拖拉機副變速撥叉工藝和銑夾具設計[3D-PROE]

【溫馨提示】壓縮包內含CAD圖有預覽點開可看。打包內容里dwg后綴的文件為CAD圖，可編輯，無水印，高清圖，壓縮包內文檔可直接點開預覽，需要原稿請自助充值下載，所見才能所得，請細心查看有疑問可以咨詢QQ：11970985或197216396 附錄DEVELOPMENT AND APPLICATION OF PLASTICS MOLDING CAD/CAM/CAE SYSTEMABSTRACT: this paper describes features of plastics molding CAD/CAM/CAE integrated system and process of applying the system to practice. Development and application of I-DEAS (integrated design engineering software) were performed in view of actual plastics molding. The results show that plastics molding CAD/CAM/CAE system is a practical and efficient technique which is worth spreading.KEY WORDS: plastics molding CAD/CAM/CAE； integrated； I-DEAS1. introductionPlastics molding is the main method of producing plastics product. It develops in high speed but its history is short. Plastics molding is also used extensively. According to the statistics, the quantity of plastics molding is about 28% of that of all molding, but the traditional design of plastics molding is low efficient, long periodic and wasteful. It contradicts with the development of plastics industry. With the development of technique in computer, numerical control and plastics fluid, plastics molding CAD/CAM/CAE has been applied extensively at present2. plastics Molding CAD/CAM/CAE system2.1 process of plastics molding CAD/CAM/CAEThe integration of CAD/CAM/CAE changes the traditional mode of producing molding. Fig.1 show the integrated process.In traditional design, it is required to produce actual solid molding to evaluate the appearance and test the function of product when the product construction is finished. By contrast, in CAD/CAM/CAE system, by using solid geometry modeling users can display the picture of product vividly on graphic terminal, evaluate the appearance and modeling technology through observing the screen, and need not produce actual solid modeling. By using finite Fig1 process of plastics molding CAD/CAM/CAEElement method analysis software, users can also test the mechanical functions of product. The main feature of CAD/CAM system is the generation of a common database which is used for all design and manufacturing activities, so another function of geometry modeling is to provide geometry data for the families of plastics analysis and graphic numerical control, hence the redundant data is avoided, and the efficiency and prevision are improved. Three dimensional geometry solids can also be converted into two dimensional engineering drawing, so designer would be relaxed from drafting and calculating, concentrated on creative work.When finishing the preliminary design, users could check the molding technology and the extent of molding construction by using CAE software, that is to say, users should simulate the process of plastics injection before the molding is manufactured. Through the analysis of CAE software, all kinds of results are gotten in each phase of plastics injection, such as temperature, pressure, stress, filling time, cooling time, warp age and shrinkage, etc. these results are also shown with abundant modes of post process. Users can perform a quantitative or qualitative analysis. If there are some problem, the design could be correct in computer. the interaction is operated between CAD and CAE until the reasonable results are gotten. Not as the traditional process, the molding would be modified when it has been manufactured if something is wrong, so process period i shorten dramatically, and efficiency and prevision are improved. When injecting simulation is finished, if the results are reasonable, it shows the design is applicable. The next step is to finish detail design and manufacturing technology, prepare to manufacture.Recently, the technique of numerical control (NC) makes a great progress. The automatically programmed tool (APT) appeared in 1960s promoted the development of NC technology dramatically. APT is also used widely at present, but it also has some defects, such as low efficiency, etc. at present, the development orientation of NC is to merge CAD and CAM into an organic whole, so CAD/CAM is a unified software system, in which the CAD portion is interfaced inside the computer with the CAM system. Therefore the track of cutting tool is created with the mode of man-machine interaction by using the geometry data fully which is created in the phase of CAD. Now a new programming technique has been come into usinggraphic numerical control (GNC) based on graphic. In the system, cutting tool, workpiece and fixture are displayed on computer screen by generating animation, so the track of tool is optimum and safety. In sum, GNC system is very efficient and convenient.2.2 application of I-DEAS software in practiceOur advanced manufacturing technology center (AMMTEC) of harbin institute of technology makes an effort to develop integrated system of CAD/CAM/CAE. AMTEC was founded in 1992. it imported many NC machines and large style engineering software IDEAS (integrated-design engineering analysis software) with which equips IBM-RISC 6000 work station, so we have the condition to apply plastics molding CAD/CAM/CAE system to design, analysis and manufacturing of plastics molding .I-DEAS is a type of synthetically automatic software. It integrates the functions of design, drawing, engineering analysis, digital simulation of plastics molding, numerical control programming and test. The families of geometry modeling, plastics analysis and graphic numerical control constitute a plastics molding CAD/CAM/CAE system. We would design and manufacture a set of molding which produces the plastic pedal of “jetta” car (product material is nylon-66) for the first Automobile Work of city of changchun. It is difficulty to design and manufacture the molding because the shape of pedal is very complicated, so we decided to apply the families of I-DEAS to design, analysis and NC programming.I-DEAS solid modeling is an important component of I-DEAS. It supplies a set of functional tool for geometry modeling and detail mechanical design. The method of solid modeling is constructive solid geometry (CSG). The steps are in following:(1) creating basic elements, such as cubic, cylinder, sphere, etc.(2) disposing the basic elements by using Boolean operation. So the complicated geometry can be created.Using these steps, the three dimensional geometry modeling of pedal can be created. computer graphics enable the designer to study the object by rotating it on screen, enlarging a specific portion of the object to observe it in detail.Finishing the preliminary design of molding, we can perform an injecting simulation to evaluate the design by using the family of plastics analysis which uses finite element method. I-DEAS provides three methods of creating the geometry shape of finite element.from the family of solid modeling.From the family of itself.From other CAD system.Because the product modeling has been created in the family of solid modeling, we can use the first method to avoid reconstructing. After selecting elements, creating elements, creating mesh and checking modeling, we can create the finite element model used to perform plastics analysis.In this design, it is difficulty to decide where to set the gate. we can see that the pedal is slender. According to common concepts, the gate should be set in the middle of product. Welding line would come into being if this design is adopted. Therefore mechanical strength of product will be reduced. In practice using, the middle of product would bear heavy force, so it is not safety to set the gate in the middle of product. Finally we set the gate at the top of product to ensure the mechanical functions of product. In this design the fluid orientation would be consistent in the molding, and the mechanical function could be ensured, but the temperature of tip fluid will drop much more because of the long route of flowing, the fluidity of fluid becomes bad. It is necessary to raise the pressure of entrance to fill the impression, but the raising is limited in certain range, so it is possible that the impression could not be filled fully. When we simulated the process of injection, the initial result was always unreasonable that the pressures of impression exceed that of injecting jet supplying. after analyzing, we modified the injection parameters. The temperature of molding and plastics fluid are raised so that the fluidity of fluid became good. Though the correcting, the results are very satisfied. The filling time is shown is Fig.3. we can see that the filling time is 4.81 second at which is the furthest from the gate. The pressure and temperature of analysis results are also in normal range. In actual molding, we adopted corresponding steps according to the analysis results, so the qualified products were produced.DEAS GNC is a new kind of NC programming tool based on graphic. GNC system has the function of creating and operating of complicated surface elements. We could also use the method as same as that is used in plastics analysis, namely, the geometry model was gotten from the family of solid geometry modeling. Thereafter we use a set of describing instructions to define the machining process and parameter, such as cutting tool, manufacturing orientation and step, etc. the system would display the manufacturing process. At the same time the cutter location (CL) file comes into being which includes all manufacturing information but cannot be discriminated by NC machine directly, so the post-process is necessary. The post-process of GNC is different from that of normal. Normal post-process user the special principle. At present, with the rapid developing of NC technology, the number of NC system become more and more. It couldnt meet the present needs that post-process is only consistent to special machines. GNC system uses the common principle. It supplies a functional tooltext macro processor (TMP) with which user can program post-process procedure suit for all kinds of machine easily. According to the specialty of manufacturing molding and the FANUC 11system that we own, we programmed the post-process procedure of three axes that is used to operate the standard cutting location file. The result is the ISO machining codes which can be directly fed into the control computer of CNC machines, and the effect of actual machining is very good.3. conclusions(1) the integration of CAD/CAM/CAE changes the traditional production of plastics molding. User can modify and optimize the product, molding and manufacturing at the aid of computer. The efficiency is improved and the error is cut.(2) by adopting the technique of CAD/CAM/CAE, the period of design and manufacturing of molding is shorten dramatically. The cost is cut and the quality of product is improved.(3) I-DEAS software is a CAD/CAM/CAE software system including geometry modeling, plastics analysis and graphic numerical control whose function are strong and practical value is high. ReferencesLi Dequn and Xiao Jinrong. CAD technology of plastics injection molding, Molding industry. 1989.NO.12Yoram Koren computer control of manufacturing systems. McGraw-Hill Book company 1983Ulrich Rembold. Computer integrated manufacturing technology and system. Marcel dekker inc,1984 CAD/CAM/CAE系統(tǒng)得發(fā)展和應用摘要：本章主要講述塑料制品成型CAD/CAM/CAE綜合系統(tǒng)的特點和他在實際生產系統(tǒng)中的應用。I-DEAS（綜合工程設計軟件）的發(fā)展和應用是綜合考慮了塑料制品成型的現狀。結果表明塑料制品成型CAD/CAM/CAE系統(tǒng)是一個值得推廣的實用有效的技術。關鍵字：塑料制品CAD/CAM/CAE； 綜合； I-DEAS緒論塑料制品成型是生產塑料制品的主要方法，他的發(fā)展很快但是歷史卻不長。塑料制品成型的應用也是很廣闊的。據統(tǒng)計：在所有的成型中塑料制品成型的數量占28% 但是傳統(tǒng)的塑料制品設計的效率很低，周期長而且很浪費。這與目前計算機技術，數控 ，和流體塑料，塑料制品成型CAD/CAM/CAE綜合系統(tǒng)廣泛應用的塑料工業(yè)的發(fā)展相矛盾。 塑料制品成型CAD/CAM/CAE系統(tǒng)2.1 塑料制品成型CAD/CAM/CAE系統(tǒng)的過程。CAD/CAM/CAE的集成改變了傳統(tǒng)生產成型的方法。圖1表示了完整的過程。在傳統(tǒng)的設計中， 要求對產品實際的整體模作出外觀的評價并且當產品構建完成以后進行功能的測試，在CAD/CAM/CAE系統(tǒng)中，通過幾何建模的方法，用戶可以在繪圖終端上做出產品的生動圖片。通過圖形來評估外形和形體的工藝性，而不需要生產出實際的產品。通過有限元軟件的分析，用戶可以測試產品的機械性能。CAD/CAM/CAE系統(tǒng)得主要特點是有一個能夠用于設計和制造活動的通用數據庫。因此幾何建模的另一個功能就是為外形分析和圖形數字控制家族提供數據基礎。因而避免了多余的數據，而且提高了效率和預見力，三維的幾何實體也可以被畫成二維的工程圖。因此設計者可以減輕起草和計算的工作，而把精力放在創(chuàng)新設計上面。當完成初步設計時，用戶能檢查成型的技術和通過使用CAE軟件檢查成型變形的范圍， 那就是說，在模型被生產之前，用戶應該模擬塑料注射的過程。 通過CAE軟件的分析， 各種結果進入到塑料制品注射的每階段， 例如溫度，壓力，形變，填飽時間，冷卻時間，變形時間和收縮過程等等，這些結果也被后置處理以豐富的模式顯示出來。圖1 可塑性成型工藝過程CAD/CAM/CAE如果這里存在問題，設計就可以在電腦上修改。CAD和CAE之間的交互作用一直持續(xù)到得出合理的結果。不同于傳統(tǒng)的過程， 模型被制造出來后如果有錯誤才進行修改，因此處理時間被急劇縮短，并且效率和預見力被提高。 當注入模擬被完成時，如果結果是合理的，它表明設計是適用的。 下一步是完成詳細設計和生產技術，準備生產。最近，數控(NC)技術取得大的進步。 大大的促進NC 技術的發(fā)展，自動編程的工具(ATP) 在20世紀60年代出現。 ATP目前也被廣泛的使用， 但是它也有一些缺陷， 例如效率低， 等等。目前， NC的發(fā)展定向是把計算機輔助設計和計算機輔助制造合并成有機的整體， 使其成為一個統(tǒng)一的軟件系統(tǒng)，其中計算機輔助設計部分在計算機中與計算機輔助制造系統(tǒng)形成內部聯(lián)系。 因此切割工具的軌跡通過使用人機交互的方式被計算機輔助設計階段過程中創(chuàng)造的幾何學數據創(chuàng)建。 現在，一種新的編程技術開始使用基于圖表的圖表數值控制(GNC)。 在系統(tǒng)內，切割工具，工件和固定設備通過產生生動的動畫顯示在計算機屏幕上，因此工具的軌跡是最佳的和安全的。 總之，GNC系統(tǒng)非常便利和有效。 I-DEAS軟件在實際中的應用哈爾濱工業(yè)大學的先進生產技術中心(AMMTEC) 努力開發(fā)CAD/CAM/CAE的綜合系統(tǒng)。 AMTEC在1992年建立。 它進口很多數控機器和大風格的工程軟件想用其(綜合設計工程分析軟件)裝備IBM -RISC6000工作站， 我們有條件使用塑料制品成型CAD/CAM/ CAE系統(tǒng)來設計，分析和制造塑料制品。DEAS 是一種綜合的自動機械軟件。 它將設計，開發(fā)，工程分析，塑料制品的數學仿真，數字控制程序的數字模擬功能和測試集于一體。由幾何建模，可塑性分析和圖表數值控制庫形成塑造塑料制品的CAD/CAM/CAE系統(tǒng)。 我們將設計和生產一套產品， 為長春第一汽車工作生產jetta 小汽車(產品材料是尼龍-66)的塑料踏板。 因為踏板的形狀錯綜復雜所以設計和制造模型是困難得， 因此我們決定對設計，分析和NC編程使用I-DEAS。I-DEAS固定模型是I-DEAS重要的零部件。 它為幾何建模和詳細機械設計提供一套功能強大的工具。實體幾何學模型(CSG)的建立方法是有建設性的。 她的過程如下：基本元素，例如體，腔，球，等等。通過使用一元布爾運算安排基本要素。 因此可能建立錯綜復雜的幾何體。 使用這些步驟，踏板的三維幾何學模型可能被建立。計算機圖形使設計者能夠通過在屏幕上旋轉對象而研究它，放大物體的細節(jié)而詳細觀察它。完成塑造的初步設計， 我們能進行一次注入的模擬通過使用有限元法的可塑性分析的家庭評價設計。I-DEAS提供創(chuàng)建有限元的幾何學形狀的3 種方法。(1)從固定模型庫創(chuàng)建。(2)從庫自行創(chuàng)建。 (3)從其他計算機輔助設計系統(tǒng)創(chuàng)建。因為產品模型化已經創(chuàng)建在固態(tài)模型的庫里，我們能使用這種優(yōu)先的方法避免重建。 在選擇要素，建立要素，建立澆口并且檢查模型之后，我們能創(chuàng)建用來進行可塑性分析的有限元模型。 在這種設計過程中，決定在哪里確定澆口是困難。我們能看見這塊踏板是細長的。 根據普通概念，澆口應該在產品的中間確定。 如果這種設計被采用，焊接線將形成。因此產品的機械力量將被降低。在實際使用中，產品中間將承擔很重的力，因此在產品的中間確定澆口是不安全。 最后我們在產品頂上確定澆口保證產品的機械功能。 在這種設計過程中流動的方向將在塑造過程中一致， 并且機械性能可能得到保證， 但是因為流動的路線很長使流體的溫度下降的很多，流體的流動性將變壞。 因此提高入口的壓力充滿型腔是必要的，但是提高在一定范圍內受限制，因此型腔不能被完全充滿是可能的。 當我們模擬注射的過程時，最初結果總不合理：即型腔的壓力超過注入噴射提供的壓力。在分析之后，我們修改注射參數。 注射的溫度和塑料流動性被提高，因此流體的流動性變好。 通過修改，結果非常令人滿意。我們看見從澆口到最遠的流動時間是4.81秒。 分析結果的壓力和溫度也在正常范圍里。 在實際塑造過程中，我們根據分析結果采用相應步驟，因此合格的產品被生產出來。I-DEASGNC是一種新的基于圖表的數控編程工具。 GNC系統(tǒng)有建立和操作復雜表面要素的函數的功能。 我們也能使用在可塑性分析過程中使用的同一事物的方法 即：幾何學模型從立體幾何學模型化庫里得到。 此后我們使用一套詳細的參考書確定機器加工的過程和參數， 像切割工具，生產方向和生產步驟等等，系統(tǒng)將展示生產過程。 同時，產生包括全部生產信息但是不能被NC機器直接區(qū)別的刀具坐標文件， 因此后置處理是必要的。GNC的后置處理不同于正常得后置處理。 正常的后置處理使用特別的原則。 目前，隨著NC 技術的迅速發(fā)展， NC系統(tǒng)的數量變得越來越多。傳統(tǒng)后置處理只適用于專用機床，這不能滿足目前的需要。 GNC 體制使用普遍原則。 通過職能工具文本宏觀處理器(TMP)，用戶能輕易的安排適合各種機器用行的程序。 根據生產成型和我們擁有的FANUC系統(tǒng)的特點， 我們編制3軸的后置處理程序用來確定刀具標準切削位置文件。 結果作為標準ISO代碼被直接反饋到數控機床的計算機上， 并且實際機器加工的效果非常好。結論(1)CAD/CAM/CAE的綜合改變了傳統(tǒng)生產塑料制品的方法。 用戶能利用計算機修改并且優(yōu)化這種產品的造型和生產。 從而提高了效率，減少了錯誤。 (2)通過采用CAD/CAM/CAE，設計和生產模型的時間被急劇的縮短。 費用也減少了，產品的質量得到改進。 (3)I-DEAS軟件是包括幾何學模型化的CAD/CAM/CAE軟件系統(tǒng)， 包括可塑性分析和圖表數值控制，功能強大而且實際使用價值很高。引用1. 李德清 肖景榮。 塑料注入成型的計算機輔助設計技術，塑造工業(yè)。 1989年第十二期。 2. 科倫計算機控制制造系統(tǒng)。麥格勞-希爾伯克公司 1983年3. 烏爾里-克萊伯 計算機集成制造技術和系統(tǒng)。 馬賽洛德克有限公司， 1984年。第9頁哈爾濱理工大學機 械 加 工 工 藝 卡 片產品型號及名稱零件名稱撥 叉工序號2工序名稱鉆擴內孔至材料名稱HT200硬度毛坯種類鑄造毛坯毛坯重量零件凈重冷卻液柴油技 術 要 求保證孔的尺寸為保證表面粗糙度為1.6工步號工 步 內 容機 床夾具或輔具刀 具量 具T基T輔1鉆軸孔至Z535專用鉆模麻花鉆塞規(guī)7.20.183981.552鉸軸孔至Z535專用鉆模YT15鉸刀塞規(guī)7.20.31601.33班級機械-6班設計何悅審 核指導第 頁共 頁哈爾濱理工大學機 械 加 工 工 藝 卡 片產品型號及名稱零件名稱撥 叉工序號2工序名稱銑左右端面材料名稱HT200硬度毛坯種類鑄造毛坯毛坯重量零件凈重冷卻液柴油技 術 要 求保證孔的尺寸為保證表面粗糙度為1.6工步號工 步 內 容機 床夾具或輔具刀 具量 具T基T輔1銑左端面至53.5X51專用夾具三面刃銑刀卡尺20.251800.712銑右端面至51.5X51專用夾具三面刃銑刀卡尺20.251910.753班級機械-6班設計何悅審 核指導第 頁共 頁哈爾濱理工大學機 械 加 工 工 藝 卡 片產品型號及名稱零件名稱撥 叉工序號6工序名稱銑叉腳內側面材料名稱HT200硬度毛坯種類鑄造毛坯毛坯重量零件凈重冷卻液柴油技 術 要 求保證叉腳兩側面的精度工步號工 步 內 容機 床夾具或輔具刀 具量 具T基T輔1粗銑X62專用夾具硬質合金銑刀卡尺20.253060.7123班級機械-6班設計何悅審 核指導第 頁共 頁