基於車銑切削加工複合工件(簡稱車銑件;Mill/Turn Part)加工時,需要不斷交換工具機及夾具(Fixture)更換夾持,故製程規劃中夾持規劃必須能夠獲得以最少工具機交換加工次數下最少更換夾持次數,方可能達到最少設置成本及搬運成本。而本研究分別針對已知多組可行加工次序及未知加工次序之車銑件的夾具夾持分析。而已知多組可行加工次序,本研究提出兩階段之分析流程,第一階段先找尋最少工具機交換次數,再經第二階段找尋最少更換夾持的加工次序。在第二階段找尋過程,本研究提出後推製程夾持分析法,從完成工件開始考慮過渡工件(Intermediate Workpiece)夾持,依照較晚完成加工特徵的順序,逐一回推規劃每一個過渡工件的夾持,尋找加工過程中,工件於車床與銑床間交換加工次數最少中夾持更換次數最少之加工次序及夾持規劃,同時使用車床及銑床夾持自動建構,獲得夾持的方法及位置。 當加工次序為未知之車銑件時,本研究提出分支分析法規劃夾持,快速分析及計算加工夾持次序中,車銑交換的可能情形,本研究利用車銑件加工特徵間之加工在先關係(Precedence),找尋所有最少工具機交換次數下之更換夾持次數最少的加工次序,在同時也使用車床及銑床夾持自動建構,獲得夾持的方法及位置。本研究發展一套分析車銑件程式軟體系統,並提出五個工件實際例子,分別針對已知及未知可行加工次序,來驗證本研究之正確與可行性。
Since when machining a milling and turning compound part (mill/turn part) requires a number of intermediate changeovers of host machines (milling or turning) and their corresponding fixtures, a good process planning method must be able to acquire a scheme where the costs of set-up and part handling are minimal. Such a scheme includes a machining sequence of milling and turning processes and the fixturing means, i.e. the fixture type and clamping surfaces and locations, in the sequence. In this research, a process planning methodology is developed for machining a mill/turn part in the situations where there are multiple machining sequences feasible or the machining sequence is unknown. First, when there are multiple machining sequences feasible, the sequence with the least number of machine changeovers is determined. Thereafter, the least number of fixture changeovers is taken into account to modify the fixturing means. A backward clamping analysis is employed to obtain the clamping surfaces and locations. Second, when the machining sequence is unknown, a branch-and-bound process planning approach is proposed to search for the sequence with the least number of machine and fixture changeovers simultaneously. Five industry mill/turn parts were utilized to evaluate the methodology proposed. The simulation results show the robustness and effectiveness of the process planning system.
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