CA6140机床方刀架的机械加工工艺及工装夹具设计（含CAD图纸源文件）
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CA6140机床方刀架的机械加工工艺及工装夹具设计（含CAD图纸源文件）,CA6140,机床,刀架,机械,加工,工艺,工装,夹具,设计,CAD,图纸,源文件
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附录A Material Treatment and Properties Heat TreatmentHeat treatment is a term applied to a variety of procedures for changing the characteristics of metal by heating and cooling. By proper heat treatment, it is possible to obtain certain characteristics in metal such as hardness, tensile strength (ability to resist stretching), and ductility. Heat treatment can be a simple process requiring few tools. In industry, it is a highly scientific and complicated procedure requiring much equipment. Many of the projects or products made in the machine shop have little or no value until they are heat-treated. This article includes only the most elementary information about the heat treatment of steel. Heat treatment can also be done on many of the nonferrous metals such as aluminum, copper and brass. The procedures are different, however, and will not be considered here.The procedures of heat treatment of steel include hardening, tempering, annealing, and case hardening.Hardening Hardening is a process of heating and cooling steel to increase its hardness and tensile strength, to reduce its ductility, and to obtain a fine grain structure. The procedure includes heating the metal above its critical point or temperature, followed by rapid cooling. As steel is heated, a physical and chemical change takes place between the iron and carbon. The critical point, or critical temperature, is the point at which the steel has the most desirable characteristics. When steel reaches this temperaturesomewhere between 1,400 and l600Fthe change is ideal to make for a hard, strong material if ft is cooled quickly. If the metal cools slowly, it changes back to its original state. By plunging the hot metal into water, oil, or brine (quenching), the desirable characteristics are retained. The metal is very hard and strong and less ductile than before.Heating is done in a furnace fired by gas, oil, or electricity. A device called a pyrometer is attached to the furnace. This accurately registers the exact temperature in the furnace. The temperature of the metal can also be determined by observing its colour. You can make use of the colours when heat-treating simple metal parts and tools. Colours are not very accurate, however. Even the expert heat-treater will be off as much as 20F from the true temperature.The hardening procedure is:1. Point of stoves to reach the appropriate temperature 2. The metal into stoves, heating it to the critical temperature for carbon tool steel, in order to achieve this temperature, each one-inch thick about 20-30 minutes. In order to quench temperatures reached are hot, each one-inch thick about food warming 10-15 minutes. 3. Choose the appropriate coolant. Certain steels in the water cooling, while others steels in oil or water to cool. Water-carbon steel hardening is the most widely used coolant. Because water prices cheap effect. Saline water is usually added to the 9% in the ordinary salt produced. Saline help to achieve a more uniform hardness for the whole parts faster cooling. Some oil will quench slower pace. Most quench oil is mineral oil 4. Remove with tongs heated metal to vote people coolant. Thick metal coolant to enable rapid and uniformly cool. If this is the final piece of thin (like knives or leaves), to quench her while coolant to be Qiaoqu. If side cooling faster than the other side, it will produce a certain Qiaoqu. 5. The normal hardening tool steel will stiffen Biancui and have high tensile strength. It will also have to stress. If left in this state, which would make the metal occurred within stress cracks.Flashback arrestors a lower hardness and intensity and enhance resilience approach. It can eliminate the brittleness quench her. Crowded in the hardening of the metal to stiffen after a change in personal ways. Flashback is to re-heating the metal to a low or moderate temperature, and then Jileng or in the air cooling. When metal crowded heating, but also changes in their colour. These colours called tempering color. These can be observed from time to know what colour to the temperature. Of course, a more precise method is observation of high-temperature. Many parts and products are to the overall backfire. Others are part of the flashback, and the remainder are still in the hardening state.Tempering method is as follows : 1. The flashback to the overall, the entire working to put stoves Lane. Further heating to the appropriate temperature to achieve the required strength and resilience. Remove the metal and rapid cooling. 2. Small cutting tools for the flashback : A. The entire machine tool hardening, using emery cloth to remove oxide skin B. Of a piece of scrap metal to Chek thermal heating degree. C. On the metal cutting tools, the edge of blade Department placed outside this Chek hot metal D. Observer crowded color, when appropriate tool edge of blade colors to the Department, it Jileng.Anneal anneal is to soften the steel to eliminate internal stress approach. This will enable the steel easier processing. Steel heated to a temperature above the threshold and then slowly cooling. The most commonly used method is to heat the steel to stoves have it revealed. Then turn the stoves for metal slowly cooling. Another method is to use metal clay packs up and heating it to the critical temperature, then remove from stove, let it cool slowly.Case is harder to quantify black metal case, the surface or the interior floors. Through carbon added to a low-carbon steel surface, a heat treatment to the surface it can stiffen, and the center, that is, core and the Department remains soft resilience.There are many ways to measure the surface. In industry, the use of melting of cyanide (which called cyanidation). Another method is carburization industrial law. This is a one of the ways to use carbon from the。Dead, piston sales and other must withstand vibration and wear a lot of parts of the Act can be used for processing. However, the law must not be used for any benefit to himself the final.Mechanical properties of metalMechanical performance is material plus loads role in the emerging identity of the measure. In other words, the mechanical properties of metals is in a role of power or more power, with the intensity. They know the intensity of metal performance can build a solid security structure, the intensity is carrying a payload of metal (external forces) without fracture capacity.Intensity characteristics usually refer to the tensile strength, Kangwan intensity, and compressive strength, Kangniu intensity, and beam intensity, fatigue strength and impact strength. 1. Stress is a material internal resistance deformation capacity through additional load to measure stress 2. Response by the stress arising from the deformation. Response to the size of each cm deformation to express 3. Metal fracture or deformation in a flexible, external forces back to their original shape when removed. Rubber-band is what is the best example of flexibility. Rubber arm, if knob loosened, it would revert to the original shape. However, if more than a rubber arm was, it would break. Flexible metal also have the same character. 4. Limit is flexible material in stretch, added stress is not removed after they return to the former state of deformation of the greatest stress. . Flexible modules within the limits of flexibility in the volume stress and pull over. Must stress role in the deformation of materials smaller, higher volume flexible modules. Through more flexible modules of the size, we can easily identify the relative supply of different materials. For many machines and structures, chemical or cut is very important. 6. Tensile strength is the resistance of the metal to pull it off the outside. It is more important to identify the target metal one. 7. Compressive strength is the resistance of metal crushing capacity. On the role of load direction, and stretch compression precisely the opposite. Most metals have a high tensile strength and compressive strength. However, the brittleness materials such as cast iron high compressive strength, but only a medium tensile strength 8. Kangwan intensity resistance is the role of external forces cause components along the loading direction bending or curving nature. Indeed, the bending stress is a combination of pulling stress and pressure stress 9. Kangniu intensity is caused by the metal components to reverse the capacity to resist external forces 10. Sheared intensity refers to the size of the two components in the opposite direction of equal role, how strong its capability to resist 11. Fatigue strength is the resistance of various materials to the rapidly changing nature of the stress. For example piston rod or axle withstand the pressure for change is widening stress. Both sides of the winding up of tinsel fatigue fracture is another example. 12. Intensity of the impact resistance of metals is often rapid and sudden increase in load payload capacity. The impact of higher metal intensity, the energy needed to break on older. Welding will seriously affect the impact intensity, because the impact of structural strength is a sensitive nature. 13. Resilience is metal fracture, bending or reverse without breaks or damage. Resilience high metals, such as copper or wrought iron, with the load increase is the gradual damage or fracture. Resilience and low metals such as cast iron, when carrying heavy, will suddenly rupture and damage. 14. Hardness is steel or penetration resistance Yahen nature. Hardness is usually used in the standard payload Gangqiu role of the designer to express Yahen area, or used in a particular load role of the indenter specialized formed to express the depth. 15. Cryogenic nature expressed in very low temperature environment in the role of metal stress performance changes. In addition to the crystal structure and processing conditions are very sensitive, the low-temperature and high-temperature metal is also very sensitive. Some of the alloy in room temperature is applicable in the low-temperature or high temperature would have been completely destroyed. From plasticity to brittleness in low temperature damage is a very sudden changeStress and contingencyStress and contingency is not one thing, but interrelated, interdependent. Look at a White Zongsheng on a car with a simple example. The pulling force in the fibre cables entangle or endogenous force in a stress. In pulling force or stress relaxation, the roots of this stress has been lifted because of a permanent elongation. The increase in length or deformation is called contingency. Melt and welding, often resulting Qiaoqu is a contingency, it clearly shows the metal welding exist stress.Stress is the same as the pressure per square inch with the add (pounds / square inch) to calculate. To pounds / square inch as a unit of stress to bear the load load P divided by the area : S=P/A 1. Pressure stress (squeeze pressure) 2. Bringing stress (spaces stretch stress) 3. Shearing stress (cutting stress)All materials included, the result would deformation, stress, shortening or elongation. In the role of the size or shape of the load changes sometimes with the naked eye can see from the large, such as rubber-band and metal spring-loaded situation, but for the design of load bearing metal components are. This deformation only Jiwei inches. Because although great, great stress of metal in only a small contingency, but now it is generally recognized that, if materials have stress, it will have a contingency or deformation; But it must be remembered, and vice versa, that is, if the metal to pull deformation, it will produce stress, fundamentally speaking, is a stress contingency reasons.To illustrate the relationship between stress and emergency, we try to analyse pieces of a welding done stretch tests. Welding seam in the 1/2-inch thick boards completely melt revealed the double-sided docking welding seam, ban pieces in a two-inch boards cut to the width of the welding seam strength tests. Although not all welding tests have such a request, we can record measurements, including welding zone length of the stretch length of 2.0000 inches. These crimes contingency-length pilot crew detected an enormous degree plate welding test pieces show added to the stretch payload size. Examination of the cross-sectional area for the two-inch 1/2 inch equals one square inch for the hole, load and stress are the same, and deformation instructions to direct measurements of the length of 20,000 foot stretch length, the length of every inch fracture rate is a more useful data : it must deformation instructions of the readings will be divided by two drawn. This is the actual unit contingency-response unit is the original definition of the length of the sun every inch length.Trapped in the pilot test of the welding machine caught head in the stretch, gradually increase the load added ban pieces. Every time you download records and two 20,000 foot fracture rate readings.Study listed in the table on welding test results can reveal the many pieces of information. First, only a very modest stress response : 15 tons per square inch or a contingency only 1/10% 1/1000% inches / every inch length. Secondly, it appears that there are two emergency areas. For low stress in 42,000 pounds / square inch below contingency and stress proportional to the higher stress, and stress is no longer proportional response in the region of elongation considerable metal that have yielded. Distinguish between the two types of contingency identity stress called yield stress, the yield stress of this ban is 42,000 pounds / square inch. The region is below the yield stress flexibility District, and a flexible response is a response : When a payload removed after the contingency that go away. For example, steel spring is on the role of the flexible response to more than yield stress, the response is plasticity, which means that it is permanent contingency, still left down in the elimination of stress.Now we can make a correct interpretation of brittleness and plasticity. Any show with a very small plasticity contingency response or no plasticity of the material is brittleness materials. Plasticity and the role of stress in the material long plasticity region. Plasticity is an important structural materials required conditions because plasticity deformation can issue warnings on material bear stress intensity is close to its limit. Brittleness material because there is no plasticity deformation, not a destructive warning. Above analysis welding ban pieces of 14% growth in pre - rift length. Only 0.14% of the total rounds than contingency, or 1% to plasticity contingency. Generally, soft and low intensity of the nature of the material is plasticity, and the rigid and high-intensity material plasticity is very small. This is especially true of special steel : mild steel can plasticity fracture 25-35%.Surface treatmentAlmost all commonly used metals and alloys, particularly iron and steel unless a grease, paint, chemicals or other sexual poor could lose up metal protection, otherwise the air will be the erosion of some material which was corrupted into. The most serious, although not one of the most common corruption is crystal - corrosion, in which case the corrosive substances in the crystals formed between a metal corrosion. Surface treatment of material designed to prevent such corrosive to crystal. Simply attached to the oil or fat layer, because they are soft and easily damaged, so that the air can Chengxu. But the real very Zhanchou the fats, such as Yangmaozhi extracted from wool, is the protection of steel products in a temporary storage period to avoid rusting useful methods.Several large-scale structures are usually attached painting. If the metal surface is very bright, painting will get good material strength, and therefore can be treated for chemical treatment of metals, leaching of metals in phosphoric acid and other salts in the solution, because they will erode the metal to produce a thin layer of phosphate crystallization so that the surface crude, help paint Nianshangqu if painting was later occasionally hits, underneath the coating to prevent losses resulting from the expansion of the field offices from abrasions serious injuries.An important way to protect metal surfaces are electroplating, which uses electric current in the metal, chemical Buxiu very thin layer of metal. People are most familiar with the chromium plating, in the light or polishing the nickel surface plating, the very thin layer Jinzhuge. If the surface is illuminated and luster less important, usually can implant in zinc, cadmium, tin or tin-zinc alloys.Metal surfaces must be very clean, so that the thin metal bullets firmly attached to see : even a trace of fats that are sufficient to deal with damage to the surface. So first use kerosene or similar solvents to remove grease, and then use boiling alkali solution such as washing soda to remove the grease residue. Finally the metal into acid pickling and-soak in acid to remove all critical.Hard steel or zinc can soak in the melting of tin electroplating troughs can implant more thick. In this way, Tu called galvanized zinc, tin-plating is used tinplate manufacture processes. To such as nut and bolts type of small galvanized steel products, from their full Xinfen on the boxes, and then put in the heating stoves, such zinc will be combined with the steel surface to form alloys. The processes called Xinfenredu similar to the processes used chromium called chromium like to replace zinc can implant similar to the stainless steel alloy cladding.Steel products, a coating is Youci, sometimes called the enamel. Do not turn this Youci Ciqi and often referred to as the hard sheen of paint confusion, such Tu Ci You can create a layer of glossy shine and hardness close to the glass and it hits the surface layer, Tu Ciyou metal surface requires a very clean steel products using acid acid washing are apt to get clean, but can not cast iron pieces such methods, cast iron pieces have called Penwan way to get out clean. Temper overreach of small debris in the steel projectile strong spray to clean up the metal, to use the corner edge sharp debris and wipe out all the rust and filthy. Projectile debris or use a compressed air swept through metal surface, or on one wheel spinning, it hit out, spray the metal surface. Screen is used in the past instead of using Gangwan ore, but sand, the dust flew lung damage to the workers.One called anode of dealing with the protection methods can be applied in the aluminum and certain aluminum alloy, this approach is in some ways similar to electroplating law because it is necessary to make the products soak in the solution, and currents through, but current flow opposite. Currents generated oxygen to the surface of aluminum oxide into a very tenacious, products of oxygen in the air will not use it in an erosion, because it covers the entire surface is a thin layer of oxide material. This approach does not apply to steel, because steel is soft and porous oxide Tuoceng that air can enter and remain erosion lower metal.Steel and other metals can leach chemicals in surface treatment of them. These chemicals can make it a oxidation Moceng-usually a black, dark blue or brown. Everyone familiar with this method is a barrel of a blue form. Such Moceng protection role is not great, because they usually have some puncture wounds on, but if the attached oil. Tuoceng the effect that such protection can be better.附录B 材料的处理和特性热处理 热处理这一术语指的是各种各样通过加热和冷却以改变金属特性的过程。通过适当的热处理能使金属获得某种性质，例如；硬度、抗拉强度（抵抗拉伸的能力）和韧性，热处理可以是一种只需要少量工具的简单工艺。在工业上，热处理是要求有许多设备的高度科学、复杂的过程。 机加车间生产的许多制品或产品直到进行热处理之前是没有什么用处或完全没有用处的。本义只涉及有关钢的热处理的最基本的知识。对许多有色金属如铝、铜和黄铜也可以进行热处理，然而其工艺过程是不一样的，这里略而不谈。 钢的热处理方法包括淬火、回火、退火和壳体淬火。 淬火 淬火是把钢加热然后冷却以提高其硬度、抗拉强度，降低其韧性井获得细晶粒组织的方法。这个过程包括把金属加热到它的临界点，即临界温度以上然后迅速予以冷却。随着钢的加热，在铁和碳之间就发生物理变化和化学变化。临界点、即临界温度，是钢具有最理想的特性的温度。当钢达到这一温度（界于 14001600F之间），如果予以迅速冷却，这一变化对获得坚硬的高强度材料是很理想的，如果金属慢慢冷却，它就会变回到它原来的状态。把炽热的金属投人水、油或盐水（淬火），能使这种合乎需要的特性保持下来。这样金属就变得很硬，强度很高，而韧性比从前要差。 加热是在用可燃气、油或电作为热源的炉子里进行的。炉子上装有一个称作高温计的仪表。它能精确地记录炉内的实际温度。也可通过观察金属的颜色来决定金属的温度。在对简单的金属零件和工具进行热处理时可以利用这些颜色。然而颜色并不十分精确甚至熟练的热处理工人藉此所观察出的温度同真正的温度之间的误差也会达200F之多。 淬火方法如下： 1点着炉子，使之达到适当的温度 2.把金属放进炉子里，把它加热到临界温度，对于碳素工具钢，为了达到这一温度，每厚一英寸约需 20-30分钟。为了在淬火温度下达到均热，每厚一英寸约需保温10-15分钟。 3.选择适当的冷却液。某些钢种可以在水中冷却，而另一些钢种必须在油或盐水中冷却水是碳钢淬火最广泛使用的冷却液因为水价格便宜，效果也好。盐水通常是在水中加进9左右的普通盐制成。盐水有助于使达到的硬度更为均匀，使整个零件更快地冷却。油能使淬火的速度稍慢一些。大多数淬火用油是矿物油 4.用夹钳取出炽热的金属，把它投人冷却液中。搅动冷却液以便使金属迅速而均匀地冷却。如果是一块很薄的工件（像小刀或叶片），淬火时要把工件切入冷却液，使之不致翘曲。如果一侧比另一侧冷却得更快，就会产生一定的翘曲。 5.正常淬火的钢制工具会变硬变脆并具有很高的抗拉强度。它也会具有内应力。如果听任处于这种状态，这种内应力会使金属发生裂缝。 回火 回火是一种降低硬度和强度并提高韧性的方法。它能消除淬火工件的脆性。回火是在淬火之后采用的使金属尽可能变硬变韧的方法。回火是把金属再加热到较低的或适中的温度，然后急冷或在空气中冷却。当金属回火加热时，其颜色也随之发生变化。这些颜色叫做回火色。可从观察这些颜色以知道什么时候达到规定的温度。当然，更精确的方法是观察高温计。许多零件和制品都是要整体回火的。另一些是部分回火，而其余部分仍处于淬火状态。 回火方法如下： 1.对整体的回火，就把整个工件放到炉子里。再加热到适当的温度以达到所需的强度和韧性。取出金属并迅速冷却。 2.对小的切削工具的回火： a把整个切削工具淬火，用砂布把氧化皮擦去 b. 把一块废金属加热到赤热的程度。 c. 把切削工具放在金属上，刃部伸到这块赤热的金属之外 d观察回火色，当恰当的颜色达到工具刃部时，将它急冷。 退火 退火是把钢软化使之消除内应力的方法。这可以使钢更易于机加工。把钢加热到临界温度之上然后慢慢冷却。最常用的方法是把钢放到炉子里把它热透。然后把炉子熄掉，让金属慢慢冷却。另一种方法，是把金属用粘土包起来，把它加热到临界温度，然后从炉中取出，让它慢慢冷却。壳体硬化 壳体硬化是使黑色金属的外表面或壳体硬化的方法。通过把少量的碳加到低碳钢的表面，可以把它进行热处理使表面变硬，而中心，即芯部仍然是软的并具有韧性。有许多表面硬化的方法。在工业中，采用熔化的氰化物（这称作氰化法）。另一种工业方法是渗碳法。这是一种借助下述方法之一把碳从表面向内加到钢里的表面硬化方法。这些方法是：固体法、气体法、盐浴法。 锤头、活塞销以及其他必须经受大量振动和磨损的零件可以用该法进行处理。但该法决不能用于任何必须磨利的工件。金属的机械性能 机械性能是材料在外加载荷作用下所呈现的特性的量度。换句话说，机械性能是金属在一个力或几个力的作用下，所具有的强度。如果知道了金属的强度性能，就能建造一个安全坚固的结构，因此，强度是金属承受载荷（外力）而不致断裂的能力。 强度特性通常指的是抗拉强度、抗弯强度、抗压强度、抗扭强度、抗剪强度、疲劳强度和冲击强度。 1.应力 是材料内部呈现的抵抗变形的能力，应力通过外加载荷来测量 2.应变 是由应力产生的变形。应变用每厘米的变形的大小来表示 3.弹性 是金属在伸长或变形后，外力撤去时回复到原来形状的能力。橡皮筋是说明什么是弹性的最好的例子。橡皮拉长后，如果把手松开，它就会回复到原来的形状。 然而，如果把橡皮拉长超过某一点，它就会断裂。有弹性的金属也具有同样的性质。 4.弹性极限 是材料在拉伸时，所加应力去掉后还能回到未变形前状态的最大应力。 5.弹性模量 是在弹性极限范围内应力与拉力之比。在一定应力作用下材料的变形愈小，弹性模量愈高。通过比较弹性模量的大小，就能很容易确定不同材料的相对刚性，对许多机器和结构来说，刚性或刚度是非常重要的。 6.抗拉强度 是金属抵抗要把它拉断的外力的能力。它是鉴定金属的比较重要的指标之一. 7.抗压强度 是金属抵抗压碎的能力。就荷载的作用方向来说，压缩正好与拉伸相反。大多数金属都具有很高的抗拉强度和抗压强度。然而，像铸铁这样的脆性材料抗压强度很高，但只具有中等的抗拉强度 8.抗弯强度 是抵抗外力造成构件沿荷载作用方向弯曲或挠曲的性质。实际上，弯曲应力是拉应力和压应力的组合 9.抗扭强度 是金属抵抗外力造成构件扭转的能力 10.剪切强度 指的是构件在两个大小相等方向相反的力的作用下，它的抵抗能力有多强11.疲劳强度 是材料抵抗各种迅速交变的应力的性质。例如活塞杆或轴经受的是拉压交变应力。把一段金属丝来回弯曲直到断裂是疲劳的又一实例。12.冲击强度 是金属抵抗突加载荷并常常是高速载荷的能力。金属的冲击强度愈高，使之断裂所需要的能量就愈大。焊接会严重影响冲击强度，因为冲击强度是结构最敏感的一种性质。13.韧性 是金属伸长、弯曲或扭转而不致断裂或破坏的能力。韧性很高的金属，例如铜或熟铁，随着荷载的增加，破坏或断裂是逐渐进行的。而韧性低的金属，例如铸铁，当承受重载时，会突然出现断裂而破坏。14.硬度 是钢抵抗压痕或穿透的性质。硬度通常是用在标准载荷作用下特制钢球的压痕面积来表示，或是用在特定载荷作用下，专门的压头所形成的深度来表示。15.低温性质 表示在非常低的温度环境中在应力作用下金属性能发生的变化。除对晶体结构和加工条件很敏感之外，金属对低温和高温也是很敏感的。某些在室温下很适用的合金，在低温或高温下却会被完全破坏。在低温下从塑性到脆性破坏的变化是相当突然发生的。应力和应变 应力和应变不是一回事，但却相互关联，彼此依存。请看一个用一根白棕绳拖一辆汽车的简单例子。绳子的拉力在绳的纤维里产生应力或内力。在拉力或应力放松之后，这根绳子由于这个应力已产生永久伸长。长度的增加量就是变形或称应变。熔焊时常常产生的翘曲也是一种应变，它明显地表明焊接后的金属内存在着应力。 应力正如压强一样是用每平方英寸的磅数（磅平方英寸）来计算的。以磅平方英寸为单位的应力等于载荷P除以承受该载荷的面积：S=P/A l.压应力（挤压力） 2.拉应力（位伸应力） 3.剪应力（切削应力）
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