Zaozhuang Daxing Mining Co., Ltd. Zhang Haixia

The boring method is a highly precise, efficient, and cost-effective technique used for machining box hole systems. It is widely applied in industrial production, with each company customizing its own special boring machine tools based on specific requirements. The model introduced here is designed for the lifting and sliding seat processing of our G62 milling machine. This article explores the innovative ideas, technologies, and techniques implemented during the design and manufacturing process.

1. Equipment Features and Structure

This equipment is a combined die plane (see Figure 1) capable of processing both horizontal and vertical hole systems in a single clamping operation, significantly improving productivity. It supports semi-automatic operation—after finishing the horizontal holes, simply pressing the fast forward button automatically moves the tool to the vertical hole processing position. The positioning accuracy remains within 0.01mm. The design optimizes the transmission system for cost-effectiveness and features stepless speed control for work feed. One of the most notable innovations is the integration of an electronic pulse generator on a standard electrical control system instead of using CNC, making it more affordable and practical.

2. System Design

(1) Die Design Based on the structural characteristics of the machined parts, a thorough process and structure analysis was conducted to determine the optimal plan, including the positioning structure, clamping mechanism, tool holder setup, and multi-axis box design. Figure 2 shows a schematic view of the workpiece being processed.

From the structural analysis, the workpiece is positioned using references A and B. For the II, III, IV hole systems, which have relatively short overhangs, a "single-sided rear guide" layout was chosen. The guide bracket 11 is placed behind the cutter, and the tool bar 12 is rigidly connected to the multi-axis box 13 via a Morse cone. For the I-axis, where the two holes are far apart and one end has a closed surface, a "fixed and floating guide combination" was used. The fixed guide bracket 11 is stationary, while the movable guide bracket 9 slides through the 265 mm × 415 mm workpiece hole. This configuration enhances the compactness of the overall machine structure.

To ensure die accuracy and simplify assembly, the two guide bracket holes for the I-axis were processed simultaneously during manufacturing, while the others were roughed out. After assembling the multi-axis box, the appropriate tools were installed, and the remaining die-supporting holes were machined directly on the machine. This approach has proven to be fully feasible in practice.

(2) Work Feed Transmission System Design As shown in Figure 3, the system includes one fast feed motor 1 for rapid movement, one industrial feed frequency variable motor 2 for work feed and micro-feed, and an electromagnetic clutch 3 in the worm and worm gear reducer for switching between fast and work feed. The reducer is connected to a lead screw that drives the slide.

When moving quickly to the vertical hole machining position, two proximity switches 6 (see Figure 1) stop the motion. When the first switch activates, the fast feed motor stops, and after a delay, the electromagnetic clutch engages, connecting the fast feed motor 1. By setting a suitable slow speed, the second proximity switch triggers, completing accurate positioning.

The use of two proximity switches minimizes positioning errors caused by inertia during high-speed movement. This method allows for accurate positioning by combining fast and slow movements, while the delay prevents damage from sudden clutch changes. Testing confirmed that this control method achieves a repeatable positioning accuracy of 0.01mm.

(3) Application of Handwheel Electronic Pulse Generator To improve tool setting accuracy and facilitate blind hole boring, we modified the manual drive screw system and developed a hand pulse signal circuit board. This converts the pulse signal into an analog voltage, enabling micro-feeding on ordinary electrical control machines at a very low cost.

Working principle: The control board receives +24V power, and the VI point receives the pulse signal from the manual pulse generator. This signal is converted into a 0–10V analog voltage using components like the LM337 module. The handwheel's rotation speed controls the output voltage, which in turn regulates the feed motor speed via a frequency converter. This allows the axial speed to match the handwheel's rotation speed, making micro-feeding much more convenient.

The feed direction is controlled by selecting either the X-axis or Y-axis on the handwheel’s electronic pulse generator. These are connected in series to the interlock control circuit, allowing users to adjust the feed direction accordingly.

The circuit control board’s principle is illustrated in Figure 4, and the basic connection principle is shown in Figure 5.

3. Conclusion

After implementation, the special machine achieved full compliance with design specifications in terms of machining accuracy and greatly improved efficiency. The handwheel electronic pulse generator performed well and has been patented, making it suitable for upgrading conventional machine tools. The double proximity switch positioning method can be adapted for other special machines, offering new design insights for future projects.

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