ZH1105柴油机气缸体三面攻螺纹组合机床左主轴箱设计.docx
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ZH1105柴油机气缸体三面攻螺纹组合机床左主轴箱设计
摘要
本文主要介绍ZH1105柴油机气缸体三面攻螺纹组合机机床的设计。
因为工艺方案在很大程度上决定组合机床的结构配置和实用性能。
因此应根据被加工工件的特点，按组合机床常用的设计方法、充分考虑各种影响因素，并分析后拟订出可靠的工艺方案。
在设计多轴箱时,根据加工工序图确定所需设计的组合机床上完成的工艺内容，加工部位的尺寸、精度、表面粗糙度及技术要求，加工用的定位基准、压紧部位以及被加工零件的材料、硬度和在本机床加工前的加工余量。
认真分析研究并确定设计方案，计算所需的功率，设计出适合加工本工序的组合机床。
关键词：
组合机床;加工工序;多轴箱;传动系统
Abstract:
MainintroductioninthistextZH1105dieselengineaircylinderthreeoffendthedesignofthethreadcombinationmachinemachinebed,stud.Becausethecraftprojectdecidestoalargeextenttheconstructionthatcombinethemachinebedinstallswiththepracticalfunction.Sothatshouldaccordingtothecharacteristicsoftheworkpiece,accordingtocertainprinciple,knotwithcombinetheincommonusedesigninbedinmachinemethodandconsidereverykindofinfluencefactorwell,combinetheeconomicanalysisdrawupadependablecraftprojectbehind.Completeinmanystalksacombinationfor,accordingtoprocessingworkprefacediagramcertainthedesignneededmachinebedthatdesignthecraftcontents,processtheroughafixedpositionforandtechniquerequesting,processingusingbasisinsize,accuracy,surfaceofthepartandaddtopressthepartandisprocessedthematerial,degreeofhardnessofthespare.
Keywords:
Combinationmachinebed;Processtheworkpreface;
Manystalksbox;Spreadtomovethesystem
目录
0前言·····································································································································1
1、总体方案论证··················································································································3
2、计算部分···························································································································4
2．1、多轴箱的设计··············································································································4
2．2、切削转矩的计算·········································································································5
2．3、主轴直径的计算和主轴外伸尺寸的确定·································································6
2．4、切削速度的确定·········································································································6
2．5、切削功率的计算········································································································6
2．6、机床动力参数的计算·································································································7
2．6．1、电动机功率的确定·······························································································7
2．6．2、电动机的选择·······································································································7
2．7、攻螺纹主轴转速的计算·····························································································8
2．8、切削用量的计算·········································································································8
2．9、生产率计算················································································································8
2．9．1、理想生产率计算···································································································9
2．9．2、实际生产率计算··································································································9
2．9．3、机床负荷率计算··································································································9
2．10、多轴箱的传动系统设计··························································································9
2．11、根据原始依据图计算主轴坐标··············································································11
2．12、多轴箱中齿轮模数、齿数的确定··········································································12
2．13、合拢轴的位置及齿轮齿数的确定··········································································14
2．14、传动轴坐标计算·····································································································15
2．15、验算中心距误差·····································································································16
2．16、轴的校核·················································································································20
2．17、齿轮校核·················································································································22
2．18、靠模体的设计··········································································································22
3、设计部分························································································································23
4、结论································································································································24
5、小结································································································································25
致谢······································································································································25
参考文献······························································································································26
附件清单······························································································································27
0前言
组合机床主要用于平面加工和孔加工。
平面加工包括铣平面、车端面、刮平面；孔加工包括钻、扩、铰、镗孔以及倒角、切槽、攻螺纹等。
组合机床最适宜于加工各种大中型箱体类零件，如气缸体、气缸盖、变速箱体等零件。
根据课题要求、ZH1105柴油机气缸体要加工工序的特点和减少工人的劳动强度、降低生产成本和提高加工效率用组合机床对ZH1105柴油机气缸体三面上31个螺纹进行加工。
设计本组合机床时尽能的采用通用件，以降低成本。
因此本组合机床应用通用多轴箱、通用主轴、传动件、齿轮和附加机构。
通用件选用是根据所需的功率、进给力、进给速度等要求的。
多轴箱尺寸应根据加工主轴分布位置通过估算，并圆整后选用相近似尺寸的标准规格的多轴箱，据此选择结合尺寸的动力箱。
尽可能按通用部件的配套关系选用通用部件。
工艺方案的拟定是组合机床设计的关键一步。
因为工艺方案在很大程度上决定组合机床的结构配置和实用性能。
应根据工件的加工特点，充分考虑各种影响因素，经济分析的基础拟定出可靠的工艺方案。
从而确定组合机床的配置型式及结构方案应根据工件的结构特点，并进行组合机床总体方案图样文件的设计。
粗精加工分开原则，粗加工时的切削负荷较大，切削产生的热变形、较大夹压力引起的工件变形以及切削振等动，对精加工工序十分不利，影响加工尺寸精度和表面粗糙度，因此应选择粗精加工工序分开的原则。
拟定工艺方案时，在保证加工质量和操作维修方便的前提下，应适当提高工序集中程度。
因此全面分析多方因数和理决定工序集中程度。
被加工零件工序图是根据制定的工艺方案，表示所设计的组合机床完成的工序内容，加工部位的尺寸、精度、表面粗糙度及技术要求，加工用的定位基准、压紧部位等，它是组合机床设计的具体依据，也是制造、使用、调整和检验机床精度的重要文件。
被加工零件工序图是在被加工零件图基础上，突出本机床的加工内容。
加工示意图是在工艺方案和机床总体方案确定的基础上绘制的，加工示意图应与机床实际加工状态一致。
是表达工艺方案具体内容的机床工艺方案图。
它是设计刀具、夹具、多轴箱和液压、电气系统以及选择动力部件、绘制机床联系尺寸图的主要依据。
加工示意图上要标注联系尺寸、切削用量（同一主轴箱上各主轴的每分钟进给量是相等的）、工作循环、攻退量、攻进量。
机床联系尺寸总图是以被加工零件工序图和加工示意图为依据，并按选定的通用部件以及确定的专用部件的总体结构而绘制的。
是用来表示机床的配置型式、主要构成及各部件安装位置、相互的联系、运动关系和操作方位的总体布局图。
它为主轴箱、夹具等专用部件设计提供重要依据。
生产率计算卡是反映机床实际生产率和切削用量、动作时间、生产纲领及负荷率。
根据加工示意图所确定的工作循环以及切削用量，就可以计算机床生产率并编制生产率计算卡。
它是用户验收机床生产率的重要依据。
主轴箱是组合机床的重要专用部件。
它是根据加工示意图所确定的工件加工孔的数量和位置、切削用量和主轴类型设计的传递各主轴运动的动力部件。
主轴箱的设计方法是：
绘制主轴箱的设计原是依据图；确定主轴结构、轴径及齿轮模数；拟定传动系统；计算主轴、传动轴坐标，绘制坐标检查图；绘制主轴箱总图，零件图及编制组件明细表。
主轴和被加工零件在机床上是面对面安放的，因此，主轴箱主视图上的水平方向尺寸与零件工序图上的水平方向尺寸正好相反。
主轴箱传动系统的拟定：
先把全部主轴中心尽可能分布在一个或几个同心圆上，在同心圆的圆心上分别设置中间传动轴；非同心圆分布的一些主轴，也宜设置中间传动轴，然后根据已选定的各中心传动轴再取同心圆，并用最少的传动轴带动这些中心传动轴；最后通过合拢传动轴与动力箱驱动轴连接起来。
并使各主轴获得预定的转速和转向。
组合机床上攻螺纹，根据工件加工部位分布情况和工艺要求，常用攻螺纹靠模装置攻螺纹。
攻螺纹靠模装置用于同一方向纯攻螺纹工序。
由攻螺纹多轴箱和攻螺纹靠摸头组成。
靠模螺母和靠模螺杆是经过磨制并精细研配的，因而螺孔加工精度高，在润滑良好时，对铸铁加工精度可达H6～H7级精度螺孔，表面粗糙度可达Ra3.2μm。
螺孔的位置精度稍低于钻孔时的位置精度，因此螺孔的位置精度主要取决于螺纹底孔的位置精度。
攻螺纹主轴箱一般都是由电动机直接驱动。
在确定电动机功率时，要考虑丝锥工作时钝化的影响，一般取为计算功率的1.5～2.5倍（轴数少时取大值，轴数多时取小值）。
丝锥退回原位时，电动机应能迅速地停止，以避免攻螺纹靠模系统在电动机反转停止时惯性的影响，不致造成丝锥超程而破坏攻螺纹机构的原位状态。
因此，一般攻螺纹主轴都要有制动。
1总体方案论证
根据任务书的要求：
设计的组合机床要满足加工要求、保证加工精度；尽可能用通用件、以降低成本；各动力部件用电气控制、液压驱动。
因此根据任务书要求和气缸体的特点初定两种设计方案：
1.1卧式组合机床
特点：
卧式组合机床重心底、振动小运作平稳、加工精度高、占地面积大。
1.2立式组合机床
特点：
立式组合机床重心高、振动大、加工精底、占地面积小。
1.3方案比较
根据卧式组合机床和立式组合机床的特点比较可知：
为了保证螺纹孔的加工精度和结合气缸体本身的特点（左面攻14个螺纹孔、右面攻10个螺纹孔后面攻6个螺纹孔，见加工工序图）选择卧式组合机床。
1.4总体设计的思路
拟定工艺方案；根据任务书要求绘制加工工序图；根据确定的切削用量、工作循环和工作行程等绘制加工示意图；根据加工工序图、加工示意图和确定的专用部件及通用部件绘制机床联系尺寸总图。
根据“三图一卡”设机组合机床。
2计算部分
2.1多轴箱的设计计算：
组合机床的通用多轴箱的标准厚度为180mm；用于卧式多轴箱的前盖厚度为55mm，基型后盖的厚度为90mm，因此确定多轴箱的尺寸，主要是确定多轴箱的宽度B和高度H及最低主轴高度h。
如下图所示：
被加工气缸体轮廓用双点化线表示，多轴箱轮廓用粗实线表示。
多轴箱宽度B、高度H的大小主要与气缸体需要加工的螺孔的分布有关。
参考[
]P49
注：
b——工件在宽度方向相距最远的两孔距离、单位mm;
b1——最边缘主轴中心至箱体外壁距离、单位mm；
h——工件在高度方向相距最远的两孔距离、单位mm;
h1——最低主轴高度、单位mm。
公式：
B=b+2b1[1]P492—1
公式：
H=h+h1+b1[1]P492—2
已知：
b=417.020mm
b1=70～100mm[1]P31
h=275mm
h1=112.920mm
由公式2—1得：
B=b+2b1=417.020+2×（70～100）
=557.020～617.020mm
由公式2—2得：
H=h+h1+b1=275+112.920+70～100
=457.920～487.920㎜
查[1]P134表7—1：
取：
B×H=630×500mm2
2.2切削转距的计算：
2.2.1攻9—M8×1.25—7H深16的螺纹所需转据的计算
公式：
T=195×D1.4×Pw1.5[1]P44表3—52—3
注：
D—螺纹大径、单位mm；
Pw——工件的螺距、单位mm。
由公式2—3得：
T=195×D1.4×Pw1.5=195×81.4×1.251.5
≈5010N.mm≈5N.m
查[1]P44表3—5
取：
T=5N.m
2.2.2攻M10×1.5—7H深15的螺纹所需转据的计算
由公式2—3得：
T=195×D1.4×Pw1.5=195×101.4×1.51.5
≈8998.003N.mm≈8.998N.m
查[1]P44表3—5
取：
T=9N.m
2.3主轴直径的计算和主轴外伸尺寸的确定
公式：
d=6.2×（10T）1/4[1]P44表3—5（加工铸铁）2—4
注：
d—主轴直径、单位mm;
T—转距、单位mm;
D—螺纹大径、单位mm;
P—螺距、单位mm。
2.3.1攻9—M8×1.25—7H深16的螺纹所需主轴直径的计算
由公式2—4得：
d=6.2×（10T）1/4[1]P44
=6.2×（10×5）1/4=16.488mm
查[1]P44表3—5取：
d=17mm
2.3.2攻M10×1.5—7H深15的螺纹所需主轴直径的计算
由公式2—4得：
d=6.2×（10T）1/4[1]P44
=6.2×（10×9）=20mm
为了减少更换攻螺纹接杆的时间、降低操作工人的劳动强度和提高工作效率等原因，所以取攻9—M8×1.25—7H深16螺纹主轴的直径与攻M10×1.5—7H深15螺纹直径为20mm（d=20mm）。
2.3.4主轴外伸尺寸的确定
参考[1]P44得：
L=115㎜D/d1=32/20㎜
2.4切削速度的确定
参考[1]P123V=4～8m/min
2.4.1攻9—M8×1.25—7H深16的螺纹切削速度的确定
取V=3.70m/min
2.4.2攻M10×1.5—7H深15的螺纹切削速度的确定
取V=3.93m/min
2.5切削功率的计算
公式：
p=（TV）/（9740∏D）[1]P134表6—202—5
注：
T—切削转距、单位N.m;
V—切削速度、单位m.min-1;
D—被加工螺纹的直径、单位mm。
2.5.1攻9—M8×1.25—7H深16的螺纹所需切削功率的计算
由公式2—5得：
p=（TV）/（9740∏D）[1]P134
=（5×103×3.7）/（9740∏×8）
=7.561×10–2Kw
所以：
p9=9×p=9×7.561×10–2=0.6805Kw
2.5.2攻M10×1.5—7H深15的螺纹所需切削功率的计算
由公式2—5得：
p=（TV）/（9740∏D）[1]P134
=（9×103×3.93）/（9740∏×10）
=0.1157Kw
所以攻9—M8×1.25—7H深16的螺纹和攻M10×1.5—7H深15的螺纹所需总功率为：
p=0.6805+0.1157=0.7962Kw
2.6机床动力参数的计算
2.6.1电动机功率的计算
公式：
P=p/η[1]P44（η=0.7～0.8）2—6
注：
P—多轴箱所需功率、单位Kw；
p—消耗于各主轴的切削功率总和、单位Kw；
η—多轴箱的传动效率。
由公式2—6得：
P=p/η[1]P44
=0.7962/（0.7～0.8）
=0.995～1.137Kw
参考[1]P86在确定电动机功率时，要考虑丝锥工作时钝化的影响，一般取计算功率的1.5～2.5倍。
所以Pd=P×（1.5～2.5）=1.7055～2.8425Kw
2.6.2电动机的选择
考虑到轴承与轴、齿轮与轴、齿轮与齿轮、轴与箱体、轴与轴套等之间的能量损耗所以选择功率稍大一些的电动机。
参考[
]P115
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