組合專機(jī)-汽車變速箱兩端面液壓雙頭組合銑床的設(shè)計(jì),組合,專機(jī),汽車,變速箱,兩端,液壓,銑床,設(shè)計(jì) The research and development of modular machine tool The machine is a combination of a generic components and special parts of the process of high concentrated special machine. It can be a (or more), more than parts, many, many processing. The machine can complete drilling, reaming,, boring, tapping, turning, milling, grinding and rolling process, high efficiency, stable machining accuracy. Combination machine tools and other special machine tool, general, has the following features: (1) combination machine tools on the general standard of components and parts accounted for all the machine parts of 70-80%, design and manufacture of short cycle, less investment, economic effect is good. (2) the combination machine adopts many knives, and a high degree of automation, thus than general machine high production efficiency, stable product quality, low labor strength. (3) is the universal modular machine tool parts after careful design and long-term production practice, and have special test batches, therefore the stable structure, manufacture, use and maintenance work and reliable. (4) in combination machine processing parts, with special jig, tools and equipment, processing technology and equipment, the quality of on the technical level of operators. (5) when the products processed update, using other types of special machine, its most parts to discard. In general, the combination of machine parts and standard parts can be reused, without further design and manufacturing. (6) combination machine tools to represent combination machine tools, in order to adapt to the cycle of large-scale production needs. Although there are many advantages of modular machine tool, but also disadvantages: (1) the variability of modular machine tool, a universal reconfigured sometimes 10% ~ 20% of the parts can't reuse, and refitted. When large quantities (2) universal modular machine tool parts not for a certain kind of machine design, it is a relatively wide adaptability. This will make the combination machine tools, special machine is a complex structure. The classification of 1.2 combination machine tools Combination machine tools and large portfolio is two kinds of small combination machine tools, they not only in volume and power are the size and type in structure and allocation, etc have great difference. Here, the configuration of the large combination machine tools. Large portfolio of machine configuration can be divided into three categories: 1.2.1 has fixed fixture were a combination machine tools This kind of modular machine tool fixtures and workbench are stationary. To realize dynamic slide into motion, smooth realization of dynamic box on the cutting. According to the dynamic box and spindle box of resettlement way, and can be divided into the following kinds: (1) the horizontal combination machine tools (horizontal) power box, (2) vertical combination machine tools (power box installed vertically), (3) tilted combination machine tools (power box installed); tilted (4) complex combination machine tools (power box with the installation of two or more). Given the fixture with multistage (portable) combination machine tools This kind of combination machine tools installation in the jig straight moving workbench or turn on the job, and do according to certain takt time interval, make Labour movement or get conversion. This kind of machine configuration, common four. (1) with the machine moving workbench, this kind of machine can make the fixture and workpiece beeline reciprocating movement. (2) with the rotary worktable, this machine tool fixtures and workpiece axis of rotation, round vertical can turn on the work in each workstation are usually equipped with workpiece. (3) drum machine, the machine tool for fixture and workpiece axis rotation around level can be. This machine of horizotal one-sided or horizontal commonly, but less USES double configuration of three. In addition, it also has FuSheShi except installation horizontal power components, perpendicular to the drum rebirth in the plane of the turn power components installed. (4) the central pillar machine, the machine has the mesa of larger diameter annular rotary worktable. On the central installation, the installation power components, but also in the workbench around are installed power components, horizontal and fixture is installed in the rotary table, this machine is generally complex. 1.2.3 turret spindle box type combination machine tools Turret spindle box type combination machine tools are divided into two classes: the uniaxial turret head type combination machine tools and multiaxial turret type combination machine tools. The former head of the turret each combination can be installed a rigid surfaces. The latter turret head each combination can be installed a spindle box surface. This machine general configuration types are: (1) turn tower only realize spindle box by cutting movement, the processing components, by the slide realize feed movement, (2) turn tower spindle box installed in turn on the slide spindle box tower, which can realize the cutting and feeding movement. One turret and spindle box type combination machine tools may be composed of three type double or, at the same time, the two or three of workpiece surface processing. 130 combination machine tools of technology Combination machine tools can be accomplished, milling process is flat surface, driving devicees, drilling, reaming, boring, reaming, tapping, deep hole drilling, economic, cutting, etc. Along with the development of integrated automation technology, the combination of complete machine can process is expanding constantly, except in the process, but also can complete car outside the circle, car, car indexing, cutting surface and thread, rolling, YuanZhuMian inside hole cut surface grinding, polishing, peace, and even honing, stamping, welding, and heat treatment, assembling, automatic measurement and check, etc. The development direction of 1.4 combination machine tools In recent years, combination machine tools in automobiles, tractors, diesel engine, motor, instruments, sewing machine, bicycle, valves, mining machinery, metallurgy, aviation, textile machinery and military department has won extensive use, some small batch production department also began to promote the use of. China in combination machine tools and the cycle will achieve rapid development, and its development direction for: To improve the level 1.4.1 general parts The main measure of general component level standard is: variety specification complete, the static and dynamic performance parameters, the technology of advanced high accuracy and precision, provides better. Currently should pay attention to develop strong milling machine, high precision of high-power dynamic slippery 1ta series boring head with high precision, and adaptive sliding and small batch production, the fast speed in power components and supporting components. Mechanical drive power components has stable performance, high reliability, etc. At present, mechanical drive power components used communication frequency conversion variable speed motors and dc servo motor, so as to make mechanical drive power components added new competition ability. Power components with steel rail, using the ball screw, static guide and aero-static bearing, tooth-type belts and other new structure, bearing parts by welding structure, etc. Due to the increase of precision and parts of dynamic and static performance, which is obviously improve the machining precision workpiece surface roughness. 1.4.2 increase productivity Currently combination machine tools and the cycle of increasing productivity, cycle time is generally 1 ~ 2 minutes, only 10 ~ 30 seconds. The main methods to improve productivity is to improve the machine tool layout, increase and decrease of machining tool, cutting dosages, improve the machining allowance, work to improve the reliability and shorten the assistant time etc. In order to reduce the loss of the cycle of the cycle, parking, electronic computers are flexible management of the cycle. 1.4.3 enlarge machining scope Now combination machine tools and the cycle is completed a general has a few processes of workpieces, and is often used to finish all the processing procedure. Workpiece, Besides finished graphic milling, drilling past, reaming holes, tapping, economic, boring, has now expanded to finish machining, grinding and cutting, fine boring and machining (such as inspection, automatic assembly, cleaning, etc) and the classification of print test procedure. 1.4.4 improve the machining accuracy Now in the combination machine tools and the cycle again into a lot of machining processes, such as: 1, fine boring hole processing position in 0.02 millimeters. In order to make the cycle can guarantee machining precision, stability and has been widely adopted automatically measuring tools and techniques that are automatically compensated, adjustable knives don't stop. 1.4.5 increased automation Currently combination machine tools and the cycle is developing very rapidly, and more and more combination machine tools for composition, modular machine tool itself is the cycle is the development direction of automatic. Therefore, the key is to solve the workpiece clamp pressure automation and handling automation. 1.4.6 improve combination machine tools and automatic line Small batch production to improve the productivity of some of the cabinet, in recent years the development process of adjustable knives of combination machine tools and automatic line, they are using digital control program. In the early development of many varieties, grouping processing combination machine tools and automatic line, also created automatically change and change automatic machine, combination of spindle box for small batch production process can be automatically replaced the spindle box on the combination machine tools. Using a tool that can complete the whole process of a workpiece machining, can play the role of a line. Especially the development of digital control program for the development of this kind of machine tools, creating more favourable conditions. 1.4.7 researchason super-mini combination machine tools In order to adapt to the instrument industry small box processing need, creating super-mini combination machine tools are required. This machine by the hydraulic head more super-mini pneumatic configuration, small size, high efficiency, and can achieve high machining accuracy. 1.4.8 developing special combination machine tools and automatic line Along with the development of technology, the combination of machine has been used to specific objects designed according to the general, but can be used as varieties of batch production, processing products according to your own user needs, process equipment, tools and machining certain objects can be composed of efficient tool. 組合機(jī)床的研究與發(fā)展 組合機(jī)床是由大量的通用部件和少量專用部件組成的工序集中的高效專用機(jī)床。它能夠?qū)σ环N（或多種）零件進(jìn)行多刀、多軸、多面、多工位加工。在組合機(jī)床上可以完成鉆孔、擴(kuò)孔、鉸孔、鏜孔、攻絲、車削、銑削、磨削及滾壓等工序，生產(chǎn)效率高，加工精度穩(wěn)定。 組合機(jī)床與通用機(jī)床、其他專用機(jī)床比較，具有以下特點(diǎn)： (1)組合機(jī)床上的通用部件和標(biāo)準(zhǔn)零件約占全部機(jī)床零、部件總量的70~80%，因此設(shè)計(jì)和制造的周期短，投資少，經(jīng)濟(jì)效果好。 (2)由于組合機(jī)床采用多刀加工，并且自動(dòng)化程度高，因而比通用機(jī)床生產(chǎn)效率高，產(chǎn)品質(zhì)量穩(wěn)定，勞動(dòng)強(qiáng)度低。 (3)組合機(jī)床的通用部件是經(jīng)過周密設(shè)計(jì)和長(zhǎng)期生產(chǎn)實(shí)踐考驗(yàn)的，又有專門廠成批制造，因此結(jié)構(gòu)穩(wěn)定、工作可靠，使用和維修方便。 (4)在組合機(jī)床上加工零件時(shí)，由于采用專用夾具、刀具和導(dǎo)向裝置等，加工質(zhì)量靠工藝裝備保證，對(duì)操作工人的技術(shù)水平要求不高。 (5)當(dāng)被加工產(chǎn)品更新時(shí)，采用其他類型的專用機(jī)床時(shí)，其大部部件要報(bào)廢。用組合機(jī)床時(shí)，其通用部件和標(biāo)準(zhǔn)零件可以重復(fù)利用，不必另行設(shè)計(jì)和制造。 (6)組合機(jī)床易于聯(lián)成組合機(jī)床自動(dòng)線，以適應(yīng)大規(guī)模的生產(chǎn)需要。 組合機(jī)床雖然有很多優(yōu)點(diǎn)，但也還有缺點(diǎn)： (1)組合機(jī)床的可變性較萬能機(jī)床低，重新改裝時(shí)有10%~20%的零件不能重復(fù)利用，而且改裝時(shí)勞動(dòng)量較大。 (2)組合機(jī)床的通用部件不是為某一種機(jī)床設(shè)計(jì)的，它是具有較廣的適應(yīng)性。這樣，就使組合機(jī)床的結(jié)構(gòu)較專用機(jī)床稍為復(fù)雜些。 1.2組合機(jī)床的分類 組合機(jī)床有大型組合機(jī)床與小型組合機(jī)床兩大類，它們不僅在體積和功率上有大小之別，而且在結(jié)構(gòu)和配置型式等方面也有很大的差異。這里主要說明大型組合機(jī)床的配置型式。大型組合機(jī)床的配置型式可分為三大類： 1.2.1具有固定式夾具的單工位組合機(jī)床 這類組合機(jī)床夾具和工作臺(tái)都固定不動(dòng)。動(dòng)力滑臺(tái)實(shí)現(xiàn)進(jìn)給運(yùn)動(dòng)，滑臺(tái)上的動(dòng)力箱實(shí)現(xiàn)切削主運(yùn)動(dòng)。根據(jù)動(dòng)力箱和多軸箱的安置方式不同，又可分為以下幾種： (1)臥式組合機(jī)床（動(dòng)力箱水平安裝）； (2)立式組合機(jī)床（動(dòng)力箱垂直安裝）； (3)傾斜式組合機(jī)床（動(dòng)力箱傾斜安裝）； (4)復(fù)合式組合機(jī)床（動(dòng)力箱具有上述兩種以上的安裝狀態(tài)）。 1.2.2具有移動(dòng)式夾具的（多工位）組合機(jī)床 這類組合機(jī)床的夾具安裝在直線移動(dòng)工作臺(tái)或回轉(zhuǎn)工作臺(tái)上，并按照一定的節(jié)拍時(shí)間作間歇移動(dòng)或轉(zhuǎn)動(dòng)，使工位得到轉(zhuǎn)換。這類機(jī)床的配置型式，常見的有以下四種。 (1)具有移動(dòng)工作臺(tái)的機(jī)床，這類機(jī)床的夾具和工件可作直線往復(fù)移動(dòng)。 (2)具有回轉(zhuǎn)工作臺(tái)的機(jī)床，這種機(jī)床的夾具和工件可繞垂直軸線回轉(zhuǎn)，在回轉(zhuǎn)工作臺(tái)上每個(gè)工位通常都裝有工件。 (3)鼓輪式機(jī)床，這種機(jī)床的夾具和工件可繞水平軸線回轉(zhuǎn)。此種機(jī)床一般為臥式單面或臥式雙面，而較少采用三面配置。此外也有輻射式的，它除了安裝臥式動(dòng)力部件外，還在垂直于鼓輪回轉(zhuǎn)的平面上安裝動(dòng)力部件。 (4)中央立柱式機(jī)床，這種機(jī)床具有臺(tái)面直徑較大的環(huán)形回轉(zhuǎn)工作臺(tái)。在工作臺(tái)中央安裝立柱，立柱上安裝動(dòng)力部件，而在工作臺(tái)的周圍還安裝有臥式動(dòng)力部件，工件和夾具則安裝在回轉(zhuǎn)工作臺(tái)上，這種機(jī)床一般都是復(fù)合式的。 1.2.3轉(zhuǎn)塔多軸箱式組合機(jī)床 轉(zhuǎn)塔多軸箱式組合機(jī)床分為兩類：?jiǎn)屋S轉(zhuǎn)塔動(dòng)力頭式組合機(jī)床和多軸轉(zhuǎn)塔頭式組合機(jī)床。前者轉(zhuǎn)塔頭的每個(gè)結(jié)合面可安裝一個(gè)剛性主軸。后者轉(zhuǎn)塔頭的每個(gè)結(jié)合面可安裝一個(gè)多軸箱。這種機(jī)床一般配置型式有： (1)轉(zhuǎn)塔式多軸箱只實(shí)現(xiàn)切削運(yùn)動(dòng)，被加工零件安裝在滑臺(tái)上，由滑臺(tái)實(shí)現(xiàn)進(jìn)給運(yùn)動(dòng)； (2)轉(zhuǎn)塔式多軸箱安裝在滑臺(tái)上，轉(zhuǎn)塔式多軸箱既實(shí)現(xiàn)切削主運(yùn)動(dòng)又實(shí)現(xiàn)進(jìn)給運(yùn)動(dòng)。 其中，轉(zhuǎn)塔多軸箱式組合機(jī)床可能組成雙面式或三面式，同時(shí)對(duì)工件的兩、三個(gè)平面進(jìn)行加工。 1.3組合機(jī)床的工藝范圍 組合機(jī)床可完成的工藝有銑平面、刮平面、車端面、鉆孔、擴(kuò)孔、鏜孔、鉸孔、攻絲、倒锪窩、鉆深孔、切槽等。隨著綜合自動(dòng)化技術(shù)的發(fā)展，組合機(jī)床可完成的工藝范圍也在不斷擴(kuò)大，除了上述工藝外，還可完成車外圓、車錐面、車弧面、切削內(nèi)外螺紋、滾壓孔、拉削內(nèi)外圓柱面和平面、磨削、拋光、珩磨，甚至還可以進(jìn)行沖壓、焊接、熱處理、裝配、自動(dòng)測(cè)量和檢查等。 1.4組合機(jī)床的發(fā)展方向 近幾年組合機(jī)床在汽車、拖拉機(jī)、柴油機(jī)、電機(jī)、儀器、縫紉機(jī)、自行車、閥門、礦山機(jī)械、冶金、航空、紡織機(jī)械及軍工等部門已獲得廣泛的使用，一些中小批量生產(chǎn)部門也開始推廣使用。我國在組合機(jī)床及其自動(dòng)線上將獲得較快的發(fā)展，其發(fā)展方向?yàn)椋? 1.4.1提高通用部件的水平 衡量通用部件水平的主要標(biāo)準(zhǔn)是：品種規(guī)格齊全，動(dòng)、靜態(tài)性能參數(shù)先進(jìn)，工藝性好，精度高和精度保持性好。 目前應(yīng)注意開發(fā)適應(yīng)強(qiáng)力銑削的大功率動(dòng)力滑臺(tái)，高精度鏜削頭和高精度滑臺(tái)，以及適應(yīng)中、小批生產(chǎn)的快調(diào)、速換動(dòng)力部件和支承部件。 機(jī)械驅(qū)動(dòng)的動(dòng)力部件具有性能穩(wěn)定，工作可靠等優(yōu)點(diǎn)。目前，機(jī)械驅(qū)動(dòng)的動(dòng)力部件應(yīng)用了交流變頻調(diào)速電機(jī)和直流伺服電機(jī)等，使機(jī)械驅(qū)動(dòng)的動(dòng)力部件增添了新的競(jìng)爭(zhēng)能力。 動(dòng)力部件采用鑲鋼導(dǎo)軌、滾珠絲杠、靜壓導(dǎo)軌、靜壓軸承、齒形皮帶等新結(jié)構(gòu)，支承部件采用焊接結(jié)構(gòu)等。由于提高了部件的精度和動(dòng)、靜態(tài)性能，因而使被加工的工件精度明顯提高，表面粗糙度減小。 1.4.2提高生產(chǎn)率 目前組合機(jī)床及其自動(dòng)線的生產(chǎn)率不斷提高，循環(huán)時(shí)間一般是1~2分鐘，有的只用10~30秒。提高生產(chǎn)率的主要方法是改善機(jī)床布局，增加同時(shí)加工的刀具，減少加工余量，提高切削用量，提高工作可靠性以及縮短輔助時(shí)間等。為了減少自動(dòng)線的停車損失，提高自動(dòng)線的柔性，采用電子計(jì)算機(jī)進(jìn)行自動(dòng)線的管理。 1.4.3擴(kuò)大工藝范圍 現(xiàn)在組合機(jī)床及其自動(dòng)線一般已不是完成一個(gè)工件的某幾道工序，而常常是用于完成工件的全部加工工序。除過去完成平面銑削、鉆孔、擴(kuò)孔、锪孔、攻絲、粗鏜孔外，現(xiàn)在已擴(kuò)大到能完成車削、磨削、拉削、精鏜以及非切削加工（如檢查、自動(dòng)裝配、清洗、試驗(yàn)以及打印分類等）工序。 1.4.4提高加工精度 現(xiàn)在在組合機(jī)床及其自動(dòng)線上又納入了很多精加工工序，如進(jìn)行1級(jí)精鏜，保證孔加工位置度在0.02毫米。為了使自動(dòng)線能穩(wěn)定地保證加工精度，已廣泛采用自動(dòng)測(cè)量和刀具自動(dòng)補(bǔ)償技術(shù)，保證調(diào)刀不停車。 1.4.5提高自動(dòng)化程度 目前組合機(jī)床及其自動(dòng)線發(fā)展十分迅速，越來越多的組合機(jī)床用于組成自動(dòng)線，組合機(jī)床本身則是全自動(dòng)方向發(fā)展的。為此，重點(diǎn)是解決工件夾壓自動(dòng)化和裝卸自動(dòng)化。 1.4.6提高組合機(jī)床及其自動(dòng)線的可調(diào)性 為了提高中小批生產(chǎn)的一些箱體件的生產(chǎn)率，近幾年來發(fā)展了可調(diào)的多工序多刀具的組合機(jī)床及其自動(dòng)線，它們大多采用數(shù)字程序控制。除早期發(fā)展的多品種、成組加工的組合機(jī)床及其自動(dòng)線外，還創(chuàng)造了自動(dòng)換刀和自動(dòng)更換多軸箱的組合機(jī)床，還有用于加工中小批生產(chǎn)箱體零件的可自動(dòng)更換對(duì)多軸箱的組合機(jī)床。用一臺(tái)這樣的機(jī)床就能完成一種工件的全部工序加工，能起到一條流水線的作用。特別是數(shù)字程序控制的發(fā)展，為發(fā)展這種機(jī)床創(chuàng)造了更有利的條件。 1.4.7創(chuàng)制超小型組合機(jī)床 為了適應(yīng)儀器儀表工業(yè)小箱體加工需要，創(chuàng)制超小型組合機(jī)床是必需的。這種機(jī)床多由超小型氣動(dòng)液壓頭配置而成，體積小，效率高，并能達(dá)到高的加工精度。 1.4.8發(fā)展專用組合機(jī)床及其自動(dòng)線 隨著組合機(jī)床技術(shù)的發(fā)展，過去一直被認(rèn)為需按具體加工對(duì)象專門設(shè)計(jì)，而是可以作為通用品種進(jìn)行成批生產(chǎn)的，用戶根據(jù)自己加工產(chǎn)品的需要，配上刀具及工藝裝備，即可組成加工一定對(duì)象的高效機(jī)床。 閱讀書目 [1] 章宏甲.黃誼主編．液壓傳動(dòng)[M]. 北京:機(jī)械工業(yè)出版社.1993 [2] 大連組合機(jī)床研究所編.組合機(jī)床設(shè)計(jì)第一冊(cè)[M]．北京:機(jī)械工業(yè)出版社.1975 [3] 大連組合機(jī)床研究所編.組合機(jī)床參考圖冊(cè)[M].北京:機(jī)械工業(yè)出版社.1975 [4] 彭文生等主編．機(jī)械設(shè)計(jì)[M]．華中理工大學(xué)出版社.2001 [5] 唐增寶等主編．機(jī)械設(shè)計(jì)課程設(shè)計(jì)[M]．華中理工大學(xué)出版社.1999 [6]沈陽工學(xué)院等編.組合機(jī)床設(shè)計(jì)[M]. 上海: 上海科學(xué)技術(shù)出版社.1985 [7] 大連組合機(jī)床研究所編.組合機(jī)床設(shè)計(jì)第二冊(cè)[M]．北京:機(jī)械工業(yè)出版社.1975 [8]金屬切削機(jī)床設(shè)計(jì). 上海:上?？茖W(xué)技術(shù)文獻(xiàn)出版社[M].1986 [9]金屬切削機(jī)床(下冊(cè)). 北京:機(jī)械工業(yè)出版社[M].1990 [10]趙大興等主編.工程圖學(xué) .湖北科學(xué)技術(shù)出版社[M].2005 [11] 左健民主編.液壓與氣壓傳動(dòng).機(jī)械工業(yè)出版社[M].2002