柱塞泵體零件加工專用機(jī)床設(shè)計(jì)[加工均布7個(gè)孔]
柱塞泵體零件加工專用機(jī)床設(shè)計(jì)[加工均布7個(gè)孔],加工均布7個(gè)孔,柱塞泵體零件加工專用機(jī)床設(shè)計(jì)[加工均布7個(gè)孔],柱塞,零件,加工,專用,機(jī)床,設(shè)計(jì)
附錄：
外文資料與中文翻譯
外文資料：
The Development Of Machine Tool Technology
and automatic line
Machine Tool and Machine Tool Automatic Line is a dedicated and efficient automation technology and equipment, at present, it is still a high-volume machinery to achieve efficient, high quality and economical production of key equipment, which is widely used in automobiles, tractors, diesel and compressed machines and many other industrial production. In particular, the automotive industry, is a combination of machine tools and automatic lines largest user. Such as the German Volkswagen plant in Salzgitter engine plant, used in the early 90's metal-cutting machine tool is automatic line (60%), machines (20%) and processing center (20%). Clearly, the mass production of the machinery industry, a lot of used equipment is a combination of machine and automatic line. Therefore, combination machine tool and its automatic line level of technical performance and integrated automation, the large extent determines these industries, a product of the production efficiency, product quality and business organization of production Jiegou, Yezai determine a company's products competitiveness.
現(xiàn)代組合機(jī)床和自動(dòng)線作為機(jī)電一體化產(chǎn)品，它是控制、驅(qū)動(dòng)、測(cè)量、監(jiān)控、刀具和機(jī)械組件等技術(shù)的綜合?反映。 Combination of machine tools and automatic lines of modern mechatronic product as it is to control, drive, measure, monitor, tool and machinery components such as a comprehensive reflection of technology. 近20年來，這些技術(shù)有長(zhǎng)足進(jìn)步，同時(shí)作為組合機(jī)床主要用戶的汽車和內(nèi)燃機(jī)等行業(yè)也有很大的變化，其?產(chǎn)品市場(chǎng)壽命不斷縮短，品種日益增多且質(zhì)量不斷提高。 The past 20 years, these technologies have made considerable progress, as well as a combination of machine tool user industries such as automobile and internal combustion engines, there are big changes in the market life of their products continue to shorten, increasing variety and quality improved. 這些因素有力地推動(dòng)和激勵(lì)了組合機(jī)床和自動(dòng)線技術(shù)的?不斷發(fā)展。 These factors effectively promote and encourage the combination of machine and automatic line technology continues to evolve.
1 A combination of varieties of key development tools
在組合機(jī)床這類專用機(jī)床中，回轉(zhuǎn)式多工位組合機(jī)床(圖2)和自動(dòng)線占有很重要的地位。 In the combination of these special purpose machine tools, the rotary multi-station machines (Figure 2) and automatic line plays an important role. 因?yàn)檫@?兩類機(jī)床可以把工件的許多加工工序分配到多個(gè)加工工位上，并同時(shí)能從多個(gè)方向?qū)ぜ膸讉€(gè)面進(jìn)行加工，此?外，還可以通過轉(zhuǎn)位夾具(在回轉(zhuǎn)工作臺(tái)機(jī)床上)或通過轉(zhuǎn)位、翻轉(zhuǎn)裝置(在自動(dòng)線上)實(shí)現(xiàn)工件的五面加工或全部?加工，因而具有很高的自動(dòng)化程度和生產(chǎn)效率，被汽車、摩托車和壓縮機(jī)等工業(yè)部門所采用。 Because these two types of machine parts can be assigned to many manufacturing processes on multiple processing station, and also from several different directions on the workpiece surface processing, In addition, you can also switch to digital clamp (work in rotation machine tool) or by translocation, flip device (in the automatic line) to achieve a five-face machining parts or all of processing, so they have a high degree of automation and production efficiency, a car, motorcycle and compressors and other industrial sectors used.
根據(jù)有關(guān)統(tǒng)計(jì)資料，德國(guó)在1990～1992年期間，回轉(zhuǎn)式多工位組合機(jī)床和自動(dòng)線的產(chǎn)量約各占組合機(jī)床總數(shù)?的50%左右。According to statistics, Germany in 1990 and 1992, combined multistation rotary machine and automatic production lines around each combination of machine tool about 50% of the total.
應(yīng)指出，回轉(zhuǎn)式多工位組合機(jī)床實(shí)際上是一種特殊型式的小型自動(dòng)線，適合于加工輪廓尺寸≤250mm的中小?件。 Be noted that multi-station rotary machine is actually a combination of special types of small automatic lines for processing outline size of ≤ 250mm of small pieces. Compared with the automatic line, in the processing of the same parts of the case, the combination of multi-station rotary machine tool operations share is about a small area than the automated line 2 / 3.
2、 beat time to further reduce the automatic line
目前，以大批量生產(chǎn)為特征的轎車和輕型載貨車，其發(fā)動(dòng)機(jī)的年產(chǎn)量通常為60萬(wàn)臺(tái)左右，實(shí)現(xiàn)這樣大的批量?生產(chǎn)，回轉(zhuǎn)式多工位組合機(jī)床和自動(dòng)線在三班運(yùn)行的情況下，其節(jié)拍時(shí)間一般為20～30秒，當(dāng)零件生產(chǎn)批量更大?時(shí)，機(jī)床的節(jié)拍時(shí)間還要更短些(表1)。
At present, characterized by mass production of cars and light trucks, the engine's output is usually around 60 million units, to achieve such a large volume production, multi-position rotary combination of machine tools and automatic lines in the case of three-shift operation , the tact time is generally 20 to 30 seconds, when the greater part of production volume, the machine cycle times should be shorter (Table 1). In the 70's, automatic line to achieve such a short beat, often used side by side duplex or set the two-lane approach, that is, determining the automatic line of the beat, the longest processing operation processes through the same process in parallel two station, if more restrictive process, then the same through the use of two automatic lines to balance the automatic line system processing rhythm. 顯然，這樣就要增加設(shè)備投資和作業(yè)面積。 Apparently, this would increase the investment in equipment and operating area.
縮短基本時(shí)間的主要途徑是采用新的刀具材料和新穎刀具，以通過提高切削速度和進(jìn)給速度來縮短基本時(shí)間。 The main way to shorten the basic time is the introduction of new materials and novel tool tool to enhance the cutting speed and feed through to shorten the basic time rate. ?例如，德國(guó)大眾汽車廠在加工鋁合金缸蓋燃燒室側(cè)面時(shí)，采用PCD銑刀，銑削速度高達(dá)3075m/min，進(jìn)給速度達(dá)?3600mm/min；又如，在鏜削灰鑄鐵缸體的缸孔時(shí)，采用裝有三個(gè)可轉(zhuǎn)位CBN刀片的新穎鏜刀頭，切削速度達(dá)?800m/min，進(jìn)給速度為1500mm/min，加工深度為146mm的缸孔，其實(shí)際加工時(shí)間僅為5.8s，比傳統(tǒng)加工工藝可縮?短2/3的加工時(shí)間。 For example, the German Volkswagen plant in the processing of aluminum alloy cylinder head combustion chamber side, the use of PCD milling cutters, milling speeds of up to 3075m/min, feed speed 3600mm/min; another example, in boring gray cast iron cylinder block of the cylinder bore When used with three indexable boring head new CBN inserts, cutting speed up to 800m/min, feed rate 1500mm/min, processing depth of 146mm the cylinder bore, the actual processing time of only 5.8s, compared traditional processing process can be shortened 2 / 3 of the processing time.
縮短輔助時(shí)間主要是縮短包括工件輸送、加工模塊快速引進(jìn)以及加工模塊由快進(jìn)轉(zhuǎn)換為工進(jìn)后至刀具切入工件?所花的時(shí)間。 Reduce the auxiliary time is shortened, including parts delivery, processing and rapid introduction of the module and processing module is converted to work by the fast-forward to the tool after the cut into the workpiece into the time spent. To shorten this part of the air travel time, generally used to improve workpiece (workpiece direct transmission) or the accompanying fixtures and processing module transmission speed fast speed. 目前，隨行夾具的輸送速度可達(dá)60m/min或更高些，加工模塊快速移動(dòng)速度達(dá)40m/min。 At present, the accompanying transmission speeds up to 60m/min fixture or later some, fast-moving speed of processing modules 40m/min. At present, the accompanying high-speed conveyor fixture common control with electro-hydraulic proportional valve or cyclonical driven conveyer. The late 70s, Honsberg body in its processing of automatic transmission line on the use of electro-hydraulic proportional valve controlled delivery device. Movement of the conveyor curves. As the electro-hydraulic proportional valve control system has a good start and braking performance, and the system structure is simple, so far, this conveyor being used by many automated line.
3、the rapid progress of flexible combination machine
十多年來，作為組合機(jī)床重要用戶的汽車工業(yè)，為迎合人們個(gè)性化需求，汽車變型品種日益增多(圖5)，以多?品種展開競(jìng)爭(zhēng)已成為汽車市場(chǎng)競(jìng)爭(zhēng)的特點(diǎn)之一，這使組合機(jī)床制造業(yè)面臨著變型多品種生產(chǎn)的挑戰(zhàn)。 10 years, as the combination of machine tools important to the user's automobile industry, to meet the individual needs of people, cars become growing varieties (Figure 5), a multi-species competition has become one of the characteristics of market competition car, making Machine Tool Manufacturing industry faces many varieties of variant production challenges. 為適應(yīng)多品?種生產(chǎn)，傳統(tǒng)以加工單一品種的剛性組合機(jī)床和自動(dòng)線必須提高其柔性。 To meet the multi-species production and processing of a single species of conventional machine tools and automatic lines rigid composite to improve its flexibility. In the 70's, numerical control system reliability has been greatly improved, it is to late 70s and early 80s, as Alfing, Hüller-Hille and Ex-cell-o and other companies have developed a flexible machining modules, and automatic line ( FTL), from CNC machine tools and flexible combination of automatic line has increased every year. 1988 to 1992, Japan Machine Tool and automatic line (including some other form of special machine tools) production NC rate has reached 32% ~ 39%, output NC rate of 35% to 51%; the German Machine Tool and automatic line production The NC rate of 18% and 62%, 45% of the value NC ~ 66% (Table 2). These figures show that over the past decade, the development of NC machine tool combination is very rapid. Should be noted that since the 90's into the car even more intense market competition, product market and further reduce the life of the new models and shorter development cycle (now usually 35 months), car varieties growing, so automotive industry to flexible automation increasing demand for technical equipment. Such as Toyota Motor Corporation, in the end of this century's goal is to subordinate the factory the company flexible manufacturing system's coverage reached 100%.很顯然，組合機(jī)床及其自動(dòng)線在保持其高生產(chǎn)效率的條件下，進(jìn)一步提高其柔性?就愈來愈具有重要意義。 Obviously, combination machine tool and its production line while maintaining its high productivity conditions, further enhancing its flexibility on the more important.
組合機(jī)床的柔性化主要是通過采用數(shù)控技術(shù)來實(shí)現(xiàn)的。Flexible modular machine tool is mainly through the use of numerical control technology to achieve. Development of flexible modular machine tool and an important prerequisite for flexible automatic line is the development of CNC machining module, which has a long history of development of processing technology for the development of CNC machining center modules to provide a mature experience. NC modules formed by the flexible modular machine tool and flexible automatic lines, can be changed through the application and the automatic tool changer CNC program to automatically replace the multi-axle box and change the processing itinerary of the working cycle, cutting parameters and processing location, in order to adapt to change type variety of processing. ?柔性組合機(jī)床和柔性自動(dòng)線用的數(shù)控加工模塊，按其數(shù)控坐標(biāo)(軸)數(shù)，主要有單坐標(biāo)(Z)、雙坐標(biāo)(XZ、YZ、?ZU和ZB等)和三坐標(biāo)(XYZ)加工模塊；按其主軸數(shù)，有單軸和多軸加工模塊，也有單軸和多軸復(fù)合加工模塊。
Single-axis machining module by the NC slide and spindle assembly (or axle box, including for multi-axle box) form. Two-axis machining module by the cross slide and spindle CNC Components, such as two-coordinate CNC milling module. Column moving type CNC coordinate processing module (Figure 6), the tool can be realized in the three coordinate movement, according to workpiece varieties and processing tasks with Tool, tool change and the required mechanical hand tools, high Flexible. This processing module is flexible automatic line processing of multi species one of the most important modules.
立柱移動(dòng)式CNC三坐標(biāo)加工模塊可利用X軸和Y軸的聯(lián)動(dòng)來實(shí)現(xiàn)周邊銑削工藝，特別是在銑削象變速箱體這類剛?性較差的工件時(shí)，可采用較小直徑的銑刀，實(shí)現(xiàn)高速(切削速度達(dá)2500m/min)周邊銑削，由此減小加工時(shí)的切削?力和工件的變形。 Mobile column CNC machining module can make use of X coordinate axis and Y axis of the linkage to achieve the peripheral milling process, particularly in the milling body such as the transmission of less rigid workpiece, we can use smaller diameter cutter, high-speed (cutting speed up to 2500m/min) milling around, thus reducing processing time of cutting force and workpiece deformation. This is more than double coordinate milling module for milling cutters with large diameter to be superior. Multi-axis machining module is another important module, mainly for processing box and disc type work flexible combination of machine tools and flexible automatic lines.這類模塊有多?種不同的結(jié)構(gòu)形式，但基本上可分為自動(dòng)換箱式多軸加工模塊(圖7)、轉(zhuǎn)塔式多軸加工模塊(圖8)和回轉(zhuǎn)工作臺(tái)式?多軸加工模塊(圖9)。 How such module structure of different forms, but basically can be divided into automatic processing module for box-type multi-axis (Figure 7), turret multi-axis machining module (Figure 8) and multi-axis machining module Rotary Table (Figure 9). As for box-type module automatically be set in a special multi-axle box to store more and more libraries axle box, it can be used to process more parts of different species. 而轉(zhuǎn)塔式和回轉(zhuǎn)工作臺(tái)式多軸加工模塊，由于在轉(zhuǎn)塔頭和回轉(zhuǎn)工作臺(tái)上允許裝的多軸箱數(shù)量有限?(一般為4～6個(gè))，所以這種加工模塊只能實(shí)現(xiàn)有限品種的加工。 The turret and multi-axis machining module Rotary Table, due to the turret head and turn the table to allow installation of a limited number of multi-axle box (usually 4 to 6 months), so this processing module can only achieve limited variety of processing.
在自動(dòng)線上采用CNC三坐標(biāo)加工模塊和轉(zhuǎn)塔式多軸加工模塊，不僅可實(shí)現(xiàn)不同品種工件的加工，而且在自動(dòng)線?節(jié)拍時(shí)間內(nèi)(如果節(jié)拍時(shí)間允許的話)，這類加工模塊還可以在同一個(gè)加工工位上通過其自動(dòng)換刀或換箱，依次實(shí)?現(xiàn)多道加工工序(粗鏜、半精鏜和精鏜；鉆孔、擴(kuò)孔和攻絲)，從而減少自動(dòng)線的加工工位數(shù)，縮短自動(dòng)線的長(zhǎng)度?。 CNC Coordinate with automatic online processing modules and turret multi-axis machining modules, not only enables workpieces of different varieties, but also in the automatic line beat of time (if time permits, then the beat), this type of processing module can also be in the same processing station on the exchange through its automatic tool changing or box, and then click to realize multi-channel processing operation (rough boring, semi-fine boring and precision boring; drilling, reaming and tapping), thereby reducing the processing work automatically line the median, Automatic line to shorten the length. ?單軸和多軸復(fù)合加工模塊是一種三坐標(biāo)數(shù)控加工模塊，可通過自動(dòng)換刀或自動(dòng)更換多軸箱而實(shí)現(xiàn)單軸加工或多軸加工。 Single and multi-axis coordinate complex processing module is a CNC machining modules, can be automatically replaced by ATC, or multi-axle box and the realization of single-axis machining or multi-axis machining.值得提及的是，在80年代中期德國(guó)Honsberg公司推出的CNCMACH模塊化系統(tǒng)(圖10)是很有特色的一種模塊化系統(tǒng)，該系統(tǒng)充分應(yīng)用模塊化結(jié)構(gòu)原理，在作為系統(tǒng)基礎(chǔ)模塊的?CNC三坐標(biāo)模塊上，通過增減各種不同的功能模塊，拼裝成各種不同坐標(biāo)或不用工藝用途的加工模塊。 It is worth mentioning that in the mid 80s the company introduced CNCMACH Germany Honsberg modular system are characteristic of a modular system, modular structure of the full application of the principle as a basic module of the CNC system CMM module, through changes in various functional modules, assembled into a variety of different processes do not use coordinates or processing modules. Specifically, from the coordinates, except coordinate, it can also form two-coordinate and single-axis machining module; view from the Tool can be installed in libraries and multi-axle box tool libraries, can be realized individually or axle box of tools automatic replacement can also be followed to achieve the replacement tool and multi-axle box.
CNC?MACH系統(tǒng)，不僅在機(jī)械結(jié)構(gòu)方面，而且在控制和軟件等方面也是模塊化的。 CNC MACH system, not only in the mechanical structure, but also in control and software is modular and so on. Therefore, the use of the system modules can be easily assembled into flexible transfer lines (FTL), flexible manufacturing cell (FMC) or flexible manufacturing system (FMS). In addition to the various CNC machining modules, the robot and servo-driven machine tools and jigs is also flexible combination of a key component of flexible automatic lines. Particularly in the flexible nature of automatic online, now more common use of air-frame gantry robot automatic loading and unloading workpieces, for workpiece transfer position or flipped. For the handling of different workpieces can be set in the automatic line next to the gripper base in order to achieve the automatic gripper change. Fixture equipped with servo drives, to adapt to different job families in the automatic clamping work pieces.
該線采用的數(shù)控加工模塊有四個(gè)雙坐標(biāo)數(shù)控銑削模?塊、六個(gè)數(shù)控轉(zhuǎn)塔式多軸加工模塊和六個(gè)數(shù)控三坐標(biāo)加工模塊。 The line used in CNC machining module has four double-axis NC milling module, six CNC turret CNC multi-axis machining module and six coordinate processing module. Secondary station and the cleaning station operations by the robot workstation installation folder. As the composition of automatic wire processing module is NC, when the transformation process from a workpiece to another workpiece processing, simply by changing the NC program on the line, without the need for machinery, adjustment and modification.
4、 the increasing degree of integrated automation
近十年來，為進(jìn)一步提高工件的加工精度和減少工件在生產(chǎn)過程中的中間儲(chǔ)存、搬運(yùn)以及縮短生產(chǎn)流程時(shí)間，將工件加工流程中的一些非切削加工工序(如工序間的清洗、測(cè)量、裝配和試漏等)集成到自動(dòng)線或自動(dòng)線組成的生產(chǎn)系統(tǒng)中(圖15)，以實(shí)現(xiàn)工件加工、表面處理、測(cè)量和裝配等工序的綜合自動(dòng)Over the past decade, in order to further improve the machining accuracy of workpiece and the workpiece during the production process to reduce intermediate storage, handling and production processes to shorten the time the workpiece machining process in some non-cutting operations (such as inter-process cleaning, measurement, assembly and leak testing, etc.) integrated into the automated line or automatic line production system consisting of (Figure 15), in order to achieve workpiece machining, surface treatment, measurement and assembly processes of integrated automation.
清洗 Clean：In the automatic line and automatic line consisting of production systems, cleaning equipment, parts of the process is mainly used for cleaning and parts between the final cleaning.
工件的工序間清洗主要是為下一道工序創(chuàng)造必要的工作條件。 Between the cleaning processes the workpiece is mainly for the next process to create the necessary conditions of work. For example, the workpiece blank in the painting before, after processing the workpiece datum, deburring, the measurements carried out before and a variety of cleaning before assembly.
當(dāng)今，鑒于我們?nèi)祟愘囈陨娴沫h(huán)境日益受到工業(yè)污染的破壞，環(huán)境保護(hù)已引起人們的普遍重視。 Today, in view of the survival of our human environment is increasingly damaged by industrial pollution; environmental protection has attracted much attention. 近年來，國(guó)內(nèi)外越來越關(guān)注工業(yè)清洗對(duì)環(huán)境的污染。 In recent years, more and more concerned with industrial cleaning at home and abroad on the environment. 這就促使許多工業(yè)部門的零件清洗轉(zhuǎn)向應(yīng)用水劑清洗(采用酸性、中性或堿性清洗液，清洗液中主要含有磷酸鹽、活性劑和絡(luò)合劑等)，這種水劑清洗主要根據(jù)工件清洗質(zhì)量要求而采用噴淋(分散清洗)和浸漬(集中清洗)兩種工藝。 This has prompted many industries move on aqueous parts cleaning washing (using acidic, neutral or alkaline cleaning liquid, cleaning liquid containing mainly phosphate, active agents and complexing agents, etc.), primarily on the basis of such aqueous cleaning workpiece quality requirements and use of cleaning spray (distributed cleaning) and immersion (concentrated cleaning) are two processes.
基于環(huán)境保護(hù)、現(xiàn)場(chǎng)操作工人的保健和清洗工藝的合理化等要求，目前，清洗機(jī)已普遍采用封閉式布局，整個(gè)清洗過程是自動(dòng)進(jìn)行的，設(shè)備控制采用可編程控制器，并自動(dòng)監(jiān)控所有機(jī)械動(dòng)作和工藝技術(shù)參數(shù)。 Based on environmental protection, health care workers, field operations and cleaning process of rationalization and other requirements, now, cleaning machine has been widely used closed-end layout, Zheng Ge cleaning process is automatic and programmable controller equipment control, and automatic monitoring of all mechanical action and technical parameters. In such washing machines integrated evaporation, filtration, material recovery and processing devices, as shown in Figure 16 is a German Benz steering shell cleaning process. The washing machine is closed layout, the cleaning process is conducted in a closed system, through a cleaning fluid purification support system to achieve the recycling of cleaning fluid. In this system, as a purification unit is a core component of purification and recycling modules cleaning. The module consists of ultra-fine filters and evaporator joint composition, use of the integrated purification equipment and cleaning fluid produced by distilled water, re-used for parts cleaning and rinsing.
5、Automatic measurement
在自動(dòng)線上采用自動(dòng)測(cè)量旨在對(duì)工件的加工質(zhì)量進(jìn)行監(jiān)控。 Automatic line automatic measurement of the workpiece to the processing quality control. In recent years, due to the increasingly automated line to shorten cycle times, the accuracy of the workpiece and the measurement and also become increasingly demanding production conditions, therefore the automatic measurement system must not only work with high speed and high work precision, and to have strong anti-environmental interference (such as chips, dust, steam coolant, oil, vibration and temperature, etc.) capability or some interference with the measurement system can automatically compensate the amount of performance.
在自動(dòng)線上，自動(dòng)測(cè)量可分為加工前測(cè)量和加工后測(cè)量。 The automatic line, automatic measurement can be divided into pre-processing measurement and processed measurements.
加工前測(cè)量是在工件加工前通過測(cè)量以確定工件的特征，并利用測(cè)量結(jié)果來調(diào)整刀具相對(duì)于工件待加工部位的位置，然后進(jìn)行相應(yīng)的加工。 Processing before the measurement is in the workpiece before the workpiece by measuring to determine the characteristics and use measurements to adjust the tool position relative to the location of
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