| Deep hole machining is an indispensable process for machining engine blocks and engine cylinder heads.With the development of engine technology,the technical requirements required for machining deep holes are becoming higher and higher,and the processing difficulty is also increasing.In deep hole machining,abnormal wear and damage of the tool may cause serious consequences such as scrapping of the workpiece and damage to the machine tool.How to avoid this phenomenon more scientifically and intelligently is an important issue to ensure the stable and efficient operation of the machining system.Therefore,researching the deep hole machining process monitoring technology,realizing the real-time monitoring of the wear condition of deep hole machining tools,the early warning of tool abnormal state and the prediction of tool life are of great significance for the efficient and precise machining of key parts of the engine.This research is an important part of the tool intelligent management system project implemented by CHINA NATIONAL HEVEY DUTY TRUCK GROUP CO.,LTD,mainly carrying out the application research of the tool monitoring system in the gun drilling machine.The main research work is as follows:(1)The machine structure of the TRS gun drill special machine used by CHINA NATIONAL HEVEY DUTY TRUCK GROUP CO.,LTD,the structure of Siemens 840D numerical control system,and the processing technology and process equipment of TRS gun drill special machine were analyzed.(2)The machining mechanism of the deep drilling of the gun drill was studied,and the failure mode and reasons of the gun drill during the machining process were analyzed.The orthogonal cutting experiment was carried out to optimize the existing gun drilling process parameters,which reduced the cost while improving production efficiency.(3)Based on the Siemens 840D CNC system used in the TRS gun drill,the tool monitoring system was designed and developed.The system can collect the machining process parameters such as power,voltage and current of the gun drill special machine,and realize data acquisition,data storage,data display and data analysis.(4)The real-time monitoring,data acquisition and data analysis and processing of the gun drilling process were carried out,and the key characteristic variables of the tool online monitoring were obtained.The machine tool spindle torque was analyzed to directly,accurately and quickly reflect the machining status of the gun drill,and the determination was made.The monitoring threshold is used to effectively monitor the processing of the gun drill.The purpose of reducing the occurrence probability of the gun drill failure mode,improving the tool life and avoiding the mass quality accidents is achieved,and the application value of the tool monitoring system in actual production is realized. |
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