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精密模具零件加工的磨削加工工藝

      精密模具零件加工的磨削加工工藝

      模(mo)具(ju)(ju)(ju)(ju)配(pei)件(jian)(jian)(jian)(jian)是(shi)指裝配(pei)模(mo)具(ju)(ju)(ju)(ju)的(de)(de)零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)或部(bu)件(jian)(jian)(jian)(jian)；也可以指損壞后重(zhong)新安裝上的(de)(de)模(mo)具(ju)(ju)(ju)(ju)零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)或部(bu)件(jian)(jian)(jian)(jian)。精(jing)密模(mo)具(ju)(ju)(ju)(ju)一般是(shi)由許多(duo)零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)構成(cheng)，可以分為兩類：工(gong)(gong)藝零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)和(he)結構零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)。工(gong)(gong)藝零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)直接對(dui)成(cheng)型(xing)產品質量造成(cheng)影響，工(gong)(gong)藝零(ling)(ling)(ling)件(jian)(jian)(jian)(jian)的(de)(de)決勝品質在當下(xia)的(de)(de)精(jing)密模(mo)具(ju)(ju)(ju)(ju)配(pei)件(jian)(jian)(jian)(jian)均用(yong)精(jing)加(jia)工(gong)(gong)手段(duan)(duan)來完成(cheng)。精(jing)密加(jia)工(gong)(gong)過程關系到精(jing)密模(mo)具(ju)(ju)(ju)(ju)的(de)(de)壽命和(he)成(cheng)型(xing)產品，在精(jing)密模(mo)具(ju)(ju)(ju)(ju)配(pei)件(jian)(jian)(jian)(jian)加(jia)工(gong)(gong)中的(de)(de)精(jing)加(jia)工(gong)(gong)階段(duan)(duan)除采(cai)用(yong)慢(man)走絲線切割、電(dian)火花(hua)成(cheng)型(xing)等工(gong)(gong)藝手段(duan)(duan)外，另采(cai)用(yong)的(de)(de)方法即是(shi)在半(ban)精(jing)加(jia)工(gong)(gong)后，熱處理基礎上磨削加(jia)工(gong)(gong)。

       那么在(zai)精(jing)密(mi)模(mo)具(ju)(ju)(ju)配件(jian)(jian)加(jia)工(gong)(gong)(gong)的(de)(de)(de)(de)磨(mo)削加(jia)工(gong)(gong)(gong)階(jie)段(duan)需要控制(zhi)好(hao)零(ling)件(jian)(jian)的(de)(de)(de)(de)變形、內應力(li)、形狀公差及(ji)尺寸精(jing)度等許多(duo)技(ji)術參(can)數。在(zai)具(ju)(ju)(ju)體(ti)的(de)(de)(de)(de)生產實踐中，操作困難較多(duo)，但是(shi)在(zai)東莞市(shi)時利(li)和(he)15年的(de)(de)(de)(de)精(jing)密(mi)加(jia)工(gong)(gong)(gong)經驗中可以總結分析的(de)(de)(de)(de)出可以借鑒的(de)(de)(de)(de)方(fang)法：一、從模(mo)具(ju)(ju)(ju)的(de)(de)(de)(de)精(jing)加(jia)工(gong)(gong)(gong)過(guo)程控制(zhi)精(jing)密(mi)模(mo)具(ju)(ju)(ju)配件(jian)(jian)加(jia)工(gong)(gong)(gong)，我們可以針對不同(tong)的(de)(de)(de)(de)模(mo)具(ju)(ju)(ju)零(ling)件(jian)(jian)、不同(tong)的(de)(de)(de)(de)材(cai)質、不同(tong)的(de)(de)(de)(de)形狀和(he)不同(tong)的(de)(de)(de)(de)技(ji)術要求進(jin)行適應性(xing)加(jia)工(gong)(gong)(gong)，提供(gong)選擇性(xing)方(fang)案。通過(guo)對加(jia)工(gong)(gong)(gong)過(guo)程的(de)(de)(de)(de)控制(zhi)，達(da)到(dao)更好(hao)的(de)(de)(de)(de)加(jia)工(gong)(gong)(gong)效果(guo)和(he)經濟(ji)性(xing)是(shi)大(da)多(duo)數精(jing)密(mi)模(mo)具(ju)(ju)(ju)配件(jian)(jian)加(jia)工(gong)(gong)(gong)企業關注(zhu)的(de)(de)(de)(de)重(zhong)點。精(jing)密(mi)模(mo)具(ju)(ju)(ju)配件(jian)(jian)加(jia)工(gong)(gong)(gong)的(de)(de)(de)(de)工(gong)(gong)(gong)藝過(guo)程一般為：粗加(jia)工(gong)(gong)(gong)—半精(jing)加(jia)工(gong)(gong)(gong)—（淬火、調質）—精(jing)密(mi)磨(mo)削—電加(jia)工(gong)(gong)(gong)—鉗工(gong)(gong)(gong)修整—組裝(zhuang)加(jia)工(gong)(gong)(gong)。

       在(zai)精(jing)(jing)密模具配件加工(gong)(gong)(gong)的(de)磨(mo)削加工(gong)(gong)(gong)階段主要(yao)采用的(de)機(ji)床(chuang)(chuang)有三種主要(yao)類型：平面磨(mo)床(chuang)(chuang)、內外圓磨(mo)床(chuang)(chuang)及工(gong)(gong)(gong)具成型磨(mo)削機(ji)床(chuang)(chuang)。精(jing)(jing)加工(gong)(gong)(gong)磨(mo)削時要(yao)嚴格控制磨(mo)削變(bian)形和磨(mo)削裂(lie)紋的(de)出(chu)現，哪怕是工(gong)(gong)(gong)件表面的(de)顯微裂(lie)紋，否則在(zai)后(hou)續的(de)工(gong)(gong)(gong)作中也會(hui)漸(jian)漸(jian)顯露出(chu)來。因此，精(jing)(jing)密磨(mo)削時的(de)進(jin)刀(dao)量要(yao)小，磨(mo)削中冷卻要(yao)充分，盡量選擇冷卻液介質，加工(gong)(gong)(gong)余(yu)量在(zai)0.01mm內的(de)零件要(yao)盡量恒溫(wen)磨(mo)削。

       磨(mo)(mo)削(xue)(xue)加(jia)工(gong)(gong)(gong)中要(yao)及(ji)時修整(zheng)砂輪，保持砂輪的(de)(de)銳(rui)利，當砂輪鈍化后會在(zai)工(gong)(gong)(gong)件表(biao)(biao)面(mian)(mian)(mian)滑擦、刻(ke)劃(hua)、擠壓(ya)，造成工(gong)(gong)(gong)件表(biao)(biao)面(mian)(mian)(mian)燒傷、顯微(wei)裂痕或產(chan)生(sheng)溝槽，對以后的(de)(de)使用(yong)顯著(zhu)地降低效用(yong)。盤類、板類零件的(de)(de)加(jia)工(gong)(gong)(gong)大部(bu)分采用(yong)平(ping)(ping)面(mian)(mian)(mian)磨(mo)(mo)床加(jia)工(gong)(gong)(gong)，加(jia)工(gong)(gong)(gong)長而(er)薄(bo)的(de)(de)薄(bo)板件時，有一(yi)定(ding)的(de)(de)加(jia)工(gong)(gong)(gong)難度(du)。加(jia)工(gong)(gong)(gong)前在(zai)磨(mo)(mo)床磁力臺(tai)的(de)(de)強力吸(xi)引(yin)下，工(gong)(gong)(gong)件原先存在(zai)某種彎曲產(chan)生(sheng)平(ping)(ping)直形(xing)變(bian)，貼近于工(gong)(gong)(gong)作臺(tai)表(biao)(biao)面(mian)(mian)(mian)，待磨(mo)(mo)削(xue)(xue)后，工(gong)(gong)(gong)件又在(zai)原應力作用(yong)下變(bian)形(xing)回(hui)復，測量(liang)板件厚度(du)時顯示一(yi)致，但由于變(bian)形(xing)回(hui)復，平(ping)(ping)面(mian)(mian)(mian)度(du)達不到精密模具配件加(jia)工(gong)(gong)(gong)應該(gai)的(de)(de)要(yao)求，解決的(de)(de)方(fang)法是磨(mo)(mo)削(xue)(xue)前以等(deng)高(gao)墊(dian)鐵(tie)墊(dian)在(zai)工(gong)(gong)(gong)件下面(mian)(mian)(mian)，四周(zhou)用(yong)擋(dang)塊擋(dang)住工(gong)(gong)(gong)件防止走動，磨(mo)(mo)削(xue)(xue)時磨(mo)(mo)頭(tou)進(jin)刀量(liang)要(yao)小，用(yong)多次走刀方(fang)式完成基(ji)(ji)準平(ping)(ping)面(mian)(mian)(mian)，基(ji)(ji)準平(ping)(ping)面(mian)(mian)(mian)加(jia)工(gong)(gong)(gong)好一(yi)面(mian)(mian)(mian)后，可用(yong)這一(yi)基(ji)(ji)準平(ping)(ping)面(mian)(mian)(mian)吸(xi)附在(zai)磁力臺(tai)上(shang)，通過如上(shang)所述的(de)(de)磨(mo)(mo)削(xue)(xue)方(fang)法可改善大部(bu)分工(gong)(gong)(gong)件平(ping)(ping)面(mian)(mian)(mian)度(du)。