盘角齿轮盘角齿轮及钻孔夹具设计【正时齿轮】【含CAD图纸、文档全套】【GJ系列】
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盘角齿轮加工工艺及钻孔夹具设计(文献综述)1.金属切削手册M,上海金属切削技术协会编:上海科学技术出版社,1984切削用量的合理选择在确定了刀具几何参数后,还需选定切削用量参数才能进行切削加工。目前许多工厂是通过切削用量手册,实践总结或工艺实验来选择切削用量。制定切削用量时应考虑加工余量,刀具耐用度、机床功率、表面粗糙度、刀具刀片的刚度和强度等因素。粗车切削用量的选择对于粗加工,在保证刀具一定耐用度前提下,要尽可能提高在单位时间内的金属切除量,提高切削用量都能提高金属切削量,但是考虑到切削用量对刀具耐用度的影响程度,所以,在选择粗加工切削用量时,应优先选用大的背吃刀,其次选较大的进给量,最后根据刀具耐用度选定一个合理的切削速度,这样选择可减少切削时间,提高生产率。背吃刀量应根据加工余量和加工系统的刚性确定。精加工切削用量的选择选择精加工或半精工切削用量的原则是在保证加工质量的前提下,兼顾必要的生产率。进给量根据工件表面粗糙度的要求来确定。精加工时切削速度的切削速度应避开积屑瘤区,一般硬质合车刀采用高速切削。孔加工刀具的种类和用途孔加工刀具按其用途可分为两大类:一类是钻头,它主要用于在实心材料上钻孔(有时也用于扩孔)。根据钻头构造及用途不同,又可分为麻花钻、扁钻、中心钻及深孔钻等;另一类是对已有孔进行再加工的刀具,如扩孔钻、铰刀及镗刀等。(一)麻花钻麻花钻是一种形状复杂的孔加工刀具,它的应用较为广泛。常用来钻精度较低和表面较粗糙的孔。用高速钢钻头加工的孔精度可达IT11IT13,表面粗糙度可达6.325;用硬质合金钻头加工时则分别可达IT10IT11和3.212.5。(二)中心钻中心钻用于加工中心孔。有三种形式:中心钻、无护锥60复合中心钻及带护锥60复合中心钻。中心钻在结构上与麻花钻类似。为节约刀具材料,复合中心钻常制成双端的。钻沟一般制成直的。复合中心钻工作部分由钻孔部分和锪孔部组成。钻孔部与麻花钻同样,有倒锥度及钻尖几何参数。锪孔部制成60锥度,保护锥制成120锥度。复合中心钻工作部分的外圆须经斜向铲磨,才能保证锪孔部和锪孔部与钻孔部的过渡部分具有后角。(三)深孔钻一般深径比(孔深与孔径比)为510的孔即为深孔。加工深径比较大的深孔可用深孔钻。深孔钻的结构有多种形式,常用的主要有外排屑深孔钻、内排屑深孔钻、喷吸钻等等。(四)扩孔钻扩孔钻用于已有孔的扩大,一般加工精度可达IT10IT11,表面粗糙度可达3.212.5,通常作为孔的半精加工刀具。扩孔钻的类型主要有两种,即整体锥柄扩孔钻和套式扩孔钻。(五)锪钻锪钻用于加工各种埋头螺钉沉头座、锥孔、凸台面等。 2 机械加工工艺手册第1卷M .孟少龙编 机械工业出版社,1991一、基准的概念及分类 零件上用以确定其它点、线、面的位置所依据的那些点、线、面称为基准。根据其功用的不同,可分为设计基准、工艺基准两大类。(一)设计基准在零件图上用以确定其它点、线、面的基准,称为设计基准。(二)工艺基准零件在加工、测量、装配等工艺过程中使用的基准统称工艺基准。工艺基准又可分为:1装配基准 在零件或部件装配时用以确定它在机器中相对位置的基准。2测量基准 用以测量工件已加工表面所依据的基准。例如以内孔定位用百(千)分表测量外圆表面的径向跳动,则内孔就是测量外圆表面径向跳动的测量基准。3工序基准 在工序图中用以确定被加工表面位置所依据的基准。所标注的加工面的位置尺寸称工序尺寸。工序基准也可以看作工序图中的设计基准。图6-1 所示为钻孔工序的工序图,图a、b分别表示两种不同的工序基准和相应的工序尺寸。4定位基准 用以确定工件在机床上或夹具中正确位置所依据的基准。如轴类零件的中心孔就是车、磨工序的定位基准。如图6-2所示的齿轮加工中,从图a可看出,在加工端面E及内孔F的第一道工序中,是以毛坯外圆面A及端面B确定工件在夹具中的位置的,故A、B面就是该工序的定位基准。图b是加工齿轮端面B及外圆A的工序,用E、F面确定工件的位置,故E、F面就是该工序的定位基准,由于工序尺寸方向的不同,作为定位基准的表面也就不同。作为基准的点、线、面有时在工件上并不一定实际存在(如孔和轴的轴线、某两面之间的对称中心面等),在定位时是通过有关具体表面起定位作用的,这些表面称定位基面。例如在车床上用顶尖拨盘安装一根长轴,实际的定位表面(基面)是顶尖的锥面,但它体现的定位基准是这根长轴的轴线。因此,选择定位基准,实际上既选择恰当的定位基面。二、定位基准的选择原则根据定位基面表面状态,定位基准又可分为粗基准和精基准。凡是以未经过机械加工的毛坯表面作定位基准的,称为粗基准,粗基准往往在第一道工序第一次装夹中使用。如果定位基准是经过机械加工的,称为精基准。精基准和粗基准的选择原则是不同的。(一)粗基准的选择粗基准的选择,主要考虑如何保证加工表面与不加工表面之间的位置和尺寸要求,保证加工表面的加工余量均匀和足够,以及减少装夹次数等。具体原则有以下几方面:1如果零件上有一个不需加工的表面,在该表面能够被利用的情况下,应尽量选择该表面作粗基准。2如果零件上有几个不需要加工的表面,应选择其中与加工表面有较高位置精度要求的不加工表面作第一次装夹的粗基准。3如果零件上所有表面都需机械加工,则应选择加工余量最小的毛坯表面作粗基准。4同一尺寸方向上,粗基准只能用一次。5粗基准要选择平整、面积大的表面。(二)精基准的选择选择精基准时,主要应考虑如何保证加工表面之间的位置精度、尺寸精度和装夹方便,其主要原则是:1基准重合原则 即选设计基准作本道加工工序的定位基准,也就是说应尽量使定位基准与设计基准相重合。这样可避免因基准不重合而引起的定位误差。2基准统一原则 在零件加工的整个工艺过程中或者有关的某几道工序中尽可能采用同一个(或一组)定位基准来定位,称为基准统一原则。3互为基准原则 若两表面间的相互位置精度要求很高,而表面自身的尺寸和形状精度又很高时,可以采用互为基准、反复加工的方法。4自为基准原则 如果只要求从加工表面上均匀地去掉一层很薄的余量时,可采用以加工表面本身作定位基准。3 机床夹具设计手册M,王光斗,王春福编 上海科学技术出版社,2000。第一节 专用夹具的设计方法一、专用夹具的基本要求和设计步骤1专用夹具的基本要求(1)保证工件加工的各项精度要求 (2)提高生产效率 (3)工艺性好(4)使用性好 2专用夹具的设计步骤(1)明确设计任务,收集设计资料 (2)拟定夹具结构方案,绘制夹具草图 确定工件的定位及夹紧方案,设计定位及夹紧装置。 确定夹具的对刀或导向方案,并设计对刀或导向装置。 确定其他元件或装置的结构形式,如定位键、分度装置、预定位装置及吊装元件等。 确定夹具体结构形式及夹具在机床上的安装方式,绘制草图。(3)进行必要的分析计算 如:工件加工精度高时应进行定位误差、加工精度分析。(4)绘制夹具总图 (5)绘制夹具的零件图 绘制总图顺序:用双点划线将工件的外形轮廓、定位基面、夹紧表面及加工表面画在各视图相应位置上,待加工表面的加工余量可用网纹线或粗实线表示。在总图中工件可看作透明体,不遮挡后面的线条。依次画出定位、夹紧、对刀、导向元件或装置的具体结构,再画出夹具体,将各元件或装置连成一个整体。标注尺寸、公差和技术要求。编制夹具的明细表及标题栏。夹具中的非标零件都要绘制零件图,并按总图要求确定零件的尺寸、公差及技术要求。4 机床夹具设计手册M,东北重型机械学院编 上海科学技术出版社,1979。二、夹具总图尺寸及技术要求的制订1夹具总图上应标注的尺寸和公差(1) 夹具外形的最大轮廓尺寸 (2) 影响定位精度的尺寸及公差 (3) 影响对刀精度的尺寸及公差 (4) 影响夹具在机床上安装精度的尺寸及公差 (5) 影响夹具精度的尺寸和公差 (6) 其他装配尺寸和公差 2 夹具总图上公差值的确定(1)直接影响工件加工精度的夹具公差(2)与工件上未注公差的加工尺寸对应的夹具公差 3 夹具总图上应标注的技术要求钻床夹具设计特点一、钻床夹具的主要类型钻床夹具简称钻模,主要用于加工孔及螺纹。它主要由钻套、钻模板、定位及夹紧装置夹具体组成。其主要类型有以下几种。(1)固定式钻模 在使用中,这类钻模在机床上的位置固定不动,而且加工精度较高,主要用于立式钻床上加工直径较大的单孔或摇臂钻床加工平行孔系。(2)回转式钻模 这类钻模上有分度装置,因此可以在工件上加工出若干个绕轴线分布的轴向或径向孔系。(3)翻转式钻模 主要用于加工小型工件不同表面上的孔,孔径小于f8f10mm。它可以减少安装次数,提高被加工孔的位置精度。其结构较简单,加工钻模一般手工进行翻转,所以夹具及工件应小于10 kg为宜。(4)盖板式钻模 这种钻模无夹具体,其定位元件和夹紧装置直接装在钻模板上。钻模板在工件上装夹,适合于体积大而笨重的工件上的小孔加工。夹具、结构简单轻便,易清除切屑;但是每次夹具需从工件上装卸,较费时,故此钻模的质量一般不宜超过10 kg。(5)滑柱式钻模 滑柱式钻模是带有升降钻模板的通用可调夹具。这种钻模有结构简单、操作方便、动作迅速、制造周期短的优点,生产中应用较广。二、钻模的设计要点1钻 套钻套安装在钻模板或夹具体上,用来确定工件上加工孔的位置,引导刀具进行加工,提高加工过程中工艺系统的刚性并防振。钻套可分为标准钻套和特殊钻套两大类。(1)固定钻套(2)可换钻套 (3)快换钻套 (4)特殊钻套 2钻模板钻模板用于安装钻套,确保钻套在钻模上的正确位置,钻模板多装在夹具体或支架上,常见的钻模板有:(1)固定式钻模板 (2)铰链式钻模板 (3)可卸(分离)式钻模板 (4)悬挂式钻模板 5manual machining process M, Lee Mechanical Industry Press, 1990.Order the preparation of the machining process Process outlined in Section I First, the production process and process (A) of the production process The production process refers to the raw materials into finished the whole process. A production process including raw materials, semi-finished products, components, standard parts, tools, equipment, equipment purchase, transport, inspection, custody, special tools, special tooling, special equipment design and manufacture of production such as preparation and rough manufacturing, machining, heat treatment, surface treatment, product assembly and debugging, performance testing, and product packaging, shipping and so on. (B) process Direct change in the production process the production of the object shape, size, relative position and performance of the process, known as the process can be different ways to complete the process. And therefore the process can be divided into specific casting, forging, stamping, welding, machining and special processing, heat treatment, surface treatment, assembly and other processes. Mechanical processing methods, the direct object to change the processing of shape, size and surface properties, making the process of finished products, known as the machining process. Machining process by a certain number of processes in order of composition. 1. Processes Refers to a process or a group of workers in a workplace at the same time with one or several parts of the completion of that part of continuous process. Division process is mainly based on place of work is changing and whether the continuous processing. Continuous here means that the work processes required for completion of other work can not be inserted into the content, or processing stage. Process is composed of the basic unit of the process, but also the development of production plans for the basic unit of economic accounting. Process can be broken down into installation position, the step-by-step, take the knife and other components. 2. Installation Refers to the installation of the workpiece (or assembly unit) through the first fixture after the completion of that part of the process. 3. Public spaces Position is defined as a fixture, the workpiece in the machine tool on the percentage of completion of each location on the part of the process. 4. Step Step refers to the surface in the processing (or assembly of continuous surface) remains unchanged, the same processing tools and the same cutting conditions, the completion of that part of continuous processes. Step-by-step process works is the basic unit of composition. 5. Cutting Tool is the tool relative to the workpiece surface by a cutting of that portion of the work completed. Each step may include taking a walk several times a knife or knives. Second, the role of technology and type of order (A) the role of Process Products or parts provided for manufacturing process and method of operation, such as the document is called the Process Technology. Process is to guide the production of production, of the rationale for the production of the main technical document processing, acceptance testing, production scheduling and making arrangements for the main basis. (B) program and the production of the type of production 1. The production of the Program, including spare parts and the means of production, including waste products. 2. The production of type Production management by batch or continuous production, the production scale is divided into three types, namely, one-piece production, mass production and mass production. Third, the principle of the preparation process planning, methods and steps (A) the preparation of the principles of Process Nature, feasibility, reasonableness and good working conditions. (B) the preparation of the main basis for Process Product assembly drawings and parts diagram, program and type of production and so on. (C) Process of preparation methods and steps Fourth, parts of the structure of process Refers to the structure of technology in meeting the requirements under the premise of the use of, manufacture, maintenance and economic feasibility. Parts of the process can be used in different ways to manufacture, each of the processes are determined by the characteristics of processes of evaluation of parts of the structure is based on technology. How to analyze the method of the machining process with the production of parts of the structure of technology. To sum up, available from the following analysis: 1. Parts or by the laws of some simple surfaces, such as flat, rotating surface, spiral surface, such as involute surface composition, to avoid erratic singular surface, otherwise the processing will be difficult. 2. Parts of the size of the surface should be standardized and normalized. Such as holes, screw, shaft, such as the size of standardized, normalized, to be used in standard processing tool, but also easy to meet with the standard and user-friendly processing, assembly and use of the user. 3. Parts of the surface shape should be adapted to the shape of the processing tool. Otherwise, processing will increase the difficulty. 4. As far as possible to reduce the processing area. Not only reduces the processing workload, but also to ensure good contact. 5. Parts of the structure should ensure that the introduction of processing and exit the tool. 6. Parts of the structure should be able to minimize the processing time of the number of clamping and tool changing. 7. Does not require processing should not be designed rough surface processing face, do not ask for much of the surface not designed for high-precision, small surface roughness value. 8. Should be able to accurate positioning, clamping and reliable, easy processing, easy measurements. The basic principles of positioning the workpiece 1. Six-point rule Any of a free rigid body in space has six degrees of freedom, namely along the space axes X, Y, Z three directions and the movement around the axis of rotation of this coordinate. The substance of the workpiece position is to restrict the freedom of the workpiece. This shows that the workpiece close to the machine when the main table or fixture on the support of these six points, its six degrees of freedom that all restrictions would be a complete work to determine the location. Workpiece positioning with a reasonable distribution of the six supporting points and the positioning of the workpiece touch the base to limit the work of the six degree of freedom to fully determine the location of the workpiece, known as the six-point rule. Six-point set is the basic law of the workpiece positioning for the actual production, the effect is to support the role of a certain shape geometry, which used to limit the freedom of the workpiece geometry is positioning components. 2. Fully positioning, not entirely due to positioning and orientation Processing, the workpiece six degrees of freedom is completely restricted the location of the position as full. However, the production process does not require any type of full-targeted. Should limit the number of degrees of freedom and freedom which should be calling for a decision on processing the workpiece. For example, in a long-axis milling on the dissolution of a two keyway, keyway processing requirements in addition to its own width, depth and length, the need to ensure that the size of groove from shaft end and the external circular groove of the symmetry axis. At this point around the axis of rotation of the workpiece do not have to limit the degree of freedom as long as the limit of five degrees of freedom that is it. Workpiece six degrees of freedom have not been completely restricted positioning phenomenon is known as incomplete. Surface grinder in the grinding of the flat plate parts is not entirely an example of positioning. To meet the processing requirements under the premise of not using positioning is permitted. However, according to processing requirements should be limited to the degree of freedom is not allowed without restriction, and it certainly can not guarantee the processing requirements, due to the phenomenon known as positioning. 3. Phenomena have been targeted Linkage map processing materials such as small hole at the time of the first positioning means. Workpiece to be repeated a limited degree of freedom is called off position. Under normal circumstances should be avoided as far as possible have been targeted. However, under certain conditions, have been targeted not only allowed, but is necessary. At this point should take appropriate measures to improve the position and orientation between the base of the positional accuracy between the components, in order to avoid interference. Such as long-axis turning, the workpiece clamping between the top two, have been restricted by the five degrees of freedom must be limited (in addition to its axis of rotation around the outside of the degree of freedom), but in order to increase the rigidity of the workpiece, often used with the tool carrier This limits the duplication of the axis direction of the workpiece in addition to the two other than the mobile freedom, there have been targeting the phenomenon. At this point should be carefully adjusted with the tool, making it the center of the center as far as possible consistent with the top.
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