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XKA5032AC数控立式升降台铣床自动换刀装置设计
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  • XKA5032AC数控立式升降台铣床自动换刀装置(刀库式)的设计
    目 录
    I
    摘要 ………………………………………………………………………………………I
    Abstract ………………………………………………………………………………………II
    1 绪论 1
    1.1 数控机床知识 1
    1.2 数控铣床的分类 1
    1.2.1 数控立式铣床 1
    1.2.2 卧式数控铣床 2
    1.2.3 立、卧式两用数控铣床 2
    1.3 数控铣床的结构特征 2
    1.3.1 数控铣床的主轴特征 2
    1.3.2 控制机床运动的坐标特征 3
    1.4 数控铣床的主要功能及加工对象 3
    1.4.1 数控铣床的功能 3
    1.4.2 自动换刀装置(ATC)及其形式 3
    1.4.3 自动换刀装置应当满足的基本要求 5
    2 总体方案的确定 5
    2.1 XKA5032A/C数控立式升降台铣床及其主要参数 5
    2.1.1 其主要结构特点 6
    2.1.2 其主要规格及技术参数 6
    2.2 初定其自动换刀装置的设计参数 7
    2.3 确定其自动换刀装置的形式 7
    3 刀库的设计 8
    3.1 确定刀库容量 8
    3.2 确定刀库形式 9
    3.3 刀库结构设计 9
    3.4 初估刀库驱动转矩及选定电机 11
    3.4.1 初选电动机与降速传动装置 11
    3.4.2 初估刀库驱动转矩 11
    3.5 刀库转位机构的普通圆柱蜗杆传动的设计 11
    3.6 刀库驱动转矩的校核 15
    3.7 花键联接的强度计算 15
    3.8 夹紧机构插销剪切强度的校核 16
    3.9 确定刀具的选择方式 16
    3.10 刀库的定位与刀具的松夹 17
    4 刀具交换装置的设计 18
    4.1 确定换刀机械手形式 18
    4.2 换刀机械手的工作原理 19
    4.3 机械手的自动换刀过程的动作顺序 20
    4.4 机械手回转轴4上的齿轮齿条设计 21
    4.5 自动换刀装置的相关技术要求 21
    4.5.1 主轴准停装置 21
    4.5.2 换刀机械手的安装与调试 22
    4.6 自动换刀程序的编制 22
    5 自动换刀装置的控制原理 23
    5.1 自动换刀装置的液压系统原理图 23
    5.2 自动换刀装置换刀动作的顺序控制过程 24
    6 典型零件的设计 24
    6.1 联轴器 24
    6.1.1 联轴器的选用 25
    6.1.2 联轴器的校核 25
    6.2 选择离合器的类型 25
    6.3 蜗杆蜗轮传动设计的一些相关技术要求 25
    6.4 托架的设计 25
    鸣 谢 26
    参考文献 28
    摘要
    本论文介绍的是XKA5032A/C数控立式升降台铣床自动换刀装置(刀库式)的设计.刀库式的自动换刀装置是由刀库和刀具交换装置(换刀机械手)组成。它是多工序数控机床上应用最广泛的换刀装置,其整过换刀过程比较复杂。首先把加工过程中需要使用的全部刀具安装在标准的刀柄上,在机床外进行尺寸预调后,按一定的方式装入刀库。换刀时,先在刀库中进行选刀,由机械手从刀库和主轴上取出刀具,然后交换位置,把新刀插入主轴,旧刀放回刀库。存放刀具的刀库具有较大的容量,其容量为六把刀具,采用盘形结构,安装在机床的左侧立柱上。因为XKA5032A/C数控立式升降台铣床外形及其他性能参数等均与THK6363型自动换刀数控镗铣床相似,所以本机床的自动换刀装置的设计将仿效THK6363型自动换刀数控镗铣床换刀装置,设计成采用轴向放置的鼓盘式刀库形式和回转式双臂机械手组成。
    刀具按预定工序的先后顺序插入刀库的刀座中,使用时按顺序转到取刀位置。用过的刀具放回原来的刀座内,也可以按加工顺序放入下一个刀座内。该法不需要刀具识别装置,驱动控制也比较简单,工作可靠。但刀库中每一把刀具在不同工序中不能重复使用,为了满足加工需要只有增加刀具的数量和刀库的容量,这就降低了刀具和刀库的利用率。此外,装刀时必须十分谨慎,如果刀具不按顺序装在刀库中,将会产生严重的后果。顺序选刀是在加工之前,将加工零件所需刀具按照工艺要求依次插入刀库的刀套中,顺序不能有差错。加工时按顺序调刀。适合加工批量较大、工件品种数量较少的中、小型自动换刀装置。可知数控铣床用4把刀就可完成大多数的铣削加工。所以这个容量为6把刀的刀库,几乎不存在加工过程中需要重复利用刀具的情况,所以刀具的选择方式确定为顺序选择刀具。
    两手互相垂直的回转式单臂双手机械手的优点是换刀动作可靠,换好时间短,缺点是刀柄精度要求高,结构复杂,联机调整的相关精度要求高,机械手离加工区较近。一般来说,这种机械手用于刀库刀座轴线与机床主轴轴线垂直,刀库为径向存取刀具形式的自动换刀装置,因此,在XKA5032A/C数控立式升降铣床的自动换刀装置中可采用这种机械手形式。

    关键词:数控铣床;自动换刀装置;刀库;换刀机械手
    Abstract
    This thesis introduction is the design that the XKA5032 A/C number controls the sign type working panel lifter miller to change the knife device(the knife database type) automatically.The knife database type automatically change the knife device is have by the knife database and the knife to exchange device(change the knife the machine hand) to constitute.It is many work ordinal numbers to control the top of the tool machine to apply to change the knife device most extensively, it is whole to lead to change the knife process more complicated.First process process in need to be use of all knifes have to install on the haft of the standard, pressing certain way to pack into the knife database after the tool machine carry on size to prepare to adjust outside.Be in the knife database carry on choosing knife first while change the knife, is taken out knife to have from the knife database and the principal axis by the machine hand, then exchange position, insert the new knife into the principal axis, the old knife puts back a knife database.The knife database that deposits knife to have has bigger capacity, its capacity has for six knifes, adopting the dish form structure, the left side that installs in the tool machine signs pillar up.The XKA5032 A/C number controls the sign type working panel lifter miller shape and other function parameter etc.s to all change the knife with THK6363 typeses automatically number to control the boring miller likeness, so this tool machine changes the knife the design of the device to change the knife in the wake of THK6363 typeses automatically automatically the number control the boring miller to change the knife device, the design becomeses the adoption stalk toward the drum dish type knife database form and the turn-over type double the arm machine hand for place to constitute.
    The knife has to press to schedule to the work preface insert the knife of the knife database order of sequence, usage turn to take knife position in order.The knife for using puts back the original knife inside, can also press to process sequence to put into the next knife.That method doesn't need the knife to identify device, driving a control also more simple, work credibility.But the knife database in each knife have in the different work preface and can't repeat an usage, for satisfying to process to need to only increase the capacity of the quantity and the knife database that the knife have, this utilization that lowers knife to have with the knife database.Have to be very careful while packing knife in addition, if the knife doesn't in order have to pack in the knife database, will produce serious result.Sequence's choosing knife is before process, will process the knife that spare parts need to have to request to be one by one in order in the knife set of insert the knife database according to the craft, the sequence can't have mistake.Process adjust knife in order.Suit to process a batch quantity to compare greatly,the work piece the species quantity less of medium,small scaled the auto change the knife device.Can know the number controls miller to use 4 make the knife complete most milling and can pare to process.So this capacity is 6 knife databases of knifes, almost the nonentity process to need to make use of the circumstance that the knife have again in the process, so the knife have of the choice method assurance for in proper order choice the knife have.
    Two hands are mutual perpendicular of the advantage of the turn-over type single arm hands machine hand change the knife action credibility, changing good time short, the weakness is the haft accuracy to have high request, structure complications, the linking machine adjust of the related accuracy have high request, the machine hand leaves to process area nearer.Generally speaking, this kind of machine hand useds for the knife database knife the stalk line and the tool machine principal axis stalk line perpendicular, the knife database has a form to change the knife device automatically toward the access knife for the path, therefore can adopt this kind of machine hand form in the XKA5032 A/C number control the sign type rise and fall miller the auto change the knife the device.

    Keywords: numerical control milling machines ;Automatic tool changer ;Tool storage ;tool changing-manipulator
    该机床推荐使用的最大切削范围如下:
    铣切钢:钢的含碳量0.45%,抗拉强度600N/mm2。铣刀直径100mm,齿数4;
    铣切宽度50mm,铣切深度3 mm;主轴转速750 r/min,进给量750mm/min。
    铣切灰铸铁:材料HT200,硬度HB150~225。铣刀直径250mm,齿数14;
    铣切宽度150mm,铣切深度3.7 mm;主轴转速47.5 r/min,进给量300mm/min

    2.2初定其自动换刀装置的设计参数
    在铣削轮廓时,为了保证一次连续地加工出全部表面,应选用半径小于工件最小轮廓半径的刀具,而在实际的生产加工中,常尽量选用直径较大的铣刀,因为大直径铣刀刚性好,耐用度高。由XKA5032A/C数控立式升降台铣床推荐使用的最大切削范围可知,当铣切钢时,铣刀直径为100 mm。当铣灰铸铁时,铣刀直径达250mm。因此,为了满足该机床的实际加工能力与生产情况,在设计其自动换刀装置时,应该根据最大的刀具直径来设计,即设计的换刀装置能交换250mm的刀具。
    初估最大直径刀具的重量为8kgf。
    2.3确定其自动换刀装置的形式
    数控机床的自动换刀装置的结构形式多种多样,选择何种形式,主要取决于机床的种类、工艺范围以及刀具的种类和数量等。
    由于XKA5032A/C数控立式升降台铣床是一种使用范围较广的机床,且其可加工零件的精度要求也较高,比较上章介绍的几种换刀形式,决定选用带刀库的自动换刀形式。
    带刀库的自动换刀装置是由刀库和刀具交换装置(换刀机械手)组成。它是多工序数控机床上应用最广泛的换刀装置,其整过换刀过程比较复杂。首先把加工过程中需要使用的全部刀具安装在标准的刀柄上,在机床外进行尺寸预调后,按一定的方式装入刀库。换刀时,先在刀库中进行选刀,由机械手从刀库和主轴上取出刀具,然后交换位置,把新刀插入主轴,旧刀放回刀库。存放刀具的刀库可具有较大的容量,它既可以安装在主轴箱的侧面或上方,也可以作为独立部件安装在机床以外。
    XKA5032A/C数控立式升降台铣床主轴箱上方没有好的安装位置,安装在机床外又要增加刀具运输时间,降低效率,所以安装在机床侧面最合适,有些部件交错的地方,作适当的调整。因为XKA5032A/C数控立式升降台铣床外形及其他性能参数等均与THK6363型自动换刀数控镗铣床相似,所以本机床的自动换刀装置的设计将仿效THK6363型自动换刀数控镗铣床换刀装置,设计成由由盘式刀库和回转式双臂机械手组成。
    ...
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XKA5032AC数控立式升降台铣床自动换刀装置设计_下载(doc格式) 技术文档