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1、鑄件孔位偏移借料的定量判斷法 烏丹賓館 烏尼內(nèi)容提要 許多單孔、多孔的套類、連桿、箱體等鑄件,由于制造工藝和技術(shù)水平等因素的影響,造成孔位變形、變位、孔距變化、壁厚不均、裂縫、缺口、縮孔、歪斜、偏心等鑄件缺陷。因此,在加工、劃線中必須借料才能保證加工質(zhì)量。在現(xiàn)有的技術(shù)文獻(xiàn)中,借料往往采用多次試劃法、定性分析來確定。本文采用定量判斷法,運(yùn)用借料量的具體表達(dá)式進(jìn)行借料,在實際使用中效果較好。此法簡便,利于操作,能大大提高劃線加工效率,降低加工成本,減少產(chǎn)品的報廢率。關(guān)鍵詞 孔位偏移 借料 定量判斷法一、前言與背景本人在賓館從事鉗工機(jī)修,工作多年,對鑄件中支架、連桿、箱體、套類等坯件的劃線與加工,碰
2、到制造工藝、技術(shù)水平、人員素質(zhì)等因素的綜合影響,造成鑄件變形、變位、孔距變化、壁厚不均、裂縫、缺口、縮孔、歪斜、偏心等鑄件缺陷,因此在加工過程或者在劃線過程中,如果不通過正確的借料,會造成許多半成品的報廢。本人通過赤峰市范圍內(nèi)各大鑄造廠和機(jī)械制造廠的初步調(diào)查:不正確借料造成的報廢占整體加工過程中報廢70%以上,因此對這些形狀復(fù)雜的鑄件,除了在加工中借料外,還必須在劃線中借料。如果在劃線中能通過正確借料,那么在加工中就能保證技術(shù)要求,不出現(xiàn)報廢品。如果通過劃線借料不能保證加工要求的,就直接報廢,不必要下道工序的加工,造成人、財、物、機(jī)、具等資源的浪費。因此鉗工中,對劃線工的綜合素質(zhì)要求比較高,同
3、時在鉗工的各操作崗位中,劃線具有相當(dāng)重要的地位和作用,通過劃線便于復(fù)雜工件的裝夾,便于及時發(fā)現(xiàn)處理不合格的毛坯,通過劃線可使誤差不大的不合格品變成合格的產(chǎn)品,同時劃線中借料技術(shù)好壞直接反映劃線工的技術(shù)素質(zhì),體現(xiàn)產(chǎn)品的質(zhì)量和企業(yè)的效益。我們在從事劃線崗位時,碰到箱體類等鑄件,需要借料時往往是通過眼睛看,憑經(jīng)驗多次的試劃、調(diào)整來進(jìn)行借料,費時、費力。查找有關(guān)資料、教材、技術(shù)文獻(xiàn),如各種版本的鉗工工藝學(xué)、機(jī)械制造工藝等有關(guān)資料,對劃線中的借料部分也只是介紹定性分析,通過試劃調(diào)整來解決,沒有明確的表達(dá)借料量的大小和借料量的方向,大大降低了劃線效率,同時增加了鑄件的報廢?,F(xiàn)介紹一種定量分析法,得出借料量
4、的具體表達(dá)式及能否借料的判斷式,即借料定量判斷法。在實際工作中,直接運(yùn)用此法,便于掌握,利于操作,大大提高了劃線效率和劃線質(zhì)量,降低鑄件的報廢率。二、定量判斷法的表達(dá)式(一)套類鑄件的定量判斷表達(dá)式。如圖所示的圓環(huán)是一個鑄件的毛坯,其內(nèi)外圓都要加工,由于鑄造原因造成內(nèi)外圓偏心較大,需要內(nèi)外圓同時借料才能確定。設(shè)圓環(huán)毛坯尺寸,外圓直徑d1,內(nèi)孔直徑D2,最大壁厚為hmax,最小壁厚為hmin,設(shè)加工后外圓直徑為D2,內(nèi)孔為d1,見下圖一。,設(shè)外圓單邊加工余量為1、內(nèi)孔單邊加工余量為2,借料后外圓最少加工余量為1min,內(nèi)孔最少加工余量為2min,斜線部分為加工余量,內(nèi)外圓中心偏心量為a,見下圖一
5、。不借料劃線時,見上圖二,加工后工件出現(xiàn)偏心,不能保證產(chǎn)品要求。采用借料劃線時,見上圖三。1、確定偏心量a根據(jù)圖3列方程: hmax+(D1/2 - a)= D1/2+ hmin+a解得:a=(hmax-hmin)/22、根據(jù)a判斷能否借料假設(shè)圓環(huán)借料后如下圖所示:若1min0或2min0,或hminh標(biāo)(h標(biāo)為加工后的要求壁厚)則不能借料,此時即1-x0或2-(a-x)1 +2,因此,不能借料的條件是a1 +2或hminh標(biāo)若1min=0或2min=0或hmin=h標(biāo)時雖能借料但屬于危險品若ah標(biāo),則能借料借料有二種情況:A、 當(dāng)a1 和2中的大值者,則可以一孔借料,借料量為a,另一孔不借料
6、。B、 當(dāng)1 和2大值者a0,2 min =2-(a-x)0可得借料范圍:a-2x1 +2或hminh標(biāo),則不能借料,此時為報廢品;若a=1 +2或hmin=h標(biāo),此時為危險品;若a1 +2時,此時可以通過借料保證加工要求,借料量為:X=a/2+(1-1)/2借料方向為兩圓同時向中心靠。借料范圍為:a-2 x1當(dāng)a1 、2中的大值者,可利用一孔借料另一孔不借料,取1 、2中的大值的圓借料,也可以兩圓同時借料,最好的借料是兩圓同時借料。當(dāng)1 、2中的大值a0,孔距偏大,當(dāng)a1+2,則不能借料;若a =1+2,即1min=0, 2min=0,雖能借料,但不能絕對保證加工要求,屬危險品;若a1+2,
7、則通過借料,才能保證加工要求。借料也有兩種情況:A、 當(dāng)a1 和2中的大值者,則可以一孔借料,借料量為a,另一孔不借料。B、 當(dāng)1 和2大值者a0時,兩孔同時向內(nèi)借料,當(dāng)a0時,兩孔同時向外借料。確定借料范圍和借料量根據(jù)圓環(huán)的分析,同理兩孔的借料范圍為a-2 x1 +2,則不能借料,此時為報廢品;若a=1 +2此時為危險品;若a1 +2時,此時可以通過借料保證加工要求,借料量為:X= a/2 +(1-2)/2借料方向為兩孔同時向中心靠。借料范圍為:a-2 x1當(dāng)a1 、2中的大值者,可利用一孔借料另一孔不借料,取1 、2中的大值的孔借料,也可以兩孔同時借料,最好的借料是兩孔同時借料。當(dāng)1 、2
8、中的大值a1+2,則必須兩孔同時借料,否則不能保證加工要求。(三)三角形的三孔借料法,借料方法同上,在確定第三孔中心時,先確定兩孔的借料點,再確定第三孔的借料點。見下圖示:以O(shè)1O3、O1O3劃圓弧得到交點O3即為第三孔的借料點。三、實際應(yīng)用舉例例一現(xiàn)有一套筒坯件,經(jīng)實測尺寸如下圖示,請通過借料劃出坯件加工線。解:根據(jù)題意可求得:1 =(48-40)/2=42 =(26-20)/2=3 求偏心量a=(hmax-hmin)/2=(17.5-9.5)/2=4 判斷能否借料:因為a=41 +2=7,或hmin=9.5h標(biāo)=6.5,所以能借料。 確定借料方向:O1向右借,O2向左借。 確定借料范圍和借
9、料量:根據(jù)a-2x1,xO1向右借料量,借料范圍為0x4借料量:x=a/2+(1-2)/2=4/2+(4-3)/2=2.5討論:若此題采用O1或O2單獨借料,因為a=4=1,故為出現(xiàn)危險品。例二:某一連桿的二孔坯件經(jīng)測得如下圖解:孔距偏移量a=B0- B0=40-36=41=(18-10)/2=4 2=(22-12)/2=5 因為a=4(1+2)且,a1和a2,所以此題可以一孔借料,若一孔借料,則以右孔借料為好;若采用兩孔同時借料,則兩孔同時往外借,設(shè)左孔向左借料量為x,右孔向右借料量為a-x。X=a/2+(1-2)/2=4/2+(4-5)/2=1.5討論:在上題中采用一孔借料時雖能保證加工要
10、求,但對加工造成麻煩,切削會造成單邊切削,不利于切削加工,甚至?xí)霈F(xiàn)危險品。四、借料的定量判斷法的推廣應(yīng)用及效果我們把這種方法從在教學(xué)中每年向?qū)W生推廣,學(xué)生畢業(yè)后在實際工作中運(yùn)用此法感覺簡單、方便,便于掌握,減少許多借料中的誤區(qū),提高工作效率,降低了產(chǎn)品報廢率,通過與各企業(yè)相關(guān)技術(shù)工人技術(shù)交流,把此法推廣給他們,他們也得到了積極的采用。通過運(yùn)用此法與不運(yùn)用此法的調(diào)查,得出如下調(diào)查結(jié)論:同一坯件劃線時間降低一倍以上,勞動調(diào)度降低一倍以上,劃線效率提高50%以上,對工人的綜合技術(shù)素質(zhì)降低要求,產(chǎn)品的報廢降低30%以上。當(dāng)然,運(yùn)用定量判斷法還需要定性分析,也有必要一定的試劃法和調(diào)整法,將此法應(yīng)用于多
11、孔距偏心借料,有待進(jìn)一步探討。內(nèi)部資料請勿外傳9JWKffwvG#tYM*Jg&6a*CZ7H$dq8KqqfHVZFedswSyXTy#&QA9wkxFyeQ!djs#XuyUP2kNXpRWXmA&UE9aQGn8xp$R#͑GxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv
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36、#&ksv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89AmYWv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$U*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz84!z89Amv$UE9wEwZ#QcUE%&qY
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38、7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$U*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89AmYWv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9Cpb
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42、pP$vSTT#&ksv*3tnGK8!z89AmYWv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$U*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89Amv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89A
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52、K8!z89AmYWv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqvUE%&qYp
53、Eh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89AmYWv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$U*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89Amv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGp
54、P$vSTT#&ksv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxGjqv$UE9wEwZ#QcUE%&qYpEh5pDx2zVkum&gTXRm6X4NGpP$vSTT#&ksv*3tnGK8!z89AmYWv*3tnGK8!z89AmYWpazadNu#KN&MuWFA5uxY7JnD6YWRrWwcvR9CpbK!zn%Mz849GxG
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