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外文翻译超高速靠模工具机进行航空零件的制造.doc

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外文翻译超高速靠模工具机进行航空零件的制造.doc

附录A英文资料UltrahighspeedprofilerforaircraftpartmachiningDHP120BdevelopmentgoalsandperformanceKazuyaTanakaManagerDesigningSect.II,EngineeringDept.I1.InstructionItisgenerallysaidthattheconditionssurroundingtheaircraftindustryhavebeenlessthanoptimalsincetheterroristattackofSeptember11,2001,buttheJapaneseaircraftindustryseemstobeinaslightlydifferentsituation.ThisisobservationissupportedbythefactthattheDefenseAgencysPXadvancedantisubmarinepatrolplaneandCXcargotransportplaneprojectshavebeenapproved,andBoeingandAirbusrelatedcontracthavenotdeclinesignificantly.Thankstotheseandotherfactors,suchasthefactthattheindustryisenteringtheequipmentreplacementphase,theJapaneseaircraftindustryiscurrentlyinrelativelygoodshape.Undertheinfluenceoftheglobalmarketneeds,thereisverystrongdemandforreducingthecostsofcivilaircraftparts.Tomeetthisdemand,aircraftmanufacturersandjobshopscontractedtosupplypartstothemhavebeenworkinghardtoreducecostandimprovemanufacturingtechnologyandproductivity.Thenumberofaircraftproducedbymanufacturersofsmalljetaircraftisincreasingatamuchfasterratethanthenumberofaircraftproducedbymanufacturersmoreorlessspecializinginlargeraircraft,suchasBoeingandAirbus.Despitethesteadygrowthofdemand,jobshopsundercontractwiththeseaircraftmanufacturersarebeingfacedwithincreasingpressuresforcostreduction.TheemergenceofsoutheastAsiancountriescapableofproducingpartsatlowcoasthasmadepricecompetitionfiercer.TheChineseaircraftindustryisburstingwithenergybecausejobshopsinChinacannowcompetewithJapanesejobshopsinleadtimeandqualityinadditiontobeingabletoproducepartsatlowercoasts.Giventheseglobaltrendtrends,itcanbesaidthattheJapaneseaircraftindustryspositionisdelicateinthecompetitivemarket.Inspiteofleadtimeandqualitysuperiority,theJapaneseaircraftindustryisfightingasteeplyuphillbattleinpricecompetition.Tohelpcopewiththesituationasamachinetoolmanufacturer,SNKhasdevelopedDHP120B,anadvanced5axisultrahighspeedhorizontalprofilerthatisatoncemostcosteffectiveandhighlyproductive.Therestofthisarticleintroducesthenewprofiler.2.BackgroundBriefHistoryofProfilerDevelopmentatSNKSincethedevelopmentofSM13SparMillwith13numericallycontrolledaxesin1967,SNKhasdevelopedmanymachinetoolsdesignedforaircraftpartsmachiningandfiveaxisprofilers,anddeliveredmanymachinestospecialtyjobshopsbothinJapanandabroad.Oneofthelargermachinesrecentlydevelopedanddeliveredisatwogantry,ABaxistype,threespindlefiveaxisprofilerwitha64meterlongbedwitha4meterwideworkingsurfacePhoto1.AsshowninPhoto1,theseprofilerareverticalspindlemachinesthatenabletheoperatortosetupalargeworkpieceonthebedinastableposition.Astimepassed,however,thewayaircraftpartsaremanufacturedhaschangedmachiningofforgings,whichusedtobethemethodofmanufacturingaircraftparts,begantobereplacedbythemethodofmachiningcomplexpartsoutofsolidmaterialinordertoreducethenumberandweightofparts.Thismeantremovingmostofthematerialduringmachining.Useofhighspeedmachining,whichisdesignedtoincreaseproductivity,alsodramaticallyincreasedthevolumeofmetalremovedperhour,makingverticalspindlemachinesanunrealisticchoicefromthestandpointofchipremoval.Tomeetthechangingneeds,SNKdevelopedHPS4BPhoto2,alarge5axishighspeed,horizontal,tiltingtable–typeprofilerdesignedspecificallyforhighspeedmachiningofcomplexpartsoutofsolidmaterial,easysetupandefficientchipremoval.Thenewmachinewasputonexhibitatthe1998Chicagoshowandwashailedbyaircraftpartsjobshops.Since,however,HPS4Bisalargemachinewitha210mmachineenvelope,itwastoolargeandtooexpensiveforsmallerjobshops.Todemonstratethesuperiorofthemachineconceptandeasyoperatorofferedbythistypeofmachine,SNKdevelopedamachinebasedonasimilarconcept.Thismachine,HPS120B,isacompactandreasonablyprice5axishighspeedhorizontalprofilerPhoto3andwasexhibitedatthe2000Chicagoshow.ThismachinewasacclaimedforitsperformanceandeconomyandhasnowbecomeoneofthegreatestvalueaddedmodelsoftheSNKprofiler.Marketneeds,however,havechangedrapidly,andtherehasbeenincreasingpressureforcostreduction,asmentionedearlier.Recognizingtheneedforahighspeedprofilercapableofperformingmachinewithunprecedentedefficiency,SNKdevelopeditsnewest5axisultrahighspeedhorizontalprofiler,UHP120,thatinheritstheacclaimedfeaturesoftheHPSseriesofprofiler,andputthemachineonexhibitatthe2001EMOshow.3.UHP120BDevelopmentGoalsandPerformanceTheaimofdevelopmentofUHP120Bistooffertousersacosteffectivemachinethatboostsproductivityinthemachiningofmediumandsmallsizedpartsofaluminum,amaterialwidelyusedinaircraftapplications.UsingHPS120B,whichhasprovenperformanceinthefieldofhighspeedmachine,asabasemachine,SNKdevelopedUHP120BPhoto4throughextensiveresearchanddevelopment.Therestofthissectionintroducesprincipaltechnologiesincorporatedintothenewmachinetoachievethegoalsofthemachine.Forinformationonthemachinesmainspecifications,pleaseseeNewProductNewsinthisreport.1Technologytoachievehighproductivity1DevelopinghighspeedhighpowerspindleunitItisgenerallysaidthatthereisnolimittocuttingspeedsusedinthemachiningofaluminumtomanufactureaircraftparts.Thekeytoincreasingproductivityinsuchmachiningistofindawaytoachievehighmetalremovalratesathighcuttingspeeds.Tothisend,wedevelopedanew75kW,32,000min1,highspeedhighpowerspindleunitwithacompact,powerfuldrivemotorforthenewprofiler.ThishighperformancespindleunitranksamongthehighestintermsofspindlespeedandpowerforthespindleconfigurationisequippedforHSKE63toolsaccordingtouserneeds.Thespindlebearingsareequippedwithanunderracelubricationsystemtoenhancereliabilityofhighspeedmachiningduringlongtimeoperation.2IncreasingfeedratesHighaxisfeedratesandhighacceleration/decelerationcapabilitiesareimportantfactorsdirectlyaffectingmachiningtimeandmachiningaccuracythatcanbeachievedinhighspeedmachining.Forthelinearaxes,twindrivesystemsandtowmotordrivemechanismshavebeenemployedtoincreasetherigidityofthedrivesystem,toincreasefeedratesandmaximizeacceleration/deceleration,andtoincreaseproductivity.Asaresult,themaximumcuttingfederatesof40m/minand4800deg/minhavebeenachievedforthelinearaxes,respectively.WebelievethatUHP120Branksamongthebestintermsofspindleandaxisandaxisfeedcapabilityinthefieldofthemachiningofaluminumaircraftparts.3MinimizingmovingmassesReducingthemovingmassalongeachaxisisaneffectivewaytomakeaxismovementfasterandachieveahighlevelofdynamicresponsiveness.UHP120Bhasbeendesignedasamovingramtype,insteadofamovingcolumntype,machine,thestructuraldesignhasbeenoptimizedthroughminimizationofthemovingmassesandcomputeraidedstructuralanalysestomakethemachinestructureverylightandstiff.ThespindleheadandthespindleheadsaddleinstalledontheZaxisramaremadeofaspeciallightweightalloywhosecoefficientofthermalexpansioniscomparabletothatofironsoastoreducetheweightsofthemovingpartsandminimizedeflectionsoftheramaxisduetoYaxisaccelerationacceleration/deflectionsorZaxisextension.Althoughthespeciallightweightalloyisstillexpensive,itisusedbecauseofitsaccuracyandperformanceadvantages.4EndlessrotationofCaxisAshipringsystemhasbeenbuiltintotheCaxismechanismtoenableendlessrotationofCaxis,therebyeliminatingtheneedtorewindCaxis,adrawbackofafiveaxismachinewithAandCrotaryaxes.Thus,rewindmotion,whichwouldbeunavoidableonaconventionalmachine,cuttermarksleftwhilethecutterisnotmovinginrelationtotheworkpiece,andextracareneededduringNCprogramminghavebeeneliminated.Therotationspeedshavebeenincreased,andthetimerequiredfordecelerationalongthelineraxes,whichusedtoslowdownCaxismovement,hasbeenminimizedsoastoshortenmachiningtime.5TiltingtableUHP120Bisequippedwithatiltingtablesystem,whichisthesametypeasthetiltingtableusedontheHPSseriesfiveaxisprofilersandwaswellreceivedbyitsusers.Withthistiltingtable,theworkpiececanbesetuponthetabletiltedintoastablehorizontalposition.Machiningoperationscanbeperformedwhilethetableisintheverticalpositionsothatlargevolumesofchipsproducedduringhighspeedmachiningcanberemovedfromthemachiningzonequickly.Thus,theproblemofchipremovalhasbeensolvedwhilemaintainingahighlevelofproductivity.6HighspeedcontrolHighspeedfiveaxismachiningofaircraftpartsrequiresevaluatingmanydatablocksaheadandprocessingdatablocksathighspeed,asformachiningofautomobilediesandmolds.Cuttingtoolsmustalsobeprovidedwithfiveaxiscontrolorientedfeaturessuchasfiveaxistoollengthanddiametercompensation.TheprecisioncontouringcapacityofUHP120Bhasbeenupgradedforhighspeedfiveaxiscontrol.HighspeedcontrolorientedfeaturesnewlyaddedtoincreaseproductivityincludeFineHPCCHighPrecisionContourControl,whichcontrolsrotaryandlinearaxismovementaccuratelyandsmoothly,tooltipcontrol,andthreedimensionalcutterdiametercompensation.7SafetyandenvironmentalfeaturesAsspindlespeedsandfederatesincrease,therisksposedbyflyingchipsandbrokencuttersincrease.Toensuresafetyformthesedangers,themachiningareaincludingthehighspeedspindleiscompletelyenclosedbyasplashguard.ThroughthesplashguardwindowsoraTVmonitorinstalledoutsidethemachiningarea,theoperatorcanmonitormachiningoperationsand

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