木制樓梯扶手彎頭專用數控加工機床的研制和應用
新聞來源：網絡 發布時間：2012-10-20
木(mu)(mu)制(zhi)(zhi)(zhi)樓梯(ti)(ti)扶手(shou)彎頭(tou)的(de)(de)加(jia)(jia)工(gong)(gong)(gong)(gong)一直(zhi)是(shi)困擾木(mu)(mu)制(zhi)(zhi)(zhi)樓梯(ti)(ti)扶手(shou)加(jia)(jia)工(gong)(gong)(gong)(gong)企(qi)業(ye)的(de)(de)難(nan)題(ti)，受(shou)當(dang)前扶手(shou)彎頭(tou)加(jia)(jia)工(gong)(gong)(gong)(gong)方(fang)法(fa)的(de)(de)限制(zhi)(zhi)(zhi)，生(sheng)產率和質量都滿足不了(le)市場(chang)的(de)(de)需要，嚴重影響著(zhu)木(mu)(mu)制(zhi)(zhi)(zhi)樓梯(ti)(ti)扶手(shou)的(de)(de)廣(guang)泛應(ying)用(yong)。東北林業(ye)大學林業(ye)與(yu)木(mu)(mu)工(gong)(gong)(gong)(gong)機械(xie)工(gong)(gong)(gong)(gong)程技術中(zhong)(zhong)心研制(zhi)(zhi)(zhi)與(yu)開(kai)發的(de)(de)木(mu)(mu)制(zhi)(zhi)(zhi)樓梯(ti)(ti)扶手(shou)彎頭(tou)專(zhuan)用(yong)數(shu)控加(jia)(jia)工(gong)(gong)(gong)(gong)機床(chuang)，具有(you)生(sheng)產效率高、加(jia)(jia)工(gong)(gong)(gong)(gong)精度高、機床(chuang)成倍低的(de)(de)特點，完全符合我(wo)國木(mu)(mu)制(zhi)(zhi)(zhi)樓梯(ti)(ti)扶手(shou)加(jia)(jia)工(gong)(gong)(gong)(gong)企(qi)業(ye)的(de)(de)需要，可為企(qi)業(ye)在(zai)市場(chang)競爭中(zhong)(zhong)創造可觀的(de)(de)市場(chang)利益，是(shi)木(mu)(mu)制(zhi)(zhi)(zhi)樓梯(ti)(ti)扶手(shou)加(jia)(jia)工(gong)(gong)(gong)(gong)企(qi)業(ye)值得擁(yong)有(you)的(de)(de)、高檔次的(de)(de)、經(jing)濟實(shi)用(yong)的(de)(de)專(zhuan)用(yong)樓梯(ti)(ti)加(jia)(jia)工(gong)(gong)(gong)(gong)機床(chuang)。
1.木制樓(lou)梯扶手(shou)彎頭(tou)專用數控(kong)加工機(ji)床的研制
由于木制(zhi)(zhi)(zhi)(zhi)樓梯(ti)扶手彎(wan)頭(tou)是一(yi)個(ge)典型(xing)的(de)(de)空(kong)間曲面型(xing)零件，運(yun)用(yong)普(pu)通(tong)木工(gong)機(ji)床及仿形(xing)機(ji)床很難(nan)保證加工(gong)面的(de)(de)形(xing)成。為(wei)此，利用(yong)數控(kong)機(ji)床加工(gong)，通(tong)過調用(yong)預(yu)先(xian)編制(zhi)(zhi)(zhi)(zhi)好的(de)(de)各種木制(zhi)(zhi)(zhi)(zhi)樓梯(ti)扶手彎(wan)頭(tou)曲線輪廓(kuo)形(xing)狀的(de)(de)數控(kong)程序，實現木制(zhi)(zhi)(zhi)(zhi)樓梯(ti)扶手彎(wan)頭(tou)的(de)(de)在線自(zi)動加工(gong)，該加工(gong)方法不僅減少了(le)許多輔助(zhu)模具和夾具，而且提(ti)高了(le)木制(zhi)(zhi)(zhi)(zhi)樓梯(ti)扶手彎(wan)頭(tou)的(de)(de)加工(gong)質量和生產率。木制(zhi)(zhi)(zhi)(zhi)樓梯(ti)扶手彎(wan)頭(tou)專(zhuan)用(yong)數控(kong)加工(gong)機(ji)床的(de)(de)研制(zhi)(zhi)(zhi)(zhi)充分體現了(le)如下(xia)幾點：
1.1運動性能好，加工(gong)質量穩定可靠
通(tong)過對(dui)木(mu)制(zhi)(zhi)樓梯(ti)扶(fu)(fu)手(shou)彎(wan)頭(tou)零件的(de)(de)分析，可(ke)知木(mu)制(zhi)(zhi)樓梯(ti)扶(fu)(fu)手(shou)彎(wan)頭(tou)是由(you)四(si)(si)個空(kong)間(jian)曲面(mian)(mian)組成(cheng)(cheng)的(de)(de)，頂面(mian)(mian)、帶凹槽的(de)(de)底(di)面(mian)(mian)和兩個側(ce)面(mian)(mian)，其中(zhong)(zhong)(zhong)兩個側(ce)面(mian)(mian)的(de)(de)曲線(xian)(xian)輪廓形(xing)狀是相(xiang)同的(de)(de)，四(si)(si)個面(mian)(mian)是以(yi)端(duan)截(jie)面(mian)(mian)的(de)(de)縱(zong)向(xiang)中(zhong)(zhong)(zhong)心(xin)面(mian)(mian)對(dui)稱的(de)(de)；端(duan)截(jie)面(mian)(mian)中(zhong)(zhong)(zhong)心(xin)的(de)(de)法向(xiang)中(zhong)(zhong)(zhong)心(xin)線(xian)(xian)的(de)(de)形(xing)狀形(xing)成(cheng)(cheng)了(le)木(mu)制(zhi)(zhi)樓梯(ti)扶(fu)(fu)手(shou)彎(wan)頭(tou)的(de)(de)空(kong)間(jian)形(xing)狀。采用三把成(cheng)(cheng)型銑刀加(jia)工木(mu)制(zhi)(zhi)樓梯(ti)扶(fu)(fu)手(shou)彎(wan)頭(tou)零件，可(ke)以(yi)保(bao)證四(si)(si)個空(kong)間(jian)曲面(mian)(mian)的(de)(de)曲線(xian)(xian)輪廓形(xing)狀，只要成(cheng)(cheng)型銑刀的(de)(de)運動(dong)軌(gui)跡與木(mu)制(zhi)(zhi)樓梯(ti)扶(fu)(fu)手(shou)彎(wan)頭(tou)端(duan)截(jie)面(mian)(mian)中(zhong)(zhong)(zhong)心(xin)的(de)(de)法向(xiang)中(zhong)(zhong)(zhong)心(xin)線(xian)(xian)相(xiang)平行，分三道工序就可(ke)加(jia)工出成(cheng)(cheng)型的(de)(de)木(mu)制(zhi)(zhi)樓梯(ti)扶(fu)(fu)手(shou)彎(wan)頭(tou)。
木(mu)制(zhi)(zhi)樓(lou)梯(ti)扶(fu)(fu)手(shou)(shou)彎(wan)(wan)(wan)頭(tou)(tou)端(duan)截面中心的(de)(de)法向中心線(xian)是(shi)一條空(kong)(kong)(kong)(kong)間(jian)(jian)曲線(xian)，是(shi)上行(xing)直線(xian)、下(xia)行(xing)直線(xian)河空(kong)(kong)(kong)(kong)間(jian)(jian)轉(zhuan)接弧(hu)(hu)線(xian)組(zu)成(cheng)的(de)(de)，根(gen)據空(kong)(kong)(kong)(kong)間(jian)(jian)轉(zhuan)接弧(hu)(hu)線(xian)形(xing)狀(zhuang)的(de)(de)不(bu)同沒，可(ke)以(yi)得到(dao)不(bu)同形(xing)狀(zhuang)的(de)(de)空(kong)(kong)(kong)(kong)間(jian)(jian)樓(lou)梯(ti)扶(fu)(fu)手(shou)(shou)彎(wan)(wan)(wan)頭(tou)(tou)，一般常(chang)用(yong)的(de)(de)是(shi)空(kong)(kong)(kong)(kong)間(jian)(jian)轉(zhuan)接圓(yuan)弧(hu)(hu)。現以(yi)空(kong)(kong)(kong)(kong)間(jian)(jian)轉(zhuan)接圓(yuan)弧(hu)(hu)形(xing)成(cheng)的(de)(de)空(kong)(kong)(kong)(kong)間(jian)(jian)樓(lou)梯(ti)扶(fu)(fu)手(shou)(shou)彎(wan)(wan)(wan)頭(tou)(tou)形(xing)狀(zhuang)為(wei)例(li)，分(fen)(fen)(fen)配機(ji)(ji)床(chuang)的(de)(de)運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)，建立符合(he)笛卡(ka)兒坐(zuo)標規則的(de)(de)直線(xian)坐(zuo)標系，空(kong)(kong)(kong)(kong)間(jian)(jian)直線(xian)需(xu)(xu)要(yao)(yao)保證刀(dao)(dao)具(ju)(ju)與(yu)(yu)(yu)工件(jian)(jian)X、Y、Z三(san)(san)個(ge)直線(xian)坐(zuo)標軸(zhou)(zhou)聯動(dong)(dong)(dong)(dong)(dong)(dong)；空(kong)(kong)(kong)(kong)間(jian)(jian)曲線(xian)需(xu)(xu)要(yao)(yao)保證刀(dao)(dao)具(ju)(ju)與(yu)(yu)(yu)工件(jian)(jian)X、Y、Z三(san)(san)個(ge)直線(xian)坐(zuo)標軸(zhou)(zhou)聯動(dong)(dong)(dong)(dong)(dong)(dong)外，還(huan)要(yao)(yao)保證圍繞(rao)X、Y兩條直線(xian)坐(zuo)標軸(zhou)(zhou)的(de)(de)擺動(dong)(dong)(dong)(dong)(dong)(dong)（A、B兩個(ge)方(fang)向運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)），即空(kong)(kong)(kong)(kong)間(jian)(jian)轉(zhuan)接圓(yuan)弧(hu)(hu)需(xu)(xu)要(yao)(yao)保證刀(dao)(dao)具(ju)(ju)與(yu)(yu)(yu)工件(jian)(jian)X、Y、Z、A、B五(wu)個(ge)方(fang)向的(de)(de)相(xiang)對(dui)(dui)運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)，由于該(gai)圓(yuan)弧(hu)(hu)繞(rao)Y軸(zhou)(zhou)的(de)(de)擺動(dong)(dong)(dong)(dong)(dong)(dong)非常(chang)小，不(bu)影響木(mu)制(zhi)(zhi)樓(lou)梯(ti)扶(fu)(fu)手(shou)(shou)彎(wan)(wan)(wan)頭(tou)(tou)的(de)(de)加(jia)(jia)工質(zhi)(zhi)(zhi)量(liang)，可(ke)忽略不(bu)計的(de)(de)。因(yin)此，加(jia)(jia)工木(mu)制(zhi)(zhi)樓(lou)梯(ti)扶(fu)(fu)手(shou)(shou)彎(wan)(wan)(wan)頭(tou)(tou)只需(xu)(xu)要(yao)(yao)保證刀(dao)(dao)具(ju)(ju)與(yu)(yu)(yu)工件(jian)(jian)X、Z、A、B四(si)個(ge)方(fang)向相(xiang)對(dui)(dui)運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)即可(ke)。分(fen)(fen)(fen)配相(xiang)對(dui)(dui)運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)時，如果把運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)全部(bu)(bu)分(fen)(fen)(fen)配給(gei)刀(dao)(dao)具(ju)(ju)或工件(jian)(jian)勢必增加(jia)(jia)該(gai)部(bu)(bu)件(jian)(jian)的(de)(de)重量(liang)，使該(gai)部(bu)(bu)件(jian)(jian)結構復雜，影響加(jia)(jia)工質(zhi)(zhi)(zhi)量(liang)，在采用(yong)均勻分(fen)(fen)(fen)配的(de)(de)方(fang)式，即刀(dao)(dao)具(ju)(ju)完成(cheng)Y、Z兩個(ge)方(fang)向的(de)(de)相(xiang)對(dui)(dui)運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)，工作臺及工件(jian)(jian)完成(cheng)X、A兩個(ge)方(fang)向的(de)(de)相(xiang)對(dui)(dui)運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)。通過合(he)理分(fen)(fen)(fen)配機(ji)(ji)床(chuang)的(de)(de)相(xiang)對(dui)(dui)運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)簡化了(le)機(ji)(ji)床(chuang)的(de)(de)傳動(dong)(dong)(dong)(dong)(dong)(dong)和嘉購尺寸，也保證了(le)機(ji)(ji)床(chuang)的(de)(de)運(yun)(yun)(yun)(yun)動(dong)(dong)(dong)(dong)(dong)(dong)性能及加(jia)(jia)工質(zhi)(zhi)(zhi)量(liang)的(de)(de)穩定。
1.2機(ji)床機(ji)構簡(jian)單應用面廣
根(gen)據(ju)對木(mu)制(zhi)樓(lou)(lou)梯(ti)扶手(shou)彎頭(tou)的(de)(de)裝夾方案(an)和(he)(he)工(gong)(gong)(gong)藝內(nei)容的(de)(de)分析，確定專(zhuan)用數(shu)控(kong)加(jia)(jia)工(gong)(gong)(gong)機(ji)(ji)床(chuang)(chuang)為立(li)式(shi)結(jie)(jie)構。常見的(de)(de)立(li)式(shi)機(ji)(ji)床(chuang)(chuang)布局有龍(long)門式(shi)、立(li)柱式(shi)河單臂(bei)式(shi)3種。單臂(bei)式(shi)機(ji)(ji)床(chuang)(chuang)支承件(jian)市(shi)由床(chuang)(chuang)身、立(li)柱和(he)(he)橫梁三者的(de)(de)結(jie)(jie)合，具有可(ke)加(jia)(jia)工(gong)(gong)(gong)橫行尺(chi)寸較大的(de)(de)工(gong)(gong)(gong)件(jian)，運(yun)動學性能好(hao)，機(ji)(ji)床(chuang)(chuang)的(de)(de)占地面(mian)積較小的(de)(de)特(te)點，因(yin)此，單臂(bei)式(shi)機(ji)(ji)床(chuang)(chuang)的(de)(de)結(jie)(jie)構最能滿足(zu)木(mu)制(zhi)樓(lou)(lou)梯(ti)扶手(shou)彎頭(tou)專(zhuan)用數(shu)控(kong)加(jia)(jia)工(gong)(gong)(gong)機(ji)(ji)床(chuang)(chuang)的(de)(de)要求，故笨(ben)木(mu)制(zhi)樓(lou)(lou)梯(ti)扶手(shou)彎頭(tou)專(zhuan)用數(shu)控(kong)加(jia)(jia)工(gong)(gong)(gong)機(ji)(ji)床(chuang)(chuang)采用單臂(bei)式(shi)X、Y、Z三坐標聯(lian)動結(jie)(jie)構形(xing)式(shi)。
通過對木(mu)(mu)制(zhi)(zhi)樓(lou)梯扶(fu)手(shou)(shou)彎(wan)(wan)頭(tou)的(de)(de)空間(jian)結(jie)(jie)構分析(xi)，得(de)出采用三(san)把成型銑刀(dao)，分三(san)道工序即(ji)可加(jia)(jia)工木(mu)(mu)制(zhi)(zhi)樓(lou)梯扶(fu)手(shou)(shou)彎(wan)(wan)頭(tou)，其中木(mu)(mu)制(zhi)(zhi)樓(lou)梯扶(fu)手(shou)(shou)彎(wan)(wan)頭(tou)專(zhuan)用數(shu)控(kong)加(jia)(jia)工機床(chuang)的(de)(de)刀(dao)具保證Y、Z兩個方向的(de)(de)相對運動(dong)(dong)，工作臺及工件保證X、B兩個方向的(de)(de)相對運動(dong)(dong)，由于三(san)道工序的(de)(de)夾具也與木(mu)(mu)制(zhi)(zhi)樓(lou)梯扶(fu)手(shou)(shou)彎(wan)(wan)頭(tou)專(zhuan)用數(shu)控(kong)加(jia)(jia)工機床(chuang)工作臺具有相對運動(dong)(dong)。因此，減少(shao)了(le)木(mu)(mu)制(zhi)(zhi)樓(lou)梯扶(fu)手(shou)(shou)彎(wan)(wan)頭(tou)專(zhuan)用數(shu)控(kong)加(jia)(jia)工機床(chuang)的(de)(de)運動(dong)(dong)維樹，簡化(hua)了(le)結(jie)(jie)構，降低了(le)成本。
在木制(zhi)樓梯(ti)扶(fu)手(shou)彎(wan)(wan)頭(tou)三道工(gong)(gong)(gong)(gong)(gong)序(xu)(xu)的(de)(de)(de)(de)(de)加(jia)工(gong)(gong)(gong)(gong)(gong)中，木制(zhi)樓梯(ti)扶(fu)手(shou)彎(wan)(wan)頭(tou)專用(yong)(yong)數控(kong)加(jia)工(gong)(gong)(gong)(gong)(gong)機床保證(zheng)(zheng)刀具(ju)Y、Z兩個(ge)方向(xiang)(xiang)和(he)工(gong)(gong)(gong)(gong)(gong)作(zuo)臺(tai)X方向(xiang)(xiang)的(de)(de)(de)(de)(de)相(xiang)對運(yun)(yun)動(dong)(dong)，夾(jia)具(ju)保證(zheng)(zheng)B方向(xiang)(xiang)的(de)(de)(de)(de)(de)相(xiang)對運(yun)(yun)動(dong)(dong)，其中Y、Z、X方向(xiang)(xiang)的(de)(de)(de)(de)(de)相(xiang)對運(yun)(yun)動(dong)(dong)通過(guo)調整木制(zhi)樓梯(ti)扶(fu)手(shou)彎(wan)(wan)頭(tou)專用(yong)(yong)數控(kong)加(jia)工(gong)(gong)(gong)(gong)(gong)機床的(de)(de)(de)(de)(de)程序(xu)(xu)即(ji)可得到，B方向(xiang)(xiang)的(de)(de)(de)(de)(de)相(xiang)對運(yun)(yun)動(dong)(dong)則需(xu)要(yao)通過(guo)三套(tao)(tao)專用(yong)(yong)夾(jia)具(ju)來(lai)保證(zheng)(zheng)。因(yin)此，在木制(zhi)樓梯(ti)扶(fu)手(shou)彎(wan)(wan)頭(tou)加(jia)工(gong)(gong)(gong)(gong)(gong)中，即(ji)可以(yi)采用(yong)(yong)三臺(tai)專用(yong)(yong)數控(kong)加(jia)工(gong)(gong)(gong)(gong)(gong)機床、三套(tao)(tao)夾(jia)具(ju)完成(cheng)三道工(gong)(gong)(gong)(gong)(gong)序(xu)(xu)的(de)(de)(de)(de)(de)加(jia)工(gong)(gong)(gong)(gong)(gong)，也(ye)可根據加(jia)工(gong)(gong)(gong)(gong)(gong)企(qi)(qi)業(ye)的(de)(de)(de)(de)(de)實際(ji)情況，采用(yong)(yong)一臺(tai)專用(yong)(yong)的(de)(de)(de)(de)(de)加(jia)工(gong)(gong)(gong)(gong)(gong)機床、三套(tao)(tao)夾(jia)具(ju)來(lai)完成(cheng)三道工(gong)(gong)(gong)(gong)(gong)序(xu)(xu)的(de)(de)(de)(de)(de)加(jia)工(gong)(gong)(gong)(gong)(gong)。這(zhe)種(zhong)生(sheng)(sheng)產模式既滿足(zu)大型木制(zhi)樓梯(ti)扶(fu)手(shou)彎(wan)(wan)頭(tou)加(jia)工(gong)(gong)(gong)(gong)(gong)企(qi)(qi)業(ye)資金雄(xiong)厚、生(sheng)(sheng)產及(ji)廠房(fang)規模大的(de)(de)(de)(de)(de)生(sheng)(sheng)產需(xu)要(yao)，同時又適合中、小型加(jia)工(gong)(gong)(gong)(gong)(gong)企(qi)(qi)業(ye)自己薄(bo)弱、生(sheng)(sheng)產及(ji)廠房(fang)規模小的(de)(de)(de)(de)(de)實際(ji)需(xu)求。
1.3機床操作簡單，安(an)全(quan)性高
木(mu)制(zhi)(zhi)(zhi)(zhi)樓(lou)(lou)梯(ti)扶手(shou)(shou)彎(wan)頭專用(yong)數(shu)控加(jia)工機床是通過調用(yong)預先編(bian)制(zhi)(zhi)(zhi)(zhi)好的各種木(mu)制(zhi)(zhi)(zhi)(zhi)樓(lou)(lou)梯(ti)扶手(shou)(shou)彎(wan)頭曲(qu)線輪廓形(xing)(xing)狀(zhuang)的數(shu)控程(cheng)序，實現木(mu)制(zhi)(zhi)(zhi)(zhi)樓(lou)(lou)梯(ti)扶手(shou)(shou)彎(wan)頭在(zai)線自動加(jia)工的，即以(yi)木(mu)制(zhi)(zhi)(zhi)(zhi)樓(lou)(lou)梯(ti)扶手(shou)(shou)彎(wan)頭的數(shu)學描述理論為基礎(chu)的，改變描述參數(shu)的參數(shu)值(zhi)，可得到(dao)不同形(xing)(xing)狀(zhuang)和尺寸的木(mu)制(zhi)(zhi)(zhi)(zhi)樓(lou)(lou)梯(ti)扶手(shou)(shou)彎(wan)頭。因此，加(jia)工時(shi)，只(zhi)要技(ji)術人員預先編(bian)制(zhi)(zhi)(zhi)(zhi)好所需加(jia)工的木(mu)制(zhi)(zhi)(zhi)(zhi)樓(lou)(lou)梯(ti)扶手(shou)(shou)彎(wan)頭曲(qu)線輪廓形(xing)(xing)狀(zhuang)的數(shu)控程(cheng)序。