I. Appearance and Brief Introduction of Pinzheng CNC Deep Hole Drilling Machine

The appearance of Pinzheng CNC deep hole drilling machine is shown in figure 1- 1.

Figure 1- 1

Brief introduction of Pinzheng CNC deep hole drilling machine;

Deep-hole drilling: It has been playing an important role in production since 1982 came into being. At present, there is an urgent demand for the delivery of mold production in the market. Deep hole machining machine tools are fast and convenient, without reaming, and become an indispensable tool in one step. Moreover, the investment recovery cost is fast, which is a sharp weapon to seize the market.

Second, the advantages of deep-hole drill in design

Machining deep holes such as combined water channel, hot runner, pin hole, oil pump deep hole and roller hole. Our deep-hole drill has the following advantages in design:

1. The workbench, base body, upright post and lifting platform are all made of FC30 cast iron, which achieves the best shock absorption effect during processing.

2. The lathe bed and the workbench base are integrally formed, with the same structure and strong bones and muscles, and there is no design that the column is separated from the workbench.

3. The slide rail and workbench guide rail adopt V-shaped guide rail to ensure accurate guidance and no side clearance on the square rail. There is no hunting phenomenon when sliding, and it can keep sliding smoothly. Under strong pressure, the bearing seat and sliding seat are more closely combined. The two contact and can be uniformly stressed. Long-term exercise can maintain stable dynamic and static accuracy, prolong the life of parts and improve the processing quality.

4. After heat treatment and polishing, the slide rail can ensure durability and rigidity.

5. Adopt good oil pump design, control the flow and pressure, and ensure the service life.

6. In addition, CNC tool changing system device is adopted, just press the control key lightly, and pneumatic tool locking system is adopted. It is convenient to change tools.

7. Paper tape and magnet filter device can filter the scrap iron and trace elements in cutting oil during steel processing, and recycle them.

Three. Revised specification table of deep hole drill

Specification table of deep hole drill

The model mgd-813mgd-10/5mgd-1520mgd-1525.

Form (mm)

Worktable size 400 x1500 600 x 2000 800 x 2300 800 x 2800.

The work area is1300x600x800 (z1) x400 (z2)1500x600x1000 2000x1000x1500 2500x.

T-groove18mmx63mmx5 22x34x5 22x34x7 22x34x7

principal axis

Spindle feed stroke 800100012501500

The spindle feed speed (mm/min) is 20-5000mm.

Spindle diameter φ 120

The distance from the spindle end to the table top is 70mm.

electric motor

Spindle (kW) 7.5 kW

Magnetic separator (W) 25W

Paper tape filter 25W

Iron remover (W) 0.375

Hydraulic pump 10HPx6P

Lubricating oil pump 150Wx2

handling ability

The machining depth is 800100012501500.

Drilling capacity φ 3-25mm (32)

Oil pressure system

Cutting oil drum (L) 1800LT

High-pressure pump pressure (kg/cm2) 0- 120

High-pressure pump displacement (liter/minute) 5-70

Maximum load (kg) 1000 3000 5000 7000

Mechanical net weight (kg) is about 9000 10500 14500 16500.

It covers an area of about 3125x2046app.5000x5000app.5500x500app.6000x6000.

Part II: Analysis of NC machining process.

Requirements: According to the geometric characteristics and technical requirements of drawings, using the knowledge of NC machining technology, select machining methods, clamping and positioning methods, reasonably select cutting tools and geometric parameters used in machining, divide machining procedures and steps, arrange machining routes and determine cutting parameters. On this basis, it can complete the compilation of NC machining process documents for moderately complex parts (process analysis of at least two parts).

1. Machining slot holes on planar cam parts. The external contour has been completed, and the part material is HT200.

Figure 2. 1

1, part drawing process analysis

The inner and outer contours of the cam groove are composed of straight lines and circular arcs, which clearly and completely describe the relationship between geometric elements. The surface roughness of cam groove side and two inner holes is required to be Ra 1.6. The perpendicularity between the inner and outer contour surfaces of the cam groove and the hole and the bottom surface is required. The material of the parts is HT200, which has good cutting performance.

According to the above analysis, the machining of the cam groove and the inner and outer contours of the two holes should be divided into two stages: rough machining and finish machining to ensure the surface roughness requirements. At the same time, the bottom surface A is positioned to improve the clamping stiffness and meet the verticality requirements.

2. Determine the clamping scheme

According to the structural characteristics of the parts, when machining two holes, the bottom surface A should be used for positioning (process holes can be set if necessary), and the screw platen mechanism should be used for clamping. When machining the inner and outer contours of the cam groove, the positioning method of "two holes on one side" is adopted, and the bottom surface A and two holes are taken as the positioning datum.

3, determine the processing sequence and feed route

Determine the processing sequence according to the principle of base surface first, coarse first and fine second. Therefore, two holes used as positioning datum should be machined first, and then the inner and outer contour surfaces of the cam groove should be machined. In order to ensure the machining accuracy and separate rough machining from finish machining, the drilling-rough hinge-fine hinge scheme is adopted for the machining of two holes. The feed route includes two parts: plane feed and depth feed. When feeding the plane, the convex profile cuts in from the tangent direction and the concave profile cuts in from the transition arc. In order to make the surface of cam groove have better surface quality, forward milling is adopted. There are two methods for deep feed: one is milling back and forth in XOY plane (or YOX plane) and gradually feeding to a given depth; Another method is to drill a machining hole first, and then feed the tool from the machining hole to a predetermined depth.

4, tool selection

According to the characteristics of parts, eight kinds of tools are selected, as shown in the following table:

No, don't. Description of tool machining surface

Specification name quantity knife length/mm

1 T0 1？ 5 center drill 1 drill? 5 mm center hole

2 T02？ 19.6 bit 1 45? 20-hole rough machining

3 T03？ 1 1.6 bit 1 30? Rough machining of 12 hole

4 T04？ 20 reamer 1 45? 20-hole dressing

5 T05？ 12 reamer 1 30? 12 hole finishing

6t06 90 chamfering milling cutter 1? 20-hole chamfering 1.5× 45

7 T07？ 6 High-speed steel end mill120 Roughing the bottom fillet R0.5 of the inside and outside contour of cam groove

8 T08？ 6 carbide end milling cutter 1 20 finish machining the inner and outer contour of cam groove

5. Selection of cutting parameters

Leave a milling allowance of 0. 1㎜ when finishing the internal and external contours of the cam groove, and a hinge allowance of 0. 1㎜ when finishing the two holes. Spindle speed is 1000 rpm.

Second, the processing technology analysis and examples of shaft parts

Carburizing spindle 1 root (as shown in Figure 2-2), 40 in each batch, made of 20Cr, except for internal and external threads, S 0.9 ~ C59. The process of carburized parts is complicated, so it is necessary to draw a rough machining process sketch (as shown in the figure).

Spindle machining process

Work sequence and steps, contents and requirements of machine tools and equipment (omitted), fixtures, tools and measuring tools.

1 The car should be sized according to the process sketch.

Technological requirements: (1) drill a central hole φ2 at one end. (2) 1: 5 taper and Morse 3 # inner cone coloring inspection show that the contact surface is more than 60%. (3) The radial runout from the excircle to the center hole to be ground should not be greater than 0. 1.

CA6 140 Morse 3 Reamer Morse 3 Plug Gauge 1: 5 Ring Gauge

cheque

2 quenching heat treatment S0.9-C59

3 car decarbonization. One end is firmly clamped and the other end is centered.

& lt 1 & gt； At the end face of the lathe, ensure that the length from the step on the right end face of φ36 to the shaft end is 40.

& lt2> drill φ5B central hole.

& lt3> quarrel

Turn the end face, take the total length of 340 to the size, and continue to drill to the depth of 85 and 60 for chamfering.

cheque

Four cars, one clip and one roof CA6 140

& lt 1 & gt； Chem 30×1.5–6g Large diameter of left thread and Ф Ф 30JS5 to

Φ30

& lt2> car φ25 to φ25, length 43.

& lt3> cars φ35 to φ35

& lt4> turning grinding wheel overtravel groove

5 cars turn around, one clip and one roof.

& lt 1 & gt； Turn M30×1.5–6g thread major diameter and φ30JS5 to φ30.

& lt2> car φ40 to φ40

& lt3> turning grinding wheel overtravel groove

6 Milling 19 Two Planes to Dimensions

7 heat treatment HRC59

8 center holes are ground at both ends.

9. Grind two tips (the other end is plugged with a cone) M 1430A.

& lt 1 & gt； Roughly grind the φ40 excircle, leaving a margin of 0. 1 ~ 0. 15.

& lt2> Roughly grind the φ30js excircle to φ30t (two places).

& lt3> Rough grinding 1:5 taper, leaving grinding allowance.

10 V-shaped fixture for grinding inner circle (Ф 30JS5 is positioned on the second outer circle) M 1432A

Milling allowance of Morse 3 # inner cone (refitted with Morse 3 # cone plug)

0.2~0.25

1 1 thermal low-temperature aging treatment (baking) to eliminate internal stress.

12 car is clamped at one end and equipped with a center frame at the other end.

& lt 1 & gt； Drill φ 10.5 hole, and use guide sleeve to locate it, so that the thread will not attack Z-2027.

& lt2> Turn around, drill φ5 and tap M6-6h internal thread.

& lt3> Countersunk 60 Central Hole

& lt4> Drilling hole Ф10.5× 25 for turning sleeve drill sleeve (thread unchanged)

& lt5> 60 countersunk drill with a surface roughness of 0.8 and a center hole of 60.

cheque

13 pliers Insert the tapping sleeve into the taper hole.

& lt2> Tapping M12–6h Internal thread to size.

14 research center hole Ra0.8

15 cylindrical grinding workpiece is sandwiched between two centers.

& lt 1 & gt； Fine grinding the excircles of φ40 and φ35φ25 to size.

& lt2> Milling M30× 1.5 M30× 1.5 left thread to 30.

& lt3> semi-fine grinding Ф 30JS52 to Ф 30

& lt4> Fine grind the taper of 1:5 to size, and check the ring gauges with contact surface greater than 85% by coloring method.

16 grinding workpiece is sandwiched between two centers to grind threads.

& lt 1 & gt； Grind M30×1.5–6g left thread to M33× 1.5 left ring gauge.

& lt2> grind m30×1.5–6g thread to M33× 1.5 ring gauge.

17 grinding center hole Ra0.4

18 excircle grinding and fine grinding, the workpiece is sandwiched between two centers M 1432A.

Fine grind 2-φ30 to size, and pay attention to the form and position tolerance.

19 internal grinding workpiece is installed in V-shaped fixture. On the basis of1–Ф 30 excircle, finely grind Morse No.3 inner taper hole (located with 2 –Ф30JS5 excircle without plug-in), and the contact surface is more than 80%. Pay attention to the technical requirements of "1" and "2" mg148.

cheque

20 generally clean and apply antirust oil, and the warehousing workpiece is hung vertically.

Some notes on the processing of this kind of shaft parts;

1. Two central holes are used as positioning datum, which conforms to the principle of datum coincidence and datum unification mentioned above.

2. First, take the excircle as the rough datum, turn the end face and drill the center hole, then rough turn the excircle with the two center holes as the positioning datum, and then process the taper hole with the rough turn excircle as the positioning datum. This is the principle of mutual reference, which makes the machining have a more accurate positioning reference every time. No.3 Morse cone requires high accuracy. Therefore, taking the 2-Ф 30JS5 excircle as the positioning datum, V-shaped fixture is needed to meet the requirements of form and position tolerance. When turning the cone in the car, one end is clamped with claws, the other end is placed on the center frame, and the excircle is also used as the fine reference.

3. When semi-finishing and finishing the excircle, the cone plug is used, and the central hole of the cone plug is used as the positioning benchmark for finishing the excircle surface of the shaft.

Requirements for conical plugs:

(1) The cone plug has high precision, so as to ensure that the conical surface of the cone plug is highly coaxial with its central hole.

② The cone plug should not be replaced after installation, so as to reduce the installation error caused by repeated installation.

(3) The outer diameter of the conical plug should be externally threaded near the shaft end, so as to facilitate the removal of the conical plug.

4. The spindle is carburized and quenched with 20Cr low-carbon alloy steel, and a 2.5-3 mm decarburized layer is left on the surface of the parts (M30× 1.5-6g left, M30× 1.5-6g, M 12-6h, M6-6h) that do not need quenching.

5. The quenched thread cannot be processed on the lathe. If the thread is turned first and then quenched, the thread will be deformed. Therefore, the thread is generally not allowed to be hardened, and it is necessary to leave a layer of carbon on the diameter and length of the threaded part in the workpiece. For internal threads, a 3 mm decarburization layer should be left at the orifice.

6. In order to ensure the accuracy of the center hole, the center hole of the workpiece is not allowed to be hardened. Therefore, the total length of the blank is extended by 6 mm.

7. In order to ensure the grinding accuracy of the workpiece excircle, the process of grinding the center hole should be arranged after heat treatment, and the surface roughness should be fine. When grinding the excircle, the roundness of the workpiece is mainly affected by the coaxiality of the two central holes and the roundness error of the central hole.

8. In order to eliminate grinding stress, low-temperature aging process (baking) is arranged after rough grinding.

9. In order to obtain a high-precision excircle, grinding is divided into rough grinding, semi-fine grinding and fine grinding. Fine grinding is carried out on a high-precision grinder.

Part III: Compiling NC machining program.

Requirements: According to the technical requirements of drawings and the instruction format and programming method specified by CNC machine tools, the machining program of typical parts with moderate complexity can be correctly compiled, or the machining program of more complicated parts can be compiled by using CAD/CAM automatic programming software. (at least two parts).

A, shaft parts (1) NC machining program.

The parts are shown in Figure 3. 1.

The blank is a 42㎜ bar, which is cut axially from the right end to the left end; Each feed depth of rough machining is1.5mm2, and the feed speed is 0.15mm2/r; The finishing allowance is 0.5㎜ in X direction, 0. 1㎜ in Z direction, and the cutting blade width is 4㎜. The origin of the workpiece program is shown in Figure 3. 1.

This part is a typical shaft part with a simple structure and an axial dimension of 80㎜. It can be clamped by a three-jaw chuck, and the intersection of the rotating shaft of the workpiece and the right side surface is selected as the origin of the machining coordinate system.

1. Select the tool number and determine the tool change point.

According to the machining requirements, three sets of tools are selected: 1 is the rough turning tool on the left side of the excircle, No.2 is the finish turning tool on the left side of the excircle, and No.3 is the excircle cutting tool, and the tool changing point coincides with the tool setting point.

2. Determine the processing route

1) Roughing the excircle. Cut the outer contour from right to left, and use rough turning cycle.

2) Finishing the excircle. Chamfering at the left end → 20mm excircle → Chamfering → 30mm excircle → Chamfering → 40mm excircle.

(3) cut off

3 Select cutting parameters

See table 3. 1 for the selected cutting parameters.

Table 3. 1 Selecting cutting parameters

Rotation speed command feed speed (mm/r) tool

Roughing the excircle M43 0. 15 1

Finishing excircle M44 0. 1 2

Cut off M43 0. 1 2

Writing program

O000 1

m03t 0 10 1 M43 f 0. 15

G00 X43.Z0

G0 1X0。

G00X42.Z0。

G7 1 U2。 R0.3

g 7 1 p 1 Q2 u 0.25 w 0. 1 f 0. 15

N 1 G0 1 X 18。

X20。 Z- 1。

Z-20。

X28。

X30。 Z-2 1。

Z-50。

X38。

X40。 Z-5 1。

Z-82。

N2 X44。

G00Z0

M00

M03 M44 T0202

G70 P 1 Q2

G00Z5。

M00

M03 M43 T0303

G00 Z-44。

G0 1X0。

X44。

G00Z5。

M30

Second, compile the NC machining program for shaft parts (2)

Machining parts as shown in Figure 3-2, the material is 45 steel, and the blank is 60× 122.

1. Tool: T1-93 cemented carbide right-deviation tool;

T2-3mm wide carbide tool, d 1- left tooth tip.

Machining process material cutter

T 1 carbide for excircle.

Slotted cemented carbide T2

This part is a typical shaft part with simple structure, and its axial dimension is 1.20 ㎜. It can be clamped by a three-jaw chuck, and the intersection of the rotating shaft of the workpiece and the right side surface is selected as the origin of the machining coordinate system.

2. Select the tool number and determine the tool replacement point.

According to the machining requirements, two sets of tools are selected:No. 1 is the lathe tool with a thick left side of the excircle, No.2 is the excircle cutter and groove cutter, and the tool changing point coincides with the tool setting point.

3. programming; arrange

Program instruction description

n 10 G56 S300 M3 M7 t 1； Select tools and set process data.

n20g 96 S50 LIMS = 3000 f 0.3； Set the constant linear speed of rough turning.

n30 G0 X65 Z0； Quickly approach the workpiece and prepare the end face of the lathe.

n40 g 1x-2； Automobile end face

n50 G0 X65 z 10； retract

n60 CNAME = " LK2 "； Contour call

n70 r 105 = 1 r 106 = 0.2 r 108 = 4 r 109 = 0

r 1 10 = 2 r 1 1 1 = 0.3 r 1 12 = 0. 15； Blank loop parameter setting

N80 LCYC95 calls LCYC95 for circular contour rough machining.

n90 G96 S80 LIMS = 3000 f 0. 15； Set the constant linear speed of finish turning.

n 100 r 105 = 5； Adjust cycle parameters

n 1 10 lcyc 95； Call LCYC95 to finish the machining of circular contour.

n 120 G0 x 100 z 150； Remove the knife quickly and prepare to change it.

n 125 G97； Cancel constant linear velocity

n 130 T2 f . 1 S250； Effectively replace T2 cutter D 1 and adjust the process data.

n 140 G0 X42 Z-33； Quickly guide the tool to the left side of groove Z.

n 150 lce XP 2 P8； Call subroutine to cut 8 slots 8 times.

n 160 G0 x 100 z 150 M9； Quickly remove the tool and cool it.

n 170 M2； end of program

LK2

n 10g 1x 0 Z0；

n20 G3 X20 Z- 10 CR = 10；

n30 g 1 Z-20；

n40 G2 X30 Z-25cr = 5；

n50 g 1x 39.98 CHF = 2.8 18；

n60 Z- 100；

n70 X60 Z- 105；

n80 m 17；

LCEXP2

n 10g 9 1g 1 X- 14；

n20 G4 S2；

n30 g 1 x 14；

n40 G0 Z-8；

n50 G90 m 17；

Part IV: Drawing CAD parts.

References: [1] Machining Technology, edited by Fan Chongluo and Xie Liming, published by Southeast University Press and printed for the sixth time in April 2002.

[2] NC Programming Processing Technology edited by Zhang Sidi and He Shuxin, published by Chemical Industry Press, printed in Beijing in June 2005 1 time.

[3] Fundamentals of Numerical Control Technology, edited by Han Hongluan, was published by Machinery Industry Press and printed for the second time in 2000.

[4] CNC Machine Tools and Programming, edited by Liu Shuhua, published by Mechanical Engineering Press, 0 1 third printing.

[5] Fundamentals of Mechanical Manufacturing Technology, edited by Fu Shuigen, published by Tsinghua University Publishing House, printed 1 time in 2003.