I. Introduction Third, the development of domestic CNC grinding
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In modern industrial production, the production of medium- and small-batch parts accounts for an increasing proportion of the number of products, and the complexity and precision requirements of parts have rapidly increased. Traditional ordinary machine tools have become increasingly difficult to adapt to modern production requirements. With high precision, high efficiency, multi-use, can complete the characteristics of complex surface processing, especially the rapid development of computer technology and widely used in CNC systems, the main functions of the numerical control device is almost entirely achieved by software, hardware can almost Universal, making it more flexible and more powerful.
Competition in manufacturing has evolved from the early days of lowering labor costs and product costs, increasing the overall efficiency and quality of the enterprise, to the full competition of customer requirements and active development of new products, and will face knowledge-technology-products. The updating cycle is getting shorter and shorter, and the product volume is getting smaller and smaller, and the requirements on quality and performance are higher. At the same time, the society's awareness on environmental protection and green manufacturing continues to increase. Therefore, the agile and advanced manufacturing technology will become the main means for enterprises to win the competition and survive and develop. The combination of computer information technology and manufacturing automation technology is becoming more and more compact, and as an important basis for automated flexible production, the proportion of CNC machine tools in the production of machine tools will increase.
Second, the status of CNC grinding and the main CNC system
Surface grinders use CNC systems relatively late with respect to lathes, milling machines, etc. because of their special requirements for numerical control systems. In the past ten years, with the help of CNC technology, the continuous dressing of grindstones, automatic compensation, automatic exchange of grinding wheels, multi-tables, automatic transmission and clamping of workpieces and other operating functions have been realized, and numerical control technology has gradually become popular on surface grinding machines. In recent years, large-scale machine tool exhibitions in Hanover, Tokyo, Chicago, and China, CNC grinders accounted for the majority of the entire grinding machine exhibits. For example, Germany's BLOHM company, ELB company and other famous grinding machine manufacturers no longer produce ordinary grinding machines, Japan's Gang Ben, Nikko and other companies also produced full-featured CNC grinding machines in batches. While developing high-end CNC grinding machines, they also actively developed medium- and low-grade CNC grinding machines.
A few years ago, BRILLIANT series CNC coordinate grinding machines produced by German ELB Company had vertical and horizontal CNC axes and hydraulic control in the longitudinal direction. The wheel dressing used diamond wheels installed on the workbench. The scope of application was wide; SUPER-BRILLIANT series It is a three-axis CNC plane and a profile grinding machine. The bed body is made of natural granite with extremely high geometric precision. The guide rails use linear rolling guide rails. The mechanical drive has no recoil so as to ensure that the workpiece has a good surface finish. BRILLIANT-FUTURE is the above two A series of improved products, the bed made of artificial granite, longitudinally using static pressure guide rails, toothed belt drive, vertical and horizontal guideways for pre-loaded linear rolling guides, ball screw drives, three-axis CNC-controlled AC servo motors, 0.5 Îœm measurement resolution. At the same time, ELB has developed grinding machines with the latest technology, namely CAM-MASTER series flexible grinding units based on mechatronics and computer technology, CAD-MASTER series and COMPACT-MASTER series of grinding machining centers, with the most control axes. It can reach up to 24 axes. In addition, due to the full implementation of the modular design, the special grinding machine shortens the manufacturing cycle. ELB also developed a variety of high-efficiency special-purpose grinding machines, such as SFVG100/2 special grinding machine, with tiltable grinding head, continuous dressing, and slow feed. , Inclined into the grinding function, with 11 CNC control axis, such as the same grinding center. British JONES & SHIPMAN company and American AB company developed A-B8600 numerical control system for FORMAT5 type NC flat grinding, CNC control hydraulic valve, drive longitudinal adjustable speed movement, horizontal and grinding head feed ball screw pair, DC servo motor Drive, intermittent wheel dressing, CRT graphic simulation display. At the same time can also be used with other types of CNC system to meet the requirements of different users.
At present, with the continuous increase in the level of semiconductor integration, the newly introduced systems are becoming smaller and smaller in appearance, more and more compact in structure, and the functions of remote communication, remote diagnosis, multi-machine networking, etc. have been added; the operation interface to the WINDOWS system has been improved. , increase the mouse, remote control and other operating parts. FANUC Corporation mainly introduced 18I, 16I, 20I, and 21I systems this year. SIEMENS is a compact system with 840D, 810D, and 802D. Some manufacturers such as: Taiwan Precision Machinery Research and Development Center developed PA8000NT series CNC controller, using the WINDOWS NC operating system, and NT real-time multiplex processing core, a single program processing speed of 2000 blocks / second, single pre Up to 1000 readings, AART (Adaptive Conditioning Technology) and parameter optimization learning functions, enabling the following error to approach zero, the software processing path filter can reduce the cutting process, due to excessive acceleration changes Mechanical resonance generated to improve surface roughness; Servo-flexible, analog servo interface with +, -10V, and international standard SERCOS digital servo communication interface; PLC program design includes ladder diagram, structure statement, function block, and instruction Five grammars, such as code and flow chart, are easy to design, communicate and maintain; with remote communication of the computer, and instant remote maintenance function; control axes and spindles can be expanded up to 64 axes, and I/O points can be extended to 792/528 points. Pentium processor, high-speed PLC processing speed up to 25K.
In addition to the world's most famous numerical control system manufacturers such as SIEMENS and FANUC, which have developed and produced many systems suitable for plane or profile grinding, some flat-milling mills have also actively developed numerical control systems suitable for their grinding machines. There are:
SINUMERIK 840D system from Siemens AG, which has more than 20 servo axes, coordinate continuous stroke control, manual data input or input via external computer, remote diagnosis, stroke change as the diameter of the grinding wheel decreases, and dressing amount of grinding wheel is automatically compensated. Ball screw gap error compensation.
The Siemens 3G system was specially developed for grinding and was equipped with an operation prompting device for human-machine dialogue. When the axis is tilted, linear and circular interpolations are also possible. The operating cycles often occur during grinding, such as Swing the main shaft, interrupt the execution of the program with an external signal, cut into the grinding wheel, and perform special dressing functions such as grinding wheel dressing to program a fixed cycle program. It can not only use an external measuring device (switching signal), but also can directly compare the control device with the final size when connecting a suitable measuring head.
The 8400CNC and 8600CNC CNC series produced by American ALLEY-BRANDLY Company are suitable for lathes, milling machines and grinding machines. The 8400CNC can control up to six servo axes, any two axes can perform circular interpolation, and any three axes can perform spiral interpolation. , 6-axis linear interpolation. The 8600CNC series can control up to 17 coordinates, including 8 participating interpolation axes, 8 bit control axes and 1 spindle, with graphic display, extended branch program, display processing time, high-speed program verification, tool life monitoring and other functions.
Japanese FANUC Corporation has developed OG high-speed high-performance CNC system, in which O-GSG is suitable for surface grinders. According to the different shapes of the grinding parts, there are four different grinding methods, with the tilt angle control function of the grinding wheel axis. Grinding, fine grinding, and non-sparking grinding A complete set of grinding cycles, the position compensation function of the grinding wheel after rolling and trimming, the control function of the dresser relative to the normal direction of the dressing wheel, trimming of the arc radius compensation function of the outer edge of the roller, and the shape of the grinding wheel Display function and grinding parameter display, etc. The minimum setting unit of the system is 0.1μm. It is a "compact" type CNC system and the price is lower.
There is also the UNICON system developed jointly by German ELB and the University. Japanese Ogaki Iron Works OSP5000G-G, OSP30-NF and other self-developed flat and form grinding CNC systems, its OSP5000G-G can control up to 9 coordinates, of which 6 coordinates can be linked, with 12-inch color display, man-machine Dialog programming, automatic determination of the cutting factor, floppy input can be used, included in the FMS system, the minimum pulse equivalent, moving equivalent and detection equivalent are 0.1μm, and the closed-loop induction synchronizer is also used on the flat grinding.
In addition, although the Pingma mill uses a CNC machine system, it develops its own software and uses it more suitable for plane and profile grinding. For example, the German company JUNG is based on Siemens SINUMERIK 810, and uses the company's special software with JUNG KONTUR. The programming language shapes and reshapes the grinding wheel and has graphically assisted operation functions. Japan's Okamoto Corporation developed the OPL language for grinding machining on FANUC's CNC hardware.
Today's linear motor, dynamic balance and other technologies and processes have been increasingly developed, which has greatly improved the ergonomics of the machine tool. Appropriate measurement technology applications have enhanced the use of CNC systems and enhanced the machine's electrical automatic control functions.
China began to produce CNC surface grinders in the 1980s. Each development company has gone through its own research and developed in cooperation with universities and research institutes to directly introduce a mature CNC system. For example: Hangzhou Machine Tool Plant is a 50-year-old manufacturer specializing in the production of surface grinders. It has been producing CNC grinding machines since the mid-1980s, and has successively developed and produced MGK7132 horizontal axis remnants and high-precision flat grinding, and MK7130 series of ordinary CNCs. Flat Grinding, MLK7140 CNC Cascade Grinding Mill, MGK7120, MK7163, MK7150 Horizontal Shaft Moment Recessing CNC Grinding, MKY7760 Vertical Shaft NC Duplex Grinding, MKY7660, MKY7650/101 Horizontal Shaft NC Duplex Grinding, and HZ-K1610, HZ- K2010, HZ-050 CNC, HZ-KD2010, HZ-K3015, HZ-K3020, HZ-K4020 and other special CNC gantry plane and guide rail grinding machine. The development and application of numerical control systems include single-board machine systems developed in cooperation with universities and scientific research institutes, as well as self-developed simple control systems based on single-chip microcomputers and mature numerical control systems produced by numerical control engine manufacturers.
The MGK7120 high-precision grinding machine produced by the company uses the POWER MATE-D dual-axis CNC system from FANUC of Japan to control the feed of the grinding head, and the minimum feed amount is 0.1μm. It has the function of automatically completing the grinding cycle.
MKY7650/101 fully automatic CNC double face grinder is a technical cooperation product with Italian VIOTTO company. It adopts Siemens SIMATIC S5-115U programmable controller and CRT display. The left and right grinding heads of the machine are driven by a two-axis DC servo motor. The machine tool can Manual adjustment and automatic grinding cycle selection. Equipped with Italian Malpos E9 measuring system, two measuring heads, one measuring grindstone, feedback grinding wheel wear amount to the control system for grinding wheel compensation, another measuring head measuring the grinded workpiece and inputting the measurement result to the control system , Servo motor for compensation feed; left and right grinding head with VIOTTO grating position measurement control, to achieve the whole machine from the workpiece feeding to the grinding of the closed-loop and fully automatic processing.
HZ- 050CNC special-purpose grinding machine for CNC linear rolling guides is a special grinding machine developed for the third scientific and technological research project of Shanghai Science and Technology Combined Production key industrial projects. Both the surface grinding function and the forming grinding function, it uses the 8400MP CNC system produced by the United States AB company, the machine tool has 7 CNC axes, X, Y, Z three grinding head feed axis and U, V, W three roots The grinding wheel dressing axis is directly controlled by the system, and the other axis Q is the horizontal grinding wheel horizontal feeding (for the grinding plane) through the SLC programmable controller plus the IMC positioning module, and the system I/O port inputs the 8400MP host to control its position. It has the ability of automatic dressing such as grinding wheel or gap wheel dressing compensation feeding continuously during grinding.
HZ-KD2010 Six-axis CNC gantry type double-grinding head surface grinder adopts FANUC-0MC numerical control system. It uses four CNC axes to control the horizontal and vertical feed of two grinding heads, and uses a PMC axis to control the grinding wheel of the peripheral grinding head. The dresser diamond pen feeds, and another PMC axis controls the indexing rotation of the universal grinding head. Make full use of system performance, reduce production costs and increase the cost-effectiveness of machine tools.
IV. Development Prospects of CNC Grinding Machine in Hangzhou Machine Tool Plant
The development of CNC grinders at Hangzhou Machine Tool Plant has already reached considerable strength. As the main engine manufacturer, the CNC system at Hangzhou Machine Tool Plant should be developed. It has already gone through the process of relying solely on system suppliers and having its own preliminary development capabilities. However, the application of numerical control system is still improving the performance of mechanical transmission chain, replacing the mechanical handwheel, and simple machining cycle. Compared with the advanced level, there are still many gaps. In the machine tool accuracy, automation function, processing efficiency, usability, etc. Many problems that need improvement and breakthroughs need to be resolved. I think that we should summarize the various structures and product use processes of the various types of products currently produced by the factory, analyze their lengths and gains, and determine what kind of automatic functions the product will compete for, and how to gradually develop a plan to facilitate learning and work. Emphasis on the development of CNC software, conditional introduction of technology or expatriate learning, keep pace with development trends, combine market requirements with hardware, apply new technologies and new functions one by one in product manufacturing, to narrow the gap with the world advanced level .
With the improvement of the performance and availability of CNC systems, the price is becoming more reasonable, so that the price of CNC grinders and ordinary grinders is accepted by the majority of users. At the same time, the requirements for advanced manufacturing and automation technologies are increasing in production, and the use of CNC grinding machines is increasing. It will also become more and more extensive. CNC flat-grinding and other grinding machines will be developed in the direction of machining more flexible high-end grinding machining centers and more efficient special-purpose CNC grinding machines. We believe that with the deepening of computer and information technology revolutions, CNC grinding machines will have great progress in terms of their intelligence and system information control. How to keep up with the pace of history, find a development path that suits our own characteristics, and look for breakthroughs in technological progress are the focus of our work, because this is a key issue that concerns the future development and survival of the company. 