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滑移式起重夹钳装置主机的加工工艺设计【2张CAD图纸+毕业论文】【答辩通过】

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关键词：: 滑移起重夹钳装置主机加工工艺设计全套 cad 图纸毕业论文答辩通过

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摘要

机械夹钳机构是机械制造装备的重要组件,当夹钳机构钳口开口因夹持不同尺寸大型工件而有较大变化时,存在夹持力波动很大的情况,因而很难保证夹持的可靠性,甚至造成夹持机构功能失效。

本文详细介绍了夹钳装置设计过程和一些零件加工工艺方法,快速成型加工和数控加工，薄壁零件在加工过程中容易变形,加工精度难以保证,如果能采用合适加工工艺,完全可以解决这一问题。

本文针对典型的轴类零件数控加工工艺的分析,给出了对于一般零件数控加工工艺分析的方法。

关键字：夹持力；夹钳装置；加工工艺设计；夹钳强度

ABSTRACT

The mechanical clamping mechanism is an important component part of mecha nical manufacturing equipment. There exists a situation of large fluctuation in clamping force while the vice jaw opening of clamping mechanism has rather large variations on account of clamping large-scaled work-pieces of different dimensions, therefore it is very difficult to ensure the reliability of clamping or even causing failure on the function of clamping mechanism.

The processing method and jig designing process of some cylinder body were introduced. In the processing of thin wall cylinder components, they are easy to distort, so it is very difficult to guarantee the precision.

At last，technology analysis is very important, on the basis of analyzing technologies of shaft components' NC processing, the methods of usual components' NC processing technologies were given out, which was significant for actual manufacture and enhancing products' quality.

Keywords：clamping force；Clamping devices；processing craft designing；shaft components process

摘要I

ABSTRACTII

1前言1

1.1 起重夹钳国内外发展情况1

1.2 起重夹钳加工的发展情况3

1.3 研究的主要内容及解决的主要问题3

2100KG起重夹钳装置机构原理和作用4

2.1100KG起重夹钳装置机构的结构4

2.2 100KG 起重夹钳装置机构的基本原理5

3100KG 起重夹钳装置机构的材料选择5

3.1100KG 起重夹钳装置机构结构优化分析5

3.2 起重夹钳装置主机的钳臂的材料选择9

3.3 起重夹钳装置主机的钳口的材料选择10

3.4夹钳机构运动过程的可靠性研究11

4100KG 起重夹钳装置主要部件的加工工艺设计14

4.1利用快速成型进行加工设计14

4.2轴类零件的数控加工工艺设计17

4.3薄壁零件加工工艺设计20

4.4用线切割加工吊臂的加工设计23

5结论25

参考文献26

致谢28

1前言

1.1 起重夹钳国内外发展情况

工业革命之后，随着工业化的大步发展，各种起重夹钳的应用也逐渐广泛起来了。

在90年代，国外一些工业强国对夹钳的研究已有了较大突破。

1996年，日本三菱商事株式会社（MCG）与太原重型机械集团公司合作，研制成功七台板坯夹钳搬运起重机，该产品已达到90年代初国外同类产品的先进水平[1]。国内的起重夹钳的研究起步较晚，在新中国成立以前，中国基本上没有自主研发的能力。1993年2月16日太原重型机器厂举行了70t动力开闭式板坯夹钳试车演示会。在试车演示会上，该产品通过了空载和负荷试车的考验，性能达到了设计要求，可供连铸厂和热连轧厂用作板坯起吊或一般取物作业。该夹钳装置采用PC控制，有多重电气保护和重新起动回路，能检测和显示钳口开度和板坯厚度，比我国经常使用的重力夹钳的生产率高，操作方便而且安全可靠[2]。

200年宝山钢铁股份有限公司生产的一种钳式起重机夹钳在传统的钳式起重机夹钳的结构基础上，将夹钳的二个钳腿中的一个钳腿的中部拐角处自上而下形成分叉状并构成二个支钳腿，二个支钳腿与另一个钳腿仍呈交叉状，以此形成了“三钳腿”的结构。在起吊长规格模具钢时，依靠一个钳腿中的二个支钳腿以及另一个钳腿可以牢固地接触到模具钢侧面，增加了钳腿与模具钢侧中的接触点和面积，较传统的夹钳相比，本实用新型的夹钳更适合于进行起吊模具钢，它既避免了起吊的模具钢发生倾翻现象，又提高夹钳的使用功能；2006年山西某公司生产的热板坯动力夹钳起重机其夹钳的技术关键：(1)利用螺杆传动实现钳以臂水平开闭运动。(2)通过优化设计和模拟试验确定了合理的倾斜角，使夹持力足够大，而外形尺寸最小。(3)夹钳的开闭机构采用了磁粉离合器和零速检测开关，控制钳口对板的初始夹紧力和钳口的初始夹紧运动，并实现对电动机过载的保护。(4)首次采用了多对钳臂，实现对长、短板的夹取，这在国外也是首创[3]。（5）采用两大套独立的开闭机构，可以实现斜坯的夹取；2008年河南某公司生产的100T多用途旋转铝铸锭夹钳起重机主要创新点是多种吊具更换完成多种作业，夹钳部分采用了全液压装置，液压旋转、液压夹紧、松开，钳齿的形状和材料耐高温耐磨，任意板宽均有齿尖相接触；采用绕性钢绳斜拉三角形防摆等，均为国内领先水平。同年太原重型机械集团有限公司生产的六爪式动力板坯夹钳，其上横梁分别通过三个连接铰轴与三个开闭梁连接，每个开闭梁安装有开闭机构和双向螺杆及螺母，双向螺杆及螺母上的轴连接钳臂，开闭机构通过驱动装置带动链轮、链条传动双向螺杆，双向螺杆回转使螺母带动一对钳臂作开闭运动。本发明与现有技术相比，不仅适用板坯规格范围大，板坯堆取更加灵活方便，而且尺寸小、自重轻。大连华锐股份有限公司生产的防摇板坯夹钳起重机包括桥架、大车行运机构、小车、卷筒、吊架、动滑轮，钢丝绳，板坯夹钳，特征是：所述的“十”字形吊架由相互垂直的两个直梁构成，于两直梁的两端顶面处依序设I#、II#、III#、IV#吊点，于I#、II#、III#、IV#吊点处分别装设由支座支承的两个动滑轮，与小车I#、II#卷筒相对应的动滑轮上、分别用钢丝绳经缠绕连接构成四绳四边“V”字形式的钢丝绳系；于“十”字型吊架的某一直梁的两端底面对称连接板坯夹钳；本实用新型不仅设计合理，结构紧凑，在大车及小车运行方向上既不摇摆，又不旋转，使得板坯夹钳定位准确、夹取迅速，而且提高作业生产效率，以及具有操作安全，使用十分方便等优点[4]。

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内容简介：: 湖南理工学院毕业设计（论文）中期检查表毕业设计（论文）题目滑移式起重夹钳装置主机的加工工艺设计学生姓名钮科学号14071902394院别机械工程学院专业机械设计制造及其自动化指导教师谭湘夫检查日期2011年4月15日指导教师检查情况记载及修改意见：已完成任务：在毕业设计前一阶段，该生主要完成了以下工作。写出了毕业设计开题报告；收录了参考文献；去工厂进行了实地考察；翻译了英语文献；写作了毕业设计论文的前言和目录情况记载：2010.12.10 下达毕业设计任务书2010.12.20再次下达设计前准备工作：查阅文献，撰写开题报告；实习；安排设计任务、收集资料（要求收集20篇参考文献），教会学生上图书馆网站下载科研论文（大部分学生不会下载论文）2011.2.23 检查学生对国内外起重夹钳技术的发展及应用情况的了解程度、给学生讲解夹钳装置的工作原理；作好制作夹钳模型的准备工作2011.2.27 要求学生将3000字的与本课题有关的英文文献译成中文；布置写毕业设计（论文）开题报告2011.3.2 与学生见面，检查开题报告撰写情况，该生完成任务较好2011.3.7 收集开题报告，修改学生的开题报告2011.3.9 讲解常用夹钳装置的结构分类；确定起重夹钳设计方案2011.3.19 要求该生做滑移式起重夹钳装置主机的加工工艺设计2011.3.30 带学生到机器有限公司实习2011.4.7 在机器公司制作夹钳模型，到工业品市场买电机等电器元件2011.4.12 要求写作前言2011.4.15 要求撰写毕业设计（论文）初稿指导教师意见：该生前期工作完成很好，能积极思考问题，完成了毕业设计前期计划，可开始下一步论文写作工作。签名： 2011.4.15注：此表用于指导教师在学生毕业设计（论文）初稿完成后对学生执行任务书情况进行中期检查时用，由指导教师填写。毕业设计（论文）任务书课题名称：滑移式起重夹钳装置主机的加工工艺设计学生姓名：钮科院别：机械工程学院专业：机械设计制造及其自动化指导教师：谭湘夫 2010年12月1日1、主题词、关键词：夹钳机构；加工工艺设计；钳臂加工；吊臂加工；轴的加工；工艺装备的选择；滑移式重力自动开关装置加工2、毕业设计（论文）内容要求：(1) 查阅文献资料, 其中中文文献不得少于15篇，外文文献不少于3篇，将其中一篇外文文献（不少于3000英文单词）翻译成中文（将中英文装订在一起）。写出国内外起重夹钳技术的发展及应用情况、夹钳装置的工作原理、夹钳装置的工作要求及性能(2) 进行常用夹钳装置的分类及夹钳装置的工艺总体装配设计夹钳装置主要零部件如钳臂、吊臂、轴等零件的加工工艺设计；工艺装备的选择(3) 滑移式重力自动开关装置加工工艺设计(4) 用铅笔绘夹钳装置主要部件图六张；还要求用AUTOCAD将上述图绘出(5) 交论文初稿（纸质打印稿）(6) 说明书的撰写要求认真、准确、条理清晰，文中引用的文献要依次编号，其序号用方括号括起，如5、6，置于右上角，文献内容必须严格按照引用的先后顺序依次在毕业设计(设计（论文）)的最后列出，文档运用 “word长篇文档排版技巧”，按学院毕业设计手册要求的格式与样式排版，用公式编辑器编辑公式，毕业设计说明书正文字数在1.5万字以内,交打印稿与电子稿3、文献查阅指引:1刘兰生. 摩擦式夹钳紧力的简捷计算J.起重运输机械，1989，（1）：-. 2顾必冲. 一种自动的夹钳控制装置J. 港口装卸， 1991，(3):13-16.3 谢华郗江云，李建红.装配设计M. 北京：机械工业出版社， 2007.4倪泽娅. 重力式板坯夹钳的开发与研制J. 重型机械科技, 2006， (2):14-17. 5 利用百度搜索工具查阅相关内容的最新进展6利用湖南理工学院图书馆电子阅览室查阅、收集相关资料7一定要找到三篇与论文有关的英文原版参考文献，参考文献至少1篇其中外文文献不少于3篇，将一篇外文文献（不少于3000英文单词）翻译成中文4、毕业设计（论文）进度安排：第1周实习;设计前准备工作，接受工艺设计任务、收集资料（18篇参考文献）第2、4周了解课题背景、国内外起重夹钳技术的发展及应用情况、夹钳装置的工作原理；作好制作准备工作；将3000字的与本课题有关的英文文献译成中文；交毕业设计（论文）开题报告第5、6周进行常用夹钳装置的分类及夹钳装置的工艺总体装配设计；第7、8周夹钳装置主要零部件如钳臂、吊臂、轴等零件的加工工艺设计；旋转棘轮重力自动开关装置加工工艺设计;毕业设计（论文）中期检查；第9、10周用铅笔和AUTOCAD绘夹钳装置主要零部件图各六张；交论文初稿（纸质）；第11、12周制作夹钳设备第13、14周整理设计说明书，交毕业设计终稿（要交WORD文档和PDF文档两种格式的电子稿)；准备毕业答辩第15周交毕业设计（论文）答辩申请暨资格审查表；毕业答辩教研室意见：该课题与机械设计制造及其自动化专业培养目标结合紧密，内容丰富、要求合理，课题的难易程度适中，适合本科生作毕业设计用，进度安排合理。负责人签名：注：本任务书一式三份，由指导教师填写，经教研室审批后一份下达给学生，一份交指导教师，一份留系里存档。毕业设计（论文）开题报告课题名称：滑移式起重夹钳装置主机的加工工艺设计学生姓名：钮科系别：机械工程学院专业：机械制造及其自动化指导教师：谭湘夫 2011年 2月 25 日一、综述国内外对本课题的研究动态，说明选题的依据和意义：夹钳装置是夹钳起重机的取物装置 ,夹钳起重机能否可靠地工作,主要取决于夹钳的性能。夹钳装置是夹钳起重机的取物装置,它与起重机的几个工作机构配合,可从铸锭车上拧断汤道,夹取钢锭,将钢锭装人均热炉,再从均热炉取出加热后的钢锭送进运锭车或直接放到辊道上运往初轧机。此外,夹钳起重机还可用来拨移钢锭车或夹上清炉耙清理炉底。夹钳起重机在完成上述工艺程序时,由于运行速度较快,振动大,夹持的又往往是红热的钢锭,因此夹钳装置的各个零部件除应有足够的强度外,还应有良好的夹持性能,保证夹持的钢锭不至从钳口脱落本次毕业设计题目是“滑移式起重夹钳装置主机的加工工艺设计”。二、研究的基本内容，拟解决的主要问题：(1) 查阅文献资料, 其中中文文献不得少于15篇，外文文献不少于3篇，将其中一篇外文文献（不少于3000英文单词）翻译成中文（将中英文装订在一起）。写出国内外起重夹钳技术的发展及应用情况、夹钳装置的工作原理、夹钳装置的工作要求及性能(2) 进行常用夹钳装置的分类及夹钳装置的工艺总体装配设计夹钳装置主要零部件如钳臂、吊臂、轴等零件的加工工艺设计；工艺装备的选择(3) 滑移式重力自动开关装置加工工艺设计(4) 用铅笔绘夹钳装置主要部件图六张；还要求用AUTOCAD将上述图绘出(5) 交论文初稿（纸质打印稿）三、研究的步骤、方法、措施及进度安排：1、查阅相关文献资料，充分利用校图书馆的数字资源，了解目前国内外起重夹钳技术的发展及应用情况，夹钳装置的工作原理；2、进行常用夹钳装置的分类及夹钳装置的工艺总体装配设计；夹钳装置主要零部件如钳臂、吊臂、轴等零件的加工工艺设计；旋转棘轮重力自动开关装置加工工艺设计;3、运用AUTOCAD绘夹钳装置主要零件图；4、制作夹具设备。5、按南湖学院相关要求整理完成毕业设计。进度安排：第1周实习;设计前准备工作，接受工艺设计任务、收集资料（18篇参考文献）第2、4周了解课题背景、国内外起重夹钳技术的发展及应用情况、夹钳装置的工作原理；作好制作准备工作；将3000字的与本课题有关的英文文献译成中文；交毕业设计（论文）开题报告第5、6周进行常用夹钳装置的分类及夹钳装置的工艺总体装配设计；第7、8周夹钳装置主要零部件如钳臂、吊臂、轴等零件的加工工艺设计；旋转棘轮重力自动开关装置加工工艺设计;毕业设计（论文）中期检查；第9、10周用铅笔和AUTOCAD绘夹钳装置主要零部件图各六张；交论文初稿（纸质）；第11、12周制作夹钳设备第13、14周整理设计说明书，交毕业设计终稿（要交WORD文档和PDF文档两种格式的电子稿)；准备毕业答辩第15周交毕业设计（论文）答辩申请暨资格审查表；毕业答辩四、主要参考文献：1刘兰生. 摩擦式夹钳紧力的简捷计算J.起重运输机械，1989，（1）：-. 2顾必冲. 一种自动的夹钳控制装置J. 港口装卸， 1991，(3):13-16.3 谢华郗江云，李建红.装配设计M. 北京：机械工业出版社， 2007.4倪泽娅. 重力式板坯夹钳的开发与研制J. 重型机械科技, 2006， (2):14-17. 5 仝国伟; 起重机运行歪斜及其改善措施J.金属加工(冷加工)2010，24.6 李正民; 板坯夹钳搬运起重机J.太原科技1996，03.7 曹自立; 642525t板坯夹钳起重机试制成功J.起重运输机械1994，04.五、指导教师意见：该生的课题的深度、广度以及工作量均适合作为毕业生的毕业设计，该生查阅了大量文献资料，课题研究前期准备工作已完成，研究内容与方法以及进度安排合理可行。签名：六、教研室意见：签名：注：此表由学生本人填写，一式三份，一份留系里存档，指导教师和学生本人各保存一份。湖南理工学院毕业设计（论文）每周交流记录表毕业设计（论文）题目滑移式起重夹钳装置主机的加工工艺设计学生姓名钮科学号14073102394院别机械工程学院专业机械设计制造及其自动化指导教师谭湘夫检查日期日期交流内容第二周主要讲解毕业设计的格式，下达毕业设计任务。第三周检查文献，撰写开题报告。第四周搜索资料，和老师一起研究确定方案。第五周把设计中出现的问题告诉老师一起寻找解决方案。第六周上交开题报告，老师指导修改其中的错误。第七周中期检查。指导老师督促学生设计进度。第八周完善毕业设计，下达撰写毕业说明书。第九周上交装配图与CAD图，老师检阅图纸并指导学生修改。第十周评论毕业设计论文。第十一周毕业设计答辩资格检查。第十二周准备毕业答辩。指导教师意见：该生每周按时报到，及时找指导老师交流，积极思考，努力讨论发现研究设计中出现的问题。并且能够按时完成老师下达的任务，独立完成论文的写作、符合要求。签名： COMPUTER-AIDED CNC PROGRAMMINGFOR THE MACHINING OF NON-TYPICAL PARTSGrzegorz NikielGrzegorz NIKIEL, Ph.D., Eng., University of Bielsko-Biaa, Department ofManufacturing Technology and Automation, 43-309 Bielsko-Biaa, ul. Willowa 2,gnikielath.bielsko.pl1. Introduction Many manufacturing firms, especially medium and small, has to solve problem of production development and search of new customers. In many cases this leads to the assortment enlarging of already manufactured products. Often this is joined with implementation of the new manufacturing processes. In conditions of market competition it demands high flexibility which is often got in way replacing of conventional manufacturing resources by the modern CNC tool machines 1. This is essentials condition for more efficient development, higher quality and faster adoption to new requirements 2. For maintenance of the low costs of manufacturing for production of small and medium batches very often the Group Technology is applied 3. With help of grouping of the manufactured components into families more efficient the machines, devices, workers are used. In the processes planning one from most important tasks is the CNC machine tool programming 4, 5. Very often the CAD/CAM systems are used from reason their possibility of flexible programming. In the case of typical components such approach the positive results gives, though it demands an efficient co-operations between constructors and technologist. Sometimes from different reasons it is impossible, especially when the Group Technology is applied. Usually the part programs for machining of single components are created, but the modern CNC controllers offer some methods of programming, which to machining of some similar components can be used. Such methods are:1.Cycles 6. The cycles are design for machining of typical surfaces (the holes, threads, slots etc.). Usually a parametric description of machined surfaces is applied which enable the easy and fast changes of their geometry. Unfortunately they be characterized by small flexibility and small influence onto strategy of machining, dependent only from the parameters of cycle. In the modern controllers it permit onto a Workshop Oriented Programming (WOP), i.e. programming directly by the operators, often aided by a dialog programming (sometimes a conversational programming called). Therefore this is relative simple programming method, very often used in industrial practice.2.Parametric programming 5, 6. A typical part program is executed from beginning to end in one run. In parametric programming the execution of part program can run into different way (e.g. by conditional instruction IF. THEN. use). In addition, a multiple repetition of the part program fragment is accessible (REPEAT loop, WHILE loop etc.). Furthermore, the arithmetical functions and other advanced functions are possible. The axis positions, feed and speed functions, etc. can be specified by a parametric expressions (by R-parameters use). Into this way it was been possible to create own machining cycles also. This approach demands high skills of programming and is very labour-consuming also. Exact verification of the program is necessary, in this its immunity in the dangerous situations (e.g. joined with application of incorrect value of the input parameters). Therefore in view of above mentioned defects it is infrequently used in industrial practice.3. Programming based on the freely defined contours. The task depends on defining of machined contour and its automatic conversion to the CNC codes. If the automatic cutter radius compensation (the G41 and G42 functions) is not used then additionally a equidistant has to be generated. This sub-task is easy to realization if mentioned contour is represented in a CAD system with help of the Offset function. Second sub-task often is realized in way of export of graphic form of the tool path to the typical formats of data exchange (DXF, HPGL etc.). In next step by the suitable postprocessors use (for example the solution given in 7) conversion of tool path onto the CNC codes is performed. From practical regards this approach in generality for the simple operations is applied, e.g. a laser cutting, a water jet cutting etc. A solution integrating both sub-tasks in one application program are applied also the AutoCUT is the best example 8. In practice this solution is not applied too often although it possesses many advantages.In the conditions of small batch production a process planning to the CNC programming is often restricted 9. In this situation large meaning has integration of the CAD/CAM systems with omission of CAPP stage. The Features idea is then a effective method of data exchange 10, 11, 12. When the Group Technology is used, after supplement by appropriate data bases and knowledge bases, it can be best solution for production of typical elements 13, 14. In case of non-typical parts such approach generally is ineffective. Mainly in view of the widely applied methods of Features recognizing which limit number of the Feature types 10, 12. Maybe in future a solution will bring integration of CAD/CAM/CNC systems based on the STEP-NC standards (ISO 14649, ISO 10303:238) 15, 16 which will replace traditionally applied CNC programming with G-codes onto thing of the neutral format of data exchange.2. Analysis of the examplesPresented below examples of the group CNC machining are a fragment of production program from the small firm. Generally this components have non-typical shapes, they are manufactured from hard materials (e.g. austenitic stainless steel), usually needed the special jigs and fixtures, in the conditions of small batch production. The planning processes in this case demand a participation of technologists with large experience. A specific character of accessible tool machines for defining of the method of CNC programming should to consider also. After execution of detailed analysis onto subject of the discussed methods the following conclusions were formulated: The machined shapes exclude applying of the standard cycles. Most of the programs is design for the complicated profiles machining. From here description of these profiles is largest problem. Moreover, machining of the components is performed on the different tool machines, equipped in different controller. For most of machined components the exact drawing documentation is not made. In a production order the general drawings are included, often described by parametric dimensions. Then current values of this parameters are given also. Short series and large variety of the components demands fast modifying of current production program. Fast CNC programming and the programs implementation is necessary, best directly at tool machine (WOP). Often the operators of tool machines possess large knowledge and experience in the area of manufacturing technology, sufficient for preparation of simple program (in range of the technology). Fast preparation of the tool path is limitation only. General conclusion is such, that in presented case use of the universal CAD/CAM systems for CNC programming is very difficult. Moreover, it joins with high costs of shopping and trainings for the workers. Low flexibility of this method is expected also, especially time of programming can be a great problem. In this situation a parametric programming as the best solution was considered. But, as it was shew on the examples, the parametric programming can be realized in different way.2.1. Example I the grooved rollers finish machiningFinish machining of the grooved rollers family was subject of research (Fig. 1). Basic changing dimensions for rollers were external diameter d, working profile length L and profile angle . The profile of co-operate roller is moved by half pitch. Finish machining is performed by turning with use of tool with the V type rhombic insert (nose angle equal 35), where the nose radius r is equal 0,4 mm (Fig. 1). The tool reference point is located in the insert nose center. For each pair of rollers their profile is designed in a CAD environment according to the dimensions of rolling elements. A fast method of tool path generation was the main subject of performed research. First of all generating of the tool path (only finishing, without rough machining which is programmed in a manual mode) and forming it in accordance with requirements of appropriate language. As has been mentioned above the use of parametric program was considered. With help of the advanced programming methods (e.g. transformations of co-ordinate system, sub-programs etc.) it was been possible to achievement the aim of this study. However, number of the machined rollers is very small (some per year). Therefore another approach was accepted. Because for each roller a exact CAD model is prepared (2D model), it was used to CNC programming. For achievement of this aim the following activities was considered: For each used CNC controller the framework of part program is created, including program header, technological functions, tool functions and program end (without tool path). In a CAD environment the model co-ordinate system is assigned to the workpiece co-ordinate system. In the semi-automatic mode from the model of working surface a tool path is extracted with use the Offset function. Manually the run-in path and the run-out path is added. For different elements of tool path (with working interpolation or with rapid interpolation) different attributes of line were applied. The designed tool path is converted to a numerical form in semi-automatic mode by special program (written in LISP language) and inserted to the part program (created previously). User has to show only first element of the tool path, further analysis is worked out on basis of the drawing data base (Fig. 2). Finally the part program is verified, the cutting parameters values are corrected and a graphical simulation of machining is executed (Fig. 3). Total time of program planning (without preparing of CAD model) then about some minutes. An universal postprocessor was not applied (e.g. 7) because format of the CNC program can be easily adapt to requirements of controller. Furthermore time of designing became significantly shortened. 2.2. Example II the multi-edge rings profile machining The multi-edge rings profile machining was subject of the research (Fig. 4). On the face three zones of grooves are machined. Number of grooves (n1, n2, n3) results from companies recommendations. In every zone the constant value of pitch S is kept. The grooves dimensions (S, F, G) and the chamfer dimension w are changing and they have to be contain in the recommended limits. Their values are calculated for the constant diameters D1 and D2 (given in a production order). Just after complete determining of grooves geometrical form the machining operation can be designed. The rings are machined by tool with square insert (S type) Fig. 4. The tool reference point is located in the insert nose center. In order to clearly determine of the remaining ring dimensions the following dependences were accepted (according to the recommendations):and the geometrical dependences are described as follows (Fig. 4):what causes that the S, w and F dimensions in given ranges have to be changed until total number of grooves will not be a natural number. The above task as a optimization problem has treated where three decision values are given (S, w and F) and the constrains is given according to equation (1). The criterion function is calculated according to equation (2). The problem of optimization has solved by the Hooke-Jeves method use 17. When ring geometry is finally determined then calculations of tool path elements is very simple tool is moved along equidistant. Therefore was assumed that this two tasks will be solved by means of one program (Fig. 5), a similar approach was showed in 18. After introduction of value of well-known dimensions (e.g. from production order) the value of remaining dimensions are automatically calculated. If user accepts this values then the part program is generated automatically (in non-parametric form). In opposite case user can improve values of dimensions and their correctness is checked by program. After execution of simulation (Fig. 6) the part program can be transmitted to CNC controller. 2.3. Example III the eccentric seal rings machiningThe eccentric seal rings machining was subject of the research. The external surface of ring which have shape of cone, is machined in analyzed operation. (Fig. 7). A machining datum is located on the internal cylindrical surface (with diameter D) and on the face surface. The groove with diameter dr is made as option. Steel cylindrical ring is a semi-product (from acid-resistant steel or from stainless steel). Described operation comprise two stages: the roughing machining (removal of considerable allowance on part of ring) and finish machining (for obtainment of the exact shape). The shape accuracy has larger importance than the surface roughness (the exploational requirements) 19. The operation is executed by use of typical tool with rhombic insert (C type). In the part program a linear position of tool (linear co-ordinates Z and X) and an angular position of spindle (angular co-ordinate C) have to be joint. Initially a 3D parametric model making was analyzed (e.g. in AutoDesk Inventor environment) and use it for generating of the part program (e.g. in EdgeCAM environment 20, 21). Finally another approach was accepted a parametric program was used for rings machining. This decision is justified by following premises: larger influence onto machining strategy, especially due to the machined materials; possibility of program set-up directly at the machine tool, even by machine operators; easy and fast changes of part program execution; considerably smaller size of program; high cost of the CAM systems. Nevertheless this solution own one important disadvantage the group program has to work in accordance to very complicated algorithm. Especially, where calculations of co-ordinate points on the cone have to be carried out. Moreover, cutter radius compensation is performed (automatic cutter radius compensation is impossible). In this situation efficiency of a CNC controller can to make significant limitation. It was checked that time of calculation at full implementation of mentioned algorithm on the CNC controller is too long in relation to required speed of machining. Simplifying of the program was indispensable for correct realization of this operation.The final form of proposed CNC program is showed in Fig. 8. The main program (PIERSCIEN.MPF) is fixed for the rings family, where the machining in a parametric form is described. A subprogram (DANE.SPF) is a data set (in the R-parameters form) which dimensions of the concrete ring define (from a design documentation). Moreover, mentioned subprogram contains the technological parameters (a speed, a feed, etc.) and co-ordinates of the selected points on the machined surface. These points are required to calculation other remaining coordinates in the part program. Mentioned coordinates are determined by use of an additional program, working in the external computer 19. To tasks of this program should help user at data introducing (Fig. 9), the necessary calculations and the subprogram saving in accordance with requirements of given CNC controller. In next step the part program simulation can be performed (Fig. 10). In last step the part program is sent to a CNC controller. In proposed form the main program contains about 190 blocks, the subprogram about 150 blocks. If it was accepted first from considered solutions then part program is considerably longer. Presented part program generates about 80100 thousands of the tool movements. 3. A CNC programming in off-line modeA CNC programming directly on the machine tools (in on-line mode) is very difficult, even sometime impossible. Advanced methods of parametric programming (calculation on the parameters, the structural functions, the jumps etc.) demand exact verification of the algorithm. Exclude this functions usually such part programs use simple methods for the co-ordinates giving. A graphical simulation of parametric programs was not been possible to execute in wide applied popular CAM systems (from reason of the rules of their work). Moreover, often in industrial practice fast conversion a NC program to other language is required. From this in practice sometimes one should to create specialized software 22. Therefore the original system for NC programs analysis and simulation was realized 23 Fig. 3, Fig. 6, Fig. 10. Acceleration and facilitation of programming in off-line mode,especially for parametric programs is main purpose. Discussed system contains typical modules specialized editor, graphical simulation module, offset registers, parameters table, programs database, serial transmission module, etc. As base language was accepted Sinumerik 840D/810D (Siemens) because largest set of functions it contains. Onto its basis was created original, internal programming language (where work philosophy is based on the APT system idea). Therefore the work of this system runes in accordance with presented architecture Fig. 11. A preprocessor translates the part program written in language of concrete controller (Siemens, Fanuc, Heidenhain) onto its internal language. Simultaneously syntactic correctness of the part program is checked. In this form the CNC program is analyzed and executed through processor and in analogical form is remembered. In next step this program can be simulated or translated by postprocessor onto CNC program for other controllers. If necessary is including a new language then should to make only new postprocessor or preprocessor, without necessity of changes in the processor. Common procedures for analyses and simulation, included in the processor, simplify adaptation of the system to new tasks.4. ConclusionIn all presented above examples the typical CNC programming methods use was analyzed. Both cycles as programming with help of the Computer Aided Manufacturing systems (CAM) based on parametric solid models were ineffective. For all analyzed surfaces their geometry is significantly different from geometry of the standard cycles. If CAM software is used then has to be prepared exact model of the machined part (by CAD software). In conditions of small batch production no always this is possible. Use of described methods of programming can be often one real solution. Presented approach possesses many advantages. Firstly, significantly reduce the part programming time (to some minutes). The CNC programs can be generated by operators directly at tool machine. Possession of the exact drawings of machined parts is not required (with except of first presented example). Correctness of the generated programs is very high, applying of additional verification (e.g. graphical simulation) usually does not join from modification (except changes of machining parameter values). Significantly is decreased time and cost of the programs start. More expensive CAM software are not necessary. This approach could reduce the number of program changeovers and decrease programs length. The disadvantages of presented approach are naturally also. Firstly, is necessary additional time onto analysis of problem, solution proposing and often additional software preparing. Formulating of the complex geometric dependences for a tool path calculation demands large knowledge from area of mathematics and geometry. Moreover, a user should to know to write this formulas in the form of computer programs. Such approach does not have to generate additional costs onto shopping of the commercial programming systems because are accessible their free non-commercial versions (e.g. used by author Borland Turbo Delphi, AutoLISP or Visual Basic for Application available as the programming interfaces for AutoCAD, Inventor, etc.).In opinion of author in situation of process planning for the parts about non-typical shapes, especially when Group Technology is used, applying of non-typical methods of CNC programming is required also. Then use of unconventional tools of computer aid is necessary. Described in this paper solutions are the best example of this approach.References 1 B.Z. GONG: The processing of parts with group technology in an individual CNC machining center. Journal of Materials Processing Technology, 129(2002)1, 645-648. 2 J. BALIC: Model of automated computer aided NC machine tools programming. Journal of Achievements in Materials and Manufacturing Engineering.17(2006), 1-2, 309-312. 3 I. KURIC, J. KUBA: Development of CAPP systems based on group technology. Proc. of Int. Conf. Computer Integrated Manufacturing, Zakopane 2001, 285-292. 4 M. DJASSEMI: An Efficient CNC Programming Approach Based on Group Technology. Journal of Manufacturing Systems, 19(2000), 213-217. 5 M. DJASSEMI: A Parametric Programming Technique For Efficient CNC Machining Operations. Computers and Industrial Engineering, 35(1998)1, 33-36. 6 M. LYNCH: Parametric Programming for CNC Machines Tools and Touch Probes. Society of Manufacturing Engineers, 1996. 7 Translator on-line DXF-CNC. /index.html. 8 AutoCUT. Instytut Zaawansowanych Technologii Wytwarzania, Krakw. http:/www.ios.krakow.pl/cadcam/autocut.php. 9 S.R.K. JASTHI, P.N. RAO, N.K. TEWARI: Studies on process plan representation in CAPP systems. Computer Integrated Manufacturing Systems, 8(1995)3, 173-184. 10 G. VOSNIAKOS: An Intelligent Software System for the automatic generation of NC programs from wireframe models of 2-1/2D mechanical parts.Computer Integrated Manufacturing Systems, 11(1998)1-2, 53-65. 11 P.G. MAROPOULULOS: Review of research in tooling technology, process modelling and process planning. Part II: Process planning. Computer Integrated Manufacturing Systems, 8(1995)1, 13-20. 12 J. GAO, D.T. ZHENG, N. GINDY: Extraction of machining features for CAD/CAM integration. Journal of Advanced Manufacturing Technology, 24(2004), 573-581. 13 P. SHILPAN: Design features + process knowledge = automated CNC programming. Modern Machine Shop, 67(1994)6, 78-85. 14 M. SIEMITKOWSKI, W. PRZYBYLSKI: Modelling and simulation analysis of process alternatives in the cellular manufacturing of axially symmetric parts. Journal of Advanced Manufacturing Technology, 32(2007), 516-530. 15 A. NASSEHI, S.T. NEWMAN, R.D. ALLEN: The Application of Multi-Agent Systems for STEP-NC Computer Aided Planning of Prismatic Components. Journal of Machine Tools & Manufacture, 46(2006), 559-574.计算机辅助数控编程应用于非典型零件的加工（Grzegorz Nikiel博士，波兰别尔斯克-比亚瓦，制造技术与自动化学院）1. 简介许多制造公司，尤其是中，小型要解决生产发展和新客户的搜索问题。在许多情况下，这导致了生产的产品品种已扩大。通常这是加入了新的制造工艺的实施。在市场竞争条件下的高灵活性的要求往往是在传统的制造资源取代了现代数控工具机的方式得到了。这是更有效的发展要领，质量更高，更快的速度为新的要求条件。对于生产成本低的中小批量生产，往往成组技术维护应用。随着所制造的部件组合成的家庭更有效地帮助机器，设备，工人使用。在规划的过程中最重要的任务之一是数控机床的编程。很多时候的CAD / CAM系统所使用的原因，他们的灵活编程的可能性。在典型情况下，这种做法元件积极成果提供，但它要求建设者和技术人员之间有效的合作行动。有时从不同的原因，是不可能的，尤其是在成组技术被应用。通常为单一成分加工的零件程序的创建，但现代CNC控制器提供了一些编程方法，这在一些类似部件的加工可以使用。这种方法是：1.周期。设计的周期是典型的表面加工（孔，螺纹，槽等）。通常是加工表面参数描述适用于几何形状，使他们容易和快速变化。不幸的是他们的特点和灵活性，小到小的加工策略的影响，只能从周期的参数而定。在现代控制它允许一个研讨会上面向编程（WOP），即通过编程往往一个对话框编程（有时称为会话编程）资助的经营者，直接。因此，这是相对简单的编程方法，往往应用于工业实践。2.参数化编程。一个典型的一部分，执行程序从开始到结束一分。参数规划的一部分，程序的执行可能遇到不同的方式（例如，如果.然后.使用条件指令）。此外，对部分程序段多重复访问（重复循环，而循环等）。此外，算术功能和其他先进的功能是可能的。轴的位置，饲料和速度的功能等，可以指定一个参数表达式（由R -参数的使用）。一直到这一点，有人可能创造自己的加工周期也途径。这种方法需要高技能的编程劳动，是非常耗时也。该方案的精确验证是必要的，这在危险情况下的豁免权（例如，对输入参数的应用程序加入了不正确的值）。因此，在上述缺陷的看法是很少用于工业实践。3.规划自由定义轮廓的基础。这个任务依赖于加工轮廓及其自动转换到数控代码定义。如果自动刀具半径补偿（即G41和G42的功能的）不使用，则有另外一个等距离的产生。此子任务是很容易实现的，如果提到轮廓CAD系统中的代表 - 与OFFSET函数的帮助。第二个子任务往往体现在对工具的路径图形形式的出口方式向数据交换（DXF文件，HPGL格式等）的典型格式。在合适的后处理器的使用（例如7中给出的解决方案）数控刀具上的代码路径转换下一步就是执行。从实际方面的一般性的简单的操作，这种方法被应用，例如：激光切割，水射流切割等一个解决方案，集成两个分在一个应用程序任务也适用 - 在AutoCUT就是最好的例子。这个解决方案是在实践中往往没有应用，虽然它具有许多优点。在小批量生产的条件下工艺设计到数控编程通常限制9。在这种情况下有较大意义的CAD / CAM与遗漏的CAPP系统集成的阶段。想法是那么的特点的数据交换的有效方法。当使用成组技术后，通过适当的数据库和知识库的补充，它可以最佳解决方案的典型元素的生产。在非典型零件通常情况下这种做法是无效的。主要是在识别特征的看法，普遍采用的方法的特征类型限制数。也许在未来的解决方案将带来的CAD / CAM /数控的STEP - NC的标准为基础的系统集成（异14649，国际标准化组织10303:238）将取代传统的东西运用到数控G代码编程中立的数据交换格式。2.分析的例子下面的例子集团主办的数控加工的生产计划由小企业的片段。一般来说，这部分有不典型形状，它们是从硬质材料（如奥氏体不锈钢），通常需要在小批量生产的条件的特殊夹具及固定装置，制造。规划进程在这种情况下需要一个大的经验与技术专家的参与。可访问工具机的数控编程的方法确定具体的角色应

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