技术领域technical field
本发明涉及零件加工技术领域，具体是涉及一种超微型零件的加工方法。The invention relates to the technical field of parts processing, in particular to a method for processing ultra-miniature parts.
背景技术Background technique
在机械加工领域，对于体积超小，同时对表面质量和精度要求高的零件加工一直是业内的难题，尤其在大批量生产时，由于没有合适的加工工艺，严重影响产能和交付能力。In the field of mechanical processing, it has always been a problem in the industry to process parts that are ultra-small in size and require high surface quality and precision. Especially in mass production, due to the lack of suitable processing technology, the production capacity and delivery capacity are seriously affected.
对于超微型的零件加工，传统做法通常是采用虎钳或气动夹具进行夹持加工，受本身结构限制，活动的钳口与滑轨之间会存在一定的配合间隙，如果一次装夹多个同型号的超微型零件，通常只有1至2个零件被有效夹持，因此一般每次只会装夹1～2个零件，严重制约了超微型零件的加工效率。同时受工艺限制，每次装夹都存在一定的对位误差，因此零件的加工精度和一致性并不好。同时由于零件太小，人工装夹、卸夹都非常困难，另外在加工过程中零件边缘会产生不同程度的毛刺，尤其是铝合金或紫铜等软黏材质，产生的毛刺后期很难去除。For the processing of ultra-miniature parts, the traditional method is usually to use vise or pneumatic clamps for clamping processing. Due to the limitation of its own structure, there will be a certain fit gap between the movable jaws and the slide rail. Usually only 1 to 2 parts are effectively clamped for ultra-miniature parts of the model, so generally only 1 to 2 parts are clamped at a time, which seriously restricts the processing efficiency of ultra-miniature parts. At the same time, limited by the process, there is a certain alignment error in each clamping, so the machining accuracy and consistency of the parts are not good. At the same time, because the parts are too small, manual clamping and unloading are very difficult. In addition, different degrees of burrs will be generated on the edges of the parts during the processing process, especially for soft and sticky materials such as aluminum alloy or copper, which are difficult to remove in the later stage.
发明内容Contents of the invention
本发明的目的是提供一种能显著提高超微型零部件生产效率、加工精度和加工质量的方法。The purpose of the invention is to provide a method that can significantly improve the production efficiency, processing accuracy and processing quality of ultra-miniature components.
为了实现上述的目的，本发明提供的超微型零件的加工方法包括以下步骤：在坯料的第一侧均匀排布，利用CNC设备加工出多个零件半成品，使得各个零件半成品的第一端独立分离，各个零件半成品的第二端通过连接部连接在一起；在坯料的第一侧填充粘结剂，粘结剂包括石膏粉、消泡剂和水；进行消泡及固化处理；对零件半成品的第一端端面进行铣加工；对坯料的第二侧进行铣加工，去除连接部；分离及清洗各个零件半成品。In order to achieve the above object, the processing method of ultra-miniature parts provided by the present invention includes the following steps: uniformly arrange on the first side of the blank, and use CNC equipment to process a plurality of semi-finished parts, so that the first ends of each semi-finished part are independently separated , the second ends of the semi-finished parts of each part are connected together through the connecting part; the first side of the blank is filled with a binder, the binder includes gypsum powder, defoaming agent and water; defoaming and curing treatment is carried out; Milling on the first end face; milling on the second side of the blank to remove the connection; separate and clean the semi-finished parts.
由上述方案可见，首先在坯料的第一侧内加工出零件半成品的第一端，保持零件半成品的第二端通过连接部连接在一起，然后在坯料的第一侧内填充粘结剂，使各个零件半成品的第一端通过粘结剂连接在一起；然后铣去坯料第二侧上的连接部，使得零件半成品的第二端独立分离，接着除去粘结剂，得到多个独立的零件成品，通过采用该种方法，能批量生产多个超微型零件，有效提高生产效率，将零件半成品连接在一起再进行铣加工，既能免除单个零件半成品在加工过程中的夹持和定位，避免加工部位产生毛刺，同时又能提高各个零件的加工精度，保证各个零件的质量一致。It can be seen from the above scheme that firstly, the first end of the semi-finished part is processed in the first side of the blank, and the second end of the semi-finished part is kept connected together through the connecting part, and then the adhesive is filled in the first side of the blank, so that The first ends of the individual part blanks are joined together by an adhesive; the connection on the second side of the blank is then milled away, allowing the second ends of the part blank to be separated independently, followed by removal of the adhesive, resulting in multiple individual finished parts , by adopting this method, multiple ultra-miniature parts can be produced in batches, which can effectively improve production efficiency. The semi-finished parts of the parts are connected together and then milled. Burrs are generated on the part, and at the same time, the machining accuracy of each part can be improved to ensure the consistent quality of each part.
进一步的方案是，在加工零件半成品前，需准备坯料，准备坯料包括：选取厚度大于零件目标厚度的坯料；将坯料放入整平机中整平，使得坯料的翘曲度小于0.2mm。A further solution is to prepare the blank before processing the semi-finished part. The preparation of the blank includes: selecting a blank whose thickness is greater than the target thickness of the part;
进一步的方案是，在粘结剂中，石膏粉与水的配比比例为100:30，消泡剂占石膏粉与水的调和物总重的1‰～3‰。A further solution is that, in the binder, the proportion of gypsum powder and water is 100:30, and the defoamer accounts for 1‰ to 3‰ of the total weight of the mixture of gypsum powder and water.
进一步的方案是，粘结剂填充在相邻两个零件半成品之间并高出零件半成品的第一端端面0.3mm～0.5mm。A further solution is that the adhesive is filled between two adjacent part semi-finished products and is 0.3 mm to 0.5 mm higher than the first end surface of the part semi-finished products.
进一步的方案是，消泡及固化处理包括：将坯料放入真空箱内进行抽真空处理，处理时间为15s～20s，然后静置30min～35min，使得粘结剂脱水凝固。A further solution is that the defoaming and curing treatment includes: putting the billet into a vacuum box for vacuuming treatment for 15s-20s, and then standing for 30min-35min, so that the binder is dehydrated and solidified.
进一步的方案是，对零件半成品的第一端端面进行铣加工包括：待粘结剂固化后，将坯料的第一侧表面铣成平整的面，使所有零件半成品的第一端端面暴露在外；对所有零件半成品的第一端端面进行精加工。A further solution is that milling the first end faces of the semi-finished parts includes: after the binder is cured, milling the first side surface of the blank into a flat surface, so that the first end faces of all semi-finished parts are exposed; Finish machining of the first end face of all part semi-finished products.
进一步的方案是，对坯料的第二侧进行铣加工还包括：对所有零件半成品的第二端端面进行精加工。A further solution is that milling the second side of the blank further includes: finishing the second end faces of all semi-finished parts.
进一步的方案是，分离及清洗各个零件半成品包括：将坯料拆分为多个第一碎块；将第一碎块放入碳酸钠溶液中进行软化处理，并浸泡第一预设时间；将第一碎块进一步拆分为第二碎块；将第二碎块放入稀盐酸中进行溶解分离处理，并浸泡第三预设时间；待粘结剂融化后，将第二碎块放在滤网中进行冲洗筛选处理，使零件半成品与粘结剂分离。A further solution is that separating and cleaning the semi-finished products of each part includes: splitting the blank into a plurality of first fragments; putting the first fragments into sodium carbonate solution for softening treatment, and soaking for a first preset time; A fragment is further divided into a second fragment; the second fragment is put into dilute hydrochloric acid for dissolution and separation, and soaked for a third preset time; after the binder is melted, the second fragment is placed in a filter Washing and screening are carried out in the net to separate the semi-finished parts from the binder.
进一步的方案是，在填充粘结剂前，对坯料的第一侧进行清洗。A further solution is to clean the first side of the blank before filling with the binder.
附图说明Description of drawings
图1是本发明实施例的流程图。Fig. 1 is a flowchart of an embodiment of the present invention.
图2是本发明实施例步骤S1中坯料的结构图。Fig. 2 is a structural diagram of the blank in step S1 of the embodiment of the present invention.
图3是本发明实施例步骤S2中坯料的剖视图。Fig. 3 is a cross-sectional view of the blank in step S2 of the embodiment of the present invention.
图4是图3中A处的放大图。Fig. 4 is an enlarged view at point A in Fig. 3 .
图5是本发明实施例步骤S4中坯料的结构图。Fig. 5 is a structural diagram of the blank in step S4 of the embodiment of the present invention.
图6是本发明实施例步骤S6中坯料的剖视图。Fig. 6 is a cross-sectional view of the blank in step S6 of the embodiment of the present invention.
图7是图6中B处的放大图。Fig. 7 is an enlarged view at B in Fig. 6 .
图8是本发明实施例步骤S7中坯料的剖视图。Fig. 8 is a cross-sectional view of the blank in step S7 of the embodiment of the present invention.
图9是图8中C处的放大图。Fig. 9 is an enlarged view at point C in Fig. 8 .
图10是本发明实施例步骤S8中第一碎块的结构示意图。Fig. 10 is a schematic structural diagram of the first fragment in step S8 of the embodiment of the present invention.
以下结合附图及实施例对本发明作进一步说明。The present invention will be further described below in conjunction with the accompanying drawings and embodiments.
具体实施方式Detailed ways
参见图1至图10，图1是本发明实施例的流程图。Referring to FIG. 1 to FIG. 10 , FIG. 1 is a flowchart of an embodiment of the present invention.
在步骤S1中，准备坯料1。本实施例要加工的超微型零件外形尺寸为1.60mm×1.60mm,厚度为3mm,为了加工该超微型零件，需选取厚度大于零件目标厚度的坯料1，优选坯料1的厚度比零件目标厚度大0.3mm～0.5mm，坯料1的外形尺寸优选为166mm×120mm×3.5mm。将坯料1放入整平机中进行整平，使得坯料1的翘曲度小于0.2mm，如图2所示。In step S1, a blank 1 is prepared. The dimensions of the ultra-miniature parts to be processed in this embodiment are 1.60mm×1.60mm, and the thickness is 3mm. In order to process the ultra-miniature parts, it is necessary to select a blank 1 with a thickness greater than the target thickness of the part. The thickness of the blank 1 is preferably larger than the target thickness of the part. 0.3 mm to 0.5 mm, and the outer dimensions of the blank 1 are preferably 166 mm×120 mm×3.5 mm. The blank 1 is put into a leveling machine for leveling, so that the warpage of the blank 1 is less than 0.2 mm, as shown in FIG. 2 .
在步骤S2中，在坯料1的第一侧通过CNC机床加工出多个零件半成品2，多个零件半成品2均匀排布，使得各个零件半成品2的第一端独立分离，各个零件半成品2的第二端则通过连接部5连接在一起。In step S2, a plurality of part semi-finished products 2 are processed by a CNC machine tool on the first side of the blank 1, and the plurality of part semi-finished products 2 are evenly arranged, so that the first ends of each part semi-finished product 2 are independently separated, and the first ends of each part semi-finished product 2 The two ends are connected together through the connecting portion 5 .
加工时，坯料1的边缘到最接近的一排零件半成品2之间要预留足够的边料3，各个零件半成品2的第二端到坯料1的底部预留大于或等于0.3mm厚度的连接部5，以保证各个零件半成品2之间的连接稳定性，如图3和图4所示。During processing, enough side material 3 should be reserved between the edge of the blank 1 and the nearest row of part semi-finished products 2, and a connection with a thickness greater than or equal to 0.3 mm should be reserved between the second end of each part semi-finished product 2 and the bottom of the blank 1 Part 5, to ensure the stability of the connection between the semi-finished products 2 of each part, as shown in Figure 3 and Figure 4.
然后执行步骤S3，清洗零件半成品2。Then step S3 is executed to clean the semi-finished part 2 .
将整板坯料1进行清洗，去除坯料1上残留的废屑及油污，清洗完成后，待坯料1降至室温才可进行下一工序。The entire blank 1 is cleaned to remove waste and oil stains remaining on the blank 1. After the cleaning is completed, the next process can only be carried out after the blank 1 has dropped to room temperature.
在步骤S4中，在坯料1的第一侧内填充粘结剂4，粘结剂4包括石膏粉、消泡剂和水，在本实施例中石膏粉优选为硬石膏粉，消泡剂优选为石膏消泡剂。In step S4, a binder 4 is filled in the first side of the blank 1, the binder 4 includes gypsum powder, a defoamer and water, in this embodiment the gypsum powder is preferably anhydrite powder, and the defoamer is preferably For gypsum defoamer.
粘结剂4的调配方法包括：The deployment method of binder 4 comprises:
(1)按比例要求准备石膏粉、水和消泡剂，其中，石膏粉与水的配比比例为100:30，消泡剂占石膏粉与水的调和物总重的1‰～3‰；(1) Prepare gypsum powder, water and defoamer according to the requirements in proportion. The ratio of gypsum powder to water is 100:30, and the defoamer accounts for 1‰～3‰ of the total weight of the mixture of gypsum powder and water. ;
(2)将消泡剂全部倒入水中并搅拌均匀；(2) Pour all the defoamer into water and stir evenly;
(3)将消泡剂和水的混合溶液缓慢倒入石膏粉中，一边添加一边搅拌，直至搅拌均匀，搅拌时间需控制在1分钟以内；(3) Slowly pour the mixed solution of defoamer and water into the gypsum powder, and stir while adding, until the stirring is uniform, and the stirring time should be controlled within 1 minute;
(4)将调配好的流质状粘结剂4均匀填充在坯料1的第一侧内，并用硬纸板刮平表面，使得粘结剂4表面高出坯料1约0.3mm～0.5mm,或者以目视看不见各个零件半成品2为准，如图5所示。(4) Evenly fill the prepared liquid adhesive 4 in the first side of the blank 1, and scrape the surface with a cardboard, so that the surface of the adhesive 4 is about 0.3 mm to 0.5 mm higher than the blank 1, or The semi-finished product 2 of each part that cannot be seen visually shall prevail, as shown in FIG. 5 .
然后执行步骤S5,进行消泡及固化处理，包括：Then perform step S5 to perform defoaming and curing treatment, including:
将填充了粘结剂4的坯料1放入真空箱内进行抽真空处理，腔内负压值保持在0.08Mpa～0.1Mpa,保持时间为15s～20s。The blank 1 filled with the binder 4 is put into a vacuum box for vacuum treatment, and the negative pressure in the cavity is kept at 0.08Mpa-0.1Mpa for 15s-20s.
消泡处理后，采用真空吸夹具吸持坯料1并保持坯料1的第一侧表面水平向上，然后在温度≥20℃，空气湿度≤80％的环境下，静置30min～35min,使得粘结剂4脱水凝固。石膏粉的主要成分为CaSO4，CaSO4与水反应生成CaSO4·2H2O，CaSO4·2H2O在空气中失水后逐渐凝固成硬块，将所有的零件半成品2以及边料3粘结在一起，形成一个整体，既方便夹持零件半成品2进行后续加工，同时又不会对各个零件半成品2造成任何损伤，在加工时，还能有效防止各个零件半成品的边缘产生毛刺。After the defoaming treatment, use a vacuum suction fixture to hold the blank 1 and keep the first side surface of the blank 1 horizontally upward, and then let it stand for 30 to 35 minutes in an environment with a temperature ≥ 20°C and an air humidity ≤ 80% to make the bonding Agent 4 was dehydrated and solidified. The main component of gypsum powder is CaSO4 , CaSO4 reacts with water to generate CaSO4 2H2 O, CaSO4 2H2 O gradually solidifies into a hard block after losing water in the air, and sticks all parts semi-finished products 2 and trim 3 Together to form a whole, it is convenient to clamp the semi-finished parts 2 for subsequent processing, and at the same time, it will not cause any damage to the semi-finished products 2 of each part. During processing, it can also effectively prevent burrs on the edges of the semi-finished parts.
在步骤S6中，对零件半成品2的第一端端面进行铣加工。In step S6 , milling is performed on the first end surface of the semi-finished part 2 .
具体地，待粘结剂4固化后，将坯料1的背面即第二侧侧面吸附在对应的真空夹具上，采用直径为100mm的端铣刀在坯料1的第一侧上整面铣去0.15mm～0.2mm,在此过程中要保证所有零件半成品2的第一端端面均能铣到。接着再精修一刀，切削深度控制在0.01mm～0.015mm内，切削速度控制在600mm/min,以获得良好的表面质量，同时避免堆积毛刺，如图6和图7所示。Specifically, after the adhesive 4 is cured, the back side of the blank 1, that is, the second side, is adsorbed on the corresponding vacuum fixture, and an end mill with a diameter of 100 mm is used to mill off 0.15 mm of the entire surface of the first side of the blank 1. mm ~ 0.2mm, in this process, it is necessary to ensure that the first end faces of the semi-finished products 2 of all parts can be milled. Then refine a knife, the cutting depth is controlled within 0.01mm ~ 0.015mm, and the cutting speed is controlled at 600mm/min to obtain good surface quality and avoid accumulation of burrs, as shown in Figure 6 and Figure 7.
在步骤S7中，对坯料1的第二侧进行铣加工。In step S7, the second side of the blank 1 is milled.
具体地，利用压缩空气清理干净坯料1，然后通过真空吸夹具吸持坯料1并保持坯料1的第二侧表面水平向上。采用直径100mm的端铣刀在坯料1的第二侧上整面铣去连接部5，使所有零件半成品2的第二端不直接连接，然后对所有零件半成品2的第二端端面进行精修，使得所有零件半成品2的厚度公差控制在±0.015mm内，如图8和图9所示。Specifically, the blank 1 is cleaned with compressed air, and then the blank 1 is sucked by a vacuum suction jig and the second side surface of the blank 1 is kept horizontally upward. Use an end mill with a diameter of 100mm to mill the entire surface of the second side of the blank 1 to remove the connecting portion 5, so that the second ends of all parts semi-finished products 2 are not directly connected, and then finish the second end faces of all parts semi-finished products 2 , so that the thickness tolerance of all semi-finished products 2 is controlled within ±0.015mm, as shown in Figure 8 and Figure 9.
然后执行步骤S8,板料分离。Then execute step S8, sheet material separation.
具体地，将坯料1内的所有零件半成品2连同粘结剂4一起拆分为多个第一碎块，第一碎块的尺寸控制在5mm～8mm以内，即每一第一碎块内包含四个左右的零件半成品2，如图10所示。Specifically, all the part semi-finished products 2 in the blank 1 are disassembled together with the binder 4 into a plurality of first fragments, and the size of the first fragments is controlled within 5 mm to 8 mm, that is, each first fragment contains Four or so parts semi-finished products 2, as shown in Figure 10.
接着执行步骤S9，执行浸泡软化处理。Next, step S9 is executed to perform soaking and softening treatment.
将所有第一碎块一起放入浓度为20％的碳酸钠溶液中，并浸泡第一预设时间,在浸泡过程中每隔第二预设时间搅动一次，第一预设时间优选为1h,第二预设时间优选为2h。粘结剂4的主要成分是CaSO4·2H2O，CaSO4·2H2O与碳酸钠溶液发生化学反应生成不溶于水的碳酸钙、溶于水的硫酸钠和水，使得固化后的粘结剂4逐渐软化，同时边浸泡边搅动既能使得CaSO4·2H2O与碳酸钠溶液充分反应，又能通过外力搅动将部分粘结剂4与零件半成品2分离，使得粘结剂4和零件半成品2之间发生松动，有利于后续溶解分离。Put all the first fragments into a sodium carbonate solution with a concentration of 20%, and soak for the first preset time, and stir once every second preset time during the soaking process, the first preset time is preferably 1h, The second preset time is preferably 2 hours. The main component of binder 4 is CaSO4 2H2 O, and CaSO4 2H2 O reacts with sodium carbonate solution to generate water-insoluble calcium carbonate, water-soluble sodium sulfate and water, so that the cured adhesive The binder 4 is gradually softened, while soaking and stirring can not only make CaSO4 2H2 O fully react with the sodium carbonate solution, but also separate part of the binder 4 from the semi-finished part 2 through external stirring, so that the binder 4 and Looseness occurs between the semi-finished parts 2, which is conducive to subsequent dissolution and separation.
然后执行步骤S10，执行溶解分离处理。Then step S10 is executed to perform dissolution and separation processing.
将第一碎块进一步拆分为第二碎块，第二碎块的尺寸小于第一碎块的尺寸；在此过程中，工人需佩戴硅胶防护手套，防止灼伤皮肤。The first fragment is further split into the second fragment, the size of the second fragment is smaller than the size of the first fragment; during this process, workers need to wear silicone protective gloves to prevent skin burns.
将第二碎块放入配比浓度1mol/L的稀盐酸中，并浸泡第三预设时间，直至粘结剂4溶解。在此过程中，残留在零件半成品2表面上的碳酸钙和稀盐酸反应生成易溶于水的氯化钙、水和二氧化碳，以此实现粘结剂4与零件半成品2的分离，避免粘结剂4附着在零件半成品2的表面。Put the second fragment into dilute hydrochloric acid with a ratio concentration of 1mol/L, and soak for a third preset time until the binder 4 dissolves. During this process, the calcium carbonate remaining on the surface of the part semi-finished product 2 reacts with dilute hydrochloric acid to generate water-soluble calcium chloride, water and carbon dioxide, so as to realize the separation of the binder 4 from the part semi-finished product 2 and avoid sticking The agent 4 is attached to the surface of the semi-finished part 2.
接着执行步骤S11，执行冲洗筛选处理。Next, step S11 is executed to execute flushing and screening processing.
待粘结剂4溶解后，将第二碎块放在细滤网中并用清水冲洗、筛选出所有零件半成品2，使零件半成品2与粘结剂4完全分离，最后留下成品的零件。After the binder 4 is dissolved, put the second piece into a fine filter and rinse with clean water to screen out all the parts semi-finished products 2, so that the parts semi-finished products 2 and the binder 4 are completely separated, and finally leave the finished parts.
一般情况下，在确认成品的零件无杂质后，需执行步骤S12，清洗成品零件，以保证零件的表面质量。Generally, after confirming that the finished parts are free of impurities, step S12 needs to be performed to clean the finished parts to ensure the surface quality of the parts.
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910840749.XACN110549071B (en) | 2019-09-06 | 2019-09-06 | Processing methods of ultra-miniature parts |
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201910840749.XACN110549071B (en) | 2019-09-06 | 2019-09-06 | Processing methods of ultra-miniature parts |
| Publication Number | Publication Date |
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| CN110549071Atrue CN110549071A (en) | 2019-12-10 |
| CN110549071B CN110549071B (en) | 2022-02-11 |
| Application Number | Title | Priority Date | Filing Date |
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| CN201910840749.XAActiveCN110549071B (en) | 2019-09-06 | 2019-09-06 | Processing methods of ultra-miniature parts |
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| CN (1) | CN110549071B (en) |
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| CN109318498A (en)* | 2018-08-16 | 2019-02-12 | 深圳技师学院（深圳高级技工学校） | A kind of processing method of thin-walled parts |
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| JP2004088099A (en)* | 2002-08-06 | 2004-03-18 | Matsushita Electric Ind Co Ltd | Circuit board manufacturing method, communication equipment |
| CN1835155A (en)* | 2005-03-14 | 2006-09-20 | 闳晖实业股份有限公司 | Ultra-thin plastic key module and manufacturing method thereof |
| CN102350620A (en)* | 2011-09-29 | 2012-02-15 | 中国航空工业集团公司洛阳电光设备研究所 | Processing method of thin-wall semi-shell part |
| CN104148891A (en)* | 2014-07-03 | 2014-11-19 | 重庆一名模型有限公司 | Automobile sample piece production process |
| CN108655669A (en)* | 2018-05-18 | 2018-10-16 | 陕西测易机电设备有限公司 | A kind of processing method of space flight and aviation thin-walled parts |
| CN109318498A (en)* | 2018-08-16 | 2019-02-12 | 深圳技师学院（深圳高级技工学校） | A kind of processing method of thin-walled parts |
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