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UNIVERSITY
本 科 畢 業(yè) 論 文（設(shè) 計(jì)）
題目： 六孔臥式組合鉆床設(shè)計(jì)
學(xué) 院：
姓 名：
學(xué) 號(hào)：
專 業(yè)： 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
年 級(jí)：
指導(dǎo)教師： XXXXXXXX職 稱：副教授
二0一二 年 5月
摘要
隨著我國(guó)經(jīng)濟(jì)的發(fā)展，工業(yè)生產(chǎn)在國(guó)民經(jīng)濟(jì)中占據(jù)著尤為重要的地位。鉆床作為機(jī)械制造和修配工廠必不可少的設(shè)備，具有廣泛用途的通用性機(jī)床，可對(duì)零件進(jìn)行鉆孔，擴(kuò)孔，鉸孔，锪平面和攻螺紋等加工。同時(shí)鉆床又存在著加工精度，加工效率不高等缺陷。在我國(guó)，組合鉆床發(fā)展已有28年的歷史，其科研和生產(chǎn)都具有相當(dāng)?shù)幕A(chǔ)，應(yīng)用也已深入到很多行業(yè)。是當(dāng)前機(jī)械制造業(yè)實(shí)現(xiàn)產(chǎn)品更新，進(jìn)行技術(shù)改造，提高生產(chǎn)效率和高速發(fā)展必不可少的設(shè)備之一。它的特征是高效、高質(zhì)、經(jīng)濟(jì)實(shí)用，因而被廣泛應(yīng)用于工程機(jī)械、交通、能源、軍工、輕工、家電等行業(yè)。我國(guó)傳統(tǒng)的組合鉆床及組合機(jī)床自動(dòng)線主要采用機(jī)、電、氣、液壓控制，它的加工對(duì)象主要是生產(chǎn)批量比較大的大中型箱體類和軸類零件，完成鉆孔、擴(kuò)孔、鉸孔，加工各種螺紋、鏜孔、在孔內(nèi)鏜各種形狀槽等。
本文設(shè)計(jì)的六孔臥式組合鉆床，作為一種專用機(jī)床其生產(chǎn)效率高，加工精度高，特別適合于加工一些有多個(gè)孔并對(duì)孔的位置精度要求高的工件。
關(guān)鍵詞 ：鉆床；六孔；臥式；組合鉆床；加工精度；床身；導(dǎo)軌；主軸箱
19
Abstract
With the development of our national economy, industrial production in the national economy occupy a very important position. Drilling machinery manufacturing and repair factory as essential equipment, with wide application of universal machine tool, the parts for drilling, reaming, reaming, reaming and tapping processing plane. While drilling has the processing precision, processing efficiency is not high. In our country, the combination drilling machine development has 28 years of history, its scientific research and production, have a considerable foundation, application also penetrated into many industries. Is the machinery manufacturing industry to realize product updates, technical innovation, improve the production efficiency and the rapid development of one of the essential equipment. It is characterized by high efficiency, high quality, economical and practical, so it has been widely used in engineering machinery, transportation, energy, industry, light industry, household appliances industry. Our traditional combination drilling machine and the combined machine tool automatic line mainly uses the machine, electricity, gas, hydraulic control, its processing object is mainly the production lot larger-and medium-bold type and shaft parts, finished drilling, reaming, reaming, the processing of thread, boring, in various shapes such as Kong Neitang tank.
This design six-hole horizontal combination drilling machine, as a kind of special machine for its high production efficiency, high processing precision, particularly suitable for processing with a plurality of holes and the position precision of the holes demanding workpiece.
Key words: drilling machine; tin; horizontal; combination drilling machine; precision machining; bed; rail; spindle box
目 錄
1. 機(jī)床設(shè)計(jì)的目的，內(nèi)容，要求 1
1.1 設(shè)計(jì)目的 1
1.2 設(shè)計(jì)內(nèi)容 1
1.3 設(shè)計(jì)要求 1
1.4 調(diào)查研究 1
1.5 擬定方案 2
1.6 工作圖設(shè)計(jì) 2
2. 組合機(jī)床的總體設(shè)計(jì) 2
2.1 組合機(jī)床方案的制定 2
2.1.1 制定工藝方案 2
2.1.2 確定組合機(jī)床的配置形式和結(jié)構(gòu)方案 3
2.2 工藝的確定 4
2.2.1 確定工序間余量 4
2.2.2 選擇切削用量 4
2.2.3 確定切削力，切削扭矩，切削功率 4
2.2.4 選擇刀具結(jié)構(gòu) 5
2.2.5 確定軸向進(jìn)給力 5
2.2.6 確定進(jìn)給速度，行程 5
2.3 齒輪箱的設(shè)計(jì) 5
2.3.1確定傳動(dòng)線路圖 6
2.3.2帶傳動(dòng)的設(shè)計(jì) 6
2.3.2.1定V帶型號(hào)和帶輪直徑 6
2.3.2.1 帶輪材料與結(jié)構(gòu) 7
2.3.3 傳動(dòng)軸的設(shè)計(jì) 7
2.3.3.1 軸Ⅰ的設(shè)計(jì) 7
2.3.3.2 主軸的設(shè)計(jì) 10
2.3.4 齒輪的設(shè)計(jì) 11
2.3.4.1 齒輪的材料 11
2.3.4.2 齒輪的參數(shù)設(shè)計(jì) 12
2.3.5 主軸箱的設(shè)計(jì) 15
2.4. 床身的設(shè)計(jì) 15
參考文獻(xiàn) 17
致謝 18
1. 機(jī)床設(shè)計(jì)的目的，內(nèi)容，要求
1.1 設(shè)計(jì)目的
機(jī)床設(shè)計(jì)畢業(yè)設(shè)計(jì)，其目的在于通過機(jī)床主運(yùn)動(dòng)機(jī)械變速傳動(dòng)系統(tǒng)的結(jié)構(gòu)設(shè)計(jì)，使我們?cè)跀M定傳動(dòng)和變速的結(jié)構(gòu)方案過程中，得到設(shè)計(jì)構(gòu)思，方案的分析，結(jié)構(gòu)工藝性，機(jī)械制圖，零件計(jì)算，編寫技術(shù)文件盒查閱資料等方面的綜合訓(xùn)練。樹立正確的設(shè)計(jì)思想，掌握基本的設(shè)計(jì)方法，使自己具有初步的結(jié)構(gòu)分析，結(jié)構(gòu)設(shè)計(jì)和計(jì)算能力。
1.2 設(shè)計(jì)內(nèi)容
（1）運(yùn)動(dòng)設(shè)計(jì) 根據(jù)給定的被加工零件，確定機(jī)床的切削用量，通過分析比較擬定傳動(dòng)方案和傳動(dòng)系統(tǒng)圖，確定傳動(dòng)副的傳動(dòng)比及齒輪的齒數(shù)，并計(jì)算主軸的實(shí)際轉(zhuǎn)速和標(biāo)準(zhǔn)的相對(duì)誤差。
（2）動(dòng)力設(shè)計(jì) 根據(jù)給定的工件，計(jì)算傳動(dòng)軸的直徑，齒輪的模數(shù)，確定動(dòng)力箱，計(jì)算多軸尺寸及設(shè)計(jì)傳動(dòng)路線，完成裝配草圖后，要驗(yàn)算傳動(dòng)軸的直徑，齒輪模數(shù)是否在允許范圍內(nèi)，還要驗(yàn)算主軸的靜剛度。
（3）結(jié)構(gòu)設(shè)計(jì) 進(jìn)行主運(yùn)動(dòng)傳動(dòng)軸系，變速機(jī)構(gòu)，主軸主件，箱體，潤(rùn)滑與密封等的布置和機(jī)構(gòu)設(shè)計(jì)，既繪制裝配圖和零件工作圖。
（4）編寫設(shè)計(jì)說明書
1.3 設(shè)計(jì)要求
評(píng)價(jià)機(jī)床性能的優(yōu)劣主要是根據(jù)技術(shù)經(jīng)濟(jì)指標(biāo)來判定的。技術(shù)先進(jìn)合理，亦即質(zhì)優(yōu)價(jià)廉才會(huì)受到用戶的青睞，在國(guó)內(nèi)和國(guó)外市場(chǎng)上才有競(jìng)爭(zhēng)力。機(jī)床設(shè)計(jì)的技術(shù)經(jīng)濟(jì)指標(biāo)可以從滿足性能要求，經(jīng)濟(jì)效益和人機(jī)關(guān)系等方面進(jìn)行分析。
1.4 調(diào)查研究
研究市場(chǎng)和用戶對(duì)設(shè)計(jì)機(jī)床的要求，然后檢索有關(guān)資料。其中包括情報(bào)，預(yù)測(cè)，實(shí)驗(yàn)研究結(jié)果，發(fā)展趨勢(shì)，新技術(shù)應(yīng)用以及相應(yīng)的圖紙資料等。甚至還可以通過網(wǎng)絡(luò)檢索技術(shù)查閱先進(jìn)國(guó)家的相關(guān)資料和專利等。通過對(duì)上述資料的分析研究，擬定適當(dāng)?shù)姆桨?，以保證機(jī)床的質(zhì)量和提高生產(chǎn)率，使用戶有較好的經(jīng)濟(jì)效益。
1.5 擬定方案
通?？梢詳M定出幾個(gè)方案進(jìn)行分析比較，每個(gè)方案包括的內(nèi)容有：工藝分析，主要技術(shù)要求，總布局，傳動(dòng)系統(tǒng)，控制操作系統(tǒng)，電系統(tǒng)，主要部件的結(jié)構(gòu)草圖，實(shí)驗(yàn)結(jié)果及技術(shù)經(jīng)濟(jì)分析等。
在制定方案時(shí)應(yīng)注意以下幾個(gè)方面：
（1） 當(dāng)使用和制造出現(xiàn)矛盾時(shí)，應(yīng)滿足使用要求，其次才是盡可能便于制造，要盡量用先進(jìn)的工藝和創(chuàng)新的結(jié)構(gòu);
（2） 設(shè)計(jì)必須以生產(chǎn)實(shí)踐和科學(xué)實(shí)驗(yàn)為依據(jù)，凡是未經(jīng)過實(shí)踐考驗(yàn)的方案，必須經(jīng)過實(shí)驗(yàn)驗(yàn)證可靠后才能用于設(shè)計(jì)
（3） 繼承與創(chuàng)新相結(jié)合，盡量采用先進(jìn)工藝，迅速提高生產(chǎn)力，為實(shí)現(xiàn)四個(gè)現(xiàn)代化服務(wù)，注意吸取前人和國(guó)外的經(jīng)驗(yàn)，并在此基礎(chǔ)上有所創(chuàng)新和發(fā)展；
1.6 工作圖設(shè)計(jì)
首先，在選定工藝方案并確定機(jī)床配置形式，結(jié)構(gòu)方案基礎(chǔ)上，進(jìn)行方案圖紙的設(shè)計(jì)。這些圖紙包括：該加工零件工序圖，加工示意圖，機(jī)床聯(lián)系尺寸圖和生產(chǎn)率計(jì)算卡。并初步擬定主軸箱輪廓尺寸，才能確定機(jī)床各部件間的相互關(guān)系。
其次，繪制機(jī)床的總裝圖，部分部件裝配圖，液壓系統(tǒng)圖，PLC接線圖和梯形圖。
然后，整理機(jī)床有關(guān)部件與主要零件的設(shè)計(jì)計(jì)算書，編制各類零件明細(xì)表，編寫機(jī)床說明書等技術(shù)文件。
最后，對(duì)有關(guān)圖紙進(jìn)行工藝審查和標(biāo)準(zhǔn)化審查。
2. 組合機(jī)床的總體設(shè)計(jì)
2.1 組合機(jī)床方案的制定
2.1.1 制定工藝方案
零件加工工藝將決定組合機(jī)床的加工質(zhì)量，生產(chǎn)率，總體布局和夾具結(jié)構(gòu)等。所以，在制定工藝方案時(shí)，必須計(jì)算分析被加工零件圖，并深入現(xiàn)場(chǎng)了解零件的形狀，大小，材料，硬度，剛度，加工部位的結(jié)構(gòu)特點(diǎn)加工精度，表面粗糙度，以及定位，加緊方法，工藝過程等。所采用的刀具及切削用量，生產(chǎn)率要求，現(xiàn)場(chǎng)采用的環(huán)境和條件等。并收集國(guó)內(nèi)外有關(guān)技術(shù)資料，制定出合理的工藝方案。根據(jù)被加工零件的零件圖（圖1），定出工藝方案
（1）加工孔的主要技術(shù)要求
加工6個(gè)Φ20，深100mm的通孔
孔的位置度公差為Φ0.1mm，孔在同一平面上
工件材料為#45鋼
要求生產(chǎn)綱領(lǐng)為年生產(chǎn)6萬件，單班制生產(chǎn)
圖1 加工零件圖
(2)工藝分析
加工該孔時(shí)，孔的位置度公差為Φ0.1，可采用一次性鉆孔
2.1.2 確定組合機(jī)床的配置形式和結(jié)構(gòu)方案
（1）被加工零件的加工精度
被加工零件需要在組合機(jī)床上完成的加工工序及應(yīng)保證的加工精度，是制造機(jī)床方案的主要依據(jù)。該工件的加工孔的精度要求不高，可采用鉆孔組合機(jī)床，工件各孔見位置精度為Φ0.1mm,安排加工時(shí)可通過一次鉆孔完成。在該工序孔的表面粗糙度要求為Ra25mm。采取提高機(jī)床原始制造精度和工件定位基準(zhǔn)精度并減少夾壓變形等措施就可以了。為此，機(jī)床通常采用位置式齒輪動(dòng)力裝置，進(jìn)給采用液壓系統(tǒng)，人工夾緊。
（2）被加工零件特點(diǎn)
這主要指零件的材料，硬度，形狀，剛度定位精準(zhǔn)面的特點(diǎn)，他們對(duì)機(jī)床工藝方案制定有著重要的影響。此工件材料為#45鋼，硬度為HB170-200，孔在整個(gè)工件上呈60度均勻分配，采用多孔同步加工，零件的剛度足夠，工件的受力不大，震動(dòng)，發(fā)熱變形對(duì)對(duì)工件影響不大。
由于該零件的中心線與定位基準(zhǔn)面平行，可采用臥式機(jī)床
（3）零件的生產(chǎn)批量
零件的生產(chǎn)批量是決定采用單工位，多工位，自動(dòng)線或按中小批量生產(chǎn)特點(diǎn)設(shè)計(jì)組合機(jī)床的重要因素。按設(shè)計(jì)要求生產(chǎn)綱領(lǐng)為年產(chǎn)6萬件，從工件外形及輪闊尺寸，為了減少加工時(shí)間，采用多軸頭。
（4） 機(jī)床使用步置
使用組合機(jī)床對(duì)車間布置情況，工序間的聯(lián)系，使用廠的技術(shù)能力和自然條件等一定的要求。再根據(jù)用戶實(shí)際情況來選擇什么樣的組合機(jī)床。
綜合以上所述：通過對(duì)零件的結(jié)構(gòu)特點(diǎn)，加工部位，尺寸精度，表面粗糙度和技術(shù)要求，定位，夾緊方式，工藝方法，并定出影響機(jī)床的總體布局和技術(shù)性能等方面的考慮，最終決定采用六軸頭多工位同步鉆床。
2.2 工藝的確定
2.2.1 確定工序間余量
為使加工過程順利進(jìn)行并保證加工精度，必須合理地確定工序間余量。生產(chǎn)中常用查表給出的組合機(jī)床對(duì)孔加工的工序余量，由于在本鉆床上只進(jìn)行粗鉆，為達(dá)到最終Φ20的要求后面還要進(jìn)行鉸孔，所以這次的鉆孔直徑為Ф19.5，直徑上工序余量為0.5mm
2.2.2 選擇切削用量
確定了在組合機(jī)床上完成的工藝內(nèi)容了，就可以著手選擇切削用量了。因?yàn)樗O(shè)計(jì)的組合機(jī)床為多軸同步加工，在大多數(shù)情況下所選擇切削用量根據(jù)經(jīng)驗(yàn)比一般通用機(jī)床單刀加工低30%左右。多軸主軸箱上所有刀具共用一個(gè)進(jìn)給系統(tǒng)，通常為標(biāo)準(zhǔn)動(dòng)力滑臺(tái)，工作時(shí)要求所有刀具的每分鐘進(jìn)給量相同，且等于動(dòng)力滑臺(tái)的每分鐘進(jìn)給量（mm/min）。因此，同一主軸箱可設(shè)計(jì)成不同轉(zhuǎn)速和不同的每轉(zhuǎn)進(jìn)給量與其相適應(yīng)。以滿足不同直徑的加工要求，即：
n1.×f1=n2×f2=…=ni×fi=vf （1-1）
式中：n1.， n2 ，n2-——各主軸轉(zhuǎn)速 （r/min）
f1。f2.fi ——各主軸進(jìn)給量（mm/r）
vf——?jiǎng)恿_(tái)每分鐘進(jìn)給量（mm/min）
由于該工件的加工精度，工件材料，工作條件，技術(shù)要求都是相同的。按照經(jīng)濟(jì)的選擇滿足加工要求的原則，采用查表的方法得：鉆頭直徑D=19.5mm，材料為高速鋼，進(jìn)給量f=0.1mm/r，切削速度v=20mm/min
2.2.3 確定切削力，切削扭矩，切削功率
根據(jù)選定的切削用量確定切削力，作為選擇動(dòng)力部件及夾具設(shè)計(jì)的依據(jù)；確定切削扭矩，用以確定主軸及其他傳動(dòng)件（齒輪，傳動(dòng)軸）的尺寸；確定切削功率，用以選擇主電動(dòng)機(jī)功率，通過查表計(jì)算如下：
軸向力：
F=N （1-2）
計(jì)算得：F=9.81?61.2?19.51?0.10.7=2335.9N
鉆削扭矩 ：
M=N?m (1-3)
計(jì)算得：M=9.81?0.0311?19.52?0.10.8 =18.4N?m
鉆削功率：
PC=2∏Mn W (1-4)
計(jì)算得：PC=2?3.14?18.4?3.3=385.2W
式中：f—沒轉(zhuǎn)進(jìn)給量（mm/r）
n—鉆頭轉(zhuǎn)速（r/s）
2.2.4 選擇刀具結(jié)構(gòu)
工件的布氏硬度在HB170-240，孔徑D為19.5mm，刀具的選擇高速鋼鉆頭（W18Cr4V）.為了使工作可靠，結(jié)構(gòu)簡(jiǎn)單，選擇標(biāo)準(zhǔn)Ф19.5的麻花鉆。
2.2.5 確定軸向進(jìn)給力
F進(jìn)=∑Fi=6?2335.9=14015.4N
式中：Fi——各主軸加工時(shí)產(chǎn)生的軸向力
由于滑臺(tái)工作時(shí)，除了要克服各主軸的軸向進(jìn)給力，還要克服滑臺(tái)移動(dòng)時(shí)所產(chǎn)生的摩擦力。因而選擇滑臺(tái)的最大進(jìn)給力應(yīng)大于14.1KN。
2.2.6 確定進(jìn)給速度，行程
滑臺(tái)的進(jìn)給速度分為快進(jìn)，工進(jìn)，快退，所以要求液壓系統(tǒng)能實(shí)現(xiàn)3
種速度間的轉(zhuǎn)換。其中快進(jìn)行程為200mm，工進(jìn)110mm，快退310mm。
2.3 齒輪箱的設(shè)計(jì)
2.3.1確定傳動(dòng)線路圖
圖2 傳動(dòng)示意圖
1.電動(dòng)機(jī) 2.小帶輪 3.大帶輪 4.傳動(dòng)軸 5.小齒輪 6.主軸 7.大齒輪
2.3.2帶傳動(dòng)的設(shè)計(jì)
2.3.2.1定V帶型號(hào)和帶輪直徑
定V型帶型號(hào)和直徑
工作情況系數(shù)
KA=1.1
計(jì)算功率
PC= KAP=1.1?2.5=2.75
PC=3KW
小帶輪轉(zhuǎn)速
n1=1440r/min
選帶型號(hào)
A型
小帶輪直徑
由表得
取D1=90mm
大帶輪直徑
D2=(1-ε)D1n1/n2
取D2=224mm
大帶輪轉(zhuǎn)速
n2=(1-ε)D1n1/D2=576
n2=576r/min
計(jì)算帶長(zhǎng)
求Dm
Dm=（D1+D2）/2
Dm=157mm
求Δ
Δ= （D2-D1）/2
Δ=67 mm
初取中心距
a=650mm
帶長(zhǎng)
L=ЛDm+2a+Δ2/a
Ld=787.5mm
基準(zhǔn)長(zhǎng)度
L=800mm
求中心距和包角
中心距
a=130mm
小輪包角
α1=180o-60o（D2-D1）/a =121.3>120o
α1=121.3o
求帶根數(shù)
帶速
v= ЛD1n1/(60?1000)
v=6.78m/s
傳動(dòng)比
i= n1/ n2
i=2.5
帶根數(shù)
由表得 P0=1.07kw; Ka=0.83 KL=0.85; ΔP0=0.17 Z=PC/(P+ΔP0) Ka KL=2.87
取Z=3
求軸上載荷
張緊力
F0=128N
軸上載荷
FQ=2Z F0sin(a1/2)
FQ=665.1N
2.3.2.1 帶輪材料與結(jié)構(gòu)
當(dāng)帶速v<30/s的傳動(dòng)帶，其帶輪一般用HT200制造。所以帶輪的材料選擇HT200。當(dāng)帶輪的直徑D<2-3d時(shí)常采用實(shí)心式，中等尺寸是常采用腹板式。所以小帶輪采用實(shí)心式，大帶輪采用腹板式。
2.3.3 傳動(dòng)軸的設(shè)計(jì)
2.3.3.1 軸Ⅰ的設(shè)計(jì)
（1） 軸的選材
軸的材料為40Cr，調(diào)質(zhì)處理，齒輪表面在進(jìn)行高頻淬火
（2）計(jì)算齒輪受力
由于軸上齒輪對(duì)稱分布所以徑向受力相互抵消
（3）計(jì)算支撐反力
垂直面反力
F1=665N ,FR1=997.5N, FR2=332.5N
(4) 軸的結(jié)構(gòu)圖
圖3 傳動(dòng)軸的結(jié)構(gòu)
（5）軸的受力圖
圖4 軸的受力圖
(6) 軸的垂直面受力圖
圖5 軸的垂直面受力圖
（7） 軸的彎矩圖
圖6 軸的彎矩圖
最大彎矩M=40232.5N?mm
（8）軸的扭矩圖
圖7 軸的扭矩圖
最大轉(zhuǎn)矩為47750n?mm
（9） 軸的當(dāng)量彎矩圖
圖8 軸的當(dāng)量彎矩圖
計(jì)算齒輪受力
齒輪螺旋角
β=0
齒輪直徑：小輪
大輪
=50
=150
小齒輪受力：轉(zhuǎn)矩
圓周力
徑向力
軸向力
=47750N?mm
=1910N
=695.2N
=0N
小齒輪軸受力圖
見圖4
計(jì)算支撐反力
垂直面反力
=997.5N
=332.5N
垂直面受力圖
見圖5
水平面受力圖
忽略重力
畫軸彎矩圖
垂直面彎矩圖
見圖6
畫軸扭矩圖
軸受轉(zhuǎn)矩
T=
T=47750N?mm
扭矩圖
見圖7
許用應(yīng)力
許用應(yīng)力
用插入法查表得：[]=102.5Mpa
[]=60Mpa
[]=102.5Mpa
[]=60Mpa
應(yīng)力修正系數(shù)
ɑ=0.59
畫當(dāng)量彎矩圖
當(dāng)量轉(zhuǎn)矩
ɑT=0.59×47750
ɑT=28172N?mm
當(dāng)量彎矩
在小齒輪中間截面處
在左軸頸處
=
見圖8
=40737N?mm
=49115N?mm
當(dāng)量彎矩圖
見圖8
校核軸徑
齒根圓直徑
=43.75
43.75mm
軸徑
18.9<43.75
=20.2<40mm
2.3.3.2 主軸的設(shè)計(jì)
本鉆床共有六根主軸，鉆頭安裝在主軸上。故對(duì)主軸的強(qiáng)度剛度要求較高。為滿足要求材料選擇45號(hào)鋼，初定直徑35mm。熱處理為調(diào)質(zhì)處理，表面硬度為220-250HBS。
軸的設(shè)計(jì)與校核過程與上類似。
（1）主軸1的結(jié)構(gòu)圖如下
圖9 主軸1的結(jié)構(gòu)圖
（2）主軸2的結(jié)構(gòu)圖
圖10 主軸2的結(jié)構(gòu)圖
2.3.4 齒輪的設(shè)計(jì)
2.3.4.1 齒輪的材料
齒輪傳動(dòng)要求齒輪表面具有較高的硬度與耐磨性，同時(shí)齒根還要具有較高的強(qiáng)度。在齒輪傳動(dòng)過程中由于小齒輪直徑小每個(gè)齒重復(fù)嚙合的次數(shù)更多，導(dǎo)致小齒輪過早失效。所以小齒輪選擇40Cr,大齒輪為#45鋼，表面熱處理均為表面淬火。
2.3.4.2 齒輪的參數(shù)設(shè)計(jì)
齒面接觸疲勞強(qiáng)度計(jì)算
1.初步計(jì)算
轉(zhuǎn)矩T1
T1=18400N?mm
齒寬系數(shù)ψd
查表得ψd=1.0
ψd=1.0
接觸疲勞極限 σHlim1
σHlim1=710Mpa
σHlim2=580Mpa
初步計(jì)算的許用接觸應(yīng)力[σH]
[σH1]=0.9 ?σHlim1
[σH2]= 0.9 ?σHlim2
[σH1]=639Mpa
[σH2]=522Mpa
初步計(jì)算的小齒輪直徑d1
取d1=50mm
初步齒寬b
b=40mm
2.校核計(jì)算
圓周速度v
v= =1.35m/s
v=1.35m/s
精度等級(jí)
選6級(jí)
齒數(shù)z和模數(shù)m
初取z1=20,z2=i?z1=60
m=d1/ z1=2.5
m=2.5
z1=20
z2=60
使用系數(shù)KA
KA=1.25
動(dòng)載系數(shù)KV
KV=1.1
齒間載荷分配系數(shù)KHa
齒間載荷分配系數(shù)KHa
Ft=2T1/d1=817.7N KAFt/b=22.7N/mm<100N/mm εa=[1.88-3.2(1/ z1+1/ z2)]cosβ =1.64
Zε==0.79
由此得KHa= =1.6
εa=1.64
Zε=0.79
KHa=1.6
齒向載荷分布系數(shù)KHβ
=A+B()2+C?10-3b =1.11+0.16()2+0.47?10-3?40
=1.75
=1.75
載荷系數(shù)K
K=KA KV KHa KHβ
K=3.85
彈性系數(shù)ZE
查表得
ZE=189.8
節(jié)點(diǎn)區(qū)域系數(shù)ZH
ZH=2.5
接觸最小安全系數(shù)SHmin
SHmin=1.25
接觸壽命系數(shù)ZN
ZN1=1.18
許用接觸應(yīng)力[σH]
[σH1]= =670MPa
[σH2]= =580MPa
[σH1]=670MPa
[σH2]=580MPa
驗(yàn)算
計(jì)算結(jié)果表明，接觸疲勞強(qiáng)度較為合理，輪尺寸無需調(diào)整。
=572.4Mpa
< [σH2]
（3）確定傳動(dòng)主要尺寸
實(shí)際分度圓直徑d
d1=mz1=2.5?20=50mm
=mz2=2.5?60=150mm
d1=50mm
=150mm
中心距a
a=
a=100mm
齒寬b
b=40mm
齒根彎曲疲勞強(qiáng)度
重合度系數(shù)
Yε=0.25+
Yε=0.71
齒間載荷分配系數(shù)KFa
KFa=1/ Yε
KFa=1.41
齒向載荷分布系數(shù)KFβ
b/h=7.1 查表得
KFβ=1.5
載荷系數(shù)K
K= KA KV KFa KFa=2.9
K=2.9
齒形系數(shù)YFa
YFa1=2.9
YFa2=2.32
應(yīng)力修正系數(shù)YSa
YSa1=1.53 YSa2=1.74
彎曲疲勞極限σFlim
σFlim1=620MPa
σFlim2=450MPa
彎曲最小安全系數(shù)SFmin
SFmin=1.6
彎曲壽命系數(shù)YN
YN1=0.95
YN2=0.97
尺寸系數(shù)YX
YX=1.0
許用彎曲應(yīng)力[σF]
[σF1]=
[σF2]=
[σF1]= 356.25MPa
[σF2]=272.8MPa
驗(yàn)算
σF1= YSa1 YFa1 Yε
σF2=σF1
傳動(dòng)無過載，故不作靜強(qiáng)度校核 其余的齒輪配合情況與這一對(duì)相同，所以參數(shù)完全一樣
σF1=203.5 MPa< [σF1]
σF2=185.1 MPa
其余的齒輪配合情況與這一對(duì)相同，所以參數(shù)完全一樣
2.3.5 主軸箱的設(shè)計(jì)
主軸箱是鉆床的重要部件，它上面安裝有鉆床的傳動(dòng)系統(tǒng)以及主軸。其結(jié)構(gòu)的合理性和性能的好壞直接影響著機(jī)床的制造成本；影響著鉆床對(duì)零件加工的精度，同時(shí)也影響著機(jī)床的工作效率和壽命等。因此，主軸具有足夠的靜態(tài)剛度和良好的動(dòng)態(tài)性能，較小的熱變形和內(nèi)應(yīng)力，并易于加工制造裝配等才能滿足鉆床對(duì)床身的要求。為保證鉆床的加工精度，應(yīng)嚴(yán)格保證主軸箱各壁孔間的位置精度。主軸箱鑄造后為使性能穩(wěn)定應(yīng)進(jìn)行時(shí)效處理。加工時(shí)使用鏜床一次鏜同一軸上的兩個(gè)壁孔。
主軸箱的材料采用HT200，通過鑄造成型。內(nèi)壁孔的精度等級(jí)為IT6，Ra1.6。
2.4. 床身的設(shè)計(jì)
（1）床身對(duì)鉆床性能的影響及其要求
床身是鉆床的主要支撐件，他支撐著鉆床的床頭箱，溜板，尾座等部件。承受著切削力，重力，摩擦力等靜態(tài)力的作用。其結(jié)構(gòu)的合理性和性能的好壞直接影響著機(jī)床的制造成本；影響著鉆床各部件間的相對(duì)位置精度，和鉆床在工作中各運(yùn)動(dòng)部件的相對(duì)運(yùn)動(dòng)軌跡的準(zhǔn)確性，從而影響工件的加工質(zhì)量，還影響機(jī)床刀具的耐用度，同時(shí)也影響著機(jī)床的工作效率和壽命等。因此，床身具有足夠的靜態(tài)剛度和良好的動(dòng)態(tài)性能，較小的熱變形和內(nèi)應(yīng)力，并易于加工制造裝配等才能滿足鉆床對(duì)床身的要求。
（2）床身的結(jié)構(gòu)設(shè)計(jì)
鉆床工作時(shí)，主要受到水平方向和垂直方向的切削力的作用，使床身在水平面和垂直面內(nèi)發(fā)生彎曲，以及在這些分力作用下的扭矩，其中，影響最大的是床身水平面的彎曲。因此，在床身不太長(zhǎng)的情況下，主要應(yīng)提高床身在水平面內(nèi)的剛度。所以在床身的長(zhǎng)度方向多布置幾個(gè)著力點(diǎn)，而且使主軸箱在靜止的時(shí)候重心落在左側(cè)的床腿間。床身的結(jié)構(gòu)如圖11。
圖11 床身
參考文獻(xiàn)
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致謝
本次畢業(yè)設(shè)計(jì)得以順利完成，首先要感謝指導(dǎo)老師XXXXXXXX教授，班主任曾一凡教授，以及院里的各位老師。其次，也要感謝同學(xué)們對(duì)我的熱情幫忙。有了你們的幫助才讓我解決一個(gè)個(gè)的難題，在這里我對(duì)大家表示衷心的感謝！
附錄：
外文資料與中文翻譯
外文資料：
The Development Of Machine Tool Technology
and automatic line
Machine Tool and Machine Tool Automatic Line is a dedicated and efficient automation technology and equipment, at present, it is still a high-volume machinery to achieve efficient, high quality and economical production of key equipment, which is widely used in automobiles, tractors, diesel and compressed machines and many other industrial production. In particular, the automotive industry, is a combination of machine tools and automatic lines largest user. Such as the German Volkswagen plant in Salzgitter engine plant, used in the early 90's metal-cutting machine tool is automatic line (60%), machines (20%) and processing center (20%). Clearly, the mass production of the machinery industry, a lot of used equipment is a combination of machine and automatic line. Therefore, combination machine tool and its automatic line level of technical performance and integrated automation, the large extent determines these industries, a product of the production efficiency, product quality and business organization of production Jiegou, Yezai determine a company's products competitiveness.
現(xiàn)代組合機(jī)床和自動(dòng)線作為機(jī)電一體化產(chǎn)品，它是控制、驅(qū)動(dòng)、測(cè)量、監(jiān)控、刀具和機(jī)械組件等技術(shù)的綜合?反映。 Combination of machine tools and automatic lines of modern mechatronic product as it is to control, drive, measure, monitor, tool and machinery components such as a comprehensive reflection of technology. 近20年來，這些技術(shù)有長(zhǎng)足進(jìn)步，同時(shí)作為組合機(jī)床主要用戶的汽車和內(nèi)燃機(jī)等行業(yè)也有很大的變化，其?產(chǎn)品市場(chǎng)壽命不斷縮短，品種日益增多且質(zhì)量不斷提高。 The past 20 years, these technologies have made considerable progress, as well as a combination of machine tool user industries such as automobile and internal combustion engines, there are big changes in the market life of their products continue to shorten, increasing variety and quality improved. 這些因素有力地推動(dòng)和激勵(lì)了組合機(jī)床和自動(dòng)線技術(shù)的?不斷發(fā)展。 These factors effectively promote and encourage the combination of machine and automatic line technology continues to evolve.
1 A combination of varieties of key development tools
在組合機(jī)床這類專用機(jī)床中，回轉(zhuǎn)式多工位組合機(jī)床(圖2)和自動(dòng)線占有很重要的地位。 In the combination of these special purpose machine tools, the rotary multi-station machines (Figure 2) and automatic line plays an important role. 因?yàn)檫@?兩類機(jī)床可以把工件的許多加工工序分配到多個(gè)加工工位上，并同時(shí)能從多個(gè)方向?qū)ぜ膸讉€(gè)面進(jìn)行加工，此?外，還可以通過轉(zhuǎn)位夾具(在回轉(zhuǎn)工作臺(tái)機(jī)床上)或通過轉(zhuǎn)位、翻轉(zhuǎn)裝置(在自動(dòng)線上)實(shí)現(xiàn)工件的五面加工或全部?加工，因而具有很高的自動(dòng)化程度和生產(chǎn)效率，被汽車、摩托車和壓縮機(jī)等工業(yè)部門所采用。 Because these two types of machine parts can be assigned to many manufacturing processes on multiple processing station, and also from several different directions on the workpiece surface processing, In addition, you can also switch to digital clamp (work in rotation machine tool) or by translocation, flip device (in the automatic line) to achieve a five-face machining parts or all of processing, so they have a high degree of automation and production efficiency, a car, motorcycle and compressors and other industrial sectors used.
根據(jù)有關(guān)統(tǒng)計(jì)資料，德國(guó)在1990～1992年期間，回轉(zhuǎn)式多工位組合機(jī)床和自動(dòng)線的產(chǎn)量約各占組合機(jī)床總數(shù)?的50%左右。According to statistics, Germany in 1990 and 1992, combined multistation rotary machine and automatic production lines around each combination of machine tool about 50% of the total.
應(yīng)指出，回轉(zhuǎn)式多工位組合機(jī)床實(shí)際上是一種特殊型式的小型自動(dòng)線，適合于加工輪廓尺寸≤250mm的中小?件。 Be noted that multi-station rotary machine is actually a combination of special types of small automatic lines for processing outline size of ≤ 250mm of small pieces. Compared with the automatic line, in the processing of the same parts of the case, the combination of multi-station rotary machine tool operations share is about a small area than the automated line 2 / 3.
2、 beat time to further reduce the automatic line
目前，以大批量生產(chǎn)為特征的轎車和輕型載貨車，其發(fā)動(dòng)機(jī)的年產(chǎn)量通常為60萬臺(tái)左右，實(shí)現(xiàn)這樣大的批量?生產(chǎn)，回轉(zhuǎn)式多工位組合機(jī)床和自動(dòng)線在三班運(yùn)行的情況下，其節(jié)拍時(shí)間一般為20～30秒，當(dāng)零件生產(chǎn)批量更大?時(shí)，機(jī)床的節(jié)拍時(shí)間還要更短些(表1)。
At present, characterized by mass production of cars and light trucks, the engine's output is usually around 60 million units, to achieve such a large volume production, multi-position rotary combination of machine tools and automatic lines in the case of three-shift operation , the tact time is generally 20 to 30 seconds, when the greater part of production volume, the machine cycle times should be shorter (Table 1). In the 70's, automatic line to achieve such a short beat, often used side by side duplex or set the two-lane approach, that is, determining the automatic line of the beat, the longest processing operation processes through the same process in parallel two station, if more restrictive process, then the same through the use of two automatic lines to balance the automatic line system processing rhythm. 顯然，這樣就要增加設(shè)備投資和作業(yè)面積。 Apparently, this would increase the investment in equipment and operating area.
縮短基本時(shí)間的主要途徑是采用新的刀具材料和新穎刀具，以通過提高切削速度和進(jìn)給速度來縮短基本時(shí)間。 The main way to shorten the basic time is the introduction of new materials and novel tool tool to enhance the cutting speed and feed through to shorten the basic time rate. ?例如，德國(guó)大眾汽車廠在加工鋁合金缸蓋燃燒室側(cè)面時(shí)，采用PCD銑刀，銑削速度高達(dá)3075m/min，進(jìn)給速度達(dá)?3600mm/min；又如，在鏜削灰鑄鐵缸體的缸孔時(shí)，采用裝有三個(gè)可轉(zhuǎn)位CBN刀片的新穎鏜刀頭，切削速度達(dá)?800m/min，進(jìn)給速度為1500mm/min，加工深度為146mm的缸孔，其實(shí)際加工時(shí)間僅為5.8s，比傳統(tǒng)加工工藝可縮?短2/3的加工時(shí)間。 For example, the German Volkswagen plant in the processing of aluminum alloy cylinder head combustion chamber side, the use of PCD milling cutters, milling speeds of up to 3075m/min, feed speed 3600mm/min; another example, in boring gray cast iron cylinder block of the cylinder bore When used with three indexable boring head new CBN inserts, cutting speed up to 800m/min, feed rate 1500mm/min, processing depth of 146mm the cylinder bore, the actual processing time of only 5.8s, compared traditional processing process can be shortened 2 / 3 of the processing time.
縮短輔助時(shí)間主要是縮短包括工件輸送、加工模塊快速引進(jìn)以及加工模塊由快進(jìn)轉(zhuǎn)換為工進(jìn)后至刀具切入工件?所花的時(shí)間。 Reduce the auxiliary time is shortened, including parts delivery, processing and rapid introduction of the module and processing module is converted to work by the fast-forward to the tool after the cut into the workpiece into the time spent. To shorten this part of the air travel time, generally used to improve workpiece (workpiece direct transmission) or the accompanying fixtures and processing module transmission speed fast speed. 目前，隨行夾具的輸送速度可達(dá)60m/min或更高些，加工模塊快速移動(dòng)速度達(dá)40m/min。 At present, the accompanying transmission speeds up to 60m/min fixture or later some, fast-moving speed of processing modules 40m/min. At present, the accompanying high-speed conveyor fixture common control with electro-hydraulic proportional valve or cyclonical driven conveyer. The late 70s, Honsberg body in its processing of automatic transmission line on the use of electro-hydraulic proportional valve controlled delivery device. Movement of the conveyor curves. As the electro-hydraulic proportional valve control system has a good start and braking performance, and the system structure is simple, so far, this conveyor being used by many automated line.
3、the rapid progress of flexible combination machine
十多年來，作為組合機(jī)床重要用戶的汽車工業(yè)，為迎合人們個(gè)性化需求，汽車變型品種日益增多(圖5)，以多?品種展開競(jìng)爭(zhēng)已成為汽車市場(chǎng)競(jìng)爭(zhēng)的特點(diǎn)之一，這使組合機(jī)床制造業(yè)面臨著變型多品種生產(chǎn)的挑戰(zhàn)。 10 years, as the combination of machine tools important to the user's automobile industry, to meet the individual needs of people, cars become growing varieties (Figure 5), a multi-species competition has become one of the characteristics of market competition car, making Machine Tool Manufacturing industry faces many varieties of variant production challenges. 為適應(yīng)多品?種生產(chǎn)，傳統(tǒng)以加工單一品種的剛性組合機(jī)床和自動(dòng)線必須提高其柔性。 To meet the multi-species production and processing of a single species of conventional machine tools and automatic lines rigid composite to improve its flexibility. In the 70's, numerical control system reliability has been greatly improved, it is to late 70s and early 80s, as Alfing, Hüller-Hille and Ex-cell-o and other companies have developed a flexible machining modules, and automatic line ( FTL), from CNC machine tools and flexible combination of automatic line has increased every year. 1988 to 1992, Japan Machine Tool and automatic line (including some other form of special machine tools) production NC rate has reached 32% ~ 39%, output NC rate of 35% to 51%; the German Machine Tool and automatic line production The NC rate of 18% and 62%, 45% of the value NC ~ 66% (Table 2). These figures show that over the past decade, the development of NC machine tool combination is very rapid. Should be noted that since the 90's into the car even more intense market competition, product market and further reduce the life of the new models and shorter development cycle (now usually 35 months), car varieties growing, so automotive industry to flexible automation increasing demand for technical equipment. Such as Toyota Motor Corporation, in the end of this century's goal is to subordinate the factory the company flexible manufacturing system's coverage reached 100%.很顯然，組合機(jī)床及其自動(dòng)線在保持其高生產(chǎn)效率的條件下，進(jìn)一步提高其柔性?就愈來愈具有重要意義。 Obviously, combination machine tool and its production line while maintaining its high productivity conditions, further enhancing its flexibility on the more important.
組合機(jī)床的柔性化主要是通過采用數(shù)控技術(shù)來實(shí)現(xiàn)的。Flexible modular machine tool is mainly through the use of numerical control technology to achieve. Development of flexible modular machine tool and an important prerequisite for flexible automatic line is the development of CNC machining module, which has a long history of development of processing technology for the development of CNC machining center modules to provide a mature experience. NC modules formed by the flexible modular machine tool and flexible automatic lines, can be changed through the application and the automatic tool changer CNC program to automatically replace the multi-axle box and change the processing itinerary of the working cycle, cutting parameters and processing location, in order to adapt to change type variety of processing. ?柔性組合機(jī)床和柔性自動(dòng)線用的數(shù)控加工模塊，按其數(shù)控坐標(biāo)(軸)數(shù)，主要有單坐標(biāo)(Z)、雙坐標(biāo)(XZ、YZ、?ZU和ZB等)和三坐標(biāo)(XYZ)加工模塊；按其主軸數(shù)，有單軸和多軸加工模塊，也有單軸和多軸復(fù)合加工模塊。
Single-axis machining module by the NC slide and spindle assembly (or axle box, including for multi-axle box) form. Two-axis machining module by the cross slide and spindle CNC Components, such as two-coordinate CNC milling module. Column moving type CNC coordinate processing module (Figure 6), the tool can be realized in the three coordinate movement, according to workpiece varieties and processing tasks with Tool, tool change and the required mechanical hand tools, high Flexible. This processing module is flexible automatic line processing of multi species one of the most important modules.
立柱移動(dòng)式CNC三坐標(biāo)加工模塊可利用X軸和Y軸的聯(lián)動(dòng)來實(shí)現(xiàn)周邊銑削工藝，特別是在銑削象變速箱體這類剛?性較差的工件時(shí)，可采用較小直徑的銑刀，實(shí)現(xiàn)高速(切削速度達(dá)2500m/min)周邊銑削，由此減小加工時(shí)的切削?力和工件的變形。 Mobile column CNC machining module can make use of X coordinate axis and Y axis of the linkage to achieve the peripheral milling process, particularly in the milling body such as the transmission of less rigid workpiece, we can use smaller diameter cutter, high-speed (cutting speed up to 2500m/min) milling around, thus reducing processing time of cutting force and workpiece deformation. This is more than double coordinate milling module for milling cutters with large diameter to be superior. Multi-axis machining module is another important module, mainly for processing box and disc type work flexible combination of machine tools and flexible automatic lines.這類模塊有多?種不同的結(jié)構(gòu)形式，但基本上可分為自動(dòng)換箱式多軸加工模塊(圖7)、轉(zhuǎn)塔式多軸加工模塊(圖8)和回轉(zhuǎn)工作臺(tái)式?多軸加工模塊(圖9)。 How such module structure of different forms, but basically can be divided into automatic processing module for box-type multi-axis (Figure 7), turret multi-axis machining module (Figure 8) and multi-axis machining module Rotary Table (Figure 9). As for box-type module automatically be set in a special multi-axle box to store more and more libraries axle box, it can be used to process more parts of different species. 而轉(zhuǎn)塔式和回轉(zhuǎn)工作臺(tái)式多軸加工模塊，由于在轉(zhuǎn)塔頭和回轉(zhuǎn)工作臺(tái)上允許裝的多軸箱數(shù)量有限?(一般為4～6個(gè))，所以這種加工模塊只能實(shí)現(xiàn)有限品種的加工。 The turret and multi-axis machining module Rotary Table, due to the turret head and turn the table to allow installation of a limited number of multi-axle box (usually 4 to 6 months), so this processing module can only achieve limited variety of processing.
在自動(dòng)線上采用CNC三坐標(biāo)加工模塊和轉(zhuǎn)塔式多軸加工模塊，不僅可實(shí)現(xiàn)不同品種工件的加工，而且在自動(dòng)線?節(jié)拍時(shí)間內(nèi)(如果節(jié)拍時(shí)間允許的話)，這類加工模塊還可以在同一個(gè)加工工位上通過其自動(dòng)換刀或換箱，依次實(shí)?現(xiàn)多道加工工序(粗鏜、半精鏜和精鏜；鉆孔、擴(kuò)孔和攻絲)，從而減少自動(dòng)線的加工工位數(shù)，縮短自動(dòng)線的長(zhǎng)度?。 CNC Coordinate with automatic online processing modules and turret multi-axis machining modules, not only enables workpieces of different varieties, but also in the automatic line beat of time (if time permits, then the beat), this type of processing module can also be in the same processing station on the exchange through its automatic tool changing or box, and then click to realize multi-channel processing operation (rough boring, semi-fine boring and precision boring; drilling, reaming and tapping), thereby reducing the processing work automatically line the median, Automatic line to shorten the length. ?單軸和多軸復(fù)合加工模塊是一種三坐標(biāo)數(shù)控加工模塊，可通過自動(dòng)換刀或自動(dòng)更換多軸箱而實(shí)現(xiàn)單軸加工或多軸加工。 Single and multi-axis coordinate complex processing module is a CNC machining modules, can be automatically replaced by ATC, or multi-axle box and the realization of single-axis machining or multi-axis machining.值得提及的是，在80年代中期德國(guó)Honsberg公司推出的CNCMACH模塊化系統(tǒng)(圖10)是很有特色的一種模塊化系統(tǒng)，該系統(tǒng)充分應(yīng)用模塊化結(jié)構(gòu)原理，在作為系統(tǒng)基礎(chǔ)模塊的?CNC三坐標(biāo)模塊上，通過增減各種不同的功能模塊，拼裝成各種不同坐標(biāo)或不用工藝用途的加工模塊。 It is worth mentioning that in the mid 80s the company introduced CNCMACH Germany Honsberg modular system are characteristic of a modular system, modular structure of the full application of the principle as a basic module of the CNC system CMM module, through changes in various functional modules, assembled into a variety of different processes do not use coordinates or processing modules. Specifically, from the coordinates, except coordinate, it can also form two-coordinate and single-axis machining module; view from the Tool can be installed in libraries and multi-axle box tool libraries, can be realized individually or axle box of tools automatic replacement can also be followed to achieve the replacement tool and multi-axle box.
CNC?MACH系統(tǒng)，不僅在機(jī)械結(jié)構(gòu)方面，而且在控制和軟件等方面也是模塊化的。 CNC MACH system, not only in the mechanical structure, but also in control and software is modular and so on. Therefore, the use of the system modules can be easily assembled into flexible transfer lines (FTL), flexible manufacturing cell (FMC) or flexible manufacturing system (FMS). In addition to the various CNC machining modules, the robot and servo-driven machine tools and jigs is also flexible combination of a key component of flexible automatic lines. Particularly in the flexible nature of automatic online, now more common use of air-frame gantry robot automatic loading and unloading workpieces, for workpiece transfer position or flipped. For the handling of different workpieces can be set in the automatic line next to the gripper base in order to achieve the automatic gripper change. Fixture equipped with servo drives, to adapt to different job families in the automatic clamping work pieces.
該線采用的數(shù)控加工模塊有四個(gè)雙坐標(biāo)數(shù)控銑削模?塊、六個(gè)數(shù)控轉(zhuǎn)塔式多軸加工模塊和六個(gè)數(shù)控三坐標(biāo)加工模塊。 The line used in CNC machining module has four double-axis NC milling module, six CNC turret CNC multi-axis machining module and six coordinate processing module. Secondary station and the cleaning station operations by the robot workstation installation folder. As the composition of automatic wire processing module is NC, when the transformation process from a workpiece to another workpiece processing, simply by changing the NC program on the line, without the need for machinery, adjustment and modification.
4、 the increasing degree of integrated automation
近十年來，為進(jìn)一步提高工件的加工精度和減少工件在生產(chǎn)過程中的中間儲(chǔ)存、搬運(yùn)以及縮短生產(chǎn)流程時(shí)間，將工件加工流程中的一些非切削加工工序(如工序間的清洗、測(cè)量、裝配和試漏等)集成到自動(dòng)線或自動(dòng)線組成的生產(chǎn)系統(tǒng)中(圖15)，以實(shí)現(xiàn)工件加工、表面處理、測(cè)量和裝配等工序的綜合自動(dòng)Over the past decade, in order to further improve the machining accuracy of workpiece and the workpiece during the production process to reduce intermediate storage, handling and production processes to shorten the time the workpiece machining process in some non-cutting operations (such as inter-process cleaning, measurement, assembly and leak testing, etc.) integrated into the automated line or automatic line production system consisting of (Figure 15), in order to achieve workpiece machining, surface treatment, measurement and assembly processes of integrated automation.
清洗 Clean：In the automatic line and automatic line consisting of production systems, cleaning equipment, parts of the process is mainly used for cleaning and parts between the final cleaning.
工件的工序間清洗主要是為下一道工序創(chuàng)造必要的工作條件。 Between the cleaning processes the workpiece is mainly for the next process to create the necessary conditions of work. For example, the workpiece blank in the painting before, after processing the workpiece datum, deburring, the measurements carried out before and a variety of cleaning before assembly.
當(dāng)今，鑒于我們?nèi)祟愘囈陨娴沫h(huán)境日益受到工業(yè)污染的破壞，環(huán)境保護(hù)已引起人們的普遍重視。 Today, in view of the survival of our human environment is increasingly damaged by industrial pollution; environmental protection has attracted much attention. 近年來，國(guó)內(nèi)外越來越關(guān)注工業(yè)清洗對(duì)環(huán)境的污染。 In recent years, more and more concerned with industrial cleaning at home and abroad on the environment. 這就促使許多工業(yè)部門的零件清洗轉(zhuǎn)向應(yīng)用水劑清洗(采用酸性、中性或堿性清洗液，清洗液中主要含有磷酸鹽、活性劑和絡(luò)合劑等)，這種水劑清洗主要根據(jù)工件清洗質(zhì)量要求而采用噴淋(分散清洗)和浸漬(集中清洗)兩種工藝。 This has prompted many industries move on aqueous parts cleaning washing (using acidic, neutral or alkaline cleaning liquid, cleaning liquid containing mainly phosphate, active agents and complexing agents, etc.), primarily on the basis of such aqueous cleaning workpiece quality requirements and use of cleaning spray (distributed cleaning) and immersion (concentrated cleaning) are two processes.
基于環(huán)境保護(hù)、現(xiàn)場(chǎng)操作工人的保健和清洗工藝的合理化等要求，目前，清洗機(jī)已普遍采用封閉式布局，整個(gè)清洗過程是自動(dòng)進(jìn)行的，設(shè)備控制采用可編程控制器，并自動(dòng)監(jiān)控所有機(jī)械動(dòng)作和工藝技術(shù)參數(shù)。 Based on environmental protection, health care workers, field operations and cleaning process of rationalization and other requirements, now, cleaning machine has been widely used closed-end layout, Zheng Ge cleaning process is automatic and programmable controller equipment control, and automatic monitoring of all mechanical action and technical parameters. In such washing machines integrated evaporation, filtration, material recovery and processing devices, as shown in Figure 16 is a German Benz steering shell cleaning process. The washing machine is closed layout, the cleaning process is conducted in a closed system, through a cleaning fluid purification support system to achieve the recycling of cleaning fluid. In this system, as a purification unit is a core component of purification and recycling modules cleaning. The module consists of ultra-fine filters and evaporator joint composition, use of the integrated purification equipment and cleaning fluid produced by distilled water, re-used for parts cleaning and rinsing.
5、Automatic measurement
在自動(dòng)線上采用自動(dòng)測(cè)量旨在對(duì)工件的加工質(zhì)量進(jìn)行監(jiān)控。 Automatic line automatic measurement of the workpiece to the processing quality control. In recent years, due to the increasingly automated line to shorten cycle times, the accuracy of the workpiece and the measurement and also become increasingly demanding production conditions, therefore the automatic measurement system must not only work with high speed and high work precision, and to have strong anti-environmental interference (such as chips, dust, steam coolant, oil, vibration and temperature, etc.) capability or some interference with the measurement system can automatically compensate the amount of performance.
在自動(dòng)線上，自動(dòng)測(cè)量可分為加工前測(cè)量和加工后測(cè)量。 The automatic line, automatic measurement can be divided into pre-processing measurement and processed measurements.
加工前測(cè)量是在工件加工前通過測(cè)量以確定工件的特征，并利用測(cè)量結(jié)果來調(diào)整刀具相對(duì)于工件待加工部位的位置，然后進(jìn)行相應(yīng)的加工。 Processing before the measurement is in the workpiece before the workpiece by measuring to determine the characteristics and use measurements to adjust the tool position relative to the location of