螺旋槽电解工具磨床数控化再制造技术研究与实现
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摘要
近年来,随着我国金属切削加工技术和刀具技术的快速发展,硬质合金孔加工刀具尤其是整体式硬质合金孔加工刀具的应用越来越多,对其要求也越来越高。螺旋槽加工是整体式硬质合金孔加工刀具制造中的一道关键工序,对刀具性能影响很大。目前,国内工具制造业在螺旋槽加工方面普遍缺乏专有设备,螺旋槽的加工质量差、加工效率低,已成为制约刀具加工质量和加工效率提高的一个瓶颈问题。论文基于设备数控化再制造的思想,研究了如何将闲置的普通电解工具磨床数控化再制造为螺旋槽专用加工设备,它对于提高螺旋槽的加工质量和加工效率以及增量盘活企业存量资产都有较大的实际意义。
首先,论文介绍了普通电解工具磨床的结构和工作原理,分析了当前整体式硬质合金孔加工刀具螺旋槽的加工现状和存在的问题。在此基础上,提出了通过电解工具磨床的数控化再制造技术来解决螺旋槽加工问题的思路。
接着,确定了数控化再制造的总体方案。进行了机床传动部分的导轨、传动机构、工作台纵向移动机构、磨头升降机构、工件转动和自动分度机构等的再制造设计,并基于开放式数控系统原理,确定了螺旋槽加工专用数控系统的研制方案。
在上述研究的基础上,设计了数控系统的硬件、软件系统,探讨了通过改变传感器的布置和安装方式提高机床原点返回精度的方法,研究了螺旋插补算法的具体实现方法,实现了螺旋槽加工的CAD/CAM/CNC一体化。
最后,进行了数控系统与机床本体的联机调试,并将数控化再制造的电解工具磨床实际应用于某工具企业的螺旋槽加工中。应用表明:再制造机床加工质量和加工效率明显提高,再制造成本显著低于新购同类设备费用,取得了较好的应用效果。
In recent years, with the rapid development of metal cutting technology and cutter technology in our country, more and more hard alloy revolving cutters, especially the total hard alloy revolving cutters are used. So more requirements are demanded. The processing of spiral flute is the key working procedure during the course of machining total hard alloy revolving cutter. Which greatly influence the performance of a cutter. At present, the special equipment for processing the spiral flute is universally lagged in the tool machining industry in our country. This leads to bad processing quality and low processing efficiency of the spiral flute. Thus it becomes a bottle-neck problem of restricting enhancing the processing quality and processing efficiency of the cutter. Based on the thinking of equipment numerical controlled remanufacturing, how to turn the ordinary electrolytic tool grinder which left unused into the special equipment for processing the spiral flute by numerical controlled remanufacturing technology is researched in the paper. It is of biggish practical meaning to both enhancing the processing quality and processing efficiency of the spiral flute and making enterprise stock assets to be used efficiently as the increment.
At first, the structure and work principle of ordinary electrolytic tool grinder is introduced in the paper. The current actuality and problem of processing the spiral flute in total hard alloy revolving cutter is analyzed. Based on this, an idea of resolving the spiral flute processing problem is proposed. That is putting the numerical controlled remanufacturing technology into the electrolytic tool grinder.
In succession, the total scheme on numerical controlled remanufacturing is established. The transmission part of machine tool is remanufactured, such as the guide-way, transmission mechanism, drive mechanism for X-axis of work-stable, mechanism for grinding wheel up and down, mechanism for workpiece rotation and automatic indexing, and so on. And based on the principle of open architecture CNC system, the development scheme on the special CNC system for processing the spiral flute is fixed on.
Based on the above research, the hardware and software system of the CNC system is designed. Enhancing the precision of returning machine origin by changing the disposal and installation way of the sensors is discussed. At same time, the idiographic implementation approach of the spiral interpolation arithmetic is researched. And the
首先,论文介绍了普通电解工具磨床的结构和工作原理,分析了当前整体式硬质合金孔加工刀具螺旋槽的加工现状和存在的问题。在此基础上,提出了通过电解工具磨床的数控化再制造技术来解决螺旋槽加工问题的思路。
接着,确定了数控化再制造的总体方案。进行了机床传动部分的导轨、传动机构、工作台纵向移动机构、磨头升降机构、工件转动和自动分度机构等的再制造设计,并基于开放式数控系统原理,确定了螺旋槽加工专用数控系统的研制方案。
在上述研究的基础上,设计了数控系统的硬件、软件系统,探讨了通过改变传感器的布置和安装方式提高机床原点返回精度的方法,研究了螺旋插补算法的具体实现方法,实现了螺旋槽加工的CAD/CAM/CNC一体化。
最后,进行了数控系统与机床本体的联机调试,并将数控化再制造的电解工具磨床实际应用于某工具企业的螺旋槽加工中。应用表明:再制造机床加工质量和加工效率明显提高,再制造成本显著低于新购同类设备费用,取得了较好的应用效果。
In recent years, with the rapid development of metal cutting technology and cutter technology in our country, more and more hard alloy revolving cutters, especially the total hard alloy revolving cutters are used. So more requirements are demanded. The processing of spiral flute is the key working procedure during the course of machining total hard alloy revolving cutter. Which greatly influence the performance of a cutter. At present, the special equipment for processing the spiral flute is universally lagged in the tool machining industry in our country. This leads to bad processing quality and low processing efficiency of the spiral flute. Thus it becomes a bottle-neck problem of restricting enhancing the processing quality and processing efficiency of the cutter. Based on the thinking of equipment numerical controlled remanufacturing, how to turn the ordinary electrolytic tool grinder which left unused into the special equipment for processing the spiral flute by numerical controlled remanufacturing technology is researched in the paper. It is of biggish practical meaning to both enhancing the processing quality and processing efficiency of the spiral flute and making enterprise stock assets to be used efficiently as the increment.
At first, the structure and work principle of ordinary electrolytic tool grinder is introduced in the paper. The current actuality and problem of processing the spiral flute in total hard alloy revolving cutter is analyzed. Based on this, an idea of resolving the spiral flute processing problem is proposed. That is putting the numerical controlled remanufacturing technology into the electrolytic tool grinder.
In succession, the total scheme on numerical controlled remanufacturing is established. The transmission part of machine tool is remanufactured, such as the guide-way, transmission mechanism, drive mechanism for X-axis of work-stable, mechanism for grinding wheel up and down, mechanism for workpiece rotation and automatic indexing, and so on. And based on the principle of open architecture CNC system, the development scheme on the special CNC system for processing the spiral flute is fixed on.
Based on the above research, the hardware and software system of the CNC system is designed. Enhancing the precision of returning machine origin by changing the disposal and installation way of the sensors is discussed. At same time, the idiographic implementation approach of the spiral interpolation arithmetic is researched. And the
引文
[1] 刘飞,张晓东,杨丹.制造系统工程.第二版.北京:国防工业出版社.2000
[2] Jay Lee.关于未来制造业的战略思考.中国机械工程, 1999, 10(4):1～3
[3] 徐滨士等.21 世纪的再制造工程.中国机械工程,2000,11(1-2):36～40
[4] 陈辉,党庆波.再制造工程的研究与建议.煤矿机械,2003(8):109～111
[5] 国内外孔加工刀具发展概况研究(1). http://e-cuttech.com/news/ReadNews.asp? NewsID=125& BigClassID=17&SmallClassID=15&SpecialID=17
[6] http://info.wujin.hc360.com/2005/10/18093719897.shtml
[7] 朱心红.PC 平台开放式数控系统前景展望.机械制造,2002,40(10):25～27
[8] 李佳特.数控技术的现状、发展趋势.世界制造技术与装备市场,2001(1):34～37
[9] 文广,马宏伟.数控技术的现状及发展趋势.机械工程师,2003(1):9～12
[10]胡仲翔等.机床数控化再制造技术研究.机械加工与自动化,2004(8):17～19
[11]王望龙,张甲英,胡仲翔.普通机床的数控化再制造技术.装甲兵工程学院学报,2003,17(3):25～28
[12]李亚非,吴康雄,易继军.旧机床的数控化再制造技术探讨.机械,2006(2):55～57
[13]孙玉华,张曙.德国机床数控化再制造的实践与研究.制造业自动化,2000,22(11):50～53
[14]李昌琪[译].工具和刀具磨床的新发展.世界制造技术与装备市场,2002(6):46～48
[15]Hu Z Q,Zhang Y T,Song S J. The research on key technologies of numerical control cam grinding machine tool. Key Engineering Materials,2004,259-260:746～750
[16]Riddiford R. CNC tool grinding. Cutting Tool Engineering,2001,53(12): 44～47
[17]Kaiser Russell. Facts about grinding. Manufacturing Engineering,2000,125(3):78,80～85
[18]http://www.engineeringtalk.com/news/wal/wal113.html
[19]Lim H S,Fathima K,Senthil Kumar A,Rahman M. A fundamental study on the mechanism of electrolytic in-process dressing (ELID) grinding. International Journal of Machine Tools and Manufacture,2002,42(8):935～943
[20]Hsieh Jung-Fa,Lin Psang Dain. Production of multifluted drills on six-axis CNC tool-grinding machine. International Journal of Machine Tools and Manufacture,2003,43(11):1117～1127
[21]Zhang C Y,Wang G C,Pei H J. Effect of Characteristics of the Grinding Wheel on Cemented Carbide Cutting Tool Sharpening. Key Engineering Materials,2004,258-259:50～54
[22]Jennings Martin. CNC tool grinding with diamond and CBN wheels from Harlequin. Industrial Diamond Review,2002,62(595):232～235
[23]YK-006D 数控电解工具磨床. http://www.ykghjc.com.cn/
[24]孙新印. 2MK9025 数控螺旋槽工具磨床简介.精密制造与自动化,2002(4):42～42
[25]咸阳机床厂推出数控万能工具磨床.工具技术,2000(2):50～50
[26]李敏芳.CIMT2003 工具、刃具磨床展品评述.精密制造与自动化,2003(4):4～6
[27]孙勇,于湘慧,刘玉莲等.电解磨削技术及应用前景.机械工程师,1996(5):29～30
[28]胡黄卿,薛湘鹰.硬质合金工件电解磨削加工研究.机械加工与自动化,2001(2):15～17
[29]孙永安,李县辉,张永乾.硬质合金的电解磨削加工.轴承,2002(2):18～20
[30]何玉勇.喷油嘴中孔座面磨床的数控改造技术[硕士论文].武汉:中国地质大学,2003:15～16
[31]陆启建,刘明灯.数控技术的新进展.制造技术与机床,2002(5):5～8
[32]尹家凡,王孙安.基于 PC 的开放式数控系统的研究.机床与液压,2003(2):88～90
[33]Chalmer R E. Open-architecture CNC continues advancing. Manufacturing Engineering, 2001,126(7):48～52
[34]Jannone da Silva E,Biff M,De Oliveira J F G. The Development of an Open Architecture Control System for CBN High Speed Grinding. Journal of the Brazilian Society of Mechanical Sciences and Engineering,2004,26(1):51～55
[35]Ashby J E. PC based CNC control system integration and operation issues. ISA TECH/EXPO Technology Update Conference Proceedings,2001,413 I:439～449
[36]Pritschow G,Altintas Y,Jovane F,Koren Y,etc. Open controller architecture-Past, present and future. CIRP Annals-Manufacturing Technology,2001,50(2):463～470
[37]Rober Stephen J,Shin Yung C. Modeling and control of CNC machines using a PC-based open architecture controller. Mechatronics,1995,5(4):401～420
[38]盛定高.基于 PC 开放式数控系统的特征及优势.机床电器,2002(5):20～24
[39]赵春红,秦现生,唐虹.基于 PC 的开放式数控系统研究.机械科学与技术,2005,24(9):1108～1113
[40]周泽华.金属切削原理.第二版.上海:上海科学技术出版社,1993
[41]邵建华,陈清运,刘鹄然.MQ6025A 轻型万能工具磨床的数控改造.机械研究与应用,2004,17(1):38～40
[42]朱家生,李国龙,尹超,刘飞.一种双主轴六头印制线路板数控钻床的开发与应用.现代制造工程,2005(10):15～18
[43]胡江林,张伟.刀具螺旋槽成形原理及其计算机模拟.工具技术,2004,38(6):40～42
[44]D S Sheth,S Malkin.CAD/CAM for geometry and process analysis of helical groove machining.Annals of the CIRP,1990,39(1):129～132
[45]刘井玉,刘华明,王延福.螺旋刀刃曲线的统一模型——普通螺旋线.工具技术,1998,32(6):24～26
[46]罗良玲,刘旭波.基于时间分割法的圆柱螺旋线直接插补算法.南昌大学学报(工科版),2001,23(4):57～59
[47]吴辉,宁亭.螺旋线及正弦曲线的一种快速插补算法.华中理工大学学报,1995,23(5):57～59
[48]叶配青,王立平,张辉. CAD/CAM/CNC 集成系统的研究.工具技术,2000,34(11):9～12
[2] Jay Lee.关于未来制造业的战略思考.中国机械工程, 1999, 10(4):1～3
[3] 徐滨士等.21 世纪的再制造工程.中国机械工程,2000,11(1-2):36～40
[4] 陈辉,党庆波.再制造工程的研究与建议.煤矿机械,2003(8):109～111
[5] 国内外孔加工刀具发展概况研究(1). http://e-cuttech.com/news/ReadNews.asp? NewsID=125& BigClassID=17&SmallClassID=15&SpecialID=17
[6] http://info.wujin.hc360.com/2005/10/18093719897.shtml
[7] 朱心红.PC 平台开放式数控系统前景展望.机械制造,2002,40(10):25～27
[8] 李佳特.数控技术的现状、发展趋势.世界制造技术与装备市场,2001(1):34～37
[9] 文广,马宏伟.数控技术的现状及发展趋势.机械工程师,2003(1):9～12
[10]胡仲翔等.机床数控化再制造技术研究.机械加工与自动化,2004(8):17～19
[11]王望龙,张甲英,胡仲翔.普通机床的数控化再制造技术.装甲兵工程学院学报,2003,17(3):25～28
[12]李亚非,吴康雄,易继军.旧机床的数控化再制造技术探讨.机械,2006(2):55～57
[13]孙玉华,张曙.德国机床数控化再制造的实践与研究.制造业自动化,2000,22(11):50～53
[14]李昌琪[译].工具和刀具磨床的新发展.世界制造技术与装备市场,2002(6):46～48
[15]Hu Z Q,Zhang Y T,Song S J. The research on key technologies of numerical control cam grinding machine tool. Key Engineering Materials,2004,259-260:746～750
[16]Riddiford R. CNC tool grinding. Cutting Tool Engineering,2001,53(12): 44～47
[17]Kaiser Russell. Facts about grinding. Manufacturing Engineering,2000,125(3):78,80～85
[18]http://www.engineeringtalk.com/news/wal/wal113.html
[19]Lim H S,Fathima K,Senthil Kumar A,Rahman M. A fundamental study on the mechanism of electrolytic in-process dressing (ELID) grinding. International Journal of Machine Tools and Manufacture,2002,42(8):935～943
[20]Hsieh Jung-Fa,Lin Psang Dain. Production of multifluted drills on six-axis CNC tool-grinding machine. International Journal of Machine Tools and Manufacture,2003,43(11):1117～1127
[21]Zhang C Y,Wang G C,Pei H J. Effect of Characteristics of the Grinding Wheel on Cemented Carbide Cutting Tool Sharpening. Key Engineering Materials,2004,258-259:50～54
[22]Jennings Martin. CNC tool grinding with diamond and CBN wheels from Harlequin. Industrial Diamond Review,2002,62(595):232～235
[23]YK-006D 数控电解工具磨床. http://www.ykghjc.com.cn/
[24]孙新印. 2MK9025 数控螺旋槽工具磨床简介.精密制造与自动化,2002(4):42～42
[25]咸阳机床厂推出数控万能工具磨床.工具技术,2000(2):50～50
[26]李敏芳.CIMT2003 工具、刃具磨床展品评述.精密制造与自动化,2003(4):4～6
[27]孙勇,于湘慧,刘玉莲等.电解磨削技术及应用前景.机械工程师,1996(5):29～30
[28]胡黄卿,薛湘鹰.硬质合金工件电解磨削加工研究.机械加工与自动化,2001(2):15～17
[29]孙永安,李县辉,张永乾.硬质合金的电解磨削加工.轴承,2002(2):18～20
[30]何玉勇.喷油嘴中孔座面磨床的数控改造技术[硕士论文].武汉:中国地质大学,2003:15～16
[31]陆启建,刘明灯.数控技术的新进展.制造技术与机床,2002(5):5～8
[32]尹家凡,王孙安.基于 PC 的开放式数控系统的研究.机床与液压,2003(2):88～90
[33]Chalmer R E. Open-architecture CNC continues advancing. Manufacturing Engineering, 2001,126(7):48～52
[34]Jannone da Silva E,Biff M,De Oliveira J F G. The Development of an Open Architecture Control System for CBN High Speed Grinding. Journal of the Brazilian Society of Mechanical Sciences and Engineering,2004,26(1):51～55
[35]Ashby J E. PC based CNC control system integration and operation issues. ISA TECH/EXPO Technology Update Conference Proceedings,2001,413 I:439～449
[36]Pritschow G,Altintas Y,Jovane F,Koren Y,etc. Open controller architecture-Past, present and future. CIRP Annals-Manufacturing Technology,2001,50(2):463～470
[37]Rober Stephen J,Shin Yung C. Modeling and control of CNC machines using a PC-based open architecture controller. Mechatronics,1995,5(4):401～420
[38]盛定高.基于 PC 开放式数控系统的特征及优势.机床电器,2002(5):20～24
[39]赵春红,秦现生,唐虹.基于 PC 的开放式数控系统研究.机械科学与技术,2005,24(9):1108～1113
[40]周泽华.金属切削原理.第二版.上海:上海科学技术出版社,1993
[41]邵建华,陈清运,刘鹄然.MQ6025A 轻型万能工具磨床的数控改造.机械研究与应用,2004,17(1):38～40
[42]朱家生,李国龙,尹超,刘飞.一种双主轴六头印制线路板数控钻床的开发与应用.现代制造工程,2005(10):15～18
[43]胡江林,张伟.刀具螺旋槽成形原理及其计算机模拟.工具技术,2004,38(6):40～42
[44]D S Sheth,S Malkin.CAD/CAM for geometry and process analysis of helical groove machining.Annals of the CIRP,1990,39(1):129～132
[45]刘井玉,刘华明,王延福.螺旋刀刃曲线的统一模型——普通螺旋线.工具技术,1998,32(6):24～26
[46]罗良玲,刘旭波.基于时间分割法的圆柱螺旋线直接插补算法.南昌大学学报(工科版),2001,23(4):57～59
[47]吴辉,宁亭.螺旋线及正弦曲线的一种快速插补算法.华中理工大学学报,1995,23(5):57～59
[48]叶配青,王立平,张辉. CAD/CAM/CNC 集成系统的研究.工具技术,2000,34(11):9～12