摘要：設(she)計(ji)簡單(dan)工(gong)裝，將鉆頭或絲(si)錐安裝在三爪自定心(xin)卡盤上(shang)，零件安裝在工(gong)裝上(shang)，刀具(ju)不停轉動，零件借助工(gong)裝進行(xing)進給(gei)運動，構成(cheng)切(qie)削模式，完成(cheng)鉆孔及(ji)攻螺紋加工(gong)，加工(gong)效率大為提(ti)高。
車床加(jia)(jia)工時(shi)(shi)，零(ling)件(jian)(jian)連續轉(zhuan)動(dong)(dong)，相對(dui)其他機床加(jia)(jia)工效(xiao)率較(jiao)高(gao)。但是對(dui)于零(ling)件(jian)(jian)較(jiao)小(xiao)、數量較(jiao)多的情況，反復在(zai)卡盤上安裝與拆(chai)卸零(ling)件(jian)(jian)，輔助(zhu)時(shi)(shi)間較(jiao)長，相對(dui)效(xiao)率下降。為縮短(duan)輔助(zhu)時(shi)(shi)間、提高(gao)加(jia)(jia)工效(xiao)率，研(yan)究設計將刀具安裝在(zai)卡盤上連續轉(zhuan)動(dong)(dong)，零(ling)件(jian)(jian)僅作進給(gei)運動(dong)(dong)，更(geng)換零(ling)件(jian)(jian)時(shi)(shi)，刀具可以繼續轉(zhuan)動(dong)(dong)，且更(geng)換零(ling)件(jian)(jian)簡單(dan)方便(bian)、時(shi)(shi)間短(duan)。
某公司加工一批六角螺母零件，規格M20，需(xu)要(yao)鉆孔、攻(gong)螺紋，采用(yong)將鉆頭或(huo)絲錐安裝在卡盤(pan)上(shang)(shang)進行切削運(yun)動，零件安裝在刀(dao)架上(shang)(shang)進行進給運(yun)動的方法，取得(de)了較好(hao)的效果(guo)。
該螺(luo)(luo)母(mu)(mu)(mu)材(cai)料(liao)是(shi)45鋼，毛(mao)(mao)坯(pi)為(wei)冷(leng)鍛坯(pi)料(liao)，內孔(kong)留2mm加(jia)(jia)(jia)工(gong)(gong)(gong)余(yu)量，外六方輪廓尺寸基本均勻，無需(xu)加(jia)(jia)(jia)工(gong)(gong)(gong)。加(jia)(jia)(jia)工(gong)(gong)(gong)時需(xu)要先去除內孔(kong)2mm余(yu)量，然后(hou)用絲(si)(si)錐(zhui)(zhui)攻(gong)螺(luo)(luo)紋完成(cheng)(cheng)。用車床加(jia)(jia)(jia)工(gong)(gong)(gong)螺(luo)(luo)母(mu)(mu)(mu)絲(si)(si)扣是(shi)將單(dan)個螺(luo)(luo)母(mu)(mu)(mu)卡在(zai)(zai)三(san)(san)爪自定(ding)(ding)心卡盤上，然后(hou)用車刀(dao)加(jia)(jia)(jia)工(gong)(gong)(gong)內孔(kong)及絲(si)(si)扣，或將鉆(zhan)頭(tou)、絲(si)(si)錐(zhui)(zhui)安(an)(an)(an)裝(zhuang)在(zai)(zai)車床尾座(zuo)上，用鉆(zhan)頭(tou)鉆(zhan)孔(kong)，用絲(si)(si)錐(zhui)(zhui)加(jia)(jia)(jia)工(gong)(gong)(gong)絲(si)(si)扣。采用上述兩種方法，都是(shi)將單(dan)個螺(luo)(luo)母(mu)(mu)(mu)毛(mao)(mao)坯(pi)安(an)(an)(an)裝(zhuang)在(zai)(zai)卡盤上，螺(luo)(luo)母(mu)(mu)(mu)轉動，車刀(dao)或鉆(zhan)頭(tou)（絲(si)(si)錐(zhui)(zhui)）作(zuo)進給(gei)運動，反復操作(zuo)，耗時耗力，加(jia)(jia)(jia)工(gong)(gong)(gong)效率低(di)。為(wei)提高加(jia)(jia)(jia)工(gong)(gong)(gong)速度，研究(jiu)決(jue)定(ding)(ding)設計(ji)簡單(dan)工(gong)(gong)(gong)裝(zhuang)，將鉆(zhan)頭(tou)或絲(si)(si)錐(zhui)(zhui)安(an)(an)(an)裝(zhuang)在(zai)(zai)三(san)(san)爪自定(ding)(ding)心卡盤上，作(zuo)回(hui)轉運動，而待加(jia)(jia)(jia)工(gong)(gong)(gong)螺(luo)(luo)母(mu)(mu)(mu)安(an)(an)(an)裝(zhuang)在(zai)(zai)工(gong)(gong)(gong)裝(zhuang)上，作(zuo)進給(gei)運動，構成(cheng)(cheng)加(jia)(jia)(jia)工(gong)(gong)(gong)模式(shi)。
依據鉆頭(tou)或(huo)絲錐(zhui)旋(xuan)轉(zhuan)、螺(luo)母(mu)進行進給運動的思路，將(jiang)(jiang)鉆頭(tou)或(huo)絲錐(zhui)安裝(zhuang)(zhuang)(zhuang)(zhuang)在(zai)三爪自(zi)定(ding)心卡盤上(shang)，設計簡易工(gong)(gong)(gong)裝(zhuang)(zhuang)(zhuang)(zhuang)，待(dai)加工(gong)(gong)(gong)螺(luo)母(mu)安裝(zhuang)(zhuang)(zhuang)(zhuang)在(zai)工(gong)(gong)(gong)裝(zhuang)(zhuang)(zhuang)(zhuang)里，將(jiang)(jiang)工(gong)(gong)(gong)裝(zhuang)(zhuang)(zhuang)(zhuang)安裝(zhuang)(zhuang)(zhuang)(zhuang)在(zai)刀(dao)架(jia)上(shang)，由刀(dao)架(jia)進行軸向移(yi)動，實現進給運動。鉆孔方(fang)式和工(gong)(gong)(gong)裝(zhuang)(zhuang)(zhuang)(zhuang)設計如圖1所示(shi)。
圖1 鉆孔方(fang)式(shi)及(ji)工裝設計簡圖
1.車床(chuang)卡盤 2.鉆頭 3.支(zhi)撐彎板(ban) 4.刀架 5.聯接板(ban) 6.聯接螺(luo)(luo)栓(shuan)7.緊定螺(luo)(luo)栓(shuan) 8.待加(jia)工螺(luo)(luo)母 9.底板(ban) 10.前端板(ban) 11.鉆套 12.上蓋板(ban)
安(an)(an)(an)裝(zhuang)(zhuang)(zhuang)螺(luo)(luo)(luo)母的工(gong)(gong)裝(zhuang)(zhuang)(zhuang)由(you)(you)支(zhi)(zhi)撐(cheng)彎(wan)板(ban)(ban)(ban)3、聯(lian)(lian)接板(ban)(ban)(ban)5、聯(lian)(lian)接螺(luo)(luo)(luo)栓6、定(ding)位螺(luo)(luo)(luo)栓7、鉆(zhan)套(tao)11、上蓋板(ban)(ban)(ban)12、前(qian)端(duan)板(ban)(ban)(ban)10和(he)底板(ban)(ban)(ban)9等組(zu)成。支(zhi)(zhi)撐(cheng)彎(wan)板(ban)(ban)(ban)3安(an)(an)(an)裝(zhuang)(zhuang)(zhuang)在車床刀架上，聯(lian)(lian)接板(ban)(ban)(ban)5兩側加(jia)工(gong)(gong)長孔，由(you)(you)聯(lian)(lian)接螺(luo)(luo)(luo)栓6與支(zhi)(zhi)撐(cheng)彎(wan)板(ban)(ban)(ban)聯(lian)(lian)接。由(you)(you)于存在長孔，聯(lian)(lian)接板(ban)(ban)(ban)可以在支(zhi)(zhi)撐(cheng)彎(wan)板(ban)(ban)(ban)上上下(xia)移動，確定(ding)加(jia)工(gong)(gong)位置，緊(jin)定(ding)螺(luo)(luo)(luo)栓7安(an)(an)(an)裝(zhuang)(zhuang)(zhuang)在上蓋板(ban)(ban)(ban)12上，待加(jia)工(gong)(gong)螺(luo)(luo)(luo)母安(an)(an)(an)裝(zhuang)(zhuang)(zhuang)到工(gong)(gong)裝(zhuang)(zhuang)(zhuang)里后(hou)，擰緊(jin)螺(luo)(luo)(luo)栓，將其鎖住。鉆(zhan)套(tao)11安(an)(an)(an)裝(zhuang)(zhuang)(zhuang)在前(qian)端(duan)板(ban)(ban)(ban)里，用(yong)于引(yin)導鉆(zhan)頭或絲(si)錐，保證加(jia)工(gong)(gong)準確。鉆(zhan)套(tao)采(cai)用(yong)45鋼(gang)材料(liao)，淬(cui)火處(chu)理，以保證耐磨(mo)性(xing)。上蓋板(ban)(ban)(ban)12、前(qian)端(duan)板(ban)(ban)(ban)10、底板(ban)(ban)(ban)9和(he)聯(lian)(lian)接板(ban)(ban)(ban)5等采(cai)用(yong)焊接方式組(zu)成整體。其寬度(du)等于待加(jia)工(gong)(gong)螺(luo)(luo)(luo)母的六角最(zui)大尺寸。
加(jia)工前，先將鉆頭安(an)裝(zhuang)在三(san)爪自定(ding)心(xin)卡盤上(shang)鎖緊(jin)(jin)。然后(hou)將支撐板3安(an)裝(zhuang)在車床刀架上(shang)，鎖緊(jin)(jin)。將工裝(zhuang)安(an)裝(zhuang)到支撐板上(shang)，找平，將聯接螺栓擰上(shang)，稍稍擰緊(jin)(jin)一(yi)些。
首件(jian)加(jia)(jia)(jia)工(gong)(gong)，將待(dai)加(jia)(jia)(jia)工(gong)(gong)螺(luo)(luo)(luo)母(mu)(mu)從側(ce)面放(fang)到工(gong)(gong)裝(zhuang)(zhuang)里，以不超過(guo)工(gong)(gong)裝(zhuang)(zhuang)寬度為(wei)宜，擰緊(jin)(jin)(jin)(jin)緊(jin)(jin)(jin)(jin)定(ding)螺(luo)(luo)(luo)栓7，將螺(luo)(luo)(luo)母(mu)(mu)固(gu)定(ding)。找(zhao)正。上(shang)下(xia)移(yi)動(dong)(dong)(dong)(dong)聯(lian)接板(ban)(ban)(ban)5，垂直(zhi)車床(chuang)軸(zhou)線移(yi)動(dong)(dong)(dong)(dong)刀(dao)架(jia)中(zhong)滑板(ban)(ban)(ban)，確定(ding)鉆(zhan)(zhan)套中(zhong)心與車床(chuang)回轉中(zhong)心的(de)位(wei)置(zhi)，確認兩者(zhe)重合(he)后(hou)，擰緊(jin)(jin)(jin)(jin)聯(lian)接螺(luo)(luo)(luo)栓6，鎖緊(jin)(jin)(jin)(jin)滑板(ban)(ban)(ban)，找(zhao)正結(jie)束。加(jia)(jia)(jia)工(gong)(gong)開(kai)(kai)始(shi)，主軸(zhou)帶動(dong)(dong)(dong)(dong)鉆(zhan)(zhan)頭(tou)旋轉，向前(qian)軸(zhou)向移(yi)動(dong)(dong)(dong)(dong)刀(dao)架(jia)小滑板(ban)(ban)(ban)，鉆(zhan)(zhan)頭(tou)通(tong)過(guo)鉆(zhan)(zhan)套引導開(kai)(kai)始(shi)鉆(zhan)(zhan)孔(kong)操作(zuo)。鉆(zhan)(zhan)頭(tou)透(tou)過(guo)聯(lian)接板(ban)(ban)(ban)上(shang)的(de)孔(kong)后(hou)，確定(ding)鉆(zhan)(zhan)孔(kong)結(jie)束。向后(hou)移(yi)動(dong)(dong)(dong)(dong)刀(dao)架(jia)小滑板(ban)(ban)(ban)，鉆(zhan)(zhan)頭(tou)離開(kai)(kai)工(gong)(gong)裝(zhuang)(zhuang)，松開(kai)(kai)緊(jin)(jin)(jin)(jin)定(ding)螺(luo)(luo)(luo)栓7，從側(ce)面放(fang)入第二(er)個螺(luo)(luo)(luo)母(mu)(mu)，首件(jian)螺(luo)(luo)(luo)母(mu)(mu)被擠出。再次(ci)擰緊(jin)(jin)(jin)(jin)緊(jin)(jin)(jin)(jin)定(ding)螺(luo)(luo)(luo)栓7，鎖緊(jin)(jin)(jin)(jin)螺(luo)(luo)(luo)母(mu)(mu)。移(yi)動(dong)(dong)(dong)(dong)刀(dao)架(jia)小滑板(ban)(ban)(ban)，第二(er)次(ci)加(jia)(jia)(jia)工(gong)(gong)開(kai)(kai)始(shi)。整個加(jia)(jia)(jia)工(gong)(gong)過(guo)程鉆(zhan)(zhan)頭(tou)始(shi)終保持旋轉，僅是(shi)刀(dao)架(jia)作(zuo)軸(zhou)向移(yi)動(dong)(dong)(dong)(dong)，由于首件(jian)加(jia)(jia)(jia)工(gong)(gong)找(zhao)正已完成，后(hou)續(xu)加(jia)(jia)(jia)工(gong)(gong)無需找(zhao)正過(guo)程，大(da)大(da)提高(gao)了加(jia)(jia)(jia)工(gong)(gong)效率。
在攻制內螺(luo)紋(wen)(wen)時(shi)，為防止由于機床絲杠與絲錐之間產生(sheng)的(de)傳(chuan)動誤差，造成(cheng)螺(luo)紋(wen)(wen)亂扣(kou)現象的(de)發(fa)生(sheng)，設(she)計專(zhuan)用攻螺(luo)紋(wen)(wen)工(gong)裝卡頭，如圖(tu)2所示。
圖(tu)2 絲錐攻螺紋工(gong)裝設計簡(jian)圖(tu)
1.絲錐 2.鉆套 3.緊定螺栓4.卡箍 5.圓(yuan)柱(zhu)銷
卡(ka)(ka)箍4一端安裝在(zai)三爪自(zi)定(ding)心卡(ka)(ka)盤上，另一端里(li)孔安裝鉆(zhan)套(tao)(tao)，它既是鉆(zhan)套(tao)(tao)的安裝套(tao)(tao)，又是鉆(zhan)套(tao)(tao)的導向套(tao)(tao)，兩者(zhe)配合為(wei)小間(jian)隙配合。在(zai)卡(ka)(ka)箍上軸向穿(chuan)透加(jia)工(gong)長(chang)孔，用(yong)(yong)以(yi)與圓柱銷(xiao)5配合使(shi)用(yong)(yong)。鉆(zhan)套(tao)(tao)用(yong)(yong)于夾持絲錐(zhui)，該零件采用(yong)(yong)45鋼材料，淬(cui)火處理。圓柱銷(xiao)5與鉆(zhan)套(tao)(tao)為(wei)過盈配合，起到帶動(dong)(dong)鉆(zhan)套(tao)(tao)旋轉(zhuan)作(zuo)用(yong)(yong)，并(bing)與卡(ka)(ka)箍上長(chang)孔相配合，能使(shi)鉆(zhan)套(tao)(tao)存在(zai)4mm的軸向竄動(dong)(dong)，用(yong)(yong)以(yi)消除傳動(dong)(dong)誤差，防止亂扣。緊(jin)定(ding)螺栓(shuan)3主(zhu)要(yao)起緊(jin)固絲錐(zhui)作(zuo)用(yong)(yong)。
攻(gong)螺(luo)(luo)紋套扣加工時(shi)，首(shou)先卸下鉆頭(tou)，將(jiang)攻(gong)螺(luo)(luo)紋工裝卡頭(tou)安(an)裝在三爪自定心卡盤上，鎖緊。安(an)裝在刀架上的(de)工裝位置保持不變，將(jiang)準備攻(gong)螺(luo)(luo)紋的(de)螺(luo)(luo)母(mu)送入工裝中，擰緊圖1中的(de)緊定螺(luo)(luo)栓7，即可(ke)攻(gong)螺(luo)(luo)紋。主軸帶動絲(si)錐(zhui)(zhui)轉動，刀架向前移動，當絲(si)錐(zhui)(zhui)的(de)切削部(bu)分穿(chuan)過螺(luo)(luo)母(mu)以(yi)后，主軸反轉退刀，刀架向后移動，第一個(ge)螺(luo)(luo)母(mu)攻(gong)螺(luo)(luo)紋完成。接著送入第二個(ge)螺(luo)(luo)母(mu)，同時(shi)擠出第一個(ge)螺(luo)(luo)母(mu)，重復(fu)上述操(cao)作，如此循環即可(ke)。
同樣的(de)(de)車(che)床加工方式，利(li)用簡(jian)單工裝，改變刀具和(he)零件的(de)(de)安裝位置，實現了刀具作切(qie)削(xue)運(yun)(yun)動、零件作進給運(yun)(yun)動，加快了切(qie)削(xue)速度(du)，簡(jian)化了操作程序，省力省時，加工效率大為提高。