人人文库网 > 图纸下载 > 毕业设计 > 液压钻机本体组合机床设计[1]【4张CAD图纸+毕业答辩论文】

附录Ⅱ：生产效率卡.doc

液压钻机本体组合机床设计[1]【4张CAD图纸+毕业答辩论文】

资源目录

液压钻机本体组合机床设计[1]【全套CAD图纸+毕业答辩论文】.rar

附录Ⅱ：生产效率卡.doc---(点击预览)

说明书.doc---(点击预览)

翻译.doc---(点击预览)

目录摘要（3页）.doc---(点击预览)

任务书（2页）.doc---(点击预览)

A0-主轴箱装配图.dwg

A0-加工示意图.dwg

A0-完成零件图.dwg

A0-联系尺寸图.dwg

压缩包内文档预览：

编号：451499 类型：共享资源大小：1014.81KB 格式：RAR 上传时间：2015-07-07 上传人：好资料QQ****51605 IP属地：江苏

45
积分

版权申诉 word格式文档无特别注明外均可编辑修改；预览文档经过压缩，下载后原文更清晰！ 立即下载

关键词：: 液压钻机本体组合机床设计全套 cad 图纸毕业答辩论文

资源描述：

摘要Ⅰ

AbstractⅡ

第1章绪论1

第2章组合机床概述2

2.1组合机床的基本概述2

2.2组合机床的发展概况2

2.3组合机床的特点3

2.4组合机床的分类和组成4

第3章组合机床总体设计6

3.1组合机床总体方案的选择6

3.2组合机床配置形式的选择7

3.3被加工零件工序图的绘制7

3.4加工示意图的绘制9

3.5组合机床总体尺寸联系图的绘制15

3.6组合机床夹具设计17

3.7生产效率卡的计算和编写21

第4章组合机床多轴箱设计23

4．1概述23

4．2主轴箱设计原始资料23

4．3主轴形式及其各部分尺寸的确定24

4．4主轴和传动轴直径的确定与校核24

4．5齿轮传动路线的设计26

4．6多轴箱坐标设计29

4．7主轴箱的润滑、变速和手柄轴的设置31

4．8组合机床主轴箱总图的设计39

第5章产品的经济性分析40

结论41

致谢42

参考文献43

专题液压钻机本体工艺规程的编制44

附录Ⅰ：55

附录Ⅱ：80

摘要

本设计的说明书是按照所设计的TXU-75钻机本体组合机床所撰写的。主要包括零件的工艺性分析，总体方案的确定，三图一卡的设计以及主轴箱的设计。

该组合机床主要针对TXU-75钻机本体上的双面5孔进行粗加工而设计的，由于组合机床自身的特点可以提高生产效率，减轻工人的劳动强度，便于管理和集中生产，能提高加工精度，提高自动化程度，扩大工艺范围。所以设计制造组合机床是机械制造业的必备的工作母机。

关键词：组合机床、加工工序图、机床尺寸联系图、生产效率卡、主轴箱

Abstract

This graduation design is designed according to the TXU-75 drills tool machine.Mainly include the craft analysis of the spare parts, the total project really settled, three the figures in one design of the card and the design of the principal axis box.

The two-sided boreses should combine tool machine to mainly drill the machine essence to TXU-75s carry on thick process but design of, because of combine the tool machine oneself of the characteristics can raise the production efficiency, easing the worker's labor strength, easy to management and concentrate production, can raise to process accuracy, exaltation automation degree, extend craft scope.So design manufacturing combination the tool machine is the essential machine tool of the machine manufacturing industry.

Keyword:Combine tool machine,process work preface diagram,the tool machine size contact diagram , produce efficiency card,principal axis box.

第1章绪论

大学生活就要和我们挥手说再见了，在回首这四年的生活留下的是许多美好的回忆，四年中有过许多的收获，当然也失去了很多。无论是年龄还是思想上，我都成熟了不少，也正是有这次机会在大学这座象牙塔上学习，才能使我在以后的日子里能更好的工作，走向时社会有更多的知识丰富头脑来适应今天这个竞争激烈的天地。

四年的大学生活即将结束，毕业设计是对我们四年学习收获的最好检验，同时也是一次很好的锻炼机会。这次设计与以前的不同的是，这是在我们以前所学的理论课和专业课的基础上所完成的，不是某一课程的单独检验。通过这次设计，锻炼了我分析问题的能力，也促使我更好的利用图书馆这一书海世界，翻阅了各种资料、手册、期刊等。

本方案是根据TXU-75米钻机上的部件，本体的图纸要求，所设计的用来加工其本体的组合机床。

设计前，我通过去具体地点进行调研，收集了第一手资料，同时也得到了工厂师傅以及技术人员的热心指导。在整个设计过程中，知道老师不仅耐心指导，同时也给予我很多启发。

虽然四年中我们学习了不少理论知识，但我的实践经验却很有限，而且理论不能和实践很好的相联系，因此在这次设计中不免有许多的错误和缺点，恳请广大老师和同学们给予指导，以鉴今后。

全部文件.gif

A0-主轴箱装配图.gif

A0-被加工零件工序图.gif

A0-机床联系尺寸图.gif

A0-加工示意图.gif

字数统计.gif

内容简介：: 黑龙江科技学院毕业设计（论文）任务书姓名：尹水生任务下达日期： 2006 年 3 月 13 日设计（论文）开始日期： 2006 年 3 月 13日设计（论文）完成日期： 2006 年 6 月23日一、设计（论文）题目：液压钻机本体组合机床设计二、专题题目：液压钻机本体加工工艺三、设计的目的和意义：为了提高本体的加工效率，节省劳动时间和减轻工人劳动强度，所以设计组合机床，用来加工液压钻机本体，它具有生产效率高、工艺范围广、加工精度高、自动化程度高、可调整性等优点。四、设计（论文）主要内容：本设计的说明书是按照所设计的TXU-75钻机本体组合机床所撰写的，主要包括零件的工艺性分析，总体方案的确定，三图一卡的设计以及主轴箱的设计五、设计目标：提高生产率、扩大工艺范围、提高加工精度、提高自动化程度、提高组合机床及其自动线的可调整性、减轻工人的劳动强度，实现大批量生产，降低加工成本六、进度计划： 3月13日3月19日动员大会，初步了解设计题目，上网、图书馆查阅相关资料。3月20日3月26日实地参观实习，搜索有关的技术资料。3月274月2日熟悉和整理实习期间所收集的资料，准备设计。4月3日4月16日方案设计（绘制被加工零件工序图、绘制加工示意图、绘制机床联系尺寸图）。4月17日5月14日结构设计（动力部件的选择、组合机床生产效率的计算、组合机床部件及零件设计、主轴箱的设计计算、绘制主轴箱总图。5月15日6月11日专题设计（液压钻机本体的工艺规程的编制）。6月12日6月18日外文资料的翻译。6月19日6月25日编写说明书、CAD出图、准备答辩七、参考文献资料： 1.从凤廷、迟建山。组合机床。第二版。上海科学技术出版社 2.大连组合机床研究所编组合机床设计。机械工业出版社 3.顾崇衔机械制造工艺学。陕西科学技术出版社 4.王启平.机床夹具设计.哈尔滨工业大学指导教师：院（系）主管领导：年月日目录摘要Abstract第1章绪论1第2章组合机床概述22.1组合机床的基本概述22.2组合机床的发展概况22.3组合机床的特点32.4组合机床的分类和组成4第3章组合机床总体设计63.1组合机床总体方案的选择63.2组合机床配置形式的选择73.3被加工零件工序图的绘制73.4加工示意图的绘制93.5组合机床总体尺寸联系图的绘制153.6组合机床夹具设计173.7生产效率卡的计算和编写21第4章组合机床多轴箱设计2341概述2342主轴箱设计原始资料2343主轴形式及其各部分尺寸的确定2444主轴和传动轴直径的确定与校核2445齿轮传动路线的设计2646多轴箱坐标设计2947主轴箱的润滑、变速和手柄轴的设置3148组合机床主轴箱总图的设计39第5章产品的经济性分析40结论41致谢42参考文献43专题液压钻机本体工艺规程的编制44附录：55附录：80摘要本设计的说明书是按照所设计的TXU-75钻机本体组合机床所撰写的。主要包括零件的工艺性分析，总体方案的确定，三图一卡的设计以及主轴箱的设计。该组合机床主要针对TXU-75钻机本体上的双面5孔进行粗加工而设计的，由于组合机床自身的特点可以提高生产效率，减轻工人的劳动强度，便于管理和集中生产，能提高加工精度，提高自动化程度，扩大工艺范围。所以设计制造组合机床是机械制造业的必备的工作母机。关键词：组合机床、加工工序图、机床尺寸联系图、生产效率卡、主轴箱Abstract This graduation design is designed according to the TXU-75 drills tool machine.Mainly include the craft analysis of the spare parts, the total project really settled, three the figures in one design of the card and the design of the principal axis box. The two-sided boreses should combine tool machine to mainly drill the machine essence to TXU-75s carry on thick process but design of, because of combine the tool machine oneself of the characteristics can raise the production efficiency, easing the workers labor strength, easy to management and concentrate production, can raise to process accuracy, exaltation automation degree, extend craft scope.So design manufacturing combination the tool machine is the essential machine tool of the machine manufacturing industry.Keyword:Combine tool machine,process work preface diagram,the tool machine size contact diagram , produce efficiency card,principal axis box.2附录：快速成型技术和系统的回顾快速成型制造技术已经为很快地直接地从计算机辅助设计系统创造 3D立体产品出现。这些技术在工业成型制造中起着重要的作用。这一篇文章回顾了 RP&M 的主要技术和应用程序。RP&M的原则和技术在这里被展现。在这些新的技术方面的一些现有的问题和研究议题被介绍。我们也在使用快速设计原型作为较进一步的例证。关键字：快速成型，分层堆积制造简介产品制造工业正在面对二个重要的挑战性的任务:(1) 缩减产品发展时间的; (2) 制造产品的小整批尺寸产品和多种类型产品在柔性方面的改进，CAD和CAM已经着重改良传统的生产设计和制造形式。然而, 对于新产品的迅速发展在和计算机辅助制造的计算机辅助设计的真实整合中有一些障碍。虽然可观的研究已经在过去被为计算机辅助设计和制造业整合, 像功能辨识, CNC 程序规划和程序计划，但是 CAD 和 CAM 之间还是存在着一些空白区域:（1）3D立体模型和原尺的迅速创造。（2）创建复杂模型表面产品的成本问题这是一篇和快速成型有关的指导性文章RP& M 能做什么为了从实质上短缩发展中的图案，铸模和原形的时间,一些制造业的企业已经启动使用迅速设计成型方法作为制造复杂图案和元件设计方法。在过去几年内, 多种新的快速制造业的技术, 通常叫做快速成型制造 (RP&M)的技术已经出现; 这项技术发展包含 Stereolithography;SLS;FDM;LOM;BPM和3D印刷。这些技术能够直接地产生来自 CAD 数据库的实际的物件。他们通常都有一个的重要功能: 加工零件模型时用堆积成型方法要多于材料切除法。这就把3D模型的加工简化到2D书屋堆积成型，因此便能直接的调用计算机模型数据库中的模型直接加工。RP&M 的基本程序如图 1 所示，一个零件首先被模型制造者做出一个几何模型, 例如一个实体模型。零件进入一系列的平行截面块之内然后算术地被区分之。对于每个模块, 硬化或缀合，路径已经产生,在图2 中显示。这些硬化或粘合路径直接地被用俩作为加工指令加工工件材料。在一个层被建造之后, 一个新的层被用同样的方法建在先前的那个层上。因此，模型是从底层一步步建到高层的。在摘要中, 迅速成型设计的犯法包含两个方面：: 数据准备和模型生产。图-1 固体模型实例图-2 切片扫描RP&M 的目前应用领域虽然 RP&M 技术仍然在他的早期阶段,但是一些工业公司 , 像德克萨斯仪器公司，克莱斯勒公司, 安培公司和福特电动机公司已经从技术改良下列三个方面的他们的产品发展获益。工程学设计视觉化。概念上的模型在产品设计非常重要。设计者使用计算机中的CAD程序产生他们的设计观念。然而，无论工程师用CAD能够多么好的解释蓝图和复杂工件的图像，它仍然非常困难的完全地展示实际的复杂产品将会看起来像什么。一些错误可能仍然从工程师和设计者的检查中逃脱。实际物件的触觉有时能揭露未预料到的问题。闪烁一个较好的设计。由RP&M产生一个较好的设计思路，复杂工件的成型加工能够在短时间内建造, 因此工程师能非常快地评估一个设计。证明和最佳化。改良产品质量总是制造加工中的一个重要议题。由传统的方法, 模型的研发或者一个最佳化的有效设计是要耗费大量时间和资金的。在此对比, RP&M 成型能被很快地设计加工再没有现成的用工具工作和劳动力的情况下。结果证明设计观念变的很简单; 产品质量能被在有限制的时间里和可负担成本的前提下得到改善。反复。就像汽车工业，厂家经常把性产品投放到市场中。产品投放市场的时间快慢是在今天的竞争市场中区分胜利者和失败者的主要因素之一。由于 RP&M 技术存在，在一个短时间内完成多样化设计是可能的。总体上减少模型的研发时间。制造业我们能使用 RP&M 成型技术作为可生产研究。在产品的设计初期提供一个实物模型，我们能加速程序计划和工具工作设计的程序。除此之外，由于正确地描述复杂的几何形状，这种方法能帮助在工场上解释蓝图方面减少问题的出现。另外的一个应用程序正在为铸模用工具工作研发。这种方法也能为铸件被用作主图案。市场为了协助产品售卖，一个原型能用来示范观念，设计主意,同时也代表了一个公司的生产能力。实际模型的真实举例说明设计的可行性。同时, 原型能用来修正设计得到客户的回应，以便最后的产品将会符合客户的需求。及时的领会客户的想法, 方法在90年代是市场竞争的关键。及时的领会客户的想法在90年代是市场竞争的关键。RP& M 技术有潜力能确定提高产品质量。主要有两方面: 几乎没有几何形状方面的限制; 分层堆积制造方式允许从CAD到CAM的直接的简单的接口，而完全忽略了计算机辅助设计程序。快速原型制造和制造技术正如以前被提到的。有几种遵循“生长”和“添加制造”的原理的现代生产方式。在这些技术的主要不同点有二个方面: (1) 选用的材料(2) 零件制造技术。以下部分将会在这两方面详细地说明快速原型制造。光敏液相固化法 (SLA)SLA 被Charle Hull发明的3D立体系统Inc.2。它是首个商业化的快速原型制造技术并且应用的最广泛。用的材料是液体树脂。在光的照射之下, 小的分子 (单体)聚合成较大的分子。基于这个原则,零件在如图 3 所显示的一个盛放液体树脂的桶中制造出来SLA 机器制造原型是借激光探头在液体表面上追寻分层路线制造的。与数控机床得之字形切削路径不同,探头沿着平行线移动，然后再沿着垂直的方向。在液体下面有一个提升的支撑面。表面就在广可以照射的深度。激光光线在检流计驱动镜子旁边的 X 和 Y 轴中被水平地偏斜，以便它移动。树脂的表面生产一个固体形状。在一层被建造之后,支撑面下降一个用户指定的距离，一层液体树脂的新涂料覆盖了原始层。一个扫帚帮助填充用来制造下一层的新的树脂。激光在已经做好的一层上画新的层。这样，模型从底部到顶端的逐层建造出来。当所有的层被完成的时候，原型被制造了大约95% 。后续制造要等到原型完全凝固之后。这在一个充满紫外线的烤箱中制做。SLA有一些值得提及的特点。材料：有五种商业化得的原型材料。它们全是树脂。支持：因为一个模型在液体被产生,在制造过程中，悬于零件(在下面不支持)之上的下垂或者飘浮离开。原型如此需要一些初步设计支持直到它被制造或固化。支持可能是柱子，桥和构架。有时需要输入或者把硬加入填充在的薄壁件。这些附加的物体在模型原型的制造的过程中产生和必须在模型完成之后清除。模型准确性和表现性。被达成的准确性是大约 0.1% 的全部尺寸而且除了不超过 0.5% 之外以较大的大小。层厚度是在 0.004 和 0.03之间。目前，被 3D立体系统公司做的 SLA 机器是在 RP& M 系统之中的最精确的机器。photopolymer 制作的原型是易碎的而且可能不够结实来抵抗高的压迫力测试。同时, ，材料的收缩可能会使原型变形。再循环。 Photopolymers 是thermoset材料和不能够再一次为重复使用被融化。选区激光绕结法(SLS)动态同步传输套式公司 (奥斯汀 TX) 用在德克萨斯大学的机械工程部门被卡尔 Deckard 和约瑟 Beaman 研发的 SLS 系统提供治疗液体的系统替代5代品. SLS 使用对泉华的一个二氧化碳激光连续数层的粉代替液体。在 SLS 处理粉的表层在工作地方之上被一个替换柜台滚筒机制应用。粉状材料被些微地在它的熔点下面预先加热到温度。激光光线在粉状表面上追踪跨区段加热对泉华温度的粉。以便粉保证被激光扫描到。不是被激光扫描的粉将会适当地保持视为对粉下层的支持,这在减少扭曲方面是有帮助的。当跨区段的层被完成的时候, 滚筒消除粉的另层在那之上为下途径泉华一。图 5 演示SIS 的工作原理。 SIS 有一些特征。材料。 SIS 使用各类型的材料包括 polycarbonate ， pvc ，ABS ，尼龙，树脂， polyster ， polypropane ，聚亚安酯作为投资投掷腊的样板的生产。能够使用金属制的和陶瓷粉的机器正在研发过程中。支持。 SLS 系统通常不需要预先设计支持结构。在建筑物期间，如支持在每个层上的为不融合的粉末处理。做模型准确性和表现。平均的准确性为一个部份由从 -0.005 到 +0.015 达成了范围直径和 15高度。层厚度是在 0.003 和 0.02之间。产品可能遭受收缩和变形由于冷却。那二个因素能根据选择更小颗粒的粉末所限制, 和在粉末的软化处理点上面的高方面比和空气流程温度的粉状粒子除去, 但是在泉华点下面。再循环。原型能是粉碎成粉末以便重复使用。熔丝沉积成型法(FDM)快速原型系统-3D立体制造模型由Stratasys 公司研发用来的构造以被挤出的热后可塑性的材料的沉淀为基础的部份呼叫 FDM. 在一个 FDM 程序中，一个热后可塑性细丝材料进入一个加热的 FDM中之后被挤出。 FDM 头的运动被计算机控制。在飞的挤出头内，细丝进入设备内被一个反抗加热器融化。喷头追踪部份的一个每跨区段层的精确部分。当喷头在空间的x轴和y轴移动时拉丝材料就在喷头内进行预热然后再从喷头挤出。当它工作的时候，材料以 1/10s的速度直接堆积在工作点上。在一层堆积完成后, 喷头按照程序预先设计好的为堆积下一层在 z 方向移动。每层的堆积都是对先前的堆积作加固。图 6 演示FDM 的工作原理。FDM 有下列的主要特征:材料。 FDM 技术为样板的堆积提供了多种模型材料和颜色。可提供的材料有填充了塑料的聚合物质的尼龙 , 和腊。专有的尼龙 , 和投资投掷变大。所有的材料是无毒的而且可能有不同的颜色。而且有消耗材料最小的方法。没有在硬化之后的被需要。支撑情况。在许多情况下， FDM 程序不需要支持生产部份。 FDM 喷头喷出的锡先是材料在空便凝固。在上层部分，支撑能力可能仍然是减少扭曲部分所必要的。模型准确性。全部的宽度是误差在 0.005。连续的制成薄板在 0.001-0.05之间, 而壁厚范围从 0.01 到 0.25 之间。用FDM制作原型时有1.2%的收缩率。性能。3D立体模型加工的边框是121212。模型加工的速度是60r/s。选区片层粘结法(LOM)LOM 程序教工零件用的是纸塑料，金属或者是钢件。LOM 要加工一个钢件工件需要按照预先设计好的程序来进行，然后激光在CAD的引导下加工出需要的形状。涂层能被黏在一起或焊接。多余的材料要莫被移走要莫就作为下一层喷涂的基础。图 7 演示LOM 的工作原理。 LOM 有如下特征:材料。事实上任何的箔 (材料) 都能被应用: 纸，金属，塑料，纤维，合成物质材料，玻璃或合成物。 Helisys 公司现在使用纤维素箔。支撑情况. LOM 程序使用使用电晶体的材料因此通常不需要预先设计。支援结构。模型准确表现性. 模型能准确的表现实物构造在 0.005之间。而且因为材料的使用不收缩或者扭曲。层的厚度是在 0.002 和 0.02之间. 用这些材料制造的原型不易碎而且由于用 photopolymers 做成的那些的原型。能力. LOM 机器 LOM-1015 使用一个 40瓦特二氧化碳激光器。LOM-1015 构造的原型范围的大小是 151015.因为只需要描绘切断去代替诊断一个硬化区域,LOM 相比之下就要快一些。Ballistic particle manufacturing (BPM)感知冲击粒子制造业技术是由一个感知系统使用一个 piezo 驱动的喷墨机制射击融化的材料的小滴, 同时冷却在先前存放的层之上。一个层由在移动 x轴和 y轴方向的小滴喷嘴喷射产生。从碟子的底部指定一个距离，一个新的层在先完一个成的层的顶端产生。自动化动力学公司也独立地研发了一部相似的机器。图 8 演示 BPM 的工作原理。图-8 BPM 工作原理 BPM 的特征是:材料。材料应该容易地被融化而且凝固,例如热后可塑性物质，铝和腊。感知系统现在使用的是蜡,自动化动力学公司使用铝。支持。在构造模型程序时，对于突出部份和空虚结构的支持是必要的,支持的材料是水溶性的蜡的合成物质。当模型被完成的时候, 支持物被用温水洗去。模型准确表现性。全部的准确性是 +0.004之间。层厚度大约在0.0035之间。没有表现报告。能力。 BPM 打印机可以用32个喷墨喷嘴并排排列在50/ m 的范围内每秒喷射10000个小液滴。最大的工作块尺寸是 12 2 12。三维印刷(3D Printing) 三维空间的印刷技术是由麻萨诸塞州学会研发的。在3D立体印刷程序中，一个3D立体模型进入计算机的2D 跨区段层之内被切成薄片。在一个圆筒中,喷层的粉放在活塞的顶端和床子上, 然后喷墨头按照程序把层粉喷到指定位置的模型上，那里的信息由计算机模型库提供出喷涂所需要的相应的信息。在一层完成之后, 活塞放下滑到预先定义的距离，一个新层按照上一步的方法继续建立出来。当整个部份完成的时候，热处理是提高层与层之间的粘结所必要的, 然后去除层粉。图 9 演示 3D立体印刷的工作程序的原理。3D立体印刷有如下的特征:材料。 3D立体印刷程序能使用铝-氧化物和矾土-矽石陶瓷粉。材料是无定形的或胶质的碳化物支持。由于 3D立体印刷技术，支持结构的设计就显得没有必要了,因为在喷涂程序进行时层粉在每一层都能保留它的自然形态。模型准确表现性。小数量数据可从3D立体印刷中获得因为它仍然在测试的阶段中。对于测试的样品，层厚度是 178 和最小尺寸是 0.017v。能力。 3D立体印刷程序能用来生产功能的部份和加工原型。现在的最大部份尺寸是 121224。这种技术在构筑模型是最大潜能是 2021 ，厚度100nm，以每小时0.18m的速度构建每层。当一层完成以后，活塞下降一个提前设定好的距离，一新的粉层喷洒出来，并有选择的粘结。当整个零件完成的时候，为了提高粘结层的结合需要必要的热处理，然后除去没有粘结的层。图9显示了3维印刷的工作过程。3维印刷的特点综述如下：材料. 三维印刷可以利用氧化铝和铝-矽陶瓷粉。黏合剂是无定形或者胶体的碳化矽。支撑体。利用三维印刷技术，零件的职称结构是不需要设计的，因为每层没有粘结的形成了一个天然的支撑。模型精度. 三维印刷适应于数量较少的加工，因为它还在测试阶段。对于测试样本，层的厚度是178m，最小的尺寸是0。017。三维印刷能够制造功能性零件或刀具的原型。现在最大的工件尺寸是121224。这项技术在大约每层2秒（0.18mh-1）生产率情况下，有能够生产尺寸超过2020零件的潜力。结论对于加工者保持竞争力，生产特点，质量，成本和推向市场的时间是重要因素。快速原型系统给制造产品更快，提供了机会，并且比传统的加工方法成本低。因为RP&M能够极大的缩短产品的开发周期，越来越多的商品利用了这个速度，由计算机设计的产品能够生产味精准的模型。而这些模型能够被感知，看到，研究，测试和比较。讨论了几种新的有发展前景的快速原型制造。他们都是基于一层一层堆积的原理。它们中的每一个考虑到精度，材料种类和机器成本都有各自的特点。还讨论了一些显露出来的问题和研究成果。这是一个快速发展的领域。快速垸行制造技术的能力和潜力吸引着非常多的工厂为这项技术投资。非常期待为了研究和发展那些技术能有更多的努力，这样，它们可以广泛的应用于制造工业。A review of rapid prototyping technologies and systemsRapid Prototyping and Manufacturing (RP&M) technologies have emerged for quickly creating 3D products directly from computer-aided design systems. These technologies significantly improve the present prototyping practices in industry. This paper reviews the main technologies and applications of RP&M. The principles and the features of those RP&M technologies are presented. Some existing problems and research isles on these new technologies are introduced. Keywords; raid prototyping, layered manufacturingINTRODUCTIONProduct manufacturing industry is facing two important challenging tasks: (I) substantial reduction of product development time; and (2) improvement on flexibility for manufacturing small batch size products and a variety of types of products, Computer-aided design and manufacturing (CAD and CAM) have significantly improved the traditional production design and manufacturing. However, there arc a number of obstacles in true integration of computer-aided design with computer-aided manufacturing for rapid development of new products. Although substantial research has been done in the past for computer-aided design and manufacturing integration, such as feature recognition, CNC programming and process planning, the gap between CAD and CAM remains unfilled in the following aspects:(1) rapid creation of 3D models and prototypes. (2) (2) cost-effective production of patterns and moulds with complex surfaces. This is a tutorial paper of rapid prototyping and manufacturing (RP& M).What RP& M can doTo substantially shorten the time for developing patterns, moulds, and prototypes, some manufacturing enterprises have started to use rapid prototyping methods for complex patterns making and component prototyping. Over the past few years, a variety of new rapid manufacturing technologies, generally called Rapid Prototyping and Manufacturing (RP & M), have emerged; the technologies developed include Stereolithography; Selective Laser Sintering (SLS), Fused Deposition Manufacturing (FDM), Laminated Object Manufacturing(LOM), Ballistic Particle Manufacturing (BPM), and Three Dimensional Printing (3D Printing). These technologies are capable of directly generating physical objects from CAD databases. They have a common important feature: the prototype part is produced by adding materials rather than removing materials. This simplifies the3D part producing processes to 2D layer adding processes such that apart can be produced directly from its computer model.The basic process of RP& MAs shown in Figure 1 a part is first modelled by a geometric modeller such as a solid modeller. The part is then mathematically sectioned (sliced) into a series of parallel cross-section pieces. For each piece, the curing or binding paths are generated, shown in Figure2. These curing or binding paths are directly used to instruct the machine for producing the part by solidifying or binding a line of material. After a layer is built, anew layer is built on the previous one is the same way. Thus, the model is built layer by layer from the bottom to top. In summary, the rapid prototyping activities consist of two parts: data preparation and model production.Current application areas of RP&MAlthough RP&M technologies are still at their early stage, a number of industrial companies such as Texas Instruments, Inc., Chrysler Corporation, Amp Inc. and Ford Motor Co. have benefited from applying the technologies to improve their product development in the following three aspects.Figure 1 The solid model of an objectDesign engineeringVisualization. Conceptual models are very important in product design. Designers use CAD to generate computer representations of their design concepts. However, no matter how well engineers interpret blue prints and how excellent CAD images of complex objects are, it is still very difficult to visualize exactly what the actual complex products will look like. Some errors may still escape from the review of engineers and designers. The touch of the physical objects can reveal unanticipated problems and sometimes .spark a better design. With RP& M, the prototype of a complex part can be built in short time, therefore engineers can evaluate a design very quickly.Verification and optimization. Improving product quality is always an important issue of manufacturing. With the traditional method, developing of prototypes to validate or optimize a design is often time consuming and costly. In contrast, an RP&M prototype can be produced quickly without substantial tooling and labor cost. Consequently, the verification of design concepts becomes simple; the product quality can be improved within the limited time frame and with affordable cost. Iteration. Just like the automotive industry, manufacturers often put new product models into market. Time to market is one of the key features to separate winners from the losers in todays competitive market. With RP&M technology, it is possible to go through multiple design iterations within a short time and subs. tantially reduce the model development time.ManufacturingWe can use the RP&M prototype for producibility studies. By providing a physical product at an earlier design stage, we can speed up process planning and tooling design. In addition, by accurately describing complex geometry, the prototype can help reduce problems in interpreting the blue prints on the shop floor. Another application is tooling development for moulds. The prototypes can also be used as master patterns for castings.MarketingTo assist product sales, a prototype can be used to demonstrate the concept, design ideas, as well as the companys ability to produce it. The reality of the physical model illustrates the feasibility of the design. Also, the prototype can be used to gain customers feedback for design modifications so that the final product will meet customers requirements. Meeting customers demands in a timely, manner is the key to penetrating the market in the 1990s. RP& M technologies have the potential to ensure that quality products are developed quickly for two major reasons: there are almost no restrictions on geometrical shapes; and the layered manufacturing allows a direct and very simple interface from CAD to CAM which almost completely eliminates the need for computer-aided process planning.RAPID PROTOTYPING ANDMANUFACTURING TECHNOLOGIESAs mentioned earlier, there are .several technologies available for model production based on the principle of growing or additive machining. The major differences among these technologies are in two aspects: (1) materials used; and (2) part building techniques. The following sections will explain in detail these rapid prototyping technologies with respect to the above two aspects.StereolithographyStereolithography apparatus (SLA)SLA was invented by Charle Hull of 3D Systems Inc.2. It is the first commercially available rapid prototyper and is considered as the most widely used prototyping machine. The material used is liquid photo-curable resin, acrylate. Under the initiation of photons, small molecules (monomers) arc polymerized into large molecules. Based on this principle, the part is built in a vat of Liquid resin as shown in Figure 3. The SLA machine creates the prototype by tracing layer cross-sections on the surface of the liquid photopolymer pool with a laser beam. Unlike the contouring or zig-zag cutter movement used in CNC machining, the beam traces in parallel lines, or vectorizing first in one direction and then in the orthogonal direction. An elevator table in the resin vat rests just below the liquid .surface whose depth is the light absorption limit. The laser beam is deflected horizontally in X and Y axes by galvanometer-driven mirrors so that it move. across the surface of the resin to produce a solid pattern. After a layer is built, the elevator drops a user-specified distance and a new coating of liquid resin covers the solidified layer. A wiper helps spread the viscous polymer over for building the next layer. The laser draws a new layer on the top of the previous one. In this way, the model is built layer by layer from bottom to top. When all layers are completed, the prototype is about 95% cured. Post-curing is needed to completely solidify the prototype. This is done in a fluorescent oven where ultraviolet light floods the object (prototype). There are several features worthy of mention of $LA.Material. There are five commercially available photopolymers. All of them are a kind of acrylate. Support. Because a model is created in liquid, the overhanging regions of the part (unsupported below) sag or float away during the building process. The prototype thus needs some predesigned support until it is cued or solidfied. The support can be pillars, bridges and trusses. Sometimes posts or internal honeycomb sections are needed to add rigidity to tall thin-walled shapes during the process. These additional features are built on the model parts and have to be trimmed after the model building is completed.Model accuracy and performance. The accuracy achieved is about 0.1% of the overall dimension and deteriorates with larger sizes but no more than 0.5%. The layer thickness is between 0.004 and 0.03. Presently, the SLA machines made by 3D Systems Inc. are the most accurate machines among the RP& M systems. The photopolymer-made prototype is brittle and may not be strong enough to withstand high stress testing. Also, the shrinkage of the material may make the prototype deform.Recycling. Photopolymers are thermoset material and cannot be melted again for reuse.Selective laser sintering (SLS)DTM Corp. (Austin TX) offers an alternative to liquid-curing systems with its SLS systems which were developed by Carl Deckard and Joseph Beaman at the Mechanical Engineering Department of University of Texas at Austin45. SLS uses a carbon dioxide laser to sinter successive layers of powder instead of liquid. In SLS processes a thin layer of powder is applied by a counter-rotating roller mechanism onto the work place. The powder material is preheated to a temperature slightly below its melting point. The laser beam traces the cross-section on the powder surface to heat up the powder to the sintering temperature .so that the powder. scanned by the laser is bonded. The powder that is not scanned by the laser will remain in place to serve as the support to the next layer of powder, which aids in reducing distortion. When a layer of the cross-section is completed, the roller levels another layer of powder over the sintered one for the next pass. Figure 5 shows the working principle of SIS. SIS has several features. Material. SIS uses a wide range of materials for model production including polycarbonate, PVC (polyvinyl chloride), ABS (acrylonirile butadine styrene), nylon, resin, polyster, polypropane, polyurethane and investment casting wax. The machine that is capable of using metal and ceramic powder is in the process of development.Support. The SLS systems usually do not need pre-designed support structures. The unfused powder on every layer acts as a support during the building process. Model accuracy and performance. The average accuracy achieved ranges from +0.005 to+0.015 for a part with 12 diameter and 15 height. The layer thickness is between 0.003 and 0.02. The product may suffer shrinkage and war page due to sintering and cooling. Those two factors can be partly eliminated by choosing powder particles which have a small size, and a high aspect ratio and air flow temperature above the softening point of the powder, but below the sintering point.Recycling. The prototype can be crushed into powder for reuse.Fused deposition modelling (FDM)Rapid prototyping system-3D modeler developed by Stratasys Inc.-constructs parts based on deposition of extruded thermoplastic materials called FDM process6. In an FDM process, a spool of thermoplastic filament feeds into a heated FDM extrusion head. The movement of the FDM head is controlled by computer. Inside the flying extrusion head, the filament is melted into liquid by a resistant heater. The head traces an exact outline of each cross-section layer of the part. As the head moves horizontally in x and y axes the thermoplastic material is extruded out a nozzle by a precision pump. The material solidifies in 1/10 s as it is directed on to the workplace. After one layer is finished, the extrusion head moves up a programmed distance in z direction for building the next layer. Each layer is bonded to the previous layer through thermal heating. Figure 6 shows the working principle of FDM. The FDM has the following main features:Material. The FDM technology allows a variety of modeling materials and colors for model building. Available materials are wax-filled plastic adhesive material, proprictay nylon, and investment casting wax. Proprietary nylon, and investment casting wax. All the materials are non-toxic and can be in different colors. There is minimum material wastage in the method. No post-curing is required. Support. In many cases, the FDM process does not need support to produce part. The FDM extrusion head forms a precision horizontal support in mid-air as it solidifies. For overhanging parts, a .support may still be required to reduce part distortion.Model accuracy and performance. The overall tolerance is 0.005. Successive laminations are within the range of 0.001-0.05, and wall thickness ranges from 0.01 to 0.25. The prototype built in the FDM process has 1.2% of the maximum shrinkage. Capacity. The working envelope of the 3D modeller is up to 12 x 12 x 12. The 3D modeller operation speed is up to 900 rain-I (15 s-).Laminated object manufacturing (LOM)The LOM processes produce parts from bonded paper plastic, metal or composite sheet stock. LOM machines bond a layer of sheet material to a stack of previously formed laminations, and then a laser beam follows the contour of part of a cross-section generated by CAD to cut it to the required shape. The layers can be glued or welded together. The excess material of every sheet is either removed by vacuum suction or remains as next lavers support. Figure 7 shows the working principle of LOM. The features of LOM are as follows:Material. Virtually any foil (sheet material) can be applied: paper, metals, plastics, fibres, synthetic materials, glass or composites. Helisys Inc. uses cellulose foils now.Support. The LOM process uses solid-state materials and therefore usually does not need pre-designed .support structure.Model accuracy and performance. The models can be constructed with the accuracy of -I-0.005 and do not shrink or distort because of the use of sheet material. The thickness of a layer is between 0.002 and 0.02. The materials used make the prototypes less fragile than those made from photopolymers.Capacity. The LOM machine LOM-1015 uses a 40 watt carbon dioxide laser beam. The size of the prototypes that can be constructed by LOM-1015 is 15 10 15. Since only profile cutting is needed instead of curing a solid area, LOM is comparatively faster. Ballistic particle manufacturing Ballistic particle manufacturing (BPM)The ballistic particle manufacturing technique, developed by Perception Systems uses a piezo-driven inkjet mechanism to shoot droplets of melted materials, which cold-weld together, onto a previously deposited layer. A layer is created by moving the droplet nozzle in x and y directions. After a layer is formed, the base plate lowers a specified distance and a new layer is created on the top of the previous one. Automated Dynamics Co. also developed a similar machine independently. Figure 8 shows the working principle of BPM. The features of BPM are:Material. The materials should be easily melted and solidified, such as thermoplastics, aluminium, and wax. Perception Systems inc. now uses wax, Automated Dynamics Co. aluminium. Support. During model building processes, support structures for overhangs and voids are needed, The material for the support is a water-soluble synthetic wax. When the model is completed, it is washed off by warm water.Model accuracy and performance. The overall accuracy is +0.004. The layer thickness is about 0.0035. No performance is reported.Capacity. The BPM printer can spray 50/m droplets of wax at a rate of I0000 droplets s- 1with an array of 32 inkjet nozzles. The maximum work piece size is 12 212”. Three-dimensional printing (3D Printing) Three-dimensional printing was developed at Massachusetts Institute of Technology. In the 3D Printing process, a 3D model is sliced into 2D cross-section layers in computer. A layer of powder is spread on the top of the piston, the powder bed, in a cylinder, and then an inkjet printing head projects droplets of binder material onto the powder at the place where the solidification is required according to the information from the computer model. After one layer is completed, the piston drops a predefined distance and a new layer of powder is spread out and selectively glued. When the whole part is completed, heat treatment is required to enhance the bonding of the glued powder, and then the unbonded powder is removed. Figure 9 shows the working process of 3D Printing. Features of 3D Printing are summarized below:Materials. The 3D Printing process can use aluminum-oxide and alumina-silica ceramic powders. The binder material is amorphous or colloidal silicon carbide. SSupport. With the 3D Printing technique, the design of support structure for the part is not needed, since the unbonded powder of each layer remains to form a natural support during the layering process.Model accuracy and performance. Little quantitative data are available since 3D Printing is still in the testing stage. For the testing sample, the layer thickness is 178#m and the minimum feature size is 0.017v.Capacity. The 3D Printing process can be used to produce both functional parts and tooling for prototypes. The current maximum part size is 12 12 24. The technique has the potential of building parts over 20 21 layers that are 100 m thick at a rate of approxi-mantely 2 s per layer-0.18 m h-1.CONCLUSIONSProduct features, quality, cost and time to market are important factors for a manufacturer to remain competitive. Rapid prototyping systems offer the opportunities to make products faster, and usually at lower costs than using conventional methods. since RP&M can substantially reduce the product development cycle time, more and more businesses are taking advantage of the speed at which product design generated by computers can be converted into accurate models that can be held, viewed, studied, tested, and compared. Several new and promising rapid prototyping manufacturing techniques were discussed. They are all based on material deposition layer by layer. Each of them has particular features in terms of accuracy, material variety and the cost of the machine. Some present problems and research issues were also discussed. This is a rapid development area. Capacities and the potential of rapid prototyping technologies have attracted a wide range of industries to invest in these technologies. It is expected that greater effort is needed for research and development of those technologies so that they will be widely used in product-oriented manufacturing industries.REFERENCES1 Kimble, LL The selective laser sintering process: applications of a new manufacturing technology PED Intell. Des. Manfg Prot. Vol 50 (1992)2 Jacobs, PF Rapid Prototyping & Manufacturing-Fundamentals of StereoLithography SME (1992)3 Kruth, JP Material incress manufacturing by rapid prototyping techniques Ann. CIRP Vol 42 No 2 (1991) pp 603-6144 Deckard, CR and Beaman, JJ Recent advances in selective laser sinlering Fourteenth Conf. Production Research and Technology (1987) pp 447-4525 Deckard, CR and Beaman, JJ Solid freeform fabrication and selective powder sintering Proc. 15th NAMRCSME (1987) pp 636-6406 Crump, SS Fast, precise, safe proto .types with FDM PED Intell. Des. Manfg Proto. Vol 50 (1992)7 Wohlers, IT Make fiction fact fast, Manfg Engng Vol 106 No 3 (1991) pp 44-49 8 Sachs, E, Cima, M, Williams, P, Brancazio, D and Comic, J Three dimensional printing: rapid tooling and prototypes directly from a CAD model J. Engng Ind. Tram. ASME Vol 114 (1992) pp 481-4889 Mortenson, ME Geometric Modeling (lst Ed.) John Wiley (1985)10 Ellis, JL, Kedem, G, Lyerly, TC and Thielmand, DO The raycasting engine and ray representations: a technical summary InL J. CompuL Geom. AppL Vol 1 No 4 (1991) pp 347-38011 Ellis, JL, Kedem, G, Marisa, R, Menon, J and Volcker, H Breaking barriers in solid modeling Mech. Engng Vol 113 No 2 (1991) pp 28-3412 Yah, X and Gu, P CSG-based model preparation for rapid prototyping Int. Mechanical Engineering Congress & Exhibition, ASME Winter Annual Meeting Chicago, Illinois, ASME, 94- WA/BE-12 (1994)13 Hartmann, K, Krishnan, R, Merz, R, Neplotnik, G, Prinz, FB, Schultz, L, Terk, M and Weiss, LE Robot-assisted shape deposi tion manufacturing Proc.1994 IEEE Int. Conf. Robotics and Automation San Diego, IEEE (May 1994)14 CAD/CAM Publishing Inc. Factors affecting part accuracy Rapid Proto. Rep. Vol 2 No 4 (April 1992) pp 4-715 Bjoke, O How to make stereolithography into a practical tool for tool production Ann. CIRP Vol 41 No I pp 175-17716 lwanaga, S, Kurihara, F, Ohkawa, M and Igarashi, K Influence of material characterization on dimensional stability Third Int. Conf. Rapid Prototyping (June 1992) pp 77-9017 Narahara, H and Saito, K Fundamental analysis of single layer created by three dimensional photofabrication Th/rd Int. Conf.

温馨提示:
1: 本站所有资源如无特殊说明，都需要本地电脑安装OFFICE2007和PDF阅读器。图纸软件为CAD,CAXA,PROE,UG,SolidWorks等.压缩文件请下载最新的WinRAR软件解压。
2: 本站的文档不包含任何第三方提供的附件图纸等，如果需要附件，请联系上传者。文件的所有权益归上传用户所有。
3.本站RAR压缩包中若带图纸，网页内容里面会有图纸预览，若没有图纸预览就没有图纸。
4. 未经权益所有人同意不得将文件中的内容挪作商业或盈利用途。
5. 人人文库网仅提供信息存储空间，仅对用户上传内容的表现方式做保护处理，对用户上传分享的文档内容本身不做任何修改或编辑，并不能对任何下载内容负责。
6. 下载文件中如有侵权或不适当内容，请与我们联系，我们立即纠正。
7. 本站不保证下载资源的准确性、安全性和完整性, 同时也不承担用户因使用这些下载资源对自己和他人造成任何形式的伤害或损失。

人人文库网所有资源均是用户自行上传分享，仅供网友学习交流，未经上传用户书面授权，请勿作他用。