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1、附錄2 外文翻譯（外文部分） ADVANCED MACHINING PROCESSES As the hardware of an advanced technology becomes more complex, new and visionary approaches to the processing of materials into useful products come into common use. This has been the trend in machining processes in recent years.. Advanced methods o

2、f machine control as well as completely different methods of shaping materials have permitted the mechanical designer to proceed in directions that would have been totally impossible only a few years ago. Parallel development in other technologies such as electronics and computers have made ava

3、ilable to the machine tool designer methods and processes that can permit a machine tool to far exceed the capabilities of the most experienced machinist. In this section we will look at CNC machining using chip-making cutting tools. CNC controllers are used to drive and control a great variety

4、 of machines and mechanisms, Some examples would be routers in wood working; lasers, plasma-arc, flame cutting, and waterjets for cutting of steel plate; and controlling of robots in manufacturing and assembly. This section is only an overview and cannot take the place of a programming manual for a

5、specific machine tool. Because of the tremendous growth in numbers and capability of computers ,changes in machine controls are rapidly and constantly taking place. The exciting part of this evolution in machine controls is that programming becomeseasier with each new advanced in this technology. A

6、dvantages of Numerical Control A manually operated machine tool may have the same physical characteristics as a CNC machine, such as size and horsepower. The principles of metal removal are the same. The big gain comes from the computer controlling the machining axes movements. CNC-controlled m

7、achine tools can be as simple as a 2-axis drilling machining center (Figure O-1). With a dual spindle machining center, the low RPM, high horsepower spindle gives high metal removal rates. The high RPM spindle allows the efficient use of high cutting speed tools such as diamonds and small diameter c

8、utters (Figure O-2). The cutting tools that remove materials are standard tools such as milling cutters, drills, boring tools, or lathe tools depending on the type of machine used. Cutting speeds and feeds need to be correct as in any other machining operation. The greatest advantage in CNC machinin

9、g comes from the unerring and rapid positioning movements possible. A CNC machine does dot stop at the end of a cut to plan its next move; it does not get fatigued; it is capable of uninterrupted machining error free, hour after hour. A machine tool is productive only while it is making chips.

10、Since the chip-making process is controlled by the proper feeds and speeds, time savings can be achieved by faster rapid feed rates. Rapid feeds have increased from 60 to 200 to 400 and are now often approaching 1000 inches per minute (IPM). These high feed rates can pose a safety hazard to anyone w

11、ithin the working envelope of the machine tool. Complex contoured shapes were extremely difficult to product prior to CNC machining .CNC has made the machining of these shapes economically feasible. Design changes on a part are relatively easy to make by changing the program that directs the ma

12、chine tool. A CNC machine produces parts with high dimensional accuracy and close tolerances without taking extra time or special precautions, CNC machines generally need less complex work-holding fixtures, which saves time by getting the parts machined sooner. Once a program is ready and produ

13、ction parts, each part will take exactly the same amount of time as the previous one. This repeatability allows for a very precise control of production costs. Another advantage of CNC machining is the elimination of large inventories; parts can be machined as needs .In conventional production often

14、 a great number of parts must be made at the same time to be cost effective. With CNC even one piece can be machined economically .In many instances, a CNC machine can perform in one setup the same operations that would require several conventional machines. With modern CNC machine tools a trai

15、ned machinist can program and product even a single part economically .CNC machine tools are used in small and large machining facilities and range in size from tabletop models to huge machining centers. In a facility with many CNC tools, programming is usually done by CNC programmers away from the

16、CNC tools. The machine control unit (MCU) on the machine is then used mostly for small program changes or corrections. Manufacturing with CNC tools usually requires three categories of persons. The first is the programmer, who is responsible for developing machine-ready code. The next person involve

17、d is the setup person, who loads the raw stork into the MCU, checks that the correct tools are loaded, and makes the first part. The third person is the machine and unloads the finished parts. In a small company, one person is expected to perform all three of these tasks. CNC controls are gener

18、ally divided into two basic categories. One uses a ward address format with coded inputs such as G and M codes. The other users a conversational input; conversational input is also called user-friendly or prompted input. Later in this section examples of each of these programming formats in machinin

19、g applications will be describes. CAM and CNC CAM systems have changed the job of the CNC programmer from one manually producing CNC code to one maximizing the output of CNC machines. Since CNC machine tools are made by a great number of manufacturers, many different CNC control units are in u

20、se. Control units from different manufacturers use a variety of program formats and codes. Many CNC code words are identical for different controllers, but a great number vary from one to another. To produce an identical part on CNC machine tools with different controllers such as one by FANCU,

21、 OKUMA or DYNAPATH, would require completely different CNC codes. Each manufacturer is constantly improving and updating its CNC controllers. These improvements often include additional code words plus changes in how the existing code works. A CAM systems allows the CNC programmer to concentrat

22、e on the creation of an efficient machining process, rather then relearning changed code formats. A CNC programmer looks at the print of a part and then plans the sequence of machining operations necessary to make it (Figure O-3). This plan includes everything, from the selection of possible CNC mac

23、hine tools, to which tooling to use, to how the part is held while machining takes place. The CNC programmer has to have a thorough understanding of all the capacities and limitations of the CNC machine tools that a program is to be made for. Machine specifications such as horsepower, maximum spindl

24、e speeds, workpiece weight and size limitations, and tool changer capacity are just some of the considerations that affect programming. Another area of major importance to the programmer is the knowledge of machining processes. An example would be the selection of the surface finish requirement

25、 specified in the part print. The sequence of machining processes is critical to obtain acceptable results. Cutting tool limitations have to be considered and this requires knowledge of cutting tool materials, tool types, and application recommendations. A good programmer will spend a considera

26、ble amount of time in researching the rapidly growing volume of new and improved tools and tool materials. Often the tool that was on the cutting edge of technology just two years ago is now obsolete. Information on new tools can come from catalogs or tool manufacturers' tooling engineers. Help in t

27、ool selection or optimum tool working conditions can also be obtained from tool manufacturer software. Examples would be Kennametal's "TOOLPRO", software designed to help select the best tool grade, speed, and feed rates for different work materials in turning application. Another very important fea

28、ture of "TOOLPRO" is the display of the horsepower requirement for each machining selection. This allow the programmer to select a combination of cutting speed, feed rate, and depth of cut that equals the machine's maximum horsepower for roughing cuts. For a finishing cut, the smallest diameter of t

29、he part being machined is selected and then the cutting speed varied until the RPM is equal to the maximum RPM of the machine. This helps in maximizing machining efficiency. Knowing the horsepower requirement for a cut is critical if more than one tool is cutting at the same time. Software for

30、a machining center application would be Ingersoll Tool Company's "Actual Chip Thickness", a program used to calculate the chip thickness in relation to feed-per-tooth for a milling cutter, especially during a shallow finishing cut. Ingersoll's "Rigidity Analysis" software ealculates tool deflection

31、for end mills as a function of tool stiffness and tool force. To this point we looked at some general qualifications that a programmer should possess. Now we examine how a CAM system works. Point Control Company's SmartCam system uses the following approach. First, the programmer makes a mental

32、 model of the part to be machined. This includes the kind of machining to be performed-turning or milling. Then the part print is studied to develop a machining sequence, roughing and finishing cuts, drilling, tapping, and boring operations. What work-holding device is to be used, a vise or fixture

33、or clamps? After these considerations, computer input can be started. First comes the creation of a JOBPLAN. This JOBPLAN consists of entries such as inch or metric units, machine type, part ID, type of workpiece material, setup notes, and a description of the required tools. This line of info

34、rmation describes the tool by number, type, and size and includes the appropriate cutting speed and feed rate. After all the selected tools are entered, the file is saved. The second programming step is the making of the part. This represents a graphic modeling of the projected machining operat

35、ion. After selecting a tool from the prepared JOBPLAN, parameters for the cutting operation are entered. For a drill, once the coordinate location of the hole and the depth are given, a circle appears on that spot. If the location is incorrect, the UNDO command erases this entry and allows you to gi

36、ve new values for this operation. When an end mill is being used, cutting movements (toolpath) are usually defined as lines and arcs. As a line is programmed, the toolpath is graphically displayed and errors can be corrected instantly. At any time during programming, the command SHOWPATH will s

37、how the actual toolpath for each of the programmed tools. The tools will be displayed in the sequence in which they will be used during actual machining. If the sequence of a tool movement needs to be changed, a few keystrokes will to that. Sometimes in CAM the programming sequence is different

38、 from the actual machining order. An example would be the machining of a pocket in a part. With CAM, the finished pocket outline is programmed first, then this outline is used to define the roughing cuts to machine the pocket. The roughing cuts are computer generated from inputs such as depth and wi

39、dth of cut and how much material to leave for the finish cut. Different roughing patterns can be tried out to allow the programmer to select the most efllcient one for the actual machining cuts. Since each tool is represented by a different color, it is easy to observe the toolpath made by each one.

40、 A CAM system lets the programmer view the graphics model from varying angles, such as a top, front, side, or isometric view. A toolpath that looks correct from a top view, may show from a front view that the depth of the cutting tool is incorrect. Changes can easily be made and seen immediatel

41、y. When the toolpath and the sequence of operations are satisfactory, machine ready code has to be made. This is as easy as specifying the CNC machine that is to be used to machine the part. The code generator for that specific CNC machine during processing accesses four different files. The JO

42、BPLAN file for the tool information and the GRAPHICE file for the toolpath and cutting sequence. It also uses the MACHINE DEFINE file which defines the CNC code words for that specific machine. This file also supplies data for maximum feed rates, RPM, toolchange times, and so on. The fourth file tak

43、ing part in the code generating process is the TEMPLATE file. This file acts like a ruler that produces the CNC code with all of its parts in the right place and sequence. When the code generation is complete, a projected machining time is displayed. This time is calculated from values such as feed

44、rates and distances traveled, noncutting movements at maximum feed rates between points, tool change times, and so on. The projected machining time can be revised by changing tooling to allow for higher metal removal rates or creating a more efficient toolpath. This display of total time required ca

45、n also be used to estimate production costs. If more then one CNC machine tool is available to machine this part, making code and comparing the machining time may show that one machine is more efficient than the others. CAD/CAM Another method of creating toolpath is with the use of a Computer-

46、aided Drafting (CAD) file. Most machine drawings are created using computers with the description and part geometry stored in the computer database. SmartCAM, though its CAM CONNECTION, will read a CAD file and transfer its geometry represents the part profile, holes, and so on. The programmer still

47、 needs to prepare a JOBPLAN with all the necessary tools, but instead of programming a profile line by line, now only a tool has to be assigned to an existing profile. Again, using the SHOWPATH function will display the toolpath for each tool and their sequence. Constant research and developments in

48、 CAD/CAM interaction will change how they work with each other. Some CAD and CAM programs, if loaded on the same computer, make it possible to switch between the two with a few keystrokes, designing and programming at the same time. The work area around the machine needs to be kept clean and cl

49、ear of obstructions to prevent slipping or tripping. Machine surfaces should not be used as worktables. Use proper lifting methods to handle heavy workpieces, fixtures, or heavy cutting tools. Make measurements only when the spindle has come to a complete standstill. Chips should never be handled wi

50、th bare hands. Before starting the machine make sure that the work-holding device and the workpiece are securely fastened. When changing cutting tools, protect the workpiece being machined from damage, and protect your hands from sharp cutting edges. Use only sharp cutting tools. Check that cut

51、ting tools are installed correctly and securely. Do not operate any machine controls unless you understand their function and what they will do. The Early Development Of Numerically Controlled Machine Tools The highly sophisticated CNC machine tools of today, in the vast and diverse range

52、 found throughout the field of manufacturing processing, started from very humble beginnings in a number of the major industrialized countries. Some of the earliest research and development work in this field was completed in USA and a mention will be made of the UK's contribution to this numerical

53、control development. A major problem occurred just after the Second World War, in that progress in all areas of military and commercial development had been so rapid that the levels of automation and accuracy required by the modern industrialized world could not be attained from the lab our int

54、ensive machines in use at that time. The question was how to overcome the disadvantages of conventional plant and current manning levels. It is generally ackonwledged that the earliest work into numerical control was the study commissioned in 1947 by the US government. The study's conclusion was tha

55、t the metal cutting industry throughout the entire country could not copy with the demands of the American Air Force, let alone the rest of industry! As a direct result of the survey, the US Air Force contracted the Persons Corporation to see if they could develop a flexible, dynamic, manufacturing

56、system which would maximize productivity. The Massachusetts Institute of Technology (MIT) was sub-contracted into this research and development by the Parsons Corporation, during the period 1949-1951,and jointly they developed the first control system which could be adapted to a wide range of machin

57、e tools. The Cincinnati Machine Tool Company converted one of their standard 28 inch "Hydro-Tel" milling machines or a three-axis automatic milling made use of a servo-mechanism for the drive system on the axes. This machine made use of a servomechanism for the drive system on the axes, which contro

58、lled the table positioning, cross-slide and spindle head. The machine cab be classified as the first truly three axis continuous path machine tool and it was able to generate a required shape, or curve, by simultaneous slide way motions, if necessary. At about the same times as these American a

59、dvances in machine tool control were taking Place, Alfred Herbert Limited in the United Kingdom had their first Mutinous path control system which became available in 1956.Over the next few years in both the USA and Europe, further development work occurred. These early numerical control development

60、s were principally for the aerospace industry, where it was necessary to cut complex geometric shapes such as airframe components and turbine blades. In parallel with this development of sophisticated control systems for aerospace requirements, a point-to-point controller was developed for more gene

61、ral machining applications. These less sophisticated point-to-point machines were considerably cheaper than their more complex continuous path cousins and were used when only positional accuracy was necessary. As an example of point-to-point motion on a machine tool for drilling operations, the typi

62、cal movement might be fast traverse of the work piece under the drill's position-after drilling the hole, anther rapid move takes place to the next hole's position-after retraction of the drill. Of course, the rapid motion of the slideways could be achieved by each axis in a sequential and independe

63、nt manner, or simultaneously. If a separate control was utilisec for each axis, the former method of table travel was less essential to avoid any backlash in the system to obtain the required degree of positional accuracy and so it was necessary that the approach direction to the next point was alwa

64、ys the same. The earliest examples of these cheaper point-to-point machines usually did not use recalculating ball screws; this meant that the motions would be sluggish, and sliderways would inevitably suffer from backlash, but more will be said about this topic later in the chapter. The early

65、NC machines were, in the main, based upon a modified milling machine with this concept of control being utilized on turning, punching, grinding and a whole host of other machine tools later. Towards the end of the 1950s,hydrostatic slideways were often incorporated for machine tools of highly precis

66、ion, which to sonic extent overcame the section problem associated with conventional slideway response, whiles averaging-out slideway inaccuracy brought about a much increased preasion in the machine tool and improved their control characteristics allows "concept of the machining center" was the product of this early work, as it allowed the machine to manufacture a range of components using a wide variety of machining processes at a single set-up, without transfer of workpieces to other variety