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無錫職業(yè)技術學院
機械加工工藝過程卡片
產品型號
零件圖號
A4
產品名稱
回程盤
零件名稱
三爪自定心卡盤(K11320)盤絲
共 1頁
第 1頁
材料牌號
45
毛坯種類
棒料
毛坯外形尺寸
每毛坯可制作數
1
每臺件數
1
備注
大批生產
工序號
工序名稱
工序內容
車間
工段
設備
工藝裝備
工時/min
10
鑄造
鑄工
造型
準終
單件
20
車
夾持毛坯外圓,粗車平面螺紋端面和內孔
金工
車
數控車床CAK6140
山特維克刀具(CNMM16 06 8-PR-GC4025),游標卡尺
0.1h
1
30
車
精車平面螺紋端面和內孔
金工
車
數控車床CAK6140
山特維克刀具(CNMM16 06 8-PR-GC4025),游標卡尺
0.1h
1
40
車
掉頭崩夾持內孔Φ120mm內孔,粗、精加工外圓Φ203
金工
車
數控車床CAK6140
山特維克刀具(CNMM16 06 8-PR-GC4025),游標卡尺
0.1h
1
50
車
粗、精加工端面
金工
車
數控車床CAK6140
山特維克刀具(CNMM16 06 8-PR-GC4025),游標卡尺
0.1h
1
60
銑
銑平面螺紋
金工
銑
數控銑床MVC850B
ED5立銑刀,ED2立銑刀,游標卡尺
0.4h
1
70
滾齒
滾斜齒輪
金工
滾齒
滾齒機
0.3h
1
80
清洗,去毛刺
金工
銑
數控銑床MVC850B
0.1h
1
90
檢驗
金工
銑
數控銑床MVC850B
山特維克刀具(CNMM12 04 08-QF-GC4025),游標卡尺
0.1h
1
140
入庫
編制 (日期)
審核 (日期)
標準化 (日期)
會簽
(日期)
標記
處數
更改文件號
簽字
日期
標記
處數
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簽字
日期
建模步驟:
1、繪制草圖
2、回轉得到實體
3、繪制卡槽
4、陣列60個卡槽
5、繪制螺旋線
6、繪制截面
7、掃掠
8、修剪旋入口和旋出口
無錫職業(yè)技術學院
畢業(yè)設計(論文)
論文題目:四爪單動卡盤(k72200)絲杠工藝設計與程序編制
所屬系部:
指導老師: 職 稱:
學生姓名: 班級、學號:
專 業(yè):
2014年4月10 日
II
四爪單動卡盤(k72200)絲杠工藝設計與程序編制
摘要:隨著科技的不斷發(fā)展,數控技術在企業(yè)中發(fā)揮越來越重要的作用。本設計通過對數控加工的工藝特點、加工零件工藝性等進行分析,選擇正確的加工方法,設計合理的加工工藝過程,充分發(fā)揮數控加工的優(yōu)質、高效、低成本的特點。設計說明書以三爪自動定心卡盤盤絲零件為例,根據被加工工件的材料、輪廓形狀、加工精度等選用合適的機床,制定加工方案,確定零件的加工順序,各工序所用刀具,夾具和切削用量等,編寫加工零件的程序。?
關鍵詞:工藝過程;加工方案;切削用量;編寫程序Four claws single-acting chuck (k72200) screw process design and programming
Abstract:With the continuous development of science and technology, numerical control technology is playing a more and more important role in the enterprise.This design through to the nc machining process characteristics, such as machining parts manufacturability analysis, to select the correct processing methods, design the reasonable machining process, give full play to the nc machining of the characteristics of high quality, high efficiency and low cost.Design specification to three jaw self centering chuck plate wire parts as an example, according to the shape of the material, the outline of the processed workpiece, choose suitable machine tools machining precision, processing scheme, determine the machining sequence of parts, each working procedure used tool, fixture and cutting dosages, writing program of machining parts..?
Key words :process;Processing scheme;Cutting parameter;Write a program
目 錄
摘要 I
Abstract II
一 ?零件的工藝分析 1
(一)零件的功用、結構及特點 1
(二)主要加工表面及其要求 1
二 毛坯的選擇 2
(一)確定毛坯的類型,制造方法和尺寸度及其公差 2
(二)確定毛坯技術要求 2
三 基準的選擇 2
四 ?擬定機械加工路線 3
(一)確定各表面的加工方法 3
(二)擬定加工路線 3
(三)工藝分析 3
五 機床的選擇及工藝裝備 3
(一)機床的選擇 3
(二)選擇刀具 4
(三)選擇量具 4
六?確定切削用量參數 4
(一)粗車端面 4
(二)粗車內孔 4
(三)粗車外圓 5
(四)精車端面 5
(五)精車內孔 5
(六)確定精車時的切削余量 5
七 三維圖的繪制及自動編程參數設計 6
(一)三維圖的繪制 6
(二)自動編程參數設置 10
八 程序的編制 14
(一)工序10、20程序 14
(二)工序30、40程序 15
(三)工序50程序 15
總 結 17
參考文獻 18
一 ?零件的工藝分析
(一)零件的功用、結構及特點
? 三爪卡盤裝夾工件的原理是,利用卡盤扳手轉動圓周上的三個傘齒中的任一個。從而帶動盤絲平面螺紋轉動并帶動三個卡爪一齊移動,起到自定心裝夾工件作用,在工作中承受一定的載荷,因此要求其有一定的強度和耐磨性。
(二)主要加工表面及其要求
?①內孔
?孔徑為Φ120mm的孔是定位用的,表面粗糙度Ra=3.2um,倒角人C1,公差等級為IT8~12,位置度要求為0.01mm,圓柱度為0.008mm,垂直端面度為0.01mm,基準為A,要求較高需要合理的安排加工工藝。
②外圓
表面尺寸要求為Φ203mmmm,公差等級為IT8~12,外圓表面素線以孔軸為基準,無較高的要求。
③端面
外端面粗糙度Ra=3.2um,此加工面做為基準面,平面度要求較高0.02mm
④平面螺紋
此平面螺紋由阿基米德螺旋線方程式構成,r(θ)= a+ b(θ)
式中:
b—阿基米德螺旋線系數,mm/°,表示每旋轉1度時極徑的增加(或減?。┝浚?
θ—極角,單位為度,表示阿基米德螺旋線轉過的總度數;
a—當θ=0°時的極徑,mm。
利用卡盤扳手轉動圓周上的三個傘齒中的任一個。從而帶動盤絲平面螺紋轉動并帶動三個卡爪一齊移動,所以要求較高,端面垂直度為0.012mm
⑤斜齒輪
利用卡盤扳手轉動圓周上的三個傘齒中的任一個,斜齒輪也跟著轉動,從而平面螺紋也跟著動,進而三爪也跟著動。加工表面無較高要求。
二 毛坯的選擇
(一)確定毛坯的類型,制造方法和尺寸度及其公差
①該零件的材料為20Cr/20CrMnTi,設計要求生產類型為成批生產,根據形狀,選用金屬模砂型機器鑄造。
②選擇零件的一端面作為分型面鑄造出帶孔的圓棒料。
③由零件圖技術要求知該零件精度要求較高,毛坯為精密的鑄件,鑄件尺寸公差為CT9加工余量等級按CT9-MA-H/G級。各表面單邊余量3.0mm。
(二)確定毛坯技術要求
①鑄件不應有裂紋、砂眼、和局部縮松、氣孔及夾渣等缺陷,鑄件表面應清除毛刺同、結瘤和粘砂等。
②球化退火處理硬度為207~229HBW,以降低硬度,改善切削加工性,并為淬火作好組織上的準備,材料為20Cr/20CrMnTi。
③未注倒角0.5x45 ,其余粗糙度Ra=6.3um。
三 基準的選擇
由零件圖中的技術要求可知該零件的尺寸較多是以平面螺紋端面為設計基準,且圖中內孔表面和平面螺紋尺寸精度要求較高,根據粗精基準選擇原則和基準重合統(tǒng)一原則,確定各表面的基準如下表所示:
序號
加工部位
?? 基準選擇
1
孔及其平面螺紋端面
外圓輪廓及端面(粗基準)
2
外圓輪廓
內孔中心線和端面A
3
端面和斜齒輪
內孔中心線和端面A
?四 ?擬定機械加工路線
(一)確定各表面的加工方法
根據各加工表面的加工精度和表面粗糙度要求,選定如下加工方法:
端面加工為車削;
孔的加工為車削;
外圓加工為車削;
平面螺紋加工為銑削;
斜齒輪加工為滾齒。
(二)擬定加工路線
???? 加工方案如下表:
工序號
內容
設備
10
夾持毛坯外圓,粗車平面螺紋端面和內孔
臥式車床
20
精車平面螺紋端面和內孔
臥式車床
30
掉頭崩夾持內孔Φ120mm,粗、精加工外圓
臥式車床
40
粗、精加工端面
臥式車床
50
銑平面螺紋
立式銑床
60
滾斜齒輪
滾齒機
70
清洗,去毛刺
?
80
檢驗
?
(三)工藝分析
此工藝按工藝集中原則組織工序,許多工序可在同一機床上完成,減少了工件的裝夾次數,易于保證加工面的質量,需要的機床少,減少了工件在工序間的運輸,減少輔助時間和準備時間。
?
五 機床的選擇及工藝裝備
(一)機床的選擇
(1) 工序10、20、40
由于有些工序包括多個工步,該零件形狀較規(guī)則,為減少裝卸刀具次數和時間,保證工件質量,選用CA6140型臥式車床比較合適。
?(2) 工序50
?根據工件的尺寸選用MVC850B立式銑床。
(3)工序60
根據工件的形狀選擇滾齒機
(二)選擇刀具
該零件特形表面,成批生產,一般采用通用或標準刀具,臥式車床上粗車端面和外圓可選用90°外圓車刀,內孔選用25方內孔車刀,銑平面螺紋選用ED5mm立銑刀和ED3mm立銑刀,斜齒輪選擇滾齒刀。
(三)選擇量具
該零件屬批量生產,一般采用通用量具。
(1)外圓和內孔加工量具
外圓表面 公差值T=0.23mm,查表得計量器具不確定度允許值為 =.00018,查表得,所選用的計量器具達不到GB 3177—1997規(guī)定的 。則重新計算安全裕度A’, A’= =0.002
由于零件最大實體尺寸:203mm
則基驗收極限尺寸: 由分析得應選用0~250mm游標卡尺
(2)端面量具
需要測量平行度,所以選用0-25mm的外徑千分尺
?六?確定切削用量參數
(一)粗車端面
(1)粗車端面
?步驟如下是:
①確定背吃刀量 :端面單邊總余量3mm,一次走刀加工1.0mm。
②確定進給量f:根據表查得f=0.6~0.9mm/r;根據機床的橫向進給量,取f=0.8mm/r。
③確定進給量f:根據 表查得 =235,m=0.20, ?修正系數 刀具壽命選T=60min,故=72.2m/min
④確定機床主軸轉速n:根據表查得相近較小的機床轉速為n=420r/min,所以實際切削速度 =80m/min
(二)粗車內孔
①確定背吃到量 :總加工余量為3.0mm,一次走刀加工1mm。
②確定進給量f:根據表5-102查得f=0.6~0.9mm/r;根據機床的縱向進給量,取f=0.81mm/r。
③確定切削速度 :根據表查得 =235,m=0.20, =0.15, =0.45,修正系數 =0.87, =1.0, =0.8, =0.81, =1.0,刀具壽命T=60min,故 =55.98m/min
④確定機床主軸轉速n:
根據表查得相近較小的機床轉速為n=320r/min,所以實際切削速度 =54.26m/min
(三)粗車外圓
①背吃刀量的ap的選擇:查《簡明機械加工工藝手冊》 可知A=(50-46)/2=2mm,單邊留0.5mm做精車余量,取粗車背吃刀量ap=1mm。
②確定進給量f:查查《簡明機械加工工藝手冊》 可知,f=0.4~0.5mm/r,根據機床說明書,初步選定f=0.45mm/r.
③確定切削速度Vc:查查《簡明機械加工工藝手冊》 可知,Vc=2.17~2.667m/s,考慮到進給量較大取Vc=2m/s。
④確定主軸轉速n,由公式:n=1000v/πd=(1000×2)/(3.14×30)=5.31r/s
根據機床說明書,取n=12.5r/s。此時切削速度為:Vc=πdn/1000=(3.14×30×12.5)/1000=1.18m/s
(四)精車端面
①確定背吃刀量 ,端面單邊剩余余量為1mm,二次走刀加工, =0.5mm。
②確定進給量f:根據表查得f=0.6~0.9mm,查表5-5得f=0.61mm/r。
③確定切削速度 :根據表查得 修正系數 =77.47m/min
④機床主軸轉速n:
根據表查得相近較小的機床轉速為n=250r/min,所以實際切削速度 =71.44m/min.
(五)精車內孔
①確定背吃刀量 :側壁加工余量為0.5mm,一次走刀加工完成, =0.5mm.
② 確定進給量f:根據表查得f=0.6~0.9mm/r,取f=0.5mm.
③確定切削速度 修正系 =0.87, =1.24, 刀具壽命選T=60min,故
④確定機床主軸轉速n:
根據表查得相近較小的機床轉速為n=250r/min,所以實際切削速度 =94.985 m/min
(六)確定精車時的切削余量
①確定背吃刀量ap 取ap=0.25mm。
②確定進給速度f 查《簡明機械加工工藝手冊》,預估計切削速度VC>1.66m/s時,查得f=0.25~0.39mm/r,根據機床說明書,取f=0.30mm/r。
③確定切削速度VC與機床主軸轉速,可知VC=2.17~2.667m/s,根據機床說明書,取VC=2.4m/s.
④按公式得主軸轉速:
n=(1000V)/πd=(1000×2.4)/(3.14×203)=0.822r/s。
按機床說明書,取n=16.66r/s。按公式算得切削速度為:
VC=(π·d·n)/1000=(3.14×203×16.4)/1000=11.9m/s。
由于精車切削力較小,故一般不需校驗,最后選定精車切削用量為:ap=0.25mm,f=0.30mm/r,VC=2.39m/s,n=500r/min
七 三維圖的繪制及自動編程參數設計
(一)三維圖的繪制
繪制回轉草圖
繪制斜齒輪草圖
拉伸草圖
在繪制如下草圖
拉伸上步驟畫的草圖
同理反面拉伸草圖
陣列特征
繪制平面螺紋截面線串
繪制界面線串后,進行掃略
繪制一個曲面修建
同理修建另一頭
最后求和
(二)自動編程參數設置
本零件的編程運用UGNX6.0編制,首先繪制好零件實體圖后,如圖所示為UGNX6.0工作界面與零件實體圖。
(1)創(chuàng)建機床坐標系,首先雙擊菜單欄里的,進入安全設置選項里面設定安全平面30mm
圖4.12
(2)設計銑削幾何體,雙擊右邊導航器里的WORKPIECE,進行設置加工工件與加工毛坯。毛坯建法:先將工件隱藏,在草圖上回轉草圖,再在編輯菜單里進行互換顯示與隱藏。
(3)創(chuàng)建刀具
UG課程的時候,老師說過做UG仿形加工有三個步驟:①用什么刀具加工;②確定對零件件加工方法;③選擇零件加工的操作命令。我現在創(chuàng)建操作平面立銑外輪廓,選擇Ф5的立銑刀,去除外部毛坯材料。如圖所示。
按照以上操作再創(chuàng)建其他刀具。最后建成直徑3mm的平底銑刀精加工
圖4.15 建立刀具
(4)創(chuàng)建刀具軌跡,上UG課程的時候,老師說過做UG仿形加工有三個步驟:①用什么刀具加工;②對什么零件進行加工;③怎么加工。現在第三步如下圖所示。
A、粗加工,選擇型腔銑開粗
設置切削區(qū)域
設置切削模式,步距,每刀切削深度
設置非切削參數
設置主軸轉速和切削速度
刀具軌跡
2D仿真
同理在選擇ED3mm的立銑刀精加工
八 程序的編制
(一)工序10、20程序
順序號
程序內容
程序說明
O0001
程序名
N10
M03S400T0101
啟動主軸1號刀粗車
N20
G0X210Z3
快速定位靠近工件
N30
G90X110Z2F150
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總 結
通過此次畢業(yè)設計,我們基本上掌握了零件的工藝過程的分析、工藝文件的編制,了解了一些機械制造技術基礎的知識,切身體會到了從毛坯到成品的工藝過程,從而對于本課有一個較為清析的輪廓印像。學會了查相關手冊、選擇使用工藝裝備等等。
總的來說,這次課程設計,使我們在基礎理論知識的綜合運用及正確解決實際問題等方面得到了一次較好的訓練,提高了我們的思考、解決問題、創(chuàng)新設計的能力,為以后的工藝設計打下較好的基礎。
對于這門課程我們還只有一個初步的認識,所以請老師多多指正批評。如果要想更好的掌握這門課技術,還需要我們進一步的學習與實踐,在實際的工作中不斷的積累經驗,這樣我們才能更好的學好這門技術,更好地了解機械制造工業(yè),從而為以后的工作打下堅固的基礎。
參考文獻
【1】王愛玲.現代數控機床實用操作技術[M].北京:國防工業(yè)出版社,2O05.
【2】金捷 劉小菡 主編. 機械制造技術與訓練項目.上海:復旦大學出版社,2010
【3】唐應謙.數控加工工藝學[M].北京:中國勞動社會保障出版社,2000.
【4】熊熙.數控加工實訓教程[M].北京:化學工業(yè)出版社,2003.
【5】劉立.數控車床編程與操作[M].北京:北京理工大學出版社,2006.
【6】楊仲岡.數控加工技術.北京:機械工業(yè)出版社,2001.
【7】于華.數控機床的編程及實例.北京:機械工業(yè)出版社,1996.
【8】王先逵.機械制造工藝學.北京:機械工業(yè)出版社,1995.
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