用科學方法解決上刀盤存在的問題

1. 存在的問題

上刀盤在機加工后對其進行符合性檢驗時，發現C槽和D槽的傾斜角d度數不正確。明明是按圖中傾斜角d編程加工的，為什么會出現這種情況，是什么原因造成的呢？

2. 分析研究

只能從上刀盤的圖樣的審核、設備的選型、刀具的選擇、工件的就位與定位、加工基準起點的確定和加工方法等整體機加工工藝的全過程入手，采用排除法逐項進行分析研究，找出其存在問題的原因并提出解決方法。

（1）圖樣方面。視圖投影關系正確，尺寸標注準確，有沒有什么不妥之處。

（2）設備的選型。采用帶回轉工作臺的中型數控鏜床。能滿足用程序加工和分頭要求，有沒有什么不妥之處。

（3）刀具的選擇。采用棒類立銑刀。能滿足同時端面銑和圓周銑的要求，有沒有什么不妥之處。

（4）上刀盤的就位和定位。通過三塊等高墊塊將上刀盤水平置于數控鏜床的回轉工作臺上，用百分表按上刀盤外圓找正，調節上刀盤轉動中心線與數控鏜床回轉工作臺轉動中心線同心后定位裝夾。就位和定位方法符合加工法則中規定的準確要求，有沒有什么不妥之處。

（5）E槽和F槽加工基準起點的確定

（6）E槽和F槽加工。按以上基準點為起點，以（L/2－B）分步進刀，按角度d為傾斜方向，采用兩軸半方式編程，用棒銑刀加工E斜槽和F斜槽及相關A和B上面；工作臺轉90°。

3. 問題的發現和解決

從以上各項分析過程來看，好像是條條都有道理，但是問題畢竟存在，其原因到底處在哪里呢？困惑中筆者聯想到上下刀盤轉動剪切鋼帶的工作過程，其剪切過程類似于斜齒輪副傳動，由于斜齒輪中任何一個斜齒條在不同的位置上時，在俯視圖中投影的傾斜角度是不同的。

4. 符合性檢驗

（1）電子測量臂檢驗：由于數控鏜床的精度等因素對加工準確度有一些影響，加工好的斜面槽是否符合設計要求，用常規方法對其進行檢驗難度很大。為保證檢驗的可靠性，本例選用精度很高的電子測量臂對各斜面槽和相隔度數進行檢驗，結果各尺寸均達到圖樣要求。

（2）實物安裝檢驗：通過在用戶現場對上刀盤和下刀盤及相關剪刃的安裝，手動和空載轉動試驗，證實上刀盤和下刀盤中的剪刃在剪切點處位置正確，滿足設計要求。

5. 結語

通過上述對上刀盤存在問題的分析，根據加工起點所處的具體位置，運用三視圖投影原理找到了產生問題的根源，重新確定傾斜角d的度數。經過重新編程、加工，到圓滿地安裝試車達到設計要求。說明了一個道理：當遇見一個復雜的問題時不要畏懼，不要退縮，要用自己掌握的科學知識給與評判，提出符合客觀實際的方式方法給以解決。

Solve the problem of upper cutter head with scientific method 1. When the cutter head is checked after machining, it is found that the angle D of C slot and d slot is not correct. Is clearly according to the Diagram d inclined programming processing, why this situation, what causes it? 2. The analysis and research can only start from the whole process of machining technology, such as the examination of the drawing of the upper cutter head, the selection of the equipment, the selection of the cutting tools, the positioning and positioning of the workpiece, the determination of the machining datum and the machining method By using the method of exclusion to analyze and study item by item, find out the reason of the existing problems and put forward the solution. (1) graphic aspect. The view is projected correctly, the dimensions are correct, and there is nothing wrong with it. (2) equipment selection. MEDIUM-SIZED CNC boring machine with rotary table. Can satisfy with the procedure processing and the separate request, has any improper place. (3) selection of cutting tools. End Mill with bar type. Can meet the requirements of both end milling and peripheral milling, there is nothing wrong with it. (4) the positioning and positioning of the upper cutter head. The upper cutter head is horizontally placed on the rotary table of the NC boring machine through three equal height spacers, and the outer circle of the upper cutter head is aligned with the dial indicator Adjust the center line of rotation of upper cutter head and the center line of rotation of NC boring machine. Positioning and positioning methods in line with the accuracy of the rules of processing requirements, there is no problem. (5) determination of the starting point for processing e and F slots (6) processing e and F slots. According to the above datum point as the starting point, with (L / 2-b) step-by-step Cutter, according to the Angle d as the inclined direction, using two-axis and half-way programming, using rod milling cutter to process e Chute and f Chute and related a and B above;. 3. The discovery and solution of the problem from the above analysis process, seems to be all reasonable, but the problem exists, the reason in the end where? In my perplexity, I think of the working process of cutting steel strip with up and down cutter disk, which is similar to the transmission of helical gear pair The tilt angle of the projection is different in the overhead view. 4. Conformity Test (1) electronic measuring arm test: Because the accuracy of NC boring machine and other factors have some impact on the accuracy of processing, whether the sloped groove meets the design requirements or not, it is very difficult to test it by conventional methods. In order to ensure the reliability of the inspection, the electronic measuring arm with high precision is selected to check the slope groove and the degree of separation. (2) in-kind installation inspection: through the installation of the upper and lower cutter disks and the related cutting edges on the user's site, manual and no-load rotation tests, it is proved that the cutting edges in the upper cutter disks and the lower cutter disks are in the correct position at the cutting point and meet the design requirements. 5. Conclusion through the above analysis of the problems on the cutter head, according to the specific position of the starting point of the machining, using the principle of three-view projection to find out the root of the problem, re-determine the degree of d inclination angle. After reprogramming, processing, to a successful installation test to meet the design requirements. It illustrates a truth: When encountering a complex problem, do not be afraid, do not shrink back, to use their own scientific knowledge to judge, put forward in line with the objective and practical ways to solve.