9 Steps Trapezoidal Screw Process
Using a whirlwind milling machine to process a trapezoidal screw can be carried out as follows:
1.Design and planning
- Carry out detailed design and process planning according to the specifications and requirements of the trapezoidal screw. Determine the screw pitch, profile angle, diameter and other parameters, as well as processing accuracy requirements.
- Select the appropriate whirling tool and tool holder system to ensure that the material and geometry of the tool can adapt to the processing requirements of the trapezoidal screw. Generally speaking, for materials with higher hardness, carbide tools can be chosen.
2.Equipment inspection and debugging
- Check whether all functions of the cyclone Whirling machine are normal, including spindle rotation, tool feed, cooling system, etc. Ensure that the accuracy and stability of the machine tool meet processing requirements.
- Install and debug the cutting tool to ensure that the cutting tool is firmly installed and has good concentricity with the machine tool spindle. Adjust the extension length and angle of the tool to match the parameters of the trapezoidal screw to be processed.
3.Artifact preparation
- Prepare the trapezoidal screw blank to be processed. Ensure that the size and quality of the blank meet the requirements and that there are no obvious defects on the surface.
- Install the screw blank on the chuck or fixture of the Whirling machine, ensuring that the installation is firm and the positioning is accurate. Special fixtures can be used to ensure the stability and accuracy of the screw during processing.
4.Parameter settings
- According to the material, size and processing requirements of the trapezoidal screw, set appropriate cutting parameters, including cutting speed, feed speed, cutting depth, etc. Generally speaking, for materials with higher hardness, the cutting speed should be appropriately reduced to reduce tool wear; the feed speed and cutting depth should be reasonably adjusted according to processing efficiency and accuracy requirements.
- Set the helix angle and direction of rotation of the Whirling machine to match the pitch and profile angle of the trapezoidal screw. Ensure that the tool can cut along the correct spiral path during machining.
5.roughing
- Start the Whirling machine for rough machining. In the roughing stage, the main purpose is to quickly remove most of the allowance and improve processing efficiency. Larger cutting depth and feed speed can be used, but care should be taken to control the cutting force to avoid tool damage or workpiece deformation.
- Regularly check the tool wear during processing and replace seriously worn tools in a timely manner to ensure processing quality and efficiency.
6.finishing
- After rough machining is completed, finish machining is performed. Reduce the cutting depth and feed speed, and increase the cutting speed to obtain higher machining accuracy and surface quality.
- Pay attention to controlling the temperature during processing to avoid workpiece deformation or tool wear due to excessive temperature. A cooling system can be used to cool the tool and workpiece and reduce the processing temperature.
7.Quality check
- After the processing is completed, the trapezoidal screw is inspected for quality. Mainly check whether the dimensional accuracy, surface roughness, tooth shape accuracy, etc. meet the design requirements. Measuring equipment such as measuring tools and profilometers can be used for measurement.
- For parts that do not meet the requirements, appropriate trimming or reprocessing will be carried out until the quality requirements are met.
8.Surface treatment
According to the use requirements of the trapezoidal screw, surface treatment is carried out, such as quenching, carburizing, chromium plating, etc., to improve the hardness, wear resistance and corrosion resistance of the screw.
9.Cleaning and packaging
- Clean the processed trapezoidal screw to remove surface oil, chips and other impurities. Cleaning agents and compressed air can be used.
- Pack the screw and take appropriate protective measures to prevent damage during transportation and storage.
In short, using a Whirling machine to process trapezoidal screws requires sufficient preparation, reasonable setting of processing parameters, strict control of quality during processing, and appropriate follow-up processing to ensure that the processed trapezoidal screws meet design requirements and usage standards.
Advantages Of Whirling Milling For Trapezoidal Screw
In the field of machinery manufacturing, the trapezoidal screw, as an important transmission component, is widely used in various equipment. As an efficient processing method, Whirling machine brings many advantages to the production of trapezoidal screws.
Efficiency
Whirling has the characteristics of high speed and high efficiency, which can greatly improve production efficiency. Compared with traditional processing methods, Whirling can complete the processing of trapezoidal screws in a shorter time, reducing production costs.
High precision
Whirling can achieve high-precision processing and ensure that the size and accuracy of the trapezoidal screw meet the requirements. The tool rotates at high speed to achieve a smoother surface and a more accurate thread shape.
Strong adaptability
Whirling can be adapted to the processing of trapezoidal screws of different materials, different diameters, and different pitches. You only need to replace the corresponding cutting tools and adjust the processing parameters to process trapezoidal screws of different specifications.
High degree of automation
Modern Whirling equipment usually has a high degree of automation and can achieve automated processing. Through programming control, automatic control of the processing process can be realized, improving production efficiency and product quality.
What are the disadvantages of Whirling for trapezoidal screw?
The disadvantages of trapezoidal screw rod processing by Whirling mainly include the following points:
1.High equipment cost
Large initial investment
- Whirling equipment is usually more expensive, and its purchase cost may be several times or more higher than traditional turning and other processing equipment. This is a huge burden for some small businesses or processing units with limited funds.
- For example, a high-performance Whirling equipment may require an investment of hundreds of thousands or even millions of yuan, while ordinary lathes and other equipment are relatively low-priced.
High maintenance costs
- The structure of Whirling equipment is relatively complex and requires high maintenance, requiring professional technicians to operate and maintain it. This also increases the maintenance cost of the equipment.
- For example, the equipment’s cutting tools need to be replaced regularly, and the cutting tools are relatively expensive. At the same time, the control system and other components of the equipment also need to be maintained and upgraded regularly to ensure the normal operation of the equipment.
2.High processing technology requirements
High skill requirements for operators
- Whirling requires operators to have a high technical level and rich experience. Operators need to be familiar with the operation methods of the equipment, the selection and adjustment of cutting tools, and the setting of processing parameters. Otherwise, processing quality problems will easily occur.
- For example, operators need to master precise tool installation and adjustment techniques to ensure that the relative position of the tool and workpiece is accurate. At the same time, cutting parameters need to be set reasonably according to different workpiece materials and processing requirements to obtain the best processing results.
Programming is difficult
- Whirling usually requires the use of CNC programming technology, and programming is relatively difficult. For some complex-shaped trapezoidal screws, the programming work is more complicated and requires professional programmers to operate.
- For example, during the programming process, multiple factors such as tool path planning, cutting parameter settings, and helix angle adjustment need to be considered to ensure processing accuracy and efficiency.
3.Limited processing range
Not suitable for small batch production
- Whirling equipment is usually suitable for mass production. For small batch production, the equipment adjustment and preparation time is long, the cost is high, and it is not economical.
- For example, for some single-piece or small-batch trapezoidal screw processing tasks, it may be more flexible and economical to use traditional turning and other processing methods.
There are certain restrictions on the shape of the workpiece
- Whirling is mainly suitable for processing cylindrical workpieces. For some trapezoidal screws with complex shapes, multiple clamping and adjustments may be required, making processing more difficult.
- For example, for some trapezoidal screws with special shapes, such as screws with special-shaped structures at the ends, Whirling may not be able to meet the requirements, and other processing methods need to be used for auxiliary processing.
4.Noise and vibration generated during processing
Noise pollution
- During the cyclone milling process, the high-speed rotation of the tool will produce loud noise, which will have a certain impact on the health of the operator and the working environment.
- For example, in some machining shops, the noise from cyclone milling equipment can exceed 80 decibels, and long-term exposure to this environment can easily lead to health problems such as hearing loss.
Vibration affects processing accuracy
- The vibration generated during whirling milling may affect the machining accuracy and surface quality. Especially for some high-precision trapezoidal screw processing tasks, vibration may cause problems such as dimensional deviation and increased surface roughness.
- For example, when processing high-precision trapezoidal screws, effective vibration reduction measures need to be taken, such as using vibration damping pads, adjusting cutting parameters, etc., to reduce the impact of vibration on the processing quality.