高速旋转下刀柄与刀具系统的平衡
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<TD width="65%"> <A href="http://www.c-cnc.com"><SPAN class=bluebb>中国数控机床网</SPAN></A> > <A href="/news/index.asp"><SPAN class=f14t2>新闻中心</SPAN></A> > <SPAN class=f14t2>新品与技术</SPAN> </TD>
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<TD class=f14 align=middle colSpan=4 height=1><B><FONT color=#000080>高速旋转下刀柄与刀具系统的平衡</FONT></B></TD></TR>
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<TD align=middle bgColor=#00468c colSpan=4 height=16><FONT color=#ffffff>NEWS.C-CNC.COM 2008-3-10 来源： 阅读：
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121次 <A title=生意人使用生意宝,生意越来越旺盛! href="javascript:d=document;t=d.selection?(d.selection.type!='None'?d.selection.createRange().text:''):(d.getSelection?d.getSelection():'');void(netsunkey=window.open('http://www.netsun.com/bin/store.cgi?info=本站为您提供的增值服务（由生意宝提供技术支持）；一旦注册成为生意宝会员，您只需要右键轻轻一点，就能实现商机资讯保存管理等功能，轻松拥有自己的生意门户，全新的个人创业以及企业互联网营销模式体验就此开始，更多信息请查阅帮助中心！&title='+escape(d.title)+'&url='+escape(d.location.href)+'&excerpt='+escape(t),'netsunkey','location=yes,toolbar=yes,menubar=yes,status=yes,resizable=yes,scrollbars=yes,width=748,height=520,left=80,top=80'));netsunkey.focus();"><IMG alt=生意人使用生意宝,生意越来越旺盛! src="http://www.chmcw.com/upload/news/RCL/13220_95gxoacoop2.gif" border=0></A> </FONT></TD></TR>
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<H1 align=left><FONT size=2>1.刀柄与刀具系统平衡的必要性</FONT></H1>
<P align=center><FONT size=2><STRONG>表1<BR></STRONG><IMG style="WIDTH: 607px; HEIGHT: 342px" height=429 src="http://www.chmcw.com/upload/news/RCL/13220_djfxed2008310161943.gif" width=771></FONT><BR> </P>
<DD>由于刀片材料与涂层技术的发展，可承受的切削速度不断提高，对钢来说切削速度可达250m/min，甚至达到350m/min；对铝及铝合金的切削速度可达1,200m/min，甚至1,800m/min（见表1）。机床的主轴转速也在不断提高，由4,000r/min提高到6,000r/min、8,000r/min，特别是近年来主轴的开发，主轴转速可达24,000r/min或更高，这样，对实现高速及超高速切削成为可能。<BR>
<DD>在主轴设计方面，主轴转速与DN值（主轴轴径X转速），一般可达500,000～1,500,000左右，以ISO30、ISO40及ISO50的主轴为例，目前可达到的水平见表2。<BR>
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<CAPTION><FONT size=2><STRONG>表2</STRONG></FONT></CAPTION>
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<TD><FONT size=2>DN值 </FONT></TD>
<TD><FONT size=2>主轴轴径d <BR>mm </FONT></TD>
<TD><FONT size=2>主轴轴孔ISO </FONT></TD>
<TD><FONT size=2>最高转速n <BR>r/min<BR> </FONT></TD></TR>
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<TD align=right><FONT size=2>500,000 </FONT></TD>
<TD rowSpan=3><FONT size=2>45 </FONT></TD>
<TD rowSpan=3><FONT size=2>30 </FONT></TD>
<TD align=right><FONT size=2>11,111<BR> </FONT></TD></TR>
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<TD><FONT size=2>1,000,000 </FONT></TD>
<TD><FONT size=2>22,222<BR> </FONT></TD></TR>
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<TD><FONT size=2>*l,500,000 </FONT></TD>
<TD><FONT size=2>33,333<BR> </FONT></TD></TR>
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<TD align=right><FONT size=2>500,000 </FONT></TD>
<TD rowSpan=3><FONT size=2>60 </FONT></TD>
<TD rowSpan=3><FONT size=2>40 </FONT></TD>
<TD align=right><FONT size=2>8,333<BR> </FONT></TD></TR>
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<TD><FONT size=2>1,000,000 </FONT></TD>
<TD><FONT size=2>16,667<BR> </FONT></TD></TR>
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<TD><FONT size=2>*l,500,000 </FONT></TD>
<TD><FONT size=2>25,000<BR> </FONT></TD></TR>
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<TD align=right><FONT size=2>500,000 </FONT></TD>
<TD rowSpan=2><FONT size=2>80 </FONT></TD>
<TD rowSpan=2><FONT size=2>50 </FONT></TD>
<TD align=right><FONT size=2>6,250<BR> </FONT></TD></TR>
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<TD><FONT size=2>*l,000,000 </FONT></TD>
<TD><FONT size=2>12,500<BR> </FONT></TD></TR></TBODY></TABLE></TD></TR>
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<TD><FONT size=2>注：带* 者为该规格的极限转速<BR> </FONT></TD></TR></TBODY></TABLE><BR>
<DD>高转速每齿较小进给从而达到较大的金属切削量，比低转速每齿大进给的生产效率高70％～100％，而且由于切削扭矩的减少，大大降低工件的切削变形。对机床来说是向着高速化和轻型化发展，这是目前金属切削的一个重要的发展趋势，一般转速超过 8,000r/min被认为是高速主轴。<BR>
<DD>由于主轴转速不断提高，对刀柄与刀具系统的平衡问题变得越来越重要，未经过平衡的刀柄与刀具系统转速越高离心力越大。以50号刀柄为例，不对称性一般为250gmm，如果在15,000r/min的速度下旋转，将产生635N的径向力，即使经过精细的动平衡到1gmm，在15,000r/min速度下旋转，仍会产生2N的径向力。这种径向力达到一定程度时将使刀具系统产生振动，其结果是：被加工表面质量下降，刀具寿命缩短，甚至影响到主轴轴承的加速磨损，严重者将会使刀具和主轴损坏。<BR>
<H1><FONT size=2>2.不平衡的定义</FONT></H1><BR>
<DD>不平衡是一个旋转体的质量轴线（惯量轴线）与实际的旋转轴线不重合。其单位为不平衡的质量与该质量中心至实际旋转轴线的距离的乘积，以gmm计量。不平衡有3种表现形式。
<OL><BR>
<LI><B>静力不平衡（单平面）</B> 表现在一个旋转体的质量轴线与旋转轴线不重合，但平行于旋转轴线，因此不平衡将发生在单平面上。不平衡所产生的离心力作用于两端支承上是相等的、同向的（图1）。<BR>
<LI><B>偶力不平衡</B> 表现在一个旋转体的质量轴线与旋转轴线不重合，但相交于旋转体重心，不平衡所产生的离心力作用于两端支承是相等而180°反向的（图2）。<BR>
<LI><B>动力不平衡</B> （双平面）表现在一个旋转体的质量轴线与旋转轴线不重合，而且既不平行也不相交，因此不平衡将发生在两个平面上，可以认为动力不平衡是静力不平衡和偶力不平衡的组合，不平衡所产生的离心力作用于两端支承，既不相等且向量角度也不相同（图3）。</LI></OL>
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<TD><FONT size=2><IMG src="http://www.chmcw.com/upload/news/RCL/13220_zcokfa2008310162139.gif"><BR><STRONG>图1</STRONG> </FONT></TD></TR></TBODY></TABLE>
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<TD><FONT size=2><IMG src="http://www.chmcw.com/upload/news/RCL/13220_2uq1ob2008310162319.gif"><BR><STRONG>图2</STRONG> </FONT></TD></TR></TBODY></TABLE>
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<TD><FONT size=2><IMG src="http://www.chmcw.com/upload/news/RCL/13220_1adjn82008310162337.gif"><BR><STRONG>图3</STRONG></FONT></TD></TR></TBODY></TABLE>
<H1><FONT size=2>3．解决不平衡的方法</FONT></H1>
<DD>机床用的刀具系统是通过锥柄与机床主轴由卡爪自动拉紧，一般短刀柄组成的短刀具系统可视为静力单平面不平衡，长刀柄组成的长刀具系统肯定是动力双平面不平衡（图4）。<BR>特别是精镗刀，由于镗刀杆及滑块的偏移更是动力双平面不平衡。<BR>
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<TD><FONT size=2><IMG style="WIDTH: 526px; HEIGHT: 278px" height=316 src="http://www.chmcw.com/upload/news/RCL/13220_nu3d0s2008310162429.gif" width=469><BR>(a) </FONT>
<P><FONT size=2><IMG style="WIDTH: 549px; HEIGHT: 377px" height=411 src="http://www.chmcw.com/upload/news/RCL/13220_oq8qze2008310162728.gif" width=619><BR>(b)</FONT></P></TD></TR></TBODY></TABLE>
<P align=center><B><FONT size=2>图4</FONT></B></P></TD></TR></TBODY></TABLE><BR>
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<TD><FONT size=2><IMG style="WIDTH: 408px; HEIGHT: 282px" height=317 src="http://www.chmcw.com/upload/news/RCL/13220_twfo9s2008310162814.gif" width=427><BR>(a) </FONT></TD></TR>
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<TD><FONT size=2><IMG style="WIDTH: 426px; HEIGHT: 435px" height=479 src="http://www.chmcw.com/upload/news/RCL/13220_tpegrc2008310162831.gif" width=443><BR>(b) </FONT></TD></TR>
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<TD><FONT size=2>图5</FONT></TD></TR></TBODY></TABLE><BR>
<DD>对于短刀柄来说，国外的一些厂家，采用在刀柄的某个方向与部位铣去一些金属以达到刀柄本身的静力单平面平衡，可以将普通刀柄的不平衡值从250gmm下降至50gmm甚至更低，这在500r/min以下是可以的，但加上刀具以后或在更高转速的情况下，显然不够了。因此国外的一些厂家在刀柄上增加了两个偏心环或平衡块，进行动平衡，可以调到5gmm或3gmm。意大利D'ANDREA公司利用平衡环上的两个平衡块，通过小型刀具动平衡仪，根据软件所指示的数据，可以迅速地调到1gmm，其结构见图5a，图5b为调整原理，T2及T3为平衡块的离心力，C为T2及T3的合力，可抵消刀具系统的离心力U。<BR>
<DD>上面谈到的是刀柄式刀具系统本身由于不对称或质量分布不均所产生的不平衡，可以采用静平衡或动平衡的办法达到要求的平衡效果，但主轴与刀柄是锥面接触，其公差带将直接影响刀具系统质量轴线的偏移，将扩大刀具系统的不平衡值或者使之处于不稳定状态（图6）。因此，必须提高锥度精度，一般厂目前仍使用AT5标准，即锥度公差为5µm，而D'ANDREA公司已采用AT3标准，即3µm。这将大大提高刀具系统与主轴的安装精度及稳定性，但在高速旋转下，这微小的偏差也会因离心力的作用而扩大化，加上主轴本身的变形，常规的ISO7388锥柄已经不能满足高速或超高速的需要，一般上限为8,000r/min，最大不应超过10,000r/min。自1993年德国开发了短锥的HSK锥柄，它的静刚度和动刚度以及接合精度均优于ISO7388锥柄，是最适合于高速及超高速旋转的刀柄系统（图7）。<BR>
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<TD><FONT size=2><IMG style="WIDTH: 567px; HEIGHT: 405px" height=449 src="http://www.chmcw.com/upload/news/RCL/13220_21q5fr2008310162946.gif" width=544><BR><STRONG>图6</STRONG> </FONT></TD></TR></TBODY></TABLE>
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<TD><FONT size=2><IMG style="WIDTH: 586px; HEIGHT: 354px" height=504 src="http://www.chmcw.com/upload/news/RCL/13220_kpc9bx200831016305.gif" width=803><BR><STRONG>图7</STRONG></FONT></TD></TR></TBODY></TABLE><BR>
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<TD><BR>
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<CAPTION><FONT size=2><BR> </FONT></CAPTION>
<CAPTION><FONT size=2><STRONG>表3</STRONG></FONT></CAPTION>
<CAPTION></CAPTION>
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<TR align=middle bgColor=#c5cb9a>
<TD><FONT size=2>转速n<BR>r/min </FONT></TD>
<TD><FONT size=2>不平衡公差值U<BR>g·mm<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>6,000 </FONT></TD>
<TD><FONT size=2>50<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>8,000 </FONT></TD>
<TD><FONT size=2>2.98<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>10,000 </FONT></TD>
<TD><FONT size=2>2.39<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>12,000 </FONT></TD>
<TD><FONT size=2>1.99<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>14,000 </FONT></TD>
<TD><FONT size=2>1.71<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>16,000 </FONT></TD>
<TD><FONT size=2>1.49<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>18,000 </FONT></TD>
<TD><FONT size=2>1.33<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>20,000 </FONT></TD>
<TD><FONT size=2>1.19<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>22,000 </FONT></TD>
<TD><FONT size=2>1.09<BR> </FONT></TD></TR>
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<TD align=right><FONT size=2>24,000 </FONT></TD>
<TD><FONT size=2>0.99<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>26,000 </FONT></TD>
<TD><FONT size=2>0.92<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>28,000 </FONT></TD>
<TD><FONT size=2>0.85<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>30,000 </FONT></TD>
<TD><FONT size=2>0.80<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>32,000 </FONT></TD>
<TD><FONT size=2>0.75<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>34,000 </FONT></TD>
<TD><FONT size=2>0.70<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>36,000 </FONT></TD>
<TD><FONT size=2>0.66<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>38,000 </FONT></TD>
<TD><FONT size=2>0.63<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>40,000 </FONT></TD>
<TD><FONT size=2>0.60<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>42,000 </FONT></TD>
<TD><FONT size=2>0.57<BR> </FONT></TD></TR>
<TR align=middle>
<TD align=right><FONT size=2>43,000 </FONT></TD>
<TD><FONT size=2>0.56<BR> </FONT></TD></TR></TBODY></TABLE><BR> </TD></TR></TBODY></TABLE><BR>
<H1><FONT size=2>4.平衡的精度等级与不平衡公差值的计算</FONT></H1><BR>
<DD>平衡的精度等级有两个相类似的标准，即ISO1940/1及ANSI.S2.19-1989，以“G”来规定某种转速的条件下的不平衡公差值，或某不平衡公差值允许使用的最高转速，“G”等级单位为mm/s。从GO.4～G4000共分11级，其中G6.3为一般机床零件的公差等级，G2.5为高速旋转体的公差等级。刀柄及刀具系统应执行G2.5等级标准。从表3中可以查出当转速为6,000r/min时，不平衡公差值为50gmm，在8,000r/min时为2.98gmm，在10,000r/min时为2.39gmm，在24,000r/min时为0.99gmm（表3及图8)。<BR>不平衡公差值及离心力可按下式计算：
<CENTER><BR><IMG style="WIDTH: 213px; HEIGHT: 101px" height=210 src="http://www.chmcw.com/upload/news/RCL/13220_itvn2p2008310163132.gif" width=326></CENTER><BR>式中：U——不平衡公差值，g·mm<BR>
<DD>G——“G”等级，mm/s<BR>
<DD>M——刀柄质量，kg<BR>
<DD>N——主轴转速，r/min<BR>
<DD>F——离心力，N
<P align=center><FONT size=2><IMG style="WIDTH: 505px; HEIGHT: 706px" height=890 src="http://www.chmcw.com/upload/news/RCL/13220_yruvmk2008310163053.gif" width=622></FONT></P>
<P align=center><STRONG>图8</STRONG></P></DD></TD></TR></TBODY></TABLE></TD></TR></TBODY></TABLE></TD></TR></TBODY></TABLE></TD></TR></TBODY></TABLE>
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