(3) Pulling and milling inner hole
1 Put the positioning shown in Figure 4 into the inner hole of the spindle, connect the lubricating oil tube from the rear end of the spindle hole to the oil hole of the milling cutter, and insert the part of the guide sleeve of the milling cutter into the inner hole of the positioning sleeve.
Install the arbor on the 2 tool holder and adjust the center height of the arbor.
3 Upper ferrule, one end of the workpiece card, one end of the frame, the drawing cutter is connected with the arbor, and the inner hole of the drawing is reversely fed. The rake angle of the broach is 10°, the back angle is 5°, the main declination is 8°～10°, the radial distance between the two knives is adjusted to 49.5mm, the symmetry is less than 0.01mm, and the blade material is W18Cr4V. Since the cutting speed of the drawing is not high, the surface roughness of the inner hole is not required, so rolling processing is required to improve the surface quality.
(4) When rolling and rolling, the workpiece clamping is the same as that of the drawing and milling, and the milling cutter is replaced with a roller and the cutter bar is connected, and the inner hole is rolled by the forward feeding. The main factors affecting rolling are interference, rolling speed v, feed rate f and cutting fluid. The choice of these parameters is as follows:
1 The selection of the interference is in principle to make the rolling pressure as small as possible to ensure the required dimensional accuracy and surface roughness. The selection of the interference should not only take into account the microscopic unevenness of the original surface by plastic deformation, but also the elastic deformation of the workpiece in the radial direction. When the rolling interference is greater than 0.1 mm, the cylinder can be guaranteed. The drawing requirements, but the life of the roller and the roller of the roller will be reduced, how to improve the service life of the roller? Through repeated tests, when the rolling amount is controlled at 0.04~0.06mm, the requirements of the pattern are guaranteed and the length is extended. The service life of the roller is therefore a margin of 0.04 to 0.06 mm when the inner hole is pulled and milled.
2Rolling speed v has little effect on the surface roughness of rolling, mainly affecting production efficiency. The increase of speed is limited by the machine tool system. If the speed is too fast, the machine will vibrate and the spiral will be generated on the machined surface. Increase the temperature rise between the workpiece and the ball, accelerate the wear of the roller shaft and the ball, affect the workpiece size and surface roughness. After several tests, the cylinder rolling speed was determined to be v=50 mm/min.
3 Feeding amount f is the main parameter in the cylinder rolling process, which directly affects the surface roughness and processing efficiency of the workpiece after rolling. After the test, the feed rate is changed under the condition that the spindle rotation speed and the interference amount are unchanged. Increasing the feed rate from the original f=0.2mm/r to f=0.4mm/r can ensure that the workpiece meets the requirements of the pattern, shortens the time required for single-piece processing, and doubles the work efficiency.
4 Correct selection of cutting fluid can reduce the surface roughness value after rolling parts, reduce the rolling pressure and machine power consumption, improve the life of the rolling tool, reduce the thermal deformation of the workpiece, and use the mixture of oil and kerosene in the total loss system. The cost of the agent is high, and the use of the filtered waste total loss system oil can still achieve the desired effect and reduce the cost.
In summary, when the inner hole is pulled and milled, the remaining amount is 0.4~0.6mm, the speed at the time of rolling is v=50mm/min, the feed rate is f=0.4mm/r, and the filtered total loss system is used as oil. Cutting fluid is a reasonable processing method. After production practice, it proves that the selection of process plan and processing parameters is reasonable. The drawing cutter and roller are simple in structure and reliable in positioning, which can ensure the requirements of the pattern and improve the efficiency and output.
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