Drive the timely action of the outside of the spring profiler
July 28 18:00:43, 2025
The design of the wave spring surface is critical when used in electromagnetic clutches and brakes, as the shape of the curved surface significantly influences their performance. Proper selection and design of the wave spring surface are essential to ensure the clutch and brake operate with high sensitivity, precision, fatigue resistance, and a long service life. Moreover, the design must guarantee that there is no gap larger than 0.1 mm between the outer ring of the armature and the inner circle when flattened under force. The fit between the armature and its components must be precise to ensure the reliability of the system.
It is known that the wave spring has three evenly distributed waveforms along the circumference, spaced 120 degrees apart. The troughs are partially fixed, while the crests remain free. Using the symmetry principle from mechanics, one-third of the ring is simplified into a mechanical model. A concentrated load, approximately 6.66 kg, is applied at the midpoint of the outer edge along the thickness direction. One end of the third ring is fixed, and the finite element mesh is generated accordingly. Using ADINA software, displacement data for each node is calculated, showing the actual deformation of the wave spring under load. By applying symmetry, the full surface displacement data can be reconstructed, which is then processed by a custom program to prepare the mold for spring forming.
To create the machining program, the finite element data, originally in polar coordinates, must be converted into Cartesian coordinates accepted by CNC machines. Manually programming such a large dataset is impractical due to the high workload and risk of errors. Instead, the data files are read using BASIC language, allowing the generation of NC code for the CNC machine. Initially, the program processes the entire circle in steps, but this results in a rough surface due to the spacing between nodes. To meet the required surface finish, the data is refined so that the radius difference between adjacent circles is reduced to 0.25 mm. Two programs are created: one for roughing and another for finishing. The same approach is applied to the die by reversing the Z-axis direction.
The processing method and data transmission strategy depend on the size of the program. During roughing, the program is small (around 36KB), allowing it to be transferred offline. However, the finishing program is much larger (nearly 800KB), exceeding the CNC's memory capacity. Therefore, online processing is necessary, where the PC controls the machine tool in real-time, sending data as it is processed. This ensures continuous operation without interruption.
Data transmission during online processing is crucial for stability and accuracy. A point-to-point connection is used, with handshake protocols between the PC and the CNC machine via RS232. The communication software on the PC and the DNC function of the CNC system enable two-way data transfer. The process begins by opening the communication software, transferring the program file, and setting the machine to DNC mode. As the CNC buffer fills, it sends a signal to pause the PC, and once it has space, it requests more data. This cycle continues until the entire program is completed.
Processing parameters vary between roughing and finishing. During roughing, larger cutting depths and faster feed rates are used with standard milling cutters to remove material efficiently. In finishing, smaller cuts and slower feeds are applied with a ball-end mill to achieve a smooth surface. These settings ensure the final surface meets the requirements for wave spring forming.
In conclusion, using online processing technology, a wave spring forming mold can be machined on a basic CNC machine. This method provides a viable solution for automated programming and machining of complex surfaces. While it enhances the utilization of CNC tools, it is best suited for contour-based machining rather than parts requiring tight dimensional tolerances.
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