GY01-154@机床夹具柔性化技术研究及设计
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机械毕业设计全套
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GY01-154@机床夹具柔性化技术研究及设计,机械毕业设计全套
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SECTION 1 Basic Types and Functions of Jigs and Fixtures UNIT 1 Purpose of Tool Design OBJECTIVES After completing this unit, the student should be able to: List the objectives of tool design. Identify the source of specified design data. TOOL DESIGN Tool design is the process of designing and developing the tools, and techniques necessary to improve manufacturing efficiency and productivity. It gives industry the machines and special tooling needed for todays high-speed, high-volume production. It does this at a level of quality and economy that will insure that the cost of the product is competitive. Since no single tool or process can serve all forms of manufacturing, tool design is an ever-changing, growing process of creative problem solving. TOOL DESIGN OBJECTIVES The main objective of tool design is to lower manufacturing costs while maintaining quality and increased production. To accomplish this, the tool designer must satisfy the following objectives: Provide simple, easy-to operate tools for maximum efficiency. Reduce manufacturing expenses by producing parts at the lowest possible cost. Design tools that consistently produce parts of high quality. Increase the rate of production with existing machine tools. Design the tool to make it foolproof and to prevent improper use. Select materials that will give adequate tool life. Provide protection in the design of the tools for maximum safety of the operator. TOOL DESIGN IN MANUFACTURING As an important part of manufacturing, tool design occupies a position between product design and product production. First, the need for a product is determined. Then, the drawings and specifications are developed. The product designer forward this information to the process planning engineer. The process planning engineer, working closely with the product designer and the tool designer, plans the methods that will be used to product the part. Occasionally, the product designer changes or modifies a design to simplify or speed up production. Normally, the product designer sets the production rate and the part design, and chooses the machine tools. Deadlines are scheduled and a budget is set up. The tool designer must plan within this framework. 第篇 夹具的基本类型与功能 第章 夹具设计的目的 学习目标 学习完该章后，学生应具备下述能力： 列举出夹具设计的目的 鉴别原始设计资料数据及其来源 夹具设计概述 夹具对于改进制造技术的效能、提高生产率是十分必要的。其设计既是一个是设计过程，也是一个创新过程。现代工业生产要求在保证质量的前提下降低成本，提高生产率，扩大生产规模，工艺装备与专用夹具的设计就是为了满足这些要求而进行的 。由于不存在万能的制造装备或工艺手段，因此，夹具设计是一个不断变化、不断进步的创造性地解决制造技术问题的过程。 夹具设计的目的 夹具设计的主要目的，是在保证产品质量的前提下降低成本，提高生产率。为达此目的，夹具设计师必须切实做到以下几点： 所设计的夹具应功能完备，结构简单，操作方便。 以尽可能最低的成本生产零件，切实降低制造费用。 所设计的夹具应保证所加工零件质量的连续一致性。 利用企业现有机床设备来提高生产率。 所设计的夹具应保证定位无误，且 具有防止误操作的功能。 选择适当的材料 ，确保其有足够的使用寿命。 应确保操作者能得到最大限度的安全保护。 夹具设计在制造过程中的地位 夹具设计介于产品设计与其生产之间，是制造过程的一个重要组成部分。首先，设计前对产品的各种要求是已经明确了的；其次，产品图纸与说明书也已经具备。产品设计人员将上述信息传递给工艺设计人员，工艺设计人员则据此规划设计制造零件的工艺方法。因此，工艺设计人员与产品设计人员和夹具设计人员应密切合作。 有时，产品设计人员会更改设计，以简化生产工艺，或提高生产效率。一般说来，是产品设计人员决定了零件的设计、生产率及机床的选择。预决算也由他们制定出来。夹具设计人员应在上述框架之内开展设计工作。 1-1 nts 设计方案策划 在设计方案策划方面所花费功夫的多少，在很大程度上决定着一个夹具设计方案的成败。夹具设计方案策划是有一定程序的。有关待生产产品的资料及说明书等都已经过评估，以便能设计出最为高效和低耗的夹具。在设计方案策划阶段，夹具设计人员要非常仔细地研究分析零件图样和生产工艺，他们必须对零件及其工艺过程有十分清楚的了解。 零件图样 夹具设计人员收到了如图 1-1 所示的待加工零件的图样后，就要对其进行分析。分析零件图样时应充分考虑下列直接影响 夹具设计方案的基本要素： 零件所有的尺寸和形状 零件材料的种类及状态 所选择的机械加工方法的特点 零件需要达到的精度等级 零件需要加工的数量 零件的定位表面和夹紧表面 工艺过程文件 图所示为一工艺过程文件。它是由工艺设计师设计的加工工序及工序流程的详细表格。根据各公司的需要，工艺过程文件可以有多种形式。但起码来说，它应包括每一道加工工序的简要说明，以及各工序所选用的机床。在设计夹具时，也需要参考工艺过程文件。工艺过程文件可包括下述内容： 每一工序所选用的机床种类及规格 每一 工序所选用的刀具种类及规格 PLANNING THE DESIGN The amount of planning in a tools design greatly affects its success or failure. This is an orderly process. All of the information and specifications pertaining to the proposed product are evaluated so that the most efficient and cost-effective tool design can be selected. During this phase, the tool designer carefully studies the part drawing and the production plan. The tool designer must understand the part and the manufacturing processes. Part Drawings The tool designer receives a duplicate of the part drawing, which will be used to make the part, Figure 1-1. When analyzing the part drawing, the tool designer must consider several general factors that directly influence the design choices. These factors are: Overall size and shape of the part Type and condition of the material used for the part Type of machining operation to be performed Degree of accuracy required Number of piece to be made Locating and clamping surface Production Plan The production plan, Figure 1-2 , is an itemized list of the manufacturing operations and the sequence of the operations chosen by the process planning engineer. The production plan can take many forms, depending on the needs of each company. At the least, it should include a brief description of each machining operation and the machine tool designated for these operations. The tool designer also uses this plan to assist in the design. The production plan can include the following: Type and size of machine tool specified for each operation Type and size of cutters specified for each operation 图 1-1零件图 通孔 0.19 沉孔 0.38 深 0.25 A WAS.750 NO. REVISIONS(修改 ) DATE(日期 ) BEST MACHINE CO.(顶好机械公司 ) Baltimore Maryland(马里兰州巴尔德摩 ) TITLE（名称） SLIDE STOP（滑动挡块） DATE(日期 ) MATL. SAE 4130 SCALE(比例 ) TOLERANCES（公差） ANGLES（角度） =0.015 0-30 =0.005 UNLESS OTHERWISE SPECIFIED(未标注处 ) PART NO. (零件号 ) 50791 1-2 nts 工序流程 该零件的上一道加工工序内容 除了零件图样和工艺过程文件外，还允许夹具设计人员花费一定的时间和金钱用于设计中。利用上述信息，加上一点创造力与经验，夹具设计人员就可开始策划多种设计方案以供选择。 设计方案选择 第一步需要解决的问题是选择夹具设计方案。为了确保得到最佳方案，夹具设计始终遵循这一既定流程。在这一阶段，夹具设计人员必须对各种重要的信息进行认真分析，以回答下述问题： 需要采用专用工夹具吗？需要对现有设备进行改装吗？ 采用单主轴机床还是多主轴机床？ 夹具是专用的还是多用途的？ 降低夹具成本的措施确实有效吗？ 如果需要的话，各工序应采用何种类型的量具？ 上述问题及与该夹具设计相关的其它问题解决之后，夹具设计人员就开始进行方案优选。通过优选，一个高效、可靠、性能价格比高的设计方案就确定了。 工夹具设计人员的职责 工夹具设计人员在制造业中要担负许多责任。除了技术设计外，工夹具设计人员也可能要承担材料进货、工具室监理及工具检查等责任。工夹具设计人员应清楚这些额外职责的范围。 设计 在设计阶段，夹具设计人员的任务是根据设计方案来绘制草图和图样。设计图样一般要经过主设计师的批准。但在 小公司里面，则经常是由夹具设计人员完全作主。 监管 夹具设计人员的监管范围通常由公司规模所决定，如图 1-3。监管责任可能是单一领域，如设计或制造；也可能是整个工夹具部。在任何一种情况下，具备领导别人的能力总是有好处的。 在解决设计问题时，工具间的一帮熟练技工是夹具设计人员经常要利用的。这些从事工具制造的熟练技工往往能轻易找到解决问题的方法，而一个夹具设计人员的技能水平无论如何高超，却不一定很快看得出来。基于这一原因，夹具设计人员与工具制造技工建立良好的关系是很有好处的。在夹具设计过程中，设计人员与制造人员的 良好合作，可以说是决定设计成败的根本。夹具设计人员不要试图单枪匹马把问题搞定。协同攻关使任务的完成变得容易，而多听取专家意见则能扩大视野。 sequence of operations Previous machining operations performed on the part In addition to the part drawing and production plan, the tool designer is informed of the amount of time and money that is available to spend on the design. Using this information and a little creativity and experience, the tool designer begins to study the design alternatives. Alternatives One of the first steps in problem solving is determining the alternative solutions. The same process is used in tool design to insure that the best method is chosen. During this phase of the design, the tool designer must analyze all important information in order to answer the following questions: Should special tooling be used or existing equipment modified? Should multiple-spindle or single spindle machine be used? Should the tool be single or multipurpose? Will the savings justify the cost of the tool? What type of the gauge, if any, should be used to check each operation? Answering these questions, and others related to the specific task, the tool designer develops alternatives solutions. From these alternative solutions, the efficient, dependable, and cost-effective design is chosen. CHALLENGES TO THE TOOL DESIGNER The tool designer has many manufacturing responsibilities. In addition to technical design duties, the tool designer may be responsible for obtaining materials, toolroom supervision, and tool inspection. The tool designer should understand the extent of these additional duties. Design In this phase, the tool designer is responsible for developing the drawing and sketches of the tool design ideas. Design drawing are usually subject to approval by a chief designer. However, in smaller companies, the tool designer quite often makes the tooling decisions. Supervision The extent of a designer s supervision is normally determined by the size of the company. Figure 1-3. Supervision for a single section, such as design or toolmaking, or for the entire tooling department, may become the tool designers responsibility. In either case, the ability to lead others is helpful. One resource a tool designer may often use to help resolve design problems is the group of skilled people in the toolroom. Regardless of the level of skill a designer possesses, these skilled toolmakers can often see solutions that may not be obvious to the designer. For this reason it is always a good idea to build a good working relationship with your toolmakers. In tool design, a cooperative relationship between the designer and the toolmakers is essential. Not only does working together make the task at hand easier, but using the available expertise also makes more sense than trying to do the job alone. 1-3 ntsBEST MACHINE COMPANY(顶好机械公司 ) Baltimore Maryland(马里兰州巴尔德摩 ) PART # 50791 PART NAME Slide Stop QUANTITY 7500 ORDER #13762 零件号： 50791 零件名称：滑动挡块 数量： 7500 定单号： 13762 DWG #D-50791 PROCESS PLANNER(工艺制定 ) REVISION # Page 1 of 1 图号： #D-50791 R.E.Tucker 修改标记： # 共页第页 OPR# 工序号 DESCRIPTION 工序内容 DEPT. 工段 MACHINE TOOL 机床及编号 Cutoff - .875.500 s tock to 1.250 length. .875.500毛坯切断，至长度 1.250 Drill - .19 hole thru .19孔钻通 Counterbore - .38 .25 Deep 锪沉孔 0.38深 .25 Mill - .38.38 and .19.38 shoulders 铣台阶 .38.38 及 .19.38 Deburr 去毛刺 Inspect Visual and dimensional 检查：外形与几何尺寸 #68 Cutoff Rm. 68工段 切断室 #66 Drilling 66钻工段 #66 Drilling 66钻工段 #37 Milling 37铣工段 #7 Finishing 7清理工 段 #7 Finishing 7清理工段 Abrasive Cutoff Saw #68-19 砂轮锯切机 #68-19 Drill Press #66-141 钻床 #66-141 Drill Press #66-141 钻床 #66-141 Horiz. Mill #37-804 卧式铣床 #37-804 Tumbler #7-1053 滚筒机 #7-1053 None 无 Receiving gauge (1) ; Pin Gauge (2) 外量规 (1件 ) ; 塞规 (2 件 ) Side milling cutters(2) 三面刃铣刀 (2件 ) Counterbore with pilot 带导向杆锪钻 Drill 钻头 Cutoff wheel 切断砂轮 4.5001 .375.19 .187 (3/16) 10.62 # -50791-3 # -50791-1/2 Fixture #S-50791-1 铣夹具 #S-50791-1 Jig #J-50791-1 钻模 #J-50791-1 Jig #J-50791-1 钻模 #J-50791-1 None 无 OPR# 工序号 TOOL DESCRIPTION 刀夹量具种类 SIZE. 尺寸 SPEC. TOOL 专用刀夹量具 Figure 1-2 Production plan（图 1-2 工艺过程文件） 1-4 nts 采购 夹具设计人员经常负有采购制造夹具的材料的责任。在此情况下，夹具设计人员往往要依赖供应商来提供材料和零件。最好是选择服务范围全面的公司作为供应商。好的供应商能依靠其相关产品，来协助进行夹具设计和疑难问题的解决。在作最终决定之前，要充分考虑这些重要因素。另外需要考虑的一点是，供应商能否在需要时提供必要的零配件。一般情况下，购买专门供货商提供的零配件，要比自行制造便宜得多。鉴于很多专门供货商都能提供上述服务，最终决定选择哪一家，主要应考虑其供货是否最为及时、高效和守信用。 检验 夹具设计人员经常被要求去检查 制造完工的夹具，以确保其能满足各项指标。这一检查，或叫功能试验，首先能确保夹具本身符合其图纸要求；其次，由于一部分试验用的工件已经用该夹具生产出来，且经过严格检查，所以也能确保用该夹具生产的零件能符合零件图纸要求。在夹具转交给生产部门以后，夹具设计人员还应定期对其进行检查，以确保其精度保持在规定的公差之内。图 1-4. Procurement Often a tool designer is responsible for obtaining the materials to make the tool. In these situations, the tool designer normally relies on vendors or salespeople to supply materials and parts that meet the design specifications. When selecting a vendor, a good practice is to choose the company that offers the most service to its customers. Services such as design assistance and problem solving, where their product is involved, are important factors to consider before making a final selection. Another point to consider is whether or not the vendor can supply special parts or components when necessary. Generally, the specialty vendors can furnish special items for much less than those items cost to make in-house. Since most specialty vendors offer these services, the decision should be made on a basis of which vendor can meet the designers needs in the most timely, efficient, and dependable manner. Inspection Many times the tool designer is required to inspect the finished tool to insure that it meets specifications. This inspection, or functional tryout, is normally conduced in two phases. First, the tool itself is inspected for compliance with the tool drawing. Second, several test parts are produced with the tool and are carefully checked to insure that they conform to the specifications shown in the part print. After the tool has been turned over to the production department, the tool designer should make periodic checks during production to insure that the specified tolerances are maintained, Figure 1-4. Figure 1-3 The tool design departments in most manufacturing organizations use a combination of drawing boards (A) and Computer Aided Design(CAD)workstations (B) to create the necessary tool design drawing (Photo courtesy of Advanced Technologies Center). 图 1-3 在大多数制造部门，夹具设计部门使用组合图板及 CAD 设计夹具图纸 (高技术中心提供图片 ) Figure 1-4 The tool designer consults the machinist to determine how well the jig or fixture performs. 图 1-4 夹具设计人员与技师协商解决夹具问题 1-5 nts REQUIREMENTS TO BECOME A TOOL DESIGNER In order to perform the functions of a tool designer, an individual must have the following skills: The ability to make mechanical drawings and sketches An understanding of modern manufacturing methods, tools, and techniques A creative mechanical ability An understanding of basic toolmaking methods A knowledge of technical mathematics through practical trigonometry SUMMARY The following important concepts were presented in this unit: Tool design is the process of designing and developing tooling devices, methods, and procedures to aid in improving overall manufacturing efficiency and productivity. The primary objective of tool design is lowering manufacturing costs while maintaining consistent quality and increased production. The tool designers use part drawings and production plan in developing alternative design solutions for efficient, dependable, and cost-effective tool designs. Tool des
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