Our company is a specialized manufacturer of processing shaft parts, processing tens of millions of shaft parts or even over 100 million pieces per year. Each type of shaft has a special process. A reasonable process must take into account various factors such as production cost, processing efficiency and rational allocation of resources under the premise of ensuring quality. Therefore, the optimization and improvement of the process will be given to the factory. Bring more benefits. Figure 1 is a kind of automobile guide rod parts processed by our company, the material is 45 steel.
This shaft is characterized by a V-shaped groove on the cylinder surface. The groove length is 21mm and the groove depth is 0.3mm. How to process the V-shaped groove? Several scenarios are presented below and analyzed.
Milling
Mill the V-groove as shown in Figure 2. The shaft is fixed by a clamp on a vertical milling machine, and the V-groove is milled from the upper end with a milling cutter. Since the groove is too long and the milling amount is large, the surface roughness value of the groove is generally about R a=3.2 μm, and the tool is easily worn out when worn; and the milling cutter wears extremely fast, and the service life of the milling cutter is about 1,500 pieces. The cost of the tool increases; and only a single process can be used, and the processing efficiency is low. Each machine tool processes more than 200 pieces per day, and the production cost increases. After a period of production, such high cost processing costs make the profit of processing this product extremely low and the prospects are not good.
Broaching
After consideration, we used a broach to pull the groove on the lathe, as shown in Figure 3. After the test, because the groove is too long, the turning tool is easy to be used, causing tool waste, and the tool life is about 1 000. Although the surface roughness value of the groove is generally about R a=2.5μm, the efficiency is not high, and each machine tool processes 300 to 500 pieces per day, and the processing cost is still high. This method is also not ideal.
3. Stamping
As shown in Fig. 4, the shaft is fixed by a clamp, and the cutter is punched from the upper end into the V-shaped groove. Because the shaft is long, the press has great force and it is easy to bend the shaft, which is potentially dangerous; and the groove surface roughness value is generally about R a=4.5μm. At the edge of the tolerance, the tool is easy to be worn after wear; The service life is about 10,000 pieces, and each machine tool processes about 1,000 pieces per day. This method has been greatly improved compared with the previous two solutions, but there are also potential defects.
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