基于模块化的大型动梁式复合型立车设计与应用

Design and application of a large moving-beam composite vertical lathes based on modularity

  • 摘要: 针对目前国产大型数控立式车床加工方面精度不高、加工复杂零件效率低下、轴向尺寸相差较大的问题,研发设计了一种ϕ1 600 mm规格的大型动梁式车铣复合数控立式车床。基于数控立式车床在模块化及多功能方面的潜在能力,深度剖析其在车铣复合方面的结构设计,采用模块化及数字化设计技术,设计出包括高精度主轴结构和横梁多档定位锁紧精度保持性等关键技术的研究情况,对机床的主机结构重新进行规划布局。该机床主要由底座、立柱、横梁、滑枕、主轴、刀库、三种轴驱动机构及两组驱动变速箱单元,共11个模块组成。借助有限元分析软件,在相同约束及切削条件下,模拟真实极限工况,进行仿真分析,对比新、老结构的静态参数,结表明,两轴方向刚性提升15%以上,主要部位形变量减少10%;结合切削等测试手段,验证技术指标两轴定位精度实测值达0.012 mm,高于进口设备,优于设定指标;结合应用效果,验证了复合型机床在加工过程中的效率提升显著,证明了本结构设计的正确性,为复合型车床的发展提供理论支撑与实践指导。

     

    Abstract: To address the issues of low machining accuracy, inefficient processing of complex parts, and significant variations in axial dimensions in domestic large-scale CNC vertical lathes, a ϕ1 600 mm moving-beam turning-milling compound CNC vertical lathes was developed. The structural design for turning-milling compound machining was optimized through modular and digital design technologies. Key technical research was conducted on high-precision spindle structures and multi-gear positioning accuracy retention for the crossbeam, leading to a reconfiguration of the machine's main structure. The lathe comprises 11 modules, including the base, column, crossbeam, ram, spindle, tool magazine, three sets of axis drive mechanisms, and two drive gearbox units. Finite element analysis was performed under identical constraints and cutting conditions to simulate extreme working conditions. Comparative static analysis between the new and old structures indicates that rigidity in both axial directions increases by over 15%, while deformation of main components decreases by 10%. Cutting tests confirm that the two-axis positioning accuracy reaches 0.012 mm, surpassing imported equipment and exceeding specified indicators. Application results demonstrate that the compound machine tool significantly improves processing efficiency, validating the structural design and providing theoretical and practical guidance for compound lathe development.

     

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