非对称零件高精度组合深孔加工技术研究
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摘要
本文以某型号XXX-4型自动阀体为研究对象，主要研究不锈钢非对称零件高精度细深组合孔系的镗孔加工工艺，XXX-4型自动阀体是某型号武器充气系统气路控制的关键部件，其中阀体组合内孔尺寸精度、形位公差及表面粗糙度要求很高，加工难度大，多年来该零件的加工一直是我单位的技术难点和急需解决的技术问题。XXX-4型阀体是在XXX-3型阀体的基础上发展起来的，它采用双联结构以增加零件工作的可靠性，外形为非对称结构，材料为抗氢脆奥氏体不锈钢，阀体组合内孔加工有较大的技术难度。我所曾对XXX-3型号阀体镗孔进行过多次工艺实验，取得了一定的成绩，但一些关键技术没有彻底解决，加工质量稳定性不高，未用于实际生产。
我们在此基础上对XXX-4阀体高精度组合孔系镗孔技术进行了深入的研究，仔细分析加工对象的结构功能和工艺难点，论文重点解决以下技术问题：
(1)根据零件的设计要求及材料的切削特点，利用正交试验方法对工件材料的切削参数及刀具的主要参数进行优化，得出满足设计要求科学合理的试验参数，作为刀具设计及工艺试验的基础；
(2)根据零件的非对称结构特点，从工艺系统设计着手，应用
现场动平衡测试技术等解决了加工中工艺系统的动平衡设计，减小由
于工件结构不对称引起的离心力对加工精度的影响;
(3)利用有限元分析方法对几种刀具方案进行分析，优化设计
了高刚度整体硬质合金内冷却可转位锉刀，解决了刀具悬伸较长，刀
具刚性不足及耐磨性等问题对加工精度的影响，使得刀具的制造成本
大大降低，刀杆可以重复使用，降低了刀具的刃磨制造难度;
(4)通过引进适于现场测量的高精度气动量仪，解决了现场高
精度在位测量技术。保证了工件一次装夹，完成加工，避免了工件因
留量计量造成重复装夹误差影响加工精度;在加工中根据工件加工的
实测尺寸的误差情况，采用相应误差补偿技术，及时消除了刀具磨损、
对刀误差、刀具变形等因素对加工精度的影响，提高了加工精度及合
格率;
(5)利用有限元分析方法，对工件装夹变形进行计算，根据加
工精度要求确定合理的装夹力矩。使用精密扭力螺丝刀对工件装夹力
矩进行精确控制，解决了高精度零件加工的精密装夹变形问题。确保
工件装夹可靠，同时变形较小，使得工件的夹紧力控制从以前的依赖
工人经验的定性控制转为更加科学合理的定量控制，消除了人为因素
对加工精度的影响;
(6)对实验结果利用SPC分析方法对形成零件主要要素进行工
艺能力分析，提出了相应改进措施;通过以上各技术的综合应用，使
产品质量和合格率大大提高。并可供类似零件的加工提供参考。
This paper is regarding automatic valve named xxx-4 as the research object. The craft about how to machine a knockdown hole system in a stainless steel part that is not symmetrical is studied primarily. The automatic valve named xxx~4 is the part of some type weapon. This part is to control the air path of the charge system. In the part named XXX-4 valve there are some holes with strict dimension, position tolerance and roughness . It is very difficult to machine. The machining of the part is all along a technical problem that is solved urgently by us. This type of valve named XXX-4 is developed on the foundation that the XXX-3 type valve. It adopts a coupling configuration to increase working dependability. The shape is not symmetry construction. The material is an anti- hydrogen frailty austenitic stainless steel. There are some bigger technical difficulties in machining the knockdown inside the hole system. We have many experiments on XXX-3 and got some achievement without the key technology, so we can' t
reach ideal quality and efficiency. So it did not used for the actual production
We go deep into the boring technology of XXX-4 valve and carefully analyse the object's construction function and the
difficult point of craft. The paper point resolves below technique problems:
According to design request of the part and characteristics of the material, optimize machining parameter and main parameter of the tool by the hand over experiment method, get the science reasonable parameter that can satisfy request of design. It is the base to design tools.
According to not symmetry construction characteristics of the parts we designed the outset from the craft system, solved the moving equilibrium design of the craft system by the test technique of the moving equilibrium at the spot and reduced the precision influence which is caused by anisomerous construction of the work piece.
Make use of the analysis method of limited element, we designed the high rigid carbide tool that can be cooled inside. We solved some problems those can influence precision: stretch out longer, rigidity of the tools not enough and abrasion resistance not enough and so on. It makes the tool manufacturing cost consumedly lower. The tool pole can repeat the usage. The tools are easy to make.
Using the accuracy measure instrument we can do precision measure. We just need a time to clamp to finish machining, so avoided the error influence because of repetition to install work piece. According to the dimension error that is actual to measure at process of work piece and using the technique of the homologous error compensates, we can avoid the error influence because of abrasion of tool, checking tool and distortion of tool and so on. So precision and qualified rate can be improved.
Make use of the analysis method of limited element, distortion of the work piece that is caused by clamping is
calculated. According to request of machining precision reasonable clamping moment is made sure. Using the tool of precise torque screw can solve the distortion problem in the process of clamping. The work piece is installed dependable. The distortion is small. So the force of clamping can be controlled reasonable.
The SPC analysis method is used to analyze the main element, analyze ability of craft and get the corresponding improved measure. All of above, these measures can improve product efficiency and percentage of certified product and can offer reference to the machining of similar parts.
Adopting this craft we can lift high-efficiency, reduce the manufacturing cost, process the quantity stability. If this lesson can be success, we will get the importance social performance with the economic performance.
我们在此基础上对XXX-4阀体高精度组合孔系镗孔技术进行了深入的研究，仔细分析加工对象的结构功能和工艺难点，论文重点解决以下技术问题：
(1)根据零件的设计要求及材料的切削特点，利用正交试验方法对工件材料的切削参数及刀具的主要参数进行优化，得出满足设计要求科学合理的试验参数，作为刀具设计及工艺试验的基础；
(2)根据零件的非对称结构特点，从工艺系统设计着手，应用
现场动平衡测试技术等解决了加工中工艺系统的动平衡设计，减小由
于工件结构不对称引起的离心力对加工精度的影响;
(3)利用有限元分析方法对几种刀具方案进行分析，优化设计
了高刚度整体硬质合金内冷却可转位锉刀，解决了刀具悬伸较长，刀
具刚性不足及耐磨性等问题对加工精度的影响，使得刀具的制造成本
大大降低，刀杆可以重复使用，降低了刀具的刃磨制造难度;
(4)通过引进适于现场测量的高精度气动量仪，解决了现场高
精度在位测量技术。保证了工件一次装夹，完成加工，避免了工件因
留量计量造成重复装夹误差影响加工精度;在加工中根据工件加工的
实测尺寸的误差情况，采用相应误差补偿技术，及时消除了刀具磨损、
对刀误差、刀具变形等因素对加工精度的影响，提高了加工精度及合
格率;
(5)利用有限元分析方法，对工件装夹变形进行计算，根据加
工精度要求确定合理的装夹力矩。使用精密扭力螺丝刀对工件装夹力
矩进行精确控制，解决了高精度零件加工的精密装夹变形问题。确保
工件装夹可靠，同时变形较小，使得工件的夹紧力控制从以前的依赖
工人经验的定性控制转为更加科学合理的定量控制，消除了人为因素
对加工精度的影响;
(6)对实验结果利用SPC分析方法对形成零件主要要素进行工
艺能力分析，提出了相应改进措施;通过以上各技术的综合应用，使
产品质量和合格率大大提高。并可供类似零件的加工提供参考。
This paper is regarding automatic valve named xxx-4 as the research object. The craft about how to machine a knockdown hole system in a stainless steel part that is not symmetrical is studied primarily. The automatic valve named xxx~4 is the part of some type weapon. This part is to control the air path of the charge system. In the part named XXX-4 valve there are some holes with strict dimension, position tolerance and roughness . It is very difficult to machine. The machining of the part is all along a technical problem that is solved urgently by us. This type of valve named XXX-4 is developed on the foundation that the XXX-3 type valve. It adopts a coupling configuration to increase working dependability. The shape is not symmetry construction. The material is an anti- hydrogen frailty austenitic stainless steel. There are some bigger technical difficulties in machining the knockdown inside the hole system. We have many experiments on XXX-3 and got some achievement without the key technology, so we can' t
reach ideal quality and efficiency. So it did not used for the actual production
We go deep into the boring technology of XXX-4 valve and carefully analyse the object's construction function and the
difficult point of craft. The paper point resolves below technique problems:
According to design request of the part and characteristics of the material, optimize machining parameter and main parameter of the tool by the hand over experiment method, get the science reasonable parameter that can satisfy request of design. It is the base to design tools.
According to not symmetry construction characteristics of the parts we designed the outset from the craft system, solved the moving equilibrium design of the craft system by the test technique of the moving equilibrium at the spot and reduced the precision influence which is caused by anisomerous construction of the work piece.
Make use of the analysis method of limited element, we designed the high rigid carbide tool that can be cooled inside. We solved some problems those can influence precision: stretch out longer, rigidity of the tools not enough and abrasion resistance not enough and so on. It makes the tool manufacturing cost consumedly lower. The tool pole can repeat the usage. The tools are easy to make.
Using the accuracy measure instrument we can do precision measure. We just need a time to clamp to finish machining, so avoided the error influence because of repetition to install work piece. According to the dimension error that is actual to measure at process of work piece and using the technique of the homologous error compensates, we can avoid the error influence because of abrasion of tool, checking tool and distortion of tool and so on. So precision and qualified rate can be improved.
Make use of the analysis method of limited element, distortion of the work piece that is caused by clamping is
calculated. According to request of machining precision reasonable clamping moment is made sure. Using the tool of precise torque screw can solve the distortion problem in the process of clamping. The work piece is installed dependable. The distortion is small. So the force of clamping can be controlled reasonable.
The SPC analysis method is used to analyze the main element, analyze ability of craft and get the corresponding improved measure. All of above, these measures can improve product efficiency and percentage of certified product and can offer reference to the machining of similar parts.
Adopting this craft we can lift high-efficiency, reduce the manufacturing cost, process the quantity stability. If this lesson can be success, we will get the importance social performance with the economic performance.
引文
[1]孟少农 机械制造工艺手则，机械工业出版社 1998．11
[2]王先奎．精密加工技术实用手则，机械工业出版社 2001．9
[3]袁哲俊 精密和超精密加工技术，机械工业出版社 1999．7
[4]汪国健 深孔的镗铰加工安徽屯溪塑料机械厂，工具技术 2001．12
[5]林哲山 深孔加工刀具-刚性镗铰刀的应用，机械工程师 1994．4
[6]庞浩 深孔加工的综述，机械工艺师 1996．10
[7]张平宽 深孔精整加工工艺，机械制造 1995．12
[8]张平宽 深孔抛磨加工原理分析，1995．12
[9]樊铁镔 深孔加工技术综述，工具技术 1994．
[10]李英明 以铰代磨加工小深孔，机械制造 1998．10
[11]王义民．精密小孔的高效珩磨工艺．磨料磨具与磨削，1997．2
[12]吴华年XXX-3阀体加工技术研究，内部资料 1998
[13]曾孝云 阀体组合铰削加工总结 2000．12
[14]周志平 细长深孔加工的几种方案，机电产品开发与创新 2002．2
[15]王世清 孔加工技术，石油工业出版社 1993
[16]翼春荣 削扁镗杆与阻尼减振在深孔加工中的应用 1994．2
[17]姜德志 加工偏心零件的车夹具，工程机械 1997．8
[18]屈维德 机械振动手则，机械工业出版社 2000．5
[19]刘国强等 动平衡计算在长曲轴车削时的应用，2002．4
[20]党社义 精密偏心深孔的加工 中原量仪厂 1999．12
[21]李宇斌 旋转机械转子的现场动平衡，流体机械 1994．9
[22]邵福林 旋转机械转子现场动平衡，有色设备 1995．5
[23]熊文湘 精密加工中的装夹技术，航天工艺 1995．4
[24]费琼洲 精密夹具精度设计，机械设计及制造 2000．8
[25]朱燕堂．应用概率统计方法 西北工业大学出版社，1990．8
[26]机械工程手册(第二版) 机械工业出版社 1995．11
[27]肖诗刚 刀具材料的新进展，机械工艺师 1993．3
[28]刀具设计技术 袁哲俊 机械工业出版社 1996．9
[29]陈精一，蔡国忠．ANSYS使用指南．北京：中国铁道出版社，2001．1
[30]于春泾编．机械制造检测技术手则，机械工业出版社 2000．12
[31]航空工艺装备(量具)设计手则，国防工业出版社 1986．9
[32]丛培田单面现场动平衡解析三点加重法试验研究，新技术新工艺 1997．8
[33]李伟 应用现场动平衡技术的一点体会，机械设计及制造 1998．12
[34]谢志江 转子双面现场动平衡的不卸试重平衡法 重大学报 2002．9
[35]毕文昌 转子现场动平衡的特点及失衡量的分析，机械科学与技术 1997．3
[36]陈敬平 转子现场动平衡的相对影响系数法，振动、测试与诊断 1994．12
[37]振通907现场平衡仪使用说明书
[38]张公绪、孙静．SPC与SPD工程，北京公绪质量研究中心 2003．5
[39]曾孝云 阀体(镗孔)加工技术(GF报告) 2002．12
[40]谢玉凤 XX-4钢切削性能研究，内部资料 1997
[2]王先奎．精密加工技术实用手则，机械工业出版社 2001．9
[3]袁哲俊 精密和超精密加工技术，机械工业出版社 1999．7
[4]汪国健 深孔的镗铰加工安徽屯溪塑料机械厂，工具技术 2001．12
[5]林哲山 深孔加工刀具-刚性镗铰刀的应用，机械工程师 1994．4
[6]庞浩 深孔加工的综述，机械工艺师 1996．10
[7]张平宽 深孔精整加工工艺，机械制造 1995．12
[8]张平宽 深孔抛磨加工原理分析，1995．12
[9]樊铁镔 深孔加工技术综述，工具技术 1994．
[10]李英明 以铰代磨加工小深孔，机械制造 1998．10
[11]王义民．精密小孔的高效珩磨工艺．磨料磨具与磨削，1997．2
[12]吴华年XXX-3阀体加工技术研究，内部资料 1998
[13]曾孝云 阀体组合铰削加工总结 2000．12
[14]周志平 细长深孔加工的几种方案，机电产品开发与创新 2002．2
[15]王世清 孔加工技术，石油工业出版社 1993
[16]翼春荣 削扁镗杆与阻尼减振在深孔加工中的应用 1994．2
[17]姜德志 加工偏心零件的车夹具，工程机械 1997．8
[18]屈维德 机械振动手则，机械工业出版社 2000．5
[19]刘国强等 动平衡计算在长曲轴车削时的应用，2002．4
[20]党社义 精密偏心深孔的加工 中原量仪厂 1999．12
[21]李宇斌 旋转机械转子的现场动平衡，流体机械 1994．9
[22]邵福林 旋转机械转子现场动平衡，有色设备 1995．5
[23]熊文湘 精密加工中的装夹技术，航天工艺 1995．4
[24]费琼洲 精密夹具精度设计，机械设计及制造 2000．8
[25]朱燕堂．应用概率统计方法 西北工业大学出版社，1990．8
[26]机械工程手册(第二版) 机械工业出版社 1995．11
[27]肖诗刚 刀具材料的新进展，机械工艺师 1993．3
[28]刀具设计技术 袁哲俊 机械工业出版社 1996．9
[29]陈精一，蔡国忠．ANSYS使用指南．北京：中国铁道出版社，2001．1
[30]于春泾编．机械制造检测技术手则，机械工业出版社 2000．12
[31]航空工艺装备(量具)设计手则，国防工业出版社 1986．9
[32]丛培田单面现场动平衡解析三点加重法试验研究，新技术新工艺 1997．8
[33]李伟 应用现场动平衡技术的一点体会，机械设计及制造 1998．12
[34]谢志江 转子双面现场动平衡的不卸试重平衡法 重大学报 2002．9
[35]毕文昌 转子现场动平衡的特点及失衡量的分析，机械科学与技术 1997．3
[36]陈敬平 转子现场动平衡的相对影响系数法，振动、测试与诊断 1994．12
[37]振通907现场平衡仪使用说明书
[38]张公绪、孙静．SPC与SPD工程，北京公绪质量研究中心 2003．5
[39]曾孝云 阀体(镗孔)加工技术(GF报告) 2002．12
[40]谢玉凤 XX-4钢切削性能研究，内部资料 1997