During the use of the crusher, the cone sleeve is the most easily damaged component of the equipment. The length of the cone sleeve is generally 160 cm. In the past, when processing the cone sleeve, due to its long length, the conventional operation method of clamping and pushing on the lathe could not fix the cone sleeve. After continuous exploration and attempts, a lathe process flow that can perfectly fix the cone sleeve was finally produced.
Design and Manufacture of Auxiliary Fixtures
During the operation and processing of the lathe, the auxiliary fixture plays a vital role. It can not only offset the vibration of the copper cone sleeve during processing, but also eliminate the rotation torque. The auxiliary fixture itself uses a chuck to connect and position the clamping flange. It needs to be clamped on one end of the clamped cone sleeve with the flange and 8 M16 screws to fix it. It is used to replace the chuck, and the dial on the chuck is connected to the connecting rod to form the dial device of the lathe. The chuck and the workpiece form a unified whole, and finally the clamping of the workpiece is completed.
Design and Production of Rolling Bracket
The height of the rolling bracket can be adjusted according to the shape requirements of the copper taper sleeve. When processing the copper taper sleeve, first tighten the long taper sleeve, and then enlarge the other end of the long taper sleeve on the two rolling wheels of the fixture. And the position of the long taper sleeve is in the same position as the axis of the spindle. When the taper of the copper taper sleeve needs to be adjusted, the copper taper sleeve can be processed by adjusting the diameter difference between the large and small heads of the rolling bracket and adjusting the slope of the screw rod.
Selection of Machining Tools
Since the copper cone sleeve is long and the rigidity of the copper material itself is poor. Therefore, it is necessary to strictly control the cutting force, vibration degree and cutting temperature during processing. If the cutting force is too large during processing, it is easy to cause the copper cone sleeve to bend and deform. The accuracy of the geometric shape of the copper cone sleeve and the quality of the cone sleeve surface cannot be guaranteed.
At the same time, if the degree of vibration and the cutting temperature during the cutting process are not controlled within a certain range, it will also have a certain impact on the quality of the finished copper cone sleeve. Therefore, it is particularly important to select cutting tools. At present, the most commonly used and suitable tools in my country are those with a main deflection angle of 93 degrees, a secondary deflection angle of 30 degrees, a front angle of 0 degrees, and a back angle of 5 degrees. The roundness of the rough machining tip is about R0.5-R1, and a certain cutting groove needs to be left on the front cutting face.
Cutting Amount Control
In the process of copper taper sleeve processing, the amount of cutting is also a very critical process. Whether the cutting amount is appropriate will directly affect the quality and roughness of the surface of the final copper taper sleeve, and is also directly related to whether it can be cut and formed. Under the condition that the forming can be guaranteed, the cutting feed rate is proportional to the surface roughness.
And the roughness has a direct impact on the quality of the copper taper sleeve. Under normal circumstances, the cutting parameters currently used in my country are a speed of 2500 revolutions per minute, a feed rate of 0.3 mm per minute, and a cutting depth of 0.02 mm. Among the parameters of cutting amount, the back cutting amount and the spindle speed have little effect on the roughness of the copper taper sleeve surface.
Selection of Tool Materials
Since the material of the processed cone sleeve is cast copper, the rigidity of the material itself is not strong, the hardness is not high, and it is not particularly sticky. Therefore, a sharper tool should be selected as a construction tool. At present, the tool generally selected for the processing of copper cone sleeves in my country is YW1 or YW2 carbide turning tools for rough processing and fine processing. This kind of tool is sharper, and the cutting depth can be controlled not to be too large. This is conducive to reducing the elastic deformation and vibration of the process system.
Rough Turning Process
During the turning process of the copper cone sleeve, it is necessary to perform rough processing first and then fine processing to finally complete the final product. When performing rough processing, first, the top needs to support the internal control plug of the blank. Turn the outer circle at a distance of about 100 mm from another section until the circle is seen. The length is preferably about 3-5 mm greater than the roller width, and the surface roughness is about 1.6. Add the copper cone sleeve to the roller device until the processing position, and the cone sleeve is in full contact with the equipment. After that, remove the tailstock and plug, clamp the long tool bar on the middle support plate, and then install the YWl tool for clamping the rough turning tool.
Due to the long tool bar length, the cutting depth needs to be greater than 3-5 mm each time during rough turning. After the rough turning is completed, adjust the offset of the roller according to the different calculation results each time to achieve the purpose of adjusting the slope of the taper sleeve. And the cutting depth also needs to be carefully and carefully calculated. After knowing the relationship of the remaining length, make multiple adjustments. To the greatest extent, ensure that the processed taper sleeve can meet the subsequent processing requirements.
Finishing Turning Process
After the rough turning process is completed, a part of the finishing allowance should be left. When performing fine processing procedures, it should be noted that the tool tip must be installed at the same height as the center line of the taper sleeve. This can avoid the formation of hyperbolic phenomenon, the speed should be controlled within 60, and the allowance should be controlled within 0.5-1.8 mm. Because the contact surface is arc-shaped during processing, the roughness is generally above 1.6. Therefore, the tool tip of the processing tool must be ground with an oilstone. After machining the inner hole, the center should be used to support the plug, and the large and small pallets should be used to move in and out at the same time for rough turning and fine turning of the outer circle to meet the requirements of the drawing.
Because of the special tool feeding of the CW61100 lathe, there are 8 tool feeding directions, including longitudinal and transverse feeding, which can be carried out simultaneously. In this way, the taper can be processed without tool connection, and there will be no particularly large geometric size errors. Another way is to use the concentric plug to support the inner hole and turn the outer circle, and the coaxiality of the inner and outer circles can be controlled between 0.05-0.1 mm. Therefore, it will not cause too much roundness error, so that it can meet the quality requirements of the processing.
Quality Inspection after Turning
After the copper taper sleeve is turned, in order to ensure that the processing accuracy and processing size meet the final requirements. It is also necessary to conduct quality inspection on the long copper taper sleeve to ensure the detection accuracy and accuracy. Before the inspection, the detection position of the copper taper sleeve needs to be determined, and the wall thickness of the large and small heads at the detection position is uniform. You can use a 0-25mm micrometer to measure the wall thickness of the four points of the crosshairs of the reducer and reducer. If the thickness is uniform, it can generally pass the inspection. Because the finished product has a certain taper, the long and short distances must be equal during measurement. This can maximize the accuracy and precision of the measurement and ensure that the length of the four points is uniform.
