POSITIONING SYSTEM WITH ADJUSTABLE CLAMPING FORCE AND MILLING EQUIPMENT FOR RAIL TRANSIT HONEYCOMB WORKPIECE
20220379418 · 2022-12-01
Assignee
- Qingdao University Of Technology (Qingdao, CN)
- QINGDAO KAWS INTELLIGENT MANUFACTURING CO. LTD. (Qingdao, CN)
Inventors
- Changhe Li (Qingdao, CN)
- Zhuang SHI (Qingdao, CN)
- Aiguo QIN (Qingdao, CN)
- Bo LIU (Qingdao, CN)
- Yun CHEN (Qingdao, CN)
- Huajun Cao (Qingdao, CN)
- Zongming ZHOU (Qingdao, CN)
- Naiqing Zhang (Qingdao, CN)
- Qidong WU (Qingdao, CN)
- Bingheng LU (Qingdao, CN)
- Teng Gao (Qingdao, CN)
- Yanbin Zhang (Qingdao, CN)
- Min Yang (Qingdao, CN)
- Mingzheng LIU (Qingdao, CN)
- Xiaoming WANG (Qingdao, CN)
Cpc classification
B23Q11/10
PERFORMING OPERATIONS; TRANSPORTING
B25J9/0084
PERFORMING OPERATIONS; TRANSPORTING
B23C9/00
PERFORMING OPERATIONS; TRANSPORTING
B23Q3/069
PERFORMING OPERATIONS; TRANSPORTING
Y10T409/309016
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T409/304032
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B23Q11/1076
PERFORMING OPERATIONS; TRANSPORTING
B23C3/00
PERFORMING OPERATIONS; TRANSPORTING
B23Q11/1046
PERFORMING OPERATIONS; TRANSPORTING
International classification
B23C9/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
Positioning system with an adjustable clamping force and milling equipment for a rail transit honeycomb workpiece. The positioning system includes a positioning apparatus, including a positioning table to support a workpiece, and a clamping apparatus, including a turntable, which is fixedly disposed on a periphery of the positioning table, a top of the turntable is connected to a mechanical arm, a pressure plate is disposed at an end of the mechanical arm, the pressure plate being capable of cooperating with the positioning table to clamp the workpiece, working regions of all the clamping apparatuses being capable of covering a machining surface of the workpiece, when machining is performed in an intersection region, a clamping apparatus corresponding to the region clamps the workpiece, and when machining is performed in a non-intersection region, a clamping apparatus corresponding to the region dodges, and an adjacent clamping apparatus clamps the workpiece.
The present invention discloses a positioning system with an adjustable clamping force and a milling equipment for a rail transit honeycomb workpiece. The positioning system includes: a positioning apparatus, including a positioning table to support a workpiece; and a clamping apparatus, including a turntable, where the turntable is fixedly disposed on a periphery of the positioning table, a top of the turntable is connected to a mechanical arm, a pressure plate is disposed at an end of the mechanical arm, and the pressure plate is capable of cooperating with the positioning table to clamp the workpiece, where there are a plurality of clamping apparatuses, working regions of adjacent clamping apparatuses have an intersection, and working regions of all the clamping apparatuses are capable of covering a machining surface of the workpiece; and when machining is performed in an intersection region, a clamping apparatus corresponding to the region clamps the workpiece, and when machining is performed in a non-intersection region, a clamping apparatus corresponding to the region dodges, and an adjacent clamping apparatus clamps the workpiece.
Claims
1. A positioning system with an adjustable clamping force for a rail transit honeycomb workpiece, comprising: a positioning apparatus, comprising a positioning table to support a workpiece; and a clamping apparatus, comprising a turntable, wherein the turntable is fixedly disposed on a periphery of the positioning table, a top of the turntable is connected to a mechanical arm, a pressure plate is disposed at an end of the mechanical arm, and the pressure plate is capable of cooperating with the positioning table to clamp the workpiece, wherein there are a plurality of clamping apparatuses, working regions of adjacent clamping apparatuses have an intersection, and working regions of all the clamping apparatuses are capable of covering a machining surface of the workpiece; and when machining is performed in an intersection region, a clamping apparatus corresponding to the region clamps the workpiece, and when machining is performed in a non-intersection region, a clamping apparatus corresponding to the region dodges, and an adjacent clamping apparatus clamps the workpiece.
2. The positioning system with an adjustable clamping force according to claim 1, wherein the mechanical arm comprises a main arm connected to the turntable, the main arm is hinged with a side portion of a middle arm, the middle arm is connected to the pressure plate by an end joint, the main arm and the middle arm are capable of swinging up and down independently, and the end joint is capable of driving the pressure plate to rotate in a direction of a plate surface of the pressing plate, so that the pressure plate is always parallel to a workpiece surface.
3. The positioning system with an adjustable clamping force according to claim 2, wherein an end portion of the middle arm is further hinged with a connecting rod, the connecting rod is hinged with a rocker that swings up and down, the rocker is connected to the main arm, and the rocker and the main arm swing independently.
4. The positioning system with an adjustable clamping force according to claim 3, wherein the connecting rod is disposed in parallel to the main arm, and a connection point between the connecting rod and the middle arm, a connection point between the connecting rod and the rocker, a connection point between the main arm and the middle arm, and a connection point between the main arm and the rocker are connected to form a parallelogram.
5. The positioning system with an adjustable clamping force according to claim 1, wherein a pressure sensor is inserted into the pressure plate, and an end surface of the pressure sensor is flush with an end surface of the pressure plate.
6. The positioning system with an adjustable clamping force according to claim 2, wherein the turntable comprises a main rotating body that is rotatable horizontally, and the main rotating body is connected to the main arm.
7. The positioning system with an adjustable clamping force according to claim 6, wherein the main rotating body and the pressure plate rotate synchronously, and have a same rotation angle and opposite rotation directions, to keep the pressure plate and the workpiece always pressed in a same orientation.
8. The positioning system with an adjustable clamping force according to claim 1, wherein a plurality of positioning adjustment apparatuses are fixedly disposed on a peripheral side of the positioning table, to implement six-point positioning of the workpiece; and the positioning adjustment apparatus comprises a positioning element, and a bottom of the positioning element is connected to an up-and-down reciprocating apparatus to adjust a height of the positioning element.
9. The positioning system with an adjustable clamping force according to claim 8, wherein the positioning element is higher than the positioning table to position a side portion of the workpiece.
10. A milling equipment for a rail transit honeycomb workpiece, comprising the positioning system with an adjustable clamping force according to claim 1.
11. The milling equipment according to claim 10, further comprising a milling machine, wherein the milling machine is connected to a minimum quantity lubrication spray angle control apparatus by a machine tool spindle, the minimum quantity lubrication spray angle control apparatus is connected to a nozzle, and the minimum quantity lubrication spray angle control apparatus is disposed above the positioning table.
12. The milling equipment according to claim 11, wherein the minimum quantity lubrication spray angle control apparatus comprises a high elevation rod, the high elevation rod is connected to a low elevation mechanism, the low elevation mechanism is connected to the nozzle to finely adjust a nozzle elevation, and the nozzle is connected to an atomizer by a universal joint cooling pipe.
13. The milling equipment according to claim 12, wherein the high elevation rod is hinged with a spindle connecting member to coarsely adjust the nozzle elevation, the spindle connecting member is connected to the machine tool spindle, and the nozzle extends to a milling cutter at a bottom of the machine tool spindle.
14. The milling equipment according to claim 13, wherein the spindle connecting member is of an arc-shaped plate-type structure, and the arc-shaped plate-type structure is engaged outside the machine tool spindle.
15. The milling equipment according to claim 12, wherein the low elevation mechanism comprises a low elevation rotating member that is rotatable in a vertical direction, the low elevation rotating member has a groove to accommodate and fix a horizontal swing angle mechanism, the horizontal swing angle mechanism comprises a ball joint rotating member, the ball joint rotating member is connected to the nozzle, and the ball joint rotating member is rotatable in a horizontal direction to drive the nozzle to adjust a horizontal swing angle.
16. The milling equipment according to claim 11, wherein a horizontal swing angle range of the nozzle is [15°-45°].
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The accompanying drawings constituting a part of the present invention are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and descriptions thereof are used to explain the present invention, and do not constitute an improper limitation of the present invention.
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[0069] In the drawings, to show positions of parts, a distance or a size between the parts is exaggerated, and schematic diagrams are only used for illustration, where I large dynamic beam-type gantry milling machine, II machine tool fixture positioning apparatus, III machine tool fixture clamping apparatus, IV minimum quantity lubrication spray angle control apparatus, V aluminum alloy honeycomb plate, and VI machine tool spindle; II-1 positioning table, II-1-1 threaded hole, II-1-2 pin shaft, and II-1-3 mounting base; II-2 positioning adjustment apparatus, and II-3 lifting ring; III-1 turntable, III-1-1 mounting base, III-1-2 stepped shaft hole, III-1-3 cylindrical cavity, and III-1-4 threaded hole; III-2 stepped shaft, and III-2-1 groove; III-3 tapered roller bearing, III-4 worm gear, III-5 inner hexagon screw, III-6 main rotating body, III-7 bearing retaining ring, III-8 shaft end cover, III-9 inner hexagon screw, III-10 worm shaft, III-10-1 shaft ring, III-11 deep groove ball bearing, III-12 coupling, III-13 turntable drive motor, III-13-1 motor shaft, III-14 inner hexagon screw, III-15 drive motor, III-16 support plate, III-17 outer hexagon screw, III-18 tapered roller bearing, III-19 connecting member, III-20 main arm, III-21 deep groove ball bearing, III-22 rocker, III-22-1 hole, III-23 tapered roller bearing, III-24 drive motor, III-25 inner hexagon screw, III-26 inner hexagon screw, III-27 pin, III-28 connecting rod, III-28-1 hole, III-28-2 hole, III-29 pin, III-30 sleeve, III-31 middle arm, III-31-1 hole, III-31-2 hinged support, III-32 pin, III-33 pin connecting sleeve, III-34 pin, III-35 pin connecting sleeve, III-36 pin, III-37 end joint drive motor, III-38 fastening screw, III-39 end joint, III-40 end fastening member, III-41 front end small motor, III-42 fastening screw, III-43 pressure plate, III-44 pressure sensor, and III-45 screw; IV-1 spindle connecting member, IV-1-1 arc structure, IV-1-2 threaded hole, IV-1-3 through hole, IV-1-4 threaded hole, IV-2 cross recessed screw, IV-3 hinged support, IV-3-1 end threaded hole, IV-3-2 hexagonal groove, IV-4 high elevation rod, IV-4-1 through hole, IV-4-2 through hole, IV-4-3 through hole, IV-5 hexagonal fastening nut, IV-6 angle fastening bolt, IV-7 housing, IV-7-1 threaded hole, IV-7-2 stepped inner hole, IV-7-3 stepped through hole, IV-7-4 threaded hole, IV-8 cross recessed screw, IV-9 servo motor, IV-9-1 motor shaft, IV-10 cross recessed pan head screw, IV-11 motor bracket, IV-11-1 threaded hole, IV-12 cross recessed screw, IV-13 pin, IV-14 coupling sleeve, IV-15 shaft, IV-16 bevel gear, IV-17 round end key, IV-18 baffle plate, IV-19 screw, IV-20 bevel gear, IV-21 shaft, IV-22 deep groove ball bearing, IV-23 round end key, IV-24 sleeve, IV-25 deep groove ball bearing, IV-26 sleeve, IV-27 straight gear, IV-28 round end key, IV-29 sleeve, IV-30 deep groove ball bearing, IV-31 end housing, IV-32 cross recessed pan head screw, IV-33 middle plate, IV-34 low elevation rotating member, IV-34-1 through hole, IV-34-2 spherical surface, IV-34-3 flat structure, IV-35 countersunk screw, IV-36 straight gear, IV-37 sleeve, IV-38 deep groove ball bearing, IV-39 pan head screw, IV-40 ball joint rotating member, IV-40-1 flat through hole, IV-41 shaft, IV-42 synchronous pulley pin, IV-43 synchronous belt, IV-44 synchronous pulley, IV-45 synchronous pulley, IV-46 countersunk screw, IV-47 deep groove ball bearing, IV-48 steering gear bracket, IV-48-1 flat through hole, IV-49 synchronous pulley pin, IV-50 steering gear, IV-50-1 steering gear shaft, IV-51 nozzle, IV-52 universal joint cooling pipe, and IV-53 atomizer; and VI-1 sleeve, and VI-2 front cover.
DETAILED DESCRIPTION
[0070] It should be pointed out that the following detailed descriptions are all illustrative and are intended to provide further descriptions of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meanings as those usually understood by a person of ordinary skill in the art to which the present invention belongs.
[0071] Table 1 shows a process route solution for machining an aluminum alloy honeycomb plate V. It can be learned from the table that in a process 30, the aluminum alloy honeycomb plate V needs to be first positioned and clamped. Nowadays, there are generally three types of fixtures applied to the honeycomb plate. A first type is a bonding method in which a honeycomb bottom plate is bonded for positioning and holding. This manner also has obvious defects of being not environmentally friendly, increasing a labor amount, prolonging a production cycle, and being time-consuming and laborious. A second type is a vacuum adsorption method in which a workpiece is adsorbed on a vacuum plate by using a principle of an atmospheric pressure difference. This method for adsorbing the plate to fix the workpiece requires sufficiently good sealing performance. That is, before machining, it needs to lay a sealing strip according to a machining technology of the workpiece. If a process of a through hole is machined, it needs to consider to avoid a position of the through hole during the laying of the sealing strip. Therefore, in this machining method, when a workpiece in a different process needs to be changed, a path of the sealing strip needs to be changed for relaying. In addition, during machining, unreliable sealing and a decrease or failure of a clamping force are caused, thereby affecting the machining precision. A third type is a fixture for clamping a periphery of an aluminum honeycomb plate. Although the fixture does not affect a clamping force during machining, because a size of the aluminum alloy honeycomb plate V is relatively large, and the clamping force is not as close as possible to a machining region, unreliable machining is caused. Therefore, if the pressure plate can perform pressing near the required machining region, and as a cutting path of a machine tool spindle changes, the pressure plate can always implement pressing in real time near the machining region according to a program of the cutting path, that is, implement pressing along with a movement, the defects in the foregoing several clamping manners can be well resolved.
TABLE-US-00001 TABLE 1 Process route solution for machining aluminum alloy honeycomb plate Process Process Machining number name Process content equipment 10 Hot Hot-press an aluminum honeycomb Hot-pressing pressing and an aluminum plate into a machine honeycomb plate blank through composite molding 20 Check Check the honeycomb plate blank 30 Milling Perform high-speed vertical milling Gantry of a through hole and a through milling cavity (where a lower plate of the machine honeycomb plate is referred to as a rough reference) 40 Deburring Remove sharp edges and burrs, and blow chips 50 Final Check according to requirements of check a check process card
Embodiment 1
[0072] In a typical implementation of the present invention, as shown in
[0073] The large dynamic beam-type gantry milling machine I is a three-axis dynamic beam-type milling machine. That is, movements in three directions of X, Y, and Z are all driven by using a screw rod driven by a motor, and the rotation of the screw rod drives a slider to move along a direction of the screw rod, to implement movements of the machine tool spindle in the three directions of X, Y, and Z.
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[0076] The positioning adjustment apparatus includes a cylinder and a positioning element, the positioning element is disposed at a top of the cylinder, and a height of the positioning element may be adjusted through a cylinder action. The cylinder may adjust the height of the positioning element according to a thickness of the workpiece, to improve the positioning reliability during machining.
[0077] A threaded hole II-1-1 is provided on the positioning table II-1, and the cylinder of the positioning adjustment apparatus II-2 is fixedly mounted on the positioning table II-1 by using screws. To meet a six-point positioning principle, one positioning adjustment apparatus II-2 is arranged in a center line of a wide side of the positioning table II-1, four positioning adjustment apparatuses II-2 are arranged on a long side of the positioning table II-1, and the positioning element is higher than the positioning table, and may be attached to a side portion of the aluminum alloy honeycomb plate.
[0078] The positioning table II-1 serving as a main positioning surface of the aluminum alloy honeycomb plate V limits a movement freedom of a Z axis and rotational freedoms of an X axis and a Y axis of the workpiece, and the four positioning adjustment apparatuses II-2 on the long side and the one positioning adjustment apparatus II-2 on the wide side are used for limiting movement freedoms of the X axis and the Y axis and a rotational freedom of the Z axis. After the six-point positioning principle is met, it is considered that the workpiece is generally in a shape of a cuboid and is a large workpiece. Therefore, if fewer positioning adjustment apparatuses II-2 on the long side are used as positioning members, because a size of the workpiece is excessively large, and problems such as an offset of a position of the workpiece during milling machining and unreliable positioning may be caused, the positioning adjustment apparatuses II-2 are evenly arranged to ensure reliable positioning of the workpiece during machining.
[0079] The lifting ring II-3 is arranged for hoisting the large fixture, and is mounted on four pin shafts II-1-2 on the positioning table II-1.
[0080] A mounting base II-1-3 is disposed on the positioning table II-1, and is used for mounting with the machine tool table in a connection manner.
[0081] The machine tool fixture clamping apparatus III includes a turntable and a mechanical arm disposed on the turntable. A structure of the machine tool fixture clamping apparatus is described below.
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[0085] The worm gear structure and the worm structure fit with each other. That is, a worm gear III-4 in
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[0091] Herein, the structures of the parts of the mechanical arm have been introduced.
[0092] How the parts of the machine tool fixture clamping apparatus III implement the movement of the mechanism is described above by using the mechanical structure.
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[0094] Considering a weak rigidity in the L direction and the W direction of the honeycomb core, the pressure plate III-43 can apply a pressure to only V in the T direction. However, if the pressing force is excessively large, the honeycomb core is also plastically deformed to collapse. Therefore, it needs to ensure that the pressing force applied by the machine tool fixture clamping apparatus III is within a proper range, to implement reliable and effective pressing while ensuring that the honeycomb core is not plastically deformed.
[0095] It is obtained by analyzing a stress-strain of compression of an aluminum honeycomb as follows:
[0096] 1. Elastic deformation stage (AB section): In this stage, a honeycomb wall is equivalent to that an elastic rod is under an action of forward compression, a stress and a strain have a linear relationship, and after being unloaded, the aluminum honeycomb can be restored to an original shape. The rule of deformation at this stage is the same as that of elastic deformation of a solid material. However, a point corresponds to yield strength of the aluminum honeycomb, and a value of the point may be calculated by using Formula (1):
[0097] where E, is an elastic modulus of an aluminum honeycomb basis material; k is a constraint factor of an end surface of a honeycomb cell; t is a wall thickness of the honeycomb cell, that is, a thickness of the aluminum honeycomb basis material; b is a side length of a cell with a wall thickness of t; l is a side length of a cell with a wall thickness of 2t; v is a Poisson ratio of the aluminum honeycomb basis material; and θ is an acute angle between adjacent honeycomb cells. For a regular hexagonal honeycomb, k=5.73.
[0098] 2. Stable yield stage (BC section): As the stress increases, an aluminum honeycomb wall loses stability, and is yielded and folded, and this process is repeated continuously. As a result, the stress in this interval appears to continuously oscillate in a specific interval instead of being always stable and increasing or decreasing in one direction. A yield plateau stress of an important parameter of a static compression mechanical behavior of the aluminum honeycomb is generally an average stress at this stage of compression of the aluminum honeycomb. The yield plateau stress of the honeycomb of a hexagonal pin at this stage may be obtained by using Formula (2):
[0099] where σ, is the yield strength of the aluminum honeycomb basis material.
[0100] 3. Densification stage (CD section): After the yield plateau stage is completed, all the honeycomb cells are folded. In this case, a gap between the honeycomb walls is relatively small, and the stress needs to be greatly increased for continuously compressing strains having a relatively small gap. The stage continues until the aluminum honeycomb is completely densified.
[0101] It can be learned according to the analysis of a stress-strain compression curve of the honeycomb core that a compressive stress applied by the pressure plate III-23 in the T direction of the honeycomb should be in the AB stage, so that it can be ensured that the applied pressure does not cause the honeycomb core to be yielded and deformed, and after the fixture releases, the honeycomb core may be restored to an original shape. It can be learned from the typical schematic stress-strain diagram of the compression of the aluminum honeycomb that in a direction of the pressing force, it is ensured that a maximum stress applied by the pressure plate III-23 is less than a maximum linear elastic stress (that is, the yield strength).
[0102] Assuming that an area of the pressure plate acting on the honeycomb surface is A, and the clamping force of the pressure plate is F.sub.Y, a formula for the maximum compressive stress that the pressure plate may apply may be obtained:
[0103] where σ.sub.Y is a magnitude of the stress applied by the pressure plate.
[0104] It can be learned according to the foregoing Formula (3) that when a honeycomb size parameter such as a thickness of the honeycomb cell wall of the honeycomb core or a side length of the honeycomb cell changes, the mechanical arm may pre-input a new parameter of the honeycomb core according to a set program, and recalculate a proper application range of the pressing force according to the formula. The operation is as follows: A surface pressure sensor III-44 is mounted inside the pressure plate III-43. When the pressure plate III-43 starts to act on the aluminum alloy honeycomb plate V, the surface pressure sensor III-44 starts to work, transmits a signal to a computer, displays in real time a value of pressure applied by the pressure plate III-43, controls the mechanical arm by using a computer control system, and ensures that a value of a stress caused by the pressure of the pressure plate is always within a maximum stress range that the honeycomb core can bear.
[0105] Because a height of the honeycomb core is generally tens of millimeters, a strain in the AB section is very small, and a product of the height of the honeycomb core and the strain in the AB section is an amount of elastic deformation of the height of the honeycomb core. Therefore, whether to consider an error caused by the amount of elastic deformation needs to be determined according to precision of the machining workpiece. If the error caused by the amount of elastic deformation needs to be considered due to a requirement of the machining precision, error compensation needs to be performed; and if the required machining precision can be met, no error compensation is needed.
[0106] Theoretical analysis on that the honeycomb surface may be damaged due to an excessive large pressing force, and is plastically deformed has been made above, and a maximum value of the pressing force that can be applied is determined. Then, an application range of the pressing force of the pressure plate III-43 needs to be considered to be as close as possible to a cutting machining position to make the pressure plate tightly fixed and reliable.
[0107] First, it needs to learn a milling force when the milling cutter mills the honeycomb workpiece at a high speed.
[0108] A formula for calculating a plane milling force of the honeycomb core is as follows:
[0109] It is assumed that a coordinate system of the workpiece is Xw−Yw, R a cutting tool radius, ω is a cutting speed, and a cutting tool machining locus function is ƒ(x);
[0110] a cutting tool center may be represented as (x(t), ƒ(x);
[0111] a coordinate system of a cutting tip is (x(t)+R sin wt, ƒ(x)+R cos wt);
[0112] each honeycomb wall may be described by using a linear function: y=a.sup.i x+b.sup.i, where i represents an i.sup.th honeycomb wall in a cutting region, a is 0 or 1.732 or −1.732, and b depends on a position of a cell wall; and
[0113] coordinates of x at a starting point of an i.sup.th cell wall are considered to be x.sub.o.sup.i, and coordinates of an end point may be calculated as
where l is a length of the cell wall.
[0114] A constraint equation that the cutting tool and a honeycomb unit need to meet is:
[0115] A condition function H.sub.1(x) is:
[0116] In this case, R cos wt may be calculated as follows:
R cos wt=H.sub.1(x)√{square root over (R.sup.2−(x.sub.0.sup.i−x).sup.2)} (6)
[0117] R cos wt is substituted into the constraint equation, and a time t during which the cell wall is in a cutting state may be obtained by using the following formula:
ƒ(x(t))+H.sub.1(x)√{square root over (R.sup.2−(x.sub.0.sup.i−x(t)).sup.2)}−a.sup.ix(t)−b.sup.i=0 (7)
[0118] In addition, a formula for calculating an inlet angle of the i.sup.th honeycomb cell wall cut at any time is:
[0119] An azimuth angle γ of each honeycomb cell wall is defined as an angle between the cell wall and Xw. Therefore, two components of forces in Xw and Yw directions may be derived from the following formula:
[0120] A second condition function H.sub.2(x) is:
[0121] A total cutting force for milling the honeycomb core is obtained as follows:
[0122] The theoretical analysis of a resisting torque formed by the pressure plate III-43 on the workpiece is as follows:
[0123] It is known that the milling forces on the honeycomb core in X and Y directions are F.sub.Yw,F.sub.Xw and a pressing force F.sub.Y of the pressure plate. Assuming that a linear distance between an entrance position at which the milling cutter starts to cut the workpiece and a center position at which the pressure plate applies a pressure is L, the milling force for milling the honeycomb plate produces a torque effect on the workpiece, that is, F.sub.w.Math.L, where F.sub.w is a sum of the milling forces of the honeycomb core and the honeycomb plate. To avoid that the position of the workpiece changes during machining and ensure reliable positioning, it needs to make a torque formed by a friction force F.sub.ƒ formed at the pressure plate III-43 be capable of offsetting the torque of the milling force. That is:
F.sub.ƒ=F.sub.Y.Math.μ=qA.Math.μ (12)
ƒ=q.Math.μ (13)
[0124] where q is a single pressure applied by each point of the pressure plate to the workpiece; and ƒ is a single static friction force formed by the single pressure.
[0125] As shown in
[0126] where F.sub.w is the milling force, and L is a distance from the milling force to a rotation center.
[0127] Because the pressure plate III-43 is required to be as close to the cutting region as possible, a largest distance L herein is √{square root over (c.sup.2+d.sup.2)}. Due to the known milling force, a minimum pressing force that the pressure plate III-43 can apply may be calculated according to double integral. Then, according to the foregoing formula (3), to avoid a maximum pressing force that can be applied by plastic deformation of the honeycomb core, the application range of the pressing force of the pressure plate III-43 may be obtained.
[0128] For a linkage working method of the machine tool fixture clamping apparatus III formed by six mechanical arms and a machine tool cutting path, according to positions of the mechanical arms and the position of the workpiece, an X-axis and Y-axis coordinate system is established, the working range of the mechanical arm is clearly divided in a workpiece coordinate system, and each region obtained through division works through cooperation between the mechanical arms. As regions passed during machine tool cutting are different, in a reached different region, a mechanical arm is responsible for the region for cooperation and clamping. As shown in
[0129] First, in determining the position and layout of the mechanical arms, it is necessary to ensure that the maximum working range of the four adjacent mechanical arms that can form a rectangle has a common coverage. That is, four circles with a radius of R in the figure have a common intersection. The machining of any point on the workpiece can be covered only after the intersection is ensured. However, if the intersection is excessively large, a problem of mutual interference between the mechanical arms III occurs. To ensure that there is an intersection and no interference problem occurs, a geometric relationship in the figure may be obtained:
[0130] According to the foregoing formula, a range of n may be calculated, and after the arrangement positions of the mechanical arms are obtained, the mechanical arms are separately mounted in the proper positions. As shown in the figure, the positions of the mechanical arms have been distributed according to the size of the workpiece, and the positions of the six mechanical arms in the figure are named “upper left”, “lower left”, “upper”, “lower”, “upper right”, and “lower right” respectively. “Upper left”, “upper”, and “upper right” are equidistantly distributed along an x-axis direction, “lower left”, “lower” and “lower right” are equidistantly distributed along the x-axis direction, “upper left” and “lower left” are equally divided on two sides of a long side of the workpiece V along a y axis at a distance of m, “upper” and “lower” are equally divided on two sides of the long side of the workpiece V along the y axis at the distance of m, and “upper right” and “lower right” are equally divided on two sides of the long side of the workpiece V along the y axis at the distance of m.
[0131] Second, an aspect of programming a numerical control machine tool. The numerical control machine tool has a machine tool origin, a reference point, a working origin, and a cutter calibration point. The machine tool origin is an origin of a machine tool coordinate system, and is a datum point of another coordinate system such as the workpiece coordinate system or a programming coordinate system, and the machine tool reference point. The numerical control machine tool implements a plan of the cutting path during machining in a manner of programming coordinates. The programming coordinate system is a coordinate system established by a programmer according to a component pattern, a machining technology, and the like. The programmer uses a specific point of the workpiece as an origin of the workpiece coordinate system, and this point is used as the working origin. The cutter calibration point is a starting point at which a cutting tool moves relative to the workpiece during machining of the numerical control machine tool, and the program starts from this point. In
[0132] Third, an aspect of dividing the working region of the mechanical arm. After the point o is determined as the working origin, and the workpiece coordinate system is established, a machining path of the workpiece V is programmed according to a machining technology process required by the workpiece V. A working range of each mechanical arm is a circle with a radius of R. It can be learned according to arrangement positions of the mechanical arms that there is a common working range between every two mechanical arms, and the common working range between every two mechanical arms is made to lines parallel to the x axis and parallel to the y axis in the workpiece coordinate system, to divide the working range into 13 working regions. After the working region is divided, each corresponding region has a specific coordinate region in the workpiece coordinate system. A cooperation relationship between the mechanical arms of the six positions is then programmed. The program is enabled to follow as follows: When the milling cutter performs milling machining in a region A1, the “upper left” mechanical arm dodges, and the “lower left” and “upper” mechanical arms jointly implement pressing on the region A1; when the milling cutter performs milling machining in a region A2, the “upper left” and “lower left” mechanical arms jointly implement pressing on the region A2; when the milling cutter performs milling machining in a region A3, the “lower left” mechanical arm dodges, and the “upper left” and “lower” mechanical arms jointly implement pressing on the region A3; when the milling cutter performs milling machining in a region A4, the “upper left” and “upper” mechanical arms jointly implement pressing on the region A4; when the milling cutter performs milling machining in a region A5, the “lower left” and “lower” mechanical arms jointly implement pressing on the region A5; when the milling cutter performs milling machining in a region A6, the “lower” mechanical arm implements pressing on the region A6; when the milling cutter performs milling machining in a region A7, the “upper” and “lower” mechanical arms jointly implement pressing on the region A7; when the milling cutter performs milling machining in a region A8, the “upper” mechanical arm implements pressing on the region A8; when the milling cutter performs milling machining in a region A10, the “lower right” and “lower” mechanical arms jointly implement pressing on the region A10; when the milling cutter performs milling machining in a region A11, the “upper right” mechanical arm dodges, and the “lower right” and “upper” mechanical arms jointly implement pressing on the region A11; when the milling cutter performs milling machining in a region A12, the “upper right” and “lower right” mechanical arms jointly implement pressing on the region A12; and when the milling cutter performs milling machining in a region A13, the “lower right” mechanical arm dodges, and the “upper right” and “lower” mechanical arms jointly implement pressing on the region A13. In the 13 regions, the regions A2, A4, A5, A7, A9, A10, or A12 is a common intersection region between every two mechanical arms. Therefore, it is implemented only through cooperation between the two corresponding mechanical arms that have an intersection. The region A1, A3, A6, A8, A11, or A13 is a range covered by a single mechanical arm. However, considering a case that the single mechanical arm in this region may interfere with the machine tool spindle, the mechanical arm in this region is selected to dodge, and an adjacent mechanical arm is responsible for pressing.
[0133] As shown in
[0134] As shown in
[0135] As shown in
[0136]
[0137] As shown in
[0138]
[0139] A specific working mode of the minimum quantity lubrication spray angle control apparatus is as follows:
[0140] First, an airflow field distribution in a milling region may be determined due to parameters such as a shape and a size of the cutting tool, a milling manner, and a rotation speed of the milling cutter. When a position of a nozzle elevation is considered, because a micro-droplet may enter the milling region more easily under assistance of radial flow, it needs to select to spray atomization from a direction of the radial flow in an airflow field. Therefore, by adjusting the high elevation mechanism, that is, the angle between the hinged support IV-3 and the high elevation rod IV-4, and according to an angle of the radial flow in the airflow field, a proper angle α of the elevation may be determined, and the angle is within a range of the angle of the radial flow.
[0141] Then, the low elevation mechanism is adjusted. That is, the servo motor IV-9 transmits a torque by using the gear train, and controls the rotation of the low elevation rotating member IV-34, to finely adjust the elevation of the nozzle IV-51. Because the aluminum alloy honeycomb plate V includes the upper and lower plates, and is of an aluminum alloy honeycomb core structure in the middle, during vertical milling machining, with insertion of the milling cutter, the elevation of the nozzle IV-51 is finely adjusted properly, and the micro-droplet can be better sprayed into a thin wall surface of the middle aluminum alloy honeycomb core instead of being large-area rebounded on an upper aluminum plate surface. In this way, a better minimum quantity lubrication effect is achieved.
[0142] Finally, the horizontal swing angle mechanism is adjusted. That is, the steering gear IV-50 transmits a torque by using the synchronous belt, and controls horizontal rotation of the ball joint rotating member IV-40, to finely adjust the horizontal swing angle of the nozzle IV-51. Because the middle honeycomb core is of a periodic porous thin wall structure, it needs to select the most proper spray horizontal swing angle according to characteristics of a hexagon.
[0143] According to the characteristic that each inner angle of a regular hexagon is 120°, an angle with a feature is selected for analysis. Within 0°-180°, a larger angle formed by an incident angle and a reflection angle indicates better spreadability of the droplet and a better lubrication effect. Therefore, the analysis is divided into 5 stages herein:
[0144] When the incident angle is 0°-30°, the spreadability of the droplet is poor, and the lubrication effect is poor;
[0145] when the incident angle is 30°-45°, the spreadability of the droplet is relatively poor, and the lubrication effect is relatively poor;
[0146] when the incident angle is 45°, the spreadability of the droplet is general, and the lubrication effect is general;
[0147] when the incident angle is 45°-60°, the spreadability of the droplet is relatively good, and the lubricating effect is relatively good; and
[0148] when the incident angle is 60°-90°, the spreadability of the droplet is good, and the lubricating effect is good.
[0149] The analysis of the incident angle includes the following four cases:
[0150] Case 1: As shown in
[0151] Case 2: As shown in
[0152] Case 3: As shown in
[0153] Case 4: As shown in
[0154] It can be found through the analysis of the foregoing four cases that, assuming that when the cutting direction of the milling cutter is horizontal to the right, if case 1 and case 3 are selected, two thin wall surfaces have good lubrication effects, and four thin wall surfaces have poor lubrication effects; and if case 2 and case 4 are selected, four thin wall surfaces have relatively good lubrication effects, and two thin wall surfaces have poor lubrication effects. Case 3 and case 4 are rejected due to a reason of the cutting path. Then, it can be learned through the analysis of case 1 and case 2 that the six thin wall surfaces cannot be simultaneously in a state that the droplets have relatively good spreadability regardless of angles of the nozzle. Therefore, it needs to adjust the horizontal swing angle of the nozzle as much as possible to make four of the six surfaces be in a state that the spreadability is relatively good. Therefore, in a process of adjusting the horizontal swing angle of the nozzle from 0° to 90°, it is found that the most suitable adjustment range of the horizontal swing angle is greater than or equal to 15° and less than or equal to 45°, so that the four of the six surfaces can be in the state that the droplets have relatively good spreadability.
[0155] By using the foregoing cooperation between the high elevation mechanism and the low elevation mechanism, the elevation can be adjusted, and the spray distance, that is, the target distance can be properly adjusted. A calculation for the theoretical analysis of the nozzle distance is as follows:
[0156] Boundary conditions for the droplet to attach are as follows:
[0157] A movement of an oil droplet in MQL atomization is mainly controlled by resistance of the airflow field. Therefore, under specific air flow, the nozzle distance has a great impact on a hitting speed of the oil droplet. First, two necessary dimensionless parameters are given, including the following content:
[0158] Weber number of the droplet:
[0159] where ρ.sub.d is a liquid density of the droplet; V.sub.In, is a normal incident speed of the droplet; d.sub.d is a diameter of the droplet; and σ is a surface tension.
[0160] Laplace number of the droplet:
[0161] The Laplace number represents a ratio of the surface tension to a viscous force acting on fluid.
[0162] where μ a liquid viscosity of the droplet.
[0163]
[0164] If two forms of “bonding” and “spreading” are both regarded as an “adhesion” form, the following formula needs to be met:
We<We.sub.c=A.Math.Lα.sup.−0.18 (18)
[0165] The droplet may be attached, and a formula (19) is derived:
[0166] where V.sub.Inc is a critical normal incident speed of the droplet.
[0167]
[0168] where x is an axial distance from the nozzle to the cutting tool and the workpiece surface, θ is an angle range in which the nozzle may spray; d.sub.0 is an outlet diameter of the nozzle; V.sub.x is a droplet speed at the position x; and V.sub.0 is an outlet speed of the nozzle.
[0169] A formula for solving the outlet speed of the nozzle is:
[0170] where is air flow.
[0171] Considering that an effect of the elevation α is to spray a small droplet to a cutting region as much as possible, there is:
V.sub.x=V.sub.In/cos α (22)
[0172] It can be learned from the formulas (19), (20), (21), and (22), a critical nozzle distance for the droplet to adhere is:
[0173] The positioning system in the present invention can provide a reliable clamping force, and can adjust a pressing force, so that clamping and unloading are convenient and quick. The linkage working method for the machine tool cutting path of the fixture is suitable for machining a large-size honeycomb workpiece. That is, the fixture may perform clamping near a machining region at which the cutting tool is machined, thereby ensuring the reliability of machining to the greatest extent. In addition, it is environmentally friendly because the mechanical structure is used. The equipment further includes the minimum quantity lubrication spray angle control apparatus, which can follow a movement of the machine tool spindle during machining and automatically adjust the angle at any time, and the theoretical analysis of the horizontal swing angle of the nozzle and the target distance is further made for the characteristic of the hexagonal structure of the honeycomb core, so that the angle at which the nozzle performs spraying is more adaptable to changes during machining, and the minimum quantity lubrication can better assist in cutting machining. By using the positioning system and the milling equipment in the present invention, the equipment compartment bottom plate in the rail transit core components can be mass-produced. When the equipment compartment bottom plate is machined, no form and position errors generate, and when the honeycomb plate is milled, the jet flow parameters are adjusted and controlled, to avoid defects of the honeycomb plate and ensure the cushioning performance when the honeycomb plate is applied to rail vehicles. The present invention can serve subways and high-speed railways, and resolve technical problems in the industry field, but is not limited thereto.
[0174] The specific implementations of the present invention are described above with reference to the accompanying drawings, but are not intended to limit the protection scope of the present invention. Those skilled in the art should understand that various modifications or deformations may be made without creative efforts based on the technical solutions of the present invention, and such modifications or deformations shall fall within the protection scope of the present invention.