C8955型铲磨床数控化改造关键技术的研究
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摘要
目前,我国存在大量的普通铲磨机床,甚至还有相当的一部分已经处于闲置状态,而在国内对数控化铲磨床生产的企业还没有出现,面对这一问题,本文以C8955型铲磨床为研究对象,对该机床进行了数控化改造。
本文首先对C8955型铲磨床的加工原理从理论上进行了分析和研究,提出了C8955型铲磨床数控化改造具体实施的相关步骤和方法；通过所选择的西门子840D数控系统,采用电子凸轮方法,代替了原有的机械传动链,解决了C8955型铲磨床的联动问题；通过光栅和旋转编码器形成的全闭环系统,保证了机床的加工精度；通过机械、动力学的原理和查阅进给系统的相关要求,对C8955型铲磨床的磨削力以及所需的滚珠丝杠进行了计算,解决了丝杠的选型；通过对C8955型铲磨床在加工过程中的干涉检验问题进行了研究,采用了图形分析计算法,解决了铲磨过程中的砂轮外径的选择问题；通过C8955型铲磨床的加工工艺路线,提出了数控化的加工艺过程,建立起数控化铲磨床加工过程的数学模型,编制出数控加工程序,实现了数控化的加工；通过VC++软件和选择的西门子840D数控系统的子程序编程说明,编制出相应的加工界面,操作人员只要将被加工滚刀的相关参数输入所设计的界面中就可以自动进行加工了。
通过对改造后的C8955型铲磨床进行调试和加工,使改造后的C8955型铲磨床的加工精度有了明显的提高,及时地提高生产设备地自动化水平,可实现一人控制多台这样的数控机床同时进行工作。这样就可以降低了操作员的数量,节省了劳动力,降低了劳动费用；改造后的机床性能高、质量好、还可以作为新的数控床继续使用多年。
At present, a large number of general relief grinding machine are used in our country and a lot of shovel grinder has been idle, Spade grinding machine of NC has not been produced in our country, Faced with this problem, C8955-type shovel grinder is used to study in this article and it is used for the transformation of NC.
First of all, the principle of C8955-type shovel grinder processing was carried out analysis and research in this article. Steps and methods of C8955-type shovel grinder have been proposed in the process of transformation of NC. Using selected Siemens 840D CNC system, electronic cam is instead of the original mechanical transmission chain, C8955 type shovel grinder linkage question is resolved by the use of electronic cam. Closed-loop system is formed by the grating and the rotary encoder to ensure the machining accuracy. By the principle of the mechanical and kinetic and the requirements of the feed system, the grinding force and ball were calculated, the choice of Screw is resolved. The hob and wheel of the interference problem is studied in the C8955 -type shovel grinder CNC transformation process, the selection of wheel diameter is solved by graphical analysis calculation. According to the principle of C8955-type shovel grinder, analysised and designed of CNC machining process, mathematical model is created, the NC machining program is weaved. Faced with this problem, the machining interface is weaved by VC++ software and selected the Siemens 840D CNC system programming, the relevant parameter of hob is inputted interface by the operator, NC shovel grinder can be automatically processed.
After transformation, the C8955 shovel grinder is used for debugging and handling, Machining accuracy and the level of automation of the production equipment has been significantly enhanced and perfect. An operator can control a large number of CNC machine to operate. Reduced the number of operating personnel, labored savings, reduced labor costs. The numerical transformation of machine has high performance and quality, It can continue to use for many years as a new CNC.
本文首先对C8955型铲磨床的加工原理从理论上进行了分析和研究,提出了C8955型铲磨床数控化改造具体实施的相关步骤和方法；通过所选择的西门子840D数控系统,采用电子凸轮方法,代替了原有的机械传动链,解决了C8955型铲磨床的联动问题；通过光栅和旋转编码器形成的全闭环系统,保证了机床的加工精度；通过机械、动力学的原理和查阅进给系统的相关要求,对C8955型铲磨床的磨削力以及所需的滚珠丝杠进行了计算,解决了丝杠的选型；通过对C8955型铲磨床在加工过程中的干涉检验问题进行了研究,采用了图形分析计算法,解决了铲磨过程中的砂轮外径的选择问题；通过C8955型铲磨床的加工工艺路线,提出了数控化的加工艺过程,建立起数控化铲磨床加工过程的数学模型,编制出数控加工程序,实现了数控化的加工；通过VC++软件和选择的西门子840D数控系统的子程序编程说明,编制出相应的加工界面,操作人员只要将被加工滚刀的相关参数输入所设计的界面中就可以自动进行加工了。
通过对改造后的C8955型铲磨床进行调试和加工,使改造后的C8955型铲磨床的加工精度有了明显的提高,及时地提高生产设备地自动化水平,可实现一人控制多台这样的数控机床同时进行工作。这样就可以降低了操作员的数量,节省了劳动力,降低了劳动费用；改造后的机床性能高、质量好、还可以作为新的数控床继续使用多年。
At present, a large number of general relief grinding machine are used in our country and a lot of shovel grinder has been idle, Spade grinding machine of NC has not been produced in our country, Faced with this problem, C8955-type shovel grinder is used to study in this article and it is used for the transformation of NC.
First of all, the principle of C8955-type shovel grinder processing was carried out analysis and research in this article. Steps and methods of C8955-type shovel grinder have been proposed in the process of transformation of NC. Using selected Siemens 840D CNC system, electronic cam is instead of the original mechanical transmission chain, C8955 type shovel grinder linkage question is resolved by the use of electronic cam. Closed-loop system is formed by the grating and the rotary encoder to ensure the machining accuracy. By the principle of the mechanical and kinetic and the requirements of the feed system, the grinding force and ball were calculated, the choice of Screw is resolved. The hob and wheel of the interference problem is studied in the C8955 -type shovel grinder CNC transformation process, the selection of wheel diameter is solved by graphical analysis calculation. According to the principle of C8955-type shovel grinder, analysised and designed of CNC machining process, mathematical model is created, the NC machining program is weaved. Faced with this problem, the machining interface is weaved by VC++ software and selected the Siemens 840D CNC system programming, the relevant parameter of hob is inputted interface by the operator, NC shovel grinder can be automatically processed.
After transformation, the C8955 shovel grinder is used for debugging and handling, Machining accuracy and the level of automation of the production equipment has been significantly enhanced and perfect. An operator can control a large number of CNC machine to operate. Reduced the number of operating personnel, labored savings, reduced labor costs. The numerical transformation of machine has high performance and quality, It can continue to use for many years as a new CNC.
引文
[1]鄢细林.CA6132普通车床数控化改造[D].中国石油大学,2009.
[2]徐滨士.再制造工程的巨大价值[N].中国矿业报,2004,11,4..
[3]李善术.数控机床及其应用[M].北京：机械工业出版社,2002：50-55.
[4]周延佑.世界数控系统的发展与机床数控化改造[J].中国机电日报,2003,3(16).
[5]曹仁涛,马庆伟.普通机床数控化改造技术问题研究[J].甘肃科技,2008,24(14)：59-61.
[6]江琦.机床改造的必要性及其改造方法[J].中国机械资讯网.2005-12-19：1-4.
[7]南方.论我国数控机床发展[J].数控机床市场,2004,(6)：56-59.
[8]张忠捷.普通机床数控化改造的优点和方法[J].机械管理开发,2008,23(4)：74-75,78.
[9]王磊.一个新兴的工业领域----机床大修与数控化改造[J].黑龙江科技信息.2003.第9期.
[10]高志强.ZFWZ12型滚齿机数控改造的研究[D].沈阳农业大学,2008.
[11]徐滨士.废旧产品再制造可节约一半成本[EB/OL].新华网.2009-09-09.
[12]浅谈机床数控化的发展趋势及改造问题[EB/OL].文章佳工网http://www.new maker.com/art7795.html.
[13]2010-2015年中国数控机床市场深度调研及投资前景战略研究报告[R]：2010,：1-4.
[14]赵中敏.机床数控化改造的研究[J].煤矿机电,2005,(5)：77-79.
[15]王洪章,宋建武,机床数控化改造业的发展前景与改造方案分析[J].第十八卷.第二期,2005：58-60.
[16]北京发那科机电有限公司.数控系统的发展[J].制造技术与机床,2001,8：48-49.
[17]宋建武.侯书林.杨丽.CA6140普通车床数控化改造设计[J].煤矿机械.2006-07：6-8.
[18]李圆.基于SINUMERIK802S的CA6140车床数控化改造[D].浙江工业大学,2008.
[19]罗永顺.机床数控化改造实例[M].北京：机械工业出版社,2010.
[20]朱永刚.西门子数控系统在齿轮加工机床数控化改造中的应用[J].制造技术与机床,2006.第10期：120-122.
[21]Tan Jie Ming,Dai Yi,Shi Xiu Min. Application of electronic gear in servo system of CNC lathe[J]. Manufacturing Atomation,2009(31) 7.
[22]C8955铲磨床说明书[S],大连机床厂,1988：1-87.
[23]王润孝.数控机床原理及应用[M].陕西：西北工业大学出版社,2003.
[24]林宋.现代数控机床[M].北京：化学工业出版社,2003.
[25]王洪章,宋建武.机床数控化改造业的发展前景与改造方案分析[J].张家口职业技术学院学报,2005,18(2)：58-61.
[26]SINUMERIK 840D NC system manuals[S]. Siemens company,2009.10.09:85-15.
[27]梁毕俊喜,俞涛,李强.基于西门子840D的轧辊磨床数控系统研究与开发[J].制造技术与机床,2006.(2)：31-33.
[28]Sinumerik840D/840Di/810D Description of Function.Special Functions[S].2004. SIEM ENS.
[29]谭雪松,张黎骅,漆向军Pro/ENGINEER基础教程[M].北京：人民邮电出版社,2009.
[30]黄云,黄智,现代砂带磨削技术及工程应用[M].重庆：重庆大学出版社,2009-6-1.
[31]成大先,机械设计手册,机械传动,北京：化学工业出版社.2004.(11)3-49.
[32]董鹏英.数控机床滚珠丝杠副的选用与计算[J].精密制造与自动化.2002.
[33]A Barsov.Cutting tool production[M].Moscow:Mir publisher.1978:197-184.
[34]四川省机械工业局.复杂刀具设计手册.北京：机械工业出版社,1979：232.
[35]李志胜.高硬齿面双圆弧齿轮滚刀的研究[D],机械科学研究院.2008.7.22-29.
[36]吴道全,万光现,林树兴等.金属切削原理及刀具[M].重庆：重庆大学出版社.1994：212-214.
[37]聂刚,吴序堂,毛世明.铲齿成型刀具铲磨干涉校验的解析方法[J].西安：西安交通大学机械工程学院.1997：1-14.
[38]Qicheng lao, Jing Ge. Calibration and Calculation of Interference in Hob Relief Grind-ing[C].2011 International Conference on Precision Engineering and Non-Traditional Machining (PENTM 2011). Advanced Materials Research Vol.411:144-148.
[39]LI Guolong, SUN Menghui, LI Xianguang. Improved Relief Grinding Method of Gear Hob with Equal Relief Angle[J].Chinese Journal of Mechanical Engineering.2011(5).
[40]谭浩强.VC++程序设计[M].北京：清华大学出版社.2003：33-50.
[41]薛定宇,陈阳泉.高等应用数学问题的MATLAB求解[M].北京：清华大学出版社.2004.
[42]Forsythe G E,Malcolm M A,Moler C B. Computer methods for mathematical Computations[M].Englewood Cliffs:Prentice-Hall,1977:24-55.
[43]Bjarne stroustrup.The C++ Programming Language(3rd Edition) [M].Addison-wesley Pub Co,1997.
[44]袁哲俊.刘华明.唐宜胜.齿轮刀具设计[M].北京：新时代出版社.1983：.229-287.
[45]西门子公司.西门子840D数控系统编程说明书[M].2009.10.
[46]Simatic HMI Protool/Pro基于Windows系统的组态[S].用户手册.
[47]Sinumerik840D/840Di/810D user's manual[S].2003.HMI Configuring paekage pro Tool /Pro Option. SINUMERIK.SIEMENS. /Pro Option. SINUMERIK.SIEMENS.
[48]王爱玲.现代数控原理及控制系统[M].北京：国防工业出版社,2002.
[49]The compilation of teaching materials group,English for Numerical Control Technology [M].Higher Education Press,2009.
[2]徐滨士.再制造工程的巨大价值[N].中国矿业报,2004,11,4..
[3]李善术.数控机床及其应用[M].北京：机械工业出版社,2002：50-55.
[4]周延佑.世界数控系统的发展与机床数控化改造[J].中国机电日报,2003,3(16).
[5]曹仁涛,马庆伟.普通机床数控化改造技术问题研究[J].甘肃科技,2008,24(14)：59-61.
[6]江琦.机床改造的必要性及其改造方法[J].中国机械资讯网.2005-12-19：1-4.
[7]南方.论我国数控机床发展[J].数控机床市场,2004,(6)：56-59.
[8]张忠捷.普通机床数控化改造的优点和方法[J].机械管理开发,2008,23(4)：74-75,78.
[9]王磊.一个新兴的工业领域----机床大修与数控化改造[J].黑龙江科技信息.2003.第9期.
[10]高志强.ZFWZ12型滚齿机数控改造的研究[D].沈阳农业大学,2008.
[11]徐滨士.废旧产品再制造可节约一半成本[EB/OL].新华网.2009-09-09.
[12]浅谈机床数控化的发展趋势及改造问题[EB/OL].文章佳工网http://www.new maker.com/art7795.html.
[13]2010-2015年中国数控机床市场深度调研及投资前景战略研究报告[R]：2010,：1-4.
[14]赵中敏.机床数控化改造的研究[J].煤矿机电,2005,(5)：77-79.
[15]王洪章,宋建武,机床数控化改造业的发展前景与改造方案分析[J].第十八卷.第二期,2005：58-60.
[16]北京发那科机电有限公司.数控系统的发展[J].制造技术与机床,2001,8：48-49.
[17]宋建武.侯书林.杨丽.CA6140普通车床数控化改造设计[J].煤矿机械.2006-07：6-8.
[18]李圆.基于SINUMERIK802S的CA6140车床数控化改造[D].浙江工业大学,2008.
[19]罗永顺.机床数控化改造实例[M].北京：机械工业出版社,2010.
[20]朱永刚.西门子数控系统在齿轮加工机床数控化改造中的应用[J].制造技术与机床,2006.第10期：120-122.
[21]Tan Jie Ming,Dai Yi,Shi Xiu Min. Application of electronic gear in servo system of CNC lathe[J]. Manufacturing Atomation,2009(31) 7.
[22]C8955铲磨床说明书[S],大连机床厂,1988：1-87.
[23]王润孝.数控机床原理及应用[M].陕西：西北工业大学出版社,2003.
[24]林宋.现代数控机床[M].北京：化学工业出版社,2003.
[25]王洪章,宋建武.机床数控化改造业的发展前景与改造方案分析[J].张家口职业技术学院学报,2005,18(2)：58-61.
[26]SINUMERIK 840D NC system manuals[S]. Siemens company,2009.10.09:85-15.
[27]梁毕俊喜,俞涛,李强.基于西门子840D的轧辊磨床数控系统研究与开发[J].制造技术与机床,2006.(2)：31-33.
[28]Sinumerik840D/840Di/810D Description of Function.Special Functions[S].2004. SIEM ENS.
[29]谭雪松,张黎骅,漆向军Pro/ENGINEER基础教程[M].北京：人民邮电出版社,2009.
[30]黄云,黄智,现代砂带磨削技术及工程应用[M].重庆：重庆大学出版社,2009-6-1.
[31]成大先,机械设计手册,机械传动,北京：化学工业出版社.2004.(11)3-49.
[32]董鹏英.数控机床滚珠丝杠副的选用与计算[J].精密制造与自动化.2002.
[33]A Barsov.Cutting tool production[M].Moscow:Mir publisher.1978:197-184.
[34]四川省机械工业局.复杂刀具设计手册.北京：机械工业出版社,1979：232.
[35]李志胜.高硬齿面双圆弧齿轮滚刀的研究[D],机械科学研究院.2008.7.22-29.
[36]吴道全,万光现,林树兴等.金属切削原理及刀具[M].重庆：重庆大学出版社.1994：212-214.
[37]聂刚,吴序堂,毛世明.铲齿成型刀具铲磨干涉校验的解析方法[J].西安：西安交通大学机械工程学院.1997：1-14.
[38]Qicheng lao, Jing Ge. Calibration and Calculation of Interference in Hob Relief Grind-ing[C].2011 International Conference on Precision Engineering and Non-Traditional Machining (PENTM 2011). Advanced Materials Research Vol.411:144-148.
[39]LI Guolong, SUN Menghui, LI Xianguang. Improved Relief Grinding Method of Gear Hob with Equal Relief Angle[J].Chinese Journal of Mechanical Engineering.2011(5).
[40]谭浩强.VC++程序设计[M].北京：清华大学出版社.2003：33-50.
[41]薛定宇,陈阳泉.高等应用数学问题的MATLAB求解[M].北京：清华大学出版社.2004.
[42]Forsythe G E,Malcolm M A,Moler C B. Computer methods for mathematical Computations[M].Englewood Cliffs:Prentice-Hall,1977:24-55.
[43]Bjarne stroustrup.The C++ Programming Language(3rd Edition) [M].Addison-wesley Pub Co,1997.
[44]袁哲俊.刘华明.唐宜胜.齿轮刀具设计[M].北京：新时代出版社.1983：.229-287.
[45]西门子公司.西门子840D数控系统编程说明书[M].2009.10.
[46]Simatic HMI Protool/Pro基于Windows系统的组态[S].用户手册.
[47]Sinumerik840D/840Di/810D user's manual[S].2003.HMI Configuring paekage pro Tool /Pro Option. SINUMERIK.SIEMENS. /Pro Option. SINUMERIK.SIEMENS.
[48]王爱玲.现代数控原理及控制系统[M].北京：国防工业出版社,2002.
[49]The compilation of teaching materials group,English for Numerical Control Technology [M].Higher Education Press,2009.