螺帽加工方法與工藝

　　螺(luo)(luo)(luo)帽(mao)(mao)(mao)的(de)主要加工(gong)(gong)方(fang)法(fa)(fa)是(shi)(shi)：螺(luo)(luo)(luo)帽(mao)(mao)(mao)切(qie)(qie)削(xue)(xue)(xue)(xue)(xue)：一(yi)般(ban)是(shi)(shi)指用成(cheng)(cheng)(cheng)形(xing)(xing)(xing)(xing)(xing)工(gong)(gong)具(ju)或(huo)(huo)磨具(ju)在(zai)工(gong)(gong)件上加工(gong)(gong)螺(luo)(luo)(luo)帽(mao)(mao)(mao)的(de)方(fang)法(fa)(fa)，包括車(che)削(xue)(xue)(xue)(xue)(xue)、銑(xian)削(xue)(xue)(xue)(xue)(xue)、攻絲、螺(luo)(luo)(luo)紋、磨削(xue)(xue)(xue)(xue)(xue)、旋(xuan)切(qie)(qie)等。防松(song)動(dong)螺(luo)(luo)(luo)母起源于(yu)(yu)國外，它(ta)是(shi)(shi)以特殊的(de)工(gong)(gong)程(cheng)(cheng)(cheng)塑(su)料永(yong)久的(de)附著在(zai)螺(luo)(luo)(luo)紋上，使內外螺(luo)(luo)(luo)紋在(zai)縮(suo)緊過(guo)程(cheng)(cheng)(cheng)，工(gong)(gong)程(cheng)(cheng)(cheng)塑(su)料被擠壓而產(chan)生(sheng)強大的(de)反作用力(li)，極大地增(zeng)加了內外螺(luo)(luo)(luo)紋之間的(de)摩擦力(li)，提供了對振動(dong)的(de)絕(jue)對阻(zu)力(li)。在(zai)車(che)削(xue)(xue)(xue)(xue)(xue)、銑(xian)削(xue)(xue)(xue)(xue)(xue)和(he)磨削(xue)(xue)(xue)(xue)(xue)螺(luo)(luo)(luo)帽(mao)(mao)(mao)時，工(gong)(gong)件的(de)每一(yi)圈、機(ji)床(chuang)的(de)傳動(dong)鏈(lian)確保(bao)車(che)刀(dao)、銑(xian)刀(dao)或(huo)(huo)砂輪(lun)沿工(gong)(gong)件軸向準(zhun)確、均勻(yun)地移動(dong)一(yi)條導軌。在(zai)攻絲或(huo)(huo)螺(luo)(luo)(luo)紋加工(gong)(gong)過(guo)程(cheng)(cheng)(cheng)中，刀(dao)具(ju)(絲錐或(huo)(huo)板齒)相對于(yu)(yu)工(gong)(gong)件旋(xuan)轉，預先形(xing)(xing)(xing)(xing)(xing)成(cheng)(cheng)(cheng)的(de)螺(luo)(luo)(luo)帽(mao)(mao)(mao)凹槽引導刀(dao)具(ju)(或(huo)(huo)工(gong)(gong)件)沿軸向移動(dong)。螺(luo)(luo)(luo)帽(mao)(mao)(mao)滾(gun)(gun)壓：一(yi)種(zhong)形(xing)(xing)(xing)(xing)(xing)成(cheng)(cheng)(cheng)滾(gun)(gun)壓模以產(chan)生(sheng)工(gong)(gong)件塑(su)性變形(xing)(xing)(xing)(xing)(xing)以獲得螺(luo)(luo)(luo)帽(mao)(mao)(mao)的(de)方(fang)法(fa)(fa)。與切(qie)(qie)削(xue)(xue)(xue)(xue)(xue)法(fa)(fa)相比，軋制(zhi)不是(shi)(shi)一(yi)種(zhong)金屬切(qie)(qie)削(xue)(xue)(xue)(xue)(xue)過(guo)程(cheng)(cheng)(cheng)。它(ta)不是(shi)(shi)去(qu)除金屬以形(xing)(xing)(xing)(xing)(xing)成(cheng)(cheng)(cheng)所需的(de)輪(lun)廓，而是(shi)(shi)根據(ju)滾(gun)(gun)子(zi)拉深模的(de)鏡像(xiang)形(xing)(xing)(xing)(xing)(xing)成(cheng)(cheng)(cheng)螺(luo)(luo)(luo)帽(mao)(mao)(mao)，這是(shi)(shi)一(yi)種(zhong)非切(qie)(qie)割(ge)螺(luo)(luo)(luo)帽(mao)(mao)(mao)成(cheng)(cheng)(cheng)形(xing)(xing)(xing)(xing)(xing)過(guo)程(cheng)(cheng)(cheng)。滾(gun)(gun)壓螺(luo)(luo)(luo)帽(mao)(mao)(mao)時，輥模通過(guo)移動(dong)基材(cai)(cai)將(jiang)(jiang)螺(luo)(luo)(luo)帽(mao)(mao)(mao)形(xing)(xing)(xing)(xing)(xing)狀壓入工(gong)(gong)件毛坯(pi)。由于(yu)(yu)輥柄將(jiang)(jiang)形(xing)(xing)(xing)(xing)(xing)成(cheng)(cheng)(cheng)材(cai)(cai)料錯位的(de)根部，材(cai)(cai)料將(jiang)(jiang)從(cong)徑向和(he)軸向從(cong)根部流出，軋輥的(de)形(xing)(xing)(xing)(xing)(xing)狀將(jiang)(jiang)在(zai)工(gong)(gong)件毛坯(pi)中形(xing)(xing)(xing)(xing)(xing)成(cheng)(cheng)(cheng)螺(luo)(luo)(luo)帽(mao)(mao)(mao)形(xing)(xing)(xing)(xing)(xing)狀。下圖顯示了滾(gun)(gun)壓螺(luo)(luo)(luo)帽(mao)(mao)(mao)和(he)切(qie)(qie)削(xue)(xue)(xue)(xue)(xue)螺(luo)(luo)(luo)帽(mao)(mao)(mao)的(de)微觀結構變化。

　　軋制主要用于加工外螺帽。地腳螺栓埋深和彎鉤都是為了保證螺栓與基礎的摩擦力，不至于使螺栓發生拔出破壞。地腳螺栓有固定沒有強烈振動和沖擊的設備等作用。標準件指結構、尺寸、畫法、標記等各個方面已經完全標準化，并由專業廠生產的常用的零(部)件，如螺紋件、鍵、銷、滾動軸承等等。標準化程度高，行業通用性強的機械零部件和元件，也被稱為通用件。在加工前，毛坯的直徑應大致等于螺帽的中間直徑。對于精度較高的螺帽，應根據材料性能計算和工藝試驗確定毛坯直徑的選擇。超過或低于適當直徑的螺帽將被加工成不合格的螺帽。毛坯外徑過小，不能充分流入輥模；毛坯尺寸過大，會對輥筒和輥架產生不必要的壓力，對螺帽軋制設備造成損壞。大多數滾壓螺帽是60°頂角螺帽，所使用的滾子有一個鋒利的齒頂，通常帶有弧邊，以方便材料的滲透。每顆牙齒側面的30°確保了使材料在軸向和徑向以可控制和預定的方式流動所需的力。下圖顯示了螺帽滾輪。根據軋制模具的不同，螺帽軋制可分為兩種類型：研磨線和軋制線材。
　　兩個帶(dai)螺(luo)帽(mao)(mao)齒形(xing)的(de)(de)(de)線(xian)摩擦(ca)板(ban)錯開1~2個螺(luo)距相對排列，靜(jing)極(ji)板(ban)固定(ding)，移動(dong)(dong)(dong)板(ban)沿(yan)與靜(jing)極(ji)板(ban)平行(xing)的(de)(de)(de)往(wang)復直線(xian)運動(dong)(dong)(dong)。當工件(jian)被送(song)入兩個板(ban)之間(jian)時，移動(dong)(dong)(dong)的(de)(de)(de)板(ban)向(xiang)前(qian)滾動(dong)(dong)(dong)，使表面發生塑性變(bian)形(xing)并形(xing)成螺(luo)帽(mao)(mao)。鋼絲摩擦(ca)是在鋼絲研磨(mo)機或自動(dong)(dong)(dong)車(che)床上用(yong)自動(dong)(dong)(dong)開合螺(luo)帽(mao)(mao)滾壓頭進行(xing)的(de)(de)(de)，適用(yong)于(yu)標準緊固件(jian)和其它螺(luo)帽(mao)(mao)聯軸(zhou)器的(de)(de)(de)批量(liang)生產，效率相當高，可達每(mei)分鐘50件(jian)。用(yong)這種方法加工的(de)(de)(de)螺(luo)帽(mao)(mao)外徑一(yi)般不(bu)大于(yu)25 mm，長度一(yi)般不(bu)大于(yu)100 mm。根(gen)據不(bu)同的(de)(de)(de)進給(gei)方式，將(jiang)軋線(xian)分為三種形(xing)式：軸(zhou)向(xiang)螺(luo)帽(mao)(mao)滾子從車(che)削中心(xin)尾座的(de)(de)(de)末端開始，沿(yan)工件(jian)坯料中心(xin)線(xian)移動(dong)(dong)(dong)形(xing)成螺(luo)帽(mao)(mao)。軸(zhou)向(xiang)滾子的(de)(de)(de)一(yi)般加工范圍為直徑1.5~228 mm。