挤出螺杆的指状铣刀包络加工方法研究
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摘要
随着塑料材料在工业、农业以及日常生活中应用量的迅速增高，各式螺旋挤压混合技术广泛应用于塑料工业的成形工业中。挤出螺杆作为注塑挤出工艺的核心部件，它的形状越来越复杂，其加工技术也越来越受到人们的重视。如何提高复杂形状挤出螺杆的加工质量、加工效率以及如何降低成本，成为目前人们主要关注的问题。传统对挤出螺杆的加工一般应用成形法并在改进机械式机床或三轴数控机床上加工，采用自磨圆角或锥形的高速钢棒铣刀。随着螺杆形状和性能要求的提高，成形法加工效率和加工质量已经不能满足人们的要求。针对目前挤出螺杆连续变螺棱、变导程、变棱圆、变底径等复杂廓形，本文在研究挤出螺杆几何特性及螺旋面成形原理的基础上，提出了一种高效、经济、实用的挤出螺杆加工技术——指状铣刀包络加工方法，这种加工方法通过铣刀位置变化能够有效的对挤出螺杆棱圆进行包络加工，并且利用一把标准刀具能够实现在一根螺杆上连续变螺棱、变导程、变深等复杂形状的加工，加工效率比较高。
本文通过对空间自由曲面、螺旋曲面加工方法的研究和归纳总结，进而建立加工过程模型，利用啮合原理及优化方法求解，最终确定了利用指状铣刀包络加工螺杆棱圆的刀具空间轨迹。文中设计了指状铣刀包络法所用的铣头装置，研究挤出螺杆的指状铣刀加工过程、设计合理的加工工艺、进行误差分析并减少加工误差、分析了工件的加工等一系列求解空间刀具轨迹数控技术关键问题，并且运用C++BuiIder编程语言来实现上述算法并编制易操作的软件界面。
本项目研究在国内率先提出了在四轴联动数控机床上利用指状铣刀包络加工挤出螺杆的加工方法，重点是对螺杆棱圆的包络加工，并研制了加工所用机床。指状铣刀包络加工挤出螺杆时刀具切削平稳，加工效率高，其应用前景十分广阔。本方法无疑改变了国内挤出螺杆加工的现状，对提高我国挤压机行业的技术水平，推动国民经济的发展，将起到积极的作用。
Along with the rapid development of plastic material using in industry, agriculture anddaily life, all kinds of spiral extrusion commixture technology are widely used in the plasticsforming industry. As the key part of extrusion technology, the shapes of extrusion screw aremore and more complicated; the processing technology also takes more and more people'svalue. How to enhance the processing quality of the extrusion screw, the processing efficiencyas well as how to reduce the cost have been concerned by present people. The traditionalprocessing method of extrusion screw usually uses forming process processing on theimproving machinery or three axes numerical control machine tool, adopting autogenouslygrinding round angle or conic high-speed steel milling cutter. But along with the improvementof the demand on the shape and function of extrusion screw, the processing efficiency andquality of forming process cannot be satisfied. In the view of complexity of the changeablepitch, changeable bottom diameter, changeable spiral angle of extrusion screw, this articlestudied on the base of studying the theory of geometry characteristic and helicoids forming,the article proposed a kind of highly effective, economical and practical extrusion screwprocessing technology: finger cutter envelope machining. This processing method mayprocess prismatic roundness of extrusion screw with envelope machining efficiently throughthe change of finger cutter's location, and it can realize the complicated processing ofchangeable pitch, changeable bottom diameter and changeable spiral angle in the sameextrusion screw.
On the base of studying and summarizing the processing method of free curved surface and spiral curved surface, building the model of processing process, finding the solution by making use of the engage principle and optimization method, in the end this article determines the method and step of the finger cutter spiral curved surface's processing cutting tool space trajectory which uses the finger cutter envelope, designs the mill head which used in the milling cutter envelope to research the processing process of finger cutter's milling cutter, design reasonable processing craft, carry on the error analysis and reduce processing error and analyze the work piece processing and so on a series of key solutions to NC technology of space cutting path, and utilize the C++BULIDER programming language, CAD/CAM software, SOLIDWORKS processing simulation software to realize the above algorithm and the simulation processing process.
This research takes the lead in proposing the processing method of using the finger cutter envelope to milling the finger cutter on the base of four axes linkages NC machine in china, and developed the processing machine. It realizes smoother cutting of cutter, higher quality of finger cutter's surface, more efficiency of processing when the finger cutter processed extrusion screw with envelope Machining. The application had broad prospect. This processing method is no doubt changes the national situation of processing extrusion screw as well as played the positive role to enhance the technical level of extruder industry in our country and impel the development of national economy.
本文通过对空间自由曲面、螺旋曲面加工方法的研究和归纳总结，进而建立加工过程模型，利用啮合原理及优化方法求解，最终确定了利用指状铣刀包络加工螺杆棱圆的刀具空间轨迹。文中设计了指状铣刀包络法所用的铣头装置，研究挤出螺杆的指状铣刀加工过程、设计合理的加工工艺、进行误差分析并减少加工误差、分析了工件的加工等一系列求解空间刀具轨迹数控技术关键问题，并且运用C++BuiIder编程语言来实现上述算法并编制易操作的软件界面。
本项目研究在国内率先提出了在四轴联动数控机床上利用指状铣刀包络加工挤出螺杆的加工方法，重点是对螺杆棱圆的包络加工，并研制了加工所用机床。指状铣刀包络加工挤出螺杆时刀具切削平稳，加工效率高，其应用前景十分广阔。本方法无疑改变了国内挤出螺杆加工的现状，对提高我国挤压机行业的技术水平，推动国民经济的发展，将起到积极的作用。
Along with the rapid development of plastic material using in industry, agriculture anddaily life, all kinds of spiral extrusion commixture technology are widely used in the plasticsforming industry. As the key part of extrusion technology, the shapes of extrusion screw aremore and more complicated; the processing technology also takes more and more people'svalue. How to enhance the processing quality of the extrusion screw, the processing efficiencyas well as how to reduce the cost have been concerned by present people. The traditionalprocessing method of extrusion screw usually uses forming process processing on theimproving machinery or three axes numerical control machine tool, adopting autogenouslygrinding round angle or conic high-speed steel milling cutter. But along with the improvementof the demand on the shape and function of extrusion screw, the processing efficiency andquality of forming process cannot be satisfied. In the view of complexity of the changeablepitch, changeable bottom diameter, changeable spiral angle of extrusion screw, this articlestudied on the base of studying the theory of geometry characteristic and helicoids forming,the article proposed a kind of highly effective, economical and practical extrusion screwprocessing technology: finger cutter envelope machining. This processing method mayprocess prismatic roundness of extrusion screw with envelope machining efficiently throughthe change of finger cutter's location, and it can realize the complicated processing ofchangeable pitch, changeable bottom diameter and changeable spiral angle in the sameextrusion screw.
On the base of studying and summarizing the processing method of free curved surface and spiral curved surface, building the model of processing process, finding the solution by making use of the engage principle and optimization method, in the end this article determines the method and step of the finger cutter spiral curved surface's processing cutting tool space trajectory which uses the finger cutter envelope, designs the mill head which used in the milling cutter envelope to research the processing process of finger cutter's milling cutter, design reasonable processing craft, carry on the error analysis and reduce processing error and analyze the work piece processing and so on a series of key solutions to NC technology of space cutting path, and utilize the C++BULIDER programming language, CAD/CAM software, SOLIDWORKS processing simulation software to realize the above algorithm and the simulation processing process.
This research takes the lead in proposing the processing method of using the finger cutter envelope to milling the finger cutter on the base of four axes linkages NC machine in china, and developed the processing machine. It realizes smoother cutting of cutter, higher quality of finger cutter's surface, more efficiency of processing when the finger cutter processed extrusion screw with envelope Machining. The application had broad prospect. This processing method is no doubt changes the national situation of processing extrusion screw as well as played the positive role to enhance the technical level of extruder industry in our country and impel the development of national economy.
引文
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[2] Z. Tadmor, I. Klein. Engineering Principls of Plasticating Extrusion. New York, 1970:21-25.
[3] Anon. The History of Extrusion. Plastics London, 1953:78-85.
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[7] W．Michael．Extrusion Design and Engineering Computations．New York：Mecmillan，1997．
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[9] 王江华，兰猛．螺杆铣床的数控改造．制造技术与机床，1995，(5)：36—36．
[10] 聂秋根，肖尧先．不规则螺旋槽的数控加工．机械制造，1996，(2)：25—26．
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[12] 余雷．变导程螺旋包络运动分析．江苏机械制造与自动化，2000，(1)：20—22．
[13] 战祥乐，赵战峰．不等深螺杆的数控加工．机械与模具，2005，31(5)：45-47．
[14] 付玉升，王家钦，刘彤等．食品膨化挤出螺杆的内旋风铣削加工方法研究．机械设计与制造，2005，(6)：103-104．
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[16] 易先中．螺旋面数控加工的前置处理研究．石油机械，1999，27(7)．
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[18] 王志梅．变螺距变底径螺杆数控加工程序的编程．机械工人，2001，(5)：39—40．
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[23] 梁补女，张震宇，刘彦国．基于AutOCAD平台的数控铣床自动编程系统的开发．机械研究与应 用，2003，16(2)：53—54．
[24] 周济，周艳红等．数控加工技术．北京：国防工业出版社，2002．
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[29] 刘雄伟等．数控加工理论与编程技术．北京：机械工业出版社，1994．
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[31] 尤德崑．我国螺杆加工技术的现状及水平．石油机械，1993，21(5)：5—10．
[32] 王兴天．挤出机的现状与发展．塑料科技，1994，(01)：41-51．
[33] 卿艳梅，周南桥，彭响方．单螺杆挤出机中熔体混合理论的研究．工程塑料应用，2003，31(01)：23—26．
[34] 冯彦洪，瞿金平，任鸿烈，周南桥．单螺杆挤出机熔融机理研究的发展．中国塑料，2002，16(06)：9-14．
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[36] 李德溥，郭建亮，杨绮云，徐克非．结构参数对双螺杆挤压机系统特性影响的研究．包装与食品机械，2001，19(04)：7-10．
[37] 王海宝，王家序，吴光杰．加料段固体塞的力学模型及其几何参数对输送能力的影响．轻工机械，2003，(02)：15-17．
[38] 梁基照．挤出机螺杆计量段几何参数的优化设计．轻工机械，1995，(2)：42-44．
[39] 李春瑜．旋风铣削螺纹的径向误差分析与对策．机械工艺师，1997，(5)：32．
[40] 乐美豪．我国螺杆制造技术的现状和发展趋势．第一届全国螺杆设计制造技术会议，2000，(1)：3—8．
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[43] 孙伟等．变螺距螺杆加工的研究．吉林工学院学报，1995，16(4)：28—31．
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[2] Z. Tadmor, I. Klein. Engineering Principls of Plasticating Extrusion. New York, 1970:21-25.
[3] Anon. The History of Extrusion. Plastics London, 1953:78-85.
[4] K. Wilczynski. Plastics and Rubbers Processing and Application, 1993, (13):102-106.
[5] W. Tedder. A New Theory of Solid Conveying in Single Screw Extruders, SPE, 1971,(10):35-40.
[6] 朱复华．单螺杆挤出过程的研究：(博士学位论文)．北京：北京化工大学，1997．
[7] W．Michael．Extrusion Design and Engineering Computations．New York：Mecmillan，1997．
[8] 陈文瑛等译．塑料挤出．北京：中国轻工业出版社，1996．
[9] 王江华，兰猛．螺杆铣床的数控改造．制造技术与机床，1995，(5)：36—36．
[10] 聂秋根，肖尧先．不规则螺旋槽的数控加工．机械制造，1996，(2)：25—26．
[11] 张辉，徐海峥，尹文生等．异形螺杆的数控加工．塑料，1999，(3)：32—34．
[12] 余雷．变导程螺旋包络运动分析．江苏机械制造与自动化，2000，(1)：20—22．
[13] 战祥乐，赵战峰．不等深螺杆的数控加工．机械与模具，2005，31(5)：45-47．
[14] 付玉升，王家钦，刘彤等．食品膨化挤出螺杆的内旋风铣削加工方法研究．机械设计与制造，2005，(6)：103-104．
[15] 王可等．螺杆制造技术的现状与发展．第一届全国螺杆设计制造技术会议，1999：23-27．
[16] 易先中．螺旋面数控加工的前置处理研究．石油机械，1999，27(7)．
[17] 王可，赵文珍，唐宗军等．异形螺杆加工所用无瞬心包络法原理与实践．制造技术与机床，1999，(2)：37—38．
[18] 王志梅．变螺距变底径螺杆数控加工程序的编程．机械工人，2001，(5)：39—40．
[19] 栗全庆．图形编程——数控加工自动编程技术的发展方向．组合机床与自动化加工技术，1996，(5)：36—39．
[20] 毕承恩，丁乃建等．现代数控机床上、下册．北京：兵器工业出版社，1996．
[21] 廉云国，张永洪．加工中心设计与应用．北京：机械工业出版社，1995．
[22] 栗全庆，周锦国，刘军．一种数控加工图形自动编程系统．洛阳工学院学报，1996，17(4)：63-67．
[23] 梁补女，张震宇，刘彦国．基于AutOCAD平台的数控铣床自动编程系统的开发．机械研究与应 用，2003，16(2)：53—54．
[24] 周济，周艳红等．数控加工技术．北京：国防工业出版社，2002．
[25] 王水来等．曲面沿参数线加工的实时轨迹生成．机械工业自动化，1997，19(3)：29—31．
[26] James E Bobrow. NC machine tool path generation from CSG part representations. Computer-Aided Design, 1985,17(2):69-76.
[27] 刘雄伟．自由曲面的三坐标NC加工编程．组合机床与自动化加工技术，1991(6)：21-27．
[28] Kwangsoo Kim and John E. Biegel. A Path Generation Method for Sculptured Surface Manufacture. Sculptured surface manufacture, 1988,14(2):95-101.
[29] 刘雄伟等．数控加工理论与编程技术．北京：机械工业出版社，1994．
[30] 喻道远等．空间自由曲面数控编程中刀位轨迹的计算方法及存在的问题．机械工业自动化，1997，19(1)：21-27．
[31] 尤德崑．我国螺杆加工技术的现状及水平．石油机械，1993，21(5)：5—10．
[32] 王兴天．挤出机的现状与发展．塑料科技，1994，(01)：41-51．
[33] 卿艳梅，周南桥，彭响方．单螺杆挤出机中熔体混合理论的研究．工程塑料应用，2003，31(01)：23—26．
[34] 冯彦洪，瞿金平，任鸿烈，周南桥．单螺杆挤出机熔融机理研究的发展．中国塑料，2002，16(06)：9-14．
[35] 罗荣森，刘廷华．新型螺杆元件挤出动力学特征的实验研究．塑料，1998，(05)：7—16．
[36] 李德溥，郭建亮，杨绮云，徐克非．结构参数对双螺杆挤压机系统特性影响的研究．包装与食品机械，2001，19(04)：7-10．
[37] 王海宝，王家序，吴光杰．加料段固体塞的力学模型及其几何参数对输送能力的影响．轻工机械，2003，(02)：15-17．
[38] 梁基照．挤出机螺杆计量段几何参数的优化设计．轻工机械，1995，(2)：42-44．
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