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Chapter 47: Exceeding Expected Accuracy

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    The modification work of C616 lasted for eight days in total before it was finally completed.  Just when Teacher Tang and the others were gearing up to test the performance of the modified machine tool, Guan Fei put down the work at hand and went to do other things.  He selected a piece of very white paper, then controlled the muscles of his hand, dipped the tip of the needle in ink, and made dots of ink on different positions on the paper.  These ink dots are very small, and the needle tip lifts up quickly as soon as it touches the surface of the paper, leaving only very light ink marks. Even with the naked eye, it takes a lot of effort to see them.  The distance between the ink dots is also very wide and scattered. There are only more than ten marks on the entire 32-karat white paper.  Then he took the piece of paper and showed it to the entire brigade and educated youth one by one, and asked them what they saw.  Of course, 97% of people didn¡¯t see anything. Those who did saw either missed a few ink dots or couldn¡¯t identify the patterns between the ink dots.  "This is a rabbit!" When Xie Guoping was called out by the bank leader and Guan Fei put the white paper in front of him, he recognized the pattern composed of ink dots at a glance under the bright sunlight.  The pattern was very rough, and a dozen dots could hardly form a fine outline, but he still recognized it.  "Okay! Touch it again, what's on it?" Guan Fei exclaimed happily and immediately took out a steel piece from his pocket.  The steel block is not big, the length and width of the front are each ten centimeters, and the thickness is three centimeters. The surface has been turned very smooth, and when placed in front of you, it is enough to make a human figure shine through.  When Xie Guoping saw the steel piece at first glance, he felt that the smooth surface seemed to have some very subtle shadows, but it was difficult to take it over and take a closer look, so he reached out and touched the steel piece after the order.  His fingertips touched the surface, and after a slight slide, he felt that there were indeed some protrusions on the surface of the steel plate.  This kind of protrusion was not obvious. Even he had to touch it back and forth for a while before he said with uncertainty: "It seems like three lines? The one on the right is parallel to the edge, and the one in the middle feels flat at first, but  After careful identification, it should be slightly tilted to the left. I can't feel the exact amount. The left side is more skewed. It obviously feels that it is tilted by at least one degree. " "Very good, I will report to the technical school tomorrow.  , your future position has been adjusted!" Guan Fei patted his shoulder with satisfaction and ordered.  "Huh?" Xie Guoping opened his mouth and was very resistant to this order.  He now works in a bank. He doesn't have to train, his clothes are clean all day long, and he doesn't have to be exposed to wind or sun. Not to mention how comfortable it is.  He was very reluctant to ask him to give up his job in the bank and go to work in the factory.  If I had known earlier, I would not have been so attentive and followed the order. I thought I could show off in front of the brigade commander, but who knew that he was asked to leave the factory!  "I'm not asking you to turn a lathe, but I'm going to train you and several other comrades to become fine tuners! Don't worry, it's not tiring at all, it's just that the requirements are a bit high. In addition, after you go there, I will give you a three-level salary increase!  If you finally pass and become a trainee debugger, your salary will rise to one hundred and twenty yuan!" Guan Fei said seductively with a smile.  After he personally did the debugging work, he felt the high requirements of the work and the indispensability of high-precision debuggers to precision manufacturing, so he immediately put down the work at hand and selected suitable people from among everyone to carry out the work.  Special training.  The direction of training is to continuously strengthen their tactile sensitivity and fine visual observation abilities.  In addition, in order to protect their most important eyes and hands, they need to receive special skin protection and vision care, and their diet will be adjusted accordingly, so that they can have the most delicate and sensitive fingers and the sharpest vision.  Daily training will also allow them to continuously observe and touch the most subtle changes, and gradually increase the difficulty to enhance their identification ability in this area.  In order to prevent them from being overworked and becoming less sensitive, they must rest frequently.  It can be said that the cost of training a qualified high-quality precision debugger is at least dozens of times that of an ordinary worker!  Everyone is cultivating such talents, but Guan Fei has a more scientific training method and system, and I believe he can quickly cultivate his own high-level fine tuners.  Under the orders of the army chief and the temptation of high wages, Xie Guoping accepted this new position without much resistance.  When he arrived at the technical school, he found that there were twenty people picked out with him.  But there are only three people who are as good at fine observation and touch as him. The others either have super eyesight or a keen touch, which only has one-sided advantage.  Here, they are given intensive training according to different requirements.  Every afternoon, I also visit other students¡¯ technician knowledge training to learn about the structure and operation of machine tools.??, worker operating procedures and other various mechanical and processing knowledge.  In addition, the technical school opened fire for this group of people separately from others, and enjoyed the special treatment that the 291st Brigade had never had before.  After ten days of short intensive training, they began to assemble the second CNC lathe under the guidance of Guan Fei.  ?This is a novel and painful experience for them.  Guan Fei¡¯s requirements are too strict. If something goes wrong, they will have to start over.  Xie Guoping and others had never done similar work before. All kinds of machine tool knowledge were crammed into them at the last minute, and they often made mistakes when doing it.  They also have no biological accessory brain to help them, and rely entirely on their natural vision and touch to make judgments. They are much worse than Guan Fei. They often feel that there is absolutely no problem, but they are still picked out for mistakes and asked to rework.  Fortunately, Guan Fei was very strict and taught knowledge without any reservations. He started from the most basics and allowed them to learn and improve bit by bit.  Moreover, his observation ability is far better than that of others. If he feels that someone has reached his limit, he will immediately let him rest to avoid overexertion and the degradation of his own characteristics.  So Xie Guoping and the others are not physically tired and feel more relaxed than working in a bank.  Guan Fei taught Xie Guoping and others, once again ignoring Teacher Tang and the others' ardent expectations, and began to modify the heavy lathe.  At the same time, he also always paid attention to the growth of Xie Guoping and others, often giving them suggestions and making up lessons to improve their theoretical and practical levels.  "Lao Guan, you have been giving us a hard time for almost a month. How long are you going to delay the trial processing of C616 after modification?" Guan Fei is enjoying teaching here, but Teacher Tang and the others really can't wait any longer. Collectively,  Find Guan Fei and strongly request trial processing to confirm the transformation effect of C616.  With more contact with everyone, Teacher Tang and others began to follow the example of Zhang Shengguo and others, calling Guan Fei "Laoguan", even though the youngest among them was seven or eight years older than Guan Fei.  "Okay, okay, let's go try out the performance of the improved lathe. How about it?" Guan Fei was so entangled by them that he had no choice but to agree to test the car now.  ¡°That¡¯s great, I¡¯ve been waiting so long that my hair is almost turning gray, and finally it¡¯s here!¡± Everyone excitedly embraced Guan Fei and came to the first C616 machine tool that had been renovated.  Not far away is the second lathe that Xie Guoping and the others assembled by hand, but the second one is the second one, which is more touching than the first one that they personally participated in.  In terms of classification, CNC lathes are also a branch of automatic lathes.  But the biggest difference between it and traditional automatic lathes is that traditional automatic lathes rely on time distribution axes, shaped tools, cams, prototypes, etc., and use mechanized means to achieve automatic processing.  The biggest problem with this model is that it is dedicated to a special machine. Once the workpiece production of this lathe is set in advance, it is difficult to change the type of processing after it is finalized.  CNC lathes are much more flexible than automatic lathes. You only need to input different stroke parameters to control the lathe to perform different processing and cut various required workpieces.  However, it also has its own shortcomings, that is, modeling in advance is quite troublesome.  Mathematical means control, of course, the workpiece model must be established through mathematical means before processing, so that the machining process can be accurately and quantitatively controlled.  Computers in this era are expensive gadgets. Not only do they have low processing power, they are also extremely expensive.  The data processing power required to build a model is simply beyond the capacity of ordinary small and medium-sized computers, and can only be performed by large computers.  Therefore, unless there are some large manufacturing plants that have such special computers and high-precision automatic machining centers for production, ordinary factories simply do not have the economic ability to bear such high costs.  ???????????????????????????????????????????????  This is a tiring job. Every change of each component must be represented by a mathematical model, and then the processing parameters are derived, and finally programmed.  This kind of process is not something that ordinary factories can easily implement.  "It's a pity that these consensuses do not apply to Guan Fei.  The first task he has to complete is to determine the coordinate system of the lathe. A CNC lathe is not a smart lathe. All parameters are entered by the program. He doesn¡¯t even know the coordinates of the lathe. Doesn¡¯t that mean he¡¯s messing around?  This work was carried out very quickly. Before the lathe was purchased, the manufacturer had given fixed coordinates.  He only needs to reposition the changed coordinate system after the transformation to complete this step.  The next step is to set the workpiece coordinates.  Guan Fei fixed a machining rod-like material on the fixture, then started the original manual control system of the lathe, made a trial cut on the workpiece, and obtained its coordinate parameters.  In the same way, the four knives reincarnate one after another, all determined their respective coordinates.  The above is the tool setting, which is no different from manual operation. ????????????????????? But after determining various relevant parameters, the next step in programming is nothing more than the stroke control of rotation speed, cutting speed, tool advance, and tool retraction.  Guan Fei thought for a moment, then squatted down in front of the control panel to enter relevant parameters. He completed the input of the entire program in less than two minutes.  "Is this good?" Professor Tang squatted beside him, watching his entire input process without blinking, and was surprised that the control input was completed so easily.  ¡°CNC lathe control itself is actually very simple. It is speed one, speed two; feed one, feed two and other stroke parameters. They only need to be expressed through mathematical formulas, which is very easy to implement" Guan Fei said with a smile.  "But workpiece modeling is very troublesome. This is the second half of what he did not say.  ¡°So what¡¯s next?¡± Teacher Tang and others were eager to learn, and with a high desire for knowledge, they asked about the actual operating steps of CNC lathes that were unfamiliar to them.  "Then press the switch and it will run automatically. Mr. Tang, why don't you give it a try?" Guan Fei gave up the console and suggested with a smile.  "Okay!" Mr. Tang did his part and went up happily. He took a deep breath, stretched out his thumb, and pressed hard on the red button.  Woo  the signal of the Single -board Machine Control Center, the motor is powered on and started to operate.  The chuck began to rotate rapidly with the workpiece, and the automatic rotary tool holder rotated, stretched out the first knife, and slowly leaned on it. ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? The tool passes over the surface of the workpiece, sparks flying out, and the seemingly hard rough surface of the workpiece is easily chipped, quickly rolled back, and turned into a long twist, which continues to sway with the movement of the workpiece.  Whoosh!  The iron filings finally detached from the surface of the workpiece, splashed out, and landed on the machine tool plate.  Due to the extremely high heat, steam rises in contact with the deposited lubricant.  "This is cross-section processing, which is the initial shaping of the workpiece." Guan Fei motioned to the onlookers to step back slightly to avoid getting burned by the iron filings.  As everyone watched eagerly, one layer of the blank was peeled off and turned into a shiny steel rod.  The knife holder moves back, the turntable rotates, and the second knife takes the place of the previous one and slowly moves forward again.  The iron filings were flying again, but there were much less.  "This time it is finishing machining, and you can clearly see that the cutting amount has been reduced. The main issues to consider when changing tools are tool positioning compensation. Since the center positions of the tools do not necessarily coincide, you cannot simply change the location of the first tool  The contact points serve as the positioning parameters of subsequent tools and need to be confirmed one by one before setting the tool." Guan Fei explained the key points of this link to Teacher Tang and others.  Teacher Tang and others nodded repeatedly and stared at the workpiece processing very attentively.  The two teachers also carefully took out their notebooks and recorded them in detail.  The other teachers were also whispering to each other.  "This processing speed is much faster. After the initial processing is completed, it immediately enters the finishing process without any pause!" "Yes, and since there is no need to remove the workpiece, change the lathe and recalibrate the tool, the processing accuracy seems to be good.  It is better than the traditional manual lathe. Brigadier Guan said that the processing accuracy of the modified lathe can be improved. I was a little skeptical at first, but now it seems that the contrast is indeed obvious!" Guan Fei listened to the whispers of others and did not participate, just talking to him.  Teacher Tang constantly exchanged opinions and explained various problems in the processing process to him.  Finishing machining was also completed quickly, and the tool holder was changed again, this time for thread processing on the semi-finished product.  If the iron filings on the cut surface were thick and large at the beginning, the iron filings appearing on the knife edge are much thinner now, and traces of them fall out, revealing the clear threads on the steel rod.  This speed is faster. After changing the tool again, cross-cut the workpiece, cut it into two sections, and a silver screw is completed.  The total time taken was two minutes and forty-two seconds!  "Too fast!" "If other factories adopt this processing method, the work efficiency will be improved by how much. I think it will definitely be more than seven times!" All the teachers exclaimed. Teacher Tang couldn't wait to shut down the machine tool and get closer.  Observe.  After observing for a while, he picked up the prepared vernier caliper, depth vernier scale, outer diameter micrometer, etc. and measured every detail of the screw from beginning to end.  Everyone else held their breath and watched him test.  During this period, Guan Fei hand-drawn a workpiece processing design drawing, marking out his preset dimensional accuracy.  The workpiece is very largeThe order was quickly completed. After everyone took it and circulated it, it was handed over to Teacher Tang.  "Teacher Tang, what's the error?" Others asked hurriedly when they saw Teacher Tang finishing the measurement.  "Don't worry, don't worry, let me take a look" Teacher Tang took the drawing and compared the data carefully, then raised his head and said with a complex expression: "Compare the data read from the vernier caliper with the data marked on the drawing  ¡­There is no error!¡± ¡°How is that possible?¡± The teachers collectively cried out.  They all faced Guan Fei, waiting for him to clarify their doubts. No processed parts can be without errors, it's just about the size of the error.  Teacher Tang said there was no error, but they would never believe it.  "There are still errors" Guan Fei took the caliper, compared it seriously for a while, then raised his head and said, "The minimum accuracy of the vernier caliper can only measure one hundred microns. And the actual accuracy of this machined part is different from the drawing data.  It's within a hundred microns, so it can't be measured. I just measured it, and based on my observations and experience, the error should be between thirty and forty microns, which is better than my initial expectation." "Thirty!  "To forty microns!" The teachers were completely unable to calm down. When Guan Fei said that the accuracy could reach fifty microns, they already thought it was a satellite launch and they were just listening to a joke.  But the actual results turned out to be higher than the design expectations, which made them unable to react other than being dumbfounded.  Thirty to forty microns, isn¡¯t this higher than the processing accuracy of many domestic precision manufacturing plants?
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