空气压缩机曲轴的加工工艺及夹具设计

XXX大学本科毕业设计曲轴加工工艺及夹具设计学生姓名：谭剑军学生学号：20104010131001院院系：继续教育学院年级专业：机械制造及自动化指导教师：孙付春二〇一二年五月成都大学本科毕业设计目录目录摘要···········································································································1一、绪论······································································································1二、零件分析··································································································2㈠零件的作用·······························································································2㈡零件的工艺分析·························································································2三、工艺规程设计···························································································4㈠确定毛坯的制造形式···················································································4㈡基面的选择·······························································································41.粗基准选择·························································································42.精基准的选择······················································································43.制定工艺路线······················································································44.机械加工余量、工序尺寸及毛坯尺寸的确定···············································65.确定切削用量及基本工时·······································································96.时间定额计算及生产安排······································································29四、专用夹具设计··························································································38㈠加工曲拐上端面油孔夹具设计······································································381.定位基准的选择··················································································382.切削力的计算与夹紧力分析···································································383.夹紧元件及动力装置确定······································································384.钻套、衬套及夹具体设计······································································395.夹具精度分析·····················································································41㈡加工曲拐上侧面油孔夹具设计······································································411.定位基准的选择··················································································422.切削力的计算与夹紧力分析···································································423.夹紧元件及动力装置确定······································································424.钻套、衬套及夹具体设计······································································435.夹具精度分析·······························································错误!未定义书签。㈢铣曲拐端面夹具设计····························································错误!未定义书签。1.定位基准的选择··················································································452.定位元件的设计··················································································453.铣削力与夹紧力计算············································································464.对刀块和塞尺设计···············································································46五、结论·····································································································48参考文献········································································································49成都大学本科毕业设计摘要【摘要】毕业设计是对空气压缩机曲轴零件的机械加工工艺、夹具的设计,在曲轴零件的加工工艺过程中轴与轴中心线之间要有位置要求,以毛坯轴两端定位先加工两中心孔,以两端中心孔定位再粗、精加工各轴的表面，然后以粗、精后的两轴径定位钻螺纹、铣键槽和铣曲拐端面，采用专用夹具加工两斜油孔，最后粗、精磨各轴。在夹具的设计过程中，主要以V形块和支承板来定位，靠直压板和弹簧来夹紧，钻拐径两孔采用长型快换钻套，在钻拐径倾斜30的孔时采用平面倾斜的夹具体，在钻拐径倾斜040的孔时使用的是卧式钻床，铣面时2个V形块与铣刀不能干涉，因此V形块高度要降低，夹具设计要方便、简单。【关键词】曲轴，加工工艺，夹具设计。成都大学本科毕业设计绪论第1页共49页一、绪论夹具结构设计在加深对课程基本理论的理解和解决工程实际问题能力的培养发挥着极其重要的作用。选择曲轴的夹具设计能很好的综合考查所学知识。设计内容主要包括：工艺路线的确定，夹具方案的优选，各种图纸的绘制，设计说明书的编写等。机械加工工艺是规定产品或零件机械加工工艺过程和操作方法，是指导生产的重要技术性文件。它直接关系到产品的质量、生产率及其加工产品的经济效益，生产规模的大小、工艺水平的高低以及解决各种工艺问题的方法和手段都要通过机械加工工艺来体现，因此工艺规程编制的好坏是生产该产品质量的重要保证重要依据。利用好的夹具可以保证加工质量，机床夹具的首要任务是保证加工精度，特别是保证被加工工件的加工面与定位面以及被加工表面相互之间的位置精度。提高生产率，降低成本，使用夹具后可以减少划线、找正等辅助时间，且易于实现多工位加工。扩大机床工艺范围，在机床上使用夹具可使加工变得方便，扩大机床工艺范围。减轻工人劳动强度，保证生产安全。成都大学本科毕业设计零件分析第2页共49页二、零件分析㈠零件的作用空气压缩机上的曲轴，它位于空气压缩机连杆处，曲轴产生旋转运动，带动连杆使活塞产生往复运动，并将旋转转为直线运动，它在工作过程中将承受周期性的复杂的交变载荷。其主要作用是传递转矩，是连杆获得所需的动力。㈡零件的工艺分析空气压缩机的曲轴零件，它的外表面上有多个平面需要进行加工，此外各表面上还需加工一系列螺纹孔和键槽。因此可将其分为两组加工表面，它们相互间有一定的位置要求它们之间有一定的位置要求.现分析如下:1.以拐径为Ø95mm为中心的加工表面:拐径Ø950.0360.071mm加工及其倒圆角,两个Ø8的斜油孔,两个油孔孔口倒角，它的加工表面的位置要求是Ø950.0360.071mm圆跳动公差为0.01mm。2.以轴心线两端轴为中心的加工表面：1：10锥度面的键槽240.0520mm并左端倒角，端面Ø15mm深16.8mm的中心孔,2个M12深24mm的螺纹孔，各轴的外圆表面,右端面Ø950.0250.003mm的孔Ø300.0840mm。主要的位置要求：(1)键槽240.0520mm×110mm与1：10锥度轴心线的对称度公差为0.10mm。(2)1：10锥度轴心线对A-B轴心线的的圆跳动公差0.025mm；(3)Ø900.220.57mm轴表面的圆柱度公差为0.01mm两组加工表面之间主要的位置要求：曲轴拐径Ø950.0360.071mm轴心线与A-B轴心线的平行度公差Ø0.03mm又以上分析可知，对于这两组加工表面而言，可以先加工其中一组表面，然后借助于专用夹具加工另一组表面，并保证他们的位置精度要求。3.零件加工工艺过程设计分析和主要问题：(1)曲轴在铸造时，右端Ø950.0250.003mm要在直径方向上留出工艺尺寸量，铸造尺寸为105mm，这样为开拐前加工出工艺键槽准备。该工艺键槽与开拐工装配合传递扭转。(2)为保证加工精度，对所有加工的部位均应采用粗、精加工分开的原则。(3)曲轴加工应充分考虑在切削时平衡装置。①车削拐径用专用工装及配重装置。110±0.1图2-1车削拐径成都大学本科毕业设计零件分析第3页共49页②粗、精车轴径及粗、精磨轴径都应在曲轴拐径的对面加装配重。图2-2车、磨轴径（4）1：10锥度环规与塞规要求配套使用，环规检测曲轴锥度，塞规检测与之配套的电机转子锥孔或联轴器锥孔