| The turn-chasing-broaching process is an important rough and semi-finish process of the crankshaft’s journal. This paper took this process and its supporting tool system as research objects, analyzed the performance of the tool system and experimentally researched the whole cutting process.The assembly precision of the tool system was analyzed and the results showed that the tool system was qualified for processing. Based on the. dimension chain theory, the assembly chain between the tool disk and the tool holder was optimized and redesigned. The related tolerance value has been amplified from12μm to24um and25μn which improved the rationality and efficiency. The dynamic assembly dimension chain principle was put forward based on the previous analysis, the main influencing factors were analyzed and a general formula was deduced.The failure forms and wear mechanism of the tool was analyzed. The C type tool was chosen as experimental subject for the orthogonal experiment of cutting life. Based on the results, the Taylor formula of cutting life was regression analyzed using the least square method. And according to the relative coefficient of processing, the cutting life models of different materials were established.A whole turn-chasing-broaching process was designed by the analysis of the process. For each kind of tool of each step, the cutting experiment was completed, then the optimal cutting parameters were settled by appropriate reference. The optimal parameters of each tool are as followed, R type tool:Vc=120m/min, f=0.35mm/r, C type tool:Vc=180m/min, f=0.35mm/r, V type tool:Vc=180m/min, f=0.3mm/r, comb type tool:Vc=260m/min, f=0.15mm/r. Not only the results of the optimal parameters but also the results of other parameters have a vital reference value of the localization of the turn-chasing-broaching process. |
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