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EG-6203四通道超声波轴承清洗机送料机构设计【14张CAD图纸+毕业论文】

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关键词：: eg 通道超声波轴承清洗机送料机构设计

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摘要

随着市场对产品质量要求的日益严格和国际上对环保要求力度的加强，我国精密零件清洗工业受到极大的挑战，长期在精密零件清洗领域占据主导地位的ODS类清洗工艺由于破坏臭氧层而被禁止使用，作为代替品出现的一些氯代烃清洗剂，水基清洗剂和碳氢溶剂由于分别具有毒性，水处理繁琐，清洗效果较差以及不易干燥，安全性较差等缺点。阻碍了国内清洗工业的发展。

本文主要对EG-6203型的轴承的生产中的清洗的工序的清洗设备的设计，它也是利用当今的科技超声波清洗代替了原来的机械清洗，工作过程如下：将要清洗的轴承放入自动上料机构的上料圆盘，上料圆盘在减速电机的带动下旋转，通过离心力的作用，轴承在挡料板的作用下，推料进入导归轨，再依次进入推料气缸的位置，在感应接触开关控制气缸在送料之前，上料台的导轨下有退磁器将轴承的磁性去掉，然后进入超声波清洗槽，然后是甩干槽，最后进入注脂包装生产线。本次设计的EG-6203型轴承超声波清洗机是PLC控制的全自动超声波清洗机。其具备了自动送料、自动感应退磁、自动记数、全程清洗喷淋风干、全程监控报警的功能。为现在的轴承制造业大大提高效率，使产品合格率大大提升。

关键词：超声波；轴承清洗机；上料机构；自动控制。

Abstract

With the market increasingly stringent requirements on product quality and the strengthening of the international requirements of environmental protection. Our precision parts cleaning industry is facing a great challenge. For the destruction of the ozone layer , the ODS class cleaning crafts are prohibited from using which has dominated for a long time in the field of precision parts cleaning. As a substitute for the emergence of some chlorinated hydrocarbon cleaning agents, Water-based cleaning agent and hydrocarbon solvents are toxic, water treatment is cumbersome. Besides, cleaning effect is less effective and hard to dry, what’s more, the security is low and other shortcomings. All those shortcomings have hindered the development of the domestic cleaning industry.

This paper focuses on the cleaning apparatus of the cleaning step in the production of the type EG-6203 bearing’s design. It uses current technology ultrasonic cleaning instead of the original mechanical cleaning, work processes are as follows: we take the bearing which has been cleaned in the automatic feed mechanism feeding disc, The feeding disc were rotated by the gear motor. Through the effects of Centrifugal force, and bearing in the role of a blocking plate Pusher are putted into the rail. And then turn into the pusher cylinder position. Sensor contact switch control cylinder before feeding back porcelain magnetic bearing is removed, and then into the ultrasonic cleaning tank, and then drying tank, and finally into the greasing packaging production line, feed station on the rail. The design of the EG-6203 bearing ultrasonic cleaning machine is PLC controlled automatic ultrasonic cleaning machine. With automatic feeding, auto-sensing demagnetization, automatic counting, the entire cleaning spray dried, monitor the entire alarm function. Now bearing manufacturing greatly improve efficiency, greatly enhance the rate of qualified products.

Key words: Ultrasonic wave；Bearing cleaning machine；Feeding mechanism；Automatic control.

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摘要III

AbstractIV

目录V

1 绪论1

1.1 课题来源1

1.2 课题意义1

1.2.1 超声波清洗的特点1

1.2.2 现代超声波在轴承清洗中的发展趋势2

1.3超声波的分类及其主要工作器件2

1.3.1 通用超声波清洗机3

1.3.2 超声清洗机用的超声波发生器3

1.3.3 专用超声波清洗机5

2 总体方案设计7

2.1 总体方案设计的综述7

2.2 超声波发生器8

2.2.1 超声波发生器的简述8

2.2.2 超声波发生器的原理8

2.3 清洗槽8

2.4 自动送料机构10

3 清洗槽的具体设计12

3.1 导轨的结构12

3.2 清洗油泵、风机的设计12

3.3 油喷针和风喷嘴设计14

4 自动送料机构的设计15

4.1原理、结构及工作过程15

4.2轴的设计及校核15

4.3轴承的设计和校核18

4.4挡料板的设计20

4.5齿轮的校核20

4.5.1 齿轮的失效形成20

4.5.2 齿轮设计的要求21

4.5.3 齿轮的设计及校核21

5 自动控制电路25

5.1 PLC简介25

5.1.1 下列为I/O分配表26

5.1.2 下列为本设计的程序符号注释表27

5.1.3 人机界面控制30

5.1.4 本程序的梯形图30

6 结论与展望32

6.1结论32

6.2不足之处及未来展望32

致谢33

参考文献34

1 绪论

1.1 课题来源

由于我在一家轴承制造厂家进行实习，在轴承的清洗过程中涉及到轴承的清洗，而轴承的清洗机在市场上有很多种，本人实习的公司用的是先进的超声波轴承清洗机，所以我就选取超声波轴承清洗机上的一个机构——送料机构进行设计。

人类对蝙蝠做实验并第一次发现超声波的时间是在1900年，第一次创造出超声波是1930年，首次创造出声强和声波频率都可以控制的超声波装置是在1918年,超声波清洗机在1951年首次出现的。超声清洗，是利用超声波的振动，加到洗涤液中，产生共振，从而用来洗去固体表面污渍的方法。当今,超声清洗凭借它独特的清洗效果，广泛地应用于各个行业。随着现代工业的发展，轴承制造业也相应的快速发展起来。当前的阶段，随着改革开放，我国加入世贸组织，我国逐步展开的工业化改造，迅速发展的新兴工业，快速增加的轴承需求，轴承制造业也随之蓬勃的发展起来，随着改革的深入，某些地区更为突出，出现了很多新的轴承制造企业。例如南通地区，过去几乎没有轴承制造厂，而近几年已迅速发展到100余家，并且增长没有放缓，继续上升。随着该行业的快速的发展，竞争也相应的变得更加的激烈，随之对清洗轴承的标准也变的高了，所以关于轴承清洗设备的需求数量变大。

1.2 课题意义

在市场经济的环境下，对产品质量要求越来越高。为保证产品质量，许多企业在产品生产过程中，将采用清洗工艺来提高产品质量，为企业创造良好的经济效益。当前在一些工业产品生产过程中，超声波清洗的优点是价格经济，洗净效果良好，特别是在国际社会对于环境要求更加苛刻的条件下，有利于环保。超声清洗机可以应用于清洗体形大小不一，形状复杂，清洁度要求高的工件。例如可用于清洗手机零件、飞机零件、电脑零件、动车发动机零件、精密轴承零件、花键、垫片、车刀、锯片、钻石、注射器和各种显微镜镜头等；还可以用于清洗电路板、晶片及超导器件、电子显象管内的精密零件、电磁性元件、硅片、插座、相关的核材料、电极引线等电子类产品。

我国加入WTO后，国外越来越多的厂家已经落户中国，产品质量竞争和静音轴承的开发、应用也势在必行，提高轴承洁净度水平也可促进和改善现有轴承的清洗技术和工艺管理水平，同时也是提高我国轴承行业国际竞争力的有效手段之一。

1.2.1 超声波清洗的特点

超声波清洗与其它清洗相比具有洗净率高、残留物少,清洗时间短,清洗效果好，凡是能被液体浸到的被清洗件，超声对它都有清洗作用。不受清洗件表面形状限止，例深孔、狭缝、凹槽。都能得到清洗。由于超声波发生器采用D类工作放大,换能器的电声效率高，因此超声清洗具有高效节能。它是一种真正高速、高质量、能易实现自动化的清洗技术。若清洗剂采用非ODS清洗剂则具有绿色环保清洗作用。超声清洗对玻璃、金属等反射强的物体其清洗效果好，而不适宜纺织品、多孔泡沫塑料、橡胶制品等声吸收强的材料。

电子材料加工成型后的清洗：如晶片、硅片、压电陶瓷片等电子材料是供给元器件厂家的产品，其产品出厂前必须清洗，特别是做出口业务的厂家，其产品清洗成为一大难题，超声波清洗是最有效的途径。以下是超声波清洗技术的具体应用范围：

(1) 机械行业：防锈油脂的去除；量具的清洗；机械零部件的除油除锈；发动机、化油器及汽车零件的清洗；过滤器、滤网的疏通清洗等。

(2) 表面处理行业：电镀前的除油除锈；离子镀前清洗；磷化处理；清除积炭；清除氧化皮；清除抛光膏；金属工件表面活化处理等。

(3) 仪器仪表行业：精密零件的高清洁度装配前的清洗等。

(4) 电子行业：印刷线路板除松香、焊斑；高压触点等机械电子零件的清洗等。

(5) 医疗行业：医疗器械的清洗、消毒、杀菌、实验器皿的清洗等。

(6) 半导体行业：半导体晶片的高清洁度清洗。

(7) 钟表首、饰行业：清除油泥、灰尘、氧化层、抛光膏等。

(8) 化学、生物行业：实验器皿的清洗、除垢。

(9) 光学行业：光学器件的除油、除汗、清灰等。

(10) 纺织印染行业：清洗纺织锭子、喷丝板等。

(11) 石油化工行业：金属滤网的清洗疏通、化工容器、交换器的清洗等。

1.2.2 现代超声波在轴承清洗中发展趋势

轴承在当今的国民生产的应用是非常广泛的。中国是轴承生产大国，清洗是轴承的合套后的一道重要的工序。清洗的好坏决定了轴承的合格率。轴承的内外圈在加工打磨之后就产生了细小的颗粒和磁性。在自动化之前，直至现在一些小厂还沿用独立的退磁机去磁然后用机械式的液体压力清洗。这样大大浪费劳动力和减少工作效率。在超声波的出现后，现在采用的超声波清洗，由发生器输出超音频振荡电功率，经换能器将电功率换成超声机械振动，清洗液在超声振动下，产生具有数千万个大气压的微核波，形成液面与被清洗面间的高速核气流，使粘附被清洗件表面的各类污物剥落使产品合格率大大提升，同时提高效率，减少劳动力。

本次毕业设计的四通道超声波轴承清洗机是采用PLC控制的全自动的超声波清洗机。在PLC自动控制器的控制下自动送料、自动感应退磁、自动记数、全程清洗喷淋风干、全程监控报警在现代化的制造加工。

生产过程中，消耗于送料的时间损失是组成零件单件加工时间的一部分，它属于辅助时间。要想提高生产率，减少生产中的辅助时间将是非常重要的一个环节。而要想减少辅助时间，就必须提高生产的自动化程度。自动送料机构就是为实现生产中送料工序自动化而设计的一种专用机构。在以前的轴承清洗中的清洗、退磁都分开进行的，在如今全自动的生产中大大节约了时间，节约了生产成本。同时还按用户特殊要求研制、开发、生产了用于清洗软磁器件、精密轴承零件的专用超声波清洗设备，在生产中发挥了良好的作用加之超声波清洗和自动送料和退磁、清洗同步进行使如今的轴承的制造清洗的效率大大提高，减少劳动力，也使产品合格率大大提升。

内容简介：: 编号无锡太湖学院毕业设计（论文）相关资料题目： EG-6203四通道超声波轴承清洗机送料机构设计信机系机械工程及自动化专业学号： 0923242学生姓名：马佳富指导教师：范圣耀（职称：副教授）（职称：）2013年5月25日目录一、毕业设计（论文）开题报告二、毕业设计（论文）外文资料翻译及原文三、学生“毕业论文（论文）计划、进度、检查及落实表”四、实习鉴定表无锡太湖学院毕业设计（论文）开题报告题目： EG-6203四通道超声波轴承清洗机送料机构设计信机系机械工程及自动化专业学号： 0923242 学生姓名：马佳富指导教师：范圣耀（职称：副教授）（职称：）2012年11月25日课题来源由于我在一家轴承制造厂家进行实习，在轴承的清洗过程中涉及到轴承的清洗，而轴承的清洗机在市场上有很多种，本人实习的公司用的是先进的超声波轴承清洗机，所以我就选取超声波轴承清洗机上的一个机构送料机构进行设计。科学依据（包括课题的科学意义；国内外研究概况、水平和发展趋势；应用前景等）（1）课题科学意义超声波清洗(简称超声清洗)是将超声波的振动加人到洗涤液中用以清洗固体表面的方法。现在,超声清洗以其独特的清洗效果泛地应用于机械、电子、电脑、轻工、医疗、化工、五金、仪表、电镀等行业。在市场经济的环境下，对产品质量要求越来越高。为保证产品质量，许多企业在产品生产过程中，将采用清洗工艺来提高产品质量，为企业创造良好的经济效益。当前在一些工业产品生产过程中，应用超声波清洗是一种洗净效果好，价格经济，有利于环保的清洗工艺。超声波清洗机可以应用于清洗各式各样体形大小，形状复杂，清洁度要求高的许多工件。(2）超声波轴承清洗机的研究状况及其发展前景轴承在当今的国民生产的应用是非常广泛的。中国是轴承生产大国，清洗是轴承的合套后的一道重要的工序。清洗的好坏决定了轴承的合格率。轴承的内外圈在加工打磨之后就产生了细小的颗粒和磁性。在自动化之前，直至现在一些小厂还沿用独立的退磁机去磁然后用机械式的液体压力清洗。这样大大浪费劳动力和减少工作效率。在超声波的出现后，现在采用的超声波清洗，由发生器输出超音频振荡电功率，经换能器将电功率换成超声机械振动，清洗液在超声振动下，产生具有数千万个大气压的微核波，形成液面与被清洗面间的高速核气流，使粘附被清洗件表面的各类污物剥落使产品合格率大大提升，同时提高效率，减少劳动力。以下是超声波清洗技术的具体应用范围：(1) 机械行业：防锈油脂的去除；量具的清洗；机械零部件的除油除锈；发动机、化油器及汽车零件的清洗；过滤器、滤网的疏通清洗等。 (2) 表面处理行业：电镀前的除油除锈；离子镀前清洗；磷化处理；清除积炭；清除氧化皮；清除抛光膏；金属工件表面活化处理等。 (3) 仪器仪表行业：精密零件的高清洁度装配前的清洗等。 (4) 电子行业：印刷线路板除松香、焊斑；高压触点等机械电子零件的清洗等。 (5) 医疗行业：医疗器械的清洗、消毒、杀菌、实验器皿的清洗等。 (6) 半导体行业：半导体晶片的高清洁度清洗。 (7) 钟表首、饰行业：清除油泥、灰尘、氧化层、抛光膏等。 (8) 化学、生物行业：实验器皿的清洗、除垢。研究内容熟悉超声波清洗技术的发展历程，特别是近十几年来提出的对于轴承进行的全自动的清洗技术。熟练掌握超声波清洗设备的分类，超声波清洗时的工艺流程以及相关的要求；了解超声波清洗机的内部主要器件及其作用；掌握超声波送料机构上的各个零件的大小、受力情况，使其能够在安全系数内安全工作；对PLC技术在超声波清洗装备中的应用，使设备能够进行全自动清洗。拟采取的研究方法、技术路线、实验方案及可行性分析（1）实验方案将超声波清洗机分成几个主要组成部分，对每个部分块进行介绍分析；对送料机构进行受力分析及校核；对校核后的轴取合适的直径，在最经济的条件下，轴能在安全系数的条件下安全工作；对自动送料机构进行plc设计。（2）研究方法在理想的工作条件下，分析轴的受力情况，绘制轴的矩形图。在理想的工作条件下，对轴上各个零件进行受力分析，选取合适的零件。研究计划及预期成果研究计划：2012年10月12日-2012年12月25日：按照任务书要求查阅论文相关参考资料，填写毕业设计开题报告书。2013年1月11日-2013年3月5日：填写毕业实习报告。2013年3月8日-2013年3月14日：按照要求修改毕业设计开题报告。2013年3月15日-2013年3月21日：学习并翻译一篇与毕业设计相关的英文材料。2013年3月22日-2013年4月11日：送料机构的设计。2013年4月12日-2013年4月25日：plc的设计。2013年4月26日-2013年5月21日：毕业论文撰写和修改工作。预期成果：了解超声波清洗技术的发展历程，熟练掌握超声波清洗设备的分类，超声波清洗时的工艺流程以及相关的要求；了解超声波清洗机的内部主要器件及其作用；掌握超声波清洗机内部相关器件的结构、工作原理和注意条件；对超声波清洗机的总的电路图有所了解；掌握超声波送料机构上的各个零件的大小、受力情况；使其能够在安全系数内安全工作对PLC技术在超声波清洗装备中的应用，使设备能够进行全自动清洗。特色或创新之处PLC技术在超声波清洗装备中的应用，使设备能够进行全自动清洗。采用固定某些参量、改变某些参量来研究问题的方法，思路清晰，简洁明了，行之有效。已具备的条件和尚需解决的问题实验方案思路已经非常明确，通过对送料机构中轴的设计，选取合适的轴承、齿轮以及其他安装在轴上的零件。对轴上的润滑尚未讨论分析。指导教师意见指导教师签名：年月日教研室（学科组、研究所）意见教研室主任签名：年月日系意见主管领导签名：年月日无锡太湖学院毕业设计（论文）外文资料翻译院（系）：信机系专业：机械工程及自动化班级：机械95班姓名：马佳富学号： 0923242 外文出处：中国期刊网附件：译文；原文；评分表 2013年 5 月Fundamentals of Mechanical Design And TheoryMechanical design means the design of things and systems of a mechanical naturemachines, products, structures, devices, and instruments. For the most part mechanical design utilizes mathematics, the materials sciences, and the engineering-mechanics sciences. The total design process is of interest to us. How does it begin? Does the engineer simply sit down at his desk with a blank sheet of paper? And, as he jots down some ideas, what happens next? What factors influence or control the decisions which have to be made? Finally, then, how does this design process end? Sometimes, but not always, design begins when an engineer recognizes a need and decides to do something about it. Recognition of the need and phrasing it in so many words often constitute a highly creative act because the need may be only a vague discontent, a feeling of uneasiness, of a sensing that something is not right. The need is usually not evident at all. For example, the need to do something about a food-packaging machine may be indicated by the noise level, by the variations in package weight, and by slight but perceptible variations in the quality of the packaging or wrap. There is a distinct difference between the statement of the need and the identification of the problem. Which follows this statement? The problem is more specific. If the need is for cleaner air, the problem might be that of reducing the dust discharge from power-plant stacks, or reducing the quantity of irritants from automotive exhausts. Definition of the problem must include all the specifications for the thing that is to be designed. The specifications are the input and output quantities, the characteristics of the space the thing must occupy and all the limitations on these quantities. We can regard the thing to be designed as something in a black box. In this case we must specify the inputs and outputs of the box together with their characteristics and limitations. The specifications define the cost, the number to be manufactured, the expected life, the range, the operating temperature, and the reliability. There are many implied specifications which result either from the designers particular environment or from the nature of the problem itself. The manufacturing processes which are available, together with the facilities of a certain plant, constitute restrictions on a designers freedom, and hence are a part of the implied specifications. A small plant, for instance, may not own cold-working machinery. Knowing this, the designer selects other metal-processing methods which can be performed in the plant. The labor skills available and the competitive situation also constitute implied specifications. After the problem has been defined and a set of written and implied specifications has been obtained, the next step in design is the synthesis of an optimum solution. Now synthesis cannot take place without both analysis and optimization because the system under design must be analyzed to determine whether the performance complies with the specifications. The design is an iterative process in which we proceed through several steps, evaluate the results, and then return to an earlier phase of the procedure. Thus we may synthesize several components of a system, analyze and optimize them, and return to synthesis to see what effect this has on the remaining parts of the system. Both analysis and optimization require that we construct or devise abstract models of the system which will admit some form of mathematical analysis. We call these models mathematical models. In creating them it is our hope that we can find one which will simulate the real physical system very well. Evaluation is a significant phase of the total design process. Evaluation is the final proof of a successful design, which usually involves the testing of a prototype in the laboratory. Here we wish to discover if the design really satisfies the need or needs. Is it reliable? Will it compete successfully with similar products? Is it economical to manufacture and to use? Is it easily maintained and adjusted? Can a profit be made from its sale or use? Communicating the design to others is the final, vital step in the design process. Undoubtedly many great designs, inventions, and creative works have been lost to mankind simply because the originators were unable or unwilling to explain their accomplishments to others. Presentation is a selling job. The engineer, when presenting a new solution to administrative, management, or supervisory persons, is attempting to sell or to prove to them that this solution is a better one. Unless this can be done successfully, the time and effort spent on obtaining the solution have been largely wasted. Basically, there are only three means of communication available to us. There are the written, the oral, and the graphical forms. Therefore the successful engineer will be technically competent and versatile in all three forms of communication. A technically competent person who lacks ability in any one of these forms is severely handicapped. If ability in all three forms is lacking, no one will ever know how competent that person is! The competent engineer should not be afraid of the possibility of not succeeding in a presentation. In fact, occasional failure should be expected because failure or criticism seems to accompany every really creative idea. There is a great to be learned from a failure, and the greatest gains are obtained by those willing to risk defeat. In the find analysis, the real failure would lie in deciding not to make the presentation at all. Introduction to Machine Design Machine design is the application of science and technology to devise new or improved products for the purpose of satisfying human needs. It is a vast field of engineering technology which not only concerns itself with the original conception of the product in terms of its size, shape and construction details, but also considers the various factors involved in the manufacture, marketing and use of the product. People who perform the various functions of machine design are typically called designers, or design engineers. Machine design is basically a creative activity. However, in addition to being innovative, a design engineer must also have a solid background in the areas of mechanical drawing, kinematics, dynamics, materials engineering, strength of materials and manufacturing processes. As stated previously, the purpose of machine design is to produce a product which will serve a need for man. Inventions, discoveries and scientific knowledge by themselves do not necessarily benefit people; only if they are incorporated into a designed product will a benefit be derived. It should be recognized, therefore, that a human need must be identified before a particular product is designed. Machine design should be considered to be an opportunity to use innovative talents to envision a design of a product is to be manufactured. It is important to understand the fundamentals of engineering rather than memorize mere facts and equations. There are no facts or equations which alone can be used to provide all the correct decisions to produce a good design. On the other hand, any calculations made must be done with the utmost care and precision. For example, if a decimal point is misplaced, an otherwise acceptable design may not function. Good designs require trying new ideas and being willing to take a certain amount of risk, knowing that is the new idea does not work the existing method can be reinstated. Thus a designer must have patience, since there is no assurance of success for the time and effort expended. Creating a completely new design generally requires that many old and well-established methods be thrust aside. This is not easy since many people cling to familiar ideas, techniques and attitudes. A design engineer should constantly search for ways to improve an existing product and must decide what old, proven concepts should be used and what new, untried ideas should be incorporated. New designs generally have “bugs” or unforeseen problems which must be worked out before the superior characteristics of the new designs can be enjoyed. Thus there is a chance for a superior product, but only at higher risk. It should be emphasized that if a design does not warrant radical new methods, such methods should not be applied merely for the sake of change. During the beginning stages of design, creativity should be allowed to flourish without a great number of constraints. Even though many impractical ideas may arise, it is usually easy to eliminate them in the early stages of design before firm details are required by manufacturing. In this way, innovative ideas are not inhibited. Quite often, more than one design is developed, up to the point where they can be compared against each other. It is entirely possible that the design which ultimately accepted will use ideas existing in one of the rejected designs that did not show as much overall promise. Psychologists frequently talk about trying to fit people to the machines they operate. It is essentially the responsibility of the design engineer to strive to fit machines to people. This is not an easy task, since there is really no average person for which certain operating dimensions and procedures are optimum. Another important point which should be recognized is that a design engineer must be able to communicate ideas to other people if they are to be incorporated. Initially the designer must communicate a preliminary design to get management approval. This is usually done by verbal discussions in conjunction with drawing layouts and written material. To communicate effectively, the following questions must be answered: (1) Does the design really serve a human need? (2) Will it be competitive with existing products of rival companies? (3) Is it economical to produce? (4) Can it be readily maintained? (5) Will it sell and make a profit? Only time will provide the true answers to the preceding questions, but the product should be designed, manufactured and marketed only with initial affirmative answers. The design engineer also must communicate the finalized design to manufacturing through the use of detail and assembly drawings. Quite often, a problem well occur during the manufacturing cycle. It may be that a change is required in the dimensioning or telegramming of a part so that it can be more readily produced. This falls in the category of engineering changes which must be approved by the design engineer so that the product function will not be adversely affected. In other cases, a deficiency in the design may appear during assembly or testing just prior to shipping. These realities simply bear out the fact that design is a living process. There is always a better way to do it and the designer should constantly strive towards finding that better way. Machining Turning The engine lathe, one of the oldest metal removal machines, has a number of useful and highly desirable attributes. Today these lathes are used primarily in small shops where smaller quantities rather than large production runs are encountered. The engine lathe has been replaced in todays production shops by a wide variety of automatic lathes such as automatic of single-point tooling for maximum metal removal, and the use of form tools for finish and accuracy, are now at the designers fingertips with production speeds on a par with the fastest processing equipment on the scene today. Tolerances for the engine lathe depend primarily on the skill of the operator. The design engineer must be careful in using tolerances of an experimental part that has been produced on the engine lathe by a skilled operator. In redesigning an experimental part for production, economical tolerances should be used. Turret Lathes Production machining equipment must be evaluated now, more than ever before, in terms of ability to repeat accurately and rapidly. Applying this criterion for establishing the production qualification of a specific method, the turret lathe merits a high rating. In designing for low quantities such as 100 or 200 parts, it is most economical to use the turret lathe. In achieving the optimum tolerances possible on the turret lathe, the designer should strive for a minimum of operations. Automatic Screw Machines Generally, automatic screw machines fall into several categories; single-spindle automatics, multiple-spindle automatics and automatic chucking machines. Originally designed for rapid, automatic production of screws and similar threaded parts, the automatic screw machine has long since exceeded the confines of this narrow field, and today plays a vital role in the mass production of a variety of precision parts. Quantities play an important part in the economy of the parts machined on the automatic to set up on the turret lathe than on the automatic screw machine. Quantities less than 1000 parts may be more economical to set up on the turret lathe than on the automatic screw machine. The cost of the parts machined can be reduced if the minimum economical lot size is calculated and the proper machine is selected for these quantities. Automatic Tracer Lathes Since surface roughness depends greatly upon material turned, tooling, and fees and speeds employed, minimum tolerances that can be held on automatic tracer lathes are not necessarily the most economical tolerances. Is some case, tolerances of 0.05mm are held in continuous production using but one cut. Groove width can be held to 0.125mm on some parts. Bores and single-point finishes can be held to 0.0125mm. On high-production runs where maximum output is desirable, a minimum tolerance of 0.125mm is economical on both diameter and length of turn. Milling With the exceptions of turning and drilling, milling is undoubtedly the most widely used method of removing metal. Well suited and readily adapted to the economical production of any quantity of parts, the almost unlimited versatility of the milling process merits the attention and consideration of designers seriously concerned with the manufacture of their product. As in any other process, parts that have to be milled should be designed with economical tolerances that can be achieved in production milling. If the part is designed with tolerances finer than necessary, additional operations will have to be added to achieve these tolerancesand this will increase the cost of the part. Grinding is one of the most widely used methods of finishing parts to extremely close tolerances and low surface roughness. Currently, there are grinders for almost for almost every type of grinding operation. Particular design features of a part dictate to a large degree the type of grinding machine required. Where processing costs are excessive, parts redesigned to utilize a less expensive, higher output grinding method may be well worthwhile. For example, wherever possible the production economy of center less grinding should be taken advantage of by proper design consideration. Although grinding is usually considered a finishing operation, it is often employed as a complete machining process on work which can be ground down from rough condition without being turned or otherwise machined. Thus many types of forgings and other parts are finished completely with the grinding wheel at appreciable savings of time and expense. Classes of grinding machines include the following: cylindrical grinders, center less grinders, internal grinders, surface grinders, and tool and cutter grinders. The cylindrical and center less grinders are for straight cylindrical or taper work; thus splices, shafts, and similar parts are ground on cylindrical machines either of the common-center type or the center less machine. Thread grinders are used for grinding precision threads for thread gages, and threads on precision parts where the concentricity between the diameter of the shaft and the pitch diameter of the thread must be held to close tolerances. The internal grinders are used for grinding of precision holes, cylinder bores, and similar operations where bores of all kinds are to be finished. The surface grinders are for finishing all kinds of flat work, or work with plain surfaces which may be operated upon either by the edge of a wheel or by the face of a grinding wheel. These machines may have reciprocating or rotating tables.The machine design is through designs the new product or improves the old product to meet the human need the application technical science. It involves the project technology each domain, mainly studies the product the size, the shape and the detailed structure basic idea, but also must study the product the personnel which in aspect the and so on manufacture, sale and use question. Carries on each kind of machine design work to be usually called designs the personnel or machine design engineer. 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, engineer material, materials mechanics and machine manufacture technology has the deep elementary knowledge. 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 product Must 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 conservativenes, 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. Newly designs itself can have the question occurrence which many flaws and has not been able to expect, only has after these flaws and the question are solved, can manifest new goods come into the market the product superiority. Therefore, a performance superior product is born at the same time, also is following a higher risk. Should emphasize, if designs itself does not request to use the brand-new method, is not unnecessary merely for the goal which transform to use the new method. In 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. 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. In order to carry on the effective exchange, needs to solve the following problem: (1) designs whether this product truly does need for the people? Whether there is competitive ability (2) does this product compare with other companies existing similar products? (3) produce this kind of product is whether economical? (4) product service is whether convenient? (5) product whether there is sale? Whether may gain? Only has the time to be able to produce the correct answer to above question. But, the product design, the manufacture and the sale only can in carry on to the above question preliminary affirmation answer foundation in. Project engineer also should through the detail drawing and the assembly drawing, carries on the consultation together with the branch of manufacture to the finally design proposal. Usually, can have some problem in the manufacture process. Possibly can request to some components size or the common difference makes some changes, causes the components the production to change easily. But, in the project change must have to pass through designs the personnel to authorize, guaranteed cannot damage the product the function. Sometimes, when in front of product assembly or in the packing foreign shipment experiment only then discovers in the design some kind of flaw. These instances exactly showed the design is a dynamic process. Always has a better method to complete the design work, designs the personnel to be supposed unceasingly diligently, seeks these better method. Recent year, the engineer material choice already appeared importantly. In addition, the choice process should be to the material continuously the unceasing again appraisal process. The new material unceasingly appears, but some original materials can obtain the quantity possibly can reduce. The environmental pollution, material recycling aspect and so on use, workers health and security frequently can attach the new limiting condition to the choice of material. In order to reduce the weight or saves the energy, possibly can request the use different material. Comes from domestic and international competition, to product service maintenance convenience request enhancement and customers aspect the and so on feedback pressure, can urge the people to carry on to the material reappraises. Because the material does not select when created the product responsibility lawsuit, has already had the profound influence. In addition, the material and between the material processing interdependence is already known by the people clearly. Therefore, in order to can and guarantees the quality in the reasonable cost under the premise to obtain satisfaction the result, project engineer makes engineers all to have earnestly carefully to choose, the determination and the use material. Makes any product the first step of work all is designs. Designs usually may divide into several explicit stages: (a) preliminary design; (b) functional design; (c) production design. In the preliminary design stage, the designer emphatically considered the product should have function. Usually must conceive and consider several plans, then decided this kind of thought is whether feasible; If is feasible, then should makes the further improvement to or several plans. In this stage, the question which only must consider about the choice of material is: Whether has the performance to conform to the request material to be possible to supply the choice; If no, whether has a bigger assurance all permits in the cost and the time in the limit develops one kind of new material. In the functional design and the engineering design stage, needs to make a practical feasible design. Must draw up the quite complete blueprint in this stage, chooses and determines each kind of components the material. Usually must make the prototype or the working model, and carries on the experiment to it, the appraisal product function, the reliability, the outward appearance and the service maintenance and so on. Although this kind of experiment possibly can indicate, enters in the product to the production base in front of, should replace certain materials, but, absolutely cannot this point take not earnestly chooses the material the excuse. Should unify the product the function, earnestly carefully considers the product the outward appearance, the cost and the reliability. Has the achievement very much the company when manufacture all prototypes, selects the material should the material which uses with its production in be same, and uses the similar manufacture technology as far as possible. Like this has the advantage very much to the company. The function complete prototype if cannot act according to the anticipated sales volume economically to make, or is prototypical and the official production installment has in the quality and the reliable aspect is very greatly different, then this kind of prototype does not have the great value. Project engineer is best can completely complete the material in this stage the analysis, the choice and the determination work, but is not remains it to the production design stage does. Because, is carries on in the production design stage material replacement by other people, these people are inferior to project engineer to the product all functions understanding. I n the production design stage, is should completely determine with the material related main question the material, causes them to adapt with the existing equipment, can use the existing equipment economically to carry on the processing, moreover the material quantity can quite be easy to guarantee the supply. In the manufacture process, inevitably can appear to uses the material to make some changes the situation. The experience indicated that, may use certain cheap materials to take the substitute. However, in the majority situation, in will carry on the production later to change the material to have in to start before the production to change the price which the material will spend to have to be higher than. Completes the choice of material work in the design stage, may avoid the most such situations. Started after the production manufacture to appear has been possible to supply the use the new material is replaces the material the most common reason. Certainly, these new materials possibly reduce the cost, the improvement product performance. But, must carry on the earnest appraisal to the new material, guarantees its all performance all to answer the purpose. Must remember that, the new material performance and the reliable very few pictures materials on hand such understood for the people. The majority of products expiration and the product accident caused by negligence case is because in selects the new material to take in front of substitution material, not truly understood their long-term operational performance causes. The product responsibility lawsuit forces designs the personnel and the company when the choice material, uses the best procedure. In the material process, five most common questions are: (a) did not understand or cannot use about the material application aspect most newly the best information paper; (b) has not been able to foresee and to consider the dusk year possible reasonable use (for example to have the possibility, designs the personnel also to be supposed further to forecast and the consideration because product application method not when creates consequence. ecent years many products responsibilities lawsuit case, because wrongly uses the plaintiff which the product receives the injury to accuse produces the factory, and wins the decision); (c) uses the material data not entire perhaps some data are indefinite, works as its long-term performance data is the like this time in particular; (d) the quality control method is not suitable and not after the confirmation; (e) the personnel which completely is not competent for the post by some chooses the material. 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.机械设计基础及理论机械设计基础是指机械装置和机械系统机器、产品、结构、设备和仪器的设计。大部分机械设计需要利用数学、材料科学和工程力学知识。我们对整个设计过程感兴趣。它是怎样开始的,工程师是不是仅仅坐在铺着白纸的桌旁就可以开始设计了呢？当他记下一些设想后,下一步应该做些什么？什么因会影响或者控制着应该做出的决定。最后，这一设计过程是怎样结束的呢？有时虽然并不总是如此，工程师认识到一种需要并且决定对此做一些工作时设计就开始了。认识到这种需要并用语言将其清楚地叙述出来常常是一种高度创造性的工作。因为这种需要可能只是一个模糊的不满一种不舒服的感觉。或者是感觉到了某些东西是不正确的。这种需要往往不是很明显的。例如对食品包装机械进行改进的需要，可能是由于噪音过大、包装重量的变化、包装质量的微小的但是能够察觉得出来的变化等表现出来的。叙述某种需要和随后要解决的问题之间有着明显的区别。要解决的问题是比较具体的。如果需要干净的空气。要解决的问题可能是降低发电厂烟囱的排尘量或者是降低汽车排除的有害气体。确定问题阶段应该制订设计对象所有的要求。这些设计要求包括输入量、输出两特性、设计对象所占据的空间尺寸以及这些参量的所有制约因素。我们可以把设计对象看作是黑箱中的某种东西。在这种情况下，我们必须具体确定黑箱的输入和输出以及它们的特性和制约因素。这些设计要求将规定生产成本、产量、预期寿命、工作范围、操作温度和可靠性。还存在着许多由于设计人员所处的特定环境或者由于问题本身的性质所产生的隐含设计要求。某个工厂中可利用的制造工艺和设备会对设计人员的工作有所限制，因而成为隐含的设计要求的一部分。例如一个小工厂中可能没有冷变形加工机械设备。因此，设计人员就必须选择这个工厂中能够进行的其他的金属加工方法。工人的技术水平和市场上的竞争情况也是隐含的设计要求的组成部分。在确定了要解决的问题并且形成了一系列的书面的和隐含的设计要求之后设计工作的下一阶段是进行综合以获得最优的结果。因为只有通过对所设计的系统进行分析，才能确定其性能是否满足设计要求。因此，不进行分析和优化就不能进行综合。设计工作是一个反复进行的过程。在这个过程中我们要经历几个阶段，在对结果进行评价后，再返回到前面的阶段。因此，我们可以先综合系统中的几个零件。对它们进行分析和优化。然后再进行综合看它们对系统的其他部分有时么影响。分析和优化都要求我们建立或者做出系统的抽象模型，以便对此进行数学分析。我们将这些模型称为数学模型。在建立数学模型时，我们希望能够找到一个可以很好地模拟实际物理系统的数学模型。评价是整个设计过程中的一个重要阶段。评价是对一个成功的设计的最后检验通常包括样机的实验室实验。在此阶段我们希望弄清楚设计能否真正满足所有的要求。它是否可靠在与类似的产品的竞争中它能否获胜制造和使用这种产品是否经济。它是否易于维护和调整能否从它的销售或使用中获得利润。与其他人就设计方案进行交流和沟通是设计过程的最后和关键阶段。毫无疑问有许多伟大的设计、发明或创造之所以没有为人类所利用。就是因为创造者不善于或者不愿意向其他人介绍自己的成果。提出方案是一种说服别人的工作。当一个工程师向经营、管理部门或者其主管人员提出自己的新方案时，就是希望向他们说明或者证明自己的方案是比较好的。只有成功地完成这项工作，为得出这个方案所花费的大量时间和精力才不会被浪费掉。人们基本上只有三种表达自己思想的方式，即文字材料、口头表述和绘图。因此，一个优秀的工程师除了掌握技术之外，还应该精通这三种表达方式。如果一个技术能力很强的人在上述三种表达方式中的某一种的能力较差他就会遇到很大的困难。如果上述三种能力都很差，那将永远没有人知道他是一个多么能干的人。一个有能力的工程师不应该害怕在提出自己的方案时遭到失败的可能性。事实上，偶然的失败肯定会发生的。因为每一个真正有创造性的设想似乎总是有失败或批评伴随着它。从一次失败中可以学到很多东西。只有不怕遭受失败的人们才能取得最大的收获。总之，决定不把方案提交出来才是真正的失败。机械设计概论机械设计是一门通过设计新产品或者改进产品来满足人类需求的应用技术科学。它是一个广阔的工程技术领域，不仅要研究产品在尺寸、形状和详细结构等方面的基本构思。还要考虑产品在制造、销售和使用等方面的有关问题。进行各种机械设计工作的人员通常被称为设计人员或者设计工程师。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新性，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等方面具有深厚的基础知识。如前面所述，机械设计的目的是生产能够满足人类需求的产品。发明、发现和科学知识本身并不一定能给人类带来益处，只有当它们被用在产品上才能产生效益。因而，应该认识到再一个特定产品进行设计之前，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设计人员运用创造性的才能进行产品设计、系统分析和制订产品的制造工艺的一个良机。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再一个好的设计中做出所需的全部决定。另一方面，应该认真精确地进行所有运算。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，就恢复采用原来的方法。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。由于许多人易于墨守成规，这样做并不是一件容易的事情。以为设计工程师应该不断的探索改进现有产品的办法。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办法，就没有必要仅仅为了变革的目的而采用新办法。在设计的初始阶段，应该允许设计人员充分发挥创造性，不受各种约束。即使产生了许多不切合实际的想法也会在设计的早期即绘制生产图纸之前被改正掉。只有这样，才不至于堵塞创新得思路。通常要提出几套设计方案？然后加以比较。很有可能在最后选定的方案中?采用了某些未被接受的方案中的一些想法。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。另一个应该被认识到的重要问题是设计工程师必须能够同其他有关人员进行交流和沟通。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沟通并得到批准。这一般是通过口头讨论草图和文字材料进行的。为了有效地进行交流，需要解决下列问题 1 所要设计的这个产品是否真正为人们所需要 2 此产品与其他公司的现有产品相比有无竞争能力 3 生产这种产品是否经济 4 产品的维修是否方便 5 产品有无销路是否可以盈利只有时间才能对上述问题给出正确的答案。但是产品的设计、制造和销售只能在对上述问题的初步肯定答案的基础上进行。设计工程师还应该通过零件图和装配图与制造部门一起对最终设计方案进行沟通。通常，在制造过程中会出现某个问题。可能会要求对某个零件尺寸或公差作一些修改，使零件的生产变得容易。但是，工程上的修改必须要经过设计人员批准。以保证不会损伤产品的功能。有时，在产品的装配时或者装配外运前的试验中才发现设计中的某些缺陷。这些事例恰好说明了设计是一个动态过程。总是存在着更好的方法来完成设计工作。设计人员应该不断努力寻找这些更好的方法。机械加工车削。普通车床作为最早的金属切削机床中的一种，目前仍然有许多有用的和为人们所需要的特性。现在这些机床主要用在规模较小的工厂中进行小批量的生产而不是进行大批量的生产。在现在的生产车间中，普通车床已经被种类繁多的自动车床所取代，诸如自动仿形车床、六角车床和自动螺丝车床。现在设计人员已经熟知先利用单刃刀具去除大量的金属余量然后利用成型刀具获得表面光洁度和精度这种加工方法的优点。这种加工方法的生产速度与现在工厂中使用的最快的加工设备的速度相等。普通车床的加工偏差主要依赖于操作者的技术熟练程度。设计工程师应该认真地确定由熟练工人在普通车床上加工的试验零件的公差。在把试验零件重新设计为生产零件时应该选用经济的公差。六角车床对生产加工设备来说，目前比过去更着重评价其是否具有精确的和快速的重复加工能力。应用这个标准来评价具体的加工方法，六角车床可以获得较高的质量评定。在为小批量的零件100200件，设计加工方法时采用六角车床时最经济的。为了在六角车床上获得尽可能小的公差值设计人员应该尽量将加工工序的数目减至最少。自动螺丝车床、自动螺丝车床、通常被分为以下几种类型：单轴自动、多轴自动和自动夹紧车床。自动螺丝车床最初是被用来对螺钉和类似的带有螺纹的零件进行自动化和快速加工的。但是这种车床的用途早就超过了这个狭窄的范围。现在它在许多种类的精密零件的大批量生产中起者重要的作用。工件的数量对采用自动螺丝车床所加工零件的，经济性有较大的影响。如果工件的数量少于1000件，在六角车床上进行加工比在自动螺丝车床上加工要经济得多。如果计算出最小经济批量，并且针对工件批量正确地选择机床，就会降低零件的加工成本。自动仿形车床，因为零件的表面粗糙度在很大程度上取决于工件材料、刀具、进给量和切削速度，采用自动仿形车床加工得到的最小公差不一定是最经济的公差。在某种情况下在连续生产过程中，只进行一次切削加工时的公差可以达到0.5mm。对于某些零件，槽宽的公差可以达到0.125 mm。镗孔和采用单刃刀具进行精加工时，公差可达到0.0125 mm。在希望获得最大产量的大批量生产中，进行直径和长度的车削时的最小公差值为0.125 mm时是最经济的。铣削除了车削和钻削，铣削无疑是应用最广泛的金属切削方法。

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