CN214024613U - System for controlling bottom surface processing flatness of large metal box type workpiece - Google Patents
System for controlling bottom surface processing flatness of large metal box type workpiece Download PDFInfo
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- CN214024613U CN214024613U CN202022746945.1U CN202022746945U CN214024613U CN 214024613 U CN214024613 U CN 214024613U CN 202022746945 U CN202022746945 U CN 202022746945U CN 214024613 U CN214024613 U CN 214024613U
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Abstract
A system for controlling the bottom surface processing planeness of a large-scale metal box type workpiece is used for accurately controlling the bottom surface planeness of the large-scale metal box type workpiece, and relates to the technical field of machining of mechanical workpieces, in particular to the technical field of accurately controlling the planeness of the bottom surface of the large-scale metal box type workpiece, and the system comprises a workpiece with a crankshaft seat hole coaxiality to be installed, a first supporting piece, a second supporting piece, a third supporting piece and a fourth supporting piece, wherein four supporting point positions are established by taking the space vector direction of the workpiece supporting surface as a reference, the four supporting point positions are respectively a first fulcrum, a second fulcrum, a third fulcrum and a fourth fulcrum, the first fulcrum and the second fulcrum are arranged on any side b1 of the workpiece supporting surface, and the third fulcrum and the fourth fulcrum are arranged on a side b2 corresponding to the side b 1; the problem of four pivots on the work piece uneven atress take place to warp is solved.
Description
Technical Field
The utility model provides a system for controlling large-scale metal box formula work piece bottom surface machining plane degree, is applicable to large-scale box formula, the inside work piece that need install very high accurate bent axle seat hole axiality, belongs to work piece processing technology field, concretely relates to system for controlling large-scale metal box formula work piece bottom surface machining plane degree.
Background
Referring to a drawing of a crankcase part, tolerance requirements such as bottom surface flatness, crankshaft seat hole coaxiality and parallelism between the bottom surface flatness and the crankshaft seat hole are generally marked, and space form and position errors between the bottom surface and the crankshaft seat hole are specified.
In the detection process of the part, the crankshaft seat hole coordinate is referred, the position of the fulcrum is adjusted, the processing state can be mostly restored, data show that the flatness of the bottom surface and the coaxiality of the seat hole are both qualified, but in the assembly state, the position relation between the bottom surface assembled on the base and the crankshaft seat hole may present another situation, the flatness of the bottom surface is qualified, and the coaxiality of the crankshaft seat hole is poor.
Based on the traditional thinking, the bottom surface only plays a role in connection and fixation, and the crankshaft seat hole is assembled with a crankshaft transmission component, the requirement on the bottom surface is usually much lower than that of the crankshaft seat hole, for example, the coaxiality of the crankshaft seat hole is 0.03mm, the planeness of the bottom surface is 0.10mm, the influence of the planeness of the bottom surface on the coaxiality of the crankshaft seat hole is seriously ignored, according to the marking, if the planeness of the base of the connection box body is ideal, the coaxiality of the assembled crankshaft seat hole can be 0.23mm under the extreme condition, which is obviously not allowed, in fact, the planeness of the bottom surface marked by a drawing has no significance on processing, even if the bottom surface meeting the requirement of the drawing is processed, the bottom surface is a secondary waste product in an assembly link, and the processing of the bottom surface only follows a more severe standard.
For the object with two supporting points, referring to Bessel point theory, when the two supporting points are located at 2/9 positions away from two ends respectively and at equal distances, the bending deformation of the object is minimum; for an object with three supporting points, as long as the gravity center of the object is positioned in a triangle formed by the three supporting points, the object is always in a stable moment balance state, and ideally, the gravity center of the object is superposed with the gravity center of the triangle formed by the three supporting points; the object with four supporting points is stressed only at the three supporting points of a triangle formed by the three supporting points where the gravity center of the object is positioned, and the other supporting point is not stressed; if the object is not deformed, the object is stressed by only three of the fulcrums, the three fulcrums are all in a physical non-concurrent force moment balance state, the gravity center of the object and the positions of the fulcrums are determined, a moment equation can be listed, and the stress magnitude of each fulcrum is theoretically solved.
For the processing of the bottom surface, two and three fulcrums are ideal schemes, however, based on the influence of factors such as workpiece material and structural mechanical property, clamping and pressing, cutting stress and the like, the practical situation of mechanical processing is that four or more fulcrums become necessary, all the fulcrums are stressed and cannot be quantized, so that the false impression of stress is caused, the workpiece is twisted and bent, and the theory and the reality have contradiction.
SUMMERY OF THE UTILITY MODEL
Based on above problem, the utility model provides a system for controlling large-scale metal box formula work piece bottom surface machining flatness has solved four fulcrum atresss on the work piece uneven and takes place the problem of warping.
For solving the above technical problem, the utility model discloses a technical scheme as follows:
the system for controlling the machining flatness of the bottom surface of the large-size metal box type workpiece comprises a workpiece with a crank seat hole to be installed, a first supporting piece, a second supporting piece, a third supporting piece and a fourth supporting piece, wherein four supporting point positions are respectively a first supporting point, a second supporting point, a third supporting point and a fourth supporting point which are established by taking the space vector direction of the workpiece supporting surface as a reference, the first supporting piece and the second supporting point are arranged on any one side b1 of the workpiece supporting surface, the third supporting point and the fourth supporting point are arranged on a side b2 corresponding to the side b1, the first supporting piece supports the first supporting point, the second supporting piece supports the second supporting point, the third supporting piece and the fourth supporting piece form an integrated equal-arm lever which respectively supports the third supporting point and the fourth supporting point, and the supporting points of the equal-arm lever and the first supporting point and the second supporting point form an isosceles triangle.
Further, the third fulcrum and the fourth fulcrum are arc fulcrums.
Preferably, the third support member and the fourth support member are height-adjustable support members, the first fulcrum and the second fulcrum are disposed on the side b1 of the upper plane of the workpiece, the third fulcrum and the fourth fulcrum are disposed on the side b2 corresponding to the side b1, the third fulcrum and the fourth fulcrum are located on the bessel point of the side b2 for reducing the torsional deformation, the first support member supports the first fulcrum, the second support member supports the second fulcrum, the third support member supports the third fulcrum, and the fourth support member supports the fourth fulcrum.
Further, still include fifth support piece, percentage table, magnetic gauge stand and lathe, the lathe Z axle is arranged in to the magnetic gauge stand, the percentage table is connected on the magnetic gauge stand, fifth support piece is altitude mixture control formula support piece.
Compared with the prior art, the beneficial effects of the utility model are that:
1. the utility model discloses but wide application in the processing of large-scale box formula work piece, like the processing of natural gas compressor crankcase, high horsepower diesel engine crankcase, high-power diesel engine crankcase and other large-scale crankcase for the oil and gas exploration and development well drilling. The utility model discloses successfully being applied to the processing that this company's appearance machining dimension reached 5x1.3x1.04 meters, heavily reaches the crankcase of 9 tons many times, adorns the bent axle that reaches 5 meters, heavily reaches 3 tons for a long time. The verification proves that the crankshaft box body processing flatness improving device has obvious effects on improving the crankshaft box body processing flatness and guaranteeing the concentricity of the crankshaft holes.
2. In the prior art, if the flatness problem of the casting blank body can not be found before processing, after the processing is completed, because of the elasticity of the workpiece metal material, the processed two surfaces can be bent, the crankshaft bush hole can return to the non-concentricity of the original casting, and the probability of the occurrence of the condition of the large-scale crankshaft box body is larger.
3. If the workpiece is directly used without detection after machining, the crankshaft and the bearing bush pivot of the crankcase are seriously abraded and even burnt and the like because the crankshaft box body machining plane and the crankshaft hole concentricity have deflection. Even if the detection is carried out after the processing is finished, the concentricity of the crankshaft hole is qualified, and the concentricity of the crankshaft hole is not ideal after the assembly due to the flatness problem of the crankcase body, so that faults such as the bush burning of the crankshaft often occur in the field operation.
4. The technology can well solve the problems of the processing planeness of the upper surface and the lower surface of the large-sized crankcase body and the coaxiality of the crankshaft hole. The Bessel supporting point principle is met through the first fulcrum, the second fulcrum, the third fulcrum and the fourth fulcrum respectively, stress of all points is the same, a stable balance state is formed, torsion and bending deformation of a workpiece are minimized as far as possible, and the problem that deformation occurs due to uneven stress of the four fulcrums on the workpiece is solved. According to the utility model discloses carry out two planar processing about the large-scale box formula work piece, can realize the accurate cooperation in box and bent axle hole, reach bent axle hole concentricity standard requirement.
5. In terms of a machined part body, the value of a large crankcase body which is detected and machined by the technology is 38-110 ten thousand yuan, the value of a large crankshaft is 32-95 ten thousand yuan, in addition, the crankcase body is mainly used for pressurizing and conveying natural gas, if the crankshaft is shut down due to tile burning, parts such as crankshafts, the crankcase body and bearing bushes of the same type are replaced, the construction period such as machining, transportation and installation is required to be at least more than half a month, and the daily gas transmission amount of one compressor unit reaches 100-200 ten thousand m3Every day of production stoppage, the economic loss of 100-200 ten thousand yuan is caused, and meanwhile, the adverse effect on national energy safety is possibly caused. Therefore, the technology createsThe direct and indirect economic benefits and social benefits are very obvious, and the method has unexpected technical effects.
Drawings
FIG. 1 is a schematic view of force analysis in example 1;
FIG. 2 is a schematic structural view of example 2;
fig. 3 is a schematic structural diagram of another working state of the present embodiment 2;
FIG. 4 is a structural diagram of another operating state in embodiment 2;
FIG. 5 is a schematic view of force analysis in example 2.
The workpiece comprises a workpiece 1, a first support 2, a second support 3, a third support 4, a fourth support 5 and a fifth support 6.
Detailed Description
The present invention will be further described with reference to the accompanying drawings. Embodiments of the present invention include, but are not limited to, the following examples.
Example 1
As shown in fig. 1, a system for controlling the machining flatness of the bottom surface of a large-sized metal box type workpiece includes a workpiece 1 with a crank seat hole to be installed, a first supporting member 2, a second supporting member 3, a third supporting member 4 and a fourth supporting member 5, wherein four supporting point positions are respectively a first fulcrum, a second fulcrum, a third fulcrum and a fourth fulcrum with the space vector direction of the supporting surface of the workpiece 1 as a reference, wherein the third fulcrum and the fourth fulcrum are arc fulcrums and are used for reducing friction between the workpiece 1 and the third supporting member 4 and the fourth supporting member 5; the first fulcrum and the second fulcrum are arranged on any one side b1 of the supporting surface of the workpiece 1, the third fulcrum and the fourth fulcrum are arranged on a side b2 corresponding to the side b1, the first supporting piece 2 supports the first fulcrum, the second supporting piece 3 supports the second fulcrum, the third supporting piece 4 and the fourth supporting piece 5 form an integrated equal-arm lever which supports the third fulcrum and the fourth fulcrum respectively, and the fulcrums of the equal-arm lever, the first fulcrum and the second fulcrum form an isosceles triangle.
The working principle is as follows: the equilibrium principle analysis of the equiarm lever is carried out as follows:
1. based on the principle of the equal-arm lever, the two moments acting on the equal-arm lever are equal in magnitude and distance from the fulcrum of the equal-arm lever to the forces F3 and F4, namely
F3×L3＝F4×L4 (1)
L3＝L4 (2)
Wherein F3 is the supporting force of the third supporting member 4, L3 is the moment arm of the third supporting member 4, F4 is the supporting force of the fourth supporting member 5, L4 is the moment arm of the fourth supporting member 5, which can be obtained from formula (1) and formula (2), and F3 is F4;
then, the action force is the reaction force: f0 ═ F3+ F4 (3);
2. f4, F1, and F2 form an isosceles triangle, and since the moment arms L1 and L2 of F1 and F2 are equal, i.e., L3 is equal to L4, F1 is equal to F2(4), which can be obtained from formula (3) and formula (4) and from the principle of statics:
G＝F0+F1+F2 (5)；
wherein G is gravity, F1 is the supporting force of the first supporting member 2, L1 is the moment arm of the first supporting member 2, F2 is the supporting force of the second supporting member 3, and L2 is the moment arm of the second supporting member 3;
3. the center of first fulcrum and second fulcrum is got apart from, according to moment balance principle, then has:
F0×a＝G×(a/2) (6)
wherein a is the upper and side b of the workpiece 11The length of the adjacent edge is obtained by substituting equation (5) into equation (6):
F0×a＝(F0+F1+F2)×(a/2) (7)
this is simplified by equation (7): f0 ═ F1+ F2 (8);
4. from formula (3) and formula (8), F3+ F4 ═ F1+ F2, and since F3 ═ F4 and F1 ═ F2, F1 ═ F2 ═ F3 ═ F4 can be obtained.
Based on the derivation process, it can be known that the equal-arm lever is equivalent to a balance device, the degree of freedom of the workpiece 1 in the gravity direction is always maintained, an isosceles triangle formed by the fulcrum of the equal-arm lever and the first fulcrum and the second fulcrum forms a stable moment balance state, the first fulcrum, the second fulcrum, the third fulcrum and the fourth fulcrum meet the Bessel point principle, the stress is consistent, the torsion and bending deformation of the workpiece 1 are minimum, and the problem that the four fulcrums on the workpiece 1 deform due to uneven stress is solved.
The gas storage project compressor unit experiment was performed based on the above example 1, and the following table was obtained:
the detection data show that the coaxiality of the assembled crankshaft seat hole is changed due to the flatness problem of the bottom surface in the machining process, the crankshaft is locked in the rotation process, severe plastic deformation is caused, unit faults are caused, single direct economic loss is large, and similar faults can be avoided if the strictest standard is executed.
The machining accuracy was verified based on example 1 above:
optionally extracting 5 CFC boxes (size of 2195mm × 792mm × 762 mm/mass of 2000kg), and comparing the conventional processing method with the processing scheme
For example 1 protocol repeatability verification:
Bottom surface flatness data were arbitrarily extracted from 1 6CFB boxes (size 4239 mm. times.1300 mm. times.1045 mm/mass 10000kg) processed 1 time by the conventional processing method and 3 times by example 1:
by using the traditional processing method, the processing precision and the repeatability are not guaranteed, in the embodiment 1, the bottom surface flatness and the processing defective index caused by the bottom surface flatness problem are reduced to 0% from 90%, and the achievement is remarkable.
Example 2
As shown in fig. 4, the third supporting member 4 and the fourth supporting member 5 are height-adjustable supporting members, the first fulcrum and the second fulcrum are disposed on the upper plane side b1 of the workpiece 1, the third fulcrum and the fourth fulcrum are disposed on the side b2 corresponding to the side b1, the third fulcrum and the fourth fulcrum are located at the bessel point where the side b2 reduces the torsional deformation, the first supporting member 2 supports the first fulcrum, the second supporting member 3 supports the second fulcrum, the third supporting member 4 supports the third fulcrum, and the fourth supporting member 5 supports the fourth fulcrum.
In this embodiment, the magnetic force gauge further comprises a fifth supporting member 6, a dial indicator, a magnetic gauge seat and a machine tool, the magnetic gauge seat is arranged on the Z axis of the machine tool, the dial indicator is connected to the magnetic gauge seat, the fifth supporting member 6 is a height-adjustable supporting member, and the method for determining the bezier point of the side b2 for reducing the torsional deformation comprises the following steps:
S1, as shown in fig. 2, the bottom surface of the workpiece 1 in the turned state is roughly milled, the first supporting member 2 supports the first fulcrum, the second supporting member 3 supports the second fulcrum, and the third supporting member 4 and the fourth supporting member 5 are placed on the side b 2;
s1, as shown in fig. 3, placing the fifth support member 6 at the geometric center position on the side b2 until the third support member 4 and the fourth support member 5 on the side b2 are not in contact with the workpiece 1;
s2, moving the machine tool to a designated position S1 on the bottom surface of the workpiece 1 corresponding to the tail end of any one end of the side b2, enabling the dial indicator to contact the workpiece 1 until the reading is zero, moving the machine tool to a designated position S2 on the bottom surface of the workpiece 1 corresponding to the tail end of the other end of the side b2, and recording the reading difference m of the two position dial indicators;
s3, adjusting the height of the third support 4 to make the third support 4 contact with the workpiece 1, adjusting the height of the fourth support 5 to make the fourth support 5 contact with the workpiece 1, and removing the fifth support 6;
s4, as shown in fig. 4, the positions of the third supporting member 4 and the fourth supporting member 5 are adjusted on the side b2 until the difference between the dial indicator readings of the designated position S1 of the bottom surface of the workpiece 1 and the designated position S2 of the bottom surface of the workpiece 1 is recovered to m, at this time, the position of the third supporting member 4 is the bessel point of the third supporting point, and the position of the fourth supporting member 5 is the bessel point of the fourth supporting point.
The working principle is as follows: as shown in fig. 5, a workpiece 1 with a weight M is placed on a quadrilateral formed by forces F1, F2, F3 and F4, the centroid of the quadrilateral is O, the barycentric coordinates of the workpiece 1 are (x, y), and the following formula of moment balance is:
[(F1+F2)-(F3+F4)]×(a/2)-yM＝0 (1)
[(F2+F4)-(F1+F3)]×(b/2)-xM＝0 (2)
F1+F2+F3+F4-M＝0 (3)
wherein F1 is the supporting force of the first supporting member 2, F2 is the supporting force of the second supporting member 3, F3 is the supporting force of the third supporting member 4, F4 is the supporting force of the fourth supporting member 5, a is the supporting force of the upper and side b of the workpiece 11The length of one adjacent edge, b the distance from the third supporting part 4 to the fourth supporting part 5, is obtained by solving the following formulas (1), (2) and (3):
F4＝G/2-F3-yG/a (4)
F2＝F3+yG/a+xG/b (5)
F1＝G/2-F3-xG/a (6)
the centroid of the workpiece 1 coincides with the centroid of the quadrangle formed by the first fulcrum, the second fulcrum, the third fulcrum and the fourth fulcrum, that is, x is 0 and y is 0, and the centroid is obtained by substituting equations (4), (5) and (6):
F1＝F2＝F3＝F4
based on the derivation process, it can be known that, when the workpiece 1 is machined conventionally, the clamping pressure plate is released, and the finish milling bottom surface in a free state is deformed as shown in fig. 3 if high supports such as the first support, the second support, the third support and the fourth support are adopted, so that the torsional deformation of the workpiece 1 needs to be reduced by the third support 4 and the fourth support 5 of the height-adjustable supports, and the bessel point is found.
Based on the above example 2, the following table was obtained for the gas storage project compressor unit experiment:
the detection data show that the coaxiality of the assembled crankshaft seat hole is changed due to the flatness problem of the bottom surface in the machining process, the crankshaft is locked in the rotation process, severe plastic deformation is caused, unit faults are caused, single direct economic loss is large, and similar faults can be avoided if the strictest standard is executed.
The machining accuracy was verified based on the above example 2:
optionally extracting 5 CFC boxes (size of 2195mm × 792mm × 762 mm/mass of 2000kg), and comparing the conventional processing method with the processing scheme
For example 2 protocol repeatability verification:
bottom surface flatness data were arbitrarily extracted from 1 6CFB boxes (size 4239 mm. times.1300 mm. times.1045 mm/mass 10000kg) processed 1 time by the conventional processing method and 3 times by example 1:
by using the traditional processing method, the processing precision and the repeatability are not guaranteed, in the embodiment 2, the bottom surface flatness and the processing defective index caused by the bottom surface flatness problem are reduced to 0% from 90%, and the achievement is remarkable.
The embodiment of the present invention is the above. The above embodiments and the specific parameters in the embodiments are only for the purpose of clearly expressing the verification process of the utility model, and are not used to limit the patent protection scope of the present invention, the patent protection scope of the present invention is still subject to the claims, all the structural changes equivalent to the contents of the description and the drawings of the present invention should be included in the protection scope of the present invention.
Claims (4)
1. A system for controlling the bottom surface processing flatness of a large metal box type workpiece comprises a workpiece (1) with a crankshaft seat hole to be installed, wherein a first supporting piece (2) and a second supporting piece are arranged on the workpiece (1)(3) Third support piece (4) and fourth support piece (5), its characterized in that: taking the space vector direction of the supporting surface of the workpiece (1) as a reference, constructing four supporting point positions which are respectively a first supporting point, a second supporting point, a third supporting point and a fourth supporting point, wherein the first supporting point and the second supporting point are arranged on any one side b of the supporting surface of the workpiece (1)1The third fulcrum and the fourth fulcrum are arranged on the edge b1Corresponding edge b2The first supporting piece (2) supports a first fulcrum, the second supporting piece (3) supports a second fulcrum, the third supporting piece (4) and the fourth supporting piece (5) form an integrated equal-arm lever to support a third fulcrum and a fourth fulcrum respectively, and the fulcrums of the equal-arm lever, the first fulcrum and the second fulcrum form an isosceles triangle.
2. The system for controlling the bottom processing flatness of the large-sized metal box type workpiece according to claim 1, is characterized in that: the third fulcrum and the fourth fulcrum are arc fulcrums.
3. The system for controlling the bottom processing flatness of the large-sized metal box type workpiece according to claim 1, is characterized in that: the third supporting piece (4) and the fourth supporting piece (5) are height-adjusting type supporting pieces, and the first fulcrum and the second fulcrum are arranged on the upper plane side b of the workpiece (1) 1The third fulcrum and the fourth fulcrum are arranged on the edge b1Corresponding edge b2Above, the third fulcrum and the fourth fulcrum are located at side b2At the Bessel point for reducing the torsional deformation, the first support (2) supports a first fulcrum, the second support (3) supports a second fulcrum, the third support (4) supports a third fulcrum, and the fourth support (5) supports a fourth fulcrum.
4. The system for controlling the bottom processing flatness of the large-sized metal box type workpiece according to claim 1, is characterized in that: still be provided with fifth support piece (6), percentage table, magnetometer stand on the holding surface of work piece (1), the magnetometer stand is arranged in on the lathe Z axle, and the percentage table is connected on the magnetometer stand, and fifth support piece (6) are altitude mixture control formula support piece.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN112453960A (en) * | 2020-11-24 | 2021-03-09 | 中国石油天然气集团有限公司 | Method for controlling machining flatness of bottom surface of large metal box type workpiece |
| CN112453960B (en) * | 2020-11-24 | 2024-04-30 | 中国石油天然气集团有限公司 | Method for controlling bottom surface machining flatness of large metal box type workpiece |
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