制定分離叉軸的加工工藝設(shè)計(jì)銑R4槽的銑床夾具（生產(chǎn)綱領(lǐng)：中批生產(chǎn)）

資源目錄里展示的全都有，所見即所得。下載后全都有,請(qǐng)放心下載。原稿可自行編輯修改=【QQ：401339828 或11970985 有疑問可加】 標(biāo)準(zhǔn)機(jī)械加工工序卡片 機(jī)械加工工藝卡片 產(chǎn)品型號(hào) 零部件圖號(hào) 產(chǎn)品名稱 零部件名稱 分離叉軸 共 5 頁(yè) 第 1 頁(yè) （工序簡(jiǎn)圖） 車間 工序號(hào) 工序號(hào)稱 材料牌號(hào) 1 毛坯種類 毛坯外形尺寸 每毛坯可制件數(shù) 每臺(tái)件數(shù) 1 1 設(shè)備名稱 設(shè)備型號(hào) 設(shè)備編號(hào) 同時(shí)加工件數(shù) 夾具編號(hào) 夾具名稱 切削液 工位器具編號(hào) 工位器具名稱 工布工時(shí) 機(jī)動(dòng) 輔助 工步號(hào) 工步內(nèi)容 工藝裝備 主軸速度(r/min) 切削速度(m/min) 進(jìn)給量(mm/r) 背吃刀量(mm) 進(jìn)給次數(shù) 工步工時(shí) 機(jī)動(dòng) 輔助 1 車ф25mm端面 普通車床，通用夾具，外圓車刀 531 108.6 0.18 1 1 2 車ф25mm外圓并倒角 普通車床，通用夾具，外圓車刀 531 116 1.0 1 1 3 車ф24mm端面 普通車床，通用夾具，外圓車刀 531 100.8 0.18 1 1 4 車ф24mm外圓并倒角 普通車床，通用夾具，外圓車刀 531 116 1.0 1 1 設(shè)計(jì)（日期） 校對(duì)（日期） 審核（日期） 標(biāo)準(zhǔn)化（日期） 會(huì)簽（日期） 標(biāo)記 處數(shù) 更改文件編號(hào) 簽字 日期 標(biāo)記 處數(shù) 更改文件號(hào) 簽字 日期 標(biāo)準(zhǔn)機(jī)械加工工序卡片 機(jī)械加工工藝卡片 產(chǎn)品型號(hào) 零部件圖號(hào) 產(chǎn)品名稱 零部件名稱 分離叉軸 共 5頁(yè) 第 2 頁(yè) （工序簡(jiǎn)圖） 車間 工序號(hào) 工序號(hào)稱 材料牌號(hào) 2 毛坯種類 毛坯外形尺寸 每毛坯可制件數(shù) 每臺(tái)件數(shù) 1 1 設(shè)備名稱 設(shè)備型號(hào) 設(shè)備編號(hào) 同時(shí)加工件數(shù) 夾具編號(hào) 夾具名稱 切削液 工位器具編號(hào) 工位器具名稱 工布工時(shí) 機(jī)動(dòng) 輔助 工步號(hào) 工步內(nèi)容 工藝裝備 主軸速度(r/min) 切削速度(m/min) 進(jìn)給量(mm/r) 背吃刀量(mm) 進(jìn)給次數(shù) 工步工時(shí) 機(jī)動(dòng) 輔助 1 精車ф25mm外圓 普通車床，通用夾具，外圓車刀 531 108.6 0.18 1 1 設(shè)計(jì)（日期） 校對(duì)（日期） 審核（日期） 標(biāo)準(zhǔn)化（日期） 會(huì)簽（日期） 標(biāo)記 處數(shù) 更改文件編號(hào) 簽字 日期 標(biāo)記 處數(shù) 更改文件號(hào) 簽字 日期 標(biāo)準(zhǔn)機(jī)械加工工序卡片 機(jī)械加工工藝卡片 產(chǎn)品型號(hào) 零部件圖號(hào) 產(chǎn)品名稱 零部件名稱 換擋軸 共 5 頁(yè) 第 3 頁(yè) （工序簡(jiǎn)圖） 車間 工序號(hào) 工序號(hào)稱 材料牌號(hào) 3 毛坯種類 毛坯外形尺寸 每毛坯可制件數(shù) 每臺(tái)件數(shù) 1 1 設(shè)備名稱 設(shè)備型號(hào) 設(shè)備編號(hào) 同時(shí)加工件數(shù) 夾具編號(hào) 夾具名稱 切削液 工位器具編號(hào) 工位器具名稱 工布工時(shí) 機(jī)動(dòng) 輔助 工步號(hào) 工步內(nèi)容 工藝裝備 主軸速度(r/min) 切削速度(m/min) 進(jìn)給量(mm/r) 背吃刀量(mm) 進(jìn)給次數(shù) 工步工時(shí) 機(jī)動(dòng) 輔助 1 銑鍵槽 銑床，專用夾具 300 23.6 0.15 3 設(shè)計(jì)（日期） 校對(duì)（日期） 審核（日期） 標(biāo)準(zhǔn)化（日期） 會(huì)簽（日期） 標(biāo)記 處數(shù) 更改文件編號(hào) 簽字 日期 標(biāo)記 處數(shù) 更改文件號(hào) 簽字 日期 標(biāo)準(zhǔn)機(jī)械加工工序卡片 機(jī)械加工工藝卡片 產(chǎn)品型號(hào) 零部件圖號(hào) 產(chǎn)品名稱 零部件名稱 共 5 頁(yè) 第 4 頁(yè) （工序簡(jiǎn)圖） 車間 工序號(hào) 工序號(hào)稱 材料牌號(hào) 4 毛坯種類 毛坯外形尺寸 每毛坯可制件數(shù) 每臺(tái)件數(shù) 1 1 設(shè)備名稱 設(shè)備型號(hào) 設(shè)備編號(hào) 同時(shí)加工件數(shù) 夾具編號(hào) 夾具名稱 切削液 工位器具編號(hào) 工位器具名稱 工布工時(shí) 機(jī)動(dòng) 輔助 工步號(hào) 工步內(nèi)容 工藝裝備 主軸速度(r/min) 切削速度(m/min) 進(jìn)給量(mm/r) 背吃刀量(mm) 進(jìn)給次數(shù) 工步工時(shí) 機(jī)動(dòng) 輔助 1 銑R4弧 銑床，專用夾具 37.5 26.5 0.15 1 設(shè)計(jì)（日期） 校對(duì)（日期） 審核（日期） 標(biāo)準(zhǔn)化（日期） 會(huì)簽（日期） 標(biāo)記 處數(shù) 更改文件編號(hào) 簽字 日期 標(biāo)記 處數(shù) 更改文件號(hào) 簽字 日期 標(biāo)準(zhǔn)機(jī)械加工工序卡片 機(jī)械加工工藝卡片 產(chǎn)品型號(hào) 零部件圖號(hào) 產(chǎn)品名稱 零部件名稱 換擋軸 共 5 頁(yè) 第 5 頁(yè) （工序簡(jiǎn)圖） 車間 工序號(hào) 工序號(hào)稱 材料牌號(hào) 5、6 毛坯種類 毛坯外形尺寸 每毛坯可制件數(shù) 每臺(tái)件數(shù) 1 1 設(shè)備名稱 設(shè)備型號(hào) 設(shè)備編號(hào) 同時(shí)加工件數(shù) 夾具編號(hào) 夾具名稱 切削液 工位器具編號(hào) 工位器具名稱 工布工時(shí) 機(jī)動(dòng) 輔助 工步號(hào) 工步內(nèi)容 工藝裝備 主軸速度(r/min) 切削速度(m/min) 進(jìn)給量(mm/r) 背吃刀量(mm) 進(jìn)給次數(shù) 工步工時(shí) 機(jī)動(dòng) 輔助 1 去除毛刺 2 終檢 設(shè)計(jì)（日期） 校對(duì)（日期） 審核（日期） 標(biāo)準(zhǔn)化（日期） 會(huì)簽（日期） 標(biāo)記 處數(shù) 更改文件編號(hào) 簽字 日期 標(biāo)記 處數(shù) 更改文件號(hào) 簽字 日期 機(jī)械加工工藝過程卡片 產(chǎn)品型號(hào) 零件圖號(hào) 產(chǎn)品名稱 零件名稱 分離叉軸 共 1 頁(yè) 第 1 頁(yè) 材 料 牌 號(hào) 45鋼 毛 坯 種 類 鍛件 毛坯外形尺寸 每毛坯件數(shù) 1 每 臺(tái) 件 數(shù) 1 備 注 工 序 號(hào) 工 名 序 稱 工 序 內(nèi) 容 車 間 工 段 設(shè) 備 工 藝 裝 備 工 時(shí) 準(zhǔn)終 單件 鍛造 鍛 1 調(diào)制處理 金工 普通車床 通用夾具 2 車 車端面及外圓Φ25mm和Φ24mm，并倒角。 金工 普通車床 通用夾具 3 車 精車外圓Φ25mm。 金工 普通車床 通用夾具 4 銑 銑鍵槽 金工 銑床 專用銑夾具 5 銑 銑R4弧 金工 銑床 專用銑夾具 6 去除毛刺 鉗工 7 終檢 設(shè) 計(jì)（日 期） 校 對(duì)（日期） 審 核（日期） 標(biāo)準(zhǔn)化（日期） 會(huì) 簽（日期） 標(biāo)記 處數(shù) 更改文件號(hào) 簽 字 日 期 標(biāo)記 處數(shù) 更改文件號(hào) 簽 字 日 期 哈爾濱理工大學(xué) 機(jī)械制造工藝學(xué) 課程設(shè)計(jì)說明書 設(shè)計(jì)題目 指定分離叉軸的加工工藝，設(shè)計(jì)銑R4槽的銑床夾具（生產(chǎn)綱領(lǐng)：中批生產(chǎn)） 班 別 機(jī)設(shè)09-1 學(xué) 號(hào) 0930120105 設(shè) 計(jì) 者 王子同 指導(dǎo)教師 陶福春 評(píng)定成績(jī) 分 設(shè)計(jì)日期 2011 年 11 月 28 日至 12 月 16 日 目錄 設(shè)計(jì)任務(wù)書……………………………………………………………………………………………3 課程設(shè)計(jì)說明書正文…………………………………………………………………………………4 序言……………………………………………………………………………………………………4 一、零件的分析……………………………………………………………………………………4 二、工藝規(guī)程設(shè)計(jì)…………………………………………………………………………………4 （一）確定毛坯的制造形式……………………………………………………………………4 （二）基面的選擇………………………………………………………………………………4 （三）制定工藝路線……………………………………………………………………………5 （四）機(jī)械加工余量、工序尺寸及毛坯尺寸的確定…………………………………………5 （五）確定切削用量及基本工時(shí)………………………………………………………………6 三、專用夾具設(shè)計(jì)…………………………………………………………………………………8 （一）設(shè)計(jì)主旨…………………………………………………………………………………8 （二）夾具設(shè)計(jì)…………………………………………………………………………………8 四、課程設(shè)計(jì)心得體會(huì)……………………………………………………………………………10 參考文獻(xiàn)………………………………………………………………………………………………10 哈爾濱理工大學(xué) 機(jī)械制造工藝學(xué)課程設(shè)計(jì)任務(wù)書 設(shè)計(jì)題目 指定分離叉軸的加工工藝，設(shè)計(jì)銑R4槽的銑床夾具（生產(chǎn)綱領(lǐng)：中批生產(chǎn)） 設(shè)計(jì)內(nèi)容：1.繪制加工工件圖，計(jì)算機(jī)繪圖 1張 2.制定零件的加工工藝過程 2張 3.填寫零件加工工藝過程卡 1張 4.所有工序的工序卡 1套 5.指定工序夾具的全套圖紙 1份 6.編寫設(shè)計(jì)說明書 1份 班 級(jí) 機(jī)設(shè)09-1 學(xué) 號(hào) 0930120105 學(xué)生姓名 王子同 指導(dǎo)教師 陶福春 系 主 任 陶福春 2011 年 12 月 15 日 序言 機(jī)械制造工藝學(xué)課程設(shè)計(jì)是在我們學(xué)完了大學(xué)的全部基礎(chǔ)課、技術(shù)基礎(chǔ)課以及大部分專業(yè)課之后進(jìn)行的。這是我們?cè)谶M(jìn)行畢業(yè)設(shè)計(jì)之前對(duì)所學(xué)各課程的一次深入的綜合性的鏈接，也是一次理論聯(lián)系實(shí)際的訓(xùn)練。因此，它在我們的大學(xué)學(xué)習(xí)生活中占有十分重要的地位。 就我個(gè)人而言，我希望能通過這次課程設(shè)計(jì)對(duì)自己未來將從事的工作進(jìn)行一次適應(yīng)性訓(xùn)練，從中鍛煉自己分析問題、解決問題的能力，為今后參加祖國(guó)的現(xiàn)代化建設(shè)打下一個(gè)良好的基礎(chǔ)。 由于能力所限，設(shè)計(jì)尚有許多不足之處，懇請(qǐng)各位老師給予指教。 一、零件的分析 （一）零件的作用 題目所給定的零件是汽車離合器內(nèi)裝載分離叉的載體軸。其主要作用，一是傳遞轉(zhuǎn)矩，使分離叉可以在垂直軸線的平面上往復(fù)擺動(dòng)；二是當(dāng)分離叉在軸線方向上處在不同的位置上時(shí)，承受分離叉作用在其上的靜摩擦載荷。由于該零件在工作中所承受的載荷不是很大，所以零件幾乎只是起連接作用。 （二）零件的工藝分析 分離叉軸共有兩組加工表面，它們相互間有一定的位置要求?，F(xiàn)分述如下： 1.φ25mm的軸線為中心的加工表面。 這一組加工表面包括：φ25-0.08 -0.12mm的外圓表面及其倒角，φ24-0.1 -0.2mm的外圓表面及其倒角。其中，主要加工表面為φ25-0.08 -0.12mm的外圓表面。 2.φ24-0.1 -0.2mm的端面為基準(zhǔn)的加工表面。 這一組加工表面包括：φ24-0.1 -0.2mm的端面，φ25-0.08 -0.12mm的端面，距φ24-0.1 -0.2mm的端面為236.5mm的R4mm的弧，從距φ24-0.1 -0.2mm的端面242mm至276mm的鍵槽。其中，弧與鍵槽底面相互平行。 由以上分析可知，對(duì)于這兩組加工表面而言，可以先加工第一組表面然后加工第二組表面，第二組表面中的弧可以借助于專用夾具加工。 二、工藝規(guī)程設(shè)計(jì) （一）確定毛坯的制造形式 零件材料為45鋼?？紤]到汽車在運(yùn)行中要經(jīng)常換擋，零件在工作過程中經(jīng)常承受交變載荷，因此應(yīng)該選用鍛件，以使金屬纖維盡量不被切斷，保證零件工作可靠。由于零件年產(chǎn)量已達(dá)到中批生產(chǎn)水平，而且零件的輪廓尺寸不大，故可采用模鍛成形。這對(duì)于提高生產(chǎn)率、保證加工質(zhì)量也是有利的。 （二）基面的選擇 基面的選擇是工藝規(guī)程設(shè)計(jì)中的重要工作之一?；孢x擇的正確、合理，可以保證加工質(zhì)量，提高生產(chǎn)效率。否則，就會(huì)使加工工藝過程問題百出，嚴(yán)重的還會(huì)造成零件大批報(bào)廢，是生產(chǎn)無(wú)法進(jìn)行。 1.粗基準(zhǔn)的選擇 對(duì)于一般的軸類零件而言，以外圓作為粗基準(zhǔn)是完全合理的。對(duì)于本零件來說也同樣適用。同時(shí)按照有關(guān)粗基準(zhǔn)的選擇原則（即當(dāng)零件有不加工表面時(shí)，應(yīng)以這些不加工表面作為粗基準(zhǔn)；以重要表面、加工余量較小的表面作為粗基準(zhǔn)；粗基準(zhǔn)應(yīng)盡量避免重復(fù)使用在同一尺寸方向上通常只允許使用一次；以質(zhì)量較好的毛坯作為粗基準(zhǔn)），選取軸頸為φ25-0.08 -0.12mm的外圓表面作為粗基準(zhǔn)。 2.精基準(zhǔn)的選擇 精基準(zhǔn)的選擇主要應(yīng)該考慮基準(zhǔn)重合的問題。當(dāng)設(shè)計(jì)基準(zhǔn)與工序基準(zhǔn)不重合時(shí)，應(yīng)該進(jìn)行尺寸換算。以φ25mm外圓及φ24mm端面作為精基準(zhǔn)。銑R4槽時(shí)以前兩個(gè)基準(zhǔn)和鍵槽作為精基準(zhǔn)。 （三）制定工藝路線 制定工藝路線的出發(fā)點(diǎn)，應(yīng)當(dāng)是使零件的幾何形狀、尺寸精度及位置精度等技術(shù)要求能得到合理的保證。在生產(chǎn)綱領(lǐng)已確定為中批生產(chǎn)的條件下，可以采用通用機(jī)床配以專用工夾具，并盡量使工序集中來提高生產(chǎn)率。除此以外，還應(yīng)考慮經(jīng)濟(jì)效果，以便降低生產(chǎn)成本。 工藝路線方案： 工序1：車端面和外圓φ25mm,φ24mm及其倒角，以φ25mm外圓作為粗基準(zhǔn)，選用CA6140臥式車床和三爪卡盤。 工序2：將加工軸反向裝夾精車外圓φ25mm，選用CA6140車床和三爪卡盤。 工序3：銑鍵槽，以φ25mm外圓及φ24mm端面作為基準(zhǔn)，選用X63臥式銑床加工。 工序4：銑R4弧，以φ25mm外圓和φ24mm端面以及鍵槽為基準(zhǔn)，選用X63臥式銑床加工。 工序5：去除毛刺。 工序6：終檢。 以上工藝過程詳見機(jī)械加工工藝過程卡片和機(jī)械加工工序卡片。 （四）機(jī)械加工余量、工序尺寸及毛坯尺寸的確定 “分離叉軸”零件材料為45鋼，硬度為220-260HBW，毛坯重量約為3kg，生產(chǎn)類型為中批生產(chǎn)，可采用在鍛錘上合模模鍛毛坯。 根據(jù)上述原始資料及加工工藝，分別確定各加工表面的機(jī)械加工余量、工序尺寸及毛坯尺寸如下： 1.外圓表面（φ25mm及φ24mm） 考慮其加工長(zhǎng)度為448.5mm，加工外圓表面直徑為φ25mm及φ24mm，為簡(jiǎn)化模鍛毛坯的外形，現(xiàn)直接取其外圓表面直徑為φ31.8mm。φ25mm及φ24mm表面為自由尺寸公差，表面粗糙度值要求分別為0.8μm和6.3μm，此時(shí)直徑余量2Z=6.8mm已能滿足加工要求。 2.外圓表面沿軸線長(zhǎng)度方向的加工余量及公差 查《機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)》（以下簡(jiǎn)稱《工藝手冊(cè)》）表2.2-14，其中鍛件重量為3kg，鍛件復(fù)雜形狀系數(shù)為S1，鍛件材質(zhì)系數(shù)取M1，鍛件輪廓尺寸（長(zhǎng)度方向）>315～500mm，故長(zhǎng)度方向偏差為+1.3 -0.7mm。 長(zhǎng)度方向的余量查《工藝手冊(cè)》表2.2～2.5，其余量值規(guī)定為2.0～2.7mm，現(xiàn)取為2.0mm。 （五）確定切削用量及基本工時(shí) 工序1：粗車端面、外圓及倒角。本工序采用計(jì)算法確定切削用量。 1.加工條件 工件材料：45鋼調(diào)質(zhì)，σb=0.60GPa，模鍛。 加工要求：粗車φ25mm、φ24mm端面和φ25mm、φ24mm及其倒角，表面粗糙度值為6.3μm。 機(jī)床：CA6140臥式車床。 刀具：刀片材料為YT15，刀桿尺寸為16mm×25mm，κr=90o，γo=15o，αo=8o，rε=0.5mm。 2.計(jì)算切削用量 （1）粗車φ25mm，φ24mm端面。 1)確定端面最大加工余量：已知毛坯長(zhǎng)度方向的加工余量為2+1.3 -0.7mm，考慮7o的模鍛拔模斜度，則毛坯長(zhǎng)度方向的最大加工余量Zmax=7.5mm。分三次加工，ap=3mm計(jì)。長(zhǎng)度加工公差按IT12級(jí)，取-0.46mm（入體方向）。 2)確定進(jìn)給量?：根據(jù)《切削用量簡(jiǎn)明手冊(cè)》（第3版）（以下簡(jiǎn)稱《切削手冊(cè)》）表1.4，當(dāng)?shù)稐U尺寸為16mm×25mm，ap≤3mm以及工件直徑為25mm時(shí) ?=0.18mm/r 按CA6140車床說明書取?=0.51mm/r 3)計(jì)算切削速度：按《切削手冊(cè)》表1.27，切削速度的計(jì)算公式可算出 νc=115m/min 4）確定機(jī)床主軸轉(zhuǎn)速： ns=1151r/min 按機(jī)床說明書，與1151r/min相近的機(jī)床轉(zhuǎn)速為1120r/min。所以實(shí)際切削速度ν=111.83r/min。 5）計(jì)算切削工時(shí)：按《工藝手冊(cè)》表6.2-1，取 l=31.8/2mm=15.9mm，l1=2mm,l2=0,l3=0 tm=(15.9+2)/(1120×0.18)×3min=0.266min (2)粗車φ25mm外圓，同時(shí)應(yīng)校驗(yàn)機(jī)床功率及進(jìn)給機(jī)構(gòu)強(qiáng)度。 1）背吃刀量：?jiǎn)芜呌嗔縕=1.3mm，可一次切除。 2）進(jìn)給量：根據(jù)《切削手冊(cè)》表1.4，選用?=0.5mm/r。 3）計(jì)算切削速度：見《切削手冊(cè)》表1.27 νc=116m/min 4）確定主軸轉(zhuǎn)速： ns=1154r/min 按機(jī)床選取n=1120r/min。所以實(shí)際切削速度為 ν=112.54r/min 5）切削工時(shí)： t=20.201min (3)車φ24mm外圓柱面 取ap=1mm，?=0.51mm/r(《切削手冊(cè)》表1.6，Ra=6.3μm,刀尖圓弧半徑rε=0.1mm) 切削速度 νc=105m/min n=1338r/min 按機(jī)床說明書取 n=1400r/min 則此時(shí)： ν=109.9m/min 切削工時(shí) t=0.008min 工序2：精車φ25mm外圓 背吃刀量：?jiǎn)芜呌嗔縕=0.3mm，可一次切除。 進(jìn)給量：根據(jù)《切削手冊(cè)》表1.4，選用?=0.3mm/r。 計(jì)算切削速度：見《切削手冊(cè)》表1.27 νc=115m/min 確定主軸轉(zhuǎn)速： ns=1465r/min 按機(jī)床選取n=1400r/min。所以實(shí)際切削速度為 ν=109.9r/min 切削工時(shí)： t=1.1min 工序3：銑鍵槽 每齒進(jìn)給量： ?z=0.06mm/z 切削速度：參考有關(guān)手冊(cè)，確定ν=25m/min。 采用高速鋼鑲齒三面刃銑刀，dw=25mm,齒數(shù)z=3。則 ns=318r/min 現(xiàn)選用X63臥式銑床，根據(jù)機(jī)床使用說明書，取nw=300r/min，故實(shí)際切削速度為 ν=23.6m/min 當(dāng)nw=300r/min時(shí)，工作臺(tái)的每分鐘進(jìn)給量?m應(yīng)為 ?m=54mm/min 查機(jī)床說明書，接近的有?m=60mm/min，故選用該值。 切削工時(shí)：利用零件圖，可得出銑刀的行程為34mm。因此，機(jī)動(dòng)工時(shí)為 tm=0.57min 工序4：銑R4弧 每齒進(jìn)給量： ?z=0.1mm/z 切削速度：參考有關(guān)手冊(cè)，確定ν=30m/min。 采用凸圓弧銑刀，圓弧半徑r=4mm，dw=225mm,齒數(shù)z=20。則 ns=38r/min 現(xiàn)選用X63臥式銑床，根據(jù)機(jī)床使用說明書，取nw=37.5r/min，故實(shí)際切削速度為 ν=26.5m/min 當(dāng)nw=37.5r/min時(shí)，工作臺(tái)的每分鐘進(jìn)給量?m應(yīng)為 ?m=60mm/min 查機(jī)床說明書，剛好有?m=60mm/min，故直接選用該值。 切削工時(shí)：利用作圖法，可得出銑刀的行程為15mm。因此，機(jī)動(dòng)工時(shí)為 tm=0.25min 三、專用夾具設(shè)計(jì) 為了提高勞動(dòng)生產(chǎn)率，保證加工質(zhì)量，降低勞動(dòng)強(qiáng)度，通常需要設(shè)計(jì)專用夾具。 經(jīng)過與指導(dǎo)教師的協(xié)商，決定設(shè)計(jì)工序 銑R4弧的銑床夾具。本夾具將用于銑床。刀具為高速鋼凸圓弧銑刀，對(duì)工件進(jìn)行銑R4弧加工。 （一）設(shè)計(jì)主旨 本夾具主要用來銑R4弧，這個(gè)弧在加工中需要一定的技術(shù)要求。在加工到本道工序時(shí)，鍵槽已經(jīng)加工好， R4的弧需要借助已加工的鍵槽和外圓表面定位進(jìn)行加工。本道工序不需要考慮精度問題，因此，本道工序加工時(shí)，主要應(yīng)考慮如何提高勞動(dòng)生產(chǎn)率，降低勞動(dòng)強(qiáng)度。 （二）夾具設(shè)計(jì) 1、定位基準(zhǔn)的選擇 由零件圖可知，R4的弧的中心線應(yīng)對(duì)已加工鍵槽底面有平行度要求，其設(shè)計(jì)基準(zhǔn)為已加工的鍵槽底面。為了使定位誤差為零，應(yīng)該選擇以已加工鍵槽定位的自動(dòng)定心夾具。但這種自動(dòng)定心夾具在結(jié)構(gòu)上將過于復(fù)雜，因此這里只選用以已加工鍵槽為主要定位基面。 為了簡(jiǎn)化夾具結(jié)構(gòu)，準(zhǔn)備采用手動(dòng)夾緊裝置。 2、切削力及夾緊力的計(jì)算 切削刀具：凸圓弧銑刀，Φ8mm,z=20,則 = 式中，=650,=3.1mm,=1.0,=0.08min,=0.72,=40mm,(在加工面上測(cè)量的近似值)，=0.86,=225mm，=0.86,=0,=20，所以 ==1456N 水平分力：=1.1=3203N 垂直分力：=0.3=873N 在計(jì)算切削力時(shí)必須考慮安全系數(shù)，安全系數(shù)K=. 式中 K1—基本安全系數(shù)，=1.5； K2—加工性質(zhì)系數(shù)，=1.1； K3—刀具鈍化系數(shù)，=1.1； K4—斷續(xù)切削系數(shù)，=1.1. 于是 F’== 為克服水平切削力，實(shí)際夾緊力N應(yīng)為 所以 N=1234 式中，和為夾具定位面及夾緊面上的摩擦系數(shù)，=0.25. 3、 定位誤差分析 （1）定位元件尺寸及公差的確定。 本夾具的主要定位元件是和鍵槽配合的突起塊和兩個(gè)V型塊底座和兩個(gè)由螺母夾緊的夾緊塊，該與鍵槽配合的凸起塊的尺寸與公差現(xiàn)規(guī)定與本零件在工作時(shí)與其相配的鍵槽的尺寸與公差相同。 （2）確定兩夾緊塊及V型底座的中心距 有零件圖可知；兩夾緊塊及兩V型塊底座在不影響加工面加工的前提下可做一定調(diào)整。 （3）計(jì)算定位誤差 加工尺寸R4的弧的定位誤差，由于定位基準(zhǔn)與工序尺寸重合，故ΔB=0. 5、夾具設(shè)計(jì)及操作的簡(jiǎn)要說明 如前所述，在設(shè)計(jì)夾具時(shí)，為提高勞動(dòng)生產(chǎn)率，應(yīng)該首先著眼于機(jī)動(dòng)夾緊，本道工序的銑床夾具就選擇手動(dòng)夾緊。本工序由于是粗加工，切削力較小，夾緊工件可以采用手動(dòng)夾緊，這可以使夾具簡(jiǎn)化，降低勞動(dòng)強(qiáng)度，使操作簡(jiǎn)便。 四、課程設(shè)計(jì)心得體會(huì) 緊張而又辛苦的三周課程設(shè)計(jì)結(jié)束了，當(dāng)我快要完成老師下達(dá)給我的任務(wù)的時(shí)候，我仿佛經(jīng)過一次翻山越嶺，登上了高山之巔，頓感心曠神怡，眼前豁然開朗。 課程設(shè)計(jì)是我們專業(yè)課程知識(shí)綜合應(yīng)用的實(shí)踐訓(xùn)練，這是我們邁向社會(huì)、從事職業(yè)工作前一個(gè)必不可少的過程。“千里之行始于足下”，通過這次課程設(shè)計(jì)，我深深體會(huì)到這句千古名言的真正含義。我今天認(rèn)真的進(jìn)行課程設(shè)計(jì)，學(xué)會(huì)腳踏實(shí)地地邁開這一步，就是為明天能穩(wěn)健的在社會(huì)大潮中奔跑打下堅(jiān)實(shí)的基礎(chǔ)。 說實(shí)話，課程設(shè)計(jì)真是有點(diǎn)累。然而，當(dāng)我已著手清理自己的設(shè)計(jì)成果，仔細(xì)回味這三個(gè)周的心路歷程，一種少有的成功喜悅即刻使我倦意頓消。雖然這是我剛學(xué)會(huì)走完的第一步，是我人生中一點(diǎn)小小的勝利，然而它令我感到自己成熟了許多，令我有一種“春眠方覺曉”的感悟。 通過課程設(shè)計(jì)，使我深深體會(huì)到，干任何事都必須耐心、細(xì)致。課程設(shè)計(jì)過程中，許多計(jì)算有時(shí)不免令我感到有些心煩意亂；有兩次因?yàn)椴恍⌒奈矣?jì)算出錯(cuò)，只能好不情愿的重來。但一想起老師平時(shí)對(duì)我們的耐心教導(dǎo)，想到今后自己應(yīng)當(dāng)承擔(dān)的社會(huì)責(zé)任，想到世界上因?yàn)槟承┬男〉氖д`而出現(xiàn)的令世人震驚的事故，我不禁時(shí)刻提心自己，一定要養(yǎng)成一種高度負(fù)責(zé)、一絲不茍的良好習(xí)慣。這次課程設(shè)計(jì)使我在工作作風(fēng)上得到一次難得的磨練。 短短的三周課程設(shè)計(jì)，使我發(fā)現(xiàn)了自己所掌握的知識(shí)是真正的如此匱乏，自己綜合應(yīng)用所學(xué)的專業(yè)知識(shí)的能力是如此的不足，幾年來學(xué)習(xí)了那么多的課程，今天才知道自己并不會(huì)用。想到這里我真的有點(diǎn)心急了。老師卻對(duì)我說，這說明課程設(shè)計(jì)確實(shí)是你有了收獲了。老師的親切勉勵(lì)像春雨注入我的心田，使我更加自信了。 最后，我要衷心的感謝老師。使您的嚴(yán)厲批評(píng)喚醒了我，使您的敬業(yè)精神感動(dòng)了我，是您的諄諄教導(dǎo)啟發(fā)了我，是您的殷切期望鼓舞了我。我感謝老師您今天又為我增添了一副堅(jiān)硬的翅膀。 五、參考文獻(xiàn) 1、艾興，肖詩(shī)剛主編，切削用量簡(jiǎn)明手冊(cè)。北京：機(jī)械工業(yè)出版社，1994 2、李益民主編，機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)。北京：機(jī)械工業(yè)出版社，1994 3、哈爾濱工業(yè)大學(xué)，上海工業(yè)大學(xué)主編，機(jī)床夾具設(shè)計(jì)。上海：上?？茖W(xué)技術(shù)出版社，1983 4、李洪主編。機(jī)械加工工藝手冊(cè)。北京：北京出版社，1990 5、王紹俊主編，機(jī)械制造工藝簡(jiǎn)明手冊(cè)。北京：機(jī)械工業(yè)出版社，1987 6、趙家齊編，機(jī)械制造工藝學(xué)課程設(shè)計(jì)指導(dǎo)。北京: 機(jī)械工業(yè)出版社，1994 10 英文資料 High-speed milling High-speed machining is an advanced manufacturing technology, different from the traditional processing methods. The spindle speed, cutting feed rate, cutting a small amount of units within the time of removal of material has increased three to six times. With high efficiency, high precision and high quality surface as the basic characteristics of the automobile industry, aerospace, mold manufacturing and instrumentation industry, such as access to a wide range of applications, has made significant economic benefits, is the contemporary importance of advanced manufacturing technology. For a long time, people die on the processing has been using a grinding or milling EDM (EDM) processing, grinding, polishing methods. Although the high hardness of the EDM machine parts, but the lower the productivity of its application is limited. With the development of high-speed processing technology, used to replace high-speed cutting, grinding and polishing process to die processing has become possible. To shorten the processing cycle, processing and reliable quality assurance, lower processing costs. 1 One of the advantages of high-speed machining High-speed machining as a die-efficient manufacturing, high-quality, low power consumption in an advanced manufacturing technology. In conventional machining in a series of problems has plagued by high-speed machining of the application have been resolved. 1.1 Increase productivity High-speed cutting of the spindle speed, feed rate compared withtraditional machining, in the nature of the leap, the metal removal rate increased 30 percent to 40 percent, cutting force reduced by 30 percent, the cutting tool life increased by 70% . Hardened parts can be processed, a fixture in many parts to be completed rough, semi-finishing and fine, and all other processes, the complex can reach parts of the surface quality requirements, thus increasing the processing productivity and competitiveness of products in the market. 1.2 Improve processing accuracy and surface quality High-speed machines generally have high rigidity and precision, and other characteristics, processing, cutting the depth of small, fast and feed, cutting force low, the workpiece to reduce heat distortion, and high precision machining, surface roughness small. Milling will be no high-speed processing and milling marks the surface so that the parts greatly enhance the quality of the surface. Processing Aluminum when up Ra0.40.6um, pieces of steel processing at up to Ra0.2 ~ 0.4um. 1.3 Cutting reduce the heat Because the main axis milling machine high-speed rotation, cutting a shallow cutting, and feed very quickly, and the blade length of the workpiece contacts and contact time is very short, a decrease of blades and parts of the heat conduction. High-speed cutting by dry milling or oil cooked up absolute (mist) lubrication system, to avoid the traditional processing tool in contact with the workpiece and a lot of shortcomings to ensure that the tool is not high temperature under the conditions of work, extended tool life. 1.4 This is conducive to processing thin-walled parts High-speed cutting of small cutting force, a higher degree of stability, Machinable with high-quality employees compared to the company may be very good, but other than the company's employees may Suanbu Le outstanding work performance. For our China practice, we use the models to determine the method of staff training needs are simple and effective. This study models can be an external object, it can also be a combination of internal and external. We must first clear strategy for the development of enterprises. Through the internal and external business environment and organizational resources, such as analysis, the future development of a clear business goals and operational priorities. According to the business development strategy can be compared to find the business models, through a comparative analysis of the finalization of business models. In determining business models, a, is the understanding of its development strategy, or its market share and market growth rate, or the staff of the situation, and so on, according to the companies to determine the actual situation. As enterprises in different period of development, its focus is different, which means that enterprises need to invest the manpower and financial resources the focus is different. So in a certain period of time, enterprises should accurately selected their business models compared with the departments and posts, so more practical significance, because the business models are not always good, but to compare some aspects did not have much practical significance, Furthermore This can more fully concentrate on the business use of limited resources. Identify business models, and then take the enterprise of the corresponding departments and staff with the business models for comparison, the two can be found in the performance gap, a comparative analysis to find reasons, in accordance with this business reality, the final identification of training needs. The cost of training is needed, if not through an effective way to determine whether companies need to train and the training of the way, but blind to training, such training is difficult to achieve the desired results. A comparison only difference between this model is simple and practical training. 1.5 Can be part of some alternative technology, such as EDM, grinding high intensity and high hardness processing High-speed cutting a major feature of high-speed cutting machine has the hardness of HRC60 parts. With the use of coated carbide cutter mold processing, directly to the installation of a hardened tool steel processing forming, effectively avoid the installation of several parts of the fixture error and improve the parts of the geometric location accuracy. In the mold of traditional processing, heat treatment hardening of the workpiece required EDM, high-speed machining replace the traditional method of cutting the processing, manufacturing process possible to omit die in EDM, simplifying the processing technology and investment costs . High-speed milling in the precincts of CNC machine tools, or for processing centre, also in the installation of high-speed spindle on the general machine tools. The latter not only has the processing capacity of general machine tools, but also for high-speed milling, a decrease of investment in equipment, machine tools increased flexibility. Cutting high-speed processing can improve the efficiency, quality improvement, streamline processes, investment and machine tool investment and maintenance costs rise, but comprehensive, can significantly increase economic efficiency. 2 High-speed milling High-speed milling the main technical high-speed cutting technology is cutting the development direction of one of it with CNC technology, microelectronic technology, new materials and new technology, such as technology development to a higher level. High-speed machine tools and high-speed tool to achieve high-speed cutting is the prerequisite and basic conditions, in high-speed machining in the performance of high-speed machine tool material of choice and there are strict requirements. 2.1 High-speed milling machine in order to achieve high-speed machining General use of highly flexible high-speed CNC machine tools, machining centers, and some use a dedicated high-speed milling, drilling. At the same time a high-speed machine tool spindle system and high-speed feeding system, high stiffness of the main characteristics of high-precision targeting and high-precision interpolation functions, especially high-precision arc interpolation function. High-speed machining systems of the machine a higher demand, mainly in the following areas: General use of highly flexible high-speed CNC machine tools, machining centers, and some use a dedicated high-speed milling, drilling. At the same time a high-speed machine tool spindle system and high-speed feeding system, high stiffness of the main characteristics of high-precision targeting and high-precision interpolation functions, especially high-precision arc interpolation function. High-speed machining systems of the machine a higher demand, mainly in the following areas: High-speed milling machine must have a high-speed spindle, the spindle speed is generally 10000 ~ 100000 m / min, power greater than 15 kW. But also with rapid speed or in designated spots fast-stopping performance. The main axial space not more than 0 .0 0 0 2 m m. Often using high-speed spindle-hydrostatic bearings, air pressure-bearing, mixed ceramic bearings, magnetic bearing structure of the form. Spindle cooling general use within the water or air cooled. High-speed processing machine-driven system should be able to provide 40 ~ 60 m / min of the feed rate, with good acceleration characteristics, can provide 0.4 m/s2 to 10 m/s2 acceleration and deceleration. In order to obtain good processing quality, high-speed cutting machines must have a high enough stiffness. Machine bed material used gray iron, can also add a high-damping base of concrete, to prevent cutting tool chatter affect the quality of processing. A high-speed data transfer rate, can automatically increase slowdown. Processing technology to improve the processing and cutting tool life. At present high-speed machine tool manufacturers, usually in the general machine tools on low speed, the feed of the rough and then proceed to heat treatment, the last in the high-speed machine on the half-finished and finished, in improving the accuracy and efficiency at the same time, as far as possible to reduce processing Cost. 2.2 High-speed machining tool High-speed machining tool is the most active one of the important factors, it has a direct impact on the efficiency of processing, manufacturing costs and product processing and accuracy. Tool in high-speed processing to bear high temperature, high pressure, friction, shock and vibration, such as loading, its hardness and wear-resistance, strength and toughness, heat resistance, technology and economic performance of the basic high-speed processing performance is the key One of the factors. High-speed cutting tool technology development speed, the more applications such as diamond (PCD), cubic boron nitride (CBN), ceramic knives, carbide coating, (C) titanium nitride Carbide TIC (N) And so on. CBN has high hardness, abrasion resistance and the extremely good thermal conductivity, and iron group elements between the great inertia, in 1300 ℃ would not have happened significant role in the chemical, also has a good stability. The experiments show that with CBN cutting tool HRC35 ~ 67 hardness of hardened steel can achieve very high speed. Ceramics have good wear resistance and thermal chemical stability, its hardness, toughness below the CBN, can be used for processing hardness of HRC <5 0 parts. Carbide Tool good wear resistance, but the hardness than the low-CBN and ceramics. Coating technology used knives, cutting tools can improve hardness and cutting the rate, for cutting HRC40 ~ 50 in hardness between the workpiece. Can be used to heat-resistant alloys, titanium alloys, hightemperature alloy, cast iron, Chungang, aluminum and composite materials of high-speed cutting Cut, the most widely used. Precision machining non-ferrous metals or non-metallic materials, or the choice of polycrystalline diamond Gang-coated tool. 2.3 High-speed processing technology High-speed cutting technology for high-speed machining is the key. Cutting Methods misconduct, will increase wear tool to less than high-speed processing purposes. Only high-speed machine tool and not a good guide technology, high-speed machining equipment can not fully play its role. In high-speed machining, should be chosen with milling, when the milling cutter involvement with the workpiece chip thickness as the greatest, and then gradually decreased. High-speed machining suitable for shallow depth of cut, cutting depth of not more than 0.2 mm, to avoid the location of deviation tool to ensure that the geometric precision machining parts. Ensure that the workpiece on the cutting constant load, to get good processing quality. Cutting a single high-speed milling path-cutting mode, try not to interrupt the process and cutting tool path, reducing the involvement tool to cut the number to be relatively stable cutting process. Tool to reduce the rapid change to, in other words when the NC machine tools must cease immediately, or Jiangsu, and then implement the next step. As the machine tool acceleration restrictions, easy to cause a waste of time, and exigency stop or radical move would damage the surface accuracy. In the mold of high-speed finishing, in each Cut, cut to the workpiece, the feed should try to change the direction of a curve or arc adapter, avoid a straight line adapter to maintain the smooth process of cutting. 3 Die in high-speed milling processing of Milling as a highly efficient high-speed cutting of the new method,in Mould Manufacturing has been widely used. Forging links in the regular production model, with EDM cavity to be 12 ~ 15 h, electrodes produced 2 h. Milling after the switch to high-speed, high-speed milling cutter on the hardness of HRC 6 0 hardened tool steel processing. The forging die processing only 3 h20min, improve work efficiency four to five times the processing surface roughness of Ra0.5 ~ 0.6m, fully in line with quality requirements. High-speed cutting technology is cutting technology one of the major developments, mainly used in automobile industry and die industry, particularly in the processing complex surface, the workpiece itself or knives rigid requirements of the higher processing areas, is a range of advanced processing technology The integration, high efficiency and high quality for the people respected. It not only involves high-speed processing technology, but also including high-speed processing machine tools, numerical control system, high-speed cutting tools and CAD / CAM technology. Die-processing technology has been developed in the mold of the manufacturing sector in general, and in my application and the application of the standards have yet to be improved, because of its traditional processing with unparalleled advantages, the future will continue to be an inevitable development of processing technology Direction. 4 Numerical control technology and equipping development trend and countermeasure Equip the engineering level, level of determining the whole national economy of the modernized degree and modernized degree of industry, numerical control technology is it develop new developing new high-tech industry and most advanced industry to equip (such as information technology and his industry, biotechnology and his industry, aviation, spaceflight, etc. national defense industry) last technology and getting more basic most equipment. Marx has ever said "the differences of different economic times, do not lie in what is produced, and lie in how to produce, produce with some means of labor ". Manufacturing technology and equipping the most basic means of production that are that the mankind produced the activity, and numerical control technology is nowadays advanced manufacturing technology and equips the most central technology. Nowadays the manufacturing industry all around the world adopts numerical control technology extensively, in order to improve manufacturing capacity and level, improve the adaptive capacity and competitive power to the changeable market of the trends. In addition every industrially developed country in the world also classifies the technology and numerical control equipment of numerical control as the strategic materials of the country, not merely take the great measure to develop one's own numerical control technology and industry, and implement blockading and restrictive policy to our country in view of " high-grade, precision and advanced key technology of numerical control " and equipping. In a word, develop the advanced manufacturing technology taking numerical control technology as the core and already become every world developed country and accelerate economic development in a more cost-effective manner, important way to improve the overall national strength and national position. Numerical control technology is the technology controlled to mechanical movement and working course with digital information, integrated products of electromechanics that the numerical control equipment is the new technology represented by numerical control technology forms to the manufacture industry of the tradition and infiltration of the new developing manufacturing industry, namely the so-called digitization is equipped, its technological range covers a lot of fields: (1)Mechanical manufacturing technology; (2)Information processing, processing, transmission technology; (3)Automatic control technology; (4)Servo drive technology; (5)Technology of the sensor; (6)Software engineering ,etc.. Development trend of a numerical control technology The application of numerical control technology has not only brought the revolutionary change to manufacturing industry of the tradition, make the manufacturing industry become the industrialized symbol , and with the constant development of numerical control technology and enlargement of the application, the development of some important trades (IT , automobile , light industry , medical treatment ,etc. ) to the national economy and the people's livelihood of his plays a more and more important role, because the digitization that these trades needed to equip has already been the main trend of modern development. Numerical control technology in the world at present and equipping the development trend to see, there is the following several respect [1- ] in its main research focus. 5 A high-speed, high finish machining technology and new trend equipped The efficiency, quality are subjavanufacturing technology. High-speed, high finish machining technology can raise the efficiency greatly , improve the quality and grade of the products, shorten production cycle and improve the market competitive power. Japan carries the technological research association first to classify it as one of the 5 great modern manufacturing technologies for this, learn (CIRP) to confirm it as the centre in the 21st century and study one of the directions in international production engineering. In the field of car industry, produce one second when beat such as production of 300,000 / vehicle per year, and many variety process it is car that equip key problem that must be solved one of; In the fields of aviation and aerospace industry, spare parts of its processing are mostly the thin wall and thin muscle, rigidity is very bad, the material is aluminium or aluminium alloy, only in a situation that cut the speed and cut strength very small high, could process these muscles, walls. Adopt large-scale whole aluminium alloy method that blank " pay empty " make the wing recently, such large-scale parts as the fuselage ,etc. come to substitute a lot of parts to assemble through numerous rivet , screw and other connection way, make the intensity , rigidity and dependability of the component improved. All these, to processing and equipping the demand which has proposed high-speed, high precise and high flexibility. According to EMO2001 exhibition situation, high-speed machining center is it give speed can reach 80m/min is even high , air transport competent speed can up to 100m/min to be about to enter. A lot of automobile factories in the world at present, including Shanghai General Motors Corporation of our country, have already adopted and substituted and made the lathe up with the production line part that the high-speed machining center makes