支承座工藝及夾具設(shè)計(jì)【含9張CAD圖紙、說(shuō)明書】
資源目錄里展示的全都有,所見(jiàn)即所得。下載后全都有,請(qǐng)放心下載。原稿可自行編輯修改=【QQ:401339828 或11970985 有疑問(wèn)可加】
目 錄
摘要··········································································································································Ⅰ
Abstract·····································································································································Ⅱ
緒論············································································································································1
1工藝工裝設(shè)計(jì)任務(wù)·················································································································2
2零件的技術(shù)要求分析·············································································································3
2.1 零件的材料分析·············································································································3
2.2 零件的形狀及尺寸分析·································································································3
2.3 零件的工藝性要求·········································································································4
3零件毛坯選擇及毛坯圖設(shè)計(jì)·································································································5
3.1 確定毛坯的類型及制造方法·························································································5
3.2 確定毛坯形狀、尺寸及公差·························································································5
4機(jī)械加工工藝規(guī)程的制定·····································································································8
4.1 主要加工表面定位基準(zhǔn)的選擇·····················································································8
4.1.1精基準(zhǔn)的選擇···············································································································8
4.1.2粗基準(zhǔn)的選擇···············································································································9
4.2擬定機(jī)械加工工藝路線··································································································9
4.2.1 確定各加工表面的加工方法······················································································9
4.2.2 擬定加工工藝路線·····································································································10
4.2.3 工藝路線分析比較·····································································································12
4.3確定機(jī)械加工工序余量、工序尺寸及表面粗糙度·······················································12
4.3.1 底面·····························································································································13
4.3.2 上端面·························································································································13
4.3.3 中心圓孔·····················································································································13
4.3.4 孔4×Φ26mm···············································································································14
4.4選擇機(jī)械加工設(shè)備及工藝裝備·····················································································14
4.5確定工序的切削用量及基本工時(shí)·················································································14
4.5.1粗銑底面,精銑底面····································································································14
4.5.2粗銑上端面,半精銑上端面························································································17
4.5.3鏜ф52中心孔············································································································19
4.5.4銑側(cè)表面·····················································································································20
4.5.5鉆、擴(kuò)、鉸Φ26孔····································································································22
4.5.6插削80×80方孔·········································································································23
4.5.7鏜ф52側(cè)孔·················································································································23
5夾具設(shè)計(jì)·······························································································································25
5.1夾具總體方案的確定····································································································25
5.1.1定位方案及定位元件的選擇·····················································································25
5.1.2夾緊方案及夾緊元件的選擇·····················································································25
5.1.3夾緊力的計(jì)算·············································································································27
5.1.4夾具的安裝及對(duì)刀方案的選擇和設(shè)計(jì)·····································································27
5.1.5夾具體的結(jié)構(gòu)和尺寸的確定·····················································································28
5.2繪制夾具裝配圖············································································································28
結(jié)論··········································································································································29
致謝··········································································································································30
參考文獻(xiàn)··································································································································31
摘 要
本文主要介紹了支承座工藝工裝的設(shè)計(jì),全文共分為工藝部分和工裝部分這兩大部分來(lái)闡述所設(shè)計(jì)的支承座的設(shè)計(jì)方法和工作原理。
工藝部分主要是對(duì)零件的材料性能、形狀及尺寸和工藝性的分析,從而確定毛坯類型和制造方法,按照所確定的毛坯尺寸和公差來(lái)確定機(jī)械加工工藝規(guī)程。在工藝設(shè)計(jì)過(guò)程中,最大的難點(diǎn)是定位基準(zhǔn)的選擇和機(jī)械加工工藝路線的確定。通過(guò)確定機(jī)械加工工序余量、工序尺寸及表面粗糙度來(lái)選擇機(jī)械加工設(shè)備及工藝裝備。
工裝部分主要介紹了支承座專用夾具的設(shè)計(jì),在確定夾具總體設(shè)計(jì)方案時(shí),支承座專用夾具能否完成好工件的定位和夾緊達(dá)到所要求的技術(shù)要求顯得尤為重要。在確定定位方案、定位原件、夾緊方案、夾緊原件的時(shí)候,應(yīng)綜合考慮相關(guān)的影響因素和原則,從而完善夾具的設(shè)計(jì)。其中在確定夾緊力大小的時(shí)候,應(yīng)首先考慮夾緊力的方向和作用點(diǎn)。應(yīng)保證夾具夾緊力和軸向力方向一致,為防止工件在加工過(guò)程中產(chǎn)生振動(dòng)和轉(zhuǎn)動(dòng),采用鉤形壓板夾具夾緊工件,以防止工件轉(zhuǎn)動(dòng),在設(shè)計(jì)過(guò)程中應(yīng)當(dāng)考慮到側(cè)壁的定位和剛性能否達(dá)到技術(shù)要,并采用適當(dāng)?shù)姆绞絹?lái)解決這個(gè)問(wèn)題。
關(guān)鍵詞:工藝,夾具,定位,毛坯
Abstract
This paper mainly introduces the design of Bearing block technics and frock. The whole text is divided into technics part and frock part, which is to expound the design methods and working principle of the designed Bearing block.
Technics part mainly analyzes on the material properties, shape, size and technical capability. And then make sure the roughcast types and manufacturing methods, in accordance with the defined dimensions and tolerances to determine a point of order for machining process. In the process of technics design, the biggest difficulty are the selection for orientation benchmark and the confirmation on the route of processing technics. By confirming the margin and size of working procedure and surface roughness, people select mechanical processing facility and technics equipment.
Frock part mainly introduces the design of special clamp for Bearing block. In the process of confirming the rough design scheme of clamp, it is particularly important whether the special clamp can achive good positioning and clamping the workpiece to the required technical requirements. When determining the orientation program, positioning material, clamping program and clamping material, people should consider the impact of relevant factors and principles, consequently improving the design of clamp. In the process of determining the clamping force, people should consider the direction of clamping force and the acting point first. Should ensure that fixture clamping force and the axial force direction, in order to prevent the workpiece during processing produce vibration and rotation, the Hook clamp to preventing the workpiece rotation, during the design process should take into account the wall positioning and rigidity to achieve technology and adopt an appropriate way to solve this problem.
Key Words: technics,clamp,orientation,roughcast
緒 論
畢業(yè)設(shè)計(jì)是我們對(duì)大學(xué)所學(xué)各課程的一次綜合性的總復(fù)習(xí),同時(shí)也是一次理論聯(lián)系實(shí)踐的訓(xùn)練。通過(guò)大學(xué)的學(xué)習(xí)是實(shí)踐,我希望能在這次畢業(yè)設(shè)計(jì)能體現(xiàn)出所學(xué)所想;還能學(xué)習(xí)到更多更廣的知識(shí),鍛煉自己獨(dú)立分析問(wèn)題解決問(wèn)題的能力。
零件的工藝部分主要是通過(guò)對(duì)零件的材料,尺寸及形狀分析來(lái)選擇毛坯,從而來(lái)制定機(jī)械加工工藝規(guī)程。零件在工藝規(guī)程之后,就要按工藝規(guī)程順序進(jìn)行加工。在加工中除了需要機(jī)床、刀具、量具之外,成批生產(chǎn)時(shí)還要用機(jī)床夾具。它們是機(jī)床和工件之間的連接裝置,使工件相對(duì)于機(jī)床獲得正確的位置。機(jī)床夾具的好壞將直接影響工件加工表面的位置精度。通常把確定工件在機(jī)床上或夾具中占有正確位置的過(guò)程,稱為定位。當(dāng)工件定位后,為了避免在加工中受到切削力、重力等的作用而破壞定位,還應(yīng)該用一定的機(jī)構(gòu)或裝置將工件加以固定。使工件在加工過(guò)程中保持定位位置不變的操作,稱為夾緊。將工件定位、夾緊的過(guò)程稱為裝夾。工件裝夾是否正確、迅速、方便和可靠,將直接影響工件的加工質(zhì)量、生產(chǎn)效率、制造成本和操作安全。機(jī)床夾具在生產(chǎn)中應(yīng)用十分廣泛。 機(jī)床夾具的作用可歸納為以下幾個(gè)方面:保證加工精度、提高生產(chǎn)效率、減少勞動(dòng)強(qiáng)度 。機(jī)床夾具應(yīng)滿足的基本要求包括以下幾方面:保證加工精度、夾具的總體方案應(yīng)與年生產(chǎn)綱領(lǐng)相適應(yīng)、安全,方便,減輕勞動(dòng)強(qiáng)度、排屑順暢、夾具應(yīng)有良好的強(qiáng)度,剛度和結(jié)構(gòu)工藝性。
1 工藝工裝設(shè)計(jì)任務(wù)
支承座的工藝工裝設(shè)計(jì)可以培養(yǎng)學(xué)生正確的設(shè)計(jì)思想方法、嚴(yán)謹(jǐn)?shù)目茖W(xué)態(tài)度和良好的工作作風(fēng),樹立自信心;培養(yǎng)學(xué)生運(yùn)用所學(xué)的理論知識(shí)和技能解決實(shí)際問(wèn)題的能力及素質(zhì);培養(yǎng)學(xué)生獲取信息和綜合處理信息的能力,提高文字和語(yǔ)言表達(dá)能力。
安排加工工藝,安排工藝流程,并設(shè)計(jì)夾具。首先進(jìn)行有關(guān)資料的查詢,零件圖分析,填寫工藝卡片,進(jìn)行夾具的設(shè)計(jì),了解設(shè)計(jì)的任務(wù),熟練應(yīng)用機(jī)械設(shè)計(jì)制造基礎(chǔ)知識(shí)和電腦繪圖軟件。
本課題要求學(xué)生應(yīng)在校外短期調(diào)研的基礎(chǔ)上,在老師的指導(dǎo)下在校內(nèi)獨(dú)立完成,學(xué)生最終完成:計(jì)算機(jī)打印的設(shè)計(jì)圖紙總量A0四張以上、設(shè)計(jì)計(jì)算說(shuō)明書1.2萬(wàn)字以上。
2 零件的技術(shù)要求分析
2.1零件的材料性能分析
題目所給的零件為支承座,主要用于連接軸類零件的作用。故材料選用HT200 ,屬于鑄鐵,含碳量大于2.11%的鐵碳合金,力學(xué)性能比鋼差。但具有優(yōu)良的鑄造性、減震性、耐磨性等特點(diǎn),加之價(jià)格低廉,生產(chǎn)設(shè)備和工藝簡(jiǎn)單,其優(yōu)勢(shì)是鑄造性能優(yōu)異,最適合作為大型殼體類零件。
2.2零件的形狀及尺寸分析
支承座零件如圖所示,零件為一定位支撐座,有一長(zhǎng)320mm,寬180mm,高36mm的長(zhǎng)方形底座;中心為一突起圓柱,圓柱中心有一Ф52mm的圓孔及80x80mm的方孔;圓柱兩側(cè)分別有一條三角形筋板,加強(qiáng)工件的強(qiáng)度,延長(zhǎng)使用壽命。零件總長(zhǎng)320mm,總高156mm,總寬180mm。
圖2-1工件圖
圖2-2工件圖
2.3零件的工藝性要求
由于該零件結(jié)構(gòu)簡(jiǎn)單,表面粗糙度要不是非常的高,故在機(jī)械加工時(shí)采用普通銑削即可完成零件表面的加工,采用普通鏜床來(lái)完成對(duì)中心圓孔Ф52mm和圓柱體側(cè)面Ф52圓孔的加工。通過(guò)設(shè)計(jì)專用夾具來(lái)完成對(duì)4個(gè)Ф26mm通孔的加工。鑄件運(yùn)用自然時(shí)效處理,鑄件不得有氣孔,砂眼,縮孔等缺陷。
3 零件毛坯選擇及毛坯圖設(shè)計(jì)
3.1確定毛坯的類型及制造方法
零件材料為HT200,考慮到法蘭盤在運(yùn)動(dòng)過(guò)程中經(jīng)常承受變載荷與沖擊載荷的作用,并且零件年產(chǎn)量能夠達(dá)到20000件,已經(jīng)達(dá)到了大批量生產(chǎn)的水平,而且零件的輪廓尺寸并不大,故選用砂型機(jī)械造型鑄造的方法來(lái)完成毛坯的制造。這對(duì)于提高生產(chǎn)效率,保證加工質(zhì)量也能起到一定的好處。
3.2確定毛坯形狀、尺寸及公差
零件的中心孔精度高,因?yàn)橹行目滓鳛槎ㄎ豢?,還要與心軸配合使用,所以給中心孔的公差要小一些。在鏜削中心孔時(shí),為了節(jié)省加工時(shí)間與刀具的壽命,中心孔設(shè)計(jì)成為階梯孔,以便退刀。
該零件質(zhì)量約為25.09kg。由參考文獻(xiàn)《機(jī)械加工工藝人員手冊(cè)》可知,其生產(chǎn)類型為大批生產(chǎn),毛坯的鑄造方法選用砂型機(jī)器造型,又由于零件的內(nèi)腔孔要鑄出,故要放型芯。此外為消除系統(tǒng)參與應(yīng)力,鑄造后要安排時(shí)效處理。由參考文獻(xiàn)《實(shí)用機(jī)械制造工藝設(shè)計(jì)手冊(cè)》表2-3表2-4可知,該種鑄件的尺寸公差等級(jí)CT8~10級(jí),加工余量等級(jí)為G級(jí),取MA為10級(jí)。
各主要表面的加工余量等級(jí)如下表:
表1-1
加工表面
基本尺寸
加工等級(jí)
加工余量
說(shuō)明
底面
320
G
6
底面精加工
上表面
140
H
7
頂面降一級(jí)雙側(cè)加工
Ф52孔
Ф52
H
7
孔降一級(jí)雙側(cè)加工
圖3-1 支承座毛坯圖
圖3-2支承座毛坯圖
圖3-3支承座毛坯圖
4 機(jī)械加工工藝規(guī)程的制定
4.1主要加工表面定位基準(zhǔn)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,可以保證加工質(zhì)量,提高生產(chǎn)效率。如果基面選擇不當(dāng),就會(huì)在加工過(guò)程中問(wèn)題百出,造成工藝效果不好,嚴(yán)重的還會(huì)造成零件的大批量報(bào)廢,是生產(chǎn)無(wú)法繼續(xù)進(jìn)行,給企業(yè)帶來(lái)經(jīng)濟(jì)損失。
4.1.1精基準(zhǔn)的選擇
選擇精基準(zhǔn)時(shí),應(yīng)能保證加工精度和裝夾可靠方便,可按下列原則選取。
(1)基準(zhǔn)重合原則
采用設(shè)計(jì)基準(zhǔn)作為定位基準(zhǔn)稱為基準(zhǔn)重合。為避免基準(zhǔn)不重合而引起的基準(zhǔn)不重合誤差,保證加工精度應(yīng)遵循基準(zhǔn)重合原則。
(2)基準(zhǔn)統(tǒng)一原則
在工件的加工過(guò)程中盡可能地采用統(tǒng)一的定位基準(zhǔn),稱為基準(zhǔn)統(tǒng)一原則(也稱基準(zhǔn)單一原則或基準(zhǔn)不變?cè)瓌t)。
工件上往往有多個(gè)表面要加工,會(huì)有多個(gè)設(shè)計(jì)基準(zhǔn)。要遵循基準(zhǔn)重合原則,就會(huì)有較多定位基準(zhǔn),因而夾具種類也較多。為了減少夾具種類,簡(jiǎn)化夾具結(jié)構(gòu),可設(shè)法在工件上找到一組基準(zhǔn),或者在工件上專門設(shè)計(jì)一組定位面,用它們來(lái)定位加工工件上多個(gè)表面,遵循基準(zhǔn)統(tǒng)一原則。為滿足工藝需要,在工件上專門設(shè)計(jì)的定位面稱為輔助基準(zhǔn)。采用基準(zhǔn)統(tǒng)一原則時(shí),若統(tǒng)一的基準(zhǔn)面和設(shè)計(jì)基準(zhǔn)一致,則又符合基準(zhǔn)重合原則。此時(shí),既能獲得較高的精度,又能減少夾具的種類,這是最理想方案。
(3)自為基準(zhǔn)原則
當(dāng)某些表面精加工要求加工余量小而均勻時(shí),選擇加工表面本身作為定位基準(zhǔn)。遵循自為基準(zhǔn)原則時(shí),不能提高加工面的位置精度,只是提高加工面本身的精度。
(4)互為基準(zhǔn)原則
為了使加工面間有較高的位置精度,又為了使其加工余量小而均勻,可采用反復(fù)加工、互為基準(zhǔn)原則。
(5)保證工件定位準(zhǔn)確、夾緊可靠、操作方便的原則
所選精基準(zhǔn)應(yīng)能保證工件定位準(zhǔn)確、穩(wěn)定、夾緊可靠。精基準(zhǔn)應(yīng)該是精度較高、表面粗糙度值最小、支撐面積較大的表面。當(dāng)用夾具裝夾時(shí),選擇的精基準(zhǔn)面還應(yīng)使夾具結(jié)構(gòu)簡(jiǎn)單、操作方便
4.1.2粗基準(zhǔn)的選擇
在機(jī)械加工的起始工序中,一開(kāi)始選擇的基準(zhǔn),必然是粗基準(zhǔn)。由于毛坯表面比較粗糙,各表面之間的位置精度較低,就構(gòu)成了粗基準(zhǔn)選擇的特殊性。為了合理的選擇粗基準(zhǔn),一般應(yīng)遵循以下原則。
(1)當(dāng)零件上有一些表面不需要進(jìn)行機(jī)械加工,且不加工表面與加工表面之間具有一定的相互位置精度要求時(shí),應(yīng)以不加工表面中與加工表面相互位置精度要求較高的不加工表面作為粗基準(zhǔn)。
(2)當(dāng)零件上有較多的表面需要加工時(shí),粗基準(zhǔn)的選擇,應(yīng)有利于個(gè)加工表面均能獲得合理的加工余量。
(3)粗基準(zhǔn)的選擇,應(yīng)盡可能使加工表面的金屬切除量總和最小。
當(dāng)以粗基準(zhǔn)定位加工一些表面時(shí),在加工出來(lái)的表面中,應(yīng)有一些表面便于作為后續(xù)加工的精基準(zhǔn)。
分析該零件,該零件符合粗基準(zhǔn)選擇原則,即當(dāng)零件有不加工表面時(shí)應(yīng)以與加工表面要求相對(duì)位置精度要求較高的不加工表面作為粗基準(zhǔn),現(xiàn)選取工件底座的上表面為粗基準(zhǔn),利用專用夾具以工件底座的上表面兩側(cè)作為定位表面以消除Y方向的移動(dòng),利用條形V型塊以Ф140中心圓柱體夾緊定位消除X,Z方向自由度,兩夾具共同作用,限制了X、Y、Z的轉(zhuǎn)動(dòng)。
4.2擬定機(jī)械加工工藝路線
4.2.1確定各加工表面的加工方法
工藝路線的擬定是工藝規(guī)程制定過(guò)程中的關(guān)鍵階段,是工藝規(guī)程指定的總體設(shè)計(jì)。所擬定的工藝路線是合理與否,不但影響加工質(zhì)量和生產(chǎn)效率,而且影響到工人,設(shè)備,工藝裝備及生產(chǎn)場(chǎng)地等的合理利用,從而影響生產(chǎn)成本。因此,工藝路線的擬定應(yīng)在仔細(xì)分析零件圖,合理確定毛坯的基礎(chǔ)上,結(jié)合具體的生產(chǎn)類型和生產(chǎn)條件,并依據(jù)下面所述的一般性原則來(lái)進(jìn)行,其主要工作包括各加工表面加工方法與加工方案的選擇,工序集中與分散程度的確定,工序順序的安排,定位與夾緊方案的確定等內(nèi)容。設(shè)計(jì)時(shí)一般提出幾種方案,通過(guò)分析對(duì)比,從中選擇最佳方案。
在選擇加工表面的加工方法和加工方案的時(shí)候,應(yīng)綜合考慮下列因素:
(1)加工表面的技術(shù)要求
(2)工件材料的性質(zhì)
(3)工件的形狀和尺寸
(4)生產(chǎn)類型
(5)具體生產(chǎn)條件
(6)特殊要求
綜合上訴因素,分析該零件。支承座的結(jié)構(gòu)對(duì)稱,精度要求不高。需要銑削上下平面,下平面作為定位,特別需要精銑;還需要鏜削Ф52的中心孔和側(cè)孔;由于對(duì)四個(gè)Ф26孔的表面粗糙度要求不高,采用鉆四個(gè)Ф26孔;中間的方孔需要普通插床插削;為使零件的幾何形狀,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)已確定為大批量生產(chǎn)的條件下,可采用組合鉆床配以專用夾具,并盡量使工序集中來(lái)提高生產(chǎn)率,除此以外還應(yīng)考慮經(jīng)濟(jì)效果,以便降低生產(chǎn)成本。
4.2.2擬定加工工藝路線
分析零件圖,依據(jù)各個(gè)表面加工要求精度形位公差配合關(guān)系以及技術(shù)要求,還有各種加工方法能達(dá)到的經(jīng)濟(jì)精度,以及基準(zhǔn)的合理選擇確定了以下兩種工藝路線方案:
工藝路線方案一:
工序Ⅰ:對(duì)毛坯進(jìn)行砂型鑄造
工序Ⅱ:自然時(shí)效
工序Ⅲ:噴砂,上漆
工序Ⅳ:銑削工件的下表面
工步一:粗銑工件下表面
工步二:精銑工件下表面
工步三:精銑工件下表面
工序Ⅴ:銑工件上端面
工步一:粗銑工件上端面
工步二:半精銑工件上端面
工序Ⅵ:鏜削Ф52中心孔,
工步一:粗鏜Ф52孔
工步二:半精鏜Ф52孔
工步三:精鏜Ф52孔
工序Ⅶ:鏜削加工Ф52的側(cè)孔
工序Ⅷ:鉆四個(gè)Ф26的孔
工步一:鉆四個(gè)Ф26的孔
工步二:擴(kuò)四個(gè)其中一個(gè)Ф26的孔
工步三:繼續(xù)鉸孔擴(kuò)后的Ф26的孔
工序Ⅸ:插削80X80的方孔
工序Ⅹ:去毛邊
工序ⅩⅢ:終檢
工藝路線方案二:
工序Ⅰ:對(duì)毛坯進(jìn)行砂型鑄造
工序Ⅱ:自然時(shí)效
工序Ⅲ:噴砂,上漆
工序Ⅳ:銑削工件的下表面
工步一:粗銑工件下表面
工步二:精銑工件下表面
工步三:精銑工件下表面
工序Ⅴ:銑工件上端面
工步一:粗銑工件上端面
工步二:半精銑工件上端面
工序Ⅵ:鏜削Ф52中心孔,
工步一:粗鏜Ф52孔
工步二:半精鏜Ф52孔
工步三:精鏜Ф52孔
工序Ⅶ:銑削工件的側(cè)表面,用以定位
工序Ⅷ:鉆四個(gè)Ф26的孔
工步一:鉆四個(gè)Ф26的孔
工步二:擴(kuò)四個(gè)Ф26的孔其中一個(gè)
工步三:繼續(xù)鉸四個(gè)Ф26的孔其中一個(gè)
工序Ⅸ:插削80X80的方孔
工序Ⅹ:鏜削加工Ф52的側(cè)孔
工序ⅩⅢ:去毛邊
工序ⅪⅤ:終檢
4.2.3工藝路線分析比較
工藝路線方案一,采用工序集中原則組織工序,鏜孔加工集中、鉆四個(gè)Ф26孔在組合機(jī)床上加工,易于保證加工面的相互位置,縮短工藝路線減少裝夾次數(shù),提高自動(dòng)化生產(chǎn)和生產(chǎn)效率;但是由于本零件形狀不規(guī)則,結(jié)構(gòu)復(fù)雜,夾具定位、夾緊不易實(shí)現(xiàn)。工藝方案二,按工序分散原則,各間的銑削到專用夾具上加工,提高加工精度,減少裝夾時(shí)間,提高勞動(dòng)生產(chǎn)率和經(jīng)濟(jì)效益,孔加工放在組合機(jī)床上加工,易保證兩孔軸線的平行度及位置精度,減少輔助時(shí)間和終結(jié)時(shí)間,減少工件在工序之間的傳輸和裝夾次數(shù)。由于本零件形狀不規(guī)則,加工面分散,而且生產(chǎn)綱領(lǐng)為大批生產(chǎn),可采用組合機(jī)床加工,可以采用專用夾具,減少裝夾次數(shù),提高自動(dòng)化生產(chǎn)和生產(chǎn)效率。綜合上述兩個(gè)工藝方案的優(yōu)缺點(diǎn),選擇工藝方案二較合適。
4.3確定機(jī)械加工工序余量、工序尺寸及表面粗糙度
支承座材料為HT200,硬度為156~197HBS,毛坯質(zhì)量約為25.09kg,生產(chǎn)類型為大批生產(chǎn),采用砂型機(jī)械造型鑄造。查《機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)》表2.2-5,毛坯鑄造精度等級(jí)取10G,
根據(jù)上述資料確定各加工余量,工序尺寸及表面粗糙度如下
表1-2
序號(hào)
工序內(nèi)容
加工余量
基本尺寸
表面粗糙度Ra
1
粗銑下底面
2
320
3.2
2
精銑下底面
0.25
320
1.6
3
粗銑上端面
3
R140
3.2
4
半精銑上端面
1.2
R140
1.6
5
粗鏜Ф52中心孔
2
R52
6.3
6
半精鏜Ф52中心孔
1.5
R52
3.2
7
精鏜Ф52中心孔
0.8
R52
1.6
8
銑側(cè)面
1.2
40
3.2
9
插80×80方孔
80
3.2
10
粗鏜加工Ф52側(cè)孔
2
R52
6.3
11
半精鏜Ф52側(cè)孔
1.5
R52
3.2
4.3.1底面
(1)毛坯:421mm
(2)粗銑底面:370.1mm Z=5mm
(3)精銑底面:36mm Z=1mm
4.3.2上端面
(1)毛坯:1631mm
(2)粗銑上端面:1550.1mm 2Z=8mm
(3)半精銑上端面:156mm Z=1.2mm
4.3.3中心圓孔
查《機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)》表2.2—1至2.2—4,加工余量4mm,所以其孔毛坯名義直徑為Φ381mm。參照《機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)》2.3—8至2.3—12,確定各工序尺寸及余量為:
(1)毛坯: Φ381mm
(2)粗鏜: Φ50mm 2Z=12mm
(3)半精鏜:Φ51mm Z=1.5mm
(4)精鏜: Φ52±0.04mm Z=0.8mm
4.3.4 孔4×Φ26mm
(1)鉆: Φ25 2Z=15mm
(2)擴(kuò)鉆:Φ25.8 2Z=1.8mm
(3)絞: Φ26 Z=0.2mm
4.4選擇機(jī)械加工設(shè)備及工藝裝備
在選擇機(jī)械加工設(shè)備及工藝裝備的時(shí)候,我們主要應(yīng)該考慮所選擇的設(shè)備能夠完成此次機(jī)械加工的技術(shù)要求,例如:能夠保證加工出來(lái)的產(chǎn)品達(dá)到所規(guī)定的尺寸精度,位置精度,表面粗糙度等要求。根據(jù)4.3中我們所確定的加工方法和步驟及應(yīng)該達(dá)到的技術(shù)要求,我們將選用X5032立式升降臺(tái)銑床,T6111臥式銑鏜床,組合鉆床以及鉗臺(tái),再配以銑刀、鉆頭、鉸刀、鏜刀、卡尺、專用檢具、銑夾具、鉆夾具、專用夾具等工具來(lái)完成此次機(jī)械加工任務(wù)。
4.5確定工序的切削用量及基本工時(shí)
4.5.1 粗銑底面,精銑底面
(1)選擇刀具
鑲齒套式面銑刀 直徑d = 160mm Z = 16 參照《金屬切削手冊(cè)》第二版
(2)確定切削用量
由于表面粗糙度為3.2,我們采用粗、精加工 經(jīng)查表可知,單邊余量為6mm,這里取粗銑加工余量為5mm
確定切削深度 可走刀一次完成:粗銑= 5mm 精銑=0.8mm
參照《金屬切削手冊(cè)》第二版 表9—12
確定進(jìn)給量f :粗銑fz = 0.20 mm/z 精銑fz = 0.05mm/r
(3)確定切削速度Vc
由《金屬切削手冊(cè)》第二版表9—14可知
粗銑時(shí)Vc = 39.2m/min 精銑Vc = 20m/min
由公式 …………………………………………..(4.1)
則n粗銑 = 78.03 r/min n精銑= 39.8r/min
由《機(jī)械加工工藝手冊(cè)》表4—16—1可知
標(biāo)準(zhǔn)轉(zhuǎn)數(shù)可取 n粗銑 = 80r/min
由《機(jī)械加工工藝手冊(cè)》 表4—16—1
標(biāo)準(zhǔn)轉(zhuǎn)數(shù)可取 n精銑 = 40 r/min
(4)選擇銑刀壽命
根據(jù)《機(jī)械加工工藝手冊(cè)》第一卷表9.4—7
T = 180T/min
(5)銑削力功率計(jì)算
由《機(jī)械加工工藝手冊(cè)》 表3—25可知
……………………(4.2)
— 銑削寬度
— 銑削力系數(shù)
— 每齒進(jìn)給量
— 銑刀半徑
— 銑削深度
— 齒數(shù)
由表3—25可知精銑切削力功率計(jì)算因素:
= 50 = 96 = 0.05 = 80 = 0.8 = 16
則 = 1042N
(6)校核機(jī)床功率(一般不校核粗加工工序)
由《機(jī)械加工工藝手冊(cè)》表3—25可知修正系數(shù)
則實(shí)際的圓周切削力應(yīng)為Fz = 10421.057=1101.47N
銑削功率Pm為
Pm = FzV…………………………......(4.3)
Pm = 44.06Kw
由《機(jī)械加工工藝手冊(cè)》第一卷表9.1—7得X5032的機(jī)床功率為9.09Kw,若取效率為0.85 則9.090.85 = 7.7265Kw > 44.06Kw 故機(jī)床功率足夠,同時(shí)X5032最高加工表面粗糙度可達(dá)= 1.6mm,則滿足加工要求。
(7)時(shí)間定額計(jì)算
機(jī)動(dòng)時(shí)間 由《機(jī)械加工工藝手冊(cè)》 P248 可知
基本時(shí)間 ………………………………(4.4)
Mz= fzZn ……………………..…………..(4.5)
— 加工行程(mm)
z — 銑刀齒數(shù)
fz — 銑刀每齒進(jìn)給量(mm/z)
n — 銑刀每分鐘轉(zhuǎn)數(shù) (r/min)
— 銑削深度
— 行程次數(shù)
Mz — 水平進(jìn)給量(mm/min)
當(dāng)主偏角=90o時(shí),根據(jù)《機(jī)械加工工藝手冊(cè)》
…………………….(4.6)
= 1~3 取 = 2
= 320
i = 2
= 0.5(160-)+2=18
Mz= fzZn=0.21680=256
所以 粗銑 = 2.66min
精銑 == 21.25min
故此 基本時(shí)間=T粗銑+T精銑= 2.66min+21.25min =23.91min
輔助時(shí)間:由 《機(jī)械加工工藝手冊(cè)》表7—29
可知:工作時(shí)裝上及取下零件所需輔助時(shí)間為0.47min
再由表7—30可知有關(guān)定程的輔助時(shí)間為
0.23+0.04+1.40 = 2.27min
最后得出工序定額時(shí)間為: 23.91+0.47+2.27=26.65min
4.5.2 粗銑上端面,半精銑上端面
(1)選擇刀具
鑲齒套式面銑刀 直徑d = 160mm Z = 16 參照《金屬切削手冊(cè)》第二版
(2)確定切削用量
由于表面粗糙度為3.2,我們采用粗、半精加工 經(jīng)查表可知,單邊余量為7mm,這里取粗銑加工余量為6mm
確定切削深度 可走刀一次完成: 粗銑= 5.8mm 半精銑= 1.2mm
確定進(jìn)給量f : fz 粗銑= 0.20 mm/z fz半精銑 = 0.12 mm/z
參照《金屬切削手冊(cè)》第二版 表9—12
(3)確定切削速度Vc
由《金屬切削手冊(cè)》第二版表9—14可知
粗銑時(shí)Vc = 39.2m/min 半精銑時(shí)Vc =25.4 m/min
由公式 ………………………..…………………..(4.1)
則 n粗銑 = 78.03 r/min n半精銑= 50.32r/min
由《機(jī)械加工工藝手冊(cè)》表4—16—1可知
標(biāo)準(zhǔn)轉(zhuǎn)數(shù)可取 n粗銑 = 80r/min
由《機(jī)械加工工藝手冊(cè)》 表4—16—1
可取 n半精銑= 50r/min
(4)選擇銑刀壽命
根據(jù)《機(jī)械加工工藝手冊(cè)》第一卷表9.4—7
T = 180T/min
(5)銑削力功率計(jì)算
由《機(jī)械加工工藝手冊(cè)》 表3—25可知
………………………….(4.2)
— 銑削寬度
— 銑削力系數(shù)
— 每齒進(jìn)給量
— 銑刀半徑
— 銑削深度
— 齒數(shù)
由表3—25可知半精銑切削力功率計(jì)算因素:
= 50 = 96 = 0.12 = 80 = 1.2 = 16
則 = 2301N
(6)校核機(jī)床功率(一般不校核粗加工工序)
由《機(jī)械加工工藝手冊(cè)》表3—25可知修正系數(shù)
則實(shí)際的圓周切削力應(yīng)為Fz = 23011.057=2432.33N
銑削功率Pm為 : Pm = FzV……………………………..(4.3)
Pm = 60.80Kw
由《機(jī)械加工工藝手冊(cè)》第一卷表9.1—7得X5032的機(jī)床功率為9.09Kw,若取效率為0.85 則9.09×0.85 = 7.7265Kw > 60.80Kw 故機(jī)床功率足夠,同時(shí)X5032最高加工表面粗糙度可達(dá)= 1.6mm,則滿足加工要求。
(7)時(shí)間定額計(jì)算
機(jī)動(dòng)時(shí)間 由《機(jī)械加工工藝手冊(cè)》 P248 可知
基本時(shí)間 ………………….………(4.4)
Mz= fzZn ………………………………..(4.5)
— 加工行程(mm)
z — 銑刀齒數(shù)
fz — 銑刀每齒進(jìn)給量(mm/z)
n — 銑刀每分鐘轉(zhuǎn)數(shù) (r/min)
— 銑削深度
— 行程次數(shù)
Mz — 水平進(jìn)給量(mm/min)
當(dāng)主偏角=90o時(shí),根據(jù)《機(jī)械加工工藝手冊(cè)》
……………….(4.6)
= 1~3 取 = 2
= 320
= 0.5(160-)+2=18
i = 2
Mz= fzZn=0.21680=256 mm/min
所以 粗銑 = 2.66min
半精銑== 7.08min
故此 基本時(shí)間=T粗銑+T半精銑= 2.66min+7.08min = 9.74min
輔助時(shí)間:由 《機(jī)械加工工藝手冊(cè)》表7—29
可知:工作時(shí)裝上及取下零件所需輔助時(shí)間為0.47min
再由表7—30可知有關(guān)定程的輔助時(shí)間為
0.23+0.04+1.20 = 2.07min
最后得出工序定額時(shí)間為: 9.74+0.47+2.27=12.28min
4.5.3 鏜ф52中心孔
(1)選擇刀具
由《刀具課程設(shè)計(jì)指導(dǎo)書》查得
鏜桿為Φ36200,刀頭為101036
由《機(jī)械加工工藝手冊(cè)》第二卷表11.2—17可知
選臥式鏜床T6111,主軸轉(zhuǎn)速范圍為20—1000轉(zhuǎn)
(2)選擇切削用量 由《實(shí)用機(jī)械制造工藝設(shè)計(jì)手冊(cè)》表8-15可知
鏜削用量 ap粗鏜=6mm ap半精鏜=1.5mm ap精鏜=0.8mm
(3)計(jì)算切削速度 由《實(shí)用機(jī)械制造工藝設(shè)計(jì)手冊(cè)》表8-15可知
切削速度 V粗鏜 =2m/s V半精鏜 = 3m/s V精鏜 = 3m/s
(4)選擇計(jì)算轉(zhuǎn)速
由公式(1.1)可得 n粗 = 1000V粗/πd = 12.73r/min
n半精 = 1000V半精/πd = 18.73r/min
n精 = 1000V精/πd = 18.73r/min
又由《機(jī)械制造工藝設(shè)計(jì)手冊(cè)》4.7—1選擇標(biāo)準(zhǔn)轉(zhuǎn)速分別為
n粗 = 14r/min
n半精 = 20r/min
n精 = 20r/min
(5)時(shí)間定額計(jì)算
基本時(shí)間機(jī)動(dòng)時(shí)間
由公式(1.4)
由公式 1=+(3~5)………………………….……(4.7)
可知 1=6
2=3~5 取 2=4mm
=44mm
i=1
n= fn=114=14mm/min
可知 粗鏜 = =3.71min
同理: 半精鏜=4.33min
精鏜 =4.33min
故此 基本時(shí)間=T粗鏜+T半精鏜+T精鏜=3.71min+4.33min +4.33min= 12.37min
輔助時(shí)間:由 《機(jī)械加工工藝手冊(cè)》表7—29
可知:工作時(shí)裝上及取下零件所需輔助時(shí)間為0.47min
再由表7—30可知有關(guān)定程的輔助時(shí)間為
0.23+0.04+1.80 = 2.67min
最后得出工序定額時(shí)間為: 12.37+0.47+2.67=15.51min
4.5.4銑側(cè)表面
(1)選擇刀具
鑲齒套式面銑刀 直徑d = 80mm Z = 10 參照《金屬切削手冊(cè)》第二版
(2)確定切削用量
由于表面粗糙度為3.2,我們采用粗加工 經(jīng)查表可知,單邊余量為1mm,這里取粗銑加工余量為1mm
確定切削深度 可走刀一次完成: 粗銑= 1mm
參照《金屬切削手冊(cè)》第二版 表9—12
確定進(jìn)給量f : fz粗銑 = 0.2 mm/z
(3)確定切削速度Vc
由《金屬切削手冊(cè)》第二版表9—14可知
粗銑時(shí)Vc = 40m/min
由公式(1.1)
可得 n粗銑 = 159.23 r/min
由《機(jī)械加工工藝手冊(cè)》表4—16—1可知
標(biāo)準(zhǔn)轉(zhuǎn)數(shù)可取 n粗銑 = 160r/min
(4)選擇銑刀壽命
根據(jù)《機(jī)械加工工藝手冊(cè)》第一卷表9.4—7
T = 180T/min
(5)時(shí)間定額計(jì)算
機(jī)動(dòng)時(shí)間 由公式(1.4),(1.5)
Mz= fzZn
— 加工行程(mm)
z — 銑刀齒數(shù)
fz — 銑刀每齒進(jìn)給量(mm/z)
n — 銑刀每分鐘轉(zhuǎn)數(shù) (r/min)
— 銑削深度
— 行程次數(shù)
Mz — 水平進(jìn)給量(mm/min)
可知 當(dāng)主偏角=90o時(shí),根據(jù)《機(jī)械加工工藝手冊(cè)》
公式(1.6) ……………….(4.6)
= 1~3 取 = 2
= 50
= 0.5(80-)+2=6.28mm
i = 1
Mz= fzZn=0.210160=320 mm/min
所以 粗銑 = 0.18min
故此 基本時(shí)間=T粗銑=0.18min
輔助時(shí)間:由 《機(jī)械加工工藝手冊(cè)》表7—29
可知:工作時(shí)裝上及取下零件所需輔助時(shí)間為0.47min
再由表7—30可知有關(guān)定程的輔助時(shí)間為
0.23+0.04+1.40 = 2.27min
最后得出工序定額時(shí)間為: 0.18+0.47+2.27=2.92min
4.5.5鉆、擴(kuò)、鉸Φ26孔
(1)選取鉆刀:Φ25麻花鉆頭、Φ25.7高速鋼錐柄擴(kuò)孔鉆 、Φ26高速鋼鉸刀
(2)鉆孔的進(jìn)給量:查《實(shí)用機(jī)械制造工藝設(shè)計(jì)手冊(cè)》表8-10
進(jìn)給量 鉆=1.2mm/r 擴(kuò)=2.4mm/r 鉸=2.6mm/r
(3)鉆孔的切削速度:查《實(shí)用機(jī)械制造工藝設(shè)計(jì)手冊(cè)》表8-12
切削速度 V鉆=0.45m/s V擴(kuò)=0.22m/s V鉸=0.20m/s
確定主軸轉(zhuǎn)速:引用公式1.1
n鉆=== 5.7r/s
n擴(kuò)=== 2.69r/s
n鉸=== 2.45r/s
按照機(jī)床說(shuō)明書,取n鉆=5.5r/s n擴(kuò)=2.69r/s n鉸= 2.45r/s
(4)切削工時(shí):
引用公式(1.4)
刀具行程: L==36+1+3=40mm
得到 鉆==5.85 min
擴(kuò)==6.20 min
鉸==6.28 min
輔助時(shí)間:由 《機(jī)械加工工藝手冊(cè)》表7—29
可知:工作時(shí)裝上及取下零件所需輔助時(shí)間為0.7
收藏
編號(hào):83155571
類型:共享資源
大?。?span id="vpbkafo" class="font-tahoma">591.21KB
格式:ZIP
上傳時(shí)間:2022-05-01
50
積分
- 關(guān) 鍵 詞:
-
含9張CAD圖紙、說(shuō)明書
支承
工藝
夾具
設(shè)計(jì)
CAD
圖紙
說(shuō)明書
- 資源描述:
-
資源目錄里展示的全都有,所見(jiàn)即所得。下載后全都有,請(qǐng)放心下載。原稿可自行編輯修改=【QQ:401339828 或11970985 有疑問(wèn)可加】
展開(kāi)閱讀全文
- 溫馨提示:
1: 本站所有資源如無(wú)特殊說(shuō)明,都需要本地電腦安裝OFFICE2007和PDF閱讀器。圖紙軟件為CAD,CAXA,PROE,UG,SolidWorks等.壓縮文件請(qǐng)下載最新的WinRAR軟件解壓。
2: 本站的文檔不包含任何第三方提供的附件圖紙等,如果需要附件,請(qǐng)聯(lián)系上傳者。文件的所有權(quán)益歸上傳用戶所有。
3.本站RAR壓縮包中若帶圖紙,網(wǎng)頁(yè)內(nèi)容里面會(huì)有圖紙預(yù)覽,若沒(méi)有圖紙預(yù)覽就沒(méi)有圖紙。
4. 未經(jīng)權(quán)益所有人同意不得將文件中的內(nèi)容挪作商業(yè)或盈利用途。
5. 裝配圖網(wǎng)僅提供信息存儲(chǔ)空間,僅對(duì)用戶上傳內(nèi)容的表現(xiàn)方式做保護(hù)處理,對(duì)用戶上傳分享的文檔內(nèi)容本身不做任何修改或編輯,并不能對(duì)任何下載內(nèi)容負(fù)責(zé)。
6. 下載文件中如有侵權(quán)或不適當(dāng)內(nèi)容,請(qǐng)與我們聯(lián)系,我們立即糾正。
7. 本站不保證下載資源的準(zhǔn)確性、安全性和完整性, 同時(shí)也不承擔(dān)用戶因使用這些下載資源對(duì)自己和他人造成任何形式的傷害或損失。
裝配圖網(wǎng)所有資源均是用戶自行上傳分享,僅供網(wǎng)友學(xué)習(xí)交流,未經(jīng)上傳用戶書面授權(quán),請(qǐng)勿作他用。