40变速箱上盖加工工艺编制及夹具设计【铣箱体结合面+钻右端面孔】【三维SW工件】
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湖南科技大学机械加工工艺过程卡片产品型号零件图号产品名称变速箱零件名称变速箱上箱体共 页第 页材 料 牌 号HT200毛 坯 种 类金属型铸件毛坯外形尺寸926368208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 工 时 准终 单件01铸造金属型铸造毛坯02回火热处理03探伤检验10粗铣平面以顶面为粗基准,粗铣箱体结合面机加立式铣床专用铣夹具5.35.320钻孔组合上下箱体钻出两个定位销孔2-20H7机加立式钻床钻床夹具2.41.230粗铣平面以结合面为基准,粗铣箱盖顶面机加立式铣床铣床夹具3.21.140粗铣平面以结合面为基准两销定位,粗铣前后端面机加双面铣床铣床夹具6.33.250粗铣平面以结合面为基准两销定位,粗铣右端面机加卧式铣床铣床夹具4460半精铣结合面以顶面为基准,半精铣箱体结合面机加立式铣床专用铣夹具5.45.470半精铣平面以结合面为基准,半精铣箱体顶面机加立式铣床铣床夹具3.51.180半精铣平面以结合面为基准两销定位,半精铣前后端面至图纸要求机加双面铣床铣床夹具4290半精铣平面以结合面为基准两销定位,半精铣右端面至图纸要求机加卧式铣床铣床夹具3.53.5100精铣结合面以顶面为基准,精铣箱体结合面机加立式铣床专用铣夹具4.24.2110钻孔以结合面为基准,用心轴穿过120,钻14-18组装孔;钻顶面5-M12-7H螺纹底孔5-10;钻两肋板中间凸台M301.5-7H螺纹底孔27机加立式钻床专用钻夹具202.6120钻孔以结合面为基准,钻右端面3-22通孔、2-M16-7H螺纹底孔2-14;机加卧式钻床专用夹具102.5130钻孔以结合面为基准,两销定位,钻前后面12-M16-7H螺纹底孔12-14;钻右侧肋板2-70通孔、背面凸台2-26通孔、左侧肋板26通孔;机加卧式钻床钻床夹具123140粗镗孔以结合面为基准两销定位,粗镗14-18组装孔、右侧肋板2-70通孔、背面凸台2-26通孔、左侧肋板26通孔、右端面3-22通孔机加立式钻床钻床夹具61.6150粗镗孔组合上下箱体,以顶面为基准两销定位,粗镗三轴孔200、150、130机加卧式钻床钻床夹具124160粗镗孔组合上下箱体,以顶面为基准两销定位,粗镗右侧轴孔150机加卧式钻床钻床夹具44170半精镗孔组合上下箱体,以顶面为基准两销定位,半精镗轴孔200、150、130机加卧式钻床钻床夹具102.5180半精镗孔组合上下箱体,以顶面为基准两销定位,半精镗右侧轴孔150机加卧式钻床钻床夹具33190精镗孔 组合上下箱体,以顶面为基准两销定位,精镗三轴孔200、150、130机加卧式钻床钻床夹具8.52200精镗孔组合上下箱体,以顶面为基准两销定位,精镗右侧轴孔150机加卧式钻床钻床夹具22210锪孔对台阶面上的组装孔14-18进行30锪平;对孔2-26进行45锪平;对3-22通孔在右端面内侧进行36锪平机加立式钻床钻床夹具51.2220攻丝对顶面5-M12-7H螺纹底孔攻丝至图纸要求;对肋板间凸台M301.5-7H螺纹底孔攻丝至图纸要求;机加立式钻床钻床夹具51230攻丝对前后侧面12-M16-7H螺纹底孔攻丝至图纸要求;对右侧2-M16-7H螺纹底孔攻丝至图纸要求机加卧式钻床钻床夹具31240倒角各螺纹孔处倒角145;主轴孔出倒角245,其余轴孔倒角145;其余各处需倒角部位倒角145机加车床车床夹具51250补底漆箱体内部加工面涂红色耐油底漆260检查检查零件是否符合要求 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 期湖 南 科 技 大 学英文文献翻译学 生 姓 名: 郭凯 学 院: 机电工程学院 专业及班级: 机械设计制造及其自动化六班 学 号: 1103010603 指 导 教 师: 刘厚才 2015年 5月 28日Analysis of machining processAbstractIn the machining process, the machining error due to various reasons are inevitable, if not through the correct, effective way to control these errors, directly affects the machining quality, a serious impact on production. So this paper discusses the practical improvement of machining technology according to the mechanical machining error.Key words:machine work; error;process technologyIntroductionWith the development of modern machining technology, the machining requirement of the parts is continuously improved, and the parts can meet the pattern and improve the machining accuracy.In this paper, the reasons for machining errors are analyzed, and the effective technology for reducing machining errors is proposed. After machining the machining parts, whether the workpiece meets the requirement, and the accuracy of the workpiece is within the permissible error range first. It is embodied in three aspects: dimension accuracy, geometry accuracy and position accuracy. When the parts are processed to meet the accuracy requirements, is a qualified workpiece.A.Arrangement of machining operationWhen arranging the processing sequence, pay attention to the following points.a.When the parts need to be processed in stages, the rough machining of each surface is arranged, and the finishing machining is arranged at the end.b.In order to shorten the transportation distance in the workshop, to avoid the flow of the workpiece, the processing sequence should consider the arrangement of the workshop equipment.c.According to the function and technical requirements of the parts: the main parts of the main parts of the main, the main surface of the district separate, and then focus on the main surface of the processing order.d.Parts processing generally starts with the processing of the finish datum, and then processed the other main and minor surfaces by the reference of the precision.B.The principle of process planningThe principle of the process is quality, high yield and low cost, that is, the premise of ensuring product quality, to strive for the best economic benefits. In the concrete formulation, should also pay attention to the following questions:a.Advanced technologyIn the development of process planning, we need to understand the development of the technology and technology in the domestic and foreign, and use the advanced technology and equipment as far as possible through the necessary technology test.b.Economic rationalityUnder certain production conditions, there may be some technological plan for the technical requirements of parts of the parts. At this point, it should be through the cost accounting or contrast, choose to determine the most reasonable economic plan, making the product production costs minimum.c.Good working condition and avoiding environmental pollutionIn the formulation of the technical regulations, pay attention to ensure that the workers operation with good, safe labor conditions. Therefore, in the process plan, to try to take mechanization or automation measures, so as to reduce the heavy manual labor. In addition, to comply with the relevant provisions of the national environmental protection law, to avoid the pollution of the environment.There are three aspects of product quality, productivity and economy sometimes contradictory, so the reasonable technological process should be handled well, which reflects the unity of the three.C.Error and its causes of machininga.Error of machine toolIn machining tool relative to workpiece forming motion is generally accomplished by machine tool. Therefore, the machining accuracy of workpiece depends on the accuracy of machine tool. The error of machine tool has a great influence on the machining accuracy of the workpiece: (1) the rotary error of the spindle; (2) the rail error; (3) the transmission chain error.b.Geometric error of cutterThe influence of cutting tools error on machining accuracy varies with the variety of tools. The tool dimensions forming tool generating machining tool, tool manufacturing error will directly affect the workpiece machining accuracy; and the general tool, the manufacturing error have no direct impact on the machining accuracy of workpiece.c.Error caused by force distortion in process systemstiffness of workpiece. In the process system if the workpiece stiffness relative to the machine tool, cutting tool, fixture is relatively low, in under the action of the cutting force, workpiece due to lack of rigidity caused by the deformation influence on machining accuracy is relatively large. (3) tool stiffness. Lathe tool surface (y) in the normal direction of the stiffness, the deformation can be ignored. The boring hole with the smaller diameter, the stiffness of the tool bar, the deformation of the cutter bar have a great influence on the machining accuracy. (3) stiffness of machine tool parts. There are many components in machine tool parts, and there is no suitable calculation method for machine tool parts. At present, the stiffness of machine tool is mainly determined by experiment method. The deformation is not linear with the load, the load curve and the unloading curve do not coincide, the unloading curve is lagging behind the load curve. Between two curves contained the area is set on the cyclic loading and unloading of the loss of the energy it consumes in friction work and contact deformation work; first after unloading and deformation to restore to the first loading starting point, indicating that the residual deformation existed. After repeatedly after loading and unloading, loading point of curve to and unloading curves overlap the end, residual deformation gradually decreases to zero.d.Error caused by heat distortion of process systemThe thermal deformation of the process system has a great effect on the machining accuracy, especially in the precision machining and the large machining. The machining errors caused by the thermal deformation can sometimes account for 50% of the total error.D.Improvement error of technological measuresThrough the error analysis, there are inevitable errors in machining process, but it can still be reduced by various means. The following measures are put forward to improve the processing error.a.Reduce the original error. Because the machine is a complicated system, there are many influencing factors, the accuracy of the fixture, measuring and cutting tool itself workpiece in machining force, heating, tool wear are the original error, in order to avoid the original error accumulation effect on machining accuracy. It is needed to test them in machining process, and the corresponding solution is adopted according to different error, and the error is reduced.b.Transfer error method:Error sensitive directions is refers to through the normal direction of the blade surface is processing the maximum error of the direction and tangential direction for non sensitive direction error, error of non sensitive direction, the effect is small. The essence of the transfer error method is to shift the error from the sensitive direction to the non sensitive direction. So in the process of processing should try to shift the processing error to the non sensitive direction, improve the processing precision.c.Error compensation method. For some cannot reduce the original error, by imposing artificial contrary to the direction of the original error equal to the size of the error, through this way to offset the original error, error compensation method to control the impact of machining error.(1) error compensation method: this method is artificially created a new original error, thus compensation or offset the original process system inherent in the original error, to reduce the machining errors, improve machining accuracy.(2) error canceling method: use the original a primitive error to partially or completely offset the original original error or another original errord.Differentiation or homogenization of the original error(1) the original error (packet) differentiation method: differentiation of the original error method is break up the whole into parts. For complex workpiece, if in the machining process, the misalignment errors of corresponding processing, the error in every process of accumulation, the error will continue to expand, directly affects the machining accuracy. Therefore, the corresponding means should be taken, the rough or workpiece size by segmentation for the N group, the size of the workpiece size range reduced to the original 1/n. The error range is also reduced to the original 1/n. Then, in the small range, adjust the accuracy of the relative workpiece, and reduce the impact of the original error to the processing part.(2) are the original error method: for the fit precision requirements very high shaft or hole, the lapping tool in the tool and workpiece relative motion, through surface friction and wear, to the workpiece for trace cutting error will continue to reduce. The error method is to find out the differences between them, and then to modify the processing or benchmark.E.Development of machining technologyThe mechanical processing technology will develop along the trend of automation, and it plays a very big role in the future society, and the main force of the national economic development lies in the motive of the mechanical technology. However, in the actual situation, the mechanical machining need to change the resources of the daily gradient, which becomes a stumbling block for the development of mechanical technology toward the direction of automation. However, with the advent of the new century, the popularization and application of computer will be flexible and applied in the development of mechanical technology. When the computer gradually replaces the human, this also alleviates the problem of the shortage of resources in a certain degree.At the same time, it is also a good direction to realize the eco - development of machining process, which can promote the sustainable development of the society, and make the development more green and pollution-free. Now the technology has become increasingly mature, basically have a complete set of their own system. In our country has many enterprises of satellite mechanical processing technology for the research in many aspects and find their own way out of the new skills, but also for the future development of micro mechanical laid the foundation.ConclusionIn this paper, the reasons of machining errors are analyzed, and some methods and measures of improving machining accuracy are given. For the vast majority of mechanical processing and technical personnel, how to reduce the errors of mechanical process, we must first clear influence of machining error of several pathways and factors. Therefore, this paper for the study of machining error is has a certain practical application value, for machining error control has good instruction significance. This also lay a good foundation for the development of machining technology in the future.8浅析机械加工工艺摘要在机械加工中,加工误差由于各种原因不可避免地存在,如不通过正确、有效地方式来控制,这些误差直接影响加工质量,严重影响生产。因此本文根据机械加工误差产生的原因来探讨机械加工工艺的实际改善。 关键词:机械加工;误差;加工工艺 引言随着现代加工技术的发展,对零件的加工要求也在不断提高,保证零件符合图样,提高加工精度。本文针对机械加工产生误差的原因进行剖析,并提出减少加工误差的有效工艺措施。对加工件进行机械加工后,加工件是否满足要求,先检验工件精度是否在允许误差范围内。具体体现在三个方面:尺寸精度、几何形状精度、相互位置精度。当零件加工后满足这些精度要求时,才是一个合格的工件。 一、机械加工工序的安排 在安排加工顺序时,应当注意以下几点。 (1)当零件需要分阶段进行加工时,首先安排各表面的粗加工,其次安排半精加工,最后再安排主要表面的精加工与光整加工。 (2)为了缩短工件在车间内的运输距离,以避免工件的往返流动,加工顺序应当考虑车间设备的布置情况。 (3)根据零件的功用与技术要求:先把零件的主、次要表面进行区分开,然后再着重考虑主要表面的加工顺序。 (4)零件加工一般首先从精基准的加工开始,然后再以精基准定位进行加工其他主、次要表面。 二、工艺规程制订的原则 工艺规程制订的原则是优质、高产与低成本,即在保证产品质量的前提下,来争取最好的经济效益。在进行具体制定时,还应当注意以下问题: 1、技术上的先进性 在制订工艺规程时,需要了解国内外本行业工艺技术的发展,通过必要的工艺试验,尽可能的采用先进适用的工艺与工艺装备。 2、经济上的合理性 在一定的生产条件下,可能会出现几种能保证零件技术要求的工艺方案。此时,应当通过成本核算或者相互对比,选择确定经济上最合理的方案,使得产品生产成本最低。 3、良好的劳动条件、避免环境污染 在制订工艺规程时,要注意保证在工人操作时有良好的、安全的劳动条件。所以,在工艺方案上,要尽量的采取机械化或者自动化措施,从而减轻工人繁重的体力劳动。此外,要符合国家环境保护法的有关规定,避免污染环境。 产品质量、生产率与经济性三个方面有时会相互矛盾,所以,合理的工艺规程应当处理好这些矛盾,体现这三者的统一。 三、机械加工产生的误差及其原因 1、机床的误差 加工中刀具相对于工件的成形运动一般都是通过机床完成的,因此,工件的加工精度在很大程度上取决于机床的精度。机床制造误差对工件加工精度影响较大的有:(1)主轴回转误差;(2)导轨误差;(3)传动链误差。 2、刀具的几何误差 刀具误差对加工精度的影响随刀具种类的不同而不同。采用定尺寸刀具成形刀具展成刀具加工时,刀具的制造误差会直接影响工件的加工精度;而对一般刀具,其制造误差对工件加工精度无直接影响。 3、工艺系统受力变形产生的误差 (1)工件刚度。工艺系统中如果工件刚度相对于机床、刀具、夹具来说比较低,在切削力的作用下,工件由于刚度不足而引起的变形对加工精度的影响就比较大。(3)刀具刚度。外圆车刀在加工表面法线(y)方向上的刚度很大,其变形可以忽略不计。镗直径较小的内孔,刀杆刚度很差,刀杆受力变形对孔加工精度就有很大影响。(3)机床部件刚度。机床部件由许多零件组成,机床部件刚度迄今尚无合适的简易计算方法,目前主要还是用实验方法来测定机床部件刚度。变形与载荷不成线性关系,加载曲线和卸载曲线不重合,卸载曲线滞后于加载曲线。两曲线线间所包容的面积就是载加载和卸载循环中所损耗的能量,它消耗于摩擦力所做的功和接触变形功;第一次卸载后,变形恢复不到第一次加载的起点,这说明有残余变形存在,经多次加载卸载后,加载曲线起点才和卸载曲线终点重合,残余变形才逐渐减小到零。 4、工艺系统受热变形引起的误差 工艺系统热变形对加工精度的影响比较大,特别是在精密加工和大件加工中,由热变形所引起的加工误差有时可占工件总误差的50%。 四、改进误差的工艺措施 通过对误差的分析,在机加过程中不可避免的存在加工误差,但是仍可以通过各种方式尽量减小加工误差。下面对改进加工误差提出了几点措施。 1、 减少原始误差。由于机床加工是一个复杂的系统,存在很多影响因素,夹具、量具及刀具本身的精度,工件在加工中受力、受热,刀具磨损等均属于原始误差,为了避免原始误差积累影响加工精度。需要在加工过程中对其进行检验,根据不同的误差原因采用相应的解决措施,减小原始误差。 2、转移原始误差法: 误差敏感方向是指通过刀刃的加工表面的法线方向也就是产生加工误差最大的那个方向,切线方向为误差非敏感方向,误差非敏感方向,影响小。转移原始误差法实质是将误差转移到从敏感方向转移到非敏感方向上。所以在加工过程中应设法将加工误差转移到非敏感方向,提高加工精度。 3、 误差补偿法。对于某些无法减小的原误差,可采用人为施加与原误差大小相等方向相反的误差,通过这种方式抵消原误差,采取误差补偿的方法以控制其对零件加工误差的影响。 (1)误差补偿法:该方法是人为地造出一种新的原始误差,从而补偿或抵消原来工艺系统中固有的原始误差,达到减少加工误差,提高加工精度的目的。 (2)误差抵消法:利用原有的一种原始误差去部分或全部地抵消原有原始误差或另一种原始误差 4、分化或均化原始误差 (1)分化原始误差(分组)法:分化原始误差法的思想就是化整为零。对于复杂的工件,如果在机加过程中,不对误差进行相应的处理,则误差在每一道工序中累积叠加,误差会不断地扩大,直接影响到加工件的精度。所以应采取相应的手段,将毛坯或工件尺寸经分割为n组,每组工件的尺寸范围就缩减为原来的1/n。误差范围也相应的缩小到原来的1/n。然后在小范围内,调整刀具相对工件的准确位置,最大限度地减少了原始误差对加工件影响。 (2)均化原始误差法:对于配合精度要求很高的轴或孔,研具在与加工件相对运动,通过表面的摩擦和磨损,对加工件进行微量削切,误差不断减少。均化误差法就是通过有工件与工具表面的相互比较和检查,从中找出它们之间的差异,然后再进行相互修正加工或基准加工。 五、机械加工工艺的发展 机械加工工艺将沿着自动化的趋势发展,对未来的社会起到很大的决定性作用,而国民经济发展主力在于机械工艺的动力所在。但是在现实的状况下,机械加工所需要资源日渐变少,这就成为了机械工艺向着自动化方向发展的绊脚石。然而,随着新世纪的到来,计算机的普及与应用,将灵活的运用在机械工艺自动化的研发中。当计算机逐步代替人力的时候,这在某一程度上也缓解了资源不足这个问题。 同时,实现机械加工工艺生态化发展也是一个不错的方向,既可以推动社会的可持续发展,又可以使得发展更加的绿色化,无污染化。如今机械加工的技术已经越来越来成熟,基本上已经有了自己一套完整的体系。在我国有已经有许多企业单位对卫星机械加工技术进行了多方面的研究,并且自己摸索出了新的技巧,也为以后微型机械的发展奠定了基础。 结语本文通过分析机械加工误差的成因,有针对性的给出了若干具体的提高机械加工精度的方法和措施。对于广大机械加工技术人员而言,如何降低机械加工误差,首先必须要明确影响机械加工误差的若干途径和因素,因此,本文对于机械加工误差的探讨是有一定实际应用价值的,对于机械加工误差的控制具有较好的指导借鉴意义。这也为了以后机械加工工艺的发展奠定了良好的基础。
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