現在工業(ye)產(chan)(chan)品(pin)開發(fa)周(zhou)期(qi)和制(zhi)造周(zhou)期(qi)越(yue)來越(yue)短(duan)，企業(ye)對產(chan)(chan)品(pin)的質量(liang)要求越(yue)來越(yue)高。同時(shi)，產(chan)(chan)品(pin)的品(pin)種(zhong)也越(yue)來越(yue)多，產(chan)(chan)品(pin)的批量(liang)也越(yue)來越(yue)小(xiao)，這對鈑金行業(ye)是個挑戰，所以就要求鈑金加(jia)工設備具有高生產(chan)(chan)效率、高柔性及較低的生產(chan)(chan)成本(ben)。數控沖床節省了大(da)量(liang)的生產(chan)(chan)成本(ben)，縮短(duan)了生產(chan)(chan)周(zhou)期(qi)，具有較大(da)的加(jia)工范圍與(yu)加(jia)工能力，可以及時(shi)適應市(shi)場與(yu)產(chan)(chan)品(pin)的變化。

數控沖床的特點

數(shu)控沖(chong)床的(de)鈑金加(jia)工(gong)可以一(yi)次性(xing)自(zi)動完(wan)成多(duo)種復雜孔形(xing)的(de)生產，可按(an)要求加(jia)工(gong)不同尺(chi)寸、孔距(ju)和形(xing)狀的(de)孔，也(ye)可用小沖(chong)壓(ya)模具，以步沖(chong)方(fang)(fang)式(shi)沖(chong)大圓孔、方(fang)(fang)形(xing)孔和各(ge)種形(xing)狀的(de)曲線輪廓，還可以進行特(te)許工(gong)藝加(jia)工(gong)。 數(shu)控沖(chong)床目前以其方(fang)(fang)便、快捷、精度高(gao)而被國內很多(duo)有實力(li)的(de)廠家(jia)所使用，其大特(te)點包(bao)括以下(xia)七(qi)方(fang)(fang)面(mian)。

⑴使用(yong)方便，節省開模費用(yong)。數控轉(zhuan)塔沖(chong)床可進行(xing)復雜的(de)成(cheng)形加(jia)工，更適用(yong)于對板材成(cheng)形要求較高的(de)企業。通(tong)過簡單的(de)模具組合，相對于傳統沖(chong)壓而(er)言(yan)，節省了大量(liang)的(de)模具費用(yong)，可以(yi)使用(yong)低成(cheng)本和短(duan)周期(qi)加(jia)工小批(pi)量(liang)、多(duo)樣化的(de)產(chan)品。

⑵加工效率相(xiang)似的(de)數(shu)控(kong)沖床與激(ji)光切割機相(xiang)比，整機價格是其三分之一左右，且后(hou)續(xu)維護成本(ben)低(di)，性(xing)價比高。數(shu)控(kong)沖床的(de)模具使用成本(ben)相(xiang)對于激(ji)光機消耗的(de)氮氣、氧氣而言要低(di)很多。

⑶加工精度(du)高，具有穩(wen)定的加工質(zhi)量。數(shu)控沖(chong)床沖(chong)切精度(du)高，沖(chong)切毛刺小，工件平整度(du)好，后續加工量少，廢(fei)品率低，成形質(zhi)量高，數(shu)沖(chong)的加工尺寸(cun)精度(du)一(yi)般可達0.1mm，產品的尺寸(cun)一(yi)致(zhi)性(xing)好。

⑷數控(kong)沖床可對(dui)工(gong)件單獨(du)加(jia)工(gong)或用群命令對(dui)工(gong)件批量加(jia)工(gong)，提高生(sheng)產效率。數控(kong)沖床的加(jia)工(gong)速度(du)(du)快(kuai)，一般(ban)的液壓式設(she)備沖程率可達(da)500～600次/min，有(you)的甚(shen)至高達(da)900次/min，大定位(wei)速度(du)(du)可達(da)100m/min。

⑸對于大尺(chi)寸(cun)板材(cai)基本可一次加工(gong)就能完成，而傳統的大尺(chi)寸(cun)板材(cai)加工(gong)需多工(gong)序在很多不(bu)同的設備上完成。這樣由于減(jian)少(shao)(shao)了(le)(le)(le)中(zhong)間環節(jie)、減(jian)少(shao)(shao)了(le)(le)(le)后處理工(gong)序、減(jian)少(shao)(shao)了(le)(le)(le)模(mo)具(ju)設計等，且(qie)通過簡單(dan)的模(mo)具(ju)集成式(shi)，大大節(jie)約了(le)(le)(le)勞動力，降低(di)了(le)(le)(le)生產成本。

⑹加工(gong)零件改變(bian)時，一般只(zhi)需要更改數控程(cheng)序，可節省(sheng)生(sheng)產準備時間。

⑺對操(cao)作人員的素質要求較高，對維修人員的技(ji)術要求更高。

數控沖床的加工方式

數控沖(chong)(chong)床的加(jia)(jia)工(gong)(gong)(gong)方(fang)(fang)(fang)式(shi)可(ke)以分為單(dan)(dan)沖(chong)(chong)、多(duo)方(fang)(fang)(fang)向(xiang)的連(lian)(lian)(lian)續沖(chong)(chong)裁、單(dan)(dan)次(ci)成(cheng)(cheng)(cheng)形(xing)(xing)、同(tong)(tong)(tong)方(fang)(fang)(fang)向(xiang)的連(lian)(lian)(lian)續沖(chong)(chong)裁、蠶食、陣列成(cheng)(cheng)(cheng)形(xing)(xing)和連(lian)(lian)(lian)續成(cheng)(cheng)(cheng)形(xing)(xing)。單(dan)(dan)沖(chong)(chong)即單(dan)(dan)次(ci)完成(cheng)(cheng)(cheng)沖(chong)(chong)孔，包(bao)括圓(yuan)(yuan)周分布、圓(yuan)(yuan)弧分布、直線分布、柵格孔的分布。多(duo)方(fang)(fang)(fang)向(xiang)的連(lian)(lian)(lian)續沖(chong)(chong)裁是(shi)使用小模(mo)具加(jia)(jia)工(gong)(gong)(gong)大(da)孔的加(jia)(jia)工(gong)(gong)(gong)方(fang)(fang)(fang)式(shi)。單(dan)(dan)次(ci)成(cheng)(cheng)(cheng)形(xing)(xing)是(shi)按模(mo)具形(xing)(xing)狀一次(ci)淺拉深成(cheng)(cheng)(cheng)形(xing)(xing)的加(jia)(jia)工(gong)(gong)(gong)方(fang)(fang)(fang)式(shi)。同(tong)(tong)(tong)方(fang)(fang)(fang)向(xiang)的連(lian)(lian)(lian)續沖(chong)(chong)裁是(shi)使用長方(fang)(fang)(fang)形(xing)(xing)模(mo)具部分重疊(die)的加(jia)(jia)工(gong)(gong)(gong)方(fang)(fang)(fang)式(shi)，可(ke)以進行切邊、加(jia)(jia)工(gong)(gong)(gong)長形(xing)(xing)孔等。蠶食是(shi)使用小圓(yuan)(yuan)模(mo)以較小的步(bu)距進行連(lian)(lian)(lian)續沖(chong)(chong)制弧形(xing)(xing)的加(jia)(jia)工(gong)(gong)(gong)方(fang)(fang)(fang)式(shi)。陣列成(cheng)(cheng)(cheng)形(xing)(xing)是(shi)在大(da)板上加(jia)(jia)工(gong)(gong)(gong)多(duo)件不同(tong)(tong)(tong)或相(xiang)同(tong)(tong)(tong)的工(gong)(gong)(gong)件的加(jia)(jia)工(gong)(gong)(gong)方(fang)(fang)(fang)式(shi)。連(lian)(lian)(lian)續成(cheng)(cheng)(cheng)形(xing)(xing)是(shi)成(cheng)(cheng)(cheng)形(xing)(xing)比模(mo)具尺(chi)寸大(da)的成(cheng)(cheng)(cheng)形(xing)(xing)加(jia)(jia)工(gong)(gong)(gong)的方(fang)(fang)(fang)式(shi)，如加(jia)(jia)工(gong)(gong)(gong)滾臺(tai)階、滾筋、大(da)尺(chi)寸百葉窗等。

數(shu)控沖床技術(shu)的(de)發展趨勢

目前，世界上(shang)數控技術及(ji)其裝(zhuang)備(bei)發(fa)展的(de)(de)趨(qu)(qu)勢主(zhu)要有(you)：高速、高精加工(gong)技術及(ji)裝(zhuang)備(bei)的(de)(de)新趨(qu)(qu)勢，效率、質量是先(xian)進制造(zao)技術的(de)(de)主(zhu)體；5軸(zhou)聯(lian)動加工(gong)和復合加工(gong)機床快速發(fa)展；智(zhi)能化、開(kai)放式、網絡化的(de)(de)生產方式。

數(shu)控沖(chong)床是(shi)按照事先(xian)編制好的(de)(de)(de)加(jia)(jia)(jia)(jia)工(gong)(gong)程(cheng)(cheng)(cheng)序(xu)自(zi)動(dong)地對板(ban)(ban)料(liao)進行沖(chong)裁(cai)加(jia)(jia)(jia)(jia)工(gong)(gong)。在鈑(ban)金件(jian)(jian)生產過程(cheng)(cheng)(cheng)中，進行數(shu)控程(cheng)(cheng)(cheng)序(xu)設(she)(she)計(ji)(ji)時，無(wu)論是(shi)手(shou)工(gong)(gong)編程(cheng)(cheng)(cheng)還(huan)是(shi)自(zi)動(dong)編程(cheng)(cheng)(cheng)，在編程(cheng)(cheng)(cheng)前要對所加(jia)(jia)(jia)(jia)工(gong)(gong)的(de)(de)(de)零(ling)件(jian)(jian)進行工(gong)(gong)藝分析(xi)，然后擬定(ding)加(jia)(jia)(jia)(jia)工(gong)(gong)方案。制定(ding)正確(que)合(he)(he)理(li)的(de)(de)(de)加(jia)(jia)(jia)(jia)工(gong)(gong)工(gong)(gong)藝還(huan)要選(xuan)擇合(he)(he)適的(de)(de)(de)模(mo)具(ju)及加(jia)(jia)(jia)(jia)工(gong)(gong)速度，在數(shu)控程(cheng)(cheng)(cheng)序(xu)的(de)(de)(de)設(she)(she)計(ji)(ji)中，更(geng)應注意一些(xie)程(cheng)(cheng)(cheng)序(xu)設(she)(she)計(ji)(ji)的(de)(de)(de)工(gong)(gong)藝方法(fa)。如果忽視了(le)一些(xie)工(gong)(gong)藝細節(jie)問題，有時即(ji)使加(jia)(jia)(jia)(jia)工(gong)(gong)程(cheng)(cheng)(cheng)序(xu)是(shi)正確(que)的(de)(de)(de)，但由于加(jia)(jia)(jia)(jia)工(gong)(gong)程(cheng)(cheng)(cheng)序(xu)的(de)(de)(de)不合(he)(he)理(li)，也(ye)同樣無(wu)法(fa)加(jia)(jia)(jia)(jia)工(gong)(gong)出合(he)(he)格(ge)的(de)(de)(de)零(ling)件(jian)(jian)。進行數(shu)控程(cheng)(cheng)(cheng)序(xu)設(she)(she)計(ji)(ji)時應盡可(ke)能保證板(ban)(ban)料(liao)有良好的(de)(de)(de)剛性，可(ke)適當地多(duo)留一些(xie)連接點，合(he)(he)理(li)地利用沖(chong)切(qie)的(de)(de)(de)M代碼和配置加(jia)(jia)(jia)(jia)工(gong)(gong)的(de)(de)(de)路徑。

系列化的板材加(jia)工設備

我(wo)國(guo)機(ji)床(chuang)(chuang)行(xing)(xing)業(ye)(ye)在世(shi)界機(ji)床(chuang)(chuang)工(gong)(gong)業(ye)(ye)體系(xi)和全球(qiu)機(ji)床(chuang)(chuang)市場中占有重要地位，但目前我(wo)國(guo)仍然算不上機(ji)床(chuang)(chuang)強國(guo)。與(yu)世(shi)界機(ji)床(chuang)(chuang)強國(guo)相比，我(wo)國(guo)機(ji)床(chuang)(chuang)行(xing)(xing)業(ye)(ye)在中高(gao)檔(dang)機(ji)床(chuang)(chuang)方面的(de)競爭力(li)不強。此外，受(shou)到(dao)國(guo)內外復(fu)雜經濟形(xing)勢的(de)影響(xiang)，我(wo)國(guo)機(ji)床(chuang)(chuang)行(xing)(xing)業(ye)(ye)發(fa)展回歸(gui)新(xin)常態，產業(ye)(ye)向中高(gao)端轉型(xing)升級(ji)的(de)要求(qiu)迫切。為(wei)迎合(he)(he)這(zhe)一(yi)加(jia)工(gong)(gong)理(li)念(nian)，國(guo)內外的(de)廠家不斷開發(fa)與(yu)完善其(qi)設(she)計制(zhi)造(zao)技術，為(wei)鈑金加(jia)工(gong)(gong)業(ye)(ye)提(ti)供了系(xi)列化的(de)板(ban)材(cai)加(jia)工(gong)(gong)設(she)備，如：沖壓剪切復(fu)合(he)(he)機(ji)、激光沖裁(cai)復(fu)合(he)(he)機(ji)。

沖壓剪切復合機

數(shu)控沖(chong)(chong)床單機(ji)(ji)在(zai)迅速發展的(de)同時，附(fu)屬自動化裝置及其延伸(shen)產品也有了(le)長足進步(bu)。數(shu)控沖(chong)(chong)剪(jian)復(fu)(fu)合加工機(ji)(ji)就是其中之一，數(shu)控沖(chong)(chong)剪(jian)復(fu)(fu)合機(ji)(ji)是將(jiang)數(shu)控沖(chong)(chong)床和(he)數(shu)控直角剪(jian)板機(ji)(ji)組(zu)合在(zai)一起，共用一套(tao)數(shu)控系統(tong)、一個工作臺和(he)一個液壓站(zhan)，實現了(le)結構緊(jin)湊，提高了(le)生(sheng)產效率和(he)優(you)化了(le)生(sheng)產工藝。圖1為(wei)薩(sa)瓦尼尼S4沖(chong)(chong)剪(jian)復(fu)(fu)合中心。

圖1 薩瓦尼(ni)尼(ni)S4沖剪復合中心

數控沖剪(jian)復(fu)合(he)機床在使用(yong)(yong)的(de)過(guo)程(cheng)中，板材(cai)(cai)沖孔、成形及剪(jian)切過(guo)程(cheng)一次完成，由原材(cai)(cai)料直(zhi)接生(sheng)成工(gong)(gong)件，替代了(le)傳統的(de)沖剪(jian)分離的(de)加工(gong)(gong)工(gong)(gong)序(xu)，減少了(le)約60％的(de)加工(gong)(gong)時間，提(ti)高了(le)加工(gong)(gong)效率，節省材(cai)(cai)料6％～10％，提(ti)高了(le)材(cai)(cai)料的(de)利用(yong)(yong)率，降(jiang)低(di)了(le)生(sheng)產(chan)成本。數控沖剪(jian)復(fu)合(he)機還預留了(le)可與倉庫、自動(dong)上料機械手和堆垛(duo)等裝置配(pei)套的(de)接口，為(wei)進(jin)一步拓展自動(dong)化，構(gou)成數控沖剪(jian)板材(cai)(cai)柔性加工(gong)(gong)生(sheng)產(chan)線提(ti)供了(le)方便。

激光沖裁復合機

激光(guang)(guang)(guang)(guang)(guang)沖(chong)裁復(fu)(fu)合(he)(he)機是將(jiang)激光(guang)(guang)(guang)(guang)(guang)作(zuo)為特殊模(mo)具的(de)替(ti)代品(pin)(pin)，主要用(yong)于加(jia)(jia)(jia)工(gong)(gong)任意形狀和(he)高質(zhi)量(liang)沖(chong)孔的(de)精密鈑金(jin)產品(pin)(pin)。由于當時國(guo)內鈑金(jin)行業發展的(de)局限性，這(zhe)(zhe)種復(fu)(fu)合(he)(he)機的(de)應用(yong)一(yi)直很(hen)少，隨著鈑金(jin)行業的(de)迅(xun)速發展，激光(guang)(guang)(guang)(guang)(guang)切(qie)(qie)割(ge)機的(de)普及(ji)(ji)應用(yong)，沖(chong)裁、激光(guang)(guang)(guang)(guang)(guang)復(fu)(fu)合(he)(he)機的(de)應用(yong)將(jiang)會(hui)越來越多。從(cong)沖(chong)壓加(jia)(jia)(jia)工(gong)(gong)到激光(guang)(guang)(guang)(guang)(guang)加(jia)(jia)(jia)工(gong)(gong)、或從(cong)激光(guang)(guang)(guang)(guang)(guang)加(jia)(jia)(jia)工(gong)(gong)到沖(chong)壓加(jia)(jia)(jia)工(gong)(gong)可在瞬間切(qie)(qie)換。通過同步控(kong)制，在嵌(qian)套排樣(yang)及(ji)(ji)多件(jian)沖(chong)切(qie)(qie)加(jia)(jia)(jia)工(gong)(gong)中(zhong)，以往在所(suo)有(you)沖(chong)壓加(jia)(jia)(jia)工(gong)(gong)結束后再進(jin)行激光(guang)(guang)(guang)(guang)(guang)加(jia)(jia)(jia)工(gong)(gong)的(de)加(jia)(jia)(jia)工(gong)(gong)順序，可變為沖(chong)壓和(he)激光(guang)(guang)(guang)(guang)(guang)交替(ti)進(jin)行的(de)加(jia)(jia)(jia)工(gong)(gong)方(fang)式(shi)，因(yin)此(ci)不會(hui)浪費加(jia)(jia)(jia)工(gong)(gong)時間。這(zhe)(zhe)樣(yang)，消除了沖(chong)壓加(jia)(jia)(jia)工(gong)(gong)中(zhong)的(de)材料(liao)應力等造成的(de)累計誤(wu)差，從(cong)而消除了影響工(gong)(gong)件(jian)品(pin)(pin)質(zhi)的(de)因(yin)素。圖2為 AMADA生產的(de)光(guang)(guang)(guang)(guang)(guang)纖激光(guang)(guang)(guang)(guang)(guang)復(fu)(fu)合(he)(he)機LC-

結束語

我國(guo)已連續多年成為(wei)世(shi)界大(da)的(de)(de)機(ji)(ji)床(chuang)裝(zhuang)備(bei)(bei)(bei)生產國(guo)、消費(fei)國(guo)和進(jin)口國(guo)。未(wei)來10年，電子與(yu)通(tong)訊設(she)備(bei)(bei)(bei)、航(hang)空航(hang)天裝(zhuang)備(bei)(bei)(bei)、軌道交通(tong)裝(zhuang)備(bei)(bei)(bei)、電力裝(zhuang)備(bei)(bei)(bei)、汽車、船舶、工程(cheng)機(ji)(ji)械與(yu)農(nong)業機(ji)(ji)械等重點(dian)(dian)產業的(de)(de)快速發展(zhan)，以(yi)及新(xin)材料、新(xin)技(ji)術(shu)的(de)(de)不斷進(jin)步將對(dui)數(shu)(shu)控(kong)機(ji)(ji)床(chuang)與(yu)基(ji)礎(chu)裝(zhuang)備(bei)(bei)(bei)提出新(xin)的(de)(de)戰略性(xing)需(xu)求(qiu)和轉(zhuan)型(xing)挑戰。對(dui)數(shu)(shu)控(kong)機(ji)(ji)床(chuang)與(yu)基(ji)礎(chu)制造(zao)(zao)(zao)裝(zhuang)備(bei)(bei)(bei)的(de)(de)需(xu)求(qiu)將由中低檔向高檔轉(zhuan)變、由單機(ji)(ji)向包括機(ji)(ji)器(qi)人上下料和在線檢測功能的(de)(de)制造(zao)(zao)(zao)單元和成套系統轉(zhuan)變、由數(shu)(shu)字化向智能化轉(zhuan)變、由通(tong)用機(ji)(ji)床(chuang)向量體裁衣的(de)(de)個性(xing)化機(ji)(ji)床(chuang)轉(zhuan)變，電子與(yu)通(tong)訊設(she)備(bei)(bei)(bei)制造(zao)(zao)(zao)裝(zhuang)備(bei)(bei)(bei)將是新(xin)的(de)(de)需(xu)求(qiu)熱點(dian)(dian)。