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长430 DA468 发动机 曲轴 加工 工艺 专用 机床 夹具 设计 430 CAD 图纸 说明书

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SY-025-BY-2毕业设计（论文）任务书学生姓名院系汽车与交通工程学院专业、班级指导教师姓名职称教授从事专业车辆工程是否外聘是否题目名称DA468型发动机曲轴加工工艺与专用机床夹具设计一、设计（论文）目的、意义车辆工程专业主要培养汽车设计制造方面的应用型人才，进行汽车零件加工工艺规程与专用机床夹具设计，能使学生综合运用所学专业知识，如机械制图、测量与公差配合、金属材料与热处理、工程力学、机械制造基础、机械设计、汽车设计、汽车制造工艺等，通过理论联系实际，使这些知识得到进一步巩固、加深和拓展，熟悉机械加工工艺规程编制、机床夹具设计的方法，培养学生设计能力和解决实际问题的能力，对CAD绘图、运用设计资料（如手册、图册、技术标准、规范等）以及进行经验估算等技能得到综合训练，力求设计合理，理论联系实际，设计手段具有一定的先进性。二、设计（论文）内容、技术要求（研究方法）设计内容：1.选题的背景、目的及意义；2.分析曲轴零件图和绘制毛坯图；3.制定零件加工工艺路线；4.进行工序设计；5.制定二套夹具设计方案；6.绘制夹具图纸；7.编写设计说明书。技术要求：1.明确设计内容和要求；2.熟悉教材和相关设计指导书，准备设计资料和手册等；3.熟悉绘图软件，提高识图和绘图能力；4.合理制定曲轴零件成批生产的工艺路线；5.合理设计工序，具有工艺尺寸链计算能力；7.设计二套典型专用机床夹具，具有定位误差分析计算的能力；8.绘制夹具装图和非标准零件图；9.设计应理论联系实际，不断发现问题解决问题，方案正确、计算准确、设计合理、图纸及撰写规范。三、设计（论文）完成后应提交的成果曲轴零件图一张，毛坯图一张，曲轴加工工艺规程一套，曲轴加工专用机床夹具二套；CAD绘制专用机床夹具装配图、零件图折合0号图纸3张以上，设计说明书15000字以上。四、设计（论文）进度安排（1）知识准备、调研、收集资料、完成开题报告 第12周（2.283.11）（2）整理资料、提出问题、撰写设计说明书草稿、绘制图纸草图 第35周（3.144.1）（3）理论联系实际、分析问题、解决问题，完成分析零件图和绘制毛坯图、制定曲轴加工工艺路线、进行工序设计、制定夹具设计方案、CAD绘制夹具装配图等部分设计内容，中期检查 第68周（4.44.22）（4）改进完成设计，改进完成设计说明书，指导教师审核，学生修改 第912周(4.255.20)（5）评阅教师评阅、学生修改 第13周（5.235.27） （6）毕业设计预答辩 第14周（5.306.34）（7）毕业设计修改 第1516周（6.66.17）（8）毕业设计答辩 第17周（6.206.24）五、主要参考资料1.汽车制造工艺学2.机械制造工艺学3.机械制造工艺学课程设计指导书4.机床夹具设计手册5.机械加工工艺手册6.机械制造工艺学简明设计手册7.东北重型机械学院，洛阳工学院，第一汽车制造厂职工大学编.机床夹具设计手册.上海科学技术出版社8.机床夹具设计图册9.罗仁芝.6108曲轴机械加工工艺浅析.高等职业教育(天津职业大学学报),2006.0110.祝小军，黄晓峰.小型柴油机曲轴生产线新工艺的应用研究.小型内燃机,2006.0411.赵佩凤,周来宏.曲轴粗加工的工艺方法.组合机床与自动化加工技术,2009.0112.网络资源，超星数字图书馆13.近几年相关专业CNKI网络期刊等六、备注指导教师签字：年 月 日教研室主任签字： 年 月 日 毕业设计（论文）开题报告设计（论文）题目: DA468发动机曲轴加工工艺 与专用机床夹具设计 院 系 名 称:专 业 班 级:学 生 姓 名:导 师 姓 名:开 题 时 间:指导委员会审查意见： 签字： 年 月 日SY-025-BY-3毕业设计（论文）开题报告学生姓名辛文系部汽车与交通工程学院专业、班级车辆07-5班指导教师姓名石美玉职称教授从事专业车辆工程是否外聘是否题目名称DA468型发动机曲轴加工工艺与专用机床夹具设计一、 课题研究现状、选题目的和意义1. 课题研究现状随着科学技术的迅猛发展和市场需求的变化及竞争加剧，传统的制造技术发展到了一个崭新的阶段；随着我国经济的持续高速发展，人们生活水平不断提高，汽车已经走进了我们的日常生活，渐渐成为一种普通消费品；随着市场对汽车需要量的增加和制造技术的发展，到了本世纪初，小作坊的生产方式已经不能满足需要，而各种新的制造工艺和新式高效机床的出现，使汽车和发动机的制造技术出现了飞跃。因此，人们对汽车的性能要求也在不断提高，不论是经济性、动力性，还是稳定性、安全性，甚至是排放性等各方面都要逐一考虑。这就需要传统制造技术和汽车专业技术相互结合，在满足汽车动力性的同时满足其经济性与生产效率，也就是工艺性。而要想使整车的工艺性完美，对各零件的加工也是最为重要的。福特汽车公司在1908年建立第一条流水线生产单一品种廉价的A型车始，汽车和发动机生产进入第二发展阶段。这时主要用各种高效专用及组合机床组织机械化流水生产。并出现了两种不同的生产组织形式:一是以福特公司为代表，建立大型综合厂，另一种是以通用公司为代表，采用高效专用机床组织多品种专业化生产。在这个阶段，制造技术发展迅速，各种先进的工艺和高效生产机床如多轴立车，曲轴多刀车床，加工缸体和缸盖等壳体零件的多轴钻，憧，攻丝组合机床等相继在生产中采用。发动机产量急剧增加，生产效率迅速提高，现代大量生产的雏形已初步形成。由于多品种专业化生产具有生产管理灵活，更换品种容易，能及时提供市场所需的产品等优点，使得通用公司超过福特公司而成为世界上最大的汽车公司。发动机作为汽车的心脏，其质量的优劣是衡量汽车性能的重要标准。我国各汽车制造商也十分重视发动机的研发和制造，各汽油机、柴油机制造厂已掌握了较先进的技术，具备一定的生产能力。发动机零件精度高，结构复杂，但比较典型，制造工艺比较成熟，工艺水平普遍高于其它总成，生产工艺过程和组织形式具有一系列的特点，这表现在生产的专业化、系列化、多品种，产过程的自动化，包括自动线的广泛采用和加工过程综合自动化的发展等方面。产品的系列化是提高发动机制造技术水平的前提和条件，而自动化的流水生产又对生产专业化提出了迫切的要求。而曲轴是发动机中最重要的零件之一，是承受冲击载荷传递动力的关键零件，是在柴油机的机体、缸盖、曲轴、连杆、凸轮轴5大件中最难以保证加工质量的零件。它的作用是把活塞的往复直线运动变成旋转运动，将作用在活塞的气体压力变成扭矩，用来驱动工作机械和发动机各辅助系统进行工作。由于曲轴工况条件恶劣，在工作时承受着不断变化的压力、惯性力和它们的力矩作用，因此对曲轴的材质、毛坯加工技术、精度、表面粗糙度、热处理和表面强化及动平衡等要求都十分严格。在大批量生产的前提下，传统生产工艺已不能满足当前设计和生产的要求，在长时间、高速度运转下，曲轴很容易过早地出现失效或断裂现象，严重影响了曲轴的寿命和整机的可靠性。目前，世界各国的发动机生产企业对曲轴加工都十分重视，都在不断更新曲轴加工设备改进加工工艺，以提高曲轴加工质量，延长使用寿命。我国的各大发动机生产厂经过多年的学习和探索，已经掌握了很多较为先进的血轴加工技术，生产效率较高，生产线中的大部分设各也已国产化。发动机曲轴生产得到较大的发展，总量已具相当的规模，无论是设计水平，还是产品品种、质量、生产规模、生产方式都有很大的发展。曲轴在发动机中是承受载荷传递动力的重要零部件，也是发动机五大零部件中最难以保证加工质量的零部件，其性能、水平直接影响整机的性能水平及可靠性。因此，各工业发达国家十分重视曲轴生产，不断改进其材质及加工手段，以提高其性能水平，满足发动机行业的需要。近几年来，国内曲轴加工发展十分迅速。尤其是发动机曲轴。先进的加工工艺加工出的曲轴质量好、效率高且稳定。而欧美等汽车工业发达的国家，经过多年的积累，通过计算机三维设计，利用有限元分析方法对曲轴的各项强度指标进行分析，使曲轴在初期达到完美的设计。在加工工艺方面，由于国外大多采用了先进的数控设备，而国内大多以手动设备为主，精度差，这就要求我们在实际设计加工工艺的过程中充分考虑各方面的因素，在借鉴国外先进的工艺方案的同时充分考虑现有设备资源的利用和改造，达到少投入，大收益。2. 选题目的和意义发达国家的发展经验告诉我们，工业化是迈向现代化的必经之路。而制造业，特别是装备制造业是实现工业化的主力军，是实现现代化的原动力，发展制造业始终是振兴经济、实现现代化的最佳路径。曲轴是发动机中用于传递动力的核心零件，由于工况条件恶劣，且承受复杂的冲击载荷，因此对曲轴的材质、NI精度、表面质量、动平衡等的要求都十分严格。又由于曲轴的材料为高强度合金钢，难于加工和断屑，而且曲轴主轴颈和连杆轴颈几何形状复杂，因此作为发动机五大零件之一的曲轴，其加工难度、加工工艺复杂程度在发动机各零部件中都首屈一指，它的结构参数和加工工艺水平直接影响着整机的尺寸和重量，以及发动机的可靠性和寿命。世界各国的发动机生产企业对曲轴。加工都十分重视，都在不断更新曲轴加工设备改进加工工艺，以提高曲轴加工质量，延长使用寿命。我国的各大发动机生产厂经过多年的学习和探索已经掌握了很多较为先进的血轴加工技术，生产效率较高，生产线中的大部分设各也已国产化。但是，在一些关键工序所采用的关键工艺上，我们还是非常依赖国外的技术，需要使用国外的设备和刀具。因此，我们还需进一步研究曲轴加工工艺，尤其是要深入研究关键工艺和关键设备，这对提升曲轴乃至发动机的生产水平都是相当重要的。二、设计（论文）的基本内容、拟解决的主要问题1.基本内容1).选题的背景、目的及意义；2).分析曲轴零件图和绘制毛坯图；3).制定零件加工工艺路线；4).进行工序设计；5).制定二套夹具设计方案；6).绘制夹具图纸；7).编写设计说明书。2. 拟解决的主要问题1).分析零件图，运用工艺知识选择加工基准据实际生产条件确定工艺方案及相应加工方法；2).夹紧与定位对比分析，受力分析与夹紧方案和工作原理及组成；3).使用AUTOCAD软件，绘制专用车床夹具，提高用软件制图本领；三、技术路线（研究方法）调研和查阅资料选定样本并用CAD绘制发动机曲轴零件图掌握曲轴加工方法、所用工装夹具工艺卡片填写专用夹具设计工艺过程设计 利用CAD绘图完成设计说明书四、进度安排1.第12周（2.283.11） 知识准备、调研、收集资料、完成开题报告。2.第35周（3.144.1） 整理资料、提出问题、撰写设计说明书草稿、绘制图纸草图。3.第68周（4.44.22） 理论联系实际、分析问题、解决问题，完成分析零件图和绘制毛坯图、制定曲轴加工工艺路线、进行工序设计、制定夹具设计方案、CAD绘制夹具装配图等部分设计内容，中期检查。4.第912周(4.255.20) 改进完成设计，改进完成设计说明书，指导教师审核，学生修改。5.第13周（5.235.27） 评阅教师评阅、学生修改。6.第14周（5.306.34） 毕业设计预答辩。7.第1516周（6.66.17）毕业设计修改。8.第17周（6.206.24） 毕业设计答辩。五、参考文献1.王先奎.机械加工工艺手册, 北京:机械工业出版社,2008.062.王宝玺，贾庆祥.汽车制造工艺学, 北京:机械工业出版社,2007.033.王先逵.机械制造工艺学,第二版.北京：机械工业出版社，2006.4.崇凯.机械制造技术基础课程设计指导书,北京:化学工业出版社,2006.125.李昌年.机床夹具设计与制造,北京：机械工业出版社，2006.6.孙丽媛.机械制造工艺及专用夹具设计指导,北京：冶金工业出版，20027.李益民.机械制造工艺学简明设计手册,北京:机械工业出版社,2000.048.夏长高,潘茂辉,束永平. 基于CAD /CAE的曲轴设计研究,2010.129.赵佩凤,周来宏.曲轴粗加工的工艺方法.组合机床与自动化加工技术，2009.0110.曲轴连杆颈车床的设计与应用，200811.盛小兵.曲轴圆角滚压强化工艺中曲轴变形的研究，200812.祝小军，黄晓峰.小型柴油机曲轴生产线新工艺的应用研究.小型内燃机，2006.0413.罗仁芝.6108曲轴机械加工工艺浅析.高等职业教育(天津职业大学学报)，2006.0114.高广阔，刘景峰，辜祖勋. 轿车发动机曲轴材料及工艺的研究,2005.0615.杨宝田.4D型柴油机曲轴加工工艺设计 硕士论文，200416.曲轴粗加工关键工艺及设备的比较，2003.0117.车削曲轴连杆颈的可调整夹具，2002.1218.严桃平，赵迎生. 车用发动机典型零部件的加工新工艺,200219.刘光华,张永秀,李瑞. 发动机曲轴的强度、材料与工艺,2001.0920.Zienkiewicz OC，Taylor R LThe Finite Element MethodButterworth-Heinemann，2000六、备注指导教师意见：签字： 年 月 日摘 要本设计主要围绕发动机曲轴的工艺规程和专用夹具设计进行研究，其内容包括了解曲轴结构，确定曲轴的生产类型及相关的技术要求。在此基础上，选择毛坯，确定毛坯的尺寸公差和机械加工余量，绘制毛坯图。并在认真详细分析零件图后，进行基准的选择，制定了表面加工方法，划分加工阶段，根据生产类型确定工序的集中和分散，合理地安排工序，编排合适的工艺路线；进行详细计算，包括：加工余量、工序尺寸和公差的确定、切削用量的计算及时间定额的计算。从而制定出一套合理的机械加工工艺卡片和机械加工工序卡片。 第二部分主要围绕专用钻床类夹具进行设计。首先明确夹具设计的主要任务，通过确定定位元件，导向装置，夹紧机构得出夹具的结构方案，查阅相关国家标准，绘画夹具装配图。总之，曲轴加工工艺的安排以及专用夹具的设计是一项非常复杂的高难度工作，它是一种需大批量生产的零件，且技术要求比较高，为了确保产品的质量和水平，设计工作按照科学的程序进行，分清主次。关键词：曲轴；加工工艺；定位；夹紧；钻孔；夹具设计ABSTRACTIn this paper the technological procedure and proprietary drilling fixture design of the engine crankshaft were studied, whose contents included that the use of crankshaft, the production type of crankshaft of and the relevant technical requirements. On this basis, the rough was chosen, and the size of the rough was determined, and the mechanical allowances were determined. A rough map was drawn. After carefully detailed analysis of the parts, the reference was chosen, the development of surface processing methods was determined, and the demarcation of the processing stages was divided. According to the production process the type of centralization and decentralization was determined, the process was reasonably arranged, and the order and orchestrates a suitable process line were set up. Then some detail was calculated, such as allowance, processes size and the determination of tolerance. The amount of calculation and the calculation of the fixed time was cut. Thus a set of reasonable card processing machinery and mechanical processes cards were drawn up.The second part of the design was the focus of this issue which was difficult, who was mainly centered on proprietary drilling fixture design, Z525-use vertical drilling, drilling middle-hole design process by which a drilling fixture. Firstly fixture was designed to clear the major tasks identified by positioning components, guidance devices, clamping body fixture structure, access to the relevant national standards, painting fixture assembly. In short, the processing arrangements of crankshaft and the design of special fixture are a very complex difficult work. It is required in mass production. The technical requirements are relatively high. In order to ensure the quality and level of design the design work was carried out in accordance with the procedures of science, the relation between primary and secondary was distinguished.Keywords: Bent axle； Processing technical； Cutting parameters； FixtureDesignII附录AInvestigation on Pressure Impact in ConcretePumping Hydraulic System Abstract：The pressure impact in hydraulic systems of such concrete pumping machinery as trailer concrete pump，transported concrete pump，and truck mounted concrete pump，is a key factor affecting their reliability and usage lifeBased on the pressure forming principle of the oil in a hydrostatic closed pressure chamber，the mechanism of producing pressure impact is analyzed synthetically，and the theory that oil flow matches requirement， and pump displacement control harmonizes valve shifting time control，to mitigate pressure impact，is put forwardThe quantitative controlling parameters about shifting time and displacement control are introduced to realize accurate controlThe experiment investigations of pressure impact property and its control are carried through on an experimental system which is able to simulate concrete pumping conditionThe basic law that pressure impact and controlling parameters vary with working condition respectivelyThe feasibility and validity of the technology proposed in this paper to control pressure impact are confirmed.Keywords: Pressure impact；Hydraulic system； Concrete pumping machinery1 IntroductionDuring working process of such concrete machinery as trailer concrete pump，transported concrete pump，and truck mounted concrete pump，two oil cylinders drive two concrete delivery cylinders respectively，and quickly switch direction with the possible highest frequency of more than 30 times per minute，which generates serious hydraulic impactIt is an important factor resulting in bad performance and low use reliability of the machine， and vibration，noise and overheating etcso its a key of improving concrete pumping machinerys reliability to gain a mastery of pressure impact property in concrete pumping hydraulic system and its controlling technologySuch technological measures as follows were taken to reduce pressure impact：(1)installation of a hydraulic accumulator or unloading valves，(2) change of sliding spools structure，(3)control of the switching speed of sliding spool，etc1Though these measures play an important role in absorption of pressure surges，there are obvious limitations， and they are passive measuresLiterature.2. investigated the switching process of concrete pumping hydraulic system，and put forward active measure of regulating oil pumps displacement to reduce pressure impactLiterature3studied the intrinsic relationship between shifting time and pressure impact，and proposed a new concept of optimal shifting timeTherefore，in this paper, experiments were conducted to find out pressure impact forming law， and both oil pumps displacement and directionalcontrol valves shifting time were controlled simultaneously to seek optimal control scheme for effective reduction of pressure impact2 Experimental principleThe pressure variation of the oil in a pressure chamber depends upon the difference between volumes of the oil flowing in and out the chamber2Its obvious that effective reduction of this difference is of positive significance for depressing pressure impact As far as concrete pumping hydraulic system is concerned, the pressure impact resulting from the main oil cylinders stroke terminal lies upon the suitability of shifting time to a great extent3So its feasible and effective for absorbing pressure impact to accurately control oil pumps displacement according to hydraulic systems requirement，and combine it with shifting time control techniqueWhat is shown in Fig.1 is the principle drawing of the experimental system sued to study characteristics of pressure impact in concrete pumping hydraulic system and its controlling techniquesThe main oil pump(1)is a swash-plate type axial piston pump，which is provided with the function of constant horsepower control。negative flow contr01The pressured oil used to contr01 oil pumps displacement comes from tilting systemIn this controlling oil line，a 3-way,2-position directional valve(11)with one solenoid and a pressure reducing valve(12)are installed in seriesWhen the solenoid of valve(11)is de-energized，the pressured oil from tilting system is stopped，and the pressured oil in the displacement control device of oil pump(1)is introduced into oil reservoir simultaneously by the valve(11)Here，the oil pressure in the displacement control device is zero or very low，the oil pumps displacement can come to maximumOn the other hand，when the solenoid of valve(11)is energized，the pressured oil coming from tilting system is introduced by the valve(11)，and is decompressed by pressure reducing valve (12)，and comes into the displacement control device，so 8s to make oil pumps displacement be reduced to minimum or zero.Two hydraulic cylinders(6.1,6.2)are connected in series，and four check valves and four throttle valves，which perform the functions of suction and cushioningare installed on the cylindersTwo non-contacting sensors(9,10)are used to provide shifting signalsFour pressure sensors are installed at the testing points M1，M2，M3 and M4 respectivelyThe signals provided by these sensors are collected and analyzed synchronously by a spectrum instrument and a microcomputerThe sampling frequency is 1 kHzThe sampling time is one minutes at a time so as to gain several pressure signals during shifting from a samplingDuring the experimental process，the pressure signals only during such shifting process as oil cylinders(6.1and 6.2)extends and retracts to the end respectively were analyzedWhen the sensor(10)obtains the signal of cylinder(6.2)retracting stroke terminal，the electrical system gives the instrument for regulating oil pumps displacement to decrease its swash-plates angle，and gives signal to make valves(8，7)shift after a certain time 1ag During such shifting process，the shifting time of valve(1)depends on following two factors：one is the sensor(10)s installation position relative to the cylinder(6.2)；the other is the shifting time lag iethe difference between the times when main oil pump(1)begins regulating displacement and when the hydro-piloted directional contr01 valve (7)begins to shiftIn order to simplify the experiments，the sensor(10)s installation position relative to the cylinder(6.2)is changeless，and the oil pumps displacement regulating time is also invariableThe difference between the times when the oil pumps displacement begins to reduce and when begins to increase is 0.2s3 Experimental results and analysis Figure.2 shows the curves of pressure versus time，which were measured at points M1 and M2 when time lag At.is 0.12sIt can be seen from the curves shown in Fig.2 that the pressure impact extent in the chamber in which the testing point M1 is situated decreases gradually along with an increase in the working pressureThe main reason is that the pump adopts constant power control，in response to the rise of the working pressure，the swash-plates tilting angle is decreased，and pumps displacement is reduced。the main oil cylinders velocity becomes smallerSo the pressure impact decreasesIts also seen from Fig.2 that there are two pressure peaks in the curves measured at testing point M1.The time of producing those two pressure peaks corresponds with the two transitional positions of directional control valve(7)during its spool shiftsFigure3 shows the curves of pressure versus time，which were measured at points M1 and M3 when time lag At：is 0.09s，and the working pressure is10 MpaIt can be seen from Fig3 that the second pressure peak in the curve measured at point M1 is much smaller than the first oneThe main reason is as follows：when the sliding spool of directional control valve(7)moves to the first transitional position，its impossible that obvious variation of swashplates tilting angle takes place，and the oil flow is still big When the sliding spool of directional control valve(7) moves to the second transitional position，swash-plates tilting angle has become relatively small，and the oil flow is also smallTherefore，the volume difference of the oil between flowing in and flowing out the pressure chamber at the second transitional position is much smaller than at the first transitional position，which results in that the second pressure peak is much smaller than the first oneIt can be seen；by a comparison between Fig2(a)and Fig3，that the time lag At：has obvious influence upon pressure impact at the testing point M1Too short time lag.附录B混凝土运输车中液压泵压力的影响摘要 本文介绍了混凝土运输车中液压泵中的压力大小对整个液压系统的影响，液压泵的压力大小是影响整个工作系统的可靠性和使用寿命的关键因素，如何确定液压油在封闭液压缸中产生的压力的大小，要通过综合和理论上进行分析才能确定该工况下产生压力的影响，比如，油流量的要求，泵排量的控制，协调阀反应时间的控制，通过这些方面的控制，通过改变其中任何一个都可以减轻压力对整个系统的影响，只要通过定量控制这些参数的变化时间以及位移的控制就能做到，本文介绍了为实现准确控制，通过实验调查压力的影响以及控制其影响的实验系统，这个实验系统能够模拟混凝土泵在工作情况中的基本参数，这种压力的影响和控制参数的不同分别与工作条件的可行性和有效性的技术，本文提出了如何控制压力影响进行了验证。关