自动钢管无屑切割机的研究与设计说明

1、摘 要本文在详细分析钢管无屑切断特点的基础上，基于金属塑性加工原理，开发了一种钢管无屑切割机，主要进行了无屑滚切原理分析、无屑切割机总体方案以与机械结构设计和计算，无屑切割机虚拟样机设计。提出了一种创新的无屑切割机构，选择了新型的直线电机传动方法并设计了整机的自动控制系统，最佳地满足了钢管定尺度的无屑切割工艺要求。钢管切割的传统机械生产加工工艺大多应用切削加工方法来制造有精确的尺寸和形状要求的零件，生产过程中坯料的30以上成为切屑，这不仅浪费大量的材料和能源，而且占用大量的机床设备和人力。采用无屑滚切的工艺，工件不需要或只需要少量切削加工即可，大大节约了材料、设备和人力。在结构设计上，使用Pro/E软件建立了切管机机械系统的三维实体模型和力学模型，分析和评估了系统的性能，从而为物理样机的设计和制造提供了参考依据。通过利用虚拟样机技术，从设计的初始阶段概念设计阶段就对整体系统进行了完整的分析，观察并试验了各组成部件的相互运动情况，使用系统仿真插件在各种虚拟环境中真实地模拟系统的运动，直接在计算机上修改设计缺陷，仿真试验不同的设计方案，对整个系统不断的改进，最后获得最优化的设计方案。本文在

2、研究了钢管无屑切割机结构特点的基础上依托Pro/E软件为平台，实现了无屑切管机的可视化、自动化和参数化设计。系统地提高了设计、三维造型的效率和准确性。实现了设计计算、数据修正、三维造型与绘制工程图纸的有机结合，同时也为同类产品的设计提供了有益参考。在动力、传动、控制方面，根据直线电机的结构特点、性能优势和控制特性配合PLC控制，设计出结构紧凑、动态响应快、精度高、振动和噪声小、节能、高效的切管机系统。本文通过选用两台直线电机成功地解决了切管机系统中定位、卸料和进给的直线运动问题。关键词：切管机；无屑滚切；系统设计；PLC控制；虚拟样机AbstractOn the basis of the characteristic analysis of steel pipechip-less cutting, the paper develops a steel pipe chip-less cutting machine, basing on the principium of plastic working of metals. Mainly on the analysis of the pr

3、inciple of chip-less of hobbing, chip-less cutting machinegeneral planning and mechanical structure design and calculation, virtual prototype design of chip-less cutting machine,put forward an innovative cutting Chip-less agencies, Select a new type of linear motor drive method and design the machines automatic control system, meet the requirements of chip-less cutting of set-scale steel pipe at best.The traditional mechanical processing technology of steel cutting mainly is the method of cuttin

4、g to The manufacture precise size and shape parts as required, more than 30% of the billet quality turns into chip in this production process. This is not only a waste of a large number of materials and energy and use up a lot of machine and human.If chip-free cutting process was used, work piece will became mechanical parts with only a little cutting or none, which greatly saving materials, equipment and human.In structural design, we have established a pipe cutting machine mechanical system of

5、 three-dimensional solid model and the mechanical model, analysis and assessment of the performance of the system with Pro/E software,so as to provide a reference to physical prototype design and manufacturing. Through the use of virtual prototyping technology, from the initial stages of design - conceptual design phase of the overall system on a complete analysis of observation and test the various components of the mutual movement of components, plug-ins using the system simulation environment

6、 in a variety of virtual real simulate the movement system directly on the computer modify the design defects, simulation experiment with different design, the entire system of continuous improvement, and finally obtain the optimal design, for the manufacture of the physical prototype of the fully prepared to do. This paper realize the visualization, automation and parameters in chip-less pipe cutting machine design based on Pro/E software after studied the structural characteristics of chip-les

7、s steel pipecutting machine.Improved the efficiency and accuracy systematically in design, three-dimensional modeling. Achieved a seamlessintegration between design, calculation,dataamendment, three-dimensional modeling and engineerdrawing, as well as provided a useful reference to the design of similar products at the same time.About power, transmission, control, design a fast, dynamic response and high precision, according to the structure of linear motor characteristics, performance character

8、istics and control with the advantages of PLC control, which is small vibration and noise, energy saving, efficient system of pipe cutting machine.In this paper, by using two linear motors have successfully resolved the pipe cutting machine positioning system, and discharge into the problem to the linear motion.Key words:Pipecutting machine; Chip-lesscutting; System design; PLC control; Virtual prototype目 录摘要IAbstractII目录IV第一章绪论11.1 课题提出背景与研究的目的和意义11.1.1 选题背景11.1.2 研究目的和意义11.2 切管工艺与设备技术发展综述21.2.

9、1 切管机的种类31.2.2 国外切管机与技术的发展概况31.3 课题研究的主要容5第二章无屑滚切的原理72.1 无屑滚切的工艺过程72.2 无屑滚切的工艺特点82.3 工艺参数分析计算92.4 切削功率的理论计算122.4.1 理论假设122.4.2 正压力的理论计算122.4.3 摩擦面积的理论计算132.4.4 切削功率的理论计算13第三章系统方案设计153.1 功能要求153.2 功能分析163.3 功能方案综合163.3.1 柔性进给163.3.2 刚性进给18第四章结构设计与计算204.1 刀架组合的设计计算214.1.1 刀轴214.1.1.1 刀轴的材料214.1.1.2 刀轴的强度、刚度校核计算224.1.1.3 刀轴的振动稳定性校核计算234.1.2 刀片的设计计算254.2 进刀与退刀机构的设计计算284.2.1 径向进给导轨的设计计算294.2.2 轴向运动转化为径向运动的结构设计314.2.3 轴向运动与径向运动的组合设计334.3 定位与卸料装置的设计34第五章传动系统设计365.1 主切削运动的传动375.2 进给运动的传动425.3 定位与卸料运动的传动46第六章电气自动控制系统设计496.1 系统控制功能分析496.2 PLC介绍516.3 PLC的选型526.4 I/O地址分配与控制流程图53第七章总结与展望56参考文献57 / 第一章 绪论在钢材生产以与机械制造过程中，对管材按定尺长度要求进行切割是必不可少的加工工序。在机械加工企业，以前所采用的钢管切割方法主要有锯割、车削、砂轮切割、气焊切割、电火花线切割、激光切割等方法。这些钢管切割方法在不同程度上都存在着切割效率低、工人劳动强度大、材料消耗等缺点1。锯割中严重的摩擦消耗了大量的能源，同时产生大量的锯屑，浪费大量的钢材，相对应的锯片损耗也很严重。车削产生切屑，材料成材率低，既耗能又浪费材料。

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