齒輪軸承座零件的加工工藝和粗鏜、半精鏜、精鏜φ52的工裝夾具設(shè)計(jì)參考素材
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夾具設(shè)計(jì)的綜述1 前言 機(jī)械加工工藝及夾具設(shè)計(jì)是全面綜合運(yùn)用有關(guān)專業(yè)課程的理論和實(shí)踐知識(shí)進(jìn)行加工工藝及夾具設(shè)計(jì)的一次重要實(shí)踐。機(jī)床夾具是在機(jī)床上裝夾工件的一種裝置,其作用是使工件相對(duì)于機(jī)床和刀具有一個(gè)正確的位置,并且在加工過程中保持這個(gè)位置不變。夾具不僅能保證工件的加工精度、提高加工效率,還能減輕工人的勞動(dòng)強(qiáng)度、降低產(chǎn)品的制造成本、擴(kuò)大機(jī)床的使用范圍。制造技術(shù)已經(jīng)是生產(chǎn)、國(guó)際經(jīng)濟(jì)競(jìng)爭(zhēng)、產(chǎn)品革新的一種重要手段,所有國(guó)家都在尋求、獲得、開發(fā)和利用它。它正被看作是現(xiàn)代國(guó)家經(jīng)濟(jì)上獲得成功的關(guān)鍵因素。機(jī)械加工工藝規(guī)程是規(guī)定產(chǎn)品或零部件機(jī)械加工工藝過程和操作方法等的工藝文件,是一切有關(guān)工生產(chǎn)人員都應(yīng)嚴(yán)格執(zhí)行、認(rèn)真貫徹的紀(jì)律性文件。生產(chǎn)規(guī)模的大小、工藝水平的高低以及解決各種工藝問題的方法和手段都要通過機(jī)械加工工藝規(guī)程來體現(xiàn)。而機(jī)床夾具是在機(jī)床上用以裝夾工件的一種裝置,其作用是使工件相對(duì)于機(jī)床或刀具有個(gè)正確的位置,并在加工過程中保持這個(gè)位置不變。它們的研究對(duì)機(jī)械工業(yè)有著很重要的意義。2 機(jī)械加工工藝及夾具設(shè)計(jì)的發(fā)展21 發(fā)展歷史 從1949年以來,我國(guó)機(jī)械工業(yè)有了很大的發(fā)展,已經(jīng)成為工業(yè)中產(chǎn)品門類比較齊全、具有相當(dāng)規(guī)模和一定技術(shù)基礎(chǔ)的產(chǎn)業(yè)部門之一,其機(jī)械加工和夾具也有很大的發(fā)展,但是與工業(yè)發(fā)達(dá)國(guó)家相比,我們這方面的水平還存在著階段性的差距,主要表現(xiàn)在機(jī)械產(chǎn)品質(zhì)量和水平不夠高,加工工藝過程不合理,夾具應(yīng)用也比較少,使其加工工人勞動(dòng)強(qiáng)度大,加工出來的產(chǎn)品也不理想。22發(fā)展現(xiàn)狀 現(xiàn)在,各工業(yè)化國(guó)家都把制造技術(shù)視為當(dāng)代科技發(fā)展為活躍的領(lǐng)域和國(guó)際間科技競(jìng)爭(zhēng)的主戰(zhàn)場(chǎng),制定了一系列振興計(jì)劃、建立世界級(jí)制造技術(shù)中心,紛紛把先進(jìn)制造技術(shù)列為國(guó)家關(guān)鍵技術(shù)和優(yōu)先發(fā)展領(lǐng)域。 機(jī)械加工工藝及夾具隨著制造技術(shù)的發(fā)展也突飛猛進(jìn)。機(jī)械加工工藝以各個(gè)工廠的具體情況不同,其加工的規(guī)程也有很大的不同。突破已往的死模式。使其隨著情況的不同具有更加合理的工藝過程。也使產(chǎn)品的質(zhì)量大大提高。制定加工工藝雖可按情況合理制定,但也要滿足其基本要求:在保證產(chǎn)品質(zhì)量的前提下,盡可能提高勞動(dòng)生產(chǎn)率和降低加工成本。并在充分利用本工廠現(xiàn)有生產(chǎn)條件的基礎(chǔ)上,盡可能采用國(guó)內(nèi)、外先進(jìn)工藝技術(shù)和經(jīng)驗(yàn)。還應(yīng)保證操作者良好的勞動(dòng)條件。但我國(guó)現(xiàn)階段還是主要依賴工藝人員的經(jīng)驗(yàn)來編制工藝,多半不規(guī)定工步和切削用量,工時(shí)定額也憑經(jīng)驗(yàn)來確定,十分粗略,缺乏科學(xué)依據(jù),難以進(jìn)行合理的經(jīng)濟(jì)核算。機(jī)床夾具最早出現(xiàn)在18世紀(jì)后期。隨著科學(xué)技術(shù)的不斷進(jìn)步,夾具已從一種輔助工具發(fā)展成為門類齊全的工藝裝備。國(guó)際生產(chǎn)研究協(xié)會(huì)的統(tǒng)計(jì)表明,目前中、小批多品種生產(chǎn)的工件品種已占工件種類總數(shù)的85左右?,F(xiàn)代生產(chǎn)要求企業(yè)所制造的產(chǎn)品品種經(jīng)常更新?lián)Q代,以適應(yīng)市場(chǎng)的需求與競(jìng)爭(zhēng)。然而,一般企業(yè)都仍習(xí)慣于大量采用傳統(tǒng)的專用夾具,一般在具有中等生產(chǎn)能力的工廠里,約擁有數(shù)千甚至近萬套專用夾具;另一方面,在多品種生產(chǎn)的企業(yè)中,每隔34年就要更新5080左右專用夾具,而夾具的實(shí)際磨損量?jī)H為1020左右。特別是近年來,數(shù)控機(jī)床、加工中心、成組技術(shù)、柔性制造系統(tǒng)(FMS)等新加工技術(shù)的應(yīng)用,對(duì)機(jī)床夾具提出了如下新的要求:1)能迅速而方便地裝備新產(chǎn)品的投產(chǎn),以縮短生產(chǎn)準(zhǔn)備周期,降低生產(chǎn)成本;2)能裝夾一組具有相似性特征的工件;3)能適用于精密加工的高精度機(jī)床夾具;4)能適用于各種現(xiàn)代化制造技術(shù)的新型機(jī)床夾具;5)采用以液壓站等為動(dòng)力源的高效夾緊裝置,以進(jìn)一步減輕勞動(dòng)強(qiáng)度和提高勞動(dòng)生產(chǎn)率;6)提高機(jī)床夾具的標(biāo)準(zhǔn)化程度。23發(fā)展趨勢(shì)長(zhǎng)期以來,加工工藝編制是由工藝人員憑經(jīng)驗(yàn)進(jìn)行的。如果由幾位工藝員各自編制同一個(gè)零件的工藝規(guī)程,其方案一般各不相同,而且很可能都不是最佳方案。這是因?yàn)楣に囋O(shè)計(jì)涉及的因素多,因果關(guān)系錯(cuò)綜復(fù)雜。CAPP將是機(jī)械加工工藝的發(fā)展趨勢(shì),它不僅提高了工藝設(shè)計(jì)的質(zhì)量,而且使工藝人員從繁瑣重復(fù)的工作中擺脫出來,集中精力去考慮提高工藝水平和產(chǎn)品質(zhì)量問題。231夾具的發(fā)展趨勢(shì)現(xiàn)代機(jī)床夾具的發(fā)展趨勢(shì)主要表現(xiàn)為標(biāo)準(zhǔn)化、高效化、精密化和柔性化等四個(gè)方面。(1)標(biāo)準(zhǔn)化 機(jī)床夾具的目的就在于提高生產(chǎn)效率,這樣也就必使其具有標(biāo)準(zhǔn)化和通用化,而機(jī)床夾具的標(biāo)準(zhǔn)化與通用化是相互聯(lián)系的兩個(gè)方面。目前我國(guó)已有夾具零件及部件的國(guó)家標(biāo)準(zhǔn):GB/T2148T225991以及各類通用夾具、組合夾具標(biāo)準(zhǔn)等。機(jī)床夾具的標(biāo)準(zhǔn)化,有利于夾具的商品化生產(chǎn),有利于縮短生產(chǎn)準(zhǔn)備周期,降低生產(chǎn)總成本。(2)高效化 高效化夾具主要用來減少工件加工的基本時(shí)間和輔助時(shí)間,以提高勞動(dòng)生產(chǎn)率,減輕工人的勞動(dòng)強(qiáng)度。常見的高效化夾具有自動(dòng)化夾具、高速化夾具和具有夾緊力裝置的夾具等。例如,在銑床上使用電動(dòng)虎鉗裝夾工件,效率可提高5倍左右;在車床上使用高速三爪自定心卡盤,可保證卡爪在試驗(yàn)轉(zhuǎn)速為9000r/min的條件下仍能牢固地夾緊工件,從而使切削速度大幅度提高。目前,除了在生產(chǎn)流水線、自動(dòng)線配置相應(yīng)的高效、自動(dòng)化夾具外,在數(shù)控機(jī)床上,尤其在加工中心上出現(xiàn)了各種自動(dòng)裝夾工件的夾具以及自動(dòng)更換夾具的裝置,充分發(fā)揮了數(shù)控機(jī)床的效率。(3)精密化 機(jī)床夾具的精度會(huì)直接影響到零件的加工精度,而隨著機(jī)械產(chǎn)品精度的日益提高,勢(shì)必相應(yīng)提高了對(duì)夾具的精度要求。精密化夾具的結(jié)構(gòu)類型很多,例如用于精密分度的多齒盤,其分度精度可達(dá)0.1;用于精密車削的高精度三爪自定心卡盤,其定心精度為5m。這些精密化的夾具為以后零件加工的精度提供了保證。(4)柔性化 機(jī)床夾具的柔性化與機(jī)床的柔性化相似,它是指機(jī)床夾具通過調(diào)整、組合等方式,以適應(yīng)工藝可變因素的能力。工藝的可變因素主要有:工序特征、生產(chǎn)批量、工件的形狀和尺寸等。具有柔性化特征的新型夾具種類主要有:組合夾具、通用可調(diào)夾具、成組夾具、模塊化夾具、數(shù)控夾具等。為適應(yīng)現(xiàn)代機(jī)械工業(yè)多品種、中小批量生產(chǎn)的需要,擴(kuò)大夾具的柔性化程度,改變專用夾具的不可拆結(jié)構(gòu)為可拆結(jié)構(gòu),發(fā)展可調(diào)夾具結(jié)構(gòu),將是當(dāng)前夾具發(fā)展的主要方向。231機(jī)械加工制造技術(shù)的發(fā)展趨勢(shì)(1)特種加工 它是指一些物理的、化學(xué)的加工方法,如電火花加工、電解加工、超聲波加工、激光加工、離子束加工等。特種加工方法的主要對(duì)象是難加工材料的加工,如金剛石、陶瓷等超硬材料的加工,其加工精度可達(dá)分子級(jí)加工單位或原子級(jí)加工單位,所以它又常常是精密加工和超精密加工的重要手段。特種加工與傳統(tǒng)加工相結(jié)合的復(fù)合加工有較大的發(fā)展前途。(2)快速成形 利用離散、堆積成形概念,可將一個(gè)三維實(shí)體分解為若干二維實(shí)體制造出來,再經(jīng)堆積而構(gòu)成三維實(shí)體。(3)精密工程 它包括精密加工的超精密加工技術(shù)、微細(xì)加工和超微細(xì)加工技術(shù)、微型機(jī)械和納米技術(shù)等方面。當(dāng)前,以納米技術(shù)為代表的超精密加工技術(shù)和以微細(xì)加工為手段的微型機(jī)械技術(shù)有重要意義,它們代表了這一時(shí)期精密工程的方向。(4)傳統(tǒng)加工工藝的改造和革新 這一方面的技術(shù)潛力很大,如高速切削、超高速切削、強(qiáng)力磨削、超硬材料磨具的出現(xiàn)都對(duì)加工理論的發(fā)展、加工質(zhì)量和效率的提高有重要意義。另一方面,舊設(shè)備的改造和挖潛,如普通機(jī)床改造成數(shù)控機(jī)床等,對(duì)機(jī)械工業(yè)的發(fā)展和提高是不容忽視的。3 簡(jiǎn)單的評(píng)述綜上,機(jī)械加工藝及夾具隨著科技的發(fā)展都使計(jì)算機(jī)技術(shù)、數(shù)控技術(shù)、控制論及系統(tǒng)工程與制造技術(shù)的結(jié)合為制造系統(tǒng),形成現(xiàn)代制造工程學(xué)。而物料流、能量流、信息流是組成制造系統(tǒng)的三個(gè)基本要素?,F(xiàn)代加工都為集成化的系統(tǒng)加工,這雖減輕了工人的勞動(dòng)強(qiáng)度,但同時(shí)對(duì)工人的知識(shí)水平要求較高。這需要我們?nèi)轿坏恼J(rèn)知現(xiàn)代科技知識(shí)。因此,在以后的學(xué)習(xí)中需要我們?nèi)轿坏膶W(xué)習(xí)其各個(gè)相關(guān)領(lǐng)域的知識(shí),不能只注重一點(diǎn),為將來的人才戰(zhàn)略提出了新的要求。英文翻譯:Overview of the fixture design1 IntroductionMachining process and fixture design is a comprehensive process and fixture design is an important practical use of theoretical and practical knowledge of the relevant professional courses. Machine tool fixture is a device for clamping the workpiece on the machine, its role is so that the workpiece to have a correct position relative to the machine and tool, and to maintain this position unchanged in theprocess. The fixture can not only guarantee the accuracy of the workpiece processing, improve processing efficiency, but also reduce the labor intensity of workers, reducing the manufacturing costs of products, expanding the use of the machine. Manufacturing technology production, international economic competition, an important means of product innovation, all countries seeking to acquire, develop and exploit it. It is being seen as a key factor in the success of the modern state economy.Mechanical process planning is the process of the specified products or components machining process and methods of operation and other documents, all relevant work production personnel should be strictly enforced, conscientiously implement the disciplinary file. The size of the production scale, technology level of a variety of process issues, methods and means to go through the machining process specification to reflect. Machine tool fixture is a device used for clamping the workpiece on the machine, and its role is to enable the workpiece relative to the correct location of the machine or tool, and in the process to maintain this position. Their research on the machinery industry has very important significance.The development of the two machining process and fixture design 2.1 history of the development Since 1949, Chinas machinery industry has been greatly developed and has become a relatively complete industrial products, with one of the considerable size and some technology-based sectors, machining and fixture also has a great development, but industrial developed countries, the level of our stage gap, mainly in the quality and level of mechanical products is not high enough, the machining process is unreasonable, fixture applications is relatively small, its processing workers in labor-intensive, processing out of the product is not satisfactory. 2.2 Development of Now, industrialized countries have manufacturing technology as the development of modern science and technology to the main battlefield of the active area and in the international technology competition to develop a series of revitalization plan, the establishment of the center of world-class manufacturing technology, have advanced manufacturing technology as a key national technologies and priority areas of development. Machining process and fixture with the development of manufacturing technology is also advancing rapidly. Machining process to the specific circumstances of each plant, the processing procedures are very different. Breakthrough in previous years, the death mode. It as the situation different with a more reasonable process. Also greatly improve the quality of the product. Development of processing technology, although according to reasonable development, but also to meet their basic requirements: the premise of ensuring product quality, maximize productivity and reduce processing costs. Domestic and foreign advanced technology and experience and, as far as possible on the basis of full use of the existing production conditions of the factory. It should also ensure good working conditions for the operator. Present stage still mainly rely on the experience of the craft workers to the preparation process, most do not require working steps and cutting, fixed working hours rule of thumb to determine, very rough, the lack of scientific basis, it is difficult to make reasonable economic accounting. The machine tool fixtures first appeared in the late 18th century. With the continuous progress of science and technology, the fixture has evolved from a tool developed into a complete range of process equipment. Association for the Study of international production statistics show that now, about 85 percent of the workpiece varieties of small batch production of many varieties accounted for the total number of workpiece types. The modern production requires a variety of products manufactured by the enterprise often replace old ones, in order to meet market demand and competition. However, most enterprises are still accustomed to a large number of traditional special fixture, usually in the factory with medium production capacity, about thousands or even ten thousand sets of special fixtures; the other hand, multi-product production enterprise, every 3 to 4 years is necessary to update 50 to about 80% of special fixtures, fixture wear only about 10 to 20 percent. In recent years, CNC machine tools, machining centers, group technology, flexible manufacturing system (FMS) application of new processing technologies, the machine tool fixture the following new requirements: 1) can quickly and easily equip the commissioning of new products, to shorten the cycle of production preparation, reduce production costs; 2) clamping a workpiece with similar characteristics; 3) high-precision jigs and fixtures for precision machining; 4) can be applied to new jigs and fixtures for a variety of modern manufacturing technology; 5) efficient clamping device, hydraulic station power source in order to further reduce labor intensity and improve labor productivity; 6) Increase the degree of standardization of the machine tool fixture. 2.3 Development Trend of Over the years, the machining process planning is carried out empirically by the craft workers. By several craft their own preparation process specification of the same parts, its programs are generally of the same, and probably not the best option. This is because the process design involves many factors, the complexity of the causal relationship. CAPP will be the development trend of the machining process, it not only improves the quality of the process design and process to extricate itself from a tedious repetitive work, concentrated effort to consider raising the level of technology and product quality issues. 2.3.1 fixture development trends Development trends of the modern machine tool fixture mainly four aspects of standardization, efficiency, precision and flexibility. (1) The purpose of the standardization of machine tool fixture is to improve production efficiency, so that he will make with the standardization and universal standardization and generalization of the machine tool fixture two aspects are interrelated. National standards of China has a fixture parts and components: GB/T2148 T2259-91, and a variety of universal fixture, modular fixture standards. Standardization of jigs and fixtures, commercial production of the fixture, to shorten the production preparation period, reducing the total cost of production. (2) efficient efficient fixture mainly used to reduce the the workpiece basic time and auxiliary time, to improve labor productivity, reduce labor intensity. Efficient common folder with automated fixtures, high-speed jig and fixture clamping force device. For example, the electric vise clamping the workpiece in a milling machine, the efficiency can be increased about five times; on a lathe using high-speed three-jaw self-centering chuck, to ensure that the jaws are still firmly under the conditions of the test speed is 9000r/min to clamp the workpiece, so that the cutting speed is greatly improved. In addition to efficient, automated fixture in the production lines, automatic line configuration on the CNC machine tools, especially in the machining center fixture of a variety of automatic workpiece clamping and automatic replacement of the fixture device, give full play to the CNC machine tools efficiency. (3) the accuracy of precision machine tool fixture will directly affect the machining accuracy, with the increasing accuracy of mechanical products, is bound to a corresponding increase in the precision of the fixture. Precision fixture structure type, for example, the precision of multi-gear, its indexing accuracy up to 0.1; for precision turning, precision jaw self-centering chuck, centering accuracy of 5m These precision fixture to provide a guarantee for the accuracy of the later parts processing. (4) the flexibility of the flexible machine tool fixture and the flexibility of the machine, it refers to the ability to machine fixture by way of adjustment, combined to suit the process variables. Variables of the process are: process characteristics, production volume, the workpiece shape and size. The new fixture types with flexible features: modular fixture, universal adjustable clamp, group fixtures, modular fixtures, CNC jig. In order to meet the needs of the many varieties of modern mechanical industry, small and medium volume production, expand the degree of flexibility of the fixture to change the special fixtures2.3.1 machining manufacturing technology trends(1) special processing it refers to some physical, chemical processing methods, such as electrical discharge machining, electrochemical machining, ultrasonic machining, laser processing, ion beam processing. The main object of the special processing method is the processing of difficult materials, such as diamond, ceramics and other superhard materials processing, and its precision up to molecular level processing units, or atomic-scale processing units, so it is often the precision machining and ultra precision machining an important tool. Special processing and processing a combination of composite processing have a greater future development.(2) rapid prototyping using discrete accumulation of forming the concept of a three-dimensional entities can be decomposed into a number of two-dimensional entity created by the accumulation of a three-dimensional entities.(3) precision engineering, including precision machining of ultra-precision processing technology, micro-machining and ultra-fine processing technology, micro-mechanical and nano-technology. At present, ultra-precision processing technology as the representative of nanotechnology and micro-mechanical technology as a means of micromachining is important, they represent the direction of the precision engineering of this period.(4) the transformation and modernization of the traditional processing technology in this field potential, such as high-speed cutting, ultra-high-speed cutting, strong grinding, abrasive superhard materials processing theory of development, processing, quality and efficiency The increased significance. On the other hand, the transformation of the old equipment and tapping the potential, such as general machine tools transformed into CNC machine tools, the development and improvement of the machinery industry can not be ignored.3 commentsIn summary, the machining process and jig With the development of science and technology, computer technology, CNC technology, control dealt with systems engineering and manufacturing technology combined with manufacturing systems, the formation of the modern manufacturing engineering. Material flow, energy flow, information flow is the three basic elements that make up the manufacturing system. Modern processing for the processing of integrated systems, which reduce the labor intensity, but at the same time require a higher level of knowledge of the workers. This need our full range of cognitive modern scientific and technological knowledge. Therefore, in the future learning needs our full range of learning its various related fields of knowledge, can not focus only on the proposed new requirements for future human resources strategy.15 摘要 本次設(shè)計(jì)內(nèi)容涉及了機(jī)械制造工藝及機(jī)床夾具設(shè)計(jì)、金屬切削機(jī)床、公差配合與測(cè)量等多方面的知識(shí)。齒輪軸承座的加工工藝規(guī)程和鏜齒輪軸承座粗鏜、半精鏜、精鏜52的工裝夾具設(shè)計(jì)是包括零件加工的工藝設(shè)計(jì)、工序設(shè)計(jì)以及專用夾具的設(shè)計(jì)三部分。在工藝設(shè)計(jì)中要首先對(duì)零件進(jìn)行分析,了解零件的工藝再設(shè)計(jì)出毛坯的結(jié)構(gòu),并選擇好零件的加工基準(zhǔn),設(shè)計(jì)出零件的工藝路線;接著對(duì)零件各個(gè)工步的工序進(jìn)行尺寸計(jì)算,關(guān)鍵是決定出各個(gè)工序的工藝裝備及切削用量;然后進(jìn)行專用夾具的設(shè)計(jì),選擇設(shè)計(jì)出夾具的各個(gè)組成部件,如定位元件、夾緊元件、引導(dǎo)元件、夾具體與機(jī)床的連接部件以及其它部件;計(jì)算出夾具定位時(shí)產(chǎn)生的定位誤差,分析夾具結(jié)構(gòu)的合理性與不足之處,并在以后設(shè)計(jì)中注意改進(jìn)。關(guān)鍵詞:切削用量 夾緊 定位 誤差。 Abstract This design involves the mechanical manufacturing process and machine tool fixture design, metal cutting machine tools, tolerance and measurement, and other aspects of knowledge.The gear bearing manufacturing process and boring gear bearing rough boring half fineboring fine boring Phi 52 fixture design including machining process design, process design and fixture design in three parts. In the process of design should first understand the analysis of parts, parts of the process to design a blank structure, and choose the good components the processing datum, designs the process routes of the parts; then the parts of each labor step process size calculation, is the key to decide the craft equipment and the cutting process of the various design parameters; then a special fixture, the fixture selection for the various components of the design, such as connecting parts positioning elements and clamping elements, guide element, fixture and machine tool and other components; positioning error is calculated when the fixture, analysis the rationality and shortcoming of fixture structure, improve and design in later.Key words: cutting the amount of clamping and positioning error.摘要I序 言1第1章 零件的分析21.1 零件的作用21.2 零件的工藝分析2第2章 工藝規(guī)程設(shè)計(jì)32.1 確定毛坯的制造形式32.2 基面的選擇32.2.1 粗基準(zhǔn)的選擇原則32.2.2 精基準(zhǔn)選擇的原則32.3 制訂工藝路線42.4 加工余量的確定52.5 機(jī)械工序尺寸及毛皮尺寸的確定、切削用量及基本工時(shí)的確立7第3章 鏜床夾具設(shè)計(jì)263.1 問題的提出263.2定位基準(zhǔn)的選擇263.3 定位誤差的分析與計(jì)算263.3.1 定位誤差的分析263.3.2 定位誤差計(jì)算273.4夾緊力的確定27總 結(jié)29參考文獻(xiàn)30II 序 言機(jī)械制造業(yè)是制造具有一定形狀位置和尺寸的零件和產(chǎn)品,并把它們裝備成機(jī)械裝備的行業(yè)。機(jī)械制造業(yè)的產(chǎn)品既可以直接供人們使用,也可以為其它行業(yè)的生產(chǎn)提供裝備,社會(huì)上有著各種各樣的機(jī)械或機(jī)械制造業(yè)的產(chǎn)品。我們的生活離不開制造業(yè),因此制造業(yè)是國(guó)民經(jīng)濟(jì)發(fā)展的重要行業(yè),是一個(gè)國(guó)家或地區(qū)發(fā)展的重要基礎(chǔ)及有力支柱。從某中意義上講,機(jī)械制造水平的高低是衡量一個(gè)國(guó)家國(guó)民經(jīng)濟(jì)綜合實(shí)力和科學(xué)技術(shù)水平的重要指標(biāo)。齒輪軸承座的加工工藝規(guī)程和鏜齒輪軸承座粗鏜、半精鏜、精鏜52工裝夾具設(shè)計(jì)是在學(xué)完了機(jī)械制圖、機(jī)械制造技術(shù)基礎(chǔ)、機(jī)械設(shè)計(jì)、機(jī)械工程材料等進(jìn)行畢業(yè)設(shè)計(jì)之后的下一個(gè)教學(xué)環(huán)節(jié)。正確地解決一個(gè)零件在加工中的定位,夾緊以及工藝路線安排,工藝尺寸確定等問題,并設(shè)計(jì)出專用夾具,保證零件的加工質(zhì)量。本次設(shè)計(jì)也要培養(yǎng)自己的自學(xué)與創(chuàng)新能力。因此本次設(shè)計(jì)綜合性和實(shí)踐性強(qiáng)、涉及知識(shí)面廣。所以在設(shè)計(jì)中既要注意基本概念、基本理論,又要注意生產(chǎn)實(shí)踐的需要,只有將各種理論與生產(chǎn)實(shí)踐相結(jié)合,才能很好的完成本次設(shè)計(jì)。本設(shè)計(jì)選用齒輪軸承座來進(jìn)行工藝編制與夾具設(shè)計(jì),以說明書、繪圖為主,設(shè)計(jì)手冊(cè)與國(guó)家標(biāo)準(zhǔn)為附來進(jìn)行詳細(xì)說明。第1章 零件的分析1.1 零件的作用齒輪軸承座零件一般都是用鑄鐵、鋼等材料鑄造而成。有軸承的地方就要有支撐點(diǎn),軸承的內(nèi)支撐點(diǎn)是軸,外支撐就是常說的軸承座。由于一個(gè)軸承可以選用不同的軸承座,而一個(gè)軸承座同時(shí)又可以選用不同類型的軸承,因此,帶來軸承座的品種很多。軸承座快易優(yōu)有收錄,許多國(guó)外大的軸承公司也都有自己的軸承座型錄。但是同樣的軸承座型號(hào)在不同的公司樣本里的標(biāo)記也不完全相同。對(duì)于標(biāo)準(zhǔn)軸承座不同的應(yīng)用場(chǎng)合,可選擇不同材料的軸承座如:灰口鑄鐵鐵、球墨鑄鐵和鑄鋼、不銹鋼、塑料的特殊軸承座。料。1.2 零件的工藝分析齒輪軸承座共有六處加工表面、兩處螺紋、三處孔及一處槽 ,其間有一定位置要求。分述如下:1、齒輪軸承座87底面、80底面2、齒輪軸承座87頂面、80頂面、寬70臺(tái)階3、齒輪軸承座寬25槽、寬13.5槽4、齒輪軸承座52孔5、齒輪軸承座80孔6、齒輪軸承座87底面上的3-M6螺紋7、齒輪軸承座87頂面上的3-M6螺紋第2章 工藝規(guī)程設(shè)計(jì)2.1 確定毛坯的制造形式鑄件有多種分類方法:按其所用金屬材料的不同,分為鑄鋼件、鑄鐵件、鑄銅件、鑄鋁件、鑄鎂件、鑄鋅件、鑄鈦件等。而每類鑄件又可按其化學(xué)成分或金相組織進(jìn)一步分成不同的種類。如鑄鐵件可分為灰鑄鐵件、球墨鑄鐵件、蠕墨鑄鐵件、可鍛鑄鐵件、合金鑄鐵件等;按鑄型成型方法的不同,可以把鑄件分為普通砂型鑄件、金屬型鑄件、壓鑄件、離心鑄件、連續(xù)澆注件、熔模鑄件、陶瓷型鑄件、電渣重熔鑄件、雙金屬鑄件等。其中以普通砂型鑄件應(yīng)用最多,約占全部鑄件產(chǎn)量的80%。而鋁、鎂、鋅等有色金屬鑄件,多是壓鑄件。2.2 基面的選擇基面的選擇是工藝規(guī)程設(shè)計(jì)中的重要工作之一?;孢x擇的正確、合理,可以保證質(zhì)量,提高生產(chǎn)效率。否則,就會(huì)使加工工藝過程問題百出,嚴(yán)重的還會(huì)造成零件大批報(bào)廢,使生產(chǎn)無法進(jìn)行。2.2.1 粗基準(zhǔn)的選擇原則1)如果必須首先保證工件上加工表面與不加工表面 之間的位置要求,應(yīng)以不加工表面作為粗基準(zhǔn)。如果在工件上有很多不需加工的表面,則應(yīng)以其中與加工面位置精度要求較高的表面作粗基準(zhǔn)。2)如果必須首先保證工件某重要表面的加工余量均勻,應(yīng)選擇該表面作精基準(zhǔn)。3)如需保證各加工表面都有足夠的加工余量,應(yīng)選加工余量較小的表面作粗基準(zhǔn)。4)選作粗基準(zhǔn)的表面應(yīng)平整,沒有澆口、冒口、飛邊等缺陷,以便定位可靠。5)粗基準(zhǔn)一般只能使用一次,特別是主要定位基準(zhǔn),以免產(chǎn)生較大的位置誤差。由以上及零件知,選用工件中心線作為定位粗基準(zhǔn)。2.2.2 精基準(zhǔn)選擇的原則選擇精基準(zhǔn)時(shí)要考慮的主要問題是如何保證設(shè)計(jì)技術(shù)要求的實(shí)現(xiàn)以及裝夾準(zhǔn)確、可靠、方便。精基準(zhǔn)選擇應(yīng)當(dāng)滿足以下要求:用設(shè)計(jì)基準(zhǔn)作為定位基準(zhǔn),實(shí)現(xiàn)“基準(zhǔn)重合”,以免產(chǎn)生基準(zhǔn)不重合誤差。當(dāng)工件以某一組精基準(zhǔn)定位可以較方便地加工很多表面時(shí),應(yīng)盡可能采用此組精基準(zhǔn)定位,實(shí)現(xiàn)“基準(zhǔn)統(tǒng)一”,以免生產(chǎn)基準(zhǔn)轉(zhuǎn)換誤差。當(dāng)精加工或光整加工工序要求加工余量盡量小而均勻時(shí),應(yīng)選擇加工表面本身作為精基準(zhǔn),即遵循“自為基準(zhǔn)”原則。該加工表面與其他表面間的位置精度要求由先行工序保證。為獲得均勻的加工余量或較高 的位置精度,可遵循“互為基準(zhǔn)”、反復(fù)加工的原則。有多種方案可供選擇時(shí)應(yīng)選擇定位準(zhǔn)確、穩(wěn)定、夾緊可靠,可使夾具結(jié)構(gòu)簡(jiǎn)單的表面作為精基準(zhǔn)。2.3 制訂工藝路線制定工藝路線的出發(fā)點(diǎn),應(yīng)當(dāng)使零件的幾何形狀、尺寸精度及位置精度等技術(shù)要求能得到合理的保證,在生產(chǎn)綱領(lǐng)已確定的情況下,可以考慮采用萬能性機(jī)床配以專用工具,并盡量使工序集中來提高生產(chǎn)率。此外,還應(yīng)當(dāng)考慮經(jīng)濟(jì)效果,以便使生產(chǎn)成本盡量下降。表3.1 工藝路線工序號(hào) 工序內(nèi)容工序01金屬型澆注工序02時(shí)效處理以消除內(nèi)應(yīng)力工序03粗銑、半精銑87底面;粗銑、半精銑80底面工序04 粗銑、半精銑87頂面;粗銑、半精銑80頂面;粗銑、半精銑臺(tái)階工序05 銑寬25槽;銑寬13.5槽工序06粗鏜、半精鏜、半精80孔;倒角145工序07 粗鏜、半精鏜、半精52孔;倒角145工序08鉆、攻87底面3-M6螺紋工序09鉆、攻87頂面3-M6螺紋工序10去毛刺工序11檢驗(yàn)至圖紙要求工序12包裝并入庫(kù)2.4 加工余量的確定由機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.3-1知,生產(chǎn)類型屬于大批大量生產(chǎn),精度等級(jí)CT8級(jí),加工余量等級(jí)F。1、 87底面的加工余量87底面長(zhǎng)100mm,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表2.2-4知,單邊加工余量Z=3.0mm。表面粗糙度Ra3.2,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.4-8知,兩步銑削(即粗銑、半精銑)可滿足其精度要求。粗銑 單邊余量Z=2.5半精銑 單邊余量Z=0.52、 80底面的加工余量80底面長(zhǎng)80mm,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表2.2-4知,單邊加工余量Z=3.0mm。表面粗糙度Ra3.2,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.4-8知,兩步銑削(即粗銑、半精銑)可滿足其精度要求。粗銑 單邊余量Z=2.5半精銑 單邊余量Z=0.53、 87頂面的加工余量87頂面長(zhǎng)49mm,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表2.2-4知,單邊加工余量Z=3.0mm。表面粗糙度Ra3.2,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.4-8知,兩步銑削(即粗銑、半精銑)可滿足其精度要求粗銑 單邊余量Z=2.5半精銑 單邊余量Z=0.54、 80頂面的加工余量87頂面長(zhǎng)49mm,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表2.2-4知,單邊加工余量Z=3.0mm。表面粗糙度Ra3.2,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.4-8知,兩步銑削(即粗銑、半精銑)可滿足其精度要求粗銑 單邊余量Z=2.5半精銑 單邊余量Z=0.55、 臺(tái)階的加工余量臺(tái)階長(zhǎng)140mm,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表2.2-4知,單邊加工余量Z=3.0mm。表面粗糙度Ra3.2,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.4-8知,兩步銑削(即粗銑、半精銑)可滿足其精度要求粗銑 單邊余量Z=2.5半精銑 單邊余量Z=0.56、 臺(tái)階的加工余量臺(tái)階長(zhǎng)140mm,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表2.2-4知,單邊加工余量Z=3.0mm。表面粗糙度Ra3.2,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.4-8知,兩步銑削(即粗銑、半精銑)可滿足其精度要求粗銑 單邊余量Z=2.5半精銑 單邊余量Z=0.57、 80的加工余量80孔直徑80mm,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表2.2-4知,單邊加工余量Z=2.5mm。表面粗糙度Ra1.6,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.4-8知,兩步銑削(即粗銑、半精銑)可滿足其精度要求粗鏜 單邊余量Z=2.0半精鏜 單邊余量Z=0.4精鏜 單邊余量Z=0.18、 52的加工余量52孔直徑52mm,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表2.2-4知,單邊加工余量Z=2.5mm。表面粗糙度Ra1.6,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.4-8知,兩步銑削(即粗銑、半精銑)可滿足其精度要求粗鏜 單邊余量Z=2.0半精鏜 單邊余量Z=0.4精鏜 單邊余量Z=0.19、 寬25槽、寬13.5槽、兩面3-M6螺紋的加工余量 以上的加工表面,因尺寸不大,故采用實(shí)心鑄造,精度要求不高,查機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表1.4-7知,加工滿足其精度要求。2.5 機(jī)械工序尺寸及毛皮尺寸的確定、切削用量及基本工時(shí)的確立工序01:金屬型澆注工序02:時(shí)效處理以消除內(nèi)應(yīng)力工序03:粗銑、半精銑87底面;粗銑、半精銑80底面工步一:粗銑87底面1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取600當(dāng)600r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(50-)25.9mm工步二:半精銑87底面1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取800當(dāng)800r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(50-)25.9mm工步三:粗銑80孔底面1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取600當(dāng)600r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(60-)27.4mm工步四:半精銑80孔底面1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取800當(dāng)800r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(50-)25.9mm工序04:粗銑、半精銑87頂面;粗銑、半精銑80頂面;粗銑、半精銑臺(tái)階工步一:粗銑87頂面1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取600當(dāng)600r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(50-)25.9mm工步二:半精銑87頂面1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取800當(dāng)800r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(50-)25.9mm工步三:粗銑80孔頂面1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取600當(dāng)600r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(60-)27.4mm工步四:半精銑80孔頂面1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取800當(dāng)800r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(50-)25.9mm工步五:粗銑臺(tái)階1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取600當(dāng)600r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(80-)41.8mm工步六:半精銑臺(tái)階1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取800當(dāng)800r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(80-)41.8mm工序05:銑寬25槽;銑寬13.5槽工步一:銑寬25槽1. 選擇刀具刀具選取立銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取600當(dāng)600r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(25-)25.5mm工步二:銑寬13.5槽1. 選擇刀具刀具選取端面銑刀,。2. 決定銑削用量1)決定銑削深度2)決定每次進(jìn)給量及切削速度按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-36,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取600當(dāng)600r/min時(shí)按機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)表4.2-37,數(shù)控銑床XK7132標(biāo)準(zhǔn)選取3)計(jì)算工時(shí)=0.5+(d-) =13工作臺(tái)的水平進(jìn)給量(mm/min)工作臺(tái)的垂直進(jìn)給量(mm/min)銑削寬度(垂直于銑刀軸線方向測(cè)量的切削層尺寸)(mm)銑削深度(平行于銑刀軸線方向測(cè)量的切削層尺寸)(mm)d銑刀直徑(mm)=0.5+(d-)=0.5+(13.5-)14mm工序06:粗鏜、半精鏜、精鏜80孔;倒角145工步一:粗鏜75孔至791加工條件加工要求:粗鏜75孔至79,單側(cè)加工余量Z=2.0mm。機(jī)床:選用T4163C坐標(biāo)鏜床和專用夾具。刀具:硬質(zhì)合金單刃鏜刀。2、選擇切削用量(1)選擇切削深度由于單側(cè)加工余量Z=2.0mm,故可在一次鏜去全部余量,則=2.0(2)選擇進(jìn)給量根據(jù)【6】實(shí)用機(jī)械加工工藝手冊(cè)(以下簡(jiǎn)稱工藝手冊(cè))表11-313,查得粗鏜時(shí),硬質(zhì)合金刀頭,加工材料鑄鐵:=120m/min f=0.1-1.0mm/r則484r/min 根據(jù)簡(jiǎn)明手冊(cè)表4.2-204.2-61,選擇f=0.35mm/r,n=500r/min。(3)計(jì)算基本工時(shí) 切削工時(shí): ,則機(jī)動(dòng)工時(shí)為 L=(20+2+3)mm=25mm故有 =0.143min工步二:半精鏜79孔至79.81加工條件加工要求:半精鏜79孔至79.8,單側(cè)加工余量Z=0.4mm。機(jī)床:選用T4163C坐標(biāo)鏜床和專用夾具。刀具:硬質(zhì)合金單刃鏜刀。2、選擇切削用量(1)選擇切削深度由于單側(cè)加工余量Z=0.4mm,故可在一次鏜去全部余量,則=0.4 mm(2)選擇進(jìn)給量根據(jù)【6】實(shí)用機(jī)械加工工藝手冊(cè)(以下簡(jiǎn)稱工藝手冊(cè))表11-313,查得粗鏜時(shí),硬質(zhì)合金刀頭,加工材料鑄鐵:=150m/min f=0.1-1.0mm/r則599r/min 根據(jù)簡(jiǎn)明手冊(cè)表4.2-204.2-61,選擇f=0.2mm/r,n=600r/min。(3)計(jì)算基本工時(shí) 切削工時(shí): ,則機(jī)動(dòng)工時(shí)為 L=(20+0.4+3)mm=23.4mm故有 =0.195min工步三:精鏜79.8孔至801加工條件加工要求:精鏜79.8孔至80,單側(cè)加工余量Z=0.1mm。機(jī)床:選用T4163C坐標(biāo)鏜床和專用夾具。刀具:硬質(zhì)合金單刃鏜刀。2、選擇切削用量(1)選擇切削深度由于單側(cè)加工余量Z=0.1mm,故可在一次鏜去全部余量,則=0.1 mm(2)選擇進(jìn)給量根據(jù)【6】實(shí)用機(jī)械加工工藝手冊(cè)(以下簡(jiǎn)稱工藝手冊(cè))表11-313,查得粗鏜時(shí),硬質(zhì)合金刀頭,加工材料鑄鐵:=200m/min f=0.1-1.0mm/r則797r/min 根據(jù)簡(jiǎn)明手冊(cè)表4.2-204.2-61,選擇f=0.1mm/r,n=800r/min。(3)計(jì)算基本工時(shí) 切削工時(shí): ,則機(jī)動(dòng)工時(shí)為 L=(20+0.1+3)mm=23.1mm故有 =0.289min工序四:倒角145工序07:粗鏜、半精鏜、精鏜52孔;倒角145工步一:粗鏜47孔至511加工條件加工要求:粗鏜47孔至51,單側(cè)加工余量Z=2.0mm。機(jī)床:選用T4163C坐標(biāo)鏜床和專用夾具。刀具:硬質(zhì)合金單刃鏜刀。2、選擇切削用量(1)選擇切削深度由于單側(cè)加工余量Z=2.0mm,故可在一次鏜去全部余量,則=2.0(2)選擇進(jìn)給量根據(jù)【6】實(shí)用機(jī)械加工工藝手冊(cè)(以下簡(jiǎn)稱工藝手冊(cè))表11-313,查得粗鏜時(shí),硬質(zhì)合金刀頭,加工材料鑄鐵:=75m/min f=0.1-1.0mm/r則469r/min 根據(jù)簡(jiǎn)明手冊(cè)表4.2-204.2-61,選擇f=0.35mm/r,n=500r/min。(3)計(jì)算基本工時(shí) 切削工時(shí): ,則機(jī)動(dòng)工時(shí)為 L=(100+2+3)mm=105mm故有 =0.600min工步二:半精鏜51孔至51.81加工條件加工要求:半精鏜51孔至51.8,單側(cè)加工余量Z=0.4mm。機(jī)床:選用T4163C坐標(biāo)鏜床和專用夾具。刀具:硬質(zhì)合金單刃鏜刀。2、選擇切削用量(1)選擇切削深度由于單側(cè)加工余量Z=0.4mm,故可在一次鏜去全部余量,則=0.4 mm(2)選擇進(jìn)給量根據(jù)【6】實(shí)用機(jī)械加工工藝手冊(cè)(以下簡(jiǎn)稱工藝手冊(cè))表11-313,查得半精鏜時(shí),硬質(zhì)合金刀頭,加工材料鑄鐵:=100m/min f=0.1-1.0mm/r則615r/min 根據(jù)簡(jiǎn)明手冊(cè)表4.2-204.2-61,選擇f=0.2mm/r,n=600r/min。(3)計(jì)算基本工時(shí) 切削工時(shí): ,則機(jī)動(dòng)工時(shí)為 L=(100+0.4+3)mm=103.4mm故有 =0.862min工步三:精鏜51.8孔至521加工條件加工要求:精鏜51.8孔至52,單側(cè)加工余量Z=0.1mm。機(jī)床:選用T4163C坐標(biāo)鏜床和專用夾具。刀具:硬質(zhì)合金單刃鏜刀。2、選擇切削用量(1)選擇切削深度由于單側(cè)加工余量Z=0.1mm,故可在一次鏜去全部余量,則=0.1 mm(2)選擇進(jìn)給量根據(jù)【6】實(shí)用機(jī)械加工工藝手冊(cè)(以下簡(jiǎn)稱工藝手冊(cè))表11-313,查得粗鏜時(shí),硬質(zhì)合金刀頭,加工材料鑄鐵:=130m/min f=0.1-1.0mm/r則797r/min 根據(jù)簡(jiǎn)明手冊(cè)表4.2-204.2-61,選擇f=0.1mm/r,n=800r/min。(3)計(jì)算基本工時(shí) 切削工時(shí): ,則機(jī)動(dòng)工時(shí)為 L=(100+0.1+3)mm=103.1mm故有 =1.289min工序四:倒角145工序08:鉆、攻底面3-M6螺紋工步一:鉆底面3-M6螺紋底孔5.1選用高速鋼錐柄麻花鉆(工藝表3.16) 由切削表2.7和工藝表4.216查得 (切削表2.15) 624r/min 按機(jī)床選取n=600r/min 切削工時(shí): ,則機(jī)動(dòng)工時(shí)為工步二:攻3-M6螺紋選擇M6mm高速鋼機(jī)用絲錐 等于工件螺紋的螺距,即f=0.45mm/r398r/min 按機(jī)床選取n=400r/min切削工時(shí): ,則機(jī)動(dòng)工時(shí)為 工序09:鉆、攻頂面3-M6螺紋工步一:鉆頂面3-M6螺紋底孔5.1選用高速鋼錐柄麻花鉆(工藝表3.16) 由切削表2.7和工藝表4.216查得 (切削表2.15) 624r/min 按機(jī)床選取n=600r/min 切削工時(shí): ,則機(jī)動(dòng)工時(shí)為工步二:攻3-M6螺紋選擇M6mm高速鋼機(jī)用絲錐 等于工件螺紋的螺距,即f=0.45mm/r398r/min 按機(jī)床選取n=400r/min切削工時(shí): ,則機(jī)動(dòng)工時(shí)為 工序10:去毛刺工序11:檢驗(yàn)至圖紙要求工序12:包裝并入庫(kù) 第3章 鏜床夾具設(shè)計(jì) 對(duì)于成批生產(chǎn)的零件,大多采用專用機(jī)床夾具。在保證加工質(zhì)量、操作方便、滿足高效的前提下,亦可部分采用通用夾具。本加工工藝規(guī)程中,所用夾具均為專用夾具,需專門設(shè)計(jì)、制造,這里對(duì)齒輪軸承座的加工工藝規(guī)程和鏜齒輪軸承座粗鏜、半精鏜、精鏜52工裝夾具設(shè)計(jì)進(jìn)行分析。3.1 問題的提出 本夾具主要用于鏜孔,精度要求是Ra1.6,因此本道工序加工精度要求較高,為此,即考慮如何提高生產(chǎn)效率上,也要考慮精度。3.2定位基準(zhǔn)的選擇選擇80孔及80孔底面和工作一側(cè)來定位,其中,80孔底面和為80孔底面第一定位基準(zhǔn),與特制定位銷和襯套相配合限制三個(gè)自由度,其中一個(gè)80孔為第二定位基準(zhǔn),與特制定位銷外圓相配合限制兩個(gè)自由度,工件一側(cè)為第三定位基準(zhǔn),與支承釘相配合限制一個(gè)自由度,屬于完全定位。3.3 定位誤差的分析與計(jì)算3.3.1 定位誤差的分析1.基準(zhǔn)不重合來帶的定位誤差: 夾具定位基準(zhǔn)與工序基準(zhǔn)不重合,兩基準(zhǔn)之間的位置誤差會(huì)反映到被加工表面的位置上去,所產(chǎn)生定位誤差稱之為基準(zhǔn)轉(zhuǎn)換誤差。2.間隙引起的定位誤差 在使用心軸、銷、定位套定位時(shí),定位面與定位元件間的間隙可使工件定心不準(zhǔn)產(chǎn)生定位誤差。3.與夾具有關(guān)的因素產(chǎn)生的定位誤差1)定位基準(zhǔn)面與定位元件表面的形狀誤差。2)導(dǎo)向元件、對(duì)刀元件與定位元件間的位置誤差,以及其形狀誤差導(dǎo)致產(chǎn)生的導(dǎo)向誤差和對(duì)刀誤差。3)夾具在機(jī)床上的安裝誤差,即對(duì)定誤差導(dǎo)致工件相對(duì)刀具主軸或運(yùn)動(dòng)方向產(chǎn)生的位置誤差。4)夾緊力使工件與定位元件間的位置誤差,以及定位元件、對(duì)刀元件、導(dǎo)向元件、定向元件等元件的磨損。 3.3.2 定位誤差計(jì)算定位元件為一面、一心軸、一擋銷,誤差分析如下:1、定位誤差:式中:T工件定位孔的孔徑公差 T定心心軸的軸徑公差 工件定位孔與定位心軸的最小配合間隙2、夾緊安裝誤差,對(duì)工序尺寸的影響較小,取=03、磨損造成的加工誤差:通過不超過0.005mm,誤差總合:+=0.108mm0.3mm從上分析,所設(shè)計(jì)的夾具能滿足零件的加工精度要求。3.4夾緊力的確定(1)切屑力計(jì)算查表1-2-3 圓周力: 徑向力: 軸向力:其中:查機(jī)床夾具手冊(cè)表1-2-4,表1-2-5表1-2-6由上得:Fc=725N,F(xiàn)p=459N,F(xiàn)f=695N(2)夾緊力的計(jì)算 選用夾緊螺釘夾緊機(jī) 由 其中f為夾緊面上的摩擦系數(shù),取 F=+G G為工件自重 夾緊螺釘: 公稱直徑d=8mm,材料45鋼 性能級(jí)數(shù)為6.8級(jí) 螺釘疲勞極限: 極限應(yīng)力幅:許用應(yīng)力幅:螺釘?shù)膹?qiáng)度校核:螺釘?shù)脑S用切應(yīng)力為 s=3.54 取s=4 得 滿足要求 經(jīng)校核: 滿足強(qiáng)度要求,夾具安全可靠總 結(jié)本次課程設(shè)計(jì)綜合了大學(xué)里所學(xué)的專業(yè)知識(shí),是理論與實(shí)際相結(jié)合的一次考驗(yàn)。通過這次設(shè)計(jì),我的綜合運(yùn)用知識(shí)的能力有了很大的提高,尤其是看圖,繪圖,設(shè)計(jì)能力為我今后的工作打下了良好的基礎(chǔ)。在此過程中,我進(jìn)一步加深了對(duì)課本知識(shí)的理解,進(jìn)一步了解了零件的工藝以及夾具設(shè)計(jì)過程。收獲頗豐。首先,我要感謝老師對(duì)畢業(yè)設(shè)計(jì)的指導(dǎo)。本次設(shè)計(jì)是在老師的悉心指導(dǎo)和幫助下完成的,我的機(jī)械工藝知識(shí)有限,在設(shè)計(jì)中常常碰到問題,是老師不厭其煩的指導(dǎo),不斷的點(diǎn)撥迷津,提供相關(guān)資料,才使設(shè)計(jì)順利完成。老師的耐心講解,使我如沐春風(fēng),不僅如此,老師嚴(yán)謹(jǐn)?shù)闹螌W(xué)態(tài)度和高尚的敬業(yè)情操深深打動(dòng)了我,在此,我向老師表示最真誠(chéng)的感謝。同時(shí),感謝同班同學(xué)的支持和幫助,使我更好的完成了畢業(yè)設(shè)計(jì)。我也非常感謝我的父母。在學(xué)習(xí)和生活上,他們一直都很支持我,使我能全身心地投入到學(xué)習(xí)中,在此,我想對(duì)我的父母說:你們辛苦了,我會(huì)盡最大的努力來讓你們過上最幸福的日子,請(qǐng)相信我。最后,很感謝閱讀這篇課程設(shè)計(jì)的人們。感謝你們抽出寶貴的時(shí)間來閱讀這篇課程設(shè)計(jì)。參考文獻(xiàn)1 張耀宸主編.機(jī)械加工工藝設(shè)計(jì)手冊(cè).北京:航空工業(yè)出版社,19892 肖繼德,陳寧平主編. 機(jī)床夾具設(shè)計(jì)(第2版). 北京:機(jī)械工業(yè)出版社20053 浦林祥主編.金屬切削機(jī)床夾具設(shè)計(jì)手冊(cè)(第2版).北京:機(jī)械工業(yè)出版社,19954 任嘉卉主編. 公差與配合手冊(cè).北京:機(jī)械工業(yè)出版社,19935東北工學(xué)院機(jī)械零件設(shè)計(jì)手冊(cè)編寫組 編. 機(jī)械零件設(shè)計(jì)手冊(cè).北京:冶金工業(yè)出版社,19836江南大學(xué)鄭修本主編. 機(jī)械制造工藝學(xué)(第二版).北京:機(jī)械工業(yè)出版社,19997上海理工大學(xué)陸劍中,孫家寧主編. 金屬切削原理與刀具(第4版).北京:機(jī)械工業(yè)出版社,20058劉力,王冰主編. 機(jī)械制圖(第二版).北京:高等教育出版社,20049陳于萍,高曉康編著. 互換性與測(cè)量技術(shù)(第二版).北京:高等教育出版社,200510張龍勛主編. 機(jī)械制造工藝學(xué)課程設(shè)計(jì)知道書及習(xí)題. 北京:機(jī)械工業(yè)出版社,199911孟憲棟,劉彤安主編. 機(jī)床夾具圖冊(cè).北京:機(jī)械工業(yè)出版社,199914江洪,酈祥林,李仲興編著. Solidworks2006基礎(chǔ)教程(第2版).北京:機(jī)械工業(yè)出版社,200629
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