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CHANGZHOU INSTITUTE OF TECHNOLOGY 畢業(yè)設(shè)計(jì)（論文）材料 題目： 儀表殼自動(dòng)化壓裝機(jī)的設(shè)計(jì) 二級(jí)學(xué)院（直屬學(xué)部）： 機(jī)電工程學(xué)院 專(zhuān) 業(yè)：機(jī)械設(shè)計(jì)與制造及其自動(dòng)化 班級(jí)： 06機(jī)單 學(xué)生姓名： 陳天平 學(xué)號(hào)： 06010603 指導(dǎo)教師姓名： 劉天軍 職稱(chēng)： 副教授 評(píng)閱教師姓名： 云介平 職稱(chēng)： 副教授 序號(hào) 名 稱(chēng) 數(shù)量 備注 1 畢業(yè)設(shè)計(jì)（論文）選題申報(bào)表 1 2 畢業(yè)設(shè)計(jì)（論文）任務(wù)書(shū) 1 3 畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告 1 4 畢業(yè)設(shè)計(jì)（論文）進(jìn)展情況記錄 1 5 畢業(yè)論文（設(shè)計(jì)說(shuō)明書(shū)） 1 6 圖紙 7 7 英文翻譯 1 2010 年 6 月 注：畢業(yè)設(shè)計(jì)（論文）工作結(jié)束后，請(qǐng)將該封面目錄中各項(xiàng)材料收齊統(tǒng)一放入學(xué)生“畢業(yè)設(shè)計(jì)（論文）資料袋”中。無(wú)法放入資料袋中的可另放，但要在備注欄注明存放處。 常州工學(xué)院機(jī)電工程學(xué)院畢業(yè)設(shè)計(jì)說(shuō)明書(shū) 第一章 引言 1.1 序言 畢業(yè)設(shè)計(jì)是完成了全部基礎(chǔ)課，技術(shù)基礎(chǔ)課，專(zhuān)業(yè)課以及參加了生產(chǎn)實(shí)現(xiàn)之后，在大學(xué)四年學(xué)習(xí)中最后一個(gè)學(xué)期進(jìn)行的。這是畢業(yè)之前對(duì)所學(xué)各課程的一次深入的綜合性的總復(fù)習(xí)，也是一次理論聯(lián)系實(shí)際的訓(xùn)練，通過(guò)這次畢業(yè)設(shè)計(jì)對(duì)未來(lái)從事的工作進(jìn)行一次適應(yīng)性訓(xùn)練，從中鍛煉分析能力，解決問(wèn)題能力，為今后的工作打下基礎(chǔ)。 通過(guò)本次畢業(yè)設(shè)計(jì)，得到以下的收獲與訓(xùn)練： 1. 能熟悉運(yùn)用理論力學(xué)，機(jī)械設(shè)計(jì)等課程的專(zhuān)業(yè)知識(shí)及設(shè)計(jì)計(jì)算。 2. 結(jié)構(gòu)設(shè)計(jì)的能力，能運(yùn)用學(xué)過(guò)的知識(shí)，完成零件的結(jié)構(gòu)與設(shè)計(jì)，并通過(guò)學(xué)過(guò)的軟件完成繪圖。 3. 學(xué)會(huì)使用圖表及手冊(cè)資料。熟悉查找與本課題相關(guān)的各種資料名稱(chēng)，出處，能做到熟悉運(yùn)用。 1.2 課題來(lái)源 本課題來(lái)源于常州紅梅電力設(shè)備廠，壓裝機(jī)可用于試制產(chǎn)品的壓裝，壓裝空間適用于各種產(chǎn)品。 應(yīng)用的設(shè)計(jì)原理：采用高質(zhì)量的交流伺服電機(jī)，減速器，PLC傳動(dòng)方式，具有導(dǎo)向裝置。向下壓入的速度可調(diào)，采用無(wú)級(jí)調(diào)速方式。本課題旨在解決儀表生產(chǎn)中的錐形薄片壓入儀表殼中的工序自動(dòng)化問(wèn)題，既要保證壓入的位置，同時(shí)必須保證錐形薄片在同一位置產(chǎn)生精度相同的變形。本課題要求學(xué)生自動(dòng)化錐形薄片自動(dòng)化壓裝系統(tǒng)設(shè)計(jì)的壓裝機(jī)設(shè)計(jì)，完成壓裝機(jī)構(gòu)的運(yùn)動(dòng)分析、工序設(shè)計(jì)、結(jié)構(gòu)設(shè)計(jì)及關(guān)鍵零部件設(shè)計(jì)。該課題與生產(chǎn)實(shí)踐相結(jié)合，有較高的實(shí)用價(jià)值和借鑒價(jià)值，該課題主要培養(yǎng)學(xué)生產(chǎn)品設(shè)計(jì)的綜合能力，協(xié)同工作能力等。 壓裝機(jī)可采用手動(dòng)/自動(dòng)程序兩種操縱方式進(jìn)行控制。 1.3設(shè)計(jì)要求 本課題旨在解決儀表生產(chǎn)中的錐形薄片壓入儀表殼中的工序自動(dòng)化問(wèn)題，既要保證壓入的位置，同時(shí)必須保證錐形薄片在同一位置產(chǎn)生精度相同的變形。本課題要求學(xué)生自動(dòng)化錐形薄片自動(dòng)化壓裝系統(tǒng)設(shè)計(jì)的壓裝機(jī)設(shè)計(jì)，完成壓裝機(jī)構(gòu)的運(yùn)動(dòng)分析、工序設(shè)計(jì)、結(jié)構(gòu)設(shè)計(jì)及關(guān)鍵零部件設(shè)計(jì)。該課題與生產(chǎn)實(shí)踐相結(jié)合，有較高的實(shí)用價(jià)值和借鑒價(jià)值，該課題主要培養(yǎng)學(xué)生產(chǎn)品設(shè)計(jì)的綜合能力，協(xié)同工作能力等。 技術(shù)指標(biāo)：每分鐘完成任務(wù)15只金屬儀表盤(pán)的壓裝,壓裝精度滿(mǎn)足生產(chǎn)要求。 第二章 壓裝機(jī)的設(shè)計(jì) 2.1 儀表殼 圖2-1錐形薄片 將錐形薄片壓入儀表殼，既要保證壓入的位置，同時(shí)必須保證錐形薄片在同一位置產(chǎn)生精度相同的變形，以完成儀表生產(chǎn)中的錐形薄片壓入儀表殼中的工序自動(dòng)化問(wèn)題。 2.2 裝配夾具 圖2-2裝配夾具 如圖2-2所示，裝備夾具用來(lái)固定錐形薄片，使其有準(zhǔn)確的壓裝。 2.3 壓頭 （a） （b）壓頭 圖2-3 如圖2-3所示，錐形薄片利用裝備夾具的定位，由凸輪1將其固定(圖a)，外軸采用凸輪下降，其下端的錐形面使錐形薄片壓緊于裝配夾具里，然后內(nèi)軸下降使下端的沖壓頭將錐形薄片的翼耳翻轉(zhuǎn)并固定在裝配夾具的凸緣上，壓裝完畢，內(nèi)外軸向上縮回（圖b）。 2.4凸輪機(jī)構(gòu)的設(shè)計(jì) 凸輪機(jī)構(gòu)因機(jī)構(gòu)中有一特征凸輪而得名。凸輪是指具有曲線(xiàn)輪廓或凹槽等特定形狀的構(gòu)件。凸輪通過(guò)高副接觸帶動(dòng)從動(dòng)件實(shí)現(xiàn)預(yù)期的運(yùn)動(dòng)，這樣構(gòu)成的機(jī)構(gòu)成為凸輪結(jié)構(gòu)。 凸輪機(jī)構(gòu)可分為平面凸輪機(jī)構(gòu)，空間凸輪機(jī)構(gòu)等類(lèi)型。凸輪機(jī)構(gòu)廣泛用于各種機(jī)構(gòu)中，特別是自動(dòng)機(jī)械，自動(dòng)控制裝置和裝配生產(chǎn)線(xiàn) 2.4.1凸輪機(jī)構(gòu)的組成 凸輪機(jī)構(gòu)一般是由凸輪，從動(dòng)件和機(jī)架組成的一種高副機(jī)構(gòu)?！?-3】 2.4.2凸輪機(jī)構(gòu)的類(lèi)型 凸輪機(jī)構(gòu)可根據(jù)凸輪的形狀，從動(dòng)件的形狀和運(yùn)動(dòng)方式及凸輪與從動(dòng)件維持高副的 接觸方法來(lái)分別分類(lèi)?！?-3】 (1).按照凸輪的形狀分類(lèi)：移動(dòng)凸輪機(jī)構(gòu)，盤(pán)型凸輪機(jī)構(gòu)和圓柱凸輪機(jī)構(gòu)。其中盤(pán)型凸輪機(jī)構(gòu)是凸輪機(jī)構(gòu)中最基本的結(jié)構(gòu)形式，應(yīng)用最廣。 (2). 按照從動(dòng)件的形狀分類(lèi)：尖端從動(dòng)件凸輪機(jī)構(gòu)，曲面從動(dòng)件凸輪機(jī)構(gòu)，滾子從動(dòng)件凸輪機(jī)構(gòu)和平底從動(dòng)件凸輪結(jié)構(gòu)。 (3).按照從動(dòng)件的運(yùn)動(dòng)形式分：移動(dòng)從動(dòng)件和擺動(dòng)從動(dòng)件凸輪機(jī)構(gòu)。 (4).按照凸輪與從動(dòng)件維持高副接觸的方法分：力封閉型凸輪機(jī)構(gòu)和形封閉型凸輪機(jī)構(gòu)。其中形封閉型凸輪機(jī)構(gòu)又可分為：槽型凸輪機(jī)構(gòu)，等寬凸輪機(jī)構(gòu)，等徑凸輪機(jī)構(gòu)和共軛凸輪機(jī)構(gòu)。【1-3】 2.4.3從動(dòng)件常用運(yùn)動(dòng)規(guī)律特征比較及適用場(chǎng)合【20-23】 表2-1 從動(dòng)件常用運(yùn)動(dòng)規(guī)律 運(yùn)動(dòng)規(guī)律 相應(yīng)方程 Vmax=（hw/?o）× amax=(hw2/?o2)× 沖擊 應(yīng)用場(chǎng)合 多項(xiàng)式 等速 1.00 ∞ 剛性 低速輕載荷 等加速等減速 2.00 4.00 柔性 中速輕載荷 3-4-5多項(xiàng)式 1.88 5.77 無(wú) 高速中載荷 三角函數(shù) 正弦加速度 2.00 6.28 無(wú) 中高速輕載荷 余弦加速度 1.57 4.93 柔性 中低速中載荷 2.4.4 運(yùn)動(dòng)規(guī)律的組合 從表1-1列出的基本運(yùn)動(dòng)規(guī)律及其方程的運(yùn)動(dòng)特征可以看出，由于存在沖擊或加速度的最大值amax較大，使得基本運(yùn)動(dòng)規(guī)律應(yīng)用于高速場(chǎng)合時(shí)的運(yùn)動(dòng)和動(dòng)力性能較差。為了克服基本運(yùn)動(dòng)規(guī)律的缺陷，通常將不同的基本規(guī)律進(jìn)行組合，以得到運(yùn)動(dòng)和動(dòng)力性 能較佳的新的運(yùn)動(dòng)規(guī)律，一般也稱(chēng)這種運(yùn)動(dòng)規(guī)律為組合式運(yùn)動(dòng)規(guī)律。 組合式運(yùn)動(dòng)規(guī)律必須遵循以下兩條原則：【2,3,9,17】 一，為避免剛性沖擊，位移曲線(xiàn)和速度曲線(xiàn)必須連續(xù)；對(duì)于中、高速凸輪機(jī)構(gòu)，還應(yīng)該避免柔性沖擊，也就是要求曲線(xiàn)也必須連續(xù)。所以，當(dāng)用不同運(yùn)動(dòng)規(guī)律組合起來(lái)行成從動(dòng)件完整的運(yùn)動(dòng)規(guī)律時(shí)，各段運(yùn)動(dòng)規(guī)律的位移、速度和加速度曲線(xiàn)在連接點(diǎn)處的值應(yīng)分別相等，這也是運(yùn)動(dòng)規(guī)律組合時(shí)應(yīng)滿(mǎn)足的邊界條件。 二，應(yīng)使用組合后的運(yùn)動(dòng)規(guī)律的最大速度值vmax、最大加速度值amax、最大躍度值jmax和vmax與amax的乘積mmax=vmax×amax的值盡可能小。若從動(dòng)件的負(fù)載是靜態(tài)的，如彈簧力、重力和靜態(tài)力的工作阻力，則驅(qū)動(dòng)轉(zhuǎn)矩與速度成正比，所以，vmax較小，則靜態(tài)驅(qū)動(dòng)轉(zhuǎn)矩也較小。另外，vmax還與機(jī)構(gòu)壓力角有關(guān)，vmax較小，使得最大壓力角amax也小，這樣，可使凸輪設(shè)計(jì)得較小。amax較小，則慣性力較小。躍度反映了慣性力變化的情況，jmax較小可減少機(jī)構(gòu)的振動(dòng)。mmax稱(chēng)為機(jī)構(gòu)的動(dòng)力特征值，當(dāng)mmax較小時(shí)，由從動(dòng)件的慣性引起的凸輪驅(qū)動(dòng)轉(zhuǎn)矩也較小，再設(shè)計(jì)高速凸輪機(jī)構(gòu)時(shí)考慮這一因素。 2.4.5 從動(dòng)件運(yùn)動(dòng)規(guī)律的選擇【3,9,17】 從動(dòng)件運(yùn)動(dòng)的選擇除了要滿(mǎn)足機(jī)械的具體工作要求外，還應(yīng)使凸輪機(jī)構(gòu)具有良好的動(dòng)力特性，以及應(yīng)使所設(shè)計(jì)的凸輪廓線(xiàn)便于加工等。而這些往往又是互相制約的，因此，在選擇或設(shè)計(jì)從動(dòng)件的運(yùn)動(dòng)規(guī)律時(shí)，必須根據(jù)使用場(chǎng)合、工作條件等分清主次綜合考慮，確定選擇或設(shè)計(jì)的運(yùn)動(dòng)規(guī)律的主要依據(jù)。 (1) 當(dāng)機(jī)械的工作過(guò)程要求從動(dòng)件實(shí)現(xiàn)一定的工作行程，而對(duì)運(yùn)動(dòng)規(guī)律無(wú)特殊要求時(shí)，應(yīng)選擇使凸輪機(jī)構(gòu)具有較好的動(dòng)力特性和便于加工的運(yùn)動(dòng)規(guī)律。對(duì)于低速輕載的凸輪機(jī)構(gòu)，因?yàn)檫@時(shí)動(dòng)力特性不是主要的，可主要從凸輪廓線(xiàn)便于加工考慮，選擇圓弧、直線(xiàn)等便于加工的曲線(xiàn)作為凸輪廓線(xiàn)。而對(duì)于速度較高的凸輪機(jī)構(gòu)，應(yīng)主要考慮其動(dòng)力特性，避免產(chǎn)生較大的沖擊。 (2) 當(dāng)機(jī)械的工作過(guò)程對(duì)從動(dòng)件的運(yùn)動(dòng)規(guī)律有特殊要求時(shí)，而凸輪的轉(zhuǎn)速又高時(shí)，應(yīng)從滿(mǎn)足工作需出發(fā)來(lái)選擇從動(dòng)件的運(yùn)動(dòng)規(guī)律，其次考慮其動(dòng)力特性和便于加工。 (3) 當(dāng)機(jī)械的工作過(guò)程對(duì)從動(dòng)件的運(yùn)動(dòng)規(guī)律有特殊要求，而凸輪的轉(zhuǎn)速又較高時(shí)，應(yīng)兼顧兩者來(lái)設(shè)計(jì)從動(dòng)件的運(yùn)動(dòng)規(guī)律。通?？蛇x用組合運(yùn)動(dòng)規(guī)律來(lái)滿(mǎn)足這種要求。 (4) 在選擇或設(shè)計(jì)從動(dòng)件運(yùn)動(dòng)規(guī)律時(shí)，除了要考慮其沖擊特性外，還應(yīng)考慮其具有的最大速度vmax、最大加速度amax、最大躍度jmax和mmax較小。這些因素會(huì)影響到機(jī)械系統(tǒng)工作的平穩(wěn)性，因此總希望其越小越好，特別是對(duì)于高速凸輪加工，這一點(diǎn)尤其重要。 2.4.6凸輪廓線(xiàn)的設(shè)計(jì)【5-21】 此壓裝機(jī)在凸輪軸上裝有三個(gè)盤(pán)型凸輪。設(shè)從動(dòng)件的運(yùn)動(dòng)規(guī)律為等速。 第一個(gè)凸輪用于將裝配夾具夾緊，已知凸輪軸心與從動(dòng)件轉(zhuǎn)軸之間的中心距a=16cm，凸輪基圓半徑rb=4cm，從動(dòng)件長(zhǎng)度l=16cm，擺角Φ=400.。 第二個(gè)凸輪用于壓緊錐形薄片，將其固定，已知凸輪軸心與從動(dòng)件轉(zhuǎn)軸之間的中心 距a=16cm，凸輪基圓半徑rb=7cm，從動(dòng)件長(zhǎng)度l=16cm，擺角Φ=200。 第三個(gè)凸輪用于將薄片的翼耳壓翻轉(zhuǎn)，已知凸輪軸心與從動(dòng)件轉(zhuǎn)軸之間的中心距a=16cm，凸輪基圓半徑rb=6cm，從動(dòng)件長(zhǎng)度l=14cm，擺角Φ=200。 利用反轉(zhuǎn)法原理設(shè)計(jì)凸輪輪廓?！?-5】 設(shè)凸輪的輪廓曲線(xiàn)已按預(yù)定的從動(dòng)件運(yùn)動(dòng)規(guī)律設(shè)計(jì)。當(dāng)凸輪以角速度w1繞軸O轉(zhuǎn)動(dòng)時(shí)，從動(dòng)件的尖頂沿凸輪輪廓曲線(xiàn)相對(duì)其導(dǎo)路按預(yù)定的運(yùn)動(dòng)規(guī)律移動(dòng)?，F(xiàn)設(shè)想給整個(gè)凸 輪機(jī)構(gòu)加上一個(gè)公共角速度-w1，此時(shí)凸輪將不動(dòng)。根據(jù)相對(duì)運(yùn)動(dòng)原理，凸輪和從動(dòng)件之間的相對(duì)運(yùn)動(dòng)并未改變。這樣從動(dòng)件一方面隨導(dǎo)路以角速度-w1繞軸O轉(zhuǎn)動(dòng)，另一方面又在導(dǎo)路中按預(yù)定的規(guī)律作往復(fù)移動(dòng)。由于從動(dòng)件尖頂始終與凸輪輪廓相接觸，顯然，從動(dòng)件在這種復(fù)合運(yùn)動(dòng)中，其尖頂?shù)倪\(yùn)動(dòng)軌跡即是凸輪輪廓曲線(xiàn)。這種以凸輪作動(dòng)參考系，按相對(duì)運(yùn)動(dòng)原理設(shè)計(jì)凸輪輪廓曲線(xiàn)的方法稱(chēng)為反轉(zhuǎn)法(如圖1-4)。 圖2-4反轉(zhuǎn)法原理 凸輪輪廓曲線(xiàn)設(shè)計(jì)步驟： 1） 選取適當(dāng)?shù)牡谋壤撸鞒鰪膭?dòng)件的位移線(xiàn)圖，并將推程和回程區(qū)間位移曲線(xiàn)的橫坐標(biāo)各分成若干等份，將設(shè)凸輪一得偏角為零，則凸輪二的偏角相對(duì)凸輪一為400，凸輪三相對(duì)凸輪一為900。如圖2-5所示。 圖2-5從動(dòng)件運(yùn)動(dòng)位移線(xiàn)圖 該機(jī)構(gòu)要求凸輪的動(dòng)作為:第一個(gè)凸輪先運(yùn)動(dòng)夾緊裝配夾具，然后第二個(gè)凸輪將其固定，最后第三個(gè)凸輪將錐形薄片的翼耳壓翻過(guò)來(lái)。返回時(shí)，第二個(gè)凸輪先縮回，然后 是第三個(gè)凸輪，最后是第一個(gè)凸輪。 圖2-5中縱坐標(biāo)代表從動(dòng)件的擺角ψ，因此縱坐標(biāo)的比例尺是1mm代表多少度。 2） 以D0為圓心、以rb為半徑作為基圓，并根據(jù)已知的中心距a，確定從動(dòng)件轉(zhuǎn)軸A的位置A0。然后以A0為圓心，以從動(dòng)件桿長(zhǎng)l為半徑作圓弧，交基圓于C0。A0C0即代表從動(dòng)件的初始位置，C0即為從動(dòng)件滾子圓心的初始位置。 3） 以D0為圓心，以a為半徑作轉(zhuǎn)軸圓，并自A0點(diǎn)開(kāi)始沿著-ω方向?qū)⒃搱A分成如圖1-5中橫坐標(biāo)對(duì)應(yīng)的區(qū)間和等份，得點(diǎn)A1,A2,...。他們代表反轉(zhuǎn)過(guò)程中從動(dòng)件轉(zhuǎn)軸A依次占據(jù)的位置。 4） 以上述各點(diǎn)為圓心，以從動(dòng)件桿長(zhǎng)l為半徑，分別作圓弧，交基圓于C1,C2,...各點(diǎn)，得線(xiàn)段A1C1,A2C2...;以A1C1,A2C2，...為一邊，分別作∠C1A1B1,∠C2A2B2,...使他們分別等于圖1-5中對(duì)應(yīng)的角位移，得線(xiàn)段A1B1,A2B2,...。這些線(xiàn)段即代表反轉(zhuǎn)過(guò)程中從動(dòng)件所依次占據(jù)的位置。B1,B2,...即為反轉(zhuǎn)過(guò)程中從動(dòng)件滾子圓心的運(yùn)動(dòng)軌跡。 5） 將點(diǎn)B0,B1,B2,...連成光滑的曲線(xiàn)，即得凸輪的理論輪廓線(xiàn)?！?-5,11-23】 圖2-6凸輪一輪廓曲線(xiàn) 圖2-7凸輪二輪廓曲線(xiàn) 圖2-6為第一個(gè)凸輪的輪廓曲線(xiàn)，圖2-7為第二個(gè)凸輪的輪廓曲線(xiàn)，圖2-8為第三個(gè)凸輪的輪廓曲線(xiàn) 圖2-8凸輪三輪廓曲線(xiàn) 2.4.7凸輪輪廓的加工方法【15-16】 （一）銑、銼削加工 用于低速、輕載場(chǎng)合的凸輪 （二）數(shù)控加工 用于高速、重載的場(chǎng)合，加工精度高。 2.4.8凸輪機(jī)構(gòu)的壓力角 壓力角 ：凸輪機(jī)構(gòu)從動(dòng)件速度方向與該點(diǎn)受力方向的夾角。 對(duì)直動(dòng)從動(dòng)件凸輪機(jī)構(gòu)[a]=30～38° 擺動(dòng)從動(dòng)件凸輪機(jī)構(gòu)[a]=40～50°工作行程 [a]=70~80° 回程 2.5軸的設(shè)計(jì) 圖2-9軸 根據(jù)軸徑選鍵，Φ20選的平鍵b×h為8×7（圖2-9），配合為Φ20H7/k6,Φ25H7/k6（如圖2-10）【1-3,11-18】 圖2-10軸 圖2-10為凸輪軸，圖2-11和2-12分別為控制壓和夾緊凸輪的軸。 圖2-11軸 圖2-12軸 第三章 減速箱的設(shè)計(jì) 3.1 減速箱的示意圖 圖3-1減速箱示意圖 3.2各主要部件的選擇 表3-1 分析對(duì)象 過(guò)程分析 結(jié)論 動(dòng)力源 一般選用交流電動(dòng)機(jī) 三相交流電動(dòng)機(jī) 帶 V帶允許的傳動(dòng)比大,結(jié)構(gòu)緊湊 V帶 齒輪 直齒傳動(dòng)平穩(wěn) 高速級(jí)、低速級(jí)都可用直齒 軸承 此減速器軸承承受軸向載荷很小 球軸承 聯(lián)軸器 有吸振和緩沖能力,耐久性好 彈性柱銷(xiāo)聯(lián)軸器 3.3電動(dòng)機(jī)的選擇 壓裝機(jī)每分鐘壓15個(gè)，即減速箱輸出為15r/min, 查表知V帶傳動(dòng)常用傳動(dòng)比范圍 為2～4,單級(jí)圓柱齒輪的傳動(dòng)比范圍為3～6,則電動(dòng)機(jī)的轉(zhuǎn)速的可選范圍為： 因此,可選同步轉(zhuǎn)速為1500r/min的電動(dòng)機(jī)，型號(hào)為Y112M-4?！?6-28】 3.4 分配傳動(dòng)比 表3-2 傳動(dòng)比分配 分析對(duì)象 過(guò)程分析 結(jié)論 分配傳動(dòng)比 傳動(dòng)系統(tǒng)的總傳動(dòng)比i=nm/nw(式3-2)其中i是傳動(dòng)系統(tǒng)的總傳動(dòng)比，多級(jí)串聯(lián)傳動(dòng)系統(tǒng)的總傳動(dòng)等于各級(jí)傳動(dòng)比的連乘積；nm是電動(dòng)機(jī)的滿(mǎn)載轉(zhuǎn)速，r/min；nw 為工作機(jī)輸入軸的轉(zhuǎn)速，r/min。 計(jì)算如下? nm=1440r/min nw =15r/min i=nm/nw=1440/15=96 V帶,初取 則減速器傳動(dòng)比為:i減=i/i帶(式3-3) =96/4=24 按展開(kāi)式布置,考慮沒(méi)有潤(rùn)滑條件,為使兩級(jí)齒輪直徑相近, 取高速級(jí) ,則低速級(jí)i2=i減/i1=6 3.5 V帶傳動(dòng)的設(shè)計(jì)【9,17】 已知電動(dòng)機(jī)的功率P=3.8kw,轉(zhuǎn)速N=1500r/min。 1、由于載荷平穩(wěn),選用普通V帶。 2、確定計(jì)算功率，取工況系數(shù)KA =1 Pca=KAP=1*4=4（式3-4） 3、 選擇帶型 根據(jù)Pca 與N=1500r/min,由《機(jī)械設(shè)計(jì)手冊(cè)》確定選用A型 4、 確定帶輪基準(zhǔn)直徑并驗(yàn)算帶速 初取主動(dòng)輪的基準(zhǔn)直徑 dd1=90 mm V=πdd1n1/(601000)（式3-5） = =6.7824m/s<25 m/s 于是從動(dòng)輪基準(zhǔn)直徑dd2= dd1i01=904=360mm 5、確定普通V帶的基準(zhǔn)長(zhǎng)度和傳動(dòng)中心距Ld 根據(jù)0.7(dd1+ dd2)90 因此,主動(dòng)輪上的包角合適。 7．計(jì)算普通V帶的根數(shù)Z 由 n1=1500r/min，dd1=90 mm，i=4，查手冊(cè)得 PO=0.68Kw △PO=0.17Kw 查表得K=0.93, KL=1.03由（式3-10）得 故取Z=5. 8.計(jì)算預(yù)緊力F0 查表得q=0.10kg/m, （式3-11） =99.2N 9.計(jì)算作用在軸上的壓軸力Fp 由 Fp=2ZF0 sin（式3-12）得 Fp=2ZF0 sin=2 5 99.2sin=968.5N 10.V帶輪的選擇 由主、從動(dòng)輪的基準(zhǔn)直徑,選用輪輻式V帶輪 其寬度B=(Z-1)e+2f（式3-13） =(5-1)12+27=62mm 3.6 設(shè)計(jì)高速級(jí)齒輪 表3-3 高速級(jí)齒輪設(shè)計(jì) 分析對(duì)象 過(guò)程分析 結(jié)論 選精度等級(jí)材料和齒數(shù) 1.選用直齒圓柱齒輪傳 2.選用7級(jí)精度 3.材料選擇。小齒輪材料為40Cr（調(diào)質(zhì)），硬度為280HBS，大齒輪材料為45鋼（調(diào)質(zhì)），硬度為240HBS，二者材料硬度差為40HBS。 4.選小齒輪齒數(shù)Z1＝２4， 5.大齒輪齒數(shù)Z2＝ｉ1·Z1＝4×24=96 小齒輪材料為40Cr（調(diào)質(zhì)），硬度為 280HBS，大齒輪材料為 45鋼（調(diào)質(zhì)），硬度為240HBS 按齒面接觸強(qiáng)度設(shè)計(jì) 按式試算，即 （式3-14） １）確定公式內(nèi)的各計(jì)算數(shù)值 （１）試選 （2）計(jì)算小齒輪傳遞的轉(zhuǎn)矩 　　 （3）由 《機(jī)械設(shè)計(jì)》表12.13，選取齒寬系數(shù) （4）由表《機(jī)械設(shè)計(jì)》表12.12查得材料的彈性影響系數(shù) （5）由圖《機(jī)械設(shè)計(jì)》圖12.17c按齒面硬度查得小齒輪的接觸疲勞強(qiáng)度極限，大齒輪的接觸疲勞強(qiáng)度極限 （6）計(jì)算應(yīng)力循環(huán)次數(shù)，由《機(jī)械設(shè)計(jì)》表12.15，估計(jì) 　　　?。ㄊ?-15） 　　　　 （7）由圖《機(jī)械設(shè)計(jì)》查得接觸疲勞強(qiáng)度壽命系數(shù) （8）計(jì)算接觸疲勞強(qiáng)度許用應(yīng)力 　取失效概率為１％，安全系數(shù)為S=1，得 （式3-16） 按齒面接觸強(qiáng)度設(shè)計(jì) 　　　 　　　　 ２）計(jì)算 ?。ǎ保┰囁阈↓X輪分度圓直徑，由計(jì)算公式3-14得 　　　 ?。ǎ玻┯?jì)算圓周速度 　　　 ?。ǎ常┯?jì)算齒寬ｂ ?。ǎ矗┯?jì)算齒寬與齒高比 　　　模數(shù) 　　　 （５）計(jì)算載荷系數(shù)K 　　　已知使用系數(shù) 　　　根據(jù)，７級(jí)精度，由圖12.9查得動(dòng)載荷系數(shù) 　　　 查表得 　　　　 故載荷系數(shù) 　（６）按實(shí)際的載荷系數(shù)校正所算得的分度圓直徑，得 （７）計(jì)算模數(shù)m 　　 　 按齒面接觸強(qiáng)度設(shè)計(jì),模數(shù)m=1.656mm 按齒根彎曲強(qiáng)度設(shè)計(jì) 由式?。ㄊ?-16） １） 確定計(jì)算參數(shù) （１）計(jì)算載荷系數(shù) 　　　　 （2）查取齒形系數(shù) 由《機(jī)械設(shè)計(jì)》圖12.21查得　 ?。?）查取應(yīng)力校正系數(shù) 　　　由《機(jī)械設(shè)計(jì)》圖12.22查得　 ?。?）由《機(jī)械設(shè)計(jì)》圖12.23c查得，小齒輪的彎曲疲勞強(qiáng)度極限 　　　　大齒輪的彎曲疲勞強(qiáng)度極限 （5）由《機(jī)械設(shè)計(jì)》查得彎曲疲勞強(qiáng)度壽命系數(shù) 　　　　　 （6）計(jì)算彎曲疲勞許用應(yīng)力 　　　取彎曲疲勞安全系數(shù)S＝1.4，得 　　　 　　　 （7）計(jì)算大小齒輪的 　　　　 　　　　大齒輪的數(shù)據(jù)大 ２） 設(shè)計(jì)計(jì)算 按齒面彎曲強(qiáng)度設(shè)計(jì),模數(shù)m=1.313mm， 但是因?yàn)閭鬟f動(dòng)力的齒輪模數(shù)應(yīng)取大于等于1.5mm,所以模數(shù)取m=1.5mm 對(duì)比計(jì)算結(jié)果 對(duì)比計(jì)算結(jié)果，由齒面接觸疲勞強(qiáng)度計(jì)算的模數(shù)大于由齒根彎曲疲勞強(qiáng)度計(jì)算的模數(shù)，由于齒輪模數(shù)m的大小主要取決于彎曲強(qiáng)度所決定的承載能力,而齒面接觸疲勞強(qiáng)度所決定的承載能力,僅與齒輪直徑(即模數(shù)與齒數(shù)的乘積)有關(guān),可取由彎曲強(qiáng)度算得的模數(shù)1.313并就近圓整為標(biāo)準(zhǔn)值m=1.5mm,按接觸疲勞強(qiáng)度算得的分度圓直徑來(lái)計(jì)算應(yīng)有的齒數(shù)。于是由 則 按齒根彎曲強(qiáng)度設(shè)計(jì),得模數(shù) m>1.313,綜合比較可得高速級(jí)兩齒數(shù): 幾何尺寸計(jì)算 (1)計(jì)算分度圓直徑 (2)計(jì)算中心距 圓整為102 (3)計(jì)算齒輪寬度 取； 中心距 分度圓直徑 齒輪寬度 3.7 設(shè)計(jì)低速級(jí)齒輪 根據(jù)表3-3的計(jì)算方法，得：小齒輪材料為40Cr（調(diào)質(zhì)），硬度為280HBS，大齒輪材料為45鋼（調(diào)質(zhì)），硬度為240HBS，小齒輪齒數(shù)Ｚ1＝33，大齒輪齒數(shù)Ｚ2＝ｉ2·Ｚ1＝6×33=198，模數(shù)m=2.430mm，中心距a=211mm，分度圓直徑d1=57.75mm =346.5mm,齒輪寬度B2=60mm B1=65mm。 3.8齒輪潤(rùn)滑方式的選擇 因?yàn)闈?rùn)滑脂承受的負(fù)荷能力較大、粘附性較好、不易流失，齒輪靠機(jī) 體油的飛濺潤(rùn)滑。I，II，III軸的速度因子，查機(jī)械設(shè)計(jì)手冊(cè)可選用鈉基潤(rùn)滑劑2號(hào)。【1-3,18】 3.9密封方式的選擇 由于I，II，III軸與軸承接觸處的線(xiàn)速度，所以采用氈圈密封。 第四章 聯(lián)軸器的設(shè)計(jì)選擇 聯(lián)軸器的選型【21-23】 聯(lián)軸器是用來(lái)連接進(jìn)給機(jī)構(gòu)的兩根軸使之一起回轉(zhuǎn)以傳遞扭矩和運(yùn)動(dòng)的一種裝置。機(jī)器運(yùn)轉(zhuǎn)時(shí)，被連接的兩軸不能分離，只有停車(chē)后，將聯(lián)軸器拆開(kāi)，兩軸才能脫開(kāi)。 目前聯(lián)軸器的類(lèi)型繁多，有液壓式、電磁式和機(jī)械式。機(jī)械式聯(lián)軸器是應(yīng)用最廣泛的一種，它借助于機(jī)械構(gòu)件相互間的機(jī)械作用力來(lái)傳遞扭矩，大致可將聯(lián)軸器劃分為剛性聯(lián)軸器和彈性聯(lián)軸器兩類(lèi)。 （1）剛性聯(lián)軸器可分為以下兩類(lèi)。 ①固定式聯(lián)軸器，主要有套筒聯(lián)軸器、凸緣聯(lián)軸器和夾殼聯(lián)軸器等。 ②可移式聯(lián)軸器，主要有齒輪聯(lián)軸器、十字滑塊聯(lián)軸器和萬(wàn)向聯(lián)軸器等。 （2）彈性聯(lián)軸器可分為以下兩類(lèi)。 ①金屬?gòu)椥约?lián)軸器，主要有套筒聯(lián)軸器、膜片聯(lián)軸器和波形管聯(lián)軸器等。 ②非金屬?gòu)椥月?lián)軸器，主要有輪胎式聯(lián)軸器、整圈橡膠聯(lián)軸器和橡膠塊聯(lián)軸器等。 凸緣聯(lián)軸器 凸緣聯(lián)軸器是把兩個(gè)帶有凸緣的半聯(lián)軸器分別與兩軸連接，然后用螺栓把兩個(gè)半聯(lián)軸器聯(lián)成一體，以傳遞動(dòng)力和扭矩。凸緣聯(lián)軸器還有兩種對(duì)中，另一種則是共同與另一部分環(huán)相配合而對(duì)中。前者在裝拆時(shí)軸必須作軸向移動(dòng)，后者則無(wú)此缺點(diǎn)。連接螺栓可以采用半精制的普通螺栓，此時(shí)螺栓桿與釘孔壁間存有間隙，扭矩靠半聯(lián)軸器結(jié)合面間的摩擦力來(lái)傳遞；也可采用鉸質(zhì)孔用螺栓，此時(shí)螺栓桿與釘孔為過(guò)渡配合，靠螺栓桿承受擠壓與剪切來(lái)傳遞扭矩凸緣聯(lián)軸器可制成帶防護(hù)邊的或不帶防護(hù)邊的。 凸緣聯(lián)軸器的材料可用HT250或碳鋼，重載或圓周速度大于30m/s時(shí)應(yīng)用鑄鋼或鍛鋼。 凸緣聯(lián)軸器對(duì)于所連接的兩軸的對(duì)中性要求很高，當(dāng)兩軸間有位移與傾斜存在時(shí)，就在機(jī)件內(nèi)引起附加載荷，使工作情況惡化，這是它的主要缺點(diǎn)。但由于其結(jié)構(gòu)簡(jiǎn)單、成本低以及可傳遞較大扭矩，故當(dāng)轉(zhuǎn)速低、無(wú)沖擊、軸的剛度大以及對(duì)中性較好時(shí)亦常采用。 根據(jù)工作需要選擇凸緣聯(lián)軸器 根據(jù)軸徑選折YLD5凸緣聯(lián)軸器具體參數(shù)如下：（機(jī)械設(shè)計(jì)手冊(cè)表29.2-5P29-26） 型號(hào) 許用轉(zhuǎn)矩 [T] 許用轉(zhuǎn)速 （n） 軸孔直徑 軸孔長(zhǎng)度 D D0 螺栓 L0 重量 m 轉(zhuǎn)動(dòng)慣量 mm 數(shù)量 n 直徑 d (r/min) mm N.m 鐵 鋼 鐵 鋼 Y型 J J1型 mm mm Y型 J J1型 kg Kg/m2 YLD5 63 5500 9000 28 28 62 4 100 80 4 M8 128 92 3.19 0.013 圖4.1凸緣聯(lián)軸器 第五章 總結(jié) 本次畢業(yè)設(shè)計(jì)完成壓裝機(jī)構(gòu)的運(yùn)動(dòng)分析、工序設(shè)計(jì)、結(jié)構(gòu)設(shè)計(jì)及關(guān)鍵零部件設(shè)計(jì) 。此壓裝機(jī)主要依靠三個(gè)凸輪的運(yùn)動(dòng)實(shí)現(xiàn)。第一個(gè)凸輪通過(guò)其擺動(dòng)從動(dòng)件控制夾緊軸的水平移動(dòng)，第二個(gè)與第三個(gè)凸輪通過(guò)其擺動(dòng)從動(dòng)件，分別控制內(nèi)軸與外軸垂直移動(dòng)，使其定位和沖壓。進(jìn)行了結(jié)構(gòu)設(shè)計(jì)及關(guān)鍵零部件設(shè)計(jì)，其中有儀表殼的尺寸，裝配夾具形狀及尺寸，從動(dòng)件的位移線(xiàn)圖的設(shè)計(jì)，凸輪的設(shè)計(jì)，其中為了壓裝機(jī)的運(yùn)作設(shè)計(jì)了減速箱，減速箱里包括電機(jī)的選擇，V帶的設(shè)計(jì)和齒輪的設(shè)計(jì)，最后選擇了連接壓裝機(jī)和減速箱的聯(lián)軸器。 本次設(shè)計(jì)的儀表殼的自動(dòng)化壓裝機(jī)具有結(jié)構(gòu)簡(jiǎn)單，可以保證錐形薄片在同一位置產(chǎn)生精度相同的變形的特點(diǎn)。在設(shè)計(jì)過(guò)程中遇到了各種實(shí)際問(wèn)題，比如在方案論證過(guò)程中，通過(guò)各種途徑查閱了大量資料，一步步改良完善方案；在著手畫(huà)裝配圖的過(guò)程中，視圖的規(guī)范畫(huà)法，如何表達(dá)視圖才能達(dá)到最佳的效果等，這些都需要我在畫(huà)圖的過(guò)程中，真正將自己擺在一個(gè)設(shè)計(jì)人員的角度，從實(shí)際出發(fā)，充分考慮加工事實(shí)，將圖畫(huà)的更準(zhǔn)確，這使我將來(lái)從事設(shè)計(jì)能更加得心應(yīng)手；在裝配圖畫(huà)完之后，開(kāi)始標(biāo)注尺寸公差與配合，工差配合是每個(gè)設(shè)計(jì)人員都需要重視的問(wèn)題，它從另一個(gè)方面體現(xiàn)了一個(gè)設(shè)計(jì)人員的基本素質(zhì)， 第六章 致謝 在此次的設(shè)計(jì)中，我要非常感謝劉天軍老師的悉心指導(dǎo)，他淵博的知識(shí)，開(kāi)闊的思維，勇于創(chuàng)新實(shí)踐精神，嚴(yán)謹(jǐn)求實(shí)的治學(xué)態(tài)度，兢兢業(yè)業(yè)一絲不茍的工作作風(fēng)，時(shí)刻督促我努力學(xué)習(xí)和工作。從論文的選題、實(shí)踐研究到撰寫(xiě)，期間一直得到劉老師的悉心指導(dǎo)和關(guān)懷。每個(gè)星期他都會(huì)抽出時(shí)間來(lái)輔導(dǎo)我們的設(shè)計(jì)，時(shí)刻關(guān)注我們的設(shè)計(jì)進(jìn)程，及時(shí)糾正設(shè)計(jì)中的錯(cuò)誤，隨時(shí)提出寶貴的建議，積極鼓勵(lì)我們勤思考、勤探討、勤查閱，真正將四年所學(xué)的知識(shí)融會(huì)貫通，應(yīng)用起來(lái)得心應(yīng)手，使我獲益匪淺。再次對(duì)劉老師的辛勤工作表示深深的感謝！ 感謝劉天軍老師在畢業(yè)設(shè)計(jì)期間給我提出了寶貴的要求和建議，他的嚴(yán)格要求不斷的激勵(lì)我，在后來(lái)的設(shè)計(jì)中不斷改進(jìn)，使設(shè)計(jì)更加完善。 陳天平 2010年6月1日 參考文獻(xiàn) 1. 徐景康，蔡慧官.機(jī)械設(shè)計(jì)[M].北京：機(jī)械工業(yè)出版社，2001.217-320 2. 濮良貴，紀(jì)明剛.機(jī)械設(shè)計(jì)[M].北京：高等教育出版社，1996.197-220 3. 張紹甫，徐景康.機(jī)械零件[M].北京：機(jī)械工業(yè)出版社，1995.27-150 4. 潘沛霖，陳秀.機(jī)械課程設(shè)計(jì)圖冊(cè)[M].北京：高等教育出版社，1989 5. 高俊亭.機(jī)械制圖裝配圖圖集[M].北京：清華大學(xué)出版社，1985 6. 張春宜，郝廣平，劉敏.減速器設(shè)計(jì)實(shí)例精解[M].機(jī)械工藝出版社，2009.261-300 7. 吳宗澤.機(jī)械零件習(xí)題集[M].北京：高等教育出版社，1983.53-58 8. 徐灝.新編機(jī)械設(shè)計(jì)師手冊(cè)（上、下）[M].北京：機(jī)械工業(yè)出版社，1995 9. 沈世德.機(jī)械原理[M].北京：機(jī)械工業(yè)出版社，2002.65-270 10. 成大先.機(jī)械設(shè)計(jì)手冊(cè)[M].北京：化學(xué)工業(yè)出版社，2004 11. 朱冬梅，胥北瀾.畫(huà)法幾何及機(jī)械制圖[M].北京：高等教育出版社，2000.123-150 12. 孟憲源，姜琪.機(jī)械構(gòu)型與應(yīng)用[M].北京：機(jī)械工業(yè)出版社，2004.791-792 13. 李璨，張憲民.Mechanisms and Machines Theory. [M].武漢：武漢理工大學(xué)，2002.36-48 14. 姜琪.機(jī)構(gòu)運(yùn)動(dòng)方案及機(jī)構(gòu)設(shè)計(jì)[M].高等教育出版社.1991.5.36-78 15. 侯秀針.機(jī)械系統(tǒng)設(shè)計(jì)[M].哈爾濱工業(yè)大學(xué)出版社.2003.4.100-324 16. 王先逵.機(jī)械制造工藝學(xué)[M].北京.機(jī)械工業(yè)出版社.2006.1.56-211 17. 沈世德.機(jī)械原理[M].北京機(jī)械工業(yè)出版社.2002.2.78-109 18. 徐錦康.機(jī)械設(shè)計(jì)[M].第二版.北京機(jī)械工業(yè)出版社.2002.4.23-156 19. 廖念釗.互換性與測(cè)量技術(shù)基礎(chǔ)[M].北京中國(guó)計(jì)量出版社.2003.3.78-109 20. 王文斌.機(jī)械設(shè)計(jì)手冊(cè)第2卷[M].北京機(jī)械工業(yè)出版社.2004.8 21. 王文斌.機(jī)械設(shè)計(jì)手冊(cè)第4卷[M].北京機(jī)械工業(yè)出版社.2004.8 22. 侯秀針編.機(jī)械系統(tǒng)設(shè)計(jì)[M].哈爾濱工業(yè)大學(xué)出版社.1998.12 23. 曾惟慶.徐曾蔭編:機(jī)構(gòu)設(shè)計(jì)[M]. 機(jī)械工業(yè)出版社. 1993.7 24.王昆，何小柏，汪信遠(yuǎn)主編.機(jī)械設(shè)計(jì)課程設(shè)計(jì)，高等教育出版社，1995年12月第一版 25.濮良貴，紀(jì)名剛主編.機(jī)械設(shè)計(jì)（第七版），高等教育出版社，2001年7月第七版 26.洪鐘德.簡(jiǎn)明機(jī)械設(shè)計(jì)手冊(cè)，同濟(jì)大學(xué)出版社，2002年5月第一版 27.周明衡.減速器選用手冊(cè)，化學(xué)工業(yè)出版社，2002年6月第一版 28.劉希平.工程機(jī)械構(gòu)造圖冊(cè)，機(jī)械工業(yè)出版社，2002年6月第一版 29.劉朝儒，彭福蔭，高治一編.機(jī)械制圖（第四版），高等教育出版社，2001年8月第四版 30.朱鴻業(yè).PLC在摩擦壓裝機(jī)設(shè)計(jì)中的應(yīng)用[J],2008年4期 24 英文翻譯 【附】英文原文 翻譯文獻(xiàn)：Five-axis milling machine tool kinematic chain design and analysis 作者：E.L.J. Bohez 文獻(xiàn)出處：International Journal of Machine Tools & Manufacture 42 (2002) 505–520 翻譯頁(yè)數(shù)： Five-axis milling machine tool kinematic chain design and analysis 1. Introduction The main design specifications of a machine tool can be deduced from the following principles: ● The kinematics should provide sufficient flexibility in orientation and position of tool and part. ● Orientation and positioning with the highest possible speed. ● Orientation and positioning with the highest possible accuracy. ● Fast change of tool and workpiece. ● Save for the environment. ● Highest possible material removal rate. The number of axes of a machine tool normally refers to the number of degrees of freedom or the number of independent controllable motions on the machine slides.The ISO axes nomenclature recommends the use of a right-handed coordinate system, with the tool axis corresponding to the Z-axis. A three-axis milling machine has three linear slides X, Y and Z which can be positioned everywhere within the travel limit of each slide. The tool axis direction stays fixed during machining. This limits the flexibility of the tool orientation relative to the workpiece and results in a number of different set ups. To increase the flexibility in possible tool workpiece orientations, without need of re-setup, more degrees of freedom must be added. For a conventional three linear axes machine this can be achieved by providing rotational slides. Fig. 1 gives an example of a five-axis milling machine. 2. Kinematic chain diagram To analyze the machine it is very useful to make a kinematic diagram of the machine. From this kinematic (chain) diagram two groups of axes can immediately be distinguished: the workpiece carrying axes and the tool carrying axes. Fig. 2 gives the kinematic diagram of the five-axis machine in Fig. 1. As can be seen the workpiece is carried by four axes and the tool only by one axis.The five-axis machine is similar to two cooperating robots, one robot carrying the workpiece and one robot carrying the tool.Five degrees of freedom are the minimum required to obtain maximum flexibility in tool workpiece orientation,this means that the tool and workpiece can be oriented relative to each other under any angle. The minimum required number of axes can also be understood from a rigid body kinematics point of view. To orient two rigid bodies in space relative to each other 6 degrees of freedom are needed for each body (tool and workpiece) or 12 degrees. However any common translation and rotation which does not change the relative orientation is permitted reducing the number of degrees by 6. The distance between the bodies is prescribed by the toolpath and allows elimination of an additional degree of freedom, resulting in a minimum requirement of 5 degrees. 3.Literature review One of the earliest (1970) and still very useful introductions to five-axis milling was given by Baughman [1] clearly stating the applications. The APT language was then the only tool to program five-axis contouring applications. The problems in postprocessing were also clearly stated by Sim [2] in those earlier days of numerical control and most issues are still valid. Boyd in Ref. [3] was also one of the early introductions. Beziers’ book [4] is also still a very useful introduction. Held [5] gives a very brief but enlightening definition of multi-axis machining in his book on pocket milling. A recent paper applicable to the problem of five-axis machine workspace computation is the multiple sweeping using the Denawit-Hartenberg representation method developed by Abdel-Malek and Othman [6]. Many types and design concepts of machine tools which can be applied to five-axis machines are discussed in Ref. [7] but not specifically for the five-axis machine. he number of setups and the optimal orientation of the part on the machine table is discussed in Ref. [8]. A review about the state of the art and new requirements for tool path generation is given by B.K. Choi et al. [9]. Graphic simulation of the interaction of the tool and workpiece is also a very active area of research and a good introduction can be found in Ref. [10]. 4. Classification of five-axis machines’ kinematic structure Starting from Rotary (R) and Translatory (T) axes four main groups can be distinguished: (i) three T axes and two R axes; (ii) two T axes and three R axes; (iii) one T axis and four R axes and (iv) five R axes. Nearly all existing five-axis machine tools are in group (i). Also a number of welding robots, filament winding machines and laser machining centers fall in this group. Only limited instances of five-axis machine tools in group (ii) exist for the machining of ship propellers. Groups (iii) and (iv) are used in the design of robots usually with more degrees of freedom added. The five axes can be distributed between the workpiece or tool in several combinations. A first classification can be made based on the number of workpiece and tool carrying axes and the sequence of each axis in the kinematic chain. Another classification can be based on where the rotary axes are located, on the workpiece side or tool side. The five degrees of freedom in a Cartesian coordinates based machine are: three translatory movements X,Y,Z (in general represented as TTT) and two rotational movements AB, AC or BC (in general represented as RR).Combinations of three rotary axes (RRR) and two linear axes (TT) are rare. If an axis is bearing the workpiece it is the habit of noting it with an additional accent. The five-axis machine in Fig. 1 can be characterized by XYABZ. The XYAB axes carry the workpiece and the Z-axis carries the tool. Fig. 3 shows a machine of the type XYZAB
, the three linear axes carry the tool and the two rotary axes carry the workpiece. 5. Workspace of a five-axis machine Before defining the workspace of the five-axis machine tool, it is appropriate to define the workspace of the tool and the workspace of the workpiece. The workspace of the tool is the space obtained by sweeping the tool reference point (e.g. tool tip) along the path of the tool carrying axes. The workspace of the workpiece carrying axes is defined in the same way (the center of the machine table can be chosen as reference point).These workspaces can be determined by computing the swept volume [6].Based on the above-definitions some quantitative parameters can be defined which are useful for comparison, selection and design of different types of machines. 6.Selection criteria of a five-axis machine It is not the objective to make a complete study on how to select or design a five-axis machine for a certain application. Only the main criteria which can be used to justify the selection of a five-axis machine are discussed. 6.1. Applications of five-axis machine tools The applications can be classified in positioning and contouring. Figs. 12 and 13 explain the difference between five-axis positioning and five-axis contouring. 6.1.1. Five-axis positioning Fig. 12 shows a part with a lot of holes and flat planes under different angles, to make this part with a three axis milling machine it is not possible to process the part in one set up. If a five-axis machine is used the tool can process. More details on countouring can be found in Ref. [13]. Applications of five-axis contouring are: (i) production of blades, such as compressor and turbine blades; (ii) injectors of fuel pumps; (iii) profiles of tires; (iv) medical prosthesis such as artificial heart valves; (v) molds made of complex surfaces. 6.1.2. Five-axis contouring Fig. 13 shows an example of five-axis contouring, tomachine the complex shape of the surface we need to control the orientation of the tool relative to the part during cutting. The tool workpiece orientation changes in each step. The CNC controller needs to control all the five-axes simultaneously during the material removal process. More details on countouring can be found in Ref. [13]. Applications of five-axis contouring are: (i) production of blades, such as compressor and turbine blades; (ii) injectors of fuel pumps; (iii) profiles of tires; (iv) medical prosthesis such as artificial heart valves; (v) molds made of complex surfaces. 6.2. Axes configuration selection The size and weight of the part is very important as a first criterion to design or select a configuration. Very heavy workpieces require short workpiece kinematic chains. Also there is a preference for horizontal machine tables which makes it more convenient to fix and handle the workpiece. Putting a heavy workpiece on a single rotary axis kinematic chain will increase the orientation flexibility very much. It can be observed from Fig. 4that providing a single horizontal rotary axis to carry the workpiece will make the machine more flexible. In most cases the tool carrying kinematic chains will be kept as short as possible because the toolspindle drive must also be carried. 6.3.five-axes machining of jewelry A typical workpiece could be a flower shaped part as in Fig. 14. This application is clearly contouring. The part will be relatively small compared to the tool assembly. Also small diameter tools will require a high speed spindle. A horizontal rotary table would be a very good option as the operator will have a good view of the part (with range 360°). All axes as workpiece carrying axes would be a good choice because the toolspindle could be fixed and made very rigid. There are 20 ways in which the axes can be combined in the workpiece kinematic chain (Section 4.2.1). Here only two kinematic chains will be considered. Case one will be a T
T
T
R
R
kinematic chain shown in Fig. 15. Case two will be a R
R
T
T
T
kinematic chain shown in Fig. 16. For model I a machine with a range of X=300mmY=250 mm, Z=200 mm, C=n 360° and A=360°, and a machine tool table of 100 mm diameter will be considered. For this kinematic chain the tool workspace is a single point. The set of tool reference points which can be selected is also small. With the above machine travel ranges the workpiece workspace will be the space swept by the center of the machine table. If the centerline of the two rotary axes intersect in the reference point, a prismatic workpiece workspace will be obtained with as size XYZ or 300×250×200 mm3. If the centerlines of the two rotary axes do not intersect in the workpiece reference point then the workpiece workspace will be larger. It will be a prismatic shape with rounded edges. The radius of this rounded edge is the excentricity of the bworkpiece reference point relative to each centerline. Model II in Fig. 15 has the rotary axes at the beginning of the kinematic chain (R
R
T
T
T
). Here also two different values of the rotary axes excentricity will be considered. The same range of the axes as in model I is considered. The parameters defined in Section 5 are computed for each model and excentricity and summarized in Table 1. It can be seen that with the rotary axes at the end of the kinematic chain (model I), a much smaller machine tool workspace is obtained. There are two main reasons for this. The swept volume of the tool and workpiece WSTOOLWSWORK is much smaller for model I. The second reason is due to the fact that a large part of the machine tool workspace cannot be used in the case of model I, because of interference with the linear axes. The workspace utilization factor however is larger for the model I with no excentricity because the union of the tool workspace and workpiece workspace is relatively smaller compared with model I with excentricity e=50 mm. The orientation space index is the same for both cases if the table diameter is kept the same. Model II can handle much larger workpieces for the same range of linear axes as in model I. The rotary axes are here in the beginning of the kinematic chain, resulting in a much larger machine tool workspace then for model I. Also there is much less interference of the machine tool workspace with the slides. The other 18 possible kinematicchain selections will give index values somewhat in between the above cases. 6.4. rotary table selection Two machines with the same kinematic diagram (T
T
R
R
T) and the same range of travel in the linear axes will be compared (Fig. 17). There are two options for the rotary axes: two-axis table with vertical table (model I), two-axis table with horizontal table (model II). Tables 2 and 3 give the comparison of the important features. It can be observed that reducing the range of the rotary axes increases the machine tool workspace. So model I will be more suited for smaller workpieces with operations which require a large orientation range, typically contouring applications. Model II will be suited for larger workpieces with less variation in tool orientation or will require two setups. This extra setup requirement could be of less importance then the larger size. The horizontal table can use pallets which transform the internal setup to external setup. The larger angle range in the B-axes 105 to +105, Fig. 17. Model I and model II T
T
R
R
T machines. compared to 45 to +20, makes model I more suited for complex sculptured surfaces, also because the much higher angular speed range of the vertical angular table. The option with the highest spindle speed should be selected and it will permit the use of smaller cutter diameters resulting in less undercut and smaller cutting forces. The high spindle speed will make the cutting of copper electrodes for die sinking EDM machines easier. The vertical table is also better for the chip removal. The large range of angular orientation, however, reduces the maximum size of the workpiece to about 300 mm and 100 kg. Model II with the same linear axes range as model I, but much smaller range in the rotation, can easily handle a workpiece of double size and weight. Model II will be good for positioning applications. Model I cannot be provided with automatic workpiece exchange, making it less suitable for mass production. Model II has automatic workpiece exchange and is suitable for mass production of position applications. Model I could, however, be selected for positioning applications for parts such as hydraulic valve housings which are small and would require a large angular range. 7.New machine concepts based on the Stewart platform Conventional machine tool structures are based on Carthesian coordinates. Many surface contouring applications can be machined in optimal conditions only with five-axis machines. This five-axis machine structure requires two additional rotary axes. To make accurate machines, with the required stiffness, able to carry large workpieces, very heavy and large machines are required. As can be seen from the kinematic chain diagram of the classical five-axis machine design the first axis in the chain carries all the subsequent axes. So the dynamic responce will be limited by the combined inertia. A mechanism which can move the workpiece without having to carry the other axes would be the ideal. A new design concept is the use of a ‘HEXAPOD’. Stewart [16] described the hexapod principle in 1965. It was first constructed by Gough and Whitehall [20] in 1954 and served as tire tester. Many possible uses were proposed but it was only applied to flight simulator platforms. The reason was the complexity of the control of the six actuators. Recently with the amazing increase of speed and reduction in cost of computing, the Stewart platform is used by two American Companies in the design of new machine tools. The first machine is the VARIAX machine from the company Giddings and Lewis, USA. The second machine is the HEXAPOD from the Ingersoll company, USA. The systematic design of Hexapods and other similar systems is discussed in Ref. [17]. The problem of defining and determining the workspace of virtual axis machine tools is discussed in Ref. [18]. It can be observed from the design of the machine that once the position of the tool carrying plane is determined uniquely by the CL date (point + vector), it is still possible to rotate the tool carrying platform around the tool axis. This results in a large number of possible length combinations of the telescopic actuators for the same CL data. 8.Conclusion Theoretically there are large number of ways in which a five-axis machine can be built. Nearly all classical Cartesian five-axis machines belong to the group with three linear and two rotational axes or three rotational axes and two linear axes. This group can be subdivided in six subgroups each with 720 instances.If only the instances with three linear axes are considered there are still 360 instances in each group. The instances are differentiated based on the order of the axes in both tool and workpiece carrying kinematic chain.If only the location of the rotary axes in the tool and workpiece kinematic chain is considered for grouping five-axis machines with three linear axes and two rotational axes, three groups can be distinguished. In the first group the two rotary axes are implemented in the workpiece kinematic chain. In the second group the two rotary axes are implemented in the tool kinematic chain. In the third group there is one rotary axis in each kinematic chain. Each group still has twenty possible instances. To determine the best instance for a specific application area is a complex issue. To facilitate this some indexes for comparison have been defined such as the machine tool workspace, workspace utilization factor, orientation space index, orientation angle index and machine tool space efficiency. An algorithm to compute the machine tool workspace and the diameter of the largest spherical dome which can be machined on the machine was outlined. The use of these indexes for two examples was discussed in detail. The first example considers the design of a five-axis machine for jewelry machining. The second example illustrates the selection of the rotary axes options in the case of a machine with the same range in linear axes. 翻譯題名：Five-axis milling machine tool kinematic chain design and analysis 期刊與作者：E.L.J. Bohez 出版社： International Journal of Machine Tools & Manufacture 42 (2002) 505–520 ● 英文譯文 摘要： 現(xiàn)如今五軸數(shù)控加工中心已經(jīng)非常普及。大部分機(jī)床的運(yùn)動(dòng)學(xué)分析都 基于笛卡爾直角坐標(biāo)系。本文羅列了現(xiàn)有的概念設(shè)計(jì)與實(shí)際應(yīng)用，這些從理論上都基于自由度的綜合。一些有用的參數(shù)都有所規(guī)定，比如工件使用系數(shù)，機(jī)床空間效率，方向空間搜索以及方向角等。每一種概念，它的優(yōu)缺點(diǎn)都有所分析。選擇的標(biāo)準(zhǔn)及機(jī)器參數(shù)設(shè)置的標(biāo)準(zhǔn)都給出來(lái)了。據(jù)于Stewart平臺(tái)的新概念最近行業(yè)內(nèi)已有介紹并作簡(jiǎn)短討論。 1.緒論 設(shè)計(jì)一臺(tái)數(shù)控機(jī)床主要要遵循以下規(guī)則： 1，刀具和工件在空間方向上要有足夠的靈活性。 2，方向和位置的改變要盡可能的快。 3，方向和位置的改變要盡可能的準(zhǔn)確。 4，刀具和工件快速變、換。 5，環(huán)保 6，切削材料速度快 一臺(tái)數(shù)控機(jī)床的軸的數(shù)目通常取決于其自由度數(shù)目或者獨(dú)立控制運(yùn)動(dòng)的導(dǎo)軌數(shù)目。國(guó)際標(biāo)準(zhǔn)委員會(huì)推薦通過(guò)右手笛卡兒坐標(biāo)系來(lái)命名坐標(biāo)軸，刀具相應(yīng)的為Z軸。一個(gè)三軸銑床有三條導(dǎo)軌，X,Y,Z向，它們可用來(lái)在長(zhǎng)度范圍內(nèi)可以在任意位置移動(dòng)。加工過(guò)程中刀具軸的位置始終不變。這就限制了刀具相對(duì)于工件在方向上變化的靈活性，并且導(dǎo)致許多偏差的出現(xiàn)。為了盡可能的提高刀具相對(duì)于工件的靈活性，無(wú)需重啟，必須要加入多個(gè)自由度。對(duì)于傳統(tǒng)三軸機(jī)床來(lái)說(shuō)這可以通過(guò)提供旋轉(zhuǎn)滑臺(tái)來(lái)實(shí)現(xiàn)。圖1給出了一個(gè)五軸銑床的例子。 圖1 五軸數(shù)控機(jī)床 1.運(yùn)動(dòng)鏈圖表 通過(guò)制作機(jī)器的運(yùn)動(dòng)鏈圖表對(duì)于機(jī)器的分析來(lái)說(shuō)十分有用。通過(guò)運(yùn)動(dòng)簡(jiǎn)圖可知兩組軸可以迅速的區(qū)分開(kāi)：工件裝夾軸和刀具軸。圖2給出了圖1.五軸機(jī)床的運(yùn)動(dòng)鏈簡(jiǎn)圖。由圖上可以看出工件由四根軸承載，刀具僅在一根軸上。這個(gè)五軸機(jī)床與兩工位操作機(jī)器人很相似，一個(gè)機(jī)器人夾住工件，另一個(gè)夾住刀具。為了獲得刀具工件方向上的最大自由，五個(gè)自由度已是最低要求，這就意味著工件和刀具可以在任意角度位置相對(duì)定位。最低需求的軸數(shù)也可以通過(guò)剛體運(yùn)動(dòng)學(xué)的方法來(lái)分析。兩個(gè)剛體在空間確定相對(duì)位置，每個(gè)剛體需要6個(gè)到12個(gè)自由度。然而由于任意的移動(dòng)或轉(zhuǎn)動(dòng)并不改變相對(duì)位置就允許將自由度減少到6.兩個(gè)剛體之間的距離通過(guò)刀具軌跡來(lái)描述，并且允許去掉一個(gè)額外的自由度，結(jié)果也就是5個(gè)自由度。 圖2 運(yùn)動(dòng)鏈圖 2.參考文獻(xiàn) 最早（1970年）到目前并且仍就有參考價(jià)值的對(duì)五軸數(shù)控銑床的介紹之一是由 Baughman提出的并清楚的闡述了它的應(yīng)用（附錄1有他的介紹）。APT語(yǔ)言隨后成為唯一的五軸輪廓加工的編程語(yǔ)言之一。后處理階段的問(wèn)題也在數(shù)控發(fā)展的早期由Sim清楚的表述出來(lái)（附錄2有對(duì)他的介紹），并且大部分問(wèn)題到現(xiàn)在仍然有效。Boyd（詳見(jiàn)附錄3）也是最早引進(jìn)數(shù)控機(jī)床的先驅(qū)之一。Beziers的書(shū)（見(jiàn)附錄4）也是非常有用的介紹。Held（見(jiàn)附錄5）在他的小型銑削加工的書(shū)里對(duì)多軸機(jī)床也有非常簡(jiǎn)短但啟發(fā)性的定義。目前一篇適用于解決五軸數(shù)控機(jī)床工作空間計(jì)算的文章，通過(guò)使用Denawit-Hartenberg發(fā)表并由 Abdel-Malek and Othman（見(jiàn)附錄6）改進(jìn)的算法 應(yīng)用于多弧段切削。許多對(duì)機(jī)床的類(lèi)型和概念設(shè)計(jì)，這些可以被應(yīng)用于五軸機(jī)床，Ref都有討論（見(jiàn)附錄8）.關(guān)于對(duì)刀具路徑生成的技巧和新需求由B.K. Choi et al給出（見(jiàn)附錄9）。工件與刀具的圖像模擬也是研究的熱點(diǎn)并且可以在Ref（見(jiàn)附錄10）的書(shū)是一個(gè)好的入門(mén)讀物。 3.五軸機(jī)床運(yùn)動(dòng)結(jié)構(gòu)的分類(lèi) 從R軸（旋轉(zhuǎn)軸）和T軸（移動(dòng)軸）劃分大致可以分為四大部分：（i）3個(gè)移動(dòng)軸和2個(gè)轉(zhuǎn)動(dòng)軸；（ii）2個(gè)T軸和3個(gè)R軸；（