CN115157007A - Machining allowance analysis method for large cylindrical forging - Google Patents
Machining allowance analysis method for large cylindrical forging Download PDFInfo
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Abstract
The invention provides a machining allowance analysis method of a large cylindrical forging, and belongs to the technical field of machining allowance analysis. The method comprises the following steps: s1, mounting a blank forging on a vertical lathe, and uniformly dividing a plurality of buses in the circumferential direction of the blank forging along the axial direction; s2, measuring the outer circle radius and the inner hole radius of the bus at different heights, finding out the minimum value of the allowance, and calculating to obtain the outer circle initial machining allowance and the inner hole initial machining allowance of the bus; and S3, adjusting the distance to be pushed by the vertical lathe clamping jaw according to the distribution of the initial machining allowance of the excircle and the initial machining allowance of the inner hole, and calculating the distribution of the machining allowance of the excircle and the machining allowance of the inner hole after pushing till the optimal allowance value is distributed. According to the invention, the minimum value of the allowance in the excircle radius and the inner hole radius of each bus is taken as a representative numerical value, so that the data volume of subsequent calculation can be greatly reduced, the analysis process is simplified, and the efficiency is improved; and effective data are provided for evaluating the machining allowance, and the analysis precision is greatly improved.
Description
Technical Field
The invention relates to the technical field of machining allowance analysis, in particular to a machining allowance analysis method of a large cylindrical forging.
Background
In the machining process, redundant metal on the surface to be machined on the blank forging piece needs to be removed, and the machined surface with the design requirement is obtained. The thickness of the metal layer reserved (to be cut off) on the surface of the blank forging is called as machining allowance, and the machining allowance directly influences the surface quality and the machining efficiency of a formed workpiece and influences the machining cost. The surface of a large cylindrical forging in a blank state often has external defects such as scratches, cracks, irregular pits and the like, and the defects can greatly reduce the surface machining allowance and have serious adverse effects on subsequent machining. Therefore, it is very important to estimate the machining allowance of the large cylindrical forging in the blank state before machining. If the allowance estimation is wrong, the forging cannot be machined, and therefore machining time is wasted. How to accurately estimate the machining allowance is one of the key problems to be solved.
In the existing machining process of large cylindrical forgings, a blank forging is usually fixed on a vertical lathe chuck for central positioning, then machining sizes of all points are detected, a craftsman estimates a machining adjusting method and machining allowance calculation of the blank forging in all directions according to the design sizes and experience, and if an insufficient machining position is found, the uniform machining allowance of a workpiece is ensured by means of lines. Therefore, the central positioning of the blank forging piece in the initial state plays a decisive role in whether the blank forging piece can meet the design size requirement of the drawing in future. Because large-scale cylindric forging weight is big, borrow the line to promote every time and all need the overhead traveling crane to assist, it is long to occupy the overhead traveling crane time, and operating efficiency is low, leads to central point to put the location improper, will seriously influence machining efficiency. Based on this, the number of times of the play of the blank forging must be reduced as much as possible. In addition, the blank forge piece moves on the vertical lathe chuck, the machining allowance changes at different positions are different, and finding a proper position through manual estimation is troublesome, generally speaking, in order to ensure accuracy, detection data are more, the manual analysis is difficult, and an ideal result is not easy to achieve; moreover, due to the fact that the influence of human factors is large, errors are prone to occur, the situation of repeated and repeated alignment is caused, the quality of a processed product is difficult to guarantee, a lot of unnecessary troubles and losses are brought to the processing process, and the improvement of production efficiency is limited.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a machining allowance analysis method of a large cylindrical forging.
In order to achieve the purpose, the invention is realized by the following technology:
a machining allowance analysis method for a large cylindrical forging comprises the following steps:
s1, mounting a blank forging on a vertical lathe, and uniformly dividing a plurality of buses in the circumferential direction of the blank forging along the axial direction;
s2, measuring the excircle radius and the inner hole radius of the blank forging at different heights of the bus, finding out the minimum value of the allowance of the excircle radius and the inner hole radius at different heights of each bus, and calculating to obtain the excircle initial machining allowance and the inner hole initial machining allowance at the bus;
and S3, adjusting the distance to be pushed by the vertical lathe clamping jaw according to the distribution conditions of the initial machining allowance of the outer circle and the initial machining allowance of the inner hole of the plurality of buses, and calculating the distribution conditions of the machining allowance of the outer circle and the machining allowance of the inner hole after pushing till the optimal allowance value distribution is reached.
Further, in step S1, the number of the bus bars is 4-16.
Further, in step S1, the bus line delimiting direction is a clockwise direction.
Further, in step S2, a radius measurement method or a return line measurement method is used to measure the outer circle radius and the inner hole radius of the blank forging at different heights of the bus.
Further, when measured by a radius measuring method, the outer circle initial machining allowance and the inner hole initial machining allowance are calculated by the following formulas, respectively:
the initial machining allowance of the excircle = the minimum actually measured radius of the excircle-the excircle diameter of the drawing/2;
the initial machining allowance of the inner hole is = the diameter/2-the maximum actually measured radius of the inner hole in the drawing;
the minimum actually measured radius of the excircle and the maximum actually measured radius of the inner hole are the minimum allowance of the excircle radius and the inner hole radius obtained by measurement, and the excircle diameter and the inner hole diameter of the drawing are the diameters required by the drawing.
Further, when the measurement is performed by a wire returning measurement method, the initial machining allowance of the outer circle and the initial machining allowance of the inner hole are respectively calculated by the following formulas:
the initial machining allowance of the excircle is = (reference circle diameter/2 + external backset datum number-maximum backset number of the excircle) -drawing excircle diameter/2;
the initial machining allowance of the inner hole is = the diameter/2- (reference circle diameter/2-inner return line reference number + maximum inner hole return line number) of the inner hole in the drawing;
the outer return line reference number and the inner return line reference number are respectively the distance from an outer perpendicular line and an inner perpendicular line to a reference circle, and the outer return line number and the inner return line number are respectively the distance from the outer perpendicular line to the outer wall of the blank forging and the distance from the inner perpendicular line to the inner wall of the blank forging.
Further, measuring the outer circle radius and the inner hole radius of the blank forging at every 200-300mm of the bus.
Further, the distance that the vertical lathe clamping jaw needs to push comprises a horizontal pushing distance from 0 degrees to 180 degrees and/or a horizontal pushing distance from 90 degrees to 270 degrees.
Further, the distribution condition of the excircle machining allowance after the pushing and the inner hole machining allowance after the pushing are calculated through the following formula;
the excircle machining allowance after pushing = the excircle initial machining allowance- (a × cos θ + b × sin θ);
the inner hole machining allowance after pushing = inner hole initial machining allowance + a × cos θ + b × sin θ;
where θ is the angle of the generatrix, and a and b are the horizontal pushing distance from 0 ° to 180 ° and the horizontal pushing distance from 90 ° to 270 °, respectively.
Further, the machining allowance analysis method of the large cylindrical forging adopts Excel spreadsheet processing data.
Compared with the prior art, the invention has the advantages that:
according to the invention, the inner hole radius and the outer circle radius of multiple points at different heights of multiple buses are measured, the minimum value of the allowance in the outer circle radius and the inner hole radius of each bus is further found, then the initial machining allowance of the outer circle and the inner hole is calculated through the minimum value of the allowance, the distribution conditions of the outer circle machining allowance and the inner hole machining allowance after the pushing are obtained through calculation of a preset formula, errors generated by manual estimation are avoided, and the subsequent analysis is carried out by taking the minimum value of the allowance in the outer circle radius and the inner hole radius as a representative value, so that on one hand, the calculated data volume can be greatly reduced, the analysis process is simplified, and the analysis efficiency is improved; on the other hand, the numerical value can represent the maximum value of the metal cutting amount of the blank forging at the bus, effective data are provided for evaluating the machining allowance of the blank forging, the analysis precision is greatly improved, and the machining allowance uniformity of the large cylindrical forging in the machining process is effectively guaranteed.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a schematic structural diagram of a bus bar distribution manner according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a method for measuring the outer radius and the inner radius by a backstreaming measurement method according to an embodiment of the present invention;
FIG. 3 is a schematic structural diagram of a push-to-activate manner according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of Excel spreadsheet-aided data processing when using radius measurements in accordance with an embodiment of the present invention;
FIG. 5 is a schematic structural diagram of Excel spreadsheet-aided data processing when a backspacing measurement method is employed in an embodiment of the present invention;
FIG. 6 is a data distribution diagram of the number of inner hole returns and the number of outer circle returns at different heights of a certain blank forging, which are measured when a return measurement method is adopted in embodiment 1 of the present invention;
fig. 7 is a distribution diagram of the machining allowance of a blank forged piece after being pushed and activated in embodiment 1 of the present invention.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. In addition, the terms "comprising," "including," and "having" are intended to be non-limiting, i.e., other steps and other ingredients can be added that do not affect the results. Materials, equipment and reagents are commercially available unless otherwise specified.
For a better understanding of the invention, and not as a limitation on the scope thereof, all numbers expressing quantities, percentages, and other numerical values used in the present invention are to be understood as being modified in all instances by the term "about". Accordingly, unless expressly indicated otherwise, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained. At the very least, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.
After the blank forging is fixed on the vertical lathe chuck, the position of the forging needs to be adjusted by means of lines, so that the quality of the machined forging is guaranteed. The vertical lathe borrowing line, also commonly called 'borrowing' and 'serial borrowing', and the like means that the machining allowance is uniform by adjusting the position (including horizontal displacement and pad angle) of a blank forging on a vertical lathe chuck. Because the central position is only roughly positioned when the blank forging is clamped on the flower disc of the vertical lathe, accurate positioning cannot be achieved, and therefore after the machining size of the forging is detected, if an insufficient machining position is found, the workpiece allowance uniformity needs to be guaranteed by means of lines. In the prior art, the line borrowing value is estimated by manually analyzing detection data and an empirical method, so that the analysis difficulty is high, errors are easy to occur, and the quality and the production efficiency of workpieces are reduced. Therefore, the line borrowing scheme can be determined scientifically and efficiently, and the method is the target which is expected to be achieved by each standing car.
The embodiment of the invention provides a machining allowance analysis method of a large cylindrical forging, which comprises the following steps:
s1, mounting a blank forging on a vertical lathe, referring to fig. 1, and uniformly dividing a plurality of buses in the circumferential direction of the blank forging along the axial direction (namely the height direction of the blank forging);
s2, measuring the excircle radius and the inner hole radius of the blank forging at different heights of the bus, finding out the minimum value of the allowance of the excircle radius and the inner hole radius at different heights of each bus, and calculating to obtain the excircle initial machining allowance and the inner hole initial machining allowance at the bus;
and S3, adjusting the distance to be pushed by the vertical lathe clamping jaw according to the distribution conditions of the initial machining allowance of the outer circle and the initial machining allowance of the inner hole of the plurality of buses, calculating the distribution conditions of the machining allowance of the outer circle and the machining allowance of the inner hole after pushing, and repeating the process until the optimal allowance value distribution is reached.
According to the invention, firstly, the data of the inner hole and the outer circle radius of multiple points at different heights of a plurality of buses are measured, the minimum value of the allowance in the outer circle radius and the inner hole radius of each bus is further found, then the initial machining allowance of the outer circle and the inner hole is calculated through the minimum value of the allowance, and the distribution conditions of the outer circle machining allowance and the inner hole machining allowance after pushing are calculated through a preset formula, so that errors generated by manual estimation are avoided, and in addition, the subsequent analysis is carried out by taking the minimum value of the allowance in the outer circle radius and the inner hole radius as a representative value, so that on one hand, the calculated data amount can be greatly reduced, the analysis process is simplified, and the analysis efficiency is improved; on the other hand, the numerical value can represent the maximum value of the metal cutting amount of the blank forging at the bus, effective data are provided for evaluating the machining allowance of the blank forging, the analysis precision is greatly improved, and the machining allowance uniformity of the large cylindrical forging in the machining process is effectively guaranteed. Therefore, the machining allowance analysis method is used as an analysis processing method of the line borrowing and pushing data of the blank forging, has the advantages of accuracy, simplicity, high efficiency and suitability for production, realizes semi-automation of the analysis method, and avoids the problems of repeated lifting, line borrowing and alignment of the large blank forging.
For simplicity of description, the present invention refers to a large cylindrical forging in the as-forged state as a blank forging that includes three dimensions, namely, an outer radius, an inner radius, and a height. After the blank forging is installed on a vertical lathe, the horizontal direction is the angle between the buses, and the vertical direction is the axial data or height data corresponding to the buses, namely the excircle radius and the inner hole radius data.
Specifically, in the step S1, the number of the bus bars is 4-16, and the bus bars are determined according to the size of a blank forging. When the blank forging piece is smaller, the number of the bus bars can be smaller, for example, 4 bus bars are provided, the included angle of each bus bar is 90 degrees and is sequentially distributed at the angular positions of 0 degrees, 90 degrees, 180 degrees and 270 degrees, when the blank forging piece is larger, the included angle of each bus bar can be 8 bus bars, the included angle of each bus bar is 45 degrees and is sequentially distributed at the angular positions of 0 degrees, 45 degrees, 90 degrees, 135 degrees, 180 degrees, 225 degrees, 270 degrees and 315 degrees, even more bus bars are provided, for example, 16 bus bars are provided, the included angle of each bus bar is 22.5 degrees and is sequentially distributed at the angular positions of 0 degrees, 22.5 degrees, 45 degrees, 67.5 degrees, 90 degrees, 112.5 degrees, 135 degrees, 157.5 degrees, 180 degrees, 202.5 degrees, 225 degrees, 247.5 degrees, 270 degrees, 292.5 degrees, 315 degrees and 337.5 degrees. When the accuracy required for the measurement is high, the number of the bus bars can be increased appropriately to improve the representativeness of the measurement data.
The above-mentioned angular position is based on the distribution direction of the vertical lathe clamping jaws, generally speaking, the number of the vertical lathe clamping jaws is 4, and the four clamping jaws are respectively distributed on the angular orientations of 0 degree, 90 degrees, 180 degrees and 270 degrees.
In order to facilitate the definition of the angle of the bus and the marking of the angle of the bus, the bus definition direction is clockwise, because the vertical lathe usually rotates anticlockwise, and the marking and marking angles are more convenient and fast clockwise.
In the step S2, after a bus is defined, a plurality of detection points are set at different heights of the bus by taking the bus as a reference, wherein the detection points comprise an inner hole detection point and an outer circle detection point, then the outer circle radius of the outer circle detection point and the inner hole radius of the inner hole detection point are measured, an outer circle radius and an inner hole radius data set of the blank forging at different heights of the bus are obtained, then minimum radius data in the outer circle radius data set are found, namely the minimum allowance value of the outer circle radius of the bus, the data represent the condition that the metal cutting amount of the outer wall of the blank forging is maximum, and the maximum radius data in the inner hole radius data set are found, namely the minimum allowance value of the inner hole radius of the bus, and the data represent the condition that the metal cutting amount of the inner wall of the blank forging is maximum. And after finding the minimum value of the allowance, calculating to obtain the initial machining allowance of the outer circle and the initial machining allowance of the inner hole at the position of the bus.
Specifically, the methods for measuring the outer circle radius at the outer circle detection point and the inner hole radius at the inner hole detection point include a radius measurement method and a wire return measurement method, which are all the prior art in the field and are not described herein again.
When the radius measurement method is adopted for measurement, the measured data are the excircle measured radius and the inner hole measured radius, and the initial allowance calculation formula is as follows:
the initial machining allowance of the excircle = the minimum actually measured radius of the excircle-the excircle diameter of the drawing/2;
the initial machining allowance of the inner hole is = the diameter/2-the maximum actually measured radius of the inner hole in the drawing;
the minimum actually measured radius of the excircle and the maximum actually measured radius of the inner hole are the minimum allowance values of the excircle radius and the inner hole radius obtained by measurement in the step S2 of the invention, and the excircle diameter and the inner hole diameter of the drawing are the diameters required by the drawing.
When the measurement is performed by a back-line measurement method, the measurement diagram is shown in fig. 2, and the outer circle radius and the inner hole radius are calculated by the following formulas:
the excircle radius = reference circle diameter/2 + external return line reference number-excircle return line number;
the inner hole radius = the reference circle diameter/2 + the reference number of the inner return lines-the number of the inner hole return lines;
wherein, outer backset datum number is the distance of plumb line to reference circle outward, and inner backset datum number is the distance of plumb line to reference circle, and outer round backset number is the distance of plumb line to blank forging outer wall outward, and inner round backset number is the distance of plumb line to blank forging inner wall.
Based on this, the initial margin calculation formula is as follows:
the initial machining allowance of the excircle is = (reference circle diameter/2 + external backset datum number-maximum backset number of the excircle) -drawing excircle diameter/2;
the initial machining allowance of the inner hole is = the diameter/2- (reference circle diameter/2-reference number of inner return lines + maximum number of inner return lines) of the inner hole in the drawing;
the maximum outer circle return line number subtracted from the sum of the reference circle radius and the reference number of the outer return line is the minimum actually measured outer circle radius, the maximum inner hole return line number added to the difference between the reference circle radius and the reference number of the inner return line is the maximum actually measured inner hole radius, and the minimum outer circle radius and the maximum inner hole radius are the minimum residual values of the outer circle radius and the inner hole radius measured in the step S2.
Optionally, the outer circle radius and the inner hole radius of the blank forging are measured at every 200-300mm interval of the bus bar. Namely, one detection point is arranged at intervals of 200-300mm along the axial direction of the blank forging, so that the coverage surface of data can be ensured, and the optimization precision of the allowance value is improved.
In the step S3, whether line-borrowing pushing is needed is analyzed according to the distribution of the initial machining allowance of the outer circles and the initial machining allowance of the inner holes of the plurality of busbars, that is, whether the initial machining allowance of the outer circles and the inner holes of the different busbars is small or not, if the problems exist, the distance (namely pushing data) which needs to be pushed by the vertical lathe clamping jaw is adjusted, the distance (namely pushing data) is shown in fig. 3, and the distance (namely pushing data) comprises horizontal pushing from 0 ° to 180 ° direction (hereinafter referred to as 0 ° pushing) and horizontal pushing from 90 ° to 270 ° direction (hereinafter referred to as 90 ° pushing), wherein a and b in the drawing are respectively "0 ° pushing" and "90 ° pushing" data, and the distribution of the machining allowance of the outer circles and the machining allowance of the inner holes after pushing is calculated by the following formulas;
the excircle machining allowance after pushing is = the excircle initial machining allowance plus delta P;
△P＝-(a×cosθ+b×sinθ)；
the inner hole machining allowance after pushing is = the inner hole initial machining allowance plus delta P';
△P'＝a×cosθ+b×sinθ；
wherein, the delta P and the delta P' are respectively an excircle allowance increment value and an inner hole allowance increment value of an angle theta after pushing, the theta is an angle of a bus, and a and b are respectively a horizontal pushing distance from 0 degree to 180 degrees and a horizontal pushing distance from 90 degrees to 270 degrees.
It should be noted that the calculation results of Δ P and Δ P' may be positive or negative values, and the values of a and b may also be positive or negative values. a is positive indicating pushing from 0 ° to 180 °, and negative indicating pushing from 180 ° to 0 °. And after the distribution conditions of the excircle machining allowance and the inner hole machining allowance after the pushing are obtained through calculation, the allowance distribution at the moment is observed, if the satisfactory state cannot be achieved, the pushing data is further improved, the result gradually approaches to perfect, and the optimal allowance value distribution is achieved.
In addition, it should be noted that the "push by 0 ° data and the" push by 90 ° data may be adjusted simultaneously, may be adjusted separately, or may be adjusted only one of them, which is specifically selected according to actual needs.
The optimal margin value distribution means that all the margins of the blank forge piece meet the requirements of a drawing, and the margins are distributed uniformly when being small or the margins are distributed uniformly when being insufficient but not enough. In other words, the smallest of the outer circle machining allowance and the inner hole machining allowance at the plurality of bus bars cannot be increased by adjusting the activation data any more. The minimum machining allowance distribution is uniform, and the detection point and the corresponding data are equal or the 3-point minimum allowance which is not in the same semicircle is equal.
The machining allowance analysis method is simple, and related data can be processed in an auxiliary mode through the Excel spreadsheet. Illustratively, FIGS. 4-5 are tables of data processing for calculating the outer circumference allowance and inner bore allowance after plunge using the radius measurement and the return line measurement, respectively. The spreadsheet comprises a display area (4 upper square frames which are sequentially an inner hole initial allowance, an outer circle initial allowance, a push-to-live outer circle machining allowance and a push-to-live inner hole machining allowance from left to right and from top to bottom), a drawing data input area and a measurement data input area.
Referring to fig. 4, when the radius measurement method is used, the drawing data input area includes the drawing inner hole diameter (i.e., inner diameter) and the drawing outer circle diameter (i.e., outer diameter), and the tolerance phase is used for auxiliary analysis and can be filled or not filled. The measured data input area comprises the angle of the bus, the measured radius of the excircle (shown in figure 4 as measured radius of the excircle), the measured radius of the inner hole (shown in figure 4 as measured radius of the inner hole) and the survival data (comprising 0-degree pushing and 90-degree pushing). The calculation process of the display area is preset according to the calculation formula, the measured outer circle actual measurement radius and the measured inner hole radius obtained through measurement are input into the measurement data input area, the numerical value distribution conditions of the outer circle initial allowance and the inner hole initial allowance of the display area are observed, whether line pushing is needed or not is analyzed, if needed, data are input at the positions of 0-degree pushing and 90-degree pushing, the distribution conditions of the outer circle machining allowance and the inner hole machining allowance after pushing in the display area are observed, the pushing data are adjusted until the minimum one of the outer circle machining allowance and the inner hole machining allowance in the display area cannot be increased through adjusting the pushing data, the optimal allowance value distribution state is judged to be reached, the pushing data are stopped to be adjusted, and the position of the forge piece blank on the vertical lathe is the optimal machining posture.
Referring to fig. 5, when the return line measurement method is used, the drawing data input area includes the drawing inner hole diameter (i.e., inner diameter), the drawing outer circle diameter (i.e., outer diameter), the reference circle diameter (i.e., reference), the reference number of the inner return line and the reference number of the outer return line, and the wall thickness. The measured data input area comprises the angle of the bus, the excircle return line number and the inner hole return line number. Inputting the maximum number of returns of the outer circle and the maximum number of returns of the inner hole obtained by measurement in a measurement data input area, observing the numerical value distribution condition of the initial allowance of the outer circle and the initial allowance of the inner hole in a display area, analyzing whether line-borrowing pushing is needed, if so, inputting data at the positions of '0-degree pushing' and '90-degree pushing', observing the distribution condition of the machining allowance of the outer circle and the machining allowance of the inner hole after pushing in the display area, adjusting the pushing data until the minimum value of the machining allowance of the outer circle and the machining allowance of the inner hole in the display area can not be increased by adjusting the pushing data, judging that the optimal allowance value distribution state is reached, stopping adjusting the pushing data, and determining the position of the blank forge piece on the vertical lathe as the optimal machining attitude.
It should be noted that, when calculating the machining allowance of the outer circle after the push and the machining allowance of the inner hole after the push, the unit required in the Excel spreadsheet is "radian", so the angle θ needs to be converted from "degree" to "radian", and the conversion relationship between the two is: degrees pi/180 = radian.
The invention utilizes the spreadsheet made by Excel to assist in completing the analysis of the blank forging machining allowance data and the determination of the pushing scheme, and has the following advantages:
1. the distribution condition of the machining allowance is obtained immediately after measurement data are input in instantaneity;
2. visibility: the change condition of the machining allowance of the inner hole and the outer circle in each angle direction can be reflected vividly;
3. interactivity: the survival data can be continuously adjusted, and the distribution condition of the processing allowance of the display area is observed in real time until the optimal allowance value distribution is reached;
4. diversity: the machining allowance of the outer circle or the inner hole can be analyzed independently, and more than one machining allowance of the inner hole and the outer circle can be comprehensively analyzed simultaneously;
5. reliability: errors which may occur in manual calculation can be avoided;
6. learning the sex: the understanding of new employees on the line borrowing method can be rapidly improved, and the working capacity is improved.
The invention will be further illustrated with reference to the following specific examples. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. The following examples are examples of experimental procedures not specified under specific conditions, generally according to the conditions recommended by the manufacturer.
Example 1
The embodiment of the invention provides a machining allowance analysis method of a large cylindrical forging, which comprises the following steps:
s1, mounting a blank forging on a vertical lathe, uniformly dividing 8 buses in the circumferential direction of the blank forging along the axial direction (namely the height direction of the blank forging), wherein the distribution mode of the buses is shown in FIG. 1, the included angle of each bus is 90 degrees, and the 8 buses are sequentially distributed at the angular positions of 0 degree, 45 degrees, 90 degrees, 135 degrees, 180 degrees, 225 degrees, 270 degrees and 315 degrees in the clockwise direction;
s2, measuring the excircle radius and the inner hole radius of the blank forging at different heights of each bus in 8 buses, finding out the minimum value of the allowance of the excircle radius and the inner hole radius at different heights of each bus, and calculating to obtain the excircle initial machining allowance and the inner hole initial machining allowance of the bus;
in the embodiment, a wire returning measurement method is adopted to measure the excircle radius and the inner bore radius, specifically, 6 detection points are set at different heights of a bus in total, the interval between every two detection points is 200-300mm, then the number of inner bore return wires and the number of outer bore return wires at the 6 heights of the bus are measured, the excircle radius at the excircle detection point and the inner bore radius at the inner bore detection point are calculated, fig. 6 exemplarily shows the number of inner bore return wires and the number of outer bore return wires at the detection points at different heights of the bus at different angles of a certain blank forging, the excircle radius and the inner bore radius of the blank forging are calculated, the maximum value of the number of inner bore return wires and the number of outer bore return wires in each row is input into a measurement data input area in an Excel spreadsheet, the maximum number of outer circle return wires in one row is 118 as shown by 0 degrees, the maximum number of inner bore return wires is 102, the minimum value of the allowance in the excircle radius and the inner bore radius is calculated, and the initial machining allowance of the excircle at the bus are further calculated according to the minimum value of the allowance; specifically, a drawing inner hole diameter (i.e., inner diameter) 5613mm, a wall thickness 346mm, a reference circle diameter (i.e., reference) 5970mm, a return line reference number 300mm and a drawing outer circle diameter (i.e., outer diameter calculated by inner diameter and wall thickness) 5959mm can be input in a drawing data input area in advance in an Excel spreadsheet, and then the following formulas are set to obtain an outer circle initial machining allowance and an inner hole initial machining allowance through one-step calculation:
the initial machining allowance of the excircle is = (reference circle diameter/2 + external backset datum number-maximum backset number of the excircle) -drawing excircle diameter/2;
the inner hole initial machining allowance = the inner hole diameter/2- (reference circle diameter/2-inner return line reference number + maximum inner hole return line number) of the drawing.
S3, adjusting the distance to be pushed by the vertical lathe clamping jaw according to the distribution conditions of the initial machining allowance of the outer circle and the initial machining allowance of the inner hole of the plurality of buses, wherein the distance comprises '0-degree pushing' and '90-degree pushing' data, then calculating the distribution conditions of the machining allowance of the outer circle and the machining allowance of the inner hole after pushing according to the following formulas, namely observing the numerical distribution of the machining allowance of the outer circle and the machining allowance of the inner hole after pushing in the display area, and when the '0-degree pushing' and '90-degree pushing' pushing data are-10 and-2 in the figure 7, the numerical distribution of the machining allowance of the outer circle and the machining allowance of the inner hole after pushing in the display area can be seen, after pushing, the minimum machining allowance of the outer circle is increased from 0.5mm to 9.0mm, and simultaneously the minimum machining allowance of the inner hole is increased from 2.5mm to 8.2mm, so that the distribution of the machining allowance is more uniform, and adjusting the '0-degree pushing' and '90-degree pushing' data for a plurality of times until the numerical distribution of the machining allowance of the outer circle and the machining allowance of the inner hole in the display area cannot reach the optimal blank '0-degree pushing' and the '90-degree pushing' data, and the optimal forging is considered as the forge piece is increased;
the excircle machining allowance after pushing is = the excircle initial machining allowance plus delta P;
△P＝-(a×cosθ+b×sinθ)；
the inner hole machining allowance after pushing is = the inner hole initial machining allowance plus delta P';
△P'＝a×cosθ+b×sinθ；
the angle theta is the angle of the bus, and a and b are the horizontal pushing distance from 0 degree to 180 degrees and the horizontal pushing distance from 90 degrees to 270 degrees respectively.
Compared with the traditional manual calculation mode, the method has the obvious advantages that through conservative statistics, in terms of efficiency and quality, the cost is saved by more than 2000 yuan each time, statistics is carried out according to 200 times of calculation every year, the cost is saved by more than 40 ten thousand yuan, and the generated invisible benefits cannot be measured.
Although the present disclosure has been described above, the scope of the present disclosure is not limited thereto. Various changes and modifications may be made by those skilled in the art without departing from the spirit and scope of the present disclosure, and these changes and modifications are intended to fall within the scope of the present disclosure.
Claims (10)
1. A machining allowance analysis method of a large cylindrical forging is characterized by comprising the following steps:
s1, mounting a blank forging on a vertical lathe, and uniformly dividing a plurality of buses in the circumferential direction of the blank forging along the axial direction;
s2, measuring the excircle radius and the inner hole radius of the blank forging at different heights of the bus, finding out the minimum value of the allowance of the excircle radius and the inner hole radius at different heights of each bus, and calculating to obtain the excircle initial machining allowance and the inner hole initial machining allowance at the bus;
and S3, adjusting the distance to be pushed by the vertical lathe clamping jaw according to the distribution conditions of the initial machining allowance of the outer circle and the initial machining allowance of the inner hole of the plurality of buses, and calculating the distribution conditions of the machining allowance of the outer circle and the machining allowance of the inner hole after pushing till the optimal allowance value distribution is reached.
2. The machining allowance analysis method of the large cylindrical forging according to claim 1, wherein in the step S1, the number of the bus bars is 4-16.
3. The machining allowance analysis method of the large cylindrical forging according to claim 1, wherein in the step S1, the bus line delimiting direction is a clockwise direction.
4. The machining allowance analysis method of the large cylindrical forging piece according to claim 1, wherein in the step S2, the excircle radius and the inner hole radius of the blank forging piece at different heights of the bus are measured by adopting a radius measurement method or a return line measurement method.
5. The machining allowance analysis method of a large cylindrical forging according to claim 4, wherein when the measurement is performed by a radius measurement method, the outer circle initial machining allowance and the inner hole initial machining allowance are calculated by the following formulas:
the initial machining allowance of the excircle = the minimum actually measured radius of the excircle-the excircle diameter of the drawing/2;
the initial machining allowance of the inner hole is = the diameter/2-the maximum actually measured radius of the inner hole in the drawing;
the minimum actually measured radius of the excircle and the maximum actually measured radius of the inner hole are the minimum allowance of the excircle radius and the inner hole radius obtained by measurement, and the excircle diameter and the inner hole diameter of the drawing are the diameters required by the drawing.
6. The machining allowance analysis method of a large cylindrical forging piece according to claim 4, wherein when the machining allowance is measured by a return line measurement method, the initial machining allowance of the outer circle and the initial machining allowance of the inner hole are respectively calculated by the following formulas:
the initial machining allowance of the excircle is = (reference circle diameter/2 + external backset datum number-maximum backset number of the excircle) -drawing excircle diameter/2;
the initial machining allowance of the inner hole is = the diameter/2- (reference circle diameter/2-inner return line reference number + maximum inner hole return line number) of the inner hole in the drawing;
the outer return line reference number and the inner return line reference number are respectively the distance from an outer perpendicular line and an inner perpendicular line to a reference circle, and the outer return line number and the inner return line number are respectively the distance from the outer perpendicular line to the outer wall of the blank forging and the distance from the inner perpendicular line to the inner wall of the blank forging.
7. The machining allowance analysis method of a large cylindrical forging piece according to claim 1, wherein the outer circle radius and the inner hole radius of the blank forging piece are measured at every 200-300mm of the generatrix.
8. The machining allowance analysis method of a large-sized cylindrical forging piece according to claim 1, wherein the distance which the vertical lathe clamping jaws need to push comprises a horizontal pushing distance from 0 degrees to 180 degrees and/or a horizontal pushing distance from 90 degrees to 270 degrees.
9. The machining allowance analysis method of the large cylindrical forging piece according to claim 8, wherein the distribution condition of the machining allowance of the pushed outer circle and the machining allowance of the pushed inner hole is calculated through the following formula;
the excircle machining allowance after pushing = the excircle initial machining allowance- (a × cos θ + b × sin θ);
the inner hole machining allowance after pushing = inner hole initial machining allowance + a × cos θ + b × sin θ;
where θ is the angle of the generatrix, and a and b are the horizontal pushing distance from 0 ° to 180 ° and the horizontal pushing distance from 90 ° to 270 °, respectively.
10. The machining allowance analysis method of the large cylindrical forging according to claim 1, wherein data is processed by using an Excel spreadsheet.
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