Machining Process Optimization Of The Injector Body Based On UG And VERICUT Technology

High pressure common rail system is an important component to determine the dynamic performance of diesel engine,and the injector body is one of the three components of the fuel supply system.In this paper,combining with practical experience,the existing processing technology was analyzed,and the defects of the process were found.The reasonable process route and processing parameters were obtained through optimization,and the risk of colliding during debugging was improved through the simulation of virtual machine tool.Finally,the experimental verification was completed.(1)There is great room for improvement in the current processing technology.Parts in the processing process there are many times of clamping,turnover,repeated positioning,more dispersed process characteristics.In mass production,the quality of parts is not easy to control,and take up too much labor.Can not meet the current intelligent manufacturing,energy-saving consumption reduction initiative.(2)Optimize the processing process.According to the characteristics of the machine’s performance and structure,the process is rearranged,and the original part of milling is integrated into a turning center equipment by using the power cutter holder,so that the process becomes centralized.Based on the characteristics of double spindle and double pole tower,two optimization schemes of "one clip one top" and "balanced vehicle" are put forward for the key process.A small batch comparative test was carried out on the two turning schemes.By comparing the test results,the "balanced car" scheme was finally selected in the optimization scheme.(3)Conduct virtual trial cutting for the optimized process.Model the machine tool and parts in UG and VERICUT software,establish the coordinate system of each movement axis,and establish the movement tree of the machine tool.The parts are programmed in the UG CAM module,the cutting status of the tool and the moving parts is checked by UG in the front file of the tool rail,and the VERICUT is used to verify the correctness and interference of the program in the back file of the tool rail,so as to eliminate the hidden danger of the test cut collision.The optimized theoretical beat matches the virtual trial beat.Virtual trial cut plays an important role in shortening the debugging window period.(4)Verification and optimization of cut test.The virtual trial-cut program,tooldata and other documents are sorted out and input into the machine for trial-cut.The actual processing beat of the machine was recorded,and the actual beat was consistent with the virtual beat after the auxiliary action time was corrected.Compared with CPK value and surface roughness of key dimensions before and after optimization,the CPK capacity of the optimized process is much higher than that of the current process,and its surface quality is also better.The failure analysis of the tool in the key process shows that the failure of the tool is mainly caused by the insufficient wear resistance of the tool.After the new process production line is followed up,it is found that the new process has obvious reduction in cost from the aspects of tool consumption and labor,the product quality is improved,and the optimization effect is better.Through test and verify tracking,new equipment and process achieved ideal result,the application of the virtual try cutting technology guarantee the security of the debugging process focus brings higher accuracy stability,balance the car application could improve the ability of the key size of CPK,the optimization of cutting tool to further improve the production capacity,reduce the cost.