CN112894266A - Machining method of ring forging with complex special-shaped cross section - Google Patents
Machining method of ring forging with complex special-shaped cross section Download PDFInfo
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Abstract
The invention discloses a machining method of a complex special-shaped cross section ring forging, which specifically comprises the following steps: rough machining: according to the required size, the blank is roughly machined, allowance is uniformly reserved along the profile on one side of the blank, the deformation of the blank is measured, semi-finish turning is carried out after the blank is placed in a free state, the allowance is uniformly reserved along the profile on one side of the blank, the deformation of the blank is measured after the semi-finish turning is finished, each area of the blank A, B, C, D, E, F, G, H, I, J, K, L, M is respectively subjected to finish machining, and the ring forging with the complex special-shaped section is obtained after the ring forging is machined to the required size of the forging. By adjusting the processing process route, selecting a proper cutter, optimizing cutting parameters and controlling the cutter to be used, the processing time of a single product is 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%.
Description
Technical Field
The invention belongs to the technical field of production and processing of forgings, and particularly relates to a machining method of a ring forging with a complex special-shaped cross section.
Background
The forging is a workpiece or a blank obtained by forging and deforming a blank by a certain method. The blank is subjected to pressure to generate plastic deformation, so that the mechanical property of the blank can be changed. The forging is divided into cold forging and warm forging and hot forging according to the temperature of the blank during processing. Cold forging is generally carried out at room temperature, and hot forging is carried out at a temperature higher than the recrystallization temperature of the billet. The metal looseness and holes can be eliminated through forging, so that the mechanical property of the forging is improved.
The processing is a general term for a process of converting raw materials and semi-finished products into target required products through certain procedures and modes. In the existing processing technology of the forge piece, after the product is machined, water immersion flaw detection is needed, and the surface roughness of the product must be smaller than Ra1.6 mu m (smaller than 0.63 mu m). Due to the fact that the product material is difficult to process and the requirement on surface quality is high, the conventional processing method is adopted, the processing time of the product is long, and the surface roughness of the processed product cannot meet the requirement of 3-level (the miscellaneous wave value is less than or equal to 15 percent) in the ultrasonic flaw detection (inspection standard P29TF82 CL-B), so that a large number of products are unqualified in flaw detection. At present, there are some relevant documents on the processing technology of forgings, such as:
1. patent application CN201910427314.2 discloses a high-precision bearing forging processing method, which comprises the following steps: blank detection, part reference processing, other end face processing, inner diameter cutting of a bearing outer ring, third detection, polishing and fourth detection. The processing method detects the appearance and the interior of the blank before production, screens defective products in time before processing, reduces resource waste and improves the qualification rate of finished products; the machining method adopts a mode of combining rough machining and finish machining for machining, so that the condition of large one-time cutting amount is avoided, the defect of vibration of the cutter is reduced, and the service life of the cutter is ensured; in the machining method, the part in machining is cooled by cooling liquid with the temperature of 18-22 ℃ in the whole machining process of the lathe, the temperature difference change of the environment is ensured, the influence of the temperature on the part machining is reduced, and the machining precision is improved; adopt paint spraying sign to the defective products, be favorable to the differentiation of defective products, the outflow of effectual defective products of avoiding. However, the surface quality and other aspects of the product prepared by the scheme can not meet the requirements of aerospace materials.
2. Patent application CN201210574369.4 discloses a processing technique method of an impeller in a nuclear main pump of a nuclear power station, which is completed by 2m vertical lathe, a five-axis linkage processing center, five-axis programming software UG, processing software HyperMILL, a post-processing module RCS, a simulation system VERICUT, a special cutter bar and a cutter design through multiple program optimization. The technical scheme has the advantages that the software, the 2-meter vertical lathe, the five-axis machining center and the tool can be used for machining a complete blade on a whole forged piece, the method is different from the traditional method of casting or welding for manufacturing the blade, the machined surface roughness can reach Ra3.2, the surface of the blade is polished to reach more than Ra0.8, the molded lines of the blade are scanned by utilizing a joint arm for detection of the blade, the scanned data is compared with standard three-dimensional model data, and the final detection result of a simulation piece and a plurality of product pieces shows that the blade airfoil of the impeller completely meets the requirement of a design drawing. It can be seen that the solution may be effective in improving the surface roughness of the product, but the required requirements of aerospace materials are not met in terms of the surface quality of the product and the like.
Therefore, the existing processing method of the forge piece has the defects of unsatisfactory processing quality and long processing time. The main reasons for the defects of the prior art are obtained by analyzing the reasons of the existing problems: (1) when semi-finish turning and finish turning are carried out, a blade is not properly selected; (2) the feed track during semi-finish turning and finish turning cutting is not reasonable enough; (3) the cutting parameters are not reasonable enough.
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%.
Drawings
In order to illustrate the embodiments of the present invention or the technical solutions in the prior art more clearly, the drawings needed in the description of the embodiments or the prior art will be briefly introduced below, it is obvious that the drawings in the following description are only some examples of the present invention, and for a person skilled in the art, without inventive step, other drawings can be obtained according to these drawings:
FIG. 1 is a schematic structural diagram of semi-finish turning of a complex special-shaped cross-section ring forging of the present application;
FIG. 2 is a schematic structural diagram of the finish machining of the complex special-shaped section ring forging.
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.
Claims (10)
1. The machining method of the ring forging with the complex special-shaped cross section is characterized by comprising 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.
2. The method of machining a ring forging of complex odd-shaped cross section of claim 1, wherein: 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 contour of the blank is less than 1 mm.
3. The method of machining a ring forging of complex odd-shaped cross section of claim 1, wherein: 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.
4. The method of machining a ring forging of complex odd-shaped cross section of claim 1, wherein: in the step (2), the blank is uniformly left with a margin 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.
5. The method of machining a ring forging of complex odd-shaped cross section of claim 1, wherein: 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.
6. The method of machining a ring forging of complex odd-shaped cross section of claim 1, wherein: in the step (3), the finish machining speed is 30-40 m/min, the feeding is 0.08-0.1 mm/r, and the cutting depth is 0.1-0.15 mm.
7. The method of machining a ring forging of complex odd-shaped cross section of claim 1, wherein: 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.
8. The method of machining a ring forging of complex odd-shaped cross section of claim 1, wherein: in the step (3), the area of the blank A, C, D, E, G, J, K, L is finely processed according to the requirement, so that the surface roughness of the blank reaches Ra1.6 mu m 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.
9. The method of machining a ring forging of complex odd-shaped cross section of claim 1, wherein: in step (3), the radius of the cutting edge used for finishing is 1.2mm, or the radius of the cutting edge is 0.8 and the feeding is less than or equal to 0.08 mm/R.
10. The method of machining a ring forging of complex odd-shaped cross section of claim 1, wherein: the deformation measurement mode is as follows: 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.
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Inventor after: Zhuang Yong Inventor after: Huang Chengzhi Inventor after: Liu Chaohui Inventor after: Wu Yongan Inventor after: Yang Lianghui Inventor before: Zhuang Yong Inventor before: Liu Chaohui Inventor before: Wu Yongan Inventor before: Huang Chengzhi Inventor before: Yang Lianghui |
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Application publication date: 20210604 |