CN114473035B - Method for machining spindle mortises of turbochargers - Google Patents
Method for machining spindle mortises of turbochargers Download PDFInfo
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- CN114473035B CN114473035B CN202210337530.XA CN202210337530A CN114473035B CN 114473035 B CN114473035 B CN 114473035B CN 202210337530 A CN202210337530 A CN 202210337530A CN 114473035 B CN114473035 B CN 114473035B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D37/00—Broaching machines or broaching devices
- B23D37/22—Broaching machines or broaching devices for special purposes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D43/00—Broaching tools
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Milling, Broaching, Filing, Reaming, And Others (AREA)
Abstract
The invention discloses a method for processing a spindle mortise of a turbocharger, which can thoroughly improve the broaching surface quality, improve the broaching qualification rate and reduce the sharpening labor intensity by optimizing the broaching slot type, the chip flute depth, the grouping structure configuration and the like. The method comprises the following steps: s1, roughly machining two side surfaces of a mortise through broaching to form a V-shaped groove, and finely machining an arc surface at the bottom of the mortise; s2, rough machining and finish machining are conducted on the chamfer of the groove opening of the mortise through broaching; s3, precisely machining a christmas tree groove with a mortise through broaching; s4, machining two side faces of the mortises through broaching, and machining and forming the Christmas mortises through broaching.
Description
Technical Field
The invention relates to the technical field of turbochargers, in particular to a method for machining a spindle mortice of a turbocharger.
Background
The main shaft is a critical component of the exhaust gas turbocharger, which may be referred to as the "heart," and functions to provide power during machine operation. The mortises of the main shaft of the supercharger are Christmas tree mortises, the mortises are particularly important structures, the processing quality of the mortises directly affects the assembly precision of turbine blades, even the efficiency and vibration value of the whole machine, and the mortises are the most complex and key processing procedures in the processing of the main shaft of the supercharger.
The processing of christmas tree groove type adopts comparatively general broaching mode at present, and main advantage is: 1. the broaching efficiency is high, the complete broaching of the Christmas tree groove type only needs about 7-8 minutes, and if an advanced numerical control broacher is adopted, the overall efficiency can be improved by 30-40%;2. the broaching quality is stable, the whole set of cutter can process nearly 10 main shafts at a time within the reasonable service life of the cutter, and the later cutter can be sharpened for 3-4 times, so that the durability of the cutter can be further improved;
christmas tree grooves on the main shaft of the supercharger have extremely high precision requirements, roughness requirements Ra1.6 and profile requirements: the minimum position is 0.03, and the maximum position is 0.06, thus providing extremely high requirements for the design of broaches for machining Christmas tree groove shapes. The design of the broach for processing the Christmas tree groove mainly has the following difficulties; 1. the broach adopts a gradually-formed design, and the tooth lift and the margin distribution of each cutter must be considered; 2. the broaching tool is a common horizontal broaching machine, and the operation stability of the broaching tool needs to be considered; 3. the whole set of broach is the combination of a plurality of cutters, and the structure of the formed broach and the influence on the groove shape are mainly considered, so that the profile requirement of the groove shape of the final Christmas tree is ensured; 4. the whole set of broaches are large in number, convenience and high efficiency of sharpening tools must be considered, and labor intensity of workers is reduced; 5. the depth of the chip flute in the structure of the forming broach directly affects the warpage of the scrap iron, thereby causing the difference of the surface roughness of the parts.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a method for processing a spindle mortise of a turbocharger.
The purpose of the invention is realized in the following way:
a method of machining a turbocharger spindle dovetail, comprising the steps of:
s1, roughly machining two side surfaces of a mortise through broaching to form a V-shaped groove, and finely machining an arc surface at the bottom of the mortise;
s2, rough machining and finish machining are conducted on the chamfer of the groove opening of the mortise through broaching;
s3, precisely machining a christmas tree groove with a mortise through broaching;
s4, machining two side faces of the mortises through broaching, and machining and forming the Christmas mortises through broaching.
Preferably, in the step S1, the mortise is rough machined from the outside to the inside by multiple broaching.
Preferably, the step S1 includes:
s11, broaching by a broach, wherein the tooth lift of each tooth of the broach is 0.05mm, 74 teeth are added, and 73 th teeth and 74 th teeth of the tail are equal-height teeth;
s12, broaching by a broach, wherein the tooth lift of each tooth of the broach is 0.05mm, 74 teeth are total, and the 1 st tooth and the 2 nd tooth are transition teeth, and are not involved in cutting, so that the cutter collision is prevented; tail teeth 73 and 74 are equal-height teeth;
s13, broaching by a broach, wherein the tooth lift of each tooth of the broach is 0.05mm, 74 teeth are added, and the 1 st, 2 nd and 3 rd teeth are transition teeth, and are not involved in cutting, so that the cutter collision is prevented; the 73 rd teeth and the 74 th teeth of the tail are equal-height teeth.
Preferably, the step S1 further includes: s14, finishing the cambered surface at the bottom of the mortise, wherein the tooth lift of each tooth of the broach is divided into three sections of 0.061mm, 0.05mm and 0.03mm from outside to inside, 76 teeth are formed, and the 1 st tooth, the 2 nd tooth and the 3 rd tooth are transition teeth, do not participate in cutting, and prevent the broach from being bumped; the 72 th to 76 th teeth of the tail are equal-height teeth.
Preferably, in the step S2, the tooth lift amount of each tooth of the broach is divided into two sections of 0.04mm and 0.01mm from outside to inside, 60 teeth are altogether, 56 th to 60 th teeth of the tail are equal-height teeth, 1 st to 45 th teeth are used for rough machining at the mortise chamfer, and 46 th to 60 th teeth are used for finish machining at the mortise chamfer.
Preferably, in the step S2, the chip flute of the broach adopts a "straight" flute bottom.
Preferably, in the step S3, the tooth lift amount of each tooth of the broach is 0.015mm, the number of teeth of the broach is 81 teeth, and the 78 th to 81 th teeth of the tail are equal-height teeth.
Preferably, in the step S3, the chip flute of the broach adopts a special-shaped flute bottom corresponding to the christmas tree flute-shaped mortise.
Preferably, in the step S4, the tooth lift amount of each tooth of the broach is 0.01mm, 38 teeth are total, the 1 st to 17 th teeth are machined on two side surfaces, and the 18 th to 38 th teeth are tongue-and-groove shaping teeth.
Preferably, in the step S4, the chip flute of the broach adopts a special-shaped flute bottom corresponding to the christmas tree flute-shaped mortise.
Due to the adoption of the technical scheme, the invention has the following beneficial effects:
1. in the S2 process, optimizing the structure processing mortise chamfer and two side faces of the original cutter into processing chamfer only, reducing abrasion of a cutting edge and fundamentally reducing the possibility of tooth breakage or cutter breakage by a method of reducing the tooth lift and increasing the number of teeth;
the structure of the front section broaching chamfer of the original cutter is changed from a herringbone bottom to a straight bottom, so that the labor intensity of a worker for sharpening the cutter is greatly reduced;
the 45 th to 57 th tooth of the tail part of the original cutter is transferred to the optimized S4, so that the whole contour degree of the mortise is guaranteed to be formed by broaching once, errors caused by processing of the cutter and the region are avoided, and the problem of out-of-tolerance detection of the contour degree of the mortise is avoided in design principle.
2. In the step S3, the tooth lift of the original cutter is reduced, the number of teeth is increased, and the broaching quantity of each tooth is reduced;
in order to avoid the phenomenon that scrap iron is piled up in the chip groove to cause the extrusion injury and the napping of the pulled surface during broaching, the depth and the groove type of the chip groove are adjusted, so that the chip groove depths of different areas are formed according to the irregular shape of the tenon groove molded line, the chip rate is increased, the phenomena of extrusion injury and napping are avoided, and the product quality is improved.
3. In the step S4, the grooving forming and broaching of the whole cutter of the original cutter is optimized to be simultaneously carried out on two sides of the grooving and the grooving forming and broaching, so that the whole contour degree of the grooving is ensured to be formed by one broaching, errors caused by the processing of the dividing cutter and the dividing region are avoided, and the problem of out-of-tolerance detection of the contour degree of the grooving is avoided in design principle;
the depth of the chip flute at the two sides of the broaching tenon slot at the 45 th tooth to the 57 th tooth of the tail part of the broach is optimized, a new slot type is introduced, the phenomena of extrusion injury and napping are avoided, and the product quality is improved.
Drawings
FIG. 1 is a diagram showing the processing position of a rough tongue-and-groove broach in step S11;
FIG. 2 is a schematic diagram of a tongue-and-groove rough broach in step S11;
FIG. 3 is a view showing the processing position of the rough tongue-and-groove broach in step S12;
FIG. 4 is a schematic diagram of the tongue-and-groove rough broach in step S12;
FIG. 5 is a view showing the processing position of the rough tongue-and-groove broach in step S13;
FIG. 6 is a schematic diagram of the tongue-and-groove rough broach in step S13;
FIG. 7 is a diagram showing the finish broaching position at the bottom R of the dovetail groove in step S14;
FIG. 8 is a schematic diagram of the finish broach at the bottom R of the dovetail slot in step S14;
FIG. 9 is a diagram of the finish broach machining position at the mortise chamfer in step S2;
FIG. 10 is a schematic diagram of the finish broach at the chamfer of the mortise and tenon in step S2;
FIG. 11 is a diagram showing the processing position of the tongue-and-groove fine broach in step S3;
FIG. 12 is a schematic diagram of the tongue-and-groove fine broach in step S3;
FIG. 13 is a view showing the two sides of the mortise and the machining position of the forming broach in step S4;
fig. 14 is a schematic view of the two sides of the mortise and the forming broach in step S4.
Detailed Description
A method of machining a turbocharger spindle dovetail, comprising:
s1, roughly machining two side surfaces of a mortise through broaching to form a V-shaped groove, and finely machining an arc surface at the bottom of the mortise;
s2, rough machining and finish machining are conducted on the chamfer of the groove opening of the mortise through broaching;
s3, precisely machining a christmas tree groove with a mortise through broaching;
s4, finishing two side faces of the mortise by broaching, and forming the christmas tree groove.
The step S1 comprises the following steps:
s11, a tongue-and-groove rough broach, wherein the tooth lift of each tooth is 0.05mm, the total teeth are 74 teeth, the 73 th teeth and the 74 th teeth of the tail are equal-height teeth, and the whole broach is processed for removing large allowance, and the whole broach is shown in fig. 1 and 2.
S12, a tongue-and-groove rough broach, wherein the tooth lift of each tooth is 0.05mm, 74 teeth are provided, and the 1 st tooth and the 2 nd tooth are transition teeth, do not participate in cutting, and prevent the cutter from being knocked; the 73 rd teeth and the 74 th teeth of the tail are equal-height teeth, and the whole cutter is used for removing large allowance, and the whole cutter is processed in a mode of being shown in fig. 3 and 4.
S13, a tongue-and-groove rough broach, wherein the tooth lift of each tooth is 0.05mm, 74 teeth are provided, and the 1 st, 2 nd and 3 rd teeth are transition teeth, do not participate in cutting, and prevent the cutter from being knocked; the 73 rd teeth and the 74 th teeth of the tail are equal-height teeth, and the whole cutter is used for removing large allowance, and the whole cutter is processed in a mode of being shown in fig. 5 and 6.
S14, a fine broach at the bottom R of the mortise adopts different tooth lift amounts according to different broaching areas, wherein the tooth lift amounts of each tooth are respectively 0.061mm, 0.05mm and 0.03mm, 76 teeth are total, and 1 st, 2 nd and 3 rd teeth are transition teeth which do not participate in cutting and prevent the cutter from being knocked; the 72 th to 76 th teeth of the tail are equal-height teeth, and the whole cutter is finished by removing a small part of allowance and the bottom of the R groove, which are shown in fig. 7 and 8.
S2 is as follows: the tooth lift of each tooth of the fine broach at the mortise chamfer is different according to the different broaching areas, the tooth lift is respectively 0.04mm and 0.01mm, 60 teeth are formed, and the 56 th to 60 th teeth at the tail are equal-height teeth. The 1 st to 45 th teeth are rough machining at the chamfer of the mortise, the 46 th to 60 th teeth are finish machining at the chamfer of the mortise, and the chip flute shape optimizes the herringbone bottom of the original structure to be a straight bottom. When the front cutter surface of the cutter is sharpened, a special angle sizing block is needed to convert the groove bottom of the herringbone bottom from tilting into a horizontal bottom parallel to the workbench. The optimization is to directly design the straight bottom, thereby reducing the processing difficulty, reducing the cutter sharpening difficulty, improving the sharpening efficiency, and reducing the labor intensity, as shown in fig. 9 and 10.
S3 is as follows: the tooth lift of each tooth of the mortise finish broach is reduced to 0.015mm from 0.019mm of the original cutter, the number of teeth of the broach is increased to 81 teeth from 60 teeth of the original cutter, and 78 th to 81 th teeth of the tail are equal-height teeth. The chip flute optimizes the original tool as a 'parallel' bottom parallel to the cutting edge as a special-shaped groove bottom which changes along with the mortises of the Christmas tree, and increases the chip capacity during broaching, as shown in figures 11 and 12.
S4 is as follows: the 1 st to 17 th teeth are used for processing the two sides of the mortise, and the tooth lift of each tooth is 0.01mm; the 18 th to 38 th are tongue-and-groove shaping teeth; 38 teeth total; the chip flute optimizes the original tool as a 'parallel' bottom parallel to the cutting edge as a different bottom with the change of the christmas tree mortises, and increases the chip capacity during broaching, see fig. 13 and 14.
The concrete improvement of the invention is as follows:
1. in the S2 process, the structure processing mortise chamfer and two side faces of the original cutter are optimized to be processed into chamfer only, the tooth lift amount is reduced from 0.036mm to 0.01mm, meanwhile, the tooth number at the broaching chamfer is increased from 44 teeth to 60 teeth, the cutting amount of each tooth is reduced, the abrasion of a cutting edge is reduced, and the possibility of tooth breakage or cutter breakage is fundamentally reduced; the structure of the front section broaching chamfer of the original cutter is changed from a herringbone bottom to a straight bottom; grinding of the herringbone bottom requires that the bottom of the groove is adjusted to be horizontal from an inclined state through a sizing block, and a grinding wheel head frame of grinding equipment deflects by 15 degrees during sharpening; after the grinding wheel head frame of the grinding equipment is changed into a straight bottom, a sizing block is not required to be used, and the grinding wheel head frame of the grinding equipment is directly deflected by 15 degrees, so that the labor intensity of workers is greatly reduced; the 45 th to 57 th teeth of the tail part of the original cutter are transferred to the optimized broach, so that the whole profile of the dovetail groove is guaranteed to be broached and formed once, errors caused by the processing of the dividing regions of the cutter are avoided, and the problem of out-of-tolerance detection of the profile of the dovetail groove is avoided in design principle;
2. in the step S3, the tooth lift amount is reduced to 0.015mm, and the tooth number is increased from 60 teeth to 81 teeth, so that the broaching amount of each tooth is reduced; in order to avoid the phenomenon that scrap iron is piled in a chip groove to cause the extrusion damage and the napping of a pulled surface during broaching, the chip groove depth dimension of an original cutter is optimized from 27.87 to 27.06, and R40 is changed to R25, so that chip groove depths of different areas are formed according to the irregular shape of a mortice molded line, the chip rate is increased, the phenomena of extrusion damage and napping are avoided, and the product quality is improved.
3. In the step S4, the grooving forming and broaching of the whole cutter of the original cutter is optimized to be simultaneously carried out on two sides of the grooving and the grooving forming and broaching, so that the whole contour degree of the grooving is ensured to be formed by one broaching, errors caused by the processing of the dividing cutter and the dividing region are avoided, and the problem of out-of-tolerance detection of the contour degree of the grooving is avoided in design principle; the 45 th to 57 th teeth of the broach tail are transferred to the 1 st to 17 th teeth, the chip flute depth of the segment is increased, the arc structure of R25 is increased, the chip capacity of the two side sections of the broach is optimized, the phenomena of crushing and galling are avoided, the product quality is improved,
and (3) product processing test verification: according to the optimized design method, the production of the Christmas tree mortises and broachs is carried out, and the production verification is carried out for a plurality of times, so that the inspection and verification of factory professional inspection personnel are passed, and the design requirement of the drawing is met.
Finally, it is noted that the above-mentioned preferred embodiments are only intended to illustrate rather than limit the invention, and that, although the invention has been described in detail by means of the above-mentioned preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention as defined by the appended claims.
Claims (1)
1. A method of machining a turbocharger spindle dovetail, comprising the steps of:
s1, roughly machining two side surfaces of a mortise through broaching to form a V-shaped groove, and finely machining an arc surface at the bottom of the mortise;
in the step S1, the mortises are roughly machined from outside to inside through multiple broaching;
the step S1 includes:
s11, broaching by a broach, wherein the tooth lift of each tooth of the broach is 0.05mm, 74 teeth are added, and 73 th teeth and 74 th teeth of the tail are equal-height teeth;
s12, broaching by a broach, wherein the tooth lift of each tooth of the broach is 0.05mm, 74 teeth are total, and the 1 st tooth and the 2 nd tooth are transition teeth, and are not involved in cutting, so that the cutter collision is prevented; tail teeth 73 and 74 are equal-height teeth;
s13, broaching by a broach, wherein the tooth lift of each tooth of the broach is 0.05mm, 74 teeth are added, and the 1 st, 2 nd and 3 rd teeth are transition teeth, and are not involved in cutting, so that the cutter collision is prevented; tail teeth 73 and 74 are equal-height teeth;
s14, finishing the cambered surface at the bottom of the mortise, wherein the tooth lift of each tooth of the broach is divided into three sections of 0.061mm, 0.05mm and 0.03mm from outside to inside, 76 teeth are formed, and the 1 st tooth, the 2 nd tooth and the 3 rd tooth are transition teeth, do not participate in cutting, and prevent the broach from being bumped; the 72 th to 76 th teeth of the tail part are equal-height teeth;
s2, rough machining and finish machining are conducted on the chamfer of the groove opening of the mortise through broaching;
in the step S2, the tooth lift of each tooth of the broach is divided into two sections of 0.04mm and 0.01mm from outside to inside, 60 teeth are altogether, 56 th to 60 th teeth of the tail are equal-height teeth, 1 st to 45 th teeth are used for rough machining of the chamfer of the mortise, and 46 th to 60 th teeth are used for finish machining of the chamfer of the mortise;
in the step S2, the chip pocket type of the broach adopts a straight slot bottom;
s3, precisely machining a christmas tree groove with a mortise through broaching;
in the step S3, the tooth lift of each tooth of the broach is 0.015mm, the number of teeth of the broach is 81 teeth, and the 78 th to 81 th teeth of the tail are equal-height teeth;
in the step S3, the chip pocket of the broach adopts a special-shaped slot bottom corresponding to the slot-shaped mortises of the Christmas tree;
s4, machining two side faces of the mortises through broaching, and machining and forming the Christmas mortises through broaching;
in the step S4, the tooth lift of each tooth of the broach is 0.01mm, 38 teeth are formed, the 1 st to 17 th teeth are two side face machining teeth, and the 18 th to 38 th teeth are tongue-and-groove shaping teeth;
in the step S4, the chip flute of the broach adopts a special-shaped flute bottom corresponding to the Christmas tree flute-shaped tenon flute.
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| CN202210337530.XA CN114473035B (en) | 2022-03-31 | 2022-03-31 | Method for machining spindle mortises of turbochargers |
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