CN112001049A - Method for punching and cutting internal hexahedron - Google Patents
Method for punching and cutting internal hexahedron Download PDFInfo
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- 238000005520 cutting process Methods 0.000 title claims abstract description 107
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- 238000003754 machining Methods 0.000 description 5
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Abstract
The internal hexahedron low-cutting manufacturing method comprises the steps of firstly reducing the back cutting amount by increasing a prefabricated bottom hole, so as to achieve the purpose of reducing cutting force, then establishing a low-cutting model to analyze the change characteristics of the method, then determining the minimum back cutting amount during manufacturing according to the manufacturing error standards of an internal hexahedron and a wrench, and finally controlling the reasonable back cutting amount and the diameter of the prefabricated bottom hole by adopting an amplification coefficient or a preferred coefficient mode according to the load; the inner hexahedron is processed by adopting a few-cutting manufacturing method, so that the cutting force is reduced on the premise of ensuring the service performance of the inner hexahedron, the precision reduction caused by overlarge punching force is eliminated, the interference on the strength design of parts is avoided, and the manufacturing energy consumption is reduced.
Description
Technical Field
The invention relates to the technical field of punching and cutting manufacturing, in particular to a punching and cutting manufacturing method of an inner hexahedron.
Background
The mass production of the internal hexahedron of standard fasteners such as screws, bolts and the like mostly adopts an upsetting mode, and the punching is generally adopted, wherein the mass production is small, the trial production or the abnormal non-standard is not suitable for the upsetting due to the process limitation. The punching needs to prefabricate the bottom hole, and the punching procedure is arranged after the previous machining is finished, so that the larger impact is brought to the base body of the semi-finished part, the deformation of the base body is caused, and especially for a slender rod piece, the disappearance of the previous machining precision is caused by the overlarge punching force. In the threaded cartridge valve and the hydraulic servo control system device, a large number of precise slender rod pieces for adjustment, feedback and fastening exist, the limitation of self structural characteristics and use occasions is realized, the adjustment and fastening can only be realized in the form of an inner hexahedron, the influence of precision requirements is also realized, all the geometric elements except the inner hexahedron can only be processed by adopting a core-moving precise numerical control machine once, and finally, the processing of the inner hexahedron is completed by singly adopting a hydraulic press for punching. The cutting force during punching the inner hexahedron directly influences the precision formed by the previous processing and the design requirement on the strength of the part, the diameter of a prefabricated bottom hole subjected to traditional punching is smaller than the opposite side dimension of the inner hexahedron, after the basic dimension is selected according to the structure of the traditional inner hexahedron, the punching force is determined accordingly, in order to avoid punching deformation, the radial dimension of a base body can be increased according to the punching force during design, material waste is caused, and unnecessary influence is brought to other designs. In order to avoid punching deformation and interference on related designs, the problem of reducing the cutting force during punching is fundamental to solve, and the reduction of the cutting force can effectively save energy and reduce consumption.
Disclosure of Invention
The invention aims to provide a method for manufacturing an inner hexahedron by punching, which is used for reducing cutting force during punching of the inner hexahedron.
The technical problem solved by the invention is realized by adopting the following technical scheme:
the method for punching and cutting the inner hexahedron comprises the following specific steps:
1. technical scheme for determining reduction of cutting force of inner hexahedron punching manufacturing method
Based on the previous machining process, the back draft during punching is reduced by increasing the diameter of the prefabricated bottom hole, and the diameter size of the prefabricated bottom hole of the inner hexahedron punching manufacturing method is larger than the corresponding size of the opposite side of the inner hexahedron, so that the back draft can be reduced, and the cutting force is reduced accordingly.
2. Less-cutting model for establishing inner hexahedron punching manufacturing method
According to the selected technical scheme for reducing the cutting force, a less-cutting model is established, a plane coordinate system is established by taking the circle center of the prefabricated bottom hole as an origin, the center of the inner hexahedron is located at the origin of the coordinate system, and one group of opposite sides of the inner hexahedron is parallel to the x axis. Along with the increase of the diameter of the bottom hole, the circle of the bottom hole is intersected with the side of the inner hexahedron, the side which is closer to the vertex is selected as an intersection point, the distance between the vertex and the intersection point is half of the cutting back tool consumption, and the coordinates of the intersection point, namely the coordinates of the intersection point are solved
The intersection point coordinate is obtained by solving the formula (1) as
s/2) and converted to the vertex coordinates of (
s/2), calculating a low cutting back draft equation by coordinates of the vertex and the intersection point:
and (3) calculating a bottom hole diameter equation according to the formula (2):
taking the size of the opposite side as an undetermined constant, and solving a change rate equation of the cutting back draft along with the diameter of the bottom hole by the diameter of the bottom hole in the formula (2):
taking the dimension of the opposite side as an undetermined constant, and obtaining a change rate equation of the diameter of the bottom hole along with the small cutting back bite by calculating the small cutting back bite in the formula (3):
in formulae (1) to (5): x is the number ofAX-axis coordinates for the vertices;
xBx-axis coordinate of intersection, yBY-axis coordinates of the intersection points;
s is the size of the opposite side of the inner hexahedron;
d is the bottom hole diameter, the theoretical constraint is (s,
)；
a′pifor less cutting back, the theoretical constraint is (0,
)。
3. determining the minimum back draft of the interior hexahedron punch-cutting manufacturing method
Under the influence of actual manufacturing deviation and use abrasion, the diameter of the bottom hole cannot reach the upper limit value of theoretical constraint, and the cutting back cutting depth is less than the lower limit value of the theoretical constraint; the influencing factors include: the size deviation of the inner hexahedron opposite sides, the size deviation of the wrench opposite sides and the size deviation of the wrench opposite corners. In order to ensure the normal use of the inner hexahedron, the minimum back-draught amount needs to be determined, and the coefficient is amplified on the basis, so that the normal use can be still realized after certain abrasion is carried out in the later period. The factors for restricting the minimum back draft include: the size of the opposite side of the inner hexahedron reaches an upper deviation limit value, the size of the opposite side of the wrench reaches a lower deviation limit value, and the size of the opposite side of the wrench reaches a lower deviation limit value; the above all reach ultimate size simultaneously, and the spanner inflection point contacts with interior plane after rotatory around the initial point, and the distance between contact point and interior hexahedron summit is the limit restraint to minimum back draft sword volume promptly.
And (3) the inflection point is rotated around the origin and restored to a state that the opposite side where the inflection point is located is parallel to the x axis, the coordinate of the inflection point is solved, the inflection point is the intersection point of the opposite side and the diagonal edge, and then an inflection point coordinate equation:
the inflection point coordinate obtained by solving the formula (6) is (
s′min2) and from this the equation for the maximum keyhole diameter at low cut is derived:
substituting the maximum opposite side size of the inner hexahedron and the maximum bottom hole diameter obtained by the formula (7) into the formula (2) to obtain a minimum back-draught equation:
and (3) after the minimum back draft calculated by the formula (8) is amplified, obtaining a formula (3), and obtaining a designed bottom hole diameter equation by taking the minimum opposite side size of the inner hexahedron:
in formulae (6) to (9): x is the number ofCX-axis coordinate of inflection point, yCY-axis coordinates of inflection points;
eminis the minimum diagonal dimension of the wrench;
s′minthe minimum opposite side size of the wrench;
d' is the maximum bottom hole diameter;
d' is the design bottom hole diameter;
a″pithe minimum back bite is obtained;
smaxthe maximum opposite side size of the inner hexahedron;
sminthe minimum opposite side size of the inner hexahedron;
is the amplification factor.
Wherein, the diameter of the maximum bottom hole is close to the minimum diagonal size of the wrench, and the minimum back tool-lifting amount can be calculated and replaced by the minimum diagonal size of the wrench.
4. Back draft and bottom hole diameter of optimized inner hexahedron punching manufacturing method
The amplification factor can be selected according to the requirement of bearing torque of the inner hexahedron, the minimum back tool absorption amount is directly amplified, and the smaller the amplification factor is, the larger the diameter of the designed bottom hole is; according to the change characteristic between the low cutting back draft and the diameter of the bottom hole, the reduction influence of the designed larger diameter of the bottom hole after the bottom hole passes through the rapid change area on the low cutting back draft is smaller, the diameter of the bottom hole can be determined to be 1.03-1.05 times of the size of the inner hexahedron opposite side, preferably 1.04 times of the size of the inner hexahedron opposite side directly according to the transition area, and the optimization coefficient is replaced into formula (2) to obtain the optimization back draft equation:
substituting the preferable back bite obtained by the formula (10) into the formula (3) to obtain a preferable bottom hole diameter equation:
in formulas (10) and (11): a'piThe preferable amount of the back eating is;
mu is the optimal coefficient of the diameter of the designed bottom hole;
d' "is the preferred bottom hole diameter.
The preferred bottom hole diameter obtained by the formula (11) is designed with accuracy, the upper and lower deviation limit values are within the bottom hole diameter range determined by the preferred coefficient, and the upper and lower deviations are designed according to the magnitude of the internal hexahedron bearing torque. If the maximum opposite side size of the inner hexahedron is adopted to calculate the optimal back draft in the formula (10), a larger back draft numerical value can be obtained relative to the theoretical basic value, and if the minimum opposite side size of the inner hexahedron is adopted to calculate the optimal bottom hole diameter in the formula (11), a smaller bottom hole diameter numerical value can be obtained relative to the theoretical basic value, and the numerical orientations of the two values are favorable for the use reliability of the finally formed inner hexahedron.
The minimum back draft is obtained by the formula (8), the back draft corresponding to the amplification factor of 2 and the optimal factor of 1.04 is positioned between the maximum back draft and the minimum back draft, when the optimal factor of 1.04 is adopted, the back draft of 49.5 percent can be approximately reduced relative to the theoretical base value, and the back draft obtained by adopting the priority factor is changed in equal proportion with the size of the opposite sides of the inner hexahedron; when the amplification factor is 2, the back bite amount can be reduced by 18-71% relative to the theoretical base value, and the reduction rate of the back bite amount obtained by adopting the amplification factor is increased along with the increase of the size of the opposite side of the inner hexahedron; the selection mode and the size of the coefficient are determined according to the torque load. According to the above related formulas, the maximum bottom hole diameter, the minimum back cut, the preferred bottom hole diameter and the preferred back cut corresponding to the sizes of the opposite sides can be obtained by numerical calculation in combination with the manufacturing of the inner hexahedron and the standard limit deviation size of the wrench.
The optimal back draft and the unilateral back draft are compared numerically, the numerical calculation accepting error is neglected, the numerical ratio of the front side to the rear side is approximately 0.51 on the whole, namely the optimal back draft obtained by the optimal coefficient taking 1.04 is approximately 0.51 of the theoretical value of the unilateral back draft. Based on the method, when the few-cutting design is carried out, the diameter of the bottom hole can be directly calculated by the product of the minimum opposite side size of the inner hexahedron and the optimal coefficient, and the corresponding back draft can be directly calculated by the product of the theoretical side length value of the inner hexahedron and the ratio of 0.51, so that the calculation process of the few-cutting design can be simplified. The diameter of the bottom hole is preferably reasonable contraction of the maximum diameter of the bottom hole, and the contraction ratio is reduced along with the increase of the size of the opposite sides of the inner hexahedron. The preferred back draft is the further enlargement of the minimum back draft, and the enlargement ratio tends to increase as the size of the opposite sides of the inner hexahedron increases.
The maximum bottom hole diameter corresponding to the minimum back cutting amount does not reach the diagonal size of the inner hexahedron, and the bottom hole diameter is designed to be gradually reduced along with the increase of the amplification factor; the preferable back bite when the preferable coefficient is 1.04 is positioned between the maximum back bite and the minimum back bite; the weakest link of the whole basal body is still the opposite angle of the internal hexahedron, and the strength of the basal body is not influenced by the enlarged bottom hole with less cutting design.
5. Low-cutting manufacturing accuracy control of inner hexahedron punching manufacturing method
In the invention, in the step 2), after the size of the opposite side and the diameter of the bottom hole are given, the cutting back cutting amount can be calculated according to the formula (2); after the size of the opposite side is given, the cutting back draft can be given according to the requirement, and the corresponding diameter of the bottom hole is calculated by the formula (3); the mutual variation characteristics between the two can be obtained from the formulas (4) and (5). The change rate of the cutting back draft less along with the diameter of the bottom hole is mainly divided into two stages, the cutting back draft less along with the diameter of the bottom hole is sharply reduced in the initial stage, the change after transition tends to be smooth, and the whole change rate process tends to be reduced. The diameter of the bottom hole changes gently along with the small cutting back tool consumption, the overall change rate also tends to be reduced, and the feedback of the small cutting back tool consumption on the diameter d of the bottom hole is in a tightening state. According to the change relation between the small cutting back draft and the diameter of the bottom hole, on the premise of not influencing the use of the inner hexahedron, the design value of the diameter of the bottom hole should exceed a rapid change area, and the large error of the small cutting back draft caused by the manufacturing deviation of the diameter of the bottom hole is avoided. The deviation range of the small cutting back tool-cutting amount is fed back to the precision requirement of the diameter of the bottom hole to be in a contraction trend, and after the deviation requirement of the small cutting back tool-cutting amount is given, the deviation precision requirement of the diameter of the bottom hole is higher than that of the small cutting back tool-cutting amount, so that the precision manufacturing capability when the diameter of the bottom hole is processed needs to be considered when the deviation requirement of the small cutting back tool-cutting amount is designed. Given the manufacturing tolerances of the preferred bottom hole diameter, the upper and lower deviation values of the preferred bottom hole diameter should fall within the range of the bottom hole value range determined by the preference coefficient.
In the invention, each plane of the inner hexahedron obtained by the manufacturing method is divided into a plurality of parts by the reserved part of the prefabricated bottom hole after punching, and the separated surfaces on the same side are in the same profile.
Has the advantages that: according to the invention, the diameter of the prefabricated bottom hole is enlarged, and the back tool depth during punching is reduced, so that the technical effect of reducing the cutting force is achieved; the cutting force obtained according to the preferred coefficient can be reduced by about 49.5 percent relative to the theoretical basic value on the original basis, the cutting force is effectively reduced, the interference on the design strength is avoided, the problem of precision reduction caused by punching deformation is solved, and the energy consumption of punching processing is effectively reduced.
Drawings
FIG. 1 is a schematic view of a few-cut model in a preferred embodiment of the present invention.
FIG. 2 is a graph showing the variation of the back draft with the diameter of the bottom hole according to the preferred embodiment of the present invention.
FIG. 3 is a graph of the rate of change of backdraft with bottom hole diameter for a preferred embodiment of the invention.
FIG. 4 is a graph showing the variation of the back draft with the diameter of the bottom hole according to the preferred embodiment of the present invention.
FIG. 5 is a graph of the rate of change of backdraft with bottom hole diameter characteristic of a preferred embodiment of the present invention.
FIG. 6 is a schematic view of a minimum back draft model in a preferred embodiment of the present invention.
FIG. 7 is a comparative illustration of the back draft for various punching modes in the preferred embodiment of the present invention.
FIG. 8 is a schematic view of a punched product in a preferred embodiment of the present invention.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further explained below by combining the specific drawings.
Referring to fig. 1 to 8, the method for manufacturing the inner hexahedron by punching comprises the following specific steps:
1. technical scheme for determining reduction of cutting force of inner hexahedron punching manufacturing method
Based on the previous machining process, the back cutting amount during punching is determined to be reduced by increasing the diameter of the prefabricated bottom hole, and the diameter size of the prefabricated bottom hole of the small-cutting manufacturing method is larger than the corresponding internal hexahedron opposite side size, so that the back cutting amount is reduced, and the cutting force is reduced accordingly.
2. Less-cutting model for establishing inner hexahedron punching manufacturing method
According to the selected cutting force reduction technical scheme, a less-cutting model is established, and a plane coordinate system is established by taking the circle center of the bottom hole as an origin OThe hexahedron center is located at the coordinate system origin O, and one set of opposite sides is parallel to the x-axis. The distance between the points A and B is a half a 'less than the cutting back clearance when the intersection point of the circle of the bottom hole and the side of the inner hexahedron is selected as B as the diameter d of the bottom hole increases, and the intersection point closer to the vertex A is selected as B'pi/2, solving the coordinates (x) of the point BB,yB) I.e. by
The coordinate of the point B is obtained by solving the formula (1) as (
s/2) and converting the coordinate of the point A into (
s/2), calculating a low cutting back draft equation by coordinates of the point A and the point B:
and (3) calculating a bottom hole diameter equation according to the formula (2):
d in the formula (2) is derived to reduce the cutting back clearance a 'by taking the opposite side dimension s as a undetermined constant'piRate of change equation with bottom hole diameter d:
a 'in the formula (3) is determined by taking the opposite side dimension s as a undetermined constant'piObtaining the diameter d of the bottom hole according to a'piThe rate of change equation of (c):
in formulae (1) to (5): s is the size of the opposite side of the inner hexahedron;
d is the bottom hole diameter, the theoretical constraint is (s,
)；
a′pifor less cutting back, the theoretical constraint is (0,
)。
3. determining the minimum back draft of the interior hexahedron punch-cutting manufacturing method
The pilot hole diameter d cannot reach the upper limit value of theoretical constraint and the cutting back clearance a 'is small due to the influence of actual manufacturing variation and use abrasion'piThe lower limit value of theoretical constraint cannot be reached; the influencing factors include: the size deviation of the inner hexahedron opposite sides, the size deviation of the wrench opposite sides and the size deviation of the wrench opposite corners. In order to ensure the normal use of the inner hexahedron, the minimum back bite amount a ″ needs to be determinedpiAnd the coefficient is amplified on the basis to ensure that the rubber belt can still be normally used after being subjected to certain abrasion in the later period. Restrain minimum back draft apiThe factors are as follows: the size of the opposite side of the inner hexahedron reaches an upper deviation limit value, the size of the opposite side of the wrench reaches a lower deviation limit value, and the size of the opposite side of the wrench reaches a lower deviation limit value; all the above reach the limit size simultaneously, the wrench inflection point C rotates around the origin O and then contacts with the inner plane, and the distance between the contact point and the top point of the inner hexahedron is the minimum back bite a ″piIs limited by the limit of (c).
The inflection point C is rotated around the origin O and restored to the state that the opposite side of the inflection point C is parallel to the x axis, and the coordinate (x) of the inflection point C is solvedC,yC) And the inflection point C is the intersection point of the opposite side and the diagonal bevel edge, then the coordinate equation of the point C is as follows:
the coordinate of the point C is obtained by solving the formula (6) as
s′min2) and from this the equation for the maximum keyhole diameter at low cut is derived:
the maximum opposite side size s of the inner hexahedronmaxAnd d' obtained from the formula (7) is substituted for the formula (2) to obtain a minimum back draft equation:
the minimum back bite a ″, which is determined by the formula (8)piAfter amplification, the formula (3) is generated, and the minimum opposite side size s of the inner hexahedron is takenminObtaining a designed bottom hole diameter equation:
in formulae (6) to (9): e.g. of the typeminIs the minimum diagonal dimension of the wrench;
s′minthe minimum opposite side size of the wrench;
d' is the maximum bottom hole diameter;
d' is the design bottom hole diameter;
a″pithe minimum back bite is obtained;
smaxthe maximum opposite side size of the inner hexahedron;
sminthe minimum opposite side size of the inner hexahedron;
is the amplification factor.
Wherein the diameter d' of the maximum bottom hole and the minimum diagonal dimension e of the wrenchminAnd (5) approaching to calculate the minimum back bite a ″piMinimum diagonal dimension e of usable wrenchminInstead.
4. Back draft and bottom hole diameter of optimized inner hexahedron punching manufacturing method
The magnification factor can be selected according to the requirement of the bearing torque of the inner hexahedron, and is the minimum back draft a ″piThe smaller the amplification factor is, the larger the designed bottom hole diameter d' is; according to the low cutting back clearance a'piAnd a characteristic of change in the pilot hole diameter d, wherein a design pilot hole diameter d 'after passing over a sharp change region is increased for a small cutting back clearance a'piThe reduction influence is small, the designed bottom hole diameter d' can be determined to be 1.03-1.05 s, preferably 1.04s according to the transition region, and the preferable coefficient mu is substituted into the formula (2) to obtain the preferable back-draught equation:
the preferable back draft a ″ 'obtained by equation (10)'piThe equation for the preferred bottom hole diameter is substituted for equation (3):
in formulas (10) and (11): a'piThe preferable amount of the back eating is;
mu is the optimal coefficient of the diameter of the designed bottom hole;
d' "is the preferred bottom hole diameter.
The preferred bottom hole diameter d' ″ obtained by the equation (11) is designed with accuracy so that the upper and lower deviation limit values fall within the range of the bottom hole diameter determined by the preferred coefficient μ and the upper and lower deviations are designed according to the magnitude of the hexahedral load-bearing torque. If the maximum side-to-side size s of the inner hexahedron is adopted in the formula (10)maxCalculating the preferred amount of backfeed a'piThe maximum value of the back draft can be obtained relative to the theoretical basic value, and if the minimum side-to-side dimension s of the inner hexahedron is adopted in the formula (11)minCalculating the preferred bottom hole diameter d', relative to the theoretical basisThe value of the diameter of the bottom hole can be obtained to be smaller, and the numerical orientation of the bottom hole is favorable for the use reliability of the finally formed inner hexahedron.
The minimum back bite a' is obtained by the formula (8)piThe back draft corresponding to the amplification factor of 2 and the optimal factor of mu of 1.04 is between the maximum and the minimum back draft, when the optimal factor of mu is 1.04, the back draft which is 49.5 percent lower than the theoretical basic value can be reduced, and the back draft obtained by adopting the optimal factor of mu is changed in equal proportion with the size of the opposite sides of the inner hexahedron; when the amplification factor is 2, the back bite amount can be reduced by 18-71% relative to the theoretical base value, and the reduction rate of the back bite amount obtained by adopting the amplification factor is increased along with the increase of the size of the opposite side of the inner hexahedron; the selection mode and the size of the coefficient are determined according to the torque load. According to the related formula, the maximum bottom hole diameter d 'and the minimum back bite amount a' corresponding to the sizes of the opposite sides can be obtained by carrying out numerical calculation by combining the manufacturing of the inner hexahedron and the standard limit deviation size of the wrenchpiPreferably bottom hole diameter d' "and preferably back draft a ″.pi。
Preferably, the amount of a 'to be eaten back'piAmount of knife to be taken on one sidepiThe numerical values are compared, and the numerical value ratio of the front and rear values is approximately 0.5 as a whole, i.e., the preferable back draft a 'obtained by taking the coefficient μ of 1.04 is ignored'piApproximate single-side back draft api0.5 of theory. Based on this, when designing the cutting-less, the diameter of the bottom hole can be directly from the smallest opposite side dimension s of the inner hexahedronminAnd the optimal coefficient mu, and the corresponding back draft can be directly calculated by the product of the theoretical value of the side length of the inner hexahedron and the ratio of 0.5, so that the process of designing and calculating the small cutting can be simplified. Preferably, the bottom hole diameter d 'is a reasonable contraction of the maximum bottom hole diameter d', which tends to decrease as the dimensions of the opposite sides of the inner hexahedron increase. Preferably, the amount of a 'is to be taken'piIs to the minimum back draft apiThe enlargement ratio is increased along with the increase of the size of the opposite sides of the inner hexahedron.
Minimum back bite a ″)piThe corresponding maximum bottom hole diameter d' is notThe diagonal size of the inner hexahedron is reached, and the diameter d' of the bottom hole is designed to be gradually reduced along with the increase of the amplification factor; preferably, the coefficient μ is 1.04, and the preferable back draft is "a'piThe cutter is positioned between the maximum cutter carrying capacity and the minimum cutter carrying capacity; the weakest link of the whole basal body is still the opposite angle of the internal hexahedron, and the strength of the basal body is not influenced by the enlarged bottom hole with less cutting design.
5. Low-cutting manufacturing accuracy control of inner hexahedron punching manufacturing method
In the present invention, in step 2), the small cutting back clearance a 'can be calculated from the formula (2) after the side-to-side dimension s and the pilot hole diameter d are given'pi(ii) a After the dimension s of the opposite side is given, the small cutting back clearance a 'can be given according to the requirement'piAnd calculating the corresponding diameter d of the bottom hole by the formula (3); the mutual variation characteristics between the two can be obtained from the formulas (4) and (5). Little cutting back draft a'piThe change rate along with the diameter d of the bottom hole is mainly divided into two stages, and the back cutting amount a 'is reduced along with the increase of the diameter d of the bottom hole in the initial stage'piThe change after the transition tends to be gentle, and the whole change rate process tends to be reduced. Bottom hole diameter d following small cutting back clearance a'piThe change of (2) is gentle, the overall change rate also tends to be reduced, and the cutting back cutting amount a 'is reduced'piThe feedback of the diameter d of the bottom hole is in a tightening state. According to the low cutting back clearance a'piAnd the variation relation between the pilot hole diameter d, the design value of the pilot hole diameter d should exceed the abrupt variation region without affecting the use of the inner hexahedron, so as to avoid the small cutting back clearance a 'caused by the manufacturing variation of the pilot hole diameter d'piIs relatively large. Little cutting back draft a'piThe deviation range of (2) is fed back to the accuracy requirement of the bottom hole diameter d, and the cutter back cutting amount a 'is given in a shrinkage trend'piThe deviation accuracy of the pilot hole diameter d is required to be higher than the small cutting back draft a'piThe deviation accuracy of (1) is such that the back clearance a 'is small in design'piThe deviation of (3) is required in consideration of the precision manufacturing capability in machining the bottom hole diameter d.
According to the above embodiment, the dimension s of the opposite sides of the inner hexahedron is 6mmDesigning the diameter of the low-cutting bottom hole by using a preferred coefficient of 1.04, and substituting the preferred bottom hole diameter d ' into a related formula to obtain the preferred bottom hole diameter d ' of 6.24mm, the maximum bottom hole diameter d ' of 6.72mm and the single-side back bite amount apiIs 3.46mm, corresponding to the preferable back draft a'pi1.75mm, and the diameter of the bottom hole determined by the preferred coefficient is 6.18-6.3 mm. It is preferable that the production error of the pilot hole diameter d ' ″ is. + -. 0.015mm, the obtained pilot hole diameter falls within the preferable range, and the small-cut preferable back-cut amount a ' ″ corresponding to the vertical deviation 'piThe range is 1.696-1.806 mm, and the reduction rate of the back knife-off amount relative to the theoretical basic value is 47.8-51%.
According to the above-described embodiment, the obtained partial prefabricated bottom hole 1 of the inner hexahedron, in which the respective planes are retained after punching, is divided into a plurality of parts, and the partitioned surfaces 2 on the same side are in the same profile.
Claims (9)
1. The inner hexahedron punching and cutting manufacturing method comprises the steps of adopting a punch to punch a base body with a prefabricated bottom hole to manufacture the inner hexahedron, and is characterized in that the diameter of the prefabricated bottom hole is larger than the opposite side size of the inner hexahedron formed after punching and cutting by the punch, the diameter of the prefabricated bottom hole is increased when the prefabricated bottom hole is processed, the diameter of the prefabricated bottom hole is larger than the opposite side size of the inner hexahedron, and the inner hexahedron is punched and cut after the increased prefabricated bottom hole is processed, and the method comprises the following specific steps:
1) aiming at the manufacturing method for increasing the diameter of the prefabricated bottom hole, a few-cutting model of the internal hexahedron punching manufacturing method is established, and the variation relation between the small-cutting back cutting amount, the size of the opposite side of the internal hexahedron and the diameter of the bottom hole is determined;
2) determining the minimum back-cut amount according to the standard requirements of the manufacturing errors of the inner hexahedron and the wrench and the small cutting model in the step 1);
3) the method for determining the small cutting back tool consumption and the bottom hole diameter of the inner hexahedron punching manufacturing method has two determination modes, specifically the following steps:
3.1, directly carrying out coefficient amplification on the minimum back draft obtained in the step 2) to obtain the amplified back draft, and converting the amplified back draft into the designed diameter of the bottom hole;
3.2 obtaining the optimal diameter of the bottom hole with less cutting directly by the product of the optimal coefficient and the size of the opposite side of the inner hexahedron, and converting the optimal diameter into the optimal back cutting amount;
4) determining the manufacturing error of the diameter of the bottom hole:
4.1, limiting the manufacturing error of the designed bottom hole diameter obtained in the step 3.1), wherein the manufacturing error of the designed bottom hole diameter is smaller than the error requirement of the back draft obtained by amplifying the coefficient;
4.2 defining a manufacturing error for the preferred bottom hole diameter obtained in step 3.2), determining a range of values for the preferred bottom hole diameter from the preferred coefficient range, the manufacturing error value for the preferred bottom hole diameter falling within the range of values.
2. The method for producing an internal hexahedron by punching as claimed in claim 1, wherein each plane of the internal hexahedron obtained by the method is divided into a plurality of parts by a part of the prefabricated bottom hole remaining after punching, and the partitioned surfaces on the same side are in the same profile.
3. The method for producing an internal hexahedron by punching according to claim 1, wherein the method for producing an internal hexahedron by punching comprises the following specific steps:
and establishing a plane coordinate system by taking the circle center of the prefabricated bottom hole as an origin, wherein the center of the inner hexahedron is positioned at the origin of the coordinate system, and one group of opposite sides is parallel to the x axis. Along with the increase of the diameter of the bottom hole, the circle of the bottom hole is intersected with the side of the inner hexahedron, the side which is closer to the vertex is selected as an intersection point, the distance between the vertex and the intersection point is half of the cutting back tool consumption, and the coordinates of the intersection point, namely the coordinates of the intersection point are solved
The coordinate of the intersection point is obtained by solving the formula (1)
And converted to vertex coordinates of
Calculating a small cutting back draft equation by using the coordinates of the vertexes and the intersection points:
and (3) calculating a bottom hole diameter equation according to the formula (2):
taking the size of the opposite side as an undetermined constant, and solving a change rate equation of the cutting back draft along with the diameter of the bottom hole by the diameter of the bottom hole in the formula (2):
taking the dimension of the opposite side as an undetermined constant, and obtaining a change rate equation of the diameter of the bottom hole along with the small cutting back bite by calculating the small cutting back bite in the formula (3):
in formulae (1) to (5): x is the number ofAX-axis coordinates for the vertices;
xBx-axis coordinate of intersection, yBY-axis coordinates of the intersection points;
s is the size of the opposite side of the inner hexahedron;
d is the diameter of the bottom hole, the theoretical constraint is
a′piFor reducing the cutting back cutting load, the theoretical constraint is
4. The method for producing an internal hexahedron by punching according to claim 1, wherein the steps of determining the minimum back-cut in step 2) and the diameter of the bottom hole in step 3.1) are as follows:
and (3) the inflection point is rotated around the origin and restored to a state that the opposite side where the inflection point is located is parallel to the x axis, the coordinate of the inflection point is solved, the inflection point is the intersection point of the opposite side and the diagonal edge, and then an inflection point coordinate equation:
the inflection point coordinate obtained by solving the formula (6) is
And thus the equation for the maximum bottom hole diameter at the time of low cutting is converted:
substituting the maximum opposite side size of the inner hexahedron and the maximum bottom hole diameter obtained by the formula (7) into the formula (2) to obtain a minimum back-draught equation:
and (3) after the minimum back draft calculated by the formula (8) is amplified, obtaining a formula (3), and obtaining a designed bottom hole diameter equation by taking the minimum opposite side size of the inner hexahedron:
in formulae (6) to (9): x is the number ofCX-axis coordinate of inflection point, yCY-axis coordinates of inflection points;
eminis the minimum diagonal dimension of the wrench;
s′minthe minimum opposite side size of the wrench;
d' is the maximum bottom hole diameter;
d' is the design bottom hole diameter;
a″pithe minimum back bite is obtained;
smaxthe maximum opposite side size of the inner hexahedron;
sminthe minimum opposite side size of the inner hexahedron;
is the amplification factor.
5. The method for producing an internal hexahedron by punching according to claim 1, wherein the preferred bottom hole diameter and the preferred back draft in step 3.2) are as follows:
substituting the optimization coefficient into the formula (2) to obtain an optimization back-cut quantity equation:
substituting the preferable back bite obtained by the formula (10) into the formula (3) to obtain a preferable bottom hole diameter equation:
in formulas (10) and (11): a'piThe preferable amount of the back eating is;
mu is the optimal coefficient of the diameter of the designed bottom hole;
d' "is the preferred bottom hole diameter.
6. The method for producing an inner hexahedron by punching according to claim 1 or 5, wherein the preferable coefficient is in a range of 1.03 to 1.05.
7. The method for producing an internal hexahedron die cut according to claim 4, wherein the maximum bottom hole diameter is close to the minimum diagonal dimension of the wrench, and the maximum bottom hole diameter is replaced with the minimum diagonal dimension of the wrench in calculating the minimum back bite.
8. The method for producing an inner hexahedron according to claim 4, wherein the influence factors of the minimum back draft include: the size deviation of the inner hexahedron opposite sides, the size deviation of the wrench opposite sides and the size deviation of the wrench opposite corners.
9. The method for producing an internal hexahedron by punching according to claim 1 or 4, wherein the minimum backdraft is a distance between a contact point where an inflection point of the wrench is rotated around an origin to be in contact with the internal plane when an upper deviation limit value of a side dimension of the internal hexahedron and a lower deviation limit value of a side dimension and a diagonal dimension of the wrench are simultaneously reached, and an apex of the internal hexahedron.
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