Deep hole machining plays an important role in the mechanical field. The deep hole processing is difficult, the processing workload is large, the processing environment is bad, and the guide key of the tool is particularly worn.
Problem raised
The processing technology of the original deep hole cutter of our company is: the amount of grinding of the guide key, which is to be mounted on the deep hole cutter body and then equipped with the grinding guide key. The general size is 0.02mm smaller than the nominal size of the cutter. Taking the deep hole drill as an example, the following is a description of the state of the drill bit produced in the original process as shown in Fig. 1.
The guide key of the bit body presses the hole wall under the action of the cutting force. Although there is extreme pressure lubricating oil* during drilling, the guide key and the hole wall are still in the boundary friction state, causing the guide key to wear sharply.
In response to the above problems, we applied the dynamic pressure lubrication theory to the deep hole tool guide key and achieved good results.
2. Guide key modification and parameter calculation
The original guide key structure is shown in Figure 1. First, the modified size of the guide key is explained below, according to the calculation of the minimum oil film for dynamic pressure lubrication:
h min ≥{h}=S(Rz1+Rz2) where R z1 and R z2 are the surface roughness value of the workpiece hole and the surface roughness value of the guide key, respectively, when rough and semi-fine, the bit is machined The hole roughness value can be 6.3 μm, and the fine boring hole can be 3.2 μm. The safety factor of the deep hole tool can be smaller, S=2.
Now take the drill bit as an example to calculate h min ={h}=S(R z1+R z2)=2×(6.3+0.8)=14.2(μm), because the minimum oil film thickness is 0.014 2mm, so the deep hole drill is outside the guide key. The circle size is 2hmin=0.028mm smaller than the workpiece hole.
During processing, the guide key is mounted on the tooling tire to a size smaller than the nominal size of the drill bit by 0.03 mm, as shown in Figure 2.
After grinding, the 1° bevel is ground on the bottom surface of the guide key (depending on experience). The direction is that the lubricating oil flows in from the big end and the small end flows out, as shown in Figure 3. Figure 4 is a schematic view showing the formation of a dynamic pressure oil film.
The machined guide key is attached to the bit body as shown in FIG.
3. Conclusion
With the modified guide key, the practice has proved that the wear of the deep hole cutter is greatly reduced and the tool life is improved.
Metal processing online noun explanation:
Extreme Pressure Lubricant: A lubricant that contains extreme pressure additives that can withstand heavy loads and shock loads and reduce mechanical wear. Particularly suitable for use in extreme pressure lubrication. For example, hyperbolic gear oil and industrial gear oil are extreme pressure lubricants, and internal combustion engine oils should also have certain extreme pressure performance.
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