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The high efficiency and specificity of engine crankshaft processing machines is a typical feature of crankshaft manufacturing equipment. According to China Machine ToolNet (Machine35.com), the basic requirements for “high-efficiency special-purpose†machine tools are high stiffness, high speed and high power. The basic characteristic of an efficient special-purpose machine tool is the “tailored†type, which provides personalized products according to the needs of users.
Overall solution requirements
High-efficiency special-purpose machine tools belong to “Lean Machine Toolâ€, which eliminates redundant functions and have high efficiency and highly targeted characteristics. The supply of modern high-efficiency dedicated machine tools is a total solution. The overall solution has the following requirements:
1. Requirements from the development of equipment to put into operation after the use of collaborative engineering - with upstream and downstream partners (suppliers) and users, through the design of different places to establish a dynamic alliance. The joint development runs through the entire process and serves the customers throughout the product life cycle.
2. Require suppliers to be familiar with user products (including new products that are forecasted to be developed in the medium term), be familiar with user processes, have programming capabilities, use equipment optimization capabilities, and complete sets of process equipment capabilities and integration capabilities, so that they can integrate process systems, logistics systems, and information systems. Become a manufacturing unit and the corresponding personnel training.
3. Require suppliers to have independent technological innovation capabilities, provide not only comprehensive, but also must be the "best" solution that the contemporary technology level can achieve. Enable suppliers to achieve user demand "pull" independent innovation. At the same time, multiple innovations accumulated during the joint development process with users lay the foundation for the "originality" of the products developed.
4. It also requires suppliers to have economic analysis capabilities, be able to propose several options and quotations based on user funds (including dynamic funds), and provide users with investment return cycle and profitability analysis.
5. Users are required to provide drawings of the workpieces to be machined or their typical workpiece drawings and technical requirements; the productivity (one-piece processing man-hour) and the quality level (which should be appropriately high and existing levels) should be achieved; the workpieces are processed before and after the machining of the machine. In this case, the machine tool can be immediately put into production as soon as it reaches the factory, and the processing efficiency and processing quality can meet or exceed the original requirements of the user immediately and stably, and the benefits can be quickly created.
Three Examples of Typical Crankshaft Efficient Special Machine Tool Application
1. CNC car - Pulling machine
The car pull technology originated from a technology patent in the United States and has gradually developed during crankshaft machining. The current development is more common, and it is widely used abroad in the machining of main shafts and connecting rods for semi-finished crankshafts. Pulling technology can be divided into three types: linear pull, inner rotary tool pull and external rotary tool pull. The pulling process was developed around 1983. During the short period of five years from 1983 to 1988, the car pulling process developed from a straight-line type to a rotary type. By 1988, it had developed a car-car pulling technology. So far it has pulled. The cutting method is also gradually replaced by the combing process. The main features are: one set can complete all concentric turning, and the same machine is used to complete the car-vehicle processing, high efficiency, through the use of special chucks and tools The system realizes the advantages of flexible machining, simple machine maintenance and low maintenance cost, and is particularly suitable for crankshafts that do not need to be machined on the balance block side and have a sinking groove on the journal. Among them, the broaching process can be replaced by an efficient combing technique. The combing process is usually carried out in the final step of the process, and high-speed finishing can be achieved with a small amount of radial feed and longitudinal turning. The use of combing knife process has the advantages of high precision, high efficiency, easy cleaning of chips and small amount of axial feed.
2. CNC high speed milling machine
The CNC high-speed external milling technology developed in the mid-1990s has a higher efficiency than the CNC turning, CNC internal milling and vehicle-vehicle pulling. Take the four-turn crankshaft as an example: The CNC car-turning process requires two machining operations for the connecting rod journal, and the CNC high-speed milling operation can be completed in one operation (application of workpiece rotation and milling cutter feed servo control technology can be performed. One-piece clamping does not change the follower of the crankshaft's turning center to track the crankshaft's connecting rod journal. It has the following advantages: high cutting speed (up to 350m/min), short cutting time, short process cycle time, and low cutting force Lower workpiece temperature rise, higher tool life, fewer tool changes, higher machining accuracy, and better flexibility. Therefore, high-speed CNC milling will be the development direction of rough machining of crankshaft main journal and connecting rod journal.
3. CNC milling machine
CNC milling is a technology that emerged in the mid-1980s. The CNC milling performance index is higher than ordinary milling. Especially for forged steel crankshafts, inner milling is more conducive to chip breaking and rigidity. The CNC internal milling and milling process is currently one of the most advanced machining methods for crankshaft connecting rod neck rough machining in the world. In particular, the high-power forging steel crankshaft machining inner milling process is preferred. The inner milling machine has a variety of processing methods. The most commonly used is the crankshaft fixed CNC crankshaft inner milling process. The main features are: high production efficiency, good machining accuracy, wide application range and good flexibility, and its representative process equipment Germany's HELLER company developed the CNC crankshaft milling machine series. Its main functional features are: fixed after crankshaft is fixed; milling cutter follows link-neck milling; machine tool bed is integrated structure of composite material; electronic synchronous motor is driven at both ends of the workpiece; dry cutting, high machining accuracy and cutting efficiency Advanced features. The control system can generate automatic machining programs by inputting the basic parameters of the parts.
Reasonable Application of Typical Crankshaft Efficient Special Machine Tool
Crankshaft efficient special-purpose machine tools also have its processing limitations. Only by properly applying suitable machining tools can the crankshaft machine tool be able to exert high-efficiency and specificity, thereby improving the processing efficiency of the process.
1. When the crankshaft journal has a sinking groove, the CNC milling machine cannot process; if the crankshaft journal sinking groove, the CNC high-speed milling machine and CNC milling machine can not be processed, but the CNC car - pull machine Can be easily processed.
2. When the side of the balance block needs to be machined, the CNC milling machine tool should be the preferred machine tool because the inner milling cutter disk is positioned outside the circle and has good rigidity. It is especially suitable for machining large-scale forged steel crankshafts; at this time, it is not suitable for CNC machine-turning machine tools. Because the side of the balance block of the crankshaft needs to be processed, CNC machine-turning machine is used for machining. The side of the balance block is intermittently cut, and the crankshaft speed is very high. Under this working condition, the chipping phenomenon is serious.
3. When the journal of the crankshaft has no undercut and the sides of the counterweight do not need to be machined, in principle, several machine tools can process it. When processing car crankshafts, the main journals are CNC machine-turning machine tools, and the use of CNC high-speed external milling machines for connecting rod necks should be the best and most efficient machining option; when machining large forged crankshafts, the main journals and connecting rods are both The use of numerically controlled milling machines is reasonable.
The crankshaft can be divided into larger forged steel crankshafts and lightweight car crankshafts. Forged steel crankshaft journals generally have no undercuts, and the side surfaces need to be machined with a large margin; the crankshafts of car crankshafts generally have undercut grooves, and The side does not need to be processed. Therefore, it can be concluded that: machining forged steel crankshaft CNC milling machine tools, machining spindle crankshaft car using CNC car - pull machine, connecting rod neck using CNC high speed milling machine is a more reasonable and efficient processing options.
High-efficiency specificity is a typical feature of crankshaft manufacturing equipment. Due to the special structure of the crankshaft itself, the particularity of its processing machine is determined. Only by properly applying suitable machining tools can the crankshaft machine tool be able to exert its high-efficiency and specificity, thereby improving the processing efficiency of the process.