模具高速銑削加工技術(shù)--中英文翻譯.pdf

1英 文 說 明 /loecvte/jsviMoldhigspedmilingprocesingtechnolgyH nmanH H H FoctorsResarcheUnit;InstiuteofsoundandpreventionvibrationRsearch.UniversityofSouthamptonso17.IBJ.UK K K KTheabstractIntroducedthehighspeedm ilinginthem oldprocesingapplicationaswelastheinfluence,andbriefintroductionhighspeedm ilingenginebedstructure,controlsytem andcuttingtool.Hascariedonthesim pleanalysitothehighspeedprocesingcraft.K eyK K K wordhigspedmiling;moldprocesingFirst,forewordInthem odernm oldproduction,alongwithtom odelsartisticandthefunctionm ustobtainm oreandm orehigh,m odelstheinternalstructuretodesignm oreandm orecomplex,them oldcontourdesigndaybydayisalsocomplex,thefrecurvedsurfaceacountsfortheproportiontoincreaseunceasingly,thecorrespondingm oldstructurealsodesignsm oreandm orecomplex.Thesealsetahigherequestothem oldprocesingtechnology,notonlyshouldguarantethehighm anufactureprecisonandthesurfacequality,m oreoverm ustpursuetheprocesingsurfaceartistic.Alongwithisunceasinglythoroughtothehighspeedprocesingengineeringresarch,isprocesingtheenginebed,thenumericalcontrolsytem ,thecuttingtoolsytem ,CAD/especialyCorrelationtechnologyandsoonCAMsoftwaredevelopsunceasinglyundertheim petus,highspeedprocessthetechnologym oreandm orem anytoapplyinthem oldcavityprocesingandthem anufacture.Thenumericalcontrolhigh-speedcuttingprocesingtookinthem oldm anufactuream ostim portantadvancedm anufacturetechnology,isthecollectionishighlyefctive,highquality,thelowconsumptioninabodyadvancedm anufacturetechnology.Isoppositeinthetraditionalm achining,itscuttingspeed,entredtothespeedhadtheverybigenhancem nt,m oreovercutthem echanism nottobesam e.Thehigh-speedcuttingcausedthem achiningtohavetheleap,itspecifcpowerm talexcisonratenhanced30%40%,thecutting2forcerduced30%,thecuttingtoolworkingdurabilityenhanced70%,rem ainedhotlylargescalerducesintheworkpieccutting,thelowstepshuddervanishednearly.Alongwiththecuttingspeedenhancem nt,unitim esem ifnishedm aterialsm aterialrem ovingrateincreased,thecuttingtim ereduced,theprocesingeficencyenhanced,thusreducedtheproductm anufacturecyle,nhancedtheproductm arketcompetivepower.Athesam etim e,thehighspeedprocesingsm alam ountentredquicklycausesthecuttingforcetoreduce,thescraphighspeeddischargedreducedtheworkpieccuttingforceandthetherm alloaddistorts,enhancestherigiditytobebadandthethinwalcomponentsm achiningpossibility.Becausecuttingforcereducing,therotationalspeedenhancem ntcausesthecuttingsytem theoperatingfrequencytobefarwaytheenginebedthelowstepnaturalfrequency,buttheworkpiecsurfaceroughnesism ostsensitvetothelstepfrequency,fromthisreducedthesurfaceroughnes.Inm oldhighhardstelstock(HRC45HRC65)intheprocesingproces,usesthehigh-speedcuttingtobepossibletosubstiutefortheworkingprocedurewhichtheelctricalfinishingandrubstruncatespolishes,thushasavoidedtheelctrodem anufactureandthetim e-consumingelctricalfinishing,largescalerducedfiterspolishingwithtothrowthelightquantity.Thinwalm oldworkpiecm oreandm oreneedswhichregardingsomem arketsin,thehighspeedm ilingalsom aysm oothlycomplet,m oreoverinthehighspeedm ilingCNprocesingcentr,am oldatireclam psm aycompletthem ultiplexstepofprocesing.Thehighspeedprocesingtechnologyhashadthehugeinfluencetothem oldprocesingcraft,changedthetraditionalm oldprocesingtousetheannealing m ilingprocesing heatreatm nt torubtruncatesortheelctricsparkm achiningm anualypolishes,polishesandsoonthecomplexlongtechnicalproces,evenm ightusethehigh-speedcuttingprocesingsubstiutionoriginalcompletworkingprocedure.Thehighspeedprocesingtechnologybesidesm ayapplyinthehardm oldcavitydirectprocesing(inparticularhalfprecisonworkandprecisonwork),inEDMaspectandsoonelctrodeprocesing,fastypem anufacturealsoobtainedtheidespreadapplication.Them asproductionspractieindicatedthat,theapplicationhigh-speedcuttingtechnologym aysaveinthem oldfollowingprocesing80%handworktogrindthetim eapproxim ately,savestheprocesingcostexpensenearly30%,them oldfaceworkprecisonm ayreach1m ,thecuttingtoolcuttingeficencym aenhanceonetim e.Second,higspedmilingprocesingengiebed3Thehigh-speedcuttingtechnologyisoneofm achiningtechnologym aindevelopmentdirections,italongwithfoundationtechnologytheandsoonCNtechnology,m icroelectronictechnology,newm aterialandnewstructuredevelopmentbutstepsahigherstair.Becausethem oldprocessparticularselashighspeedprocesingtechnologyowncharacteristic,(procesdenginebed,numericalcontrolsytem ,cuttingtooltothem oldhighspeedprocesingrelatedtechnologyandthecraftsytem andsoon)proposedprocesdahigherequestcomparedtothetraditionalm old.1.H ighH H H stablengiebedstrutpartThehigh-speedcuttingenginebedlathebedandsoonsupportsthepartobesupposedtohaverywelm oves,thestaicrigdity,hotrigdityandbestdam pingcharacteristic.Them ajorityofenginebedsalusehighrade,thehighrigidityandGaoKangzhangthegrayirontookthestrutpartm aterial,someenginebedcompaniesalsoincreasethehighdam pingcharacteristicinthefoundationpolym erconcret,byincreaseitsvibration-proofandthetherm ostability,thisnotonlym aguarantetheenginebedprecisonistable,alsom aypreventwhencuttingthecuttingtoolinspirestrem bls.Usetheenclosedlathebeddesign,theoveralcastinglathebed,thesym m etrical lathebedstructureandhasthedenselycoveredstifenerandsoonalsoenhancestheenginebedstableim portantm easure.Someenginebedcompanies resarchanddevelopmentdepartm entsindesignproces,butalsousesthem odalityanalysiandthefinitelem ntstructurecomputationandsoon,optim zedthestructure,stablycausestheenginebedstrutpartobereliable.2.EngiebedmainaxleThehighspeedenginebedm ainaxleperform anceistherealizationhigh-speedcuttingprocesingim portantcondition.Thehigh-speedcuttingenginebedm ainaxlerotationalspeedscopeis10000100000m/Min,them ainaxlepowerisbiggerthan15kW.Isnotbiggerthan0.005mm throughthem ainaxlecompresdairoforaxilplaybetwenthecoolingsytem controlhiltandthem ainaxle.Alsorequestthem ainaxletohavethefastverticalspeed,toasigntheperform ancewhichthepositonisfasttops(nam elytohaveextrem lyhighangleadditionandsubtractionspeed),thereforethehighspeedm ainaxleoftenusestheliquidstaicpresurebearingtype,theairstaicpresurebearingtype,thetherm o-compresionnitridingsilcon(Si3N4)theceram icbearingm agnetism aerosolbearingtypeisostructuralism form .Lubricatesusestechnologyandsoonoilgaslubrication,splashlubrication.Them ainaxlecoolsusesthem ainaxleinteriorwatercoolinggeneralyoraircooled.43.ThengiebedactuatesthesytemInordertosatisfythem oldhighspeedprocesingtheneed,highspeedprocesstheenginebedtheactuationsytem tobesupposedtohavethefollowingcharacteristic:(1)highenteringforsped.Theresarchindicatedthat,regardingthem inordiam etrcuttingtool,enhancestherotationalspeedandeachtoothentrsforthequantityisadvantageousinreducesthecuttingtoolatriton.Atpresntcomm onlyusedentringforthespeedrangeis2030m/Min,likeusesleadsgreatlythebalbearingguidescrewtransm ision,entrsm ayreach60m/forthespeedMin;Usethestraightlineelctricalm chinerythenm ayenabletoachieve120m/tothespeein.(2)highaccelration.Hasthegoodacelrationcharacteristictothethredim ensionalcomplexcurvedsurfacesilhouetehighspeedprocesingrequestactuationsytem ,therequestprovidesthedriverwhichthehighrapidadvanceorprogresgives(toentrspeedapproxim ately40m/quicklyMin,the3Doutlineprocesingspeedis10m/Min),canprovide0.4m/S2to10m/Thes2acelrationandreducesthespeed.Theenginebedm anufacturerm ostlyusestheentireclosedlooppositonservo-controlslightlytolead,thegreatsize,thehighradebalbearingguidescreworleadsgreatlym anyguidescrews.Alongwiththeelctricalm chinerytechnologydevelopment,theadvancedstraightlineelctricm otoralreadywaspublished,andthesuccesappliedintheCNenginebed.Theadvancedstraightlinedirectm otordriveenabletheCNenginebednolongertohavethem asinertia,inadvance,questionandsoonlagandvibration,speduptheservospeedofresponse,increasedtheservo-controlprecisonandtheenginebedprocesingprecison.4.NumericalcontrolsystemTheadvancednumericalcontrolsytem isguarantedthem oldcomplexcurvedsurfacehighspeedprocesingqualityandtheeficencykeyaspect,them oldhigh-speedcuttingprocesingtothenumericalcontrolsytem basicrequestis:A.Highspeednumericalcontrolreturnroute(Digitalcontrolloop),including:32orabove64bitparalelprocesorsand1.5Gbharddisk;Extrem lyshortstraightlineelctricalm achinerysam plingtim e.B.Speedandacelrationfed-forwardcontrol(Fedforwardcontrol);Digtalctuationsytem crawlingcontrol(Jerkcontrol).C.Advancedinsertsm akesupthem ethod(toinsertbasedontheNURBStransectm akes5up),byobtainsthegoodsurfacequality,theprecisesizeandthehigheomtryprecison.D.Pretratm ent(Look-ahead)function.Therequesthasthelargecapacitycushionregister,m ayreadinadvanceandinspectsm anysegmnts(forexam pletheDMGenginebedtobepossibletoreach500segmnts,theSim enssytem m ayreacha10002000segmnt),inordertowhenisprocesdthesuperficalshape(curvature)changesm aypromptlyadoptchangesform easureandsoonspeedbyavoidscuttingandsoon.E.Theerorcompensatoryfunction,includingbecausethestraightlineelctricalm chinery,them ainaxleandsoongivesoffheathehoterorwhichcausestocompensate,thequadrantlerorcompensates,them easurem ntsytem erorcompensatesandsoonthefunction.Inaddition,them oldhigh-speedcuttingprocesingveryisalsohightothedatatransm isionspeedrequest.F.Thetraditionaldataconnection,liketheRS232serialm outhtransm iionspeedis19.2kb,butm anyadvancedprocesingscentrshaveusedtheetherlocalreanetwork(Ethernet)tocaryonthedatatransm ision,thespeedm ayreach200kb.5.CoolinglubricationThehighspeedprocesingusesthebeltcoatingthehardaloytools,inhighspeed,thehightem peraturesituationdoesnotneedthecuttingcompound,thecuttingeficencytobehigher.Thisibecause:Them ilingm ainaxlehighspeedrevolves,thecuttingcompoundifachievedthecuttingare,firstm ustovercometheenorm ouscentrifugalforce;Evenifitovercam ethecentrifugalforcetoentrthecuttingare,alsowaspossibleasresultofthecuttingarehightem peraturebuttoevaporateim m diately, thecoolingefctverysm aldidnotevenhave;Athesam etim ethecuttingcompoundcancausethecuttingtooledgeofaswordthetem peratureintensechange,iseasytocausethecraktheproduction,thereforem ustpicktheoilused/Gascoolinglubricationdrytpecuttingway.Thiswaym ausethecompresdgasrapidlythecuttingwhichthecuttingareproduces,thusthem asivecuttingshotlywilcaryoff,athesam etim em ightform sextrem lythinm icroscopicprotectivefilm aftertheatomizationlubricatingoilinthecuttingtooledgeofaswordandtheworkpiecsurface,butefctivelywillengthenthecuttingtoollifeandenhancesthecomponentsthesurfacequality.Third,hig-spedcutingprocesingcutingtolThecuttingtoolisinthehigh-speedcuttingprocesingoneofm ostactiveim portantfactors,itisafectingtheprocesingeficency,theproductioncostandtheproduct6procesingprecisondirectly.Thecuttingtoolm ustwithstandloadandsoonhightem perature,highpresure,friction,im pactandvibrationinthehighspeedprocesingproces,thehigh-speedcuttingcuttingtoolshouldhavethegoodm achinecapabilityandthetherm ostability,nam elyhasthegoodanti-im pact,thewearbilityandresitsheathewearycharacteristic.Thehigh-speedcuttingprocesingcuttingtooltechnologicaldevelopmentspeedisveryquick,applicationm anylikediam onds(PCD),cubicboronnitride(CBN),ceram iccuttingtool,coatinghardaloy,(carbon)tianiumnitrideshardaloyTIC(N)andsoon.Intheprocesingcastironandinthealoystelcuttingtool,thehardaloyisthem ostcomm onlyusedcuttingtoolm aterial.Hardaloytoolsresitancetoweargood,butthesolidityratiocubeboronnitrideandtheceram icsarelow.Inordertoenhancedegreofhardnesandthesuperficalyatractivefines,usesthecuttingtoolcoatingtechnology,thecoatingm aterialforthetianiumnitrides(TiN),thealuminiumnitridetianium(TiALN)andsoon.Thecoatingtechnologycausesthecoatingbythesolecoatingdevelopmentform ultilayerd,them anykindsofcoatingm aterialcoating,hasbecomeoneofenhancem nthigh-speedcuttingabilityesntialtechnical.Thediam etrinthe1040mm scope,alsohasthecarbontianiumnitridescoatingthehardaloybitobeabletoprocestheLuoriverdegreofhardnestobesm alerthan42m aterials,butthetianiumnitridesaluminumcoatingcutingtoolcanprocestheLuoriverdegreofhardnesis42evenhigherm aterials.Whenhigh-speedcuttingstelproducts,thecuttingtoolm aterialshouldselcthehotrigdityandthefatiguestrengthhighPkindofhardaloy,thecoatinghardaloy,thecubicboronnitride(CBN)andtheCBNcompoundcuttingtoolm aterial(WBN)andsoon.Thecuttingcastiron,shouldselcthefinegrainKkindofhardaloytocaryontheroughm achining,selctsthecompoundnitridedsilconceram icsorthecrystalcombinationcubeboronnitride(PCNB)thecompoundcuttingtoolcariesontheprecisonwork.Whenpreciseprocesingnon-ferousm etalornonmetalicm aterial,shouldselctcrystalcombinationdiam ondPCDortheCVDdiam ondcoatingcuttingtool.Whenchoiceuttingparam etr,inviewofthecirularshearbladeandabalm ilingcutter,shouldpayatentiontotheefctivediam etrtheconcept.Thehighspeedm ilingcuttingtoolshouldpresthebalancedesignm anufacture.Thecuttingtoolfrontanglem ustbesm alerthantheconventionalcuttingtoolfrontangle,theclearnceangleislightlybig.Thehostvice-cuttingedgeatchmentpointshouldthecavetoortheleadngle,increasethevertexangle,preventstheknifepointplacehotatriton.Shouldenlargenearbytheknifepointthecuttingedgelengthandthecuttingtoolm aterialvolume,enhancesthecuttingtoolrigidity.Isafe7intheguaranteandsatisfiestheprocesingrequestunderthecondition,thecuttingtoolhangsextndsasfarspossibleshort,cutterbodycentraltoughnesisfriendswith.Thehiltm ustbesturdierthanthecuttingtooldiam etr,connectsthehandletoasumebutactualythepyram idal,byincreaseitsrigidity.Asfarspossiblecntraltherefrigerantholeinthecuttingtoolandthecuttingtoolsytem . balendm ilm ustconsiderefctivelycutsthelength,thecuttingedgem ustbeasfarspossibleshort,twospiralgroovesbalsendm ilusualyusesinthethickm ilcomplexcurvedsurface,fourspiralgroovesbalsendm ilusualyusesinthefinem ilcomplexcurvedsurface.Fourth,moldhigspedprocesingcraftThehighspeedprocesingincludingtakerem ovestherem ainderasthegoalroughm achining,theresidualroughm achining,aswelastakegainsthehighradeprocesingsurfaceandtheslightstructureasthegoalhalfprecisonwork,theprecisonworkandthem irorsurfaceprocesingandsoon.1.RoughmachinigThem oldroughm achiningesntialtargetispursuesintheunittim em aterialrem ovingrate,andishalfprecisonworkpreparationworkpiecgeomtryoutline.Inthehighspeedprocesingroughm achiningshouldadoptthecraftplanisthehighcuttingspeed,GaoJingivingrateandthesm alcuttingspecifcationscombination.Thecontourprocesingwayisoneprocesingwaywhichthem ultiudinousCAMsoftwareusesgeneraly.UsingispiralcontourandsoontheZaxiscontourtwoayswhicharem any,alsoisinprocesstheregiononlytim etofed,indoesnotliftheknifeinthesituationtoproducecontinuouslythesm oothcuttingtoolway,entrs,drawsbacktheknifewaytousethecirularrctocutinto,tocut.Thespiralcontourwaycharacteristicis,hasnotaitedthehighlevelbetwenthekniferoadm igration,m ayavoidfrequentlyliftingtheknife,fedingtothecomponentssurfacequalityinfluenceandm echanicaldevicenonesentialconsuming.Toistepandtheflatsiteprocesseparately,thecomputationsuitscontourandsuitstheusesim lar3Dbiastheregion,andm ayusethespiralway,inverylitleliftsthecuttingtoolwayhichtheknifeinthesituationproducesoptim zes,obtainsthebetersurfacequality.Inthehighspeedprocesing,certainlym ustadoptthecirularrctocutinto,tocuttheconnectionway,aswelasthecirularrctransiton,avoidschangingthecuttingtooltoentrsuddenlyforthedirection,theprohibitionusedirectunderknifeconnectionway,avoidsburyingthecuttingtooltheworkpiec.Whenprocessthem oldcavity,shouldavoidthecuttingtoolverticalinsertionorkpiecunder,butshoulduseinclinestheknife8way(comm onlyusedangleofbankfor2030),bestusesthescrewtypeunderknifebytoreducethecuttingtoolload.Whenprocessthem oldcore,shouldundertheknifethenlevelcutintotheworkpiecasfarspossiblefirstfromtheworkpiec.Thecuttingtoolcutsinto,cutshentheworkpiecshoulduseasfarspossibleinclinesthetype(orroundarc-type)cutsinto,cuts,verticalyavoidscuttinginto,cutting.Useclim bsupthetypecuttingtobepossibletoreducethecuttingheat,reducesthecuttingtoolstresandtheworkhardeningdegre,im provestheprocesingquality.2.H alfH H H precisonworkThem oldhalfprecisonworkesntialtargetiscausestheworkpiecoutlineshapesm oothly,surfacefinishrem aindereven,thisespecialyisim portantregardingthetoolstelm old,becauseitwilafectim etheprecisonworkcuttingtoollayerofcuttingarechangeandcuttingtoolloadchange,thusinfluencecuttingprocesstabilityandprecisonworksurfacequality.Theroughm achiningisbasedonthevolumem odel,theprecisonworkthenisbasedonthefacem old.BeforedevelopsCAD/TheCAMsytem tothecomponentsgeomtrydescriptionisnotcontinual,afterbecausehasnotdescribedinfrontoftheroughm achining,theprecisonworkprocessthem odeltheaverageinform ation,thereforetheroughm achiningsurfacesurplusprocesingrem ainderdistributionandthegreatsurplusprocesingrem ainderisunknown.Thereforeshouldfity-fitytheprecisonworkstrategycaryontheoptim zationaftertoguarantehalfprecisonworktheworkpiecsurfacehastheevensurplusprocesingrem ainder.Theoptim zedprocesincludes:Aftertheroughm achiningtheoutlinecomputation,thegreatsurplusprocesingrem aindercomputation,thebiggestperm isionprocesingrem ainderdeterm ination,isbiggerthanthebiggestperm isionprocesingrem aindertheprofiledistrict(forexam pletransitonradiusandsoonscoopchannel,cornerism alerthanroughm achiningcuttingtoolradiusregion)aswelaswhenhalfprecisonworktheknifeheartpathcomputationtothesurplusprocesingrem ainderandsoon.Theexistingm oldhighspeedprocessCAD/TheCAMsoftwarehasthesurplusprocesingrem ainderanalysifunctionm ostly,andcanactacordingtothesurplusprocesingrem ainderthesizeandthedistributionsituationusesthereasonablehalfprecisonworkstrategy.AfterliketheMasterCAMsoftwareprovidedhastiedtheshapem iling(Pencilm iling)andthesurplusm iling(Restm iling)andsoonthem ethodelim natestheroughm achiningthesurplusprocesingrem ainderbigquoinbytoguarantethefollowing9workingprocedurevenprocesingrem ainder.3.PrecisonworkThem oldhighspeedprecisonworkstrategyisdecidedbythecuttingtoolandtheworkpiecontactpoint,butthecuttingtoolandtheworkpiecontactpointbutchangesalongwiththeprocesingsurfaceurvedsurfaceslopeandthecuttingtoolefctiveradiuschange.Regardingbythecomplexcurvedsurfaceprocesingwhichm anycurvedsurfacecombinationbutbecomes,shouldcaryonthecontinuoustreatingasfarspossibleinaworkingprocedure,butisnotcariesontheproc