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英文原文:
Disc Brakes
Disc brakes are used on the front wheels of most cars and on all four wheels on many cars. A disc rotor is attached to the wheel hub and rotates with the tire and wheel. When the driver applies the brakes, hydraulic pressure from the master cylinder is used to push friction linings against the rotor to stop it.
In the disc brake rotor assembly, the rotor is usually made of cast iron. The hub may be manufactured as one piece with the rotor or in two parts. The rotor has a machined braking surface on each face. A splash shield, mounted to the steering knuckle, protects the rotor from road splash.
A rotor may be solid or ventilated. Ventilated designs have cooling fins cast between the braking surfaces. This construction considerably increases the cooling area of the rotor casting. Also, when the wheel is in motion, the rotation of these fan-type fins in the rotor provides increased air circulation and more efficient cooling of the brake. Disc brakes do not fade even after rapid, hard brake applications because of the rapid cooling of the rotor.
The hydraulic and friction components are housed in a caliper assembly. The caliper assembly straddles the outside diameter of the hub and rotor assembly. When the brakes are applied, the pressure of the pistons is exerted through the shoes in a ‘clamping’ action on the rotor. Because equal opposed hydraulic pressures are applied to both faces of the rotor throughout application, no distortion of the rotor occurs, regardless of the severity or duration of application. There are many variations of caliper designs, but they can all be grouped into two main categories: moving and stationary caliper. The caliper is fixed in one position on the stationary design. In the moving design, the caliper moves in relation to the rotor.
Most late-model cars use the moving caliper design. This design uses a single hydraulic piston and a caliper that can float or slide during application. Floating designs ‘float’ or move on pins or bolts. In sliding designs, the caliper sideways on machined surfaces. Both designs work in basically the same way.
In the single piston floating caliper, the single-piston caliper assembly is constructed from a single casting that contains one large piston bore in the inboard section of the casting.
In the single piston floating caliper, the single-piston caliper assembly is constructed from a single casting that contains one large piston bore in the inboard section of the casting.Inboard refers to the side of the casting nearest the center line of the car when the caliper is mounted. A fluid inlet hole and bleeder valve hole are machined into the inboard section of the caliper and connect directly to the piston bore.
The caliper cylinder bore contains a piston and seal. The seal has a rectangular cross section. It is located in a groove that is machined in the cylinder bore. The seal fits around the outside diameter of the piston and provides a hydraulic seal between the piston and the cylinder wall. The rectangular seal provides automatic adjustment of clearance between the rotor and shoe and linings following each application. When the brakes are applied, the caliper seal is deflected by the hydraulic pressure and its inside diameter rides with the piston within the limits of its retention in the cylinder groove. When hydraulic pressure is released, the seal relaxes and returns to its original rectangular shape, retracting the piston into the cylinder enough to provide proper running clearance. As brake linings wear, piston travel tends to exceed the limit of deflection of the seal; the piston therefore slides in the seal to the precise extent necessary to compensate for lining wear.
The top of the piston bore is machined to accept a sealing dust boot. The piston in many calipers is steel, precision ground, and nickel chrome plated, giving it a very hard and durable surface. Some manufacturers are using a plastic piston. This is much lighter than steel and provides for a much lighter brake system. The plastic piston insulates well and prevents heat from transferring to the brake fluid. Each caliper contains two shoe and lining assemblies. They are constructed of a stamped metal shoe with the lining riveted or bonded to the shoe and are mounted in the caliper on either side of the rotor. One shoe and lining assembly is called the inboard lining because it fits nearest to the center line of the car. The other is called the outboard shoe and lining assembly.
As already mentioned, the caliper is free to float on its two mounting pins or bolts. Teflon sleeves in the caliper allow it to move easily on the pins. During application of the brakes, the fluid pressure behind the piston increases. Pressure is exerted equally against the bottom of the piston and the bottom of the cylinder bore. The pressure applied to the piston is transmitted to the inboard shoe and lining, forcing the lining against the inboard rotor surface. The pressure applied to the bottom of the cylinder bore forces the caliper to move on the mounting bolts toward the inboard side, or toward the air. Because the caliper is one piece, this movement causes the outboard section of the caliper to apply pressure against the back of the outboard shoe and lining assembly, forcing the lining against the outboard rotor surface. As the line pressure builds up, the shoe and lining assemblies are pressed against the rotor surfaces with increased force, bringing the car to a stop.
The application and release of the brake pressure actually causes a very slight movement of the piston and caliper. Upon release of the braking effort, the piston and caliper merely relax into a released position. In the released position, the shoes do not retract very far from the rotor surfaces.
外文翻譯：
盤(pán)式制動(dòng)器
許多汽車(chē)所有四個(gè)車(chē)輪，盤(pán)式制動(dòng)器是用在大多數(shù)轎車(chē)的前輪上。制動(dòng)盤(pán)安裝在輪轂上隨著輪胎和車(chē)輪轉(zhuǎn)動(dòng)。當(dāng)汽車(chē)制動(dòng)時(shí)，液壓主缸推動(dòng)摩擦片使其停止轉(zhuǎn)動(dòng)。 在盤(pán)式制動(dòng)器的轉(zhuǎn)動(dòng)部件中，制動(dòng)盤(pán)通常是使用鑄鐵制造。輪轂和制動(dòng)盤(pán)可制造為一體或兩部分。制動(dòng)盤(pán)的每個(gè)面都要加工為制動(dòng)表面。一塊防護(hù)板，安裝在轉(zhuǎn)向節(jié)上，保護(hù)制動(dòng)盤(pán)不被飛濺物污染。
制動(dòng)盤(pán)可以是實(shí)心或有通風(fēng)孔。擁有通風(fēng)孔的制動(dòng)盤(pán)表面之間設(shè)有散熱片。這種結(jié)構(gòu)大大提高了制動(dòng)盤(pán)的散熱面積。此外，當(dāng)車(chē)輪在運(yùn)動(dòng)時(shí)，這些風(fēng)扇型散熱片在制動(dòng)盤(pán)旋轉(zhuǎn)時(shí)增大空氣流通并提供更有效的制動(dòng)冷卻。盤(pán)式制動(dòng)器不會(huì)受熱變形，即使快速、強(qiáng)制制動(dòng)，原因就是制動(dòng)盤(pán)的快速冷卻。
液壓和摩擦部件都安裝在制動(dòng)鉗總成中。制動(dòng)鉗跨越輪轂和制動(dòng)盤(pán)外徑。當(dāng)制動(dòng)器作用時(shí)，通過(guò)活塞推動(dòng)制動(dòng)塊在夾緊制動(dòng)盤(pán)的過(guò)程中產(chǎn)生壓力。由于在制動(dòng)過(guò)程中液壓壓力等于應(yīng)用于制動(dòng)盤(pán)兩側(cè)，制動(dòng)盤(pán)沒(méi)有出現(xiàn)變形，無(wú)論過(guò)程的壓力多大和持續(xù)時(shí)間。也有許多種制動(dòng)鉗，但他們都可以分為兩大類(lèi)：移動(dòng)和固定卡鉗。固定式卡鉗是固定在一個(gè)固定的設(shè)計(jì)位置上。在移動(dòng)式設(shè)計(jì)中，制動(dòng)卡鉗相對(duì)于制動(dòng)盤(pán)移動(dòng)。 大多數(shù)晚期制造的汽車(chē)使用移動(dòng)式卡鉗。在設(shè)計(jì)中采用一個(gè)單獨(dú)的液壓活塞和能夠在制動(dòng)過(guò)程中滑動(dòng)或擺動(dòng)的卡鉗。在滑動(dòng)設(shè)計(jì)中卡鉗在導(dǎo)向銷(xiāo)上移動(dòng)。在擺動(dòng)式設(shè)計(jì)中，卡鉗在垂直表面內(nèi)擺動(dòng)。這兩種設(shè)計(jì)的工作方式基本相同。
在單活塞浮動(dòng)卡鉗中，單活塞卡鉗大多是由一個(gè)單一的鑄件構(gòu)成，其中包含一個(gè)大型鉆孔作為鑄件的內(nèi)側(cè)部分。內(nèi)側(cè)是指卡鉗安裝時(shí)靠近汽車(chē)鑄件的一面。制動(dòng)液入口孔和排氣孔的加工成的卡鉗內(nèi)側(cè)部分，直接連接到活塞孔。
制動(dòng)鉗缸包含一個(gè)活塞和密封圈。該密封圈具有矩形截面。它坐落在一個(gè)在缸體的加工孔槽。適合的密封活塞周?chē)耐鈴?，并提供了活塞與缸壁液壓密封件。長(zhǎng)方形的密封圈提供制動(dòng)盤(pán)和制動(dòng)塊之間的間隙自動(dòng)調(diào)整。當(dāng)汽車(chē)制動(dòng)時(shí)，密封圈在活塞給予的摩擦力作用下變形。當(dāng)液壓壓力釋放，密封放松，并變回其原來(lái)的長(zhǎng)方形，回縮進(jìn)入氣缸的正常運(yùn)行提供足夠的間隙活塞。由于制動(dòng)器襯片的磨損，活塞行程往往超過(guò)了密封圈地?fù)隙认拗?。因此，活塞密封圈能夠精確對(duì)襯片的磨損進(jìn)行補(bǔ)償。
加工活塞的頂部孔安裝一個(gè)密封防塵罩。在許多卡鉗活塞是鋼制造的，精密研磨，鍍鉻和鎳，給它一個(gè)非常艱難和持久的表面。一些制造商使用的是塑料活塞。這遠(yuǎn)遠(yuǎn)比鋼輕,提供一個(gè)更輕的制動(dòng)系統(tǒng)。活塞的塑料絕緣良好，并防止傳遞制動(dòng)液的熱量。每個(gè)鉗包含兩個(gè)背板和摩擦襯塊組件。他們粘接或鉚接或壓嵌在一起，并在卡鉗中安裝在制動(dòng)盤(pán)的兩側(cè)。最接近汽車(chē)中心的制動(dòng)襯塊被稱(chēng)為內(nèi)側(cè)制動(dòng)襯塊。另一側(cè)稱(chēng)為外側(cè)制動(dòng)襯塊。
正如已經(jīng)提到的，浮動(dòng)卡鉗是在兩個(gè)導(dǎo)向銷(xiāo)上固定。在汽車(chē)制動(dòng)時(shí)，活塞后面的液體壓力增加。壓力施加在活塞的底部和氣缸底部。作用于活塞的壓力傳遞到內(nèi)側(cè)制動(dòng)襯塊上，迫使制動(dòng)盤(pán)與內(nèi)側(cè)制動(dòng)塊摩擦。作用于氣缸孔底部的壓力迫使制動(dòng)卡鉗向著內(nèi)側(cè)端的導(dǎo)向銷(xiāo)移動(dòng)。由于制動(dòng)鉗的移動(dòng)，使外側(cè)制動(dòng)襯塊與制動(dòng)盤(pán)接觸，迫使外側(cè)制動(dòng)襯塊對(duì)制動(dòng)盤(pán)摩擦。隨著制動(dòng)壓力的積累，內(nèi)外制動(dòng)塊反相壓緊制動(dòng)盤(pán)，，使汽車(chē)停了下來(lái)。
制動(dòng)壓力釋放實(shí)際上會(huì)產(chǎn)生一個(gè)相對(duì)活塞和卡鉗非常輕微的運(yùn)動(dòng)。在釋放的工程中，活塞及制動(dòng)卡鉗只是進(jìn)入到一個(gè)放松和釋放的位置。在釋放的位置，制動(dòng)襯塊從制動(dòng)盤(pán)的表面收回。
英文原文：
China's engineers and users also stay in QianPan HouGu on the idea, and, before and after the application of the disc brake is commercial vehicle braking performance increase the optimal scheme. Because HouGu type brake on the temperature, the braking performance is very big, lead to the front axle attenuation disc brakes to bear on the part of the load, cause too much of the disc brake, brake piece of life of overload shorter. For cars in the braking process, because the role of the front, inertial load always takes all the car load 70% 80%, so the front wheel brake force to than the rear wheels. Manufacturers to cut costs, use the front disc brake, rear wheel drum brake mix of matching method. The QianPan HouGu type mixed brake, this is mainly due to the cost considerations. With the rapid development of China's national economy, the average consumer safety and environmental requirements of cars is increasing day by day, the miniature car industry from tiny truck started, the transition to tiny coaches, and then promoted to use tiny cars as transport, become the necessity of historical development; On the other hand, all miniature car companies already will capital and power steering mini car industry, to adapt to the different needs of consumers out mini car products, some private enterprises will also mini car into the breach of the car market as, constantly of price war, make mini car prices have no longer "too high", and began to close to ordinary people.
Disc brake caliper disc and main overall type two kinds, modern car on the application of the most caliper disc brake, it is the rotation of the element is brake disc, fixed element is brake caliper. And, according to the brake caliper movement way and can be divided into set caliper disc brake, sliding caliper disc brake caliper disc brake and, including sliding caliper disc brake application more widely. The working principle of caliper disc brake is similar to a bicycle brake, braking process, the brake caliper will brake piece of extrusion to brake disc, along with the brake disc and lining block of the friction between the gradually will fall speed. And sliding caliper disc brake is brake caliper can be relatively brake disc axial sliding; Only in the inside of the brake disc set oil cylinders, and the outside of the brake block is in the grips attached on the body. Disc brakes in use process, also can appear fault, among them the more common wind resistance, underpowered and brake system has noise etc.
Disc brake parts of fever in a narrow focus on the brake lining block, the unit and pressure than drum brakes, brake lining large block and clamp body of the piston direct contact with, so the quantity of heat of braking extremely easily to the brake fluid. So, make disc brakes easy to produce gas resistance phenomenon. But, if take corresponding measures, also can prevent air resistance happens.
Miniature and affordable in our country are big car market, in recent years the domestic demand expansion drive the car market demand for miniature of the increase. Authorities say China's economy has entered into the platform, the moderate growth will pull the stable growth of car market. Last year, Chinese each enterprise benefits to improve, per capita disposable income increase, cause individual needs to improve the car; Countries carrying out the strategy for western development, to WeiChe market is tremendous potential demand of no doubt. From 0.9 to 1.6 L L, the price is suitable for China's national conditions, suitable for the current status of the development of the China is. Automobile brake clamps body stent is one of important parts, along with the car now design processing development of manufacturing technology, the brake clamps body in support of materials and processing method and so on is also in constant development, identify processing technology and clamping plan and design, attain thus to the automobile brake clamps body stents processing technology further deeper understanding.
The main use of the software has Pro/e, ANSYS and CAPP. Pro/E software using 3 d entity the exact modeling, intuitive parts to reproduce the parts, accurate experience design intention, for parts of the process arrangement after help. Pro/E Mechanica module and the software ANSYS software, finite element analysis, combining do analysis processing produces in the process of the maximum displacement and the maximum stress, and the cutting tool for cutting dosages of the size of the choice to provide reliable basis. This topic use CAPP software developed including making the process route and process design, the complete process documents and improve the process of standardization and standardization. Early detection and solve. According to the retrieval, this in processing industries, and no one made the corresponding introduction. Pro/E software can be accurately to establish various large and complex models. ANSYS software in products manufacturing advance found potential problems, but its modeling ability are weak. The two tools combined, foster strengths and circumvent weaknesses, give full play to the advantages of two kinds of software research and development, is the first choice of complex mechanical structure scheme.This is also I choose the two software reasons. Previous engineering personnel with Pro/E complete three dimensions solid parts design, then use to Mechanica parts structure finite element analysis to find the place, and weak structure is improved. And I'm Pro/E, ANSYS will be applied to the design process of parts, make the past only in process actual implementation, can come into the open process defect, process design stage in can and
The error after reflects the workpiece machining allowance method to calculate is, by definition, the processing, surface: its smallest machining allowance (Zbmin) are processing parts of two adjacent step freeways will limit of the difference of the minimum size; Its the biggest machining allowance (Zbmax) are processing parts of two adjacent step freeways will limit of the difference of the largest size. Inside surface processing, the minimum machining allowance is processed spares the maximum limit adjacent freeways will step size poor; Its the biggest machining allowance is processing components work of two adjacent step of the difference of the minimum size limit.
The assistant time and basic time coincidence method, using the workbench processing center, get the staff in the cutting process completed work, and then, for auxiliary of the area is larger, and the volume of parts and relatively small, so can use one processing DuoGe parts to make the parts, the piece processing time as little as the basis, double the nc machining center area can also arranged four parts. The rotary worktable, two workpiece in processing at the same time, the clamping workpiece, the other two rotating, processing of just install two workpiece.
Selection of cutting parameter and the formulation of &fair standards. Choose the right to improve the cutting dosages, cutting efficiency and guarantee the necessary tools durability and economy, ensure machining quality, has the vital role. Reasonable choice when processing cutting dosages should first choose a as far as possible big, secondly, optimizing the back of choice a larger feeding, and the last in the cutting tool durability, process system stiffness, machine tool power under the terms of the license, the rational choice of cutting speed. &fair standards also says time is fixed in a certain technology organization established under the condition of complete unit out products (such as a parts) or a job (such as a process that must be consumed time). &fair standards is not only, also be the measure index productivity arrange production plan, the calculations of the productioncost is an important basis for new or expansion of the factory, is also (or workshop) computing devices and workers number of basis.
Brake caliper disc brake the car body is the critical, brake movement is in the grips body on the final. Installed in clamp body on parts and 16 pieces. One of the more important parts: brake caliper piston, piston callipers at the stents, sealing ring, friction piece, brake caliper shaft pins, spring of and purge screw, etc. Studio, brake fluid through the clamp body JinYou mouth will be pressure to brake caliper Detroit, and by the brake friction pressure before the pistons will to block, press the brake disc, and make clamp body in the brake caliper shaft pins, driving the sliding friction, also after pressure brake disc brake, complete action. The car brake disc brake caliper body shape, structure, material complex special for QT450-10, hardness is HB143-217, machining allowance for 3 mm, form and position tolerances stricter requirements. This product is the important parts, and related to China's automobile brake disc importied problem. In the existing gm in machine tool is completed or processing difficult brake caliper body, especially the lumen of processing, tank must determine the process, to ensure the quality of the processing equipment. Because in general on the machine processing, so blank datum positioning to repeated use, the request to have the precise location of the datum plane, this and use machining center is a very big difference. Such as we are in the process of slot PNE480 CNC machine even with pure inside the car, to ensure that slot cavity type, detection is precision with anatomical projection and after adjustment method of projection.
Were now being mass production craft ready to work, according to the auto industry "high starting point, large quantities of specialization," the policy, we have identified on the domestic equipment, save funds, and choose the XK6040 CNC milling machine.
外文文獻(xiàn)翻譯:
中國(guó)的工程師和用戶(hù)還停留在前盤(pán)后鼓的理念上，而前、后盤(pán)式制動(dòng)器的應(yīng)用才是商用車(chē)提高制動(dòng)性能的最佳方案。由于后鼓式制動(dòng)器在溫度升高后，制動(dòng)性能衰減很大，導(dǎo)致前軸上盤(pán)式制動(dòng)器承受不應(yīng)承擔(dān)的過(guò)多負(fù)載，致使盤(pán)式制動(dòng)器的過(guò)載，制動(dòng)片壽命的縮短。因轎車(chē)在制動(dòng)過(guò)程中，由于慣性的作用，前輪的負(fù)荷通常占汽車(chē)全部負(fù)荷的70%－80%，所以前輪制動(dòng)力要比后輪大。生產(chǎn)廠(chǎng)家為了節(jié)省成本，就采用了前輪盤(pán)式制動(dòng)，后輪鼓式制動(dòng)的混合匹配方式。采用前盤(pán)后鼓式混合制動(dòng)器，這主要是出于成本上的考慮。隨著我國(guó)國(guó)民經(jīng)濟(jì)的快速發(fā)展，普通消費(fèi)者對(duì)汽車(chē)安全和環(huán)保要求日益提高，微型汽車(chē)行業(yè)從微型貨車(chē)起步，過(guò)渡到微型客車(chē)，再提升到使用微型轎車(chē)作為代步工具，成為歷史發(fā)展的必然；另一方面，所有微型汽車(chē)企業(yè)已將主要資金和力量轉(zhuǎn)向微型轎車(chē)行業(yè)，推出適應(yīng)消費(fèi)者不同需求的微型轎車(chē)產(chǎn)品，一些民營(yíng)企業(yè)也將微型轎車(chē)作為進(jìn)入汽車(chē)市場(chǎng)的突破口，不斷的價(jià)格大戰(zhàn)，使得微型轎車(chē)價(jià)格已不再“曲高和寡”，開(kāi)始貼近普通百姓。
盤(pán)式制動(dòng)器主要有鉗盤(pán)式和全盤(pán)式兩種，現(xiàn)代汽車(chē)上應(yīng)用最多的就是鉗盤(pán)式制動(dòng)器，它的旋轉(zhuǎn)元件是制動(dòng)盤(pán)，固定元件是制動(dòng)鉗。而根據(jù)制動(dòng)鉗的運(yùn)動(dòng)方式又可分為定鉗盤(pán)式制動(dòng)器、滑動(dòng)鉗盤(pán)式制動(dòng)器和鉗盤(pán)式制動(dòng)器，其中滑動(dòng)鉗盤(pán)式制動(dòng)器應(yīng)用更廣。鉗盤(pán)式制動(dòng)器的工作原理就類(lèi)似于自行車(chē)上的剎車(chē)，在制動(dòng)過(guò)程中，制動(dòng)鉗將制動(dòng)塊擠壓到制動(dòng)盤(pán)上，隨著制動(dòng)盤(pán)和襯塊之間的摩擦逐漸的將速度降下來(lái)。而滑動(dòng)鉗盤(pán)式制動(dòng)器就是制動(dòng)鉗可以相對(duì)制動(dòng)盤(pán)作軸向滑動(dòng)；只在制動(dòng)盤(pán)的內(nèi)側(cè)設(shè)置油缸，而外側(cè)的制動(dòng)塊則附裝在鉗體上。盤(pán)式制動(dòng)器在使用過(guò)程中，也會(huì)出現(xiàn)故障，其中比較常見(jiàn)的有氣阻、制動(dòng)力不足和制動(dòng)時(shí)有噪聲等。
盤(pán)式制動(dòng)器的發(fā)熱部位集中在很窄的制動(dòng)襯塊上，其單位壓力又比鼓式制動(dòng)器大，制動(dòng)襯塊和鉗體的活塞直接接觸，因此制動(dòng)時(shí)的熱量極易傳給制動(dòng)液。這樣，使盤(pán)式制動(dòng)器容易產(chǎn)生氣阻現(xiàn)象。但是，若采取相應(yīng)的措施，也可防止氣阻現(xiàn)象的發(fā)生。 微型及普及型汽車(chē)在我國(guó)有很大市場(chǎng)，近年來(lái)內(nèi)需擴(kuò)大帶動(dòng)了對(duì)微型汽車(chē)市場(chǎng)需求量的增加。有關(guān)部門(mén)認(rèn)為中國(guó)經(jīng)濟(jì)已經(jīng)進(jìn)入適度增長(zhǎng)的平臺(tái)，這必將拉動(dòng)汽車(chē)市場(chǎng)的穩(wěn)定增長(zhǎng)。去年，中國(guó)各企業(yè)效益好轉(zhuǎn)，居民可支配收入增加，致使個(gè)人對(duì)汽車(chē)需求提高；國(guó)家實(shí)施西部大開(kāi)發(fā)戰(zhàn)略，對(duì)微車(chē)市場(chǎng)無(wú)疑也是巨大的潛在需求。從0.9L到1.6L，價(jià)格適合我國(guó)國(guó)情,適合正在發(fā)展的中國(guó)的現(xiàn)況。汽車(chē)制動(dòng)器鉗體支架是汽車(chē)重要零件之一，隨著現(xiàn)在設(shè)計(jì)加工制造技術(shù)的發(fā)展，制動(dòng)器鉗體支架的材料及加工手段等也在不斷發(fā)展，確定加工工藝與裝夾方案及設(shè)計(jì)，從而達(dá)到對(duì)汽車(chē)制動(dòng)器鉗體支架加工工藝進(jìn)一步更深了解。
主要用到的軟件有Pro/ENGINEER、ANSYS和CAPP。利用Pro/E軟件進(jìn)行三維實(shí)體零件的精確建模,直觀(guān)地再現(xiàn)了零件，準(zhǔn)確體會(huì)設(shè)計(jì)意圖，為零件以后的工藝安排提供幫助。Pro/E軟件的Mechanica模塊和ANSYS軟件結(jié)合起來(lái)做有限元分析,分析加工過(guò)程中產(chǎn)生的最大位移和最大應(yīng)力,為切削用量和刀具尺寸的選擇提供可靠的依據(jù)。本課題利用CAPP軟件編制出包括制訂工藝路線(xiàn)和工序設(shè)計(jì)在內(nèi)的完整工藝文件，提高了工藝的標(biāo)準(zhǔn)化和規(guī)范化。早發(fā)現(xiàn)并解決。根據(jù)查新檢索，這在加工行業(yè)里，還沒(méi)有人作過(guò)相應(yīng)的介紹。 Pro/ E 軟件可以精確地建立各種龐大復(fù)雜的模型。ANSYS軟件在產(chǎn)品制造前預(yù)先發(fā)現(xiàn)潛在的問(wèn)題，但它的建模能力比較弱。這2 個(gè)工具結(jié)合起來(lái),揚(yáng)長(zhǎng)避短, 充分發(fā)揮2 種軟件的優(yōu)勢(shì),是研究開(kāi)發(fā)復(fù)雜機(jī)械結(jié)構(gòu)的首選方案。這也是我選擇這兩個(gè)軟件的原因。以往工程人員利用Pro/E完成三維實(shí)體零件設(shè)計(jì)，再運(yùn)用Mechanica對(duì)零件結(jié)構(gòu)進(jìn)行有限元分析，找出結(jié)構(gòu)薄弱的地方，從而進(jìn)行改進(jìn)。而我是將Pro/E、ANSYS應(yīng)用到零件的工藝過(guò)程設(shè)計(jì)當(dāng)中，使得過(guò)去只有在工藝過(guò)程的實(shí)際實(shí)施中，才能暴露出來(lái)的工藝缺陷，在工藝設(shè)計(jì)階段就能夠及本工件采用誤差復(fù)映法計(jì)算加工余量，其定義是：外表面加工時(shí)，其最小加工余量（Zbmin）是被加工零件相鄰兩工步的兩個(gè)最小極限尺寸之差;其最大加工余量（Zbmax）是被加工零件相鄰兩工步的兩個(gè)最大極限尺寸之差。內(nèi)表面加工時(shí)，其最小加工余量是被加工零件相鄰兩工步的最大極限尺寸之差;其最大加工余量是被加工零件相鄰兩個(gè)工步的最小極限尺寸之差。
采用輔助時(shí)間與基本時(shí)間重合的方法，采用雙工作臺(tái)的加工中心，使工作人員在工件切削加工過(guò)程中完成輔助工作，另外，因?yàn)楣ぷ髋_(tái)的面積比較大，而零件的體積相對(duì)來(lái)說(shuō)又很小，所以可以采用一次加工多個(gè)零件的辦法，使得零件的單件加工時(shí)間盡可能少，經(jīng)查得雙工作臺(tái)數(shù)控加工中心的面積可以同時(shí)排布四個(gè)零件。采用旋轉(zhuǎn)工作臺(tái)，兩個(gè)工件在加工的同時(shí)，裝夾另外兩個(gè)工件，工作臺(tái)旋轉(zhuǎn)，加工剛剛安裝的兩個(gè)工件。
切削用量的選擇和工時(shí)定額的制定。正確地選擇切削用量，對(duì)提高切削效率，保證必要的刀具耐用度和經(jīng)濟(jì)性，保證加工質(zhì)量，具有重要的作用。合理選擇加工時(shí)切削用量應(yīng)該首先選擇一個(gè)盡量大的背吃刀量，其次選擇一個(gè)較大的進(jìn)給量，最后在刀具耐用度，工藝系統(tǒng)剛度，機(jī)床功率許可的條件下,選擇合理的切削速度。工時(shí)定額也稱(chēng)時(shí)間定額是在一定的技術(shù)組織條件下制定出來(lái)的完成單位產(chǎn)品（例如一個(gè)零件）或某項(xiàng)工作（如一個(gè)工序）所必須消耗的時(shí)間。工時(shí)定額不僅是衡量生產(chǎn)率的指標(biāo)，也是安排生產(chǎn)計(jì)劃，計(jì)算生產(chǎn)成本的重要依據(jù)，也是新建或擴(kuò)建工廠(chǎng)（或車(chē)間）時(shí)計(jì)算設(shè)備和工人數(shù)量的依據(jù)。
制動(dòng)鉗體是轎車(chē)盤(pán)式制動(dòng)器上的關(guān)鍵件，制動(dòng)動(dòng)作是在鉗體上最終完成的。安裝在鉗體上的零件有11種共16件。其中比較重要的零件有：制動(dòng)鉗活塞，制動(dòng)鉗支架，活塞密封圈，摩擦塊，制動(dòng)鉗軸銷(xiāo)，彈簧片與放氣螺塞等。工作室，制動(dòng)液通過(guò)鉗體進(jìn)油口將壓力傳給制動(dòng)鉗活塞，然后由制動(dòng)活塞將壓力傳給前摩擦塊，壓緊制動(dòng)盤(pán)，并使鉗體在制動(dòng)鉗軸銷(xiāo)上滑動(dòng)，帶動(dòng)后摩擦，也壓緊制動(dòng)盤(pán)，完成制動(dòng)動(dòng)作。轎車(chē)盤(pán)式制動(dòng)器制動(dòng)鉗體外形復(fù)雜，結(jié)構(gòu)特殊，材料為QT450-10，硬度為HB143-217，加工余量為3mm，形位公差要求較嚴(yán)。該產(chǎn)品是汽車(chē)重要零部件，并關(guān)系到我國(guó)汽車(chē)盤(pán)式制動(dòng)器實(shí)現(xiàn)國(guó)產(chǎn)化的問(wèn)題。在現(xiàn)有通用機(jī)床上完成或加工難度較大的制動(dòng)鉗體，尤其是內(nèi)腔槽型的加工，就必須確定合理的工藝流程，采用工裝來(lái)保證加工的質(zhì)量。因?yàn)樵谕ㄓ脵C(jī)床上加工，所以毛坯基準(zhǔn)面定位要重復(fù)使用，就要求有精確的定位基準(zhǔn)面，這與用加工中心加工是有很大差異的。如槽型加工我們是在PNE480數(shù)控機(jī)床上用單刀精車(chē)內(nèi)腔，來(lái)保證槽型精度，檢測(cè)是用解剖投影和投影后修正的方法。
目前正進(jìn)行大批量生產(chǎn)的工藝準(zhǔn)備工作，根據(jù)汽車(chē)工業(yè)“高起點(diǎn)，大批量，專(zhuān)業(yè)化”的方針，我們確定了立足國(guó)內(nèi)設(shè)備，節(jié)省資金投入，選用了XK6040數(shù)控銑床。