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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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编号:201311171435356615    类型:共享资源    大小:58.00KB    格式:DOC    上传时间:2013-11-17
  
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附录A:英文资料Ultra-high-speedprofilerforaircraftpartmachiningDHP-120B:developmentgoalsandperformanceKazuyaTanakaManagerDesigningSect.II,EngineeringDept.I1.InstructionItisgenerallysaidthattheconditionssurroundingtheaircraftindustryhavebeenlessthanoptimalsincetheterroristattackofSeptember11,2001,buttheJapaneseaircraftindustryseemstobeinaslightlydifferentsituation.ThisisobservationissupportedbythefactthattheDefenseAgency’s“PX”(advancedanti-submarinepatrolplane)and“CX”(cargotransportplane)projectshavebeenapproved,andBoeing-andAirbus-relatedcontracthavenotdeclinesignificantly.Thankstotheseandotherfactors,suchasthefactthattheindustryisenteringtheequipmentreplacementphase,theJapaneseaircraftindustryiscurrentlyinrelativelygoodshape.Undertheinfluenceoftheglobalmarketneeds,thereisverystrongdemandforreducingthecostsofcivilaircraftparts.Tomeetthisdemand,aircraftmanufacturersandjobshopscontractedtosupplypartstothemhavebeenworkinghardtoreducecostandimprovemanufacturingtechnologyandproductivity.Thenumberofaircraftproducedbymanufacturersofsmalljetaircraftisincreasingatamuchfasterratethanthenumberofaircraftproducedbymanufacturersmoreorlessspecializinginlargeraircraft,suchasBoeingandAirbus.Despitethesteadygrowthofdemand,jobshopsundercontractwiththeseaircraftmanufacturersarebeingfacedwithincreasingpressuresforcostreduction.TheemergenceofsoutheastAsiancountriescapableofproducingpartsatlowcoasthasmadepricecompetitionfiercer.TheChineseaircraftindustryisburstingwithenergybecausejobshopsinChinacannowcompetewithJapanesejobshopsinleadtimeandqualityinadditiontobeingabletoproducepartsatlowercoasts.Giventheseglobaltrendtrends,itcanbesaidthattheJapaneseaircraftindustry’spositionisdelicateinthecompetitivemarket.Inspiteoflead-timeandqualitysuperiority,theJapaneseaircraftindustryisfightingasteeplyuphillbattleinpricecompetition.Tohelpcopewiththesituationasamachinetoolmanufacturer,SNKhasdevelopedDHP-120B,anadvanced5-axisultra-high-speedhorizontalprofilerthatisatoncemostcost-effectiveandhighlyproductive.Therestofthisarticleintroducesthenewprofiler.2.Background:BriefHistoryofProfilerDevelopmentatSNKSincethedevelopmentofSM-13SparMill(with13numericallycontrolledaxes)in1967,SNKhasdevelopedmanymachinetoolsdesignedforaircraftpartsmachiningandfive-axisprofilers,anddeliveredmanymachinestospecialtyjobshopsbothinJapanandabroad.Oneofthelargermachinesrecentlydevelopedanddeliveredisatwo-gantry,A&B-axis-type,three-spindlefive-axisprofilerwitha64-meter-longbedwitha4-meter-wideworkingsurface(Photo1).AsshowninPhoto1,theseprofilerareverticalspindlemachinesthatenabletheoperatortosetupalargeworkpieceonthebedinastableposition.Astimepassed,however,thewayaircraftpartsaremanufacturedhaschanged:machiningofforgings,whichusedtobethemethodofmanufacturingaircraftparts,begantobereplacedbythemethodofmachiningcomplexpartsoutofsolidmaterialinordertoreducethenumberandweightofparts.Thismeantremovingmostofthematerialduringmachining.Useofhigh-speedmachining,whichisdesignedtoincreaseproductivity,alsodramaticallyincreasedthevolumeofmetalremovedperhour,makingverticalspindlemachinesanunrealisticchoicefromthestandpointofchipremoval.Tomeetthechangingneeds,SNKdevelopedHPS-4B(Photo2),alarge5-axishigh-speed,horizontal,tilting-table–typeprofilerdesignedspecificallyforhigh-speedmachiningofcomplexpartsoutofsolidmaterial,easysetupandefficientchipremoval.Thenewmachinewasputonexhibitatthe1998Chicagoshowandwashailedbyaircraftpartsjobshops.Since,however,HPS-4Bisalargemachinewitha2×10mmachineenvelope,itwastoolargeandtooexpensiveforsmallerjobshops.Todemonstratethesuperiorofthemachineconceptandeasyoperatorofferedbythistypeofmachine,SNKdevelopedamachinebasedonasimilarconcept.Thismachine,HPS-120B,isacompactandreasonably-price5-axishigh-speedhorizontalprofiler(Photo3)andwasexhibitedatthe2000Chicagoshow.Thismachinewasacclaimedforitsperformanceandeconomyandhasnowbecomeoneofthegreatestvalue-addedmodelsoftheSNKprofiler.Marketneeds,however,havechangedrapidly,andtherehasbeenincreasingpressureforcostreduction,asmentionedearlier.Recognizingtheneedforahigh-speedprofilercapableofperformingmachinewithunprecedentedefficiency,SNKdevelopeditsnewest5-axisultra-high-speedhorizontalprofiler,UHP-120,thatinheritstheacclaimedfeaturesoftheHPSseriesofprofiler,andputthemachineonexhibitatthe2001EMOshow.3.UHP-120B:DevelopmentGoalsandPerformanceTheaimofdevelopmentofUHP-120Bistooffertousersacost-effectivemachinethatboostsproductivityinthemachiningofmedium-andsmall-sizedpartsofaluminum,amaterialwidelyusedinaircraftapplications.UsingHPS-120B,whichhasprovenperformanceinthefieldofhigh-speedmachine,asabasemachine,SNKdevelopedUHP-120B(Photo4)throughextensiveresearchanddevelopment.Therestofthissectionintroducesprincipaltechnologiesincorporatedintothenewmachinetoachievethegoalsofthemachine.Forinformationonthemachine’smainspecifications,pleaseseeNewProductNewsinthisreport.1)Technologytoachievehighproductivity(1)Developinghigh-speedhigh-powerspindleunitItisgenerallysaidthatthereisnolimittocuttingspeedsusedinthemachiningofaluminumtomanufactureaircraftparts.Thekeytoincreasingproductivityinsuchmachiningistofindawaytoachievehighmetalremovalratesathighcuttingspeeds.Tothisend,wedevelopedanew75kW,32,000min-1,high-speedhigh-powerspindleunitwithacompact,powerfuldrivemotorforthenewprofiler.Thishigh-performancespindleunitranksamongthehighestintermsofspindlespeedandpowerforthespindleconfigurationisequippedforHSK-E63toolsaccordingtouserneeds.Thespindlebearingsareequippedwithanunder-racelubricationsystemtoenhancereliabilityofhigh-speedmachiningduringlong-timeoperation.(2)IncreasingfeedratesHighaxisfeedratesandhighacceleration/decelerationcapabilitiesareimportantfactorsdirectlyaffectingmachiningtimeandmachiningaccuracythatcanbeachievedinhigh-speedmachining.Forthelinearaxes,twindrivesystemsandtow-motor-drivemechanismshavebeenemployedtoincreasetherigidityofthedrivesystem,toincreasefeedratesandmaximizeacceleration/deceleration,andtoincreaseproductivity.Asaresult,themaximumcuttingfederatesof40m/minand4800deg/minhavebeenachievedforthelinearaxes,respectively.WebelievethatUHP-120Branksamongthebestintermsofspindleandaxisandaxisfeedcapabilityinthefieldofthemachiningofaluminumaircraftparts.(3)MinimizingmovingmassesReducingthemovingmassalongeachaxisisaneffectivewaytomakeaxismovementfasterandachieveahighlevelofdynamicresponsiveness.UHP-120Bhasbeendesignedasamovingramtype,insteadofamovingcolumntype,machine,thestructuraldesignhasbeenoptimizedthroughminimizationofthemovingmassesandcomputer-aidedstructuralanalysestomakethemachinestructureverylightandstiff.ThespindleheadandthespindleheadsaddleinstalledontheZ-axisramaremadeofaspeciallightweightalloywhosecoefficientofthermalexpansioniscomparabletothatofironsoastoreducetheweightsofthemovingpartsandminimizedeflectionsoftheramaxisduetoY-axisaccelerationacceleration/deflectionsorZ-axisextension.Althoughthespeciallightweightalloyisstillexpensive,itisusedbecauseofitsaccuracyandperformanceadvantages.(4)EndlessrotationofC-axisAshipringsystemhasbeenbuiltintotheC-axismechanismtoenableendlessrotationofC-axis,therebyeliminatingtheneedtorewindC-axis,adrawbackofafive-axismachinewithAandCrotaryaxes.Thus,rewindmotion,whichwouldbeunavoidableonaconventionalmachine,cuttermarksleftwhilethecutterisnotmovinginrelationtotheworkpiece,andextracareneededduringNCprogramminghavebeeneliminated.Therotationspeedshavebeenincreased,andthetimerequiredfordecelerationalongthelineraxes,whichusedtoslowdownC-axismovement,hasbeenminimizedsoastoshortenmachiningtime.(5)TiltingtableUHP-120Bisequippedwithatiltingtablesystem,whichisthesametypeasthetiltingtableusedontheHPS-seriesfive-axisprofilersandwaswell-receivedbyitsusers.Withthistiltingtable,theworkpiececanbesetuponthetabletiltedintoastablehorizontalposition.Machiningoperationscanbeperformedwhilethetableisintheverticalpositionsothatlargevolumesofchipsproducedduringhigh-speedmachiningcanberemovedfromthemachiningzonequickly.Thus,theproblemofchipremovalhasbeensolvedwhilemaintainingahighlevelofproductivity.(6)High-speedcontrolHigh-speedfive-axismachiningofaircraftpartsrequiresevaluatingmanydatablocksaheadandprocessingdatablocksathighspeed,asformachiningofautomobilediesandmolds.Cuttingtoolsmustalsobeprovidedwithfive-axiscontrolorientedfeaturessuchasfive-axistoollengthanddiametercompensation.TheprecisioncontouringcapacityofUHP-120Bhasbeenupgradedforhigh-speedfive-axiscontrol.High-speedcontrolorientedfeaturesnewlyaddedtoincreaseproductivityincludeFineHPCC(HighPrecisionContourControl),whichcontrolsrotaryandlinearaxismovementaccuratelyandsmoothly,tooltipcontrol,andthree-dimensionalcutterdiametercompensation.(7)SafetyandenvironmentalfeaturesAsspindlespeedsandfederatesincrease,therisksposedbyflyingchipsandbrokencuttersincrease.Toensuresafetyformthesedangers,themachiningareaincludingthehigh-speedspindleiscompletelyenclosedbyasplashguard.ThroughthesplashguardwindowsoraTVmonitorinstalledoutsidethemachiningarea,theoperatorcanmonitormachiningoperationsand
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