帶式輸送機(jī)傳動(dòng)裝置設(shè)計(jì)【蝸輪蝸桿減速器】【F=700N V=6.5m-s D=350mm 】
帶式輸送機(jī)傳動(dòng)裝置設(shè)計(jì)【蝸輪蝸桿減速器】【F=700N V=6.5m-s D=350mm 】,蝸輪蝸桿減速器,F=700N V=6.5m-s D=350mm ,帶式輸送機(jī)傳動(dòng)裝置設(shè)計(jì)【蝸輪蝸桿減速器】【F=700N,V=6.5m-s,D=350mm,輸送,傳動(dòng),裝置,設(shè)計(jì),蝸輪,蝸桿,減速器,mm
設(shè) 計(jì)課題名稱:帶式輸送機(jī)傳動(dòng)裝置設(shè)計(jì)設(shè)計(jì)時(shí)間: 系 部: 班 級(jí): 姓 名: 指導(dǎo)教師: 答辯情況答辯教師: 年 月 日評(píng)語(yǔ)成績(jī)?cè)u(píng)定 指導(dǎo)教師: 年 月 日揚(yáng)州工業(yè)職業(yè)學(xué)院 2任務(wù)書機(jī)械系(部):專業(yè): 班級(jí): 姓名指導(dǎo)教師職稱課題名稱帶式輸送機(jī)傳動(dòng)裝置設(shè)計(jì)課 題 工 作 內(nèi) 容1、 電動(dòng)機(jī)2、聯(lián)軸器3、蝸桿減速器4、開(kāi)式齒輪傳動(dòng)5、鏈傳動(dòng)6、滾筒7、輸送帶原始數(shù)據(jù): 輸送帶工作拉力:F=7000N 輸送帶速度:V=6.5m/min 滾筒直徑:D=350mm工作條件: 單班制,單向運(yùn)轉(zhuǎn),載荷平穩(wěn)。動(dòng)力來(lái)源: 電動(dòng)機(jī),三相交流,電壓380/220V設(shè)計(jì)要求: 使用期限5年,成批生產(chǎn),總減速比允差5%;體積最小,強(qiáng)度足夠。設(shè)計(jì)內(nèi)容: 1、按給定條件設(shè)計(jì)減速器裝置; 2、完成減速器裝配圖一張; 9-UR 3、零件圖兩張:減速器從動(dòng)齒輪和輸出軸; $XX* ;4、編制減速器輸出軸加工工藝,填寫加工工藝卡和工序卡;5、編寫減速器輸出軸數(shù)控加工程序;6、設(shè)計(jì)計(jì)算說(shuō)明書1份。指標(biāo)要求一、 減速器裝配圖和零件圖繪制 1、手工繪制草圖,利用AutoCAD軟件繪制裝配圖(0#,打印稿和電子稿各一份)和零件圖(3#,打印稿和電子稿)。 2、用所學(xué)軟件繪制減速器及從動(dòng)齒輪和輸出軸的三維圖(打印稿和電子稿各一份)。二、加工工藝編制按實(shí)際加工要求編寫加工工藝,并按企業(yè)或給定格式填寫加工工藝卡和工序卡。三、設(shè)計(jì)說(shuō)明書的撰寫 1、畢業(yè)設(shè)計(jì)說(shuō)明書按學(xué)院規(guī)定的撰寫格式、要求和紙張格式裝訂成冊(cè),內(nèi)容順序?yàn)椋悍饷?、中英文摘要、目錄、說(shuō)明書正文、參考書目錄、小結(jié)、封底。2、設(shè)計(jì)說(shuō)明書的論證要有科學(xué)根據(jù),要有說(shuō)服力;計(jì)算部分須指出公式來(lái)源并說(shuō)明公式中的符號(hào)所代表的意義,公式中所有常數(shù)或系數(shù)必須正確,計(jì)算結(jié)果要足夠準(zhǔn)確,計(jì)算中采用的數(shù)據(jù)及計(jì)算結(jié)果可列表表示3、說(shuō)明書要求章節(jié)分明,層次清楚,文理通順,圖表、簡(jiǎn)圖規(guī)范、清晰,不得用徒手畫。進(jìn)程安排1、根據(jù)畢業(yè)設(shè)計(jì)任務(wù),收集、閱讀整理有關(guān)資料,擬訂并確定設(shè)計(jì)方案; 1周2、設(shè)計(jì)傳動(dòng)裝置,繪制草圖,利用軟件繪制裝配圖、零件圖、三維圖; 4周 3、編制輸出軸加工工藝,填寫工藝卡和工序卡; 1周4、編寫輸出軸數(shù)控加工程序; 1周5、編寫說(shuō)明書,整理并完成畢業(yè)設(shè)計(jì)論文; 1周6、畢業(yè)設(shè)計(jì)成果審閱、評(píng)閱、答辯。主要參考文獻(xiàn)1、機(jī)械零件設(shè)計(jì)手冊(cè),機(jī)械工業(yè)出版社2、機(jī)械設(shè)計(jì)手冊(cè),機(jī)械工業(yè)出版社3、機(jī)械制造工藝與裝備,高等教育出版社 4、機(jī)械設(shè)計(jì)基礎(chǔ),機(jī)械工業(yè)出版社5、機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì)指導(dǎo)書,機(jī)械工業(yè)出版社6、數(shù)控機(jī)床加工程序編制,機(jī)械工業(yè)出版社7、機(jī)械制圖國(guó)家標(biāo)準(zhǔn),機(jī)械工業(yè)出版社注:以實(shí)際采用的參考文獻(xiàn)為準(zhǔn)起止日期2011年11月7日到2012年1月8日系(部)蓋章: 教研室主任(簽字): 年 月 日 年 月 日說(shuō)明:任務(wù)書由指導(dǎo)教師根據(jù)課題的具體情況填寫,經(jīng)系部審核蓋章后生效。此任務(wù)書要求按固定格式雙面打印,在畢業(yè)設(shè)計(jì)工作開(kāi)始前一周內(nèi)填寫并發(fā)給學(xué)生。設(shè)計(jì)1 . 前言這次設(shè)計(jì)的的要求連續(xù)單向運(yùn)轉(zhuǎn),載荷平穩(wěn)。室內(nèi)工作環(huán)境惡劣(灰塵較大,環(huán)境最高溫度35度)還要求維修方便,股選用的是展開(kāi)式二級(jí)圓柱齒輪減速器。在這次課程設(shè)計(jì)過(guò)程中,為了更好地達(dá)到培養(yǎng)設(shè)計(jì)能力的要求,應(yīng)養(yǎng)成獨(dú)立思考嚴(yán)肅認(rèn)真,精益求精的好習(xí)慣,還要綜合考慮多種因素,要采取多種辦法進(jìn)行比較分析。最重要的是,通過(guò)這次的課程設(shè)計(jì),要學(xué)會(huì)機(jī)械設(shè)計(jì)的一般規(guī)律,樹立正確的設(shè)計(jì)思想,還要學(xué)會(huì)用計(jì)算機(jī)繪圖。2.傳動(dòng)裝置的總體設(shè)計(jì)2.1.比較和選擇傳動(dòng)方案這次設(shè)計(jì)的的要求連續(xù)單向運(yùn)轉(zhuǎn),載荷平穩(wěn)。室內(nèi)工作環(huán)境惡劣(灰塵較大,環(huán)境最高溫度35度)還要求維修方便,股選用的是展開(kāi)式二級(jí)圓柱齒輪減速器。本傳動(dòng)設(shè)計(jì)的機(jī)構(gòu)特點(diǎn)是:減速器橫向尺寸較小,兩大齒輪浸油深度可大致相同,結(jié)構(gòu)較復(fù)雜,軸向尺寸大,中間軸較長(zhǎng),剛度差,中間軸承潤(rùn)滑較困難。結(jié)構(gòu)如下:2.2電動(dòng)機(jī)的選擇 輸送帶工作拉力F/KN=7 輸送帶工作速度v(m/s)=6.5 滾筒直徑D(mm)=3502.1.1電動(dòng)機(jī)類型 選用Y 系列三相異步電動(dòng)機(jī)2.2.2確定電動(dòng)機(jī)功率傳動(dòng)裝置中各部分的效率,查機(jī)械課程設(shè)計(jì)手冊(cè)表1-7由電動(dòng)機(jī)至工作機(jī)之間的總效率: 其中 分別為聯(lián)軸器,軸承,蝸桿,齒輪,鏈和卷筒的傳動(dòng)效率。查表可知=0.99(彈性鏈軸器)=0.97(滾子軸承)=0.73單頭蝸桿)=0.90鑄造的開(kāi)式齒輪傳動(dòng))=0.96(滾子鏈)=0.98(卷筒) 所以: 電動(dòng)機(jī)輸出功率 所以電動(dòng)機(jī)所需工作效率為: 2.2.3確定電動(dòng)機(jī)轉(zhuǎn)速采取同步轉(zhuǎn)速1500r/min2.2.4選定電動(dòng)機(jī)查處電動(dòng)機(jī)型號(hào)為Y112M-4,起額定功率4KW,滿載轉(zhuǎn)速1440r/min.基本符合題目所需的要求2.3計(jì)算總傳動(dòng)比和分配各級(jí)傳動(dòng)比3.1.1.3確定電動(dòng)機(jī)轉(zhuǎn)速 1) 電動(dòng)機(jī)的轉(zhuǎn)速:卷筒軸的工作轉(zhuǎn)速: 所以電動(dòng)機(jī)轉(zhuǎn)速的可選范圍為: 根據(jù)機(jī)械設(shè)計(jì)基礎(chǔ)中查的蝸桿的傳動(dòng)比在一般的動(dòng)力傳動(dòng)中 在這個(gè)范圍內(nèi)的電動(dòng)機(jī)的同步轉(zhuǎn)速有1000r/min和1500r/min,3000r/min.三種傳動(dòng)比方案,綜合考慮電動(dòng)機(jī)和傳動(dòng)裝置的情況來(lái)確定最后的轉(zhuǎn)速,為降低電動(dòng)機(jī)的重量和成本,可以選擇同步轉(zhuǎn)速1500r/min。根據(jù)同步轉(zhuǎn)速查表10-100確定電動(dòng)機(jī)的型號(hào)為Y112M-4。 3.1.2 計(jì)算總傳動(dòng)比和各級(jí)傳動(dòng)比的分配 各級(jí)傳動(dòng)比的分配 由于為蝸桿傳動(dòng),傳動(dòng)比都集中在蝸桿上,其他不分配傳動(dòng)比。 3.1.3 計(jì)算傳動(dòng)裝置的運(yùn)動(dòng)和動(dòng)力參數(shù)3.1.3.1分配各級(jí)傳動(dòng)比根據(jù)機(jī)械設(shè)計(jì)課程設(shè)計(jì)指導(dǎo)書可取鏈條傳動(dòng)i1=3開(kāi)式齒輪傳動(dòng)i2=3那么分配到蝸輪蝸桿上的傳動(dòng)比i3=243.65/(3X3)=26.8 3.1.3.2 功率 蝸桿的功率:p=4*0.99=3.96kW 蝸輪的功率:p=3.96*0. 8*0.99=3.1kW.轉(zhuǎn)矩 將所計(jì)算的結(jié)果列表:參數(shù)傳動(dòng)比i26.8效率0.990.790.904.傳動(dòng)零件的設(shè)計(jì)計(jì)算4.1蝸桿蝸輪設(shè)計(jì)計(jì)算計(jì)算項(xiàng)目計(jì)算內(nèi)容計(jì)算結(jié)果4.1.1選擇材料4.1.2確定許用壓力 時(shí)蝸輪材料的許用接觸當(dāng)時(shí)蝸輪材料的許用彎曲應(yīng)力初步估計(jì)Vs的值滑動(dòng)系數(shù)影響系數(shù)Zvs應(yīng)力循環(huán)的次數(shù) 接觸強(qiáng)度壽命系數(shù)Zn 彎曲強(qiáng)度壽命系數(shù)Yn 許用接觸應(yīng)力 許用彎曲應(yīng)力 4.1.3按接觸疲勞強(qiáng)度設(shè)計(jì)載荷系數(shù)K 傳動(dòng)比i 初步估計(jì)蝸桿傳動(dòng)效率確定蝸桿的頭數(shù) 蝸輪齒數(shù) 確定模數(shù)及蝸桿直徑 確定蝸桿傳動(dòng) 基本參數(shù)4.1.4求蝸輪圓周數(shù)度并校核效率 蝸輪分度圓導(dǎo)程角 實(shí)際傳動(dòng)比i 蝸輪的實(shí)際轉(zhuǎn)速n 蝸輪的圓周數(shù)度v 滑動(dòng)速度Vs 嚙合效率 攪油效率0.940.99 軸承效率0.980.99 蝸桿的傳動(dòng)效率 4.1.5校核蝸輪的齒面接觸強(qiáng)度材料彈性系數(shù)Ze 使用系數(shù)Ka 動(dòng)載系數(shù)Kv 載荷系數(shù) = 蝸輪實(shí)際轉(zhuǎn)矩T2 滑動(dòng)速度影響系數(shù)Zvs 許用接觸應(yīng)力H 校核蝸桿輪齒接觸疲勞強(qiáng)度 4.1.6校核蝸輪齒根彎曲強(qiáng)度蝸輪綜合齒形系數(shù) 導(dǎo)程角系數(shù) 校核彎曲強(qiáng)度 4.1.7熱平衡校核初步估計(jì)散熱面積A 周圍空氣的溫度t 熱散系數(shù)K 熱平衡校核 4.1.8計(jì)算蝸桿傳動(dòng)主要尺寸中心距 a=200mm 蝸桿齒頂圓直徑da1 蝸桿齒根圓直徑df1 導(dǎo)程角 蝸桿軸向齒距 Px1 蝸桿齒寬b1 蝸輪分度圓直徑d2 蝸輪喉圓直徑de2 蝸輪齒根圓直徑df2 蝸輪齒頂圓直徑da2 蝸輪齒寬b2 蝸輪齒頂圓弧半徑 蝸輪螺旋角 4.1.9蝸輪蝸桿的結(jié)構(gòu)設(shè)計(jì) 蝸桿 選40Cr,表面淬火4555HRC;由表8-7查得, 蝸輪邊緣選擇ZCuSn10P1。金屬模鑄造查表8-7得許用壓力為查表8-7查圖8-13得Vs3/s,查圖8-14得Zvs=0.93(浸油潤(rùn)滑)。=60N2jL=6063.713651610=223204800Zn=0.68Yn=0.55由式(8-6) =2200.930.68= 由式(8-7)=Yn =700.55=從K=11.4 取 K=1.2 由%=%0.835 查表11-1 =2-3 取=2=i=26.82=53.654 由式(8-10) 由表8-1取m=6.3,d=63查表8-4按i=25,m=6.3,d=63得基本參數(shù)為:中心距a=190,=2,=50,X2=-0.206=m=6.350=330mm =arctan m/d=arctan 26.3/63=11度18分35秒i=/=53/2=26.5n=n1/i=1420/26.5=53.6r/mm Vs= 查表8-10 取0.96 取 0.98 得:=0.9030.960.98=0.85查表8-8 Ze=155 查表8-9 Ka=1(間隙工作) 由于V2=0.9373m/s,Kv=11.1,取Kv=1 =1(載荷平穩(wěn)) 查圖8-14 Zvs=0.93 H= 2200.930.68=139.13N/mm =125.62H=139.13 按=/cos =53/cos =54 查圖7-32 = 4.0及=+0.246 =1-/120=1-111835/120=0.906 =11.12 F=38.5 取t=20C 從K=1417.5 取K=17W/(mC) 由式(8-14) =54.13C 85C 蝸桿分度圓直徑 d1=63mm da1=d1+2ham=63+216.3=76mm df1=d1-2m(ha+c )=63-26.3(1+0.2)=48mm =111835 Px1=m=3.146.3=20mm d2=334mm de2da2+1.5m=350+1.56.3=359.5mmdf2=d2-2hf2 =d2-2m(ha-X2+C) =334-26.3(1-0.246+0.2) =320mm da2=d2+2m(ha+X2)=334+26.3(1+0.246)= 350mm b20.75da1=0.7576=57mm Ra2 =d1/2-m=63/2-6.3=25mm = =111835蝸桿和軸做成一體,即蝸桿軸。蝸輪采用輪箍式,青銅輪緣與鑄造鐵心采用H7/s6配合,并加臺(tái)肩和螺釘固定,螺釘選6個(gè)40CrZCuSn10P1Vs3/sZvs=0.93=223204800K=1.2i=26.8=2=54m=6.3,d=63=2,=54X2=+0.246I=26.5N=53.6r/minVsKa=1Kv=1 =1H=139.13合格合格A=1.11m合格a=200mm da1=76mm=111835 b1=93mmd2=334mm=1118355.軸的設(shè)計(jì)計(jì)算及校核5.1輸出軸的設(shè)計(jì)計(jì)算項(xiàng)目計(jì)算內(nèi)容計(jì)算結(jié)果5.1.1軸的材料的選擇,確定許用應(yīng)力5.1.2按扭轉(zhuǎn)強(qiáng)度,初步估計(jì)軸的最小直徑5.1.3軸承和鍵5.1.4軸的結(jié)構(gòu)設(shè)計(jì) 5.1.4.1、徑向尺寸的確定 5.1.4.2、軸向尺寸的確定5.1.5軸的強(qiáng)度校核 5.1.5.1計(jì)算蝸輪受力 5.1.5.2計(jì)算支承反力5.1.5.3彎矩5.1.5.4當(dāng)量彎矩5.1.5.5分別校核5.1.5.6鍵的強(qiáng)度校核考慮到減速器為普通中用途中小功率減速傳動(dòng)裝置,軸主要傳遞蝸輪的轉(zhuǎn)矩。d 軸伸安裝聯(lián)軸器,考慮補(bǔ)償軸的可能位移,選用無(wú)彈性元件的聯(lián)軸器,由轉(zhuǎn)速和轉(zhuǎn)矩得Tc=KT=1.59.5502.799/63.67=315Nm查表GB 4323-84 HL3選無(wú)彈性擾性聯(lián)軸器,標(biāo)準(zhǔn)孔徑d=38mm,即軸伸直徑為38mm 。 采用角接觸球軸承,并采用凸緣式軸承蓋,實(shí)現(xiàn)軸承系兩端單向固定,軸伸處用C型普通平鍵聯(lián)接,實(shí)現(xiàn)周向固定。用A型普通平鍵連接蝸輪與軸 從軸段d1=38mm開(kāi)始逐漸選取軸段直徑,d2起固定作用,定位軸肩高度可在(0.070.1)d范圍內(nèi),故d2=d1+2h38(1+20.07)=43.32mm,該直徑處安裝密封氈圈,標(biāo)準(zhǔn)直徑。應(yīng)取d2=45mm;d3與軸承的內(nèi)徑相配合,為便與軸承的安裝,取d3=50mm,選定軸承型號(hào)為7210CJ,d4與蝸輪孔徑相配合。按標(biāo)準(zhǔn)直徑系列,取d4=53mm;d5起定位作用,由h=(0.070.1)d=(0.070.1)53=3.715.3mm,取h=4mm,d5=60mm;d7與軸承配合,取d7=d3=50mm;d6為軸承肩,查機(jī)械設(shè)計(jì)手冊(cè),取d6=57mm。與傳動(dòng)零件相配合的軸段長(zhǎng)度,略小于傳動(dòng)零件的輪轂寬。輪轂的寬度B2=(1.21.5)d4=(1.21.5)53=63.679.5mm,取b=70mm,聯(lián)軸段L4=68mm,聯(lián)軸器十字滑塊聯(lián)軸器B2=60mm,取聯(lián)軸段L1=58mm。與軸承配合的軸段長(zhǎng)度,查軸承寬度為20mm,取擋油板厚為1mm,則L7=21mm,其他軸段的尺寸長(zhǎng)度與箱體等的設(shè)計(jì)有關(guān),蝸輪端面與箱體的距離取1015mm,軸承端面與箱體內(nèi)壁的距離取5mm;分箱面取5565mm,軸承蓋螺釘至聯(lián)軸器距離1015mm,初步估計(jì)L2=55mm,軸承環(huán)寬度為8mm,兩軸承的中心的跨度為130mm,軸的總長(zhǎng)為263mm。蝸輪的分度圓直徑d=334mm; 轉(zhuǎn)矩T=513.27Nm蝸輪的切向力Ft=2T/d=2513.27/334=3073.47N蝸輪的徑向力Fr=Fttan/cos=3073.47tan20/cos111835=1158.4蝸輪軸向力Fx=Fttan=3073.47tan111835=619.72N水平平面 N垂直平面Fv1=N水平平面彎矩:垂直平面彎矩:合成彎矩: 單向運(yùn)轉(zhuǎn),轉(zhuǎn)矩為脈動(dòng)循環(huán) a=0.6aT=0.6513270=307962Mmm截面 Mea=Mel=aT=0.6428430=307962Mmm考慮到鍵d1=105%36.02=37.821mm;d2=105%38.69=40.62mm。實(shí)際直徑分別為38mm和53mm,強(qiáng)度足夠。應(yīng)為選用A型平鍵聯(lián)接,根據(jù)軸徑d=53,由GB1095-79,查鍵寬b=16mm;鍵高h(yuǎn)=10mm,因?yàn)檩嗇灥拈L(zhǎng)度為70mm,故取標(biāo)準(zhǔn)鍵長(zhǎng)60mm。將l=L-b=60-16=44mm,k=0.4h=0.410=4mm 查得靜荷時(shí)的許用擠壓應(yīng)力p=120p,所以擠壓強(qiáng)度足夠由普通平鍵標(biāo)準(zhǔn)查得軸槽深t=6mm,轂槽深t1=4.3mm選用45號(hào)鋼,正火處理 b=600MPa b1=55MPad=38mmd1=38mmd2=45mmd3=d7=50mmd4=53mmd5=60mmd6=57mmL1=58mmL2=55mmL7=21mmL=263mmd=334mmT=513.27Nm合格b=16mmh=10mmk=4mmt=6mmt1=4.3mm5.2蝸桿軸的設(shè)計(jì)計(jì)算項(xiàng)目計(jì)算內(nèi)容計(jì)算結(jié)果5.2.1軸的材料的選擇,確定許用應(yīng)力5.2.2按扭轉(zhuǎn)強(qiáng)度,初步估計(jì)軸的最小直徑5.2.3軸承5.2.4軸的結(jié)構(gòu)設(shè)計(jì)5.2.4.1徑向尺寸的確定5.2.4.2軸向尺寸的確定考慮到減速器為普通中用途中小功率減速傳動(dòng)裝置,軸主要傳遞蝸輪的轉(zhuǎn)矩。d 軸伸安裝聯(lián)軸器,考慮補(bǔ)償軸的可能位移,選用彈性拄銷聯(lián)軸器,由轉(zhuǎn)速n和轉(zhuǎn)矩Tc=KT=1.523.77=35.66Nm 查表GB 4323-84 選用HL2彈性柱銷聯(lián)軸器,標(biāo)準(zhǔn)孔徑d=30mm,即軸伸直徑為30mm采用角接觸球軸承,并采用凸緣式軸承蓋,實(shí)現(xiàn)軸承系兩端單向固定。從軸段d1=30mm開(kāi)始逐漸選取軸段直徑,d2起固定作用,定位軸肩高度可在(0.070.1)d范圍內(nèi),故d2=d1+2h30(1+20.07)=34.2mm,該直徑處安裝密封氈圈,標(biāo)準(zhǔn)直徑。應(yīng)取d2=35.5mm;d3與軸承的內(nèi)徑相配合,為便與軸承的安裝,取,選定軸承型號(hào)為7208CJ。d4起定位作用,由h=(0.070.1)d3=(0.070.1)40=2.84mm,取h=3mm,d4=d8=40+3=43mm;d5=d7=35mm,d6取蝸桿齒頂圓直徑d6=60mm。由GB5014-85查聯(lián)軸段長(zhǎng)度80mm,與軸承配合的軸段長(zhǎng)度,查軸承寬度為18mm,取擋油板厚為1mm,其他軸段的尺寸長(zhǎng)度與箱體等的設(shè)計(jì)有關(guān),蝸桿端面與箱體的距離取1015mm,軸承端面與箱體內(nèi)壁的距離取5mm;分箱面取5565mm,軸承蓋螺釘至聯(lián)軸器距離1015mm,軸承環(huán)寬度為8mm ,蝸桿軸總長(zhǎng)460mm選用45號(hào)鋼,正火處理 b=600MPa b1=55MPad1=30mmd2=35.5mmd3=d9=40mmd5=d7=35mmd6=60mmL=460mm6.箱體的設(shè)計(jì)計(jì)算6.1 箱體的結(jié)構(gòu)形式和材料采用下置剖分式蝸桿減速器(由于V=1m/s4m/s)鑄造箱體,材料HT150。6.2鑄鐵箱體主要結(jié)構(gòu)尺寸和關(guān)系 名稱 減速器型式及尺寸關(guān)系箱座壁厚 =11mm 箱蓋壁厚1 1=10mm箱座凸緣厚度b1,箱蓋凸緣厚度b,箱座底凸緣厚度b2 b=1.5=16mm b1=1.51=15mm b2=2.5=28mm地腳螺釘直徑及數(shù)目 df=19mm n=6軸承旁聯(lián)接螺栓直徑 d1=14mm箱蓋,箱座聯(lián)接螺栓直徑 d2=10mm 螺栓間距 150mm軸承端蓋螺釘直徑 d3=9mm 螺釘數(shù)目4檢查孔蓋螺釘直徑 d4=6mmDf,d1,d2至外壁距離 df,d2至凸緣邊緣距離 C1=26,20,16 C2=24,14軸承端蓋外徑 D2=140mm 軸承旁聯(lián)接螺栓距離 S=140mm軸承旁凸臺(tái)半徑 R1=16mm軸承旁凸臺(tái)高度 根據(jù)軸承座外徑和扳手空間的要求由結(jié)構(gòu)確定箱蓋,箱座筋厚 m1=9mm m2=9mm蝸輪外圓與箱內(nèi)壁間距離 12mm蝸輪輪轂端面與箱內(nèi)壁距離 10mm7.鍵等相關(guān)標(biāo)準(zhǔn)的選擇本部分含鍵的選擇聯(lián)軸器的選擇,螺栓,螺母,螺釘?shù)倪x擇墊圈,墊片的選擇,具體內(nèi)容如下:7.1鍵的選擇查表10-33機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì):A型普通平鍵,b*h=8*7GB1095-79軸與相配合的鍵:A型普通平鍵,b*h=16*10GB1095-79,3軸與聯(lián)軸器相配合的鍵A型普通平鍵b*h=12*8A 型,8*7A型, 16*10A型, 12*8GB1095-797.2聯(lián)軸器的選擇 根據(jù)軸設(shè)計(jì)中的相關(guān)數(shù)據(jù),查表10-43機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì),選用聯(lián)軸器的型號(hào)HL3。 GB5014-85HL3GB5014-857.3螺栓,螺母,螺釘?shù)倪x擇考慮到減速器的工作條件,后續(xù)箱體附件的結(jié)構(gòu),以及其他因素的影響選用 螺栓GB5782-86, M10*35, 數(shù)量為3個(gè) M12*100, 數(shù)量為6個(gè) 螺母GB6170-86 M10 數(shù)量為2個(gè) M12, 數(shù)量為6個(gè)螺釘GB5782-86 M6*20 數(shù)量為2個(gè) M8*25, 數(shù)量為24個(gè) M6*16 數(shù)量為12個(gè) *(參考機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì)圖10-8裝配圖)M10*35M12*100M10M12M6*20M8*25M6*167.4銷,墊圈墊片的選擇選用銷GB117-86,B8*30,數(shù)量為2個(gè)選用墊圈GB93-87數(shù)量為8個(gè)選用止動(dòng)墊片1個(gè)選用石棉橡膠墊片2個(gè)選用08F調(diào)整墊片4個(gè)*(參考機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì)圖10-8裝配圖)GB117-86B8*30GB93-87止動(dòng)墊片石棉橡膠墊片08F調(diào)整墊片有關(guān)其他的標(biāo)準(zhǔn)件,常用件,專用件,詳見(jiàn)后續(xù)裝配圖 8.減速器結(jié)構(gòu)與潤(rùn)滑的概要說(shuō)明在以上設(shè)計(jì)選擇的基礎(chǔ)上,對(duì)該減速器的結(jié)構(gòu),減速器箱體的結(jié)構(gòu),軸承端蓋的結(jié)構(gòu)尺寸,減速器的潤(rùn)滑與密封,減速器的附件作一簡(jiǎn)要的闡述。8.1 減速器的結(jié)構(gòu)本課題所設(shè)計(jì)的減速器,其基本結(jié)構(gòu)設(shè)計(jì)是在參照機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì)圖10-8裝配圖的基礎(chǔ)上完成的,該項(xiàng)減速器主要由傳動(dòng)零件(蝸輪蝸桿),軸和軸承,聯(lián)結(jié)零件(鍵,銷,螺栓,螺母等)。箱體和附屬部件以及潤(rùn)滑和密封裝置等組成。箱體為剖分式結(jié)構(gòu),由I箱體和箱蓋組成,其剖分面通過(guò)蝸輪傳動(dòng)的軸線;箱蓋和箱座用螺栓聯(lián)成一體;采用圓錐銷用于精確定位以確保和箱座在加工軸承孔和裝配時(shí)的相互位置;起蓋螺釘便于揭開(kāi)箱蓋;箱蓋頂部開(kāi)有窺視孔用于檢查齒輪嚙合情況及潤(rùn)滑情況用于加住潤(rùn)滑油,窺視孔平時(shí)被封住;通氣器用來(lái)及時(shí)排放因發(fā)熱膨脹的空氣,以放高氣壓沖破隙縫的密封而致使漏油;副標(biāo)尺用于檢查箱內(nèi)油面的高低;為了排除油液和清洗減速器內(nèi)腔,在箱體底部設(shè)有放汕螺塞;吊環(huán)螺栓用來(lái)提升箱體,而整臺(tái)減速氣的提升得使用與箱座鑄成一體的吊鉤;減速氣用地腳螺栓固定在機(jī)架或地基上。8.2減速箱體的結(jié)構(gòu)該減速器箱體采用鑄造的剖分式結(jié)構(gòu)形式具體結(jié)構(gòu)詳見(jiàn)裝配圖8.3軸承端蓋的結(jié)構(gòu)尺寸詳見(jiàn)零件工作圖8.4減速器的潤(rùn)滑與密封蝸輪傳動(dòng)部分采用潤(rùn)滑油,潤(rùn)滑油的粘度為118cSt(100C)查表5-11機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì)軸承部分采用脂潤(rùn)滑,潤(rùn)滑脂的牌號(hào)為ZL-2查表5-13機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì)8.5減速器附件簡(jiǎn)要說(shuō)明該減速器的附件含窺視孔,窺視孔蓋,排油孔與油蓋,通氣空,油標(biāo),吊環(huán)螺釘,吊耳和吊鉤,起蓋螺釘,其結(jié)構(gòu)及裝配詳見(jiàn)裝配圖。具體結(jié)構(gòu)詳見(jiàn)裝配圖具體結(jié)構(gòu)裝配圖詳見(jiàn)零件工作圖潤(rùn)滑油118Cst潤(rùn)滑脂ZL-2 詳見(jiàn)裝配圖7 箱體的設(shè)計(jì)計(jì)算7.1 箱體的構(gòu)形式和材料采用下置剖分式蝸桿減速器(由于V=5m/s)鑄造箱體,材料HT150。7.2 箱體主要結(jié)構(gòu)尺寸和關(guān)系 名稱 減速器型式及尺寸關(guān)系箱座壁厚 =11mm 箱蓋壁厚1 1=10mm箱座凸緣厚度b1,箱蓋凸緣厚度b,箱座底凸緣厚度b2 b=1.5=16mm b1=1.51=15mm b2=2.5=28mm地腳螺釘直徑及數(shù)目 df=19mm n=6軸承旁聯(lián)接螺栓直徑 d1=14mm箱蓋,箱座聯(lián)接螺栓直徑 d2=10mm 螺栓間距 150mm軸承端蓋螺釘直徑 d3=9mm 螺釘數(shù)目4檢查孔蓋螺釘直徑 d4=6mmDf,d1,d2至外壁距離 df,d2至凸緣邊緣距離 C1=26,20,16 C2=24,14軸承端蓋外徑 D1=80mm D2=125mm軸承旁聯(lián)接螺栓距離 S=140mm軸承旁凸臺(tái)半徑 R1=16mm軸承旁凸臺(tái)高度 根據(jù)軸承座外徑和扳手空間的要求由結(jié)構(gòu)確定箱蓋,箱座筋厚 m1=9mm m2=9mm蝸輪外圓與箱內(nèi)壁間距離 12mm蝸輪輪轂端面與箱內(nèi)壁距離 10mm8 螺栓等相關(guān)標(biāo)準(zhǔn)的選擇本部分含螺栓,螺母,螺釘?shù)倪x擇墊圈,墊片的選擇,具體內(nèi)容如下:8.1 螺栓,螺母,螺釘?shù)倪x擇考慮到減速器的工作條件,后續(xù)箱體附件的結(jié)構(gòu),以及其他因素的影響選用螺栓GB5782-86 M10*35 數(shù)量為3個(gè) M12*100 數(shù)量為6個(gè)螺母GB6170-86 M10 數(shù)量為2個(gè) M10 數(shù)量為6個(gè)螺釘GB5782-86 , M6*20 數(shù)量為2個(gè) M8*25 數(shù)量為24個(gè) M6*16 數(shù)量為12個(gè)*(參考裝配圖)M10*35M12*100M10M12M6*20M8*25M6*168.2 銷,墊圈墊片的選擇 選用銷GB117-86,B8*30, 數(shù)量為2個(gè)選用墊圈GB93-87 數(shù)量為8個(gè)選用止動(dòng)墊片 1個(gè)選用石棉橡膠墊片 2個(gè)選用08F調(diào)整墊片 4個(gè)*(參考裝配圖)GB117-86B8*30GB93-87止動(dòng)墊片石棉橡膠墊片08F調(diào)整墊片有關(guān)其他的標(biāo)準(zhǔn)件,常用件,專用件,詳見(jiàn)后續(xù)裝配圖9 減速器結(jié)構(gòu)與潤(rùn)滑的概要說(shuō)明在以上設(shè)計(jì)選擇的基礎(chǔ)上,對(duì)該減速器的結(jié)構(gòu),減速器箱體的結(jié)構(gòu),軸承端蓋的結(jié)構(gòu)尺寸,減速器的潤(rùn)滑與密封,減速器的附件作一簡(jiǎn)要的闡述。9.1 減速器的結(jié)構(gòu)本課題所設(shè)計(jì)的減速器,其基本結(jié)構(gòu)設(shè)計(jì)是在參照裝配圖的基礎(chǔ)上完成的,該項(xiàng)減速器主要由傳動(dòng)零件(蝸輪蝸桿),軸和軸承,聯(lián)結(jié)零件(鍵,銷,螺栓,螺母等)。箱體和附屬部件以及潤(rùn)滑和密封裝置等組成。箱體為剖分式結(jié)構(gòu),由I箱體和箱蓋組成,其剖分面通過(guò)蝸輪傳動(dòng)的軸線;箱蓋和箱座用螺栓聯(lián)成一體;采用圓錐銷用于精確定位以確保和箱座在加工軸承孔和裝配時(shí)的相互位置;起蓋螺釘便于揭開(kāi)箱蓋;箱蓋頂部開(kāi)有窺視孔用于檢查齒輪嚙合情況及潤(rùn)滑情況用于加住潤(rùn)滑油,窺視孔平時(shí)被封?。煌馄饔脕?lái)及時(shí)排放因發(fā)熱膨脹的空氣,以放高氣壓沖破隙縫的密封而致使漏油;副標(biāo)尺用于檢查箱內(nèi)油面的高低;為了排除油液和清洗減速器內(nèi)腔,在箱體底部設(shè)有放汕螺塞;吊環(huán)螺栓用來(lái)提升箱體,而整臺(tái)減速氣的提升得使用與箱座鑄成一體的吊鉤;減速氣用地腳螺栓固定在機(jī)架或地基上。(具體結(jié)構(gòu)詳見(jiàn)裝配圖)9.2 減速箱體的結(jié)構(gòu)該減速器箱體采用鑄造的剖分式結(jié)構(gòu)形式具體結(jié)構(gòu)詳見(jiàn)裝配圖9.3 速器的潤(rùn)滑與密封蝸輪傳動(dòng)部分采用潤(rùn)滑油,潤(rùn)滑油的粘度為118cSt(100C)查表10.6機(jī)械設(shè)計(jì)課程設(shè)計(jì)指導(dǎo)書 潤(rùn)滑油118Cst軸承部分采用脂潤(rùn)滑,潤(rùn)滑脂的牌號(hào)為ZL-2查表10.7設(shè)計(jì)課程設(shè)計(jì)指導(dǎo)書 潤(rùn)滑脂ZL-29.4 減速器附件簡(jiǎn)要說(shuō)明該減速器的附件含窺視孔,窺視孔蓋,排油孔與油蓋,通氣空,油標(biāo),吊環(huán)螺釘,吊耳和吊鉤,起蓋螺釘,其結(jié)構(gòu)及裝配詳見(jiàn)裝配圖??偨Y(jié)作為一名學(xué)生,類似的設(shè)計(jì)是十分有意義,而且是十分必要的。在已度過(guò)里我們大多數(shù)接觸的是專業(yè)基礎(chǔ)課。我們?cè)谡n堂上掌握的僅僅是專業(yè)基礎(chǔ)課的理論面,如何去鍛煉我們的實(shí)踐面?如何把我們所學(xué)到的專業(yè)基礎(chǔ)理論知識(shí)用到實(shí)踐中去呢?我想做類似的大作業(yè)就為我們提供了良好的實(shí)踐平臺(tái)。在做本次課程設(shè)計(jì)的過(guò)程中,我感觸最深的當(dāng)數(shù)查閱大量的設(shè)計(jì)手冊(cè)了。為了讓自己的設(shè)計(jì)更加完善,更加符合工程標(biāo)準(zhǔn),一次次翻閱機(jī)械設(shè)計(jì)手冊(cè)是十分必要的,同時(shí)也是必不可少的。我們是在作設(shè)計(jì),但我們不是藝術(shù)家。他們可以拋開(kāi)實(shí)際,盡情在幻想的世界里翱翔,我們是工程師,一切都要有據(jù)可依.有理可尋,不切實(shí)際的構(gòu)想永遠(yuǎn)只能是構(gòu)想,永遠(yuǎn)無(wú)法升級(jí)為設(shè)計(jì)。 作為一名專業(yè)學(xué)生掌握一門或幾門制圖軟件同樣是必不可少的,由于本次大作業(yè)要求用 AUTOCAD制圖,因此要想更加有效率的制圖,我們必須熟練的掌握它。 雖然過(guò)去從未獨(dú)立應(yīng)用過(guò)它,但在學(xué)習(xí)的過(guò)程中帶著問(wèn)題去學(xué)我發(fā)現(xiàn)效率好高,記得大一CAD時(shí)覺(jué)得好難就是因?yàn)槲覀儧](méi)有把自己放在使用者的角度,單單是為了學(xué)而學(xué),這樣效率當(dāng)然不會(huì)高。邊學(xué)邊用這樣才會(huì)提高效率,這是我作本次課程設(shè)計(jì)的第二大收獲。但是由于水平有限,難免會(huì)有錯(cuò)誤,還望老師批評(píng)指正。參考資料1.機(jī)械原理 孫桓、陳作模、葛文杰主編高等教育出版社 2006年2.機(jī)械設(shè)計(jì) 濮良貴 紀(jì)名剛主編 高等教育出版社 2001年3.機(jī)械設(shè)計(jì)手冊(cè) 吳宗澤 羅圣田主編 高等教育出版社 1993年4.機(jī)械設(shè)計(jì)課程設(shè)計(jì) 劉俊龍 何在洲主編 機(jī)械工業(yè)出版社 1992年5.機(jī)械設(shè)計(jì)課程設(shè)計(jì) 盧頌峰 王大康主編 北京工業(yè)大學(xué)出版社 1993年6.機(jī)械設(shè)計(jì)課程設(shè)計(jì)蔡廣新 主編 機(jī)械工業(yè)出版社2002年7.中國(guó)機(jī)械設(shè)計(jì)大典第六卷 中國(guó)機(jī)械工程學(xué)會(huì)、中國(guó)機(jī)械設(shè)計(jì)大典編軸加工工藝設(shè)計(jì)分析加工程序左端O0903程序名T0505換五號(hào)端面車刀M03S600主軸正轉(zhuǎn),主軸轉(zhuǎn)速600mm/rG00X100Z100快速定位至換刀點(diǎn)X52Z3快速移動(dòng)至循環(huán)點(diǎn)Z-1G01X0F50車1mm的端面Z3X52F100Z-2X0F50Z2Z52F100Z-3X0F50Z3G00X100Z100退回?fù)Q刀點(diǎn)M05主軸停止T0101換一號(hào)刀M03S600主軸正轉(zhuǎn)、轉(zhuǎn)速600r/minG00X100Z100換刀點(diǎn)G00X28Z2快速移至循環(huán)起點(diǎn)G71U1R0.5F100定義G71粗車內(nèi)徑循環(huán),每刀切深為1mm,退刀量1mmG71P10Q20U-0.5W0F0.2粗車路線N10至N20 ,X軸留精車余量0.5mm,Z軸精車余量為0,粗車進(jìn)給為0.2mm/rN10G00X32車削加工輪廓起始行,到倒角延長(zhǎng)線G01Z0Z-26X20N20Z21G00X100Z100快速返回?fù)Q刀點(diǎn)T0101精車M03S800主軸正轉(zhuǎn),精車轉(zhuǎn)速為1000r/minG00X20Z2快速定位至安全起點(diǎn)G70P10Q20F0.1精車全部加工面G00X100Z100退刀至換刀點(diǎn)M05主軸停止M00程序暫停T0202換2號(hào)刀M03S500主軸正轉(zhuǎn),主軸轉(zhuǎn)速500r/minG00X51Z2快速移至循環(huán)起點(diǎn)G71U1R1每刀切深為1mm,退刀量1mmG71P10Q20U0.5W0F0.2粗車路線N10至N20 ,X軸留精車余量0.5mm,Z軸精車余量為0,粗車進(jìn)給為0.2mm/rN10G00X36運(yùn)行X軸至倒角起點(diǎn)處G01Z0 X38Z-1倒角1x45Z-35車38mm的外圓柱面X45車45mm的外圓柱面Z-46N20X50G00X100Z100快速退回?fù)Q刀點(diǎn)M05主軸停止M00程序暫停M03S1000精車主軸正轉(zhuǎn),主軸轉(zhuǎn)速1000r/minG00X51Z2快速移至循環(huán)起點(diǎn)G70P30Q40F0.1精車全部加工面G00X100Z100快速退回?fù)Q刀點(diǎn)M05主軸停止M30程序結(jié)束,并返回程序開(kāi)頭右端O9032程序名T0505換五號(hào)端面車刀M03S600主軸正轉(zhuǎn),主軸轉(zhuǎn)速600mm/rG00X100Z100快速定位至換刀點(diǎn)X52Z3快速移動(dòng)至循環(huán)點(diǎn)Z-1G01X0F50車1mm的端面Z3X52F100Z-2X0F50Z2Z52F100Z-3X0F50Z3G00X100Z100M05M30T020235右偏外圓粗車刀M03S600主軸正轉(zhuǎn),主軸轉(zhuǎn)速600r/minG00X100Z100快速退回?fù)Q刀點(diǎn)G00X51Z2快速移動(dòng)至循環(huán)起點(diǎn)G71U1R1每刀切深為1mm,退刀量1mmG71P10Q20U0.5W0F0.2粗車路線N10至N20 ,X軸留精車余量0.5mm,Z軸精車余量為0,粗車進(jìn)給為0.2mm/rN10G00X15.8運(yùn)行X軸至倒角起點(diǎn)處G01Z0X19.8Z-2倒角Z-18車螺紋M18mmG01X38Z-72G01X20Z-80車20mm的外圓柱面N20X50G00X100Z100快速退回?fù)Q刀點(diǎn)T0202精車M03S1000主軸正轉(zhuǎn),主軸轉(zhuǎn)速1000r/minG00X51Z2快速移動(dòng)至循環(huán)起點(diǎn)G70P10Q20F0.1精車外圓柱各部分G00X100Z100快速退回?fù)Q刀點(diǎn)M05主軸停止M00程序暫停M03S350主軸正轉(zhuǎn),主軸轉(zhuǎn)速350r/mmX22G01X16F10G00X100F100快速退回X100mmZ100Z100mmM05主軸停止M00程序暫停G00X100Z100快速退回?fù)Q刀點(diǎn)M05主軸停止M30程序結(jié)束,并返回程序開(kāi)頭揚(yáng)州工業(yè)職業(yè)技術(shù)學(xué)院數(shù)控加工工序卡產(chǎn)品名稱或代號(hào)零件名稱零件圖號(hào)軸軸車間使用設(shè)備數(shù)控車間CA6140工藝序號(hào)程序編號(hào)10%0001夾具名稱夾具編號(hào)三爪卡盤1工步號(hào) 工步作業(yè)內(nèi)容加工面刀具號(hào)刀補(bǔ)量主軸轉(zhuǎn)速進(jìn)給速度背吃刀量備注1車端面端面T0101860r/min129mm/min1mm2三爪卡盤夾持工件,中心架支撐,車端面見(jiàn)平,用尾架頂尖頂住中心孔,粗車57外圓,直徑留余量1mm,粗車38mm,45mm,50mm(2處),52mm,62mm外圓輪廓及臺(tái)階,直徑、長(zhǎng)度均留余量3mm外圓T0101700r/min140mm/min1.5mm編制審核批準(zhǔn)共 5 頁(yè)第 1頁(yè)揚(yáng)州工業(yè)職業(yè)技術(shù)學(xué)院數(shù)控加工工序卡產(chǎn)品名稱或代號(hào)零件名稱零件圖號(hào)軸軸車間使用設(shè)備數(shù)控車間CA6140工藝序號(hào)程序編號(hào)10%0001夾具名稱夾具編號(hào)三爪卡盤1工步號(hào) 工步作業(yè)內(nèi)容加工面刀具號(hào)刀補(bǔ)量主軸轉(zhuǎn)速進(jìn)給速度背吃刀量備注3調(diào)頭,三爪卡盤夾持工件另一端,中心架支撐,車斷面,保證總長(zhǎng)363mm,鉆中心孔,用尾架頂尖頂住,粗車38mm,45mm,50mm(2處),52mm,62mm外圓輪廓及臺(tái)階,直徑、長(zhǎng)度均留余量1mm外圓T0101700r/min140mm/min1.5mm編制審核批準(zhǔn)共 5 頁(yè)第2 頁(yè)揚(yáng)州工業(yè)職業(yè)技術(shù)學(xué)院數(shù)控加工工序卡產(chǎn)品名稱或代號(hào)零件名稱零件圖號(hào)軸軸車間使用設(shè)備數(shù)控車間CA6140工藝序號(hào)程序編號(hào)20%0002夾具名稱夾具編號(hào)三爪卡盤1工步號(hào) 工步作業(yè)內(nèi)容加工面刀具號(hào)刀補(bǔ)量主軸轉(zhuǎn)速進(jìn)給速度背吃刀量備注5雙頂尖裝夾,半精車臺(tái)階,車62,57mm,外圓輪廓車到圖紙尺寸,外圓T0202700r/min140mm/min1.5mm7 調(diào)頭,雙頂尖裝夾,精車余下的外圓輪廓及臺(tái)階,車38,50mm(2處),52直徑留余量0.5mm(磨削余量),倒角外圓T0101700r/min79.6mm/min0.25mm編制審核批準(zhǔn)共 5 頁(yè)第3 頁(yè)揚(yáng)州工業(yè)職業(yè)技術(shù)學(xué)院數(shù)控加工工序卡產(chǎn)品名稱或代號(hào)零件名稱零件圖號(hào)軸軸 車間使用設(shè)備數(shù)控車間M1432A工藝序號(hào)程序編號(hào)10%0001夾具名稱夾具編號(hào)1工步號(hào) 工步作業(yè)內(nèi)容加工面刀具號(hào)刀補(bǔ)量主軸轉(zhuǎn)速進(jìn)給速度背吃刀量備注8磨削加工38,50mm(2處),52達(dá)到圖紙規(guī)定尺寸粗糙度要求外圓300r/min100mm/min0.5mm9修研兩端,去毛刺10發(fā)黑處理編制審核批準(zhǔn)共 5 頁(yè)第 4頁(yè)揚(yáng)州工業(yè)職業(yè)技術(shù)學(xué)院數(shù)控加工工序卡產(chǎn)品名稱或代號(hào)零件名稱零件圖號(hào)軸軸車間使用設(shè)備數(shù)控車間工藝序號(hào)程序編號(hào)10%0001夾具名稱夾具編號(hào)1工步號(hào) 工步作業(yè)內(nèi)容加工面刀具號(hào)刀補(bǔ)量主軸轉(zhuǎn)速進(jìn)給速度背吃刀量備注11檢驗(yàn)12入庫(kù)編制審核批準(zhǔn)共 5 頁(yè)第 5頁(yè)揚(yáng)州工業(yè)職業(yè)技術(shù)學(xué)院機(jī)械加工工藝過(guò)程卡片產(chǎn)品圖號(hào)零件圖號(hào)1產(chǎn)品名稱軸零件名稱軸共2頁(yè)第1頁(yè)材 料 牌 號(hào)45#毛 坯 種 類型材毛坯外形尺寸65370每毛坯件數(shù)1每 臺(tái) 件 數(shù)1備 注 工 序 工 名 序 稱 工 序 內(nèi) 容車間設(shè) 備工 藝 裝 備工 時(shí)準(zhǔn)終單件1下料下料65370機(jī)加工鋸床鋸床夾具,量具,鋸條2車 三爪卡盤夾持工件,中心架支撐,車端面見(jiàn)平,用尾架頂尖頂住中心孔,粗車57外圓,直徑留余量1mm,粗車38mm,45mm,50mm(2處),52mm,62mm外圓輪廓及臺(tái)階,直徑、長(zhǎng)度均留余量3mm機(jī)加工車床車夾具,量具,車刀3車調(diào)頭,三爪卡盤夾持工件另一端,中心架支撐,車斷面,保證總長(zhǎng)363mm,鉆中心孔,用尾架頂尖頂住,粗車38mm,45mm,50mm(2處),52mm,62mm外圓輪廓及臺(tái)階,直徑、長(zhǎng)度均留余量1mm機(jī)加工車床車夾具,量具,車刀4熱調(diào)質(zhì)處理HB220-250熱處理熱處理熔爐5車雙頂尖裝夾,半精車臺(tái)階,車62,57mm,外圓輪廓車到圖紙尺寸, 機(jī)加工車床車夾具,量具,車刀6車 調(diào)頭,雙頂尖裝夾,精車余下的外圓輪廓及臺(tái)階,車38,50mm(2處),52直徑留余量0.5mm(磨削余量),倒角機(jī)加工車床車夾具,量具,車刀 設(shè) 計(jì)(日 期) 校 對(duì)(日期)審 核(日期)標(biāo)準(zhǔn)化(日期)會(huì) 簽(日期)標(biāo)記處數(shù)更改文件號(hào)簽 字 日 期標(biāo)記處數(shù)更改文件號(hào)簽 字 日 期揚(yáng)州工業(yè)職業(yè)技術(shù)學(xué)院機(jī)械加工工藝過(guò)程卡片產(chǎn)品圖號(hào)零件圖號(hào)產(chǎn)品名稱軸零件名稱軸共2頁(yè)第2頁(yè)材 料 牌 號(hào)45#毛 坯 種 類型材毛坯外形尺寸65370每毛坯件數(shù)1每 臺(tái) 件 數(shù)1備 注 工 序 工 名 序 稱 工 序 內(nèi) 容車間設(shè) 備工 藝 裝 備工 時(shí)準(zhǔn)終單件7磨磨削加工38,50mm(2處),52達(dá)到圖紙規(guī)定尺寸粗糙度要求機(jī)加工磨床8鉗修研兩端,去毛刺機(jī)加工10檢檢驗(yàn)機(jī)加工量具11庫(kù)入庫(kù)車間 設(shè) 計(jì)(日 期) 校 對(duì)(日期)審 核(日期)標(biāo)準(zhǔn)化(日期)會(huì) 簽(日期)標(biāo)記處數(shù)更改文件號(hào)簽 字 日 期標(biāo)記處數(shù)更改文件號(hào)簽 字 日 期長(zhǎng)春理工大學(xué)光電信息學(xué)院畢業(yè)設(shè)計(jì)Introduction to the common speed reducerDevice overview:Reducer is the prime mover and work machine independent closed between the transmission device, used to reduce speed and increase torque, in order to meet the job needs, also used for growth in some occasions, known as the accelerator.When choosing reducer should be according to the selection of working machine conditions, technical parameters, the performance of the engine, the factors such as economy, comparing the gabarite of different types and varieties of reducer, transmission efficiency and carrying capacity, quality, price, etc., choose the most suitable speed reducer.Reducer is a relatively sophisticated machinery, the use of its purpose is to reduce rotation speed, increase torque.Structural characteristics ofReducer is mainly composed of transmission parts (gear or worm), shaft, bearing, box and its accessories. Its basic structure has three parts:1gear, shaft and bearing combinationPinion and shaft made of an organic whole, gear shaft, this structure is used in the gear shaft and the diameter of the diameter of the weather related, if the diameter of the shaft is d, the gear tooth root circle diameter for df, when df - d 6 7 mn or less, this structure should be adopted. And when df - d 6 7 mn, separated with gear and shaft for the two parts of the structure, such as low speed shaft and large gear. The gear and shaft circumferential fixed flat linkage, shaft parts shaft shoulder, shaft sleeve and bearing cover is used as the axial fixation. Two shaft adopts the deep groove ball bearings. This combination, the less used to bear radial load and axial load. When the axial load is larger, should adopt angular contact ball bearing, taper roller bearing and deep groove ball bearing and thrust bearing of composite structures. Bearing is the use of the gear rotates splashing through the thin oil, lubrication. Box medium oil pool of the lubricating oil, the rotation gear splash splash into the lid on the inner wall of the inner flow box side groove to points, through the oil flow into the bearing. Nu when oiled gear circumferential speed 2 m/s, or less grease lubricated bearings should be adopted, in order to avoid possible wash it splashing through the thin oil lubricating grease, the oil retaining ring can be used to separate it. To prevent loss of lubricating oil and dust into the trunk, between bearing end cover and outrigger shaft equipped with sealing element.2 bodyEnclosure is the important part in the reducer parts. It is the base of the transmission parts, should have sufficient strength and rigidity.Cabinet is usually made of grey cast iron, for overloading or cast steel casing impact load reducer can also be used. Monomer production reducer, in order to simplify the process, to reduce the cost, can use steel plate welded box.Gray cast iron has good casting and vibration reduction performance. To facilitate the shafting parts installation and disassembly, made along the axis line horizontal split-casing box body. On the box cover and the lower box body with a bolt connection into a whole. The connecting bolt of the bearing should be close to the bearing hole, and the bearing seat at the side of convex set, should have enough supporting material surface, in order to place the connecting bolt, and to ensure that the wrench to tighten bolts need to space. In order to ensure the body has enough stiffness, plus support rib near the bearing hole. In order to ensure the stability and reduce as much as possible on the basis of speed reducer in the mechanical processing of base plane of the area, the case base is generally not used the complete plane.3 reducer fittingsIn order to guarantee the normal work of the speed reducer, in addition to combination of gear, shaft, bearing and the structure design of box body is to give enough attention, also should be considered as reducer oil lubricating oil pool, oil discharge, check the oil level height, processing, maintenance when assembling and disassembling of the box cover and the box of accurate positioning, loading auxiliary parts and components, such as reasonable selection and design.1) inspection to check the meshing condition of transmission parts, and to infuse lubricating oil contents, should be set in the appropriate location of the box body inspection hole. Inspection hole is located in the top lid can be observed directly on the gear mesh part. Normally, inspection hole of cover plate on the box cover with screws.2) the ventilator speed reducer is working, the casing temperature, gas expansion pressure, to make overall thermal air free to discharge, to maintain pressure balance inside and outside, not make the lubricating oil or shaft extension along the points box surface seal leakage cracks and other, usually on the top of the box body installed ventilator.3) bearing cover for the fixed shaft parts of axial position and carry axial load, the bearing hole on both ends with bearing cover closed. Bearing bore of flange type and embedded two kinds. Use hex bolt fixed on the box body, bearing cover is overhang shaft hole, which is equipped with sealing device. Flange type bearing cover has the advantage of tear open outfit, easy to adjust the bearing, but compared with the embedded bearing cover, the number of parts is bigger, the size is bigger, appearance is not smooth.4) positioning pin every time in order to ensure the container cover, remained bearing hole processing accuracy, should be in before finishing the bearing hole, in the box cover and the box seats on the connecting flange of the locating pin. Placed vertically on both sides of the enclosure on the connecting flange, symmetrical body should be symmetrical arrangement, in order to avoid mistake.5) oil level indicator to check the oil in the oil pool reducer hight, often maintain oil pool with just the right amount of oil, usually in the box body is convenient for observation, the oil level is relatively stable, installing the oil level indicator.6) oil drain plug oil change, dirty oil and cleaner emissions, should be in the box seat, at the bottom of the oil pool of the lowest opening oil drain hole location, usually with a screw oil drain plug, oil drain plug and body joint face between gasket shall be leak proof.7) seal screw for strengthening qi box, usually during assembly on housing subdivision surface coated with sodium silicate or sealant, when remove often due to the cementation close is difficult to open. So often the appropriate placement of the box cover connecting flange, work out 2 screw holes, screwing in enlightening the box with a cylindrical side or flat side box screws. Gyration rev box screws can will cover on top. Small reducer also dont have rev. Cases of screw, when the lid with a screwdriver to pry out of the box cover, and the box can be the same as the size of the screw to the connecting bolt at the flange.Main loadMachine with reducer connection work load condition is more complex, has much effect on the speed reducer, is one of the important factors, selection and calculation speed reducer the load state of the work machine (motivation) is the load condition, usually divided into three categories:(1) - even load;(2) - medium impact load;(3) - strong impact load.Design programA, the original design information and data1 the type of prime mover, specifications, speed, power (or torque), the startup characteristic, short-term overload capacity, the moment of inertia, etc.2 the type of machine, specifications, use, speed, power (or torque). Working system: the constant load or changing load and variable load load diagram; Rev., braking and short-time overload torque, start frequency; Shock and vibration levels; Direction of rotation, etc.3the prime mover for machine and connection way of the reducer, shaft and if there is a radial force and axial force.4installation type (reducer and prime mover, the relative position of working machine, vertical and horizontal).5transmission ratio and its error is allowed.6the size and weight requirements.7to the degree of service life, safety and reliability requirements.8environmental temperature, dust concentration, air velocity and environmental conditions such as ph value; (if there is a circulating lubrication and cooling conditions, lubrication station) and the limitation on the vibration and noise.9to the requirements of operation and control.10 the source of material, blank, standard parts and inventory.11factory manufacturing capabilities.12on volume, cost and price requirements.13, the delivery date.The article in the first four is a prerequisite, other aspects according to conventional design, such as the design life is generally! Years. Used for important occasions, reliability should be higher.Second, select the type of gear reducer and installation typeThree, set at the beginning of each process methods and parametersSelected performance level, set at the beginning of the main parts of the gear and the material, heat treatment, finishing methods, lubrication, and lubrication oil.Fourth, determine the transmission seriesAccording to the total transmission ratio, to determine the transmission series and all levels of the transmission ratio.Five, the initial geometry parametersEarly calculate gear transmission center distance (or pitch diameter), modulus and other geometric parameters.Six, the overall design schemeDetermine the structure of the reducer, shaft size, span and the bearing model, etc.Seven, checkCheck the strength of the gear, shaft, key load, calculation of bearing life.Eight, lubrication cooling calculationTo determine the speed reducer and accessoryTen, gear carburized depth is determinedWhen necessary for tooth form and tooth to fix quantity calculation process data.Eleven, drawing construction drawingIn the design should implement national and industry related standards.Using the classification1 reducer in use can be divided into two categories, general reducer and special reducer, design, manufacture and use of the two characteristics of each are not identical. 70-80 - s of the 20th century, reducer technology has made great development in the world, and closely integrated with the development of new technology revolution. The main types: gear reducer; Worm gear reducer; Gear - worm reducer; Planetary gear reducer.2general reducer has a helical gear reducer (including parallel shaft helical gear reducer, worm gear reducer, bevel gear reducer, etc.), planetary gear reducer, cycloid pin wheel reducer, the worm gear and worm reducer, planetary friction type mechanical stepless variable speed machine, and so on.1) cylindrical gear reducerSingle stage level 2, level 2, level 2 above. Decorate a form: expansion, shunt type, coaxial type.2) cone gear reducerUsed for the input shaft and output shaft position into the intersection.3) worm gear reducerIs mainly used for transmission ratio 10 occasions, I drive more compact structure. Its defect is low efficiency. Wide application of Archimedes worm gear reducer.4) gear - worm reducerIf gear drive level at high speed, the structure is compact;If worm transmission at high speed, high efficiency.5) planetary gear reducerWith a range of high transmission efficiency, transmission ratio, transmission power is 12 w 50000 kw, small volume and weight3common types of reducer1) the main characteristics of worm gear and worm reducer is a reverse self-locking function, can have a large reduction ratio, the input shaft and output shaft is not in the same axis, is not in the same plane. But generally larger, transmission efficiency is not high, the accuracy is not high.2) harmonic reducer harmonic drive is to use the elastic deformation of flexible components controlled to transfer movement and power, small size, high precision, but the disadvantage is that soft wheel life is limited, dont impact resistance, rigidity compared with metal parts. Input speed cannot be too high.3) planetary gear reducer, its advantage is more compact in structure, return clearance is small, high precision, long service life, rated output torque can do a lot of. But the price a little expensive. Reducer: in short, generally after the machine power in design and manufacture, the rated power will not change, at this time, the greater the speed, the smaller is the torque (or torque); Speed is smaller, the greater the torque.The transmission ratio distribution principle1 to make the bearing capacity of transmission at all levels are equal;2 make all levels of transmission gear oil immersion depth is roughly similar in;3minimize the reducer for the shape of the size or weight, etcModel selectionAs far as possible choose close to ideal reduction ratio:Reduction ratio = / servo motor speed reducer output shaft speedTorque calculation:For the life of the reducer, torque calculation is very important, and should pay attention to the maximum torque value of the acceleration (TP), which is superMaximum load torque of reducer.Apply power is usually the servo on market model for power, the applicability of the speed reducer is very high, can remain above 1.2 coefficient of work, but in use can also with their own needs to decide:There are two main points:A. choose servo motor output maximum diameter of axle diameter of axle is not greater than form.B. If the computed torque, rotational speed can meet the normal operation, but in the net output servo have insufficient phenomenon, we can in the motor drive, do current limit control, or on the mechanical shaft torque protection, it is very necessary.Installation methodThe correct installation, use and maintenance of the reducer, it is an important link in ensure the normal operation of machinery and equipment. When you install reducer, therefore, please be sure to use related matters in strict accordance with the following installation, assembly and use seriously.The first step is to install before confirm the motor and reducer are intact, and strict inspection of motor and reducer connected each part size matches, here is the positioning convex table of the machine, input shaft and gear reducer groove size and tolerance, etc.The second step is to unscrew the gear reducer dustproof holes on flange lateral screw, adjust the clamping ring dustproof holes and side holes to make it align with each other, and insert the socket head screw. After taking the motor shaft key.The third step is to connect the motor and the reducer nature. Connection must be to ensure the output gear reducer input shaft and motor shaft concentricity is consistent, and the outer flange is parallel. Such as concentricity is inconsistent, can lead to broken motor shaft or reducer gear wear and tear.Check the maintenanceDifferent lubricant mixed ban each other. Oil level screw, oil drain plug and the location of the ventilator is determined by the installation position. Their relative position refer to the installation drawing to determine that speed reducer.One, the oil level checkCut off the power supply, prevent to get an electric shock! Waiting for reducer cooling!Remove the oil level screw check filled with oil.Install the oil level screw.Second, the check of oilCut off the power supply, prevent to get an electric shock! Waiting for reducer cooling!Open the oil plug, pick up sample.Check the oil viscosity index- if oil significantly turbidity, it is recommended that the replacement as soon as possible.To bring oil level screw speed reducer- check the oil level, whether qualified- the installation of oil level screw3the oil replacementAfter cooling oil viscosity increases with difficulty, reducer should be under the running temperature oil change.Cut off the power supply, prevent to get an electric shock! Waiting for reducer cooled down no burning danger!Note: when an oil change speed reducer should still keep warm.Under the oil drain screw one by oil pan.Open the oil level screw, ventilator and oil drain plug.All the oil out.Install drain plug.Injection with brand new oil.Oil shall conform to the installation location.Check the oil level in the oil level screw.Tighten the oil level screw and ventilator.Failure to solveSpeed reducer leakage oil cause analysis and solutionAnalysis of the causes1the pressure inside the tankIn closed reducer, each pair of gears meshing friction will emit heat, according to the Boyle trails by specific law, as the lengthen of running time, the deceleration box temperature gradually raised, and the reduction volume inside the case, so the pressure increase, in the case of lubricating oil splash, sprinkle on the inner wall of the deceleration box. Because the permeability of oil is strong, the overall pressure, which a seal is lax and the oil bleeding out from where.2the structure of the speed reducer design is not reasonable cause oil leakageSuch as design of reducer without ventilation hood, pressure reducer can not be achieved, in the pressure more and more high, oil leakage occurs.3amount to muchReducer in the process of operation, oil pool was badly agitation, lubricating oil splash around in the machine, if the amount is overmuch, make a lot of the place such as lubricating oil accumulation in the shaft seal, joint surface and lead to leakage.4improper maintenance technologyIn equipment maintenance, due to the combined surface dirt removal is not complete, or sealant improper selection, seal, not timely replacement of seals, etc way can also cause oil leakage.Treatment schemeGovernance using polymer composite materials to repair speed reducer leakage oil, polymer composite materials based on polymer, metal or ceramic powder, fiber and other materials for, under the action of curing agent, curing catalyst of composite materials. All kinds of material in performance from each other each other, to produce synergistic effect, the comprehensive performance is better than the original ingredients of composite materials. Have extremely strong sticky relay, mechanical properties, and chemical corrosion resistance and other performance, and therefore is widely used in metal equipment, mechanical wear, scratches, pits, cracks, leakage, repair such as casting sand holes, and chemistry of chemical storage tank, reaction tank, pipe anti-corrosion protection and restoration. For reducer static seal leakage point can use the ka wah polymer composite materials and technology field leakage of governance, without disassembly, polymer composite materials in the leakage of external governance, save time and effort, the effect is immediate, the product has excellent adhesion, oil resistance, and 350% of the tensile strength, overcome the impact of reducer vibration, well solved for many years for the enterprise is unable to solve the problem. If reducer running in static seal leak, the oil level of emergency repairing adhesive available surface engineering technologies NianDu, so as to achieve the aim of eliminate oil leakage.Development trend1high level and high performance. Widely used cylindrical gear carburizing and quenching, grinding, carrying capacity increased by more than 4 times, small volume, light weight, low noise, high efficiency and high reliability.2modular combination design. Basic parameters using priority number, size, parts versatility and interchangeability, series of easy to expand and newer, conducive to tissue mass production and reduce cost.3style diversification, variant design. To get rid of the traditional single base installation, added a hollow shaft mounted, floating bearing base, motor and reducer one-piece, different types, such as multiple mounting surface
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