外文翻譯--用于提高大批量零件生產(chǎn)率的五面加工中心

1、<p><b>　　中文2650字</b></p><p><b>　　畢業(yè)設(shè)計英文翻譯</b></p><p>　　課 題 名 稱： </p><p>　　學(xué) 生 姓 名： </p&g

2、t;<p>　　指 導(dǎo) 教 師： </p><p>　　所 在 系 部： </p><p>　　專 業(yè) 名 稱： </p><p>　　Five-Face Machining Center To

3、Boost Productivity of Large Parts</p><p>　　Hideo Tamon</p><p><b>　　Manager</b></p><p>　　Machining Section , Manufacturing Dept</p><p>　　1.Introductio

4、n</p><p>　　Meeting increasingly diverse machining needs and making effective use of a limited supply of personnel and available space are among the most important goals for machine tool manufacturers , and k

5、ey considerations in finding ways to achieve them are “productivity” and “accuracy.”</p><p>　　To achieve higher machining accuracy and productivity, SNK’s Shinodayama Work has been continuing to modernize it

6、s production facilities and improve the production environment. As of the early 1960s,there were a total of 310 machine tools at Shinedayama Works, but the have now been replaced by only 70 highly productive machines. Gu

7、ided consistently by top management’s philosophy centered on “pursuit of automation ” and “functional improvement,” Shinodayama Works has been working to increase prod</p><p>　　Over the period of ten years f

8、rom 1990 all factory buildings were modified into temperature-controlled factories so as to ensure the consistent accuracy of the machining and the assembly (including unit assembly) processes by stabilizing machine and

9、work piece accuracy.</p><p>　　As a result, the machining capacity of Shinodayama Works became larger than necessary to machine large parts to be used in SNK products; it became large enough to machine other

10、parts under contract for other companies. </p><p>　　This article will introduce to the readers the advantages of the five-face machining center in terms of productivity. These advantages will be demonstrated

11、 in a discussion of the machining of a turbine casing of a large generator, which is of a cylindrical assembly of complex configuration. The turbine casing is machined with SNK’s newly developed HF-8M Multi-Center, a lar

12、ge, high-performance, precision five-face machining center installed at Shinodayama Works.</p><p>　　2.Configuration of the Work piece (Turbine Casing)</p><p>　　As shown in figure 1,the turbine c

13、asing to be machine on the HF-8M is of split cylinder configuration. The dimensions of the turbine casing are also shown in Figure 1.The casing is made of steel and weighs about 70 tons. The machining processes of this w

14、ork piece can be summarized as follows:</p><p>　　Process A: Machining of mating surfaces and drilling of screw and bolt holes. </p><p>　　Process B: Machining of outside flange surfaces and drill

15、ing of holes</p><p>　　Process C: ID machining</p><p>　　Process D: Machining of flange surface and drilling of fastening screw holes</p><p>　　3.Comparison Between Five-face Machining

16、 and Conventional Machining</p><p>　　For the processes A to D mentioned in Section 2, the machine tools required for the machining method using a five-face machining center and the machining method using con

17、ventional machine tools were compared (Table 1).</p><p>　　As shown in the table, use of a five-face machining center is advantageous in terms of production control and work piece machining accuracy because t

18、he movement of the work piece from machine to machine and setup changes (including alignment) that would be required for different machines in the conventional machining method can be minimized by using a five-face machi

19、ning center.</p><p>　　4.Function of HF-8M Multi-Center Capable of Performing All Machining Operations</p><p>　　This section describes the functions and characteristics of the HF-8M that is capab

20、le of performing all machining operations for a turbine casing, along with some newly devised machining methods.</p><p>　　1) Using various attachments and automation devices</p><p>　　The HF-8M a

21、t SNK is equipped with a seven-attachment automatic attachment changer (ACC) (Photo) and a 100-tool automatic too changer (ATC). By allowing the machine to change attachments and cutting tools automatically as necessary,

22、 the range of machining operations that can be carried out in one setup can be expanded, and efficiency improvement and automation can be achieve.</p><p>　　The machining of the turbine casing required four t

23、ypes of attachments including a newly developed attachment:</p><p>　?。瓵ngular attachment </p><p>　　．Extension attachment</p><p>　?。甎niversal attachment (with a calibration system)&l

24、t;/p><p>　?。甋ide cutter attachment (newly developed) </p><p>　　2) Universal attachment + arbitrary-plane machining function</p><p>　　As shown in Figure 1, the work piece has many fla

25、nge surfaces and holes protruding beyond the outside surface of the casing. They are arranged radically from the central axis of the casing, are inclined from the axis direction and are off the radial axes.</p>&l

26、t;p>　　The conventional machining method is to use an inclined attachment mounted on a horizontal machining center while the work piece is rotated and positioned on a rotary table.</p><p>　　With the HF-8M,

27、 a universal attachment (with a calibration system) was used in combination with the arbitrary-plane machining function (Photo 3)</p><p>　　The arbitrary-plane machining function allows arbitrary program coor

28、dinate axes (coordinate axes relative to which rotation, inclination and shift are defined arbitrarily to be defined for the work piece coordinate system. If machining operations are programmed on coordinate planes relat

29、ive to the coordinate axes thus defined, the coordinates are automatically converted to machine coordinates. This is a very useful function used mainly for simultaneous three-axis machining carried out using a un</p&g

30、t;<p>　　This function has made the milling of outside flange surfaces and the drilling of holes possible without changing equipment or making setup changes.</p><p>　　Setup-and alignment-related factor

31、s contributing to inaccuracies inherent in machining operations performed on a horizontal machining center, such as deflection of the work piece set up on the table and deviation of the central axis of rotary table rotat

32、ion, have also been eliminated. Since a five-face machining center permits consistently accurate positioning within the machining envelope, accuracy of machined parts can be enhanced.</p><p>　　3) Finish cont

33、ouring of large holes with a side cutter</p><p>　　Another challenge in the machining of the turbine casing is the machining of inside diameter (ID) grooves. The turbine casing has many ID ring grooves that n

34、eed to be machined.</p><p>　　The convention machining method is to assemble the two halves of the split casing and perform ID machining of the assembled split casing on a large turning lathe.</p><

35、p>　　On the HF-8M, each of the two halves of the split casing was set up on the table (with the mating surfacing upward) as shown in Photo 5, and finish contouring was carried out with a combination of a side cutter a

36、ttachment and a high-performance side cutter.</p><p>　　To achieve high roundness accuracy, the following measures were taken:</p><p>　　(1) Five adjustment for high machine accuracy</p>&l

37、t;p>　　The maximum inside diameter of the work piece is about 3,500 mm, and its roundness tolerance is 0.05 mm.</p><p>　　When performing ID machining on a large machine tool, it is very difficult to achiev

38、e a roundness of 0.05 mm on an inside diameter exceeding 3,000 mm. Prior to machining, we inspected the accuracy of the machine and adjusted the positioning accuracy of X-Y Y-Z and X-Z planes. We also fine-adjusted round

39、ness with a DBB* system to enhance machine accuracy. As a result, we were able to achieve a post-machining roundness of 0.04 mm, which was within the tolerance range. </p><p>　　(2) Development of small-head

40、type side cutter attachment and high-performance side cutter.</p><p>　　Circular machining with a side cutter is not advantageous if the goal is high-speed machining. This is because cutter diameter, groove c

41、urvature and groove configuration are restricted by the size and length of the attachment head (spindle unit). To realize high-speed machining, therefore, a short attachment with a small head designed specifically for si

42、de cutter applications was developed, and a small-diameter side cutter was mounted on the attachment spindle.</p><p>　　Use of a side cutter for finishing is not advantageous over turning in terms of machinin

43、g time and surface finish quality. In cooperation with a cutting tool manufacturer, therefore SNK developed, through a series of cutting tests, high-performance cutters capable of meeting the surface finish requirements.

44、</p><p><b>　　5.summary</b></p><p>　　By performing all machining operations for a turbine casing for a large generator on an HF-8M Multi-Center, we have proved the feasibility of the

45、“effective use of a limited supply of personnel and available space” mentioned at the outset, and superiority of the five face machining center over conventional machine tools. The results obtained can be summarized as f

46、ollows:</p><p>　　(1) The need to move a heavy work piece from machine to machine has been eliminated, and lead time losses have been reduced.</p><p>　　(2) By improving machine tool functions and

47、 capabilities, machining processes have been streamlined and minimized so as to reduce man-hours required for setup changes and alignment and to dramatically increase the metal removal rate.**</p><p>　　(3) B

48、ecause of the stability of the setups, the five-axis machining method is superior over conventional method in terms of machining accuracy.</p><p>　　* Double Ball Bar (DBB) System: an instrument for measuring

49、 the motion accuracy of a machine.</p><p>　　** Metal removal rate: the percentage of cutting time in total machining time.</p><p>　　6.Closing Remarks</p><p>　　I believe that the mac

50、hining of the generator turbine casing reported in this article has clearly shown the importance of machine capability and of streamlining and integration of machine tools. If a conventions machining approach were taken,

51、 the machining operations reported here would require at least three large machine tools and considerable floor space. I do not think there are many companies that own such facilities.</p><p>　　In the early

52、1960s,more than 300 machine tools used to clutter SNK’s factories. Those machines have now been replaced by a minimum number of multifunction machines that can be kept in full operation, including the latest models of fi

53、ve-face machining centers. With these facilities, productivity can be increased and more effective use of infrastructure can be made by increasing unmanned operation time and high-speed high-federate machining. </p>

54、;<p>　　用于提高大批量零件生產(chǎn)率的五面加工中心</p><p>　　Hideo Tamon</p><p><b>　　經(jīng)理</b></p><p><b>　　制造部門，加工部分</b></p><p><b>　　1．引言</b></p>

55、<p>　　對于機(jī)床制造商而言，滿足逐漸增長的不同的加工要求和有效地利用有限的個人和可用空間是最重要的目標(biāo)。完成這個目標(biāo)的關(guān)鍵是“生產(chǎn)率”與“精度”。</p><p>　　為達(dá)到更高的加工生產(chǎn)率與精度，SNK’s Shinodayama工廠一直致力于提高生產(chǎn)設(shè)備的現(xiàn)代化和提高生產(chǎn)環(huán)境。</p><p>　　早在二十世紀(jì)六十年代，在SNK’s Shinodayama工廠總共有三百一

56、十臺相當(dāng)高產(chǎn)量的機(jī)床。引導(dǎo)于“追求自動化”和“提高功能”的高層管理的原則，SNK’s Shinodayama工廠一直致力于提高生產(chǎn)率和使設(shè)備更合理。在這個過程中，對于提高生產(chǎn)率最有幫助的一個唯一動作是在一個結(jié)構(gòu)中引進(jìn)用于加工五面工件的機(jī)床。</p><p>　　從1990開始的十年期間內(nèi)，所有工廠的建筑物已經(jīng)修改成溫控式。他們通過平穩(wěn)機(jī)器和提高工件的精度來滿足加工和裝配(包括單元裝配)過程的持續(xù)的精度。</

57、p><p>　　總之，SNK’s Shinodayama工廠的加工能力足夠大可以去加工用于SNK產(chǎn)品中的大批量零件，也可以在與其他公司簽訂合同的情況下加工其他零件。</p><p>　　這篇文章將介紹給出讀者的是按照生產(chǎn)率來說，五面加工中心的優(yōu)勢。而這些優(yōu)勢將在對大型渦輪機(jī)發(fā)電機(jī)鑄件的加工中得到證明。這臺大型渦輪機(jī)發(fā)電機(jī)鑄件是復(fù)雜結(jié)構(gòu)的圓柱形裝配件。渦輪機(jī)鑄件是在SNK最新發(fā)明的HF-8M多功

58、能中心上加工而成的。這個被安裝在SNK’s Shinodayama工廠多功能中心是一個大型的高性能的精密的五面加工中心。</p><p><b>　　2.工件的結(jié)構(gòu)</b></p><p>　　如圖一所示，在HF-8M多功能中心上加工的渦輪機(jī)鑄件是一個圓柱形構(gòu)造的分離結(jié)構(gòu)。這個渦輪機(jī)鑄件的尺寸也如圖所示。這個鑄件有大約七十噸鐵制造而成的. 對這個鑄件的加工步驟總結(jié)如下

59、：</p><p>　　步驟A：對配合表面進(jìn)行加工與鉆螺紋孔和螺釘孔</p><p>　　步驟B：加工外凸緣表面和鉆孔</p><p><b>　　步驟C：內(nèi)徑加工</b></p><p>　　步驟D：加工凸緣表面和鉆連接螺紋孔</p><p>　　3.五面加工與傳統(tǒng)加工的比較</p>

60、<p>　　在第二部分提到的A到D的加工步驟中，我們對一個五面加工中心與傳統(tǒng)的機(jī)床使用的加工方法進(jìn)行了比較。如表格所示，按照生產(chǎn)控制與工件加工精度來說，使用五面加工中心是具有優(yōu)勢的。因為工件在機(jī)床之間的移動與結(jié)構(gòu)的改變(包括校準(zhǔn))能夠通過使用一個五面加工中心來最小化。而這些在傳統(tǒng)方法中需要在不同的機(jī)器之間得到實現(xiàn)。</p><p>　　4.能夠完成所有加工操作的HF-8M多功能中心的功能</p

61、><p>　　這個部分描述的是的HF-8M功能與特點。對于渦輪機(jī)鑄件來說，它能完成所有的加工操作與一些最新發(fā)明的加工方法。</p><p>　　(1)使用不同的附件與自動化裝置 在SNK的HF-8M配備了一個有七個附件的自動化附件轉(zhuǎn)換裝置與一個帶有一百刀的自動刀具轉(zhuǎn)換裝置。通過機(jī)床去自動改變附件與切削刀具是有必要的。這樣一來在一個結(jié)構(gòu)中被執(zhí)行的加工操作的范圍能夠被擴(kuò)大，并且能夠改善效率與完成自

62、動化。</p><p>　　渦輪機(jī)鑄件的加工需要四種類型的附件，包括一個最新發(fā)明的附件：</p><p><b>　　*角形附件</b></p><p><b>　　*擴(kuò)展附件</b></p><p>　　*通用附件（帶有校準(zhǔn)系統(tǒng)）</p><p>　　*側(cè)銑刀附件（最新發(fā)明

63、的）</p><p>　　(2)通用的附件帶有標(biāo)準(zhǔn)程序加工的功能 如圖一所示，工件有很多突出鑄件外表面的凸緣表面與孔。它們從鑄件的軸中心被輻射狀地排列。它們從軸的方向被傾斜地放置并且遠(yuǎn)離輻射狀的斧。傳統(tǒng)的加工方法是當(dāng)工件在一個旋轉(zhuǎn)臺上旋轉(zhuǎn)和定位時，使用一個承載于一個臥式加工中心上的傾斜附件。HF-8M應(yīng)用了結(jié)合了靈活面的加工系統(tǒng)的通用的附件（帶有校準(zhǔn)系統(tǒng)）。對于工件協(xié)調(diào)系統(tǒng)來說，這個靈活的面加工功能通過靈活程序協(xié)

64、調(diào)各個軸而被定義了。（與旋轉(zhuǎn)、傾斜和移動相關(guān)的協(xié)調(diào)軸被靈活定義了）。如果在校準(zhǔn)面上，我們對于被定義了的協(xié)調(diào)的軸的加工操作編制了程序，這個協(xié)調(diào)系統(tǒng)也自動地轉(zhuǎn)換到機(jī)床協(xié)調(diào)器上。這是一個非常有用的功能。它主要用于模擬被一個通用附件所執(zhí)行的三軸加工。當(dāng)這個功能被使用的時候，知道刀尖的位置是非常重要的。通過刀具準(zhǔn)確度的調(diào)整與使用一個有角度的系統(tǒng)，這個功能成為了可能。這個功能不需要改變設(shè)備后使結(jié)構(gòu)改變，可以銑外凸緣面和鉆盡可能多的孔。由于在臥式加工

65、中心中與生俱來加工操作的不精確而帶來的結(jié)構(gòu)與相關(guān)的校準(zhǔn)因素已經(jīng)被消除了。譬如：工件擺放在工作臺上的缺陷與旋轉(zhuǎn)臺上旋轉(zhuǎn)裝置中心軸的分離。當(dāng)一個五面加工中心在加工范圍內(nèi)允許持</p><p>　　(3)用一個側(cè)銑刀工具完成大孔的輪廓加工 在加工渦輪機(jī)鑄件的另外一個挑戰(zhàn)是加工內(nèi)徑槽。這個渦輪機(jī)鑄件有很多需要加工的內(nèi)徑槽。傳統(tǒng)的加工方法是裝配兩個分離鑄件的一半部分并且在車床上對分配好的分離鑄件進(jìn)行內(nèi)徑加工。</p&

66、gt;<p>　　在HF-8M上，每個分成兩部分的分離鑄件被擺放在工作臺上（有一個面朝上的配合表面），如圖五所示，并且完成輪廓加工是由側(cè)銑刀附件與高性能的側(cè)銑刀切削工具所完成。</p><p>　　(1)高加工精度的調(diào)整 工件內(nèi)徑的最大尺寸是3500毫米，并且它的公差是0、05毫米。當(dāng)在一個大型機(jī)床上完成內(nèi)徑加工時在一個內(nèi)徑超過3000毫米的零件上很難達(dá)到0、05毫米的圓公差。在加工之前，我們假設(shè)加

67、工精度，然后調(diào)整X、Y、Z軸的定位精度，調(diào)整X-Y、Y-Z、X-Z面的尺寸。我們也使用雙球桿系統(tǒng)很好地調(diào)整圓度來提高加工精度。因此，我們能完成在0、04毫米公差范圍的定位加工的圓形。</p><p>　　(2)小頭型面切削附件與高性能面切削工具的發(fā)展 如果目標(biāo)是高速加工，帶有一個面切削工具的環(huán)行加工不是有利的。這是因為切削直徑，槽的彎曲與結(jié)構(gòu)受附件頭部尺寸與長度的限制（軸單元）。為了實現(xiàn)高速加工，我們發(fā)明了帶有一

68、個小頭的小的附件，為的是面切削的應(yīng)用。在整個車削中，按照加工時間與表面完成質(zhì)量來說，使用一個面切削工具來完成一個任務(wù)不是有利的。與一個切削刀具制造工具合作，因此，SNK通過一系列切削測試，發(fā)明了能滿足表面完成要求的高性能的切削刀具。</p><p><b>　　5．總論</b></p><p>　　通過在HF-8M上完成對一個大型渦輪機(jī)發(fā)電機(jī)鑄件所有的加工操作，我們已

69、經(jīng)證明了文章開頭所提到的有效使用有限的人力資源與可用空間的可能性。，并且證明了五面加工中心與傳統(tǒng)機(jī)床相比的優(yōu)越性。這些結(jié)果總結(jié)如下：</p><p>　　消除了在機(jī)床之間移動大批量零件的必要性與減少了前期準(zhǔn)備時間。</p><p>　　通過提高機(jī)床的功能與能力，加工過程已經(jīng)被融合與最小化了，這樣可以來減少用于結(jié)構(gòu)改變和校準(zhǔn)所需的人工時間并且根本地增加提到的置換速度。</p>

70、<p>　　由于結(jié)構(gòu)的穩(wěn)定性，按照加工精度來說，五軸加工方法是優(yōu)于傳統(tǒng)方法的。</p><p><b>　　6．結(jié)束語</b></p><p>　　我相信在這篇文章中提到的渦輪機(jī)發(fā)電機(jī)鑄件的加工已經(jīng)顯示了加工能力與線性綜合機(jī)床的重要性。如果一個傳統(tǒng)的加工方法被采用，文章中提到的加工操作至少需要三臺大型車床與相當(dāng)大的場地。我不認(rèn)為我們有很多擁有如此設(shè)施的工廠。