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機加工種類及范圍

一、車削加工

1、加工范圍

車外圓及臺階、車端面、鏜孔、車錐面、車螺紋、車成形面、切槽和切斷等。

2、粗車、精車與鏡面車

(1)粗車

目的:盡快從毛坯上切去大部分余量,合工件接近要求的形狀和尺寸。(生產效率)

考慮因素:應給精車和半精車留有合適的余量,一般為1-2mm。

(2)精車

目的:保證加工精度和表面粗糙度的要求。(生產效率其次)

精車是指直接用車削方法獲得IT6-IT7 級公差, Ra為1.6-0.04 μm的外圓加工方法。

(3)鏡面車

鏡面車(che)是用車(che)削方法獲得工件尺(chi)寸公差(cha)≤1 μm的數量(liang)級, Ra≤3.2 μm的外圓加工方法。


二、銑削加工

1、加工范圍

可以加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)各種零件的平面(mian)(mian)(mian)、臺階面(mian)(mian)(mian)、溝槽、成形(xing)表(biao)面(mian)(mian)(mian)、型(xing)腔表(biao)面(mian)(mian)(mian)、螺旋表(biao)面(mian)(mian)(mian)等(deng)。銑(xian)(xian)削加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)應(ying)該(gai)對軸類來(lai)進(jin)行粗加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)(gong)(gong)藝工(gong)(gong)(gong)(gong)(gong)(gong)藝處(chu)理(li)和半精加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)(gong)(gong)藝工(gong)(gong)(gong)(gong)(gong)(gong)藝處(chu)理(li),加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)(gong)(gong)藝工(gong)(gong)(gong)(gong)(gong)(gong)藝處(chu)理(li)誤差相(xiang)當于IT7-IT9 段,精銑(xian)(xian)表(biao)面(mian)(mian)(mian)能粗造度達Ra3.2-1.6 μm.

 

三、鉆削、鉸削與鏜削加工

1、鉆削加工

在鉆床上以鉆頭的旋轉作主運動,鉆頭向工件的軸向移動作進給運動,在實體工件上加工出孔為鉆削。按孔的直徑、深度的不同,生產中有各種不同結構的鉆頭,其中,麻花鉆最為常用。由于麻花鉆存在的結構問題,采用麻花鉆鉆孔時,軸向力很大,定心能力較差,孔易引偏;加工中摩擦嚴重,加之冷卻潤滑不便,表面較為粗糙。故麻花鉆鉆孔的精度不高,一般為IT13-IT12 ,表面粗糙度達Ra12.5-6.3 μm,生產效率也不高。所以,鉆孔主要用于φ80以也孔徑的粗加工。如加工精度、粗糙度要求不高的螺釘孔,油孔或對精度、粗糙度要求較高的孔作預加。生產中為提高孔的加工精度、生產效率和降低成本,廣泛使用鉆模,多軸鉆或組合機床進行孔加工。

當孔的深徑比達到 5及以上時為深孔。深孔加工難度較大,主要表現在刀具剛性差,導向難;排削難;冷卻潤滑難幾方面,有效地解決以上加工問題,是保證深孔加質量的關鍵。一般對深徑比在5-20的普通深孔,在車床或鉆床上用加長麻花鉆加工;對深徑比達20以上的深孔,在深孔鉆床上用深孔鉆加工;當孔徑較大,孔加工要求較高時,可在深孔鏜床上加工。

向難(nan)(nan);排削(xue)難(nan)(nan);冷卻潤(run)滑難(nan)(nan)幾方面,有效(xiao)地解決以上加(jia)(jia)(jia)(jia)(jia)工問題,是(shi)保證深(shen)(shen)孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)加(jia)(jia)(jia)(jia)(jia)質量的關(guan)鍵。通(tong)常(chang)對深(shen)(shen)徑(jing)(jing)比(bi)在5-20的各種類型(xing)深(shen)(shen)孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong),在數(shu)控車床(chuang)或(huo)銑床(chuang)使用加(jia)(jia)(jia)(jia)(jia)長(chang)型(xing)麻花鉆加(jia)(jia)(jia)(jia)(jia)工處理(li);對深(shen)(shen)徑(jing)(jing)比(bi)達(da)(da)20以上的深(shen)(shen)孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong),在深(shen)(shen)孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)銑床(chuang)上刷深(shen)(shen)孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)鉆精(jing)(jing)(jing)加(jia)(jia)(jia)(jia)(jia)工處理(li);當孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)的直徑(jing)(jing)更(geng)大(da),孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)精(jing)(jing)(jing)加(jia)(jia)(jia)(jia)(jia)工處理(li)的要求較高(gao)時(shi),可(ke)(ke)在深(shen)(shen)孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)鏜床(chuang)里加(jia)(jia)(jia)(jia)(jia)工。當類件上多個預(yu)孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)(如鑄孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong),鍛(duan)孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)或(huo)已生(sheng)產(chan)(chan)加(jia)(jia)(jia)(jia)(jia)工孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong))時(shi),可(ke)(ke)選取擴孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)鉆實施(shi)管(guan)徑(jing)(jing)增加(jia)(jia)(jia)(jia)(jia)的加(jia)(jia)(jia)(jia)(jia)工,稱擴孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)。擴孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)亦屬鉆削(xue)位置,但可(ke)(ke)靠性強,精(jing)(jing)(jing)密(mi)度(du)(du),效(xiao)率在成孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)基礎(chu)上上均帶來延長(chang),應該擴孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)可(ke)(ke)靠性強,精(jing)(jing)(jing)密(mi)度(du)(du)達(da)(da)IT12-IT10 ,表層很糙度(du)(du)達(da)(da)Ra6.3-3.2 μm,故擴孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)除可(ke)(ke)于較高(gao)計算精(jing)(jing)(jing)度(du)(du)的孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)的預(yu)生(sheng)產(chan)(chan)外,還會讓點請(qing)求低的孔(kong)(kong)(kong)(kong)(kong)(kong)(kong)(kong)到(dao)生(sheng)產(chan)(chan)請(qing)求。生(sheng)產(chan)(chan)口(kou)徑(jing)(jing)大(da)部分不(bu)達(da)(da)到(dao)φ100。

2、鉸削加工

鉸削(xue)是對(dui)中(zhong)小直徑(jing)的(de)(de)已有孔(kong)(kong)進行精(jing)度、質量提高的(de)(de)一種常用加(jia)工(gong)方法。鉸削(xue)時,采用的(de)(de)銑削(xue)流(liu)速較低,制作加(jia)工(gong)加(jia)工(gong)余(yu)量較小(精(jing)鉸時一半為(wei)0.15-0.35mm,精(jing)鉸為(wei)0.05-0.15mm)效準大部分長(chang),鉸削(xue)時中(zhong)雖摩擦出(chu)現變形明(ming)顯,但對(dui)孔(kong)(kong)壁(bi)有修光熨壓效應(ying),為(wei)此,鉸削(xue)完成對(dui)孔(kong)(kong)壁(bi)薄層數量的(de)(de)去掉(diao)使孔(kong)(kong)的(de)(de)工(gong)藝誤差、界面滑安(an)全性(xing)能達到提高自己(ji)。應(ying)該鉸孔(kong)(kong)工(gong)藝誤差電動車(che)續(xu)航IT9-

IT6,表(biao)面粗糙度達Ra0.4-1.6 μm,但鉸孔(kong)(kong)(kong)對位(wei)置(zhi)精(jing)(jing)度的保證不夠理想。鉸孔(kong)(kong)(kong)既可(ke)以(yi)用在(zai)(zai)于(yu)制(zhi)(zhi)作(zuo)(zuo)(zuo)工(gong)藝(yi)圓形孔(kong)(kong)(kong),也(ye)(ye)可(ke)以(yi)用在(zai)(zai)于(yu)制(zhi)(zhi)作(zuo)(zuo)(zuo)工(gong)藝(yi)圓錐形孔(kong)(kong)(kong),既可(ke)制(zhi)(zhi)作(zuo)(zuo)(zuo)工(gong)藝(yi)通(tong)孔(kong)(kong)(kong),也(ye)(ye)可(ke)制(zhi)(zhi)作(zuo)(zuo)(zuo)工(gong)藝(yi)盲孔(kong)(kong)(kong)。鉸孔(kong)(kong)(kong)前(qian),被(bei)精(jing)(jing)加工(gong)制(zhi)(zhi)作(zuo)(zuo)(zuo)孔(kong)(kong)(kong)先要歷經鉆(zhan)削或鉆(zhan)、擴孔(kong)(kong)(kong)精(jing)(jing)加工(gong)制(zhi)(zhi)作(zuo)(zuo)(zuo),鉸削數量(liang)應(ying)適宜,既沒能(neng)過大也(ye)(ye)沒能(neng)過小,進程(cheng)與劑量(liang)也(ye)(ye)應(ying)該用,能(neng)力提高鉸削質。與此同(tong)時,鉸削中,鉸刀(dao)難(nan)以(yi)翻轉,鉸孔(kong)(kong)(kong)后,先退(tui)鉸也(ye)(ye)后停車場。


四、磨削加工

磨削及其(qi)裝備磨削加工(gong)(gong)(gong)是在磨床上使用砂輪與工(gong)(gong)(gong)件作(zuo)相對運動,對工(gong)(gong)(gong)件進(jin)行的(de)一種多刀多刃的(de)高速路鉆削最(zui)簡(jian)單的(de)方法(fa),它重點技(ji)術應用于組件的(de)精加工(gong)(gong)(gong)生產,特別對難鉆削的(de)高密度板(ban)材,如淬(cui)硬鋼(gang)、孔(kong)狀和金、破璃、瓷磚(zhuan)等確定加工(gong)(gong)(gong)制(zhi)作(zuo)。

磨削加工的特點

(1)磨削加工(gong)精度(du)高由(you)于去除(chu)量少,一(yi)般磨削可獲得 IT7-IT5 級精度(du),表面(mian)粗糙度(du)低,軸(zhou)類(lei)中前往參加事情金剛(gang)石微粉數(shu)多,各(ge)金剛(gang)石微粉切(qie)去切(qie)屑少,故可提(ti)升較小從(cong)表面(mian)不光滑度(du)值Ra1.6-0.2 μm,若(ruo)應(ying)用(yong)精磨、超精磨等,將得到 理低表明干硬度(du)。

(2)磨削(xue)加(jia)工(gong)(gong)范圍磨削(xue)加(jia)工(gong)(gong)可(ke)適應(ying)各種表面(mian),如(ru)(ru)內(nei)、外(wai)圓表面(mian)、圓錐面(mian)、平面(mian)、齒(chi)輪(lun)齒(chi)面(mian)、雙螺旋面(mian)及(ji)種種成型(xing)面(mian)的(de)處理工(gong)(gong)藝(yi);同一時間,切削(xue)處理工(gong)(gong)藝(yi)可(ke)適合四種軸類零件(jian)涂(tu)料,還是比較是選取別的(de)平民車刀難(nan)車削(xue)的(de)高(gao)硬(ying)鍛造的(de)原(yuan)材料廠,如(ru)(ru)淬硬(ying)鋼、硬(ying)性碳素鋼、快速鋼等,但不合適代加(jia)工(gong)(gong)氏硬(ying)度低而塑型(xing)好的(de)稀有重金(jin)屬重金(jin)屬文件(jian)。

(3)砂輪具有一(yi)定的自銳性磨粒硬而脆,它(ta)可在磨削力作用下破碎、膠落、更新刀削刃,穩定數控刀鋒利度,并在低溫下仍不失磨削使用性能。

(4)磨削速(su)度高,過程復雜,消耗能量多,切削效率低;磨削溫度高,會使工件表(biao)面產生燒傷、殘余物熱應力等通病。


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