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Machine Design
With the scientific and technological progress and social changes in demand, machine design theory and technology are also constantly development. Computer technology and the rapid progress of technology, machine design methods for the development of a strong technical support. Computer-aided design (CAD) and computer-aided engineering (Computer Aided Engineering, Machine Tools initials CAE0 in the various stages of design has been applied, the experience has changed the traditional design methods, machine design from the traditional design of the computer-aided design, Qualitative to quantitative design design, static and linear and nonlinear analysis to dynamic analysis, from feasibility to design the best design of the transition.
NC technology development and applications, the transmission makes machine tools and structure has undergone major changes. Servo drive system can easily achieve a single machine and multi-axis movement linked to possible to omit the heavy machinery complex transmission system, structure and layout to produce great changes.
With the development of the production, the needs of the community is changing. In the mechanical manufacturing industry, a variety of species, small batch production of the increasing demand, resulting in a corresponding to the FMS (FMS) and other advanced manufacturing systems. FMS NC machine tools is the core equipment. Pre-FMS, can be said to be "machine-based system" that, according to the characteristics of the existing machine to a FMS. However, traditional machine tools (including numerical control machine tools) does not take into account when designing it in the application of FMS, in the functional constraints on the development of the FMS. FMS the development of machine has set new requirements for machine tools designed to "system-based machine design development" direction, that is, in machine design to consider how to better adapt to FMS, and other advanced manufacturing systems requirements, for example, Time and space with flexible, and the proximity to the logistics and so on, which means the design of machine tools has made new demands. Machine design is based on the design of the type set. Universal machine used serialized design. Series of products are innovative design type, the other is a variant design type. Some machines, such as the composition of a combination of machine design type.
In the type of innovative design, machine tools overall programme (including motor function and structure of the programme layout of the programme) may be the selection of the design (also known as the trial design) or a 10% design (also known as the analytical design). The former is used analog analysis, a method of reasoning programme, is the innovative design of the method used in general while the latter used as a method of generating the analytical programme, innovation ability, it is still studying development.
Machine Design steps
Machine tools and demands of different types, design steps are also different. In accordance with the new principles for processing the innovative design of the machine should be the steps; into a series of machine tool products should be designed serialization of the steps; higher degree of universal machine products, such as machine tools should be modular design combination of the steps .
I.determine the structure principle
According to the preliminary design, the machine is designed to determine the structure of the main principles of the programme include:
(1) that uses the technology of the machine, including the processing of the material type, shape, quality and size range.
(2) productivity, including the processing of the types, quantities and the required productivity.
(3) performance requirements of the accuracy of processing (user orders design) or the accuracy of machine tools, stiffness, heat distortion, noise and other performance indicators.
(4) the main parameters that determine the processing machine room and the main parameters.
(5) drive machine-driven approach and a motor-driven hydraulic-driven approach. Motor-driven approach in general have driven motor, stepper motor drive and servo motor drive. Drive and the determination of not only the cost of the machine, will also directly affect the mode of transmission established.
(6) of the main principles of parts and components should meet the requirements and principles of the structure, and sometimes needed to draft the design, identification of key components of home-made or HS.
(7) costs and production cycle or whether orders for factory planning products, should determine the cost and production cycle indicators.
II. Design
Design of the contents
(1) motor function design including the identification of the number of machines required for movement, form (linear motion, the Rotary Movement), features (the main movement, feeding movement, other sports) and the order, the final draw of the machine function map.
(2) the basic parameters of the design parameters, including size, movement and dynamic parameters of the design parameters.
(3) transmission system design, including transmission, transmission and drive system schematic design plans.
(4) the overall layout of the structure including the distribution of motor function, the overall layout of the form and structure of the whole programme
Design plans.
(5) control, including control system design and control theory, control system design plans.
III.structural design
Design of the machine drive system to determine the structure of the major principles of the programme, design parts assembly, the main parts for analysis calculated or refine the design of hydraulic principles and the corresponding assembly of hydraulic components, electrical control system design schematics and the corresponding Installation of electrical wiring diagram, machine design and improve the hand and the contact size map.
IV. Process Design
Who all the self-made machine parts map, the preparation of standard parts, GM parts and pieces of home-made schedules, writing Design Manual, Manual, the designated machine test methods and standards, and other technical documentation.
V. Machine Tool Evaluation
On a machine designed by performance analysis and comprehensive evaluation. May be designed by computer modeling of the machine, get a prototype of the so-called math, also known as the virtual prototype. A virtual prototype of a machine designed by kinematic simulation, in the actual prototype test before they are made out a comprehensive assessment, can greatly reduce the risk of new product development, shorten the development cycle and improve the quality of development.
These steps can be repeated, that the design with satisfactory results achieved so far. In the design process, design and evaluation of repeated a design can improve the success rate.
VI.design type
Upon completion of the above steps, the physical prototype manufacture, test and comment. According to physical prototype comment on the results of the modified design, the final product design type.
On the deep processing of the technological requirements
Deep processing, is the top priority of this design. The so-called deep hole, the hole is that when processing the ratio of length and diameter of about 10 times, often on the accuracy and surface finish requirements and higher, the use of processing methods in general are more difficult to meet.
I. Deep processing issues that must be addressed:
1) poor tool rigidity slender and easy to cause the tool deflection and friction with the hole wall, and therefore the head knives are correctly oriented to ensure the introduction of sets; At the same time, bearing in accordance with the need for holders to reduce the deformation and vibration Arbor.
2) is not easy from cuttings, the use of feed grade or high-pressure cutting fluid through the
inner row and outer row chip from the tool structure.
3) tool cooling difficulties, access to high-pressure cutting fluid cooling of the tool fully.
II. Deep processing of type:
Combine the characteristics of deep-hole machining, deep hole processing technology on the difficulties, the method has been overcome.
1) Deep processing grade feed:
Ordinary twist drill head in cast iron or steel pieces on the 6 ~ 10mm diameter drill hole below, the general should not be a deep-drilling of 6 ~ 10 times greater than the aperture. When the direction of horizontal drilling, the steel pieces in the deep drilling should not last more than 6 times the diameter, in the cast iron up to about 10 times the aperture. If the processing of the hole depth of more than this range, can be classified into methods for processing, that is, in the drilling process, so that bit processing automatically after a certain depth from the workpiece in order to discharge swarf and cooling, and then re-forward processing, constant back and forth until the process has finished (each drill deep, cast iron pieces from 3 to 6 times the diameter; steel pieces from 0.5 ~ 2 times the aperture, the deeper hole when taking a small value). This process is suitable for drilling deep holes of small diameter, but the productivity and precision mechanics are relatively low.
2) Feeding a deep-hole processing
It is mainly used various types of special segment, and with the next shot, transmission-oriented systems, such as cutting fluid input in the deep-hole drilling machine, hinges, boring and the presentation materials. Discharged from the way the chip can be especially Chip (on the hinge, there is also boring things forward or backward Chip) and with Chip; from a number of cutting edge, can be divided into single-blade, double-edged and multi-blade, cutting edge can be high-speed steel or carbide. Cutter head have a different number of block-oriented support in the process-oriented role play to ensure flatness of the hole, but also from the role of squeezed light to improve the processing of the surface finish hole.
Chip has a deep-hole drilling in a single tube and dual tube Chip Chip (ie, jet drilling). Chip fear of double tube drill pipe than Chip Chip fear deep-hole drilling and drilling outside the processing efficiency and higher accuracy. The deep hole on the barrier is expected to set at the completion of unloading Nesting Nesting knife, cut off the mandrel fitted with a knife and the knife folder to make it against the mandrel, the feed through a dedicated device to cut off, cut to the core diameter rod 4 / 5 ~ 5 / 6 will be back to cut off the knife, a little outside the mandrel to break out.
In general, the use of inside than outside the Chip Chip processing large diameter, obtained by processing high precision and surface finish.
III. The main points of deep-hole processing
Machine tools and processing of the previous process, and attention should check the following:
1) axis-oriented tool sets, Bar sets of bearings, such as the centerline of the workpiece support different sets of axis degrees should meet the requirement.
2) check whether the system is cutting fluid flow and normal work is a multi-edge special deep-hole drilling with Chip (jet drilling suction) of the spray suction effect, in particular, should seriously check.
3) the workpiece should be the upper end of the processing center hole, and to avoid drilling I n the slope.
4) Does the shape of a normal chip. With the workpiece material, tool geometry, cutting parameters and so on. The two separated by a certain direction of each curl inward cutting the best shape to avoid the formation of the ribbon cuttings straight.
5) The higher the speed of processing through-hole, when the drill bit is about to pass, it is best to stop or deceleration to prevent damage to the bit and the exit.
6) should be avoided in the processing of parking, such as the need to stop, they should first stop into the tool and return to some distance, and then stop the pump and the rotation of the main campaign to prevent the tool in the hole a "killed" phenomenon.