輸送機帶輪沖壓成形工藝與模具設(shè)計（落料拉深復(fù)合模+反拉深模具）,輸送,機帶輪,沖壓,成形,工藝,模具設(shè)計,落料拉深,復(fù)合,反拉深,模具 畢業(yè)設(shè)計（論文）答辯考核記錄表 機電工程學(xué)院 專業(yè) ：機械工程 班級：機械工程144 姓名：朱同 題 目： 輸送機帶輪沖壓成形工藝設(shè)計及模具設(shè)計 考 核 項 目 滿分值 得分 設(shè)計過程中的態(tài)度和能力表現(xiàn)（指導(dǎo)教師在答辯前填好） 1．學(xué)習(xí)態(tài)度 5 2．基本理論與專業(yè)知識掌握情況及獨立分析和解決問題的能力 15 評閱人評定 3．畢業(yè)設(shè)計（論文）、譯文 5 設(shè)計（論文）的質(zhì)量 （評委當場評定） 4．畢業(yè)設(shè)計（論文）質(zhì)量（設(shè)計結(jié)構(gòu)方案、圖紙、計算、外文） 30 5．設(shè)計（論文）的新見解及成果 5 答 辯 情 況 （評委當場評定） 6．自述情況 10 7．回答問題 30 評委簽字： 合計 幾 點 說 明： A、1．2由指導(dǎo)教師填寫3.由評閱人答辯前填好，否則該生不得進行答辯。 B、4．5．6．7由評委獨立評定。設(shè)計（論文）質(zhì)量的外文部分為5分，中文部分為20分。每個學(xué)生的外文翻譯不得少于3000漢字，另外必須用中、外文書寫畢業(yè)設(shè)計（論文）摘要。譯文需指導(dǎo)教師審改簽字，確認非抄襲，并附上原文，系、學(xué)院、教務(wù)處有權(quán)抽查考核。發(fā)現(xiàn)抄襲取消答辯資格，并追究指導(dǎo)教師責(zé)任。沒有外文翻譯不得參加答辯。 C、每一答辯小組答辯委員會不得少于5人。核分時將各評委所給分數(shù)去掉一個最高分和一個最低分后，再算其平均分數(shù)，并依此由各學(xué)院答辯委員會根據(jù)“優(yōu)秀”者嚴控（15%—20%）、“良”者適控（30%-40%）、“不及格”者慎重的原則加以平衡，按優(yōu)、良、中、及格、不及格五級記載。 2018年 06月 15日 Maciej SZAFARCZYK Jarosaw CHRZANOWSKI Radosaw GOCINIAK Warsaw University of Technology, Warsaw, Poland STRAIN GAUGE TOOL PROBE FOR NC LATHES Keywords: tool probe, strain gauge sensor, tool wear measurement, direct tool wear measurement. ABSTRACT The main role of tool probes in NC machine tools. The probes used now in industry and their drawbacks. The original concept of a tool probe using full strain gauge bridges for orientation of tool edges in four directions: +X, -X, +Z, -Z and for direct tool wear measurement. 1. INTRODUCTION The rapid development of all areas of manufacturing technology and the aim to reduce costs, increase precision and to shorten production time are enforcing the use of modern production technology. Dimensional parameters are the most commonly encountered quality characteristics of workpieces. Conventional machine tools are gradually being replaced in production plants by modern manufacturing systems, components of which, in the case of machining, are CNC machines. Main new CNC machines operate several different tools. To increase dimensions accuracy of components manufactured in CNC lathes we must use tool setting systems to know how the tools are located on the machine. Using traditional techniques, tool setting is time consuming and can be prone to human error. A touch probe system is an inspection equipment that allows a machine tool to perform geometrical measurements inside its working area, but besides tool tip coordinate identification, we must have information about tool wear. * The project has been financed from Multi-Year Programme PW-004, Institute for Sustainable Technologies - National Research Institute (ITeE - PIB) From all elements of manufacturing systems cutting edges wear is the fastest. In case of total wear we must replace a worn out tool with a sharp one. Cutting edge wear starts from first moment when touching the working material. Tool wear may be gradually, in case mechanical, chemical or temperature activity in turning process and we call them natural wear. In some cases tool wear is sudden when we have forces above the yield point and we call them catastrophic tool breakage (KSO). 2. INDUSTRIAL TOOL SETTING SYSTEMS When clamping a new tool on the machine or after the replacement of a worn out tool with a sharp one we must have information about orientation of tool edge. During writing the part program, the path of the tool tip is described by an assumed system co-ordinates, without knowing how the tools will be located in the machine. The corrective coordinates are defined during the orientation of the tool tip by the tool probe, and are then entered for every tool in the tool table stored in the machine control unit. While interpreting, the machine controller adjusts the points of the edge path by the values read from tool table. Figure 1 presents use of a standard touch trigger probe system for determination of X co-ordinate of the tool edge. Fig. 1. The use of a standard touch trigger probe system for determination of X co-ordinate of the tool edge 1. When tool tip touches probe stylus, the contact sensors in its result are opened, the value of the coordinate of the location of the saddle, which is read from the machine measuring system, is automatically entered into the register of the control unit reflecting the number of the measured tool and then the saddle motion is switched off. These probes only need to signalize that contact between tool tip and probe stylus was occurred. Standard tool setting system used touch-trigger probes. The most known is RP3 probing system (Figure 2) designed by Renishaw 2, 3. Fig. 2. Renishaw RP3 probe 3. The sensing of contact between workpiece and the probe is done by electric switches, witch strongly determine the repeatability and accuracy of probing. The original touch-trigger probe also called kinematic resistive Probe” (Figure 3), works with a set of three cylindrical pegs attached to the stylus. Each of them rests on two separated electric contacts that gives altogether six points of constraint for the six degrees of freedom of the stylus. An electric circuit is built out of these contacts, which is closed, when the stylus is in its neutral position. When the stylus touches the tool tip a further constraint point is added and so the pressure on one of the original constraint points is reduced, which changes the resistance of the electric circuit. The contact between stylus and tool tip is signaled when a certain threshold value of resistance is exceeded. Fig. 3. Touch-trigger probe 4. 3. INDUSTRIAL TOOL MONITORING SYSTEMS KSO must be detected very fast and after that we must provide necessary changes in turning process. That means that automation of turning process needs automatic detect and properly react in case of KSO. Method and range of this monitoring depend on process type. We have many industrial systems which can detect KSO. Natural wear is difficult to measure, but we dont need fast reaction from monitoring systems the reason are continuous changes of tool wear value. We have many industrial types of tool monitoring systems (Figure 4.), we measure: - cutting forces - effective power - torque - acoustic emission - differential pressure - distance measuring with cooling lubricant - jet barrier using laser, air or cooling lubricant Fig. 4. Tool monitoring systems (Nordmann). 5 We can mark out two types of monitoring in-process: monitoring and post-process tool monitoring. POST-PROCESS TOOL MONITORING Post-process tool monitoring is tantamount to geometry control of the tool cutting edge before or after the chip producing process with feelers, light barriers, or similar devices. Pro: - Sometimes high certainty of detection of breakage - Typically easier usage Contra: - Measurement can lengthen the production time - Machine is only stopped after tool breakage, i.e. possible damage to the work piece or the machine or the tool holder as a result of the forces incurred - Not all testing methods are free of wear IN-PROCESS TOOL MONITORING Indirect control during the metal cutting process of effective power, cutting force, or acoustic emission. Pro: - The measurement does not extend the production time - Machine is stopped at the moment of tool breakage - No additional installations (e.g. control switch) are necessary near the tool - Loss-free sensors. Contra: - Does not offer 100% guarantee of detection for all tool breakage - Sometimes the breakage is only detected when the next work piece is cut, e.g. in the case of thread cutting control with effective power and breakage at the moment of reversal of spin direction. All above industrial systems are not provide direct natural tool wear measurement. These methods mainly detect moment of the tool breakage or measure physical process parameters and based on these data, calculate natural tool wear. Mathematical description must include many process variables (e.g. heat expansion), consequently method based on mathematical models may have many errors even in self mathematical model which is only approximation of real process. 4. ORIGINAL PROBES FOR DIRECT TOOL WEAR MEASUREMENT AND FOR TOOL SETTING DESIGNED IN WARSAW UNIVERSITY OF TECHNOLOGY - STRAIN GAUGE PROBE A. PROBE FOR TOOL SETTING This is a new probe for identification of a tool tip co-ordinates on an NC lathes and for tool setting 6. The main part of this probe is a round bar. Stylus with crash protection device is connected with bar. The bar has two parallel flat surfaces on a part of its length. They are oriented under angle 45 in respect to X and Z axes of NC lathe (Figure 5). Fig. 5. Original measurement conception 7. Four strain gauges are glued on those flat surfaces (two of them are placed on the one side and the two other on the opposite side), the strain gauges are connected in a full bridge with all active gauges. This original design allows the possibility of tool tip co-ordinate identification in four directions of tool movement (-X, +X, -Z, +Z NC lathe axes) using only one full bridge sensor. When tool tip touches the probe stylus and moves forward, it deforms the flat and flexible part of bar. The maximum value of deformation must be kept below yield point defined by material properties. An actual value of analog electrical signal from strain gauges is compared continuously with a defined level of signal. When compared signals are equal, the comparator sends a signal to a NC machine controller to read value of the co-ordinate of location of the saddle from linear scale. The probe accuracy is placed in repeatability of generating this signal by comparator. Acceptable repeatability must be near 1m. B. PROBE FOR MEASURING TOOL WEAR Next probe is designed for both tool co-ordinate identification and tool wear evaluation in turning (Figure 7). The newest conception gives a possibility measuring the natural wear at the tool tip in the same time as identification of the tool co-ordinates. It is significant that both measuring components of the probe meet directly on the cutting plate. This allowed for elimination of errors e.g. unequal heat expansion of the seat and this plate. Strain gauges are mounted on the flexible sleeve and on the flat part of the bar (Figure 8). Worn part of the tool tip touches the first plate mounted on the bar, in next step base part of the tip (not worn) touches the second plate mounted on the sleeve. We have signals from both full strain bridges. Fig. 7. Tool probe for measuring tool wear. Fig. 8. Probe construction. Measurement of the new insert is used as a reference. During measurements after machining the obtained value is subtracted from the reference one and calculates current wear of the cutting edge (KE) (Figure 9). Fig. 9. KE calculation. When tool moves and touches plate mounted on the bar and flexing the bar. Reaching defined level of signal from strain gauges mounted on the bar is signaled by sending digital signal to machine control unit to identify tool tip coordinate. We also have continuous analog signal from gauges and we can calculate this signal to the value of plate dislocation. When tool moves forward not worn part of the tool tip touches second plate mounted on the sleeve and flexing the sleeve. Reaching defined level of signal is signaled by sending digital signal to control unit to remember actual analog value from gauges mounted on the bar. This value (subtracted to the reference one) is the current tool wear value (KE). We will try to use Siemens Siwarex U (Figure 10)- weighing module as a transducer. We can connect to them 2 full strain bridges and sending signals to machine control unit. We also consider building own control unit with cooperation with polish company ZEPWN 8. Fig. 10. Siemens Siwarex U weighing module 9. 5. CONCLUSION This probe will be an alternate solution in comparison with a standard tool probe. The strain gauges were never being used as a main part of a tool probe. The results of first tests demonstrate, that a probe with a strain gauge sensor based on presented original measurement conception, is suitable for both orientating the tool tip in the NC lathe co-ordinates and for tool wear measurement. After all tests we will try to adjust the probe for industrial application. REFERENCES 1. Coleman D., Waters F.: Fundamentals of touch trigger probing. 1997, Touch Trigger Press 2. Renishaw.: RP1 & RP2 Tool Setting Probe data sheet 3. RP3 Tool Setting Probe data sheet 4. A. Weckenmann, T. Estler, G. Peggs, D. McMurtry.: Probing Systems in Dimensional Metrology CIRP Annals STC P, 53/2/2004, p. 657 5. www.nordmann.de 6. Szafarczyk M., Winiarski A.: Tool probe. Patent application P.378785 Warszawa, 02.2006 r. 7. Gociniak R.: Strain gauge tool probe for NC lathes. 2006 IV International Conference on Machining and Measurement of Sculptured Surfaces 8. Zakad Elektroniki Pomiarowej Wielkoci Nieelektrycznych .pl 9. Siemens Siemens Siwarex U (One and Two-Channel Model) Equipment Manual. Relase 06/2005 應(yīng)變計刀具測量頭的數(shù)控車床 應(yīng)變計刀具測量頭的數(shù)控車床 關(guān)鍵詞：刀具探針、應(yīng)變式傳感器、刀具磨損的測量、直接測量刀具磨損 摘要： 在數(shù)控機床中刀具探測器是非常重要的。在現(xiàn)代工業(yè)中探測器的應(yīng)用及缺 點。按照常規(guī)的想法，刀具探測器充滿張力，測量儀橋梁刀具邊緣接受簡單指示，在切削刃的四個方向： + X，一X， + Z和- Z定向刀具磨損的直接測量中全部使用應(yīng)變橋。 1.導(dǎo)言 各領(lǐng)域制造技術(shù)的快速發(fā)展，以降低成本，提高精度和縮短生產(chǎn)時間的目標促進了現(xiàn)代生產(chǎn)技術(shù)的應(yīng)用。量綱參數(shù)是最常遇到的工件質(zhì)量特性 。常規(guī)機床正在逐步被生產(chǎn)廠中的現(xiàn)代化生產(chǎn)系統(tǒng)，機械加工的組成部分，數(shù)控機床所取代。主要的新的數(shù)控機床能操作幾種不同的刀具。 為了增加數(shù)控車床加工部件的尺寸精度，我們必須使用刀具設(shè)置系統(tǒng)來知道刀具是如何定位刀具機床上的。使用傳統(tǒng)的技術(shù)，刀具設(shè)置既耗費時間，又容易發(fā)生人為錯誤。觸摸探測系統(tǒng)是一種檢測設(shè)備，它允許機床在其工作區(qū)進行幾何測量，但除了刀尖坐標識別，我們還必須得到關(guān)于刀具磨損的信息。 該技術(shù)已被國家可持續(xù)技術(shù)研究所（IteE-PIB）資助研究多年。在制造系統(tǒng)所有組成部分中，切削刃磨損是最快的。如果達到磨損量，我們必須更換磨損刀具具急劇的那一個。切削刃磨損從第一次接觸的時候工作材料。我們必須將已磨損的刀具用一把鋒銳的刀具更換。切削刃磨損從第一次接觸的工作材料開始的時候。刀具的磨損可能是逐步的情況下，如果發(fā)生在機械，化學(xué)或溫度活動過程中，我們把他們稱作自然磨損。在某些情況下，刀具的磨損是突然的——當我們施加屈服點以上的壓力時，我們稱這種情況為災(zāi)難性的刀具破損（KSO）。 2.工業(yè)刀具設(shè)置系統(tǒng) 當把一把新刀具夾緊在機床上或更換完舊的刀具后，我們必須得到有關(guān)切削刃方向的信息。在編寫這部分程序時，刀尖路徑被一個假想的坐標系統(tǒng)描述出來，而不知道如何把這些刀具定位到機床中。糾正坐標是指通過刀具探針得到的刀尖位置，然后進入存儲在機器控制單元的所有刀具的工具表中。機床控制器就可以通過讀取工具表中的數(shù)據(jù)來調(diào)節(jié)刀具邊緣點路徑。 圖1 使用標準觸摸觸發(fā)探針系統(tǒng)系統(tǒng)確定刀具X坐標[ 1 ] 當?shù)都庥|及探針筆會使接觸傳感器打開，讀自機床測量系統(tǒng)的鞍架定位坐標值，會自動進入反映測量刀具數(shù)目的控制單元登記，然后鞍架運動停止。這些探針只需要表明刀尖和探針筆之間的聯(lián)系。 標準的工具設(shè)置系統(tǒng)使用觸摸式觸發(fā)探頭,最知名是由Renishaw設(shè)計的RP3探測系統(tǒng)（圖2）設(shè)計的雷尼紹[2,3] 。 圖2 雷尼紹RP3探針[ 3 ] 工件和探針之間的接觸是由電氣開關(guān)控制的，它強烈確定了探測的重要性和準確性。 原來的觸摸式觸發(fā)探頭也被稱為“運動電阻探針”（圖3），工作時有一套共三個圓柱形套筒相連在探針上。每個擁有兩個分開的電動聯(lián)系，使有六個自由度的筆共有六個方向的約束。一個封閉的電圈把他們聯(lián)系起來，這時探針位于他們的中間位置。當探針接觸到刀尖就會增加一點遠處的約束，而原來的約束受到的壓力會降低，這樣就改變了電圈的電阻。當超出一定的電阻值，探針與刀尖之間的聯(lián)系會以信號的形式傳出。 圖3 觸摸觸發(fā)探測器[ 4 ] 3.工業(yè)刀具監(jiān)控系統(tǒng) KSO檢測必須非?？?，然后我們必須在過程變化中提供必要的調(diào)整，這意味著調(diào)整過程的自動化需要自動檢測和適當?shù)姆磻?yīng)以免發(fā)生KSO。這種檢測的方法和范圍依靠過程的類型。 自然磨損是難以測量的，但我們并不需要監(jiān)測系統(tǒng)的快速反應(yīng)，原因是刀具磨損量的不斷變化。 我們有許多工業(yè)類型的刀具監(jiān)測系統(tǒng)（圖4） ，我們可以測量： 1、切削力 2.有效的功率 3、扭矩 4、聲發(fā)射 5、差壓 -冷卻潤滑劑遠程測量 -利用激光，空氣或冷卻潤滑劑噴射界限 圖4 刀具監(jiān)測系統(tǒng)（三代）[ 5 ] 我們來看生產(chǎn)過程刀具檢測和后處理刀具監(jiān)測兩種類型。 后處理刀具監(jiān)測 后處理工具監(jiān)測等于使用測隙規(guī)，遮光板或類似設(shè)備進行切削生產(chǎn)過程前或后的切削刃幾何測量。 優(yōu)點： (1) 有時高精度破損檢測 (2) 通常情況下更容易使用 缺點： (1) 測量會延長生產(chǎn)時間 (2) 機床只有刀具破損后才停止，否則可能會對工件，機床或刀柄產(chǎn)生損壞 (3) 并非所有的測試方法都不產(chǎn)生磨損 生產(chǎn)過程刀具檢測 在整個金屬切削過程中，有效功率，切削力或聲波的間接控制。 優(yōu)點： (1) 測量不延長生產(chǎn)時間 (2) 在刀具破損時機器立即停止 (3) 在靠近刀具時不需要額外的必須裝置（如控制開關(guān)） (4) 不需要傳感器。 缺點： (1) 不能提供100 ％的保證檢測所有的刀具破損 (2) 有時只有當下一個工件被切削時才能檢測到破損，例如在控制有效功率切削螺紋時，破損發(fā)生在旋轉(zhuǎn)方向逆轉(zhuǎn)時。 所有以上工業(yè)系統(tǒng)都不能提供直接的自然刀具磨損測量。這些方法主要是時刻檢測刀具的破損或測量物理過程參數(shù)，并根據(jù)這些數(shù)據(jù)來計算自然刀具磨損。 數(shù)學(xué)描述必須包括許多過程變量（如熱膨脹），因此基于數(shù)學(xué)模型的方法可能有許多錯誤，甚至在自我數(shù)學(xué)模型中也是只是逼近真實過程。 4.波蘭華沙大學(xué)設(shè)計的用于直接刀具測量和刀具設(shè)置的新型探針——應(yīng)變儀探針 A:刀具設(shè)置的探針 這是一個數(shù)控車床刀尖坐標確定和刀具設(shè)置的新型探針。它的主要部分是有一個圓桿，有著碰撞保護裝置的尖筆和圓桿連在一起。在圓桿的長度方向的一部分上有兩個平行的平面，它們相對于數(shù)控車床的X軸和Z軸面向下45度 （圖5） 。 圖5 原件測量的概念[ 7 ] 把四個應(yīng)變片貼在這些平面（其中兩個安置在一個面，而其它的兩個在相反的面上），應(yīng)變片連接在一個有全部壓力表的全橋上。這種新型設(shè)計使刀尖坐標確定在刀具的四個運動方向（數(shù)控車床主軸的-X,+X,-Z,+Z方向），并只使用一個全橋傳感器成為可能。 但刀尖觸碰到探針筆并向前移動時，這會使圓桿的水平易彎曲部分變形。變形的最大值必須保持在材料性能的屈服點以下。 將從應(yīng)變片的模擬電信號獲得的實際值不斷地與已定義的信號水平相比較。當信號相同時，就發(fā)送一個信號給數(shù)控機床控制器來從直尺上讀取鞍架的定位坐標。比較產(chǎn)生這一信號的重復(fù)性決定了探針的精度?？山邮艿闹貜?fù)性接近1微米。 B:用于測量刀具磨損的探針 下面探針設(shè)計的目的是為了校準時刀具坐標的識別和刀具磨損的評價（圖7）。最新的概念提供了一種在同一時間測量刀尖自然磨損的可能來作為刀具坐標的識別。重要的是探針的所有測量部分直接相會在扦插板上。這樣利于消除錯誤，如作為和板材的不均勻熱膨脹。應(yīng)變儀安裝在柔軟的套筒的圓桿的平面部分（圖8）。當?shù)都獾钠茡p部分接觸到安裝在圓桿的第一塊板，然后刀尖的基礎(chǔ)部分（沒有破損的）接觸到安裝在套筒上的第二塊板，我們就能從全橋應(yīng)變儀上得到信號。 圖7 刀具探針測量刀具的磨損 圖8 探索建設(shè) 新鑲嵌件的測量是用來作為一個參考。再加工后測量所獲得值是參考值與目前切削刃磨損計算量（柯）的差值（圖9）。 圖9 柯計算 當?shù)毒咭苿硬⒔佑|到安裝在圓桿上的板并使桿彎曲，從安裝到圓桿上的應(yīng)變儀得到的信號達到規(guī)定水平時，就會給機床控制單元傳送一個數(shù)字信號來確定刀尖坐標。我們連續(xù)不斷地從應(yīng)變儀獲得模擬信號并計算它們來得到板的偏差值。當?shù)毒呦蚯耙苿拥兜都獾姆瞧茡p部分，接觸到安裝在套筒上的第二塊板并使其變形并達到規(guī)定水平信號時，就會給控制單元發(fā)送一個數(shù)字信號來記憶從安裝在圓桿上的應(yīng)變儀上獲取的實際模擬值。這個值（減去參考數(shù)1）就是當前的刀具磨損量（柯）。 我們將嘗試使用西門子Siwarex u （圖10） -稱重模塊作為一個傳感器。 我們可以用兩個全橋應(yīng)變儀連接他們并向機床控制單元發(fā)送信號。我們也相同波蘭公司ZEPWN [ 8 ] 合作建立我們自己的控制單元。 圖10 西門子Siwarex U -稱重模塊[ 9 ] 5 結(jié)論 這個探測器與一個標準的刀具探針相比，將是一個替代的解決方案。應(yīng)變儀從來沒有被用來作為一個刀具探針的主要部分。第一次測試結(jié)果表明，該探針與應(yīng)變傳感器在原來測量概念的基礎(chǔ)上，適合于所有的數(shù)控車床刀尖坐標定位和刀具磨損測量。我們將努力調(diào)整以滿足工業(yè)需求。 參考資料 1 .Coleman D., Waters F.：接觸觸發(fā)探測基礎(chǔ)。 1997年 2 .Renishaw. ： RP1和RP2工具設(shè)置探討-數(shù)據(jù)表 3 . RP3工具設(shè)置探針-數(shù)據(jù)表 4 .A. Weckenmann, T. Estler, G. Peggs, D. McMurtry. ：探測系統(tǒng) 5 . www.nordmann.de 6 .Szafarczyk M., Winiarski A. ：工具探針。 專利申請P.378785 華沙， 02.2006 7 .Go?ciniak R.：應(yīng)變工具探針的數(shù)控車床。 8 .Zak?ad Elektroniki Pomiarowej Wielkosci Nieelektrycznych www.zepwn.com.pl 9 .西門子Siwarex u（一，雙通道模式）設(shè)備手冊。Relase 06/2005 10