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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)配件(jian)(jian)是(shi)指(zhi)裝配模(mo)具(ju)(ju)的零(ling)(ling)(ling)(ling)件(jian)(jian)或(huo)部(bu)件(jian)(jian)；也可以指(zhi)損壞(huai)后重新安裝上的模(mo)具(ju)(ju)零(ling)(ling)(ling)(ling)件(jian)(jian)或(huo)部(bu)件(jian)(jian)。精(jing)(jing)密模(mo)具(ju)(ju)一般是(shi)由許多零(ling)(ling)(ling)(ling)件(jian)(jian)構成，可以分為兩類：工藝零(ling)(ling)(ling)(ling)件(jian)(jian)和結構零(ling)(ling)(ling)(ling)件(jian)(jian)。工藝零(ling)(ling)(ling)(ling)件(jian)(jian)直(zhi)接對成型(xing)產品質量造成影(ying)響，工藝零(ling)(ling)(ling)(ling)件(jian)(jian)的決(jue)勝品質在(zai)當下(xia)的精(jing)(jing)密模(mo)具(ju)(ju)配件(jian)(jian)均用(yong)精(jing)(jing)加工手段(duan)來完成。精(jing)(jing)密加工過(guo)程關系到(dao)精(jing)(jing)密模(mo)具(ju)(ju)的壽命和成型(xing)產品，在(zai)精(jing)(jing)密模(mo)具(ju)(ju)配件(jian)(jian)加工中的精(jing)(jing)加工階(jie)段(duan)除采用(yong)慢走絲線(xian)切(qie)割(ge)、電火花成型(xing)等(deng)工藝手段(duan)外，另(ling)采用(yong)的方(fang)法即(ji)是(shi)在(zai)半精(jing)(jing)加工后，熱處(chu)理基礎上磨(mo)削加工。

       那么在(zai)精(jing)密(mi)模(mo)具(ju)(ju)配(pei)件(jian)加(jia)(jia)(jia)工(gong)(gong)的(de)(de)(de)(de)磨削加(jia)(jia)(jia)工(gong)(gong)階段(duan)需(xu)要(yao)控(kong)制(zhi)好(hao)零件(jian)的(de)(de)(de)(de)變形(xing)、內(nei)應力、形(xing)狀公差及尺寸精(jing)度等(deng)許多技(ji)術(shu)參數。在(zai)具(ju)(ju)體的(de)(de)(de)(de)生產實踐中，操作困難較多，但是在(zai)東(dong)莞市(shi)時(shi)利和(he)15年的(de)(de)(de)(de)精(jing)密(mi)加(jia)(jia)(jia)工(gong)(gong)經驗中可(ke)以(yi)總結分析的(de)(de)(de)(de)出可(ke)以(yi)借(jie)鑒的(de)(de)(de)(de)方(fang)(fang)法：一(yi)、從模(mo)具(ju)(ju)的(de)(de)(de)(de)精(jing)加(jia)(jia)(jia)工(gong)(gong)過(guo)程控(kong)制(zhi)精(jing)密(mi)模(mo)具(ju)(ju)配(pei)件(jian)加(jia)(jia)(jia)工(gong)(gong)，我們(men)可(ke)以(yi)針對不同的(de)(de)(de)(de)模(mo)具(ju)(ju)零件(jian)、不同的(de)(de)(de)(de)材質(zhi)、不同的(de)(de)(de)(de)形(xing)狀和(he)不同的(de)(de)(de)(de)技(ji)術(shu)要(yao)求進行適(shi)應性(xing)加(jia)(jia)(jia)工(gong)(gong)，提供選(xuan)擇性(xing)方(fang)(fang)案(an)。通過(guo)對加(jia)(jia)(jia)工(gong)(gong)過(guo)程的(de)(de)(de)(de)控(kong)制(zhi)，達到更好(hao)的(de)(de)(de)(de)加(jia)(jia)(jia)工(gong)(gong)效果和(he)經濟性(xing)是大多數精(jing)密(mi)模(mo)具(ju)(ju)配(pei)件(jian)加(jia)(jia)(jia)工(gong)(gong)企(qi)業關(guan)注的(de)(de)(de)(de)重點。精(jing)密(mi)模(mo)具(ju)(ju)配(pei)件(jian)加(jia)(jia)(jia)工(gong)(gong)的(de)(de)(de)(de)工(gong)(gong)藝過(guo)程一(yi)般為：粗(cu)加(jia)(jia)(jia)工(gong)(gong)—半(ban)精(jing)加(jia)(jia)(jia)工(gong)(gong)—（淬火、調質(zhi)）—精(jing)密(mi)磨削—電(dian)加(jia)(jia)(jia)工(gong)(gong)—鉗(qian)工(gong)(gong)修(xiu)整—組裝加(jia)(jia)(jia)工(gong)(gong)。

       在精(jing)密(mi)模具配(pei)件(jian)(jian)加工(gong)(gong)的(de)磨削(xue)(xue)(xue)加工(gong)(gong)階段(duan)主要(yao)采(cai)用的(de)機(ji)床(chuang)有三(san)種主要(yao)類型(xing)：平(ping)面(mian)磨床(chuang)、內(nei)外圓磨床(chuang)及工(gong)(gong)具成型(xing)磨削(xue)(xue)(xue)機(ji)床(chuang)。精(jing)加工(gong)(gong)磨削(xue)(xue)(xue)時要(yao)嚴格控(kong)制(zhi)磨削(xue)(xue)(xue)變形和磨削(xue)(xue)(xue)裂紋的(de)出(chu)現，哪怕是工(gong)(gong)件(jian)(jian)表面(mian)的(de)顯微(wei)裂紋，否則在后續的(de)工(gong)(gong)作中也會(hui)漸漸顯露出(chu)來。因(yin)此(ci)，精(jing)密(mi)磨削(xue)(xue)(xue)時的(de)進刀(dao)量要(yao)小，磨削(xue)(xue)(xue)中冷(leng)卻要(yao)充分(fen)，盡量選擇冷(leng)卻液介(jie)質，加工(gong)(gong)余(yu)量在0.01mm內(nei)的(de)零件(jian)(jian)要(yao)盡量恒(heng)溫磨削(xue)(xue)(xue)。

       磨(mo)削(xue)(xue)加(jia)工(gong)(gong)(gong)(gong)中要(yao)及時修(xiu)整砂輪，保持砂輪的(de)(de)銳利，當砂輪鈍化后(hou)會在工(gong)(gong)(gong)(gong)件表面(mian)(mian)(mian)(mian)(mian)滑擦、刻劃、擠壓(ya)，造(zao)成工(gong)(gong)(gong)(gong)件表面(mian)(mian)(mian)(mian)(mian)燒傷、顯微裂痕或(huo)產(chan)生溝(gou)槽，對(dui)以后(hou)的(de)(de)使用(yong)(yong)顯著地降低效用(yong)(yong)。盤類、板類零件的(de)(de)加(jia)工(gong)(gong)(gong)(gong)大(da)(da)部(bu)分采(cai)用(yong)(yong)平(ping)(ping)(ping)面(mian)(mian)(mian)(mian)(mian)磨(mo)床加(jia)工(gong)(gong)(gong)(gong)，加(jia)工(gong)(gong)(gong)(gong)長而薄(bo)的(de)(de)薄(bo)板件時，有(you)一(yi)定的(de)(de)加(jia)工(gong)(gong)(gong)(gong)難度(du)。加(jia)工(gong)(gong)(gong)(gong)前在磨(mo)床磁力臺的(de)(de)強力吸引(yin)下(xia)(xia)，工(gong)(gong)(gong)(gong)件原(yuan)先存在某種彎(wan)曲產(chan)生平(ping)(ping)(ping)直形變(bian)(bian)，貼近(jin)于工(gong)(gong)(gong)(gong)作(zuo)臺表面(mian)(mian)(mian)(mian)(mian)，待磨(mo)削(xue)(xue)后(hou)，工(gong)(gong)(gong)(gong)件又在原(yuan)應力作(zuo)用(yong)(yong)下(xia)(xia)變(bian)(bian)形回(hui)復(fu)，測量板件厚度(du)時顯示一(yi)致，但由于變(bian)(bian)形回(hui)復(fu)，平(ping)(ping)(ping)面(mian)(mian)(mian)(mian)(mian)度(du)達不到精(jing)密模具配(pei)件加(jia)工(gong)(gong)(gong)(gong)應該的(de)(de)要(yao)求，解(jie)決的(de)(de)方(fang)(fang)法是磨(mo)削(xue)(xue)前以等高墊鐵墊在工(gong)(gong)(gong)(gong)件下(xia)(xia)面(mian)(mian)(mian)(mian)(mian)，四周用(yong)(yong)擋塊(kuai)擋住工(gong)(gong)(gong)(gong)件防止(zhi)走動(dong)，磨(mo)削(xue)(xue)時磨(mo)頭進刀量要(yao)小，用(yong)(yong)多次走刀方(fang)(fang)式(shi)完成基準(zhun)平(ping)(ping)(ping)面(mian)(mian)(mian)(mian)(mian)，基準(zhun)平(ping)(ping)(ping)面(mian)(mian)(mian)(mian)(mian)加(jia)工(gong)(gong)(gong)(gong)好一(yi)面(mian)(mian)(mian)(mian)(mian)后(hou)，可用(yong)(yong)這一(yi)基準(zhun)平(ping)(ping)(ping)面(mian)(mian)(mian)(mian)(mian)吸附在磁力臺上，通過如(ru)上所述(shu)的(de)(de)磨(mo)削(xue)(xue)方(fang)(fang)法可改善大(da)(da)部(bu)分工(gong)(gong)(gong)(gong)件平(ping)(ping)(ping)面(mian)(mian)(mian)(mian)(mian)度(du)。