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柴油機齒輪室蓋鉆鏜專機總體及夾具設(shè)計
摘要：為保證ZH1105W柴油機齒輪室蓋孔加工及保證相應的位置精度，設(shè)計一臺鉆鏜組合機床。在完成“三圖一卡”的基礎(chǔ)上，完成夾具設(shè)計。
根據(jù)ZH1105W柴油機齒輪室蓋的工序圖分析其精度、表面粗糙度、技術(shù)要求、加工部位尺寸、形狀結(jié)構(gòu)、材料硬度、工件剛性及零件的批量的大小不同，確定被加工零件工藝方法和工藝過程，確定該組合機床的總體設(shè)計方案；考慮該零件表面結(jié)構(gòu)的不規(guī)則性但有較高精度的孔需要加工，定位基準選擇“一面雙孔”是最佳的方法。選擇通用導套，保證零件上孔的位置精度。選用液壓滑臺來保證所需要的進給力。動力箱和機床底座都是經(jīng)過嚴格的計算后再選擇合適的標準件，減少機床設(shè)計周期和成本；在夾具設(shè)計方面采用“一面兩銷”的定位方案保證被加工孔的準確定位和尺寸精度。考慮到需要的夾緊力比較大和手動夾緊的局限性，選用了液壓自動夾緊的方案，提供穩(wěn)定的夾緊力，減少工人的操作時間并且滿足中批量生產(chǎn)的要求。
此次設(shè)計的組合機床，結(jié)構(gòu)簡單、維護方便，大量使用了通用部件來降低制造成本，達到了設(shè)計的要求。
關(guān)鍵詞：齒輪室蓋；組合機床； 總體設(shè)計； 夾具；
Overall and jig design of drilling and boring modular machine for the diesel engine gear cap
Abstract: In order to guarantee the hole processing and the corresponding position precision of the ZH1105W diesel engine gear cap, to drilling and the boring modular machine is designed. It mainly completes the jig design bases on “three charts and a card”.
According to the working procedure chart of the ZH1105W diesel engine’s gear cap analysis work piece’s precision, the surface roughness, the specification, the processing spot size, the shape structure, material degree of hardness, the work piece rigidity and the different of the components batch size to definite technique and technological process, determine aggregate machine-tool’s overall plan. Consider to the irregularity components but have high accuracy holes to be processing. So, “two holes at a face” is the best localization plan. Choiceing the general leads the wrap to Guarantee the hole of the components’ position precision. In order to guarantee the needs of the entering strength, we select hydraulic pressure sliding table. The power box and the engine bed are the standard parts base on our strict computation, so that we can greatly reduce the engine bed design cycle and the cost; In the jig aspect, we use the "two sells at the same face" for the localization plan. Only this way, we can guarantee the hole the accurate localization and the size precision. Considered to the strength of the manual clamps quite be small, selecting the hydraulic pressure clamps is the best way. It could provide stably clamps the strength, reduced worker's operating time and to satisfy the volume production request greatly.
Besides satisfying the processing request, the structure is simple, the maintenance is convenient. The general parts are massively used to reduce the production cost and meet the design requirements.
Key words: The gear cap; Modular machine-tool; Overall design; Jig;