缸头零件5个螺纹孔钻孔夹具及专机设计【钻顶面5-φ5.0m孔】【说明书+CAD】
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编号无锡太湖学院毕业设计(论文)相关资料题目: 缸头5个螺纹孔钻孔专机设计 信机 系 机械工程及自动化专业学 号: 0923155学生姓名: 黄 丽 萍 指导教师: 刘新佳 (职称:副教授) (职称: )2013年5月25日目 录一、毕业设计(论文)开题报告二、毕业设计(论文)外文资料翻译及原文三、学生“毕业论文(论文)计划、进度、检查及落实表”四、实习鉴定表无锡太湖学院毕业设计(论文)开题报告题目: 缸头5个螺纹孔钻孔专机设计 信机 系 机械工程及自动化 专业学 号: 0923155 学生姓名: 黄丽萍 指导教师: 刘新佳 (职称:副教授 ) (职称: )2012年11月23日 课题来源本课题来源于工程生产实际。科学依据(包括课题的科学意义;国内外研究概况、水平和发展趋势;应用前景等)(1)课题的科学意义 随着工业生产规模化、专业化、集中化、高度机械化乃至自动化的步伐的加快,在进行工件加工时,要求考虑使用专用机床和夹具。组合机床和组合机床自动线是一种专用高效自动化技术装备,目前,由于它仍是大批量机械产品实现高效、高质量和经济性生产的关键装备,因而被广泛应用于汽车、拖拉机、内燃机和压缩机等许多工业生产领域。某企业因生产发展需要,拟开发缸头5个螺纹孔钻孔专机,因此选定缸头5个螺纹孔钻孔专机设计为本次设计课题。(2)国内外研究概况、水平和发展趋势: 我国加入WTO以后,制造业所面临的的机遇和挑战并存。组合机床行业适时调整战略,采取了积极的应对策略,出现了产销两旺的良好势头,截止2002年9月份,组合机床行业企业仅组合机床产品一项,据不完全统计产量已达800余台,产值达3个亿以上,较2001年同比增长了10%以上,另外组合机床行业工业增加值、产品销售率、全员工资总额、出口交货值等经济指标均有不同程度的增长,新产品,新技术较去年均有大幅度提高,可见行业企业运营状况良好。 组合机床及其自动线是集机电于一体的综合自动化程度较高的制造技术和成套工艺装备。它的特征是高效、高质、经济实用,因而被广泛应用于工程机械、交通、能源、军工、轻工、家电等行业。我国传统的组合机床及组合机床自动线主要采用机、电、气、液压控制,它的加工对象主要是生产批量比较大的大中型箱体类和轴类零件(近几年研制的组合机床加工连杆、板件等也占一定份额)。随着技术的不断进步,一种新型的组合机床柔性组合机床越来越受到人们的青睐,它应用多位主轴箱、可换主轴箱、编码随行夹具和刀具的自动更换,配以可编程控制器、数字控制等,能任意改变工作循环控制和驱动系统,并能灵活适应多品种加工的可变可调的组合机床。另外,近年来组合机床加工中心、数控组合机床、机床辅机(清洗机、装配机、综合测量机,试验机、输送线)等在组合机床行业中所占份额也越来越大。 研究内容学习独立查阅参考文献的能力;完成缸头5个螺纹孔钻孔专机总体结构和主要部件(机床夹具、组合机床多轴箱)设计;能够绘制出加工工序图,加工示意图,填写机床生产率计算卡。拟采取的研究方法、技术路线、实验方案及可行性分析本课题是根据工程实际的需要所做的研究,是工厂在现实生产作业中对于改进零件加工工艺方案,提高工厂的生产率和质量,为减少生产成本,取得更好的经济效益而提出来的。我所设计的组合机床内容包括初步确定专机设计总体方案,绘制加工工序图和加工零件图,绘制机床联系尺寸图,编制生产率卡,设计机床夹具,绘制机床夹具总图,设计机床多轴箱,绘制多轴箱总图。研究计划及预期成果研究计划:2012年11月12日-2012年12月2日:按照任务书要求查阅论文相关参考资料,填写毕业设计开题报告书。2012年12月3日-2013年1月20日:进行毕业实训。2013年1月21日-2013年3月1日:填写毕业实习报告,并开始着手毕业设计零件图纸的分析2013年3月1日-2013年3月8日:专业机床总体方案初步构思。2013年3月11日-2013年3月15日:专业机床总体方案设计。2013年3月18日-2013年3月29日:绘制零件加工工序图。2013年4月1日-2013年4月5日:绘制机床联系尺寸图。2013年4月8日-2013年4月12日:填写生产率计算卡。2013年4月15日-2013年4月26日:专用夹具的设计。2013年4月29日-2013年5月10日:多轴箱的设计,草图绘制。2013年5月13日-2013年5月17日:检查,修改,完善说明书。2013年5月20日-2013年5月25日:资料整理装订,准备答辩。预期成果:设计图样及设计说明书一套特色或创新之处从企业实际需求出发,在全面分析被加工零件的基础上,指出现有设备的不足,不仅工人劳动强度大,而且生产效率低,不利于保证零件加工精度,采用组合机床的创新设计可解决上述问题。已具备的条件和尚需解决的问题已经进过专业课程设计等的相关训练,还经过毕业实习的实习。此外,为了本次毕业设计进行了前期调研,相关资料的搜集,已做好技术设计的相关准备工作,设计思路及方案已基本明确。但任有问题尚需解决,如组合机床整体方案的设计、多轴箱的设计等,还需根据零件图进行详细的分析设计等,其中依旧存在着一定问题。指导教师意见 指导教师签名:年 月 日教研室(学科组、研究所)意见 教研室主任签名: 年 月 日系意见 主管领导签名: 年 月 日英语原文: Integrated Machine and Control DesignAbstract In this paper, we describe a systematic design procedure for reconfigurable machine tools and their associated control systems. The starting point for the design is a set of operations that must be performed on a given part or part family. These operations are decomposed into a set of functions that the machine must perform and the functions are mapped to machine modules, each of which has an associated machine control module. Once the machine is constructed from a set of modules, the machine control modules are connected. An operation sequence control module, user interface control module, and mode-switching logic complete the control design. The integration of the machine and control design and the reconfigurability of the resulting machine tool are described in detail.I. IntroductionIn todays competitive markets, manufacturing systems must quickly respond to changing customer demands and diminishing product life cycles. Traditional transfer lines are designed for high volume production, operate in a fixed automation paradigm, and therefore cannot readily accommodate changes in the product design. On the other hand, conventional CNC-based “flexible” manufacturing system offer generalized flexibility but are generally slow and expensive since they are not optimized for any particular product or a family of products.An effort at the University of Michigan aims to develop the theory and enabling technology for reconfigurable machining systems. Instead of building a machining system from scratch each time a new part is needed, an existing system can be reconfigured to produce the new part. In this paper, we describe how an integrated machine and control design strategy can result in machine tools which can be quickly and easily configured and reconfigured.In order to provide exactly the functionality and capacity needed to process a family of parts, RMTs are designed around a given family of parts. Given a set of operations to be performed, RMTs can be configured by assembling appropriate machine modules. Each active module in the library has a control module associated with it. As the mechanical modules are assembled, the control modules will be connected and the machine will be ready to operate. Extensive and time-consuming specialized control system design will not be required. Section II describes how the machine is designed from a set of basic machine modules,This research was supported in part by the NSF-ERC connected in a well-defined fashion, and Section III describes how the control is similarly assembled from a library of control modules. This modular construction of the machine and control allows for many levels of reconfigurability as described in Section IV. The paper concludes with a description of future work in Section V.II. Machine DesignOngoing work on manufacturing system configuration at the University of Michigan addresses the problem of starting from a part (or part family) description and extracting the machining operations necessary to produce the part(s). The operations are grouped according to tolerance, order of execution, and desired cycle time of the system, with the intention that each operation “cluster” can be produced on a single machine tool. The operation cluster considered here is to drill a set of holes for the cam tower caps on V6 and V8 cylinder heads shown in Figure 1. The input to the reconfigurable machine tool design procedure is the cutter location data generated by a process planner for this operation cluster. data includes positioning and drilling information.The RMT design procedure consists of three main stages: task clarification, module selection, and evaluation. After a brief literature review, these three stages will be outlined in this section.A. Related researchSince reconfigurability is a relatively new concept in machining systems, there is little, if any, published literature on the design of reconfigurable machine tools. However, modular machine tools have been on the market for several years, and some of the published articles on modular robots, modular machines and assembly do have some relevance to the design of reconfigurable machine tools. For example, Shinno and Ito proposed a methodology for generating the structural configuration of machine tools. They decomposed the machine tool structures into simple geometric forms: e.g. boxes, cylinders, etc. Yan and Chen 21, 1 extended this work to the machining center structural design. 12 adapted Itos method for modular machine tool synthesis and developed a method for enumerating machine tool modules. Paradis and Khosla 15 determined the modular assembly configuration which is optimally suited to perform a specific task. On the systems front, Rogers and Bottaci 16 discussed the significance of reconfigurable manufacturing systems, and Owen et al. 13 developed a modular reconfigurable manufacturing system synthesis program for educational purposes.In our work, traditional methods of motion representation and topology (i.e. screw theory, graph theory, etc.) are employed to capture the characteristics of RMTs. These mathematical schemes are used for topological synthesis, function-decomposition, and mapping procedures; details can be found in 9. Figure 1B.Task clarificationThe design of an RMT begins with task clarification, which entails analyzing the cutter location data to determine the set of functions which are necessary to accomplish the desired kinematic motions. There are three steps. First, graphs are generated which abstractly representationPositionFeedSpindleCoolantt1t2t3t4t5t6t7t8Fig. 3. High-level operation sequence, showing causal dependencies and concurrencies.This abstract representation of the sequence of operations is derived from the CL data, and will be used to design the sequencing control the motions. These graphs are then decomposed into functions, and finally the functions are mapped onto machine modules which exist in the library.A graph representation of the machine tool structure allows for systematic enumeration of alternate configurations and also provides a method of identification of nonisomorphic graphs. The graph representation is also used for bookkeeping to assign machine modules to the graph elements. A graph consists of a set of vertices connected together by edges. In using a graph as an abstract representation of a machine tool structure, we define two different types of vertices: type 0 and type 1. A vertex represents a physical object with two ports; each port represents the location on the object where it can be attached to a neighboring object. A type 0 vertex has input and output ports that are in-line with respect to each other, whereas a type 1 vertex has input and output ports that are perpendicular to each other. Machining tasks are also classified as type 0 or type 1, depending on whether the tool is parallel or perpendicular to the workpiece.C. Module selectionCommercially available modules are selected from the module library for each of the functions (structural as well as kinematic) that were mapped to the graph in the task clarification stage. The data stored for each module in the library includes the homogenous transformation matrix representing its kinematic or structural function, the twist vector supplemented by range of motion information, a compliance matrix representing the module stiffness, module connectivity information, and power requirements (for active modules such as spindles and slides).The first step in module selection is to compare the homogeneous transformation matrices of the modules with the task requirement matrix such that when appropriate modules are selected to meet the task requirements, the product of all module matrices should be equal to the desired task matrix: T = T1 T2 Tn. Again, there may be many possible choices of modules for a given structural configuration. Figure 6 shows how different slides, spindles, and structural elements can be assembled according to the graph of Figure 4.A slide module, with its CAD model and transformation matrix, is shown in Figure 7. It is capable of one direction of linear motion, indicated by the 1 variable in its transformation matrix. Its database entry, shown in Table I, stores not only its transformation matrix but also the manufacturer name, model number, initial position, power level, and motion data. The twist vector is augmented by information on the minimum, initial, and maximum displacement of the module.TABLE IDatabase information and documentation for the machinemodule shown in Figure 7.ManufacturerSUHNERModel NameUA 35-ACInitial Position1 0 0 02 0 1 0 0 366 0 0 1 1004 0 0 0 1 577Twist vector 0 0 0 0 1 0 TRange of motion -155 0 155 Max. force5500NCompliance matrix,Etc.Power requirements,Connectivity information, . . .(a) V6 machine (b) V8 machineFig. 2. Reconfigurable machine tool designs for the two different parts.D. EvaluationOnce a set of kinematically-feasible modules have been selected, the resulting machine design must be evaluated. The criteria for evaluation of the reconfigurable machine tools synthesized by the above systematic procedure include the work envelope, the number of degrees of freedom, the number of modules used, and the dynamic stiffness.The number of kinematic degrees of freedom of the machine tool must be kept to a minimum required to meet the requirements, both to reduce the actuation power and minimize the chain of errors. Machine tool designs which are generated using this methodology for the example parts of Figure 1 are shown in Figure 8.The resulting designs must be evaluated with respect to the expected accuracy. The stiffness of the entire machine tool, one of the most important factors in performance, is estimated based on the module compliance matrices and the connection method.III. Control DesignAs the machine is built from modular elements, so is the control. In this work, we focus on the logic control for sequencing and coordination of the machine modules; a discrete-event system formalism is used 6. There is one control module associated with each active machine module; we refer to these as machine control modules. In the machine design, there are passive elements which connect the active elements together. In the control design, there must also be“glue” modules which connect the machine control modules. The overall architecture of the control system for an RMT is shown in Figure 9.The structure is similar for either of the two machines shown in Figure 8; for the V8 machine, there is no Y -axis control module. As shown, the machine control modules are at the lowest level; these interact directly with the mechanical system. Three modules handle the mode switching logic. In this section, we briefly describe each of these types of control modules as well as their interaction and coordination.A. Machine control modulesEach machine control module has a well-defined interface specification: it accepts discrete-event commands from a given set, and returns discrete-event responses from a given set. Within the control module will be all of the continuousvariable control, such as servo control for axes. This continuous control is designed using standard PID algorithms and the axis parameters such as inertia, power, lead screw pitch, which come from the machine module definition. In addition, each machine control module will contain controls for any machine services associated with the machine module, such as lubrication or coolant. Thus, each machine control module is a self-contained controller for the machine module it accompanies, and can be designed and tested independently of the rest of the machine.Fig.10.Slide ControllerThe design of a machine control module must be done only once for each machine module in the library. Whenever the machine module is used in a machine design, the control module can be used in the associated control design. The control module may be used independently, with its own processing power, I/O and a network connection to the rest of the control system, or it may be used as a piece of the overall machine controller which is implemented in a centralized fashion.B. Operation sequenceThe operation sequence module is defined from the high level sequence extracted from the cutter location data shown in Figure 3. C. Modular control structureThe user interface control module interacts with the user through a set of pushbuttons to turn the control system on and off, switch between control modes, and single-step through the operation sequence. Its main functions are to pass the user commands through to the rest of the controller, and to display the current state of the machine to the user.IV. Conclusions and Future WorkHistorically, machine tool design has been experience based. In this research, we described a mathematical basis for synthesis and evaluation of Reconfigurable Machine Tools and their associated controllers. This research work has addressed both the generation of machine tool configurations and modular control design. The systematic design process begins with the machining requirements.The presented methodology for synthesis of machine tools allows a library of machine modules to be precompiled and stored in a database, self-contained with controllers and ready to be used in any machine design. The methodology also ensures that all kinematically viable and distinctly different configurations are systematically enumerated to reduce the chance of missing a good design.We have already developed a Java-based program which automates the machine design process; we are currently incorporating the control design procedure within the existing framework.The authors would like to acknowledge the support and invaluable feedback from the industrial members of the ERC who have participated in this project.中文译文组合机床与控制设计摘要在本文中,我们描述一个系统的设计程序的可重构机床及其控制系统。为设计的出发点是一组操作,必须在一个给定的部分或部分家庭进行。这些操作被分解成一组的功能,机器必须执行的功能映射到机器模块,每一个都有一个相关联的机器控制模块。一旦机器构造的一组模块,电机控制模块连接。操作顺序控制模型模块,用户接口控制模块,模式切换逻辑,完成控制设计。集成的机械和控制设计的机床的可重构性进行了详细的描述。 引言在当今竞争激烈的市场,制造系统必须快速响应不断变化的客户需求和产品生命周期逐渐减少。传统的传输线是专为大批量的生产,在一个固定的自动化模式操作,因此不能很容易地容纳在产品设计上的变化。另一方面,传统的数控系统的“柔性”制造系统提供广义柔度但通常是缓慢的和前沉思的因为他们不是任何特定产品或一类产品的优化。 在密歇根大学的努力,旨在发展理论和可重构制造系统的使能技术。而每一次新的部分是需要从头开始建立一个加工系统,现有的系统可以重新配置,以产生新的部分。在本文中,我们描述了如何一体机和控制设计策略能够使机床能够迅速和容易地配置和重新配置。为了提供准确的功能和容量,需要处理的零件族,RMTs设计围绕一个给定的零件族。给定一组要执行的操作,可以通过安装合适的机器RMTs模块配置。在图书馆,每个有源模块与控制模块。当我装配机械模块,控制模块将被连接的机器将准备就绪。广泛的和耗时的专用控制系统的设计不需要。第二部分介绍了机器的设计,从一组基本的机械模块。 支持这项研究部分由NSF-ERC连接在一个明确的时尚,和第三部分的文士如何控制同样是由控制模块里图书馆。这种模块化施工机械和控制允许多层次的可重构性描述在第四章本文的结论的描述未来的工作在第五部分。机械设计在密歇根大学对制造系统的配置正在进行的工作的一部分地址从起动问题(或部分家庭)的描述和提取的加工操作需要产生部分(的)。的操作是根据公差组合,执行顺序,和所需的时间周期的系统,与意向每个操作“集群”可以在一个单一的机床生产。使用集群是为凸轮塔帽上的V6和V8气缸头,如图1所示的一套孔钻。对可重构机床设计过程的输入是由工艺师生成此操作化集群的刀位数据。数据包括定位和钻井资料。RMT设计过程分为三个主要阶段:任务澄清,模块的选择,评价。一个简短的文献回顾后,这三个阶段将在本节概述。A:相关研究 由于可重构加工系统中一个相对较新的概念,是很少的,如果任何,对可重构机床设计文献。然而,组合机床已在市场上几年,一些已发表的文章在模块化机器人,模块化的机器和装配有可重构机床设计的一些相关。例如,Shinno和Ito提出了一种方法,用于生成机床的结构配置。他们的机床结构分解成简单的几何形式:如盒,圆筒,等。燕、陈 21 , 1 扩展这项工作的加工中心结构设计。 12 适用于组合机床的合成和ITO的方法开发一个枚举机床模块的方法。Paradis和Khosla 15 确定模块化组件的配置是最适合执行特定的任务。在系统前,罗杰斯和Bottaci 16 讨论了可重构制造系统的意义,和欧文等人。 13 开发的模块化可重构制造系统综合程序用于教育目的。在我们的工作中,传统的运动表示和拓扑方法(即螺旋理论,图论,等)被用于捕获的皮肤的特点。这些数学方法用于拓扑合成,功能分解,和绘图程序;细节中可以找到 9 。图1B:任务说明 一个机床设计从任务澄清,这需要对刀具位置数据来确定所需要的函数集来完成所需的运动运动。有三个步骤。首先,图表生成抽象表示。PositionFeedSpindleCoolantt1t2t3t4t5t6t7t8 图3这样的操作序列的抽象表示来自CL数据,将被用来设计顺序控制的动作。这些图被分解为功能,和最后的功能映射到机床模块中存在的图书馆。该机床结构的图形表示允许备用配置系统的枚举,还提供了一种的不同构的图形识别方法。图表示也用于簿记分配机模块的图形元素。一个图包括一组由边缘连接在一起的顶点。在使用图形作为机床结构的抽象表示,我们定义了顶点的两种不同的类型:0型和1型。一个顶点表示的物理对象的两个端口,每个端口的位置;代表的对象,它可以连接到一个相邻的对象。0型顶点有输入和输出端口,尊重对方在线,而1型顶点具有输入和输出端口,互相垂直的。加工任务也分为0型或1型,这取决于该工具是平行或垂直于工件。C.模块的选择市售的模块,从模块库中选为每个函数(结构以及运动),映射到任务澄清阶段图。在图书馆的每个模块存储的数据包括齐次变换矩阵表示其运动或结构功能,扭曲矢量辅以运动信息的范围,代表刚柔度矩阵模块,模块的连接信息,和功率要求(有源模块如主轴和幻灯片)。在模块选择的第一步是要比较的齐次变换矩阵的模块与任务需求矩阵,在适当的时候选择模块以满足任务的要求,所有模块矩阵的乘积应等于所需的任务矩阵:T = T1 T2TN,可能有一个给定的结构的模块配置许多可能的选择。图6显示不同的幻灯片,主轴的结构元素,并可按图4组装。滑动模块,其CAD模型转化为矩阵,如图7所示。它能够线性运动的一个方向,通过它的变换矩阵的 1变量表示。它的数据库条目,见表1,不仅存储其变换矩阵,而且制造商的名称,型号,初始位置,功率电平,和运动数据。扭曲向量是增加了信息的最小值,初始模块的最大位移。表1组合机床的数据库信息和文件在图7中显示出来ManufacturerSUHNERModel NameUA 35-ACInitial Position1 0 0 02 0 1 0
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