【作者】 高波；

【导师】 杨崇倡；

【作者基本信息】 东华大学 ， 机械设计及理论， 2013， 硕士

【摘要】 喷丝板作为制造化学纤维的重要装备——纺丝机的核心高精密度零件,其高精度是保证纤维成品质量及良好纺丝工艺的关键因素。喷丝板底孔的孔型、结构和精度都将直接影响到成形纤维的性能。喷丝板属于精密产品,各道工序的精度要求都很高,其中的孔道加工属于典型的大深径比微小孔加工,孔道加工时间占整个喷丝板加工时间的80%。底孔的加工质量和时间直接影响整个喷丝板的加工时间和后续纤维成形的质量。国内喷丝板制造厂通常采用人工方法对底孔进行加工,即先用麻花钻进行粗加工,再用扁钻进行铰孔底的工艺。在现有的喷丝板底孔加工工艺中,不可避免的将出现刀具和孔底不对心、刀具磨损、断刀、钻屑堆积等问题,稍有疏忽,即会造成整板报废。因此,要实现底孔的自动化加工,必须针对加工过程中的刀具、切削工艺、自动监测等问题进行研究,开发出集刀具监测、磨损检测、排屑等功能于一体的底孔自动化加工装备和工艺。本文首先介绍了国内外喷丝板加工的现状与发展,分析了国内外底孔加工存在的问题,底孔的尺寸精度要求和加工工艺过程等。国外基本上实现数控加工,国内则依靠传统手工加工,在加工过程中会出现刀具折断、留底厚不统一和效率低下等问题。其次在底孔全自动化加工装备等方面,针对微小盲孔难排屑、刀具磨损补偿及扁钻容易折断等难题,提出主轴中空数控走位清屑、使用对刀仪实现刀具磨损补偿及刀具在线折断检测等特殊功能,在原有加工中心的基础上增加自动化加工所需的相关辅助功能。在喷丝板底孔的全自动加工方面,由于传统手工刀具的工艺并不适应本自动化加工系统,因此需要对刀具和工艺进行优化。本课题重点研究了精钻全自动加工相应的切削参数及针对微小钻头刚性的问题,提出采用数控程序暂停的方法保证统一留底厚。扁钻是底孔加工中最重要的刀具,本课题针对底孔角度对纺丝的影响,设计了不同角度的扁钻进行孔底加工,并通过试验得出相应的最优切削参数,针对扁钻尖部易折断等问题,提出采用尖部倒角优化的方法进行优化,并针对实际加工中出现的各类问题进行分析总结,通过对各影响因素的合理调节,在国内首次实现了喷丝板底孔的全自动加工,加工出的底孔光洁度可达1.6,留底厚精度保证在±0.01mm。最后,在上述研究的基础上,针对加工过程进行优化,成功设计出了刀具在线观测系统,加工前通过采用本系统进行刀具跳动检测,提高了每把刀具加工的孔数和底孔加工的质量及效率。该产品填补了国内喷丝板加工领域的空白,目前已投入工厂生产使用。更多还原

【Abstract】 Spinneret, one key component of a spinning machine, is an important equipment for the manufacture of chemical fibers. The high precision of spinneret is the crucial element to ensure the quality of fiber goods and spinning technology. The performance of fiber products is directly with the spinneret hole type, structure and precision. The spinneret is a precision part with high accuracy requirements of each process, in which the channels belong to the typical large depth and width with the tiny hole machining processing, channel processing time accounted for 80% of the time throughout the spinneret processing. The processing quality and time of the bottom directly affect the spinneret processing time and the quality of the subsequent fiber forming.The domestic spinneret factory usually use manual methods of bottom hole processing, that is first with a twist drill roughing and then with a spade drill reaming the hole bottom. Existing bottom hole of the spinneret process inevitably will occur the tools do not match the bottom of the hole, tool wear, drill break, drill cuttings accumulation and other issues. Even if a little negligence will cause the entire board scrapped. Therefore, we must study drills, the cutting process and automatic monitoring to achieve the automated processing of bottom hole and develop a tool monitoring, wear detection, chip removal and other functions in one automated processing equipment and process.This paper first introduces the situation and development of the domestic and international spinneret processing, analysis of the problems of bottom hole processing inner and abroad, the dimensional accuracy requirements and processing process of the bottom hole. Foreign countries almostly achieve CNC-machine manufacture, the domestic rely on traditional manual processing with problems of tool break, bottom thickness is not uniform and inefficient processing and so on.Secondly, to solve difficulties about small blind hole chip removal, tool wear compensation and spade drill easily broken we put forward to use spindle Hollow CNC to clear debris with G code, tool wear compensation and tool online break detection and other special features on the bottom fully automated processing equipment. We firstly achieve the automatic processing of the spinneret bottom, processing surface finish up to 1.6 and bottom thickness with ± 0.5 μm.In the automatic processing of the bottom hole of the spinneret spinneret, traditional process does not adapt to the automated processing system, and therefore it need to optimize. The issues focus on to develop drilling characteristics of different materials, cutting parameter optimization and the angle optimization suitable with spade drill. The issues also put forward to using method of NC program suspended to guarantee bottom thickness owing to tiny drill rigid. Spade drill is the most important tool in the hole machining, owing to the influence on the spinning of different angles drill, the issues design the different angles of the spade drill to manufacture hole bottom and drawn corresponding optimal cutting parameters through the test. For the problem of spade drill broken, we use the tip chamfer method to optimize and summarize the various problems arising in the actual processing, we finally achieve fully automated processing target through reasonable adjustment each factor.Finally, on the basis of these studies, we design tool online observation system to optimize the above processing, before processing we use this system to detect tool pulse, greatly increase the number of holes by each drill and improve the quality and efficiency of processing. This product fills the spinneret processing field blank of the domestic and has been put into production in factory.更多还原