This paper explores the impact of the new era environment on the innovation and application of machine tool manufacturing technology through the exploration of the third industrial revolution caused by many factors, and proposes a new prospect for the future development of machine tools.
In the 21st century, humanity officially entered the third industrial revolution era. As an important member of modern advanced manufacturing, the machine tool manufacturing industry is also advancing with the times and undergoing rapid changes.
Russian six-leg parallel machine tool
The intersection of energy and communication broke out in the industrial revolution
Following the first industrial revolution in which the steam engine was born and the release of cheap newspapers, and the invention of the telephone and telegraph and the second industrial revolution that triggered the convergence of the power industry, the intersection of Internet computer communication technology and new energy triggered the third industry. revolution. This revolution began in the early 21st century and was first triggered by Germany. It is expected that there will be a reserve period of 25-35 years from now on, and a new round of industrial revolution will continue to flourish.
It is not difficult to find that a large amount of resources are consumed; oil exploitation cannot keep up with the needs of developing countries such as China and India; air pollution caused by exhaust gas and soot emissions; water pollution of rivers, lakes and seas caused by discharge of waste water and harmful substances; The urbanization of moderation, the destruction of ecological environment caused by factors such as farmland occupation and deforestation; and the rising labor costs are the reasons for the third industrial revolution.
The impact of the third industrial revolution on machine tool manufacturing technology
Affected by the third industrial revolution, machine tool manufacturing technology has focused on energy conservation, environmental protection, green and other aspects of research and development, and high efficiency, high speed, high precision, etc. are always the goal pursued by the machine tool industry. The collection of these essences is a prelude to the machine revolution. We may wish to focus on these results.
Structural innovation of machine tools
Invention of parallel machine tools
At the end of the last century, G&L of the United States debuted the prototype of the parallel machine tool at the Chicago International Machine Tool Show. It is a six-legged measurement platform, and the machine tool has evolved from a traditional C-type drive chain structure to a parallel motion.
The so-called parallel machine tool is based on the spatial parallel mechanism, replacing some hardware with numerical control software, replacing some mechanical devices with electronic devices and components, and quickly changing the relative position of the tool and the workpiece by changing the length of the truss bar and the position of the moving fulcrum. The position changes, thus breaking the tandem kinematics principle of the traditional machine tool based on the Cartesian coordinate system.
Parallel machine tools are developing in the direction of series and parallel due to their weak rigidity and other factors. China's Tsinghua University, Haliang, Changzheng machine tools and other units in this area of ​​research and development in the international leading position.
Inverted vertical vehicle invention
Inverted vertical vehicles invented by EMAG in Germany are particularly suitable for high-volume processing of lightweight rotary parts. Immediately, novel models such as inverted machining centers, inverted composite machining centers and inverted welding machines came into being.
Innovation in processing technology
Compound processing
The composite machining machine and technology are undoubtedly the Fuxing of large-scale workpiece processing manufacturers. This is because the integration of the process greatly reduces the idle time in the middle of the workpiece, so the tact time is significantly shortened compared with the conventional equipment in the whole production process; Fixed assets investment of multiple machine tools; reduced warehouse use area, reduced storage costs; shortened replacement time.
In the mid-1990s, the Austrian WFL invented the turning and milling complex machining center. Japan's MAZAK company believes that DoneInOne is the development direction of CNC machine tools, that is, it can complete all processes on one machine.
laser processing
With the continuous development of laser cutting and laser forming technology, DMG's DML40SL can directly import CAD drawings into processing. Three linear axes, two deflection mirror rotary axes and one focus axis. The laser beam is incident on the surface of the workpiece at an angular extent of less than 200 for processing.
The laser pulsation mode YAG, the laser power is 100W, the laser beam diameter is Φ0.04~0.1mm, and the metal removal rate is 25mm3/min.
Ultrasonic vibration processing
Special milling cutters, drill bits or grinding wheels made of industrial diamond particles, precision machining of superhard materials with 20,000 times/s ultrasonic vibration high frequency tapping.
The spindle speed of the machine tool is 6,000r/min, the driving power is 10kW, and the spindle high-frequency vibration power is 1.5kW.
Water cutting
The water jet is to press ordinary water through an ultra-high pressure pressurizer, pressurize it to 380Mpa (55,000 psi) or higher, and then pass through a small nozzle (with a diameter of Φ0.01- Φ0.04mm). A water arrow with a speed of 915 m/s (about 3 times the speed of sound) is used for cutting. Waterjets are divided into two types: pure water waterjets and abrasive waterjets.
Flexible Manufacturing (FMS)
The analysis of FMS should focus on the total control system, transport trolley, exchange pallet library and washing machine. The machine tool (mainly horizontal plus) is only one of the units for processing parts. Because of the FMS developed and developed by robotics, the main function is not only to test the adaptive ability of the processing unit, but also to take into account the ability of moving objects around the workstation and the ability to respond to remote sensing data.
Intelligent manufacturing
Intelligentization is one of the important components of advanced manufacturing technology. It integrates information technology, optoelectronic technology, communication technology and sensing technology to promote the continuous improvement of machine tool manufacturing. Japanese companies such as MAZAK and OKUMA have obtained a number of patents in research and development in this area. As a system supplier, HEIDENHAIN GmbH has integrated adaptive feed control (AFC: AdaptiveFeedControl), automatic calibration and optimized machine accuracy (KinematicOpt) and intelligent chatter control (ACC: ActiveChatterControl) in their software. For the user to choose.
Today's high-end machine tools are generally equipped with a thermal deformation control system to ensure the stable working accuracy of the machine. Like Yasuda of Japan, the high-precision horizontal coordinate machining center developed by them has a “body temperature control deviceâ€, and the anti-collision function is ever-changing and endless.
The intelligent processing of the Swiss GF AgieCharmilles Group is carried out around the improvement of the craftsmanship. Their Mikron series of intelligent machining modules help users control the milling process for higher performance, higher quality and safety.
Micro-nano manufacturing
The nano-grinding machine independently developed by Shanghai Machine Tool Works Co., Ltd. is mainly used for nano-precision grinding of micro electromechanical optical components such as super-hard brittle, super-hard alloy, die steel and electroless nickel. Processing range: aspherical surface diameter <φ10mm, positioning accuracy? 0.1μm (100nm), repeat positioning accuracy? 0.05μm (50nm), surface roughness Ra<0.01μm (10nm), with on-line measurement compensation processing, grinding wheel in-machine trimming And online sharpening function.
Two revolutionary initiatives
3D printing
3D printing came into being in the third industrial revolution and it is a novel processing method for manufacturing. Additive manufacturing enables the machining of high-precision, complex profiles of metal and non-metal parts. This precision machining method avoids tool interference and can process the irradiated part where the laser beam is blocked.
There are many kinds of 3D printing technology, such as laser powder molding method, molten plastic molding method, photosensitive resin molding method, etc. The technical principle is that no matter what kind of molding method, the raw material plus layer method is used to form 3D objects, each time printing The layer of material is only 0.1-0.2mm thick. Compared with the two-dimensional printer, the 3D printer has one dimension, that is, the Z-axis. The material is stacked layer by layer through the movement of the XYZ axis, such as molten plastic molding, nozzle spraying. The molten plastic wire and the three-dimensional movement of the substrate can accumulate 3D objects (equal to a layer of glue).
Liquid nitrogen freezing
MAG has developed a cutting-edge cooling system called “Ultra-Cryogenic Liquid Nitrogen Cooling Cutting Technologyâ€, which has revolutionized the machine tool industry. Mr. Li Li, President of MAG Asia Pacific, said, “The promotion of this technology will have a revolutionary impact on the machine tool and tool industry. High efficiency and long life will reduce the consumption of machine tools and tools, while reducing the consumption of earth resourcesâ€.
The cutting heat in the cutting process causes the tool to wear fast when machining superhard materials, the tool consumption is large, and the tool consumption cost even exceeds the cost of the machine tool. The introduction of ultra-low temperature liquid nitrogen cooling cutting technology enables liquid nitrogen to be produced in the micropores of the cutting edge of the insert through the center of the spindle and the center of the shank. The heat generated by the cutting of the tool is nitrogenized by liquid (the boiling point of liquid nitrogen is -320 ° C). The moment is taken away, especially in the processing of super-hard materials and composite materials, the cutting speed can be greatly improved, and the tool life can be greatly extended.
According to MAG's cutting test statistics for several years, when processing difficult-to-cut materials such as titanium, nickel-based alloy, ductile iron or vermicular cast iron, the metal removal rate can be increased by an average of 3 times, and the tool life can be extended by an average of 2 times. This means that one machine can be used as three machines, and one blade can be used as two blades, which greatly saves equipment, space, personnel use and tool and energy consumption.
The technology is environmentally friendly. Usually, the means of metal cutting and cooling is to use coolant or cooling oil, and the coolant or cooling oil not only pollutes the environment, but also needs to be recycled, and the oil mist is not treated well or even unsafe conditions such as combustion and fire, and nitrogen is a safe gas and naturally discharged. There is no pollution in the air and no recycling is required.
Future machine tool outlook
Inexplicable winding machine
Parts for materials such as carbon fiber can be processed by winding.
Orbital milling machine
The machine tool is also a moving train. The front wheel is a milling cutter to flatten the damaged rail; the rear wheel is a grinding wheel that polishes the milled rail.
Dagu slogan and MAZAK model
Japan's Daxie proposed that the future development direction of machine tools should be: SPACECENTER has the characteristics of high speed (SPEED), high efficiency (POWER), high precision (ACCURACY), communication (COMMUNICATION), and environmental protection (ECOLOGY).
MAZAK builds the future machine model and is: spindle speed 100,000r/min, acceleration 8g, cutting speed 2 Mach, synchronous tool change, dry cutting, trucking, milling, laser machining, grinding and measuring.
The Yangtze River is not rolling, and the waves are always pushing forward. In the third industrial revolution, the advanced manufacturing technology, its development speed, its change cycle will be faster than any period in history, so the development of CNC machine tools in the new era will make us dizzy and promote social development. Continuous improvement.
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