单柱校正压装液压机设计.doc

1目录摘要··········································································Abstract·····································································第1章绪论·································································11.1课题背景·····························································11.2发展趋势·····························································1第2章方案论证···························································32.1传动方案的论证·····················································32.2控制元件的分析·····················································4第3章液压机的设计及参数选择·········································5第4章工况分析···························································64.1动力（负载）分析及负载循环图··································64.1.1摩擦负载······················································64.1.2惯性负载······················································64.1.3工作负载······················································74.1.4负载循环图···················································84.2运动分析及运动循环图·············································84.2.1位移循环图Lt·············································84.2.2速度循环图···················································9第章确定液压系统主要参数··········································105.1确定液压缸几何尺寸··············································105.2计算液压缸所需流量··············································135.3计算系统所需的压力··············································135.4绘制冲压机主缸工况图···········································155.5液压缸主要零件的结构材料及技术要求·························175.5.1液压缸的基本参数··········································175.5.2液压缸的类型和安装方式··································185.5.3液压缸的主要零件及技术要求·····························185.6液压缸结构参数的计算···········································195.6.1计算液压缸的厚度··········································195.6.2液压缸油口的计算··········································215.6.3缸底厚度的计算·············································215.7液压缸的校合······················································225.7.1液压缸中背压力的校合·····································2225.7.2活塞杆的校合···············································23第6章拟订液压原理图··················································24第7章液压元件和液压油的选择········································267.1液压泵的选择······················································267.1.1确定泵的最大工作压力·····································267.1.2确定液压泵的流量QP和排量qp···························277.1.3选择液压泵的规格··········································287.1.4确定驱动液压缸的功率·····································287.2电动机的选择······················································297.3控制阀的选择······················································297.4管道（导管）的选择·················································317.4.1管道内径的确定·············································317.4.2管道壁厚b的计算···········································327.5确定油箱的容量···················································337.5.1液压油的选择···············································347.5.2过滤器的选择···············································347.6联轴器的设计·····················································34第8章液压系统的性能验算·············································368.1管路系统压力损失·················································368.1.1沿程压力损失的计算·······································378.1.2管路内的局部压力损失·····································388.1.3阀类元件的局部压力损失··································388.2液压冲击的计算···················································398.3液压系统热分析及其计算·········································418.3.1液压泵功率损失产生的热流量（热量）·····················418.3.2液压系统的散热计算·······································42第9章限程装置的设计··················································44第10章机架的设计······················································4510.1机架材料的选择··················································4610.2肋的作用··························································46第11章液压系统的安装与调试·········································4711.1液压系统的安装··················································4711.1.1安装前的准备工作·········································4711.1.2管子加工···················································4711.2液压系统的调试··················································4811.2.1调试前的检查··············································4811.2.2启动液压泵·················································48311.2.3系统排气···················································4911.2.4系统耐压实验··············································4912.2.5负载试车···················································49结论··········································································50致谢··········································································51参考文献·····································································52第1章绪论1.1课题背景液压传动开始应用于十八世纪末，但在工业上被广泛应用的时间比较短。有大幅度的发展也就在近50年。因此，与其它传动方式比还是一项年轻的技术。当今液压技术广泛应用于工程机械、起重运输、冶金工业、农用机械，轻工业和机床工业。随着液压技术的不断发展，液压技术也广泛应用在高科技高精度的行业，如机床行业。它能代替人们一部分频繁而笨重的劳动，能在条件恶劣的环境中工作。特别在数控机床这类要求精度较高的领域有着不可代替的作用，出现了液压传动的自动化机床，组合机床和自动生产线等。在国防工业中，如飞机，坦克、火炮等都普遍采用了液压传动装置和液压控制装置。1.2发展趋势当今研究的主要内容是高压粘性流体在密闭容器中流动规律和系统中承受高压的粘性流体的运动规律。液压系统有着独特的优势。其有着体积小，重量轻，可实现无级变速，运动平稳，结构简单，操作方便，工作寿命长，液压元件易于通用化、标准化、系列化的特点。基于以上优点，处于新兴技术的液压系统4在近些年得到了大幅度的发展，还有着广泛的发展空间。它正向高压化、高速花、集成化、大流量、大功率、高效率、长寿命、低噪音的方向发展。液压传动可以用很小的功率控制速度、方向。使用适当的节流技术可使执行元件的精度达到最高。其布局安装有很大的灵活性，同体积重量比却比其他机械小的多。因此能构成其他方法难以组成的复杂系统。液压传动能实现低速大吨位运动。采用适当的节流技术可使运动机构的速度十分平稳。经过五周的毕业实习，让我们学到了很多以前没有学到的知识，也让以前学到的书本上的知识和现实生产相结合，让我门的专业知识有了进一步提高。特别是对液压系统有了更深的了解。在此基础上我们进一步分析Y41系列单柱校正压装液压机。它是一种多功能的中小型液压机床，适用于轴类零件、型材的校正和轴套类零件的压装。通过观察测绘，进行了毕业设计。在指导老师的指导下，我对设计多次改进，通过查阅相关资料手册，并多次向指导老师请教，对以前不懂的知识有了更好的认识。通过这次设计，我把大学所学的知识穿了线，知道了各知识之间的联系，对以后的工作有了很大的帮助。5第2章方案论证2.1传动方案的论证目前冲压机床的传动方式主要有：液压式、气压式、电动式和机械传动方式等。传动装置的选择正确与否，直接决定着冲压机的好坏。1.气压传动的结构简单，成本低，易于实现无级变速；气体粘性小阻力损失小，流速快，防火防爆。但是空气易于压缩，负载对传动特性的影响大，不易在低温环境下工作。空气不易被密封，传动功率小。2.电气传动的优点是传动方便，信号传递迅速，标准化程度高，易于实现自动化，缺点是平稳性差，易受到外界负载影响。惯性大，换向慢，电气设备和元件要耗用大量的有色金属。成本高，受温度、湿度、震动、腐蚀等环境的影响大。3.机械传动准确可靠，操作简单，负载对传动特性几乎没有影响。传动效率高，制造容易和维护简单。但是，机械传动一般不能进行无级调速，远距离操作困难，结构也比较复杂等。4.液压传动与以上几种传动方式比较有以下优点：获得力和力矩很大，体积小，重量轻，能在大范围内实现无级调速，运动平稳，设计简单，操作方便，工作寿命长，易于通用化、标准化、系列化。它有很广阔的发展空间。从各方面考虑，液压传动系列基本符合设计要求，能达到预期的标准。所以，此次设计将采用液压传动。62.2控制元件的分析液压传动中主要有以下几种控制元件实现冲头的下压、保压和返回的过程。1.手动换向阀用人工操作控制阀芯的运动。手动换向阀又分为手动和脚动两种。优点是操作简单、灵活、容易控制。2.电磁换向阀通过电磁铁产生的电磁力来使阀芯运动，达到油路的转换。但由于受电磁铁吸引力的限制，电磁换向阀流量不能过大而且需要在回路中增加减速装置。3.插装阀是一种新型的开关式阀体，结构以锥阀为基础单位，配以不同的先导阀可实现对液流的方向、压力和流量大小的控制。其结构简单，动作反应快，适合高压大流量的场合。从设计课题上考虑，手动控制阀比较符合设计要求，完全可以满足性能要求，而且经济。所以选用手动换向阀。7第3章液压机的设计及参数选择当决定采用液压传动时，其设计步骤大体可分以下几步：1.明确设计依据进行工况分析。2.确定液压系统的主要参数。3.拟订液压系统原理图。4.液压元件及液压油的选择。5.液压系统性能验算。6.绘制正式工作图和编制技术文件。设计一台液压机，其工作循环为：快速下行，减速下压，快速退回。由设计题目及已知参数可确定：冲压力FW：100吨=100×1000×9.8=0.98×106N生产率：4次/分=1次/15秒工作行程：500mm=0.5m最大冲压厚度：20mm=0.02m滑块的重量G：1.0×104N根据工艺要求，快速下降所用的时间为9s，运行的距离为0.48m。工进所用的时间为1s，运行的距离为0.02m。快退返回的时间为5s，其运行的距离为0.50m。得到各个工艺路线的速度参数如下：快速下行：行程：480mm速度：53mm/s减速下压：行程：20mm速度：20mm/s快退：行程：500mm速度：100mm/s单次循环的总时间是：9+1+5=15s液压缸采用Y型密封圈。其机械效率一般为0.9-0.95之间，本液压缸的效率取：m=0.95。