数控落地铣镗床培训教材通用系列

数控落地铣镗床培训教材(机械、液压部分)机床型号:TK6916/20/26/32系列中华人民共和国齐齐哈尔二机床（集团）有限责任公司1目录1.安全注意事项··································································21.1概述············································································21.2警示标牌在机床上的位置·················································52.机床的总体介绍·······························································62.1机床概述······································································62.2机床参数······································································13静压导轨简介··································································14.纵向坐标（X轴）····························································34.1概述（床身/滑座）·························································34.2床身、滑座的结构特点····················································35.竖直坐标（Y坐标）·························································45.1概述············································································55.2立柱结构特性································································65.3主轴箱平衡系统·····························································66主轴进给坐标（Z、W坐标）··············································76.1概述············································································77.传动系统······································································108机床液压、润滑及刀具冷却系统········································198.1泵站液压原理·····························································198.2滑座液压原理·······························································28.3主轴箱液压原理····································错误!未定义书签。8.4精度补偿·····································································88.5滑枕润滑·············································错误!未定义书签。8.6主轴箱内部润滑····································错误!未定义书签。8.7平衡锤钢丝绳及滑轮轴承的润滑···············错误!未定义书签。8.9液压故障及排除····························································78.10冷却系统····································································29维护与保养·····································································39.1日常维护、保养····························································39.2定期维护·····································································410故障诊断与排除······························································610.1常见故障及排除方法·····················································610.2机床报警、CRT显示故障··············································7数控落地铣镗床培训教材(机械、液压部分)21.安全注意事项1.1概述操作前请仔细阅读本教材或使用说明书，以免对操作人员及环境设备造成伤害或损坏。本教材为机械液压部分。安全注意事项的等级按「危险」、「警告」、「注意」区分。具体含义如下：危险如果不正确地操作，则会造成伤亡、严重人身事故或财产损失。警告如果不正确地操作，则会造成不能恢复的人身伤害或财产损失。注意如果不正确地操作，则会造成轻度的人身伤害或财产损失。1.1.1危险切削过程中不应接近主轴测量尺寸、对样板、手摸加工面或将头贴近观察。必须接近主轴时，应确认机床主轴已处于完全停止的状态；更换刀具时，主轴不应转动。应确认机床主轴已处于完全停止的状态。数控落地铣镗床培训教材(机械、液压部分)31.1.2警告机床的吊运安装应由专业人员进行，严格执行相关的安全操作规程；机床的调整应按使用说明书中的方法进行，应停机调整；每半月检查一次平衡锤与主轴箱的钢丝绳或接头有无损坏，发现钢丝绳或接头有损坏应及时更换新钢丝绳和接头，否则可能产生严重后果；用户不应改动机床内设参数,若有必要，须请生产厂确认后，派专人修改参数；不要过度牵引、弯曲手控盒的电缆线。不使用手控盒时，应将其放在特定位置。以免由于不小心落下，可能会产生误动作或损坏手控盒；严禁用户私自改装本设备。若必须改装，请向本公司询问。由用户私自改装而引起的一切故障、事故等不在保修范围之内，本公司不负任何责任；为避免因对本机床理解不足及误操作可能引起的危险，操作者应为充分理解操作方法的专门责任人，其他人员不应该接触本机床。操作者必须阅读并充分理解全套使用说明书及数控系统的编程、操作、诊断等作业指导资料，并接受专门的培训。1.1.3注意数控落地铣镗床培训教材(机械、液压部分)4安装调试人员需要具备专门的安装调试技能。在安装调试前，安装调试的相关人员根据需要必须阅读全套或部分使用说明书及数控系统的编程、操作、诊断等作业指导资料，并接受专门的培训；非电气专业人员不应接触机床电气系统；切削部位及操作位置必须有足够亮度的照明；移动部件接近极限位置时应减速运行；主轴换挡变速，应在主轴停止运行后，再进行换档；机床运行中若发生突发事件，应马上按动红色急停按钮停机。待问题处理后，方可重新启动机床；机床防护罩上、主轴箱、走台及尾箱下禁止站人或放置物品；本机床适合加工燃点较高的黑色、有色金属；本机床附近不许存在有害气体、液体、粉尘；工作时，操作人员绝对不应离开，应在机床操作位置监视工作情况；取放特殊附件及重大的零件时，要与其他人员密切配合，动作协调、安全可靠。检查吊具、钢丝绳是否完好；为避免切削时铁屑飞溅伤人的情况发生，操作者应在操作间内工作。只有在主轴停止旋转时，操作者才可在操作间外的可伸缩的走台中工作；使用特殊附件时，其工作扭矩和最高转速应符合附件使用说明书的要求；数控落地铣镗床培训教材(机械、液压部分)5如发生因切削时间长，热膨胀使镗轴或滑枕移动困难时，请不要强行移动；新安装的机床，应在运行一个月、三个月、六个月时更换液压油。以后每六个月更换液压油一次，并清理油箱、清洗滤油器。滤油器发出报警信号后，请尽快通过泵站上的切换手柄将油路切换到另一清洁的滤油器上。然后清洗堵塞的滤油器；机床报警时，请先停机查明原因，排除故障后，再重新启动机床；停机前，各轴应低速运动，将镗轴、方滑枕缩回，其它移动部件运行至安全位置。1.2警示标牌在机床上的位置序号警示用语或安全标志警示标牌所在位置1闪电标牌电柜门上、各分线盒上2主轴切削时禁止靠近主轴箱正面3走台下禁止站人走台侧面数控落地铣镗床培训教材(机械、液压部分)62.机床的总体介绍2.1机床概述机床稳定工作的环境条件：环境温度：10～40℃相对湿度：≤80％电源：三相380V±10%，50HZ±2%空气介质：空气中粉尘浓度不得大于10mg/m3，不得含酸、碱、盐和腐蚀性气体。2.1.1机床的主要结构TK6916/20/26/32系列数控落地铣镗床为滑枕移动式结构，即主传动系统安装在主轴箱箱体内，主轴箱采用整体式包容结构，将滑枕包容在箱体内。铣轴装在方滑枕内带动镗轴旋转，镗轴可在铣轴内水平自由移动。机床各运动轴规定如下：X轴：滑座在床身导轨上的水平移动Y轴：主轴箱在立柱导轨上的垂直移动Z轴：镗轴在滑枕内的水平移动W轴:滑枕在主轴箱方孔内的水平移动V轴:回转工作台的直线移动B轴:回转工作台的旋转移动U轴：平旋盘滑板的直线移动C轴：附件绕主轴的回转运动A轴：附件绕其C轴的回转运动对机床各运动轴的规定及方向见下面图示：数控落地铣镗床培训教材(机械、液压部分)7见下面简图，机床主要由多节拼接而成的床身、滑座、立柱、主轴箱、滑枕、液压泵站、电气等部分组成。其中床身固定在基础上，滑座在床身上水平运动（X轴）；立柱固定在滑座上，主轴箱侧挂在立柱导轨上，并沿立柱导轨垂直运动（Y轴），另外立柱为中空结构，空腔内装平衡重锤，通过链条和钢丝绳与主轴箱连接；主轴箱内部有主传动和滑枕系统，滑枕沿主轴箱方孔做水平运动（W轴）；而主轴组件又装在滑枕内部，其中铣轴带动镗数控落地铣镗床培训教材(机械、液压部分)8轴做主轴回转运动，镗轴在铣轴内还可水平运动（Z轴）。机床由独立液压站集中供油，各分支系统有独立油泵。床身水平导轨、立柱垂向导轨及主轴箱内水平导轨均采用恒压闭式静压导轨。机床若装有自动换刀系统，则该系统主要由沿导轨移动的机械手、安装在立柱后面的刀库，以及放在立柱后走台上的液压泵站等部分组成；在立柱正面装有随主轴箱移动或单独升降的操作走台，为操作者提供了工作空间；排屑器放置在转台和床身之间。另外机床还配备了刀具冷却泵站、液压泵站、油冷却机、电柜等装置。2.1.2主要用途与适用范围TK6916/20/26/32系列数控落地铣镗床可进行箱体的孔系镗孔加工，以及钻孔、扩孔、铰孔、切螺纹、切沟槽和平面的铣削加工。用回转工作台可进行相对方向镗孔和多面加工。还可以用小直径铣刀以铣削方式代替大孔的镗削，用轮廓控制方式铣削斜数控落地铣镗床培训教材(机械、液压部分)9面，框形平面、大孔端面。此外还可以加工坐标精度较高的孔。最适合加工：a）形状复杂、加工精度要求高、通用机床无法加工或很难保证加工质量的零件。b）具有复杂曲线或曲面轮廓的零件。c