模具高速铣削加工技术--------外文翻译.docx

MoldhighspeedmillingprocessingtechnologyTheabstractIntroducedthehighspeedmillinginthemoldprocessingapplicationaswellastheinfluence,andbriefintroductionhighspeedmillingenginebedstructure,controlsystemandcuttingtool.Hascarriedonthesimpleanalysistothehighspeedprocessingcraft.Keywordhighspeedmilling;moldprocessingFirst,forewordInthemodernmoldproduction,alongwithtomodelsartisticandthefunctionmustobtainmoreandmorehigh,modelstheinternalstructuretodesignmoreandmorecomplex,themoldcontourdesigndaybydayisalsocomplex,thefreecurvedsurfaceaccountsfortheproportiontoincreaseunceasingly,thecorrespondingmoldstructurealsodesignsmoreandmorecomplex.Theseallsetahigherrequesttothemoldprocessingtechnology,notonlyshouldguaranteethehighmanufactureprecisionandthesurfacequality,moreovermustpursuetheprocessingsurfaceartistic.Alongwithisunceasinglythoroughtothehighspeedprocessingengineeringresearch,isprocessingtheenginebed,thenumericalcontrolsystem,thecuttingtoolsystem,CAD/especiallyCorrelationtechnologyandsoonCAMsoftwaredevelopsunceasinglyundertheimpetus,highspeedprocessesthetechnologymoreandmoremanytoapplyinthemoldcavityprocessingandthemanufacture.Thenumericalcontrolhigh-speedcuttingprocessingtookinthemoldmanufactureamostimportantadvancedmanufacturetechnology,isthecollectionishighlyeffective,highquality,thelowconsumptioninabodyadvancedmanufacturetechnology.Isoppositeinthetraditionalmachining,itscuttingspeed,enteredtothespeedhadtheverybigenhancement,moreovercutthemechanismnottobesame.Thehigh-speedcuttingcausedthemachiningtohavetheleap,itsspecificpowermetalexcisionrateenhanced30%40%,thecuttingforcereduced30%,thecuttingtoolworkingdurabilityenhanced70%,remainedhotlylargescalereducesintheworkpiececutting,thelowstepshuddervanishednearly.Alongwiththecuttingspeedenhancement,unittimesemifinishedmaterialsmaterialremovingrateincreased,thecuttingtimereduced,theprocessingefficiencyenhanced,thusreducedtheproductmanufacturecycle,enhancedtheproductmarketcompetitivepower.Atthesametime,thehighspeedprocessingsmallamountenteredquicklycausesthecuttingforcetoreduce,thescraphighspeeddischargedreducedtheworkpiececuttingforceandthethermalloaddistorts,enhancestherigiditytobebadandthethinwallcomponentsmachiningpossibility.Becausecuttingforcereducing,therotationalspeedenhancementcausesthecuttingsystemtheoperatingfrequencytobefarawaytheenginebedthelowstepnaturalfrequency,buttheworkpiecesurfaceroughnessismostsensitivetothelowstepfrequency,fromthisreducedthesurfaceroughness.Inmoldhighhardsteelstock(HRC45HRC65)intheprocessingprocess,usesthehigh-speedcuttingtobepossibletosubstitutefortheworkingprocedurewhichtheelectricalfinishingandrubstruncatespolishes,thushasavoidedtheelectrodemanufactureandthetime-consumingelectricalfinishing,largescalereducedfitter,spolishingwithtothrowthelightquantity.Thinwal1moldworkpiecemoreandmoreneedswhichregardingsomemarketsin,thehighspeedmillingalsomaysmoothlycomplete,moreoverinthehighspeedmillingCNCprocessingcenter,amoldattireclampsmaycompletethemultiplexstepofprocessing.Thehighspeedprocessingtechnologyhashadthehugeinfluencetothemoldprocessingcraft,changedthetraditionalmoldprocessingtousezztheannealing-*millingprocessingfheattreatment-*torubtruncates'7or"theelectricsparkmachiningfmanuallypolishes,polishes"andsoonthecomplexlongtechnicalprocess,evenmightusethehigh-speedcuttingprocessingsubstitutionoriginalcompleteworkingprocedure.Thehighspeedprocessingtechnologybesidesmayapplyinthehardmoldcavitydirectprocessing(inparticularhalfprecisionworkandprecisionwork),inEDMaspectandsoonelectrodeprocessing,fasttypemanufacturealsoobtainedthewidespreadapplication.Themassproductionspracticeindicatedthat,theapplicationhigh-speedcuttingtechnologymaysaveinthemoldfollowingprocessing80%handworktogrindthetimeapproximately,savestheprocessingcostexpensenearly30%,themoldfaceworkprecisionmayreach1m,thecuttingtoolcuttingefficiencymayenhanceonetime.Second,highspeedmillingprocessingenginebedThehigh-speedcuttingtechnologyisoneofmachiningtechnologymaindevelopmentdirections,italongwithfoundationtechnologytheandsoonCNCtechnology,microelectronictechnology,newmaterialandnewstructuredevelopmentbutstepsahigherstair.Becausethemoldprocessesparticularaswellashighspeedprocessingtechnologyowncharacteristic,(processedenginebed,numericalcontrolsystem,cuttingtooltothemoldhighspeedprocessingrelatedtechnologyandthecraftsystemandsoon)proposedprocessedahigherrequestcomparedtothetraditionalmold.1. HighstableenginebedstrutpartThehigh-speedcuttingenginebedlathebedandsoonsupportstheparttobesupposedtohaveverywellmoves,thestaticrigidity,hotrigidityandbestdampingcharacteristic.Themajorityofenginebedsallusehighgrade,thehighrigidityandGaoKangzhangthegrayirontookthestrutpartmaterial,someenginebedcompaniesalsoincreasethehighdampingcharacteristicinthefoundationpolymerconcrete,byincreasesitsvibration-proofandthethermostability,thisnotonlymayguaranteetheenginebedprecisionisstable,alsomaypreventwhencuttingthecuttingtoolinspirestrembles.Usestheenclosedlathebeddesign,theoverallcastinglathebed,thesymmetricallathebedstructureandhasthedenselycoveredstiffenerandsoonalsoenhancestheenginebedstableimportantmeasure.Someenginebedcompanies,researchanddevelopmentdepartmentsindesignprocess,butalsousesthemodalityanalysisandthefiniteelementstructurecomputationandsoon,optimizedthestructure,stablycausestheenginebedstrutparttobereliable.2. EnginebedmainaxleThehighspeedenginebedmainaxleperformanceistherealizationhigh-speedcuttingprocessingimportantcondition.Thehigh-speedcuttingenginebedmainaxlerotationalspeedscopeis10000100000mMin,themainaxlepowerisbiggerthan15kW.Isnotbiggerthan0.005unthroughthemainaxlecompressedairoforaxialplaybetweenthecoolingsystemcontrolhiltandthemainaxle.Alsorequeststhemainaxletohavethefastverticalspeed,toassigntheperformancewhichthepositionisfaststops(namelytohaveextremelyhighangleadditionandsubtractionspeed),thereforethehighspeedmainaxleoftenusestheliquidstaticpressurebearingtype,theairstaticpressurebearingtype,thethermo-compressionnitridingsilicon(Si3N4)theceramicbearingmagnetismaerosolbearingtypeisostructuralismform.Lubricatesusestechnologyandsoonoilgaslubrication,splashlubrication.Themainaxlecoolsusesthemainaxleinteriorwatercoolinggenerallyoraircooled.3. TheenginebedactuatesthesystemInordertosatisfythemoldhighspeedprocessingtheneed,highspeedprocessestheenginebedtheactuationsystemtobesupposedtohavethefollowingcharacteristic:(1) highenteringforspeed.Theresearchindicatedthat,regardingtheminordiametercuttingtool,enhancestherotationalspeedandeachtoothentersforthequantityisadvantageousinreducesthecuttingtoolattrition.Atpresentcommonlyusedenteringforthespeedrangeis20'30mMin,likeusesleadsgreatlytheballbearingguidescrewtransmission,entersmayreach60mforthespeedMin;Usesthestraightlineelectricalmachinerythenmayenabletoachieve120mtothespeedMin.(2) highacceleration.Hasthegoodaccelerationcharacteristictothethreedimensionalcomplexcurvedsurfacesilhouettehighspeedprocessingrequestactuationsystem,therequestprovidesthedriverwhichthehighrapidadvanceorprogressgives(toenterspeedapproximately40mquicklyMin,the3Doutlineprocessingspeedis10mMin),canprovide0.4mS2to10mThes2accelerationandreducesthespeed.Theenginebedmanufacturermostlyusestheentireclosedlooppositionservo-controlslightlytolead,thegreatsize,thehighgradeballbearingguidescreworleadsgreatlymanyguidescrews.Alongwiththeelectricalmachinerytechnologydevelopment,theadvancedstraightlineelectricmotoralreadywaspublished,andthesuccessappliedintheCNCenginebed.TheadvancedstraightlinedirectmotordriveenabletheCNCenginebednolongertohavethemassinertia,inadvance,questionandsoonlagandvibration,speduptheservospeedofresponse,increasedtheservo-controlprecisionandtheenginebedprocessingprecision.4. NumericalcontrolsystemTheadvancednumericalcontrolsystemisguaranteedthemoldcomplexcurvedsurfacehighspeedprocessingqualityandtheefficiencykeyaspect,themoldhigh-speedcuttingprocessingtothenumericalcontrolsystembasicrequestis:A. Highspeednumericalcontrolreturnroute(Digitalcontrolloop),including:32orabove64bitparallelprocessorsand1.5Gbharddisk;Extremelyshortstraightlineelectricalmachinerysamplingtime.B. Speedandaccelerationfeed-forwardcontrol(Feedforwardcontrol);Digitalactuationsystemcrawlingcontrol(Jerkcontrol).C. Advancedinsertsmakesupthemethod(toinsertbasedontheNURBStransectmakesup),byobtainsthegoodsurfacequality,theprecisesizeandthehighgeometryprecision.D. Pretreatment(Look-ahead)function.Therequesthasthelargecapacitycushionregister,mayreadinadvanceandinspectsmanysegments(forexampletheDMGenginebedtobepossibletoreach500segments,theSimenssystemmayreacha10002000segment),inordertowhenisprocessedthesuperficialshape(curvature)changesmaypromptlyadoptchangesformeasureandsoonspeedbyavoidscuttingandsoon.E. Theerrorcompensatoryfunction,includingbecausethestraightlineelectricalmachinery,themainaxleandsoongivesoffheatthehoterrorwhichcausestocompensate,thequadrantalerrorcompensates,themeasurementsystemerrorcompensatesandsoonthefunction.Inaddition,themoldhigh-speedcuttingprocessingveryisalsohightothedatatransmissionspeedrequest.F. Thetraditionaldataconnection,liketheRS232serialmouthtransmissionspeedis19.2kb,butmanyadvancedprocessingscentershaveusedtheetherlocalareanetwork(Ethernet)tocarryonthedatatransmission,thespeedmayreach200kb.5. CoolinglubricationThehighspeedprocessingusesthebeltcoatingthehardalloytools,inhighspeed,thehightemperaturesituationdoesnotneedthecuttingcompound,thecuttingefficiencytobehigher.Thisisbecause:Themillingmainaxlehighspeedrevolves,thecuttingcompoundifachievedthecuttingarea,firstmustovercometheenormouscentrifugalforce;Evenifitovercamethecentrifugalforcetoenterthecuttingarea,alsowaspossibleasaresultofthecuttingareahightemperaturebuttoevaporateimmediately,thecoolingeffectverysmal1didnotevenhave;Atthesametimethecuttingcompoundcancausethecuttingtooledgeofaswordthetemperatureintensechange,iseasytocausethecracktheproduction,thereforemustpicktheoi1used/Gascoolinglubricationdrytypecuttingway.Thiswaymayusethecompressedgasrapidlythecuttingwhichthecuttingareaproduces,thusthemassivecuttingshotlywillcarryoff,atthesametimemightformsextremelythinmicroscopicprotectivefilmaftertheatomizationlubricatingoilinthecuttingtooledgeofaswordandtheworkpiecesurface,buteffectivelywilllengthenthecuttingtoollifeandenhancesthecomponentsthesurfacequality.Third,high-speedcuttingprocessingcuttingtoolThecuttingtoolisinthehigh-speedcuttingprocessingoneofmostactiveimportantfactors,itisaffectingtheprocessingefficiency,theproductioncostandtheproductprocessingprecisiondirectly.Thecuttingtoolmustwithstandloadandsoonhightemperature,highpressure,friction,impactandvibrationinthehighspeedprocessingprocess,thehigh-speedcuttingcuttingtoolshouldhavethegoodmachinecapabilityandthethermostability,namelyhasthegoodanti-impact,thewearabilityandresistsheatthewearycharacteristic.Thehigh-speedcuttingprocessingcuttingtooltechnologicaldevelopmentspeedisveryquick,applicationmanylikediamonds(PCD),cubicboronnitride(CBN),ceramiccuttingtool,coatinghardalloy,(carbon)titaniumnitrideshardalloyTIC(N)andsoon.Intheprocessingcastironandinthealloysteelcuttingtool,thehardalIoyisthemostcommonlyusedcuttingtoolmaterial.HardalIoytoolsresistancetoweargood,butthesolidityratiocubeboronnitrideandtheceramicsarelow.Inordertoenhancedegreeofhardnessandthesuperficiallyattractivefineness,usesthecuttingtoolcoatingtechnology,thecoatingmaterialforthetitaniumnitrides(TiN),thealuminiumnitridetitanium(TiALN)andsoon.Thecoatingtechnologycausesthecoatingbythesolecoatingdevelopmentformultilayered,themanykindsofcoatingmaterialcoating,hasbecomeoneofenhancementhigh-speedcuttingabilityessentialtechnical.Thediameterinthe10"40mmscope,alsohasthecarbontitaniumnitridescoatingthehardalloybittobeabletoprocesstheLuoriverdegreeofhardnesstobesmallerthan42materials,butthetitaniumnitridesaluminumcoatingcuttingtoolcanprocesstheLuoriverdegreeofhardnessis42evenhighermaterials.Whenhigh-speedcuttingsteelproducts,thecuttingtoolmaterialshouldselectthehotrigidityandthefatiguestrengthhighPkindofhardalloy,thecoatinghardalloy,thecubicboronnitride(CBN)andtheCBNcompoundcuttingtoolmaterial(WBN)andsoon.Thecuttingcastiron,shouldselectthefinegrainKkindofhardalloytocarryontheroughmachining,selectsthecompoundnitridedsiliconceramicsorthecrystalcombinationcubeboronnitride(PCNB)thecompoundcuttingtoolcarriesontheprecisionwork.Whenpreciseprocessingnon-ferrousmetalornonmetalliematerial,shouldselectcrystalcombinationdiamondPCDortheCVDdiamondcoatingcuttingtool.Whenchoicecuttingparameter,inviewofthecircularshearbladeandaballmillingcutter,shouldpayattentiontotheeffectivediametertheconcept.Thehighspeedmillingcuttingtoolshouldpressthebalancedesignmanufacture.Thecuttingtoolfrontanglemustbesmallerthantheconventionalcuttingtoolfrontangle,theclearanceangleisslightlybig.Thehostvice-cuttingedgeattachmentpointshouldthecavettoortheleadangle,increasesthevertexangle,preventstheknifepointplacehotattrition.Shouldenlargenearbytheknifepointthecuttingedgelengthandthecuttingtoolmaterialvolume,enhancesthecuttingtoolrigidity.Issafeintheguaranteeandsatisfiestheprocessingrequestunderthecondition,thecuttingtoolhangsextendsasfaraspossibleshort,cutterbodycentraltoughnessisfriendswith.Thehiltmustbesturdierthanthecuttingtooldiameter,connectsthehandletoassumebutactuallythepyramidal,byincreausesinthefinemillcomplexcurvedsurface.Fourth,moldhighspeedprocessingcraftThehighspeedprocessingincludingtakeremovestheremainderasthegoalroughmachining,theresidualroughmachining,aswellastakegainsthehighgradeprocessingsurfaceandtheslightstructureasthegoalhalfprecisionwork,theprecisionworkandthemirrorsurfaceprocessingandsoon.1. RoughmachiningThemoldroughmachiningessentialtargetispursuesintheunittimematerialremovingrate,andishalfprecisionworkpreparationworkpiecegeometryoutline.Inthehighspeedprocessingroughmachiningshouldadoptthecraftplanisthehighcuttingspeed,GaoJingivingrateandthesmallcuttingspecificationscombination.ThecontourprocessingwayisoneprocessingwaywhichthemultitudinousCAMsoftwareusesgenerally.UsingisspiralcontourandsoontheZaxiscontourtwowayswhicharemany,alsoisinprocessestheregiononlytimetofeed,indoesnotlifttheknifeinthesituationtoproducecontinuouslythesmoothcuttingtoolway,enters,drawsbacktheknifewaytousethecirculararctocutinto,tocut.Thespiralcontourwaycharacteristicis,hasnotwaitedthehighlevelbetweenthekniferoadmigration,mayavoidfrequentlyliftingtheknife,feedingtothecomponentssurfacequalityinfluenceandmechanicaldevicenonessentialconsuming.Toissteepandtheflatsiteprocessesseparately,thecomputationsuitscontourandsuitstheusesimilar3Dbiastheregion,andmayusethespiralway,inverylittleliftsthecuttingtoolwaywhichtheknifeinthesituationproducesoptimizes,obtainsthebettersurfacequality.Inthehighspeedprocessing,certainlymustadoptthecirculararctocutinto,tocuttheconnectionway,aswellasthecirculararctransition,avoidschangingthecuttingtooltoentersuddenlyforthedirection,theprohibitionusedirectunderknifeconnectionway,avoidsburyingthecuttingtooltheworkpiece.Whenprocessesthemoldcavity,shouldavoidthecutting