| Under the requirement of Gansu Province Tianshui Spark machine tool limited liability company, formulated the machining processes of to machining a large rotor hub of a type of aerogenerator. Then designed a suit of special machine base on the machining processes, and the special machine must have some flexibility by request.This article focus on to satisfied the requirement of practical production, and expatiated on the whole courses of how to formulated the machining processes, refitted C61200 to made the lathe have radial move function, designed special cutting tools which matched with the special boring & milling machine, special tool magazine and drilling model. This design demanded the integrative application of knowledge, technique and method about mechanical design, 2D/3D CAD, virtual assembly technology, finite element analysis (FEA) on structural statics and(or) dynamics of mechanism and function analysis of mechanism motion simulation.Consider from different respects, this paper has made several sets of machining processes according to the characteristics of the rotor hub. After think over combining actual conditions of Tianshui Spark machine tool Co., Ltd., such as the existing production equipment, manufacture, technical level and investment funds, etc, through comparing and discussing repeatedly, have confirmed a set of processing route finally. Above this foundation, designed the special cutting tools, the special tool magazine and the drilling model according to the characteristics of each working surface on the workpiece. One of this workpiece's important characteristics is the size is big: the outline dimension is 3200×3200×2100(mm). In order to process this orifice end surface, refitted C61200 horizontal lathe which a product of Spark machine tool Co., Ltd. to made the lathe have radial move function. The interior of rotor hub has an auriform appendix structure, above has a group of coaxial bore which has bigger external bore and lesser internal bore is need to processing. Because the space is restricted and the accuracy requirement is high, so this part is a focal point and difficult point of the whole processing course. In order to machining the coaxial bore and their end surface, After designed repeatedly, then designed a specially composite boring tool which to process the coaxial bore and a radial-moveable inner end-surface turning tool which to process the end surface. At the same time, in order to machining four raised plane in each orifice, designed a indexable right-angle milling cutter and a indexable right-angle two axes drilling cutter. In addition, designed a special tool magazine to store the special cutting tools as mention above. This special tool magazine is not only used to store the special cutting tools not in use, can also be match with spindle to loading or unloading the special cutting tool. Otherwise, the workpiece has 387 holes need to drill, in order to increase processing efficiency and ensure machining precision, has designed two sets of drilling model.The whole course of this project was using 3D CAD software SolidWorks to design. In the early period of this design, using the plug-in of SolidWorks like e-Drawings, Animator to have regularly intercourse with other designer of the same group, tutor, and the technical director of Tianshui Spark machine tool Co., Ltd., and modified or reinforced the design constantly. After the whole scheme is approved by technical director in charge, then began to design the concrete part. In the medium term of this design, using the plug-in of SolidWorks such as COSMOSWorks, COSMOSMotion to carry on finite element analysis(FEA) on structural statics and(or) dynamics of mechanism and function analysis of mechanism motion simulation. And using MATLAB which a Software of scientific engineering calculation to carry on calculating, drawing to the result of simulation. Using this method to analyze and verify the feasibility of this design. In the later period of this design, using AutoCAD and PCCAD to dimension and carry out standard on the 2D engineering drawings which generated by SolidWorks. All engineering drawings was devolved on Tianshui Spark machine tool Co., Ltd. after audited by the technical director in charge. |
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