CN117961426A - Method for improving machining quality of thin-wall bowl-shaped soft magnetic material parts - Google Patents
Method for improving machining quality of thin-wall bowl-shaped soft magnetic material parts Download PDFInfo
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- 238000000137 annealing Methods 0.000 claims abstract description 45
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- 238000007514 turning Methods 0.000 claims description 42
- 238000001816 cooling Methods 0.000 claims description 39
- 238000010438 heat treatment Methods 0.000 claims description 31
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Abstract
The invention provides a method for improving the machining quality of thin-wall bowl-shaped soft magnetic material parts, which adopts a method combining die forging forming and traditional machining, and after blank forging is finished, the method comprises the steps of firstly arranging complete annealing to eliminate forging stress, homogenizing a structure, refining particles, improving the cutting performance of the blank, and then arranging machining. The magnetic steel cover part is subjected to stress relief annealing after rough machining due to the fact that the rough machining process is more in removing allowance and poor in structural rigidity, and machining stress is eliminated. After the magnetic steel component is processed, recrystallization annealing is needed to stabilize the magnetic performance and reach the magnetic performance required by the technology. The blank cutting allowance of the invention is small, the production efficiency is high, and the material utilization rate is improved by 177%. The die forging technology is adopted for forming processing, so that the rough machining process of the conventional machining of bars is omitted, and the processing period is shortened by 30%. Saving a great deal of cutters, manpower and equipment loss and the energy consumption cost of water, oil and the like in the processing process.
Description
Technical Field
The invention belongs to the technical field of processing of weak-rigidity special-shaped magnetic steel components, and particularly relates to a method for improving the processing quality of thin-wall bowl-shaped soft magnetic material parts.
Background
The soft magnetic material has the characteristics of high magnetic permeability and low coercivity, and is easy to magnetize and demagnetize. The soft magnetic material with the mark of 1J50 belongs to a soft magnetic alloy with high magnetic conductivity and high saturation magnetic induction intensity. The magnetic flux-cored wire has high magnetic permeability and high saturation magnetic induction intensity, and is used for various miniature transformers, choke rings, relays, micro motors, other magnetic circuit elements and the like during high magnetic induction operation. Because of the special physical properties, the materials are widely applied to electronic industry, aviation industry, automatic control, precision instruments, meters and special mechanical manufacturing. However, the magnetic material parts have fewer forming modes all the time, most parts still adopt the bar stock processing of traditional processing mode, the processing period is long, the processing efficiency is low, the material removal rate is high, the waste is serious, the cost is increased, and the mass production of the seeker products can not be met. Secondly, the magnetic material has poor cutting performance, high cutting temperature during processing, poor processing surface quality and low tool durability.
The thin-wall bowl-shaped soft magnetic material part of the guide head product belongs to a weak-rigidity special-shaped magnetic steel magnetic assembly, the inner and outer spherical wall thickness is only 1mm, four ribs on the bottom surface are cantilever beams, the structural rigidity is poor, and the processing is extremely easy to deform. Because the bar stock is adopted for forming, when the inner spherical surface and the outer spherical surface are turned, firstly, the solid bar stock is required to be processed into a plurality of steps, then the allowance is gradually removed, and finally, the part with the wall thickness of only 1mm is processed. The turning sphere is initially cut intermittently, the tool tip load and cutting force are large, the machining allowance is large, the number of times of feeding is large, and the machinability of the soft magnetic alloy 1J50 is poor, so that only low-rotation-speed and low-feed machining can be adopted, and the efficiency is extremely low. The utilization rate of the finished product material is 2.9%, the waste of raw materials is extremely high, and the 1J50 material is expensive and has high cost. And because the soft magnetic material has poor cutting performance, the cutter has quick abrasion, the service life is low, and the surface roughness of the part is poor.
Disclosure of Invention
The invention aims to provide a method for improving the processing quality of thin-wall bowl-shaped soft magnetic material parts, and the technical problems in the prior art are overcome.
Therefore, the technical scheme provided by the invention is as follows:
A method for improving the machining quality of thin-wall bowl-shaped soft magnetic material parts comprises the following steps:
step 1) die forging blank forming: blanking, heating, extruding and forging to form two parts, namely a bowl-shaped assembly I and a bowl-shaped assembly II, respectively;
Step 2) heat treatment: annealing the bowl-shaped assembly I and the bowl-shaped assembly II;
step 3) rough and finish machining is carried out on the bowl-shaped assembly I;
step 4) rough machining and finish machining are carried out on the bowl-shaped assembly II;
step 5) combined processing: combining the first bowl-shaped assembly and the second bowl-shaped assembly after rough machining and finish machining;
step 6) bench workers;
Step 7) recrystallization annealing heat treatment.
The forging heating temperature in the step 1) is 950-1150 ℃, and the forging extrusion force is 450-500 tons.
In the step 2), the annealing temperature is 950-980 ℃, the annealing temperature is heated to be less than or equal to 600 ℃/h, the heat preservation time is 2-3h, and the cooling mode adopts the cooling mode of 150 ℃/h to be less than or equal to 600 ℃ and then the furnace is taken out for air cooling.
Step 3) the specific process of rough and finish machining the bowl-shaped assembly one is as follows:
(1) Turning a step circle, turning an end face, cutting a groove and turning an inner spherical surface;
(2) Turning an end face, an outer circle and an outer sphere, and reserving a process table as a precision machining process reference;
(3) And (3) heat treatment: the annealing temperature is 900-950 ℃, the heating is carried out at the speed of less than or equal to 300 ℃/h to the annealing temperature, the heat preservation time is 2-3h, the vacuum degree P is less than or equal to 1 multiplied by 10 < -1 > Pa, the cooling mode is 100-150 ℃/h to the speed of less than or equal to 600 ℃, and the furnace is cooled to the temperature of less than or equal to 200 ℃ and is taken out of the furnace for air cooling;
(4) Turning an end face, finely boring, and finely turning an inner spherical surface to reach the required precision;
(5) Turning a process table, namely cutting the end face by a small number of cutters, removing the process table, and ensuring the flatness to be 0.05;
(6) And (5) drilling a threaded bottom hole and making threads.
Step 4) rough machining and finish machining are carried out on the bowl-shaped assembly II, and the specific process is as follows:
(1) Turning end surfaces and excircles of two ends, and roughly boring an inner hole;
(2) Positioning and clamping the excircle of the small end of the upper channel, turning a large end surface, roughly and finely turning an annular groove, turning the spherical surface of the inner cavity, finely boring a hole, finely turning the excircle, and taking the excircle as a positioning reference of the lower channel clamping;
(3) Positioning the excircle of the upper path, roughly and finely turning the outer spherical surface, the small end surface and the excircle;
(4) Milling four-side gaps, milling four steps in an inner cavity, and drilling holes;
(5) Turning a process table, namely cutting the end face by a small number of cutters, and removing the process table;
(6) Clamping the bowl-shaped assembly II by using a clamp and a compression nut, and turning a small end face, an annular groove and a boring hole;
(7) Deburring and threading.
The specific process of the combined processing of the step 5) is as follows:
(1) Combining the bowl-shaped assembly I and the bowl-shaped assembly II into a component without installing a screw;
(2) Numbering the bowl-shaped assembly I and the bowl-shaped assembly II;
(3) Combining the bowl-shaped assembly I and the bowl-shaped assembly II together by using screws to form a new assembly;
(4) And (3) carrying out wire cutting on the assembly according to the requirement, wherein the wire running times are not less than 2 times, and the flatness of the bottom surface after the machining is finished is less than 0.1.
The specific process of the bench worker in step 6) is as follows:
(1) Removing the screw;
(2) Chamfering the edges of the first bowl-shaped assembly and the second bowl-shaped assembly by 0.3;
(3) Cleaning parts, and blow-drying and circulation;
(4) And recombining the bowl-shaped assembly I and the bowl-shaped assembly II according to the serial numbers-corresponding pairs, and circulating in pairs.
The annealing temperature of the recrystallization annealing heat treatment in the step 7) is 1140-1180 ℃, the heat preservation time is 3-5h, the vacuum degree P is less than or equal to 5 multiplied by 10 < -2 > Pa, and the cooling mode adopts air cooling after cooling to the temperature of less than or equal to 600 ℃ at 100-150 ℃ per hour.
(1) When in middle grooving, the grooving cutter bar is a steel cutter bar with an internal cooling passage, the diameter of the steel cutter bar is phi 22-phi 25, the thickness of a cutter blade is 4-5mm, the length of a cutting edge is 14-16mm, the front angle of the cutting edge is 8-10 degrees, and the arc of a cutter point is R0.2-R0.3;
When the inner spherical surface is finely turned in the step (4), the cutter bar is a steel cutter bar with an inner cooling passage, the principal deflection angle is 106-107.5 degrees, the length of the cutting edge of the cutter blade is 15-16mm, the circular arc of the cutter point is R0.4-R0.5, the front angle of the cutter blade is 0 degrees, the rear angle is 4-5 degrees, and the cutter blade is provided with a Ti-Al-Si-N nano plating layer.
The beneficial effects of the invention are as follows:
the invention adopts a method combining die forging forming and traditional machining, has small blank cutting allowance, high production efficiency and improves the material utilization rate by 177 percent. The die forging technology is adopted for forming processing, so that the rough machining process of the conventional machining of bars is omitted, and the processing period is shortened by 30%. Saving a great deal of cutters, manpower and equipment loss and the energy consumption cost of water, oil and the like in the processing process.
After the blank forging is finished, the invention firstly arranges complete annealing to eliminate forging stress, homogenizes the structure, refines particles, improves the cutting performance of the blank, and then arranges mechanical processing. The magnetic steel cover part is subjected to stress relief annealing after rough machining due to the fact that the rough machining process is more in removing allowance and poor in structural rigidity, and machining stress is eliminated. After the magnetic steel component is processed, recrystallization annealing is needed to stabilize the magnetic performance and reach the magnetic performance required by the technology.
According to the invention, the assembly relation of the bowl-shaped assembly I and the bowl-shaped assembly II is combined, and before four rib plates are cut on line by two parts, the two rib plates are combined by using screws according to the assembly relation, so that the structural stability of the thin-wall bowl-shaped part is improved, and the machining precision and the machining surface quality of the part are improved.
The invention firstly eliminates forging stress through complete annealing after the blank of the bowl-shaped assembly I (magnetic steel cover) is formed, changes the microstructure structure of the blank, improves plastic forming performance, removes most of stress generated by machining allowance in the course of rough machining through stress relief annealing after rough machining, and finally performs recrystallization degradation after finishing, thereby not only homogenizing the structure and stabilizing the magnetic performance, but also releasing the stress of parts. The bowl-shaped assembly II (magnetic steel seat) has relatively stable structure and slightly better processing performance, and the removal amount of the inner cavity material is small, so that heat treatment is not arranged after rough machining. By reasonably securing heat treatment, deformation in machining is controlled.
Aiming at the difficult processing characteristics of soft magnetic materials and the structural characteristics of the inner cavity of the magnetic steel cover, when the method is used for processing the spherical surface and the grooving of the inner cavity of the magnetic steel cover part, the steel cutter bar with an inner cooling passage is selected as the cutter bar, and the cooling effect in the cutting process is better. The cutter bar with larger diameter and larger blade thickness is selected, so that the rigidity of the processing system is improved, and the processing vibration is reduced. Longer cutting edge length, avoiding the occurrence of interference phenomenon of the striking knife and the orifice. The cutting force is reduced by selecting a larger front angle, and the cutting slot is lighter and faster. And the larger tool nose is arc, the smaller relief angle and the strength of the tool nose and the cutting edge are improved. The blade coating is made of a Ti-Al-Si-N nano plating layer made of ultrafine particle materials with very high hardness, so that the wear resistance is good, the durability of the cutter is improved, and the durability of the cutter is improved.
Drawings
FIG. 1 is a schematic view of a bowl-shaped magnetic steel cover blank in an embodiment of the invention;
FIG. 2 is a schematic view of a bowl-shaped magnetic steel seat blank in an embodiment of the invention;
FIG. 3 is a schematic diagram of a rough machining process of a bowl-shaped magnetic steel cover in an embodiment of the invention;
FIG. 4 is a schematic diagram of a finishing process of a bowl-shaped magnetic steel cover in an embodiment of the invention;
FIG. 5 is a schematic diagram of a rough machining process of a bowl-shaped magnetic steel seat in an embodiment of the invention;
FIG. 6 is a schematic diagram of a finish machining process of a bowl-shaped magnetic steel seat in an embodiment of the invention;
FIG. 7 is a diagram of a bowl-shaped magnetic steel seat finishing fixture in an embodiment of the invention;
FIG. 8 is a schematic diagram of a finish machining and clamping of a bowl-shaped magnetic steel seat in an embodiment of the invention;
FIG. 9 is a schematic view of a wire-cut front assembly in accordance with an embodiment of the present invention;
FIG. 10 is a front view of a wire cutting assembly in accordance with an embodiment of the present invention;
FIG. 11 is a left side view of FIG. 10;
FIG. 12 is a schematic view of a bowl-shaped magnetic steel cover part in an embodiment of the invention;
fig. 13 is a schematic view of a bowl-shaped magnetic steel seat part in an embodiment of the invention.
In the figure: 1. bowl-shaped magnetic steel cover; 2. bowl-shaped magnetic steel seat; 3. a first screw; 4. a clamp body; 5. a second screw; 6. a clamp body; 7. a compression nut; 8. a first process table; 9. and a second process stage.
Detailed Description
Further advantages and effects of the present invention will become apparent to those skilled in the art from the disclosure of the present specification, by describing the embodiments of the present invention with specific examples.
The exemplary embodiments of the present invention will now be described with reference to the accompanying drawings, however, the present invention may be embodied in many different forms and is not limited to the examples described herein, which are provided to fully and completely disclose the present invention and fully convey the scope of the invention to those skilled in the art. The terminology used in the exemplary embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like elements/components are referred to by like reference numerals.
Unless otherwise indicated, terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art. In addition, it will be understood that terms defined in commonly used dictionaries should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense.
Example 1
The invention provides a method for improving the machining quality of thin-wall bowl-shaped soft magnetic material parts, which comprises the following steps:
step 1) die forging blank forming: blanking, heating, extruding and forging to form two parts, namely a bowl-shaped assembly I and a bowl-shaped assembly II, respectively;
Step 2) heat treatment: annealing the bowl-shaped assembly I and the bowl-shaped assembly II;
step 3) rough and finish machining is carried out on the bowl-shaped assembly I;
step 4) rough machining and finish machining are carried out on the bowl-shaped assembly II;
step 5) combined processing: combining the first bowl-shaped assembly and the second bowl-shaped assembly after rough machining and finish machining;
step 6) bench workers;
Step 7) recrystallization annealing heat treatment.
After the blank forging is finished, the invention firstly arranges complete annealing to eliminate forging stress, homogenizes the structure, refines particles, improves the cutting performance of the blank, and then arranges mechanical processing. The magnetic steel cover part (bowl-shaped assembly I) has more removing allowance and poor structural rigidity in the rough machining process, and stress relief annealing is arranged after the rough machining, so that machining stress is eliminated. After the magnetic steel component is processed, recrystallization annealing is needed to stabilize the magnetic performance and reach the magnetic performance required by the technology.
The invention adopts a method combining die forging forming and traditional machining, replaces the existing bar forming mode by the die forging forming mode, solves the problem of single forming mode of soft magnetic materials, reduces the machining allowance, has high production efficiency and improves the material utilization rate by 177 percent. The die forging technology is adopted for forming processing, so that the rough machining process of the conventional machining of bars is omitted, and the processing period is shortened by 30%. Saving a great deal of cutters, manpower and equipment loss and the energy consumption cost of water, oil and the like in the processing process.
Example 2
On the basis of the embodiment 1, the invention provides a method for improving the processing quality of thin-wall bowl-shaped soft magnetic material parts, wherein the forging heating temperature in the step 1) is 950-1150 ℃, and the forging extrusion force is 450-500 tons.
The forging temperature ranges from 950 ℃ to 1150 ℃; the extrusion force required by simulation and calculation is about 450 tons, and a 630-ton four-column oil press is adopted in the process, so that the transfer speed in the extrusion process of the forging is increased, and the temperature loss of the forging in the transfer process is reduced, and the extrusion force required to be increased due to the temperature reduction is compensated.
Example 3
On the basis of the embodiment 1, the invention provides a method for improving the processing quality of thin-wall bowl-shaped soft magnetic material parts, wherein in the step 2), the annealing temperature is 950-980 ℃, the annealing temperature is less than or equal to 600 ℃/h, the heat preservation time is 2-3h, and the cooling mode adopts the cooling mode of 150 ℃/h to less than or equal to 600 ℃ and then discharging and air cooling.
After forging the blank, arranging a complete annealing heat treatment, eliminating forging stress, homogenizing the structure, refining particles, improving the cutting performance of the blank, and then arranging machining.
Example 4
For further detailed description of the present invention, the method of the present invention will be specifically described with reference to the bowl-shaped magnetic steel cover 1 (bowl-shaped assembly one) and the bowl-shaped magnetic steel base 2 (bowl-shaped assembly two) based on the embodiment 1. The method comprises the following specific steps:
Step 1) die forging blank forming: forming two parts blanks of the bowl-shaped magnetic steel cover 1 shown in the figure 1 and the bowl-shaped magnetic steel seat 2 shown in the figure 2 through blanking, heating and extrusion forging; the extrusion molding is performed by using a soft magnetic alloy 1J50 bar stock, the magnetic steel cover is extruded by using a bar stock with the diameter of (phi 95x 24) mm, and the magnetic steel seat is extruded by using a bar stock with the diameter of (phi 95x 19); the forging temperature range of the magnetic steel cover and the magnetic steel seat is 950-1150 ℃; the extrusion force required by simulation and calculation is about 450 tons, and a 630-ton four-column oil press is adopted in the process, so that the transfer speed in the extrusion process of the forging is increased, and the temperature loss of the forging in the transfer process is reduced, and the extrusion force required to be increased due to the temperature reduction is compensated.
Step 2) heat treatment: the blanks of the bowl-shaped magnetic steel cover 1 and the bowl-shaped magnetic steel seat 2 are completely annealed, so that forging stress can be effectively eliminated, a structure is homogenized, grains are thinned, cutting performance of the blanks is improved, annealing temperature (950-980) is improved, heating standard is that the blanks are heated to the annealing temperature at the speed of less than or equal to 600 ℃/h, heat preservation time (2-3) h, and cooling mode is that the blanks are discharged from a furnace for air cooling after being cooled to the temperature of less than or equal to 600 ℃ at the speed of 150 ℃/h;
step 3) rough machining and finish machining of the bowl-shaped magnetic steel cover 1 (shown in fig. 3 and 4):
(1) And (3) vehicle: positioning by using a phi 75 inner hole and a large end surface, and turning two step circles;
(2) And (3) vehicle: the two-step circle processed in the above way is positioned, the end face is turned, the boring hole phi 79H10, the cutting groove phi 89H10 and the internal spherical surface SR47H11 are turned. Aiming at the difficult processing characteristics of soft magnetic materials and the structural characteristics of the inner cavity of the magnetic steel cover, when in grooving, the grooving cutter bar is made of steel cutter bars with inner cooling passages, the cooling effect in the cutting process is better, the diameter (phi 22-phi 25) of the cutter bars is larger, the thickness (4-5) of the cutter blades is larger, the rigidity of a processing system is improved, and the processing vibration is reduced. Meanwhile, the length of the cutting edge is increased, the maximum cutting depth is increased to (14-16) mm and is greatly deeper than the groove depth of the part by 5mm, and the cutting edge can be fed safely and greatly during cutting, so that the phenomenon of cutter collision is avoided. The cutting force is reduced by selecting a larger front angle (8-10 degrees), and the cutting slot is lighter and faster. The arc of the tool nose is R0.2-R0.3, and simultaneously, the back angle is reduced, and the strength of the tool nose and the cutting edge is improved. And the blade coating is increased, and the durability of the cutter is improved. When the inner spherical surface is turned, the diameter of the cutter bar is increased, the rigidity of the cutter bar is improved, and the machining vibration is reduced. The cutter bar is made of steel with an inner cooling passage, the cooling effect is better in the cutting process, the main deflection angle is adjusted to be 106-107.5 degrees, meanwhile, the length of the cutting edge of the blade is changed to be 15-16mm, and the direct machining of the part orifice interference can be avoided when the spherical surface is turned in a vehicle without the need of cutter connection. Increasing the rake angle of the insert to 0 deg., reducing plastic deformation of the cutting layer, reducing frictional resistance to chip flow past the rake face, and thus reducing cutting forces, cutting heat and cutting power. The arc of the tool nose is R0.4-R0.5, so that the tool nose strength is improved. The back angle is reduced to 4 degrees to 5 degrees, the thickness of the blade is increased, the strength of the cutting edge and the cutter head is improved, and the heat conducting area and the heat containing volume are increased. The blade coating is made of a Ti-Al-Si-N nano plating layer made of ultrafine particle materials with very high hardness, so that the wear resistance is good, and the durability of the cutter is improved;
(3) And (3) vehicle: turning an end face, turning an outer circle and an outer sphere, and reserving a first process table 8 as a standard of a finish machining process;
(4) And (3) heat treatment: and (5) carrying out stress relief annealing heat treatment to eliminate processing stress. The annealing temperature is 900-950 ℃, the heating standard is that the annealing temperature is not higher than 300 ℃/h, the heat preservation time is 2-3h, the vacuum degree P is not higher than 1 multiplied by 10 -1 Pa, the cooling mode is that (100-150) DEG C/h is adopted for cooling to not higher than 600 ℃, and then the furnace is cooled to not higher than 200 ℃ for discharging and air cooling;
(5) And (3) vehicle: turning an end surface, finely boring a hole phi 81H9, and finely turning an inner spherical surface to reach the precision required by a drawing; (6) vehicle: turning a first process table 8, cutting the end face by a small number of multiple cutters, removing the first process table 8, and ensuring the flatness to be 0.05;
(7) Pliers: and (5) drilling a threaded bottom hole and making threads.
Step 4) rough machining and finish machining of the bowl-shaped magnetic steel seat 2 (shown in fig. 5 and 6):
(1) And (3) vehicle: turning end surfaces and excircles of two ends, and roughly boring an inner hole;
(2) And (3) vehicle: the excircle of the small end of the upper channel is positioned and clamped, the large end surface is turned, the annular groove is roughly and finely turned, the spherical surface of the inner cavity is turned, the hole is finely bored, the excircle phi 95h8 is finely turned, the second process table 9 is reserved, and the second process table is used as a positioning reference for the clamping of the lower channel;
(3) And (3) vehicle: positioning the excircle of the upper path phi 95h8, roughly and finely turning the outer spherical surface, the small end surface and the excircle;
(4) Numerical control: milling four-side gaps, milling four steps in an inner cavity, and drilling holes;
(5) And (3) vehicle: turning a second process table 9, cutting the end face by a small amount by multiple cutters, and removing the second process table 9;
(6) And (3) vehicle: turning a small end face, an annular groove and a boring hole;
according to the structural characteristics of the magnetic steel seat, clamping deformation caused by direct clamping at the small end of the vehicle is large, and clamping is unstable, so that a clamp is needed, as shown in fig. 7; clamping apparatus The hole is matched with the excircle of phi 95h8, and the large end face is abutted against the two holes of the clampThe end face is pressed by a pressing nut 7 to press the magnetic steel seat part, and the end face, the annular groove and the boring hole are turned; the schematic diagram after clamping is shown in fig. 8;
The fixture comprises a fixture body 4 and a fixture body 6, wherein the fixture body 4 is used for clamping a lathe, the fixture body 6 is used for clamping the bowl-shaped magnetic steel seat 2, the fixture body 4 and the fixture body 6 are connected through a second screw 5, and a compression nut 7 is used for compressing the bowl-shaped magnetic steel seat 2 part and the fixture body 6.
(7) Pliers: deburring and threading.
Step 5) combined processing:
(1) Pliers: combining the magnetic steel cover and the magnetic steel seat into a magnetic steel assembly without installing screws;
(2) Carving: the magnetic steel cover and the magnetic steel seat are engraved and numbered;
(3) Pliers: combining the magnetic steel cover and the magnetic steel seat together by using 4 first screws 3 to form a new magnetic steel assembly; as shown in fig. 9;
(4) Wire cutting: and (3) carrying out linear cutting on the magnetic steel component according to the drawing requirement, wherein the wire running times are not less than 2 times, paying attention to controlling the deformation of the component, and the flatness of the bottom surface after the processing is completed is less than 0.1. As shown in fig. 10 and 11;
step 6) bench worker:
(1) Disassembling the first 4 screws 3 and returning to a warehouse;
(2) Chamfering the edges of the two parts by 0.3;
(3) Cleaning parts, drying and circulating, ensuring no stains, rust and the like;
(4) The two parts are recombined according to the serial numbers, and the two parts are in paired circulation without installing screws.
Step 7) recrystallization annealing heat treatment:
and (3) carrying out recrystallization heat treatment on the finished magnetic steel component, removing stress, homogenizing the structure and stabilizing the magnetic performance. The annealing temperature is 1140-1180 ℃, the heat preservation time is 3-5h, the vacuum degree P is less than or equal to 5 multiplied by 10 -2 Pa, and the cooling mode adopts air cooling after cooling to the temperature of less than or equal to 600 ℃ at the temperature of (100-150) DEG C/h.
The finished magnetic steel cover part and the bowl-shaped magnetic steel seat 2 part are respectively shown in fig. 12 and 13.
In summary, compared with the prior art, the invention has the following improvements:
1. die forging forming and traditional machining combined concept
In the prior art, two thin-wall bowl-shaped soft magnetic material parts are directly formed by adopting bar stock, when the inner spherical surface and the outer spherical surface are turned, firstly, the solid bar stock is required to be processed into a plurality of steps, then, the allowance is gradually removed, and finally, the part with the wall thickness of only 1mm is processed. The turning sphere is initially cut intermittently, the tool tip load and cutting force are large, the machining allowance is large, the number of times of feeding is large, and the machinability of the soft magnetic alloy 1J50 is poor, so that only low-rotation-speed and low-feed machining can be adopted, and the efficiency is extremely low.
The present invention combines the die forging formation with conventional machining. The die forging is a technological method for obtaining the forging by pressing and deforming the blank in a die cavity of a forging die and filling the die cavity. The die forging forming blank has smaller cutting allowance, high production efficiency and 177 percent improvement of material utilization rate. From the set of processing flow, the die forging technology is adopted for forming processing, so that the rough processing procedure of conventional machining of bars is omitted, and the processing period is shortened by 30%. Saving a great deal of cutters, manpower and equipment loss and the energy consumption cost of water, oil and the like in the processing process.
2. Analysis of heat treatment Process
From the microstructure analysis, since the soft magnetic alloy 1J50 is mainly composed of a twin austenite structure, the twin boundaries therein are the main cause of the poor plasticity thereof. To achieve plastic working of a metal having a microstructure such as soft magnetic alloy 1J50, it is necessary to change its microstructure by complete annealing to improve plastic formability. Thus, after forging of the blank is completed, the forging stress is firstly eliminated by arranging complete annealing, the structure is homogenized, grains are refined, the cutting performance is improved, and then machining is arranged. The magnetic steel cover part is subjected to stress relief annealing after rough machining due to the fact that the rough machining process is more in removing allowance and poor in structural rigidity, and machining stress is eliminated. After the magnetic steel component is processed, recrystallization annealing is needed to stabilize the magnetic performance and reach the magnetic performance required by the technology.
3. Structural process analysis
The two parts are thin-wall parts, the inner and outer spherical wall thickness is only 1mm, the four ribs on the bottom surface are cantilever beams, the structural rigidity is poor, and the processing is extremely easy to deform. Before the two parts are cut into four rib plates on line according to the assembly relation and the use condition by combining the assembly relation of the magnetic steel cover and the magnetic steel seat, the two parts are combined by using screws according to the assembly relation, and the structural stability of the thin-wall bowl-shaped part is improved, so that the machining precision and the machining surface quality of the part are improved.
4. Deformation control measures in machining
1) And after the blank is formed, the forging stress is firstly eliminated through complete annealing, the microstructure of the magnetic steel cover part is changed, the plastic forming performance is improved, the stress generated by most of machining allowance is removed in the rough machining process through stress relief annealing after rough machining, and finally, recrystallization degradation is carried out after finishing, so that the structure is homogenized, the magnetic performance is stabilized, and meanwhile, the stress of the part is relieved. Compared with a magnetic steel cover, the magnetic steel seat has relatively stable structure, slightly better processing performance and less removal amount of inner cavity materials, so that heat treatment is not arranged after rough machining.
2) In the aspect of cutting tool selection, aiming at the difficult processing characteristics of soft magnetic materials and the structural characteristics of the inner cavity of the magnetic steel cover, when the spherical surface and the grooving of the inner cavity of the magnetic steel cover part are processed, the steel cutter bar with an inner cooling passage is selected as the cutter bar, and the cooling effect in the cutting process is better. The cutter bar with larger diameter and larger blade thickness is selected, so that the rigidity of the processing system is improved, and the processing vibration is reduced. Longer cutting edge length, avoiding the occurrence of interference phenomenon of the striking knife and the orifice. The cutting force is reduced by selecting a larger front angle, and the cutting slot is lighter and faster. And the larger tool nose is arc, the smaller relief angle and the strength of the tool nose and the cutting edge are improved. The blade coating is made of a Ti-Al-Si-N nano plating layer made of ultrafine particle materials with very high hardness, so that the wear resistance is good, the durability of the cutter is improved, and the durability of the cutter is improved.
3) The clamping mode is reasonably selected, the magnetic steel cover part is clamped and positioned through a reserved process table in the finish machining process, the change after compaction generally cannot exceed 0.05mm, and the deformation is controlled to be minimum. The magnetic steel seat part reduces clamping deformation through reserving a process table and a clamp, and controls machining precision and stability of machining quality.
(4) The reasonable processing method has the advantages that the magnetic steel cover and the magnetic steel seat part are of thin-wall bowl-shaped structures, the inner and outer spherical wall thickness is only 1mm, the four ribs on the bottom are cantilever beams, the structural rigidity is poor, and the processing is extremely easy to deform. Before the cantilever beam is cut on line, the parts are combined to form a magnetic steel assembly, the whole assembly is cut on line, the stability of a processing structure is improved, and the processing deformation of the parts is controlled.
According to the invention, various factors influencing the processing deformation of the weak-rigidity special-shaped magnetic steel magnetic component are comprehensively considered from the two aspects of structure and process, and corresponding measures are taken, so that the processing quality and the stability of the processing quality of the weak-rigidity special-shaped magnetic steel magnetic component are effectively improved.
The foregoing examples are merely illustrative of the present invention and are not intended to limit the scope of the present invention, and all designs that are the same or similar to the present invention are within the scope of the present invention.
Claims (9)
1. A method for improving the machining quality of thin-wall bowl-shaped soft magnetic material parts is characterized by comprising the following steps of: the method comprises the following steps:
step 1) die forging blank forming: blanking, heating, extruding and forging to form two parts, namely a bowl-shaped assembly I and a bowl-shaped assembly II, respectively;
Step 2) heat treatment: annealing the bowl-shaped assembly I and the bowl-shaped assembly II;
step 3) rough and finish machining is carried out on the bowl-shaped assembly I;
step 4) rough machining and finish machining are carried out on the bowl-shaped assembly II;
step 5) combined processing: combining the first bowl-shaped assembly and the second bowl-shaped assembly after rough machining and finish machining;
step 6) bench workers;
Step 7) recrystallization annealing heat treatment.
2. A method for improving the processing quality of thin-walled bowl-shaped soft magnetic material parts according to claim 1, characterized by: the forging heating temperature in the step 1) is 950-1150 ℃, and the forging extrusion force is 450-500 tons.
3. A method for improving the processing quality of thin-walled bowl-shaped soft magnetic material parts according to claim 1, characterized by: in the step 2), the annealing temperature is 950-980 ℃, the annealing temperature is heated to be less than or equal to 600 ℃/h, the heat preservation time is 2-3h, and the cooling mode adopts the cooling mode of 150 ℃/h to be less than or equal to 600 ℃ and then the furnace is taken out for air cooling.
4. A method for improving the processing quality of thin-walled bowl-shaped soft magnetic material parts according to claim 1, characterized by: step 3) the specific process of rough and finish machining the bowl-shaped assembly one is as follows:
(1) Turning a step circle, turning an end face, cutting a groove and turning an inner spherical surface;
(2) Turning an end face, an outer circle and an outer sphere, and reserving a process table as a precision machining process reference;
(3) And (3) heat treatment: the annealing temperature is 900-950 ℃, the heating is carried out at the speed of less than or equal to 300 ℃/h to the annealing temperature, the heat preservation time is 2-3h, the vacuum degree P is less than or equal to 1 multiplied by 10 < -1 > Pa, the cooling mode is 100-150 ℃/h to the speed of less than or equal to 600 ℃, and the furnace is cooled to the temperature of less than or equal to 200 ℃ and is taken out of the furnace for air cooling;
(4) Turning an end face, finely boring, and finely turning an inner spherical surface to reach the required precision;
(5) Turning a process table, namely cutting the end face by a small number of cutters, removing the process table, and ensuring the flatness to be 0.05;
(6) And (5) drilling a threaded bottom hole and making threads.
5. A method for improving the processing quality of thin-walled bowl-shaped soft magnetic material parts according to claim 1, characterized by: step 4) rough machining and finish machining are carried out on the bowl-shaped assembly II, and the specific process is as follows:
(1) Turning end surfaces and excircles of two ends, and roughly boring an inner hole;
(2) Positioning and clamping the excircle of the small end of the upper channel, turning a large end surface, roughly and finely turning an annular groove, turning the spherical surface of the inner cavity, finely boring a hole, finely turning the excircle, and taking the excircle as a positioning reference of the lower channel clamping;
(3) Positioning the excircle of the upper path, roughly and finely turning the outer spherical surface, the small end surface and the excircle;
(4) Milling four-side gaps, milling four steps in an inner cavity, and drilling holes;
(5) Turning a process table, namely cutting the end face by a small number of cutters, and removing the process table;
(6) Clamping the bowl-shaped assembly II by using a clamp and a compression nut, and turning a small end face, an annular groove and a boring hole;
(7) Deburring and threading.
6. A method for improving the processing quality of thin-walled bowl-shaped soft magnetic material parts according to claim 1, characterized by: the specific process of the combined processing of the step 5) is as follows:
(1) Combining the bowl-shaped assembly I and the bowl-shaped assembly II into a component without installing a screw;
(2) Numbering the bowl-shaped assembly I and the bowl-shaped assembly II;
(3) Combining the bowl-shaped assembly I and the bowl-shaped assembly II together by using screws to form a new assembly;
(4) And (3) carrying out wire cutting on the assembly according to the requirement, wherein the wire running times are not less than 2 times, and the flatness of the bottom surface after the machining is finished is less than 0.1.
7. A method for improving the processing quality of thin-walled bowl-shaped soft magnetic material parts according to claim 6, wherein: the specific process of the bench worker in step 6) is as follows:
(1) Removing the screw;
(2) Chamfering the edges of the first bowl-shaped assembly and the second bowl-shaped assembly by 0.3;
(3) Cleaning parts, and blow-drying and circulation;
(4) And recombining the bowl-shaped assembly I and the bowl-shaped assembly II according to the serial numbers-corresponding pairs, and circulating in pairs.
8. A method for improving the processing quality of thin-walled bowl-shaped soft magnetic material parts according to claim 1, characterized by: the annealing temperature of the recrystallization annealing heat treatment in the step 7) is 1140-1180 ℃, the heat preservation time is 3-5h, the vacuum degree P is less than or equal to 5 multiplied by 10 < -2 > Pa, and the cooling mode adopts air cooling after cooling to the temperature of less than or equal to 600 ℃ at 100-150 ℃ per hour.
9. A method for improving the tooling quality of thin-walled bowl-shaped soft magnetic material parts according to claim 4, wherein: (1) When in middle grooving, the grooving cutter bar is a steel cutter bar with an internal cooling passage, the diameter of the steel cutter bar is phi 22-phi 25, the thickness of a cutter blade is 4-5mm, the length of a cutting edge is 14-16mm, the front angle of the cutting edge is 8-10 degrees, and the arc of a cutter point is R0.2-R0.3;
When the inner spherical surface is finely turned in the step (4), the cutter bar is a steel cutter bar with an inner cooling passage, the principal deflection angle is 106-107.5 degrees, the length of the cutting edge of the cutter blade is 15-16mm, the circular arc of the cutter point is R0.4-R0.5, the front angle of the cutter blade is 0 degrees, the rear angle is 4-5 degrees, and the cutter blade is provided with a Ti-Al-Si-N nano plating layer.
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