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外文翻译--基于三维设计的浮动式制动卡钳的车床夹具的研制.doc

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外文翻译--基于三维设计的浮动式制动卡钳的车床夹具的研制.doc

英文原文Developmentofthe3DDesignedLatheFixtureofaFloatBrakeCaliperPANJinkun1,ZUOWanli2,LUDongsheng21SchoolofMechanicalEngineering,NanjingInstituteofTechnology,Nanjing211167,P.R.China2CollegeofMechanicalPowerEngineering,NanjingUniversityofTechnology,Nanjing210009,P.R.ChinaAbstractAccordingtothetechniquerequestsofthebrakecaliperintheprocessofproduction,aspecialfixtureoffloatbrakecaliperhasbeendevelopedbasedon3Ddesigninthispaper.Thedevelopmentprocessandverifieddatafrom3Dmodelingandkinematicssimulationforthisspecialfixtureshowthatthis3Ddesignedprocesscanconvenientlyforecasttheassemblyinterferenceofthefixtureandaccuratelyaddthemassofleadbrickbeforetheprototypeismade.Inthiswaythefluttercausedbytheunbalancedlathefixturecanbeeliminatedandtheprecisionofrunouttoleranceincylinderholecomparedwithmachinetoolspindlecanbeimproved,thustheprocessingqualityofthecylinderholeinabrakecalipercanbegreatlyguaranteed.Keywords3Ddesignbrakecaliperslathefixture1IntroductionIntheproductionofthefloatdiscbrakecaliperofanautomobile,duetothecomplexityofitsstructure,aspecialfixtureisneededforinstallingandclampingthebrakecaliper.Accordingtothetechniquerequestsofthebrakecaliperintheprocessing,aspecialfixtureoffloatbrakecaliperisdevelopedbasedon3Ddesigninthispaperandits3Dmodelisassembledvirtually.Throughthemechanismsimulationfunctionof3Ddesignsoftware,thebalanceofalathefixtureisanalyzed1.Theresultsshowthatthedesignprocesscanexpedientlyforecastsomefactorswhichaffectthequalityoftechnicalequipmentsuchasassemblyinterference2andthemachiningstabilityofthelathefixturebeforetheprototypeismade.Thisdesignprocesscannotonlyavoidthedesignerrorsinthetraditionaldesign,butalsoimprovethedesignqualityofproducts.23DdesignofthespeciallathefixtureThemanufactureobjectofthespecialfixtureisthebrakecaliperofafloatdiscbrake,shownasFigure1itsmachiningsurfaceisthecylinderholeofthebrake.Thefigureshowswhenthecylinderholeisbeingprocessed,itsaxisandthemachinespindlerotationaxismustbeincoincidence.Duetoirregularshapestructureofthebrakecaliper,theflutterwhichiscausedbytheunbalancemassposedbythefixtureandtheworkpiecewouldaffectthemachiningaccuracyandroundnessofthecylinderholesizeintheactualprocessing,andsomeprecisionrequirementofgeometrictolerancesuchasparallelismbetweenthetwocylinderholes.Toavoidtheproblemsinthedesignprocessofthelathefixtureofthebrakecaliper,aspecialfixtureisdevelopedbasedon3Ddesigninthispaper.Accordingtotheshapestructuralcharacteristicsofthebrakecaliperandtheclampingrequirementsofthelathefixture,thecylinderholeshouldbecompletedafteraclampingofthelathefixtureinthewholeprocessing.Theflangeneedsthemountingholeofmachinetoolspindleandlocationholeofthefixtureonbothsidesofthecenterasamiddlewareconnectingthemachinetoolspindleandthefixture.Itisensuredthattheaxisoftheprocessingcylinderholeofthecaliperbodywhichislocatedandclampedonthefixtureandthemachinespindleaxisofrotationneedcoincidence3,asshowninFigure2.Themodelingprocessofotherpartsofthespecialfixtureisnotdepictedindetailinthispaper,pleaserefertoReference4.Thenthesepartsareassembledintotwocomponents,upanddown,asshowninFigure3andFigure4.Thewholefixtureisdividedintotwocomponentswhenitisbeingassembled.Thiscanavoidthepartsbeingmissedorinstalledwronglyintheassemblyprocess.Inthecomponentdown,asthebenchmarkofflange,thecounterbalanceisfixedwithbolts.Thecounterbalancewouldberegulatedinbalancewhenthefixtureisproduced.Inthecomponentup,asthebenchmarkofthefixture,thelocatingplateisfixedwithsevenbolts.Thenasthebenchmarkofthelocatingplate,theupperhalfpartoftwothreadedstudsarerotatedintothelocatingplate,andthepressureplateisclampedonthethreadedstudsbybolts.Inthefixture,thepressureplateisindirectcontactwiththeworkpiece,soitisundergreatstress.Therefore,thematerialof45Mn2isselected,whichneedstreatmentofquenchingandtempering.Matchingblockneednottobefixedintothefixtureduringtheinitialassemblyandthemassofmatchingblockisdeterminedbytheresultofmotionsimulation.Figure1BrakecalipersFigure2FlangeFigure3ComponentdownFigure4ComponentupAftertheassembliesofcomponentupandcomponentdownarecompleted,theyarecombinedinanewcomponentunit,withtheboltsandnuts,asshowninFigure5shows.Duetoadoptinghierarchicalassembly5,itisrationalinthepracticalproductionprocessandthepartsmanagementiseasy,whichcaneffectivelyshortenthedesigncycle.Figure5Componentunit13BalanceanalysisofthekinematicsofthespeciallathefixtureThemassofeachpartneedstobedeterminedbeforetheprocessofkinematicssimulationofthespeciallathefixture.AsisshowninFigure6,thematerialanddensityofeachpartisdefinedbymenucommandmechanism/qualityattributes,asTable1shows,thevolumeandmassofpartarecalculatedoutby3Ddesignsoftware.Weselectcarbonsteelasthematerialofotherstandardpartssuchastheboltsandnuts,itsdensityis7.85g/cm3.IntheprocessofdefiningthemassonPro/E,unitconversionalsoneedsattention.Figure6DissectionfigureofthefixtureTable1MaterialanddensityofthemainpartsoffixtureNumberPartnameMaterialDensityg/cm31counterbalanceA37.852flangeHT2007.23fixtureHT2007.24matchingblocklead11.375locating457.856pressureplate45Mn27.85Establishingcomponentunite,andthen,componentunit1wouldbeassembledonthemainshaftasthebenchmarkofmachinespindleaxisbythewayofconnectionpinconnection,asisshowninFigure7.Afterenteringamechanicmodel,thegravityissetinadefaultvalue.Inthecolumnofdirection,wesetX1,other0.Addedinamotor,itsrotationrateis360r/min.Thenarunisestablishedwithitssettings,dynamictypeandopeninggravityinthecolumnofexternalload.Tillthen,thekinematicssimulationprocesscanrun.Inordertoreduceflutterofthecylinderhole,thebalanceofaspecialfixtureistakenasthekeyanalysisinthispaper6,7.Theobjectiveofbalanceanalysisistomaketheholisticcentroidofthefixtureandtheworkpieceinthemachinespindleaxisofrotation.Thus,weshoulddeterminetheholisticcentroidofthefixtureandtheworkpiecefirst.Thenthedistancebetweenholisticandspindleaxiscanbeobtained.Thedistancebetweentheholisticandspindleaxisshouldinclinetozeroasfaraspossiblebyadjustmentofthemassofthematchingblock.ThedetailedlocationsofcentroidsinthreedirectionsofX,Y,ZcanbeobtainedthroughthemeasuringfunctionofPro/E.BecauseofsettingthemachinespindleaxisofrotationastheZaxis,thedistanceofthecentroidrelativetothecentrerotationcanbedeterminedonlyinneedofthemaximumofthecentroidatthedirectionofXorY.ThemeasurementresultsoffixturesimulatedmotionwithoutamatchingblockisshowninFigure8.Whenthefixtureturnedabout90°,themaximumdeviationdistanceofthecentroidis–22.08mminthedirectionofX.Onlybydoingthatcanweknowthatthecentroidisnotontheaxisasaresultitdoesnotmeetthebalancerequirement.Figure7ComponentuniteFigure8PositioncurveofcentroidwithoutmatchingblockInordertomeetthebalancerequirementamatchingblockneedtobeaddedtoadjustthecentroid,asshowninFigure4.Afteraddingthematchingblock,returntoanalyzeandthenremeasure.Theresultisthatthecentroidisstillnotontheaxis,butthedistanceofthecentroidrelativetotheaxisisshortened.Inthecaseofincreasingthethicknessofthematchingblock,themodificationandmeasurementisexecutedagainandagaininthesimulationprocess.Throughanumberoftests,anidealdistanceofthecentroidrelativetotheaxisisobtained.Thevalueis1.5107mm,asFigure9shows,soitcanbeconsideredthatthecentroidisontheaxis,andtheresultsatisfiesthebalancerequirements.Accordingtothesimulationresultwithamatchingblock,aleadbrickwhosethicknessis30

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