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附录A6 PLANER6.1 DEFINITIONA planer is a machine tool which is used for machining flat metallic surfaces by means of single-point cutting tool. The job (fitted on its table) moves against a fixed cutting tool. This process of machining is called planning. The table travels slower during the cutting stroke and faster during the reverse stroke.6.2 DIFFERENCE BETWEEN SHAPER, SLOTTER AND PLANERAll the three machine tools generally machine flat metallic surfaces by means of single-point cutting tools. The main difference between a shaper, a slotter and a planer are given in Table TYPES OF PLANING MACHINESThere are two types of planers in general use, namely, the double-column planer and the openside planer.6.3.1 Double-Column PlanerThe double-column planer has two columns which support the crossrail and house the elevating screw and controls for the machine (Fig. 6.1).图 Openside PlanerAn openside planer has only one column or housing to support the crossrail and toolheads. This change in design makes this planer suitable to handle irregular shaped workpieces, which could extend outwards over the other side of the table. The rest of the parts of an openside planer are the same as those of a double-column planer.此处有表格6.16.4 PLANER SIZEThe size of the planer is determined by the maximum length of the table stroke, width of the table, and the maximum gap between the table and the housing or the crossrail or the height of the work which can pass through the housing and underneath the crossrail. An openside planer can generally handle a job of a large size than its height. Its size is given in terms of its crossrail height and length of table stroke.6.5 BASIC PARTS OF A PLANERThe basic parts of a planer are bed, column, crossrail, table, tool head and table drive mechanism (Figs. 6.1 and 6.2).The basic parts of a double-column planer are the same as those of an openside planer.6.5.1 BedThe bed of a planer (Figs.6.1 and 6.2) is extremely heavy and made by a rigid casting. The bed supports the column/columns and all moving parts of the machine. It has accurately finished bed-ways on which the table slides.6.5.2 ColumnA double-column planer has two vertical columns, one on each side of the bed (Fig.6.1). They support the crossrail and also house the elevating screws and controls for the machine. An openside planer has only one column.6.5.3 CrossrailThe crossrail is supported on the columns (Fig.6.1) and it carries the saddle and the tool head. It is a rigid casting and provides guides for transverse travel of the saddle. The feed rod screw for controlling the movement of the cutting tool is also located in the crossrail.The crossrail can be adjusted vertically by means of vertical screws (Fig.6.1) housed in each of the column. The crossrail when clamped should be parallel to the table, because the accuracy of the surface depends upon the accuracy of the movement of the cutting tool. Figure 6.3 shows the position of the crossrail and the table when they are parallel (in full lines, position 1) and also when they are not parallel(in dotted lines, position 2).To check parallelism, hold a dial indicator in the tool post with its point touching the table. Now move the tool head crosswise. No change in the reading of the dialindicator means that the crossrail and the table are parallel. A change in reading means that the crossrail and the table are not parallel to each other.6.5.4 TableThe planer table is in the form of a thick plate (Figs.6.1and 6.2).It is machined with precision. The table travels on bed-ways which are also machined with precision. The table has T-slots for fixing the workpieces on it with the help of T-bolts. It also has accurately reamed noles for locating stops. These stops actuate the reverse lever and hence reverse the motion of the table.T-slots as well as holes should be kept free from nicks and burrs. he shanks of the stops should never be forced into the holes with a hammer as this will result in the surface of the table getting upset and table accuracy destroyed.6.5.5 Tool HeadThe tool head or head of a planer is similar to that of a shaper, both in construction and in operation (Fig.6.1and6.2).The tool is first inserted in the slot with packings and then tightened. The tool head is moved by means of a feed screw. It can also be swiveled for making angular cuts. It can be set over in either direction to provide tool clearance, while making vertical or angular cuts.6.6 TABLE DRIVE MECHANISMSThe table drive of a planer can be obtained by rack and spur gears, spiral rack and worm wheel, crank arrangements and hydraulic transmission.6.6.1 Rack and Spur Gear Table DriveThe basic diagram of a rack and spur gear table drive is given in Fig.6.4.This table consists of a compound gear train with two intermediate compound gears(1st intermediate gear and 2nd intermediate gear).The driving pinion is situated on one end of the gear train while the driven bull gear is situated at the other end. This bull gear drives the rack which is fitted at the bottom of the table. Hence the table moves. The pinion gets its drive from the electric motor through a belt drive. The cutting stroke is at a slower speed than the return stroke. The quick return of the table is achieved by means of adjustable stops on the sides of the table. These stops come in contact with a level at the end of each cutting stroke and engage high speed gears in the driving train of gears.此处图 Rack and Worm Gear DriveIn this method the rack on the underside of the planer table is driven by a worm gear. The axis of the shaft of the worm gear is at an angle to the centerline of the table. The rest of the drive is similar to that already explained in Section .6.3 Hydraulic DriveIn this system the table of a planer gets its reciprocating motion from a piston which moves to and fro with hydraulic power. Oil is used as a working fluid and the hydraulic pressure is generated by a variable-delivery electric pump. The speed of the piston is changed by adjusting the amount of oil delivered by the pump.A schematic diagram of a hydraulic drive is given in Fig.6.5.Oil from the pump flows through port B in the valve through discharge line E to the cylinder. Hence the piston is moved to the left. When the table reaches the end of its stroke, a dog or trip moves the valve to the right so that valve ports A and B come in alignment with the lines D and S. In this position the piston moves to the right. The oil in the head end of the cylinder returns through lines S and valve port B to the oil reservoir.6.7 SPEEDS AND FEEDS IN PLANINGSpeeds of cutting metals on a planning machine and feeds of the tool or the depths of cut, are very important for all operation. The conditions vary from shop to shop, and therefore, the values of speeds and feeds cannot be exact. Table 6.2 gives the values of planning speeds and feeds for high-speed steel tools. These values can act as a guide for the selection of speeds and feeds for planning different metals.此处表6.2 表6.3Higher speeds with finer feeds are possible on a planer for tungsten-carbide-tipped tools. The speeds can increase say up to 50-70 m/min. Table 6.3 gives the speeds and feeds for planning with tungsten-carbide-tipped tools.6.8 PLANER TOOLSCutting tools used on a planer (Fig.6.6) are similar in shape to those used on a lathe machine (Figs.8.1to 8.4), but are somewhat larger in size (see also Chapter 8).A planer machines flat surfaces while a lathe turns circular jobs. During the cutting operation, a lathe tool springs away from the work when it is set at exact centre height, but in the case of a planer the tool digs into the work if its cutting edge is set in advance of the plane of support (Fig.6.7). This digging in of the tool is avoided by forging the cutting tool in such a way that its cutting edge is located behind the plane of support (Fig.6.7). The choice of tool depends upon the type of operation to be performed.此处图6.7Figure 6.8 shows a gang planer tool which is especially adapted for surfacing large castings. The tool holder holds a number of cutting tools set in such a way that each tool makes a light cut. Hence, a gang planer tool carries a feed and depth of cut much greater than that is possible with a single tool point. In this case there is a lesser tendency to break out at the end of the cut.此处图6.86.9 PLANER OPERATIONSThe workpice is clamped on to the planer table, before any planning operation starts. Clamping involves the use of such item as nuts, bolts, T-bolts, studs, washers, shims, step blocks, toe dogs, stops, strap clamps, C-clamps, etc.Any type of planer operation can be split in a suitable combination of the operations such as horizontal surfacing, planning at an angle and making a groove. These operations will be discussed in detail here.6.9.1 Planing Horizontal SurfacesTake, for example, a flanged cast-iron cover for horizontal planing (Fig.6.9). It is easy to clamp it on a planer table with the flanged side resting on the table. Now adjust the crossrail ti the correct height and set up the clamp screws.此处图6.9Place the roughing tool in the tool holder so that it is perpendicular to the work. The tool should be placed against two clamping bolts on the side to avoid the shifting of the tool due to lateral thrust. Tighten the cutting tool bolts so that the clamps are parallel with the clapper. (It should be kept in mind that clamps must not be tilted with reference to the clapper.)Position and set the stroke for machining surface A (Fig.6.9). Adjust the depth of cut so that the metal dose not break and leave a ragged edge at the end of the stroke .This condition is checked at the end of the first stroke. If the metal is teared off, reduce the depth of cut. The machining is completed in a number of cuts until about 0.5 mm metal is left for finishing. Prepare the work for finishing by breaking the front edge of the surface (the edge at which the finishing tool begins to cut) with a coarse double-cut file. This is done to remove the scale on the outer surface of the casting as the scale spoils the cutting edge of the finishing tool.The job should be finishing in more than one cut and also to the required size. It is better to use smaller cuts than one larger cut, as a larger cut may lead to an undersized job in case the cut is set deeper than required.Now turn the job so that the machined surface touches the table. No leveling of the job is required in this case. After clamping, machine this side. The surface will automatically come parallel to the first machined surface. The other surfaces are also planed in the same manner, after properly clamping the job in position.Care has to be taken while finishing thin castings. They are planed rough on all sides to remove the scale, which in turn also reduces the internal stresses developed during the cooling process of the casting. Thereafter, the casting is machined to the required dimensions. The vertical sides, or the sides at 90,are planed by using the tool feed.Planing at an Angle and Grooving Workpieces can be planed at an angle for inclined surfaces or dovetails or for V-shaped grooves, etc. The tool head assembly is swung around the centre axis, with respect to the saddle, to the required inclination or angle. The angle could be set with the help of the graduations on the circular part. It is recommended that the set inclination should be checked with the help of a dial-gauge as shown in Fig.6.10. This is done to take care of the error induced due to wear and tear of the graduated parts.To check the angle setting, mount the dial-indicator in the tool holder (Fig.6.10). Set the protractor at the desired angle and clamp it to the table of the planer. Take the reading when the dial is in contact with the protractor in position A. Now bring the tool holder down to position B and note the reading. If both the reading, (i.e. at A and B) are the same, then the setting is correct.Now clamp the job on the table and plane it. The surface will be planed at the desired angle by feeding the tool. A V-block job has been taken to explain the process of planing at an angle or groove planing on a planer (Fig.6.11). The horizontal and vertical sides of the V-block are planed as explained earlier in Section 6.9.1.此处图6.10The V-groove of the V-block is symmetrical about its axis and is at 45to it (Fig.6.11). Set the tool head at 45,according to the procedure explained earlier, clamp it in position by tightening the bolt A. Set the tool block at an angle less than 45and clamp it in position by tightening bolt B. The tool block is set at less than 45to prevent the cutting tool dragging over the planed surface on the return stroke.Clamp the V-block on the table so that the V-groove is on the top (Fig 6.11). The saddle should be moved into position for the first roughing cut on the V-block. Start the cut with the hand feed, moving downward. While doing this the saddle should remain in the same position on the crossrail .Complete the rough cutting and the finishing cut on one side of V.Now, without disturbing the tool setting, reverse the V-block (turn it by 180) and clamp it again. The projection of the V-block in the table slot aligns the job lengthwise. Now repeat the roughing cuts and the finishing cuts. The reversing of the job ensures machining at the same angle and alignment of the V with the centre axis of the tongue.此处图6.11Use of Jigs and Fixtures on a PlanerPlaning Curved Surfaces A concave surface could be planed on a planer with the help of a fixture. The fixture in this case consists of a radial arm pivoted on a bracket (Fig.6.12). The bracket is fixed on the cross member on the housing of the planer. The feed screw of the slide is removed and the slide is fastened to the radial arm.The cross feed causes the saddle to traverse the crossrail during the planing operation. At the same time the tool, which is being guided by the radial arm, planes a curved concave surface. The height of the cutting edge of the tool is determined by the angular position of the cross arm (Fig.6.12 position A and B). The locus of the different positions of the cutting edge of the tool is indicated by the arc AB. Hence, a similar surface is planed.此处图6.12Planing a Helix A helix with a long pitch may be difficult to plane on some milling machines but it can be easily cut on a planer with the help of a fixture (Fig.6.13). During this operation the work is mounted between the planer centres. The fixture consists of a clamp with a weight and inclined bar. Its upper end A is attached to the planer housing and the lower end B is fixed to the planer bed. The pitch of the helix depends upon the inclination of the inclined bar.The table with the clamp bar moves near the lower end of the inclined bar. As the clamp bar is being guided in the angular position, it gradually rises as the work turns clockwise through a small arc. Thus the cutting tool cuts a helix as shown in Figure 6.13.此处图6.13 附录B电刨6.1定义刨床是一种用于金属表面加工使其平坦所采用的单刃刀具的机床。在其表上安装一个固定的切割工具进行往复运动。这一加工过程称为刨。该表面在切割过程中运行较慢在反向进程中运行较快。6.2成型机、开槽和刨床的区别三个机床一般都是通过单点切削工具作用于金属表面使其平整。成型机、开槽和刨床的区别参见表6.16.3刨床的类型在一般使用当中,刨床通常分为两种类型即双柱刨床和部分开放刨床6.3.1双柱刨床双柱刨床是指有两列立柱,用以支撑横梁和稳定上升螺丝,控制机器的刨床(图6.1)6.3.2 Openside刨床一个openside刨床只有一列立柱支撑横木和工具头的稳定。这种设计上的变化适合于处理不规则形状的工件,可扩展到工作台外部的另一端。它其余的部分与双柱刨床相同。此处有表格6.16.4刨床尺寸该刨床的尺寸取决于行程表的最大长度,工作台的宽度,以及工作台和箱体、横梁之间的最大差距,或者是可以通过箱体和横梁下方产品的高度。一个openside刨床一般可以处理比它的高度高的零件。它的大小取决于横梁高度和工作台冲程的长度。6.5一个电刨基础件一个刨床的基本部分是床身、立柱、横梁、工作台、工具头和工作台驱动机制(图6.1和6.2)。双柱刨床的基本部分与openside刨床相同。6.5.1床身一个刨床(表6.1和6.2)的床身非常沉,用刚性铸件制成。该床身支撑单个或多个立柱和机器的所有运动部件。它按照床身轨道通过床身滑动准确地完成。6.5.2立柱一个双柱刨床有两个垂直立柱,床身没变各一个(图6.1)。他们支持的横梁,稳定上升螺丝,控制机器。一个openside刨床只有一个立柱。6.5.3横梁横梁由多个立柱支撑(图6.1),它承载着座板和工具头。这是一个钢性铸件,并为座板的横向移动提供指导。控制刀具移动的供料杆螺丝也被安装在横梁上。该横梁可以利用垂直螺丝(图6.1)在每个立柱上进行垂直方向的调整。当横梁钳紧时,应平行于工作台,因为表面的准确性取决于刀具运动时的准确性。图6.3显示了横梁的位置,它们平行时(全行,位置1)和不平行时(在虚线,位置2)工作台的情况。为了检查平行性,把握工具架上针盘指示表随着触碰工作台产生的点数。现在横向移动工具头。当针盘指示表读数没有变化时,意味着横梁和工作台是平行的。当读数变化时则意味着横梁和表是不平行于对方。6.5.4工作台刨床工作台是以板(表.6.1和6.2)的形式存在。它属于精密加工。工作台沿着车床轨道运行,这也是精密加工方法。工作台有用于帮助固定T型螺栓工件的T型槽。它也有准确用于定点的铰大孔。这些点启动换向手柄,因此改变了工作台的运转。T型槽以及孔应保持无缺口和毛刺。他不能强制与铁锤一起进入孔中,因为这将导致工作台表面混乱甚至直接被毁坏。6.5.5工具头在建造和运行中,工具头或刨床头类似于一个成型机(表6.1和6.2)。首先用工具把填料填入槽中,然后拧紧。工具头依靠给料螺旋运输机运行,也可以转进行角度切割。在进行垂直或角度切割时,为了提供工具的径向间隙,工具头可以在任意方向调整转换。6.6工作台驱动机制一个刨床的工作台靠齿条和直尺圆柱齿轮,螺旋齿条和蜗轮,曲柄轴布置和液体传动装置组成6.6.1齿条和齿轮工作台驱动齿条和蜗轮工作台驱动的基础线图见表6.4。该工作台由带有两个中型混合齿轮(第一和第二中型齿轮)的混合齿轮系列组成。驱动轴齿轮位于齿轮系列的一端,而驱动大驱动齿轮位于另一端。大齿轮驱动安装在工作台底部的齿条,从而使工作台移动。通过传送带的传送,电动机驱动轴齿轮。与返回行程相比,切闲程速度较慢。工作台的快速返回是依靠工作台另一端的调整点来实现的。这些点与同一水平的每个切闲程相联系并且使高速齿轮在齿轮驱动过程中能够咬合。此处图齿条和涡轮驱动在这种方法中,刨床工作台底部上的齿条靠涡轮驱动。涡轮轴的轴线是相对于工作台中心线的角度。该驱动器的其余部分与6.6.1节已经出现的解释相似。6.6.3液压传动在这个系统中刨床的工作台会利用活塞的来回移动与液压动力做往复运动。石油被当作工缀体来使用,液压则是靠变量传递电动泵产生。活塞的速度靠泵运送石油的调整量改变。液压传动原理图见表6.5。石油从泵流出通过端口B,在活口处通过排出线E到达气缸。因此,活塞移动到左边。当工作台到行程另一端时,a dog或流程移动活门到右侧,以便使阀口A和B与线D和S校直。在这个位置上活塞移动到右侧。石油在汽缸的顶部停止通过线S和阀门B返回到达油壶。6.7速度和进料器计划编制 在刨床上切割材料的速度和工具的供给或者切割的厚度对于整个造作至关重要。由于车间与车间的情况不同,因此速度和进料的数值不能精确。表6.2指出刨削加工速度的数值和高速钢化工具的供给。这些数值能够作为一个速度的选择性的指导和加工不同材料的供给。此处表6.2 表6.3用钨硬质合金工具的刨床可能会产生更高的速率和更精细的供给。速度可以提高到50-70m/min。表6.3给出了钨硬质合金工具的速度和加工的供给。6.8电刨工具刨床用的切割工具(表6.6)与用于车床机器的工具(表8.1到8.4)在形状上是相似的,但是尺寸稍大(也见于第8章)。车床轮流循环工作时刨床使表面变平。在切割操作运行过程中,当它设置中央精确高度时车床工具远离机件。至于刨床,如果它的切割边缘设置在支撑的刨子前面,则工具用于机件。该挖掘在工具上被位于支撑刨床后方的锻造型切割工具避免(表6.7).关于工具的选择取决于要执行的操作类型。此处图6.7图6.8显示了全套刨床工具特别适用于大型铸件表面。该工具持有人持有一定数量的刀具,并且对每个工具的轻型切割方式进行设置。因此,全套刨床工具带动的进料器和切割的厚度可能比单点工具完成的更好。在这种情况下,在切
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