CN101637862B - Process for processing side wall of aluminum alloy bodywork of rail vehicle - Google Patents
Process for processing side wall of aluminum alloy bodywork of rail vehicle Download PDFInfo
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Abstract
The invention relates to a process for processing a side wall of an aluminum alloy bodywork of a rail vehicle, which comprises the following steps: processing a single side wall board, namely carrying out mechanical processing except window cutting; assembling and welding the side wall board, namely assembling and welding all aluminum alloy profiles together, and polishing welding seams; integrally clamping the side wall, namely fixing the side wall on a workbench; measuring a side wall window, namely measuring the design size of the window and the processing size at a processing position, and inputting the measurement result to a numerical control processing center; integrally processing the side wall window, namely calling a numerical control processing program to process the window; and polishing the side wall window, and finally handing over a side wall finished product. By adopting the process flows of firstly assembling and welding all aluminum alloy profiles forming the side wall together and then cutting and processing the window, the process can effectively control the influence of welding deformation on the processing precision of the window, ensure the processing precision of the side wall, improve the appearance quality of the product, improve the production efficiency, reduce the labor intensity of workers, and reduce the production cost.
Description
Technical field
The present invention relates to a kind of rolling stock aluminum alloy bodywork processing technology, particularly the processing technology of side wall in the car body belongs to vehicle body of railway vehicle manufacturing technology field.
Background technology
In the past, the car body of rail vehicle mostly adopts carbon steel, perhaps stainless steel material, the side wall of car body, roof, underframe, floor etc. are all formed by a few bulk sheet materials weldings, wherein, when the processing side wall, generally be earlier at each the piece sheet material that is used to weld, go out window by the dimensioned of window on the side wall, and then will welding mutually between each sheet material, polish at last, operation such as repairing, and then finish the processing of side wall.
In the production process of present rail vehicle, the car body of especially present high-speed track vehicle, in order to reach light-weighted requirement, mostly adopting aluminium alloy is main material, and main hollow (bivalve) thin-wall aluminum alloy profile of growing up that adopts.In the aluminum alloy bodywork actual production process, generally the processing technology of Cai Yonging is at present: use conventional carbon steel process equipment, cutter, milling parameter, after the first single-piece work, weld adjusting again, this processing technology production efficiency is low, the cost height.
The processing of aluminum alloy materials is different from ordinary carbon steel, stainless steel, aluminum alloy materials hardness is low, viscosity is big, and cutting is easy, but plastic deformation is big, particularly for the processing of aluminium alloy extrusions, carry out weld job on the aluminium alloy extrusions of and length length big at area, hot cracking tendency is big, and the welding stress deformation problem is very outstanding.After monomer processing meets the design size requirement, through welding, length over ends of body size, side wall window size, the interior suspender member installation site of car etc. all can produce overproof, can not reach designing requirement, increase workman's adjusting labour intensity, influence the presentation quality of whole locomotive body, and fixedly prediction of the distortion that this process produced, caused by many uncertain factors, so can not artificially control, the designing requirement of side wall also just can't guarantee.
Summary of the invention
Main purpose of the present invention is to address the above problem and is not enough, provide a kind of and can effectively control welding deformation, guarantee the process for processing side wall of aluminum alloy bodywork of rail vehicle of side wall machining accuracy, not only can improve the product appearance quality, enhance productivity, can also reduce labor strength, reduce production costs.
For achieving the above object, described process for processing side wall of aluminum alloy bodywork of rail vehicle:
It may further comprise the steps:
(1) single-piece framed side wallboard processing: to the machining of each piece aluminium alloy extrusions except that the window cutting of forming side wall;
(2) framed side wallboard assembly welding: each the piece aluminium alloy extrusions assembling that will form side wall welds together, and forms side wall, will weld afterwards formed weld seam and polish, and makes the framed side wallboard surface smoothing after the welding;
(3) the whole clamping of side wall: with overhead traveling crane side wall handling to side wall is processed on the workbench, adjusted side wall, the surface of side wall and the upper surface of workbench are fitted tightly, utilize of the two ends clamping of the clamping device of workbench, simultaneously side wall is located with side wall;
(4) side wall window is measured: utilize measuring instrument measurement window design size, the processing dimension with special measurement probe detection window Working position place is input to numerical control machining center with measurement result;
(5) the whole processing of side wall window: call nc program window is processed;
(6) side wall window polishing: the allowance of window is polished, make it concordant with the side wall inner surface;
(7) the side wall finished product is surrendered: the processing and the installation of side wall interior trim object, at last with the whole handling of the side wall that machines to next process.
In above-mentioned (4) step, during with the processing dimension at special measurement probe detection window Working position place, adopt two kinds of metering systems, a kind of is to adopt the mode of once having surveyed all window sizes, another kind is to adopt whenever to machine a window, measures the mode of next window size again.
In above-mentioned (5) step, the structure of side wall window is step-like, be divided into three layers from the inside to the outside, the inboard relatively large milling cutter of two-layer employing tool diameter is processed, outermost one deck adopts the less relatively milling cutter of tool diameter to process, and the milling direction during process window adopts climb cutting.
Content to sum up, the present invention adopted will form side wall earlier each piece aluminium alloy extrusions assembly welding together, carry out the technological process of the machining of window again, can effectively control the influence of welding deformation like this to the window machining accuracy, guarantee the side wall machining accuracy, not only can improve the product appearance quality, enhance productivity, can also reduce labor strength, reduce production costs.
Description of drawings
Fig. 1 processing process figure of the present invention;
Fig. 2 side wall integral installation of the present invention clamping structure schematic diagram;
Fig. 3 window of the present invention adds cutter feed path schematic diagram in man-hour.
As shown in Figure 1 to Figure 3, side wall 1, side wall processing workbench 2, long riser 3, short riser 4, swing arm 5, processing tool 6, T type groove 7, weld seam 8, pressing plate 9, bolt 10.
The specific embodiment
Below in conjunction with the accompanying drawing and the specific embodiment the present invention is described in further detail:
In the aluminum alloy bodywork of high-speed track vehicle (present embodiment is an example with the EMU of 200 kilometers of speed per hours), substantially comprise three big modules, roof module, side wall module and underframe module, wherein, roof module is made of 7 elongated section bars, the side wall module constitutes (totally 2 of side walls 1 by 14 section bars, each side wall 1 is made of 7 section bars), the underframe module comprises 4 elongated section bars, above material is all the section bar of growing up about length 20m, and the processing of these section bars of growing up is finished in 27 meters two main shaft gantry machining centers basically.
The integral body processing of side wall 1 is mainly finished on F00KE60 rice double five-shaft numerical control machining center.F00KE double machining center is the five-shaft numerical control machining center that is specifically designed to processing side wall of aluminum alloy bodywork 1, equipment has two workbench positions, machine adopted movable gantry structure, the X-axis stroke is 61.6m, the Y-axis stroke is 4.3m, Z axle stroke is 1.5m, A axle moving range+/-105 °, C axle moving range＞365 °; Electrical spindle for machine tool power is 42KW, and the main shaft maximum (top) speed is 16000 rev/mins; Tool magazine can hold 14 cutters simultaneously, and that handle of a knife adopts is HSK100A; Simultaneously equipment configuration advanced Renishaw measuring probe; Advanced SIEMENSSinumerik 840D operating system has been adopted in CNC control, and the band circular saw clamps the form of annular saw with cutter on the main shaft, and the maximum depth of cut of saw blade is 160mm.
Because there is not plane processing substantially in side wall 1, characteristics at aluminum alloy materials are good toughness simultaneously, poor rigidity, material structure is a hollow material, cutting form mostly is interrupted cut, and impulsive force is big, so add man-hour at the aluminum alloy bodywork section bar to side wall 1, the cutter that uses mainly adopts Japanese import OSG brand to contain cobalt high speed slotting cutter, and the sword number is single-blade and twolip.Select the advantage of slotting cutter to be: low price, it is effective to cut aluminum alloy, tool wear is little, noise is little, in addition at the milling cutter length direction, is satisfying under the prerequisite of processing content, select short milling cutter as far as possible, it is very big that workpiece surface quality is improved, and can improve the precision of processing work, can also further reduce noise.The sword number of milling cutter determines according to actual conditions that when the cutting hollow material slotting cutter that adopts mostly is the twolip milling cutter greatly at present, and because of the cutting strength of twolip milling cutter is stable, cutting speed is fast, the chip removal smoothness.
Under the condition that technology allows, adopt the bigger cutter of corner radius to carry out high-speed milling as far as possible.In milling process, smear metal of splashing and tipping have very high kinetic energy, may cause personal injury, therefore, process system must have high-level safeguard procedures, according to test, corresponding one of the cutter of different-diameter destroys rotating speed, therefore, in certain range of speeds, the maximum gauge of use cutter is subjected to the restriction of security.
In the aluminium alloy extrusions process, need high-speed equipment, adopt the high speed high-rate cutting to raise the efficiency, reduce plastic deformation, avoid occurring the thin-walled place and can't cut and tear phenomenon.
Aluminium alloy extrusions Milling Process parameter:
| The cutter title | Rotation speed n | Feed speed vf | Cutting |
| φ | |||
| 4 centre drills | 3000 | Z direction 100 | --- |
| φ 5.5 drill bits | 5000 | Z direction 700 | --- |
| φ 6.6 drill bits | 5000 | Z direction 700 | --- |
| φ 9.8 drill bits | 5000 | Z direction 700 | --- |
| φ 12 drill bits | 4000 | Z direction 700 | --- |
| φ 14 drill bits | 5000 | Z direction 600 | --- |
| φ 20 drill bits | 5000 | Z direction 600 | --- |
| Φ 75 metal saws | 4000 | 700～1000 | --- |
| φ 400 saw blades | 4000 | 1000 | --- |
| Φ 160 dish milling cutters | 3600 | 1200 | --- |
| |
10000-12000 | 1800-2200 | 5-12 |
| φ 20 milling cutters | 8000-9000 | 1500-2000 | 5-15 |
| φ 30 milling cutters | 7000-8000 | 1200-1600 | 5-15 |
As shown in Figure 1, process for processing side wall of the present invention may further comprise the steps:
(1) single-piece framed side wallboard processing:
Formed by seven aluminium alloy extrusions assembly weldings in the side wall 1, to each piece aluminium alloy extrusions machining except that the window cutting, this operation is finished on 27 meters pairs of main shaft gantry machining centers.
(2) framed side wallboard assembly welding:
Seven blocks of aluminium alloy extrusions that single-piece work is finished, handling is to F00KE60 rice double five-shaft numerical control machining center, and the connected structure by each piece aluminium alloy extrusions dual-side, seven blocks of section bars are plugged on together mutually, weld at splicing position, to weld the formed weld seam in back again and polish, make side wall 1 surface smoothing after the welding.
(3) the whole clamping of side wall:
With overhead traveling crane side wall 1 handling to side wall is processed on the workbench 2, adjusted side wall 1, the surface of side wall 1 and the upper surface of workbench 2 are fitted tightly, utilize of the two ends clamping of the clamping device of workbench 2, simultaneously with side wall 1 location side wall 1.
Process after side wall 1 welding, side wall 1 section after the welding is the workpiece of a curved surface as shown in Figure 2 as can be seen, wants to make the surface of side wall 1 and the upper surface of workbench 2 to fit tightly, and must use processing tool 6 as shown in Figure 2.
Because the main processing of side wall 1 just is the processing of window, and position of window is in the position of third and fourth piece section bar of side wall 1, so processing tool 6 emphasis are fixed this two blocks of section bars, saves very big cost like this, and improved the economy of frock.
During design processing tool 6, want the processing part that the characteristics of 3 of weld seams are arranged according to side wall 1, upper surface at processing tool 6 has designed 3 T type grooves 7, the use of T type groove 7 is: at first because the weld seam 8 of a projection is arranged between two blocks of material of welding back side wall 1, T type groove 7 can get out of the way weld seam 8, and the position of T type groove 7 is just in time below 3 weld seams 8; Secondly when that T type groove 7 gets out of the way weld seam 8 in the middle of processing tool 6 upper surfaces, can also adopt pressing plate 9 structures, with bolt 10 securing members such as grade section bar is compressed, can guarantee that like this side wall 1 presses close to the upper surface of processing tool 6 more, thereby the vibration when making process window can be reduced to minimum.
The machining benchmark of side wall 1 also is to locate by the processing tool 6 of design, Z-direction is to locate by the upper surface of processing tool 6 certainly, and the location of Y direction will lean on processing tool 6 to guarantee, because side wall 1 this workpiece is more special, mainly be that side wall 1 is unlike our workpiece of processing was all very little in the past, side wall 1 is very long, so we have just designed the long riser 3 and the short riser 4 at clamping device two ends when design processing tool 6, short riser 4 is Y-axis zero points, workpiece will be come to the Y-axis dead-center position when clamping workpiece.
(4) side wall window is measured:
Because side wall 1 is to process after the welding again, this just has the problem of individual welding deformation, so need to measure the welding deformation situation of side wall 1 by advanced Renishaw measuring probe, the processing dimension by dark detection window Working position place just, probe can measured X, Y, the Z size on any one, then measurement result is input to numerical control machining center, so just can processes qualified workpiece.
Process of measurement can adopt dual mode, and a kind of is to adopt the mode of once having surveyed all window sizes, and another kind is to adopt whenever to machine a window, measures the mode of next window size again.Find through after the test of many times: once surveyed all windows than a lot of times of window saving of window measurement of every processing, but selected a kind of mode in back can improve the certainty of measurement of window.
Window on the side wall 1 is arranged side by side, and the problem that should note in the measuring process has: at first will check the welding deformation of side wall 1 before the measurement, if side wall 1 welding deformation is little, minimizing measurement point that can be suitable can be saved Measuring Time like this; If side wall 1 distortion is very big, just must as much as possiblely measure, could guarantee like this to add and can not damage workpiece man-hour.
(5) the whole processing of side wall window:
After the Renishaw probe measurement is finished, will call nc program window will be processed, according to the processing content-window shape of side wall 1, the basic selection
Two kinds of specification slotting cutters.
Because, side wall 1 is become by the hollow and thin-walled section bar assembly welding of growing up, so have a lot of oblique gussets on the window section, therefore in process, not only to consider process window (step-like window, little inboard, the outside is big), to consider that simultaneously mill off plays the oblique gusset of booster action, if there is not the oblique gusset of mill off, because of window is step-like cause, not only Da Mo workload can increase, and the polishing difficulty also can be very big, can cause not having the gusset repeated friction and the bump milling cutter of mill off simultaneously, very big to cutter wear, even the situation of milling cutter tipping appears easily, and this just requires very high to the cutter path in the process, and we should accomplish the least possible wearing and tearing cutter, again workpiece is processed the shape of drawing requirement, cutter path is good, can reduce very big polishing workload, and cutter wear is also little simultaneously.
Through after the test of many times, feed path as shown in Figure 3, the place that circle is drawn at four angles mainly is exactly to remove the surplus that oblique gusset stays, with the workload that reduces to polish.As for the milling direction, preferably adopt climb cutting, reason is that the noise of climb cutting is little, cutter wear is little, the machined surface quality of processing work.
Cutter path has been from having seen three layers in appearance, mainly is that the step-like structure by window decides, and to outer surface, window divides three layers of step shape from the inner surface of side wall 1, and window size is big in the inner part, and window size is little in the outer part, inboard two-layer employing
Milling cutter process, reason is
Milling cutter processing noise little, the amount of feeding is big, cutting strength is big, the machined surface quality height.And skin has adopted
Milling cutter, mainly be because the decision of the size at four angles of window, the manual observation while process runs into and manually adjusts the speed of mainshaft and the amount of feeding multiplying power knob when stud is arranged, principle is the low feeding of high rotating speed, general selection
The milling cutter rotating speed be 9000r/min, feed engagement is 0.25mm.
Just finish the processing of a window like this according to feed path, other windows just machine with same path.
(6) side wall window polishing:
Because it is step-like that the structure of window is, thus when process window, all can leave certain allowance, avoid with side wall 1 all on earth, its allowance makes it level and smooth by the polishing operation at last, and is concordant with side wall 1 surface.
(7) the side wall finished product is surrendered:
The processing and the installation of side wall 1 interior trim object, as suspender member, the processing of through hole etc., last, with the side wall 1 whole handling that machines to next process.
As mentioned above, given in conjunction with the accompanying drawings and embodiments scheme content can derive the similar techniques scheme.In every case be the content that does not break away from technical solution of the present invention, to any simple modification, equivalent variations and modification that above embodiment did, all still belong in the scope of technical solution of the present invention according to technical spirit of the present invention.
Claims (5)
1. process for processing side wall of aluminum alloy bodywork of rail vehicle is characterized in that it may further comprise the steps:
(1) single-piece framed side wallboard processing: to the machining of each piece aluminium alloy extrusions except that the window cutting of forming side wall;
(2) framed side wallboard assembly welding: each the piece aluminium alloy extrusions assembling that will form side wall welds together, and forms side wall, will weld afterwards formed weld seam and polish, and makes the framed side wallboard surface smoothing after the welding;
(3) the whole clamping of side wall: with overhead traveling crane side wall handling to side wall is processed on the workbench, adjusted side wall, the surface of side wall and the upper surface of workbench are fitted tightly, utilize of the two ends clamping of the clamping device of workbench, simultaneously side wall is located with side wall;
(4) side wall window is measured: utilize measuring instrument measurement window design size, the processing dimension with Renishaw measuring probe detection window Working position place is input to numerical control machining center with measurement result;
(5) the whole processing of side wall window: call nc program window is processed;
(6) side wall window polishing: the allowance of window is polished, make it concordant with the side wall inner surface;
(7) the side wall finished product is surrendered: the processing and the installation of side wall interior trim object, with the whole handling of the side wall that machines to next process.
2. process for processing side wall of aluminum alloy bodywork of rail vehicle according to claim 1, it is characterized in that: in above-mentioned (4) step, with the processing dimension at Renishaw measuring probe detection window Working position place, adopt the mode of once having surveyed all window sizes.
3. process for processing side wall of aluminum alloy bodywork of rail vehicle according to claim 1, it is characterized in that: in above-mentioned (4) step, processing dimension with Renishaw measuring probe detection window Working position place, adopt and whenever machine a window, measure the mode of next window size again.
4. according to each described process for processing side wall of aluminum alloy bodywork of rail vehicle of claim 1 to 3, it is characterized in that: in above-mentioned (5) step, the structure of side wall window is step-like, be divided into three layers from the inside to the outside, the inboard relatively large milling cutter of two-layer employing tool diameter is processed, and outermost one deck adopts the less relatively milling cutter of tool diameter to process.
5. process for processing side wall of aluminum alloy bodywork of rail vehicle according to claim 4 is characterized in that: the milling direction during described process window adopts climb cutting.
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Address after: Jihongtan town Chengyang District Shandong city Qingdao province Jinhong road 266111 No. 88 Patentee after: CRRC QINGDAO SIFANG CO., LTD. Address before: 266111 Qingdao, Chengyang District, Shandong Province town of Hong Hu spines Patentee before: CSR Qingdao Sifang Locomotive and Rolling Stock Co., Ltd. |