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翻译—基于事例推理的夹具设计研究与应用.pdf

前钢板弹簧吊耳加工工艺及钻2-10.5孔夹具设计[含CAD图纸，工序卡，工艺过程卡，说明书]

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前钢板弹簧吊耳加工工艺及钻2-10.5孔夹具设计[含CAD图纸，工序卡，工艺过程卡，说明书].zip

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关键词：: 含CAD图纸，工序卡，工艺过程卡，说明书钢板弹簧吊耳工艺及钻2 钢板弹簧吊耳加工孔夹具设计[ 钢板弹簧吊耳加工工艺及夹具设计 10.5孔夹具钢板弹簧吊耳工艺过程卡钢板弹簧吊耳工艺夹具设计

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　　　本次设计内容涉及了机械制造工艺及机床夹具设计、金属切削机床、公差配合与测量等多方面的知识。

　　　吊耳前钢板弹簧加工工艺规程及其钻侧孔的夹具设计是包括零件加工的工艺设计、工序设计以及专用夹具的设计三部分。在工艺设计中要首先对零件进行分析，了解零件的工艺再设计出毛坯的结构，并选择好零件的加工基准，设计出零件的工艺路线；接着对零件各个工步的工序进行尺寸计算，关键是决定出各个工序的工艺装备及切削用量；然后进行专用夹具的设计，选择设计出夹具的各个组成部件，如定位元件、夹紧元件、引导元件、夹具体与机床的连接部件以及其它部件；计算出夹具定位时产生的定位误差，分析夹具结构的合理性与不足之处，并在以后设计中注意改进。

　　　　关键词：工艺、工序、切削用量、夹紧、定位、误差。

ABSTRCT

　　　This design content has involved the machine manufacture craft and the engine bed jig design, the metal-cutting machine tool, the common difference coordination and the survey and so on the various knowledge.

　　　The reduction gear box body components technological process and its the processing hole jig design is includes the components processing the technological design, the working procedure design as well as the unit clamp design three parts. Must first carry on the analysis in the technological design to the components, understood the components the craft redesigns the semi finished materials the structure, and chooses the good components the processing datum, designs the components the craft route; After that is carrying on the size computation to a components each labor step of working procedure, the key is decides each working procedure the craft equipment and the cutting specifications; Then carries on the unit clamp the design, the choice designs the jig each composition part, like locates the part, clamps the part, guides the part, to clamp concrete and the engine bed connection part as well as other parts; Position error which calculates the jig locates when produces, analyzes the jig structure the rationality and the deficiency, and will design in later pays attention to the improvement.

　　　Keywords: The craft, the working procedure, the cutting specifications, clamp, the localization, the error

序言…………………………………………………………………1

一. 零件分析 ……………………………………………………2

　　　1.1 零件作用 ………………………………………………2

　　　1.2零件的工艺分析 …………………………………………3

二. 工艺规程设计…………………………………………………4

　　　2.1确定毛坯的制造形式 ……………………………………4

　　　2.2基面的选择传 ……………………………………………5

　　　2.3制定工艺路线 ……………………………………………8

　　　2.4机械加工余量、工序尺寸及毛坯尺寸的确定 …………6

　　　2.5确定切削用量及基本工时………………………………6

三夹具设计……………………………………………………8

　　　3.1问题的提出………………………………………………8

　　　3.2定位基准的选择…………………………………………8

　　　3.3切削力及夹紧力计算……………………………………9

　　　3.4定位误差分析……………………………………………11

　　　3.5夹具设计及操作简要说明………………………………15

总结………………………………………………………………17

致谢………………………………………………………………18

参考文献 …………………………………………………………19

　　　　　　　　　　　　　　　　序言

　　　机械制造业是制造具有一定形状位置和尺寸的零件和产品，并把它们装备成机械装备的行业。机械制造业的产品既可以直接供人们使用，也可以为其它行业的生产提供装备，社会上有着各种各样的机械或机械制造业的产品。我们的生活离不开制造业，因此制造业是国民经济发展的重要行业，是一个国家或地区发展的重要基础及有力支柱。从某中意义上讲，机械制造水平的高低是衡量一个国家国民经济综合实力和科学技术水平的重要指标。

　　　前钢板弹簧吊耳的加工工艺规程及其铣距离64mm的Φ44外圆的内侧面的夹具设计是在学完了机械制图、机械制造技术基础、机械设计、机械工程材料等进行课程设计之后的下一个教学环节。正确地解决一个零件在加工中的定位，夹紧以及工艺路线安排，工艺尺寸确定等问题，并设计出专用夹具，保证零件的加工质量。本次设计也要培养自己的自学与创新能力。因此本次设计综合性和实践性强、涉及知识面广。所以在设计中既要注意基本概念、基本理论，又要注意生产实践的需要，只有将各种理论与生产实践相结合，才能很好的完成本次设计。

　　　本次设计水平有限，其中难免有缺点错误，敬请老师们批评指正。

零件的分析

零件的作用

前钢板弹簧吊耳的主要作用是载重后，使钢板能够得到延伸，伸展，能有正常的缓冲作用。因此汽车前钢板弹簧吊耳零件的加工质量会影响汽车的工作精度、使用性能和寿命。汽车前钢板弹簧吊耳主要作用是减震功能、阻尼缓冲部分功能、导向功能

1.2 零件的工艺分析

　　　前钢板弹簧吊耳零件图上可以看出，它有两组加工表面，这两组加工面之间也有一定的位置要求，现将这两组加工面分述如下：

　　　1. 以Ø44mm端面和中间外圆为基准加工面

这一组加工面包括：一个的Ø25mm孔以及各个端面

　　　2. 以Φ10.5孔和端面为中心的加工面，这组加工面主要是其余各孔及其槽和宽44mm的2个Φ44外圆的外侧面

　　　　　　　二. 工艺规程设计

确定毛坯的制造形式

　　　零件材料为KTH350，考虑到工件运行时经常受到冲击性载荷，采用这种材料零件的强度也能保证。由于零件成批生产，而且零件的轮廓尺寸不大，选用锻造，锻造精度为2级，能保证铸件的尺寸要求，这从提高生产率和保证加工精度上考虑也是应该的。

全部文件.jpg

前钢版弹簧吊耳零件图.jpg

前钢版弹簧吊耳毛坯图.jpg

夹具装配图.jpg

夹具体.jpg

菱形轴.jpg

半圆轴.jpg

工序卡.png

工艺卡.png

内容简介：: 1 ApplicationApplicationApplicationApplication andandandand developmentdevelopmentdevelopmentdevelopment OfOfOfOf casecasecasecase basedbasedbasedbasedreasoningreasoningreasoningreasoning ininininfixturefixturefixturefixturedesigndesigndesigndesign Abstract:Abstract:Abstract:Abstract: Based on the case based designing(CBD)methodology,the fixture similarity is in two respects: the function and the structure information. Then, the computer aided fixture design systemiscreatedoncasebased reasoning (CBR),in which the attributes of the main features of workpiece and structure of fixture as case index code are designed for the retrieve of the similar cases, and the structure and hierarchical relation of case library are setupforstore.Meanwhile,the algorithmbasedontheknowledge guided in the retrieve of the similar cases, the strategy of case adapt at ion and case storage in which the case ident if cat ion number is used to distinguish from similar cases are presented. The applicationofthesysteminsome projects improves the design efficiency and gets a good result . Keywords:Keywords:Keywords:Keywords:casebased reasoning;fixturedesign;computer aided design(CAD) Fixtures are devices that serve as the purpose of holding the workpiece securelyandaccurately,and maintaining a consistent relationship withrespecttothetoolswhile machining.Becausethefixture structure depends on the feature of the product and the status of the process planning in the enterprise, its design is the bottleneck during manufacturing, whichrestrainstoimprovethe efficiency and leadtime. And fixture 2 design is a complicated process, based onexperiencethatneeds comprehensive qualitative knowledge aboutanumberofdesignissues includingworkpiececonfiguration, manufacturing processes involved, and machining environment. This is also a very time consuming work when using traditionalCADtools(suchas Unigraphics, CATIA or Pro/E), which are good at performing detailed design tasks, but provide few benefits for taking advantage of the previous design experience and resources, which are precisely the key factors in improving the efficiency. The methodology of case basedreasoning(CBR)adaptsthe solution of a previously solved case to build a solution for a new problem with the following four steps: retrieve, reuse, revise, and retain 1. This is a more useful method than the use of an expert systemtosimulatehumanthought because proposing a similar case and applying a few modifications seems to be self explanatory and more intuitive tohumans.Sovariouscasebased designsupporttoolshavebeen developedfornumerousareas2-4, such as in injection molding and design, architectural design, die castingdie design, process planning, and also in fixture design. Sun used six digitals to compose the index code that included workpieceshape,machineportion, bushing, the 1stlocating device, the 2nd locating device and clamping device5. But the system cannot be used for other fixture types except for drill fixtures, and cannot solve the problem of storage of the same index code that needs to be retained, which is very important in CBR6. 1 Construction of a Case Index and 3 Case Library 1.1 Case index Thecaseindexshouldbe composedofallfeaturesofthe workpiece,whicharedistinguished from different fixtures. Using all of them wouldmake the operation in convenient. Because the forms of the parts are diverse, and the technology requirementsofmanufacture inthe enterprise also develop continuously, lots of features used as the case index will make the search rate slow, and the mainfeatureunimportant,forthe reason that the relative weight which is allotted to every feature must diminish. And on the other hand, it is hard to include all the features in the case index. Therefore,consideringthe practicality and the demand of rapid design, the case index includes both the major feature of the workpiece and the structure of fixture. The case index code is made up of 16 digits: 13 digits for case features and 3 digits for case identification number. The first 13 digits represent 13 features. Each digit is corresponding to an attribute of the feature, which may be one of“*”, “？”, “1”, “2”, “A” , “B” , “Z” , etc. In which, “*” means anyone, “?” uncertain, “0” nothing. The system rules: fixture type, workpiece shape, locating model cannot be “*”or“?”. When the system is designed, the attribute information of the three items does not have these options,whichmeansthecertain attribute must be selected. The last three digits are the case identification number, which means the 13 digits of the case feature are the 4 same, and the number of these three digits is used for distinguishing them. The system also rules: “000”is a prototypecase,whichisusedfor retrieval, and other cases are “001”, “ 002 ” ,which are used for referencecasestobesearchedby designers. If occasionally one of them needs to be changed as the prototype case, first it must be required to apply to change the one to “000”, and the former is changed to referential case automatically. The construction of the case index code is shown in Fig.1. 1.2 Case library The case library consists of lots of predefined cases. Case representation is one of the most important issues in case based reasoning. So compounding with the index code,. 1.3 Hierarchical form of Case Thestructuresimilarityofthe fixture is representedas the whole fixture similarity, components similarity and component similarity. So the whole fixture case library, components case library,componentcaselibraryof fixtureareformedcorrespondingly. Usuallydesigninformationofthe whole fixture is composed of workpiece information and workpiece procedure information, which represent the fixture satisfyingthespecificallydesigning function demand. The whole fixture case is made up of function components, which are described by the function componentsnames and numbers. The componentscaserepresentsthe members.(functioncomponentand 5 other structure components ，main driven parameter, the number, and their constrain relations.)The component case (the lowest layer of the fixture) is the structure of function component and othercomponents.Inthemodern fixturedesigntherearelotsof parametric standard parts and common non standard parts. So the component caselibraryshouldrecordthe specification parameter and the way in which it keeps them. 2 Strategy of Case Retrieval Inthecasebaseddesignof fixtures ,the most important thing is the retrieval of the similarity, which can help to obtain the most similar case, and to cut down the time of adaptation. According to the requirement of fixture design, the strategy of case retrieval combinesthewayofthenearest neighbor and knowledge guided. That is, first search on depth, then on breadth; the knowledge guided strategy means to search on the knowledge rule from root to the object, which is firstly searched by the fixture type, then by the shape of the workpiece, thirdly by the locating method. For example, if the case index code includes the milling fixture of fixture type, the search is just for all millingfixtures,thenforboxof workpiece shape, the third for 1plane+ 2pine of locating method. If there is no match of it, then the search stops on depth, and returns to the upper layer, and retrieves all the relative cases on breadth. Retrieval algorithms: 1)Accordingtothecaseindex informationoffixturecaselibrary, search the relevant case library; 2)Match the case index code with the code of each case of the case library, 6 and calculate the value of the similarity measure; 3)Sorttheorderofsimilarity measure, the biggest value, which is the most analogical case. Similarity between two cases is based on the similarity between the two cases.features.Thecalculationof similarity measure depends on the type of the feature. The value of similarity can be calculated for numerical values, for example, compareWorkpiece with the weight of 50kg and 20kg. The value can also be calculated between non numerical values, for example, now the first 13 digits index code is all non numericalvalues.Thesimilarity measure of a fixture is calculated as follows: where S is the similarity measure of current fixture, n is the number of the index feature,is the weight of each feature,is the similarity measure of the attributeof the i2th feature with the attributeof relative feature of the j-th case in the case library.Atthesametime, , the value counts as follows: . Whereis the value of the index attribute of the i-th feature, andis 7 the value of attribute of the relative i-th feature of the j-th case in case library. So there are two methods to select the analogical fixture. One is to set the value.Ifthevaluesofsimilarity measure of current cases were less than a given value, those cases would not be selected as analogical cases. When the case library is initially set up, and there are only a few cases, the value can be setsmaller.Iftherearelotsof analogical cases, the value should get larger. The other is just to set the number of the analogical cases (such as10), which is the largest value of similaritymeasurefromthesorted order. 3CaseadaptationandCase Storage 3.1 Case adaptation Themodificationofthe analogical case in the fixture design includes the following three cases: 1) The substitution of components and the component; 2) Adjustingthedimensionof components and the component while the form remains; 3) The redesign of the model. If the components and component of the fixture are common objects, they can be edited, substituted and deleted with tools, which have been designed. 3.2 Case storage Before saving a new fixture case in thecase library, the designermust consider whether the saving is valuable. Ifthecasedoesnotincreasethe knowledge of the system, it is not necessary to store it in the case library. If it is valuable, then the designer must analyzeitbefore savingittosee whetherthecaseisstoredasa prototype case or as reference case. A 8 prototype case is a representation that can describe the main features of a case family. A case family consists of those cases whose index codes have the same first 13 digits and different last three digits in the case library. The last three digits of a prototype case are always “000” . A reference case belongs to the same family as the prototype case and is distinguished by the different last three digits. From the concept that has been explained, the following strategies are adopted: 1) If a new case matches any existing case family, it has the same first 13 digits as an existing prototype case, so the case is not saved because it is represented well by the prototype case. Or is just saved as a reference case (the last 3 digits are not “000”, and not the same with others) in the case library. 2) If a new case matches any existing case family and is thought to bebetteratrepresentingthiscase family than the previous prototype case, then the prototype case is substituted by thisnewcase,andtheprevious prototype case is saved as a reference case. 3) If a new case does not match any existing case family, a new case family will be generated automatically and the case is stored as the prototype case in the case library. 4ProcessofCBRinFixture Design According to the characteristics of fixture design, the basic information of the fixture design such as the name of fixture, part, product and the designer, etc. must be input first. Then the fixture file is set up automatically, in which all 9 componentsofthefixtureareput together.Thenthemodelofthe workpiece is input or designed. The detailedinformationaboutthe workpiece is input, the case index code is set up, and then the CBR begins to search the analogical cases, relying on the similarity measure, and the most analogicalcaseisselectedout.If needed, the case is adapted to satisfy the current design, and restored into the caselibrary.Theflowchartofthe process is shown in Fig.3. 5 Illustrating for Fixture Design by CBR This is a workpiece (seeFig.4). Its material is 45# steel. Its name is seat. Its shape is block, and the product batch size is middle, etc.Afixture is turning fixture that serves to turn the hole, which needs to be designed. The value of feature, attribute, case index code and weight of the workpiece is show n in Tab.2. 10 Through searching, and calculating the similarity, the case index code of the mostsimilarcaseis 19325513321402000, and the detailed information is show n in Tab. 3. The similarity is calculated as follows: So the value of similarity measure ofthefixturewhichneedstobe designed with the most analogical

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