CN106694969A - 汽车大灯灯罩光亮面加工方法及用于该加工方法的切削液 - Google Patents
汽车大灯灯罩光亮面加工方法及用于该加工方法的切削液 Download PDFInfo
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Abstract
汽车大灯灯罩光亮面加工方法，包括以下步骤：①、粗加工：取两块模具料，采用单轴数控铣对两块模料分别进行粗加工，得到型腔镶块初坯和型芯镶块初坯；②、精加工：采用高速数控铣对型腔镶块初坯和型芯镶块初坯的光亮面进行精加工，在加工型腔镶块过程中，采用切削液对型腔镶块进行间歇性雾化喷射；在加工型芯镶块过程中，采用切削液对型腔镶块进行直接喷洒，得到型腔镶块和型芯镶块。本方案采用切削液与加工设备高速旋转配合，在高温和降温转换过程对模料进行二次加热，提高模料硬度、精密度和光洁度，无需抛光处理，就能获得产品光亮面。
Description
技术领域
本发明涉及一种汽车大灯灯罩光亮面加工方法，以及用于该加工方法的切削液，属于注塑模具领域。
背景技术
传统汽车大灯灯罩模具的型芯和型腔光亮面（表面）采用手工打光或电子打光方式进行表面抛光处理。通过手工打光速度慢，效率低，在吊装过程中容易将模具的楞角碰坏，特别是模具的分型面碰坏，影响模具合模，造型成型产品产生飞边，影响产品质量。同时容易将模料的表面防腐蚀组织破坏，降低模具使用寿命。电子打光光洁度差，产品表面容易出现光斑，产品质量低。
发明内容
本发明的目的是为了克服已有技术的缺点，提供一种无需抛光处理，采用切削液与加工设备高速旋转配合，在高温和降温转换过程对模料进行二次加热，提高模料硬度、精密度和光洁度，从而使产品表面光亮的汽车大灯灯罩光亮面加工方法。
本发明的另一目的是提供一种用于该加工方法的切削液。
本发明汽车大灯灯罩光亮面加工方法的技术方案是：其特征在于包括以下步骤：
①、粗加工：取两块模具料，采用单轴数控铣对两块模料分别进行粗加工，得到型腔镶块初坯和型芯镶块初坯；
②、精加工：采用高速数控铣对型腔镶块初坯和型芯镶块初坯的光亮面进行精加工，在加工型腔镶块过程中，采用切削液对型腔镶块进行间歇性雾化喷射；在加工型芯镶块过程中，采用切削液对型腔镶块进行直接喷洒，得到型腔镶块和型芯镶块。
本发明公开了一种汽车大灯灯罩光亮面的加工方法，整个加工程序只有两个步骤，第一步，粗加工，取两块模具料，采用单轴数控铣对两块模料分别进行粗加工，得到型腔镶块初坯和型芯镶块初坯；第二步，精加工，采用高速数控铣对型腔镶块初坯和型芯镶块初坯的光亮面进行精加工，在加工过程中，高速旋转的刀具对模具料切削，会产生高温，在加工型腔镶块时，由于模具的型腔镶块光亮面呈凹槽形，可采用间歇性喷雾方式，将雾化的切削液喷射到切削区，高速气流带着雾化成微小液滴的切削液渗透到切削区，在高温下迅速汽化，吸收大量热量，达到较好的冷却效果，同时没有液体残留，只需将切削后的碎屑清除即可。在加工型芯镶块时，由于模具的型芯镶块光亮面呈凸块形，可采用直接喷洒切削液的方式，将液态切削液直接喷射到切削区进行吸热、降温，达到冷却效果，同时液态切削液可将切断的碎屑冲出，无需可清除碎屑。在高温与降温过程中，相当于是对模具料的切削区域进行二次热处理，使该区域的模具料硬度和光洁度更高，从而提高产品光亮面（表面）光洁度，提升产品质量和档次。本方案与传统技术相比，不仅减少加工工序，节省加工成本，提高加工效率，并且切削液具有良好的冷却和清洗作用，能形成金属表面保护膜，防锈、防磨、耐腐蚀，延长模具使用寿命。
本发明一种用于汽车大灯灯罩光亮面加工的切削液，按容积比例，其主要成分包括矿物油10%、乳化剂1%、助溶剂0.5%、防腐剂5.2%、抗磨添加剂0.1%、极压剂1%、消泡剂0.5%、防腐杀菌剂1.2%和水80%。所述的矿物油为环烷基基础油、烷烃、环烷烃或环烷芳烃。所述的乳化剂为烷基酚聚氧乙烯醚、脂肪醇聚氧乙烯醚、山梨糖醇聚氧乙烯醚、脂肪酸酰胺或磺酸盐。所述的助溶剂为醇类、醇胺类或醇醚类。所述的防腐剂为苯羧酸、磺酸或亚硝酸盐。所述的抗磨添加剂为二烷基硫代磷酸盐。所述的极压剂为硫、磷、氯或碘。所述的消泡剂为硅油、聚醚类、植物油或高级醇。所述的防腐杀菌剂为甲醛释放型。
附图说明
图1是本发明的型腔镶块示意图；
图2是本发明的型芯镶块示意图。
具体实施方式
本发明涉及一种汽车大灯灯罩光亮面加工方法，如图1、图2所示，包括以下步骤：
①、粗加工：取两块模具料，采用单轴数控铣对两块模料分别进行粗加工，得到型腔镶块初坯和型芯镶块初坯；
②、精加工：采用高速数控铣对型腔镶块初坯和型芯镶块初坯的光亮面3进行精加工，在加工型腔镶块过程中，采用切削液对型腔镶块进行间歇性雾化喷射；在加工型芯镶块过程中，采用切削液对型腔镶块进行直接喷洒，得到型腔镶块1和型芯镶块2。
本发明公开了一种汽车大灯灯罩光亮面的加工方法，整个加工程序只有两个步骤，第一步，粗加工，取两块模具料，采用单轴数控铣对两块模料分别进行粗加工，得到型腔镶块初坯和型芯镶块初坯；第二步，精加工，采用高速数控铣对型腔镶块初坯和型芯镶块初坯的光亮面3进行精加工，在加工过程中，高速旋转的刀具对模具料切削，会产生高温，在加工型腔镶块时，由于模具的型腔镶块光亮面呈凹槽形，可采用间歇性喷雾方式，将雾化的切削液喷射到切削区，高速气流带着雾化成微小液滴的切削液渗透到切削区，在高温下迅速汽化，吸收大量热量，达到较好的冷却效果，同时没有液体残留，只需将切削后的碎屑清除即可。在加工型芯镶块时，由于模具的型芯镶块光亮面呈凸块形，可采用直接喷洒切削液的方式，将液态切削液直接喷射到切削区进行吸热、降温，达到冷却效果，同时液态切削液可将切断的碎屑冲出，无需可清除碎屑。在高温与降温过程中，相当于是对模具料的切削区域进行二次热处理，使该区域的模具料硬度和光洁度更高，从而提高产品光亮面（表面）光洁度，提升产品质量和档次。本方案与传统技术相比，不仅减少加工工序，节省加工成本，提高加工效率，并且切削液具有良好的冷却和清洗作用，能形成金属表面保护膜，防锈、防磨、耐腐蚀，延长模具使用寿命。
本发明还涉及一种用于汽车大灯灯罩光亮面加工的切削液，其主要成分按容积比例，包括矿物油10%、乳化剂1%、助溶剂0.5%、防腐剂5.2%、抗磨添加剂0.1%、极压剂1%、消泡剂0.5%、防腐杀菌剂1.2%和水80%。所述的矿物油为环烷基基础油、烷烃、环烷烃或环烷芳烃，主要起润滑作用。所述的乳化剂为烷基酚聚氧乙烯醚、脂肪醇聚氧乙烯醚、山梨糖醇聚氧乙烯醚、脂肪酸酰胺或磺酸盐，也起润滑作用，使用后可获得较好的表面质量。所述的助溶剂为醇类、醇胺类或醇醚类，主要起清洗作用。所述的防腐剂为苯羧酸、磺酸或亚硝酸盐，主要起防腐蚀作用。所述的抗磨添加剂为二烷基硫代磷酸盐。所述的极压剂为硫、磷、氯或碘，可形成耐磨保护膜，起耐磨作用。所述的消泡剂为硅油、聚醚类、植物油或高级醇，主要起消除泡沫作用。所述的防腐杀菌剂为甲醛释放型，主要起杀菌作用。
实施例1：加工型腔光亮面
采用718模具料，刀具为钨钢刀，切削量为0.2—0.4mm，转速5000转/分，进给率2500m/min，加工时产生300—400℃的高温，此时，喷以雾化切削液，会慢慢地降低高温至70—80℃，在高温产生至降低过程，相当于是对模具料进行二次热处理，使模具料的硬度和光亮度更高。并且由于型腔面为一个凹槽型镶块，采用雾化切削液，切削液在加工过程中就雾化，没有液体残留。
实施例2：加工型芯光亮面
采用718模具料，刀具为钨钢刀，切削量为0.2—0.4mm，转速5000转/分，进给率2500m/min，加工时产生300—400℃的高温，此时，直接喷切削液液体，因为型芯面为一块凸状镶块，切削液喷下后会自动流走，并且能带走碎屑，无需清洗型芯。其冷却效果与加工型腔光亮面相同。
Claims (10)
1.汽车大灯灯罩光亮面加工方法，其特征在于包括以下步骤：
①、粗加工：取两块模具料，采用单轴数控铣对两块模料分别进行粗加工，得到型腔镶块初坯和型芯镶块初坯；
②、精加工：采用高速数控铣对型腔镶块初坯和型芯镶块初坯的光亮面（3）分别进行精加工，在加工型腔镶块过程中，采用切削液对型腔镶块进行间歇性雾化喷射；在加工型芯镶块过程中，采用切削液对型腔镶块进行直接喷洒，得到型腔镶块（1）和型芯镶块（2）。
2.用于汽车大灯灯罩光亮面加工的切削液，其特征在于按容积比例，包括矿物油10%、乳化剂1%、助溶剂0.5%、防腐剂5.2%、抗磨添加剂0.1%、极压剂1%、消泡剂0.5%、防腐杀菌剂1.2%和水80%。
3.如权利要求2所述的用于汽车大灯灯罩光亮面加工的切削液，其特征在于所述的矿物油为环烷基基础油、烷烃、环烷烃或环烷芳烃。
4.如权利要求2所述的用于汽车大灯灯罩光亮面加工的切削液，其特征在于所述的乳化剂为烷基酚聚氧乙烯醚、脂肪醇聚氧乙烯醚、山梨糖醇聚氧乙烯醚、脂肪酸酰胺或磺酸盐。
5.如权利要求2所述的用于汽车大灯灯罩光亮面加工的切削液，其特征在于所述的助溶剂为醇类、醇胺类或醇醚类。
6.如权利要求2所述的用于汽车大灯灯罩光亮面加工的切削液，其特征在于所述的防腐剂为苯羧酸、磺酸或亚硝酸盐。
7.如权利要求2所述的用于汽车大灯灯罩光亮面加工的切削液，其特征在于所述的抗磨添加剂为二烷基硫代磷酸盐。
8.如权利要求2所述的用于汽车大灯灯罩光亮面加工的切削液，其特征在于所述的极压剂为硫、磷、氯或碘。
9.如权利要求2所述的用于汽车大灯灯罩光亮面加工的切削液，其特征在于所述的消泡剂为硅油、聚醚类、植物油或高级醇。
10.如权利要求2所述的用于汽车大灯灯罩光亮面加工的切削液，其特征在于所述的防腐杀菌剂为甲醛释放型。
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