支持复杂零件快速、柔性和精密制造的关键技术研究与应用
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摘要
制造业是一个国家或地区经济发展的重要支柱,它的发展水平标志着该国家或地区的综合实力的强弱。现代制造业更多地面向多品种、小批量的制造任务。作为其中的重要的组成部分,复杂零件由于装夹难度大、工艺设计困难,它的快速精密制造已成为现代制造技术中的重要课题。
采用李蓓智教授等提出的一种非传统的工件安装技术和能够主动寻位与状态记忆的通用夹具系统(Initiative Location and State Memory—IL&SM),可以实现对任意形状复杂零件的可靠定位和装央。它通过寻位元件主动确定工件在寻位箱中的位置,预紧后注入低熔点合金凝固保持工件的初始安装姿态,并由它提供均匀的夹持力。工位转换时,安装初始状态得以保留。同时,使用六面可拆卸的寻位箱,工件可以分六个方位面进行加工,各个方位面加工工序均类似,因而工艺可以实现标准化。
作者主要研究支持复杂零件快速、柔性和精密制造的关键技术研究与应用。主要包含以下四部分:
1.现有商用软件的工程应用研究
作者对常用的CAD/CAM软件的特点进行了分析和评价,选择了UG作为本文复杂零件数字化加工的软件平台,并对UG提供的二次开发工具进行了研究。
2.支持复杂零件高效率生产的数控技术研究
在复杂零件实际加工中,要获得较好的加工质量,选择合适的工艺参数和要素显得尤为重要。作者对影响加工质量的一些工艺参数,包括刀具、切削用量(进给率、切削深度与宽度)、进退刀方式、精加工行距、走刀方式、工步余量与偏差等进行了分析,并对影响这些参数选择的因素进行了综合分析,得出了理想的选择方案和确定原则。这些工艺知识可以更有效地指导工艺方案设计和NC编程。
3.基于UG平台和工步特征知识库的CAPP/NC系统研发
介绍了与unigraphic NX软件无缝集成的CAPP系统,开发系统的目的将加工的各种零件所获得的经验以数据库的形式保存下来,便于查询,达到快速的生成对应加工特征的合理加工参数,从而能快速的、精密的完成零件的加工制造。
4.高效、柔性、多工位数控铣夹具研制与应用
针对现在加工制造过程中柔性夹具的瓶颈,作者论述了多工位、
Manufacturing is an important support of economy development to a country or area. Its development indicate synthesis strength to a country or area. Modern manufacturing face varieties, small batch producing, As one of important parts of them, for the difficult of install and process design to the complex part, its speediness and precision manufacture have become one of import subject to modern manufacturing technology.Using a kind of non-tradition workpiece install technology and initiative location Etstate memory -IL&SM put forward by Prof. Lee etc. it realizing credibility location an install to random shape complex part. Through seek-location element fix part on seek-location box, then after beforehand tightening, injecting low melting point alloy and freeze to hold the original install pose of the part, and provided uniformity hold power. When transform machining position, it can reserve the original installing location. At the same time, using seek-location box whose six side can be knocked down, the manufacturing of the workpart may dispart into six oriention. Its working process is similar on each oriention. So the process can realize standardization.Writer mainly study the key-point technology and application of support complex part fast, flexible and precision manufacture, including below four parts mainly:1, study the existing commercial software applied on engineering Writer analyzed and appraised the feature of CAD/CAM software incommon use, chose UG as software flat about complex part numeric manufacture, and study the second development tool of UG.2, study NC technology of support complex part high efficiency producing.In course of complex part manufacture practically, in order to achieving better quality, it is very important to choose reasonable process parameters and factors. Writer analyzed some process parameters affect
machining quality, including cutter, cutting dosage (federate, cutting deep, cutting width), advance and retract mode, finish machining row distance, cut mode, cut step excess and deviation etc. and synthesis analyzed the factors affect the choose of process parameters, conclude ideal choose scheme and rule. These process knowledge can more efficiently instruct processing plan design and NC programming3.research and develop CAPP/NC system ,based on UG flat and cut step character repositoryIntroduced CAPP system seamless integrate with unigraphic NX, the aim is to save the practice of machining parts by database for querying. We can achieve reasonable machining parameters corresponding to machining feature and complete manufacturig rapidly and precisely.4. high effective, flexible, multistage NC mill fixture application and developmentRegarding to the bottle-neck of the flexible fixture in manufacture, writer state high effective, flexible, multistage NC mill fixture application and development: the design of IL&SM general fixture and following fixture, and discuss common course of fixture design by real instance.
采用李蓓智教授等提出的一种非传统的工件安装技术和能够主动寻位与状态记忆的通用夹具系统(Initiative Location and State Memory—IL&SM),可以实现对任意形状复杂零件的可靠定位和装央。它通过寻位元件主动确定工件在寻位箱中的位置,预紧后注入低熔点合金凝固保持工件的初始安装姿态,并由它提供均匀的夹持力。工位转换时,安装初始状态得以保留。同时,使用六面可拆卸的寻位箱,工件可以分六个方位面进行加工,各个方位面加工工序均类似,因而工艺可以实现标准化。
作者主要研究支持复杂零件快速、柔性和精密制造的关键技术研究与应用。主要包含以下四部分:
1.现有商用软件的工程应用研究
作者对常用的CAD/CAM软件的特点进行了分析和评价,选择了UG作为本文复杂零件数字化加工的软件平台,并对UG提供的二次开发工具进行了研究。
2.支持复杂零件高效率生产的数控技术研究
在复杂零件实际加工中,要获得较好的加工质量,选择合适的工艺参数和要素显得尤为重要。作者对影响加工质量的一些工艺参数,包括刀具、切削用量(进给率、切削深度与宽度)、进退刀方式、精加工行距、走刀方式、工步余量与偏差等进行了分析,并对影响这些参数选择的因素进行了综合分析,得出了理想的选择方案和确定原则。这些工艺知识可以更有效地指导工艺方案设计和NC编程。
3.基于UG平台和工步特征知识库的CAPP/NC系统研发
介绍了与unigraphic NX软件无缝集成的CAPP系统,开发系统的目的将加工的各种零件所获得的经验以数据库的形式保存下来,便于查询,达到快速的生成对应加工特征的合理加工参数,从而能快速的、精密的完成零件的加工制造。
4.高效、柔性、多工位数控铣夹具研制与应用
针对现在加工制造过程中柔性夹具的瓶颈,作者论述了多工位、
Manufacturing is an important support of economy development to a country or area. Its development indicate synthesis strength to a country or area. Modern manufacturing face varieties, small batch producing, As one of important parts of them, for the difficult of install and process design to the complex part, its speediness and precision manufacture have become one of import subject to modern manufacturing technology.Using a kind of non-tradition workpiece install technology and initiative location Etstate memory -IL&SM put forward by Prof. Lee etc. it realizing credibility location an install to random shape complex part. Through seek-location element fix part on seek-location box, then after beforehand tightening, injecting low melting point alloy and freeze to hold the original install pose of the part, and provided uniformity hold power. When transform machining position, it can reserve the original installing location. At the same time, using seek-location box whose six side can be knocked down, the manufacturing of the workpart may dispart into six oriention. Its working process is similar on each oriention. So the process can realize standardization.Writer mainly study the key-point technology and application of support complex part fast, flexible and precision manufacture, including below four parts mainly:1, study the existing commercial software applied on engineering Writer analyzed and appraised the feature of CAD/CAM software incommon use, chose UG as software flat about complex part numeric manufacture, and study the second development tool of UG.2, study NC technology of support complex part high efficiency producing.In course of complex part manufacture practically, in order to achieving better quality, it is very important to choose reasonable process parameters and factors. Writer analyzed some process parameters affect
machining quality, including cutter, cutting dosage (federate, cutting deep, cutting width), advance and retract mode, finish machining row distance, cut mode, cut step excess and deviation etc. and synthesis analyzed the factors affect the choose of process parameters, conclude ideal choose scheme and rule. These process knowledge can more efficiently instruct processing plan design and NC programming3.research and develop CAPP/NC system ,based on UG flat and cut step character repositoryIntroduced CAPP system seamless integrate with unigraphic NX, the aim is to save the practice of machining parts by database for querying. We can achieve reasonable machining parameters corresponding to machining feature and complete manufacturig rapidly and precisely.4. high effective, flexible, multistage NC mill fixture application and developmentRegarding to the bottle-neck of the flexible fixture in manufacture, writer state high effective, flexible, multistage NC mill fixture application and development: the design of IL&SM general fixture and following fixture, and discuss common course of fixture design by real instance.
引文
[1] 周济,周艳红.数控加工技术[M].2002.国防工业出版社
[2] 《实用数控加工技术》编委会.实用数控加工技术[M].1994.兵器工业出版社
[3] 杨旭静,谢晖,盛晓敏,钟志华.提高自由曲面数控加工精度的技术研究.湖南大学学报,2002(5):80-92
[4] 王飞.车床主轴径向圆跳动对加工精度影响的探导.现代机械,2002(1):55-56
[5] Yah Shu-tian, Liu Tao, Wu Zai-xin, Hu Chi-bing, Hu Li-zhi. A New Method for Locating Calculation of Arbitrary Spatial Straight Line or Plane in NC Machining. Journal of Xiamen University(Natural Science), 2002, 41(9): 149-150
[6] C. N. Chu. Feed-Rate Optimization of Ball End Milling Considering Local Shape Features. Annals of CIRP, 1997, 46(1): 433-436
[7] 彭芳瑜,穆海华,周云飞,周济,瞿坦.大型叶片五坐标数控加工进给速度优化.机械科学与技术,2003,22(2):215-217
[8] 解放,柯文,王宁生,范牧昌.基于专家系统的NC程序切削参数检验的方法研究.2003,32(3):86-90
[9] E. Meng Lim, Menq Chia-Hsiang. Integrated Planning for Precision Machining of Complex Surfaces. - part Ⅰ: Cutting Path and Feedrate Opeimization. Int. J. Mach. Tools Manufact, 1997, 37 (1): 61-75
[10] 牛文铁,徐燕申.自由曲面数控加工走刀方向的优化研究.组合机床与自动化加工技术,2003(4):54-59
[11] 林朝平.数控加工编程中工序划分的原则与要点.组合机床与自动化加工技术,2003(1):26-27
[12] 严思杰 周云飞 彭芳瑜 赖喜德.大型复杂曲面零件加工余量均布优化问题研究.华中科技大学学报,2002(10):35-37
[13] 刘晓冰,高天一.CAD技术的发展趋势和主流软件产品.中国制造业信息化,2003,32(1):41-42
[14] Unigraphics Solutions Inc. UG CAD实用教程[M]. 2002. 清华大学出版社
[15] 《金属机械加工工艺人员手册》修订组.会属机械加工工艺人员手册[M].1979.上海科学技术出版社
[16] 王先逵.机械制造工艺学[M].1995.机械工业出版社
[17] Unigraphics Solutions Inc.UG高级铣加工应用培训教程[M].2002.清华大学出版社
[18] Kim Y. S., "Form feature recognition by convex decomposition", Proc. ASME Comput. Eng. Conf., 1991.
[19] Kim Y. S., and Wilde D. J., "A convergent convex decomposition of polyhedral objects", ASME J. Mech. Des., Vol. 114, pp. 468-476, 1992.
[20] 吴家洲,吴波,杨叔子.UG软件的二次开发.精密制造与自动化,2002(1):29—31
[21] 董正卫,田立中,付宜利.UG/OPEN API编程基础[M].2002.清华大学出版社
[22] 田真真,吴战越,孟东兰.机械加工系统的优化技术探析.
[23] 李蓓智,杨建国.快速寻位与状态记忆的工件安装技术与新型夹具系统[J].中国机械工程,2000,11(10):1154-1157
[24] 李蓓智.基准自由的零件封装夹具及其工业化瓶颈、策略与技术[J].中国纺织大学学报,2000,26(4):61-64
[25] 杨建国,李蓓智.非传统工件安装技术与通用夹具系统的研究,制造业自动化,24-26
[26] Rabinow J. AIEE Transactions[J]. 1948, 67: 1308-1315
[27] Sanjay E. Sarma, Paul K. Wright. Reference Free Part Encapsulation: A New Universal Fixturing Concept[J]. Journal of Manufacturing System, 1997, 16(1): 35-47
[28] 王先逵.机械制造工艺学[M].北京.机械工业出版社.1995
[29] 秦宝荣.机械制造工艺学与机床夹具设计[M].北京.中国建材工业出版社.1995.
[30] 东北重型机械学院.洛阳工学院.机床夹具设计手册[M].上海.上海科学技术出版社.1987.
[31] 成大先.机械设计手册[M].北京.化学工业出版社.1994.
[32] 蔡毓英.HH902常温发黑系列在铸铁件上应用[0D/0E].http://www.hhblacken.com/csjgmyyyyj01.htm, 2004-2-16
[33] 林朝平.数控加工中工序划分与加工路线的确定[J].机械制造与研究,2003,(7):33—36
[34] 刘海江,张辉,陈阳等.基于CAPP需求的发动机五气缸盖特征信息模型分析[J].机械制造与自动化,2003,(2):27—30
[35] 于靖华,甄恒洲,崔艳龙等.基于知识的轴类零件CAPP系统的实现.组合机床与自动化加工技术,2003,(5):58—59
[36] 阮景奎,朱传军,宫爱红.汽车回转类零件CAPP系统的研究.现代制造工程,2003,(4):21—25
[37] 王正刚.CAPP系统工程化的关键技术研究.先进制造技术,2002.31(2):65—67
[2] 《实用数控加工技术》编委会.实用数控加工技术[M].1994.兵器工业出版社
[3] 杨旭静,谢晖,盛晓敏,钟志华.提高自由曲面数控加工精度的技术研究.湖南大学学报,2002(5):80-92
[4] 王飞.车床主轴径向圆跳动对加工精度影响的探导.现代机械,2002(1):55-56
[5] Yah Shu-tian, Liu Tao, Wu Zai-xin, Hu Chi-bing, Hu Li-zhi. A New Method for Locating Calculation of Arbitrary Spatial Straight Line or Plane in NC Machining. Journal of Xiamen University(Natural Science), 2002, 41(9): 149-150
[6] C. N. Chu. Feed-Rate Optimization of Ball End Milling Considering Local Shape Features. Annals of CIRP, 1997, 46(1): 433-436
[7] 彭芳瑜,穆海华,周云飞,周济,瞿坦.大型叶片五坐标数控加工进给速度优化.机械科学与技术,2003,22(2):215-217
[8] 解放,柯文,王宁生,范牧昌.基于专家系统的NC程序切削参数检验的方法研究.2003,32(3):86-90
[9] E. Meng Lim, Menq Chia-Hsiang. Integrated Planning for Precision Machining of Complex Surfaces. - part Ⅰ: Cutting Path and Feedrate Opeimization. Int. J. Mach. Tools Manufact, 1997, 37 (1): 61-75
[10] 牛文铁,徐燕申.自由曲面数控加工走刀方向的优化研究.组合机床与自动化加工技术,2003(4):54-59
[11] 林朝平.数控加工编程中工序划分的原则与要点.组合机床与自动化加工技术,2003(1):26-27
[12] 严思杰 周云飞 彭芳瑜 赖喜德.大型复杂曲面零件加工余量均布优化问题研究.华中科技大学学报,2002(10):35-37
[13] 刘晓冰,高天一.CAD技术的发展趋势和主流软件产品.中国制造业信息化,2003,32(1):41-42
[14] Unigraphics Solutions Inc. UG CAD实用教程[M]. 2002. 清华大学出版社
[15] 《金属机械加工工艺人员手册》修订组.会属机械加工工艺人员手册[M].1979.上海科学技术出版社
[16] 王先逵.机械制造工艺学[M].1995.机械工业出版社
[17] Unigraphics Solutions Inc.UG高级铣加工应用培训教程[M].2002.清华大学出版社
[18] Kim Y. S., "Form feature recognition by convex decomposition", Proc. ASME Comput. Eng. Conf., 1991.
[19] Kim Y. S., and Wilde D. J., "A convergent convex decomposition of polyhedral objects", ASME J. Mech. Des., Vol. 114, pp. 468-476, 1992.
[20] 吴家洲,吴波,杨叔子.UG软件的二次开发.精密制造与自动化,2002(1):29—31
[21] 董正卫,田立中,付宜利.UG/OPEN API编程基础[M].2002.清华大学出版社
[22] 田真真,吴战越,孟东兰.机械加工系统的优化技术探析.
[23] 李蓓智,杨建国.快速寻位与状态记忆的工件安装技术与新型夹具系统[J].中国机械工程,2000,11(10):1154-1157
[24] 李蓓智.基准自由的零件封装夹具及其工业化瓶颈、策略与技术[J].中国纺织大学学报,2000,26(4):61-64
[25] 杨建国,李蓓智.非传统工件安装技术与通用夹具系统的研究,制造业自动化,24-26
[26] Rabinow J. AIEE Transactions[J]. 1948, 67: 1308-1315
[27] Sanjay E. Sarma, Paul K. Wright. Reference Free Part Encapsulation: A New Universal Fixturing Concept[J]. Journal of Manufacturing System, 1997, 16(1): 35-47
[28] 王先逵.机械制造工艺学[M].北京.机械工业出版社.1995
[29] 秦宝荣.机械制造工艺学与机床夹具设计[M].北京.中国建材工业出版社.1995.
[30] 东北重型机械学院.洛阳工学院.机床夹具设计手册[M].上海.上海科学技术出版社.1987.
[31] 成大先.机械设计手册[M].北京.化学工业出版社.1994.
[32] 蔡毓英.HH902常温发黑系列在铸铁件上应用[0D/0E].http://www.hhblacken.com/csjgmyyyyj01.htm, 2004-2-16
[33] 林朝平.数控加工中工序划分与加工路线的确定[J].机械制造与研究,2003,(7):33—36
[34] 刘海江,张辉,陈阳等.基于CAPP需求的发动机五气缸盖特征信息模型分析[J].机械制造与自动化,2003,(2):27—30
[35] 于靖华,甄恒洲,崔艳龙等.基于知识的轴类零件CAPP系统的实现.组合机床与自动化加工技术,2003,(5):58—59
[36] 阮景奎,朱传军,宫爱红.汽车回转类零件CAPP系统的研究.现代制造工程,2003,(4):21—25
[37] 王正刚.CAPP系统工程化的关键技术研究.先进制造技术,2002.31(2):65—67