Deformation of the spring after clamping and forming is a critical issue in the manufacturing process. As an elastic component, the spring is subject to more complex factors that affect its accuracy compared to rigid parts. This complexity leads to unique challenges in the production process. One of the main factors influencing the precision of spring machining is the deformation that occurs during clamping, which can result in a loss of dimensional accuracy. Additionally, springs may deform after forming or during heat treatment, further reducing their overall accuracy. Therefore, minimizing deformation during clamping, forming, and heat treatment is essential for maintaining the quality of the final product. The manufacturing process of rectangular springs typically involves heating the steel to a high temperature before processing and shaping it, or alternatively, using bar processing. However, due to the need for specialized equipment for winding and the inability to meet design specifications in terms of dimensions, bar processing is often preferred. This method allows for greater control over the shape and size of the spring. Proper heat treatment plays a vital role in reducing internal stresses caused by machining operations such as turning and grinding. By strategically placing heat treatment in the middle of the process, we can eliminate residual stresses and improve the structural stability of the spring. The cutting allowance for each machining step must be carefully controlled to ensure the desired hardness and minimize residual stress, meeting the requirements specified in the drawings. To maintain the integrity of the spring during machining and heat treatment, a practical and convenient tire clamp is essential. During turning and grinding, the clamp prevents deformation, while during heat treatment, it helps correct any distortions that may occur. Additionally, the parallel head of the spring requires a spiral plug to manage the gap between the ends, ensuring proper alignment and function. Ensuring the precision of the spring is crucial for its reliable performance. After relaxation treatment, the inner and outer circles of the spring are not ground, which helps maintain the spring's residual deformation. This approach ensures that the straightness, perpendicularity, and parallelism of the spring’s ends are maintained. Achieving a straightness error of less than 0.15, a perpendicularity of less than 0.15, and a parallelism of less than 0.10 requires careful control throughout the entire manufacturing process. Understanding the mechanism behind these errors is key to improving the verticality of the spring. Due to its slender structure, the spring naturally has some straightness errors. These errors contribute to both parallelism and perpendicularity issues at the end faces. The combination of axis linearity and end face parallelism significantly affects the verticality of the spring, making it one of the most challenging aspects to control. In response to these challenges, a specialized jig—referred to as a sleeve-type fixture—is used to grind both ends of the spring after heat treatment. Three key points must be ensured: first, the spring should be ground in a free state with axial straightness below 0.15; second, both ends should be machined relative to a single reference; and third, the grinding operation should prevent any interference from the tooling. This approach ensures consistent and accurate results throughout the process.
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