RU2097163C1 - Spring production method - Google Patents

Abstract

FIELD: plastic metal working. SUBSTANCE: method comprises steps of selecting several fixed positions of one tool for forming diameter and pitch of spring and winding series of calibrating springs at different positions of other tool; determining relation of diameter and pitch of spring from location of each tool; dividing spring set according to drawing by parts with linearly changing diameter and constant pitch; according to received relation determining dependance between coordinates of both tools for initial and final points of each selected turn; according to common values of last dependances determining coordinates of tools in said points; at winding process moving tools from points with initial coordinate to points with final coordinate according to linear relations. EFFECT: enhanced efficiency. 3 cl, 10 dwg

Description

 The invention relates to the processing of metals by pressure, and in particular to methods of manufacturing springs by cold winding them on spring-coiling automatic machines with CNC, and can be used in mechanical engineering.

 Currently, when winding springs on modern models of domestic spring-loaded automatic machines in CNC, a method of manufacturing a spring is used, in which its shape specified by the drawing is divided into sections with a linearly varying diameter and constant step, the sweep length of the coil of spring is determined at each selected site, step the initial and final diameters of each selected coil, determine the coordinates of the spatial position of the tools to form the diameter and pitch of the spring at each point of its development, respectively With the diameter and pitch set in it, test winding of the spring is carried out by sequentially feeding the wire billet into the working area of the forming tools for the scan length of each selected section, during which the tools are moved to points with coordinates corresponding to the current values of the scan coordinates of the spring coil formed from the workpiece, measure the parameters of the resulting spring, and then adjust the coordinates of the forming tools and re-wind the spring (Automatic A cold coiling of wire ⌀ 0,4-2,2 mm CNC machine model A 513 F / 3. Operation manual, part III, Azov, 1989).

 For the prototype, a method of manufacturing a spring was selected, in which its shape, given by the drawing, is divided into sections with a linearly varying diameter and a constant pitch, the scan length of the coil of the spring in each selected section, the step, the initial and final diameters of each selected coil, based on the diameter and the workpiece material and the characteristics of the tools for forming the diameter and pitch of the spring, expressed in the form of functional dependences predetermined empirically or by calculation, according to the theory of plastic deformation the coordinates of the spatial position of the forming tools for each development point are set according to the diameter and spring pitch set in it and the spring is wound by sequentially feeding the wire billet into the working area of the forming tools by the scan length of each selected section, during which the tools are moved to points with coordinates corresponding to current values of the coordinates of the sweep formed from the workpiece coil spring (Navrotsky G.A. Oh. M. Engineering, 1978, p. 51-82).

 For the implementation of the method described above, workpieces of high-quality material with stable properties are required, which, firstly, significantly increases the cost of production of springs, and, secondly, requires the expansion of imports of high-quality wire, as produced in domestic wire does not meet the requirements for technical the conditions of the known method, namely, the accuracy of the wire.

 The aim of the invention is to improve the accuracy and performance of a method of manufacturing a spring.

 In FIG. 1 shows a spring; in FIG. 2, section AA in FIG. one; in FIG. 3 dependence of the diameter; in FIG. 4 the dependence of the spring pitch on the coordinates of the spatial position of the forming tools; in FIG. 5 projections of dependencies between the coordinates of the forming tools on the plane of the general coordinate system; in FIG. 6 and 7, the dependences of the coordinates of the forming tools necessary for the formation of the specified values of the diameter and pitch of the spring, from the twist angle of its coil; in FIG. 8 and 9 are graphs of the movement of the tools for forming the diameter and pitch, corresponding to the dependences of their coordinates on the length of the spring sweep (workpiece feed amount); in FIG. 10 graphs of the movement of tools for forming the diameter and pitch, calculated for an example of a specific implementation of the proposed method.

 A method of manufacturing a spring is as follows.

 Selecting a coil of wire of a given diameter, in which the wire has stable physical properties, wind a series of calibration springs, during which several fixed positions of one of the forming tools, for example, a tool for forming the diameter of the spring, are selected, and springs with different pitch are wound in each of them, covering the entire range of given values of this parameter. After winding, the parameters of the turns obtained with each new combination of spatial positions of the forming tools are measured. By processing the obtained data, the dependence of the diameter D (in Fig. 3, the dependence is interpreted as the surface Q) and the dependence of the pitch H (in Fig. 4, the surface R) on the coordinate Z of the spatial position of the tool to form the diameter of the spring and the coordinate Y of the spatial position of the tool to form her step.

The predetermined shape of the spring (Fig. 1) is divided into sections with a linearly varying diameter and constant pitch, in this example, into turns with a twist angle of the helix in the plan equal to 2π. At the starting and ending points of each selected turn, set values of diameter and pitch are determined. Substituting the value of the diameter D _i specified in the ith point under consideration (in Fig. 3, the value of D _{i is} interpreted by a plane parallel to the coordinate axes Z and Y) into the relations characterizing the dependence of the spring diameter on the location of the forming tools, one of the relationships between the Z coordinate is determined the spatial position of the tool to form the diameter of the spring and the coordinate Y of the spatial position of the tool to form its pitch (in Fig. 3 - curve 1 formed by the intersection line along erhnosti Q plane D _i). Substituting the value of the step H _i set at the same i-th point (in Fig. 4, the plane H _i parallel to the Y and Z axes) into the relations characterizing the dependence of the spring diameter on the location of the forming tools, determine the second dependence between the coordinates of the spatial position of the tools YZ (in Fig. 4, curve 2 formed by the line of intersection of the surface R by the plane H _i ).

From the obtained relations describing the relationships between the coordinates of the spatial position of the forming tools, determine the specific values of these parameters at the i-th point. In FIG. 5, these parameters are determined by the coordinates Z _i and Y _{i of the} point S of the intersection of the projections 3 and 4 of curves 1 and 2 on the common plane YO Z.

Having thus determined the coordinates Z _1i and Y _1i for the starting point of a selected i-th coil of the spring, the coordinates Z _2i and Y _{2i are} determined for the end point of this coil. Then, in random order, the coordinates Z _1i-1 and Y _1i-1 for the starting point and the coordinates Z _2i-1 and Y _2i-1 for the end point of the previous turn i-1, as well as the coordinates Z _{1i + 1} and Y _{1i + 1 are determined} for the starting point of the next turn i + 1 and the coordinates Z _{2i + 1} and Y _{2i + 1} for its end point.

 Combining these points in the corresponding spatial coordinate systems with straight line segments, graphically obtain linear dependencies, according to which, in accordance with the twist angle of the spring v, the coordinate Z of the tool’s spatial position to form the diameter of the spring (Fig. 6) and the tool’s Y coordinate of the tool’s spatial position to form it step (Fig. 7).

At the interface points of the i-th coil with coil i-1 and coil i + 1, the coincidence of the coordinates of the spatial position of the forming tools defined for these points on each of the mating sections of the spring is controlled. In this example, the coincidence of the numerical values of the coordinates Z _1i and Z _2i-1 and the coordinates Y _1i and Y _2i-1 for the first conjugation point of the i-th and i-1st turns, as well as the coincidence of the numerical values of the coordinates Z _2i and Z _{1i are controlled +1} and coordinates Y _2i and Y _{1i + 1} for the second conjugation point of the i-th and i + 1-th turns of the spring.

If the indicated numerical values do not coincide, in particular, as is the case in the considered example at the interface point of the i-th turn with i + 1, in which the coordinate Z _2i defined for the end point of the i-th turn does not coincide with the coordinate Z _{1i +1} (Fig. 6), defined for the starting point of the i + 1th turn, and also the coordinates Y _2i and Y _{1i + 1} (Fig. 7), respectively, defined for the ending point of the i-th and starting point i + 1st coil, the springs select an additional section of the coil.

 To improve the quality of the spring, it is advisable to choose the same additional section before winding the spring, and in those cases where the coordinates of the mating point defined for it on adjacent sections of the spring coincide, but the dynamics of change of coordinates along the twist angle of the mating spring turns sharply differs, as is the case , for example, at the junction point of the i-th and i-1-th turns.

For this, for example, considering the selected spring turns in the plan (Fig. 2), they depart from point "A" at which the turns i and i-1 are interfaced and from the point "B" that the turns i and i + 1 are joined at the same angle "a "to the centers of the mating turns and select new sections of the CD and EF turns. For new points of coupling, coordinates are chosen that coincide with the obtained dependences of changing the coordinates of Z and Y according to the rotation angle of the spring v: for point C, coordinates Z _3i and Y _3i , for point D coordinates Z _4i-1 and Y _4i-1 , for point E coordinates Z _{3i + 1} and Y _{3i + 1} , for point F the coordinates are Z _4i and Y _4i .

где D_i начальный диаметр витка пружины;
D_i+1 конечный диаметр витка пружины;
H шаг витка пружины;
ΔΦ угол закрутки витка пружины относительно ее оси.Next, determine the sweep length of each coil of spring so selected in accordance with the ratios

where D _{i is the} initial diameter of the coil of the spring;
D _{i + 1} final diameter of the coil of the spring;
H spring coil pitch;
ΔΦ is the twist angle of the coil of the spring relative to its axis.

 After that, the dependences of changing the coordinates Z and Y of the spatial position of the tools for forming the diameter and spring pitch along the scan length of each selected coil are determined (Figs. 8 and 9).

For winding the spring, the wire billet is sequentially fed into the working area of the forming tools by the value X _j corresponding to the scan length of the jth coil under consideration, and the tools are moved to the points where the coordinates Z _j and Y _{j of} their spatial position correspond to the current values of l _{j the} length of the sweep of the winding section of the spring.

 During the experimental verification of the proposed method on a spring-coiling machine with CNC from a wire with a diameter of 1 mm, the material BO 1.01 TUZ-1002-77 wound a spring, for which a number of calibration coil springs were pre-wound, the results of which determined the dependences D = f (Z, Y ) and H = f (Z, Y) of diameter D and spring pitch H from the coordinates Z and Y of the spatial position of the tools to form the diameter and pitch.

 Determining the specific mathematical functions from the given dependences and setting the diameter at the start and end points of each coil of the spring, the relationships between the tool coordinates Y1 = f (Z) were determined.

 Then, setting the step values at the start and end points of each coil of the spring, the relationships between the tool coordinates Y2 = f (Z) were determined, and then the coordinates of the common points of the obtained dependencies for the start and end of the coil were determined.

 According to the obtained values, the coincidence of coordinates at the points of conjugation of the turns was controlled. If the coordinates do not coincide, new interface points were selected by deviating along the scan length of adjacent coils from the interface point to their centers by Da = 3.5 mm and the coordinates of the new interface points were determined. Determining the length of the sweep of each section and the corresponding value of the feed of the workpiece, we set the dependence of the movement of the tools on the feed. In FIG. 6, in discrepancies of the CNC system, the dependence of the coordinates Z and Y of the forming tools on the value X of the workpiece feed is presented.

 In FIG. 10 shows the calculated graph of the movement of the tool for forming the diameter of the spring (curve 5) and the tool for forming its pitch (curve 6).

 The use of the invention will significantly reduce the time required to prepare the production of a series of heterogeneous springs and ensure their manufacture the first time without additional adjustment with an accuracy sufficient for the field of engineering.

Claims (3)

 1. A method of manufacturing a spring, including dividing the spring shown in the drawing into sections with a linearly varying diameter and constant pitch, preliminary calculation of the geometric parameters of each section of the coil of the spring and determining the corresponding dependence of the spatial position of the forming tools, winding the spring by sequentially feeding the wire billet into the working area deformation on the length of the sweep of each section of the coil of the spring and the movement of forming tools in the space a predetermined dependence, characterized in that the preliminary calculation of the geometric parameters of the deformation of each section of the coil of the spring and the determination of the corresponding dependence of the spatial position of the forming tools is carried out on a series of calibration springs, during the winding of which several fixed positions of one of the forming tools are selected, in each of them they are wound turns at different positions of another forming tool and with each new combination the spatial position of the forming tools measure the parameters of the coils, and then determine the dependence of the diameter and the dependence of the pitch of the coil spring on the location of each tool, setting the initial and final values of the diameter and step of each coil selected in the drawing, from the obtained relationships determine the relationships between the coordinates of the spatial position of the forming tools for the start and end points of each section of the spring sweep, and then according to the general values of the last ootnosheny determine the spatial position coordinates of the forming tools in the start and end points of said portions of the spring sweep.  2. The method according to claim 1, characterized in that when performing preliminary calculations on a series of calibration springs, the coordinates of the spatial position of the forming tools at the points of the mating spring sections are controlled, if these coordinates do not match, an additional spring section is selected in the drawing, which is obtained by retreating to the same a step from the controlled mating point to the centers of adjacent sections, and the boundary points of the additional spring section are selected as the new mating points. 3. The method according to PP. 1 and 2, characterized in that the scan length of the section of the coil of the spring is determined in accordance with the ratios

Φ ₂ = Φ ₁ + ΔΦ
where D _{i is the} initial diameter of the coil of the spring;
D _{i + 1} final diameter of the coil of the spring;
H spring coil pitch;
ΔΦ is the twist angle of the coil of the spring relative to its axis.

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