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With the development trend of multi-axis and compounding of machine tool products, and with the characteristics of high efficiency, versatility and high precision, the Dongfeng Motor Co., Ltd. equipment manufacturing plant has developed an opposed twin-shaft vertical turning center, which can be adapted Highly flexible and high-precision machining of commonly-used metal parts at both ends of full-thickness and precision machining can realize full-automatic production, and can be easily connected to an automatic production line, or be combined in series with similar machines to form a new highly automated processing line. .
In the production of automobiles and motorcycles, there are a large number of shaft and disk hub type rotary parts processing, often with large quantities, many varieties, high requirements, and complicated process contents, which brings high efficiency, high flexibility, high precision, and versatility to turning equipment. , to promote the rapid development of turning equipment. Many new technologies such as knife-assisted tools, electric drive and control, transmission and measurement have been applied. The development of related technologies has also resulted in a variety of machine tool structures.
Figure 1 Opposite Twin Spindle Vertical Turning Center
The foreign advanced machine tool industry is mature in the design and manufacturing of CNC turning centers. Its machine tool products show the development trend of multi-axis and compounding. It has the characteristics of high efficiency, multi-energy, and high precision, and represents the development direction of such machine tools. In response to this development trend, our factory has developed a counter-supplied double-spindle vertical turning center (Figure 1), which fills the gap in such domestic equipment.
Overall machine layout and performance features
The introduction of a new vertical-vehicle design concept, combined with the spindle-inverted vertical lathe and the traditional vertical-vehicle structure, adopts a machine-building layout scheme that overcomes the defects of traditional lathes. The machine design goals are expected to meet the following requirements:
1. Highly automated to achieve high efficiency and easy automation connection.
2. Easy chip removal and reliable positioning, which is conducive to processing automation and processing quality assurance.
3. Adapt to the high-precision, high-precision turning of both ends of a common metal part that is completely rough and finished.
4. The application of advanced technology (development and application of high-torque electric spindles, development and application of high-speed and high-precision feed systems, and application of power tool holders, etc.) and advanced technical indicators have been adapted to the progress of application and maintenance of domestic machine tools.
Machine tool bed, cross slide, mobile inverted spindle I, electric tool holder I, fixed positive spindle II, servo powered tool holder II, blanking robot, electrical, hydraulic, automatic centralized lubrication, air circuit and automatic cooling chip removal System components and other components, according to the specific parts processing conditions, the other equipped with the corresponding knife auxiliary tools, fixtures and automatic material loading and unloading, preparation of the corresponding CNC machining program, which constitutes a complete automated manufacturing system (Figure 2).
Figure 2 Complete automated manufacturing system
The working cycle of the machine tool is as follows: the workpiece reaches the feeding position through the feeding motor track → the spindle I descends (Z1 axis), the workpiece is lifted by the feeding cylinder to realize the end surface positioning, the clamp I is driven by the rotary oil cylinder and the spindle I grips the workpiece edge Z1, X1 axes run to tool rest I machining interval → Workpieces are processed by program → Spindle I travels along axis Z1, X1 to spindle II, the workpiece is placed on spindle II, fixture II is clamped, spindle I returns to the next cycle → tool carrier II Run along the X2, Z2 axis to the spindle II → Workpieces are processed according to the program → Fixture II is released. The blanking robot on the mounting table of the tool holder II grabs the workpiece and runs along the X2 and Z2 axes to the blanking raceway and puts down the workpiece. → The material raceway sends the workpiece out of the machine.
Obviously, the two-axis motion of the spindle I (fixture I) and the toolholder II not only completes the cutting feed function, but also has the function of automatic loading and unloading movement. With the automatic raceway, fully automatic production becomes simple and easy. , CNC spindle and feed axis movement ensure the flexibility of processing. When the basin-shaped workpiece is processed, the basin shape is downward, the tool holder I is used to process the characteristics of the basin, the tool holder II is characterized by the processing basin, and the chips are discharged smoothly, the positioning is reliable, and the processing is facilitated. Opposite double spindles and upper and lower double tool holders are simple in configuration and can realize complete machining on both ends of the workpiece. Comparing two single axis vertical lathe lines, the machine parts and floor area are less, and the workpiece transport is simpler and more reliable. These constitute the machine tool structure. biggest advantage.
Comparing with similar foreign machine tools, the machine tool structure absorbs its advantages, and the main technical performance indicators have been at the same level, the feed forward speed of each feed axis reaches 40m/min, the acceleration reaches 0.4g, and the positioning accuracy and repeat positioning accuracy reach 0.008 Mm and 0.005mm.
The maximum diameter of the workpiece can be machined workpiece φ350mm, the maximum height of 250mm, two tool holders are 8 positions, enough to meet the processing of more complex workpieces, configure the servo power tool holder, but also on the workpiece milling, drilling, tapping and other processing, The automatic detection system can also be configured to provide tool compensation and automatic tool setting functions. The rich and flexible configuration greatly meets the requirements of functional integration and multi-process technology integration.
Main technical points
1. Development of Large Torque Turning Spindle
The vertical spindle I needs to move quickly, so the servo motor spindle (as shown in Figure 3) is used to drive the spindle. Compared with the traditional mechanical spindle, the structure is simple, the volume is small, the weight is light, the noise is small, the transmission inertia is small, and the fast response is good. High speed, acceleration.
Figure 3 Spindle structure
Generally, the larger spindles and workpieces on the vertical spindle require relatively low motor speed and relatively large torque, which is significantly different from that of machining spindles. For this purpose, the spindle used in this machine has been specially developed. Its rotational speed is rated at 1000r. /min, maximum 2800r/min, torque rated 260Nm, maximum 340Nm.
The end of the spindle is equipped with a gear type absolute encoder for the spindle speed and circumferential position control feedback, and realizes the spindle C axis function, which enables the machine tool to have circumferential characteristic machining functions such as drilling, tapping and milling.
When turning the ring-shaped end face of the workpiece, constant-line speed and variable-speed cutting are often adopted until the rotation speed is limited and then the constant-speed cutting is performed, which is favorable for improving the efficiency and surface processing quality. The INDACAT company's MTC200-R CNC system and the DIAX04 series digital AC servo system were configured to facilitate its implementation.
Adopting imported precision angular contact ball bearing assembly, the bearing adopts life-cycle maintenance-free high-grade grease lubrication, adopts airtight seal, 0.1MPa pressure air flow leaks through the gap between the end cap and the spindle surface, blocking the entry of dirt, and the air filtering accuracy is 0.001mm and is dry This seal is better than contact and labyrinth seals.
The spindle motor is built in as a servo motor with high power density, the current is large, the stator winding current and the rotor induced eddy current generate a large amount of heat, which affects the bearing temperature, and forced cooling is necessary. The main shaft box body is designed to pass the water cooling channel outside the rotor and the bearing, and is forcedly cooled by water with a pressure lower than 0.3 MPa and a temperature lower than 40° C., and a rust inhibitor is added to the water. The reliable operation of the water cooling system is extremely important. The water cooling system has temperature and pressure monitoring alarms to prevent damage to the spindle.
The machine tool runs automatically, using imported rotary cylinders and hydraulic power chucks.
The spindle box body is made of cast aluminum alloy material, and its weight is reduced by 60% compared with cast iron. Decreasing the inertia improves the acceleration performance and at the same time facilitates the heat dissipation of the spindle. Considering the low hardness and easy abrasion, the main shaft hole should not be directly mounted with tight bearings. The spindle hole is lined with steel sleeves to ensure multiple high-precision repeated assembly. The air and liquid passage holes are processed in the box wall, and the pipeline is completely connected from the end of the spindle, which is neat and beautiful.
The rotating part of the main shaft is dynamically balanced, grade G2.5, and the high speed section of the main shaft runs smoothly without vibration, which is conducive to the service life and processing quality.
2. Development of high-speed, high-precision feed system
The feed system includes X1, X2, Z1, and Z2 four-axis servo control linear motion to complete the feed function of two stations.
Imported high-precision precision roller linear guide rails meet the requirements of rough machining with high load and high-precision machining. Imported grating scales are used as feedback devices for position measurement of sliding tables to form a closed-loop control system for machine tools.
The servo motor and the imported precision ball screw are used to form the feed movement system, and the motor load, inertia matching performance and system rigidity in the transmission system are carefully designed and checked. The ratio of the load inertia of each axis to the moment of inertia of the motor is controlled between 1.0 and 1.5 to ensure that the movement response is rapid; both ends of the screw are fixed and the lead screw is pre-stretched to improve the system stiffness and ensure the fine feed.
3. Electronic control system
The INDRAMAT MTC200-R CNC system is equipped with features such as high performance, high flexibility and high reliability. It has a rich set of NC programming instructions that can meet the processing requirements of various general and special machine tools. Integrated PLC controller, PLC programmer, human-machine interface and other functions; INDRAMAT company's DIAG04 series digital AC servo system, which features high precision, high speed and high reliability, and has a complete failure Diagnosis, status indication function; equipped with 10.4in (1in = 25.4mm) color liquid crystal TFT display as man-machine interface, real-time display the status of the machine tool, including the movement speed of the servo axis, the current position, the status of the detection switch of each machine tool and the actuator The status of the machine, etc.; the machine also has operation prompt function, fault diagnosis and display function, which instructs operation and maintenance personnel to use and maintain the machine tool.
Conclusion
The new vertical lathe features compact structure, good openness, and smooth evacuation. It can adapt to the high-precision, high-precision machining of the metal parts that are completely rough and finished at both ends. It can realize full-automatic production and can be conveniently Connected to an automatic production line, or in series with a machine of the same type to form a new, highly flexible automatic processing line. After the successful development of this machine tool in 2005, various performance indicators have achieved the expected goals, put into production and use well, and won the second prize of Chunyan Award in 2006 China CNC Machine Tool Exhibition, and third prize of China's automobile industry in 2007.
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