0175-柴油机气缸体顶底面粗铣组合机床总体及夹具设计【全套11张CAD图+说明书】
0175-柴油机气缸体顶底面粗铣组合机床总体及夹具设计【全套11张CAD图+说明书】,全套11张CAD图+说明书,柴油机,缸体,底面,组合,机床,总体,整体,夹具,设计,全套,11,十一,cad,说明书,仿单
柴油机气缸体顶底面粗铣组合机床总体及夹具设计柴油机气缸体顶底面粗铣组合机床总体及夹具设计摘要:本设计课题为柴油机气缸体顶底面粗铣组合机床总体及夹具设计。机床总体设计主要完成双面铣组合机床的“三图一卡”;拟订夹具的结构方案、绘制夹具总图及其零件图。根据气缸体尺寸、形状、材料、加工部位的结构和加工精度、表面粗糙度等要求,确定选用卧式双面铣组合机床;为实现工件快进和工进配以移动工作台;被加工平面为大平面,材料为HT250,故刀具选择硬质合金端铣刀。夹具安装在移动工作台之上。在被加工零件的定位方面,本方案采用了“一面两销”的定位方式,以达到较好的定位效果。夹紧是通过手动夹紧,以四个压板实现夹紧,这样能很好的防止夹紧力作用下工件产生形变。由于被加工零件体积、重量较大,故采用支承板支承。另外通过夹具误差设计分析,能够较好地保证加工精度。通过这样的设计来达到加工要求,以便能完成对柴油机气缸体顶底的粗铣,满足工厂制定的产量。关键词:组合机床; 夹具; 气缸体; 铣削The diesel of the overall modular machine tool and jig for thick mill the surface and bottom of cylinder body of the diesel engineAbstract: The diesel of the overall modular machine tool and jig are designed for thick mill the surface and bottom of cylinder body of the diesel engine. The system design mainly completes “three charts and a card” about the two-sided mill modular machine-tool. The jig design is to complete the structure plan, the assembly drawing and the parts drawing.According to the cylinder body size, the shape, the material, processing request and so on spot structure and processing precision, surface roughness, determined selects the horizontal-type two-sided mill aggregate machine-tool; In order to realize the work piece to enter quickly with the labor enters matches by moves the work table; Is processed the plane is the big plane, the material is HT250, therefore cutting tool choice hard alloy face cutter. The jig installs in moves above the work table. In is processed the components the localization aspect, this plan has used two sells at the same time the locate mode, by achieves the good localization effect. Clamps is through manual clamps, clamps by four clamps realizations, like this can very good prevent clamps under the action of force the work piece to have the deformation. Because is processed the components volume, the weight is big, therefore uses the support plate supporting. Moreover designs the analysis through the jig error, can guarantee the processing precision well.I complete the design requirements according to such design, so that I can complete to the diesel engine was mad the cylinder body goes against the bottom the thick mill, satisfy the factory formulation the output.Key words: modular machine-tool; jig; cylinder body ; milling1 1 2 1 3 1 4 580 1150 80.38 64 4 1 被加工零件 图号 名称 材料 气缸体 HT250 毛坯种类 毛坯重量 硬度 装卸工件时间取决于操作者熟练程度,本机床计算时取1min 装卸工件 工作台快进 工作台工进 工作台快退 被加工零 件数量 工序名称 顶底面粗铣 工序号 序号 加工宽度 (mm) 工作行程 (mm) 切削速度 (m/min)工步名称 备注 生产率计算卡 每分钟转速 (rmin) 铣削深度 (mm) 机加工 时间 辅助时间 共计 1 1 0.07 0.07 4 256 2.27 2.27 0.19 0.18 0.37 毛坯种类 毛坯重量 硬度 机床负荷率 装卸工件时间取决于操作者熟练程度,本机床计算时取1min 单件工时机床生产率 工序号 90% 16.2件/h 3.71min 3.71min总计 生产率计算卡 铸铁 180240 2 进给速度 (mm/min) 进给量 (mm/r) 工时(min) 目 录1 前言12 机床总体设计32.1 被加工零件分析32.2 机床结构的确定32.3 本组合机床的特点32.4 切削用量的确定32.5 各部件的造型42.6 绘制“三图一卡”73 夹具设计123.1 概述123.2 设计的前期准备133.3 定位装置的确定133.4 确定夹紧方案163.5 其他元件的设计183.6 夹具的公差配合及技术要求183.7 工序的精度分析214 总结255参考文献266 致谢277 附录28 外文翻译柔性制造摘要: 在制造中,生产率和柔性之间经常存在协调一致的问题。在该领域的一端是具有高生产率却低柔性的连续生产线;在该领域的另一端是能提供最大柔性的独立的计算机数字控制的机床,但它只能进行低生产率的制造。柔性制造出在此连续统一体中间。在制造中总是需要一个系统,这个系统比单个机床能制造更大批量且用于更多制造过程,但仍保持起柔性。关键词:柔性制造、协调一致柔性制造的定义:计算机集成制造的前一部叫做柔性制造。柔性在现在带制造环境中是一个重要的特征。它意味着一个制造系统是用途多且适应性强,同时又能进行产量相对较大的制造。柔性制造系统是多用途的,这是因为它能制造多种多样的部件。它适应性强,因为它能很快地加以改变来制造完全不同的另一种部件。这种柔性在竞争激烈的国际市场上可能成败有别。这是一个平衡的问题。独立的计算机数字控制(NC)机床有着高度的柔性,但是只能处理批量相对较小的制造。正相反,系列连续生产线能进行批来年感较大的制造,但都不灵活。柔性制造试图运用工业技术在灵活性与制造运行之间达到最佳的平衡。这些工业技术包括自动化的材料、处理、成组技术及计算机和分布数字控制。柔性制造系统(FMS)是一个独立的机床或一组机床服务于一个自动材料处理系统/它是由计算机控制的而且有对刀具处理的能力。由于它有刀具处理能力并能受计算机控制,这样的系统可以不断地重新配置来制造更加多样的部件,这就是它被称作柔性制造系统的原因。一个制造系统要成为柔性制造系统必须具备的要素有:1 计算机控制2 自动处理材料能力3 刀具处理能力柔性制造向全面集成化制造的目标迈进了重要的一步。它实现了自动化制造过程的集成化。在柔性制造中,自动化的制造机器(如车床、铣床、钻床)和自动化材料处理系统之间,通过计算机网络进行即时的沟通。柔性制造的概况:通过综合几个自动化的制造概念,柔性制造系统全面集成化的制造目标迈出了重要的一步,这些观念是:1 独立机床的计算机数字控制2 制造系统的分布式数字控制3 自动化的材料处理系统4 成组技术当这些自动化工艺、机器和观念合成到一个集成的系统时,就产生柔性制造系统。在柔性制造系统中,人和计算机起了重要作用。当然人的劳动量比手工操作的制造系统要小得多。然而,人仍然在柔性制造系统的操作中起着至关重要的作用。人的任务包括几个方面:1 设备故检、维护和修理2 刀具的变换和设置3 安装和拆卸系统4 数据输入5 部件程序的变换6 程序的开发柔性制造制系统设备象所有制造设备一样,必须友人监管以免出现失常、机器程序错误,以及故障。当发现问题时检修人员必须确定问题的根源,然后给出正确的措施。人还要采取指定的措施来维修运行不正常的机器。甚至当所有系统都正 常运行时,定期的维护也是必要的。操作人员还要根据需要设置机床,换刀具、以及重新配置系统。柔性制造系统的刀具处理能力削弱了,但并有消除,在刀具变换和设置上仍需要人力。在装卸柔性制造系统时也是这样。一旦原材料被送到自动化材料处理系统上,它就会以规定的方式,在系统中移动。然而,初装到材料系统处理系统仍然是由操作人员完成的;成品的拆卸也是同样。与计算机的交流仍需人力完成。人开发零件程序,通过计算机控制柔性制造系统。当重新配置FMS制造另一种类型零件时,他们还在必要的时候变换程序。人在柔性制造系统中劳动力密集型的成分越来越少,但仍然是很重要的。柔性制造系统中的各层次控制都是由计算机来完成的。在刀具柔性制造系统中独立的机床是由CNC来控制的。整个的系统是由DNC来控制的。自动化的材料处理系统是由计算机来控制的,其他功能如数据收集、系统监控、刀具控制、运输控制也是计算机控制的。人机交互是柔性制造系统中的关键。柔性制造的历史发展:柔性制造产生于20世纪60年代中期,当时英国莫林斯有限公司开发了24号系统。24系统是一个真正的FMS。然而,它从一开始就注定是失败的,因为自动化、集成和计算机控制技术还没有发展到能够恰好支持这一系统的程度。第一个FMS是超迁的开发。因此,最终因不能工作饿被放弃。再20世纪60年代和70年代的期于时间里,柔性制造仍是一个学术观念。然而,随着复杂计算机控制技术在20世纪70年代末和80年代初的出现,柔性制造变成为可能。在美国最初的主要用户是汽车、卡车和拖拉机制造商。柔性制造的理由:在制造中,生产率和柔性之间经常存在协调一致的问题。在该领域的一端是具有高生产率却低柔性的连续生产线;在该领域的另一端是能提供最大柔性的独立的计算机数字控制的机床,但它只能进行低生产率的制造。柔性制造出在此连续统一体中间。在制造中总是需要一个系统,这个系统比单个机床能制造更大批量且用于更多制造过程,但仍保持起柔性。连续生产线能以高生产率制造大量的零件。这条生产线需要大量的准备工作,但却能造出大量的相同的零件。它的主要缺点是即使一个部件杂设计上有小的改变都能造成整个生产线的停产和结构改变。这是一个致命的弱点,因为这意味着没有高成本,耗时停工和变化生产线结构是不能制造出不同的零件的,即使是来自同一个零件族。传统上计算机数字控制机床是用来制造少量在设计上稍有不同的零件。这种机床很适合这一用途,因为它们能迅速地改变程序开适应设计上小的或者更大的变化。然而,作为独立的机床它们不能大量地或高生产率地制造零件。柔性制造系统比独立的计算机数控机床具有更大的生产能力和更高的生产率。它们在柔性方面比不上计算机数字控制机床,但它们却相差不多,柔性制造的中间性能的特殊意义在于大多数铸造要求中等量的的生产率来制造中等量的产品,同时有足够的的柔性以快速改变结构来制造另一个零件或产品。柔性制造填补了制造中长期存在的空白。柔性制造以其基本能力给制造者提供了许多优点:1 族内具有柔性在一个零件2 随意进给零件3 同时制造不同的零件4 准备时间和产品设计到投产的时间减少了5 机床的使用更有效6 直接和见解的人力成本减少7 能加工不同的材料8 如一台机床故障能继续进行部分生产柔性制造系统的软件:软件是驱动柔性制造系统的主要的不可件的因素。FMS所要求的软件有两个基本的层次:1.操作系统软件和2.应用系统软件。操作系统软件是最高层次,是计算机制造商特别规定的并对应用软件进行监督控制。应用软件通常是由系统供应商开发和提供的,它包口所有的FMS的特定程序和例行程序。FMS的应用软件是很复杂的,而且具有很强的专利性质。对于很多公司来说,它体现了几百名工人很多年开发努力的结晶。它通常是由几个模块组成。每个模块又是有由一系列与系统内部运行的各种功能相关的计算机沉痼系和例行程序组成。这些包括从FMS主机下载的NC部分程序到机床控制器、运输和材料顺序的开发、工件的工序、模拟和刀具管理。所有这些软件模块必须得到很好的饿设计,并且能够可预测地、可靠地、相互作用地运行以便FMS能达到最高的运行效率和可接受的水平。设计不好的软件使制造商不能获得FMS的充分的柔性和潜能。由于FMS软件是柔性制造系统的命脉,它也是一个FMS的最复杂、最难以理解和在战略上重要的方面。如果构件和编码得恰当,进行了反复地测试,并且充分地运行的话,它可以使FMS达到前所未有的生产性能水平。应补充说一句,所有完成的FMS软件只有在客户的工厂中、完全运行中对该系统彻底的检查后,才能被认为是可接受的。软件设计的模块化并不一定以为着使用相同或类似的软件模块的所有都是一样的。很多FMS用户有特殊的和内行才懂的各种要求来适应于他们自己的应用和操作考虑。这样的一些要求可能会包括特殊的FMS软件模块来连接一个新的FMS和已存在的自动存储和检索系统。或者,使FMS从主机上直接接受生产要求和零件工序信息。总之,像其他计算机软件一样,FMS软件,就像开发和为之编码的人一样,独立而各具特点。重要的是生产环境下它能做什么并运行得如何。 Flexible ManufacturingAbstract: In manufacturing there have always been tradeoffs between production rates and flexible. At one end of the spectrum are transfer lines capable of high production rates, but low flexible. At the other end of the spectrum are independent CNC machines that offer m aximum flexible, but are capable only of low production rates. Flexible manufacturing falls in the middle of the continuum. There has always been need in manufacturing for a system that could produce higher volume and production runs than could independent machines, while still maintaining flexibility.Key words: flexible manufacturing, tradeoffs Flexible Manufacturing DefinedThe step preceding computer-integrated manufacturing is called flexible manufacturing.Flexible is an important characteristic in the modern manufacturing setting. It means that a manufacturing system is versatile and adaptable, while also capable of handling relatively high production runs. A Flexible manufacturing system is versatile in that it can produce a variety of parts. It is adaptable because it can be quickly modified to produce a completely different line of parts. This flexible can be the difference between success and failure in a competitive international marketplace.It is a matter of balance. Stand-alone computer numerical control machines have a high degree of flexibility, but are capable of relatively low-volume production runs. As the opposite end of spectrum transfer lines are capable of high-volume runs, but they are not very flexible. Flexible manufacturing is an attempt to use technology in such a way as to achieve the optimum balance between flexibility and production runs. These technologies include automated materials, handing, group technology, and computer and distributed numerical control.A flexible manufacturing system (FMS) is an individual machine or group of machines served by an automated materials handing system that is computer controlled and has a tool handing capability. Because of its tool handling capability and computer control, such a system can be continually reconfigured to manufacture a wide variety of parts. This is why it is called a flexible manufacturing system.The key elements necessary for a manufacturing system to qualify as an FMS are as follows:1. Computer control 2. Automated materials handling capability3. Tool handling capabilityFlexible manufacturing represents a major step toward the goal of fully integrated manufacturing. It involves integration of automated production processes. In flexible manufacturing, the automated manufacturing machine (i.e., lathe, mill, dill) and the automated materials handling system share instantaneous communication via a computer network. This is integration on a small scale. Overview of Flexible ManufacturingFlexible manufacturing takes a major step toward the goal of fully integrated manufacturing by integrating several automated manufacturing concepts:1. Computer numerical control (CNC) of individual machine tool2. Distributed material control (DNC) of manufacturing systems3. Automated materials handling systems 4. Group technology (families of parts)When these automated processes, machines, and concepts are brought together in one integrated system, an FMS is the result. Humans and computers play major roles in an FMS. The amount of human labor is much less than with a manually operated manufacturing system, of course. However, humans still play a vital role in the operation of an FMS. Human tasks include the following.1. Equipment troubleshooting, maintenance, and repair.2. Tool changing and setup.3. Loading and unloading the system.4. Data input.5. Changing of parts programs.6. Development of programs.Flexible manufacturing system equipment, like all manufacturing equipment, must be monitored for bugs, malfunctions, and breakdowns. When a problem is discovered, a human troubleshooter must identify its source and prescribe correctives measures. Humans also undertake the prescribed measures to repair the malfunctioning equipment. Even when all systems are properly functioning, periodic is necessary.Human operators also set up machines, change tools, and reconfigure systems as necessary, The tool handling capability of an FMS decreases, but does not eliminate, human involvement in tool changing and setup. The same is true of loading and unloading the FMS. Once raw material has been loaded onto the automated materials handling system, it is moved through the system in the prescribed manner. However, the original loading onto the materials handling system is still usually done by human operators, as is the unloading of finishes products.Humans are also needed for interaction with the computer. Humans develop parts programs that control the FMS via computers. They also change the programs as necessary when reconfiguring the FMS to produce another type of part or parts. Humans play less labor-intensive roles in an FMS, but the roles are still critical.Control at all levels in an FMS is provided by computers. Individual tools within an FMS are controlled by CNC. The overall system is controlled by DNC. The automated materials handling system is computer controlled, as are other functions including data collection, system monitoring, tool control, and traffic control. Human computer interaction is the key to the flexibility of an FMS.Historical Development of Flexible ManufacturingFlexible manufacturing was born in the mid-1960s when the British firm Molins, Ltd. developed its System 24. System24 was a real FMS. However, it was doomed from the outset because automation, integration, and computer control technology had not yet been developed to the point where they could properly support the system. The first FMS was a development that was ahead of its time. As such, it was eventually discarded as unworkable.Flexible manufacturing remained an academic concept through the remainder of the 1960s and 1970s. However, with the emergence of sophisticated computer control technology on the late 1970s and early 1980s, flexible manufacturing became a viable concept. The first major users of flexible manufacturing in the United States were manufacturing if automobiles, trucks, and tractors.Rationale for Flexible ManufacturingIn manufacturing there have always been tradeoffs between production rates and flexible. At one end of the spectrum are transfer lines capable of high production rates, but low flexible. At the other end of the spectrum are independent CNC machines that offer maximum flexible, but are capable only of low production rates. Flexible manufacturing falls in the middle of the continuum. There has always been need in manufacturing for a system that could produce higher volume and production runs than could independent machines, while still maintaining flexibility.Transfer lines are capable of producing large volumes of parts at high production rates. The line takes a great deal of setup, but can turn out identical parts in large quantities. Its chief shortcoming is that even minor design changes in a part can cause the entire line to be shut down and reconfigured. This is a critical weakness because it means that transfer lines cannot produce different parts, even parts from within the same family, without costly and time-consuming shutdown ad reconfiguration.Traditionally, CNC machines have been used to produce small volumes of parts that differ slightly in design. Such machines are ideal for this purpose because they can be quickly reprogrammed to accommodate minor or even major design changes. However, as independent machines they cannot produce parts in large volumes or at high production rates.An FMS can handle higher volumes and production rates than independent CNC machines. They cannot quite match such machines for flexible, but they come close. What is particularly significant about the middle ground capabilities of flexible is that most manufacturing situations require medium production rates to produce medium volumes with enough flexibility to quickly reconfigure to produce another part or product. Flexible manufacturing fills this long-standing void in manufacturing.Flexible manufacturing, with its ground capabilities, Flexible offers a number of advantages for manufacturers:1. Flexible within a family of parts.2. Random feeding of parts.3. Simultaneous production of different parts.4. Decreased setup time and lead time.5. More efficient machine usage.6. Decreased direct and indirect labor costs.7. Ability to handle different materials.8. Ability to continue some production if one machine breaks down.FMS SoftwareSoftware is the vital invisible element that actually drives the FMS. There are basic levels of software required for an FMS: 1.operating system; 2.application software. Operating system software is the highest lever, is computer manufacturer specific, and executes supervisory control over the application software. Application software is usually developed and supplied by the system supplied and includes all the FMS specific programs and routines.Application software for an FMS is complex, highly proprietary, and for many companies, represents several hundred worker-years of development effort. Generally, it is composed of several modules, each of which is made up of a series of computer programs and routines relating to various functions performed within the system. These include NC part programs download from the FMS host computer to machine tool controllers, traffic and material-handling management, work-order generation, work piece scheduling, simulation, and tool management. All these software modules must be well designed and function predictably, reliably, and interactively in order fir the FMS to perform at peak operating efficiencies and acceptable levels. Poorly designed software prevents manufacturers form achieving the full flexibility and potential capacity of FMS.FMS software, because it is the life blood of a flexible manufacturing system, is also the most complex, least understood, and strategically important aspect of an FMS. Structures and coded properly, tested rigorously, and functioning adequately, it can make an FMS productive at unprecedented performance levels. It should be added that all completed FMS software can only be considered acceptable after it has been thoroughly checked out with the system in complete operation in the customers plant.Modularity of software design does not necessarily imply that all system using the same or similar software modules are created equal. Many FMS users have highly specific and esoteric requirements to suit their own applications and operating concerns. Some of these might include specific FMS software modules to couple an already existing automatic storage and retrieval system (ASRS) to a new FMS or to have the FMS directly receive production requirements and part scheduling information from the host computer.Overall, FMS software, like other types of computer software, is as different and autonomous as the people who develop and code it. What counts is what it does and how well it performs in a manufacturing environment.11
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