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target="_blank">加工中心</a>上的多孔加工，这种孔的加工方式势必会降低加工效率，加大劳动强度，提高加工成本，除此之外，由于钻头刚性差，扭矩和轴向力等方面的问题， 在加工过程中也容易出现孔径超差（图 2）、孔壁粗糙、孔位偏移、斜孔、钻头打滑或折断（图 1）等问题，无法保证孔的加工质量。为此，提出在某些孔类如孔径大小不一等场合以铣代钻，以铣代铰的方式进行加工，一定程度上解决了当下孔加工的一些难题，保证了孔的加工质量。</p><p> </p><p><img src="/upload/images/201810/15401840307106.png" title="15401840307106.png" alt="图片.png"/></p><p>图 1 钻头折断 图 2 孔径偏大</p><p>2 数控<a href="http://www.bethel-cnc.com/" target="_blank">加工中心</a>上孔加工的策略</p><p>针对于钻削加工中存在的问题，提出几点在数控铣 床上孔的加工策略。</p><p>2.1 以铣代钻</p><p>螺旋铣孔的过程是由主轴的“自转”和主轴绕孔中心“公转”的 2 个运动复合而成，刀具的中心轨迹不再是直线而是螺旋线，加工过程中既有径向进给同时又有轴向进给（图 3），螺旋铣削可以实现斜面、型槽、孔加工等。</p><p><img src="/upload/images/201810/15401840574218.png" title="15401840574218.png" alt="图片.png"/> </p><p>2.2 采用螺旋铣孔的优点</p><p>（1）螺旋铣孔时，铣刀的侧刃是断续进行切削加工 的，因此降低了刀刃与工件的接触时间，降低了切削区的温度，提高了刀具的使用寿命。</p><p>（2）易于排屑，由于使用的刀具直径小于孔径，在切 削过程中可以避免切屑对已加工表面的损伤。</p><p>（3）可以实现一把刀具加工不同大小的孔，节省换刀 时间和次数，降低加工准备时间和提高加工效率。</p><p>3 插铣代替铰孔</p><p><span style="color:#231F20">钻削过程之所以出现孔径偏大</span><span style="font-family: 'PMingLiU','serif';color:#231F20;letter-spacing:-6px">、</span><span style="color:#231F20;letter-spacing:-1px">钻歪等问题，主要是</span><span style="color:#231F20;letter-spacing:-0">刀具在转动过程中容易出现摆动，钻头的旋转轴线与主</span><span style="color:#231F20">轴的旋转轴线之间会偏离一个角度</span> <span style="font-family:'Lucida Sans Unicode','sans-serif';color:#231F20">α</span><span style="color:#231F20">，钻头尾部和轴线</span><span style="color:#231F20">位置也会发生了变化，这样钻头在进行自转的同时进行公转的过程中产生一个附加角度 </span><span style="font-family: 'Lucida Sans Unicode','sans-serif';color:#231F20">△φ</span><span style="color:#231F20">，导致钻头几何轴</span><span style="color:#231F20">线</span><span style="font-family: 'PMingLiU','serif';color:#231F20">、</span><span style="color:#231F20">钻头旋转轴线和主轴旋转轴线不重合而引起的加工误差，致使孔径超差，而在采用铣刀加工方式时，其铣刀</span><span style="color:#231F20;letter-spacing:-1px">的偏离角度 </span><span style="font-family:'Lucida Sans Unicode','sans-serif';color:#231F20">α </span><span style="color:#231F20;letter-spacing:-1px">和附加角度 </span><span style="font-family:'Lucida Sans Unicode','sans-serif';color:#231F20">△φ </span><span style="color: #231F20;letter-spacing:0">较钻头会降低很多，因此</span><span style="color:#231F20;letter-spacing:1px">采用插铣式的加工方法一定程度上提高了孔的尺寸公 </span><span style="color:#231F20">差</span><span style="font-family:'PMingLiU','serif';color:#231F20;letter-spacing: -2px">。</span><span style="color:#231F20">特别是对于孔径小且表面质量要求高的销孔类，比如加工</span> <span style="font-family:'Lucida Sans Unicode','sans-serif';color:#231F20">φ</span><span style="font-family:'Times New Roman','serif';color:#231F20">6</span> <span style="font-size:6px;line-height:101%;font-family:'Times New Roman','serif';color:#231F20;position:relative;top:-5px">+0.012</span><span style="font-size:6px;line-height:101%;font-family:'Times New Roman','serif';color:#231F20;position:relative;top:-5px;letter-spacing:-0"> </span><span style="color:#231F20;letter-spacing:-1px">的销孔，粗糙度为</span> <span style="font-family:'Times New Roman','serif';color:#231F20;letter-spacing:-0">1.</span><span style="font-family:'Times New Roman','serif';color:#231F20">6</span> <span style="font-family:'Lucida Sans Unicode','sans-serif';color:#231F20">μ</span><span style="font-family: 'Times New Roman','serif';color:#231F20">m</span><span style="color: #231F20;letter-spacing:-1px">，采用先钻后铰的加</span><span style="color:#231F20;letter-spacing:-1px">工方式，铰出来的孔超差</span><span style="font-family:'Times New Roman','serif';color:#231F20">+</span><span style="font-family:'Times New Roman','serif';color:#231F20;letter-spacing:-0">0</span><span style="font-family:'Times New Roman','serif';color:#231F20;letter-spacing:-0">.</span><span style="font-family:'Times New Roman','serif';color:#231F20;letter-spacing:-0">00</span><span style="font-family:'Times New Roman','serif';color:#231F20">3</span> <span style="font-family:'Times New Roman','serif';color:#231F20">mm</span><span style="color:#231F20;letter-spacing: -1px">，而改用合金铣刀采用</span><span style="color:#231F20;letter-spacing:-1px">插铣方式进行加工，则公差在可控范围之内</span><span style="font-family:'PMingLiU','serif';color:#231F20">。</span></p><p><span style="font-family:'PMingLiU','serif';color:#231F20"><img src="/upload/images/201810/15401841554594.png" title="15401841554594.png" alt="图片.png"/></span></p><p>3 交叉孔的加工</p><p>从图 4 的钻头受力平衡的角度来分析，当刀具在进行切削过程中，其受力是平衡的：其关系 F1+F4=F8+F10，F5=F6;如果钻交叉孔，在钻第二个孔时钻头因受力不平衡而 出现钻头打滑，导致钻出斜孔，如图 5 所示，若采用以铣代钻的方式进行加工，由于铣刀的切削刃在圆周上，轴向没有出现力不平衡的现象，因此就可以避免打刀、钻出斜孔的问题。</p><p><img src="/upload/images/201810/15401841837140.png" title="15401841837140.png" alt="图片.png"/></p><p>4 结语</p><p>铣孔比起钻孔在轴向的稳定性好，不受孔径大小的限制，可实现一刀多用，比如可以代替钻孔、扩孔、铰孔、 锪孔等，避免传统孔加工中频繁换刀的问题，同时也避免了钻削中难排屑、层间易分层的现象，是实现高效、低缺陷、高质量制孔的一种有效加工方式。</p><p><br/></p><p><br style="page-break-before:always" clear="all"/> </p><p><br/></p></div> <div class="blank30"></div> <!-- tag --> <div class="blank10"></div> 标签： <a href='/index.php?case=tag&act=show&t=wap&tag=%E5%8A%A0%E5%B7%A5%E4%B8%AD%E5%BF%83' 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