本科毕业论文-十字轴夹具课程设计（包含全套图纸及工序卡）.doc

航空制造工程学院机械制造工艺课程设计设计课题：十字轴零件机械加工工艺规程设 专业： 机械设计制造及其自动化 班级： 姓名： 学号： 评分： 指导老师：（签字） 2013年11月18日 目 录1零件的工艺分析12机械加工工艺设计22.1确定生产类型22.2确定毛坯22.2.1确定毛坯种类22.2.2确定锻件加工余量及形状33工艺规程设计43.1选择定位基准43.2制定工艺路线43.3表面加工方法的确定53.4加工阶段的划分53.5工序顺序的安排63.6确定工艺路线64机械加工余量、工序尺寸及公差的确定74、1工序1铣四轴端面74、2工序2粗车四轴外圆84、3工序3半精车四轴外圆94、4工序4钻孔，攻螺纹，锪锥面94、5工序5钻四轴向轴中心孔，锪锥面104、6工序6渗碳淬火114、7工序7精磨四轴外圆、端面115夹具设计125.1定位基准的选择125.2定位加紧方案125.3 夹具元设计件的计算135.3.1夹紧力作用点135.3.2夹紧力的方向135.3.3夹紧方案14 5.4 夹具装配图的绘制15 5.4 夹具体主要零件图的绘制166体会与展望197参考文献191零件的工艺分析 零件的材料为20GrMoTi，需要模锻，模锻性能优良，工艺较复杂，但尺寸精确，加工余量少，为此以下是十字轴需要加工的表面以及加工表面之间的位置要求：1、四处25外圆及四个8、6的内孔、2、右端面5060内孔及M8丝孔。3、25外圆的同轴度为0.007，位置度为0.02，两端的对称度均为0.05.由上面分析可知，可以先上四爪卡盘粗车，然后上弯板采用专用夹具压紧、找正进行加工，并且保证形位公差精度要求。并且此零件没有复杂的加工曲面，所以根据上述技术要求采用常规的加工工艺均可保证。 图1、十字轴零件图2机械加工工艺设计2.1确定生产类型 已知此十字轴零件的生产纲领为5000件/年，零件的质量是0.83Kg/个，查机械制造工艺设计简明手册第2页表1.1-2，可确定该拨叉生产类型为中批生产，所以初步确定工艺安排为：加工过程划分阶段；工序适当集中；加工设备以通用设备为主，大量采用专用工装。2.2确定毛坯2.2.1确定毛坯种类零件结构又比较简单，生产类型为中批生产，故选择锻模锻造毛坯。查机械制造工艺设计简明手册第41页表2.2-5,选用铸锻件尺寸公差等级为CT-10。毛坯尺寸11411429；毛坯图如下：2.2.2确定锻件加工余量及形状查机械制造工艺设计简明手册第41页表2.2-5，选用加工余量为MA-H级，并查表2.2-4确定各个加工面的锻件机械加工余量， 如下表所示：简 图加工面代号基本尺寸加工余量等级加工余量说明a25H2双 侧加 工b25H双 侧加 工c25H3双 侧加 工d25H3双 侧加 工3工艺规程设计3.1选择定位基准（1）粗基准的选择：作为粗基准的表面应平整，没有飞边、毛刺或其他表面缺欠。该工件选择25外圆面和左端面作为粗基准。采用左端面作粗基准加工右端面，可以为后续工序准备好精基准（2）精基准的选择：考虑要保证零件的加工精度和装夹准确方便，依据“基准重合”原则和“基准统一”原则，以粗加工后25的轴线为主要的定位精基准，采用小弯板为辅助的定位精基准。3.2制定工艺路线生产过程是指将原材料转变为成品的全过程。它包括原材料的准备、运输和保存，生产的准备，毛坯的制造，毛坯经过加工、热处理而成为零件，零件、部件经装配成为产品，机械的质量检查及其运行试验、调试，机械的油漆与包装等。工艺过程是指在生产过程中，通过改变生产对象的形状、相互位置和性质等，使其成为成品或半成品的过程。机械产品的工艺过程又可分为铸造、锻造、冲压、焊接、机械加工、热处理、装配、涂装等工艺过程。其中与原材料变为成品直接有关的过程，称为直接生产过程，是生产过程的主要部分。而与原材料变为产品间接有关的过程，如生产准备、运输、保管、机床与工艺装备的维修等，称为辅助生产。由于零件加工表面的多样性、生产设备和加工手段的加工范围的局限性、零件精度要求及产量的不同，通常零件的加工过程是由若干个顺次排列的工序组成的。工序是加工过程的基本组成单元。每一个工序又可括哪些工序，由被加工零件的复杂程度、加工精度要求及其产量等因素决定。3.3表面加工方法的确定根据零件的几何形状、尺寸精度及位置精度等技术要求，以及加工方法所能达到的经济精度，在生产纲领已确定的情况下,可以考虑采用万能性机床配以专用工卡具,并尽量使工序集中来提高生产率。除此之外，还应当考虑经济效果，以便使生产成本尽量下降。查机械制造课程设计指导书10页表1-6、1-7、1-8， 选择零件的加工方法及工艺路线方案如下： 十字轴零件加工方案加 工项 目尺寸公差等级粗糙度加工方案备注 25外 圆IT86.3粗车-半精车表1-6左 右端 面IT1012.5粗 车表1-6 25外 圆IT86.3粗车-半精车表1-8上 下端 面IT1012.5粗 车表1-7 23孔IT93.2钻-铰表1-7内螺纹M8IT63.2攻螺纹表1-10 6孔IT1212.5钻表1-7 8孔IT1212.5钻表1-73.4加工阶段的划分在粗加工阶段。首先将精基准准备好，使后续工序都可以采用精基准定位加工，保证其他加工表面的精度要求；首先25圆面作为粗基准粗车右端面及25，然后以此圆轴线及端面为精基准加工其他面和孔。在采用小弯板加工 另一部分，以保证其形位公差之要求。选用工序集中原则安排十字轴的加工工序。该零件的生产类型为大批生产，可3.5工序顺序的安排机械加工工序（1）遵循“先基准后其他”原则，首先加工基准25外圆轴线及端面 。（2）遵循“先粗后精”原则，先安排粗加工工序，后安排精加工工序。（3）遵循“先主后次”原则，先加工主要表面（4）遵循“先面后孔”原则，先加工外圆面、端面，再加工孔，确定工艺路3.6确定工艺路线工序号工序名称机床装备 工艺装备10调度15热处理20粗车四端面使长度为109CA6240三抓卡盘、车刀、游标卡尺25粗车四轴到26.5CA6240三抓卡盘、车刀、游标卡尺30半精右车四轴到25.3CA6240三抓卡盘、车刀、游标卡尺35钻孔2360孔攻螺纹孔M8Z528专用夹具、钻头铰刀、丝锥40钻6、8孔Z3040专用夹具、钻头锥度铰刀 45热处理 50精磨四个轴到25、轴长108M120三抓卡盘、砂轮、游标卡尺55去毛刺60检查入库加工设备和工艺设备1 机床的选择：采用CA6140普通车床、Z535立式钻床、磨床2 选择夹具：该零件的生产纲领为大批生产，所以采用专用夹具。3 选择量具：采用塞规,双用游标卡尺。4机械加工余量、工序尺寸及公差的确定4、1工序1铣四轴端面1、工件材料:20CrMnTi，=1018Mpa，模锻。机床：卧式车床CA6140刀具：YT15圆柱车刀，齿数Z=6，依据手册，由切削深度，以及加工类型（不经粗铣的半精铣），选用粗齿。2、计算切削用量根据刀具材料以及加工类型，依据机械工艺简明手册查表=0.12mm，。采用硬质合金圆柱车刀，=50mm，Z=6，则，由机床说明书取，于是。刀具每分钟进给量为=662.4mm/min.3、计算基本时间本工序为相同的四个工步4、计算其他时间 t1=6%t=29.2s5、 单件时间计算 td=t+t1=486.4s+29.2s=515.6s4、2工序2粗车四轴外圆1、加工条件机床：卧式车床C6140刀具：YT5外圆车刀，由于=1018Mpa，加工材料为结构钢，选用前角25，系统刚性足够，切削深度不大应选用较小主偏角，依据手册主偏角范围1015，由于取较小主偏角可以提高刀具寿命，因此选择10，根据前角大小，以及加工类型（粗车），查的相应的=8，刀杆尺寸为。2、计算切削用量根据加工尺寸确定背吃刀量为工件直径靠近20mm，刀具材料为硬质合金，背吃刀量0.6mm，有工艺手册查表得，通过查表法确定切削速速，根据纵车外圆的切削速度表，并根据以上得出的切削标准，选出对应的切削速度为，由机床说明书取转速为=相应的转速为3、计算基本时间本工序为四个相同工步4、计算其他时间 t1=6%t=0.8s5、单件时间计算 td=t+t1=13.32s+0.8s=14.12s4、3工序3半精车四轴外圆1、 加工条件2、 机床：卧式车床CA6140刀具：YT15外圆车刀，由于=1018Mpa，加工材料为结构钢，查表得前角范围1215，由于工件硬度低，前角需大一点，因此选用前角=15，刀杆尺寸为，刀尖半径取。2、计算切削用量根据切削尺寸及加工要求。 按表面粗糙度选取切削用量：根据刀具的相关参数，并选择有利于下步磨削最终达到最终的加工要求的表面粗糙度，查的进给量为。用查表法确定切削速度，依据表加工工艺手册表14-13（硬质合金外圆纵车削的切削速度）。，根据机床说明书，取，计算切削速度3、计算基本时间本工序为四个相同工步基本时间4、计算其他时间 t1=6%t=0.5s 6、单件时间计算 td=t+t1=9s+0.5s=9.5s4、4工序4钻孔，攻螺纹，锪锥面1、加工条件机床：立式钻床Z518。刀具：6mm中心钻；M8丝锥；60锪钻。确定切削用量钻孔由材料=1018Mpa0.748Gpa，查表取。依据钻直径以及进给量查表确定，计算转速，车床为无极转速因此转速不需修正。攻螺纹查表取，切削速度计算公式：查表确定各系数：，3、计算基本时间加工各步的走刀长度、进给量、转速分别为4、计算其他时间 t1=6%t=0.43s 5、单件时间计算 td=t+t1=7.11s+0.43s=7.54s4、5工序5钻四轴向轴中心孔，锪锥面为了尽量保证6mm和8mm同轴，采用一次装卡，连续加工的方法，这也有利于节约工时，提高生产效率，减小工人劳动强度。先加工8mm的孔，后加工6mm的孔，这样可以减小加工6mm孔的走刀距离和加工时受的阻力，从而减小加工误差。由于这些孔的加工精度较低，因此只进行粗加工就可以满足要求，以下就对切削用量作具体的阐述。1、加工条件工件材料:20CrMnTi，=1018Mpa，模锻。机床：卧式钻床刀具：中心钻8mm, ；20. 6mm，。 2、计算切削用量根据刀具材料以及加工类型，依据=1018Mpa0.748Gpa, ，由机械工艺简明手册查表得加工8mm孔的进给量以及切削速度分别为，计算得，查表的机床恰有此转速。加工6mm孔的进给量以及切削速度分别为，转速计算结果与8mm为了简化加工过程采用与加工8mm孔一样的转速。3、计算基本时间加工各轴两孔的走刀长度、进给量、转速分别为4、计算其他时间 t1=6%t=5.8s 5、单件时间计算 td=t+t1=97.2s+5.8s=103s4、6工序6渗碳淬火渗碳深度严格控制为1.72.2，淬火硬度为HRC58604、7工序7精磨四轴外圆、端面1、加工条件机床：外圆磨床。磨轮：由表14-22（磨轮的选择）确定砂轮材料为白刚玉，粒度为46，粘结剂为陶瓷的平型砂轮，砂轮直径d=250mm,厚度h=6mm。2、确定切削用量由加工要求。由于加工类型是直接精磨，且粗糙度为3、计算基本时间 t=70s4+62s4=528s 4、计算其他时间 t1=6%t=31.6s 5、单件时间计算 td=t+t1=528s+31.6s=559.6s5夹具设计5.1定位基准的选择以纸面为xoz轴，建立左手坐标系；分析加工该工件需要的自由度：孔的直径6：由刀具确定；孔的位置：需要限制沿X轴的平动，沿Y轴的平动两个第一类自由度；孔与端部的垂直度：需要限制绕X的转动，绕Y轴的转动两个第一类自由度；总共要限制：沿X轴的平动，沿Y轴的平动，绕X的转动，绕Y轴的转动四个第一类自由度；因此，可让工件的下端面为定位基面，8孔为另一定位基准，对工件进行定位加紧。5.2定位加紧方案1) 定位方案在下端面放置支承平面，可以限制沿Z轴的平动，绕X的转动，绕Y轴的转动三个自由度；在底部8孔中加一短定位销，可以限制沿X轴的平动，沿Y轴的平动；这样，总共限制了：沿X轴的平动，沿Y轴的平动，沿Z轴的平动，绕X的转动，绕Y轴的转动五个自由度；2) 夹紧方案通过两个U型叉插在水平的两个轴颈上，通过螺栓给工件一个向下的加紧力。同时，两个U型叉插的连续使用，也使工件在绕Z轴的转动上受到限制。5.3 夹具元件的设计计算5.3.1夹紧力作用点如图，由于加工的切削力向下，而支承平面会给工件一个向上的力，为了使工件受力平衡，在工件的轴颈上，对称的加上两个作用力。5.3.2夹紧力的方向由于工件与支承平面的接触仅靠重力维持，将导致工件在放置和加工的时候受力不稳，因此，在工件的轴颈上，对称的加上两个向下的作用力，可使工件在Z方向上加紧。同时，两个对称的U型叉，又使工件在绕Z轴的转动上受到了一定的限制。5.3.3夹紧方案如图，为工件的夹紧方案，两个U型叉分别给轴颈两个向下的力，与支承平面给工件的向上的力相平衡，起到了夹紧的作用。同时，如果刀具给工件绕Z轴的转矩时，U型叉也能限制工件旋转。5.4 夹具装配图的绘制这是零件的总装配图5.5 夹具体主要零件图的绘制这是夹具体。这是钻套支承。这是U型叉。CAD图纸见附图十字轴毛坯图见附图;十字轴零件图见附图；夹具体零件图见附图； 钻6孔夹具装配图见附图。6体会与展望 在课设一月的时间里，既要做科技创新，又要课程设计，还得兼顾招聘会。下发课题后，花了几天的时间找零件、设计相应夹具，在尽量少犯错误的情况下，完成课设。里面不免出错，还请老师纠正。在这次课程设计中，我重点看了机械制造装备，翻阅了夹具手册，在钻模和铣床夹具中选择了前者，了解到其主要用于钻床上钻、扩、铰或攻螺纹。加工中心易引起振动，因此夹具的受力元件要有足够的强度和刚度，夹紧机构所提供的夹紧力应足够大，并要求有较好的自锁性能。在符合其设计要求的情况下，得到这套组合夹具。设计过程中翻阅了设计手册，在网上查找了十字轴相关资料，确定可以使用钻孔专用夹具来加工中心孔。通过分析十字轴图纸，确定工艺路线，花费两天，绘制了零件、夹具图纸。 这次课设不仅复习了机械制图的知识点、巩固所学，锻炼了我的手绘能力，还为接下来的毕业设计提供了经验。感谢罗老师在百忙之中批阅我们的课程设计。7参考文献 1赵家奇.机械制造工艺学课程设计指导书M.北京：机械工业出版社,2006.2曾志新,吕明.机械制造技术基础M.湖北:武汉理工大学出版社,2001.3李益明.机械制造工艺设计简明手册M.北京：机械工业出版社,1993.4肖诗纲.切削用量手册M.北京：机械工业出版社,1993.5上海柴油机厂工艺设备研究所.金属切削机床夹具设计手册M.北京：机械工业出版社，1987.6钟日铭.Pro/ENGINEER野火版3.0完全实例导航M.北京：机械工业出版社，2006.7李凯岭.机械制造技术基础M.北京：科学出版社，2007.需要全套图纸可以发信息到邮箱523546640十字轴零件图十字轴钻孔专用夹具图请您删除一下内容，O(_)O谢谢！Many people have the same mixed feelings when planning a trip during Golden Week. With heaps of time, the seven-day Chinese请您删除一下内容，O(_)O谢谢！National Day holiday could be the best occasion to enjoy a destination. However, it can also be the easiest way to ruin how you feel about a place and you may become more fatigued after the holiday, due to battling the large crowds. During peak season, a dream about a place can turn to nightmare without careful planning, especially if you travel with children and older people. As most Chinese people will take the holiday to visit domestic tourist destinations, crowds and busy traffic are inevitable at most places. Also to be expected are increasing transport and accommodation prices, with the possibility that there will be no rooms available. It is also common that youllwait in the line for one hour to get a ticket, and another two hours at the site, to only see a tiny bit of the place due to the crowds. Last year, 428 million tourists traveled in China over the week-long holiday in October. Traveling during this period is a matter that needs thorough preparation. If you are short on time to plan the upcoming Golden Week it may not be a bad idea to avoid some of the most crowded places for now. There is always a place so fascinating that everyone yearns for. Arxan is a place like this. The beauty of Arxan is everlasting regardless of the changing of four seasons. Bestowed by nature, its spectacular seasonal landscape and mountains are just beyond word. Arxan is a crucial destination for the recommended travelling route, China Inner Mongolia Arxan Hailar Manzhouli. It is also the joint of the four prairies across the Sino-Mongolian border, where people gravitate towards the exotic atmosphere mixed with Chinese, Russian, and Mongolia elements. As a historic site for the Yitian Battle, Arxan still embodies the spirit of Genghis Khan. Walking into Arxan, you will be amazed by a kaleidoscope of gorgeous colors all the year round - the Spring azaleas blooming red in the snow, the Summer sea wavering blue in the breeze, the Autumn leaves painted in yellow covering volcanic traces, and the Winter woods shining white on the vast alpine snowscape. Hinggan League Arxan city is situated in the far eastern area of Inner Mongolia Autonomous Region. Its full name Haren Arxan means hot holy water in the Mongolian language. Arxan is a tourism city in the northern frontier with a blend of large forest, grand prairies, vast snowfield, heaven lake cluster, thermium, as well as volcanic cluster. It is a rare and unique ecotourism base filled with healthy sunshine, clean air and unspoiled green. Nestled close to the countrys largest virgin forest, and known for its spring and ecological environment, Arxan is marveled at by many tourists as the purest land on earth. You cannot miss out the Autumn of Arxan. It is definitely the best with brightly-colored scenery full of emotions. Autumn in the northern part of the country comes earlier than the South. A September rain followed by the footprints of Autumn brings more colors to the once emerald green mountain and blooming grassland. Shutterbugs flock to see for themselves the marvel of splendid colors around the mountains and waters, many of whom have travel a long distance and even camp here only to capture a moment of the nature wonder. The silver birch turns golden, while the larch is still proudly green. You will find yourself drowned in the intoxicating red of the wild fruits as well as the glamour of flowers in full blown. And your heart will be lingering on the woods as its time for the wild fruits to ripe. The picturesque Arxan in Autumn is indeed a fairyland only exists in a dream that satisfies all your fantasies. If itrains heavily on Saturday night, some elderly Chinese will say it is because Zhinu, or the Weaving Maid, is crying on the day she met her husband Niulang, or the Cowherd, on the Milky Way. Most Chinese remember being told this romantic tragedy when they were children on Qixi, or the Seventh Night Festival, which falls on the seventh day of the seventh lunar month, which is usually in early August. This year it falls on Saturday, August 2. Folklore Story As the story goes, once there was a cowherd, Niulang, who lived with his elder brother and sister-in-law. But she disliked and abused him, and the boy was forced to leave home with only an old cow for company. The cow, however, was a former god who had violated imperial rules and was sent to earth in bovine form. One day the cow led Niulang to a lake where fairies took a bath on earth. Among them was Zhinu, the most beautiful fairy and a skilled seamstress. The two fell in love at first sight and were soon married. They had a son and daughter and their happy life was held up as an example for hundreds of years in China. Yet in the eyes of the Jade Emperor, the Supreme Deity in Taoism, marriage between a mortal and fairy was strictly forbidden. He ordered the heaven troop to catch Zhinu back. Niulang grew desperate when he discovered Zhinu had been taken back to heaven. Driven by Niulangs misery, the cow told him to turn its hide into a pair of shoes after it died. The magic shoes whisked Niulang, who carried his two children in baskets strung from a shoulder pole, off on a chase after the empress. The pursuit enraged the empress, who took her hairpin and slashed it across the sky creating the Milky Way which separated husband from wife. But all was not lost as magpies, moved by their love and devotion, formed a bridge across the Milky Way to reunite the family. Even the Jade Emperor was touched, and allowed Niulang and Zhinu to meet once a year on the seventh night of the seventh month. This is how Qixi came to be. The festival can be traced back to the Han Dynasty (206 BC-AD 220). Traditionally, people would look up at the sky and find a bright star in the constellation Aquila as well as the star Vega, which are identified as Niulang and Zhinu. The two stars shine on opposite sides of the Milky Way. Customs In bygone days, Qixi was not only a special day for lovers, but also for girls. It is also known as the Begging for Skills Festival or Daughters Festival. In this day, girls will throw a sewing needle into a bowl full of water on the night of Qixi as a test of embroidery skills. If the needle floats on top of the water instead of sinking, it proves the girl is a skilled embroiders. Single women also pray for finding a good husband in the future. And the newly married women pray to become pregnant quickly. Tradition transformed The love story of Niulang and Zhinu, and the Qixi Festival have been handed down for generations. Yet these ancient traditions and customs are slowly dying out. Many modern Chinese, particularly youngsters, seem to know more about St Valentines Day on February 14, characterized by bouquets of roses, chocolates and romantic candlelight dinners, than they do about their home-grown day for lovers. Even Qixi is nowadays referred to as the Chinese Valentines Day. More and more young Chinese people begin to celebrate this day in a very similar way as that in western countries. Fewer people than ever will gaze at the heavens on Saturday to pick out the two stars shining bright on either side of the Milky Way, that is, if people even know on which day Qixi falls. There are ready reminders dotted about, in the form of big ads saying Sales on Chinese Valentines Day! in shops, hotels and restaurants. But few young women will mark the festival with their boyfriends, or take part in traditional activities to pray for cleverness. A large-scale of exhibition on the Silk Road opened to the public in the National Museum on Thursday. The exhibition displays more than 400 treasures from Shaanxi province, Gansu province and 14 other regions. It is largest scale exhibition that shows the history of the Silk Road in recent years. AsAPECis going on in Beijing, the exhibit aims to show the world this brilliant section of history. The Silk Road is a series of trade and cultural transmission routes that were central to cultural interaction through regions of the Asian continent. It connected the West and East by linking traders, merchants, pilgrims, monks, soldiers, nomads, and urban dwellers from China and India to the Mediterranean Sea during various periods of time. I met my dear hubby in 2009 the second year I was in my school and it was the first year when he came here. We became colleagues. And there was nothing special happening during that year. He was just a kind and humble brother graduated from the same college as me. But we did not know each other till he became my colleague and his office desk was just in front of me. There was only a glass between us. So actually we could see each other when we both look up. But it is not the main reason that really draws us close. How we become close to each other was something seems quite natural. We went out to play badminton with other colleagues and we sometimes chatted for a while. He is a man of few words but somehow sometimes will say something really humorous. Then one day, to my great surprise, I found a pot of beautiful flower on my desk. It was just the flower I had talked about with my colleague the other day, and I thought it was her who put the flower there. But the truth is not. It was the humble guy sitting in front of me. He just simply said ,”well, I caught sight of this flower and thought that its beautiful and you may like it”. I wonder why I was moved because of these simple words and present. Maybe it is the sincerity and the true self that impress me. I thanked him and some colleagues walked past my desk would appreciate the beautiful flower and they noticed that something romance happened there. Then later on, there were some little surprises once in a while. Once, there was something wrong with my drawer and I had complained about it unconsciously. And he fixed it for me. Then the other day, he placed several pink diamond roses beside the flower with a piece of paper saying” I love you more than I can say! Diamond stands for marriage, rose stand for love. I hope you are mine, become my wife. You are the only girl who I really want to spend the rest of my life to stand by.” Although there were some grammar errors but I got what he meant. He meant so clear and so direct. And actually, I accepted him some days earlier. I was just waiting for him to break the ice. So finally, the common interests and the common understanding brought us to