How to improve rotor finishing efficiency
Figure 1 shows an example of a rotor finishing car with a carbide turning tool. The disc insert 1 is made of cemented carbide with an outer diameter of 60 to 100 mm and an inclination of the blade of 6 to 7 degrees. The disc blade is clamped to the cutter body 2 with a hexagon socket screw 3 and a pressure plate 4. The cutter body is fixed on the spindle 5, and three rolling bearings are arranged between the spindle and the cutter seat 7, so that the spindle can freely rotate in the cutter seat. The disc turning tool is mounted on the tool holder by means of the handle 6.
The cutting edge of the disc turning tool is several times longer than that of the ordinary turning tool, and the tool wear is correspondingly reduced. Moreover, the cutting edge is rotating, which is good for guiding the cutting heat, and the service life of the tool is more than 30 times higher than that of the ordinary turning tool.
Disc turning tools can also be used on ordinary rotor finishing lathes. As shown in Fig. 2, during the machining, the bearing sleeve of the rotor 8 is supported by the positioning bushing 9 to ensure the coaxiality of the outer circumference of the core and the bearing gear. There must be a tilt angle θ between the tool and the workpiece.
The size of this angle will affect the force condition of the tool, the wear rate and the roughness of the workpiece. When θ=0°, the tool can't rely on the workpiece to rotate, and the local edge wears faster; when θ=90°, the tool and the workpiece have the same linear velocity and cannot be cut. Practice has proved that the most suitable tilt angle is 18 ° ~ 20 °, at this time the linear speed of the tool is about 25 ~ 30% of the line speed of the workpiece.
When using the disc turning tool to revolve the outer core of the rotor core, the required size can be obtained with only one pass, and the roughness is not more than 3.2. The cutting amount is 4~10 times larger than that of the ordinary turning tool, and the cutting speed can reach 250~300 m/min, which can increase the productivity by more than 4 times. For the motor rotor below the No. 5 base, the outer circumference of one rotor core per vehicle takes an average of 50 seconds.
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