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四川大学锦城学院机械加工工序卡产品型号及规格图 号名 称工艺文件编号共 7 页泵 盖第1页 材料牌号及名称毛坯外型尺寸HT150零件毛重零件净重硬 度1.4kg180-200HB设 备 型 号设 备 名 称X51立式铣床专 用 工 艺 装 备名 称代 号铣夹具机动时间单件工时定额每台件数1技 术 等 级冷 却 液亚硝酸钠工序号工步号工 序 及 工 步 内 容刃 具量 检 具切 削 用 量代 号名 称代 号名称切削速度（米/分）切削深度（毫米）进给量（毫米/转）转速（转/分）301铣A面（大端面）端铣刀游标卡尺89.53.00.2475编 制校 对会 签复 制修改标记处 数文件号签 字日 期修改标记处 数文件号签 字日 期四川大学锦城学院机械加工工序卡产品型号及规格图 号名 称工艺文件编号共 7 页泵 盖第2页材料牌号及名称毛坯外型尺寸HT150零件毛重零件净重硬 度1.4kg180-200HB设 备 型 号设 备 名 称Z525立式钻床专 用 工 艺 装 备名 称代 号钻夹具机动时间单件工时定额每台件数1技 术 等 级冷 却 液亚硝酸钠工序号工步号工 序 及 工 步 内 容刃 具量 检 具切 削 用 量代 号名 称代 号名称切削速度（米/分）切削深度（毫米）进给量（毫米/转）转速（转/分）401锪平4-18深2锪孔刀游标卡尺13.62.00.22752钻9孔麻花钻游标卡尺17.94.50.25475编 制校 对会 签复 制修改标记处 数文件号签 字日 期修改标记处 数文件号签 字日 期四川大学锦城学院机械加工工序卡产品型号及规格图 号名 称工艺文件编号共 7 页 泵 盖第3页 材料牌号及名称毛坯外型尺寸HT150零件毛重零件净重硬 度1.4kg180-200HB设 备 型 号设 备 名 称X51立式铣床专 用 工 艺 装 备名 称代 号铣夹具机动时间单件工时定额每台件数1技 术 等 级冷 却 液亚硝酸钠工序号工步号工 序 及 工 步 内 容刃 具量 检 具切 削 用 量代 号名 称代 号名称切削速度（米/分）切削深度（毫米）进给量（毫米/转）转速（转/分）501铣宽24的槽麻花钻游标卡尺69.12.00.25275编 制校 对会 签复 制修改标记处 数文件号签 字日 期修改标记处 数文件号签 字日 期四川大学锦城学院机械加工工序卡产品型号及规格图 号名 称工艺文件编号共 7 页 泵 盖第4页 材料牌号及名称毛坯外型尺寸HT150零件毛重零件净重硬 度1.4kg180-200HB设 备 型 号设 备 名 称Z525立式钻床专 用 工 艺 装 备名 称代 号钻夹具机动时间单件工时定额每台件数1技 术 等 级冷 却 液亚硝酸钠工序号工步号工 序 及 工 步 内 容刃 具量 检 具切 削 用 量代 号名 称代 号名称切削速度（米/分）切削深度（毫米）进给量（毫米/转）转速（转/分）601钻2-8孔麻花钻游标卡尺17.64.00.25475编 制校 对会 签复 制修改标记处 数文件号签 字日 期修改标记处 数文件号签 字日 期四川大学锦城学院机械加工工序卡产品型号及规格图 号名 称工艺文件编号共 7 页 泵 盖第5页 材料牌号及名称毛坯外型尺寸HT150零件毛重零件净重硬 度1.4kg180-200HB设 备 型 号设 备 名 称Z525立式钻床专 用 工 艺 装 备名 称代 号钻夹具机动时间单件工时定额每台件数1技 术 等 级冷 却 液亚硝酸钠工序号工步号工 序 及 工 步 内 容刃 具量 检 具切 削 用 量代 号名 称代 号名称切削速度（米/分）切削深度（毫米）进给量（毫米/转）转速（转/分）701配作2-5孔麻花钻游标卡尺9.022.50.25575编 制校 对会 签复 制修改标记处 数文件号签 字日 期修改标记处 数文件号签 字日 期四川大学锦城学院机械加工工序卡产品型号及规格图 号名 称工艺文件编号共 7 页 泵 盖第6页 材料牌号及名称毛坯外型尺寸HT150零件毛重零件净重硬 度1.4kg180-200HB设 备 型 号设 备 名 称Z525立式钻床专 用 工 艺 装 备名 称代 号钻夹具机动时间单件工时定额每台件数1技 术 等 级冷 却 液亚硝酸钠工序号工步号工 序 及 工 步 内 容刃 具量 检 具切 削 用 量代 号名 称代 号名称切削速度（米/分）切削深度（毫米）进给量（毫米/转）转速（转/分）801钻孔至15麻花钻游标卡尺15.57.50.252752扩15孔至17.8扩孔钻游标卡尺4.21.40.57683铰19.8孔至20铰刀游标卡尺9.330.10.10198编 制校 对会 签复 制修改标记处 数文件号签 字日 期修改标记处 数文件号签 字日 期四川大学锦城学院机械加工工序卡产品型号及规格图 号名 称工艺文件编号共 7 页 泵 盖第7页 材料牌号及名称毛坯外型尺寸HT150零件毛重零件净重硬 度1.4kg180-200HB设 备 型 号设 备 名 称Z525立式钻床专 用 工 艺 装 备名 称代 号钻夹具机动时间单件工时定额每台件数1技 术 等 级冷 却 液亚硝酸钠工序号工步号工 序 及 工 步 内 容刃 具量 检 具切 削 用 量代 号名 称代 号名称切削速度（米/分）切削深度（毫米）进给量（毫米/转）转速（转/分）901钻8孔麻花钻游标卡尺17.64.00.254752扩8孔至10.2扩孔钻游标卡尺2.1771.10.57683攻丝M12丝锥量规7.50.90.10272编 制校 对会 签复 制修改标记处 数文件号签 字日 期修改标记处 数文件号签 字日 期四川大学锦城学院机械工程系Department of mechanical engineering of Sichuan University Jincheng College 泵盖零件的三维造型与加工工艺设计Three dimensional modeling and process design of pump cover parts 题 目 泵盖零件的三维造型与加工工艺设计 系 名： 专业班级： 学生姓名： 学 号： 指导教师姓名： 指导教师职称： 二一四 年 十 月 日目 录摘要1引 言2第一章 零件的分析3第二章 工艺规程的设计42.1确定毛坯的的制造形式42.2制订工艺路线4摘 要：本次设计内容涉及了机械制造工艺及机床夹具设计、金属切削机床、公差配合与测量等多方面的知识。泵盖加工工艺规程及其钻扩铰18H7孔的夹具设计是包括零件加工的工艺设计、工序设计以及专用夹具的设计三部分。在工艺设计中要首先对零件进行分析，了解零件的工艺再设计出毛坯的结构，并选择好零件的加工基准，设计出零件的工艺路线；接着对零件各个工步的工序进行尺寸计算，关键是决定出各个工序的工艺装备及切削用量；然后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：工艺、工序、切削用量、夹紧、定位、误差。ABSTRCT：The design of the content relates to the machinery manufacturing technology and machine tool fixture design, metal cutting machine tool, tolerance and measuring and other aspects of knowledge.Fixture design process of drilling pump cover and reaming holes is designed with 18H7 include part machining process design, process design and fixture three. In process design should first of all parts for analysis, to understand part of the process to design blank structure, and choose the good parts machining datum, design the process routes of the parts; then the parts of each step in the process to the size calculation, the key is to determine the craft equipment and the cutting dosage of each working procedure design; then the special fixture, the fixture for the various components of the design, such as the connecting part positioning devices, clamping element, a guide element, fixture and machine tools and other components; positioning error calculated by the analysis of fixture, jig structure the rationality and the deficiency, pay attention to improving and will design in.Key words: process, process, cutting dosage, clamping, positioning, error.引 言机械制造业是制造具有一定形状位置和尺寸的零件和产品，并把它们装备成机械装备的行业。机械制造业的产品既可以直接供人们使用，也可以为其它行业的生产提供装备，社会上有着各种各样的机械或机械制造业的产品。我们的生活离不开制造业，因此制造业是国民经济发展的重要行业，是一个国家或地区发展的重要基础及有力支柱。从某中意义上讲，机械制造水平的高低是衡量一个国家国民经济综合实力和科学技术水平的重要指标。泵盖的加工工艺规程及其钻扩铰18H7孔的夹具设计是在学完了机械制图、机械制造技术基础、机械设计、机械工程材料等进行设计之后的下一个教学环节。正确地解决一个零件在加工中的定位，夹紧以及工艺路线安排，工艺尺寸确定等问题，并设计出专用夹具，保证零件的加工质量。本次设计也要培养自己的自学与创新能力。因此本次设计综合性和实践性强、涉及知识面广。所以在设计中既要注意基本概念、基本理论，又要注意生产实践的需要，只有将各种理论与生产实践相结合，才能很好的完成本次设计。本次设计水平有限，其中难免有缺点错误，敬请老师们批评指正。第一章 零件的分析 泵盖共有六组加工表面，现分述如下：1、A面（即大端面）2、4-18孔，4-9孔3、宽24槽4、2-8孔5、2-5孔6、18孔7、8孔，M12螺纹第二章 工艺规程的设计 2.1 、确定毛坯的的制造形式由零件图可知，其材料为HT150，该材料具有较高的强度、耐磨性、耐热性及减振性，适用于承受较大应力，要求耐磨的零件。该零件上主要加工面为大端面，4-18孔，4-9孔，宽24的槽，2-8孔，2-5孔，18孔，8孔，M12螺纹。根据零件材料确定毛坯为铸件，已知零件的类型为大批量生产，故毛坯的铸造方法用砂型机器造型。此外，为消除残余应力，铸造后安排人工时效处理。由机械加工工艺手册查得该种铸造公差等级为CT1011，加工余量等级MA选择H级。2.2 、制订工艺路线（1）、工艺路线方案一：工序10：铸造工序20：时效工序30：铣A面（大端面）工序40：锪平4-18深2，钻4-9孔工序50：铣宽24的槽工序60：钻2-8孔工序70：配作2-5孔工序 80：钻、扩、铰18H7孔工序90：钻8孔、扩、攻M12-7H工序100：清洗去毛刺工序110：验收工序120：入库（2）、工艺路线方案二：工序10：铸造工序20：时效工序30：铣A面（大端面）工序40：铣宽24的槽工序50：锪平4-18深2，钻4-9孔工序60：钻2-8孔工序70：配作2-5孔工序 80：钻、扩、铰18H7孔工序90：钻8孔、扩、攻M12-7H工序100：清洗去毛刺工序110：验收工序120：入库（3）、工艺方案的分析：上述两个工艺方案的特点在于：方案一与方案二的区别是：方案一把钻4-18孔及9孔放的相对靠前，这样做为后面工序24槽的加工提供了定位基准，节约了夹具设计的时间，提高了生产效率，故我们采用方案一：具体的工艺过程如下：工序10：铸造工序20：时效工序30：铣A面（大端面）工序40：锪平4-18深2，钻4-9孔工序50：铣宽24的槽工序60：钻2-8孔工序70：配作2-5孔工序 80：钻、扩、铰18H7孔工序90：钻8孔、扩、攻M12-7H工序100：清洗去毛刺工序110：验收工序120：入库7三维实体造型的软件非常多，比如Pro/E、CATIA、UG（Unigraphics）、Solidworks等，这里选用UG NX6.0 作为三维实体造型的软件进行建模。打开UG6.0软件如图1-1所示，点击新建按钮，在此注意，UG所新建的文件名必须是字母或数字，中文名将无法创建和打开，新建如图1-2所示。 图1-1 打开UG 图1-2新建新建好后跳入UG界面，点击草图按钮进入到建模模块，如图1-3所示。 图1-3进入UG建模模块首先绘制草图1（工件左端面）所示参数及其界面如图1-4所示。 图1-4 草图1 拉伸草图1，如图1-5所示。 图1-5 拉伸1进入草图界面后，绘制草图2（4-9孔、2-5孔），如图1-6所示 图1-6 草图2拉伸草图2并与拉伸草图1求差，如图1-7所示 图1-7 拉伸2 拉伸3（沉孔18深2），具体参数如图1-8所示 图1-8 拉伸3上步操作之后所得图形如图1-9所示 图1-9 画草图3（R20半圆弧及与其相连的矩形框），如图1-10所示 图1-10 草图3拉伸草图3并与拉伸2求和，如图1-11所示 图1-11 拉伸3画草图4（R15及与其相连部分），图形如图1-12所示 图1-12 草图4拉伸草图4并与拉伸3求和，如图1-13所示 图1-13 拉伸4孔命令（18H7孔深22），如图1-14所示 图1-14 孔命令孔1坐标位置确定，如图1-15、1-16和1-17所示 图1-15 图1-16 图1-17沉孔24深2，如图1-18、1-19和1-20所示 图1-18 图1-19 图1-208深65孔，如图1-21、1-22和1-23所示 图1-21 图1-22 图1-2310深35孔，如图1-24、1-25和1-26所示 图1-24 图1-25 图1-26插入设计特征螺纹，如图1-27和1-28所示 图1-27 图1-282-8孔，如图1-29、1-30、1-31和1-32所示 图1-29 图1-30 图1-31 图1-32将画好的工件隐藏，隐藏之后如图1-33所示 图1-33格式移动至图层250，如图1-34所示 图1-34将图层250隐藏，如图1-35和1-36所示 图1-35 图1-36倒圆角R10，如图1-37所示 图1-37倒圆角R2，如图1-38所示 图1-38着色处理，如图1-39所示 图1-39处理之后，如图1-40所示 图1-40 Mechanical engineering design 1. The meaning of design To design is to formulate a plan for the satisfaction of human need .in the beginning the particular need to the satisfied may be quite well-defined. Here are two examples of well-defined needs.1. How can we obtain large quantities of power cleanly, safely, and economically without using fossil fuels and without damaging the surface of the earth?2. This gear shaft is giving trouble; there have been eight failures in the last six weeks. Do something about it.On the other hand the particular need to be satisfied may be so nebulous and ill-defined that a considerable amount of thought and effort is necessary in order to state it clearly as a problem requiring a solution. Here are two examples.1. Lots of people are killed in airplane accidents.2. In big cities there are too many automobiles on the streets and highways. This second type of design situation is characterized by the fact that neither the need nor the problem to be solved has been identified. Note, too, that the situation may contain many problems. We can classify design too. For instance: 1. Clothing design 7. Bridge design 2. Interior design 8. Computer-aided design 3. Highway design 9. Heating system design 4. Landscape design 10. Machine design 5. Building design 11. Engineering design 6. Ship design 12. Process design In fact there are an endless number, since we can classify design according to the particular article or product or according to the professional field.In contrast to scientific or mathematical problems, design problems have no unique answers; it is absurd, for example, to request the “correct answer” to a design problem, because there is none. In fact a “good” answer today may well turn out to be a “poor” answer tomorrow, if there is a growth of knowledge during the period or if there are other structure or societal changes.Almost everyone is involved with design in one way or another, even in daily living, because problems are posed and situations arise which must be solved. Consider the design of a family vacation. There may be seven different places to go, all the different distances from home. The costs of transportation are different for each, and some of the options require overnight stops on the way. The children would like to go to a lake or seashore resort. The wife would prefer to go to a large city with department store shopping, theatres, and nightclubs. The husband prefers a resort with a golf course. When these needs and desires are related to time and money, various solutions may be found. Of these there may or may not be one or more optimal solutions. But the solution chosen will include the travel route, the stops, the mode of transportation, and the names and locations of resorts, motels, camping sites, or other away-from-home facilities. It is hard to see that there is really a rather large group of interrelated complex factors involved in arriving at one of the solutions to the vacation design problem. A design is always subject to certain problem-solving constraints. For example, two of the constraints on the vacation design problem are the time and money available for the vacation. Note, too, that there are also constraints on the solution, in the case above some of those constraints are the desire and needs of each of the family members. Finally, the design solution found might well be optimal. In this case an optimal solution is obtained when each and every family member can say that he or she had a good time. A design problem is not a hypothetical problem at all. Design has an authentic purposethe creation of an end result by taking definite acting or the creation of something having physical reality. In engineering the word “design ” conveys different meaning to different persons. Some think of a designer as one who employs the drawing board to draft the details of a gear, clutch, or other machine member. Others think of design as the creation of a complex system, such as a communications network. In some areas of engineering the word design has been replaced by other terms such as systems engineering or applied decision theory. But no matter what words are used to describe the design function, in engineering it is still the process in which scientific the principles and the tools of engineeringmathematics, computers, graphics, and Englishare used to produce a plan which, when carried out, will satisfy a human need. 2. The phases of design The total design process is of interest to us, how does it begin? Does the engineer simply sit down at his or her desk with a blank sheet of paper and jot down some ideas? What happens next? What factors influence or control the decisions, which have to be made? Finally, how does this design process end? The complete process, from start to finish, is often outlined as in Figure. The process begins with a recognition of a need and a decision to do something about it, after many iterations, the process ends with the presentation of the plans for satisfying the need, we should examine these steps in the design process in detail.3. Mechanical engineering designMechanical design means the design of things and system of a mechanical naturemachines, products, structures, devices, and instruments. For the most part, mechanical design utilizes mathematics, the materials sciences, and the engineering mechanical science.Mechanical engineering design includes all mechanical design, but it is a broader study because it includes all the disciplines of mechanical engineering, such as the thermal-fluids sciences, too. Aside from the fundamental sciences that are required, the first studies in mechanical engineering design are in mechanical design, and hence this is the approach taken in this book.4. Design Process and StagesMechanical design is either to formulate all engineering plan for the satisfaction for the specified need or to solve an engineering problem. It is 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 all considers the various factors involved in the manufacture, marketing and use of product. Mechanical design involves a range of disciplines in materials, mechanics, heat, flow, control, electronics and production.Mechanical design should be considered to be an opportunity to use innovative talents to envision a design of a product, to analyze the system and then make sound judgments on how the 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 required to produce a good design. On the other hand, any calculations must be done with the utmost care and precision. For example, if a decimal point is misplaced, an otherwise acceptable design may not function.Mechanical design may be simple or enormously complex, easy or difficult, mathematical or nonmathematical, it may involve a trivial problem or one of great importance. Good design is the orderly and interesting arrangement of all idea to provide certain results and effects. A well-designed product is functional, efficient, and dependable. Such a product is less expensive than a similar poorly designed product that does not function properly and must constantly be repaired.People who perform the various functions of mechanical design are typically called designers, or design engineers. Mechanical 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, manufacturing processes. The designer must first carefully define the problem, using an engineering approach, to ensure that any proposed solution will solve the right problem. It is important that the designer begin by identifying exactly how he or she will recognize a satisfactory alternative, and how to distinguish between two satisfactory alternatives in order to identify the better. So industrial designers must have creative imagination, knowledge of engineering, production techniques, tools, machines, and materials to design a new product for manufacture, or to improve an existing product. In the modern industrialized world, the wealth and living standards of a nation are closely linked with their capabilities design and manufacturing engineering products. It can be claimed that the advancement of mechanical design and manufacturing can remarkably promote the overall level of a countrys industrialization. Many countries are playing more and more vital role in the global manufacturing industry. To accelerate such an industrializing process, highly skilled design engineers having extensive knowledge and expertise are needed. 5. Mechanical design processProduct design requires much research and development. Many concept of an idea must be studied, tried, refined, and then either used or discarded. Although the content of each engineering problem is unique, the designers follow the similar process to solve the problems. The complete process is often outlined as in figures. The design process usually begins with a specification of a solution. We sometimes allude to a design cycle, but the process may contain a design cycle plus design implementation, which involves actual production based upon the design. The design cycle can involve the original thoughts, sketches, and knowledge that in the specification stage produce engineering drawings. Computer-aid design is now employed to implement a cycle in which various designs or design ideas may be tested or simulated.6. Contents of Mechanical Design Mechanical design is an important technological basic course in mechanical engineering education. Its objective is to provide the concepts, procedures, data, and decision analysis techniques necessary to design machine elements commonly found in mechanical devices and systems; to develop engineering students competence of mechanical design that is the primary concern of machinery manufacturing and the key to manufacturing good products.Mechanical design covers the following contents:1Provides an introduction to the design process, problem formulation, safety factors. 2Reviews the material properties and static and dynamic loading analysis, including beam, vibration and impact loading.3Reviews the fundamentals of stress and defection analysis.4Introduces static failure theories and fracture-mechanics analysis for static loads.5Introduces fatigue-failure theory with the emphasis on stress-life approaches to high-cycle fatigue design, which is commonly used in the design of rotation machinery.6Discusses thoroughly the phenomena of wear mechanisms, surface contact stress, and surface fatigue.7Investigates shaft design using the fatigue-analysis techniques.8Discusses fluid-film and rolling-element bearing theory and application.9Gives a thorough introduction to the kinematics, design and stress analysis of spur gears, and a simple introduction to helical, bevel, and worm gearing. 10Discusses spring design including helical compression, extension, and torsion springs.11Deals with screws and fasteners including power screw and preload fasteners.12Introduces the design and specification of disk and drum clutches and brakes.机械工程设计1. 设计的意义 设计是制定一项计划，以便满足人类的需要。在开始的特别需要的满足可能相当明确。这里有两个例子明确界定的需要。 1. 我们怎样才能获得大量的电力干净，安全，经济上不使用化石燃料和不破坏了地球表面的？ 2. 这是给齿轮轴麻烦;有8个失误，在过去6个星期。做点什么。 另一方面，尤其需要得到满足可能是这样模糊不清和不明确，有相当数量的思路和努力是必要的，以国家显然是一个问题需要解决。这里有两个例子。 1 .很多人死于飞机事故。 2 .在大城市有太多汽车的街道和高速公路。 这第二种类型的设计局势的特点是一个事实，即既不需要也不是要解决的问题已被确定。请注意，也这种情况可能包含许多问题。 我们也可以分类设计。例如： 1 .服装设计 7 .桥梁设计 2 .室内设计 8 .计算机辅助设计 3 .公路设计 9 .供暖系统设计 4 .景观设计 10 .机械设计 5 .建筑设计 11 .工程设计 6 .船舶设计 12 .工艺设计 事实上有一个无休止一些，因为我们可以把设计的特定物品或产品或根据专业领域。 相反，科学或数学问题，设计独特的问题没有答案，这是荒谬的，例如，要求“正确答案”的设计问题，因为没有人反对。事实上是一个“良好”的回答今天很可能成为一种“穷人”的答案明天，如果有一个增长知识，或在此期间如果有其他结构或社会的变化。 几乎每个人都参与了设计一种或另一种方式，即使在日常生活中，由于提出的问题和情况时，必须予以解决。考虑设计一个家庭度假。可能有7个不同的地方去，所有不同的距离回家。运输费用的不同，每一个，而有些选项需要通宵站的道路上。孩子们要到一个湖泊或海边度假胜地。妻子宁愿去大城市的百货商店购物，剧院，和夜总会。丈夫喜欢度假的一个高尔夫球场。当这些需要和愿望是与时间和金钱，各种解决方案，可能会发现。这些有可能是也可能不是一个或多个最优解。但是，该解决方案将包括选择旅行路线，站，运输方式，以及姓名和地点度假村，汽车旅馆，露营地，或其他以外，来自家庭的设施。这是很难看到，确实是一个相当大组相互关联的复杂因素，在达成一个解决办法，度假设计问题。 外观设计一直受到某些解决问题的制约。例如，有两个制约因素的度假设计问题是时间和金钱用于度假。请注意，也也有限制的解决方案，如果上述的一些制约因素的愿望和需要，每个家庭成员。最后，设计解决方案，发现很可能是最佳的。在这种情况下，一个最佳的解决方案时，得到的每一个家庭成员可以说，他或她的好时机。设计的问题不是一个假设的问题。设计有一个真实的目的，建立一个最终的结果，采取一定的代理或建立了