ZH1105柴油机气缸体三面粗镗组合机床设计说明书.doc
0目录1前言····································································································12组合机床总体设计··············································································32.1组合机床工艺方案的制定···································································32.1.1工艺基准面的分析··········································································32.1.2加工工艺的分析·············································································32.1.3确定机床完成工艺时的一些限制······················································32.2组合机床配置型式的选择···································································32.2.1组合机床配置型式··········································································32.2.2选择机床配置型式和结构方案的一些问题·········································32.3确定切削用量及选择刀具····································································42.3.1选择切削用量·················································································42.3.2计算切削力、切削扭矩及切削功率···················································62.3.3选择刀具结构···············································································102.4组合机床总体设计三图一卡························································102.4.1被加工零件工序图········································································102.4.2加工示意图·················································································112.4.3机床尺寸联系图···········································································132.4.4机床生产率计算卡········································································163夹具设计···························································································183.1夹具设计的基本要求和步骤·······························································183.1.1夹具设计的基本要求·····································································183.1.2夹具设计的步骤···········································································183.2定位方案的确定···············································································193.2.1零件的工艺性分析········································································193.2.2定位方案的论证·············································································193.2.3误差分析·····················································································203.2.4导向装置·····················································································223.3夹紧方案的确定···············································································223.3.1夹紧装置的确定···········································································223.3.2夹紧力的确定···············································································243.3.3油缸的选择·················································································253.4夹具体的设计··················································································264结论··································································································27参考文献······························································································28致谢····································································································29附录····································································································30ZH1105C柴油机气缸体三面粗镗组合机床设计(夹具设计)1ZH1105柴油机气缸体三面粗镗组合机床总体及夹具设计摘要:柴油机气缸体是大批量生产的零件。为了提高生产效率,满足被加工零件的精度要求,本课题设计了一台用于ZH1105柴油机气缸体三面粗镗孔的组合机床。本文介绍了该组合机床总体设计和夹具设计的思路,全文共分两个部分。首先是总体设计,采用单工位三面粗镗孔组合机床,考虑的因素有刀具、切削用量、切削力、切削扭矩及切削功率等,通过计算选择主轴直径、外伸尺寸、接杆型号、滑台、动力箱等通用部件,再确定动力部件的工作循环及工作行程,完成机床总体设计。其次是夹具设计,通过对被加工零件的全面分析,采用三面定位和固定镗模板可换导套导向;夹紧装置采用液压夹紧机构,直接夹紧与工件上;夹具体为框架式结构,有良好的刚性,使夹具能长期保持可靠的精度和稳定性。该组合机床不仅能保证加工精度,还能提高加工效率。整个机床布局合理,夹紧可靠,精度较高,使用操作方便,提高了工作效率,达到了设计要求。关键词:气缸体;组合机床;粗镗;夹具2Thedesignoftheoverallandjigofthemodularmachine-toolfordrillingandboringinthebodyofZH1105dieselAbstract:Thecylinderbodyofdieselismadeforlargemassproduction.Inordertoenhancetheproductionefficiencyandmeettheprecisionrequestedofthecomponentsprocessed,thetopicisproducedfordesigningacombinedmachine-tool,whichisusedtoroughlyboretheholesoftheZH1105dieselenginecylinder.Thedesignwasintroducedoftheoverallandjigofthecombinedmachine-toolandthetopicconsistsoftwoparts.Thefirstpartisoveralldesign,adoptingthecombinedmachine-toolwithsinglelocationthreefacesdrillingandroughlyboretheholes,consideringsuchfactorsastool,cuttingparameter,cuttingforce,cuttingtorqueandcuttingpower,andsoon.Thuscommonpartssuchasslidingtable,thepowerboxandsoon,werechousedbycalculatingspindlediameter,andtheextendsizes,thelink-polemodel.Thentheoperatingcycleandthedistanceweredetermined.Thustheoveralldesignwascompleted.Finally,thetechnologicaldrawingwasfiguredoutofthepartwhichneedtobemanufactured,thegeneraldrawingofmodularmachinetool,anddrawingofcutterdisplayandtheefficiencycardofmanufacture.Thesecondpartisthejigdesign,havinganalyzedtheworkpiece,thelocationplanadoptedthree-facelocation;theguidingequipmentusedthefixedboreplatewithreplaceableborebush;theclampusesthehydraulicpressuredevice,itdirectlypressesontheworkpiece,thejig-bodyutilizetheframestructure,possessfinerigidity,causesthejigtomaintaingoodlong-termprecision.Thiscombinedmachine-toolnotonlyhasguaranteedthedrillholeprecisionefficiency.Thelayingoutofthemachine-toolisreasonable,thelocationofworkpieceisreliably,theaccuracyishigh,theoperationiseasy,enhancedtheworkingefficiency,andmeetwiththedesignrequestwell.Keywords:Thecylinderbody;Modularmachinetool;Roughboretheholes;JigZH1105C柴油机气缸体三面粗镗组合机床设计(夹具设计)31前言组合机床是根据加工需要,以大量通用部件为基础,配以少量专用部件组成的一种高效专用机床。组合机床主要用于平面加工和孔加工。平面加工包括铣平面、车端面、刮平面;孔加工包括钻、扩、铰、镗孔以及倒角、切槽、攻螺纹等。组合机床最适宜于加工各种大中型箱体类零件,如气缸体、气缸盖、变速箱体等零件。目前,组合机床在汽车、拖拉机、仪器仪表、军工及缝纫机、柴油机、纺织、航空等部门,应用越来越普遍。组合机床主要适用于棱体类零件和杂体的孔面加工,生产效率高,研制周期短,便于设计、制造和使用维修,配置灵活,且自动化程度高,劳动强度低。在将来,组合机床将向五个方面发展:高速化、高精度化、复合化、高科技含量化以及环保化。同时,在自动化方面,将会进一步提高1。组合机床的设计,目前基本上有两种情况:其一,是根据具体加工对象的具体情况进行专门设计,这是当前最普遍的做法。其二,随着组合机床在我国机械行业的广泛使用,广大工人总结自己生产和使用组合机床的经验,发现组合机床不仅在其组成部件方面有共性,可设计成通用部件,而且一些行业在完成一定工艺范围内组合机床是极其相似的,有可能设计为通用机床,这种机床称为“专能组合机床”2。这种组合机床就不需要每次按具体加工对象进行专门设计和生产,而是可以设计成通用品种,组织成批生产,然后按被加工的零件的具体需要,配以简单的夹具及刀具,即可组成加工一定对象的高效率设备。在组合机床设计过程中,为了降低组合机床的制造成本,应尽可能地使用通用件和标准件。目前,我国设计制造的组合机床,其通用部件和标准件约占部件总数的7080%,其它2030%是专用零部件1。考虑到近年来,各种通用件和标准件都出台了新的标准及标注方法,为了方便以后组合机床的维修,整个组合机床的通用件和标准件配置,都采用了新标准。本毕业设计课题是ZH1105柴油机气缸体三面钻镗孔组合机床的设计,来源于江动集团江淮动力股份有限公司。本组合机床有四人完成,本人将进行总体及夹具设计。组合机床的设计过程包括前期调研,总体设计,技术设计和工作设计。总体设计,包括工艺分析、定位基准的选择、滑台型式的选择、通过选择切削用量选择刀具;还需编制“三图一卡”,即加工工序图,加工示意图,机床联系尺寸图,生产率计算卡。技术设计就是根据总体设计已经确定的“三图一卡”,设计主轴箱等专用部件正式总图;工作设计即绘制各个专用部件的施工图样,编制各零部件明细表1。夹具设计是组合机床设计中的一个重要组成部分,是按照某一道工序的加工要求,把一些事先制造好的标准件和部件进行组装而成的夹具,夹具通常由使用单位根据要求自行设计和制造,适用于产品固定且批量较大的生产中。其设计过程主要包括:对机床总体设计方案的论证、定位夹紧方案的论证、定位误差分析、夹紧力的计算、夹紧缸的选用。本组合机床夹具属于专用夹具,其定位装置、夹