A method for machining large-size components with super-large equipment processing capabilities

Abstract

This invention provides a method for machining large-sized components with superior processing capabilities, belonging to the field of mechanical processing technology. The method includes the following steps: 1) Setting up a support frame to hoist and clamp the large-sized component to be machined onto the support frame; 2) Hoisting the support frame and the large-sized component together onto the gantry milling machine's gantry working platform and clamping them securely; 3) Moving the gantry working platform so that part of the area to be milled on the large-sized component is within the machining area; 4) The power head of the gantry milling machine performs left-right and up-down feeds to machine the surfaces and holes of the area to be milled on the large-sized component; 5) Moving the gantry working platform to move the large-sized component away from the machining area, releasing the support frame from the gantry working platform, lifting and rotating the support frame to rotate the remaining area to be milled on the power head side, and clamping the support frame securely onto the gantry working platform; 6) Repeating the above steps until the machining of the large-sized component is completed. This invention's machining method is low-cost and highly efficient.

Description

Technical Field

[0001] This invention relates to the field of machining technology, and in particular to a method for machining large-scale components with super-large equipment processing capabilities. Background Technology

[0002] A gantry milling machine consists of a column, crossbeam, power head, and work platform. The power head can move left and right (Y-axis) on the crossbeam, the power head spindle can extend and retract up and down (Z-axis), and the work platform can move forward and backward (X-axis) perpendicular to the crossbeam. Gantry milling machines have machining functions such as boring, drilling, milling, and grooving. Equipped with high-precision rotary tables, right-angle milling heads, and other functional accessories, they can perform five-sided machining, making them ideal equipment for machining large parts such as steam turbines, generators, and heavy machinery in industries such as metallurgy, energy, and power.

[0003] In practical work, large disc-shaped workpieces of varying sizes are often required, with their length and width exceeding the width between the columns of a gantry milling machine. These workpieces cannot move freely back and forth under the columns with the worktable, making milling on the gantry milling machine impossible. For parts exceeding the maximum allowable machining size of the gantry milling machine, it is necessary to outsource to larger equipment to meet the machining requirements. However, outsourcing the machining of single or small quantities of workpieces is not only costly and time-consuming, but also attracts few willing manufacturers. To achieve the machining of large disc-shaped workpieces on existing gantry milling machines, this method fully utilizes the space protruding from the power head of the gantry milling machine and combines tooling to achieve milling of the workpiece plane. Therefore, it provides a method for machining large-sized parts exceeding the machine's machining capabilities. Summary of the Invention

[0004] The purpose of this invention is to provide a method for machining large-sized components with superior equipment processing capabilities, solving the technical problem that large-sized components cannot be milled on existing gantry milling machines, resulting in high outsourcing costs. The machining method provided by this invention enables the milling of large-sized components on existing gantry milling machines without outsourcing, while maintaining the required precision, reducing costs, and improving work efficiency.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] A method for machining large-sized components exceeding the processing capacity of existing equipment, comprising the following steps: A gantry milling machine and a support frame are used to machine the large-sized components.

[0007] (1) Set up a support frame, hoist the large-sized parts to be processed onto the support frame, and clamp and fix the support frame to the large-sized parts;

[0008] (2) Hoist the support frame and the large-size component as a whole onto the gantry working platform of the gantry milling machine, and clamp and fix the gantry working platform and the support frame;

[0009] (3) Move the gantry work platform so that part of the milling area of ​​the large-sized component is in the machining area;

[0010] (4) The power head of the gantry milling machine feeds left and right and up and down to mill the machining surface of the large-size component to be milled and to drill the hole in the area to be milled.

[0011] (5) Move the gantry work platform to move the large-sized parts away from the processing area, loosen the support frame from the gantry work platform, lift the support frame and rotate it so that the other parts of the large-sized parts to be milled are rotated to the side of the power head, and clamp and fix the support frame on the gantry work platform.

[0012] (6) Repeat steps (3)-(5) until the machining of the plane and holes of the large-size parts is completed.

[0013] Furthermore, in step (1), the specific method for setting up the support frame is as follows:

[0014] First, several upper plates are set on the upper surface of the platform. The upper plates are fixed to the platform by welding. Then, several lower pads are set on the lower surface of the platform. The platform and the lower pads are fixed by welding. The diameter of the circumference formed by the several lower pads is close to and not greater than the width of the gantry working platform.

[0015] Then, with the side of the platform with the lower pad welded on facing upwards, the lower pad surface is milled as a whole using a gantry milling machine. After milling, the platform is rotated 180° so that the side of the platform with the upper plate welded on facing upwards. The upper plate surface is then milled using the machined plane of the lower pad as a reference to ensure the parallelism of the upper and lower planes. After milling, the support frame is obtained.

[0016] Further, in step (1), the specific method for clamping and fixing the support frame and the large-size component is as follows: a long screw is passed through the bolt hole on the support frame, a first fixing plate is placed on the long screw, and the first fixing plate is placed on the large-size component, and the first fixing plate is fixed with a nut.

[0017] Furthermore, in step (2), the specific method for clamping and fixing the gantry work platform and the support frame is as follows: use long bolts to pass through the bolt holes of the gantry work platform and the support frame, and use nuts to fix the gantry work platform and the support frame.

[0018] Further, in step (4), the specific method of milling is as follows: the power head spindle is equipped with a milling cutter disc, the power head moves left and right along the Y-axis so that the milling cutter disc is above the edge of the plane to be milled, the spindle moves downward so that the milling cutter disc lightly scrapes the plane to be machined, the spindle moves downward with a depth of cut of 2mm, the rotation speed is 300r / min, and the feed is 100mm / min.

[0019] Furthermore, in step (4), the specific method of drilling is as follows: the spindle of the power head is replaced with a twist drill bit, and the twist drill bit is set to a rotation speed of 300 r / min and a feed of 0.3 mm / r to drill the plane hole.

[0020] The present invention, by adopting the above-described technical solution, has the following beneficial effects:

[0021] 1. This invention utilizes the structural characteristics of gantry milling machines to provide a method for machining large-size parts, enabling the machining of large-size parts larger than those of gantry milling machines, improving the machining capabilities of existing gantry milling machines, and saving machining costs. It is suitable for machining single-piece or small-batch large-size parts in a factory.

[0022] 2. The platform of this invention has a lower pad plate circumferentially arranged on its lower surface, and the surface of the lower pad plate is milled flat so that when the support frame is rotated, the bottom of the lower pad plate can still be completely on the gantry working platform, maintaining firm support; the upper plate surface is milled with the surface of the lower pad plate as a reference to ensure the parallelism of the upper and lower planes, thereby ensuring that the reference surface remains consistent after the support frame is rotated. This allows for the production of qualified planes even after several rotations of large-sized parts. The support frame has high rigidity, simple structure, and low cost.

[0023] 3. The processing method provided by this invention can mill large-sized parts on existing gantry milling machines without outsourcing, with a short processing cycle, while ensuring the required precision of large-sized parts, resulting in low processing cost and high work efficiency. Attached Figure Description

[0024] Figure 1 This is a schematic diagram illustrating the processing of large-scale components according to the present invention;

[0025] Figure 2 This is a schematic diagram of the support frame of the present invention.

[0026] In the attached diagram, 1-support frame, 11-platform, 111-first vertical rod, 112-second vertical rod, 113-first horizontal rod, 114-second horizontal rod, 115-third vertical rod, 116-first short vertical rod, 117-second short vertical rod, 118-first diagonal rod, 119-second diagonal rod, 120-third diagonal rod, 121-fourth diagonal rod, 12-upper plate, 13-lower pad, 14-bolt hole, 2-large component, 3-gantry milling machine, 31-gantry working platform, 32-power head, 33-column, 34-crossbeam, 4-long screw, 5-first fixing plate. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and preferred embodiments. However, it should be noted that many details listed in the specification are merely to provide the reader with a thorough understanding of one or more aspects of the present invention, and these aspects of the invention can be implemented even without these specific details.

[0028] like Figure 1-2 As shown, a method for machining large-sized components exceeding the processing capacity of advanced equipment is described. This method utilizes a gantry milling machine and a support frame to machine large-sized components, and includes the following steps:

[0029] (1) Set up support frame 1, hoist the large-sized part 2 to be processed onto support frame 1, clamp and fix support frame 1 and large-sized part 2, so that large-sized part 2 is fixed on support frame 1.

[0030] (2) Hoist the support frame and the large-sized component as a whole onto the gantry working platform 31 of the gantry milling machine 3, clamp and fix the gantry working platform 31 and the support frame 1, so that the support frame and the large-sized component are fixed as a whole onto the gantry working platform 31.

[0031] (3) Move the gantry work platform 31 so that part of the milling area of ​​the large component 2 is in the processing area; the processing area is between the two columns 33 of the gantry milling machine 3 and the processing area is below the crossbeam 34 of the gantry milling machine 3;

[0032] (4) The power head 32 of the gantry milling machine 3 performs left and right and up and down feed to mill the machining surface of the large-size component 2 to be milled, and to drill the hole in the milling area;

[0033] (5) Move the gantry work platform 31 to move the large-size component 2 away from the processing area, loosen the support frame 1 from the gantry work platform 31, lift the support frame 1 and rotate it so that the other parts of the large-size component 2 to be milled are rotated to the side of the power head 32, and clamp and fix the support frame 1 on the gantry work platform 31.

[0034] (6) Repeat steps (3)-(5) until the machining of the plane and holes of the large-size parts is completed.

[0035] This invention utilizes the structural characteristics of gantry milling machines to provide a method for machining large-sized parts, enabling the machining of large-sized parts larger than those produced by gantry milling machines. This improves the machining capabilities of existing gantry milling machines while saving machining costs, and is suitable for machining single-piece or small-batch large-sized parts in a factory.

[0036] In step (1), the specific method for setting up the support frame 1 is as follows: First, several upper flat plates 12 are set on the upper surface of the platform 11. The upper flat plates 12 are fixed to the platform 11 by welding. Then, several lower pads 13 are circumferentially set on the lower surface of the platform 11. The platform 11 and the lower pads 13 are fixed by welding. The diameter of the circumference formed by the several lower pads 13 is close to and not greater than the width of the gantry working platform 31. Then, with the side of the platform 11 with the lower pads 13 welded on facing up, the lower pad surface is milled as a whole by the gantry milling machine 3. The lower pads 13 need to be milled flat as a whole after being welded to the platform 11 to ensure that the reference surface is still consistent after rotating the support frame 1. After milling, the platform is rotated 180° to make the flat surface... The upper plate 12 is welded to the platform 11 with the side facing upwards. The upper plate surface is milled based on the plane of the lower pad 13 to ensure the parallelism of the upper and lower planes. After milling, the support frame 1 is obtained. The lower pad 13 is set on the circumference of the lower surface of the platform 11 and the lower pad surface is milled flat so that when the support frame 1 is rotated, the lower pad 13 at the bottom can still be completely on the gantry working platform 31 to maintain firm support. The upper plate surface is milled based on the plane of the lower pad 13 to ensure the parallelism of the upper and lower planes. This ensures that the reference surface of the support frame 1 remains consistent after rotation, so that the large-size parts 2 can still be machined into qualified planes after several rotations. The support frame 1 has high rigidity, simple structure and low cost.

[0037] like Figure 2As shown, this method requires several repeated clamping to complete the milling of the plane. During the processing, the processed plane is prone to being uneven. Therefore, a corresponding support frame 1 is required for auxiliary processing. The support frame 1 includes a platform 11, several upper plates 12 and several lower pads 13. Several upper plates 12 are set on the upper surface of the platform 11 and are fixed to the platform 11 by welding. Several lower pads 13 are circumferentially set on the lower surface of the platform 11 and are fixed to the platform 11 by welding. Platform 11 includes a first vertical rod 111, a second vertical rod 112, a first horizontal rod 113, and a second horizontal rod 114. The two ends of the first vertical rod 111 are fixedly connected to one end of the first horizontal rod 113 and one end of the second horizontal rod 114, respectively. The two ends of the second vertical rod 112 are fixedly connected to the other ends of the first horizontal rod 113 and one end of the second horizontal rod 114, respectively. A third vertical rod 115 is fixedly connected to the middle of the first horizontal rod 113 and the second horizontal rod 114. A first short vertical rod 116 is fixedly connected to the middle of the third vertical rod 115 and the middle of the second vertical rod 112. A first diagonal rod 118 is provided between the first vertical rod 111 and the second horizontal rod 114. The first vertical rod 111 and the first horizontal rod 114... A second diagonal bar 119 is provided between the second vertical bar 112 and the second horizontal bar 114, a third diagonal bar 120 is provided between the second vertical bar 112 and the first horizontal bar 113, and a fourth diagonal bar 121 is provided between the second vertical bar 112 and the first horizontal bar 113. Several bolt holes 14 are provided on the first vertical bar 111, the second vertical bar 112, the first horizontal bar 113, the second horizontal bar 114, the third vertical bar 115, the first short vertical bar 116, the second short vertical bar 117, the first diagonal bar 118, the second diagonal bar 119, the third diagonal bar 120 and the fourth diagonal bar 121. The purpose of providing bolt holes 14 is to clamp and fix the large-size component 2 to the support frame 1 with long bolts 4 and nuts, and to clamp and fix the support frame 1 and the large-size component 2 together to the gantry working platform 31 with long bolts 4 and nuts.

[0038] In step (1), the specific method for clamping and fixing the support frame 1 and the large-size component 2 is as follows: a long screw 4 is passed through the bolt hole 14 on the support frame 1, a first fixing plate 5 is placed on the long screw 4, and the first fixing plate 5 is placed on the large-size component 2, and the first fixing plate 5 is fixed with a nut.

[0039] In step (2), the specific method for clamping and fixing the gantry work platform 31 and the support frame 1 is as follows: use long bolts 4 to pass through the bolt holes 14 of the gantry work platform 31 and the support frame 1, and use nuts to fix the gantry work platform 31 and the support frame 1.

[0040] In step (4), the specific method of milling is as follows: the power head spindle is equipped with a milling cutter disc, the power head moves left and right along the Y-axis so that the milling cutter disc is above the edge of the plane to be milled, the spindle moves downward so that the milling cutter disc lightly scrapes the plane to be machined, the spindle moves downward with a depth of 2mm, the speed is 300r / min, and the feed is 100mm / min.

[0041] In step (4), the specific method of drilling is as follows: the spindle of the power head is replaced with a twist drill bit, and the twist drill bit is set to a speed of 300 r / min and a feed of 0.3 mm / r to drill the plane hole.

[0042] For large-sized parts that exceed the machining range of a gantry milling machine, larger equipment is usually sought for processing. This process increases the search time, the back-and-forth transfer of large-sized parts, and the processing cost and production cycle of the large-sized parts. The purpose of the support frame design is to make full use of the characteristics of the large-sized parts to be processed, and to achieve the processing of larger-sized workpieces under the processing capacity of existing equipment, thereby achieving the effect of cost reduction and efficiency improvement.

[0043] Example

[0044] A method for machining large-sized components exceeding the processing capacity of existing equipment, comprising the following steps: A gantry milling machine and a support frame are used to machine the large-sized components.

[0045] (1) Set up the support frame 1. First, set several upper plate 12s on the upper surface of the platform 11. The upper plate 12s are fixed to the platform 11 by welding. Then, set several lower pads 13s circumferentially on the lower surface of the platform 11. The platform 11 and the lower pads 13 are fixed by welding. The diameter of the circumference formed by the several lower pads 13s is close to and not greater than the width of the gantry working platform 31. Then, with the side of the platform 11 with the lower pads 13 welded on facing upwards, the lower pad surface is milled as a whole by the gantry milling machine 3. After milling, rotate the platform 180° so that the side of the platform 11 with the upper plate 12 welded on faces upward. Use the plane of the lower pad 13 as a reference to mill the upper plate surface, ensuring the parallelism of the upper and lower planes. After milling, the support frame 1 is obtained. Hoist the large-size part 2 that needs to be processed onto the support frame 1. Use a long screw 4 to pass through the bolt hole 14 on the support frame 1. Place the first fixing plate 5 on the long screw 4 and place the first fixing plate 5 on the large-size part 2. Use nuts to fix the first fixing plate 5.

[0046] (2) The support frame and the large-size component are hoisted together onto the gantry working platform 31 of the gantry milling machine 3. Long bolts 4 are passed through the bolt holes 14 of the gantry working platform 31 and the support frame 1, and nuts are used to fix the gantry working platform 31 and the support frame 1.

[0047] (3) Move the gantry work platform 31 so that part of the milling area of ​​the large component 2 is in the processing area; the processing area is between the two columns 33 of the gantry milling machine 3 and the processing area is below the crossbeam 34 of the gantry milling machine 3.

[0048] (4) The power head 32 of the gantry milling machine 3 performs left and right and up and down feed to mill the machining surface of the large-size component 2. The power head spindle is equipped with a milling cutter head. The power head moves left and right along the Y-axis so that the milling cutter head is above the edge of the plane to be milled. The spindle moves downward so that the milling cutter head lightly scrapes the plane to be machined. The spindle cuts 2mm downward, the speed is 300r / min, and the feed is 100mm / min. After the milling is completed, the hole in the area to be milled is drilled. The power head spindle is replaced with a twist drill bit. The twist drill bit is set to a speed of 300r / min and a feed of 0.3mm / r to drill the plane hole.

[0049] (5) Move the gantry work platform 31 to move the large-size component 2 away from the processing area, loosen the support frame 1 from the gantry work platform 31, lift the support frame 1 and rotate it so that the other parts of the large-size component 2 to be milled are rotated to the side of the power head 32, and clamp and fix the support frame 1 on the gantry work platform 31.

[0050] (6) Repeat steps (3)-(5) until the machining of the plane and holes of the large-size parts is completed.

[0051] The processing method provided by this invention can mill large-sized parts on existing gantry milling machines without outsourcing, with a short processing cycle, while ensuring the required precision of large-sized parts, resulting in low processing cost and high work efficiency.

[0052] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method of machining large scale parts with super machine tool capabilities, characterized by: The machining method is to use a gantry boring and milling machine and a support frame to machine large-size parts, comprising the following steps: (1) setting up a support frame, hoisting a large-size part to be machined on the support frame, clamping and fixing the support frame and the large-size part; (2) hoisting the support frame and the large-size part as a whole to a gantry working platform of the gantry boring and milling machine, clamping and fixing the gantry working platform and the support frame; (3) moving the gantry working platform so that part of the large-size part to be milled is in a machining area; (4) the power head of the gantry boring and milling machine feeds left and right and up and down to mill the machined surface of the large-size part to be milled and drill the hole in the large-size part to be milled; (5) moving the gantry working platform so that the large-size part leaves the machining area, loosening the support frame and the gantry working platform, hoisting the support frame to rotate, rotating other part of the large-size part to be milled to the side of the power head, clamping and fixing the support frame on the gantry working platform; (6) repeating the steps (3)-(5) until the machining of the large-size part is completed. In step (1), the specific setting method of the support frame is as follows: First, a plurality of upper plates are arranged on the upper surface of the platform, and the upper plates are fixed to the platform by welding, and then a plurality of lower pads are arranged circumferentially on the lower surface of the platform, and the platform and the lower pads are fixed by welding, and the diameters of the plurality of lower pads forming the circumference are close to and not greater than the width of the gantry working platform; Then, the side of the platform with the lower pads is welded upward, the lower pad surface is milled as a whole by the gantry boring and milling machine, after the milling is completed, the platform is turned over by 180°, the side of the platform with the upper plates is welded upward, the lower pad surface is milled as a reference, the parallelism of the upper and lower plates is ensured, and the support frame is obtained after the milling is completed.

2. A method of machining large scale parts with super device machining capability according to claim 1, characterized in that: In step (1), the specific method of clamping and fixing the support frame and the large-size part is as follows: a long screw is used to pass through the bolt hole of the support frame, a first fixing plate is placed on the long screw, and the first fixing plate is placed on the large-size part, and the first fixing plate is fixed by using a nut.

3. A method of machining large scale parts with super device machining capability according to claim 1, characterized in that: In step (2), the specific method of clamping and fixing the gantry working platform and the support frame is as follows: a long screw is used to pass through the bolt hole of the gantry working platform and the support frame, and the gantry working platform and the support frame are fixed by using a nut.

4. The method of claim 1, wherein: In step (4), the specific method of milling is as follows: the main shaft of the power head is equipped with a milling cutter, the power head moves left and right along the Y axis so that the milling cutter is above the edge of the plane to be milled, the main shaft moves downward so that the milling cutter lightly scrapes the machined surface, the main shaft moves downward by 2mm, the rotating speed is 300r / min, and the feeding speed is 100mm / min.

5. The method of claim 1, wherein: In step (4), the specific method of drilling is as follows: the main shaft of the power head is replaced with a twist drill, the twist drill is set to a rotating speed of 300r / min and a feeding speed of 0.3mm / r to drill the plane hole.

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