance of the 16 width dimension below the point) as much as possible.

Measuring from the tip, drawing the position lines (from the tips 2635, 8442, 10630, 15699, 21522 and 26039) of the check points on the non-working edge, programming and roughly milling by using a numerical control machine tool and finely milling the working edge, and measuring the size of each check point at any time and adjusting the feed amount in the milling process.

And fifthly, the oil cylinder and the manual tightening devices are all withdrawn (all the manual tightening devices are withdrawn to the limit to avoid feed interference), and then the non-working side rail bottom milling is carried out by utilizing the programming of a numerical control machine.

3. Thirdly, installing the clamp, namely, arranging the heel end AT the position corresponding to the electromagnet AT the most end, wherein the distances between the left and right switch rail heel ends extending out of the electromagnet bodies are 160, then tightly pushing all the oil cylinders except the most front end and manual pushing devices (the number of the manual pushing devices AT the heel end can be one less), and paying attention to the existence of micro-deformation of the rolling section of the switch rail heel end, and performing table making and adjustment alignment according to the AT lateral position;

and finally, the heel end faces the X axis, the numerical value is input into a workpiece coordinate system for milling the running face, 1/40 running faces are milled by utilizing the numerical control machine tool programming, the feed amount is adjusted during milling, the width and height sizes of two measuring points at the tail end of the tip end are ensured, and the lapping straightness with the working edge and the running face is noticed.

The unit of the numerical value without unit is millimeter mm, and the oil cylinder for fixing the steel rail in the drawing can be set as required by those skilled in the art, and the embodiment provides only one implementation manner, but is not limited to this implementation manner.

The present embodiment utilizes the existing 28 meters stroke machine tool to complete the processing of 47 meters of workpieces, saves the equipment investment, and expands the functions of the existing equipment, so that the production of the CN42# turnout switch rail can be carried out.

Finally, it should also be noted that the above list is only one specific embodiment of the invention. It is obvious that the invention is not limited to the above embodiments, but that many variations are possible. All modifications which can be derived or suggested by a person skilled in the art from the disclosure of the present invention are to be considered within the scope of the invention.

Claims

1. A step-by-step processing method of an overlong turnout switch rail is characterized by comprising the following steps:

step 1, placing one end of a steel rail, which contains a reference end face, in a stroke range of a machine tool, aligning a tool through the reference end face of the steel rail, and machining a bolt hole in the stroke range of the machine tool, wherein the reference end face of the steel rail is a tip end face or a heel end face;

step 2, moving the workpiece, moving the adjacent unmachined hole section and the last bolt hole machined in the previous time into the stroke range of the machine tool, calculating the zero point coordinate of the actual reference end surface by using the existing coordinate value and the positioning size of the last bolt hole machined in the previous time, and machining the bolt hole of the section;

step 3, if the unprocessed hole section exists after the step 2 is finished, continuously moving the workpiece, and processing the bolt hole of the next section until all the bolt hole cutters are connected;

step 4, moving the workpiece, moving the tip of the switch rail and the front variable cross-section area to the stroke range of a machine tool, taking the end face of the tip as a reference, firstly milling while not working, then carrying out rough milling and finish milling while working, and finally finishing the milling of the rail bottom;

and 5, moving the workpiece, moving the end surface of the heel end of the switch rail and part of the milling tail end of the working edge to the stroke range of a machine tool, taking the end surface of the heel end of the switch rail as a processing reference, slowly entering and micro-cutting the end surface of the switch rail within a range of 2-3m away from the milling tail end of the working edge by using a milling cutter of a travelling crane surface, covering the forming size of the milling cutter of the working edge for subsequent milling until the measurement of the section size meets the requirement of a drawing, and finishing the processing when the working edge of the lap joint of the flat ruler and the travelling.

2. The step-by-step processing method of the overlength turnout switch rail according to claim 1, wherein during the first hole processing in the step 1, a cutter is used for lightly scratching the surface of the corresponding steel rail, the distance from a reference end surface is measured, and the machine tool coordinate is corrected according to the distance;

and 2, when the first hole is machined in the step 2, lightly scratching the surface of the corresponding steel rail by using a cutter, measuring the distance between the cutter and the last bolt hole machined in the previous time, and correcting the coordinate.

3. The step-by-step machining method for the overlength switch blade according to claim 1 or 2, wherein the last bolt hole selected in the step 1 is relatively close to the adjacent unprocessed threaded hole.

4. The step-by-step processing method of the overlength turnout switch rail according to claim 1, wherein the step 2 is determined by using the existing coordinate value of the last bolt hole of the previous processing of the cutter bar, the cutter bar is composed of an operation end part and a fixed tail part, the aperture of the operation end part is smaller than that of the last bolt hole of the previous processing by 0.2mm, and the fixed tail part is used for being fixedly connected with a standard cutter handle; when the bolt is used, the coordinates are manually adjusted, so that the operation end part extends into the last bolt hole machined in the previous time.

5. The step-by-step processing method for the overlength turnout switch rail according to claim 1, wherein when the first piece is manufactured in the step 5, the cutter is reserved for more than 1mm in height and the upward direction of the working side respectively, and the feed is gradually adjusted according to the processing amount of 0.2-0.5mm per cutter.

6. The step-by-step processing method for the overlength switch blade according to claim 1, wherein when the milling and clamping sections in the steps 4 and 5 are overlapped with the drilling and clamping sections in the steps 1-3 in sequence, the drilling and the milling can be completed simultaneously, and the clamping times are reduced.