1 附錄 A 四 工位組合機床的設計與研制 摘要 摘要：本文介紹了一種用于加工載重汽車輪轂的單面立式 30 軸鉆、擴、鉸組合機床，以及機床的設計方法、結構、性能特點和使用操作等。 關鍵詞：組合機床 ;輪轂 ;設計 ;研制 四工位組合機床用于對載重汽車前、中后輪轂 10-27+0.033孔的鉆、擴、鉸加工。此類機床過去已有的設備相對落后，電氣系統、液壓系統及機床主要部件相對過時和陳舊。本文介紹的組合機床有較先進的電氣控制系統和液壓系統，機床的運行采用三菱可編程控制器程序控制，程序可根據加工流程圖進行調整，變成方便靈活。它集粗鉆、擴加工和精鉸加用于一身，自成體系地形成一條圓形加工流水線。該設備占地面積小，加工精度高，性能穩定可靠，是汽車制造工廠加工輪轂不可多得的設備。它是由專用底座，專用主軸箱，專用夾具及鉆模板， THL86 立柱， HY80系列滑臺及 TD80A動力頭， AHY125A回轉工作臺等組 成。 組合機床的技術發展 1.1 組合機床 組合機床是一種專用高效自動化技術裝備，目前，由于它仍是大批量機械產品實現高效、高質量和經濟性生產的關鍵設備，因而被廣泛應用于汽車、拖拉機、內燃機和壓縮機等許多工業生產領域。所以說組合機床的技術性能和綜合自動化水平，在很大程度上決定了這些工業部門產品的生產效率、產品質量和企業生產組織的結構，也很大程度上決定了企業產品的競爭力。 現在組合機床作為機電一體化產品，它是控制、驅動、測量、監控、刀具和機械組建等技術的綜合反映。近 年來，這些技術有長足進步，同時作為組合 機床組要用戶的汽車和內燃機等行業也有很大的變化，其產品市場壽命不斷縮短，品種日益增多且質量不斷提高。這些因素有力地推動和激勵 2 了組合機床的不斷發展。 1.2 組合機床品種的發展 在組合機床這類專用機床中 ,回轉式多工位組合機床和自動線占有很重要的地位。因為這兩類機床可以把工件的許多加工工序分配到多個加工工位上 ,并同時能從多個方向對工件的幾個面進行加工 ,此外 ,還可以通過轉位夾具 (在回轉工作臺機床上 ) 或通過轉位、翻轉裝置 (在自動線上 ) 實現工件的五面加工或全部加工 ,因而具有很高的自動化程度和生產效率 ,被汽車、摩托 車和壓縮機等工業部門所采用。 根據有關統計資料 ,德國在 1990 1992 年期間 ,回轉式多工位組合機床和自動線的產量約各占組合機床總數的 50 % 左右。應指出 ,回轉式多工位組合機床實際上是一種特殊型式的小型自動線 , 適合于加工輪廓尺寸 250mm 的中小件。與自動線相比 , 在加工同一種工件的情況下 ,回轉式多工位組合機床所占作業面積要比自動線約小 2/ 3 。 1.3 組合機床柔性化進展迅速 十多年來 ,作為組合機床重要用戶的汽車工業 ,為迎合人們個性化需求 ,汽車變型品種日益增多 ,以多品種展開競爭已成為汽車市場競 爭的特點之一 ,這使組合機床制造業面臨著變型多品種生產的挑戰。為適應多品種生產 ,傳統以加工單一品種的剛性組合機床和自動線必須提高其柔性。在 70 年代 ,數控系統的可靠性有了很大的提高 ,故到 70 年代末和 80 年代初 ,像 Alfing 、 Hller2 的運動特性曲線。由于電液比例閥控制系統 Hille 和 Ex2cell2o 等公司相繼開發出數控加工模塊和柔性自動線 (F TL) ,從此數控組合機床和柔性自動線逐年增多。在 1988 年至 1992 年間 ,日本組合機床和自動線 (包括部分其它形式的專用機床 ) 產量的數控化率已達 32 % 39 % , 產值數控比率達 35 % 51 % ; 德國組合機床和自動線產量的數控化，發動機變型品種日益增多的趨向率為18 % 62 % , 產值數控化率達 45 % 66 % 四工位組合機床的設計 3 .1 工藝方案的確定 組合機床是針對某種零件或某道工工序而設計的，工藝方案又是組合機床設計的關鍵，它是根據被加工零件的結構特點、加工部位、加工的尺寸精度、粗糙度以及其他技術要求來確定設計的。 被加工件是汽車輪轂零件，在前道立車工序上已加工出 280-0.1的定位圓，要求在 375 的圓周面上加工出 10 個 27+0.033的孔，其位置公差為 0 0.12，粗糙度為 3.2。根據以上要求，工藝方案應確定粗精加工分開進行，即先鉆 25的孔，然后擴孔到 26.6，再精餃孔到 27，考慮到零件的加工精度和工序集中原則，粗精加工合并成一道工序在一臺機床上進行。由此確定機床的鉆、擴、鉸三個工位，加之裝卸工件工位，故命名為四工位組合機床。 .2 配置型式及其結構方案 機床的配置型式主要取決于被加工零件的加工精度和工藝方案，既要考慮能實現工藝方案以保證零件的加工精度、技術要求和生產效率；又要考慮操作方便，易于維 修，冷卻和排屑情況良好。該機床的配置型式屬于大型組合機床，總重量約為 21t，總功率 17.5kW四套專用夾具安裝在直徑 1250m 的回轉工作臺上，形成四個工位，與之對應的立柱上安裝 HY80標準滑臺，滑臺上安裝標準動力頭和專用主軸箱，主軸箱的加工中心與回轉工作臺的回轉中心對中，成垂直立式布局。裝卸工件和加工工件可同時進行，互不干擾，既機床的切削時間和輔助時間重合，從而提高機床的工作效率。 組合機床的主要組成部分 .1 床身 床身部件必須有足夠的承載能力和足夠的剛度動態性能及過載儲備稀疏，以保證各部件之間能長 期保持其正確的相對位置。組合機床的剛度和部件之間的精度保持性要由床身部件來保證。本機床的床身不見主要由回轉工作臺底座、立座底座、立柱和立柱墊等構成。它們起著組合機床的基礎骨架作用。床身部件包括配重在內的重量達組合機床總重量的 70%以上，因而具有良好 4 的剛性和抗振性能，為保證機床的加工精度奠定了良好的基礎。 .2 滑臺 滑臺之用來實現進給運動的動力部件，它主要由滑臺，滑臺座和液壓油缸三部分組成。滑臺座固定在立柱上，液壓油缸體固定在滑座上，活塞桿與滑臺相互連接，工作時，液壓油缸固定，活塞桿帶著滑臺在滑座的導軌上作往返運動。本機床液壓滑臺屬于大型滑臺，有足夠的能量儲備。滑臺的工作有快進、共進和快退三種狀態。其動作是由電氣系統和液壓系統共同控制的。在滑臺上安裝有動力頭和主軸箱，滑臺頂部裝有鋼絲繩滑輪組，另一端在立柱中裝有配重塊，目的是使滑臺在滑座上移動輕便，并可防止滑臺端過重而下滑。 .3 動力頭及主軸箱 動力頭是主軸運動的驅 動裝置，它帶動主軸箱的各個輸出主軸使刀具作主體運動。本機床鉆、擴、餃孔刀具直徑分別為 25mm、 26.6mm和 27mm，被加工零件材料為 35CrMoV，硬度 HRC28 32， 考慮到扭矩儲備系數，機床采用標準 TD80A 型動力頭，主電機為 15KW。轉速為 970r/min，輸出軸轉速為 475r/min。主軸箱是組合機床重要部件之一，其作用是根據被加工件的加工要求，安排各主軸的位置，并將電機的動力按不同的轉速比輸出分配給各工作主軸，使主軸得到要求的轉速和轉向，以滿足對零件的加工。主軸箱主軸的排列根據被加工零件的工藝要 求進行設計，并與回轉工作臺上的夾具工位向對應，主軸箱的傳動齒輪及傳動軸可選標準件。 .4 主軸及鉆模板 主軸的結構取決于零件的加工工藝以及主軸的受力情況。對于鉆削加工的主軸，受軸向切削力較大，應采用推力球軸承或滾錐軸承定位。主軸與刀具的連接方式采用莫氏 3#導向套接桿，刀具的長短比例可視加工情況調整接桿。用于鉆、擴孔加工的主軸轉速為 175r/min。切削速度 V=13.7m/min,進刀量 S=0.17mm/r.鉸孔加工的主軸轉速為 50r/min，切削速度 V=4.24m/min，進 5 刀量 S=0.6mm/r，進刀速 度 Sv=30mm/min。 鉆模板主要起對刀具的輔助定位作用，防止刀具在加工時擺動，從而提高被加工件的精度。 .5 回轉工作臺 回轉工作臺是多工位組合機床的輸送部件。本機床的回轉工作臺分四個工位， 1 工位用于裝、卸工件， 2.3.4 分別是鉆、擴、鉸工位。回轉工作臺作單方向的回轉運動，相當于一條圓形自動生產線，其結構緊湊，生產效率高，可以方便的實現電氣自動控制。該機床是齒盤定位回轉工作臺，其主要組成有：花盤、工作臺體、多齒定位盤、集屑槽、呼吸器、卡緊油缸、活塞、轉位齒輪、轉位離合器、液壓閥、轉位齒條等。回轉工作臺 的齒盤是圓周分布的一對相互嚙合的端面齒輪，靠圓周多齒嚙合定位，具有定位精度高和剛性好的特點，所以在轉臺上無論徑向力、軸向力或切向力，都可以起到自動定心的作用。 .6 夾具 夾具使用來防止并固定被加工零件的。正確選擇加工用定位基準是確保加工精度的重要條件。夾具的尺寸精度和安裝精度的高低直接影響到零件的加工精度，本機床共有四套尺寸相同的夾具，均布在回轉工作臺上并與回轉臺中心形成同心圓流水線。夾具主要有四個夾具體、定位圈、夾緊油缸等組成。每套夾具有四個夾緊油缸，等分固定在夾具體的四個方向上，夾緊工件時受力均衡， 防止零件變形。定位圈時夾具的關鍵部件，必須使四套夾具的定位圈尺寸公差相一致，而且四套夾具的回轉中心與回轉工作臺的回轉中心也應絕對重合，才能保證零件的加工精度。 .7 液壓系統 機床的液壓系統相當于人體的血液喜歡系統，被加工零件的夾緊、放松，工作臺的抬起、旋轉和落下，動力頭滑臺的快進、共進和快退等都是靠液壓系統來實現。液壓系統主要由液壓站集中控制，液壓電機為 22KW，液壓泵為變量葉片泵，滑臺的動作是由一個三位五通電磁閥和調速閥來控制。回轉工 6 作臺的抬起、落下、回轉和復位，以及工件的夾緊和放松，主要由三個兩位四 通電磁閥來控制。另外專設一路由程序控制的對液壓滑臺自動定時潤滑。 .8 電氣系統 本機床采用 F1-60MR 三菱可編程控制器作為中央控制樞紐。它是由中、大規模集成電路組成，具有強大的邏輯控制功能和邏輯存儲功能，響應速度快，功耗小，體積小，受命小，可靠性高，通用性強，可不受條件限制地對程序進行在線編程、調試和修改。它可以實現對程序的自我診斷和故障檢測，可進行邏輯運算和編程的控制，定時和計數的控制，可以容易地實現機、電、液一體化。電氣系統的交流在、輸出控制主要有主軸電機，液壓電機，冷卻電機。直流輸出主要控制液壓站的十路電磁閥。 電氣系統的硬件主要有可編程控制器、變壓器、接觸器、操縱按鈕和保險器、整流二極管和續流二極管 、以及行程開關等組成；軟件主要包括主程序，同時有為程序服務的各個期間的輸入輸出地址標和程序梯形圖等。 機床的操作分調整和自動兩種方式，調整方式為手動控制機床的單步操作；自動方式由程序控制按加工流程圖實現自動循環。 .9 冷卻系統 機床外部設有專用的帶腳輪的冷卻箱，便于維修和清理，冷卻泵電機為0.12KW。容量為 50L/min，冷卻水到達鉆模板后分成三路，每一路有 10個導向水嘴，對應于 10 把刀具，俄有效地實現刀具的冷卻。冷卻泵在滑臺工進時由程序控制自動啟動，實施對被加工工件的冷卻，工進到終點時自動關閉。 4 組合機床的安裝調試及精度檢驗 在組裝過程中始終貫穿著對系統部件的不斷調試，以及對影響加工尺寸的主要部件的自身精度和結合精度進行調整。 系統的調試是根據各個系統的要求和機床工作循環圖的要求來對電氣系統、液壓系統、冷卻系統、主機系統自身和相互之間進行有關調整。 對主要部件自身精度和結合精度進行調整是指以下幾個方面： 7 （ 1）機床側底座、立柱底座的安裝水平。 （ 2）機床側底座、立柱底座、機床導軌的扭曲。 （ 3）主軸孔軸線的徑向跳動。 （ 4）主軸孔軸線對機床導軌的平行度。 （ 5）夾具襯套孔軸線或樣件孔軸線對導軌的平 行度。 （ 6）主軸和夾具襯套孔或樣件孔對導軌的等距度。 （ 7）回轉工作臺的回轉中心與主軸箱的加工中心的同軸度。 5 試車 當工件狀態旋鈕開關置于“調整”位置時，操作各按鈕如夾緊、放松、前進、后退等，可進行機床的單步動作，此功能主要用于機床試運行或刀具的調整等。當開關置于“自動”狀態時，機床的動作完全由程序自動進行控制，每次裝卸完工件后，只需按“夾緊”、“抬起”按鈕，機床就會自動循環、周而復始的工作下去，直到按“停止”按鈕為止，此功能主要用于對零件的自動加工。 經試車運轉一切正常，并對零件進行了加工試切驗證， 經過機械工業部第十七計測試中心檢測，尺寸公差及精度符合零件圖紙的技術要求。 6 本組合機床特點 (1)機床上的通用部件和標準零件約占機床零部件總量的 以上，因此設計和制造的周期短，經濟效益好。 (2)機床采用專用的夾具、刀具及鉆模板，一次性調整后，其加工質量全靠工藝裝備來保證，對操作人員的技術水平要求不高，且勞動強度低。 (3)該設備占地面積小，加工精度高，性能穩定可靠，是汽車制造廠加工輪轂的專 用設備。 (4)機床有鉆、擴、鉸及裝卸四個工位，裝卸及加工同步進行，因此機床的生產效率高，每小時可加工零件 件以上，加工質量穩定。 8 (5)機床采用可編程控制程序控制，因而自動化程度高，且機床的動作在不改變電氣線路的情況下可在線編制程序，隨機調整。 附錄 B Design and reseach of four engineering location association lathes17 ABSTRACT Abstract:This text introduce one is it process form , truck of hub vertical 30 axle get into , expand , cut with scissors and make the lathe up to use for, And lathe design method , structure , performance characteristic and uses and operates etc.ing. Keywords: Combination machine； Hub Design； Reseach Preface Four worker location association lathe use for10-27+0.033 to drill , hub of hole under truck , expand , cutting with scissors processing. This kind of existing equipment in the past of lathe lagged behind relatively, electric system , hydraulic pressure system and main part of lathe were relatively out of date and outmoded. Association lathe that this text introduce have more advanced electric control system and hydraulic pressure system, the operation of the lathe adopts Mitsubishis programmable controller procedure to control, the procedure can adjust according to processing the flow chart , become convenient and flexible. It is thick to bore , is it process and not precise to is it is it is it all over , afford to establish ones own system to used in to add to cut with scissors to expand for it 9 to collect. This equipment is small in floor space, the machining accuracy is high, it is reliable that performance is steady, it is the manufacturing plant of the automobile that processes the equipment with rare hub. It is by the special-purpose base , special-purpose main shaft case, special-purpose jig and boring the template , THL86 post, HY80 serial slippery platform and TD80A power head, AHY125A turn round workingbench ,etc. make up. 1. Make the technical development of the lathe up 1.1 Association lathe It is the automatic technical equipment of a kind of special-purpose university to make the lathe up, At present. Because it is still the key equipment that the engineering goods in enormous quantities were realized high-efficiently , the high quality and economy produced, Widely used in such a lot of industry production fields as the automobile , tractor , internal-combustion engine and compressor ,etc. So say that makes the technical feature of the lathe and comprehensive automation level up , determine these industrial department production efficiency , product quality and enterprise of product produce the structure organized to a great extent, have determined the competitiveness of the enterprise products to a great extent too. Make the lathe up as the integrated products of electromechanics now, It controls, urges, measures, control, the comprehensive reflection of technology that the cutter and machinery are set up ,etc. The past 20 years, Technology the make considerable progress, at the same time as make up lathe group want automobile and internal-combustion engine of user trade change a great deal too, Its life-span of product market is shortening constantly, the variety increases day by day and quality is being improved constantly. These factors have promoted and encouraged making the constant development of the lathe up effectively. Make the development of the variety of lathe up 10 In making the lathe up this kind of special-purpose lathe , Turning round type many workers location association lathes and transfer machine occupy very important status. Because two lathe these can is it get a lot of location , Engineer of processing , have to assign a lot of processing process of work piece, and can process several of the work piece from a lot of directions at the same time , In addition, Can also through transfer to location jig (turn workingbench round at the lathe ) or through transfer to location , upset device (at transfer machine ) realize 5 processing or processing of work piece, Therefore have very high automatic degree and production efficiency , is adopted by such industrial departments as the automobile , motorcycle and compressor ,etc. According to relevant statistical data, Germany is here 1990-1992 During annual ,Person who turn round many worker location association lathe and output of transfer machine is it is it make about 50 , lathe of total amount up to take each to invite. Should point out , Turning round type many workers location association lathes are a small-scale transfer machine of a kind of special pattern in fact, Suited to processing medium and small one of the size 250mm of outline. Compared with transfer machine, In case of processing the same kind of work pieces, person who turn round many worker location association lathe account for homework area invite than transfer machine 2/ 3little. Make the flexibility progress of the lathe up rapidly During the last ten years, Regarded as the auto industry which makes important users of the lathe up , In order to cater to individualized demands of people, Automobile person who become variety increases day by day, Is it become characteristic , automobile of market competition one of already to compete with many variety, This is it make up lathe manufacturing industry face many variety challenge of production of becoming etc. to make. In order to adapt to many variety production, With process single rigidity of variety make up the lathe and 11 transfer machine must raise his flexibility tradition. In the 1970s, the dependability of the numerical control system was improved a lot, So with the beginning of the eighties by the end of the seventies, like Alfing , H Movement characteristic curve of ller2. Because electric liquid proportion valve control system Hille and Ex2cell2o ,etc. company develop numerical control process module and flexible transfer machine in succession (F TL), Numerical control made the lathe and flexible transfer machine up and increased year by year from then on. Between 1988 and 1992, Japan made the lathe and transfer machine (the special-purpose lathe including some other forms ) up the numerical control rate of the output has already reached 32- 39, The numerical control rate of output value reaches 35- 51; Germany make lathe and numerical control , transfer machine of output up, engine for 18 - 62 trend rate that variety increase day by day of becoming etc., the numerical control rate of output value is up to 45 %-66 % 2 The designs of four engineering location association lathes 2.1 Sureness of a craft scheme Make up lathe to a certain part or some Engineer process and design, The craft scheme is the key to making the lathe up to design, It according to process into structure characteristic of part , process position , size precision , roughness and other specification requirement that process is it is it design to confirm to come. It is an automobile hub to process one .In before whether dish set up car the processes last 280-0.1localization round already, Require that processes the hole of 10 times 27+0.033 on circumference one of 375, The persons on a public errand of its position are 0-0. 12, The roughness is 3. 2. Craft scheme should confirm crude finish machining goes on separately , Namely get into 25 hole first, then reaming reach 26. 6, precise dumpling hole reach 27, Consider the machining accuracy and process of the part concentrate the principle , thick finish machining 12 is amalgamated a process is carried on on a lathe. Therefore confirm drill of lathe , expand , cut with scissors three worker person, in addition worker of loading and unloading work piece location, so named four engineering location association lathes . 2.2 Dispose the pattern and structure scheme The disposition pattern of the lathe depends on the machining accuracy of the part and craft scheme processed mainly, Should consider that can realize the craft scheme soes as to ensure the machining accuracy , specification requirement and production efficiency of the part ; And also it is easy to operate to consider, easy to maintain, cool and arrange the bits in sound conditionly . The disposition pattern of this lathe belongs to and makes the lathe up large-scaly, Total weight is about 21t, total power 17. 5kW Four sets of special-purpose jigs are installed on the gyration workingbench of diameter 1250m, Form four pieces of engineering location , Install HY80 standard slippery platform with its corresponding post, Install the standard power head and special-purpose main shaft case on the slippery platform, Gyration centre on and cant turn machining center , main shaft of case round workingbench of to in, become the vertical vertical overall arrangement. Loading and unload the work piece and processing the work piece can go on at the same time , does not interfere each other, Already cutting time and auxiliary time of the lathe has been coincident, thus improve the working efficiency of the lathe . 3.Make the main component of the lathe up 3.1 Lathe bed The lathe bed part must be enough bearing capacity and enough dynamic performance of rigidity and overload and store sparsly, so as to ensure that can keep its correct relative position for a long time between every part. Make up rigidity and precision keeping of part of lathe guarantee by the lathe bed part 13 Lathe this lathe bed is it turn workingbench base round , set up of base , post and post cushion ,etc. form mainly to disappear. They play a making the basic skeleton of the lathe up role. Lathe bed part including counterweight weight is it make lathe total more than 70% of weight up to reach, therefore have good rigidity and antivibration performance , settle good foundation for guaranteeing the machining accuracy of the lathe . 3.2 Slippery platform To is it is it enter give power part of sport to realize to used for slippery platform, It mainly by slippery platform, slippery pedestal and hydraulic pressure cylinder 3 part make up. The slippery pedestal is fixed on post, the cylinder block of hydraulic oil is fixed on slide , cylinder rod and slippery platform join each other, When working, hydraulic pressure cylinder regular, cylinder rod bring slippery platform make round sport at guide of slide. This slippery platform of hydraulic pressure of lathe belongs to the large-scale slippery platform, enough energy stores . Slippery work of platform is it enter , stock and soon retreat 3 kinds of states altogether soon to have. Its movement was controlled together by the electric system and hydraulic pressure system. Install power heads and main shaft case on the slippery platform , is equipped with the pulley block of steel wire rope on the slippery tops , another end contains the counterweight one in the post, the purpose is to make the slippery platform move lightly on the slide , and can prevent the slippery ends from being overweight and glide . 3.3 Power head and main shaft case The power head is the drives of sports of the main shaft , It drive each , main shaft of case output main shaft make cutter decide body sport. This lathe is got into, expanded , the diameter of hole cutter of dumpling is 25mm , 26 respectively. 6mm and 27mm, It is 35CrMoV to process the part material, hardness HRC28-32, Consider the torsion stores coefficient , the lathe adopts the power very beginning 14 of standard Model TD80A , the main electrical machinery is 15KW. The rotational speed is 970r/min, the rotational speed of the output shaft is 475r/min. The main shaft case makes one of the important parts of the lathe up , Function its according to process processing of piece require , arrange every position of main shaft, is it distribute every work main shaft to output power of electrical machinery according to different rotating ratio, make the main shaft get the rotational speed required and change direction, Israel satisfies the processing of the part. 3.4 Main shaft and boring the template The structure of the main shaft depends on receiving the strength situation of the processing technology of the part and main shaft . For get into main shaft processed to sharpen , cut strength to be relatively heavy axial , should adopt thrust ball bearing or get away the bearing of the awl orientate. Main shaft and connection way of cutter adopt 3 lead set connect pole , size proportion of cutter can is it process situation change and answer the pole to depend on. The rotational speed of main shaft that used for boring , reaming is processed is 175r/min. Cut speed V =13. 7m/min, feed amount S =0. 17mm/r. The rotational speed of main shaft of reaming and proce