宏程序在数控车床改装冷旋压设备中的具体应用

宏程序可以高度概括刀具轨迹,弥补数控系统提供循环不足的缺点。本次设备改装中正是利用了宏程序的适应性,对改装后的粗旋轮和精旋轮进行轨迹编程,使得改装后的数控旋压装置,能够整合手工旋压和数控双轮旋压的优点,旋压出符合图纸要求的工件。在设备改装中旋轮采用经济实用的金刚砂轮区别于手工旋压的轴承轮,也区别于数控双轮旋压的橡胶轮,是本次改装的亮点。增加的两工位毛坯定位装置也给手工旋压装置和数控双轮旋压装置在毛坯定位方面提供了参考。     

行星滚轮旋压装置

带金属外罩的某些机械零件 ,如汽车转向轴承和离合器轴承外罩的压边工装在有关刊物上曾有介绍 ,有的采用模具在压力机上弯边 ,有的采用旋压工艺在车床或其他旋转机械上卷边。本文是在综合相关工装各自特点的基础上推出一种新型的行星滚轮旋压装置。该装置安装在 1 2ｍｍ台钻上 ,具有高效、经济、结构紧凑、被旋压表面光洁无毛刺的优点。1　工作原理该装置是摩擦滚轮周转轮系中的行星轮系的一个实际应用。与台钻钻杆轴连接为一体的滚轮盘在旋转时 ,通过滚压轮与被旋压工件接触产生的摩擦力导致三个滚压轮均匀地旋转。在施加的轴向力作用下迫…     

金属薄壁筒体对轮旋压技术进展及应用探析

对轮旋压是成形大型高强金属薄壁筒体的关键技术。分别从塑变机理、成形精度影响与控制、组织演变与缺陷、对轮旋压设备等四方面概述了金属薄壁筒体对轮旋压技术的最新研究进展,指出时变非线性特点导致塑性流动控制困难是对轮旋压技术工程化应用的瓶颈。剖析了对轮旋压技术难点,分析探讨了其发展趋势,揭示出多源混动的对轮主动强力柔性旋压工艺对超高强金属、大尺寸薄壁筒体精密旋压成形的借鉴意义。     

旋转餐厅转台摩擦驱动机构的改进设计

当前,旋转餐厅多采用摩擦驱动式转台。其工作原理是:电机经减速机构传至摩擦轮副,再带动固定在转台下端的驱动圈,使转台转动。转台由固定于其下端的内、外导轨支承在垂直支承轮上,水平支承轮在一侧导轨内保证转台绕中心转动(如图1所示)。摩擦驱动式转台的驱动机构通常由电机、行星摆线针轮减速机以及由摩擦轮、压紧轮、驱动圈组成的摩擦副构成(如图2所示)。由于转台为非定轴传动,所以我们设计了随动机构,电动机、减速机都是采用立式集中固定在随动机构上,摩擦轮直接固定在减速机的输出轴上。这样的设计可大大降低占用的空间,减少设备层。但…     

一种三驱动六连杆夹具的设计与分析

一种三驱动六连杆夹具能够解决工件加工过程中由于人工干预工件调整引起的工作效率低、调整准确性差和操作危险性高的问题,如压弯成形和不规则剪板成形等。其工作原理:在六杆机构的两侧滑块及旋转曲柄上分别安装驱动,限制六杆机构的三个自由度。当两侧滑块静止时,六杆机构相当于四杆机构,工件充当连架杆,能够实现工件的平面旋转和移动。当旋转曲柄静止时,滑块前后移动可实现工件平面前后位移补偿,同时避免四杆机构死点的出现。通过对其进行运动效果模拟,该夹具能够达到预期效果。     

自适应可变形轮腿式移动机构

提出一种可自适应切换移动模式的轮腿式移动机构,通过欠驱动切换设计以提高移动机构在复杂地形的移动能力。该移动机构无需驱动单元即可在类轮模式和轮腿模式之间进行模式切换,减小了变形驱动模块的复杂度以及机构的整体质量。该机构在平坦路面上机构以类轮模式行走,遇到障碍时旋转车身可切换成轮腿模式通过。对该机构在两种运动模式下直行、转弯、越障等过程进行理论分析并建立动力学仿真模型,得到并验证机构转弯半径函数及最大越障高度等。制作一台理论样机验证其可行性。理论分析与实验结果表明,该机构具有传统轮式机构行驶稳定性以及腿式机构高越障性,且自适应切换可显著提高其地面通过能力。     

冷态旋转锻造

冷态旋转锻造是一种高精度的无切削加工工艺,锻后无飞边或少飞边,光洁度和生产率均高,并可加工一般切削机床难以加工的特殊工件。本文介绍了该厂旋转锻造设备的机构原理、工件冷锻的应力应变分析以及圆锥变形角、模具圆弧半径的选取。本文还介绍了一种针形工件的试验过程和工艺参数以及该厂应用冷态旋转锻造的实例。     

冷态旋转锻造

冷态旋转锻造是一种高精度的无切削加工工艺,锻后无飞边或少飞边,光洁度和生产率均高,并可加工一般切削机床难以加工的特殊工件。本文介绍了该厂旋转锻造设备的机构原理、工件冷锻的应力应变分析以及圆锥变形角、模具圆弧半径的选取。本文还介绍了一种针形工件的试验过程和工艺参数以及该厂应用冷态旋转锻造的实例。     

钣制带轮近净成形技术及应用前景

钣制带轮以其精度高、节能、节材、动平衡好、无环境污染等特点,逐步淘汰铸/锻造后经机加工生产的其他形式的传统带轮,具有良好的社会效益和经济效益.钣制带轮是以金属板料为毛坯,经过落料、拉深等冲压工序制成圆筒状,然后将其装夹在带有顶压座的芯模上,使其随主轴一起旋转,通过若干不同齿形的旋压成形轮分别沿径向施加压力而成形.分析钣制带轮近净成形技术的研究现状,阐述应用近净成形技术生产带轮的优点,介绍带轮数控旋压设备的发展趋势,最后论述钣制带轮近净成形技术的发展以及应用情况.     

对轮旋压工艺

提出了一种少无金属切削新的加工工艺－对轮旋压工艺。该工艺不仅能满足工件外表面精度的要求,而且还能保证内表面的精度要求,是对传统芯模旋压工艺的完善。这对于加工大直径、高精度的管类件具有重要的意义。     

Study on compound spinning technology of large thin-walled parts with ring inner ribs and curvilinear generatrix

Given their rapid development, aerospace and other high-tech industries are in urgent need of process technology for large complex thin-walled shells represented by large thin-walled parts with ring inner ribs and curvilinear generatrix. To make up for the deficiency in existing forming methods, this paper presents a compound spinning process that integrates counter-roller spinning, multi-neck spinning, and hot spinning. The finite element models for the counter-roller spinning and multi-neck spinning forming of such parts are established, and these models can simulate the influences of different spinning process parameters on workpiece maximum equivalent stress and maximum ovality. The 2A12 aluminum alloy tube blank is used in this paper. The process parameters for obtaining the counter-roller spinning for such parts are as follows: a feed ratio of 1.0 mm/r and a roller nose radius of 8 mm. The process parameters of multi-neck spinning are as follows: a feed ratio of 3.0 mm/r and a roller nose radius of 80 mm; and the forming temperature of hot spinning is 200–250 °C. Verification by a compound spinning test found that the numerical simulation results are consistent with the process test results. The process parameters can be used for guiding the actual production of large thin-walled parts with ring inner ribs and curvilinear generatrix.     

机器视觉在尺寸在线检测中的应用

机器视觉在制造系统检测与监视领域占有重要的地位。介绍了一种可应用于工业现场的机器视觉坯（工）件尺寸检测原理、系统硬软件和精度分析结果，并介绍了实验验证的结果。     

Finite element analysis and experimental investigation on deformation mechanism of non-axisymmetric tube spinning

This paper developed 3D elastoplastic finite element analysis (FEA) models to investigate non-axisymmetric tubes neck spinning. The three-roller mandreless neck spinning process was simulated by commercial FEA software, MSC. Marc. The distribution of the transient von Mises stresses in the contact zone between the roller and the blank, and the equivalent plastic strains after spinning were obtained. The locations and causes of fractures were analyzed. The thickness distribution of the spun workpiece was investigated numerically and experimentally. It shows that during 3D non-axisymmetric tubes spinning, diametral elongation and fractures mostly occur at the opening end of workpiece, which considered as the primary location of defects. Fractures may also occur easily at the initial spinning area, which may be considered a secondary location of defects. The distributions of equivalent stresses and strains are non-uniform during both offset and oblique 3D non-axisymmetric tubes spinning. The maximum stress and strain values occur at the location where the biggest offset or inclination is induced, while the minimum values occur at the opposite location of 180° away from the maximum values. For the oblique tube, however, the strain distribution changes gradually along the axial direction, which is different from that of the offset tube. Thinning occurs during forward path spinning and thickening occurs during backward path spinning. Therefore, for multipath neck spinning processes, forward and backward paths should be applied alternately to avoid excessive thinning or thickening of workpiece.     

回转式烘干机的CAD系统研制

文中介绍了回转式烘干机的结构及工作原理,叙述了回转式烘干机CAD系统的组成结构及相关设计计算、分析、图形生成的内容,填补了这类设备国内CAD系统的空白,具有较大的适用性和推广应用价值.     

一种新型旋压切割机的研制

介绍了一种新型旋压切断机床。该机床具有旋压切断功能,特别适用于压缩机壳体等大型圆柱薄壁筒形件的切断加工。分析了加工对象以及总功能需求,介绍了机床的设计方案、技术特色、总体结构、机械系统、控制系统、旋压工艺流程以及结构改进。实践表明,该机床性能可靠、工作稳定、制造成本低,是一种低成本、低消耗的加工设备。     

Numerical simulation and experiment study on hollow spinning process for square cross-section cone

Spinning process is investigated to reveal the mechanism of square cross-section spinning without mandrel. The finite element model with the roller path formula as a boundary condition is established. Forge3D software is used to simulate the spinning process, and the accuracy of the finite element model is verified through experiment. From the stress–strain field, the residual stress on the surface of the workpiece is small after square cross-section cone hollow spinning and the maximum deformation locates on the middle part of the slope surfaces of the workpiece. The strain field distribution and the same Δr in different rotation round are the cause of the slight curvature that appears on the cross-section edge. The wall thickness decreases after hollow spinning, and the upper wall thickness is larger than the lower part.     

An identification method for spindle rotation error of a diamond turning machine based on the wavelet transform

This paper presents an identification method for the spindle rotation error from the flatness error in the workpiece surface. The spindle rotation error is identified by the wavelet transform, Weierstrass function, and power spectral density (PSD). The flatness error comprises various errors of the machine tool, such as spindle rotation error, guideway error, motor error, and ball screw error, therefore, wavelet transform is used to process the measured result of the workpiece and the signal is decomposed into high-frequency and low-frequency signal. Weierstrass function is used to fit the spindle rotation error. According to the PSD analysis of the processed signal in the frequency domain, the spindle rotation error is identified from the measured flatness error, this method provides a basis for the identification of machine tool errors.     

人字齿轴辊自动堆焊机

目前能实现自动化堆焊设备少,且使用效果差、劳动强度大、能耗高,针对轴辊齿面硬度高、耐磨性好、耐疲劳性强和特殊的齿形要求,提出了基于堆焊技术和PLC技术人字齿轴辊自动堆焊机的设计思路,阐述了人字轴辊自动堆焊机的整体设计,介绍了自动堆焊机焊接系统、送丝装置、焊剂输送系统和工件回转机构等设计与制作过程。实践表明,该自动堆焊机具有运行稳定、加工的齿形多样、堆焊层质量高、能实现补焊和修复特点,并实现轴辊循环再利用。     

Finite element simulation and experimental investigation on the forming forces of 3D non-axisymmetrical tubes spinning

3D non-axisymmetrical tube (NAT) spinning is a kind of new spinning technology, which breaks through the restriction that only axisymmetrical hollow parts could be produced by traditional spinning technology. The research on the spinning force aims to optimize the machine design and the processing parameters selection. The neck-spinning process of the 3D NAT is simulated by 3D elastic–plastic finite element software, MARC. The characteristics of the neck-spinning force of 3D NAT are compared with that of the axisymmetrical tube (AT) spinning. The effect of the main forming parameters, such as offset amount, oblique angle, nominal reduction of blank radius, feed rate and path direction, on the spinning forces have been studied theoretically and experimentally. It shows that during 3D NAT spinning, the spinning forces varies periodically with the revolution angle of the roller around the blank; the spinning force during backward path spinning is greater than that of forward path spinning. The simulation results conform well to the experimental ones.