外文翻譯--發(fā)動(dòng)機(jī)曲軸復(fù)合加工技術(shù)成為發(fā)展趨勢(shì)

1、外文翻譯Crank the engine of development of processing technology trendsAfter entering the 21st century, the engine crankshaft manufacture process, tools in all aspects. Leadership for nearly half a century of many knives cutting process and manual process, due to the low and the poor flexible machining

2、precision, is gradually from the stage of history. High-speed, high efficient compound processing technology and equipment quickly into the automobile and automobile parts manufacturing, high efficient compound processing technology in the crankshaft production process in a degree of application, an

3、d will be the inevitable developing trend.The crankshaft processing technology and equipment statusAt present, the domestic older crankshaft production by ordinary machine and the most special machine, production efficiency and automation is relatively low. Balancing device generally adopted the cra

4、nkshaft lathe cutting knife shaft neck and neck connecting shaft, working procedure quality stability, easy to produce large processing stress, difficult to achieve reasonable limits.but. Widely used as ordinary precision MQ8260 crankshaft grinding machine for the coarse grinding and fine grinding,

5、polishing, grinding, usually by artificial operation, the processing quality instability, dimension tolerance.One of the main characteristics of old line is too common, processing equipment, ductile iron crankshaft assembly line has 35 to 40 sets of equipment. The author examines the domestic a cran

6、kshaft forging steel production, the neck and the milling spindles and nc precise neck connecting shaft neck and neck car after a number of processes to finishing processes. Grinding side So this line of more than 60 sets of equipment, product line, site turnaround occupied large area, the productio

7、n efficiency is completely by multiple devices decomposition processes and allowance to improve.But today's car engine crankshaft manufacture is facing the following problemsIt is based on the above situation, since the beginning of the 21st century, high-speed, high precision, high efficient co

8、mpound processing technology and equipment in automobile crankshaft manufacture rapidly, production efficiency improved, so the crankshaft production line production equipment engine number was reduced. The author once in a car engine crankshaft production line equipment, including heat treatment, s

9、urface strengthening) only 13 equipment, product line, short cycle of high efficiency, easy machining quality control.The crankshaft compound machining technology developmentIn the late 1980s, Germany BOEHRINGER company and HELLER company developed perfect crankshaft car - car pulled machine, this p

10、rocess is turning process and crankshaft crankshaft wheeled craft perfect combination, high production efficiency and machining precision, good flexibility, high automation degree, in short time, especially for the sword of the crankshaft is heavy cutting groove, processing can be directly after the

11、 crankshaft jingmo, save the coarse grinding process. Therefore, the crankshaft car - car pull processing technology is an international popular in balancing the crankshaft processing.In the mid 1990s appeared new CNC milling machine makes the crankshaft high-speed balancing process and the cranksha

12、ft on a new step. CNC milling and CNC within the crankshaft speed milling, internal and external crankshaft mill has disadvantages: not easy to knife and cutting speed is low (usually less than 160m/min), the cutting time longer, more investment, circulation machine for a long time. And CNC milling

13、speed, has the following advantages of the crankshaft, high speed cutting ($350m/min), cutting time is shorter, process cycle time is shorter, cutting force is lesser, low temperature workpiece, the tool life, high in fewer knife, machining accuracy is higher, flexible better. Therefore, CNC milling

14、 is outside the crankshaft high-speed balancing the development direction of the crankshaft. According to expert introduction, crankshaft car, car, suitable for shaft neck is heavy cutting groove, the balance blocks side of the crankshaft; without processing But the milling process is not high axial

15、 have heavy cutting slots of the crankshaft. The milling machine for Germany BOEHRINGER company VDF 315 OM - 4 with the high-speed milling machine, it is specially designed for the German BOEHRINGER automobile engine crankshaft design and manufacture of CNC milling machine, the flexible application

16、of workpiece and milling equipment for servo control technology, can a year-end clamping don't change the crankshaft rotary center, and following the crankshaft connecting shaft neck milling. VDF 315 OM - 4 with high-speed milling and integration of the composite structure of bed, workpiece, ele

17、ctronic synchronization driver ends with dry cutting machining, high precision, high efficient cutting, This machine use 840D CNC control system, SIEMENS through input parts of basic parameters can be automatically generate processing procedure, can be processed in length and diameter of 4.5-700mm 3

18、80mm in all kinds of crankshaft connecting within its axis, ± 0.02 mm diameter error for.By comparison, balancing the popular process of crankshaft is: by car and main journal and high-speed milling process, the neck and the high speed milling speed servo tend to outside, adopt dry milling mach

19、ining. Because the overseas such equipment, product processing cost price is expensive, some domestic tool manufacturers (e.g., qinghai second machine manufacturing Co., LTD) successively developed nc crankshaft lathe, milling machine, high-speed nc crankshaft lathe, nc crankshaft car special machin

20、e.The crankshaft grinding precision CNC cylindrical grinder with domestic situation has quite common, product processing precision has considerable improvement. To meet the increasing demands of the crankshaft, crankshaft grinding machining forward high requirements. In addition to modern crankshaft

21、 grinding machine with high static, dynamic stiffness and high machining accuracy, still require a high grinding efficiency and more flexible. In recent years, the more the requirement of crankshaft grinding machine with stable machining precision of the crankshaft grinding machine, therefore, provi

22、ded the process capability coefficient, which means 1.67 experiment.it Cp requirement of crankshaft grinding machine processing tolerance than the crankshaft given half of tolerance. With modern drive and control technology, measurement and control (cubicborazin CBN grinding and advanced machine), t

23、he application of components for crankshaft grinding high-precision grinding efficiency, created conditions. As a kind of connecting with the grinding process neck. It reflects the comprehensive application of these new technologies specific results achieved. With this technology can significantly i

24、mprove grinding crankshaft connecting the grinding efficiency, neck and flexible machining precision machining. On the neck for connecting with the crankshaft grinding, with spindle rotation axis, neck for clamping down at once and for all the neck. Connecting grinding In grinding process, grinding

25、head swinging into to realize reciprocating the eccentric, tracking the connecting rod neck for turning grinding. To realize the X axis with grinding, but must have high dynamic performance, still must have enough, to ensure the tracking accuracy requirements of neck connecting shape tolerance. The

26、application of CBN wheels is connecting with neck important condition of grinding. Due to the high resistance CBN wheels in the grinding process, the diameter of the grinding wheel is almost constant, a dressing grinding 600-800 can crank. CBN wheels can also adopts high grinding speed, in general c

27、an adopt the crankshaft grinding up to 120 140m/s grinding speed, high grinding efficiency. Fixture systemFixture first appeared in the 18th century fixture later. Along with the science and technology unceasing progress, already from a fixture auxiliary tool development becomes a complete range of

28、process equipment. 1 The machine tool's fixtureThe international association for the study of the production of statistics shows that in the present, and small batch production of workpiece varieties of workpiece species varieties has total 85%. Modern production requirements of products manufac

29、tured by enterprises, in order to adapt to the frequently update market demand and competition. However, general enterprises are still used the traditional special jig, usually in a medium production capacity of the plant, to have about 10,000 sets of even special jig, On the other hand, in many var

30、ieties of production enterprises, every 3 4 years will update 50 80% special jig and fixture actual wear only for 10-20%. Especially in recent years, nc machine tools and machining center, the group technology, flexible manufacturing systems (FMS) new processing technology, the application of the ma

31、chine tool's fixture to put forward new requirements as follows: 1) can be quickly and easily equipment production of new products, to shorten the production preparation period, lower production cost, 2) can have a group of clamping workpiece similarity characteristics, 3) could be used for prec

32、ision machining precision machine tool fixtures, 4) to be applicable to all kinds of modern manufacturing technology of the new type of machine tool fixtures, 5) adopts hydraulic power station with such as high clamping device, to further reduce the labor intensity and improve labor productivity,To

33、improve the standardization of the machine tool's fixture. 2 the development direction of modern the machine tool's fixtureThe development direction of modern the machine tool's fixture is mainly for standardization, precision and efficiency and flexibility in four aspects.The standardiz

34、ation of the machine tool's fixture standardization and generalization is two aspects. At present already fixture parts and components of the national standard (GB / : T2148 T2259-91 and general-purpose fixture, modular fixture standard etc. The standardization of the machine tool's fixture,

35、 fixture commercialized, shorten production preparation period, lower the total cost of production. (2) precision mechanical products with the increasing accuracy, certainly will raise the accuracy requirement of the fixtures. Precision toolings structure types, such as many more precision indexing

36、gear disk, the degree of accuracy ± 0.1mm " the third turning precision for the high precision, o.d.meter for mounting 5 muon m.(3) is mainly used to reduce highlyeffective efficient fixtures processing time and auxiliary time of basic, in order to improve productivity and reduce labor int

37、ensity. Common highlyeffective clip clamps, automatic high-speed fixture and clamping force.on device fixture etc. For example, in the use of electric machine jaw vice clamping work-piece, can improve the efficiency of about five times, In the third claw using high-speed lathe, can assure card from

38、chuck claws in test speed for 9000r/min conditions can still firmly clamping workpiece, thereby cutting speed increase. Currently, except in the production line, automatic line configure corresponding efficient, automatic fixtures, nc machine tools, especially in machining center appeared on the var

39、ious automatic clamping work-piece jig automatic replacement and fixture device, give full play to the efficiency of nc machine tools. (4) flexible，of the machine tool's fixture flexible and adaptable machine, it is similar to the flexibility to the machine tool's fixture through adjustment,

40、 etc, in order to adapt to the combination of process variables. Process variable factors include: production batch process characteristic, shape and size of workpiece, etc. Has the characteristics of new jig flexibility are mainly: modular fixture, general adjustable clamp, group clamps, modular fi

41、xture, CNC jig, etc. In order to adapt to the modern machinery industry many varieties, and the need for mass production, expand the degree of flexibility, change the fixture structure of special jig for detachable down adjustable structure, development, is the current fixture structure clamp the ma

42、in development direction 發(fā)動(dòng)機(jī)曲軸復(fù)合加工技術(shù)成為發(fā)展趨勢(shì)進(jìn)入21世紀(jì)以后，發(fā)動(dòng)機(jī)曲軸在制造工藝、刀具等方面都發(fā)生了巨大的變化。領(lǐng)導(dǎo)了近半個(gè)多世紀(jì)的多刀車削工藝和手工磨削工藝，由于加工精度低和柔性差等原因，正在逐步退出歷史舞臺(tái)。高速、高效的復(fù)合加工技術(shù)及裝備迅速進(jìn)入汽車及零部件制造業(yè)，高速高效復(fù)合加工技術(shù)在曲軸加工生產(chǎn)中已有相當(dāng)程度的應(yīng)用，并將是其必然發(fā)展趨勢(shì)。 曲軸加工技術(shù)設(shè)備現(xiàn)狀 目前，國(guó)內(nèi)較陳舊的曲軸生產(chǎn)線多數(shù)由普通機(jī)床和專用機(jī)床組成，生產(chǎn)效率和自動(dòng)化程度相對(duì)較低。粗加工設(shè)備一般采用多刀車床車削曲軸主軸頸及連桿軸頸，工序質(zhì)量穩(wěn)定性差，容易產(chǎn)生較大的加工應(yīng)力，難以

43、達(dá)到合理的加工余量。精加工普遍采用MQ8260等普通曲軸磨床進(jìn)行粗磨、半精磨、精磨、拋光，通?？咳斯げ僮鳎庸べ|(zhì)量不穩(wěn)，尺寸一致性差。老式生產(chǎn)線一個(gè)主要的特點(diǎn)就是普通設(shè)備太多，按加工球墨鑄鐵曲軸來(lái)計(jì)算，一條生產(chǎn)線有3540臺(tái)設(shè)備。筆者曾考查過(guò)國(guó)內(nèi)某一鍛鋼曲軸生產(chǎn)線，粗加工采用普通外銑加工主軸頸和連桿頸，然后數(shù)控精車主軸頸和連桿頸，再經(jīng)過(guò)多道工序的磨削方轉(zhuǎn)入精加工工序。所以這條生產(chǎn)線設(shè)備達(dá)60多臺(tái)，導(dǎo)致產(chǎn)品周轉(zhuǎn)線長(zhǎng)、場(chǎng)地占用面積大，其生產(chǎn)效率完全是靠多臺(tái)設(shè)備分解工序和余量來(lái)提高的。而當(dāng)今的汽車發(fā)動(dòng)機(jī)曲軸制造業(yè)面臨的卻是以下幾個(gè)問(wèn)題 正是基于以上情況，進(jìn)入21世紀(jì)以來(lái)，高速、高精、高效的復(fù)合加工技

44、術(shù)及裝備在汽車曲軸制造業(yè)中得到了迅速的應(yīng)用，生產(chǎn)效率得到了很大提高，因此發(fā)動(dòng)機(jī)曲軸生產(chǎn)線中生產(chǎn)設(shè)備數(shù)量得以減少。筆者曾在某一轎車發(fā)動(dòng)機(jī)曲軸生產(chǎn)線看到，全線設(shè)備（包括熱處理、表面強(qiáng)化）只有13臺(tái)設(shè)備左右，產(chǎn)品周轉(zhuǎn)線短、加工效率高、易于質(zhì)量控制管理。曲軸復(fù)合加工技術(shù)的發(fā)展20世紀(jì)80年代后期，德國(guó)BOEHRINGER公司和HELLER公司開發(fā)出了完善的曲軸車車?yán)瓩C(jī)床，該加工工藝是將曲軸車削工藝與曲軸車?yán)に囃昝澜Y(jié)合，生產(chǎn)效率高、加工精度好、柔性強(qiáng)、自動(dòng)化程度高、換刀時(shí)間短，特別適合有沉割槽曲軸的加工，加工后曲軸可直接進(jìn)行精磨，省去粗磨工序。因此，曲軸車車?yán)庸すに囀悄壳皣?guó)際上曲軸粗加工中流行的加工

45、工藝之一。20世紀(jì)90年代中期出現(xiàn)的新型CNC高速曲軸外銑機(jī)床使曲軸粗加工工藝又上了一個(gè)新臺(tái)階。CNC曲軸內(nèi)銑與CNC高速曲軸外銑對(duì)比，內(nèi)銑存在以下缺點(diǎn)：不容易對(duì)刀、切削速度較低（通常不大于160m/min）、非切削時(shí)間較長(zhǎng)、機(jī)床投資較多、工序循環(huán)時(shí)間較長(zhǎng)。而CNC高速曲軸外銑具有以下優(yōu)點(diǎn)：切削速度高（可高達(dá)350m/min）、切削時(shí)間較短、工序循環(huán)時(shí)間較短、切削力較小、工件溫升較低、刀具壽命高、換刀次數(shù)少，加工精度更高、柔性更好。因此，CNC高速曲軸外銑將是曲軸粗加工的發(fā)展方向。據(jù)專家介紹，曲軸車車?yán)瓩C(jī)床特別適合于軸頸有沉割槽、平衡塊側(cè)面不用加工的曲軸；而高速外銑則不能加工軸向有沉割槽的曲軸

46、。該銑床為德國(guó)BOEHRINGER公司的VDF 315 OM-4高速隨動(dòng)外銑床，它是德國(guó)BOEHRINGER公司專為汽車發(fā)動(dòng)機(jī)曲軸設(shè)計(jì)制造的柔性數(shù)控銑床，該設(shè)備應(yīng)用工件回轉(zhuǎn)和銑刀進(jìn)給伺服連動(dòng)控制技術(shù)，可以一次裝夾不改變曲軸回轉(zhuǎn)中心，并隨動(dòng)跟蹤銑削曲軸的連桿軸頸。VDF 315 OM-4高速隨動(dòng)外銑采用復(fù)合材料一體化結(jié)構(gòu)床身，工件兩端電子同步旋轉(zhuǎn)驅(qū)動(dòng)，具有干式切削、加工精度高、切削效率高等特點(diǎn)；該銑床使用SIEMENS 840D CNC控制系統(tǒng)，通過(guò)輸入零件的基本參數(shù)即可自動(dòng)生成加工程序，可以加工長(zhǎng)度在450700mm、回轉(zhuǎn)直徑在380mm以內(nèi)的各種曲軸，連桿軸頸直徑誤差為±0.02m

47、m。 由上可以看出，曲軸粗加工比較流行的工藝是：主軸頸采用車?yán)に嚭透咚偻忏?，連桿頸采用高速外銑，而且傾向于高速隨動(dòng)外銑，全部采用干式切削。由于國(guó)外此類設(shè)備價(jià)格昂貴，產(chǎn)品加工成本很高，國(guó)內(nèi)一些機(jī)床生產(chǎn)廠家（如青海第二機(jī)床制造有限責(zé)任公司）相繼開發(fā)出了數(shù)控曲軸車床、數(shù)控高速曲軸銑床，數(shù)控曲軸車?yán)瓩C(jī)床等專用機(jī)床。 曲軸精加工采用國(guó)內(nèi)數(shù)控磨床磨削情況已相當(dāng)普遍，產(chǎn)品加工精度已有相當(dāng)程度的提高。為滿足曲軸日益提高的加工要求，對(duì)曲軸磨床提出了很高的要求?，F(xiàn)代曲軸磨床除了要有很高的靜態(tài)、動(dòng)態(tài)剛度和很高的加工精度外，還要求有很高的磨削效率和更多的柔性。近年來(lái)，更要求曲軸磨床具有穩(wěn)定的加工精度，為此，對(duì)曲軸磨

48、床的工序能力系數(shù)規(guī)定了Cp1.67，這意味著要求曲軸磨床的實(shí)際加工公差要比曲軸給定的公差小一半。隨著現(xiàn)代驅(qū)動(dòng)和控制技術(shù)、測(cè)量控制、CBN（立方氮化硼）砂輪和先進(jìn)的機(jī)床部件的應(yīng)用，為曲軸磨床的高精度、高效磨削加工創(chuàng)造了條件。一種稱之為連桿頸隨動(dòng)磨削的工藝。正是體現(xiàn)了這些新技術(shù)綜合應(yīng)用的具體成果。這種隨動(dòng)磨削工藝可顯著地提高曲軸連桿頸的磨削效率、加工精度和加工柔性。在對(duì)連桿頸進(jìn)行隨動(dòng)磨削時(shí)，曲軸以主軸頸為軸線進(jìn)行旋轉(zhuǎn)，并在一次裝夾下磨削所有連桿頸。在磨削過(guò)程中，磨頭實(shí)現(xiàn)往復(fù)擺動(dòng)進(jìn)給，跟蹤著偏心回轉(zhuǎn)的連桿頸進(jìn)行磨削加工。要實(shí)現(xiàn)隨動(dòng)磨削，X軸除了必須具有高的動(dòng)態(tài)性能外，還必須具有足夠的跟蹤精度，以確保

49、連桿頸所要求的形狀公差。CBN砂輪的應(yīng)用是實(shí)現(xiàn)連桿頸隨動(dòng)磨削的重要條件。由于CBN砂輪耐磨性高，在磨削過(guò)程中砂輪的直徑幾乎是不變的，一次修整可磨削600800條曲軸。CBN砂輪還可以采用很高的磨削速度，在曲軸磨床上一般可采用高達(dá)120140m/s的磨削速度，磨削效率很高。 機(jī)床夾具夾具最早出現(xiàn)在18世紀(jì)后期。隨著科學(xué)技術(shù)的不斷進(jìn)步，夾具已從一種輔助工具發(fā)展成為門類齊全的工藝裝備。1機(jī)床夾具的現(xiàn)狀國(guó)際生產(chǎn)研究協(xié)會(huì)的統(tǒng)計(jì)表明，目前中、小批多品種生產(chǎn)的工件品種已占工件種類總數(shù)的85左右。現(xiàn)代生產(chǎn)要求企業(yè)所制造的產(chǎn)品品種經(jīng)常更新?lián)Q代，以適應(yīng)市場(chǎng)的需求與競(jìng)爭(zhēng)。然而，一般企業(yè)都仍習(xí)慣于大量采用傳統(tǒng)的專用夾

50、具，一般在具有中等生產(chǎn)能力的工廠里，約擁有數(shù)千甚至近萬(wàn)套專用夾具；另一方面，在多品種生產(chǎn)的企業(yè)中，每隔34年就要更新5080左右專用夾具，而夾具的實(shí)際磨損量?jī)H為1020左右。特別是近年來(lái)，數(shù)控機(jī)床、加工中心、成組技術(shù)、柔性制造系統(tǒng)（FMS）等新加工技術(shù)的應(yīng)用，對(duì)機(jī)床夾具提出了如下新的要求： 1）能迅速而方便地裝備新產(chǎn)品的投產(chǎn)，以縮短生產(chǎn)準(zhǔn)備周期，降低生產(chǎn)成本； 2）能裝夾一組具有相似性特征的工件； 3）能適用于精密加工的高精度機(jī)床夾具； 4）能適用于各種現(xiàn)代化制造技術(shù)的新型機(jī)床夾具； 5）采用以液壓站等為動(dòng)力源的高效夾緊裝置，以進(jìn)一步減輕勞動(dòng)強(qiáng)度和提高勞動(dòng)生產(chǎn)率； 6） 提高機(jī)床夾具的標(biāo)準(zhǔn)化程

51、度。2現(xiàn)代機(jī)床夾具的發(fā)展方向現(xiàn)代機(jī)床夾具的發(fā)展方向主要表現(xiàn)為標(biāo)準(zhǔn)化、精密化、高效化和柔性化等四個(gè)方面。（1） 標(biāo)準(zhǔn)化 機(jī)床夾具的標(biāo)準(zhǔn)化與通用化是相互聯(lián)系的兩個(gè)方面。目前我國(guó)已有夾具零件及部件的國(guó)家標(biāo)準(zhǔn)：GB/T2148T225991以及各類通用夾具、組合夾具標(biāo)準(zhǔn)等。機(jī)床夾具的標(biāo)準(zhǔn)化，有利于夾具的商品化生產(chǎn)，有利于縮短生產(chǎn)準(zhǔn)備周期，降低生產(chǎn)總成本。（2）精密化 隨著機(jī)械產(chǎn)品精度的日益提高，勢(shì)必相應(yīng)提高了對(duì)夾具的精度要求。精密化夾具的結(jié)構(gòu)類型很多，例如用于精密分度的多齒盤，其分度精度可達(dá)±0.1"；用于精密車削的高精度三爪自定心卡盤，其定心精度為5m。（3）高效化 高效化夾具主要用來(lái)減少工件加工的基本時(shí)間和輔助時(shí)間，以提高勞動(dòng)生產(chǎn)率，減輕工人的勞動(dòng)強(qiáng)度。常見的高效化夾具有自動(dòng)化夾具、高速化夾具和具有夾緊力裝置的夾具等。例如，在銑床上使用電動(dòng)虎鉗裝夾工件，效率可提高5倍左右；在車床上使用高速三爪自定心卡盤，可保證卡爪在試驗(yàn)轉(zhuǎn)速為9000r/min的條件下仍能牢固