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减速机机体工艺及铣削前后端面专用夹具设计

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关键词：: 减速机体工艺铣削前后先后端面专用夹具设计

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夹具体A2.dwg
夹具装配图a0.dwg
工艺过程卡片.doc
弧形压块A4.dwg
机体毛坯图A1.dwg
机体零件图A1.dwg
机械加工工序卡.doc
机械毕业设计外文翻译.doc
设计说明书.doc
铰链压板.dwg

摘　要
本文主要介绍WHX112减速机机体工艺及铣削前后端面专用夹具设计。通过CAD软件完成对铣床夹具的设计制造。
设计的重点是选定零件铣床夹具，通过CAD设计软件对钻床夹具进行绘制设计，然后将各零件进行装配，完成设计，以及利用UG对夹具进行虚拟制造。因此本文要全面的多方位的介绍cad软件，并详细对各个零件的设计与绘制的过程。进行专用夹具的设计，选择设计出夹具的各个组成部件，如定位元件、夹紧元件、引导元件、夹具体与机床的连接部件以及其它部件；计算出夹具定位时产生的定位误差，分析夹具结构的合理性与不足之处，并在以后设计中注意改进。

关键词：机体，铣削前后端面，CAD软件，虚拟设计制造，夹具

Abstract
This paper mainly introduces WHX112 recuder the process before and after the body and special fixture design of end milling. Through the CAD software to complete the design and manufacturing of milling machine fixture.
The design focuses on selected parts milling fixture, drilling fixture drawing design through the CAD design software, and then the part assembly, complete the design, and the use of UG for fixture on virtual manufacturing. Therefore, this paper introduces the multidimensional should fully CAD software, and the detailed design of each part and drawing process. Design of special fixture, fixture for the various components of the design, such as the connecting part positioning device, clamping device, a guide element, clamp and the machine tool and other components; calculate fixture positioning errors when positioning, analysis of the rationality and deficiency of fixture structure, pay attention to improving and will design in.

Keywords: machine, milling front end and the back end, CAD software, virtual design and manufacturing, fixture

摘　要 1
Abstract 2
第1章绪论 4
1.1概述 4
1.2机械加工工艺流程 4
第2章零件工艺的分析 5
2.1零件的工艺分析 5
2.2确定毛坯的制造形式 5
2.3箱体零件的结构工艺性 5
第3章拟定箱体加工的工艺路线 6
3.1定位基准的选择 6
3.1.1精基准的选择 6
3.1.2基准的选择 6
3.2加工路线的拟定 7
第4章机械加工余量，工序尺寸及毛坯尺寸的确定 9
第5章确定切削用量及基本工时 10
第6章铣前后端面的夹具设计 26
6.1 研究原始质料 26
6.2 定位、夹紧方案的选择 26
6.3切削力及夹紧力的计算 26
6.4 误差分析与计算 26
6.5定位销选用 26
6.6确定夹具体结构和总体结构 26
6.7 夹具设计及操作的简要说明 26
总结 29
参考文献 30
致谢 31

工艺过程卡片.jpg

弧形压块A4.png

机体零件图A1.png

机体毛坯图A1.png

机械加工工序卡.jpg

夹具体A2.png

夹具装配图a0.png

铰链压板.png

目录.jpg

全部文件.jpg

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内容简介：: 产品型号零件图号机械加工工艺过程卡片产品名称零件名称 WHX112 型机体共页第页材料牌号 HT20-40 毛坯种类模锻件毛坯外形尺寸每毛坯件数 1 每台件数 1 备注大批量生产工时工序号工名序称工序内容车间工段设备工艺装备准终单件1 铸造金工2 清砂清除浇注系统，冒口，型砂，飞边，飞刺等金工3 热处理人工时效处理金工4 涂漆非加工面涂防锈漆金工5 铣以分割面定位装夹工件，铣底面，保证高度尺寸242.5mm 金工卧式铣床 X63 专用夹具，三面刃铣刀，卡板 6 铣以底面定位，按线找正，装夹工件，铣分割面留磨量0.5-0.8mm 金工卧式铣床 X63 专用夹具，三面刃铣刀，卡板7 磨磨分割面，保证尺寸240mm 金工平面磨床M7130 专用夹具，砂轮，卡板8 钻、扩钻 4-16 孔金工立式钻床 Z535 专用夹具，扩孔钻，麻花钻，塞规钻 4-10 孔金工立式钻床 Z535 专用夹具，扩孔钻，麻花钻，塞规扩 4-11 孔金工立式钻床 Z535 专用夹具，扩孔钻，麻花钻，塞规钻 4-13 孔金工立式钻床 Z535 专用夹具，扩孔钻，麻花钻，塞规9 钻、攻钻 3-6 孔金工组合钻床专用夹具，丝锥，麻花钻，塞规攻 3-M6 孔金工组合钻床专用夹具，丝锥，麻花钻，塞规10 钻、铰钻，铰 2-6mm 的锥销孔，装入锥销金工立式钻床 Z535 专用夹具，铰刀，麻花钻，塞规11 铣粗铣前后端面，保证尺寸260mm 金工卧式铣床 X63 专用夹具，三面刃铣刀，卡板设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工艺过程卡片产品名称零件名称 WHX112 型机体共页第页材料牌号 HT20-40 毛坯种类模锻件毛坯外形尺寸每毛坯件数 1 每台件数 1 备注大批量生产工时工序号工名序称工序内容车间工段设备工艺装备准终单件12 铣精铣前后端面，保证端面A的垂直度为0.048 金工卧式铣床 X63 专用夹具，三面刃铣刀，卡板13 铣粗铣左右端面，保证尺寸260mm 金工卧式铣床 X63 专用夹具，三面刃铣刀，卡板14 铣精铣左右端面，保证端面A的垂直度为0.048 金工卧式铣床 X63 专用夹具，三面刃铣刀，卡板15 镗粗镗蜗杆面110mm轴承孔，留加工余量0.2-0.3mm 金工镗床 T68 专用夹具，YT30 镗刀，塞规16 检验对粗膛孔进行检验金工镗床 T68 专用夹具，YT30 镗刀，塞规 17 镗半精镗蜗杆面110mm轴承孔，留加工余量0.1-0.2mm 金工镗床 T68 专用夹具，YT30 镗刀，塞规18 镗精镗至图纸要求尺寸，保证分割面与轴承孔的位置度公差为0.02mm 金工镗床 T68 专用夹具，YT30 镗刀，塞规19 钻用带有锥度90度的锪钻锪轴承孔内边缘，倒角 4-45度金工立式钻床Z535 专用夹具，丝锥，麻花钻，塞规20 钳撤箱，清理飞边，毛刺金工21 钳合箱，装锥销，紧固金工22 检验检查各部尺寸及精度金工23 入库入库金工设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工序卡片产品名称零件名称 WHX112 型机体共页第页车间工序号工序名称材料牌号金工 5 铣 HT20-40毛坯种类毛坯外形尺寸每毛坯可制件数每台件数模锻件 1 1设备名称设备型号设备编号同时加工件数卧式铣床 X63夹具编号夹具名称切削液工序工时 (分)工位器具编号工位器具名称准终单件主轴转速切削速度进给量切削深度工步工时工步号工步内容工艺装备 r/min m/min mm/r mm 进给次数机动辅助1 以分割面定位装夹工件，铣底面，保证高度尺寸 242.5mm以分割面定位装夹工件，铣底面，保证高度尺寸242.5mm475 2.49 427 4 1 0.55 0.19设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工序卡片产品名称零件名称 WHX112 型机体共页第页车间工序号工序名称材料牌号金工 6 HT20-40毛坯种类毛坯外形尺寸每毛坯可制件数每台件数模锻件 1 1设备名称设备型号设备编号同时加工件数卧式铣床 X63夹具编号夹具名称切削液工序工时 (分)工位器具编号工位器具名称准终单件主轴转速切削速度进给量切削深度工步工时工步号工步内容工艺装备 r/min m/min mm/r mm 进给次数机动辅助1 以底面定位，按线找正，装夹工件，铣分割面留磨量 0.5-0.8mm 专用夹具，三面刃铣刀，卡板 400 32.4 24 0.2 1 15设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工序卡片产品名称零件名称 WHX112 型机体共页第页车间工序号工序名称材料牌号金工 7 HT20-40毛坯种类毛坯外形尺寸每毛坯可制件数每台件数模锻件 1 1设备名称设备型号设备编号同时加工件数平面磨床 M7130夹具编号夹具名称切削液工序工时 (分)工位器具编号工位器具名称准终单件主轴转速切削速度进给量切削深度工步工时工步号工步内容工艺装备 r/min m/min mm/r mm 进给次数机动辅助1 磨分割面，保证尺寸 240mm 专用夹具，砂轮，卡板 400 32.4 24 0.2 1 15设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工序卡片产品名称零件名称 WHX112 型机体共页第页车间工序号工序名称材料牌号金工 8 钻 HT20-40毛坯种类毛坯外形尺寸每毛坯可制件数每台件数模锻件 1 1设备名称设备型号设备编号同时加工件数立式钻床 Z535夹具编号夹具名称切削液组合钻床工序工时 (分)工位器具编号工位器具名称准终单件主轴转速切削速度进给量切削深度工步工时工步号工步内容工艺装备 r/min m/min mm/r mm 进给次数机动辅助1 钻 4-16 孔专用夹具，扩孔钻，麻花钻，塞规 400 31.42 34.2 16 1 32.5 8钻 4-10 孔专用夹具，扩孔钻，麻花钻，塞规 400 31.4 31.8 10 1 10扩 4-11 孔专用夹具，扩孔钻，麻花钻，塞规 400 31 26.4 11 1 102 12钻 4-13 孔专用夹具，扩孔钻，麻花钻，塞规 400 31.42 26.4 13 1 413 12设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工序卡片产品名称零件名称 WHX112 型机体共页第页车间工序号工序名称材料牌号金工 9 钻，攻 HT20-40毛坯种类毛坯外形尺寸每毛坯可制件数每台件数模锻件 1 1设备名称设备型号设备编号同时加工件数组合钻床夹具编号夹具名称切削液工序工时 (分)工位器具编号工位器具名称准终单件主轴转速切削速度进给量切削深度工步工时工步号工步内容工艺装备 r/min m/min mm/r mm 进给次数机动辅助1 钻 3-6 孔专用夹具，丝锥，麻花钻，塞规 400 31.42 36.6 6 1 51 6攻 3-M6 孔专用夹具，丝锥，麻花钻，塞规 400 4.9 6 6 1 140 4设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工序卡片产品名称零件名称 WHX112 型机体共页第页车间工序号工序名称材料牌号金工 10 钻、铰 HT20-40毛坯种类毛坯外形尺寸每毛坯可制件数每台件数模锻件 1 1设备名称设备型号设备编号同时加工件数立式钻床 Z535夹具编号夹具名称切削液工序工时 (分)工位器具编号工位器具名称准终单件主轴转速切削速度进给量切削深度工步工时工步号工步内容工艺装备 r/min m/min mm/r mm 进给次数机动辅助1 钻，铰 2-6mm 的锥销孔，装入锥销专用夹具，铰刀，麻花钻，塞规 530 41.6 45.6 6 1 32设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工序卡片产品名称零件名称 WHX112 型机体共页第页车间工序号工序名称材料牌号金工 11，12 铣 HT20-40毛坯种类毛坯外形尺寸每毛坯可制件数每台件数模锻件 1 1设备名称设备型号设备编号同时加工件数卧式铣床 X63 1夹具编号夹具名称切削液专用夹具工序工时 (分)工位器具编号工位器具名称准终单件主轴转速切削速度进给量切削深度工步工时工步号工步内容工艺装备 r/min m/min mm/r mm 进给次数机动辅助1 粗铣前后端面，保证尺寸 260mm 专用夹具，三面刃铣刀，卡板 37.5 26.5 0.2 2 1 20.8 8.22 精铣前后端面，保证端面 A 的垂直度为 0.048 专用夹具，三面刃铣刀，卡板 37.5 26.5 0.15 0.45 1 180 27设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工序卡片产品名称零件名称 WHX112 型机体共页第页车间工序号工序名称材料牌号金工 13，14 铣 HT20-40毛坯种类毛坯外形尺寸每毛坯可制件数每台件数模锻件 1 1设备名称设备型号设备编号同时加工件数卧式铣床 X63 1夹具编号夹具名称切削液专用夹具工序工时 (分)工位器具编号工位器具名称准终单件主轴转速切削速度进给量切削深度工步工时工步号工步内容工艺装备 r/min m/min mm/r mm 进给次数机动辅助1 粗铣左右端面，保证尺寸260mm 专用夹具，三面刃铣刀，卡板 37.5 26.5 0.2 2 1 20.8 8.22 精铣左右端面，保证端面A的垂直度为0.048 专用夹具，三面刃铣刀，卡板 37.5 26.5 0.15 0.45 1 180 27设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期产品型号零件图号机械加工工序卡片产品名称零件名称 WHX112 型机体共页第页车间工序号工序名称材料牌号金工 15,17 HT20-40毛坯种类毛坯外形尺寸每毛坯可制件数每台件数模锻件 1 1设备名称设备型号设备编号同时加工件数镗床 T68夹具编号夹具名称切削液工序工时 (分)工位器具编号工位器具名称准终单件主轴转速切削速度进给量切削深度工步工时工步号工步内容工艺装备 r/min m/min mm/r mm 进给次数机动辅助1 粗镗蜗杆面 110mm 轴承孔，留加工余量 0.2-0.3mm 专用夹具，YT30 镗刀，塞规 800 300 0.37 2.2 1 69 82 半精镗蜗杆面 110mm 轴承孔，留加工余量 0.1-0.2mm 专用夹具，YT30 镗刀，塞规 800 300 0.27 0.2 1 73 9设计（日期）校对（日期）审核（日期）标准化（日期）会签（日期）标记处数更改文件号签字日期标记处数更改文件号签字日期Introduction to Modern Control TheorySeveral factors provided the stimulus for the development of modern control theory: a. The necessary of dealing with more realistic models of system.b. The shift in emphasis towards optimal control and optimal system design. c. The continuing developments in digital computer technology. d. The shortcoming of previous approaches. e. Recognition of the applicability of well-known methods in other fields of knowledge.The transition from simple approximate models, which are easy to work with, to more realistic models, produces two effects. First, a large number of variables must be included in the models. Second, a more realistic model is more likely to contain nonlinearities and time-varying parameters. Previously ignored aspects of the system, such as interactions with feedback through the environment, are more likely to be included. With an advancing technological society, there is a trend towards more ambitious goals. This also means dealing with complex system with a large number of interacting components. The need for greater accuracy and efficiency has changer the emphasis on control system performance. The classical specifications in terms of percent overshoot, setting time, bandwidth, etc. have in many cases given way to optimal criteria such as mini mum energy, minimum cost, and minimum time operation. Optimization of these criteria makes it even more difficult to avoid dealing with unpleasant nonlinearities. Optimal control theory often dictates that nonlinear time-varying control laws are used, even if the basic system is linear and time-invariant. The continuing advances in computer technology have had three principal effects on the controls field. One of these relates to the gigantic supercomputers. The size and the class of the problems that can now be modeled, analyzed, and controlled are considerably large than they were when the first edition of this book was written. The second impact of the computer technology has to so with the proliferation and wide availability of the microcomputers in homes and I the work place, classical control theory was dominated by graphical methods because at the time that was the only way to solve certain problems, Now every control designer has easy access to powerful computer packages for systems analysis and design. The old graphical methods have not yet disappeared, but have been automated. They survive because of the insight and intuition that they can provide, some different techniques are often better suited to a computer. Although a computer can be used to carry out the classical transform-inverse transform methods, it is used usually more efficient for a computer to integrate differential equations directly.The third major impact of the computers is that they are now so commonly used as just another component in the control systems. This means that the discrete-time and digital system control now deserves much more attention than it did in the past.Modern control theory is well suited to the above trends because its time-domain techniques and its mathematical language (matrices, linear vector spaces, etc.) are ideal when dealing with a computer. Computers are a major reason for the existence of state variable methods.Most classical control techniques were developed for linear constant coefficient systems with one input and one output (perhaps a few inputs and outputs). The language of classical techniques is the Laplace or Z-transform and transfer functions. When nonlinearities ad time variations are present, the very basis for these classical techniques is removed. Some successful techniques such as phase-plane methods, describing function s, and other ad hoc methods, have been developed to alleviant this shortcoming. However, the greatest success has been limited to low-order systems. The state variable approach of modern control theory provides a uniform and powerful method of representing systems of arbitrary order, linear or nonlinear, with time-varying or constant coefficient. It provides an ideal formulation for computer implementation and is responsible for much of the progress in optimization theory. Modern control theory is a recent development in the field of control. Therefore, the name is justified at least as a descriptive title. However, the foundations of modern control theory are to be found in other well-established fields. Representing a system in terms of state variables is equivalent to the approach of Hamiltonian mechanics, using generalized coordinates and generalized moment. The advantages of this approach have been well-known I classical physics for many years. The advantages of using matrices when dealing with simultaneous equations of various kinds have long been appreciated in applied mathematics. The field of linear algebra also contributes heavily to modern control theory. This is due to the concise notation, the generality of the results, and the economy of thought that linear algebra provides. Mechanism of Surface Finish Production There are basically five mechanisms which contribute to the production of a surface which have been machined. There are: (1) The basic geometry of the cutting process. In, for example, single point turning the tool will advance a constant distance axially per revolution of the work piece and the resultant surface will have on it, when viewed perpendicularly to the direction of tool feed motion, a series of cusps which will have a basic form which replicates the shape of the tool in cut. (2) The efficiency of the cutting operation. It has already been mentioned that cutting with unstable built-up-edges will produce a surface which contains hard built-up-edge fragments which will result in a degradation of the surface finish. It can also be demonstrated that cutting under adverse conditions such as apply when using large feeds small rake angles and low cutting speeds, besides producing conditions whichcontinuous shear occurring in the shear zone, tearing takes place, discontinuous chips of uneven thickness are produced, and the resultant surface is poor. This situation is particularly noticeable when machining very ductile materials such as copper and aluminum. (3) The stability of the machine tool. Under some combinations of cutting conditions: work piece size , method of clamping, and cutting tool rigidity relative to the machine tool structure, instability can be set up in the tool which causes it to vibrate. Under some conditions the vibration will built up and unless cutting is stopped considerable damage to both the cutting tool and work piece may occur. This phenomenon is known as chatter and in axial turning is characterized by long pitch helical bands on the work piece surface and short pitch undulations on the transient machined surface.(4) The effectiveness of removing sward. In discontinuous chip production machining, such as milling or turning of brittle materials, it is expected that the chip (sward) will leave the cutting zone either under gravity or with the assistance of a jet of cutting fluid and that they will not influence the cut surface in any way. However, when continuous chip production is evident, unless steps ate taken to control the swarf it is likely that it will impinge on the cut surface and mark it. Inevitably, this marking beside a looking unattractive, often results in a poorer surface finishing, (5) The effective clearance angle on the cutting tool. For certain geometries of minor cutting edge relief and clearance angles it is possible to cut on the major cutting edge and burnish on the minor cutting edge. This can produce a good surface finish but, of course, it is strictly a combination of metal cutting and metal forming and is not to be recommended as a practical cutting method. However, due to cutting tool wear, these conditions occasionally arise and lead to a marked change in the surface characteristics.现代的控制理论简介下列几方面为现代控制理论发展的促进因素: 1.处理更多的现实模型系统的必要性2.强调向最佳的控制和最佳的系统设计的升级3.数字化计算机技术的持续发展.4.当前技术的不成熟.众所周知的方法在其它知识领域的适用性得到承认.从容易解决的简单近似的模型到更多的现实模型的转变产生了两种效果：首先，模型必须包括很多的变量。其次，一个十分逼真的模型是尽可能的包括非线性和随时间变化的参数。早先的忽略了系统的一些方面，例如很有可能的一方面就是在环境中有着反馈的交互作用。在现代科技高度发达的社会，存在一种非常雄心的目标的趋势，这也意味着要处理有着很多相互关联成分的复杂系统，高精确度与高效率的需要改变了控制系统的执行重点。在超频百分比，时间设置，频宽等等方面的经典规范，在很多情况下解决了优化标准如最小能量，最小花费，最小时间控制，优化这些标准时很难避免和不开心的非线性打交道。即使基础系统是线性的和不随时间变化的，优化控制理论显示非线性时间变化控制也被应用到了。不停发展的计算机技术在控制领域创造了三条最重要的影响。其中一项是有关数字化的超级计算机，较之这本书首印时期，现在能模拟，分析，控制的问题的大小和种类都要大得惊人。计算机技术的第二个问题就是必须处理微型计算机在家庭和工作地的扩散与广泛的可靠性。古典的控制理论是以图画似的方法为主导的. 因为在时间那是唯一的解决确定的问题的途径。为了系统分析和设计,现在每一个控制设计者很容易有机会接近强大的计算机内部。老的图画似的方法不但没有消失, 并且还使其自动化了.它们之所以能生存是因为提供了洞察力与直觉，许多不同的技术经常能更适合于计算机。虽然计算机能被用于执

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