CN112001049B - Method for manufacturing inner hexahedron by punching and cutting - Google Patents
Method for manufacturing inner hexahedron by punching and cutting Download PDFInfo
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- 238000005520 cutting process Methods 0.000 title claims abstract description 155
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 57
- 238000004080 punching Methods 0.000 title claims abstract description 43
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- G—PHYSICS
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
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Abstract
The manufacturing method of the inner hexahedron with less cutting firstly adopts the mode of increasing the prefabricated bottom hole to reduce the back cutting amount so as to achieve the aim of reducing the cutting force, then establishes a less cutting model to analyze the change characteristic of the method, then determines the minimum back cutting amount during manufacturing according to the manufacturing error standard of the inner hexahedron and the wrench, and finally controls the reasonable back cutting amount and the diameter of the prefabricated bottom hole in a mode of adopting an amplification coefficient or a preferable coefficient according to the load size; the inner hexahedron is processed by adopting a small-cutting manufacturing method, the cutting force is reduced on the premise of guaranteeing the service performance of the inner hexahedron, the precision reduction caused by overlarge punching force is eliminated, the interference to the strength design of parts is avoided, and meanwhile, 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 inner hexahedron of standard fasteners such as screws, bolts and the like mostly adopts a upsetting mode, and small-quantity trial production or special-shaped nonstandard process limitation is not suitable for upsetting and generally adopts punching. The punching process is arranged after the front machining is finished, so that larger impact is brought to the substrate of the semi-finished part, the substrate is deformed, and particularly for an elongated rod piece, the punching force is too large, so that the front machining precision is lost. 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 threaded cartridge valve and the hydraulic servo control system device are limited by the structural characteristics and the use occasions, the threaded cartridge valve and the hydraulic servo control system device can only adopt an inner hexahedral form for adjustment and fastening, and can only adopt a core-moving type precise numerical control machine tool to finish machining of all geometric elements except the inner hexahedron at one time, and finally, a hydraulic press is adopted for punching and cutting to finish machining of the inner hexahedron. 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 parts, the diameter of a prefabricated bottom hole of the traditional punching is smaller than the opposite side size of the inner hexahedron, the punching force is also determined after the basic size is selected according to the traditional inner hexahedron structure, and in order to avoid punching deformation, the radial size of a matrix can be increased according to the punching force during design, so that material waste is caused and unnecessary influence is brought to other designs. In order to avoid punching deformation and interference to related designs, the reduction of cutting force during punching is the root of the problem, and the reduction of cutting force can effectively save energy and reduce consumption.
Disclosure of Invention
The invention provides a manufacturing method for punching and cutting an inner hexahedron, which aims to reduce the cutting force during punching and cutting the inner hexahedron.
The technical problems solved by the invention are realized by adopting the following technical scheme:
The manufacturing method of the inner hexahedron comprises the following specific steps:
1. technical scheme for determining cutting force reduction of inner hexahedron punching and cutting manufacturing method
Based on the machining process of the front channel, the back cutting amount is determined to be reduced by adopting a mode of increasing the diameter of the prefabricated bottom hole, and the diameter size of the prefabricated bottom hole of the inner hexahedron punching and cutting manufacturing method is larger than the corresponding opposite side size of the inner hexahedron, so that the back cutting amount is reduced, and the cutting force is also reduced.
2. Few-cutting model for establishing internal hexahedral punching and cutting manufacturing method
According to the selected cutting force reduction technical scheme, a few-cutting model is established, a plane coordinate system is established by taking the center of a circle of a prefabricated bottom hole as an origin, the center of an internal hexahedron is positioned at the origin of the coordinate system, and one group of opposite sides are parallel to an x-axis. Along with the increase of the diameter of the bottom hole, the circle of the bottom hole intersects with the edge of the inner hexahedron, and the distance between the vertex and the intersection point is half of the small cutting back cutting tool, and the coordinates of the intersection point are solved, namely
Solving the intersection point coordinate of%S/2), and converted to vertex coordinates (/ >)S/2), the small-cutting back-draft equation is calculated by the vertex and the intersection point coordinates:
calculating according to the formula (2) to obtain a bottom hole diameter equation:
Taking the opposite side size as a constant to be determined, deriving the bottom hole diameter in the formula (2) to obtain a change rate equation of the small cutting back draft along with the bottom hole diameter:
Taking the opposite side size as a constant to be determined, and deriving the small cutting back draft in the formula (3) to obtain a change rate equation of the bottom hole diameter along with the small cutting back draft:
In the formulas (1) to (5): x A is the x-axis coordinate of the vertex;
x B is the x-axis coordinate of the intersection point, and y B is the y-axis coordinate of the intersection point;
s is the opposite side size of the inner hexahedron;
d is the bottom hole diameter, theoretical constraint is (s, )；
A' pi is the back-cut, theoretical constraint is (0,)。
3. Determining minimum back cutting tool size of internal hexahedron punching and cutting manufacturing method
The diameter of the bottom hole cannot reach the upper limit value of theoretical constraint due to the influence of actual manufacturing deviation and use abrasion, and the lower limit value of theoretical constraint cannot be reached due to the small cutting back cutting amount; influencing factors include: the inner hexahedron opposite side size deviation, the wrench opposite side size deviation and the wrench opposite side size deviation. In order to ensure normal use of the inner hexahedron, the minimum back cutting tool amount needs to be determined, and the coefficient is amplified on the basis, so that the inner hexahedron can still be normally used after being worn to a certain degree in the later period. The constraint minimum back draft factors are: the opposite side size of the inner hexahedron reaches an upper deviation limit value, the opposite side size of the wrench reaches a lower deviation limit value, and the opposite side size of the wrench reaches a lower deviation limit value; the limit size is achieved at the same time, the inflection point of the wrench contacts with the inner plane after rotating around the original point, and the distance between the contact point and the vertex of the inner hexahedron is the limit constraint on the minimum back cutting tool.
And (3) rotating the inflection point around the origin to recover to a state that the opposite side where the inflection point is positioned is parallel to the x-axis, solving the coordinate of the inflection point, wherein the inflection point is the intersection point of the opposite side and the diagonal bevel edge, and then obtaining an inflection point coordinate equation:
The inflection point coordinate obtained by the solution of (6) is% S' min/2) and thereby to solve the maximum bottom hole diameter equation for less cutting:
substituting the largest opposite side dimension of the inner hexahedron and the largest bottom hole diameter obtained in the formula (7) into the formula (2) to obtain the smallest back draft equation:
The minimum back cutting tool amount obtained in the formula (8) is amplified and substituted into the formula (3), and the minimum opposite side size of the inner hexahedron is taken, so that a designed bottom hole diameter equation is obtained:
In the formulas (6) to (9): x C is the x-axis coordinate of the inflection point, and y C is the y-axis coordinate of the inflection point;
e min is the minimum diagonal dimension of the wrench;
s' min is the minimum edge-to-edge dimension of the wrench;
d' is the maximum bottom hole diameter;
d' is the diameter of the designed bottom hole;
a' pi is the minimum back knife draft;
s max is the largest opposite side dimension of the inner hexahedron;
s min is the minimum opposite side dimension of the inner hexahedron;
delta is the amplification factor.
The maximum bottom hole diameter is close to the minimum diagonal dimension of the wrench, and the minimum back cutting tool amount can be calculated to be replaced by the minimum diagonal dimension of the wrench.
4. Back draft and bottom hole diameter of preferably inner hexahedron punching and cutting manufacturing method
The amplification factor can be selected according to the bearing torque requirement of the inner hexahedron, and is the direct amplification of the minimum back cutting tool draft, and the smaller the amplification factor is, the larger the diameter of the designed bottom hole is; according to the change characteristics between the small cutting back draft and the bottom hole diameter, the design of the increase of the bottom hole diameter after crossing the sharp change region has less influence on the reduction of the small cutting back draft, preferably the bottom hole diameter can be directly determined according to the transition region to be 1.03-1.05 times of the inner hexahedral opposite side size, preferably 1.04 times of the inner hexahedral opposite side size, and the preferred coefficient is substituted into formula (2) to obtain the preferred back draft equation:
substituting the preferred back draft calculated in the formula (10) into the formula (3) to obtain a preferred bottom hole diameter equation:
In the formulas (10) and (11): a' "pi is the preferred back draft;
μ is a design bottom hole diameter preference factor;
d' "is the preferred bottom hole diameter.
In the case of the precise design of the preferred bottom hole diameter determined by the equation (11), the limit value of the vertical deviation should fall within the range of the bottom hole diameter determined by the preference coefficient, and the vertical deviation is designed according to the magnitude of the internal hexahedral torque. If the maximum opposite side dimension of the inner hexahedron is adopted to calculate the preferred back cutting tool amount in the formula (10), a larger back cutting tool amount value can be obtained relative to a theoretical base value, and if the minimum opposite side dimension of the inner hexahedron is adopted to calculate the preferred bottom hole diameter in the formula (11), a smaller bottom hole diameter value can be obtained relative to the theoretical base value, and the numerical orientation of the two values is favorable for the use reliability of the finally formed inner hexahedron.
The minimum back cutting amount is obtained by the formula (8), the back cutting amount corresponding to the amplification coefficient of 2 and the optimization coefficient of 1.04 is positioned between the maximum back cutting amount and the minimum back cutting amount, when the optimization coefficient of 1.04 is obtained, the back cutting amount can be approximately reduced by 49.5% relative to the theoretical base value, and the back cutting amount obtained by adopting the priority coefficient is changed in equal proportion with the opposite side size of the inner hexahedron; when the amplification factor is 2, the back cutting amount can be reduced by 18-71% relative to the theoretical base value, and the reduction rate of the back cutting amount obtained by adopting the amplification factor tends to increase along with the increase of the size of the opposite sides of the inner hexahedron; the coefficient selection mode and the coefficient selection size are determined according to the torque load. According to the related formulas, the maximum bottom hole diameter, the minimum back cutting tool amount, the preferred bottom hole diameter and the preferred back cutting tool amount corresponding to the opposite side sizes can be obtained by carrying out numerical calculation by combining the manufacturing of the inner hexahedron and the standard limit deviation size of the wrench.
And (3) carrying out numerical comparison on the preferred back draft and the unilateral back draft, neglecting numerical calculation taking errors, and enabling the numerical ratio of the front side to the rear side to be approximately 0.51 as a whole, namely obtaining the preferred back draft which is approximately 0.51 of the unilateral back draft theoretical value by taking the preferred coefficient to be 1.04. Based on the above, when designing the small cutting design, the bottom hole diameter can be directly calculated by the product of the minimum opposite side dimension of the inner hexahedron and the optimal coefficient, and the corresponding back cutting amount can be directly calculated by the product of the theoretical value of the side length of the inner hexahedron and the ratio of 0.51, so that the process of calculating the small cutting design can be simplified. Preferably, the bottom hole diameter is reasonably contracted to the maximum bottom hole diameter, and the contraction ratio overall tends to decrease with the increase of the inner hexahedral opposite side size. Preferably, the back draft is further amplified to the minimum back draft, and the amplification ratio tends to increase as the size of the opposite sides of the inner hexahedron increases.
The diameter of the largest bottom hole corresponding to the minimum back cutting tool amount does not reach the diagonal dimension of the inner hexahedron, and the diameter of the designed bottom hole is gradually reduced along with the increase of the amplification factor; the preferred back draft when the preferred coefficient takes 1.04 is between the maximum back draft and the minimum back draft; the weakest link of the whole matrix is still the diagonal position of the inner hexahedron, and the strength of the matrix is not influenced by the enlarged bottom hole with less cutting design.
5. Control of manufacturing accuracy of less cutting in manufacturing method of punching of inner hexahedron
In the invention, in the step 2), after the opposite side size and the bottom hole diameter are given, the small cutting back cutting tool draft can be calculated according to the formula (2); after the opposite side size is given, the back cutting tool size can be given as required, and the corresponding bottom hole diameter is calculated by the formula (3); the mutual variation characteristics between the two can be obtained by the formula (4) and the formula (5). The change rate of the small-cutting back draft along with the diameter of the bottom hole mainly comprises two stages, wherein the small-cutting back draft is rapidly reduced along with the diameter increase of the bottom hole in the initial stage, the change after transition tends to be gentle, and the whole change rate process is in a decreasing trend. The change of the bottom hole diameter along with the small cutting back draft is more gentle, the overall change rate also shows a decreasing trend, and the feedback of the small cutting back draft to the bottom hole diameter d shows a tightening state. According to the change relation between the small-cutting back cutting amount and the bottom hole diameter, on the premise of not influencing the use of the inner hexahedron, the design value of the bottom hole diameter should exceed the abrupt change area, so that larger errors of the small-cutting back cutting amount due to manufacturing deviation of the bottom hole diameter are avoided. The precision requirement fed back to the bottom hole diameter by the deviation range of the small cutting back draft is in a shrinkage trend, and after the deviation requirement of the small cutting back draft is given, the deviation precision requirement of the bottom hole diameter is higher than the deviation precision of the small cutting back draft, so that the precision manufacturing capability in processing the bottom hole diameter needs to be considered when the deviation requirement of the small cutting back draft is designed. Given the manufacturing tolerances of the preferred bottom hole diameters, the top-bottom deviation of the preferred bottom hole diameters should fall within the bottom hole value range determined by the preferred coefficients.
In the present invention, the prefabricated bottom hole of the inner hexahedron, which is obtained by the above manufacturing method, is divided into a plurality of parts by the reserved part after punching, and the separated surfaces on the same side are positioned in the same molded surface.
The beneficial effects are that: the diameter of the prefabricated bottom hole is enlarged, and the back cutting amount 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 relative to the theoretical basic value can be reduced by about 49.5% on the original basis, the cutting force is effectively reduced, the interference to 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 diagram of a small-cut model in a preferred embodiment of the invention.
FIG. 2 is a graph showing the back draft as a function of bottom hole diameter in accordance with a preferred embodiment of the present invention.
FIG. 3 is a graph showing the back draft versus bottom hole diameter variation rate in a preferred embodiment of the present invention.
FIG. 4 is a graph showing the back draft as a function of bottom hole diameter in accordance with a preferred embodiment of the present invention.
FIG. 5 is a graph showing the back draft versus bottom hole diameter variation rate in a preferred embodiment of the present invention.
FIG. 6 is a schematic diagram of a minimum back draft model in a preferred embodiment of the present invention.
FIG. 7 is a schematic diagram showing the comparison of the back draft of 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 invention.
Detailed Description
The invention is further described with reference to the following detailed drawings in order to make the technical means, the creation characteristics, the achievement of the purpose and the effect of the implementation of the invention easy to understand.
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 cutting force reduction of inner hexahedron punching and cutting manufacturing method
Based on the machining process of the front channel, the back cutting amount is determined to be reduced by adopting a mode of increasing the diameter of the prefabricated bottom hole, and the diameter of the prefabricated bottom hole in the small-cutting manufacturing method is larger than the corresponding inner hexahedral opposite side size, so that the back cutting amount is reduced, and the cutting force is also reduced.
2. Few-cutting model for establishing internal hexahedral punching and cutting manufacturing method
According to the selected cutting force reduction technical scheme, a few-cutting model is established, a plane coordinate system is established by taking the center of a bottom hole as an origin O, the center of an internal hexahedron is positioned at the origin O of the coordinate system, and one group of opposite sides are parallel to an x-axis. Along with the increase of the diameter d of the bottom hole, the circle of the bottom hole and the edge of the inner hexahedron generate an intersection point, the intersection point which is closer to the vertex A is selected as B, the distance between the point A and the point B is half of the small cutting back cutting tool amount a' pi/2, and the coordinate (x B,yB) of the point B is solved, namely
The coordinates of the point B are obtained by solving the formula (1)S/2), and converted to A point coordinates (/ >) S/2), calculating a small-cutting back-draft equation from the coordinates of the point A and the point B:
calculating according to the formula (2) to obtain a bottom hole diameter equation:
Taking the opposite side dimension s as a undetermined constant, deriving d in the formula (2) to obtain a change rate equation of the small-cutting back draft a' pi along with the diameter d of the bottom hole:
Taking the opposite side size s as a undetermined constant, deriving a 'pi in the formula (3) to obtain a change rate equation of the bottom hole diameter d along with a' pi:
In the formulas (1) to (5): s is the opposite side size of the inner hexahedron;
d is the bottom hole diameter, theoretical constraint is (s, )；
A' pi is the back-cut, theoretical constraint is (0,)。
3. Determining minimum back cutting tool size of internal hexahedron punching and cutting manufacturing method
The diameter d of the bottom hole cannot reach the upper limit value of theoretical constraint due to the influence of actual manufacturing deviation and use abrasion, and the lower limit value of theoretical constraint cannot be reached due to the small cutting back draft a' pi; influencing factors include: the inner hexahedron opposite side size deviation, the wrench opposite side size deviation and the wrench opposite side size deviation. In order to ensure normal use of the inner hexahedron, the minimum back cutting tool draft a' pi needs to be determined, and the coefficient amplification is carried out on the basis, so that the inner hexahedron can still be normally used after being worn for a certain time in the later period. The constraint on the minimum back draft a "pi is: the opposite side size of the inner hexahedron reaches an upper deviation limit value, the opposite side size of the wrench reaches a lower deviation limit value, and the opposite side size of the wrench reaches a lower deviation limit value; the limit size is achieved at the same time, the inflection point C of the wrench contacts with the inner plane after rotating around the original point O, and the distance between the contact point and the vertex of the inner hexahedron is the limit constraint on the minimum back cutting tool draft a' pi.
And (3) rotating the inflection point C around the origin O to recover to a state that the opposite side where the inflection point C is positioned is parallel to the x-axis, solving the coordinate (x C,yC) of the inflection point C, wherein the inflection point C is the intersection point of the opposite side and the diagonal bevel edge, and then carrying out a C point coordinate equation:
The coordinate of the point C is obtained by solving the formula (6) S' min/2) and thereby to solve the maximum bottom hole diameter equation for less cutting:
Substituting the largest opposite side dimension s max of the inner hexahedron and d' obtained in the formula (7) into the formula (2) to obtain the minimum back draft equation:
The minimum back cutting tool amount a' pi obtained in the formula (8) is amplified and substituted into the formula (3), and the minimum opposite side size s min of the inner hexahedron is taken, so that a designed bottom hole diameter equation is obtained:
In the formulas (6) to (9): e min is the minimum diagonal dimension of the wrench;
s' min is the minimum edge-to-edge dimension of the wrench;
d' is the maximum bottom hole diameter;
d' is the diameter of the designed bottom hole;
a' pi is the minimum back knife draft;
s max is the largest opposite side dimension of the inner hexahedron;
s min is the minimum opposite side dimension of the inner hexahedron;
delta is the amplification factor.
Wherein the maximum bottom hole diameter d' is close to the minimum diagonal dimension e min of the wrench, the calculated minimum back draft a "pi may be replaced with the minimum diagonal dimension e min of the wrench.
4. Back draft and bottom hole diameter of preferably inner hexahedron punching and cutting manufacturing method
The amplification factor delta can be selected according to the bearing torque requirement of the inner hexahedron, is the direct amplification of the minimum back draft a 'pi, and the smaller the amplification factor delta is, the larger the diameter d' of the designed bottom hole is; according to the variation characteristics between the small-cutting back draft a 'pi and the bottom hole diameter d, the reduction of the small-cutting back draft a' pi is less affected by the increase of the design bottom hole diameter d 'after crossing the sharp-change region, the design bottom hole diameter d' can be determined to be 1.03-1.05 s, preferably 1.04s, according to the transition region, and the preferred coefficient μ is substituted into formula (2) to obtain the preferred back draft equation:
substituting the preferred back draft a' "pi calculated in equation (10) into equation (3) to obtain the preferred bottom hole diameter equation:
In the formulas (10) and (11): a' "pi is the preferred back draft;
μ is a design bottom hole diameter preference factor;
d' "is the preferred bottom hole diameter.
In the case of the precise design of the preferred bottom hole diameter d' "determined by the equation (11), the limit value of the vertical deviation should fall within the bottom hole diameter range determined by the preferred coefficient μ, and the vertical deviation should be designed depending on the magnitude of the internal hexahedral load torque. If the maximum opposite side dimension s max of the inner hexahedron is adopted in the formula (10), the preferred back cutting amount a '"pi is calculated, a larger back cutting amount value can be obtained relative to a theoretical base value, and if the minimum opposite side dimension s min of the inner hexahedron is adopted in the formula (11), the preferred bottom hole diameter d'" is calculated, a smaller bottom hole diameter value can be obtained relative to the theoretical base value, and the numerical orientation of the two is favorable for the use reliability of the finally formed inner hexahedron.
The minimum back draft a' pi is obtained by the formula (8), the amplification coefficient delta is 2, the back draft corresponding to the optimal coefficient mu is 1.04 and is positioned between the maximum back draft and the minimum back draft, when the optimal coefficient mu is 1.04, the back draft can be reduced by 49.5 percent relative to the theoretical base value, and the back draft obtained by adopting the optimal coefficient mu is changed in equal proportion with the opposite side size of the inner hexahedron; when the amplification factor delta is 2, the back cutting amount can be reduced by 18-71% relative to the theoretical base value, and the reduction rate of the back cutting amount obtained by adopting the amplification factor delta tends to increase along with the increase of the size of the opposite sides of the inner hexahedron; the coefficient selection mode and the coefficient selection size are determined according to the torque load. According to the related formulas, the maximum bottom hole diameter d ', the minimum back draft a' pi, the preferred bottom hole diameter d 'and the preferred back draft a' pi corresponding to the opposite side sizes can be obtained by carrying out numerical calculation in combination with the standard limit deviation size of the inner hexahedron manufacture and the spanner.
The preferred back draft a '"pi is compared with the single-side back draft a pi in numerical comparison, the error is ignored in numerical calculation, and the numerical ratio of the front and the rear is approximately 0.5 as a whole, namely, the preferred back draft a'" pi obtained by taking the preferred coefficient mu to 1.04 is approximately 0.5 of the theoretical value of the single-side back draft a pi. Based on the above, in the case of the small-cutting design, the bottom hole diameter can be directly calculated by the product of the minimum opposite side dimension s min of the inner hexahedron and the optimal coefficient mu, and the corresponding back cutting amount 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 calculating the small-cutting design can be simplified. Preferably, the bottom hole diameter d '"is a reasonable shrinkage of the maximum bottom hole diameter d', with the shrinkage ratio generally tending to decrease as the size of the opposite side of the inner hexahedron increases. Preferably, the back draft a' "pi is a further enlargement of the minimum back draft a" pi, the enlargement ratio as a whole tending to increase with an increase in the size of the opposite side of the inner hexahedron.
The maximum bottom hole diameter d ' corresponding to the minimum back draft a ' pi does not reach the diagonal dimension of the inner hexahedron, and the designed bottom hole diameter d ' gradually decreases with the increase of the amplification factor delta; the preferred back draft a' "pi for a preferred coefficient μ of 1.04 is between the maximum back draft and the minimum back draft; the weakest link of the whole matrix is still the diagonal position of the inner hexahedron, and the strength of the matrix is not influenced by the enlarged bottom hole with less cutting design.
5. Control of manufacturing accuracy of less cutting in manufacturing method of punching of inner hexahedron
In the invention, in the step 2), after the opposite side size s and the bottom hole diameter d are given, the small-cutting back-draft a' pi can be calculated according to the formula (2); after the opposite side dimension s is given, the small cutting back draft a' pi can be given according to the requirement, and the corresponding bottom hole diameter d is calculated by the formula (3); the mutual variation characteristics between the two can be obtained by the formula (4) and the formula (5). The change rate of the small-cutting back draft a 'pi along with the diameter d of the bottom hole mainly comprises two stages, the small-cutting back draft a' pi is rapidly reduced along with the increase of the diameter d of the bottom hole in the initial stage, the change after transition is smooth, and the whole change rate process is in a decreasing trend. The change of the bottom hole diameter d along with the small cutting back draft a 'pi is gentle, the overall change rate also tends to be reduced, and the feedback of the small cutting back draft a' pi to the bottom hole diameter d is in a tightening state. According to the change relation between the small-cutting back draft a 'pi and the bottom hole diameter d, on the premise of not influencing the use of the inner hexahedron, the design value of the bottom hole diameter d should exceed the steep change area, so that larger errors of the small-cutting back draft a' pi caused by manufacturing deviation of the bottom hole diameter d are avoided. The precision requirement that the deviation range of the small cutting back draft a 'pi is fed back to the bottom hole diameter d is in a shrinkage trend, and after the deviation requirement of the small cutting back draft a' pi is given, the deviation precision requirement of the bottom hole diameter d is higher than the deviation precision of the small cutting back draft a 'pi, so that the precision manufacturing capability in the process of machining the bottom hole diameter d needs to be considered when the deviation requirement of the small cutting back draft a' pi is designed.
According to the embodiment, the inner hexahedron opposite side size s is 6mm, the preferable coefficient 1.04 is adopted to design the diameter of the small cutting bottom hole, the preferable bottom hole diameter d ' "is 6.24mm according to the related formula, the maximum bottom hole diameter d ' is 6.72mm, the unilateral back draft a pi is 3.46mm, the corresponding preferable back draft a '" pi is 1.75mm, and the bottom hole diameter range determined according to the preferable coefficient is 6.18-6.3 mm. The manufacturing error of the diameter d '"of the bottom hole is preferably + -0.015 mm, the diameter range of the bottom hole is within the preferred range, the preferable back draft a'" pi of the small cutting corresponding to the up-down deviation is 1.696-1.806 mm, and the reduction rate of the back draft relative to the theoretical basic value is 47.8-51%.
According to the above embodiment, the obtained inner hexahedron has the respective planes divided into the plurality of portions by the partially preformed bottom holes 1 remaining after the punching, and the separated faces 2 on the same side are in the same profile.
Claims (8)
1. The method for manufacturing the inner hexahedron by punching the matrix with the prefabricated bottom hole by adopting the punch is characterized in that the diameter of the prefabricated bottom hole is larger than the opposite side size of the inner hexahedron formed by punching by adopting the punch, when the prefabricated bottom hole is processed, the diameter of the prefabricated bottom hole is increased, so that the diameter of the prefabricated bottom hole is larger than the opposite side size of the inner hexahedron, and after the increased prefabricated bottom hole is processed, the inner hexahedron is processed by punching, and the method comprises the following specific steps of:
1) Aiming at a manufacturing method for increasing the diameter of a prefabricated bottom hole, a small-cutting model of an inner hexahedral punching and cutting manufacturing method is established, and the change relation between the small-cutting back cutting amount and the inner hexahedral opposite side size and the bottom hole diameter is determined;
2) Determining the minimum back cutting amount according to the standard requirements of manufacturing errors of the inner hexahedron and the wrench and by the less cutting model in the step 1);
3) The method for determining the small cutting back cutting amount and the bottom hole diameter of the inner hexahedron punching and cutting manufacturing method has two determining modes, and is concretely as follows:
3.1 directly carrying out coefficient amplification on the minimum back cutting amount obtained in the step 2) to obtain amplified back cutting amount, and converting the amplified back cutting amount to obtain the diameter of the designed bottom hole;
3.2 directly obtaining the preferable bottom hole diameter which is cut less by the product of the preferable coefficient and the inner hexahedron opposite side size, and obtaining the preferable back cutting tool amount through conversion;
4) Determining manufacturing errors of the bottom hole diameter:
4.1 limiting manufacturing errors on the diameter of the designed bottom hole obtained in the step 3.1), wherein the manufacturing errors on the diameter of the designed bottom hole are smaller than the error requirement on the back cutting tool amount obtained by coefficient amplification;
4.2 defining a manufacturing error for the preferred bottom hole diameter obtained in step 3.2), determining a value range of the preferred bottom hole diameter according to a preferred coefficient range, the value of the manufacturing error for the preferred bottom hole diameter falling within the value range;
The method comprises the steps of establishing a plane coordinate system by taking the center of a prefabricated bottom hole as an origin, establishing a plane coordinate system by taking the center of the prefabricated bottom hole as the origin, setting the center of an internal hexahedron at the origin of the coordinate system, enabling one group of opposite sides to be parallel to an x axis, intersecting the circle of the bottom hole with the side of the internal hexahedron along with the increase of the diameter of the bottom hole, selecting the circle closer to an apex as an intersection point, enabling the distance between the apex and the intersection point to be half of the cutting back cutting tool, and solving the coordinates of the intersection point, namely
Solving the intersection point coordinate from the formula (1) asAnd converted to obtain vertex coordinates as/> The small cutting back draft equation is calculated by the vertex and intersection point coordinates:
calculating according to the formula (2) to obtain a bottom hole diameter equation:
Taking the opposite side size as a constant to be determined, deriving the bottom hole diameter in the formula (2) to obtain a change rate equation of the small cutting back draft along with the bottom hole diameter:
Taking the opposite side size as a constant to be determined, and deriving the small cutting back draft in the formula (3) to obtain a change rate equation of the bottom hole diameter along with the small cutting back draft:
In the formulas (1) to (5): x A is the x-axis coordinate of the vertex;
x B is the x-axis coordinate of the intersection point, and y B is the y-axis coordinate of the intersection point;
s is the opposite side size of the inner hexahedron;
d is the bottom hole diameter, theoretical constraint is
A' pi is the small back-cutting tool-taking amount, and the theoretical constraint is that
2. The method of manufacturing an internal hexahedron according to claim 1, wherein the respective planes of the internal hexahedron obtained by the manufacturing method are divided into a plurality of parts by the partially preformed bottom hole remaining after the punching, and the separated surfaces on the same side are in the same mold surface.
3. The method for manufacturing the inner hexahedron by punching according to claim 1, wherein the minimum back cutting amount in the step 2) and the designed bottom hole diameter in the step 3.1) are determined as follows:
And (3) rotating the inflection point around the origin to recover to a state that the opposite side where the inflection point is positioned is parallel to the x-axis, solving the coordinate of the inflection point, wherein the inflection point is the intersection point of the opposite side and the diagonal bevel edge, and then obtaining an inflection point coordinate equation:
The inflection point coordinates obtained by the solution of (6) are And thus the equation for the maximum bottom hole diameter at low cut:
substituting the largest opposite side dimension of the inner hexahedron and the largest bottom hole diameter obtained in the formula (7) into the formula (2) to obtain the smallest back draft equation:
The minimum back cutting tool amount obtained in the formula (8) is amplified and substituted into the formula (3), and the minimum opposite side size of the inner hexahedron is taken, so that a designed bottom hole diameter equation is obtained:
In the formulas (6) to (9): x C is the x-axis coordinate of the inflection point, and y C is the y-axis coordinate of the inflection point;
e min is the minimum diagonal dimension of the wrench;
s' min is the minimum edge-to-edge dimension of the wrench;
d' is the maximum bottom hole diameter;
d' is the diameter of the designed bottom hole;
a' pi is the minimum back knife draft;
s max is the largest opposite side dimension of the inner hexahedron;
s min is the minimum opposite side dimension of the inner hexahedron;
delta is the amplification factor.
4. The method of manufacturing the inner hexahedron according to claim 1, wherein the preferable bottom hole diameter and the preferable back draft in the step 3.2) are as follows:
substituting the preference coefficients into equation (2) to obtain the preference back draft equation:
substituting the preferred back draft calculated in the formula (10) into the formula (3) to obtain a preferred bottom hole diameter equation:
In the formulas (10) and (11): a' "pi is the preferred back draft;
μ is a design bottom hole diameter preference factor;
d' "is the preferred bottom hole diameter.
5. The method of manufacturing an internal hexahedron punch as set forth in claim 1 or 4, wherein the preferable coefficient range is 1.03 to 1.05.
6. The method of manufacturing an internal hexahedron punch of claim 4, wherein the maximum bottom hole diameter is approximately the smallest diagonal dimension of the wrench, and the smallest diagonal dimension of the wrench can be used in place of the maximum bottom hole diameter in calculating the smallest back draft.
7. The method of manufacturing an internal hexahedron punch as set forth in claim 4, wherein the influence factors of the minimum back draft include: the inner hexahedron opposite side size deviation, the wrench opposite side size deviation and the wrench opposite side size deviation.
8. The method of manufacturing an internal hexahedron punch as set forth in claim 1 or 4, wherein the minimum back draft is a distance between a contact point, which is a contact point with an internal plane after a wrench inflection point rotates around an origin, and an internal hexahedral vertex when an internal hexahedral opposite side size reaches an upper deviation limit value and an opposite side size and a diagonal side size of the wrench reach a lower deviation limit value at the same time.
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| JP2006297439A (en) * | 2005-04-19 | 2006-11-02 | Nissan Motor Co Ltd | Device and method for processing cylindrical flange part |
| CN108241774A (en) * | 2016-12-23 | 2018-07-03 | 恩格尔奥地利有限公司 | For simulating the method for forming process |
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| JP2006297439A (en) * | 2005-04-19 | 2006-11-02 | Nissan Motor Co Ltd | Device and method for processing cylindrical flange part |
| CN108241774A (en) * | 2016-12-23 | 2018-07-03 | 恩格尔奥地利有限公司 | For simulating the method for forming process |
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| 基于ABAQUS的薄壁圆筒零件车削加工变形补偿计算;陈双喜;;组合机床与自动化加工技术;20081120(第11期);全文 * |
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