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XK718立式數(shù)控床身銑床 工作臺面（寬×長） 900×1800mm 主軸最高轉(zhuǎn)速 6000轉(zhuǎn) XK718立式數(shù)控床身銑床 XK718立式數(shù)控床身銑床，是我廠消化吸收國外最新技術而生產(chǎn)的高性能、高精度、高可靠性的機床。具備在重負荷切削及斷續(xù)切削條件下保持良好的精度和剛性，具備高可靠性和穩(wěn)定性的,是航天、航空、兵器、汽車等行業(yè)用于加工復雜零件和模具的理想裝備。 一、 機床主要技術參數(shù)： 項 目 單 位 規(guī) 格 工作臺 工作臺尺寸（寬×長） mm 900×1800 T型槽數(shù)量×槽寬×間距 mm 5×22×165 工作臺最大承重 kg 1600 行程 工作臺行程(X軸) mm 1600 滑鞍行程 (Y軸) mm 900 主軸箱行程(Z軸) mm 680 主 軸 主軸錐孔 BT 50 主軸轉(zhuǎn)速 r/min 20～6000 主軸電機功率 kw 18.5/22 主軸最大扭矩 N.m 140 主軸端面至工作臺距離 mm 160～840 主軸中心至立柱距離 mm 950 進給 切削進給速度 mm /min 1～4000 快速移動速度 mm /min 10000 X/Y/Z進給電機額定扭矩 N.m 30/40/30 冷卻 刀具冷卻泵流量 L/min 66 刀具冷卻泵壓力揚程 米 15 精 度 定位精度 mm ±0.010 重復定位精度 mm ±0.008 其他 機床高度尺寸 mm 3173 機床地基面積 mm 6150×3930 機床總重量 kg 18000kg 機床總功率 Kw 50 二、 機床結(jié)構(gòu)及性能說明： 1. 主軸部件 1) 整體精密主軸部件選用臺灣旭泰主軸制造公司的產(chǎn)品，主軸具有卸荷結(jié)構(gòu)，保護主軸軸承免受外力沖擊，保證了主軸的高精度，延長了主軸的使用壽命，具有高的剛性和抗震性； 2) 主軸軸承采用德國FAG公司的高精度精密主軸軸承，回轉(zhuǎn)精度高，精度的保持性長久； 3) 主軸采用18.5/22KW主軸電機驅(qū)動，主軸恒功率范圍寬，扭矩大，轉(zhuǎn)速高，最高轉(zhuǎn)速可達6000RPM； 4) 配置主軸恒溫油冷卻箱，保證了主軸的熱穩(wěn)定性及高精度。 2. 立柱、床身及工作臺部件 1) 機床的床身、立柱、主軸箱等重要結(jié)構(gòu)件均采用高強度鑄鐵，鑄件經(jīng)二次回火，抗震性能好，以滿足工件的強力切削及精度要求； 2) 立柱、床身采用加厚筋板布局，床身采用寬距四導軌布局，減小了受力變形，滿足重載運動及切削； 3) 三向?qū)к壘捎镁匦位瑒訉拰к壐苯Y(jié)構(gòu)，導軌面經(jīng)高頻淬硬和磨削，配合采用聚四氟乙烯貼塑的導軌，提高了主軸箱與立柱及工作臺的連接剛性，確保了加工的動態(tài)精度； 3. 傳動系統(tǒng) 1) X、Y、Z直線坐標軸由AC伺服電機驅(qū)動，并通過德國KTR聯(lián)軸器直接與滾珠絲杠連接，從而消除了傳動鏈的間隙，提高了位置精度； 2) X、Y、Z直線坐標軸均采用經(jīng)預加載荷的高精度雙螺母滾珠絲杠，該絲杠兩端的支撐為高精度成組軸承，形成雙推結(jié)構(gòu)配置，且對滾珠絲杠進行預應力拉伸安裝，從而提高了進給傳動系統(tǒng)的剛度并避免快速移動帶來的熱變形，定位精度高； 4. 主軸箱垂向平衡系統(tǒng) 采用重錘平衡及園柱導向方式，確保了Z向運動的平穩(wěn)性； 5. 氣壓系統(tǒng) 液源三大件、氣閥、氣缸采用合資的上海新益氣動元件公司的產(chǎn)品，提高了可靠性； 6. 潤滑系統(tǒng) 1) 配置廣東日華（合資）中央自動潤滑系統(tǒng)，對所有滑動導軌面、滾動導軌面和滾動絲桿部件，通過定量分配潤滑系統(tǒng)進行自動供油潤滑 2) 各進給系統(tǒng)的滾動軸承和其他部件中的滾動軸承用3#特種潤滑脂進行潤滑。 7. 冷卻及切屑沖刷系統(tǒng) 配置臺灣高壓多級冷卻泵,配備大流量冷卻切削液站，即能充分冷卻加工中的刀具和工件，又能對切屑起沖刷作用。 8. 排屑系統(tǒng) 機床配置自動鏈式排屑器及集屑小車，分離切屑及切削液。 9. 電柜空調(diào) 為了保證該機床具有高的可靠性，選用了高品質(zhì)的電氣元件，采用防護等級達IP54以上的電柜，并裝電柜空調(diào)，對電柜降溫、除濕。 10. 防濺全防護罩 本機床具有防濺全防護罩，具有開門暫停加工運行保護功能，并在操作面板上安裝功能起用選擇開關。 11. 人機通訊： 機床配有便攜式電子手輪，RS232通訊接口，5米長電纜，實現(xiàn)機床與計算機之間的數(shù)據(jù)傳輸，用儲存卡通過PCMCIA接口進行DNC運行。 12. 機床工作環(huán)境 1) 環(huán)境溫度：0～40℃ 2) 電 源：380V±10%，三相50HZ±1%， 總?cè)萘?0KVA 3) 相對濕度：≤90% 4) 主軸松刀氣缸壓縮空氣：6bar， 排量0.5m3/min 三、 機床所配數(shù)控系統(tǒng)的說明： CNC數(shù)控系統(tǒng)配置FANUC系統(tǒng)，主要功能如下： 1． 10.4″LCD顯示器，原裝操作面板，界面具有中文顯示功能； 2． 三軸聯(lián)動； 3． 刀具軌跡圖形顯示功能； 4． 具備刀具半徑和長度補償、刀具參數(shù)數(shù)據(jù)管理功能； 5． 坐標值公英制編程及絕對/相對增量編程功能； 6． 后臺編程功能； 7． 故障自診斷、錯誤報警顯示功能； 8． 絲杠螺距誤差補償功能； 9． 反向間隙補償功能； 10． 具備銑、鉆、鉸、攻、鏜等固定循環(huán)G代碼功能； 11． 機床所配置的其他標準功能的表述見FANUC系統(tǒng)樣本。 四、 機床主要配套件的說明： 序號 名 稱 配套廠商 1 數(shù)控系統(tǒng)FANUC 0i-MC 北京FANUC公司 2 主軸交流伺服驅(qū)動系統(tǒng) 北京FANUC公司 3 進給交流伺服驅(qū)動系統(tǒng) 北京FANUC公司 4 精密主軸部件 臺灣旭泰主軸公司 5 主軸軸承 德國FAG公司 6 滾珠絲杠 臺灣銀泰公司 7 主軸松刀機構(gòu) 臺灣豪澄公司 8 滾珠絲杠軸承 日本NSK公司 9 主軸恒溫油冷凍箱 上海永翼機械有限公司 10 自動潤滑系統(tǒng) 廣東日華（合資） 11 數(shù)控聯(lián)軸器 臺灣靖泰有限公司 12 電纜輸送鏈 上海江川機件廠 13 同步齒形帶 日本UNITTA公司 14 主要電氣元件 法國施耐德公司 15 氣源三大件、氣閥氣缸 新益氣動元件(合資)公司 16 壓力開關 德國REXROTH 17 導軌不銹鋼防護罩 上海萬銀機械制造有限公司 18 全罩 上海振飛機床附件公司 19 電柜空調(diào) 上海永翼機械有限公司 五、 驗收標準 1) JB/T 8329.1-1999《數(shù)控床身銑床 精度檢驗條件》 2) 機床合格證明書 六、 機床隨機標準附件 1. 地腳螺釘 2. 機床墊圈 3. 沖屑氣槍一把 4. 鏈式自動排屑器 七、 機床可選配置（價格另計） 1 配德國ZF變速箱，實現(xiàn)主軸560M.N的大扭矩加工 4.4萬元 2 四軸聯(lián)動，煙臺TK13400E立臥數(shù)控轉(zhuǎn)臺 8.0萬元 第 5 頁 共 5 頁 XK718 Mechanical Design Abstract:A machine is a combination of mechanisms and other components which transforms, transmits. Examples are engines, turbines, vehicles, hoists, printing presses, washing machines, and movie cameras. Many of the principles and methods of design that apply to machines also apply to manufactured articles that are not true machines. The term "mechanical design" is used in a broader sense than "machine design" to include their design. the motion and structural aspects and the provisions for retention and enclosure are considerations in mechanical design. Applications occur in the field of mechanical engineering, and in other engineering fields as well, all of which require mechanical devices, such as switches, cams, valves, vessels, and mixers. Keywords: Mechanical Design mechanisms Design Process The Design Process Designing starts with a need real.Existing apparatus may need improvements in durability, efficiency, weight, speed, or cost. New apparatus may be needed to perform a function previously done by men, such as computation, assembly, or servicing. With the objective wholly or partly In the design preliminary stage, should allow to design the personnel fully to display the creativity, not each kind of restraint. Even if has had many impractical ideas, also can in the design early time, namely in front of the plan blueprint is corrected. Only then, only then does not send to stops up the innovation the mentality. Usually, must propose several sets of design proposals, then perform the comparison. Has the possibility very much in the plan which finally designated, has used certain not in plan some ideas which accepts. When the general shape and a few dimensions of the several components become apparent, analysis can begin in earnest. The analysis will have as its objective satisfactory or superior performance, plus safety and durability with minimum weight, and a competitive cost. Optimum proportions and dimensions will be sought for each critically loaded section, together with a balance between the strengths of the several components. Materials and their treatment will be chosen. These important objectives can be attained only by analysis based upon the principles of mechanics, such as those of static for reaction forces and for the optimum utilization of friction; of dynamics for inertia, acceleration, and energy; of elasticity and strength of materials for stress and deflection; of physical behavior of materials; and of fluid mechanics for lubrication and hydrodynamic drives. The analyses may be made by the same engineer who conceived the arrangement of mechanisms, or, in a large company, they may be made by a separate analysis division or research group. Design is a reiterative and cooperative process, whether done formally or informally, and the analyst can contribute to phases other than his own. Product design requires much research and development. Many Concepts of an idea must be studied, tried, and then either used or discarded. Although the content of each engineering problem is unique, the designers follow the similar process to solve the problems. Product liability suits designers and forced in material selection, using the best program. In the process of material, the most common problems for five (a) don't understand or not use about the latest application materials to the best information, (b) failed to foresee and consider the reasonable use material may (such as possible, designers should further forecast and consider due to improper use products. In recent years, many products liability in litigation, the use of products and hurt the plaintiff accused manufacturer, and won the decision), (c) of the materials used all or some of the data, data, especially when the uncertainty long-term performance data is so, (d) quality control method is not suitable and unproven, (e) by some completely incompetent persons choose materials. Through to the above five questions analysis, may obtain these questions is does not have the sufficient reason existence the conclusion. May for avoid these questions to these questions research analyses the appearance indicating the direction. Although uses the best choice of material method not to be able to avoid having the product responsibility lawsuit, designs the personnel and the industry carries on the choice of material according to the suitable procedure, may greatly reduce the lawsuit the quantity. May see from the above discussion, the choice material people should to the material nature, the characteristic and the processing method have comprehensive and the basic understanding. Finally, a design based upon function, and a prototype may be built. If its tests are satisfactory, the initial design will undergo certain modifications that enable it to be manufactured in quantity at a lower cost. During subsequent years of manufacture and service, the design is likely to undergo changes as new ideas are conceived or as further analyses based upon tests and experience indicate alterations. Sales appeal. Some Rules for Design In this section it is suggested that, applied with a creative attitude, analyses can lead to important improvements and to the conception and perfection of alternate, perhaps more functional, economical, and durable products. To stimulate creative thought, the following rules are suggested for the designer and analyst. The first six rules are particularly applicable for the analyst. 1. A creative use of need of physical properties and control process. 2. Recognize functional loads and their significance. 3. Anticipate unintentional loads. 4. Devise more favorable loading conditions. 5. Provide for favorable stress distribution and stiffness with minimum weight. 6. Use basic equations to proportion and optimize dimensions. 7. Choose materials for a combination of properties. 8. Select carefully, stock and integral components. 9. Modify a functional design to fit the manufacturing process and reduce cost. 10. Provide for accurate location and noninterference of parts in assembly. Machinery design covers the following contents. 1. Provides an introduction to the design process , problem formulation ,safety factors. 2. Reviews the material properties and static and dynamic loading analysis , Including beam , vibration and impact loading. 3. Reviews the fundamentals of stress and defection analysis. 4. Introduces fatigue-failure theory with the emphasis on stress-life approaches to high-cycle fatigue design, which is commonly used in the design of rotation machinery. 5. Discusses thoroughly the phenomena of wear mechanisms, surface contact stresses ,and surface fatigue. 6. Investigates shaft design using the fatigue-analysis techniques. 7. Discusses fluid-film and rolling-element bearing theory and application 8. Gives a thorough introduction to the kinematics, design and stress analysis of spur gears , and a simple introduction to helical ,bevel ,and worm gearing. 9. Discusses spring design including compression ,extension and torsion springs. 10. Deals with screws and fasteners including power screw and preload fasteners. 11. Introduces the design and specification of disk and drum clutches and brakes. Machine Design The complete design of a machine is a complex process. The machine design is a creative work. Project engineer not only must have the creativity in the work, but also must in aspect and so on mechanical drawing, kinematics, engineerig material, materials mechanics and machine manufacture technology has the deep elementary knowledge. One of the first steps in the design of any product is to select the material from which each part is to be made. Numerous materials are available to today's designers. The function of the product, its appearance, the cost of the material, and the cost of fabrication are important in making a selection. A careful evaluation of the properties of a. material must be made prior to any calculations. Careful calculations are necessary to ensure the validity of a design. In case of any part failures, it is desirable to know what was done in originally designing the defective components. The checking of calculations (and drawing dimensions) is of utmost importance. The misplacement of one decimal point can ruin an otherwise acceptable project. All aspects of design work should be checked and rechecked. The computer is a tool helpful to mechanical designers to lighten tedious calculations, and provide extended analysis of available data. Interactive systems, based on computer capabilities, have made possible the concepts of computer aided design (CAD) and computer-aided manufacturing (CAM). How does the psychologist frequently discuss causes the machine which the people adapts them to operate. Designs personnel''s basic responsibility is diligently causes the machine to adapt the people. This certainly is not an easy work, because certainly does not have to all people to say in fact all is the most superior operating area and the operating process. Another important question, project engineer must be able to carry on the exchange and the consultation with other concerned personnel. In the initial stage, designs the personnel to have to carry on the exchange and the consultation on the preliminary design with the administrative personnel, and is approved. This generally is through the oral discussion, the schematic diagram and the writing material carries on. If front sues, the machine design goal is the production can meet the human need the product. The invention, the discovery and technical knowledge itself certainly not necessarily can bring the advantage to the humanity, only has when they are applied can produce on the product the benefit. Thus, should realize to carries on before the design in a specific product, must first determine whether the people do need this kind of product Must regard as the machine design is the machine design personnel carries on using creative ability the product design, the system analysis and a formulation product manufacture technology good opportunity. Grasps the project elementary knowledge to have to memorize some data and the formula is more important than. The merely service data and the formula is insufficient to the completely decision which makes in a good design needs. On the other hand, should be earnest precisely carries on all operations. For example, even if places wrong a decimal point position, also can cause the correct design to turn wrongly. A good design personnel should dare to propose the new idea, moreover is willing to undertake the certain risk, when the new method is not suitable, use original method. Therefore, designs the personnel to have to have to have the patience, because spends the time and the endeavor certainly cannot guarantee brings successfully. A brand-new design, the request screen abandons obsoletely many, knows very well the method for the people. Because many person of conservativeness, does this certainly is not an easy matter. A mechanical designer should unceasingly explore the improvement existing product the method, should earnestly choose originally, the process confirmation principle of design in this process, with has not unified it after the confirmation new idea. EXTENDING BEARING LIFE Abstract：Nature works hard to destroy bearings, but their chances of survival can be improved by following a few simple guidelines. Extreme neglect in a bearing leads to overheating and possibly seizure or, at worst, an explosion. But even a failed bearing leaves clues as to what went wrong. After a little detective work, action can be taken to avoid a repeat performance. Keywords: bearings failures life Bearings fail for a number of reasons，but the most common are misapplication，contamination，improper lubricant，shipping or handling damage，and misalignment. The problem is often not difficult to diagnose because a failed bearing usually leaves telltale signs about what went wrong． However，while a postmortem yields good information，it is better to avoid the process altogether by specifying the bearing correctly in The first place．To do this，it is useful to review the manufacturers sizing guidelines and operating characteristics for the selected bearing. Equally critical is a study of requirements for noise, torque, and runout, as well as possible exposure to contaminants, hostile liquids, and temperature extremes. This can provide further clues as to whether a bearing is right for a job. 1 Why bearings fail About 40% of ball bearing failures are caused by contamination from dust, dirt, shavings, and corrosion. Contamination also causes torque and noise problems, and is often the result of improper handling or the application environment．Fortunately, a bearing failure caused by environment or handling contamination is preventable，and a simple visual examination can easily identify the cause． Conducting a postmortem il1ustrates what to look for on a failed or failing bearing．Then，understanding the mechanism behind the failure, such as brinelling or fatigue, helps eliminate the source of the problem. Brinelling is one type of bearing failure easily avoided by proper handing and assembly. It is characterized by indentations in the bearing raceway caused by shock loading－such as when a bearing is dropped-or incorrect assembly. Brinelling usually occurs when loads exceed the material yield point(350,000 psi in SAE 52100 chrome steel)．It may also be caused by improper assembly, Which places a load across the races．Raceway dents also produce noise，vibration，and increased torque. A similar defect is a pattern of elliptical dents caused by balls vibrating between raceways while the bearing is not turning．This problem is called false brinelling. It occurs on equipment in transit or that vibrates when not in operation. In addition, debris created by false brinelling acts like an abrasive, further contaminating the bearing. Unlike brinelling, false binelling is often indicated by a reddish color from fretting corrosion in the lubricant. False brinelling is prevented by eliminating vibration sources and keeping the bearing well lubricated. Isolation pads on the equipment or a separate foundation may be required to reduce environmental vibration. Also a light preload on the bearing helps keep the balls and raceway in tight contact. Preloading also helps prevent false brinelling during transit. Seizures can be caused by a lack of internal clearance, improper lubrication, or excessive loading. Before seizing, excessive, friction and heat softens the bearing steel. Overheated bearings often change color，usually to blue-black or straw colored．Friction also causes stress in the retainer，which can break and hasten bearing failure． Premature material fatigue is caused by a high load or excessive preload．When these conditions are unavoidable，bearing life should be carefully calculated so that a maintenance scheme can be worked out． Another solution for fighting premature fatigue is changing material．When standard bearing materials，such as 440C or SAE 52100，do not guarantee sufficient life，specialty materials can be recommended. In addition，when the problem is traced back to excessive loading，a higher capacity bearing or different configuration may be used． Creep is less common than premature fatigue．In bearings．it is caused by excessive clearance between bore and shaft that allows the bore to rotate on the shaft．Creep can be expensive because it causes damage to other components in addition to the bearing． 0ther more likely creep indicators are scratches，scuff marks，or discoloration to shaft and bore．To prevent creep damage，the bearing housing and shaft fittings should be visually checked． Misalignment is related to creep in that it is mounting related．If races are misaligned or cocked．The balls track in a noncircumferencial path．The problem is incorrect mounting or tolerancing，or insufficient squareness of the bearing mounting site．Misalignment of more than 1/4·can cause an early failure． Contaminated lubricant is often more difficult to detect than misalignment or creep．Contamination shows as premature wear．Solid contaminants become an abrasive in the lubricant．In addition。insufficient lubrication between ball and retainer wears and weakens the retainer．In this situation，lubrication is critical if the retainer is a fully machined type．Ribbon or crown retainers，in contrast，allow lubricants to more easily reach all surfaces． Rust is a form of moisture contamination and often indicates the wrong material for the application．If the material checks out for the job，the easiest way to prevent rust is to keep bearings in their packaging，until just before installation． 2 Avoiding failures The best way to handle bearing failures is to avoid them．This can be done in the selection process by recognizing critical performance characteristics．These include noise，starting and running torque，stiffness，nonrepetitive runout，and radial and axial play．In some applications, these items are so critical that specifying an ABEC level alone is not sufficient． Torque requirements are determined by the lubricant，retainer，raceway quality(roundness cross curvature and surface finish)，and whether seals or shields are used．Lubricant viscosity must be selected carefully because inappropriate lubricant，especially in miniature bearings，causes excessive torque．Also，different lubricants have varying noise characteristics that should be matched to the application. For example，greases produce more noise than oil． Nonrepetitive runout(NRR)occurs during rotation as a random eccentricity between the inner and outer races，much like a cam action．NRR can be caused by retainer tolerance or eccentricities of the raceways and balls．Unlike repetitive runout, no compensation can be made for NRR. NRR is reflected in the cost of the bearing．It is common in the industry to provide different bearing types and grades for specific applications．For example，a bearing with an NRR of less than 0.3um is used when minimal runout is needed，such as in disk—drive spindle motors．Similarly，machine—tool spindles tolerate only minimal deflections to maintain precision cuts． Consequently, bearings are manufactured with low NRR just for machine-tool applications． Contamination is unavoidable in many industrial products，and shields and seals are commonly used to protect bearings from dust and dirt．However，a perfect bearing seal is not possible because of the movement between inner and outer races．Consequently，lubrication migration and contamination are always problems． Once a bearing is contaminated, its lubricant deteriorates and operation becomes noisier．If it overheats，the bearing can seize．At the very least，contamination causes wear as it works between balls and the raceway，becoming imbedded in the races and acting as an abrasive between metal surfaces．Fending off dirt with seals and shields illustrates some methods for controlling contamination． Noise is as an indicator of bearing quality．Various noise grades have been developed to classify bearing performance capabilities． Noise analysis is done with an Anderonmeter, which is used for quality control in bearing production and also when failed bearings are returned for analysis. A transducer is attached to the outer ring and the inner race is turned at 1,800rpm on an air spindle. Noise is measured in andirons, which represent ball displacement in μm/rad. With experience, inspectors can identify the smallest flaw from their sound. Dust, for example, makes an irregular crackling. Ball scratches make a consistent popping and are the most difficult to identify. Inner-race damage is normally a constant high-pitched noise, while a damaged outer race makes an intermittent sound as it rotates. Bearing defects are further identified by their frequencies. Generally, defects are separated into low, medium, and high wavelengths. Defects are also referenced to the number of irregularities per revolution. Low-band noise is the effect of long-wavelength irregularities that occur about 1.6 to 10 times per revolution. These are caused by a variety of inconsistencies, such as pockets in the race. Detectable pockets are manufacturing flaws and result when the race is mounted too tightly in multiplejaw chucks. Medium-hand noise is characterized by irregularities that occur 10 to 60 times per revolution. It is caused by vibration in the grinding operation that produces balls and raceways. High-hand irregularities occur at 60 to 300 times per revolution and indicate closely spaced chatter marks or widely spaced, rough irregularities. Classifying bearings by their noise characteristics allows users to specify a noise grade in addition to the ABEC standards used by most manufacturers. ABEC defines physical tolerances such as bore, outer diameter, and runout. As the ABEC class number increase (from 3 to 9), tolerances are tightened. ABEC class, however, does not specify other bearing characteristics such as raceway quality, finish, or noise. Hence, a noise classification helps improve on the industry standard.