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西安工業(yè)大學(xué)北方信息工程學(xué)院
畢業(yè)設(shè)計(jì)(論文)開題報(bào)告
題目：臥式車床主傳動(dòng)系統(tǒng)的結(jié)構(gòu)設(shè)計(jì)
系 別 機(jī)電信息系
專 業(yè) 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
班 級(jí) B100205
姓 名 黃仁奕
學(xué) 號(hào) B10020509
導(dǎo) 師 姚慧
2013年 12月3日
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1.畢業(yè)設(shè)計(jì)（論文）綜述（題目背景、研究意義及國內(nèi)外相關(guān)研究情況）
1.1題目背景、研究意義
現(xiàn)代臥式車床主傳動(dòng)系統(tǒng)設(shè)計(jì)不但要滿足動(dòng)力參數(shù)和運(yùn)動(dòng)參數(shù)的要求，還要盡量設(shè)計(jì)出結(jié)構(gòu)簡單、工藝性好、工作平穩(wěn)的傳動(dòng)系統(tǒng)。天水星火機(jī)床有限責(zé)任公司生產(chǎn)的CW61100E型臥式車床是國內(nèi)該系列的代表性產(chǎn)品，其結(jié)構(gòu)和功能都已經(jīng)比較完善。但是隨著科學(xué)技術(shù)的迅猛發(fā)展，產(chǎn)品在某些功能方面已經(jīng)不能適應(yīng)市場的需求，因此對(duì)其進(jìn)行改進(jìn)勢(shì)在必行。[1]
1.2國內(nèi)外相關(guān)研究情況
1.2.1國內(nèi)外數(shù)控機(jī)床現(xiàn)狀：
近年來我國企業(yè)的數(shù)控機(jī)床占有率逐年上升，在大中企業(yè)已有較多的使用，在中小企業(yè)甚至個(gè)體企業(yè)中也普遍開始使用。在這些數(shù)控機(jī)床中，除少量機(jī)床以FMS模式集成使用外，大都處于單機(jī)運(yùn)行狀態(tài)，并且相當(dāng)部分處于使用效率不高，管理方式落后的狀態(tài)。[2]
與國外的數(shù)控機(jī)床相比，我國數(shù)控機(jī)床還存在以下幾方面的問題：
產(chǎn)品質(zhì)量、可靠性及服務(wù)等能力不強(qiáng)。國產(chǎn)機(jī)床在質(zhì)量、交貨期和服務(wù)等方面與國外著名品牌相比存在較大的差距。在質(zhì)量方面，國產(chǎn)數(shù)控系統(tǒng)的可靠性指標(biāo)MTBF與國際先進(jìn)數(shù)控系統(tǒng)相差較大。國產(chǎn)數(shù)控車床、加工中心的MTBF與國際上先進(jìn)水平也有較大差距。
自主創(chuàng)新能力不足。長期以來，我國機(jī)床制造業(yè)的基礎(chǔ)、共性技術(shù)研究工作主要在行業(yè)性的研究院所進(jìn)行。能力薄弱，技術(shù)創(chuàng)新投入不足，引進(jìn)消化吸收能力差，低水平生產(chǎn)能力過剩，自主創(chuàng)新能力不高，缺乏優(yōu)秀技術(shù)人才。雖然國產(chǎn)數(shù)控機(jī)床制造商通過技術(shù)引進(jìn)、海內(nèi)外并購重組以及國外采購等獲得了一些先進(jìn)數(shù)控技術(shù)，但缺乏對(duì)基礎(chǔ)共性技術(shù)的研究，忽視了自主開發(fā)能力的培育，企業(yè)的市場響應(yīng)速度慢。
功能部件發(fā)展滯后。機(jī)床是由各種功能部件（主軸單元及主軸頭、滾珠絲杠副、回轉(zhuǎn)工作臺(tái)和數(shù)控伺服系統(tǒng)等）在床身、立柱等基礎(chǔ)機(jī)架上集裝而成的，功能部件是數(shù)控機(jī)床的重要組成部分。數(shù)控機(jī)床整體技術(shù)與數(shù)控機(jī)床功能部件的發(fā)展是相互依賴、共同發(fā)展的，所以功能部件的創(chuàng)新也深深地影響著數(shù)控機(jī)床的發(fā)展。我國數(shù)控機(jī)床功能部件已有一定規(guī)模，電主軸、主軸單元、數(shù)控系統(tǒng)等也有專門的制造廠家，其中個(gè)別產(chǎn)品的制造水平接近國際先進(jìn)水平。但整體上，我國機(jī)床功能部件發(fā)展緩慢、品種少、產(chǎn)業(yè)化程度低，精度指標(biāo)和性能指標(biāo)的綜合情況還不過硬。目前，滾珠絲杠、數(shù)控刀架、電主軸等功能部件僅能滿足中低檔數(shù)控機(jī)床的配套需要。衡量數(shù)控機(jī)床水平的高檔數(shù)控系統(tǒng)、高速精密電主軸、高速滾動(dòng)功能部件等還依賴進(jìn)口。[3]
1.2.2數(shù)控機(jī)床發(fā)展趨勢(shì)：
高速、精密、復(fù)合、智能和綠色是數(shù)控機(jī)床技術(shù)發(fā)展的總趨勢(shì)。[4]主要表現(xiàn)在：
1. 機(jī)床復(fù)合技術(shù)進(jìn)一步擴(kuò)展隨著數(shù)控機(jī)床技術(shù)進(jìn)步，復(fù)合加工技術(shù)日趨成熟；被更多人接受，復(fù)合加工機(jī)床發(fā)展正呈現(xiàn)多樣化的態(tài)勢(shì)。
2.智能化技術(shù)有新突破數(shù)控機(jī)床的智能化技術(shù)有新的突破，在數(shù)控系統(tǒng)的性能上得到了較多體現(xiàn)。
3.機(jī)器人使柔性化組合效率更高機(jī)器人與主機(jī)的柔性化組合得到廣泛應(yīng)用，使得柔性線更加靈活、功能進(jìn)一步擴(kuò)展、柔性線進(jìn)一步縮短、效率更高。
4.精密加工技術(shù)已從原來的絲級(jí)（0.01mm）提升到目前的微米級(jí)（0.001mm），有些品種已達(dá)到0.05μm左右；從這些事實(shí)技術(shù)可以看出整個(gè)機(jī)加工進(jìn)入亞微米、納米級(jí)超精加工時(shí)代。
5.功能部件性能不斷提高功能部件不斷向高速度、高精度、大功率和智能化方向發(fā)展，并取得成熟的應(yīng)用。[5]
2.本課題研究的主要內(nèi)容和擬采用的研究方案、研究方法或措施
2.1本課題研究的主要內(nèi)容
（1）針對(duì)CW61100E型臥式車床主傳動(dòng)系統(tǒng)的要求，分析其功能和原理，設(shè)計(jì)其主傳動(dòng)系統(tǒng)，并進(jìn)行相應(yīng)的計(jì)算和分析；
（2）繪制該傳動(dòng)系統(tǒng)的裝配圖和關(guān)鍵零部件圖。
2.2研究方案
機(jī)床的主傳動(dòng)系統(tǒng)用于實(shí)現(xiàn)機(jī)床的主運(yùn)動(dòng)，在機(jī)床傳動(dòng)中實(shí)現(xiàn)主運(yùn)動(dòng)變速的方法有電氣傳動(dòng)和液壓傳動(dòng)的變速運(yùn)動(dòng)，還有機(jī)械變速等多種形式。
機(jī)械傳動(dòng)在機(jī)械工程中應(yīng)用非常廣泛，主要是指利用機(jī)械方式傳遞動(dòng)力和運(yùn)動(dòng)的傳遞。圖1所示為機(jī)械傳動(dòng)形式。
圖 1 機(jī)械傳動(dòng)形式
1-交流電動(dòng)機(jī)；2-變速機(jī)構(gòu)；3-主軸
機(jī)械傳動(dòng)主要由以下幾部分組成:
(l)定比傳動(dòng)機(jī)構(gòu):具有固定傳動(dòng)比或固定傳動(dòng)關(guān)系的傳功機(jī)構(gòu)，如帶傳動(dòng)、齒輪傳動(dòng)、蝸桿傳動(dòng)、齒輪齒條傳動(dòng)、螺桿傳動(dòng)。
(2)變速機(jī)構(gòu)：改變機(jī)床部件運(yùn)動(dòng)的機(jī)構(gòu)。如滑動(dòng)齒輪變速機(jī)構(gòu)、離合器式齒輪變速機(jī)構(gòu)等。
(3)換向機(jī)構(gòu)：變換機(jī)床部件運(yùn)動(dòng)方向的機(jī)構(gòu)。為了滿足加工的不同需要(例如車螺紋時(shí)刀具的進(jìn)給和返回，車右旋螺紋和左旋螺紋等)。機(jī)床的主傳動(dòng)部件和進(jìn)給傳動(dòng)部件往往需要正、反向的運(yùn)動(dòng)?？梢灾苯永秒妱?dòng)機(jī)反轉(zhuǎn)，也可以利用齒輪換向機(jī)構(gòu)等。
(4)操縱機(jī)構(gòu)：用來實(shí)現(xiàn)機(jī)床運(yùn)動(dòng)部件變速、換向、啟動(dòng)、停止、制動(dòng)及調(diào)整的機(jī)構(gòu)。常見的操縱機(jī)構(gòu)包括乎柄、手輪、杠桿、凸輪、齒輪齒條、撥叉、滑塊及按鈕等。
(5)箱體及其他裝置箱體用以支承和連接各機(jī)構(gòu)，并保證它們相互位置的精度。為了保證傳動(dòng)機(jī)構(gòu)的正常工作，還要設(shè)有開停裝置、制動(dòng)裝置、潤滑與密封裝置等。
液壓傳動(dòng)是以液體作為工作介質(zhì)來進(jìn)行能量傳遞的一種傳動(dòng)形式，它通過能量轉(zhuǎn)換裝置（液壓泵），將原動(dòng)機(jī)（電動(dòng)機(jī)）的機(jī)械能轉(zhuǎn)變?yōu)橐后w的壓力能，然后通過封閉管道、控制元件等，由另一能量裝置（液壓缸、液壓馬達(dá)）將液體的壓力能轉(zhuǎn)變?yōu)闄C(jī)械能，以驅(qū)動(dòng)負(fù)載和實(shí)現(xiàn)執(zhí)行機(jī)構(gòu)所需的直線或旋轉(zhuǎn)運(yùn)動(dòng)。圖2所示為液壓傳動(dòng)形式。
圖 2 液壓傳動(dòng)形式
1-交流電動(dòng)機(jī)；2-油泵；3-油箱；4-液壓控制裝置；5-液動(dòng)機(jī)；6-主軸
液壓傳動(dòng)主要由以下幾部分組成:
(1)動(dòng)力元件—油泵。其作用是將電動(dòng)機(jī)輸入的機(jī)械能轉(zhuǎn)換為液體的壓力能，是能量轉(zhuǎn)換裝置(能源)。
(2)執(zhí)行機(jī)構(gòu)—油缸或油馬達(dá)。其作用是把油泵輸人的液體壓力能轉(zhuǎn)變?yōu)楣ぷ鞑考臋C(jī)械能.它也是一種能量轉(zhuǎn)換裝置(液動(dòng)機(jī))。
(3)控制元件—各種閥。其作用是控制和調(diào)節(jié)油液的壓力、流量(速度)及流動(dòng)方向。
(4)輔助裝置—油箱、油管、濾油器、壓力表等。其作用是創(chuàng)造必要的條件，以保證液壓系統(tǒng)正常工作。
(5)工作介質(zhì)—礦物油。它是傳遞能量的介質(zhì)。
機(jī)械傳動(dòng)與液壓傳動(dòng)相比較，其主要優(yōu)點(diǎn)如下:
(l)傳動(dòng)比準(zhǔn)確，適用于定比傳動(dòng);
(2)實(shí)現(xiàn)回轉(zhuǎn)運(yùn)動(dòng)的結(jié)構(gòu)簡單。能傳遞較大的扭矩;
(3)故障容易發(fā)現(xiàn)，便于維修。
因此，機(jī)械傳動(dòng)主要用于速度不太高的有級(jí)變速傳動(dòng)中。根據(jù)CW61100E臥式機(jī)床的要求，選擇機(jī)械傳動(dòng)方式。傳動(dòng)簡圖如圖3所示。
圖 3 傳動(dòng)簡圖
1-交流電動(dòng)機(jī)；2-帶傳動(dòng)；3-齒輪變速機(jī)構(gòu)；
I、II、III-傳動(dòng)軸；IV-主軸
機(jī)床的動(dòng)力由交流電動(dòng)機(jī)提供，經(jīng)過V帶傳動(dòng)至變速箱內(nèi)，箱內(nèi)變速機(jī)構(gòu)由多根傳動(dòng)軸及多組齒輪副組成，動(dòng)力經(jīng)過變速機(jī)構(gòu)傳遞至主軸輸出。
2.3研究方法與措施
1.參數(shù)擬定：根據(jù)機(jī)床類型，規(guī)格和其他特點(diǎn)，了解典型工藝的切削用量，結(jié)合世界條件和情況，并與同類機(jī)床對(duì)比分析后確定：極限轉(zhuǎn)速和，公比（或級(jí)數(shù)Z），主傳動(dòng)電機(jī)功率N。
2.傳動(dòng)設(shè)計(jì)：根據(jù)擬定的參數(shù)，通過結(jié)構(gòu)網(wǎng)和轉(zhuǎn)速圖的分析，確定轉(zhuǎn)動(dòng)結(jié)構(gòu)方案和轉(zhuǎn)動(dòng)系統(tǒng)圖，計(jì)算各轉(zhuǎn)動(dòng)副的傳動(dòng)比及齒輪的齒數(shù)，并驗(yàn)算主軸的轉(zhuǎn)速誤差。
3.動(dòng)力計(jì)算和結(jié)構(gòu)草圖設(shè)計(jì)：估算齒輸模數(shù)m和直徑d，選擇和計(jì)算反向離合器，制動(dòng)器。將各傳動(dòng)件及其它零件在展開圖和剖面圖上做初步的安排，布置和設(shè)計(jì)。
4.軸和軸承的驗(yàn)算：在結(jié)構(gòu)草圖的基礎(chǔ)上，對(duì)一根傳動(dòng)軸的剛度和該軸系的軸承的壽命進(jìn)行驗(yàn)算。
5.主軸變速箱裝配設(shè)計(jì)：主軸變速箱裝配圖是以結(jié)構(gòu)草圖為“底稿”，進(jìn)行設(shè)計(jì)和會(huì)制的。圖上各零件要表達(dá)清楚，并標(biāo)注尺寸和配合。
3.本課題研究的重點(diǎn)及難點(diǎn)，前期已開展工作。
3.1的難點(diǎn)與重點(diǎn)
在進(jìn)行主傳動(dòng)系統(tǒng)設(shè)計(jì)時(shí)需要對(duì)各主要技術(shù)參數(shù)和特性參數(shù)較高、低檔減速比、主軸額定轉(zhuǎn)速、功率損失等進(jìn)行計(jì)算, 對(duì)這些參數(shù)的相互關(guān)系和相互影響以及對(duì)結(jié)構(gòu)性能的影響進(jìn)行分析。我們自己資料比較少，因?yàn)橐ㄟ^互聯(lián)網(wǎng)和圖書館來查找相關(guān)資料。
主傳動(dòng)系統(tǒng)的運(yùn)動(dòng)設(shè)計(jì)通常是根據(jù)機(jī)床的主要技術(shù)參數(shù)和要求，擬定主軸傳動(dòng)轉(zhuǎn)速圖，可能會(huì)遇到齒輪的布置不合理，滑移齒輪的結(jié)構(gòu)形式不當(dāng)?shù)?，因此，要從幾分設(shè)計(jì)方案中選出最佳方案，然后計(jì)算齒輪的齒數(shù)及皮帶輪直徑等，最后繪制傳動(dòng)系統(tǒng)圖。
3.2前期已展開工作
通過查找資料，已經(jīng)了解CW61100E臥式機(jī)床主要參數(shù)和規(guī)格，確定傳動(dòng)系統(tǒng)的設(shè)計(jì)方案和整體結(jié)構(gòu)，為下一步的設(shè)計(jì)計(jì)算以及繪制裝配圖做好準(zhǔn)備。
4.本課題的工作方案及進(jìn)度計(jì)劃（按周次填寫）
（1）1—3周：調(diào)研并收集資料；
（2）4—6周：確定該主傳動(dòng)系統(tǒng)的設(shè)計(jì)方案和整體結(jié)構(gòu)；
（3）7—11周：完成該主傳動(dòng)系統(tǒng)的結(jié)構(gòu)設(shè)計(jì)計(jì)算；
（4）12—15周：完成該主傳動(dòng)系統(tǒng)的裝配圖；
（5）16-18周：完成論文撰寫，準(zhǔn)備答辯。
指導(dǎo)教師意見（對(duì)課題的深度、廣度及工作量的意見）：
指導(dǎo)教師： 年 月 日
所在系審查意見：
系主管領(lǐng)導(dǎo)： 年 月 日
參考文獻(xiàn)
[1] 王宏 張永生 李采芝 安波. CW61100E 數(shù)控改造中的主傳動(dòng)設(shè)計(jì)[J].
蘭州理工大學(xué)材料學(xué)院, 2007,36(1):28-75
[2] 許郁生.中國機(jī)床工業(yè)的發(fā)展和市場需求[J]. 中國機(jī)床工具工業(yè)協(xié)會(huì),2005.45(1).12-13
[3] 盛伯浩.我國數(shù)控機(jī)床現(xiàn)狀與技術(shù)發(fā)展策略.現(xiàn)代金屬加工,2005(6):38-45
[4] 魯方霞 鄧朝暉. 數(shù)控機(jī)床的發(fā)展趨勢(shì)及國內(nèi)發(fā)展現(xiàn)[J].2006.40(3):44-48
[5] 高文章. 數(shù)控機(jī)床的技術(shù)發(fā)展趨勢(shì)[J]. 北京數(shù)控技術(shù)開發(fā)中心. 1995.23(2).45-46
[6] 陳鐵鳴 主編 《機(jī)械設(shè)計(jì)》，哈爾濱工業(yè)大學(xué)出版社，2003.8 :38-49
[7] 機(jī)床設(shè)計(jì)手冊(cè)[M] . 北京: 機(jī)械工業(yè)出版社, 1982.(5):12-45
[8] 王愛玲 主編 《現(xiàn)代數(shù)控機(jī)床》，國防工業(yè)出版社，2003.(4):43-69
[9] 禹宏云. 數(shù)控車床主傳動(dòng)鏈設(shè)計(jì)[ J] . 機(jī)械傳動(dòng), 2001,( 2) : 41- 43.
[10] 文懷興, 夏田. 數(shù)控機(jī)床系統(tǒng)設(shè)計(jì)[M] . 北京: 化學(xué)工業(yè)出版社, 2006. 7:23-25
[11] 陳嬋娟. 數(shù)控車床設(shè)計(jì)[M] .北京: 化學(xué)工業(yè)出版社, 2006.10:12-13
[12] 孫靖民.機(jī)械結(jié)構(gòu)優(yōu)化設(shè)計(jì).哈爾濱工業(yè)大學(xué)出版社,1985.12:78-79
[13] 湯文成,車床主傳動(dòng)設(shè)計(jì)專家系統(tǒng)的研究.機(jī)床,1990,(4):44-47
[14] 吳玉厚著.數(shù)控機(jī)床電主軸單元技術(shù)[M].北京：機(jī)械工業(yè)出版社，2010.2.3-5
[15] 李秀英,滕弘飛.機(jī)床優(yōu)化設(shè)計(jì)[M] .北京:機(jī)械工業(yè)出版社,1989.6.5-7
[16] M.Weck,M.Schmidt,A new method for determining geometric accuracy in the axis of movement of machine tools,Precision Engineering 8(2)(1986) 97–103.
[17] G.X.Zhang,R.Quyang,B.Lu,et al.,A displacement method for machine geometry calibration,Annals of the CIRP 37(1)(1988)515–518.
[18] G.Q.Chen,J.X.Yuan,J.Ni,A displacement measurement approach for machine geometric error assessment,International Journal of Machine Tools& Manufacture 41(2001)149–161.
外文翻譯
Treating and the modern mould make high speed
One, summarizes
1 the present situation that the mould makes at present and trend
The mould is important handicraft equipment , occupies decisive position in industrid departments such as consumer goods , electrical equipment electron , automobile , aircraft fabrication. The mould is important handicraft equipment , occupies decisive position in industrid departments such as consumer goods , electrical equipment electron , automobile , aircraft fabrication. Industrial product part rough process 75%, the finish machining 50% and plastic part 90% will be completed from the mould. The Chinese mould market demand already reaches scale of 500 hundred million yuan at present. The automobile mould , the annual growth rate covering piece of mould especially will exceed 20 %; Also prompt building material mould development , various heterotype material the mould , wall surface and floor mould become new mould growth point , plastic doors and windows and plastic drain-pipe increase to exceeding 30 by in the upcoming several years %; The home appliance mould annual growth rate will exceed 10 %; The IT industry year increases % speed equally exceeding 20 , the need to the mould accounts for 20 of mould marketplace %.2004 annual Chinese machine tools implements industry output value
will continue to increase. Our country mould fabrication market potential is enormous. The basis data counts , in recent years, our country mould year gross output value reaches 3 billion U. S. dollar , entrance exceeds 1 billion U. S. dollar, exceed 100 million U. S. dollar outlet. Increase by from 25% to increase to 2005 50% of 1995. The expert foretells that abroad: Asia portion being occupied by in mould fabrication in the whole world, will from 25% to increase to 2005 50% of 1995.
Chinese mould industry has been expanding by leaps and bounds , has formed east China and two big South China bases, and has expanded gradually arriving at other province. In 2002 (Shandong , Anhui , Sichuan) in 1996 ~, mould manufacturing industry output value annual average growth 14% , grows by 25% in 2003. In 2003 our country mould output value is 45 billion RMB. The gross product place occupies the world the 3rd, exports a mould increases 33.5% compared to last year 336,800,000 U. S. dollar. But, contents low our country technology moulds already pile up in excess of requirement , very most support of accurate , complicated top grade mould imports. Every year the entrance mould exceeds 1 billion U. S. dollar. Exceed 100 million U. S. dollar outlet.
Precise mould accuracy requires that 3 mu ms , large-scale moulds require that 8000 satisfied kN agree well with model force injection machine request in 2 ~; The minitype mould needs the request satisfying the diameter 1 mm silent stock tube. At present, adopt quick-cutting to produce a mould already becoming the general trend that the mould makes, a few moulds have produced a manufacturer in abroad , high-speed machine tool large area has substituted the electric spark machine tool , quick-cutting has improved the mould efficacy greatly. Machine tool enterprise aims at mould manufacturing enterprises , some treating centres 60% all above of the machine tool producing a factory sells treating enterprise to a mould. The mould fabrication enterprise substituting the electric spark finish machining mould gradually in abroad has adopt quick-cutting already commonly , quick-cutting has produced a mould already becoming the general trend that the mould makes gradually , has improved the mould efficacy and mass greatly. Adopt quick-cutting to replace electric spark producing a mould , can get on the stick obviously , improves mould accuracy , life time growing.
2 high speed processes application in making in the mould
2.1 quick-cutting merit:
1) cutter high rotation rate and the machine tool height enter be given to and high acceleration , improve metal excision rate greatly;
2) quick-cutting diminutions cut a force;
3) quick-cutting heat major part generate heat from the cuttings entrainment , workpiece being short;
4) quick-cutting cut down vibration , improve treating mass;
2.2 high speed treating apply to the beneficial result that the mould processes
1) fleetness rough process and half finish machining, improve treating efficiency;
2) high speed high-accuracy finish machining replace only entire the height processing , indicating mass , form accuracy rise , 50%, cuts down repair a mill by hand than EDM processes a potentiation;
3) cuts the surface processing final molding stiffly , improve surface mass , form accuracy, the treating (not only being that surface harshness is low, and the surface radiance is high) , being used for complicated surface has more advantage;
4) the surface loss that EDM treating produces , improve mould life-span 20%;
5) processes an electrode rapidly combining with the CAD/CAM technology , especially, the form is complicated , thin-wall is similar to an electrode.
3 adopt quick-cutting to process a mould needing the problem solving
In in the homeland, since the aspect cause such as fund , technology , the quick-cutting applying produce a mould be in the initial stage stage. Return the machine tool , cutter , handicraft back to existence as well as some problem of aspect needs to proceed orderly other solve.
The shortcoming is that finished cost is high, correct cutter sigmatism have comparatively high demand, can not have used big cutters , need to have the complicated computer programming technology to be used for support , equipment running cost height.
Two, the high speed processing a mould's processes a machine tool
Mould finish machining and hard cutting treating require that the numerical control high-speed machine tool , form board , model put up the precision processing need , high-effect numerical control machine tool etc.The mould aiming at produces a lot of machine tool enterprise , some treating centres 60% all above of the machine tool producing a factory sells enterprise to a mould.
The fixed assets having 5 billion yuan without exception in the upcoming several years throws into mould industry , 80% is the machine tool buying a mould process equipment , just saying every year having 4 billion yuan of RMB to buy Jinqie among them.
At present average our country numerical control machine tool utilization ratio approximately 20%, the high-speed machine tool utilization ratio 3 ~ 5%. Also, mould enterprise has the unit suitable to buy a high-speed machine tool , complies with 6000 ~ 40000 rmp's to have.
1 high-speed machine tool technology parameter demands
Process centre chief axis high-power , high rotation rate , satisfied rude finish machining; The finish machining mould wants to need to reach 15000 ~ 20000 rmp like the cutter , the machine tool with minor diameter. Generally, the chief axis rotation rate machine tool under 10000 rpm can carry out rough process and half finish machining , cannot reach the finish machining accuracy;
Have no way to reach 400 the above m/min cutting speed.
2 five scrolls of machine tools application increases a trend
1) treating route is nimble , the surface form is complicated;
2) treating range is big , the various type mould suitable processes;
3) cuts life-span of condition easy to cut down cutter wear , to raise a cutter,;
3 the softwares buying CAD/CAM and high-speed machine tools assort
On the grounds of the machine tool , major part counting , having several billions U. S. dollar to be used to enter port every year, the electromachining machine tool and the high-speed machine tool need to import.
Three, quick-cutting mould cutter technology
Quick-cutting processes the cutter needing allocating proper quick-cutting. Progressing processing cutter material's in high speed has urged development of high speed treating. The cutter , knife edge headquarter and high tenacity base gathering crystal strengthening the ceramics cutter being able to be used giving consideration to high hardness experience and observe carbide alloy coating becoming possibility. Gather the crystal cube nitriding boron (PCBN) bit, whose hardness may amount to 3500 ~ 4500 HV. Gather crystal miamond (PCD) it's hardness but amount to 6000 ~ 10000 HV. Germany SCS , Japan Mitsubishi (magical steel) and Sumitomo ,
Switzerland Shanteweike , USA Kenna are in recent years swiftly large wait for the famous abroad cutter company to successively have debuted the respective quick-cutting cutter, not only cutter having average structural steel of quick-cutting, the ceramics cutter still having direct quick-cutting of energy quenching hard steel is waiting for an effect to surpass the hard cutter, especially the coating cutter appears all of a sudden , bringing into play in quenching half finish machining and finish machining of hard steel. New cutter material and cutter technology appearing already make the bottleneck problem that high speed has processed no longer be able to appear on the cutter.
But, expensive entrance cutter price also blocks quick-cutting mould key factor.
Above to come to saying the cutter and the cutter holder acceleration reach 3 gs the sort, the cutter circular runout needs to be smaller than 0.015 mm, but the knife length is unable greater than 4 times cutters diameter. The reality according to SANDVIK company has counted , the carbide alloy has stood on in the entirety using carbon nitriding titanium (TICN) coating when milling cutters (58 HRC) carry out high speed bright metal chopping , rough process cutter linear speed has been 100 m/min about , whose linear speed has exceeded but 280 m/min when finish machining and microstoning. Such demands to cutter material (include the hardness , tenacity , red hardness keep the form (include row of crumbs function , surface accuracy , dynamic balance sex etc. (cutting the function) , the cutter under high temperature state)) as well as cutter life-span all has very highly.
Experience according to in the homeland mould high speed finish machining, linear speed has exceeded 400 ~ 800 m/min when adopt the young diameter ball head milling cutter to carry out mould finish machining. The machine tool choosing sufficient high-speed's cuts mould finish machining stiffly.
Delcam adopt 0.8 mm diameter cutter to process the narrow slot , rotation rate 40000 rpm , 0.1 mm depth, feed speed 30 m/min.
1 chooses the cutter parameter , the cutter waits if shouldering an anterior angle. The cutter requires that the ability processing request shock resistance tenacity more highly , requiring that heat resistance pounds than average is strong;
2 adopts various method improving cutter life-span , reduces cutter cost.
3 adopt the high speed hilt , HSK hilt , heat pressing applying the most being at present to pretend to grip a cutter. Pay attention to a cutter pretend to grip overall in the day afer tomorrow dynamic balance;
4current cutter enterprise has already done many jobs in the field of the technology resolving the quick-cutting cutter , serving facing the cutter processing may help to solve much problem , the cutter has produced a manufacturer becoming the main body , the reference cutter has produced the technology parameter that the manufacturer provides.
Four, improve quick-cutting mould efficiency technology
1 cutter diameter and the length choice
2 HSM and the EDM choice
3 does cutting and the lubricating cooling
4 feeds choice: Move forward generally giving amounts
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