1935_金剛石鋸片磨弧機(jī)設(shè)計(jì)
1935_金剛石鋸片磨弧機(jī)設(shè)計(jì),金剛石,鋸片磨弧機(jī),設(shè)計(jì)
黃河科技學(xué)院畢業(yè)設(shè)計(jì)開題報(bào)告表課題名稱 金剛石鋸片磨弧機(jī)設(shè)計(jì)課題來源 教師擬訂 課題類型 AX 指導(dǎo)教師 李長詩學(xué)生姓名 任志強(qiáng) 專 業(yè) 機(jī)械設(shè)計(jì)制造及其自動化 學(xué) 號 080105012一、調(diào)研資料的準(zhǔn)備根據(jù)任務(wù)書的要求,在做本課題前,查閱了與課題相關(guān)的資料有:機(jī)械設(shè)計(jì)、機(jī)械制圖、機(jī)械制造工藝學(xué)、沖壓成型工藝與模具設(shè)計(jì)、冷沖模課程設(shè)計(jì)與畢業(yè)設(shè)計(jì)指導(dǎo)等以及與設(shè)計(jì)相關(guān)的手冊。二、設(shè)計(jì)的目的與要求 畢業(yè)設(shè)計(jì)是大學(xué)教學(xué)中最后一個(gè)實(shí)踐性教學(xué)環(huán)節(jié),通過該設(shè)計(jì)過程,可以檢驗(yàn)學(xué)生所學(xué)的知識,同時(shí)培養(yǎng)學(xué)生處理工程中實(shí)際問題的能力,因此意義特別重大。1. 結(jié)構(gòu)設(shè)計(jì);2. 編寫設(shè)計(jì)說明書設(shè)計(jì)說明書不少于 6000 字;4. 查閱文獻(xiàn)資料不少于 12 篇,其中外文資料不少于 2 篇;獻(xiàn)綜述不少于 3000 字。三、設(shè)計(jì)的思路與預(yù)期成果 1、設(shè)計(jì)思路首先:根據(jù)本次設(shè)計(jì)相關(guān)要求查找資料,做好設(shè)計(jì)的準(zhǔn)備工作。其次:依據(jù)要實(shí)現(xiàn)的功能要求計(jì)算并選擇或設(shè)計(jì)出合適的電機(jī)及各種零件,畫出裝配圖及其零件圖。2、預(yù)期的成果(1)完成文獻(xiàn)綜述一篇,不少與 3000 字,與專業(yè)相關(guān)的英文翻譯一篇,不少于 3000 字(2)完成內(nèi)容與字?jǐn)?shù)都不少于規(guī)定量的畢業(yè)設(shè)計(jì)說明書一份(3)繪制裝配圖,部分零件圖四、任務(wù)完成的階段內(nèi)容及時(shí)間安排第 1~2 周 查閱資料,調(diào)研,方案論證,寫開題報(bào)告;第 3~4 周 寫文獻(xiàn)綜述,翻譯外文資料,擬定總體設(shè)計(jì)方案;第 5~11 周 結(jié)構(gòu)設(shè)計(jì)與控制設(shè)計(jì)。第 12~13 周 撰寫研究論文。第 14~15 周 驗(yàn)收,答辯,總結(jié)等。五、完成設(shè)計(jì)所具備的條件因素本人已修完機(jī)械設(shè)計(jì)、機(jī)械制圖、液壓與氣壓傳動、金屬工藝學(xué)、機(jī)械制造技術(shù)基礎(chǔ)、沖壓成型工藝與模具設(shè)計(jì)、冷沖模課程設(shè)計(jì)與畢業(yè)設(shè)計(jì)指導(dǎo)等課程,借助圖書館的相關(guān)文獻(xiàn)資料,以及相關(guān)的網(wǎng)絡(luò)等資源。指導(dǎo)教師簽名: 日期: 課題來源:(1)教師擬訂;(2)學(xué)生建議;(3)企業(yè)和社會征集;(4)科研單位提供課題類型:(1)A—工程設(shè)計(jì)(藝術(shù)設(shè)計(jì)) ;B—技術(shù)開發(fā);C—軟件工程;D—理論研究;E—調(diào)研報(bào)告(2)X—真實(shí)課題;Y—模擬課題;Z—虛擬課題要求(1) 、 (2)均要填,如 AY、BX 等。 畢業(yè)設(shè)計(jì) 文獻(xiàn)綜述院 ( 系 ) 名 稱 工 學(xué) 院 機(jī) 械 系專 業(yè) 名 稱 機(jī) 械 設(shè) 計(jì) 制 造 及 其 自 動 化學(xué) 生 姓 名 任 志 強(qiáng) 指 導(dǎo) 教 師 李 長 詩 2012 年 03 月 10 日 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)綜述) 第 0 頁摘 要隨著汽車、航空和航天技術(shù)的飛速發(fā)展,對材料性能及加工技術(shù)的要求日益提高。新型材料如碳纖維增強(qiáng)塑料、顆粒增強(qiáng)金屬基復(fù)合材料(PRMMC)及陶瓷材料得到廣泛應(yīng)用。這些材料具有強(qiáng)度高、耐磨性好、熱膨脹系數(shù)小等特性,這決定了對它們進(jìn)行機(jī)加工時(shí)刀具的壽命非常短。開發(fā)新型耐磨且穩(wěn)定的超硬切削刀具是許多高校、科研院所和企業(yè)研究的課題。 金剛石集力學(xué)、光學(xué)、熱學(xué)、聲學(xué)、光學(xué)等眾多優(yōu)異性能于一身,具有極高的硬度,摩擦系數(shù)小,導(dǎo)熱性高,熱膨脹系數(shù)和化學(xué)惰性低,是制造刀具的理想材料。本文對近年來金剛石刀具的應(yīng)用發(fā)展作一概述。關(guān)鍵詞:新型材料,強(qiáng)度高,超硬,刀具AbstractWith the rapid development of automotive, aviation and aerospace technology, the increasing demand for the material properties and processing technology. New materials such as carbon fiber reinforced plastics, particle reinforced metal matrix composites (PRMMC) and ceramic materials are widely used. These materials have high strength, good wear resistance, small thermal expansion coefficient, which determines the tool life when machining is very short. The development of new wear-resistant and stable superhard cutting tool in many universities, research institutes and corporate research topics. Diamond set mechanical, optical, thermal, acoustic, optical, etc. a number of excellent performance in a high hardness, low coefficient of friction and high thermal conductivity, low thermal expansion coefficient and chemical inertness, is an ideal material for manufacturing tools. For an overview on the development of the diamond tool manufacturing methods in recent years.Keywords: new materials, high strength, super-hard, tool1 金剛石圓盤鋸工作性能 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)綜述) 第 1 頁采用喜利得 D-LP32/DS-TS32 型金剛石圓盤鋸切割、分塊。1.1 D-LP32/DS-TS32 圓盤鋸主要技術(shù)參數(shù)最大功率:32KW;額定電壓:400V-50HZ;液壓泵量:40-100L/min;最大工作壓力:210bav;最大切割深度:73㎝;(通過技術(shù)配套改進(jìn),可適當(dāng)加深)機(jī)重:38㎏。1.2 金剛石圓盤鋸切割工法金剛石圓盤鋸切割是液壓馬達(dá)驅(qū)動金剛石圓盤鋸高速運(yùn)轉(zhuǎn)來研磨被切割體,完成切割工作。由于使用金剛石單晶做為研磨材料,故此可以對石材、鋼筋混凝土等堅(jiān)硬物體進(jìn)行切割。切割是在液壓馬達(dá)驅(qū)動下進(jìn)行的,液壓泵運(yùn)轉(zhuǎn)平穩(wěn),并且可以通過高壓油管遠(yuǎn)距離控制操作,也可通過導(dǎo)軌的不同安裝形式實(shí)現(xiàn)任意角度的切割,所以切割過程中不但操作安全方便,而且震動和噪音很小,被切割物體能在幾乎無擾動的情況下被分離。切割過程中高速運(yùn)轉(zhuǎn)的金剛石鋸片靠水冷卻,并將研磨碎屑帶走。1.3 工作原理金剛石鋸片在液壓或電動馬達(dá)帶動下,沿軌道方向移動,高速回轉(zhuǎn),研磨、切削鋼筋混凝土。切割安裝見下圖。 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)綜述) 第 2 頁1.4 施工特點(diǎn)a、金剛石墻鋸機(jī)切割面光滑整齊。b、切割中鋸機(jī)的移動方向受軌道控制,切割位置準(zhǔn)確。c、無振動、低噪音、環(huán)保、安全無污染。d、切割厚度可以根據(jù)鋸片的大小調(diào)整。1.5 適用范圍a、一般鋼筋混凝土墻、板切割、拆除或開門洞。b、切割面要求光滑、平直、美觀的混凝土切割。c、切割深度根據(jù)鋸片大小調(diào)整,目前采用 Φ1600mm 金剛石圓盤鋸最大切割深度可達(dá) 600mm。 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)綜述) 第 3 頁1.6 技術(shù)標(biāo)準(zhǔn)切割鋸片與切割深度鋸片直徑與切割深度的關(guān)系見下表鋸片直徑與切割深度的關(guān)系鋸片直徑 mm 800 1200 1600切割深度 mm 330 530 730軌道安裝偏差控制在 3mm 以內(nèi),鋸片固定完成后檢查調(diào)整鋸片與切割面的垂直度。平行于墻體切割樓板時(shí),距離墻邊最小切割距離為 30mm。金剛石圓盤鋸切割混凝土墻體 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)綜述) 第 4 頁1.7 施工工藝流程固定導(dǎo)軌 安裝設(shè)備機(jī)具連接相關(guān)操作系統(tǒng)確定切割斷面位置切 割設(shè)置安全防護(hù)設(shè)施1.7.1 圓盤鋸固定——導(dǎo)軌安裝導(dǎo)道使用 HILTI 專用導(dǎo)軌,導(dǎo)軌固定采用喜利得高強(qiáng)度錨栓,安裝過程使用激光定位儀保證軌道連接的直線度。1.7.2 切割參數(shù)的選擇液壓馬達(dá)驅(qū)動金剛石圓盤高速運(yùn)轉(zhuǎn),磨削混凝土被切割塊,切割過程中用水冷卻,并沖走粉屑。切割過程中保證金剛石圓周線速度達(dá)到 5-8m/s,才能進(jìn)行有效切割,這可通過控制操作盤進(jìn)行調(diào)控,但每次切割深度不要超過200mm,采用淺切快跑的方式來回進(jìn)行逐步加深的切割,否則,一旦金剛石鋸片受力變形,不能保證其剛性平面度,會影響切割速度,甚至?xí)l(fā)生機(jī)械傷害事故。吊裝 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)綜述) 第 5 頁2 金剛石薄壁鉆工作性能2.1 切割原理鋼筋混凝土鉆孔是由鉆孔機(jī)帶動金剛石薄壁鉆頭加壓、回轉(zhuǎn),鉆頭胎體金剛石顆粒研磨切削鋼筋和混凝土完成鉆孔切割工作。鉆進(jìn)過程中采用冷卻水、并攜帶出磨削下來的粉屑。2.2 工程特點(diǎn)低噪音、無振動、無粉塵污染。對結(jié)構(gòu)無不良影響,使用簡單、靈活,施工速度快。可以進(jìn)行 0-90 度范圍變角度鉆孔。排孔也可以實(shí)現(xiàn)切割分離。2.3 適用范圍鉆孔施工適用于任何混凝土構(gòu)筑物,一次成孔孔徑為 ф14-ф350mm,孔深可達(dá) 6m。采用連續(xù)排孔法施工,可實(shí)現(xiàn)各種形狀洞口的切割及各種構(gòu)筑物拆除。2.4 技術(shù)標(biāo)準(zhǔn)采用十字畫線法確定鉆孔中心,孔位偏差不超過 3mm。利用連續(xù)鉆孔進(jìn)行切割時(shí),鉆孔采用 ф89mm 或 ф108mm 孔徑施工,一米長度方向上布置鉆孔數(shù)為12~13 個(gè)。切割直線偏差小于 20mm。2.5 施工工序2.5.1 放線確定鉆孔位置在該環(huán)型梁上確定打吊裝孔位置。2.5.2 底座的安裝采用 M16 化學(xué)錨栓或脹栓固定基座,保持機(jī)頭、鉆頭和鉆孔位置在同一垂直面內(nèi)。放線定位 固定機(jī)座 鉆孔 取出巖芯 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)綜述) 第 6 頁2.5.3 鉆孔人工施加前進(jìn)力,控制力度均勻。2.5.4 取芯將鉆具內(nèi)的混凝土取出,進(jìn)一步鉆進(jìn),直至設(shè)計(jì)深度。參考文獻(xiàn)[1] 唐存印.幾種金剛石工具鋸切石材分析.珠寶科技,2004-5.[2] 劉琛,劉慶.一種新型的激光金剛石鋸片專用砂帶磨弧機(jī).金剛石與磨料磨具工程,2004-4.[3] 呂長利,毛德志.影響金剛石鋸片性能內(nèi)在因素初探.工業(yè)金剛石,2004-2.[4] 陳冀渝.高使用壽命的金剛石鋸片.建材工業(yè)信息,2002-9.[5] 王忠義,張?jiān)撇?影響金剛石圓鋸片切割因素的探討,2001-9.[6] 現(xiàn)代實(shí)用機(jī)床設(shè)計(jì)編委會. 現(xiàn)代實(shí)用機(jī)床設(shè)計(jì)手冊[M]. 機(jī)械工業(yè)出版社, 2006.[7] 王先逵.磨削加工[M].機(jī)械工業(yè)出版社,2008.[8] 龍振宇,李良軍,伍奴美,任亨斌.機(jī)械設(shè)計(jì)手冊[M],國家工科基礎(chǔ)課程機(jī)械基礎(chǔ)教學(xué)基地,2003. 畢業(yè)設(shè)計(jì)文獻(xiàn)翻譯院 ( 系 ) 名 稱 工 學(xué) 院 機(jī) 械 系專 業(yè) 名 稱 機(jī) 械 設(shè) 計(jì) 制 造 及 其 自 動 化學(xué) 生 姓 名 任 志 強(qiáng)指 導(dǎo) 教 師 李 長 詩2012 年 03 月 10 日 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)翻譯) 第 0 頁Abrasive belt grinding technology in the machinery industryAbstractSituation and characteristics of the abrasive belt grinding technology, discusses the development trends of the abrasive belt grinding technology. In the construction machinery industry, some of the higher parts of the long axis of traditional processing technology is generally a coarse grinding and a grinding a few processes of roughing a fine car, parts machining surface finishing rely mainly on a cylindrical grinder with a grinding wheel grinding to achieve. For some of the aspect ratio of a slender rod, such as various types of hydraulic cylinder piston rod, ordinary wheel grinding will be the limit of the range of processing, abrasive belt grinding with its significant advantages, and reveal the head and feet .Keywords: abrasive belt grinding, development, processing1 OverviewAbrasive belt grinding process, is the ring of abrasive belt on the cylindrical contact roller and the tension pulley, tension in the state, so that the processing of high-speed rotation of the abrasive belt surface and the workpiece surface in contact, and in certain under pressure, a grinding process on the workpiece surface relative friction movement (cutting motion). Abrasive belt grinding into a round of compression with pressure are two ways shown in Figure 1.Wheel pressure grinding method, the contact roller to put pressure on the surface of metal in the contact wheel and the workpiece axis spacing A = 1/2 (D + d) such grinding method due to contact pressure, the unit of time removal capacity, high efficiency, and thus applicable to the coarse and fine grinding of the inner cylindrical surface and plane. Put pressure on the workpiece grinding surface pressure grinding method using abrasive belt, due to tensioner pulley bracket to the workpiece direction tilted at an angle α, contact wheel and the workpiece axis spacing interaction A '> 1/2 ( D + d). Compared with round pressure 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)翻譯) 第 1 頁grinding method, the smaller the contact pressure with the pressure method, the amount of metal removed per unit time is also small, mainly used for grinding circular surface, conical and other shaped surface, in particular, to the finishing polish based.Belt and grinding wheel belong to a multi-tooth micro-edge cutting tool, its processing characteristics are basically the same, the only difference shapes.2 the current state of developmentIn foreign countries, some industrial countries due to the rapid development of various types of abrasive belt grinding machine, the function of the abrasive belt grinding has gone far beyond the range for rust, rough grinding, polishing, etc., the processing efficiency of grinding wheel ~ 20 times the processing quality can be comparable to conventional grinding, machining accuracy is close to or reach the same level with the grinding wheel, while the utilization of the machine power than any metal cutting machine tools are high, and its range of applications throughout the various industries, almost all materials (eg, timber, rubber, all kinds of metal) can wear g the Shuai 0 workers. According to the information, the United States each year of the grinding wheel and abrasive belt production ratio of approximately 1: 1. In the famous engineering machinery enterprises CaterPiller, abrasive belt grinding occupies an important position.Following the introduction of the new technology of high voltage electrostatic plant sand in the country to ensure that the abrasive in the abrasive belt surface of the "orientation", so that the sand, some belt manufacturers, such as Zhengzhou White Dove Group (grinding wheels), the Shanghai wheel plant so with a good sharp. With the development of the binder, water-resistant oil-resistant resin strong belt of the emergence of the abrasive belt grinding performance is significantly improved. Although the models of all kinds of abrasive belt grinding machine is not yet complete, but the development and use of abrasive belt grinding device is feasible.3 Characteristics of three abrasive belt grinding 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)翻譯) 第 2 頁(1)The abrasive belt grinding "cutting" said. Abrasive belt grinding, high efficiency, up to 10 times the milling, 5 to 20 times the normal grinding wheel.(2)The abrasive belt grinding also has a "cold state" grinding said. Friction and heat due to the processing time is less and due to the abrasive cooling time interval, can effectively reduce the deformation of the workpiece and burns, machining accuracy is generally ordinary wheel grinder machining accuracy can be achieved, some of the dimensional accuracy of ± 0. 005 mm, a maximum of ± 0. 0012mm.(3)The abrasive belt grinding with the grinding of said "flexibility". The abrasive belt grinding workpiece flexible contacts, running and polishing the role of the surface roughness up to Ra0.8 ~ 0.2μm.(4)Abrasive belt grinding device structure is simple, low cost, minimal wear contact wheel, abrasive belt can maintain constant speed, short transmission chain, the machine power up to 85% utilization.(5)Auxiliary time. Positioning of the workpiece clamping, multiple replacement of the abrasive belt to complete all processing, do not need to like the wheel as balance and trim work.(6) adaptability, simple operation, safe and reliable.4 The main structure and the grinding amount of abrasive belt grinding deviceThere are several different structure of abrasive belt grinding unit. A device from the motor output shaft direct drive abrasive belt, the other is by the device of the motor by grinding spindle drive belt, a device for grinding.For the first device, which is characterized by the contact wheel mounted directly on and fixed with 1:5 taper in the motor output shaft, the device has the abrasive belt tensioner and quick-change control mechanism, see Figure 2. Grinding device can make use of the clamping frame installed in a variety of metal cutting machine tools, grinding, so called general-purpose abrasive belt grinding device. 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)翻譯) 第 3 頁In such a device, the tension wheel and contact wheel should adopt a uniform texture nylon material. Contact roller and tensioner pulley are high-speed rotating parts, the tension wheel speed up to more than 5 000 r / min, the response to these two parts after processing in order to ensure safety and improve the smoothness of the entire device, dynamic balance unbalanced weight trials, and strive to minimize.The belt line speed by the maximum allowable limit restrictions, generally selected as 25 m / s,. Workpiece per revolution abrasive belt along the workpiece axis vertical feed the general control of finishing in less than half of the abrasive belt width may be appropriate to reduce the number of In addition, the granularity of the abrasive grinding surface roughness has a direct relationship, the smaller the particle size, the lower the value of the surface roughness after grinding. When used, should ensure that there is plenty of coolant and dust removal equipment.5 direction of development of abrasive belt grindingCompared with the conventional processing method, the abrasive belt grinding is indeed a high-quality, high efficiency, low consumption of novel processing methods. At the same time, the long axis of the less rigid or thin wall sleeve parts, design and manufacture of some simple structure, easy to manufacture, easy to operate abrasive belt grinding device, installed in the general machine instead of grinding machines to carry out efficient finishing is feasible the.In other countries, the belt grinding to the following direction:(1) machine power continued to grow. The abrasive belt grinding machine (kw) for more than 200 have emerged.(2) increase the belt speed. 100 m / s and above the development of high-speed abrasive belt grinding machine is in progress.(3) increase the width of the belt, to improve processing efficiency, the widest reached 4.9m. 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)翻譯) 第 4 頁(4) to extend the life of the belt. From the initial 2 ~ 4h to 8 - 12h.(5) with the amount of grinding of abrasive belt grinding, the grinding unit time have been able to reach general metal cutting machine tools unit time cutting, abrasive belt grinding finishing push strong mill cutting stage, and to grind on behalf of the car to the mill on behalf of the milling and planing to grind on behalf of the trend.With the belt grinding process used in the continuous promotion of the domestic construction machinery industry, and the abrasive belt manufacturing process of continuous improvement and development is bound to a wider range of abrasive belt grinding machines and devices. It can be expected that the abrasive belt grinding process in the construction machinery manufacturing industry is bound to receive due attention and further development.砂帶磨削技術(shù)在工程機(jī)械行業(yè)的應(yīng)用摘要介紹砂帶磨削技術(shù)的概況和特點(diǎn),論述砂帶磨削技術(shù)的展趨勢。在工程機(jī)械行業(yè)中,一些要求較高的長軸類零件傳統(tǒng)的加工工藝一般為粗車一精車一粗磨一精磨幾道工序,零件加工表面的精加工主要依靠在外圓磨床上用砂輪磨削來實(shí)現(xiàn)。而對于一些長徑比很大的細(xì)長桿件,如各類液壓缸的活塞桿,采用普通砂輪磨削就會受到加工范圍的限制,砂帶磨削正以其顯著的優(yōu)勢而嶄露頭腳。關(guān)鍵詞:砂帶磨削,發(fā)展,加工 1 概述砂帶磨削工藝,就是將環(huán)形砂帶套在接觸輪和張緊輪的外圓上,在張緊的狀態(tài)下,使高速旋轉(zhuǎn)的砂帶表面與工件的加工表面相接觸,并在一定的壓力作用下,以產(chǎn)生的相對摩擦運(yùn)動(切削運(yùn)動)對工件表面進(jìn)行磨削加工的一種工藝方法。砂帶磨削分為輪壓式和帶壓式兩種方法. 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)翻譯) 第 5 頁對于輪壓式磨削法,即接觸輪施壓于工件表面上,此時(shí)接觸輪與工件的軸間距A=1/2(D+d)此種磨削方式由于接觸壓力大,單位時(shí)間內(nèi)金屬的去除量大,效率高,因而適用于內(nèi)、外圓表面和平面的粗、精磨削。對于帶壓式磨削法,即用砂帶施壓于工件磨削表面,此時(shí)因張緊輪支架向工件方向傾斜了一個(gè)角度 α,接觸輪與工件軸間距互 A′>1/2(D+ d) 。與輪壓式磨削法相比,帶壓法的接觸壓力較小,單位時(shí)間內(nèi)去除的金屬量亦小,主要用于磨削圓弧面、圓錐面和其它異形表面,尤其以精加工拋光為主。砂帶和砂輪一樣,同屬于一種多齒微刃型切削工具,其加工特性基本相同,所不同的只是形狀各異而已。2 目前的發(fā)展?fàn)顩r在國外,一些工業(yè)發(fā)達(dá)國家由于各種類型砂帶磨床的迅速發(fā)展,砂帶磨削的功能已遠(yuǎn)遠(yuǎn)超出了用于除銹、粗磨、拋光等范圍,其加工效率為砂輪磨削的 5~20 倍,加工質(zhì)量可與一般常規(guī)的磨削方法相媲美,加工精度已接近或達(dá)到與砂輪磨削相同的水平,而機(jī)床功率的利用率卻比任何金屬切削機(jī)床都高,其應(yīng)用范圍遍及各個(gè)行業(yè),幾乎對所有材料(如木材、橡膠、各種金屬)都可進(jìn)行磨 g 帥 0 工。據(jù)有關(guān)資料介紹,美國每年的砂輪與砂帶產(chǎn)量之比約為 1: 1。在著名的工程機(jī)械企業(yè) CaterPiller 公司,砂帶磨削就占有重要的地位。在國內(nèi)繼引進(jìn)了高壓靜電植砂新工藝,保證了磨粒在砂帶表面的“定向排列” ,使砂,一些砂帶生產(chǎn)廠家如鄭州白鴿集團(tuán)(即中國第二砂輪廠) 、上海砂輪廠等都相帶具有良好的鋒利性。同時(shí),隨著粘結(jié)劑的發(fā)展,耐水耐油的全樹脂強(qiáng)力砂帶的出現(xiàn),使砂帶的磨削性能得到顯著提高。雖然目前我國各類砂帶磨床的型號尚不完備,但研制和使用一些砂帶磨削裝置是切實(shí)可行的。3 砂帶磨削的特點(diǎn)(1) 砂帶磨削具有“快削法”之稱。砂帶磨削效率高,已達(dá)到銑削的 10 倍,普通砂輪磨削的 5~20 倍。 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)翻譯) 第 6 頁(2) 砂帶磨削還具有“冷態(tài)”磨削之稱。由于加工時(shí)摩擦生熱少,且因磨粒散熱時(shí)間間隔長,可有效地減少工件變形和燒傷,加工精度一般可達(dá)到普通砂輪磨床的加工精度,有的尺寸精度已達(dá)到±0. 005 mm,最高可達(dá)到±0. 0012mm。(3) 砂帶磨削具有“彈性”磨削之稱。由于砂帶磨削與工件是柔性接觸,具有較好的跑合和拋光作用,工件表面粗糙度可達(dá) Ra0.8~0.2μm。(4) 砂帶磨削設(shè)備結(jié)構(gòu)簡單,制造成本低,接觸輪極少磨損,可使砂帶保持恒速,傳動鏈短,機(jī)床功率利用率可達(dá) 85%。(5) 輔助時(shí)間少。工件裝夾一次定位后,可多次更換砂帶完成全部加工,無需象砂輪那樣進(jìn)行平衡及修整工。(6)適應(yīng)性強(qiáng),操作簡單,安全可靠。4 砂帶磨削裝置的主要結(jié)構(gòu)及磨削用量砂帶磨削裝置有幾種不同的結(jié)構(gòu)。一種是由電機(jī)輸出軸直接傳動砂帶的裝置,另一種是由電機(jī)經(jīng)磨削主軸傳動砂帶的裝置,還有一種是供內(nèi)圓磨削使用的裝置。對于第一種裝置,它的特點(diǎn)是接觸輪直接安裝并固定在具有 1:5 錐度的電機(jī)輸出軸上,該裝置具有砂帶張緊及快換操縱機(jī)構(gòu).因?yàn)檫@種磨削裝置可以借助夾持架安裝在多種金屬切削機(jī)床上進(jìn)行磨削加工,故稱其為通用砂帶磨削裝置。在這種裝置中,張緊輪和接觸輪宜采用質(zhì)地均勻的尼龍材料制成。由于接觸輪和張緊輪都是高速旋轉(zhuǎn)的零件,張緊輪的轉(zhuǎn)速可達(dá) 5 000 r/ min 以上,為保證安全并提高整個(gè)裝置的工作平穩(wěn)性,加工后應(yīng)對這兩種零件進(jìn)行動平衡試驗(yàn),力求將不平衡重減到最小。砂帶的線速度受允許的最大極限限制,一般選為 25 m/s。工件每轉(zhuǎn)砂帶沿工件軸線的縱向進(jìn)給量一般控制在砂帶寬度的一半以內(nèi),精加工時(shí)可適當(dāng)減少一些。另外,磨粒的粒度與磨削的表面粗糙度有直接關(guān)系,粒度越小,磨削后的表面粗糙度數(shù)值越 黃河科技學(xué)院畢業(yè)設(shè)計(jì)(文獻(xiàn)翻譯) 第 7 頁低。使用時(shí),應(yīng)保證有充足的冷卻潤滑液和相應(yīng)的除塵設(shè)備。5 砂帶磨削的發(fā)展方向與一般常規(guī)的加工方法相比較,砂帶磨削的確是一種優(yōu)質(zhì)、高效、低消耗的新穎的加工方法。同時(shí),對于剛性較差的長軸或薄壁套筒零件,設(shè)計(jì)制造一些結(jié)構(gòu)簡單、制造容易、操作方便的砂帶磨削裝置,安裝在通用機(jī)床上代替磨床來進(jìn)行高效的精加工是切實(shí)可行的。在國外,砂帶磨削技術(shù)正在向以下方向發(fā)展:(1)機(jī)床功率不斷增大。 200 kw 以上的砂帶磨床已經(jīng)出現(xiàn)。(2)提高砂帶速度。正在進(jìn)行 100 m/s 以上高速砂帶磨床的研制。(3)則增大砂帶的寬度,提高加工效率,最寬已達(dá) 4.9m 以上。(4)延長砂帶的使用壽命。已從初期的 2~4h 提高到目前的 8— 12h。(5)隨著砂帶磨削的磨削用量不斷提高,單位時(shí)間內(nèi)的磨削量已能夠達(dá)到通用金屬切削機(jī)床單位時(shí)間內(nèi)的切削量,從而把砂帶磨削由精加工推向強(qiáng)力磨削的階段,并出現(xiàn)了以磨代車,以磨代銑和以磨代刨的趨勢。隨著砂帶磨削工藝在國內(nèi)工程機(jī)械行業(yè)的不斷推廣使用,以及砂帶制造工藝的不斷完善和發(fā)展,必將出現(xiàn)種類更多的砂帶磨床和裝置??梢灶A(yù)料,砂帶磨削工藝在工程機(jī)械制造業(yè)中必將得到應(yīng)有的重視和進(jìn)一步的發(fā)展。
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