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1
摘 要
組合機床要求完成曲軸箱箱蓋底面12孔的加工,文本包括鉆孔和多軸箱的整體設(shè)計的設(shè)計多軸的組合。如果根據(jù)“三圖一卡”,是根據(jù)原地圖上的頭匯編的分類機的整體設(shè)計,方案著重于所選擇的處理,并確定如何機器設(shè)置確定“三圖一卡”基于程序傳輸系統(tǒng)的結(jié)構(gòu)頭設(shè)計,通過不同程序,并最終給出最佳的解決方案。
關(guān)鍵詞:組合機床;定位 ;主軸箱;夾具
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Abstract
Combination machine tools required to complete the crankcase cover bottom hole processing, text including the design of the drilling and the overall design of spindle box of multi-axis combination. If according to figure 1 \"three CARDS\", is based on the original map head assembly as well as the design of classifier, the program focuses on the choice of treatment, and to determine how the machine Settings determine figure 1 \"three CARDS\" based on the structure of transmission system design, program through the different programs, and ultimately the best solution is given.
Keywords: Modular machine tool; Location ; Spindle Box ;Fixture Synchronizing;
目 錄
摘 要 1
Abstract 2
1 緒 論 3
1.1 課題背景和研究目的 3
1.3 課題研究趨勢及前景 3
1.4 課題主要研究內(nèi)容 3
2 組合機床的總體設(shè)計 4
2.1 總體方案論證 4
2.1.1 被加工零件工藝性的分析 4
2.1.2 機床配置型式的選擇 4
2.2 確定切削用量及選擇刀具 5
2.2.1 確定切削用量 5
2.2.2 確定所需的切削力、切削扭矩以及切削功率 5
2.3 鉆孔組合機床總體設(shè)計“三圖一卡”的編制 6
2.3.1 被加工零件工序圖 7
2.3.3 機床尺寸聯(lián)系總圖 11
2.3.4 機床生產(chǎn)率計算卡 13
3 多軸箱的設(shè)計 16
3.1 繪制多軸箱設(shè)計原始依據(jù)圖 16
3.2 齒輪模數(shù)選擇 17
3.3 多軸箱的傳動設(shè)計 17
4 組合機床夾具設(shè)計 20
4.2 鉆12-8孔夾具設(shè)計 20
4.2.1 研究原始質(zhì)料 20
4.2.2 定位基準(zhǔn)的選擇 20
4.2.3 夾具方案的設(shè)計選擇 20
4.2.4 切削力及夾緊力的計算 21
4.2.5 誤差分析與計算 22
4.2.6 夾具設(shè)計及操作的簡要說明 22
結(jié) 論 24
參考文獻 25
致 謝 26
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1 緒 論
1.1 課題背景和研究目的
社會在不斷發(fā)展,加工技術(shù)也在不斷發(fā)展,傳統(tǒng)的工具不能完全滿足新形勢的需求。傳統(tǒng)的機械零件只有一個單桿,單軸和單加工,生產(chǎn)效率低,加工精度不穩(wěn)定,為了克服傳統(tǒng)機床,工程和技術(shù)人員的相應(yīng)的設(shè)計,特別是特殊的機器。本機是以一種專業(yè)化的設(shè)計、制造工藝為基礎(chǔ)的,其零件的設(shè)計與制造,因此,與傳統(tǒng)機床相比,專用機床過于昂貴,設(shè)計制造周期長。為了解決傳統(tǒng)機床和專用機床之間的矛盾,為了提高效率降低成本以便批量生產(chǎn),可以發(fā)展組合機床。這種機床可以完成鉆孔、擴孔、銑削、磨削加工,生產(chǎn)效率高,加工精度穩(wěn)定,越來越多的工程師的關(guān)注。本課題為曲軸箱箱蓋底面12孔組合鉆床及夾具設(shè)計,有利于提高大批量生產(chǎn)的生產(chǎn)效率,提高加工精度穩(wěn)定性,節(jié)約各方面的資源。
1.3 課題研究趨勢及前景
近年來,雖然我國組合機床的銷售業(yè)績逐漸上升,但是一些公司生產(chǎn)的精度和功能組合機床仍不能滿足市場的需求。創(chuàng)新是一個企業(yè)不斷發(fā)展的根本,在現(xiàn)在科技經(jīng)濟快速發(fā)展的潮流下,傳統(tǒng)的組合機床一直落后于世界的平均水平,企業(yè)需要使自身創(chuàng)新能力達到一個新的平臺。我國組合機床設(shè)備還存在相當(dāng)大的差距,我國組合機床技術(shù)在高速設(shè)備,精度高、靈活性加工性能、模塊化、可調(diào)變量,通信技術(shù)的應(yīng)用將是未來主要的發(fā)展方向。
1.4 課題主要研究內(nèi)容
本次畢業(yè)設(shè)計的課題是曲軸箱箱蓋底面12孔組合鉆床及夾具設(shè)計,組合機床要求完成對曲軸箱箱蓋底面孔的加工,這臺組合鉆床是立式鉆床。對于這臺組合鉆床的設(shè)計包括總體設(shè)計和主軸箱的設(shè)計,在設(shè)計的過程中要用到以前學(xué)過的知識,如:機床、刀具、夾具、計算機輔助設(shè)計等方面的知識,還需要做到理論結(jié)合實際。
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2 組合機床的總體設(shè)計
2 組合機床的總體設(shè)計
2.1 總體方案的簡要論證
2.1.1 被加工零件(曲軸箱蓋)工藝性的分析
本次加工零件為曲軸箱蓋,材料HT200,GB/T 9439-2010,材料硬度(HB):163~255HB零件的材料是灰鑄鐵,加工12個φ8底孔,生產(chǎn)綱領(lǐng)為5萬臺。
圖2-1曲軸箱蓋零件
2.1.2 機床配置型式的選擇
由于被加工零件是在曲軸箱蓋底面上,確定設(shè)計的組合機床的配置型式為單工位立式單面鉆組合機。
2.1.3定位基準(zhǔn)的選擇
在鉆削底孔時,以底面作為定位基準(zhǔn),在工件側(cè)面采用三面定位,以滿足底孔與曲軸箱箱蓋底面加工的位置要求。
2.2 確定切削用量及選擇刀具
2.2.1 確定切削用量
選擇合理切削用量,對于組合機床的加工精度和生產(chǎn)率都有非常大的影響。組合機床多軸箱上的主軸刀具都同用一個進給系統(tǒng)。組合機床設(shè)計成多軸同步加工的時候,正常狀態(tài)切削用量會比一般通用機床單刀加工的低30%左右。
==……=
式中: ,,……為各主速
,,……為各主軸進量
為動力滑臺每分給量(mm/min)
,查閱《機械工人切削手冊》可知,布氏硬度為160~220時高速鋼鉆頭的切削用量:φ8mm,進給量,切度。
2.2.2 確定所需的切削力、切削扭矩以及切削功率
查表計算:
布氏硬度:HB=-1/3(-)
=255-(255-163) /3
=224.3
切削力:F=26D
=268
=848.3 N
切削扭矩:T=10
=10
=2120.2 Nmm
切削功率:P=Tv/9740D
=1556.910/(97403.148)
=0.087kw
轉(zhuǎn)速: n=v/πd
=10/(3.148)
=398 r/min
式中:HB為布氏硬度, F為切削力,D為鉆頭直徑 ,f為每轉(zhuǎn)進給量,T為切削扭矩,V為切度(m/min),P為切削功率(kw) ,n為轉(zhuǎn)速。
2.2.3 選擇刀具結(jié)構(gòu)
曲軸箱蓋底面的布氏硬度范圍為,孔徑D =8mm,在這種情況下應(yīng)選擇18Cr4V)作為刀具材料,采取Φ8麻花鉆作為刀具。
2.3 鉆孔組合機床總體設(shè)計“三圖一卡”的編制
“三圖一卡”指的是: 加工零件工序圖、機床聯(lián)系尺寸圖、加工示意圖、編制生產(chǎn)率卡。
2.3.1 被加工零件工序圖
曲軸箱箱蓋底面底孔加工工序圖如圖
加工零件圖是一個基礎(chǔ)的具體組合機床的設(shè)計,調(diào)整使用機器時,用于檢查重要技術(shù)文件的準(zhǔn)確性。
處理部分流程圖應(yīng)包括下列內(nèi)容:
a .圖紙上應(yīng)該顯示出被加工零件的形狀和尺寸和相關(guān)的機械設(shè)計部分的結(jié)構(gòu)形狀和大小。特別是當(dāng)你需要設(shè)置中間導(dǎo)套,應(yīng)該表達的內(nèi)部零件,裝飾墻壁和有關(guān)結(jié)構(gòu)的形狀和大小,為了檢查工件和夾具,工具發(fā)生干涉。
b與定位基準(zhǔn)圖應(yīng)該表達處理,夾緊的夾緊部分和方向的壓力,因此,反過來,作為支持,限制,夾緊的設(shè)計指導(dǎo)。
c在圖上應(yīng)該顯示的大小處理表面,精度、表面粗糙度、形狀位置尺寸精度和技術(shù)要求(包括工藝要求和機器以確保部分)。
d .圖也應(yīng)該表明加工零件的名稱,編號,硬度,材料,重量,加工余量的部分。
2.3.2 加工示意圖
下圖為曲軸箱蓋上鉆床加工示意圖。
加工示意圖的計算
(1)導(dǎo)向套的選擇 考慮主軸剛度,工件的同時,位置精度主要取決于夾具。
1)選擇導(dǎo)向類型 刀具導(dǎo)分直徑,線度,選擇固定式導(dǎo)向。
2)導(dǎo)向套的參數(shù) 刀具的直擇固定導(dǎo)置,如圖所示:
固定裝置的配合:
選擇固定導(dǎo)向,采用鉆孔的工藝方法,D取G7或F8,D1取,刀具導(dǎo)向部徑為g6 。
導(dǎo)向裝置的布置
(3)初定主軸類型、尺寸、外伸長度 由于軸的材料為,剪切彈性模量,剛性主軸取ψ =1/4()/m,所以, 主軸徑為:
d =B,計算得16.7mm
式中:d為軸直徑為軸所受的轉(zhuǎn)矩(N·mm)B為系數(shù)
本設(shè)計全部12根主軸直徑都取20mm,主軸外伸長度都取115mm,D/為32/20.。
(4)選擇刀具接桿 多軸箱每個主軸的外伸長度和刀具的長度都是定值,所以要設(shè)置一個可調(diào)環(huán)節(jié)(主軸與刀具之間)用來保證多軸刀具能同時到達加工終了位置,這個這個可調(diào)節(jié)在組合機床上是通過可以調(diào)整的刀具接桿來解決的。
刀具接桿參數(shù):
d (h6)
(h6)
L
20
20 2
莫氏1號
12.065
88
40
46
13
(5)多軸箱端面到工件底面的距離 是加工示意圖最為重要的聯(lián)系尺寸。這一距離越小越好,這樣可以縮短刀具懸伸和工作行程。這一距離的兩個決定的因素,其中一個是主軸上刀具、接桿、主軸等,因為結(jié)構(gòu)和相互聯(lián)系所要求的最小軸向尺寸;還有的是機床總布局所要求的聯(lián)系尺寸。這兩者是相互聯(lián)系和制約的。
(6)動力部件工作循環(huán)
a)工作進給長度的確定 工作進給長度=加工部位的長度L+刀具切入長度+切出長度,切入長度這里取7mm,又因為鉆孔為通孔,所以沒有,故=7+18+10=35mm
b)快速進給長度的確定 因考慮刀具能從接桿錐柄孔內(nèi)取出,所以確定為75mm
c)快速退回長度的確定 。由已確定的快速進給和工作進給長度可知,= +=75+35=110mm
d)動力部件總行程的確定 動力部件總行程除了滿足= +外,還要考慮前后備量。前備量距離不應(yīng)小于15~20mm。后備量是考慮刀具從接桿中取出所需要的距離,因此后備量應(yīng)大于77mm,s所以,
動力部件總行程=110+20+80=210mm
2.3.3 機床尺寸聯(lián)系總圖
選用動力部件主要選擇型號、動力滑臺和動力箱。
1)驅(qū)動形式 選擇HY系列液壓滑臺。
2)軸向進給力 滑臺進給力
(式中為各主軸加工時所產(chǎn)生的軸向力)
滑臺工作要克服各主軸的向力和滑臺產(chǎn)生的摩擦力。所以最大進給力應(yīng)該大于=。
3)進給速度 本系統(tǒng)給速度=。選擇壓滑臺,工作進度范圍,快速速度。
4)滑臺行程 滑臺的行程除了要保證足夠的工作行程之外,還應(yīng)留有前備量和后備量。這里取前備量為20mm,后備量80mm,滑臺總行程>工作行程+前備量+后備量。
行程L>110+20+80=210mm,取L=250mm。型號確定為壓動臺
(2)估動力箱
=/η
=
式中:η為多軸箱的傳動效率,加屬時η=0.8~0.9;有屬時η=0.7~0.8,這里取η=0.8.
動力箱選用Y100L—6B5的1TD25IA型動力箱,動力箱輸出軸至箱底面高度為125mm。
各參數(shù):
(3)確定裝料高度 取裝料高度為880mm。
(4)中間底座輪廓尺寸 中間底座采用側(cè)底座1CC251。
(5)確定多軸箱輪廓尺寸 寬度B 和高度H 可確定為:B=400 H=400,主軸箱輪廓尺寸B H=400400 mm。
2.3.4 機床生產(chǎn)率計算卡
A. 理想生產(chǎn)率Q
Q為生產(chǎn)綱領(lǐng),這與全年工時總數(shù)K有關(guān),一般情況下,單班生產(chǎn)K取2350 h,所以
Q = 年產(chǎn)量/K
= 50000/2350
= 21.28(件/h)
B.實際生產(chǎn)率
(件/h)
--------生產(chǎn)一個零件所需的爾時間,min,,計算公式如下
=
=2.519min
式中:
—進給程長度(mm)
—每分給量(mm/min)
—死留時間,在動力部件進給下這里取10r
—動力部件快速行程速度——直線移動或回轉(zhuǎn)工作臺進行一次工位轉(zhuǎn)換時間,取0.1min;
—裝卸工作時間,取1.5 min
所以
60/2.519
23.82 件/h
C.機床負荷率
=
式中:Q為機床的理產(chǎn)率(件/h)
A為年生領(lǐng)(件)
為年工作時間,單班制工作時間1833h
D. 生產(chǎn)率計算卡
被加工
零件
圖號
種類
鑄件
名稱
曲軸箱蓋
重量
材料
硬度
工序
鉆8底孔
工序號
工時/min
序號
工步
工作行程
切速/
進給量/(·r-1)
進給速度/(·min-1)
工作時間
輔助
1
安裝工件
0.5
2
工件定位夾緊
0.25
3
上動力部件快進
75
12000
0.006
4
上動力部件工進
35
10
0.1
39.8
0.88
5
死擋鐵停留
0.025
6
上動力部件快退
110
12000
0.009
7
工件松開
0.25
8
卸下工件
0.5
備注
累計
0.88
1.515
單件總工時
2.395
機床生產(chǎn)率
21.28 件/h
理論生產(chǎn)率
23.82件/h
負荷率
89.34%
4 組合機床夾具設(shè)計
3 多軸箱的設(shè)計
3.1 多軸箱設(shè)計原始依據(jù)圖
(1)多軸箱設(shè)計原始依據(jù)圖
軸號
主軸外伸尺寸
工序
內(nèi)容
切削用量
f
Vf
1,2,3,4,5,6,7,8,9,10,11,12
32/20
115
鉆Φ8
398
10
0.1
39.8
(2) 主軸外尺寸及切削用量如下表
(3)動力部件
1TD25IA型動力箱電機功率1.5KW,轉(zhuǎn)速940 r/min,驅(qū)動軸轉(zhuǎn)速520 r/min。
3.2 齒輪模數(shù)選擇
組合機床采用滾珠軸承主軸。
齒輪模數(shù)m可按下式估算:
m=(30~32)=32×
式中:m—齒數(shù)
P——齒輪傳率(kw)
Z——嚙合齒中輪數(shù)
N——輪速
3.3 多軸箱的傳動設(shè)計
驅(qū)動軸O
軸1
軸2
軸3
軸4
軸5
軸6
X
0
-320
-320
-225
-110
110
225
Y
-70
70
125
125
125
125
軸7
軸8
軸9
軸10
軸11
軸12
X
320
320
225
110
110
225
Y
70
-70
-125
-125
-125
-125
2) 各軸傳動軸傳動比
1)已知12個主軸轉(zhuǎn)速均為400r/min,驅(qū)動軸轉(zhuǎn)速為520 r/min,故總傳動比為u=400/520=1/1.3
2)因為主軸數(shù)目較多且分散,先減速選取兩個中間軸13,14,分別聯(lián)系各個主軸再提速,即u1=1.41
3)計算出中間軸與主軸的傳動比u2=1.08
(2) 計算各齒輪齒數(shù)
A0-13=A0-14=m(z0+z13)=225 m取4
z0=z13=z14=56
所以驅(qū)動軸與兩根中間軸的齒數(shù)都為56。
A14-5=m(z14+z5)=
z14/z5=1.08
z14=44 z5=41
中間軸傳動到軸5,中間軸齒數(shù)為44,主軸5齒數(shù)為41。
同理,中間軸傳動到軸6,中間軸齒數(shù)為33,主軸齒數(shù)為30。
中間軸傳動到軸7,中間軸齒數(shù)為31,主軸齒數(shù)為28。
12根主軸為中心對稱分布,對稱的主軸齒數(shù)相同。
上式 :m——齒輪模數(shù)
A——軸與軸的距離 mm
(3)分度圓直徑的計算
D0=D13=D14=mxz0=224 mm
D5=mxz5=204 mm
D6=mxz6 =120mm
D7=mxz7=112 mm
得到總圖
4 組合機床夾具設(shè)計
我的設(shè)計任務(wù)是曲軸箱箱蓋缸孔底面螺紋底孔組合鉆床及夾具設(shè)計。
4.2 鉆12-8孔夾具設(shè)計
4.2.1 研究原始質(zhì)料
本夾具主要用來鉆曲軸箱蓋底面12個8mm孔。加工時應(yīng)保證孔與底面的距離。找到定位基準(zhǔn)來保證技術(shù)要求。
4.2.2 定位基準(zhǔn)的選擇
選底面跟側(cè)面同時定位,對加工工件采用三面定位,從而來滿足孔與底面的位求。
4.2.3 夾具方案的設(shè)計選擇
上述定位基準(zhǔn)必須與同一工件在每個進程中參考步驟重合的情況下是用相同的定位基準(zhǔn)進行加工。本節(jié)中與三個定位所述安裝基準(zhǔn)面,并且它們也鞍上設(shè)計基準(zhǔn)的其他元素,因此,該安裝基準(zhǔn)面作為定位基準(zhǔn),避免了引用不是偶然誤差,幫助輸送大的表面積,提高相對位置精度。有份以上示圖,根據(jù)本程序,底部和側(cè)面定位基準(zhǔn)的選舉。
4.2.4 切削力及夾緊力的計算
查表可得:
切削力公式:
查表得:
切削力:F=26D
=268
=848.3 N
實際所需夾緊力參考表得:
安全系數(shù)K可按下式計算:
式中:為各種因素的安全系數(shù),查表可得:
所以
實際夾緊力較小選用手動螺旋夾緊機構(gòu)。
取,,
螺旋夾緊時產(chǎn)生的夾緊力,有::
查得:
其中:
:
采用該夾緊機構(gòu)工作是可靠的。
4.2.5 誤差分析與計算
孔與斜側(cè)面為線性尺寸一般公差。
取(中等級)即 :尺寸偏差為、
⑴ 定位誤差:定位尺寸公差,方向與加工方向垂直。。
⑵ 夾緊安裝誤差,對工序尺寸的影響均小
⑶ 磨損造成的加工誤差:不超過
⑷ 夾具相對刀具位置誤差:公差取
誤差總和:
4.2.6 夾具設(shè)計及操作的簡要說明
選擇手動夾緊機構(gòu)。這樣的結(jié)構(gòu)簡單的夾緊機構(gòu),可靠夾緊很大的通用性,夾具各種各樣的應(yīng)用。
結(jié) 論
這次畢業(yè)設(shè)計讓我對零件制造工藝、加工工藝和夾具設(shè)計有進一步的了解,也加深了所學(xué)的基本知識的學(xué)習(xí)和理解。畢業(yè)設(shè)計是最有效的理論與實踐方法。在具體設(shè)計過程中,必須考慮所有方面的問題,還要有正確的設(shè)計理論,在實踐中,經(jīng)常會有各種各樣的問題。所以,必須考慮在設(shè)計機制的設(shè)計是合理的,無論是工作在實踐中,不僅考慮理論的可行性,我學(xué)會了從實際加工零件和夾具的設(shè)計。
設(shè)計中,考慮到零件材料加工困難,成本問題,選擇的部件和組件是操作簡單,一般標(biāo)準(zhǔn)部件,以最低的成本實現(xiàn)從現(xiàn)在最先進的處理。這個設(shè)計的空白部分生產(chǎn)成品,中間經(jīng)過銑、鉆孔、等等。在夾具設(shè)計中,首先確定工件的基準(zhǔn),然后通過兩個銷定位,固定夾緊工件的夾具。在設(shè)計過程中計算刀具的切削力,夾具的夾緊力,等等,然后通過微機繪圖軟件繪制零件圖和裝配圖。整個設(shè)計過程將前我學(xué)會了機械制造技術(shù)和設(shè)備,機械制圖、公差配合,工程材料及熱處理過程和良好的知識串聯(lián)起來,鞏固了所學(xué)的知識,提高了我的學(xué)習(xí)能力。是沒有大問題的設(shè)計,基本滿足要求。但是存在一些缺點:
(1)理解工藝設(shè)計知識,很多知識學(xué)習(xí)不到位;
(2)夾具設(shè)計中不能進行分析比較,提出了計劃是不夠的。
參考文獻
[1] 謝家瀛. 組合機床設(shè)計簡明手冊[M].北京: 機械工業(yè)出版社,2002.
[2] 陳立德.機械制造裝備設(shè)計[M].北京:高等教育出版社,2010.
[3] 沈陽工業(yè)大學(xué)、大連鐵道學(xué)院、吉林工業(yè)學(xué)院編. 組合機床設(shè)計[M]. 上海: 上??茖W(xué)技術(shù)出版社,1985.
[4] 吳宗澤. 機械零件設(shè)計手冊[M]. 北京: 機械工業(yè)出版社,2004.
[5] 聞邦椿. 機械設(shè)計手冊[M]. 北京: 機械工業(yè)出版社,2010.
[6] 趙如福.金屬機械加工工藝人員手冊[M].上海:上??茖W(xué)技術(shù)出版社,1990.
[7] 孫麗媛.機械制造工藝及專用夾具設(shè)計指導(dǎo)[M].北京:冶金工業(yè)出版社,2003.
[8] 東北工學(xué)院機械設(shè)計、機械制圖教研室.機械零件設(shè)計手冊[M].北京:冶金工業(yè)出版社,1974.4
[9] 王先逵.機械制造工藝學(xué)[M].機械工業(yè)出版社,2000.
[10] 馬賢智.機械加工余量與公差手冊[M].中國標(biāo)準(zhǔn)出版社,1994.12.
[11] 劉文劍.夾具工程師手冊[M].黑龍江科學(xué)技術(shù)出版社,1987.
[12] 王光斗.機床夾具設(shè)計手冊[M].上海科學(xué)技術(shù)出版社,2002.8.
[13] Machine Tools N.chernor 1984.
[14] Machine Tool Metalworking John L.Feirer 1973.
致 謝
此次畢業(yè)設(shè)計是在指導(dǎo)老師趙海霞老師的指導(dǎo)下完成的,畢設(shè)所涉及到的內(nèi)容,趙老師都給了我很多悉心的指導(dǎo)和寶貴的建議,老師耐心的講解讓我收獲頗多。同時,老師還教給我許多專業(yè)知識和相關(guān)的設(shè)計方法。在此真誠地向百忙之中給我指導(dǎo)幫助的趙老師表示感謝。
最后還應(yīng)該感謝的是金陵科技學(xué)院,是學(xué)院給了我提高自己的機會和條件。使我通過學(xué)習(xí)變得更加成熟;學(xué)院給我了這次畢業(yè)設(shè)計機會,讓我在進入社會之前有這么好的鍛煉機會,相信今后走上工作崗位后,此次經(jīng)歷將是一筆財富。
畢 業(yè) 設(shè) 計(論 文)外 文 參 考 資 料 及 譯 文
譯文題目: The aggregate machine-tool
組合機床
學(xué)生姓名: 學(xué) 號:
專 業(yè):
所在學(xué)院:
指導(dǎo)教師:
職 稱:
20xx年 2月 27日
附錄:畢業(yè)設(shè)計外文翻譯原文
The aggregate machine-tool
Author: Pramila Rani
Nilanjan Sarkar
Eric Vanman
Summary: The aggregate machine-tool machining center may cause the demand which the processing manufacturing industry adapts changes unceasingly, uses the pool of labor power effectively, and has the competitive power in global scale's market.
Key word: aggregate machine-tool
The aggregate machine-tool is based on general parts, according to the specific shape and work piece machining process of the special components and fixture design, semi-automatic or automatic special machine. Editor this segment] The aggregate machine-tool machining The aggregate machine-tool usually adopts the multiracial, knife, more processes, and multi-faceted or multistage and processing, production efficiency than general machine high several times or more. Due to the standardization and serialization general parts have, can according to need flexible configuration, can shorten the cycle of design and manufacture. Therefore, the combination machine has the advantages of low cost and high efficiency, in large, large production is widely used, and the automatic production line can be used to composition.
The aggregate machine-tool for processing general box or special shape of parts. Processing, work piece rotate, generally by the tool and work piece rotate movement and tools for the relative motion, to realize in drilling, reaming, economic hole, reaming, boring, cutting and milling, and the processing thread and fiber-end surface etc. Some combination machine adopts clamping work piece machining head to rotate, feeding movement by the tool for, also can achieve some ax symmetrical parts (such as the flywheel, automobile rear half axle, etc.) of the circle and the process.
Combination machine parts classification
General parts according to the function can be divided into power components and parts, transmission parts, supporting the control and auxiliary parts. Power components are provided for The aggregate machine-tool in the movement and moving parts. Main motivation, cutting head and dynamic slide.
Supporting components are installed power to slide into to institutions, cutting head or fixture, have side base, base, support, adjustable bracket, column and column base, etc.
Transmission parts is used to transport or spindle box to the processing of the main parts, workstation dividing rotating table, the annular dividing rotating table, drum and to-and-fro moving workbench, etc.
Control components are used to control the machine parts, automatic working cycle is hydraulic pressure station and electrical cabinets and control console, etc. Auxiliary parts are lubrication device and cooling device and scraps discharge device etc.
The development of modular machine tool
In order to make the aggregate machine-tool in small batch production, often applied to the structure, the application of group technology and craft of similar parts in a centralized modular machine tool, in order to improve the machining efficiency. This machine has two kinds of common, spindle box The aggregate machine-tool and turn tower The aggregate machine-tool.
The aggregate machine-tool of future development will be more adopts stepless motor and transmission of ball screw, etc, to simplify structure and shorten the production beat, Using digital control system and spindle box, jig automatic replacement system, in order to improve the process adjustability, Flexible manufacturing systems and into.
The aggregate machine-tool is take the general part as a foundation, matches by presses the work piece specific shape and the processing technological design special-purpose part and the jig, the composition semiautomatic or the automatic special purpose machine. The aggregate machine-tool selects the method which generally multiple spindle, the multi-knives, the multi-working procedures, many or the multi-locations simultaneously process, production efficiency ratio general engine bed high several times to several dozens times. Because the general part already the standardization and the serration, might according to need to dispose nimbly, could reduce the design and the manufacturing cycle. The multi-axle-boxes are aggregate machine-tool's core parts. It selects the common parts, carries on the design according to the special-purpose request, in the aggregate machine-tool design's process, is one of work load big parts. It is acts according to the work piece processing hole quantity which and the position the working procedure chart and the processing schematic drawing determined, the cutting specifications and the main axle type design transmission various main axles movement power unit. Its power from the general power box, installs together with the power box in to feed sliding table, may complete drills, twists and so on working processes.
This topic designed has used in the top head hole processing the drill hole aggregate machine-tool. According to the top head hole components size which must process carries on the aggregate machine-tool general multi-axle-boxes the design, draws up the multi-axle-box primitive basis chart, the definite main axle and the gear modulus, determined the transmission system, calculates the main axle and drive shaft's coordinate. Through the above design, realized a top head one-sided six processing to complete, has achieved the design requirements well。
To meet the combination of CNC machine tools of development, it is a component of the NC machine tool NC module. Portfolio machine is modular combination of CNC machine tools brought about by the inevitable result is the combination of CNC machine tools necessary foundation, NC module so greatly enriched the portfolio of generic pieces of machine tools, it will cause combination of General Machine Type of a fundamental change. NC modules, according to their coordinates NC (axis) of mainly single coordinates, dual coordinates and coordinates. Its spindle number, single and multi-axis module, there are single and multi-axis
composite processing module. NC module development, there are mainly two kinds of ways: First, the existing the aggregate machine-tool tools should be relatively common items, the NC General of the design. At present there is also domestic NC is developing one-dimensional slider, NC two-dimensional (Cross) Waterloo Taiwan, the NC rotary table, all this is the way the NC is based on the characteristics of the development of NC The unique the aggregate machine-tool tool parts, such as automatic replacement of multi-axis spindle box, the NC rotary knife, NC for the manipulator, NC for me, such as mechanical hand. The past 10 years, machine tools and automatic line group in the highly efficient, high productivity, flexibility and the use of parallel (synchronous) works develop more reasonable and more savings in the programmed has made a lot of progress. In particular the automobile industry, in order to improve the performance of motor vehicles, precision machining of components made a number of new demands, so the machine performance requirements are also higher.
In recent years, with numerical control technology, electronics technology, computer technology, such as the development of machine tools combination of mechanical structure and control system has also undergone a tremendous change. With the the aggregate machine-tool tools of development:
1) . NC. A combination of CNC machine tools, not only a complete change from the previous relay circuit composed of a the aggregate machine-tool tool control system, and the head. Also the mechanical structure and composition of machine parts universal standards has or is undergoing an enormous change。
2) . Modular. NC plus one two modular greatly enrich the composition of the Universal machine parts, it will cause universal machine combination of a fundamental change,According to modularization design theory, the modules of aggregate machine tool are divided in this paper on the basis of function analysis. Taking UG software as developing flat, the parametric 3D modeling module bank is set up. The database for storing the data used in design is also set up at the same time. Under the guiding of the system, users can complete such tasks as module choice, module combination, and calculation, etc.Therefore,computer aided modularization design of aggregate machine tool can be realize..
3) . High-speed. As high-speed processing can greatly reduce the surface roughness and cutting force components, greatly reducing cutting temperature, increase productivity, the machine's high-speed research is rising, especially NC machine tool movements and the main feed velocity has reached an alarming high-speed . For example, the U.S. production of processing center, spindle speed up to 15 000-60 000r/min, table fast forward speed of up to 90-120 m / min. Conform to the trend of high-speed machines, machine tools combination of speed getting higher and higher. For example, the German Volkswagen plant in the processing of aluminum cylinder head combustion chamber side, the use of PCD cutter and milling speed of up to 3 075m/min, feed rate of 3 600mm/min, the CBN has adopted the installation of the new boring knife blade processing Kevin Gray Rail, the cutting speed of 800 m / min, feed rate of I 500 mm / min. 4, precision of. As the realization of NC machine tools, thus increasing the accuracy of processing machine, so that some of the past seem difficult to achieve the accuracy of processing has been realized today.5. Protection of the whole. Completely closed the machine is now a major characteristic, whether single or machine tool production lines, are all closed by the housings, electrical, hydraulic full use of air alignment. All closed protection, not only production line machine tools and their aesthetic appearance, but also improve the safety, reliability and ease of maintenance.
Machine tools and automatic combination of technical development trend line
Combination of automated machine tools and machine tool portfolio is a dedicated high-performance line of automation technology and equipment, at present, it is still a large number of mechanical products for efficient, high-quality and economic production of key equipment, have been widely used in automobiles, tractors, internal combustion engines and compression machines and many other areas of industrial production. Which, in particular the automotive industry is the combination of the largest machine tool and automatic line users? Such as the German Volkswagen plant in Salzgitter engine plant, used in the early 90's metal-cutting machine is automatic line (60%), Modular Machine Tool (20%) and processing center (20%). It is clear that mass production of machinery in the industrial sector, a large number of combinations used in machine tool equipment and automatic lines. Therefore, the the aggregate machine-tool and automatic line technical performance and the level of integrated automation, determine to a large extent the industrial sector production efficiency, product quality and production structure, but also enterprise products to a large extent determines the competitiveness.
Modern machine tools and automatic line combinations as a mechanical-electrical integration products, it is the control-driven, measurement, monitoring, tool and machinery components, such as a comprehensive reflection of technology. Over the past 20 years, these technologies have made considerable progress, at the same time as the main users of combined machine tool and automotive industries, such as internal combustion engines have a lot of changes in the market for their products continue to shorten life expectancy, increasing variety and quality improved. These factors promote and stimulate the the aggregate machine-tool tools and automatic lines for the continuous development of technology.
1 combination of tools focused on the development of varieties
Machine tools in the portfolio in such a dedicated machine, rotary combination of multi-machine and automatic line plays an important role. Because these two types of machine can work in many of the processes assigned to the position on a number of processing and at the same time from different directions on the work piece surface for processing a few, in addition, can also switch fixture (in the rotary table machine) or by translocation, inversion devices (in the automatic online) the realization of the five parts or all of the processing process, which has a high degree of automation and production efficiency, by a car, motorcycle and compressors used in industrial sectors such as .
According to the statistics, Germany in 1990 and 1992, rotary combination of multi-machine and automatic production lines each the aggregate machine-tool tool about 50% of the total.
It should be noted that rotary combination of multi-machine is a special type of small automatic lines, the outline of the size suitable for processing small and medium-sized pieces of ≤ 250mm. Compared with the automatic line, with a work piece in the processing of cases, multi-rotary machine share portfolio automatically operating area than a small line of about 2 / 3.
At present, characterized by mass production of cars and light trucks, the engine output is usually around 60 million units, the realization of such a large volume, multi-station rotary machine and automatic line combinations in the three cases the operation, the beat period of 20 to 30 seconds, when a greater volume of production parts, the machine would also like to beat the time shorter. In the 70's, automatic line in order to achieve such a short period of the beat, often side by side duplex to be used or set up two ways, namely, the decision of the automatic line rhythms, processes the longest processing time through parallel processing of two identical workers spaces, if more restrictive process, then the same through the use of two automatic lines to balance the processing line system automatically beat. It is clear that this is necessary to increase investment in equipment and operating area. Automatic beat short lines, mainly by shortening the time and support the basic time to achieve.
There are two virtues that are low cost and high efficiency in modular machine tools, which is widely used in batch production. This text introduces an automatic control system of multi-station modular machine tool. Applying PLC to control the modular machine tool can raise the automation extent and work efficiency and reduce a great deal of hardware wiring,so the dependability of the machine tool is also increased.
組合機床
作者: Pramila Rani
Nilanjan Sarkar
Eric Vanman
摘要:組合機床加工中心可使加工制造業(yè)適應(yīng)不斷變化的需求,有效利用勞動力資源,并在全球范圍的市場上更具競爭力。
關(guān)鍵詞:組合機床
組合機床是以通用部件為基礎(chǔ),配以按工件特定形狀和加工工藝設(shè)計的專用部件和夾具,組成的半自動或自動專用機床??倷C床的加工一般采用多軸,多方面的或多級加工,生產(chǎn)效率比通用機床高幾倍至幾十倍。由于標(biāo)準(zhǔn)化和序列化通用部件的使用,可以根據(jù)需要靈活配置,縮短設(shè)計和制造周期。因此,結(jié)合機低成本和高效率的優(yōu)點,,在大型生產(chǎn)制造中得到廣泛的應(yīng)用。
組合機床一般用于加工箱體類或非凡外形的零件。加工時,工件一般不旋轉(zhuǎn),由刀具的旋轉(zhuǎn)運動和刀具與工件的相對進給運動,來實現(xiàn)鉆孔、擴孔、锪孔、鉸孔、鏜孔、銑削平面、切削內(nèi)外螺紋以及加工外圓和端面等。一些組合機床采用夾緊工件加工頭旋轉(zhuǎn),可以實現(xiàn)一些軸對稱的零件(如飛輪、汽車后輪半軸等等)的加工循環(huán)過程。
1.部件分類
通用部件按功能可分為動力部件、支承部件、輸送部件、控制部件和輔助部件五類。動力部件是為組合機床提供主運動和進給運動的部件。主要有動力箱、切削頭和動力滑臺。
支承部件用以安裝動力滑臺,包括各種底座和支架;輸運部件用以輸送工件或主軸箱至加工工位;控制部件用以控制機床的自動工作循環(huán)。
輸送部件是用以輸送工件或主軸箱至加工工位的部件,主要有分度回轉(zhuǎn)工作臺、環(huán)形分度回轉(zhuǎn)工作臺、分度鼓輪和往復(fù)移動工作臺等。
控制部件是用以控制機床的自動工作循環(huán)的部件,有液壓站、電氣柜和操縱臺等。輔助部件有潤滑裝置、冷卻裝置和排屑裝置等。
2.組合機床的發(fā)展
為了使組合機床能在中小批量生產(chǎn)中得到應(yīng)用,往往需要應(yīng)用成組技術(shù),把結(jié)構(gòu)和工藝相似的零件集中在一臺組合機床上加工,以提高機床的利用率。這類機床常見的有兩種:主軸箱式組合機床和轉(zhuǎn)塔式組合機床。
組合機床未來的發(fā)展將更多的采用調(diào)速電動機和滾珠絲杠等傳動,以簡化結(jié)構(gòu)、縮短生產(chǎn)節(jié)拍;采用數(shù)字控制系統(tǒng)和主軸箱、夾具自動更換系統(tǒng),以提高工藝可調(diào)性;以及納入柔性制造系統(tǒng)等。
組合機床一般采用多軸、多刀、多工序、多面或多工位同時加工的方式,生產(chǎn)效率比通用機床高幾倍至幾十倍。由于通用部件已經(jīng)標(biāo)準(zhǔn)化和系列化,可根據(jù)需要靈活配置,能縮短設(shè)計和制造周期。多軸箱聚合是機床的核心部件,它選擇的共同部分,根據(jù)專用要求進行設(shè)計,在聚合機床設(shè)計的過程中是工作量大部件之一。根據(jù)工件加工孔的數(shù)量和位置工序圖,加工示意圖確定切削規(guī)范和主軸類型設(shè)計傳輸各種主要動力裝置軸運動。
這個設(shè)計用于頂部頭孔加工鉆孔機床。根據(jù)大小頭孔頂部組件進行聚合機床一般設(shè)計、草擬原始依據(jù)圖,確定主軸和齒輪模數(shù),確定傳動系統(tǒng),計算主軸和傳動軸的協(xié)調(diào)。通過以上的設(shè)計達到設(shè)計要求。
為了滿足數(shù)控組合機床的發(fā)展,誕生一個組件的數(shù)控機床數(shù)控模塊。模塊化數(shù)控機床的組合是數(shù)控機床的必要基礎(chǔ)。數(shù)控模塊極大地豐富了投資組合的通用機床,使一般機器類型的組合發(fā)生根本性的改變。數(shù)控模塊根據(jù)它們的坐標(biāo)控制,數(shù)控軸的主要有單坐標(biāo)、雙坐標(biāo)和坐標(biāo)。其主軸有單一和多軸復(fù)合處理模塊。目前國內(nèi)數(shù)控發(fā)展一維二維數(shù)控轉(zhuǎn)臺,如多軸自動更換主軸箱,數(shù)控旋轉(zhuǎn)刀,機械手等。在過去的10年里,機床的高效、高生產(chǎn)率、靈活性有了很大的進步。尤其是汽車行業(yè),為了提高汽車的性能,零部件精密加工提出許多新的要求。因此,機器性能要求也更高。
近年來,隨著數(shù)控技術(shù)、電子技術(shù)、計算機技術(shù),機床的發(fā)展相結(jié)合的機械結(jié)構(gòu)和控制系統(tǒng)也經(jīng)歷了巨大的變化。機床的發(fā)展如下:
(1)數(shù)控 數(shù)控機床的機械結(jié)構(gòu)和組成部分已經(jīng)或正在經(jīng)歷一個巨大變化的通用標(biāo)準(zhǔn)。
(2)模塊化 數(shù)控的一兩個模塊極大地豐富通用機械的組成部分,它將導(dǎo)致通用機械一個根本性的改變。根據(jù)模塊化設(shè)計理論,在總機床模塊劃分的基礎(chǔ)上,以UG軟件為開發(fā)平面時,建立參數(shù)化三維模塊,設(shè)計中使用的數(shù)據(jù)庫來存儲數(shù)據(jù)也設(shè)置在同一時間。在系統(tǒng)指導(dǎo)下,用戶可以完成這樣的模塊選擇、模塊組合和計算等。因此,計算機輔助模塊化可以實現(xiàn)組合機床設(shè)計。
(3)高速 高速處理可以大大降低切削力和表面粗糙度,大大降低切削溫度,提高生產(chǎn)率。現(xiàn)在數(shù)控機床運動和主給水速度已經(jīng)達到了驚人的高速。例如,美國生產(chǎn)的加工中心主軸轉(zhuǎn)速15000-60000r/min。快進速度高達90-120米/分鐘。符合趨勢的高速機,機床的速度變得越來越高。例如,德國大眾汽車工廠的處理鋁氣缸蓋燃燒室,PCD刀具的使用和銑削速度3075米/分鐘。3600毫米/分鐘的進給速率。CBN采取了新的鏜刀刀片的安裝處理凱文?格雷鐵路的切割速度800米/分鐘,進給500毫米/分鐘,4精度。數(shù)控機床的出現(xiàn),增加加工機械的準(zhǔn)確性,所以一些過去似乎難以實現(xiàn)的加工現(xiàn)在不是問題。整體保護,完全封閉是現(xiàn)在機器的一個主要特點,封閉的外殼、電氣、液壓充分利用空氣對齊。所有封閉的保護,不僅生產(chǎn)線機床及其式樣美觀,而且提高安全性、可靠性,并且易于維護。
自動機床和機床組合是一個專用的高性能的自動化技術(shù)和設(shè)備。目前,它仍然是大量機械產(chǎn)品高效、高質(zhì)量和經(jīng)濟生產(chǎn)的關(guān)鍵設(shè)備,已經(jīng)廣泛應(yīng)用于汽車、拖拉機、內(nèi)燃機和壓縮機器和其他許多工業(yè)生產(chǎn)領(lǐng)域。尤其是汽車行業(yè)最大的組合機床的用戶。比如德國大眾在薩爾茨基特發(fā)動機廠,90年初的金屬切削機床中使用自動線(60%)、組合機床(20%)和加工中心(20%)。很明顯,大規(guī)模生產(chǎn)機械在工業(yè)部門,大量的用于組合機床設(shè)備和自動生產(chǎn)線。因此,組合機床和自動生產(chǎn)線的技術(shù)性能和綜合自動化的水平,在很大程度上決定工業(yè)部門的生產(chǎn)效率、產(chǎn)品質(zhì)量和生產(chǎn)結(jié)構(gòu),但也在很大程度上決定了企業(yè)產(chǎn)品的競爭力。
現(xiàn)代機床和自動線組合作為機電一體化產(chǎn)品,它是測量、監(jiān)視、工具和機械組件,如技術(shù)的綜合反映。在過去的20年里,這些技術(shù)取得了很大的進展,同時結(jié)合機床和汽車行業(yè)的主要用戶,這些因素推動和刺激總機床工具和自動生產(chǎn)線技術(shù)的不斷發(fā)展。
組合工具集中在品種開發(fā),在組合機床專用機器和自動旋轉(zhuǎn)組合線起著重要的作用,因為這兩種機器可以工作的許多過程分配給這個職位處理,同時從不同的方向?qū)ぜ砻孢M行處理。此外,還可以切換夾具(在轉(zhuǎn)盤機)或易位,反演設(shè)備(自動在線)的實現(xiàn)五個部分或全部處理過程,具有高自動化程度和生產(chǎn)效率。被用于汽車、摩托車和壓縮機工業(yè)等行業(yè)。
據(jù)統(tǒng)計,德國在1990年和1992年,旋轉(zhuǎn)組合多機和自動生產(chǎn)線每個聚合機床工具約占總數(shù)的50%。
應(yīng)該注意,旋轉(zhuǎn)組合多機是一種特殊類型的小型自動生產(chǎn)線,適合加工大小輪廓中小件≤250毫米。和自動生產(chǎn)線加工工件的情況下,自動操作區(qū)域比小大約2/3。
目前,在大規(guī)模生產(chǎn)的汽車和輕型卡車中,發(fā)動機的輸出通常是6000萬臺左右,實現(xiàn)如此大的體積,多工位旋轉(zhuǎn)機和線自動組合不可少,節(jié)拍時間的20到30秒。在70年代,為了實現(xiàn)短時間內(nèi)的自動行程加工,經(jīng)常并排使用或設(shè)置兩種方式,即自動的決定行節(jié)奏,通過并行處理流程,限制性更強的過程,然后通過使用兩個相同的自動生產(chǎn)線平衡生產(chǎn)線系統(tǒng)。很明顯,這是必要的,以增加設(shè)備投資和操作區(qū)域。自動打短線路,主要是通過縮短時間和支持的基本實現(xiàn)。
有兩個優(yōu)點,在模塊化機床成本低、效率高,廣泛用于批量生產(chǎn)。本文介紹了多工位組合機床的自動控制系統(tǒng)。應(yīng)用PLC控制組合機床可以提高自動化程度和工作效率,減少大量的硬件接線,因此機床的可靠性也會增加。