WO2019052267A1 - 一种超声振动辅助螺旋铣磨螺纹方法 - Google Patents

一种超声振动辅助螺旋铣磨螺纹方法 Download PDF

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WO2019052267A1
WO2019052267A1 PCT/CN2018/094355 CN2018094355W WO2019052267A1 WO 2019052267 A1 WO2019052267 A1 WO 2019052267A1 CN 2018094355 W CN2018094355 W CN 2018094355W WO 2019052267 A1 WO2019052267 A1 WO 2019052267A1
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tool
grinding wheel
ultrasonic vibration
cutter
thread
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PCT/CN2018/094355
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English (en)
French (fr)
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张建富
冯平法
查慧婷
郁鼎文
吴志军
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清华大学
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23G—THREAD CUTTING; WORKING OF SCREWS, BOLT HEADS, OR NUTS, IN CONJUNCTION THEREWITH
    • B23G1/00—Thread cutting; Automatic machines specially designed therefor
    • B23G1/36—Thread cutting; Automatic machines specially designed therefor by grinding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23G—THREAD CUTTING; WORKING OF SCREWS, BOLT HEADS, OR NUTS, IN CONJUNCTION THEREWITH
    • B23G1/00—Thread cutting; Automatic machines specially designed therefor
    • B23G1/44—Equipment or accessories specially designed for machines or devices for thread cutting

Definitions

  • the invention belongs to the field of mechanical processing and tool technology, and more particularly to an ultrasonic assisted spiral milling thread method.
  • Hard and brittle materials that are represented by optical glass, silicon carbide ceramics, and high volume fractional particle reinforced metal matrix composites are widely used in aerospace, optical components, automobiles, electronic packaging, etc. due to their excellent physical, chemical and mechanical properties. field. Threaded connection is a widely used method of joining parts. For hard and brittle materials, thread processing is very difficult due to the high brittleness and high hardness of the material itself.
  • the methods for processing threaded parts mainly include tap tapping and milling.
  • tap tapping and milling For high-hardness and high-brittle materials, high-speed steel tapers and hard alloy taps used in traditional tapping methods not only have problems such as fast tap wear and low machining accuracy, but also due to excessive torque. Broken taps cause valuable parts to be scrapped. If manual tapping is used, not only is production efficiency low, but also a lot of manpower and money is wasted. Thread milling processing, although for the general metal materials, the thread size precision is high, but for hard and brittle materials, the tool wear is very serious, resulting in rapid reduction of machining accuracy.
  • the pre-formed method, the welding method and the bonding method are often used to inlay the machined threaded metal parts on the hard and hard-to-machine materials, but the connection of these different materials is poor in temperature adaptability and complicated in process. The cost is higher.
  • thread forming grinding methods are also used (such as Chinese patent CN201210494730.2, a hard and brittle material small hole thread forming grinding method).
  • the method adopts a disc-shaped forming grinding wheel; a spiral formed by a combination of a cutter shaft and a center of a hole shaft, a rotation of a disc-shaped forming grinding wheel, a revolving of a disc-shaped forming grinding wheel around a hole shaft, and an axial feeding of a disc-shaped forming grinding wheel Grinding method.
  • the method adopts spiral milling to process and shape, the spindle rotation speed is from 1000r/min to 30000r/min, and other processing parameters are selected according to the nature of the hard and brittle material, the thread size and the processing requirements. For example, the principle error value ⁇ satisfies the following formula:
  • ⁇ is the principle error value
  • ⁇ 0 is the actual machining error threshold
  • D is the standard internal thread nominal diameter
  • P is the pitch.
  • the disc-shaped grinding wheel trimming method adopted by the method is complicated, and the abrasive wear on the grinding wheel is serious.
  • the material with high brittleness micro-cracks are easily generated in the processed material, which affects the service life of the parts.
  • ultrasonic assisted vibration processing is not limited by the thermoelectric characteristics of the material, and the cutting force is small and the cutting temperature is low during the processing. Its unique intermittent processing technology makes it have little influence on the microstructure of processed materials, which is of great significance for improving the reliability of hard and brittle materials. However, it has not been used in the field of thread processing of hard and hard materials.
  • the object of the invention is to solve the problems of fast wear of hard and hard-to-machine materials, fast scraping of parts, low scraping of parts and low processing efficiency, and an ultrasonic vibration assisted spiral milling threading method, the invention is mainly used for hard and brittle difficult-to-machine materials. Thread processing, this processing method can effectively reduce the cutting force during machining, improve the thread processing quality and processing efficiency, and improve tool wear.
  • the invention relates to an ultrasonic vibration assisted spiral milling threading method, which is characterized in that the method adopts a profiling grinding wheel cutter, and the cutter is mounted on the spindle of the ultrasonic processing machine tool through an ultrasonic vibration tool holder; the tool axis is parallel to the axis center of the threaded hole of the workpiece to be processed.
  • the method adopts the rotation of the contouring grinding wheel cutter, the revolving of the contouring grinding wheel tool around the threaded hole axis and the axial feeding of the contouring grinding wheel tool, and the four-way motion of the contouring grinding wheel tool with the axial vibration of the ultrasonic vibration tool holder.
  • the spiral milling method adopts a profiling grinding wheel cutter, and the cutter is mounted on the spindle of the ultrasonic processing machine tool through an ultrasonic vibration tool holder; the tool axis is parallel to the axis center of the threaded hole of the workpiece to be processed.
  • the method adopts the rotation of the contouring grinding
  • the workpiece is fixed, and the tool revolves at the same time as the eccentricity e along the axis of the threaded hole by a spiral trajectory; wherein, the eccentricity e, the pitch P, the profiling wheel
  • the tool axial feed speed V f and the revolution speed ⁇ , and the diameter d of the middle cutter bar respectively satisfy the requirements of formulas (1) to (3):
  • D is the nominal diameter of the standard internal thread
  • D S is the diameter of the contour of the tool head, D S ⁇ D 1
  • D 1 is the standard internal thread diameter D 1 .
  • the principle error ⁇ generated by the thread size satisfies the requirement of formula (4):
  • the introduction of ultrasonic vibration can effectively reduce the cutting force of hard and brittle materials during thread processing, avoiding the tapping of the tap due to insufficient strength during the tapping process; the feed rate of the tool during machining can be obtained. Effectively improved, the processing efficiency can be further improved, and the tool wear condition is also improved; the ultrasonic vibration processing process can reduce microcracks on the surface of hard and brittle material processing, and can improve the reliability of use of hard and brittle materials; in addition, the same type of ultrasound
  • the vibration-assisted milling tool can process a wide range of diameters and is suitable for small batches and multiple types of processing.
  • 1 is a schematic view showing the principle of the ultrasonic vibration assisted spiral milling thread method of the present invention
  • FIG. 2 is a schematic cross-sectional view of a profile grinding wheel of a tool head according to the present invention
  • Figure 3 is a schematic view showing the manner of connecting the cutter and the ultrasonic vibration shank in the present invention
  • 1 ultrasonic machining machine spindle 1 ultrasonic machining machine spindle; 2 ultrasonic vibration tool holder; 3 contour grinding wheel tool; 4 workpiece; 5 eccentricity; 6 tool revolution movement; 7 tool ultrasonic vibration; 8 spindle rotation motion; 9 tool bar diameter; 10 diamond abrasive grain; 11 tool head profile grinding wheel diameter; 12 thread tolerance zone; 13 tool actual outer contour; 14 tool end cone surface; 15 tool end thread; 16 center cooling hole; 17 tool end straight rod.
  • the invention provides an ultrasonic vibration assisted spiral milling threading method, the schematic diagram of which is shown in Fig. 1.
  • the method adopts a contouring grinding wheel cutter 3, which passes the ultrasonic vibration machining handle of the ultrasonic machining machine tool (the invention adopts The conventional ultrasonic machining machine 2 is mounted on the spindle 1 of the ultrasonic machining machine; the axis of the tool is parallel to the center of the axis of the threaded hole of the workpiece to be processed, and the method adopts the rotation of the contouring wheel cutter 3 (arrow 8 as shown in Fig. 1), The revolving grinding wheel cutter 3 revolves around the axis of the threaded hole (arrow 6 as shown in Fig.
  • the arrow 7 shown in Fig. 1 is a spiral milling method in which four kinds of motions are combined.
  • the profile grinding wheel cutter 3 is selected according to the size of the required thread and the processing precision requirement, and the connection mode of the profile grinding wheel cutter and the ultrasonic vibration shank 2.
  • the workpiece is fixed, and the tool revolves with the eccentricity e (ie, the reference numeral 5 shown in Figure 1) along the axis of the threaded hole in a spiral path (ie, the tool axis and the tool are processed).
  • the central axis of the threaded hole does not coincide); wherein, the eccentricity e, the pitch P, the axial feed speed V f of the profiled grinding tool and the revolution speed ⁇ , and the diameter d of the middle cutter of the tool (as shown in Fig. 2(a)
  • the reference numeral 9) shown satisfies the requirements of equations (1) to (3), respectively:
  • D is the nominal diameter of the standard internal thread
  • D S is the diameter of the contour of the cutter head (as shown in Figure 2 (a), reference numeral 11);
  • D 1 is the standard internal thread diameter D 1 ;
  • the contoured grinding wheel of the head of the profiling grinding wheel tool 3 is as shown in Fig. 2(a), and the cross-sectional shape of the contouring grinding wheel of the head of the tool 3 is matched with the standard thread shape, and ⁇ is shown in Fig. 2(a).
  • the angle of the thread is shown in Fig. 2(a).
  • the surface of the profiled grinding wheel on the head of the tool 3 is plated with diamond abrasive grains 10.
  • the diamond particle size on the tool is selected according to the hardness and brittleness of the material and the precision of the thread processing.
  • the grain size of the abrasive grains ranges from 100/120 to 270/325.
  • the size of the base of the cutter head needs to consider the thickness of the abrasive coating.
  • the diameter D S of the tool head contouring grinding wheel is smaller than the standard internal thread diameter: D S ⁇ D 1 ; the tool bar cannot touch the internal thread diameter D 1 during the machining process, so the tool bar diameter d should satisfy: e +d/2 ⁇ D 1 .
  • the connecting manner of the profiling grinding wheel tool 3 and the ultrasonic vibrating tool holder 2 is as shown in FIG. 3, including: the tool connecting end is connected with the ultrasonic vibrating tool holder 2 by a cone-shaped cutting type 14, as shown in FIG. 3(a); The thread 15 is connected with the ultrasonic vibration spindle shank 2, as shown in Fig. 3(b); the cutter connection end adopts a rod-shaped section 17, and is connected with the ultrasonic vibration shank 2 through a spring ferrule, as shown in Fig. 3(c). Show.
  • the protection of the present invention cannot be affected by the specific connection method.
  • the contouring grinding wheel cutter 3 is provided with a central cooling hole 16 along its axial direction for the outflow of the cutting fluid, on the one hand, flushing and removing the chips, cooling the cutting area; on the other hand, cooling the ultrasonic vibration shank caused by the ultrasonic vibration Internal heat.
  • the present invention uses a profiling tool to machine a thread, the thread size will produce a certain error, called the principle error ⁇ , ⁇ should be controlled at least within one third of the allowable machining error ⁇ 0 , to meet Formula (4) requires:
  • M10 threading was performed on a silicon carbide particle reinforced aluminum matrix composite having a volume fraction of 63%, and the thread precision required was 6H.
  • the nominal diameter D of the internal thread of M10 is 10 mm
  • the pitch P is selected to be 1.5 mm
  • the thread diameter D 1 can be selected to be 8.6 mm.
  • Profiling the grinding wheel tool head particle size of diamond abrasive grains selected electroplating 200/230 contoured grinding wheel diameter D s 8.3mm selected surface thereof, the tool head, the tool diameter d of the central arbor choice 4mm, and ultrasonic vibration cutter blade The connection method of the shank adopts a conical section connection mode, the diameter of the central cooling hole of the tool axial direction is 2 mm, and the amplitude A of the tool end is maintained at 5-7 ⁇ m.
  • the profiled grinding wheel tool of the embodiment is installed on the spindle of the Ultrasonic 50 ultrasonic machining machine tool produced by DMG through the ultrasonic vibration tool holder of the ultrasonic processing machine tool.
  • the spindle speed of the machine tool is the revolution speed ⁇ , 5000r/min, and the tool axial feed speed V is selected. f is 6 mm/min.
  • the spiral milling method of motion composite is used for thread machining. During the machining process, the cutting force is reduced by more than 70% compared to conventional milling and threading.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)

Abstract

一种超声振动辅助螺旋铣磨螺纹方法，使用仿形砂轮刀具（3），通过超声振动刀柄（2）将仿形砂轮刀具（3）安装在超声加工机床主轴（1）上；刀具轴线与螺纹孔轴线中心平行设置，采取仿形砂轮刀具（3）的自转、仿形砂轮刀具（3）绕螺纹孔轴线的公转和仿形砂轮刀具（3）轴向给进、以及仿形砂轮刀具（3）随超声振动刀柄（2）的轴向振动四种运动复合而成的螺旋铣削方式。超声振动辅助螺旋铣磨螺纹方法能有效降低硬脆难加工材料在螺纹加工过程中的切削力，改善刀具磨损情况。

Description

一种超声振动辅助螺旋铣磨螺纹方法 技术领域
本发明属于机械加工及工具技术领域，更具体地，涉及一种超声辅助螺旋铣磨螺纹方法。
技术背景
以光学玻璃、碳化硅陶瓷、高体积分数颗粒增强金属基复合材料为代表的硬脆难加工材料由于优良的物理、化学及力学性能，被广泛应用于航空航天、光学元件、汽车、电子封装等领域。螺纹连接是一种应用十分广泛的零件连接方法，而对于硬脆难加工材料，由于材料本身的高脆性和高硬度，其螺纹加工十分困难。
目前螺纹零件加工的方法主要有丝锥攻丝和铣削加工。对于高硬度、高脆性的材料，传统的攻丝方法所使用的高速钢丝锥、硬质合金丝锥等，在加工过程中不仅存在丝锥磨损快、加工精度低等问题，而且因扭矩过大常使丝锥折断造成贵重零件报废。若采用手动攻丝，不仅生产效率低，而且浪费大量人力和资金。螺纹铣削加工，虽然对于一般金属材料，所加工的螺纹尺寸精度较高，但对于硬脆难加工材料，其刀具磨损十分严重，导致加工精度迅速降低。另外，也常采用预置件法、焊接法和粘接法等将加工好的螺纹金属件镶嵌在硬脆难加工材料上，但对于这些异种材料连接，其温度的适应性较差，工艺复杂，费用较高。对于陶瓷等硬脆材料，也采用螺纹成形磨削加工方法(如中国专利CN201210494730.2，一种硬脆材料小孔螺纹成形磨削方法)。该方法采用盘状成型砂轮；采取刀轴与孔轴中心平行、盘状成型砂轮的自转、盘状成型砂轮绕孔轴的公转和盘状成型砂轮轴向进给三种运动复合而成的螺旋磨削方式。该方法采取螺旋铣削方式加工成形，主轴转速在1000r/min～30000r/min，根据硬脆难加工材料的性质、螺纹大小及加工要求选择其他加工参数，如原理性误差值δ满足如下公式：
Figure PCTCN2018094355-appb-000001
其中，δ为原理性误差值，δ 0为实际加工误差阈值，D为标准内螺纹公称直径，P为螺距。
理论上，盘状成型砂轮螺旋磨削螺纹孔时，只有当刀盘倾斜安装且倾斜角度等于螺纹角度时，加工不会产生干涉，即不会产生原理性误差。但是由于机床结构、工件结构和操作等方面的限制，尤其是加工小孔螺纹，刀具倾斜加工较难实现，因此生产实践中很少采用刀盘倾斜的加工方式。若采用刀轴与孔轴中心平行的方式加工，因盘形刀具在沿螺旋轨迹加工，砂轮与已加工螺纹表面必然存在干涉导致螺纹形状超差，即产生原理性误差。但该方法采用 的盘状砂轮截型修整较为复杂，砂轮上磨粒磨损较为严重，对脆性很高的材料，加工后材料中易产生微裂纹，影响零件的使用寿命。
近年来，特种加工技术在硬脆难加工材料中得到了广泛的应用，如激光加工、电火花加工、高压磨料水射流加工、超声辅助振动加工等。其中超声辅助振动加工，不受材料热电特性限制，在加工过程中，切削力小，切削温度低。其独特的断续加工工艺，使得其对加工后材料的组织影响很小，这对于提高硬脆难加工材料零件的使用可靠性，具有极为重要的意义。但目前仍未被运用在硬脆难加工材料的螺纹加工领域。
发明内容
本发明的目的是为了解决硬脆难加工材料丝锥磨损快、折断导致零件报废和加工效率低等问题，提供一种超声振动辅助螺旋铣磨螺纹方法，本发明主要用于硬脆难加工材料的螺纹加工，该加工方法可以有效降低加工过程中的切削力，提高螺纹加工质量和加工效率，改善刀具磨损。
本发明采用的技术方案是：
一种超声振动辅助螺旋铣磨螺纹方法，其特征在于，该方法采用仿形砂轮刀具，该刀具通过超声振动刀柄安装在超声加工机床主轴上；刀具轴线与被加工工件的螺纹孔轴线中心平行，该方法采取仿形砂轮刀具的自转、仿形砂轮刀具绕螺纹孔轴线的公转和仿形砂轮刀具轴向给进、以及仿形砂轮刀具随超声振动刀柄的轴向振动四种运动复合而成的螺旋铣削方式。
可选地，以所述螺旋铣削方式加工过程中，工件固定不动，刀具在自转的同时，以偏心距e沿螺纹孔轴线以螺旋轨迹公转；其中，偏心距e，螺距P、仿形砂轮刀具轴向进给速度V f和公转速度ω，以及刀具中部刀杆的直径d分别满足公式(1)～(3)要求：
Figure PCTCN2018094355-appb-000002
Figure PCTCN2018094355-appb-000003
d<D 1，且
Figure PCTCN2018094355-appb-000004
式中，D为标准内螺纹公称直径，D S为刀具头部仿形砂轮直径，D S<D 1；D 1为标准内螺纹小径D 1。
可选地，该方法进行螺纹加工时，螺纹尺寸产生的原理性误差δ满足公式(4)要求：
Figure PCTCN2018094355-appb-000005
式中，η为刀具头部仿形砂轮直径D S与标准内螺纹公称直径D的比例系数，即D S＝ηD； A为刀具随超声振动刀柄振动的振幅。
本发明的特点及有益效果：
超声振动作用的引入，能够有效降低硬脆难加工材料在螺纹加工过程中的切削力，避免丝锥因强度不足在攻丝过程中发生折断而使零件报废；加工过程中刀具的进给速度可以得到有效提高，能够进一步提高加工效率，刀具磨损情况也有所改善；超声振动加工工艺可以减少硬脆材料加工表面的微裂纹,能够提高硬脆难加工材料零件的使用可靠性；另外，同一型号的超声振动辅助铣磨刀具可以加工多种直径系列的螺纹，适合小批量多品种的加工需求。
附图说明
图1为本发明的超声振动辅助螺旋铣磨螺纹方法原理示意图；
图2为本发明中所涉及的刀具头部仿形砂轮的截面形状示意图；
图3为本发明中所涉及的刀具与超声振动刀柄连接的方式示意图；
图中：1超声加工机床主轴；2超声振动刀柄；3仿形砂轮刀具；4工件；5偏心距；6刀具公转运动；7刀具超声振动；8主轴旋转运动；9刀具的刀杆直径；10金刚石磨粒；11刀具头部仿形砂轮直径；12螺纹公差带；13刀具实际外轮廓；14刀具端部锥面；15刀具端部螺纹；16中心冷却孔；17刀具端部直杆。
具体实施方式
以下结合附图和具体实施例对本发明的技术方案详细说明如下：
本发明提出的一种超声振动辅助螺旋铣磨螺纹方法，其原理图如图1所示，该方法采用仿形砂轮刀具3，该刀具通过超声加工机床的超声振动刀柄(本发明所采用的常规的超声加工机床)2安装在超声加工机床主轴1上；刀具轴线与被加工工件的螺纹孔轴线中心平行，该方法采取仿形砂轮刀具3的自转(如图1中所示箭头8)、仿形砂轮刀具3绕螺纹孔轴线的公转(如图1中所示箭头6)和仿形砂轮刀具3轴向给进、以及仿形砂轮刀具3随超声振动刀柄2的轴向振动(如图1中所示箭头7)四种运动复合而成的螺旋铣削方式。
所述仿形砂轮刀具3根据所需螺纹的尺寸和加工精度要求，以及该仿形砂轮刀具与超声振动刀柄2的连接方式进行选取。
在螺旋铣削加工过程中，工件固定不动，刀具在自转的同时，以偏心距e(即图1中所示附图标记5)沿螺纹孔轴线以螺旋轨迹公转(即刀具轴线与刀具所加工螺纹孔的中心轴线不重合)；其中，偏心距e，螺距P、仿形砂轮刀具轴向进给速度V f和公转速度ω，以及刀具中部刀杆的直径d(如图2(a)中所示附图标记9)分别满足公式(1)～(3)要求：
Figure PCTCN2018094355-appb-000006
Figure PCTCN2018094355-appb-000007
d<D 1，且
Figure PCTCN2018094355-appb-000008
式中，D为标准内螺纹公称直径，D S为刀具头部仿形砂轮直径(如图2(a)中所示附图标记11)；D 1为标准内螺纹小径D 1；
所述仿形砂轮刀具3头部的仿形砂轮如图2(a)所示，刀具3头部的仿形砂轮截面形状与标准螺纹形状相匹配，图2(a)中所示α即为螺纹的牙型角。刀具3头部的仿形砂轮表面镀有金刚石磨粒10，刀具上的金刚石粒度选择根据材料的硬度及脆性性质及螺纹加工精度要求，磨粒粒度范围在100/120～270/325。所选择的金刚石粒度越大，对于高硬度材料切削能力越好；然而粒度越大，螺纹加工精度就越难保证。另外，刀具头部基体尺寸需要考虑磨粒镀层厚度，金刚石磨粒越大，需要预留的尺寸就越大，才能保证刀具头部仿形砂轮的实际外轮廓13落在螺纹公差带12内，如图2(b)所示。精加工时，磨粒宜选用细磨料，以保证尺寸及其精度的可靠性。在设计时，刀具头部仿形砂轮的直径D S小于标准内螺纹小径：D S<D 1；刀杆在加工过程中不能碰到内螺纹小径D 1，因此刀杆直径d应满足：e+d/2<D 1。
所述仿形砂轮刀具3与超声振动刀柄2的连接方式如图3所示，包括：刀具连接端采用锥面截型14与超声振动刀柄2连接，如图3(a)所示；采用螺纹15与超声振动主轴刀柄2连接，如图3(b)所示；刀具连接端采用杆状截型17，通过弹簧卡套与超声振动刀柄2连接，如图3(c)所示。不能因为具体连接方式的不同而影响对本发明的保护。
所述仿形砂轮刀具3沿其轴向设有中心冷却孔16，用于切削液的流出，一方面可以冲刷和排除切屑，冷却切削区域；另一方面可以冷却超声振动引起的超声振动刀柄内部发热。
理论上，本发明在使用仿形砂轮刀具进行加工螺纹时，螺纹尺寸会产生一定的误差，称为原理性误差δ，δ至少应当控制在允许的加工误差δ 0的三分之一以内，满足公式(4)要求：
Figure PCTCN2018094355-appb-000009
式中，η为刀具头部仿形砂轮直径D S与标准内螺纹公称直径D的比例系数，即D S＝ηD；A为刀具随超声振动主轴刀柄振动的振幅。
实施例：对体积分数为63％的碳化硅颗粒增强铝基复合材料进行M10螺纹加工，加工螺纹精度要求为6H。
根据实施例要求可知，M10内螺纹公称直径D为10mm，螺距P选择1.5mm，螺纹小 径D 1可选择为8.6mm。刀具头部的仿形砂轮选择粒度为200/230的金刚石磨粒电镀在其表面，刀具头部仿形砂轮直径D s选择8.3mm，刀具中部刀杆的直径d选择4mm，刀具与超声振动刀柄的连接方式采用锥面截型连接方式，刀具轴向的中心冷却孔直径为2mm，刀具末端振幅A保持在5～7μm。将本实施例仿形砂轮刀具通过超声加工机床的超声振动刀柄安装在DMG公司生产的Ultrasonic 50超声加工机床主轴上，机床主轴转速即公转速度ω选择5000r/min，刀具轴向进给速度V f为6mm/min。开启超声振动功能，则按仿形砂轮刀具的自转、仿形砂轮刀具绕螺纹孔轴线的公转和仿形砂轮刀具轴向给进、以及仿形砂轮刀具随超声振动刀柄的轴向振动四种运动复合而成的螺旋铣削方式进行螺纹加工。在加工过程中，相比普通铣磨螺纹加工，切削力降低幅度超过70％。

Claims (7)

  1. 一种超声振动辅助螺旋铣磨螺纹方法，其特征在于，该方法采用仿形砂轮刀具，该刀具通过超声振动刀柄安装在超声加工机床主轴上；刀具轴线与被加工工件的螺纹孔轴线中心平行，该方法采取仿形砂轮刀具的自转、仿形砂轮刀具绕螺纹孔轴线的公转和仿形砂轮刀具轴向给进、以及仿形砂轮刀具随超声振动刀柄的轴向振动四种运动复合而成的螺旋铣削方式。
  2. 根据权利要求1所述的螺旋铣磨螺纹方法，其特征在于，所述仿形砂轮刀具根据所需螺纹的尺寸和加工精度要求，以及该仿形砂轮刀具与超声振动刀柄的连接方式进行选取。
  3. 根据权利要求1或2所述的螺旋铣磨螺纹方法，其特征在于，以所述螺旋铣削方式加工过程中，工件固定不动，刀具在自转的同时，以偏心距e沿螺纹孔轴线以螺旋轨迹公转；其中，偏心距e，螺距P、仿形砂轮刀具轴向进给速度V f和公转速度ω，以及刀具中部刀杆的直径d分别满足公式(1)～(3)要求：
    Figure PCTCN2018094355-appb-100001
    Figure PCTCN2018094355-appb-100002
    d<D 1，且
    Figure PCTCN2018094355-appb-100003
    式中，D为标准内螺纹公称直径，D S为刀具头部仿形砂轮直径，D S<D 1；D 1为标准内螺纹小径D 1。
  4. 根据权利要求1-3中任一项所述的螺旋铣磨螺纹方法，其特征在于，所述仿形砂轮刀具，该刀具头部的仿形砂轮表面镀有金刚石磨粒，磨粒粒度范围为100/120～270/325。
  5. 根据权利要求2所述的螺旋铣磨螺纹方法，其特征在于，所述仿形砂轮刀具与超声振动刀柄的连接方式包括：采用锥面截型与超声振动刀柄连接；刀具连接端采用螺纹与超声振动刀柄连接；刀具连接端采用杆状截型，通过弹簧卡套与超声振动刀柄连接。
  6. 根据权利要求1-5中任一项所述的螺旋铣磨螺纹方法，其特征在于，所述仿形砂轮刀具沿其轴向设有中心冷却孔，用于切削液的流出。
  7. 根据权利要求3所述的螺旋铣磨螺纹方法，其特征在于，该方法进行螺纹加工时，螺纹尺寸产生的原理性误差δ满足公式(4)要求：
    Figure PCTCN2018094355-appb-100004
    式中，η为刀具头部仿形砂轮直径D S与标准内螺纹公称直径D的比例系数，即D S＝ηD；A为刀具随超声振动刀柄振动的振幅。
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