基于VERICUT的四圆弧齿轮成形磨削加工仿真

根据成形法磨削加工原理,应用VERICUT软件对四圆弧齿廓齿轮进行数控仿真加工。首先根据数控成形磨齿机建立机床模型、毛坯模型,并依据四圆弧齿廓齿轮成形磨削砂轮截形建立砂轮模型,再参照机床结构和成形磨削运动编写仿真数控程序,最后在VERICUT软件平台进行四圆弧齿轮的数控仿真加工并对仿真结果进行分析。分析结论表明,仿真加工能够满足设计精度要求,且数控程序是正确的。     

数控成形砂轮磨齿机床几何误差分析与函数补偿法

以QCYK7332A数控成形砂轮磨齿机为例,对机床误差进行了分析。应用多体系统理论以及齐次坐标变换建立了几何误差模型,得到了此模型下砂轮尖的6个自由度误差表达式,并在此基础上以机床B轴为例,说明了运动轴误差转化到磨具上,从而引起所加工齿轮的齿距、齿形、压力角等误差。为了减小误差,提出了函数补偿法,并以测量机床的X轴角度误差为例,说明机床误差预测以及实时误差补偿的过程,为提高数控成形砂轮磨齿机精度、减小机床的几何误差提供了理论依据。     

基于螺旋理论的蜗杆砂轮磨齿机空间误差建模及解耦补偿

为提点高六轴数控蜗杆砂轮磨齿机的加工精度,提出了基于螺旋理论的空间误差建模及解耦补偿方法。首先,用旋量对机床移动运动副与转动运动副进行了描述,在此基础上进行了六轴蜗杆砂轮磨齿机运动学建模及考虑41项几何误差的空间误差建模;基于Paden-Kahan子问题,对空间误差模型进行逆解,求解了各轴的补偿运动量。     

精密磨齿条夹具的设计

在一些精密机床及测量仪中往往有精度较高的淬硬齿条这种零件,需进行磨削加工,但一般工厂无合适的加工设备加工这种零件,因这种零件一般数量较少,如专门为此设计齿条磨床,不但费用大,而且要很长周期,不能解决面临的生产实际问题,我们在处理这种加工问题时,采用了一种比较简单而且比较省钱省时的方法,即采取工艺措施,充分利用现有设备。具体解决办法是:设计一套精密磨齿条夹具,将其安装在磨齿机上进行齿条磨削加工。我们选择的是Y7163A立式锥形砂轮磨齿机(我厂生产的磨齿机),并对该机床的机械结构及电气动采取适当措施,如锁紧工作台,脱开分齿运动,使     

重庆机床集团成功亮相CCMT2012

在CCMT2012展会上，重庆机床集团参展面积达近400平方米。集团本部首推与英国PTG合作研发的YW7232CNC数控高效精密万能磨齿机。Yw7232CNC型磨齿机同时具有蜗杆砂轮磨和成形砂轮磨两种功能，此项技术填补了国内空白。该磨齿机加工精度可达GB／T10095．1-2008标准3-4级，与传统磨齿机相比，     

在Y7150型磨齿机上磨削齿条

多年来,我厂在生产Y54A插齿机过程中,曾对该机床的主要关键件之一,刀轴上的大齿条进行磨削加工,经过长期生产验证,已较稳定的达到6D_b级精度,现将其加工方法介绍如下。众所周知,Y7150型磨齿机在磨削圆柱齿轮时具有如下几个运动:1.砂轮的旋转运动;2.磨头的往复运动;3.展成运动;4.分度运动;5.进给运动;6.火花调整机构。在磨削齿条时,由于是直线齿廓,用Y7150机床进行磨削时,除与磨削圆柱齿轮有其相同的运动,如砂轮的旋转运动、磨头的往复运动、火花调     

直驱工件主轴传动链测试

工件主轴作为蜗杆砂轮磨齿机中的关键部件,其驱动精度和响应速度对整个机床至关重要,工件主轴采用直驱结构是为了达到现代数控蜗杆砂轮磨齿机高精度、高效率的加工要求,文中对直驱工件主轴在不同砂轮转速下的跟随误差及相应转速下工件主轴和砂轮主轴均匀性误差进行了测试,为砂轮主轴工作转速的设定提供了依据。     

蜗杆砂轮磨齿机传动精度测试方案

匈牙利生产的ＴＹＰＦＫＰ３２６型蜗杆砂轮磨齿机,早年由我国一汽集团等单位进口不少,现已进入大修期。在使用仪器对其进行精度检测和误差环节分析诊断以前,我们先对其工作原理和传动链特点进行了剖析,以制定科学、合理、便于实现的测试方案,达到最佳测试效果。此项工作对其它同类磨齿机也有借鉴作用。１　机床工作原理与传动链图　　此机床采用蜗杆型砂轮与工件同步运动,以展成法连续磨削加工。原说明书所附传动链图如附图所示,其中从工作台到电动机２为分度链,电动机２到齿条为差动链。匈牙利ＴＹＰＦＫＰ３２６型蜗杆砂轮磨齿机…     

莱斯豪尔磨齿机——齿轮加工机床的巨头

2007年9月德国汉诺威国际机床展会上,目前国际上齿轮加工机床三大巨头悉数参展,均以气势恢宏的展台展出了其新近推出的新产品。其中,瑞士莱斯豪尔（REISHAUER）公司推出的新产品尤为引人注目,一个为云集该公司多项独创的蜗杆砂轮磨齿机新技术的数控蜗杆砂轮磨齿机RZ303C;另一个为目前国际上蜗杆砂轮磨齿加工直径范围最大的机床——莱斯豪尔公司RZ1000蜗杆砂轮磨齿机。     

中国机床市场近期需求一瞥

汽车行业:加工箱体类零件的加工中心、加工回转体零件的数控车床和车削中心、数控高速滚齿机、数控蜗杆砂轮磨齿机、曲轴磨床、曲轴车拉机床、凸轮轴磨床、活塞车床等。机械基础件及机床工具行业:各类加工中心、数控车床数控大平面砂轮磨齿机、数控坐标磨床、数控导轨磨床、数控内圆磨床、精密小孔珩磨机、数控万能工具铣床、数控蜗杆砂轮磨齿     

Applications of Artificial Intelligence to Grinding Operations via Neural Networks

In recent years, artificial intelligence played an important role in machine tool automation. Artificial neural networks, as one of the artificial intelligence algorithms, has superiority in representing the relation between the inputs and outputs of the multi-variable system. Hence, it can be applied to sophisticated operations such as grinding operation. The aim of this research is to use artificial neural networks as the brain of grinding machine controller. The target of this controller was to achieve the desired workpiece surface roughness under grinding wheel surface topography variations. The core of the system consists of two multi-layers feed forward artificial neural networks based on back error propagation learning algorithm. The first one was used for process design to achieve the desired surface roughness. It extracts suitable process variables such as grinding wheel speed and feed rate. The second one monitors the cutting operation using sensors' readings. It extracts the different controlling decisions; these are accept the process, redesign the process or start dressing operation under automatic control. According to these decisions, a PC master control program generates the appropriate control codes and sends them to the machine controllers to take the required actions.     

Applications of Artificial Intelligence to Grinding Operations via Neural Networks

In recent years, artificial intelligence played an important role in machine tool automation. Artificial neural networks, as one of the artificial intelligence algorithms, has superiority in representing the relation between the inputs and outputs of the multi‐variable system. Hence, it can be applied to sophisticated operations such as grinding operation. The aim of this research is to use artificial neural networks as the brain of grinding machine controller. The target of this controller was to achieve the desired workpiece surface roughness under grinding wheel surface topography variations. The core of the system consists of two multi‐layers feed forward artificial neural networks based on back error propagation learning algorithm. The first one was used for process design to achieve the desired surface roughness. It extracts suitable process variables such as grinding wheel speed and feed rate. The second one monitors the cutting operation using sensors' readings. It extracts the different controlling decisions; these are accept the process, redesign the process or start dressing operation under automatic control. According to these decisions, a PC master control program generates the appropriate control codes and sends them to the machine controllers to take the required actions.     

A manufacturing model of helical groove on rotary burr and a universal post processing method

A systematic machining theory and precision method to determine cutter location in a grinding system is presented for rotary burr. First, the helical cutting edge on various kinds of revolving surfaces is built. Then, based on the geometry model of the helical cutting edge, the smooth spiral rake surface with constant normal rake angle and flank surface can been formed during the one-pass grinding process by this method. No interference between the grinding wheel and workpiece happens by the wheel special rotation. The method has the characteristic of detaching the grinding wheel path solution from specified machining conditions. The grinding wheel path is suitable for different NC machine tools through post processing. Meanwhile, a mechanism kinematic model of the NC machine tool is built, and a generalized algorithm for post-processing of multi-axis NC machine tools is presented. This model is applied to arbitrary configuration of NC machine tool, and the motion value for each axis will be generated by the inputting structure and motion parameters of the machine tool. The model, together with the machining method mentioned in this paper, make the calculation and generation of the grinding wheel path simpler and universal. At last, the validity of the method given in the paper is identified by an example of grinding.     

近似面齿轮传动的齿面拓扑修形主动设计

为了提高面齿轮的磨齿效率,采用不做齿向进给运动的大半径盘形砂轮磨齿得到的面齿轮具有近似齿面,然而该近似面齿轮与双向修形小轮的啮合性能不够理想.因此进一步通过啮合理论重新构造小轮齿面,并根据预设的啮合性能对该新构造的小轮齿面进行拓扑修形设计,以控制近似面齿轮传动的啮合性能.小轮的拓扑修形齿面采用盘形砂轮局部点共轭法磨齿加工,建立了小轮拓扑修形齿面与加工参数之间的线性方程.用实例说明了所提方法的应用,齿面接触分析结果与给定的啮合性能基本一致.     

缓进给强力磨削工艺及磨削机理的试验与研究

本文阐述了缓进给磨削的特点。这是一种新型的平面磨削加工工艺,缓进给磨削时,砂轮的切削深度大,金属切除率高,比普通磨削高100～1000倍。它可有效地用于型面或平面磨削,并能在一次或几次行程内磨完全深,无须进行诸如铣、刨等粗加工工序。本文还论述了缓进给磨削23000千瓦燃气轮机叶片根槽的机床、砂轮、金刚石滚轮、冷却液的应用以及工艺和磨削机理等。缓进给磨削中关键的问题之一是大面积烧伤和裂纹的产生。因而,本文还叙述了缓进给磨削的切屑形成机理。试验结果表明,当出现烧伤时,工件上的温度由通常的100～130℃会突然上升到1000℃以上。正确选择砂轮、进给速度及冷却液的供应,可以控制工件表面光洁度、形状和公差。     

Mathematical modeling and machining parameter optimization for the surface roughness of face gear grinding

Face gear is an important part in the power transmission of helicopter, but its grinding is a difficult problem. In order to enhance the finishing machining surface quality of face gear, the mathematical formula of the residual height of motion trajectory of abrasive grains was obtained, and the model of grinding surface roughness of face gear was corrected. In addition, machining parameter optimization for grinding surface roughness on a five-axis blade grinding machine was investigated by orthogonal experiment method. The experiment results indicated that disk wheel spindle speed and feed velocity of the disk wheel are more significant effect factors among the three factors. The calculation results of model showed that the maximum error comparing with the experiment results is not more than 13.5 %, which suggests that the mathematical model is reasonable.     

曲轴随动磨削砂轮架运动学分析

曲轴随动磨削是一种新型曲轴精加工方法,其中砂轮架运动精度对曲轴的加工精度有很大的影响.为了获取砂轮架的运动规律,首先计算了砂轮架运动的位移及速度函数,然后在AD-AMS中对曲轴随动磨削过程进行了仿真,将得到的砂轮架运动的各项参数曲线和MATLAB中的理论曲线进行对比,验证了砂轮架运动函数的正确性,确定了砂轮架运动的理论位移及速度函数,为实现对砂轮架运动的精确控制奠定了基础.     

可在线更换磨削轮的砂带磨削机床的研制

介绍了应用于机器人磨削加工系统中的可在线更换磨削轮的砂带磨削机床的结构原理。阐述了在线更换磨削轮的砂带磨削机床的磨削方式及其磨削力控制结构原理。     

多颗粒金刚石小砂轮磨削仿真及实验

建立了多颗粒金刚石小砂轮轴向进给磨削工程陶瓷的磨粒运动轨迹模型,通过改变砂轮转速、陶瓷件转速、轴向进给速度,揭示加工参数变化和磨粒运动规律的关系。通过不同加工参数下实际的陶瓷加工实验,分析了进给速度对边缘碎裂、磨削力、金刚石磨粒耗损的影响规律,得到的实验分析结果和仿真结果一致。实验运用了合适的实验方案和测力系统,并利用边缘检测和轮廓曲线拟合的方法实时追踪检测金刚石顶尖曲率半径变化来定性分析金刚石磨粒的磨损情况。研究结果为如何利用合理的进给速度控制陶瓷材料的边缘碎裂,减少工件和砂轮磨具的损伤提供了借鉴。     

DEVELOPMENT OF AN OPTICAL SCANNER TO STUDY WEAR ON THE WORKING SURFACE OF GRINDING WHEELS

The efficiency of the grinding operation is highly dependent on the grinding wheel surface topography. Several methods for the evaluation of the grinding wheel surface have been developed in the last few years. In some of these methods, the grinding wheel has to be removed from the machine for an evaluation using a microscope or a profilometer. Some other methods are able to measure the topography at the grinding machine, but they do not give detailed information about grain distribution and wear. This paper shows a new method to map the grinding wheel surface. The proposed system is based on an optical scanner capable of measuring the light beam reflected from the wear flat areas on the abrasive grains over the whole wheel peripheral surface. The Mapping System for Grinding Wheels (MSGW) is able to acquire data with the wheel running at the work speed (30 m/s)and the measurement carried out on the grinding machine without stopping. The system is applied on a surface grinding operation where an Alj0₃grinding wheel is used. The results show that the system can be used to map the wear flats at the grinding wheel surface and also to analyze the wear phenomena efficiently.