CN115793180A - Light conduction box and assembly process thereof - Google Patents
Light conduction box and assembly process thereof Download PDFInfo
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- CN115793180A CN115793180A CN202310046848.7A CN202310046848A CN115793180A CN 115793180 A CN115793180 A CN 115793180A CN 202310046848 A CN202310046848 A CN 202310046848A CN 115793180 A CN115793180 A CN 115793180A
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Abstract
The invention discloses a light conduction box and an assembly process thereof, relating to the field of light conduction boxes; the light conduction box comprises a bottom plate and a top plate, the front side, the rear side, the left side and the right side of the bottom plate are respectively welded with a front frame, a rear frame, a left side plate and a right side plate, an inclined support used for supporting a reflector assembly is welded among the bottom plate, the rear frame, the left side plate and the right side plate, a triangular structure is formed among the inclined support, the bottom plate and the rear frame, and the inclined support is an inclined edge; the left side plate, the right side plate, the front frame and the rear frame are also welded with the top plate; the inclined support is provided with a support for supporting a reflector assembly; the assembly process comprises the working procedures of part machining, part tailor-welding, heat treatment and the like, can overcome the stress generated by machining and welding through mutual constraint and process between structures, and reduces the shape and size change of parts made of aluminum alloy materials due to the stress under the condition of long-term use.
Description
Technical Field
The invention relates to the field of light conduction boxes, in particular to a light conduction box and an assembly process thereof.
Background
The main functions of the large-scale laser device light conduction box are to guide and transmit the laser beam (after the installation of the reflection lens), and to provide a stable and clean operating environment for the laser beam. The light conduction box needs to ensure the position stability of the reflection lens arranged on the light conduction box, and the relative position stability of each part of the light conduction box is ensured firstly, namely, the part forming the light conduction box cannot generate deformation except errors under the condition of long-term use, so that the part forming the light conduction box is prevented from deviating.
The main manufacturing material of the light conduction box is aluminum alloy, and the light conduction box has the physical properties of large volume and weight, and more parts, so that the welding positions are more; welding stress at each position can cause the shape and the size of a part to change due to the welding stress, and the long-term stability of the structure size cannot be ensured; secondly, the size of the aluminum alloy for manufacturing the optical transmission box is large, the aluminum alloy can deform during cutting machining when being subjected to size machining, deformation stress can be remained due to aluminum alloy deformation, and the deformation stress can lead to deformation of the aluminum alloy for a long time, so that the position of a reflecting lens mounted on the optical transmission box is influenced.
Disclosure of Invention
One object of the present invention is: in view of the above problems, the present invention provides a light guide box, which overcomes the stress generated by machining and welding by the mutual constraint between the structures, and reduces the shape and size change of the parts made of aluminum alloy material due to the stress under the condition of long-term use.
Another object of the invention is: in view of the above problems, an assembly process of a light guide box is provided, which eliminates or reduces as much as possible the stress (including the stress generated by machining and welding) generated when the light guide box is assembled, so as to achieve the purpose of reducing the shape and size changes of parts made of aluminum alloy materials due to the stress under the condition of long-term use.
The technical scheme adopted by the invention is as follows: a light conduction box comprises a bottom plate, the bottom plate and a top plate, wherein the front side, the rear side, the left side and the right side of the bottom plate are respectively welded with a front frame, a rear frame, a left side plate and a right side plate; the left side plate, the right side plate, the front frame and the rear frame are also welded with the top plate; and a support member for supporting the mirror assembly is arranged on the inclined support member.
An assembly process for assembling a light-conducting box, said light-conducting box comprising the steps of:
s1: machining parts, namely machining the aluminum alloy into parts with designed shapes, structures and sizes and deformation lower than 0.1mm/m by the steps S11 and S12, wherein the parts comprise a bottom plate, a front frame, a rear frame, a left side plate, a right side plate, an inclined support, a top plate and a support;
s11: rough machining, namely performing rough machining on the aluminum alloy, wherein the parameters of the rough machining are as follows: the diameter of the cutter is 12mm-25mm; the maximum cutting width is 0.9mm-3mm; the maximum cutting depth is 12mm-30mm; the rotating speed of the main shaft is 12000rpm-12100rpm, and the feed per tooth is 0.15mm-0.2mm; the number of the cutter edges is 3-5;
s12: finish machining, wherein finish machining is carried out on the aluminum alloy subjected to rough machining, and parameters of the finish machining are selected as follows: the diameter of the cutter is 10mm-20mm; the maximum cutting width is 1mm-2mm; the maximum cutting depth is 8mm-30mm; the rotating speed of the main shaft is 13000rpm-15500rpm, and the feeding of each tooth is 0.07mm-0.1mm; the number of the cutting edges of the cutter is 3-5;
s2: welding parts in a splicing manner; welding and fixing the bottom plate, the inclined supporting piece, the rear frame, the left side plate and the side plate in pairs to form a semi-finished product;
s3: carrying out first heat treatment; carrying out heat treatment on the semi-finished product to eliminate welding stress;
s4: welding; welding a front frame and a rear frame on the basis of the semi-finished product subjected to heat treatment to form a light transmission box;
s5: and the second heat treatment is carried out on the light conduction box for eliminating the welding stress.
Further, before performing step S1, the surface of the aluminum alloy needs to be cleaned or/and surface-treated; before proceeding to step S11, each part needs to be cleaned.
Further, in step S12, when finishing the corners of the aluminum alloy, the spindle rotation speed is matched to 30% of the spindle rotation speed in step S3.
Further, in the step S11 or/and the step 12, when the extension length of the tool is not greater than four times the diameter of the tool, the spindle rotation speed is the spindle rotation speed in the step S11 or/and the step S12; when the extension length of the tool exceeds four times the diameter of the tool, the rotating speed of the spindle is the speed after the rotating speed of the spindle is reduced proportionally in the step S11 or/and the step S12.
Further, in the step S11 or/and the step S12, the cutting tool is set in an oblique waist-shaped setting manner; and the oblique line span in the oblique waist-shaped lower cutter mode is not less than 3 times of the diameter of the cutter.
Further, in the step S11 or/and the step S12, the cutter is set in a manner of oblique waist-shaped setting; and the oblique line span in the oblique waist-shaped lower cutter mode is not less than 3 times of the diameter of the cutter.
Further, in the step S1, a tool clamp is adopted to clamp the aluminum alloy, and the aluminum alloy has clamping allowance.
Further, after step S3 is completed, step S31 is performed: correcting the shape; performing shape correction on the semi-finished product according to the data requirement; and after step S31 is completed, mounting a support for supporting the mirror assembly on the cross support; and after the support is installed, carrying out numerical milling on the installation reference and the support surface of the reflector assembly of the support.
Further, in step S2 and step S4, the welding mode is laser welding, and pins and normal temperature curing resin glue are required to perform the prefabrication butt joint before the parts are welded.
Further, after the prefabricated butt joint is completed, the welding between the parts is completed within 3 h.
Further, in step S2 and step S4, the welding type between the parts is any one of symmetric fillet welding, symmetric butt welding, and asymmetric composite welding.
Further, the part material of the light conduction box is aluminum alloy 6061-T6 or/and aluminum alloy 5A06; in the step S2 or S4, aiming at the aluminum alloy 6061-T6, the heat treatment mode is heating to 140-145 ℃, keeping the temperature for 235-245 min, and then discharging from the furnace for air cooling; or heating the aluminum alloy 5A06 along with the furnace, preserving the heat for 1-1.5h at 310-330 ℃, discharging the aluminum alloy from the furnace and air cooling the aluminum alloy after the heat preservation is finished.
Further, after the step S5, the welding seam of the optical conduction box is detected in an air tightness manner by using a helium detection method.
Further, need seal the part fretwork position before carrying out the helium and detect, the fretwork position that sealed structure includes the part has the closing plate through bolted connection, set up joint strip between closing plate and the part to welding seam between the part is located outside the sealing washer.
In summary, due to the adoption of the technical scheme, the invention has the beneficial effects that:
1. the invention is provided with the inclined support, the reflector component can be arranged on the inclined support, the bottom plate and the rear frame form a triangular stable structure, the left side plate and the right side plate constrain two sides of the inclined support, and mutual constraint among parts is realized under the condition that the rear frame, the left side plate and the right side plate are simultaneously constrained by the top plate, so that the stress generated by machining and welding is overcome, and the shape and size change of the parts made of aluminum alloy materials due to the stress under the condition of long-term use is reduced;
2. according to the invention, the machining parameters of the machine tool are limited, so that the deformation of the aluminum alloy after cutting is less than 0.1mm/m, the machining stress (deformation stress) caused by cutting in the aluminum alloy is effectively reduced, and the deformation of the part machined from the aluminum alloy is controlled within an error range;
3. the whole light conduction box is split into two times of heat treatment, so that on one hand, the process error accumulation can be reduced, and the deformation of the shape and the size of the light conduction box after the heat treatment meets the requirement of being less than one thousandth, or the dimensional tolerance and the form and position tolerance meet the requirement of being less than 1mm; on the other hand, the stability of the structure size of the light conduction box can be ensured under the environment of long-term use, and the light conduction box is prevented from deforming under the long-term action of welding stress;
4. the structure and the process (including a part machining process and a welding process) are used as an entry point, so that the structural stability of the light conduction box is improved structurally, and the mounting position stability of the reflector is improved; the part machining and welding process in the process can reduce the corresponding stress residue, effectively avoid the change of the shape and the size of the light transmission box caused by the stress under the condition of long-term use, and further realize the stability of the installation position of the reflector.
Drawings
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic three-dimensional structure of a light-conducting box according to the present disclosure;
FIG. 2 is a schematic front view of a light guide housing according to the present disclosure;
FIG. 3 isbase:Sub>A schematic sectional view along the line A-A in FIG. 2;
FIG. 4 is a schematic view of the welding process of step S3 of the present invention;
FIG. 5 is a schematic view of a symmetrical fillet weld according to the present invention;
FIG. 6 is a schematic view of a symmetrical butt weld proposed by the present invention;
FIG. 7 is a schematic view of an asymmetric composite weld according to the present invention;
FIG. 8 is a schematic view of the invention showing the use of a sealing plate to seal the hollow out position of a part;
FIG. 9 is a schematic view of a detection system for helium detection according to the present disclosure;
the labels in the figure are: 1-a bottom plate; 2-a diagonal bracing member; 3-right side plate; 4-a front frame; 5-a top plate; 6-rear frame; 7-a support; 8-left side plate; 9-docking position; 10-pin holes; 11-sealing plate.
Detailed Description
All of the features disclosed in this specification, or all of the steps in any method or process so disclosed, may be combined in any combination, except combinations of features and/or steps that are mutually exclusive.
Any feature disclosed in this specification may be replaced by alternative features serving equivalent or similar purposes, unless expressly stated otherwise. That is, unless expressly stated otherwise, each feature is only an example of a generic series of equivalent or similar features.
Example 1
As shown in fig. 1 to 4, a light guide box comprises a bottom plate, a bottom plate and a top plate 5, wherein the front, back, left and right sides of the bottom plate 1 are respectively welded with a front frame 4, a back frame 6, a left side plate 8 and a right side plate 3, an inclined support 2 for supporting a reflector assembly is welded between the bottom plate 1, the back frame 6, the left side plate 8 and the right side plate 3, a triangular structure is formed between the inclined support 2 and the bottom plate 1 and the back frame 6, and the inclined support 2 is an inclined edge; the left side plate 8, the right side plate 3, the front frame 4 and the rear frame 6 are also welded with the top plate 5; a support 7 for supporting a mirror assembly is provided on the diagonal support 2.
Specifically, in this embodiment, the inclined strut members 2 are welded between the bottom plate 1, the rear frame 6, the left side plate 8 and the right side plate 3, a face triangle structure is formed between the bottom plate, the rear frame 6 and the inclined strut members 2, a triangular structure is formed at the butt joint position 9 between the left side plate 8 or the right side plate 3 and the bottom plate 1, the inclined strut members 2 and the rear frame 6, both the triangular structure and the triangular structure are stable structures, and under the condition that the rear frame 6, the left side plate 8 and the right side plate 3 are simultaneously constrained by the top plate 5, the top plate 5 is further constrained by the front frame 4, the rear frame 6, the left side plate 8, the right side plate 3 and the bottom plate 1, so that mutual constraint between parts is realized, so that the residual stress in the parts or the residual stress in welding cannot cause excessive deformation of the material under the constraint condition, that the constraint overcomes the stress generated by machining and welding, and the shape and size change of the parts made of the aluminum alloy material under the condition of long-term use is reduced.
Example 2
A process for assembling a light guide housing according to embodiment 1, comprising the steps of:
s1: machining parts, namely machining the aluminum alloy into parts with designed shapes, structures and sizes and deformation amount lower than 0.1mm/m by the steps S11 and S12, wherein the parts comprise a bottom plate 1, a front frame 4, a rear frame 6, a left side plate 8, a right side plate 3, an inclined strut member 2, a top plate 5 and a strut member 7;
s11: rough machining, wherein the rough machining is carried out on the aluminum alloy, and the parameters of the rough machining are selected as follows: the diameter of the cutter is 12mm-25mm; the maximum cutting width is 0.9mm-3mm; the maximum cutting depth is 12mm-30mm; the rotating speed of the main shaft is 12000rpm-12100rpm, and the feeding of each tooth is 0.15mm-0.2mm; the number of the cutting edges of the cutter is 3-5;
s12: finish machining, wherein finish machining is carried out on the aluminum alloy subjected to rough machining, and parameters of the finish machining are selected as follows: the diameter of the cutter is 10mm-20mm; the maximum cutting width is 1mm-2mm; the maximum cutting depth is 8mm-30mm; the rotating speed of the main shaft is 13000rpm to 15500rpm, and the feeding of each tooth is 0.07mm to 0.1mm; the number of the cutting edges of the cutter is 3-5;
s2: welding parts in a splicing manner; welding and fixing the bottom plate, the inclined strut member 2, the rear frame 6, the left side plate 8 and the side plates in pairs to form a semi-finished product;
s3: carrying out first heat treatment; carrying out heat treatment on the semi-finished product to eliminate welding stress;
s4: welding; welding the front frame 4 and the rear frame 6 on the basis of the semi-finished product subjected to heat treatment to form a light-conducting box;
s5: and the second heat treatment is carried out on the light conduction box for eliminating the welding stress.
In this embodiment, the light guide box is made of aluminum alloy, which has lower hardness and soft structure compared with other common metals, such as ferrous metal and other non-ferrous metals, so that the aluminum alloy will not damage the tool due to the physical properties of the aluminum alloy when contacting the tool for high-speed cutting.
In the present embodiment, the machine tool for cutting is a non-specific basis as long as the parameters required in the present embodiment can be achieved.
In this embodiment, after the aluminum alloy is rough-machined in step S11, the aluminum alloy is machined to a size close to the target size, and then the aluminum alloy is machined to the target size by fine machining, and the deformation of the aluminum alloy can reach less than 0.1mm/m by selecting the parameters of rough machining and fine machining disclosed in this embodiment.
It should be noted that, the faster the spindle rotates, the less the tool damages the material, i.e. the faster the tool cuts the aluminum alloy, the shorter the time for peeling the material of the aluminum alloy, and the smaller the corresponding residual stress, so that the deformation of the aluminum alloy after being processed is smaller; however, too high a rotational speed can cause the tool to vibrate when contacting the aluminum alloy; specifically, the higher the rotation is, the larger the vibration is, and the amplitude generated by the vibration can cause the cutting position of the cutter to deviate, so that the size guarantee of the cutter is influenced; on the other hand, the higher the rotating speed is, the higher the vibration frequency is, when the cutter is used for cutting aluminum alloy, the vibration can enable the cutter to cut different positions of the surface of the aluminum alloy, so that the surface quality of the aluminum alloy is influenced, and unacceptable vibration traces such as raised grains and the like are generated; even more, the large vibrations can lead to direct breakage of the tool.
Specifically, in the present embodiment, since the main purpose of the roughing is efficient cutting, i.e., the amount of material removed per unit time is large so as to reach the target dimension as quickly as possible, the torque requirement for the roughing is large, not less than 0.88 n.m. Since the purpose of finishing is primarily to trim the machined profile, i.e. the amount of material removed per unit time is relatively small, the torque requirement for finishing is small, not less than 0.57 n.m.
Further, in the present embodiment, four possible implementation data selections of rough machining are proposed, specifically as shown in table 1.
TABLE 1 practical data for roughing (units in mm without special remarks)
| Group of embodiments | Diameter of the tool | Type of working | Maximum cut width | Maximum cutting depth | Spindle speed rpm | Feed per tooth | Number of cutting edges | Torque demand ox, |
| Group | ||||||||
| 1 | 25 | |
3 | 30 | 12000 | 0.15 | 4 | 16.89 |
| 2 groups of | 20 | |
3 | 30 | 12000 | 0.2 | 3 | 15.31 |
| |
16 | |
3 | 30 | 12000 | 0.2 | 3 | 14.91 |
| 4 groups of | 12 | Roughing | 0.9 | 12 | 12100 | 0.75 | 3～5 | 0.88 |
In this example, four possible implementation data options for finishing are presented, as detailed in table 2.
TABLE 2 Perform data (units in mm without special reference)
| Group of embodiments | Diameter of the tool | Type of working | Maximum cut width | Maximum cutting depth | Spindle speed rpm | Feed per tooth | Number of cutting edges | Torque demand ox, rice |
| A group of | 20 | Finish machining | 2 | 30 | 13000 | 0.1 | 3～5 | 5.37 |
| Two groups of | 16 | Finish machining | 1.5 | 20 | 14500 | 0.08 | 3～5 | 2.29 |
| Three groups | 12 | Finish machining | 1 | 12 | 15000 | 0.08 | 2～4 | 0.88 |
| Four |
10 | |
1 | 8 | 15500 | 0.07 | 2～3 | 0.57 |
Further, the same aluminum alloys were processed by combining the rough processing data and the finish processing data, and the data of the maximum deformation amounts finally obtained are shown in table 3.
TABLE 3 maximum deflection test data (units in mm/m without special reference)
| Rough machining and finish machining with maximum deformation | A group of | Two groups of | Three groups | Four |
| Group | ||||
| 1 | 0.095 | 0.09 | 0.075 | 0.055 |
| 2 groups of | 0.08 | 0.07 | 0.065 | 0.045 |
| 3 groups of | 0.08 | 0.065 | 0.06 | 0.06 |
| 4 groups of | 0.06 | 0.055 | 0.04 | 0.035 |
From this, it can be seen that the maximum deformation amount of the aluminum alloy can be realized to be less than 0.1mm/m by the embodiment of the present embodiment.
In the embodiment, the light transmission box is divided into two welding steps and two heat treatments, and the first heat treatment in the step S2 eliminates the welding stress existing in the tailor-welded part in the step S1; step S4, second heat treatment is to eliminate welding stress existing in the welding in the step S3; the welding stress is eliminated successively, so that overlarge size change caused by stress accumulation in the welding process is avoided, and the purpose of reducing process errors is achieved; the deformation of the shape and the size of the light conduction box after heat treatment can reach the requirement of less than one thousandth, or the dimensional tolerance and the form and position tolerance can reach the requirement of less than 1 mm.
It should be noted that, in step S1, at least the bottom plate, the cross brace 2, the rear frame 6, the left side plate 8 and the right side plate 3 are welded, because the above parts are essential parts for fixing the cross brace 2 and stabilizing the brace 7, if there is only one part welded, there is a direction of free deformation between the parts during the heat treatment process, so that the purpose of mutual constraint cannot be achieved, and the requirement of stable size cannot be met.
To be further described, in the present embodiment, in step S1, the bottom portion should be welded in advance, and if the bottom portion includes the bottom plate 1 and the supporting legs, the bottom plate 1 and the supporting legs should be welded in advance; and after the bottom welding is finished, the mounting positions of other follow-up parts are machined, so that higher combination precision is formed, the integral deformation after the direct splicing welding can be effectively reduced, and the same mounting reference is provided for the mounting welding of other parts mounted on the bottom.
In the present embodiment, the welding sequence in step S3 is to weld the front frame 4 and then weld the top plate 5, so that the top plate 5 can be supported during assembly, thereby achieving the purpose of reducing the variation in the installation dimension of the top plate 5.
In summary, the structure and the process (including the part machining process and the welding process) are used as the entry point, so that the structural stability of the light guide box is improved structurally, and the mounting position stability of the reflector is improved; the part machining and welding process in the process can reduce the corresponding stress residue, effectively avoid the change of the shape and the size of the light conduction box under the condition of long-term use due to the stress, and further realize the stable installation position of the reflector.
Example 3
On the basis of the embodiment 2, a practical specific implementation mode is further provided.
In an alternative embodiment, before step S1, the aluminum alloy surface is cleaned or/and surface-treated; before proceeding to step S11, each part needs to be cleaned.
Specifically, the cleaning or/and surface treatment of the aluminum alloy requires cleaning of the surface of the aluminum alloy to be processed, such as oil stain, residual metal chips and surface oxide layer, especially the residual hard metal chips and surface oxide layer on the surface, which may damage the cutting tool, thereby affecting the cutting accuracy of the aluminum alloy; for the installation of aluminum alloy, the tool clamp clamps the aluminum alloy as much as possible, but clamp marks need to be avoided, and because the aluminum alloy generates the clamp marks, stress concentration easily exists at the position of the clamp marks, so that the aluminum alloy is easily broken at the position of the clamp marks in the using process, and the clamp marks can also influence the relative deformation of aluminum alloy parts at two sides of the clamp marks, thereby increasing the difficulty that the deformation of aluminum alloy processing reaches less than 0.1mm/m. In the welding process, residues and impurities on the surface of the part can enter the welding position, so that impurities are generated at the welding position; oil contamination into the weld site can cause blistering of the weld site. In the embodiment, an organic solvent (such as absolute ethyl alcohol) is adopted to remove oil stains, and nylon soft hair brushes, brush rollers and the like are used for brushing the surface of the part; and then spraying clear water to the cleaning position in a high-pressure spraying mode, and air-drying to finish the cleaning of the surface of the part. The beneficial effects of using absolute ethyl alcohol as an organic solvent to remove oil stains at least comprise the following points: firstly, the absolute ethyl alcohol is volatile, so that the surface of the part is not worried about residue; secondly, the absolute ethyl alcohol can be mixed with water in any proportion, so that the aim of easy removal during part surface cleaning is fulfilled. And secondly, the output pressure of the high-pressure spraying is more than 15Mpa, so that residues and impurities on the surface of the part can be effectively removed.
In this embodiment, the surface treatment is performed mainly by anodic oxidation with concentrated sulfuric acid.
In an alternative embodiment, in step S12, when finishing the corners of the aluminum alloy, the spindle rotation speed is matched to 30% of the spindle rotation speed in step S3, so as to reduce the vibration of the tool, thereby reducing the damage to the aluminum alloy; for the corner position of the aluminum alloy, the rotating speed of a main shaft for processing the aluminum alloy is reduced, the resonant frequency and amplitude of a cutter can be effectively reduced, and the damage to the aluminum alloy is reduced. Specifically, taking the first set of practical data in finishing in example 2 as an example, when finishing the corner of the aluminum alloy, the spindle speed should be 390rpm.
In an optional specific embodiment, in step S11 or/and step S12, when the protruding length of the tool is not greater than four times the diameter of the tool, the spindle rotation speed is the spindle rotation speed in step S11 or/and step S12; when the extension length of the tool exceeds four times the diameter of the tool, the rotating speed of the spindle is the speed after the rotating speed of the spindle is reduced proportionally in the step S11 or/and the step S12.
In an optional specific embodiment, in step S11 or/and step S12, the cutting tool is set in an oblique waist-shaped cutting mode; the oblique line span in the oblique waist-shaped lower cutting mode is not less than 3 times of the diameter of the cutter; namely, a first set of practical implementation data in rough machining and a first set of practical implementation data in finish machining in embodiment 2 are taken as examples; in rough machining, the diameter of a cutter is 25mm, and if the extension length of the cutter is less than 100mm, the rotating speed of a main shaft is 12000 when the aluminum alloy is roughly machined; if the extension length of the cutter is 125mm, the extension length of 125mm is 25% more than that of 100mm, so that the rotating speed of the main shaft is reduced by 25%, namely the rotating speed of the main shaft is 9000rpm; in a similar way, when the aluminum alloy is subjected to finish machining, the extension length of the cutter is matched with the rotating speed of the main shaft in the same way.
It should be noted that, matching the extension length of the tool with the rotation speed of the spindle can effectively prevent the force arm of the tool from being too large, and achieve the purpose of reducing the probability of the tool breaking.
In a practical specific implementation manner, in step S11 or/and step S12, the tool is assembled in a hot-assembly manner, and a specific process of assembling the tool in the hot-assembly manner is to heat the tool shank at a high temperature to expand the tool shank when the tool is combined with the tool shank, then press the tool into the tool shank, and cool the tool shank to achieve clamping of the tool by the tool shank; the cutter adopts the mode assembly of hot dress, can prevent effectively that the cutter from breaking away from the handle of a knife when carrying out big cutting depth processing, guarantees production and processing safety.
It should be noted that, especially when the diameter of the tool is larger than 16mm, the tool must be assembled by hot-fitting, and the assembly by screw clamping is prohibited, because the clamping force of screw clamping is lower than that of hot-fitting, and when the rough machining or/and the finish machining are performed on the aluminum alloy by using the parameters disclosed in example 2, the screw-clamped tool easily separates from the tool holder, thereby causing an accident.
In a practical embodiment, in step S2 or/and step S3, the oblique waist-shaped lower tool is adopted as the tool lower tool, so that a large amount of metal chips are generated in the case of high-speed cutting of aluminum alloy, and the oblique waist-shaped lower tool can effectively avoid the clamping of the metal chips, thereby avoiding the possibility of tool breakage.
It should be noted that the oblique waist-shaped knife-down manner is a conventional knife-down manner in the art, and a specific knife-down manner is not described in a too large manner in this specification.
Furthermore, the oblique line span in the oblique waist-shaped lower cutter mode is not less than 3 times of the diameter of the cutter, and under the condition of normal cutting processing, the oblique line span of the oblique waist-shaped lower cutter is 1-2 times of the diameter of the cutter; in the embodiment, when the aluminum alloy is processed at a high speed in the embodiment 2, the metal chips cannot be discharged in time due to the conventional oblique waist-shaped lower cutter oblique line span, so that the metal chips are blocked, and further the possibility of cutter breakage is easily caused; and the diagonal span is adjusted to be not less than 3 times of the diameter of the cutter, so that enough space can be provided for metal chips under the condition that the aluminum alloy is cut at high speed, and the purpose of avoiding the metal chips is achieved. A situation of knife break occurs.
In an optional specific implementation manner, in the step S1, a tool clamp is used for clamping an aluminum alloy, wherein the aluminum alloy has a clamping allowance; as described in example 2, the tool for aluminum alloy could not retain the clamp mark, but in the actual production process, it was difficult to stably fix the aluminum alloy without retaining the clamp mark, especially in the case of being cut at high speed; therefore, the clamping allowance reserved in advance through the aluminum alloy can be removed in the subsequent processing, namely, the aluminum alloy tool can reserve clamping marks under the condition that the aluminum alloy has the tool allowance, and the clamping marks cannot influence the performance of the aluminum alloy.
Example 4
In an alternative embodiment, after step S3 is completed, step S31 is performed: correcting the shape; the semi-finished product is corrected according to the data requirement, the correction process is a prediction process, and the correction process is mainly used for correcting the requirement that form and position tolerance (such as perpendicularity, flatness, straightness and the like) exceeds the designed deformation requirement; if not, correction is not needed; in this embodiment, if the shape correction is necessary, the shape correction in step S21 must be performed after the first heat treatment in step S2 is completed; specifically, the shape correction process is arranged after the first heat treatment in step S2 in order to cause an excessive change in the shape of the part during the recovery heat treatment; that is, if the shape correction in step S21 is performed before the first heat treatment in step S2, the shape correction process is restored to the design requirement of the form and position tolerance, but the material is deformed under the action of high temperature, and a small deformation generated at the butt joint position 9 during the welding stress relief may be superimposed on the deformation generated in the shape correction process, so that the deformation amount is uncontrollable; therefore, the shape correction in step S21 must be performed after the first heat treatment in step S2 is completed.
Further, after step S31 is completed, the support 7 for supporting the mirror assembly is mounted on the cross brace 2, the support 7 is a part for mounting the mirror assembly, the support 7 is mounted on the cross brace 2, and the form and position tolerance of the cross brace 2 is essential for ensuring the position of the support 7, and further essential for ensuring the accuracy of the mounting position of the mirror assembly, so the process of mounting the support 7 on the cross brace 2 should be after the shape correction process.
Furthermore, after the support 7 is installed, the installation reference and the support surface of the reflector assembly of the support 7 are subjected to numerical milling; the numerical milling is to perform the numerical milling on the support piece 7, a numerical control five-axis machine tool is adopted to perform one-step processing in place, the required angle error is less than 10 milliradians, the position error is less than 0.07mm, and the planeness is less than 0.05mm, so that the accuracy and the precision of the installation position of the reflector component are ensured.
It should be noted that, in step S1 and step S2, the advantage of not assembling the front frame 4 and the top plate 5 is that it is convenient for the milling head to process several milling positions when milling the support 7, and the effect of blocking the cutter is avoided.
An optional specific implementation manner, in step S2 and step S4, the welding mode adopts laser welding, the material of the part is aluminum alloy, the deformation is easy to occur during and after the welding process, and the assembly precision is affected, therefore, the problem is solved by adopting laser welding in the embodiment, the laser welding can form good defect-free, the mechanical property is close to that of wood, and the laser welding has obvious advantages compared with argon arc welding in terms of welding residual stress, welding efficiency and welding deformation.
Further, pins and normal-temperature-cured resin adhesives are required to be adopted for prefabricating and butt-jointing before welding the parts, namely, welding is required to be carried out after the prefabricating and butt-jointing step is finished before the step S2 and the step S4, namely, the prefabricating and butt-jointing are carried out on each part by utilizing the pins, and the normal-temperature-cured resin adhesives are coated on a butt-joint combination interface; in the embodiment, an auxiliary tool is not selected to additionally constrain and fix the part, the corresponding part precision is made to meet the design requirement (generally, IT 6) before welding, pins for butt joint are prefabricated, the tool is matched with the pin to form a qualified size by utilizing the higher precision of the pin as much as possible, and the purposes of saving cost and improving efficiency are achieved.
Specifically, before step S2 and step S4, a normal temperature curing resin adhesive, such as a DG-3 resin adhesive, is coated on the butt joint position 9 between the parts; positioning and pre-installing by using a pin, checking the size, removing redundant normal-temperature cured resin adhesive after the normal-temperature cured resin adhesive is cured, cleaning a welding groove, and waiting for welding; the pin is matched with the pin hole 10 to realize positioning; as shown in fig. 1 to 4, the front frame 4 and the top plate 5 are prefabricated and butted when they are welded.
According to an optional specific implementation mode, after the prefabricated butt joint is completed, the welding between the parts is completed within 3h, and the situation that the performance of the material is reduced due to the fact that excessive oxidation occurs at the position of a welding groove is avoided.
In step S2 and step S4, the welding type between the parts is any one of symmetric fillet welding, symmetric butt welding and asymmetric composite welding, the welding type is selected according to the situation, the three welding types are adopted to butt weld the parts, the deformation caused by overlarge welding stress during local welding can be effectively controlled, and the result is obtained through a large number of process tests.
Specifically, if two parts are vertically butted and materials of the other part are arranged on two sides of one part, symmetrical fillet welding is preferably adopted, and symmetrical fillet welding (welding seam 1 and welding seam 2) is synchronously performed, as shown in fig. 5; if the two parts are butted in the parallel direction, symmetrical butt welding is preferably adopted, and symmetrical butt welding (welding seam 3 and welding seam 4) is synchronously welded, as shown in figure 6; if the two parts are butted vertically and there is material on only one side between the two parts, an asymmetric hybrid weld is preferably used, i.e., a fillet weld (weld 5) is first applied, the fillet weld being on the side with material, and then a butt weld (weld 6) is applied, the butt weld being on the side without material, as shown in fig. 7.
Furthermore, the diameter of the welding wire for welding is selected to be 1.2mm-1.6mm, the width of a light spot is 2.5mm-3.5mm, and the welding speed is 30mm/min-40mm/min; specifically, the diameter of the welding wire for butt welding should be 1.6mm in the embodiment, the width of the light spot should be 3.5mm, and the welding speed should be 40mm/min; the diameter of the welding wire for fillet welding is 1.2mm, the width of the light plate is 2.5-3mm, and the welding speed is 30mm/min.
Further, the filling capacity is poor due to the fact that the diameter of the welding wire is too small, the situation that two or more times of fusion welding are needed is easy to occur in the welding process, so that welding stress and deformation can be improved, the bending radius is large due to the fact that the diameter of the welding wire is too large, and automatic wire feeding cannot be achieved; the welding wire diameter within the range can be selected to complete the filling of the welding seam at one time, so that the welding defect caused by multiple welding is avoided; the width of the light spot is too large, the laser energy is dispersed, so that the depth of the welding seam is reduced, the width of the light spot is too small, the laser energy is too concentrated, the depth of the welding seam is too large, and the welding effect can be ensured in the aluminum alloy material by using the width of the light spot; the welding speed can affect the welding width and the depth of a welding seam, and when the welding speed is too low, gas or water molecules in the environment can enter a material in a molten state to form air holes, so that the welding quality is affected; welding speed is too big, and welding width and welding depth are not up to standard, and the part butt joint is unstable, leads to the part to connect unstably, so, selects this welding speed can effectively guarantee welding quality.
In an optional specific embodiment, the part material of the light-conducting box is aluminum alloy 6061-T6 or/and aluminum alloy 5A06; in the step S2 or S4, aiming at the aluminum alloy 6061-T6, the heat treatment mode is heating to 140-145 ℃, keeping the temperature for 235-245 min, and then discharging from the furnace for air cooling; or raising the temperature of the aluminum alloy 5A06 along with the furnace, preserving the heat for 1 to 1.5 hours at the temperature of between 310 and 330 ℃, and discharging the aluminum alloy from the furnace for air cooling after the heat preservation is finished; the heat preservation temperature is too low or/and the heat preservation time is too short, the welding stress can not be released or is not fully released, and the effect of removing the welding stress can not be achieved; the metal phase of the material is changed due to the overhigh heat preservation temperature, so that the performance of the material is influenced; too long a holding time will increase the production cost.
In an alternative embodiment, after step S5, the helium gas detection method is used to perform the air tightness detection on the weld of the optical transmission box, and the leakage rate is less than 1x10 -5 Pa*m 3 The product/s is a qualified product.
Specifically, the helium detection comprises the following steps:
s6: detection preparation, wherein hollow positions of parts need to be sealed before helium detection is carried out, as shown in fig. 8, the sealed structure comprises that the hollow positions of the parts are connected with a sealing plate 11 through bolts, a sealing rubber strip is arranged between the sealing plate 11 and the parts, and a welding seam between the parts is positioned outside the sealing ring to complete sealing of the light transmission box; and transmitting the light which completes the sealing work to the box to be placed in a vacuum environment, such as a vacuum bag; the light transmitted to the box after the sealing operation is called as a detected piece hereinafter, the inside of the detected piece is connected with a pressure gauge and a relief valve, and the inside of the detected piece is communicated with the outside through the relief valve;
s7: connecting a detection system, as shown in fig. 9, wherein the interior of the detected piece is communicated with a helium storage tank; and detecting with a helium mass spectrometer, in this embodiment, the helium mass spectrometer is an inflixon LX218 helium mass spectrometer;
s8: replacing, namely opening an air valve, quickly filling helium into the detected piece to replace the air in the detected piece, and closing the air valve until the helium concentration is more than 10% in volume fraction;
s9: filling helium; after the step S8, continuously filling helium into the detected piece, so that the pressure in the detected piece reaches a positive pressure of 500Pa, and maintaining the pressure for more than 30 min;
s10: a suction gun of the helium mass spectrometer is used for moving along the surface of the detected piece, particularly the position of the welding seam, and recording whether leakage exists at the position of the welding seam.
The invention is not limited to the foregoing embodiments. The invention extends to any novel feature or any novel combination of features disclosed in this specification and any novel method or process steps or any novel combination of features disclosed.
Claims (15)
1. A light-conducting box characterized by: the reflecting mirror assembly comprises a bottom plate (1) and a top plate (5), wherein the front, the back, the left side and the right side of the bottom plate (1) are respectively welded with a front frame (4), a rear frame (6), a left side plate (8) and a right side plate (3), an inclined support (2) for supporting a reflecting mirror assembly is welded among the bottom plate (1), the rear frame (6), the left side plate (8) and the right side plate (3), a triangular structure is formed among the inclined support (2), the bottom plate (1) and the rear frame (6), and the inclined support (2) is an inclined edge; the left side plate (8), the right side plate (3), the front frame (4) and the rear frame (6) are further welded with the top plate (5); and a support (7) for supporting the reflector assembly is arranged on the inclined support (2).
2. A process for assembling a light guide box according to claim 1, wherein: the method comprises the following steps:
s1: machining parts, namely machining the aluminum alloy into parts with designed shapes, structures and sizes and deformation lower than 0.1mm/m by the steps S11 and S12, wherein the parts comprise a bottom plate (1), a front frame (4), a rear frame (6), a left side plate (8), a right side plate (3), an inclined strut member (2), a top plate (5) and a strut member (7);
s11: rough machining, namely performing rough machining on the aluminum alloy, wherein the parameters of the rough machining are as follows: the diameter of the cutter is 12mm-25mm; the maximum cutting width is 0.9mm-3mm; the maximum cutting depth is 12mm-30mm; the rotating speed of the main shaft is 12000rpm-12100rpm, and the feeding of each tooth is 0.15mm-0.2mm; the number of the cutter edges is 3-5;
s12: and (3) finish machining, wherein finish machining is performed on the aluminum alloy subjected to rough machining, and parameters of the finish machining are selected as follows: the diameter of the cutter is 10mm-20mm; the maximum cutting width is 1mm-2mm; the maximum cutting depth is 8mm-30mm; the rotating speed of the main shaft is 13000rpm-15500rpm, and the feeding of each tooth is 0.07mm-0.1mm; the number of the cutter edges is 3-5;
s2: welding parts; welding and fixing the bottom plate, the inclined supporting piece (2), the rear frame (6), the left side plate (8) and the side plates in pairs to form a semi-finished product;
s3: carrying out first heat treatment; carrying out heat treatment on the semi-finished product to eliminate welding stress;
s4: welding; welding a front frame (4) and a rear frame (6) on the basis of the semi-finished product subjected to heat treatment to form a light transmission box;
s5: and the second heat treatment is carried out on the light conduction box for eliminating the welding stress.
3. The process of assembling a light-conducting box according to claim 2, wherein: before the step S1, the surface of the aluminum alloy needs to be cleaned or/and subjected to surface treatment; before proceeding to step S11, each part needs to be cleaned.
4. The process of assembling a light-conducting box according to claim 2, wherein: in step S12, the spindle rotation speed is matched to 30% of the spindle rotation speed in step S3 when finishing the corners of the aluminum alloy.
5. The process of assembling a light-conducting box according to claim 2, wherein: in the step S11 or/and the step 12, when the extension length of the cutter is not more than four times of the diameter of the cutter, the rotating speed of the spindle is the rotating speed of the spindle in the step S11 or/and the step S12; when the extension length of the tool exceeds four times the diameter of the tool, the rotating speed of the spindle is the speed after the rotating speed of the spindle is reduced proportionally in the step S11 or/and the step S12.
6. The process of assembling a light-conducting box according to claim 2, wherein: in the step S11 or/and the step S12, the cutter setting mode adopts an oblique waist-shaped cutter setting mode; and the oblique line span in the oblique waist-shaped lower cutter mode is not less than 3 times of the diameter of the cutter.
7. The process of assembling a light conducting housing according to claim 2, wherein: in the step S11 or/and the step S12, the cutter setting mode adopts an oblique waist-shaped cutter setting mode; and the oblique line span in the oblique waist-shaped lower cutter mode is not less than 3 times of the diameter of the cutter.
8. The process of assembling a light-conducting box according to any one of claims 2 to 7, wherein: in the step S1, a tool clamp is adopted to clamp the aluminum alloy, and the aluminum alloy has clamping allowance.
9. The process of assembling a light-conducting box according to claim 2, wherein: after step S3 is completed, step S31 is performed: correcting the shape; performing shape correction on the semi-finished product according to the data requirement; and after step S31 is completed, mounting a support (7) for supporting the mirror assembly on the cross support (2); after the support (7) is installed, the installation reference and the supporting surface of the reflector assembly of the support (7) are subjected to numerical milling.
10. The process of assembling a light-conducting box according to claim 2, wherein: in the step S2 and the step S4, the welding mode is laser welding, and pins and normal temperature curing resin glue are required to perform the prefabrication butt joint before the parts are welded.
11. The process of assembling a light-conducting box according to claim 10, wherein: after the prefabricated butt joint is completed, the welding between the parts is completed within 3 h.
12. The process of assembling a light-conducting box according to claim 2, wherein: in step S2 and step S4, the welding type between the parts is any one of symmetric fillet welding, symmetric butt welding, and asymmetric composite welding.
13. A process of assembling a light-conducting box according to any one of claims 9-12, wherein: the part material of the light transmission box is aluminum alloy 6061-T6 or/and aluminum alloy 5A06; in the step S2 or S4, aiming at the aluminum alloy 6061-T6, the heat treatment mode is heating to 140-145 ℃, keeping the temperature for 235-245 min, and then discharging from the furnace for air cooling; or raising the temperature of the aluminum alloy 5A06 along with the furnace, preserving the heat for 1 to 1.5 hours at the temperature of between 310 and 330 ℃, and discharging the aluminum alloy from the furnace for air cooling after the heat preservation is finished.
14. The process of assembling a light conducting housing according to claim 2, wherein: and after the step S5, performing air tightness detection on the welding line of the light transmission box by adopting a helium detection method.
15. The process of assembling a light conducting cabinet according to claim 14, wherein: need seal to part fretwork position before carrying out the helium and detect, the fretwork position that sealed structure includes the part has closing plate (11) through bolted connection, set up joint strip between closing plate (11) and the part to welding seam between the part is located outside the sealing washer.
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| CN116100213A (en) * | 2023-04-11 | 2023-05-12 | 四川科新机电股份有限公司 | Large stainless steel sheet welding anti-deformation device and method |
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