In the field of machinery manufacturing, box parts are a common type of structural parts and are widely used in various mechanical equipment. Due to its complex structure and high precision requirements, the processing technology of box parts is particularly critical. This article will comprehensively and professionally explain the processing technology of box parts to help readers better understand and master relevant knowledge.
Content：
Part 1. Structural characteristics of box parts
Part 2. Processing requirements for box parts
Part 3. Precision machining of box parts
Part 4. Inspection of box parts
1. Structural characteristics of box parts
Complex geometric shapes
Box parts are usually composed of multiple surfaces, holes, slots and other structures, and the interior may be cavity-shaped, with thin and uneven walls. This complex structure requires precise control of many aspects during the design and manufacturing process of the box parts.
High precision requirements
The processing of box parts not only requires the parallelism and perpendicularity of each surface to meet the design requirements, but also involves the position accuracy of the holes. These are key factors to ensure the normal operation of the box parts.
Material properties
The commonly used materials for box parts are cast iron or cast steel. The cutting performance of these materials is relatively poor, which increases the difficulty of processing.
2. Processing requirements for box parts
Ensure dimensional and shape accuracy
During the processing of box parts, the accuracy of size and shape must be strictly controlled to meet the requirements of assembly and use.
Position accuracy
The position accuracy of the holes is particularly important for box parts, because the accuracy of the hole positions is directly related to the operation accuracy and stability of the entire mechanical system.
Surface roughness
In order to ensure the contact stiffness and mutual position accuracy of the box parts, the shape accuracy and surface roughness of the main planes need to reach higher standards.
Follow-up processing
In addition to the machining itself, the box parts also need to undergo a series of subsequent treatments after completion of processing, such as cleaning, rust prevention and painting to improve their appearance quality and durability.
Precision machining of box parts
The finishing of box parts is a process that requires extremely high precision, which is directly related to the assembly quality and performance of the entire mechanical system. When finishing the box parts, special attention needs to be paid to the following issues:
Machine and tool selection
In order to achieve high-precision processing results, high-precision machine tools and cutting tools must be used. This includes, but is not limited to, high-efficiency equipment such as CNC vertical lathes, CNC vertical machining centers, and horizontal machining centers, as well as high-precision tools dedicated to box finishing.
Optimization of processing parameters
During the finishing process, parameters such as cutting speed and feed rate need to be precisely controlled. Parameter settings that are too high or too low may affect the processing quality, such as generating excessive cutting forces that cause part deformation, or the processing efficiency is too low.
Temperature and deformation control
During the finishing process, due to the long continuous cutting time, overheating is easy to occur, resulting in inaccurate part dimensions or reduced surface quality. Therefore, measures need to be taken such as using coolant, reasonably arranging processing sequence and rest time to control temperature and reduce thermal deformation.
Hole machining accuracy
Hole processing in box parts is a part that requires special attention, especially for holes that require extremely high position accuracy and coaxiality. Boring, reaming, reaming and other methods should be used to ensure the dimensional accuracy and surface quality of the holes. At the same time, attention should be paid to the positional relationship between holes to avoid deviations.
Workpiece clamping method
Correct clamping method is crucial to ensure processing accuracy. Appropriate tooling should be designed to ensure the stability of the workpiece during processing and avoid processing errors caused by improper clamping. For example, using the method of transitional threaded holes can complete milling and drilling of large surfaces in one clamping, effectively improving flatness.
4. Inspection of box parts
The inspection of box parts is a key step to ensure that they meet the accuracy and performance requirements of the mechanical system. During the inspection process, many details need to be paid attention to.
Measuring tools
In order to achieve high-precision measurement results, it is necessary to use high-stability and high-efficiency measurement tools, such as three-dimensional coordinate measuring machines. These devices can achieve a series of precise measurements of the dimensions, flatness, coaxiality, etc. of the box parts.
Configure measurement accessories
Measurements in deep holes and cavities require appropriate extension rods and styli, such as test base extension rods, star-shaped styli, etc., to ensure measurement accuracy.
Determine positioning
Before measuring, it is necessary to clarify the positioning method of the box parts. Commonly used are three mutually perpendicular surfaces for positioning or a plane with two perpendicular holes for positioning. This helps to improve the repeatability and stability of the measurement.
Consider mounting methods
Considering that box parts are relatively large in size and heavy in weight, convenience, repeatability and stability should be ensured when clamping. They can be placed directly on the work surface for measurement, or they can be fixed using universal clamps or simple clamps.
Observe the precautions
When measuring, you should ensure that the parts are wiped clean and free of burrs, keep the surface accuracy of the measurement elements high, and choose an appropriate measurement speed to avoid mistaken movement of the parts, especially when there are many sizes. At the same time, for locations that are difficult to measure directly, multiple clamping or indirect measurement methods can be considered.
Analyze measurement data
The measured data needs to be carefully analyzed, especially the key parameters such as hole dimensional accuracy, cylindricity, and coaxiality, which must be analyzed in conjunction with the actual conditions of processing and assembly to ensure the accuracy and reliability of the measurement results.
Confirm measurement skills
When measuring the hole axis, you can first measure the surface that is perpendicular to the hole, and then input the vector direction of the surface into the vector direction of the automatic circle (cylinder) measurement, assuming that the hole is theoretically perpendicular to the surface. When measuring perpendicularity, the proportional relationship between the axis length of the hole and the surface must be judged based on experience. If the hole depth is relatively shallow and the surface is relatively large, and the hole is the benchmark, the result may be out of tolerance (actually it is good). You can Consider measuring with a mandrel inserted into the hole or measuring with the two holes sharing a common axis.
GPM has 20 years experience in CNC machining of different kinds of precision parts. We have worked with customers in many industries, including semiconductor, medical equipment, etc., and are committed to providing customers with high-quality, precise machining services. We adopt a strict quality management system to ensure that every part meets customer expectations and standards.
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Post time: May-27-2024