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Machine Design
With the scientific and technological progress and social changes in demand, machine design theory and technology are also constantly development. Computer technology and the rapid progress of technology, machine design methods for the development of a strong technical support. Computer-aided design (CAD) and computer-aided engineering (Computer Aided Engineering, Machine Tools initials CAE0 in the various stages of design has been applied, the experience has changed the traditional design methods, machine design from the traditional design of the computer-aided design, Qualitative to quantitative design design, static and linear and nonlinear analysis to dynamic analysis, from feasibility to design the best design of the transition.
NC technology development and applications, the transmission makes machine tools and structure has undergone major changes. Servo drive system can easily achieve a single machine and multi-axis movement linked to possible to omit the heavy machinery complex transmission system, structure and layout to produce great changes.
With the development of the production, the needs of the community is changing. In the mechanical manufacturing industry, a variety of species, small batch production of the increasing demand, resulting in a corresponding to the FMS (FMS) and other advanced manufacturing systems. FMS NC machine tools is the core equipment. Pre-FMS, can be said to be "machine-based system" that, according to the characteristics of the existing machine to a FMS. However, traditional machine tools (including numerical control machine tools) does not take into account when designing it in the application of FMS, in the functional constraints on the development of the FMS. FMS the development of machine has set new requirements for machine tools designed to "system-based machine design development" direction, that is, in machine design to consider how to better adapt to FMS, and other advanced manufacturing systems requirements, for example, Time and space with flexible, and the proximity to the logistics and so on, which means the design of machine tools has made new demands. Machine design is based on the design of the type set. Universal machine used serialized design. Series of products are innovative design type, the other is a variant design type. Some machines, such as the composition of a combination of machine design type.
In the type of innovative design, machine tools overall programme (including motor function and structure of the programme layout of the programme) may be the selection of the design (also known as the trial design) or a 10% design (also known as the analytical design). The former is used analog analysis, a method of reasoning programme, is the innovative design of the method used in general while the latter used as a method of generating the analytical programme, innovation ability, it is still studying development.
Machine Design steps
Machine tools and demands of different types, design steps are also different. In accordance with the new principles for processing the innovative design of the machine should be the steps; into a series of machine tool products should be designed serialization of the steps; higher degree of universal machine products, such as machine tools should be modular design combination of the steps .
I.determine the structure principle
According to the preliminary design, the machine is designed to determine the structure of the main principles of the programme include:
(1) that uses the technology of the machine, including the processing of the material type, shape, quality and size range.
(2) productivity, including the processing of the types, quantities and the required productivity.
(3) performance requirements of the accuracy of processing (user orders design) or the accuracy of machine tools, stiffness, heat distortion, noise and other performance indicators.
(4) the main parameters that determine the processing machine room and the main parameters.
(5) drive machine-driven approach and a motor-driven hydraulic-driven approach. Motor-driven approach in general have driven motor, stepper motor drive and servo motor drive. Drive and the determination of not only the cost of the machine, will also directly affect the mode of transmission established.
(6) of the main principles of parts and components should meet the requirements and principles of the structure, and sometimes needed to draft the design, identification of key components of home-made or HS.
(7) costs and production cycle or whether orders for factory planning products, should determine the cost and production cycle indicators.
II. Design
Design of the contents
(1) motor function design including the identification of the number of machines required for movement, form (linear motion, the Rotary Movement), features (the main movement, feeding movement, other sports) and the order, the final draw of the machine function map.
(2) the basic parameters of the design parameters, including size, movement and dynamic parameters of the design parameters.
(3) transmission system design, including transmission, transmission and drive system schematic design plans.
(4) the overall layout of the structure including the distribution of motor function, the overall layout of the form and structure of the whole programme
Design plans.
(5) control, including control system design and control theory, control system design plans.
III.structural design
Design of the machine drive system to determine the structure of the major principles of the programme, design parts assembly, the main parts for analysis calculated or refine the design of hydraulic principles and the corresponding assembly of hydraulic components, electrical control system design schematics and the corresponding Installation of electrical wiring diagram, machine design and improve the hand and the contact size map.
IV. Process Design
Who all the self-made machine parts map, the preparation of standard parts, GM parts and pieces of home-made schedules, writing Design Manual, Manual, the designated machine test methods and standards, and other technical documentation.
V. Machine Tool Evaluation
On a machine designed by performance analysis and comprehensive evaluation. May be designed by computer modeling of the machine, get a prototype of the so-called math, also known as the virtual prototype. A virtual prototype of a machine designed by kinematic simulation, in the actual prototype test before they are made out a comprehensive assessment, can greatly reduce the risk of new product development, shorten the development cycle and improve the quality of development.
These steps can be repeated, that the design with satisfactory results achieved so far. In the design process, design and evaluation of repeated a design can improve the success rate.
VI.design type
Upon completion of the above steps, the physical prototype manufacture, test and comment. According to physical prototype comment on the results of the modified design, the final product design type.
On the deep processing of the technological requirements
Deep processing, is the top priority of this design. The so-called deep hole, the hole is that when processing the ratio of length and diameter of about 10 times, often on the accuracy and surface finish requirements and higher, the use of processing methods in general are more difficult to meet.
I. Deep processing issues that must be addressed:
1) poor tool rigidity slender and easy to cause the tool deflection and friction with the hole wall, and therefore the head knives are correctly oriented to ensure the introduction of sets; At the same time, bearing in accordance with the need for holders to reduce the deformation and vibration Arbor.
2) is not easy from cuttings, the use of feed grade or high-pressure cutting fluid through the
inner row and outer row chip from the tool structure.
3) tool cooling difficulties, access to high-pressure cutting fluid cooling of the tool fully.
II. Deep processing of type:
Combine the characteristics of deep-hole machining, deep hole processing technology on the difficulties, the method has been overcome.
1) Deep processing grade feed:
Ordinary twist drill head in cast iron or steel pieces on the 6 ~ 10mm diameter drill hole below, the general should not be a deep-drilling of 6 ~ 10 times greater than the aperture. When the direction of horizontal drilling, the steel pieces in the deep drilling should not last more than 6 times the diameter, in the cast iron up to about 10 times the aperture. If the processing of the hole depth of more than this range, can be classified into methods for processing, that is, in the drilling process, so that bit processing automatically after a certain depth from the workpiece in order to discharge swarf and cooling, and then re-forward processing, constant back and forth until the process has finished (each drill deep, cast iron pieces from 3 to 6 times the diameter; steel pieces from 0.5 ~ 2 times the aperture, the deeper hole when taking a small value). This process is suitable for drilling deep holes of small diameter, but the productivity and precision mechanics are relatively low.
2) Feeding a deep-hole processing
It is mainly used various types of special segment, and with the next shot, transmission-oriented systems, such as cutting fluid input in the deep-hole drilling machine, hinges, boring and the presentation materials. Discharged from the way the chip can be especially Chip (on the hinge, there is also boring things forward or backward Chip) and with Chip; from a number of cutting edge, can be divided into single-blade, double-edged and multi-blade, cutting edge can be high-speed steel or carbide. Cutter head have a different number of block-oriented support in the process-oriented role play to ensure flatness of the hole, but also from the role of squeezed light to improve the processing of the surface finish hole.
Chip has a deep-hole drilling in a single tube and dual tube Chip Chip (ie, jet drilling). Chip fear of double tube drill pipe than Chip Chip fear deep-hole drilling and drilling outside the processing efficiency and higher accuracy. The deep hole on the barrier is expected to set at the completion of unloading Nesting Nesting knife, cut off the mandrel fitted with a knife and the knife folder to make it against the mandrel, the feed through a dedicated device to cut off, cut to the core diameter rod 4 / 5 ~ 5 / 6 will be back to cut off the knife, a little outside the mandrel to break out.
In general, the use of inside than outside the Chip Chip processing large diameter, obtained by processing high precision and surface finish.
III. The main points of deep-hole processing
Machine tools and processing of the previous process, and attention should check the following:
1) axis-oriented tool sets, Bar sets of bearings, such as the centerline of the workpiece support different sets of axis degrees should meet the requirement.
2) check whether the system is cutting fluid flow and normal work is a multi-edge special deep-hole drilling with Chip (jet drilling suction) of the spray suction effect, in particular, should seriously check.
3) the workpiece should be the upper end of the processing center hole, and to avoid drilling I n the slope.
4) Does the shape of a normal chip. With the workpiece material, tool geometry, cutting parameters and so on. The two separated by a certain direction of each curl inward cutting the best shape to avoid the formation of the ribbon cuttings straight.
5) The higher the speed of processing through-hole, when the drill bit is about to pass, it is best to stop or deceleration to prevent damage to the bit and the exit.
6) should be avoided in the processing of parking, such as the need to stop, they should first stop into the tool and return to some distance, and then stop the pump and the rotation of the main campaign to prevent the tool in the hole a "killed" phenomenon.
機床設計
隨著科學技術的進步和社會需求的變化，機床的設計理論和技術也在不斷的發(fā)展。計算機技術和分析技術的飛速進步，為機床設計方法的發(fā)展提供了有力的技術支撐。計算機輔助設計（CAD）和計算機輔助工程（Computer Aided Engineering,縮寫CAE0已在機床設計的各個階段得到了應用，改變了傳統(tǒng)的經驗設計方法，使機床設計由傳統(tǒng)的人工設計向計算機輔助設計，由定性設計向定量設計，有靜態(tài)和線性分析向動態(tài)和非線性分析，由可行性設計向最佳設計過渡。
數控技術的發(fā)展與應用，使得機床的傳動與結構發(fā)生了重大變化。伺服驅動系統(tǒng)可以方便地實現機床的單軸運動及多軸聯(lián)動，從而可以省去復雜笨重的機械傳動系統(tǒng)，使其結構及布局產生很大的變化。
隨著生產的發(fā)展，社會需求也在發(fā)生變化。在機械制造業(yè)中，多種品種，小批量生產的需求日益增加，因此出現了與之相適應的FMS（柔性制造系統(tǒng)）等先進制造系統(tǒng)。數控機床是FMS的核心裝備。前期的FMS，可以說是“以機床為主的系統(tǒng)”，即根據現有的機床的特點來構成FMS。但是，傳統(tǒng)的機床（包括數控機床）設計時并未考慮到它在FMS中的應用，因此在功能上制約了FMS的發(fā)展。FMS的發(fā)展對機床提出了新的要求，要求機床設計向“以系統(tǒng)為主的機床設計發(fā)展”方向發(fā)展，即在機床設計時就要考慮他如何更好地適應FMS等先進制造系統(tǒng)的要求，例如要求具有時空柔性，與物流的可接近性等等，這就對機床設計的方法學提出了新的要求。機床的設計方法是根據其設計類型而定的。通用機床采用系列化設計方法。系列中基型產品屬創(chuàng)新設計類型，其他屬變型設計類型。有些機床，如組合機床屬組合設計類型。
在創(chuàng)新設計類型中，機床總體方案（包括運動功能方案和結構布局方案）的產生方法可采用分析式設計（又稱試行設計）或創(chuàng)成式設計（又稱解析式設計）。前者是用類比分析，推理方法產生方案，是目前創(chuàng)新設計一般采用的方法；后者則用創(chuàng)成解析的方法生成方案，創(chuàng)新能力強，這種方法尚在研究發(fā)展之中。
機床設計步驟
機床的類型和要求不同，設計步驟也不同。按新的原理進行加工的機床應按創(chuàng)新設計的步驟進行；成系列的機床產品應按系列化設計的步驟進行；通用化程度較高的機床產品，例如組合機床應按模塊化設計的步驟進行。
I.確定結構原理
根據初步設計方案，確定被設計機床的結構原理方案的主要內容包括：
（1）用途 即機床的工藝范圍，包括加工件的材料類型，形狀，質量和尺寸范圍等。
（2）生產率 包括加工件的類型，批量及所要求的生產率。
（3）性能指標 加工件要求的精度（用戶定貨設計）或機床的精度，剛度，熱變形，噪聲等性能指標。
（4）主要參數 即確定機床的加工空間和主要參數。
（5）驅動方式 機床的驅動方式有電動機驅動和液壓驅動方式。電動機驅動方式中又有普通電動機驅動，步進電動機驅動與伺服電動機驅動。驅動方式的確定不僅與機床的成本有關，還將直接影響傳動方式的確定。
（6）結構原理 主要零部件應滿足的要求和結構原理，有時還需進行草圖設計，確定關鍵零部件自制還是外協(xié)。
（7）成本及生產周期 無論是訂貨還是工廠規(guī)劃產品，都應確定成本及生產周期方面的指標。
II.總體設計
總體設計的內容
（1）運動功能設計 包括確定機床所需運動的個數，形式（直線運動，回轉運動），功能（主運動，進給運動，其它運動）及排列順序，最后畫出機床的運動功能圖。
（2）基本參數設計 包括尺寸參數，運動參數和動力參數設計。
（3）傳動系統(tǒng)設計 包括傳動方式，傳動原理圖及傳動系統(tǒng)圖設計。
（4）總體結構布局設計 包括運動功能分配，總體布局結構形式及總體結構方案圖設計。
（5）控制系統(tǒng)設計 包括控制方式及控制原理，控制系統(tǒng)圖設計。
III.結構設計
設計機床的傳動系統(tǒng)，確定各主要結構的原理方案，設計部件裝配圖，對主要零件進行分析計算或優(yōu)化，設計液壓原理和相應的液壓部件裝配圖，設計電氣控制系統(tǒng)原理圖和相應的電氣安裝接線圖，設計和完善機床總裝圖和總聯(lián)系尺寸圖。
IV工藝設計
機床的全部自制零件圖，編制標準件，通用件和自制件明細表，撰寫設計說明書，使用說明書，指定機床的檢驗方法和標準等技術文檔。
V機床整機綜合評價
對所設計的機床進行整機性能分析和綜合評價?？蓪λO計的機床進行計算機建模，得到所謂的數學化樣機，又稱虛擬樣機。采用虛擬樣機對所設計的機床進行運動學仿真，在實際樣機試造出來之前對其進行綜合評價，可以大大減少新產品研制的風險，縮短研制的周期，提高研制的質量。
上述步驟可以反復進行，知道達到設計結果滿意為止。在設計過程中，設計與評價反復進行可以提高一次設計成功率。
VI定型設計
在上述步驟完成后，可進行實物樣機的制造，實驗及評論。根據實物樣機的評論結果進行修改設計，最終完成產品的定型設計。
關于深孔加工的工藝要求
深孔加工 ，是本設計的重中之重 。所謂深孔，就是當加工孔的長度與直徑之比達10倍左右，往往對精度及表面光潔度又有較高要求，使用一般的加工方法就比較難滿足。
I.深孔加工必須解決的問題：
1） 刀具細長剛度差，易引起刀具偏斜及與孔壁摩擦，因此在刀頭上均具有導向套來保證正確引入；同時，根據需要設置刀桿支承以減少刀桿的變形和振動。
2） 切屑不易排出，采用分級進給或者通過高壓切削液的內排和外排刀具結構排出切屑。
3） 刀具冷卻困難，通入高壓切削液對刀具進行充分冷卻。
II．深孔加工的類型：
結合深孔加工的特點，關于深孔加工的工藝困難，已有相應的方法進行克服。
1）分級進給深孔加工：
使用普通麻花鉆頭在鑄鐵件或鋼件上鉆直徑6~10mm以下的孔時，一般一次鉆深不宜大于6~10倍孔徑。當鉆孔方向為水平時，在鋼件上一次鉆深不宜大于6倍孔徑，在鑄鐵上可達10倍左右孔徑。如果加工的孔深超過這個范圍時，可采用分級進給的加工方法，即在鉆削過程中，使鉆頭加工一定深度后自動退出工件，借以排出切屑，并進行冷卻，然后再重新向前加工，不斷往復，直至加工完畢（每次鉆深，鑄鐵件取3~6倍孔徑；鋼件取0.5~2倍孔徑，孔較深時取小值）。這種加工方法適于鉆削較小直徑的孔深，但生產率及技工精度都比較低。
2）一次進給深孔加工
它主要是用各種類型的特殊刀頭，并配備形影的接桿、傳動導向系統(tǒng)、切削液輸入器等，在深孔機床上進行鉆、鉸、鏜及套料加工。從切屑的排出方式，可分外排屑（對鉸、鏜還可有向前或向后外排屑）及內排屑；從切削刃數目，可以分單刃、雙刃及多刃，切削刃可采用高速鋼或硬質合金。刀頭上均具有不同數量的導向支承塊，在加工過程中起導向作用，保證孔的平直度，同時也起擠光作用，提高加工孔的表面光潔度。
內排屑深孔鉆具有單管內排屑和雙管內排屑（即噴射鉆）。雙管內排屑深恐鉆比單管內排屑深恐鉆及外排屑深孔鉆的加工效率和精度都較高。對不通的深孔進行套料時，在套料完成后卸下套料刀，裝上芯棒切斷刀并使它的刀夾靠在芯棒上，通過專用進給裝置進行切斷，切斷到芯棒直徑4/5~5/6便退回切斷刀，稍加外力把芯棒折斷取出。
一般來說，采用內排屑比外排屑的加工直徑大，獲得的加工精度和表面光潔度高。
III.深孔加工的工作要點
機床在前及加工過程中，應檢查和注意如下幾點：
1） 主軸、刀具導向套、刀桿支承套、工件支承套等中心線的不同軸度應符合要求。
2） 檢查切削液系統(tǒng)是否暢通和正常工作，特備是多刃內排屑深孔鉆（噴吸鉆）的噴吸效應，尤其應該認真檢查。
3） 工件的加工端面上部應有中心孔，并避免在斜面上鉆孔。
4） 切屑形狀是否正常。它與工件材料、刀具幾何形狀、切削用量等有關。兩條分離而每條按一定方向向內卷曲的切削形狀最好，應避免形成直的帶狀切屑。
5） 采用較高速度加工通孔，當鉆頭即將鉆通時，最好停車或降速，防止損壞鉆頭和出口處。
6） 應避免在加工過程中停車，如必須停車，則應先停止進給并將刀具退回一段距離，然后停止油泵和主運動的旋轉，以防刀具在孔中產生“咬死”現象。