2269 薄壁墻板零件的工藝分析、專用夾具設(shè)計(jì)、數(shù)控加工

2269 薄壁墻板零件的工藝分析、專用夾具設(shè)計(jì)、數(shù)控加工,薄壁,零件,工藝,分析,專用,夾具,設(shè)計(jì),數(shù)控,加工 道夫墻板零件加工工藝過程卡工序號工序名稱 工序內(nèi)容 加工基準(zhǔn) 工藝裝備0 油漆 打磨光毛坯面5 銑 粗銑 3- ?45 搭子平面（其高度一致、接觸均勻）R355 底面 普通銑床10 鉗工 刻十字中心線，劃 11-?25 臺階線 ZFA211-4112A-Gy1 劃線樣板，鉗臺15 鉆 鉆 11-?25 孔，鉆 11- ?35 臺階孔 普通鉆床20 銑 粗精銑上平面，粗精銑 ?140F8 孔 以 3- ?45 搭子平面為基準(zhǔn)數(shù)控銑床25 銑 粗銑中間側(cè)面、70×8×18凹槽以 3- ?45 搭子平面為基準(zhǔn)數(shù)控銑床30 銑粗精銑兩邊側(cè)面，保證以 3- ?45 搭子平面為基準(zhǔn)數(shù)控銑床35 銑 粗精銑 R355 底面 粗精銑 R355 上表面數(shù)控銑床40 銑 精粗銑 20P9 鍵槽 以 3- ?45 搭子平面為基準(zhǔn)數(shù)控銑床45 銑 粗精銑圓周面及其三角缺口 以 3- ?45 搭子平面為基準(zhǔn)數(shù)控銑床50 鉆 鉆全部孔、螺紋孔（除 2-?8H8 孔） 以 3- ?45 搭子平面為基準(zhǔn)普通鉆床55 鉗工 劃 2-?8H8 孔線（作拉孔校對線） 鉗臺60 鉸 粗精鉸 2-?8H8 孔 以 3- ?45 搭子平面為基準(zhǔn)鉸刀65 鉗工 去毛刺70 檢驗(yàn) 成對檢驗(yàn)⊥ 0.2 A檢驗(yàn)平臺、平尺、千分尺75 鉗工 作成對記號，打制造編號80 入庫 加工面上防銹油刀具清單卡工步號工步內(nèi)容 刀具號刀具規(guī)格 主軸轉(zhuǎn)速/r.min-1進(jìn)給速度/mm.min-1長度補(bǔ)償H半徑補(bǔ)償D備注0 粗銑上平面T01 ?160mm 的八齒端銑刀298 596 H01 D015 精銑上平面T01 ?160mm 的八齒端銑刀398 573 H01 D0110 粗銑?140F8孔T02 ?60mm 立銑刀 2刃796 398 H02 D02 H=100mm15 精銑?140F8孔T02 ?60mm 立銑刀 2刃1061 530.5 H02 D02 H=100mm20 粗銑中間側(cè)面T03 ?32mmEM2 刃 1791 716.4 H03 D03 H=87mm25 粗銑兩邊側(cè)面T03 ?32mmEM2 刃 1492 746 H03 D03 H=87mm30 精銑兩邊側(cè)面T03 ?32mmEM2 刃 1990 716.4 H03 D03 H=87mm35 粗銑70×8×18凹槽T04 ?50mm 雙面刃銑刀1146 458.4 H04 D0440 精銑70×8×18凹槽T04 ?50mm 雙面刃銑刀1273 458 H04 D0445 粗銑 20P9鍵槽T05 ?12mm 鍵槽銑刀 4777 1910.8 H05 D0550 精銑 20P9鍵槽T06 ?16mm 立銑刀 2刃3980 1432.8 H06 D0655 粗銑圓周面T07 ?80mm 立銑刀 2刃597 298.5 H07 D0760 精銑圓周面T07 ?80mm 立銑刀 2刃796 286.56 H07 D07 中原工學(xué)院畢 業(yè) 論 文 (設(shè) 計(jì) )開 題 報(bào) 告課題名稱：薄壁墻板零件的工藝分析、專用夾具設(shè)計(jì)、數(shù)控加工 畢業(yè)設(shè)計(jì)起止時(shí)間：2006 年 3 月 5 日 ～ 6 月 25 日(共 17 周)學(xué)生姓名： 學(xué)號：專 業(yè)： 班級： 指導(dǎo)教師： 報(bào)告日期： 1．本課題所涉及的內(nèi)容國內(nèi)(外) 研究現(xiàn)狀綜述機(jī)器零件的尺寸、形狀、位置等精度要求按實(shí)際使用情況各有所側(cè)重，某些零件精度雖然要求不高，由于結(jié)構(gòu)形狀上的因素(形狀尺寸大、厚度薄、剛性差)，卻難以保證所要求的加工精度。例如紡織機(jī)械中的絡(luò)絲機(jī)、并絲機(jī)和捻絲機(jī)等薄壁墻板零件，加工工藝過程中出現(xiàn)的一些質(zhì)量問題，大致都屬于這種情況。而在薄壁墻板的加工工藝中的夾具選擇是一個(gè)在眾多生產(chǎn)問題中需要國內(nèi)外都急需解決的現(xiàn)狀。在機(jī)械加工的成組批量生產(chǎn)中選擇合適的夾具是機(jī)械加工中的一個(gè)關(guān)鍵問題，夾具選擇不合理，會(huì)導(dǎo)致夾具體出現(xiàn)體積大，精度差，輔助時(shí)間長，工序繁瑣等諸多問題，直接影響到生產(chǎn)效率，造成生產(chǎn)成本偏高。在現(xiàn)時(shí)的一些工廠中，采用普通設(shè)備加工零件時(shí)，有很多仍然采用手動(dòng)夾緊的方法，尤其在大尺寸零件的加工過程中存在夾具選擇不合理的問題。例如在生產(chǎn)梳棉機(jī)道夫圓墻板零件時(shí)，由于零件的整體外形尺寸較大，傳統(tǒng)的手動(dòng)夾緊夾具存在很明顯的輔助時(shí)間長的缺點(diǎn)。在薄壁墻板的生產(chǎn)中，大多也是采用手動(dòng)夾緊，然而在要求大批量生產(chǎn)工件時(shí)，需要頻繁的扳動(dòng)螺來夾緊或松開工件，同時(shí)還必須注意夾緊力的大小和工件的相對位置保證加工精度，可見傳統(tǒng)夾具體的手動(dòng)夾緊是很不合理的，不僅夾緊時(shí)費(fèi)力而且很難保證加工精度，而且存在安全隱患。傳統(tǒng)夾具生產(chǎn)效率低，主要是因?yàn)楣と嗽诩庸み^程中要同時(shí)對三個(gè)壓板都進(jìn)行夾緊操作，在夾緊中因?yàn)椴荒鼙ＷC三個(gè)壓板的壓緊力，在加工過程中工件容易發(fā)生震動(dòng)，影響加工精度 針對這一問題我們在傳統(tǒng)夾具的基礎(chǔ)上，嘗試引入鉸桿杠桿式壓板和汽缸組合元件，使用氣動(dòng)夾緊代替原來的手動(dòng)夾緊，以此來尋求提高生產(chǎn)效率的方法。在氣壓傳動(dòng)夾具中，活塞桿端作為壓緊力輸出裝置直接加壓于工件的情況極少在實(shí)際生產(chǎn)中，下列兩種夾緊方式比較常用：1） 通過杠桿式壓板夾緊工件；2）通過鉸桿杠桿式壓板夾緊工件。由于鉸桿杠桿式壓板屬于二次串聯(lián)曾力機(jī)構(gòu)，曾力效果要明顯高于杠桿式壓板，因而在加工過程中工件所需壓緊力一定的條件下，二次串聯(lián)曾力機(jī)構(gòu)能顯著減小汽缸的直徑引入鉸桿杠桿式壓板和汽缸元件。同時(shí)在生產(chǎn)薄壁墻板或者其他零件時(shí)都要求采用工序集中，減少工件裝夾次數(shù)，特別是當(dāng)該零件各加工表面有相互位置精度要求時(shí)，最適宜在一次裝夾中把各表面都加工出來，這樣既有利于保證這些表面的相互位置，又可以減少裝卸工件的輔助時(shí)間。因此，在薄壁墻板零件的生產(chǎn)中，要保證其加工精度的要求，我認(rèn)為目前需要在夾具的選擇以及夾具夾緊方面進(jìn)行改善，也就是用于薄壁墻板的的各個(gè)表面的加工或者是孔加工的夾具設(shè)計(jì)進(jìn)行探討。改進(jìn)生產(chǎn)是各大廠家提高生產(chǎn)效率主要攻堅(jiān)項(xiàng)目，機(jī)械加工效率是夾具系統(tǒng)合理性的綜合反映。在傳統(tǒng)薄壁墻板的加工夾具的基礎(chǔ)上提出改進(jìn)，這樣夾具在具有傳統(tǒng)夾具優(yōu)點(diǎn)的同時(shí)，具有了更強(qiáng)的靈活性和可靠性，大大提高了機(jī)械加工的效率完全滿足現(xiàn)代夾具高效。同時(shí)對于其他類型的零件的加工業(yè)可以基于同類原理進(jìn)行借鑒此類夾具系統(tǒng)。夾具作為工藝系統(tǒng)中重要的一部分還有很大的技術(shù)空間，也有很大的市場前景。但很多企業(yè)不是很重視這一道工序，對其投入不大，所以在設(shè)計(jì)過程中要盡量注重起制造成本。2．本課題有待解決的主要關(guān)鍵問題經(jīng)過三個(gè)禮拜的畢業(yè)調(diào)研和查閱資料，我對本課題的主要意圖還是有一定的了解，大至了解了要完成的設(shè)計(jì)任務(wù)，綜合起來，我認(rèn)為最需要解決的主要問題有：根據(jù)選定機(jī)床及數(shù)控系統(tǒng)編制數(shù)控加工程序和根據(jù)數(shù)控加工工藝確定裝夾方案，設(shè)計(jì)專用夾具一套，加工過程中零件的裝夾。機(jī)床和數(shù)控系統(tǒng)的選定是根據(jù)給定的零件圖紙對零件進(jìn)行工藝分析，確定若干工藝方案，再對工藝方案進(jìn)行比較，確定最終方案。方案確定之后選擇數(shù)控加工設(shè)備、切削刀具、切削用量以及數(shù)控加工工藝設(shè)計(jì)。最后根據(jù)數(shù)控加工機(jī)床和零件工藝方案編制數(shù)控加工程序，根據(jù)數(shù)控加工工藝設(shè)計(jì)夾具。關(guān)鍵問題就在程序的編制和夾具的設(shè)計(jì)。3．對課題要求及預(yù)期目標(biāo)的可行性分析 (包括解決關(guān)鍵問題技術(shù)和所需條件兩方面)上述已經(jīng)闡述了需要解決的關(guān)鍵問題是程序的編制和夾具的設(shè)計(jì)。程序的編制需要把以前學(xué)過的數(shù)控技術(shù)相關(guān)內(nèi)容進(jìn)行相應(yīng)的復(fù)習(xí)，重新去認(rèn)識數(shù)控機(jī)床上程序的編制，根據(jù)給定任務(wù)書的零件確定零件工藝方案，結(jié)合數(shù)控技術(shù)課本的 NC程序設(shè)計(jì)對零件的加工編制出數(shù)控程序。要解決這一方面問題必須要借助于相關(guān)的理論書籍，當(dāng)然這還遠(yuǎn)遠(yuǎn)不夠，雖然當(dāng)今的網(wǎng)絡(luò)共享很豐富，使我對數(shù)控程序編制的了解有幫助，但還是需要我的個(gè)人付出努力，畢竟網(wǎng)絡(luò)資源是有限的。因此這一問題的解決必須要多向?qū)熣埥?，有需要的話還要到廠去找相關(guān)的數(shù)據(jù)資料。 夾具結(jié)構(gòu)的選擇取決于加工后的表面狀況，如機(jī)械加工、電火花加工，磨加工等等。所以要解決這一問題不僅要對一般的夾具結(jié)構(gòu)有所了解，還要對零件的材料特性，加工前的表面狀況和加工后的表面要求有詳盡的了解。目前的數(shù)控夾具結(jié)構(gòu)有很多種，但是要找到一種適用薄壁墻板零件加工的方法對薄壁墻板的加工精度要求幾乎符合理論程度，還有待于對各種夾具方案的深入了解，通過相互比較，最后選擇一種加工效率高并經(jīng)濟(jì)效益好的裝夾方法?？傊瓿蛇@一項(xiàng)目需要多查閱相關(guān)的資料和自己不斷的思考創(chuàng)新。4．完成本課題的工作計(jì)劃及進(jìn)度安排3.8--3.21 調(diào)研與實(shí)習(xí)，英文文獻(xiàn)翻譯及編寫實(shí)習(xí)報(bào)告。3.22—4.18 總體方案設(shè)計(jì)，工藝方案，裝夾方案設(shè)計(jì)。寫出方案論證報(bào)告。4.19—4.30 加工工藝草案，專用夾具草圖。5.1—6.9 數(shù)控加工方案設(shè)計(jì)，機(jī)床，刀具及切削用量選擇與計(jì)算。詳細(xì)設(shè)計(jì)（工藝，夾具，程序） ，整理設(shè)計(jì)任務(wù)書。6.11—6.16 定稿6.18—6.23 評審6.17—6.19 畢業(yè)答辯6.19—6.25 修改畢業(yè)設(shè)計(jì)5．指導(dǎo)教師審閱意見指導(dǎo)教師(簽字)：　　　　　　 年 月 日6．指導(dǎo)小組意見指導(dǎo)小組組長(簽字)：　　　　　　 年 月 日 說明：1. 本報(bào)告前 4 項(xiàng)內(nèi)容由承擔(dān)畢業(yè)論文(設(shè)計(jì)) 課題任務(wù)的學(xué)生獨(dú)立撰寫；2. 本報(bào)告必須在第八學(xué)期開學(xué)兩周內(nèi)交指導(dǎo)教師審閱并提出修改意見；3. 學(xué)生須在小組內(nèi)進(jìn)行報(bào)告，并進(jìn)行討論；4. 本報(bào)告作為指導(dǎo)教師、畢業(yè)論文(設(shè)計(jì)) 指導(dǎo)小組審查學(xué)生能否承擔(dān)該畢業(yè)設(shè)計(jì) (論文)課題和是否按時(shí)完成進(jìn)度的檢查依據(jù)，并接受學(xué)校的抽查。數(shù)控加工程序題目名稱：薄壁墻板零件的工藝分析、專用夾具設(shè)計(jì)、數(shù)控加工院系名稱：機(jī)電學(xué)院班 級： 學(xué) 號： 學(xué)生姓名： 指導(dǎo)教師： O001(粗銑上平面.cut)N08 G92 X0.000 Y0.000 Z200.000N10 T01 M06N12 G90 G00 G54 X-175.000 Y55.000 S298 Mo3 N14 G43 Z200.000 H01N16 G41 D01N20 G01 X-71.239 F596N28 G02 X71.239 Y55.000 I71.239 J-55.000N30 G01 X175.000N32 Z97.000 F596N34 G00 X-175.000 Y60.000N36 Z97.000N38 G01 Z97.000 F596N40 X-67.082 F596N42 G02 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