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Machine Design
With the scientific and technological progress and social changes in demand, machine design theory and technology are also constantly development. Computer technology and the rapid progress of technology, machine design methods for the development of a strong technical support. Computer-aided design (CAD) and computer-aided engineering (Computer Aided Engineering, Machine Tools initials CAE0 in the various stages of design has been applied, the experience has changed the traditional design methods, machine design from the traditional design of the computer-aided design, Qualitative to quantitative design design, static and linear and nonlinear analysis to dynamic analysis, from feasibility to design the best design of the transition.
NC technology development and applications, the transmission makes machine tools and structure has undergone major changes. Servo drive system can easily achieve a single machine and multi-axis movement linked to possible to omit the heavy machinery complex transmission system, structure and layout to produce great changes.
With the development of the production, the needs of the community is changing. In the mechanical manufacturing industry, a variety of species, small batch production of the increasing demand, resulting in a corresponding to the FMS (FMS) and other advanced manufacturing systems. FMS NC machine tools is the core equipment. Pre-FMS, can be said to be "machine-based system" that, according to the characteristics of the existing machine to a FMS. However, traditional machine tools (including numerical control machine tools) does not take into account when designing it in the application of FMS, in the functional constraints on the development of the FMS. FMS the development of machine has set new requirements for machine tools designed to "system-based machine design development" direction, that is, in machine design to consider how to better adapt to FMS, and other advanced manufacturing systems requirements, for example, Time and space with flexible, and the proximity to the logistics and so on, which means the design of machine tools has made new demands. Machine design is based on the design of the type set. Universal machine used serialized design. Series of products are innovative design type, the other is a variant design type. Some machines, such as the composition of a combination of machine design type.
In the type of innovative design, machine tools overall programme (including motor function and structure of the programme layout of the programme) may be the selection of the design (also known as the trial design) or a 10% design (also known as the analytical design). The former is used analog analysis, a method of reasoning programme, is the innovative design of the method used in general while the latter used as a method of generating the analytical programme, innovation ability, it is still studying development.
Machine Design steps
Machine tools and demands of different types, design steps are also different. In accordance with the new principles for processing the innovative design of the machine should be the steps; into a series of machine tool products should be designed serialization of the steps; higher degree of universal machine products, such as machine tools should be modular design combination of the steps .
I.determine the structure principle
According to the preliminary design, the machine is designed to determine the structure of the main principles of the programme include:
(1) that uses the technology of the machine, including the processing of the material type, shape, quality and size range.
(2) productivity, including the processing of the types, quantities and the required productivity.
(3) performance requirements of the accuracy of processing (user orders design) or the accuracy of machine tools, stiffness, heat distortion, noise and other performance indicators.
(4) the main parameters that determine the processing machine room and the main parameters.
(5) drive machine-driven approach and a motor-driven hydraulic-driven approach. Motor-driven approach in general have driven motor, stepper motor drive and servo motor drive. Drive and the determination of not only the cost of the machine, will also directly affect the mode of transmission established.
(6) of the main principles of parts and components should meet the requirements and principles of the structure, and sometimes needed to draft the design, identification of key components of home-made or HS.
(7) costs and production cycle or whether orders for factory planning products, should determine the cost and production cycle indicators.
II. Design
Design of the contents
(1) motor function design including the identification of the number of machines required for movement, form (linear motion, the Rotary Movement), features (the main movement, feeding movement, other sports) and the order, the final draw of the machine function map.
(2) the basic parameters of the design parameters, including size, movement and dynamic parameters of the design parameters.
(3) transmission system design, including transmission, transmission and drive system schematic design plans.
(4) the overall layout of the structure including the distribution of motor function, the overall layout of the form and structure of the whole programme
Design plans.
(5) control, including control system design and control theory, control system design plans.
III.structural design
Design of the machine drive system to determine the structure of the major principles of the programme, design parts assembly, the main parts for analysis calculated or refine the design of hydraulic principles and the corresponding assembly of hydraulic components, electrical control system design schematics and the corresponding Installation of electrical wiring diagram, machine design and improve the hand and the contact size map.
IV. Process Design
Who all the self-made machine parts map, the preparation of standard parts, GM parts and pieces of home-made schedules, writing Design Manual, Manual, the designated machine test methods and standards, and other technical documentation.
V. Machine Tool Evaluation
On a machine designed by performance analysis and comprehensive evaluation. May be designed by computer modeling of the machine, get a prototype of the so-called math, also known as the virtual prototype. A virtual prototype of a machine designed by kinematic simulation, in the actual prototype test before they are made out a comprehensive assessment, can greatly reduce the risk of new product development, shorten the development cycle and improve the quality of development.
These steps can be repeated, that the design with satisfactory results achieved so far. In the design process, design and evaluation of repeated a design can improve the success rate.
VI.design type
Upon completion of the above steps, the physical prototype manufacture, test and comment. According to physical prototype comment on the results of the modified design, the final product design type.
On the deep processing of the technological requirements
Deep processing, is the top priority of this design. The so-called deep hole, the hole is that when processing the ratio of length and diameter of about 10 times, often on the accuracy and surface finish requirements and higher, the use of processing methods in general are more difficult to meet.
I. Deep processing issues that must be addressed:
1) poor tool rigidity slender and easy to cause the tool deflection and friction with the hole wall, and therefore the head knives are correctly oriented to ensure the introduction of sets; At the same time, bearing in accordance with the need for holders to reduce the deformation and vibration Arbor.
2) is not easy from cuttings, the use of feed grade or high-pressure cutting fluid through the
inner row and outer row chip from the tool structure.
3) tool cooling difficulties, access to high-pressure cutting fluid cooling of the tool fully.
II. Deep processing of type:
Combine the characteristics of deep-hole machining, deep hole processing technology on the difficulties, the method has been overcome.
1) Deep processing grade feed:
Ordinary twist drill head in cast iron or steel pieces on the 6 ~ 10mm diameter drill hole below, the general should not be a deep-drilling of 6 ~ 10 times greater than the aperture. When the direction of horizontal drilling, the steel pieces in the deep drilling should not last more than 6 times the diameter, in the cast iron up to about 10 times the aperture. If the processing of the hole depth of more than this range, can be classified into methods for processing, that is, in the drilling process, so that bit processing automatically after a certain depth from the workpiece in order to discharge swarf and cooling, and then re-forward processing, constant back and forth until the process has finished (each drill deep, cast iron pieces from 3 to 6 times the diameter; steel pieces from 0.5 ~ 2 times the aperture, the deeper hole when taking a small value). This process is suitable for drilling deep holes of small diameter, but the productivity and precision mechanics are relatively low.
2) Feeding a deep-hole processing
It is mainly used various types of special segment, and with the next shot, transmission-oriented systems, such as cutting fluid input in the deep-hole drilling machine, hinges, boring and the presentation materials. Discharged from the way the chip can be especially Chip (on the hinge, there is also boring things forward or backward Chip) and with Chip; from a number of cutting edge, can be divided into single-blade, double-edged and multi-blade, cutting edge can be high-speed steel or carbide. Cutter head have a different number of block-oriented support in the process-oriented role play to ensure flatness of the hole, but also from the role of squeezed light to improve the processing of the surface finish hole.
Chip has a deep-hole drilling in a single tube and dual tube Chip Chip (ie, jet drilling). Chip fear of double tube drill pipe than Chip Chip fear deep-hole drilling and drilling outside the processing efficiency and higher accuracy. The deep hole on the barrier is expected to set at the completion of unloading Nesting Nesting knife, cut off the mandrel fitted with a knife and the knife folder to make it against the mandrel, the feed through a dedicated device to cut off, cut to the core diameter rod 4 / 5 ~ 5 / 6 will be back to cut off the knife, a little outside the mandrel to break out.
In general, the use of inside than outside the Chip Chip processing large diameter, obtained by processing high precision and surface finish.
III. The main points of deep-hole processing
Machine tools and processing of the previous process, and attention should check the following:
1) axis-oriented tool sets, Bar sets of bearings, such as the centerline of the workpiece support different sets of axis degrees should meet the requirement.
2) check whether the system is cutting fluid flow and normal work is a multi-edge special deep-hole drilling with Chip (jet drilling suction) of the spray suction effect, in particular, should seriously check.
3) the workpiece should be the upper end of the processing center hole, and to avoid drilling I n the slope.
4) Does the shape of a normal chip. With the workpiece material, tool geometry, cutting parameters and so on. The two separated by a certain direction of each curl inward cutting the best shape to avoid the formation of the ribbon cuttings straight.
5) The higher the speed of processing through-hole, when the drill bit is about to pass, it is best to stop or deceleration to prevent damage to the bit and the exit.
6) should be avoided in the processing of parking, such as the need to stop, they should first stop into the tool and return to some distance, and then stop the pump and the rotation of the main campaign to prevent the tool in the hole a "killed" phenomenon.
機(jī)床設(shè)計(jì)
隨著科學(xué)技術(shù)的進(jìn)步和社會(huì)需求的變化，機(jī)床的設(shè)計(jì)理論和技術(shù)也在不斷的發(fā)展。計(jì)算機(jī)技術(shù)和分析技術(shù)的飛速進(jìn)步，為機(jī)床設(shè)計(jì)方法的發(fā)展提供了有力的技術(shù)支撐。計(jì)算機(jī)輔助設(shè)計(jì)（CAD）和計(jì)算機(jī)輔助工程（Computer Aided Engineering,縮寫CAE0已在機(jī)床設(shè)計(jì)的各個(gè)階段得到了應(yīng)用，改變了傳統(tǒng)的經(jīng)驗(yàn)設(shè)計(jì)方法，使機(jī)床設(shè)計(jì)由傳統(tǒng)的人工設(shè)計(jì)向計(jì)算機(jī)輔助設(shè)計(jì)，由定性設(shè)計(jì)向定量設(shè)計(jì)，有靜態(tài)和線性分析向動(dòng)態(tài)和非線性分析，由可行性設(shè)計(jì)向最佳設(shè)計(jì)過(guò)渡。
數(shù)控技術(shù)的發(fā)展與應(yīng)用，使得機(jī)床的傳動(dòng)與結(jié)構(gòu)發(fā)生了重大變化。伺服驅(qū)動(dòng)系統(tǒng)可以方便地實(shí)現(xiàn)機(jī)床的單軸運(yùn)動(dòng)及多軸聯(lián)動(dòng)，從而可以省去復(fù)雜笨重的機(jī)械傳動(dòng)系統(tǒng)，使其結(jié)構(gòu)及布局產(chǎn)生很大的變化。
隨著生產(chǎn)的發(fā)展，社會(huì)需求也在發(fā)生變化。在機(jī)械制造業(yè)中，多種品種，小批量生產(chǎn)的需求日益增加，因此出現(xiàn)了與之相適應(yīng)的FMS（柔性制造系統(tǒng)）等先進(jìn)制造系統(tǒng)。數(shù)控機(jī)床是FMS的核心裝備。前期的FMS，可以說(shuō)是“以機(jī)床為主的系統(tǒng)”，即根據(jù)現(xiàn)有的機(jī)床的特點(diǎn)來(lái)構(gòu)成FMS。但是，傳統(tǒng)的機(jī)床（包括數(shù)控機(jī)床）設(shè)計(jì)時(shí)并未考慮到它在FMS中的應(yīng)用，因此在功能上制約了FMS的發(fā)展。FMS的發(fā)展對(duì)機(jī)床提出了新的要求，要求機(jī)床設(shè)計(jì)向“以系統(tǒng)為主的機(jī)床設(shè)計(jì)發(fā)展”方向發(fā)展，即在機(jī)床設(shè)計(jì)時(shí)就要考慮他如何更好地適應(yīng)FMS等先進(jìn)制造系統(tǒng)的要求，例如要求具有時(shí)空柔性，與物流的可接近性等等，這就對(duì)機(jī)床設(shè)計(jì)的方法學(xué)提出了新的要求。機(jī)床的設(shè)計(jì)方法是根據(jù)其設(shè)計(jì)類型而定的。通用機(jī)床采用系列化設(shè)計(jì)方法。系列中基型產(chǎn)品屬創(chuàng)新設(shè)計(jì)類型，其他屬變型設(shè)計(jì)類型。有些機(jī)床，如組合機(jī)床屬組合設(shè)計(jì)類型。
在創(chuàng)新設(shè)計(jì)類型中，機(jī)床總體方案（包括運(yùn)動(dòng)功能方案和結(jié)構(gòu)布局方案）的產(chǎn)生方法可采用分析式設(shè)計(jì)（又稱試行設(shè)計(jì)）或創(chuàng)成式設(shè)計(jì)（又稱解析式設(shè)計(jì)）。前者是用類比分析，推理方法產(chǎn)生方案，是目前創(chuàng)新設(shè)計(jì)一般采用的方法；后者則用創(chuàng)成解析的方法生成方案，創(chuàng)新能力強(qiáng)，這種方法尚在研究發(fā)展之中。
機(jī)床設(shè)計(jì)步驟
機(jī)床的類型和要求不同，設(shè)計(jì)步驟也不同。按新的原理進(jìn)行加工的機(jī)床應(yīng)按創(chuàng)新設(shè)計(jì)的步驟進(jìn)行；成系列的機(jī)床產(chǎn)品應(yīng)按系列化設(shè)計(jì)的步驟進(jìn)行；通用化程度較高的機(jī)床產(chǎn)品，例如組合機(jī)床應(yīng)按模塊化設(shè)計(jì)的步驟進(jìn)行。
I.確定結(jié)構(gòu)原理
根據(jù)初步設(shè)計(jì)方案，確定被設(shè)計(jì)機(jī)床的結(jié)構(gòu)原理方案的主要內(nèi)容包括：
（1）用途 即機(jī)床的工藝范圍，包括加工件的材料類型，形狀，質(zhì)量和尺寸范圍等。
（2）生產(chǎn)率 包括加工件的類型，批量及所要求的生產(chǎn)率。
（3）性能指標(biāo) 加工件要求的精度（用戶定貨設(shè)計(jì)）或機(jī)床的精度，剛度，熱變形，噪聲等性能指標(biāo)。
（4）主要參數(shù) 即確定機(jī)床的加工空間和主要參數(shù)。
（5）驅(qū)動(dòng)方式 機(jī)床的驅(qū)動(dòng)方式有電動(dòng)機(jī)驅(qū)動(dòng)和液壓驅(qū)動(dòng)方式。電動(dòng)機(jī)驅(qū)動(dòng)方式中又有普通電動(dòng)機(jī)驅(qū)動(dòng)，步進(jìn)電動(dòng)機(jī)驅(qū)動(dòng)與伺服電動(dòng)機(jī)驅(qū)動(dòng)。驅(qū)動(dòng)方式的確定不僅與機(jī)床的成本有關(guān)，還將直接影響傳動(dòng)方式的確定。
（6）結(jié)構(gòu)原理 主要零部件應(yīng)滿足的要求和結(jié)構(gòu)原理，有時(shí)還需進(jìn)行草圖設(shè)計(jì)，確定關(guān)鍵零部件自制還是外協(xié)。
（7）成本及生產(chǎn)周期 無(wú)論是訂貨還是工廠規(guī)劃產(chǎn)品，都應(yīng)確定成本及生產(chǎn)周期方面的指標(biāo)。
II.總體設(shè)計(jì)
總體設(shè)計(jì)的內(nèi)容
（1）運(yùn)動(dòng)功能設(shè)計(jì) 包括確定機(jī)床所需運(yùn)動(dòng)的個(gè)數(shù)，形式（直線運(yùn)動(dòng)，回轉(zhuǎn)運(yùn)動(dòng)），功能（主運(yùn)動(dòng)，進(jìn)給運(yùn)動(dòng)，其它運(yùn)動(dòng)）及排列順序，最后畫出機(jī)床的運(yùn)動(dòng)功能圖。
（2）基本參數(shù)設(shè)計(jì) 包括尺寸參數(shù)，運(yùn)動(dòng)參數(shù)和動(dòng)力參數(shù)設(shè)計(jì)。
（3）傳動(dòng)系統(tǒng)設(shè)計(jì) 包括傳動(dòng)方式，傳動(dòng)原理圖及傳動(dòng)系統(tǒng)圖設(shè)計(jì)。
（4）總體結(jié)構(gòu)布局設(shè)計(jì) 包括運(yùn)動(dòng)功能分配，總體布局結(jié)構(gòu)形式及總體結(jié)構(gòu)方案圖設(shè)計(jì)。
（5）控制系統(tǒng)設(shè)計(jì) 包括控制方式及控制原理，控制系統(tǒng)圖設(shè)計(jì)。
III.結(jié)構(gòu)設(shè)計(jì)
設(shè)計(jì)機(jī)床的傳動(dòng)系統(tǒng)，確定各主要結(jié)構(gòu)的原理方案，設(shè)計(jì)部件裝配圖，對(duì)主要零件進(jìn)行分析計(jì)算或優(yōu)化，設(shè)計(jì)液壓原理和相應(yīng)的液壓部件裝配圖，設(shè)計(jì)電氣控制系統(tǒng)原理圖和相應(yīng)的電氣安裝接線圖，設(shè)計(jì)和完善機(jī)床總裝圖和總聯(lián)系尺寸圖。
IV工藝設(shè)計(jì)
機(jī)床的全部自制零件圖，編制標(biāo)準(zhǔn)件，通用件和自制件明細(xì)表，撰寫設(shè)計(jì)說(shuō)明書，使用說(shuō)明書，指定機(jī)床的檢驗(yàn)方法和標(biāo)準(zhǔn)等技術(shù)文檔。
V機(jī)床整機(jī)綜合評(píng)價(jià)
對(duì)所設(shè)計(jì)的機(jī)床進(jìn)行整機(jī)性能分析和綜合評(píng)價(jià)?？蓪?duì)所設(shè)計(jì)的機(jī)床進(jìn)行計(jì)算機(jī)建模，得到所謂的數(shù)學(xué)化樣機(jī)，又稱虛擬樣機(jī)。采用虛擬樣機(jī)對(duì)所設(shè)計(jì)的機(jī)床進(jìn)行運(yùn)動(dòng)學(xué)仿真，在實(shí)際樣機(jī)試造出來(lái)之前對(duì)其進(jìn)行綜合評(píng)價(jià)，可以大大減少新產(chǎn)品研制的風(fēng)險(xiǎn)，縮短研制的周期，提高研制的質(zhì)量。
上述步驟可以反復(fù)進(jìn)行，知道達(dá)到設(shè)計(jì)結(jié)果滿意為止。在設(shè)計(jì)過(guò)程中，設(shè)計(jì)與評(píng)價(jià)反復(fù)進(jìn)行可以提高一次設(shè)計(jì)成功率。
VI定型設(shè)計(jì)
在上述步驟完成后，可進(jìn)行實(shí)物樣機(jī)的制造，實(shí)驗(yàn)及評(píng)論。根據(jù)實(shí)物樣機(jī)的評(píng)論結(jié)果進(jìn)行修改設(shè)計(jì)，最終完成產(chǎn)品的定型設(shè)計(jì)。
關(guān)于深孔加工的工藝要求
深孔加工 ，是本設(shè)計(jì)的重中之重 。所謂深孔，就是當(dāng)加工孔的長(zhǎng)度與直徑之比達(dá)10倍左右，往往對(duì)精度及表面光潔度又有較高要求，使用一般的加工方法就比較難滿足。
I.深孔加工必須解決的問(wèn)題：
1） 刀具細(xì)長(zhǎng)剛度差，易引起刀具偏斜及與孔壁摩擦，因此在刀頭上均具有導(dǎo)向套來(lái)保證正確引入；同時(shí)，根據(jù)需要設(shè)置刀桿支承以減少刀桿的變形和振動(dòng)。
2） 切屑不易排出，采用分級(jí)進(jìn)給或者通過(guò)高壓切削液的內(nèi)排和外排刀具結(jié)構(gòu)排出切屑。
3） 刀具冷卻困難，通入高壓切削液對(duì)刀具進(jìn)行充分冷卻。
II．深孔加工的類型：
結(jié)合深孔加工的特點(diǎn)，關(guān)于深孔加工的工藝?yán)щy，已有相應(yīng)的方法進(jìn)行克服。
1）分級(jí)進(jìn)給深孔加工：
使用普通麻花鉆頭在鑄鐵件或鋼件上鉆直徑6~10mm以下的孔時(shí)，一般一次鉆深不宜大于6~10倍孔徑。當(dāng)鉆孔方向?yàn)樗綍r(shí)，在鋼件上一次鉆深不宜大于6倍孔徑，在鑄鐵上可達(dá)10倍左右孔徑。如果加工的孔深超過(guò)這個(gè)范圍時(shí)，可采用分級(jí)進(jìn)給的加工方法，即在鉆削過(guò)程中，使鉆頭加工一定深度后自動(dòng)退出工件，借以排出切屑，并進(jìn)行冷卻，然后再重新向前加工，不斷往復(fù)，直至加工完畢（每次鉆深，鑄鐵件取3~6倍孔徑；鋼件取0.5~2倍孔徑，孔較深時(shí)取小值）。這種加工方法適于鉆削較小直徑的孔深，但生產(chǎn)率及技工精度都比較低。
2）一次進(jìn)給深孔加工
它主要是用各種類型的特殊刀頭，并配備形影的接桿、傳動(dòng)導(dǎo)向系統(tǒng)、切削液輸入器等，在深孔機(jī)床上進(jìn)行鉆、鉸、鏜及套料加工。從切屑的排出方式，可分外排屑（對(duì)鉸、鏜還可有向前或向后外排屑）及內(nèi)排屑；從切削刃數(shù)目，可以分單刃、雙刃及多刃，切削刃可采用高速鋼或硬質(zhì)合金。刀頭上均具有不同數(shù)量的導(dǎo)向支承塊，在加工過(guò)程中起導(dǎo)向作用，保證孔的平直度，同時(shí)也起擠光作用，提高加工孔的表面光潔度。
內(nèi)排屑深孔鉆具有單管內(nèi)排屑和雙管內(nèi)排屑（即噴射鉆）。雙管內(nèi)排屑深恐鉆比單管內(nèi)排屑深恐鉆及外排屑深孔鉆的加工效率和精度都較高。對(duì)不通的深孔進(jìn)行套料時(shí)，在套料完成后卸下套料刀，裝上芯棒切斷刀并使它的刀夾靠在芯棒上，通過(guò)專用進(jìn)給裝置進(jìn)行切斷，切斷到芯棒直徑4/5~5/6便退回切斷刀，稍加外力把芯棒折斷取出。
一般來(lái)說(shuō)，采用內(nèi)排屑比外排屑的加工直徑大，獲得的加工精度和表面光潔度高。
III.深孔加工的工作要點(diǎn)
機(jī)床在前及加工過(guò)程中，應(yīng)檢查和注意如下幾點(diǎn)：
1） 主軸、刀具導(dǎo)向套、刀桿支承套、工件支承套等中心線的不同軸度應(yīng)符合要求。
2） 檢查切削液系統(tǒng)是否暢通和正常工作，特備是多刃內(nèi)排屑深孔鉆（噴吸鉆）的噴吸效應(yīng)，尤其應(yīng)該認(rèn)真檢查。
3） 工件的加工端面上部應(yīng)有中心孔，并避免在斜面上鉆孔。
4） 切屑形狀是否正常。它與工件材料、刀具幾何形狀、切削用量等有關(guān)。兩條分離而每條按一定方向向內(nèi)卷曲的切削形狀最好，應(yīng)避免形成直的帶狀切屑。
5） 采用較高速度加工通孔，當(dāng)鉆頭即將鉆通時(shí)，最好停車或降速，防止損壞鉆頭和出口處。
6） 應(yīng)避免在加工過(guò)程中停車，如必須停車，則應(yīng)先停止進(jìn)給并將刀具退回一段距離，然后停止油泵和主運(yùn)動(dòng)的旋轉(zhuǎn)，以防刀具在孔中產(chǎn)生“咬死”現(xiàn)象。