活塞加工工艺及夹具设计

一、设计题目活塞零件的工加工艺及工艺夹具设计二、原始资料(1)被加工零件的零件图1张(2)生产类型:（中批或大批大量生产）三、上交材料1．绘制零件图1张2．毛坯图1张3．编制机械加工工艺过程综合卡片1套4．编制机械加工工艺卡片（仅编制所设计夹具对应的那道工序的机械加工工艺卡片）1套5．绘制夹具装配图（A0或A1）1张6．绘制夹具中1个零件图（A1或A2。装配图出来后，由指导教师为学生指定需绘制的零件图，一般为夹具体）。1张7．编写课程设计说明书（约5000-8000字）。1份四、进度安排本课程设计要求在3周内完成。1．第l～2天查资料，熟悉题目阶段。2．第3～7天，完成零件的工艺性分析,确定毛坯的类型、制造方法和机械加工工艺规程的设计并编制出零件的机械加工工艺卡片。3．第8～10天，完成夹具总体方案设计（画出草图，与指导教师沟通，在其同意的前提下，进行课程设计的下一步）。4．第11～13天，完成夹具总装图的绘制。5．第14～15天，零件图的绘制。6．第16～18天，整理并完成设计说明书的编写。7．第19天，完成图纸和说明书的输出打印。五、指导教师评语成绩：指导教师日期摘要机械制造技术基础课程设计是我们在学完了大学的全部基础课、专业基础课以及专业课后进行的。这是我们在进行毕业设计之前对所学的各科课程一次深入的综合性总复习，也是一次理论联系实际的训练。因此，他在我们的大学五年生活中占有重要的地位。我这次设计的是CA6102发动机的活塞，有零件图、毛坯图、夹具装配图、各一张，机械加工工艺过程卡片和与所设计夹具对应那道工序的工序卡片各一张。首先我们要熟悉零件，题目所给的零件是CA6102发动机的活塞。了解了活塞的作用，接下来根据零件的性质和零件图上各端面的粗糙度确定毛坯的尺寸和机械加工余量。然后我们再根据定位基准先确定精基准，后确定粗基准，最后拟定活塞的工艺路线图，制定该工件的夹紧方案，画出夹具装配图。就我个人而言，我希望通过这次课程设计对自己未来将从事的工作进一步适应性的训练，希望自己在设计中能锻炼自己的分析问题、解决问题、查资料的能力，为以后的工作打下良好的基础。由于能力有限，设计尚有很多不足之处，希望各位老师给予指导。AbstractCoursedesignofmachinerymanufacturingtechnologyisthatwelearnallthebasiccoursesUniversity,professionalbasiccoursesandspecializedcoursesfor.Thisisourpriortograduationdesignofsciencecoursesanin-depthandcomprehensivereviewofthetotal,isalsoatheorywithpracticaltraining.Therefore,heoccupiesanimportantpositioninourfouryearsofUniversitylife.ThisdesignistheCA6102enginepiston,partsmap,MaoPitu,fixtureassembly,afixturepartsofthemapsheet,processcardmachiningprocesswiththecardandthecorrespondingfixturedesignedbytheprocessofeachone.Firstofallwemustfamiliarwiththeparts,thepartssubjecttotheCA6102enginepiston.Understandingofthepistoneffect,thenaccordingtothenatureofpartsandcomponentsinthefaceofthemapontheroughnessdeterminethesizeandmechanicaljiagongyuliang.Accordingtoanotherlocationandthenwesetthebenchmarkfinefirstbase,establishedafterthebenchmarkcrude,finalizingthepistonoftheroadmap,theenactmentoftheworkpiececlampingprogramme,todrawfixtureassembly.Personally,Ihopethatthroughthecurriculumdesignoftheirfuturetrainingwillbefurtherengagedintheworkofadaptive,hopetheycanexercisetheiranalysisoftheproblem,problemsolving,checktheinformationinthedesignoftheability,tolayagoodfoundationforthelaterwork.Becauseoflimitedcapacity,therearealotofdesigndeficiencies,Ihopethatteachersgiveguidance.目录前言························································································11零件的分析················································································21.1活塞的功用、结构特点及工作条件············································21.2活塞的主要加工表面及技术要求·············································32工艺规程设计···········································································42.1活塞的毛坯材料及制造方法···················································42.2定位基准的选择··································································42.3制定工艺路线·····································································52.3.1工艺路线方案一··············································52.3.2工艺路线方案二··············································62.3.3工艺方案的比较与分析·····································62.4机械加工余量及工序尺寸······················································62.5切削用量的选择····································································82.6工序时间的计算···································································103专用夹具设计···········································································153.1设计主旨··········································································153.2夹具的设计·······································································153.2.1定位基准的选择············································153.2.2定位误差分析···············································153.2.3定位误差分析计算············································153.2.4切削力及夹紧力的计算···································173.2.5夹具设计及操作的简要说明·····························174结论·······················································································18参考文献····················································································20前言我国的汽车行业正在飞速发展，汽车的动力部分也在不断改进，活塞是汽车动力不可缺少的一部分，它的工作情况会直接影响汽车的运行状态。所以，如何能使活塞的生产高效率、高质量，省成本、省时间是我们今天汽车行业的努力方向。随着汽车整车对发动机的动力性、经济性、环保性及可靠性的要求越来越严格，活塞已发展成为集轻质高强度新材料、异型外圆复合型面、异型销孔等多项新技术于一体的高技术含量的产品，以保证活塞的耐热性、耐磨性、平稳的导向性和良好的密封功能，减少发动机的摩擦功损失，降低油耗、噪声和排放。为满足以上的功能要求，通常将活塞的外圆设计成异型外圆(中凸变椭圆)，即垂直于活塞轴线的横剖面为椭圆或修正椭圆，且椭圆度沿轴线方向按一定的规律变化(如图1所示)，椭圆度精度达0.005mm；活塞纵剖面的外轮廓为高次函数的拟合曲线，轮廓精度为0.005～0.01mm；为提高活塞的承载能力，以提高发动机的升功率，通常将高负荷活塞的销孔设计成微内锥型或正应力曲面型(异型销孔),销孔尺寸精度达IT4级，轮廓精度为0.003mm。活塞作为典型的汽车关键零部件，在切削加工方面具有很强的工艺特点。目前，国内活塞制造行业通常是由通用机床和结合活塞工艺特点的专用设备组成机加工生产线，因此，专用设备就成为活塞切削加工的关键设备，其功能和精度将直接影响最终产品的关键特性的质量指标。本文根据活塞加工的一个特殊工序来对其夹具的设计，使其加工过程得以顺利进行，保证活塞销孔的位置及精度的准确性，同时也借助这个夹具的设计，来提高活塞加工的效率，解决活塞的定位、夹紧问题，为活塞的加工提供一个更方便的路径。由于能力有限，设计尚有很多不足之处，希望各位老师给予指导。1零件的分析1.1活塞的功用、结构特点及工作条件活塞是曲柄连杆机构中的主要零件之一，是发动机的心脏。在活塞压缩行程终了时，燃烧室内的工作混合气被火花塞点燃后爆发，产生强大的压力，推动活塞沿气缸向下运动，并通过连杆使活塞的直线往复运动变为曲柄的旋转运动，这就是发动机动力的来源。活塞的第一个作用就是使发动机做功。发动机做功是由进气、压缩、爆发、排气四个行程来完成的一个工作循环的。不断地循环，发动机才能连续地工作，这就要求发动机内活塞顶以上的空间要有非常好的密封效果。密封是活塞的第二个作用。发动机在点燃爆发时，温度高达2000~2500，主要靠活塞和活塞环将高温传给气缸壁，再由气缸壁外侧水套内的循环水将热量带走。活塞的第三个作用是传热。活塞由头部（环槽、环岸和绝热槽）、裙部和顶部三部分组成。1顶部。汽车发动机大多采用平