数控机床的刀柄为何老坏

 
<span style="color: rgb(85, 85, 85); font-size: 15px; letter-spacing: 1px; text-indent: 2em; font-family: -apple-system-font, BlinkMacSystemFont, "Helvetica Neue", "PingFang SC", "Hiragino Sans GB", "Microsoft YaHei UI", "Microsoft YaHei", Arial, sans-serif; text-align: justify;”>刀柄是切削刀具和机床主轴之间的关键性接口，刀柄失效会导致刀柄不能发挥作用，造成刀具寿命变短和切削过程的不可靠。


<p style="margin: 0px 16px 20px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(255, 76, 0);”>典型的刀柄失效有以下几种形式：

<span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>- 切屑缠绕刀柄，由于刀柄、工件和切屑之间的摩擦，刀柄形成磨损。
<span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>- 断续的切削力导致刀柄的表面疲劳。
<span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>- 切削力导致的刀柄变形。
<span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>- 切削热和切削温度导致刀柄材料结构的相变。
<span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>- 刀柄的氧化和腐蚀。
<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>- 备件、配件和连接表面的磨损。

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(255, 76, 0);”>那么，该如何判断何时更换刀柄呢？

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(255, 76, 0);”>检查机床主轴磨损和自动换刀装置对准

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>磨损的主轴会导致跳动问题，影响刀柄的精度，降低可实现的工件质量和加工效率。可以对机床主轴的质量进行评估，比如检查其T.I.R.（径向跳动）。

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>保持ATC（自动换刀装置）的对准至关重要。如果ATC 没有很好地夹持刀柄，会对主轴和刀柄造成损害，而且刀具性能和刀具寿命会明显降低。

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(255, 76, 0);”>01 <span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(255, 76, 0);”>刀柄磨损的评估

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>磨损的刀柄将不能提供良好的精度并且会迅速磨损刀具，也会导致加工表面粗糙度差，甚至可能损害机床主轴。

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(255, 76, 0);”>锥面磨损/ 微动磨损

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>检查定位锥面是否磨损或损坏。锥面的任何问题都会直接影响加工精度，如果锥面有任何缺陷，则应该更换刀柄。

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>如果锥面上有很明显的痕迹，可能发生了微动磨损。当两个刚性部件（刀柄和主轴）相互摩擦就会产生微动磨损，微动磨损是由于刀柄锥面和主轴间配合不好导致，磨损会产生振动和热。如果在锥面上会看见小铜色的凹点或痕迹，这说明刀柄正在磨损。微动磨损往往容易被误认为是氧化，一旦出现明显的微动磨损，刀柄就应该被更换。如果新的刀柄会迅速发生微动磨损，或者刀柄粘在主轴中，则表示主轴需要再研磨。

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>当刀柄插入主轴时，磨损的锥面会引起偏心定位，这就是所谓的” 跳动”。在加工中跳动会引起刀具的过早磨损和失效，还会引起过度振动导致加工表面粗糙度差，此时就需要额外的加工来对其进行修正。振动也会导致主轴的疲劳生热和主轴轴承的损坏。T.I.R.（径向跳动）用来测量在刀柄总成中刀具的轴向变形量，每0.02mm 的跳动刀具的寿命会减少10%。

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(255, 76, 0);”>衬套和弹簧夹头

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>衬套具有特殊的槽和图案，能坚固地夹紧刀具，因此会比夹头更快地磨损。磨损的衬套会使刀具更早地失效，当衬套磨损明显时就应该进行替换以保持刀具- 刀柄总成的精度和性能。

<p style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; overflow-wrap: break-word !important;”> 

<p style="margin: 0px 16px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; clear: both; min-height: 1em; letter-spacing: 1px; line-height: 1.75em; overflow-wrap: break-word !important;”><span style="margin: 0px; padding: 0px; max-width: 100%; box-sizing: border-box !important; word-wrap: break-word !important; color: rgb(85, 85, 85); font-size: 15px;”>如果衬套外径或内径有任何损伤就应该将它替换。刀具在衬套的内径中旋转，会对其造成损伤，所以要查看内径中的痕迹，一旦发生损伤，衬套就不能有效地夹紧刀柄，会导致夹紧力和精度的降低。