曲轴零件的机械加工工艺及夹具设计解读.docx
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曲轴零件的机械加工工艺及夹具设计解读
曲轴零件的机械加工工艺及夹具设计
摘要:
曲轴是机器的关键部件之一,主要用于往复式机械,在柴油机中与活塞连接,通
过其旋转运动转换成活塞的直线运动。
其材质大体分为两类:
一是钢锻曲轴,二是球墨
铸铁曲轴。
曲轴关键技术是整个产业中占有非常重要的地位。
曲轴在发动机中是非常难以加工的零件之一。
在发动机中,曲轴工作需要承载巨大载荷,工作条件极其恶劣,对曲轴材质以及毛坯加工技术、精度、表面粗糙度、热处理和表面强化、动平衡等要求都十分严格。
本设计结合实际进行理论分析,在保证产品质量,提高生产效率,降低生产成本的的前提下,对曲轴零件的工艺进行优化设计。
从目前的总体水平看,低下的生产率,落后的技术和设备,粗糙的机械性能导致毛坯铸造工艺存在不稳定,精度低、废品率高等等问题。
球墨铸铁具有良好的切削性能,也能进行热处理和表面硬化来提高曲轴疲劳强度和耐磨性。
在本次设计中曲轴的材质为球墨铸铁。
本设计利用所学知识,查找资料设计可取的工艺路线,选取了加工工艺完善也比较精密和经济的作为方案,并设计其中一到二个工序的加工夹具。
夹具设计的思路如下:
(1)根据设计任务书收集设计资料;
(2)初步拟订夹具的结构方案、绘制零件图;(3)绘制夹具总装图。
关键词:
曲轴球墨铸铁工艺路线夹具
R180dieselenginecrankshaftprocessdesignandfixture
design
ABSTRACT:
ThegraduationdesignisaboutR180dieselenginecrankshaftprocess
designanditstwoprocesstofixturedesign.
曲轴零件的机械加工工艺及夹具设计
Crankshaftisoneofthekeypartsofdieselengine,thematerialcanbedividedintotwocategories:
oneisforgedsteelcrankshaft,2itisductileironcrankshaft.Thecrankshaftkeytechnologyisoneofthemostconcernofthewholeindustry.Isenginecrankshaftunderimpactload,thepoweroftheimportantpartsoftheenginefivebigoneofthemostdifficulttoguaranteemachiningquality.Becausecrankshaftworkingconditions,materialforcrankshaftblankandprocessingtechnology,precision,surfaceroughness,heattreatmentandsurfacestrengtheningisverystrict,dynamicbalance,etc.
ThisdesignbasedonAutoCAD,drawthecorrespondingpartdrawinganddesigndesirableprocessroutefindingoutinformation,andselecttheprocessingcraftismorepreciseandtheeconomyasasolution.
Fixturedesigntrainofthoughtis:
(1)cleardesigntask,designinformationcollection;2)toformulatethefixturestructurescheme,thestructureofthedrawingsketch;(3)mapclampassembly.
Keywords:
ThecrankshaftDuctileironProcessroutefixture
目
录
1前言....................................................................................................................
1
1.1
绪论......................................................................................................................................
6
1.2
曲轴的概念..........................................................................................................................
6
1.3
曲轴的制造技术..................................................................................................................
6
1.3.1曲轴材料.............................................................................................................
8
1.3.2曲轴加工.............................................................................................................
8
1.4
论文结构..............................................................................................................................
9
2曲轴零件工艺设计.........................................................................................
01
2.1
分析零件...........................................................................................................................
10
2.1.1零件的作用.............................................................................................................
10
2.1.2零件的工艺分析......................................................................................................
10
2.2
确定生产类型....................................................................................................................
10
2.3
确定毛坯............................................................................................................................
10
2.3.1
确定毛坯种类........................................................................................................
10
2.3.2
确定铸件加工余量................................................................................................
11
2.3.3
绘制曲轴零件毛坯图............................................................................................
11
2.4
机械加工工艺过程设计.................................................................................................
11
2.4.1
选择定位基准........................................................................................................
11
2.4.2
选择表面加工方法................................................................................................
11
2.4.3
确定工艺过程方案................................................................................................
12
2.5
选择加工设备与工艺装备...............................................................................................
14
2.5.1
选择机床................................................................................................................
15
2.5.2
选择夹具................................................................................................................
15
2.5.3
选择刀具................................................................................................................
16
2.5.4
选择量具................................................................................................................
16
2.6
确定工序尺寸...................................................................................................................
16
2.7
确定切削用量及时间定额...............................................................................................
19
2.7.1
工序070(粗车长头)切削用量及时间定额
.....................................................19
2.7.2
工序130(钻孔Ф14.2)切削用量及时间定额
..................................................22
2.7.3
工序240(铣K面)切削用量及时间定额.........................................................
23
2.8
填写工艺规程卡...............................................................................................................
25
2.8.1
机械加工工序卡片................................................................................................
25
2.8.2
机械加工工艺过程卡片........................................................................................
25
3曲轴零件第一套夹具设计.............................................................................
62
3.1
明确设计任务、收集分析原始资料...............................................................................
26
3.1.1
加工工件的零件图................................................................................................
26
3.1.2
设计任务书............................................................................................................
26
3.1.3
工序简图................................................................................................................
26
3.1.4
分析原始资料........................................................................................................
26
曲轴零件的机械加工工艺及夹具设计
3.2
确定夹具的结构方案.......................................................................................................
72
3.2.1
根据六点定位规则确定工件的定位方式............................................................
72
3.2.2
选择定位元件,设计定位装置............................................................................
72
3.2.3
分析计算定位误差..............................................................................................
82
3.2.4
确定工件的夹紧装置..........................................................................................
92
3.3
绘制夹具结构草图...........................................................................................................
03
3.3.1
拟订夹具总装图的尺寸、公差与配合以及技术要求.......................................
30
3.3.2
绘制夹具总装图....................................................................................................
13
4曲轴零件第二套夹具设计.............................................................................
23
4.1明确设计任务、收集分析原始资料...............................................................................
23
4.1.1
加工工件的零件图................................................................................................
23
4.1.2
设计任务书............................................................................................................
23
4.1.3
工序简图..............................................................................................................
23
4.1.4
分析原始资料........................................................................................................
23
4.2确定夹具的结构方案...............................................................................................
33
4.3夹具定位误差分析...................................................................................................
33
4.4拟订夹具总装图的尺寸、公差与配合及技术要求...............................................
3
4.4.1
尺寸、公差与配合................................................................................................
33
4.4.2
制订技术条件........................................................................................................
43
4.5绘制夹具总装图...............................................................................................................
43
总
结.................................................................................................................
53
致
谢.................................................................................................................
63
参考文献
.............................................................................................................
73
附录A机床........................................................................................................
83
附录B夹具........................................................................................................
93
附录C刀具........................................................................................................
04
附录D量具........................................................................................................
04
1前言
1.1绪论
(一)、研究的目的及意义
随着科学技术的迅猛发展和市场需求的变化及竞争加剧,传统的制造技术发展到了一个崭新的阶段;随着我国经济