车床变速箱中拔叉（831006）及专用夹具设计【铣φ40外圆端面】【说明书+CAD】
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Study on the Effect of Ultrasonic Surface Rolling Processing Parameters on the Surface Roughness of Q345 Hydraulic Prop Guangyi Meia, Kehua Zhangb and Jinfu Dingc Transportation College of Zhejiang Normal University, JinHua 321004, China amgy, b mature, c zsddif Keywords: Ultrasonic rolling, Machining parameter, Surface roughness, Hydraulic prop Abstract. The surface roughness of the hydraulic prop had an important effect on the wear resistance, fatigue strength and property of fit. The ultrasonic surface rolling extrusion (USRE) processing experiment was employed to improve the surface roughness of the hydraulic prop, some machine parameters such as the tools transfer magnitude, feed were studied in detail, the contact style roughness tester( Mahr S2) was used to test the surface roughness of the workpiece. The experiment results showed that the USRE could improve the surface roughness evidently, the Ra value from 0.976m reduce to 0.105 m by one-hit machining. The feed was linear with the surface roughness, and when the tools amplitude was 6.58.5, there were a better surface roughness Ra 0.090m. USRE processing the surface time and again could improve the surface state. Introduction The hydraulic prop was a tangent pile that could be used fit the hinge the top beam or exclusive use; it was the matching equipment for mechanized mining. The hydraulic prop was the important mine safety appliance, the machining surface quality have important effect on the usability: 1.effect on the abrasion resistance, the surface roughness have an important effect on beginning period of the friction, far from that as little as may be surface roughness, there are a best parameter for the friction about 0.321.25m. 2. Effect on the fatigue strength, the uneven surface and flaw on the surface would cause stress concentration and bring about fatigue and fracture, so the contact surface should be finished and enhance the fatigue strength.3.effect on the corrosion resistance, the corrosion matter are easy to accumulate on the roughness surface, so reducing the surface roughness could enhance the corrosion resistance.4.effect on the property of fit, if mating on the rough surface the tolerance clearance would be increased by the wear and tear of the property of fit, so the precision and rigidity of fit would be cut down, it would impact the stationarity and the reliability1,2,3. So the mating surface must be finished. In order to high effective improve the surface state of the workpiece, a new machining technology ultrasonic surface rolling processing (USRP) was put forward, the USRP used the ultrasonic vibration to supply the energy to extrude the surface of workpiece 4, 5 This processing method has the fewer elasticity pressure, friction force, and surface roughness would reduce soon, and the surface hardness and abrasion resistance enhances observably. In this processing, the processing parameter such as axial direction, static pressure and amplitude of vibration decided the last surface state 6, 7. Ultrasonic Rolling Experimental System and Principle Ultrasonic Rolling Experiment Device. The ultrasonic rolling experiment device was shown in Fig. 1; it was composed of ultrasonic generator 8, transducer 6, amplitude transformer 5 and toolhead 2. The ultrasonic oscillation was translated to the mechanical vibration by the transducer, the amplitude was enlarged by the amplitude transformer, and then the energy was translated to the toolhead for finishing. The toolhead 2 was screwed joint with device, in the processing the relative rotative were generated between the workpiece surface and the toolhead. Advanced Materials Research Vols. 102-104 (2010) pp 591-594Online available since 2010/Mar/09 at (2010) Trans Tech Publications, Switzerlanddoi:10.4028/AMR.102-104.591All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of TTP,. (ID: 40-30/12/10,04:12:50) The Processing Principle. In the ultrasonic rolling processing, the toolhead generated mechanical vibration that was caused by the ultrasonic generator and feed along the workpiece surface. So the static pressure and ultrasonic vibration were translated to the workpiece surface (as the Fig. 2 show). The macro-scale elasto-plastic deformation would generate by the extrude action. After processing, some recovery of elasticity would take place on the processed surface. So the plastic flow would change the asperity of workpiece, reduce the surface roughness and enhance the combination property of the finished surface 5. Fig. 1 The Schematic of the Ultrasonic Rolling Device Fig. 2 Principle of USRP 3 Fig. 3 The photo of the locale processing Experiment Materials and Conditions Experiment Materials. The experiment materials was Q345 hydraulic prop whose dimension was 97980mm, the element of Q345 steel was almost same with the 16Mn steel, there are some trace alloy element V, Ti and Nb in the Q345, this trace alloy element would grain refinement and enhance the tenacity, so the synthesis mechanic of the Q345 steel were improved large scale. The initial surface roughness value was Ra 0.4m. Experiment Condition. The conventional processing technic of hydraulic prop were lapping first and then polishing, the needed surface roughness value was Ra 0.4m. In this experiment, the ultrasonic rolling processing was used to substrate the lapping and polishing. The experiment was carried on NC turning machine, the locale processing photo was shown in Fig. 3. The surface roughness value was measured by the Mahr S2. Experiment Results and Discussion The Processing Amplitude Impacted on the Surface Roughness of Workpiece. The ultrasonic rolling processing was employed to study the amplitude impact on the surface roughness value, the experiment parameter were that speed of main shaft was 710 rmin, the feed was 0.12 mmr, and the static pressure was 140N, processing the surface three times. The amplitude VS surface roughness was shown in Fig. 4, the relative of the amplitude and surface was not monotonic function, suitable to 592Digital Design and Manufacturing Technology enlarge the amplitude would improve the surface roughness, but excess some value the surface roughness value would deteriorate. Fig. 4 The relation between the amplitude of tool and surface roughness The Feed Impact on the Surface Roughness. The experiment was employed to study the feed impacted on the surface roughness, the ultrasonic rolling processing with different feed was carried, the feed VS surface roughness relative was shown in Fig. 5, and the feed was linear relation with surface roughness. Fig. 5 The relation between the surface roughness and feed The Processing Static Pressure Iimpacted on the Surface Roughness. In the ultrasonic rolling processing, the tools with some static pressure and definite feed speed to processing the rotate workpiece surface to make the workpiece materials elasticity and plasticity deformation. After the tools pass by the workpiece surface would take place elastic recovery. The metal flow would caused the vale being filled with the asperity， so the surface roughness would be improved. As Fig. 6 showed that the static pressure increased and the surface roughness reduced. Fig. 6 The relation between static pressure and surface roughness The Spindle Speed and Axial Feed Impacted on the Surface Roughness. The ultrasonic rolling processing experiment was employed to study the spindle speed and axial feed impacted on the surface roughness, the processing parameter was static pressure 140N and amplitude 13m, every workpiece was processed three times and the relative of the spindle speed and axial feed VS surface Advanced Materials Research Vols. 102-104593 roughness was shown in Fig. 7. Surface roughness value increased with the raising of the axial feed and spindle speed. Fig. 7 The effect of the spindle speed and axial feed for the surface roughness Conclusions In this research the ultrasonic rolling processing experiment was employed to substitute the conventional rolling processing technic. The effect rule of the spindle speed, axial feed, static pressure and amplitude impacted on surface roughness value was investigated, if the processing parameter selected suitably, the surface roughness value would improve evidently and reach about Ra 0.1 um. So the ultrasonic rolling processing could efficiently replace the lapping and polishing in the hydraulic prop finishing processing. In ultrasonic rolling processing with 20KHz work frequency, the rational processing parameter for the Q345 hydraulic prop: spindle speed 710 r/min, axial feed 0.12mm/r, the static pressure 140N, amplitude 13.2m , the roller radii 3mm and the roller materials adopted the cemented carbide. Acknowledgement The authors gratefully acknowledge the funding for this work from Natural Science Foundation of Zhejiang Province (Grant No. Y106187) References 1 L.F. Han, S.G. Qu and W. Xia: Machine Tool and Hydraulics, (2007), p. 19-21 (in Chinese) 2 M.H. El-Axi and M.M. El-Khabeery: Journal of Materials Processing Technology, (2003), p. 82-89 3 D.P. Wang, N.X. Song, T. Wang, et a1: Journal of Tianjin University, (2007), p. 228-233 (in Chinese) 4 X.J. Liu: Mechanical Research and Application, (2007), p. 38-39 (in Chinese) 5 L. Chen: Journal of Materials Processing Technology, (2008), p. 439-450 (in Chinese) 6 F.G. Cao: Chemical Industry Press, Beijing 2005 (in Chinese) 7 G.Y. Lv, Y.L. Zhu, et al: China Surface Engineering, (2007), p. 38-41 (in Chinese) 594Digital Design and Manufacturing TechnologyDigital Design and Manufacturing Technology doi:10.4028/AMR.102-104 Study on the Effect of Ultrasonic Surface Rolling Processing Parameters on theSurface Roughness of Q345 Hydraulic Prop doi:10.4028/AMR.102-104.591 References1 L.F. Han, S.G. Qu and W. Xia: Machine Tool and Hydraulics, (2007), p. 19-21 (inChinese) 2 M.H. El-Axi and M.M. El-Khabeery: Journal of Materials Processing Technology, (2003),p. 82-89doi:10.1016/S0924-0136(02)00269-8 3 D.P. Wang, N.X. Song, T. Wang, et a1: Journal of Tianjin University, (2007), p. 228-233(in Chinese) 4 X.J. Liu: Mechanical Research and Application, (2007), p. 38-39 (in Chinese) 5 L. Chen: Journal of Materials Processing Technology, (2008), p. 439-450 (in Chinese) 6 F.G. Cao: Chemical Industry Press, Beijing 2005 (in Chinese) 7 G.Y. Lv, Y.L. Zhu, et al: China Surface Engineering, (2007), p. 38-41 (in Chinese)外文资料翻译论机电一体化的发展现代科学技术的不断发展，极大地推动了不同学科的交叉与渗透，导致了工程领域的技术革命与改造,在机械工程领域，由于微电子技术和计算机技术的迅速发展及其向机械工业的渗透所形成的机电一体化，使机械工业的技术结构、产品机构、功能与构成、生产方式及管理体系发生了巨大变化，使工业生产由“机械电气化”迈入了“机电一体化”为特征的发展阶段。一、机电一体化概要机电一体化是指在机构得主功能、动力功能、信息处理功能和控制功能上引进电子技术，将机械装置与电子化设计及软件结合起来所构成的系统的总称。机电一体化发展至今也已成为一门有着自身体系的新型学科，随着科学技术的不但发展，还将被赋予新的内容,但其基本特征可概括为：机电一体化是从系统的观点出发，综合运用机械技术、微电子技术、自动控制技术、计算机技术、信息技术、传感测控技术、电力电子技术、接口技术、信息变换技术以及软件编程技术等群体技术，根据系统功能目标和优化组织目标，合理配置与布局各功能单元，在多功能、高质量、高可靠性、低能耗的意义上实现特定功能价值，并使整个系统最优化的系统工程技术,由此而产生的功能系统，则成为一个机电一体化系统或机电一体化产品。因此，“机电一体化”涵盖“技术”和“产品”两个方面,只是，机电一体化技术是基于上述群体技术有机融合的一种综合技术，而不是机械技术、微电子技术以及其它新技术的简单组合、拼凑。这是机电一体化与机械加电气所形成的机械电气化在概念上的根本区别,机械工程技术有纯技术发展到机械电气化，仍属传统机械，其主要功能依然是代替和放大的体力,但是发展到机电一体化后，其中的微电子装置除可取代某些机械部件的原有功能外，还能赋予许多新的功能，如自动检测、自动处理信息、自动显示记录、自动调节与控制自动诊断与保护等,即机电一体化产品不仅是人的手与肢体的延伸，还是人的感官与头脑的眼神，具有智能化的特征是机电一体化与机械电气化在功能上的本质区别。二、机电一体化的发展状况机电一体化的发展大体可以分为3个阶段,20世纪60年代以前为第一阶段，这一阶段称为初级阶段,在这一时期，人们自觉不自觉地利用电子技术的初步成果来完善机械产品的性能。特别是在第二次世界大战期间，战争刺激了机械产品与电子技术的结合，这些机电结合的军用技术，战后转为民用，对战后经济的恢复起了积极的作用,那时研制和开发从总体上看还处于自发状态,由于当时电子技术的发展尚未达到一定水平，机械技术与电子技术的结合还不可能广泛和深入发展，已经开发的产品也无法大量推广,20世纪7080年代为第二阶段，可称为蓬勃发展阶段。这一时期，计算机技术、控制技术、通信技术的发展，为机电一体化的发展奠定了技术基础。大规模、超大规模集成电路和微型计算机的迅猛发展，为机电一体化的发展提供了充分的物质基础。这个时期的特点是：mechatronics一词首先在日本被普遍接受，大约到20世纪80年代末期在世界范围内得到比较广泛的承认；机电一体化技术和产品得到了极大发展；各国均开始对机电一体化技术和产品给以很大的关注和支持。20世纪90年代后期，开始了机电一体化技术向智能化方向迈进的新阶段，机电一体化进入深入发展时期。一方面，光学、通信技术等进入了机电一体化，微细加工技术也在机电一体化中崭露头脚，出现了光机电一体化和微机电一体化等新分支；另一方面对机电一体化系统的建模设计、分析和集成方法，机电一体化的学科体系和发展趋势都进行了深入研究。同时，由于人工智能技术、神经网络技术及光纤技术等领域取得的巨大进步，为机电一体化技术开辟了发展的广阔天地。这些研究，将促使机电一体化进一步建立完整的基础和逐渐形成完整的科学体系。三、机电一体化的发展趋势机电一体化是集机械、电子、光学、控制、计算机、信息等多学科的交叉综合，它的发展和进步依赖并促进相关技术的发展和进步。因此，机电一体化的主要发展方向如下：3.1智能化智能化是21世纪机电一体化技术发展的一个重要发展方向。人工智能在机电一体化建设者的研究日益得到重视，机器人与数控机床的智能化就是重要应用。这里所说的“智能化”是对机器行为的描述，是在控制理论的基础上，吸收人工智能、运筹学、计算机科学、模糊数学、心理学、生理学和混沌动力学等新思想、新方法，模拟人类智能，使它具有判断推理、逻辑思维、自主决策等能力，以求得到更高的控制目标。诚然，使机电一体化产品具有与人完全相同的智能，是不可能的，也是不必要的。但是，高性能、高速的微处理器使机电一体化产品赋有低级智能或人的部分智能，则是完全可能而又必要的。3.2模块化模块化是一项重要而艰巨的工程。由于机电一体化产品种类和生产厂家繁多，研制和开发具有标准机械接口、电气接口、动力接口、环境接口的机电一体化产品单元是一项十分复杂但又是非常重要的事。如研制集减速、智能调速、电机于一体的动力单元，具有视觉、图像处理、识别和测距等功能的控制单元，以及各种能完成典型操作的机械装置。这样，可利用标准单元迅速开发出新产品，同时也可以扩大生产规模。这需要制定各项标准，以便各部件、单元的匹配和接口。由于利益冲突，近期很难制定国际或国内这方面的标准，但可以通过组建一些大企业逐渐形成。显然，从电气产品的标准化、系列化带来的好处可以肯定，无论是对生产标准机电一体化单元的企业还是对生产机电一体化产品的企业，规模化将给机电一体化企业带来美好的前程。3.3网络化20世纪90年代，计算机技术等的突出成就是网络技术。网络技术的兴起和飞速发展给科学技术、工业生产、政治、军事、教育义举人么日常生活都带来了巨大的变革。各种网络将全球经济、生产连成一片，企业间的竞争也将全球化。机电一体化新产品一旦研制出来，只要其功能独到，质量可靠，很快就会畅销全球。由于网络的普及，基于网络的各种远程控制和监视技术方兴未艾，而远程控制的终端设备本身就是机电一体化产品。现场总线和局域网技术是家用电器网络化已成大势，利用家庭网络将各种家用电器连接成以计算机为中心的计算机集成家电系统，使人们在家里分享各种高技术带来的便利与快乐。因此，机电一体化产品无疑朝着网络化方向发展。3.4微型化微型化兴起于20世纪80年代末，指的是机电一体化向微型机器和微观领域发展的趋势。国外称其为微电子机械系统（MEMS），泛指几何尺寸不超过1cm3的机电一体化产品，并向微米、纳米级发展。微机电一体化产品体积小 、耗能少、运动灵活，在生物医疗、军事、信息等方面具有不可比拟的优势。微机电一体化发展的瓶颈在于微机械技术，微机电一体化产品的加工采用精细加工技术，即超精密技术，它包括光刻技术和蚀刻技术两类。3.5绿色化工业的发达给人们生活带来了巨大变化。一方面，物质丰富，生活舒适；另一方面，资源减少，生态环境受到严重污染。于是，人们呼吁保护环境资源，回归自然。绿色产品概念在这种呼声下应运而生，绿色化是时代的趋势。绿色产品在其设计、制造、使用和销毁的生命过程中，符合特定的环境保护和人类健康的要求，对生态环境无害或危害极少，资源利用率极高。设计绿色的机电一体化产品，具有远大的发展前途。机电一体化产品的绿色化主要是指，使用时不污染生态环境，报废后能回收利用。3.6系统化系统化的表现特征之一就是系统体系结构进一步采用开放式和模式化的总线结构。系统可以灵活组态，进行任意剪裁和组合，同时寻求实现多子系统协调控制和综合管理。表现之二是通信功能的大大加强，一般除RS232外，还有RS485、DCS人格化。未来的机电一体化更加注重产品与人的关系，机电一体化的人格化有两层含义。一层是，机电一体化产品的最终使用对象是人，如何赋予机电一体化产品人的智能、情感、人性显得越来越重要，特别是对家用机器人，其高层境界就是人机一体化。另一层是模仿生物机理，研制各种机电一体花产品。事实上，许多机电一体化产品都是受动物的启发研制出来的。四、典型的机电一体化产品机电一体化产品分系统(整机)和基础元、部件两大类。典型的机电一体化系统有：数控机床、机器人、汽车电子化产品、智能化仪器仪表、电子排版印刷系统、CADCAM系统等。典型的机电一体化元、部件有：电力电子器件及装置、可编程序控制器、模糊控制器、微型电机、传感器、专用集成电路、伺服机构等。这些典型的机电一体化产品的技术现状、发展趋势、市场前景分析从略。五、我国发展“机电一体化”面临的形势和任务机电一体化工作主要包括两个层次：一是用微电子技术改造传统产业，其目的是节能、节材，提高工效，提高产品质量，把传统工业的技术进步提高一步；二是开发自动化、数字化、智能化机电产品，促进产品的更新换代。(一)我国“机电一体化”工作面临的形势1. 我国用微电子技术改造传统工业的工作量大而广，有难度2. 我国用机电一体化技术加速产品更新换代，提高市场占有率的呼声高，有压力。3. 我国用机电一体化产品取代技术含量和附加值低，耗能、耗水、耗材高，污染、扰民产品的责任重，有意义。在我国工业系统中，能耗、耗水大户，对环境污染严重的企业还占相当大的比重。近年来我国的工业结构、产品结构虽然几经调整，但由于多种原因，成效一直不够明显。这里面固然有上级领导部门的政出多门问题，有企业的“故土难离”“死守故业”问题，但不可否认也有优化不出理想的产业，优选不出中意的产品问题。上佳的答案早就摆在了这些企业的面前，这就是发展机电一体化，开发和生产有关的机电一体化产品。机电一体化产品功能强、性能好、质量高、成本低，且具有柔性，可
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