CN111289321A - Preparation process of sheet metal tensile sample - Google Patents
Preparation process of sheet metal tensile sample Download PDFInfo
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- CN111289321A CN111289321A CN202010124008.4A CN202010124008A CN111289321A CN 111289321 A CN111289321 A CN 111289321A CN 202010124008 A CN202010124008 A CN 202010124008A CN 111289321 A CN111289321 A CN 111289321A
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- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/286—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q involving mechanical work, e.g. chopping, disintegrating, compacting, homogenising
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- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/286—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q involving mechanical work, e.g. chopping, disintegrating, compacting, homogenising
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- G01N2203/00—Investigating strength properties of solid materials by application of mechanical stress
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Abstract
The invention discloses a preparation process of a metal plate tensile sample, which mainly comprises four main procedures of sample blank cutting, sample blank rough machining, sample blank shoulder opening machining and sample blank primary shoulder sawing. The preparation process of the tensile sample of the metal plate, which is provided by the invention, can be implemented on the traditional processing equipment such as the traditional plate shearing machine, the sawing machine, the vertical milling machine, the double-shoulder machine tool and the like, aiming at the defects and shortcomings of the traditional process, the processing capacity of the tensile sample of the metal plate is improved by simply upgrading the process, adjusting and optimizing the process under the conditions of not reducing the working efficiency, not updating the equipment, not increasing the manpower and material resources and other cost expenses, and the targeted design is carried out aiming at key and difficult links in the preparation process of the tensile sample of the metal plate, so that the form and position precision and the size deviation of the processed sample are fundamentally ensured to meet the requirements of the latest national standard GB/T228.1-2010, and the product qualification rate can reach 98 percent by taking the latest national standard as.
Description
Technical Field
The application belongs to the technical field of metal plate physical property detection, and particularly relates to a preparation process of a metal plate tensile sample.
Background
For a metal plate tensile sample, the latest national standard (GB/T228.1-2010) is based on the national standard of the last edition, the shape precision and the size precision are both greatly improved, the shape deviation is definitely +/-0.12 mm, and the size tolerance is improved to +/-0.10 mm from +/-0.50 mm.
At present, the traditional preparation process of the sheet metal tensile sample adopted by enterprises comprises the following steps:
1. cutting a sample blank with a specified length on a plate shearing machine;
2. processing the width of the sample blank to a specified size by using a vertical milling machine, and directly using the processed sample blank as a shoulder of a finished product tensile sample;
3. and (3) carrying out shoulder opening processing on the central parallel section of the sample blank by using a double-shoulder opening machine tool, and if the processed finished tensile sample is unqualified due to larger size, completely operating the shoulder opening processing program again.
The traditional processing technology adopted at present has large processing deviation, and the processed product has deviation in shape, position and size of a finished tensile sample, and the main deviation forms are shown in fig. 1 (a in fig. 1 is a structural diagram of a qualified sample), including length direction out-of-tolerance (shown in b in fig. 1), width direction oblique cutting (shown in c in fig. 1), width direction oblique cutting (shown in d in fig. 1) and the like. The metal plate tensile sample prepared by the traditional processing technology is taken as the standard of judgment, and the product percent of pass is 90% at most. The traditional machining process adopted at present is difficult to manufacture a tensile sample with high precision requirement (meeting the latest national standard (GB/T228.1-2010)), and even serious consequences such as overproof form and position tolerance of the sample, sample blank scrapping and the like can be caused.
Disclosure of Invention
In order to solve the technical problems, the invention provides a preparation process of a metal plate tensile sample, which can be used for preparing the tensile sample with high precision requirement and has high product qualification rate.
The technical scheme adopted for achieving the aim of the invention is that the preparation process of the metal plate tensile sample comprises the following steps:
(1) cutting a sample blank:
cutting a sample blank on a test material to be tested, wherein the length dimension and the width dimension of the sample blank are respectively greater than the design length dimension and the design width dimension of the tensile test sample;
(2) rough machining of a sample blank:
rough machining is carried out on the sample blank, appearance defects of the long side edge of the sample blank are removed, and a sample blank intermediate blank is obtained, wherein the width dimension of the sample blank intermediate blank is smaller than that of the sample blank and larger than the design width dimension of the tensile sample;
(3) and (3) shouldering a sample blank:
(3-1) rough crushing: processing and removing a material entity except the shoulder width of the intermediate blank of the sample blank to obtain a first shouldering sample blank with a middle sunken section and first-stage shoulders at the front end and the rear end;
(3-2) rough machining: processing and removing a material entity except the shoulder width of the middle depressed section of the first shouldering sample blank to form a central parallel section and two-stage shoulders at the front end and the rear end at the geometric center of the middle depressed section to obtain a second shouldering sample blank;
(3-3) finishing: performing finish machining on the central parallel section, wherein the single-side tool depth is 1/60-1/20 of the width of the central parallel section of the tensile sample, and the width size and the length size of the center parallel section after finish machining are respectively the same as those of the central parallel section of the tensile sample, so that a final sample blank is obtained;
(4) sawing a first-level shoulder of the sample blank:
and cutting to remove the primary shoulders at the front end and the rear end of the final sample blank, and ensuring that the length directions of the residual materials of the final sample blank are symmetrical during cutting so as to cut the tensile sample from the final sample blank.
Further, in the step (1), cutting the sample blank on a plate shearing machine or a sawing machine;
in the step (2), rough machining is carried out on a sample blank on a milling machine;
in the step (3), the sample blank is shouldered on a double-shouldered machine tool;
and (4) sawing the first-stage shoulder of the sample blank on a sawing machine or a plate shearing machine.
Further, in the step (3), before the rough-working in the step (3-1), the method further includes:
(3-0) adjusting and correcting machine tool equipment:
a) adjusting the position symmetry of the machining tool: checking whether the coordinate parameters of the two processing tools used in the sample blank shoulder-opening processing procedure are symmetrical relative to a reference zero point or not, and if not, adjusting the coordinate parameters of the two processing tools to be symmetrical relative to the reference zero point;
b) adjusting the dimensional consistency of the processing tool: through the matching of workpieces, the consistency of the external dimensions of the two processing tools is ensured;
c) adjusting the fixity of the tailstock of the machine tool: and reinforcing the tailstock of the machine tool so as to prevent the tailstock of the machine tool from displacing in the machining process.
Further, in the step (3), after the finishing in the step (3-3), the method further includes:
(3-4) Final inspection: detecting the size parameters of the central parallel section and the secondary shoulders at the front end and the rear end of the final sample blank, judging whether the size parameters are consistent with the design size of the tensile sample, and if so, entering the step (4); if the two are not consistent, the step (3-3) is carried out, and the finishing is carried out again.
Further, before the secondary finishing, the method further comprises:
adjusting the position symmetry of the machining tool: and checking whether the coordinate parameters of the two processing tools used in the sample blank shoulder-opening processing procedure are symmetrical relative to a reference zero point, and if not, adjusting the coordinate parameters of the two processing tools to be symmetrical relative to the reference zero point.
Further, in the step (3-3), during finish machining, the one-side cutting feed is 1/50-1/30 of the width of the central parallel section of the tensile sample, the rotation speed of the main shaft is 400-500 r/min, the feeding speed of the machining tool in the length direction of the tensile sample is 20-30 mm/min, and the feeding speed in the width direction of the tensile sample is 3-5 mm/min.
Further, in the step (3-1), the rotation speed of the main shaft is 250-350 r/min during rough machining, the feeding speed of the machining tool in the length direction of the tensile sample is 30-60 mm/min, and the feeding speed of the machining tool in the width direction of the tensile sample is 5-8 mm/min during rough machining.
Further, in step (4), saw cutting the first shoulder of the sample blank, including:
(4-1) drawing a center line on the processing surface of the final sample blank along the length direction, wherein the center line passes through the geometric center of the final sample blank and is used as the length reference of sawing;
(4-2) marking a processing line at the set positions on the two sides of the geometric center on the central line, and symmetrically cutting and removing the primary shoulders at the front end and the rear end of the final sample blank along the processing line to ensure that the length directions of the residual materials of the final sample blank are symmetrical so as to cut the tensile sample from the final sample blank.
Based on the same inventive concept, the invention also provides a control device, which comprises a memory and a processor connected with the memory, wherein the memory is stored with program codes, and the processor is used for reading the program codes from the memory so as to execute the sheet metal tensile sample preparation process.
Based on the same inventive concept, the present invention also provides a computer-readable storage medium storing program code, which, when executed by a processor, can implement the above-mentioned sheet metal tensile specimen preparation process.
According to the technical scheme, the preparation process of the metal plate tensile sample mainly comprises four main processes of sample blank cutting, sample blank rough machining, sample blank shoulder cutting machining and sample blank primary shoulder sawing. Wherein:
a sample blank cutting process is characterized in that a sample blank is cut on a sample to be detected, the length dimension and the width dimension of the cut sample blank are respectively larger than the designed length dimension and the designed width dimension of a tensile sample, and considering that the processing precision of the sample blank cutting process is limited, enough material entities are reserved in the length direction and the width direction, and the finish machining of the length direction and the width direction of the sample is adjusted to the final procedure, so that the adverse effects of the processing procedures in the midway on the length and the asymmetry of the sample are avoided, and the accuracy and the symmetry of the finished tensile sample are ensured.
In the prior art, due to the limited cutting precision, the processed samples have poor length consistency, and the processing of the subsequent procedures can cause the offset of the central parallel section of the samples, thereby causing the out-of-tolerance (asymmetric length direction) of the finished tensile samples in the length direction.
The rough machining process of the sample blank is to rough machine the sample blank to remove the appearance defects (including but not limited to burrs, sample blank big and small heads, non-parallelism, a shear hardening area and the like) of the long side of the sample blank.
The rough machining process of the sample blank is only used as a preparation process of finish machining in the width direction, and the finish machining in the width direction is reserved to the shoulder opening machining of the sample blank with higher machining precision so as to ensure the precision of the shoulder size of the finished tensile sample. In the prior art, after the length dimension is determined, the width of the sample blank is directly machined to a specified dimension to be used as a shoulder of a finished product tensile sample, and due to a series of problems of large machining deviation, difficulty in controlling sample clamping and the like of an adopted milling machine, the width of the sample is easy to be out of tolerance, and further the finished product tensile sample is off-cut (the width direction is asymmetric).
The sample blank shoulder-opening processing procedure is the most important processing procedure in the preparation process of the metal plate tensile sample provided by the invention, and directly determines the dimensional precision and the form and position precision of a sample finished product. The working procedure mainly comprises three independent sub-working procedures of rough-breaking processing, rough processing and finish processing. Wherein:
and the rough breaking processing sub-procedure is used for processing and removing material entities except the shoulder width of the intermediate blank of the sample blank to obtain a first shoulder opening sample blank with a middle concave section and first-level shoulders at the front end and the rear end, wherein the middle concave section is used as a processing object of subsequent rough processing and finish processing, namely a blank of a finished tensile sample. The first-level shoulders at the front end and the rear end are used as clamping positions for three independent sub-process machining, so that the quality of a finished tensile sample is prevented from being influenced by operations such as clamping and the like. The rough-breaking processing sub-procedure can effectively solve the problems that the processing precision of the procedure in the width direction is insufficient, and the shape and position tolerance of the sample in the width direction is beyond standard due to uneven clamping, air suspension and the like caused by equipment and human factors.
And a rough machining sub-process, which is used for machining and removing the material entity except the shoulder width of the middle sunken section so as to form a central parallel section and two-stage shoulders at the front end and the rear end at the geometric center of the middle sunken section. And the rough machining sub-procedure obtains a second shouldering sample blank, the appearance size of the second-stage shoulder is the same as that of the finished product tensile sample, the length of the central parallel section is the same as that of the finished product tensile sample, and the width of the central parallel section is larger than that of the finished product tensile sample. The rough machining sub-process aims to remove material entities outside the central parallel section of the finished tensile sample to the maximum extent, reduce the tool consumption of finish machining and ensure that the finish machining is carried out smoothly, stably and efficiently.
And a finishing sub-process for finishing the central parallel section to make the width and length of the finished central parallel section the same as those of the tensile sample, thereby obtaining a final sample blank. The fine processing sub-process is the most central step in the preparation process of the metal plate tensile sample, and due to the rough processing sub-process, the processing amount of the fine processing sub-process in the width direction is extremely small, the single-side tool cutting amount is only 1/60-1/20 of the width of the central parallel section of the tensile sample, and the smaller the tool cutting amount is, the smaller the processing deviation possibly caused is, and the processing precision of the central parallel section is further ensured.
And a step of sawing first-stage shoulders of the sample blank, which is used for cutting and removing the first-stage shoulders at the front end and the rear end of the final sample blank, wherein the first-stage shoulders are only used as clamping positions, the first-stage shoulders are substantially areas of the sample blank exceeding the length of the finished tensile sample in length, the first-stage shoulders are cut off through the step, the length direction of the residual materials of the final sample blank is ensured to be symmetrical during cutting, and the residual materials are the finished tensile sample. The machining precision of the central parallel section of the core structure of the finished product tensile sample is ensured by the fine machining sub-process, and the second-level shoulder (namely the shoulder of the finished product tensile sample) and the central parallel section do not need to be machined in the first-level shoulder process of the sample blank sawing process, so that the machining precision of the finished product tensile sample is ensured.
Compared with the prior art, the preparation process of the tensile sample of the metal plate, which is provided by the invention, can be implemented on the traditional processing equipment such as the traditional plate shearing machine, the sawing machine, the vertical milling machine, the double-shoulder machine tool and the like, aiming at the defects and shortcomings of the traditional process, the processing capacity of the tensile sample of the metal plate is improved by simply upgrading the process, adjusting and optimizing the process under the condition of not reducing the working efficiency, updating the equipment, increasing the manpower and material resources and other cost expenses, and the targeted design is carried out aiming at the key and difficult links in the preparation process of the tensile sample of the metal plate, so that the form and position precision and the size deviation of the processed sample are fundamentally ensured to meet the requirements of the latest national standard (GB/T228.1-2010), and the product qualification rate can reach 98 percent by taking the latest national standard (GB/T228.1-2010) as the.
Drawings
FIG. 1 is a schematic diagram of a deflection structure of a finished tensile specimen;
fig. 2 is a schematic structural diagram of a sample blank of the process for preparing a metal plate tensile sample in example 1 of the present invention;
fig. 3 is a schematic structural diagram of a sample blank intermediate blank of the process for preparing a metal plate tensile sample in example 1 of the present invention;
fig. 4 is a schematic structural diagram of a first shouldering sample blank of the process for preparing a metal plate tensile sample in embodiment 1 of the invention;
fig. 5 is a schematic structural diagram of a second shouldering sample blank of the process for preparing a metal plate tensile sample in embodiment 1 of the invention;
fig. 6 is a schematic structural diagram of a final sample blank of the process for preparing a tensile sample of a metal plate in example 1 of the present invention;
fig. 7 is a schematic structural diagram of a final sample blank of the process for preparing a tensile sample of a metal plate in example 1 of the present invention when being cut;
fig. 8 is a schematic structural diagram of a tensile sample of the process for preparing a metal plate tensile sample in example 1 of the present invention;
description of reference numerals: 10-blank of the sample blank; 20-sample blank intermediate blank; 30-first opening a shoulder sample blank; 40-second shoulder opening sample blank; 50-final sample blank; 60-tensile sample, 61-central parallel segment, 62-first-level shoulder; 1-a middle recessed section; 2-first-level shoulder; 3-roughly machining a central parallel section; 4-second level shoulder; 5-finishing the central parallel section; 6-center line; 7-processing line.
Detailed Description
In order to make the present application more clearly understood by those skilled in the art to which the present application pertains, the following detailed description of the present application is made with reference to the accompanying drawings by way of specific embodiments.
Example 1:
in the embodiment of the invention, the preparation process of the metal plate tensile sample comprises the following steps:
(1) cutting a sample blank:
cutting a sample blank 10 on a test material to be tested, wherein the length dimension and the width dimension of the sample blank 10 are respectively larger than the designed length dimension and the designed width dimension of the tensile test sample 60, and the structure of the sample blank 10 is shown in FIG. 2;
(2) rough machining of a sample blank:
rough machining is carried out on the sample blank 10, the appearance defects of the long side edge of the sample blank 10 are removed, a sample blank intermediate blank 20 is obtained, the width dimension of the sample blank intermediate blank 20 is smaller than that of the sample blank 10 and larger than the design width dimension of the tensile sample 60, and the structure of the sample blank intermediate blank 20 is shown in figure 3;
(3) and (3) shouldering a sample blank:
(3-1) rough crushing: processing and removing material entities except the shoulder widths of the intermediate blank 20 of the sample blank to obtain a first shouldering sample blank 30 with a middle concave section 1 and first-stage shoulders 2 at the front end and the rear end, wherein the structure of the first shouldering sample blank 30 is shown in FIG. 4;
(3-2) rough machining: processing and removing a material entity except the shoulder width of the middle depressed section 1 of the first shouldering sample blank 30 to form a central parallel section 3 and two-stage shoulders 4 at the front end and the rear end at the geometric center part of the middle depressed section 1, so as to obtain a second shouldering sample blank 40, wherein the structure of the second shouldering sample blank 40 is shown in fig. 5;
(3-3) finishing: finishing the central parallel section 3, wherein the single-side tool depth is 1/60-1/20 of the width of the central parallel section 61 of the tensile sample 60, the width and length of the finished central parallel section 5 are respectively the same as those of the central parallel section 61 of the tensile sample 60, and a final sample blank 50 is obtained, wherein the structure of the final sample blank 50 is shown in FIG. 6;
(4) sawing a first-level shoulder of the sample blank:
the first shoulder portions 1 at the front and rear ends of the final blank 50 are cut off, and the remaining material length direction of the final blank 50 is secured to be symmetrical at the time of cutting, so that a tensile sample 60 is cut out from the final blank 50, and the structure of the tensile sample 60 is shown in fig. 7.
The preparation process of the tensile sample of the metal plate can be implemented on the basis of the traditional processing equipment of the existing plate shearing machine, sawing machine, vertical milling machine, double-shoulder machine tool and the like in the physical property detection room of the metal plate, and the processing capacity of the tensile sample of the metal plate is improved simply through process upgrading, process adjustment and optimization on the premise of not updating the equipment, increasing the investment and reducing the processing efficiency.
Each process step of the process for preparing the tensile sample of the metal plate is described in detail below with reference to a specific embodiment, and the process for preparing the tensile sample of the metal plate comprises the following steps:
(1) cutting a sample blank: implemented on a conventional guillotine shear or a conventional sawing machine.
A sample blank 10 is cut out from a test sample, the length and width dimensions of the sample blank 10 are respectively larger than the designed length and width dimensions of the tensile test sample 60, and the structure of the sample blank 10 is as shown in fig. 2.
The purpose of this process is to cut a sample blank 10 from a large-area plate (sample to be tested), and to select a plate shearing machine or a sawing machine for sawing or shearing according to the thickness of the plate. The cut sample blank 10 is rectangular, the length is greater than the designed length of the tensile sample 60, the width is greater than the designed width of the maximum width position (the first-stage shoulder 62) of the tensile sample 60, and the sample blank 10 has larger machining allowance on the premise of meeting the requirements of all aspects in terms of length and width.
Because the processing precision of the procedure is limited, the finish machining of the length direction of the sample is adjusted to the final procedure, so that the adverse effect of each processing procedure on the length and asymmetry of the sample in the midway is avoided, and the precision and symmetry of the length processing of the finished tensile sample are ensured.
(2) Rough machining of a sample blank: implemented on a conventional milling machine.
Rough machining is carried out on the sample blank 10, the appearance defects of the long side edge of the sample blank 10 are removed, a sample blank intermediate blank 20 is obtained, the width dimension of the sample blank intermediate blank 20 is smaller than that of the sample blank 10 and larger than the design width dimension of the tensile sample 60, and the structure of the sample blank intermediate blank 20 is shown in fig. 3.
The purpose of this process is to remove the defects such as deckle edge, burr, the big end and small end of sample blank, nonparallel, shear hardening district of sample blank 10, because the both ends of sample blank 10 length direction are cut in the final process, therefore this process only processes the width of sample blank 10, after removing the limit defect on both sides limit on the width, the material width reduces to a certain extent, but still is greater than the width of the biggest width department (one-level shoulder 62) of tensile sample 60.
If a plurality of samples are processed simultaneously, the sample blank is recommended not to be scattered after milling is finished, the whole process is transferred to the next process, and the consistency of sample clamping of the next process is ensured.
The process is different from the traditional process in parameter and function setting, is only used as a preparation process of width direction finish machining, and keeps the width direction finish machining to a double shoulder opening process with higher machining precision so as to ensure the accuracy of the shoulder size of a finished product sample.
(3) And (3) shouldering a sample blank: the process directly determines the size precision and the shape and position precision of the finished sample, is the most important processing process in the set of preparation method, and an operator needs to carefully adjust process parameters and strictly operate according to the following requirements. Before this process begins, the double-shouldered machine tool (having two milling cutters arranged along the width direction of the workpiece, wherein the two milling cutters are distributed on two sides of the width direction of the workpiece, so as to realize synchronous shouldering processing on two sides) needs to be adjusted and calibrated, that is:
(3-0) adjusting and correcting machine tool equipment:
a) adjusting the positional symmetry of a machining tool (hereinafter, referred to as a milling cutter): and checking whether the coordinate parameters of the two milling cutters used in the sample blank shoulder-opening machining procedure are symmetrical relative to a reference zero point, and if not, adjusting the coordinate parameters of the two milling cutters to make the two milling cutters symmetrical relative to the reference zero point.
b) Adjusting the size consistency of the milling cutter: and the matching of the workpieces ensures that the two milling cutters have the same external dimension. The diameter of the two milling cutters may be abraded asynchronously due to some reasons, the problem is easily caused by the asymmetry (deviation) of the width direction of a finished product sample, a pair of new horizontal milling cutter heads should be replaced at the same time, and the new milling cutter and the old milling cutter are forbidden to be used together.
c) Adjusting the fixity of the tailstock of the machine tool: and reinforcing the tailstock of the machine tool so as to prevent the tailstock of the machine tool from displacing in the machining process. The tailstock of the machine tool integrates clamping bench vice at the outer side of the sample and is fastened on a T-shaped workbench of the machine tool together with the clamping bench vice, the bench vice and the clamping jaw fixed at the inner side complete the fixation of the sample during machining, the bench vice can be influenced by the horizontal cutting component force of a milling cutter during machining (sample length) in the X-axis direction, if the tailstock is not firmly fixed, the sample blank can slide backwards along with the tailstock, and the machining in the length direction of the sample is asymmetric.
The sample blank shoulder-opening processing procedure comprises 5 sub-procedures of rough-breaking processing, rough processing, finish processing and final inspection and reprocessing:
(3-1) rough crushing: and (3) processing and removing material entities except the shoulder width of the sample blank intermediate blank 20 to obtain a first shoulder-opening sample blank 30 with a middle concave section 1 and first-stage shoulders 2 at the front end and the rear end, wherein the structure of the first shoulder-opening sample blank 30 is shown in FIG. 4.
Specifically, the single-side cutting depth of the rough-breaking processing is 1/15-1/5 of the width of the central parallel section 61 of the tensile sample 60, the rotating speed of a main shaft is 250-350 r/min, the feeding speed of a processing tool in the length direction of the tensile sample is 30-60 mm/min, and the feeding speed of the processing tool in the width direction of the tensile sample is 5-8 mm/min.
The process is an innovative process compared with the traditional process, and can effectively solve the problem that the form and position tolerance in the width direction of the sample is overproof due to the fact that the process is not smooth in clamping and uneven in clamping and caused by equipment and human factors in the width direction.
(3-2) rough machining: and (3) processing and removing material entities except the shoulder width of the middle recessed section 1 of the first shouldering sample blank 30 to form a central parallel section 3 and two-stage shoulders 4 at the front end and the rear end at the geometric center of the middle recessed section 1, so as to obtain a second shouldering sample blank 40, wherein the structure of the second shouldering sample blank 40 is shown in fig. 5.
Specifically, the rough machining one-side cutting depth is 1/15-1/5 of the width of the central parallel section 61 of the tensile sample 60, the main shaft rotating speed is 250-350 r/min, the feeding speed of the machining tool in the length direction of the tensile sample is 30-60 mm/min, and the feeding speed of the machining tool in the width direction of the tensile sample is 5-8 mm/min.
The processing aim of the rough machining process is to remove the material entity outside the parallel section of the finished product sample to the maximum extent, reduce the tool consumption of finish machining and ensure that the finish machining is smoothly and efficiently carried out.
(3-3) finishing: and (3) finishing the central parallel section 3, wherein the one-side tool depth is 1/60-1/20 of the width of the central parallel section 61 of the tensile sample 60, the width dimension and the length dimension of the finished central parallel section 5 are respectively the same as those of the central parallel section 61 of the tensile sample 60, and a final sample blank 50 is obtained, and the structure of the final sample blank 50 is shown in FIG. 6.
The finishing process is the most central step in the whole set of processing technology, in order to ensure the position, shape, dimensional accuracy requirement and processed surface finish quality of the parallel section of the sample, the single-side cutting amount of the finishing process is 1/50-1/30 of the width of the central parallel section of the tensile sample, such as 1/50, 1/48, 1/45, 1/42, 1/40, 1/36, 1/33, 1/30, and the like, and the processed amount in the length direction of the sample is the same as the rough processed amount and is the length dimension of the central parallel section 61 of the tensile sample 60.
In order to ensure the smoothness of the parallel section, the rotation speed of a finishing spindle is 400-500 r/min, the feeding speed of a processing tool in the length direction of a tensile sample is 20-30 mm/min, and the feeding speed of the processing tool in the width direction of the tensile sample is 3-5 mm/min. The finish machining process is completed by matching the higher spindle rotating speed with the lower feeding multiplying factor, and the spindle rotating speed, the feeding multiplying factor and other machining parameters are strictly forbidden to be suspended or adjusted in the sample length direction feeding machining process unless safety or other necessary factors are involved, so that the finish degree of a machined surface is prevented from being influenced.
(3-4) Final inspection: detecting the size parameters of the central parallel section and the secondary shoulders at the front end and the rear end of the final sample blank, judging whether the size parameters are consistent with the design size of the tensile sample, and if so, entering the step (4); if the difference is not the same, the process proceeds to step (3-3) and re-finishing is performed, and the re-finishing is set as an independent sub-step (3-5) for distinguishing from step (3-3).
After the processing is finished, the machine should be stopped firstly, safety is confirmed, and then the sample is detected on the clamping bench clamp: if the detection is qualified, the hydraulic jaw can be loosened, and the sample is integrally removed. If a plurality of workpieces are processed simultaneously, the workpieces are recommended not to be scattered, and the whole process is transferred to the next process (4) for sawing the first-level shoulder of the sample blank. If the sample is unqualified due to the larger size, the method enters (3-5) reprocessing.
(3-5) reprocessing: the final blank 50 is again finished.
Before reprocessing, the coordinate parameters of two milling cutters during reprocessing are properly and symmetrically adjusted, and a finishing task is independently performed once, so that the finishing task can be finished at high speed and high efficiency.
The re-machining process is the same as the finish machining process, and the coordinate parameters are basically consistent with the coordinate parameters, so that the coordinate parameters of the two processes are corrected before the re-machining process is started every time, and if the coordinate parameters are different, the coordinate parameters are adjusted synchronously. That is, whether the coordinate parameters of the two machining tools used in the shoulder-opening machining process of the sample blank are symmetrical with respect to the reference zero point is checked, and if the coordinate parameters are asymmetrical, the coordinate parameters of the two machining tools are adjusted to be symmetrical with respect to the reference zero point.
In the traditional process, the reprocessing is to carry out all the shoulder opening procedures all the time, but only the finishing procedure is used, and other procedures belong to equipment idle running and have no practical effect. In the present embodiment, the independent rework process (i.e., the transfer finish process) is provided, thereby improving the process efficiency of the rework process.
(4) Sawing a first-level shoulder of the sample blank: and sawing the first-stage shoulder of the sample blank on a sawing machine or a plate shearing machine.
The first shoulder portions 1 at the front and rear ends of the final blank 50 are cut off, and the remaining material length direction of the final blank 50 is secured to be symmetrical at the time of cutting, so that a tensile sample 60 is cut out from the final blank 50, and the structure of the tensile sample 60 is shown in fig. 8.
Specifically, the step (4) of sawing the first-level shoulder of the sample blank comprises the following two steps:
(4-1) drawing a center line 6 on the working surface of the final blank 50 in the longitudinal direction, wherein the center line 6 passes through the geometric center of the final blank, and the center line 6 is taken as the length reference for sawing, as shown in FIG. 7. In order to cut out a sample with symmetrical length direction, no burr and regular notch pattern from the final sample blank, a metal band sawing machine is recommended to be selected for sawing.
(4-2) drawing a processing line 7 at a set position on both sides of the geometric center on the center line 6, and cutting symmetrically along the processing line 7 to remove the primary shoulder portions 2 at the front and rear ends of the final blank sample, as shown in fig. 7, to ensure the remaining material length direction symmetry of the final blank sample 50, to cut out a tensile specimen 60 from the final blank sample 50.
Example 2:
based on the same inventive concept, the present embodiment provides a control apparatus comprising a memory and a processor connected to the memory, the memory having stored thereon program codes, the processor being configured to read the program codes from the memory to perform the sheet metal tensile specimen preparation process of embodiment 1 above. The control equipment can be specifically a PLC controller, an industrial personal computer and the like.
Example 3:
based on the same inventive concept, the present embodiment provides a computer-readable storage medium storing program code, which, when executed by a processor, can implement the sheet metal tensile specimen preparation process of embodiment 1 described above.
Application example:
a certain steel mill enterprise is provided with a special metal plate physical property detection chamber, and traditional processing equipment such as a plate shearing machine, a sawing machine, a vertical milling machine, a double-shoulder machine tool and the like are arranged in the metal plate physical property detection chamber, and the traditional processing equipment can be independently controlled to operate and can also be controlled by one controller to operate simultaneously. The metal plate physical property detection chamber is used for preparing a metal plate tensile sample by adopting a traditional process, the yield is low, and the tensile sample meeting the new national standard can be difficult to prepare, so that the tensile sample is subjected to outsourcing processing.
Then, the process improvement is carried out, and the process for preparing the tensile sample of the metal plate material in the embodiment 1 is adopted. On the premise of not updating equipment, increasing investment and reducing processing efficiency, the processing capacity of the sheet metal tensile sample is improved simply through process upgrading, process adjustment and program optimization, a sample with a certain specification (shoulder width, center parallel segment length, total sample length 25, 20, 80 and 260mm) is processed as an example, the tensile sample is generally prepared in multiple steps, and the accuracy of a detection result is ensured, wherein the specific processing process is as follows:
(1) cutting a sample blank: the purpose of this process is to cut a sample blank 10 from a large-area plate (sample to be tested), and to select a plate shearing machine or a sawing machine for sawing or shearing according to the thickness of the plate. The blank 10 is preferably 35 mm wide by 500mm long while satisfying various requirements, and the structure of the blank 10 is shown in fig. 2.
(2) Rough machining of a sample blank: the purpose of this process is to remove the defects such as burrs, the big and small ends of the blank 10, the non-parallelism, and the shear hardening zone, and the intermediate blank 20 has the width and length of 29 × 500mm, and the structure of the intermediate blank 20 is shown in fig. 3.
A plurality of samples are processed simultaneously, the sample blank is recommended not to be scattered after milling is finished, the whole process is transferred to the next process, and the consistency of sample clamping of the next process is guaranteed.
(3) And (3) shouldering a sample blank: the process directly determines the size precision and the shape and position precision of the finished sample, is the most important processing process in the set of preparation method, and an operator needs to carefully adjust process parameters and strictly operate according to the following requirements. Before this process begins, the double-shouldered machine tool (having two milling cutters arranged along the width direction of the workpiece, wherein the two milling cutters are distributed on two sides of the width direction of the workpiece, so as to realize synchronous shouldering processing on two sides) needs to be adjusted and calibrated, that is:
(3-0) adjusting and correcting machine tool equipment:
a) adjusting the positional symmetry of a machining tool (hereinafter, referred to as a milling cutter): and checking whether the coordinate parameters of the two milling cutters used in the sample blank shoulder-opening machining procedure are symmetrical relative to a reference zero point, and if not, adjusting the coordinate parameters of the two milling cutters to make the two milling cutters symmetrical relative to the reference zero point. For example, the machining width is 20mm, the datum reference point is +10.00, the diameters of Y, Z milling cutters are both 60mm, Y, Z milling cutters are symmetrical relative to the datum reference point, and then the coordinate of a Y milling cutter is-30.00, and the coordinate of a Z milling cutter is + 50.00.
b) Adjusting the size consistency of the milling cutter: and the matching of the workpieces ensures that the two milling cutters have the same external dimension. The diameter of the two milling cutters may be abraded asynchronously due to some reasons, the problem is easily caused by the asymmetry (deviation) of the width direction of a finished product sample, a pair of new horizontal milling cutter heads should be replaced at the same time, and the new milling cutter and the old milling cutter are forbidden to be used together.
c) Adjusting the fixity of the tailstock of the machine tool: and reinforcing the tailstock of the machine tool so as to prevent the tailstock of the machine tool from displacing in the machining process. The tailstock of the machine tool integrates clamping bench vice at the outer side of the sample and is fastened on a T-shaped workbench of the machine tool together with the clamping bench vice, the bench vice and the clamping jaw fixed at the inner side complete the fixation of the sample during machining, the bench vice can be influenced by the horizontal cutting component force of a milling cutter during machining (sample length) in the X-axis direction, if the tailstock is not firmly fixed, the sample blank can slide backwards along with the tailstock, and the machining in the length direction of the sample is asymmetric.
The sample blank shoulder-opening processing procedure comprises 5 sub-procedures of rough-breaking processing, rough processing, finish processing and final inspection and reprocessing:
(3-1) rough crushing: and (3) processing and removing material entities except the shoulder width of the intermediate blank 20 of the sample blank, wherein the milling cutter cutting consumption on each side in the width direction is 2mm, the main shaft rotating speed is 300r/min, the feeding speed of the milling cutter in the length direction of the tensile sample is 45mm/min, and the feeding speed of the milling cutter in the width direction of the tensile sample is 7mm/mi, so that a first shoulder-opening sample blank 30 with a middle concave section 1 (the size is 25mm wide and 300mm long) and first-stage shoulder parts 2 (the shoulder width is 29mm) at the front end and the rear end is obtained, and the structure of the first shoulder-opening sample blank 30 is shown in figure 4.
(3-2) rough machining: the material entity except the shoulder width of the middle depressed section 1 of the first shouldering sample blank 30 is machined and removed, the tool cutting amount on one side is 2mm, the entity removing task of 4mm is completed on two sides, the machining amount is set to be 80mm in the length direction of the sample, the rotating speed of the main shaft is 300r/min, the feeding speed of the machining tool in the length direction of the tensile sample is 50mm/min, and the feeding speed in the width direction of the tensile sample is 6mm/min, so that a central parallel section 3 (the size is 21 mm wide and 80mm long) and two-stage shoulders 4 (the shoulder width is 29mm) at the front end and the rear end (located at the inner side of the first-stage shoulder with the width of 29mm) are formed at the geometric center of the middle depressed section 1, and a second shouldering sample blank 40 is obtained, and the structure of the second shouldering sample blank 40.
(3-3) finishing: the center parallel section 3 was subjected to finish machining with a single-side tool depth of 0.5mm, a set machining volume in the sample length direction of 80mm together with the rough machining, a spindle rotation speed of 450r/min, a feed speed of the machining tool in the tensile sample length direction of 25mm/min, and a feed speed in the tensile sample width direction of 4 mm/min. The finish machining process is completed by matching the higher spindle rotating speed with the lower feeding multiplying factor, and the spindle rotating speed, the feeding multiplying factor and other machining parameters are strictly forbidden to be suspended or adjusted in the sample length direction feeding machining process unless safety or other necessary factors are involved, so that the finish degree of a machined surface is prevented from being influenced. The size of the center parallel segment 5 after finishing was 20 × 80mm in width and length (the primary shoulder and the secondary shoulder were not machined in this step and thus were unchanged in size), and a final blank 50 was obtained, and the structure of the final blank 50 was as shown in fig. 6.
(3-4) Final inspection: after the processing is finished, the machine should be stopped firstly, safety is confirmed, and then the sample is detected on the clamping bench clamp: if the detection is qualified, the hydraulic jaw can be loosened, the sample is integrally removed, the sample is recommended not to be scattered, and the whole process is integrally transferred to the next procedure; if the sample is unqualified due to the overlarge size, the Y, Z milling cutter coordinate parameters in the reprocessing program are properly and symmetrically adjusted, the reprocessing program is started, and a reprocessing task is independently performed once, so that the finishing task can be finished at high speed and high efficiency.
(4) Sawing a first-level shoulder of the sample blank: in order to cut out a sample 60 having a symmetrical longitudinal direction, no burr, and a regular notch pattern from the final sample blank 50, it is recommended to select a metal band sawing machine for sawing. In order to ensure the cleanness and tidiness of the rolled surface, a central line is drawn in the length direction of the processed surface of the final sample blank 50 to be used as a length reference for sawing by a sawing machine, processing lines are drawn at the positions 130 mm on two sides of the central line in the length direction of the sample blank, and one shoulder on two sides is symmetrically sawed.
Thus, high precision processing of 20/25-260 gauge tensile specimens was completed, and other gauge tensile specimens were proposed by the process modification referred to in this example.
Through the embodiment, the invention has the following beneficial effects or advantages:
the preparation process of the tensile sample of the metal plate, provided by the invention, can be implemented on the traditional processing equipment such as the traditional plate shearing machine, the sawing machine, the vertical milling machine, the double-shoulder machine tool and the like, aiming at the defects and shortcomings of the traditional process, the processing capacity of the tensile sample of the metal plate is improved by simply upgrading the process, adjusting and optimizing the process under the condition of not reducing the working efficiency, not updating the equipment, not increasing the manpower and material resources and any other cost, and the targeted design is carried out aiming at key and difficult links in the preparation process of the tensile sample of the metal plate, so that the form and position precision and the size deviation of the processed sample are fundamentally ensured to meet the requirements of the latest national standard (GB/T228.1-2010), and the product qualification rate can reach 98 percent by taking the latest national standard (GB/T228.1-2010) as the judgment standard.
As will be appreciated by one skilled in the art, embodiments of the present invention may be provided as a method, system, or computer program product. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, and the like) having computer-usable program code embodied therein.
The present invention is described with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each flow and/or block of the flow diagrams and/or block diagrams, and combinations of flows and/or blocks in the flow diagrams and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart flow or flows and/or block diagram block or blocks.
These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the functions specified in the flowchart flow or flows and/or block diagram block or blocks.
While the preferred embodiments of the present application have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all alterations and modifications as fall within the scope of the application.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present application without departing from the spirit and scope of the application. Thus, if such modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is intended to include such modifications and variations as well.
Claims (10)
1. A preparation process of a metal plate tensile sample is characterized by comprising the following steps:
(1) cutting a sample blank:
cutting a sample blank on a test material to be tested, wherein the length dimension and the width dimension of the sample blank are respectively greater than the design length dimension and the design width dimension of the tensile test sample;
(2) rough machining of a sample blank:
rough machining is carried out on the sample blank, appearance defects of the long side edge of the sample blank are removed, and a sample blank intermediate blank is obtained, wherein the width dimension of the sample blank intermediate blank is smaller than that of the sample blank and larger than the design width dimension of the tensile sample;
(3) and (3) shouldering a sample blank:
(3-1) rough crushing: processing and removing a material entity except the shoulder width of the intermediate blank of the sample blank to obtain a first shouldering sample blank with a middle sunken section and first-stage shoulders at the front end and the rear end;
(3-2) rough machining: processing and removing a material entity except the shoulder width of the middle depressed section of the first shouldering sample blank to form a central parallel section and two-stage shoulders at the front end and the rear end at the geometric center of the middle depressed section to obtain a second shouldering sample blank;
(3-3) finishing: performing finish machining on the central parallel section, wherein the single-side tool depth is 1/60-1/20 of the width of the central parallel section of the tensile sample, and the width size and the length size of the center parallel section after finish machining are respectively the same as those of the central parallel section of the tensile sample, so that a final sample blank is obtained;
(4) sawing a first-level shoulder of the sample blank:
and cutting to remove the primary shoulders at the front end and the rear end of the final sample blank, and ensuring that the length directions of the residual materials of the final sample blank are symmetrical during cutting so as to cut the tensile sample from the final sample blank.
2. The process for preparing a tensile specimen of sheet metal according to claim 1, wherein: in the step (1), cutting the sample blank on a plate shearing machine or a sawing machine;
in the step (2), rough machining is carried out on a sample blank on a milling machine;
in the step (3), the sample blank is shouldered on a double-shouldered machine tool;
and (4) sawing the first-stage shoulder of the sample blank on a sawing machine or a plate shearing machine.
3. The process for preparing a tensile specimen of sheet metal according to claim 1, wherein: in the step (3), before the rough-cutting machining in the step (3-1), the method further comprises:
(3-0) adjusting and correcting machine tool equipment:
a) adjusting the position symmetry of the machining tool: checking whether the coordinate parameters of the two processing tools used in the sample blank shoulder-opening processing procedure are symmetrical relative to a reference zero point or not, and if not, adjusting the coordinate parameters of the two processing tools to be symmetrical relative to the reference zero point;
b) adjusting the dimensional consistency of the processing tool: through the matching of workpieces, the consistency of the external dimensions of the two processing tools is ensured;
c) adjusting the fixity of the tailstock of the machine tool: and reinforcing the tailstock of the machine tool so as to prevent the tailstock of the machine tool from displacing in the machining process.
4. A process for preparing a sheet metal tensile specimen according to claim 3, wherein: in the step (3), after the finishing in the step (3-3), the method further comprises:
(3-4) Final inspection: detecting the size parameters of the central parallel section and the secondary shoulders at the front end and the rear end of the final sample blank, judging whether the size parameters are consistent with the design size of the tensile sample, and if so, entering the step (4); if the two are not consistent, the step (3-3) is carried out, and the finishing is carried out again.
5. The process for preparing a tensile specimen of sheet metal according to claim 4, wherein: before the secondary finishing, the method further comprises the following steps:
adjusting the position symmetry of the machining tool: and checking whether the coordinate parameters of the two processing tools used in the sample blank shoulder-opening processing procedure are symmetrical relative to a reference zero point, and if not, adjusting the coordinate parameters of the two processing tools to be symmetrical relative to the reference zero point.
6. The process for preparing a tensile specimen of sheet metal according to claim 1, wherein: in the step (3-3), during finish machining, the one-side tool cutting amount is 1/50-1/30 of the width of the central parallel section of the tensile sample, the rotating speed of a main shaft is 400-500 r/min, the feeding speed of a machining tool in the length direction of the tensile sample is 20-30 mm/min, and the feeding speed of the machining tool in the width direction of the tensile sample is 3-5 mm/min.
7. The process for preparing a tensile specimen of sheet metal according to claim 1, wherein: in the step (3-1), during rough machining, the rotating speed of the main shaft is 250-350 r/min, the feeding speed of the machining tool in the length direction of the tensile sample is 30-60 mm/min, and the feeding speed of the machining tool in the width direction of the tensile sample is 5-8 mm/min.
8. The process for preparing a tensile specimen of sheet metal according to claim 1, wherein: in step (4), saw cut the first grade shoulder of sample base, include:
(4-1) drawing a center line on the processing surface of the final sample blank along the length direction, wherein the center line passes through the geometric center of the final sample blank and is used as the length reference of sawing;
(4-2) marking a processing line at the set positions on the two sides of the geometric center on the central line, and symmetrically cutting and removing the primary shoulders at the front end and the rear end of the final sample blank along the processing line to ensure that the length directions of the residual materials of the final sample blank are symmetrical so as to cut the tensile sample from the final sample blank.
9. A control apparatus characterized by: comprising a memory having program code stored thereon and a processor coupled to the memory for reading the program code from the memory to perform the sheet metal tensile specimen preparation process of any of claims 1-8.
10. A computer-readable storage medium characterized by: the computer readable storage medium stores program code that, when executed by a processor, may implement the sheet metal tensile specimen preparation process of any of claims 1-8.
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