電極片沖孔、落料、彎曲連續模設計

電極片沖孔、落料、彎曲連續模設計,畢業設計,設計 1英文說明英文說明 highhighhighhigh speedspeedspeedspeed millingmillingmillingmilling processingprocessingprocessingprocessing technologytechnologytechnologytechnologyHnmanHnmanHnmanHnman FoctorsFoctorsFoctorsFoctors RessearchRessearchRessearchRessearch UnitUnitUnitUnit;Institute;Institute;Institute;Institute ofofofof soundsoundsoundsound andandandand preventionpreventionpreventionprevention vibrationvibrationvibrationvibration Rsearch.Rsearch.Rsearch.Rsearch.UnUnUnUniv iv iv iversityersityersityersity ofofofof SouthamptonSouthamptonSouthamptonSouthampton so17so17so17so17.IBJ.UK.IBJ.UK.IBJ.UK.IBJ.UKTheTheTheThe abstractabstractabstractabstractIntroduced the high speed milling in the mold processing application aswell as the influence,and brief introduction high speed milling engine bed structure,controlsystem and cutting tool.Has carried on the simple analysis to the high speed processingcraft.KeyKeyKeyKey wordwordwordwordhighhighhighhigh speedspeedspeedspeed milling;milling;milling;milling;mmmmoldoldoldold processingprocessingprocessingprocessingFirst,First,First,First,forewordforewordforewordforewordIn the modern mold production,along with to models artistic and the function mustobtain more and more high,models the internal structure to design more and more complex,the mold contour design day by day is also complex,the free curved surface accounts for theproportion to increase unceasingly,the corresponding mold structure also designs more andmore complex.These all set a higher request to the mold processing technology,not onlyshould guarantee the high manufacture precision and the surface quality,moreover mustpursue the processing surface artistic.Along with is unceasingly thorough to the high speedprocessing engineering research,is processing the engine bed,the numerical control system,the cutting tool system,CAD/especially Correlation technology and so on CAM softwaredevelops unceasingly under the impetus,high speed processes the technology more andmore many to apply in the mold cavity processing and the manufacture.The numerical control high-speed cutting processing took in the mold manufacture amost important advanced manufacture technology,is the collection is highly effective,highquality,the low consumption in a body advanced manufacture technology.Is opposite in thetraditional machining,its cutting speed,entered to the speed had the very big enhancement,moreover cut the mechanism not to besame.The high-speed cutting caused the machiningto have the leap,its specific power metal excision rate enhanced 30%40%,the cutting2force reduced 30%,the cutting tool working durability enhanced 70%,remained hotly largescale reduces in the work piece cutting,the low step shudder vanished nearly.Along withthe cutting speed enhancement,unit time semifinished materials material removing rateincreased,the cutting time reduced,the processing efficiency enhanced,thus reduced theproduct manufacture cycle,enhanced the product market competitive power.At the sametime,the high speed processing small amount entered quickly causes the cutting force toreduce,the scrap high speed discharged reduced the work piece cutting force and thethermal load distorts,enhances the rigidity to be bad and the thin wall componentsmachining possibility.Because cutting force reducing,the rotational speed enhancementcauses the cutting system the operating frequency to be far away the engine bed the low stepnatural frequency,but the work piece surface roughness is most sensitive to the low stepfrequency,from this reduced the surface roughness.In mold high hard steel stock(HRC45HRC65)in the processing process,uses the high-speed cutting to be possible tosubstitute for the working procedure which the electrical finishing and rubs truncatespolishes,thus has avoided the electrode manufacture and the time-consuming electricalfinishing,large scale reduced fitters polishing with to throw the light quantity.Thin wallmold work piece more and more needs which regarding some markets in,the high speedmilling also may smoothly complete,moreover in the high speed milling CNC processingcenter,a mold attire clamps may complete the multiplex step of processing.The high speed processing technology has had the huge influence to the moldprocessing craft,changed the traditional mold processing to use the annealing millingprocessing heat treatment to rub truncates or the electric spark machining manually polishes,polishes and so on the complex long technical process,even might usethe high-speed cutting processing substitution original complete working procedure.Thehigh speed processing technology besides may apply in the hard mold cavity directprocessing(in particular half precision work and precision work),in EDM aspect and so onelectrode processing,fast type manufacture also obtained the widespread application.Themass productions practice indicated that,the application high-speed cutting technology maysave in the mold following processing 80%handwork to grind the time approximately,saves the processing cost expense nearly 30%,the mold face work precision may reach 1 m,the cutting tool cutting efficiency may enhance one time.Second,Second,Second,Second,highhighhighhigh speedspeedspeedspeed millingmillingmillingmilling processingprocessingprocessingprocessing engineengineengineengine bedbedbedbed3The high-speed cutting technology is one of machining technology main developmentdirections,it along with foundation technology the and so on CNC technology,microelectronic technology,new material and new structure development but steps a higherstair.Because the mold processes particular as well as high speed processing technologyown characteristic,(processed engine bed,numerical control system,cutting tool to themold high speed processing related technology and the craft system and so on)proposedprocessed a higher request compared to the traditional mold.1.1.1.1.HighHighHighHigh stablestablestablestable engineengineengineengine bedbedbedbed strutstrutstrutstrut partpartpartpartThe high-speed cutting engine bed lathe bed and so on supports the part to be supposedto have very well moves,the static rigidity,hot rigidity and best damping characteristic.Themajority of engine beds all use high grade,the high rigidity and Gao Kangzhang the grayiron took the strut part material,some engine bed companies also increase the high dampingcharacteristic in the foundation polymer concrete,by increases its vibration-proof and thethermostability,this not only may guarantee the engine bed precision is stable,also mayprevent when cutting the cutting tool inspires trembles.Uses the enclosed lathe bed design,the overall casting lathe bed,the symmetrical lathe bed structure and has the denselycovered stiffener and so on also enhances the engine bed stable important measure.Someengine bed companies research and development departments in design process,but alsouses the modality analysis and the finite element structure computation and so on,optimizedthe structure,stably causes the engine bed strut part to be reliable.2.2.2.2.EngineEngineEngineEngine bedbedbedbed mainmainmainmain axleaxleaxleaxleThe high speed engine bed main axle performance is the realization high-speed cuttingprocessing important condition.The high-speed cutting engine bed main axle rotationalspeed scope is 10000100000m/Min,the main axle power is bigger than 15kW.Is notbigger than 0.005mm through the main axle compressed air of or axial play between thecooling system control hilt and the main axle.Also requests the main axle to have the fastvertical speed,to assign the performance which the position is fast stops(namely to haveextremely high angle addition and subtraction speed),therefore the high speed main axleoften uses the liquid static pressure bearing type,the air static pressure bearing type,thethermo-compression nitriding silicon(Si3N4)the ceramic bearing magnetism aerosolbearing type isostructuralism form.Lubricates uses technology and so on oil gas lubrication,splash lubrication.The main axle cools uses the main axle interior water cooling generallyor air cooled.43.3.3.3.TheTheTheThe engineengineengineengine bedbedbedbed actuatesactuatesactuatesactuates thethethethe systemsystemsystemsystemIn order to satisfy the mold high speed processing the need,high speed processes theengine bed the actuation system to be supposed to have the following characteristic:(1)(1)(1)(1)highhighhighhigh enteringenteringenteringentering forforforfor speed.speed.speed.speed.The research indicated that,regarding the minor diameter cutting tool,enhances therotational speed and each tooth enters for the quantity is advantageous in reduces the cuttingtool attrition.At present commonly used entering for the speed range is 2030m/Min,likeuses leads greatly the ball bearing guide screw transmission,enters may reach 60m/for thespeedMin;Uses the straight line electrical machinery then may enable to achieve 120m/tothe speedMin.(2)(2)(2)(2)highhighhighhigh acceleration.acceleration.acceleration.acceleration.Has the good acceleration characteristic to the three dimensional complex curvedsurface silhouette high speed processing request actuation system,the request provides thedriver which the high rapid advance or progress gives(to enter speed approximately 40m/quicklyMin,the 3D outline processing speed is 10m/Min),can provide 0.4m/S2 to 10m/Thes2 acceleration and reduces the speed.The engine bed manufacturer mostly uses the entire closed loop position servo-controlslightly to lead,the great size,the high grade ball bearing guide screw or leads greatly manyguide screws.Along with the electrical machinery technology development,the advancedstraight line electric motor already was published,and the success applied in the CNCengine bed.The advanced straight line direct motor drive enable the CNC engine bed nolonger to have the mass inertia,in advance,question and so on lag and vibration,sped upthe servo speed of response,increased the servo-control precision and the engine bedprocessing precision.4.4.4.4.NumericalNumericalNumericalNumerical controlcontrolcontrolcontrol systemsystemsystemsystemThe advanced numerical control system is guaranteed the mold complex curved surfacehigh speed processing quality and the efficiency key aspect,the mold high-speed cuttingprocessing to the numerical control system basic request is:A.High speed numerical control return route(Digital control loop),including:32 or above64 bit parallel processors and 1.5Gb hard disk;Extremely short straight line electricalmachinery sampling time.B.Speed and acceleration feed-forward control(Feed forward control);Digital actuationsystem crawling control(Jerk control).C.Advanced inserts makes up the method(to insert based on the NURBS transect makes5up),by obtains the good surface quality,the precise size and the high geometry precision.D.Pretreatment(Look-ahead)function.The request has the large capacity cushion register,may read in advance and inspects many segments(for example the DMG engine bed to bepossible to reach 500 segments,the Simens system may reach a 10002000 segment),inorder to when is processed the superficial shape(curvature)changes may promptly adoptchanges for measure and so on speed by avoids cutting and so on.E.The error compensatory function,including because the straight line electrical machinery,the main axle and so on gives off heat the hot error which causes to compensate,thequadrantal error compensates,the measurement system error compensates and so on thefunction.In addition,the mold high-speed cutting processing very is also high to the datatransmission speed request.F.The traditional data connection,like the RS232 serial mouth transmission speed is 19.2kb,but many advanced processings centers haveused the ether local area network(Ethernet)to carry on the data transmission,the speed may reach 200kb.5.5.5.5.CoolingCoolingCoolingCooling lubricationlubricationlubricationlubricationThe high speed processing uses the belt coating the hard alloy tools,in high speed,thehigh temperature situation does not need the cutting compound,the cutting efficiency to behigher.This is because:The milling main axle high speed revolves,the cutting compound ifachieved the cutting area,first must overcome the enormous centrifugal force;Even if itovercame the centrifugal force to enter the cutting area,also was possible as a result of thecutting area high temperature but to evaporate immediately,the cooling effect very small didnot even have;At the same time the cutting compound can cause the cutting tool edge of asword the temperature intense change,is easy to cause the crack the production,thereforemust pick the oil used/Gas cooling lubrication dry type cutting way.This way may use thecompressed gas rapidly the cutting which the cutting area produces,thus the massivecuttings hotly will carry off,at the same time might forms extremely thin microscopicprotective film after the atomization lubricating oil in the cutting tool edge of a sword andthe work piece surface,but effectively will lengthen the cutting tool life and enhances thecomponents the surface quality.Third,Third,Third,Third,high-speedhigh-speedhigh-speedhigh-speed cuttingcuttingcuttingcutting processingprocessingprocessingprocessing cuttingcuttingcuttingcutting tooltooltooltoolThe cutting tool is in the high-speed cutting processing one of most active importantfactors,it is affecting the processing efficiency,the production cost and the product6processing precision directly.The cutting tool must withstand load and so on hightemperature,high pressure,friction,impact and vibration in the high speed processingprocess,the high-speed cutting cutting tool should have the good machine capability and thethermostability,namely has the good anti-impact,the wearability and resists heat the wearycharacteristic.The high-speed cutting processing cutting tool technological developmentspeed is very quick,application many like diamonds(PCD),cubic boron nitride(CBN),ceramic cutting tool,coating hard alloy,(carbon)titanium nitrides hard alloy TIC(N)and soon.In the processing cast iron and in the alloy steel cutting tool,the hard alloy is the mostcommonly used cutting tool material.Hard alloy tools resistance to wear good,but thesolidity ratio cube boron nitride and the ceramics are low.In order to enhance degree ofhardness and the superficially attractive fineness,uses the cutting tool coating technology,the coating material for the titanium nitrides(TiN),the aluminium nitride titanium(TiALN)and so on.The coating technology causes the coating by the sole coating development formultilayered,the many kinds of coating material coating,has become one of enhancementhigh-speed cutting ability essential technical.The diameter in the 1040mm scope,also hasthe carbon titanium nitrides coating the hard alloy bit to be able to process the Luo riverdegree of hardness to be smaller than 42 materials,but the titanium nitrides aluminumcoating cutting tool can process the Luo river degree of hardness is 42 even higher materials.When high-speed cutting steel products,the cutting tool material should select the hotrigidity and the fatigue strength high P kind of hard alloy,the coating hard alloy,the cubicboron nitride(CBN)and the CBN compound cutting tool material(WBN)and so on.Thecutting cast iron,should select the fine grain K kind of hard alloy to carry on the roughmachining,selects the compound nitrided silicon ceramics or the crystal combination cubeboron nitride(PCNB)the compound cutting tool carries on the precision work.Whenprecise processing non-ferrous metal or nonmetallic material,should select crystalcombination diamond PCD or the CVD diamond coating cutting tool.When choice cuttingparameter,in view of the circular shear blade and a ball milling cutter,should pay attentionto the effective diameter the concept.The high speed milling cutting tool should press thebalance design manufacture.The cutting tool front angle must be smaller than theconventional cutting tool front angle,the clearance angle is slightly big.The host vice-cutting edge attachment point should the cavetto or the lead angle,increases the vertex angle,prevents the knife point place hot attrition.Should enlarge nearby the knife point the cuttingedge length and the cutting tool material volume,enhances the cutting tool rigidity.Is safe7in the guarantee and satisfies the processing request under the condition,the cutting toolhangs extends as far as possible short,cutter body central toughness is friends with.The hiltmust be sturdier than the cutting tool diameter,connects the handle to assume but actuallythe pyramidal,by increases its rigidity.As far as possible centralthe refrigerant hole in thecutting tool and the cutting tool system.Aball end mill must consider effectively cuts thelength,the cutting edge must be as far as possible short,two spiral grooves balls end millusually uses in the thick mill complex curved surface,four spiral grooves balls end millusually uses in the fine mill complex curved surface.Fourth,Fourth,Fourth,Fourth,moldmoldmoldmold highhighhighhigh speedspeedspeedspeed processingprocessingprocessingprocessing craftcraftcraftcraftThe high speed processing including take removes the remainder as the goal roughmachining,the residual rough machining,as well as take gains the high grade processingsurface and the slight structure as the goal half precision work,the precision work and themirror surface processing and so on.1.1.1.1.RoughRoughRoughRough machiningmachiningmachiningmachiningThe mold rough machining essential target is pursues in the unit time materialremoving rate,and is half precision work preparation work piece geometry outline.In thehigh speed processing rough machining should adopt the craft plan is the high cutting speed,Gao Jin giving rate and the small cutting specifications combination.The contourprocessing way is one processing way which the multitudinous CAM software usesgenerally.Using is spiral contour and so on the Z axis contour two ways which are many,also is in processes the region only time to feed,in does not lift the knife in the situation toproduce continuously the smooth cutting tool way,enters,draws back the knife way to usethe circular arc to cut into,to cut.The spiral contour way characteristic is,has not waited thehigh level between the knife road migration,may avoid frequently lifting the knife,feedingto the components surface quality influence and mechanical device nonessential consuming.Tois steep and the flat site processes separately,the computation suits contour and suits theuse similar 3D bias the region,and may use the spiral way,in very little lifts the cutting toolway which the knife in the situation produces optimizes,obtains the better surface quality.In the high speed processing,certainly must adopt the circular arc to cut into,to cut theconnection way,as well asthe circular arc transition,avoids changing the cutting tool toenter suddenly for the direction,the prohibition use direct under knife connection way,avoids burying the cutting tool the work piece.When processes the mold cavity,shouldavoid the cutting tool vertical insertion work piece under,but should use inclines the knife8way(commonly used angle of bank for 2030),best uses the screw type under knife by toreduce the cutting tool load.When processes the mold core,should under the knife thenlevel cut into the work piece as far as possible first from the work piece.The cutting toolcuts into,cuts when the work piece should use as far as possible inclines the type(or roundarc-type)cuts into,cuts,vertically avoids cutting into,cutting.Uses climbs up the typecutting to be possible to reduce the cutting heat,reduces the cutting tool stress and the workhardening degree,improves the processing quality.2.2.2.2.HalfHalfHalfHalf precisionprecisionprecisionprecision workworkworkworkThe mold half precision work essential target is causes the work piece outline shapesmoothly,surface finish remaind