0524-MG250591-WD型采煤機(jī)右搖臂殼體的加工工藝規(guī)程及數(shù)控編程
0524-MG250591-WD型采煤機(jī)右搖臂殼體的加工工藝規(guī)程及數(shù)控編程,mg250591,wd,采煤,搖臂,殼體,加工,工藝,規(guī)程,數(shù)控,編程
第1頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體加工單位材料零件凈重每臺數(shù)量毛坯種類外 形 尺 寸重 量每件加工數(shù)量機(jī)1ZG30Mn23170.29鑄序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具0鑄鑄15劃115080(俯視,N1-N1)44290128(俯視,N-N)3工藝基準(zhǔn)塊位置打樣沖孔43-M36-6H10銑1. 15080100槽(俯視,N1-N1)機(jī)1WD130A4182. 90128槽(俯視,N-N)15焊水道鉚20鉗領(lǐng)工藝基準(zhǔn)塊按圖焊好機(jī)142第2頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具25鏜3-M36-6H底孔鉆好機(jī)1WD130A4330鉆套3-M36-6H扣機(jī)1Z30804235劃一、劃檢毛坯各部機(jī)1二、以電機(jī)孔為準(zhǔn),照顧 面,保證各孔及臺面位48置正確,各部位余量均勻夠干,劃下列尺寸線:1工藝基準(zhǔn)(塊)面線 38700.2 200.14215H7與240H7兩孔中心連線繞工件一周三檢查線必須劃出40銑按線找正銑:機(jī)1X2102440一、8700.2上面墊起放于工作臺上1工藝基準(zhǔn)(塊)面銑留余量4二工藝基準(zhǔn)(塊)面放于工作臺上第3頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具11. 8700.2銑成878,余量均勻留兩面2200.1上面銑留余量4下面銑留余量4上面銑留余量445劃鏜孔線1215H7與240H7兩孔中心連線繞工件一周機(jī)1462400H7行孔及外圓十字圓線(劃在兩端)3100H7行孔十字圓線4260H7行孔十字圓線(劃在兩端)5240H7行孔十字圓線6215H7行孔十字圓線7120H7行孔十字圓線(兩處)8135H7行孔十字圓線(劃在兩端)9105H7行孔十字圓線 (D-D)1050F9行孔50鏜工藝基準(zhǔn)(塊)面放于工作臺上,按8700.2上面拉機(jī)14200第4頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具直找正,A-A視圖上面向床頭一、1400H7行孔及外圓(1)490鏜成482(2)400H7鏜成392(3)250鏜成242(4)560h7鏜成568(5)645鏜成653(6)各止口端面鏜留余量42 100H7行孔(1)110鏜成102(2)100H7鏜成92(3)75H7鏜成67(4)30鉆好(5)各止口、臺面均留余量43260H7行孔(1)315鏜成307(2)260H7鏜成252(3)170H7鏜成162第5頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具(4)160H8鏜成152(5)行孔各尺寸面均鏜留余量44135H7行孔(調(diào)個兩面鏜)(1)135H7鏜成127(2)125H7鏜成117(3)各尺寸臺面鏜留余量4(4)200.1兩面之間銑剩余部分按粗加工后形成的尺寸鏜好5105H7行孔(D-D)(1)105H7鏜成97(2)臺面鏜留余量4二工件調(diào)個,主視圖示向床頭1500H8行孔(1)500H8、505、一刀下鏜成492,斜面按粗加工后尺寸鏜好(2)340H8鏜成332(3)各尺寸端面鏜留余量4第6頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具2240H7行孔(1)304刀檢鏜好(2)240H7鏜成232(3)170H7鏜成162(4)230鏜成222(5)行孔各尺寸面鏜留余量43215H7行孔(1)275鏜成267(2)215H7鏜成207(3)296鏜成288(4)320刀檢鏜好(5)行孔各尺寸面鏜留余量44120H7行孔(兩處)(1)130鏜成122(2)120H7鏜成112(3)90H7鏜成82(4)2-M332-6H鉆成30第7頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具(5)320刀檢鏜好(6)各止口臺面鏜留余量45430H7行孔(1)492鏜成484(2)430H7鏜成422(3)280H7鏜成272(4)430刀檢鏜好(5)行孔各尺寸面鏜留余量4650F9行孔(1)50F9行孔鉆擴(kuò)鏜好(2)窩銑好(3)M12-6H底孔鉆好(4)電機(jī)行孔外圓鏜成13540055焊電機(jī)行孔外圓殘圓鉚60鉗振動時效機(jī)1414第8頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具65劃一重新劃檢毛坯各部機(jī)145二劃下列尺寸線1工藝基準(zhǔn)(塊)面線 38700.2 200.14215H7與240H7兩孔中心連線繞工件一周70銑一8700.2上面墊起放于工作臺上機(jī)1X2012A4401工藝基準(zhǔn)(塊)面銑好二工藝基準(zhǔn)(塊)面放于工作臺上18700.2兩面銑好2200.1上面銑好803.下面銑好4上面銑好75劃劃鏜孔線機(jī)1451215H7與240H7兩孔中心連線繞工件一周第9頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具2400H7行孔及外圓十字圓線(劃在兩端)3100H7行孔十字圓線4260H7行孔十字圓線(劃在兩端)5240H7行孔十字圓線6215H7行孔十字圓線7120H7行孔十字圓線(兩處)8135H7行孔十字圓線(劃在兩端)9105H7行孔十字圓線 (D-D)80鏜工藝基準(zhǔn)(塊)面放于工作臺上,A-A視圖上面向面機(jī)1BFT1304100向床頭,按8700.2上面拉直找正(誤差0.02)拉坐標(biāo)鏜:一、1400H7行孔及外圓(1)490鏜好(2)400H7鏜成(3)360鏜好(4)250鏜好(5)560h7鏜成562(6)645鏜好第10頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具(7)各止口端面鏜留余量12100H7行孔(1)110鏜成102(2)100H7鏜成(3)75H7鏜成(4)100外圓鏜好(5)各止口、臺面均鏜留余量13260H7行孔(1)315鏜成313(2)260H7鏜成(3)170H7鏜成(4)160H8(5)行孔各尺寸端面均鏜留余量14135H7行孔(調(diào)個兩面鏜)(1)135H7鏜成(2)125H7鏜成(3)鏜成第11頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具(4)鏜成(5)各尺寸臺面鏜留余量1(6)200.1兩面之間銑剩余部分鏜好(包括倒角)5105H7行孔 (D-D)(1)105H7鏜成(2)臺面鏜留余量1二、工件調(diào)個,主視圖示向床頭,按8700.2上面拉直找正(誤差0.02)1430H7行孔,按400H7半精鏜后尺寸找正(1)490鏜好(2)430H7鏜成(3)300及5鏜好(4)280H7鏜成(5)刀檢鏜好(6)行孔各尺寸端面均鏜留余量12120H7行孔(兩處)(1)130鏜好第12頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具(2)120H7鏜成(3)90H7鏜成(4)100鏜好(5)320刀檢鏜好(6)130及5鏜好(7)各止口臺面鏜留余量14215H7行孔(1)275鏜好(2)215H7鏜成(3)296鏜好(4)320刀檢鏜好(5)行孔各尺寸面鏜留余量15240H7行孔(1)304刀檢鏜好(2)240H7鏜成(3)170H7鏜成(4)230鏜好(5)行孔各尺寸面鏜留余量1第13頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具6500H8行孔按半精后的170H7找正(誤差0.2)(1)500H8、一刀鏜成斜面按半精加工后尺寸鏜好(2)505鏜好(3)340H8鏜成(4)190鏜好(5)各尺寸端面鏜留余量185鏜一、工藝基準(zhǔn)(塊)面放于工作臺上,A-A視圖上面機(jī)1BFT1304204向床頭,按8700.2上面拉直找正(誤差0.01)拉坐標(biāo)精鏜以下各行孔,精鏜時包括止口、端面、倒角及環(huán)溝1主軸對正400H7行孔及外圓,按半精后400H7找正(誤差0.01)(1)400H7行孔及外圓鏜好(2)數(shù)控編程銑3-356R槽2(1)100H7行孔鏜好(2)槽銑好第14頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具(3)M12-6H底孔鉆好3260H7行孔鏜好4(1)135H7行孔鏜好(調(diào)個兩面鏜)(2)槽銑好 (3)2-M12-6H底孔鉆好5(1)105H7行孔鏜好(D-D)(2)槽銑好(3)2-M12-6H底孔鉆好6按90H7孔找正,2-M332底孔擴(kuò)好,45窩锪好二、工件調(diào)個,主視圖示向床頭,按8700.2上面拉直找正(誤差0.01)1按260H7孔找正(誤差0.01)(1)500H8行孔鏜好(2)3-R40鏜好第15頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具2240H7行孔鏜好3215H7行孔鏜好4(1)120H7行孔鏜好(兩處)(2)R槽銑好 5按120H7孔找正(誤差0.01)(1)50F7行孔鏜好(2)槽銑好(3)M12-6H底孔鉆好90劃1主視圖左上部190365槽線機(jī)14152(337)332330及20 (H-H)413252R580250R63-M20-6H7M272-6H (B-B)第16頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具826 (B-B)9M332-6H (C-C)1012540R槽線 (主視及E-E)1120 (A-A及B向)1210(保證與20相通) (B向)14M332-6H (B-B)95鏜一、1主視圖左上部190365槽銑好機(jī)1WD130A4382(337)33216窗口銑好330R 銑好,20鉆好 (H-H)413252R銑好580250R20銑好62-M12-6H底孔鉆好7M221.5-6H底孔鉆好,窩锪好10鉆好(H1-H1)85-M16-6H底孔鉆好94-M12-6H底孔鉆好103-M20-6H底孔鉆好11M272-6H底孔鉆好,窩锪好(保證與30相第17頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具通) (B-B)1226鉆好并锪窩 (B-B)13M332 -6H底孔鉆好,窩锪好,干平部位鏜銑好(C-C)1412540R槽銑好 (主視及E-E)15M332-6H底孔鉆好,窩锪好,干平部位鏜銑好(B-B)二、重新把活,10鉆好,窩锪好100劃一、主視圖示機(jī)141212-M12-6H2M332-6H36-M12-6H42-M10-6H (E-E)52-M12-6H第18頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具66-M16-6H7430H7120H7兩孔中心連線8215H7孔橫向中心線9240H7孔橫向中心線10500H8孔橫向中心線二、B向1215H7孔橫向中心線2170H7孔橫向中心線3260H7孔橫向中心線4560h7外圓與30孔中心連線5M221.5- 6H630三、1M332-6H (E-E)2M332-6H (N-N)33-M36-6H(俯視)4M272-6H (B-B)四俯視第19頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具12-M12-6H2M221.5-6H (H1-H1)35-M16-6H44-M12-6H105鏜12-M12-6H底孔機(jī)1WD130A482M221.5-6H底孔 (H1-H1)35-M16-6H底孔44-M12-6H底孔110鉆一、主視圖示機(jī)1Z3080458(一)按線鉆12-M12-6H底孔鉆好2M332-6H鉆套好,窩锪好36-M12-6H底孔鉆好42-M10-6H底孔鉆好 (E-E)52-M12-6H底孔鉆好66-M16-6H鉆套好第20頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具(二)上胎鉆116-M12-6H底孔鉆好C332-438027-M12-6H底孔鉆好C332-438137-M12-6H底孔鉆好C332-4382412-M16-6H鉆套好C332-4383二、B向1(1)14-26-6H鉆好并锪窩C332-4384A(2)5-25H7預(yù)鉆成16,窩锪好28-M12-6H底孔C332-438537-M12-6H底孔C332-438647-M12-6H底孔C332-4387520鉆好,窩锪好(保證與10相通)(A-A)6M221.5-6H鉆套好7套2-M33-6H扣830鉆好三、1M332-6H鉆套好,窩锪好 (E-E)2M272-6H鉆套好,窩锪好 (B-B)第21頁共21頁冷加工工藝過程卡片產(chǎn)品型號MG250/591-WD零件圖號20MJ0601產(chǎn)品名稱采煤機(jī)零件名稱右搖臂殼體序號工序工 序 內(nèi) 容車間設(shè)備工 藝 裝 備工等工時單件備注夾具刃具量具輔具3M332-6H鉆套好,窩锪好 (N-N)4套5-M16-6H扣(俯視)115鉗一、領(lǐng)序號14、15、16堵按圖焊好機(jī)1440二、套扣1套所有M12-6H扣2套M221.5-6H,5-M16-6H扣 (俯視)3套M272-6H扣 (B-B)(C-C)4套M332-6H扣(兩處) (B-B)(C-C)120鉗去刺,清理機(jī)1420125鉗1水壓實驗機(jī)1C357-772A4242合格后清凈吹干130涂涂漆裝摘 要采煤機(jī)直接用于煤炭的地下開采,是煤炭生產(chǎn)中最主要的機(jī)械設(shè)備之一。改革開放以來,我國的采煤機(jī)研發(fā)有了長足的發(fā)展,但在性能和可靠性上與世界先進(jìn)國家的采煤機(jī)相比,還存在一定的差距。為此,開發(fā)高產(chǎn)高效礦井綜合配套技術(shù)是我國煤炭科技發(fā)展的主攻方向。為提升產(chǎn)品設(shè)計質(zhì)量,完善快速設(shè)計和個性設(shè)計手段,采煤機(jī)的創(chuàng)新設(shè)計尚需要加大研究力度。MG250/591-WD型電牽引采煤機(jī)是在雞西煤機(jī)有限公司多年研制電牽引采煤機(jī)成功技術(shù)的基礎(chǔ)上開發(fā)制造成功的。我這次設(shè)計的主要任務(wù)是對MG250/591-WD型采煤機(jī)右截割部搖臂殼體進(jìn)行加工工藝規(guī)程設(shè)計。創(chuàng)新之處在于在設(shè)計過程中根據(jù)具體情況應(yīng)用了數(shù)控編程。關(guān)鍵字: 采煤機(jī) 加工工藝規(guī)程 數(shù)控編程AbstractCoal mining machine uses in the coal directly underground mining, is in the coal production one of most main mechanical devices. Since the reform and open policy, the coal mining machine research and development had the considerable development, But compares in the performance and in the reliability with the world advanced countries coal mining machine, also has certain disparity. Therefore, the development high production highly effective mine pit synthesis necessary technology is our country coal science and technology development main attack direction. In order to promote the product design quality, the consummation fast design and the individuality design method, the coal mining machine innovation design still needed to increase the research dynamics. The MG250/591-WD electricity hauling coal mining machine is develops in the JiXi coal machine limited company many year development electricity hauling coal mining machine success technology foundation makes successfully. The author this design primary mission is carries on the processing technological process design to the MG250/591-WD coal mining machine right cutting department rocking shaft shell. Place of the innovation lay in the design process acts according to the special details to apply the numerical control programming. Key words: Coal mining machine Processing technological process Numerical control programming目錄摘要 Abstract 第 1 章緒論 1第 2 章MG250/591-WD型采煤機(jī)概述 42.1 MG250/591-WD型采煤機(jī)簡介 42.2 工作原理 42.3 采煤機(jī)結(jié)構(gòu)組成及其各部分的功用 52.3.1 截割部 52.3.2 牽引部 62.3.3 行走部 62.3.4 液壓傳動部 62.3.5 冷卻噴霧系統(tǒng) 62.3.6 電氣系統(tǒng) 62.4 主要技術(shù)特點 7 2.5 主要技術(shù)參數(shù)及配套設(shè)備 82.5.1 主要技術(shù)參數(shù) 82.5.2 主要配套設(shè)備 9第 3 章 MG250/591-WD型采煤機(jī)右搖臂殼體工藝規(guī)程設(shè)計 113.1 殼體零件的功用和結(jié)構(gòu)特點 11 3.1.1 殼體零件的功用 11 3.1.2 殼體零件的結(jié)構(gòu)特點 11 3.1.3 礦井用殼體零件的特點 113.2殼體零件的主要技術(shù)要求 123.3零件圖樣分析 13 3.4 工藝分析 143.5 加工工藝規(guī)程 14第 4 章 右搖臂殼體數(shù)控加工工藝 154.1 數(shù)控加工工藝的內(nèi)容 154.2 數(shù)控加工工藝的特點 154.3 加工中心的選擇 154.4 數(shù)控加工工藝分析與設(shè)計 194.4.1 零件加工的可行性分析 194.4.2 零件的工藝性分析 194.4.3 走刀路線的選擇 204.4.4 對刀點與換刀點的確定 204.4.5 加工余量的確定 214.4.6 切削用量的選擇 214.5 加工中心的工藝及工藝裝備 224.5.1 工藝性分析 224.5.2 工藝過程設(shè)計 224.5.3 零件的裝夾 234.6 加工中心編程的特點 244.7 零件主要工序數(shù)控程序編制 24第 5 章 工藝過程的技術(shù)經(jīng)濟(jì)分析 28第 6 章 綠色制造 30第 7 章 專題論文 32結(jié)論 38致謝 39參考文獻(xiàn) 40附錄1外文翻譯及原文 42附錄2數(shù)控加工程序 56附錄3工藝規(guī)程 77IV附錄1外文翻譯及原文外文翻譯寬槽圓柱凸輪數(shù)控加工技術(shù)的研究摘要:針對傳統(tǒng)銑削方法加工圓柱凸輪所產(chǎn)生的一些問題,提出了一種針對槽寬大于刀具直徑的圓柱凸輪槽的數(shù)控銑削加工方法。通過分析研究,建立了一種正確的坐標(biāo)轉(zhuǎn)換模型,并依此加工出符合要求的寬槽圓柱凸輪。關(guān)鍵詞:數(shù)控加工坐標(biāo)轉(zhuǎn)換寬槽圓柱凸輪圓柱凸輪槽一般是按一定規(guī)律環(huán)繞在圓柱面上的等寬槽。對圓柱凸輪槽的數(shù)控銑削加工必須滿足以下要求:1.圓柱凸輪槽的工作面即兩個側(cè)面的法截面線必須嚴(yán)格平行;2.圓柱凸輪槽在工作段必須等寬。這是保證滾子在圓柱凸輪槽中平穩(wěn)運動的必要條件。當(dāng)圓柱凸輪槽寬度不大時,可以找到相應(yīng)直徑的立銑刀沿槽腔中心線進(jìn)行加工,比較容易加工出符合上述要求的圓柱凸輪槽。據(jù)現(xiàn)有資料介紹,目前圓柱凸輪的銑削加工都是用這種辦法來實現(xiàn)。由于這種方法有太多的局限性,給實際銑削加工帶來許多困難。例如一旦找不到與槽寬尺寸相等的標(biāo)準(zhǔn)刀具時,就必須對刀具進(jìn)行改制。 對于槽寬尺寸較大的圓柱凸輪槽,很難找到直徑與槽寬相等的標(biāo)準(zhǔn)刀具。即使有相應(yīng)的刀具,還要考慮機(jī)床主軸輸出功率及主軸和工裝夾具剛度的限制,特別是機(jī)床主軸結(jié)構(gòu)對刀具的限制。例如數(shù)控機(jī)床主軸頭為724的40號內(nèi)錐,配用JT40的工具系統(tǒng),則最大只能使用20mm的立銑刀(不論直柄還是錐柄)。這對于槽寬為38mm的圓柱凸輪(就是本文所敘述的加工凸輪)來說是無法加工的,必須尋求新的加工方法。 下面根據(jù)實踐經(jīng)驗和分析研究,介紹一種用直徑小于凸輪槽寬的立銑刀對圓柱凸輪槽進(jìn)行數(shù)控加工的方法,稱之為寬槽圓柱凸輪的數(shù)控加工。一、加工工藝圓柱凸輪槽是環(huán)繞在圓柱面上的等寬槽,其加工時沿圓周表面銑削的范圍往往大于360,適于用帶有數(shù)控回轉(zhuǎn)臺的立式數(shù)控銑床進(jìn)行加工。根據(jù)圓柱凸輪的實際結(jié)構(gòu),選用帶鍵的心軸作凸輪加工時徑向和周向定位基準(zhǔn),以心軸的臺肩作軸向定位基準(zhǔn),并用心軸前端部的螺紋通過螺母壓緊圓柱凸輪。圓柱凸輪的軸向和徑向尺寸一般較大,為了克服由于懸臂加工時切削力所造成的心軸變形和加工過程中產(chǎn)生的振顫,使用一個支承于尾座上的、與數(shù)控轉(zhuǎn)臺的回轉(zhuǎn)軸線同軸的頂尖頂住心軸中心孔作輔助支承。 圓柱凸輪槽的底部在每一個截面 上通常是等深的,一般選用平底圓柱立銑刀加工。圓柱凸輪銑削加工前通常是一個實心的圓柱體,要經(jīng)過開槽、粗加工、半精加工、精加工等工序;由于槽腔寬度較大,因此,除開槽工序及粗加工工序的一部分刀位軌跡可以沿槽腔的中心線生成之外,其余刀位軌、跡則必須是沿槽腔中心線向左、右兩邊按相應(yīng)的距離等距偏置生成,如圖1所示。圖 1圓柱凸輪槽的二維展開圖二、求解模型在圓柱凸輪槽的數(shù)控加工中,如何求出每道工序中加工兩個側(cè)表面的刀位軌跡是其中的關(guān)鍵。對于圓柱表面上的凸輪槽,通常是先將圓柱面展開,在XOS平面內(nèi)求出該工序加工兩個側(cè)表面的刀位軌跡的展開曲線XS;然后通過坐標(biāo)轉(zhuǎn)換,將展開曲線XS轉(zhuǎn)換為四坐標(biāo)機(jī)床上的刀位軌跡。下面討論任一加工工序中展開曲線XS的求解方法,以及生成最后刀位軌跡的坐標(biāo)轉(zhuǎn)換方法。 1.展開曲線XS的求解如圖2所示,其中Lo為圓柱凸輪槽的中心線,對于第i道工序,Lli和Lri分別為該工序?qū)⒁庸さ牟矍坏淖?、右兩個側(cè)表面展開曲線,此槽寬為Bi,加工刀具半徑為r(顯然2rBi),加工此槽腔左、右側(cè)面的刀位軌跡展開曲線為CLli和CLri,設(shè)Po為槽腔中心線上的一個點,no為槽腔中心線在Po點處的法矢,那么左、右刀位軌跡展開曲線上對應(yīng)點Pli和Pri的計算方法為:(1)圖 2圓柱凸輪槽的二維展開圖將Po點沿著槽腔中心線移動,即可以求出該工序刀位軌跡在XOS平面內(nèi)的展開曲線XS;按照加工工序,依次改變每道工序中的槽寬度Bi,即可求出加工所需槽腔所有刀位軌跡的展開曲線。 2.沿凸輪槽中心線加工的坐標(biāo)轉(zhuǎn)換方法以上計算是在圓柱面的展開平面內(nèi)進(jìn)行的,為了求出加工圓柱凸輪槽腔的刀位軌跡,必須將平面內(nèi)的展開曲線轉(zhuǎn)換到圓柱面上。 假設(shè)轉(zhuǎn)動軸為繞X軸的A軸,Pi為刀位軌跡上的一個刀位點,它在二維平面展開曲線上的坐標(biāo)為(x,s),在四坐標(biāo)機(jī)床上的坐標(biāo)為(x,y,z,a)。由于圓柱凸輪槽腔通常是等深的,因此,z坐標(biāo)在設(shè)置為所需要加工的深度值之后,在加工中是不變的;對于其余三個坐標(biāo),構(gòu)造出以下坐標(biāo)轉(zhuǎn)換公式: (2)式中,R為圓柱凸輪軸的半徑。上式是目前普遍使用的坐標(biāo)轉(zhuǎn)換公式,對于用標(biāo)準(zhǔn)刀具沿凸輪槽中心線銑削加工圓柱凸輪是正確的。 3.對上式在寬槽圓柱凸輪加工中產(chǎn)生問題的分析當(dāng)將上式推廣應(yīng)用于寬槽圓柱凸輪的數(shù)控加工時,通過坐標(biāo)轉(zhuǎn)換計算的刀位軌跡在實際加工中卻產(chǎn)生了一些問題。在圓柱凸輪槽加工完畢后,為了檢驗是否符合要求,用直徑等于圓柱凸輪滾子的檢具進(jìn)行檢驗,卻發(fā)現(xiàn)所加工的槽寬窄不等、有卡殼的現(xiàn)象。仔細(xì)觀察,原來加工出來的槽腔的法截面并不總是上下等寬的矩形槽,而有時是上寬下窄的喇叭槽。為了弄清楚其中的原因,對公式(2)所表示的坐標(biāo)轉(zhuǎn)換方法進(jìn)行了深入的分析和研究。 如圖3所示,由公式(1)可知,加工槽腔兩個側(cè)表面的刀位軌跡線上的Pl和Pr點是由槽腔中心線上的Po等距偏置而得,按公式(2)轉(zhuǎn)換之后,Pl和Pr點對應(yīng)的轉(zhuǎn)角并不等于Po點的轉(zhuǎn)角,也即Pl和Pr對應(yīng)的刀軸矢量VlVl與Po點對應(yīng)的刀軸矢量VoVo不平行,因此,加工出來的槽腔自然就成了上寬下窄喇叭槽,而不是所需要的上下等寬的矩形槽。設(shè)截面與軸線的夾角為,圓柱凸輪軸的半徑為R,刀軸矢量VlVl與VoVo的角度誤差為:a(B/2r)sin/R(3) 圖 3圓柱凸輪槽加工示意圖由公式(3)可知,當(dāng)0,也即凸輪槽中心線與圓柱軸線垂直時,角度誤差為零,即槽腔是上下等寬的矩形口;當(dāng)90,也即凸輪槽中心線與圓柱軸線平行時,角度誤差達(dá)到最大,此時槽腔的喇叭口現(xiàn)象最嚴(yán)重;當(dāng)090時,隨著的增大,角度誤差越大,喇叭口現(xiàn)象也就越嚴(yán)重。實際加工出現(xiàn)的現(xiàn)象與上述分析完全一致,這說明公式(3)的分析是完全正確的。 4.寬槽圓柱凸輪數(shù)控加工的坐標(biāo)轉(zhuǎn)換方法 由上面的分析可知,公式(2)造成凸輪槽為上寬下窄喇叭口的主要原因是,Pl和Pr點對應(yīng)的轉(zhuǎn)角是按照這兩個點自己的弧長值Sl和Sr來計算的,而Sl和Sr是不等于槽腔中心點Po的弧長值So。因此,如果Pl和Pr點對應(yīng)的轉(zhuǎn)角均按照槽腔中心點Po的弧長值So來計算,就可以消除這種喇叭槽現(xiàn)象。根據(jù)這種思路,重新構(gòu)造坐標(biāo)轉(zhuǎn)換公式。 在圓柱面的二維展開平面上,設(shè)槽腔中心線展開曲線上的一個點為Po(xo,so),加工兩個側(cè)表面上對應(yīng)刀位點在展開曲線上的點為Pl(xl,sl)和Pr(xr,sr),那么,坐標(biāo)轉(zhuǎn)換公式為: (4) 應(yīng)用公式(4)生成的刀位軌跡加工圓柱凸輪槽時,結(jié)果完全符合上述的設(shè)想,加工出來的圓柱凸輪槽已經(jīng)沒有了上寬下窄的喇叭槽現(xiàn)象,而是真正的上下等寬矩形槽。參考文獻(xiàn):1.Chang W C,Van Y T.Researching Design Trens for the Redesign of Product From Design Studies 2003.24(2):173_1802.Mou J,Liu C R.An error correction method for CNC machine tools using reference parts.transactions of NAMRE/SME,1994.3.Sutton G P.The machine tool task forch. Bal Harbour Bal Habour Hotel,1980.4.Gene F.Franklin Feedback control of Dynamis .systems,4E.英文原文Wide Trough Column Cam Numerical Control Processing ResearchSummary: Some questions produces which in view of the traditional milling method processing column cam, proposed one kind in view of the trough spaciously in the cutting tool diameter column cam path numerical control milling processing method. Through the analysis research, has established one kind of correct coordinates transformation model, and processes according to this conforms to the request wide trough column cam.Keywords: Numerical control processing Coordinates Transformation width trough column camMain TextThe column cam path is generally surrounds according to the certain rule in the round cylinder and so on the wide trough. Must satisfy below to the column cam path numerical control milling processing requests: 1.The column cam path working surface namely two sides plane of normal section lines must be strict parallel; 2.The column cam path must wait for the width in the work section. This is guarantees the roller in the column cam path the steady motion essential condition. When column cam path width not big, may find the corresponding diameter the end mill to carry on the processing along the trough cavity middle line, compared with is easy to process conforms to the above request column cam path. According to the existence information introduced that, at present the column cam milling processing all is realizes with this means. Because this method has too many limitations, brings many difficulties for the actual milling processing. For example when cannot find with the trough width size equal standard cutting tool, must carry on to the cutting tool changes the system.Regarding the trough width size big column cam path, is very difficult to find the diameter and the trough width equal standard cutting tool. Even if has the corresponding cutting tool, but also must consider the engine bed main axle output and the main axle and the work clothes jig rigidity limit, specially engine bed main axle structure to cutting tool limit. For example the numerical control engine bed host axle neck is 7: 24 40 inner cones, uses for parts JT40 the tool system, then most greatly only can use 20mm end mill (no matter straight handle bit holder). This regarding the trough width is the 38mm column cam (is processing cam which this article narrates) said is unable to process, must seek the new processing method.Under and analyzes the research according to the experience, introduced one kind is smaller than the cam path width end mill with the diameter to carry on the numerical control processing to the column cam path the method, calls it the width trough column cam numerical control processing.First, Processing craftThe column cam path is surrounds in the round cylinder and so on the width trough, when its processing often is bigger than 360. along the circumference surface milling scopeIs suitable for with to have the numerical control rotary abutment the vertical numerical control milling machine to carry on the processing. According to the column cam actual structure, selects the belt key the spindle makes when the cam processing the radial direction and the week to the localization datum, makes the axial localization datum by the spindle ledge, and the nose thread contracts the column cam with the spindle in front of through the nut. The column cam axial and the radial direction size is generally big, in order to overcome because the bracket processes time the cutting force creates in the spindle distortion and the processing process produces inspires trembles, uses a supporting on the tailstock, withstands the spindle center bore with the numerical control turnplate rotation spool thread coaxial apex to make the auxiliary supporting.The column cam path base on each section usually is and so on deep, selects the flat base column end mill processing generally. Before the column cam milling processing usually is a solid circular cylinder, must pass through working procedure and so on slot, rough machining, half precision work, precision work; Because the trough cavity width is big, Therefore, except the trough working procedure and a rough machining working procedure part of knives positions path may along beside the trough cavity middle line production, other knife position paths then must be along the trough cavity center alignment left, are right nearby two according to the Corresponding . Figure 1 column cam path two-dimensional developed viewSecond, Solution modelIn the column cam path numerical control processing, how extracts in each working procedure to process two sides surfaces the knife position path is key. Regarding the periphery on cam path, usually is launches first the round cylinder, extracts this working procedure in the XOS plane to process two sides surfaces the knife position path to launch curve XS; Then transforms through the coordinates, will launch the curve XS transformation will be on four coordinates engine beds knife position path. Under discusses no matter what in a processing working procedure launches curve XS the solution method, as well as production final knife position path coordinates transformation method.1.Launches curve XS the solutionLike chart 2 shows, Lo is the column cam path middle line, regarding the i working procedure, Lli and Lri respectively the trough cavity which is going to process be this working procedure left, the right two sides surface launches the curve, this width is Bi, processes the cutting tool radius is r (obviously 2r Bi), processes this cavity to be left, the right side knife position path launches the curve is CLli and CLri ,supposes Po is in a trough cavity middle line spot, Po is the trough cavity middle line in the Po place law arrow, Then is left, the right knife position path launches in the curve corresponding points pli and the pri computational method is: (1) Figure 2 column cam path two-dimensional developed viewPo along the trough cavity middle line migration, namely may extract this working procedure knife position path to launch curveXS in the XOS plane; According to the processing working procedure, changes in each working procedure in turn trough width Bi, then extracts the processing to need the trough cavity all knives position path to launch the curve.2.Along cam path middle line processing coordinates transformation methodAbove the computation is launches in the plane in the round cylinder to carry on, in order to extract the processing column cam path cavity the knife position path, must launch the plane in the curve to transform to the round cylinder in.The supposition rotating axis for circles Xaxis A axis, pi is in a knife position path knife position spot, it launches in the curve in the two-dimensional surface the coordinates for (x,s), on four coordinates engine beds coordinates is (x,y,z,a).。Because the column cam path cavity usually is and so on deep, therefore, the z coordinates in establish after depths which needs to process, in the processing is invariable; Below (2)In the formula, R is the column cam shaft radius. The previous type is the present universal use coordinates transformation formula, regarding uses the standard cutting tool to process the column cam along the cam path middle line milling is correct.3.Has the question analysis to the previous type in the width trough column cam processingWhen applies the previous type promotion in the width trough column cam numerical control processing, has had some questions actually through the coordinates transformation computation knife position path in the actual processing. Finished after the column cam path processing, in order to examine whether conforms to the requirement, with the diameter was equal to the column cam bowl examines has carries on the examination, discovered actually processes the trough width does not wait for the phenomenon which, has jams. The careful observation, processes originally on trough cavity plane of normal section not always inferior width rectangular trough, but sometimes is on under the width the narrow loudspeaker trough. In order to clarify reason, (2) expressed the coordinates transformation method to the formula to carry on the thorough analysis and the research.Like chart 3 shows, (1) may know by the formula, processes the trough cavity two sides surfaces knife position path on-line pl and the pr spot is by the trough cavity middle line in po equal-space bias but, (2) transforms after the formula, pl and the pr point correspondence corner is not equal to a Po corner, also is pl and pr corresponding cutter bar vector vlvl and po point correspondence cutter bar vector vovo not parallel, therefore, processes the trough cavity has become on under naturally the width the narrow loudspeaker trough, but is not on inferior width rectangular trough which needs. Supposes the section and the spool thread included angle for theta, the column cam shaft radius is R, cutter bar vector VlVl and VoVo theangle error is:a(B/2r)sin/R (3)a)Cylinder cam slot sketch map b)The A-A cuts to face enlarge the sketch mapChart 3 Column cam path processing schematic drawing(3) may know by the formula, when= 0, when is the cam path middle line and the column spool thread vertical, the angle error is a zero, namely the trough cavity is on the inferior width rectangular mouth; When= 90, when is the cam path middle line and the column spool thread parallel, the angle error achieved biggest, this time the trough cavity trumpet-shaped object phenomenon is most serious; When 0 90, along with increasing, angle error bigger, the trumpet-shaped object phenomenon is also more serious. The actual processing appears the phenomenon is completely consistent with the above analysis, this explained formula (3) the analysis is entirely accurate.4.Wide trough column cam numerical control processing coordinates transformation methodMay know by the above analysis, the formula (2) creates the cam path for on width under the narrow trumpet-shaped object main reason is, pl and the pr point correspondence corner is defers to these two, but sl and sr which selects own arc length value sl and sr calculates are is not equal to trough cavity central point po arc length value so. Therefore, if pl and the pr point correspondence corner defers to trough cavity central point po arc length value so to calculate, may eliminate this kind of loudspeaker trough phenomenon. According to this kind of mentality, again structure coordinates transformation formula.Two-dimensional launches in the plane in the round cylinder, supposes the trough cavity middle line to launch in the curve a spot is po (xo,So), processes on two sides surfaces to correspond the knife position spot in to launch in the curve the spot is pl (xl,sl) and pr (xr,pr), then, the coordinates transformation formula is: (4)The application formula (4) produces when knife position path processing column cam path, the result conforms to the above tentative plan completely, processes the column cam path already did not have on under the width the narrow loudspeaker trough phenomenon, but was the true on inferior wide rectangle trough.Reference:1.Chang W C,Van Y T.Researching Design Trens for the Redesign of Product From Design Studies 2003.24(2):173_1802.Mou J,Liu C R.An error correction method for CNC machine tools using reference parts.transactions of NAMRE/SME,1994.3.Sutton G P.The machine tool task forch. Bal Harbour Bal Habour Hotel,1980.4.Gene F.Franklin Feedback control of Dynamis .systems,4E.14
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