reborn industrial empire

Full text without ads Chapter 439 Internal Stress Problem [Three updates please vote for me]

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The bed of a machine tool refers to the frame and base of the machine tool, such as the bed, columns, workbench, beams, bedside boxes, slides, shells, and other components. Full text without advertisements

They are mainly assembled together through forging and welding to support the machine tool.

But it is inevitable that when these assemblies and parts are cast, welded, and machined in the future, they will face an internal stress problem.

Internal stress means that when an object is deformed due to external force, corresponding internal stress will be generated from the inside to resist this external force and maintain the original shape of the object.

Just like a steel plate, if it is a flat piece and placed there, it will remain unchanged, but if it is cut and thinned, it will warp and maintain its original shape.

This kind of internal stress often becomes a big inducement that affects the machining accuracy of machine tools.

Most of today's machine tools focus on CNC, high-precision machine tools, and the accuracy is getting higher and higher. Especially CNC machine tools that appear as industrial base machines often have precision requirements that can reach a few zero-thousandths of a micron.

This is only a machine tool that meets the current needs of Huayang Power for automotive workpieces. If it is upgraded to a machine tool that can be used to process electronic integrated precision components, its precision will be even higher, reaching the level of nanometers.

Of course, such methods can only be mastered by Americans, Japanese, and Germans. As far as China's machine tool manufacturing industry is concerned, it is already very good if it can keep up with the pace of the world.

As a machine tool research institute under Huayang Precision, it was established from a very poor place. Although their capabilities are relatively high and they have some high-precision five-axis linkage CNC machine tools brought by Jin Xiaoqiang from Japan, in order to compete with those in the world

Compared with the leading machine tool manufacturing giants, they still have a long way to go.

Not to mention compared with international large-scale high-precision machine tool manufacturers, even compared with Nanyang Machine Tool of China and Dalian Machine Tool, Huayang Precision Machine Tool Research Institute is just a start-up.

Child.

Don't look at Nanyang Machine Tool and Dalian Machine Tool. Although the machine tools they make are stupid, big and crude, and there is a considerable gap between them and international machine tools, they are still companies that have been immersed in the machine tool industry for decades, and they have

Quite a solid foundation and system theory. (Free download of full text e-book)

Our Huayang Seiko Machine Tool Research Institute is just a kid compared to others. Although the talent, equipment, and research atmosphere are superior to them, when it comes to the real foundation,

It's far worse than others.

As a researcher who has been engaged in the machine tool industry for nearly 20 years, Zhang Hainan is very clear about this, so even though Jin Xiaoqiang gave him very generous conditions and gave him and his research and development methods, he created the best

Scientific research conditions, but he still does not intend to use the method of destroying the talent to train his employees. He adopts the stupidest, but indeed the most solid method to train his team.

They started manufacturing machine tools, not directly copying the Mazak machine tools that Jin Xiaoqiang bought for them, but starting from the simplest machine tool bed design and manufacturing.

When he first formulated this development plan, his young and energetic students majoring in mechanical automation from major prestigious universities across the country still didn't understand it.

Some people even went to Jin Xiaoqiang to report the situation and said they could not understand Zhang Hainan's development plan.

After all, in everyone's opinion, about 200 people gathered together to disassemble and assemble Mazak machine tools, and then reassemble, survey, operate the machine tools, and record data. They have been doing this kind of work for almost two years.

Regarding the design principles of Mazak's machine tools, how to install, how to reset, how to work, and even the CNC model and electronic control system of this machine tool, everyone has clearly understood it. With such a foundation, why

Do you want to go back to the most basic and least technical machine tool bed design?

However, when Jin Xiaoqiang faced these students who came to him to report problems, he just said, go back and study, follow the steps of Engineer Zhang, don't be unconvinced, and wait until the bed of the machine tool is built to speak.

In this way, the group of students reluctantly returned to the Airport Research Institute and continued to work on machine tool bed design with Zhang Hainan.

Zhang Hainan's approach on how to persuade these students is also very simple. Since they are willing to do it, they can directly copy the dimensions of the machine tool parts, as well as the installation ideas and installation procedures of the Japanese, and completely copy them 100%.

A machine tool was brought out, and then they were asked to use this assembly machine tool to compare with the two Mazak machine tools for finishing.

I didn’t know this until I did it, but I was shocked when I realized that there is so much knowledge in this seemingly simple machine tool bed design.

This machine tool bed is assembled from hundreds or thousands of steel parts, including cast parts and welded parts. During the processing of these parts, they each have certain internal stresses, and then when

When these parts are put together through assembly and welding, they may not be visible in the short term.

However, after a long time, or when machining is faced with various external force impacts or vibrations, the internal stress of these assemblies will explode collectively.

The conflict of various internal stresses will have a fatal impact on the stability of the machine tool and the accuracy required for finishing. There is also the problem of noise. The machine tools made by the Japanese are so quiet that it is almost inaudible, but

Not to mention the noise of the machine tools they made by imitating cats and tigers, it is completely comparable to those produced by Nanyang Machine Tool Factory and Dalian Machine Tool Factory.

After such a simple experiment, these students were convinced. It turned out that the manufacturing of this machine tool bed was not simple and could not be completed simply.

Looking back and thinking about it again, no wonder Teacher Zhang was so nervous when he was dismantling the Japanese machine tools. He even asked them to conduct very accurate mapping of the screws the Japanese screwed on the machine tools.

How many turns and how much force was used can be calculated.

There is a lot of knowledge about why people use so much force to tighten the screws, and why they tighten it so many times. The purpose of doing this is to solve the conflict of internal stress of the machine tool bed and allow the machine tool to perform fine machining.

It’s time to reach a state of perfect balance!

After understanding this truth, these students are no longer as impatient as they were at the beginning. Everyone agreed with Teacher Zhang's machine tool research and development plan. If they want to do it, they must do it down-to-earth, starting from the first step of machine tool development.

The body begins.

But when we really started researching, we discovered that just how to solve the internal stress conflicts between the components of the machine tool bed made everyone scratch their heads.

Most of the bed parts of these machine tools are made of steel castings and machined parts. These machine parts are more or less purely subject to certain internal stresses.

If these parts are used to assemble a car or something, the requirements may not be so high. However, if these parts are required to assemble an industrial machine that can process more precise parts, the internal stress of these parts will be a problem.

, it is necessary to attract their attention.

In the 1960s and 1970s, when CNC machine tools started to develop and processing technology took off rapidly, people had no good way to remove the internal stress of steel. The best way was to store it in the open air.

Let these parts go through the most severe test of nature, such as sun, rain, severe cold, heat, day and night changes, seasonal changes, etc., so that the internal stress of these parts can be naturally released.

This principle is the same as that in ancient shipbuilding, the wood for shipbuilding was taken outside and displayed in the open air.

However, doing so takes a long time, takes up space, and wastes time and money. Later, people also adopted some other methods, such as buying these steel parts underground for half a year, immersing them in sea water, etc.

However, the methods of doing this are not as good as natural aging.

In the end, it was the Germans who were the first to make a breakthrough in heat treatment, using thermal aging, that is, artificial aging, to eliminate the internal stress of this material.

Later, someone invented the method of audio vibration to eliminate internal stress, and these methods have achieved good results in eliminating the internal stress of these parts, greatly improving the processing speed of the current addition bed frame.

It has become the world's mainstream method of machine tool frame processing.

After getting those students and unifying everyone's research and development concepts, Zhang Hainan began to lead these students and began to explore step by step methods and processes for processing machine tool beds.

Technology like this is definitely strictly blocked by Germany, Japan, and the United States, so currently even Nanyang Machinery Factory and Dalian Machinery Factory, which are nationally renowned large-scale machine tool processing enterprises.

There are not many ways to solve the internal stress of the workpiece. Many of them still use open-air display to release the internal stress.

This is a high-end machine tool they process, so they use parts that release internal stress as the bed frame. If they are dealing with small businesses or low-profit orders, they will simply ignore you and just give them to you.

You use parts that have not been released or are not released completely to make machine tools for you.

It is conceivable that if the quality of the machine tools produced in this way is good, then there is something wrong!

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