400方車銑轉(zhuǎn)復(fù)合滑枕設(shè)計
400方車銑轉(zhuǎn)復(fù)合滑枕設(shè)計,400方車銑轉(zhuǎn)復(fù)合滑枕設(shè)計,方車銑轉(zhuǎn),復(fù)合,設(shè)計
附錄A
盡管復(fù)合加工具有常規(guī)單一加工無法比擬的優(yōu)勢，
Key Technology and Application Prospect of Turning/Milling Machining
One, overview
加工效率與精度是金屬加工領(lǐng)域追求的永恒目標(biāo)。隨著數(shù)控技術(shù)、計算機(jī)技術(shù)、機(jī)床技術(shù)以及加工工藝技術(shù)的不斷發(fā)展，傳統(tǒng)的加工理念已不能滿足人們對加工速度、效率和精度的要求。在這樣的背景下，復(fù)合加工技術(shù)應(yīng)運(yùn)而生。一般來說，復(fù)合加工是指在一臺加工設(shè)備上能夠完成不同工序或者不同工藝方法的加工技術(shù)的總稱。目前的復(fù)合加工技術(shù)主要表現(xiàn)為2種不同的類型，一種是以能量或運(yùn)動方式為基礎(chǔ)的不同加工方法的復(fù)合；另一種是以工序集中原則為基礎(chǔ)的、以機(jī)械加工工藝為主的復(fù)合，車銑復(fù)合加工是近年來該領(lǐng)域發(fā)展最為迅速的加工方式之一。
The machining efficiency and precision is the eternal pursuit of the field of metal processing. With the continuous development of numerical control technology, computer technology, machine tool technology and processing technology, processing the traditional concept has been unable to meet the requirement for the processing speed, efficiency and accuracy. In this context, emerge as the times require complex processing technology. In general, composite processing refers to those processing technology is able to accomplish different processes or different process in a processing equipment. Composite processing technology at present mainly 2 types, one is the composite of different processing methods on energy or movement based; another is the process principle as the foundation, the machining process based composite, car milling compound machining is in recent years the development of one of the most processing method of rapid.
目前的航空產(chǎn)品零件突出表現(xiàn)為多品種小批量、工藝過程復(fù)雜，并且廣泛采用整體薄壁結(jié)構(gòu)和難加工材料，因此制造過程中普遍存在制造周期長、材料切除量大、加工效率低以及加工變形嚴(yán)重等瓶頸。為了提高航空復(fù)雜產(chǎn)品的加工效率和加工精度，工藝人員一直在尋求更為高效精密的加工工藝方法。車銑復(fù)合加工設(shè)備的出現(xiàn)為提高航空零件的加工精度和效率提供了一種有效解決方案。
The aviation product parts currently outstanding performance for multi variety and small batch, complicated process, and is widely used in thin wall structure and difficult to cut materials, so the manufacturing process prevalent long manufacturing cycle, material removal volume, low machining efficiency and machining deformation serious bottleneck. In order to improve the machining efficiency and precision of aviation complex products, technical personnel have been seeking more processing method of high precision. The car milling compound machining equipment provides an effective solution to improve the precision and efficiency of aviation parts.
與常規(guī)數(shù)控加工工藝相比，復(fù)合加工具有的突出優(yōu)勢主要表現(xiàn)在以下幾個方面。
Compared with the conventional CNC machining process, highlight the advantages of composite processing is mainly manifested in the following aspects.
（1）縮短產(chǎn)品制造工藝鏈，提高生產(chǎn)效率。
(1) to shorten the product manufacturing process chain, improve production efficiency.
車銑復(fù)合加工可以實(shí)現(xiàn)一次裝卡完成全部或者大部分加工工序，從而大大縮短產(chǎn)品制造工藝鏈。這樣一方面減少了由于裝卡改變導(dǎo)致的生產(chǎn)輔助時間，同時也減少了工裝卡具制造周期和等待時間，能夠顯著提高生產(chǎn)效率。
Car milling compound machining can achieve a card to complete all or most of the machining process, thus greatly shorten the product manufacturing process chain. So on the one hand, reduce the clamping change in the auxiliary production time, but also reduce the fixture manufacturing cycle and waiting time, can significantly improve production efficiency.
（2）減少裝夾次數(shù)，提高加工精度。裝卡次數(shù)的減少避免了由于定位基準(zhǔn)轉(zhuǎn)化而導(dǎo)致的誤差積累。同時，目前的車銑復(fù)合加工設(shè)備大都具有在線檢測的功能，可以實(shí)現(xiàn)制造過程關(guān)鍵數(shù)據(jù)的在位檢測和精度控制，從而提高產(chǎn)品的加工精度。
(2) reduce clamping times, improve the machining accuracy. Clamp times to reduce the accumulation of errors due to the locating datum transformation. At the same time, the current car milling compound machining equipment mostly with online detection function, can realize the detection and control precision in the manufacturing process of critical data, so as to improve the product processing precision.
（3）減少占地面積，降低生產(chǎn)成本。雖然車銑復(fù)合加工設(shè)備的單臺價格比較高，但由于制造工藝鏈的縮短和產(chǎn)品所需設(shè)備的減少，以及工裝夾具數(shù)量、車間占地面積和設(shè)備維護(hù)費(fèi)用的減少，能夠有效降低總體固定資產(chǎn)的投資、生產(chǎn)運(yùn)作和管理的成本。
(3) reduce the occupied area, reduces the production cost. Although the car milling compound machining equipment of single price is relatively high, but due to the reduction of the manufacturing process chain is shortened and the products required equipment, and fixtures, reducing the occupied area and the number of workshop equipment maintenance cost, can effectively reduce the overall fixed asset investment, operation and management costs.
The key technologies of the two, composite processing
盡管復(fù)合加工具有常規(guī)單一加工無法比擬的優(yōu)勢，但實(shí)際上目前在航空制造領(lǐng)域里車銑復(fù)合加工的利用率并未得到充分發(fā)揮。其關(guān)鍵原因在于車銑復(fù)合加工在航空制造領(lǐng)域的應(yīng)用時間還比較短，適用于航空零件結(jié)構(gòu)工藝特性的車銑復(fù)合加工工藝、數(shù)控編程技術(shù)、后置處理以及仿真技術(shù)尚處于摸索階段。為了充分發(fā)揮車銑復(fù)合加工設(shè)備的效能，提高產(chǎn)品的加工效率和精度，必須全面攻克和解決上述關(guān)鍵基礎(chǔ)，并實(shí)現(xiàn)集成化應(yīng)用。
Although the composite processing can not compared with the conventional single processing advantages, but at present in the field of aviation manufacturing using car milling compound machining rate have not been brought into full play. The key reason is that the application time car milling compound machining in aviation manufacturing industry is relatively short, and is applicable to the structural characteristics of aviation parts machining process, NC programming, post processing and simulation technology is still in the exploratory stage. In order to give full play to car milling compound machining equipment efficiency, improve processing efficiency and accuracy of product, must overcome and solve the key, and to realize the integrated application.
1、車銑復(fù)合加工的工藝技術(shù)
The processing technology 1, car milling compound machining
與常規(guī)加工設(shè)備不同的是，一臺車銑復(fù)合加工中心實(shí)際上相當(dāng)于一條生產(chǎn)線。如何根據(jù)零件工藝特性和車銑復(fù)合加工的工藝特點(diǎn)制定合理的工藝路線、裝卡方法和選用合理的刀具是實(shí)現(xiàn)高效精密加工的關(guān)鍵。工序集中是復(fù)合加工最為鮮明的工藝特點(diǎn)。因此，科學(xué)合理的工藝路線是提高車銑復(fù)合加工效率和精度的關(guān)鍵因素。以瑞士寶美公司的S192F銑車復(fù)合加工中心為例，該機(jī)床具有五軸銑、車削、鏜削、鉆孔、鋸斷以及自動進(jìn)料等功能，采用FANUC 31i數(shù)控系統(tǒng)，具有刀矢平滑、超強(qiáng)前瞻、高速插補(bǔ)等功能，特別適合軸類、回轉(zhuǎn)類等零件的高速精密加工。在航空葉輪加工中，該加工中心具有突出的優(yōu)勢。當(dāng)采用棒料作為葉輪毛坯時，常規(guī)的葉輪加工工藝路線首先利用數(shù)控車床車削葉輪外部輪廓，然后精車加工基準(zhǔn)；在此基礎(chǔ)上利用五軸數(shù)控加工中心進(jìn)行開槽、粗加工、半精加工以及型面和輪轂的精加工；最后在五軸加工中心或鉆孔設(shè)備上進(jìn)行孔加工。而采用S192F銑車加工中心不僅可以通過一次裝卡完成上述工藝的全部加工，而且當(dāng)采用棒料進(jìn)行加工時還可以通過鋸斷、自動送料等功能實(shí)現(xiàn)葉輪的批量加工，整個過程無需人工干預(yù)可以全部自動完成。其工藝路線的設(shè)置可采用如下方式：主軸裝卡棒料→粗車葉輪外部輪廓→精車外部輪廓→五軸銑削開槽→流道粗加工→流道半精加工→流道精加工→鉆孔→背主軸裝卡→車削葉輪底部平面→鉆孔?？梢钥闯?，一次裝卡即完成全部葉輪加工工序，加工效率及精度可以得到大幅提高。
Different from the conventional processing equipment, a car milling compound machining center is actually equivalent to a production line. According to the process characteristics of parts machining process characteristics and the reasonable process route, clamping method and selecting tool is the key to realize high precision machining. The process is the most distinct characteristics of the composite processing technology. Therefore, a scientific and reasonable process route is the key factor to improve the efficiency and precision of machining. The S192F milling Swiss baomei, compound machining center as an example, the machine tool has five axis milling, turning, boring, drilling, sawing and automatic feeding function, using FANUC 31I numerical control system, with cutter vector smoothing, super prospective, high speed interpolation function, especially suitable for shaft, rotary type and other parts of the high-speed precision machining. In the air impeller machining, the machining center has a prominent advantage. When the bar as the impeller impeller rough machining process route, the first use of CNC lathe turning impeller outer contour, and then machining fine car benchmark; finish machining based on slotted, make use of the five axis CNC machining center roughing, semi finishing and surface and wheel hub; the last hole machining on the five axis machining center of drilling equipment. While the use of S192F milling machining center can not only by processing a card to complete the process, and when the bar material processing can also through cutting, automatic feeding function realization of batch processing of the impeller, the whole process needs no manual intervention can be done automatically. The process of setting can be as follows: spindle clamping rod material, coarse to fine car impeller outer contour outline, five axis milling groove, machining, channel to channel semi finishing finishing, hole drilling, the back spindle clamping, turning impeller bottom plane, drilling. As can be seen, a card to complete the processing, the processing efficiency and accuracy can be greatly improved.
對于具有雙刀架的車銑加工中心，雙刀塔的設(shè)備都具有雙通道的控制系統(tǒng)，上下刀架可單獨(dú)控制，同步加工可以通過代碼中的同步
For turning and milling machining center with twin turret, control system of double knife tower equipment with dual channel, upper and lower cutter can be separately controlled synchronous processing, can be synchronized in the code。
NC programming technology 2, car milling compound machining
車銑復(fù)合加工技術(shù)的發(fā)展，也對數(shù)控編程技術(shù)提出了更高的要求，這也是制約車銑復(fù)合加工設(shè)備在實(shí)際生產(chǎn)應(yīng)用中的一個瓶頸環(huán)節(jié)。由于車銑復(fù)合加工投入實(shí)際生產(chǎn)的應(yīng)用時間較短，在沒有專業(yè)的復(fù)合加工解決方案的情況下，通常是利用通用CAM軟件規(guī)劃出部分加工程序，然后工藝人員再對程序進(jìn)行手工整合，以滿足復(fù)合加工機(jī)床對加工程序的要求。這種解決方法對工藝人員的要求非常高。與傳統(tǒng)的數(shù)控編程技術(shù)相比，車銑復(fù)合加工的程序編制難點(diǎn)主要體現(xiàn)在以下幾個方面。
Development of turn milling technology, also put forward higher requirements on the NC programming technology, which is restricted to car milling compound machining equipment in actual production application a bottleneck. Because the car milling compound machining in actual production application time is short, in the absence of composite processing professional solution for the case, often using the general CAM software programming part program, and then process again to procedures manual integration, so as to meet the requirements of compound processing machine tool for processing program. This very high resolution request for technology personnel. Compared with the traditional NC programming technology, programming difficulty turning milling compound machining is mainly reflected in the following aspects.
（1）工藝種類繁雜。對于工藝人員來說，不僅要能掌握數(shù)控車削、多軸銑削、鉆孔等多種加工方式的編程方法，而且對于工序間的銜接與進(jìn)退刀方式需要準(zhǔn)確界定。因此在進(jìn)行數(shù)控編程時，需要對當(dāng)前工序加工完成后的工序模型和加工余量的分布有直觀的認(rèn)識，以便于下一道工序的程序編制和進(jìn)退刀的設(shè)置。
(1) the process of various. For technical personnel, not only to master the programming method of NC turning, milling, drilling and other multi axis machining methods, but also for the connection between processes and advance and retract mode requires accurate definition. Therefore in the NC programming, need distribution on the process model and the process of machining allowance after completion of an intuitive understanding, to facilitate the next step of the program and the advance and retreat knife set.
（2）程序編制過程中的串并行順序的確定必須嚴(yán)格按照工藝路線確定。許多零件在車銑復(fù)合加工中心上加工時可實(shí)現(xiàn)從毛料到成品的完整加工，因此加工程序的編制結(jié)果必須同工藝路線保持一致。同時，對于多通道并行加工也需要在數(shù)控加工程序編制的過程中進(jìn)行綜合考慮?？梢?，為實(shí)現(xiàn)高效的復(fù)合加工應(yīng)該發(fā)展工藝-編程-仿真一體化的工藝解決方案。
(2) the program in order to determine the parallel string must be in strict accordance with the process route is determined. Many parts in car milling compound machining center can realize complete machining from the blank to finished products, thus making program must be consistent with the results of process route. At the same time, for the multiply-channel parallel processing also need to be considered in the process of NC programming. Visible, should process development process - programming simulation integration solution for composite processing to achieve efficient.
(3）對于車銑復(fù)合加工的某些功能，目前的通用CAM軟件尚不支持。與常規(guī)單臺設(shè)備加工相比，車銑復(fù)合加工具備的機(jī)床運(yùn)動和加工功能要復(fù)雜的多，目前的通用CAM軟件尚不足以完全支持這些先進(jìn)功能的程序編制，如在線測量、鋸斷、自動送料、尾座控制等。因此，利用通用CAM軟件編制出來的程序仍然需要大量的手工或交互的方式才能應(yīng)用于自動化的車銑復(fù)合加工。
(3) for some function car milling compound machining, general CAM software at present is not supported. Compared with the conventional machining equipment, machine tool motion and processing functions car milling compound machining has a much more complex, general CAM software at present is still not enough to fully support these advanced features of the program, such as online measuring, sawing, automatic feeding, tailstock control etc.. Therefore, car milling compound machining using general CAM software compiled program still needs a lot of manual or interactive mode can be applied in automation.
（4）加工程序的整合。目前通用CAM軟件編制完成后的NC程序之間是相互獨(dú)立的，要實(shí)現(xiàn)車銑復(fù)合這樣復(fù)雜的自動化完整加工，需要對這些獨(dú)立的加工程序進(jìn)行集成和整合。這種整合必須以零件的工藝路線為指導(dǎo)，首先確定出哪些程序是并行的，然后對不同工藝方法的加工順序進(jìn)行確定，并給出準(zhǔn)確的換刀、裝卡更換、基準(zhǔn)轉(zhuǎn)化以及進(jìn)退刀指令等。
(4) the integration process. At present complete general CAM software after the NC procedure is independent of each other, in order to realize the automation of complete machining of composite milling such complex, the need for integration and integration of these independent processing program. This integration must be part of the process route as a guide, first determine which programs are parallel, then the processing sequence of different methods were determined, and accurate tool change, card replacement, datum transformation and advance and retract instruction etc..
可以看出，車銑復(fù)合加工數(shù)控程序編制難度非常大，而目前的通用CAM軟件用于車銑復(fù)合加工仍然存在很多缺陷和不足。為彌補(bǔ)這些不足，在現(xiàn)有通用CAD/CAM軟件的基礎(chǔ)上開發(fā)適用于產(chǎn)品工藝和復(fù)合加工設(shè)備的專用編程系統(tǒng)是一種更為現(xiàn)實(shí)的解決方案。這一方面降低了軟件購置的重復(fù)投資，同時也能避免由于編程平臺不統(tǒng)一而造成的工藝知識不能重用、人員配置復(fù)雜等缺陷。
As can be seen, car milling Compound Machining NC programming is very difficult, and in general CAM software currently used for car milling compound machining still exist many defects and shortcomings. To compensate for these shortcomings, special programming system based on existing on general CAD/CAM software development for product process and composite processing equipment is a more realistic solution. On the one hand, reduces repeated investment software purchase, but also can avoid the resulting not unified programming platform of process knowledge cannot be reused, staffing complex defects.
3 、車銑復(fù)合加工的后置處理技術(shù)
Post processing technology 3, car milling compound machining
與數(shù)控編程技術(shù)相對應(yīng)，車銑復(fù)合加工由于工藝方法復(fù)雜、運(yùn)動部件多等原因，從而對目前的后置處理軟件及技術(shù)提出了更高的要求。與常規(guī)數(shù)控設(shè)備相比，其后置處理的難點(diǎn)主要體現(xiàn)在以下幾個方面。
And the numerical control programming technology should be relative, car milling compound machining due to process complex, moving parts much wait for a reason, and put forward the higher request to the post processing software and technology at present. Compared with the conventional numerical control equipment, and its post processing difficulty is mainly reflected in the following aspects.
（1）不同工序間的銜接運(yùn)動要求嚴(yán)格準(zhǔn)確。由于在車銑復(fù)合設(shè)備上進(jìn)行的加工工藝種類繁多，因此在當(dāng)前工序加工完成之后必須及時、準(zhǔn)確地完成加工方式、刀具、運(yùn)動部件的自動切換，以保證加工過程的正確和安全。為了達(dá)到這個目的，一方面要求設(shè)置合理的進(jìn)退刀方式以及自動換刀、冷卻液開和停的時機(jī)，另外更為重要的是在進(jìn)行當(dāng)前工序加工時需要設(shè)定其他非運(yùn)動部件所處的位置。這樣才能避免機(jī)床在換刀和加工過程中運(yùn)動部件與非運(yùn)動部件之間的碰撞，確保加工過程安全穩(wěn)定。
(1) link motion in different process requirements strictly. As the processing technology were in turn milling equipment is various, so after the current process manufacturing process must be timely, accurately complete automatic switching process, tool, the moving parts of the machining process, to ensure proper and safe. In order to achieve this goal, a hand setting reasonable advance and retract and timing automatic tool change, coolant and stop, and more importantly in the process need to configure the other non moving parts location. In order to avoid collision between the machine movement in the tool change and processing components and non moving parts, to ensure the safe and stable machining process.
（2）需要對工藝順序和數(shù)控程序進(jìn)行自動判定。由于復(fù)合加工中工藝路線相對較長，依靠人工去對后置完成后的NC代碼進(jìn)行組織和集成不僅效率低而且也容易導(dǎo)致錯誤的發(fā)生。理想的解決方法是在后置處理過程中能夠?qū)庸ろ樞蚝偷段晃募刑N(yùn)含的工藝方法進(jìn)行自動判定，并能在后置處理完成后的NC代碼中自動保持。為此，數(shù)控編程完成后的刀位文件信息中不僅需要包含相應(yīng)的工藝方法、刀位信息，還需要包含對應(yīng)的加工順序、所采用的刀具種類和編號，這樣才能在后置處理的過程中達(dá)到工藝順序、工藝方法和刀具的自動判定。
(2) the need for a process sequence and NC program automatically judge. The process route of complex machining is relatively longer, rely on artificial to the post after the completion of the NC code organization and integration is not only the low efficiency but also easily lead to mistakes. The ideal solution is to process contains the processing order and the cutter location file in automatically judge during the post process, and in the post processing after the completion of the NC code automatically maintain. Therefore, the NC programming after the completion of the cutter location file information needs not only contains the process method, the cutter location information, also need to tool type and number contained processing sequence, corresponding to the sequence of the process, so as to achieve, in the process of post processing in process method and tool automatically.
不同加工方式的后置處理技術(shù)。車銑復(fù)合加工的后置處理程序不僅要求能夠?qū)崿F(xiàn)多軸數(shù)控銑削、車削、鉆削加工的后置處理，還要能夠?qū)崿F(xiàn)鋸斷、自動進(jìn)料、尾座控制以及程序循環(huán)調(diào)用等功能，車銑復(fù)合加工的后置處
Post processing technology of different processing methods. Post processing program car milling compound machining requires not only the realization of multiply axis NC milling, turning, drilling and post processing, but also can realize the cutting, automatic feeding, tailstock control and program loop calls the function, post office car milling compound machining.
Four, the conclusion
目前的復(fù)合加工裝備正朝著更大工藝范圍、更高效率、大型化以及模塊化的方向發(fā)展。航空產(chǎn)品制造領(lǐng)域一直是先進(jìn)制造技術(shù)發(fā)揮作用的重要舞臺，隨著航空產(chǎn)品更新?lián)Q代速度的日益加快，工序分散的加工設(shè)備將逐漸被工序集中的柔性自動化裝備所取代，這為復(fù)合加工技術(shù)提供了更為廣闊的發(fā)展和應(yīng)用空間。
Composite processing equipment is currently moving toward greater scope, process more efficient, large-scale and modular development direction. Manufacturing aerospace products has always been an important stage of advanced manufacturing technology play a role, along with the aviation products renewal speed is accelerating, flexible automation equipment processing equipment dispersed process will gradually be replaced by this process, composite processing technology provides more wider space for the development and application.
附錄B
車銑復(fù)合加工的關(guān)鍵技術(shù)與應(yīng)用前景
一、 概述
加工效率與精度是金屬加工領(lǐng)域追求的永恒目標(biāo)。隨著數(shù)控技術(shù)、計算機(jī)技術(shù)、機(jī)床技術(shù)以及加工工藝技術(shù)的不斷發(fā)展，傳統(tǒng)的加工理念已不能滿足人們對加工速度、效率和精度的要求。在這樣的背景下，復(fù)合加工技術(shù)應(yīng)運(yùn)而生。一般來說，復(fù)合加工是指在一臺加工設(shè)備上能夠完成不同工序或者不同工藝方法的加工技術(shù)的總稱。目前的復(fù)合加工技術(shù)主要表現(xiàn)為2種不同的類型，一種是以能量或運(yùn)動方式為基礎(chǔ)的不同加工方法的復(fù)合；另一種是以工序集中原則為基礎(chǔ)的、以機(jī)械加工工藝為主的復(fù)合，車銑復(fù)合加工是近年來該領(lǐng)域發(fā)展最為迅速的加工方式之一。
目前的航空產(chǎn)品零件突出表現(xiàn)為多品種小批量、工藝過程復(fù)雜，并且廣泛采用整體薄壁結(jié)構(gòu)和難加工材料，因此制造過程中普遍存在制造周期長、材料切除量大、加工效率低以及加工變形嚴(yán)重等瓶頸。為了提高航空復(fù)雜產(chǎn)品的加工效率和加工精度，工藝人員一直在尋求更為高效精密的加工工藝方法。車銑復(fù)合加工設(shè)備的出現(xiàn)為提高航空零件的加工精度和效率提供了一種有效解決方案。
與常規(guī)數(shù)控加工工藝相比，復(fù)合加工具有的突出優(yōu)勢主要表現(xiàn)在以下幾個方面。
1）縮短產(chǎn)品制造工藝鏈，提高生產(chǎn)效率。
車銑復(fù)合加工可以實(shí)現(xiàn)一次裝卡完成全部或者大部分加工工序，從而大大縮短產(chǎn)品制造工藝鏈。這樣一方面減少了由于裝卡改變導(dǎo)致的生產(chǎn)輔助時間，同時也減少了工裝卡具制造周期和等待時間，能夠顯著提高生產(chǎn)效率。
2）減少裝夾次數(shù)，提高加工精度。裝卡次數(shù)的減少避免了由于定位基準(zhǔn)轉(zhuǎn)化而導(dǎo)致的誤差積累。同時，目前的車銑復(fù)合加工設(shè)備大都具有在線檢測的功能，可以實(shí)現(xiàn)制造過程關(guān)鍵數(shù)據(jù)的在位檢測和精度控制，從而提高產(chǎn)品的加工精度。
3）減少占地面積，降低生產(chǎn)成本。雖然車銑復(fù)合加工設(shè)備的單臺價格比較高，但由于制造工藝鏈的縮短和產(chǎn)品所需設(shè)備的減少，以及工裝夾具數(shù)量、車間占地面積和設(shè)備維護(hù)費(fèi)用的減少，能夠有效降低總體固定資產(chǎn)的投資、生產(chǎn)運(yùn)作和管理的成本。
二、復(fù)合加工的關(guān)鍵技術(shù)
盡管復(fù)合加工具有常規(guī)單一加工無法比擬的優(yōu)勢，但實(shí)際上目前在航空制造領(lǐng)域里車銑復(fù)合加工的利用率并未得到充分發(fā)揮。其關(guān)鍵原因在于車銑復(fù)合加工在航空制造領(lǐng)域的應(yīng)用時間還比較短，適用于航空零件結(jié)構(gòu)工藝特性的車銑復(fù)合加工工藝、數(shù)控編程技術(shù)、后置處理以及仿真技術(shù)尚處于摸索階段。為了充分發(fā)揮車銑復(fù)合加工設(shè)備的效能，提高產(chǎn)品的加工效率和精度，必須全面攻克和解決上述關(guān)鍵基礎(chǔ)，并實(shí)現(xiàn)集成化應(yīng)用。
1、車銑復(fù)合加工的工藝技術(shù)
與常規(guī)加工設(shè)備不同的是，一臺車銑復(fù)合加工中心實(shí)際上相當(dāng)于一條生產(chǎn)線。如何根據(jù)零件工藝特性和車銑復(fù)合加工的工藝特點(diǎn)制定合理的工藝路線、裝卡方法和選用合理的刀具是實(shí)現(xiàn)高效精密加工的關(guān)鍵。工序集中是復(fù)合加工最為鮮明的工藝特點(diǎn)。因此，科學(xué)合理的工藝路線是提高車銑復(fù)合加工效率和精度的關(guān)鍵因素。以瑞士寶美公司的S192F銑車復(fù)合加工中心為例，該機(jī)床具有五軸銑、車削、鏜削、鉆孔、鋸斷以及自動進(jìn)料等功能，采用FANUC 31i數(shù)控系統(tǒng)，具有刀矢平滑、超強(qiáng)前瞻、高速插補(bǔ)等功能，特別適合軸類、回轉(zhuǎn)類等零件的高速精密加工。在航空葉輪加工中，該加工中心具有突出的優(yōu)勢。當(dāng)采用棒料作為葉輪毛坯時，常規(guī)的葉輪加工工藝路線首先利用數(shù)控車床車削葉輪外部輪廓，然后精車加工基準(zhǔn)；在此基礎(chǔ)上利用五軸數(shù)控加工中心進(jìn)行開槽、粗加工、半精加工以及型面和輪轂的精加工；最后在五軸加工中心或鉆孔設(shè)備上進(jìn)行孔加工。而采用S192F銑車加工中心不僅可以通過一次裝卡完成上述工藝的全部加工，而且當(dāng)采用棒料進(jìn)行加工時還可以通過鋸斷、自動送料等功能實(shí)現(xiàn)葉輪的批量加工，整個過程無需人工干預(yù)可以全部自動完成。其工藝路線的設(shè)置可采用如下方式：主軸裝卡棒料→粗車葉輪外部輪廓→精車外部輪廓→五軸銑削開槽→流道粗加工→流道半精加工→流道精加工→鉆孔→背主軸裝卡→車削葉輪底部平面→鉆孔?？梢钥闯?，一次裝卡即完成全部葉輪加工工序，加工效率及精度可以得到大幅提高。
對于具有雙刀架的車銑加工中心，雙刀塔的設(shè)備都具有雙通道的控制系統(tǒng)，上下刀架可單獨(dú)控制，同步加工可以通過代碼中的同步語句來實(shí)現(xiàn)。為充分發(fā)揮設(shè)備的加工能力，可以在加工條件允許的前提下，通過雙刀架的同步操作實(shí)現(xiàn)零件的多個工序同時加工?？梢酝ㄟ^上下刀架的同步設(shè)置，在粗車外形的同時完成內(nèi)孔的粗鏜加工，從而進(jìn)一步提高加工效率。通過上下刀架的同步運(yùn)動，完成一系列孔的加工，不僅提高了加工的效率，同時還可以通過鉆孔軸向力的相互抵消來減少工件變形的影響。為實(shí)現(xiàn)這種功能，需要在前期工藝設(shè)計的時候?qū)に嚪桨高M(jìn)行系統(tǒng)深入的研究，確定工藝路線的串行和并行順序，并通過對加工程序的合理組合實(shí)現(xiàn)上述功能。
2、車銑復(fù)合加工的數(shù)控編程技術(shù)
車銑復(fù)合加工技術(shù)的發(fā)展，也對數(shù)控編程技術(shù)提出了更高的要求，這也是制約車銑復(fù)合加工設(shè)備在實(shí)際生產(chǎn)應(yīng)用中的一個瓶頸環(huán)節(jié)。由于車銑復(fù)合加工投入實(shí)際生產(chǎn)的應(yīng)用時間較短，在沒有專業(yè)的復(fù)合加工解決方案的情況下，通常是利用通用CAM軟件規(guī)劃出部分加工程序，然后工藝人員再對程序進(jìn)行手工整合，以滿足復(fù)合加工機(jī)床對加工程序的要求。這種解決方法對工藝人員的要求非常高。與傳統(tǒng)的數(shù)控編程技術(shù)相比，車銑復(fù)合加工的程序編制難點(diǎn)主要體現(xiàn)在以下幾個方面。
1）工藝種類繁雜。對于工藝人員來說，不僅要能掌握數(shù)控車削、多軸銑削、鉆孔等多種加工方式的編程方法，而且對于工序間的銜接與進(jìn)退刀方式需要準(zhǔn)確界定。因此在進(jìn)行數(shù)控編程時，需要對當(dāng)前工序加工完成后的工序模型和加工余量的分布有直觀的認(rèn)識，以便于下一道工序的程序編制和進(jìn)退刀的設(shè)置。
2）程序編制過程中的串并行順序的確定必須嚴(yán)格按照工藝路線確定。許多零件在車銑復(fù)合加工中心上加工時可實(shí)現(xiàn)從毛料到成品的完整加工，因此加工程序的編制結(jié)果必須同工藝路線保持一致。同時，對于多通道并行加工也需要在數(shù)控加工程序編制的過程中進(jìn)行綜合考慮?？梢?，為實(shí)現(xiàn)高效的復(fù)合加工應(yīng)該發(fā)展工藝-編程-仿真一體化的工藝解決方案。
3）對于車銑復(fù)合加工的某些功能，目前的通用CAM軟件尚不支持。與常規(guī)單臺設(shè)備加工相比，車銑復(fù)合加工具備的機(jī)床運(yùn)動和加工功能要復(fù)雜的多，目前的通用CAM軟件尚不足以完全支持這些先進(jìn)功能的程序編制，如在線測量、鋸斷、自動送料、尾座控制等。因此，利用通用CAM軟件編制出來的程序仍然需要大量的手工或交互的方式才能應(yīng)用于自動化的車銑復(fù)合加工。
4）加工程序的整合。目前通用CAM軟件編制完成后的NC程序之間是相互獨(dú)立的，要實(shí)現(xiàn)車銑復(fù)合這樣復(fù)雜的自動化完整加工，需要對這些獨(dú)立的加工程序進(jìn)行集成和整合。這種整合必須以零件的工藝路線為指導(dǎo)，首先確定出哪些程序是并行的，然后對不同工藝方法的加工順序進(jìn)行確定，并給出準(zhǔn)確的換刀、裝卡更換、基準(zhǔn)轉(zhuǎn)化以及進(jìn)退刀指令等。
可以看出，車銑復(fù)合加工數(shù)控程序編制難度非常大，而目前的通用CAM軟件用于車銑復(fù)合加工仍然存在很多缺陷和不足。為彌補(bǔ)這些不足，在現(xiàn)有通用CAD/CAM軟件的基礎(chǔ)上開發(fā)適用于產(chǎn)品工藝和復(fù)合加工設(shè)備的專用編程系統(tǒng)是一種更為現(xiàn)實(shí)的解決方案。這一方面降低了軟件購置的重復(fù)投資，同時也能避免由于編程平臺不統(tǒng)一而造成的工藝知識不能重用、人員配置復(fù)雜等缺陷。
3、車銑復(fù)合加工的后置處理技術(shù)
與數(shù)控編程技術(shù)相對應(yīng)，車銑復(fù)合加工由于工藝方法復(fù)雜、運(yùn)動部件多等原因，從而對目前的后置處理軟件及技術(shù)提出了更高的要求。與常規(guī)數(shù)控設(shè)備相比，其后置處理的難點(diǎn)主要體現(xiàn)在以下幾個方面。
（1）不同工序間的銜接運(yùn)動要求嚴(yán)格準(zhǔn)確。由于在車銑復(fù)合設(shè)備上進(jìn)行的加工工藝種類繁多，因此在當(dāng)前工序加工完成之后必須及時、準(zhǔn)確地完成加工方式、刀具、運(yùn)動部件的自動切換，以保證加工過程的正確和安全。為了達(dá)到這個目的，一方面要求設(shè)置合理的進(jìn)退刀方式以及自動換刀、冷卻液開和停的時機(jī)，另外更為重要的是在進(jìn)行當(dāng)前工序加工時需要設(shè)定其他非運(yùn)動部件所處的位置。這樣
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