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4110柴油机活塞零件机械加工工艺及夹具设计【5张CAD图纸+毕业论文】【答辩通过】

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关键词：: 柴油机活塞零件机械加工工艺夹具设计全套 cad 图纸毕业论文答辩通过

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摘要

机械制造技术基础课程设计是我们在学完了大学的全部基础课、专业基础课以及专业课后进行的。这是我们在进行毕业设计之前对所学的各科课程一次深入的综合性总复习，也是一次理论联系实际的训练。因此，他在我们的大学四年生活中占有重要的地位。

我这次的课题是镗销孔活塞零件专用夹具的设计，有活塞零件图、毛坯图、夹具装配图、夹具零件图各一张以及非标零件图五张，机械加工工艺过程卡片和与所设计夹具对应那道工序的工序卡若干张。首先我们要熟悉零件，题目所给的零件是汽车活塞。了解了活塞的作用，接下来根据零件的性质和零件图上各端面的粗糙度确定毛坯的尺寸和机械加工余量。然后我们再根据定位基准先确定精基准，后确定粗基准，最后拟定活塞的工艺路线图，制定该工件的夹紧方案，画出夹具装配图。

就我个人而言，我希望通过这次课程设计对自己未来将从事的工作进一步适应性的训练，希望自己在设计中能锻炼自己的分析问题、解决问题、查资料的能力，为以后的工作打下良好的基础。

由于能力有限，设计尚有很多不足之处，希望各位老师给予指导。

关键词：夹具；活塞；零件图；

Abstract

Machinofacture technology curriculum design is that we mimic all basic courses , technology basic course and major part having completed university being in progress after the specialized course. This is that we always review before the graduation practice being in progress to what be learned every thorough comprehensiveness of course,be also that a theory contacts actual training , it occupies important position therefore, in our university for four years life.

Abstract with the pin hole boring piston parts special fixture design, piston parts diagram, blank map,jig assembly drawing, fixture parts each piece and non-standard parts of figure five. Machining process with the card and the corresponding fixture designed by the procedures of the process of several card. First of all, we must familiar with the parts, subject to the parts is piston understanding of the role, followed in accordance with the nature of parts and components in the face of the map on the roughness of rough determine the size and mechanical Jiagongyuliang. According to another location and then we set the benchmark fine first base, established after the benchmark crude, piston finalizing the road map process, the enactment of the workpiece clamping programme, to draw fixture assembly.

For me personally, I hope that through the curriculum design of their future will be further engaged in the work of adaptive training, in the hope that their design can exercise their own analysis, problem solving, the ability to search information, the work laid for the future A good foundation.

Because of limited capacity, there are a lot of design deficiencies, I hope that teachers give guidance.

Key words:fixture;piston;part drawing;

年月日II

摘要III

AbstractIV

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

2零件的分析2

2.1 活塞的作用2

2.2 活塞的结构组成2

2.3 活塞的主要技术条件分析3

3 零件的工艺规程设计4

3.1确定零件的生产纲领4

3.2 确定毛坯的材料和制造形式4

3.2.1 毛坯的材料选择4

3.2.2 毛坯的制造方法4

3.3 定位基准的选择4

3.3.1 粗基准的选择5

3.3.2 精基准的选择5

3.4 制定工艺路线6

3.5 活塞毛坯尺寸、加工余量、工序尺寸的确定8

3.5.1 活塞毛坯尺寸的确定8

3.6确定切削用量及工时定额9

3.6.5 止口的切削用量16

4.1 机床夹具的作用及组成18

4.2 机床夹具设计过程18

4.3 夹具的初步设计方案18

4.4定位方案设计19

4.4.1 定位元件选择19

4.4.2 定位误差的分析与计算19

4.4.3 液压缸的设计20

4.5夹紧方案设计21

4.5.1 夹紧元件的选取21

4.5.2 夹紧力的分析与计算22

4.5.3 原动力计算22

5 结论与展望24

5.1 结论24

5.2 不足之处及未来展望24

致谢25

参考文献26

1绪论

1.1 本课题的研究内容和意义

工艺工装毕业设计是在机械制造工艺学及机床夹具等课程的基础上，进行生产实习基础上进行的一个重要环节，它要求学生全面地综合运用本课程及有关选修课程的理论和实践知识，进行零件加工工艺规程设计和机床夹具设计。

工具的制造对人类的影响是极其巨大。从某种程度上说，工具的先进水平决定着生产力的高低也是伴随着劳动工具的发展与变革。制造业是任何一个发达国家的基础工业，是一个国家综合国力的重要体现。然而在制造业中，夹具工业又是制造业的基础，得到了各个国家的高度重视。尤其在今天以知识为驱动的全球化经济浪潮中，由于激烈的市场竞争，夹具工业的内涵、深度和广度都发生着深刻变化，各种新的夹具设计、制造加工方法不断的出现，推动我们社会的不断向前发展。

1.2 国内外的发展概况

夹具工业是现代工业的基础。它的技术水平在很大程度上决定了产品的质量和市场的竞争力，在如此严峻的行业背景下，我国的技术人员经过不断地改革和创新使得我国的模具水平有了较大的提高。大型、复杂、精密、高效和长寿命的夹具又上了新的台阶。夹具是每个机制制造方面目前普遍用的，它可以大批量生产，节省人力物资，效率相对高，操作方便，结构合理，它的成本低廉，适合广大人群所承受的能力。

通过课程设计的准备工作，进一步提高我们独立调研能力以及专业的业务素质。并通过文献查阅，现场收集资料等工作锻炼解决夹具工程技术的问题的能力；能巩固深化扩充我们的专业知识，并通过课程设计中对涉及到的问题的分析研究，提出我们自己的见解和观点；通过课程设计，树立良好的工作思想和细致、严谨、科学的工作态度，为将来成为一个未来的工程师奠定良好的基础。

1.3 本课题应达到的要求

这次设计使我能综合运用机械制造工艺学中的基本理论，并结合生产实习中学到的实践经验和知识，独立的分析和解决工艺问题，初步具备了设计一个中等复杂程度零件的工艺规程的能力和运用夹具设计的基本原理和方法，拟订夹具设计方案，完成夹具结构设计的能力，为未来从事的工作打下良好的基础。

由于能力有限，设计尚有很多不足之处，希望各位老师给予指导。

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内容简介：: 无锡太湖学院2009届本科生毕业设计（论文）翻译A diesel engine works【Abstract】In a diesel engine cylinder, the piston in the part of the work cycle of compressed gas,and in another part of the work cycle of the combustion gas mixture within the cylinder so the piston top surface expansion high pressure (about 116 120Kgf/cm2)under high temperature (about 569C) gas role, and the pressure through the piston pin, connecting rod to the crankshaft. Can be seen that the piston is a long time under high temperature and high pressure in continuous reciprocating motion of the load, its load and working conditions were appalling. During the design process of the piston will be designed to ensure long-term stability of the work piston. The design of the work done by a brief introduction as follows:Diesel Engine Piston 180C reasonable processing technology is important, the role of parts and technology program analysis, preparation of rough form and process manufacturing line, through the analysis, comparison, use of the relative concentration of processing programs, and ultimately more reasonable to determine the mechanical line processing. The development process of rough line the main consideration, finishing arrangements, choice of processing methods, centralized and decentralized processes, such as processing the order requirements. Then determine the allowance, process size, after the analysis of the characteristics of the process, select the appropriate processing equipment and technical equipment. Calculated look-up table to determine the next major piston cutting process and the mapping of processes card, the design of the final fixture. Fixture design, it is necessary to take various aspects into account, the strict requirements of the fixture a direct impact on the surface of the workpiece processing position accuracy. Therefore, the machine tool design fixture design is an important task is the processing of one of the most active. During the graduation project in a specially designed positioning accuracy, simple structure and easy-to-use precision pin hole boring jig.Keywords: Piston; Technology; processing equipment; cutting; FixtureAny type of machine that obtains mechanicalenergy directly from the expenditure of the chemical energy of fuel burned in a combustion chamber that is an integral part of the engine. Four principal types of internal-combustion engines are in general use: the Otto-cycle engine, the diesel engine, the rotary engine, and the gas turbine. For the various types of engines employing the principle of jet propulsion, see Jet Propulsion; Rocket. The Otto-cycle engine, named after its inventor, the German technician Nikolaus August Otto, is the familiar gasoline engine used in automobiles and airplanes; the diesel engine, named after the French-born German engineer Rudolf Christian Karl Diesel, operates on a different principle and usually uses oil as a fuel. It is employed in electric-generating and marine-power plants, in trucks and buses, and in some automobiles. Both Otto-cycle and diesel engines are manufactured in two-stroke and four-stroke cycle models.The essential parts of Otto-cycle and diesel engines are the same. The combustion chamber consists of a cylinder, usually fixed, that is closed at one end and in which a close-fitting piston slides. The in-and-out motion of the piston varies the volume of the chamber between the inner face of the piston and the closed end of the cylinder. The outer face of the piston is attached to a crankshaft by a connecting rod. The crankshaft transforms the reciprocating motion of the piston into rotary motion. In multicylindered engines the crankshaft has one offset portion, called a crankpin, for each connecting rod, so that the power from each cylinder is applied to the crankshaft at the appropriate point in its rotation. Crankshafts have heavy flywheels and counterweights, which by their inertia minimize irregularity in the motion of the shaft. An engine may have from 1 to as many as 28 cylinders.The fuel supply system of an internal-combustion engine consists of a tank, a fuel pump, and a device for vaporizing or atomizing the liquid fuel. In Otto-cycle engines this device is either a carburetor or, more recently, a fuel-injection system. In most engines with a carburetor, vaporized fuel is conveyed to the cylinders through a branched pipe called the intake manifold and, in many engines, a similar exhaust manifold is provided to carry off the gases produced by combustion. The fuel is admitted to each cylinder and the waste gases exhausted through mechanically operated poppet valves or sleeve valves. The valves are normally held closed by the pressure of springs and are opened at the proper time during the operating cycle by cams on a rotating camshaft that is geared to the crankshaft. By the 1980s more sophisticated fuel-injection systems, also used in diesel engines, had largely replaced this traditional method of supplying the proper mix of air and fuel. In engines with fuel injection, a mechanically or electronically controlled monitoring system injects the appropriate amount of gas directly into the cylinder or inlet valve at the appropriate time. The gas vaporizes as it enters the cylinder. This system is more fuel efficient than the carburetor and produces less pollution.In all engines some means of igniting the fuel in the cylinder must be provided. For example, the ignition system of Otto-cycle engines described below consists of a source of low-voltage, direct-current electricity that is connected to the primary of a transformer called an ignition coil. The current is interrupted many times a second by an automatic switch called the timer. The pulsations of the current in the primary induce a pulsating, high-voltage current in the secondary. The high-voltage current is led to each cylinder in turn by a rotary switch called the distributor. The actual ignition device is the spark plug, an insulated conductor set in the wall or top of each cylinder. At the inner end of the spark plug is a small gap between two wires. The high-voltage current arcs across this gap, yielding the spark that ignites the fuel mixture in the cylinder.Because of the heat of combustion, all engines must be equipped with some type of cooling system. Some aircraft and automobile engines, small stationary engines, and outboard motors for boats are cooled by air. In this system the outside surfaces of the cylinder are shaped in a series of radiating fins with a large area of metal to radiate heat from the cylinder. Other engines are water-cooled and have their cylinders enclosed in an external water jacket. In automobiles, water is circulated through the jacket by means of a water pump and cooled by passing through the finned coils of a radiator. Some automobile engines are also air-cooled, and in marine engines sea water is used for cooling.Unlike steam engines and turbines, internal-combustion engines develop no torque when starting, and therefore provision must be made for turning the crankshaft so that the cycle of operation can begin. Automobile engines are normally started by means of an electric motor or starter that is geared to the crankshaft with a clutch that automatically disengages the motor after the engine has started. Small engines are sometimes started manually by turning the crankshaft with a crank or by pulling a rope wound several times around the flywheel. Methods of starting large engines include the inertia starter, which consists of a flywheel that is rotated by hand or by means of an electric motor until its kinetic energy is sufficient to turn the crankshaft, and the explosive starter, which employs the explosion of a blank cartridge to drive a turbine wheel that is coupled to the engine. The inertia and explosive starters are chiefly used to start airplane engines.The ordinary Otto-cycle engine is a four-stroke engine; that is, in a complete power cycle, its pistons make four strokes, two toward the head (closed head) of the cylinder and two away from the head. During the first stroke of the cycle, the piston moves away from the cylinder head while simultaneously the intake valve is opened. The motion of the piston during this stroke sucks a quantity of a fuel and air mixture into the combustion chamber. During the next stroke, the piston moves toward the cylinder head and compresses the fuel mixture in the combustion chamber. At the moment when the piston reaches the end of this stroke and the volume of the combustion chamber is at a minimum, the fuel mixture is ignited by the spark plug and burns, expanding and exerting a pressure on the piston, which is then driven away from the cylinder head in the third stroke. During the final stroke, the exhaust valve is opened and the piston moves toward the cylinder head, driving the exhaust gases out of the combustion chamber and leaving the cylinder ready to repeat the cycle.The efficiency of a modern Otto-cycle engine is limited by a number of factors, including losses by cooling and by friction. In general, the efficiency of such engines is determined by the compression ratio of the engine. The compression ratio (the ratio between the maximum and minimum volumes of the combustion chamber) is usually about 8 to 1 or 10 to 1 in most modern Otto-cycle engines. Higher compression ratios, up to about 15 to 1, with a resulting increase of efficiency, are possible with the use of high-octane antiknock fuels. The efficiencies of good modern Otto-cycle engines range between 20 and 25 percentin other words, only this percentage of the heat energy of the fuel is transformed into mechanical energyTheoretically, the diesel cycle differs from the Otto cycle in that combustion takes place at constant volume rather than at constant pressure. Most diesels are also four-stroke engines but they operate differently than the four-stroke Otto-cycle engines. The first, or suction, stroke draws air, but no fuel, into the combustion chamber through an intake valve. On the second, or compression, stroke the air is compressed to a small fraction of its former volume and is heated to approximately 440C (approximately 820F) by this compression. At the end of the compression stroke, vaporized fuel is injected into the combustion chamber and burns instantly because of the high temperature of the air in the chamber. Some diesels have auxiliary electrical ignition systems to ignite the fuel when the engine starts and until it warms up. This combustion drives the piston back on the third, or power, stroke of the cycle. The fourth stroke, as in the Otto-cycle engine, is an exhaust stroke. The efficiency of the diesel engine, which is in general governed by the same factors that control the efficiency of Otto-cycle engines, is inherently greater than that of any Otto-cycle engine and in actual engines today is slightly more than 40 percent. Diesels are, in general, slow-speed engines with crankshaft speeds of 100 to 750 revolutions per minute (rpm) as compared to 2500 to 5000 rpm for typical Otto-cycle engines. Some types of diesel, however, have speeds up to 2000 rpm. Because diesels use compression ratios of 14 or more to 1, they are generally more heavily built than Otto-cycle engines, but this disadvantage is counterbalanced by their greater efficiency and the fact that they can be operated on less expensive fuel oils. By suitable design it is possible to operate an Otto-cycle or diesel as a two-stroke or two-cycle engine with a power stroke every other stroke of the piston instead of once every four strokes. The power of a two-stroke engine is usually double that of a four-stroke engine of comparable size.The general principle of the two-stroke engine is to shorten the periods in which fuel is introduced to the combustion chamber and in which the spent gases are exhausted to a small fraction of the duration of a stroke instead of allowing each of these operations to occupy a full stroke. In the simplest type of two-stroke engine, the poppet valves are replaced by sleeve valves or ports (openings in the cylinderwall that are uncovered by the piston at the end of its outward travel). In the two-stroke cycle, the fuel mixture or air is introduced through the intake port when the piston is fully withdrawn from the cylinder. The compression stroke follows, and the charge is ignited when the piston reaches the end of this stroke. The piston then moves outward on the power stroke, uncovering the exhaust port and permitting the gases to escape from the combustion chamber.In the 1950s the German engineer Felix Wankel developed an internal-combustion engine of a radically new design, in which the piston and cylinder were replaced by a three-cornered rotor turning in a roughly oval chamber. The fuel-air mixture is drawn in through an intake port and trapped between one face of the turning rotor and the wall of the oval chamber. The turning of the rotor compresses the mixture, which is ignited by a spark plug. The exhaust gases are then expelled through an exhaust port through the action of the turning rotor. The cycle takes place alternately at each face of the rotor, giving three power strokes for each turn of the rotor. Because of the Wankel engines compact size and consequent lesser weight as compared with the piston engine, it appeared to be an important option for automobiles. In addition, its mechanical simplicity provided low manufacturing costs, its cooling requirements were low, and its low center of gravity made it safer to drive. A line of Wankel-engine cars was produced in Japan in the early 1970s, and several United States automobile manufacturers researched the idea as well. However, production of the Wankel engine was discontinued as a result of its poor fuel economy and its high pollutant emissions. Mazda, a Japanese car manufacturer, has continued to design and innovate the rotary engine, improving performance and fuel efficiency.A modification of the conventional spark-ignition piston engine, the stratified charge engine is designed to reduce emissions without the need for an exhaust-gas recirculation system or catalytic converter. Its key feature is a dual combustion chamber for each cylinder, with a prechamber that receives a rich fuel-air mixture while the main chamber is charged with a very lean mixture. The spark ignites the rich mixture that in turn ignites the lean main mixture. The resulting peak temperature is low enough to inhibit the formation of nitrogen oxides, and the mean temperature is sufficiently high to limit emissions of carbon monoxide and hydrocarbon.柴油机的工作原理【摘要】在柴油机气缸内，活塞在一部分工作循环压缩气体，而在另一部分工作循环气缸内混合气体燃烧膨胀使活塞顶面承受高温（约569C）高压（约116120Kgf/cm2）气体的作用，并把压力通过活塞销、连杆传给曲轴。可见，活塞是在高温高压下作长时间连续变负荷的往复运动，它的负荷和工作环境很恶劣。在本设计中将对活塞的加工工艺进行设计，以保证活塞长久稳定工作。现将设计中所做的工作简要介绍如下：柴油机活塞加工工艺合理性是很重要的，通过对零件的作用及工艺方案分析，拟定毛坯的制造形式及工艺路线，通过分析、比较，采用了相对集中加工工艺方案，最终确定比较合理的机械加工工艺路线。制定工艺路线时主要考虑粗、精加工安排、加工方法选择、工序集中与分散、加工顺序等方面的要求。接着确定加工余量、工序尺寸，经过对工序特点的分析，恰当选择相应加工设备和工艺装备。接下来经过计算查表确定活塞各主要工序的切削用量并绘制工序卡片，最后设计夹具。设计夹具时，要多方面考虑，严格要求，机床夹具的好坏直接影响工件加工表面的位置精度。所以，机床夹具设计是装备设计中的一项重要的工作，是加工过程中最活跃的因素之一。在本毕业设计中特别设计了定位准确、结构简单和使用方便的精镗销孔夹具。关键字：活塞；工艺路线；加工设备；切削用量；夹具任何通过燃料在气缸中燃烧，使燃油的化学能转化为机械能，从而获得动力的引擎都成为内燃机。最常见的内燃机有四种：奥托循环式发动机，柴油机，转子发动机和煤气机。根据这四种发动机的优点，把它们应用于不同的工况。奥托循环式发动机，是根据其发明者，德国机械师尼古拉斯.奥格事特.奥托的名字来命名的。是飞机上很常见的一种发动机；而柴油机是由法籍德国工程师Rudolf Christian Karl Diesel命名的。它是一种用柴油作为燃料的先进的发动机。普遍用在电子控机械、战斗机、公共汽车、货车以及一些小车上。奥托式发动机和柴油机的工作方式都是二冲程或者四冲程。奥托式发动机和柴油机的基本构造都是一样的。压缩燃烧室是由一个一段由缸盖另一端由活塞之间的空间所形成。活塞的上下运动使得气缸与活塞间的空间发生大小变化，从而改变压缩空间的大小。活塞与曲轴之间通过连杆相互连接。曲轴将活塞的运动转化成旋转式的运动。多气缸式发动机的曲轴，在每一个气缸处都会多一个称为曲拐的结构部分。这样每个气缸的动力才能很好的传递给曲轴，是曲轴的转动平稳。曲轴上接有飞轮并有平衡坑。这样能够使曲轴运动的惯性最小化，达到平衡的目的。不同的发动机会有一个到二十四个等的气缸。内燃机的燃料供给系统又油箱、油泵、和分油管以及使液体燃料雾化的机构组成。在奥托式发动机上，并不是靠化油器来进行燃油雾化的，而是利用燃油的直接喷入，一直到现在都是如此。在大多数发动机上，燃料都是通过化油器雾化后通过压气机进入进气管道。在部分发动机的排气系统中，也会用到类似的装置来通过利用废气的能量对进气充量进行压缩。燃料平均分配给各个汽缸，而废气则通过排气门排出。进排气门的开闭都是通过凸轮轴的转动从而牵动气门弹簧作用到挺杆，在正确的时间是气门开闭。在上世纪80年代，缸内直喷技术开始用于内燃机领域，从很大程度上代替了传统的燃油与空气相混合的技术。在有直喷装置的发动机上，燃料会通过喷射系统在正确的时刻喷入汽缸或者进气管。这样燃料就会在汽缸里混合，这比化油器混合更充分，污染更小。所有的发动机上，火花塞的位置都必须适宜。比如奥托式发动机的点火系统包括低压电源，即具有变压性质的初级线圈，从而导出直流电。电流会被一个机械式的定时调节器在一秒钟内方向发生多次变化。初级线圈中电流的扰动会产生脉冲，从而会在次级线圈中产生高压电流。这个高压电流会被分电器分配到各个汽缸，件叫做火花，一个安装在汽缸顶部被叫做火花塞的零件。在火花塞末端的两极间有一个间隙，高压电流会击穿这个点火间隙，从而点燃汽缸中的混合气体。由于燃烧室的温度太高，所有的发动机都必须有相应的冷却系统。一些飞机、汽车、和船只上的舷外发动机采用风冷。这些采用风冷的发动机都必须有很多散热片，一边有较大的散热面积，从而很好的带走汽缸的热量。除此之外的还有水冷系统，它是在发动机的汽缸中设有水套来达到冷却的目的。在汽车上，冷却液借助水泵的压力在水套中流动，带走热量。还有一些汽车是利用风冷，海上船只则是用海水作为冷却的介质。与蒸汽机和涡轮机不同，内燃机在发动时并不会产生转

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