平面滚压塑性精成形和搓丝复合机的研制
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摘要
本论文是我的导师宋玉泉教授关于超塑性与塑性总体研究的一个组成部分。针对目前金属表面精加工中磨削所存在的缺陷与不足，尤其是对较软金属无法进行磨削加工的问题，宋老师根据连续局部塑性成形的原理，提出了采用滚压工艺加工金属表面，并对滚压工艺和设备作了专门研究。和滚压工艺相类似，搓丝也具有连续局部塑性成形的特点，宋老师据此又创造性地提出了将原有的滚压设备通过改造，重新设计出平面滚压和搓丝的复合加工设备——平面滚压塑性精成形和搓丝复合机。
平面滚压塑性精成形和搓丝复合机突破原有滚压设备只能进行滚压加工的限制，在机床的左右两端分别设有滚压工作台和搓丝工作台，从而使该设备能够同时完成平面滚压加工和螺纹搓丝加工，实现了“一机两用”。根据这一指导思想并结合液压牛头刨床的结构和相关搓丝设备，在确定滚压和搓丝两种工艺参数的基础上，提出了设备的总体设计方案，并完成了机床整机结构的设计，继而本文重点将对设备的液压系统、横向数控进给系统的机械传动装置以及搓丝机构进行设计。
As a mature processing procedure, the grinding technology is widely used in machine manufacuring industry. At present, altough the grinding process technology is used in precise processing the planes of metal workpieces, consumption of the grinding wheel is inevitable, and cooling fluid should be successively supplied in order to avoid grinding burn. Besides, there exist conglutination and jam in grinding , so it's a difficult prblem to grind for the non-ferrous metal workpieces, which isn't resolved.
Roller burnishing for metal planes which is one of the precise procesing technologies, successive patial plastic deformaton happens when the rolling pressure is exerted on the metal suface, so that the ultimate quality and performance of parts are improved and elevated, according to the principle that plastic deformation occurs under a cettain conditon. The technology has the following advatanges: high efficency, low consumption, low cost and adequate processing quality, also the machine is simple, the operation is convenient and the automatizaon is prone to be achieved.
Aimed at the problems and disadvantages of grinding, our research institute has made a series of systemic research on the techonoly and equipment of roller burnishing for metal plane, so that a deeper understanding of technological parameters of roller burnshing has been acquried, and by the reconstruction of the primary shaping machine, the specialized equipment used for roller burnershing for the plane is obtained.
From a lofty level, there are four follwing processing procedures: forging (including roller burnishing, extrusion and pressing), foundary (including die-casting and casting), powder metallurgy and cutting (including turing, milling, grinding etc). Theerinto, thread rolling is of high quality, high effiency, low cost and advanced processing procedure, which is one of thread cold press rolling technologies. The procedure is similary with roller burnishng in principle. That is to say, it is utilized by plasticity of metal material in the cold state and make the workpiece produce plastical deformation under the pressure of the thread rolling die, so that the corrsponding threads can be extruded. Especially for high effiency and high mechanical property precise parts with threads, it will show great advantage.
This paper is one important integral part of total research of my tutor Song Yuquan Professorhich is related to successive patial plastic precise deformaton and precise processing. First of all, according to the design alternative about the plastic and precise processing machine based on hydraulic shaper in the patent of utility model of Song Yuquan "Plastical processing device for metal planes".Exactly speaking, the motion direction of ram of the hydraulic shaper is considerd as power organ of X direction motion; the feed motion of the workbench is considerd as Y direation motion; Z direction feed motion device and it's control system are designed and manufactured by ourselves. At present, the Z direction feed device has been manufactured and completed, and the reconstructor of the hydraulic shaper is also fixed and debuged. As is known that the principle of the thread rolling technology is similary with roller burnnishing, and the two technologies both belong to successive partial plastic deformaton technology. Based on the above consideration and development work of roller burnishing plastic and precise processing technology and equipment for plane, Teacher Song advanced an innovative idea of roller burnishing and thread rolling compound machine with great consideration. Based on the roller burnishing specilized machine developed by our institute, the compound machine is reconstructed systemically and the function of thread rolling is added so that a new type machine-roller burnishing and thread rolling compound machine is formed. The machine can compelete precise roller burnishing of the planar parts on one end, and the thread rolling is completed on the other end, that is to say "two functions, one machine", so the basic scheme and design reason are determined. Under Teacher Song's guidance, the roller burnishing plastic and precise processing for plane and thread rolling compound machine is developed based on the characteristics and requirements of the two technologies roller burnishing for metal plane and thread rolling and combined with the work characteristics of the hydraulic pressure shaping machine. This paper is only a starting phase for the machine's design, so it still need a quantity of improvement, supplement and perfection work to turn into the model machine with low cost, automatic control, steady service and excellent operational characteristics.
Under the premise of data-collection and commentary in the rearch field the following work has been completed in the paper: according to the rearching findings of at home and broard and the rolling burnishing experiment carried through by our institute, the technological parameters of roller burnishing and thread rolling are determined respectively, and the quantities and characteristics of execution units are nailed down and the general design scheme of the machine is determined; according to the comparison with the characteristic of planing technology by the burnishing and thread rolling processing technologies, thread rolling set is added so that the the general machine's structer is determined and the three-dimensional assembly drawing and the plane views are drafted; the hydraulic pressure system of the machine is designed, principle drawing of hydraulic pressure system is drafted and the main parameters and structer form of the both pole piston hydraulic cylinder are determined and the main elements such as the hydraulic pump and hydraulic valves are selected; the drive mechanisms of the workbench is designed and especially it is important to complete numerical control innovation of the machine units of traverse feed driving system and critical components in the machine units are designed and calculated.
Compared with former roller burnishing specialized equipment, roller burnishing and thread rolling are carried out with the result that the function of the machine becomes more powerful. This machie synthetically employs mechanical skill, hydraulics, electronic technology and computer technology. The main movement in X direction is hydraulic transimmission which has some advantages, such as wide regulating velocity range, smooth velocities and the light impact at automatic reversing time; the workbench feeding locomotion in Y direction is realized by the numerical control way which can meet the requirement of accuracy of traverse feed amount in roller burnishing; the feeding device and the control system in Z direction are used to accurately adjust feed mount in Z direction in roller burnishing in order to adjust the burnishing force with the accuracy of 0.01mm, and the force transducer is employed to messure the burnishing force in roller burnishing processing. Roller burnishing and thread rolling compound machine is of high automation degree, precisely reord burnishing speed, burnishing force, and burnishing time, and automatically produce the force-time cureved line, speed-time curved line etc. Meanwhile the auto feed device will be used for thread rolling which will advance production rate greatly.
平面滚压塑性精成形和搓丝复合机突破原有滚压设备只能进行滚压加工的限制，在机床的左右两端分别设有滚压工作台和搓丝工作台，从而使该设备能够同时完成平面滚压加工和螺纹搓丝加工，实现了“一机两用”。根据这一指导思想并结合液压牛头刨床的结构和相关搓丝设备，在确定滚压和搓丝两种工艺参数的基础上，提出了设备的总体设计方案，并完成了机床整机结构的设计，继而本文重点将对设备的液压系统、横向数控进给系统的机械传动装置以及搓丝机构进行设计。
As a mature processing procedure, the grinding technology is widely used in machine manufacuring industry. At present, altough the grinding process technology is used in precise processing the planes of metal workpieces, consumption of the grinding wheel is inevitable, and cooling fluid should be successively supplied in order to avoid grinding burn. Besides, there exist conglutination and jam in grinding , so it's a difficult prblem to grind for the non-ferrous metal workpieces, which isn't resolved.
Roller burnishing for metal planes which is one of the precise procesing technologies, successive patial plastic deformaton happens when the rolling pressure is exerted on the metal suface, so that the ultimate quality and performance of parts are improved and elevated, according to the principle that plastic deformation occurs under a cettain conditon. The technology has the following advatanges: high efficency, low consumption, low cost and adequate processing quality, also the machine is simple, the operation is convenient and the automatizaon is prone to be achieved.
Aimed at the problems and disadvantages of grinding, our research institute has made a series of systemic research on the techonoly and equipment of roller burnishing for metal plane, so that a deeper understanding of technological parameters of roller burnshing has been acquried, and by the reconstruction of the primary shaping machine, the specialized equipment used for roller burnershing for the plane is obtained.
From a lofty level, there are four follwing processing procedures: forging (including roller burnishing, extrusion and pressing), foundary (including die-casting and casting), powder metallurgy and cutting (including turing, milling, grinding etc). Theerinto, thread rolling is of high quality, high effiency, low cost and advanced processing procedure, which is one of thread cold press rolling technologies. The procedure is similary with roller burnishng in principle. That is to say, it is utilized by plasticity of metal material in the cold state and make the workpiece produce plastical deformation under the pressure of the thread rolling die, so that the corrsponding threads can be extruded. Especially for high effiency and high mechanical property precise parts with threads, it will show great advantage.
This paper is one important integral part of total research of my tutor Song Yuquan Professorhich is related to successive patial plastic precise deformaton and precise processing. First of all, according to the design alternative about the plastic and precise processing machine based on hydraulic shaper in the patent of utility model of Song Yuquan "Plastical processing device for metal planes".Exactly speaking, the motion direction of ram of the hydraulic shaper is considerd as power organ of X direction motion; the feed motion of the workbench is considerd as Y direation motion; Z direction feed motion device and it's control system are designed and manufactured by ourselves. At present, the Z direction feed device has been manufactured and completed, and the reconstructor of the hydraulic shaper is also fixed and debuged. As is known that the principle of the thread rolling technology is similary with roller burnnishing, and the two technologies both belong to successive partial plastic deformaton technology. Based on the above consideration and development work of roller burnishing plastic and precise processing technology and equipment for plane, Teacher Song advanced an innovative idea of roller burnishing and thread rolling compound machine with great consideration. Based on the roller burnishing specilized machine developed by our institute, the compound machine is reconstructed systemically and the function of thread rolling is added so that a new type machine-roller burnishing and thread rolling compound machine is formed. The machine can compelete precise roller burnishing of the planar parts on one end, and the thread rolling is completed on the other end, that is to say "two functions, one machine", so the basic scheme and design reason are determined. Under Teacher Song's guidance, the roller burnishing plastic and precise processing for plane and thread rolling compound machine is developed based on the characteristics and requirements of the two technologies roller burnishing for metal plane and thread rolling and combined with the work characteristics of the hydraulic pressure shaping machine. This paper is only a starting phase for the machine's design, so it still need a quantity of improvement, supplement and perfection work to turn into the model machine with low cost, automatic control, steady service and excellent operational characteristics.
Under the premise of data-collection and commentary in the rearch field the following work has been completed in the paper: according to the rearching findings of at home and broard and the rolling burnishing experiment carried through by our institute, the technological parameters of roller burnishing and thread rolling are determined respectively, and the quantities and characteristics of execution units are nailed down and the general design scheme of the machine is determined; according to the comparison with the characteristic of planing technology by the burnishing and thread rolling processing technologies, thread rolling set is added so that the the general machine's structer is determined and the three-dimensional assembly drawing and the plane views are drafted; the hydraulic pressure system of the machine is designed, principle drawing of hydraulic pressure system is drafted and the main parameters and structer form of the both pole piston hydraulic cylinder are determined and the main elements such as the hydraulic pump and hydraulic valves are selected; the drive mechanisms of the workbench is designed and especially it is important to complete numerical control innovation of the machine units of traverse feed driving system and critical components in the machine units are designed and calculated.
Compared with former roller burnishing specialized equipment, roller burnishing and thread rolling are carried out with the result that the function of the machine becomes more powerful. This machie synthetically employs mechanical skill, hydraulics, electronic technology and computer technology. The main movement in X direction is hydraulic transimmission which has some advantages, such as wide regulating velocity range, smooth velocities and the light impact at automatic reversing time; the workbench feeding locomotion in Y direction is realized by the numerical control way which can meet the requirement of accuracy of traverse feed amount in roller burnishing; the feeding device and the control system in Z direction are used to accurately adjust feed mount in Z direction in roller burnishing in order to adjust the burnishing force with the accuracy of 0.01mm, and the force transducer is employed to messure the burnishing force in roller burnishing processing. Roller burnishing and thread rolling compound machine is of high automation degree, precisely reord burnishing speed, burnishing force, and burnishing time, and automatically produce the force-time cureved line, speed-time curved line etc. Meanwhile the auto feed device will be used for thread rolling which will advance production rate greatly.
引文
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