JZC750混凝土搅拌机设计【说明书+CAD】
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附录1英文原文英文原文COSTSTUDYOFHIGHSPEEDCUTTINGUNDERDRYANDWETCONDITIONSFORMACHININGPROCESSESOPTIMIZATION1INTRODUCTIONTHEAIMOFTHISSTUDYISTOOPTIMIZETHEMACHININGPROCESSESBYINVESTIGATINGTHERELATIONSHIPBETWEENTHEHIGHSPEEDMACHININGHSMANDTHETOOLLIFEFORTHECUTTINGCONDITIONSUNDERTESTINGFURTHERMORE,STUDYINGTHEEFFECTOFCUTTINGFLUIDONTHESELECTEDWEARCRITERION,ANDRELATIONSHIPBETWEENDIFFERENTWEARCRITERIAANDMACHININGCOSTFORTHECUTTINGINSERTSUNDERHSMTHISINVESTIGATIONSHOWEDTHATWEARRATEISPROPORTIONALTOCUTTINGSPEEDSUPPORTEDWITHSIMILAROBSERVATIONS12,18,19STUDYINGTHECORRELATIONBETWEENHIGHWEARRATESATHIGHCUTTINGSPEEDANDMACHININGCOSTS,PROVIDESBETTERUNDERSTANDINGONTHEPERFORMANCEOFTHISPOLICYANDTHEBENEFITOFITSADOPTIONCURRENTLY,LITTLEORNODATAHAVEBEENPUBLISHEDRELATINGTHELIFECYCLECOSTS,TOOLPERFORMANCE,WORKPIECESURFACEROUGHNESSANDWORKPIECEDIMENSIONALACCURACYWHENUSINGSOLIDANDINDEXABLECUTTERS10HOWEVER,STUDIESHAVEFOUNDTHATTOOLCOSTSINMETALCUTTINGMACHINESAREATHIRDOFTHECOSTOFPRODUCINGPARTSTHEREFOREREDUCINGPRODUCTCOSTISTHEFIRSTOBJECTIVEOFATOOLMANAGEMENTSYSTEM16THEBENEFITSOFADOPTINGTHISRESEARCHGUIDELINEWILLHELPDETERMINETHEOPTIMALMACHININGCOSTANDTOOLREPLACEMENTPOLICYBASEDONDIFFERENTWEARCRITERIONVALUESADDITIONALLYTHISSTUDYPROVIDESINSIGHTINPROCESSCONTROLANDHELPSTHEMANAGERSINTHEEARLYPROCESSPLANNINGSTEPSTOASSOCIATEFACTORSSUCHASPREVENTIVEMAINTENANCE,LEVELSOFINVENTORY,ANDMACHININGCOST2EXPERIMENTALSTUDYTHESTUDYDEVELOPEDAGUIDELINEOFCHOOSINGTHERIGHTCUTTINGTOOL,CUTTINGSPEED,ANDSELECTINGTHEAPPROPRIATEWEARCRITERIAOFTHECUTTINGTOOLINSERTSFORTHEWORKMATERIALUNDERSTUDYINTHISSTUDYVARIABLEWEARCRITERIARANGINGFROM0LMMTO06MMTOOLLIFELIMITWERETAKENINTOCONSIDERATIONTHISEXPERIMENTWASCONDUCTEDINACCORDANCEWITHTHEINTERNATIONALSTANDARDORGANIZATIONISO3685199346THETESTWASDONEONACLAUSING1300VARIABLESPINDLESPEEDMACHINEWITHAMAXIMUMPOWEROF75HPSEEFIGURE31THETOOLWEARMEASUREMENTSWEREPERFORMEDUSINGANOPTICALMICROSCOPEWITHAMAGNIFICATIONOFUPTO300TIMES,ANDASCANNINGELECTRONMICROSCOPESEMTHEROTATIONALSPEEDOFTHEWORKPIECEWASMEASUREDBEFOREEVERYCUTBYAHT5100HANDHELDDIGITALTACHOMETERTOINSURETHATTHEWORKPIECEWASACCURATELYRUNNINGATTHEEXACTCUTTINGSPEEDONTHEOTHERHAND,THEWORKPIECEMATERIALWASREPLACEDWHENTHELENGTH/DIAMETERRATIOREACHES10,BASEDONISO3685199346,TOENSUREWORKPIECESTABILITYANDSAFETYTWOPRECUTWERECARRIEDOUTWITH12MMDEPTH,TOCLEANUPTHETHINLAYEROFRUST,ANDTOENSUREWORKPIECESTRAIGHTNESSFIGURE1THETUNINGMACHINEUSEDDURINGTHETEST21WORKPIECEANDCUTTINGINSERTSINTHISSTUDY,HOTROLLEDASTM4140STEELWASSELECTEDASTHEWORKPIECEMATERIALTHEWORKPIECEPROPERTIESARELISTEDASFOLLOWSDESCRIPTIONHOTROLLEDALLOYSTEELBARS,SAE4140HUNSH4140DIMENSIONS15CMDIAMETERX6225CMLENGTHHEATTREATMENTVACUUMDEGASSED/PROCESSED,CALALTREATED,ANNEALEDANDSPECIALSTRAIGHTENED,CONFORMINGTOASTMA322ANDA304CHEMICALCOMPOSITIONSTHECOMPOSITIONOFTHEWORKPIECEMATERIALISLISTEDINTABLE31ACCORDINGTOTHEASTMSTANDARDSTHEEXPERIMENTWASCARRIEDOUTINACCORDANCEWITHTHEINTERNATIONALSTANDARDORGANIZATIONISO36859346,THEEXPERIMENTWASSTOPPEDANDTHEWORKPIECEWASCHANGEDWHENTHELENGTH/DIAMETERRATIOREACHED10TOMEETTHEREQUIREMENTSOFISO368546THEHARDNESSOFEACHBARWASCHECKEDACROSSTHEDIAMETER,ANDTHEAVERAGEHARDNESSMEASUREMENTWAS29HRCTHETYPESOFTESTEDCUTTINGTOOLINSERTSARELISTEDONTABLE31ACCORDINGTOTHEISODESIGNATIONTHREETYPESOFCUTTINGINSERTSWEREUSEDINTHEEXPERIMENTASILLUSTRATEDINTABLE32ANDTHECOATINGPROPERTIESAREALSOLISTEDINTABLE33THECONFIGURATIONOFTHEINVESTIGATEDTHREECUTTINGINSERTSWASTHESAMEASLISTEDINTABLE34THEGENERALCUTTINGINSERTASSEMBLEDGEOMETRYISSHOWNINFIGURE32THEINSERTSWEREMOUNTEDRIGIDLYONATOOLHOLDERAREDEPICTEDINFIGURE33WITHANISODESIGNATIONOFSVJBR2525M16TABLE1CHEMICALCOMPOSITIONOFASTM4140STEELUSEDINTHETESTCUTTINGINSERTSISODESIGNATIONSUBSTRATEGRADECOMPANYUNCOATEDCEMENTEDCARBIDEVBMT160408KC313KENNAMETALTIALNVBMT160408KC313KC5010KENNAMETALTINTICNTINVBMT160408KC313KC732KENNAMETALTABLE2TYPESOFTHETESTEDCUTTINGINSERTSCARBONMANGANESEPHOSPHORUSSULFURSILICONNICKELCHROMIUM040910017002024010101TIN0008ALUMINUM0030VANADIUM0002CALCIUM00064MOLLY02COPPER012TABLE3COATINGSPROPERTIESCOATINGTHICKNESSNUMBEROFLAYERSTIALN351TINTICNTIN33T1T3TICNINTERMEDIATE22COOLANTPROPERTIESITISACOMMONBELIEFTHATCOOLANTEMULSIONHELPSINREDUCINGWEARRATEANDCUTTINGTEMPERATURETHECOOLANTUSEDINTHETESTWASWATERBASEDEMULSIONHASCOMMERCIALNAMENOVICKITISMIXEDWITHWATERATACONCENTRATIONOF10THECOOLANTCOMPOSITIONINCLUDESTHELISTEDCHEMICALSINTABLE5PREVIOUSRESEARCHERSONTHEBETTERCOOLANTSTREAMDIRECTIONSMADEDIFFERENTSUGGESTIONSTAYLOR17INDICATEDTHATTOREDUCETOOLWEARTHECUTTINGFLUIDISTOBEDIRECTEDATTHEBACKOFTHECHIPDIRECTIONAPIGOTTANDCOLWELL47FOUNDTHATBYUSINGHIGHSTREAMJETOFCOOLANTAIMEDINDIRECTIONBITWASABLETOREDUCETOOLWEARSMARTANDTRENT48INVESTIGATEDTHEDIRECTIONOFCOOLANTINREDUCINGTHETOOLWEARANDFOUNDTHATTHEMOSTEFFECTIVEDIRECTIONBETWEENALLOTHERSUGGESTEDOPTIONSWASDIRECTIONBTHEREFORE,COOLANTWASAPPLIEDINDIRECTIONBASLISTEDINFIGURE34FROMANOZZLEWITHDIAMETEROF13CMANDAFLOWRATEOF71LITERS/MINUTEHOWEVER,THECURRENTSTUDYSHOWEDTHATTHISISNOTNECESSARILYTRUEINALLCASESASCOOLANTEXTENDSTHETOOLLIFEITWASFOUNDTHATCOOLANTEMULSIONHELPEDREDUCETOOLLIFEBYACTIVATINGCERTAINWEARMECHANISMATHIGHSPEEDMACHININGHSMDETAILEDEXPLANATIONSOFTHISTYPEOFCOOLANTEFFECTWILLBEDISCUSSEDINCHAPTER5FURTHERMORE,ABRIEFSUMMARYANDEXPLANATIONOFTYPESANDUSAGEOFCOOLANTWILLBECOVEREDINCHAPTER5TABLE4ASSEMBLEDCUTTINGTOOLGEOMETRYTOOLGEOMETRYDIMENSIONNOSERADIUS08MMBAKERAKEANGLE0ENDRELIEFANGLE5ENDCUTTINGEDGEANGLE52SIDECUTTINGEDGEANGLE30SIDERAKEANGLE0SIDERELIEFANGLE5TABLE5COOLANTCHEMICALCOMPOSITIONSSULFATE2030AROMATICALCOHOL35PROPYLENEGLYCOLETHER35PETROLEUMOIL3035NONIONICSURFACTANT35CHLORINATEDALKENEPOLYMER2030ANGULARTOOLDESIGNATIONBACKRAKE0SIDERAKE0ENDRELIEF5SIDERELIEF5ENDCUTTINGEDGE52SIDECUTTINGEDGE3NOSERADIUS088MMNOSERADIUSCUTTINGBACKRAKEANGLESIDERAKEANGLEFIGURE2ASSEMBLEDTOOLGEOMETRYFIGURE3PHOTOGRADPHOFTHECUTTINGINSERTFIXEDONTHETOOLHOLDERABFIGURE4COOLANTSTREAMDIRECTION3CUTTINGCONDITIONSBASEDONI80368546FIVECUTTINGSPEEDSWEREUSEDTHROUGHOUTTHETESTINGASLISTEDONTABLE6CUTTINGSPEEDSCORRESPONDINGTO410M/MINFORTHECOATEDCARBIDETOOLSAND180M/MINFORTHEUNCOATEDCARBIDETOOLSWEREAPPROXIMATELYTHEUPPERLIMITOFTHEAPPLICATIONRANGESINCEANYFURTHERINCREMENTRESULTEDINVERYSHORTCUTTINGTOOLLIFEORPREMATURETOOLDAMAGESOONAFTERTHETESTWASSTARTEDTHETURNINGEXPERIMENTSWERECARRIEDOUTUNDERDRYANDWETCUTTINGCONDITIONSATDIFFERENTCUTTINGSPEEDS,WHILEFIXINGBOTHFEEDRATEAT014MM/REVANDDEPTHOFCUTAT1MMFIVECUTTINGSPEEDSWERESELECTEDFORTHETHREETYPESOFCUTTINGINSERTS,ASLISTEDINTABLE364EXPERIMENTALPROCEDUREOFTOOLLIFETESTINGACLAUSING1300LATHEWITHMAXIMUM75HPWASUSEDFALLOYSTEELSAE4140HWORKPIECE,ANDTHETURNINGPROCESSWASCARRIEDOUTINTHEWAYORTHETURNINGOFTHEHOTROLLEDPREVIOUSLYDESCRIBEDATACHOMETERWASUSEDTOMEASURETHEROTATIONALSPEEDBEFOREEACHSINGLECUTOCCURREDONTHEWORKPIECEINORDERTOENSURETHATTHECUTTINGWASPERFORMEDATTHEEXACTSPEEDANOPTICALMICROSCOPEWASUSEDTOMEASURETHEFLANKWEAROFTHECUTTINGINSERTSTHEEXPERIMENTWASTERMINATEDIFEITHEROFTHETWOFOLLOWINGCONDITIONSOCCURRED1THEMAXIMUMFLANKWEAR07MMAND/OR2THEAVERAGEFLANKWEAR06MMPRELIMINARYEXPERIMENTSWERECARRIEDOUTINORDERTODETERMINETHEWEARLIMITITWASFOUNDTHATTHECUTTINGINSERTSWEREWORNOUTREGULARLYONTHEFLANKSIDETHERFORE,VBNAX07MM,ISCHOSENTOBETHEWEARLIMITFORTHETOOLLIFETHEFLANKWEARWASOBSERVEDANDMEASUREDATVARIOUSCUTTINGINTERVALSTHROUGHOUTTHEEXPERIMENTSFIGURE5SHOWSFLANKWEARASAFUNCTIONOFCUTTINGTIMEFORTHECEMENTEDCARBIDEKC313UNDERDRYANDWETCONDITIONS,ANDINCLUDESONLYTHREECUTTINGSPEEDSFORCLARITYFIGURE6PRESENTSTHEFLANKWEARASAFUNCTIONOFCUTTINGTIMEFORSANDWICHCOATEDINSERTSKC732UNDERDRYANDWETCONDITIONSFIGURE7SHOWSTHEFLANKWEARASAFUNCTIONOFCUTTINGTIMEFORTIALNCOATEDCUTTINGINSERTSKC5010PREVIOUSFIGURESINCLUDEDTHREECUTTINGSPEEDSCLARITYOFCUTTINGSPEEDCURVESAREPRESENTEDATTHEATTACHEDAPPENDIXFORBOTHCONDITIONSOFMACHININGTHEAFOREMENTIONEDFIGURES,PRESENTTHEEFFECTOFCOOLANTEMULSIONINEXTENDINGTHETOOLLIFEFORTHEKC313,ANDKC732CUTTINGINSERTSESPECIALLYAFTER3MINUTESFORKC313,ANDAFTER7MINUTESFORKC732OFCUTTINGHOWEVER,THEUSAGEOFCOOLANTEMULSIONONKC5010SHOWEDNEGATIVEINFLUENCEFIGURE5,ANDFIGURE6SHOWTHATATANYSETOFTURNINGCONDITIONS,THEFLANKWEARINCREASEDATAHIGHERRATEATDRYCUTTINGDURINGTHEGRADUALWEARSTAGEFIGURE7SHOWSTHATATANYSETOFTURNINGCONDITIONS,THEFLMKWEARINCREASEDATAHIGHERRATEATWETCUTTINGDURINGTHEGRADUALWEARSTAGETHEEXPLANATIONOFTHISMATERIALBEHAVIORWILLBECOVEREDINDETAILTHOUGHOUTCHAPTER5WEARMECHANISMSOFKC5010UNDERWETCONDITIONAFTERGRADUALWEARSTAGETHECURVESLOOKPARALLELTOEACHOTHERTHISSHOWSTHATFLANKWEAROCCURSATTHESAMERATEUNDERDRYANDWETCUTTINGCONDITIONSTHEPREVIOUSFIGURESSHOWTHATFLANKWEARCURVESWENTTHROUGHTHREESTAGESOFWEARRUNNINGINWEARSTAGE,GRADUALWEARSTAGEORSTEADYSTATEWEAR,ANDFOLLOWEDBYRAPID,FATALWEARSIMILAROBSERVATIONSWEREDOCUMENTEDBYCHUBBANDBILLINGHAM11,HARON12THEFOLLOWINGTERMINOLOGIESAREUSEDINITIALORRUNNINGINWEARSTAGETAKESPLACEDUETOTHERAPIDBREAKDOWNOFTHEEDGE,WHICHISSHOWNBYTHEINITIALHIGHWEARRATEINTHEGRAPHOFWEARAGAINSTTIMECURVES1,2,AND3INFIGURE6THISSTAGEISDECREASEDASTHECUTTINGSPEEDINCREASEDGRADUALWEARSTAGETHEFIGURESOFTHETHREETYPESOFCUTTINGINSERTS,AFTERTHEINITIALWEARHASTAKENPLACE,INDICATINGASTEADYGRADUALSTAGEONTHEINSERTWEARWILLFORMHOWEVER,ITWILLINCREASEWITHLESSDRAMATICPATTERNTHANTHEINITIALSTAGERAPID,FATALWEARTHEFINALSTAGEOFWEAR,WHICHLEADSTOACATASTROPHICFAILUREOFTHECUTTINGINSERTSRAPIDFATALWEARREVEALEDBOTHFLANKANDLARGECRATERFORMATIONTHATWEAKENEDTHETOOLEDGEANDUNDERSUSTAINEDRESISTANCETOTHEHIGHCUTTINGFORCES,CAUSEDITTOFRACTURETESTINGMETHODSINDICATEDRAPIDBREAKDOWNTOOKPLACEDURINGCUTTINGCAUSINGSEVEREDAMAGETOTAKEPLACEONTHEWORKPIECESURFACETHEREFORE,IMAGININGTHATTHECATASTROPHICFAILURETOOKPLACEDURINGTHEFINALCUTTINGPASSATTHEWORKPIECESURFACE,ITISHIGHLYLIKELYTHATTHEWORKPIECEHASTOBESCRAPPEDTABLE6CUTTINGSPEEDSUSEDINTHETESTFORTHESPECIFICTYPEOFINSERTSCUTTINGINSERTCUTTINGSPEEDM/MINKC3136090120150180KC5010210260310360410KC732210260310360410CEMENTEDCARBIDEKC313WETDRYFIGURE5FLANKWEARASAFUNCTIONOFCUTTINGTIMEFORKC313DRYANDWETTINTICNTINKC732WETDRYFIGURE6FLANKWEARASAFUNCTIONOFCUTTINGTIMEFORKC732DRYANDWETTIALNKC5010WETDRY00OTT05101520253035404550556065TIMEMINFIGURE37FLANKWEARASAFUNCTIONOFCUTTINGTIMEFORKC5010DRYANDWET附录2外文翻译在干燥和潮湿的条件下研究高速切削的费用以及便于机械制造过程的优化1介绍这项研究的目的是在已知试验的切削条件下通过对高速加工与刀具间的寿命之间的关系的调查，来优化选择机械加工过程。此外，在具有可选择的磨损标准下研究切削液的影响，以及研究不同的磨损标准与处于高速加工过程中切削用具的加工费用之间的关系。这项调查研究显示磨损率与切削速度成比例，观察到的12，18，19证明了这一结论。通过研究在高速切削条件下的高磨损率和加工费用之间的彼此关系，可以更好得了解这项方案的执行过程以及采用这种方案所带来的效益。目前，几乎没有或者说没有数据来解释当使用坚固以及带分度的切削机10时，所需的生命周期的费用，刀具性能，工件的表面粗糙度和尺寸精度。但是，这项研究发现金属切削机床中的刀具费用是加工零件所需费用的三分之一。因此降低制造费用是刀具经营系统16的首要目标。采用这项研究的指导方针的好处有在不同的磨损标准价值的基础上，它将帮助决定最合理的加工费用以及刀具的更换方案。这项研究另外还提供了程序控制的可视性以及帮助经理在早期的处理计划中与某些因素进一步联系起来。比如，这些因素指的是定期检修，存货水平和加工费用。2实验性研究研究形成了选择正确的切削刀具，切削速度以及选择处于研究过程中用来加工工件材料的切削工具的合理磨损标准的指导方针。这项研究还考虑了各种不同的磨损标准范围为01MM到06MM刀具寿命的限制。本实验是根据国际标准ISO3685199346而进行的。试验是在多主轴高速机床上进行的，该机床型号为CLAUSING1300，最大动力为75HP（图1）刀具磨损量的测量采用放大倍数为300的光学显微镜，并且该显微镜装有电子显微扫描仪（SEM）。为了确保工件是在极其精确的切削速度下进行，工件的旋转速度是在每一次切削之前由数字转速表（HT5100）测量所得。另一方面，根据ISO3685199346当工件材料的长度与直径比达到10时，该工件材料就的被替换，这是为了确保工件的稳定性与安全性。为了清除灰尘薄膜以及确保工件的直线度，两次试切的深度应为12MM。图1实验所用的车床21工件与切削刀具在这次实验中，热轧钢ASTM4140被选择作为工件材料。以下列出了工件属性描述热扎合金钢条，SAE4140HUNSH4140。尺寸直径15CM，轴线方向长6225CM。热处理真空处理，CALAL处理，退火和调制处理，形成ASTMA322和A304。化学成分依据ASTM标准，工件的化学成分在表1中已给出。实验的执行是符合国际标准组织ISO36859346的，当工件的长度与直径比为10时，该实验就停止进行并且替换工件，目的是为了符合ISO368546的规定。每根钢条的硬度通过直径比被测量的，以及平均硬度的测量值为29HRC。依据ISO规定，表1列出了实验期间所用的各种切削刀具。表2列出了实验中所用的三种切削工具，表33给出了涂层种类，表34列出了被检测的三种切削刀具的结构。图2给出了普通切削刀具的几何角度。根据ISO标准SUJBR2525M16所规定，图3描绘出了刀具牢固地安装在刀夹上的情况。表1实验所用的ASTM4140钢的化学成分切削刀具ISO标准基材级配公司未涂碳VBMT160408KC313KENNAMETALTIALNVBMT160408KC313KC5010KENNAMETALTIN_TICN_TINVBMT160408KC313KC732KENNAMETAL表2实验所用的各种切削刀具碳04锰091磷0017硫002硅024镍010铬101锡0008铝0030钒0002钙00064钼02铜012表3涂层物涂层厚度层数TIALN35U1TITICNTIN3U3T1T3TICN中间体22冷却物普遍认为冷却乳化液能帮助降低磨损率和切削温度。实验所用冷却液是以乳化液为基础的水溶液，商业上称作NOVICK。其中含水量为10。冷却液的化学成分在表5已列出。以前的研究人员就更好的冷却液的流向有着不同的意见。TAYLOR17表明为了减少刀具磨损率切削液的流向应在切屑的背后（A向）。PIGOTT和COLWELL47发现通过使用高喷射流的冷却液对准B向就能减少刀具磨损率。SMART和TRENT48调查了降低刀具磨损的冷却液方向并且发现在所有的建议中最有效的方向是B向。因此，图4所用的冷却液以直径为13CM的喷嘴流出，流速为71L/MIN方向是B向。但是，目前的研究表明在所有作为冷却液而增加刀具寿命的事例中，这种方案并不是十分正确的。研究发现通过某中磨损机制的作用如高速机床（HSM），冷却乳化液帮助减少了刀具磨损率。这种冷却液的效果的详细解释将在第5章介绍。另外，第5章还覆盖了冷却液的简历种类解释以及使用方法。表4切削刀具的几何数据刀具几何TOOLGEOMETRY尺寸刀尖圆弧半径NOSERADIUS08MM前角BAKERAKEANGLE0后角ENDCUTTINGEDGEANGLE5副偏角ENDCUTTINGEDGEANGLE52余偏角SIDECUTTINGEDGEANGLE30副前角SIDERAKEANGLE0副后角SIDERELIEFANGLE5表5冷却剂的化学成分硫芳香酒精丙烯甘醇以太20303535石油润滑油3035非离子表面活化剂35氯化烯烃聚合物2030DESIGNATIONBACKRAKE0SIDERAKE0ENDRELIEF5SIDERELIEF5ENDCUTTINGEDGE_52SIDECUTTINGEDGE_3NOSERADIUS088MMNOSERADIUSCUTTINGBACKRAKEANGLESIDERAKEANGLE图2刀具几何图3安装在刀夹上的切削刀具照片AB图4冷却液的流向3切削条件根据ISO368546规定，表6列出了整个实验过程所用的五种切削速度。切削速度为410M/MIN对应的刀具涂层含碳，180M/MIN对应的刀具涂层不含碳，这两种速度大约达到了应用范围的最高极限。如果速度再增加的话将会导致刀具的寿命再实验开始时很短时间内就耗尽或很快损坏。车削实验是在干燥，潮湿以及不同切削速度的条件下进行的，然而两种实验所需的进给量和切削深度各自为014MM/REV，1MM。表6
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