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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)配(pei)件是(shi)指裝(zhuang)配(pei)模(mo)具(ju)(ju)的(de)零(ling)(ling)件或(huo)部件；也(ye)可以(yi)指損壞后重(zhong)新安裝(zhuang)上的(de)模(mo)具(ju)(ju)零(ling)(ling)件或(huo)部件。精(jing)密模(mo)具(ju)(ju)一般(ban)是(shi)由許多零(ling)(ling)件構成(cheng)(cheng)，可以(yi)分為(wei)兩類：工(gong)藝(yi)零(ling)(ling)件和結(jie)構零(ling)(ling)件。工(gong)藝(yi)零(ling)(ling)件直(zhi)接(jie)對(dui)成(cheng)(cheng)型產品(pin)質量造成(cheng)(cheng)影響，工(gong)藝(yi)零(ling)(ling)件的(de)決勝品(pin)質在(zai)(zai)(zai)當下(xia)的(de)精(jing)密模(mo)具(ju)(ju)配(pei)件均用精(jing)加(jia)(jia)(jia)工(gong)手段來(lai)完成(cheng)(cheng)。精(jing)密加(jia)(jia)(jia)工(gong)過程關系到(dao)精(jing)密模(mo)具(ju)(ju)的(de)壽(shou)命和成(cheng)(cheng)型產品(pin)，在(zai)(zai)(zai)精(jing)密模(mo)具(ju)(ju)配(pei)件加(jia)(jia)(jia)工(gong)中的(de)精(jing)加(jia)(jia)(jia)工(gong)階段除采(cai)用慢走絲線切(qie)割、電(dian)火花(hua)成(cheng)(cheng)型等工(gong)藝(yi)手段外，另采(cai)用的(de)方法即是(shi)在(zai)(zai)(zai)半精(jing)加(jia)(jia)(jia)工(gong)后，熱(re)處理基礎上磨削加(jia)(jia)(jia)工(gong)。

       那么在(zai)精(jing)密模(mo)(mo)(mo)具(ju)配件(jian)加(jia)工(gong)(gong)(gong)的(de)(de)(de)(de)(de)(de)磨削(xue)加(jia)工(gong)(gong)(gong)階段需要(yao)控制好零件(jian)的(de)(de)(de)(de)(de)(de)變形(xing)、內應(ying)力、形(xing)狀(zhuang)(zhuang)公(gong)差及尺寸(cun)精(jing)度等許多(duo)技術參數。在(zai)具(ju)體的(de)(de)(de)(de)(de)(de)生(sheng)產實踐中，操作困難(nan)較多(duo)，但是在(zai)東(dong)莞市時(shi)利(li)和(he)15年的(de)(de)(de)(de)(de)(de)精(jing)密加(jia)工(gong)(gong)(gong)經驗中可(ke)以(yi)總結(jie)分析的(de)(de)(de)(de)(de)(de)出(chu)可(ke)以(yi)借鑒的(de)(de)(de)(de)(de)(de)方法(fa)：一(yi)、從模(mo)(mo)(mo)具(ju)的(de)(de)(de)(de)(de)(de)精(jing)加(jia)工(gong)(gong)(gong)過(guo)程(cheng)控制精(jing)密模(mo)(mo)(mo)具(ju)配件(jian)加(jia)工(gong)(gong)(gong)，我們可(ke)以(yi)針對(dui)(dui)不(bu)(bu)(bu)同(tong)的(de)(de)(de)(de)(de)(de)模(mo)(mo)(mo)具(ju)零件(jian)、不(bu)(bu)(bu)同(tong)的(de)(de)(de)(de)(de)(de)材質(zhi)、不(bu)(bu)(bu)同(tong)的(de)(de)(de)(de)(de)(de)形(xing)狀(zhuang)(zhuang)和(he)不(bu)(bu)(bu)同(tong)的(de)(de)(de)(de)(de)(de)技術要(yao)求進(jin)行(xing)適應(ying)性(xing)加(jia)工(gong)(gong)(gong)，提供選擇性(xing)方案。通過(guo)對(dui)(dui)加(jia)工(gong)(gong)(gong)過(guo)程(cheng)的(de)(de)(de)(de)(de)(de)控制，達到更好的(de)(de)(de)(de)(de)(de)加(jia)工(gong)(gong)(gong)效果(guo)和(he)經濟性(xing)是大多(duo)數精(jing)密模(mo)(mo)(mo)具(ju)配件(jian)加(jia)工(gong)(gong)(gong)企業關注(zhu)的(de)(de)(de)(de)(de)(de)重點(dian)。精(jing)密模(mo)(mo)(mo)具(ju)配件(jian)加(jia)工(gong)(gong)(gong)的(de)(de)(de)(de)(de)(de)工(gong)(gong)(gong)藝(yi)過(guo)程(cheng)一(yi)般為：粗加(jia)工(gong)(gong)(gong)—半精(jing)加(jia)工(gong)(gong)(gong)—（淬火、調(diao)質(zhi)）—精(jing)密磨削(xue)—電加(jia)工(gong)(gong)(gong)—鉗工(gong)(gong)(gong)修整—組裝加(jia)工(gong)(gong)(gong)。

       在(zai)(zai)(zai)精(jing)密模具配件加(jia)工(gong)的(de)(de)磨(mo)(mo)(mo)(mo)(mo)削(xue)(xue)加(jia)工(gong)階段(duan)主要(yao)(yao)(yao)(yao)采(cai)用的(de)(de)機(ji)床(chuang)(chuang)有(you)三種主要(yao)(yao)(yao)(yao)類(lei)型：平面磨(mo)(mo)(mo)(mo)(mo)床(chuang)(chuang)、內(nei)外(wai)圓磨(mo)(mo)(mo)(mo)(mo)床(chuang)(chuang)及工(gong)具成型磨(mo)(mo)(mo)(mo)(mo)削(xue)(xue)機(ji)床(chuang)(chuang)。精(jing)加(jia)工(gong)磨(mo)(mo)(mo)(mo)(mo)削(xue)(xue)時要(yao)(yao)(yao)(yao)嚴格控(kong)制磨(mo)(mo)(mo)(mo)(mo)削(xue)(xue)變形和磨(mo)(mo)(mo)(mo)(mo)削(xue)(xue)裂(lie)紋(wen)的(de)(de)出現，哪怕(pa)是(shi)工(gong)件表面的(de)(de)顯(xian)微(wei)裂(lie)紋(wen)，否則(ze)在(zai)(zai)(zai)后續(xu)的(de)(de)工(gong)作(zuo)中也(ye)會(hui)漸漸顯(xian)露出來。因此(ci)，精(jing)密磨(mo)(mo)(mo)(mo)(mo)削(xue)(xue)時的(de)(de)進刀量(liang)要(yao)(yao)(yao)(yao)小，磨(mo)(mo)(mo)(mo)(mo)削(xue)(xue)中冷(leng)(leng)卻(que)要(yao)(yao)(yao)(yao)充(chong)分，盡量(liang)選(xuan)擇冷(leng)(leng)卻(que)液(ye)介質，加(jia)工(gong)余量(liang)在(zai)(zai)(zai)0.01mm內(nei)的(de)(de)零件要(yao)(yao)(yao)(yao)盡量(liang)恒溫(wen)磨(mo)(mo)(mo)(mo)(mo)削(xue)(xue)。

       磨削(xue)(xue)加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)中要(yao)(yao)及時(shi)修整砂輪(lun)(lun)(lun)，保(bao)持(chi)砂輪(lun)(lun)(lun)的(de)(de)銳利(li)，當砂輪(lun)(lun)(lun)鈍化(hua)后會在工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)表面滑擦、刻劃(hua)、擠壓，造成(cheng)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)表面燒傷、顯(xian)微(wei)裂痕或產(chan)生溝槽，對以后的(de)(de)使用(yong)顯(xian)著地降低效用(yong)。盤(pan)類、板(ban)類零件(jian)(jian)的(de)(de)加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)大部分(fen)采用(yong)平(ping)(ping)面磨床加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)，加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)長而薄(bo)的(de)(de)薄(bo)板(ban)件(jian)(jian)時(shi)，有一(yi)(yi)定的(de)(de)加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)難度。加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)前在磨床磁力臺的(de)(de)強力吸引(yin)下，工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)原先存在某種彎(wan)曲產(chan)生平(ping)(ping)直形變，貼近于工(gong)(gong)(gong)(gong)(gong)(gong)(gong)作臺表面，待磨削(xue)(xue)后，工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)又在原應力作用(yong)下變形回復，測量板(ban)件(jian)(jian)厚度時(shi)顯(xian)示一(yi)(yi)致，但(dan)由于變形回復，平(ping)(ping)面度達(da)不到精密模具配件(jian)(jian)加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)應該的(de)(de)要(yao)(yao)求，解決的(de)(de)方法是磨削(xue)(xue)前以等高墊(dian)鐵墊(dian)在工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)下面，四周用(yong)擋(dang)塊擋(dang)住(zhu)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)防(fang)止走動，磨削(xue)(xue)時(shi)磨頭進刀量要(yao)(yao)小，用(yong)多次走刀方式完成(cheng)基(ji)準(zhun)(zhun)平(ping)(ping)面，基(ji)準(zhun)(zhun)平(ping)(ping)面加工(gong)(gong)(gong)(gong)(gong)(gong)(gong)好一(yi)(yi)面后，可(ke)用(yong)這一(yi)(yi)基(ji)準(zhun)(zhun)平(ping)(ping)面吸附在磁力臺上，通過如(ru)上所(suo)述的(de)(de)磨削(xue)(xue)方法可(ke)改善大部分(fen)工(gong)(gong)(gong)(gong)(gong)(gong)(gong)件(jian)(jian)平(ping)(ping)面度。