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YD480氣缸蓋螺釘孔加工專機說明書
產(chǎn)品結構的分析
YD480柴油機由下列機構和系統(tǒng)組成：
①機體和氣缸蓋；②曲柄連桿機構；③供給系；④配氣機構
⑤；點火系；⑥冷卻系；⑦潤滑系；⑧起動裝置。
氣缸蓋是柴油機重要大件之一，裝在氣缸體上部，用于密封氣缸的上平面。它與活塞頂共同形成燃燒室空間。氣缸蓋上通常裝有噴油器，進、排氣門，進、排氣管和搖臂軸總成等，以及進、排氣道，冷卻水套和油道布置在上面。
氣缸蓋的作用是密封氣缸，與活塞頂部一起組成燃燒室，因此承受很大的機械負荷和熱負荷。氣缸蓋中有進、排氣門及其氣道、火花塞或噴油器，對于非直噴柴油機來說還有渦流室或預燃室，對頂置凸輪內(nèi)燃機來說還有凸輪軸及其軸承等。為了保證燃燒室的可靠密封，氣缸蓋上螺栓孔的位置的布置應合理，螺栓孔的加工精度要求應高，否則無法密封氣缸，氣缸表面尚未工作就發(fā)生很大的變形，這樣，活塞環(huán)不能很好地工作，漏氣增加，氣缸磨損加劇，機油消耗大增。
氣缸蓋受到燃氣的加熱和氣體的作用，會產(chǎn)生較大的熱應力和彎曲應力，如剛度不足或使用不當，就會產(chǎn)生變形甚至于開裂，引起漏氣和沖破氣缸墊的故障。
氣缸蓋與機體的連接是通過氣缸蓋螺栓孔用氣缸蓋螺栓連接的。氣缸蓋螺栓孔總共有10個，其中有兩個孔兼作位孔定，兩個定位孔在加工中心加工。另八個孔在此專機上加工。
組合機床方案的制定
1、根據(jù)被加工零件的：精度要求、加工工序內(nèi)容
由于所加工的孔直徑φ15，深90屬于深長孔，組合機床采用臥式，左右主軸箱先后從兩面加工。采用鉆削就可以達到所需要求。八個孔在一次鉆削中完成，這樣符合工序集中原則。
2、根據(jù)被加工零件的特點
根據(jù)被加工零件的形狀、結構特點，以及近代機械加工主要發(fā)展方向中工序集中的原則，考慮設計組合機床，運用多刀(相同或不同刀具)集中在一臺機床上同時完成8個孔的加工，從而提高生產(chǎn)率。而且，提高了工序集中程度，減少機床臺數(shù)、占地面積、節(jié)省人力，取得理想的效益。本機床屬于同類型工序集中，簡化了循環(huán)和結構這8個孔間有相對位置要求，工序集中，以獲得較高的位置精度，便于裝配。
3、根據(jù)零件的生產(chǎn)批量，確定機床的復雜程度、通用化程度；零件的結構工藝性、加工精度、機床調整的可能性及經(jīng)濟性對配置都有不同的影響。為使工件在流水線上運輸方便，采用側面朝下的安裝方法，手動插銷、液壓夾緊工件的固定式夾具型式，不僅縮短安裝時間，而且提高了定位精度。這樣機床就選用臥式，夾具設計相對容易，切屑易排出，不影響加工精度。根據(jù)經(jīng)驗及類比，將刀具導向靠近工件，減少刀具與導向的間隙，提高主軸與導向的同軸度，能達到產(chǎn)品圖紙及工藝文件提出的工藝要求。
4、確定組合機床的配置型式
在確定機床配置型式時首先要考慮如何穩(wěn)定地保證零件的加工精度。影響加工精度的因素有夾具誤差和加工誤差兩方面。
夾具誤差：一般精加工的夾具公差為零件公差的1/3～1/5；粗加工時，夾具精度可略低，但不能太低。夾具型式也有影響。
由于YD480氣缸蓋的連接螺孔的加工屬于深孔加工，存在以下主要問題：
（1） 排屑困難 因切屑易阻塞使扭矩增大，造成個別鉆頭經(jīng)常折斷。
（2） 刀具冷卻困難 冷卻液不易進入加工空間，鉆頭嚴重發(fā)熱，使用壽命降低。
（3） 鉆孔軸線歪斜面 由于鉆頭細長，剛性差，特別是刃磨不對稱時，鉆孔更易偏斜。
針對YD480氣缸蓋的連接螺孔的具體情況，可采取從兩邊加工，既提高了效率，又解決了深長孔的加工問題。但存在加工直線性的誤差，解決此誤差的辦法是將夾具體導向孔的中心距公差提高到±0.008mm，同時工件定位孔之間公差達到±0.04；在鉆套、襯套加工時嚴格控制內(nèi)孔與外圓的同軸度，并之工件加工達到公差要求。
通過比較，確定選用臥式雙面加工的組合機床。選HY50A-Ⅰ液壓滑臺
多軸箱功率P=P切削+P空轉+P損失
P空轉 ——空轉功率 （按《組合機床設計筒明手冊》中表4-6選取P空轉=8*0.045KW=0.36KW）
P損失——與負荷成正比的功率損失，一般可取傳遞功率的1/%
P損失=1/%* P切削=1/%*2.536=0.025KW
P==P切削+P空轉+P損失=2.536+0.36+0.025=2.921KW
故選YD50AY動力頭
電動機型號Y132M2-6
電動機功率5.5KW
電動機轉速n=960r/min
輸出軸轉速n=480r/m
5、切削用量的確定
由氣缸蓋零件圖可知：材料HT200，HB=170～240HBS或HT250, HB=187～255HBS加工孔徑D=15,采用高速鋼鉆頭進行加工,根據(jù)高速鋼鉆頭切削用量表可選取切削速度v=13m/s,f=0.22mm/r根據(jù)組合機床切削力、切削轉矩、切削轉矩的計算公式可計算每根主軸的切削力F、切削轉矩T及切削功率P
F=26Df0.8HB0.6
公式中HB=HBmax-1/3(HBmax-HBmin)=255-1/3(255-187)=232
F=26Df0.8HB0.6 =26*15*0.220.8*2320.6=3049N
T=10D1.9f0.8HB0.6=10*151.9*0.220.8*2320.6=13352N·m
P=TV/9740πD=13352*13/9740*3.14*15=0.436kw
8根主軸的總進給力8F=8*3049=24392N
8根主軸的切削功率8P=8*0.436=3.488KW
對功率進行正P總/0。8=3.488/0.8=4.36
多軸箱
6、動力部件的選用
HY50A-Ⅰ滑臺的最大進給力F=32000N
工藝方案的制定
一、被加工零件的分析：
根據(jù)被加工零件的精度要求、加工部位尺寸8-φ15、形狀、結構特點、詳見氣缸蓋零件圖YD480-03101a。
材料：HT200 硬度：170～240
（或材料：HT250 硬度 ：187～255）
生產(chǎn)批量：大批量。
所加工的孔直徑φ15，深90屬于深長孔，其位置度為φ0.4,表面粗糙度Ra12.5,一次切削較難加工，也給排屑 帶動困難。所以此孔分兩個工步分別從兩面鉆削，使之接通。
二、對機床夾具的本要基求：
1、 穩(wěn)定地保證工件的加工精度；
2、 提高機械加工的勞動生產(chǎn)率；
3、 結構簡單，有良好的結構工藝性和勞動條件；
4、 應能降低工件的制造成本。
本專機用于加工八個氣缸蓋螺栓連接孔
三、工件的定位方案和夾緊部位選擇
工件上的八個孔為通孔,沿孔方向的自由度可不予限制.但實際上以工件底面定位時,必須限制該方向的自由度,故應按完全定位設計夾具,并力求遵循基準重合原則,以減少定位誤差對加工精度的影響.
定位方式著重考慮兩種方案.
方案一、
從考慮定位方便的觀點出發(fā)，以底面、一側面、一端面定位，其優(yōu)點是工件安裝方便，但違背了基準重合和統(tǒng)一原則，不利于保證加工要求。
方案二、
從遵守基準重合和統(tǒng)一原則的觀點出發(fā)，以底面、及底面上兩孔定位，其優(yōu)點是工件定位精度高，符合基準重合和統(tǒng)一原則，有利于保證加工要求。但夾具結構相對方案一要復雜些。。
根據(jù)YD480-03101a氣缸蓋機械加工工藝過程卡，可知機體氣缸蓋的加工情況,再考慮加工工藝基準的一致性，決定工件側面朝下，以底面、底面上兩定位孔為基準，夾緊頂面。保證基面與加工部位間的位置關系，使其利于加工精度，且工件不宜變形。
氣缸蓋上有許多孔需要加工，而且有些孔要求有較高的精度，它們分別在不同的工序中加工，又要在幾次安裝下進行。因此采用一面雙孔定位；采用一面雙孔定位具有以下特點：
a） 可以簡便地消除六個自基準帶來的由度，使工件獲得穩(wěn)定可靠的定位；
b） 有同時加工零件五個表面化的可能性，既能高度集中工序，又有利于提高各表面的位置精度。
c） “一面雙孔”可做為零件從粗加工到精加工全部工序的定位基準，使零件整個工藝過程基準統(tǒng)一，從而減少由基準轉換帶來的累積誤差，有利于保證零件的加工精度。同時，使機床各工序的許多部件（如夾具）實現(xiàn)通用化，有利于縮短設計制造周期，降低成本。
d） 易于實現(xiàn)自動化定位、夾緊并有利于防止切屑落于定位基面上。
總之,采用一面兩孔定位,符合定位基準與設計基準重合原則;這樣減少基準不符的誤差,保證加工精度.同時能保證工件穩(wěn)定定位,采用已加工的大平面作為定位平面尤為重要;又符合基準統(tǒng)一原則,在各臺機床上采用共同的基準面來加工零件不同表面上的孔.
從保證加工要求和夾具的結構復雜程度兩方面進行綜合分析比較，按方案二設計夾具比較合理。
為了保證加工精度及技術要求，作為定位基準的平面和銷孔必須規(guī)定相應的尺寸精度、表面粗糙度及位置精度要求。工件二定位銷孔2-φ18，中心距400±0.015。定位孔的位置度φ0.08, 表面粗糙度Ra1.6,
保證規(guī)定加工精度實現(xiàn)的條件:
(1) 夾具的有關制造誤差(制造)
這個誤差主要包括夾具制造時的兩項誤差:確定刀具位置的元件和引導刀具的元件與定位元件間的位置誤差;定位元件與夾具安裝到機床上的安裝基面間的位置誤差.
(2) 夾具的安裝誤差(安裝)
即是夾具在機床上定位誤差.
(3) 加工誤差(加工)
指工件在切削過程中所產(chǎn)生的誤差.如機床的工作精度,刀具的磨損和跳動,刀具相對工件加工位置的調整誤差,以及工藝系統(tǒng)在加工過程中的彈性變形.
為了保證工件的加工精度,必須使上述所有誤差對工件的綜合影響,控制在工件所允許的公差δ工范圍之內(nèi),即:
=制造+安裝+加工≤δ工
為了使δ工合理分配到機械加工中產(chǎn)生的各個環(huán)節(jié),,通常在夾具設計時夾具上定位元件之間,定位元件與引導元件之間,以及其它相關尺寸和相互位置的公差,一般取工件上相應公差的～,最常用的是～.因粗加工的δ工大,夾具上相應的公差取小的比例.
制造≤δ工
如圖工件采用一面兩孔定位，若采用兩個圓柱銷定位時，常會產(chǎn)生過定位現(xiàn)象，即左銷套上工件后右銷很難同時套上。為了避免這種定位干涉，應該將兩銷之一在聯(lián)線的垂直方向上削去兩邊。
1、 確定圓柱銷的定位直徑和偏差
定位孔的直徑2-φ18,為了減少工件的移動誤差，并考慮到定位銷制造時可能達到的精度，取圓柱銷的定位直徑與偏差為φ18（mm）
2、確定菱形銷的結構的尺寸和偏差
菱形銷必須滿足中心偏差的補償量為:
2△Lg+2△Lx-△1=2×0.04+2×0.015- 0.006=0.104
根據(jù)算得銷的直徑為φ18；右邊削邊銷的寬度和直徑可計算，同時也可以采用查表法：根據(jù)華東地區(qū)大專院校試用教材《機械制造工藝學》表2-2,查得直徑為18的菱形銷的圓錐銷柱部分寬度b為4mm.
為了達到上面要求的0.104mmm的中心距的補償量,b和△2之間必須滿足下列關系:
△ 2 =
==0。011
求得△2以后,確定菱形銷圓柱部分直徑的尺寸及偏差,一般有兩種方法:
D2
從3~6
＞6~8
＞8~20
＞20~25
＞25~32
32~40＞
＞40~50
b
2
3
4
5
7
7
8
B
D2-0。5
D2-1
D2-2
D2-3
D2-4
D2-5
根據(jù)△2求出菱形銷圓柱部分定位直徑的最大極限尺寸為:
d2=D2-△2=18-0。011=17。989mm,此時算出的銷為最小尺寸即dmax=17。989，通常削邊銷的一般制造精度,取其直徑公差帶h6,則菱形銷圓柱部分定位直徑及其偏差為:
φ17.989mm,或φ18
四、定位誤差
a) 移位定位誤差
分析左端圓柱銷定位情況?？讖溅?8，公差δD1=0.02； 銷徑φ18，公差為δd1=0。009，最小間隙△1=0.10-0.094=0.006,這時銷與孔的最大間隙為:
1=△1+δD1+δd1=0.006+0.02+0.009=0.035<δ工=×0.4=0.1333;將使1將使一批工件孔的中心偏離銷的中心,其中心偏聽偏離誤差范圍,是以1為直徑的圓,圓心即為銷的中心。
b)轉角誤差
按菱形銷圓柱部分定位直徑尺寸為φ18mm來計算,
△θ=tg ()
=tg ()
=tg 0.00009625
△ θ=19.85″此時轉角誤差較小能滿足定位要求.
五、工件的夾緊：
工件在定位后，因加工中還要受到切削力、及工件自重等影響，將使工件產(chǎn)生移動或振動，破壞工件的正確定位，故必須用夾緊機構，將工件固定在定元件上。為了改善勞動條件各提高生產(chǎn)率，在大批量生產(chǎn)中采用液壓動力裝置來代替人力夾緊。
1、夾緊方案通常需滿足以下要求：
⑴夾得穩(wěn)——夾緊時不能破壞工件穩(wěn)定的正確定位；夾緊機構的動作應平 穩(wěn)，有足夠的剛度和強度。夾緊力由頂面指向定位底面，符合夾得穩(wěn)要求。
⑵夾得牢——夾緊力要合適，過小易使工件離動或振動，過大易使工件變形或損傷，影響加工精度。此外，夾緊機構要有自鎖作用，即原始力去除后工件仍能保證夾緊狀態(tài)而不松開。
⑶夾得快——夾緊機構應盡量簡單、緊湊、操作時安全省力，迅速方便，以減輕工人勞動強度，縮短輔助時間，提高生產(chǎn)效率。
2、夾緊力的方向的確定：
⑴夾緊力的作用方向應不破壞工件定位的準確性，即夾緊力的方向朝向定位其準，保證工件與定位元件可靠地接觸。故此方案夾緊力由頂面指向定位底面，符合夾得穩(wěn)要求。沒有破壞工件穩(wěn)定的正確定位。
⑵夾緊力方向應使工件變形盡可能小。
⑶夾緊力方向應使所需夾緊力盡可能小。
此方案采用雙面加工，左邊切削力向右，與夾緊力方向一致，這時所需的夾緊力最小，所以，左邊切削工件的深度可以適當放大一點，右邊切削力向左，與夾緊力方向相反，右邊切削工件的深度可以適當放小一點。
3、夾緊力的作用點的選擇
⑴ 夾緊力應落在支承元件上或幾個支承元件所形成的支承面內(nèi)。
⑵夾緊力應落在工件剛度較好的部位上。
⑶夾緊力應盡量靠近加工面.
以上三點詳見具總圖，夾緊力落在支承元件上或幾個支承元件所形成的支夾承面內(nèi)。夾緊力應落在工件剛度較好的部位上。夾緊力應盡量靠近加工面，這三點基本滿足要求。
液壓夾緊用高壓油產(chǎn)生動力，工作原理及結構與氣動夾緊相似。其共同的優(yōu)點是：操作簡單省力，動力迅速，使輔助時間大為減少。而液壓夾緊還另有一些優(yōu)點是：
⑴油壓可達600N/cm2以上，比氣壓高十幾倍。故油缸比汽缸尺寸小得多。
⑵油壓不可壓縮，故夾緊剛愎自用 性大，工作平穩(wěn)，夾緊木可靠。
⑶噪聲小，勞動條件好。
液壓夾緊特別適用于強力切削及加工大型工件時的多處夾緊
4、夾緊力大小確定：
F=26×D×f0。8×HB0。6
T=10×D1。9×f0。8×HB0。6
HB=187～255（HT250） 或 HB=170～240（HT200） D=15
取HB= HBmax-（HBmax- HBmin）
HB=255-（255-187）=232
取V=13m/min f=0.22mm/r
F=26×D×f0。8×HB0.6
=26×15×0.220。8×2320。6=3049(N)
T=10×151。9×0.220。8×2320。6=13352(N.mm)
F總= F×8=3049×8=24392(N)
P===0.436(KW)
對功率進行修正==0.545
加工孔數(shù)8個直徑都是15
P總=0.545×8=4.364
本工序采用T5057Ⅱ油缸提供壓力，然后再通過斜楔-滾柱增力機構，如夾具總圖采用斜楔滾子的摩擦系數(shù)比平面之間的磨擦系數(shù)D/d倍，因而夾緊機構獲得較大的夾緊力。
參照李慶濤主編的機械工業(yè)出版社出版《機床夾具設計》P83頁
W總=ip總Q總 W總= F總=24392(N)=2393.2Kg
W=K×W總
根據(jù)機床和夾具的某些特殊情況,還要乘以必須的的修正系數(shù)K.在通常情況下,取 K=1.5～2.5,
對夾緊力和切削力方向相反的情況下,取 K=2.5～3 此時,取K=3
W=K×W總=3×2393.2=7179.2
斜楔-滾柱增力機構查表3-8ip1=2.9 然后還有一個杠桿機構ip2=70/109=0.642
W= ip1。ip2.Q 總
由于此夾緊采用兩個油缸,所以Q總=2×Q
W= ip1。ip2.Q 總 7179.6=2.9×0.642×2×Q
Q=1928(Kg)
即活塞桿的作用力。參照下列油缸參數(shù)表：
根所需的油缸活塞桿作用力選取油缸為T5037ⅡA工作壓力為40(公斤力/平方厘米),I活塞桿的作用力是2012Kg力：
六、鉆套、鉆模板結構及總體設計：
為了適應此鉆孔，采用可換鉆套，外帶襯套，其孔尺寸和公差查閱相關手冊；八個加工孔兩邊相距較遠，故采用固定式鉆模板，鉆模板上兩個定位銷導向孔之間以及各個鉆套之間的距離應按工件的公差縮小，在設計夾具時還要保左鉆模板上的支承塊在同一平面上，帶肩套的端面應與定位面平行，鉆套的軸線與定位面垂直。各加工孔的鉆套與定位孔之間應有足夠的精度等。左右鉆模板對應孔要有足夠的同軸度，在兩鉆模板之間用一個框架式的頂板在上面固定，兩個油缸安裝在頂板上.
綜上分析,本夾具能夠滿足生產(chǎn)要求,和精度要求.
12
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)代組合機床和自動線作為機電一體化產(chǎn)品，它是控制、驅動、測量、監(jiān)控、刀具和機械組件等技術的綜合?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，這些技術有長足進步，同時作為組合機床主要用戶的汽車和內(nèi)燃機等行業(yè)也有很大的變化，其?產(chǎn)品市場壽命不斷縮短，品種日益增多且質量不斷提高。 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和激勵了組合機床和自動線技術的?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
在組合機床這類專用機床中，回轉式多工位組合機床(圖2)和自動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. 因為這?兩類機床可以把工件的許多加工工序分配到多個加工工位上，并同時能從多個方向對工件的幾個面進行加工，此?外，還可以通過轉位夾具(在回轉工作臺機床上)或通過轉位、翻轉裝置(在自動線上)實現(xiàn)工件的五面加工或全部?加工，因而具有很高的自動化程度和生產(chǎn)效率，被汽車、摩托車和壓縮機等工業(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)有關統(tǒng)計資料，德國在1990～1992年期間，回轉式多工位組合機床和自動線的產(chǎn)量約各占組合機床總數(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.
應指出，回轉式多工位組合機床實際上是一種特殊型式的小型自動線，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)動機的年產(chǎn)量通常為60萬臺左右，實現(xiàn)這樣大的批量?生產(chǎn)，回轉式多工位組合機床和自動線在三班運行的情況下，其節(jié)拍時間一般為20～30秒，當零件生產(chǎn)批量更大?時，機床的節(jié)拍時間還要更短些(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給速度來縮短基本時間。 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，德國大眾汽車廠在加工鋁合金缸蓋燃燒室側面時，采用PCD銑刀，銑削速度高達3075m/min，進給速度達?3600mm/min；又如，在鏜削灰鑄鐵缸體的缸孔時，采用裝有三個可轉位CBN刀片的新穎鏜刀頭，切削速度達?800m/min，進給速度為1500mm/min，加工深度為146mm的缸孔，其實際加工時間僅為5.8s，比傳統(tǒng)加工工藝可縮?短2/3的加工時間。 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.
縮短輔助時間主要是縮短包括工件輸送、加工模塊快速引進以及加工模塊由快進轉換為工進后至刀具切入工件?所花的時間。 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60m/min或更高些，加工模塊快速移動速度達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，作為組合機床重要用戶的汽車工業(yè)，為迎合人們個性化需求，汽車變型品種日益增多(圖5)，以多?品種展開競爭已成為汽車市場競爭的特點之一，這使組合機床制造業(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. 為適應多品?種生產(chǎn)，傳統(tǒng)以加工單一品種的剛性組合機床和自動線必須提高其柔性。 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，組合機床及其自動線在保持其高生產(chǎn)效率的條件下，進一步提高其柔性?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.
組合機床的柔性化主要是通過采用數(shù)控技術來實現(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. ?柔性組合機床和柔性自動線用的數(shù)控加工模塊，按其數(shù)控坐標(軸)數(shù)，主要有單坐標(Z)、雙坐標(XZ、YZ、?ZU和ZB等)和三坐標(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.
立柱移動式CNC三坐標加工模塊可利用X軸和Y軸的聯(lián)動來實現(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，可采用較小直徑的銑刀，實現(xiàn)高速(切削速度達2500m/min)周邊銑削，由此減小加工時的切削?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?種不同的結構形式，但基本上可分為自動換箱式多軸加工模塊(圖7)、轉塔式多軸加工模塊(圖8)和回轉工作臺式?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. 而轉塔式和回轉工作臺式多軸加工模塊，由于在轉塔頭和回轉工作臺上允許裝的多軸箱數(shù)量有限?(一般為4～6個)，所以這種加工模塊只能實現(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.
在自動線上采用CNC三坐標加工模塊和轉塔式多軸加工模塊，不僅可實現(xiàn)不同品種工件的加工，而且在自動線?節(jié)拍時間內(nèi)(如果節(jié)拍時間允許的話)，這類加工模塊還可以在同一個加工工位上通過其自動換刀或換箱，依次實?現(xiàn)多道加工工序(粗鏜、半精鏜和精鏜；鉆孔、擴孔和攻絲)，從而減少自動線的加工工位數(shù)，縮短自動線的長度?。 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. ?單軸和多軸復合加工模塊是一種三坐標數(shù)控加工模塊，可通過自動換刀或自動更換多軸箱而實現(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)充分應用模塊化結構原理，在作為系統(tǒng)基礎模塊的?CNC三坐標模塊上，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)，不僅在機械結構方面，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)控加工模塊有四個雙坐標數(shù)控銑削模?塊、六個數(shù)控轉塔式多軸加工模塊和六個數(shù)控三坐標加工模塊。 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)過程中的中間儲存、搬運以及縮短生產(chǎn)流程時間，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、測量、裝配和試漏等)集成到自動線或自動線組成的生產(chǎn)系統(tǒng)中(圖15)，以實現(xiàn)工件加工、表面處理、測量和裝配等工序的綜合自動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，國內(nèi)外越來越關注工業(yè)清洗對環(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)部門的零件清洗轉向應用水劑清洗(采用酸性、中性或堿性清洗液，清洗液中主要含有磷酸鹽、活性劑和絡合劑等)，這種水劑清洗主要根據(jù)工件清洗質量要求而采用噴淋(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、現(xiàn)場操作工人的保健和清洗工藝的合理化等要求，目前，清洗機已普遍采用封閉式布局，整個清洗過程是自動進行的，設備控制采用可編程控制器，并自動監(jiān)控所有機械動作和工藝技術參數(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
在自動線上采用自動測量旨在對工件的加工質量進行監(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.
在自動線上，自動測量可分為加工前測量和加工后測量。 The automatic line, automatic measurement can be divided into pre-processing measurement and processed measurements.
加工前測量是在工件加工前通過測量以確定工件的特征，并利用測量結果來調整刀具相對于工件待加工部位的位置，然后進行相應的加工。 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