一:車削
車削中工(gong)件旋(xuan)轉,形(xing)成(cheng)主切(qie)削運動。刀(dao)具(ju)沿平行(xing)旋(xuan)轉軸線運動時,就(jiu)形(xing)成(cheng)內(nei)、外園柱面。刀(dao)具(ju)沿與軸線相(xiang)交的(de)斜線運動,就(jiu)形(xing)成(cheng)錐面。仿形(xing)車床(chuang)或數控車床(chuang)上,可(ke)(ke)以控制刀(dao)具(ju)沿著一條曲(qu)(qu)線進(jin)給,則形(xing)成(cheng)一特(te)定的(de)旋(xuan)轉曲(qu)(qu)面。采用成(cheng)型車刀(dao),橫(heng)向進(jin)給時,也可(ke)(ke)加工(gong)出旋(xuan)轉曲(qu)(qu)面來。車削還可(ke)(ke)以加工(gong)螺紋面、端平面及(ji)偏(pian)心軸等。車削加工(gong)精度一般為IT8—IT7,表面粗糙度為6.3—1.6μm。精車時,可(ke)(ke)達IT6—IT5,粗糙度可(ke)(ke)達0.4—0.1μm。車削的(de)生產率較(jiao)高(gao),切(qie)削過程比較(jiao)平穩(wen),刀(dao)具(ju)較(jiao)簡單。
二:銑削
主(zhu)切(qie)(qie)削(xue)(xue)運(yun)動(dong)(dong)是(shi)刀(dao)具(ju)的(de)(de)(de)(de)旋(xuan)轉。臥銑(xian)時,平面(mian)的(de)(de)(de)(de)形(xing)成(cheng)是(shi)由(you)銑(xian)刀(dao)的(de)(de)(de)(de)外園面(mian)上的(de)(de)(de)(de)刃形(xing)成(cheng)的(de)(de)(de)(de)。立(li)銑(xian)時,平面(mian)是(shi)由(you)銑(xian)刀(dao)的(de)(de)(de)(de)端(duan)面(mian)刃形(xing)成(cheng)的(de)(de)(de)(de)。提(ti)高(gao)銑(xian)刀(dao)的(de)(de)(de)(de)轉速(su)可以獲得較(jiao)(jiao)高(gao)的(de)(de)(de)(de)切(qie)(qie)削(xue)(xue)速(su)度(du),因此生產(chan)率較(jiao)(jiao)高(gao)。但由(you)于(yu)銑(xian)刀(dao)刀(dao)齒的(de)(de)(de)(de)切(qie)(qie)入(ru)、切(qie)(qie)出,形(xing)成(cheng)沖擊,切(qie)(qie)削(xue)(xue)過程容易產(chan)生振動(dong)(dong),因而限制了表(biao)面(mian)質量的(de)(de)(de)(de)提(ti)高(gao)。這種(zhong)沖擊,也加劇了刀(dao)具(ju)的(de)(de)(de)(de)磨損和破損,往(wang)往(wang)導(dao)致硬(ying)質合(he)金刀(dao)片(pian)的(de)(de)(de)(de)碎裂。在(zai)切(qie)(qie)離工(gong)件(jian)的(de)(de)(de)(de)一般時間(jian)內,可以得到一定冷卻(que),因此散熱條件(jian)較(jiao)(jiao)好(hao)。按照銑(xian)削(xue)(xue)時主(zhu)運(yun)動(dong)(dong)速(su)度(du)方(fang)向與工(gong)件(jian)進給(gei)方(fang)向的(de)(de)(de)(de)相(xiang)同或相(xiang)反,又分為順銑(xian)和逆銑(xian)。
順
銑
銑(xian)(xian)削(xue)力的水平分力與工(gong)件的進給(gei)(gei)方向相同,工(gong)件臺進給(gei)(gei)絲杠與固定螺(luo)母之間一(yi)般有(you)間隙存(cun)在,因(yin)此切(qie)削(xue)力容易引(yin)起(qi)工(gong)件和工(gong)作臺一(yi)起(qi)向前竄動,使進給(gei)(gei)量突然增大,引(yin)起(qi)打刀(dao)。在銑(xian)(xian)削(xue)鑄件或鍛件等表面有(you)硬(ying)度的工(gong)件時,順銑(xian)(xian)刀(dao)齒(chi)首(shou)先接觸工(gong)件硬(ying)皮,加劇了銑(xian)(xian)刀(dao)的磨損。
逆 銑
可以避免順銑(xian)時(shi)發生的(de)(de)(de)竄動現象。逆(ni)銑(xian)時(shi),切(qie)削厚度從(cong)零開始逐(zhu)漸增大(da),因而(er)刀(dao)刃開始經歷了一段在(zai)切(qie)削硬化的(de)(de)(de)已加工表面(mian)上擠(ji)壓滑行的(de)(de)(de)階段,加速了刀(dao)具的(de)(de)(de)磨損(sun)。同時(shi),逆(ni)銑(xian)時(shi),銑(xian)削力將工件上抬,易引起振動,這是(shi)逆(ni)銑(xian)的(de)(de)(de)不利之(zhi)處。
銑削(xue)的加工精(jing)度一般可達IT8—IT7,表面粗糙度為6.3—1.6μm。
普通(tong)銑(xian)削一般只能(neng)加(jia)工(gong)平面,用成形銑(xian)刀也可以加(jia)工(gong)出(chu)固定(ding)的(de)(de)曲面。數(shu)控(kong)銑(xian)床可以用軟件通(tong)過數(shu)控(kong)系統控(kong)制幾(ji)個軸按一定(ding)關系聯動,銑(xian)出(chu)復雜曲面來,這時一般采用球(qiu)頭銑(xian)刀。數(shu)控(kong)銑(xian)床對加(jia)工(gong)葉輪機械的(de)(de)葉片、模(mo)具(ju)的(de)(de)模(mo)芯和型腔等形狀(zhuang)復雜的(de)(de)工(gong)件,具(ju)有特(te)別(bie)重要的(de)(de)意義(yi)。
三:刨削
刨削時,刀具(ju)的往(wang)復直線運動為切(qie)削主運動。因此,刨削速度不可(ke)能(neng)太高(gao),生產率較(jiao)低。刨削比銑削平(ping)穩(wen),其加(jia)工精(jing)度一(yi)般(ban)可(ke)達IT8—IT7,表面(mian)粗糙度為Ra6.3—1.6μm,精(jing)刨平(ping)面(mian)度可(ke)達0.02/1000,表面(mian)粗糙度為0.8—0.4μm。
四:磨削
磨(mo)削(xue)(xue)以砂(sha)(sha)輪(lun)或(huo)其它(ta)磨(mo)具對(dui)工件進行加工,其主運動是砂(sha)(sha)輪(lun)的旋轉。砂(sha)(sha)輪(lun)的磨(mo)削(xue)(xue)過(guo)程實(shi)際上(shang)是磨(mo)粒(li)對(dui)工件表面的切(qie)削(xue)(xue)、刻(ke)削(xue)(xue)和滑擦三種作(zuo)用(yong)(yong)的綜合效應(ying)。磨(mo)削(xue)(xue)中,磨(mo)粒(li)本身也由尖銳逐漸磨(mo)鈍,使(shi)切(qie)削(xue)(xue)作(zuo)用(yong)(yong)變(bian)差,切(qie)削(xue)(xue)力變(bian)大。當切(qie)削(xue)(xue)力超過(guo)粘合劑強(qiang)度時(shi),圓(yuan)鈍的磨(mo)粒(li)脫落,露出一層新的磨(mo)粒(li),形成砂(sha)(sha)輪(lun)的“自銳性”。但切(qie)屑(xie)和碎(sui)磨(mo)粒(li)仍(reng)會(hui)將(jiang)砂(sha)(sha)輪(lun)阻塞。因(yin)而(er),磨(mo)削(xue)(xue)一定時(shi)間(jian)后,需(xu)用(yong)(yong)金(jin)剛石車刀等對(dui)砂(sha)(sha)輪(lun)進行修整。
磨(mo)(mo)削(xue)時,由于(yu)刀刃很多,所以(yi)(yi)加工(gong)時平(ping)(ping)穩、精度高。磨(mo)(mo)床是精加工(gong)機床,磨(mo)(mo)削(xue)精度可(ke)(ke)達(da)IT6—IT4,表面粗糙(cao)度Ra可(ke)(ke)達(da)1.25—0.01μm,甚(shen)至(zhi)可(ke)(ke)達(da)0.1—0.008μm。磨(mo)(mo)削(xue)的另一特(te)點是可(ke)(ke)以(yi)(yi)對淬硬(ying)的金屬(shu)材料進行(xing)加工(gong)。因此,往往作為(wei)最終加工(gong)工(gong)序。磨(mo)(mo)削(xue)時,產生(sheng)熱量(liang)大,需有(you)充分(fen)的切削(xue)液進行(xing)冷卻。按功能不(bu)同,磨(mo)(mo)削(xue)還可(ke)(ke)分(fen)為(wei)外園(yuan)磨(mo)(mo)、內(nei)孔磨(mo)(mo)、平(ping)(ping)磨(mo)(mo)等。
五:鉆削與鏜削
在(zai)(zai)鉆(zhan)(zhan)床上(shang)(shang)(shang),用鉆(zhan)(zhan)頭(tou)(tou)旋(xuan)轉鉆(zhan)(zhan)削孔(kong)(kong)(kong)(kong)(kong)(kong),是(shi)孔(kong)(kong)(kong)(kong)(kong)(kong)加(jia)工的(de)最常用方(fang)法。鉆(zhan)(zhan)削的(de)加(jia)工精(jing)度較低(di),一(yi)般(ban)只能達到(dao)IT10,表(biao)面粗(cu)糙(cao)(cao)度一(yi)般(ban)為(wei)12.5—6.3μm在(zai)(zai)鉆(zhan)(zhan)削后(hou)常常采(cai)用擴孔(kong)(kong)(kong)(kong)(kong)(kong)和(he)鉸(jiao)孔(kong)(kong)(kong)(kong)(kong)(kong)來進行(xing)(xing)半精(jing)加(jia)工和(he)精(jing)加(jia)工。擴孔(kong)(kong)(kong)(kong)(kong)(kong)采(cai)用擴孔(kong)(kong)(kong)(kong)(kong)(kong)鉆(zhan)(zhan),鉸(jiao)孔(kong)(kong)(kong)(kong)(kong)(kong)采(cai)用鉸(jiao)刀(dao)(dao)進行(xing)(xing)加(jia)工。鉸(jiao)削加(jia)工精(jing)度一(yi)般(ban)為(wei)IT9—IT6,表(biao)面粗(cu)糙(cao)(cao)度為(wei)Ra1.6—0.4μm。擴孔(kong)(kong)(kong)(kong)(kong)(kong)、鉸(jiao)孔(kong)(kong)(kong)(kong)(kong)(kong)時,鉆(zhan)(zhan)頭(tou)(tou)、鉸(jiao)刀(dao)(dao)一(yi)般(ban)順著原(yuan)底孔(kong)(kong)(kong)(kong)(kong)(kong)的(de)軸(zhou)線,無(wu)法提高孔(kong)(kong)(kong)(kong)(kong)(kong)的(de)位(wei)置(zhi)(zhi)精(jing)度。鏜(tang)孔(kong)(kong)(kong)(kong)(kong)(kong)可以較正(zheng)孔(kong)(kong)(kong)(kong)(kong)(kong)的(de)位(wei)置(zhi)(zhi)。鏜(tang)孔(kong)(kong)(kong)(kong)(kong)(kong)可在(zai)(zai)鏜(tang)床上(shang)(shang)(shang)或(huo)車床上(shang)(shang)(shang)進行(xing)(xing)。在(zai)(zai)鏜(tang)床上(shang)(shang)(shang)鏜(tang)孔(kong)(kong)(kong)(kong)(kong)(kong)時,鏜(tang)刀(dao)(dao)基(ji)本(ben)與車刀(dao)(dao)相同,不同之處是(shi)工件不動,鏜(tang)刀(dao)(dao)在(zai)(zai)旋(xuan)轉。鏜(tang)孔(kong)(kong)(kong)(kong)(kong)(kong)加(jia)工精(jing)度一(yi)般(ban)為(wei)IT9—IT7,表(biao)面粗(cu)糙(cao)(cao)度為(wei)Ra6.3—0.8mm。。
鉆削加(jia)工 鏜(tang)床(chuang)加(jia)工 車床(chuang)加(jia)工
六:齒面加工
齒(chi)輪(lun)齒(chi)面加(jia)工方法可分為(wei)兩大類:成(cheng)(cheng)形(xing)法和展成(cheng)(cheng)法。成(cheng)(cheng)形(xing)法加(jia)工齒(chi)面所(suo)使用的(de)機床(chuang)一般為(wei)普通銑(xian)(xian)床(chuang),刀具(ju)為(wei)成(cheng)(cheng)形(xing)銑(xian)(xian)刀,需要兩個(ge)簡單成(cheng)(cheng)形(xing)運動:刀具(ju)的(de)旋(xuan)轉運動和直線移動。展成(cheng)(cheng)法加(jia)工齒(chi)面的(de)常(chang)用機床(chuang)有(you)滾齒(chi)機、插(cha)齒(chi)機等。
七:復雜曲面加工
三(san)維(wei)曲(qu)(qu)面(mian)(mian)的切削(xue)加(jia)工(gong)(gong)(gong),主(zhu)要采(cai)用(yong)(yong)仿(fang)形(xing)銑(xian)和數(shu)控銑(xian)的方法(fa)(fa)或特種加(jia)工(gong)(gong)(gong)方法(fa)(fa)(見(jian)本節(jie)八)。仿(fang)形(xing)銑(xian)必須有(you)原(yuan)型(xing)作為(wei)靠模。加(jia)工(gong)(gong)(gong)中(zhong)球(qiu)頭(tou)(tou)(tou)(tou)(tou)仿(fang)形(xing)頭(tou)(tou)(tou)(tou)(tou),一(yi)直以一(yi)定壓力(li)接觸原(yuan)型(xing)曲(qu)(qu)面(mian)(mian)。仿(fang)形(xing)頭(tou)(tou)(tou)(tou)(tou)的運(yun)動(dong)變換為(wei)電感量,加(jia)工(gong)(gong)(gong)放大控制銑(xian)床三(san)個軸的運(yun)動(dong),形(xing)成刀(dao)(dao)頭(tou)(tou)(tou)(tou)(tou)沿曲(qu)(qu)面(mian)(mian)運(yun)動(dong)的軌跡(ji)。銑(xian)刀(dao)(dao)多(duo)采(cai)用(yong)(yong)與(yu)仿(fang)形(xing)頭(tou)(tou)(tou)(tou)(tou)等半(ban)徑(jing)的球(qiu)頭(tou)(tou)(tou)(tou)(tou)銑(xian)刀(dao)(dao)。數(shu)控技術的出現為(wei)曲(qu)(qu)面(mian)(mian)加(jia)工(gong)(gong)(gong)提供了更有(you)效(xiao)的方法(fa)(fa)。在(zai)(zai)數(shu)控銑(xian)床或加(jia)工(gong)(gong)(gong)中(zhong)心上加(jia)工(gong)(gong)(gong)時(shi),是(shi)通過球(qiu)頭(tou)(tou)(tou)(tou)(tou)銑(xian)刀(dao)(dao)逐點按坐標(biao)值(zhi)加(jia)工(gong)(gong)(gong)而(er)成。采(cai)用(yong)(yong)加(jia)工(gong)(gong)(gong)中(zhong)心加(jia)工(gong)(gong)(gong)復雜(za)曲(qu)(qu)面(mian)(mian)的優點是(shi):加(jia)工(gong)(gong)(gong)中(zhong)心上有(you)刀(dao)(dao)庫,配備幾十把刀(dao)(dao)具。曲(qu)(qu)面(mian)(mian)的粗、精加(jia)工(gong)(gong)(gong),可(ke)用(yong)(yong)不同(tong)刀(dao)(dao)具對(dui)(dui)凹曲(qu)(qu)面(mian)(mian)的不同(tong)曲(qu)(qu)率半(ban)徑(jing),也可(ke)選用(yong)(yong)適當的刀(dao)(dao)具。同(tong)時(shi),可(ke)在(zai)(zai)一(yi)次安裝中(zhong)加(jia)工(gong)(gong)(gong)各種輔助表(biao)面(mian)(mian),如孔(kong)、螺紋、槽等。這(zhe)樣充(chong)分保證了各表(biao)面(mian)(mian)的相對(dui)(dui)位置精度。
八:特種加工
特種加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)方(fang)法(fa)是指(zhi)區別于傳統切削(xue)加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)方(fang)法(fa),利用化學(xue)(xue)、物理(電(dian)(dian)、聲、光、熱、磁(ci))或電(dian)(dian)化學(xue)(xue)方(fang)法(fa)對工(gong)(gong)(gong)(gong)件材(cai)料進行加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)的一系(xi)列加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)方(fang)法(fa)的總稱。這些加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)方(fang)法(fa)包括(kuo):化學(xue)(xue)加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(CHM)、電(dian)(dian)化學(xue)(xue)加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(ECM)、電(dian)(dian)化學(xue)(xue)機械加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(ECMM)、電(dian)(dian)火花加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(EDM)、電(dian)(dian)接觸加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(RHM)、超聲波(bo)加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(USM)、激光束(shu)加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(LBM)、離子(zi)(zi)束(shu)加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(IBM)、電(dian)(dian)子(zi)(zi)束(shu)加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(EBM)、等離子(zi)(zi)體加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(PAM)、電(dian)(dian)液加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(EHM)、磨料流加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(AFM)、磨料噴射加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(AJM)、液體噴射加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(HDM)及各(ge)類復合加(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)等。
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