CN111992739B - Plastic spherical surface polishing-free turning process - Google Patents
Plastic spherical surface polishing-free turning process Download PDFInfo
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- CN111992739B CN111992739B CN202010875076.4A CN202010875076A CN111992739B CN 111992739 B CN111992739 B CN 111992739B CN 202010875076 A CN202010875076 A CN 202010875076A CN 111992739 B CN111992739 B CN 111992739B
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- 238000000034 method Methods 0.000 title claims abstract description 33
- 239000004033 plastic Substances 0.000 title claims abstract description 22
- 229920003023 plastic Polymers 0.000 title claims abstract description 22
- 210000004907 gland Anatomy 0.000 claims description 18
- 238000003825 pressing Methods 0.000 claims description 16
- 238000003754 machining Methods 0.000 claims description 11
- 238000010438 heat treatment Methods 0.000 claims description 8
- 238000005520 cutting process Methods 0.000 claims description 7
- 238000001746 injection moulding Methods 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 4
- 238000007493 shaping process Methods 0.000 claims description 2
- 238000012545 processing Methods 0.000 abstract description 8
- 238000004519 manufacturing process Methods 0.000 abstract description 3
- 230000006835 compression Effects 0.000 description 7
- 238000007906 compression Methods 0.000 description 7
- 230000000694 effects Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000005498 polishing Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B1/00—Methods for turning or working essentially requiring the use of turning-machines; Use of auxiliary equipment in connection with such methods
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Taps Or Cocks (AREA)
- Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
Abstract
The invention relates to a polishing-free turning process for a plastic spherical surface, which solves the problems of concentricity, tool joint mark joint, turning chip removal, turning smoothness and the like, improves the processing efficiency, shortens the manufacturing period, reduces the labor cost and meets the higher spherical surface quality requirement.
Description
Technical Field
The invention belongs to the technical field of valve body processing, and relates to a polishing-free turning process for a plastic spherical surface.
Background
The spherical surface of the valve ball of the traditional plastic ball valve is manufactured by adopting an injection molding blank and a post-turning process, the surface smoothness of the spherical surface manufactured by the turning process is not high enough, irregular turning marks are left, and the problem of large friction resistance to the rotation of the valve ball is caused, so that the spherical surface needs to be polished manually. The uncertain factors of manual polishing are many, the local polishing of the spherical surface is uneven, the concentricity is not easy to guarantee, the labor cost and the consumption cost of polishing cloth are high, and the dust pollution of a workshop is large, and particularly for the requirements of high precision and high smoothness of a valve ball of a ball valve, the defects of the traditional process are prominent, so that a new process needs to be developed to solve the problems.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the above problems in the prior art are overcome.
The technical scheme adopted by the invention for solving the technical problems is as follows: the provided plastic spherical surface polishing-free turning process comprises the following steps:
(1) obtaining a valve ball blank through injection molding, wherein the outer surface of the valve ball blank is a spherical surface, a rotating shaft positioning groove is arranged on the spherical surface, a central through hole is formed in the center of the valve ball blank, an end face is arranged at one end of the central through hole, one side with the end face is an A side, and the side corresponding to the A side is a B side;
(2) the valve ball blank is subjected to stress relief and shaping through heating;
(3) a three-jaw chuck of a lathe is used as a first clamp, the first clamp extends into the central through hole from the side B and tightly supports the central through hole of the valve ball blank, the end face of the valve ball blank and the central through hole are machined in the direction from the side A to the side B, the machining area of the central through hole is half of the depth of the central through hole, and after the machining is finished, the first clamp leaves the central through hole of the valve ball blank;
(4) the first clamp clamps the outer surface of the second clamp, the central through hole is sleeved on the second clamp from the side A, the sleeving depth is half of the depth of the central through hole, a bolt is screwed down, a rubber ring is longitudinally compressed and radially expanded, the central through hole is tensioned, the other half area of the central through hole is firstly machined by a lathe, then the outer surface of the valve ball blank is machined, and the outer surface of the valve ball blank is machined to a position which is reserved for 3 mm away from the end surface;
(5) and loosening the bolt, taking out the valve ball blank, sleeving the central through hole on the second clamp from the side B, and lathing the part of the outer surface of the valve ball blank, which is reserved for 3 mm, so as to finish machining.
As a preferred embodiment of the invention, the injection molding temperature in the step (1) is 190-210 ℃, the pressure is 7.0-7.5 MPa, and the cooling time is 600-1000 s.
As a preferred embodiment of the present invention, the heating method in step (2) is: setting the heating temperature of the oven to 80 ℃, putting the valve ball blank into the oven to be heated for 8 hours, stopping heating, naturally cooling at the temperature, and taking out after 8 hours.
As a preferred embodiment of the present invention, the turning in step (4) is performed using an R4 cutter, the cutting feed is 4mm, the spindle speed is 2000 rpm, and the step pitch is 0.05 mm.
As a preferred embodiment of the present invention, in the step (4), the second jig includes a jig main body, a first rubber ring, a first pressing ring, a second rubber ring, a second pressing ring, a third rubber ring, a pressing cover, and a bolt, the jig main body has a first surface, a second surface corresponding to the first surface, an inner annular surface, and an outer annular surface corresponding to the inner annular surface, the jig main body is provided with a first through hole, the first through hole penetrates from the first surface to the second surface, the outer annular surface has a first step annular surface, a second step annular surface, and a third step annular surface, a diameter of the first step annular surface is greater than a diameter of the second step annular surface, a diameter of the second step annular surface is greater than a diameter of the third step annular surface, the first step pressing ring is sleeved on the third step annular surface, the border of first clamping ring is equipped with first groove ring, first rubber circle hold in first groove ring is intra-annular, second clamping ring cover is located on the third step anchor ring, the border of second clamping ring is equipped with second groove ring, second rubber circle hold in second groove ring is intra-annular, the gland lid is located on the first surface, the border of gland is equipped with the third groove ring, the third rubber circle hold in the third groove ring is intra-annular be equipped with the second through-hole on the gland, the central line of first through-hole with the central line of second through-hole is on same straight line, the bolt inserts in second through-hole and the first through-hole.
As a preferred embodiment of the invention, the outer diameter of the first step ring surface is 1 time of the nominal size of the ball valve, and the length of the first step ring surface is 40-60 mm; the outer diameter of the second step ring surface is 0.8 times of the nominal size of the ball valve, and the length of the second step ring surface is 25-30 mm; the outer diameter of the third step ring surface is 0.6 times of the nominal size of the ball valve, and the length of the third step ring surface is 50-60 mm.
As a preferred embodiment of the present invention, the first through hole has a diameter of 10 to 50mm and a length of 50 to 140 mm; an internal thread is arranged in the first through hole.
As a preferred embodiment of the present invention, the outer diameter of the first compression ring is equal to the outer diameter of the second step ring surface, the inner diameter of the first compression ring is matched with the outer diameter of the third step ring surface, and the length of the first compression ring is 25-30 mm; the outer diameter of the second pressing ring is equal to that of the second step ring surface, the inner diameter of the second pressing ring is matched with that of the third step ring surface, and the length of the second pressing ring is 25-30 mm.
As a preferred embodiment of the invention, the outer diameter of the gland is equal to the outer diameter of the second step ring surface, the inner diameter of the gland is matched with the outer diameter of the third step ring surface, and the length of the gland is 25-30 mm.
As a preferred embodiment of the present invention, the first, second and third groove rings each have an outer diameter of 0.7 times the nominal size of the ball valve, and the first, second and third groove rings each have a length of 3-4 mm.
The invention has the beneficial effects that: the problems of concentricity, tool joint mark joint, turning chip removal, turning smoothness and the like are solved, the processing efficiency of the process is improved, the manufacturing period is shortened, the labor cost is reduced, and the process meets the higher spherical surface quality requirement.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without inventive exercise. Wherein,
FIGS. 1 to 4 are step diagrams of the polishing-free turning process for plastic spherical surfaces according to the invention;
FIG. 5 is a schematic structural diagram of a second fixture of the polishing-free turning process for plastic spherical surfaces according to the present invention;
FIGS. 6 to 11 are step diagrams of the plastic spherical surface polishing-free turning process of the present invention.
Wherein: 1 is a clamp body, 11 is a second surface, 12 is an inner ring surface, 13 is an outer ring surface, 14 is a first through hole, 15 is a first step ring surface, 16 is a second step ring surface, 17 is a third step ring surface, 2 is a first rubber ring, 3 is a first press ring, 4 is a second rubber ring, 5 is a second press ring, 6 is a third rubber ring, 7 is a press cover, 71 is a second through hole, 81 is a valve ball blank, 82 is a spherical surface, 83 is a rotating shaft positioning groove, 831 is a first fixing hole, 832 is a second fixing hole, 84 is a central through hole, 85 is an end surface, 86 is a first clamp, 87 is a second clamp, 871 is a first clamp accessory, 872 is a second clamp accessory, 88 is reserved at a position of 3 mm.
Detailed Description
The present invention will be further described with reference to specific examples, but the scope of the present invention is not limited to these examples.
For convenience of understanding, the polishing-free turning process for plastic spherical surfaces according to the present invention and the conventional turning process for plastic spherical surfaces are described in table 1 below:
TABLE 1
In the step 4, the second fixture 87 is a special variable-diameter fixture, and the whole machining process only needs the lathe chuck and the special fixture, so that the operation steps are reduced, the operation error and the fixture centering error are reduced, and the problem of low concentricity precision in the traditional spherical surface machining is solved. The special clamp comprises the following components in parts by weight:
the second jig 87 includes a jig main body 1, a first rubber ring 2, a first press ring 3, a second rubber ring 4, a second press ring 5, a third rubber ring 6, a gland 7, and a bolt (not shown). For ease of understanding, the above structure will now be described in detail:
referring to fig. 5, as shown in fig. 5, the fixture is in a step-shaped cylindrical shape, the middle is hollowed, the weight is reduced, the fixture body 1 is used for being fixed on a three-jaw chuck of a lathe, the fixture body 1 is horizontally placed along a center line, and the three-jaw chuck clamps an outer circle of the leftmost end of the fixture body 1 to play a role in positioning. Assuming that the rightmost longitudinal plane thereof is a first surface (not shown), the leftmost longitudinal plane is a second surface 11, a first through hole 14 penetrating from the first surface to the second surface 11 along the center line is provided in the jig main body 1, the diameter of the first through hole 14 is 10 to 50mm, the depth is 50 to 140mm, and the first through hole 14 is provided with an internal thread of M10 at the first surface. The hole wall of the first through hole 14 is an inner ring surface 12, the outer side surface of the clamp body 1 is an outer ring surface 13, as shown in fig. 1, the stepped ring surface of the outer ring surface 13 is sequentially provided with a first stepped ring surface 15, a second stepped ring surface 16 and a third stepped ring surface 17 from left to right, the diameters of the three stepped ring surfaces are sequentially reduced from left to right, the length of the first stepped ring surface 15 is 40-60mm, the diameter is about 1 time of the nominal size (dn) of the ball valve, the outer diameter of the second stepped ring surface 16 is 0.8dn, the length is 25-30mm, the outer diameter of the third stepped ring surface 17 is 0.6dn, the width is 50-60mm, the first press ring 3, the second press ring 5 and the press cover 7 are all sleeved on the third stepped ring surface 17, wherein the press cover 7 also covers the first surface, the press cover 7 is provided with a second through hole 71, the center line of the first through hole 14 and the center line of the second through hole 71 are on the same straight line, bolts are inserted into the second through-hole 71 and the first through-hole 14. A first groove ring (not shown) is arranged at the edge of the first pressing ring 3, the first rubber ring 2 is accommodated in the first groove ring, a second groove ring (not shown) is arranged at the edge of the second pressing ring 5, the second rubber ring 4 is accommodated in the second groove ring, a third groove ring (not shown) is arranged at the edge of the gland 7, and the third rubber ring 6 is accommodated in the third groove ring. The outer diameter of the first compression ring 3 is as large as that of the second step ring surface 16, the inner diameter of the first compression ring 3 is just matched with that of the third step ring surface 17, the length of the first compression ring 3 is 25-30mm, the outer diameters of the first groove ring, the second groove ring and the third groove ring are all 0.7dn, and the length of the first groove ring, the second groove ring and the third groove ring is 3-4 mm. First clamping ring 3, second clamping ring 5, gland 7 cover are in proper order on anchor clamps main part 1, form 3 groove rings of 3 rubber circles 6. First rubber circle 2, first clamping ring 3, second rubber circle 4, second clamping ring 5, third rubber circle 6, gland 7 equipment are on anchor clamps main part 1, and first rubber circle 2, second rubber circle 4 and third rubber circle 6 are not compressed, and with central through-hole from gland 7 to the direction cover of first clamping ring 3 advance, the central through-hole of ball just in time sheathes in, treat behind the 2 rubber circles of telescope, just in time stop, the cover degree of depth is the half degree of depth of spheroid central through-hole. And then the bolt is screwed, the rubber ring is longitudinally compressed and radially expanded, and the central through hole is tensioned, so that the fastening and positioning effects are achieved.
The working principle of the clamp is as follows: the center through hole of the injection molding blank is supported by the lathe three-jaw chuck in the first clamping, the clamping precision is improved by automatic positioning, the end cover and the center through hole opposite to the clamping end are machined in the clamping, and the machining length is half of the length of the blank hole. The processing hole becomes the locating hole of special fixture, gets into the clamping of second time, and through screwing up the bolt, the rubber circle axial compression of anchor clamps, radial grow, prop tight central through-hole, the elastic principle automatic calibration center of rubber, positioning accuracy still keeps the fixed advantage of lathe three-jaw, and the benchmark of processing the sphere is secure. The key of the precision of the processing spherical surface is the positioning precision, so the special fixture solves the problem of concentricity.
In the step 4, to achieve the polishing-free effect, the problems of tool mark receiving and cutting must be solved first. In the new process, an R4 cutter is adopted, and a numerical control program measure is matched, so that a good processing effect is formed. The R2, R4 and R5 cutters are the circular arc-shaped cutters, the radius of the circular arc-shaped cutters is 2mm, 4mm and 5mm, and only the R4 cutter can cut the surface of a sphere and form a smooth surface in the process of procedure measures. The cutting capacity of the R4 cutter just meets the design machining allowance, spherical surface secondary turning is not needed, and the final spherical surface outer diameter is just reached.
The process reservation measures are as follows: the 3 mm is reserved on the left to avoid the tool from being damaged on the second clamp 87.
Numerical control program measures: the feed amount, the rotating speed of a lathe spindle, the step distance and the diameter are set, and the four parameters are optimized and matched, so that the surface smoothness is improved. The specific tests are shown in table 2 below:
TABLE 2
Through comparison, the cutting feed amount is determined to be 4mm, the rotating speed of the main shaft is 2000 r/min, the step pitch is 0.05mm, the optimal surface smoothness machining effect is achieved, and the efficiency is highest.
Removing the cutting measures: the cutter moves synchronously, high-pressure gas is adopted to blow and sweep the cutter, cutting is directionally eliminated, the cutter cannot be wound on the spherical surface 82, and mutual friction between plastics is avoided.
The invention relates to a plastic spherical surface polishing-free turning process and a traditional process, which are shown in the following table 3:
TABLE 3
In conclusion, the polishing-free turning process for the plastic spherical surface, provided by the invention, has the advantages that the processing efficiency is improved, the manufacturing period is shortened, the labor cost is reduced, higher spherical surface quality is obtained, and the sustainable development property is better.
In light of the foregoing description of the preferred embodiment of the present invention, many modifications and variations will be apparent to those skilled in the art without departing from the spirit and scope of the invention. The technical scope of the present invention is not limited to the content of the specification, and must be determined according to the scope of the claims.
Claims (8)
1. A plastic spherical surface polishing-free turning process is characterized by comprising the following steps:
(1) obtaining a valve ball blank through injection molding, wherein the outer surface of the valve ball blank is a spherical surface, a rotating shaft positioning groove is arranged on the spherical surface, a central through hole is formed in the center of the valve ball blank, an end face is arranged at one end of the central through hole, one side with the end face is an A side, and the side corresponding to the A side is a B side;
(2) the valve ball blank is subjected to stress relief and shaping through heating;
(3) a three-jaw chuck of a lathe is used as a first clamp, the first clamp extends into the central through hole from the side B and tightly supports the central through hole of the valve ball blank, the end face of the valve ball blank and the central through hole are machined in the direction from the side A to the side B, the machining area of the central through hole is half of the depth of the central through hole, and after the machining is finished, the first clamp leaves the central through hole of the valve ball blank;
(4) the first clamp clamps the outer surface of the second clamp, the central through hole is sleeved on the second clamp from the side A, the sleeving depth is half of the depth of the central through hole, a bolt is screwed down to enable a rubber ring to be longitudinally compressed and radially expanded, the central through hole is tightly tightened, the other half area of the central through hole is firstly machined by a lathe, then the outer surface of the valve ball blank is machined, wherein the outer surface of the valve ball blank is machined to a position which is reserved for 3 mm away from the end surface, the second clamp comprises a clamp main body, a first rubber ring, a first pressure ring, a second rubber ring, a second pressure ring, a third rubber ring, a gland and a bolt, the clamp main body is provided with a first surface, a second surface corresponding to the first surface, an inner ring surface and an outer ring surface corresponding to the inner ring surface, the clamp main body is provided with a first through hole, and the first through hole penetrates from the first surface to the second surface, the outer ring surface is provided with a first step ring surface, a second step ring surface and a third step ring surface, the diameter of the first step ring surface is larger than that of the second step ring surface, the diameter of the second step ring surface is larger than that of the third step ring surface, the first pressing ring is sleeved on the third step ring surface, the edge of the first pressing ring is provided with a first groove ring, the first rubber ring is accommodated in the first groove ring, the second pressing ring is sleeved on the third step ring surface, the edge of the second pressing ring is provided with a second groove ring, the second rubber ring is accommodated in the second groove ring, the gland is covered on the first surface, the edge of the gland is provided with a third groove ring, the third rubber ring is accommodated in the third groove ring, and the gland is provided with a second through hole, the center line of the first through hole and the center line of the second through hole are on the same straight line, the bolt is inserted into the second through hole and the first through hole, the turning adopts an R4 cutter, the cutting feed amount is 4mm, the rotating speed of a main shaft is 2000R/min, and the step distance is 0.05 mm;
(5) and loosening the bolt, taking out the valve ball blank, sleeving the central through hole on the second clamp from the side B, and lathing the part of the outer surface of the valve ball blank, which is reserved for 3 mm, so as to finish machining.
2. The plastic spherical surface polishing-free turning process according to claim 1, characterized in that: in the step (1), the injection molding temperature is 190-210 ℃, the pressure is 7.0-7.5 MPa, and the cooling time is 600-1000 s.
3. The plastic sphere polishing-free turning process according to claim 1, wherein the heating method in the step (2) comprises the following steps: setting the heating temperature of the oven to 80 ℃, putting the valve ball blank into the oven to be heated for 8 hours, stopping heating, naturally cooling at the temperature, and taking out after 8 hours.
4. The plastic spherical surface polishing-free turning process according to claim 1, characterized in that: the outer diameter of the first step ring surface is 1 time of the nominal size of the ball valve, and the length of the first step ring surface is 40-60 mm; the outer diameter of the second step ring surface is 0.8 times of the nominal size of the ball valve, and the length of the second step ring surface is 25-30 mm; the outer diameter of the third step ring surface is 0.6 times of the nominal size of the ball valve, and the length of the third step ring surface is 50-60 mm.
5. The plastic spherical surface polishing-free turning process according to claim 1, characterized in that: the diameter of the first through hole is 10-50mm, and the length of the first through hole is 50-140 mm; an internal thread is arranged in the first through hole.
6. The plastic spherical surface polishing-free turning process according to claim 1, characterized in that: the outer diameter of the first pressure ring is equal to the outer diameter of the second-step ring surface, the inner diameter of the first pressure ring is matched with the outer diameter of the third-step ring surface, and the length of the first pressure ring is 25-30 mm; the outer diameter of the second pressing ring is equal to that of the second step ring surface, the inner diameter of the second pressing ring is matched with that of the third step ring surface, and the length of the second pressing ring is 25-30 mm.
7. The plastic spherical surface polishing-free turning process according to claim 1, characterized in that: the outer diameter of the gland is equal to that of the second step ring surface, the inner diameter of the gland is matched with that of the third step ring surface, and the length of the gland is 25-30 mm.
8. The plastic spherical surface polishing-free turning process according to claim 1, characterized in that: the outer diameters of the first groove ring, the second groove ring and the third groove ring are 0.7 times of the nominal size of the ball valve, and the lengths of the first groove ring, the second groove ring and the third groove ring are 3-4 mm.
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| CN202010875076.4A CN111992739B (en) | 2020-08-27 | 2020-08-27 | Plastic spherical surface polishing-free turning process |
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| CN202010875076.4A CN111992739B (en) | 2020-08-27 | 2020-08-27 | Plastic spherical surface polishing-free turning process |
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| CN113352121B (en) * | 2021-06-29 | 2022-04-19 | 苏州工业园区博斯塔机械有限公司 | Use method of floating ball drilling tool for vertical machining |
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| JP2000280101A (en) * | 1999-03-29 | 2000-10-10 | Okuma Corp | Curved surface processing method |
| CN202283600U (en) * | 2011-10-31 | 2012-06-27 | 南京肯迈得机床制造有限公司 | Numerical control spherical lathe |
| CN104227027A (en) * | 2014-09-02 | 2014-12-24 | 浙江美德机械有限公司 | Special lathe for spherical product |
| CN107639448A (en) * | 2016-07-22 | 2018-01-30 | 李波 | A kind of lathe |
| CN108971518A (en) * | 2018-09-05 | 2018-12-11 | 山东迈特力重机有限公司 | A kind of Lager ball head processing special tooling and method |
| CN209532115U (en) * | 2018-06-29 | 2019-10-25 | 菏泽学院 | A kind of bolt sphere processing special horizontal lathe |
| CN210909104U (en) * | 2019-11-26 | 2020-07-03 | 成都科安达精工机械有限责任公司 | External diameter elastic clamp |
-
2020
- 2020-08-27 CN CN202010875076.4A patent/CN111992739B/en active Active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2000280101A (en) * | 1999-03-29 | 2000-10-10 | Okuma Corp | Curved surface processing method |
| CN202283600U (en) * | 2011-10-31 | 2012-06-27 | 南京肯迈得机床制造有限公司 | Numerical control spherical lathe |
| CN104227027A (en) * | 2014-09-02 | 2014-12-24 | 浙江美德机械有限公司 | Special lathe for spherical product |
| CN107639448A (en) * | 2016-07-22 | 2018-01-30 | 李波 | A kind of lathe |
| CN209532115U (en) * | 2018-06-29 | 2019-10-25 | 菏泽学院 | A kind of bolt sphere processing special horizontal lathe |
| CN108971518A (en) * | 2018-09-05 | 2018-12-11 | 山东迈特力重机有限公司 | A kind of Lager ball head processing special tooling and method |
| CN210909104U (en) * | 2019-11-26 | 2020-07-03 | 成都科安达精工机械有限责任公司 | External diameter elastic clamp |
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