CN111002003B - Efficient and long-service-life hydraulic valve main hole machining method - Google Patents
Efficient and long-service-life hydraulic valve main hole machining method Download PDFInfo
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- CN111002003B CN111002003B CN201911343244.9A CN201911343244A CN111002003B CN 111002003 B CN111002003 B CN 111002003B CN 201911343244 A CN201911343244 A CN 201911343244A CN 111002003 B CN111002003 B CN 111002003B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P17/00—Metal-working operations, not covered by a single other subclass or another group in this subclass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
- B23B27/06—Profile cutting tools, i.e. forming-tools
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B27/00—Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
- B23B27/10—Cutting tools with special provision for cooling
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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
- B23D77/00—Reaming tools
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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
- B23D77/00—Reaming tools
- B23D77/006—Reaming tools with means for lubricating or cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B2200/00—Details of cutting inserts
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- B23B2200/286—Positive cutting angles
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- B23B—TURNING; BORING
- B23B2200/00—Details of cutting inserts
- B23B2200/32—Chip breaking or chip evacuation
- B23B2200/328—Details of chip evacuation
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23B—TURNING; BORING
- B23B2222/00—Materials of tools or workpieces composed of metals, alloys or metal matrices
- B23B2222/28—Details of hard metal, i.e. cemented carbide
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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
- B23D2277/00—Reaming tools
- B23D2277/20—Number of cutting edges
- B23D2277/206—Eight
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D2277/00—Reaming tools
- B23D2277/24—Materials of the tool or the intended workpiece, methods of applying these materials
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Abstract
The invention discloses a high-efficiency and long-service-life hydraulic valve main hole machining method, and belongs to the technical field of hole machining. According to the processing method, the hydraulic valve main hole is processed by sequentially using the oil port three-edge forming cutter, the three-edge reaming cutter and the eight-edge reaming cutter, the forming hole is formed at one time by using the oil port three-edge forming cutter, the service life is long, and the cutting efficiency is high; the unequal design of the three-blade expanding cutter is matched with the layered structure design, so that the vibration of expanding cutting is reduced, the expanding machining allowance is large, the concentricity of the main hole of the intermittent hydraulic valve is ensured, and the machining precision and the machining efficiency are high; by utilizing the unequal combination of the eight-blade reaming reamer and the unequal tooth design, the vibration of a cutter for reaming is greatly reduced, and the surface roughness and the cylindricity of a main hole of the hydraulic valve, the reaming allowance and the cutting efficiency are improved; the hydraulic valve machining device has the advantages of high machining efficiency, good machining precision, long service life of the cutter and the like, and the problem that the hydraulic valve is scrapped due to the fact that cuttings are left to block a pore channel is effectively solved.
Description
Technical Field
The invention relates to a method for processing a hydraulic valve hole, in particular to a method for processing a main hole of a hydraulic valve with high efficiency and long service life.
Background
The hydraulic valve is a key part in hydraulic machinery, as shown in fig. 1, a valve body 100 of the hydraulic valve is internally provided with a main valve hole 101 and a plurality of oil ducts 102 which are communicated with each other, the oil ducts 102 are communicated with the main valve hole 101, corresponding hydraulic valve channels are formed by adjusting a valve core in the main valve hole 101, and the machining precision of the valve holes directly influences the product performance and the service life of the hydraulic valve. In the hydraulic valve, a main hole of the hydraulic valve has the highest precision requirement, the main technical indexes of the main hole are that the surface roughness Ra of an oil port is less than or equal to 1.6, the cylindricity of the main hole is less than or equal to 0.01mm, and the quality of the processing quality of the main hole can directly influence the stability of the whole hydraulic system and the performance of the hydraulic valve.
The common hydraulic valve hole machining process generally comprises drilling, rough boring, semi-fine boring, reaming, honing and the like, wherein the drilling is mainly used for drilling a valve hole blank hole, a plurality of cast hydraulic valve bodies are formed into blank holes during casting, the drilling is not needed, the rough boring, the semi-fine boring and the fine boring are mainly used for sub-reaming, the surface roughness and the straightness of the valve hole are ensured, the reaming is mainly used for obtaining higher cylindricity, and the honing is used for finally correcting the surface roughness and the cylindricity of the valve hole. The inner hole of the blank of the valve body of the hydraulic valve is cast with the communicated oil passages, so that the difficulty of intermittent machining exists when the main hole of the hydraulic valve is machined, machining chips easily enter other oil passages and are inconvenient to clean, the incomplete cleaning and the residual chips are usually one of the main reasons of the unqualified hydraulic valve, and the defect is difficult to find. The main material for casting the valve body of the hydraulic valve is gray iron, nodular iron or vermicular cast iron, the cylindricity and surface roughness of the main hole of the hydraulic valve are high, and the method is also one of the processing difficulties of the main hole of the hydraulic valve. Therefore, the problems of low processing efficiency, short service life of a cutter, high defective rate of products and the like generally exist in the existing valve hole processing technology.
The machining of the main hole of the hydraulic valve is one of the research hotspots in the field of machining, and a plurality of machining processes and machining tools appear. Chinese patent application No. 201510852048.X discloses an efficient machining method of a precision valve hole, which comprises the steps of drilling, reaming, coarse reaming, fine reaming, edgeless reaming, extruding, hole cutting, checking and the like, wherein the roughness of the machined hole reaches an Ra value of 0.8-0.4 mu m, the ovality circle error is 0.01-0.02mm, the taper error is 0.01-0.025mm, and the size precision of the hole can be controlled within 0.01 mm. The rough reamer, the finish reamer and the edgeless reaming and extruding cutter adopted in the application are all of a common cutter structure, the cutting amount VC of the rough reamer is 6m/min, the cutting amount VC of the finish reamer is 4m/min, the cutting amount VC of the edgeless reaming and extruding cutter is 2m/min, the machining efficiency is low, and the service life and the machining efficiency of the cutter cannot meet the high-efficiency and long-life machining requirements of a main hole of a hydraulic valve easily.
Disclosure of Invention
1. Technical problem to be solved by the invention
The invention aims to overcome the defects of low processing efficiency, poor processing precision, short cutter life and the like in the conventional hydraulic valve main hole processing, and provides a high-efficiency and long-service-life hydraulic valve main hole processing method; by utilizing the unequal design of the three-edge reamer and matching with the layered structure design, on one hand, the vibration of reaming and cutting is reduced, and the reaming processing with high-efficiency large metal removal amount can be carried out, on the other hand, the three-edge reamer has a very good cutting guide effect, the concentricity of the main hole of the intermittent hydraulic valve is ensured, the processing precision and the processing efficiency are high, the chips are small chips, and the problem that the residual chips block the hole channel is effectively solved; by utilizing the unequal combination of the eight-blade reaming reamer and the unequal tooth design, the vibration of a cutter for reaming is greatly reduced, the surface roughness and the cylindricity of the main hole of the hydraulic valve are improved, the reaming allowance and the cutting efficiency can be improved, and the intermittent and efficient finish machining requirement of the main hole of the hydraulic valve is met; the hydraulic valve machining device has the advantages of high machining efficiency, good machining precision, long service life of the cutter and the like, the problem of cleaning of cutting scraps is fully considered, the problem that the hydraulic valve is scrapped due to the fact that the cutting scraps are left to block a pore channel is effectively solved, and the deep hole machining with the diameter being 8-15 times can be achieved.
2. Technical scheme
In order to achieve the purpose, the technical scheme provided by the invention is as follows:
the invention relates to a high-efficiency and long-service-life hydraulic valve main hole machining method, which comprises the following steps of:
s1, reaming a main hole oil port of the hydraulic valve: an oil port of a main hole of the hydraulic valve is formed by one-step reaming by adopting an oil port three-blade forming cutter; the oil port three-edge forming cutter comprises a forming cutter handle and a forming cutter cutting part arranged at the front end of the forming cutter handle, wherein the forming cutter cutting part comprises three forming cutter cutting edges which are circumferentially divided into equal parts, a linear chip discharge groove is formed between every two adjacent forming cutter cutting edges, a plurality of steps are designed according to an oil port structure, the diameters of the steps are increased from front to back, the first step is used for pre-drilling, the second step is used for reserving a guide hole for reaming in the step S2, the rest steps are used for forming a main hole oil port of a hydraulic valve, each forming cutter cutting edge is provided with a forming cutting edge positioned on one side and an end face cutting edge positioned at the front end, and the front angle of each forming cutting edge is 0 degree;
s2, reaming a main hole of the hydraulic valve: carrying out reaming processing on the main hole of the hydraulic valve by adopting a three-blade reaming cutter, so that the main hole of the hydraulic valve is further enlarged in aperture size on the basis of the original blank hole; the three-edge reamer comprises a reamer handle and a reamer cutting part arranged at the front part of the reamer handle, wherein the reamer cutting part is provided with three spiral reamer cutting edges distributed in the circumferential direction, a reamer spiral groove is formed between every two adjacent spiral reamer cutting edges, each reamer cutting edge is provided with an end edge arranged on the end surface of the three-edge reamer and a peripheral edge arranged in the circumferential direction of the three-edge reamer, the end edges of the three reamer cutting edges are of an unequal structure on the end surface of the three-edge reamer, and the difference between the maximum value and the minimum value of an included angle between the end edges of the two adjacent reamer cutting edges on the end surface of the three-edge reamer is 5-9 degrees; the reaming cutter cutting part is provided with an inverted cone with a large front part and a small back part, the front end of the reaming cutter cutting part is provided with a layered structure, the layered structure is that the front end of the reaming cutter cutting part is provided with a reaming cutter front cutting section with the diameter smaller than the diameter of the main body part of the reaming cutter cutting part, and a reaming cutter cutting edge on the reaming cutter front cutting section is connected with a reaming cutter cutting edge of the main body part of the reaming cutter cutting part through a layered transition taper angle;
s3, expanding and reaming to process a main hole of the hydraulic valve: an eight-blade reamer is adopted to finish the main hole of the hydraulic valve, so that the size precision of the main hole of the hydraulic valve and the surface quality of the hole are improved; the eight-blade reamer comprises a reamer handle and a reamer cutting part arranged on the front part of the reamer handle, wherein the reamer cutting part is provided with eight spiral reamer cutting edges distributed circumferentially, a reamer spiral groove is formed between every two adjacent reamer cutting edges, the reamer cutting edges of the eight-blade reamer have unequal structures in the circumferential direction, and the difference between the maximum value and the minimum value of the tooth pitch included angle between every two adjacent reamer cutting edges is 6-9 degrees on the cross section of the reamer cutting part; the reamer cutting edge of the eight-blade reamer has unequal tooth structures, the tooth width of each reamer cutting edge and the tooth pitch included angle of the rear side of the reamer cutting edge in the rotating cutting direction have corresponding change rules, and the tooth pitch included angle of the rear side of each reamer cutting edge in the rotating cutting direction is larger, so that the tooth width of each reamer cutting edge is larger.
Furthermore, the oil port three-edge forming cutter, the three-edge reaming cutter and the eight-edge reaming cutter are all made of integral hard alloy materials; in step S1, the machine tool processing speed of the oil port three-edge forming cutter is 80-120 m/min, and the feed per revolution is 0.3-0.4 mm; in step S2, the machine tool machining speed of the three-blade expanding cutter is 60-100 m/min, and the feed per revolution is 0.3-0.4 mm; in step S3, the machining speed of the eight-blade reamer is 40-80 m/min, and the feed per revolution is 0.8 mm.
Furthermore, a forming cutter cooling liquid channel is arranged at the center of the oil port three-edge forming cutter, and forming cutter liquid spraying ports communicated with the forming cutter cooling liquid channel are formed in the three linear chip grooves; a reamer cooling liquid channel is arranged in the center of the three-blade reamer, and a reamer liquid spraying port communicated with the reamer cooling liquid channel is arranged in the reamer spiral groove; the center of the eight-blade reamer is provided with a reamer cooling liquid channel, and each reamer spiral groove is provided with a liquid spraying port communicated with the reamer cooling liquid channel.
Further, in the oil-port three-edge forming tool, the first clearance angle of the forming cutting edge is α 1, the second clearance angle is α 2, the first clearance angle α 1 is 13 ° to 17 °, and the second clearance angle α 2 is 23 ° to 32 °.
Furthermore, in the oil port three-edge forming cutter, the thickness of the core of the cutting edge of the forming cutter is 0.4-0.45 times of the diameter of the second step.
Furthermore, in the three-edge reamer, the back taper of the cutting part of the reamer is 100/(0.015-0.03) mm, and the included angles between the end edges of the cutting edges of two adjacent reamer are respectively 116.5 degrees, 118.5 degrees and 125 degrees.
Furthermore, the negative chamfer of the peripheral edge of the reamer cutting edge is 0 degree, and the peripheral edge of the reamer cutting edge adopts a double-edged structure and comprises a first peripheral edge and a second peripheral edge.
Furthermore, in the eight-blade reamer, the front end of the reamer cutting part is provided with a layered structure, the layered structure is that the front end of the reamer cutting part is provided with a reamer front cutting section with the diameter smaller than that of the main body part of the reamer cutting part, and a layered back angle is formed between the reamer front cutting section and the main body part of the reamer cutting part; the main body part of the reamer cutting part is provided with an inverted cone with a big front part and a small back part, and the rear side of the main body part of the reamer cutting part is provided with a tool retracting inclined plane.
Furthermore, at least one pair of the tooth pitch included angle values between the cutting edges of two adjacent reaming cutters is decimal.
Furthermore, the eight-edge reamer is of a left-handed right-handed cutting structure, and in eight reamer cutting edges, tooth pitch included angles between two adjacent reamer cutting edges are respectively 42 degrees, 44.5 degrees, 47 degrees, 48 degrees, 46 degrees, 44 degrees, 45.5 degrees and 43 degrees; the tooth widths of the reamer cutting edges corresponding to the tooth pitch included angles on the rear side of each reamer cutting edge in the rotating cutting direction are respectively 1.47mm, 1.78mm, 2.04mm, 2.15mm, 1.9mm, 1.67mm, 1.81mm and 1.58 mm.
3. Advantageous effects
Compared with the prior art, the technical scheme provided by the invention has the following remarkable effects:
(1) according to the efficient and long-life hydraulic valve main hole machining method, on the basis of a hydraulic valve main hole blank hole, three cutters, namely the oil port three-edge forming cutter, the three-edge reaming cutter and the eight-edge reaming cutter are sequentially utilized to complete machining of the hydraulic valve main hole, the stepped design of the oil port three-edge forming cutter is utilized to ensure one-step forming of a formed hole, the machined oil port is better in concentricity, high in surface finish degree, long in service life and high in cutting efficiency; by utilizing the unequal design of the three-edge reamer and matching with the layered structure design, on one hand, the vibration of reaming and cutting is reduced, and the reaming processing with high-efficiency large metal removal amount can be carried out, on the other hand, the three-edge reamer has a very good cutting guide effect, the concentricity of the main hole of the intermittent hydraulic valve is ensured, the processing precision and the processing efficiency are high, the chips are small chips, and the problem that the residual chips block the hole channel is effectively solved; by utilizing the unequal combination of the eight-blade reaming reamer and the unequal tooth design, the vibration of a cutter for reaming is greatly reduced, the surface roughness and the cylindricity of the main hole of the hydraulic valve are improved, the reaming allowance and the cutting efficiency can be improved, and the intermittent and efficient finish machining requirement of the main hole of the hydraulic valve is met; the hydraulic valve machining device has the advantages of high machining efficiency, good machining precision, long service life of a cutter and the like, the problem of scrap of the hydraulic valve due to the fact that cuttings are left to block a pore channel is fully considered, and the deep hole with the diameter of 8-15 times can be efficiently machined;
(2) according to the high-efficiency and long-service-life hydraulic valve main hole machining method, the adopted oil port three-edge forming cutter, the three-edge reaming cutter and the eight-edge reaming cutter are arranged in the machining process, the oil port three-edge forming cutter is provided with the second step design for reserving the reaming guide hole, the three-edge reaming cutter plays a guiding role in machining the eight-edge reaming cutter into a good cylindricity, the matching relation of the three cutters for machining the hydraulic valve main hole is ensured, and the high-quality machining precision of the hydraulic valve main hole is ensured;
(3) according to the high-efficiency and long-service-life hydraulic valve main hole machining method, the oil port three-edge forming cutter, the three-edge reaming cutter and the eight-edge reaming reamer are all made of integral hard alloy materials, the centers of the oil port three-edge forming cutter, the three-edge reaming cutter and the eight-edge reaming reamer are provided with cooling liquid channels, and liquid spraying ports are formed in corresponding chip discharge grooves; the machine tool processing speed of the oil port three-edge forming cutter can reach 80-120 m/min, and the feed per revolution is 0.3-0.4 mm; the machine tool machining speed of the three-edge expanding cutter can reach 60-100 m/min, and the feed per revolution is 0.3-0.4 mm; the machine tool processing speed of the eight-blade reamer can reach 40-80 m/min, and the feed per revolution is 0.8 mm; the cutter has high cutting efficiency, so that the whole main hole of the hydraulic valve can be processed more efficiently, the high-efficiency and long-service-life processing expectation is achieved, and the method is a high-efficiency and long-service-life processing solution for the hydraulic valve in the industries of engineering machinery, forklift industry, mining machinery, agricultural machinery and the like;
(4) according to the method for machining the main hole of the hydraulic valve, disclosed by the invention, in an oil port three-edge forming cutter, the first back angle of a forming cutting edge is alpha 1, the second back angle is alpha 2, the first back angle alpha 1 is 13-17 degrees, the second back angle alpha 2 is 23-32 degrees, the wear resistance of the forming cutting edge is enhanced, the service life of a stepped three-edge forming reamer is prolonged, and the surface quality of a machined hole is improved; the core thickness of the cutting edge of the forming cutter is 0.4-0.45 times of the diameter of the second step, so that the cutting strength of the step three-edge forming reamer is ensured;
(5) according to the efficient and long-service-life hydraulic valve main hole machining method, in the three-edge broaching tool, the back taper of the cutting part of the broaching tool is 100/(0.015-0.03) mm, the back taper angle is small, a very good cutting guide effect is achieved, and the straightness of broaching is guaranteed; the included angles between the end edges of the cutting edges of two adjacent reamer blades are respectively 116.5 degrees, 118.5 degrees and 125 degrees, and by adopting the design of the unequal angles, the cutting resonance is effectively reduced, the vibration of the cutter is effectively inhibited, and the reaming processing precision and the cutting stability are improved; the negative chamfering of the peripheral edge of the cutting edge of the reaming cutter is 0 degree, the peripheral edge of the cutting edge of the reaming cutter adopts a double-edged belt structure and comprises a first peripheral edge and a second peripheral edge, the double-edged belt design is adopted, so that the guiding effect of the reaming cutter is better, the cutting heat dissipation effect of the cutter is improved, and meanwhile, the double-edged belt design has a burnishing effect, so that the machined hole wall has higher smoothness and cylindricity, and a better guiding effect is provided for subsequent reaming processing;
(6) according to the efficient and long-life hydraulic valve main hole machining method, the layered structure is arranged at the front end of the cutting part of the reamer in the eight-blade reamer, the layered structure is utilized, the machining reliability of the reamer can be enhanced, the machining allowance is enlarged, the service life of the reamer is prolonged, chips can be broken to form small broken chips, the cleaning of the chips in the hole is facilitated, the method is particularly suitable for multi-channel hydraulic valve main hole interrupted hole machining, and the problem that the pore channel is blocked by the residual chips is effectively solved; the main body part of the reaming cutter cutting part is provided with an inverted cone with a big front part and a small back part, the inverted cone design has a very good cutting guide effect, and the straightness of reaming and reaming hole machining is further ensured; the rear side of the main body part of the reamer cutting part is provided with a tool withdrawal inclined plane, so that the tool is convenient to withdraw, and the surface quality of a machined hole is prevented from being damaged;
(7) according to the high-efficiency and long-service-life hydraulic valve main hole machining method, in the eight-edge reamer, at least one pair of tooth pitch included angle values between two adjacent reamer cutting edges is a decimal, and by adopting the unequal design, the cutting vibration frequencies of the cutting edges of the eight-edge reamer are different, so that the resonance of the cutting edges in the cutting process is further reduced, the reaming machining precision is ensured, the machining can be carried out at a higher cutting speed, and the reaming machining efficiency is improved;
(8) the invention relates to a method for processing a main hole of a hydraulic valve with high efficiency and long service life.A double-edged reamer is of a left-handed right-handed cutting structure in the double-edged reamer, and tooth pitch included angles between two adjacent cutting edges of the double-edged reamer are respectively 42 degrees, 44.5 degrees, 47 degrees, 48 degrees, 46 degrees, 44 degrees, 45.5 degrees and 43 degrees in the eight cutting edges of the double-edged reamer; the tooth widths of the reamer cutting edges corresponding to the tooth pitch included angles on the rear side of each reamer cutting edge in the rotating cutting direction are respectively 1.47mm, 1.78mm, 2.04mm, 2.15mm, 1.9mm, 1.67mm, 1.81mm and 1.58mm, and the unequal and unequal tooth designs of the eight-edge reamer are adopted, so that the dynamic balance of the reamer is better, the chip processing is more stable and reliable, and the processing efficiency is further improved.
Drawings
Fig. 1 is a schematic diagram illustrating distribution of valve holes and oil passages of a conventional hydraulic valve body;
FIG. 2 is a schematic flow chart of a method for machining a main bore of a high-efficiency and long-life hydraulic valve according to the present invention;
FIG. 3 is a schematic structural diagram of an oil port three-edge forming cutter in the high-efficiency and long-life hydraulic valve main hole machining method of the present invention;
FIG. 4 is an axial view of a cutting portion of an oil port three-edge forming cutter in the high-efficiency and long-life hydraulic valve main hole machining method of the invention;
fig. 5 is a schematic perspective view of a three-blade reamer in the method for processing a main hole of a hydraulic valve with high efficiency and long service life according to the present invention;
FIG. 6 is an enlarged view of a portion of the structure at K in FIG. 5;
fig. 7 is a schematic front view of a three-blade reamer in the method for machining a main hole of a hydraulic valve with high efficiency and long service life according to the present invention;
FIG. 8 is an axial view of the cutting portion of a three-edged reamer of a method of efficient, long-life hydraulic valve main bore machining of the present invention;
FIG. 9 is a schematic perspective view of an eight-blade reamer in a method for machining a main bore of a hydraulic valve with high efficiency and long service life according to the present invention;
FIG. 10 is an enlarged view of a portion of the structure of FIG. 9 at M;
FIG. 11 is a schematic front view of an eight-blade reamer in the method for machining a main bore of a hydraulic valve of the present invention with high efficiency and long service life;
FIG. 12 is a schematic diagram of a cutting edge unequal design of an eight-edge reamer in the method for machining a main bore of a hydraulic valve with high efficiency and long service life according to the present invention;
FIG. 13 is a schematic diagram of the design of unequal teeth on the cutting edge of an eight-edge reamer in the method for machining a main hole of a hydraulic valve with high efficiency and long service life.
The reference numerals in the schematic drawings illustrate:
100. a valve body; 101. a main valve bore; 102. an oil passage;
1. an oil port three-edge forming cutter; 1-1, forming a cutter handle; 1-2, forming a cutting edge of the cutter; 1-2-1, a first step; 1-2-2, a second step; 1-2-3, a third step; 1-2-4, a fourth step; 1-2-5, forming a cutting edge; 1-2-6, end face cutting edge; 1-3, a linear chip groove; 1-4, forming cutter cooling liquid channels; 1-4-1, forming a liquid spraying opening of the cutter;
2. a three-blade broaching tool; 2-1, a reamer handle; 2-2, a reamer cutting part; 2-2-1, a reamer cutting edge; 2-2-1a, an end blade; 2-2-1b, a first peripheral edge; 2-2-1c, a second peripheral edge; 2-2-2, a reamer spiral groove; 2-2-3, a reamer front cutting section; 2-2-4, layered transition taper angle; 2-2-5, chamfering the front of the reamer; 2-3, a reamer cooling liquid channel; 2-3-1, a reamer liquid spraying port; 2-4, a transition section;
3. an eight-blade reamer; 3-1, expanding a reamer handle; 3-2, reaming the reamer cutting part; 3-2-1, reaming the reamer cutting edge; 3-2-1a, a relief angle; 3-2-1b, second relief angle; 3-2-1c, relief angle; 3-2-1d, chamfering the front of the reamer; 3-2-2, expanding a reamer spiral groove; 3-2-3, expanding a reamer front cutting section; 3-2-4, layered relief angle; 3-2-5, a clearance section; 3-2-6, retracting the inclined plane; 3-3, expanding a reamer cooling liquid channel.
Detailed Description
For a further understanding of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings.
Referring to fig. 2, the method for processing the main hole of the hydraulic valve with high efficiency and long service life of the invention comprises the following steps:
s1, reaming a main hole oil port of the hydraulic valve: the hydraulic outlet valve main hole oil port is formed by one-step reaming by adopting an oil port three-blade forming cutter 1. As shown in fig. 3 and 4, the oil port three-edge forming cutter 1 comprises a forming cutter handle 1-1 and a forming cutter cutting part arranged at the front end of the forming cutter handle 1-1, the forming cutter cutting part comprises three circumferentially equally-divided forming cutter cutting edges 1-2, a linear chip discharge groove 1-3 is formed between every two adjacent forming cutter cutting edges 1-2, the forming cutter cutting edges 1-2 are designed with a plurality of steps according to an oil port structure, the diameters of the steps are increased from front to back, wherein the first step 1-2-1 is used for pre-drilling, the second step 1-2-2 is used for reserving a guide hole for reaming in the step S2, the rest steps are used for forming a main oil port of a hydraulic valve, each forming cutter cutting edge 1-2-5 on one side and an end face cutting edge 1-2-6 on the front end are arranged on each forming cutter cutting edge 1-2, the rake angle of the forming cutting edge 1-2-5 is 0 degrees.
S2, reaming a main hole of the hydraulic valve: and (3) reaming the main hole of the hydraulic valve by adopting the three-blade reaming cutter 2, so that the main hole of the hydraulic valve is further enlarged in aperture size on the basis of the original blank hole. As shown in fig. 5 to 8, the three-edged reamer 2 includes a reamer handle 2-1 and a reamer cutting part 2-2 disposed in front of the reamer handle 2-1, the reamer cutting part 2-2 has three circumferentially distributed spiral reamer cutting edges 2-2-1, a reamer spiral groove 2-2-2 is disposed between two adjacent spiral reamer cutting edges 2-2-1, each reamer cutting edge 2-2-1 has an end edge 2-2-1a disposed on an end surface of the three-edged reamer 2 and a circumferential edge disposed in the circumferential direction of the three-edged reamer 2, and the end edges 2-2-1a of the three reamer cutting edges 2-2-1 have an unequal division structure on the end surface of the three-edged reamer 2, the difference between the maximum value and the minimum value of the included angle between the end edges 2-2-1a of the cutting edges 2-2-1 of the two adjacent reamer cutting edges is 5-9 degrees; the reaming cutter cutting part 2-2 is provided with an inverted cone with a large front part and a small back part, the front end of the reaming cutter cutting part 2-2 is provided with a layered structure, the layered structure is that the front end of the reaming cutter cutting part 2-2 is provided with a reaming cutter front cutting section 2-2-3 with the diameter smaller than the diameter of the main body part of the reaming cutter cutting part 2-2, and the reaming cutter cutting edge 2-2-1 on the reaming cutter front cutting section 2-2-3 is connected with the reaming cutter cutting edge 2-2-1 on the main body part of the reaming cutter cutting part 2-2 through a layered transition taper angle 2-2-4.
S3, expanding and reaming to process a main hole of the hydraulic valve: and an eight-blade reamer 3 is adopted to finish the main hole of the hydraulic valve, so that the size precision of the main hole of the hydraulic valve and the surface quality of the hole are improved. As shown in fig. 9 to 13, the eight-blade reamer 3 includes a reamer holder 3-1 and a reamer cutting portion 3-2 disposed in front of the reamer holder 3-1, the reamer cutting portion 3-2 has eight circumferentially distributed spiral reamer cutting edges 3-2-1, a reamer spiral groove 3-2-2 is disposed between two adjacent reamer cutting edges 3-2-1, the reamer cutting edge 3-2-1 of the eight-blade reamer 3 has an unequal structure in the circumferential direction, and the difference between the maximum value and the minimum value of the pitch angle between two adjacent reamer cutting edges 3-2-1 is 6 to 9 ° in the cross section of the reamer cutting portion 3-2; the reamer cutting edge 3-2-1 of the eight-edge reamer 3 has unequal tooth structures, the tooth width of each reamer cutting edge 3-2-1 and the tooth pitch included angle of the rear side of the reamer cutting edge 3-2-1 in the rotating cutting direction have corresponding change rules, and the tooth width of each reamer cutting edge 3-2-1 is larger as the tooth pitch included angle of the rear side of each reamer cutting edge 3-2-1 in the rotating cutting direction is larger.
According to the efficient and long-life hydraulic valve main hole machining method, on the basis of a hydraulic valve main hole blank hole, three cutters, namely the oil port three-edge forming cutter 1, the three-edge reaming cutter 2 and the eight-edge reaming cutter 3, are sequentially utilized to complete machining of the hydraulic valve main hole, the stepped design of the oil port three-edge forming cutter 1 is utilized to ensure one-step forming of a formed hole, the machined oil port is better in concentricity and high in surface finish degree, and the oil port three-edge forming cutter is long in service life and high in cutting efficiency; by utilizing the unequal design of the three-edge reaming cutter 2 and matching with the layered structure design, on one hand, the vibration of reaming and cutting is reduced, and the reaming processing with high-efficiency large metal removal amount can be carried out, on the other hand, the cutting guide function is very good, the concentricity of the main hole of the intermittent hydraulic valve is ensured, the processing precision and the processing efficiency are high, the chips are small chips, and the problem that the residual chips block the hole channel is effectively solved; by utilizing the unequal combination of the unequal teeth design of the eight-blade reaming reamer 3, the vibration of a cutter for reaming is greatly reduced, the surface roughness and the cylindricity of the main hole of the hydraulic valve are improved, the reaming allowance and the cutting efficiency can be improved, and the intermittent and efficient finish machining requirement of the main hole of the hydraulic valve is met; the hydraulic valve machining device has the advantages of high machining efficiency, good machining precision, long service life of the cutter and the like, the problem of cleaning of cutting scraps is fully considered, the problem that the hydraulic valve is scrapped due to the fact that the cutting scraps are left to block a pore channel is effectively solved, and the deep hole machining with the diameter being 8-15 times can be achieved.
The present invention will be further described with reference to the following examples.
[ examples ]
Referring to fig. 2, the method for machining the main hole of the hydraulic valve with high efficiency and long service life of the embodiment includes the following steps:
s1, reaming a main hole oil port of the hydraulic valve: an oil outlet valve main hole oil port is formed by one-time reaming by adopting an oil port three-blade forming cutter 1;
s2, reaming a main hole of the hydraulic valve: carrying out reaming processing on the main hole of the hydraulic valve by adopting a three-blade reaming cutter 2, so that the main hole of the hydraulic valve is further enlarged in aperture size on the basis of the original blank hole;
s3, expanding and reaming to process a main hole of the hydraulic valve: and an eight-blade reamer 3 is adopted to finish the main hole of the hydraulic valve, so that the size precision of the main hole of the hydraulic valve and the surface quality of the hole are improved.
The high-efficiency and long-service-life hydraulic valve main hole machining method divides machining of a hydraulic valve main hole into three-edge oil port forming cutter 1, three-edge reaming cutter 2 and three-time machining forming of an eight-edge reaming cutter 3, the three-edge oil port forming cutter 1, the three-edge reaming cutter 2 and the eight-edge reaming cutter 3 are adopted in the machining process, a front procedure provides a very good guiding effect for a rear procedure, the matching relation of the three cutters for machining the hydraulic valve main hole is guaranteed, and high-quality machining precision of the hydraulic valve main hole is guaranteed. The oil port three-edge forming cutter 1, the three-edge reaming cutter 2 and the eight-edge reaming cutter 3 are all made of integral hard alloy materials; in step S1, the machine tool processing speed of the oil port three-edge forming cutter 1 is 80-120 m/min, and the feed per revolution is 0.3-0.4 mm; in step S2, the machine tool machining speed of the three-blade expanding cutter 2 is 60-100 m/min, and the feed per revolution is 0.3-0.4 mm; in step S3, the machining speed of the eight-blade reamer 3 is 40-80 m/min, and the feed per revolution is 0.8 mm. The cutter cutting efficiency is high, so that the whole hydraulic valve main hole is processed more efficiently, the high-efficiency and long-service-life processing expectation is reached, and the hydraulic valve machining tool is a high-efficiency and long-service-life processing solution for hydraulic valves in the industries such as engineering machinery, forklift industry, mining machinery and agricultural machinery. The specific structures of the oil port three-edge forming cutter 1, the three-edge expanding cutter 2 and the eight-edge expanding reamer 3 are as follows:
referring to fig. 3 and 4, the oil port three-edge forming cutter 1 in the embodiment includes a forming cutter handle 1-1 and a forming cutter cutting portion disposed at the front end of the forming cutter handle 1-1, the forming cutter cutting portion includes three forming cutter cutting edges 1-2 equally divided in the circumferential direction, a linear chip removal groove 1-3 is formed between two adjacent forming cutter cutting edges 1-2, a chip containing space of the linear chip removal groove 1-3 is large, chip removal is easier, the forming cutter cutting edge 1-2 is designed with a plurality of steps according to an oil port structure, usually 3 to 5 steps are provided, and the diameters of the steps are increased from front to back, wherein the first step 1-2-1 is used for pre-drilling, the second step 1-2-2 is used for reserving a guide hole for reaming in step S2, and the rest steps are used for forming a main hole oil port of the hydraulic valve, adopt three sword ladders to set up, the ladder hydraulic fluid port is gone out in one-step refining, and the concentricity of machine-shaping hydraulic fluid port is better. Each forming cutter cutting edge 1-2 is provided with a forming cutting edge 1-2-5 positioned on one side and an end face cutting edge 1-2-6 positioned at the front end, the front angle of the forming cutting edge 1-2-5 is 0 degree, the cutting smoothness is guaranteed, the strength of the forming cutting edge 1-2-5 is improved, the service life of the oil port three-edge forming cutter 1 is prolonged, and the service life of the oil port three-edge forming cutter 1 can reach 10000-15000 forming holes. The center of the oil port three-edge forming cutter 1 is provided with a forming cutter cooling liquid channel 1-4, forming cutter liquid spraying ports 1-4-1 communicated with the forming cutter cooling liquid channel 1-4 are formed in three linear chip grooves 1-3, cooling liquid is supplied to the forming cutter liquid spraying ports 1-4-1 through the forming cutter cooling liquid channel 1-4, and the forming cutter liquid spraying ports 1-4-1 are used for spraying the cooling liquid to a machining surface, so that the service life and the cutting efficiency of the oil port three-edge forming cutter 1 are further improved, and the processing of the stepped oil port is more efficient. As shown in fig. 4, in the oil-port three-edge forming tool 1, the first clearance angle of the forming cutting edge 1-2-5 is α 1, the second clearance angle is α 2, the first clearance angle α 1 is 13 ° to 17 °, the second clearance angle α 2 is 23 ° to 32 °, and the design of the clearance angles enhances the wear resistance of the forming cutting edge 1-2-5, improves the service life of the oil-port three-edge forming tool 1, and improves the surface quality of the machined hole. The edge widths of the forming cutting edge 1-2-5 and the end face cutting edge 1-2-6 are designed according to the processing requirements, and in the embodiment, the edge width of the forming cutting edge 1-2-5 is designed to be 0.25 mm-0.54 mm. As shown in fig. 3, the cutting edge 1-2 of the forming cutter in this embodiment sequentially has a first step 1-2-1, a second step 1-2-2, a third step 1-2-3 and a fourth step 1-2-4 from front to back, the first step 1-2-1 and the second step 1-2-2 are in conical surface transition, the slope of the conical surface is β 1, the third step 1-2-3 and the fourth step 1-2-4 are also in conical surface transition, and the slope of the conical surface is β 2; the second step 1-2-2 and the third step 1-2-3 are in vertical surface transition, and the second step 1-2-2 and the vertical surface have round corner transition. The first step 1-2-1 is a pre-drilled hole, the second step 1-2-2 is a subsequent hole expanding guide hole, and the third step 1-2-3 and the fourth step 1-2-4 are formed size holes of a processed hole. By adopting the transition design between the steps, the cutting is easier and more convenient, and the cutting vibration is reduced. Preferably, the taper slope β 1 between the first step 1-2-1 and the second step 1-2-2 is 45 °, and the taper slope β 2 between the third step 1-2-3 and the fourth step 1-2-4 is 20 ° to 30 °. In addition, in the oil port three-edge forming cutter 1, the core thickness of the cutting edge 1-2 of the forming cutter is 0.4-0.45 times of the diameter of the second step 1-2-2, so that the cutting strength of the oil port three-edge forming cutter 1 is ensured. The round jump degree of the forming cutter handle 1-1 is 5-8 mu m, the round jump degree of the cutting part of the forming cutter is 3-5 mu m, the cutting vibration is small, and the efficient machining requirement of the stepped oil port is met.
Referring to fig. 5 to 8, the three-blade reamer 2 in the embodiment includes a reamer handle 2-1 and a reamer cutting part 2-2 disposed in front of the reamer handle 2-1, the reamer cutting part 2-2 has three circumferentially distributed spiral reamer cutting edges 2-2-1, and a reamer spiral groove 2-2-2 is disposed between two adjacent spiral reamer cutting edges 2-2-1, and the three-blade design is adopted, so that a chip containing space is large, and chip removal is easier; each reamer cutting edge 2-2-1 is provided with an end edge 2-2-1a arranged on the end surface of the three-edge reamer 2 and a circumferential edge arranged on the circumference of the three-edge reamer 2, the end edges 2-2-1a of the three reamer cutting edges 2-2-1 are of an unequal structure on the end surface of the three-edge reamer 2, the difference between the maximum value and the minimum value of the included angle between the end edges 2-2-1a of two adjacent reamer cutting edges 2-2-1 on the end surface of the three-edge reamer 2 is 5-9 degrees, in the embodiment, the included angles between the end edges 2-2-1a of two adjacent reamer cutting edges 2-2-1 are preferably respectively designed to be 116.5 degrees, 118.5 degrees and 125 degrees, the vibration of the reamer cutting is reduced by adopting the unequal design of the three edges, and the vibration of the reamer is effectively inhibited, the three-blade broaching tool has the advantages that the working stability of the three-blade broaching tool is improved, the broaching machining with high-efficiency large metal removal amount can be performed, and the broaching machining precision is improved. The reaming cutter cutting part 2-2 is provided with an inverted cone with a large front part and a small rear part, the inverted cone of the reaming cutter cutting part 2-2 is 100/0.015-0.03 mm, and the reaming cutter cutting part has a very good cutting guide effect by matching with the design of the inverted cone with the large front part and the small rear part of the cutting part, so that the concentricity of an intermittent machining hole and the straightness of reaming machining are ensured, the intermittent reaming machining with high efficiency and large metal removal amount can be carried out, and the machining precision and the machining efficiency are greatly improved. Further, in the present embodiment, the front end of the reamer cutting part 2-2 is provided with a layered structure, the layered structure is that the front end of the reamer cutting part 2-2 is provided with a reamer front cutting section 2-2-3 with a diameter smaller than the diameter of the main body part of the reamer cutting part 2-2, and the reamer cutting edge 2-2-1 on the reamer front cutting section 2-2-3 is connected with the reamer cutting edge 2-2-1 on the main body part of the reamer cutting part 2-2 through a layered transition taper angle 2-2-4. By adopting the layered design, the cuttings are small broken cuttings, the cutting is efficient, the cuttings in the holes can be cleaned more easily, the method is particularly suitable for machining discontinuous holes of main holes of multi-channel hydraulic valves, and the problem that the cuttings are remained to block the hole channels is effectively solved. In addition, the angle of the front reamer chamfer 2-2-5 at the end part of the front reamer cutting section 2-2-3 is larger than the angle of the layered transition taper angle 2-2-4, the angle of the front reamer chamfer 2-2-5 is preferably 45 degrees, and the angle of the layered transition taper angle 2-2-4 is preferably 30 degrees, so that the cutting of a cutter is more stable, and the cutting efficiency is higher. A transition section 2-4 can be designed between the reamer handle 2-1 and the reamer cutting part 2-2, and the diameter of the transition section 2-4 is slightly smaller than the tail diameter of the reamer cutting part 2-2. In this embodiment, the core thickness diameter of the reamer cutting part 2-2 is preferably designed to be 0.4 to 0.6 times the diameter of the main body part of the reamer cutting part 2-2, thereby ensuring the overall strength of the cutting part 2.
As shown in fig. 7, in order to improve the service life of the three-blade broaching tool 2, a broaching tool cooling liquid channel 2-3 is arranged at the center of the three-blade broaching tool 2, and a broaching tool liquid spraying port 2-3-1 communicated with the broaching tool cooling liquid channel 2-3 is arranged in the broaching tool spiral groove 2-2-2. Preferably, the reamer liquid spraying ports 2-3-1 in the three reamer spiral grooves 2-2-2 are distributed at intervals along the axial direction of the reamer cutting part 2-2, so that the strength of the reamer and the uniformity of cooling liquid spraying are ensured. Referring to fig. 8, in this embodiment, the negative chamfer of the peripheral edge of the reamer cutting edge 2-2-1 is 0 ° to make the peripheral edge stronger, the peripheral edge of the reamer cutting edge 2-2-1 adopts a double-edged strip structure including a first peripheral edge 2-2-1b and a second peripheral edge 2-2-1c, the negative chamfer width of the peripheral edge of the reamer cutting edge 2-2-1 can be designed according to the chamfer width or the end edge cutting width, and the edge widths of the first peripheral edge 2-2-1b and the second peripheral edge 2-2-1c are generally designed to be 0.3 to 0.6 mm. The double-edged zone design is adopted, so that the guiding effect of the three-edged hole expanding cutter 2 is better, the cutting heat dissipation effect of the cutter is improved, and meanwhile, the double-edged zone design has the burnishing effect, so that the machined hole wall has higher smoothness and cylindricity.
Referring to fig. 9 to 13, the eight-blade reamer 3 in the present embodiment includes a reamer holder 3-1 and a reamer cutting portion 3-2 disposed in front of the reamer holder 3-1, the reamer cutting portion 3-2 has eight circumferentially distributed spiral reamer cutting edges 3-2-1, a reamer spiral groove 3-2-2 is disposed between two adjacent reamer cutting edges 3-2-1, the reamer cutting edge 3-2-1 of the eight-blade reamer 3 has an unequal structure in a circumferential direction, and a difference between a maximum value and a minimum value of a pitch angle between two adjacent reamer cutting edges 3-2-1 is 6 to 9 ° in a cross section of the reamer cutting portion 3-2; the reamer cutting edge 3-2-1 of the eight-edge reamer 3 has unequal tooth structures at the same time, and specifically, the tooth widths of the reamer cutting edges 3-2-1 are different, the tooth width of each reamer cutting edge 3-2-1 and the tooth pitch included angle of the rear side of the reamer cutting edge 3-2-1 in the rotating cutting direction have corresponding change rules, namely, the tooth pitch included angle of the rear side of each reamer cutting edge 3-2-1 in the rotating cutting direction is larger, the tooth width of the reamer cutting edge 3-2-1 is larger, and the tooth widths of the reamer cutting edges 3-2-1 are preferably different. By adopting the multi-blade unequal combination multi-blade unequal tooth design, when the cutting edges 3-2-1 of the reamer are subjected to reaming, each cutting edge 3-2-1 of the reamer has different vibration frequencies, the generation of cutter resonance in the cutting process is effectively avoided, the shock resistance of the eight-blade reamer is further enhanced, the vibration of the cutter in the reaming process is greatly reduced, the surface roughness and the cylindricity of a processed hole are improved, and the reaming processing allowance and the cutting efficiency can be improved. For the unequal design of the eight-edge reamer, preferably, at least one pair of numerical values of tooth pitch included angles between two adjacent reamer cutting edges 3-2-1 is decimal, and if at least one pair of the tooth pitch included angles is an angle with 'half degree', experiments show that by adopting the unequal design, resonance in the cutting process of each reamer cutting edge 3-2-1 can be further reduced, the reaming precision is ensured, the reamer can be machined at a higher cutting speed, and the reaming efficiency is improved. Specifically, in this embodiment, as shown in fig. 12 and 13, the eight-blade reamer 3 has a left-handed and right-handed cutting structure, and among the eight reamer cutting edges 3-2-1, pitch included angles between two adjacent reamer cutting edges 3-2-1 are 42 °, 44.5 °, 47 °, 48 °, 46 °, 44 °, 45.5 ° and 43 ° respectively; the tooth widths of the reamer cutting edges 3-2-1 corresponding to the tooth pitch included angle of the rear side of each reamer cutting edge 3-2-1 in the rotary cutting direction are respectively 1.47mm, 1.78mm, 2.04mm, 2.15mm, 1.9mm, 1.67mm, 1.81mm and 1.58 mm. That is, the tooth width of the reamer cutting edge 3-2-1 on the front side of the cutting direction of each pitch included angle has a consistent change rule with the tooth width of the pitch included angle, and the tooth width of the reamer cutting edge 3-2-1 corresponding to the designed large pitch included angle is correspondingly larger.
As shown in FIG. 10, in the eight-blade reamer 3, the front end of the reamer cutting portion 3-2 is provided with a layered structure in which a reamer front cutting section 3-2-3 having a diameter smaller than that of the main body portion of the reamer cutting portion 3-2 is provided at the front end of the reamer cutting portion 3-2, and a layered relief angle 3-2-4 is provided between the reamer front cutting section 3-2-3 and the main body portion of the reamer cutting portion 3-2. The length of the front cutting section 3-2-3 of the reamer can be about 5mm, 5 mm-5.5 mm is recommended, the angle of the layering back angle 3-2-4 is preferably 6 degrees, and the layering back angle 3-2-4 can be formed by relief grinding. Adopt above-mentioned layered structure, not only can strengthen the processing reliability of reaming the reamer, enlarge the machining allowance, improve the life who reams the reamer, the experiment shows, should expand the cumulative life of reamer and reach 1068 ~ 2002m, can make the smear metal break off moreover and form garrulous tiny chip, the washing of the downthehole smear metal of being convenient for has effectively solved the smear metal and has remained the problem of blockking up the pore. In the embodiment, compared with the common reamer, the machining allowance is generally 0.1-0.2 mm, the sum of the cutting allowance of the front cutting section 3-2-3 of the reamer and the cutting allowance of the main body part of the cutting part 3-2 of the reamer is preferably less than or equal to 0.4mm, the machining allowance can be generally designed to be 0.3-0.4 mm, the cutting allowance is larger, and the machining efficiency is higher. The main body part of the reaming cutter cutting part 3-2 is provided with an inverted cone with a large front part and a small rear part, the preferred inverted cone is 50/0.01-0.02 mm, the inverted cone design has a very good cutting guide effect, and the straightness of reaming and reaming hole machining is guaranteed; the rear side of the main body part of the reamer cutting part 3-2 is provided with a tool retracting inclined plane 3-2-6, the angle of the tool retracting inclined plane 3-2-6 is preferably 3-5 degrees, the tool retracting is facilitated, and the surface quality of a machined hole is prevented from being damaged. As shown in figure 11, a clearance section 3-2-5 is arranged between the reaming cutter cutting part 3-2 and the reaming cutter holder 3-1, and the diameter of the clearance section 3-2-5 is smaller than the minimum diameter of the main body part of the reaming cutter cutting part 3-2, so that the reaming resistance is reduced. In addition, in the embodiment, each reamer cutting edge 3-2-1 is provided with a first relief angle 3-2-1a, a second relief angle 3-2-1b and a third relief angle 3-2-1c, the end part of each reamer cutting edge 3-2-1 is also provided with a front chamfer 3-2-1d, a three-level relief angle design is adopted, a chip containing space is increased, chip processing is smoother, a left-handed and right-handed cutting design of the eight-edge reamer is matched, a chip removal mode is chip removal, chip removal is smooth and stable, and the processing precision and the processing efficiency of the eight-edge reamer are improved. Specific design parameters of the third-level relief angle can be determined according to processing indexes such as the diameter of the cutting part 3-2 of the reamer, in the embodiment, the first relief angle 3-2-1a is 2 degrees, the width is 0.08mm, the second relief angle 3-2-1b is 12 degrees, the width is 0.42mm, and the third relief angle 3-2-1c is 22 degrees; the front chamfer 3-2-1d of the reamer is generally designed to be an inclined chamfer of 1mm multiplied by 20 degrees. In this embodiment, the front end surface of the reamer cutting portion 3-2 is a plane, and the core thickness diameter of the reamer cutting portion 3-2 is preferably designed to be 0.7 times the diameter of the main body portion of the reamer cutting portion 3-2, thereby ensuring the overall strength of the reamer cutting portion 3-2. The cylindricity tolerance of the reamer handle 3-1 part is less than or equal to 0.01mm, and the processing stability of the reamer is improved. In addition, the center of the eight-blade reamer 3 is provided with a reamer cooling liquid channel 3-3, each reamer spiral groove 3-2-2 is provided with a liquid spraying port communicated with the reamer cooling liquid channel 3-3, the liquid spraying ports in the eight reamer spiral grooves 3-2-2 are distributed along the axial direction of the reamer cutting part 3-2 at intervals, the cutter strength and the uniformity of cooling liquid spraying are ensured, the heat dissipation effect of the reamer is improved, and the service life of the reamer is further prolonged.
According to the method for processing the main hole of the hydraulic valve with high efficiency and long service life, the accumulated service life of three cutters, namely an oil port three-edge forming cutter 1, a three-edge reaming cutter 2 and an eight-edge reaming cutter 3, reaches 1068-2002 m which is 10-27 times that of a common cutter (40-200 m); the roughness Ra of the oil port of the processed main hole of the hydraulic valve is less than or equal to 1.6, the cylindricity of the main hole of the hydraulic valve is less than or equal to 0.01mm, and the reaming chips are small chips and are not blocked, so that the main hole of the hydraulic valve and the internal oil duct can be conveniently cleaned; and the cutter group with various specifications can be customized according to the size of the main hole of the hydraulic valve, and efficient processing can be provided for different hardness materials in the hydraulic industry.
According to the efficient and long-life hydraulic valve main hole machining method, on the basis of a hydraulic valve main hole blank hole, three cutters, namely the oil port three-edge forming cutter, the three-edge reaming cutter and the eight-edge reaming cutter are sequentially utilized to complete machining of the hydraulic valve main hole, the stepped design of the oil port three-edge forming cutter is utilized to ensure one-step forming of a formed hole, the machined oil port is better in concentricity, high in surface finish degree, long in service life and high in cutting efficiency; by utilizing the unequal design of the three-edge reamer and matching with the layered structure design, on one hand, the vibration of reaming and cutting is reduced, and the reaming processing with high-efficiency large metal removal amount can be carried out, on the other hand, the three-edge reamer has a very good cutting guide effect, the concentricity of the main hole of the intermittent hydraulic valve is ensured, the processing precision and the processing efficiency are high, the chips are small chips, and the problem that the residual chips block the hole channel is effectively solved; by utilizing the unequal combination of the eight-blade reaming reamer and the unequal tooth design, the vibration of a cutter for reaming is greatly reduced, the surface roughness and the cylindricity of the main hole of the hydraulic valve are improved, the reaming allowance and the cutting efficiency can be improved, and the intermittent and efficient finish machining requirement of the main hole of the hydraulic valve is met; the hydraulic valve machining device has the advantages of high machining efficiency, good machining precision, long service life of the cutter and the like, the problem of cleaning of cutting scraps is fully considered, the problem that the hydraulic valve is scrapped due to the fact that the cutting scraps are left to block a pore channel is effectively solved, and the deep hole machining with the diameter being 8-15 times can be achieved.
It will be understood that when an element is referred to as being "secured to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for illustrative purposes only and do not represent the only embodiments.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.
The present invention and its embodiments have been described above schematically, without limitation, and what is shown in the drawings is only one of the embodiments of the present invention, and the actual structure is not limited thereto. Therefore, if the person skilled in the art receives the teaching, without departing from the spirit of the invention, the person skilled in the art shall not inventively design the similar structural modes and embodiments to the technical solution, but shall fall within the scope of the invention.
Claims (10)
1. A high-efficiency and long-service-life hydraulic valve main hole machining method is characterized by comprising the following steps:
s1, reaming a main hole oil port of the hydraulic valve: an oil outlet valve main hole oil port is formed by one-time reaming by adopting an oil port three-blade forming cutter (1); the oil port three-edge forming cutter (1) comprises a forming cutter handle (1-1) and a forming cutter cutting part arranged at the front end of the forming cutter handle (1-1), wherein the forming cutter cutting part comprises three forming cutter cutting edges (1-2) which are circumferentially equally divided, a linear chip discharge groove (1-3) is formed between every two adjacent forming cutter cutting edges (1-2), the forming cutter cutting edges (1-2) are provided with a plurality of steps according to an oil port structure, the diameters of the steps are increased from front to back, the first step (1-2-1) is used for pre-drilling, the second step (1-2-2) is used for reserving a guide hole for reaming in the step S2, the rest steps are used for forming a main hole oil port of a hydraulic valve, and each forming cutter cutting edge (1-2-5) on one side and an end face (1-2-6) on the front end are arranged on each forming cutter cutting edge (1-2) ) The front angle of the forming cutting edge (1-2-5) is 0 degree;
s2, reaming a main hole of the hydraulic valve: carrying out reaming processing on the main hole of the hydraulic valve by adopting a three-blade reaming cutter (2), so that the main hole of the hydraulic valve is further enlarged in aperture size on the basis of the original blank hole; the three-blade reamer (2) comprises a reamer handle (2-1) and a reamer cutting part (2-2) arranged at the front part of the reamer handle (2-1), wherein the reamer cutting part (2-2) is provided with three spiral reamer cutting edges (2-2-1) distributed in the circumferential direction, a reamer spiral groove (2-2-2) is arranged between every two adjacent spiral reamer cutting edges (2-2-1), each reamer cutting edge (2-2-1) is provided with an end edge (2-2-1 a) arranged on the end surface of the three-blade reamer (2) and a circumferential edge arranged in the circumferential direction of the three-blade reamer (2), and the end edges (2-2-1 a) of the three reamer cutting edges (2-2-1) have unequal structures on the end surface of the three-blade reamer (2), on the end face of the three-edge reamer (2), the difference between the maximum value and the minimum value of the included angle between the end edges (2-2-1 a) of the cutting edges (2-2-1) of two adjacent reamer is 5-9 degrees; the reaming cutter cutting part (2-2) is provided with an inverted cone with a large front part and a small rear part, the front end of the reaming cutter cutting part (2-2) is provided with a layered structure, the layered structure is that the front end of the reaming cutter cutting part (2-2) is provided with a reaming cutter front cutting section (2-2-3) with the diameter smaller than the diameter of the main body part of the reaming cutter cutting part (2-2), and a reaming cutter cutting edge (2-2-1) on the reaming cutter front cutting section (2-2-3) is connected with a reaming cutter cutting edge (2-2-1) on the main body part of the reaming cutter cutting part (2-2) through a layered transition taper angle (2-2-4);
s3, expanding and reaming to process a main hole of the hydraulic valve: an eight-blade reamer (3) is adopted to finish the main hole of the hydraulic valve, so that the size precision of the main hole of the hydraulic valve and the surface quality of the hole are improved; the eight-blade reamer (3) comprises a reamer handle (3-1) and a reamer cutting part (3-2) arranged at the front part of the reamer handle (3-1), wherein the reamer cutting part (3-2) is provided with eight spiral reamer cutting edges (3-2-1) which are distributed circumferentially, a reamer spiral groove (3-2-2) is formed between every two adjacent reamer cutting edges (3-2-1), the reamer cutting edges (3-2-1) of the eight-blade reamer (3) are of an unequal structure in the circumferential direction, and the difference between the maximum value and the minimum value of the pitch included angle between every two adjacent reamer cutting edges (3-2-1) is 6-9 degrees on the cross section of the reamer cutting part (3-2); the reamer cutting edge (3-2-1) of the eight-edge reamer (3) has an unequal tooth structure, the tooth width of each reamer cutting edge (3-2-1) and the tooth pitch included angle on the rear side of the reamer cutting edge (3-2-1) in the rotating cutting direction have corresponding change rules, and the tooth width of each reamer cutting edge (3-2-1) is larger when the tooth pitch included angle on the rear side of the reamer cutting edge (3-2-1) in the rotating cutting direction is larger; the front end of the reamer cutting part (3-2) is provided with a layered structure, the layered structure is that the front end of the reamer cutting part (3-2) is provided with a reamer front cutting section (3-2-3) with the diameter smaller than that of the main body part of the reamer cutting part (3-2), and a layered back angle (3-2-4) is formed between the reamer front cutting section (3-2-3) and the main body part of the reamer cutting part (3-2).
2. The method for machining the main hole of the hydraulic valve with high efficiency and long service life according to claim 1, wherein the method comprises the following steps: the oil port three-edge forming cutter (1), the three-edge reaming cutter (2) and the eight-edge reaming cutter (3) are all made of an integral hard alloy material; in the step S1, the machine tool processing speed of the oil port three-edge forming cutter (1) is 80-120 m/min, and the feed per revolution is 0.3-0.4 mm; in step S2, the machine tool machining speed of the three-blade expanding cutter (2) is 60-100 m/min, and the feed per revolution is 0.3-0.4 mm; in step S3, the machine tool machining speed of the eight-blade reamer (3) is 40-80 m/min, and the feed per revolution is 0.8 mm.
3. The method for machining the main hole of the hydraulic valve with high efficiency and long service life according to claim 1, wherein the method comprises the following steps: a forming cutter cooling liquid channel (1-4) is arranged at the center of the oil port three-edge forming cutter (1), and forming cutter liquid spraying ports (1-4-1) communicated with the forming cutter cooling liquid channel (1-4) are formed in the three linear chip grooves (1-3); a reamer cooling liquid channel (2-3) is arranged in the center of the three-blade reamer (2), and a reamer liquid spraying port (2-3-1) communicated with the reamer cooling liquid channel (2-3) is arranged in the reamer spiral groove (2-2-2); the center of the eight-blade reamer (3) is provided with reamer cooling liquid channels (3-3), and each reamer spiral groove (3-2-2) is provided with a liquid spraying opening communicated with the reamer cooling liquid channels (3-3).
4. A method for machining a main bore of a high-efficiency and long-life hydraulic valve according to claim 1, 2 or 3, wherein: in the oil port three-edge forming cutter (1), a first back angle of the forming cutting edge (1-2-5) is alpha 1, a second back angle is alpha 2, the first back angle is alpha 1= 13-17 degrees, and the second back angle is alpha 2= 23-32 degrees.
5. The method for machining the main hole of the hydraulic valve with high efficiency and long service life as claimed in claim 4, wherein the method comprises the following steps: in the oil port three-edge forming cutter (1), the core thickness of the cutting edge (1-2) of the forming cutter is 0.4-0.45 times of the diameter of the second step (1-2-2).
6. A method for machining a main bore of a high-efficiency and long-life hydraulic valve according to claim 1, 2 or 3, wherein: in the three-edge reamer (2), the back taper of the cutting part (2-2) of the reamer is 100/(0.015-0.03) mm, and the included angles between the end edges (2-2-1 a) of the cutting edges (2-2-1) of two adjacent reamer are respectively 116.5 degrees, 118.5 degrees and 125 degrees.
7. The method for machining the main hole of the hydraulic valve with high efficiency and long service life as claimed in claim 6, wherein the method comprises the following steps: the negative chamfering of the peripheral edge of the cutting edge (2-2-1) of the reamer is 0 degree, and the peripheral edge of the cutting edge (2-2-1) of the reamer adopts a double-edged strip structure and comprises a first peripheral edge (2-2-1 b) and a second peripheral edge (2-2-1 c).
8. A method for machining a main bore of a high-efficiency and long-life hydraulic valve according to claim 1, 2 or 3, wherein: in the eight-edge reamer (3), the main body part of the reamer cutting part (3-2) is provided with an inverted cone with a large front part and a small rear part, and the rear side of the main body part of the reamer cutting part (3-2) is provided with a tool withdrawal inclined plane (3-2-6).
9. The method for machining the main hole of the hydraulic valve with high efficiency and long service life according to claim 8, wherein the method comprises the following steps: at least one pair of tooth pitch included angle values between two adjacent reamer cutting edges (3-2-1) is decimal.
10. The method for machining the main hole of the hydraulic valve with high efficiency and long service life according to claim 9, wherein the method comprises the following steps: the eight-edge reamer (3) is of a left-handed right-handed cutting structure, and in the eight reamer cutting edges (3-2-1), tooth pitch included angles between two adjacent reamer cutting edges (3-2-1) are respectively 42 degrees, 44.5 degrees, 47 degrees, 48 degrees, 46 degrees, 44 degrees, 45.5 degrees and 43 degrees; the tooth widths of the reamer cutting edges (3-2-1) corresponding to the tooth pitch included angles on the rear side of each reamer cutting edge (3-2-1) in the rotating cutting direction are respectively 1.47mm, 1.78mm, 2.04mm, 2.15mm, 1.9mm, 1.67mm, 1.81mm and 1.58 mm.
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| CN113048110B (en) * | 2021-04-19 | 2023-06-09 | 无锡贝斯特精机股份有限公司 | Clamp hydraulic system for intermittent hole boring |
| CN113478015B (en) * | 2021-07-19 | 2023-02-24 | 重庆渝江压铸有限公司 | New energy motor shell bearing hole machining process |
| CN115055910B (en) * | 2022-07-12 | 2023-08-29 | 徐州阿马凯液压技术有限公司 | High-precision valve core hole precision machining method suitable for cast valve body |
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