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機械加工工藝過程卡
產品型號
零(部)圖號
共 1 頁
產品名稱
托架
零(部)名稱
托架
第 1 頁
材料牌號
HT100
毛坯種類
鑄件
毛坯外形尺寸
每毛坯件數
1
每臺件數
1
備 注
工序號
工序名稱
工 序 內 容
車
間
工
段
設 備
工 藝 裝 備
工 時
準終
單件
10
鑄件
2.時效處理
3.粗洗底面
4.鉆4*直徑13、4*直徑26孔
5.銑前面
6.銑削后面
7.銑削左面
8.銑削右面
9.銑削頂面
10.粗鏜,半精鏜直徑128孔
11.粗鏜半精鏜直徑60孔
12.鉆頂面各孔,并攻絲
13.鉆前面各孔并攻絲
14鉆后面各孔并攻絲
15.鉆左面各孔并攻絲
16.鉆右面各孔并攻絲
17.精鏜直徑128孔
18精鏜直徑60孔
19終檢
20清洗入庫
鑄件
2.時效處理
3.粗洗底面
4.鉆4*直徑13、4*直徑26孔
5.銑前面
6.銑削后面
7.銑削左面
8.銑削右面
9.銑削頂面
10.粗鏜,半精鏜直徑128孔
11.粗鏜半精鏜直徑60孔
12.鉆頂面各孔,并攻絲
13.鉆前面各孔并攻絲
14鉆后面各孔并攻絲
15.鉆左面各孔并攻絲
16.鉆右面各孔并攻絲
17.精鏜直徑128孔
18精鏜直徑60孔
19終檢
20清洗入庫
鑄
20
時效
時效
熱
30
銑
粗、精銑底面
金工
二
銑床 X52K
專用銑夾具,面銑刀
40
銑
粗、精銑左側面
金工
二
銑床 X52K
專用銑夾具,面銑刀
50
鉆、擴、鉸
鉆、擴、鉸2-?10孔
金工
二
鉆床 Z525
專用鉆夾具,鉆頭
60
鉆孔
鉆4-?13孔、4-?24孔
金工
二
鉆床 Z525
專用鉆夾具,鉆頭
70
鉆孔攻絲
鉆2-M10底孔,然后攻絲
金工
二
鉆床 Z525
專用鉆夾具,絲錐,鉆頭
80
粗鏜
粗鏜?75孔、?80孔
金工
二
鏜床 T68
專用鏜夾具,鏜刀
90
半精鏜
半精鏜?75孔、?80孔
金工
二
鏜床 T68
專用鏜夾具,鏜刀
100
精鏜
精鏜?75孔
金工
二
鏜床 T68
專用鏜夾具,鏜刀
110
檢
檢、檢查各部分尺寸及精度
金工
二
120
入庫
入庫、組裝入庫
金工
二
設計(日期)
審核(日期)
標準化(日期)
會簽(日期)
標記
處記
更改文件號
簽字
日期
畢業(yè)設計(論文) 文獻綜述
題目:托架機械加工工藝規(guī)程及專用夾具設計
課 題 類 別: 設計 □ 論文 □
學 生 姓 名:
學 號:
班 級:
專業(yè)(全稱):
指 導 教 師:
200 年 月
文獻綜述
1、 前言
機械加工工藝規(guī)程是規(guī)定產品或零部件機械加工工藝過程和操作方法等的工藝文件,是一切有關工生產人員都應嚴格執(zhí)行、認真貫徹的紀律性文件。生產規(guī)模的大小、工藝水平的高低以及解決各種工藝問題的方法和手段都要通過機械加工工藝規(guī)程來體現(xiàn)。而機床夾具是在機床上用以裝夾工件的一種裝置,其作用是使工件相對于機床或刀具有個正確的位置,并在加工過程中保持這個位置不變。它們的研究對機械工業(yè)有著很重要的意義。
機械的加工工藝及夾具設計是在完成了大學的全部課程之后,進行的一次理論聯(lián)系實際的綜合運用,使我對專業(yè)知識、技能有了進一步的提高,為以后從事專業(yè)技術的工作打下基礎。機械加工工藝是實現(xiàn)產品設計,保證產品質量、節(jié)約能源、降低成本的重要手段,是企業(yè)進行生產準備,計劃調度、加工操作、生產安全、技術檢測和健全勞動組織的重要依據,也是企業(yè)上品種、上質量、上水平,加速產品更新,提高經濟效益的技術保證。然而夾具又是制造系統(tǒng)的重要組成部分,不論是傳統(tǒng)制造,還是現(xiàn)代制造系統(tǒng),夾具都是十分重要的。因此,好的夾具設計可以提高產品勞動生產率,保證和提高加工精度,降低生產成本等,還可以擴大機床的使用范圍,從而使產品在保證精度的前提下提高效率、降低成本。當今激烈的市場競爭和企業(yè)信息化的要求,企業(yè)對夾具的設計及制造提出了更高的要求。
2、 發(fā)展歷史
從1949年以來,我國機械工業(yè)有了很大的發(fā)展,已經成為工業(yè)中產品門類比較齊全、具有相當規(guī)模和一定技術基礎的產業(yè)部門之一,其機械加工和夾具也有很大的發(fā)展,但是與工業(yè)發(fā)達國家相比,我們這方面的水平還存在著階段性的差距,主要表現(xiàn)在機械產品質量和水平不夠高,加工工藝過程不合理,夾具應用也比較少,使其加工工人勞動強度大,加工出來的產品也不理想。
夾具從產生到現(xiàn)在,大約可以分為三個階段:第一個階段主要表現(xiàn)在夾具與人的結合上,這是夾具主要是作為人的單純的輔助工具,是加工過程加速和趨于完善;第二階段,夾具成為人與機床之間的橋梁,夾具的機能發(fā)生變化,它主要用于工件的定位和夾,夾具與操作人員改進工作及機床性能的提高有著密切的關系,所以對夾具引起了重視;第三階段表現(xiàn)為夾具與機床的結合,夾具作為機床的一部分,成為機械加工緊。人們越來越認識到中不可缺少的工藝裝備。
3、 發(fā)展現(xiàn)狀
長期以來,加工工藝編制是由工藝人員憑經驗進行的。如果由幾位工藝員各自編制同一個零件的工藝規(guī)程,其方案一般各不相同,而且很可能都不是最佳方案。這是因為工藝設計涉及的因素多,因果關系錯綜復雜。CAPP將是機械加工工藝的發(fā)展趨勢,它不僅提高了工藝設計的質量,而且使工藝人員從繁瑣重復的工作中擺脫出來,集中精力去考慮提高工藝水平和產品質量問題。
制造業(yè)是國民經濟的基礎,隨著以計算機技術為主導的現(xiàn)代科學技術的迅速發(fā)展,以“時間驅動”為特征的市場競爭、產品更新?lián)Q代的加快、商品需求的多樣化、用戶素質的提高等使制造業(yè)面臨著巨大的挑戰(zhàn),特別像不規(guī)則零件的加工就出現(xiàn)了一些問題,在現(xiàn)階段像類的加工還沒達到現(xiàn)代自動化的水平。在現(xiàn)代的中小批量生產中,它的加工工藝還需人工畫線的方法來保證其精度,而對工件的裝夾也是通過人工的方法進行的。因此我國對類不規(guī)則零件的加工還處于效率低、成本高的階段。
機床夾具最早出現(xiàn)在18世紀后期。隨著科學技術的不斷進步,夾具已從一種輔助工具發(fā)展成為門類齊全的工藝裝備。
國際生產研究協(xié)會的統(tǒng)計表明,目前中、小批多品種生產的工件品種已占工件種類總數的85%左右?,F(xiàn)代生產要求企業(yè)所制造的產品品種經常更新?lián)Q代,以適應市場的需求與競爭。然而,一般企業(yè)都仍習慣于大量采用傳統(tǒng)的專用夾具,一般在具有中等生產能力的工廠里,約擁有數千甚至近萬套專用夾具;另一方面,在多品種生產的企業(yè)中,每隔3~4年就要更新50~80%左右專用夾具,而夾具的實際磨損量僅為10~20%左右。特別是近年來,數控機床、加工中心、成組技術、柔性制造系統(tǒng)(FMS)等新加工技術的應用,對機床夾具提出了如下新的要求:
1)能迅速而方便地裝備新產品的投產,以縮短生產準備周期,降低生產成本;
2)能裝夾一組具有相似性特征的工件;
3)能適用于精密加工的高精度機床夾具;
4)能適用于各種現(xiàn)代化制造技術的新型機床夾具;
5)采用以液壓站等為動力源的高效夾緊裝置,以進一步減輕勞動強度和提高勞動生產率;
6)提高機床夾具的標準化程度。
4、發(fā)展趨勢
隨著機械工業(yè)的迅速發(fā)展,對產品的品種和生產率提出了愈來愈高的要求,使多品種,中小批生產作為機械生產的主流,為了適應機械生產的這種發(fā)展趨勢,必然對機床夾具提出更高的要求。特別像類不規(guī)則零件的加工還處于落后階段。在今后的發(fā)展過程中,應大力推廣使用組合夾具、半組合夾具、可調夾具,尤其是成組夾具。在機床技術向高速、高效、精密、復合、智能、環(huán)保方向發(fā)展的帶動下,夾具技術正朝著高精高效模塊組合通用經濟方向發(fā)展。
(1)特種加工 它是指一些物理的、化學的加工方法,如電火花加工、電解加工、超聲波加工、激光加工、離子束加工等。特種加工方法的主要對象是難加工材料的加工,如金剛石、陶瓷等超硬材料的加工,其加工精度可達分子級加工單位或原子級加工單位,所以它又常常是精密加工和超精密加工的重要手段。特種加工與傳統(tǒng)加工相結合的復合加工有較大的發(fā)展前途。
(2)快速成形 利用離散、堆積成形概念,可將一個三維實體分解為若干二維實體制造出來,再經堆積而構成三維實體。
(3)精密工程 它包括精密加工的超精密加工技術、微細加工和超微細加工技術、微型機械和納米技術等方面。當前,以納米技術為代表的超精密加工技術和以微細加工為手段的微型機械技術有重要意義,它們代表了這一時期精密工程的方向。
(4)傳統(tǒng)加工工藝的改造和革新 這一方面的技術潛力很大,如高速切削、超高速切削、強力磨削、超硬材料磨具的出現(xiàn)都對加工理論的發(fā)展、加工質量和效率的提高有重要意義。另一方面,舊設備的改造和挖潛,如普通機床改造成數控機床等,對機械工業(yè)的發(fā)展和提高是不容忽視的。
5、設計面臨的問題
在設計中,需要對零件加工工藝方案和夾具進行設計,在確定加工工藝方案時,可能會出現(xiàn)工藝路線的不合理,甚至出現(xiàn)不能保證加工所要求達到的精度。在進行夾具設計時,可能因定位基準選擇不合理,出現(xiàn)過定位或欠定位造成加工的零件的精度得不到保證。在選擇夾緊機構時由于機構的大小,尺寸等不合理,而達不到夾緊的目的,也可能因夾緊力作用點或作用面的位置不合理而使工件產生翻轉。所以在設計過程中應制訂多套方案,以供比較選擇最優(yōu),同時還要多請教指導老師和同學,并多查閱相關的書籍來盡可能好的完成設計。
6、總結
在機械制造中,為完成需要的加工工序、裝配工序及檢驗工序等,使用著大量的夾具。利用夾具,可以提高勞動生產率,提高加工精度,減少廢品,可以擴大機床的工藝范圍,改善操作的勞動條件。因此,夾具是機械制造中的一項重要的工藝裝備。夾具設計的基礎理論一個好的機床夾具,首先要保證能加工出合格的產品。為此,所設計的夾具首先應滿足以下兩項要求:第一,在未受外力作用時,加工件對刀具和機床應保持正確的位置,即加工件應有正確的定位。第二,在加工過程中,作用于加工件上的各種外力,不應當破壞加工件原有的正確定位,即對加工件應有正確的夾緊。
綜上,機械加工藝及夾具隨著科技的發(fā)展都使計算機技術、數控技術、控制論及系統(tǒng)工程與制造技術的結合為制造系統(tǒng),形成現(xiàn)代制造工程學。而物料流、能量流、信息流是組成制造系統(tǒng)的三個基本要素?,F(xiàn)代加工都為集成化的系統(tǒng)加工,這雖減輕了工人的勞動強度,但同時對工人的知識水平要求較高。這需要我們全方位的認知現(xiàn)代科技知識。因此,在以后的學習中需要我們全方位的學習其各個相關領域的知識,不能只注重一點,為將來的人才戰(zhàn)略提出了新的要求。
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Mechanical Parts Processing Technology and Fixture Design Pick to : the machining parts of the structure and process analysis, identified the machine- finishing craft route, fixture in the mechanical processing of the status and importance, as well as the fixture design. With the increasingly development of scientific progress and the adjustment of national industry policy, project machinery industry already became no policy barriers of perfectly competitive industry Key words: technical background / development / process / positioning scheme 1 Mechanical Processing Historical Background and Its Significance Machinery manufacturing industry is an old and eternal industry full of vitality. With the development of modern industry, the mechanical product of the increasingly high demand, machinery manufacturing technology are developing rapidly. Since the founding of new China, our countrys manufacturing technology and manufacturing industry to obtain the considerable development, a considerable size and technical basis of mechanical industry system is formed basically. Years of reform and opening up, Chinas manufacturing industry to make full use of domestic and foreign two aspects of technological resources, there are plans to promote the technical transformation of enterprises, guide enterprises to take the road to rely on progress of science and technology, manufacturing technology, product quality and level and the economic benefit produced marked change, in order to promote the development of the national economy has made great contribution. Although our country manufacturing industry comprehensive technical level has been greatly improved, but compared with developed country, still have level sex difference. Enter the twenty-first Century, the economic development of our country s leading industry still is the manufacturing industry, especially after our country joins WTO, the worlds manufacturing center is developed from migration to Asia, China has cheap labor and the general consumer market, accordingly, industry of our country wants to develop, need to have appropriate technology and equipment support. Machinery industry is the equipment industry of national economy; it is content of science and technology of foundation; is new and high technology industrialization; is the basis of national defense building; is to achieve rapid economic growth of the important pillar; is to improve peoples living quality, provide consumer electrical products supply industry. It runs to national economy, the quality and efficiency of industrial structure adjustment and optimization is a very important role. 2 The Status of Machinery Industry and Development Trend With the development of society, all kinds of machinery and gradually applied to the various industry, whether in the agricultural, military, industrial, mechanical operation, leaving no efficiency, therefore, in some sense, the strength of a countrys economy, social status, and the development of machinery industry is close separable. The industrialized countries economic development course indicated that, without a strong equipment manufacturing industry, is impossible to achieve national economy industrialization, modernization and information 3 . At present, the equipment manufacturing industry development lag is restricting Chinas economic development and industrial upgrading of the important factors, increase structural adjustment strength, promote mechanical industry lasts, healthy, steady development, to change the mode of economic growth, improve quality of national economy whole, enhance the international competitiveness of the economy, security and national defense security has important and far-reaching meaning of. 3 Of Machining Process Planning 3.1 Machining Process Definition The machining process is the use of mechanical processing method of change in rough shape, size, the relative position and the nature, make its become finished or semi-finished products of the whole process. Machining process directly determines the parts and the quality and performance of products, product cost, production period has great influence, is an important part of the whole process. 3.2 Mechanical Processes The composition of mechanical machining process of the basic unit is a process. Process and is formed by mounting, station, working steps and take the knife. The process is a group of workers, in a work of the same or simultaneously on several workpieces are completed for that part of the process. Process is the formulation of labor quota, with workers and machine tool equipment, arranging operation plan and quality testing of the basic unit. The installation is a workpiece by a fixture after the completion of the procedures. The application of switch ( or displacement) when processing machine tool ( or fixture ) processing, in a fixture, the workpiece ( or cutter ) relative to the machine tool passes through several locations in order processing, in each position is done on that part of the process, called station. The multi-station processing can reduce the times of clamping, reduce the mounting error, improve productivity. The step is processing the surface in the cutting tool and the cutting parameters ( only refers to the spindle speed and feed rate ) are the same circumstances completed part of the process. 3.3 Machining Process Definition Products or components manufacturing process and operation methods of the process, called process, it is the enterprise in the production of technical guidance document. 3.4 Machining Process Planning Function and Content Machining process is ready for production work mainly on the basis of. According to its raw material and semifinished product supply, machine tool adjustment, special process equipment design and manufacturing, production scheduling, allocation of labor force, and the production cost accounting. The machining process planning and organization of production, planning and scheduling based on. It can make production schedule and the corresponding scheduling, and can be connected to the scientific process, production is balanced, smooth, to realize high quality, high yield and low consumption. Machining process card and machining process card, are the two main process documents. Machining process card, is illustrated parts machining process technology files. In a single, small batch production, to machining process card guiding production, process card various projects in the preparation of more detailed. Machining process card for each process detailed formulation, used to direct workers, used for mass production parts and mass production of the important parts in the. 3.5 Making The Machining Process Planning Principles and Steps Under certain production conditions, with minimal consumption of labor and the lowest cost, according to plans processing parts that meet requirements of the drawings, is to develop the basic principle of machining process. Formulation of machining process steps are as follows: The under parts of the production program decision production type; The analysis of parts processing technology; The choice of blank type and manufacturing method; The technological process; The process design; The process documentation. 4 Fixture Design 4.1 Fixture Design Sense In the machinery industry, how to guarantee the high precision of workpiece, the costs of processing and other substantive issues, has been engaged in the mechanical industry research questions, which in the design of fixture when we should consider the problems above, efficient fixture is the workpiece precision guarantee, how to make the fixture more efficient, more economical, the industry is the urgent need to resolve. With the development of society, the continuous improvement of technology, various high- tech technology gradually infiltrated into all sectors, how to use these high-tech to serve mankind, how to make full use of the technology in mechanical industry, it also requires machinery industry staff continued efforts, innovation. With the development of science and technology, and social needs of the market, the fixture design in progressive super to the flexible manufacturing system development. To date, the fixture is mechanical and electrical products manufacturing in the four indispensable tools, tool itself is already highly standardized, the user only needs to press varieties, specifications selection and procurement. While the mold and fixture and related products products, there is a need to make changes, usually belong to the special properties of the tool, mould has become an independent industry; fixture at home and abroad is also gradually form a dependent or independent small industry of machine tool industry. Combined clamp not only has the standardization, modularization, modular and other contemporary advanced design ideas, and in line with resource conservation principle, more suitable for green manufacturing environment protection principle. So the next fixture technology is an important direction of development unit. Machine tool fixture is usually refers to the use of clamping workpiece clamping device: for the device with various tools, also known as tool. The auxiliary tool is sometimes generalized to include in the range of machine tool fixture. According to the application range of machine tool fixture, generally can be divided into general jig, fixture and adjustable fixture. Universal jig is on general machine tools are generally accompanied by a common fixture, such as a lathe chuck, milling machine rotary table, dividing head, top seat. They have a standardized, with certain universality, can be used to install certain shape and size within the range of the workpiece without the need for special adjustment. However, in actual production, a universal fixture often can not meet the needs of various parts processing; or because of low productivity and must have the universal fixture for proper improvement; or because the shape of the workpiece, the processing requirements to be different specialized design and manufacture of a special jig, in order to solve the actual production needs. Jig is adapted to a workpiece in a processing requirements and the design and manufacturing expertise, its function mainly has the following several aspects: 1 ensure that the surface of the workpiece being processed mainly includes processing workpieces need maneuvering time of loading and unloading workpieces need the auxiliary time of two part. 2 using a dedicated fixture, workpiece installation and conversion work work can be greatly simplified, no longer need to draw the line and to find it, to shorten the working procedure non-cutting time and save line drawing this process, thereby improving the labor productivity. In production due to the adoption of multiple parallel processing workpiece fixture, enabling the simultaneous processing several parts of the motor will time and processing time of the same motor. The rotary multi-station continuous processing fixture, can be used for machining a workpiece at the same time, other workpiece loading and unloading, thereby enabling the auxiliary time and motor time coincides. In short, with the special fixture using and further improvement, can effectively shorten the process time, production to meet the evolving needs of. 3 using a dedicated fixture can expand the scope of machine tool technology. For example in lathe boring jig attached, can replace boring work; special fixture can be installed after turning the molding surface, so as to give full play to the role of general machine tools. 4, reduce the labor intensity, and ensuring safety production. According to the demand of production, using pneumatic, hydraulic or other mechanical changes, a higher degree of automation of the special fixture, to reduce the labor intensity of workers, protection of production safety and the stability of product quality and high yield of a great role. Processing large workpieces, such as the lathe bed, the lower surfaces of the screw holes on the bed, need to flip several times for processing workpieces, high labor intensity and safety. The use of electric rotary drill furniture, can improve production efficiency, reduce labor intensity, ensure safety in production. 4.2 Fixture of The Development Trend Industrial design is the development of human society and the progress of science and technology of the product, from Maurices the arts and Crafts Movement, to the German Bauhaus design revolution and the United States of America wide dissemination and promotion, industrial design after brewing, exploration, formation, development history of more than 100 years of vicissitudes. Today, industrial design has become an independent subject, and a complete set of research system. In 1980 the International Council of societies of industrial design ( ICSID ) to the industry as a clearly defined: production of industrial products, by training, technical knowledge, experience and visual experience, and indicates the material, structure, morphology, structure, color, surface processing, decoration to the new quality and specification, called industrial design. According to the specific circumstances of the time, industrial designer in the industry products are all side or a few aspects of the work, but also the need for industrial designers of packaging, publicity, display, market development and other issues to resolve pay their own technical knowledge and experience and ability of the visual evaluation, which also belongs to the scope of industrial design. Material, structure, technology is the product design material and technical basis, on one hand, technology restrict the design; on the other hand, technology is also promoting design. From the point of view of design aesthetics, technology is not only the material basis but also has its own function action, as long as good application properties of the materials, to the corresponding structure and suitable processing technology, can create a practical, aesthetic, economic products, namely in the product technology potential function. Any design are the product of the times, its different features, different features reflect the different historical periods of level of science and technology. Technology is the product of the morphological development of the pilot, new material, new technology products, is bound to bring new structure, new forms and new style. Materials, processing technology, structure, product image organic ground is contacted together, a part of the change, it will cause the whole body changes. Now, the machining process and fixture with the development of manufacturing technology also make a spurt of progress. Machining process to the various factories in different circumstances, its processing procedures are very different. Break through the past death mode. Make it with different cases has more reasonable technological process. So that product quality greatly improved. Develop processing technology can be rational, but also to meet the basic requirements: guarantee product quality under the premise, as far as possible to improve labor productivity and reduce the processing cost. And to make full use of the existing factory production conditions, as far as possible, using domestic and foreign advanced technology and experience. Should also ensure that the good working conditions. But our country present stage still rely mainly on technology personnel experience to prepare process, often does not require step and cutting amount, man-hour quota is to be determined by experience, very rough, the lack of scientific basis, difficult to carry out reasonable economic accounting International Journal of production Research Association statistics show that, at present, small batch production of many varieties of workpiece varieties accounted for about 85% of the total number of the kind of workpiece. Modern manufacturing requirements of enterprises manufacturing products constantly upgrading, to meet the needs of the market and competition. However, the general enterprises are still accustomed to the traditional special fixture, generally in the medium having a production capacity of the plant, some have thousands or even nearly 10000 sets of special fixture; on the other hand, in the production of many varieties of the company, every 3 to 4 years to update 50 80% special jig, fixture actual wear only 10 20% or so. Especially in recent years, CNC machine tools, machining center, group technology, flexible manufacturing system ( FMS ), a new processing technology of machine tool fixture, proposed the following new requirements: 1) can rapidly and conveniently and equipment of new products put into production, so as to shorten the production cycle, reduce the production cost; 2) capable of clamping a group with similar characteristics of the workpiece; 3) can be applied to precision machining of high precision machine tool fixture; 4) can be applied to all the modern manufacturing technology of new machine tool fixture; 5) adopts the hydraulic station for power efficient clamping device, in order to further reduce the labor intensity and improve labor productivity; 6) improve the standardization degree of machine tool fixture. The development trend of modern machine tool fixture mainly for standardization, efficiency, precision and flexibility in four aspects. Use better fixture, can improve labor productivity, improve processing accuracy, reduce waste, machine tool technology can expand the scope, improve the operation of labor conditions. Therefore, the fixture machinery manufacturing is an important process equipment. A good fixture is the processing of qualified products of the first condition, in order to allow the clamp has the better development, fixture industry should strengthen the production, learning and research, collaborative efforts, accelerate the use of high technology to transform and upgrade the level of technology to create the pace of jig, fixture professional technology website, make full use of modern information and network technology, and when in keeping with the innovation and development of fixture technology. Active and foreign fixture manufacturer, for joint venture and cooperation, the introduction of technology, it is the reform and development of our country industry is more effective ways of fixture.