多槽同步电火花线切割机床的研制
发布时间：2018-08-30 20:15
【摘要】：随着汽车工业的飞速发展,汽车轮胎模具的需求量也急剧增加。在轮胎模具制造中,根据型号、规格的不同,轮胎模具需要切割为多份且不等。现有的轮胎模具切割制造工艺是采用普通线切割方式一条条槽顺序切割,不仅内应力分布不均匀,产生变形,而且加工效率极低,切割时间长达7-15天。因此,研制高效、低成本的新型切槽设备显得非常迫切。本论文是针对轮胎模具分块切割加工的效率问题,在单槽、双槽电火花线切割机床的基础上,设计了一种用于轮胎模具或者大型环状零件的专用多槽线切割机床。加工时卷丝筒、工作台(工件)位置不变,多个丝架独立运动,实现一根丝对一个工件在多个位置同步进行电火花线切割加工,不仅成倍地提高生产效率,而且使工件的内应力分布更均匀,变形更小。同时可以在上好丝后再安装工件,有利于操作,并能方便地偏转丝架角度进行非对称加工,这是一种高效、优质的环形零件分块切割新技术,也是电火花线切割加工技术的进一步拓展。在结构设计上,本机床通过特殊的拓扑结构,巧妙的布置导轮组,构成了四段方向运行的电极丝加工区段,可连续、同步切割出多条窄槽。在走丝系统上,设计了电极丝恒张紧机构,保证电极丝的张紧状态。针对不同厚度和高度的环形工件,设计了可移动的夹具机构和可调高度以及角度的丝架,实现了环状零件多槽同步对称切割及不对称切割,大大提高了线切割工序的效率,为今后研制加工更多环形零件的机床提供了思路。在控制系统方案设计中,针对多槽机床同步切割的特殊性,为了避免脉冲电源空载时步进电机发生失步,限制取样电路的输出电压,从而无法实现步进电机的变速进给,课题提出了以dsPIC6010A单片机作为控制系统,具有快进、工进、加工回退和短路回退等动作控制功能,解决了普通高速走丝电火花线切割机床只能匀速进给的缺陷,极大的提高了切割效率。本课题的特色和创新在于：克服了现有切割加工轮胎模具的不足点,实现了一根丝可同时切割多条窄槽,不但提高了线切割加工效率,而且加工工件内应力分布更加均匀,变形更小,从而提高工件质量,这是一种高效优质、低成本的新机床技术方案。它的研制成功将对提高我国特种加工工艺水平,促进我国制造业高新技术的发展,尤其是对汽车轮胎模具行业提高加工效率和增强市场竞争力有着重要的理论和实际意义。
[Abstract]:With the rapid development of automobile industry, the demand of automobile tire mould also increases sharply. In the manufacture of tire mould, the tire mould needs to be cut into many parts according to the model and specifications. The existing cutting and manufacturing technology of tire mould is to use common wire cutting method to cut one slot in sequence. Not only internal stress distribution is uneven and deformation is produced, but also the processing efficiency is very low, and the cutting time is up to 7-15 days. Therefore, it is very urgent to develop a new type of slot cutting equipment with high efficiency and low cost. This paper is aimed at the efficiency of cutting tire die by block cutting. Based on single slot and double slot WEDM machine tool, a special multi-slot WEDM machine tool is designed for tire mould or large circular parts. In the process of machining, the position of the winding wire drum, the worktable (workpiece) is invariable, and the multi-wire frame moves independently, so that the WEDM of one wire to a workpiece in multiple positions can be carried out synchronously, which not only improves the production efficiency exponentially, but also increases the production efficiency of the workpiece. Moreover, the internal stress distribution of the workpiece is more uniform and the deformation is smaller. At the same time, the workpiece can be installed after the best wire, which is advantageous to operation, and can be easily processed asymmetrically by deflecting the angle of the wire rack. This is a new technology of cutting the ring parts in blocks with high efficiency and high quality. It is also the further development of WEDM technology. In the structure design, the machine tool can cut many narrow grooves continuously and synchronously through special topological structure and ingenious arrangement of guide wheel group, which forms the processing zone section of electrode wire running in four sections. A constant tensioning mechanism is designed to ensure the tensioning state of the wire. For the annular workpiece with different thickness and height, the movable fixture mechanism and the wire frame with adjustable height and angle are designed. The synchronous symmetrical cutting and asymmetric cutting of ring parts with multiple grooves are realized, and the efficiency of wire cutting process is greatly improved. It provides ideas for developing and machining more ring parts machine tools in the future. In the design of control system, in view of the particularity of synchronous cutting of multi-slot machine tool, in order to avoid the step motor losing step when the pulse power supply is no load, and limit the output voltage of sampling circuit, it is impossible to realize the variable speed feed of step motor. In this paper, the dsPIC6010A single chip microcomputer is used as the control system, which has the function of fast moving, working back, machining back and short circuit back, and solves the defect that the ordinary high speed wire WEDM machine can only feed at uniform speed. The cutting efficiency is greatly improved. The characteristic and innovation of this subject lies in: overcoming the deficiency point of the existing cutting and processing tire mould, realizing a single wire can cut several narrow grooves at the same time, not only improving the efficiency of wire cutting, but also distributing the stress in the machining workpiece more evenly. Small deformation, thus improving the quality of the workpiece, this is a high-efficiency, quality, low-cost new machine tool technology. The success of its development will be of great theoretical and practical significance to improve the level of special processing technology and promote the development of high and new technology in our manufacturing industry, especially to improve the processing efficiency and enhance the market competitiveness of automobile tire mould industry.
【学位授予单位】：广东工业大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG661
本文编号：2214170
[Abstract]:With the rapid development of automobile industry, the demand of automobile tire mould also increases sharply. In the manufacture of tire mould, the tire mould needs to be cut into many parts according to the model and specifications. The existing cutting and manufacturing technology of tire mould is to use common wire cutting method to cut one slot in sequence. Not only internal stress distribution is uneven and deformation is produced, but also the processing efficiency is very low, and the cutting time is up to 7-15 days. Therefore, it is very urgent to develop a new type of slot cutting equipment with high efficiency and low cost. This paper is aimed at the efficiency of cutting tire die by block cutting. Based on single slot and double slot WEDM machine tool, a special multi-slot WEDM machine tool is designed for tire mould or large circular parts. In the process of machining, the position of the winding wire drum, the worktable (workpiece) is invariable, and the multi-wire frame moves independently, so that the WEDM of one wire to a workpiece in multiple positions can be carried out synchronously, which not only improves the production efficiency exponentially, but also increases the production efficiency of the workpiece. Moreover, the internal stress distribution of the workpiece is more uniform and the deformation is smaller. At the same time, the workpiece can be installed after the best wire, which is advantageous to operation, and can be easily processed asymmetrically by deflecting the angle of the wire rack. This is a new technology of cutting the ring parts in blocks with high efficiency and high quality. It is also the further development of WEDM technology. In the structure design, the machine tool can cut many narrow grooves continuously and synchronously through special topological structure and ingenious arrangement of guide wheel group, which forms the processing zone section of electrode wire running in four sections. A constant tensioning mechanism is designed to ensure the tensioning state of the wire. For the annular workpiece with different thickness and height, the movable fixture mechanism and the wire frame with adjustable height and angle are designed. The synchronous symmetrical cutting and asymmetric cutting of ring parts with multiple grooves are realized, and the efficiency of wire cutting process is greatly improved. It provides ideas for developing and machining more ring parts machine tools in the future. In the design of control system, in view of the particularity of synchronous cutting of multi-slot machine tool, in order to avoid the step motor losing step when the pulse power supply is no load, and limit the output voltage of sampling circuit, it is impossible to realize the variable speed feed of step motor. In this paper, the dsPIC6010A single chip microcomputer is used as the control system, which has the function of fast moving, working back, machining back and short circuit back, and solves the defect that the ordinary high speed wire WEDM machine can only feed at uniform speed. The cutting efficiency is greatly improved. The characteristic and innovation of this subject lies in: overcoming the deficiency point of the existing cutting and processing tire mould, realizing a single wire can cut several narrow grooves at the same time, not only improving the efficiency of wire cutting, but also distributing the stress in the machining workpiece more evenly. Small deformation, thus improving the quality of the workpiece, this is a high-efficiency, quality, low-cost new machine tool technology. The success of its development will be of great theoretical and practical significance to improve the level of special processing technology and promote the development of high and new technology in our manufacturing industry, especially to improve the processing efficiency and enhance the market competitiveness of automobile tire mould industry.
【学位授予单位】：广东工业大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG661
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