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钢管去毛刺技术研究及专用装备设计
钢管
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2634 钢管去毛刺技术研究及专用装备设计,2634,钢管去毛刺技术研究及专用装备设计,钢管,毛刺,技术研究,专用,装备,设计
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河南理工大学万方科技学院本科毕业设计（论文）中期检查表指导教师： 曲海军 职称： 副教授 所在院（系）： 机械与动力工程学院 教研室（研究室）：机械制造系 题 目钢管去毛刺技术研究及专用装备设计学生姓名尚磊专业班级10专升本2班学号0816101038选题质量：（主要从以下四个方面填写：1、选题是否符合专业培养目标，能否体现综合训练要求；2、题目难易程度；3、题目工作量；4、题目与生产、科研、经济、社会、文化及实验室建设等实际的结合程度）（1）该题将机械、去毛刺加工、材料学相关原理与直缝钢管加工的原理、结构相结合，具有一定的理论性与操作性。通过完成该论文可以对机械学有基本了解，掌握一些机械学基本理论知识。（2）该题难度适中，既有理论的研究又有试验操作,同时在生产实习的设计又可以增强动手能力，提高综合素质。（3）周查阅毕业设计材料，整理适合自己的毕业设计信息并完成设计初稿,并对毕业设计进行完善。（4）对高频直缝焊管的内外毛刺进行清除，是生产高档次高频直缝焊管的一个重要工艺过程和手段，对于内毛刺清除精度要求较高的产品，如果内毛刺清除质量满足不了标准或用户要求，将无法实施批量生产。相比外毛刺的清除工作，内毛刺的清除是一项复杂工作。在实际生产过程中的许多因素均会影响到内毛刺清除质量，即内毛刺清除的精度和清除过程的稳定性。采用在线去毛刺装置，除了改善去毛刺质量，还可以提高生产质量，在实现钢管成型及去毛刺同步时，也稳定了输出质量。因此，有必要对各种影响因素进行分析，采取相应的措施，以改善高频直缝焊管内毛刺的清除效果和提高产品档次，在线去毛刺装置的设计对于提高生产质量和节约生产成本有着重要意义。二、开题报告完成情况： 开题报告已如期按要求完成，并上交审核。三、阶段性成果： 1.在资料的收集与整理过程中，对磨粒加工有初步了解，掌握部分相关磨粒加工学原理。 2.认真学习关于机械学、磨粒加工、材料学等有关理论知识，为下一阶段的工作打下坚实的基础。 3.完成开题报告。 4.列出论文题纲，着手理论部分。 5.同时搜集喷油嘴去毛刺的相关资料，有待进一步分析整理。四、存在主要问题： 1资料收集还不全面，一些理论与应用相结合的实践做的还不好2部分公式推导还不熟练3. Word文字排版、公式编辑不太熟练4.CAD、Proe软件操作不熟练五、指导教师对学生在毕业实习中，劳动、学习纪律及毕业设计（论文）进展等方面的评语指导教师： （签名） 年 月 日河南理工大学万方科技学院本科毕业设计（论文）开题报告题目名称钢管去毛刺技术研究及专用装备设计学生姓名 尚磊专业班级10专升本2班学号0816101038一、 选题的目的和意义：近年来，通过引进国外先进技术及对引进技术的消化吸收，我国高频直缝焊管的生产技术装备水平不断提高，高频直缝焊管的产品质量和档次也有了很大的提升，产品的用途越来越广泛。对高频直缝焊管的内外毛刺进行清除，是生产高档次高频直缝焊管的一个重要工艺过程和手段，对于内毛刺清除精度要求较高的产品，如果内毛刺清除质量满足不了标准或用户要求，将无法实施批量生产。相比外毛刺的清除工作，内毛刺的清除是一项复杂工作。在实际生产过程中的许多因素均会影响到内毛刺清除质量，即内毛刺清除的精度和清除过程的稳定性。采用在线去毛刺装置，除了改善去毛刺质量，还可以提高生产质量，在实现钢管成型及去毛刺同步时，也稳定了输出质量。因此，有必要对各种影响因素进行分析，采取相应的措施，以改善高频直缝焊管内毛刺的清除效果和提高产品档次，在线去毛刺装置的设计对于提高生产质量和节约生产成本有着重要意义。二、 国内外研究综述：在焊管刚刚开始兴起的19 世纪4050 年代,人们对电焊管内毛刺的清除是没什么要求的。后来由于工业的发展, 如汽车、锅炉、石油等行业需要比较精密的焊管, 强调要求清除焊管内毛刺, 这才开始电焊管内毛刺清除装置的研制与开发。20 世纪60 年代, 我国绝大部分焊管生产企业的焊管机组都是101.6 mm ( 4 in) 以下的, 到了70 年代中期才开始研制电焊管内毛刺清除装置。原首钢焊管厂首先开始使用固定式刀架, 先由人工调整, 将刀架上的刀片对准需要切削的毛刺。虽然试生产石油管已达到一个较高的水平, 内毛刺残留高度仅为00.2 mm, 但由于原料、成型、焊接、合格率等因素的影响, 还需要做进一步的研究。后来又采用了浮动式( 弹簧或气动) 刀架, 如我国在20 世纪80年代初从日本引进的90 mm 焊管机组就是采用了弹簧浮动式刀架。我国采用的是螺旋弹簧, 而国外采用的是板式弹簧。这种刀架存在需要熟练工人操作, 起动动作要慢, 弹簧必须调至合适压力等不利因素, 从而影响其进一步发展。当时国外的刀架由3 个部件组成, 如美国Nelson 工具公司的清除内毛刺刀架采用了板式弹簧, 通过其支承力使刀头伸入毛刺中, 利用刀削原理刮削毛刺。其优点是结构简单, 制造方便; 其缺点是弹簧经常处于高温、潮湿的空气以及氧化铁皮飞扬的环境下很容易失效, 弹力消失, 刮出的毛刺常常达不到要求。 21 世纪初，江苏徐州某钢管公司引进了139.7mm、73 mm 两种规格的液压式内毛刺清除装置，用于219 mm 焊管机组ERW油套管的开发生产。该装置的刀头为环形刀, 刀座和刀座架可在垂直方向上相对调整, 下支承辊轮的胀缩通过液压管路在操作台上进行调整, 固定架具有沿垂直方向调整的功能, 沿中心杆轴线调整和旋转的功能。其刀头使用寿命长, 调整方便、精确, 液压压力稳定, 大大提高了ERW直缝焊油套管内毛刺的清除质量和焊管机组的作业率, 保证了焊缝状态的稳定性。三、 毕业设计（论文）所用的主要技术与方法：1.在学校图书馆查阅相关资料；2.在工厂的进行毕业实习；3.通过老师和工程师的指导；4.通过对相关资料和数据的理论计算和分析；5.用AotuCAD进行画图。四、 主要参考文献与资料获得情况：1 刘志俭.ERW直缝焊管内毛刺清除装置的发展J.钢管2006（3）：7-122 雷建德. 提高高频直缝焊管内毛刺清除质量的措施J.钢管2005（4）：17-203 秦宗旺等. 去毛刺技术手册M. 北京：宇航出版社，1995. 4 机械零件去毛刺工艺J 中国农业机械出版社 1998（1）5 陈静刚. 机械式直缝焊管内毛刺清除装置J.机械制造与自动化2006（3）：70-71，74 6 康霞明. 直缝焊管内毛刺清除装置结构原理分析J.焊管2005（5）：54-557 杭情. 直缝焊管内毛刺刨刀J.焊管2005（4）：31-318 王文瀚. 焊接技术手册M. 郑州: 河南科学技术出版社, 19999 曹福永.新型高频焊接钢管制造工艺的开发J .冶金设备. 2002（6）：78-7810 关振中. 激光加工工艺学手册M. 北京：中国计量出版社，1998.11 熊有伦等.去毛刺技术M. 北京：机械工业出版社，1993.12 王承义. 机械手及其应用M. 北京：机械工业出版社，1981.五、 毕业设计（论文）进度安排（按周说明）1-4周进行并完成毕业实习报告；5周完成开题报告；6-9周查阅毕业设计材料，整理适合自己的毕业设计信息并完成设计初稿；10-12周对毕业设计进行完善；13-14周完成毕业设计；15周 毕业设计上交导师准备答辩；16周 进行毕业答辩。六、 指导教师审批意见： 指导教师： （签名）年 月 日 3河南理工大学万方科技学院本科毕业设计外文资料与中文翻译院（系部） 机械与动力工程系 专业名称 机械设计制造及其自动化 年级班级 08级机制5班 学生姓名 尚 磊 指导教师 曲海军 2011年 5月 15日 NC Technology1、Research current situation of NC lathe in our timesResearch and development process to such various kinds of new technologies as numerical control lathe , machining center , FMS , CIMS ,etc. of countries all over the world, linked to with the international economic situation closely. The machine tool industry has international economy to mutually promote and develop, enter 21 alert eras of World Affairs, the function that peoples knowledge plays is more outstanding , and the machine tool industry is regarded as the foundation of the manufacturing industry of the machine, its key position and strategic meaning are more obvious. Within 1991-1994 years, the economic recession of the world, expensive FMS, CIMS lowers the temperature, among 1995-2000 years, the international economy increases at a low speed, according to requisition for NC lathe and the world four major international lathes exhibition in order to boost productivity of users of various fields of present world market (EMO , IMTS , JIMTOF , China CIMT of Japan of U.S.A. of Europe), have the analysis of the exhibit, there are the following several points mainly in the technical research of NC lathe in our times:（1）、Pay more attention to new technology and innovationWorldwide , are launching the new craft , new material , new structure , new unit , research and development of the new component in a more cost-effective manner, developmental research of for instance new cutter material , the new electric main shaft of main shaft structure , high speed , high-speed straight line electrical machinery ,etc. Regard innovating in improvement of the processing technology as the foundation, for process ultra and hard difficult to cut material and special composite and complicated part , irregular curved surface ,etc. research and develop new lathe variety constantly.（2）、Improve the precision and research of machine toolingIn order to improve the machining accuracy of the machining center , are improving rigidity of the lathe , reduction vibration constantly, dispel hotly and out of shape, reduce the noise , improve the precision of localization of NC lathe , repeat precision , working dependability , stability , precision keeping, world a lot of country carry on lathe hot error , lathe sport and load out of shape software of error compensate technical research, take precision compensate , software compensate measure improve , some may make this kind of error dispel 60% already. And is developing retrofit constantly, nanometer is being processed.（3）、Improve the research of the machine tooling productivityWorld NC lathe, machining center and corresponding some development of main shaft , electrical machinery of straight line , measuring system , NC system of high speed, under the prerequisite of boosting productivity.（4）、What a lot of countries have already begun to the numerical control system melt intelligently, openly, study networkedlyA、 elligent research of the numerical control systemMainly showing in the following aspects: It is intelligent in order to pursue the efficiency of processing and process quality, the self-adaptation to the processing course is controlled, the craft parameter produces research automatically; Join the convenient one in order to improve the performance of urging and use intelligently, to the feedback control , adaptive operation , discerning automatically load selects models automatically , since carries on research whole definitely ,etc. of the electrical machinery parameter; There are such research of the respect as intelligent automatic programming , intelligent man-machine interface , intelligence diagnosing , intelligent monitoring ,etc.B、 The numerical control system melts and studies openMainly showing in the following aspects: The development of the numerical control system is on unified operation platform, face the lathe producer and support finally, through changing, increasing or cutting out the structure target(numerical control target ), form the seriation, and can use users specially conveniently and the technical know-how is integrated in the control system, realize the open numerical control system of different variety , different grade fast, form leading brand products with distinct distinction. System structure norm of the open numerical control system at present, norm , disposing the norm , operation platform , numerical control systematic function storehouse and numerical control systematic function software developing instrument ,etc. are the core of present research to pass through.C、Meeting the manufacture system of the production line , demand for the information integration of the manufacturing company networkedly greatly of numerical control equipment, it is a basic unit of realizing the new manufacture mode too.2、Classification of the machining center（1）Process according to main shaft space position when it classifies to be as follows, horizontal and vertical machining center.Horizontal machining center, refer to the machining center that the axis level of the main shaft is set up . Horizontal machining center for 3-5 sport coordinate axis, a common one three rectilinear motion coordinate axis and one turn the coordinate axis of sports round (turn the workingbench round), it can one is it is it finish other 4 Taxi processing besides installing surfaces and top surfaces to insert to install in work piece, most suitable for processing the case body work piece . Compared with strength type machining center it, the structure is complicated, the floor space is large, quality is large, the price is high.Vertical machining center, the axis of the main shaft of the vertical machining center, in order to set up vertically, its structure is mostly the regular post type, the workingbench is suitable for processing parts for the slippery one of cross, have 3 rectilinear motion coordinate axis generally , can find a room for one horizontal numerical control revolving stage (the 4th axle ) of axle process the spiral part at workingbench. The vertical machining center is of simple structure, the floor space is small, the price is low, after allocating various kinds of enclosures , can carry on the processing of most work pieces .Large-scale gantry machining center, the main shafts are mostly set up vertically, is especially used in the large-scale or with complicated form work piece , is it spend the many coordinate gantry machining center to need like aviation , aerospace industry , some processing of part of large-scale steam turbine.Five machining centers, this kind of machining center has function of the vertical and horizontal machining center, one is it after inserting , can finish all five Taxi processing besides installing the surface to install in work piece, the processing way can make form of work piece error lowest , save 2 times install and insert working, thus improve production efficiency , reduce the process cost.(2)Classify by craft useIs it mill machining center to bore, is it mill for vertical door frame machining center , horizontal door frame mill the machining center and Longmen door frame mill the machining center to divide into. Processing technology its rely mainly on the fact that the door frame is milled, used in case body, shell and various kinds of complicated part special curve and large processes , curved surface of outline process, suitable for many varieties to produce in batches small.Complex machining center, point five times and compound and process mainly, the main shaft head can be turned round automatically, stand, lie and process, after the main shaft is turned round automatically, realize knowing that varies in the horizontal and vertical direction.(3)Classify by special functionSingle workingbench , a pair of workingbench machining center;Single axle , dual axle , three axle can change machining center , main shaft of case;Transfer vertically to the tower machining center and transfer ;One hundred sheets of storehouses adds the main shaft and changes one one hundred sheets of machining centers;One hundred sheets of storehouses connects and writes hands to add the main shaft and change one hundred sheets of machining centers; One hundred sheets of storehouses adds the manipulator and adds one pair of main shafts to transfer to the tower machining center.3、Development trend of the current numerical control latheAt present, the advanced manufacturing technology in the world is rising constantly, such application of technology as ultrafast cutting , ultraprecision processing ,etc., the rapid development of the flexible manufacturing system and integrated system of the computer one is constant and ripe, have put forward higher demand to the process technology of numerical control. Nowadays the numerical control lathe is being developed in several following directions.（1）. The speed and precision at a high speed , high accuracy are two important indexes of the numerical control lathe , it concerns directly that processes efficiency and product quality. At present, numerical control system adopt-figure number, frequency high processor, in order to raise basic operation speed of system. Meanwhile , adopt the super large-scale integrated circuit and many microprocessors structure, in order to improve systematic data processing ability , namely improve and insert the speed and precision of mending operation. Adopt the straight line motor and urge the straight line of the lathe workingbench to be servo to enter to the way directly, it is quite superior that its responds the characteristic at a high speed and dynamically. Adopt feedforward control technology , make it lag behind error reduce greatly , thus improve the machining accuracy cut in corner not to track.For meet ultrafast demand that process, numerical control lathe adopt main shaft motor and lathe structure form that main shaft unite two into one, realize frequency conversion motor and lathe main shaft integrate , bearing , main shaft of electrical machinery adopt magnetism float the bearing , liquid sound pigeonhole such forms as the bearing or the ceramic rolling bearing ,etc. At present, ceramic cutter and diamond coating cutter have already begun to get application.（2）. Multi-functional to is it change all kinds of machining centers of organization (a of capacity of storehouse can up to 100 of the above ) automatically to furnished with, can realize milling paring , boring and pares , bores such many kinds of processes as paring , turning , reaming , reaming , attacking whorl ,etc. to process at the same time on the same lathe , modern numerical control lathe adopt many main shaft , polyhedron cut also , carry on different cutting of way process to one different position of part at the same time. The numerical control system has because adopted many CPU structure and cuts off the control method in grades, can work out part processing and procedure at the same time on a lathe , realize so-called the front desk processes , the backstage supporter is an editor . In order to meet the needs of integrating the systematic one in flexible manufacturing system and computer, numerical control system have remote serial interface , can network , realize data communication , numerical control of lathe, can control many numerical control lathes directly too.（3）. Intelligent modern numerical control lathe introduce the adaptive control technology, according to cutting the change of the condition, automatic working parameter, make the processing course can keep the best working state , thus get the higher machining accuracy and roughness of smaller surface , can improve the service life of the cutter and production efficiency of the equipment at the same time . Diagnose by oneself , repair the function by oneself, among the whole working state, the system is diagnosed, checked by oneself to CNC system and various kinds of equipment linking to each other with it at any time. While breaking down , adopt the measure of shutting down etc. immediately , carry on the fault alarm, brief on position , reason to break down ,etc. Can also make trouble module person who take off automatically , put through reserve module , so as to ensure nobody demand of working environment. For realize high trouble diagnose that requires , its development trend adopts the artificial intelligence expert to diagnose the system.（4）. Numerical control programming automation with the development of application technology of the computer, CAD/CAM figure interactive automatic programming has already get more application at present, it is a new trend of the technical development of numerical control. It utilize part that CAD draw process pattern , is it calculate the trailing punishing to go on by cutter orbit data of computer and then, thus produce NC part and process the procedure automatically, in order to realize the integration of CAD and CAM. With the development of CIMS technology , the full-automatic programming way in which CAD/CAPP/CAM integrates has appeared again at present, it, and CAD/CAM systematic programming great difference their programming necessary processing technology parameter neednt by artificial to participate in most, get from CAPP database in system directly.（5）. The dependability of the dependability maximization numerical control lathe has been the major indicator that users cared about most all the time . The numerical control system will adopt the circuit chip of higher integrated level , will utilize the extensive or super large-scale special-purpose and composite integrated circuit, in order to reduce the quantity of the components and parts , to improve dependability . Through the function software of the hardware, in order to meet various kinds of demands for controlling the function, adopt the module , standardization , universalization and seriation of the structure lathe noumenonn of the hardware at the same time , make not only improve the production lot of the hardware but also easy to is it produce to organize and quality check on. Still through operating and starting many kinds of diagnostic programs of diagnosing , diagnosing , diagnosing off-line online etc. automatically, realize that diagnoses and reports to the police the trouble to hardware , software and various kinds of outside equipment in the system. Utilize the warning suggestion, fix a breakdown in time; Utilize fault-tolerant technology, adopt and design the important part redundantly , in order to realize the trouble resumes by oneself; Utilize various kinds of test , control technology , exceed Cheng , one one hundred sheets of damages , interfering , cutting out ,etc. at the time of various kinds of accidents as production, carry on corresponding protection automatically.（6）. Control system miniaturization systematic miniaturization of numerical control benefit and combine the machine , electric device for an organic whole. Adopt the super large-scale integrated component , multi-layer printed circuit board mainly at present, adopt the three-dimensional installation method , make the electronic devices and components must use the high density to install, narrow systematic occupying the space on a larger scale. And utilize the new-type slim display of colored liquid crystal to substitute the traditional cathode ray tube, will make the operating system of numerical control miniaturize further. So can install it on the machine tool conveniently, benefit the operation of the numerical control lathe correctly even more.本文出自：Shigley J E. Mechanical Engineering Design. New York: McGraw-Hill, 1998数控技术1、当前世界NC机床的研究现状世界各国对数控机床、加工中心以至FMS、CIMS等各种新技术的研究与发展进程，是与世界经济形势紧密相连的。机床工业有世界经济相互促进和发展，进入21世界知识机警时代，人们的知识所起的作用更加突出，而机床工业作为机器制造业的基础，其重点地位与战略意义也更加明显。在19911994年间，世界经济衰退，昂贵的FMS，CIMS降温，19952000年间，世界经济在低速增长，根据当前世界市场各方面用户为提高生产率对NC机床的要求以及世界四大国际机床展（欧洲的EMO、美国的IMTS、日本的JIMTOF、中国的CIMT）上展品的分析，当前世界NC机床的技术研究主要有以下几点：（1）、更加重视新技术和创新在世界范围内，对新工艺、新材料、新结构、新单元、新元件的研究开发工作正在大力开展，如新的刀具材料、新的主轴结构、高速电主轴、高速直线电机等的开发研究。以加工工艺的改进创新为基础，为加工超硬、难切削材料及特殊复合材料及复杂零件、不规则曲面等在不断研究开发新机种。（2）、提高机床加工的精度和研究为了提高加工中心的加工精度，不断提高机床的刚度、减少振动，消除热变形，降低噪声，提高NC机床的定位精度、重复精度、工作可靠性、稳定性、精度保持性，世界很多国家都在进行机床热误差、机床运动及负载变形误差的软件补偿技术研究，并采取精度补偿、软件补偿等措施加以改善，有的已经可以使此类误差消除60%。并在不断开发精细加工，纳米加工。（3）、提高机床加工生产率的研究世界NC机床、加工中心及相应的高速点主轴、直线电机、测量系统、NC系统的开发，均以提高生产率为前提。（4）、许多国家都已经开始对数控系统的智能化、开放化、网络化研究A、数控系统的智能化的研究主要表现在：为追求加工效率和加工质量的智能化，对加工过程的自适应控制，工艺参数自动生成进行研究；为提高驱动性能及使用连接方便的智能化，对反馈控制、电机参数的自适应运算、自动识别负载自动选定模型、自整定等进行研究；还有智能化的自动编程、智能化的人机界面、智能诊断、智能监控等方面的研究。B、数控系统开放化研究主要表现在：数控系统的开发在统一的运行平台上，面向机床厂家和最终拥护，通过改变、增加或剪裁结构对象（数控对象），形成系列化，并可方便地将用户的特殊应用和技术诀窍集成到控制系统中，快速实现不同品种、不同档次的开放式数控系统，形成具有鲜明个性的名牌产品。目前开放式数控系统的体系结构规范、通行规范、配置规范、运行平台、数控系统功能库以及数控系统功能软件开发工具等是当前研究的核心。C、数控装备的网络化将极大地满足生产线制造系统、制造企业对信息集成的需求，也是实现新的制造模式的基础单元。2、加工中心的分类（1）按主轴加工时的空间位置分类有：卧式和立式加工中心。卧式加工中心，是指主轴轴线水平设置的加工中心。卧式加工中心一般具有35个运动坐标轴，常见的是三个直线运动坐标轴和一个回转运动坐标轴（回转工作台），它能在工件一次装夹完成除安装面和顶面以外的其余4个面的加工，最适合加工箱体类工件。它与力式加工中心相比，结构复杂，占地面积大，质量大，价格高
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