Research on the manufacturing error control of the inner cone of the threaded cartridge relief valve sleeve
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摘要: 螺紋插裝式溢流閥閥套精加工采用碳氮共滲后磨削的制造工藝，內錐面的形位誤差會影響溢流閥的使用壽命和靜動態特性，制造過程需要精準控制內錐面的誤差。通過對工藝分析建立制造誤差模型并應用研究，由此獲得內錐面自身角度的合理誤差范圍，以及內錐角誤差與磨削量之間的變化關系。根據閥套結構特點設計專用的檢測裝置，并對檢測原理和測量誤差進行分析，通過誤差校對提高檢測精度。對熱處理后的閥套進行軸向尺寸分組，并采用基準統一原則，保證磨削制造精度的穩定性。根據檢測原理和誤差模型對試磨件進行誤差計算，并據此調整磨削參數，使制造誤差合格；后續制造時采用檢測裝置快速測量閥套的密封圓軸向尺寸，使制造誤差均落在控制范圍內，保證批量生產的可控性。研究表明，基于某型溢流閥的設計及工藝參數，內錐面自身角度的實際制造誤差控制以±0.8°為宜，對應的密封圓軸向最大磨削公差為0.186 mm、修正后的最小磨削公差為0.075 mm；實驗驗證了誤差模型的準確性，所述檢測方法的角度測量誤差為0.06°、密封圓軸向尺寸測量誤差為2 μm，因角度測量誤差帶來的最大、最小磨削量范圍偏差可通過內錐角實際制造誤差的收縮進行補償；所研究的理論與方法也為其他內錐面的制造控制及逆向工程提供了系統的方法。Abstract: The precision machining of the threaded cartridge relief valve sleeve is a manufacturing process of grinding after carbonitriding. The shape and position error of inner cone will affect the service life and static and dynamic characteristics of the relief valve. This requires the need of manufacturing process to accurately control the error of the inner cone. Based on the process analysis, a manufacturing error model was established and applied to obtain a reasonable error range of the inner cone angle and to determine the relationship between the inner cone angle error and the grinding amount. According to the structural characteristics of the valve sleeve, a special detection device was designed and the detection principle and measurement error were analyzed to improve the detection accuracy through error proofreading. After heat treatment, the valve sleeve was divided into axial size groups and the unified principle of datum was adopted to ensure the stability of grinding accuracy. According to the detection principle and error model, the error calculation of the grinding test piece was carried out, and the grinding parameters were adjusted accordingly to make a qualified manufacturing error. In the subsequent manufacturing, the axial dimension of the detection sealing circle of the valve sleeve is quickly measured by the detection device, so that the manufacturing error falls within the control range, ensuring the controllability of the batch production. Based on the design and process parameters of a relief valve, results reveal that the control error of the inner cone’s own angle should be ±0.8°. The corresponding maximum grinding tolerance value of the axial direction of the sealing circle is 0.186 mm, while the corrected minimum grinding tolerance is 0.075 mm. Through experiments, the accuracy of the error model is verified. The angle measurement error of the detection method is 0.06°, while the measurement error of the axial dimension of the sealing circle is 2 μm. The deviation of the maximum grinding amount and the minimum grinding amount range caused by the angle measurement error is compensated by the shrinkage of the actual manufacturing error of the inner cone angle. The theory and method also provide a systematic process for manufacturing control and reverse engineering of the other inner cone.
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Key words:
- relief valve /
- thread cartridge /
- valve sleeve /
- inner cone /
- inner cone angle /
- manufacturing error
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圖 1 閥套閥芯裝配圖
Figure 1. Assembly drawing of the valve sleeve and valve core
1—Valve sleeve; 2—Valve spool; 3—Valve block; N—Inner cone; W—Outer cone; k—Sealing line; d0—Matching circle diameter; d1—Seal circle diameter; Dp—Oil inlet diameter; F1—Charge spring pressure; F2—Return spring pressure
圖 2 閥套結構圖
Figure 2. Structure of the valve sleeve
α—Inner cone angle of valve sleeve; L0—Positioning size of sealing line; L1—Size of the datum shift; y—Contact seal section; e—Base level of transfer; h—Positioning reference plane; D1—Contact seal diameter; Di—Great circle of cone; D0—Match the diameter of the inner hole
圖 3 角度偏差分析原理圖
Figure 3. Schematic of angle deviation analysis
θ—Lower deviation angle; β—Upper deviation angle; Dc—Center circle diameter; α/2—Half angle of inner cone; ζ1—Maximum grind amount in normal direction; λ1—Axial dimension corresponding to the maximum normal grinding amount; ζ2—Sealing circle normal grinding amount; λ2—Axial grinding amount of seal circle; La—Axial position of seal circle before grinding; Lb—Axial position of seal circle after grinding
圖 7 角度檢測裝置結構圖
Figure 7. Structure of the angle detection device
r—Acute angle of contact; L2—Length of the tool to measure the angle; dt—Diameter of support circle; d2—Diameter of the outer circle of the inspection tool; d3—Small circle diameter of detection; d4—Large circle diameter of detection
圖 8 磨削量檢測裝置結構圖
Figure 8. Structure of the grinding quantity detection device
L3—Length of grinding gauge; d5—Sealing circle diameter of detection
圖 9 浮動支撐結構圖
Figure 9. Floating support structure drawing
μ—Floating support interference; ε—Amount of clearance of the retaining ring
圖 10 角度檢測原理圖
Figure 10. Schematic of angle detection
δ1—Length of the opposite side of the half angle; δ2—Adjacent side length of half-angle; α′/2—Actual half angle; L4—Large circle detection axial length; L5—Small circle detection axial length
圖 11 檢測示意圖
Figure 11. Measurement diagram
1—Workbench; 2—Height ruler; 3—Dial indicator
圖 12 測量誤差因素。（a）兩軸傾斜偏移；（b）兩端面不平行
Figure 12. Factors of measurement error: (a) two-axis tilt offset; (b) two ends are not parallel
表 1 溢流閥計算參數
Table 1. Overflow valve calculation parameters
Parameter Value Great circle of cone, Di/mm 10.43 Oil inlet diameter, Dp/mm 6 Contact seal diameter, D1/mm 9.25 Inner cone angle of valve sleeve, α/(°) 65 Maximum grind amount in normal direction, ζ1/mm 0.1 
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表 2 檢測數據
Table 2. Test data
Parameter/mm Value Small circle diameter of detection, d3 6.573 Large circle diameter of detection, d4 9.919 Sealing circle diameter of detection, d5 9.252 Angle fixture length, L2 46.813 Length of grinding gauge, L3 45.233 Large circle detection axial length, L4 48.145 Small circle detection axial length, L5 50.750 Axial position of seal circle before grinding, La 48.692 Axial position of seal circle after grinding, Lb 48.653
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