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畢業(yè)設(shè)計（論文）
開題報告
型材鉚接機機械結(jié)構(gòu)設(shè)計
題 目： 型材鉚接機機械結(jié)構(gòu)設(shè)計
專業(yè)學院：
專 業(yè)：
學生姓名：
指導教師：
2016年3月5日
一、課題名稱：型材鉚接機機械結(jié)構(gòu)設(shè)計
二、主要依據(jù)
1. 設(shè)計的背景和意義
擺輾技術(shù)的新發(fā)展已經(jīng)引起世界各國的重視。在過去幾年國際機床展覽會上也不斷有擺輾機展出?？梢姅[輾技術(shù)決不是像西德奧穆科公司所說的“ 已經(jīng)銷聲匿跡” ,而正在大力研究并取得新的進展。
擺輾技術(shù)開始提出是為了鍛造, 英國和波蘭做了大量研究工作, 但作為擺輾熱鍛,目前在設(shè)備和模具方面尚存在一些問題, 還沒有大量使用。我國在這方面作了很多研究, 在汽車半軸等的擺輾熱鍛方面巳取得了可喜的成績, 值得進一步研究。
擺動輾壓成形技術(shù)能夠擺輾其他鍛造成形工藝難以成形的零件, 如汽車的VE 泵端面凸輪、差速器錐齒輪、離合器盤轂、汽車半軸, 摩托車的端面齒輪、啟動棘輪、磁電機軸套、單向器飛塊、差速輪, 揚聲器的導磁體, 槍械的調(diào)節(jié)塞、轉(zhuǎn)向齒圈, 高壓電器的靜觸頭、動觸頭、動觸頭片等形狀復雜、精度要求高的零部件, 已經(jīng)在汽車、摩托車、五金、兵器、電器等行業(yè)獲得了廣泛的工業(yè)應(yīng)用。因此, 應(yīng)加大研究和推廣擺動輾壓成形技術(shù)力度, 它不僅有著巨大的經(jīng)濟效益, 并而且也有著廣闊的發(fā)展前景。
2.國內(nèi)擺動輾壓現(xiàn)狀
“擺動輾壓”是一種先進的壓力加工技術(shù)和工藝，與傳統(tǒng)壓力加工工藝及技術(shù)相比，擺輾工藝及設(shè)備具有不可比擬的優(yōu)越性：加工時，擺輾力只有傳統(tǒng)鍛造力的5％～20％，從而大大減少了設(shè)備，廠房，基礎(chǔ)，安裝的費用并可完成普通壓力加工工藝難以完成的薄盤類和復雜形狀零件的成形。因此可以用較小噸位設(shè)備代替大型設(shè)備。一般說來，它可較普通平鍛機投資低5倍以上；較普通鍛錘類設(shè)備效率提高3倍以上。同時，擺輾摸具結(jié)構(gòu)簡單，換模方便，模具壽命長也是一大優(yōu)點。擺輾加工后，零件有較好的金屬流線，特別是冷擺輾后，由于冷作硬化使抗拉強度和硬度有較大提高，因此可用低碳合金鋼，成形后達到高碳合金鋼的強度。
目前國內(nèi)已設(shè)計、制造了公稱壓力達36, 100,300, 1000, 1600, 2000, 3000, 4000, 6300 kN 等規(guī)格的立式擺輾機, 公稱壓力從1000~ 4000 kN 的臥式擺輾機, 以及用于冷鉚接工藝的擺輾鉚接機。此外還制成了多用途擺輾機、橫軋??擺輾復合機、轉(zhuǎn)動輾壓機等。
擺輾機身結(jié)構(gòu)與國外差異較大, 除有框架式、四柱式外, 還有焊接結(jié)構(gòu); 擺頭結(jié)構(gòu)除有滾動軸承式外, 還有球面靜壓軸承式和平面靜壓軸承式。國外擺輾機的擺頭運動軌跡是由內(nèi)、外兩個偏心圓環(huán)的轉(zhuǎn)動來獲得的, 而國內(nèi)擺輾機的擺頭運動軌跡主要是采用偏心楔形塊來獲得的。
周德成、王家勛、張猛、陸其仁、劉漢貴等對擺輾機擺頭驅(qū)動電機功率的計算以及擺輾機設(shè)備噸位的計算進行了大量研究。
裴偉才、胡亞民、裴興華、程培源、劉漢貴、王廣春等對擺輾機擺動機構(gòu)的運動學及其運動軌跡進行了詳細的分析研究。
倪紹科、周德成、李文錄、閻紹澤等對擺輾機擺頭所需的平面靜壓推力軸承、液體球軸承的選擇等方面進行了分析與研究。
三、研究內(nèi)容
1、根據(jù)設(shè)計要求，提出如下設(shè)計方案：
2．工作原理：電機通過聯(lián)軸器與油缸桿連接，電機轉(zhuǎn)動時可帶動油缸桿旋轉(zhuǎn)，油缸桿在液壓油作用下可上下移動，鉚接頭有一定角度實現(xiàn)擺動輾壓。
3．主要完成的設(shè)計任務(wù)：
（1）家用鉚接機的設(shè)計計算；
（2）家用鉚接機裝配圖繪制
（3）家用鉚接機零件圖繪制
4. 技術(shù)設(shè)計路線
調(diào)研擺動輾壓鉚接機的結(jié)構(gòu)和工作原理→根據(jù)設(shè)計要求確定設(shè)計方案→設(shè)計主要零部件結(jié)構(gòu)尺寸→畫出CAD裝配圖→拆畫各主要零部件的零件圖。
四、研究計劃及預期成果
研究計劃：
2015年12月～2016年2月：根據(jù)指導教師下達畢業(yè)設(shè)計任務(wù)書，搜集資料，完成文獻綜述，外文翻譯, 確定方案，完成開題報告。
2016年3月5開題報告答辯；
2016年3月23日～2016年5月初：完成裝配圖、主要零部件圖和畢業(yè)設(shè)計說明書
2016年5月初～2016年5中旬：在老師的建議下對畢業(yè)設(shè)計文獻進行修改整理
2016年5月下旬：完成畢業(yè)設(shè)計全部資料，答辯。
預期成果：
（1）型材鉚接機機械結(jié)構(gòu)設(shè)計說明書；
（2）相關(guān)零件圖、裝配圖
五、特色或創(chuàng)新之處
1.本鉚接機的設(shè)計特點
經(jīng)過充分調(diào)查研究我認為該型材鉚接機優(yōu)點如下：
（1）鉚釘成形力小，僅為沖鉚的1/10，鉚釘無不良變形，鉚接表面光潔美觀。
（2）無振動，低噪音，低能耗，操作方便安全。
（3）效率高，成本低。
（4）易于實現(xiàn)自動化。
2.創(chuàng)新之處：
（1）集旋轉(zhuǎn)與上下移動于一體的液壓缸；
（2）可根據(jù)需要更換不同型號鉚接頭。
六、指導教師意見
指導教師簽名：
年 月 日
英文原文
Basic Machining Operations and Cutting Technology
Basic Machining Operations
Machine tools have evolved from the early foot-powered lathes of the Egyptians and John Wilkinson's boring mill. They are designed to provide rigid support for both the workpiece and the cutting tool and can precisely control their relative positions and the velocity of the tool with respect to the workpiece. Basically, in metal cutting, a sharpened wedge-shaped tool removes a rather narrow strip of metal from the surface of a ductile workpiece in the form of a severely deformed chip. The chip is a waste product that is considerably shorter than the workpiece from which it came but with a corresponding increase in thickness of the uncut chip. The geometrical shape of workpiece depends on the shape of the tool and its path during the machining operation.
Most machining operations produce parts of differing geometry. If a rough cylindrical workpiece revolves about a central axis and the tool penetrates beneath its surface and travels parallel to the center of rotation, a surface of revolution is produced, and the operation is called turning. If a hollow tube is machined on the inside in a similar manner, the operation is called boring. Producing an external conical surface uniformly varying diameter is called taper turning, if the tool point travels in a path of varying radius, a contoured surface like that of a bowling pin can be produced; or, if the piece is short enough and the support is sufficiently rigid, a contoured surface could be produced by feeding a shaped tool normal to the axis of rotation. Short tapered or cylindrical surfaces could also be contour formed.
Flat or plane surfaces are frequently required. They can be generated by radial turning or facing, in which the tool point moves normal to the axis of rotation. In other cases, it is more convenient to hold the workpiece steady and reciprocate the tool across it in a series of straight-line cuts with a crosswise feed increment before each cutting stroke. This operation is called planning and is carried out on a shaper. For larger pieces it is easier to keep the tool stationary and draw the workpiece under it as in planning. The tool is fed at each reciprocation. Contoured surfaces can be produced by using shaped tools.
Multiple-edged tools can also be used. Drilling uses a twin-edged fluted tool for holes with depths up to 5 to 10 times the drill diameter. Whether the
drill turns or the workpiece rotates, relative motion between the cutting edge and the workpiece is the important factor. In milling operations a rotary cutter with a number of cutting edges engages the workpiece. Which moves slowly with respect to the cutter. Plane or contoured surfaces may be produced, depending on the geometry of the cutter and the type of feed. Horizontal or vertical axes of rotation may be used, and the feed of the workpiece may be in any of the three coordinate directions.
Basic Machine Tools
Machine tools are used to produce a part of a specified geometrical shape and precise I size by removing metal from a ductile material in the form of chips. The latter are a waste product and vary from long continuous ribbons of a ductile material such as steel, which are undesirable from a disposal point of view, to easily handled well-broken chips resulting from cast iron. Machine tools perform five basic metal-removal processes: I turning, planning, drilling, milling, and grinding. All other metal-removal processes are modifications of these five basic processes. For example, boring is internal turning; reaming, tapping, and counter boring modify drilled holes and are related to drilling; bobbing and gear cutting are fundamentally milling operations; hack sawing and broaching are a form of planning and honing; lapping, super finishing. Polishing and buffing are variants of grinding or abrasive removal operations. Therefore, there are only four types of basic machine tools, which use cutting tools of specific controllable geometry: 1. lathes, 2. planers, 3. drilling machines, and 4. milling machines. The grinding process forms chips, but the geometry of the abrasive grain is uncontrollable.
The amount and rate of material removed by the various machining processes may be I large, as in heavy turning operations, or extremely small, as in lapping or super finishing operations where only the high spots of a surface are removed.
A machine tool performs three major functions: 1. it rigidly supports the workpiece or its holder and the cutting tool; 2. it provides relative motion between the workpiece and the cutting tool; 3. it provides a range of feeds and speeds usually ranging from 4 to 32 choices in each case.
Speed and Feeds in Machining
Speeds, feeds, and depth of cut are the three major variables for economical machining. Other variables are the work and tool materials, coolant and geometry of the cutting tool. The rate of metal removal and power required for machining depend upon these variables.
The depth of cut, feed, and cutting speed are machine settings that must be established in any metal-cutting operation. They all affect the forces, the power, and the rate of metal removal. They can be defined by comparing them to the needle and record of a phonograph. The cutting speed (V) is represented by the velocity of- the record surface relative to the needle in the tone arm at any instant. Feed is represented by the advance of the needle radially inward per revolution, or is the difference in position between two adjacent grooves. The depth of cut is the penetration of the needle into the record or the depth of the grooves.
Turning on Lathe Centers
The basic operations performed on an engine lathe are illustrated. Those operations performed on external surfaces with a single point cutting tool are called turning. Except for drilling, reaming, and lapping, the operations on internal surfaces are also performed by a single point cutting tool.
All machining operations, including turning and boring, can be classified as roughing, finishing, or semi-finishing. The objective of a roughing operation is to remove the bulk of the material as rapidly and as efficiently as possible, while leaving a small amount of material on the work-piece for the finishing operation. Finishing operations are performed to obtain the final size, shape, and surface finish on the workpiece. Sometimes a semi-finishing operation will precede the finishing operation to leave a small predetermined and uniform amount of stock on the work-piece to be removed by the finishing operation.
Generally, longer workpieces are turned while supported on one or two lathe centers. Cone shaped holes, called center holes, which fit the lathe centers are drilled in the ends of the workpiece-usually along the axis of the cylindrical part. The end of the workpiece adjacent to the tailstock is always supported by a tailstock center, while the end near the headstock may be supported by a headstock center or held in a chuck. The headstock end of the workpiece may be held in a four-jaw chuck, or in a type chuck. This method holds the workpiece firmly and transfers the power to the workpiece smoothly; the additional support to the workpiece provided by the chuck lessens the tendency for chatter to occur when cutting. Precise results can be obtained with this method if care is taken to hold the workpiece accurately in the chuck.
Very precise results can be obtained by supporting the workpiece between two centers. A lathe dog is clamped to the workpiece; together they are driven by a driver plate mounted on the spindle nose. One end of the Workpiece is mecained;then the workpiece can be turned around in the lathe to machine the other end. The center holes in the workpiece serve as precise locating surfaces as well as bearing surfaces to carry the weight of the workpiece ?and to resist the cutting forces. After the workpiece has been removed from the lathe for any reason, the center holes will accurately align the workpiece back in the lathe or in another lathe, or in a cylindrical grinding machine. The workpiece must never be held at the headstock end by both a chuck and a lathe center. While at first thought this seems like a quick method of aligning the workpiece in the chuck, this must not be done because it is not possible to press evenly with the jaws against the workpiece while it is also supported by the center. The alignment provided by the center will not be maintained and the pressure of the jaws may damage the center hole, the lathe center, and perhaps even the lathe spindle. Compensating or floating jaw chucks used almost exclusively on high production work provide an exception to the statements made above. These chucks are really work drivers and cannot be used for the same purpose as ordinary three or four-jaw chucks.
While very large diameter workpieces are sometimes mounted on two centers, they are preferably held at the headstock end by faceplate jaws to obtain the smooth power transmission; moreover, large lathe dogs that are adequate to transmit the power not generally available, although they can be made as a special. Faceplate jaws are like chuck jaws except that they are mounted on a faceplate, which has less overhang from the spindle bearings than a large chuck would have.
Introduction of Machining
Machining as a shape-producing method is the most universally used and the most important of all manufacturing processes. Machining is a shape-producing process in which a power-driven device causes material to be removed in chip form. Most machining is done with equipment that supports both the work piece and cutting tool although in some cases portable equipment is used with unsupported workpiece.
Low setup cost for small Quantities. Machining has two applications in manufacturing. For casting, forging, and press working, each specific shape to be produced, even one part, nearly always has a high tooling cost. The shapes that may he produced by welding depend to a large degree on the shapes of raw material that are available. By making use of generally high cost equipment but without special tooling, it is possible, by machining; to start with nearly any form of raw material, so tong as the exterior dimensions are great enough, and produce any desired shape from any material. Therefore .machining is usually the preferred method for producing one or a few parts, even when the design of the part would logically lead to casting, forging or press working if a high quantity were to be produced.
Close accuracies, good finishes. The second application for machining is based on the high accuracies and surface finishes possible. Many of the parts machined in low quantities would be produced with lower but acceptable tolerances if produced in high quantities by some other process. On the other hand, many parts are given their general shapes by some high quantity deformation process and machined only on selected surfaces where high accuracies are needed. Internal threads, for example, are seldom produced by any means other than machining and small holes in press worked parts may be machined following the press working operations.
Primary Cutting Parameters
The basic tool-work relationship in cutting is adequately described by means of four factors: tool geometry, cutting speed, feed, and depth of cut.
The cutting tool must be made of an appropriate material; it must be strong, tough, hard, and wear resistant. The tool s geometry characterized by planes and angles, must be correct for each cutting operation. Cutting speed is the rate at which the work surface passes by the cutting edge. It may be expressed in feet per minute.
For efficient machining the cutting speed must be of a magnitude appropriate to the particular work-tool combination. In general, the harder the work material, the slower the speed.
Feed is the rate at which the cutting tool advances into the workpiece. "Where the workpiece or the tool rotates, feed is measured in inches per revolution. When the tool or the work reciprocates, feed is measured in inches per stroke, Generally, feed varies inversely with cutting speed for otherwise similar conditions.
The depth of cut, measured inches is the distance the tool is set into the work. It is the width of the chip in turning or the thickness of the chip in a rectilinear cut. In roughing operations, the depth of cut can be larger than for finishing operations.
The Effect of Changes in Cutting Parameters on Cutting Temperatures
In metal cutting operations heat is generated in the primary and secondary deformation zones and these results in a complex temperature distribution throughout the tool, workpiece and chip. A typical set of isotherms is shown in figure where it can be seen that, as could be expected, there is a very large temperature gradient throughout the width of the chip as the workpiece material is sheared in primary deformation and there is a further large temperature in the chip adjacent to the face as the chip is sheared in secondary deformation. This leads to a maximum cutting temperature a short distance up the face from the cutting edge and a small distance into the chip.
Since virtually all the work done in metal cutting is converted into heat, it could be expected that factors which increase the power consumed per unit volume of metal removed will increase the cutting temperature. Thus an increase in the rake angle, all other parameters remaining constant, will reduce the power per unit volume of metal removed and the cutting temperatures will reduce. When considering increase in unreformed chip thickness and cutting speed the situation is more complex. An increase in undeformed chip thickness tends to be a scale effect where the amounts of heat which pass to the workpiece, the tool and chip remain in fixed proportions and the changes in cutting temperature tend to be small. Increase in cutting speed; however, reduce the amount of heat which passes into the workpiece and this increase the temperature rise of the chip m primary deformation. Further, the secondary deformation zone tends to be smaller and this has the effect of increasing the temperatures in this zone. Other changes in cutting parameters have virtually no effect on the power consumed per unit volume of metal removed and consequently have virtually no effect on the cutting temperatures. Since it has been shown that even small changes in cutting temperature have a significant effect on tool wear rate it is appropriate to indicate how cutting temperatures can be assessed from cutting data.
The most direct and accurate method for measuring temperatures in high -speed-steel cutting tools is that of Wright &. Trent which also yields detailed information on temperature distributions in high-speed-steel cutting tools. The technique is based on the metallographic examination of sectioned high-speed-steel tools which relates microstructure changes to thermal history.
Trent has described measurements of cutting temperatures and temperature ?distributions for high-speed-steel tools when machining a wide range of workpiece materials. This technique has been further developed by using scanning electron ?microscopy to study fine-scale microstructure changes arising from over tempering of the tempered martens tic matrix of various high-speed-steels. This technique has also been used to study temperature distributions in both high-speed -steel single point turning tools and twist drills.
Wears of Cutting Tool
Discounting brittle fracture and edge chipping, which have already been dealt with, tool wear is basically of three types. Flank wear, crater wear, and notch wear. Flank wear occurs on both the major and the minor cutting edges. On the major cutting edge, which is responsible for bulk metal removal, these results in increased cutting forces and higher temperatures which if left unchecked can lead to vibration of the tool and workpiece and a condition where efficient cutting can no longer take place. On the minor cutting edge, which determines workpiece size and surface finish, flank wear can result in an oversized product which has poor surface finish. Under most practical cutting conditions, the tool will fail due to major flank wear before the minor flank wear is sufficiently large to result in the manufacture of an unacceptable component.
Because of the stress distribution on the tool face, the frictional stress in the region of sliding contact between the chip and the face is at a maximum at the start of the sliding contact region and is zero at the end. Thus abrasive wear takes place in this region with more wear taking place adjacent to the seizure region than adjacent to the point at which the chip loses contact with the face. This result in localized pitting of the tool face some distance up the face which is usually referred to as catering and which normally has a section in the form of a circular arc. In many respects and for practical cutting conditions, crater wear is a less severe form of wear than flank wear and consequently flank wear is a more common tool failure criterion. However, since various authors have shown that the temperature on the face increases more rapidly with increasing cutting speed than the temperature on the flank, and since the rate of wear of any type is significantly affected by changes in temperature, crater wear usually occurs at high cutting speeds.
At the end of the major flank wear land where the tool is in contact with the uncut workpiece surface it is common for the flank wear to be more pronounced than along the rest of the wear land. This is because of localised effects such as a hardened layer on the uncut surface caused by work hardening introduced by a previous cut, an oxide scale, and localised high temperatures resulting from the edge effect. This localised wear is usually referred to as notch wear and occasionally is very severe. Although the presence of the notch will not significantly affect the cutting properties of the tool, the notch is often relatively deep and if cutting were to continue there would be a good chance that the tool would fracture.
If any form of progressive wear allowed to continue, dramatically and the tool would fail catastrophically, i. e. the tool would be no longer capable of cutting and, at best, the workpiece would be scrapped whilst, at worst, damage could be caused to the machine tool. For carbide cutting tools and for all types of wear, the tool is said to have reached the end of its useful life long before the onset of catastrophic failure. For high-speed-steel cutting tools, however, where the wear tends to be non-uniform it has been found that the most meaningful and reproducible results can be obtained when the wear is allowed to continue to the onset of catastrophic failure even though, of course, in practice a cutting time far less than that to failure would be used. The onset of catastrophic failure is characterized by one of several phenomena, the most common being a sudden increase in cutting force, the presence of burnished rings on the workpiece, and a significant increase in the noise level.
Mechanism of Surface Finish Production
There are basically five mechanisms which contribute to the production of a surface which have been machined. These are:
(l) The basic geometry of the cutting process. In, for example, single point turning the tool will advance a constant distance axially per revolution of the workpiecc and the resultant surface will have on it, when viewed perpendicularly to the direction of tool feed motion, a series of cusps which will have a basic form which replicates the shape of the tool in cut.
(2) The efficiency of the cutting operation. It has already been mentioned that cutting with unstable built-up-edges will produce a surface which contains hard built-up-e
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