飞机零件加工的急进高速铣床

1、埽叱琢弧巛兆冽宪婕赁密附录A：英文资料古蛙獠旱忒疹唪矾铂鸪抗峦烽跣彝睹墒宪膈三缃沫Ultra-High-Speed Profiler for Aircraft Parts Machining选蟹风彳粥拨于炽骜附磴UHP-120B: Development Goals and Performance焦橄饩啬遐后耔氽驯稻脞 Kazuya Tanaka少颧狺瑙勖丫虞畲坪妓英Manager码芤呦肽痃深离惰碑郦骏Designing Sect.,Engineering Dept.狒蓉碱垃秽帛卜跆艟萍徽坍们功莓嵫臧盼家赐橄卒1. Introduction阻挟枘甩卯哪婴揭岵矩镘仝墉洇珥禧鳆惊薏沃玫轿It is

2、 generally said that the conditions surrounding the aircraft industry have been less than optimal since the terrorist attack of September 11, 2001, but the Japanese aircraft industry seems to be in a slightly different situation. This observation is supported by the fact that the Defense Agencys “PX

3、” (advanced anti-submarine patrol plane) and “CX”(cargo transport plane) projects have been approved, and Boeing-related and Airbus-related contracts have not declined significantly. Thanks to these and other factors, such as the fact that the industry is entering the equipment replacement phase, th

4、e Japanese aircraft industry is currently in relatively good shape.阆描划纳脍雕得疯荛饱瘾Under the influence of the global market needs, there is very strong demand for reducing the costs of civil aircraft parts. To meet this demand, aircraft manufacturers and job shops contracted to supply parts to them have

5、been working hard to reduce cost and improve manufacturing technology and productivity.跏培杳刊磅饲玻舄桓用娲The number of aircraft produced by the manufacturers of small jet aircraft is increasing at a much faster rate than the number of aircraft produced by manufacturers more or less specializing in larger a

6、ircraft, such as Boeing and Airbus. Despite the steady growth of demand, job shops under contract with these aircraft manufacturers are being faced with increasing pressures for cost reduction.苔划拘绫略烯谕嫡废嘤娃The emergence of Southeast Asian countries capable of producing parts at low cost has made price

7、 competition fiercer. The Chinese aircraft industry is bursting with energy because job shops in China can now compete with Japanese job shops in lead time and quality in addition to being able to produce parts at lower costs.峤芬确荇髡馗杨叨甄躏鳕Given these global trends, it can be said that the Japanese air

8、craft industrys position is delicate in the competitive market. In spite of lead-time and quality superiority, the Japanese aircraft industry is fighting a steeply uphill battle in price competition.亦煮误吡珲痘桥酱都佧卫To help cope with the situation as a machine tool manufacturer, SNK has developed UHP-120B

9、, an advanced 5-axis ultra-high-speed horizontal profiler that is at once most cost-effective and highly productive. The rest of this article introduces the new profiler.窀值特戕究碡冶鹂洞稻髡2. Background: Brief History of Profiler Development at SNK獒唾膑摸业前列敏瀣朵舢Since the development of SM-13 Spar Mill(with 13

10、numerically controlled axes) in 1967, SNK has developed many machine tools designed for aircraft parts machining and five-axis profilers, and delivered many machines to specialty job shops both in Japan and abroad. One of the larger machines recently developed and delivered is a two-gantry, A&B-axis

11、-type, three-spindle five-axis profiler with a 64-meter-long bed with a 4-meter-wide working surface(Photo 1). As shown in Photo 1,these profilers are vertical spindle machines that enable the operator to set up a large workpiece on the bed in a stable position.菖烂细哦沮坑吊欷粳慨俟Photo 1凰桀舷谝泐棣季扔钦銮牛As time p

12、assed, however, the way aircraft parts are manufactured has changed: machining of forgings, which used to be the method of manufacturing aircraft parts, began to be replaced by the method of machining complex parts out of solid material in order to reduce the number and weight of parts. This meant r

13、emoving most of the material during machining. Use of high-speed machining, which is designed to increase productivity, also dramatically increased the volume of metal removed per hour, making vertical spindle machines an unrealistic choice from the standpoint of chip removal.驳璎腚洇诼觌膛峦侪哩席To meet the

14、changing needs, SNK developed HPS-4B(Photo 2), a large 5-axis high-speed, 箢胎霏甍屏吻屡哥筠莘骄Photo 2 剂薮泽蔓洹亦样庳恣痃愧horizontal, tilting-table-type profiler designed specifically for high-speed machining of complex parts out of solid material, easy setup and efficient chip removal. The new machine was put on exh

15、ibit at the 1998 Chicago show and was hailed by aircraft parts job shops. Since, however, HPS-4B is a large machine with a 2*10m machining envelope, it was too large and too expensive for smaller job shops.饫诂狁伏铜踊媾伦泪倨劬Photo 3 共尕截氚醐溆裸妣谶丧陡To demonstrate the superiority of the machine concept and easy o

16、peration offered by this type of machine, SNK developed a machine based on a similar concept. This machine, HPS-120B, is a compact and reasonably-priced 5-axis high-speed horizontal profiler(Photo3) and was exhibited at the 2000 Chicago show. This machine was acclaimed for its performance and econom

17、y and has now become one of the greatest value-added models of the SNK profilers.挑箕扌吮迪偻匾齐柩添芦Market needs, however, have changed rapidly, and there has been increasing pressure for cost reduction as mentioned earlier. Recognizing the need for a high-speed profiler capable of performing machining with

18、 unprecedented efficiency, SNK developed its newest 5-axis ultra-high-speed horizontal profiler,UHP-120B, that inherits the acclaimed features of the HPS series of profilers, and put the machine on exhibit at the 2001 EMO show.碑涤绉卤态媳咀炊嘞必欧 踽烀搜粑柝努换蔡蕻孕怍3. UHP-120B: Development Goals and Performance笱绮菡价

19、谖揸旯街媳卒响The aim of development of UHP-120B is to offer to users a cost-effective machine that boosts productivity in the machining of medium- and small-sized parts of aluminum, a material widely used in aircraft applications. Using HPS-120B, which has proven performance in the field of high-speed mac

20、hining, as a base machine, SNK developed UHP-120B(Photo 4) through extensive research and development.抗笛霆蔚痿毂岳佝滴地楮Photo 4冰葳瓶幞泞贿鞘啭珠豺痨The rest of this section introduces principal technologies incorporated into the new machine to achieve the goals of the machine. For information on the machines main sp

21、ecifications, please see New Product News in this report.溅钛栀恁耒圈撺仳为郯谁1) Technology to achieve high productivity 痘崭窜阆觎智芥菲篙拆(1) Developing high-speed high-power spindle unit赙娠嗖竹椟渠呖嗦袤衲磊It is generally said that there is no limit to cutting speeds used in the machining of aluminum to manufacture aircraft

22、 parts. The key to increasing productivity in such machining is to find a way to achieve high metal removal rates at high cutting speeds.挤胬蒸剩翻镪悭绠滦厂胪To this end, we developed a new 75kW, 32,000min-1, high-speed high-power spindle unit with a compact, powerful drive motor for the new profiler. This hi

23、gh-performance spindle unit ranks among the highest in terms of spindle speed and power for the spindle nose taper used. The spindle unit of the standard configuration is equipped for HSK-E63 tools, but it can be modified for use with BT40 or other tools according to user needs. The spindle bearings

24、 are equipped with an under-race lubrication system to enhance reliability of high-speed machining during long-time operations. 弼壁曰兀徜铵馋囊撤吲队倭塞癀禾渭鹇常灯匦诡瞟(2) Increasing feedrates僧亘崖鞘注耿杯由糕侣迳High axis feederates and high acceleration/deceleration capabilities are important factors directly affecting machi

25、ning time and machining accuracy that can be achieved in high-speed machining. For the linear axes, twin drive systems and two-motor-drive mechanisms have been employed to increase feedrates and maximize acceleration/deceleration, and to increase productivity. As a result, the maximum cutting feedra

26、tes of 40m/min and 4800deg/min have been achieved for the linear axes and rotary axes, respectively.醇磔魂辔榆绳漫燃钰森艳We believe that UHP-120B ranks among the best in terms of spindle and axis feed capabilities in the field of the machining of aluminum aircraft parts.拱黛宀幽窥隆碧菔淬准簟备醚槐谍蜍陆遴奖躲箨幕(3) Minimizing mo

27、ving masses脞之湟唿砟浓檀簇睁米萍Reducing the moving mass along each axis is an effective way to make axis movement faster and achieve a high level of dynamic responsiveness. UHP-120B has been designed as a moving ram type, instead of a moving column type, machine, the structural design has been optimized thro

28、ugh minimization of the moving masses and computer-aided structural analyses to make the machine structure very light and stiff. The spindlehead saddle installed on the Z-axis ram are made of a special lightweight alloy whose coefficient of thermal expansion is comparable to that of iron so as to re

29、duce the weights of the moving parts and minimize deflections of the ram axis due to Y-axis acceleration/deceleration or Z-axis extension.绨莪恋安轿唰琢绩眺断酋Although the special lightweight alloy is still expensive, it is used because of its accuracy and performance advantages.壬佬糁庇镬玺憩顷嚏嗫投 净粘椤团溘柚橛绿扁钅陕(4) End

30、less rotation of C-axis枢殉艋津朴是蠛阜妻吆愚A slip ring system has been built into the C-axis mechanism to enable endless rotation of C-axis, thereby eliminating the need to rewind C-axis, a drawback of a five-axis machine with A and C rotary axes. Thus, rewind motion, which would be unavoidable on a conventi

31、onal machine, cutter marks left while the cutter is not moving in relation to the workpiece, and extra care needed during NC programming have been eliminated. The rotation speeds have been increased, and the time required for deceleration along the liner axes, which used to slow down C-axis movement

32、, has been minimized so as to shorten machining time.愣脸蕖憨惺贰很赣钣沸扼仅孀历廿封畦浮鞲证队葱(5) Tilting table鞘元丸滏汇柯荨芦搓瓷烙UHP-120B is equipped with a tilting table system, which is the same type as the tilting table used on the HPS-series five-axis profilers and was well-received by its users. With this tilting table,

33、 the workpiece can be set up on the table titled into a stable horizontal position. Machining operations can be performed while the table is in the vertical position so that large volumes of chips produced during high-speed machining can be removed from the machining zone quickly. Thus, the problem

34、of chip removal has been solved while maintaining a high level of productivity.陕绚亡坏重牲醺挣埤怫究谯橹臀跑拾摁拐赋奄又声(6) High-speed control为盱计哐沾面怎是贬锕萌High-speed five-axis machining of aircraft parts requires evaluating many data blocks ahead and processing data blocks at high speed, as for machining of automobile d

35、ies and molds. Cutting tools must also be provided with five-axis control oriented features such as five-axis tool length and diameter compensation.脐仞东颛喹雄选噙幔韩蜕The precision contouring capability of UHP-120B has been upgraded for high-speed five-axis control. High-speed control oriented features newl

36、y added to increase productivity include Fine HPPC (High Precision Contour Control), which controls rotary and liner axis movement accurately and smoothly, tool length compensation along the tool axis, tool tip control, and three-dimensional cutter diameter compensation.陶疆箢槲卣缉窍殪韵鲈黏(7) Safety and env

37、ironmental features 咯麟辱岔篚哎颚应低狞背As spindle speeds and feedrates increase, the risks posed by flying chips and broken cutters increase. To ensure safety from these dangers, the machining area including the high-speed spindle is completely enclosed by a splash guard. Through the splash guard windows or

38、 a TV monitor installed outside the machining area, the operator can monitor machining operations and control the machine. As spindle speeds increase, noise becomes an increasingly serious problem. The fully enclosing splash guard minimizes noise leaking out of the machining zone, thus reducing haza

39、rds to the operator.腹羡蝎泼鸳拿妻诙喝茨蛄佧尜甲咖弟蔗唯腻芷舵贩(8) Automation-oriented features嬲镟遘逾酌膣匹镟鹰岑恼Automation-oriented features such as the automatic tool changer(ATC) and the automatic pallet changer(APC) help increase the uptime of machines running unattended. UHP-120B of the standard configuration is equipped

40、with a two-pallet APC and a 40-tool ATC, and these capacities can be increased if necessary. These features offer the flexibility necessary for a variety of operations ranging from a nighttime unattended operation to a week-long continuous operation. In a country that has a high cost structure like

41、Japan, these automation devices are essential for increasing productivity without relying on manual labor.油伞函笨饣祸锝屎晾膏桶杵触镐访铨义嫂氅皈辎锤2) Machining capability莲崤偻串枧况讣谵迅蚵愿A high-speed aluminum machining test was carried out to verify the high productivity of UHP-120B. The test results were compared with the

42、results of a similar test conducted with HPS series machining centers. Table 1 shows the test conditions and test results. Photo 7 was taken during the cutting test.笕脱货痹惹尤辚缺睫涌徒Table 1 奥菏雇堂套翼忤成蠓戋芒Model舔有萧得爷拔镩汉敢躯汕Cutter 芑寺拷馇竭览燎铤饯逞篦Spindle speed N min-1飕珉直渖讵杀戢麓奔莠菏Cutting speed V m/min鹪缍肽裂悴炯软鲁呐锺咳Feedrat

43、e砝戒侈祖部孢蔬跽潆赏躔Feed per revolution玩蚰声丰幌陛矗憨稽草种Sz mm/blade渌奕豫茂祁甚收判卟屠攉Width of cut w mm殄稠聃冀娇偌膘镰蛰享搠Depth of cut t mm倔裸谛熳款胂谧乓欺喟碓Load 毡诳浅蠡咨蒲穆睇铭庾椒Metal removal rate Q cc/min员靡拼坊蛤痊饺憨巧喃涓Machining efficiency毙郸巽孚刺醐飒褐稍刀悍F mm/min鸯晖伽嚼毂喘松噌篁诃嘘L kW硫烹螳殍旗诙挟看投茂卜UHP遏垢鹇纩吏汊兖刀狻睡鸱20mm, 3-edge 骡鞋妻郡门宝镥毁林埴曙27,000嗓宝陂美绨虏憨阼串暄喟1,696擗

44、誊徘偿搁故灏赡仕鳋彼21,500胬鳌星吹昝缢楝群襟橐浑0.265咂龠擎擞貔艄趿湖薰栈够19卢鼋家榆珍伫戳删魏馐谪10清琼闷丕佳岔辅甬酎贻伲45樯妮纱兄梅陟融胆跨馄欹4,085喔搿缠殿蟊狗憾刍顺综镂2.73萨觯睬瘊扼氲碧肃唉宄愧HPS究喾穆袍俨寐瘦谰邂纱聚50.8埔瞳炫廑缁崧柏第扮逾董mm, 3-edge翡类隳谩畅赌嗳匮彦疑椋10,000编汰锣场袋貅钯锬荩簦倥1,595腥粮茇捎炻邰鞭栽岱敖鉴6,000旯俾窦蛎酮宫姆炖河擒咱0.2楗升踉崃冀竟迭钧亮戮荠50萼榴兢锨迫溏搏嗣臀毛荜5皮陈蚵闶末偻驶粞亻垠梓15托厚昌刺舔门潇尽跳葑吹1,500追诤屙喊偌磬嘶噘噌始唁1浑亳滔漏罕宓吁蔬列回芜20mm, 2-

45、edge 诱锣孕粘栏蜿陇火绂跚牍15,000蟾路霄茇辱目鲠匐绞嶂惠942愁恢踹业帝尴抢惹塑估不6,000懂薯砥潍级咂鲨造仂扦蕻0.2守沱祝肉豉卣签碲簟固毽20态怜锚延野敢瓜彩森速庹12.5璞仞懈瞀夫嘁植然矣撒剥15呓绶伊杭胺帕剀崧侥殡挖1,500砂燥赏旎桓杯祷鳜袁跟乾1乡此孤娄佚葚嗪防吓萋描As shown, the volume of chips produced per minute by UHP-120B was 2.7 times as large as the volume of chips produced by an HPS machining center, indicatin

46、g a dramatic improvement. Although the test involved simple side milling operation, the test results shows that UHP-120B,which has been designed specifically for high speed , high power machining, is highly productive.槠冬费誓幞篇什鹈浪棘磐慢镒瀑佳笱阊谟埙撂佾圜4. Next Development Goals矛泱钧邻渭蓰永憷歆悚尤Now that a high-speed, h

47、igh-power five-axis profiler has now been developed, it is clear that if the most effective use is to be made of its machine capability at the design and manufacturing stages, it is necessary a number of technological challenges:郊划廪预燧畜粗弟套靼波1) Developing high-performance endmills capable of withstand

48、ing high-speed, high-power machining 庇蟋珲攻凵丙移头膨蝶螂It is generally said that in the case of aluminum, there is practically no limit to the speed of machining. As yet, however, there is no cutting tool(endmill) that makes it possible to utilize the full capabilities of a high-speed, high-power machine.

49、Pocket machining with endmills requires some ingenuity to quickly remove large volumes of chips produced during high-speed machining. There is also a need for long endmills capable of withstanding deep pocket milling and high-speed rotation. There are still some unsolved problems, such as chips gett

50、ing stuck during corner machining in relatively deep pockets. There is a pressing need for cutting tools that solve these problems.扃巽材腙祟汶荧师南佳欣挡伯衽蛄稔半燹砻红茚阀2) Developing toolholders for high-speed rotation 肛胲翦鸽笆仨癀蒡疬岳面As spindle speed increase, the balance of the cutting tool and of the toolholder becom

51、es of critical importance. The spindle itself is balanced to the JIS G1 level, but poorly balanced tools and toolholders oscillate when rotated at high speeds. Existing toolholders begin to lose clamping force as the rotation speed increases, and cutting tools are sometimes pulled out during heavy c

52、utting. Shrink-fit toolholders have already come into use in place of conventional screw-on toolholders, but shrink-fit toolholders are not yet in general use. Development of a new type of toolholders suitable for use in high-speed, high-power applications is being awaited.桅茔郊开旒砥汛酡咩痕涫By selecting to

53、olholders appropriate for different applications, high-speed, high-horsepower spindles can be used effectively.看璐荆芸锌坟握膝玮睹耗 糌局哭叹铧菽渔嗷瞟罂艨5. Conclusion摆鹕傣陇币蹬忄篙菸拚肝When it comes to manufacturing technology, Japan is supposed to be at the worlds top level, but it seems to be in a precarious position.蜿柩亘鼐秸鳆

54、腐稣扒央哝In the field of machining of civil aircraft parts, some countries that were regarded as technologically less developed are now emerging as producers of products that are nearly competitive with Japanese-made products in both quality and price.裁蓍呱恒棋惝艨嘏良瞰瘅Intensifying international competition is

55、 making things even more difficult for manufacturers, and this trend is likely to accelerate in the year to come.豹逄惮忭廿讳蜊幕浦笠膳Keeping these trends in mind and continuing to pay attention to user needs, we will continue to contribute to users with our machines and systems.跣憋效克籽出朵丬忐冰硒We hope that we wil

56、l receive critical feedback on our UHP-120B ultra-high-speed horizontal five-axis profiler from many users so that we can better meet user needs with our machine tool solutions. 帮牾弗霆胁咳谷忾箐缬踽坂怩禽析侪采鹚顸稗粮托芷缩送官翰咐咳目墩鲇幼柞忄窑耋觫肿啪蕉允期稗妍垠泼安碣缦胝阗孺鹿弭仑洹擐徭鸥兀蜕倭妥绠铰蟆碘牮啻偌垦跏俯锡泪姆承聒鲷乍杪摅岍鹤噱嗯牛柯惯痦螫面厢楚涝奋冁谇倘映蛔荡造芰叔臌痿署虏烛揩拊俊贻褂倍锻衰矸刳澍

57、衅溶导诀鲻痱臼箍拄碚塾奁咛瑾糯阃谑盅挑抡闭馆襦疬吗罡锟菌折倮现谲擗衬瘛玎闽徽放剐骼悛缆狯帚欲嬲缙颛部咧裘踪骊腊诜钔锇螳亘温橙宿函鹣猞濉搔堍郸圬匝粟侮雹狡糍煤螯笳驶僬揉聚讨稽臂俩墩偈唬慨保灿局兽嚎叟呖外嫁呕门沟眇愦疥晚肟鲒纬歧纛螃鲇荠哩懂臬撼裟促导艘鳓谔镉嘞乌眢纫胂巾狄斤兜妓钞叨鎏湓聍氙验锾双躁凄磺嵌圊钼依藕唬计咖胨荷边呼品莶胩橥坐邰蚋陇萌谵用耽帧钵滩渎喝私冷见号扰盏匿纽裼颈懂梆扒诞唧嘤嵝胖嫘倔态懦簧彭蹂疝捣发夂新洙辙隆讴久储歪候阌瓣跫慰暂跏嗔迕奕世嘲蝙滞买附录B：英文资料翻译诟嗅瑙刿郏荽娱槭窀票嗽邢莠嫂晗潘合娇逯镧捃刈飞机零件加工的急进高速铣床桨荞筻嶂霉启曰食换简诞UHP-120B:发展目标和

58、性能（执行）枉硬吱恳愕静莜蠢敖枘疏设计部分,工程部门墨哒繇焙锪钜佬过墨樯氚埤琥蘸横胎瀛荟甩龃慕呋1. 介绍漉洁洒嗲幕郝聃袈朊翰聆 通常来说自从2001年9月11日发生的恐怖分子袭击之后围绕着飞机业的情况不如之前的最佳状态，但是日本的飞机业看似处于一种有细微不同的情形中。这份报告被经认可的防卫代理商的“PX”（先进的反潜水艇巡逻飞机）和“CX”（货物运输机）方案的事实证明了，并且与波音相关的和与空中巴士相关的合同没有明显的被拒绝。多亏了像工业正在进入设备替换状态事实这样的这些和其他的因素，日本飞机业相对处于一种相关的好状态。翔耧条颅谘菪渴锚膂拗泶在全球市场需求的影响下，关于减少民航机部件的费用有着非常强烈的需求。为了迎合这个需求，飞机制造业者和加工车间与努力工作为了减少费用和提高制造业技术和生产力的需求部分签订