ZH1105柴油机气缸体三面粗镗组合机床设计(夹具设计)说明书正文.doc

盐城工学院本科生毕业设计说明书20070目录1前言······························································································12组合机床总体设计··········································································32.1组合机床工艺方案的制定································································32.1.1工艺基准面的分析······································································32.1.2加工工艺的分析·········································································32.1.3确定机床完成工艺时的一些限制···················································32.2组合机床配置型式的选择································································32.2.1组合机床配置型式······································································32.2.2选择机床配置型式和结构方案的一些问题·······································32.3确定切削用量及选择刀具································································42.3.1选择切削用量············································································42.3.2计算切削力、切削扭矩及切削功率················································62.3.3选择刀具结构··········································································102.4组合机床总体设计－－三图一卡·····················································102.4.1被加工零件工序图····································································102.4.2加工示意图·············································································112.4.3机床尺寸联系图·······································································132.4.4机床生产率计算卡····································································163夹具设计······················································································183.1夹具设计的基本要求和步骤···························································183.1.1夹具设计的基本要求·································································183.1.2夹具设计的步骤·······································································183.2定位方案的确定··········································································193.2.1零件的工艺性分析····································································193.2.2定位方案的论证·········································································193.2.3误差分析················································································203.2.4导向装置················································································223.3夹紧方案的确定··········································································223.3.1夹紧装置的确定·······································································223.3.2夹紧力的确定··········································································243.3.3油缸的选择·············································································253.4夹具体的设计·············································································264结论····························································································27参考文献·························································································28致谢·······························································································29附录·······························································································30ZH1105C柴油机气缸体三面粗镗组合机床设计（夹具设计）11前言组合机床是根据加工需要，以大量通用部件为基础，配以少量专用部件组成的一种高效专用机床。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。目前，组合机床在汽车、拖拉机、仪器仪表、军工及缝纫机、柴油机、纺织、航空等部门，应用越来越普遍。组合机床主要适用于棱体类零件和杂体的孔面加工，生产效率高，研制周期短，便于设计、制造和使用维修，配置灵活，且自动化程度高，劳动强度低。在将来，组合机床将向五个方面发展：高速化、高精度化、复合化、高科技含量化以及环保化。同时，在自动化方面，将会进一步提高]1[。组合机床的设计，目前基本上有两种情况：其一，是根据具体加工对象的具体情况进行专门设计，这是当前最普遍的做法。其二，随着组合机床在我国机械行业的广泛使用，广大工人总结自己生产和使用组合机床的经验，发现组合机床不仅在其组成部件方面有共性，可设计成通用部件，而且一些行业在完成一定工艺范围内组合机床是极其相似的，有可能设计为通用机床，这种机床称为“专能组合机床”]2[。这种组合机床就不需要每次按具体加工对象进行专门设计和生产，而是可以设计成通用品种，组织成批生产，然后按被加工的零件的具体需要，配以简单的夹具及刀具，即可组成加工一定对象的高效率设备。在组合机床设计过程中，为了降低组合机床的制造成本，应尽可能地使用通用件和标准件。目前，我国设计制造的组合机床，其通用部件和标准件约占部件总数的70～80%，其它20～30%是专用零部件]1[。考虑到近年来，各种通用件和标准件都出台了新的标准及标注方法，为了方便以后组合机床的维修，整个组合机床的通用件和标准件配置，都采用了新标准。本毕业设计课题是ZH1105柴油机气缸体三面钻镗孔组合机床的设计，来源于江动集团江淮动力股份有限公司。本组合机床有四人完成，本人将进行总体及夹具设计。组合机床的设计过程包括前期调研，总体设计，技术设计和工作设计。总体设计，包括工艺分析、定位基准的选择、滑台型式的选择、通过选择切削用量选择刀具；还需编制“三图一卡”，即加工工序图，加工示意图，机床联系尺寸图，生产率计算卡。技术设计就是根据总体设计已经确定的“三图一卡”，设计主轴箱等专用部件正式总图；工作设计即绘制各个专用部件的施工图样，编制各零部件明细表]1[。夹具设计是组合机床设计中的一个重要组成部分，是按照某一道工序的加工要求，把一些事先制造好的标准件和部件进行组装而成的夹具，夹具通常由使用单位根据要求自行设计和制造，适用于产品固定且批量较大的生产中。其设计过程主要包括：对机床总体设计方案的论证、定位夹紧方案的论证、定位误差分析、夹紧力的计算、夹紧缸的选用。本组合机床夹具属于专用夹具，其定位装置、夹盐城工学院本科生毕业设计说明书20072紧装置、夹具体、导向装置和其它一些元件，均为自行设计、加工。在设计中，尽量考虑使用标准件和通用件，来缩短设计周期，减少机床后续改造的零件报废率，提高经济效益。通过设计，本组合机床能满足加工需求，保证加工精度，机床运转平稳，工作可靠，结构简单，装卸方便，便于维修、调整。各动力部分采用了电器控制，使用操作方便。提高了工作效率，预计能达到设计要求。ZH1105C柴油机气缸体三面粗镗组合机床设计（夹具设计）32．组合机床总体设计2．1组合机床工艺方案的制定2.1.1工艺基面的分析选择工艺基面和夹压部位是制定工艺方案的极其重要的问题。工艺基面选择的正确，将能实现最大限度的工序集中，从而减少机床台数，也是保证加工精度的重要条件。2.1.2加工工艺的分析分析被加工零件的工艺，亦是制定工艺方案的极其重要的问题，我们要认真的分析被加工零件加工工艺的需要和组合机床完成工艺的可能，正确的确定组合机床的加工方案。2.1.3确定机床完成工艺时的一些限制a.孔间中心距的限制在确定组合机床完成工艺时，要考虑可同时加工的最小孔中心距。由于主轴箱的主轴结构的设备导向的需要，所以近距离孔能否在同一多轴箱上同一工位加工受其限制。b.工件结构工艺性不好的限制有些工件结构工艺性不好，如箱体多层壁上的同轴线的孔径中间大两头小时，则进刀困难。当孔径大于Ф50mm时，可采用让刀的办法。多层壁同轴孔，为便于布置中间导向装置，孔中心离箱体侧壁间距离也应够。2．2组合机床配置型式的选择2．2．1组合机床的配置型式组合机床有大型和小型两种，大、小型组合机床虽有其共性，但又都有其特殊性