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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)配件(jian)是指(zhi)裝配模具(ju)的(de)(de)(de)(de)零(ling)(ling)件(jian)或(huo)部件(jian)；也可以(yi)指(zhi)損壞后重新安(an)裝上(shang)的(de)(de)(de)(de)模具(ju)零(ling)(ling)件(jian)或(huo)部件(jian)。精(jing)(jing)(jing)密模具(ju)一(yi)般是由(you)許(xu)多零(ling)(ling)件(jian)構成(cheng)，可以(yi)分為兩類：工(gong)(gong)(gong)藝(yi)(yi)(yi)零(ling)(ling)件(jian)和(he)結(jie)構零(ling)(ling)件(jian)。工(gong)(gong)(gong)藝(yi)(yi)(yi)零(ling)(ling)件(jian)直(zhi)接(jie)對成(cheng)型產(chan)品(pin)質量造成(cheng)影響，工(gong)(gong)(gong)藝(yi)(yi)(yi)零(ling)(ling)件(jian)的(de)(de)(de)(de)決勝品(pin)質在當下的(de)(de)(de)(de)精(jing)(jing)(jing)密模具(ju)配件(jian)均用(yong)精(jing)(jing)(jing)加(jia)工(gong)(gong)(gong)手段(duan)來完成(cheng)。精(jing)(jing)(jing)密加(jia)工(gong)(gong)(gong)過程(cheng)關系到精(jing)(jing)(jing)密模具(ju)的(de)(de)(de)(de)壽命(ming)和(he)成(cheng)型產(chan)品(pin)，在精(jing)(jing)(jing)密模具(ju)配件(jian)加(jia)工(gong)(gong)(gong)中的(de)(de)(de)(de)精(jing)(jing)(jing)加(jia)工(gong)(gong)(gong)階段(duan)除采用(yong)慢走(zou)絲線(xian)切割、電火花成(cheng)型等(deng)工(gong)(gong)(gong)藝(yi)(yi)(yi)手段(duan)外，另采用(yong)的(de)(de)(de)(de)方(fang)法即是在半(ban)精(jing)(jing)(jing)加(jia)工(gong)(gong)(gong)后，熱處理基(ji)礎上(shang)磨削(xue)加(jia)工(gong)(gong)(gong)。

       那么在(zai)精(jing)(jing)(jing)(jing)(jing)密(mi)模(mo)具配(pei)件(jian)(jian)(jian)(jian)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)的(de)(de)(de)磨削(xue)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)階段需要控(kong)制好零(ling)件(jian)(jian)(jian)(jian)的(de)(de)(de)變形(xing)、內應力、形(xing)狀(zhuang)公差及尺寸精(jing)(jing)(jing)(jing)(jing)度等(deng)許多技(ji)術參數。在(zai)具體的(de)(de)(de)生(sheng)產實(shi)踐(jian)中，操作困(kun)難較多，但(dan)是在(zai)東(dong)莞市(shi)時利和15年(nian)的(de)(de)(de)精(jing)(jing)(jing)(jing)(jing)密(mi)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)經驗中可以總(zong)結分(fen)析的(de)(de)(de)出可以借鑒的(de)(de)(de)方(fang)法(fa)：一(yi)、從模(mo)具的(de)(de)(de)精(jing)(jing)(jing)(jing)(jing)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)過(guo)程控(kong)制精(jing)(jing)(jing)(jing)(jing)密(mi)模(mo)具配(pei)件(jian)(jian)(jian)(jian)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)，我們可以針對不同(tong)的(de)(de)(de)模(mo)具零(ling)件(jian)(jian)(jian)(jian)、不同(tong)的(de)(de)(de)材質、不同(tong)的(de)(de)(de)形(xing)狀(zhuang)和不同(tong)的(de)(de)(de)技(ji)術要求進(jin)行(xing)適應性(xing)(xing)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)，提供選(xuan)擇性(xing)(xing)方(fang)案(an)。通過(guo)對加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)過(guo)程的(de)(de)(de)控(kong)制，達到更(geng)好的(de)(de)(de)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)效果和經濟性(xing)(xing)是大多數精(jing)(jing)(jing)(jing)(jing)密(mi)模(mo)具配(pei)件(jian)(jian)(jian)(jian)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)企業關注的(de)(de)(de)重點。精(jing)(jing)(jing)(jing)(jing)密(mi)模(mo)具配(pei)件(jian)(jian)(jian)(jian)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)的(de)(de)(de)工(gong)(gong)(gong)(gong)(gong)(gong)藝過(guo)程一(yi)般為：粗加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)—半(ban)精(jing)(jing)(jing)(jing)(jing)加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)—（淬火、調質）—精(jing)(jing)(jing)(jing)(jing)密(mi)磨削(xue)—電加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)—鉗工(gong)(gong)(gong)(gong)(gong)(gong)修(xiu)整—組裝加(jia)工(gong)(gong)(gong)(gong)(gong)(gong)。

       在精(jing)(jing)密模具(ju)(ju)配件(jian)加工的磨削(xue)(xue)(xue)加工階段主要(yao)采用的機床(chuang)有三種主要(yao)類型：平面磨床(chuang)、內(nei)外圓磨床(chuang)及工具(ju)(ju)成型磨削(xue)(xue)(xue)機床(chuang)。精(jing)(jing)加工磨削(xue)(xue)(xue)時要(yao)嚴格控(kong)制(zhi)磨削(xue)(xue)(xue)變形(xing)和磨削(xue)(xue)(xue)裂紋的出現，哪怕(pa)是工件(jian)表面的顯微(wei)裂紋，否(fou)則在后續(xu)的工作中(zhong)也會漸漸顯露(lu)出來。因此(ci)，精(jing)(jing)密磨削(xue)(xue)(xue)時的進刀量(liang)要(yao)小，磨削(xue)(xue)(xue)中(zhong)冷(leng)卻要(yao)充分，盡量(liang)選擇冷(leng)卻液介質，加工余量(liang)在0.01mm內(nei)的零件(jian)要(yao)盡量(liang)恒溫磨削(xue)(xue)(xue)。

       磨(mo)(mo)(mo)(mo)削(xue)(xue)加工(gong)(gong)(gong)(gong)中(zhong)要及時(shi)(shi)修整砂輪，保(bao)持(chi)砂輪的(de)(de)銳利，當砂輪鈍化后(hou)會在(zai)(zai)工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)表面(mian)(mian)滑擦、刻劃、擠壓(ya)，造成工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)表面(mian)(mian)燒傷(shang)、顯微(wei)裂(lie)痕或產生溝槽，對以后(hou)的(de)(de)使(shi)用(yong)顯著地降低(di)效用(yong)。盤(pan)類、板(ban)類零件(jian)(jian)(jian)的(de)(de)加工(gong)(gong)(gong)(gong)大(da)部分采(cai)用(yong)平(ping)面(mian)(mian)磨(mo)(mo)(mo)(mo)床加工(gong)(gong)(gong)(gong)，加工(gong)(gong)(gong)(gong)長(chang)而薄的(de)(de)薄板(ban)件(jian)(jian)(jian)時(shi)(shi)，有(you)一(yi)定(ding)的(de)(de)加工(gong)(gong)(gong)(gong)難度。加工(gong)(gong)(gong)(gong)前在(zai)(zai)磨(mo)(mo)(mo)(mo)床磁力(li)臺(tai)的(de)(de)強力(li)吸引下(xia)(xia)，工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)原先存(cun)在(zai)(zai)某(mou)種(zhong)彎曲(qu)產生平(ping)直形(xing)變，貼近于(yu)工(gong)(gong)(gong)(gong)作(zuo)臺(tai)表面(mian)(mian)，待磨(mo)(mo)(mo)(mo)削(xue)(xue)后(hou)，工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)又在(zai)(zai)原應(ying)力(li)作(zuo)用(yong)下(xia)(xia)變形(xing)回(hui)復，測量(liang)板(ban)件(jian)(jian)(jian)厚度時(shi)(shi)顯示(shi)一(yi)致，但由(you)于(yu)變形(xing)回(hui)復，平(ping)面(mian)(mian)度達不到精密模具配(pei)件(jian)(jian)(jian)加工(gong)(gong)(gong)(gong)應(ying)該(gai)的(de)(de)要求，解(jie)決的(de)(de)方法是磨(mo)(mo)(mo)(mo)削(xue)(xue)前以等高墊鐵(tie)墊在(zai)(zai)工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)下(xia)(xia)面(mian)(mian)，四周(zhou)用(yong)擋(dang)塊擋(dang)住工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)防(fang)止(zhi)走動(dong)，磨(mo)(mo)(mo)(mo)削(xue)(xue)時(shi)(shi)磨(mo)(mo)(mo)(mo)頭(tou)進刀(dao)量(liang)要小，用(yong)多次走刀(dao)方式完成基(ji)(ji)準(zhun)平(ping)面(mian)(mian)，基(ji)(ji)準(zhun)平(ping)面(mian)(mian)加工(gong)(gong)(gong)(gong)好一(yi)面(mian)(mian)后(hou)，可用(yong)這(zhe)一(yi)基(ji)(ji)準(zhun)平(ping)面(mian)(mian)吸附在(zai)(zai)磁力(li)臺(tai)上，通過如上所述的(de)(de)磨(mo)(mo)(mo)(mo)削(xue)(xue)方法可改善大(da)部分工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)平(ping)面(mian)(mian)度。