高速响应活塞环数控车床的开发研究

【作者】 李开顺；

【导师】 王隆太；

【作者基本信息】 扬州大学 ， 机械制造及其自动化， 2005， 硕士

【摘要】 活塞环是内燃机中的关键零件之一,其本身品质的好坏及工作状态直接影响到内燃机的性能。目前,国内活塞环内外圆自由型线的加工方法基本是采用凸轮靠模进行仿形加工,这种利用靠模仿形加工的方法,由于靠模自身的制造精度和其在工作过程中的磨损,很难保证活塞环的加工精度。活塞环型号的变更和参数的变化均需要更换靠模,靠模制造周期长,难以适应多品种、小批量激烈竞争的市场需求,而国外先进的活塞环加工设备的昂贵价格也是国内很多企业难以接受的。 本论文针对国内现有活塞环加工设备存在的不足,提出了一种新型活塞环全数控车床结构方案,即通过主轴旋转编码器所采集的角度信息和直线电机的径向位移构造“软靠模”代替常规的硬靠模完成活塞环自由型线的加工过程。使用该方案,成功解决了一系列关键技术,最终研制完成了一台活塞环数控外圆车床,该机床与靠模式活塞环车床比较具有响应速度快、加工效率高、精度好的特点。本论文的主要研究内容包括: 1、活塞环全数控加工关键技术分析。通过对活塞环自由状态轮廓曲线的分析,归纳了活塞环全数控加工所需解决的关键技术。 2、提出了一种新型活塞环全数控加工机床结构方案。针对活塞环数控加工关键技术,提出了一种用直线伺服电机作为径向进给机构,以电子凸轮作为运动控制模式实现活塞环数控加工的新型机床结构。 3、活塞环数控车床样机的研制。在原有靠模式活塞环仿形车床基础上,对机床机械结构进行了设计和改造,开发了适合活塞环车削加工的机床控制系统,成功研制了国内第一台用直线伺服电机驱动的高速响应全数控活塞环车床。 4、活塞环CAD/CAM软件的开发。成功开发了一套活塞环CAD/CAM软件,具有活塞环自由型线计算、加工特征分析、图形显示、NC程序自动生成、活塞环型线误差补偿等功能。 5、进行机床切削性能试验,获取了合适的切削加工参数。利用研制的活塞环数控车床样机对不同活塞环材料进行了实际切削试验,验证了机床切削性能,获取了在给定硬件条件下合适的切削参数。更多还原

【Abstract】 The piston ring is one of the key parts in the combustion engine. The quality and the active state of it directly affect on the performance of the combustion engine. At present, the processing method of the internal and external circle free shape-curve of the piston ring basically is the method of profile cutter with cam in home. The machining accuracy is difficult to be assured as the result of the machining accuracy and the working wear of the profiling. The profiling must be changed only because the change of the model number and parameter of the piston ring. The manufacturing cycle of the profiling is long. It is difficult to adapt the drastic rivaling market need of versatile and small-lot production. More over, the high price of the advanced foreign processing equipment of piston ring is difficult to be accepted by most domestic enterprise.In allusion to the deficiency of the existing piston ring processing equipment in our country, this article bring forward a new processing method with whole numeric control. This method is using the soft profiling which is formed with the angle information collect by basic shaft rotated code device and the radial dispersion of the linear motion actuator instead of the hard profiling to finish the manufacturing procedure of the piston ring free molded lines. Penman successfully developed a numeric control external circular lather of piston ring based on this method. This lather has the characteristic of high processing efficiency, high degree of accuracy, faster product changing etc. The primary study coverage of this article is:1.Analyse the key technology about whole numeric control processing of the piston ring. Bring forward the key technique which must be settled so that the whole numeric control processing of the piston ring can be carry out by analyzing the characteristic of the free state outline curve of the piston ring.2.Bring forward a new method of whole numeric control processing of the piston ring. Based on the key technique about the numeric control processing of the piston ring, using the linear motion actuator as the device of radial dispersion and the electronic cam as the motion control model, we bring forward a new method that can realize whole numeric control processing of the piston ring.3.Develope the new type of numeric control external circular lather of piston ring.A new type of numeric control external circular lather of piston ring was successfully developed by redesigning and reforming the lather’s mechanical structure and control system based on the original external circular forming lather of piston ring, which achieved the lead level inland.4.Develop the CAD/CAM software of the piston ring. Successfully developed a set of software about the piston ring CAD/CAM, which can analyse the free molded lines of the piston ring and automatically generate the interface program which need by numeric control processing according to variant piston rings.5.Test the machinability of the lather. Practically cut the piston ring with the numeric control external circular lather of the piston ring that has been developed. Test the machinability of the lather, and get the best cutting parameter according to the given hard condition.更多还原