细长活塞杆加工工艺及夹具设计【含CAD图纸、说明书】
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大 学毕业设计任务书学 院、系: 专 业:机械设计制造及其自动化学 生 姓 名: 学 号: 设 计 题 目:细长杆零件加工工艺及工装设计起 迄 日 期: 指 导 教 师: 系 主 任: 发任务书日期: 毕 业 设 计 任 务 书1毕业设计的任务和要求:任务及要求:绘制所给零件的零件图及毛坯图,要求图纸规范;编制机械加工工艺规程和工序卡片;并进行工装设计,同时制定装配工艺。 2毕业设计的具体工作内容:零件:超细长活塞杆,材料:27SiMn。1绘制零件及毛坯图纸;2编制超细长活塞杆的机械加工工艺规程、工序卡,并制定与两端头装配的装配工艺;3设计一道加工工序的工装。毕 业 设 计 任 务 书3对毕业设计成果的要求:1说明书一份;2绘制所给零件的零件图、毛坯图和工装夹具图,要求设计合理、图纸规范;编制机械加工工艺规程;3科技译文一份(不少于3000字符);4毕业设计工作进度计划:起 迄 日 期工 作 内 容2011年 2月 21 日 3月10日 3月11 日 4月 28 日4月29 日 5月 29 日5月 30 日 6月10日6月11日 6月20日查阅资料,学习相关专业知识和完成开题报告;翻译外文资料;绘制所给零件的零件图和毛坯图及工装图;编制机械加工工艺规程、工序卡片和装配工艺;设计一套工装;整理设计说明书等;论文答辩学生所在系审查意见:系主任:_ 年 月 日毕业设计说明书细长杆零件加工工艺及工装设计学生姓名: 学号: 学 院: 专 业: 机械设计制造及其自动化 指导教师: 机械加工工序卡片产品型号零件图号产品名称超细长活塞杆零件名称共9页第1页车间工序号工序名称材 料 牌 号10车外圆及两端27SiMn毛 坯 种 类毛坯外形尺寸每毛坯可制件数每 台 件 数无缝钢管、铸 件11设备名称设备型号设备编号同时加工件数普通车床CW618011夹具编号夹具名称切削液3爪卡盘 跟刀架工位器具编号工位器具名称工序工时 (分)准终单件62.78工步号工 步 内 容工 艺 装 备主轴转速切削速度进给量切削深度进给次数工步工时r/minm/minmm/rmm机动辅助1以外圆为基准,车削左右两端面,保证总长度大于3495四爪卡盘、跟刀架32018.090.4320.202以外圆为基准,右端倒角5x30四爪卡盘、跟刀架3顶两端,粗车外圆各部分尺寸,留余量3mm四爪卡盘、跟刀架71050.100.202162.58 设 计(日 期) 校 对(日期) 审 核(日期) 标准化(日期) 会 签(日期)标记处数更改文件号签 字 日 期标记处数更改文件号签 字 日 期机械加工工序卡片产品型号零件图号产品名称超细长活塞杆零件名称共9页第2页车间工序号工序名称材 料 牌 号15车外圆及两端27SiMn毛 坯 种 类毛坯外形尺寸每毛坯可制件数每 台 件 数无缝钢管、铸 件11设备名称设备型号设备编号同时加工件数普通车床CW618011夹具编号夹具名称切削液专用夹具工位器具编号工位器具名称工序工时 (分)准终单件36.54工步号工 步 内 容工 艺 装 备主轴转速切削速度进给量切削深度进给次数工步工时r/minm/minmm/rmm机动辅助1车削两端面,顶右端尖孔,保证尺寸3450为3452,总长3490四爪卡盘、跟刀架1508.50.20220.1082顶两端,半精车各部分尺寸,留余量11.5mm四爪卡盘、跟刀架32056.270.301.5136.43 设 计(日 期) 校 对(日期) 审 核(日期) 标准化(日期) 会 签(日期)标记处数更改文件号签 字 日 期标记处数更改文件号签 字 日 期机械加工工序卡片产品型号零件图号产品名称超细长活塞杆零件名称共9页第3页车间工序号工序名称材 料 牌 号22精车外圆27SiMn毛 坯 种 类毛坯外形尺寸每毛坯可制件数每 台 件 数无缝钢管、铸 件11设备名称设备型号设备编号同时加工件数普通车床CW618011夹具编号夹具名称切削液工位器具编号工位器具名称工序工时 (分)准终单件1.52工步号工 步 内 容工 艺 装 备主轴转速切削速度进给量切削深度进给次数工步工时r/minm/minmm/rmm机动辅助1车削两端面,顶右端顶尖,总长3490四爪卡盘、跟刀架1458.20.50.2520.042顶两端,除45尺寸部分外,其余尺寸按图纸精车,保证尺寸45mm,3450mm,圆柱度、直线度要求四爪卡盘、跟刀架710111.470.150.511.48 设 计(日 期) 校 对(日期) 审 核(日期) 标准化(日期) 会 签(日期)标记处数更改文件号签 字 日 期标记处数更改文件号签 字 日 期机械加工工序卡片产品型号零件图号产品名称超细长活塞杆零件名称共9页第4页车间工序号工序名称材 料 牌 号24磨削27SiMn毛 坯 种 类毛坯外形尺寸每毛坯可制件数每 台 件 数无缝钢管、铸 件11设备名称设备型号设备编号同时加工件数万能外圆磨床M14121夹具编号夹具名称切削液精铣夹具工位器具编号工位器具名称工序工时 (分)准终单件8.0工步号工 步 内 容工 艺 装 备主轴转速切削速度进给量切削深度进给次数工步工时r/minm/minmm/rmm机动辅助1磨成外圆,保证尺寸50+0.087 -0.025为50-0.025 -0.05,圆柱度公差0.04,直线度0.50,表面粗糙度0.8要求 四爪卡盘、跟刀架22034.520.58.0 设 计(日 期) 校 对(日期) 审 核(日期) 标准化(日期) 会 签(日期)标记处数更改文件号签 字 日 期标记处数更改文件号签 字 日 期机械加工工序卡片产品型号零件图号产品名称超细长活塞杆零件名称共9页第5页车间工序号工序名称材 料 牌 号28铣27SiMn毛 坯 种 类毛坯外形尺寸每毛坯可制件数每 台 件 数铸 件11设备名称设备型号设备编号同时加工件数立式镗铣加工中心VMC181411夹具编号夹具名称切削液工位器具编号工位器具名称工序工时 (分)准终单件4.89工步号工 步 内 容工 艺 装 备主轴转速切削速度进给量切削深度进给次数工步工时r/minm/minmm/rmm机动辅助1铣成A-A中尺寸18,K向视图尺寸300.1、15,同时保证K向垂直度要求四爪卡盘190450.080544.89 设 计(日 期) 校 对(日期) 审 核(日期) 标准化(日期) 会 签(日期)标记处数更改文件号签 字 日 期标记处数更改文件号签 字 日 期机械加工工序卡片产品型号零件图号产品名称超细长活塞杆零件名称共9页第6页车间工序号工序名称材 料 牌 号34镗孔ZG310-570毛 坯 种 类毛坯外形尺寸每毛坯可制件数每 台 件 数铸 件11设备名称设备型号设备编号同时加工件数插床B502031夹具编号夹具名称切削液镗床夹具工位器具编号工位器具名称工序工时 (分)准终单件2.09工步号工 步 内 容工 艺 装 备主轴转速切削速度进给量切削深度进给次数工步工时r/minm/minmm/rmm机动辅助1铣成G向视图R5(两处),尺寸12及垂直度要求,G向视图R3除外允许G向视图中的留铣刀R4(两处)四爪卡盘1450450.14542.092 设 计(日 期) 校 对(日期) 审 核(日期) 标准化(日期) 会 签(日期)标记处数更改文件号签 字 日 期标记处数更改文件号签 字 日 期机械加工工序卡片产品型号零件图号产品名称超细长活塞杆零件名称共9页第7页车间工序号工序名称材 料 牌 号36车ZG310-570毛 坯 种 类毛坯外形尺寸每毛坯可制件数每 台 件 数铸 件11设备名称设备型号设备编号同时加工件数普通车床CW6180B11夹具编号夹具名称切削液专用夹具工位器具编号工位器具名称工序工时 (分)准终单件5.54工步号工 步 内 容工 艺 装 备主轴转速切削速度进给量切削深度进给次数工步工时r/minm/minmm/rmm机动辅助1找正,粗镗孔32孔四爪卡盘758.020.121.2525.392精镗32+0.13 0孔四爪卡盘1600160.770.100.2520.153攻螺纹2-M6-6H,打配对标记丝锥4钳工倒圆角钳工 设 计(日 期) 校 对(日期) 审 核(日期) 标准化(日期) 会 签(日期)标记处数更改文件号签 字 日 期标记处数更改文件号签 字 日 期机械加工工序卡片产品型号零件图号产品名称超细长活塞杆零件名称共9页第8页车间工序号工序名称材 料 牌 号36车削螺纹ZG310-570毛 坯 种 类毛坯外形尺寸每毛坯可制件数每 台 件 数铸 件11设备名称设备型号设备编号同时加工件数普通车床CW6180B11夹具编号夹具名称切削液专用夹具工位器具编号工位器具名称工序工时 (分)准终单件0.80工步号工 步 内 容工 艺 装 备主轴转速切削速度进给量切削深度进给次数工步工时r/minm/minmm/rmm机动辅助1按图车M48x2-6g螺纹,其中退刀槽允许不车,但要保证螺纹有效长度38四爪卡盘、跟刀架304.5221.620.80 设 计(日 期) 校 对(日期) 审 核(日期) 标准化(日期) 会 签(日期)标记处数更改文件号签 字 日 期标记处数更改文件号签 字 日 期机械加工工序卡片产品型号零件图号产品名称超细长活塞杆零件名称共9页第9页车间工序号工序名称材 料 牌 号42抛光27SiMn毛 坯 种 类毛坯外形尺寸每毛坯可制件数每 台 件 数无缝钢管11设备名称设备型号设备编号同时加工件数抛光机11夹具编号夹具名称切削液专用夹具工位器具编号工位器具名称工序工时 (分)准终单件工步号工 步 内 容工 艺 装 备主轴转速切削速度进给量切削深度进给次数工步工时r/minm/minmm/rmm机动辅助1找正装夹,随车抛光,保证尺寸50-0.025 -0.05四爪卡盘、跟刀架 设 计(日 期) 校 对(日期) 审 核(日期) 标准化(日期) 会 签(日期)标记处数更改文件号签 字 日 期标记处数更改文件号签 字 日 期中北大学机械工程系机械加工工艺过程卡片产品型号零件图号共 3 页产品名称零件名称细长活塞杆第 1 页材料牌号27SiMn毛坯种类铸件毛坯外形尺寸3492X58每毛坯件数1每台件数1备注工序号工序名称工序内容车间工段设备工艺装备(夹具、刀具)工时准终单件15车以外圆为基准,粗车钢管两端面,半精车各部分尺寸普通车床顶尖自备77.77877.77816检用游标卡尺:0-125/0.02工位器具自备17热时效处理18校直母线直线度小于0.3mm19检用塞尺:150/0.02-0.05 平板:4mmX2mm20校直母线直线度小于0.3mm21检用塞尺:150/0.02-0.05 平板:4mmX2mm描图22车以外圆为基准,车钢管两端面,精车钢管两端各部分尺寸螺纹样圈M42x2-6g48.2448.24校图23检用游标卡尺:0-125/0.02 百分表:0-3/0.01检查焊缝处外观质量,不允许有气孔等缺陷存在,如有缺陷存在,则转谦焊接工序进行补焊并打磨光滑焊接处,补焊合格后方可转下道工序底图号24磨磨外圆尺寸,保证图纸中各精度要求普通磨床8.08.025检检查焊缝外观质量,不允许有气孔等缺陷存在用外径千分尺:25-50/0.02 百分表0-3/0.01编制审核会签装订号签字日期 机械加工工艺过程卡片产品型号零件图号共 3 页产品名称零件名称细长活塞杆第 2 页材料牌号27SiMn毛坯种类铸件毛坯外形尺寸3492X58每毛坯件数1每台件数1备注工序号工序名称工序内容车间工段设备工艺装备(夹具、刀具)工时准终单件26钳工划A-A视图中尺寸38;K向尺寸:300.1;保证对称性及垂直度要求27检验钢板尺:300mm28铣铣成A-A、K向视图中各尺寸,同时保证K向,G向视图中R5两处);尺寸12及垂直度要求,G向视图中允许留铣刀R4处(两处)数控立式升降台铣床2.092.0929检验用游标卡尺:0-125/0.02 百分表:0-3/0.01 半径样板7-14.530铣插成G向视图中的R4(两处)铣床31检验半径样板1-6.532钳工划32及R向2-M6-6H的加工位置线,同时K向倒角4处描图33检验钢板尺300校图34镗镗孔32,倒圆,同时打配对标记0.630.63底图号35 检验用游标卡尺:0-125/0.0236车按图车成M48x2-6g,其中罗退刀槽允许不车,但要保证螺纹有效长度38,其余尺寸按图车制加长丝锥自备2.082.0837检验用游标卡尺:0-125/0.02编制审核会签装订号签字日期 机械加工工艺过程卡片产品型号零件图号共 3 页产品名称零件名称细长活塞杆第 3 页材料牌号27SiMn毛坯种类铸件毛坯外形尺寸3492X58每毛坯件数1每台件数1备注工序号工序名称工序内容车间工段设备工艺装备(夹具、刀具)工时准终单件38探伤表面着色检查,不得有裂纹,满足标准JB/T79218-1999中I级要求39拉伸试验任由一根做拉伸试验,拉伸载荷为200KN,不得有异常现象拉伸工装40检验分别记录实验前后活塞杆长度、直径、叉部销轴孔直径及叉部宽度尺寸41钳工在10Mpa、20Mpa和30Mpa压力下,分别做压力试验,各稳压1分钟,然后反向程序卸压,不得发生泄露及异常现象堵头、接头自备42抛光找正装夹,随车抛光,保证尺寸41H643表面处理严格执行表面氧化工艺,氧化后用肥皂溶液浸渍,再进行浸油处理氧化作业线入库垂直吊放描图校图底图号编制审核会签装订号签字日期14 I FORGING I JANUARY / FEBRUARY 2011FLASHLESS FORGINGOF A TWO-CYLINDER CRANKSHAFT WITH SECONDARY FORM ELEMENTSIn recent years flashless precision forging of two-cylinder crank-shafts was developed at the IPH - Institut fr Integrierte Produktion Hannover gemeinntzige GmbH. Compared to conventional forging methods, flashless precision forging permits reduction of raw ma-terial required to complete the part, as well as the omission of the process steps for trimming. Due to the improved quality of the finished parts, flashless forging makes it possible to achieve functional surfaces without extensive additional reworking. To assess the industrial applicability of this forging method, IPH is researching the technology for precision forging a challenging crank-shaft, including the secondary form elements, low end and flange. This report describes the design of the forging sequence and process. The goal of the research is a three-stage forging sequence for flashless precision forging of crankshafts with secondary form elements. Flashless precision forging is conducted in closed dies. With the method described here, die closure is realized temporally separated from the forming. There is no forming until die closure. Only the sub-sequently inserted punch initiates the forming. Precision forging reaches quality levels like tolerance classes IT 8 to IT 10 Doe07, Bro99. A four-stage forging sequence of a simpli-fied two-cylinder crankshaft without any secondary form elements is depicted in Figure 1. This sequence was developed in the special Figure 1: Stage sequence for flashless precision forging of a two-cylinder crankshaft without secondary form elements Mue08.research project, SFB 489.The first and second forming step is done by lateral extrusion in a closed die. The third step consists of multi-directional forming in a semi-open die, and the fourth (and final) step is a flash-less precision forging process, again in a closed die. During the multi-directional forming step, the part is formed in ver-tical and horizontal spatial direction. The redirection of press energy was re-alized by wedges Mue08. Present developmentTo use the precision forging technol-ogy for crankshafts in industrial op-erations, it s first necessary to supple-ment the two-cylinder crankshaft with secondary form elements, low end and flange (see Figure 2), and to redesign the forging process.To reduce production times and tool Researchers seek an industrial-scale, three-stage process for precision parts, with the efficiency and finish-product quality of flashless forging. By DIPL.-ING. MATTHIAS MEYER, DIPL.-ING. (FH) MICHAEL LCKE, DR.-ING. DIPL.-OEC. ROUVEN NICKEL and PROF. DR.-ING. BERND-ARNO BEHRENSWWW.FORGINGMAGAZINE.COM I FORGING I 15costs, opportunities for omitting one or more forming steps were assessed. Tests were conducted to determine whether the staged pro-gression must be forged in four steps (comparable to the two-cylinder crankshaft without secondary form elements), or if it s feasible to scale back to a three-stage forging process. Increased tool-loads due to the omission of one forming step can have negative effects on tool wear, thus can reducing tool life.Regarding the design of the staged sequence for a two-cylinder crankshaft with secondary form elements, marginal conditions must be considered just as for the two-cylinder crankshaft without sec-Figure 2: Two-cylinder crankshaft without (left) and with (right) secondary form elements.Figure 3: Comparison of forming forces in three- and four-stage sequences.ondary form elements. The marginal conditions might be respective presses (maximum ram force and space re-quirements) as well as fold-free and free-form crack formation.Comparison of three- and four-stage sequence The three- and four-stage sequences were designed with the Finite Element Analysis (FEA)-based simulation soft-ware Forge 2009. Before each simula-tion the temperature of the part was set to 1,250C, the tool-temperature to 250C and the forming velocity to 25 mm/s. Subsequent evaluation of the material flow was conducted with re-gard to forming force, deformation de-gree, pressure dwell time, temperature distribution within the part, and the expected tool wear. The aim was a com-parison of both staged sequences. In the intermediate stages of the four-stage forging sequence, the form-ing forces at the end of the forming are similar or higher than those in the three-stage sequence. Since the major-ity of the required deformation energy is introduced during the first three forming steps, the final forming step needs considerably less forming force (see Figure 3)16 I FORGING I JANUARY / FEBRUARY 2011In the three-stage forming sequence, the extended contact times of crankshaft and base tools cause increased cooling in the area around the main bearing and the low-end bearing during the last forming step. In the area of the crank web, a comparison of three- and four-stage forging sequences shows higher temperatures for the three-stage forging sequence due to shorter contact times of work piece and tool (see Figure 6). Due to the increased forming force, tool wear for the three-stage forging sequence is considerably higher than for the four-stage sequence. It is par-ticularly notable in the area around the main bearing and the low-end bearing (see Figure 7). This is due to increased cooling of the part due to extended con-tact times. This increased locally the flow stress, and hence heightened tri-bological load, between the parts and the tool.ConclusionBased on the deliverables, it is evi-dent, that both staged progressions are feasible since critical parameter levels, like the deformation degree X = 4 are not exceeded. Due to a lower forming force and reduced tool wear, a compari-son of FEA-results indicated benefits from the four-stage forging sequence. In order to realize the three-stage se-quence the re-design of the second in-termediate stage might be necessary in an additional loop. To reduce the forming force within the three-stage forging sequence, the material distribu-tion for the second intermediate stage should be less around the main bearing and the low end bearing and deepen in the crank web. This could reduce the contact time around the main bearing and the low-end bearing and hence the cooling effect. In addition, an increased forming velocity (at present 25 mm/s) can accelerate the forming, shorten the contact time and thus reduce the ef-fort for the realization of the final form-ing stage of the three-stage forging se-quence.Summary and outlookIn continuing research it will be necessary to explore possible applica-Figure 4: Comparison of degrees of deformation.Figure 5: Comparison between the contact times.COMPARISONS BETWEEN THREE- AND FOUR-STAGE SEQUENCES:Regarding the forming force, the analysis showed an estimated 40% higher forming force in the three-stage forming sequence com-pared to the four-stage forging sequence. The predominant forming of the four-stage forging sequence within the first three forming steps is illustrated in the comparison of deformation degrees (see Figure 4). Due to the extended forming path in the last forming step, the con-tact time of tool and work piece in the three-stage forming sequence is considerably longer than in the four-stage sequence. In particulary, the difference occurs in the area around the main bearing and the low-end bearing, where contact times are between 1.0 and 1.7 seconds for the three-stage forging sequence, and between 0.7 to 1.0 second for the four-stage forming sequences. With the three-stage forging sequence, the gravure area of the crank web is not filled before the end of the forming process. Hence, the contact period in this area is short, while the four-stage forming sequence shows longer contact times between 1.0 s and 1.3 seconds (see Figure 5). WWW.FORGINGMAGAZINE.COM I FORGING I 17Figure 6: Comparison of forming temperatures.Figure 7: Comparison of tool wear.The authors are affiliated with the Institute of Integrated Production Hannover (IPH), in Hanover, Germany; visit www.iph-hannover.de. Dipl.-Ing. Matthias Meyer studied mechanical engineering at the Leibniz University of Hanover. Since June 2008 he has worked as scientific assistant at the IPH .Dipl.-Ing. (FH) Michael Lcke studied mechanical engineering at the University of Applied Science Stralsund. Since July 2007 he has worked as scientific assistant at the IPH.Dr.-Ing. Dipl.-Oec. Rouven Nickel studied economics, focusing on production management, manufacturing technology and performance measurement at the Leibniz Universitt Hannover. Subsequently, he worked as research associate at the Institute of Production Systems and Logistics (IFA). Since 2007 he has been the managing director of the IPH. In 2008 he received his doctorate in mechanical engineering at the Universitt Bremen.Prof. Dr.-Ing. Bernd-Arno Behrens studied mechanical engineering at the University of Hanover and, subsequently, worked as research associate at the Institute of Metal Forming and Metal-Forming Machines (IFUM) at the Leibniz Universitt Hannover. After receiving his doctorate in mechanical engineering he headed the Department of Application Technology at Salzgitter AG, Salzgitter, Germany. Since 2003 he has headed the IFUM at the Leibniz Universitt Hannover, and in 2005 became a member of the management board of the IPH. The authors express their thanks to the German Research Foundation (DFG) for its financial support of the SFB 489 project described here.REFERENCESBro99 Bro, G.: Entwicklung eines Verfahrens zum Przisionsschmieden von PKW-Pleueln. Dissertation, Universitt Hannover, Fortschritt-Berichte VDI, Reihe 2, Nr. 508, VDI-Verlag, Dsseldorf 1999.Doe07 Doege, E.; Behrens, B.-A.: Handbuch Umformtechnik Grundlagen, Technologien, Maschinen. Springer-Verlag, Berlin Heidelberg 2007.Mue08 Mller, S.; Mller, K.: Parameterstudie eines mehrdirektional wirkenden Werkzeugs zum gratlosen Przisionsschmieden einer Zwei-zylinderkurbelwelle. In: STAHL, Verlag Stahleisen, o. Jg. (2008), H. 3, S.38-39.tions of cross wedge rolling for the production of the first pre-form. For the two-cylinder crankshaft with secondary form elements, the first pre-form can be realized with mass concentrations in differ-ent locations. Based on this, the design of the cross wedge rolling process will be adjusted to determine the potential for rolling with multiple wedges. 2011 Penton Media, Inc. All rights reserved.
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