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Each component in the process system, including the manufacturing error of the machine tool, the tool and the fixture, the installation error, the wear and tear in use, directly affects the machining accuracy of the workpiece. In other words, in the process of processing, the process system will produce a variety of errors, which will change the position of the tool and workpiece in the process of cutting motion and influence the machining accuracy of the parts. These errors are related to the structural state and cutting process of the process system, and the main factors causing machining errors are:
(1) the geometric error of the system
The error of processing principle
The error of the machining principle is due to the error caused by the approximate machining movement or the approximate tool profile. Because of the error in the machining principle, it is called the machining principle error. As long as the principle error is within the allowable range, the machining method is still feasible.
Geometric error of machine tool
The manufacturing error, installation error and wear in the machine tool directly affect the machining accuracy of the workpiece. Among them are the spindle rotation of machine tool, the linear movement of machine tool guide and the error of machine tool drive chain.
Manufacturing error and wear of cutting tools
The manufacturing error, installation error and wear of the tool affect the machining accuracy of the workpiece. During the cutting process, the cutting edge and blade face are strongly rubbed with the workpiece and chip, causing the tool to wear. When the tool wear reaches a certain value, the surface roughness of the workpiece increases, and the chip color and shape change, accompanied by vibration. Tool wear will directly affect cutting productivity, machining quality and cost.
Jig error
The fixture error includes positioning error, clamping error, fixture installation error and tool setting error. These errors are mainly related to the accuracy of fixture manufacturing and assembly. The positioning error of the fixture will be analyzed in detail.
The position of the workpiece in the fixture is determined by the contact between the positioning base and the locating element. However, due to the manufacturing error of the positioning base surface and the working surface of the positioning element, the actual position of each workpiece in the fixture is not consistent. After processing, the size of each workpiece must vary in size, resulting in errors. The machining error caused by the incorrect positioning of the workpiece on the fixture is called the positioning error and is expressed by delta D. It includes reference displacement error and datum non coincidence error. When using adjustment method to process a batch of workpieces, the essence of positioning error is the maximum variation of process datum in the direction of processing dimension. There is no location error in the process of cutting.
The location error is caused by the manufacturing error of the workpiece and the manufacturing error of the positioning element. The matching gap between the two parts and the process datum do not coincide with the positioning datum.
Standard non coincidence error
When the machining error is caused by the non coincidence of the positioning datum and the working procedure datum, it is called the datum non coincidence error. The size of the error is equal to the tolerance between the positioning datum and the working procedure datum, which is expressed in Delta B.
When the reference displacement error is located in the fixture, the positioning datum and the limit datum can not be reclosed because of the manufacturing tolerance and the minimum fit clearance of the positioning element in the fixture base surface of the workpiece. This makes the position of the workpiece inconsistencies and causes the error of the working size. This error is called the error. The error of the reference displacement is expressed in Delta Y. Figure 1-12a is a process diagram of circular grooves and key grooves. The working procedure is A and B. Fig. 1-12b is a schematic diagram of machining. The inner hole D of the workpiece is positioned on the cylindrical mandrel, O is the axis of the mandrel, and the C is the size of the cutter. The process datum of size A is the axis of the inner hole, and the positioning datum is also the axis of the inner hole. The two coincide, and the delta B = 0. However, because of the manufacturing tolerance and the minimum fit gap between the inner hole surface of the workpiece and the axis cylinder, the positioning datum (the axis of the workpiece hole) can not coincide with the limit reference (Axis axis). The positioning datum moves a segment of the distance relative to the limit datum, because the tool is adjusted to the position of a batch of workpiece after adjusting the position. Set no longer change (same as the limit reference position). Therefore, the position change of the positioning datum affects the size of the size A, causing error to the size A, which is the reference displacement error.
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