机械和模具英语翻译.doc

毕业设计第四章：英语论文 机械和模具目前，中国正在迅速成为世界工厂。不过，当前“中国世界工厂”乃是中国迅速成为跨国公司“世界性生产基地”的同意语，中国离真正世界工厂还道路漫长。要建立真正意义上的世界工厂，必须以划时代的新技术革命为基础，把自身工业化和引进工业化结合起来，实现自身工业化和引进工业化的同时发展，这既是中国世界工厂的捷径，也是中国世界工厂的新发展道路。 当今企业的竞争集中表现在产品款式、新产品开发周期及产品生产规模方面。模具作为新产品生产的关键工装，其设计与生产日益成为新产品开发周期的决定因素。在汽车工业中，过去新车型的开发周期一般为十年，现在缩短为二到三年，福特及丰田新车型的开发周期仅为一年半，尤其是手机等电子行业， 开发周期有的仅为3个月。这就要倚赖企业提高模具设计与制造水平的能力。 精密模具高速加工技术随着数控加工设备与高性能加工刀具技术的发展而日益成熟，极大地提高了模具加工速度，减少了加工工序，缩短甚至消除了耗时的人工打模磨甚至抛光的工序，从而大大地缩短了模具的生产周期。模具的高速加工技术逐渐成为提高模具品质的最主要的手段之一 。 高速加工技术在我国刚刚起步，众多企业非常关注高速加工的发展及在模具行业的应用，以及高速加工的工艺特点，高速加工对设备、刀具的特殊要求以及高速加工对CAD/CAM系统的特殊要求。故将MAZAK精密模具高速加工技术研讨会暨现场加工展示会的资料整理成文，希望与我国从事模具高速加工的工程技术人员交流。关于高速加工的定义 高速加工是缘起自航空铝合金材料零件的加工，高水平合金涂层刀具的寿命不是主要的限制因素。高速加工主要受设备主轴速度及材料熔点的限制，一般主轴速度为5000060000r/min或更高。本文主要关注塑料模具、压铸模具、冲压模具及锻模等用的合金模具钢的高速加工，这种材料的硬度一般超过洛氏50度，故高速加工的限制因素主要是刀具寿命，而非铝加工中的主轴速度。对于小型模具细节结构的加工，主轴速度可达40000r/min以上，而大型汽车覆盖件模具的加工，一般主轴速度12000r/min以上的加工即可称为高速加工。 高速加工提高了模具加工的速度 对于精加工，从材料去除速度而言，高速加工比一般加工快四倍以上尽管高速加工采取了非常小的进给速度与切深，对粗加工而言高速加工可理解为45m3/min的切削量。 高速加工可获得高质量的加工表面 因高速加工采取了极小的进给量与切深，故可获得很高的表面质量，有时甚至可以省去钳工修光的工序，因表面质量的提高又省去了修光及火花机加工等工序所需的时间。 简化了加工工序 传统铣削加工只能在淬火之前进行，因淬火造成的变形必须要经手工修整或采用电加工最终成形。现在则可以通过高速加工完成，省去了电极材料、电极加工编程及加工，以及电加工过程所需所有费用，而且不会出现电加工所导致的表面硬化。另外，由于高速加工切削量减少，便可使用更小直径的刀具对更小的圆角半径及模具细节进行加工，节省了部分加工或手工修整工艺。减少人工修光时间及工艺的简化对缩短生产周期的贡献甚至可超过高速加工速度提高而产生的价值。 使模具修复过程变得更加方便 模具在使用过程中往往需要多次修复，以延长使用寿命，过去主要是靠电加工来完成，如果采用高速加工可以更快地完成该工作，而且可使用原NC程序，无需重新编制，且能做到精确无误。 MAZAK高速模具加工机MAZAK高速模具加工机于问世以来一直受到市场的好评，在今年更是对外发布了最新型号的级设备SMM2000U及SMM2500U。 高速加工对机床的要求 MAZAK高速模具加工机SMM2000U及SMM2500U以下功能都是标准配置： 主轴速度应能达到2000040000r/min；(MAZAK标准配备25000RPM 主轴)高刚性的机械结构；(龙门结构) 高稳定、高刚性、冷却良好的高速主轴； 精确的热补偿系统；(冷却液温度管理) 采用全闭环系统(采用德国制分辨率达0.05U的高分辨率的光栅尺) 高速处理能力的控制系统(采用高追踪性能的伺服放大器); 纳米补偿功能 具有预处理能力的控制系统。 高速加工对刀具及装夹的要求 刀夹、刀具的加速度小于3g； 刀具的径向跳动小于0.015mm； 刀长一般小于刀具直径的4倍。高速加工(HSM)对CAM系统的要求高速加工有着不同于传统加工的特殊的加工工艺要求，而数控加工的数控指令包含了所有的工艺过程，故应用于高速加工的数控自动编程系统CAM系统必须能够满足相应的特殊要求。 CAM系统应具有很高的计算编程速度 高速加工中采用非常小的进给量与切深，故对NC程序的要求比对传统系统的NC程序要求要严格得多，要求计算速度要快且方便、节约编程时间等。另外，快的编程速度使操作人员能够对多种加工工艺策略进行比较，以便采取最佳的工艺方案，并对刀具轨迹进行编辑、优化，以达到最佳的加工效率全程自动防过切处理能力及自动刀柄干涉检查 高速加工以高出传统加工近10倍的切削速度加工，一旦发生过切, 其后果不堪设想，故CAM系统必须具有全程自动防过切处理能力。传统的曲面CAM系统是局部加工的概念，极容易发生过切现象，一般都是靠人工选择干预的办法来防止，很难保证过切防护的安全性，只有通过新一代的、智能化的、面向对象的CAM系统，才能实现防过切处理全部由系统自动完成，才能真正保证其安全性。 高速加工的重要特征之一就是能够使用较小直径的刀具加工模具的细节结构。系统能够自动提示最短夹刀长度并自动进行刀具干涉检查，这对于高速加工非常重要。进给率优化处理功能 为了能够确保最大的切削效率，并保证在高速切削时加工的安全性，应根据加工瞬时余量的大小，由CAM系统自动对进给率进行优化处理。符合高速加工要求的丰富的加工策略 与传统方式相比，高速加工对加工工艺走刀方式有着特殊要求，因而要求CAM系统能够满足这些特定的工艺要求： 应避免刀具轨迹中走刀方向的突然变化，以避免因局部过切而造成刀具或设备的损坏。 应保持刀具轨迹的平稳，避免突然加速或减速。 下刀或行间过渡部分最好采用斜式下刀或圆弧下刀，避免垂直下刀直接接近工件材料。 行切的端点采用圆弧连接，避免直线连接。 除非情况必须如此，否则仍应避免全力宽切削。 残余量加工或清根加工是提高加工效率的重要手段，一般应采用多次加工或采用系列刀具从大到小分次加工，直至达到所需尺寸，避免用小刀一次加工完成。 刀具轨迹编辑优化功能非常重要，应避免多余空刀，可通过对刀具轨迹的摄像、复制、旋转等操作来避免重复计算。 刀具轨迹裁剪修复功能也很重要，可通过精确裁剪减少空刀提高效率；也可用于零件局部变化编程，仅需编辑修改边际，无需对整个模型重新编程。 高速加工对编程人员的要求与编程方式的改变 采用高速加工设备之后，对编程人员的需求量将会增加，因高速加工工艺要求严格，过切保护更加重要，故需多花时间对NC指令进行仿真检验。一般而言，高速加工编程时间比普通加工编程时间要长得多，然而却大大缩短了加工时间。为了保证高速加工设备足够的使用率，需配置更多的CAM人员。 传统CAD/CAM中，NC指令的编制是由远离加工现场的CAD/CAM工程师来完成的，因编程与加工地点分离，往往因编程人员对现场条件及加工工艺不够清楚而需要对NC指令进行反复检验与修改，影响正常使用。随着CAM系统智能化水平的提高，已经出现了新一代独立运行的智能化的CAM专业系统，其主要特点是面向对象的实体加工方式，而非传统的曲面局部加工方式。只需输入并选择加工工艺，即可自动完成编程操作。编程的复杂程度与零件的复杂程度无关，只与加工工艺有关，因而非常易于掌握，只需短时间培训即可掌握使用。在欧美发达国家，为了充分发挥NC设备操作人员的优势，缩短加工时间间隔，机侧对话式编程已经成为逐渐流行的发展趋势。ery and mold At present, China is fast becoming the factory of the world. However, the current China factory of the world China is rapidly becoming multinational corporations, global production base, agreed language from the real factory of the world, China has a long way to go. To the establishment of a genuine sense of the factory of the world, an epoch-making must be based on the new technology revolution, and the introduction of its own industrialization combined with industrialization and achieve industrialization and the introduction of its own industrialization of the development, and this is a shortcut to China factory of the world, China is also the world factory The new road to development. Todays performance on the competitiveness of enterprises in the product design, new product development cycle and product size. Mould, as the key to the production of new tooling, design and production of new products are increasingly becoming the determining factor in the development cycle. In the automobile industry, in the past the development cycle of new models generally 10 years, now shortened to two to three years, Ford and Toyota new model development cycle is only a year and a half, particularly for mobile phones, such as the electronics industry, a development cycle The only three months. This can be relied on enterprises to improve the level of mold design and manufacturing capabilities. Precision Die processing technology with high-speed CNC machining equipment and high-performance processing tool technology and the development of increasingly mature, and greatly improve the processing speed of the die to reduce the processing, reduce or even eliminate the time-consuming manual grinding or polishing a model of processes, thereby greatly reducing the mold of the production cycle. Die-processing technology has gradually become the most important quality of the die one of the means. High-speed processing technology in China has just started, and many enterprises are very concerned about the development of high-speed machining and mold industry in the application of technology and high-speed processing features, high-speed machining equipment, tools, as well as the special requirements of high-speed processing of CAD / CAM systems to the specific requirements of . MAZAK precision molds it will be high-speed processing technology seminars and exhibitions at the scene processing of written documentation, hope and die in the high-speed processing of the exchange of engineering and technical personnel. On the definition of high-speed machining Since the origin of high-speed machining is aluminum alloy materials aviation parts processing, and high alloy coating tool life is not a major limiting factor. Mainly by high-speed machining equipment and materials melting point spindle speed restrictions, the general spindle speed of 50000 to 60000 r / min or higher. This paper mainly concerns plastic mould, die-casting molds, and forging die stamping dies used in alloys such as high-speed machining die steel, the hardness of the material generally exceed Rockwell 50 degrees, the high-speed processing is the main limiting factor tool life, rather than aluminum Processing of the spindle speed. For small mold details of the structure of processing, and spindle speed of 40000 r / min more, with large auto cover mold processing, and general spindle speed of 12000 r / min above can be described as high-speed machining process. high-speed processing of the increased processing speed Die For finishing, material removal rate, the high-speed processing four times faster than the normal processing over - even though high-speed machining taken a very small feed speed and depth of cut of rough terms understandable for the high-speed processing of the 45 m3/min Cutting volume. receive high-speed processing of high-quality machined surface Due to the high-speed machining small feed rate and depth of cut, it will be very high surface quality, and sometimes omit the fitter-repair processes for improving the quality of surface and save the repair and sparks-processing machine the time required to process. simplified processing Only in the traditional milling before quenching, the deformation caused by quenching must be repaired by hand or using EDM eventually forming. Now through the high-speed processing can be completed, eliminating the electrode material, electrode processing programming and processing, and processing power required for all the costs, but there will not be caused by the processing power of the surface hardening. In addition, since the reduction of high-speed machining cutting can use smaller diameter of the tool on a smaller radius and die details of processing, and save some manual processing or finishing process. Artificial light to reduce repair time and simplify the process of shortening the production cycle can be even more than the contribution of high-speed processing speed have increased the value. to die repair process more convenient Die in the process often requires the use of multiple rehabilitation to extend the life of the past relied mainly on the processing power to complete, if the high-speed processing can be faster completion of the work, and the NC program can be used without re-establishment, but also achieve accuracy. MAZAK high-speed machining die MAZAK high-speed machining in die since the advent of the market has been praised, in this year is released the latest models of u-class equipment SMM2000U and SMM2500U. high-speed processing of the requirements of machine tool MAZAK SMM2000U high-speed machining and mold SMM2500U following features are standard configuration: spindle speed should be able to reach 20000 to 40000 r / min; (MAZAK standard 25000 RPM spindle) high rigidity of the mechanical structure; (gantry structure) high stability, high rigidity, high-speed spindle cooling good; precise thermal compensation system; (coolant temperature management) use of the whole closed-loop system (using the system resolution of 0.05 German U of high-resolution optical grating) high-speed processing ability of the control system (using high-performance tracking servo amplifier); Nano compensation pretreatment with the ability to control system. high-speed machining tool and fixture on the request of knife folder, cutter acceleration is less than 3 g; tool radial runout of less than 0.015 mm; knife-generally less than four times the diameter of the tool. High Speed Machining (HSM) on the request of CAM System Unlike traditional high-speed processing with the special processing requirements of the processing technology, and CNC machining NC directive contains all of the process, it applied to high-speed automatic processing of NC programming system - CAM systems must be able to meet the corresponding special requirements. CAM system should have a high rate of Programming The use of high-speed processing of very small feed quantity and depth of cut, so the NC procedural requirements than the traditional system of NC program to more stringent requirements for faster computing speed and convenience, saving programming time. In addition, the fast speed of the programming staff to be able to operate a variety of strategies to compare processing, in order to take the best of the programme, and tool path editing, optimization, to achieve the best efficiency of the whole process automatic cut-off handle and the ability to automatically check knife handle interference High-speed machining higher than traditional processing nearly 10 times the cutting speed processing, the event of a cut, the consequences will be unimaginable, the CAM system must have full automatic cut-off processing capabilities. Traditional surface CAM system is the concept of local processing, a very high cut-off phenomenon, and are generally rely on artificial selection intervention approach to the prevention, it is difficult to guarantee the protection of the safety of all, only through a new generation of intelligence, Object-oriented CAM system can be achieved-cutting deal with all been done automatically by the system, the only real guarantee of its security. An important feature of the high-speed processing is able to use one of the smaller diameter of the cutter mold processing the details of the structure. System can automatically prompting the shortest length of knife folder automatically and interference checking tool, which is very important for high-speed machining. Feed rate optimization function In order to ensure maximum cutting efficiency, and to ensure that high-speed cutting processing security, should be based on the size of the processing instantaneous cushion from the CAM system for automatic feed rate optimization. Comply with the requirements of high-speed machining rich processing strategy Compared with traditional methods, high-speed processing technology for the processing of cutting methods have special requirements, and requested CAM systems to meet these specific technical requirements: should avoid cutting tool path in the direction of sudden change, so as to avoid a partial cutting tool or equipment caused the damage. should maintain a smooth tool path and avoid sudden acceleration or deceleration. under the knife or between the lines, the best part of the transition under the knife used inclined arc under the knife or to avoid vertical directly under the knife close to the workpiece material. endpoint used to cut the arc connecting to avoid linear connection. unless required to do this, it should avoid full width cutting. residual processing or clean-processing is to improve the efficiency of processing an important means should be used repeatedly general processing or use of knives从大到小series points, processing, until they reach the required size, avoid using a knife to complete processing. optimization tool path editing function is very important to avoid unnecessary air knife and tool path through the camera, copying, rotating, etc. operation to avoid double-counting. Cutting repair tool path is also very important, through precise cutting to reduce air knife improve efficiency; parts can also be used for local programming changes, only marginal editorial changes without re-programming of the whole model. high-speed processing of the requirements of programmers and programming changes to the mode of High-speed processing equipment, the program will increase the demand f