User talk:Kizembending

3w.kizem.c0m CNC bending machine 1, CNC bending machine operating principle CNC bending machine is used to produce more curved space, higher dimensions, the relative bending radius of the hollow tube, especially in the car exhaust pipe, tubing on the engine. Figure 1 is a schematic diagram of CNC bending machine work, mainly by the bending axis of rotation devices, Y, B-axis adjustment device and the combination of body and mandrel into four parts to the device. Achieve the transport, turn, bend Axis of space control, complete with complex spatial shape of the hollow tube processing.

Bending rotation device rotating around the center of rotation O, the rotation angular displacement θ, angular velocity ω and the rotation torque M is the main control object; jaw will be pressed to the rotating stage pipe bending mold, together with the rotary table bending rotation, thus the tube bending; bent shaft speed, angle and bending torque is controlled by the servo motor worm shaft to achieve. 2 CNC bending machine mechanical design 2.1 Tube bending moment is calculated Pipe bending moment is calculated to determine the mechanical bender basis. Calculate the pipe bending moment, to determine the required driving torque bending machine, the servo motor power, the main shaft body size of the parts of the structure, size, clamping force and a series of parameters. According to the empirical formula [3]:

Seek bending moment. The maximum size pipe bending machine as Φ60mm, general steel tube material 20, according to specifications of Φ60 × 4mm tube bending machine to determine the maximum bending moment, the specific parameters: D = 60mm, t = 4mm, d = 52mm, ρ = 120mm, K 0 = 11.6mm and σ s = 240 MPa (see [4]), into the above formula, the bending moment is M = 6280.04N • m. K 0 - a relatively strong material factor; σ s - material yield limit (MPa) D - pipe diameter (mm) t - pipe wall thickness (mm) d - tube diameter (mm) ρ - bending radius (mm) 2.2 bending axis and bending arm design Bender bending axis is an important component, as much bending and bending under a great bearing torque, alloy steel shaft material selection, while using heat or chemical treatment methods to improve the wear resistance and fatigue strength [5]. Axis of the structure and size of the shaft parts is based on the installation, positioning and the axis of the manufacturing process and other requirements determined. Pipe is in operation, drive shaft bent arm bent and curved arm some of the auxiliary body by bending the arm of the jaws clamp the workpiece, the clamping jaw to achieve by the hydraulic cylinder. Bent arm dimensions are based on the clamping arm bent seat and seat rail clamping determined, shown in Figure 2.

Figure 2 bending and bending arm assembly axis adjustment device 3 2.3 adjusting device design Adjustment device, shown in Figure 3, the screw, with the moving mold, mold, and wrinkle-free servo cylinder, clamp cylinder and other components. Screw from the fine-tuning role. Drive screw drive shaft clamping cylinder to achieve the mold fixture and convenience of the operator in handling X pipe. Servo servo cylinder drive from the mold, with the dynamic model is also in the process of pipe to play a pivotal role to prevent the tube is deflated and the rupture curve, with the first mold clamping cylinder moving under the action of the tube pressed in the wrinkle-free mold pieces, and then with the bending axis of rotation along the tube surface to follow the movement. 2. 4 Y-B-axis combined mechanism design Y-B-axis combined mechanism, shown in Figure 4, including the implementation of transmission parts and components. Y to the feed motion rack and pinion, so smooth drive. B to rotate the use of cylindrical spur gear transmission. Y and B to the power sector is the AC servo electric motor power are 3.5KW. To have a CNC Y and B to the machine, device. Taking into account the structure of both light and also reasonable, car body with box-type structure. Triangle chuck is the executing agency, achieved through triangular tube chuck clamping and relaxation in the tube by a worm drive clip [6] led to the clamping of the tube Tight state, the first movement, to achieve a large mass ratio, large torque transmission. 2.5 Body Design

Figure 4 Y-B-axis combined mechanism such as base and box parts in a machine of the total mass in a large proportion (for example, the total mass in the machine 70% to 80%), and to a large extent affect the accuracy of machine work and vibration performance; The correct selection box base and other parts of the material and proper design of its structure and size, is to reduce the quality of the machine, improve accuracy, increase machine stiffness and wear resistance and other important way [7]. The bending machine itself by casting and welding of ways. Cabinet force situation is more complicated when bending or by torsion, the cross-section shape for its strength and stiffness has a significant impact. The machine bed horizontal structure, materials, use an ordinary gray cast iron. 2.6 bender general assembly Pro / ENGINEER is a single database design [8], so after the completion of the design part, you can use Pro / ENGINEER assembly models will be assembled parts. In accordance with the general assembly after the assembly sequence as a reference machine tool production, and to consider the computer simulation, computer simulation is the simulation of bending machine is to use the process, a reasonable assembly sequence in order to effectively implement a computer simulation, shown in Figure 5.

Figure 5 overall assembly diagram CNC bending machine movement simulation 3 The design of the product in the processing prior to motion simulation, can vividly simulated movement of products, and MPEG can be made into clear Format video, so that the virtual prototype of the computer more clearly demonstrated in front of designers and customers [9] for the design of the product into production as soon as possible, helped greatly, greatly improving design efficiency. Figure 6 is a simulation interface. The simulation mainly in the Y direction of the bending machine, direction, direction, BX with the dynamic simulation of movement direction, C the direction of mandrel movement direction of the six directions of motion simulation, the Y-axis feed, space rotation, with the dynamic simulation of the bending axis of the rotating movement and other movements in dynamic real-time three-dimensional display, so the machine can be put into production before a good understanding of the operation of various agencies to facilitate and improve the design changes, shorter design cycle bender greatly improve the bending machine design reliability; also easy to observe the process and operators to detect machine failures. CNC Tube Principle I. Introduction No matter what kind of equipment is almost always a conduit for oil, gas, fluids, etc., and in the aircraft and its engine is more played a very important position. Many varieties of pipe, large quantities of complex shapes, tube processing to bring a lot of difficulties. The elbow is the use of the traditional mold for bending the bending sets. Bending steps is roughly: 1. Set aside paragraph 1, line length, and clamping the tube. 2 bend. 3 Release the mold, remove the tube, the mold reset. According to the standard sample tube in the test tube-shaped fixture on the checking and correction. 4 Press the desired shape, the tube placed in the mold, and clamp. 5. Bending. 6 Repeat step 3 until finished pipe bend up. As the aircraft and engine number on the catheter, and catheter requires less space to save as much as possible, so the tube must be bent into various shapes, in order to avoid interference with each other in a limited space. Duct geometry is very complicated, very difficult to put it graphically portrayed. Especially in aircraft engines used on the tube, very strict manufacturing tolerances, form tolerances usually bend ± 0.64 mm, tube-side interface position tolerances must be maintained at ± 0.127 mm or less, making it is very difficult. Traditional bending processes are put into shape by aircraft or engine after the catheter (or tube) standard sample in the fixture or pipe bending machine bending test fixture on the surface for acceptance. As the tube bending angle between two adjacent curved space plane angle and straight-line distance between two curved can not be directly measured or are difficult to measure accurately, coupled with the elbow in the process of resilience and a series of process and operational issues, when the bending tube completely with the operator's experience and technical proficiency, therefore, in each tube prior to acceptance, have to make manual corrections, but there will inevitably be "repeatedly" bending, "string bend" and so on. This not only difficult to bend quality control, production efficiency is low, labor intensive and require a considerable number of the standard sample tube, bending test fixture and the fixture surface. Moreover, in order to make same type of engine swap on the tube to the standard sample must be properly kept, as the basis for each batch of production and acceptance criteria. Not only is the production of the engine standard sample, but also in the past produced all the different types of engines the standard sample, due to the supply of spare parts, must be stored to ensure that the needs of users. To produce a new type of engine, manufacturing and storage of these standards should be sample, or even save the bend fixture and test fixture. In this way, we need a large warehouse or workshop. Therefore, solving the bending equipment and techniques, as the world's aviation industry has long studied a subject. Some analysis from conventional bending process, it is easy to see, the main pipe bending can be attributed to three basic moves, that is sent to a straight line, space, corner, bend. Of course, want to bending a tube, also need some elbow secondary action, such as clamping or die clamping, release, bend die reset. All these simple bending action is mechanical action of a certain sequence combinations. Through a lot of practice, people have mastered the laws of the elbow movements, which may put these simple actions in a certain order to link up and control, to achieve elbow mechanization and automation. The use of numerical control technology, not only can bend the catheter to ensure a reliable quality and production efficiency is greatly improved, thus changing the hand bend backward. However, the duct geometry of the space is complex and difficult to design accurate drawings to express it; but also for the standard sample tube is also very difficult to measure, so the editor "pipe program" has become the use of CNC bending to solve new problems. Currently, only through trial-by-turn bend - the beginning of recorded data - try bending the tube - revised data - the last way to record data to determine the bending process. This is not only a certain amount of scrap pipe, and the efficiency is very low. In order to find new ways to speed up programming, as well as the use of automatic computer programming, to improve the current level of CNC bending, United States • Leonard Eaton in the 1970s the company developed and produced a computer-controlled CNC (CNC) bending equipment vector In recent years, the West generally used by the aircraft engine company. To further promote domestic auto bending techniques, will be introduced to do this. Second, the vector pipe technology The vector theory, the tube on the centerline of each line segment as a vector space, the basic concepts and the use of vector operations, accurately calculate the "incremental tube data" to control the vector pipe machine. Bending of the tube can also be automatically tested, and compared to standard tube-shaped data, calculate the "difference", and "difference" fix pipe program, come to the new pipe program, go under a bending tube, which is the basic characteristics of the vector pipe technology. (A) the basic concepts of vector The so-called vectors, that is, the size and direction with the amount. In the geometry of the directed line segment is an intuitive vector. From the definition of two equal starting vector can know, will be a vector parallel move, the vector remains equal to the original vector. So the starting point of the vector space can be placed at any point. (B) bending technology in the application of vector In addition to spiral shape and compound curved (ie, no straight line between two curved segments) of the special shape of the tube, but in general, it is composed of many straight line segments and curved (arc) above, and that a straight line than the round The number of arcs than 1. For example, an eight curved pipe on the arc segment will have eight and nine line segments. And both ends of the tube must be straight line segments. If the tube on the space coordinate system, and on the tube with its center line, said line segment, then the tube to the centerline of each said straight line segments. After the extended centerline of two adjacent intersections generated. Intersection point of two adjacent connection distance and direction, it means the vector magnitude and direction. The tube on the center line with a series of line segments to represent the vector space, find their intersection, and then find the "incremental tube data," which is the original idea of bending vector. Based on the above ideas, the U.S. company Eaton • Leonard made a VECTOR 1 tube measuring machine. If a pipe has eight bends, then use the VECTOR 1 tube measuring machine tube, the measuring point selection in nine straight line at any point (but at both ends of the line segment to be measured at the endpoint), and each line segment measured only once. Thus, the order can be calculated by measuring nine different measuring points of the centerline of the pipe-shaped line segment direction cosine. And then calculate the coordinates of the intersection of two adjacent vector data, and stored in the computer's memory. In other words, VECTOR 1 tube measuring machine with a, b, c ... j ten points of the coordinate data to describe the tube. As the tube position in space is more complex, with a number of points the coordinates to describe the tube, it's real easy to Tuixiang Chu tubular shape. Moreover, the data used bender not coordinate point data, but "incremental pipe data." Thus, stored in the computer memory the coordinates of the point data also must pass a series of vector operations needed to calculate the bending of the "incremental tube-shaped data." 1 sent to the distance between two DBB (Distance Between Bends). It is the end to cut straight lines and arcs of the distance between the two arcs or straight lines and the distance between the cut-off point. For the bending machine, it is a straight line before each turn sent a distance. 2 room corner POB (Plane Of Bend). It is not a two curved plane, the second bend where the plane where the first plane bending angle. For the bending machine, it is gripping collet tube rotation angle. Chuck can be used for forward rotation, reverse rotation can also be made. 3. Bending angle DOB (Degree Of Bend). It is the second line segment relative to the centerline of the center line of the first line segment angle. For the bending machine, it is transferred out of bent arm angle. Each tube has a bend three data. A certain bend in accordance with the previous data is based on data bend generated, so called "incremental tube-shaped data." This data is produced, but also by the rebound data correction, only a bending process to control vector bender, for bends. (C) the vector pipe technology Measured with a tube-shaped measuring machine to obtain the necessary data, you must also bend the pipe out. Therefore, and VECTOR 1 tube measuring machine is accompanied by VECTORBEND bender, with this device by measuring the bending of the data pipe. So the whole process of vector bending techniques are: 1 using VECTOR 1 tube measuring machine according to the standard sample test tube to take (or drawing input) tube data, edit, modify tube data; (2) test data back play, the preparation of elbow procedures; 3 Use VECTORBEND bender bending; 4. VERTOR 1 tube using automatic measuring machine inspection, and the standard sample tube data compared to the calculated difference, and with the "difference" the program automatically correct pipe; 5 re-use VECTORBEND bender tube bending qualified. The whole process is controlled by computer to complete. That is, using computer numerical control (CNC). Of course, the first step in this process, the measurement data can be tubular design drawings, the tube and both ends of each line segment intersection point of the data go directly into the computer, in order to determine the shape of the tube. Third, the vector pipe bending process technology is a breakthrough Uses vector technology to produce tube bending of great significance. 1 quick take tube test data, according to the standard sample tube programming As already said, the aircraft and engine duct shape is very complex, it is difficult or even impossible to use the design drawings to express it. Therefore, the catheter processing, production of many catheter is not in accordance with the drawings, but in accordance with catheter (or tube) to produce the standard sample, the surface on the acceptance test fixture. If you simply use CNC bending, as in the usual way to measure the tube data is difficult, even if the measured data are not accurate, plus the many factors affecting resilience, such as pipe material, diameter, wall thickness, bend corner radius and size, etc., are not necessarily the law. A series of technological problems, making difficult the establishment of elbow procedures. This can only be through "trial-by-turn bend - the beginning of recorded data - try bending the tube - revised data - to finalize the data" approach to editing elbow procedures. However, the use of VECTOR 1 tube measuring machine, this problem will be solved. It is through the tubular standard sample measurements made tube data, and revised by the rebound, the automatic preparation of VECTORBEND bender bending required procedures. This is a kind of "profiling" approach, in the actual production use much. Especially for complex tubular shapes, the large, complex calculations done by computer, which test to take to solve the general problem of tube data, so that the tube-shaped computer programming as possible, and greatly reduce the workload of the programmer's calculations. 2 quick comprehensive test tube For high-quality, efficient CNC machine tools, if there is no corresponding rapid testing methods will inevitably result in inspection time than the time required to bend much longer, thus affecting the efficiency of CNC bending machine, resulting in " Wogong "phenomenon, which is very unreasonable. VECTOR 1 tube measuring machine to solve this problem. It has a high efficiency integrated test tube of capacity (usually 7 to 8 bend of the tube, from clamping, fixed tube since the beginning of the measurement is completed, print data output tube, 3 minutes to complete), can bend the shape of a tube for rapid testing, and the standard sample tube to compare the data to determine the error value, and can print out "inspection report." This will help improve the mass production of fast components tested efficiency, help achieve test automation. It also use the "difference" the program automatically correct bend, bend reveals a new program, go elbow. This use of "difference" modified bending process, provides a new bend procedures so bent out of the tube is always close to the standard sample tube, it is actually a kind of "adaptive" control. 3 for the catheter design - create the conditions for manufacturing integration Vector bending pipe bending automation technology is the foundation for the pipe design - manufacturing integration creates the necessary conditions. • McDonnell Douglas aircraft the United States in catheter design - manufacturing integration step. It VECTOR system and design department of a large computer connected to the arrangement according to the production sector, VECTOR system to accept stored in large computer data storage within the tube and pipe preparation procedures, pipe production. The vector pipe technology to fundamentally change the face of hand bend backward technology, the bending technology a new look. It improves the bending precision, so that product quality is stable and reliable. For complex shape, difficult to bend by hand to complete the thorny issue can be resolved relatively easily, its efficiency can be increased several times, several times. We can say that vector technology is the elbow bend of a major technological breakthrough. 4.VECTOR 1 tube sheet size measuring machine can enter "tube data," according to the standard sample test tube-shaped tube-shaped data or take measurements rebound data, you can Edit the tube data, such as adding a turn, undo a curved, moving a bend, mirror, flip tube data; coordinate data with a display tube, tube-shaped incremental data, rebound data; storage and preparation of elbow procedures and other functions, its adaptability large, easy to operate, greatly reducing the production preparation period, especially adapted to the new machine in the form of the product development process and size is often the need for change. Moreover, since the VECTOR 1 tube measuring machine to obtain accurate data in the standard sample tube, and storage preservation; measured in the elbow before playing back data, the preparation of elbow procedures; coupled with automatic test - Fixed elbow program, VECTORBEND bender can bend to meet the requirements of the tube. Therefore, from the elbow point of view, no need to save a large number of tube-shaped sample and standard surface test fixture. This not only reduces production costs, but also saves a large workshop area. Fourth, the vector bend - CNC CNC pipe bending system introduced As noted above, the United States • Eaton Leonard CNC vector produced two-part pipe system that VECTOR 1 tube measuring machine and VECTORBEND (referred to as VB) Vector CNC bending machine. VECTOR 1 tube measuring machine features dozens of its main functions are: take the tube-shaped standard test sample tube data, the number of points the coordinates of the data into a tube-shaped incremental data; with incremental data to control the tube VB bender to bend, under normal circumstances is not enough, must also consider the resilience of the tube to fix the problem. Before each batch of tubes in bending, pipe bending machine with the test pieces to do the rebound test, and VECTOR 1 tube measuring machine measurements to determine the rebound data. Then fix the incremental tube data, as incremental bending process to achieve computer programming. CNC tube bender VB VECTOR 1 received from the measuring tube bending machine sent from the incremental program data and stored in the control cabinet of the computer. Bending machine like a robot, it bends according to the incremental pre-program data and machine bending action, the straight tube bent into the required shape. The following set of computer-controlled bending of the system for some specific description: (A) VECTOR 1 tube measuring machine VECTOR 1 tube measuring machine from the table, measuring arms, computers, printers, fixed tube support frame and other components. 1 Measuring Arm With computer VECTOR 1 tube measuring machine to imitate the human arm, wrist and hand made of the measuring arm. The five sections measuring arm at the elbow with arm rotation angle of the reflecting device - encoder. The measuring arm by the arm Ⅰ, Ⅱ, Ⅲ, Ⅳ and the probe. Ⅰ is a measure of arm arm of the column, it's z-axis coordinate system coincide, and can rotate around the z-axis, the angle A A recorded by the encoder. Ⅱ B toggle arm swing around, swing angle B at the encoder by the B record. Arm around the elbow section Ⅲ C swing, swing angle C of C recorded at the encoder. Ⅳ arm is equipped with a probe, which in addition to swing around the elbow section E, the swing angle E from the E record at the encoder, it can also rotate around the axis of arm Ⅲ, the angle of rotation D at the encoder from the D record. In fact, the arm Ⅲ is composed of two, that the following section together with arm Ⅳ, Ⅲ axis can rotate around its arm. Structure to ensure the arm Ⅰ, Ⅱ, Ⅲ of the center line on a plane, arm Ⅲ, Ⅳ and determined by the probe measured the center line of the pipe line segment is also a plane, and the arm Ⅳ determined with the probe tube straight line perpendicular to the centerline. The measurement arm of the five knuckle, making any measurement arm to rotate in space, which ensures that the probe can be relatively easy to measure any vector space. Meanwhile, for a fixed measuring point, the toggle is only a fixed angle, respectively, recorded by the five encoders. In order to take the tube test data, standard sample tube should be fixed on the work surface of the stent, and with the probe on the tube followed by measurement of straight line segments. When the measurement is completed, the computer to calculate the tube-shaped data storage in memory, and can coordinate point (x, y, z) in the form of tubular or incremental data (DBB, POB, DOB) in the form of output. 2 Interface The purpose of this system is designed to collect five encoder data to be handled by the computer, to complete a variety of measurement calculations. As already mentioned, VECTOR 1 measuring tube bending machine program can be compiled by a dedicated cable directly to the VB bending machine control cabinet. And VECTOR 1 tube measuring machine equipped with multiple outlets, pipe bending machine for multiple services. VECTOR 1 data transfer from the interface board on a bender to complete. (B) VECTORBEND vector CNC bending machine And VECTOR 1 tube measuring machine supporting VB bender bending machine is modular, it is the coordinate (DBB, POB, DOB), point closed-loop system. 1. Bender structure outlined (1) Bed. Bed by the plate, welded profiles, be supported in the tailstock and hydraulic tank. Bed rail with the body, elbows, mandrel institutions. Installed on the rail car, bed who have travel switch. (2) elbows. Elbows function is to complete the "bending (DOB)" campaign, the required angle bent tube. It consists of clamping bodies, die body, boost the body, driven rotary body and other components. Elbows can screw for lateral movement to adjust the bending mold centerline. (3) car. Car driven by a DC motor, to complete the "line feed (DBB)" campaign. Small car equipped with a chuck, pneumatic operation. Chuck also driven by a DC motor, complete the "space corner (POB)" campaign. (4) mandrel body. Mandrel body mounted on the bed of the tail, with its top nut can be adjusted around the mandrel, mandrel to ensure that the desired position. In the automatic bending process, the mandrel forward and backward according to the computer's instructions, by the hydraulic operation is complete. 2 hydraulic system VB bending machine hydraulic system is relatively simple. It consists of pressure-compensated piston variable displacement pumps, servo valves, pressure regulators, pressure gauges, fuel tank, oil filter and other components. It should be noted that the hydraulic actuator (cylinder) action is completed, the feedback signal is not from the "micro-switch" issue, but in the hydraulic action is complete, the necessary flow of hydraulic oil drastically reduced, the slope variable pump plate angle decreases along with, connected to the swashplate shaft on the hydraulic arm, non-contact switch by a feedback signal to make the program into the next step. Therefore, it is simple and reliable. 3. Bender features VB bender in the machinery is more perfect in some places could learn from. Mechanical characteristics are: (1) elbows along the rails for lateral movement, which is replaced after the bending mode, adjust the bend die tube groove necessary to align the machine centerline. This way than by adjusting the bed rail and the body of the tailstock center line to adjust the machine simple. (2) complete the line feed movement (DBB) of the car, in the tube bending process, the tube was pulled forward movement. In this way, remove the "positive push" to get rid of the car and bending speed of the synchronization problem, removed to increase the "positive thrust" and set the DC negative feedback system, to simplify the electrical circuit. Since being thrust on the tube bending favorable, especially in the larger diameter tube bending, the positive thrust is necessary. Thus, VB bender added boost device. (3) bending, due to the car as a load, the tube was pulled forward, in order to improve bending, pipe bending part of the wall to avoid over-thinning, reduce the rebound, increasing the boost device.