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毕业设计(论文)中期报告题目: 凸轮轴零件的数控加工工艺设计及数控编程系 别 机电信息系 专 业 机械设计制造及其自动化 班 级 姓 名 学 号 导 师 2013年3月12日1. 设计（论文）进展状况 毕业设计工作已马上到了中期，我对自己的课题有了一定深度的认识。在初期，我已经完成了原理图的设计及开题报告的相关工作。在假期的时间里，我又下载了有关于凸轮轴以及数控加工方面的外文数据，以及对其进行了翻译。并且我从开学到现在的这几个星期里对自己的凸轮轴进行了工艺分析，夹具设计以及工艺卡片的制作。1.1生产纲领 生产类型生产纲领的大小对生产组织和零件加工工艺过程起着重要的作用，它决定了各工序所需专业化和自动化的程度，以及所应选用的工艺方法和工艺装备。零件生产纲领可按下式计算： N=Qn(1+a%+b%)由此公式可以算的凸轮轴的年生产量为10万件，根据生产纲领和生产类型的关系可以确定其生产类型是大批量生产。表1生产纲领与生产类型的关系11生产类型零件的年生产纲领（件）重型零件中型零件轻型零件单件生产小批生产中批生产大批生产大量生产5510010030030010001000101020020050050050005000100100500500500050050000500001.2材料的选择凸轮轴材料的选择：由于轴的载荷通常是变载荷，或变应力，故材料应具有较好的强度和韧性；对轴的表面与支承有相对滑动的轴，还须要求较好的耐磨性。材料 常用材料与热处理：凸轮轴常用材料是20Cr，20Cr的热处理及主要机构性能（参考）如表110表2 20Cr主要机构性能材料牌号热处理毛坯直径mm硬 度HBS抗拉强度极限b (Mpa)弯曲疲劳极限-1(Mpa)扭转疲劳极限-1/Mpa屈服极限s/Mpa20Cr渗碳淬火回火153060表面HRC50608506506505504004003752802802151601601.3热处理分析轴类零件的热处理是保证轴类零件性能的重要工艺过程，它对轴类零件的如下性能有着直接的影响：61）轴类零件的制造精度：组织转变不均匀、不彻底及热处理后形成的残余应力过大轴在热处理后的加工、装配和使用过程中的变形，从而降低轴的精度，甚至报废。2）轴类零件的强度：热处理工艺制定不当、热处理操作不规范或热处理设备状态不完好，造成被处理轴的强度（硬度）达不到设计要求。3）轴的工作寿命：热处理造成的组织结构不合理、晶粒度超标等，导致主要性能如轴的韧性、抗磨损性能等下降，影响轴的工作寿命。4）轴的制造成本：作为轴制造过程的中间环节或最终工序，热处理造成的开裂、变形超差及性能超差，大多数情况下会使轴报废，即使通过修补可以使用，也会增加工时，从而增加了轴的成本。凸轮轴材料是20Cr，对强度和韧性要求比较高，而表面易磨损需渗碳。渗碳的目的就是增加轴的耐磨性能、表面硬度、抗拉强度及疲劳极限。渗碳以后首先要进行淬火，用来提高其硬度和强度极限。但淬火时会引起内应力使之变脆，所以淬火以后必须要回火，回火的目的就是用来消除淬火后的脆性和内应力，提高其塑性和冲击韧度。但是对于凸轮轴来说，半成品热处理以前还有一道重要的工序，就是要对第一和第二个凸轮之间的外圆；第五和第六个凸轮之间的外圆用两顶的装加方式进行粗磨。这样做是因为轴类零件热处理以后会产生变形，既保证其同轴度。以便在热处理以后以这两个外圆为基准进行校核。1.4 夹具的设计磨床夹具按其通用化的程度和结构特点，可以分为通用夹具、专用夹具、组合夹具和成组可调夹具等等。凸轮轴加工时采用的是传动夹头，属于组合夹具类型。组合夹具是在夹具零部件标准化的基础上发展起来的一种新型工艺装备。它是由一套预先制造好的标准元件组装而成的。这些元件有各种不同的形状、不同规格的尺寸，它们相互配合部分的尺寸精度高、硬度高、耐磨性好，且具有完全的互换性。根据加工工艺的要求，可通过选择和使用标准元件和组合元件，很快装配出机械加工、检验、装配等所需的夹具来。使用完毕，可方便地拆卸、清洗、存放、留待以后再使用。组合夹具的特点：1、灵活多变；2、保证加工质量、提高生产效率；3、节省人力和物力；4、减少夹具存放面积。组合夹具的元件按其用途不同可以分为八大类，即：基础元件、支承元件、定位元件、导向元件、压紧元件、紧固元件、辅助元件及合件。其中，紧固元件包括各种螺栓、螺钉、螺母和垫圈等这些紧固元件均为常用的标准件。图1图1 夹具图传动夹头由非标准件手柄、定位销、定位板、弹簧、螺母、压盖、定位螺钉、传动板和标准件圆柱销、螺钉组合而成。 图2 传动板传动板是整个夹具的夹具体，也是夹具的关键部位（如图2），它上面有一个锥度孔，用来装夹凸轮轴的锥形端面。锥度孔和锥度面有自锁，在磨削时对凸轮轴进行夹紧，限制其自由度。 图3定位板定位板是通过定位螺杆固定在传动板上，它的作用是用来放置定位销（如图3）所示。 图 4手柄手柄是用来装定位销的，以便于定位销在使用时方便。如图4所示图5定位销定位销是在加工时对凸轮轴进行定位，装夹时定位销应放在凸轮轴装夹端的键槽内，限制凸轮轴的转动和移动的自由度。如图5所示1.5 拟定工艺路线清洗热处理钻中心孔车螺纹外圆磨（中间轴颈，轴间轴颈，锥面）凸轮磨（凸轮以及偏心轮）辅助加工清洗去毛刺检验入1.6磨削加工1.6.1外圆磨削1、机床选定：选用最常见的有MB1320外圆磨床和MK1620端面外圆磨床2、夹紧方案：利用螺母和两顶尖进行夹紧3、刀 具：外圆磨砂轮4、切削用量的选择：切削用量选择的顺序是先确定背吃刀量ap,再确定进给量f，最后确定切削速度uc。背吃刀量ap应选择尽量大的背吃刀量，尽量在一次走刀中，把本工序加工应切除的加工余量切除掉。在粗加工时，当加工余量过大或工艺系统刚性较差时，也可分两次走刀。在这一道工序中采用一次进刀： ap（2/33/4）A（2/33/4）0.99式中 A单边余量，mm进给量f定义：工件或刀具每转一周时，刀具与工件在进给运动方向上的相对位移量。进给量的选择与背吃刀量也有关，在已选定背吃刀量为0.99的前提下，查有关手册，选择进给量为：0.8mm/r切削速度ucUcD n粗/1000式中 D刀具直径 n加工时的速度查有关手册，取加工时的主轴转速为400r/mm。所以， UcD n粗/1000 1.98400/1000 74.1mm/r1.6.2凸轮磨削1、机床选定：常选用的机床有MXBS8312A凸轮磨床和CF41数控凸轮磨床2、夹紧方案：专用夹具和机床两顶尖3、刀 具：凸轮磨专用砂轮4、削用量的选择：切削用量选择的顺序是先确定背吃刀量ap,再确定进给量f，最后确定切削速度uc。背吃刀量ap应选择尽量大的背吃刀量，尽量在一次走刀中，把本工序加工应切除的加工余量切除掉。在粗加工时，当加工余量过大或工艺系统刚性较差时，也可分两次走刀。在这一道工序中采用一次进刀：ap（2/33/4）A（2/33/4）*（0.350.4）0.230.33式中 A单边余量mm进给量f定义：工件或刀具每转一周时，刀具与工件在进给运动方向上的相对位移量。切削速度uc UcD n粗/1000式中 D刀具直径 n加工时的速度查有关手册，取加工时的主轴转速为3000r/mm。所以， UcD n粗/1000 1.983000/1000 18651600mm/r2. 存在的问题及解决措施本课题主要研究的是凸轮轴零件的数控加工，主要难点就在于对凸轮轴的上的凸轮的定位进行加工，刀具的选择等。还有就是自己的数控模拟仿真技术软件的运用还不太熟练。解决措施：认真下功夫进行软件的学习并进行多次的模拟实践，和老师进行沟通，自己查阅书籍对凸轮轴进行更深一步的了解，借鉴别人经验进行对自己的凸轮轴加工方案的修改。3. 后期工作安排（1）9 -12周：完成工艺规程方案设计以及其他的零件图绘制（2）13-14周：撰写毕业设计论文 （3）15 周： 准备论文答辩 指导教师签字： 年 月 日- 7 -毕业设计(论文)外文资料翻译系 别： 机电信息系 专 业： 机械设计制造及其自动化 班 级： 姓 名： 学 号： 外文出处： Modern Machine Shop 附 件： 1. 原文； 2. 译文 2013年3月附件一：原文Digital system in the horizontal grinder application of the status quo and developmentRaymond Cooper，AmericanModern industrial production ,small and large parts for the production of products of the increasing proportion of parts complexity and precision requirements rapidy increase , the traditional general machine tools has become increasingly difficult to met the requirements of modern production ,and a high-precision CNC machine tools ,high-efficiency ,the use of a manchine can complete comple type face processing characteristics ,in particular the rapid development of computer technology and the widespread use of digital systems ,digital devices from almost all major software functions to achieve ,almost to a hardware ,thereby making it more flexible processing ,functional stronger. Manufacturing competition from lower labour costs early, product cost and improve their overall efficiency and qualitiy of competition ,to meet customer demands comprehensive ,actively develop new products competitive ,will face knowledgetechnicalupdated products has become shorter and shorter, an increasing number of small products, and the quality ,performance requirements are higher ,Meanwhile community to environmental protection ,the growing awareness of green manufacturing .therefore advanced manufacturing technology will be quickly won the competition and survival of the enterprise ,the principal means of development .Computer information technology and manufacturing automation tas an important foundation for digital machine in the production of machine tools to share more. First digital Ping finds the status quo and digital systems primaril . First, digital ping finds the status quo and digital systems primarily . Horizontal grinder compared to the lathe ,milling machine ,using digital systems later ,the special requirements because of its digital sustems .In the past decade ,with the technical facility ,grinder ,the grinding wheel for repair ,automatic compensation ,automatic exchange grinding wheel ,and more workstations ,such as automatic transmission and Zhuangjia working inoperable realized,and digital technology in the horizontal grinder ,gradually spread .In recent Hanover ,Tokyo ,Chicago ,and other large domestic machine tool exhibition ,CNC grinder throughout the grinder ,for the majority of the exhibits ,such as Germany Blohm company ELB conpanies such famous grinder factories no longer proudce ordinary grinder Japanese Forces ,Japan ,the company also Hing bulk production facility-wide functional ping himself .in the development of high-grade digital ping himself while actively developing ,low digital ping himself. German production company a few years ago ELB brilliant series two Coordinates facility shaped grinder ,the vertical and horizontal axis for digital ,vertical for hydraulic control ,grinding wheel repair work platform installed in a roller diamonds ,the application of brodader ;SUPER-BRILLIANT series is one-dimensional and shaped grinder Snzuobiao facility ,the beds are manufactured using natural granite ,high geometric accuracy ,slide away from straight rolling guide ,driving without recoiling machinery ,thus ensuring a better working surface smoothness ; BRILIANT-FUTURE series of improvements to the above two products ,using artificial granite bed was produced by static pressure vertical guide ,Chixing belt transmission ,vertical and horizontal guide for pre reinforced straight rolling guide , Gunzhusigang transmission ,three-axis CNC control AC servo electrical ,measuring 0.5m 16ug image .ELB company has also developed the latest Technology grinder contemporary products ,and integration with computer and technology-based series of soft skills CAM-MASTER processing modules CAD-MASTER series and COMPACT-MASTER series grinding processing center ,a maximum of up to 24 axis control axis ,As the full implementation of modular.Design and anufacture of dedicated grinder cycle shortened ELB company has also developed a variety of highly efficient dedicated grinder ,such as SFVG100/2 dedicated grinder ,which will tilt Motou ,continuous improvements, toease into ,processing center . British and Amrrican companies JONES&SHIPMAN A-B company developed A-B8600 digital systems for igital FORMAT5 type ping himself form the facility hydraulic control valves ,driven vertical movement can be governor, to the use of horizontal and Motou into Gunzhusigang deputy ,Electrical DC servo driven, intermittent style grinding wheel repair ,CRT graphics simulation showed .Also be used with other types of digital systems to meet different user requirements. Currently ,the semiconductor master degrees continual incrase in the newly introduced system in the appearance of smaller ,more compact strccture functions increased distance ommuications ,remote diagnosis ,multiple plane networking etc ;Interface to the Window operating system to increase the mouse .remote operation of vehicles .Fanuc major company this year launched 18,16I,20I,21Isystem Siemens is 840D,810D,802D are tight structure type system .There are a number of manufacturers such as : Taiwan Precision CNC controls on the use of the window operating system of NC ,and NT immediate multi-processing core ,single-section procedures for processing speed 2000 pieces /s,single-section pre-1000 time to deal with a few pieces ,with Aart (pre adaptation technologies) and the parameters of the best learing function would follow error convergence to zero ,the software process sing path filter tore duce maching process gener ate dby theac leration changes excessive me chanica lreson ance ,thereby improving surface roughness ; with the use of servo flexible ,with+, -10v analogy servo interface It also provides international standards SERCOS digital servo commu ication sinter face design Tixing tu PLC procedures ,structure expressions, functional pieces ,instructions code ,flowcharts , five grammar.Facilitate design ,communication and maintenance; long-range communications with the computer, instant remote maintenance functions; control can be extended to a maximum axle and spindle axis 64. I/O points which can be expanded to 792/528 point, the introduction of Pentium processors, high-speed Plc processing speed to 25K.Apart from the world famous Siemens, Fanuc digital systems, such as professional development and production of the plant has been applied to many horizontal or shaped grinding system, a number of production plants Ping finds itself actively developed application in the digital grinder system. Notably: Siemens SINUMERIK 840D of the system, the system has more than 20 roots servo axis, the coordinates for the trip control, manual data entry or imported through external computer, remote diagnosis may reduce the grinding wheel diameter change itinerary, grinding wheel repair of automatic compensation Gunzhusigang gap error compensation, Siemens 3G system is specifically for grinding and processing development, for both dialogue with the presentation devices operate in axis tilt, can also be straight and arc widely in grinding, recurring operational cycle, such as the main axis swing, and use external signal interruption implementation procedures, grinding wheel cut, grinding wheel repair, and other special functions for the preparation of a fixed cycle procedures. Not only can use its external measurement devices (switches signal), but when connected to a suitable time to first measurement and control devices directly to the ultimate size comparison.American companies ALLEY-BRANDLY production 8400CNC digital series apply lathe, milling machine and grinder, 8400CNC up to 6 roots servo axis control, the Section 2 axle may drain, the three axis may helix spaced, six axle straight drain. 8600CNC series of coordinates to control 17, including eight in the drain axle, eight spaces control axle and one allegation that a graphic shown that the expansion of branch procedures that processing time, high-speed access procedures, cutlery life monitoring.Japanese companies developed FANUC OG high-speed high performance digital system, which 0-GSG applicable to horizontal grinder ,the grinding parts under different shapes ,four different methods of grinding ,a grinding wheel axle angle cycle of grinding wheel flow position after finishing compensation function .Compared to repair vehicles were repaired round noemal line direction control functional grinding wheel shape graphics and grinding parameters show that the functional ,system smallest unit set 0.116ugm, a “tight ” type digital systems, lower prices .There are also companies such as Germany and University jointly developed by ELB UNICON system . Japanese big cove ironworker OSP5000G-G,OSP30-NF such as self development and shaped grinding digital print system ,the maximum control OSP5000G-G nine coordinates ,which can be linked six coordinates a 12-inch hall ,intractive programming, automatic identification of cutting factor used dikrttes imported ,into automated systems .the smallest pulse equivalent ,the mobile equivalent and testing equivalent 16ug are 0.1 m ,Ping himself also used simultaneously by the entire loop detectors.Although there is the ping himself factory using digital Zhujichang system ,but self development of software ,use it more suitable for horizontal and shaped grinding ,such as German company Siemens SINUMERIK 810 Jung based ,the company specialized software used by Jung Kontur programming language for a shaped grinding wheel repair, and graphics supporting operational functions. Japan sincerely companies in Fanuc digital systems hardware companies ,the OPL development language for grinding processing ,and so on .The liner electrical ,balance ,technology ,the growing due process,and greatlt enhance the efficacy of achine tools ,the application of appropriate measurement techniques for the development.附件二：译文数控系统在平面磨床上应用现状与发展趋势雷蒙德库珀 美国现代工业生产中，中、小批量零件的生产占产品数量的比例越来越高，零件的复杂性和精度要求迅速提高，传统的普通机床已经越来越难以适应现代化生产的要求，而数控机床具有高精度、高效率、一机多用，可以完成复杂型面加工过程的特点，特别是计算机技术的迅猛发展并广泛应用于数控系统中，数控装置的主要功能几乎全有软件来实现，硬件几乎能通用，从而使其更具加工柔性，功能更加强大。 制造业的竞争已从早期降低劳动力成本、产品成本，提高企业整体效率和质量的竞争，发展到全面满足顾客要求，积极开发新产品的竞争，将面临知识技术产品的更新周期越来越短，产品批量越来越小，而对质量、性能的要求更高，同时社会对环境保护、绿色制造的意识不断加强。因此敏捷先进的制造技术将成为企业赢得竞争和生存、发展的主要手段。计算机信息技术和制造自动化技术的结合越来越紧密，作为自动化柔性生产重要基础的数控机床在生产机床中所占比例将越来越多。数控平磨现状及主要数控系统 平面磨床相对于机床、铣床等采用数控系统较晚，因为他对数控系统的特殊要求。近 十几年来，借助CNC技术，磨床上砂轮的连续休整，自动补偿，自动交换砂轮，多工作台，自动传送和装夹工件等操作工程得以实现，数控技术在平面磨床上的逐步普及。在今年汉诺威、东京、芝加哥、及国内等大型机床展览会上，CNC磨床在整个磨床展品已占大多数，如德国BLOHM公司，ELB公司等著名磨床制造厂已经不再生产普通磨床，日本的冈本，日兴等公司也成批生产全功能CNC平磨，在开发高档数控平磨的同时，积极发汉中、低档数控平磨。 前几年德国ELB公司生产的BRILLIANT系列二坐标CNC成型磨床，其垂直和横向为数控轴，纵向为液压控制，砂轮修整采用安装在工作台上的金刚石滚轮，适用范围较广；SUPER-BRILLIANT系列是三坐标CNC平面和成型磨床，床身用天然花岗岩制成，几何精度较高，导轨用直线滚动导轨，机械驱动无反冲，从而保证工件有较好的表面光洁度；BRILLIANT-FUTURE为以上二个系列的改进产品，床身用人造花岗岩制成，纵向用静压导轨，齿形带传动，垂直和横向都贵为预加荷直线滚动导轨，滚珠丝杠传动，三轴CNC控制AC伺服电机，0.5um的测量分辨率。同时ELB公司开发了具有当代最新技术的磨床产品，即以机电一体化和计算机技术为基础的CAM-MASTER系列柔性加工单元，CAD-MASTER系列和COMPACT-MASTER系列磨削加工中心，控制轴最多可达24轴，另外由于全面推行模块化设计，使专用磨床制造周期缩短，ELB公司还开发了多种高效专用磨床，如SFVGA100/2专用磨床，具有可倾斜磨头，连续休整，缓进给，斜切入磨削功能，用十一根CNC控制轴，如同一台磨加工中心。英国JONES&SHIPMAN公司与美国A-B公司开发了A-B8600数控系统用于FORMAT5型数控平磨，由CNC控制液压阀，驱动纵向可调速运动，横向与磨头进给用滚珠丝杠副，直流伺服电机驱动，间断式砂轮修整，CRT图形模拟显示