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設(shè)計(jì)說(shuō)明書
題 目：軸承支撐座零件的機(jī)械加工工藝規(guī)程及工藝裝備設(shè)計(jì)
院 別：
專 業(yè)：
姓 名：
學(xué) 號(hào)：
指導(dǎo)教師：
日 期：
原始資料
(1) 被加工零件的零件圖 1張
(2) 生產(chǎn)類型:大批生產(chǎn)
上交材料
(1) 被加工工件的零件圖 1張
(2) 工件的毛坯圖 1張
(3) 機(jī)械加工工藝過(guò)程卡片 1張
(4) 與所設(shè)計(jì)夾具對(duì)應(yīng)那道工序的工序卡片 1張
(5) 夾具裝配圖 1張
(6) 夾具體圖 1張
(7) 課程設(shè)計(jì)說(shuō)明書(5000～8000字) 1份
說(shuō)明書主要包括以下內(nèi)容（章節(jié)）
①目錄
②摘要（中外文對(duì)照的，各占一頁(yè)）
③零件工藝性分析
④機(jī)械加工工藝規(guī)程設(shè)計(jì)
⑤指定工序的專用機(jī)床夾具設(shè)計(jì)
⑥方案綜合評(píng)價(jià)與結(jié)論
⑦體會(huì)與展望
⑧參考文獻(xiàn)
課程設(shè)計(jì)說(shuō)明書一律用A4紙、縱向打印.
四、進(jìn)度安排(參考)
(1) 熟悉零件,畫零件圖 2天
(2) 選擇工藝方案,確定工藝路線,填寫工藝過(guò)程綜合卡片 5天
(3) 工藝裝備設(shè)計(jì)(畫夾具裝配圖及夾具體圖) 9天
(4) 編寫說(shuō)明書 3天
(5) 準(zhǔn)備及答辯
五、指導(dǎo)教師評(píng)語(yǔ)
成 績(jī)：
指導(dǎo)教師
日 期
成績(jī)?cè)u(píng)定
采用五級(jí)分制，即優(yōu)秀、良好、中等、及格和不及格。
優(yōu)秀：設(shè)計(jì)方案合理并新穎，設(shè)計(jì)說(shuō)明書及設(shè)計(jì)圖紙規(guī)范、內(nèi)容豐富。在設(shè)計(jì)過(guò)程中勤奮好學(xué)、有創(chuàng)新思想；
良好：設(shè)計(jì)方案合理，設(shè)計(jì)說(shuō)明書及設(shè)計(jì)圖紙比較規(guī)范、內(nèi)容比較豐富。在設(shè)計(jì)過(guò)程中勤奮好學(xué)、有創(chuàng)新思想；
中等：設(shè)計(jì)方案一般，設(shè)計(jì)說(shuō)明書及設(shè)計(jì)圖紙欠規(guī)范、內(nèi)容一般。在設(shè)計(jì)過(guò)程中比較勤奮、創(chuàng)新思想不明顯；
及格：設(shè)計(jì)方案不完善，存在一些小錯(cuò)誤，說(shuō)明書及設(shè)計(jì)圖紙欠規(guī)范、內(nèi)容一般。在設(shè)計(jì)過(guò)程中勤奮精神不夠：
不及格：設(shè)計(jì)方案有嚴(yán)重錯(cuò)誤，設(shè)計(jì)說(shuō)明書及設(shè)計(jì)圖紙不規(guī)范、內(nèi)容淺薄。在設(shè)計(jì)過(guò)程中勤奮好學(xué)精神不夠。
目錄
1摘要 1
1、零件的分析 3
1.1繪制和分析零件圖 3
2、工藝規(guī)程設(shè)計(jì) 5
2.1.毛坯的選擇 5
2.2. 確定主要加工余量 6
2.3．基面的選擇 7
2.3.1.粗基面的選擇 7
2.3.2.精基面的選擇 7
2.4.制定工藝路線 7
2.5填寫工藝過(guò)程卡 7
3、夾具的設(shè)計(jì) 10
3.1．確定加工部位，分析技術(shù)要求 10
3.2確定定位方案 10
3.3．確定夾緊方案，選擇夾緊元件和夾緊結(jié)構(gòu) 11
4、夾具結(jié)構(gòu)設(shè)計(jì) 13
4.1夾具體及其他零件設(shè)計(jì)，確定夾具詳細(xì)結(jié)構(gòu) 13
4.2定位誤差分析 13
5、夾具體繪制 14
6體會(huì)與展望 14
7、參考文獻(xiàn) 14
摘要
機(jī)械制造工藝學(xué)課程設(shè)計(jì)是我們學(xué)完了大學(xué)的全部基礎(chǔ)課、技術(shù)基礎(chǔ)課以及大部分專業(yè)課之后進(jìn)行的.這是我們?cè)谶M(jìn)行畢業(yè)設(shè)計(jì)之前對(duì)所學(xué)各課程的一次深入的綜合性的總復(fù)習(xí),也是一次理論聯(lián)系實(shí)際的訓(xùn)練,因此,它在我們四年的大學(xué)生活中占有重要的地位。
設(shè)計(jì)意義：本課程設(shè)計(jì)是重要的實(shí)踐教學(xué)環(huán)節(jié)之一。是在完成生產(chǎn)實(shí)習(xí)，學(xué)完機(jī)械制造技術(shù)基礎(chǔ)和其它專業(yè)課程之后進(jìn)行的。通過(guò)該課程設(shè)計(jì)，將所學(xué)理論與生產(chǎn)實(shí)踐相結(jié)合， 鍛煉了自己分析問(wèn)題、解決問(wèn)題的能力，在這個(gè)過(guò)程中我獨(dú)立地分析和解決了零件機(jī)械制造的工藝問(wèn)題，設(shè)計(jì)了機(jī)床專用夾具這一典型的工藝裝備，提高了結(jié)構(gòu)設(shè)計(jì)能力，為今后的畢業(yè)設(shè)計(jì)及對(duì)自己未來(lái)將從事的工作進(jìn)行了一次適應(yīng)性訓(xùn)練，從而打下了良好的基礎(chǔ)。
Machinery Manufacturing Technology curriculum design is finished we learn all the basic course of the University, technology and the most basic course after the specialized, which is our graduation project before conducting the various courses of study by an in-depth comprehensive review of the total, is also a Theory with practical training, therefore, in our four years of university life occupy an important position.
This is the cover design, parts map, rough map, one of the assembly, machining process with the card and the
Design significance: the design of this course is an important aspect of the practice of teaching. Completed internship in the production, completion of machinery manufacturing and technological foundation and other professional courses conducted. The adoption of the curriculum design, will learn theory and practice of combining production, tempered his analysis, problem-solving abilities, in the process I am an independent analysis and solution of the manufacture of mechanical parts of the problem, design a machine for this fixture A typical technology equipment, improved structural design capability for future graduates to design their own future and will be engaged in the work of an adaptation training, thus laying a good foundation.
Key words: ram; curriculum design, technology point of order, technology and equipment;
1、零件的分析
1.1繪制和分析零件圖
零件圖為了方便加工各孔和面，應(yīng)如下圖豎直放置。圖中各技術(shù)要求明確。
1.2．零件的工藝分析
此軸承支撐座共有三組加工表面，他們之間有一定的位置要求。現(xiàn)分述如下：
1. 孔為中心的加工表面。
這一組加工表面包括：一個(gè)的孔，尺寸為的與的孔相垂直的平面，還有在平面上與孔平行的5個(gè)和孔。其中，主要加工表面為孔及孔的左端面。
2. 孔為中心的加工表面。
這一組加工表面包括：一個(gè)的孔，與孔相垂直的左平面，還有在平面上與孔平行的4個(gè)M6螺孔。其中孔為主要加工表面。
3. 孔為中心的加工表面。
兩個(gè)的孔，尺寸為80的與兩個(gè)孔相垂直的平面，寬50深50的槽。兩個(gè)與孔垂直的M4螺孔。主要加工表面為的兩個(gè)孔及兩孔的四個(gè)端面。
這三組加工表面之間有著一定的位置要求，主要是：
⑴二孔的外端面對(duì)孔的外端面平行度公差為0.01。
⑵孔對(duì)孔的外端面垂直度公差為0.01。
⑶孔對(duì)孔的同軸度公差為0.01。
由以上分析可知，對(duì)于這三組加工表面而言，可以先加工其中一組表面，然后借助于專用夾具加工另一組表面，并且保證他們之間的位置精度要求。
2、工藝規(guī)程設(shè)計(jì)
2.1.毛坯的選擇
根據(jù)《工藝手冊(cè)》P410中表2.1-6可知，選擇毛坯時(shí)，應(yīng)考慮下列因素：
1）零件材料的工藝特性（如可鑄性及可塑性）以及零件對(duì)材料組織和性能的要求。
2）零件的結(jié)構(gòu)形狀和外形尺寸。
3）生產(chǎn)綱領(lǐng)的大小，它在很大程度上決定了采用某種毛坯制造方法的經(jīng)濟(jì)性。
4）現(xiàn)場(chǎng)的生產(chǎn)條件。這里主要考慮現(xiàn)場(chǎng)的毛坯制造的實(shí)際工藝水平、設(shè)備狀況以及外協(xié)的可能性和經(jīng)濟(jì)性，但同時(shí)也要考慮因生產(chǎn)發(fā)展而采用較先進(jìn)的毛坯制造方法。
零件的材料為為球墨鑄鐵QT500-7，查《工藝手冊(cè)》P65表1.2-5可知，該材料的抗拉強(qiáng)度為500Mpa，屈服強(qiáng)度為320，延伸率為7%，HB170~230。
考慮到零件結(jié)構(gòu)簡(jiǎn)單，加工工藝性好，在工作過(guò)程中受力不大，沒有經(jīng)常承受交變載荷，所以綜合考慮，選擇鑄件，由于零件達(dá)到大批生產(chǎn)的水平，而且零件的輪廓尺寸不大，重量在12Kg以下，故可采用機(jī)械造型中的砂型模鑄造，鑄造后進(jìn)行人工時(shí)效處理。這從提高生產(chǎn)率，保證加工精度上考慮，也是可行的。
2.2. 確定主要加工余量
查《工藝手冊(cè)》表2.3-6P471可知標(biāo)準(zhǔn)為GB/T11351-89中規(guī)定的鑄件機(jī)械加工余量的數(shù)值、確定方法及檢驗(yàn)與評(píng)定規(guī)則，由于是砂型鑄造，故CT為10級(jí)，MA為G級(jí)(CT為尺寸公差等級(jí)，MA為加工余量等級(jí))。其中頂面比側(cè)面、底面降一級(jí)。
查《工藝手冊(cè)》表2.3-5P468可知加工余量，下面表3.3-1為鑄件各表面加工余量，表3 .3-2為鑄件主要尺寸公差。
表2.2-1 鑄件各表面加工余量
加工表面
基本尺寸
MA
MA數(shù)值
說(shuō)明
42端面
22
G
2.5
單側(cè)加工
32端面
15
G
2.5
單側(cè)加工
20端面
15
G
2.5
單側(cè)加工
42孔
42
H
3.0
雙側(cè)加工，孔降一級(jí)
32孔
32
H
3.0
雙側(cè)加工，孔降一級(jí)
20孔
20
H
3.0
雙側(cè)加工，孔降一級(jí)
查《工藝手冊(cè)》表2.3-9P472可知鑄件尺寸公差
表2.2-2 鑄件主要尺寸公差
加工表面
總余量
毛坯尺寸
公差
42端面
6
28
2.4
32端面
6
21
2.2
20端面
6
21
2.2
42孔
6
36
2.8
32孔
6
26
2.6
20孔
6
14
2.4
2.3．基面的選擇
基面選擇是工藝規(guī)程設(shè)計(jì)中的重要設(shè)計(jì)之一，基面的選擇正確與合理，可以使加工質(zhì)量得到保證，生產(chǎn)率得到提高。否則，加工工藝過(guò)程會(huì)問(wèn)題百出，更有甚者，還會(huì)造成零件大批報(bào)廢，使生產(chǎn)無(wú)法進(jìn)行。
定位基準(zhǔn)是在加工中使工件在夾具上占有正確位置所采用的基準(zhǔn)。定位基準(zhǔn)的選擇不僅影響著加工精度，如基準(zhǔn)不重合時(shí)產(chǎn)生的定位誤差會(huì)影響著加工精度，作為一道工序的定位基準(zhǔn)必須在前道工序加工出來(lái)，因此要合理的選擇定位基準(zhǔn)，多設(shè)想幾種定位方案，比較它們的優(yōu)缺點(diǎn)，周密地考慮定位方案與加工順序的關(guān)系。（《機(jī)械制造技術(shù)基礎(chǔ)》P229）
2.3.1.粗基面的選擇
按照有關(guān)零件的粗基準(zhǔn)的選擇原則：如果必須首先保證工件某重要表面的余量均勻，就應(yīng)該選著該表面作為粗基面。由于A面是整個(gè)工件的位置精度基準(zhǔn)，所以以重要表面A為粗基準(zhǔn)加工。這樣可以保證A面的加工余量均勻，加工表面質(zhì)量高。
2.3.2.精基面的選擇
精基準(zhǔn)的選擇主要考慮基準(zhǔn)重合的問(wèn)題。選擇加工表面的設(shè)計(jì)基準(zhǔn)為定位基準(zhǔn)。采用基準(zhǔn)重合原則可以避免由定位基準(zhǔn)與設(shè)計(jì)基準(zhǔn)不重合引起的基準(zhǔn)不重合誤差，零件的尺寸精度和位置精度能可靠的得以保證。根據(jù)該支撐座的技術(shù)要求和裝配要求，選擇42孔的左端面A作為精基準(zhǔn)。零件上的很多表面都可以采用它們作為基準(zhǔn)來(lái)進(jìn)行加工。即遵循了“基準(zhǔn)統(tǒng)一”的原則。這樣就實(shí)現(xiàn)了設(shè)計(jì)基準(zhǔn)和工藝基準(zhǔn)的重合。同時(shí)也保證了被加工表面的平行度要求。
表3.4-1 主要工藝及其定位基準(zhǔn)
工序內(nèi)容
定位基準(zhǔn)
42左端面
32右端面，一個(gè)未加工表面
42孔
32孔，未加工內(nèi)表面
32孔
42孔及端面A
52端面
42左端面（A面）
32孔右端面
42左端面（A面）
兩個(gè)20孔外端面
42左端面（A面）
寬50深50槽
42左端面（A面）
2-20孔
42孔及端面A
5-15孔
42孔及端面A
5-9孔
42孔及52端面
4-M6螺紋孔
42孔及端面A
2-M4螺紋孔
42孔及端面A
2.4.制定工藝路線
制定工藝路線的出發(fā)點(diǎn)，應(yīng)當(dāng)是使零件的幾何形狀、尺寸精度及位置精度等技術(shù)要求能得到合理的保證。在生產(chǎn)綱領(lǐng)已確定為大批量生產(chǎn)的條件下，可以采用萬(wàn)能機(jī)床配以專用工夾具，并盡量使工序集中來(lái)提高生產(chǎn)率。除此以外，還應(yīng)考慮經(jīng)濟(jì)效果，以便降低生產(chǎn)成本。
工藝路線
工序1：鑄造
工序2：退火，去應(yīng)力
工序3：粗銑、半精銑42孔的兩端面
工序4：粗銑、半精銑32孔的上端面
工序5：粗銑、半精銑2-20孔的外端面
工序6：粗鏜、半精鏜、精鏜42孔
工序7：粗鏜、半精鏜、精鏜32孔
工序8：粗鏜、半精鏜、精鏜2-20的孔
工序9：粗銑、半精銑、精銑寬50深50的槽
工序10：鉆2-4、4-6、5-9的孔
工序11：攻螺紋2-M4、4-M6
工序12：锪5-15的孔
工序13：終檢
2.5填寫工藝過(guò)程卡
《機(jī)械加工工藝過(guò)程卡》：另附一頁(yè)
3、夾具的設(shè)計(jì)
3.1．確定加工部位，分析技術(shù)要求
加工寬50的槽，加工表面的粗糙度達(dá)到0.8。故需要進(jìn)行半精加工和精加工。
3.2確定定位方案
對(duì)于所要加工的槽，根據(jù)基準(zhǔn)定位原則，用固定式定位銷套在20孔，實(shí)現(xiàn)兩個(gè)自由度的定位，再以一個(gè)固定式削邊銷在42孔限制一個(gè)轉(zhuǎn)動(dòng)自由度，再以支撐板支撐A面，實(shí)現(xiàn)其余三個(gè)自由度的限制，最終完全定位。查《金屬切削機(jī)床夾具設(shè)計(jì)手冊(cè)》表2-155知，選擇A型的固定式定位銷和B型固定式削邊銷。如下圖所示尺寸：
3.3．確定夾緊方案，選擇夾緊元件和夾緊結(jié)構(gòu)
此專用夾具選用鉤形壓板與楔槽式快速夾緊裝置配合進(jìn)行夾緊，鉤形壓板可由旋轉(zhuǎn)曲線實(shí)現(xiàn)90度的轉(zhuǎn)動(dòng)，其動(dòng)力源來(lái)自于頂桿。根據(jù)《機(jī)床設(shè)計(jì)手冊(cè)》P388，圖4.6.2-1為鉤形壓板基座的選擇，表4.6.2-1為鉤形壓板基座的尺寸。
圖3-1 鉤形壓板基座
表3-1鉤形壓板基座
基本尺寸
極限偏差H9
基本尺寸
極限偏差H7
40
+0.062~
0
10
0.015～
0
80
105
106
80
14
22
34
18
12
56
圖3-2為鉤形壓板的選擇鉤形板的選擇，表3-2為鉤形壓板的尺寸。
圖3-2 鉤形壓板
表3-2 鉤形壓板尺寸
d
A
B
D
H
h
r
配用螺釘
基本尺寸
極限偏差f9
基本尺寸
極限偏差H7
6
65
40
40
-0.025～
-0.087
100
30
20
0～
-0.130
52
60
1.5
M20
4、夾具結(jié)構(gòu)設(shè)計(jì)
4.1夾具體及其它零件設(shè)計(jì)，確定夾具詳細(xì)結(jié)構(gòu)
夾具的詳細(xì)結(jié)構(gòu)如下圖所示：
4.2定位誤差分析
零件被加工的位置的設(shè)計(jì)基準(zhǔn)是兩被加工平面的中心線，加工寬50的槽時(shí)的定位基準(zhǔn)為A面，所以設(shè)計(jì)基準(zhǔn)和定位基準(zhǔn)不重合重合，因?yàn)榱慵D上沒有標(biāo)注尺寸公差，固取14級(jí)標(biāo)準(zhǔn)公差為0.62.所以，無(wú)基準(zhǔn)位移誤差。故的定位誤差是。
5、夾具體繪制
總裝圖繪制，零件圖繪制。（圖另附）
6、體會(huì)與展望
通過(guò)這兩個(gè)星期的學(xué)習(xí)，我在老師的指導(dǎo)下，取得了可喜的成績(jī)，課程設(shè)計(jì)作為《機(jī)械制造基礎(chǔ)》課程的重要環(huán)節(jié)，使理論與實(shí)踐更加接近，加深了理論知識(shí)的理解，強(qiáng)化了生產(chǎn)實(shí)習(xí)中的感性認(rèn)識(shí)。
本次課程設(shè)計(jì)主要經(jīng)歷了兩個(gè)階段，第一階段是機(jī)械加工工藝規(guī)程設(shè)計(jì)，第二階段是專用夾具設(shè)計(jì)。第一階段我運(yùn)用了基準(zhǔn)選擇、機(jī)床選用等方面的知識(shí)；夾具設(shè)計(jì)的階段運(yùn)用了工件定位、夾緊機(jī)構(gòu)及零件結(jié)構(gòu)設(shè)計(jì)等方面的知識(shí)。
經(jīng)過(guò)這三個(gè)星期的設(shè)計(jì)，我基本掌握了零件的加工過(guò)程分析及工藝文件的編制、專用夾具設(shè)計(jì)的方法和步驟，學(xué)會(huì)了查找相關(guān)手冊(cè)、說(shuō)明書等，以及選擇使用工藝裝備等等。
總之，這次設(shè)計(jì)使我在基本理論的綜合運(yùn)用及正確解決實(shí)際問(wèn)題等方面得到了一次較好的訓(xùn)練。提高了我們的思考、解決問(wèn)題創(chuàng)新設(shè)計(jì)的能力，為以后的設(shè)計(jì)工作打下了較好的基礎(chǔ)。
由于個(gè)人能力有限，所學(xué)知識(shí)還不能完全掌握，設(shè)計(jì)中還有許多錯(cuò)誤和不足，請(qǐng)各位老師和同學(xué)們多多斧正。
通過(guò)這兩個(gè)星期的學(xué)習(xí)，發(fā)現(xiàn)了自己的很多不足，自己知識(shí)的很多漏洞，看到了自己的實(shí)踐經(jīng)驗(yàn)還是比較缺乏，理論聯(lián)系實(shí)際的能力還急需提高。
參考文獻(xiàn)
[1]李洪.機(jī)械加工工藝手冊(cè)[M].北京出版社,1994.
[2]趙如福.金屬機(jī)械加工工藝人員手冊(cè)-3版[M].上海：上?？茖W(xué)技術(shù)出版社,1990.
[3]徐灝.機(jī)械設(shè)計(jì)手冊(cè)[M].北京：機(jī)械工業(yè)出版社，1991.
[4]上海柴油機(jī)廠工藝設(shè)備研究所編.金屬切削機(jī)床夾具設(shè)計(jì)手冊(cè).機(jī)械工業(yè)出版社出版，1987.
- 15 -
機(jī)械加工工序卡片
產(chǎn)品型號(hào)
零件圖號(hào)
A2
產(chǎn)品名稱
零件名稱
共
頁(yè)
第
頁(yè)
車間
工序號(hào)
工序名稱
材 料 牌 號(hào)
金工
3
HT200
毛 坯 種 類
毛坯外形尺寸
每毛坯可制件數(shù)
每 臺(tái) 件 數(shù)
鑄件
1
1
設(shè)備名稱
設(shè)備型號(hào)
設(shè)備編號(hào)
同時(shí)加工件數(shù)
立式升降銑床
X52
1
夾具編號(hào)
夾具名稱
切削液
工位器具編號(hào)
工位器具名稱
工序工時(shí) (分)
準(zhǔn)終
單件
工步號(hào)
工 步 內(nèi) 容
工 藝 裝 備
主軸轉(zhuǎn)速
切削速度
進(jìn)給量
切削深度
進(jìn)給次數(shù)
工步工時(shí)
r/min
mm/min
mm/r
mm
機(jī)動(dòng)
輔助
1
粗銑A端面(A)
專用銑夾具，硬質(zhì)合金可轉(zhuǎn)位端銑刀，
300
1.37
0.2
0.2
2
0.14
2
半精銑A端面(A)
專用銑夾具，硬質(zhì)合金可轉(zhuǎn)位端銑刀，
475
2.49
0.05
0.05
2
0.16
3
粗鏜42孔
專用鏜夾具，硬質(zhì)合金鏜刀，
800
1.67
0.25
0.25
2
0.18
4
半精鏜42內(nèi)孔至41.8
專用銑夾具，硬質(zhì)合金可轉(zhuǎn)位端銑刀，
900
1.75
0.2
0.2
2
0.18
5
精鏜42內(nèi)孔
專用鏜夾具，硬質(zhì)合金鏜刀，
1000
2.2
0.15
0.15
2
0.18
設(shè) 計(jì)（日 期）
校 對(duì)（日期）
審 核（日期）
標(biāo)準(zhǔn)化（日期）
會(huì) 簽（日期）
標(biāo)記
處數(shù)
更改文件號(hào)
簽 字
日 期
標(biāo)記
處數(shù)
更改文件號(hào)
簽 字
日 期
機(jī)械加工工藝過(guò)程卡
產(chǎn)品型號(hào)
零（部）圖號(hào)
共 1 頁(yè)
產(chǎn)品名稱
零（部）名稱
軸承支撐架
第 1 頁(yè)
材料牌號(hào)
HT200
毛坯種類
鑄件
毛坯外形尺寸
每毛坯件數(shù)
4000
每臺(tái)件數(shù)
備 注
工序號(hào)
工序名稱
工 序 內(nèi) 容
車
間
工
段
設(shè) 備
工 藝 裝 備
工 時(shí)
1
鑄造
鑄造
2
退火
退火，去應(yīng)力
3
銑
粗銑、半精銑42孔的外端面
立式銑床X52K
專用
4
銑
粗銑、半精銑42孔的外端面
立式銑床X52K
專用
5
銑
粗銑、半精銑32孔的外端面
立式銑床X52K
專用
6
銑
粗銑、半精銑2-20孔的外端面
立式銑床X52K
專用
7
鏜
粗鏜、半精鏜、精鏜42孔
臥式鏜床T68
專用
8
鏜
粗鏜、半精鏜、精鏜32孔
臥式鏜床T68
專用
9
鏜
粗鏜、半精鏜、精鏜2-20的孔
臥式鏜床T68
專用
10
銑
粗銑、半精銑、精銑寬50深50的槽
立式銑床X52K
專用
11
鉆孔
鉆2-4、4-6、5-9的孔
立式鉆床Z535
專用
12
鉆
攻螺紋2-M4、4-M6
立式鉆床Z535
專用
13
鉆
锪5-15的孔
立式鉆床Z535
專用
14
終撿
終檢
15
16
設(shè)計(jì)（日期）
審核（日期）
標(biāo)準(zhǔn)化（日期）
會(huì)簽（日期）
標(biāo)記
處數(shù)
更改文件號(hào)
簽字
日期
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.