数控加工等距型面的工具磨床改装系统设计

基于等距曲线的形成方程,分析等距型面轴和孔的磨削工方法以及磨削砂轮直径的选择要求,通过设计数控磨削附件系统,改装现有工具磨床的工作台.该附件系统的实现原理为:用曲柄机构的完成X轴和Y轴的协调运动,并采用PLC控制两台步进电机按N:1的传动比同步运转.     

用PLC改装工具磨床加工等距型面

研究了等距型面的成型方程和运动分配 ,介绍了用于等距型面加工的工具磨床机械改装及PLC软件开发。研究结果表明 :经PLC改装后的工具磨床可以提高等距型面零件的加工精度和加工效率     

等距型面与廓形曲线拟合

分析了等距型面轴的成形原理。以凸轮轴仿形磨床为对象，建立了以凸轮靠模作为输入、等距型面轴升程作为输出的磨床加工系统二阶定常线性自回归数学模型。基于此模型，提出了凸轮靠模廓形计算的新方法。试验表明，此方法加工的等距型面轴的误差较小。     

基于光电测量的等距型面轴的检测

根据等距型面曲线的廓形特征设计了一个新型的等距面轴的检测系统并研究了其检测方法和数据处理,并应用实例与在三坐标测量机上测量的结果进行了相对比较。结果表明该方法适用大批量产品的检测,能够较为精确地检测出等距型面轴的评价参数,对于评价等距型面轴的加工质量有一定的实际应用价值。     

用数控铣床加工等距型面孔

用等距型面轴与孔配合构成的联接称为等距型面联接,它具有自动定心、装拆容易、能实现间隙配合装配以及过盈配合工作等优点。利用等距型面联接代替花键联接,可以提高轴的疲劳强度,明显降低机械传动系统的振动和噪声,因等距型面的型面曲线上任意两平行切线间的距离都相等,其测量和加工都比较方便。特别是近几年,随着数控机床的推广应用,等距型面的许多加工问题也逐步得到了解决。     

等距型面正交车铣加工的仿真

等距型面在连接结构中的应用越来越广泛。由于等距型面具有特殊的截面廓形曲线,一般采用仿形车削或数控车削来进行加工。提出通过正交车铣加工等距型面,应用UG的加工模块和后处理器对等距型面进行正交车铣加工编程,建立了虚拟卧式车铣加工中心,应用VERICUT实现了等距型面正交车铣加工仿真,并对加工结果进行了比较分析。其结果表明,正交车铣能较好的完成等距型面的切削加工。     

五轴联动数控电解磨床的设计

研究了电解磨轮加工时的实际运动轨迹,得到了五轴联动数控电解磨床的五个坐标计算公式.在建立叶片型面型值点数据库的基础上,完成了叶片型面拟合、插值加密、边界处理的计算机程序,并计算出加工时的五轴联动数控电解磨床的各轴运动参数,最后实现了整体叶轮叶片数控电解磨削加工程序的自动编程.     

车铣直线包络等距三面廓形协调运动的实现

等距型面联接具有装拆方便、自动定心、应力集中小、疲劳强度高等优点。研究了等距型面的方程和运动,在普通卧式车床的进给系统上,通过一附加机构实现协调运动,车铣直线包络等距三面轴。     

SANDVIK新型刀具刀柄联接强度的力学特性分析计算

文中对型面联接中的三弧段等距型面联接进行力学分析，首先建立三弧段等距型面方程，应用有限元法确定等距型面接触点的位置，对三弧段等距型面联接中的应力分布及大小进行分析计算。结果表明，无论是轴还是轮毂，其应力分布在同一圆周上呈现与边数相同的周期，最大应力点的位置均在接触点附近靠内侧处。应用弹性力学理论，推导出接触点的曲率半径，对三弧段等距型面联接进行接触应力计算。     

实用三弧段等距型面轴的数控铣削仿真研究

从分析实用等距曲线的构成入手,推导出实用三弧段等距型面的大圆弧半径计算公式和型面曲线的数学模型,应用M asterCAM软件进行二维图形的建模,并进行数控铣削仿真,最后生成NC数控加工程序。     

端面外圆磨床成型砂轮修整器的改进

MB1632端面外圆磨床随机配套液压仿形成型砂轮修整器，其修整的成型砂轮只能磨削由一档外圆和端面构成的轴端，极大地限制了机床的加工范围。为适应G427凸轮轴设计改进的需要，对原修整器进行了改进，从而使该机床能一次磨削由多段直线、圆弧曲线构成的复杂型面。若更换靠模，可加工各种复杂的导型面。     

A practical approach for simulation and manufacturing of a ball-end mill using a 5-axis CNC grinding machine

This paper presents a detailed manufacturing model that can be used for grinding a ball-end mill using 5-axis CNC (computer numerical controlled) grinding machine. The profile of the helical groove can be calculated exactly using the given wheel profile and relative movements between the workpiece and the grinding wheel. The proposed model is related to some analytical, differential geometry and kinematics to control the motions of the workpiece and grinding wheels in grinding processes. The manufacturing model presented in this paper provides a practical and efficient method for developing the simulation software for the design and the manufacture of a ball-end mill.     

A manufacturing model of an end mill using a five-axis CNC grinding machine

This paper presents a manufacturing model of a flat-end mill using a five-axis computer numerical control (CNC) grinding machine. The profile of the helical groove can be precisely calculated using a given wheel profile and the relative movements between the workpiece and the grinding wheel. The results of the calculation of the numerical control (NC) data for all the grinding processes of the end mill are fully presented in the paper. The NC data for the machining end mill were generated from the developed program by using the given design parameters of tool geometry, wheel geometry, wheel setting, and machine setting. The effects of the design and manufacturing of the end mill were analyzed based on the computer simulation and experiment results. This study provides a practical and efficient model for the manufacturing of an end mill using a CNC grinding machine with simple programming techniques. The prediction of the end mill geometry for the designing of the proper configuration of the end mill before manufacturing and generating the NC code for machining in a CNC machine is necessary to save time and to reduce the manufacturing cost.     

等距型面轴检测方法的研究

根据曲线拟合得到的等距型面方程分析了其廓形特征,以常规的三点测量法为基础,提出了一种新的等距型面轴检测方法,设计了一个新型检测系统。该法提高了测量的准确度和精度,该系统能够精确地测量出等距型面轴的评价参数。     

无心磨床砂轮主轴的涂镀修复

无心磨床的砂轮轴经过几年的运转,由于轴径部位的磨损过限,造成不能正常工作。通过磨削去除轴径的疲劳层,再进行表面涂镀修复,最终达到修复砂轮主轴的目的。     

凸轮轴磨床数控系统的研制

介绍了研制的一种适合国情的凸轮轴磨床数控系统。该系统采用摇架式数控成形,工件转动和摇架摆动之间采用强迫耦合技术,并数字调节技术来提高工件的轮廓控制精度。介绍了该系统的技术特点和数字调节器的设计。     

浅谈焊合件传动轴的加工制造

详细介绍了转动轴的结构,并以中小型磨棒机的传动轴加工制造为例,分析了焊合件传动轴的加工制造工艺。所述加工工艺保证了传动轴达到使用要求。又可有效降低制造成本。减少生产所用周期,具有很好的实用价值。     

一种自动跟踪式中心架的研制

针对现有轴类工件加工中的夹持支撑存在的不足,设计了自动跟踪式中心架,该机构可以采用液压装置和双杠杆机构,实现了对轴颈的自适应支撑,高精度自动定心,达到了在粗磨、精磨及光磨工况中对轴类工件的刚性支撑的要求,提高了轴类工件的加工质量.该机构已经用于实际生产中.     

Performance of a newly developed torque-sensor motor

A new type of induction motor with a built-in torque sensor (called a ‘torque-sensor motor’) has been developed in order to monitor grinding torque. Its rotor shaft consists of a hollow shaft and torsion bar, each of which has a disc with equiangularly located magnets. The torque output is calculated by microcomputer from the time delay of pulses generated in detecting coils. This toque sensor has good linearity. Torque ripple and zero-point drift caused by rotational speed change are estimated to be less than 1 Nm. It is so sensitive that it can detect torque ripple from rotational error of the driving belts on the grinding machine. Further, it can accurately monitoring grinding torque by using a low pass filter to remove such torque ripple. It can also be used to estimated the time constant of the grinding wheel and workpiece system in the transient torque situation of a grinding cycle. The performance of the grinding wheel motor is as good as that of a conventional motor.