数控加工技术在机械模具制造中的应用分析

在机械模具制造过程中,数控加工技术发挥着重要的作用。数控加工技术指的是利用提前输入的程序来控制自动化机床对模具所需构件进行精密的加工。将数控加工技术科学合理地应用于机械模具制造中,能够满足机械模具制造的基本要求,能保证机械模具的精密性的同时,解决了模具结构复杂很难制造的困扰。本文就数控加工技术原理、数控加工技术的应用特征、数控加工技术在机械模具制造中的应用价值、数控加工技术在机械模具制造中的应用展开了分析与论述。     

DMC2014数控特种加工机床评述

<正>数控特种加工机床种类较多,用于模具加工制造的主要有:各类数控电火花加工机床、数控激光(复合)加工机床、模具的增材制造(3D打印)技术等。一、数控电火花加工机床数控电火花加工机床是模具加工的关键设备,在第十五届中国国际模具技术和设备展览会(DMC2014)上,境外厂商主要参展展品有:瑞士阿奇夏米尔的FORM200数控电火花成形机床、     

模具制造中的高速数控加工技术

介绍了高速数控加工技术在模具制造中的应用，分析了提高进给速度与加速度的方法以及高速数控加工对数控系统与机床的要求。通过实例．论述了模具高速加工技术中的问题与基本要求。     

数控电火花加工多型孔模具编程

数控电火花加工在模具制造中的应用越来越广泛,其中编写加工程序是其技术的关键。目前数控电火花加工机床都提供了自动编程模块,可自动生成ISO代码。但自动编程模块的功能往往具有局限性,如果能够灵活运用手工编程,就可以进行各种复杂工件的加工,实现用户的个性化操作,最大限度地发挥数控电火花加工机床的功能。     

基于UG与Vericut的复杂曲面加工仿真

现代制造过程中,复杂曲面产品增多,加工工序复杂,加工周期变长,数控程序的好坏直接影响数控加工的质量与效率。为了对计算机辅助编程生成的数控程序进行适合特定机床的验证和优化,不仅需要对刀路进行模拟,还需要对机床的运动进行仿真。本次研究以一件自由曲面工艺品的模具为例,首先在UG数控加工模块中对模具进行编程,然后利用UG和Vericut建立机床模型并导入模型G代码进行验证,最后根据机床和刀具参数对G代码进行优化。实例和结果表明,将UG加工编程与Vericut机床仿真相结合,能减少废品率,大幅度的提高加工效率。     

数控加工技术在模具制造中的应用研究

数控加工技术拥有非常优异的加工性能,在模具制造中有着非常广泛的运用。随着现代社会经济的不断发展,对模具制造精度要求越来越高,传统模具制造方式已经无法满足当下的加工需求,所以要在模具制造中充分融入数控加工技术。通过数控加工技术的运用,不仅有利于改善模具制造的精度,也有助于提高模具制造效率,甚至还能够实现模具制造的智能化转变。当下,数控加工技术在模具制造中的应用主要体现在数控铣加工、数控车加工、数控电火花加工等方面,推动着模具制造行业不断发展。     

气囊抛光数控机床后置处理算法的研究

利用坐标变换的方法,对机床的进动机构和进给机构进行运动学分析,建立了进动和进给运动方程,并根据方程和实际气囊抛光工艺提出了用于机床实际运动控制的数控自动编程后置处理算法,该算法在实验抛光加工中得到了应用.     

机械模具数控加工制造技术

近年来,随着科学技术的不断进步,机械模具实现了高速发展。借助数控加工制造技术,机械模具在整个加工环节发生了很大变化。同时,人们对机械模具的加工提出了更高要求,加工的零部件结构日益复杂且型面复杂,材料的硬度要求较高。在进行模具制造的过程中,机械模具的数据加工技术发挥着重要作用。本文分析机械模具数控加工中的具体要求,剖析模具制造中机械模具数控加工制造技术的应用和前景。     

大型覆盖件模具粗加工的数控编程技术

随着现代汽车工业的竞争日趋激烈，汽车厂家的车型换代越来越快，相应地对模具的要求也越来越高，对此我厂采取了多种措施，比如在设计上对模具结构进行优化，在铸件上采用实型铸造以减少加工量等等。但是据有关资料显示，现在发达国家的模具设计与制造周期中，数控加工及钳工抛光约占整个周期的65％，且数控加工占50％，抛光时间占15％左右，即尽可能在数控机床上完成绝大部分工作，减少钳工修磨时间。这样数控加工就成了关键工序，要提高模具的制造效率，也主要在提高数控加工效率上想办法。     

数控加工技术在机械加工制造中的应用方法探析

在机械模具加工制造的过程中,数控加工技术起到了重要的作用,已经成为了机械模具制造领域的关键性技术之一。因此,将数控加工技术应用在机械加工制造过程中,不但能够提高生产效率,满足机械模具加工的各项需求,而且极大的提高了产品的性能。本文主要对数控加工技术进行概述,然后说明了数控加工技术在机械加工制造中的应用优势,最后分析了数控加工技术在机械加工制造中的应用方法,从而保证数控加工技术在机械加工制造中的有效应用。     

Study on the generative design method and error budget of a novel desktop multi-axis laser machine for micro tool fabrications

Micro end mills made of hard or ultra-hard materials are mainly fabricated by grinding or by wire electrical discharge machining (WEDM). However, with the advances of new tool materials from ultra-hard to super-hard together with lower or no electrical conductivity such as the material of nano-polycrystalline diamond, the grinding or the WEDM method cannot be used for machining due to their ultra-low process efficiencies for such materials. Laser machining has been tested an effective method. Accordingly, multi-axis laser machines need to be designed for micro tool fabrications. In the paper, a typical micro ball end mill with relatively complex features has been analyzed by the generative design method to generate the number and properties of needed motion axes. Based on the analysis, a novel five-axis laser machine has been designed. Aiming at high-quality micro tool fabrications, the kinematics model has been derived for this five-axis laser machine and error budge has been studied for the subsequently optimum selection of key motion components.     

端面正弦直纹曲面零件的线切割加工技术

为解决端面正弦直纹曲面的加工难题,提出了利用国产高速走丝电火花线切割机床进行加工的一种方法。依据正弦直纹曲面的形成原理,分析线切割加工的运动方式。通过数控回转台与线切割机床相结合,形成实现加工所需的运动,进行了样件的实验加工,实验结果表明,设计的加工方法合理有效。     

Development of a virtual reality wire electrical discharge machining system for operation training

Wire electrical discharge machining (WEDM) uses a metallic thin wire to cut a programmed profile with high strength having sharp edges such as extrusion dies and blanking punches. However, the cost of purchasing and maintaining of WEDM equipment is very high for both the industry and general education institutions. Therefore, there are potential demands to reduce the expensive machine operation training cost, provide off-line collision-free simulation verification of the tool path, and examine the correctness of the programmed wire cutting NC codes. This paper presents the development of a virtual reality-based WEDM full machine simulation system which can emulate major functions of a real controller related to operation training and education. These functions include the tool path simulation, NC program interpretation and processing, kinematics of the machine mechanism, workpiece origin setting, etc. To demonstrate the developed system and illustrate the adopted method, the system capability is explained and shown in this paper. The research result can be used as a cost-effective interactive 3D digital tutoring system that has the benefits of improving on the inefficient, dangerous, and costly drawbacks in traditional learning and training for operating the real WEDM machine.     

纳米胶体自激脉冲空化射流抛光技术

为了满足光学复杂曲面的精密、高效加工,提出一种利用空化效应促进射流加工效率的光学表面加工方法——纳米胶体自激脉冲空化射流抛光,并研制了加工系统。采用流体动力学对纳米胶体自激脉冲空化射流抛光中的喷射过程进行了仿真,获得了周期为0.3s的自激脉冲射流典型时刻下加工流场的流体动、静压力、速度、空化效应分布规律。进行了纳米胶体自激脉冲空化射流抛光试验,结果表明该系统能够产生效果良好的自激脉冲空化射流。采用该方法对单晶硅表面进行加工可以得到表面粗糙度为Ra0.904nm(Rms1.225nm)的超光滑表面,此加工表面粗糙度质量与相同加工条件下的普通纳米胶体射流抛光相当,但其加工效率较普通纳米胶体射流抛光能够提升20%左右,能够满足光学表面高效精密加工的需要。     

复杂曲面零件电火花线切割加工系统研究

开发了以新型翻转式自动分度数控回转工作台为核心的复杂曲面电火花线切割加工系统。阐明了系统的运动规律,建立了通用数学模型,并进行了计算机仿真和样件加工实验研究。利用该数控回转工作台,采用二维加工信息流控制技术,与国产高速走丝电火花线切割机床相结合,从根本上解决复杂曲面零件高速走丝电火花线切割加工的关键技术问题,大幅度提高了线切割加工的加工质量和生产效率。该方法在模具制造中得到了良好的应用。     

An effective-wire-radius compensation scheme for enhancing the precision of wire-cut electrical discharge machines

Using a modified Denavit–Hartenberg (D–H notation), we propose with this study a methodology for generating the wire-radius-compensated NC data equations required to carry out the machining of non-column workpieces on a five-axis wire-cut electrical discharge machine (WEDM). In the proposed approach, the designed surfaces of the machined component are constructed using a 4?×?4 homogeneous transformation matrix and ruled surfaces. The modified D–H notation is then employed to derive the machine’s ability matrix and to generate the desired wire location matrices. To ensure the precision of the machining operation, the wire location matrices are modulated by a novel effective-wire-radius compensation scheme. Finally, the NC data equations required to machine the component are derived by equating the ability matrix with the modulated wire location matrix. To validate the proposed methodology, three non-column workpieces with various top and bottom basic curves are machined on a commercial WEDM. The dimensions of the machined components are then compared with those of specimens machined using the built-in WEDM compensation scheme. The results show that the components manufactured using the proposed effective-wire-radius compensation scheme are more geometrically precise than those produced using the conventional WEDM compensation method.     

Study on the Variations of Form and Position of the Wire Electrode in WEDM-HS

The electrode, a tool which is used for wire electrical discharge machining (WEDM), is a tiny flexible metal wire, therefore, in WEDM machining process, its form and position will inevitably vary because of the action of many forces, and these dynamic variations have a direct influence on machining precision and stability, especially in the high-speed WEDM (WEDM-HS) machine process; the variations of form and position have been a critical obstacle to improving machining quality and implementing multi-cut processing. In this paper, the variation regularity of wire-electrode has been investigated by experimental analysis, and some corresponding measures have been suggested to stabilize the form and position of the wire electrode in the WEDM-HS machining process.     

浅谈Band5 WEDM软件在线切割实验教学中的应用

线切割实验课是机电本科生必修的一门专业实验课,Band5 WEDM软件具有较强的绘图和编辑能力,而且简单易学。文中提出了将Band5 WEDM软件应用于线切割实验教学,即利用多媒体教学手段,在实验室机房讲授线切割编程与加工仿真的相关内容。在实验环节,将Band5 WEDM软件直接生成的3B代码程序输入到线切割数控机床进行加工。同时以5个复杂字体的加工为例,详细讲解该软件的操作方法。实验证明,使用该软件教学效果好,并能在一定程度上提高学生的学习兴趣和创新能力。     

Parameters optimization of a novel 5-DOF gasbag polishing machine tool

The research on the parameters optimization for gasbag polishing machine tools, mainly aims at a better kinematics performance and a design scheme. Serial structural arm is mostly employed in gasbag polishing machine tools at present, but it is disadvantaged by its complexity, big inertia, and so on. In the multi-objective parameters optimization, it is very difficult to select good parameters to achieve excellent performance of the mechanism. In this paper, a statistics parameters optimization method based on index atlases is presented for a novel 5-DOF gasbag polishing machine tool. In the position analyses, the structure and workspace for a novel 5-DOF gasbag polishing machine tool is developed, where the gasbag polishing machine tool is advantaged by its simple structure, lower inertia and bigger workspace. In the kinematics analyses, several kinematics performance evaluation indices of the machine tool are proposed and discussed, and the global kinematics performance evaluation atlases are given. In the parameters optimization process, considering the assembly technique, a design scheme of the 5-DOF gasbag polishing machine tool is given to own better kinematics performance based on the proposed statistics parameters optimization method, and the global linear isotropic performance index is 0.5, the global rotational isotropic performance index is 0.5, the global linear velocity transmission performance index is 1.012 3 m/s in the case of unit input matrix, the global rotational velocity transmission performance index is 0.102 7 rad/s in the case of unit input matrix, and the workspace volume is 1. The proposed research provides the basis for applications of the novel 5-DOF gasbag polishing machine tool, which can be applied to the modern industrial fields requiring machines with lower inertia, better kinematics transmission performance and better technological efficiency.     

Replication of skilled polishing technique with serial–parallel mechanism polishing machine

Currently, viscoelastic polymers are used to coat automotive body to prevent scratches. On the other hand, the application of a polymer with high viscoelasticity makes the repair polishing process of the coated body more difficult. Hence, performing the polishing process requires the operator to be technically skilled. However, the number of workers with necessary technical skill has been decreasing because of an aging population. In addition, the surface quality and process time are dependent on the proficiency level of the worker. To automate the repair polishing process, in our past research, a serial–parallel mechanism polishing machine was developed to simultaneously control the tool trajectory, tool posture, and polishing force. The present study aims to construct a replication system of a skilled polishing technique on the basis of the above three physical parameters by applying the developed polishing machine. First, the tool trajectory, tool posture, and polishing force of a skilled worker, which reflect the polishing technique, were acquired using a high-speed camera and a dynamometer. By inputting the acquired data to the developed machine, the machine can copy the polishing technique because the tool trajectory, tool posture, and polishing force can be independently controlled. From the results of the polishing test, the surface quality after polishing was comparable to that of the skilled worker output, which satisfies the criteria of surface quality.