ZH1105柴油機(jī)氣缸體三面粗鏜組合機(jī)床設(shè)計(jì)（左主軸箱設(shè)計(jì)）
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畢業(yè)設(shè)計(jì)任務(wù)書(shū)
課題：ZH1105柴油機(jī)氣缸體三面粗鏜組合機(jī)床設(shè)計(jì)（左主軸箱設(shè)計(jì)）
專(zhuān) 業(yè) 機(jī)械設(shè)計(jì)制造及其自動(dòng)化
學(xué) 生 姓 名 劉 少 衛(wèi)
班 級(jí) BMZ機(jī)制031
學(xué) 號(hào) 0361440124
指 導(dǎo) 教 師 劉 必 榮
專(zhuān) 業(yè) 系 主 任 吳 祥
發(fā) 放 日 期 2007年3月2日
一、設(shè)計(jì)（論文）內(nèi)容
課題來(lái)源于江蘇江淮動(dòng)力集團(tuán)。為保證ZH1105柴油機(jī)氣缸體三面相應(yīng)粗鏜孔的尺
寸精度及位置精度的要求，需設(shè)計(jì)一臺(tái)滿(mǎn)足三面粗鏜要求的臥式組合機(jī)床。在完成“三
圖一卡”的基礎(chǔ)上，主要完成左主軸箱裝配圖和零件圖設(shè)計(jì)任務(wù)。
二、設(shè)計(jì)（論文）依據(jù)
ZH1105柴油機(jī)氣缸體材料為HT250，其硬度是HB190-240，生產(chǎn)按兩班制執(zhí)行，
年產(chǎn)量15萬(wàn)件。各粗鏜孔的尺寸精度和位置精度及具體要求詳見(jiàn)ZH1105氣缸體的零
件圖。具體加工內(nèi)容：
左側(cè)：
1、粗鏜曲軸孔Φ194.4±0.1，，Φ124.4±0.1，；曲軸孔公共軸線到水箱面130±0.1，
與缸頭面距離300±0.1，與軸承底面垂直度要求為0.06，坐標(biāo)：X=0，Y=0；
2、粗鏜凸輪軸孔Φ36.4±0.1，;孔口倒角1X45，;坐標(biāo)： X=85.22+0.1，Y=99.48；
3、粗鏜上下平衡軸孔2-Φ61.4±0.10，;坐標(biāo)：X=127.07±0.10， Y=87±0.10
右側(cè)：
1、粗鏜凸輪軸孔Φ56.6±0.1，；孔口倒角1X45°，;坐標(biāo)：X=85.22±0.10；Y=99.48；
2、粗鏜上、下平衡軸孔2-Φ61.4±0.10，，坐標(biāo)：X=127.07±0.10，Y=87±0.10；
3、加工調(diào)速軸孔Φ24.4±0.10，，孔口倒角1X45°，，坐標(biāo)：X=34.07±0.10，
Y=86.53±0.10；
4、加工起動(dòng)軸孔Ф36.4±0.10， ，孔口倒角1X45°，，坐標(biāo)：X=107.45±0.10，
Y=8.42±0.10；
后側(cè)：
粗鏜缸套孔Ф114.4±0.10，，粗鏜Ф115±0.1，，粗鏜Ф122.4±0.10，，止口
深8，缸套孔軸線離水箱面130±0.10。
三、技術(shù)要求
1、機(jī)床應(yīng)能滿(mǎn)足加工要求，保證加工精度；
2、機(jī)床應(yīng)運(yùn)轉(zhuǎn)平穩(wěn)，工作可靠，結(jié)構(gòu)簡(jiǎn)單，裝卸方便，便于維修、調(diào)整；
3、機(jī)床應(yīng)盡量使用通用件（中間底座可自行設(shè)計(jì)）以便降低制造成本；
4、機(jī)床各動(dòng)力部件用電氣控制，液壓驅(qū)動(dòng)。
四、畢業(yè)設(shè)計(jì)（論文）物化成果的具體內(nèi)容及要求
1、設(shè)計(jì)說(shuō)明書(shū)1份，達(dá)1萬(wàn)字以上，且要符合規(guī)范要求；
2、設(shè)計(jì)圖樣全部用AutoCAD繪制，夾具裝配圖需要有手工繪制的草圖，除“三圖一
卡”外，設(shè)計(jì)的工程圖樣折合成圖幅為A0應(yīng)不少于3張；圖樣要求正確、完整、清晰，
符合規(guī)范，并力求采用新標(biāo)準(zhǔn)，
3、具體設(shè)計(jì)的圖樣有：
（1）ZH1105柴油機(jī)氣缸體三面粗鏜組合機(jī)床的 “三圖一卡”設(shè)計(jì)；
（2）左主軸箱裝配圖設(shè)計(jì)；
（3）零件圖設(shè)計(jì)。
五、畢業(yè)設(shè)計(jì)（論文）進(jìn)度計(jì)劃
起訖日期
工作內(nèi)容
備 注
3月3日～3月4日
布置任務(wù)
3月5日～3月17日
調(diào)查研究，畢業(yè)實(shí)習(xí)
3月18日～4月15日
方案論證，總體設(shè)計(jì)
4月16日～4月30日
技術(shù)設(shè)計(jì)（部件設(shè)計(jì)）
5月8日～5月23日
工作設(shè)計(jì)（零件設(shè)計(jì)）
5月24日～6月7日
撰寫(xiě)畢業(yè)設(shè)計(jì)說(shuō)明書(shū)
6月8日～6月10日
畢業(yè)設(shè)計(jì)預(yù)答辯
6月11日～6月13日
修改資料
6月14日～6月15日
評(píng)閱材料
6月16日～6月18日
畢業(yè)答辯
6月19日～6月21日
材料整理裝袋
六、主要參考文獻(xiàn)：
[1] 葉偉昌主編.機(jī)械工程及自動(dòng)化簡(jiǎn)明設(shè)計(jì)手冊(cè)(上冊(cè)).北京：機(jī)械工業(yè)出版社，2001
[2] 葉偉昌主編.機(jī)械工程及自動(dòng)化簡(jiǎn)明設(shè)計(jì)手冊(cè)(下冊(cè)).北京：機(jī)械工業(yè)出版社，2001
[3] 胡家秀主編.機(jī)械零件設(shè)計(jì)實(shí)用手冊(cè).北京：機(jī)械工業(yè)出版社，1999
[4] 李益民主編.機(jī)械制造工藝設(shè)計(jì)手冊(cè).北京：機(jī)械工業(yè)出版社，1995
[5] 艾興等主編.金屬切削用量手冊(cè).北京：機(jī)械工業(yè)出版社，1996
[6] 范云漲等主編.金屬切削機(jī)床設(shè)計(jì)簡(jiǎn)明手冊(cè).北京：機(jī)械工業(yè)出版社，1993
[7] 孟憲椅等主編.機(jī)床夾具圖冊(cè).北京：機(jī)械工業(yè)出版社，1991
[8] 韓敬禮等主編.機(jī)械電氣設(shè)計(jì)簡(jiǎn)明手冊(cè).北京：機(jī)械工業(yè)出版社，1994
[9] 謝家瀛主編.組合機(jī)床設(shè)計(jì)簡(jiǎn)明手冊(cè).北京：機(jī)械工業(yè)出版社，1999
[10] 楊培元等主編.液壓系統(tǒng)設(shè)計(jì)手冊(cè).北京：機(jī)械工業(yè)出版社，1995
[11] 大連組合機(jī)床研究所編.組合機(jī)床設(shè)計(jì).北京：機(jī)械工業(yè)出版社，1986
[12] 大連組合機(jī)床研究所編.組合機(jī)床設(shè)計(jì)參考圖冊(cè).北京：機(jī)械工業(yè)出版社，1986
[13] 李云.機(jī)械制造工藝及設(shè)備設(shè)計(jì)指導(dǎo)手冊(cè).北京.機(jī)械工業(yè)出版社. 1996
[14] 薛源順.機(jī)床夾具設(shè)計(jì).北京.機(jī)械工業(yè)出版社.2000
[15] 李益民.機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè).北京.機(jī)械工業(yè)出版社.1993
七、其他
5
附件1：
立式軸承座鉆孔組合機(jī)床設(shè)計(jì)
張銀保
劉少衛(wèi)譯
摘 要：論述了立式軸承座鉆孔組合機(jī)床設(shè)計(jì)的基本步驟，以及包括此類(lèi)組合機(jī)床設(shè)計(jì)所要注意點(diǎn)。
關(guān)鍵詞：立式軸承座鉆孔組合機(jī)床 設(shè)計(jì)
1 分工序、定工位
生產(chǎn)類(lèi)型分析
此次設(shè)計(jì)的立式軸承座鉆孔組合機(jī)床，其所加工的零件在汽車(chē)中應(yīng)用十分廣泛，應(yīng)該屬于大批量生產(chǎn)項(xiàng)目，所以在設(shè)計(jì)時(shí)應(yīng)注意到盡量使加工簡(jiǎn)單，但又不影響加工質(zhì)量。
加工方案的制定
劃分工序要考慮到生產(chǎn)的規(guī)模、加工的精度、所用機(jī)床的特點(diǎn)、機(jī)床負(fù)荷情況等。 劃分工序可以有兩種趨向：工序集中和工序分散。 工序的集中分散各有其長(zhǎng)處，一般說(shuō)來(lái)，在大批量生產(chǎn)中以提高生產(chǎn)率為主，需廣泛采用多刀、單軸與多軸自動(dòng)或半自動(dòng)機(jī)床，多軸龍門(mén)銑床、組合機(jī)床等，故采取工序集中可以獲得突出的效果。
此次設(shè)計(jì)的軸承座鉆孔組合機(jī)床很大程度上使各工序盡量集中，發(fā)揮組合機(jī)床的優(yōu)點(diǎn)，同時(shí)使各種誤差減小到最低限度。
由于此設(shè)計(jì)中所加工的零件10 個(gè)孔中部分孔距離太近，不便于加工，所以分開(kāi)為兩個(gè)工位完成，然后進(jìn)行零件位置轉(zhuǎn)換。
主要工位經(jīng)分析選取以下方案：1)裝卸、夾緊；2)鉆7個(gè)孔f13.5；3)鉆3個(gè)孔一個(gè)為f14，鉆2個(gè)螺紋底孔f14，孔號(hào)為8、9；4)鉆橫向孔f14；5)擴(kuò)鉸7個(gè)孔f14.5；6)攻絲。
2 復(fù)合刀具的切削用量的計(jì)算
切削用量的特點(diǎn)
組合機(jī)床的正常工作與合理地選用切削用量，即確定合理的切削速度和工作進(jìn)給量有很大的關(guān)系。 切削用量選的恰當(dāng)，能使組合機(jī)床減少停車(chē)損失，提高生產(chǎn)效率，延長(zhǎng)刀具壽命，提高加工質(zhì)量。
導(dǎo)套設(shè)計(jì)
被加工7個(gè)孔直徑為14.5 ，加工孔的直徑與導(dǎo)套長(zhǎng)度，導(dǎo)套內(nèi)徑尺寸，上下偏差以及孔軸線理想位置的偏移的關(guān)系。
1～7號(hào)孔，以及8～10號(hào)孔和底孔的直徑為14.5 mm ，它所需要的導(dǎo)套長(zhǎng)度為(32～40)mm ，內(nèi)徑尺寸偏差為+0.016～+0.034 ，孔軸線理想位置偏移為(0.15～0.20)mm。
孔加工切削用量計(jì)算
用高速鋼鉆頭加工此鑄件 HB=204(鉆1～7號(hào)孔，Ⅱ工位；鉆8～10號(hào)孔，Ⅲ工位)；鉆頭直徑：14.5mm；切削用量：v=(10～18)m/min，s=0.2mm/r，轉(zhuǎn)速350r/min。
用高速鋼鉆頭鉆橫向孔f16(Ⅳ工位) 加工直徑：16mm；切削用量v=(10～18)m/min；s=(0.18～0.25)mm/r；轉(zhuǎn)速350r/min。
用硬質(zhì)合金擴(kuò)孔鉆擴(kuò)鉸孔1～7號(hào)孔(Ⅴ工位) 在Ⅴ工位上，擴(kuò)鉸7個(gè)孔時(shí)，采用擴(kuò)鉸復(fù)合刀具，進(jìn)給量按擴(kuò)孔鉆選擇，切削速度按鉸刀選擇，而且進(jìn)給量應(yīng)按復(fù)合刀具最小直徑選用允許值的上限，切削速度則按復(fù)合刀具最大直徑選用允許值的上限。
加工直徑：14.5mm；切削用量：v=(8～10)m/min，s=0.25mm/r，轉(zhuǎn)速280r/min；擴(kuò)孔鉆刀桿及導(dǎo)向部分的公稱(chēng)直徑d+0.08；擴(kuò)孔鉆公差：-0.036；刀桿導(dǎo)向部分公差：-0.006～-0.0017；導(dǎo)套內(nèi)徑公差：+0.024～0.006。
孔加工常用工序間余量 擴(kuò)孔直徑為10～20，直徑上的工序余量為(1.5～2.0)mm；鉸孔直徑為10～20，直徑上的工序量為(0.10～0.20)mm(以上切削用量的選擇由東風(fēng)汽車(chē)公司設(shè)備制造廠設(shè)計(jì)科提供資料)。
3 部件選用
功率選擇標(biāo)準(zhǔn)
動(dòng)力部件用以實(shí)現(xiàn)切削刀具的旋轉(zhuǎn)和進(jìn)給運(yùn)動(dòng)或只用于進(jìn)給運(yùn)動(dòng)，此機(jī)床實(shí)現(xiàn)了切削刀具旋轉(zhuǎn)和進(jìn)給運(yùn)動(dòng)兩項(xiàng)內(nèi)容。
每一種規(guī)格的動(dòng)力頭都有一定的功率范圍，根據(jù)所計(jì)算出的切削功率及進(jìn)給功率之需要，并適當(dāng)提高切削用量的可能性，選用相應(yīng)規(guī)格的動(dòng)力頭，公式如下：
N動(dòng)>(N切+N進(jìn))/hkW。
式中：N動(dòng)為動(dòng)力頭電機(jī)功率；N切為切削功率，按各刀具選用的切削用量，由“組合機(jī)床的切削力及功率計(jì)算公式”中已求出；N進(jìn)為進(jìn)給功率，對(duì)于液壓動(dòng)力頭就是進(jìn)給油泵所消耗的功率，一般為(0.8～2)kW；h為傳動(dòng)效率，當(dāng)主軸箱少于15根時(shí)，h=0.7，多于15根時(shí)，h=0.65。
機(jī)床實(shí)際功率
此立式組合機(jī)床左右分兩個(gè)電機(jī)帶動(dòng)兩個(gè)多軸箱進(jìn)行加工。對(duì)于左半部分多軸箱刀具，在加工1～7號(hào)孔以及Ⅲ工位加工10號(hào)孔時(shí)其功率總和：
N/kW=0.29×7+0.283=2.313
因?yàn)樽笾鬏S箱少于15跟鉆頭，所以
h=0.7，N/kW=2.313/0.7=3.3
對(duì)于右半部分多軸箱刀具，在Ⅴ工位擴(kuò)鉸1～7號(hào)孔以及攻絲，鉆頭的實(shí)際功率：
N/kW=0.1427×7=1.0
因?yàn)橛抑鬏S箱少于15根鉆頭，所以
h=0.7，N/kW=1÷0.7=1.43
選用電機(jī)
由于此機(jī)床在驅(qū)動(dòng)方面沒(méi)有特殊的要求，選用普通也是最可靠的Y系列電機(jī)，它是封閉自扇冷式鼠籠型三相異步電動(dòng)機(jī)，取代J02系列的更新?lián)Q代產(chǎn)品。
左半部分所需功率為3.3kW，查Y系列三相異步電動(dòng)機(jī)表，選用Y123S24型號(hào)的電機(jī)，額定功率為5.5kW，選用此型號(hào)電機(jī)比較合適。
右半部分所需功率為1.43kW，查Y系列三相異步電動(dòng)機(jī)表，選用Y112M26型號(hào)的電機(jī)，額定功率為2.2kW，選用此型號(hào)電機(jī)比較合適。
4 夾具設(shè)計(jì)
軸承座鉆孔組合機(jī)床夾具分析
根據(jù)工件不同的生產(chǎn)條件，可以有各種不同的安裝方法：a)找正安裝法；b)夾具安裝法。
基本定位原理分析 這里討論6點(diǎn)定位中，6個(gè)自由度的消除，以便找出較合適的定位夾緊方案。一個(gè)物體在空間可以有6個(gè)獨(dú)立的運(yùn)動(dòng)，即沿X、Y、Z軸的平移運(yùn)動(dòng)，分別記為X1、Y1、Z1；繞X、Y、Z軸的轉(zhuǎn)動(dòng)，記為X2、Y2、Z2，習(xí)慣上，上述6個(gè)獨(dú)立運(yùn)動(dòng)稱(chēng)作6個(gè)自由度。如果采用一定的約束措施，消除物體的6個(gè)自由度，則物體被完全定位。例如討論長(zhǎng)方體工件時(shí)，可以在底面布置3個(gè)不共線的約束點(diǎn)，在側(cè)面布置2個(gè)約束點(diǎn)，在端面布置一個(gè)約束點(diǎn)，則底面約束點(diǎn)可以限制X2、Y2、Z23個(gè)自由度，側(cè)面約束點(diǎn)限制X1、Z12個(gè)自由度，端面約束點(diǎn)限制Y1這個(gè)自由度，就完全限制了長(zhǎng)方體工件6個(gè)自由度。夾緊力“兩要素”，方向與作用點(diǎn) 夾緊力方向應(yīng)朝向定位元件，并使所需的夾緊力最小。
確定夾緊力作用點(diǎn)的位置時(shí)應(yīng)不破壞定位。夾緊力作用點(diǎn)的位置應(yīng)盡可能靠近加工部位，以減小切削力繞夾緊力作用點(diǎn)的力矩，防止工件在加工過(guò)程中產(chǎn)生轉(zhuǎn)動(dòng)或震動(dòng)。應(yīng)保證夾緊變形不影響加工精度。夾緊力作用點(diǎn)數(shù)目應(yīng)使工件在整個(gè)接觸面上受力均勻，接觸變形小。
定位夾緊方案的確定
此零件屬于空心圓形鑄件，一般的定位元件有V形塊、定位套筒作半圓形定位，如果選用V形塊定位的話(huà)，在Z軸方向移動(dòng)以及繞X、Y軸旋轉(zhuǎn)的自由度已經(jīng)消除，在鉆頭進(jìn)行加工時(shí)，繞Z軸轉(zhuǎn)動(dòng)的自由度卻無(wú)法消除，所以用V形塊定位的方案是行不通的。如果利用半圓形定位，其結(jié)果和用V形塊是一樣的，都無(wú)法使工件在繞Z軸的方向上穩(wěn)定，最后決定利用定位套筒定位。
環(huán)形套筒以H7/K6或H7/js6的過(guò)度配合裝入夾具，零件放入套筒后，在X、Y方向的自由度消除，同時(shí)采用壓板的方法;利用球頭螺栓使壓板緊壓住工件體。
在此壓板的作用下，沿X軸旋轉(zhuǎn)X2，以及沿Z軸旋轉(zhuǎn)Z2和沿Z軸方向Z1自由度都被限制。所以在此套夾具的作用下，X1、Y1、Z1、X1、Y1等自由度完全被消除，而在壓板的壓力作用下，零件和刀具之間強(qiáng)大的摩擦力，以及在加工過(guò)程中軸向力的相互抵消，在Z的自由度也被消除。當(dāng)進(jìn)行到Ⅳ工位，加工橫向孔時(shí)，X1、Y1、Z1的自由度已被消除，X2、Y2方向自由度也已被消除，在Z2方向上，由于壓板的作用使工件在Z2方向的自由度也消除了。
5 攻絲裝置
在組合機(jī)床上攻制螺紋時(shí)，根據(jù)被加工零件加工部位的分布情況和工藝要求等，常用的攻絲方法有3種：采用攻絲動(dòng)力頭攻絲，采用攻絲裝置攻絲和采用活動(dòng)攻絲模板攻絲。
在此設(shè)計(jì)中，右半部分完成Ⅴ、Ⅵ工位的加工。電機(jī)只有5.5kW的功率，故綜合考慮選用攻絲裝置攻絲。當(dāng)整臺(tái)機(jī)床或機(jī)床的某一面全部用于完成攻絲工序時(shí)，廣泛地采用了攻絲裝置。
攻絲裝置由攻絲主軸箱和攻絲靠模頭組成，由于靠模螺母和靠模桿是經(jīng)磨削并配研的，其螺距要求與所需加工螺孔的螺距保持一定關(guān)系，并設(shè)有螺距誤差補(bǔ)償機(jī)構(gòu)。因此利用攻絲裝置進(jìn)行攻絲可以達(dá)到較高的精度。
6 組合機(jī)床冷卻裝置
機(jī)床冷卻液除對(duì)刀具和工件起冷卻作用外，還能在金屬表面形成潤(rùn)滑薄膜，起到潤(rùn)滑作用。一些冷卻液中含有碳酸鈉，亞硝酸鈉等防銹劑，它們?cè)诮饘俦砻嫘纬赡z狀吸附膜或氧化物薄膜，又能使金屬免受腐蝕的作用。因而選擇冷卻液時(shí)，應(yīng)根據(jù)組合機(jī)床完成工藝、加工方法、刀具材料以及被加工零件的材料來(lái)決定。
在加工鑄鐵件時(shí)，由于鑄鐵本身含有石墨能自身潤(rùn)滑，一般都不加冷卻液。在大量生產(chǎn)中有時(shí)為了減少加工中的鐵粉飛揚(yáng)，也增加冷卻系統(tǒng)，以改善操作條件。有時(shí)可采用蘇打水，5%的乳化液，其乳化劑的主要成分可以是氧化油膏或硫化切削油。其配方為：油膏2%～5%，粗加工取低值，精加工取高值;亞硝酸鈉0.2%～0.25%;無(wú)水碳酸鈉0.2%～0.3%。在鑄鐵工件上攻絲時(shí)，則都采用潤(rùn)滑液，以提高表面光滑度，減少功率的消耗。通常采用煤油，亦可采用硫化切削液及混合油等。
冷卻液的流量應(yīng)根據(jù)刀具的形式、直徑的大小、加工方法、切削用量等具體條件確定，組合機(jī)床的設(shè)計(jì)使用經(jīng)驗(yàn)表明，對(duì)鏜刀、鉆頭以及銑刀一類(lèi)刀具，每根刀具冷卻液的平均流量約為(2～6)L/min。國(guó)外資料推薦按加工直徑選擇，每把刀具的冷卻液流量。
7 工作循環(huán)說(shuō)明
一臺(tái)組合機(jī)床，其工作循環(huán)常常是比較復(fù)雜的，不僅有好幾個(gè)動(dòng)力頭按不同的循環(huán)進(jìn)行工作，而且這些循環(huán)還需其他部件，如移動(dòng)工作臺(tái)，回轉(zhuǎn)工作臺(tái)以及鼓輪等配合動(dòng)作。各動(dòng)力部件借助程序控制擋鐵，按規(guī)定順序進(jìn)行工作。工作循環(huán)應(yīng)當(dāng)盡可能的簡(jiǎn)單而且控制元件應(yīng)該少，否則機(jī)床的制造成本加大，安全性能也會(huì)降低。
本組合機(jī)床適合在大批量生產(chǎn)中使用，生產(chǎn)效率大大提高。為了降低成本，應(yīng)多選用復(fù)合刀具，盡量做到一次成形，減少裝夾次數(shù)。選擇合適的電機(jī)和動(dòng)力頭，選擇恰當(dāng)?shù)那邢饔昧亢颓邢魉俣取?
附件2：
Design of the Vertical Bearings Hole Drill Bed
Zhang Yinbao
Liu Shaowei
Abstract: This essay narratives the basic steps of upright axle bearing seat borehole combination and main points of designation of the combination machine tools
Keywords: The vertical axle bearing seat drills constituting a machine tool Design
1 Allotting working procedure, booking the labor place
Production type analysis
The vertical axle bearing seat machine tools designed this time and parts processed extensively apply to the use of the automobile and belong to the mass production project, therefore we should pay attention to that when designing we should make the process as simple as we can without affecting the quality.
Working out the process scheme
Dividing working procedure needs to think the production scale, accuracy, characteristics of a machine tool used and the situation of the machine tool loaded. Dividing working procedure has two kinds of tendencies: concentrating the working procedure and s dispersing working procedure. The working procedure concentrated and the dispersed have their own strong points. Generally speaking, improving efficacy in mass production need adopt multicut , single axis and polyaxis automation or semi-automatic machine tool broadly. The poleaxis and the machine tool adopt concentrating working procedure in order to gain outstanding effect.
That the axle bearing seat machine tools designed this time uses concentrating working procedureas much as possible in order to bring the merits of the combination machine tools into full play and makes the various error diminution arrive at the floor at the same time.
Because the distances between of the ten parts are too close, it is inappropriate to process. So the place is completed by two labors, then changes the locations of the parts.
The main labor place chooses the following scheme after analysis: 1) loads and unloads , clamps; 2) drills 7 holes f13.5; 3) drill 3 holes one is f14 , the other 2 are thread bottom holes f14 , hole number is 8 , 9; 4) drills transverse direction hole f14; 5) expands hinge 7 holes f14.5; 6) tapping.
2 Calculation of compound cutter cutting dosages
Cut the dosages characteristics
The regular work of a machine tool has very big something to do with to selecting and using cutting dosages reasonably, which means that choosing the appreciate cut speed and the job feed amounts ascertain rational cutting. Choosing appreciate cut dosages can make the combination machine tool cut down the parking loss, improve production efficiency, prolong the cutter increased longevity, and improve the quality of processing.
Designing the lead cover
The diameters of the 7 holes processed are is 14.5mm, followed the lead cover length, the internal diameter dimension of it, deviation and shift relations of the ideal hole axis location. The cover lengths of holes from No.1 ~ NO.7 and NO.8 ~ NO. are (32 ~ 40) mm and the bottom hole diameter are 14.5 mms, inside diameter dimension deviation is 0.016 ~ + + 0.034, ideal hole axis location offsets for (0.15 ~ 0.20) mm.
Calculation of processing a hole dosages
Use high-speed steel drill to process this casting HB = 204 (drill NO.1 ~ NO. 7 holes, II labors place; drill NO.8 ~ NO.10 hole, III labors); Bore bit diameter: 14.5 mms; Cut dosages: V = (10 ~ 18) m/min, s = (0.18 ~0.2 5mm/r, rotation rate 350 r/min.
With high-speed steel drill drill transverse direction hole f16 (IV labor, the place) processes a diameter: 16 mms; Cut dosages vs = (10 ~ 18) m/min; S = (0.18 ~ 0.25) mm/r; Rotation rate 350 r/min
Use carbide alloy reamer to expand the reaming 1 ~ 7 number holes (V labor place) on labor place V , expand to ream 7 Kong Shi , adopt to expand the hinge compound cutter, feed amounts choosing according to the reamer , cut speed choose according to the broach , enter and the upper limit should select and use permission value according to minimal diameter of compound cutter upper limit for amounts , cutting speed be that the maximum diameter selects and uses permission value according to compound cutter.
Process a diameter: 14.5 mm; Cut dosages: V = (8 ~ 10) m/min , ses = 0.25 mm/r , rotation rate 280 r/min; Reamer cutter arbor and nominal guiding part diameter d + 0.08; Reamer common difference: -0.036; Cutter arbor guiding part common difference: -0.006 ~- 0.0017; Lead the cover inside diameter common difference: + 0.024 ~ 0.006.
The hole processing procedure room margin in common use reaming is 10 ~ 20, the upper diameter working procedure margin is (1.5 ~ 2.0) mm; provides the reaming diameter to 10 ~20 ;diameter room margin is (0.10 ~ 0.20 ) mm . (all the reference offered by Dong Feng Automobile Co. equipment manufactory design section.
3 The component selection and usage
Choosing power standard
The driving force component has been used to realize the rotation and the moving forward of the cutting tooling. This machine tool has come true cutting tooling rotation and moving forward.
Each driving force head has certain power range according to the cut power and the need of the moving forward power calculated to improve the possibility of the cut dosage, choose the appreciate drive force head, the formula as follows:
N moves> (N eager + N of N entering)/ hkW.
Among it: N moves is driving force head electric motor power; N eager is cut power , the force and power already have been calculated according to each tooling’s cut dosages from "the conbination machine tool cut force and power calculation formula "; N entering is feed power , which is feed power consumed by oil pump for hydraulic pressure driving force, being (0.8 ~ 2) kW in general; H is drive efficiency , the ding-dang main spindle box is less than 15 time , h = 0.7, more than 15 time , h = 0.65.
Machine tool actual power
This upright combination machine tool retinue is allotted two electric motors drive many two axle boxes to carry out treating. To many axle boxes of half parts of left cutter, in the hole processing NO.1 ~ NO.7 and the III labor place processes 10 Kong Shi Qi power sum as well as:
N/kW = 0.29 X 7 + 0.283 = 2.313
Left main spindle box is less than 15 follows the bore bit , so
H = 0.7, N/kW = 2.313/0.7 = 3.3
To many axle boxes of half parts of right cutter, the labor V, the place expands hinge NO.1 ~ NO.7 holes and the actual power attacking silk , the bore bit actual power:
N/kW = 0.1427 X 7 = 1.0
Right main spindle box less than 15 bore bits, so
H = 0.7, N/kW = 1 / 0.7 = 1.43
Select and use an electric motor
since this machine tool has no special requirement in the field of drive, select and use the average ,also the most reliable Y series electric motor, which is close self dyadic cold fan mouse cage type three-phase asynchronization electric motor , substitutesing the J02 series renovation and upgrade product.
The left half part required power is 3.3 kW. Check the Y series three-phase asynchronization electric motor form and select and use the Y112M26 type electric motor. Fixed power is 5.5 kW . It is appreciate to select and use this type electric motor.
The right half part right required power is 1.43 kW. Check the Y series three-phase asynchronization electric motor form and select and use the Y112M26 type electric motor. Fixed power is 2.2 kW. It is appreciate to select and use this type electric motor.
4 Clamp design
The axle bearing seat drills constituting machine tool clamp analysis
According to different conditions of the workpiece, there have various installation methods: a) look for installation method; b) the clamp installation way.
The basic fixing position principle analyses：among the 6 o'clock fixes position discussed here and 6 liberty degree eliminating find out a righter allocation clamp scheme. A object can have independent 6 motion in space, which is moving along X , Y , Z-axis and separately use X1 , Y1 , Z1 to stand for ; Rotating round X , Y , Z-axis, write down for X2 , Y2 , Z2 . The 6 self-movement are called 6 liberty degree usually. If adopt certain constraint measure to remove the 6 liberty degree of the object, the object’s position will be fixed completely. Take a rectangular parallelepiped as an example, arrange 3 constraint point not on the same line in the basal plane , arrange 2 constraint point in the side , arrange a constraint point on the top face and the basal plane constraint point can restrict the three free degree X2 , Y2 , Z2. Side constraint point restricts two free degree X1 , Z1. This liberty degree on the top face restricts Y1, thus liberty 6 spends with regard to are restricted .That "two key elements " , direction and effects count the fastening motion force clamps force direction should be on the direction of the location component, making required fastening motion strenuously minimal together.
Make sure that the location of clamping the force effect point should not destroy allocation. The location of clamping the force effect point should be close the process location as much as possible in order to diminish cutting a force go round the force moment clamping the force effect point to prevent workpiece from coming into being in the process of treating rotating or shake. We should ensure that fastening motion deformation does not affect process accuracy. The number of clamp force effect point should make workpiece accept a force homogeneously on entire contact surface , contact deformation smaller.
Ascertain fix position clamping scheme
This part belongs to hollow circular casting , the same allocation component has the V shape piece , the thimble fixing position assumes arch allocation, if selecting and using V shape piece allocation, liberty degree moving and winding X , Y axis revolution in Z-axis direction already eliminates, go round the liberty degree that Z-axis turns but have no way to eliminate, therefore using the localized V shape piece scheme is impractical during the period of the bore bit carries out treating. Whose bears fruit and uses V shape piece to be the same if making use of an arch to fix position,having no way to make workpiece stabilize on the direction going round Z-axis , decide to make use of the thimble fixing position to fix position finally.
After annularity thimble excessiveness with H7/K6 or H7/js6 puts a thimble inside in coordination with putting the clamp , the part in, method removing , adopt pressure board at the same time in X , Y direction liberty degree; Make use of the ball head bolt to make pressure board hold the workpiece body down tightly.
Under here pressure board effect, along zeta-axis revolution X2,and, along Z-axis revolution Z2 and along Z-axis direction Z1, liberty degree is all restricted. X1 , Y1 , Z1 , liberty degree such as X1 , Y1 are removed completely, but under pressure board pressure effect therefore under the effect copying a clamp here,between the part and the cutter friction big and powerful, in the process of treating axial force mutuality is counteracted and , the liberty degree in Z is also removed. Should carry out Kong Shi who processes transverse direction to labor place , IV, X1 , Y1 , Z1 liberty degree have already been removed , X2 , Y2 direction liberty degree have been removed also already , the liberty degree in Z2 direction has also been eliminated on Z2 direction, since controlling the unnatural effect uses workpiece.
5 Chasing bar
Attack on combination machine tool when making thread, the part processes location distribution condition and technological requirements etc. , tapping in common use method has 3 kinds according to being processed: Adopt tapping driving force head tapping , adopt chasing bar tapping and adopt the tapping exercising tapping form board.
Labor place treating designing that middle , half parts of right are completed V , VI here. The electric motor selects and uses chasing bar tapping only when 5.5 kW power , reasons think synthetically. Some side be used to be completed when attacking silk working procedure , broad all fields pawning entire platform machine tool or machine tool have adopt a chasing bar.
The chasing bar is composed of tapping main spindle box and the tapping explorator head , is keeps certain relation, and is sets up since the explorator nut and the explorator pole are go through a grinding to match inkstone's together, to have pitch of screw error to compensate organization. The tapping making use of a chasing bar to be in progress therefore can reach higher accuracy.
6 Constitute the machine tool cooling devise
Cooling liquid gets rid of a machine tool besides playing cooling role to the cutter and workpiece , can get up in the film forming lubrication metal outside, to lubrication action. Contain sodium carbonate in a little cooling liquid, nitrous acid sodium waits for a slushing compound, their effect forming the colloidal adsorption film or oxide film , being able to make metal avert corrosion in the metal outside. Come when choosing cooling liquid as a result, to decide the material should accomplish handicraft , job operation , cutter material and the part being processed according to combination machine tool.
When processing iron casting, oneself lubricates since casting iron containing black lead per se being able to, do not add cooling liquid in general. Cooling system sometimes flying upward , also increasing by in duplicate work for cutting down iron pink in processing, to improve handling condition. May adopt the mineral , 5%'s emulsion sometimes, whose emulsifier staple can be that the oxide ointment or vulcanization cuts oil. Whose formula is: Ointment 2% ~ 5%, rough process takes low value , finish machining takes good value; Nitrous acid sodium 0.2% ~ 0.25%; Anhydrous sodium carbonate 0.2% ~ 0.3%. Adopt lubricating liquid, to improve surface smoothness then when attacking silk on cast iron workpiece,consumption cutting down power. Adopt a kerosene generally , also, may adopt vulcanization to cut liquid and blending oil and so on.
Concrete condition such as responding to the form , diameter size , job operation according to the cutter , cutting dosages ascertains the cooling liquid rate of flow , the design usage experience constituting a machine tool indicates, a kind of cutter , every average cutter cooling liquid rate of flow is (2 ~ 6) L/min about to the crescent-shaped knife with long handle knife , bore bit and milling cutter. Data recommendation chooses abroad according to processing a diameter, each the cutter cooling liquid rate of flow.
7 The job cycle is explained
One constituting machine tool , the person job cycle often is comparatively complicated, not only have several driving force head to carry out a job according to different circulation, and these circulation needs coordinating action other if the component, moving the working table , rotary table and drum wheel etc.Every driving force component is drawn support from according to the job stipulating that order is in progress controlling gear iron by program. Otherwise the job cycle is proper as far as possible simplicity moreover gating element ought to few, the machine tool cost of manufacture enlarges, the meeting also reduces the safe function.
Originally, the combination machine tool is fit to be put into use in mass production , the efficacy improves greatly. For cost reduction, should select and use the compound cutter much , try one's best to achieve once taking shape, fall off pretending to grip number of times. The head who chooses the right electric motor and driving force, chooses proper cutting dosages and cuts speed.
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