2634 鋼管去毛刺技術(shù)研究及專(zhuān)用裝備設(shè)計(jì),鋼管,毛刺,技術(shù)研究,專(zhuān)用,裝備,設(shè)備,設(shè)計(jì) 河南理工大學(xué)萬(wàn)方科技學(xué)院本科畢業(yè)設(shè)計(jì)（論文）中期檢查表指導(dǎo)教師： 曲海軍 職稱： 副教授 所在院（系）： 機(jī)械與動(dòng)力工程學(xué)院 教研室（研究室）：機(jī)械制造系 題 目 鋼管去毛刺技術(shù)研究及專(zhuān)用裝備設(shè)計(jì)學(xué)生姓名 尚磊 專(zhuān)業(yè)班級(jí) 10 專(zhuān)升本—2 班 學(xué)號(hào) 0816101038選題質(zhì)量：（主要從以下四個(gè)方面填寫(xiě)：1、選題是否符合專(zhuān)業(yè)培養(yǎng)目標(biāo)，能否體現(xiàn)綜合訓(xùn)練要求；2、題目難易程度；3、題目工作量；4、題目與生產(chǎn)、科研、經(jīng)濟(jì)、社會(huì)、文化及實(shí)驗(yàn)室建設(shè)等實(shí)際的結(jié)合程度）（1）該題將機(jī)械、去毛刺加工、材料學(xué)相關(guān)原理與直縫鋼管加工的原理、結(jié)構(gòu)相結(jié)合，具有一定的理論性與操作性。通過(guò)完成該論文可以對(duì)機(jī)械學(xué)有基本了解，掌握一些機(jī)械學(xué)基本理論知識(shí)。（2）該題難度適中，既有理論的研究又有試驗(yàn)操作,同時(shí)在生產(chǎn)實(shí)習(xí)的設(shè)計(jì)又可以增強(qiáng)動(dòng)手能力，提高綜合素質(zhì)。（3）周查閱畢業(yè)設(shè)計(jì)材料，整理適合自己的畢業(yè)設(shè)計(jì)信息并完成設(shè)計(jì)初稿,并對(duì)畢業(yè)設(shè)計(jì)進(jìn)行完善。（4）對(duì)高頻直縫焊管的內(nèi)外毛刺進(jìn)行清除，是生產(chǎn)高檔次高頻直縫焊管的一個(gè)重要工藝過(guò)程和手段，對(duì)于內(nèi)毛刺清除精度要求較高的產(chǎn)品，如果內(nèi)毛刺清除質(zhì)量滿足不了標(biāo)準(zhǔn)或用戶要求，將無(wú)法實(shí)施批量生產(chǎn)。相比外毛刺的清除工作，內(nèi)毛刺的清除是一項(xiàng)復(fù)雜工作。在實(shí)際生產(chǎn)過(guò)程中的許多因素均會(huì)影響到內(nèi)毛刺清除質(zhì)量，即內(nèi)毛刺清除的精度和清除過(guò)程的穩(wěn)定性。采用在線去毛刺裝置，除了改善去毛刺質(zhì)量，還可以提高生產(chǎn)質(zhì)量，在實(shí)現(xiàn)鋼管成型及去毛刺同步時(shí)，也穩(wěn)定了輸出質(zhì)量。因此，有必要對(duì)各種影響因素進(jìn)行分析，采取相應(yīng)的措施，以改善高頻直縫焊管內(nèi)毛刺的清除效果和提高產(chǎn)品檔次，在線去毛刺裝置的設(shè)計(jì)對(duì)于提高生產(chǎn)質(zhì)量和節(jié)約生產(chǎn)成本有著重要意義。二、開(kāi)題報(bào)告完成情況：開(kāi)題報(bào)告已如期按要求完成，并上交審核。三、階段性成果：1.在資料的收集與整理過(guò)程中，對(duì)磨粒加工有初步了解，掌握部分相關(guān)磨粒加工學(xué)原理。2.認(rèn)真學(xué)習(xí)關(guān)于機(jī)械學(xué)、磨粒加工、材料學(xué)等有關(guān)理論知識(shí)，為下一階段的工作打下堅(jiān)實(shí)的基礎(chǔ)。3.完成開(kāi)題報(bào)告。4.列出論文題綱，著手理論部分。5.同時(shí)搜集噴油嘴去毛刺的相關(guān)資料，有待進(jìn)一步分析整理。四、存在主要問(wèn)題：1．資料收集還不全面，一些理論與應(yīng)用相結(jié)合的實(shí)踐做的還不好2．部分公式推導(dǎo)還不熟練3. Word 文字排版、公式編輯不太熟練4.CAD、Proe 軟件操作不熟練五、指導(dǎo)教師對(duì)學(xué)生在畢業(yè)實(shí)習(xí)中，勞動(dòng)、學(xué)習(xí)紀(jì)律及畢業(yè)設(shè)計(jì)（論文）進(jìn)展等方面的評(píng)語(yǔ)指導(dǎo)教師： （簽名）年 月 日河南理工大學(xué)萬(wàn)方科技學(xué)院本科畢業(yè)設(shè)計(jì)（論文）開(kāi)題報(bào)告題目名稱 鋼管去毛刺技術(shù)研究及專(zhuān)用裝備設(shè)計(jì)學(xué)生姓名 尚磊 專(zhuān)業(yè)班級(jí) 10 專(zhuān)升本—2 班 學(xué)號(hào) 0816101038一、 選題的目的和意義：近年來(lái)，通過(guò)引進(jìn)國(guó)外先進(jìn)技術(shù)及對(duì)引進(jìn)技術(shù)的消化吸收，我國(guó)高頻直縫焊管的生產(chǎn)技術(shù)裝備水平不斷提高，高頻直縫焊管的產(chǎn)品質(zhì)量和檔次也有了很大的提升，產(chǎn)品的用途越來(lái)越廣泛。對(duì)高頻直縫焊管的內(nèi)外毛刺進(jìn)行清除，是生產(chǎn)高檔次高頻直縫焊管的一個(gè)重要工藝過(guò)程和手段，對(duì)于內(nèi)毛刺清除精度要求較高的產(chǎn)品，如果內(nèi)毛刺清除質(zhì)量滿足不了標(biāo)準(zhǔn)或用戶要求，將無(wú)法實(shí)施批量生產(chǎn)。相比外毛刺的清除工作，內(nèi)毛刺的清除是一項(xiàng)復(fù)雜工作。在實(shí)際生產(chǎn)過(guò)程中的許多因素均會(huì)影響到內(nèi)毛刺清除質(zhì)量，即內(nèi)毛刺清除的精度和清除過(guò)程的穩(wěn)定性。采用在線去毛刺裝置，除了改善去毛刺質(zhì)量，還可以提高生產(chǎn)質(zhì)量，在實(shí)現(xiàn)鋼管成型及去毛刺同步時(shí)，也穩(wěn)定了輸出質(zhì)量。因此，有必要對(duì)各種影響因素進(jìn)行分析，采取相應(yīng)的措施，以改善高頻直縫焊管內(nèi)毛刺的清除效果和提高產(chǎn)品檔次，在線去毛刺裝置的設(shè)計(jì)對(duì)于提高生產(chǎn)質(zhì)量和節(jié)約生產(chǎn)成本有著重要意義。二、 國(guó)內(nèi)外研究綜述：在焊管剛剛開(kāi)始興起的19 世紀(jì)40～50 年代,人們對(duì)電焊管內(nèi)毛刺的清除是沒(méi)什么要求的。后來(lái)由于工業(yè)的發(fā)展, 如汽車(chē)、鍋爐、石油等行業(yè)需要比較精密的焊管 , 強(qiáng)調(diào)要求清除焊管內(nèi)毛刺, 這才開(kāi)始電焊管內(nèi)毛刺清除裝置的研制與開(kāi)發(fā)。20 世紀(jì)60 年代, 我國(guó)絕大部分焊管生產(chǎn)企業(yè)的焊管機(jī)組都是Φ101.6 mm ( 4 in) 以下的, 到了70 年代中期才開(kāi)始研制電焊管內(nèi)毛刺清除裝置。原首鋼焊管廠首先開(kāi)始使用固定式刀架, 先由人工調(diào)整, 將刀架上的刀片對(duì)準(zhǔn)需要切削的毛刺。雖然試生產(chǎn)石油管已達(dá)到一個(gè)較高的水平, 內(nèi)毛刺殘留高度僅為0～0.2 mm, 但由于原料、成型、焊接、合格率等因素的影響, 還需要做進(jìn)一步的研究。后來(lái)又采用了浮動(dòng)式( 彈簧或氣動(dòng)) 刀架, 如我國(guó)在20 世紀(jì)80年代初從日本引進(jìn)的Φ90 mm 焊管機(jī)組就是采用了彈簧浮動(dòng)式刀架。我國(guó)采用的是螺旋彈簧, 而國(guó)外采用的是板式彈簧。2這種刀架存在需要熟練工人操作, 起動(dòng)動(dòng)作要慢, 彈簧必須調(diào)至合適壓力等不利因素, 從而影響其進(jìn)一步發(fā)展。當(dāng)時(shí)國(guó)外的刀架由3 個(gè)部件組成, 如美國(guó)Nelson 工具公司的清除內(nèi)毛刺刀架采用了板式彈簧, 通過(guò)其支承力使刀頭伸入毛刺中, 利用刀削原理刮削毛刺。其優(yōu)點(diǎn)是結(jié)構(gòu)簡(jiǎn)單, 制造方便; 其缺點(diǎn)是彈簧經(jīng)常處于高溫、潮濕的空氣以及氧化鐵皮飛揚(yáng)的環(huán)境下很容易失效, 彈力消失, 刮出的毛刺常常達(dá)不到要求。21 世紀(jì)初，江蘇徐州某鋼管公司引進(jìn)了 Φ139.7mm、Φ73 mm 兩種規(guī)格的液壓式內(nèi)毛刺清除裝置，用于 Φ219 mm 焊管機(jī)組 ERW 油套管的開(kāi)發(fā)生產(chǎn)。該裝置的刀頭為環(huán)形刀, 刀座和刀座架可在垂直方向上相對(duì)調(diào)整, 下支承輥輪的脹縮通過(guò)液壓管路在操作臺(tái)上進(jìn)行調(diào)整, 固定架具有沿垂直方向調(diào)整的功能, 沿中心桿軸線調(diào)整和旋轉(zhuǎn)的功能。其刀頭使用壽命長(zhǎng), 調(diào)整方便、精確, 液壓壓力穩(wěn)定, 大大提高了ERW 直縫焊油套管內(nèi)毛刺的清除質(zhì)量和焊管機(jī)組的作業(yè)率, 保證了焊縫狀態(tài)的穩(wěn)定性。三、 畢業(yè)設(shè)計(jì)（論文）所用的主要技術(shù)與方法：1.在學(xué)校圖書(shū)館查閱相關(guān)資料；2.在工廠的進(jìn)行畢業(yè)實(shí)習(xí)；3.通過(guò)老師和工程師的指導(dǎo)；4.通過(guò)對(duì)相關(guān)資料和數(shù)據(jù)的理論計(jì)算和分析；5.用 AotuCAD 進(jìn)行畫(huà)圖。四、 主要參考文獻(xiàn)與資料獲得情況：[1] 劉志儉.ERW 直縫焊管內(nèi)毛刺清除裝置的發(fā)展[J].鋼管 2006（3）：7-12[2] 雷建德. 提高高頻直縫焊管內(nèi)毛刺清除質(zhì)量的措施[J].鋼管 2005（4）：17-20[3] 秦宗旺等. 去毛刺技術(shù)手冊(cè)[M]. 北京：宇航出版社，1995. [4] 機(jī)械零件去毛刺工藝[J] 中國(guó)農(nóng)業(yè)機(jī)械出版社 1998（1）[5] 陳靜剛. 機(jī)械式直縫焊管內(nèi)毛刺清除裝置[J].機(jī)械制造與自動(dòng)化2006（3）：70-71，74[6] 康霞明. 直縫焊管內(nèi)毛刺清除裝置結(jié)構(gòu)原理分析[J].焊管 2005（5）：54-55[7] 杭情. 直縫焊管內(nèi)毛刺刨刀[J].焊管 2005（4）：31-31[8] 王文瀚. 焊接技術(shù)手冊(cè)[M]. 鄭州: 河南科學(xué)技術(shù)出版社, 19993[9] 曹福永.新型高頻焊接鋼管制造工藝的開(kāi)發(fā)[J] .冶金設(shè)備. 2002（6）：78-78[10] 關(guān)振中. 激光加工工藝學(xué)手冊(cè)[M]. 北京：中國(guó)計(jì)量出版社，1998.[11] 熊有倫等.去毛刺技術(shù)[M]. 北京：機(jī)械工業(yè)出版社，1993.[12] 王承義. 機(jī)械手及其應(yīng)用[M]. 北京：機(jī)械工業(yè)出版社，1981.五、 畢業(yè)設(shè)計(jì)（論文）進(jìn)度安排（按周說(shuō)明）1-4 周進(jìn)行并完成畢業(yè)實(shí)習(xí)報(bào)告；5 周完成開(kāi)題報(bào)告；6-9 周查閱畢業(yè)設(shè)計(jì)材料，整理適合自己的畢業(yè)設(shè)計(jì)信息并完成設(shè)計(jì)初稿；10-12 周對(duì)畢業(yè)設(shè)計(jì)進(jìn)行完善；13-14 周完成畢業(yè)設(shè)計(jì)；15 周 畢業(yè)設(shè)計(jì)上交導(dǎo)師準(zhǔn)備答辯；16 周 進(jìn)行畢業(yè)答辯。六、 指導(dǎo)教師審批意見(jiàn)：指導(dǎo)教師： （簽名）年 月 日 河南理工大學(xué)萬(wàn)方科技學(xué)院本科畢業(yè)設(shè)計(jì)外文資料與中文翻譯院（系部） 機(jī)械與動(dòng)力工程系 專(zhuān)業(yè)名稱 機(jī)械設(shè)計(jì)制造及其自動(dòng)化 年級(jí)班級(jí) 08 級(jí)機(jī)制 5 班 學(xué)生姓名 尚 磊 指導(dǎo)教師 曲海軍 2011 年 5 月 15 日 NC Technology1、Research current situation of NC lathe in our timesResearch and development process to such various kinds of new technologies as numerical control lathe , machining center , FMS , CIMS ,etc. of countries all over the world, linked to with the international economic situation closely. The machine tool industry has international economy to mutually promote and develop, enter 21 alert eras of World Affairs, the function that people's knowledge plays is more outstanding , and the machine tool industry is regarded as the foundation of the manufacturing industry of the machine, its key position and strategic meaning are more obvious. Within 1991-1994 years, the economic recession of the world, expensive FMS, CIMS lowers the temperature, among 1995-2000 years, the international economy increases at a low speed, according to requisition for NC lathe and the world four major international lathes exhibition in order to boost productivity of users of various fields of present world market (EMO , IMTS , JIMTOF , China CIMT of Japan of U.S.A. of Europe), have the analysis of the exhibit, there are the following several points mainly in the technical research of NC lathe in our times:（1） 、Pay more attention to new technology and innovationWorldwide , are launching the new craft , new material , new structure , new unit , research and development of the new component in a more cost-effective manner, developmental research of for instance new cutter material , the new electric main shaft of main shaft structure , high speed , high-speed straight line electrical machinery ,etc.. Regard innovating in improvement of the processing technology as the foundation, for process ultra and hard difficult to cut material and special composite and complicated part , irregular curved surface ,etc. research and develop new lathe variety constantly.（2） 、Improve the precision and research of machine toolingIn order to improve the machining accuracy of the machining center , are improving rigidity of the lathe , reduction vibration constantly, dispel hotly and out of shape, reduce the noise , improve the precision of localization of NC lathe , repeat precision , working dependability , stability , precision keeping, world a lot of country carry on lathe hot error , lathe sport and load out of shape software of error compensate technical research, take precision compensate , software compensate measure improve , some may make this kind of error dispel 60% already. And is developing retrofit constantly, nanometer is being processed.（3） 、I mprove the research of the machine tooling productivityWorld NC lathe, machining center and corresponding some development of main shaft , electrical machinery of straight line , measuring system , NC system of high speed, under the prerequisite of boosting productivity.（4） 、W hat a lot of countries have already begun to the numerical control system melt intelligently, openly, study networkedlyA、 elligent research of the numerical control systemMainly showing in the following aspects: It is intelligent in order to pursue the efficiency of processing and process quality, the self-adaptation to the processing course is controlled, the craft parameter produces research automatically; Join the convenient one in order to improve the performance of urging and use intelligently, to the feedback control , adaptive operation , discerning automatically load selects models automatically , since carries on research whole definitely ,etc. of the electrical machinery parameter; There are such research of the respect as intelligent automatic programming , intelligent man-machine interface , intelligence diagnosing , intelligent monitoring ,etc..B、 The numerical control system melts and studies openMainly showing in the following aspects: The development of the numerical control system is on unified operation platform, face the lathe producer and support finally, through changing, increasing or cutting out the structure target(numerical control target ), form the seriation, and can use users specially conveniently and the technical know-how is integrated in the control system, realize the open numerical control system of different variety , different grade fast, form leading brand products with distinct distinction. System structure norm of the open numerical control system at present, norm , disposing the norm , operation platform , numerical control systematic function storehouse and numerical control systematic function software developing instrument ,etc. are the core of present research to pass through.C、Meeting the manufacture system of the production line , demand for the information integration of the manufacturing company networkedly greatly of numerical control equipment, it is a basic unit of realizing the new manufacture mode too.2、Classification of the machining center（1）P rocess according to main shaft space position when it classifies to be as follows, horizontal and vertical machining center.Horizontal machining center, refer to the machining center that the axis level of the main shaft is set up . Horizontal machining center for 3-5 sport coordinate axis, a common one three rectilinear motion coordinate axis and one turn the coordinate axis of sports round (turn the workingbench round), it can one is it is it finish other 4 Taxi processing besides installing surfaces and top surfaces to insert to install in work piece, most suitable for processing the case body work piece . Compared with strength type machining center it, the structure is complicated, the floor space is large, quality is large, the price is high.Vertical machining center, the axis of the main shaft of the vertical machining center, in order to set up vertically, its structure is mostly the regular post type, the workingbench is suitable for processing parts for the slippery one of cross, have 3 rectilinear motion coordinate axis generally , can find a room for one horizontal numerical control revolving stage (the 4th axle ) of axle process the spiral part at workingbench. The vertical machining center is of simple structure, the floor space is small, the price is low, after allocating various kinds of enclosures , can carry on the processing of most work pieces .Large-scale gantry machining center, the main shafts are mostly set up vertically, is especially used in the large-scale or with complicated form work piece , is it spend the many coordinate gantry machining center to need like aviation , aerospace industry , some processing of part of large-scale steam turbine.Five machining centers, this kind of machining center has function of the vertical and horizontal machining center, one is it after inserting , can finish all five Taxi processing besides installing the surface to install in work piece, the processing way can make form of work piece error lowest , save 2 times install and insert working, thus improve production efficiency , reduce the process cost.(2)Classify by craft useIs it mill machining center to bore, is it mill for vertical door frame machining center , horizontal door frame mill the machining center and Longmen door frame mill the machining center to divide into. Processing technology its rely mainly on the fact that the door frame is milled, used in case body, shell and various kinds of complicated part special curve and large processes , curved surface of outline process, suitable for many varieties to produce in batches small.Complex machining center, point five times and compound and process mainly, the main shaft head can be turned round automatically, stand, lie and process, after the main shaft is turned round automatically, realize knowing that varies in the horizontal and vertical direction.(3)Classify by special functionSingle workingbench , a pair of workingbench machining center;Single axle , dual axle , three axle can change machining center , main shaft of case;Transfer vertically to the tower machining center and transfer ;One hundred sheets of storehouses adds the main shaft and changes one one hundred sheets of machining centers;One hundred sheets of storehouses connects and writes hands to add the main shaft and change one hundred sheets of machining centers; One hundred sheets of storehouses adds the manipulator and adds one pair of main shafts to transfer to the tower machining center.3、Development trend of the current numerical control latheAt present, the advanced manufacturing technology in the world is rising constantly, such application of technology as ultrafast cutting , ultraprecision processing ,etc., the rapid development of the flexible manufacturing system and integrated system of the computer one is constant and ripe, have put forward higher demand to the process technology of numerical control. Nowadays the numerical control lathe is being developed in several following directions.（1）. The speed and precision at a high speed , high accuracy are two important indexes of the numerical control lathe , it concerns directly that processes efficiency and product quality. At present, numerical control system adopt-figure number, frequency high processor, in order to raise basic operation speed of system. Meanwhile , adopt the super large-scale integrated circuit and many microprocessors structure, in order to improve systematic data processing ability , namely improve and insert the speed and precision of mending operation. Adopt the straight line motor and urge the straight line of the lathe workingbench to be servo to enter to the way directly, it is quite superior that its responds the characteristic at a high speed and dynamically. Adopt feedforward control technology , make it lag behind error reduce greatly , thus improve the machining accuracy cut in corner not to track.For meet ultrafast demand that process, numerical control lathe adopt main shaft motor and lathe structure form that main shaft unite two into one, realize frequency conversion motor and lathe main shaft integrate , bearing , main shaft of electrical machinery adopt magnetism float the bearing , liquid sound pigeonhole such forms as the bearing or the ceramic rolling bearing ,etc.. At present, ceramic cutter and diamond coating cutter have already begun to get application.（2）. Multi-functional to is it change all kinds of machining centers of organization (a of capacity of storehouse can up to 100 of the above ) automatically to furnished with, can realize milling paring , boring and pares , bores such many kinds of processes as paring , turning , reaming , reaming , attacking whorl ,etc. to process at the same time on the same lathe , modern numerical control lathe adopt many main shaft , polyhedron cut also , carry on different cutting of way process to one different position of part at the same time. The numerical control system has because adopted many CPU structure and cuts off the control method in grades, can work out part processing and procedure at the same time on a lathe , realize so-called " the front desk processes , the backstage supporter is an editor ". In order to meet the needs of integrating the systematic one in flexible manufacturing system and computer, numerical control system have remote serial interface , can network , realize data communication , numerical control of lathe, can control many numerical control lathes directly too.（3）. Intelligent modern numerical control lathe introduce the adaptive control technology, according to cutting the change of the condition, automatic working parameter, make the processing course can keep the best working state , thus get the higher machining accuracy and roughness of smaller surface , can improve the service life of the cutter and production efficiency of the equipment at the same time . Diagnose by oneself , repair the function by oneself, among the whole working state, the system is diagnosed, checked by oneself to CNC system and various kinds of equipment linking to each other with it at any time. While breaking down , adopt the measure of shutting down etc. immediately , carry on the fault alarm, brief on position , reason to break down ,etc.. Can also make trouble module person who take off automatically , put through reserve module , so as to ensure nobody demand of working environment. For realize high trouble diagnose that requires , its development trend adopts the artificial intelligence expert to diagnose the system.（4）. Numerical control programming automation with the development of application technology of the computer, CAD/CAM figure interactive automatic programming has already get more application at present, it is a new trend of the technical development of numerical control. It utilize part that CAD draw process pattern , is it calculate the trailing punishing to go on by cutter orbit data of computer and then, thus produce NC part and process the procedure automatically, in order to realize the integration of CAD and CAM. With the development of CIMS technology , the full-automatic programming way in which CAD/CAPP/CAM integrates has appeared again at present, it, and CAD/CAM systematic programming great difference their programming necessary processing technology parameter needn't by artificial to participate in most, get from CAPP database in system directly.（5）. The dependability of the dependability maximization numerical control lathe has been the major indicator that users cared about most all the time . The numerical control system will adopt the circuit chip of higher integrated level , will utilize the extensive or super large-scale special-purpose and composite integrated circuit, in order to reduce the quantity of the components and parts , to improve dependability . Through the function software of the hardware, in order to meet various kinds of demands for controlling the function, adopt the module , standardization , universalization and seriation of the structure lathe noumenonn of the hardware at the same time , make not only improve the production lot of the hardware but also easy to is it produce to organize and quality check on.. Still through operating and starting many kinds of diagnostic programs of diagnosing , diagnosing , diagnosing off-line online etc. automatically, realize that diagnoses and reports to the police the trouble to hardware , software and various kinds of outside equipment in the system. Utilize the warning suggestion, fix a breakdown in time; Utilize fault-tolerant technology, adopt and design the important part " redundantly ", in order to realize the trouble resumes by oneself; Utilize various kinds of test , control technology , exceed Cheng , one one hundred sheets of damages , interfering , cutting out ,etc. at the time of various kinds of accidents as production, carry on corresponding protection automatically.（6）. Control system miniaturization systematic miniaturization of numerical control benefit and combine the machine , electric device for an organic whole. Adopt the super large-scale integrated component , multi-layer printed circuit board mainly at present, adopt the three-dimensional installation method , make the electronic devices and components must use the high density to install, narrow systematic occupying the space on a larger scale. And utilize the new-type slim display of colored liquid crystal to substitute the traditional cathode ray tube, will make the operating system of numerical control miniaturize further. So can install it on the machine tool conveniently, benefit the operation of the numerical control lathe correctly even more.本文出自：Shigley J E. Mechanical Engineering Design. New York: McGraw-Hill, 1998數(shù)控技術(shù)1、當(dāng)前世界 NC 機(jī)床的研究現(xiàn)狀世界各國(guó)對(duì)數(shù)控機(jī)床、加工中心以至 FMS、CIMS 等各種新技術(shù)的研究與發(fā)展進(jìn)程，是與世界經(jīng)濟(jì)形勢(shì)緊密相連的。機(jī)床工業(yè)有世界經(jīng)濟(jì)相互促進(jìn)和發(fā)展，進(jìn)入 21 世界知識(shí)機(jī)警時(shí)代，人們的知識(shí)所起的作用更加突出，而機(jī)床工業(yè)作為機(jī)器制造業(yè)的基礎(chǔ)，其重點(diǎn)地位與戰(zhàn)略意義也更加明顯。在 1991—1994 年間，世界經(jīng)濟(jì)衰退，昂貴的 FMS，CIMS 降溫，1995—2000 年間，世界經(jīng)濟(jì)在低速增長(zhǎng)，根據(jù)當(dāng)前世界市場(chǎng)各方面用戶為提高生產(chǎn)率對(duì) NC 機(jī)床的要求以及世界四大國(guó)際機(jī)床展（歐洲的 EMO、美國(guó)的 IMTS、日本的 JIMTOF、中國(guó)的CIMT）上展品的分析，當(dāng)前世界 NC 機(jī)床的技術(shù)研究主要有以下幾點(diǎn)：（1） 、更加重視新技術(shù)和創(chuàng)新在世界范圍內(nèi)，對(duì)新工藝、新材料、新結(jié)構(gòu)、新單元、新元件的研究開(kāi)發(fā)工作正在大力開(kāi)展，如新的刀具材料、新的主軸結(jié)構(gòu)、高速電主軸、高速直線電機(jī)等的開(kāi)發(fā)研究。以加工工藝的改進(jìn)創(chuàng)新為基礎(chǔ)，為加工超硬、難切削材料及特殊復(fù)合材料及復(fù)雜零件、不規(guī)則曲面等在不斷研究開(kāi)發(fā)新機(jī)種。（2） 、提高機(jī)床加工的精度和研究為了提高加工中心的加工精度，不斷提高機(jī)床的剛度、減少振動(dòng)，消除熱變形，降低噪聲，提高 NC 機(jī)床的定位精度、重復(fù)精度、工作可靠性、穩(wěn)定性、精度保持性，世界很多國(guó)家都在進(jìn)行機(jī)床熱誤差、機(jī)床運(yùn)動(dòng)及負(fù)載變形誤差的軟件補(bǔ)償技術(shù)研究，并采取精度補(bǔ)償、軟件補(bǔ)償?shù)却胧┘右愿纳?，有的已?jīng)可以使此類(lèi)誤差消除 60%。并在不斷開(kāi)發(fā)精細(xì)加工，納米加工。（3） 、提高機(jī)床加工生產(chǎn)率的研究世界 NC 機(jī)床、加工中心及相應(yīng)的高速點(diǎn)主軸、直線電機(jī)、測(cè)量系統(tǒng)、 NC系統(tǒng)的開(kāi)發(fā)，均以提高生產(chǎn)率為前提。（4） 、許 多 國(guó) 家 都 已 經(jīng) 開(kāi) 始 對(duì) 數(shù) 控 系 統(tǒng) 的 智 能 化 、 開(kāi) 放 化 、 網(wǎng)絡(luò) 化 研 究A、數(shù)控系統(tǒng)的智能化的研究主要表現(xiàn)在：為追求加工效率和加工質(zhì)量的智能化，對(duì)加工過(guò)程的自適應(yīng)控制，工藝參數(shù)自動(dòng)生成進(jìn)行研究；為提高驅(qū)動(dòng)性能及使用連接方便的智能化，對(duì)反饋控制、電機(jī)參數(shù)的自適應(yīng)運(yùn)算、自動(dòng)識(shí)別負(fù)載自動(dòng)選定模型、自整定等進(jìn)行研究；還有智能化的自動(dòng)編程、智能化的人機(jī)界面、智能診斷、智能監(jiān)控等方面的研究。B、數(shù)控系統(tǒng)開(kāi)放化研究主要表現(xiàn)在：數(shù)控系統(tǒng)的開(kāi)發(fā)在統(tǒng)一的運(yùn)行平臺(tái)上，面向機(jī)床廠家和最終擁護(hù)，通過(guò)改變、增加或剪裁結(jié)構(gòu)對(duì)象（數(shù)控對(duì)象） ，形成系列化，并可方便地將用戶的特殊應(yīng)用和技術(shù)訣竅集成到控制系統(tǒng)中，快速實(shí)現(xiàn)不同品種、不同檔次的開(kāi)放式數(shù)控系統(tǒng)，形成具有鮮明個(gè)性的名牌產(chǎn)品。目前開(kāi)放式數(shù)控系統(tǒng)的體系結(jié)構(gòu)規(guī)范、通行規(guī)范、配置規(guī)范、運(yùn)行平臺(tái)、數(shù)控系統(tǒng)功能庫(kù)以及數(shù)控系統(tǒng)功能軟件開(kāi)發(fā)工具等是當(dāng)前研究的核心。C、數(shù)控裝備的網(wǎng)絡(luò)化將極大地滿足生產(chǎn)線制造系統(tǒng)、制造企業(yè)對(duì)信息集成的需求，也是實(shí)現(xiàn)新的制造模式的基礎(chǔ)單元。2、加工中心的分類(lèi)（1）按主軸加工時(shí)的空間位置分類(lèi)有：臥式和立式加工中心。臥式加工中心，是指主軸軸線水平設(shè)置的加工中心。臥式加工中心一般具有 3—5 個(gè)運(yùn)動(dòng)坐標(biāo)軸，常見(jiàn)的是三個(gè)直線運(yùn)動(dòng)坐標(biāo)軸和一個(gè)回轉(zhuǎn)運(yùn)動(dòng)坐標(biāo)軸（回轉(zhuǎn)工作臺(tái)） ，它能在工件一次裝夾完成除安裝面和頂面以外的其余 4 個(gè)面的加工，最適合加工箱體類(lèi)工件。它與力式加工中心相比，結(jié)構(gòu)復(fù)雜，占地面積大，質(zhì)量大，價(jià)格高。立式加工中心，立式加工中心主軸的軸線為垂直設(shè)置，其結(jié)構(gòu)多為固定立柱式，工作臺(tái)為十字滑臺(tái)，適合加工盤(pán)類(lèi)零件，一般具有 3 個(gè)直線運(yùn)動(dòng)坐標(biāo)軸，并可在工作臺(tái)上安置一個(gè)水平軸的數(shù)控轉(zhuǎn)臺(tái)（第 4 軸）來(lái)加工螺旋類(lèi)零件。立式加工中心結(jié)構(gòu)簡(jiǎn)單，占地面積小，價(jià)格低，配備各種附件后，可進(jìn)行大部分工件的加工。大型龍門(mén)式加工中心，主軸多為垂直設(shè)置，尤其使用于大型或形狀復(fù)雜的工件，像航空、航天工業(yè)及大型汽輪機(jī)上的某些零件的加工都需要用這類(lèi)多坐標(biāo)龍門(mén)式加工中心。五面加工中心，這種加工中心具有立式和臥式加工中心的功能，在工件一次裝夾后，能完成除安裝面外的所有五個(gè)面的加工，這種加工方式可以使工件的形狀誤差降到最低，省去二次裝夾工作，從而提高生產(chǎn)效率，降低加工成本。（2）按工藝用途分類(lèi)有：鏜銑加工中心，分為立式樘銑加工中心、臥式樘銑加工中心和龍門(mén)樘銑加工中心。其加工工藝以樘銑為主，用于箱體，殼體以及各種復(fù)雜零件特殊曲線和曲面輪廓的多工序加工，適合多品種小批量生產(chǎn)。復(fù)合加工中心，主要指五面復(fù)合加工，主軸頭可自動(dòng)回轉(zhuǎn)，進(jìn)行立，臥加工，在主軸自動(dòng)回轉(zhuǎn)后，在水平和垂直方向?qū)崿F(xiàn)知道變換。（3）按特殊功能分類(lèi)有：?jiǎn)喂ぷ髋_(tái)、雙工作臺(tái)加工中心；單軸、雙軸、三軸及可換主軸箱的加工中心；立式轉(zhuǎn)塔加工中心和臥式轉(zhuǎn)塔加工中心；刀庫(kù)加主軸換刀加工中心；刀庫(kù)接寫(xiě)手加主軸換刀加工中心；刀庫(kù)加機(jī)械手加雙主軸轉(zhuǎn)塔加工中心。3、當(dāng)今數(shù)控機(jī)床的發(fā)展趨勢(shì)：目前，世界先進(jìn)制造技術(shù)不斷興起，超高速切削、超精密加工等技術(shù)的應(yīng)用，柔性制造系統(tǒng)的迅速發(fā)展和計(jì)算機(jī)集成系統(tǒng)的不斷成熟，對(duì)數(shù)控加工技術(shù)提出了更高的要求。當(dāng)今數(shù)控機(jī)床正在朝著以下幾個(gè)方向發(fā)展。（1）.高速度、高精度化速度和精度是數(shù)控機(jī)床的兩個(gè)重要指標(biāo)，它直接關(guān)系到加工效率和產(chǎn)品質(zhì)量。目前，數(shù)控系統(tǒng)采用位數(shù)、頻率更高的處理器，以提高系統(tǒng)的基本運(yùn)算速度。同時(shí)，采用超大規(guī)模的集成電路和多微處理器結(jié)構(gòu)，以提高系統(tǒng)的數(shù)據(jù)處理能力，即提高插補(bǔ)運(yùn)算的速度和精度。并采用直線電動(dòng)機(jī)直接驅(qū)動(dòng)機(jī)床工作臺(tái)的直線伺服進(jìn)給方式，其高速度和動(dòng)態(tài)響應(yīng)特性相當(dāng)優(yōu)越。采用前饋控制技術(shù)，使追蹤滯后誤差大大減小，從而改善拐角切削的加工精度。為適應(yīng)超高速加工的要求，數(shù)控機(jī)床采用主軸電動(dòng)機(jī)與機(jī)床主軸合二為一的結(jié)構(gòu)形式，實(shí)現(xiàn)了變頻電動(dòng)機(jī)與機(jī)床主軸一體化，主軸電機(jī)的軸承采用磁浮軸承、液體動(dòng)靜壓軸承或陶瓷滾動(dòng)軸承等形式。目前，陶瓷刀具和金剛石涂層刀具已開(kāi)始得到應(yīng)用。（2）.多功能化配有自動(dòng)換刀機(jī)構(gòu)(刀庫(kù)容量可達(dá) 100 把以上)的各類(lèi)加工中心，能在同一臺(tái)機(jī)床上同時(shí)實(shí)現(xiàn)銑削、鏜削、鉆削、車(chē)削、鉸孔、擴(kuò)孔、攻螺紋等多種工序加工，現(xiàn)代數(shù)控機(jī)床還采用了多主軸、多面體切削，即同時(shí)對(duì)一個(gè)零件的不同部位進(jìn)行不同方式的切削加工。數(shù)控系統(tǒng)由于采用了多 CPU 結(jié)構(gòu)和分級(jí)中斷控制方式，即可在一臺(tái)機(jī)床上同時(shí)進(jìn)行零件加工和程序編制，實(shí)現(xiàn)所謂的“前臺(tái)加工，后臺(tái)編輯” 。為了適應(yīng)柔性制造系統(tǒng)和計(jì)算機(jī)集成系統(tǒng)的要求，數(shù)控系統(tǒng)具有遠(yuǎn)距離串行接口，甚至可以聯(lián)網(wǎng)，實(shí)現(xiàn)數(shù)控機(jī)床之間的數(shù)據(jù)通信，也可以直接對(duì)多臺(tái)數(shù)控機(jī)床進(jìn)行控制。（3）.智能化現(xiàn)代數(shù)控機(jī)床將引進(jìn)自適應(yīng)控制技術(shù)，根據(jù)切削條件的變化，自動(dòng)調(diào)節(jié)工作參數(shù)，使加工過(guò)程中能保持最佳工作狀態(tài)，從而得到較高的加工精度和較小的表面粗糙度，同時(shí)也能提高刀具的使用壽命和設(shè)備的生產(chǎn)效率。具有自診斷、自修復(fù)功能，在整個(gè)工作狀態(tài)中，系統(tǒng)隨時(shí)對(duì) CNC 系統(tǒng)本身以及與其相連的各種設(shè)備進(jìn)行自診斷、檢查。一旦出現(xiàn)故障時(shí)，立即采用停機(jī)等措施，并進(jìn)行故障報(bào)警，提示發(fā)生故障的部位、原因等。還可以自動(dòng)使故障模塊脫機(jī)，而接通備用模塊，以確保無(wú)人化工作環(huán)境的要求。為實(shí)現(xiàn)更高的故障診斷要求，其發(fā)展趨勢(shì)是采用人工智能專(zhuān)家診斷系統(tǒng)。（4）.數(shù)控編程自動(dòng)化隨著計(jì)算機(jī)應(yīng)用技術(shù)的發(fā)展，目前 CAD／CAM 圖形交互式自動(dòng)編程已得到較多的應(yīng)用，是數(shù)控技術(shù)發(fā)展的新趨勢(shì)。它是利用 CAD繪制的零件加工圖樣，再經(jīng)計(jì)算機(jī)內(nèi)的刀具軌跡數(shù)據(jù)進(jìn)行計(jì)算和后置處理，從而自動(dòng)生成 NC 零件加工程序，以實(shí)現(xiàn) CAD 與 CAM 的集成。隨著 CIMS 技術(shù)的發(fā)展，當(dāng)前又出現(xiàn)了 CAD／CAPP／CAM 集成的全自動(dòng)編程方式，它與CAD／ CAM 系統(tǒng)編程的最大區(qū)別是其編程所需的加工工藝參數(shù)不必由人工參與，直接從系統(tǒng)內(nèi)的 CAPP 數(shù)據(jù)庫(kù)獲得。（5）.可靠性最大化數(shù)控機(jī)床的可靠性一直是用戶最關(guān)心的主要指標(biāo)。數(shù)控系統(tǒng)將采用更高集成度的電路芯片，利用大規(guī)?；虺笠?guī)模的專(zhuān)用及混合式集成電路，以減少元器件的數(shù)量，來(lái)提高可靠性。通過(guò)硬件功能軟件化，以適應(yīng)各種控制功能的要求，同時(shí)采用硬件結(jié)構(gòu)機(jī)床本體的模塊化、標(biāo)準(zhǔn)化和通用化及系列化，使得既提高硬件生產(chǎn)批量，又便于組織生產(chǎn)和質(zhì)量把關(guān)。還通過(guò)自動(dòng)運(yùn)行啟動(dòng)診斷、在線診斷、離線診斷等多種診斷程序，實(shí)現(xiàn)對(duì)系統(tǒng)內(nèi)硬件、軟件和各種外部設(shè)備進(jìn)行故障診斷和報(bào)警。利用報(bào)警提示，及時(shí)排除故障；利用容錯(cuò)技術(shù)，對(duì)重要部件采用“冗余”設(shè)計(jì)，以實(shí)現(xiàn)故障自恢復(fù)；利用各種測(cè)試、監(jiān)控技術(shù)，當(dāng)生產(chǎn)超程、刀損、干擾、斷電等各種意外時(shí)，自動(dòng)進(jìn)行相應(yīng)的保護(hù)。（6）.控制系統(tǒng)小型化數(shù)控系統(tǒng)小型化便于將機(jī)、電裝置結(jié)合為一體。目前主要采用超大規(guī)模集成元件、多層印刷電路板，采用三維安裝方法，使電子元器件得以高密度安裝，較大規(guī)模縮小系統(tǒng)的占有空間。而利用新型的彩色液晶薄型顯示器替代傳統(tǒng)的陰極射線管，將使數(shù)控操作系統(tǒng)進(jìn)一步小型化。這樣可以方便地將它安裝在機(jī)床設(shè)備上，更便于對(duì)數(shù)控機(jī)床的操作使用。