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譯文題目： Combination machine and General transformation multi-axis drilling machine drilling machine
組合機(jī)床和多軸鉆床
學(xué)生姓名： 學(xué) 號(hào)：
專 業(yè)：
所在學(xué)院：
指導(dǎo)教師：
職 稱：
20xx年 2月 27日
1 Combination machine
Combination machine tool is based on general parts, according to the specific shape of workpiece and the special components and fixture design of machining process, semi-automatic or automatic special machine.
1.1 The function of combination machine
Combination machine tools usually adopts the ways of multi-axial, more knives, more processes, multi-faceted or multistage .At the same time its production efficiency is several times or more higher than general machine. Due to the standardization and serialization of general parts, we can make flexible configuration according to need to shorten the cycle of design and manufacture. Therefore, the combination machine has the advantages of low cost and high efficiency, in large, mass production is widely used, and the automatic production line can be used to composite.
Combination machine tool is usually for general box or special shape of parts. During processing, workpiece rotate, generally by the tool and workpiece rotate movement and tools for the relative motion, to realize in drilling, reaming, economic hole, reaming, boring, cutting and milling, and the processing thread and fiber-end surface etc. Some combination machine adopts clamping workpiece machining head to rotate, feeding movement by the tool for, also can achieve some axisymmettical parts (such as the flywheel, automobile rear half axle, etc.) of the circle and the process.
1.2 Combination machine parts classification
General parts according to the function can be divided into power components and parts, transmission parts, supporting the control and auxiliary parts. Power components are provided for combination machine tools in the movement and moving parts. It contains Main motivation, cutting head and dynamic slide. Supporting components are installed power to slide into to institutions, cutting head or fixture, have side base, base, support, adjustable bracket, column and column base, etc.
Transmission parts is used to transport or spindle box to the processing of the main parts, workstation dividing rotating table, the annular dividing rotating table, drum and to-and-fro moving workbench, etc
Control components are used to control the machine parts, automatic working cycle is hydraulic pressure station and electrical cabinets and control console, etc. Auxiliary parts are lubrication device and cooling device and scraps discharge device etc.
1.3 The development of modular machine tool
In order to make the combination machine tools in small batch production, often applied to the structure, the application of group technology and craft of similar parts in a centralized modular machine tool, in order to improve the machining efficiency. This machine has two kinds of common, spindle box combination machine tools and turn tower combination machine tools.
Combination machine tools of future development will be more adopts adjustable motor transmission of ball screw, etc, to simplify structure and shorten the production beat, Using digital control system and spindle box, jig automatic replacement system, in order to improve the process adjustability, Flexible manufacturing systems and into.
2 General transformation multi-axis drilling machine drilling machine
In present, China's small medium enterprises product quality production efficiency needs new increase. Processing means far from sufficient. Many small medium enterprises actual technical state equipment improvements, through strengthening its own development. Common drilling single-axis machine tools, multi-axis box drill, transformation multi-axis drilling, we could greatly shorten processing time, improve production efficiency.
2.1 Application multi-axis machining :
According general machine tools average cutting time rarely exceeds 15% total working hours. Remaining time plug-in, loading work piece, exchange tools, operation tools, measurements, iron filings so forth. Although CNC machine tools can improve 85%, some cases, even high productivity, same components, necessarily lower than average machine. Different processing methods have different characteristics, drilling process, multi-axis machining small investment increase productivity through effective measures.
2.2Advantage Multi-axis machining
Although automatic multi-axis adjustable long line applications, only limited high-volume production. Even adjustable multi-axis head expanded still far from being able small, hole complex requirements. Industrial development, large complex multi-axis machining even more compelling. For example, large-scale nuclear power plants water-wall tube plate condenser has 15000 ψ20 holes, radial drilling machine processing, simply drilling holes countersink countersunk head 842.5hours, while also crossed hours 151.1 hours. However, 8-axis CNC machining floor drilling, drilling countersink holes 171.6 hours, crossed also simple, 1.9 hours. Therefore, numerical control two axis, so proper alignment tool processing location, combined multi-axis machining can only expand accuracy can greatly enhance work efficiency, easy quickly create original processing parts. Some analysis large high-speed diesel engine 30 kinds box-shaped rod-shaped parts more than 2,000 drilling operations, 40% could automatic replacement machines using two-axis spindle box, three-axis four-axis machining head, average can reduced 20% processing time. Machine Tool Exhibition 1975 also reflected multi-axis machining using more trend.
2.3Multi-axis machining equipment
Multi-axis machining can process different holes at the same time. This not only can shorten cutting time, improve accuracy, reduce clamping positioning time, but also don’t need to calculate coordinates during CNC machine processing, reduce character blocks ,simplify programming. Processing uses following equipment: radial drilling vertical drilling, upload multi-axis head, multi-axis drilling machine, multi-axis modular machine tool spindle box heart and automatic replacement machines
Now put forward some profiles.It contains two kinds of drive ways gear drive and universal joint couplings. Our familiar, the former, more efficient, simple structure, the other can adjust wheelbase. It contains two kinds in the way of structure. The former can’t adjust wheelbase, often use gear driving, only applies high-volume production. Adaptability expands its approval multi-axis adjustable head, certain range adjustable wheelbase. Mainly mounted universal. Two kinds of universal axis: alignment device spindle. Spindle mounted adjustable bracket adjustable bracket can T-shaped slot shell move, cylindrical spindle units. They have the same type template. Former applies small batch and regular holes （pore groups hole groups different diameter circle). Latter applies larger batch-type production, small quantities turns, rigid better pitch accuracy also high, different hole requires different template. Multi-axis head can vertical drilling-type radial drilling machine, press drill itself various functions work. Multi-axis processing methods, due drilling efficiency, range relationship between limited scope.
2.3.1Multi-axle box first multi-axis standard component. U.S. Sect’s standard gear boxes, multi-axle box, etc. designed adjustable multi-axle box. 32 kinds specifications, process size from 300X300 mm 600X1050mm, working-axis up power up 22.5 kilowatts. Romani factory adjustable multi-axle box easy gear should first location near its adjustable-axis move correct location. Therefore, structure changes certain extent change can reach more than ordinary axle box smaller pitch. According group processing first multi-axle, multi-axis machine tool medium volume production. get good results, need following points :(1) work piece clamping simple, enough coolant away iron filings. (2)fixture rigidity, processing, without deformation, dividing right position.（3）Two group knives use, another set adjustment, thereby reducing tool change downtime.（4）Quality tools monitor whether blunt tool, drill grinding （5）Dimensions can detect immediately when ultra-poor.
2.3.2Multi-axis drilling machine multi-axis machining orientation, power, feed, speed processing range. Displayed Paris Exhibition multi-axis drilling machine hydraulic multi-feed. Throughout its work, fast-forward through bad, workers enter iron filings all automatically. separate variable speed, so one group can adapt different pore size hole processing needs.
2.3.3Automatic replacement machine tool spindle box medium volume production recent years automatic replacement modular machine tool spindle box. automatic replacement spindle machine Automatic replacement rotary spindle machine tool spindle box several on-adjustable hanging spindle box. Vertical horizontal patch panel first series good working procedures, so corresponding spindle box processing station, location power connection tight, work piece spindle box below, upward mobility processing. When change processing object, exchange suspension spindle box, you can pass different processes different needs. Multi-axis machine tool turret Turret install more non-adjustable universal coupling spindle box, turret can automatically switch rotary table feed motion. Through rotary table can work piece surface. Because too big, so workers4-6. spindle box too large. When machining process more objects, size larger, should automatically replace machine tool spindle box fit, its simple structure.
2.3.4Automatic replacement modular machine tool spindle box contains automatic line and standard machine parts. Non-adjustable multi-axle box and power box are fixed at horizon base .When spindle rotates, entire case fix at fastening device board. Headstock rotation and feed movement work by the standard procedure. Headstock needs few seconds. Workpiece is clamped at hydraulic sub-degree rotary table so each surface will be processed. If rotary table is equipped with discharging device, we can conduct production automation. In Variable production system, using device and corresponding controller can obtain complete processing system.
8-axis CNC drill floor Large condenser water wall tube plate holes 15,000,which linked together support plate processing. Diameter 20mm, hole depth 180 mm. Using inside cooling pipe with twist drill ,5-7 bar pressure of coolant can directly reach cutting area. Durabler than regular twist drill, large quantity. 8-axis CNC machining floor can shorten processing time
2.3.5Trends of multi-axis machining: Multi-axis machining has high production efficiency, low investment production, short preparation cycle. With the development of China's CNC technology, multi-axis machining will increase, processing efficiency will improve.
1 組合機(jī)床
組合機(jī)床是以通用部件為基礎(chǔ),配以按工件特定形狀和加工工藝設(shè)計(jì)的專用部件和夾具,組成的半自動(dòng)或自動(dòng)專用機(jī)床。
1.1組合機(jī)床的作用
組合機(jī)床一般采用多軸、多刀、多工序、多面或多工位同時(shí)加工的方式,生產(chǎn)效率比通用機(jī)床高幾倍至幾十倍。由于通用部件已經(jīng)標(biāo)準(zhǔn)化和系列化,可根據(jù)需要靈活配置,能縮短設(shè)計(jì)和制造周期。因此,組合機(jī)床兼有低成本和高效率的優(yōu)點(diǎn),在大批、大量生產(chǎn)中得到廣泛應(yīng)用,并可用以組成自動(dòng)生產(chǎn)線。
組合機(jī)床一般用于加工箱體類或特殊形狀的零件，工作時(shí)工件一般不旋轉(zhuǎn),由刀具的旋轉(zhuǎn)運(yùn)動(dòng)和刀具與工件的相對進(jìn)給運(yùn)動(dòng),來實(shí)現(xiàn)鉆孔、擴(kuò)孔、锪孔、鉸孔、鏜孔、銑削平面、切削內(nèi)外螺紋以及加工外圓和端面等。有的組合機(jī)床采用車削頭夾持工件使之旋轉(zhuǎn),由刀具作進(jìn)給運(yùn)動(dòng),也可實(shí)現(xiàn)某些回轉(zhuǎn)體類零件(如飛輪、汽車后橋半軸等)的外圓和端面加工。
1.2組合機(jī)床部件分類
通用部件按功能可分為動(dòng)力部件、支承部件、輸送部件、控制部件和輔助部件五類。動(dòng)力部件是為組合機(jī)床提供主運(yùn)動(dòng)和進(jìn)給運(yùn)動(dòng)的部件。主要有動(dòng)力箱、切削頭和動(dòng)力滑臺(tái)。
支承部件是用以安裝動(dòng)力滑臺(tái)、帶有進(jìn)給機(jī)構(gòu)的切削頭或夾具等的部件,有側(cè)底座、中間底座、支架、可調(diào)支架、立柱和立柱底座等。
輸送部件是用以輸送工件或主軸箱至加工工位的部件,主要有分度回轉(zhuǎn)工作臺(tái)、環(huán)形分度回轉(zhuǎn)工作臺(tái)、分度鼓輪和往復(fù)移動(dòng)工作臺(tái)等。
控制部件是用以控制機(jī)床的自動(dòng)工作循環(huán)的部件,有液壓站、電氣柜和操縱臺(tái)等.輔助部件有潤滑裝置、冷卻裝置和排屑裝置等。
1.3組合機(jī)床的發(fā)展
為了使組合機(jī)床能在中小批量生產(chǎn)中得到應(yīng)用,往往需要應(yīng)用成組技術(shù),把結(jié)構(gòu)和工藝相似的零件集中在一臺(tái)組合機(jī)床上加工,以提高機(jī)床的利用率.這類機(jī)床常見的有兩種,可換主軸箱式組合機(jī)床和轉(zhuǎn)塔式組合機(jī)床。
組合機(jī)床未來的發(fā)展將更多的采用調(diào)速電動(dòng)機(jī)和滾珠絲杠等傳動(dòng),以簡化結(jié)構(gòu)、縮短生產(chǎn)節(jié)拍；采用數(shù)字控制系統(tǒng)和主軸箱、夾具自動(dòng)更換系統(tǒng),以提高工藝可調(diào)性；以及納入柔性制造系統(tǒng)等。
2多軸鉆床
目前，我國中、小型企業(yè)的產(chǎn)品質(zhì)量和生產(chǎn)效率都需要有一個(gè)新的提高。但是加工手段卻遠(yuǎn)遠(yuǎn)不能滿足需要。許多中小型企業(yè)都結(jié)合自己的實(shí)際對設(shè)備的技術(shù)狀態(tài)進(jìn)行改進(jìn)，通過強(qiáng)化自身。以求自我發(fā)展。普通鉆床為單軸機(jī)床，但安裝上多軸箱就會(huì)成為多軸的鉆床，改造成多軸鉆床后，能大大地縮短加工時(shí)間，提高生產(chǎn)效率。
2.1多軸加工應(yīng)用
據(jù)統(tǒng)計(jì)，一般在車間中普通機(jī)床的平均切削時(shí)間很少超過全部工作時(shí)間的15%。其余時(shí)間是看圖、裝卸工件、調(diào)換刀具、操作機(jī)床、測量 以及清除鐵屑等等。使用 數(shù)控機(jī)床雖然能提高85%，但購置費(fèi)用大。某些情況下，即使生產(chǎn)率高，但加工相同的零件， 其成本不一定比普通機(jī)床低。故必須更多地縮短加工時(shí)間。不同的加工方法有不同的特點(diǎn)， 就鉆削加工而言，多軸加工是一種通過少量投資來提高生產(chǎn)率的有效措施。
2.2多軸加工優(yōu)勢
雖然不可調(diào)式多軸頭在自動(dòng)線中早有應(yīng)用，但只局限于大批量生產(chǎn)。即使采用可調(diào)式多軸頭擴(kuò)大了使用范圍，仍然遠(yuǎn)不能滿足批量小、孔型復(fù)雜的要求。尤其隨著工業(yè)的發(fā)展，大型復(fù)雜的多軸加工更是引人注目。例如原子能發(fā)電站中大型冷凝器水冷壁管板 有15000 個(gè)ψ20 孔，若以搖臂鉆床加工，單單鉆孔與锪沉頭孔就要842.5 小時(shí)，另外還要 劃線工時(shí)151.1 小時(shí)。但若以數(shù)控八軸落地鉆床加工，鉆锪孔只要171.6 小時(shí)，劃線也簡單,只要1.9 小時(shí),因此，利用數(shù)控控制的二個(gè)坐標(biāo)軸，使刀具正確地對準(zhǔn)加工位置，結(jié)合多軸 加工不但可以擴(kuò)大加工范圍，而且在提高精度的基礎(chǔ)上還能大大地提高工效，迅速地制造出 原來不易加工的零件。有人分析大型高速柴油機(jī)30 多個(gè)鉆孔操作中，有40%可以在自動(dòng)更換主軸箱機(jī)床中用二軸、三軸或四軸多軸頭加工，平均可減少20% 的加工時(shí)間。1975 年法國巴黎機(jī)床展覽會(huì)也反映了多軸加工的使用愈來愈多這一趨勢。
2.3多軸加工的設(shè)備
多軸加工是在一次進(jìn)給中同時(shí)加工許多孔個(gè)孔。這不僅縮短切削時(shí)間，提高精度，減少裝夾或定位時(shí)間，并且在數(shù)控機(jī)床中不必計(jì)算坐標(biāo)，減少字塊數(shù)而簡化編程。它可以采用以下一些設(shè)備進(jìn)行加工:立鉆或搖臂鉆上裝多軸頭、多軸鉆床、多軸組合機(jī)床心及自動(dòng)更換主軸箱機(jī)床。
現(xiàn)在就這方面的現(xiàn)狀作一簡介:從傳動(dòng)方式來說主要有齒輪傳動(dòng)與萬向聯(lián)軸節(jié)傳動(dòng)二種。這是大家所熟悉的。前者效率較高，結(jié)構(gòu)簡單，后者易于調(diào)整軸距。從結(jié)構(gòu)來說有不可調(diào)式與可調(diào)式二種。前者軸不能改變，多采用齒輪傳動(dòng)，僅適用于大批量生產(chǎn)。為了擴(kuò)大其適應(yīng)性，發(fā)展了可調(diào)式多軸頭，在一定范圍內(nèi)可調(diào)整軸距。它主要裝在有二種萬向。(1)萬向軸式也有二種: 具有對準(zhǔn)裝置的主軸。主軸裝在可調(diào)支架中，而可調(diào)支架能在殼體的T 形槽中移動(dòng)，并能在對準(zhǔn)的位置以螺栓固定。(2)具有公差的圓柱形主軸套。主軸套固定在與式件孔型相同的模板中。前一種適用于批量小且孔組是規(guī)則分布的工件(如孔組分布在不同直徑的圓周上)。后一種適用于批量較大式中小批量的輪番生產(chǎn)中，剛性較好，孔距精度亦高，但不同孔型需要不同的模板。多軸頭可以裝在立鉆式搖臂鉆床上，按鉆床本身所具有的各種功能進(jìn)行工作。這種多軸加工方法,由于鉆孔效率、加工范圍及精度的關(guān)系，使用范圍有限。
2.3.1多軸箱:也像多軸頭那樣作為標(biāo)準(zhǔn)部件生產(chǎn)。美國Secto公司標(biāo)準(zhǔn)齒輪箱、多軸箱等設(shè)計(jì)的不可調(diào)式多軸箱。有32 種規(guī)格，加工面積從300X300 毫米到600X1050 毫米，工作軸達(dá) 60 根，動(dòng)力達(dá)22.5 千瓦。Romai 工廠生產(chǎn)的可調(diào)多軸箱調(diào)整方便，只要先把齒輪調(diào)整到接近孔型的位置，然后把與它聯(lián)接的可調(diào)軸移動(dòng)到正確的位置。因此，這種結(jié)構(gòu)只要改變模板，就能在一定范圍內(nèi)容易地改變孔型，并且可以達(dá)到比普通多軸箱更小的孔距。 根據(jù)成組加工原理使用多軸箱或多軸頭的組合機(jī)床很適用于大中批量生產(chǎn)。為了在加工中獲 得良好的效果，必需考慮以下數(shù)點(diǎn):(1)工件裝夾簡單，有足夠的冷卻液沖走鐵屑。(2)?夾具剛性好，加工時(shí)不形變，分度定位正確。(3)使用二組刀具的可能性，以便一組使用，另一組刃磨與調(diào)整，從而縮短換刀停機(jī)時(shí)間。(4)使用優(yōu)質(zhì)刀具，監(jiān)視刀具是否變鈍，鉆頭要機(jī)磨。(5)尺寸超差時(shí)能立即發(fā)現(xiàn)。
2.3.2多軸鉆床:這是一種能滿足多軸加工要求的鉆床。諸如導(dǎo)向、功率、進(jìn)給、轉(zhuǎn)速與加工范圍等。巴黎展覽會(huì)中展出的多軸鉆床多具液壓進(jìn)給。其整個(gè)工作循壞如快進(jìn)、工進(jìn)與清除鐵屑 等都是自動(dòng)進(jìn)行。值得注意的是，多數(shù)具有單獨(dú)的變速機(jī)構(gòu)，這樣可以適應(yīng)某一組孔中不同孔徑的加工需要。
2.3.3自動(dòng)更換主軸箱機(jī)床: 為了中小批量生產(chǎn)合理化的需要，最近幾年發(fā)展了自動(dòng)更換主軸箱組合機(jī)床。 自動(dòng)更換主軸機(jī)床自動(dòng)更換主軸機(jī)床頂部是回轉(zhuǎn)式主軸箱庫，掛有多個(gè)不可調(diào)主軸箱。縱橫配線盤予先編好工作程序，使相應(yīng)的主軸箱進(jìn)入加工工位，定位緊并與動(dòng)力聯(lián)接，然后裝有工件的工作臺(tái)轉(zhuǎn)動(dòng)到主軸箱下面，向上移動(dòng)進(jìn)行加工。當(dāng)變更加工對象時(shí)，只要調(diào)換懸掛的主軸箱，就能適應(yīng) 不同孔型與不同工序的需要。 多軸轉(zhuǎn)塔機(jī)床轉(zhuǎn)塔上裝置多個(gè)不可調(diào)或萬向聯(lián)軸節(jié)主軸箱，轉(zhuǎn)塔能自動(dòng)轉(zhuǎn)位，并對夾緊在回轉(zhuǎn)工作臺(tái)的工件作進(jìn)給運(yùn)動(dòng)。通過工作臺(tái)回轉(zhuǎn)，可以加工工件的多個(gè)面。因?yàn)檗D(zhuǎn)塔不宜過大，故它的工位 數(shù)一般不超過4-6 個(gè),且主軸箱也不宜過大。當(dāng)加工對象的工序較多、尺寸較大時(shí)，就不 如自動(dòng)更換主軸箱機(jī)床合適，但它的結(jié)構(gòu)簡單。
2.3.4輪輻六軸專用鉆床: 自動(dòng)更換主軸箱組合機(jī)床由自動(dòng)線或組合機(jī)床中的標(biāo)準(zhǔn)部件組成。不可調(diào)多軸箱與動(dòng)力箱按置在水平底座上，主軸箱庫轉(zhuǎn)動(dòng)時(shí)整個(gè)裝置緊固在進(jìn)給系統(tǒng)的溜板上。主軸箱庫轉(zhuǎn)動(dòng)與進(jìn)給動(dòng)作都按標(biāo)準(zhǔn)子程序工作。主軸箱時(shí)間為幾秒鐘。工件夾緊于液壓分度回轉(zhuǎn)工作臺(tái)，以便加工工件的各個(gè)面。如果回轉(zhuǎn)工作臺(tái)配以卸料裝置，就能夠流水生產(chǎn)自動(dòng)化。在可變生產(chǎn)系統(tǒng)中采用這種裝置，并配以相應(yīng)的控制器可以獲得完整的加工系統(tǒng)。 數(shù)控八軸落地鉆床 大型冷凝器的水冷壁管板的孔多達(dá)15000 個(gè)，它與支撐板聯(lián)接在一起加工。孔徑為20 毫米，孔深180 毫米。采用具有內(nèi)冷卻管道的麻花鉆，5-7 巴壓力的冷卻液可直接進(jìn)入切削區(qū)。它比普通麻花鉆耐用，且進(jìn)給量大。為了縮短加工時(shí)間，以8 軸數(shù)控落地加工。
2.3.5多軸加工趨勢:多軸加工生產(chǎn)效率高，投資少，生產(chǎn)準(zhǔn)備周期短，產(chǎn)品改型時(shí)設(shè)備損失少。而且隨著我國數(shù)控技術(shù)的發(fā)展，多軸加工的范圍一定會(huì)愈來愈廣，加工效率也會(huì)不斷提高。