端盖零件工艺设计-毕业设计说明书-含中英文献.doc

端盖零件工艺设计摘 要本文的任务是加工工艺规程，包括被加工工件的零件图（AutoCAD格式）1张、工件的毛坯图1张、机械加工工艺过程卡片1张、对应工艺过程卡片的工序卡片3张及课程设计说明书1份。文章首先对“端盖”零件进行了简要分析，并阐述了端盖的部分作用。然后，根据零件的性质及零件图上各端面的粗糙度，确定了加工毛坯的尺寸加工余量。最后合理地拟定端盖的工艺路线图，制定部分工序中该工件的夹紧方案，并选用合适数控机床将其加工。关键词端盖；工艺规程；工艺路线；数控加工不要删除行尾的分节符，此行不会被打印II- -目 录摘 要II本文的任务是加工工艺规程，包括被加工工件的零件图（AutoCAD格式）1张、工件的毛坯图1张、机械加工工艺过程卡片1张、对应工艺过程卡片的工序卡片3张及课程设计说明书1份。II第1章 绪 论11.1 课题的研究意义11.2 课题的研究内容1第2章 端盖零件的数控加工工艺规程设计22.1 零件的分析22.1.1 零件的功用分析22.1.2 零件的工艺性分析32.2 毛坯的确定32.3 确定各表面的加工方法及选择加工机床与刀具32.4 加工方法的选择42.5 机床与刀具的选用42.6 划分加工阶段42.7 安排加工顺序42.8 拟定加工工艺路线52.9 确定加工余量、工序尺寸与公差52.10 确定切削用量及工时定额62.11 填写工艺卡片7第3章 端盖零件的三维造型及编程83.1 端盖零件的三维造型83.2 端盖零件的编程10结 论18参考文献19附录20致 谢21千万不要删除行尾的分节符，此行不会被打印。在目录上点右键“更新域”，然后“更新整个目录”。打印前，不要忘记把上面“Abstract”这一行后加一空行- III -第1章 绪 论1.1 课题的研究意义数控技术毕业设计是我们完成本专业教学计划的最后一个极为重要的实践性教学环节，是使我们综合运用所学过的基本课程，基本知识与基本技能去解决专业范围内的工程技术问题而进行的一次基本训练 。我们在完成毕业设计的同时，也培养了我们正确使用技术资料，国家标准，有关手册，图册等工具书，进行设计计算，数据处理，编写技术文件，数控编程等方面的工作能力，也为我们以后的工作打下坚实的基础，所以我们要认真对待这次综合能力运用的机会！数控编程加工是保证机械产品质量高的一种极重要的加工方式。其主要作用是：可靠地保证工件的加工质量，提高加工效率，减轻劳动强度，最大化的使零件达到设计要求。1.2 课题的研究内容论文的主要研究内容包括以下几方面：（1）参阅运用机械制造工艺学中的基本知识和理论,结合生产实习中的实践知识,独立地分析和解决工艺问题。（2）根据所学知识设计出零件的工艺规程。（3）完成工艺卡片、主要工序的工序卡。（4）完成主要零件加工的数控加工程序编制。（5）结论。获得的研究成果如下图纸全套工艺卡片三维造型图程序清单等第2章 端盖零件的数控加工工艺规程设计2.1 零件的分析 图1 端盖零件简图端盖零件的主要加工面有大平面，小平面，40平面，两个盲孔8，两个孔14，两个腰形孔，圆台2.1.1 零件的功用分析端盖应用广泛，是非常重要的机械零件之一。端盖的一般作用是：（a）轴承外圈的轴向定位；（b）防尘和密封，除本身可以防尘和密封外，也常和密封件配合以达到密封的作用；（c）位于车床电动机和主轴箱之间的端盖，主要起传递扭矩和缓冲吸震的作用，使主轴箱的转动平稳。因此该零件应具有足够的强度、钢度耐磨性和韧性，以适应端盖的工作条件。该零件的主要工作表面为左右端面以及左端面的外圆表面，在设计工艺规程时必须重点考虑。端盖加工工艺的可行性与合理性直接影响零件的质量、生产成本、使用性能和寿命等。2.1.2 零件的工艺性分析该端盖结构简单，形状普通，属于一般的盘盖类零件。主要加工表面有上端面，40圆形端面，要求其端面跳动度相对其中心轴满足0.03mm，其次就是14和8的孔，14的孔的端面为平面，可以防止加工过程中钻头钻偏，以保证孔的加工精度。该零件除表面加工外，其余的表面加工精度均比较低，不需要高精度机床加工，通过铣削，钻床的粗加工就可以达到加工要求，由此可见，该零件的加工工艺性较好。2.2 毛坯的确定由于该零件的结构比较简单，在工作工程中不会受很大的力。由于该端盖在工作过程中要承受冲击载荷，为增强其强度和冲击韧度，和较好的组织，毛坯选用铸件，该端盖的轮廓尺寸不大，为提高生产率和铸件精度，采用机器造型方法铸造毛坯，选择HT150。HT150灰铸铁具有良好的铸造性、减震性、耐磨性和切削加工性能，适合铸造该端盖零件。该零件各表面的加工余量是由各个表面的粗糙度、加工方法以及加工等级来确定的。2.3 确定各表面的加工方法及选择加工机床与刀具加工表面表面粗糙度Ra/um加工方案备注端盖上表面3.2粗铣-半精铣-精铣端盖R20圆弧面3.2粗铣-半精铣-精铣端盖R10圆弧面3.2粗铣-半精铣-精铣R3槽3.2粗铣-半精铣-精铣14孔3.2钻孔-扩孔钻-绞孔8盲孔3.2钻孔-锪孔40表面的沉孔3.2粗铣-半精铣-精铣凸台的沉孔3.2粗铣-半精铣-精铣R2.5腰形孔3.2粗铣-半精铣-精铣 2.4 加工方法的选择上端面和凸台面采用的加工方法为：粗铣-半精铣-精铣14和8孔的加工方法为：钻-扩-绞孔。2.5 机床与刀具的选用加工机床选用立式数控铣床刀具有立铣刀，麻花钻，扩孔钻，铰刀2.6 划分加工阶段该端盖加工质量要求一般，可将加工阶段分为粗加工，半精加工和精加工，首先将精基准（下端面和中心面）准备好，是后续加工工序都可以采用精基准的定位加工，保证其他表面的精度要求，然后粗铣上端面，凸台端面，圆弧表面，凸台上的14和8的孔，凸台上的沉孔，40端面的沉孔和腰形孔，在半精加工阶段完成上端面的精加工和14，8孔的钻-扩-绞孔和其他孔的加工。2.7 安排加工顺序1. 机械加工工序（1） 遵循“先基准后其他”的原则，首先加工精基准下端面（2） 遵循“先粗后精”的原则，先安排上端面，圆弧表面和凸台表面的粗加工，然后安排精加工。（3） 遵循“先表面后孔”的原则，先加工表面后进行盲孔，沉孔和腰形孔等孔加工。2. 热处理加工铸造成型后，对铸件进行热处理，可消除铸造后产生的铸造应力，提高材料的综合力学性能，端盖在工作中不承受冲击载荷，也没有各种应力，故采用退火热处理即可满足零件的加工要求。3辅助工序 在精加工后，安排进行去毛刺，清洗和终检过程。综上所述，该端盖工序安排顺序为：热处理基准加工粗加工半精加工精加工。2.8 拟定加工工艺路线工序号工序名称机床设备刀具量具1热处理-退火2粗铣下端面立式铣床立铣刀游标卡尺3精铣下端面立式铣床立铣刀游标卡尺4粗铣上端面和凸台表面立式铣床立铣刀游标卡尺5粗铣R20和R10圆弧表面立式铣床立铣刀R规6半精铣上端面和凸台表面立式铣床立铣刀游标卡尺7半精铣R20和R10圆弧表面立式铣床立铣刀R规8钻14钻床麻花钻卡尺，塞规9钻-扩-绞14钻床麻花钻，铰刀卡尺，塞规10钻8孔钻床麻花钻卡尺，塞规11钻-扩-绞8孔钻床麻花钻，铰刀卡尺，塞规12精铣上端面和凸台表面立式铣床立铣刀游标卡尺13精铣R20和R10圆弧表面立式铣床立铣刀R规14去毛刺钳工台平锉15清洗清洗机16终检塞规，卡尺2.9 确定加工余量、工序尺寸与公差在这只确定钻-绞-精绞12孔的加工余量、工序尺寸和公差。由表B-6可查得，精绞余量Z精绞=0.05mm，钻孔余量Z钻=13.0mm。查表可一次确定各工序尺寸的加工精度等级为，精绞：IT7；粗绞：IT10；钻：IT12.根据上述结果，再查标准公差数值表可确定各工步的公差值为，精绞：140+0.018mm；粗绞13.950+0.07；钻130+0.18mm，它们的关系如下图所示。2.10 确定切削用量及工时定额在这只计算钻-绞-精绞14孔此工序的切削用量和时间定额。一、 切削用量的计算(1) 钻孔工步1)背吃刀量的确定 取ap=13.0mm。2)进给量的确定 选取该工步的每转进给量f=0.1mm/r。3)切削速度的计算 俺铸铁硬度为200241HBS计算，切削速度v选取12m/min，由公式n=1000v/3.14d可求得该工序钻头转速n=389.96r/min，参照Z525型立式钻床的主轴转速，去转速n=392r/mm，再将此转速带入公式，可求出改工序的实际钻削速度为v=3.14nd/1000=12.06m/min。 (2)粗绞工步 1)背吃刀量的确定 取ap=0.98mm。 2)进给量的确定 选取该工步的每转进给量f=0.4mm/r。 3)切削速度的计算 切削速度v选取为2m/min,由公式n=1000v/3.14d可求得该工序钻头转速n=63.95r/min，参照Z525立式钻床的主轴转速，取转速n=97r/min，在将此转速代入公式，可求出该工序的实际钻削速度为v=3.14nd/1000=3.0m/min。 (3) 精绞工步 1)背吃刀量的确定 取ap=0.02mm。 2)进给量的确定 选取该工步的每转进给量f=0.3mm/r。 3)切削速度的计算 切削速度v选取为4m/min,由公式n=1000v/3.14d可求得该工序钻头转速n=127.4r/min，参照Z525立式钻床的主轴转速，取转速n=140r/min，在将此转速代入公式，可求出该工序的实际钻削速度为v=3.14nd/1000=4.4m/min。二、时间定额的计算 1.钻孔工步 钻孔的基本时间可由公式tj=L/fn=(l+l1+l2)/fn求得。式中l=20mm; l1=D/2*cotk1+(12)=9.8/2*cot54+1mm=5.3mm; l2=1mm; f=0.1mm/r; n=392mm/r。 将上述结果代入公式，则该工序的基本时间tj=(12mm+5.3mm+1mm)/(0.1mm/min*392r/min)=0.47min=28s。2.粗绞工步 绞孔的基本时间可由公式tj=L/fn=(l+l1+l2)/fn求得，式中l1，l2 按k1=15,ap=(D-d)/2=(9.96-9.8)/2=0.08的条件查的l1=0.37mm; l2=15mm;而l=12mm; f=0.4mm/r;n=97r/min。将上述结果代入公式，则该公式的基本时间tj=(12mm+0.37mm+15mm)/(0.4mm/min*97r/min)=0.7min=42s。3.精绞工步 基本时间可由公式tj=L/fn=(l+l1+l2)/fn求得，式中l1，l2 按k1=15,ap=(D-d)/2=(10-9.96)/2=0.02的条件查的l1=0.19mm; l2=13mm;而l=12mm; f=0.3mm/r;n=140r/min。将上述结果代入公式，则该公式的基本时间tj=(12mm+0.19mm+13mm)/(0.4mm/min*97r/min)=0.6min=36s。2.11 填写工艺卡片工序卡：见附录 工艺卡：见附录第3章 端盖零件的三维造型及编程3.1 端盖零件的三维造型 毛坯图 零件图 加工后的零件图3.2 端盖零件的编程上端面粗加工%N0010 G40 G17 G90 G70N0020 G91 G28 Z0.0:0030 T00 M06N0040 G0 G90 X115.5701 Y108.045 S1572 M03N0050 G43 Z10. 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H00N0060 Z2.2133N0070 G1 Z-.7867 F71.9 M08N0080 Y27.8428N0090 G2 I0.0 J22.1572 F79.9N0100 G1 Y29.4428N0110 G2 I0.0 J20.5572N0120 G1 Y23.2827N0130 Z2.2133N0140 G0 Z10.N0150 Y22.3959N0160 Z1.4266N0170 G1 Z-1.5734 F71.9N0180 Y27.4859N0190 G2 I0.0 J22.5141 F79.9N0200 G1 Y22.3959N0210 Z1.4266N0220 G0 Z10.N3460 G1 Y2.0938N3470 Z-13.5204N3480 G0 Z10.N3490 Y1.7772N3500 Z-14.307N3510 G1 Z-17.307 F71.9N3520 Y6.5627N3530 G2 I0.0 J43.4373 F79.9N3540 G1 Y1.7772N3550 Z-14.307N3560 G0 Z10.N3570 Y1.6639N3580 Z-15.0937N3590 G1 Z-18.0937 F71.9N3600 Y6.2834N3610 G2 I0.0 J43.7166 F79.9N3620 G1 Y1.6639N3630 Z-15.0937N3640 G0 Z10.N3650 M02%千万不要删除行尾的分节符，此行不会被打印。“结论”以前的所有正文内容都要编写在此行之前。- 17 -毕业设计小结参考文献1 吴慧媛 韩邦华 零件制造工艺与装备 电子工业出版社 2010.22 倪森寿 机械技术基础 人民邮电出版社 2009.43 孙燕华 AutoCAD 2005 机械制图 机械工业出版社 2006.84 邹晔 典型数控系统及应用 高等教育出版社 2005.65 顾京 数控机床加工程序编制 机械工业出版社 2009.16 过小容 李坤 UG 三维造型与数控加工编程实例精解 2009.4不要自己写，要利用word来自动生成。详情请看最后一页附录附录一附录二附录三工艺卡致 谢英文原文CNC machine toolsWhile the specific intention and application for CNC machines vary from one machine type to another, all forms of CNC have common benefits. Here are but a few of the more important benefits offered by CNC equipment.The first benefit offered by all forms of CNC machine tools is improved automation. The operator intervention related to producing workpieces can be reduced or eliminated. Many CNC machines can run unattended during their entire machining cycle, freeing the operator to do other tasks. This gives the CNC user several side benefits including reduced operator fatigue, fewer mistakes caused by human error, and consistent and predictable machining time for each workpiece. Since the machine will be running under program control, the skill level required of the CNC operator (related to basic machining practice) is also reduced as compared to a machinist producing workpieces with conventional machine tools.The second major benefit of CNC technology is consistent and accurate workpieces. Todays CNC machines boast almost unbelievable accuracy and repeatability specifications. This means that once a program is verified, two, ten, or one thousand identical workpieces can be easily produced with precision and consistency.A third benefit offered by most forms of CNC machine tools is flexibility. Since these machines are run from programs, running a different workpiece is almost as easy as loading a different program. Once a program has been verified and executed for one production run, it can be easily recalled the next time the workpiece is to be run. This leads to yet another benefit, fast change over. Since these machines are very easy to set up and run, and since programs can be easily loaded, they allow very short setup time. This is imperative with todays just-in-time (JIT) product requirements.Motion control - the heart of CNCThe most basic function of any CNC machine is automatic, precise, and consistent motion control. Rather than applying completely mechanical devices to cause motion as is required on most conventional machine tools, CNC machines allow motion control in a revolutionary manner2. All forms of CNC equipment have two or more directions of motion, called axes. These axes can be precisely and automatically positioned along their lengths of travel. The two most common axis types are linear (driven along a straight path) and rotary (driven along a circular path).Instead of causing motion by turning cranks and handwheels as is required on conventional machine tools, CNC machines allow motions to be commanded through programmed commands. Generally speaking, the motion type (rapid, linear, and circular), the axes to move, the amount of motion and the motion rate (feedrate) are programmable with almost all CNC machine tools.A CNC command executed within the control tells the drive motor to rotate a precise number of times. The rotation of the drive motor in turn rotates the ball screw. And the ball screw drives the linear axis (slide). A feedback device (linear scale) on the slide allows the control to confirm that the commanded number of rotations has taken place3. Refer to fig.1.Fig.1Though a rather crude analogy, the same basic linear motion can be found on a common table vise. As you rotate the vise crank, you rotate a lead screw that, in turn, drives the movable jaw on the vise. By comparison, a linear axis on a CNC machine tool is extremely precise. The number of revolutions of the axis drive motor precisely controls the a