Disclosure of Invention
The invention provides a machining method of a ring forging with a complex special-shaped cross section for solving the technical problems.
In order to achieve the above purpose, the invention adopts the following technical scheme:
a machining method of a ring forging with a complex special-shaped cross section comprises the steps of rough machining, semi-finish turning and finish machining, and specifically comprises the following steps:
(1) rough machining: rough machining is carried out on the blank according to the required size, allowance is uniformly reserved on the single-edge profile of the blank, the deformation of the blank is measured after the rough machining is finished, and the blank is machined to the required size of the rough machining;
(2) semi-finish turning: after rough machining is finished, placing the blank in a free state, performing semi-finish turning, uniformly reserving allowance for the single-edge profile of the blank according to the required size, measuring the deformation of the blank after the semi-finish turning is finished, and machining to the required size of rough machining;
(3) finish machining: and (3) respectively carrying out finish machining on A, B, C, D, E, F, G, H, I, J, K, L, M areas of the blank according to the required size, and obtaining the ring forging with the complicated special-shaped section after machining to the required size of the forging.
Further, in the step (1), in the rough machining process, the allowance of the single side of the blank along the molded surface is 1.5-2 mm, the deformation of the blank is controlled to be less than 0.5mm, namely, the difference between the maximum value and the minimum value of the profile of the blank is less than 1 mm.
Further, in the step (1), the cutting speed of rough machining is 30-35 m/min, the feeding is 0.25-0.35 mm/r, and the cutting depth is 2.5-3.5 mm.
Further, in the step (2), the blank is uniformly reserved with allowance of 0.45-0.55 mm along the molded surface at a single edge during semi-finish turning, and the deformation of the blank is controlled to be less than 0.2 mm.
Further, in the step (2), the cutting speed of the semi-finish turning is 25-30 m/min, the feeding is 0.25-0.35 mm/r, and the cutting depth is 1.5-2.5 mm.
Further, in the step (3), the finish machining has a cutting speed of 30-40 m/min, a feed of 0.08-0.1 mm/r and a cutting depth of 0.1-0.15 mm.
Further, in step (3), the finishing specifically comprises: processing eight areas of A, C, D, E, G, J, K, L blanks according to required sizes, uniformly reserving allowance of 0.1-0.15 mm along a molded surface of a single edge of the blanks during processing, and processing five areas of B, F, H, I, M blanks according to requirements to required sizes; then processing three areas of the blank outer diameter A, L, J according to the required size; then the tool nose is replaced, the outer diameter K area of the machined blank is changed to the required size, the inner diameter is clamped, then the tool nose is replaced, the inner diameter E, G area of the machined blank is changed to the required size, then the tool nose is replaced, the inner diameter D area of the machined blank is changed to the required size, finally the tool nose is replaced, and the end face of the inner diameter C area is machined to the required size.
Further, in step (3), the area of the blank A, C, D, E, G, J, K, L is subjected to finish machining according to requirements, so that the surface roughness of the blank reaches Ra1.6 μm required by the drawing; and a new tip is replaced after each operation is completed during the profile finishing in the region A, C, D, E, G, J, K, L.
Further, in step (3), the radius of the cutting edge used for finishing is 1.2mm, or the radius of the cutting edge used for finishing is 0.8 and the feed is less than or equal to 0.08 mm/R.
Further, the deformation amount is measured in the following manner: measuring once after loosening the claw, measuring once after loosening the claw and freely placing the claw, comparing the two, and if the deformation is more than 0.5mm, correcting the deformation of the blank and then performing semi-finishing; the time for freely placing the blank is 24-28 h.
The used equipment of this application rough machining: ordinary vertical carriage CA51125(1.25 m); cutting tool: a common hand grind welding tool YG8 or YW 2. Equipment used for semi-finishing: numerical control vertical lathe CK51125(1.25 m); cutting tool: RCMT0602M0 or WNMG 080412. Equipment used for finish machining: numerical control vertical lathe CK51125(1.25 m); cutting tool: WNMG 080412.
The following matters are noted in the finishing process:
1. a, C, D, E, G, J, K, L, the molded surface of the area of the line segment is related to the qualification rate of water immersion flaw detection, and the surface roughness must reach Ra1.6 mu m of the target size;
2. a, C, D, E, G, J, K, L the profile finish in the region of the line segment must use a new tip (4.5 tips for 1 part) which can be used for semi-finishing and first finishing;
3. the maximum sharp edge chamfer angle required by a customer drawing is 0.76mm, and the smaller the sharp edge chamfer angle is, the better the sharp edge chamfer angle is, the smaller the sharp edge chamfer angle is, the control is within 0.4mm under the condition of ensuring no burrs; in the range of ensuring the customer drawing, the outer diameter of the molded surface of the A, C, D, E, G, J, K, L line section area is processed according to the difference as much as possible, and the inner diameter is processed according to the difference as much as possible, and the thicker the wall thickness is, the higher the qualified rate of water immersion flaw detection is.
Due to the adoption of the technical scheme, the invention has the following beneficial effects:
the technical problem of the background art is solved by adjusting a processing process route, selecting a proper cutter, optimizing cutting parameters and controlling the cutter to use. By adopting the improved process machine for machining, the machining time of a single product can be saved by about 400min, the surface roughness of the product is less than Ra0.63 mu m, the surface quality of the product is greatly improved, and the flaw detection qualification rate of the product is improved from 56% to 98.5%.
Detailed Description
The following is a detailed description of the embodiments of the present invention, but the present invention is not limited to these embodiments, and any modifications or substitutions in the basic spirit of the embodiments are included in the scope of the present invention as claimed in the claims.
Example 1
A machining method of a ring forging with a complex special-shaped cross section comprises the steps of rough machining, semi-finish turning and finish machining, and specifically comprises the following steps:
(1) rough machining: rough machining is carried out on the blank according to the required size, allowance is uniformly reserved on the single-edge profile of the blank, the deformation of the blank is measured after the rough machining is finished, and the blank is machined to the required size of the rough machining;
in the rough machining process, the allowance of the single edge of the blank along the molded surface is 1.5mm, the deformation of the blank is controlled to be less than 0.5mm, namely the difference between the maximum value and the minimum value of the contour of the blank is less than 1 mm; the cutting speed of rough machining is 30m/min, the feeding is 0.25mm/r, and the cutting depth is 2.5 mm;
(2) semi-finish turning: after rough machining is finished, placing the blank in a free state, performing semi-finish turning, uniformly reserving allowance for the single-edge profile of the blank according to the required size, measuring the deformation of the blank after the semi-finish turning is finished, and machining to the required size of rough machining;
when semi-finish turning is carried out, the allowance of a single edge of the blank is uniformly kept to be 0.45mm, and the deformation of the blank is controlled to be less than 0.2 mm; the cutting speed of the semi-finish turning is 25m/min, the feeding is 0.25mm/r, and the cutting depth is 1.5 mm;
(3) finish machining: respectively carrying out fine machining on A, B, C, D, E, F, G, H, I, J, K, L, M areas of the blank according to the required size, and obtaining the ring forging with the complicated special-shaped cross section after machining to the required size of the forging;
the cutting speed of finish machining is 30m/min, the feeding is 0.08mm/r, and the cutting depth is 0.1 mm; the fine processing comprises the following specific steps: firstly, processing eight areas of the blank A, C, D, E, G, J, K, L according to the required size, uniformly reserving allowance of 0.1mm along the profile of a single edge of the blank during processing, and processing five areas of the blank B, F, H, I, M according to the requirement to the required size; then processing three areas of the blank outer diameter A, L, J according to the required size; then, a tool nose is replaced, the area K of the outer diameter of the blank is machined to a required size, the inner diameter of the blank is clamped, then the tool nose is replaced, the two areas E, G of the inner diameter of the blank are machined to the required size, then the tool nose is replaced, the area D of the inner diameter of the blank is machined to the required size, finally the tool nose is replaced, and the end face of the area C of the inner diameter is machined to the required size; performing finish machining on the A, C, D, E, G, J, K, L area of the blank as required to ensure that the surface roughness of the blank reaches Ra1.6 mu m required by the drawing; in the process of finishing the molded surface in the A, C, D, E, G, J, K, L area, the tool tip is replaced by a new tool tip after each operation is finished; the radius of the tool nose used for finishing is 1.2mm, or the radius of the tool nose is 0.8 and the feeding is less than or equal to 0.08 mm/R.
Further, the deformation amount is measured in the following manner: measuring once after loosening the claw, measuring once after loosening the claw and freely placing the claw, comparing the two, and if the deformation is more than 0.5mm, correcting the deformation of the blank and then performing semi-finishing; the time for the blank to stand freely is 24 h.
Example 2
A machining method of a ring forging with a complex special-shaped cross section comprises the steps of rough machining, semi-finish turning and finish machining, and specifically comprises the following steps:
(1) rough machining: rough machining is carried out on the blank according to the required size, allowance is uniformly reserved on the single-edge profile of the blank, the deformation of the blank is measured after the rough machining is finished, and the blank is machined to the required size of the rough machining;
in the rough machining process, the single side of the blank is uniformly left with 2mm of allowance along the molded surface, the deformation of the blank is controlled to be less than 0.5mm, namely the difference between the maximum value and the minimum value of the contour of the blank is less than 1 mm; the cutting speed of rough machining is 35m/min, the feeding is 0.35mm/r, and the cutting depth is 3.5 mm;
(2) semi-finish turning: after rough machining is finished, placing the blank in a free state, performing semi-finish turning, uniformly reserving allowance for the single-edge profile of the blank according to the required size, measuring the deformation of the blank after the semi-finish turning is finished, and machining to the required size of rough machining;
when semi-finish turning is carried out, the blank is uniformly left with a margin of 0.55mm along the molded surface, and the deformation of the blank is controlled to be less than 0.2 mm; the cutting speed of the semi-finish turning is 30m/min, the feeding is 0.35mm/r, and the cutting depth is 2.5 mm;
(3) finish machining: respectively carrying out fine machining on A, B, C, D, E, F, G, H, I, J, K, L, M areas of the blank according to the required size, and obtaining the ring forging with the complicated special-shaped cross section after machining to the required size of the forging;
the cutting speed of finish machining is 40m/min, the feeding is 0.1mm/r, and the cutting depth is 0.15 mm; the fine processing comprises the following specific steps: firstly, processing eight areas of the blank A, C, D, E, G, J, K, L according to the required size, uniformly reserving allowance of 0.15mm along the profile of a single edge of the blank during processing, and processing five areas of the blank B, F, H, I, M according to the requirement to the required size; then processing three areas of the blank outer diameter A, L, J according to the required size; then, a tool nose is replaced, the area K of the outer diameter of the blank is machined to a required size, the inner diameter of the blank is clamped, then the tool nose is replaced, the two areas E, G of the inner diameter of the blank are machined to the required size, then the tool nose is replaced, the area D of the inner diameter of the blank is machined to the required size, finally the tool nose is replaced, and the end face of the area C of the inner diameter is machined to the required size; performing finish machining on the A, C, D, E, G, J, K, L area of the blank as required to ensure that the surface roughness of the blank reaches Ra1.6 mu m required by the drawing; in the process of finishing the molded surface in the A, C, D, E, G, J, K, L area, the tool tip is replaced by a new tool tip after each operation is finished; the radius of the tool nose used for finishing is 1.2mm, or the radius of the tool nose is 0.8 and the feeding is less than or equal to 0.08 mm/R.
Further, the deformation amount is measured in the following manner: measuring once after loosening the claw, measuring once after loosening the claw and freely placing the claw, comparing the two, and if the deformation is more than 0.5mm, correcting the deformation of the blank and then performing semi-finishing; the time for the blank to rest freely was 28 h.
Example 3
A machining method of a ring forging with a complex special-shaped cross section comprises the steps of rough machining, semi-finish turning and finish machining, and specifically comprises the following steps:
(1) rough machining: rough machining is carried out on the blank according to the required size, allowance is uniformly reserved on the single-edge profile of the blank, the deformation of the blank is measured after the rough machining is finished, and the blank is machined to the required size of the rough machining;
in the rough machining process, the allowance of the single edge of the blank along the molded surface is uniformly 1.6mm, the deformation of the blank is controlled to be less than 0.5mm, namely the difference between the maximum value and the minimum value of the contour of the blank is less than 1 mm; the cutting speed of rough machining is 31m/min, the feeding is 0.27mm/r, and the cutting depth is 2.7 mm;
(2) semi-finish turning: after rough machining is finished, placing the blank in a free state, performing semi-finish turning, uniformly reserving allowance for the single-edge profile of the blank according to the required size, measuring the deformation of the blank after the semi-finish turning is finished, and machining to the required size of rough machining;
when semi-finish turning is carried out, the blank is uniformly left with a margin of 0.48mm along the molded surface, and the deformation of the blank is controlled to be less than 0.2 mm; the cutting speed of the semi-finish turning is 26m/min, the feeding is 0.28mm/r, and the cutting depth is 1.7 mm;
(3) finish machining: respectively carrying out fine machining on A, B, C, D, E, F, G, H, I, J, K, L, M areas of the blank according to the required size, and obtaining the ring forging with the complicated special-shaped cross section after machining to the required size of the forging;
the cutting speed of finish machining is 32m/min, the feeding is 0.085mm/r, and the cutting depth is 0.11 mm; the fine processing comprises the following specific steps: firstly, processing eight areas of the blank A, C, D, E, G, J, K, L according to the required size, uniformly reserving allowance of 0.11mm along the profile of a single edge of the blank during processing, and processing five areas of the blank B, F, H, I, M according to the requirement to the required size; then processing three areas of the blank outer diameter A, L, J according to the required size; then, a tool nose is replaced, the area K of the outer diameter of the blank is machined to a required size, the inner diameter of the blank is clamped, then the tool nose is replaced, the two areas E, G of the inner diameter of the blank are machined to the required size, then the tool nose is replaced, the area D of the inner diameter of the blank is machined to the required size, finally the tool nose is replaced, and the end face of the area C of the inner diameter is machined to the required size; performing finish machining on the A, C, D, E, G, J, K, L area of the blank as required to ensure that the surface roughness of the blank reaches Ra1.6 mu m required by the drawing; in the process of finishing the molded surface in the A, C, D, E, G, J, K, L area, the tool tip is replaced by a new tool tip after each operation is finished; the radius of the tool nose used for finishing is 1.2mm, or the radius of the tool nose is 0.8 and the feeding is less than or equal to 0.08 mm/R.
Further, the deformation amount is measured in the following manner: measuring once after loosening the claw, measuring once after loosening the claw and freely placing the claw, comparing the two, and if the deformation is more than 0.5mm, correcting the deformation of the blank and then performing semi-finishing; the time for the blank to stand freely was 25 h.
Example 4
A machining method of a ring forging with a complex special-shaped cross section comprises the steps of rough machining, semi-finish turning and finish machining, and specifically comprises the following steps:
(1) rough machining: rough machining is carried out on the blank according to the required size, allowance is uniformly reserved on the single-edge profile of the blank, the deformation of the blank is measured after the rough machining is finished, and the blank is machined to the required size of the rough machining;
in the rough machining process, the allowance of the single edge of the blank along the molded surface is 1.9mm, the deformation of the blank is controlled to be less than 0.5mm, namely the difference between the maximum value and the minimum value of the contour of the blank is less than 1 mm; the cutting speed of rough machining is 34m/min, the feeding is 0.33mm/r, and the cutting depth is 3.3 mm;
(2) semi-finish turning: after rough machining is finished, placing the blank in a free state, performing semi-finish turning, uniformly reserving allowance for the single-edge profile of the blank according to the required size, measuring the deformation of the blank after the semi-finish turning is finished, and machining to the required size of rough machining;
when semi-finish turning is carried out, the blank is uniformly left with a margin of 0.53mm along the molded surface, and the deformation of the blank is controlled to be less than 0.2 mm; the cutting speed of the semi-finish turning is 29m/min, the feeding is 0.33mm/r, and the cutting depth is 2.3 mm;
(3) finish machining: respectively carrying out fine machining on A, B, C, D, E, F, G, H, I, J, K, L, M areas of the blank according to the required size, and obtaining the ring forging with the complicated special-shaped cross section after machining to the required size of the forging;
the cutting speed of finish machining is 38m/min, the feeding is 0.095mm/r, and the cutting depth is 0.14 mm; the fine processing comprises the following specific steps: firstly, processing eight areas of the blank A, C, D, E, G, J, K, L according to the required size, uniformly reserving allowance of 0.14mm along the profile of a single edge of the blank during processing, and processing five areas of the blank B, F, H, I, M according to the requirement to the required size; then processing three areas of the blank outer diameter A, L, J according to the required size; then, a tool nose is replaced, the area K of the outer diameter of the blank is machined to a required size, the inner diameter of the blank is clamped, then the tool nose is replaced, the two areas E, G of the inner diameter of the blank are machined to the required size, then the tool nose is replaced, the area D of the inner diameter of the blank is machined to the required size, finally the tool nose is replaced, and the end face of the area C of the inner diameter is machined to the required size; performing finish machining on the A, C, D, E, G, J, K, L area of the blank as required to ensure that the surface roughness of the blank reaches Ra1.6 mu m required by the drawing; in the process of finishing the molded surface in the A, C, D, E, G, J, K, L area, the tool tip is replaced by a new tool tip after each operation is finished; the radius of the tool nose used for finishing is 1.2mm, or the radius of the tool nose is 0.8 and the feeding is less than or equal to 0.08 mm/R.
Further, the deformation amount is measured in the following manner: measuring once after loosening the claw, measuring once after loosening the claw and freely placing the claw, comparing the two, and if the deformation is more than 0.5mm, correcting the deformation of the blank and then performing semi-finishing; the time for the blank to rest freely was 27 h.
Example 5
A machining method of a ring forging with a complex special-shaped cross section comprises the steps of rough machining, semi-finish turning and finish machining, and specifically comprises the following steps:
(1) rough machining: rough machining is carried out on the blank according to the required size, allowance is uniformly reserved on the single-edge profile of the blank, the deformation of the blank is measured after the rough machining is finished, and the blank is machined to the required size of the rough machining;
in the rough machining process, the allowance of the single edge of the blank along the molded surface is 1.8mm, the deformation of the blank is controlled to be less than 0.5mm, namely the difference between the maximum value and the minimum value of the contour of the blank is less than 1 mm; the cutting speed of rough machining is 33m/min, the feeding is 0.3mm/r, and the cutting depth is 3.0 mm;
(2) semi-finish turning: after rough machining is finished, placing the blank in a free state, performing semi-finish turning, uniformly reserving allowance for the single-edge profile of the blank according to the required size, measuring the deformation of the blank after the semi-finish turning is finished, and machining to the required size of rough machining;
when semi-finish turning is carried out, the blank is uniformly left with a margin of 0.5mm along the molded surface, and the deformation of the blank is controlled to be less than 0.2 mm; the cutting speed of the semi-finish turning is 28m/min, the feeding is 0.3mm/r, and the cutting depth is 2.0 mm;
(3) finish machining: respectively carrying out fine machining on A, B, C, D, E, F, G, H, I, J, K, L, M areas of the blank according to the required size, and obtaining the ring forging with the complicated special-shaped cross section after machining to the required size of the forging;
the cutting speed of finish machining is 35m/min, the feeding is 0.09mm/r, and the cutting depth is 0.13 mm; the fine processing comprises the following specific steps: firstly, processing eight areas of the blank A, C, D, E, G, J, K, L according to the required size, uniformly reserving allowance of 0.12mm along the profile of a single edge of the blank during processing, and processing five areas of the blank B, F, H, I, M according to the requirement to the required size; then processing three areas of the blank outer diameter A, L, J according to the required size; then, a tool nose is replaced, the area K of the outer diameter of the blank is machined to a required size, the inner diameter of the blank is clamped, then the tool nose is replaced, the two areas E, G of the inner diameter of the blank are machined to the required size, then the tool nose is replaced, the area D of the inner diameter of the blank is machined to the required size, finally the tool nose is replaced, and the end face of the area C of the inner diameter is machined to the required size; performing finish machining on the A, C, D, E, G, J, K, L area of the blank as required to ensure that the surface roughness of the blank reaches Ra1.6 mu m required by the drawing; in the process of finishing the molded surface in the A, C, D, E, G, J, K, L area, the tool tip is replaced by a new tool tip after each operation is finished; the radius of the tool nose used for finishing is 1.2mm, or the radius of the tool nose is 0.8 and the feeding is less than or equal to 0.08 mm/R.
Further, the deformation amount is measured in the following manner: measuring once after loosening the claw, measuring once after loosening the claw and freely placing the claw, comparing the two, and if the deformation is more than 0.5mm, correcting the deformation of the blank and then performing semi-finishing; the time for the blank to rest freely was 26 h.
Comparative example 1
A machining method of a forge piece comprises the following specific steps: (1) rough machining: reserving 2mm of allowance along a single side of a molded surface according to the drawing size requirement of a customer for machining, wherein the cutting speed of rough machining is 20-25 m/min, the feeding is 0.25mm/r, and the cutting depth is 2.5 mm; controlling the surface roughness to reach the requirement of Ra6.3 mu m; (2) semi-finish turning: when semi-finish turning is carried out, the blank single-edge molded surface is uniformly left with the allowance of 0.5mm, a high-temperature alloy blade CNMG080408 is selected, and the blank deformation is controlled to be less than 0.2 mm; the cutting speed of the semi-finish turning is 20-25 m/min, the feeding is 0.15mm/r, and the cutting depth is 0.3-1 mm; controlling the surface roughness to reach the requirement of Ra3.2 mu m; (3) finish machining: processing the workpiece along various profiles according to the size of a customer drawing until the workpiece meets the size requirement, selecting a high-temperature alloy blade CNMG080408 blade, and performing finish machining at the cutting speed of 25m/min, the feed speed of 0.08mm/r and the cutting depth of 0.15 mm; the surface roughness of the blank reaches Ra1.6 mu m required by the drawing; the sharp corners were blunted to a maximum of 0.76 mm.
To further illustrate that the present invention can achieve the technical effects, the following experiments were performed:
the method of the embodiment 1-5 and the method of the comparative example 1 are adopted for processing the forged piece, the performance of the forged piece prepared by the methods is compared, and the experimental results are shown in the following table 1.
TABLE 1
Group of
|
Percent pass of product (%)
|
Water immersion flaw detection qualification rate (%)
|
Ultrasonic noise value (%)
|
Example 1
|
99.10
|
98.50
|
10.82
|
Example 2
|
98.72
|
97.64
|
12.34
|
Example 3
|
98.85
|
98.23
|
11.26
|
Example 4
|
98.82
|
97.86
|
12.05
|
Example 5
|
98.89
|
97.72
|
11.76
|
Comparative example 1
|
72.50
|
56.35
|
23.53 |
Meanwhile, the results show that: the method of the comparative example 1 can be used for processing parts, but the product is difficult to meet the requirement that the roughness is Ra1.6 mu m, the product percent of pass after machining is extremely low, and the product percent of failure reaches more than 90%; in addition, due to the problem of surface roughness of parts, product detection cannot reach grade 3 (the clutter value is less than or equal to 15%) in the ultrasonic inspection standard P29TF82CL-B, the water immersion UT qualification rate is low, the requirement of subsequent water immersion flaw detection cannot be met, and a large number of parts are unqualified. The forgings prepared in the embodiments 1-5 have the above conditions, and the product yield is greatly improved.
In summary, the present application solves the technical problems of the background art by adjusting the processing route, selecting a suitable tool, optimizing the cutting parameters, and controlling the use of the tool. By adopting the improved process machine for machining, the machining time of a single product can be saved by about 400min, the surface roughness of the product is less than Ra0.63 mu m, the surface quality of the product is greatly improved, and the flaw detection qualification rate of the product is improved from 56% to 98.5%.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.