GD956-160工業(yè)型蜂窩煤對輥成型機(jī)設(shè)計-蜂窩煤成型機(jī)含SW三維及7張CAD圖
GD956-160工業(yè)型蜂窩煤對輥成型機(jī)設(shè)計-蜂窩煤成型機(jī)含SW三維及7張CAD圖,gd956,工業(yè),蜂窩煤,對于,成型,設(shè)計,sw,三維,cad
GD956-160工業(yè)型蜂窩煤對輥成型機(jī)設(shè)計摘要 型煤加工對于有效地利用粉煤資源和保護(hù)環(huán)境是十分重要的,在我國的能源構(gòu)成中,煤炭占有十分重要的地位。據(jù)統(tǒng)計,在我國能源生產(chǎn)和消費中,煤炭約占總量的75%左右。但是,隨著采煤機(jī)械化程度的不斷的提高,粉煤在原煤中所占的比例也越來越大。粉煤比例的增加不僅降低了散煤的燃燒效率,而且嚴(yán)重地污染了環(huán)境。發(fā)展型煤是提高粉煤利用率和減少環(huán)境污染的重要途徑,研究表明,工業(yè)鍋爐,窯爐使用型煤后可比燒散煤節(jié)煤10%27%,煙塵排放量可減少50%60%,添加固硫劑后,二氧化硫的排放量可減少35%50%。因此,發(fā)展型煤對我國具有十分重要的現(xiàn)實意義。 本設(shè)計為一種用于煤炭成型加工的高壓對輥成型機(jī),包括有機(jī)架,定對輥軸和動對輥軸設(shè)置在機(jī)架中部,動對輥軸的兩端設(shè)置有加壓裝置,通過加壓裝置,動對輥軸能移動一定距離,在定對輥軸的軸端有同步外掛齒輪與聯(lián)軸裝置及三級設(shè)計減速器相連,在定對輥軸和動對輥軸上方的機(jī)架上安置有加料裝置。該機(jī)采用強(qiáng)制加料方式,液壓加載和使用安全聯(lián)軸器,從而使其型煤產(chǎn)品滿足生產(chǎn)要求。 關(guān)鍵詞:型煤; 型煤加工; 粉煤; 對輥成型機(jī)ABSTRACTCoal processing for the effective use of coal resources and environmental protection is very important, Coal occupy a very important position in our energy mix. According to statistics, Chinas energy production and consumption, coal accounts for about 75% of total. However, as the mining mechanization of a continuous increase in coal pulverized coal as a proportion is also growing. Coal proportion of the increase not only reduced the casual coal combustion efficiency, but also seriously polluted the environment. Development of coal briquette is to improve utilization and reduce environmental pollution in important ways, the study shows that industrial boilers, Kiln use briquette after comparable saving coal burning coal powder 10% 27%, soot emissions can be reduced 50% 60%. After the addition of sorbent , and sulfur dioxide emissions can be reduced 35% 50%. Therefore, the development of Chinas coal is of great practical significance.The design of the coal used in a high-pressure molding and processing of roll forming machines, including rack, set to roll axis and move on roller shaft installed in the central rack, moving to the ends of roller shaft equipped with pressure device, through compression devices, move to roll axis can move a certain distance. In determining the roll axis of the shaft to keep pace with the pylon gear coupling device design and three-reducer, In determining the roll axis and move right side of the roll axis rack placed on the feeder. The aircraft introducing compulsory feeding, hydraulic loading and the use of safety coupling, thus briquette products meet production requirements.Keywords : briquette; Coal processing; Coal; Right roll forming machine目 錄摘要1ABSTRACT2緒論71.電機(jī)選型及傳動比計算81.1選擇電動機(jī)81.1.1選擇電動機(jī)的類型和結(jié)構(gòu)形式81.1.2選擇電動機(jī)的容量81.2計算傳動裝置的總傳動比并分配各級傳動比91.2.1傳動裝置的總傳動比91.2.2分配各級傳動比92.V帶設(shè)計計算1021確定計算功率1022選擇帶型1023確定帶輪基準(zhǔn)直徑1024驗算帶的速度1125初定中心距1126確定基準(zhǔn)長度1127確定實際軸間距1228驗算小帶輪包角1229單根V帶的基本額定功率12210單根V帶的功率增量12211V帶的根數(shù)12212單根V帶的預(yù)緊力132.13小帶輪的結(jié)構(gòu)133基本參數(shù)計算144同步齒輪減速箱齒輪的設(shè)計計算154.1I軸齒輪設(shè)計計算154.1.1選擇齒輪材料154.1.2初定齒輪主要參數(shù)154.1.3校核齒面接觸疲勞強(qiáng)度184.2軸齒輪設(shè)計計算204.2.1選擇齒輪材料204.2.2初定齒輪主要參數(shù)204.2.3校核齒面接觸疲勞強(qiáng)度234.3軸齒輪設(shè)計計算254.3.1選擇齒輪材料254.3.2初定齒輪主要參數(shù)254.3.3校核齒面接觸疲勞強(qiáng)度284.4軸齒輪設(shè)計計算304.4.1選擇齒輪材料304.4.2初定齒輪主要參數(shù)304.4.3校核齒面接觸疲勞強(qiáng)度325同步齒輪減速箱軸的設(shè)計計算355.1軸的設(shè)計計算355.1.1選擇軸的材料355.1.2初步估算軸的的直徑355.1.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計355.1.4軸的受力分析365.1.5軸的強(qiáng)度計算395.2軸的設(shè)計計算405.2.1選擇軸的材料405.2.2初步估算軸的的直徑405.2.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計405.2.4軸的受力分析405.2.5軸的強(qiáng)度計算445.3軸的設(shè)計計算455.3.1選擇軸的材料455.3.2初步估算軸的的直徑455.3.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計455.3.4軸的受力分析465.3.5軸的強(qiáng)度計算515.4軸的設(shè)計計算515.4.1選擇軸的材料515.4.2初步估算軸的的直徑515.4.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計525.4.4軸的受力分析525.5.5軸的強(qiáng)度計算606.同步齒輪減速箱軸承的校核616.1I軸軸承的校核616.1.1計算軸承支反力616.1.2軸承的派生軸向力616.1.3軸承所受的軸向載荷616.1.4軸承的當(dāng)量動載荷626.1.5軸承壽命626.2II軸軸承的校核626.2.1計算軸承支反力636.2.2軸承的派生軸向力636.2.3軸承所受的軸向載荷636.2.4軸承的當(dāng)量動載荷636.2.5軸承壽命646.3III軸軸承的校核646.3.1計算軸承支反力646.3.2軸承的派生軸向力646.3.3軸承所受的軸向載荷646.3.4軸承的當(dāng)量動載荷656.3.5軸承壽命656.4IV軸軸承的校核656.4.1計算軸承支反力666.4.2軸承的派生軸向力666.4.3軸承所受的軸向載荷666.4.4軸承的當(dāng)量動載荷666.4.5軸承壽命676.5V軸軸承的校核676.5.1計算軸承支反力676.5.2軸承的派生軸向力676.5.3軸承所受的軸向載荷676.5.4軸承的當(dāng)量動載荷686.5.5軸承壽命687.同步齒輪減速箱鍵的校核687.1I軸鍵的校核687.2II軸健的校核697.3III軸健的校核697.4IV軸健的校核697.5V軸鍵的校核708.同步齒輪減速箱箱體及附件設(shè)計計算708.1箱體設(shè)計708.1.1箱體結(jié)構(gòu)設(shè)計708.2減速器附件708.2.1檢查孔及其蓋板708.2.2通氣器708.2.3軸承蓋和密封裝置718.2.4定位銷718.2.5油面指示器718.2.6放油開關(guān)718.2.7起吊裝置719機(jī)架及成型裝置的設(shè)計計算719.1型輥軸的設(shè)計719.1.1選擇軸的材料719.1.2初步估算軸的的直徑719.1.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計719.2輥心的設(shè)計729.2.1選擇輥心的材料729.2.2輥心結(jié)構(gòu)設(shè)計729.3型板的設(shè)計7310 液壓加載裝置的選型73結(jié)論74參考文獻(xiàn)75致謝76緒論1.型煤概況 隨著機(jī)械化采煤程度的提高,產(chǎn)生了大量的粉煤。粉煤的市場價值很低,造成大量的積壓。市場對型煤的需求量較大,型煤技術(shù)有很大的市場空間。同時生產(chǎn)型煤的原料煤的質(zhì)地不受限制。2.成型設(shè)備概況 成型設(shè)備是型煤生產(chǎn)中的關(guān)鍵設(shè)備,選擇成型設(shè)備應(yīng)以原煤的特性,型煤的用途及成時壓力等諸多因素為基礎(chǔ)。目前工業(yè)上應(yīng)用最廣的是對輥式成型機(jī)。另外,還有沖壓式成型機(jī),環(huán)式成型機(jī)和螺旋式成型機(jī)等3.對輥成型機(jī)概況對輥成型機(jī)可用于成型、壓塊和顆粒的高壓破碎,它的給料系統(tǒng)和輥面的設(shè)計要根據(jù)使用要求來設(shè)計。下面就對輥成型機(jī)在成型方面的應(yīng)用進(jìn)行描述。對輥成型機(jī)主要包括以下幾個主要部件:3.1同步齒輪傳動系統(tǒng)對輥成型機(jī)的同步齒輪傳動系統(tǒng)由包括兩個同步齒輪在內(nèi)的減速器,安全聯(lián)軸器等組成。安全聯(lián)軸器是一個能自動復(fù)位的機(jī)構(gòu),它可以在正常工作時驅(qū)動轉(zhuǎn)距的1.71.9倍范圍內(nèi)調(diào)整。最主要的是,同步齒輪和齒輪聯(lián)軸器的連接保證了提供給型輥完全均勻的線速度。3.2成型系統(tǒng)對輥成型機(jī)的最主要部分是型輥。由于成型壓力大,直徑大,所以采用八塊型板拼裝的方式,輥芯由鑄鋼材料鑄造而成,型板由強(qiáng)度高的耐磨材料制造。3.3液壓加載系統(tǒng)液壓加載系統(tǒng)用于提供壓力迫使浮輥向被壓實的物料和固定輥靠近。為滿足特殊的工作需要,壓力的高低和大小可以自由調(diào)整。壓力的梯度隨間距的變化而升高,通過改變液壓儲能器中氮的分壓可以在很大范圍內(nèi)調(diào)整壓力的梯度。在其他尖硬物料被壓入壓輥的間隙時液壓系統(tǒng)也用作安全裝置。1.電機(jī)選型及傳動比計算1.1選擇電動機(jī)1.1.1選擇電動機(jī)的類型和結(jié)構(gòu)形式按工作條件和要求,選用一般用途的Y系列三相異步電動機(jī),為臥式封閉結(jié)構(gòu)。1.1.2選擇電動機(jī)的容量輥子轉(zhuǎn)速:n=810r/min輥子圓周速度:v=0.40.5m/s=n/30 v=r初計算型輥半徑 = 型球體積 每塊型煤質(zhì)量 型輥周向上分布型窩個數(shù) (個)型輥軸向上分布型窩數(shù) 取整 型輥長度 取整B=630 mm輥上合力 KN阻力矩 工作機(jī)所需的功率:P=式中 =93000Nm n=10 r/min 代入上式得 P=KW電動機(jī)所需功率:P=P/從電動機(jī)到輥輪主軸之間的傳動裝置的總效率:=式中 =0.95 V帶傳動效率 =0.98 聯(lián)軸器效率 =0.99 軸承效率 =0.97 齒輪傳動效率代入上式得 =0.950.980.990.97 =0.6777 =P/=97.4/0.6777=143.2 KW選擇電動機(jī)額定功率PP,根據(jù)傳動系統(tǒng)圖和推薦的傳動比合理范圍V帶傳動的傳動比 2-4 ;單級圓柱齒輪傳動比 3-6 。所以選擇Y315L1-4電動機(jī),額定功率160kw,滿載轉(zhuǎn)速1480 r/min 。1.2計算傳動裝置的總傳動比并分配各級傳動比1.2.1傳動裝置的總傳動比=1481.2.2分配各級傳動比該傳動裝置中使用的是三級圓柱齒輪減速器,考慮到以下原則:1)使各級傳動的承載能力大致等(齒面接觸強(qiáng)度大致相等)2)使減速器能獲得最小外形尺寸和重量3)使各級傳動中大齒輪的浸油深度大致相等,潤滑最為簡便分配各級齒輪傳動比為=4。25 =4 =1.8輥輪的直徑為956mm,兩輥輪這間的間隙取1mm,所以兩輥輪的中心距為957mm。由此調(diào)節(jié)可初定同步齒輪的傳動比為2.4 。則V帶傳動的傳動比為2。2.V帶設(shè)計計算 21確定計算功率 根據(jù)工作情況 查表12-12選擇工況系數(shù) 設(shè)計功率 22選擇帶型 根據(jù)和 選擇25N窄V帶(有效寬度制)23確定帶輪基準(zhǔn)直徑 小帶輪的基準(zhǔn)直徑 參考表12-19和圖12-4取 傳動比 取彈性滑動系數(shù) 大帶輪基準(zhǔn)準(zhǔn)直徑 取標(biāo)準(zhǔn)值 實際轉(zhuǎn)速 實際傳動比 24驗算帶的速度 25初定中心距 取26確定基準(zhǔn)長度 由表12-10選取相應(yīng)基準(zhǔn)長度 27確定實際軸間距 安裝時所需最小軸間距 張緊或補(bǔ)償伸長所需最大軸間距 28驗算小帶輪包角 29單根V帶的基本額定功率 根據(jù)和 由表12-17n查得25N型窄V帶 210單根V帶的功率增量考慮傳動比的影響,額定功率的增量由表12-17n查得211V帶的根數(shù) 由表12-13查得 由表12-16查得 根 取7根212單根V帶的預(yù)緊力 由表12-142.13小帶輪的結(jié)構(gòu) 小帶輪采用實心輪結(jié)構(gòu)。 由Y280M-4電動機(jī)可知,其軸伸直徑,長度,小帶輪軸孔直徑應(yīng)取,轂長應(yīng)小于. 由表12-22查得,小帶輪結(jié)構(gòu)為實心輪 由V帶的實際傳動比,對減速器的傳動比進(jìn)行重新分配。 傳動裝置總傳動比 V帶傳動傳動比 同步齒輪的傳動比 則三級減速器的傳動比為 ,以達(dá)到傳動比的調(diào)節(jié)。則 3基本參數(shù)計算各軸的轉(zhuǎn)速、傳遞功率、轉(zhuǎn)矩軸 = =軸 軸 軸 軸 4同步齒輪減速箱齒輪的設(shè)計計算4.1I軸齒輪設(shè)計計算4.1.1選擇齒輪材料小齒輪 20CrMnTi 滲碳淬火 HRC 5662大齒輪 20CrMnTi 滲碳淬火 HRC 5662 齒輪的疲勞極限應(yīng)力按中等質(zhì)量(MQ)要求從圖14-32和圖14-24中查得 參考我國試驗數(shù)據(jù)(表14-45)后,將適當(dāng)降低:4.1.2初定齒輪主要參數(shù)初定齒輪主要參數(shù) 考慮載荷有輕微沖擊、非對稱軸承布置,取載荷系數(shù)K=2 按齒根彎曲疲勞強(qiáng)度估算齒輪尺寸,計算模數(shù): 按表14-34,并考慮傳動比,選用小齒輪齒數(shù)=24, 大齒輪齒數(shù) 取 = 102 按表14-33,選齒寬系數(shù)由圖14-14查得大小齒輪的復(fù)合齒形系數(shù)(時) 由于輪齒單向受力,齒輪的許用彎曲應(yīng)力 由于,故按小齒輪的抗彎強(qiáng)度計算模數(shù) 采用斜齒輪,按表14-2,取標(biāo)準(zhǔn)模數(shù)。初取=13(表14-33),則齒輪中心距 由于單件生產(chǎn),不必取標(biāo)準(zhǔn)中心距,取。準(zhǔn)確的螺旋角 齒輪分度圓直徑 工作齒寬 為了保證,取。齒輪圓周速度 按此速度查表14-78,齒輪精度選用8級即可,齒輪精度8-7-7(GB10095-1988)校核重合度縱向重合度 (圖14-8) 端面重合度 (圖14-3) 總重合度 4.1.3校核齒面接觸疲勞強(qiáng)度 分度圓上的切向力 由表14-39查得使用系數(shù) 動載荷系數(shù)式中 (表14-40)齒數(shù)比 將有關(guān)數(shù)據(jù)代入計算式 齒向載荷分布系數(shù) 齒向載荷分配系數(shù),根據(jù) 查表14-43 得 節(jié)點區(qū)域系數(shù),按和查圖14-11 得材料彈性系數(shù)查表14-44 得重合度系數(shù) 查圖14-12 得螺旋角系數(shù) 查圖14-13 得 由于可取 計算接觸強(qiáng)度強(qiáng)度安全系數(shù) 式中各系數(shù)的確定計算齒面應(yīng)力循環(huán)數(shù) 按齒面不允許出現(xiàn)點蝕,查圖14-37 得壽命系數(shù) 潤滑油膜影響系數(shù) 查表14-47 得 齒面工作硬化系數(shù) 按圖14-39 查得尺寸系數(shù) 按,查圖14-40 得將以上數(shù)據(jù)代入計算式 由表14-49,按一般可靠度要求,選用最小安全系數(shù)。和均大于,故安全。4.2軸齒輪設(shè)計計算4.2.1選擇齒輪材料小齒輪 20CrMnTi 滲碳淬火 HRC 5662大齒輪 20CrMnTi 滲碳淬火 HRC 5662 齒輪的疲勞極限應(yīng)力按中等質(zhì)量(MQ)要求從圖14-32和圖14-24中得 參考我國試驗數(shù)據(jù)(表14-45)后,將適當(dāng)降低:4.2.2初定齒輪主要參數(shù)按齒根彎曲疲勞強(qiáng)度估算齒輪尺寸,計算模數(shù) 按表14-34,并考慮傳動比,選用小齒輪齒數(shù)=26, 大齒輪齒數(shù) 取整 =102 按表14-33,選齒寬系數(shù)由圖14-14查得大小齒輪的復(fù)合齒形系數(shù)(時) 由于輪齒單向受力,齒輪的許用彎曲應(yīng)力 由于,故按小齒輪的抗彎強(qiáng)度計算模數(shù) 采用斜齒輪,按表14-2,取標(biāo)準(zhǔn)模數(shù)。初取=13(表14-33),則齒輪中心距 由于單件生產(chǎn),不必取標(biāo)準(zhǔn)中心距,取。準(zhǔn)確的螺旋角 齒輪分度圓直徑 工作齒寬 為了保證,取。齒輪圓周速度 按此速度查表14-78,齒輪精度選用8級即可,齒輪精度8-7-7(GB10095-1988)校核重合度縱向重合度 (圖14-8) 端面重合度 (圖14-3) 總重合度 4.2.3校核齒面接觸疲勞強(qiáng)度 分度圓上的切向力 由表14-39查得使用系數(shù) 動載荷系數(shù)式中 (表14-40)齒數(shù)比將有關(guān)數(shù)據(jù)代入計算式 齒向載荷分布系數(shù) 齒向載荷分配系數(shù),根據(jù) 查表14-43 得節(jié)點區(qū)域系數(shù),按和查圖14-11 得材料彈性系數(shù)查表14-44 得重合度系數(shù) 查圖14-12 得螺旋角系數(shù) 查圖14-13 得 由于可取 計算接觸強(qiáng)度強(qiáng)度安全系數(shù) 式中各系數(shù)的確定計算齒面應(yīng)力循環(huán)數(shù) 按齒面不允許出現(xiàn)點蝕,查圖14-37 得壽命系數(shù) 潤滑油膜影響系數(shù) 查表14-47 得 齒面工作硬化系數(shù) 按圖14-39 查得尺寸系數(shù) 按,查圖14-40 得將以上數(shù)據(jù)代入計算式 由表14-49,按一般可靠度要求,選用最小安全系數(shù)。和均大于,故安全。4.3軸齒輪設(shè)計計算4.3.1選擇齒輪材料小齒輪 20CrMnTi 滲碳淬火 HRC 5662大齒輪 20CrMnTi 滲碳淬火 HRC 5662 齒輪的疲勞極限應(yīng)力按中等質(zhì)量(MQ)要求得 參考我國試驗數(shù)據(jù)(表14-45)后,將適當(dāng)降低:4.3.2初定齒輪主要參數(shù) 按齒根彎曲疲勞強(qiáng)度估算齒輪尺寸,計算模數(shù) 按表14-34,并考慮傳動比,選用小齒輪齒數(shù)=40, 大齒輪齒數(shù) 取72 按表14-33,選齒寬系數(shù)由圖14-14查得大小齒輪的復(fù)合齒形系數(shù)(時) 由于輪齒單向受力,齒輪的許用彎曲應(yīng)力 由于,故按小齒輪的抗彎強(qiáng)度計算模數(shù) 采用斜齒輪,按表14-2,取標(biāo)準(zhǔn)模數(shù)。初取=13(表14-33),則齒輪中心距 由于單件生產(chǎn),不必取標(biāo)準(zhǔn)中心距,取。準(zhǔn)確的螺旋角 齒輪分度圓直徑 工作齒寬 為了保證,取。齒輪圓周速度 按此速度查表14-78,齒輪精度選用8級即可,齒輪精度8-7-7(GB10095-1988)校核重合度縱向重合度 (圖14-8) 端面重合度 (圖14-3) 總重合度 4.3.3校核齒面接觸疲勞強(qiáng)度 分度圓上的切向力 由表14-39查得使用系數(shù) 動載荷系數(shù)式中 (表14-40)齒數(shù)比將有關(guān)數(shù)據(jù)代入計算式 齒向載荷分布系數(shù) 齒向載荷分配系數(shù),根據(jù) 查表14-43 得節(jié)點區(qū)域系數(shù),按和查圖14-11 得材料彈性系數(shù)查表14-44 得重合度系數(shù) 查圖14-12 得螺旋角系數(shù) 查圖14-13 得 由于可取 計算接觸強(qiáng)度強(qiáng)度安全系數(shù) 式中各系數(shù)的確定計算齒面應(yīng)力循環(huán)數(shù) 按齒面不允許出現(xiàn)點蝕,查圖14-37 得壽命系數(shù) 潤滑油膜影響系數(shù) 查表14-47 得 齒面工作硬化系數(shù) 按圖14-39 查得尺寸系數(shù) 按,查圖14-40 得將以上數(shù)據(jù)代入計算式 由表14-49,按一般可靠度要求,選用最小安全系數(shù)。和均大于,故安全。4.4軸齒輪設(shè)計計算4.4.1選擇齒輪材料小齒輪 20CrMnTi 滲碳淬火 HRC 5662大齒輪 20CrMnTi 滲碳淬火 HRC 5662 齒輪的疲勞極限應(yīng)力按中等質(zhì)量(MQ)要求得 參考我國試驗數(shù)據(jù)后,將適當(dāng)降低:4.4.2初定齒輪主要參數(shù)按齒根彎曲疲勞強(qiáng)度估算齒輪尺寸,計算模數(shù) 按表14-34,并考慮傳動比,選用小齒輪齒數(shù)=24, 大齒輪齒數(shù) 取58 按表14-33,選齒寬系數(shù)由圖14-14查得大小齒輪的復(fù)合齒形系數(shù)(時) 由于輪齒單向受力,齒輪的許用彎曲應(yīng)力 由于,故按小齒輪的抗彎強(qiáng)度計算模數(shù) 采用斜齒輪,按表14-2,取標(biāo)準(zhǔn)模數(shù)。初取=13(表14-33),則齒輪中心距 由于單件生產(chǎn),不必取標(biāo)準(zhǔn)中心距,取。準(zhǔn)確的螺旋角 齒輪分度圓直徑 工作齒寬 為了保證,取。齒輪圓周速度 按此速度查表14-78,齒輪精度選用8級即可,齒輪精度8-7-7(GB10095-1988)校核重合度縱向重合度 (圖14-8) 端面重合度 (圖14-3) 總重合度 4.4.3校核齒面接觸疲勞強(qiáng)度 分度圓上的切向力 由表14-39查得使用系數(shù) 動載荷系數(shù)式中 (表14-40)齒數(shù)比將有關(guān)數(shù)據(jù)代入計算式 齒向載荷分布系數(shù) 齒向載荷分配系數(shù),根據(jù) 查表14-43 得節(jié)點區(qū)域系數(shù),按和查圖14-11 得材料彈性系數(shù)查表14-44 得重合度系數(shù) 查圖14-12 得螺旋角系數(shù) 查圖14-13 得 由于可取 計算接觸強(qiáng)度強(qiáng)度安全系數(shù) 式中各系數(shù)的確定計算齒面應(yīng)力循環(huán)數(shù) 按齒面不允許出現(xiàn)點蝕,查圖14-37 得壽命系數(shù) 潤滑油膜影響系數(shù) 查表14-47 得 齒面工作硬化系數(shù) 按圖14-39 查得尺寸系數(shù) 按,查圖14-40 得將以上數(shù)據(jù)代入計算式 由表14-49,按一般可靠度要求,選用最小安全系數(shù)。和均大于,故安全。5同步齒輪減速箱軸的設(shè)計計算5.1軸的設(shè)計計算5.1.1選擇軸的材料該軸上的齒輪的分度圓直徑和軸徑相差不大,故做成齒輪軸,選用45號鋼,調(diào)質(zhì)處理,其力學(xué)性能 5.1.2初步估算軸的的直徑 取軸徑為70mm5.1.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計5.1.3.1初步選擇滾動軸承根據(jù)軸的受力,選取30000型圓錐滾子軸承,為了便于軸承的裝配,取裝軸承處的直徑。初選滾動軸承為33015型,其尺寸為,定位軸肩高度5.1.3.2根據(jù)軸向定位的要求確定軸的各段直徑和長度軸段為圓柱形軸伸,查表21-9,的軸伸長。軸段直徑為,根據(jù)減速器與軸承端蓋的結(jié)構(gòu),確定端蓋總寬度為,考慮端蓋與帶輪間隙,。軸段安裝軸承,由于圓柱形軸伸的原因,采用雙列軸承,取,。軸段軸肩長度,按齒輪距箱體內(nèi)壁這距離取,考慮到箱體的鑄造誤差,滾動軸承應(yīng)距箱體內(nèi)壁,取,從各軸的結(jié)構(gòu)選,。軸安裝軸承,5.1.4軸的受力分析5.1.4.1作出軸的計算簡圖 5.1.4.2軸受外力的計算軸傳遞的轉(zhuǎn)矩 齒輪的圓周力 齒輪的徑向力 齒輪的軸向力 5.1.4.3求支反力在水平面內(nèi)的支反力 由得 由得 彎矩圖 在垂直面內(nèi)的支反力由得 由得 彎矩圖 扭矩圖 5.1.5軸的強(qiáng)度計算按彎扭合成強(qiáng)度條件計算由于齒輪作用力在D截面的最大合成彎矩 D截面的當(dāng)量彎矩 安全 5.2軸的設(shè)計計算5.2.1選擇軸的材料選用45號鋼,調(diào)質(zhì)處理。 5.2.2初步估算軸的的直徑 取軸徑為110mm5.2.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計5.2.3.1初步選擇滾動軸承根據(jù)軸的受力,選取30000型圓錐滾子軸承,為了便于軸承的裝配,取裝軸承處的直徑。初選滾動軸承為30222型,其尺寸為。5.2.3.2根據(jù)軸向定位的要求確定軸的各段直徑和長度軸段安裝軸承,取,。軸段安裝齒輪,齒輪左端采用套筒定位,右端使用軸肩定位。取軸段直徑,齒輪寬度為110mm,為了全套筒端面可靠地壓緊齒輪,軸段長度應(yīng)略短于齒輪輪轂寬度取。軸段軸環(huán),。軸段為齒輪軸寬度取。軸段安裝軸承,5.2.4軸的受力分析5.2.4.1作出軸的計算簡圖 5.2.4.2軸受外力的計算軸傳遞的轉(zhuǎn)矩 大齒輪的圓周力 大齒輪的徑向力 大齒輪的軸向力 小齒輪的圓周力 齒輪的徑向力 齒輪的軸向力 5.2.4.3求支反力在水平面內(nèi)的支反力由得 由得 彎矩圖 在垂直面內(nèi)的支反力由得 由得 彎矩圖 扭矩圖 5.2.5軸的強(qiáng)度計算由于齒輪作用力在D截面的最大合成彎矩 D截面的當(dāng)量彎矩 由于齒輪作用力在E截面的最大合成彎矩 E截面的當(dāng)量彎矩 安全 5.3軸的設(shè)計計算5.3.1選擇軸的材料選用45號鋼,調(diào)質(zhì)處理,其力學(xué)性能 5.3.2初步估算軸的的直徑 取軸徑為170mm5.3.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計5.3.3.1初步選擇滾動軸承根據(jù)軸的受力,選取30000型圓錐滾子軸承,取裝軸承處的直徑。初選滾動軸承為32034型,其尺寸為。5.3.3.2根據(jù)軸向定位的要求確定軸的各段直徑和長度軸段安裝軸承,取,。軸段安裝齒輪,齒輪左端采用套筒定位,右端使用軸肩定位。取軸段直徑,齒輪寬度為230mm,為了套筒端面可靠地壓緊齒輪,軸段長度應(yīng)略短于齒輪輪轂寬度取。軸段軸肩高度,取,為。5.3.4軸的受力分析5.3.4.1作出軸的計算簡圖 5.3.4.2軸受外力的計算軸傳遞的轉(zhuǎn)矩 大齒輪的圓周力 大齒輪的徑向力 大齒輪的軸向力 小齒輪的圓周力 小齒輪的徑向力 小齒輪的軸向力 5.3.4.3求支反力在水平面內(nèi)的支反力 由得 得 彎矩圖 在垂直面內(nèi)的支反力由得 由得 彎矩圖 扭矩圖 5.3.5軸的強(qiáng)度計算按彎扭合成強(qiáng)度條件計算由于齒輪作用力在D截面的最大合成彎矩 D截面的當(dāng)量彎矩 5.4軸的設(shè)計計算5.4.1選擇軸的材料選用45號鋼,調(diào)質(zhì)處理,其力學(xué)性能由表21-1查得 5.4.2初步估算軸的的直徑 取軸徑為170mm5.4.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計5.4.3.1初步選擇滾動軸承根據(jù)軸的受力,選取30000型圓錐滾子軸承,為了便于軸承的裝配,取裝軸承處的直徑。初選滾動軸承為32034型,其尺寸為。5.4.3.2根據(jù)軸向定位的要求確定軸的各段直徑和長度軸段安裝軸承,取,。軸段安裝齒輪,齒輪左端采用套筒定位,右端使用軸肩定位。取軸段直徑,齒輪寬度為130mm,為了全套筒端面可靠地壓緊齒輪,軸段長度應(yīng)略短于齒輪輪轂寬度取。軸段軸肩高度,取,。軸環(huán)寬度,取,則。軸段為中間段, ,。軸段為軸肩,。VI軸段安裝齒輪,齒輪右端采用套筒定位,左端使用軸肩定位。取軸段直徑,。II軸段安裝軸承,。5.4.4軸的受力分析5.4.4.1作出軸的計算簡圖 5.4.4.2軸受外力的計算軸傳遞的轉(zhuǎn)矩 大齒輪的圓周力 大齒輪的徑向力 大齒輪的軸向力 小齒輪的圓周力 齒輪的徑向力 齒輪的軸向力 5.4.4.3求支反力在水平面內(nèi)的支反力由得 由得 彎矩圖 在垂直面內(nèi)的支反力 由得 由得 彎矩圖 扭矩圖 5.4.5軸的強(qiáng)度計算按彎扭合成強(qiáng)度條件計算由于齒輪作用力在D截面的最大合成彎矩 D截面的當(dāng)量彎矩 5.5軸的設(shè)計計算5.5.1選擇軸的材料選用45號鋼,調(diào)質(zhì)處理。 5.5.2初步估算軸的的直徑 取軸徑為220mm5.5.3軸上零部件的選擇和軸的結(jié)構(gòu)設(shè)計5.5.3.1初步選擇滾動軸承根據(jù)軸的受力,選取20000型調(diào)心滾子軸承,為了便于軸承的裝配,取裝軸承處的直徑。初選滾動軸承為23072型,其尺寸為。5.5.3.2根據(jù)軸向定位的要求確定軸的各段直徑和長度軸段安裝軸承,取,。軸段安裝齒輪,齒輪左端采用套筒定位,右端使用軸肩定位。取軸段直徑,齒輪寬度為300mm,取。軸段軸肩高度,取,。軸環(huán)寬度,取,則。I軸段安裝軸承,。V軸段伸出軸,聯(lián)接聯(lián)軸器,取,。5.5.4軸的受力分析5.5.4.1作出軸的計算簡圖 5.5.4.2軸受外力的計算軸傳遞的轉(zhuǎn)矩 齒輪的圓周力 齒輪的徑向力 齒輪的軸向力 5.5.4.3求支反力在水平面內(nèi)的支反力由得 得 彎矩圖 在垂直面內(nèi)的支反力由得 得 彎矩圖 扭矩圖 5.5.5軸的強(qiáng)度計算按彎扭合成強(qiáng)度條件計算由于齒輪作用力在D截面的最大合成彎矩 D截面的當(dāng)量彎矩 6.同步齒輪減速箱軸承的校核6.1I軸軸承的校核初選滾動軸承為32215型,其尺寸為基本額定載荷Cr: 170kN6.1.1計算軸承支反力合成支反力 6.1.2軸承的派生軸向力 6.1.3軸承所受的軸向載荷因 6.1.4軸承的當(dāng)量動載荷 , , 6.1.5軸承壽命 因,故按計算 查得, 6.2II軸軸承的校核初選滾動軸承為32317型,尺寸為?;绢~定載荷Cr: 180kNe=0.29 Y=2.16.2.1計算軸承支反力合成支反力 6.2.2軸承的派生軸向力 6.2.3軸承所受的軸向載荷因 6.2.4軸承的當(dāng)量動載荷 , , 6.2.5軸承壽命因,故按計算查得, 6.3III軸軸承的校核初選滾動軸承為32022型,其尺寸為。e=0.43 Y=1.4基本額定載荷Cr: 245kN6.3.1計算軸承支反力合成支反力 6.3.2軸承的派生軸向力 6.3.3軸承所受的軸向載荷因 6.3.4軸承的當(dāng)量動載荷 , , 6.3.5軸承壽命因,故按計算 查得, 6.4IV軸軸承的校核初選滾動軸承為32034型,其尺寸為。e=0.44 Y=1.4基本額定載荷Cr: 520kN6.4.1計算軸承支反力合成支反力 6.4.2軸承的派生軸向力 6.4.3軸承所受的軸向載荷因 6.4.4軸承的當(dāng)量動載荷 , , 6.4.5軸承壽命因,故按計算 查得, 6.5V軸軸承的校核初選滾動軸承為23044型,其尺寸為?;绢~定載荷Cr: 760kN6.5.1計算軸承支反力合成支反力 6.5.2軸承的派生軸向力 6.5.3軸承所受的軸向載荷因 6.5.4軸承的當(dāng)量動載荷 , , 6.5.5軸承壽命因,故按計算 查得, 7.同步齒輪減速箱鍵的校核7.1I軸鍵的校核I軸的伸出軸,選用圓頭普通平鍵(C型),b=18mm,h=11mm,L=125mm,I軸傳遞的扭矩T=676940Nmm.當(dāng)鍵用45鋼制造時,主要失效形式為壓潰,通常只進(jìn)行擠壓強(qiáng)度計算., 合格7.2II軸健的校核II軸的鍵用于齒輪和軸的聯(lián)接,軸徑為,選用選用圓頭普通平鍵(C型),b=25mm,h=14mm,L=90mm,II軸傳遞的扭矩T=2509780Nmm.7.3III軸健的校核III軸的鍵用于任務(wù)書題目: GD956-160工業(yè)型蜂窩煤對輥成型機(jī)設(shè)計畢業(yè)論文主要內(nèi)容和要求:結(jié)合畢業(yè)實習(xí),采用蜂窩煤成型機(jī)設(shè)計成型技術(shù)原理;利用自重加料方式,設(shè)計一臺工業(yè)型煤成型機(jī)。輥子轉(zhuǎn)速:8-10轉(zhuǎn)/分(輥子圓周速度0.4-0.5米/秒);成型壓力:15-30kn/cm;小時產(chǎn)量: 30-35噸;型球尺寸:mm;采用液壓加載;鉸接式框架結(jié)構(gòu):采用同步式齒輪箱傳動。1、 明確該裝置的工作原理及相關(guān)的受力分析,參考設(shè)計參數(shù)確定電動機(jī)功率,完成該裝置的總體設(shè)計。2、 利用三維輔助設(shè)計,完成同步式齒輪箱設(shè)計。3、 同步齒輪傳動箱組件設(shè)計、零件圖工作圖設(shè)計。4、 編寫完成整機(jī)設(shè)計計算說明書。院長簽字: 指導(dǎo)教師簽字:翻譯部分英文原文High-speed machining and demand for the development ofHigh-speed machining is contemporary advanced manufacturing technology an important component of the high-efficiency, High-precision and high surface quality, and other features. This article presents the technical definition of the current state of development of Chinas application fields and the demand situation. High-speed machining is oriented to the 21st century a new high-tech, high-efficiency, High-precision and high surface quality as a basic feature, in the automobile industry, aerospace, Die Manufacturing and instrumentation industries gained increasingly widespread application, and has made significant technical and economic benefits. contemporary advanced manufacturing technology an important component part.HSC is to achieve high efficiency of the core technology manufacturers, intensive processes and equipment packaged so that it has a high production efficiency. It can be said that the high-speed machining is an increase in the quantity of equipment significantly improve processing efficiency essential to the technology. High-speed machining is the major advantages : improve production efficiency, improve accuracy and reduce the processing of cutting resistance.The high-speed machining of meaning, at present there is no uniform understanding, there are generally several points as follows : high cutting speed. usually faster than that of their normal cutting 5 -10 times; machine tool spindle speed high, generally spindle speed in -20000r/min above 10,000 for high-speed cutting; Feed at high velocity, usually 15 -50m/min up to 90m/min; For different cutting materials and the wiring used the tool material, high-speed cutting the meaning is not necessarily the same; Cutting process, bladed through frequency (Tooth Passing Frequency) closer to the machine-tool - Workpiece system the dominant natural frequency (Dominant Natural Frequency), can be considered to be high-speed cutting. Visibility high-speed machining is a comprehensive concept. 1992. Germany, the Darmstadt University of Technology, Professor H. Schulz in the 52th on the increase of high-speed cutting for the concept and the scope, as shown in Figure 1. Think different cutting targets, shown in the figure of the transition area (Transition), to be what is commonly called the high-speed cutting, This is also the time of metal cutting process related to the technical staff are looking forward to, or is expected to achieve the cutting speed.High-speed machining of machine tools, knives and cutting process, and other aspects specific requirements. Several were from the following aspects : high-speed machining technology development status and trends.At this stage, in order to achieve high-speed machining, general wiring with high flexibility of high-speed CNC machine tools, machining centers, By using a dedicated high-speed milling, drilling. These equipment in common is : We must also have high-speed and high-speed spindle system feeding system, Cutting can be achieved in high-speed process. High-speed cutting with the traditional cutting the biggest difference is that Machine-tool-workpiece the dynamic characteristics of cutting performance is stronger influence. In the system, the machine spindle stiffness, grip or form, a long knife set, spindle Broach, torque tool set, Performance high-speed impact are important factors.In the high-speed cutting, material removal rate (Metal Removal Rate, MRR), unit time that the material was removed volume, usually based on the machine-tool-workpiece whether Processing System chatter. Therefore, in order to satisfy the high-speed machining needs, we must first improve the static and dynamic stiffness of machine spindle is particularly the stiffness characteristics. HSC reason at this stage to be successful, a very crucial factor is the dynamic characteristics of the master and processing capability.In order to better describe the machine spindle stiffness characteristics of the project presented new dimensionless parameter - DN value, used for the evaluation of the machine tool spindle structure on the high-speed machining of adaptability. DN value of the so-called axis diameter per minute speed with the product. The newly developed spindle machining center DN values have been great over one million. To reduce the weight bearing, but also with an array of steel products than to the much more light ceramic ball bearings; Bearing Lubrication most impressive manner mixed with oil lubrication methods. In the field of high-speed machining. have air bearings and the development of magnetic bearings and magnetic bearings and air bearings combined constitute the magnetic gas / air mixing spindle.Feed the machine sector, high-speed machining used in the feed drive is usually larger lead, multiple high-speed ball screw and ball array of small-diameter silicon nitride (Si3N4) ceramic ball, to reduce its centrifugal and gyroscopic torque; By using hollow-cooling technology to reduce operating at high speed ball screw as temperature generated by the friction between the lead screw and thermal deformation.In recent years, the use of linear motor-driven high-speed system of up to Such feed system has removed the motor from workstations to Slide in the middle of all mechanical transmission links, Implementation of Machine Tool Feed System of zero transmission. Because no linear motor rotating components, from the role of centrifugal force, can greatly increase the feed rate. Linear Motor Another major advantage of the trip is unrestricted. The linear motor is a very time for a continuous machine shop in possession of the bed. Resurfacing of the very meeting where a very early stage movement can go, but the whole system of up to the stiffness without any influence. By using high-speed screw, or linear motor can greatly enhance machine system of up to the rapid response. The maximum acceleration linear motors up to 2-10G (G for the acceleration of gravity), the largest feed rate of up to 60 -200m/min or higher. 2002 world-renowned Shanghai Pudong maglev train project of maglev track steel processing, Using the Shenyang Machine Tool Group Holdings Limited McNair friendship company production plants into extra-long high-speed system for large-scale processing centers achieve . The machine feeding system for the linear guide and rack gear drive, the largest table feed rate of 60 m / min, Quick trip of 100 m / min, 2 g acceleration, maximum speed spindle 20000 r / min, the main motor power 80 kW. X-axis distance of up to 30 m, 25 m cutting long maglev track steel error is less than 0.15 mm. Maglev trains for the smooth completion of the project provided a strong guarantee for technologyIn addition, the campaign machine performance will also directly affect the processing efficiency and accuracy of processing. Mold and the free surface of high-speed machining, the main wiring with small cut deep into methods for processing. Machine requirements in the feed rate conditions, should have high-precision positioning functions and high-precision interpolation function, especially high-precision arc interpolation. Arc processing is to adopt legislation or thread milling cutter mold or machining parts, the essential processing methods.Cutting Tools Tool Material development high-speed cutting and technological development of the history, tool material is continuous progress of history. The representation of high-speed cutting tool material is cubic boron nitride (CBN). Face Milling Cutter use of CBN, its cutting speed can be as high as 5000 m / min, mainly for the gray cast iron machining. Polycrystalline diamond (PCD) has been described as a tool of the 21st century tool, It is particularly applicable to the cutting aluminum alloy containing silica material, which is light weight metal materials, high strength, widely used in the automobile, motorcycle engine, electronic devices shell, the base, and so on. At present, the use of polycrystalline diamond cutter Face Milling alloy, 5000m/min the cutting speed has reached a practical level. In addition ceramic tool also applies to gray iron of high-speed machining; Tool Coating : CBN and diamond cutter, despite good high-speed performance, but the cost is relatively high. Using the coating technology to make cutting tool is the low price, with excellent mechanical properties, which can effectively reduce the cost. Now high-speed processing of milling cutter, with most of the wiring between the Ti-A1-N composite technology for the way of multi-processing, If present in the non-ferrous metal or alloy material dry cutting, DLC (Diamond Like Carbon) coating on the cutter was of great concern. It is expected that the market outlook is very significant; Tool clamping system : Tool clamping system to support high-speed cutting is an important technology, Currently the most widely used is a two-faced tool clamping system. Has been formally invested as a commodity market at the same clamping tool system are : HSK, KM, Bigplus. NC5, AHO systems. In the high-speed machining, tool and fixture rotary performance of the balance not only affects the precision machining and tool life. it will also affect the life of machine tools. So, the choice of tool system, it should be a balanced selection of good products. Process Parameters Cutting speed of high-speed processing of conventional shear velocity of about 10 times. For every tooth cutter feed rate remained basically unchanged, to guarantee parts machining precision, surface quality and durability of the tool, Feed volume will also be a corresponding increase about 10 times, reaching 60 m / min, Some even as high as 120 m / min. Therefore, high-speed machining is usually preclude the use of high-speed, feed and depth of cut small cutting parameters. Due to the high-speed machining cutting cushion tend to be small, the formation of very thin chip light, Cutting put the heat away quickly; If the wiring using a new thermal stability better tool materials and coatings, Using the dry cutting process for high-speed machining is the ideal technology program.High-speed machining field of applicationFlexible efficient production lineTo adapt to the needs of new models, auto body panel molds and resin-prevention block the forming die. must shorten the production cycle and reduce the cost of production and, therefore, we must make great efforts to promote the production of high-speed die in the process. SAIC affiliated with the company that : Compared to the past, finishing, further precision; the same time, the surface roughness must be met, the bending of precision, this should be subject to appropriate intensive manual processing. Due to the extremely high cutting speed, and the last finishing processes, the processing cycle should be greatly reduced. To play for machining centers and boring and milling machining center category represented by the high-speed machining technology and automatic tool change function of distinctions Potential to improve processing efficiency, the processing of complex parts used to be concentrated as much as possible the wiring process, that is a fixture in achieving multiple processes centralized processing and dilute the traditional cars, milling, boring, Thread processing different cutting the limits of technology, equipment and give full play to the high-speed cutting tool function, NC is currently raising machine efficiency and speed up product development in an effective way. Therefore, the proposed multi-purpose tool of the new requirements call for a tool to complete different parts of the machining processes, ATC reduce the number of ATC to save time, to reduce the quantity and tool inventory, and management to reduce production costs. More commonly used in a multifunctional Tool, milling, boring and milling, drilling milling, drilling-milling thread-range tool. At the same time, mass production line, against the use of technology requires the development of special tools, tool or a smart composite tool, improve processing efficiency and accuracy and reduced investment. In the high-speed cutting conditions, and some special tools can be part of the processing time to the original 1 / 10 below, results are quite remarkable. HSC has a lot of advantages such as : a large number of materials required resection of the workpiece with ultrafine, thin structure of the workpiece, Traditionally, the need to spend very long hours for processing mobile workpiece and the design of rapid change, short product life cycle of the workpiece, able to demonstrate high-speed cutting brought advantages.中文譯文高速切削加工的發(fā)展及需求高速切削加工是當(dāng)代先進(jìn)制造技術(shù)的重要組成部分,擁有高效率、高精度及高表面質(zhì)量等特征。本文介紹此技術(shù)的定義、發(fā)展現(xiàn)狀、適用領(lǐng)域以及中國的需求情況。高速切削加工是面向21世紀(jì)的一項高新技術(shù),它以高效率、高精度和高表面質(zhì)量為基本特征,在汽車工業(yè)、航空航天、模具制造和儀器儀表等行業(yè)中獲得了愈來愈廣泛的應(yīng)用,并已取得了重大的技術(shù)經(jīng)濟(jì)效益,是當(dāng)代先進(jìn)制造技術(shù)的重要組成部分。高速切削是實現(xiàn)高效率制造的核心技術(shù),工序的集約化和設(shè)備的通用化使之具有很高的生產(chǎn)效率??梢哉f,高速切削加工是一種不增加設(shè)備數(shù)量而大幅度提高加工效率所必不可少的技術(shù)。高速切削加工的優(yōu)點主要在于:提高生產(chǎn)效率、提高加工精度及降低切削阻力。 有關(guān)高速切削加工的含義,目前尚無統(tǒng)一的認(rèn)識,通常有如下幾種觀點:切削速度很高,通常認(rèn)為其速度超過普通切削的5-10倍;機(jī)床主軸轉(zhuǎn)速很高,一般將主軸轉(zhuǎn)速在10000-20000r/min以上定為高速切削;進(jìn)給速度很高,通常達(dá)15-50m/min,最高可達(dá)90m/min;對于不同的切削材料和所釆用的刀具材料,高速切削的含義也不盡相同;切削過程中,刀刃的通過頻率(Tooth Passing Frequency)接近于“機(jī)床刀具工件”系統(tǒng)的主導(dǎo)自然頻率(Dominant Natural Frequency)時,可認(rèn)為是高速切削。可見高速切削加工是一個綜合的概念。1992年,德國Darmstadt工業(yè)大學(xué)的H. Schulz教授在CIRP上提出了高速切削加工的概念及其涵蓋的范圍,如圖1所示。認(rèn)為對于不同的切削對象,圖中所示的過渡區(qū)(Transition)即為通常所謂的高速切削範(fàn)圍,這也是當(dāng)時金屬切削工藝相關(guān)的技術(shù)人員所期待或者可望實現(xiàn)的切削速度。高速切削加工對機(jī)床、刀具和切削工藝等方面都有一些具體的要求。下面分別從這幾個方面闡述高速切削加工技術(shù)的發(fā)展現(xiàn)狀和趨勢。現(xiàn)階段,為了實現(xiàn)高速切削加工,一般釆用高柔性的高速數(shù)控機(jī)床、加工中心,也有釆用專用的高速銑、鉆床。這些設(shè)備的共同之處是:必須同時具有高速主軸系統(tǒng)和高速進(jìn)給系統(tǒng),才能實現(xiàn)材料切削過程的高速化。高速切削與傳統(tǒng)切削最大的區(qū)別是,“機(jī)床刀具工件”系統(tǒng)的動態(tài)特性對切削性能有更強(qiáng)的影響力。在該系統(tǒng)中,機(jī)床主軸的剛度、刀柄形式、刀長設(shè)定、主軸拉刀力、刀具扭力設(shè)定等,都是影響高速切削性能的重要因素。 在高速切削中,材料去除率(Metal Removal Rate,MRR),即單位時間內(nèi)材料被切除的體積,通常受限于“機(jī)床-刀具-工件”工藝系統(tǒng)是否出現(xiàn)“顫振”。因此,為了滿足高速切削加工的需求,首先要提高機(jī)床動靜剛度尤其是主軸的剛度特性?,F(xiàn)階段高速切削之所以能夠成功,一個很關(guān)鍵的因素在于對系統(tǒng)動態(tài)特性問題的掌握和處理能力。為了更好地描述機(jī)床主軸的剛度特性,工程上提出新的無量綱參數(shù)DN值,用以評價機(jī)床的主軸結(jié)構(gòu)對高速切削加工的適應(yīng)性。所謂DN值即“主軸直徑與每分鐘轉(zhuǎn)速之積”。新近開發(fā)的加工中心主軸DN值大都已超過100萬。為了減輕軸承的重量,還釆用了比鋼制品要輕得多的陶瓷球軸承;軸承潤滑方式大都釆用油氣混合潤滑方式。在高速切削加工領(lǐng)域,目前已開發(fā)空氣軸承和磁軸承以及由磁軸承和空氣軸承合并構(gòu)成的磁氣/空氣混合主軸。 在機(jī)床進(jìn)給機(jī)構(gòu)方面,高速切削加工所用的進(jìn)給驅(qū)動機(jī)構(gòu)通常都為大導(dǎo)程、多頭高速滾珠絲槓,滾珠釆用小直徑氮化硅(Si3N4)陶瓷球,以減少其離心力和陀螺力矩;釆用空心強(qiáng)冷技術(shù)來減少高速滾珠絲槓運(yùn)轉(zhuǎn)時由于摩擦產(chǎn)生溫升而造成的絲槓熱變形。近幾年來,用直線電機(jī)驅(qū)動的高速進(jìn)給系統(tǒng)問世,這種進(jìn)給方式取消了從電動機(jī)到工作臺溜板之間的一切中間機(jī)械傳動環(huán)節(jié),實現(xiàn)了機(jī)床進(jìn)給系統(tǒng)的零傳動。由于直線電機(jī)沒有任何旋轉(zhuǎn)元件,不受離心力的作用,可以大大提高進(jìn)給速度。直線電機(jī)的另一大優(yōu)點是行程不受限制。直線電機(jī)的次極是一段一段連續(xù)鋪在機(jī)床的床身上。次極鋪到哪里,初極工作臺就可運(yùn)動到哪里,而且對整個進(jìn)給系統(tǒng)的剛度沒有任何影響。釆用高速絲槓或直線電機(jī),能夠大大提高機(jī)床進(jìn)給系統(tǒng)的快速響應(yīng)。直線電機(jī)最高加速度可達(dá)2-10G(G為重力加速度),最大進(jìn)給速度可達(dá)60-200m/min或更高。2002年舉世矚目的上海浦東磁懸浮列車工程中的磁浮軌道鋼梁加工,釆用沈陽機(jī)床控股有限公司集團(tuán)中捷友誼公司廠生產(chǎn)的超長進(jìn)給系統(tǒng)高速大型加工中心實現(xiàn)。該機(jī)床的進(jìn)給系統(tǒng)為直線導(dǎo)軌和齒輪齒條傳動,工作臺最大進(jìn)給速度60m/min,快速行程100m/min,加速度2g,主軸最高轉(zhuǎn)速20000r/min,主電機(jī)功率80kW。其X軸的行程長達(dá)30m,切削25m長的磁浮軌道鋼梁誤差小于0.15mm,為磁懸浮列車工程的順利竣工提供了有力的技術(shù)保證。此外,機(jī)床的運(yùn)動性能也將直接影響加工效率和加工精度。在模具及自由曲面的高速切削加工中,主要釆用小切深大進(jìn)給的加工方法。要求機(jī)床在大進(jìn)給速度條件下,應(yīng)具有高精度定位功能和高精度插補(bǔ)功能,特別是圓弧高精度插補(bǔ)。圓弧加工是釆用立銑刀或螺紋刀具加工零部件或模具時,必不可少的加工方法。刀具材料的發(fā)展:高速切削技術(shù)發(fā)展的歷史,也就是刀具材料不斷進(jìn)步的歷史。高速切削的代表性刀具材料是立方氮化硼(CBN)。端面銑削使用CBN刀具時,其切削速度可高達(dá)5000m/min,主要用于灰口鑄鐵的切削加工。聚晶金剛石(PCD)刀具被稱之為21世紀(jì)的刀具,它特別適用于切削含有SiO2的鋁合金材料,而這種金屬材料重量輕、強(qiáng)度高,廣泛地應(yīng)用于汽車、摩托車發(fā)動機(jī)、電子裝置的殼體、底座等方面。目前,用聚晶金剛石刀具端面銑削鋁合金時,5000m/min的切削速度已達(dá)到實用化水平,此外陶瓷刀具也適用于灰口鑄鐵的高速切削加工;涂層刀具:CBN和金剛石刀具盡管具有很好的高速切削性能,但成本相對較高。釆用涂層技術(shù)能夠使切削刀具既價格低廉,又具有優(yōu)異性能,可有效降低加工成本?,F(xiàn)在高速加工用的立銑刀,大都釆用TiAIN系的復(fù)合多層涂鍍技術(shù)進(jìn)行處理,如目前在對鋁合金或有色金屬材料進(jìn)行干式切削時,DLC(Diamond Like Carbon)涂層刀具就受到極大的關(guān)注,預(yù)計其巿場前景十分可觀;刀具夾持系統(tǒng):刀具的夾持系統(tǒng)是支撐高速切削的重要技術(shù),目前使用最為廣泛的是兩面夾緊式工具系統(tǒng)。已作為商品正式投放巿場的兩面夾緊式工具系統(tǒng)主要有:HSK、KM、Bigplus、NC5、AHO等系統(tǒng)。 在高速切削的情況下,刀具與夾具回轉(zhuǎn)平衡性能的優(yōu)劣,不僅影響加工精度和刀具壽命,而且也會影響機(jī)床的使用壽命。因此,在選擇工具系統(tǒng)時,應(yīng)盡量選用平衡性能良好的產(chǎn)品。高速加工的切削速度為常規(guī)切速的10倍左右。為了使刀具每齒進(jìn)給量基本保持不變,以保證零件的加工精度、表面質(zhì)量和刀具的耐用度,則進(jìn)給量也必須相應(yīng)提高10倍左右,達(dá)到60m/min以上,有的甚至高達(dá)120m/min。因此,高速切削加工通常是釆用高轉(zhuǎn)速、大進(jìn)給和小切深的切削工藝參數(shù)。由于高速切削的切削余量往往很小,所形成的切屑很薄很輕,把切削時產(chǎn)生的熱量很快帶走;若釆用全新耐熱性更好的刀具材料和涂層,釆用干切削工藝也是高速切削加工的理想工藝方案。用高速加工中心組成高效率的柔性生產(chǎn)線(FTL或FML),具有小型化、柔性突出以及易于變更加工內(nèi)容等顯著特點。圖2為上汽集團(tuán)某發(fā)動機(jī)公司利用該生產(chǎn)線加工發(fā)動機(jī)機(jī)體、汽缸蓋、濾清器座等工件的實例。為了盡快適應(yīng)新車型的需要,汽車車身覆蓋件模具和樹脂防沖擋的成形模具等,均必須縮短制作周期和降低生產(chǎn)成本,因此,必須下大力推進(jìn)模具生產(chǎn)高速化的進(jìn)程。上汽集團(tuán)所屬各公司認(rèn)為:與過去的精加工相比,進(jìn)一步實現(xiàn)高精度化;同時必須滿足表面粗糙度、彎曲度的精度要求,為此應(yīng)施以適當(dāng)?shù)氖止ぞ藜庸?,由于切削速度的極大提高,與過去的精加工工序相比,加工周期應(yīng)大幅度縮短。為了發(fā)揮以車削加工中心和鏜銑類加工中心為代表的高速切削加工技術(shù)和自動換刀功能的優(yōu)勢,提高加工效率,對復(fù)雜零件的加工應(yīng)盡可能釆用集中工序的原則,即要求在一次裝夾中實現(xiàn)多道工序的集中加工,淡化傳統(tǒng)的車、銑、鏜、螺紋加工等不同切削工藝的界限,充分發(fā)揮設(shè)備和刀具的高速切削功能,是當(dāng)前提高數(shù)控機(jī)床效率、加快產(chǎn)品開發(fā)的有效途徑。為此,對刀具提出了多功能的新要求,要求一種刀具能完成零件不同工序的加工,減少換刀次數(shù),節(jié)省換刀時間,以減少刀具的數(shù)量和庫存量,有利于管理和降低制造成本。較常用的有多功能車刀、銑刀、鏜銑刀、鉆銑刀、鉆銑螺紋倒角等刀具。與此同時,在批量生產(chǎn)線上,使用針對工藝需要開發(fā)的專用刀具、復(fù)合刀具或智能刀具,可以提高加工效率和精度,減少投資。在高速切削條件下,有的專用刀具可將零件的加工時間降至原來的1/10以下,效果十分顯著。高速切削具有相當(dāng)多的好處,例如:有大量材料需要切除的工件,具有超細(xì)、薄結(jié)構(gòu)的工件,傳統(tǒng)上需要花相當(dāng)長的機(jī)動工時加工的工件以及設(shè)計變更快速、產(chǎn)品周期短的工件,均能顯示出高速切削所帶來的優(yōu)點。
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