CN110303190B - Method for processing welding groove of large part of aluminum alloy rail vehicle body - Google Patents
Method for processing welding groove of large part of aluminum alloy rail vehicle body Download PDFInfo
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- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 33
- 238000003466 welding Methods 0.000 title claims abstract description 28
- 238000012545 processing Methods 0.000 title claims abstract description 15
- 238000000034 method Methods 0.000 title claims description 18
- 238000003801 milling Methods 0.000 claims abstract description 17
- 238000003672 processing method Methods 0.000 claims abstract description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 8
- 238000005259 measurement Methods 0.000 claims abstract description 7
- 230000008859 change Effects 0.000 claims abstract description 4
- 238000003754 machining Methods 0.000 claims description 8
- 230000008569 process Effects 0.000 claims description 4
- 238000004140 cleaning Methods 0.000 claims 1
- 230000002093 peripheral effect Effects 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 12
- 238000000227 grinding Methods 0.000 abstract description 10
- 229910045601 alloy Inorganic materials 0.000 abstract 1
- 239000000956 alloy Substances 0.000 abstract 1
- 238000010586 diagram Methods 0.000 description 3
- 239000002699 waste material Substances 0.000 description 3
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- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
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- 230000009467 reduction Effects 0.000 description 1
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Abstract
本发明属于铝合金加工技术领域，涉及一种铝合金轨道车体大部件焊接坡口的加工方法，包括将铝合金型材等分区域、确定每个区域的加工坐标系(y系和z系)，计算每个区域的扭拧角θ，最后将所有测量数据输入到铣刀加工程序中，铣刀按照扭拧角θ的变化从a1区自动偏移到an区，铣刀的底面始终与铝合金型材焊接坡口平面重合，完成开坡口，解决了现有技术中采用人工划线、打磨铝合金轨道车体焊接坡口，存在报废效率高、生产制造成本高的问题。
The invention belongs to the technical field of aluminum alloy processing, and relates to a processing method for welding grooves of large parts of an aluminum alloy rail car body. , calculate the twist angle θ of each area, and finally input all the measurement data into the milling cutter processing program, the milling cutter is automatically shifted from the a1 area to the an area according to the change of the twist angle θ, and the bottom surface of the milling cutter is always in line with the aluminum The plane of the welding groove of the alloy profile is overlapped to complete the groove opening, which solves the problems of high scrapping efficiency and high manufacturing cost in the prior art by manually scribing and grinding the welding groove of the aluminum alloy rail car body.
Description
技术领域technical field
本发明属于铝合金加工技术领域，涉及一种铝合金轨道车体大部件焊接坡口的加工方法。The invention belongs to the technical field of aluminum alloy processing, and relates to a processing method for welding grooves of large parts of an aluminum alloy rail car body.
背景技术Background technique
在铝合金轨道车体大部件组对焊接时，焊接坡口的加工尺寸误差直接影响焊接强度，所以对坡口的加工误差要求较为严格。因受铝型材挤压误差的影响，机加工设备无法准确加工较长距离的焊接坡口，现有技术和方法只能通过人工划线、打磨的方式完成，人工打磨的误差较大，对于操作工人的要求也较高，同时废品率较高，效率特别低，导致生产制造成本较高。When welding the large parts of the aluminum alloy rail car body, the machining dimensional error of the welding groove directly affects the welding strength, so the requirements for the machining error of the groove are relatively strict. Due to the influence of the extrusion error of the aluminum profile, the machining equipment cannot accurately process the welding groove of a long distance. The existing technology and method can only be completed by manual scribing and grinding. The error of manual grinding is large, and the operation is difficult. The requirements of workers are also higher, and at the same time, the scrap rate is higher, and the efficiency is particularly low, resulting in higher manufacturing costs.
发明内容SUMMARY OF THE INVENTION
有鉴于此，本发明为了解决现有技术中采用人工划线、打磨铝合金轨道车体焊接坡口，存在报废效率高、生产制造成本高的问题，提供一种铝合金轨道车体大部件焊接坡口的加工方法。In view of this, in order to solve the problems of high scrapping efficiency and high manufacturing cost in the prior art by manually scribing and grinding the welding groove of the aluminum alloy rail car body, the present invention provides a welding method for large parts of the aluminum alloy rail car body. Groove processing method.
为达到上述目的，本发明提供一种铝合金轨道车体大部件焊接坡口的加工方法，包括以下步骤：In order to achieve the above-mentioned purpose, the present invention provides a processing method for the welding groove of a large part of an aluminum alloy rail car body, comprising the following steps:
A、根据图纸要求及产品特征，确定坡口的尺寸参数及刀具尺寸参数，确定加工坐标系(y系和z系)，并将工件固定在工装上；A. According to the drawing requirements and product features, determine the size parameters of the groove and the size parameters of the tool, determine the processing coordinate system (y system and z system), and fix the workpiece on the tooling;
B、将待加工的铝合金型材焊接坡口沿长度方向均匀等分为若干个区，分别为a1、a2、a3、a4……an区；B. The welding groove of the aluminum alloy profile to be processed is evenly divided into several areas along the length direction, namely a1, a2, a3, a4...an areas;
C、依次测量a1、a2、a3、a4……an每个区的y和z坐标以及扭拧角θ，所述y和z坐标为坡口两端点的坐标，所述扭拧角θ为型材端面与z系的夹角，分别记载为(y1，z1，θ1)、(y2，z2，θ2)、(y3，z3，θ3)……(yn，zn，θn)；C. Measure the y and z coordinates and twist angle θ of each area of a1, a2, a3, a4...an in turn, the y and z coordinates are the coordinates of the two ends of the groove, and the twist angle θ is the profile The angle between the end face and the z system is recorded as (y1, z1, θ 1 ), (y2, z2, θ 2 ), (y3, z3, θ 3 )...(yn, zn, θn);
D、结合工件的误差情况，编制Renishaw测量仪的测量程序，将测量结果保存在SINUMERIK 840D系统的R参数中，并编制刀具的加工程序；D. According to the error of the workpiece, compile the measurement program of the Renishaw measuring instrument, save the measurement results in the R parameter of the SINUMERIK 840D system, and compile the machining program of the tool;
E、将所有测量数据输入到铣刀加工程序中，铣刀将从a1区自动过度到a2区一直到an区，其中铣刀按照扭拧角θ的变化进行偏移，铣刀的底面始终与铝合金型材焊接坡口平面重合，完成开坡口；E. Input all measurement data into the milling cutter processing program, the milling cutter will automatically transition from the a1 area to the a2 area to the an area, where the milling cutter is offset according to the change of the twist angle θ, and the bottom surface of the milling cutter is always consistent with the The plane of the welding groove of the aluminum alloy profile is overlapped to complete the groove opening;
F、清理已加工表面及周边铝屑；F. Clean the processed surface and surrounding aluminum scraps;
G、测量铝合金型材加工尺寸及角度是否合格。G. Measure whether the processing size and angle of aluminum alloy profiles are qualified.
进一步，步骤B中相邻两个区之间的长度小于2000mm。Further, the length between two adjacent regions in step B is less than 2000mm.
进一步，步骤C中扭拧角θ的计算方法为：在对应的小区域内均先选择一个基准位置，基准位置y和z方向的坐标分别为y0和z0，a1区域的tan θ1°＝(y1-y0)/(z1-z0)，a2区域的tan θ2°＝(y2-y0)/(z2-z0)，……an区域的tanθn°＝(yn-y0)/(zn-z0)。Further, the calculation method of the twist angle θ in step C is: first select a reference position in the corresponding small area, the coordinates of the reference position y and z directions are y0 and z0 respectively, and the tan θ 1 °=(y1 -y0)/(z1-z0), tan θ 2 ° in a2 area = (y2-y0)/(z2-z0), ... tan θ n ° in an area = (yn-y0)/(zn-z0) .
进一步，步骤F使用压缩空气清理已加工表面及周边铝屑。Further, in step F, compressed air is used to clean the processed surface and surrounding aluminum chips.
进一步，步骤G使用万能角度尺及卡尺测量铝合金型材加工尺寸及角度是否合格。Further, in step G, a universal angle ruler and a caliper are used to measure whether the processing dimensions and angles of the aluminum alloy profiles are qualified.
本发明的有益效果在于：The beneficial effects of the present invention are:
1、本发明所公开的铝合金轨道车体大部件焊接坡口的加工方法，将铝合金轨道车体的待加工位置分区域定点化，采用以点划线的方式完成加工路线；分区数量越多，加工路线越精确；可以加工较长及变形量较大的铝合金型材部件；利用机械化加工方式代替人工打磨，减小加工误差，提高工作效率。1. The processing method of the welding groove of the large parts of the aluminum alloy rail car body disclosed in the present invention, the position to be processed of the aluminum alloy rail car body is divided into fixed points, and the processing route is completed in the form of a dotted line; The more accurate the processing route, the longer the aluminum alloy profile parts with large deformation can be processed; the mechanized processing method is used instead of manual grinding, which reduces the processing error and improves the work efficiency.
2、本发明所公开的铝合金轨道车体大部件焊接坡口的加工方法，通过分区测点法，将待加工区域的空间定点化，以点连线的加工方法，加工出高精度的焊接坡口，较少废品率，提高工作效率，同时也降低铝合金轨道车体大部件的制造成本。2. The processing method of the welding groove of the large parts of the aluminum alloy rail car body disclosed in the present invention, the space of the area to be processed is fixed to a point by the method of partition measurement, and the processing method of connecting the points is used to process the high-precision welding Groove, less scrap rate, improve work efficiency, and also reduce the manufacturing cost of large parts of aluminum alloy rail car body.
本发明的其他优点、目标和特征在某种程度上将在随后的说明书中进行阐述，并且在某种程度上，基于对下文的考察研究对本领域技术人员而言将是显而易见的，或者可以从本发明的实践中得到教导。本发明的目标和其他优点可以通过下面的说明书来实现和获得。Other advantages, objects, and features of the present invention will be set forth in the description that follows, and will be apparent to those skilled in the art based on a study of the following, to the extent that is taught in the practice of the present invention. The objectives and other advantages of the present invention may be realized and attained by the following description.
附图说明Description of drawings
为了使本发明的目的、技术方案和优点更加清楚，下面将结合附图对本发明作优选的详细描述，其中：In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be preferably described in detail below with reference to the accompanying drawings, wherein:
图1为理想状态下铝合金轨道车体大部件焊接坡口的结构示意图；Fig. 1 is the structural schematic diagram of the welding groove of the large part of the aluminum alloy rail car body in an ideal state;
图2为实际状态下铝合金轨道车体大部件焊接坡口的结构示意图；Fig. 2 is the structural schematic diagram of the welding groove of the large part of the aluminum alloy rail car body in the actual state;
图3为实际状态下铝合金轨道车体大部件侧视图；Figure 3 is a side view of a large part of an aluminum alloy rail car body in an actual state;
图4为图3中A处的局部放大图。FIG. 4 is a partial enlarged view of A in FIG. 3 .
具体实施方式Detailed ways
以下通过特定的具体实例说明本发明的实施方式，本领域技术人员可由本说明书所揭露的内容轻易地了解本发明的其他优点与功效。本发明还可以通过另外不同的具体实施方式加以实施或应用，本说明书中的各项细节也可以基于不同观点与应用，在没有背离本发明的精神下进行各种修饰或改变。需要说明的是，以下实施例中所提供的图示仅以示意方式说明本发明的基本构想，在不冲突的情况下，以下实施例及实施例中的特征可以相互组合。The embodiments of the present invention are described below through specific specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the drawings provided in the following embodiments are only used to illustrate the basic idea of the present invention in a schematic manner, and the following embodiments and features in the embodiments can be combined with each other without conflict.
其中，附图仅用于示例性说明，表示的仅是示意图，而非实物图，不能理解为对本发明的限制；为了更好地说明本发明的实施例，附图某些部件会有省略、放大或缩小，并不代表实际产品的尺寸；对本领域技术人员来说，附图中某些公知结构及其说明可能省略是可以理解的。Among them, the accompanying drawings are only used for exemplary description, and represent only schematic diagrams, not physical drawings, and should not be construed as limitations of the present invention; in order to better illustrate the embodiments of the present invention, some parts of the accompanying drawings will be omitted, The enlargement or reduction does not represent the size of the actual product; it is understandable to those skilled in the art that some well-known structures and their descriptions in the accompanying drawings may be omitted.
本发明实施例的附图中相同或相似的标号对应相同或相似的部件；在本发明的描述中，需要理解的是，若有术语“上”、“下”、“左”、“右”、“前”、“后”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此附图中描述位置关系的用语仅用于示例性说明，不能理解为对本发明的限制，对于本领域的普通技术人员而言，可以根据具体情况理解上述术语的具体含义。The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar components; in the description of the present invention, it should be understood that if there are terms “upper”, “lower”, “left” and “right” , "front", "rear" and other indicated orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the indicated device or element must be It has a specific orientation, is constructed and operated in a specific orientation, so the terms describing the positional relationship in the accompanying drawings are only used for exemplary illustration, and should not be construed as a limitation of the present invention. situation to understand the specific meaning of the above terms.
如图1～4所示，以加工19米左右的铝合金轨道车体型材坡口为例，在长度方向平均分为10个区，分别是al～a10区，加工过程保证铣刀中心沿坡口中心01点运动到10点，即铣刀中心的运动路线为01点到10点所构成的线段。As shown in Figures 1 to 4, taking the processing of aluminum alloy rail car body profile grooves of about 19 meters as an example, it is divided into 10 areas on average in the length direction, namely al to a10 areas. The machining process ensures that the center of the milling cutter is along the slope. The center of the mouth moves from
该铝合金轨道车体大部件焊接坡口的加工方法，包括以下步骤：The processing method of the welding groove of the large part of the aluminum alloy rail car body comprises the following steps:
A、根据图纸要求及产品特征，确定坡口的尺寸参数及刀具尺寸参数，确定加工坐标系y系和z系，并将工件固定在工装上；A. According to the drawing requirements and product characteristics, determine the size parameters of the groove and the size parameters of the tool, determine the y system and z system of the machining coordinate system, and fix the workpiece on the tooling;
B、将待加工的铝合金型材焊接坡口沿长度方向均匀等分为若干个区，分别为a1、a2、a3、a4……a10区，相邻两个区之间的长度小于2000mm；B. The welding groove of the aluminum alloy profile to be processed is evenly divided into several areas along the length direction, namely a1, a2, a3, a4...a10 areas, and the length between the two adjacent areas is less than 2000mm;
C、依次测量a1、a2、a3、a4……a10每个区的y和z坐标以及扭拧角θ，所述y和z坐标为坡口两端点的坐标，所述扭拧角θ为型材端面与z系的夹角，分别记载为(y1，z1，θ1)、(y2，z2，θ2)、(y3，z3，θ3)……(yn，zn，θ10)，其中扭拧角θ的计算方法为：在对应的小区域内均先选择一个基准位置，基准位置y和z方向的坐标分别为y0和z0，a1区域的tan θ1°＝(y1-y0)/(z1-z0)，a2区域的tan θ2°＝(y2-y0)/(z2-z0)，……an区域的tan θ10°＝(y10-y0)/(z10-z0)；C. Measure the y and z coordinates and the twist angle θ of each area of a1, a2, a3, a4...a10 in turn, the y and z coordinates are the coordinates of the two ends of the groove, and the twist angle θ is the profile. The angle between the end face and the z system is recorded as (y1, z1, θ 1 ), (y2, z2, θ 2 ), (y3, z3, θ 3 )... (yn, zn, θ10), where twist The calculation method of the angle θ is as follows: first select a reference position in the corresponding small area, the coordinates of the reference position in the y and z directions are y0 and z0 respectively, and the tan θ 1 ° in the a1 area = (y1-y0)/(z1- z0), tan θ 2 ° in the a2 area = (y2-y0)/(z2-z0), ... tan θ 10 ° in the an area = (y10-y0)/(z10-z0);
D、结合工件的误差情况，编制Renishaw测量仪的测量程序，将测量结果保存在SINUMERIK 840D系统的R参数中，并编制刀具的加工程序；D. According to the error of the workpiece, compile the measurement program of the Renishaw measuring instrument, save the measurement results in the R parameter of the SINUMERIK 840D system, and compile the machining program of the tool;
E、将所有测量数据输入到铣刀加工程序中，铣刀将从a1区自动过度到a2区一直到an区，其中铣刀按照扭拧角θ的变化进行偏移，铣刀的底面始终与铝合金型材焊接坡口平面重合，完成开坡口；E. Input all measurement data into the milling cutter processing program, the milling cutter will automatically transition from the a1 area to the a2 area to the an area, where the milling cutter is offset according to the change of the twist angle θ, and the bottom surface of the milling cutter is always consistent with the The plane of the welding groove of the aluminum alloy profile is overlapped to complete the groove opening;
F、使用压缩空气清理已加工表面及周边铝屑；F. Use compressed air to clean the machined surface and surrounding aluminum chips;
G、使用万能角度尺及卡尺测量铝合金型材加工尺寸及角度是否合格。G. Use universal angle ruler and caliper to measure whether the processing size and angle of aluminum alloy profiles are qualified.
采用本发明所公开方法加工的铝型材焊接坡口相对于现有技术人工打磨的方式，有以下优势：Compared with the manual grinding method of the prior art, the aluminum profile welding groove processed by the method disclosed in the present invention has the following advantages:
1、本方法用机械化生产代替人工打磨铝合金型材的焊接坡口，大幅度的提高了生产效率、提升了产品质量，降低了废品率及生产成本。1. This method replaces manual grinding of the welding grooves of aluminum alloy profiles with mechanized production, which greatly improves production efficiency, improves product quality, and reduces scrap rate and production cost.
2、在加工1支焊接坡口长度约19米的轨道车体下边梁时，采用现有的人工打磨方式，1名工人需使用4个小时，打磨后的最大尺寸误差为0.4mm。采用本方法后，仅使用了30分钟，加工后的最大尺寸误差仅为0.1mm。时间缩短了3.5小时，效率提升了87.5％，并提升了产品质量。2. When processing a rail car body lower beam with a welding groove length of about 19 meters, the existing manual grinding method is used. One worker needs to use it for 4 hours, and the maximum size error after grinding is 0.4mm. After using this method, it only takes 30 minutes, and the maximum dimensional error after processing is only 0.1mm. The time was shortened by 3.5 hours, the efficiency was increased by 87.5%, and the product quality was improved.
3、在加工一批160支轨道车体下边梁时，现有的人工打磨方法共产生10支废品。采用本方法后，无废品产生，降低了废品率，节约了生产成本，增加了收益。3. When processing a batch of 160 rail car body lower side beams, the existing manual grinding method produces a total of 10 waste products. After the method is adopted, no waste products are generated, the waste product rate is reduced, the production cost is saved, and the income is increased.
4、本方法优化了生产工艺，提升了产品质量，并体现了产品自动化生产。为我国制造高质量工业产品及提升生产自动化提供了借鉴方法。4. The method optimizes the production process, improves the product quality, and reflects the automated production of the product. It provides a reference method for manufacturing high-quality industrial products and improving production automation in my country.
最后说明的是，以上实施例仅用以说明本发明的技术方案而非限制，尽管参照较佳实施例对本发明进行了详细说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本技术方案的宗旨和范围，其均应涵盖在本发明的权利要求范围当中。Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be Modifications or equivalent replacements, without departing from the spirit and scope of the technical solution, should all be included in the scope of the claims of the present invention.
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