CN114260659B - Machining method for large-eccentricity porous flying block iron casting - Google Patents

Machining method for large-eccentricity porous flying block iron casting Download PDF

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CN114260659B
CN114260659B CN202210043960.0A CN202210043960A CN114260659B CN 114260659 B CN114260659 B CN 114260659B CN 202210043960 A CN202210043960 A CN 202210043960A CN 114260659 B CN114260659 B CN 114260659B
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blank
positioning
hole
eccentricity
flyweight
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CN114260659A (en
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程景龙
崔建华
胡春萍
刘良华
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Hebei Huabei Diesel Engine Co Ltd
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Hebei Huabei Diesel Engine Co Ltd
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Abstract

The invention discloses a method for processing a large-eccentricity porous flyweight iron casting, belongs to the field of machining, and comprises the step of preparing flyweight casting hairBlank, aging treatment and blank preliminary processing, wherein after the blank is sawed into a first blank, a flying block turning large-eccentricity excircle clamp is adopted to turn the flying block turning large-eccentricity 9.5 +/-0.05 mm excircle by turning instead of boring
Figure DDA0003471427290000012
Three drilling positions of drill jig capable of overturning through flyer inclined holes after first blank is cut off into second blank
Figure DDA0003471427290000011
Inclined hole, finished product making, inspection, cleaning and blow-drying, surface oil sealing, finished product warehousing and the like. According to the invention, through improving the flying block blank and designing the special fixture and the drill jig, the flying block is rapidly processed, the problems of the oversize of the pitch of three inclined holes and low processing efficiency after the flying block is processed are solved, the one-time acceptance rate after the flying block is processed reaches more than 98%, the processing efficiency is improved by 2-3 times, and the labor intensity of workers is effectively reduced.

Description

Machining method for large-eccentricity porous flying block iron casting
Technical Field
The invention relates to the technical field of machining, in particular to a method for machining a large-eccentricity porous flying block iron casting, which is used for machining the large-eccentricity porous flying block iron casting.
Background
In a hydraulic system, a hydraulic element is generally a universal part, and is mostly a large-eccentricity porous flyweight iron casting (hereinafter referred to as flyweight), the production batch is usually large, the flyweight is shaped as shown in fig. 1 and 2, and the inner arc of the flyweight is as shown in fig. 1
Figure BDA0003471427270000011
Outer arc
Figure BDA0003471427270000012
Eccentricity of 9.5 +/-0.05 mm and three positions
Figure BDA0003471427270000013
The requirements on the angle and the pitch size of the inclined hole are strict; the prior art method comprises the following steps:
(1) Preparing materials, and making a three-dimensional drawing of a casting blank as shown in figure 3;
(2) Carrying out aging treatment;
(3) Milling two end faces to ensure thickness
Figure BDA0003471427270000014
(4) Grinding two end faces to ensure thickness
Figure BDA0003471427270000015
And the parallelism is less than or equal to 0.05mm;
(5) Milling two side surfaces to ensure the size
Figure BDA0003471427270000016
And both side surfaces are opposite to
Figure BDA0003471427270000017
The symmetry degree of the holes is less than or equal to 0.3mm;
(6) And boring: machining the lower end face with the dimension of 48.75 +/-0.2 mm and the dimension of 50 +/-0.2 mm, and machining
Figure BDA0003471427270000018
Rz16mm circular arc to size, 3 multiplied by 45 degrees of orifice chamfer angle and 9.5 +/-0.05 mm of eccentricity-preserving size;
(7) And boring: machining dimension
Figure BDA0003471427270000019
A circular arc surface with the protective size of 48.75 +/-0.2 mm and the eccentric distance of 9.5 +/-0.05 mm;
(8) And boring: drill
Figure BDA00034714272700000110
Through hole, upper end expanded and reamed
Figure BDA00034714272700000111
Drill
Figure BDA00034714272700000112
Hole drilling, expanding and reaming
Figure BDA00034714272700000113
An aperture;
(9) And boring: expanding a hole
Figure BDA00034714272700000114
(10) And boring: drill
Figure BDA0003471427270000021
Uniformly distributing holes, keeping the position size of 8 +/-0.1 mm and the angle size of 30 +/-10 ', and keeping the angle size of 60 +/-10' at two positions; obtaining a finished product of the large-eccentricity porous flyweight iron casting;
(11) And inspecting a finished product;
(12) Cleaning and drying the finished product;
(13) Oil sealing treatment is carried out on the finished product processing surface;
(14) And warehousing the finished product.
Machining by the above method to form inner arc of flying block
Figure BDA0003471427270000022
Outer arc
Figure BDA0003471427270000023
Eccentricity of 9.5 +/-0.05 mm and three positions
Figure BDA0003471427270000024
The inclined hole is processed by a boring machine, so that the processing efficiency is low, and the inner arc is formed
Figure BDA0003471427270000025
Not easy to measure, and the outer arc
Figure BDA0003471427270000026
Eccentricity of 9.5 +/-0.05 mm and three positions
Figure BDA0003471427270000027
The angle of the inclined hole and the size of the pitch of the hole cannot meet the requirements of drawings; and also
Figure BDA0003471427270000028
The arc processing surface is not a semicircle, so that the measurement is troublesome (a special arc measuring tool needs to be manufactured), and the arc processing surface cannot be used as a subsequent positioning reference, so that the subsequent processing alignment is difficult; three places
Figure BDA0003471427270000029
The inclined hole can be processed only by a rotary boring machine workbench during processing, and the angle and the pitch size cannot be guaranteed due to the lower rotation precision of the boring machine workbench.
Therefore, it is necessary to develop a method for processing a porous flyweight iron casting with large eccentricity, which can solve the problems of low processing efficiency and inner circular arc existing in the prior art
Figure BDA00034714272700000210
Not easy to measure, and the outer arc
Figure BDA00034714272700000211
Figure BDA00034714272700000212
Eccentricity of 9.5 +/-0.05 mm and three positions
Figure BDA00034714272700000213
The angle of the inclined hole and the size of the pitch of the holes can not be ensured.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for processing a large-eccentricity porous flying-block iron casting, which is used for realizing the rapid processing of a flying block, solving the problems of the oversize of the hole distance of three inclined holes and low processing efficiency after the flying block is processed, ensuring that the one-time delivery qualification rate after the flying block is processed reaches more than 98 percent, improving the processing efficiency by 2-3 times and effectively reducing the labor intensity of workers.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
a method for processing a large-eccentricity porous flyweight iron casting comprises the following steps:
step 1, preparing a flying block casting blank;
step 2, carrying out aging treatment on the flying block casting blank;
step 3, fixedly mounting the flyweight casting blank subjected to the aging treatment on a lathe; turning two end faces, drilling, expanding and boring
Figure BDA0003471427270000031
Rz16mm inner hole size, 3 x 45 degree chamfer angle, cut off into 4 first blank according to length direction, guarantee the thickness size of each first blank is
Figure BDA0003471427270000032
Step 4, processing the 1 cut first blanks in the step 3, grinding two end faces and keeping the thickness dimension
Figure BDA0003471427270000033
Figure BDA0003471427270000034
And the parallelism is less than or equal to 0.05mm;
step 5, finely milling two side surfaces of the first blank to ensure the size
Figure BDA0003471427270000035
And both sides face each other
Figure BDA0003471427270000036
Figure BDA0003471427270000037
The symmetry degree of the holes is less than or equal to 0.1mm;
step 6, turning the first blank processed in the step 5 by adopting a flying block turning large-eccentricity excircle fixture, and turning two positions
Figure BDA0003471427270000038
Arc surface, the eccentricity of two sides is kept to be 9.5 plus or minus 0.05mm;
step 7, sawing the first blank processed in the step 6 into 2 second blanks, and keeping the opening size to be 3 +/-0.2 and the size of the single second blank to be more than or equal to 50;
step 8, processing the 1 sawn second blank in the step 7, and milling the upper end face to ensure that the size is 48.75 +/-0.2 mm;
step 9, drilling
Figure BDA0003471427270000039
Through hole, upper end expanded and reamed
Figure BDA00034714272700000310
Drill
Figure BDA00034714272700000311
Hole drilling, expanding and reaming
Figure BDA00034714272700000312
An aperture;
step 10, reaming
Figure BDA00034714272700000313
Step 11, machining the second blank machined in the step 10 by adopting a flyer inclined hole reversible drilling jig; drill
Figure BDA00034714272700000314
Uniformly distributing holes, keeping the position size of 8 +/-0.1 mm and the angle size of 30 +/-10 ', and keeping the angle size of 60 +/-10' at two positions; obtaining a finished product of the large-eccentricity porous flyweight iron casting;
step 12, inspecting a finished product;
step 13, cleaning and drying the finished product;
step 14, oil sealing treatment of the finished product processing surface;
and step 15, warehousing finished products.
The technical scheme of the invention is further improved as follows: in the step 1, the flying block casting blank is an integral blank, 1 blank can be processed into 8 large-eccentricity porous flying block iron casting finished products, and the specific size is as follows: the length is set to be L of 120 +/-0.8 mm; the width B is set to be 108 +/-0.5 mm and the clear size is 1020 -0.2 mm, the machining allowance b1 and b2 left on the flat single side at the two sides are both 3mm; the diameter D of the inner hole is set to phi 36 +/-0.5, and the net size isIs composed of
Figure BDA0003471427270000041
The allowance of the inner hole is 10mm; the radiuses R2 of the two outer circles are set to be 66 +/-0.5 mm, and the net size is
Figure BDA0003471427270000042
The excircle all leaves surplus 4mm, and centre-to-centre spacing h1 sets up to 7.5mm, and eccentricity h2 sets up to 9.5mm.
The technical scheme of the invention is further improved as follows: in the step 1, the flying block casting blank is cast by a metal mold.
The technical scheme of the invention is further improved as follows: in step 6, the clamp for turning the large-eccentricity excircle by the flyweight comprises a connecting part, a transition part, a positioning part and a clamping part;
the connecting part comprises a flange plate connected and positioned with a lathe spindle, a third screw for pressing and a pressing plate;
the transition part comprises a transition disc which is matched and positioned with the flange disc, a plurality of second washers and second bolts for connecting and compressing the transition disc and the flange disc, and a plurality of locking screws for fixedly connecting the positioning part with the transition disc, wherein the first bolts, the first nuts, the first washers and the locking and anti-loosening screws are used for locking and anti-loosening;
the positioning part comprises an excircle clamp body, 1 first positioning block which is respectively arranged at the upper part and the lower part and is respectively used for processing a positioning reference of a first blank when an upper eccentric semicircle and a lower eccentric semicircle are processed, a plurality of first screws and first cylindrical pins for connecting and pressing, a positioning pin and a second positioning block for angular positioning of the first blank;
a positioning key on the left side of the outer circle clamp body is connected with a key groove in the transition disc in a positioning mode, and a fit clearance and symmetry are guaranteed; the right inner hole of the outer circle clamp body is in interference fit with the outer circle in the positioning pin, so that the outer circle clamp body and the transition disc are connected into a whole and used for main positioning of the inner hole of the first blank, the symmetry and parallelism of the size of 205 +/-0.025 mm and the center are ensured by processing the upper flat part and the lower flat part, and the right inner hole of the outer circle clamp body is used as a positioning reference when the upper eccentric semicircle and the lower eccentric semicircle of the first blank are processed;
the clamping part consists of a second locking screw for locking, a third bolt installed in the outer circle clamp body, a third washer for clamping and a second nut.
The technical scheme of the invention is further improved as follows: the flange plate is made of gray cast iron HT20-40; the transition disc is made of gray cast iron HT20-40; the material used by the outer circle clamp body is a No. 20 steel plate; the second positioning block and the first positioning block are made of No. 45 steel.
The technical scheme of the invention is further improved as follows: the use process of the clamp for turning the outer circle with the large eccentricity by the flyweight is as follows: firstly, connecting the assembled excircle clamp with a lathe spindle through a phi 92H7 positioning hole and an M90mm multiplied by 6 threaded hole, and then passing the first blank processed in the step 5 through
Figure BDA0003471427270000051
The central hole is arranged on
Figure BDA0003471427270000052
In the first positioning shaft, a positioning surface on the side surface of the first blank is contacted with a second positioning block, and finally, a third bolt, a third gasket and a second nut are used for pressing; when the eccentric arc of the upper half part of the first blank is machined, firstly loosening the first nut, enabling the positioning surface at the upper end of the outer circle clamp body to be tightly attached to the first positioning block by sliding the outer circle clamp body, then locking the first nut, and finally starting a lathe to machine the eccentric arc of the upper half part of the first blank; similarly, when the eccentric circular arc of the lower half part of the first blank is processed, the outer circle clamp body only needs to slide to the direction opposite to the direction of the eccentric circular arc of the upper half part, and the rest steps are the same as those when the eccentric circular arc of the upper half part of the first blank is processed.
The technical scheme of the invention is further improved as follows: in step 11, the flyweight inclined hole reversible type drill jig comprises a clamp body for machining an inclined hole clamp, a drill plate, a drill bushing, a support, a positioning device and a pressing device;
the processing obliqueThe phi 22H7 hole of the hole clamp body is used for main positioning with the drill plate through the interference fit of phi 22H7/r 6;
Figure BDA0003471427270000053
the key groove is matched with a 4 multiplied by 16mm semicircular key to be used for angular positioning with the drill plate;
Figure BDA0003471427270000054
the position size between the hole and the phi 22H7 positioning hole is guaranteed to be 65 +/-0.015 mm, and the hole is used for angular positioning of the rotary plate by installing a steel ball, a spring and a screw plug;
the excircle of the drill plate is in interference fit with the inner hole of the clamp body of the inclined hole machining clamp for main positioning of the drill plate, and the excircle of the drill plate is in clearance fit with the positioning hole in the rotary plate for main positioning of the rotary plate; the rotary plate adopts a rotatable structure; the part of the drilling template, which is provided with the drilling sleeve, adopts a semicircular arc with the radius of R21mm, and the clearance between the part of the drilling template and the inner circular arc with the radius of R23mm is ensured;
the compression device comprises a fifth washer and a fourth nut;
the positioning device comprises a fourth screw, a fourth washer, a third nut, a semicircular key, a second cylindrical pin, a bushing, a third cylindrical pin, a fifth screw, a positioning plate and a fourth bolt.
The technical scheme of the invention is further improved as follows: the clamp body of the inclined hole machining clamp is made of gray cast iron HT20-40; the material used by the drilling template is a No. 20 steel plate; the material used by the rotary plate is a No. 20 steel plate;
the technical scheme of the invention is further improved as follows: the use process of the flyweight inclined hole reversible drilling jig is as follows: firstly, the screw plug is screwed down to make the spring bear a certain pressing force, thereby pressing the steel ball, and making the steel ball and the rotary plate in
Figure BDA0003471427270000061
The positioning taper holes are tightly attached; then the second blank processed in the step 10 is arranged on a second positioning shaft through a clearance fit of phi 15H8/f6, so that the end face of the second blank is contacted with the upper end face of the rotary plate, and the side face of the second blank is contacted with the upper end face of the rotary platePerforming angular positioning through the positioning plate, and finally pressing a second blank and drilling through a fourth nut
Figure BDA0003471427270000062
An inclined hole; after the machining is finished, the butterfly nut is properly loosened to reduce the contact force between the rotary plate and the steel ball, and then the rotary plate is rotated to enable the middle left side of the rotary plate to be in contact with the steel ball
Figure BDA0003471427270000063
The positioning taper hole is contacted with the steel ball, then the butterfly nut is used for pressing the rotary plate, and finally the middle left side of the second blank is drilled
Figure BDA0003471427270000064
An inclined hole; after the processing is finished, the butterfly nut is loosened to reduce the contact force between the rotary plate and the steel ball, and then the rotary plate is rotated to ensure that the middle side and the right side of the rotary plate are positioned
Figure BDA0003471427270000065
The positioning taper hole is contacted with the steel ball, then the butterfly nut is used for pressing the rotary plate, and finally the middle and right sides of the second blank are drilled
Figure BDA0003471427270000066
An inclined hole; three places
Figure BDA0003471427270000067
And after the inclined hole is machined, loosening the fourth nut and taking down the machined flyweight.
Due to the adoption of the technical scheme, the invention has the technical progress that:
1. according to the invention, through improving the blank of the flying block casting and designing the special fixture, the flying block is rapidly processed, the problems of the oversize of the pitch of the three inclined holes and low processing efficiency after the flying block is processed are solved, the one-time delivery qualification rate after the flying block is processed reaches more than 98%, the processing efficiency is improved by 2-3 times, the labor intensity of workers can be effectively reduced, and the mass and automatic production can be realized.
2. According to the invention, by improving the casting method of the flyweight casting blank, the original one-piece casting is changed into integral casting, so that the casting and processing difficulty is reduced, and the efficiency and quality of flyweight processing are effectively improved.
3. The clamp for turning the excircle with the large eccentricity of the flying block, which is designed and manufactured by the invention, is specially used for turning the excircle with the large eccentricity of the flying block, thereby realizing the turning of the excircle with the large eccentricity of the flying block
Figure BDA0003471427270000071
The turning instead of boring is used for machining, two flying blocks can be machined at one time, and the machining efficiency is improved by more than 3 times compared with the original technological method.
4. The flyweight inclined hole reversible drilling jig designed and manufactured by the invention is specially used for drilling three parts
Figure BDA0003471427270000072
The mm inclined hole clamp can realize three positions
Figure BDA0003471427270000073
The problem that the boring machine needs clamping and processing for three times in the original process method is solved by clamping and processing the inclined holes once, the processing efficiency is improved by more than 2 times, and the angles and the position sizes of 3 holes are well ensured.
5. The invention can solve the problems of low processing efficiency and inner circular arc in the prior art
Figure BDA0003471427270000074
Not easy to measure, and the outer arc
Figure BDA0003471427270000075
Eccentricity of 9.5 +/-0.05 mm and three positions
Figure BDA0003471427270000076
The angle of the inclined hole and the size of the pitch of the holes can not be ensured, and the improvement effect is obvious.
Drawings
FIG. 1 is a three-dimensional schematic view of a large-eccentricity porous flyweight-like iron casting according to the present invention;
FIG. 2 is a sectional view of a large eccentricity multi-hole flyweight-like iron casting according to the present invention;
FIG. 3 is a three-dimensional schematic view of a cast blank in a prior art process of the invention;
FIG. 4 is a three-dimensional schematic view of an improved flyweight casting blank of the present invention;
FIG. 5 is a top cross-sectional view of an improved flyweight casting blank of the present invention;
FIG. 6 is a side cross-sectional view of a modified flyweight matte of the present invention;
FIG. 7 is a first schematic structural diagram of a clamp for turning a large-eccentricity excircle by using a flying block in the invention;
FIG. 8 is a schematic structural diagram II of the clamp for turning the outer circle with large eccentricity by the flyweight in the invention;
FIG. 9 is a schematic three-dimensional view of the position of the flyweight turning large eccentricity outer circular fixture of the present invention;
FIG. 10 is a position-three dimensional exploded view of the flyweight turning large eccentricity outer circle clamp of the present invention;
FIG. 11 is a schematic diagram of a position two and three dimensions of a clamp for turning a large eccentricity excircle by using a flying block according to the present invention;
FIG. 12 is a two-dimensional exploded view of the position of the outer circle clamp for turning the flying mass with large eccentricity;
FIG. 13 is a first schematic structural view of a flyweight inclined hole reversible drill jig according to the present invention;
FIG. 14 is a second schematic structural view of a flyweight inclined hole reversible drill jig according to the present invention;
FIG. 15 is a three-dimensional assembly view of the position of the flyweight inclined hole reversible drill jig of the present invention;
FIG. 16 is a position-three dimensional exploded view of the flyweight inclined hole reversible jig of the present invention;
FIG. 17 is a two-dimensional and three-dimensional assembly view of the position of the flyweight inclined hole reversible drill jig of the present invention;
FIG. 18 is a two-dimensional exploded view showing the position of the flyweight inclined hole reversible jig of the present invention;
FIG. 19 is a three-dimensional assembly drawing showing positions of a flyweight inclined hole reversible drill jig according to the present invention;
FIG. 20 is a three-dimensional exploded view of the position of the flyweight inclined hole reversible drill jig of the present invention;
the clamp comprises an outer circle clamp body 1, a first bolt 2, a first nut 3, a first washer 4, a first washer 5, a first positioning block 6, a locking screw 7, a transition disc 8, a flange plate 9, a second washer 10, a second bolt 11, a first screw 12, a first cylindrical pin 13, a second screw 14, a third bolt 15, a third washer 16, a second nut 17, a positioning pin 18, a second positioning block 19, a third screw 20, a pressing plate 21, a clamp body for processing inclined holes 22, a fourth screw 23, a plug screw 24 and a spring; 25. the device comprises a steel ball 26, a second positioning shaft 27, a drilling template 28, a fourth washer 29, a third nut 30, a semicircular key 31, a rotary plate 32, a second cylindrical pin 33, a drilling sleeve 34, a bushing 35, a fifth washer 36, a fourth nut 37, a third cylindrical pin 38, a fifth screw 39, a positioning plate 40, a butterfly nut 41 and a fourth bolt.
Detailed Description
The invention is described in further detail below with reference to the following figures and examples:
in the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" \8230 \\8230;, etc. indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, and do not indicate or imply that the device or element so referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus are not to be construed as limiting the present invention.
Furthermore, the terms "first", "second" \8230; are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, the features defined as "first", "second" \8230;, may explicitly or implicitly include at least one such feature. In the description of the present invention, "a number" means at least two, e.g., two, three, etc., unless explicitly defined otherwise.
The units relating to the dimensions in the present invention are all mm.
As shown in fig. 1 to 20, a method for processing a large-eccentricity porous flyweight iron casting comprises the following steps:
step 1, preparing a flyweight casting blank;
the flyweight casting blank is an integral blank, 1 blank can be processed into 8 large-eccentricity porous flyweight iron casting finished products, and the specific size is as follows: the length L is set to be 120 +/-0.8 mm; the width B is set to be 108 +/-0.5 mm, and the net size is 102 0 -0.2 mm, the machining allowance b1 and b2 left on the flat single side at the two sides are both 3mm; the diameter D of the inner hole is set to phi 36 +/-0.5, and the net size is
Figure BDA0003471427270000091
The allowance of the inner hole is 10mm; the two outer circle radiuses R2 are set to be 66 +/-0.5 mm, and the net size is
Figure BDA0003471427270000092
The excircle all leaves surplus 4mm, and centre-to-centre spacing h1 sets up to 7.5mm, and eccentricity h2 sets up to 9.5mm. And the flying block casting blank is cast by a metal mold.
Step 2, carrying out aging treatment on the flying block casting blank;
step 3, fixedly mounting the flyweight casting blank subjected to the aging treatment on a lathe; turning two end faces, drilling, expanding and boring
Figure BDA0003471427270000101
Rz16mm inner hole size, the chamfer angle of the hole opening is 3 multiplied by 45 degrees, the hole opening is transversely cut into 4 first blanks according to the length direction, and the thickness size of each first blank is ensured to be
Figure BDA0003471427270000102
Step 4, processing the 1 cut first blanks in the step 3, grinding two end faces and keeping the thickness dimension
Figure BDA0003471427270000103
Figure BDA0003471427270000104
And the parallelism is less than or equal to 0.05mm;
step 5, finely milling two side surfaces of the first blank to ensure the size
Figure BDA0003471427270000105
And both side surfaces are opposite to
Figure BDA0003471427270000106
Figure BDA0003471427270000107
The symmetry degree of the holes is less than or equal to 0.1mm;
step 6, turning the first blank processed in the step 5 by adopting a flying block turning large-eccentricity excircle fixture, and turning two positions
Figure BDA0003471427270000108
The eccentric distance of the arc surface is kept to be 9.5 +/-0.05 mm;
the clamp for turning the excircle with the large eccentricity by the flyweights comprises a connecting part, a transition part, a positioning part and a clamping part;
the connecting part comprises a flange 8 connected and positioned with a lathe spindle, a third screw 19 for pressing and a pressure plate 20;
the transition part comprises a transition disc 7 which is matched and positioned with the flange plate 8, a plurality of second washers 9 and second bolts 10 which are used for connecting and compressing the transition disc 7 and the flange plate 8, and also comprises a plurality of first bolts 2, a first nut 3, a first washer 4 and a locking screw 6 which is used for locking and anti-loosening and is used for fixedly connecting the positioning part with the transition disc 7;
the positioning part comprises an excircle clamp body 1, a first positioning block 5, a plurality of first screws 11 and first cylindrical pins 12 for connection and compression, a positioning pin 17 and a second positioning block 18 for angular positioning of the first blank, wherein the upper part and the lower part of the first positioning block are respectively provided with 1 positioning datum for processing an upper eccentric semicircle and a lower eccentric semicircle of the first blank;
a positioning key on the left side of the outer circle clamp body 1 is connected with a key groove in the transition disc 7 in a positioning mode, and a fit clearance and symmetry are guaranteed; the right inner hole of the outer circle clamp body 1 is in interference fit with the middle outer circle of the positioning pin 17, so that the outer circle clamp body 1 and the transition disc 7 are connected into a whole and used for main positioning of the inner hole of the first blank, the symmetry and the parallelism of the size 205 +/-0.025 mm and the center are ensured by processing the upper flat part and the lower flat part, and the right inner hole is used as a positioning reference when the eccentric semicircle of the upper part and the lower part of the first blank is processed;
the clamping portion is composed of a second screw 13 for locking, a third bolt 14 installed in the outer circular clamp fixture body 1, a third washer 15 for clamping, and a second nut 16.
The flange plate 8 is made of gray cast iron HT20-40; the transition disc 7 is made of gray cast iron HT20-40; the material used by the excircle clamp fixture body 1 is a No. 20 steel plate; the materials of the second positioning block 18 and the first positioning block 5 are 45-grade steel.
The use process of the clamp for turning the excircle with the large eccentricity by the flyweight is as follows: firstly, connecting an assembled cylindrical clamp with a lathe spindle through a phi 92H7 positioning hole and an M90mm multiplied by 6 threaded hole, and then passing a first blank processed in the step 5 through
Figure BDA0003471427270000111
The central hole is arranged on
Figure BDA0003471427270000112
In the first positioning shaft, a positioning surface on the side surface of the first blank is contacted with a second positioning block 18, and finally, a third bolt 14, a third washer 15 and a second nut 16 are used for pressing; when the eccentric arc of the upper half part of the first blank is machined, firstly loosening the first nut 3, enabling the positioning surface at the upper end of the excircle fixture 1 to be tightly attached to the first positioning block 5 by sliding the excircle fixture 1, then locking the first nut 3, and finally starting a lathe to machine the eccentric arc of the upper half part of the first blank; similarly, when the eccentric arc of the lower half part of the first blank is processed, the outer circle clamp body 1 is only required to slide to and process the upper half partThe other steps are the same as those in the process of processing the eccentric circular arc of the upper half part of the first blank.
Step 7, sawing the first blank processed in the step 6 into 2 second blanks, and keeping the opening size to be 3 +/-0.2 mm and the size of a single second blank to be more than or equal to 50mm;
step 8, processing the 1 sawn second blank in the step 7, and milling the upper end face to ensure that the size is 48.75 +/-0.2 mm;
step 9, drill
Figure BDA0003471427270000113
Through hole, upper end expanded and reamed
Figure BDA0003471427270000114
Drill
Figure BDA0003471427270000115
Drilling, expanding and reaming
Figure BDA0003471427270000116
A hole;
step 10, reaming
Figure BDA0003471427270000117
Step 11, machining the second blank machined in the step 10 by adopting a flyer inclined hole reversible drilling jig; drill
Figure BDA0003471427270000121
Uniformly distributing holes, and keeping the position size of 8 +/-0.1 mm, the angle size of 30 +/-10 'and 60 +/-10' at two positions; obtaining a finished product of the large-eccentricity porous flyweight iron casting;
in step 11, the flyweight inclined hole reversible drilling jig comprises a clamp body 21 for processing an inclined hole clamp, a drilling template 27, a drilling sleeve 33, a support, a positioning device and a pressing device;
the phi 22H7 hole of the clamp body 21 for machining the inclined hole is used for main positioning with the drill plate 27 through the interference fit of phi 22H7/r 6;
Figure BDA0003471427270000122
the key slot is used for angular positioning with the drilling template 27 through matching with a 4 multiplied by 16mm semicircular key;
Figure BDA0003471427270000123
the position size between the hole and the phi 22H7 positioning hole is ensured to be 65 +/-0.015 mm, and the hole is used for angular positioning of the rotary plate 31 by installing a steel ball 25, a spring 24 and a screw plug 23;
the excircle of the drill plate 27 is mainly positioned by interference fit with the inner hole of the clamp body 21 of the inclined hole machining clamp, and the excircle of the drill plate 27 is mainly positioned by clearance fit with the positioning hole of the rotary plate 31; the rotary plate 31 adopts a rotatable structure; the part of the drilling template 27 for installing the drilling sleeve is a semicircular arc with the diameter of R21mm, and a gap between the part and an inner circular arc with the diameter of R23mm is ensured;
the compression means comprise a fifth washer 35 and a fourth nut 36;
the positioning device comprises a fourth screw 22, a fourth washer 28, a third nut 29, a half-round key 30, a second cylindrical pin 32, a bushing 34, a third cylindrical pin 37, a fifth screw 38, a positioning plate 39 and a fourth bolt 41.
The clamp body 21 of the inclined hole machining clamp is made of gray cast iron HT20-40; the material of the drilling template 27 is a No. 20 steel plate; the material of the rotary plate 31 is a No. 20 steel plate;
the flying block inclined hole reversible type drill jig is used as follows: the screw plug 23 is first screwed to apply a certain pressing force to the spring 24, thereby pressing the steel ball 25, and the steel ball 25 is engaged with the rotary plate 31
Figure BDA0003471427270000124
Figure BDA0003471427270000125
The positioning taper holes are tightly attached; then the second blank processed in the step 10 is arranged on a second positioning shaft 26 through the clearance fit of phi 15H8/f6, the end surface of the second blank is contacted with the upper end surface of a rotary plate 31, the side surface is angularly positioned through a positioning plate 39, and finally, a fourth nut 36 is used for pressing tightlySecond blank, drill
Figure BDA0003471427270000131
An inclined hole; after the processing is finished, the butterfly nut 41 is appropriately loosened to reduce the contact force between the rotary plate 31 and the steel ball 25, and then the rotary plate 31 is rotated to enable the left side in the rotary plate 31
Figure BDA0003471427270000132
The positioning taper hole is contacted with the steel ball 25, then the butterfly nut 40 is used for pressing the rotary plate 31, and finally the middle left side of the second blank is drilled
Figure BDA0003471427270000133
An inclined hole; after the processing is finished, the butterfly nut 40 is loosened to reduce the contact force between the rotary plate 31 and the steel ball 25, and then the rotary plate 31 is rotated to enable the middle right side of the rotary plate 31
Figure BDA0003471427270000134
The positioning taper hole is contacted with the steel ball 25, then the butterfly nut 40 is used for pressing the rotary plate 31, and finally the middle and right sides of the second blank are drilled
Figure BDA0003471427270000135
An inclined hole; three places
Figure BDA0003471427270000136
After the inclined hole is machined, the fourth nut 36 is loosened, and the machined flyweight is taken down.
Step 12, inspecting finished products;
step 13, cleaning and drying the finished product;
step 14, oil sealing treatment of the finished product processing surface;
and step 15, warehousing finished products.
The working principle and the using method are as follows:
analysis of a flying block processing technology before improvement:
because the machining efficiency is low after the flyweight is machined, the inner circular arc
Figure BDA0003471427270000137
Not easy to measure, and the outer arc
Figure BDA0003471427270000138
Eccentricity of 9.5 +/-0.05 mm and three positions
Figure BDA0003471427270000139
The problem of the size over-difference of the angle and the pitch of the inclined holes is mainly related to the blank of a flying block casting, the boring of an inner hole, an outer circle and three positions
Figure BDA00034714272700001310
The inclined hole process is relevant, so the above processes are mainly analyzed as follows:
1. the process of casting blank before flying block improvement:
the blank figure before the flying block is improved shows that the adopted casting method is sand casting, the flying block blank is a single piece, and the single-side machining allowance of an eccentric inner hole, an excircle, two side surfaces and a lower end surface is about 3mm; although the machining allowance is not large, the casting process is complicated, and
Figure BDA00034714272700001311
the arc processing surface is not a semicircle, so that the measurement is troublesome, and the arc processing surface cannot be used as a positioning reference of the subsequent processing, so that the subsequent processing alignment is difficult;
2. inner arc of front boring with improved flyweight
Figure BDA0003471427270000141
Outer arc
Figure BDA0003471427270000142
Eccentricity of 9.5 +/-0.05 mm and three drilling positions
Figure BDA0003471427270000143
An inclined hole process:
as shown in FIGS. 1 and 2, the inner arc of the flyweight can be seen from the flyweight design
Figure BDA0003471427270000144
Outer arc
Figure BDA0003471427270000145
Eccentricity of 9.5 +/-0.05 mm and
Figure BDA0003471427270000146
the inclined hole is processed by a boring machine, so that the processing efficiency is low, and
Figure BDA0003471427270000147
the arc processing surface is not a semicircle, so that the measurement is troublesome, and the arc processing surface cannot be used as a positioning reference of the subsequent processing, so that the subsequent processing alignment is difficult;
Figure BDA0003471427270000148
the eccentricity of the outer arc is not easy to guarantee with the size of 9.5 +/-0.05 mm due to the difficulty in alignment, and the processing efficiency is low; three places
Figure BDA0003471427270000149
The inclined hole can be processed only by a rotary boring machine workbench during processing, and the angle and the pitch size cannot be guaranteed due to the lower rotation precision of the boring machine workbench.
3. Compared with the original process method, the improved novel process method for machining the flying block has the following main innovation points and improvement points:
(1) The flyweight is changed from an original single blank into an integral blank, not only is the casting process simple, but also the subsequent processing of an inner hole and an excircle with large eccentricity can be changed from the original common boring machine processing into the processing of a numerical control lathe, the sizes of the inner hole and the excircle are easy to measure and guarantee, and the processing efficiency is improved by more than 2 times.
(2) The newly designed clamp for turning the large-eccentricity excircle by the flyweight not only realizes the large-eccentricity excircle of the flyweight
Figure BDA00034714272700001410
The turning machine is used for processing instead of boring, two flying blocks can be processed at one time, and the processing efficiency is improved by more than 3 times compared with the original processing efficiency.
(3) Novel-designed flyer inclined holeThe reversible drilling jig can realize three positions
Figure BDA00034714272700001411
Figure BDA00034714272700001412
The problem that the boring machine needs clamping and processing for three times in the original process is solved by clamping and processing the inclined holes once, the processing efficiency is improved by more than 2 times, and the angles, the position and the sizes of 3 holes are well guaranteed.
(II) the above steps are mainly analyzed as follows:
1. the improved flyweight casting blank:
as shown in FIGS. 4, 5 and 6, the blank after the flying block is improved, the casting method adopted by the method is metal mold casting, the flying block blank is an integral blank, the length of the integral blank is set to be L of 120 +/-0.8 mm (the integral blank can be divided into 4 flying blocks, the net size of the flying blocks is 24.1 mm), the width B of the integral blank is set to be 108 +/-0.5 mm (the net size of the flying blocks is 24.1 mm)
Figure BDA0003471427270000151
) The flat single side at two sides is provided with machining allowance b1 and b2 which are both 3mm, the diameter D of the inner hole is set to phi 36 +/-0.5, and the net size is
Figure BDA0003471427270000152
The allowance of the inner hole is 10mm, the radiuses R2 of the outer circles at two positions are set to be 66 +/-0.5 mm, and the net size is
Figure BDA0003471427270000153
The allowance is 4mm on the excircle, the center distance h1 is set to be 7.5mm, and the eccentricity h2 is set to be 9.5mm; the improved flyweight casting blank has small machining allowance, not only is the casting process simple, but also the subsequent machining of the inner hole and the large-eccentricity outer circle can be changed into the machining of a numerical control lathe from the original common boring machine machining, the sizes of the inner hole and the outer circle are easy to measure and guarantee, and the machining efficiency is improved by more than 2 times.
2. Turning large-eccentricity excircle clamp by using flyweights:
according to two flyweightsThe lateral outer circle and the inner hole are respectively eccentric by 9.5 +/-0.05 mm, and a special flyweight turning large-eccentricity outer circle clamp is designed; the clamp consists of a connecting part, a transition part, a positioning part and a clamping part; the connecting part comprises a third screw 19, a pressure plate 20 and a flange 8; the flange 8 is made of gray cast iron HT20-40, and has good processing performance, and good stability and wear resistance after aging treatment; during assembly, the flange plate is firstly connected with a lathe spindle through a phi 92H7 positioning hole and an M90mm multiplied by 6 threaded hole in the flange plate for positioning, and then is tightly pressed by a pressing plate 20 and a third screw 19; the transition part comprises a transition disc 7, the used material is gray cast iron HT20-40, the processing performance is good, and the transition disc has good stability and wear resistance after aging treatment; when assembling, firstly passes through the left end
Figure BDA0003471427270000154
Figure BDA0003471427270000155
The conical hole of which corresponds to that of the flange 8
Figure BDA0003471427270000156
The outer conical surfaces are matched for positioning, and then the second gasket 9 and the second bolt 10 are used for connecting and compressing; right side of the
Figure BDA0003471427270000157
Figure BDA0003471427270000158
The key groove is matched with a key with the size of 20mm multiplied by 8mm in the excircle clamp body 1 for positioning, the matching clearance is ensured to be 0.005-0.01 mm, the symmetry degree is less than or equal to 0.01mm, then the first bolt 2, the first nut 3 and the first washer 4 are used for connection and compression, and finally the locking screw 6 is used for locking and anti-loosening; the positioning part comprises an excircle clamp fixture body 1, 2 first positioning blocks 2, a first screw 11, a first cylindrical pin 12, a positioning pin 17 and a second positioning block 18; wherein the material used by the excircle clamp body 1 is a No. 20 steel plate, the hardness of the surface layer can reach HRC 55-60 after carburization and quenching treatment, and the hardness is higher than that of the surface layerGood hardness and wear resistance; the center part is not quenched, the hardness value is only HRC 18-22, the machining performance is good, and the left side of the positioning key is 20mm multiplied by 8mm and the middle part of the transition disc
Figure BDA0003471427270000161
The key grooves are connected in a locating mode, a fit clearance is guaranteed to be 0.005-0.01 mm, the symmetry degree is smaller than or equal to 0.01mm, the right phi 40H7 inner hole is in interference fit with the phi 40r6 outer circle in the locating pin 17, so that the two parts are connected into a whole and used for main locating of the inner hole of the first blank, the size is guaranteed to be 205 +/-0.025 mm, the symmetry degree and the parallelism degree of the center are smaller than or equal to 0.01mm through processing of the upper flat part and the lower flat part, and the locating reference is used for processing of the eccentric semicircles of the upper part and the lower part of the first blank; the second positioning block 18 is used for angular positioning of the first blank, the used material is No. 45 steel, and the quenching hardness reaches HRC 43-48 through heat treatment, so that the first blank has the wear-resistant characteristic. During assembly, the position size from the left end positioning surface of the second positioning block 18 to the center of the clamp is firstly adjusted to
Figure BDA0003471427270000162
Then, the first screw 11 and the first cylindrical pin 12 are used for connecting and pressing; the first positioning blocks 5 are respectively used for processing positioning references of two eccentric semicircles at the upper part and the lower part of a first blank, the used material is No. 45 steel, the hardness of the steel is HRC 43-48 through heat treatment quenching, so that the steel has the characteristic of wear resistance, when in assembly, the sizes from the positioning surfaces to the center of a clamp in the two first positioning blocks 5 are both 112 +/-0.015 mm [ (2 ]) through adjustment, and then the first positioning blocks are connected and compressed through first screws 11 and first cylindrical pins 12. The clamping part comprises a second screw 13, a third bolt 14, a third washer 15 and a second nut 16 for locking, the third bolt 14 is firstly installed in the excircle clamp body 1 during assembly, the second screw 13 is used for locking to prevent the rotation of the bolt when each blank is screwed, and finally the third washer 15 and the second nut 16 are used for clamping after the first blank is installed.
The use process of the clamp for turning the excircle with the large eccentricity by the flyweight is as follows: firstly, connecting an assembled clamp with a lathe spindle through a phi 92H7 positioning hole and an M90mm multiplied by 6 threaded hole, and then passing a first blank through
Figure BDA0003471427270000163
The central hole is arranged on
Figure BDA0003471427270000164
In the first positioning shaft, the positioning surface of the side surface of the first blank is contacted with the second positioning block 18, and finally, the third positioning shaft is pressed tightly by the third bolt 14, the third washer 15 and the second nut 16. When the eccentric arc of the upper half part of the first blank is machined, firstly, the first nut 3 is loosened, the clamp body 1 of the outer circle clamp is slid to enable the positioning surface at the upper end of the clamp body to be tightly attached to the first positioning surface 5, then, the first nut 3 is locked, and finally, a lathe is started to machine the eccentric arc of the upper half part of the first blank. In the same way, when the eccentric arc of the lower half part of the first blank is machined, the outer circle clamp body 1 only needs to slide to the direction opposite to the direction of machining the eccentric arc of the upper half part, and the rest steps are the same as those of machining the eccentric arc of the upper half part.
3. The flyweight inclined hole can be turned over to form a drill jig:
according to flyweights
Figure BDA0003471427270000171
Three points in the arc
Figure BDA0003471427270000172
The special reversible drilling jig is designed according to the processing characteristics of the inclined hole; the clamp comprises a clamp body 21 for processing the inclined hole, a drill plate 27, a drill bushing 33, a support, a positioning device and a pressing device; the material used for the clamp body 21 of the inclined hole machining clamp is gray cast iron HT20-40, so that the inclined hole machining clamp has good machining performance and good stability and wear resistance after aging treatment; the phi 22H7 hole is used for main positioning with the drill plate 27 through the interference fit of phi 22H7/r 6;
Figure BDA0003471427270000173
Figure BDA0003471427270000174
for angular positioning with the drilling template 27 by co-operation with a 4 x 16mm woodruff key;
Figure BDA0003471427270000175
The position size between the hole and the phi 22H7 positioning hole is guaranteed to be 65 +/-0.015 mm, and the phi 8 steel ball 25, the spring 24 and the screw plug 23 are installed for angular positioning of the rotary plate 31. The material of the drill plate 27 is a No. 20 steel plate, the surface hardness of the drill plate can reach HRC 55-60 after carburization and quenching treatment, and the drill plate has better hardness and wear resistance; the core is not quenched, so that the hardness value is only HRC 18-22, and the machining performance is good; the phi 22r6 excircle is used for main positioning of the drilling template 27 through interference fit with a phi 22H7 inner hole in the clamp body 21 of the clamp for processing the inclined hole;
Figure BDA0003471427270000176
the excircle is used for main positioning of the rotary plate 31 through clearance fit with a phi 30 positioning hole in the rotary plate 31; due to three positions
Figure BDA0003471427270000177
The inclined holes are formed in the surface of the inner circular arc of R23mm, and in order to reduce the distance between the drill bushing 33 and the inner circular arc and reduce the problem of hole distance out-of-tolerance caused by the swinging of the drill bit, a semi-circular arc of R21mm is adopted in the part, where the drill bushing 33 is installed, of the drill plate 27, and the gap between the semi-circular arc and the inner circular arc of R23mm is guaranteed to be 2mm. For clamping and processing three parts at one time
Figure BDA0003471427270000178
Figure BDA0003471427270000179
The inclined hole adopts a rotatable rotary plate 31 structure, the rotary plate 31 is made of 20 # steel plate, the hardness of the surface layer of the rotary plate 31 can reach HRC 55-60 after carburization and quenching treatment, and the rotary plate has better hardness and wear resistance; the core is not quenched, so that the hardness value is only HRC 18-22, and the machining performance is good; a positioning hole with a diameter of 30mm passes through the drill plate 27
Figure BDA0003471427270000181
Clearance fit of the outer circle for main positioning of the rotary plate 31The positioning device not only ensures better positioning precision, but also can flexibly rotate, and is convenient for the conversion among three drills; the phi 15H7 positioning hole is used for main positioning of the second positioning shaft 26 through interference fit with a phi 15r6 excircle in the second positioning shaft 26; three places
Figure BDA0003471427270000182
The tapered bore is used for angular positioning of the return plate 31 by cooperation with the steel ball 25.
Figure BDA0003471427270000183
The circular arc slot of (3) is used for locking the rotating plate 31. The main positioning is formed by connecting one end of a second positioning shaft 26 with a rotary plate 31 through phi 15H7/r6 interference fit, and the other end of the second positioning shaft passes through
Figure BDA00034714272700001812
The excircle is matched with a phi 15H8 inner hole in the second blank, so that the positioning is convenient and quick, and the positioning precision is higher; the angular positioning is composed of a positioning plate 39, a fifth screw 38, a third cylindrical pin 37 and the like, and the position size of the positioning center of the second blank is ensured by adjusting the positioning plate 39
Figure BDA0003471427270000184
And realizing the angular accurate positioning of the second blank. The compression part is composed of a fifth washer 35 and a fourth nut 36.
The flying block inclined hole reversible type drill jig is used as follows: the screw plug 23 is first screwed down to apply a certain pressing force to the spring 24, thereby pressing the steel ball 25, and the steel ball 25 is engaged with the rotary plate 31
Figure BDA0003471427270000185
Figure BDA0003471427270000186
The positioning taper holes are tightly attached, so that the rotary plate 31 can be prevented from loosening in the process of drilling the second blank, and the rotary plate 31 can be conveniently separated from contact when the next hole is drilled to loosen the position adjustment of the rotary plate 31. Then, the second blank is put intoThe second positioning shaft 26 is arranged on the second blank through a clearance fit of phi 15H8/f6, so that the end face of the second blank is contacted with the upper end face of the rotary plate 31. The side surface is angularly positioned by a positioning plate 39, and finally, the second blank is pressed by a fourth nut 36 to be drilled
Figure BDA0003471427270000187
An inclined hole; after the processing is finished, the butterfly nut 40 is appropriately loosened to reduce the contact force between the rotary plate 31 and the steel ball 25, and then the rotary plate 31 is rotated to enable the left side in the rotary plate 31
Figure BDA0003471427270000188
The positioning taper hole is contacted with the steel ball 25, then the butterfly nut 40 is used for pressing the rotary plate 31, and finally the middle left side of the second blank is drilled
Figure BDA0003471427270000189
And (4) inclined holes. After the processing is finished, the butterfly nut 40 is appropriately loosened to reduce the contact force between the rotary plate 31 and the steel ball 25, and then the rotary plate 31 is rotated to enable the middle right side of the rotary plate 31
Figure BDA00034714272700001810
Figure BDA00034714272700001811
The positioning taper hole is contacted with the steel ball 25, then the butterfly nut 40 is used for pressing the rotary plate 31, and finally the middle and right sides of the second blank are drilled
Figure BDA0003471427270000191
And (4) inclined holes. Three places
Figure BDA0003471427270000192
After the inclined hole is machined, the fourth nut 36 is loosened, and the flyweight is taken down. Three positions in the second blank are processed by using the flyweight inclined hole reversible drilling jig
Figure BDA0003471427270000193
Inclined holes, the second blank only needs to be clamped once to finish three positions
Figure BDA0003471427270000194
The inclined hole is machined, so that the machining efficiency is high, the machining precision is high, and mass and automatic production is easy to realize.
In conclusion, the invention realizes the rapid processing of the flying block by improving the casting method of the flying block casting blank and using the specially designed and manufactured flying block turning large-eccentricity excircle fixture and the flying block inclined hole reversible drilling jig, solves the problems of the oversize of the three inclined hole distances and the low processing efficiency after the flying block processing, ensures that the one-time inspection qualification rate after the flying block processing reaches more than 98 percent, improves the processing efficiency by 2 to 3 times, can effectively reduce the labor intensity of workers, and can realize the mass and automatic production of the flying block.

Claims (5)

1. A method for processing a large-eccentricity porous flyweight iron casting is characterized by comprising the following steps: the method comprises the following steps:
step 1, preparing a flyweight casting blank;
step 2, carrying out aging treatment on the flying block casting blank;
step 3, fixedly mounting the flyweight casting blank subjected to the aging treatment on a lathe; turning two end faces, drilling, expanding and boring
Figure FDA0003868995470000011
Rz16mm inner hole size, the chamfer angle of the hole opening is 3 multiplied by 45 degrees, the hole opening is transversely cut into 4 first blanks according to the length direction, and the thickness size of each first blank is ensured to be
Figure FDA0003868995470000012
Step 4, processing the 1 cut first blanks in the step 3, grinding two end faces and keeping the thickness dimension
Figure FDA0003868995470000013
And the parallelism is less than or equal to 0.05mm;
step 5, finely milling two side surfaces of the first blank to ensure the size
Figure FDA0003868995470000014
And both sides face each other
Figure FDA0003868995470000015
The symmetry degree of the holes is less than or equal to 0.1mm;
step 6, turning the first blank processed in the step 5 by adopting a flying block turning large-eccentricity excircle fixture, and turning two positions
Figure FDA0003868995470000016
The eccentric distance of the arc surface is kept to be 9.5 +/-0.05 mm;
the clamp for turning the excircle with the large eccentricity by the flyweights comprises a connecting part, a transition part, a positioning part and a clamping part;
the connecting part comprises a flange (8) which is connected and positioned with a lathe spindle, a third screw (19) for pressing and a pressure plate (20);
the transition part comprises a transition disc (7) which is matched and positioned with the flange plate (8), a plurality of second gaskets (9) and second bolts (10) which are used for connecting and compressing the transition disc (7) and the flange plate (8), and also comprises a plurality of first bolts (2) which are used for fixedly connecting the positioning part with the transition disc (7), a first nut (3), a first gasket (4) and locking screws (6) which are used for locking and anti-loosening;
the positioning part comprises an excircle clamp body (1), a first positioning block (5) which is respectively provided with 1 block at the upper part and the lower part and is used for processing a positioning reference of an upper eccentric semicircle and a lower eccentric semicircle of a first blank, a plurality of first screws (11) and first cylindrical pins (12) for connection and compression, a positioning pin (17) and a second positioning block (18) for angular positioning of the first blank;
a positioning key on the left side of the outer circle clamp body (1) is connected with a key groove in the transition disc (7) in a positioning mode, and fit clearance and symmetry are guaranteed; the right inner hole of the outer circle clamp body (1) is in interference fit with the outer circle in the positioning pin (17), so that the outer circle clamp body (1) and the transition disc (7) are connected into a whole and used for main positioning of the inner hole of the first blank, the symmetry and the parallelism of the size of 205 +/-0.025 mm and the center are ensured by processing the upper flat part and the lower flat part, and the right inner hole is used as a positioning reference when processing the eccentric semicircle of the upper part and the lower part of the first blank;
the clamping part consists of a second screw (13) for locking, a third bolt (14) installed in the outer circle clamp fixture body (1), a third washer (15) for clamping and a second nut (16);
the use process of the clamp for turning the outer circle with the large eccentricity by the flyweight is as follows:
firstly, connecting an assembled cylindrical clamp with a lathe spindle through a phi 92H7 positioning hole and an M90 multiplied by 6 threaded hole, and then passing a first blank processed in the step 5 through a
Figure FDA0003868995470000021
The central hole is arranged on
Figure FDA0003868995470000022
Figure FDA0003868995470000023
In the first positioning shaft, a positioning surface of the side surface of the first blank is contacted with a second positioning block (18), and finally, a third bolt (14), a third washer (15) and a second nut (16) are used for pressing; when the eccentric arc of the upper half part of the first blank is machined, firstly loosening the first nut (3), enabling the positioning surface at the upper end of the excircle fixture body (1) to be tightly attached to the first positioning block (5) by sliding the excircle fixture body (1), then locking the first nut (3), and finally starting a lathe to machine the eccentric arc of the upper half part of the first blank; similarly, when the eccentric arc of the lower half part of the first blank is machined, only the outer circle clamp body (1) is required to slide to the direction opposite to the direction for machining the eccentric arc of the upper half part, and the rest steps are the same as those for machining the eccentric arc of the upper half part of the first blank;
step 7, sawing the first blank processed in the step 6 into 2 second blanks, and keeping the opening size to be 3 +/-0.2 mm and the size of the single second blank to be more than or equal to 50;
step 8, processing the 1 sawn second blank in the step 7, and milling the upper end face to ensure that the size is 48.75 +/-0.2 mm;
step 9, drill
Figure FDA0003868995470000024
Through hole, upper end expanded and reamed
Figure FDA0003868995470000025
Drill
Figure FDA0003868995470000026
Drilling, expanding and reaming
Figure FDA0003868995470000027
An aperture;
step 10, reaming
Figure FDA0003868995470000028
Step 11, machining the second blank machined in the step 10 by adopting a flyer inclined hole reversible drilling jig; drill
Figure FDA0003868995470000029
Uniformly distributing holes, and keeping the position size of 8 +/-0.1 mm, the angle size of 30 +/-10 'and 60 +/-10' at two positions; obtaining a finished product of the large-eccentricity porous flyweight iron casting;
the flyweight inclined hole reversible drilling jig comprises a clamp body (21) for machining an inclined hole clamp, a drilling template (27), a drilling sleeve (33), a support, a positioning device and a pressing device;
the phi 22H7 hole of the clamp body (21) for machining the inclined hole is used for main positioning with the drill plate (27) through the interference fit of phi 22H7/r 6;
Figure FDA0003868995470000031
the key slot is matched with a 4 x 16mm semicircular key for angular positioning with the drilling template (27);
Figure FDA0003868995470000032
the position size between the hole and the phi 22H7 positioning hole is ensured to be 65 +/-0.015 mm, and the steel ball (25), the spring (24) and the screw plug (23) are installed,for angular positioning of the rotating plate (31);
a first excircle of the drill plate (27) is in interference fit with an inner hole in the clamp body (21) of the inclined hole machining clamp and is used for main positioning of the drill plate (27), and a second excircle of the drill plate is in clearance fit with a positioning hole in the rotary plate (31) and is used for main positioning of the rotary plate (31); the rotary plate (31) adopts a rotatable structure; the part of the drilling template (27) for mounting the drilling sleeve is a semicircular arc with the radius of R21mm, and a gap between the drilling template and an inner circular arc with the radius of R23mm is ensured;
the compression device comprises a fifth washer (35) and a fourth nut (36);
the positioning device comprises a fourth screw (22), a fourth washer (28), a third nut (29), a half-round key (30), a second cylindrical pin (32), a lining (34), a third cylindrical pin (37), a fifth screw (38), a positioning plate (39) and a fourth bolt (41);
the use process of the flyweight inclined hole reversible drilling jig is as follows: firstly, screwing a screw plug (23) to enable a spring (24) to bear a certain pressing force, so as to compress a steel ball (25), and enable the steel ball (25) to be tightly attached to a phi 8mm multiplied by 90-degree positioning taper hole in a rotary plate (31); then the second blank processed in the step 10 is arranged on a second positioning shaft (26) through a clearance fit of phi 15H8/f6, the end face of the second blank is in contact with the upper end face of a rotary plate (31), the side face of the second blank is angularly positioned through a positioning plate (39), and finally a fourth nut (36) is used for pressing the second blank, drilling and drilling
Figure FDA0003868995470000033
An inclined hole; after the machining is finished, the butterfly nut (40) is loosened properly to reduce the contact force of the rotary plate (31) and the steel ball (25), then the rotary plate (31) is rotated to enable the positioning taper hole with the diameter of 8mm multiplied by 90 degrees at the left side in the rotary plate (31) to be in contact with the steel ball (25), then the rotary plate (31) is pressed tightly by the butterfly nut (40), and finally the left side in the second blank is drilled
Figure FDA0003868995470000034
An inclined hole; after the processing is finished, the butterfly nut (40) is loosened to reduce the contact force between the rotary plate (31) and the steel ball (25), and then the rotary plate (31) is rotated to ensure that the middle side and the right side of the rotary plate (31) are positioned
Figure FDA0003868995470000041
The positioning taper hole is contacted with the steel ball (25), then the butterfly nut (40) is used for pressing the rotary plate (31), and finally the middle right side of the second blank is drilled
Figure FDA0003868995470000042
An inclined hole; three places
Figure FDA0003868995470000043
After the inclined hole is machined, loosening a fourth nut (36) and taking down the machined flying block;
step 12, inspecting a finished product;
step 13, cleaning and drying the finished product;
step 14, oil sealing treatment of the finished product processing surface;
and step 15, warehousing finished products.
2. The method for machining the large-eccentricity porous flyweight-like iron casting according to claim 1, wherein: in the step 1, the flying block casting blank is an integral blank, 1 blank can be processed into 8 large-eccentricity porous flying block iron casting finished products, and the specific size is as follows: the length L is set to be 120 +/-0.8 mm; the width B is set to be 108 +/-0.5 mm and the clear size is 102 0 -0.2 mm, the machining allowance b1 and b2 left on the flat single sides at the two sides are both 3mm; the diameter D of the inner hole is set to phi 36 +/-0.5 mm, and the net size is
Figure FDA0003868995470000044
The allowance of the inner hole is 10mm; the two outer circle radiuses R2 are set to be 66 +/-0.5 mm, and the net size is
Figure FDA0003868995470000045
The excircle all leaves surplus 4mm, and centre-to-centre spacing h1 sets up to 7.5mm, and eccentricity h2 sets up to 9.5mm.
3. The method for machining the large-eccentricity porous flyweight-like iron casting according to claim 1, wherein: in the step 1, the flying block casting blank is cast by a metal mold.
4. The method for machining the large-eccentricity porous flyweight-like iron casting according to claim 1, wherein: the flange plate (8) is made of gray cast iron HT20-40; the transition disc (7) is made of gray cast iron HT20-40; the material used by the outer circle clamp body (1) is a No. 20 steel plate; the second positioning block (18) and the first positioning block (5) are made of No. 45 steel.
5. The method for processing the large-eccentricity porous flyweight-like iron casting according to claim 1, wherein: the clamp body (21) of the inclined hole machining clamp is made of gray cast iron HT20-40; the drilling template (27) is made of a No. 20 steel plate; the material used for the rotary plate (31) is a No. 20 steel plate.
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