摘要
自动换刀装置是加工中心的重要辅助加工装置,其内部高速功能部件的发展与应用极大地提高生产效率。在实际加工中,生产商要求更高的切削速度和逐步缩短换刀时间,换刀速度也相应地成为当代加工中心水平高低的重要指标。为了适应机床业高速发展和客户不断要求更高生产效率的需求,自动换刀技术成为机床制造商相继研发的关键课题之一。对龙门机床的自动换刀装置进行总结,配置带机械手的自动换刀装置,对机械手、刀库的情况进行讨论,为研究提供一个硬件基础。
本文在充分调研国内外加工中心自动换刀技术研究现状的基础上研究高速加工使用的联接刀柄,现有刀柄和实际需求等多因素综合分析选定HSK刀柄的型号和规格;根据国际标准建立HSK刀柄和HSK工具系统的实体模型,并对HSK工具系统的工作原理进行分析;进行锥面联接分析前需建立有限元模型。
进行HSK刀柄/主轴联接性能分析,通过研究各个参数对联接锥面的接触应力和锥面间隙的影响情况,建立不同参数变化下锥面接触应力图和间隙图,进而分析各个参数对锥面联接的影响情况。基于锥面联接可靠定位的条件,得出标准刀柄不能满足锥面定位可靠的需求。
为了满足锥面联接可靠定位,提出两种改进结构的可行方案,对其结构进行联接性能分析,综合考虑这两个方案确定刀柄结构,进行动平衡计算和验证,理论计算得出该结构存在动不平衡量,采用离线测试,确定动不平衡量得位置和相位,借助平衡孔达到动平衡要求。
分析联接锥面的可靠性,进行可靠度判断,分析换刀速度与可靠性关系,换刀速度通过换刀时间衡量,可靠性由可靠度衡量,建立换刀速度-可靠性曲线,分析换刀速度与成本关系,建立换刀速度-成本曲线。
Automatic tool changer is an important auxiliary processing device on machine tool, whose internal high-speed development and application of functional components dramatically improve the production efficiency. In the cutting, the short cutting time and high cutting speed are requested, and gradually the requirement of the exchange tool time is rised, the speed of exchange tool are becoming high levels of representative indicator in the contemporary machining center. Each processing center are making their focus on the automatic tool change technology for competition. Automatic tool changer of gantry machine are summarized, and the configuration with tool changer manipulator and tool container are introduced. It provides a hardware foundation for the study.
The article on the basis of investigation on the development and research status of domestic and foreign automatic tool change technology, research linkage shank of using on the high-speed machining, comprehensive analyzing the application scope of selected HSK shank's various sizes and machine tool equipment with parameters to select high shank. According to international standard, HSK shank model and HSK tool system model are established, and work principle of HSK tool system is analyzed.
Through analyzing shank/spindle linkage/coupling performance and studying the various parameters on the performance of the coupling taper surface, it can obtain that each parameter has how effect on coupling. Based on the cone coupling's reliable conditions, it is concluded that the standard shank can't satisfy the coupling performance requirements. Improved structure is analyzed about cone coupling performance. If optimized structure meets performance, dynamic balance will be sensed. If dynamic unbalance of the structure exists, it requires the balance hole to compensate equilibrium requirements.
By analyzing the joining reliability of the shank and spindle relationship between speed and reliability, simultaneously the margin of safety judgment is carried. The reliability of tool changing speed-curve is established. One cutter replacement rate weighs through cutter replacement time measurement and the reliability weighs by the margin of safety. Through the analysis of the cutter replacement speed and cost relationship, a tool change speed-cost curve is established.
引文
[1]周建亭,杜金印.从CIMT2009看中国机床工业发展方向[J].企业论坛,科技信息,2009.15:355
[2]中国机床工具工业协会.调整、创新国产数控机床精品集中亮相CCMT2010[J].展览会信息(Exhibition),2010,2:37-39
[3]展览会信息CCMT2010展品预报[J].WMEM,2009,6:23-24
[4]李静.第6届中国数控机床展览会(CCMT2010)新闻发布会[J].制造技术与机床,2010.4:16
[5]王红利,钟晓玲.第6届中国数控机床展览会(CCMT2010)新闻发布会[J].WMEM,2010.06
[6]金志平.从CIMT2009看立式加工中心的发展[J].金属加工,2009,13:9~11
[7]徐正平.从CCMT2010看当今机床的市场需求[J].制造技术与机床,2010,6:12~14
[8]王科社,杨庆东,赵宏林.高速加工中心的快速自动换刀技术[J].制造技术与机床,2001.12:5~7
[9]王科社,盛伯浩.自动换刀装置换刀时间计量方法[J].组合机床与自动化加工技术,2001,4:44~46
[10]安海峰.谈高速加工中心的快速自动换刀技术[J].工业技术,2008,9:91
[11]王科社,杨庆东,孙志永.浅谈快速自动换刀装置[J].机械加工与自动化,2002,10:20~22
[12]刘静香,张春梅.浅谈高速加工中心及关键技术的发展[J].煤矿机械,2003,11:83~85
[13]刘瑞已.加工中心快速自动换刀装置[J].机械工程师,2004,11:84~85
[14]陈世平,石军,罗辑.高速切削加工用刀柄的发展现状[J].机械加工与自动化,2003,9:21~23
[15]杨贺来.数控机床.清华大学出版社[M],北京:交通大学出版社,2009.02
[16]许石.加工中心刀库自动换刀的控制[J].金属加工,2008,16:43~45
[17]陶松桥.加工中心刀库定位控制研究[J].机电工程技术,2008,37(9):22~23
[18]陶松桥.加工中心刀库定位控制的改进[J].设备管理与维修,2008,7:27~28
[19]刘静.双凸轮联动自动换刀技术的研究[D].大连理工大学硕士论文,2008.12
[20]http://china.toocle.com/.中国刀具商务网
[21]邱煜城.刀库之发展趋势与未来展望[J].制造技术与机床,2007,4:114~115
[22]蔡厚道,吴帏.数控机床构造[M].北京理工大学出版社,2007.02
[23]王元成.XAH/785立式加工中心换刀机构分析[J].一重技术,2007,5:76~77
[24]邓奕.数控机床结构与数控编程[M].北京:国防工业出版社,2006
[25]康运江,王西彬.刀柄及其联接系统的现状和发展[J].机械工程师,2004,6:3~5
[26]Tsutsumi M. Static and Dynamics Stiffness of 1/10 Tapered Joint for Automatic Changing[J]. Int.J.Japan Soc.Prec.Eng,1995,29(4):23-28
[27]赵宏林,高立新,丁庆新.高速切削中的刀柄技术[J].制造技术与机床,2006,7:20~23
[28]王宝金.数控镂铣机和数控加工中心的自动换刀[J].木材加工机械,2004,3:19~22
[29]赵葛霄.加工中心的自动换刀方式及PC实现方法[J].现代机械,2001,2:6~10
[30]杨树兴.计算机控制系统——理论、技术与应用[M].北京:机械工业出版社,2006
[31]黄继昌,徐巧鱼,张海贵.实用机构图册[M].北京:机械工业出版社,2008.01
[32]王贵成,王树林,董广强.高速加工工具系统[M].北京:国防工业出版社,2005.08
[33]黄树涛,贾春德,于俊一.两面夹紧刀柄的结构及特点[J].工具技术,2000,12:24~26
[34]王振宇,江崇民,李德秀.快速可靠的自动换刀机构[J].机械工程师,2006,4:132~133
[35]David L, Lewis. HSK Status Report. Manufacturing Engineering[J],1996,1:63-66
[36]许琰,王贵成,韩继光.HSK空心短锥柄的结构及其选用[J].工具技术,2004,38(6):37~40
[37]Kocherovsky. The Secrets of HSK. Cutting Tool Engineering [J],1998, (9):56-63
[38]Kocherovsky. HSK Handbook[J].1st Ed. Intelligent Concept. USA,1999
[39]李英.高速加工技术现状及其关键技术[J].重庆科技学院学报,2009,11(3):80~82
[40]陈义庄.数控机床自动换刀装置的选择及刀柄的配置[J].机床与液压,2002,228~229
[41]陈世平,李涛.HSK工工具系统的特点及选用[J].工具技术,2008,42(11):87~89
[42]杨柳欣,李松生,吉智军.HSK系列高速刀柄简介[J].制造技术与机床,2003,11:69~71
[43]Wolfgang Kelch. The ABC's of HSK[J]. Tooling and Production,1995
[44]路广,吴勇中,桂贵生.HSK刀柄/主轴联接性能分析[J].制造技术与机床,2009,2:37~40
[45]Schulz H. High Speed Machining[J]. Annals of the CIRP,1992,41(2):637-643
[46]Kahles J F. High Speed Machining[J]. Annals of the CIRP,1978,27(2):551-560
[47]薛宝丽,王贵成,刘钢.高速刀柄及其工具系统的结构与性能[J].工具技术,2008,42(10):31~34
[48]王树林,王贵成,梁彦学.HSK工具系统夹紧系统分析研究[J].现代制造工程,2002,(12):66~68
[49]徐秉业.弹塑性力学及其应用[M].北京:国防工业出版社,1994
[50]Wang Guicheng, Wu Weiguo, Shen Chungen, Wang Shulin, Zuo Jianmin. Mechanical Model of HSK Tooling System in High Speed Machining[J]. Transaction of Nanjing University of Aeronatics & Astronautics,2007,24(2):145-149
[51]Eugene I, Rivin. Tooling Structure::Interface between Cutting Edge and Machine Tool[J]. Annals of the CIRP,2000,49(2):591-634
[52]Hanna I M. Modeling the HSK Tool holder Spindle Interface[J]. ASME,2000, 11:909-926
[53]ISO 12164-1, ISO 12164-2, Hollow taper interface with flange contact surface[S].
[54]王学林,李修平,胡于进.高速加工中心的有限元分析[J].机械与电子,2005,7:52~54
[55]江克斌,屠义强,邵飞.结构分析有限元原理及ANSYS实现[M].北京:国防工业出版社,2005.06
[56]张松,艾兴.HSK主轴/刀柄联接的非线性接触分析[J].机械工程,2004,15(5):391~394
[57]张洪信.有限元基础理论与ANSYS应用[M].北京:机械工业出版社,2006.01
[58]Weck M. New Interface Machine/Tool:Hollow Shank[J]. Annals of the CIRP,1994, 43(1):345-348
[59]Andy Pistker. HSK In Search of the Perfect[J]. SME Publication, Chicago, Illinois,1998
[60]浦洪良,王树林,王贵成,梁彦学.HSK刀柄锥面过盈配合的可靠性分析[J].工具技术,2005,39(7):51~53
[61]Aoyama T, Inasaki I. Performance of HSK Tool Interfaces under High Rotational Speed[J]. Annals of the CIRP,2001,50(1):281-284
[62]浦洪良.HSK夹紧系统及其锥面配合可靠性研究[D].江苏大学硕士学位论文,2005
[63]Agapiou J. Rivin E, Xie C. Improved Toolholder/Spindle Interface for CNC Machine Tools[J].1st International Machining and Griding Conference, SME Publication, 1995,9:31-38
[64]张铁铭.HSK工具锥柄的检测与动平衡[J].工具技术,2001,35(4):27~30
[65]吕震宙,宋述芳,李洪双,袁修开.结构机构可靠性及可靠性灵敏度分析[M].北京:科学出版社,2009.09
[66]Wang Taiyong, Liu Qingjian, Wang Yunfeng. Research on Reliability Design Theory and Methods of CNC system[J]. IMECE,2009,9:247-253
[67]朱文艺,张庆乐.数控加工中心自动换刀机构动作过程及控制原理研究[J].武汉工程职业技术学院学报,2009,21(1):5~9
[68]穆塔里夫·阿赫迈德.TH6350加工中心自动换刀运动动态仿真[J].组合机床与自动化加工技术,2004,3:1~2
[69]王科社,杨庆东,张怀存.关于自动换刀装置速度和可靠性提高的讨论[J].机械,2002,29:92~93