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关键词：: 曲轴工艺规程设计系列夹具铣端面图纸磨夹具

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曲轴工艺规程设计及系列夹具设计【铣端面+磨夹具】

43页 19000字数+说明书+任务书+开题报告+外文翻译+6张CAD图纸【详情如下】

V形架夹具图 A3.dwg

任务书.doc

外文翻译--机械设计.doc

工艺工序卡片19张

曲轴工艺规程设计及系列夹具设计开题报告.doc

曲轴工艺规程设计及系列夹具设计论文.doc

曲轴模夹具装配图 A0.dwg

磨夹具装配图3 A0.dwg

计划周记进度检查表.xls

过渡盘夹具图 A1.dwg

铣端面夹具装配图 A0.dwg

铸铁夹具图 A2.dwg

摘要

　　　本次设计的主要内容包括空压机曲轴的工艺规程设计和系列夹具设计的两大方面。

制定工艺规程设计的原始资料包括：零件的图样，产品验收质量标准，产品的年生产纲领和生产类型、毛坯图样、生产条件、零件材料等。制定工艺规程设计步骤如下：审查零件的图样，工艺方案的确定，对样品进行工艺分析，零件的毛坯选择以及毛坯图说明; 工艺设计过程（包括加工段的分析，工序的集中和分散，工序顺序的安排，定位基准的选择，零件表面加工方法的选择); 制定工艺路线（工艺方案，工艺方案的比较与分析），工序间尺、公差、表面粗糙度及毛坯尺寸的确定，加工余量、切削用量、工时定额的确定，填写工艺文件。夹具设计必须满足的要求有：保证加工精度，夹具的总体方案应与年生产纲领相适应，安全、方便、减轻劳动强度，排屑顺畅，具有良好的强度、刚度和结构工艺性。夹具设计包括工件的定位，定位误差的分析与计算，夹紧机构的确定，夹具力的确定（包括方向，作用点和大小）。

关键词：工艺规程设计；夹具设计；加工余量；定位误差

摘要III

AbstractIV

目录V

1 绪论1

1.1 本课题研究的内容及意义1

1.2 国内外发展情况1

1.3 本课题应达到的要求2

2 工艺方案的确定3

2.1 曲轴零件的结构特点3

2.2 曲轴零件的技术要求3

3 零件工艺分析4

3.1 根据零件图和产品装配图，对零件进行工艺分析4

3.2 计算零件的生产纲领，确定生产类型4

4 毛坯选择和毛坯图说明5

4.1 毛坯技术分析5

4.2 确定毛坯种类和制造方法5

4.3 确定毛坯总余量5

5 工艺设计过程6

5.1 加工阶段的划分6

5.2 工序的集中与分散6

5.3 工序顺序的安排6

5.4 定位基准的选择6

5.5 零件的表面加工方法的选择6

6 制定工艺路线7

6.1 工艺路线方案一7

6.2 工艺路线方案二7

6.3 工艺方案的比较与分析8

7 工序间尺寸、公差、表面粗糙度及毛坯尺寸的确定9

8 加工余量，切削用量，工时定额的确定10

8.1 工序一：铣两端面，打中心孔10

8.1.1 工步一：铣两端面10

8.1.2 工步二：两端面打中心孔10

8.2 工序二：粗车大端主轴颈及平衡块外轮廓11

8.2.1 工步一：粗车大端Φ40主轴颈外圆面及轴肩11

8.2.2 工步二：车平衡块Φ174外轮廓11

8.3 工序三：粗车小端外轮廓12

8.3.1 工步一：粗车小端Φ40主轴颈外圆面及轴肩12

8.4 工序四：半精车大端主轴颈及倒角12

8.4.1 工步一：半精车大端Φ40主轴颈外圆面及轴肩12

8.5 工序五：精车大端主轴颈及倒角13

8.5.1 工步一：精车大端Φ40主轴颈外圆面及轴肩13

8.5.2 工步二：精车大端主轴颈上1×45°倒角14

8.6 工序六：半精车Φ40外圆面及轴肩锥面、小端锥面14

8.6.1 工步一：半精车小端Φ40主轴颈外圆面及轴肩14

8.6.2 工步二：倒Φ40主轴颈上角15

8.7 工序七：铣键槽15

8.7.1 工步一：铣键槽15

8.8 工序八：精车Φ40外圆面及轴肩锥、小端锥面16

8.9 工序九：粗车连杆轴颈及其轴肩17

8.9.1 工步一：粗车连杆轴颈及其轴肩17

8.10 工序十：半精车连杆轴颈及其轴肩17

8.10.1 工步一：半精车连杆轴颈及其轴肩17

8.11 工序十一：精车连杆轴颈及其轴肩18

8.11.1工步一：精车连杆轴颈及其轴肩18

8.12 工序十二：打通孔及打M12螺纹孔并攻丝18

8.12.1 工步一: 打通孔18

8.13 工序十三：主轴颈、连杆轴颈淬火19

8.14工序十四：磨连杆轴颈外圆及其轴肩面19

8.15工序十五：磨大端主轴颈及其轴肩面20

8.15.1工步一:磨大端主轴颈及其轴肩面20

8.16工序十六：磨小端主轴颈及其轴肩面20

8.16.1工步一:磨小端主轴颈及其轴肩面20

8.17工序十七：去毛刺21

8.18工序十八：检验21

9 专用夹具设计22

9.1 机床夹具设计概述22

9.1.1 机床夹具概述22

9.1.2 机床夹具的分类22

9.1.3 机床夹具的组成和功用22

9.1.4 夹具总体方案设计23

9.2 夹具设计24

9.2.1 问题的提出24

9.2.2 定位方式与定位基准的选择24

9.2.3 夹具机构设计24

9.2.4 定位销长度的分析26

9.2.5 定位误差的分析与计算26

10 结论与展望32

10.1 结论32

10.2 不足之处与未来展望32

致谢33

参考文献34

1 绪论

1.1 本课题研究的内容及意义

　　　本课题研究的内容是：空压机曲轴工艺规程设计和系列夹具设计，包括零件机械加工的工艺过程卡片及各工序的工序卡片，主要机械加工工序的夹具总装配图及主要零件图，并有相关的计算和说明的说明书及专业外语文献翻译。

本课题研究的意义：

　　　⑴工艺规程设计的意义：

　　　 1)指导生产的主要技术文件是工艺规程：机械加工车间生产的计划、调度，工人的操作，零件的加工质量检验，加工成本的核算，都是以工艺规程为依据的。处理生产中的问题，也常以工艺规程作为共同依据。如处理质量事故，应按工艺规程来确定各有关单位、人员的责任。

　　　 2)生产准备工作的主要依据是工艺规程：车间要生产新零件时，首先要制订该零件的机械加工工艺规程，再根据工艺规程进行生产准备。如：新零件加工工艺中的关键工序的分析研究；准备所需的刀、夹、量具（外购或自行制造）；原材料及毛坯的采购或制造；新设备的购置或旧设备改装等，均必须根据工艺来进行。

　　　 3)新建机械制造厂（车间）的基本技术文件是工艺规程：新建（改、扩建）批量或大批量机械加工车间（工段）时，应按照在车间的布置和工艺规程确定所需机床的种类和数量，再由此确定车间的面积大小、动力和吊装设备配置以及所需技术等级、工人的工种、数量等。

　　　此外，先进的工艺规程还起着交流和推广先进制造技术的作用。典型工艺规程可以缩短工厂摸索和试制的过程。因此，工艺规程的制订是对于工厂的生产和发展起到非常重要的作用，是工厂的基本技术文件。

　　　⑵夹具设计的意义：

　　　机床夹具是机械制造业中不可或缺的重要工业装备，可以保证机械加工质量、实现生产过程自动化、降低生产成本、提高生产效率、减轻劳动强度，使用专用夹具还可以改变原机床的用途和扩大机床的使用范围，实现一机多能，所以，夹具在机械加工中发挥着重要的作用。

1.2 国内外发展情况

曲轴制造技术/工艺的进展:曲轴的生产继QT800-2、QT900-2等几种牌号后，广西玉柴等经过攻关已能稳定生产QT800-6牌号的曲轴，为曲轴“以铁代钢”奠定了基础。

1 熔炼高温低硫纯净铁水的获得是生产高质量球墨铸铁的关键。国内主要是以冲天炉为主的生产设备，铁水未进行预脱硫处理；其次是高纯生铁少、焦炭质量差。目前已采用双联外加预脱硫的熔炼方法，采用冲天炉熔化铁水，经炉外脱硫，然后在感应电炉中升温并调整成分。

2 造型目前，国内已有一些曲轴生产厂家从日本、法国、加拿大等国引进气流冲击造型工艺，而且还引进了许多生产线的只有极少数厂家，如文登天润曲轴有限公司引进了德国KW铸造生产线。从总体上来讲，需改造和更新的陈旧的普通锻造设备多，同时，2 工艺方案的确定

2.1 曲轴零件的结构特点

　　　曲轴类大部分的零件的主要作用用为承载载荷、支撑传动的零件和以及保证安装在曲轴上的零件（刀具）具有一定的回转精度空间。

　　　曲轴在轴类零件的地位普通的属于异型轴，是空压机上以及其他机器的一个不可缺少的零件部分，能够承载多部分零件传输过来的力，并将活塞往复运动通过曲柄连杆机构变为旋转运动，将许多零件所做的有用功全输出去。曲轴在工作时所承受的是很大的扭转力矩以及大小和方向都有变化的弯曲力。

2.2 曲轴零件的技术要求

　　　材质，金相组织，机械性能和表面缺陷均应符合 ZBJ72016~88 《容积式压缩机用球墨铸铁技术条件》的规定。

　　　铸件应经热处理，热处理后硬度为 HB190~269 。

　　　加工后主轴径，曲拐径及圆弧过渡处均不允许有肉眼可见的毛刺，裂纹，折叠，凹痕，缩松，缩孔，夹杂物等缺陷存在。

　　　圆弧过渡应均匀，光滑，无接痕。

　　　曲轴加工后应探伤，其要求应符合 ZBJ72016-88 《容积式压缩机用球墨铸铁技术条件》的规定。

　　　锥面应进行着色检查，其接触面积不少于75%。

　　　未铸造圆角R3—R5，保留中心孔。

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曲轴工艺规程设计及系列夹具设计【铣端面+磨夹具】.gif

内容简介：: 英文原文Mechanical DesignA machine is a combination of mechanisms and other components which transforms, transmits. Examples are engines, turbines, vehicles, hoists, printing presses, washing machines, and movie cameras. Many of the principles and methods of design that apply to machines also apply to manufactured articles that are not true machines. The term mechanical design is used in a broader sense than machine design to include their design. the motion and structural aspects and the provisions for retention and enclosure are considerations in mechanical design. Applications occur in the field of mechanical engineering, and in other engineering fields as well, all of which require mechanical devices, such as switches, cams, valves, vessels, and mixers.The Design ProcessDesigning starts with a need real.Existing apparatus may need improvements in durability, efficiency, weight, speed, or cost. New apparatus may be needed to perform a function previouslydone by men, such as computation, assembly, or servicing. With the objective wholly or partly.In the design preliminary stage, should allow to design the personnel fully to display the creativity, not each kind of restraint. Even if has had many impractical ideas, also can in the design early time, namely in front of the plan blueprint is corrected. Only then, only then does not send to stops up the innovation the mentality. Usually, must propose several sets of design proposals, then perform the comparison. Has the possibility very much in the plan which finally designated, has used certain not in plan some ideas which accepts.When the general shape and a few dimensions of the several components become apparent, analysis can begin in earnest. The analysis will have as its objective satisfactory or superior performance, plus safety and durability with minimum weight, and a competitive cost. Optimum proportions and dimensions will be sought for each critically loaded section, together with a balance between the strengths of the several components. Materials and their treatment will be chosen. These important objectives can be attained only by analysis based upon the principles of mechanics, such as those of static for reaction forces and for the optimum utilization of friction; of dynamics for inertia, acceleration, and energy; of elasticity and strength of materials for stress and deflection; of physical behavior of materials; and of fluid mechanics for lubrication and hydrodynamic drives. The analyses may be made by the same engineer who conceived the arrangement of mechanisms, or, in a large company, they may be made by a separate analysis division or research group. Design is a reiterative and cooperative process, whether done formally or informally, and the analyst can contribute to phases other than his own. Product design requires much research and development. Many Concepts of an idea must be studied, tried, and then either used or discarded. Although the content of each engineering problem is unique, the designers follow the similar process to solve the problems. Product liability suits designers and forced in material selection, using the best program. In the process of material, the most common problems for five (a) dont understand or not use about the latest application materials to the best information, (b) failed to foresee and consider the reasonable use material may (such as possible, designers should further forecast and consider due to improper use products. In recent years, many products liability in litigation, the use of products and hurt the plaintiff accused manufacturer, and won the decision), (c) of the materials used all or some of the data, data, especially when the uncertainty long-term performance data is so, (d) quality control method is not suitable and unproven, (e) by some completely incompetent persons choose materials.Through to the above five questions analysis, may obtain these questions is does not have the sufficient reason existence the conclusion. May for avoid these questions to these questions research analyses the appearance indicating the direction. Although uses the best choice of material method not to be able to avoid having the product responsibility lawsuit, designs the personnel and the industry carries on the choice of material according to the suitable procedure, may greatly reduce the lawsuit the quantity. May see from the above discussion, the choice material people should to the material nature, the characteristic and the processing method have comprehensive and the basic understanding. Finally, a design based upon function, and a prototype may be built. If its tests are satisfactory, the initial design will undergo certain modifications that enable it to be manufactured in quantity at a lower cost. During subsequent years of manufacture and service, the design is likely to undergo changes as new ideas are conceived or as further analyses based upon tests and experience indicate alterations. Sales appeal.Some Rules for DesignIn this section it is suggested that, applied with a creative attitude, analyses can lead to important improvements and to the conception and perfection of alternate, perhaps more functional, economical,and durable products. To stimulate creative thought, the following rules are suggested for the designer and analyst. The first six rules are particularly applicable for the analyst.1. A creative use of need of physical properties and control process.2. Recognize functional loads and their significance.3. Anticipate unintentional loads.4. Devise more favorable loading conditions.5. Provide for favorable stress distribution and stiffness with minimum weight.6. Use basic equations to proportion and optimize dimensions.7. Choose materials for a combination of properties.8. Select carefully, stock and integral components.9. Modify a functional design to fit the manufacturing process and reduce cost.10. Provide for accurate location and noninterference of parts in assembly. Machinery design covers the following contents.1. Provides an introduction to the design process , problem formulation ,safety factors.2. Reviews the material properties and static and dynamic loading analysis ,Including beam , vibration and impact loading. 3. Reviews the fundamentals of stress and defection analysis. 4. Introduces fatigue-failure theory with the emphasis on stress-life approaches to high-cycle fatigue design, which is commonly used in the design of rotation machinery. 5. Discusses thoroughly the phenomena of wear mechanisms, surface contact stresses ,and surface fatigue. 6. Investigates shaft design using the fatigue-analysis techniques. 7. Discusses fluid-film and rolling-element bearing theory and application 8. Gives a thorough introduction to the kinematics, design and stress analysis of spur gears , and a simple introduction to helical ,bevel ,and worm gearing. 9. Discusses spring design including compression ,extension and torsion springs. 10. Deals with screws and fasteners including power screw and preload fasteners. 11. Introduces the design and specification of disk and drum clutches and brakes.Machine DesignThe complete design of a machine is a complex process. The machine design is a creative work. Project engineer not only must have the creativity in the work, but also must in aspect and so on mechanical drawing, kinematics, engineerig material, materials mechanics and machine manufacture technology has the deep elementary knowledge. One of the first steps in the design of any product is to select the material from which each part is to be made. Numerous materials are available to todays designers. The function of the product, its appearance, the cost of the material, and the cost of fabrication are important in making a selection. A careful evaluation of the properties of a. material must be made prior to any calculations. Careful calculations are necessary to ensure the validity of a design. In case of any part failures, it is desirable to know what was done in originally designing the defective components. The checking of calculations (and drawing dimensions) is of utmost importance. The misplacement of one decimal point can ruin an otherwise acceptable project. All aspects of design work should be checked and rechecked. The computer is a tool helpful to mechanical designers to lighten tedious calculations, and provide extended analysis of available data. Interactive systems, based on computer capabilities, have made possible the concepts of computer aided design (CAD) and computer-aided manufacturing (CAM). How does the psychologist frequently discuss causes the machine which the people adapts them to operate. Designs personnels basic responsibility is diligently causes the machine to adapt the people. This certainly is not an easy work, because certainly does not have to all people to say in fact all is the most superior operating area and the operating process. Another important question, project engineer must be able to carry on the exchange and the consultation with other concerned personnel. In the initial stage, designs the personnel to have to carry on the exchange and the consultation on the preliminary design with the administrative personnel, and is approved. This generally is through the oral discussion, the schematic diagram and the writing material carries on. If front sues, the machine design goal is the production can meet the human need the product. The invention, the discovery and technical knowledge itself certainly not necessarily can bring the advantage to the humanity, only has when they are applied can produce on the product the benefit. Thus, should realize to carries on before the design in a specific product, must first determine whether the people do need this kind of productMust regard as the machine design is the machine design personnel carries on using creative ability the product design, the system analysis and a formulation product manufacture technology good opportunity. Grasps the project elementary knowledge to have to memorize some data and the formula is more important than. The merely service data and the formula is insufficient to the completely decision which makes in a good design needs. On the other hand, should be earnest precisely carries on all operations. For example, even if places wrong a decimal point position, also can cause the correct design to turn wrongly.A good design personnel should dare to propose the new idea, moreover is willing to undertake the certain risk, when the new method is not suitable, use original method. Therefore, designs the personnel to have to have to have the patience, because spends the time and the endeavor certainly cannot guarantee brings successfully. A brand-new design, the request screen abandons obsoletely many, knows very well the method for the people. Because many person of conservativeness, does this certainly is not an easy matter. A mechanical designer should unceasingly explore the improvement existing product the method, should earnestly choose originally, the process confirmation principle of design in this process, with has not unified it after the confirmation new idea.High-speed machining is contemporary advanced manufacturing technology an important component of the high-efficiency, High-precision and high surface quality, and other features. This article presents the technical definition of the current state of development of Chinas application fields and the demand situation. High-speed machining is oriented to the 21st century a new high-tech, high-efficiency, High-precision and high surface quality as a basic feature, in the automobile industry, aerospace, Die Manufacturing and instrumentation industries gained increasingly widespread application, and has made significant technical and economic benefits. contemporary advanced manufacturing technology an important component part.HSC is to achieve high efficiency of the core technology manufacturers, intensive processes and equipment packaged so that it has a high production efficiency. It can be said that the high-speed machining is an increase in the quantity of equipment significantly improve processing efficiency essential to the technology. High-speed machining is the major advantages : improve production efficiency, improve accuracy and reduce the processing of cutting resistance.The high-speed machining of meaning, at present there is no uniform understanding, there are generally several points as follows : high cutting speed. usually faster than that of their normal cutting 5 -10 times; machine tool spindle speed high, generally spindle speed in -20000r/min above 10,000 for high-speed cutting; Feed at high velocity, usually 15 -50m/min up to 90m/min; For different cutting materials and the wiring used the tool material, high-speed cutting the meaning is not necessarily the same; Cutting process, bladed through frequency (Tooth Passing Frequency) closer to the machine-tool - Workpiece system the dominant natural frequency (Dominant Natural Frequency), can be considered to be high-speed cutting. Visibility high-speed machining is a comprehensive concept.1992. Germany, the Darmstadt University of Technology, Professor H. Schulz in the 52th on the increase of high-speed cutting for the concept and the scope, as shown in Figure 1. Think different cutting targets, shown in the figure of the transition area (Transition), to be what is commonly called the high-speed cutting, This is also the time of metal cutting process related to the technical staff are looking forward to, or is expected to achieve the cutting speed.High-speed machining of machine tools, knives and cutting process, and other aspects specific requirements. Several were from the following aspects : high-speed machining technology development status and trends.At this stage, in order to achieve high-speed machining, general wiring with high flexibility of high-speed CNC machine tools, machining centers, By using a dedicated high-speed milling, drilling. These equipment in common is : We must also have h igh-speed and high-speed spindle system feeding system, Cutting can be achieved in high-speed process. High-speed cutting with the traditional cutting the biggest difference is that Machine-tool-workpiece the dynamic characteristics of cutting performance is stronger influence. In the system, the machine spindle stiffness, grip or form, a long knife set, spindle Broach, torque tool set, Performance high-speed impact are important factors.In the high-speed cutting, material removal rate (Metal Removal Rate, MRR), unit time that the material was removed volume, usually based on the machine-tool-workpiece whether Processing System chatter. Therefore, in order to satisfy the high-speed machining needs, we must first improve the static and dynamic stiffness of machine spindle is particularly the stiffness characteristics. HSC reason at this stage to be successful, a very crucial factor is the dynamic characteristics of the master and processing capability.In order to better describe the machine spindle stiffness characteristics of the project presented new dimensionless parameter - DN value, used for the evaluation of the machine tool spindle structure on the high-speed machining of adaptability. DN value of the so-called axis diameter per minute speed with the product. The newly developed spindle machining center DN values have been great over one million. To reduce the weight bearing, but also with an array of steel products than to the much more light ceramic ball bearings; Bearing Lubrication most impressive manner mixed with oil lubrication methods. In the field of high-speed machining. have air bearings and the development of magnetic bearings and magnetic bearings and air bearings combined constitute the magnetic gas / air mixing spindle.Feed the machine sector, high-speed machining used in the feed drive is usually larger lead, multiple high-speed ball screw and ball array of small-diameter silicon nitride (Si3N4) ceramic ball, to reduce its centrifugal and gyroscopic torque; By using hollow-cooling technology to reduce operating at high speed ball screw as temperature generated by the friction between the lead screw and thermal deformation.In recent years, the use of linear motor-driven high-speed system of up to Such feed system has removed the motor from workstations to Slide in the middle of all mechanical transmission links, Implementation of Machine Tool Feed System of zero transmission. Because no linear motor rotating components, from the role of centrifugal force, can greatly increase the feed rate. Linear Motor Another major advantage of the trip is unrestricted. The linear motor is a very time for a continuous machine shop in possession of the bed. Resurfacing of the very meeting where a very early stage movement can go, but the whole system of up to the stiffness without any influence. By using high-speed screw, or linear motor can greatly enhance machine system of up to the rapid response. The maximum a cceleration linear motors up to 2-10G (G for the acceleration of gravity), the largest feed rate of up to 60 -200m/min or higher. 2002 world-renowned Shanghai Pudong maglev train project of maglev track steel processing, Using the Shenyang Machine Tool Group Holdings Limited McNair friendship company production plants into extra-long high-speed system for large-scale processing centers achieve . The machine feeding system for the linear guide and rack gear drive, the largest table feed rate of 60 m / min, Quick trip of 100 m / min, 2 g acceleration, maximum speed spindle 20000 r / min, the main motor power 80 kW. X-axis distance of up to 30 m, 25 m cutting long maglev track steel error is less than 0.15 mm. Maglev trains for the smooth completion of the project provided a strong guarantee for technologyIn addition, the campaign machine performance will also directly affect the processing efficiency and accuracy of processing. Mold and the free surface of high-speed machining, the main wiring with small cut deep into methods for processing. Machine requirements in the feed rate conditions, should have high-precision positioning functions and high-precision interpolation function, especially high-precision arc interpolation. Arc processing is to adopt legislation or thread milling cutter mold or machining parts, the essential processing methods.Cutting Tools Tool Material development high-speed cutting and technological development of the history, tool material is continuous progress of history. The representation of high-speed cutting tool material is cubic boron nitride (CBN). Face Milling Cutter use of CBN, its cutting speed can be as high as 5000 m / min, mainly for the gray cast iron machining. Polycrystalline diamond (PCD) has been described as a tool of the 21st century tool, It is particularly applicable to the cutting aluminum alloy containing silica material, which is light weight metal materials, high strength, widely used in the automobile, motorcycle engine, electronic devices shell, the base, and so on. At present, the use of polycrystalline diamond cutter Face Milling alloy, 5000m/min the cutting speed has reached a practical level. In addition ceramic tool also applies to gray iron of high-speed machining; Tool Coating : CBN and diamond cutter, despite good high-speed performance, but the cost is relatively high. Using the coating technology to make cutting tool is the low price, with excellent mechanical properties, which can effectively reduce the cost. Now high-speed processing of milling cutter, with most of the wiring between the Ti-A1-N composite technology for the way of multi-processing, If present in the non-ferrous metal or alloy material dry cutting, DLC (Diamond Like Carbon) coating on the cutter was of great concern. It is expected that the market outlook is very significant; Tool clamping system : Tool clamping system to support high-speed cutting is an important technology, Currently the most w idely used is a two-faced tool clamping system. Has been formally invested as a commodity market at the same clamping tool system are : HSK, KM, Bigplus. NC5, AHO systems. In the high-speed machining, tool and fixture rotary performance of the balance not only affects the precision machining and tool life. it will also affect the life of machine tools. So, the choice of tool system, it should be a balanced selection of good products. Process Parameters Cutting speed of high-speed processing of conventional shear velocity of about 10 times. For every tooth cutter feed rate remained basically unchanged, to guarantee parts machining precision, surface quality and durability of the tool, Feed volume will also be a corresponding increase about 10 times, reaching 60 m / min, Some even as high as 120 m / min. Therefore, high-speed machining is usually preclude the use of high-speed, feed and depth of cut small cutting parameters. Due to the high-speed machining cutting cushion tend to be small, the formation of very thin chip light, Cutting put the heat away quickly; If the wiring using a new thermal stability better tool materials and coatings, Using the dry cutting process for high-speed machining is the ideal technology program.High-speed machining field of applicationFlexible efficient production line To adapt to the needs of new models, auto body panel molds and resin-prevention block the forming die. must shorten the production cycle and reduce the cost of production and, therefore, we must make great efforts to promote the production of high-speed die in the process. SAIC affiliated with the company that : Compared to the past, finishing, further precision; the same time, the surface roughness must be met, the bending of precision, this should be subject to appropriate intensive manual processing. Due to the extremely high cutting speed, and the last finishing processes, the processing cycle should be greatly reduced.To play for machining centers and boring and milling machining center category represented by the high-speed machining technology and automatic tool change function of distinctions Potential to improve processing efficiency, the processing of complex parts used to be concentrated as much as possible the wiring process, that is a fixture in achieving multiple processes centralized processing and dilute the traditional cars, milling, boring, Thread processing different cutting the limits of technology, equipment and give full play to the high-speed cutting tool function, NC is currently raising machine efficiency and speed up product development in an effective way. Therefore, the proposed multi-purpose tool of the new requirements call for a tool to complete different parts of the machining processes, ATC reduce the number of ATC to save time, to reduce the quantity and tool inventory, and management to reduce production costs. More commonly used in a multifunctional Tool, milling, boring and milling, drill ing milling, drilling-milling thread-range tool. At the same time, mass production line, against the use of technology requires the development of special tools, tool or a smart composite tool, improve processing efficiency and accuracy and reduced investment. In the high-speed cutting conditions, and some special tools can be part of the processing time to the original 1 / 10 below, results are quite remarkable. HSC has a l he workpiece with ultrafine, thin structure of the workpiece, Traditionally, the need to spend very long hours for processing mobile workpiece and the design of rapid change, short product life cycle of the workpiece, able to demonstrate high-speed cutting brought advantages.ot of advantages such as : a large number of materials required resection .Aluminum (board, belt, tubes, rods, type, line, forging, powder) and die casting, casting in cars have applications, aluminum used to make aluminium paint. In the application of aluminum car from the 19 th century, 1896, the first Indian with aluminum manufacturing crankcase. After the U.S. with aluminum tank engine parts, gearing, shell parts, the 1920 s do with aluminum car parts, beginning in 1925 with the aluminum radiator do. Later, the steel deep rushed the improvement of the performance of the improvement of the process with deep blunt, car with aluminumQuantity is stagnant. In 1968-1973 the average car with aluminum quantity 21 kg/a, 1974 increased dosage to 38 kg/vehicles. In 2008 the auto industry with aluminum amount more than 25% of all aluminum consumption. 1984 model year cars on average every car with aluminum of 62114 kg, 1990 years of 90172 kg with aluminum, 2003 of 115 kg with aluminum, 2009 years up to 145 kg of aluminum.Because vacuum brazing technology development, in 1986 the United States production car almost half of mount aluminum radiator, 2009 car radiator of aluminum, rate of 90%, because the price of copper aluminum low, and aluminum radiator quality and about 50% of light than copper.In recent years, the United States, Germany, Japan, etc have introduced all aluminum car, such as audi A8 and in April 2010 Beijing international auto show global first shown on its flagship full aluminium A8L Quattro sedan, body to continue using ASF space frame structure, than with the quality of the steel body size light 40%, rigid, further promoted. The car is equipped with top W 12 engine, after a new design, not only emissions from the original 6 L went up to 613 L, more important is the first time in 12 cylinder type used on the FSI fuel injection technology, in the ascension of the power and reduce oil consumption. This engine the maximum output power is 368 kW, the maximum torque 625 kN# m, kilometres to speed up only 419 s, dynamic performance full beyond a generation of models, the average fuel consumption of 1210 L / (100 km), 12% lower.At present, the development of the car industry is facing three times challenge: to save energy and protect the environment and improve the safety, ride comfort, beautiful sex. To improve the performance of these except in the design of the improved, the most is the new material ease the car own quality. Practice has proved, in this respect aluminum is the most potential, in that its comprehensive performance or its price is better than the magnesium alloy, titanium alloy, steel and composite materials, etc. Aluminum alloy have significant weight loss effect, energy conservation and emission reduction, improve the balance of a car, ride comfort.Aluminum alloy castings can use all sorts of casting process especially die casting production method, the composition of their wide range, the work of the service of the big difference in performance. Special casting aluminum alloy choose depends on casting process (a sand, metal type, die casting, the precision casting) and product design, product requirements of the performance and related factors. In automobile manufacturing for the application of cast aluminum are:A38010 used in the manufacture of brackets, engine spare parts, steering gear cover;38310 is used in the manufacturing of the cylinder block, transmission box and components, fuel measuring instrument;31910 is used in the manufacturing of the manifold, the cylinder, block and engine components;35610 is used in the manufacturing of the cylinder lid, manifold;A35610 used to make the car wheel;B39010 used in the manufacture of resistance to inner mesh and transmission parts inside.At present, the development of the car industry is facing three times challenge: to save energy and protect the environment and improve the safety, ride comfort, beautiful sex. To improve the performance of these except in the design of the improved, the most is the new material ease the car own quality. Practice has proved, in this respect aluminum is the most potential, in that its comprehensive performance or its price is better than the magnesium alloy, titanium alloy, steel and composite materials, etc. Aluminum alloy have significant weight loss effect, energy conservation and emission reduction, improve the balance of a car, ride comfort.Aluminum alloy castings can use all sorts of casting process especially die casting production method, the composition of their wide range, the work of the service of the big difference in performance. Special casting aluminum alloy choose depends on casting process (a sand, metal type, die casting, the precision casting) and product design, product requirements of the performance and related factors. In automobile manufacturing for the application of cast aluminum are:A38010 used in the manufacture of brackets, engine spare parts, steering gear cover;38310 is used in the manufacturing of the cylinder block, transmission box and components, fuel measuring instrument;31910 is used in the manufacturing of the manifold, the cylinder, block and engine components;35610 is used in the manufacturing of the cylinder lid, manifold;A35610 used to make the car wheel;B39010 used in the manufacture of resistance to inner mesh and transmission parts inside.Lightweight is an inevitable trend in the development of contemporary car with a important task, which in turn cars on its technical lightweight development also played an important role. In order to ensure the quality and function not car affected, under the premise of maximum reduce the quality of parts, in order to achieve energy and emission reduction goals; In the car to meet the requirements of the energy conservation and emissions reduction efforts to seek its high output power, high response sex, low noise, low vibration, good handling, high reliability and comfort, etc.; The price should be declined or keep in reasonable level, and has strong business competitiveness.Lightweight effect: car lightweight made the car rolling resistance, accelerate resistance, climbing resistance decreases, they can make oil consumption is reduced, and at the same time if drove dynamic performance unchanged, through the appropriate gear ratio can also make oil consumption is reduced, the car every lightweight 1% can reduce fuel consumption by 016% 110%; Car lightweight to improve the car driving, steering, accelerate, brake athletic performance and exhaust performance, among the engines lightweight can also improve the front axle load, the share rate, and then improve the car.Manipulation stability, still can reduce the noise, vibration, high power to achieve the create conditions; Another effect is spread effect, auto parts quality are interdependent, such as the quality of the engine to reduce the chassis parts can also reduce accordingly, that is to reduce the quality of the greater than the engine reduce quality, and as of body parts lightweight make supporting its traveling department (frame, axles and wheels, suspension, etc) load down; Size and quality can be reduced, and the engine and brake are also availableTo reduce phase, reducing, usually, when the balance system in the particular site quality reduce 1 kg, give the whole system spread effect is quality reduce 115 kg to 210 kg.Aluminum is today, in the use of the second big metal materials, in transportation is the amount of the total consumption of have accounted for more than 28%, and most of the used to make cars. In the wide application of aluminum car manufacturing is nearly 30 years of appear, from the 1970 s on the most obvious car technology changes is a number one of enable light material, there are more and more aluminum parts, mainly concentrated in the body, engine, bumper, air conditioner, car wheel, decoration, car seats, etc.Engine parts with aluminum manufacturing weight loss most obvious effect, usually can reduce 30%. Since 1999, the dosage in car aluminum has more than doubled, manufacturing cars and light trucks increase the amount of more than three times. Steel and cast iron and aluminium, copper and so on, can make the dead weight of car decreased by more than 20%, the fuel economy by 12% 16%; Car on the aluminum parts can be almost all recycling, after machined once again use, already save resources and energy and reduce greenhouse gas emissions, construction of circular economy, low carbon society and life is very useful; Some of the physical properties of the aluminum alloy with the same vehicle steel, a considerable strength and stiffness, the cost is waning. So, according to the current technology to make the lightweight, the most effective way is to use aluminum instead of steel, of course, also can use part of magnesium alloys, but processing to the forming of magnesium materials performance as the aluminum, magnesium corrosion sex and fire prevention function also is far and aluminum, magnesium materials prices higher than aluminum high.At present, the whole aluminum body also is limited to high-grade car and the car, but as time goes on, the improvement of technology, manufacturing costs continue to decline, energy conservation and emission reduction of calls to an increasingly, there will be more types of car body and components used aluminum. To 21 centuries middle period, aluminum will become the main material for making cars, the dosage of than iron, and even the dosage of the steel is, when the car of the average quality will be better than 2008 type weight loss of about 65%.In the car on the application of aluminium alloy have: cast aluminum alloy, accounts for about 80 (quality) %; Deformation aluminum alloy about 19% is strong, other (aluminum after the materials, foam aluminum, aluminum powder) 1% weak. Casting aluminum alloy in cars for die-casting and casting engine, transmission mechanism, steering system and brake, walking is part and various accessories, aluminum alloy is based on board, belt deformation, foil, tubes, rods, profile, wire and forging, blunt the forms of extrusion parts used in the manufacture of all kinds of parts, aluminum foil used in the manufacture of air conditioner radiator.Automobile industry of the aluminum alloy with except on standard routine in the alloy, some of the large aluminum company and car companies or have developed a unique individual performance car aluminum alloy. Cars with typical deformation of the aluminum alloy composition and performance table respectively5 and table 6. Alcoa in 2002 registered A brand for 7085 of A-l-Zn, Mg-Cu alloy is, it has good comprehensive performance, more important is, it its quench-hardening ability is good, particularly suitable for manufacturing forging. In addition to cast aluminum alloy and deformation aluminum alloy outside, still have a foam aluminum (aluminum alloy), aluminum matrix composites, powder metallurgy aluminum alloy etc.The car body of people making especially by car body making is the essence of the automobile industry, body production car manufacturing company accounts for almost 30% of the total amount of investment. Body quality accounts for about 30% of the total quality, reduce the quality to the vehicle quality reduce play a key role. In 2009 the global auto industry for body manufacturing aluminum alloy more than 2100 k, t 2015 demand might come to 850 kt. The aluminum area with manufacturing body plank, profiles and frame profiles die casting fittings etc.The whole aluminum by people of the car body is made of aluminum extrusion framework and efficiency of shell. 20 years ago began to use the 6009 and 6010 car the physique aluminum alloy with T4 through strength, respectively, compared with the 5182-though O and 2036-T4 aluminum alloy low, but plastic is quite high, after forming can be in spray paint baking process to realize artificial aging higher strength. The two alloy can be used for rushed inside and outside wall plate made of, also can use 6009 aluminum alloy manufacture the inner wall board, but with 6010 aluminum alloy manufacture outer wall plate. The two alloy another advantage is its waste dont need repacking, can recycle and mixed recycled, great market potential.On vehicle performance requirements of the aluminum alloy plate is: in addition to meet the standards and norms of a mechanical properties and corrosion resistance outside, still should have the following performance. 1, good formability, body and cover the metal sheet forming from aviation manufacturingTransplant come over, through the stamping, aluminum alloy plate should have good formability, namely with low than the ultimate high and the forming limit (FLC, Form ing lim it curve), in different kinds of stamping deformation stress state has very high forming space. 2, the surface is the gender is strong, aluminum alloy plate must have good flanging ductility and forming surface consistent performance after color, namely the forming metal sheet surface does not appear LuoPing line (Rop ing L ine), namely slip line, it is because of the uneven grain or inclusions caused by uneven distribution of plank of uneven surface deformation, and make the surface after lacquer appear luster in inconsistent phenomenon. 3, good weldability, good weldable performance can meet in forming automobile components together after welding processing requirements. Plank of limitation should have stability, to ensure that the factory to the ram from the plate before production does not occur limitation, prevent the stamping process materials increase the yield point, LvDe induced with (Lude. S zone) and produce surface deformation uneven wrinkling, which affect the outside board surface quality. 4, excellent baking sclerosing, automobile lightweight also requires plank with high baking sclerosing, namely in stamping deformation and paint baking sheet after the yield strength have significant rise, so as to ensure stamping, painted metal sheet has the high resistance of sex, aluminum alloy plate of concave paint baking process and current steel plate stamping paint baking process compatibility.From the high speed, comfortable, beautiful, durable, lightweight, energy saving, environmental protection, reduce the comprehensive cost of performance standpoint, aluminum alloy is certainly the auto industry modernization and the first choice of lightweight materials. The auto industry as one of the pillar industry in China, the coming decades will get rapid development, the development of high performance car to improve the physique aluminum alloy automobile industry in our countrys international competitiveness and development low carbon transport vital role. Aluminium alloy with the manufacture of sheet metal sheet body (AVT, A lum inium Veh icle Techno logy) process as shown in figure 7 shows, in this process manufacturing aluminum body, the output of A car in the best 100000 cars. The first step is to strip coil winding pretreatment and spraying after a layer of lubricating oil, then dropping material and blunt made form, in a process that finish, robot will shape of sheet metal parts and pieces of adhesive in die casting of connector (Jo in ing flange). The whole body is through the spot welding, with mechanical fittings are packaged into. Adhesive for rubber hardening of the epoxy resin, firm bonding. Compared with the traditional steel body, assembly welding number reduces by 50%.Because AVT structure for glue-welding, thus has the high stiffness, strong and durable. Even without welding, aluminum alloy plate structure stiffness and steel structure stiffness equal, its quality about 60% of that for the latter. If you use AVT assembly process, the quality of structure can further reduce to 50% of the steel structure, and the stiffness is better than the steel structure of the high 30% 50%. Steel body structure of the quality (medium-sized car) about 280 kg, and the only body structure AVT for 155 kg. In the basic design and the same size, the medium-sized car AVT wrest resistant steel body stiffness is big also. These of car designer is very important, stiffness is one of key factors car design. At the same time also will produce significant economic and social benefits.The current aluminum alloy car there the physique formability sent, strength and fight depression low sex, solderability than steel plate and splicing part low resistance to corrosion not ideal, production cost is high questions, and the forming machining, weldability, production cost is restricted by the application of automobile covering the key factors, the improvement of the existing aluminum alloy composition and production process, improve the performance and the research and development of new aluminum alloy is the world materials science researchers assiduously seek, A-lL I alloy and A-lMg-Sc alloy is A development potential. The currently used body aluminum alloy plate is to use with the cold rolling bubble billet, using new craft production of cold rolling with billet with to be exploited, noA high-speed roll casting billet with (thick 1. 5 mm 2. 5 mm) is certainly not cold rolled out performance qualified thick 1. 0 mm or so thin body, with 6 mm thick roll casting billet with whether it is feasible to be research; In slab continuous casting and rolling (black this Wright method) to take billet can of course produce qualified car thin plate, but whether there is a cost competitiveness is yet to be research and test 4, because this cost advantage lies in the mass production. With the usual hot rolling method to bubble and slab continuous casting and rolling method of cold rolling with 5754 aluminum alloy casting thin performance table 10, in slab continuous casting and rolling method with cold rolled plate performance can completely billet meet the requirements.A current and the most obvious is the development trend of, aluminum with rolling factory not only should cut the size of the board into precision plate, and should be blunt made form, so that the car factory for further processing and assembly line. Car body is a kind of high precision products, aluminum companys power (Novelis), the United States aluminum company, Canada aluminum company, hydro aluminium (H ydro), Kobe steel company (Kobe Stee l Co) is the main producer. In northeast of China light alloy Co., LTD from 20 century 80 S began to research and development the car car the physique (door lining), IN 2008 the production of 5754-O aluminum alloy of various performance which conform to the D IN EN485 standard (table 11), car manufacturers rushed the door lining of 9916% yield 5, this is Chinas first batch production car sheet IN the practice of production IN the cover of a formal use.中文译文机械设计设计流程设计开始之前就要想到机器的实际性，现存的机器需要在耐用性、效率、重量、速度，或者成本上得到改善。新的机器必需具有以前机器所能执行的功能。在设计的初始阶段，应该允许设计人员充分发挥创造性，不要受到任何约束。即使产生了许多不切实际的想法，也会在设计的早期，即在绘制图纸之前被改正掉。只有这样，才不致于阻断创新的思路。通常,还要提出几套设计方案，然后加以比较。很有可能在这个计划最后决定中,使用了某些不在计划之内的一些设想。一般的当外型特点和组件部分的尺寸特点分析得透彻时，就可以全面的设计和分析。接着还要客观的分析机器性能的优越性，以及它的安全、重量、耐用性，并且竞争力的成本也要考虑在分析结果之内。每一个至关重要的部分要优化它的比例和尺寸，同时也要保持与其它组成部分相协调。也要选择原材料和处理原材料的方法。通过力学原理来分析和实现这些重要的特性，如那些静态反应的能量和摩擦力的最佳利用，像动力惯性、加速动力和能量；包括弹性材料的强度、应力和刚度等材料的物理特性，以及流体润滑和驱动器的流体力学。设计的过程是重复和合作的过程，无论是正式或非正式的进行，对设计者来说每个阶段都很重要。最后，以图样为设计的标准，并建立将来的模型。如果它的测试是符合事先要求的，则再将对初步设计进行某些修改，使它能够在制造成本上有所降低。产品的设计需要不断探索和发展。许多方案必须被研究、试验、完善，然后决定使用还是放弃。虽然每个工程学问题的内容是独特的，但是设计师可以按照类似的步骤来解决问题。产品的责任诉讼迫使设计人员和公司在选择材料时，采用最好的程序。在材料过程中，五个最常见的问题为：（a）不了解或者不会使用关于材料应用方面的最新最好的信息资料；(b)未能预见和考虑材料的合理用途（如有可能，设计人员还应进一步预测和考虑由于产品使用方法不当造成的后果。在近年来的许多产品责任诉讼案件中，由于错误地使用产品而受到伤害的原告控告生产厂家，并且赢得判决）；(c)所使用的材料的数据不全或是有些数据不确定，尤其是当其性能数据长期不更新；(d)质量控制方法不适当和未经验证；(e)由一些完全不称职的人员选择材料。通过对上述五个问题的分析，可以得出这些问题是没有充分理由而存在的结论。对这些问题的研究分析可以为避免这些问题的出现而指明方向。尽管采用最好的材料选择方法也不能避免发生产品责任诉讼，设计人员和工业界按照适当的程序进行材料选择，可以大大减少诉讼的数量。从以上的讨论可以看出，选择材料的人们应该对材料的性质，特点和加工方法有一个全面而基本的了解。在随后生产和售后服务的几年中，要接受新观念的变化，或者由试验和经验为基础，进一步分析并改进。一些设计规则在本节中，建议要运用创造性的态度来替代和改进。也许会创造出更实用、更经济、更耐用的产品。为了激发创造性思维，下列是设计和分析的建议规则。前六个规则对设计者来说特别适用。1. 要有创造性的利用所需要的物理性质和控制过程。2. 认识负载产生的影响及其意义。3. 预测没有想到的负载。4. 创造出对载荷更为有利的条件。5. 提供良好的应力分布和最小的刚度条件。6. 运用最简单的方程来优化体积和面积。7. 选择组合材料。8. 仔细选择所备的原料和不可缺少的组件。9. 调整有效的设计方案，以适应生产过程和降低成本。10. 规定好准确的位置条件为了使组件安装时不干涉。机械设计包括一下内容：1. 对设计过程、设计所需要公式以及安全系数进行介绍。2. 回顾材料特性、静态和动态载荷分析，包括梁、振动和冲击载荷。3. 回顾应力的基本规律和失效分析。4. 介绍静态失效理论和静态载荷下机械断裂分析。5. 介绍疲劳失效理论并强调在压力条件下接近高循环的疲劳设计，这通常用在旋转机械的设计中。6. 深入探讨机械磨损机理、表面接触应力和表面疲劳现象。7. 使用疲劳分析技术校核轴的设计。8. 讨论润滑油膜与滚动轴承的理论和应用。9. 深入介绍直齿圆柱齿轮的动力学、设计和应力分析，并简单介绍斜齿轮、锥齿轮和涡轮有关方面的问题。10. 讨论弹簧设计、螺杆等紧固件的设计，包括传动螺杆和预紧固件。11. 介绍盘式和鼓式离合器以及制动器的设计和技术说明。机械设计一台完整机器的设计是一个复杂的过程。机械设计是一项创造性的工作。设计工程师不仅在工作上要有创造性，还必须在机械制图、运动学、工程材料、材料力学和机械制造工艺学等方面具有深厚的基础知识。任何产品在设计时第一步就是选择产品每个部分的构成材料。许多的材料被今天的设计师所使用。对产品的功能，它的外观、材料的成本、制造的成本作出必要的选择是十分重要的。对材料的特性必须事先作出仔细的评估。仔细精确的计算是必要的，以确保设计的有效性。在任何失败的情况下，最好知道在最初设计中有有缺陷的部件。计算（图纸尺寸）检查是非常重要的。一个小数点的位置放错，就可以导致一个本可以完成的项目失败。设计工作的各个方面都应该检查和复查。计算机是一种工具，它能够帮助机械设计师减轻繁琐的计算，并对现有数据提供进一步的分析。互动系统基于计算机的能力，已经使计算机辅助设计（CAD）和计算机辅助制造（CAM）成为了可能。心理学家经常谈论如何使人们适应他们所操作的机器。设计人员的基本职责是努力使机器来适应人们。这并不是一项容易的工作，因为实际上并不存在着一个对所有人来说都是最优的操作范围和操作过程。另一个重要问题，设计工程师必须能够同其他有关人员进行交流和磋商。在开始阶段，设计人员必须就初步设计同管理人员进行交流和磋商，并得到批准。这一般是通过口头讨论，草图和文字材料进行的。如前所诉，机械设计的目的是生产能够满足人类需求的产品。发明、发现和科技知识本身并不一定能给人类带来好处，只有当它们被应用在产品上才能产生效益。因而，应该认识到在一个特定的产品进行设计之前，必须先确定人们是否需要这种产品。应当把机械设计看成是机械设计人员运用创造性的才能进行产品设计、系统分析和制定产品的制造工艺学的一个良机。掌握工程基础知识要比熟记一些数据和公式更为重要。仅仅使用数据和公式是不足以在一个好的设计中做出所需的全部决定的。另一方面，应该认真精确的进行所有运算。例如，即使将一个小数点的位置放错，也会使正确的设计变成错误的。一个好的设计人员应该勇于提出新的想法，而且愿意承担一定的风险，当新的方法不适用时，就使用原来的方法。因此，设计人员必须要有耐心，因为所花费的时间和努力并不能保证带来成功。一个全新的设计，要求屏弃许多陈旧的，为人们所熟知的方法。由于许多人墨守成规，这样做并不是一件容易的事。一位机械设计师应该不断地探索改进现有的产品的方法，在此过程中应该认真选择原有的、经过验证的设计原理，将其与未经过验证的新观念结合起来。新设计本身会有许多缺陷和未能预料的问题发生，只有当这些缺陷和问题被解决之后，才能体现出新产品的优越性。因此，一个性能优越的产品诞生的同时，也伴随着较高的风险。应该强调的是，如果设计本身不要求采用全新的方法，就没有必要仅仅为了变革的目的而采用新方法。高速切削加工是当代先进制造技术的重要组成部分，拥有高效率、高精度及高表面质量等特征。本文介绍此技术的定义、发展现状、适用领域以及中国的需求情况。高速切削加工是面向21世纪的一项高新技术，它以高效率、高精度和高表面质量为基本特征，在汽车工业、航空航天、模具制造和仪器仪表等行业中获得了愈来愈广泛的应用，并已取得了重大的技术经济效益，是当代先进制造技术的重要组成部分。高速切削是实现高效率制造的核心技术，工序的集约化和设备的通用化使之具有很高的生产效率。可以说，高速切削加工是一种不增加设备数量而大幅度提高加工效率所必不可少的技术。高速切削加工的优点主要在于：提高生产效率、提高加工精度及降低切削阻力。有关高速切削加工的含义，目前尚无统一的认识，通常有如下几种观点：切削速度很高，通常认为其速度超过普通切削的5倍；机床主轴转速很高，一般将主轴转速在10000-20000r/min以上定为高速切削；进给速度很高，通常达15-50m/min，最高可达90m/min；对于不同的切削材料和所釆用的刀具材料，高速切削的含义也不尽相同；切削过程中，刀刃的通过频率接近于“机床刀具工件”系统的主导自然频率时，可认为是高速切削。可见高速切削加工是一个综合的概念。 1992年，德国Darmstadt工业大学的H. Schulz教授在CIRP上提出了高速切削加工的概念及其涵盖的范围，如图1所示。认为对于不同的切削对象，图中所示的过渡区(Transition)即为通常所谓的高速切削範围，这也是当时金属切削工艺相关的技术人员所期待或者可望实现的切削速度。高速切削加工对机床、刀具和切削工艺等方面都有一些具体的要求。下面分别从这几个方面阐述高速切削加工技术的发展现状和趋势。现阶段，为了实现高速切削加工，一般釆用高柔性的高速数控机床、加工中心，也有釆用专用的高速铣、钻床。这些设备的共同之处是：必须同时具有高速主轴系统和高速进给系统，才能实现材料切削过程的高速化。高速切削与传统切削最大的区别是，“机床刀具工件”系统的动态特性对切削性能有更强的影响力。在该系统中，机床主轴的刚度、刀柄形式、刀长设定、主轴拉刀力、刀具扭力设定等，都是影响高速切削性能的重要因素。在高速切削中，材料去除率，即单位时间内材料被切除的体积，通常受限于“机床-刀具-工件”工艺系统是否出现“颤振”。因此，为了满足高速切削加工的需求，首先要提高机床动静刚度尤其是主轴的刚度特性。现阶段高速切削之所以能够成功，一个很关键的因素在于对系统动态特性问题的掌握和处理能力。为了更好地描述机床主轴的刚度特性，工程上提出新的无量纲参数DN值，用以评价机床的主轴结构对高速切削加工的适应性。所谓DN值即“主轴直径与每分钟转速之积”。新近开发的加工中心主轴DN值大都已超过100万。为了减轻轴承的重量，还釆用了比钢制品要轻得多的陶瓷球轴承；轴承润滑方式大都釆用油气混合润滑方式。在高速切削加工领域，目前已开发空气轴承和磁轴承以及由磁轴承和空气轴承合并构成的磁气/空气混合主轴。在机床进给机构方面，高速切削加工所用的进给驱动机构通常都为大导程、多头高速滚珠丝槓，滚珠釆用小直径氮化硅（Si3N4）陶瓷球，以减少其离心力和陀螺力矩；釆用空心强冷技术来减少高速滚珠丝槓运转时由于摩擦产生温升而造成的丝槓热变形。近几年来，用直线电机驱动的高速进给系统问世，这种进给方式取消了从电动机到工作台溜板之间的一切中间机械传动环节，实现了机床进给系统的零传动。由于直线电机没有任何旋转元件，不受离心力的作用，可以大大提高进给速度。直线电机的另一大优点是行程不受限制。直线电机的次极是一段一段连续铺在机床的床身上。次极铺到哪里，初极工作台就可运动到哪里，而且对整个进给系统的刚度没有任何影响。釆用高速丝槓或直线电机，能够大大提高机床进给系统的快速响应。直线电机最高加速度可达2-10G(G为重力加速度)，最大进给速度可达60-200m/min或更高。 2002年举世瞩目的上海浦东磁悬浮列车工程中的磁浮轨道钢梁加工，釆用沈阳机床控股有限公司集团中捷友谊公司厂生产的超长进给系统高速大型加工中心实现。该机床的进给系统为直线导轨和齿轮齿条传动，工作台最大进给速度60m/min，快速行程100m/min，加速度2g，主轴最高转速20000r/min，主电机功率80kW。其X轴的行程长达30m，切削25m长的磁浮轨道钢梁误差小于0.15mm，为磁悬浮列车工程的顺利竣工提供了有力的技术保证。此外，机床的运动性能也将直接影响加工效率和加工精度。在模具及自由曲面的高速切削加工中，主要釆用小切深大进给的加工方法。要求机床在大进给速度条件下，应具有高精度定位功能和高精度插补功能，特别是圆弧高精度插补。圆弧加工是釆用立铣刀或螺纹刀具加工零部件或模具时，必不可少的加工方法。刀具材料的发展：高速切削技术发展的历史，也就是刀具材料不断进步的历史。高速切削的代表性刀具材料是立方氮化硼（CBN）。端面铣削使用CBN刀具时，其切削速度可高达5000m/min，主要用于灰口铸铁的切削加工。聚晶金刚石（PCD）刀具被称之为21世纪的刀具，它特别适用于切削含有SiO2的铝合金材料，而这种金属材料重量轻、强度高，广泛地应用于汽车、摩托车发动机、电子装置的壳体、底座等方面。目前，用聚晶金刚石刀具端面铣削铝合金时，5000m/min的切削速度已达到实用化水平，此外陶瓷刀具也适用于灰口铸铁的高速切削加工。涂层刀具：CBN和金刚石刀具尽管具有很好的高速切削性能，但成本相对较高。釆用涂层技术能够使切削刀具既价格低廉，又具有优异性能，可有效降低加工成本。现在高速加工用的立铣刀，大都釆用TiAIN系的复合多层涂镀技术进行处理，如目前在对铝合金或有色金属材料进行干式切削时，涂层刀具就受到极大的关注，预计其巿场前景十分可观。刀具夹持系统：刀具的夹持系统是支撑高速切削的重要技术，目前使用最为广泛的是两面夹紧式工具系统。在高速切削的情况下，刀具与夹具回转平衡性能的优劣，不仅影响加工精度和刀具寿命，而且也会影响机床的使用寿命。因此，在选择工具

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