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September 17, 2003
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修复阀孔：铰刀技术

莫拉·斯塔福德

Sonnax提供各种定制铰刀和铰刀衬套，以简化磨损阀体、泵和阀的维修transmission壳体孔。每次应用可能需要对铰孔速度和进给速度进行微调，以达到适当的表面光洁度和孔径。

影响铰刀性能和铰孔质量的变量有：

  • The size of the bore being reamed.
  • 被铰孔的材料类型。
  • The amount of material being removed

基本说明

第一步是充分准备阀孔，以便正确操作。从要铰孔的孔中拆下阀门后，在溶剂箱中彻底清洁孔。清洁后，将阀/泵体水平夹紧到工作台上，使开路向上。确保不要直接夹住要铰孔的孔，因为这可能会导致变形。接下来，用煤油或丝锥等切削液填充孔™.

Some Sonnax reamers are piloted by the existing valve bore, while others require a drill jig or reamer bushing to align and guide the reamer in the bore. Before inserting the reamer, soak the fluted end of the reamer with cutting fluid. Next, insert the reamer into the bore until the reamer tip contacts the first bore to be cut.

The lead chamfer or guide tip在铰刀上有助于稳定and center the reamer. With the reamer carefully and securely positioned, use a speed handle to ream the bore in as level a manner as possible. The reaming action should be clockwise in a smooth and continuous motion, at approximately 1 to 1.5 revolutions per second. The reamer should actually pull itself through the bore, so little or no forward feed pressure should be applied to the reamer or the speed handle.

继续扩眼,直到指定的停止reamer is reached. Spin the reamer five to ten more times to allow for the removal of any excess material and for better surface finish. Using low air pressure, blow the chips free before removing the reamer from the bore.

To remove the reamer, continue turning clockwise while slowly pulling outward on the reamer. Remove any remaining debris from the bore with low air pressure and another cleaning in the solvent tank. Lubricate the bore and replacement valve with ATF. If the valve-to-bore fit is snug, repeat the reaming procedure with an air drill at 500 RPM. Once you’ve reamed a few bores and get a feel for the technique, the procedure can be fine-tuned to best suit your particular needs.

铰刀保养

切勿将铰刀向后转动或将铰刀落在金属表面或在金属表面上滚动，否则会损坏切削刃。铰孔时在铰刀上施加过大的向前力会导致表面光洁度差、材料去除不充分和零星，以及铰刀离开孔时留下材料。每次使用后，注意将切屑从铰刀中吹出。

Inspect the cutting edges of the reamer frequently for burrs, and if necessary remove them with a hone. A burr left on the cutting edge will cause rough surface finishes.

定期检查铰刀是否有磨损迹象也很重要。要寻找的磨损迹象包括：刃口磨损或磨圆、锯齿状或粗糙；铰孔难度增加，需要更大的力；表面粗糙或孔尺寸过小。如果铰刀表面粗糙或切口尺寸过小，阀门可能无法安装。此时，需要锐化或更换铰刀。

重新研磨或锐化铰刀是一个非常熟练的过程。应将铰刀带到熟悉多阶梯铰刀重磨技术的刀具/磨床车间。只有倒角浮雕应锐化，并应匹配现有的浮雕角度和宽度。在多级铰刀上，需要保持临界轴向长度，可能需要进行一些端面磨削。在任何情况下，都不能用手磨来磨铰刀。
一些有助于延长铰刀寿命并使切割更容易的提示如下：

  • 在铰刀变得很钝之前把它再磨一次
  • A well cared for reamer should get approximately 50 uses before the need for resharpening
  • 跟踪每次铰孔所需的大致时间将有助于在铰刀变钝时发出信号
  • 当一个铰刀同时切削多个孔时，进给速度将显著减慢
  • A stalled reamer will turn the cutting fluid dark in color

重要的是要记住，铰刀是一个精加工工具，应小心处理。使用后，铰刀应涂油，特别是切削刃，以防生锈。务必将铰刀单独存放在其塑料管中，以防止切割边缘出现刻痕或毛刺。



Problem
 Probable Cause
 可能的解决方案
Undersized holes
 Dull or improperly sharpened reamer
 Regrind or replace reamer.
过热
使用切削液，确保其到达所有孔并浸透铰刀。
使用适当的切削液（如：Tap Magic™).
ATF不被视为切削液。增加切削液流量。降低进给速度和/或转速
进给速度过快
检查孔入口和出口唇口是否有毛刺或未去除的余量。
降低进给速度。
孔内表面粗糙
Use speed handle for reamer rotation. Do not use a T-handle, wrenches, or ratchet.
阀门问题
检查阀芯边缘是否有划痕或毛刺。换个阀门试试。
Side loading
将阀/泵体牢固地夹在水平位置的工作台上。仅使用速度手柄。不要使用T型手柄、扳手或棘轮。
Improper reamer size
 更换铰刀。


Oversized holes
 Runout of reamer chamfer
 Regrind or replace reamer.
Dull or improperly sharpened reamer
Regrind or replace reamer.
铰刀损坏
重新研磨或更换铰刀。把铰刀放在它的保护管里。
Side loading
将阀/泵体牢固地夹在水平位置的工作台上。仅使用速度手柄。不要使用T型手柄、扳手或棘轮。
阀门问题
 Valve may be undersized. Try a different valve.


孔内表面粗糙
 铰刀钝或损坏
 Regrind or replace reamer.
Excessive feed and speed
降低进给速度和/或转速。不要将铰刀推过孔。
进给速度过快
检查孔入口和出口唇口是否有毛刺或未去除的余量。降低进给速度。
Tool marks
降低进给速度和/或转速。不要将铰刀推过孔。
排屑
Blow out chips periodically during reaming, while leaving the reamer in the bore. Increase flow of cutting fluid.
Not enough cutting fluid
 Increase flow of cutting fluid.
Poor hole preparation
 铰孔前彻底清洁孔。
错误的设备
仅使用速度手柄。不要使用T型手柄、扳手或棘轮。

Maura Stafford是Sonnax项目工程师和Sonnax TASC Force®(Technical Automotive Specialties Committee), a group of recognized industry technical specialists, transmission rebuilders and Sonnax Industries, Inc. technicians.

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