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M2120内圆磨床的改造设计【4张图纸】【优秀】

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摘要

本次设计主要针对数控磨床做部分改造，以适应加工产品时可以简单加工、精确定位、保证尺寸，提高加工效率，减轻工人劳动强度。

此次改造对机床的导轨和驱动等进给部件做一定的修改，以适应产品的需要，保证在生产中的精度及效率。

液压驱动对重复定位及尺寸的精度很难保证，使得在生产中很难提高效率。改用伺服电机驱动进给部件，可以保证机床的重复定位，使产品的精度不会因为操作者的原因而无法得到保证。

导轨是数控控制精度的一个方面，数控方式对导轨要求是具有高灵敏度，低摩擦阻力，高寿命等，所以对导轨的要求也比较高。一般的磨床采用的是滚动导轨，精度较低，摩擦阻力大，寿命不高，所以本次设计导轨采用的是滚动导轨

丝杠是控制精度的另一个方面，以前沿用的滑动丝杠传动效率低、导程精度低，不能满足高精度、高效率的要求，因此该用滚珠丝杠，滚珠丝杠传动系统是以滚珠为媒介的滚动螺旋传动的体系，它的传动效率高，是传统滚珠丝杠的2～4倍，运动平稳性好，精度高，较高的耐用性，可靠性高，无间隙，刚性好。

对于生产时产品的尺寸能进行补偿，保证产品一致性。另外对于产品的变更能及时进行调整，以适应不同的产品，尽量降低加工成本。　　

关键词：内圆磨床；数控；伺服

摘要III

AbstractIV

目录V

1 绪论1

1.1本课题的研究内容和意义1

1.2国内外的发展概况1

1.3本课题应达到的要求1

2 总设计方案2

2.1 主要规格与参数2

2.2 总设计方案分析与选定3

2.2.1机床设计改造的基本要求3

2.2.2机床设计改造的研究方法3

2.2.3机床设计的方案分析4

2.3 主要结构与性能8

2.3.1床身8

2.3.2 进给箱8

2.3.3 磨架8

2.3.4 床头8

2.3.5 砂轮修整器8

2.3.6 砂轮轴8

3 传动系统9

3.1 工件传动9

3.2 砂轮传动9

3.3 进给传动9

3.4 机床所用滚动轴承明细表9

3.5 传动带明细表10

3.6 丝杠副明细表10

4 X轴进给伺服系统的设计与计算11

4.1 进给伺服系统的控制方式的选择11

4.2 伺服系统机械传动结构设计特点12

4.3 伺服电动机的选择计算12

4.3.1选择伺服电机的三个指标及其计算12

4.3.2电动机转子惯量与负载惯量匹配12

4.3.3空载加速转矩13

4.3.4电动机的选择13

4.4 滚珠丝杠副14

4.4.1滚珠丝杠特点14

4.4.2滚珠丝杠的消隙和预加载荷14

4.4.3滚珠丝杠的支承14

4.4.4滚珠丝杠的选择计算14

4.4.5 选择丝杠轴承16

4.5 半闭环进给系统的精度16

4.5.1伺服刚度16

4.5.2滚珠丝杠的螺母的接触强度17

4.5.3 丝杠的拉压强度17

4.5.4 轴承的轴向刚度17

4.5.5 综合刚度17

4.5.6 定位精度17

4.6 导轨的选择18

4.7 涨紧套18

4.7.1 涨套的联接特点18

4.7.2涨套的选用计算18

5电气系统20

5.1概述20

5.2机床夹紧动作20

5.3工件夹紧20

5.4维护检查20

6 冷却系统21

7 润滑系统22

7.1润滑油的选择22

7.2注意事项22

7.3使用和维修22

7.4其他润滑22

8结论与展望23

8.1结论23

8.2不足之处与未来展望23

致谢24

参考文献25

附录26

1 绪论

1.1本课题的研究内容和意义

　　　磨削技术及磨床技术在机械制造行业占有极其重要的位置，磨削技术发展很快，在机械加工中起着非常重要的作用。随着高精度、高硬度机械零件数量的增加，以及精密铸造和精密锻造工艺的发展，磨床的性能、品种和产量都在不断的提高和增长。

1.2国内外的发展概况

　　　由于内圆磨床应用十分广泛，近年来，磨削技术得到了飞速发展，各种磨削新技术、新工艺和新成品层出不穷。国际上有不少著名制造商，如日本的OKAMMOTO、MITSUI三井，德国的BLOHM、ELB、ABA，瑞士的MAGERLE，意大利的FAVRATO等。在发展数控内圆磨床生产数量的同时，还要努力提高数控磨床的质量和精度。由于CBN砂轮的使用，强力磨削突破传统磨削的限制，生产倍率成倍提高，目前磨削线速度已高达120m/s，大吃深缓进给的强力磨削也得到了广泛应用。现代高精度磨削技术的发展，磨削尺寸精度达到0.1～0.3μm，表面粗糙度达到0.2～0.05μm，磨削表面变质层的残留应力均很小，明显提高了加工零件的质量。数控是内圆磨床发展的重要方面。在相当长的时期里，国外磨床的数控化率远远低于车床和铣床。在近十年来，由于数控技术的发展，适用于磨床的数控系统也有了较大发展，数控系统的性价比大大提高。目前国内高速磨削应用面不广，磨削速度一般不超过60m/s，与国外相差较大，磨削效率也相对较差，大吃深缓进给的强力磨削方法在我国生产中应用不多。随着我国机械制造业迅猛发展，国内对数控机床的要求也越来越高，自主研发了高精度机床，在控制技术方面与国外差距还很大，，主要采用PLC控制为主。国内各机床厂和机床研究所对数控磨床及磨削技术的发展投入很大，取得了一些初步进展，如CIMT展出的上海机床厂的MKY7875、云南MIGHTY公司的SGS-618II、威海机床厂的MJ7116等。

1.3本课题应达到的要求

　　　本次设计主要针对数控磨床做部分改造，以适应加工产品时，可以简单加工、精确定位、保证尺寸、提高加工效率、减轻工人劳动强度。此次改造对机床的导轨和驱动等进给部件做一定修改，以适应生产中精度和效率。需要采用伺服电机做驱动元件实现自动控制，把原来滑动丝杠螺母副，把回转运动转变为直线运动，并且采用滚动导轨，以提高精度。

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内容简介：: 英文原文英文原文Mechanical DesignAbstract:A machine is a combination of mechanisms and other components which transforms, transmits. Examples are engines, turbines, vehicles, hoists, printing presses, washing machines, and movie cameras. Many of the principles and methods of design that apply to machines also apply to manufactured articles that are not true machines. The term mechanical design is used in a broader sense than machine design to include their design. the motion and structural aspects and the provisions for retention and enclosure are considerations in mechanical design. Applications occur in the field of mechanical engineering, and in other engineering fields as well, all of which require mechanical devices, such as switches, cams, valves, vessels, and mixers.Keywords: Mechanical Design mechanisms Design ProcessThe Design ProcessDesigning starts with a need real.Existing apparatus may need improvements in durability, efficiency, weight, speed, or cost. New apparatus may be needed to perform a function previouslydone by men, such as computation, assembly, or servicing. With the objective wholly or partlyIn the design preliminary stage, should allow to design the personnel fully to display the creativity, not each kind of restraint. Even if has had many impractical ideas, also can in the design early time, namely in front of the plan blueprint is corrected. Only then, only then does not send to stops up the innovation the mentality. Usually, must propose several sets of design proposals, then perform the comparison. Has the possibility very much in the plan which finally designated, has used certain not in plan some ideas which accepts.When the general shape and a few dimensions of the several components become apparent, analysis can begin in earnest. The analysis will have as its objective satisfactory or superior performance, plus safety and durability with minimum weight, and a competitive cost. Optimum proportions and dimensions will be sought for each critically loaded section, together with a balance between the strengths of the several components. Materials and their treatment will be chosen. These important objectives can be attained only by analysis based upon the principles of mechanics, such as those of static for reaction forces and for the optimum utilization of friction; of dynamics for inertia, acceleration, and energy; of elasticity and strength of materials for stress and deflection; of physical behavior of materials; and of fluid mechanics for lubrication and hydrodynamic drives. The analyses may be made by the same engineer who conceived the arrangement of mechanisms, or, in a large company, they may be made by a separate analysis division or research group. Design is a reiterative and cooperative process, whether done formally or informally, and the analyst can contribute to phases other than his own. Product design requires much research and development. Many Concepts of an idea must be studied, tried, and then either used or discarded. Although the content of each engineering problem is unique, the designers follow the similar process to solve the problems. Product liability suits designers and forced in material selection, using the best program. In the process of material, the most common problems for five (a) dont understand or not use about the latest application materials to the best information, (b) failed to foresee and consider the reasonable use material may (such as possible, designers should further forecast and consider due to improper use products. In recent years, many products liability in litigation, the use of products and hurt the plaintiff accused manufacturer, and won the decision), (c) of the materials used all or some of the data, data, especially when the uncertainty long-term performance data is so, (d) quality control method is not suitable and unproven, (e) by some completely incompetent persons choose materials.Through to the above five questions analysis, may obtain these questions is does not have the sufficient reason existence the conclusion. May for avoid these questions to these questions research analyses the appearance indicating the direction. Although uses the best choice of material method not to be able to avoid having the product responsibility lawsuit, designs the personnel and the industry carries on the choice of material according to the suitable procedure, may greatly reduce the lawsuit the quantity. May see from the above discussion, the choice material people should to the material nature, the characteristic and the processing method have comprehensive and the basic understanding. Finally, a design based upon function, and a prototype may be built. If its tests are satisfactory, the initial design will undergo certain modifications that enable it to be manufactured in quantity at a lower cost. During subsequent years of manufacture and service, the design is likely to undergo changes as new ideas are conceived or as further analyses based upon tests and experience indicate alterations. Sales appeal.Some Rules for DesignIn this section it is suggested that, applied with a creative attitude, analyses can lead to important improvements and to the conception and perfection of alternate, perhaps more functional, economical,and durable products. To stimulate creative thought, the following rules are suggested for the designer and analyst. The first six rules are particularly applicable for the analyst.1. A creative use of need of physical properties and control process.2. Recognize functional loads and their significance.3. Anticipate unintentional loads.4. Devise more favorable loading conditions.5. Provide for favorable stress distribution and stiffness with minimum weight.6. Use basic equations to proportion and optimize dimensions.7. Choose materials for a combination of properties.8. Select carefully, stock and integral components.9. Modify a functional design to fit the manufacturing process and reduce cost.10. Provide for accurate location and noninterference of parts in assembly. Machinery design covers the following contents.1. Provides an introduction to the design process , problem formulation ,safety factors.2. Reviews the material properties and static and dynamic loading analysis ,Including beam , vibration and impact loading. 3. Reviews the fundamentals of stress and defection analysis. 4. Introduces fatigue-failure theory with the emphasis on stress-life approaches to high-cycle fatigue design, which is commonly used in the design of rotation machinery. 5. Discusses thoroughly the phenomena of wear mechanisms, surface contact stresses ,and surface fatigue. 6. Investigates shaft design using the fatigue-analysis techniques. 7. Discusses fluid-film and rolling-element bearing theory and application 8. Gives a thorough introduction to the kinematics, design and stress analysis of spur gears , and a simple introduction to helical ,bevel ,and worm gearing. 9. Discusses spring design including compression ,extension and torsion springs. 10. Deals with screws and fasteners including power screw and preload fasteners. 11. Introduces the design and specification of disk and drum clutches and brakes.Machine DesignThe complete design of a machine is a complex process. The machine design is a creative work. Project engineer not only must have the creativity in the work, but also must in aspect and so on mechanical drawing, kinematics, engineerig material, materials mechanics and machine manufacture technology has the deep elementary knowledge. One of the first steps in the design of any product is to select the material from which each part is to be made. Numerous materials are available to todays designers. The function of the product, its appearance, the cost of the material, and the cost of fabrication are important in making a selection. A careful evaluation of the properties of a. material must be made prior to any calculations. Careful calculations are necessary to ensure the validity of a design. In case of any part failures, it is desirable to know what was done in originally designing the defective components. The checking of calculations (and drawing dimensions) is of utmost importance. The misplacement of one decimal point can ruin an otherwise acceptable project. All aspects of design work should be checked and rechecked. The computer is a tool helpful to mechanical designers to lighten tedious calculations, and provide extended analysis of available data. Interactive systems, based on computer capabilities, have made possible the concepts of computer aided design (CAD) and computer-aided manufacturing (CAM). How does the psychologist frequently discuss causes the machine which the people adapts them to operate. Designs personnels basic responsibility is diligently causes the machine to adapt the people. This certainly is not an easy work, because certainly does not have to all people to say in fact all is the most superior operating area and the operating process. Another important question, project engineer must be able to carry on the exchange and the consultation with other concerned personnel. In the initial stage, designs the personnel to have to carry on the exchange and the consultation on the preliminary design with the administrative personnel, and is approved. This generally is through the oral discussion, the schematic diagram and the writing material carries on. If front sues, the machine design goal is the production can meet the human need the product. The invention, the discovery and technical knowledge itself certainly not necessarily can bring the advantage to the humanity, only has when they are applied can produce on the product the benefit. Thus, should realize to carries on before the design in a specific product, must first determine whether the people do need this kind of productMust regard as the machine design is the machine design personnel carries on using creative ability the product design, the system analysis and a formulation product manufacture technology good opportunity. Grasps the project elementary knowledge to have to memorize some data and the formula is more important than. The merely service data and the formula is insufficient to the completely decision which makes in a good design needs. On the other hand, should be earnest precisely carries on all operations. For example, even if places wrong a decimal point position, also can cause the correct design to turn wrongly.A good design personnel should dare to propose the new idea, moreover is willing to undertake the certain risk, when the new method is not suitable, use original method. Therefore, designs the personnel to have to have to have the patience, because spends the time and the endeavor certainly cannot guarantee brings successfully. A brand-new design, the request screen abandons obsoletely many, knows very well the method for the people. Because many person of conservativeness, does this certainly is not an easy matter. A mechanical designer should unceasingly explore the improvement existing product the method, should earnestly choose originally, the process confirmation principle of design in this process, with has not unified it after the confirmation new idea. Grinding and grinding technology in the machinery manufacturing industry occupies an extremely important position, grinding technology has developed rapidly, plays a very important role in machining. With the development of high-precision, high hardness increase of the number of mechanical parts, precision casting and precision forging process, the performance of the grinder, variety and production in the continuous improvement and growth.Internal grinder is widely used in recent years, grinding technology has been rapid development of grinding of all kinds of new technologies, new processes and new finished product after another. International famous manufacturers, such as Japan OKAMMOTO, Mitsui Mitsui, Germany BLOHM ELB, ABA, Switzerland MAGERLE, Italy FAVRATO. In the development of CNC grinder production quantity, but also strive to improve the quality and accuracy of CNC grinding machines. Due to the use of CBN grinding wheel, power grinding break through the limitations of traditional grinding production ratio improved several times, the grinding line speed up to 120M / s, to eat deep creep feed grinding has also been widely used. The development of modern high-precision grinding technology, grinding, size precision of 0.1 0.3m, the surface roughness of 0.2 to 0.05, the residual stress of the grinding surface of the metamorphic layer are very small, and significantly improve the quality of the machined parts. CNC is an important aspect of the development of internal grinder. Foreign grinder for a long period of time, far below the rate of NC lathes and milling machines. In the last decade, due to the development of numerical control technology, suitable for grinding machines CNC system has made great progress, numerical control systems greatly improve the cost-effective. A powerful wide domestic application of high-speed grinding surface grinding speed is generally not more than 60 m / s, larger difference and abroad, the grinding efficiency is relatively poor, eat deep creep feed grinding method applied in our production Not much. With the rapid development of Chinas machinery manufacturing industry, the domestic requirements of CNC machine tools are getting higher and higher, independent research and development of high-precision machine tools, control technology gap with foreign countries, mainly adopts PLC control-oriented. Domestic Machine Tool Plant and Machine Tool Research Institute invested heavily in the development of CNC grinding and grinding technology has made some initial progress, CIMT exhibition Shanghai Machine Tool Works MKY7875 the Yunnan MIGHTY company SGS-618II, machine tool plant in Weihai MJ7116. The design focuses on CNC grinding machines to do part of the transformation to adapt to the processed products, simple processing, precise positioning to ensure that the size, improve processing efficiency, reduce labor intensity. The transformation of feed components on the the machine rails and drive to do some modifications to adapt the accuracy and efficiency of production. Servo motor drive components to achieve automatic control, the original sliding screw nut rotary motion into linear motion, and the use of the rolling guide, in order to improve the accuracy. Nature works hard to destroy bearings, but their chances of survival can be improved by following a few simple guidelines. Extreme neglect in a bearing leads to overheating and possibly seizure or, at worst, an explosion. But even a failed bearing leaves clues as to what went wrong. After a little detective work, action can be taken to avoid a repeat performance.Bearings fail for a number of reasons，but the most common are misapplication，contamination，improper lubricant，shipping or handling damage，and misalignment. The problem is often not difficult to diagnose because a failed bearing usually leaves telltale signs about what went wrongHowever，while a postmortem yields good information，it is better to avoid the process altogether by specifying the bearing correctly in The first placeTo do this，it is useful to review the manufacturers sizing guidelines and operating characteristics for the selected bearing.Equally critical is a study of requirements for noise, torque, and runout, as well as possible exposure to contaminants, hostile liquids, and temperature extremes. This can provide further clues as to whether a bearing is right for a job.1 Why bearings failAbout 40% of ball bearing failures are caused by contamination from dust, dirt, shavings, and corrosion. Contamination also causes torque and noise problems, and is often the result of improper handling or the application environmentFortunately, a bearing failure caused by environment or handling contamination is preventable，and a simple visual examination can easily identify the causeConducting a postmortem il1ustrates what to look for on a failed or failing bearingThen，understanding the mechanism behind the failure, such as brinelling or fatigue, helps eliminate the source of the problem.Brinelling is one type of bearing failure easily avoided by proper handing and assembly. It is characterized by indentations in the bearing raceway caused by shock loadingsuch as when a bearing is dropped-or incorrect assembly. Brinelling usually occurs when loads exceed the material yield point(350,000 psi in SAE 52100 chrome steel)It may also be caused by improper assembly, Which places a load across the racesRaceway dents also produce noise，vibration，and increased torque.A similar defect is a pattern of elliptical dents caused by balls vibrating between raceways while the bearing is not turningThis problem is called false brinelling. It occurs on equipment in transit or that vibrates when not in operation. In addition, debris created by false brinelling acts like an abrasive, further contaminating the bearing. Unlike brinelling, false binelling is often indicated by a reddish color from fretting corrosion in the lubricant.False brinelling is prevented by eliminating vibration sources and keeping the bearing well lubricated. Isolation pads on the equipment or a separate foundation may be required to reduce environmental vibration. Also a light preload on the bearing helps keep the balls and raceway in tight contact. Preloading also helps prevent false brinelling during transit.Seizures can be caused by a lack of internal clearance, improper lubrication, or excessive loading. Before seizing, excessive, friction and heat softens the bearing steel. Overheated bearings often change color，usually to blue-black or straw coloredFriction also causes stress in the retainer，which can break and hasten bearing failurePremature material fatigue is caused by a high load or excessive preloadWhen these conditions are unavoidable，bearing life should be carefully calculated so that a maintenance scheme can be worked outAnother solution for fighting premature fatigue is changing materialWhen standard bearing materials，such as 440C or SAE 52100，do not guarantee sufficient life，specialty materials can be recommended. In addition，when the problem is traced back to excessive loading，a higher capacity bearing or different configuration may be usedCreep is less common than premature fatigueIn bearingsit is caused by excessive clearance between bore and shaft that allows the bore to rotate on the shaftCreep can be expensive because it causes damage to other components in addition to the bearing0ther more likely creep indicators are scratches，scuff marks，or discoloration to shaft and boreTo prevent creep damage，the bearing housing and shaft fittings should be visually checkedMisalignment is related to creep in that it is mounting relatedIf races are misaligned or cockedThe balls track in a noncircumferencial pathThe problem is incorrect mounting or tolerancing，or insufficient squareness of the bearing mounting siteMisalignment of more than 1/4can cause an early failureContaminated lubricant is often more difficult to detect than misalignment or creepContamination shows as premature wearSolid contaminants become an abrasive in the lubricantIn addition。insufficient lubrication between ball and retainer wears and weakens the retainerIn this situation，lubrication is critical if the retainer is a fully machined typeRibbon or crown retainers，in contrast，allow lubricants to more easily reach all surfaces Rust is a form of moisture contamination and often indicates the wrong material for the applicationIf the material checks out for the job，the easiest way to prevent rust is to keep bearings in their packaging，until just before installation2 Avoiding failuresThe best way to handle bearing failures is to avoid themThis can be done in the selection process by recognizing critical performance characteristicsThese include noise，starting and running torque，stiffness，nonrepetitive runout，and radial and axial playIn some applications, these items are so critical that specifying an ABEC level alone is not sufficientTorque requirements are determined by the lubricant，retainer，raceway quality(roundness cross curvature and surface finish)，and whether seals or shields are usedLubricant viscosity must be selected carefully because inappropriate lubricant，especially in miniature bearings，causes excessive torqueAlso，different lubricants have varying noise characteristics that should be matched to the application. For example，greases produce more noise than oilNonrepetitive runout(NRR)occurs during rotation as a random eccentricity between the inner and outer races，much like a cam actionNRR can be caused by retainer tolerance or eccentricities of the raceways and ballsUnlike repetitive runout, no compensation can be made for NRR.NRR is reflected in the cost of the bearingIt is common in the industry to provide different bearing types and grades for specific applicationsFor example，a bearing with an NRR of less than 0.3um is used when minimal runout is needed，such as in diskdrive spindle motorsSimilarly，machinetool spindles tolerate only minimal deflections to maintain precision cutsConsequently, bearings are manufactured with low NRR just for machine-tool applicationsContamination is unavoidable in many industrial products，and shields and seals are commonly used to protect bearings from dust and dirtHowever，a perfect bearing seal is not possible because of the movement between inner and outer racesConsequently，lubrication migration and contamination are always problemsOnce a bearing is contaminated, its lubricant deteriorates and operation becomes noisierIf it overheats，the bearing can seizeAt the very least，contamination causes wear as it works between balls and the raceway，becoming imbedded in the races and acting as an abrasive between metal surfacesFending off dirt with seals and shields illustrates some methods for controlling contaminationNoise is as an indicator of bearing qualityVarious noise grades have been developed to classify bearing performance capabilitiesNoise analysis is done with an Anderonmeter, which is used for quality control in bearing production and also when failed bearings are returned for analysis. A transducer is attached to the outer ring and the inner race is turned at 1,800rpm on an air spindle. Noise is measured in andirons, which represent ball displacement in m/rad.With experience, inspectors can identify the smallest flaw from their sound. Dust, for example, makes an irregular crackling. Ball scratches make a consistent popping and are the most difficult to identify. Inner-race damage is normally a constant high-pitched noise, while a damaged outer race makes an intermittent sound as it rotates.Bearing defects are further identified by their frequencies. Generally, defects are separated into low, medium, and high wavelengths. Defects are also referenced to the number of irregularities per revolution.Low-band noise is the effect of long-wavelength irregularities that occur about 1.6 to 10 times per revolution. These are caused by a variety of inconsistencies, such as pockets in the race. Detectable pockets are manufacturing flaws and result when the race is mounted too tightly in multiplejaw chucks.Medium-hand noise is characterized by irregularities that occur 10 to 60 times per revolution. It is caused by vibration in the grinding operation that produces balls and raceways. High-hand irregularities occur at 60 to 300 times per revolution and indicate closely spaced chatter marks or widely spaced, rough irregularities.Classifying bearings by their noise characteristics allows users to specify a noise grade in addition to the ABEC standards used by most manufacturers. ABEC defines physical tolerances such as bore, outer diameter, and runout. As the ABEC class number increase (from 3 to 9), tolerances are tightened. ABEC class, however, does not specify other bearing characteristics such as raceway quality, finish, or noise. Hence, a noise classification helps improve on the industry standard.中文译文中文译文机械设计机械设计摘要：摘要：机器是由机械装置和其它组件组成的。它是一种用来转换或传递能量的装置，例如：发动机、涡轮机、车辆、起重机、印刷机、洗衣机、照相机和摄影机等。许多原则和设计方法不但适用于机器的设计，也适用于非机器的设计。术语中的“机械装置设计” 的含义要比“机械设计”的含义更为广泛一些，机械装置设计包括机械设计。在分析运动及设计结构时，要把产品外型以及以后的保养也要考虑在机械设计中。在机械工程领域中，以及其它工程领域中，所有这些都需要机械设备，比如：开关、凸轮、阀门、船舶以及搅拌机等。关键词关键词：设计流程设计规则机械设计设计流程设计流程设计开始之前就要想到机器的实际性，现存的机器需要在耐用性、效率、重量、速度，或者成本上得到改善。新的机器必需具有以前机器所能执行的功能。在设计的初始阶段，应该允许设计人员充分发挥创造性，不要受到任何约束。即使产生了许多不切实际的想法，也会在设计的早期，即在绘制图纸之前被改正掉。只有这样，才不致于阻断创新的思路。通常,还要提出几套设计方案，然后加以比较。很有可能在这个计划最后决定中,使用了某些不在计划之内的一些设想。一般的当外型特点和组件部分的尺寸特点分析得透彻时，就可以全面的设计和分析。接着还要客观的分析机器性能的优越性，以及它的安全、重量、耐用性，并且竞争力的成本也要考虑在分析结果之内。每一个至关重要的部分要优化它的比例和尺寸，同时也要保持与其它组成部分相协调。也要选择原材料和处理原材料的方法。通过力学原理来分析和实现这些重要的特性，如那些静态反应的能量和摩擦力的最佳利用，像动力惯性、加速动力和能量；包括弹性材料的强度、应力和刚度等材料的物理特性，以及流体润滑和驱动器的流体力学。设计的过程是重复和合作的过程，无论是正式或非正式的进行，对设计者来说每个阶段都很重要。最后，以图样为设计的标准，并建立将来的模型。如果它的测试是符合事先要求的，则再将对初步设计进行某些修改，使它能够在制造成本上有所降低。产品的设计需要不断探索和发展。许多方案必须被研究、试验、完善，然后决定使用还是放弃。虽然每个工程学问题的内容是独特的，但是设计师可以按照类似的步骤来解决问题。产品的责任诉讼迫使设计人员和公司在选择材料时，采用最好的程序。在材料过程中，五个最常见的问题为：（a）不了解或者不会使用关于材料应用方面的最新最好的信息资料；(b)未能预见和考虑材料的合理用途（如有可能，设计人员还应进一步预测和考虑由于产品使用方法不当造成的后果。在近年来的许多产品责任诉讼案件中，由于错误地使用产品而受到伤害的原告控告生产厂家，并且赢得判决）；(c)所使用的材料的数据不全或是有些数据不确定，尤其是当其性能数据长期不更新；(d)质量控制方法不适当和未经验证；(e)由一些完全不称职的人员选择材料。通过对上述五个问题的分析，可以得出这些问题是没有充分理由而存在的结论。对这些问题的研究分析可以为避免这些问题的出现而指明方向。尽管采用最好的材料选择方法也不能避免发生产品责任诉讼，设计人员和工业界按照适当的程序进行材料选择，可以大大减少诉讼的数量。从以上的讨论可以看出，选择材料的人们应该对材料的性质，特点和加工方法有一个全面而基本的了解。在随后生产和售后服务的几年中，要接受新观念的变化，或者由试验和经验为基础，进一步分析并改进。一些设计规则一些设计规则在本节中，建议要运用创造性的态度来替代和改进。也许会创造出更实用、更经济、更耐用的产品。为了激发创造性思维，下列是设计和分析的建议规则。前六个规则对设计者来说特别适用。1.要有创造性的利用所需要的物理性质和控制过程。2.认识负载产生的影响及其意义。3.预测没有想到的负载。4.创造出对载荷更为有利的条件。5.提供良好的应力分布和最小的刚度条件。6.运用最简单的方程来优化体积和面积。7.选择组合材料。8.仔细选择所备的原料和不可缺少的组件。9.调整有效的设计方案，以适应生产过程和降低成本。10.规定好准确的位置条件为了使组件安装时不干涉。机械设计包括一下内容：1.对设计过程、设计所需要公式以及安全系数进行介绍。2.回顾材料特性、静态和动态载荷分析，包括梁、振动和冲击载荷。3.回顾应力的基本规律和失效分析。4.介绍静态失效理论和静态载荷下机械断裂分析。5.介绍疲劳失效理论并强调在压力条件下接近高循环的疲劳设计，这通常用在旋转机械的设计中。6.深入探讨机械磨损机理、表面接触应力和表面疲劳现象。7.使用疲劳分析技术校核轴的设计。8.讨论润滑油膜与滚动轴承的理论和应用。9.深入介绍直齿圆柱齿轮的动力学、设计和应力分析，并简单介绍斜齿轮、锥齿轮和涡轮有关方面的问题。10.讨论弹簧设计、螺杆等紧固件的设计，包括传动螺杆和预紧固件。11.介绍盘式和鼓式离合器以及制动器的设计和技术说明。机械设计机械设计一台完整机器的设计是一个复杂的过程。机械设计是一项创造性的工作。设计工程师不仅在工作上要有创造性，还必须在机械制图、运动学、工程材料、材料力学和机械制造工艺学等方面具有深厚的基础知识。任何产品在设计时第一步就是选择产品每个部分的构成材料。许多的材料被今天的设计师所使用。对产品的功能，它的外观、材料的成本、制造的成本作出必要的选择是十分重要的。对材料的特性必须事先作出仔细的评估。仔细精确的计算是必要的，以确保设计的有效性。在任何失败的情况下，最好知道在最初设计中有有缺陷的部件。计算（图纸尺寸）检查是非常重要的。一个小数点的位置放错，就可以导致一个本可以完成的项目失败。设计工作的各个方面都应该检查和复查。计算机是一种工具，它能够帮助机械设计师减轻繁琐的计算，并对现有数据提供进一步的分析。互动系统基于计算机的能力，已经使计算机辅助设计（CAD）和计算机辅助制造（CAM）成为了可能。心理学家经常谈论如何使人们适应他们所操作的机器。设计人员的基本职责是努力使机器来适应人们。这并不是一项容易的工作，因为实际上并不存在着一个对所有人来说都是最优的操作范围和操作过程。另一个重要问题，设计工程师必须能够同其他有关人员进行交流和磋商。在开始阶段，设计人员必须就初步设计同管理人员进行交流和磋商，并得到批准。这一般是通过口头讨论，草图和文字材料进行的。如前所诉，机械设计的目的是生产能够满足人类需求的产品。发明、发现和科技知识本身并不一定能给人类带来好处，只有当它们被应用在产品上才能产生效益。因而，应该认识到在一个特定的产品进行设计之前，必须先确定人们是否需要这种产品。应当把机械设计看成是机械设计人员运用创造性的才能进行产品设计、系统分析和制定产品的制造工艺学的一个良机。掌握工程基础知识要比熟记一些数据和公式更为重要。仅仅使用数据和公式是不足以在一个好的设计中做出所需的全部决定的。另一方面，应该认真精确的进行所有运算。例如，即使将一个小数点的位置放错，也会使正确的设计变成错误的。一个好的设计人员应该勇于提出新的想法，而且愿意承担一定的风险，当新的方法不适用时，就使用原来的方法。因此，设计人员必须要有耐心，因为所花费的时间和努力并不能保证带来成功。一个全新的设计，要求屏弃许多陈旧的，为人们所熟知的方法。由于许多人墨守成规，这样做并不是一件容易的事。一位机械设计师应该不断地探索改进现有的产品的方法，在此过程中应该认真选择原有的、经过验证的设计原理，将其与未经过验证的新观念结合起来。新设计本身会有许多缺陷和未能预料的问题发生，只有当这些缺陷和问题被解决之后，才能体现出新产品的优越性。因此，一个性能优越的产品诞生的同时，也伴随着较高的风险。应该强调的是，如果设计本身不要求采用全新的方法，就没有必要仅仅为了变革的目的而采用新方法。磨削技术及磨床技术在机械制造行业占有极其重要的位置，磨削技术发展很快，在机械加工中起着非常重要的作用。随着高精度、高硬度机械零件数量的增加，以及精密铸造和精密锻造工艺的发展，磨床的性能、品种和产量都在不断的提高和增长。由于内圆磨床应用十分广泛，近年来，磨削技术得到了飞速发展，各种磨削新技术、新工艺和新成品层出不穷。国际上有不少著名制造商，如日本的 OKAMMOTO、MITSUI三井，德国的 BLOHM、ELB、ABA，瑞士的 MAGERLE，意大利的 FAVRATO 等。在发展数控内圆磨床生产数量的同时，还要努力提高数控磨床的质量和精度。由于 CBN 砂轮的使用，强力磨削突破传统磨削的限制，生产倍率成倍提高，目前磨削线速度已高达120m/s，大吃深缓进给的强力磨削也得到了广泛应用。现代高精度磨削技术的发展，磨削尺寸精度达到 0.10.3m，表面粗糙度达到 0.20.05m，磨削表面变质层的残留应力均很小，明显提高了加工零件的质量。数控是内圆磨床发展的重要方面。在相当长的时期里，国外磨床的数控化率远远低于车床和铣床。在近十年来，由于数控技术的发展，适用于磨床的数控系统也有了较大发展，数控系统的性价比大大提高。目前国内高速磨削应用面不广，磨削速度一般不超过 60m/s，与国外相差较大，磨削效率也相对较差，大吃深缓进给的强力磨削方法在我国生产中应用不多。随着我国机械制造业迅猛发展，国内对数控机床的要求也越来越高，自主研发了高精度机床，在控制技术方面与国外差距还很大，，主要采用 PLC 控制为主。国内各机床厂和机床研究所对数控磨床及磨削技术的发展

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