Quality products from excellent design, but also depend on the reliable guarantee of good manufacturing, and excellent manufacturing depends on the perfect processing technology. Only by choosing the correct processing technology, can we create high-precision products, reduce production costs, improve production efficiency and create good benefits for the enterprise. Due to the manufacture of pump parts variety, complex structure, a wide range of materials, resulting in difficult processing, process quality is not easy to control. Especially single, small batch, variety of changing production patterns, processes are relatively concentrated, more require the operator to master a more comprehensive mechanical manufacturing expertise, has a good overall quality.
Pump parts complex structure, casting accounted for more than 80%, mainly cast iron parts, castings and cast stainless steel parts; less shaft parts, mainly for high-quality carbon steel, chrome steel or stainless steel parts. Pump parts processing, because of its hydraulic flow channel, taking into account the positioning fixture must be found in the correct position of the positive flow path. Avoid assembly caused after the pressure chamber and impeller runner deflection, dislocation, gap uneven or even rub, affecting product quality. In order to ensure the accuracy of manufacturing parts, the need to design the appropriate tooling, and reasonable arrangements process control process factors. Production problems are prone to the workpiece clamping, processing requirements, typical parts of the process as follows:
First, the workpiece clamping 1, the operator must be familiar with the product drawings, process files and process equipment based on the operation of production, to avoid blind production of parts scrapped;
2, when installing the fixture on the work table of the machine tool, it is necessary to wipe its positioning datum and find the relative position of the machining requirement;
3, the workpiece clamping should be the positioning surface, clamping surface, fixture positioning surface wipe clean, no glitches to ensure the positioning accuracy;
4, according to the process of positioning the standard fixture, positioning the benchmark in line with the following principles:
(1) As far as possible, the design basis, processing standard and inspection standard should be overlapped to facilitate the conversion and measurement of the processing dimension chain;
(2), as far as possible so that the processing of the same plane using the benchmark, easy to ensure the form of tolerances, such as parallelism, concentricity, verticality;
(3) The selection of roughing datum should be combined with the positioning requirements of subsequent processes, which will help improve the machining accuracy;
(4) The positioning standard of finishing process should be machined surface so that the positioning is accurate and the machining precision is high.
(5) Select the positioning base must make the workpiece positioning, easy clamping, stable and reliable processing.
5, clamping the workpiece clamping force of the appropriate size, clamping force point of action should be through the bearing surface, as close as possible to the processing surface; less rigid or dangling workpieces, should increase the auxiliary support to enhance rigidity;
6, clamping precision surface should be padded copper protection, without damage to the processed surface;
7, the processing surface should be as close as possible to the bedside box, select the appropriate tool to enhance system rigidity and improve the processing of surface roughness.
Second, processing requirements
1, the operator should be based on technical requirements and technical requirements of the drawings and process documents, and the workpiece material, precision requirements, machine tools, tools, fixtures and other circumstances, the correct choice of process route, a reasonable choice of cutting;
2, the size of the tolerance requirements in the processing should try to press the middle tolerance processing;
3, Roughing surface roughness not specified in the process specification should not be greater than Ra25. The surface roughness to be quenched in the next procedure is not greater than Ra6.3. The surface roughness before reaming is not more than Ra12.5. The surface before grinding Roughness should not be greater than Ra6.3;
4, rough chamfering, rounding, groove depth should be finishing margin to increase or deepen to ensure that after finishing the design requirements; backstroke should not be too deep and acute angle to avoid stress concentration;
5, Chamfering and free dimensions not specified in the drawings or in the process shall be made in accordance with the relevant provisions;
6, burrs generated by the procedure should be removed in this process;
7, in the large-scale processing, should always check the workpiece is loose, to prevent the impact of processing quality or accident;
8, rough, finishing in the same process, should consider the thermal expansion and contraction, processing stress and other factors affect the final dimensional accuracy;
9, cutting process, if the processing system issued an abnormal sound or roughness suddenly deteriorate, should immediately stop the car inspection;
10, the correct use of measuring tools, pay attention to the calibration before the measurement, inspection should avoid excessive force caused by measuring damage or increase measurement error;
11, after processing the workpiece should be placed on the provisions of the position apparatus, so as not to damage the processing surface;
12, after processing the workpiece should be full-time examiner passed the test after passing into the next process.
Third, the typical parts of the processing technology analysis 1, the pump processing technology:
Pumping process focus is to ensure that the assembly of the reference hole and pressure chamber flow channel the correct location. Pump processing equipment mainly lathe, vertical lathe, boring machine, etc., of which horizontal lathe for a small pump body processing, although the production efficiency is high, but inconvenient to find the processing surface and the relative position of the flow channel, often resulting in the assembly of reference holes and The center of runner is not vertical and the relative position is not accurate. Therefore, the large pump body and boring machine in more vertical machining, workpiece clamping on the work surface, the horn can be used to correct the position of the runner, compacting; and boring machine table can rotate, in a fixture in the processing of multiple side . Such as pipeline centrifugal pump using boring machine process route: (1), with the foot of the quasi-pinch to find the positive channel after clamping, respectively, car import and export flanges to ensure that the flange parallel and coincide with the center of the runner; ( 2) The water inlet flange stands on the workbench to find a positive runner and then tighten it. The quasi-impeller assembly hole of the quasi-impeller is then drilled. After the workbench is rotated 180 degrees, the bottom end of the locker truck is well secured, ensuring the assembly hole surface and flow Road location accuracy; (3), according to the drawings to complete the other processes.
2, impeller processing technology:
Impeller processing is mainly done in the lathe, the common process routes are: (1), with four claw clip impeller diameter or rear mouth ring to the center of the flow channel or front and rear cover flow channel surface for axial reference and import impeller Diameter for radial alignment after clamping, roughing the impeller inlet port leaving fine car spare 1-2mm, and the front plate; this process to ensure the relative position of the impeller flow path; (2) After the ring to find the workpiece is clamped, the rear ring, outer diameter, bore, rear cover car is good, to ensure the inner hole, outer diameter, the concentricity of the mouth ring requirements; (3) Hole positioning, fine impeller impeller front ring, to ensure the front ring and the inner hole concentricity requirements; (4), three claw clip back ring or outer diameter to locate the keyway slot to ensure the keyway symmetry; , Drilling impeller balance hole, to ensure that the size and average blade spacing, without damage to the leaves; (6), to do a balance test.
3, pump cover (or motor bracket) processing technology (pipeline pump, for example):
Pump cover structure is usually one end of the mouth connected to the motor, the other end of the step connected to the pump body. Both ends of the hole with the installation can not be completed at the same time a clamping process, such as different heart will appear quality problems. Common processing technology: (1) with four claws to clamp one end (such as the pump body connection) to find out the other end of the fine car good; (2) installed in the lathe calibration tire size, the car has one end (motor installation Only mouth) with the hole into the tire to find positive pressure, coarse car body size of the connector, so that the concentricity of both ends can be guaranteed. Then use a drill to drill all around the bolt connection hole.
4, shaft processing technology:
Slim parts processing axis machining more difficult, using a reasonable processing route supplemented by the appropriate tooling (such as the center frame), can meet the design requirements. Axis machining centering on the main hole for the positioning of the base, both ends of the outer circle can not be completed at the same time in a fixture, finishing to ensure radial beating requirements usually use two top clamp folder on the heart, high precision surface grinder carry out. Process route: (1), the rough car, were drilled at both ends of the center hole, clip a top of the outer rough car into the remaining margin, into the heat treatment process (such as quenching and tempering); (2) After the heat treatment of the shaft must be repaired center hole, clip a top of a semi-fine car, leaving fine car allowance 0.5-1mm, and the completion of the shaft thread, undercut recess processing, pay attention to retreating slot avoid sharp corners Resulting in stress concentration, affecting the strength of the shaft; (3), finishing, for less demanding parts using two top chicken heart clip, will complement the parts of the fine car into the outer; if the requirements with high precision, mass production of the shaft, Left grinding processing allowance 0.3-0.6mm; (4), milling keyway, pay attention to ensure symmetry; (5), grinding cylindrical, with two top chicken heart clip will be ground with the mating surface.
According to market information, most quality problems are related to poor manufacturing, showing the importance of the process can not be ignored. Pump manufacturing process changes in many parts, but through research and analysis are still rules to follow. The main principles of process development are: to seize the key - the correct choice of benchmarks; to grasp the key - the use of reasonable tooling assurance; decision method - the right route. Relying on the careful preparation of process personnel, combined with the operator's field experience brainstorming, the manufacture of pump parts meet the design requirements, to achieve high quality and high yield is entirely possible.
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