Day look forward to builds product line of the 4th compressor to be replaced in order to forging in the beauty cast

Iron of new day of business of production of Japanese iron and steel and stay in friendly metal company (NSSMC) says, its and the Inc. of crankshaft of international of joint-stock subsidiary Japan that stay in firm of friendly trade issue (ICI) plan builds to forging newly in the United States compressor product line.

ICI already was in the United States operation 20 years, run 3 to forging at present compressor product line, year produce nearly 2.7 million tons of crankshaft in order to satisfy the requirement with driving North America. ICI already decided to add the 4th to forging now compressor product line. After setting of product line of the 4th punch is finished, productivity will be added to about 1.5 times current, achieve 4 million / year.

NSSMC says, sale of North America car predicts future will grow 7% 5 years. Japan and Korea car manufacturer are changing the United States to the market. Because forging crankshaft is smaller, improved engine performance, fuel efficiency Yi Genggao, 3 car manufacturer that are located in Detroit are forginging cast-iron crankshaft instead crankshaft.

The servo multitask with the greatest throughout history of Shu Le company compressor put into production

Ground above 11 8 meters 15 meters rice, long, wide make an appointment with 1000 metric ton again: The company of car supplier Craemer of German Herzebrock-Clarholz area, the multitask of the biggest servo that in Shu Le company to this day makes recently production begins on compressor. The product line that production expert of this metal figuration, plastic treatment and mould is using this to bring base of 2.5 meters of 8 meters long, thick compressor produces structural member, especially car seat housing.

Compressor base need is enough big, because be in figuration process, workpiece carriage need is versed in through a few. In the past, craemer company must use two compressor in product line, by gross join of 3 automation system; Use a compressor to be able to have same treatment only now, the integral dependability that increased product line greatly — especially workpiece need not carry another compressor from a compressor again.

On this new product line, a when workpiece offers by company of Shu Le automation 3 axes high-powered multitask the system is carried, contain what make a person impressive likewise to exceed 10 meters of span. Dinky vibration ensures workpiece is carried reliably quickly, the premise condition of dependability is development of company of Shu Le automation is compositive and active decrease brace up (AVD) system, every electric machinery outputs the power that exceeds 500kW, generation 25, the total nominal pressure of 000kN.

"Obtain this kind of tall productivity to will make we can ensure the market of prospective project leads a position " executive president SiegbertGeldner sums up the manufacturing & technology of Paul Craemer Inc. : “We have confidence to be able to call in before long this investment ” .

In view of the scale that servo compressor makes the person is impressive, two use ship, special crane and 3 trucks that take 16 axes trailer, used Ford of Cong Aier of the ability between 9 climate (Erfurt) Shu Le factory carries in Dong Wei Sitefalun city (East Westphalia) client spot. Ship is overcome from Sa dark – bring Hal spy city (Saxony-Anhalt) inland haven A agrees (Aken) set out, lan Yunhe of Er of Elbe of by way of, rice spy and much Temengde – Aimusi the canal, till bright this special Hiltrup haven.

After reaching Craemer plant, inside the workshop that builds technically, this compressor base is put into 6 meters first deep base inside hole, back-to-back move is 3 meters of half tall slide block and 4 meters tall beam, pass 4 pull rod to secure 3 all assemblies take one’s place next, this cost easy to strap an expert the time of about 4 months will complete this project. This giant compressor already was the 5th takes skill of servo straight drive product line that Craemer group uses.

2 machine tools reap benefit management of work norm of countrywide mechanical industry is advanced and collective

From aid company of 2 machine tools understands, 2 machine tools have the honor to win aid the 2013 year that committee of technology of standardization of fixed number of persons of work norm of countrywide mechanical industry issues are advanced and collective. The whole nation shares 28 units selected, shandong saves those who obtain this special honour to have 2 only.

Work norm management is the main component of company production management, it is the important basis of the resource such as reasonable arrangement person, money, content. Come for years, aid 2 adding field of work norm management to do a large number of works, level of treatment man-hour quota refines treatment labor situation, level of the quota when ship-fitter refines process, outside be unifinication assist standard of the treatment, data when assembling production to offer accurate class, get used to a product to specialization the demand that produces an organization.

Accuse those who machine a machine tool to increase as number, the demand that makes to man-hour norm is higher, to ensure level of quota of man-hour of treatment of numerical control machine tool is more scientific and reasonable, aid 2 use first ” analytic type pushs disperse data to go out nonlinear function ” computation is formulary, be used at man-hour quota level make with management, completed bid of machinist trade association appoint the task making bid of meeting make known to lower levels, will have promotion application as occupation standard.

Jinan limited company of group of 2 machine tools is one furniture the large and mechanical equipment that more than 70 years of grumous innovation and enterprising consciousness, culture are accumulated creates a company. At present aid group of 2 machine tools already was Chinese dimensions facility of the largest v of heavy-duty numerical control and gold of large numerical control cut machine tool research and development to create base, chinese machinist job 100 strong, v industry is gotten army enterprise, be known as ” 3 favorable opposition of world press one of equipment manufacturer ” .

It is reported, aid the home market of big, heavy-duty mechanical compressor has 2 machine tools rate amount to 70% above, offerred product line of hundreds large punch and on 1000 heavy-duty and mechanical compressor for domestic auto industry and other industry, have many 400 (set) product fill country is blank, be known as ” the equipment ministry of Chinese auto industry ” .

Since 1997, provide product line of more than 10 punch for world-renowned Motor Corporation, have complete intellectual property at beginning to be exported to market of American high end 2001 with multitask the heavy-duty and mechanical compressor that compressor is a delegate, the product sells as far as to 50 many countries and area.

Numerical control lathe is multiple and compound dictate circularly (G70 ~ G76)

Use code of this group of G, can machine the part with more complex form, the simply when process designing specifies finish machining course and amount of penetration of a cutting tool of rough machining back, the system can be calculated automatically a rough machining course and treatment frequency, process designing efficiency is accordingly taller.

1.Outside round rough machining is compound circulate (G71)

Statement form Re of   of D of Δ of G71   U

            W Ff Ss Tt of Δ of U W of Δ of G71   Pns Qnf U

Instruction function Excision club expects semifinished product is major mental allowance, cutting is along parallel Z axis direction undertakes, see a picture 1,

Graph 1 outside round rough machining circulates

A is circular start, a-A’-B is finish machining course.

The instruction explains Δ D expresses every time cutting deepness (radius is worth) , without sign;

        E represents the amount that retreat a knife (radius is worth) , without sign;

        Ns represents finish machining line the suitable serial number of the first block;

        Nf states finish machining course is the last the suitable serial number of block;

       Δ U shows the finish machining surplus of X direction, diametical value;

            Δ W shows the finish machining surplus of Z direction.

Process designing of use loop instruction, should decide the dot that change a knife, loop nods A, cutting above all only then dot A ‘ the coordinate position with cutting terminus B. To save the auxiliary working hours of numerical control machine tool, use G00 to A of abide circling point from the dot that change a knife instruction of fast fixed position, the X coordinate of A of abide circling point is located in besides semifinished product dimension, z coordinate value and cutting only then dot A ‘ Z coordinate value is same.

Next, according to outside the statement form that round rough machining circulates and treatment craft requirement draw up G71 dictates block, there is U of two addresses accord with in dictating circularly, before one expresses to bear amount of penetration of a cutting tool, hind a finish machining surplus that shows X way. There is magic figures drawn by Taoist priests to invoke or expel spirits and bring good or ill fortune of address of P, Q in block, criterion the finish machining surplus that U of address accord with shows X way, express to bear amount of penetration of a cutting tool conversely. Quantity of back penetration of a cutting tool does not have negative worth.

A ‘ the contour line that → B is workpiece, a → A ‘ → B is finish machining course, the cutting tool when rough machining nods W of regressive Δ U /2, Δ from A, namely surplus of finish machining of automatic put apart. Ordinal date Ns describes the line that cutting tool cutting machines to the block between Nf.

1 graph shows example 2 times, process designing of instruction of loop of rough machining of the circle outside applying.

Graph 2 outside round rough machining applies circularly

N010 G50 X150 Z100

N020 G00 X41 Z0

N030 G71 U2 R1

N040 G71 P50 Q120 U0.5 W0.2 F100 

N050 G01 X0 Z0

N060 G03 X11 W-5.5 R5.5

N070 G01 W-10

N080 X17 W-10

N090 W-15

N100 G02 X29 W-7.348 R7.5

N110 G01 W-12.652

N120 X41

N130 G70 P50 Q120 F30

2.  End panel rough machining is compound circulate (G72)

Statement form D Re of Δ of G72   W

    W Ff Ss Tt of Δ of U W of Δ of G72   Pns Qnf U

Instruction function Dividing cutting is outside undertaking along direction of parallel X axis, this instruction function and G71 are identical, see a picture 3.

The instruction explains The meaning of W of U of Δ D, E, Ns, Nf, Δ , Δ and G71 are identical.

Graph rough machining of 3 end panel circulates

Graph rough machining of 4 end panel applies circularly

Example 2 show 4 times like the graph, apply process designing of instruction of loop of end panel rough machining.    

N010 G50 X150 Z100

N020 G00 X41 Z1

N030 G72 W1 R1

N040 G72 P50 Q80 U0.1 W0.2 F100 

N050 G00 X41 Z-31

N060 G01 X20 Z-20

N070 Z-2

N080 X14 Z1

N090 G70 P50 Q80 F30

3.  Fixed appearance cutting is compound circulate (G73)

Statement form K Rd of Δ of I W of Δ of G73   U

      W Ff Ss Tt of Δ of U W of Δ of G73   Pns Qnf U

Instruction function Suit treatment to cast, forge creates a kind of work of form, see a picture 5.

Graph cutting of 5 fixed appearance is compound circulate

The instruction explains Δ I states X axial always retreats a knife to measure (radius is worth) ;

Δ K states Z axial always cancels knife amount;

D represents circular time;

Ns represents finish machining line the suitable serial number of the first block;

Nf states finish machining course is the last the suitable serial number of block;

The finish machining surplus that Δ U shows X way (the diameter is worth) ;

Δ W shows the finish machining surplus of Z direction.

Fixed appearance cutting is compound the characteristic that dictates circularly, cutting tool contrail is parallel the outline at workpiece, reason suits treatment to cast the preform that makes take shape with forge. Quantity of back penetration of a cutting tool passes X axis direction to always retreat a knife to measure Δ I and Z axis direction to always retreat a knife to measure Δ K to divide respectively get with circular time D. The cutting deepness of the set that always removes a knife to estimate Δ I and Δ K value and workpiece is concerned.

Cutting of form of use solid shape is compound circular instruction, should decide the dot that change a knife, loop nods A, cutting above all only then dot A ‘ the coordinate position with cutting terminus B. Example of the path on the analysis, a nods the circling point that it is abide, a ‘ the contour line that → B is workpiece, a → A ‘ the finish machining course that → B is cutting tool, the cutting tool when rough machining backs down from A dot nod to C, regressive distance is U /2 of Δ of Δ I + respectively, w of Δ of Δ K + , after such rough machining circulate W of U /2 of Δ of surplus of finish machining of automatic put apart, Δ .

Ordinal date Ns describes the line that cutting tool cutting machines to the block between Nf.

Graph compound loop applies cutting of 6 fixed appearance

Example 3 show 6 times like the graph, apply fixed appearance cutting process designing of compound loop instruction.

X of N010 G50 100 Z100

50 Z10 of X of N020 G00

18 W5 R10 of U of N030 G73

N040 G73 P50 Q100 U0.5 W0.5 F100 

N050 G01 X0 Z1

R of N060 G03 X12 W-6 6

N070 G01 W-10

N080 X20 W-15

N090 W-13

N100 G02 X34 W-7 R7

N110 G70 P50 Q100 F30

4.  Finish machining is compound circulate (G70)

Pns Qnf of   of statement form G70 

After instruction function dictates with G71, G72, G73 rough machining ends, loop of usable finish machining dictates, make cutting tool has the precision work of A-A’-B, (if pursue 1, graph 3, graph 5) .

The instruction explains Ns expresses to assign finish machining route the ordinal date of the first block;

Nf expresses to assign finish machining route the suitable serial number of the last block;   

Instruction of loop of G70 ~ G73 calls N(ns) to come between N(nf) block, the subprogram cannot be called in block among them.

5.  End panel drill is complex dictate circularly (G74)

Statement form G74 Re

            G74 X (U) Z (W) D Ff of Δ of K R of Δ of P Δ I Q 

Instruction function Can use at interrupted cutting, if course taking a knife pursues 7, be like a X (U) with P, R the value omits, can use at bore treatment.

Graph drill of 7 end panel is complex circulate

The instruction explains E represents the amount that retreat a knife;

X states the X coordinate that B nods is worth;

U states by A the increment coordinate to B is worth;

Z states the Z coordinate that C nods is worth;

W states by A the increment coordinate to C is worth;

Δ I states shift of X axis direction is measured, without sign;

Δ K states shift of Z axis direction is measured, without sign;

Δ D states in cutting bottom cutting tool go back is measured;

F shows feed rate.

Example 4 show 8 times like the graph, use end panel drill process designing of compound loop instruction.

Graph 8 Compound loop uses end panel drill

G50 X60 Z40

G00 X0 Z2

G74 R1

G74 Z-12 Q5 F30 S250

G00 X60 Z40

6.  Outside round grooving is compound circulate (G75)

Statement form G75   Re

G75   X (U) Z (W) D Ff of Δ of K R of Δ of P Δ I Q                                                     

Instruction function Use at end panel interrupted cutting, if course taking a knife pursues 9, be like a Z (W) with Q, R the value omits, can use at outside the interrupted cutting of round chamfer.

Graph 9 outside round grooving is compound circulate

The instruction explains E represents the amount that retreat a knife;

X states the X coordinate that C nods is worth;

U states the increment coordinate that nods to C by A dot is worth;

Z states the Z coordinate that B nods is worth;

W states the increment coordinate that nods to B by A dot is worth;

Other the meaning of each symbol and G74 are identical.

Round grooving is compound outside application circular instruction, if use cutting tool is grooving knife, this cutting tool has 2 point of a knife, the knife that set left point of a knife is this cutting tool dot, the circular start A that wants set cutting tool first before process designing and target nod D, if workpiece chamfer is wide the blade that is more than grooving knife is wide, want to consider the jackknife amount of edge contrail, the blade that makes cutting tool measures Δ K to be less than grooving knife in displacement of Z axis direction is wide, the blade of grooving knife is wide the jackknife volume that measures the difference of Δ K to be edge contrail with displacement of point of a knife.

5 graphs show example 10 times, round grooving is compound outside applying circular instruction process designing.

Graph 10 outside compound loop applies round grooving

G50 X60 Z70

G00 X42 Z22 S400

G75 R1

G75 X30 Z10 P3 Q2.9 F30 

G00 X60 Z70

7.  Whorl cutting is compound circulate (G76)

Statement form G76 Dmin Rd of Δ of Pm R A Q

G76 X (U) Z (W) D Ff of Δ of Ri Pk Q

Instruction function The craft sex that this whorl cutting circulates is more reasonable, process designing efficiency is taller, if course of whorl cutting loop and feed method pursue 11.

Graph 11 whorl cutting is compound circular course and feed law

The instruction explains M states finish machining repeats a time;

R expresses inclined to the quantity that retreat a knife the unit is counted (0.01~9.9f, it is one unit with 0.1f, with 00~99 two digit word is appointed) ;

A expresses point of view of point of a knife;

Δ D states first time is rough cut deep (radius is worth) ;

Degressive formula calculates cutting deepness D2 = Δ D;

      D3 = Δ D;

      D of Δ of Dn = ;

Every time thick cut deep: D of Δ of Δ Dn = – Δ D;

Δ Dmin shows depth of the smallest cutting, be less than Δ Dmin when Dn of cutting deepness Δ , take Δ Dmin to regard cutting as deepness;

X states the X coordinate that D nods is worth;

U states the increment coordinate that nods to D by A dot is worth;

Z states D nods Z coordinate value;

W states the increment coordinate that nods to D by C dot is worth;

I states the radius of awl whorl is poor;

K shows whorl height (X direction radius is worth) ;

D shows finish machining surplus;

F shows whorl lead.

Example 6 show 12 times like the graph, apply whorl cutting process designing of compound loop instruction (finish machining frequency is 1 times, inclined it is 4mm to the quantity that retreat a knife, point of a knife is 60 ° , the smallest cut take 0.1mm greatly, finish machining surplus takes 0.1mm, whorl height is 2.4mm, cut for the first time take 0.7mm greatly, pitch is 4mm, whorl trail is 33.8mm) .

Graph compound loop applies 12 whorl cutting

G00 X60 Z10

G76 P011060 Q0.1 R0.1

G76 X33.8 Z-60 R0 P2.4 Q0.7 F4

Echelon whorl is machined in the gearshift turning on numerical control lathe

Echelon whorl plug guage

  We know, in workpiece of whorl of echelon of the turning on numerical control lathe, the exterior surface roughness of whorl cannot assure well when high speed turning, the requirement that short of machines, efficiency of the production when low speed turning very low, and turn into from high speed directly whorl random tooth can be brought about when low speed turning. Oneself pass a test, the random tooth problem when gearshift turning can use a kind of simple and practical method to try to solve, turning of higher rotate speed can be used first when turning whorl, reoccupy low speed comes fine vehicle and Xiu Guang, improved manufacturing efficiency thereby, assured the dimension precision of whorl and exterior surface roughness well.

The method of whorl of echelon of 1. gearshift turning

  Below in order to machine × of echelon whorl Tr36 6 for exemple, if the introduction wheres whorl of echelon of turning of the gearshift on the numerical control lathe of CST980T system. The echelon whorl workpiece of turning is shown 1 times like the graph.

  Because the pitch of this echelon whorl is lesser, can use inclined machine into tie-in knife law, because of the G76 whorl cutting of GSK980T system compound loop dictates even if with inclined enter means feed, reason can use G76 statement, the process designing when whorl of thick car echelon is as follows, surplus of vehicle of put apart fine.

G00 X40 Z-20;

G76 P010030 Q80 R0.05;

G76 X29 Z-85 P3500 Q100 F6;

G00 X200 Z50;

  After thick car is finished, if move rotate speed low speed to call car of original order essence directly right now, random tooth of regular meeting, produce collapse blade or bump into car accident, reason we should solve problem of lathe tool random tooth before low speed turning. Considering low speed

  Rate of feed of the lathe tool when turning is very slow, we can observe with naked eye whether lathe tool of the whorl when turning and chamfer of whorl tooth form are aimed, specific operation method is as follows:

  (1) changes workpiece coordinate to fasten, make workpiece surface is not contacted when whorl of lathe tool car, will thick lathe tool stops in positional X200 Z50 to be in after thick car, carry out after typing G50 X192 of the input below means right now, transformed coordinate department namely, be equivalent to fastening coordinate square of axis of origin edge X to shift 4mm, be more than the space with an expensive tooth a bit namely. Move rotate speed of lathe main shaft right now low, if move 25r/min, run a program afresh, thick lathe tool is less than the car workpiece surface, the position that nearing workpiece surface is mobile. If pursue,2 are shown.

  (The echelon snail groove that 2) makes lathe tool and car go is opposite afresh, because rate of lathe tool feed is very slow, right now we can see lathe tool and former the echelon snail groove that the car goes is not of coincide, lathe tool deflection a paragraph of small distance, if the graph is shown 2 times, the echelon snail groove that the purpose should make lathe tool aims a car to go out afresh namely. It is same that the principle of the operation follows in whorl of bull of the turning on numerical control lathe, the axial start position before passing turning of change whorl lathe tool namely will achieve a goal, revise the Z-20 in afore-mentioned block G00 X40 Z-20 namely. We can need space of adjustment big deeply touched through naked eye judgement, be like but first Z-20 instead – 21, after moving program, groove still does not have the echelon whorl that discovers lathe tool and car go to be opposite completely. Revise Z cost again, run a program afresh, be opposite completely till lathe tool and echelon snail groove. If pursue,3 are shown.

  (3) restores original workpiece coordinate to fasten, begin precision work Understand to facilitate and make mistake not easily, will still lathe tool moves X200 Z50 position, in type means to fall, executive G50 X208, the workpiece coordinate with original rehabilitate is, run a program afresh, OK whorl of echelon of vehicle of low speed fine. The method that the axial start position before passing turning of afore-mentioned change whorl lathe tool also is when fine vehicle will write the two profile of smooth echelon whorl, pass at the same time measure, the number that controls cutting makes whorl achieves the requirement of dimension precision.

  Through the experiment, when the revolution gloomy in high speed and low speed turning is secured, the displacement of deflection of lathe tool need is fixed, had this data, blade dies in lathe tool after, or when after wearing away, needing to change a knife, need not use repeat tone to make move again, it is directly when vehicle of low speed fine the start deflection car whorl is corresponding the position is OK. Article place lifts those who machine example to be in factory of machine tool of Guangzhou numerical control to call lathe of CJK61352ACNC numerical control to be finished, it is to lathe tool of snail of the echelon when 25r/min from 560r/min gearshift when rotate speed of lathe main shaft on Z axis need 1.8mm of deflection of towards the left.

  The axial start position before if be in,wanting the ground to change turning of whorl lathe tool of course will write the two profile of smooth echelon whorl, manufacturing efficiency will be reduced greatly, to solve this problem, we can control echelon whorl two lateral to machine a process to make up two subprograms respectively, when be being called every time, make 0.1mm of deflection of lathe tool axial, hit the point tries to need to call the number of the subprogram certainly in first of workpiece, enroll whole treatment process thereby among the program, can move automatically all the time from the lathe when processing the 2nd work namely go down, be machined till workpiece eligible.

Echelon whorl gauge

The implementation of whorl of echelon of 2. gearshift turning on lathe of simple and easy numerical control

  Because wholer like a few functions such as GSK980T, FANUC-OTE numerical control system has the existence of compound instruction to make process designing becomes simpler, but do not have such function however on lathe of a few homebred economy numerical control. At this moment we are OK will firm inclined the thick car course that takes a way makes up a subprogram, every call lathe tool to be on X axis and Z axis feed is apart from small paragraph one, try hit the point to decide the subprogram needs the time that is called by the main program in first. After thick car is finished, still narrate a method to debug with the place in article go out to turn into from high speed thick car the displacement that lathe tool of the whorl after vehicle of low speed fine needs axial to move, invent process of treatment of lateral of left and right sides of fine vehicle whorl into the subprogram respectively again, call in the main program can.

3. a few note

  (Cutting juice is added when 1) cutting, look to whether want to add a center according to the circumstance.

  (2) lathe tool turns into from high speed low speed hind should aim echelon whorl chamfer strictly, want when the operation careful and serious, cannot careless. Can use the method that restores coordinate department stage by stage, divide corrective lathe tool namely, make progressively turning goes to lathe tool ministry of tooth bottom land.

  (The knife head width of thick lathe tool of essence of 3) echelon whorl cannot differ too big, the meeting after changing a knife otherwise makes cutting surplus too large, produce the problem such as collapse row.

  (4) the whorl to a few big pitch, rotate speed of the main shaft when turning cannot exorbitant, want the highest feed rate of referenced machine tool, can happen otherwise miss the issue such as the pace.

4. conclusion

  Effective treatment proves, above is on numerical control lathe the method of whorl of gearshift turning echelon is practical, and obtained very good treatment result. If the method that waits to need a thick car feed only to whorl of triangle of additionally a few big pitch, worm is inclined into law, statified feed law make up a subprogram, debug go out to turn into from high speed thick car after the lathe tool after vehicle of low speed fine needs the displacement with mobile axial, also write profile of left and right sides of fine vehicle whorl into the subprogram respectively, in the main program its call the lieutenant general to be able to complete treatment.