A large multi-faceted spliced rotary body manufacturing method

Abstract

The application relates to the technical field of shield equipment manufacturing, and discloses a large multi-surface spliced rotary body manufacturing method, which comprises the following steps: manufacturing a center block finished product, measuring the distance from the center block connecting surface to the center by using the RENISHAW measurement method, ensuring that the distance from the connecting surface of each center block to the center is consistent, planning a center block connecting surface machining cutting path, and completing the center block finished product; manufacturing an edge block finished product, determining the edge block shape coordinates and center coordinates by using a point measurement method, reconstructing a model by using three-dimensional modeling software according to the determined edge block shape coordinates, calculating the machining allowance of the edge block center and shape, planning an edge block connecting surface machining cutting path, and completing the edge block finished product; and assembling the center block finished product and the edge block finished product into a rotary body. The manufacturing precision of the center block finished product and the edge block finished product is improved, the problem of large multi-surface machining interference or contact surface gap is solved, the trial assembly and repair process is omitted, the assembly working hours are shortened, and the operation cost is saved.

Description

Technical Field

[0001] This invention relates to the field of tunnel boring machine manufacturing technology, and in particular to a method for manufacturing a large multi-faceted, modular rotating body. Background Technology

[0002] Shield tunneling equipment, or shield tunneling equipment for short, is a large-scale specialized engineering machine for tunnel excavation that integrates optics, mechanics, electronics, hydraulics, sensing, and information technology. It has functions such as excavating and cutting soil, transporting excavated material, assembling tunnel lining, and measuring, guiding, and correcting deviations. It has high excavation speed, high degree of automation, low labor intensity for personnel, high construction quality and safety, and minimal impact on surface settlement and the environment. It is currently widely used in tunnel projects such as subways, railways, highways, municipal works, and hydropower projects.

[0003] One of the key components of a tunnel boring machine (TBM) is the cutterhead body, a large, multi-faceted, rotating structure weighing 80 tons and with a diameter of 6.3 meters. It typically consists of a central block and four side blocks connected to the central block. Because the rotating structure is a closed structure composed of five parts with eight surfaces fitting together, interference during assembly or large gaps between contact surfaces frequently occur. The existing manufacturing process involves machining the central block and three side blocks into finished products, then using the remaining side block for trial fitting to compensate for accumulated errors. This method results in an extremely cumbersome trial fitting process, is very difficult to operate, and ultimately fails to effectively guarantee manufacturing efficiency and quality, thus increasing assembly time and operating costs. Furthermore, if the trial fitting is unsuitable, it requires re-machining and re-clamping, increasing quality risks. Actual measurements often show increased machining errors, making it impossible to assemble the machine to meet the drawing requirements in one go. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a method for manufacturing large-scale multi-faceted modular rotating bodies, which completes the individual finished product processing of five parts, including the center block and side blocks, and achieves one-time assembly to meet the drawing requirements.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A method for manufacturing a large multi-faceted, modular rotating body, the multi-faceted, modular rotating body comprising a center block and edge blocks, wherein the connecting surfaces of the edge blocks are connected to the connecting surfaces of the center block, comprising:

[0007] To produce the finished center blocks, the Renishaw measurement method is used to measure the distance from the connecting surface of the center block to the center, ensuring that the distance from the connecting surface of each center block to the center is consistent. The machining cutting path of the connecting surface of the center block is planned to complete the finished center block.

[0008] To produce the finished edge block, the point measurement method is used to determine the outer shape coordinates and center coordinates of the edge block. The determined outer shape coordinates and center coordinates of the edge block are then used to reconstruct the model using 3D modeling software to calculate the machining allowance of the edge block center and outer shape. The cutting path for machining the edge block connection surface is then planned to complete the finished edge block.

[0009] Assemble the finished center block and edge blocks into a rotating body.

[0010] As a further technical solution, the finished center block is a cube structure, and the four sides of the cube structure are the connecting surfaces of the center block.

[0011] As a further technical solution, the number of the finished edge blocks is four, and when assembled into a rotating body, the four edge block connecting surfaces are simultaneously connected to the four center block connecting surfaces.

[0012] As a further technical solution, the steps for machining the center block connecting surface are as follows: first, use a face milling cutter to cut, with the face milling cutter using a reciprocating transverse cutting path; then, use a heavy-duty milling cutter to machine the center block connecting surface, thereby improving the surface roughness of the center block connecting surface to a set value.

[0013] As a further technical solution, the steps for machining the edge block connection surface are as follows: first, use a face milling cutter to cut, with the face milling cutter using a reciprocating transverse cutting path; then, use a heavy-duty milling cutter to machine the edge block connection surface, thereby improving the roughness of the edge block connection surface to a set value.

[0014] As a further technical solution, after the planned edge block connecting surface is machined and the cutting path is completed, the outer shape coordinates and center coordinates of the edge block are checked to determine the angle and allowance, and then the machining wear is compensated.

[0015] As a further technical solution, before the center block is finished, a first positioning pin hole needs to be machined on the center block; before the side block is finished, a second positioning pin hole needs to be machined on the side block; the first positioning pin hole and the second positioning pin hole are matched.

[0016] As a further technical solution, before the finished center block and the finished side block are assembled into a rotating body, they need to be trimmed, which includes removing burrs and bumps.

[0017] As a further technical solution, the specific steps for assembling the finished center block and the finished side block into a rotating body are as follows: First, fix and install the finished center block, with the side block connecting surface corresponding to the center block connecting surface. After positioning with positioning pins, measure the gap between the side block connecting surface and the center block connecting surface. After the gap is qualified, connect the side block connecting surface and the center block connecting surface with bolts.

[0018] As a further technical solution, the gap between the connecting surface of the edge block and the connecting surface of the center block is specifically measured by using a feeler gauge.

[0019] One or more technical solutions of the present invention have the following beneficial effects:

[0020] 1. This invention ensures that the distance from the connecting surfaces of the four center blocks to the center is consistent during the manufacturing process of the center block, avoiding deviations and defects during subsequent assembly. Simultaneously, this invention calculates the shape and center coordinates of the edge blocks using point measurement and 3D modeling software to reconstruct the model, accurately determining the machining allowance for the center and shape of the edge blocks. Combined with compensation for wear during machining, the edge block finished product is manufactured, ultimately achieving one-time assembly that meets the drawing requirements. This invention improves the manufacturing precision of the center and edge block finished products, solves the problems of interference or large gaps between contact surfaces during multi-faceted machining, eliminates trial assembly and rework processes, reduces operational difficulty, shortens assembly time, and saves operating costs.

[0021] 2. In planning the machining cutting paths for the center block connecting surface and the edge block connecting surface, this invention first uses a 315mm x 45-degree face milling cutter, followed by a 315mm diameter heavy-duty milling cutter, and adopts a reciprocating transverse feed. This improves machining efficiency on the one hand, and on the other hand, face milling cutters are mainly used for roughing or semi-finishing, resulting in a certain degree of roughness after machining. Using a heavy-duty milling cutter can further refine the surface, making the center block connecting surface and the edge block connecting surface smoother, improving the quality of the center block connecting surface and the edge block connecting surface, and facilitating subsequent assembly. Attached Figure Description

[0022] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0023] Figure 1 This is a schematic diagram of the splicing rotating body assembly structure of the present invention;

[0024] Figure 2 This is a measurement diagram of the external coordinates when manufacturing the edge block of this invention;

[0025] Figure 3 This is a schematic diagram of the edge block structure of the present invention;

[0026] Figure 4 This is a schematic diagram of the central block structure of the present invention;

[0027] Among them, 1 is the center piece; 2 is the edge piece. Detailed Implementation

[0028] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0029] Example 1

[0030] like Figure 1 As shown, one of the key components of a tunnel boring machine is the cutterhead body, which is a large, multi-faceted, modular rotating body, including a center block and side blocks. The connecting surfaces of the side blocks are connected to the connecting surfaces of the center block. However, traditional manufacturing processes often result in problems such as interference from multi-faceted processing or large gaps between contact surfaces. The existing manufacturing process involves processing the center block and three side blocks into finished products, and then using the remaining side block for trial fitting to compensate for accumulated errors. However, unlike existing technologies, this embodiment provides a manufacturing method for a large, multi-faceted, modular rotating body, which manufactures the center block and side blocks separately and assembles the side blocks onto the center block simultaneously, achieving one-time assembly to meet the drawing requirements.

[0031] Specifically, this includes: such as Figure 4 As shown, to manufacture the center block, since the center block is located at the center of the cutter head and the center block connecting surface is connected to the edge block connecting surface, it is necessary to ensure that the distance from the center to all four surfaces is consistent. Therefore, in this embodiment, the Renishaw measurement method is used to measure the distance from the center block connecting surface to the center. The machining is carried out with reference to the measured distance to ensure that the distance from each center block connecting surface to the center is consistent, avoiding deviations and defects during subsequent assembly. Then, this embodiment also plans the cutting path for machining the center block connecting surface. The specific steps are as follows: First, rough machining is performed using a 315mm diameter x 45-degree face milling cutter. The face milling cutter toolpath adopts a reciprocating transverse path to improve machining efficiency. Then, finish machining is performed using a 315mm diameter high-power end mill to machine the center block connecting surface and improve the surface roughness to a set value, specifically Ra3.2. The smaller the roughness Ra value, the smoother the surface. Ra3.2 means that the arithmetic mean of the absolute value of the profile offset within the sampling length is 3.2 micrometers. Roughing using a 315mm x 45-degree face milling cutter with a reciprocating transverse feed improves machining efficiency, but leaves a certain degree of roughness, which is not conducive to subsequent assembly. Finishing with a 315mm high-power end mill further refines the surface of the center block's connecting surfaces, making them smoother and improving their quality, thus facilitating subsequent assembly. In addition, in this embodiment, before completing the center block, a first locating pin hole needs to be machined on it for precise positioning during subsequent assembly. The finished center block has a cube structure, with its four sides serving as the connecting surfaces.

[0032] like Figure 2As shown, when manufacturing the finished edge block, since the outer circle of the edge block is a blank, in this embodiment, the point measurement method is used to determine the shape coordinates and center coordinates of the edge block. The determined shape coordinates and center coordinates of the edge block are then used to reconstruct the model using 3D modeling software to calculate the machining allowance of the edge block's center and shape. Specifically, the shape coordinates of the edge block are determined as follows: In this embodiment, Renizhao is selected, but other high-precision measuring tools, such as optical measuring equipment, can also be used. According to the shape of the edge block, the measurement points are reasonably distributed. In this embodiment, the edge block is divided into 12 points. The edge block is fixed on a 3D coordinate measuring instrument, and the 3D coordinate values ​​(X, Y, Z) of each point are measured sequentially using the 3D coordinate measuring instrument. The measured shape coordinates are then imported into computer software, such as CAD software, and the points are connected to form the outline of the edge block. The center coordinates of the edge block are determined by averaging the coordinates of its outline. Specifically, the average values ​​of the coordinates in the X, Y, and Z directions are calculated and used as the center coordinates of the edge block. For example, in this embodiment, the edge block has 12 points, and the coordinates of these 12 points are (X1, Y1, Z1), (X2, Y2, Z2), ..., (X... 12 ,Y 12 Z 12 If the center coordinates are (X1+X2+…+X), then the coordinates in the X direction are (X1+X2+…+X). 12 ) / 12, the same applies to the Y and Z directions.

[0033] After obtaining the aforementioned shape coordinates and center coordinates, the machining allowances for the edge block's center and shape are calculated using 3D modeling software to reconstruct the model. Specifically, the shape coordinates and center coordinates are imported into the 3D modeling software to reconstruct the model, generating the edge block's outline. Then, the outline is converted into a solid model within the model. Next, the machining allowance is calculated. First, the design dimensions and requirements of the edge block in the drawings are obtained. Then, the actual dimensions of the edge block in the solid model are obtained. The design dimensions and actual dimensions include, but are not limited to, length, width, height, and dimensions at certain key locations. For the machining allowance of the outline, the actual measured dimensions are compared with the design dimensions. For example, if the design length is Ld and the actual length is La, then the machining allowance of the outline is Ld - La. For the machining allowance of the center, it can be determined by comparing the center coordinates of the solid model with the design center coordinates. The coordinate difference in each direction is calculated, which is the machining allowance for the center.

[0034] This embodiment also outlines the cutting path for machining the edge block connection surface. The specific steps are as follows: First, rough machining is performed using a 315mm x 45-degree face milling cutter with a reciprocating transverse cutting path to improve machining efficiency. Then, finish machining is performed using a 315mm high-power end mill to machine the edge block connection surface, increasing its roughness to a set value, specifically Ra3.2. A smaller Ra value results in a smoother surface. Ra3.2 indicates that the arithmetic mean of the absolute values ​​of the profile offsets within the sampling length is 3.2 micrometers. Using a 315mm x 45-degree face milling cutter with a reciprocating transverse cutting path for rough machining improves efficiency, but it leaves a certain degree of roughness, which is not conducive to subsequent assembly. Using a 315mm high-power end mill for finish machining further refines the surface of the edge block connection surface, making it smoother and improving its quality, thus facilitating subsequent assembly. After planning the cutting path for machining the edge block connecting surfaces, the outer shape coordinates and center coordinates of the edge blocks are checked to determine the angles and allowances, and then machining wear is compensated. Among them, the angle is the edge block connecting surface angle. The center block and edge blocks are assembled together with a total of eight surfaces, of which four are connecting surfaces with the center block, and the other four are angle surfaces of adjacent edge blocks.

[0035] In addition, in this embodiment, such as Figure 3 As shown, there are four finished edge blocks. When assembled into a rotating body, the connecting surfaces of the four edge blocks are simultaneously connected to the connecting surfaces of the four center blocks. Before completing the edge block, a second locating pin hole needs to be machined on the edge block, and the second locating pin hole on the edge block matches the first locating pin hole on the center block.

[0036] After the center block and edge blocks are manufactured separately, they need to be assembled into a rotating body. Before this assembly, a finishing process is required, including removing burrs and bumps. The specific steps for assembling the center block and edge blocks into a rotating body are as follows: First, fix the center block on the cutter head body. The four edge block connecting surfaces correspond to the four center block connecting surfaces. Align the first and second locating pin holes and use locating pins for positioning. Measure the gap between the edge block connecting surfaces and the center block connecting surfaces using a feeler gauge. Once the gap is within acceptable limits, connect the edge block connecting surfaces to the center block connecting surfaces with bolts. Specifically, tighten the bolts on the edge block connecting surfaces to ensure even stress distribution on the connecting surfaces and that the gap meets the drawing requirements.

[0037] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for manufacturing a large multi-faceted, modular rotating body, the multi-faceted, modular rotating body comprising a center block and edge blocks, wherein the connecting surfaces of the edge blocks are connected to the connecting surfaces of the center block, characterized in that... include: To produce the finished center block, the Renishaw measurement method is used to measure the distance from the center block's connecting surface to the center, ensuring that the distance from the center block's connecting surface to the center is consistent for each center block. The machining cutting path for the center block's connecting surface is then planned to complete the finished center block. To produce the finished edge block, the point measurement method is used to determine the outer shape coordinates and center coordinates of the edge block. The determined outer shape coordinates and center coordinates of the edge block are then used to reconstruct the model using 3D modeling software to calculate the machining allowance of the edge block center and outer shape. The cutting path for machining the edge block connection surface is then planned to complete the finished edge block. Assemble the center block and edge blocks into a rotating body.

2. The method for manufacturing a large multi-faceted spliced ​​rotating body as described in claim 1, characterized in that, The finished center block is a cube structure, and the four sides of the cube structure are the connecting surfaces of the center block.

3. The method for manufacturing a large multi-faceted spliced ​​rotating body as described in claim 1, characterized in that, The number of finished edge blocks is four. When assembled into a rotating body, the four edge block connecting surfaces are simultaneously connected to the four center block connecting surfaces.

4. The method for manufacturing a large multi-faceted spliced ​​rotating body as described in claim 1, characterized in that, The steps for machining the connecting surface of the planned center block are as follows: first, use a face milling cutter for cutting, with the face milling cutter using a reciprocating transverse cutting path; then, use a heavy-duty milling cutter to machine the connecting surface of the center block, thereby improving the surface roughness of the connecting surface of the center block to a set value.

5. A method for manufacturing a large multi-faceted spliced ​​rotating body as described in claim 1, characterized in that, The steps for machining the edge block connection surface are as follows: first, use a face milling cutter for cutting, with the face milling cutter using a reciprocating transverse cutting path; then, use a heavy-duty milling cutter to machine the edge block connection surface, improving the surface roughness of the edge block connection surface to a set value.

6. The method for manufacturing a large multi-faceted spliced ​​rotating body as described in claim 1, characterized in that, After the planned edge block connecting surface is machined along the cutting path, the outer shape coordinates and center coordinates of the edge block are checked to determine the angle and allowance, and then machining wear is compensated.

7. A method for manufacturing a large multi-faceted spliced ​​rotating body as described in claim 1, characterized in that, Before the center block is finished, a first positioning pin hole needs to be machined on the center block; before the side block is finished, a second positioning pin hole needs to be machined on the side block; the first positioning pin hole and the second positioning pin hole are matched.

8. A method for manufacturing a large multi-faceted spliced ​​rotating body as described in claim 1, characterized in that, Before the finished center block and edge block are assembled into a rotating body, they need to be trimmed, which includes removing burrs and bumps.

9. A method for manufacturing a large multi-faceted spliced ​​rotating body as described in claim 1, characterized in that, The specific steps for assembling the finished center block and the finished side blocks into a rotating body are as follows: First, fix the finished center block in place, with the side block connecting surface corresponding to the center block connecting surface. After positioning with locating pins, measure the gap between the side block connecting surface and the center block connecting surface. Once the gap is within acceptable limits, connect the side block connecting surface and the center block connecting surface with bolts.

10. A method for manufacturing a large multi-faceted spliced ​​rotating body as described in claim 9, characterized in that, Specifically, the gap between the connecting surface of the edge block and the connecting surface of the center block is measured using a feeler gauge.

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