CN115178790A - Method for controlling machining process of surface integrity of mortise - Google Patents
Method for controlling machining process of surface integrity of mortise Download PDFInfo
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- CN115178790A CN115178790A CN202110361514.XA CN202110361514A CN115178790A CN 115178790 A CN115178790 A CN 115178790A CN 202110361514 A CN202110361514 A CN 202110361514A CN 115178790 A CN115178790 A CN 115178790A
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- mortise
- broach
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D41/00—Broaching machines or broaching devices characterised only by constructional features of particular parts
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Abstract
The invention discloses a method for controlling the machining process of the surface integrity of a mortise, which comprises the following steps: s1, broaching a mortise on a test piece by using a broach, performing metallographic examination on the surface integrity of the mortise broached on the test piece, and if the examination is unqualified, repeating the step S1 after replacing the broach; s2, processing the workpiece to be processed by using a broach; and S3, broaching a mortise on the test piece by using the broach, performing metallographic examination on the mortise broached on the test piece, and scrapping the workpiece to be machined if the mortise is unqualified. According to the processing process control method, before and after the broach is used for processing on the workpiece to be processed to broach the mortise, the broach is used for broaching the mortise on the test piece, metallographic examination is carried out on the mortise on the test piece, the surface integrity of the mortise processed on the workpiece to be processed by the broach is obtained by ensuring the processing precision of the broach before and after the broach processes the workpiece to be processed, and the purpose of controlling the processing integrity of the broaching surface of the mortise is achieved.
Description
Technical Field
The invention relates to the field of machining, in particular to a method for controlling the machining process of the surface integrity of a mortise.
Background
The aircraft engine is a power source of an aircraft, and the disk parts containing the tongue-and-groove assembled blades are the most critical components in the power operation of the whole engine and the most demanding components in the whole engine. The material of the disk parts is generally high-temperature alloy, the hardening phenomenon generated during processing is quite obvious, and the cutting processability is very poor. Usually, only the broaching method is adopted to meet the requirements of precision and roughness. Extensive practice and fault analysis have shown that in the case of failure of aircraft engine components, fatigue failure accounts for a considerable proportion, and often originates at the surface of the part.
Currently, the integrity test of the broaching surface of a part is the surface residual stress, the most important of which is the surface roughness that can be directly observed. The surface residual stress is mainly influenced by a plurality of factors such as a processing machine tool, clamping rigidity, broaching parameters, a tool abrasion state and the like, the traditional method mainly depends on destructive tests such as dissection, trial run and the like to check the surface residual stress, but for batch production parts, each part cannot be subjected to destructive check. Therefore, a scheme for controlling the surface integrity of all the machined mortises does not exist at present, and the influence factors of artificial subjective selection of quality control are large, so that the consistency of the broaching surface integrity of the mortises of parts is poor, the broaching surface integrity cannot be effectively controlled, and the quality of products produced in batches is influenced.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for controlling the surface integrity of the mortise in order to overcome the defect that the surface integrity of all the processed mortises cannot be controlled in the prior art.
The invention solves the technical problems through the following technical scheme:
a method of controlling a manufacturing process for surface integrity of a mortise slot, comprising the steps of:
s1, broaching at least one mortise on a test piece by using a broach, carrying out metallographic examination on the surface integrity of the mortise broached on the test piece, and if the examination is unqualified, repeatedly executing the step S1 after replacing the broach;
s2, processing at least one workpiece to be processed by using a broach;
and S3, broaching at least one mortise on the test piece by using a broach, carrying out metallographic examination on the surface integrity of the mortise broached on the test piece, and if the mortise is not qualified, scrapping the workpiece to be machined.
The method for controlling the machining process of the surface integrity of the mortise is characterized in that a broach is used for machining on a workpiece to be machined, the broach is used for broaching the mortise on a test piece before and after the mortise is broached, and metallographic examination is carried out on the mortise on the test piece, so that the method for controlling the machining process of the mortise is provided by ensuring the machining precision and reliability of the broach before and after the workpiece to be machined is machined, the surface integrity of the mortise machined on the workpiece to be machined is indirectly obtained, and the purpose of effectively controlling the machining integrity of all the mortise broached surfaces is achieved.
Preferably, step S3 further includes: and after the broach finishes processing the test piece, checking the cutter abrasion condition of the broach.
According to the method, the wear condition of the cutter of the broach is checked, so that whether the mortise machined on the workpiece to be machined is qualified or not is judged based on the wear condition of the broach, and another judgment index for realizing machining process control is provided.
Preferably, step S3 further includes:
and if the maximum cutter abrasion value of the broach is larger than an abrasion preset value, scrapping the workpiece to be machined.
According to the method, the workpiece to be machined is scrapped under the condition that the maximum cutter abrasion is larger than an abrasion preset value, so that the machining precision of the mortise on the workpiece to be machined is ensured.
Preferably, in step S3: the preset value of wear is 0.2mm.
The method provides a preferable numerical value for accurately judging the abrasion condition of the cutter.
Preferably, step S3 further includes: at least the last 5 teeth of the broach were inspected for tool wear.
According to the method, the wear condition of the cutter is judged in a relatively efficient mode by detecting the wear value of the last 5 teeth of the broach.
Preferably, in step S2: the number of the pieces to be processed by using the broach is 1 or 2.
According to the method, the number of the parts to be machined in one-time machining of the broach is not excessive, and the excessive number of the parts to be scrapped after the conclusion that metallographic phase inspection is unqualified is obtained by the machining process control method is avoided.
Preferably, step S1 further includes: and after the broaching of the test piece is finished by the broaching tool, checking the tool abrasion condition of the broaching tool.
According to the method, whether the mortise machined on the test piece is qualified or not is judged based on the wear condition of the broach by checking the wear condition of the broach.
Preferably, step S1 further includes:
if the maximum cutter abrasion value of the broach is larger than the abrasion preset value, the step S1 is repeatedly executed after the broach is replaced;
and if the maximum cutter abrasion value of the broach is less than or equal to the abrasion preset value, executing the step S2.
According to the method, under the condition that the maximum cutter abrasion is larger than an abrasion preset value, the mortise machined by the broach is ensured to have higher machining precision in a cutter replacing mode.
Preferably, in step S1: the preset value of wear is 0.2mm.
The method provides an optimal numerical value for accurately judging the abrasion condition of the cutter.
Preferably, step S1 further includes: at least the last 5 teeth of the broach were inspected for tool wear.
According to the method, the wear condition of the cutter is judged in a relatively efficient mode by detecting the wear value of the last 5 teeth of the broach.
Preferably, step S3 further includes: and if the detection is qualified, increasing the tool changing points of the broach, wherein the added value of the tool changing points is the same as the number of the workpieces to be machined processed by the broach.
The method provides a method suitable for obtaining the number of tool changing points during batch processing. Wherein, the new (coping) broach only needs to broach according to the tool changing point determined in the processing procedure control method, and then the processing integrity of the broaching surface of the mortise processed by the broach can be effectively controlled, so as to improve the processing efficiency in the batch processing procedure under the premise of ensuring the process control.
Preferably, the machining process control method further includes step S4: and (5) repeatedly executing the steps S1-S3, and stopping machining and replacing a new broach if the numerical value of the tool changing point is greater than or equal to the preset tool changing value.
According to the method, the time for tool changing is controlled based on the preset tool changing value, the machining efficiency is improved, and the situations that parts are scrapped due to unqualified detection and the like are avoided.
Preferably, the material of the test piece is the same as that of the workpiece to be machined.
According to the method, the material of the test piece is the same as that of the workpiece to be machined, so that the surface integrity condition of the mortise obtained by broaching the broach on the workpiece to be machined is reflected through metallographic examination of the surface integrity of the mortise on the test piece.
Preferably, the hardness, the heat treatment state and the metallographic structure of the test piece are the same as those of the workpiece to be machined.
According to the method, the hardness, the heat treatment state and the metallographic structure of the test piece are the same as those of the workpiece to be machined, so that the surface integrity condition of the mortise obtained by broaching the workpiece to be machined by the broaching tool is reflected by metallographic examination of the surface integrity of the mortise on the test piece.
Preferably, the outer diameter of the test piece is the same as the outer diameter of the workpiece to be machined.
According to the method, the outer diameter of the test piece is the same as that of the workpiece to be machined, so that the efficiency of broaching the mortises on the test piece and the workpiece to be machined in a wheel flow mode is improved, and the machining speed is increased.
The positive progress effects of the invention are as follows:
the method for controlling the machining process of the surface integrity of the mortise is characterized in that a broach is used for machining on a workpiece to be machined, the broach is used for broaching the mortise on a test piece before and after the mortise is broached, and metallographic examination is carried out on the mortise on the test piece, so that the method for controlling the machining process of the mortise is provided by ensuring the machining precision and reliability of the broach before and after the workpiece to be machined is machined, the surface integrity of the mortise machined on the workpiece to be machined is indirectly obtained, and the purpose of effectively controlling the machining integrity of the broached surface of the mortise is achieved.
Drawings
Fig. 1 is a flow chart illustrating a process control method according to an embodiment of the invention.
Fig. 2 is a schematic structural diagram of a workpiece to be processed according to an embodiment of the present invention.
FIG. 3 is a schematic illustration of the position of the tongue and groove for metallographic examination according to an embodiment of the present invention.
Detailed Description
The invention is further illustrated by the following examples, which are not intended to limit the scope of the invention.
The invention provides a method for controlling the machining process of the surface integrity of a mortise, which is used for controlling the machining process of the broaching surface integrity of the mortise of a disc part of an aero-engine.
As shown in fig. 1, the machining process control method includes the steps of:
step S1: broaching at least one mortise on the test piece by using a broach, carrying out metallographic examination on the surface integrity of the mortise broached on the test piece, and if the examination is unqualified, repeating the step S1 after replacing the broach;
step S2: processing at least one workpiece to be processed by using a broach;
and step S3: and (3) broaching at least one mortise on the test piece by using a broach, carrying out metallographic examination on the surface integrity of the mortise broached on the test piece, and if the surface integrity of the mortise broached on the test piece is not qualified, discarding the to-be-machined piece machined in the step S2.
The specific structure of the workpiece to be machined after the mortise machining is completed is shown in fig. 2, and how to machine the mortise on the surface of the part belongs to the category of the prior art, and therefore, the details are not described herein.
According to the method for controlling the machining process of the surface integrity of the mortise, the broaching tool is used for machining the workpiece to be machined, and then the same broaching tool is used for broaching the mortise on the test piece before and after the mortise is broached, metallographic examination (damage experiment) is carried out on the mortise on the test piece, and if an examination result meets requirements, the machining precision and reliability of the broaching tool in the machining step S2 of the workpiece to be machined can be guaranteed, so that the method for controlling the integrity of the machining process of the mortise is provided, the surface integrity of the mortise obtained when the broaching tool machines the workpiece to be machined is indirectly obtained, and the purpose of effectively controlling the machining integrity of the broached surface of the mortise is achieved.
Specifically, the trial pieces in steps S1 and S3 can be obtained by corresponding design and manufacture according to the material and structural design of the part to be broached (i.e., the dummy work piece). Specifically, the following conditions may be sufficient:
1. the material grade, hardness, heat treatment state, metallographic structure and the like of the test piece are required to be consistent with those of the material of the workpiece to be processed;
2. the outer diameter, the thickness, the structures and the sizes of the upper surface and the lower surface of the test piece are consistent with those of a workpiece to be machined;
3. the clamping and positioning position of the test piece when being broached by the broach must be consistent with the clamping and positioning of the workpiece to be machined.
In addition, the tooth lifting amount of the finishing broach for processing the test piece is 0.01-0.05mm, and the back angle of the finishing broach is more than or equal to 3 degrees.
The broaching speed of the broaching equipment is measured for at least 2-5 times in the actual broaching speed range of the part to be machined under the condition of no load, and the broaching speed measured each time is within +/-8% of a program set value so as to ensure the broaching quality of the part by the broaching tool. Specifically, in the present embodiment, the broaching speed of the broaching apparatus was measured 2 times for the broaching speeds of the programmed values of 5m/min,6m/min, and 7m/min, respectively, without any load, and the broaching speed was measured within ± 5% of the programmed value.
The flow details of each step in the method for controlling the machining process of the surface integrity of the mortise are as follows:
firstly, in step S1, broaching is carried out on a test piece by a broaching tool according to 2 mortises of broaching process parameters of a part at a point of 6m/min, the geometric dimension and the roughness are checked, and if the test piece is unqualified, the position of the broaching tool needs to be adjusted, or the broaching tool needs to be replaced or the processing parameters need to be debugged again until the test piece is qualified. In addition, a magnifying glass with the power of 10 times is used for carrying out tool wear inspection on the last 10 teeth of the finish broach after broaching, and the maximum tool wear values are all less than or equal to 0.2mm. If the diameter is larger than 0.2mm, the cutter is replaced. Of course, in other embodiments, the tool wear inspection may also be performed on the last 5 teeth of the finish broach after broaching, so as to improve the inspection efficiency by reducing the workload of the inspection.
And then, after the physical dimension and the roughness of the mortise are inspected and the maximum abrasion value of the cutter is inspected, cutting off 2 mortises on the test piece to carry out metallographic inspection on the surface integrity of the mortise, wherein the positions of the metallographic inspection of the mortise are shown in figure 3 (a, b, c, d and e5 area positions in total), and each position is subjected to inspection on 10 aspects of slight deformation, serious deformation, trace white layer, local large white layer, deformed strain line, local serious strain line, folding, step, tearing and foreign matter from 2 longitudinal and transverse visual angles (the distance between the sampling position and the surface of the broaching inlet and outlet is more than 5 mm) to obtain a qualified or unqualified conclusion.
And if the result of the metallographic examination is qualified, continuing to execute the step S2. And if the result of the metallographic examination is unqualified, the step S1 is executed again after the tool is changed so as to verify the quality and reliability of the newly changed tool.
In step S2, in this embodiment, the broach continues to process 2 pieces to be processed by using the parametric process in step S1, and a mortise is processed on the surface of the part. Specifically, the number of the to-be-machined parts to be machined by the broach in a single machining process should not be too large (2 in this embodiment), so as to avoid the excessive number of the parts to be scrapped after the conclusion that the metallographic examination is unqualified is obtained by the machining process control method.
In step S3, the broaching tool is used for reprocessing 2 mortises on the test piece by using the parameter process in the step S1, and a magnifying lens with the power of 10 times is used for carrying out tool wear inspection on the last 10 teeth of the fine broaching tool after broaching, wherein the maximum tool wear value is less than or equal to 0.2mm. If it is greater than 0.2mm, the tool is replaced and all the pieces to be machined processed in step S2 are discarded.
Then, the 2 mortises on the test ring need to be cut off for metallographic examination, and the positions and contents of the metallographic examination of the mortises are consistent with those in the step S1. If the result of the metallographic examination is qualified, the completeness of the surface of the mortise on the to-be-processed workpiece processed in the step S2 is qualified, and therefore, 2 tool changing points can be cumulatively increased (the number of the increased tool changing points is consistent with the number of the to-be-processed workpieces processed in the step S2).
And if the result of the metallographic examination is unqualified, discarding the workpiece to be machined in the step S2, and re-executing the step S1 after tool changing.
Furthermore, after step S3 is completed, the method further comprises step S4: and (5) repeatedly executing the steps S1-S3, and continuously accumulating the tool changing points. And if the accumulated value of the tool changing points is greater than or equal to the preset tool changing value, stopping machining and replacing a new broach. The method is specifically limited, the time for tool changing is controlled based on the preset tool changing value, the machining efficiency is improved, the situation that the detection conclusion of the mortise is unqualified due to the fact that machining continues after the preset tool changing point is exceeded, and further parts machined in the process are scrapped is avoided.
Wherein the preset tool change value is the maximum number of parts previously broached by the broach under the same process.
The statistical scheme of the tool changing points is particularly suitable for broaching new broaches which are changed in batch processing according to the tool changing point number which is continuously increased and finally determined in the step S3, and the condition that the processing number of parts is in the tool changing points can be judged to be in the range of effectively controlling the processing integrity. That is, under the same machining process, the surface machining integrity of the mortise machined by the broach can be considered to be controllable as long as the broach is still in the tool changing point.
While specific embodiments of the invention have been described above, it will be understood by those skilled in the art that this is by way of example only, and that the scope of the invention is defined by the appended claims. Various changes and modifications to these embodiments may be made by those skilled in the art without departing from the spirit and scope of the invention, and these changes and modifications are within the scope of the invention.
Claims (15)
1. A method of controlling a manufacturing process for surface integrity of a mortise, comprising the steps of:
s1, broaching at least one mortise on a test piece by using a broach, carrying out metallographic examination on the surface integrity of the mortise broached on the test piece, and if the examination is unqualified, repeatedly executing the step S1 after replacing the broach;
s2, processing at least one workpiece to be processed by using a broach;
and S3, broaching at least one mortise on the test piece by using a broach, carrying out metallographic examination on the surface integrity of the mortise broached on the test piece, and if the mortise is not qualified, scrapping the workpiece to be machined.
2. The method for controlling a surface integrity of a mortise according to claim 1, wherein the step S3 further comprises: and after the broach finishes processing the test piece, checking the cutter abrasion condition of the broach.
3. The method for controlling a manufacturing process of surface integrity of a mortise according to claim 2, further comprising in step S3:
and if the maximum tool wear value of the broach is greater than a preset wear value, scrapping the workpiece to be machined.
4. A method for controlling the surface integrity machining process of a mortise according to claim 3, wherein in the step S3: the preset value of wear is 0.2mm.
5. The method for controlling a manufacturing process of surface integrity of a mortise according to claim 2, further comprising in step S3: at least the last 5 teeth of the broach were inspected for tool wear.
6. The method for controlling a machining process of the surface integrity of a mortise according to claim 1, wherein in the step S2: the number of the pieces to be processed using the broach is 1 or 2.
7. The method for controlling a machining process of surface integrity of a mortise according to claim 1, further comprising, in the step S1: and after the broaching of the test piece is finished by the broaching tool, checking the tool abrasion condition of the broaching tool.
8. The method for controlling a surface integrity machining process of a mortise according to claim 7, further comprising, in the step S1:
if the maximum cutter abrasion value of the broach is larger than the abrasion preset value, the step S1 is repeatedly executed after the broach is replaced;
and if the maximum cutter abrasion value of the broach is less than or equal to the abrasion preset value, executing the step S2.
9. The method for controlling a machining process of the surface integrity of a mortise according to claim 8, wherein in the step S1: the preset value of wear is 0.2mm.
10. The method for controlling a surface integrity machining process of a mortise according to claim 7, further comprising, in the step S1: at least the last 5 teeth of the broach were inspected for tool wear.
11. The method for controlling a machining process of the surface integrity of a mortise according to any one of claims 1 to 10, further comprising, in step S3: and if the detection is qualified, increasing the tool changing points of the broach, wherein the added value of the tool changing points is the same as the number of the workpieces to be machined processed by the broach.
12. The method for controlling a machining process of surface integrity of a mortise according to claim 11, further comprising the step of S4: and (4) repeating the steps S1-S3, and if the numerical value of the tool changing point is greater than or equal to the preset tool changing value, stopping machining and replacing a new broach.
13. The method for controlling a machining process of the surface integrity of a mortise according to any one of claims 1 to 10, wherein the material of the test piece is the same as that of the member to be machined.
14. The method of controlling a machining process for the surface integrity of a tongue and groove as set forth in claim 13, wherein said test piece has the same hardness, heat treatment state and metallographic structure as said member to be machined.
15. The method for controlling a machining process of the surface integrity of a tongue and groove according to any one of claims 1 to 10, wherein the outer diameter of the test piece is the same as the outer diameter of the member to be machined.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202110361514.XA CN115178790A (en) | 2021-04-02 | 2021-04-02 | Method for controlling machining process of surface integrity of mortise |
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| CN202110361514.XA CN115178790A (en) | 2021-04-02 | 2021-04-02 | Method for controlling machining process of surface integrity of mortise |
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