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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

      模具(ju)(ju)配(pei)件(jian)(jian)是(shi)指(zhi)裝配(pei)模具(ju)(ju)的(de)零(ling)件(jian)(jian)或(huo)部件(jian)(jian)；也可以指(zhi)損(sun)壞后重新安裝上的(de)模具(ju)(ju)零(ling)件(jian)(jian)或(huo)部件(jian)(jian)。精(jing)(jing)(jing)密模具(ju)(ju)一般是(shi)由(you)許多零(ling)件(jian)(jian)構(gou)成，可以分為(wei)兩類：工(gong)(gong)藝零(ling)件(jian)(jian)和結構(gou)零(ling)件(jian)(jian)。工(gong)(gong)藝零(ling)件(jian)(jian)直接(jie)對(dui)成型(xing)產品質(zhi)量造成影響，工(gong)(gong)藝零(ling)件(jian)(jian)的(de)決勝品質(zhi)在(zai)當下的(de)精(jing)(jing)(jing)密模具(ju)(ju)配(pei)件(jian)(jian)均用(yong)精(jing)(jing)(jing)加工(gong)(gong)手段來完成。精(jing)(jing)(jing)密加工(gong)(gong)過程關系到精(jing)(jing)(jing)密模具(ju)(ju)的(de)壽命和成型(xing)產品，在(zai)精(jing)(jing)(jing)密模具(ju)(ju)配(pei)件(jian)(jian)加工(gong)(gong)中的(de)精(jing)(jing)(jing)加工(gong)(gong)階段除(chu)采用(yong)慢走(zou)絲線切(qie)割、電火花(hua)成型(xing)等(deng)工(gong)(gong)藝手段外，另采用(yong)的(de)方法(fa)即是(shi)在(zai)半精(jing)(jing)(jing)加工(gong)(gong)后，熱處理基礎上磨(mo)削加工(gong)(gong)。

       那么在(zai)精(jing)(jing)密(mi)模(mo)具配(pei)件(jian)(jian)(jian)加工(gong)(gong)的(de)磨(mo)(mo)削加工(gong)(gong)階(jie)段需要(yao)控制好(hao)(hao)零(ling)件(jian)(jian)(jian)的(de)變形(xing)、內應(ying)(ying)力、形(xing)狀(zhuang)公差及尺寸精(jing)(jing)度等許多技術參數。在(zai)具體(ti)的(de)生產實踐中(zhong)，操作困難較多，但是在(zai)東(dong)莞市時利(li)和15年的(de)精(jing)(jing)密(mi)加工(gong)(gong)經(jing)驗中(zhong)可以(yi)總結分析的(de)出(chu)可以(yi)借鑒的(de)方法：一、從模(mo)具的(de)精(jing)(jing)加工(gong)(gong)過程(cheng)(cheng)控制精(jing)(jing)密(mi)模(mo)具配(pei)件(jian)(jian)(jian)加工(gong)(gong)，我們(men)可以(yi)針對(dui)不同(tong)的(de)模(mo)具零(ling)件(jian)(jian)(jian)、不同(tong)的(de)材(cai)質(zhi)、不同(tong)的(de)形(xing)狀(zhuang)和不同(tong)的(de)技術要(yao)求進行適(shi)應(ying)(ying)性加工(gong)(gong)，提供選擇性方案。通過對(dui)加工(gong)(gong)過程(cheng)(cheng)的(de)控制，達(da)到(dao)更好(hao)(hao)的(de)加工(gong)(gong)效果和經(jing)濟性是大多數精(jing)(jing)密(mi)模(mo)具配(pei)件(jian)(jian)(jian)加工(gong)(gong)企業(ye)關注的(de)重點。精(jing)(jing)密(mi)模(mo)具配(pei)件(jian)(jian)(jian)加工(gong)(gong)的(de)工(gong)(gong)藝過程(cheng)(cheng)一般為：粗加工(gong)(gong)—半精(jing)(jing)加工(gong)(gong)—（淬(cui)火、調質(zhi)）—精(jing)(jing)密(mi)磨(mo)(mo)削—電加工(gong)(gong)—鉗工(gong)(gong)修整—組裝加工(gong)(gong)。

       在(zai)(zai)精(jing)密(mi)模具配件(jian)加(jia)工(gong)(gong)(gong)的(de)磨(mo)(mo)(mo)削(xue)(xue)加(jia)工(gong)(gong)(gong)階(jie)段主要(yao)(yao)采用的(de)機床(chuang)有三種主要(yao)(yao)類型：平面磨(mo)(mo)(mo)床(chuang)、內外圓磨(mo)(mo)(mo)床(chuang)及工(gong)(gong)(gong)具成(cheng)型磨(mo)(mo)(mo)削(xue)(xue)機床(chuang)。精(jing)加(jia)工(gong)(gong)(gong)磨(mo)(mo)(mo)削(xue)(xue)時(shi)要(yao)(yao)嚴格控制磨(mo)(mo)(mo)削(xue)(xue)變形和磨(mo)(mo)(mo)削(xue)(xue)裂紋的(de)出現，哪怕是(shi)工(gong)(gong)(gong)件(jian)表面的(de)顯微(wei)裂紋，否則在(zai)(zai)后續(xu)的(de)工(gong)(gong)(gong)作(zuo)中也會漸漸顯露出來。因此，精(jing)密(mi)磨(mo)(mo)(mo)削(xue)(xue)時(shi)的(de)進刀量(liang)要(yao)(yao)小，磨(mo)(mo)(mo)削(xue)(xue)中冷(leng)卻要(yao)(yao)充分，盡(jin)量(liang)選擇冷(leng)卻液介質，加(jia)工(gong)(gong)(gong)余(yu)量(liang)在(zai)(zai)0.01mm內的(de)零件(jian)要(yao)(yao)盡(jin)量(liang)恒溫(wen)磨(mo)(mo)(mo)削(xue)(xue)。

       磨(mo)(mo)削(xue)(xue)加工(gong)(gong)(gong)(gong)(gong)中要及時(shi)修整砂(sha)(sha)輪(lun)(lun)，保持砂(sha)(sha)輪(lun)(lun)的(de)(de)銳利，當砂(sha)(sha)輪(lun)(lun)鈍(dun)化后(hou)會在(zai)工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(jian)(jian)表面(mian)(mian)滑擦、刻劃、擠(ji)壓，造(zao)成(cheng)工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(jian)(jian)表面(mian)(mian)燒(shao)傷、顯微裂痕或產生溝槽，對以(yi)后(hou)的(de)(de)使用(yong)(yong)顯著(zhu)地降低效用(yong)(yong)。盤類、板(ban)類零件(jian)(jian)(jian)(jian)(jian)的(de)(de)加工(gong)(gong)(gong)(gong)(gong)大(da)(da)部(bu)分采用(yong)(yong)平面(mian)(mian)磨(mo)(mo)床(chuang)加工(gong)(gong)(gong)(gong)(gong)，加工(gong)(gong)(gong)(gong)(gong)長(chang)而薄(bo)的(de)(de)薄(bo)板(ban)件(jian)(jian)(jian)(jian)(jian)時(shi)，有一(yi)定的(de)(de)加工(gong)(gong)(gong)(gong)(gong)難度(du)。加工(gong)(gong)(gong)(gong)(gong)前(qian)在(zai)磨(mo)(mo)床(chuang)磁(ci)力臺的(de)(de)強力吸引下，工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(jian)(jian)原先存在(zai)某種彎曲產生平直形(xing)變，貼近于工(gong)(gong)(gong)(gong)(gong)作臺表面(mian)(mian)，待磨(mo)(mo)削(xue)(xue)后(hou)，工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(jian)(jian)又(you)在(zai)原應力作用(yong)(yong)下變形(xing)回復，測量(liang)板(ban)件(jian)(jian)(jian)(jian)(jian)厚度(du)時(shi)顯示(shi)一(yi)致(zhi)，但由于變形(xing)回復，平面(mian)(mian)度(du)達不到精密模(mo)具配件(jian)(jian)(jian)(jian)(jian)加工(gong)(gong)(gong)(gong)(gong)應該的(de)(de)要求，解決的(de)(de)方(fang)法(fa)是(shi)磨(mo)(mo)削(xue)(xue)前(qian)以(yi)等高墊(dian)鐵墊(dian)在(zai)工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(jian)(jian)下面(mian)(mian)，四周(zhou)用(yong)(yong)擋塊擋住工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(jian)(jian)防止走動(dong)，磨(mo)(mo)削(xue)(xue)時(shi)磨(mo)(mo)頭進刀量(liang)要小(xiao)，用(yong)(yong)多(duo)次(ci)走刀方(fang)式完成(cheng)基(ji)準平面(mian)(mian)，基(ji)準平面(mian)(mian)加工(gong)(gong)(gong)(gong)(gong)好(hao)一(yi)面(mian)(mian)后(hou)，可(ke)用(yong)(yong)這(zhe)一(yi)基(ji)準平面(mian)(mian)吸附(fu)在(zai)磁(ci)力臺上(shang)，通(tong)過如上(shang)所述的(de)(de)磨(mo)(mo)削(xue)(xue)方(fang)法(fa)可(ke)改善(shan)大(da)(da)部(bu)分工(gong)(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(jian)(jian)平面(mian)(mian)度(du)。