可转位刀片刀尖圆弧磨削成形的误差分析及补偿技术

用于可转位刀片周边刃磨的机床、夹具、数控系统的工作性能等都会影响可转位刀片刀尖圆弧加工质量。通过分析机床伺服系统特性误差、进给轴换向间隙对刀尖圆弧轮廓形状和圆弧半径尺寸的影响,提出了一种在调整数控机床螺补后基于刀尖圆弧制造误差的加工指令再设计补偿新算法,经磨削试验验证了补偿算法的技术适用性。     

无孔可转位刀片装夹偏心的磨削补偿技术

针对于无孔可转位刀片装夹偏心造成加工的误差,首先通过分析产生双顶尖定位偏心误差的原因,建立偏心距和理论单边磨削余量之间的模型,并提出了一种磨削补偿技术,编写偏心加工代码实现了刀片磨削过程中的偏心磨削。通过对SPCN正方形可转位刀片的磨削实验表明该方法能够有效地改善刀片的形状和尺寸误差,其加工稳定性也得到了较大幅度的改善。有孔刀片加工时,由于定位孔位置已知,需保证其成品刀片孔中心与磨削理论中心的同心度,因此所述方法亦适用于有孔刀片的磨削加工。     

基于视觉补偿的圆形刀片自动打磨系统

为实现圆形刀片的高效、高质量生产,设计开发了一套基于视觉补偿的圆形刀片自动打磨系统。该系统主要包括上下料装置、打磨装置以及控制系统。上下料装置可实现3片圆形刀片的同时上料和下料;打磨装置通过伺服电机控制砂轮X、Y方向的进给量,实现圆形刀片的打磨,同时通过相机实时检测打磨好的圆形刀片的刃宽和同心度,计算出补偿量并反馈给伺服电机,从而确保每次打磨的刀片尺寸都在公差范围内;控制系统以倍福CX9020为PLC控制器,通过TCP/IP协议、EtherACT协议、RS485协议以及OPCUA协议实现整个系统的通讯和控制。样机试验表明：该圆形刀片自动打磨系统运行稳定,刀片尺寸精度可控性好,生产效率高。     

FDM制件的收缩现象分析及控制措施研究

从FDM打印制件的收缩现象出发,分析了打印过程中影响制件尺寸收缩的主要因素,并依据这些因素设计了实验,着重分析温度、层厚、线宽补偿和材料收缩对制件尺寸收缩的影响,最后根据实验结果提出了控制制件收缩,获得理想尺寸的两种措施,实验证明都能有效地做出正确补偿。     

剪刃侧隙补偿及剪刃合理位置分析与研究

分析了斜刀片剪切机剪刃侧隙变化产生的原因,根据机构中各参数之间的几何关系,针对多种情况对剪刃侧隙补偿进行了详细的理论研究,得出了不同情况下的侧隙补偿曲线的轨迹方程以及侧隙补偿量的表达式,通过函数及其导数的分析,指出了各种斜刀片剪切机的优缺点和设计使用注意事项,对剪切机设计起到一定的参考和指导。最后对剪刃的合理位置进行了定性分析及总结,指出剪刃的合理位置对剪切设备的重要性,从而对剪刃侧隙补偿是否合理起到一个很好的补充。     

可转位镶片滚刀滚齿加工精度影响分析和优化

可转位镶片滚刀（简称ICI滚刀）因其高切削硬度、高加工效率及刀片更换便捷等优点在大模数批量滚齿加工中应用越来越广泛。从可转位镶片滚刀设计和实际应用角度分析了刀片搭接误差、刀片安装误差和刀片磨损对镶片滚刀加工精度的影响;采用DOE试验设计方法分析了加工参数中滚刀轴向进给速度、滚刀螺旋角补偿及走刀次数对齿轮件齿形精度的影响,并在保证加工效率的前提下通过优化加工参数来提高齿轮件齿形精度。     

刀片装偏自补偿技术

可转位刀片在刃磨安装中很容易产生偏心，影响刃磨质量和安全生产。ＤＰＭ６０型可转位刀片周边磨床采用现代数控与测量技术，通过对刀片的尺寸测量计算出偏心量，然后对原始数据进行补偿，达到了加工余量的均匀分布，从而提高了刀片磨削质量，并降低了对上料系统的精度要求。     

磨床主轴热特性分析及热变形补偿策略

针对五轴数控可转位刀片周边工具磨床建立了砂轮-主轴-轴承-主轴箱的主轴部件有限元模型,分析了主轴部件的热源及其发热量的计算公式,通过有限元仿真计算得到磨床主轴的热稳态温度场和热变形量,进行了主轴热特性分析。在不增加温度、位移传感器的基础上提出了有效的主轴热变形补偿策略,实现刀片加工精度达到5μm的精度要求。     

可转位刀片周边刃磨的新数学模型和轨迹补偿方法

基于空间曲面成型理论建立可转位刀片周边刃磨削刀轨计算的统一数学模型,给出以斜圆柱或斜圆锥面为过渡面的刀片后角推导方法;结合周边刃磨床中常有的夹具误差,给出了利用运动轨迹补偿的计算公式;以图形文件为接口,研发了一种适用可转位刀片的周边刃磨削数控指令自动生成方法。通过磨削仿真加工和现场磨制验证了试验方法的正确性,可保证刀片的几何精度在±2μm以内。     

便携式水下电动切割器的设计

针对液压动力工具水下作业液压管路长,潜水员使用不灵活的特点,进行了便携式水下电动切割器工具结构方案的设计,确定了输出功率与扭矩,分析了刀片水下阻力;采用密封壳体内部充油措施补偿水深度压力,设计了压力补偿器,确定了补偿器体积补偿量;采用了磁钢干簧管继电器非接触式开关,适于水下使用.     

Form error compensation in single-point inclined axis nanogrinding for small aspheric insert

Based on an examination of traditional arc-enveloped grinding method, a single-point inclined axis nanogrinding method is presented to grind an aspheric insert by compensating tool setting error, radius error, and residual form error. Profile data from on-machine measurement are used to obtain the tool setting error and radius error of grinding wheel, as well as the normal residual form error. Compensation method of single-point inclined axis nanogrinding is built up for generating new compensation path. Grinding test of aspheric tungsten carbide insert with diameter 9.5 mm is conducted to evaluate performances of the grinding mode and compensation method. A last form error of 200 nm in peak to valley and surface roughness of 2.243 nm in Ra are achieved. These results indicated that the form error compensation method and single-point inclined axis nanogrinding mode can significantly improve form accuracy and surface roughness of ground surface.     

M30合金牌号的工艺设计要点

以M30合金为例,根据M类硬质合金的特点和应用范围阐述了其牌号设计和原料选择。通过分析合金刀片切削试验结果,提出了M30牌号合金最佳综合性能的实现方案。     

加工In718时硬质合金涂层刀具的磨损机理

采用硬质合金涂层刀具对镍基合金In718进行了车削试验,分析了硬质合金刀具的磨损形态、磨损机理,并给出了不同条件下的刀具寿命。结果表明,涂层硬质合金切削In718时的主要磨损形式为涂层剥落。     

Experimental investigations on machinability aspects in finish hard turning of AISI 4340 steel using uncoated and multilayer coated carbide inserts

The present work deals with some machinability studies on flank wear, surface roughness, chip morphology and cutting forces in finish hard turning of AISI 4340 steel using uncoated and multilayer TiN and ZrCN coated carbide inserts at higher cutting speed range. The process has also been justified economically for its effective application in hard turning. Experimental results revealed that multilayer TiN/TiCN/Al₂O₃/TiN coated insert performed better than uncoated and TiN/TiCN/Al₂O₃/ZrCN coated carbide insert being steady growth of flank wear and surface roughness. The tool life for TiN and ZrCN coated carbide inserts was found to be approximately 19 min and 8 min at the extreme cutting conditions tested. Uncoated carbide insert used to cut hardened steel fractured prematurely. Abrasion, chipping and catastrophic failure are the principal wear mechanisms observed during machining. The turning forces (cutting force, thrust force and feed force) are observed to be lower using multilayer coated carbide insert in hard turning compared to uncoated carbide insert. From 1st and 2nd order regression model, 2nd order model explains about 98.3% and 86.3% of the variability of responses (flank wear and surface roughness) in predicting new observations compared to 1st order model and indicates the better fitting of the model with the data for multilayer TiN coated carbide insert. For ZrCN coated carbide insert, 2nd order flank wear model fits well compared to surface roughness model as observed from ANOVA study. The savings in machining costs using multilayer TiN coated insert is 93.4% compared to uncoated carbide and 40% to ZrCN coated carbide inserts respectively in hard machining taking flank wear criteria of 0.3 mm. This shows the economical feasibility of utilizing multilayer TiN coated carbide insert in finish hard turning.     

铣削粉末冶金高温合金的刀具优选试验

针对粉末冶金高温合金材料的铣削特性,选择了合理的刀片材质。通过刀具磨损与寿命对比试验,优选出了最佳的刀片牌号及几何参数。研究结果表明:SECO SEMX1505AFTN-MD20-F30M涂层硬质合金刀片适用于铣削粉末冶金高温合金,并对涂层硬质合金刀具前、后刀面的磨损形貌和失效机理进行了分析。     

A comparative study on performance of multilayer coated and uncoated carbide inserts when turning AISI D2 steel under dry environment

The present work deals with a comparative study on flank wear, surface roughness, tool life, volume of chip removal and economical feasibility in turning high carbon high chromium AISI D2 steel with multilayer MTCVD coated [TiN/TiCN/Al₂O₃/TiN] and uncoated carbide inserts under dry cutting environment. Higher micro hardness of TiN coated carbide samples (1880 HV) compared to uncoated carbide (1430 HV) is observed and depicts better resistance against abrasion. The low erosion rate was observed in TiN coated insert compared to uncoated carbide. The tool life of TiN coated insert is found to be approximately 30 times higher than the uncoated carbide insert under similar cutting conditions and produced lower surface roughness compared to uncoated carbide insert. The dominant wear mechanism was found to be abrasion and progression of wear was steady using multilayer TiN coated carbide insert. The developed regression model shows high determination coefficient i.e. R² = 0.977 for flank wear and 0.94 for surface roughness and accurately explains the relationship between the responses and the independent variable. The machining cost per part for uncoated carbide insert is found to be 10.5 times higher than the multilayer TiN coated carbide inserts. This indicates 90.5% cost savings using multilayer TiN coated inserts by the adoption of a cutting speed of 200 m/min coupled with a tool feed rate of 0.21 mm/rev and depth of cut of 0.4 mm. Thus, TiN coated carbide tools are capable of reducing machining costs and performs better than uncoated carbide inserts in machining D2 steel.     

硬质合金刀片CAD/CAM系统三维扫描测量输入技术

本文在综述了硬质合金刀片CAT/CAD/CAM一体化技术基础上,引进测量几何造型概念,详细介绍了硬质合金刀片扫描测量输入系统硬件及软件的设计特点,分析了一些特征扫描測量算法,最后给出了一个扫描测量实例。     

硬质合金可转位车刀刀片的力学特性分析

为了深入研究切削过程中可转位刀具的力学特性,以硬质合金可转位车刀刀片为例,采用三维有限元方法对金属的切削加工过程进行模拟计算。考虑实际刀片几何形状及其安装角度,基于三维建模软件SolidWorks,建立了硬质合金可转位刀片三维立体模型;通过切削力试验测得切削力,利用内嵌于SolidWorks之上的COSMOS＼works对该刀片加载求解,进行应力场分析。结果表明,利用有限元方法对硬质合金可转位刀片分析的结论与其实际加工状况较为相符,为可转位刀片的优化设计提供了一定的方法和依据。     

硬质合金车刀钎焊机

通过结构、工作原理、操作方法等介绍了一种非焊接工人也可操作使用的硬质合金刀片与刀杆焊接的车刀钎焊机.该机采用短路通电的方式加热,使钎料熔化,断电后钎料凝固,刀片与刀杆便焊接在一起;通过及时保温,可获得比火焰加热钎焊质量好的硬质合金车刀.     

采用ESC工艺提高硬质合金螺纹刀片耐用度

通过分析硬质合金螺纹刀片的形状特点,提出采用振动珩磨法对螺纹刀片进行ＥＳＣ工艺处理。螺纹车削试验结果表明,ＥＳＣ工艺可增加刀片切削稳定性,显著提高刀片耐用度。