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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- CN110303190B CN110303190B CN201910546398.1A CN201910546398A CN110303190B CN 110303190 B CN110303190 B CN 110303190B CN 201910546398 A CN201910546398 A CN 201910546398A CN 110303190 B CN110303190 B CN 110303190B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23C—MILLING
- B23C5/00—Milling-cutters
- B23C5/16—Milling-cutters characterised by physical features other than shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q17/00—Arrangements for observing, indicating or measuring on machine tools
- B23Q17/20—Arrangements for observing, indicating or measuring on machine tools for indicating or measuring workpiece characteristics, e.g. contour, dimension, hardness
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Abstract
The invention belongs to the technical field of aluminum alloy processing, and relates to a method for processing a welding groove of a large part of an aluminum alloy rail car body, which comprises the steps of dividing an aluminum alloy section into equal regions, determining a processing coordinate system (a y system and a z system) of each region, calculating a twisting angle theta of each region, inputting all measured data into a milling cutter processing program, automatically shifting a milling cutter from an a1 region to an region according to the change of the twisting angle theta, and finishing groove opening by always coinciding the bottom surface of the milling cutter with the plane of the welding groove of the aluminum alloy section.
Description
Technical Field
The invention belongs to the technical field of aluminum alloy processing, and relates to a processing method of a welding groove of a large part of an aluminum alloy rail car body.
Background
When most parts of the aluminum alloy rail car body are welded, the processing size error of the welding groove directly influences the welding strength, so the processing error requirement on the groove is strict. Because of being influenced by aluminium alloy extrusion error, the welding groove of longer distance can't accurate processing of machine tooling equipment, and prior art and method can only accomplish through the mode of artifical marking off, polishing, and the error of artifical polishing is great, and is also higher to operation workman's requirement, and the rejection rate is higher simultaneously, and efficiency is very low, leads to the production manufacturing cost higher.
Disclosure of Invention
In view of the above, the invention provides a method for processing a welding groove of a large part of an aluminum alloy rail car body, which aims to solve the problems of high scrapping efficiency and high production and manufacturing costs of the prior art caused by manually marking and polishing the welding groove of the aluminum alloy rail car body.
In order to achieve the purpose, the invention provides a method for processing a welding groove of a large part of an aluminum alloy rail car body, which comprises the following steps:
A. determining the size parameter of the groove and the size parameter of a cutter according to the drawing requirements and the product characteristics, determining a machining coordinate system (a y system and a z system), and fixing a workpiece on a tool;
B. uniformly dividing an aluminum alloy profile welding groove to be processed into a plurality of zones which are a1, a2, a3 and a4 … … an zones along the length direction;
C. sequentially measuring y and z coordinates of each area a1, a2, a3 and a4 … … an and a twisting angle theta, wherein the y and z coordinates are coordinates of two end points of the groove, the twisting angle theta is an included angle between the end surface of the section bar and a z system and is respectively recorded as (y1, z1 and theta)1)、(y2，z2，θ2)、(y3，z3，θ3)……(yn，zn，θn)；
D. Combining the error condition of the workpiece, compiling a measurement program of the Renishaw measuring instrument, storing a measurement result in an R parameter of a SINUMERIK 840D system, and compiling a machining program of a cutter;
E. inputting all the measured data into a milling cutter machining program, wherein the milling cutter automatically transits from an a1 area to an a2 area to an area, the milling cutter shifts according to the change of a twisting angle theta, and the bottom surface of the milling cutter is always overlapped with the plane of the welding groove of the aluminum alloy section to finish groove forming;
F. cleaning the processed surface and the peripheral aluminum scraps;
G. and (5) measuring whether the processing size and the angle of the aluminum alloy section are qualified or not.
Further, the length between two adjacent zones in step B is less than 2000 mm.
Further, the method for calculating the twisting angle θ in the step C includes: selecting a reference position in each corresponding small area, wherein the coordinates of the reference position in the y direction and the z direction are y0 and z0 respectively, and tan theta of a1 area1(y1-y0)/(z1-z0), tan θ of a2 region2Tan θ of … … an region (y2-y0)/(z2-z0)n°＝(yn-y0)/(zn-z0)。
Further, step F uses compressed air to clean the processed surface and the peripheral aluminum scraps.
And G, measuring whether the machining size and the angle of the aluminum alloy section are qualified or not by using a universal angle ruler and a caliper.
The invention has the beneficial effects that:
1. the invention discloses a method for processing a welding groove of a large part of an aluminum alloy rail vehicle body, which is characterized in that a position to be processed of the aluminum alloy rail vehicle body is localized in different areas, and a processing route is finished in a dot-dash line mode; the more the number of partitions, the more accurate the processing route; the aluminum alloy profile component with longer length and larger deformation can be processed; utilize mechanized processing mode to replace artifical polishing, reduce machining error, improve work efficiency.
2. According to the method for processing the welding groove of the large part of the aluminum alloy rail vehicle body, disclosed by the invention, the space of a region to be processed is fixed in point by a partition measuring point method, and the high-precision welding groove is processed by a point connection processing method, so that the rejection rate is reduced, the working efficiency is improved, and the manufacturing cost of the large part of the aluminum alloy rail vehicle body is reduced.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the means of the instrumentalities and combinations particularly pointed out hereinafter.
Drawings
For the purposes of promoting a better understanding of the objects, aspects and advantages of the invention, reference will now be made to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a schematic structural view of a welding groove of a large part of an aluminum alloy rail vehicle body in an ideal state;
FIG. 2 is a schematic structural diagram of a welding groove of a large part of an aluminum alloy rail vehicle body in an actual state;
FIG. 3 is a side view of a large part of an aluminum alloy rail car body in an actual state;
fig. 4 is a partially enlarged view of a portion a in fig. 3.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention. It should be noted that the drawings provided in the following embodiments are only for illustrating the basic idea of the present invention in a schematic way, and the features in the following embodiments and examples may be combined with each other without conflict.
Wherein the showings are for the purpose of illustrating the invention only and not for the purpose of limiting the same, and in which there is shown by way of illustration only and not in the drawings in which there is no intention to limit the invention thereto; to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of an actual product; it will be understood by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.
The same or similar reference numerals 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 is an orientation or positional relationship indicated by terms such as "upper", "lower", "left", "right", "front", "rear", etc., based on the orientation or positional relationship shown in the drawings, it is only for convenience of description and simplification of description, but it is not an indication or suggestion that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes, and are not to be construed as limiting the present invention, and the specific meaning of the terms may be understood by those skilled in the art according to specific situations.
As shown in fig. 1 to 4, taking machining of a bevel of an aluminum alloy rail car body profile of about 19 meters as an example, the bevel is equally divided into 10 zones in the length direction, i.e., zones al to a10, and the machining process ensures that the center of the milling cutter moves to 10 points along the center of the bevel at a point 01, namely, the moving route of the center of the milling cutter is a line segment formed by the point 01 to the point 10.
The processing method of the welding groove of the large part of the aluminum alloy rail car body comprises the following steps:
A. determining the size parameter of the groove and the size parameter of a cutter according to the drawing requirements and the product characteristics, determining a y system and a z system of a machining coordinate system, and fixing a workpiece on a tool;
B. uniformly dividing an aluminum alloy profile welding groove to be processed into a plurality of zones which are a1 zone, a2 zone, a3 zone and a4 … … a10 zone along the length direction, wherein the length between every two adjacent zones is less than 2000 mm;
C. sequentially measuring y and z coordinates of each area a1, a2, a3 and a4 … … a10 and a twisting angle theta, wherein the y and z coordinates are coordinates of two end points of the groove, the twisting angle theta is an included angle between the end face of the section bar and a z system and is respectively recorded as (y1, z1 and theta1)、(y2，z2，θ2)、(y3，z3，θ3) … … (yn, zn, θ 10), wherein the twist angle θ is calculated by: selecting a reference position in each corresponding small area, wherein the coordinates of the reference position in the y direction and the z direction are y0 and z0 respectively, and tan theta of a1 area1(y1-y0)/(z1-z0), tan θ of a2 region2Tan θ of … … an region (y2-y0)/(z2-z0)10°＝(y10-y0)/(z10-z0)；
D. Combining the error condition of the workpiece, compiling a measurement program of the Renishaw measuring instrument, storing a measurement result in an R parameter of a SINUMERIK 840D system, and compiling a machining program of a cutter;
E. inputting all the measured data into a milling cutter machining program, wherein the milling cutter automatically transits from an a1 area to an a2 area to an area, the milling cutter shifts according to the change of a twisting angle theta, and the bottom surface of the milling cutter is always overlapped with the plane of the welding groove of the aluminum alloy section to finish groove forming;
F. cleaning the processed surface and the peripheral aluminum scraps by using compressed air;
G. and (4) measuring whether the machining size and the angle of the aluminum alloy section are qualified or not by using a universal angle ruler and a caliper.
Compared with the manual polishing mode in the prior art, the aluminum profile welding groove processed by the method disclosed by the invention has the following advantages:
1. according to the method, the mechanical production is used for replacing manual grinding of the welding groove of the aluminum alloy section, so that the production efficiency is greatly improved, the product quality is improved, and the rejection rate and the production cost are reduced.
2. When 1 rail car body lower boundary beam with the welding groove length of about 19 meters is processed, the existing manual grinding mode is adopted, 1 worker needs to use for 4 hours, and the maximum size error after grinding is 0.4 mm. After the method is adopted, the method is only used for 30 minutes, and the maximum size error after processing is only 0.1 mm. The time is shortened by 3.5 hours, the efficiency is improved by 87.5 percent, and the product quality is improved.
3. When a batch of 160 track car body lower boundary beams are processed, 10 waste products are generated by the existing manual grinding method. After the method is adopted, no waste product is generated, the rejection rate is reduced, the production cost is saved, and the income is increased.
4. The method optimizes the production process, improves the product quality and embodies the automatic production of the product. Provides a reference method for manufacturing high-quality industrial products and improving production automation in China.
Finally, the above embodiments are only intended to illustrate the technical solutions of the present invention and not to limit the present invention, and although the present invention has been described in detail with reference to the preferred embodiments, it will be understood by those skilled in the art that modifications or equivalent substitutions may be made on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions, and all of them should be covered by the claims of the present invention.
Claims (5)
1. A processing method of a welding groove of a large part of an aluminum alloy rail car body is characterized by comprising the following steps:
A. determining the size parameter of the groove and the size parameter of a cutter according to the drawing requirements and the product characteristics, determining a machining coordinate system, and fixing a workpiece on a tool;
B. uniformly dividing a welding groove of a large part of an aluminum alloy rail car body to be processed into a plurality of zones which are a1, a2, a3 and a4 … … an zones along the length direction;
C. sequentially measuring y and z coordinates of each area a1, a2, a3 and a4 … … an and a twisting angle theta, wherein the y and z coordinates are coordinates of two end points of the groove, and the twisting angle theta is an included angle between the end surface of the profile and a z system and is respectively recorded as (y1, z1, theta 1), (y2, z2, theta 2), (y 3, z3, theta 3) … … (yn, zn, theta n);
D. combining the error condition of the workpiece, compiling a measurement program of the Renishaw measuring instrument, storing a measurement result in an R parameter of a SINUMERIK 840D system, and compiling a machining program of a cutter;
E. inputting all the measured data into a milling cutter machining program, wherein the milling cutter automatically transits from an a1 area to an a2 area to an area, the milling cutter shifts according to the change of a twisting angle theta, and the bottom surface of the milling cutter is always overlapped with the welding groove plane of the large part of the aluminum alloy rail car body to finish groove forming;
F. cleaning the processed surface and the peripheral aluminum scraps;
G. and (4) measuring whether the machining size and the angle of the large part of the aluminum alloy rail vehicle body are qualified or not.
2. The process of claim 1 wherein the length between two adjacent zones in step B is less than 2000 mm.
3. The machining method according to claim 2, wherein the twist angle θ in step C is calculated by: firstly, a reference position is selected in each corresponding small area, the coordinates of the reference position in the y direction and the z direction are y0 and z0 respectively, the tan theta 1 degree of a1 area is (y1-y0)/(z1-z0), the tan theta 2 degree of a2 area is (y2-y0)/(z2-z0), and the tan theta n degree of a … … an area is (= (yn-y 0)/(zn-z 0).
4. The process of claim 3 wherein step F uses compressed air to clean the processed surface and surrounding aluminum shavings.
5. The processing method according to claim 4, wherein step G is carried out by using a universal angle gauge and a caliper to measure whether the processing dimension and the angle of the large part of the aluminum alloy rail car body are qualified.
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