CN115793180B - Light conduction box and assembly process thereof - Google Patents

Light conduction box and assembly process thereof Download PDF

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CN115793180B
CN115793180B CN202310046848.7A CN202310046848A CN115793180B CN 115793180 B CN115793180 B CN 115793180B CN 202310046848 A CN202310046848 A CN 202310046848A CN 115793180 B CN115793180 B CN 115793180B
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welding
aluminum alloy
cutter
side plate
parts
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CN115793180A (en
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刘波
陈茂军
高巍
吴宇龙
艾琪林
孙勇
李金龙
杨伟
梁斌
方全坤
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Sichuan Xinhang Titanium Technology Co ltd
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Sichuan Future Aerospace Industrial Co ltd
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Abstract

The invention discloses a light conduction box and an assembly process thereof, and relates to the field of light conduction boxes; the light conduction box comprises a bottom plate and a top plate, the front side, the back side, the left side and the right side of the bottom plate are respectively welded with a front frame, a back frame, a left side plate and a right side plate, inclined support pieces for supporting a reflector assembly are welded among the bottom plate, the back frame, the left side plate and the right side plate, a triangular structure is formed among the inclined support pieces, the bottom plate and the back frame, and the inclined support pieces are inclined edges; the left side plate, the right side plate, the front frame and the rear frame are welded with the top plate; the inclined support piece is provided with a support piece for supporting the reflector assembly; the assembly process comprises the working procedures of part machining, welding parts, heat treatment and the like, and can overcome the stress generated by machining and welding through mutual constraint and process among structures, and reduce the shape and size change of the parts made of the aluminum alloy materials under the condition of long-term use due to the stress.

Description

Light conduction box and assembly process thereof
Technical Field
The invention relates to the field of light conduction boxes, in particular to a light conduction box and an assembly process thereof.
Background
The main functions of the large laser device light conduction box are to guide and transmit the laser beam (after the reflector is installed), and provide a stable and clean running environment for the laser beam. The light conduction box needs to ensure that the positions of the reflecting lenses arranged on the light conduction box are stable, and firstly, the relative positions of all parts of the light conduction box are ensured to be stable, namely, the parts forming the light conduction box cannot deform beyond errors under the condition of long-term use, so that the parts forming the light conduction box are prevented from shifting.
The main manufacturing material of the light conduction box is aluminum alloy, and the light conduction box has the physical properties of large volume and weight, and has more parts, so that the welding positions are more; each part is welded due to welding stress, the welding stress can cause the shape and the size of the part to change, and long-term stability of the structure size cannot be ensured; secondly, the size of the aluminum alloy for manufacturing the light-conducting box is large, deformation can occur when the aluminum alloy is subjected to size processing, namely, cutting processing, deformation stress can remain when the aluminum alloy is deformed, deformation of the aluminum alloy can occur due to the deformation stress under a long time, and the position of a reflection lens mounted on the light-conducting box is affected.
Disclosure of Invention
One object of the present invention is to: in order to solve the problems, the optical conduction box is provided, the stress generated by machining and welding is overcome through mutual constraint among structures, and the shape and size change of parts made of aluminum alloy materials under the condition of long-term use due to the stress is reduced.
Another object of the invention is: in view of the above-mentioned problems, an assembling process of a light-conducting box is provided, by which the stress (including the stress generated during machining and welding) generated when the light-conducting box is assembled is eliminated or reduced as much as possible, so as to achieve the purpose of reducing the shape and size change of the part made of the aluminum alloy material due to the stress under the condition of long-term use.
The technical scheme adopted by the invention is as follows: the light conduction box comprises a bottom plate, wherein the front side, the rear side, the left side and the right side of the bottom plate are respectively welded with a front frame, a rear frame, a left side plate and a right side plate, inclined support pieces for supporting a reflector assembly are welded among the bottom plate, the rear frame, the left side plate and the right side plate, a triangular structure is formed among the inclined support pieces, the bottom plate and the rear frame, and the inclined support pieces are inclined edges; the left side plate, the right side plate, the front frame and the rear frame are welded with the top plate; the inclined support is provided with a support for supporting the reflector assembly.
An assembling process of a light conducting box, assembling the light conducting box, comprising the following steps:
s1: machining parts, namely machining the aluminum alloy into parts with designed shapes, structures and sizes and deformation less than 0.1mm/m through the steps S11 and S12, wherein the parts comprise a bottom plate, a front frame, a rear frame, a left side plate, a right side plate, an inclined support piece, a top plate and a support piece;
s11: rough machining, namely, rough machining is carried out on the aluminum alloy, and parameters of the rough machining are selected as follows: the diameter of the cutter is 12mm-25mm; the maximum cutting width is 0.9mm-3mm; the maximum cutting depth is 12mm-30mm; spindle speed is 12000rpm-12100rpm, and feeding per tooth is 0.15mm-0.2mm; the number of the cutter edges is 3-5;
s12: finish machining, namely, finish machining the aluminum alloy subjected to rough machining, wherein the parameters of finish machining are selected as follows: the diameter of the cutter is 10mm-20mm; the maximum cutting width is 1mm-2mm; the maximum cutting depth is 8mm-30mm; the spindle rotation speed is 13000rpm-15500rpm, and the feeding of each tooth is 0.07mm-0.1mm; the number of the cutter edges is 3-5;
s2: welding parts; welding and fixing the bottom plate, the inclined support piece, the rear frame, the left side plate and the side plate to form a semi-finished product piece;
s3: performing first heat treatment; carrying out heat treatment on the semi-finished product piece to eliminate welding stress;
s4: welding; welding the front frame and the rear frame on the basis of the semi-finished product after heat treatment to form a light conduction box;
s5: and performing secondary heat treatment on the light conduction box to eliminate welding stress.
Further, before step S1 is performed, the surface of the aluminum alloy needs to be cleaned or/and surface-treated; before proceeding to step S11, it is necessary to clean the individual parts.
Further, in step S12, when finishing the corner of the aluminum alloy, the spindle rotation speed is matched according to 30% of the spindle rotation speed in step S12.
Further, in the step S11 or/and the step 12, when the extension length of the tool is not greater than four times the diameter of the tool, the spindle rotation speed is the spindle rotation speed in the step S11 or/and the step S12; when the extension length of the cutter exceeds four times of the diameter of the cutter, the spindle rotating speed is the speed after the speed is reduced in the same proportion as the spindle rotating speed in the step S11 or/and the step S12.
Further, in the step S11 or/and the step S12, the cutter is set in an oblique waist-shaped cutter setting mode; and the oblique line span in the oblique waist-shaped cutter setting mode is not smaller than 3 times of the diameter of the cutter.
Further, in the step S11 or/and the step S12, the cutter is set in an oblique waist-shaped cutter setting mode; and the oblique line span in the oblique waist-shaped cutter setting mode is not smaller than 3 times of the diameter of the cutter.
Further, in step S1, the aluminum alloy is clamped by using a tool clamp, and the aluminum alloy has a clamping allowance.
Further, after step S3 is completed, step S31 is performed: correcting the shape; performing shape correction on the semi-finished product according to the data requirements; and after step S31 is completed, mounting a support for supporting the mirror assembly on the diagonal support; after the supporting piece is installed, the installation standard and the supporting surface of the reflecting mirror component of the supporting piece are subjected to numerical milling.
Further, in step S2 and step S4, the welding mode adopts laser welding, and the pin and the normal temperature curing resin glue are required to be prefabricated for butt joint before the welding of the parts.
Further, after the prefabricated butt joint is completed, the welding between the parts is completed within 3 hours.
Further, in step S2 and step S4, the type of welding between the parts is any one of symmetrical fillet welding, symmetrical butt welding, and asymmetrical compound welding.
Further, the part material of the light conduction box is aluminum alloy 6061-T6 or/and aluminum alloy 5A06; in the step S2 or S4, the heat treatment mode is heating to 140-145 ℃ for 6061-T6 of aluminum alloy, preserving heat for 235-245 min, and discharging and air cooling; or heating the aluminum alloy 5A06 with a furnace, preserving heat for 1-1.5h at 310-330 ℃, discharging and air cooling after the heat preservation is finished.
Further, after step S5, the gas tightness of the weld of the optical conduction box is detected by using a helium gas detection method.
Further, the part hollowed-out position needs to be sealed before helium gas detection is carried out, the sealed structure comprises a sealing plate connected with the part hollowed-out position through bolts, a sealing rubber strip is arranged between the sealing plate and the part, and a welding seam between the parts is located outside the sealing ring.
In summary, due to the adoption of the technical scheme, the beneficial effects of the invention are as follows:
1. the invention is provided with the inclined support, the reflector component can be arranged on the inclined support, the inclined support forms a triangle stable structure with the bottom plate and the rear frame, the left side plate and the right side plate restrict the two sides of the inclined support, under the condition that the rear frame, the left side plate and the right side plate are simultaneously restricted by the top plate, the mutual restriction among parts is realized, the stress generated by machining and welding is overcome, and the shape and size change of the parts made of aluminum alloy materials due to the stress under the condition of long-term use is reduced;
2. according to the invention, the machining parameters of the machine tool are limited, so that the deformation of the aluminum alloy after cutting is smaller than 0.1mm/m, and the machining stress (deformation stress) generated by cutting in the aluminum alloy is effectively reduced, so that the deformation of the part machined by the aluminum alloy is controlled within an error range;
3. according to the invention, the whole light conduction box is split into two times of heat treatment, so that on one hand, the process error accumulation can be reduced, and the deformation of the shape and the size of the light conduction box after heat treatment can reach the requirement of less than one thousandth, or the dimensional tolerance and the form and position tolerance can reach the requirement of less than 1mm; on the other hand, the stability of the structural dimension of the light conduction box can be ensured under the environment of long-term use, and the deformation of the light conduction box under the long-term action of welding stress is avoided;
4. the invention structurally improves the structural stability of the light conduction box by taking the structure and the process (comprising the part machining process and the welding process) as the cut-in point, thereby improving the mounting position stability of the reflector; the parts machining and welding processes on the process reduce corresponding stress residues, effectively avoid the change of the shape and the size of the light conduction box under the condition of long-term use caused by stress, and further realize the stable installation position of the reflector.
Drawings
The invention will now be described by way of example and with reference to the accompanying drawings in which:
FIG. 1 is a schematic three-dimensional structure of a light conducting box according to the present disclosure;
FIG. 2 is a schematic diagram of a front view of a light box according to the present disclosure;
FIG. 3 isbase:Sub>A schematic cross-sectional view of the structure of FIG. 2 in the direction A-A;
FIG. 4 is a schematic diagram of the welding process of step S3 of the present invention;
FIG. 5 is a schematic view of a symmetrical fillet weld according to the present invention;
FIG. 6 is a schematic illustration of a symmetrical butt weld according to the present invention;
FIG. 7 is a schematic illustration of an asymmetric composite weld in accordance with the present invention;
FIG. 8 is a schematic view of the hollow position of a sealing part using a sealing plate according to the present invention;
FIG. 9 is a schematic diagram of a connection of a helium gas detection system according to the present disclosure;
the marks in the figure: 1-a bottom plate; 2-inclined support members; 3-right side plate; 4-a front frame; 5-top plate; 6-a rear frame; 7-a support; 8-left side plate; 9-docking position; 10-pin holes; 11-sealing plate.
Detailed Description
All of the features disclosed in this specification, or all of the steps in a method or process disclosed, may be combined in any combination, except for mutually exclusive features and/or steps.
Any feature disclosed in this specification may be replaced by alternative features serving the same or equivalent purpose, unless expressly stated otherwise. That is, each feature is one example only of a generic series of equivalent or similar features, unless expressly stated otherwise.
Example 1
As shown in fig. 1 to 4, a light conduction box comprises a bottom plate, wherein the bottom plate and a top plate 5, the front side, the rear side, the left side and the right side of the bottom plate 1 are respectively welded with a front frame 4, a rear frame 6, a left side plate 8 and a right side plate 3, a diagonal bracing piece 2 for supporting a reflector assembly is welded among the bottom plate 1, the rear frame 6, the left side plate 8 and the right side plate 3, a triangular structure is formed between the diagonal bracing piece 2 and the bottom plate 1 and the rear frame 6, and the diagonal bracing piece 2 is a diagonal edge; the left side plate 8, the right side plate 3, the front frame 4 and the rear frame 6 are also welded with the top plate 5; the tilt support 2 is provided with a support 7 for supporting the mirror assembly.
Specifically, in this embodiment, the diagonal brace 2 is welded between the bottom plate 1, the rear frame 6, the left side plate 8 and the right side plate 3, a triangular structure is formed between the bottom plate, the rear frame 6 and the diagonal brace 2, the butt joint position 9 between the left side plate 8 or the right side plate 3 and the bottom plate 1, the diagonal brace 2 and the rear frame 6 forms a triangular structure, the triangular structure and the triangular structure are both stable structures, and under the condition that the rear frame 6, the left side plate 8 and the right side plate 3 are restrained by the top plate 5, the top plate 5 is restrained by the front frame 4, the rear frame 6, the left side plate 8, the right side plate 3 and the bottom plate 1, so that mutual restraint between parts is realized, residual stress or welding residual stress in the parts cannot cause excessive deformation of materials under the restraint condition, namely, the restraint overcomes the stress generated by machining and welding, and the shape and size change of the parts made of aluminum alloy materials under the condition of long-term use is realized.
Example 2
An assembling process of the light conducting box, assembling the light conducting box of the embodiment 1, comprising the following steps:
s1: machining parts, namely machining the aluminum alloy into parts with designed shapes, structures and sizes and deformation less than 0.1mm/m through the steps S11 and S12, wherein the parts comprise a bottom plate 1, a front frame 4, a rear frame 6, a left side plate 8, a right side plate 3, a diagonal brace 2, a top plate 5 and a brace 7;
s11: rough machining, namely, rough machining is carried out on the aluminum alloy, and parameters of the rough machining are selected as follows: the diameter of the cutter is 12mm-25mm; the maximum cutting width is 0.9mm-3mm; the maximum cutting depth is 12mm-30mm; spindle speed is 12000rpm-12100rpm, and feeding per tooth is 0.15mm-0.2mm; the number of the cutter edges is 3-5;
s12: finish machining, namely, finish machining the aluminum alloy subjected to rough machining, wherein the parameters of finish machining are selected as follows: the diameter of the cutter is 10mm-20mm; the maximum cutting width is 1mm-2mm; the maximum cutting depth is 8mm-30mm; the spindle rotation speed is 13000rpm-15500rpm, and the feeding of each tooth is 0.07mm-0.1mm; the number of the cutter edges is 3-5;
s2: welding parts; welding and fixing the bottom plate, the inclined support piece 2, the rear frame 6, the left side plate 8 and the side plates in pairs to form a semi-finished product piece;
s3: performing first heat treatment; carrying out heat treatment on the semi-finished product piece to eliminate welding stress;
s4: welding; welding the front frame 4 and the rear frame 6 on the basis of the semi-finished product after heat treatment to form a light conduction box;
s5: and performing secondary heat treatment on the light conduction box to eliminate welding stress.
In this embodiment, the light conducting box is made of an aluminum alloy material, and compared with other common metals, such as ferrous metals and other nonferrous metals, the aluminum alloy has lower hardness and soft structure, so that the aluminum alloy cannot cause damage to the cutter due to the physical property of the aluminum alloy when the aluminum alloy contacts with the cutter for high-speed cutting.
In the present embodiment, the machine tool for cutting is an unspecified basis as long as the parameters required in the present embodiment can be achieved.
In this embodiment, after the aluminum alloy is rough machined in step S11, the aluminum alloy is machined to a size close to the target size, and then the aluminum alloy is machined to the target size by finish machining, and the deformation amount of the aluminum alloy can be less than 0.1mm/m by selecting the rough machining and finish machining parameters disclosed in this embodiment.
The faster the spindle rotates, the smaller the damage of the cutter to the material, namely the faster the cutter cuts the aluminum alloy, the shorter the material stripping time of the aluminum alloy, and the smaller the corresponding residual stress, so that the deformation of the aluminum alloy after being processed is smaller; however, too high a rotational speed can cause the tool to vibrate when contacting the aluminum alloy; specifically, the higher the rotation is, the larger the vibration is, and the amplitude generated by the vibration can cause the cutting position of the cutter to deviate, so that the size assurance of the cutter is affected; on the other hand, the higher the rotating speed is, the higher the vibration frequency is, and when the cutter cuts the aluminum alloy, the vibration can cause the cutter to cut different positions on the surface of the aluminum alloy, so that the surface quality of the aluminum alloy is affected, and unacceptable vibration marks such as wave marks and the like are generated; even larger vibrations can lead to direct breakage of the tool.
Specifically, in the present embodiment, since the main purpose of the rough machining is high-efficiency cutting, that is, the amount of material removed per unit time is large so as to reach the target size as soon as possible, the torque demand of the rough machining is large, not lower than 0.88 Niumi. Since the purpose of finishing is mainly to trim the finished profile, i.e. the amount of material removed per unit time is relatively small, the torque requirement for finishing is small, not less than 0.57-Niumi.
Further, in the present embodiment, four possible implementation data selections for the roughing process are presented, specifically as shown in table 1.
TABLE 1 practical data for the rough processing (unit of non-specific remarked items is mm)
Figure SMS_1
In this example, four possible implementation data selections for finishing are presented, as detailed in table 2.
TABLE 2 finishing practical implementation data (unit of non-specific remarked items is mm)
Figure SMS_2
Further, the same aluminum alloy was processed using the above-mentioned rough processing execution data and finish processing execution data in combination, and the data of the maximum deformation amount finally obtained is shown in table 3.
TABLE 3 maximum deflection test data (unit of unspecified item is mm/m)
Figure SMS_3
From this, it can be seen that the maximum deformation amount of the aluminum alloy is less than 0.1mm/m by using the embodiment in this example.
In the embodiment, the light-conducting box is divided into two welding steps and two heat treatments, and the welding stress existing in the splice welding part in the step S1 is eliminated by the first heat treatment in the step S2; the second heat treatment in the step S4 is to eliminate the welding stress existing in the welding in the step S3; the welding stress is eliminated gradually, so that the oversized dimensional change caused by stress accumulation in the welding process is avoided, and the purpose of reducing the process error is achieved; the deformation of the shape and the size of the light conduction box after heat treatment can reach the requirement of less than one thousandth, or the dimensional tolerance and the form and position tolerance can reach the requirement of less than 1 mm.
It should be noted that, in step S1, at least the bottom plate, the diagonal brace 2, the rear frame 6, the left side plate 8 and the right side plate 3 are welded, because the above parts are essential parts for fixing the diagonal brace 2 and stabilizing the brace 7, and if one part is welded, there is a free deformation direction between the parts during the heat treatment process, the purpose of mutual constraint cannot be achieved, and thus the requirement of stabilizing the dimension cannot be satisfied.
Further, in the present embodiment, in step S1, the bottom portion should be welded in advance, for example, the bottom portion includes the bottom plate 1 and the supporting leg, and the bottom plate 1 and the supporting leg should be welded in advance; and after the bottom welding is finished, the mounting positions of other subsequent parts are machined, so that higher combination precision is formed, the integral deformation after direct splice welding can be effectively reduced, and the same mounting reference is provided for the mounting and welding of other parts mounted on the bottom.
In this embodiment, the welding sequence in step S3 is to weld the front frame 4 first and then weld the top plate 5, so that the top plate 5 can be supported during assembly, so as to achieve the purpose of reducing the variation in the mounting size of the top plate 5.
In summary, by taking the structure and the process (including the part machining process and the welding process) as the cut-in point, the structural stability of the light conduction box is structurally improved, so that the mounting position stability of the reflector is improved; the parts machining and welding processes on the process reduce corresponding stress residues, effectively avoid the change of the shape and the size of the light conduction box under the condition of long-term use caused by stress, and further realize the stable installation position of the reflector.
Example 3
Further embodiments are presented which can be implemented on the basis of example 2.
An alternative embodiment, before step S1, requires cleaning or/and surface treatment of the aluminum alloy surface; before proceeding to step S11, it is necessary to clean the individual parts.
Specifically, cleaning or/and surface treatment of an aluminum alloy requires cleaning the surface of the aluminum alloy to be processed, such as oil stains, residual metal chips and surface oxide layers, particularly hard metal chips and surface oxide layers which remain on the surface, and damage the cutting tool, thereby affecting the cutting accuracy of the aluminum alloy; for the installation of aluminum alloy, frock clamp clamps the aluminum alloy as far as possible, but need to avoid producing the clamp mark on the aluminum alloy, because the aluminum alloy produces the clamp mark, its clamp mark position exists stress concentration easily to lead to the aluminum alloy to break in the clamp mark position easily in the use to the clamp mark also can influence the relative deformation of the aluminum alloy part of clamp mark both sides, thereby increases the deflection of aluminum alloy processing and reaches and be less than 0.1 mm/m's degree of difficulty. In the welding process, residues and impurities on the surface of the part possibly enter the position of the welding position so that the welding position is mixed with impurities; grease ingress into the weld site can cause bubbles to form in the weld site. In the embodiment, an organic solvent (such as absolute ethyl alcohol) is adopted to remove greasy dirt, and a nylon soft brush, a brush roller and the like are used for brushing the surface of the part; and then spraying clean water to the cleaning position by using a high-pressure spraying mode, and air-drying to finish the cleaning of the surface of the part. The beneficial effects of removing the greasy dirt by using the absolute ethyl alcohol as the organic solvent at least comprise the following points: firstly, the absolute ethyl alcohol is easy to volatilize, so that the existence of residues on the surfaces of parts is avoided; secondly, the absolute ethyl alcohol can be mixed with water in any proportion, so that the aim of easy removal during cleaning of the surface of the part is fulfilled. And secondly, the output pressure of high-pressure spraying is more than 15Mpa, so that residues and impurities on the surface of the part can be effectively removed.
In the present embodiment, the surface treatment is mainly performed by anodic oxidation with concentrated sulfuric acid.
In an alternative specific embodiment, in the step S12, when the corner of the aluminum alloy is finished, the spindle rotation speed is matched according to 30% of the spindle rotation speed in the step S12, so as to reduce the vibration of the cutter, thereby reducing the damage to the aluminum alloy; for the corner position of the aluminum alloy, the rotation speed of a main shaft for processing the aluminum alloy is reduced, so that the frequency and the amplitude of the resonance of the cutter can be effectively reduced, and the damage to the aluminum alloy is reduced. Specifically, taking the first set of possible implementation data in the finishing of example 2 as an example, the spindle rotation speed should be 390rpm when finishing the corner of the aluminum alloy.
In an alternative embodiment, in the step S11 or/and step S12, when the extension length of the tool is not greater than four times the diameter of the tool, the spindle rotation speed is the spindle rotation speed in the step S11 or/and step S12; when the extension length of the cutter exceeds four times of the diameter of the cutter, the spindle rotating speed is the speed after the speed is reduced in the same proportion as the spindle rotating speed in the step S11 or/and the step S12.
In an optional specific embodiment, in the step S11 or/and the step S12, a cutter cutting mode adopts an oblique kidney-shaped cutter cutting mode; the oblique line span in the oblique waist-shaped cutter setting mode is not smaller than 3 times of the diameter of the cutter; taking the first set of feasible implementation data in rough machining and the first set of feasible implementation data in finish machining in the example 2 as examples; in rough machining, the diameter of the cutter is 25mm, and if the extension length of the cutter is less than 100mm, the spindle rotating speed is 12000 when the aluminum alloy is rough machined; if the extension length of the cutter is 125mm, the extension length of the cutter is 25% greater than that of the cutter of 100mm, so that the rotating speed of the main shaft is reduced by 25%, namely, the rotating speed of the main shaft is 9000rpm; similarly, when the aluminum alloy is finished, the extension length of the cutter is matched with the rotating speed of the main shaft in the same way.
The extension length of the cutter is matched with the rotating speed of the main shaft, so that the moment arm of the cutter can be effectively prevented from being too large, and the aim of reducing the breakage probability of the cutter is fulfilled.
In the step S11 or/and the step S12, the cutter is assembled in a hot-charging mode, and the specific process of assembling the cutter in the hot-charging mode is to heat the cutter at a high temperature to expand the cutter when the cutter is combined with the cutter handle, then press the cutter into the cutter handle, and cool the cutter handle to realize the cutter clamping of the cutter handle; the cutter is assembled in a hot-charging mode, so that the cutter can be effectively prevented from being separated from the cutter handle when the cutter is subjected to large-cutting-depth machining, and the production and machining safety is ensured.
It should be noted that, especially when the diameter of the tool is greater than 16mm, the tool must be assembled by hot-set, and the use of screw clamping is prohibited, because the clamping force of screw clamping is lower than that of hot-set, and when the parameters disclosed in example 2 are applied to rough machining or/and finish machining of aluminum alloy, the screw clamping tool is easily separated from the tool shank, thereby causing an accident.
In the step S2 and/or the step S3, the cutter is cut in an oblique waist-shaped cutter cutting mode, a large amount of metal scraps can be generated by the aluminum alloy under the condition of high-speed cutting, and the oblique waist-shaped cutter cutting can effectively avoid scraps clamping, so that the possibility of cutter breakage is avoided.
The oblique waist-shaped cutter cutting mode is a cutter cutting mode which is conventional in the art, and the specific cutter cutting mode is not excessively described in the specification.
Further, the oblique line span in the oblique waist-shaped lower cutter mode is not smaller than 3 times of the diameter of the cutter, and is 1-2 times of the diameter of the cutter under the condition of normal cutting machining; in the present embodiment, under the condition that the aluminum alloy is processed at a high speed in example 2, the conventional oblique waist-shaped lower cutter oblique line span cannot timely discharge metal scraps, so that scraps are blocked, and the possibility of cutter breakage is further easy to occur; and the inclined line span is adjusted to be not smaller than 3 times of the diameter of the cutter, so that sufficient space can be provided for metal scraps under the condition that the aluminum alloy is cut at a high speed, and the purpose of avoiding the scraps is achieved. The condition of breaking the knife occurs.
In an optional specific embodiment, in step S1, a fixture is used to clamp an aluminum alloy, wherein the aluminum alloy has a clamping allowance; as described in example 2, the tooling of the aluminum alloy cannot retain the clamp mark, but in the actual production process, it is difficult to achieve stable fixing of the aluminum alloy without retaining the clamp mark, especially in the case of being cut at high speed; therefore, through the pre-reserved clamping allowance of the aluminum alloy, the allowance can be removed in the subsequent processing, namely, under the condition that tooling allowance exists in the aluminum alloy, the tooling of the aluminum alloy can reserve clamping marks, and the clamping marks can not influence the performance of the aluminum alloy.
Example 4
In an alternative embodiment, after step S3 is completed, step S31 is performed: correcting the shape; the method comprises the steps of performing shape correction on a semi-finished product according to data requirements, wherein the shape correction process is a prediction process, and mainly performing shape correction on the shape and position tolerance (such as verticality, planeness, straightness and the like) which exceeds the designed deformation requirement; if not, no calibration may be required; in this embodiment, if the shape correction is required, the shape correction in step S21 must be performed after the first heat treatment in step S2 is completed; specifically, the sizing process is arranged after the first heat treatment in step S2 in order to restore excessive changes to the shape of the part during the heat treatment; if the step S21 of calibrating is performed before the first heat treatment in the step S2, the calibration process is restored to the design requirement of the geometric tolerance, but the material is deformed under the action of high temperature, and the tiny deformation generated by the welding butt joint position 9 when the welding stress is eliminated may be overlapped with the deformation generated by the calibration step, so that the deformation amount is uncontrollable; therefore, the step S21 of shaping must be performed after the first heat treatment of step S2 is completed.
Further, after the completion of step S31, the support 7 for supporting the mirror assembly is mounted on the diagonal support 2, the support 7 is a part for mounting the mirror assembly, the support 7 is mounted on the diagonal support 2, and the form and position tolerance of the diagonal support 2 is a fundamental factor for securing the position of the support 7, thereby further securing the accuracy of the mounting position of the mirror assembly, so that the process of mounting the support 7 on the diagonal support 2 should be after the shape correction process.
Further, after the supporting piece 7 is installed, the installation reference and the supporting surface of the reflecting mirror component of the supporting piece 7 are subjected to a number milling; the numerical milling is to mill the supporting piece 7 in a number mode, a numerical control five-axis machine tool is adopted for machining in place at one time, the required angle error is smaller than 10 milliradians, the position error is smaller than 0.07mm, the flatness is smaller than 0.05mm, and the accuracy and precision of the installation position of the reflector component are guaranteed.
It should be noted that in step S1 and step S2, the advantage of not assembling the front frame 4 and the top plate 5 is that the milling head is convenient to process the milling position during the milling of the supporting member 7, so as to avoid the blocking effect of the cutter.
In the optional specific implementation manner, in the step S2 and the step S4, the welding mode adopts laser welding, the material of the part is aluminum alloy, deformation easily occurs during the welding process and after welding, and the assembly precision is affected.
Furthermore, the pin and the normal temperature curing resin glue are required to be adopted for prefabricating and butting before the welding of the parts, namely, the welding is required to be carried out after the prefabricating and butting step is finished before the step S2 and the step S4, namely, the prefabricating and butting is that the pin is used for prefabricating and butting each part, and the normal temperature curing resin glue is coated on a butting combination interface; in the embodiment, auxiliary tools are not selected for additional constraint and fixation of parts, the corresponding part precision is made into a design requirement (generally IT 6) before welding, and the pins for butt joint are prefabricated, so that the qualified size is formed by mutually matching the tools with higher precision as much as possible, and the purposes of saving cost and improving efficiency are achieved.
Specifically, before step S2 and step S4, the butt joint position 9 between the parts is coated with normal temperature curing resin glue, such as DG-3 resin glue; positioning and preassembling by using pins, checking the size, removing redundant normal-temperature curing resin adhesive after the normal-temperature curing resin adhesive is cured, cleaning a welding groove, and waiting for welding; the pin is matched with the pin hole 10 to realize positioning; as shown in fig. 1-4, the front frame 4 and the top plate 5 are pre-butted when they are welded.
In an alternative specific embodiment, after the prefabricated butt joint is finished, the welding between the parts is finished within 3 hours, and the phenomenon that the performance of the material is reduced due to excessive oxidation of the welding groove is avoided.
In the optional specific implementation manner, in the step S2 and the step S4, the welding type between the parts is any one of symmetrical fillet welding, symmetrical butt welding and asymmetrical compound welding, the welding type is selected according to the situation, and the three welding types are adopted to carry out butt welding on the parts, so that the deformation caused by overlarge welding stress during local welding can be effectively controlled, and the deformation is obtained through a large number of process tests.
Specifically, if two parts are vertically abutted and the material of one part is provided with the material of the other part on both sides, symmetrical fillet welding is preferably adopted, and the symmetrical fillet welding (the welding seam 1 and the welding seam 2) is synchronously welded, as shown in fig. 5; if two parts are butted in parallel, preferably symmetric butt welding is adopted, and the symmetric butt welding (the welding seam 3 and the welding seam 4) is synchronously applied, as shown in fig. 6; if two parts are vertically butted and only one side of each part is provided with a material, preferably an asymmetric composite welding is adopted, namely, welding fillet welding (welding seam 5) is firstly carried out, the fillet welding is positioned on the side provided with the material, then butt welding (welding seam 6) is carried out, and the butt welding is positioned on the side without the material, as shown in fig. 7.
Further, the diameter of a welding wire for welding is selected to be 1.2mm-1.6mm, the light spot width is 2.5mm-3.5mm, and the welding speed is 30mm/min-40mm/min; specifically, the diameter of the welding wire for butt welding should be 1.6mm in this embodiment, the spot width is 3.5mm, and the welding speed is 40mm/min; the fillet welding wire diameter should be 1.2mm, the light plate width between 2.5-3mm, and the welding speed is 30mm/min.
Further, the smaller the diameter of the welding wire is, the worse the filling capability is, and the condition that two or more times of fusion welding are needed easily occurs in the welding process, so that the welding stress and deformation are improved, the larger the bending radius is caused by the overlarge diameter of the welding wire, and the wire cannot be automatically fed; the welding wire diameter in the range is selected to finish the filling of the welding seam at one time, so that the occurrence of welding defects caused by multiple times of welding is avoided; the light spot width is too large, and the laser energy is dispersed, so that the depth of a welding line is reduced, the light spot width is too small, and the laser energy is too concentrated, so that the depth of the welding line is too large, and the welding effect in an aluminum alloy material can be improved by using the light spot width; the welding speed can influence the welding width and the welding depth, the welding speed is too low, and gas or water molecules in the environment can enter a material in a molten state to form air holes, so that the welding quality is influenced; the welding speed is too high, the welding width and the welding depth are not up to standard, the butt joint of parts is unstable, and the connection of the parts is unstable, so that the welding quality can be effectively ensured by selecting the welding speed.
In an alternative specific embodiment, the part material of the light-conducting box is aluminum alloy 6061-T6 or/and aluminum alloy 5A06; in the step S2 or S4, the heat treatment mode is heating to 140-145 ℃ for 6061-T6 of aluminum alloy, preserving heat for 235-245 min, and discharging and air cooling; or heating the aluminum alloy 5A06 with a furnace, preserving heat for 1-1.5h at 310-330 ℃, discharging and air-cooling after the heat preservation is finished; the heat preservation temperature is too low or/and the heat preservation time is too short, the welding stress cannot be released or is insufficiently released, and the effect of removing the welding stress cannot be achieved; the metal phase of the material is changed due to the over high heat preservation temperature, so that the performance of the material is affected; the long heat preservation time can increase the production cost.
In an alternative embodiment, after step S5, the gas tightness of the weld seam of the light conducting box is detected by using a helium gas detection method, and the leakage rate is less than 1x10 -5 Pa*m 3 The product of/s is a qualified product.
Specifically, helium gas detection includes the steps of:
s6: the method comprises the steps of detection preparation, wherein the hollowed-out position of a part is required to be sealed before helium detection is carried out, as shown in fig. 8, the sealed structure comprises a sealing plate 11 connected with the hollowed-out position of the part through bolts, a sealing rubber strip is arranged between the sealing plate 11 and the part, and a welding seam between the parts is positioned outside a sealing ring to finish sealing of a light-conducting box; and transmitting the light for sealing to the box to be placed in a vacuum environment, such as a vacuum bag; the light which completes the sealing work is transmitted to the box and is called as a detected piece, the pressure gauge and the air release valve are connected to the inside of the detected piece, and the inside of the detected piece is communicated with the outside through the air release valve;
s7: the connection detection system is shown in fig. 9, and the inside of the detected part is communicated with a helium storage tank; and using a helium mass spectrometer, which in this embodiment is an inflight LX218 helium mass spectrometer;
s8: replacing, namely opening a gas release valve, and rapidly filling helium into the detected part to replace air in the detected part until the concentration of the helium is more than 10% by volume, and closing the gas release valve;
s9: filling helium gas; after the step S8, continuing to fill helium into the detected part, so that the pressure in the detected part reaches positive pressure 500Pa, and maintaining the pressure for more than 30 minutes;
s10: a suction gun using a helium mass spectrometer is moved along the surface of the inspected piece, particularly the weld position, and the presence or absence of leakage at the weld position is recorded.
The invention is not limited to the specific embodiments described above. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification, as well as to any novel one, or any novel combination, of the steps of the method or process disclosed.

Claims (13)

1. An assembly process of a light conduction box is characterized in that: the light conduction box comprises a bottom plate (1) and a top plate (5), wherein the front side, the rear side, the left side and the right side of the bottom plate (1) are respectively welded with a front frame (4), a rear frame (6), a left side plate (8) and a right side plate (3), inclined support pieces (2) for supporting a reflector assembly are welded among the bottom plate (1), the rear frame (6), the left side plate (8) and the right side plate (3), a triangular structure is formed between the inclined support pieces (2) and the bottom plate (1) and between the inclined support pieces (2) and the rear frame (6), and the inclined support pieces (2) are inclined edges; the left side plate (8), the right side plate (3), the front frame (4) and the rear frame (6) are welded with the top plate (5); a support (7) for supporting the reflector assembly is arranged on the inclined support (2); assembling the light conducting box comprises the following steps:
s1: machining parts, namely machining aluminum alloy into parts with designed shapes, structures and sizes through the step S11 and the step S12, wherein the deformation amount of the parts is lower than 0.1mm/m, and the parts comprise a bottom plate (1), a front frame (4), a rear frame (6), a left side plate (8), a right side plate (3), a diagonal support member (2), a top plate (5) and a support member (7);
s11: rough machining, namely, rough machining is carried out on the aluminum alloy, and parameters of the rough machining are selected as follows: the diameter of the cutter is 12mm-25mm; the maximum cutting width is 0.9mm-3mm; the maximum cutting depth is 12mm-30mm; spindle speed is 12000rpm-12100rpm, and feeding per tooth is 0.15mm-0.2mm; the number of the cutter edges is 3-5;
s12: finish machining, namely, finish machining the aluminum alloy subjected to rough machining, wherein the parameters of finish machining are selected as follows: the diameter of the cutter is 10mm-20mm; the maximum cutting width is 1mm-2mm; the maximum cutting depth is 8mm-30mm; the spindle rotation speed is 13000rpm-15500rpm, and the feeding of each tooth is 0.07mm-0.1mm; the number of the cutter edges is 3-5;
s2: welding parts; the bottom plate, the inclined support piece (2), the rear frame (6), the left side plate (8) and the side plates are welded and fixed pairwise to form a semi-finished product piece;
s3: performing first heat treatment; carrying out heat treatment on the semi-finished product piece to eliminate welding stress;
s4: welding; welding a front frame (4) and a rear frame (6) on the basis of the semi-finished product after heat treatment to form a light conduction box;
s5: and performing secondary heat treatment on the light conduction box to eliminate welding stress.
2. The assembling process of the light guide box according to claim 1, wherein: before step S1 is carried out, cleaning or/and surface treatment is needed on the surface of the aluminum alloy; before proceeding to step S11, it is necessary to clean the individual parts.
3. The assembling process of the light guide box according to claim 1, wherein: in step S12, when finishing the corner of the aluminum alloy, the spindle rotation speed is matched according to 30% of the spindle rotation speed in step S12.
4. The assembling process of the light guide box according to claim 1, wherein: in the step S11 or/and the step 12, when the extension length of the cutter is not greater than four times the diameter of the cutter, the spindle rotation speed is the spindle rotation speed in the step S11 or/and the step S12; when the extension length of the cutter exceeds four times of the diameter of the cutter, the spindle rotating speed is the speed after the speed is reduced in the same proportion as the spindle rotating speed in the step S11 or/and the step S12.
5. The assembling process of the light guide box according to claim 1, wherein: in the step S11 or/and the step S12, an oblique kidney-shaped cutter cutting mode is adopted as a cutter cutting mode; and the oblique line span in the oblique waist-shaped cutter setting mode is not smaller than 3 times of the diameter of the cutter.
6. The assembling process of the light guide box according to any one of claims 1 to 5, wherein: in step S1, a fixture is used for clamping the aluminum alloy, and the aluminum alloy has a clamping allowance.
7. The assembling process of the light guide box according to claim 1, wherein: after step S3 is completed, step S31 is performed: correcting the shape; performing shape correction on the semi-finished product according to the data requirements; and after the completion of step S31, mounting a support (7) for supporting the mirror assembly on the diagonal support (2); after the supporting piece (7) is installed, the installation standard and the supporting surface of the reflecting mirror component of the supporting piece (7) are subjected to a number milling.
8. The assembling process of the light guide box according to claim 1, wherein: in the step S2 and the step S4, the welding mode adopts laser welding, and the pin and the normal-temperature curing resin glue are required to be adopted for prefabrication butt joint before the welding of the parts.
9. The assembling process of the light guide box according to claim 8, wherein: and after the prefabricated butt joint is finished, the welding between the parts is finished within 3 hours.
10. The assembling process of the light guide box according to claim 1, wherein: in step S2 and step S4, the type of welding between the parts is any one of symmetrical fillet welding, symmetrical butt welding, and asymmetrical compound welding.
11. The assembling process of the light guide box according to any one of claims 7 to 10, wherein: the light conduction box is made of aluminum alloy 6061-T6 or/and aluminum alloy 5A06; in the step S2 or S4, the heat treatment mode is heating to 140-145 ℃ for 6061-T6 of aluminum alloy, preserving heat for 235-245 min, and discharging and air cooling; or heating the aluminum alloy 5A06 with a furnace, preserving heat for 1-1.5h at 310-330 ℃, discharging and air cooling after the heat preservation is finished.
12. The assembling process of the light guide box according to claim 1, wherein: after step S5, the gas tightness of the weld joint of the optical conduction box is detected by adopting a helium gas detection method.
13. The assembling process of the light guide box according to claim 12, wherein: the part hollowed-out position is required to be sealed before helium gas detection is carried out, the sealed structure comprises a sealing plate (11) connected with the part hollowed-out position through bolts, a sealing rubber strip is arranged between the sealing plate (11) and the part, and a welding seam between the parts is located outside the sealing ring.
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Address after: 618400 Sichuan Deyang Shifang Economic Development Zone (Ling Jie Park) blue sky Road No. 3

Patentee after: Sichuan Xinhang Titanium Technology Co.,Ltd.

Address before: 618400 Sichuan Deyang Shifang Economic Development Zone (Ling Jie Park) blue sky Road No. 3

Patentee before: SICHUAN FUTURE AEROSPACE INDUSTRIAL Co.,Ltd.