六孔臥式組合鉆床設計

購買設計請充值后下載，資源目錄下的文件所見即所得，都可以點開預覽，資料完整，充值下載可得到資源目錄里的所有文件?！咀ⅰ浚篸wg后綴為CAD圖紙，doc,docx為WORD文檔，原稿無水印，可編輯。具體請見文件預覽，有不明白之處，可咨詢QQ:12401814 UNIVERSITY本 科 畢 業(yè) 論 文（設 計）題目： 六孔臥式組合鉆床設計 學 院： 姓 名： 學 號： 專 業(yè)： 機械設計制造及其自動化 年 級： 指導教師： XXXXXXXX職 稱：副教授 二0一二 年 5月 摘要 隨著我國經濟的發(fā)展，工業(yè)生產在國民經濟中占據著尤為重要的地位。鉆床作為機械制造和修配工廠必不可少的設備，具有廣泛用途的通用性機床，可對零件進行鉆孔，擴孔，鉸孔，锪平面和攻螺紋等加工。同時鉆床又存在著加工精度，加工效率不高等缺陷。在我國，組合鉆床發(fā)展已有28年的歷史，其科研和生產都具有相當的基礎，應用也已深入到很多行業(yè)。是當前機械制造業(yè)實現產品更新，進行技術改造，提高生產效率和高速發(fā)展必不可少的設備之一。它的特征是高效、高質、經濟實用，因而被廣泛應用于工程機械、交通、能源、軍工、輕工、家電等行業(yè)。我國傳統的組合鉆床及組合機床自動線主要采用機、電、氣、液壓控制，它的加工對象主要是生產批量比較大的大中型箱體類和軸類零件，完成鉆孔、擴孔、鉸孔，加工各種螺紋、鏜孔、在孔內鏜各種形狀槽等。本文設計的六孔臥式組合鉆床，作為一種專用機床其生產效率高，加工精度高，特別適合于加工一些有多個孔并對孔的位置精度要求高的工件。 關鍵詞 ：鉆床；六孔；臥式；組合鉆床；加工精度；床身；導軌；主軸箱 19 Abstract With the development of our national economy, industrial production in the national economy occupy a very important position. Drilling machinery manufacturing and repair factory as essential equipment, with wide application of universal machine tool, the parts for drilling, reaming, reaming, reaming and tapping processing plane. While drilling has the processing precision, processing efficiency is not high. In our country, the combination drilling machine development has 28 years of history, its scientific research and production, have a considerable foundation, application also penetrated into many industries. Is the machinery manufacturing industry to realize product updates, technical innovation, improve the production efficiency and the rapid development of one of the essential equipment. It is characterized by high efficiency, high quality, economical and practical, so it has been widely used in engineering machinery, transportation, energy, industry, light industry, household appliances industry. Our traditional combination drilling machine and the combined machine tool automatic line mainly uses the machine, electricity, gas, hydraulic control, its processing object is mainly the production lot larger-and medium-bold type and shaft parts, finished drilling, reaming, reaming, the processing of thread, boring, in various shapes such as Kong Neitang tank.This design six-hole horizontal combination drilling machine, as a kind of special machine for its high production efficiency, high processing precision, particularly suitable for processing with a plurality of holes and the position precision of the holes demanding workpiece.Key words: drilling machine; tin; horizontal; combination drilling machine; precision machining; bed; rail; spindle box 目 錄1. 機床設計的目的，內容，要求11.1 設計目的11.2 設計內容11.3 設計要求11.4 調查研究11.5 擬定方案21.6 工作圖設計22. 組合機床的總體設計22.1 組合機床方案的制定22.1.1 制定工藝方案22.1.2 確定組合機床的配置形式和結構方案32.2 工藝的確定42.2.1 確定工序間余量42.2.2 選擇切削用量42.2.3 確定切削力，切削扭矩，切削功率42.2.4 選擇刀具結構52.2.5 確定軸向進給力52.2.6 確定進給速度，行程52.3 齒輪箱的設計52.3.1確定傳動線路圖62.3.2帶傳動的設計62.3.2.1定V帶型號和帶輪直徑62.3.2.1 帶輪材料與結構72.3.3 傳動軸的設計72.3.3.1 軸的設計72.3.3.2 主軸的設計102.3.4 齒輪的設計112.3.4.1 齒輪的材料112.3.4.2 齒輪的參數設計122.3.5 主軸箱的設計152.4. 床身的設計15參考文獻17致謝18 1. 機床設計的目的，內容，要求1.1 設計目的 機床設計畢業(yè)設計，其目的在于通過機床主運動機械變速傳動系統的結構設計，使我們在擬定傳動和變速的結構方案過程中，得到設計構思，方案的分析，結構工藝性，機械制圖，零件計算，編寫技術文件盒查閱資料等方面的綜合訓練。樹立正確的設計思想，掌握基本的設計方法，使自己具有初步的結構分析，結構設計和計算能力。1.2 設計內容（1）運動設計 根據給定的被加工零件，確定機床的切削用量，通過分析比較擬定傳動方案和傳動系統圖，確定傳動副的傳動比及齒輪的齒數，并計算主軸的實際轉速和標準的相對誤差。（2）動力設計 根據給定的工件，計算傳動軸的直徑，齒輪的模數，確定動力箱，計算多軸尺寸及設計傳動路線，完成裝配草圖后，要驗算傳動軸的直徑，齒輪模數是否在允許范圍內，還要驗算主軸的靜剛度。（3）結構設計 進行主運動傳動軸系，變速機構，主軸主件，箱體，潤滑與密封等的布置和機構設計，既繪制裝配圖和零件工作圖。（4）編寫設計說明書1.3 設計要求 評價機床性能的優(yōu)劣主要是根據技術經濟指標來判定的。技術先進合理，亦即質優(yōu)價廉才會受到用戶的青睞，在國內和國外市場上才有競爭力。機床設計的技術經濟指標可以從滿足性能要求，經濟效益和人機關系等方面進行分析。1.4 調查研究 研究市場和用戶對設計機床的要求，然后檢索有關資料。其中包括情報，預測，實驗研究結果，發(fā)展趨勢，新技術應用以及相應的圖紙資料等。甚至還可以通過網絡檢索技術查閱先進國家的相關資料和專利等。通過對上述資料的分析研究，擬定適當的方案，以保證機床的質量和提高生產率，使用戶有較好的經濟效益。1.5 擬定方案 通常可以擬定出幾個方案進行分析比較，每個方案包括的內容有：工藝分析，主要技術要求，總布局，傳動系統，控制操作系統，電系統，主要部件的結構草圖，實驗結果及技術經濟分析等。 在制定方案時應注意以下幾個方面：（1） 當使用和制造出現矛盾時，應滿足使用要求，其次才是盡可能便于制造，要盡量用先進的工藝和創(chuàng)新的結構;（2） 設計必須以生產實踐和科學實驗為依據，凡是未經過實踐考驗的方案，必須經過實驗驗證可靠后才能用于設計（3） 繼承與創(chuàng)新相結合，盡量采用先進工藝，迅速提高生產力，為實現四個現代化服務，注意吸取前人和國外的經驗，并在此基礎上有所創(chuàng)新和發(fā)展；1.6 工作圖設計首先，在選定工藝方案并確定機床配置形式，結構方案基礎上，進行方案圖紙的設計。這些圖紙包括：該加工零件工序圖，加工示意圖，機床聯系尺寸圖和生產率計算卡。并初步擬定主軸箱輪廓尺寸，才能確定機床各部件間的相互關系。其次，繪制機床的總裝圖，部分部件裝配圖，液壓系統圖，PLC接線圖和梯形圖。然后，整理機床有關部件與主要零件的設計計算書，編制各類零件明細表，編寫機床說明書等技術文件。最后，對有關圖紙進行工藝審查和標準化審查。2. 組合機床的總體設計2.1 組合機床方案的制定2.1.1 制定工藝方案 零件加工工藝將決定組合機床的加工質量，生產率，總體布局和夾具結構等。所以，在制定工藝方案時，必須計算分析被加工零件圖，并深入現場了解零件的形狀，大小，材料，硬度，剛度，加工部位的結構特點加工精度，表面粗糙度，以及定位，加緊方法，工藝過程等。所采用的刀具及切削用量，生產率要求，現場采用的環(huán)境和條件等。并收集國內外有關技術資料，制定出合理的工藝方案。根據被加工零件的零件圖（圖1），定出工藝方案 （1）加工孔的主要技術要求 加工6個20，深100mm的通孔 孔的位置度公差為0.1mm，孔在同一平面上 工件材料為#45鋼 要求生產綱領為年生產6萬件，單班制生產 圖1 加工零件圖 (2)工藝分析加工該孔時，孔的位置度公差為0.1，可采用一次性鉆孔 2.1.2 確定組合機床的配置形式和結構方案 （1）被加工零件的加工精度 被加工零件需要在組合機床上完成的加工工序及應保證的加工精度，是制造機床方案的主要依據。該工件的加工孔的精度要求不高，可采用鉆孔組合機床，工件各孔見位置精度為0.1mm,安排加工時可通過一次鉆孔完成。在該工序孔的表面粗糙度要求為Ra25mm。采取提高機床原始制造精度和工件定位基準精度并減少夾壓變形等措施就可以了。為此，機床通常采用位置式齒輪動力裝置，進給采用液壓系統，人工夾緊。 （2）被加工零件特點 這主要指零件的材料，硬度，形狀，剛度定位精準面的特點，他們對機床工藝方案制定有著重要的影響。此工件材料為#45鋼，硬度為HB170-200，孔在整個工件上呈60度均勻分配，采用多孔同步加工，零件的剛度足夠，工件的受力不大，震動，發(fā)熱變形對對工件影響不大。 由于該零件的中心線與定位基準面平行，可采用臥式機床 （3）零件的生產批量 零件的生產批量是決定采用單工位，多工位，自動線或按中小批量生產特點設計組合機床的重要因素。按設計要求生產綱領為年產6萬件，從工件外形及輪闊尺寸，為了減少加工時間，采用多軸頭。（4） 機床使用步置 使用組合機床對車間布置情況，工序間的聯系，使用廠的技術能力和自然條件等一定的要求。再根據用戶實際情況來選擇什么樣的組合機床。 綜合以上所述：通過對零件的結構特點，加工部位，尺寸精度，表面粗糙度和技術要求，定位，夾緊方式，工藝方法，并定出影響機床的總體布局和技術性能等方面的考慮，最終決定采用六軸頭多工位同步鉆床。 2.2 工藝的確定 2.2.1 確定工序間余量 為使加工過程順利進行并保證加工精度，必須合理地確定工序間余量。生產中常用查表給出的組合機床對孔加工的工序余量，由于在本鉆床上只進行粗鉆，為達到最終20的要求后面還要進行鉸孔，所以這次的鉆孔直徑為19.5，直徑上工序余量為0.5mm2.2.2 選擇切削用量確定了在組合機床上完成的工藝內容了，就可以著手選擇切削用量了。因為所設計的組合機床為多軸同步加工，在大多數情況下所選擇切削用量根據經驗比一般通用機床單刀加工低30%左右。多軸主軸箱上所有刀具共用一個進給系統，通常為標準動力滑臺，工作時要求所有刀具的每分鐘進給量相同，且等于動力滑臺的每分鐘進給量（mm/min）。因此，同一主軸箱可設計成不同轉速和不同的每轉進給量與其相適應。以滿足不同直徑的加工要求，即： n1.f1=n2f2=nifi=vf （1-1）式中：n1.， n2 ，n2-各主軸轉速 （r/min）f1。f2.fi 各主軸進給量（mm/r） vf動力滑臺每分鐘進給量（mm/min） 由于該工件的加工精度，工件材料，工作條件，技術要求都是相同的。按照經濟的選擇滿足加工要求的原則，采用查表的方法得：鉆頭直徑D=19.5mm，材料為高速鋼，進給量f=0.1mm/r，切削速度v=20mm/min2.2.3 確定切削力，切削扭矩，切削功率根據選定的切削用量確定切削力，作為選擇動力部件及夾具設計的依據；確定切削扭矩，用以確定主軸及其他傳動件（齒輪，傳動軸）的尺寸；確定切削功率，用以選擇主電動機功率，通過查表計算如下： 軸向力： F=N （1-2）計算得：F=9.8161.219.510.10.7=2335.9N鉆削扭矩 ： M=Nm (1-3) 計算得：M=9.810.031119.520.10.8 =18.4Nm鉆削功率： PC=2Mn W (1-4) 計算得：PC=23.1418.43.3=385.2W式中：f沒轉進給量（mm/r） n鉆頭轉速（r/s） 2.2.4 選擇刀具結構 工件的布氏硬度在HB170-240，孔徑D為19.5mm，刀具的選擇高速鋼鉆頭（W18Cr4V）.為了使工作可靠，結構簡單，選擇標準19.5的麻花鉆。 2.2.5 確定軸向進給力 F進=Fi=62335.9=14015.4N 式中：Fi各主軸加工時產生的軸向力由于滑臺工作時，除了要克服各主軸的軸向進給力，還要克服滑臺移動時所產生的摩擦力。因而選擇滑臺的最大進給力應大于14.1KN。 2.2.6 確定進給速度，行程 滑臺的進給速度分為快進，工進，快退，所以要求液壓系統能實現3 種速度間的轉換。其中快進行程為200mm，工進110mm，快退310mm。2.3 齒輪箱的設計2.3.1確定傳動線路圖圖2 傳動示意圖 1.電動機 2.小帶輪 3.大帶輪 4.傳動軸 5.小齒輪 6.主軸 7.大齒輪2.3.2帶傳動的設計2.3.2.1定V帶型號和帶輪直徑 定V型帶型號和直徑工作情況系數 KA=1.1計算功率 PC= KAP=1.12.5=2.75PC=3KW小帶輪轉速 n1=1440r/min選帶型號A型小帶輪直徑 由表得取D1=90mm大帶輪直徑 D2=(1-)D1n1/n2取D2=224mm大帶輪轉速 n2=(1-)D1n1/D2=576n2=576r/min 計算帶長求Dm Dm=（D1+D2）/2Dm=157mm求 = （D2-D1）/2=67 mm初取中心距a=650mm帶長L=Dm+2a+2/a Ld=787.5mm基準長度 L=800mm 求中心距和包角中心距 a=130mm小輪包角1=180o-60o（D2-D1）/a =121.3120o 1=121.3o 求帶根數帶速v= D1n1/(601000)v=6.78m/s傳動比 i= n1/ n2 i=2.5帶根數 由表得 P0=1.07kw; Ka=0.83 KL=0.85; P0=0.17 Z=PC/(P+P0) Ka KL=2.87 取Z=3 求軸上載荷張緊力 F0=128N軸上載荷 FQ=2Z F0sin(a1/2)FQ=665.1N2.3.2.1 帶輪材料與結構當帶速v30/s的傳動帶，其帶輪一般用HT200制造。所以帶輪的材料選擇HT200。當帶輪的直徑D2-3d時常采用實心式，中等尺寸是常采用腹板式。所以小帶輪采用實心式，大帶輪采用腹板式。 2.3.3 傳動軸的設計 2.3.3.1 軸的設計（1） 軸的選材 軸的材料為40Cr，調質處理，齒輪表面在進行高頻淬火 （2）計算齒輪受力 由于軸上齒輪對稱分布所以徑向受力相互抵消 （3）計算支撐反力 垂直面反力F1=665N ,FR1=997.5N, FR2=332.5N (4) 軸的結構圖 圖3 傳動軸的結構 （5）軸的受力圖 圖4 軸的受力圖 (6) 軸的垂直面受力圖 圖5 軸的垂直面受力圖 （7） 軸的彎矩圖 圖6 軸的彎矩圖 最大彎矩M=40232.5Nmm （8）軸的扭矩圖 圖7 軸的扭矩圖 最大轉矩為47750nmm（9） 軸的當量彎矩圖 圖8 軸的當量彎矩圖 計算齒輪受力齒輪螺旋角=0齒輪直徑：小輪 大輪=50=150小齒輪受力：轉矩 圓周力 徑向力 軸向力=47750Nmm=1910N=695.2N=0N小齒輪軸受力圖見圖4 計算支撐反力垂直面反力=997.5N=332.5N垂直面受力圖見圖5水平面受力圖忽略重力 畫軸彎矩圖垂直面彎矩圖見圖6 畫軸扭矩圖軸受轉矩T=T=47750Nmm扭矩圖見圖7 許用應力許用應力用插入法查表得：=102.5Mpa=60Mpa=102.5Mpa=60Mpa應力修正系數=0.59 畫當量彎矩圖當量轉矩T=0.5947750T=28172Nmm當量彎矩在小齒輪中間截面處在左軸頸處=見圖8=40737Nmm=49115Nmm當量彎矩圖見圖8 校核軸徑齒根圓直徑=43.7543.75mm軸徑18.943.75=20.240mm 2.3.3.2 主軸的設計 本鉆床共有六根主軸，鉆頭安裝在主軸上。故對主軸的強度剛度要求較高。為滿足要求材料選擇45號鋼，初定直徑35mm。熱處理為調質處理，表面硬度為220-250HBS。軸的設計與校核過程與上類似。 （1）主軸1的結構圖如下 圖9 主軸1的結構圖 （2）主軸2的結構圖 圖10 主軸2的結構圖 2.3.4 齒輪的設計 2.3.4.1 齒輪的材料 齒輪傳動要求齒輪表面具有較高的硬度與耐磨性，同時齒根還要具有較高的強度。在齒輪傳動過程中由于小齒輪直徑小每個齒重復嚙合的次數更多，導致小齒輪過早失效。所以小齒輪選擇40Cr,大齒輪為#45鋼，表面熱處理均為表面淬火。2.3.4.2 齒輪的參數設計齒面接觸疲勞強度計算1.初步計算轉矩T1 T1=18400Nmm齒寬系數d 查表得d=1.0d=1.0接觸疲勞極限 Hlim1Hlim1=710MpaHlim2=580Mpa初步計算的許用接觸應力HH1=0.9 Hlim1H2= 0.9 Hlim2 H1=639MpaH2=522Mpa初步計算的小齒輪直徑d1取d1=50mm初步齒寬b b=40mm2.校核計算 圓周速度v v= =1.35m/s v=1.35m/s 精度等級選6級 齒數z和模數m 初取z1=20,z2=iz1=60m=d1/ z1=2.5 m=2.5z1=20z2=60 使用系數KA KA=1.25 動載系數KV KV=1.1 齒間載荷分配系數KHa 齒間載荷分配系數KHa Ft=2T1/d1=817.7N KAFt/b=22.7N/mm100N/mm a=1.88-3.2(1/ z1+1/ z2)cos =1.64 Z=0.79 由此得KHa= =1.6 a=1.64Z=0.79KHa=1.6齒向載荷分布系數KH =A+B()2+C10-3b =1.11+0.16()2+0.4710-340=1.75 =1.75載荷系數K K=KA KV KHa KHK=3.85彈性系數ZE 查表得ZE=189.8節(jié)點區(qū)域系數ZH ZH=2.5接觸最小安全系數SHmin SHmin=1.25接觸壽命系數ZN ZN1=1.18 許用接觸應力H H1= =670MPa H2= =580MPa H1=670MPaH2=580MPa驗算 計算結果表明，接觸疲勞強度較為合理，輪尺寸無需調整。=572.4Mpa H2（3）確定傳動主要尺寸 實際分度圓直徑d d1=mz1=2.520=50mm =mz2=2.560=150mm d1=50mm=150mm中心距a a= a=100mm齒寬bb=40mm齒根彎曲疲勞強度重合度系數 Y=0.25+ Y=0.71齒間載荷分配系數KFa KFa=1/ Y KFa=1.41齒向載荷分布系數KF b/h=7.1 查表得KF=1.5載荷系數K K= KA KV KFa KFa=2.9 K=2.9齒形系數YFa YFa1=2.9YFa2=2.32應力修正系數YSa YSa1=1.53 YSa2=1.74彎曲疲勞極限Flim Flim1=620MPa Flim2=450MPa彎曲最小安全系數SFmin SFmin=1.6彎曲壽命系數YN YN1=0.95YN2=0.97尺寸系數YX YX=1.0許用彎曲應力F F1= F2= F1= 356.25MPaF2=272.8MPa驗算 F1= YSa1 YFa1 Y F2=F1 傳動無過載，故不作靜強度校核 其余的齒輪配合情況與這一對相同，所以參數完全一樣F1=203.5 MPa F1F2=185.1 MPa其余的齒輪配合情況與這一對相同，所以參數完全一樣2.3.5 主軸箱的設計 主軸箱是鉆床的重要部件，它上面安裝有鉆床的傳動系統以及主軸。其結構的合理性和性能的好壞直接影響著機床的制造成本；影響著鉆床對零件加工的精度，同時也影響著機床的工作效率和壽命等。因此，主軸具有足夠的靜態(tài)剛度和良好的動態(tài)性能，較小的熱變形和內應力，并易于加工制造裝配等才能滿足鉆床對床身的要求。為保證鉆床的加工精度，應嚴格保證主軸箱各壁孔間的位置精度。主軸箱鑄造后為使性能穩(wěn)定應進行時效處理。加工時使用鏜床一次鏜同一軸上的兩個壁孔。 主軸箱的材料采用HT200，通過鑄造成型。內壁孔的精度等級為IT6，Ra1.6。 2.4. 床身的設計 （1）床身對鉆床性能的影響及其要求 床身是鉆床的主要支撐件，他支撐著鉆床的床頭箱，溜板，尾座等部件。承受著切削力，重力，摩擦力等靜態(tài)力的作用。其結構的合理性和性能的好壞直接影響著機床的制造成本；影響著鉆床各部件間的相對位置精度，和鉆床在工作中各運動部件的相對運動軌跡的準確性，從而影響工件的加工質量，還影響機床刀具的耐用度，同時也影響著機床的工作效率和壽命等。因此，床身具有足夠的靜態(tài)剛度和良好的動態(tài)性能，較小的熱變形和內應力，并易于加工制造裝配等才能滿足鉆床對床身的要求。 （2）床身的結構設計 鉆床工作時，主要受到水平方向和垂直方向的切削力的作用，使床身在水平面和垂直面內發(fā)生彎曲，以及在這些分力作用下的扭矩，其中，影響最大的是床身水平面的彎曲。因此，在床身不太長的情況下，主要應提高床身在水平面內的剛度。所以在床身的長度方向多布置幾個著力點，而且使主軸箱在靜止的時候重心落在左側的床腿間。床身的結構如圖11。 圖11 床身 參考文獻1邱宣懷、郭可謙、吳宗澤等.機械設計.4版.北京：高等教育出版社.2010.2劉混舉、趙河明、王春燕.機械可靠性設計.北京：國防工業(yè)出版社.2010.3楊光、席偉光、李波、陳曉岑.機械設計課程設計.2版.北京：高等教育出版社.2010.4金清肅、范順成、范曉珂.機械設計課程設計.武漢：華中科技大學出版社.2006.5王慧、呂宏、王連明.機械設計課程設計.北京：北京大學出版社.2011.6于永泗、齊民.機械工程材料.8版.大連：大連理工大學出版社.2010.7鄭文緯、吳克堅.機械原理.7版.北京：高等教育出版社.2010.8劉鴻文.材料力學.4版.北京：高等教育出版社.2010.9哈爾濱工業(yè)大學理論力學教研室.6版.北京：高等教育出版社.2004.10陳于萍、周兆元.互換性與測量技術基礎.2版.北京：機械工業(yè)出版社.2009.11何銘新、錢可強.機械制圖.5版.北京：高等教育出版社.2008.12蔣曉、沈培玉、苗青.AutoCAD2008中文版機械設計標準實例教程.北京：清華大學出版 社.2008.13成大先.機械設計手冊.單行本.軸及其聯接.M北京：化學工業(yè)出版社.2004.114韓榮第.金屬切削原理與刀具.3版.哈爾濱:哈爾濱工業(yè)大學出版社.2007.致謝 本次畢業(yè)設計得以順利完成，首先要感謝指導老師XXXXXXXX教授，班主任曾一凡教授，以及院里的各位老師。其次，也要感謝同學們對我的熱情幫忙。有了你們的幫助才讓我解決一個個的難題，在這里我對大家表示衷心的感謝！ 附錄：外文資料與中文翻譯外文資料：The Development Of Machine Tool Technologyand 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 90s 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 companys products competitiveness. 現代組合機床和自動線作為機電一體化產品，它是控制、驅動、測量、監(jiān)控、刀具和機械組件等技術的綜合反映。 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，這些技術有長足進步，同時作為組合機床主要用戶的汽車和內燃機等行業(yè)也有很大的變化，其產品市場壽命不斷縮短，品種日益增多且質量不斷提高。 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和激勵了組合機床和自動線技術的不斷發(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 在組合機床這類專用機床中，回轉式多工位組合機床(圖2)和自動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. 因為這兩類機床可以把工件的許多加工工序分配到多個加工工位上，并同時能從多個方向對工件的幾個面進行加工，此外，還可以通過轉位夾具(在回轉工作臺機床上)或通過轉位、翻轉裝置(在自動線上)實現工件的五面加工或全部加工，因而具有很高的自動化程度和生產效率，被汽車、摩托車和壓縮機等工業(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. 根據有關統計資料，德國在19901992年期間，回轉式多工位組合機床和自動線的產量約各占組合機床總數的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. 應指出，回轉式多工位組合機床實際上是一種特殊型式的小型自動線，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，以大批量生產為特征的轎車和輕型載貨車，其發(fā)動機的年產量通常為60萬臺左右，實現這樣大的批量生產，回轉式多工位組合機床和自動線在三班運行的情況下，其節(jié)拍時間一般為2030秒，當零件生產批量更大時，機床的節(jié)拍時間還要更短些(表1)。 At present, characterized by mass production of cars and light trucks, the engines 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 70s, 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給速度來縮短基本時間。 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，德國大眾汽車廠在加工鋁合金缸蓋燃燒室側面時，采用PCD銑刀，銑削速度高達3075m/min，進給速度達3600mm/min；又如，在鏜削灰鑄鐵缸體的缸孔時，采用裝有三個可轉位CBN刀片的新穎鏜刀頭，切削速度達800m/min，進給速度為1500mm/min，加工深度為146mm的缸孔，其實際加工時間僅為5.8s，比傳統加工工藝可縮短2/3的加工時間。 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. 縮短輔助時間主要是縮短包括工件輸送、加工模塊快速引進以及加工模塊由快進轉換為工進后至刀具切入工件所花的時間。 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60m/min或更高些，加工模塊快速移動速度達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，作為組合機床重要用戶的汽車工業(yè)，為迎合人們個性化需求，汽車變型品種日益增多(圖5)，以多品種展開競爭已成為汽車市場競爭的特點之一，這使組合機床制造業(yè)面臨著變型多品種生產的挑戰(zhàn)。 10 years, as the combination of machine tools important to the users 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. 為適應多品種生產，傳統以加工單一品種的剛性組合機床和自動線必須提高其柔性。 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 70s, numerical control system reliability has been greatly improved, it is to late 70s and early 80s, as Alfing, Hller-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 90s 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 centurys goal is to subordinate the factory the company flexible manufacturing systems coverage reached 100%.很顯然，組合機床及其自動線在保持其高生產效率的條件下，進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. 組合機床的柔性化主要是通過采用數控技術來實現的。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. 柔性組合機床和柔性自動線用的數控加工模塊，按其數控坐標(軸)數，主要有單坐標(Z)、雙坐標(XZ、YZ、ZU和ZB等)和三坐標(XYZ)加工模塊；按其主軸數，有單軸和多軸加工模塊，也有單軸和多軸復合加工模塊。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. 立柱移動式CNC三坐標加工模塊可利用X軸和Y軸的聯動來實現周邊銑削工藝，特別是在銑削象變速箱體這類剛性較差的工件時，可采用較小直徑的銑刀，實現高速(切削速度達2500m/min)周邊銑削，由此減小加工時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構形式，但基本上可分為自動換箱式多軸加工模塊(圖7)、轉塔式多軸加工模塊(圖8)和回轉工作臺式多軸加工模塊(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. 而轉塔式和回轉工作臺式多軸加工模塊，由于在轉塔頭和回轉工作臺上允許裝的多軸箱數量有限(一般為46個)，所以這種加工模塊只能實現有限品種的加工。 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. 在自動線上采用CNC三坐標加工模塊和轉塔式多軸加工模塊，不僅可實現不同品種工件的加工，而且在自動線節(jié)拍時間內(如果節(jié)拍時間允許的話)，這類加工模塊還可以在同一個加工工位上通過其自動換刀或換箱，依次實現多道加工工序(粗鏜、半精鏜和精鏜；鉆孔、擴孔和攻絲)，從而減少自動線的加工工位數，縮短自動線的長度。 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. 單軸和多軸復合加工模塊是一種三坐標數控加工模塊，可通過自動換刀或自動更換多軸箱而實現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Honsberg公司推出的CNCMACH模塊化系統(圖10)是很有特色的一種模塊化系統，該系統充分應用模塊化結構原理，在作為系統基礎模塊的CNC三坐標模塊上，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. CNCMACH系統，不僅在機械結構方面，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. 該線采用的數控加工模塊有四個雙坐標數控銑削模塊、六個數控轉塔式多軸加工模塊和六個數控三坐標加工模塊。 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，為進一步提高工件的加工精度和減少工件在生產過程中的中間儲存、搬運以及縮短生產流程時間，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、測量、裝配和試漏等)集成到自動線或自動線組成的生產系統中(圖15)，以實現工件加工、表面處理、測量和裝配等工序的綜合自動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. 當今，鑒于我們人類賴以生存的環(huán)境日益受到工業(yè)污染的破壞，環(huán)境保護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，國內外越來越關注工業(yè)清洗對環(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)部門的零件清洗轉向應用水劑清洗(采用酸性、中性或堿性清洗液，清洗液中主要含有磷酸鹽、活性劑和絡合劑等)，這種水劑清洗主要根據工件清洗質量要求而采用噴淋(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、現場操作工人的保健和清洗工藝的合理化等要求，目前，清洗機已普遍采用封閉式布局，整個清洗過程是自動進行的，設備控制采用可編程控制器，并自動監(jiān)控所有機械動作和工藝技術參數。 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 在自動線上采用自動測量旨在對工件的加工質量進行監(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. 在自動線上，自動測量可分為加工前測量和加工后測量。 The automatic line, automatic measurement can be divided into pre-processing measurement and processed measurements. 加工前測量是在工件加工前通過測量以確定工件的特征，并利用測量結果來調整刀具相對于工件待加工部位的位置，然后進行相應的加工。 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