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外文翻译用于提高大批量零件生产率的五面加工中心.doc

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外文翻译用于提高大批量零件生产率的五面加工中心.doc

南京工程学院毕业设计英文翻译课题名称母线槽技术参数检测线运动机构控制系统设计学生姓名指导教师所在系部专业名称南京工程学院2006年03月1日FiveFaceMachiningCenterToBoostProductivityofLargePartsHideoTamonManagerMachiningSection,ManufacturingDept1.IntroductionMeetingincreasinglydiversemachiningneedsandmakingeffectiveuseofalimitedsupplyofpersonnelandavailablespaceareamongthemostimportantgoalsformachinetoolmanufacturers,andkeyconsiderationsinfindingwaystoachievethemareproductivityandaccuracy.Toachievehighermachiningaccuracyandproductivity,SNKsShinodayamaWorkhasbeencontinuingtomodernizeitsproductionfacilitiesandimprovetheproductionenvironment.Asoftheearly1960s,therewereatotalof310machinetoolsatShinedayamaWorks,butthehavenowbeenreplacedbyonly70highlyproductivemachines.Guidedconsistentlybytopmanagementsphilosophycenteredonpursuitofautomationandfunctionalimprovement,ShinodayamaWorkshasbeenworkingtoincreaseproductivityandrationalizeitsfacilities.Duringtheprocess,asingleactionthatwasmostinstrumentalinincreasingproductivitywastheintroductionofmachinetoolsdesignedtomachinefivefacessidesoftheworkpieceinonesetup.Overtheperiodoftenyearsfrom1990allfactorybuildingsweremodifiedintotemperaturecontrolledfactoriessoastoensuretheconsistentaccuracyofthemachiningandtheassemblyincludingunitassemblyprocessesbystabilizingmachineandworkpieceaccuracy.Asaresult,themachiningcapacityofShinodayamaWorksbecamelargerthannecessarytomachinelargepartstobeusedinSNKproductsitbecamelargeenoughtomachineotherpartsundercontractforothercompanies.Thisarticlewillintroducetothereaderstheadvantagesofthefivefacemachiningcenterintermsofproductivity.Theseadvantageswillbedemonstratedinadiscussionofthemachiningofaturbinecasingofalargegenerator,whichisofacylindricalassemblyofcomplexconfiguration.TheturbinecasingismachinedwithSNKsnewlydevelopedHF8MMultiCenter,alarge,highperformance,precisionfivefacemachiningcenterinstalledatShinodayamaWorks.2.ConfigurationoftheWorkpieceTurbineCasingAsshowninfigure1,theturbinecasingtobemachineontheHF8Misofsplitcylinderconfiguration.ThedimensionsoftheturbinecasingarealsoshowninFigure1.Thecasingismadeofsteelandweighsabout70tons.ThemachiningprocessesofthisworkpiececanbesummarizedasfollowsProcessAMachiningofmatingsurfacesanddrillingofscrewandboltholes.ProcessBMachiningofoutsideflangesurfacesanddrillingofholesProcessCIDmachiningProcessDMachiningofflangesurfaceanddrillingoffasteningscrewholes3.ComparisonBetweenFivefaceMachiningandConventionalMachiningFortheprocessesAtoDmentionedinSection2,themachinetoolsrequiredforthemachiningmethodusingafivefacemachiningcenterandthemachiningmethodusingconventionalmachinetoolswerecomparedTable1.Asshowninthetable,useofafivefacemachiningcenterisadvantageousintermsofproductioncontrolandworkpiecemachiningaccuracybecausethemovementoftheworkpiecefrommachinetomachineandsetupchangesincludingalignmentthatwouldberequiredfordifferentmachinesintheconventionalmachiningmethodcanbeminimizedbyusingafivefacemachiningcenter.4.FunctionofHF8MMultiCenterCapableofPerformingAllMachiningOperationsThissectiondescribesthefunctionsandcharacteristicsoftheHF8Mthatiscapableofperformingallmachiningoperationsforaturbinecasing,alongwithsomenewlydevisedmachiningmethods.1UsingvariousattachmentsandautomationdevicesTheHF8MatSNKisequippedwithasevenattachmentautomaticattachmentchangerACCPhotoanda100toolautomatictoochangerATC.Byallowingthemachinetochangeattachmentsandcuttingtoolsautomaticallyasnecessary,therangeofmachiningoperationsthatcanbecarriedoutinonesetupcanbeexpanded,andefficiencyimprovementandautomationcanbeachieve.Themachiningoftheturbinecasingrequiredfourtypesofattachmentsincludinganewlydevelopedattachment.Angularattachment.Extensionattachment.Universalattachmentwithacalibrationsystem.Sidecutterattachmentnewlydeveloped2UniversalattachmentarbitraryplanemachiningfunctionAsshowninFigure1,theworkpiecehasmanyflangesurfacesandholesprotrudingbeyondtheoutsidesurfaceofthecasing.Theyarearrangedradicallyfromthecentralaxisofthecasing,areinclinedfromtheaxisdirectionandareofftheradialaxes.Theconventionalmachiningmethodistouseaninclinedattachmentmountedonahorizontalmachiningcenterwhiletheworkpieceisrotatedandpositionedonarotarytable.WiththeHF8M,auniversalattachmentwithacalibrationsystemwasusedincombinationwiththearbitraryplanemachiningfunctionPhoto3Thearbitraryplanemachiningfunctionallowsarbitraryprogramcoordinateaxescoordinateaxesrelativetowhichrotation,inclinationandshiftaredefinedarbitrarilytobedefinedfortheworkpiececoordinatesystem.Ifmachiningoperationsareprogrammedoncoordinateplanesrelativetothecoordinateaxesthusdefined,thecoordinatesareautomaticallyconvertedtomachinecoordinates.Thisisaveryusefulfunctionusedmainlyforsimultaneousthreeaxismachiningcarriedoutusingauniversalattachment.Whenthisfunctionisused,itisveryimportanttoknowthepositionofthetipofthecutter.ThisismadepossiblebyaccuratetoopresettinganduseofacalibrationsystemPhoto4Thisfunctionhasmadethemillingofoutsideflangesurfacesandthedrillingofholespossiblewithoutchangingequipmentormakingsetupchanges.Setupandalignmentrelatedfactorscontributingtoinaccuraciesinherentinmachiningoperationsperformedonahorizontalmachiningcenter,suchasdeflectionoftheworkpiecesetuponthetableanddeviationofthecentralaxisofrotarytablerotation,havealsobeeneliminated.Sinceafivefacemachiningcenterpermitsconsistentlyaccuratepositioningwithinthemachiningenvelope,accuracyofmachinedpartscanbeenhanced.3FinishcontouringoflargeholeswithasidecutterAnotherchallengeinthemachiningoftheturbinecasingisthemachiningofinsidediameterIDgrooves.TheturbinecasinghasmanyIDringgroovesthatneedtobemachined.TheconventionmachiningmethodistoassemblethetwohalvesofthesplitcasingandperformIDmachiningoftheassembledsplitcasingonalargeturninglathe.OntheHF8M,eachofthetwohalvesofthesplitcasingwassetuponthetablewiththematingsurfacingupwardasshowninPhoto5,andfinishcontouringwascarriedoutwithacombinationofasidecutterattachmentandahighperformancesidecutter.Toachievehighroundnessaccuracy,thefollowingmeasuresweretaken1FiveadjustmentforhighmachineaccuracyThemaximuminsidediameteroftheworkpieceisabout3,500mm,anditsroundnesstoleranceis0.05mm.WhenperformingIDmachiningonalargemachinetool,itisverydifficulttoachievearoundnessof0.05mmonaninsidediameterexceeding3,000mm.Priortomachining,weinspectedtheaccuracyofthemachineandadjustedthepositioningaccuracyofXYYZandXZplanes.WealsofineadjustedroundnesswithaDBBsystemtoenhancemachineaccuracy.Asaresult,wewereabletoachieveapostmachiningroundnessof0.04mm,whichwaswithinthetolerancerange.2Developmentofsmallheadtypesidecutterattachmentandhighperformancesidecutter.Circularmachiningwithasidecutterisnotadvantageousifthegoalishighspeedmachining.Thisisbecausecutterdiameter,groovecurvatureandgrooveconfigurationarerestrictedbythesizeandlengthoftheattachmentheadspindleunit.Torealizehighspeedmachining,therefore,ashortattachmentwithasmall

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