1308-機床夾具柔性化技術(shù)研究及設(shè)計

1308-機床夾具柔性化技術(shù)研究及設(shè)計,機床,夾具,柔性,技術(shù)研究,設(shè)計 SECTION 1 Basic Types and Functions of Jigs and FixturesUNIT 1 Purpose of Tool DesignOBJECTIVESAfter completing this unit, the student should be able to:? List the objectives of tool design.? Identify the source of specified design data.TOOL DESIGNTool design is the process of designing and developing the tools, and techniques necessary to improve manufacturing efficiency and productivity. It gives industry the machines and special tooling needed for today’s high-speed, high-volume production. It does this at a level of quality and economy that will insure that the cost of the product is competitive. Since no single tool or process can serve all forms of manufacturing, tool design is an ever-changing, growing process of creative problem solving.TOOL DESIGN OBJECTIVESThe main objective of tool design is to lower manufacturing costs while maintaining quality and increased production. To accomplish this, the tool designer must satisfy the following objectives:? Provide simple, easy-to –operate tools for maximum efficiency.? Reduce manufacturing expenses by producing parts at the lowest possible cost.? Design tools that consistently produce parts of high quality.? Increase the rate of production with existing machine tools.? Design the tool to make it foolproof and to prevent improper use.? Select materials that will give adequate tool life.? Provide protection in the design of the tools for maximum safety of the operator.TOOL DESIGN IN MANUFACTURINGAs an important part of manufacturing, tool design occupies a position between product design and product production. First, the need for a product is determined. Then, the drawings and specifications are developed. The product designer forward this information to the process planning engineer. The process planning engineer, working closely with the product designer and the tool designer, plans the methods that will be used to product the part.Occasionally, the product designer changes or modifies a design to simplify or speed up production. Normally, the product designer sets the production rate and the part design, and chooses the machine tools. Deadlines are scheduled and a budget is set up. The tool designer must plan within this framework.第１篇 夾具的基本類型與功能第１章 夾具設(shè)計的目的學習目標學習完該章后，學生應具備下述能力：?列舉出夾具設(shè)計的目的?鑒別原始設(shè)計資料數(shù)據(jù)及其來源夾具設(shè)計概述夾具對于改進制造技術(shù)的效能、提高生產(chǎn)率是十分必要的。其設(shè)計既是一個是設(shè)計過程，也是一個創(chuàng)新過程?，F(xiàn)代工業(yè)生產(chǎn)要求在保證質(zhì)量的前提下降低成本，提高生產(chǎn)率，擴大生產(chǎn)規(guī)模，工藝裝備與專用夾具的設(shè)計就是為了滿足這些要求而進行的。由于不存在萬能的制造裝備或工藝手段，因此，夾具設(shè)計是一個不斷變化、不斷進步的創(chuàng)造性地解決制造技術(shù)問題的過程。夾具設(shè)計的目的夾具設(shè)計的主要目的，是在保證產(chǎn)品質(zhì)量的前提下降低成本，提高生產(chǎn)率。為達此目的，夾具設(shè)計師必須切實做到以下幾點：? 所設(shè)計的夾具應功能完備，結(jié)構(gòu)簡單，操作方便。? 以盡可能最低的成本生產(chǎn)零件，切實降低制造費用。? 所設(shè)計的夾具應保證所加工零件質(zhì)量的連續(xù)一致性。? 利用企業(yè)現(xiàn)有機床設(shè)備來提高生產(chǎn)率。? 所設(shè)計的夾具應保證定位無誤，且具有防止誤操作的功能。? 選擇適當?shù)牟牧?，確保其有足夠的使用壽命。? 應確保操作者能得到最大限度的安全保護。夾具設(shè)計在制造過程中的地位夾具設(shè)計介于產(chǎn)品設(shè)計與其生產(chǎn)之間，是制造過程的一個重要組成部分。首先，設(shè)計前對產(chǎn)品的各種要求是已經(jīng)明確了的；其次，產(chǎn)品圖紙與說明書也已經(jīng)具備。產(chǎn)品設(shè)計人員將上述信息傳遞給工藝設(shè)計人員，工藝設(shè)計人員則據(jù)此規(guī)劃設(shè)計制造零件的工藝方法。因此，工藝設(shè)計人員與產(chǎn)品設(shè)計人員和夾具設(shè)計人員應密切合作。有時，產(chǎn)品設(shè)計人員會更改設(shè)計，以簡化生產(chǎn)工藝，或提高生產(chǎn)效率。一般說來，是產(chǎn)品設(shè)計人員決定了零件的設(shè)計、生產(chǎn)率及機床的選擇。預決算也由他們制定出來。夾具設(shè)計人員應在上述框架之內(nèi)開展設(shè)計工作。1-1 設(shè)計方案策劃在設(shè)計方案策劃方面所花費功夫的多少，在很大程度上決定著一個夾具設(shè)計方案的成敗。夾具設(shè)計方案策劃是有一定程序的。有關(guān)待生產(chǎn)產(chǎn)品的資料及說明書等都已經(jīng)過評估，以便能設(shè)計出最為高效和低耗的夾具。在設(shè)計方案策劃階段，夾具設(shè)計人員要非常仔細地研究分析零件圖樣和生產(chǎn)工藝，他們必須對零件及其工藝過程有十分清楚的了解。零件圖樣夾具設(shè)計人員收到了如圖 1-1 所示的待加工零件的圖樣后，就要對其進行分析。分析零件圖樣時應充分考慮下列直接影響夾具設(shè)計方案的基本要素：? 零件所有的尺寸和形狀? 零件材料的種類及狀態(tài)? 所選擇的機械加工方法的特點? 零件需要達到的精度等級? 零件需要加工的數(shù)量? 零件的定位表面和夾緊表面工藝過程文件圖２所示為一工藝過程文件。它是由工藝設(shè)計師設(shè)計的加工工序及工序流程的詳細表格。根據(jù)各公司的需要，工藝過程文件可以有多種形式。但起碼來說，它應包括每一道加工工序的簡要說明，以及各工序所選用的機床。在設(shè)計夾具時，也需要參考工藝過程文件。工藝過程文件可包括下述內(nèi)容：? 每一工序所選用的機床種類及規(guī)格? 每一工序所選用的刀具種類及規(guī)格PLANNING THE DESIGNThe amount of planning in a tool’s design greatly affects its success or failure. This is an orderly process. All of the information and specifications pertaining to the proposed product are evaluated so that the most efficient and cost-effective tool design can be selected. During this phase, the tool designer carefully studies the part drawing and the production plan. The tool designer must understand the part and the manufacturing processes.Part DrawingsThe tool designer receives a duplicate of the part drawing, which will be used to make the part, Figure 1-1. When analyzing the part drawing, the tool designer must consider several general factors that directly influence the design choices. These factors are:? Overall size and shape of the part? Type and condition of the material used for the part? Type of machining operation to be performed? Degree of accuracy required? Number of piece to be made ? Locating and clamping surfaceProduction PlanThe production plan, Figure 1-2 , is an itemized list of the manufacturing operations and the sequence of the operations chosen by the process planning engineer. The production plan can take many forms, depending on the needs of each company. At the least, it should include a brief description of each machining operation and the machine tool designated for these operations.The tool designer also uses this plan to assist in the design. The production plan can include the following:? Type and size of machine tool specified for each operation? Type and size of cutters specified for each operation圖 1-1 零件圖通孔?0.19沉孔?0.38深 0.25A WAS.750NO. REVISIONS(修改) DATE(日期 )BEST MACHINE CO.(頂好機械公司)Baltimore Maryland(馬里蘭州巴爾德摩 )TITLE（名稱）SLIDE STOP（滑動擋塊）DATE(日期 ) MATL.SAE 4130SCALE(比例)TOLERANCES（公差） ANGLES（角度）???=0.015 ?0?-30?????=0.005UNLESS OTHERWISE SPECIFIED(未標注處)PART NO. (零件號)507911-2 ? 工序流程? 該零件的上一道加工工序內(nèi)容除了零件圖樣和工藝過程文件外，還允許夾具設(shè)計人員花費一定的時間和金錢用于設(shè)計中。利用上述信息，加上一點創(chuàng)造力與經(jīng)驗，夾具設(shè)計人員就可開始策劃多種設(shè)計方案以供選擇。設(shè)計方案選擇第一步需要解決的問題是選擇夾具設(shè)計方案。為了確保得到最佳方案，夾具設(shè)計始終遵循這一既定流程。在這一階段，夾具設(shè)計人員必須對各種重要的信息進行認真分析，以回答下述問題：? 需要采用專用工夾具嗎？需要對現(xiàn)有設(shè)備進行改裝嗎？? 采用單主軸機床還是多主軸機床？? 夾具是專用的還是多用途的？? 降低夾具成本的措施確實有效嗎？? 如果需要的話，各工序應采用何種類型的量具？上述問題及與該夾具設(shè)計相關(guān)的其它問題解決之后，夾具設(shè)計人員就開始進行方案優(yōu)選。通過優(yōu)選，一個高效、可靠、性能價格比高的設(shè)計方案就確定了。工夾具設(shè)計人員的職責工夾具設(shè)計人員在制造業(yè)中要擔負許多責任。除了技術(shù)設(shè)計外，工夾具設(shè)計人員也可能要承擔材料進貨、工具室監(jiān)理及工具檢查等責任。工夾具設(shè)計人員應清楚這些額外職責的范圍。設(shè)計在設(shè)計階段，夾具設(shè)計人員的任務(wù)是根據(jù)設(shè)計方案來繪制草圖和圖樣。設(shè)計圖樣一般要經(jīng)過主設(shè)計師的批準。但在小公司里面，則經(jīng)常是由夾具設(shè)計人員完全作主。監(jiān)管夾具設(shè)計人員的監(jiān)管范圍通常由公司規(guī)模所決定，如圖 1-3。監(jiān)管責任可能是單一領(lǐng)域，如設(shè)計或制造；也可能是整個工夾具部。在任何一種情況下，具備領(lǐng)導別人的能力總是有好處的。在解決設(shè)計問題時，工具間的一幫熟練技工是夾具設(shè)計人員經(jīng)常要利用的。這些從事工具制造的熟練技工往往能輕易找到解決問題的方法，而一個夾具設(shè)計人員的技能水平無論如何高超，卻不一定很快看得出來。基于這一原因，夾具設(shè)計人員與工具制造技工建立良好的關(guān)系是很有好處的。在夾具設(shè)計過程中，設(shè)計人員與制造人員的良好合作，可以說是決定設(shè)計成敗的根本。夾具設(shè)計人員不要試圖單槍匹馬把問題搞定。協(xié)同攻關(guān)使任務(wù)的完成變得容易，而多聽取專家意見則能擴大視野。? sequence of operations ? Previous machining operations performed on the partIn addition to the part drawing and production plan, the tool designer is informed of the amount of time and money that is available to spend on the design. Using this information and a little creativity and experience, the tool designer begins to study the design alternatives.AlternativesOne of the first steps in problem solving is determining the alternative solutions. The same process is used in tool design to insure that the best method is chosen. During this phase of the design, the tool designer must analyze all important information in order to answer the following questions:? Should special tooling be used or existing equipment modified?? Should multiple-spindle or single –spindle machine be used?? Should the tool be single or multipurpose?? Will the savings justify the cost of the tool?? What type of the gauge, if any, should be used to check each operation?Answering these questions, and others related to the specific task, the tool designer develops alternatives solutions. From these alternative solutions, the efficient, dependable, and cost-effective design is chosen.CHALLENGES TO THE TOOL DESIGNERThe tool designer has many manufacturing responsibilities. In addition to technical design duties, the tool designer may be responsible for obtaining materials, toolroom supervision, and tool inspection. The tool designer should understand the extent of these additional duties.DesignIn this phase, the tool designer is responsible for developing the drawing and sketches of the tool design ideas. Design drawing are usually subject to approval by a chief designer. However, in smaller companies, the tool designer quite often makes the tooling decisions.SupervisionThe extent of a designer ‘s supervision is normally determined by the size of the company. Figure 1-3. Supervision for a single section, such as design or toolmaking, or for the entire tooling department, may become the tool designer’s responsibility. In either case, the ability to lead others is helpful.One resource a tool designer may often use to help resolve design problems is the group of skilled people in the toolroom. Regardless of the level of skill a designer possesses, these skilled toolmakers can often see solutions that may not be obvious to the designer. For this reason it is always a good idea to build a good working relationship with your toolmakers. In tool design, a cooperative relationship between the designer and the toolmakers is essential. Not only does working together make the task at hand easier, but using the available expertise also makes more sense than trying to do the job alone.1-3BEST MACHINE COMPANY(頂好機械公司)Baltimore Maryland(馬里蘭州巴爾德摩 )PART # 50791 PART NAME Slide Stop QUANTITY 7500 ORDER #13762零件號：50791 零件名稱：滑動擋塊 數(shù)量：7500 定單號：13762DWG #D-50791 PROCESS PLANNER(工藝制定) REVISION # Page 1 of 1圖號：#D-50791 R.E.Tucker 修改標記：# 共１頁第１頁OPR#工序號DESCRIPTION工序內(nèi)容DEPT.工段MACHINE TOOL機床及編號１２３４５６Cutoff - .875?.500 s tock to 1.250 length..875?.500 毛坯切斷，至長度 1.250Drill - ?.19 hole thru?.19 孔鉆通Counterbore - ?.38 .25 Deep锪沉孔?0.38 深.25Mill - .38?.38 and .19?.38 shoulders銑臺階.38?.38 及 .19?.38Deburr去毛刺Inspect – Visual and dimensional檢查：外形與幾何尺寸#68 Cutoff Rm.68 工段切斷室#66 Drilling66 鉆工段#66 Drilling66 鉆工段#37 Milling37 銑工段#7 Finishing7 清理工段#7 Finishing7 清理工段Abrasive Cutoff Saw #68-19砂輪鋸切機#68-19Drill Press #66-141鉆床#66-141Drill Press #66-141鉆床#66-141Horiz. Mill #37-804臥式銑床#37-804Tumbler #7-1053滾筒機#7-1053None無６４３２１Receiving gauge (1) ; Pin Gauge (2)外量規(guī)(1 件) ; 塞規(guī)(2 件 )Side milling cutters(2)三面刃銑刀(2 件)Counterbore with pilot帶導向桿锪鉆Drill鉆頭Cutoff wheel 切斷砂輪4?.500?1.375?.19.187 (3/16)10?.62#Ⅰ-50791-3#Ⅰ-50791-1/2Fixture #S-50791-1銑夾具 #S-50791-1Jig #J-50791-1鉆模 #J-50791-1Jig #J-50791-1鉆模 #J-50791-1None 無OPR#工序號TOOL DESCRIPTION刀夾量具種類SIZE.尺寸SPEC. TOOL專用刀夾量具Figure 1-2 Production plan（圖 1-2 工藝過程文件）1-4采購夾具設(shè)計人員經(jīng)常負有采購制造夾具的材料的責任。在此情況下，夾具設(shè)計人員往往要依賴供應商來提供材料和零件。最好是選擇服務(wù)范圍全面的公司作為供應商。好的供應商能依靠其相關(guān)產(chǎn)品，來協(xié)助進行夾具設(shè)計和疑難問題的解決。在作最終決定之前，要充分考慮這些重要因素。另外需要考慮的一點是，供應商能否在需要時提供必要的零配件。一般情況下，購買專門供貨商提供的零配件，要比自行制造便宜得多。鑒于很多專門供貨商都能提供上述服務(wù)，最終決定選擇哪一家，主要應考慮其供貨是否最為及時、高效和守信用。檢驗夾具設(shè)計人員經(jīng)常被要求去檢查制造完工的夾具，以確保其能滿足各項指標。這一檢查，或叫功能試驗，首先能確保夾具本身符合其圖紙要求；其次，由于一部分試驗用的工件已經(jīng)用該夾具生產(chǎn)出來，且經(jīng)過嚴格檢查，所以也能確保用該夾具生產(chǎn)的零件能符合零件圖紙要求。在夾具轉(zhuǎn)交給生產(chǎn)部門以后，夾具設(shè)計人員還應定期對其進行檢查，以確保其精度保持在規(guī)定的公差之內(nèi)。圖 1-4.ProcurementOften a tool designer is responsible for obtaining the materials to make the tool. In these situations, the tool designer normally relies on vendors or salespeople to supply materials and parts that meet the design specifications. When selecting a vendor, a good practice is to choose the company that offers the most service to its customers. Services such as design assistance and problem solving, where their product is involved, are important factors to consider before making a final selection. Another point to consider is whether or not the vendor can supply special parts or components when necessary. Generally, the specialty vendors can furnish special items for much less than those items cost to make in-house. Since most specialty vendors offer these services, the decision should be made on a basis of which vendor can meet the designer’s needs in the most timely, efficient, and dependable manner.InspectionMany times the tool designer is required to inspect the finished tool to insure that it meets specifications. This inspection, or functional tryout, is normally conduced in two phases. First, the tool itself is inspected for compliance with the tool drawing. Second, several test parts are produced with the tool and are carefully checked to insure that they conform to the specifications shown in the part print. After the tool has been turned over to the production department, the tool designer should make periodic checks during production to insure that the specified tolerances are maintained, Figure 1-4.Figure 1-3 The tool design departments in most manufacturing organizations use a combination of drawing boards (A) and Computer Aided Design(CAD)workstations (B) to create the necessary tool design drawing (Photo courtesy of Advanced Technologies Center).圖 1-3 在大多數(shù)制造部門，夾具設(shè)計部門使用組合圖板及 CAD 設(shè)計夾具圖紙( 高技術(shù)中心提供圖片)Figure 1-4 The tool designer consults the machinist to determine how well the jig or fixture performs.圖 1-4 夾具設(shè)計人員與技師協(xié)商解決夾具問題1-5REQUIREMENTS TO BECOME A TOOL DESIGNERIn order to perform the functions of a tool designer, an individual must have the following skills:? The ability to make mechanical drawings and sketches? An understanding of modern manufacturing methods, tools, and techniques? A creative mechanical ability? An understanding of basic toolmaking methods? A knowledge of technical mathematics through practical trigonometrySUMMARYThe following important concepts were presented in this unit:? Tool design is the process of designing and developing tooling devices, methods, and procedures to aid in improving overall manufacturing efficiency and productivity.? The primary objective of tool design is lowering manufacturing costs while maintaining consistent quality and increased production.? The tool designers use part drawings and production plan in developing alternative design solutions for efficient, dependable, and cost-effective tool designs.? Tool designers in addition to designing tooling, may also be responsible for toolroom supervision, procurement, and tool inspection.? To become a tool designer, an individual must be able to make mechanical drawings and sketches, understand manufacturing techniques and toolmaking methods and equipment, have a creative mechanical ability, and have a working knowledge of shop mathematics through practical trigonometry.REVIEW1. List the seven objectives of tool design.2. Determine the source of the following data by indicating 1 for the part drawing, 2 for the production plan, and 3 for additional instruction.a. Time allocationb. Overall size and shape of the partc. Required accuracyd. Sequence of operatione. Type and size of machines usedf. Money availableg. Number of pieceh. Previous machiningi. Locating surfacesj. Material specificationsk. Type of cutters neededl. Type of machining required夾具設(shè)計師應具備的基本素養(yǎng)一個夾具設(shè)計師要想勝任自身工作，必須具備下列技能：? 機械制圖及其草圖和繪制能力? 現(xiàn)代制造工藝方法、工藝裝備與技術(shù)的知識? 機械創(chuàng)新能力? 工夾具制造工藝方面的知識? 以工程適用三角為根本的技術(shù)數(shù)學知識總結(jié)本節(jié)介紹了下述重要概念：? 使用夾具的目的在于降低制造成本，提高生產(chǎn)效率。夾具設(shè)計是一個創(chuàng)造性地設(shè)計工藝裝備及技術(shù)方法的過程，這一過程需要遵循一定程序。? 夾具設(shè)計的主要目的是在保證質(zhì)量的前提下降低制造成本，提高生產(chǎn)效率。? 為了確保所設(shè)計的夾具功效、可靠性及自身制造成本低，夾具設(shè)計人員在進行方案創(chuàng)新與優(yōu)選時，要充分理解吃透零件圖紙與其制造工藝規(guī)程。? 要想成為一個夾具設(shè)計師，必須具備機械制圖及其草圖的繪制能力，掌握制造技術(shù)與工夾具制造方法、設(shè)備方面的知識，具有一定的機械創(chuàng)新能力，以及來自于工程實踐的三角學為根本的數(shù)學知識。復習1. 列出夾具設(shè)計的七種目標任務(wù)2. 確定下列資料及數(shù)據(jù)來源于何處：(1)來源于零件圖; (2)來源于工藝規(guī)程文件;(3)來源于其它資料a. 時間分配b. 零件的所有尺寸及形狀c. 應達到精度d. 加工過程的順序e. 所用機床的類型及規(guī)格f. 資金來源g. 零件的數(shù)量h. 上一工序加工內(nèi)容i. 定位表面j. 材料種類及規(guī)格k. 刀具種類l. 加工方法的類型1-6