雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì)—專機(jī)總體設(shè)計(jì)主軸箱設(shè)計(jì)
雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì)專機(jī)總體設(shè)計(jì)主軸箱設(shè)計(jì),雙頭鉆擴(kuò)鉸,專機(jī),設(shè)計(jì),總體,整體,主軸
編 號(hào) 無(wú)錫太湖學(xué)院 畢 業(yè) 設(shè) 計(jì) ( 論 文 ) 題目: 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì) 專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 信 機(jī) 系 機(jī) 械 工 程 及 自 動(dòng) 化 專 業(yè) 學(xué) 號(hào): 0923151 學(xué)生姓名: 繆成威 指導(dǎo)教師: 張大駿 (職稱:高級(jí)工程師 ) (職稱: ) 2013 年 5 月 25 日 無(wú)錫太湖學(xué)院本科畢業(yè)設(shè)計(jì)(論文) 誠(chéng) 信 承 諾 書 本人鄭重聲明:所呈交的畢業(yè)設(shè)計(jì)(論文) 雙頭鉆擴(kuò)鉸 專機(jī)設(shè)計(jì)專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 是本人在導(dǎo)師的指 導(dǎo)下獨(dú)立進(jìn)行研究所取得的成果,其內(nèi)容除了在畢業(yè)設(shè)計(jì)(論 文)中特別加以標(biāo)注引用,表示致謝的內(nèi)容外,本畢業(yè)設(shè)計(jì) (論文)不包含任何其他個(gè)人、集體已發(fā)表或撰寫的成果作品。 班 級(jí): 機(jī)械 93 學(xué) 號(hào): 0923151 作者姓名: 2013 年 5 月 25 日 I 無(wú) 錫 太 湖 學(xué) 院 信 機(jī) 系 機(jī) 械 工 程 及 自 動(dòng) 化 專 業(yè) 畢 業(yè) 設(shè) 計(jì) 論 文 任 務(wù) 書 一、題目及專題: 1、題目 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì) 2、專題 專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 二、課題來(lái)源及選題依據(jù) 課題來(lái)源:無(wú)錫市惠發(fā)特精密制造機(jī)械有限公司 減震器鋁合金缸體的圖紙,加工要求(包括實(shí)物) 。 材料:ZAlSi9Mg 缸體年產(chǎn)綱領(lǐng) 50000 件/年 三、本設(shè)計(jì)(論文或其他)應(yīng)達(dá)到的要求: 1、根據(jù)產(chǎn)品圖樣及樣品進(jìn)行工藝分析,選擇比較合理的工藝方案。 2、進(jìn)行專用機(jī)床總體設(shè)計(jì), “三圖一卡”的設(shè)計(jì)與繪制即完成本工 序的工序圖、加工示意圖、機(jī)床總圖及床身部件圖,折合不少于 3 張 A0圖紙。 3、編寫設(shè)計(jì)說(shuō)明書一份,要求對(duì)機(jī)床的總體設(shè)計(jì)部分詳細(xì)分析說(shuō)明, 并包括必要的計(jì)算,文字簡(jiǎn)潔通順,重要公式數(shù)據(jù)應(yīng)標(biāo)明出處。字 II 數(shù)一萬(wàn)字左右。 4、專業(yè)英語(yǔ)翻譯一萬(wàn)字符左右 四、接受任務(wù)學(xué)生: 機(jī)械 93 班 姓名 繆成威 五、開始及完成日期: 自 2012 年 11 月 12 日 至 2013 年 5 月 25 日 六、設(shè)計(jì)(論文)指導(dǎo)(或顧問(wèn)): 指導(dǎo)教師 簽名 簽名 簽名 教 研 室 主 任 學(xué)科組組長(zhǎng)研究所 所長(zhǎng) 簽名 系主任 簽名 2012 年 11 月 12 日 III 摘 要 組合機(jī)床是一種高效專用機(jī)床,有特定的使用條件。在確定設(shè)計(jì)機(jī)床前,應(yīng)該進(jìn)行 具體的經(jīng)濟(jì)技術(shù)分析。加工同一個(gè)機(jī)械產(chǎn)品的零件,通常會(huì)有很多種工藝方案,不同的 方案會(huì)有不同的經(jīng)濟(jì)效果,影響技術(shù)經(jīng)濟(jì)的因素有很多,有時(shí)技術(shù)指標(biāo)先進(jìn)的方案,經(jīng) 濟(jì)指標(biāo)不一定優(yōu)越。因此,需要對(duì)技術(shù)、經(jīng)濟(jì)指標(biāo)作綜合評(píng)價(jià),選出優(yōu)化方案進(jìn)行經(jīng)濟(jì) 效果評(píng)價(jià),如果滿意即可決定。 本課題是雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì)。其來(lái)源于惠發(fā)特精密機(jī)械有限公司。在設(shè)計(jì)中,通 過(guò)研究被加工零件的特點(diǎn),對(duì)相關(guān)數(shù)據(jù)進(jìn)行計(jì)算,對(duì)相關(guān)部件進(jìn)行選擇,從而確定機(jī)床 的總體布局。并繪制出被加工零件工序圖,加工示意圖,機(jī)床聯(lián)系尺寸圖和生產(chǎn)率計(jì)算 卡。在此基礎(chǔ)上擬定了主軸箱的傳動(dòng)路線,設(shè)計(jì)了軸的結(jié)構(gòu),進(jìn)行了皮帶輪及軸等相關(guān) 零件的強(qiáng)度,剛度校核,并繪制出主軸箱裝配圖。該機(jī)床對(duì)零件的兩端孔同時(shí)進(jìn)行加工, 加工的工藝性好,工件裝夾方便。采用滾珠絲杠導(dǎo)軌實(shí)現(xiàn)刀具進(jìn)給。工件采用 V 形塊定 位,液壓夾緊,一次裝夾完成不僅保證了孔的加工精度,而且還提高了加工效率,降低 了工人的勞動(dòng)強(qiáng)度。 關(guān)鍵詞:雙頭鉆擴(kuò)鉸專機(jī);組合機(jī)床;主軸箱 IV Abstract Portfolio is a highly efficient machine for machine tools, there are specific conditions of use, in determining the design of machine tools, should carry out specific economic and technical analysis. Processing products with a mechanical parts, usually have a variety of programmes, the impact of technological and economic factors are many, sometimes technical indicators advanced programmes, economic indicators do not necessarily superior, therefore, need to On the technical, economic indicators for comprehensive evaluation, comprehensive views of the majority, elected Optimization of economic evaluation, if you satisfied with the decision. This topic is designed to face double-processing machine combinations. Its benefits from the special Precision Machinery , In the design: The study was part of the processing characteristics of the relevant data, the relevant components of choice to determine the overall layout of machine tools. And the mapping of processes to be processed parts map, diagram processing, machine size map and the associated productivity calculation card. On this basis the development of the spindle box of transmission lines, the design of the shaft structure, a pulley and shaft, and other relevant parts of the strength and stiffness Verification, and spindle box assembly to map out plans and related spare parts plans. Tool Guide to achieve a ball screw feed. Workpiece positioning using V-shaped blocks, hydraulic clamp, a fixture not only guarantee the completion of the hole processing precision, but also improve the processing efficiency and reduce the labor intensity of the workers. Key words: double-face processing; combination machine; Headstock V 目 錄 摘 要 .III ABSTRACT .IV 目 錄 .V 1 緒 論 .1 1.1 惠發(fā)特精密機(jī)械有限公司簡(jiǎn)介 .1 1.2 本設(shè)計(jì)任務(wù)簡(jiǎn)介 .1 1.3 本設(shè)計(jì)應(yīng)達(dá)到的要求 .1 2 機(jī)床總體設(shè)計(jì) .2 2.1 工藝方案制定 .2 2.1.1 工件和加工部位的主要要求 .2 2.1.2 擬定工藝路線 .2 2.1.3 二種工藝線路的比較與確定及其各分析其優(yōu)缺點(diǎn) .6 2.1.4 安裝與夾緊方案的比較與確定,包括定位、夾緊、夾緊部位、形式等 .7 2.1.5 刀具、輔具的確定 .8 2.1.6 工序 .8 2.1.7 工序的集中與分散 .9 2.1.8 確定加工工藝路線 .9 2.1.9 加工工序卡片 .10 2.2 專機(jī)總體設(shè)計(jì) .11 2.2.1 確定專機(jī)的驅(qū)動(dòng)方式,切削力,切削功率、電動(dòng)機(jī)選擇等計(jì)算 .13 2.2.2 基本參數(shù)(尺寸)設(shè)計(jì) .17 2.2.3 傳動(dòng)系統(tǒng)設(shè)計(jì) .17 2.2.4 三圖一卡的設(shè)計(jì) .19 3 主軸箱的設(shè)計(jì) .27 3.1 主軸箱及其卸荷機(jī)構(gòu) .27 3.2 主軸的結(jié)構(gòu)型式 .28 3.2.1 主軸的構(gòu)造 .28 3.3 主軸的軸承選用 .29 3.3.1 幾種軸承的比較 .29 3.3.2 軸承的安裝與定位 .30 3.4 主軸剛度計(jì)算 .30 3.5 軸承壽命計(jì)算 .31 3.6 電機(jī)的安裝 .33 3.7 兩主軸箱等高與共線調(diào)節(jié) .33 4 其他設(shè)計(jì) .34 4.1 夾具 .34 4.2 進(jìn)給系統(tǒng) .34 VI 4.3 液壓原理 .34 4.4 冷卻系統(tǒng) .35 5 附件設(shè)計(jì)部分(床身部件) .36 5.1 對(duì)床身部件的具體要求 .36 5.2 選擇床身部件的材料、毛胚制造方式 .36 5.2.1 鑄造加工工藝 .36 5.2.2 焊接加工工藝 .36 5.3 對(duì)床身部件與其他部件聯(lián)系的方式確定 .36 5.3.1 床身與其余部件的整體布局 .36 5.3.2 導(dǎo)軌安裝 .36 5.3.3 排屑及冷卻液回流 .37 5.3.4 起吊問(wèn)題 .37 5.4 床身部件加工工藝方案及工藝路線確定 .37 5.4.1 加工工藝方案的比較與確定 .37 5.4.2 加工工藝路線 .39 5.5 技術(shù)要求說(shuō)明 .39 6 結(jié)論與展望 .41 致謝 .42 參考文獻(xiàn) .43 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì)專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 1 1 緒 論 1.1 惠發(fā)特精密機(jī)械有限公司簡(jiǎn)介 無(wú)錫惠發(fā)特精密機(jī)械有限公司位于無(wú)錫市惠山區(qū)堰橋鎮(zhèn)工業(yè)園,公司生產(chǎn)工藝先進(jìn), 設(shè)備齊全,技術(shù)力量雄厚。專門從事各種系列型號(hào)液壓機(jī)的生產(chǎn),其各項(xiàng)性能指標(biāo)均已 達(dá)到國(guó)外同類產(chǎn)品的水平。 公司全體員工秉承“追求卓越品質(zhì),滿足客戶需求”的經(jīng)營(yíng)理念,不斷強(qiáng)化質(zhì)量管 理,堅(jiān)持跟蹤服務(wù),已通過(guò)了 ISO9001:2000 國(guó)際質(zhì)量體系認(rèn)證,為各種內(nèi)燃機(jī)、電機(jī) 電器、汽車、摩托車、粉末冶金、軸承等良好組配創(chuàng)造了條件。同時(shí)還生產(chǎn)專用組合機(jī) 床、數(shù)控專用組合機(jī)床及三棍輪、二棍輪精密校直機(jī)。 1.2 本設(shè)計(jì)任務(wù)簡(jiǎn)介 本設(shè)計(jì)是從事專業(yè)機(jī)床設(shè)計(jì),包括總體設(shè)計(jì)、進(jìn)給系統(tǒng)、床身部件、液壓系統(tǒng)、主 軸箱設(shè)計(jì)。 課題來(lái)源于無(wú)錫市惠發(fā)特精密機(jī)械有限公司。本課題系機(jī)動(dòng)車減震器缸筒加工的專 用機(jī)床設(shè)計(jì),對(duì)于摩托車及其這一類機(jī)動(dòng)車的減震器缸筒加工均有一定得參考價(jià)值,在 減震器行業(yè)技術(shù)更新中起相當(dāng)?shù)淖饔谩?此次畢業(yè)設(shè)計(jì)任務(wù)要求機(jī)床功能得到進(jìn)一步的完善,能夠提高零件的加工精度和加 工效率,能夠降低加工成本。該零件屬摩托車減震器用,其材料為鑄鋁,要求單班制生 產(chǎn),年產(chǎn)量 5 萬(wàn)件。限于水平和經(jīng)驗(yàn),不完善之處,敬請(qǐng)批評(píng)指正。 1.3 本設(shè)計(jì)應(yīng)達(dá)到的要求 1. 對(duì)缸體加工工藝(經(jīng)簡(jiǎn)化)方案的簡(jiǎn)要分析比較。 2. 完成本工序的工序圖,加工示意圖,機(jī)床總圖及床身部件圖。 3. 設(shè)計(jì)說(shuō)明書一份,要求對(duì)機(jī)床的總體設(shè)計(jì)部分詳細(xì)分析說(shuō)明,并包括必要的計(jì)算, 文字簡(jiǎn)潔通順,重要公式數(shù)據(jù)應(yīng)注明出處。 4. 對(duì)制造廠家調(diào)研,了解其對(duì)質(zhì)量、成本要求,所設(shè)計(jì)的專機(jī)要結(jié)合廠方具體生產(chǎn) 條件。 無(wú)錫太湖學(xué)院學(xué)士學(xué)位論文 2 2 機(jī)床總體設(shè)計(jì) 2.1 工藝方案制定 機(jī)械加工工藝規(guī)程是規(guī)定產(chǎn)品或零部件機(jī)械加工工藝過(guò)程和操作方法的工藝文件。 生產(chǎn)規(guī)模的大小,工藝水平的高低以及解決各種工藝問(wèn)題的方法和手段都要通過(guò)機(jī)械加 工工藝規(guī)程來(lái)體現(xiàn)。因此,機(jī)械加工工藝規(guī)程設(shè)計(jì)是一項(xiàng)重要而又嚴(yán)肅的工作。為能具 體確切地說(shuō)明工藝過(guò)程,一般將機(jī)械加工工藝過(guò)程分為工序、安裝、工位、工步、走刀。 工藝方案制定正確與否,將決定機(jī)床能否達(dá)到“體積小,重量輕,結(jié)構(gòu)簡(jiǎn)單,使用 方便,效率高,質(zhì)量好”的要求,這是設(shè)計(jì)最重要的一步。 為使工藝方案制定的合理、先進(jìn),必須認(rèn)真分析被加工的零件圖紙,深入現(xiàn)場(chǎng)全面 了解被加工零件的結(jié)構(gòu)特點(diǎn),加工部位,尺寸精度,表面粗糙度和技術(shù)要求,定位夾緊 方式工藝方法和加工過(guò)程所采用的刀具,輔具,切屑用量。分析其優(yōu)缺點(diǎn),總結(jié)設(shè)計(jì), 制造,使用單位和操作者的豐富的實(shí)踐經(jīng)驗(yàn),以求理論緊密聯(lián)系實(shí)際,從而確定零件在 組合機(jī)床上完整的工藝(工序)內(nèi)容及方法,從而決定刀具種類,結(jié)構(gòu)型式,數(shù)量及切 屑用量等。 根據(jù)選定的工藝方案確定機(jī)床的配置形式,并制定出影響機(jī)床總體布局和技術(shù)性能 的主要部件結(jié)構(gòu)方案。既要考慮能實(shí)現(xiàn)工藝方案,以確保零件的加工精度,技術(shù)要求及 生產(chǎn)率;又要考慮機(jī)床的操作方便可靠,易于維修,且冷卻,排屑情況良好。 對(duì)于同一個(gè)零件的加工,可能會(huì)有各種不同的工藝方案和機(jī)床配置方案,在最后決 定采取哪種方案時(shí),決不能草率,要全面地看問(wèn)題,綜合分析各方面的情況,進(jìn)行多種 對(duì)比,選擇最佳方案。 2.1.1 工件和加工部位的主要要求 被加工零件為棒狀鋁合金: MgZAlSi9 牌號(hào): MgZAlSi9 代號(hào): ZL104 鑄造方法 :金屬型 熱處理: 淬火+人工時(shí)效 力學(xué)性能:抗拉強(qiáng)度 b/ Pa:145 伸長(zhǎng)率 5(%):2 布氏硬度 HBS(5/250/30):70 鑄鋁合金應(yīng)具有良好的鑄造性能,其成分應(yīng)接近共晶點(diǎn)。 雙孔加工:左端 14.5,表面粗糙度 Ra=6.3 微米 右端階梯孔 最大 43,最小 35,表面粗糙度 Ra=6.3 微米 其他技術(shù)要求見(jiàn)零件圖,要求年產(chǎn)量為 5 萬(wàn)件,單班制生產(chǎn)。實(shí)物圖如圖 2.1。 圖 2.1 實(shí)物圖 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì)專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 3 2.1.2 擬定工藝路線 根據(jù)廠方要求,該零件有兩種加工方案,一是先加工深孔再加工雙端面孔,二是先 加工雙端面孔再加工深孔。 2.1.2.1 機(jī)床設(shè)計(jì)應(yīng)滿足的基本要求 (1) 工藝范圍 機(jī)床的工藝范圍只要取決于其使用于是生產(chǎn)模式。如使用于大批量生產(chǎn)模式,工序 分散,一臺(tái)機(jī)床僅需對(duì)一種工件完成一道或幾道工序的加工,工藝范圍窄,但要求加工 效率高,自動(dòng)化程度高,應(yīng)采用專業(yè)機(jī)床。如使用于單件小批量生產(chǎn)模式,工序集中, 要求機(jī)床具有較寬的加工范圍,對(duì)加工效率和自動(dòng)化程度的要求相對(duì)低一些,應(yīng)采用普 通機(jī)床或通用機(jī)床。在多品種小批量生產(chǎn)模式,要求機(jī)床能適應(yīng)多品種工件的加工,具 有一定的工藝范圍,較高 的加工效率和自動(dòng)化程度,應(yīng)采用專門化機(jī)床。 機(jī)床的工藝范圍直接影響到機(jī)床結(jié)構(gòu)的復(fù)雜程度,設(shè)計(jì)制造成本,加工效率和自動(dòng) 化程度。對(duì)于生產(chǎn)率,就機(jī)床本身而言,工藝范圍增加,可能會(huì)使加工效率下降,但就 工件的制造全過(guò)程而言,機(jī)床工藝范圍的增加,將會(huì)減少工件的裝卸次數(shù),減少安裝, 搬運(yùn)等輔助時(shí)間,有可能使總的生產(chǎn)率提高。數(shù)控機(jī)床的出現(xiàn)較好地解決了上述矛盾。 萬(wàn)能數(shù)控機(jī)床是能進(jìn)行自動(dòng)化加工的通用機(jī)床, ,其工藝范圍往往比普通通用機(jī)床還寬, 專用數(shù)控機(jī)床的生產(chǎn)率和自動(dòng)化程度卻比普通專用機(jī)床還高,因此數(shù)控機(jī)床不僅可使用 于多品種。 小批量生產(chǎn)模式,現(xiàn)已逐步推廣應(yīng)用于大批量生產(chǎn)模式。 (2) 柔性 機(jī)床的柔性是指其適應(yīng)加工對(duì)象變化的能力。隨著時(shí)常經(jīng)濟(jì)的發(fā)展,對(duì)機(jī)床機(jī)器組 成的生產(chǎn)線的柔性要求越來(lái)越高。機(jī)床的柔性包括空間上的柔性和時(shí)間上的柔性。所謂 空間柔性是指一臺(tái)機(jī)床的工藝范圍相當(dāng)于多臺(tái)機(jī)床的工藝范圍,即機(jī)床的運(yùn)動(dòng)功能和刀 具的數(shù)目較多,工藝范圍較廣,機(jī)床能夠在同一時(shí)期內(nèi)完成。 多品種加工的能力。所謂時(shí)間上的柔性也就是結(jié)構(gòu)柔性,指的是在不同時(shí)期,機(jī)床 各部件經(jīng)過(guò)重新變化快的要求。為現(xiàn)實(shí)這項(xiàng)功能,在單位或極小批量生產(chǎn) FMS 作業(yè)線上, 可通過(guò)識(shí)別裝置對(duì)待加工的工件進(jìn)行識(shí)別,并根據(jù)其加工要求,在較短的時(shí)間內(nèi)自動(dòng)地 對(duì)機(jī)床功能進(jìn)行重構(gòu)。要重構(gòu)在較短的時(shí)間內(nèi)完成,要求機(jī)床的功能部件具有快速分離 與組合的功能。 (3) 與物流系統(tǒng)的可接近性 可接近性是指機(jī)床與物流系統(tǒng)之間進(jìn)行物料(工件,刀具,切屑等)流動(dòng)的方便程 度。對(duì)于普通機(jī)床,是由人工進(jìn)行物料流動(dòng)的,要求機(jī)床的使用,操作,清理和維護(hù)方 便和安全。對(duì)于自動(dòng)化制造系統(tǒng),是采用工件傳送帶,自動(dòng)換刀系統(tǒng)和自動(dòng)排屑系統(tǒng)等 裝置自動(dòng)進(jìn)行流動(dòng)的,要求機(jī)床的結(jié)構(gòu)便于物料的自動(dòng)流動(dòng),可靠性好。 (4) 剛度 機(jī)床的剛度是指加工過(guò)程中,在切削力的作用下,抵抗刀具相對(duì)于工作在影響加工 精度方向變形的能力。剛度包括靜態(tài)剛度,動(dòng)態(tài)剛度,熱態(tài)剛度。機(jī)床的剛度直接影響 機(jī)床的加工精度和生產(chǎn)率,因此機(jī)床應(yīng)有足夠的剛度。 無(wú)錫太湖學(xué)院學(xué)士學(xué)位論文 4 (5) 精度 要保證能加工出一定精度的工件,作為工作母機(jī)的機(jī)床必須具有更高的精度要求。 機(jī)床精度分為機(jī)床本身的精度,即空載條件下的精度(包括幾何精度,運(yùn)動(dòng)精度,傳動(dòng) 精度,定位精度等)和工作精度(加工精度) 。 (6) 生產(chǎn)率 機(jī)床的生產(chǎn)率通常是指單位時(shí)間內(nèi)機(jī)床所能加工的工件數(shù)量。機(jī)床的切屑效率越高, 輔助時(shí)間越短,則它的生產(chǎn)率越高。它是衡量生產(chǎn)技術(shù)的先進(jìn)性,生產(chǎn)組織的合理性和 工人勞動(dòng)積極性的重要指標(biāo)之一。對(duì)用戶而言,使用高效率機(jī)床,可以降低工件的加工 成本。 (7) 自動(dòng)化 自動(dòng)化機(jī)床可在無(wú)人工干預(yù)的情況下,按規(guī)定的動(dòng)作要求,通過(guò)機(jī)械,電子或計(jì)算機(jī) 的控制,自動(dòng)完成全部或部分的加工。機(jī)床的自動(dòng)化程度越高,加工精度的穩(wěn)定性越好, 還可以有效地降低工人的勞動(dòng)強(qiáng)度,便于一個(gè)工人看管多臺(tái)機(jī)床,大大地提高勞動(dòng)生產(chǎn) 率。 (8) 成本 成本感念貫穿在產(chǎn)品的整個(gè)生命周期內(nèi),包括設(shè)計(jì),制造,包裝,運(yùn)輸,使用維護(hù), 再利用和報(bào)廢處理等費(fèi)用,是衡量產(chǎn)品市場(chǎng)競(jìng)爭(zhēng)力的重要指標(biāo),應(yīng)盡可能在保證機(jī)床性 能要求的前提下,提高其性能價(jià)格比。 (9) 生產(chǎn)周期 生產(chǎn)周期(包括產(chǎn)品開發(fā)和制造周期)是衡量產(chǎn)品市場(chǎng)競(jìng)爭(zhēng)力的重要指標(biāo),為了快 速響應(yīng)市場(chǎng)需求變化,應(yīng)盡可能縮短機(jī)床的生產(chǎn)周期。這就要求盡可能采用現(xiàn)代設(shè)計(jì)方 法,縮短新產(chǎn)品的開發(fā)周期;盡可能采用現(xiàn)代制造和管理技術(shù),縮短制造周期。 2.1.2.2 機(jī)床設(shè)計(jì)方法 隨著科學(xué)技術(shù)的進(jìn)步和社會(huì)需求的變化,機(jī)床的設(shè)計(jì)理論和技術(shù)也在不斷的發(fā)展。 計(jì)算機(jī)技術(shù)和分析技術(shù)的飛速進(jìn)步,為機(jī)床設(shè)計(jì)方法的發(fā)展提供了有力的技術(shù)支撐。計(jì) 算機(jī)輔助設(shè)計(jì)和計(jì)算機(jī)輔助工程已在機(jī)床設(shè)計(jì)的各個(gè)階段得到了應(yīng)用,改變了傳統(tǒng)的經(jīng) 驗(yàn)設(shè)計(jì)方法,使機(jī)床設(shè)計(jì)由傳統(tǒng)的人工設(shè)計(jì)向計(jì)算機(jī)輔助設(shè)計(jì),由定性設(shè)計(jì)向定量設(shè)計(jì), 有靜態(tài)和線性分析向動(dòng)態(tài)和非線性分析,由可行性設(shè)計(jì)向最佳設(shè)計(jì)過(guò)渡。 數(shù)控技術(shù)的發(fā)展與應(yīng)用,使得機(jī)床的傳動(dòng)與結(jié)構(gòu)發(fā)生了重大變化。伺服驅(qū)動(dòng)系統(tǒng)可 以方便地實(shí)現(xiàn)機(jī)床的單軸運(yùn)動(dòng)及多軸聯(lián)動(dòng),從而可以省去復(fù)雜笨重的機(jī)械傳動(dòng)系統(tǒng),使 其結(jié)構(gòu)及布局產(chǎn)生很大的變化。 隨著生產(chǎn)的發(fā)展,社會(huì)需求也在發(fā)生變化。在機(jī)械制造業(yè)中,小批量生產(chǎn)需求日益 增加,因此出現(xiàn)了與之相適應(yīng)的 FMS(柔性制造系統(tǒng))等先進(jìn)制造系統(tǒng)。數(shù)控機(jī)床是 FMS 的核心裝備。前期的 FMS,可以說(shuō)是“以機(jī)床為主的系統(tǒng)” ,即根據(jù)現(xiàn)有機(jī)床的特 點(diǎn)來(lái)構(gòu)成 FMS。但是,傳統(tǒng)的機(jī)床(包括數(shù)控機(jī)床)設(shè)計(jì)時(shí)并未考慮到它在 FMS 中的應(yīng) 用,因此在功能上制約了 FMS 的發(fā)展。 FMS 的發(fā)展對(duì)機(jī)床提出了新的要求,要求機(jī)床設(shè)計(jì)向“以系統(tǒng)為主的機(jī)床設(shè)計(jì)發(fā)展” 方向發(fā)展,即在機(jī)床設(shè)計(jì)時(shí)就要考慮他如何更好地適應(yīng) FMS 等先進(jìn)制造系統(tǒng)的要求,例 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì)專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 5 如要求具有時(shí)空柔性,與物流的可接近性等等,這就對(duì)機(jī)床設(shè)計(jì)的方法學(xué)提出了新的要 求。 機(jī)床的設(shè)計(jì)方法是根據(jù)其設(shè)計(jì)類型而定的。通用機(jī)床采用系列化設(shè)計(jì)方法。系列中 基型產(chǎn)品為創(chuàng)新設(shè)計(jì)類型,其他為變型設(shè)計(jì)類型。有些機(jī)床,如組合機(jī)床為組合設(shè)計(jì)類 型。 在創(chuàng)新設(shè)計(jì)類型中,機(jī)床總體方案(包括運(yùn)動(dòng)功能方案和結(jié)構(gòu)布局方案)的產(chǎn)生方 法可采用分析式設(shè)計(jì)(又稱試行設(shè)計(jì))或創(chuàng)成式設(shè)計(jì)(又稱解析式設(shè)計(jì)) 。前者是用類比 分析,推理方法產(chǎn)生方案,是目前創(chuàng)新設(shè)計(jì)一般采用的方法,后者則用創(chuàng)成解析的方法 生成方案,創(chuàng)新能力強(qiáng),這種方法尚在研究發(fā)展之中。 2.1.2.3 機(jī)床設(shè)計(jì)步驟 機(jī)床的類型和要求不同,設(shè)計(jì)步驟也不同。按新的原理進(jìn)行加工的機(jī)床應(yīng)按創(chuàng)新設(shè) 計(jì)的步驟進(jìn)行;成系列的機(jī)床產(chǎn)品應(yīng)按系列化設(shè)計(jì)的步驟進(jìn)行;通用化程度較高的機(jī)床 產(chǎn)品,例如組合機(jī)床應(yīng)按模塊化設(shè)計(jì)的步驟進(jìn)行。 (1) 確定結(jié)構(gòu)原理 根據(jù)初步設(shè)計(jì)方案,確定被設(shè)計(jì)機(jī)床的結(jié)構(gòu)原理方案的主要內(nèi)容包括: 用途:即機(jī)床的工藝范圍,包括加工件的材料類型,形狀,質(zhì)量和尺寸范圍等。 生產(chǎn)率:包括加工件的類型,批量及所要求的生產(chǎn)率。 性能指標(biāo):加工件要求的精度(用戶定貨設(shè)計(jì))或機(jī)床的精度,剛度,熱變形,噪 聲等性能指標(biāo)。 主要參數(shù):即確定機(jī)床的加工空間和主要參數(shù)。 驅(qū)動(dòng)方式:機(jī)床的驅(qū)動(dòng)方式有電動(dòng)機(jī)驅(qū)動(dòng)和液壓驅(qū)動(dòng)方式。電動(dòng)機(jī)驅(qū)動(dòng)方式中又有 普通電動(dòng)機(jī)驅(qū)動(dòng),步進(jìn)電動(dòng)機(jī)驅(qū)動(dòng)與伺服電動(dòng)機(jī)驅(qū)動(dòng)。驅(qū)動(dòng)方式的確定不僅與機(jī)床的成 本有關(guān),還將直接影響傳動(dòng)方式的確定。 結(jié)構(gòu)原理:主要零部件應(yīng)滿足的要求和結(jié)構(gòu)原理,有時(shí)還需進(jìn)行草圖設(shè)計(jì),確定關(guān) 鍵零部件自制還是外協(xié)。 成本及生產(chǎn)周期:無(wú)論是訂貨還是工廠規(guī)劃產(chǎn)品,都應(yīng)確定成本及生產(chǎn)周期方面的 指標(biāo)。 (2) 總體設(shè)計(jì) 總體設(shè)計(jì)的內(nèi)容 運(yùn)動(dòng)功能設(shè)計(jì):包括確定機(jī)床所需運(yùn)動(dòng)的個(gè)數(shù),形式(直線運(yùn)動(dòng),回轉(zhuǎn)運(yùn)動(dòng)) ,功能 (主運(yùn)動(dòng),進(jìn)給運(yùn)動(dòng),其它運(yùn)動(dòng))及排列順序,最后畫出機(jī)床的運(yùn)動(dòng)功能圖。 基本參數(shù)設(shè)計(jì):包括尺寸參數(shù),運(yùn)動(dòng)參數(shù)和動(dòng)力參數(shù)設(shè)計(jì)。 傳動(dòng)系統(tǒng)設(shè)計(jì):包括傳動(dòng)方式,傳動(dòng)原理圖及傳動(dòng)系統(tǒng)圖設(shè)計(jì)。 總體結(jié)構(gòu)布局設(shè)計(jì):包括運(yùn)動(dòng)功能分配,總體布局結(jié)構(gòu)形式及總體結(jié)構(gòu)方案圖設(shè)計(jì)。 控制系統(tǒng)設(shè)計(jì):包括控制方式及控制原理,控制系統(tǒng)圖設(shè)計(jì)。 總體方案綜合評(píng)價(jià)與選擇 在總體方案設(shè)計(jì)階段,對(duì)其各種方案進(jìn)行綜合評(píng)價(jià),從中選擇較好的方案。 無(wú)錫太湖學(xué)院學(xué)士學(xué)位論文 6 對(duì)所選擇的方案進(jìn)行進(jìn)一步修改或優(yōu)化,確定最終方案。上述設(shè)計(jì)內(nèi)容,在設(shè)計(jì)過(guò)程中 要交叉進(jìn)行。 (3) 結(jié)構(gòu)設(shè)計(jì) 設(shè)計(jì)機(jī)床的傳動(dòng)系統(tǒng),確定各主要結(jié)構(gòu)的原理方案,設(shè)計(jì)部件裝配圖,對(duì)主要零件 進(jìn)行分析計(jì)算或優(yōu)化,設(shè)計(jì)液壓原理和相應(yīng)的液壓部件裝配圖,設(shè)計(jì)電氣控制系統(tǒng)原理 圖和相應(yīng)的電氣安裝接線圖,設(shè)計(jì)和完善機(jī)床總裝圖和總聯(lián)系尺寸圖。 (4) 工藝設(shè)計(jì) 該機(jī)床的全部自制零件圖,編制標(biāo)準(zhǔn)件,通用件和自制件明細(xì)表,撰寫設(shè)計(jì)說(shuō)明書, 使用說(shuō)明書,指定機(jī)床的檢驗(yàn)方法和標(biāo)準(zhǔn)等技術(shù)文檔。 (5) 機(jī)床整機(jī)綜合評(píng)價(jià) 對(duì)所設(shè)計(jì)的機(jī)床進(jìn)行整機(jī)性能分析和綜合評(píng)價(jià)。可對(duì)所設(shè)計(jì)的機(jī)床進(jìn)行計(jì)算機(jī)建模, 得到所謂的數(shù)學(xué)化樣機(jī),又稱虛擬樣機(jī)。采用虛擬樣機(jī)對(duì)所設(shè)計(jì)的機(jī)床進(jìn)行運(yùn)動(dòng)學(xué)仿真, 在實(shí)際樣機(jī)試造出來(lái)之前對(duì)其進(jìn)行綜合評(píng)價(jià),可以大大減少新產(chǎn)品研制的風(fēng)險(xiǎn),縮短研 制的周期,提高研制的質(zhì)量。 (6) 定型設(shè)計(jì) 在上述步驟(三)完成后,可進(jìn)行實(shí)物樣機(jī)的制造,實(shí)驗(yàn)及評(píng)論。根據(jù)實(shí)物樣機(jī)的 評(píng)論結(jié)果進(jìn)行修改設(shè)計(jì),最終完成產(chǎn)品的定型設(shè)計(jì)。 2.1.3 二種工藝線路的比較與確定及其各分析其優(yōu)缺點(diǎn) 2.1.3.1 先加工深孔方案及工藝路線 根據(jù)加工深孔時(shí)工件旋轉(zhuǎn)而刀具不轉(zhuǎn)的原理,此方案在先加工深孔時(shí)需要一個(gè)導(dǎo)航 設(shè)備,以確保刀具能夠精準(zhǔn)地校準(zhǔn)工件中心。在工件夾緊方面,工件左面可考慮選用三 爪卡盤夾具,這樣可以帶動(dòng)工件高速旋轉(zhuǎn)。由于深孔加工的特殊要求,工件若只夾緊一 側(cè),會(huì)由于震動(dòng)而導(dǎo)致誤差偏大,達(dá)不到工件的精度要求。故而需要設(shè)計(jì)一輔助夾具, 用來(lái)夾緊工件的另一側(cè),以確保工件能夠達(dá)到廠方要求。但由于工件需要高速旋轉(zhuǎn),此 輔助夾具也必須能夠高速旋轉(zhuǎn)。這一特殊要求將給此輔助夾具的設(shè)計(jì)帶來(lái)相當(dāng)大的困難, 暫考慮以同樣的三爪卡盤來(lái)夾緊工件的另一側(cè)。由于深孔加工對(duì)刀具的特殊要求,刀具 在加工時(shí)需要一個(gè)導(dǎo)航設(shè)備,以避免刀具在加工時(shí)產(chǎn)生較大的偏移。經(jīng)這樣考慮,輔助 夾具和導(dǎo)航設(shè)備的安裝又將是另一難題。若將此兩個(gè)設(shè)備以前后順序安裝于同一板墊上, 則或多或少會(huì)影響加工精度。 現(xiàn)在來(lái)考慮加工兩端面孔。我們要求兩端面孔要同時(shí)加工,這樣不僅可以提高工作 效率,對(duì)兩端孔的中心線的合一也能夠很好的解決,避免了先后加工兩端面孔時(shí)由于拆 卸工件所帶來(lái)的認(rèn)為誤差。由于這一要求,所以對(duì)夾具的設(shè)計(jì)要進(jìn)行一番考慮。現(xiàn)設(shè)計(jì) 夾具為臂桿式,左右各一個(gè),如“T”型狀,利用液壓缸夾緊,簡(jiǎn)圖如圖 2.2。 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì)專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 7 圖 2.2 夾具簡(jiǎn)圖 綜上所述,此方案需消耗人力,才力和資源比較大,成本高,方案實(shí)行比較困難。 2.1.3.2 先加工兩端孔的方案及工藝路線 兩端面孔的加工要求同步進(jìn)行,并在同時(shí)間內(nèi)完成加工任務(wù),在刀具設(shè)計(jì)方面同上 方案?,F(xiàn)在來(lái)考慮加工深孔。深孔加工要求工件高速旋轉(zhuǎn),上一方案考慮用三爪卡盤夾 緊兩端面里帶動(dòng)工件完成高速運(yùn)轉(zhuǎn)。此方案在實(shí)際亦不可行,現(xiàn)由于工件兩端面孔已經(jīng) 加工完成,故可考慮用頂針頂住工件左端面孔,依靠機(jī)床結(jié)構(gòu)對(duì)工件向左的緊壓力所產(chǎn) 生的摩擦力帶動(dòng)工件高速運(yùn)轉(zhuǎn)。根據(jù)工件右端面孔的特征,可以設(shè)計(jì)一個(gè)刀具導(dǎo)向套, 利于機(jī)床部件運(yùn)動(dòng)給工件一個(gè)向左的壓緊力。 圖 2.3 刀具導(dǎo)向套簡(jiǎn)圖 這樣便可以成功地解決工件高速運(yùn)轉(zhuǎn)所帶來(lái)的夾具設(shè)計(jì)困難問(wèn)題。此方案不僅方便 可行,而且成本低,運(yùn)用合理,完全能夠滿足加工要求。 2.1.4 安裝與夾緊方案的比較與確定,包括定位、夾緊、夾緊部位、形式等 在同一個(gè)工序中,工件每定位和夾緊一次所完成的那部分加工稱為一個(gè)安裝。此次 全部工序的完成需要兩次定位和夾緊。如表 2-1 所示。 表 2-1 鋁合金缸筒的工序和安裝 工序號(hào) 安 裝 號(hào) 安 裝 內(nèi) 容 設(shè) 備 1 1 左右兩端鉆孔 專業(yè)鉆床 2 2 加工深孔 專業(yè)鉆床 2.1.4.1 定位 無(wú)錫太湖學(xué)院學(xué)士學(xué)位論文 8 在制定工件的工藝規(guī)程時(shí),已經(jīng)初步考慮了加工中的工藝基準(zhǔn)問(wèn)題,有時(shí)還繪制了 工序簡(jiǎn)圖。設(shè)計(jì)夾具時(shí)原則上應(yīng)選該工藝基準(zhǔn)為定位基準(zhǔn)。 工件以外圓柱表面定位有兩種形式,一種是定心定位,另一種是支承定位。 (1) 定心定位 與工件以圓柱孔定心類似,用各種卡頭或彈性筒夾代替心軸或柱銷, 來(lái)定位和夾緊工件的外圓。有時(shí)也可以采用套筒和錐套來(lái)定位。 (2) V 型塊定位 工件外圓以 V 型塊定位是最常見(jiàn)的定位方式之一,兩斜面夾角有 60、90、120等,90V 型塊使用最廣泛,其定位精度和定位穩(wěn)定性介于 60和 120V 型塊之間,精度比 60V 型塊高,穩(wěn)定性比 120V 型塊高。使用 V 型塊定位的 優(yōu)點(diǎn)是對(duì)中性好,可用于非完整外圓柱表面定位。V 型塊有長(zhǎng)短之分,長(zhǎng) V 型塊限制 4 個(gè)自由度,其寬度 B 與圓柱直徑 D 之比 B/D1,短 V 型塊只能限制兩個(gè)自由度,其寬 度有時(shí)僅 2mm。它們均已標(biāo)準(zhǔn)化,可以選用,特殊場(chǎng)合也可以自行設(shè)計(jì)。 本設(shè)計(jì)采用的是 V 型塊定位的方式。 2.1.4.2 夾緊 設(shè)計(jì)夾緊機(jī)構(gòu)一般應(yīng)遵循以下主要原則: (1) 夾緊必須保證定位準(zhǔn)確可靠,而不能破壞定位; (2) 工件和夾具變形必須在允許的范圍內(nèi); (3) 夾緊機(jī)構(gòu)必須可靠。夾緊機(jī)構(gòu)各元件要有足夠的強(qiáng)度和剛度,手動(dòng)夾緊機(jī)構(gòu)必須 保證自鎖,機(jī)動(dòng)夾緊應(yīng)有聯(lián)鎖保護(hù)裝置,夾緊行程必須足夠; (4) 夾緊機(jī)構(gòu)操作必須安全、省力、方便、迅速、符合工人操作習(xí)慣; (5) 夾緊機(jī)構(gòu)的復(fù)雜程度、自動(dòng)化程度必須與生產(chǎn)綱領(lǐng)和工廠的條件相適應(yīng)。 氣動(dòng)夾緊裝置采用空氣作為夾緊裝置的動(dòng)力源。壓縮空氣具有粘度小,不污染,傳 送分配方便的優(yōu)點(diǎn)。缺點(diǎn)是夾緊力比液壓夾緊小,一般壓縮空氣工作壓力為 0.40.6MPa,結(jié)構(gòu)尺寸較大,有排氣噪音。 液壓夾緊裝置的工作原理和結(jié)構(gòu)基本上與氣動(dòng)夾緊裝置相似,它與氣動(dòng)夾緊裝置相 比有下列優(yōu)點(diǎn): 壓力油工作壓力可達(dá) 6MPa,因此液壓缸尺寸小,不需增力機(jī)構(gòu),夾緊裝置緊湊。 壓力油具有不可壓縮性,因此夾緊裝置剛度大,工作平穩(wěn)可靠。 液壓夾緊裝置噪聲小。 其缺點(diǎn)是需要有一套供油裝置,成本要相對(duì)高一些。因此適用于具有液壓傳動(dòng)系統(tǒng) 的機(jī)床和切削力較大的場(chǎng)合。本設(shè)計(jì)采用的是液壓夾緊裝置。 2.1.5 刀具、輔具的確定 孔加工復(fù)合刀具是由兩把或兩把以上單個(gè)孔加工刀具結(jié)合在一個(gè)刀體上形成的專用 刀具。這種刀具在組合機(jī)床及其自動(dòng)線上獲得廣泛使用,一般需要進(jìn)行專門設(shè)計(jì)。 孔加工復(fù)合刀具在組合機(jī)床及其自動(dòng)線上能獲得廣泛應(yīng)用,因?yàn)樗哂幸韵聝?yōu)點(diǎn): (1)生產(chǎn)效率高:用同類工藝復(fù)合刀具同時(shí)加工幾個(gè)表面時(shí),能使機(jī)動(dòng)時(shí)間重合; 用不同類型工藝復(fù)合刀具對(duì)一個(gè)或幾個(gè)表面進(jìn)行順序加工時(shí),能減少(換刀等)的輔助 時(shí)間。因此,使用孔加工復(fù)合刀具能大大提高生產(chǎn)效率。 (2)加工精度高:用孔加工復(fù)合刀具能使工件被加工表面之間獲得較高的位置精度 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì)專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 9 (如孔的同軸度、孔與端面垂直度等) ,還能減少工件的安裝次數(shù)和定位誤差,有利于提 高工件加工精度和表面質(zhì)量。 (3)加工成本低:用孔加工復(fù)合刀具可方便工序集中,從而減少工序或工位數(shù)量。 對(duì)自動(dòng)加工生產(chǎn)則可以大大節(jié)省投資,同時(shí)對(duì)工人的操作水平要求也較低。 (4)加工范圍廣:用孔加工復(fù)合刀具不僅可以在實(shí)心材料上加工出孔,也可以對(duì)已 有孔進(jìn)行擴(kuò)孔。既能加工圓柱孔、圓錐孔、螺紋孔、臺(tái)階孔以及相隔一定距離的同軸孔, 還可以锪凸臺(tái)、深孔平面等。 但是,孔加工復(fù)合刀具與單個(gè)刀具相比較,不僅需要專門設(shè)計(jì)、制造,同時(shí)刃磨也 比較麻煩。因此,孔加工復(fù)合刀具多用于成批大量生產(chǎn)的組合機(jī)床和自動(dòng)線上。應(yīng)該指 出,如果復(fù)合刀具的設(shè)計(jì)、制造、刃磨、使用不當(dāng)或在刀具管理上缺乏相應(yīng)的措施,也 難以得到預(yù)期的加工效果。綜上所述,本設(shè)計(jì)采用的是孔加工復(fù)合刀具。 2.1.6 工序 機(jī)械加工工藝過(guò)程的工序是指:一個(gè)(或一組)工人在一個(gè)工作地點(diǎn)對(duì)一個(gè)(或同 時(shí)對(duì)幾個(gè))工件連續(xù)完成的那一部分加工過(guò)程。本次畢業(yè)設(shè)計(jì)所要加工零件,為了簡(jiǎn)化 課題,零件圖已作抽象處理,只標(biāo)出內(nèi)孔結(jié)構(gòu)以便工藝分析,其余次要結(jié)構(gòu)均簡(jiǎn)略。加 工零件的零件圖如圖 2.4。 圖 2.4 零件圖(已抽象) 其加工內(nèi)容是: 對(duì)左右兩端鉆孔 加工深孔 去毛刺 這些加工內(nèi)容安排在 3 個(gè)工序中完成,如表 2-2 所示。 表 2-2 鋁合金缸筒工序安排方案 工 序 號(hào) 工 序 內(nèi) 容 設(shè) 備 1 對(duì)左右兩端鉆孔 專業(yè)鉆床 2 加工深孔 專業(yè)鉆床 3 手工去毛刺 2.1.7 工序的集中與分散 同一工件,同樣的加工內(nèi)容可以安排兩種不同的形式的工藝規(guī)程:一種是工序集中, 另一種是工序分散。 無(wú)錫太湖學(xué)院學(xué)士學(xué)位論文 10 工序集中有利于保證各加工面相互位置精度要求,有利于采用高生產(chǎn)率機(jī)床,節(jié)省 安裝工件的時(shí)間,減少工件的搬動(dòng)次數(shù)。工序分散可使每個(gè)工序使用的設(shè)備和夾具比較 簡(jiǎn)單,調(diào)整,對(duì)刀也比較容易,對(duì)操作工人的技術(shù)水平要求比較低。 采用高效自動(dòng)化機(jī)床,以工序集中的形式組織生產(chǎn),除了具有上述工序集中的優(yōu)點(diǎn)以外, 生產(chǎn)適應(yīng)強(qiáng),因而雖然設(shè)備價(jià)格昂貴,但仍然受到愈來(lái)愈多的重視。綜上所述,此次加工采用 的是工序集中的工藝規(guī)程。 2.1.8 確定加工工藝路線 根據(jù)上述內(nèi)容,對(duì)各種方案的比較,選用先加工兩端面孔再加工深孔這一方案比較合 理,也比較科學(xué),這一方案不僅降低了生產(chǎn)成本,提高了生產(chǎn)效率,同時(shí)也容易完成加工 任務(wù)。工藝路線簡(jiǎn)圖如圖 2.5 所示。 鉆 兩 端 面 孔 鉆 深 孔 圖 2.5 工藝路線簡(jiǎn)圖 2.1.9 加工工序卡片 表 2-3 加工工序卡片 產(chǎn) 品 型 號(hào) 零件圖號(hào) 01 工序號(hào) 1 共 1 頁(yè)惠發(fā)特精密機(jī) 械有限公司 產(chǎn) 品 名 稱 鋁合金 缸 筒 零件名稱 減震 器 工序名稱 鉆 孔 第 1 頁(yè) 材 料 牌號(hào) 名稱 硬 度 ZAlSi9M g 鋁合金 HBS70 毛坯 種類 毛坯外 形尺寸 每毛坯 可制造 件數(shù) 鑄造 50300 1 設(shè)備 名稱 設(shè)備 型號(hào) 同時(shí)加 工件數(shù) 專用 鉆床 1 工步 號(hào) 共步 內(nèi)容 刀具 量具 走刀 長(zhǎng)度 走刀 次數(shù) 主軸 轉(zhuǎn)速 切削 速度 進(jìn)給量 背 吃 刀 量 工步工 時(shí) 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì)專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 11 1 兩端 面鉆 孔 專用 鉆頭 游標(biāo) 卡尺 29/14 1 1000 21 0.35 0.6 2 鉆深 孔 專用鉆頭 游標(biāo)卡尺 248 1 2080 1.5 1 編制 校 對(duì) 審 核 無(wú)錫太湖學(xué)院學(xué)士學(xué)位論文 12 2.2 專機(jī)總體設(shè)計(jì) 此次畢業(yè)設(shè)計(jì)為摩托車減震器,為了簡(jiǎn)化課編號(hào)無(wú)錫太湖學(xué)院畢業(yè)設(shè)計(jì)(論文)相關(guān)資料題目: 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì) 專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 信機(jī) 系 機(jī)械工程及自動(dòng)化專業(yè)學(xué) 號(hào): 0923151學(xué)生姓名: 繆成威 指導(dǎo)教師: 張大駿(職稱:高級(jí)工程師 ) (職稱: )2013年5月25日目 錄一、畢業(yè)設(shè)計(jì)(論文)開題報(bào)告二、畢業(yè)設(shè)計(jì)(論文)外文資料翻譯及原文三、學(xué)生“畢業(yè)論文(論文)計(jì)劃、進(jìn)度、檢查及落實(shí)表”四、實(shí)習(xí)鑒定表無(wú)錫太湖學(xué)院畢業(yè)設(shè)計(jì)(論文)開題報(bào)告題目: 雙頭鉆擴(kuò)鉸專機(jī)設(shè)計(jì) 專機(jī)總體設(shè)計(jì),主軸箱設(shè)計(jì) 信機(jī) 系 機(jī)械工程及自動(dòng)化 專業(yè)學(xué) 號(hào): 0923151 學(xué)生姓名: 繆成威 指導(dǎo)教師:張大駿 (職稱:高級(jí)工程師 ) (職稱: )2012年11月25日 課題來(lái)源無(wú)錫惠發(fā)特精密機(jī)械有限公司提供,專門為摩托車減震器部件而設(shè)計(jì),此機(jī)床所加工的零件用途較廣泛,產(chǎn)品需求量大,年產(chǎn)一般在5萬(wàn)件左右,根據(jù)產(chǎn)品加工制造情況,采用雙面進(jìn)給孔加工。科學(xué)依據(jù)(包括課題的科學(xué)意義;國(guó)內(nèi)外研究概況、水平和發(fā)展趨勢(shì);應(yīng)用前景等)該工件的雙端孔,其尺寸精度、位置精度、表面粗糙度的要求都相對(duì)比較高。因此這個(gè)孔無(wú)論從產(chǎn)品角度還是從工藝角度來(lái)分析都是十分重要的。如何來(lái)高速、高效、高質(zhì)量的加工是一個(gè)具有指導(dǎo)性意義的課題。國(guó)外如英國(guó)的哈曼機(jī)械研究公司在該類項(xiàng)目的研究中具有無(wú)可爭(zhēng)辯的領(lǐng)先地位,其技術(shù)已十分完善。我國(guó)在此項(xiàng)目的研究上與他們?nèi)杂休^大的距離。 研究?jī)?nèi)容: 雙頭鉆擴(kuò)鉸專用機(jī)床設(shè)計(jì)1. 根據(jù)提供的產(chǎn)品圖樣及樣品以及產(chǎn)品結(jié)構(gòu),設(shè)計(jì)出較為合理的 加工工序和工藝方案,及工序圖的繪制。2. 雙頭鉆擴(kuò)鉸專用機(jī)床設(shè)計(jì) 專用機(jī)床總體方案設(shè)計(jì) 專用機(jī)床總體尺寸參數(shù)設(shè)計(jì)及說(shuō)明組圖 繪制加工示意圖 計(jì)算機(jī)床生產(chǎn)率,并編制出生產(chǎn)率計(jì)算卡 機(jī)床主要部件設(shè)計(jì)圖紙 對(duì)維護(hù)保養(yǎng)調(diào)試提出建議3. 設(shè)計(jì)應(yīng)達(dá)到如下要求:機(jī)床結(jié)構(gòu)表達(dá)清晰合理,說(shuō)明書工整并,有理論依據(jù)。擬采取的研究方法、技術(shù)路線、實(shí)驗(yàn)方案及可行性分析首先對(duì)被加工零件及現(xiàn)有一些加工機(jī)床、工藝要求等數(shù)據(jù)進(jìn)行采集,確定計(jì)算的方案。其次,分析零件工藝。分析現(xiàn)有所具備的條件因素,考慮到廠房,實(shí)際技術(shù)水平、制造成本和客戶訂貨要求進(jìn)行方案制定。最后,進(jìn)行機(jī)床總體設(shè)計(jì),繪制“三圖一卡”,并進(jìn)行分工,進(jìn)行主要部件設(shè)計(jì)。無(wú)錫惠發(fā)特精密機(jī)械有限公司所制造的有關(guān)此類孔加工機(jī)床,其通用部件已標(biāo)準(zhǔn)化、系列化,這就可以根據(jù)實(shí)際需要靈活配置,以縮短設(shè)計(jì)制造周期。從而使機(jī)床在大批量生產(chǎn)中得以廣泛應(yīng)用,并可組成流水線,自動(dòng)線生產(chǎn),所以此類機(jī)床研發(fā)的可能性空間很大。研究計(jì)劃及預(yù)期成果 2012年11月2013年2月 準(zhǔn)備、下廠調(diào)研、收集數(shù)據(jù)3月 4日 3月8日 查閱相關(guān)參考資料3月17日 4月15日 方案確定、總體設(shè)計(jì)4月16日 5月 3 日 總體和工件協(xié)調(diào)設(shè)計(jì)、書寫設(shè)計(jì)說(shuō)明書5月 5日 5月14日 修改、整理、廠方評(píng)定5月18日5月25日 上交、準(zhǔn)備畢業(yè)論文答辯6月1 日 6月3日 論文答辯特色或創(chuàng)新之處 相對(duì)普通通用機(jī)床,該類機(jī)床采用精確定位,特種復(fù)合刀具,進(jìn)給系統(tǒng)采用滾動(dòng)導(dǎo)軌和滾珠絲杠付,伺服系統(tǒng)采用步進(jìn)電機(jī),并用液壓夾具夾緊,因此生產(chǎn)效率比普通通用機(jī)床要高出十倍甚至幾十倍。 已具備的條件和尚需解決的問(wèn)題無(wú)錫惠發(fā)特精密機(jī)械有限公司對(duì)此零件及專用機(jī)床已擁有比較成熟的生產(chǎn)制造和工藝技術(shù)上的經(jīng)驗(yàn),并已有產(chǎn)品在生產(chǎn)減震器的廠家應(yīng)用,在工藝和加工方面具有很強(qiáng)的技術(shù)性指導(dǎo),使設(shè)計(jì)更具有可行性。指導(dǎo)教師意見(jiàn)本課題為實(shí)際生產(chǎn)中的課題,對(duì)學(xué)生綜合運(yùn)用機(jī)械制造基本理論,結(jié)合生產(chǎn)實(shí)踐知識(shí),對(duì)立解決和分析問(wèn)題有現(xiàn)實(shí)意義,且具有一定的難度,對(duì)學(xué)生起一定的鍛煉作用。指導(dǎo)教師簽名: 年 月 日教研室(學(xué)科組、研究所)意見(jiàn)教研室主任簽名: 年 月 日系意見(jiàn)主管領(lǐng)導(dǎo)簽名: 年 月 日英文原文Basic Machining Operations and Cutting TechnologyMachine tools have evolved from the early foot-powered lathes of the Egyptians and John Wilkinsons boring mill. They are designed to provide rigid support for both the workpiece and the cutting tool and can precisely control their relative positions and the velocity of the tool with respect to the workpiece. Basically, in metal cutting, a sharpened wedge-shaped tool removes a rather narrow strip of metal from the surface of a ductile workpiece in the form of a severely deformed chip. The chip is a waste product that is considerably shorter than the workpiece from which it came but with a corresponding increase in thickness of the uncut chip. The geometrical shape of workpiece depends on the shape of the tool and its path during the machining operation. Most machining operations produce parts of differing geometry. If a rough cylindrical workpiece revolves about a central axis and the tool penetrates beneath its surface and travels parallel to the center of rotation, a surface of revolution is produced, and the operation is called turning. If a hollow tube is machined on the inside in a similar manner, the operation is called boring. Producing an external conical surface uniformly varying diameter is called taper turning, if the tool point travels in a path of varying radius, a contoured surface like that of a bowling pin can be produced; or, if the piece is short enough and the support is sufficiently rigid, a contoured surface could be produced by feeding a shaped tool normal to the axis of rotation. Short tapered or cylindrical surfaces could also be contour formed. Flat or plane surfaces are frequently required. They can be generated by radial turning or facing, in which the tool point moves normal to the axis of rotation. In other cases, it is more convenient to hold the workpiece steady and reciprocate the tool across it in a series of straight-line cuts with a crosswise feed increment before each cutting stroke. This operation is called planning and is carried out on a shaper. For larger pieces it is easier to keep the tool stationary and draw the workpiece under it as in planning. The tool is fed at each reciprocation. Contoured surfaces can be produced by using shaped tools. Multiple-edged tools can also be used. Drilling uses a twin-edged fluted tool for holes with depths up to 5 to 10 times the drill diameter. Whether the drill turns or the workpiece rotates, relative motion between the cutting edge and the workpiece is the important factor. In milling operations a rotary cutter with a number of cutting edges engages the workpiece. Which moves slowly with respect to the cutter. Plane or contoured surfaces may be produced, depending on the geometry of the cutter and the type of feed. Horizontal or vertical axes of rotation may be used, and the feed of the workpiece may be in any of the three coordinate directions. Basic Machine Tools Machine tools are used to produce a part of a specified geometrical shape and precise I size by removing metal from a ductile material in the form of chips. The latter are a waste product and vary from long continuous ribbons of a ductile material such as steel, which are undesirable from a disposal point of view, to easily handled well-broken chips resulting from cast iron. Machine tools perform five basic metal-removal processes: I turning, planning, drilling, milling, and grinding. All other metal-removal processes are modifications of these five basic processes. For example, boring is internal turning; reaming, tapping, and counter boring modify drilled holes and are related to drilling; bobbing and gear cutting are fundamentally milling operations; hack sawing and broaching are a form of planning and honing; lapping, super finishing. Polishing and buffing are variants of grinding or abrasive removal operations. Therefore, there are only four types of basic machine tools, which use cutting tools of specific controllable geometry: 1. lathes, 2. planers, 3. drilling machines, and 4. milling machines. The grinding process forms chips, but the geometry of the abrasive grain is uncontrollable. The amount and rate of material removed by the various machining processes may be I large, as in heavy turning operations, or extremely small, as in lapping or super finishing operations where only the high spots of a surface are removed. A machine tool performs three major functions: 1. it rigidly supports the workpiece or its holder and the cutting tool; 2. it provides relative motion between the workpiece and the cutting tool; 3. it provides a range of feeds and speeds usually ranging from 4 to 32 choices in each case. Speed and Feeds in Machining Speeds, feeds, and depth of cut are the three major variables for economical machining. Other variables are the work and tool materials, coolant and geometry of the cutting tool. The rate of metal removal and power required for machining depend upon these variables. The depth of cut, feed, and cutting speed are machine settings that must be established in any metal-cutting operation. They all affect the forces, the power, and the rate of metal removal. They can be defined by comparing them to the needle and record of a phonograph. The cutting speed (V) is represented by the velocity of- the record surface relative to the needle in the tone arm at any instant. Feed is represented by the advance of the needle radially inward per revolution, or is the difference in position between two adjacent grooves. The depth of cut is the penetration of the needle into the record or the depth of the grooves. Turning on Lathe Centers The basic operations performed on an engine lathe are illustrated. Those operations performed on external surfaces with a single point cutting tool are called turning. Except for drilling, reaming, and lapping, the operations on internal surfaces are also performed by a single point cutting tool. All machining operations, including turning and boring, can be classified as roughing, finishing, or semi-finishing. The objective of a roughing operation is to remove the bulk of the material as rapidly and as efficiently as possible, while leaving a small amount of material on the work-piece for the finishing operation. Finishing operations are performed to obtain the final size, shape, and surface finish on the workpiece. Sometimes a semi-finishing operation will precede the finishing operation to leave a small predetermined and uniform amount of stock on the work-piece to be removed by the finishing operation. Generally, longer workpieces are turned while supported on one or two lathe centers. Cone shaped holes, called center holes, which fit the lathe centers are drilled in the ends of the workpiece-usually along the axis of the cylindrical part. The end of the workpiece adjacent to the tailstock is always supported by a tailstock center, while the end near the headstock may be supported by a headstock center or held in a chuck. The headstock end of the workpiece may be held in a four-jaw chuck, or in a type chuck. This method holds the workpiece firmly and transfers the power to the workpiece smoothly; the additional support to the workpiece provided by the chuck lessens the tendency for chatter to occur when cutting. Precise results can be obtained with this method if care is taken to hold the workpiece accurately in the chuck. Very precise results can be obtained by supporting the workpiece between two centers. A lathe dog is clamped to the workpiece; together they are driven by a driver plate mounted on the spindle nose. One end of the Workpiece is mecained;then the workpiece can be turned around in the lathe to machine the other end. The center holes in the workpiece serve as precise locating surfaces as well as bearing surfaces to carry the weight of the workpiece and to resist the cutting forces. After the workpiece has been removed from the lathe for any reason, the center holes will accurately align the workpiece back in the lathe or in another lathe, or in a cylindrical grinding machine. The workpiece must never be held at the headstock end by both a chuck and a lathe center. While at first thought this seems like a quick method of aligning the workpiece in the chuck, this must not be done because it is not possible to press evenly with the jaws against the workpiece while it is also supported by the center. The alignment provided by the center will not be maintained and the pressure of the jaws may damage the center hole, the lathe center, and perhaps even the lathe spindle. Compensating or floating jaw chucks used almost exclusively on high production work provide an exception to the statements made above. These chucks are really work drivers and cannot be used for the same purpose as ordinary three or four-jaw chucks. While very large diameter workpieces are sometimes mounted on two centers, they are preferably held at the headstock end by faceplate jaws to obtain the smooth power transmission; moreover, large lathe dogs that are adequate to transmit the power not generally available, although they can be made as a special. Faceplate jaws are like chuck jaws except that they are mounted on a faceplate, which has less overhang from the spindle bearings than a large chuck would have. Introduction of Machining Machining as a shape-producing method is the most universally used and the most important of all manufacturing processes. Machining is a shape-producing process in which a power-driven device causes material to be removed in chip form. Most machining is done with equipment that supports both the work piece and cutting tool although in some cases portable equipment is used with unsupported workpiece. Low setup cost for small Quantities. Machining has two applications in manufacturing. For casting, forging, and press working, each specific shape to be produced, even one part, nearly always has a high tooling cost. The shapes that may he produced by welding depend to a large degree on the shapes of raw material that are available. By making use of generally high cost equipment but without special tooling, it is possible, by machining; to start with nearly any form of raw material, so tong as the exterior dimensions are great enough, and produce any desired shape from any material. Therefore .machining is usually the preferred method for producing one or a few parts, even when the design of the part would logically lead to casting, forging or press working if a high quantity were to be produced. Close accuracies, good finishes. The second application for machining is based on the high accuracies and surface finishes possible. Many of the parts machined in low quantities would be produced with lower but acceptable tolerances if produced in high quantities by some other process. On the other hand, many parts are given their general shapes by some high quantity deformation process and machined only on selected surfaces where high accuracies are needed. Internal threads, for example, are seldom produced by any means other than machining and small holes in press worked parts may be machined following the press working operations. Primary Cutting Parameters The basic tool-work relationship in cutting is adequately described by means of four factors: tool geometry, cutting speed, feed, and depth of cut. The cutting tool must be made of an appropriate material; it must be strong, tough, hard, and wear resistant. The tool s geometry characterized by planes and angles, must be correct for each cutting operation. Cutting speed is the rate at which the work surface passes by the cutting edge. It may be expressed in feet per minute. For efficient machining the cutting speed must be of a magnitude appropriate to the particular work-tool combination. In general, the harder the work material, the slower the speed. Feed is the rate at which the cutting tool advances into the workpiece. Where the workpiece or the tool rotates, feed is measured in inches per revolution. When the tool or the work reciprocates, feed is measured in inches per stroke, Generally, feed varies inversely with cutting speed for otherwise similar conditions. The depth of cut, measured inches is the distance the tool is set into the work. It is the width of the chip in turning or the thickness of the chip in a rectilinear cut. In roughing operations, the depth of cut can be larger than for finishing operations. The Effect of Changes in Cutting Parameters on Cutting Temperatures In metal cutting operations heat is generated in the primary and secondary deformation zones and these results in a complex temperature distribution throughout the tool, workpiece and chip. A typical set of isotherms is shown in figure where it can be seen that, as could be expected, there is a very large temperature gradient throughout the width of the chip as the workpiece material is sheared in primary deformation and there is a further large temperature in the chip adjacent to the face as the chip is sheared in secondary deformation. This leads to a maximum cutting temperature a short distance up the face from the cutting edge and a small distance into the chip. Since virtually all the work done in metal cutting is converted into heat, it could be expected that factors which increase the power consumed per unit volume of metal removed will increase the cutting temperature. Thus an increase in the rake angle, all other parameters remaining constant, will reduce the power per unit volume of metal removed and the cutting temperatures will reduce. When considering increase in unreformed chip thickness and cutting speed the situation is more complex. An increase in undeformed chip thickness tends to be a scale effect where the amounts of heat which pass to the workpiece, the tool and chip remain in fixed proportions and the changes in cutting temperature tend to be small. Increase in cutting speed; however, reduce the amount of heat which passes into the workpiece and this increase the temperature rise of the chip m primary deformation. Further, the secondary deformation zone tends to be smaller and this has the effect of increasing the temperatures in this zone. Other changes in cutting parameters have virtually no effect on the power consumed per unit volume of metal removed and consequently have virtually no effect on the cutting temperatures. Since it has been shown that even small changes in cutting temperature have a significant effect on tool wear rate it is appropriate to indicate how cutting temperatures can be assessed from cutting data. The most direct and accurate method for measuring temperatures in high -speed-steel cutting tools is that of Wright &. Trent which also yields detailed information on temperature distributions in high-speed-steel cutting tools. The technique is based on the metallographic examination of sectioned high-speed-steel tools which relates microstructure changes to thermal history. Trent has described measurements of cutting temperatures and temperature distributions for high-speed-steel tools when machining a wide range of workpiece materials. This technique has been further developed by using scanning electron microscopy to study fine-scale microstructure changes arising from over tempering of the tempered martens tic matrix of various high-speed-steels. This technique has also been used to study temperature distributions in both high-speed -steel single point turning tools and twist drills. Wears of Cutting Tool Discounting brittle fracture and edge chipping, which have already been dealt with, tool wear is basically of three types. Flank wear, crater wear, and notch wear. Flank wear occurs on both the major and the minor cutting edges. On the major cutting edge, which is responsible for bulk metal removal, these results in increased cutting forces and higher temperatures which if left unchecked can lead to vibration of the tool and workpiece and a condition where efficient cutting can no longer take place. On the minor cutting edge, which determines workpiece size and surface finish, flank wear can result in an oversized product which has poor surface finish. Under most practical cutting conditions, the tool will fail due to major flank wear before the minor flank wear is sufficiently large to result in the manufacture of an unacceptable component. Because of the stress distribution on the tool face, the frictional stress in the region of sliding contact between the chip and the face is at a maximum at the start of the sliding contact region and is zero at the end. Thus abrasive wear takes place in this region with more wear taking place adjacent to the seizure region than adjacent to the point at which the chip loses contact with the face. This result in localized pitting of the tool face some distance up the face which is usually referred to as catering and which normally has a section in the form of a circular arc. In many respects and for practical cutting conditions, crater wear is a less severe form of wear than flank wear and consequently flank wear is a more common tool failure criterion. However, since various authors have shown that the temperature on the face increases more rapidly with increasing cutting speed than the temperature on the flank, and since the rate of wear of any type is significantly affected by changes in temperature, crater wear usually occurs at high cutting speeds. At the end of the major flank wear land where the tool is in contact with the uncut workpiece surface it is common for the flank wear to be more pronounced than along the rest of the wear land. This is because of localised effects such as a hardened layer on the un
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