【摘要】：隨著汽車工業(yè)的飛速發(fā)展,汽車輪胎模具的需求量也急劇增加。在輪胎模具制造中,根據型號、規(guī)格的不同,輪胎模具需要切割為多份且不等�，F(xiàn)有的輪胎模具切割制造工藝是采用普通線切割方式一條條槽順序切割,不僅內應力分布不均勻,產生變形,而且加工效率極低,切割時間長達7-15天。因此,研制高效、低成本的新型切槽設備顯得非常迫切。本論文是針對輪胎模具分塊切割加工的效率問題,在單槽、雙槽電火花線切割機床的基礎上,設計了一種用于輪胎模具或者大型環(huán)狀零件的專用多槽線切割機床。加工時卷絲筒、工作臺(工件)位置不變,多個絲架獨立運動,實現(xiàn)一根絲對一個工件在多個位置同步進行電火花線切割加工,不僅成倍地提高生產效率,而且使工件的內應力分布更均勻,變形更小。同時可以在上好絲后再安裝工件,有利于操作,并能方便地偏轉絲架角度進行非對稱加工,這是一種高效、優(yōu)質的環(huán)形零件分塊切割新技術,也是電火花線切割加工技術的進一步拓展。在結構設計上,本機床通過特殊的拓撲結構,巧妙的布置導輪組,構成了四段方向運行的電極絲加工區(qū)段,可連續(xù)、同步切割出多條窄槽。在走絲系統(tǒng)上,設計了電極絲恒張緊機構,保證電極絲的張緊狀態(tài)。針對不同厚度和高度的環(huán)形工件,設計了可移動的夾具機構和可調高度以及角度的絲架,實現(xiàn)了環(huán)狀零件多槽同步對稱切割及不對稱切割,大大提高了線切割工序的效率,為今后研制加工更多環(huán)形零件的機床提供了思路。在控制系統(tǒng)方案設計中,針對多槽機床同步切割的特殊性,為了避免脈沖電源空載時步進電機發(fā)生失步,限制取樣電路的輸出電壓,從而無法實現(xiàn)步進電機的變速進給,課題提出了以dsPIC6010A單片機作為控制系統(tǒng),具有快進、工進、加工回退和短路回退等動作控制功能,解決了普通高速走絲電火花線切割機床只能勻速進給的缺陷,極大的提高了切割效率。本課題的特色和創(chuàng)新在于：克服了現(xiàn)有切割加工輪胎模具的不足點,實現(xiàn)了一根絲可同時切割多條窄槽,不但提高了線切割加工效率,而且加工工件內應力分布更加均勻,變形更小,從而提高工件質量,這是一種高效優(yōu)質、低成本的新機床技術方案。它的研制成功將對提高我國特種加工工藝水平,促進我國制造業(yè)高新技術的發(fā)展,尤其是對汽車輪胎模具行業(yè)提高加工效率和增強市場競爭力有著重要的理論和實際意義。
[Abstract]:With the rapid development of automobile industry, the demand of automobile tire mould also increases sharply. In the manufacture of tire mould, the tire mould needs to be cut into many parts according to the model and specifications. The existing cutting and manufacturing technology of tire mould is to use common wire cutting method to cut one slot in sequence. Not only internal stress distribution is uneven and deformation is produced, but also the processing efficiency is very low, and the cutting time is up to 7-15 days. Therefore, it is very urgent to develop a new type of slot cutting equipment with high efficiency and low cost. This paper is aimed at the efficiency of cutting tire die by block cutting. Based on single slot and double slot WEDM machine tool, a special multi-slot WEDM machine tool is designed for tire mould or large circular parts. In the process of machining, the position of the winding wire drum, the worktable (workpiece) is invariable, and the multi-wire frame moves independently, so that the WEDM of one wire to a workpiece in multiple positions can be carried out synchronously, which not only improves the production efficiency exponentially, but also increases the production efficiency of the workpiece. Moreover, the internal stress distribution of the workpiece is more uniform and the deformation is smaller. At the same time, the workpiece can be installed after the best wire, which is advantageous to operation, and can be easily processed asymmetrically by deflecting the angle of the wire rack. This is a new technology of cutting the ring parts in blocks with high efficiency and high quality. It is also the further development of WEDM technology. In the structure design, the machine tool can cut many narrow grooves continuously and synchronously through special topological structure and ingenious arrangement of guide wheel group, which forms the processing zone section of electrode wire running in four sections. A constant tensioning mechanism is designed to ensure the tensioning state of the wire. For the annular workpiece with different thickness and height, the movable fixture mechanism and the wire frame with adjustable height and angle are designed. The synchronous symmetrical cutting and asymmetric cutting of ring parts with multiple grooves are realized, and the efficiency of wire cutting process is greatly improved. It provides ideas for developing and machining more ring parts machine tools in the future. In the design of control system, in view of the particularity of synchronous cutting of multi-slot machine tool, in order to avoid the step motor losing step when the pulse power supply is no load, and limit the output voltage of sampling circuit, it is impossible to realize the variable speed feed of step motor. In this paper, the dsPIC6010A single chip microcomputer is used as the control system, which has the function of fast moving, working back, machining back and short circuit back, and solves the defect that the ordinary high speed wire WEDM machine can only feed at uniform speed. The cutting efficiency is greatly improved. The characteristic and innovation of this subject lies in: overcoming the deficiency point of the existing cutting and processing tire mould, realizing a single wire can cut several narrow grooves at the same time, not only improving the efficiency of wire cutting, but also distributing the stress in the machining workpiece more evenly. Small deformation, thus improving the quality of the workpiece, this is a high-efficiency, quality, low-cost new machine tool technology. The success of its development will be of great theoretical and practical significance to improve the level of special processing technology and promote the development of high and new technology in our manufacturing industry, especially to improve the processing efficiency and enhance the market competitiveness of automobile tire mould industry.
【學位授予單位】：廣東工業(yè)大學
【學位級別】：碩士
【學位授予年份】：2015
【分類號】：TG661

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本文編號：2214170