关 键 词：

含CAD图纸、说明书、SW三维 壳体 左右 面孔 加工 组合 机床 总体 设计 CAD 图纸 说明书 SW 三维

资源描述：

半轴壳体左右两面孔加工组合机床的总体设计【含CAD图纸、说明书、SW三维】,含CAD图纸、说明书、SW三维,壳体,左右,面孔,加工,组合,机床,总体,设计,CAD,图纸,说明书,SW,三维

内容简介：

Science in China Series E: Technological Sciences 2009 SCIENCE IN CHINA PRESS Citation: Song Y Q, Li Z G, Wang M H, et al. Precision forming machine with rolling plate cross wedge rolling. Sci China Ser E-Tech Sci, 2009, 52(11): 31173121, doi: 10.1007/s11431-009-0339-2Precision forming machine with rolling plate cross wedge rolling SONG YuQuan, LI ZhiGang, WANG MingHui & GUAN XiaoFang Superplasticity and Plasticity Research Institute, Jilin University, Changchun 130022, China Roller cross wedge rolling（CWR）machines have high rigidity, but sector dies are difficult to process. Plate CWR machines have low rigidity and need large floor space, but plate dies are easy to process. Neither roller CWR machine nor plate CWR machine can produce larger workpieces. Based on the above conclusions, this paper presents the mechanical principle of the precision forming machine with rolling plate CWR. Then, its design principle and machine construction are presented. There are a top press roller above the upper sliding plate and a bottom press roller under the lower sliding plate. The press rollers make rolling contact with the sliding plates. The plate dies are mounted on the upper and lower sliding plates, respectively. Furthermore, the axes of both press rollers and centerline of work-piece always keep in the identical vertical plane during forming process. These make the machine re-tain advantages of high rigidity for roller CWR machine and simpleness of manufacturing dies for plate CWR machine, and abandon defects of poor rigidity for plate CWR machine and difficulty of manufac-turing dies for roller CWR machine. Moreover, the machine can produce larger workpieces. roller cross wedge rolling, plate cross wedge rolling, compound cross wedge rolling The cross wedge rolling (CWR) forming process is a metal successive partial plastic forming technology de-veloped in recent decades at home and abroad. In the field of metallurgical processing, it is an evolution from the equal cross-section rolling to the non-equal cross- section rolling. In the field of mechanical processing, the overall successive partial plastic forming is an im-provement to the subsection integral plastic forming. CWR, with the advantages of high material utilization, high energy efficiency, high production efficiency, automation and no impact noise. It occupies an impor-tant position, and has a good development prospect in modern net-shape forming and green machining tech-nology1. The research of CWR technology began in the 1960s in China. Today, we have our own advantages in the aspects of technical level and production application. Many scholars and experts in this field have made im-portant contributions. In China, the Parts Rolling Re-search Center in Beijing University of Science and Technology, headed by Hu Zhenghuan, has the over-whelming advantages and the characteristics for its se-rial work in equipment, technology and theories of roller CWR. The first plate CWR machine was manufactured by Jinan Foundry and Metalforming Machinery Re-search Institute. In Beijing Research Institute of Me-chanical & Electrical Technology, Ren Guanshengs work has been remarkable in recent years, especially about the high rigidity and high strength roller CWR machine. Any kind of manufacturing technology is composed of equipment and technology. New require-ments for new equipment are being put forward because of the development of new technology, which promotes the development of new equipment. And in turn, new Received June 8, 2009; accepted August 3, 2009 doi: 10.1007/s11431-009-0339-2 Corresponding author (email: syq ) Supported by the National Scientific and Technological Project (Grant No. 2003BA- 212C) and the “985 Project” of Jinlin University 3118 Song Y Q et al. Sci China Ser E-Tech Sci | Feb. 2009 | vol. 52 | no. 11 | 3117-3121 equipment provides important means for implementation of new technology. The development of equipment and technology by supplementing each other forms the his-torical trunk of the whole manufacture industry. The development of cross wedge rolling is no exception ei-ther. Based on the route, the paper firstly analyzes the advantages and disadvantages of the existing roller CWR and plate CWR machine, and then puts forward the working principle and structural principle of the pre-cision forming machine with rolling plate cross wedge rolling (CCWR), and subsequently describes its design and working process, and finally gives a brief discussion and conclusion. 1 Overview of the existing CWR ma-chines In the world, CWR machines mainly have three basic types: One-roll arc wedge CWR machine, roller CWR machine and plate CWR machine2. However, the two classes involving roller CWR and plate CWR are com-monly used at present. 1.1 Roller CWR machine The elemental structure and working principle of a roller CWR machine is shown in Figure 13. The top and bot-tom rollers are fixed between left frame and right frame with bearings. The top and bottom sector wedge dies are fixed on the top and bottom rollers, respectively. When the top and bottom rollers rotate in the same direction, a cylindrical billet is inputted in the die cavity between the top sector die and bottom sector die using conducting plate, and formed into axial rotary workpieces or stepp- ed shaft through successive partial compression defor-mation in radial direction and successive partial exten-sion deformation in the axial direction. Because the axes of the top and bottom rollers of the roller CWR machine lie in the same vertical plane as the centerline of the workpiece, which makes the resistance force for forming Figure 1 Roller CWR machine. 1, Power and transmission system; 2, gimbal (symmetric); 3, frame (symmetric); 4, roll (symmetric); 5, fan wedge rolling die (antisymmetry); 6, conducting plate; 7, workpiece. workpiece directly act on the top and bottom rollers and transfer to the frame through the rollers, the machine is in a good stress state. The diameter of the rollers will proportionally increase in dimension with the increasing size of the workpiece, and the rollers are supported by the frame, and these ensure that the machine has large rigidity. In addition, power transmission systems are separated from the main structure and connected with the shafts of rollers through the gimbal couplings. So, the main structure of the machine is compact. These are important advantages of the roller CWR machine. However, the shape of dies mounted on rollers is sector, which is difficult to process. Due to the limit of the di-ameter of rollers, a roller CWR machine has no capabil-ity of forming the workpiece with large size, large radial compression ratio or large axial elongation. Moreover, due to the gripping of billets by conducting plate, its accuracy varies significantly. These are the long-term problems which are difficult to solve. 1.2 Plate CWR machine The working principle of a plate CWR machine is shown in Figure 24. The identical wedge-shaped flat dies are antisymmetrically installed on the top and bot-tom rolling plates which can move in parallel relatively to each other. When the upper and lower flat dies are moving relatively to each other, the cylindrical billet laid into die cavity between the upper flat die and the lower flat die is formed into workpiece through compression deformation in the radial direction and extension defor-mation in the axial direction. The successive partial plastic forming is carried out for axial rotary workpiece. There are guide grooves on the main frame and auxiliary frame, and guides are installed on the rolling plates. The guides make sliding fit with guide grooves. During roll-ing, the top and bottom rolling plates are moving in par-allel relatively to each other, and the rolling force is added to the rolling plates and the frame. The bottom rolling plate is driven by the piston of oil cylinder for Figure 2 Plate CWR principle. 1, Cylinder; 2, rolling plate; 3, auxiliary frame; 4, main frame; 5, rack (symmetric); 6, gear (symmetric); 7, guide groove (symmetric); 8, guide (symmetric); 9, flat dies; 10, workpiece. Song Y Q et al. Sci China Ser E-Tech Sci | Feb. 2009 | vol. 52 | no. 11 | 3117-3121 3119 reciprocating motion and synchronously drives the up-per flat die to relatively slide through gear and rack, or the top rolling plate is driven by the piston of oil cylin-der for reciprocating motion, and the bottom rolling plate is fixed on the frame. The upper wedge-shaped flat die and the lower wedge-shaped flat die are installed on the top and bottom rolling plates, respectively. The rolled-piece, laid between the upper wedge-shaped flat die and the lower wedge-shaped flat die, is rolled to successive partial compression deformation in the radial direction and successive partial extension deformation in the axial direction. The plate CWR has the following advantages: simpleness of manufacturing high precision flat dies, and making a billet accurately enter into the groove of flat dies without conducting plate by design-ing the feeding groove on flat dies, which makes plate CWR have a high rolling forming precision in theory. During rolling, a cylindrical billet between the upper flat die and the lower flat die applies the counterforce di-rectly to the rolling plates and bends them so as to lower the forming precision. It is the main reason why the plate CWR machine has poor rigidity, especially for the forming of the workpieces with large size, large radial compression ratio or large axial elongation. Because the reciprocating motion of flat dies depends on the cylinder piston drive, the machine has complex structure and ocuppies large floor space. In addition, the matter that oxide skin is not easy to remove also needs to be further solved during hot rolling. 2 The design of CCWR machine From the above description, the roller CWR machine has high structure rigidity, but sector dies are difficult to process, and the gripping of workpiece is unstable, and its forming precision is poor. However, the plate CWR machine has poor rigidity and occupies a large floor space, and the flat dies are easy to manufacture, the feeding of billet is reliable and its forming precision is high. By analyzing their structure and mechanical es-sence, the main matter is that the dies are fixed with the load bearing parts for overcoming deformation resis-tance. So firstly, the sector dies should be separated from the rolling roller of the roller CWR machine and the flat dies should be separated from the rolling plate of the plate CWR machine. Then, integrate the advantages of both machines into a CCWR machine: the rollers merely undertake the resistance force for workpiece forming, rather than serve as constraints of workpiece forming, and flat dies merely serve as constraints of workpiece forming, rather than undertake the resistance force for workpiece forming. Thus, the advantages involving high rigidity and small floor space of the roller CWR ma-chine, and high forming precision and simpleness of manufacturing the dies of the plate CWR machine are retained, and in turn shortcomings involving difficulty of manufacturing sector dies and poor forming precision of the roller CWR machine, and poor rigidity and large floor space of the plate CWR machine are abandoned. According to the new idea of mechanical and structural design, we have declared the invention intitled the plas-tic plate rolling plastic precision forming machine which was later granted for a patent for invention in China5. Based on the patent, the CCWR machine consists of the following parts: the power and transmission system, the load bearing system, the forming and the die-installation system, the feeding and unloading system. This paper will describe the design of CCWR machine and struc-ture principle of each part. 2.1 Power and transmission system As shown in Figure 3(a), the output power of motor (1) is transferred from small belt pulley (2) to big belt pul-ley (4) (also as the flywheel) through belt (3), then through gear pair to big gear (6) (also as the flywheel). When closing the clutch (14) and opening clutch (8) and arrester brake (9), the power through gear pair (13) & (12) and gear pair (12) & (10) is transmitted the shaft with slow rotation in the identical direction. When opening clutches (8) and (14) and closing arrester brake (9), the machine stops working. When opening clutch (14) and arrester brake (9) and closing clutch (8), the power through gear pair (10) & (12) and gear pair (12) & (13) is transmitted to the shaft with fast rotation, the machine quickly returns to the original work position. 2.2 The key parts of main structure In Figures 3(b)(d), the top and bottom press rollers are symmetrically installed in the bearings mounted on the left and right main frames. There are gear rings symmet-rically installed on the left and right ends of the top and bottom press rollers. The trapezoidal guide grooves are eudipleurally fixed on the inner flanks of the main frames and the auxiliary frames. The trapezium guide-ways are eudipleurally fixed on both sides of the frame- work of the upper and lower sliding plates. The racks are symmetrically fixed on the outer flanks of the trapezium 3120 Song Y Q et al. Sci China Ser E-Tech Sci | Feb. 2009 | vol. 52 | no. 11 | 3117-3121 Figure 3 Structure drawing of CCWR machine. 1, Electric motor; 2, small belt pulley; 3, belt; 4, big belt pulley; 5, pinion; 6, big gear; 7, 15, gear pair; 8, 14, clutches; 9, arrester brake; 10, 12, and 12, 13, gear pairs; 11, transmission shaft; 16, main frame; 17, gear ring; 18, press roller; 19, draw rod; 20, sliding plate; 21, flat die; 22, framework of the sliding plate; 23, rack; 24, guideway; 25, guide groove; 26, workpiece; 27, pedestal; 28, gimbal; 29, workpiece box; 30, filter net of oxide skin; 31, retaining nest of the billet; 32, workpiece outlet; 33, auxiliary frame. guideways. The gear ring engages with the rack. The trapezoidal guideways on the framework of sliding plates make sliding fit with the trapezoidal guide groo- ves of the frame. The upper and lower sliding plates are eudipleurally installed on the frameworks of their own. The upper press roller keeps rolling contact with the upper sliding plate, and the lower press roller keeps rolling contact with the lower sliding plate. The upper and lower flat dies are antisymmetrically inlaid on the upper and lower sliding plates, respectively. There is a retaining nest of the billet in the billet entrance between the upper and lower flat dies. And there is a workpiece outlet in the workpiece outlet between the upper and lower flat dies. The filter net of oxide skin is mounted under the workpiece outlet, and there is a workpiece box placed on bottom of the filter net of oxide skin. 2.3 CWR forming process In Figure 3, when closing clutch (14) and opening clutch (8) and arrester brake (9), the power is tranferred through the gimbal to the top and bottom press rollers, then the top and bottom press rollers slowly rotate in the identical direction. With the gear ring driving rack and the trapezoidal guideway making sliding fit with the trapezoidal guide groove, the upper and lower flat dies move slowly in the opposite directions. Meanwhile, a billet is automatically fed into the die cavity of the upper and lower flat dies using the retaining nest to locate the billet. Under the pressures of the top and bottom press rollers to the upper and lower flat dies through the upper and lower sliding plates, the billet is formed into work-piece with cross wedge rolling. After finishing the roll-ing forming, oxide skin is percolated through the filter net of the oxide skin, and the workpiece automatically enters into the workpiece box. At this time, by opening clutches (8) and (14) and closing arrester brake (9), CCWR machine stops working. And then, by opening clutch (14) and arrester brake (9) and closing clutch (8), the machine quickly returns to the original work position. When opening clutches (8) and (14) and closing arrester brake (9) once more, the machine at original position can begin the new rolling process. 3 Discussion and conclusion 3.1 Discussion Rollers of the traditional roller CWR machine have high rigidity, but its sector dies are difficult to manufacture and of poor precision. Flat dies of the traditional plate CWR machine are easy to manufacture and of high pre-cision, but the plate structure has low rigidity. These depend on the stress state of the two machines and com- Song Y Q et al. Sci China Ser E-Tech Sci | Feb. 2009 | vol. 52 | no. 11 | 3117-3121 3121 bination of their dies and structure to a whole. In order to incorporate their advantages and abandon their short-comings, the long-standing traditional structures of roller CWR or plate CWR machines must be broken, namely, for the roller CWR machine, sector dies should be separated from rollers, and for the plate CWR ma-chine, flat dies should be separated from the rolling plates. Then with rearrangement, the precise forming machine with compound cross wedge rolling combining roller and plate (CCWR machine) is designed. The new machine has the advantages including high rigidity for roller CWR machine and high precision for plate CWR machine. This is the core idea and innovation in the paper. To implement the design of CCWR machine, it must be guaranteed that the up and down rollers can under-take the resistance force for workpiece forming and the flat dies can constrain the forming shape of workpiece. Therefore, rolling rollers will be replaced with press rollers, and gear rings are symmetrically installed on both ends of the press rollers. The racks are installed on both sides of the frameworks of the upper and lower sliding plates, and the gear rings engage with the racks. There are guideways and guide grooves installed on both sides of the frameworks of the upper and lower sliding plates, which make sliding fit with each other. When the upper and lower flat dies move in the opposite directions, a billet is being formed in the cavity of the flat dies. For the designs of the main mechanical struc-ture of the machine and the installation structure of the dies presented in the paper, it should be guaranteed that the axes of the top and bottom press rollers and the cen-terline of billet always keep on an identical vertical plane. This point belongs to the research topic of the cross wedge rolling technology and would be specially discussed in another paper. In addition, although CCWR machine has the filter net of oxide skin in the paper, to completely solve the problem that oxide skin is difficult to remove, the CCWR machine should be inclined at an angle of over 20 degrees to the ground during installation, and at the end of every rolling process, the wind auxiliary equip-ment is r used to clean t