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1、目 錄前 言11 零件的分析21.1 零件的作用21.2 零件的工藝分析32 工藝規(guī)程設(shè)計(jì)32.1 毛坯的制造形式42.2 基準(zhǔn)面的選擇42.2.1 粗基準(zhǔn)的選擇42.2.2 精基準(zhǔn)的選擇42.3 制訂工藝路線42.3.1 工藝線路方案一42.3.2 工藝路線方案二52.3.3 工藝方案的比較與分析52.4 機(jī)械加工余量、工序尺寸及毛坯尺寸的確定62.5 確定切削用量及基本工時(shí)72.5.1 工序:車(chē)削端面、外圓72.5.2 工序:粗車(chē)65,80,75,100外圓以及槽和倒角9工序 鉆擴(kuò)mm、及锪孔。轉(zhuǎn)塔機(jī)床C365L122.5.4 工序 鉆613.5, 2-M10-6H, 4-M10-6H深孔

2、深24132.5.5 工序:精車(chē)65mm的外圓及與80mm相接的端面16工序:精、粗、細(xì)鏜mm孔182.5.7 工序:銑60孔底面182.5.8 工序:磨60孔底面19工序: 鏜60mm孔底溝槽202.5.10 工序: 研磨60mm孔底面203專用夾具設(shè)計(jì)203.1 問(wèn)題的指出213.2 夾具設(shè)計(jì)213.2.1 定位基準(zhǔn)的選擇213.2.2 切削力及夾緊力的計(jì)算213.3 定位誤差的分析223.4 夾具設(shè)計(jì)及操作的簡(jiǎn)要說(shuō)明22參考資料22致謝23附 錄24前 言 畢業(yè)設(shè)計(jì)是高等工業(yè)學(xué)校教學(xué)中的一個(gè)主要組成部分,是專業(yè)學(xué)習(xí)過(guò)程是最后的一個(gè)主要的實(shí)踐性的教學(xué)環(huán)節(jié),是完成工程師基本訓(xùn)練的重要環(huán)節(jié),是

3、培養(yǎng)學(xué)生獨(dú)立思考和科學(xué)工作方法重要的實(shí)踐性的過(guò)程。 設(shè)計(jì)的目的和要求在于培養(yǎng)學(xué)生綜合運(yùn)用所學(xué)知識(shí)和技能去分析和解決機(jī)械工程實(shí)際問(wèn)題的能力.熟練生產(chǎn)技術(shù)的工作的一般方法,培養(yǎng)學(xué)生樹(shù)立工程技術(shù)必備的全局觀點(diǎn),生產(chǎn)觀點(diǎn)和經(jīng)濟(jì)觀點(diǎn)。樹(shù)立正確的設(shè)計(jì)思想和嚴(yán)肅認(rèn)真的工作態(tài)度,培養(yǎng)學(xué)生調(diào)查研究,查閱技術(shù)文獻(xiàn)資料,手冊(cè)進(jìn)行工程運(yùn)籌,圖樣的繪制及編寫(xiě)技術(shù)文件的獨(dú)立工作能力. 畢業(yè)設(shè)計(jì),通過(guò)到工廠的實(shí)際調(diào)研,對(duì)設(shè)計(jì)內(nèi)容有了基本的了解,并仔細(xì)觀察和了解各加工工序的加工過(guò)程,查閱了大量的資料,在何鶴林、鄧興貴兩位教授的指導(dǎo)下完成了設(shè)計(jì)任務(wù),并編寫(xiě)了設(shè)計(jì)說(shuō)明書(shū)。就我個(gè)人而言,我希望通過(guò)這次課程設(shè)計(jì)對(duì)自己未來(lái)將從事的工作

4、進(jìn)行一次適應(yīng)訓(xùn)練,從中鍛煉自己分析問(wèn)題、解決問(wèn)題的能力,為今后的技術(shù)工作打下一個(gè)良好的基礎(chǔ)。 由于能力和經(jīng)驗(yàn)的有限,設(shè)計(jì)尚有許多不足之處,懇請(qǐng)各位老師給予指教。 1 零件的分析1.1 零件的作用題目所給定的零件是解放牌汽車(chē)的填料箱蓋(附圖1),其主要作用是保證對(duì)箱體起密封作用,使箱體在工作時(shí)不致讓油液滲漏。填料箱主要由填料,水封環(huán),填料筒,填料壓蓋,水封管組成。填料函的作用主要是為了封閉泵殼與泵軸之間的空隙,不讓泵內(nèi)的水流不流到外面來(lái)也不讓外面的空氣進(jìn)入到泵內(nèi)。始終保持水泵內(nèi)的真空!當(dāng)泵軸與填料摩擦產(chǎn)生熱量就要靠水封管住水到水封圈內(nèi)使填料冷卻!保持水泵的正常運(yùn)行。1.2 零件的工藝分析填料箱蓋

5、的零件圖中規(guī)定了一系列技術(shù)要求:(查表1.4-28機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè))1 以65H5()軸為中心的加工表面。包括:尺寸為65H5()的軸,表面粗糙度為1.6, 尺寸為80的與65H5()相接的肩面, 尺寸為100f8()與65H5()同軸度為0.025的面. 尺寸為60h5()與65H5()同軸度為0.025的孔.2.以60h5()孔為中心的加工表面.尺寸為78與60H8()垂直度為0.012的孔底面,表面粗糙度為0.4,須研磨.3. 以60H8()孔為中心均勻分布的12孔,6-13.5,4-M10-6H深20孔深24及4-M10-6H.4.其它未注表面的粗糙度要求為6.3,粗加工可滿足

6、要求.2 工藝規(guī)程設(shè)計(jì)2.1 毛坯的制造形式零件材料為HT200,考慮到零件材料的綜合性能及材料成本和加工成本,保證零件工作的可靠,采用鑄造。由于年產(chǎn)量為1000件,屬于中批生產(chǎn)的水平,而且零件輪廓尺寸不大,故可以采用鑄造成型,這從提高生產(chǎn)率、保證加工精度上考慮,也是應(yīng)該的。此處省略 NNNNNNNNNNNNNNNNNNNNNNNN字。如需要完整說(shuō)明書(shū)和CAD圖紙等.請(qǐng)聯(lián)系 扣扣 二五一一三三四零八 另提供全套機(jī)械設(shè)計(jì)地址。  r: 工作臺(tái)移動(dòng)速度(m/min) :工作臺(tái)往返一次砂輪軸向進(jìn)給量 : 工作臺(tái)往返一次砂輪徑向進(jìn)給量則 工序: 鏜60mm孔底溝槽內(nèi)孔車(chē)刀

7、 保證t=0.5mm,d=2mm 工序: 研磨60mm孔底面采用手工研具進(jìn)行手工研磨:Z=0.01mm3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,需要設(shè)計(jì)專用夾具。經(jīng)過(guò)與指導(dǎo)老師協(xié)商,決定設(shè)計(jì)第6道工序鉆12孔的鉆床專用夾具。本夾具將用于Z3025搖臂鉆床。刀具為麻花鉆。3.1 問(wèn)題的指出本夾具主要用來(lái)鉆12孔,由于工藝要求不高,因此,在本道工序加工時(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。3.2 夾具設(shè)計(jì) 定位基準(zhǔn)的選擇由零件圖可知,12孔中,613.5在圓周上均勻分布,2M10,4M10也為對(duì)稱分布,尺寸精度為自由尺寸精度要求。其設(shè)計(jì)基準(zhǔn)為兩對(duì)稱孔中心距,由于難以使

8、工藝基準(zhǔn)與設(shè)計(jì)基準(zhǔn)統(tǒng)一,只能以65外圓面作為定位基準(zhǔn)。為了提高加工效率及方便加工,決定鉆頭材料使用高速鋼,用于對(duì)12孔進(jìn)行加工。同時(shí),為了縮短輔助時(shí)間,準(zhǔn)備采用氣動(dòng)夾緊。 切削力及夾緊力的計(jì)算刀具:高速鋼麻花鉆頭,尺寸為13.5。 則軸向力:見(jiàn)工藝師手冊(cè)表28.4F=Cdfk3.1 式中: C=420, Z=1.0, y=0.8, f=0.35 k=(F=420轉(zhuǎn)矩T=Cdfk式中: C=0.206, Z=2.0, y=0.8T=0.206功率 P=在計(jì)算切削力時(shí),必須考慮安全系數(shù),安全系數(shù) K=KKKK式中 K基本安全系數(shù),1.5; K加工性質(zhì)系數(shù),1.1;K刀具鈍化系數(shù), 1.1;K斷續(xù)切

9、削系數(shù), 1.1則 F=KF=1.5氣缸選用。當(dāng)壓縮空氣單位壓力P=0.6MP,夾緊拉桿。N= N>F鉆削時(shí) T=17.34 N切向方向所受力: F=取F=4416F> F所以,鉆削時(shí)工件不會(huì)轉(zhuǎn)動(dòng),故本夾具可安全工作。3.3 定位誤差的分析 定位元件尺寸及公差的確定。本夾具的主要定位元件為止口,而該定位元件的尺寸公差為,而孔徑尺寸為自由尺寸精度要求,可滿足加工要求。3.4 夾具設(shè)計(jì)及操作的簡(jiǎn)要說(shuō)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)首先著眼于機(jī)動(dòng)夾具,本道工序的鉆床夾具選用氣動(dòng)夾緊方式。本工序由于是粗加工,切削力較大,為了夾緊工件,勢(shì)必要增大氣缸直徑,而這將使整個(gè)夾具過(guò)于

10、龐大。因此,應(yīng)設(shè)法降低切削力。目前采取的措施有兩個(gè):一是提高毛坯精度,使最大切削深度降低,以降低切削力;二是在可能的情況下,適當(dāng)提高壓縮空氣的工作壓力(由0.5M增至0.6 M)以增加氣缸推力。結(jié)果,本夾具結(jié)構(gòu)比較緊湊。 鉆床夾具的裝配圖及零件圖分別見(jiàn)附圖3及附圖4。參考資料1.機(jī)床夾具設(shè)計(jì) 第2版 肖繼德 陳寧平主編 機(jī)械工業(yè)出版社2.機(jī)械制造工藝及專用夾具設(shè)計(jì)指導(dǎo) 孫麗媛主編 冶金工業(yè)出版社3.機(jī)械制造工藝學(xué)周昌治、楊忠鑒等 重慶大學(xué)出版社4. 機(jī)械制造工藝設(shè)計(jì)簡(jiǎn)明手冊(cè)李益民 主編 機(jī)械工業(yè)出版社5. 工藝師手冊(cè) 楊叔子主編 機(jī)械工業(yè)出版社6. 機(jī)床夾具設(shè)計(jì)手冊(cè)王光斗、王春福主編 上海科技

11、出版社7. 機(jī)床專用夾具設(shè)計(jì)圖冊(cè)南京市機(jī)械研究所 主編 機(jī)械工業(yè)出版社8. 機(jī)械原理課程設(shè)計(jì)手冊(cè) 鄒慧君主編 機(jī)械工業(yè)出版社9.金屬切削手冊(cè)第三版 上海市金屬切削技術(shù)協(xié)會(huì) 上海科學(xué)技術(shù)出版社10.幾何量公差與檢測(cè)第五版 甘永立 主編 上??茖W(xué)技術(shù)出版社 11機(jī)械制造工藝水學(xué)、機(jī)床夾具設(shè)計(jì) (教材)12機(jī)械零件設(shè)計(jì)手冊(cè)13機(jī)械制造工藝學(xué)課程設(shè)計(jì)指導(dǎo)書(shū), 機(jī)械工業(yè)出版社14機(jī)床夾具設(shè)計(jì) 王啟平主編 哈工大出版社15 汽車(chē)制造工藝學(xué) 侯家駒主編 機(jī)械工業(yè)出版社16汽車(chē)構(gòu)造與修理圖解 唐藝 主編 機(jī)械工業(yè)出版社17汽車(chē)傳動(dòng)與行使部分檢修問(wèn)答 劉文舉 主編 人民郵電出版社致謝 經(jīng)何鶴林、鄧興貴兩位教授的

12、悉心指教。為期3個(gè)月的畢業(yè)設(shè)計(jì)終于結(jié)束了,在此要感謝老師的辛勤指導(dǎo)。 通過(guò)這次走向工作實(shí)踐前的最后一次綜合練兵。使我們對(duì)自己的專業(yè)有了更進(jìn)一步的認(rèn)識(shí),清楚了自己在今后工作中的努力方向,熟悉了所學(xué)的基礎(chǔ)技術(shù)知識(shí),加深了解了自己在專業(yè)工作中一般工作方法,了解解決問(wèn)題的一般常規(guī)程序,基本上具備了一定的分析和解決問(wèn)題的能力,鍛煉了設(shè)計(jì)計(jì)算,繪圖的能力,以及建立了自己獨(dú)立思考。查閱大量資料的習(xí)慣及方法。 附 錄1.外文原文復(fù)印件2. 外文譯文3. 畢業(yè)實(shí)習(xí)報(bào)告The packing box divulges reason analysis and countermeasure abstract: Rea

13、son the packing box divulges which through the analysis petrochemistry enterprise each kind of adjustment valve in, as well as the adjustment valve divulges the harm which brings to the environment and the production, proposed some solution countermeasures. Guan Jianci: Adjusts the valve; The packin

14、g box divulges; Seal; Countermeasure1 foreword adjustment valve is the petroleum chemical industry refines oil in the installment the essential part, its use adjustment valve type many, quantity big, in the chemical production medium many is corrosiveness strong, virulent or is flammable explosive,

15、when adjusts the valve divulges, not only can create the serious raw material, the energy and the product waste, moreover also has the serious influence to the environment, even causes the serious security accident. Therefore, we have the necessity also to have to take in the petroleum chemical indu

16、stry production process to adjust the valve to divulge the question. Under causes the reason on the petroleum chemical industry installment in which the adjustment valve packing box divulges as well as prevented divulges the countermeasure, the method with the elimination makes the key discussion.2

17、adjustments valves packing box divulges the reason analysis adjustment valve divulges divides into two kinds, namely outside divulges with the interior divulges. In the majority situation, outside divulges the consequence which creates, often divulges compared to the interior seriously.In the indust

18、rial production, adjusts the valve outside to leak not only creates the raw material and the energy waste, but also can directly pollute the environment, even causes the fire, the detonation, is poisoned and so on the harm safety significant accident, the national economy creates the heavy loss for.

19、 Outside but the packing box divulges also belongs leaks. The packing box divulges reason: The packing box by the stuffing box, the padding, the padding pad as well as the padding contracts the organization and so on to be composed. The stuffing box sets on the valve body or the valve cover, plays h

20、olds the padding the role. The padding pad sets to the stuffing box base, plays the strut padding role. The padding divides the soft nature sealing compound and takes shape the padding two kinds. Takes shape the padding take the elastic material quality as the raw material, uses the mould pressing t

21、o take shape or the turning processing makes each kind of joiner curtain under, compares, takes shape the padding structure compact, sealing property good, the serviceability is stronger. The medium divulges in the sealing compound place, the reason becomes less crowded, the sealing compound for the

22、 padding gland is not strict, the padding variety or the quality does not conform to the requirement, the padding gets older or by the valve lever attrition. 3 adjusts the loss which the valve divulges creates Divulging causes which by the above situation, creates the economic loss and further becau

23、se the medium characteristic different has differently to the environment pollution degree. If is the gas medium, then very easily proliferates the dissemination in the air, its pollution radius can be bigger. The liquid medium can through have the pollution to the ground seepage, also possibly or t

24、he exile expels flood water the ditch through the open ditch, pollutes the rivers and streams lake and other environment. Former Soviet Union's nuclear power station because adjusts the valve the question to breed the unprecedented disaster, not only has caused the significant personnel casualty

25、, creates direct and the indirect economic loss and the environment destroy also with difficulty estimates. The statistical data indicated that, in the production unit approximately 20% adjustment valve existence divulges the question, creates the direct economic loss approximately composes the tota

26、l losses 5%0 in the petrified profession, take a set of 5000kt/a scale often the decompressor as the example, in the ordinary circumstances has 5,000 about the adjustment valve, divulges the economic loss by 20% adjustment valve which creates and the pollution which creates to the environment indeed

27、 may not belittle, if looked from the entire petrified profession, the situation was more serious.4 packing boxes divulge the countermeasure because the adjustment valve packing box seals divulging, as well as valve body connection spot seal divulging, is creates adjusts the key which outside the va

28、lve leaks to be at, therefore needs specially to take. The traditional soft nature padding seal, is depends on the padding gland the thrust, causes it between the valve lever and the padding as well as the padding and the stuffing box sidewall, has the certain radial direction contact stress to achi

29、eve the seal. Therefore, the gland axial force must be quite big, this creates between the padding and the valve lever rubs the torque to increase, the attrition increases, the soft nature sealing compound wears quickly, thus must frequently screw tight the packing bolt or the replacement padding, c

30、an guarantee the better seal effect. Uses the appropriate padding seal and the padding seal combination, may enhance adjusts the reliability which the valve uses, lengthens the service life. If the flexible graphite link padding combination use, only uses the flexible graphite link padding the seal

31、effect to be better than. At present in domestic uses the sole flexible graphite link padding the situation quite to be many; But in overseas, uses the flexible graphite link padding combination the application method to start popularly, and has obtained the good effect. 5 concluding remark In summa

32、ry, adjusts the valve in the petrification industrial production divulging is the not allow to neglect question, it to the production efficiency, the security as well as can bring the significant influence to the environment. The elimination adjustment valve divulges the key lies in the optimized ad

33、justment valve structure the design, adjusts the valve according to the different craft condition reasonable choice the material, enhances adjusts the valve in production process quality control level, as well as adjusts the valve according to the craft operating system optimization the shaping. Alo

34、ng with the science and technology progress, specially the new material appearance, some new structures adjustment valves put into the use, their performance good, the life is long, may satisfy production the need to develop. Reference: 1 Wang Xunju Valve use maintenance handbook s Beijing: Chinese

35、petrochemistry publishing house, 1,999 2 German ginger The petroleum chemical industry installment process tube installs design handbook second S Beijing: Chinese petrochemistry publishing house, 1,998 3 Lu Peiwen The valve selects the handbook S Beijing: Mechanical industry publishing house,中文譯文填料函

36、泄漏的原因分析及對(duì)策    摘要:通過(guò)分析石化企業(yè)各種調(diào)節(jié)閥門(mén)中填料函泄漏的原因,以及調(diào)節(jié)閥門(mén)泄漏對(duì)環(huán)境和生產(chǎn)所帶來(lái)的危害,提出了一些解決對(duì)策。    關(guān)健詞:調(diào)節(jié)閥門(mén);填料函泄漏;密封;對(duì)策1前言    調(diào)節(jié)閥門(mén)是石油化工煉油裝置中不可缺少的部分,其使用的調(diào)節(jié)閥門(mén)種類多、數(shù)量大,化工生產(chǎn)中的介質(zhì)多是腐蝕性強(qiáng)、有毒或易燃易爆的,當(dāng)調(diào)節(jié)閥門(mén)泄漏時(shí),不僅會(huì)造成嚴(yán)重的原材料、能量和產(chǎn)品的浪費(fèi),而且對(duì)環(huán)境也造成嚴(yán)重的影響,甚至引起嚴(yán)重的安全事故。因此,我們有必要也應(yīng)當(dāng)重視石油化工生產(chǎn)

37、過(guò)程中調(diào)節(jié)閥門(mén)的泄漏問(wèn)題。下面就石油化工裝置中引起調(diào)節(jié)閥門(mén)填料函泄漏的原因以及防止和消除泄漏的對(duì)策、方法做重點(diǎn)探討。2 調(diào)節(jié)閥門(mén)填料函泄漏的原因分析    調(diào)節(jié)閥門(mén)泄漏分為兩種,即外部泄漏和內(nèi)部泄漏。在大多數(shù)情況下,外部泄漏所造成的后果,往往比內(nèi)部泄漏更加嚴(yán)重。在工業(yè)生產(chǎn)中,調(diào)節(jié)閥門(mén)的外漏不但造成原材料及能源的浪費(fèi),還會(huì)直接污染環(huán)境,甚至引起火災(zāi)、爆炸、中毒等危害生命安全的重大事故,給國(guó)民經(jīng)濟(jì)造成嚴(yán)重?fù)p失。而填料函泄漏又屬于外漏。填料函泄漏的原因:填料函由填料箱、填料、填料墊以及填料壓緊機(jī)構(gòu)等組成。填料箱置于閥體或閥蓋上,起容納填料的作用。填料墊置于填料

38、箱底部,起支撐填料的作用。填料分軟質(zhì)密封填料和成型填料兩種。成型填料以彈性材質(zhì)為原料,采用模壓成型或車(chē)削加工制成各種環(huán)形密封圈,相比之下,成型填料結(jié)構(gòu)緊湊,密封性能好,適用性更強(qiáng)。    介質(zhì)在密封填料處泄漏,原因?yàn)樘盍蠅荷w松動(dòng)、密封填料不嚴(yán)密、填料品種或質(zhì)量不符合要求、填料老化或被閥桿磨損。3調(diào)節(jié)閥門(mén)泄漏造成的損失    由以上情況引起的泄漏,所造成的經(jīng)濟(jì)損失和對(duì)環(huán)境的污染程度又因介質(zhì)的特性的不同而有所不同。如果是氣體介質(zhì),則很容易在空氣中擴(kuò)散傳播,其污染半徑就會(huì)較大。液體介質(zhì)則會(huì)通過(guò)對(duì)地面的滲透產(chǎn)生污染,也可能

39、通過(guò)明溝或暗溝流人排洪渠,污染江河湖泊及其他環(huán)境。前蘇聯(lián)的切爾諾貝利核電站因?yàn)橐粋€(gè)調(diào)節(jié)閥門(mén)的問(wèn)題而釀成空前的災(zāi)難,不僅造成了重大的人員傷亡,所造成的直接和間接的經(jīng)濟(jì)損失及環(huán)境破壞也難以估量。統(tǒng)計(jì)數(shù)據(jù)表明,工業(yè)裝置中約20%的調(diào)節(jié)閥門(mén)存在泄漏問(wèn)題,所造成的直接經(jīng)濟(jì)損失約占總損失的5%0在石化行業(yè)中,以一套5000kt/a規(guī)模的常減壓裝置為例,一般情況下有5000個(gè)左右的調(diào)節(jié)閥門(mén),由其中20%的調(diào)節(jié)閥門(mén)泄漏所造成的經(jīng)濟(jì)損失和對(duì)環(huán)境造成的污染的確不可小覷,如果從整個(gè)石化行業(yè)來(lái)看,情況就更嚴(yán)重了。  4填料函泄漏對(duì)策    由于調(diào)節(jié)閥門(mén)填料函

40、密封的泄漏,以及閥體連接部位密封的泄漏,是造成調(diào)節(jié)閥門(mén)外漏的關(guān)鍵所在,所以需要特別重視。    傳統(tǒng)的軟質(zhì)填料密封,是靠填料壓蓋的軸向壓力,使之在閥桿與填料以及填料與填料箱側(cè)壁之間,產(chǎn)生一定的徑向接觸應(yīng)力而達(dá)到密封的。因此,壓蓋的軸向力必須相當(dāng)大,這就造成填料與閥桿之間摩擦轉(zhuǎn)矩增大、磨損增加、軟質(zhì)密封填料磨損快,因而須經(jīng)常擰緊壓蓋螺栓或更換填料,才能保證較好的密封效果。    采用合適的填料密封及填料密封組合,可提高調(diào)節(jié)閥門(mén)使用的可靠性,延長(zhǎng)使用壽命。如柔性石墨環(huán)填料的組合使用,比只用柔性石墨環(huán)填料的密封效果好。目前在國(guó)內(nèi)采用單一柔性石墨環(huán)填料的情況比較多;而在國(guó)外,采用柔性石墨環(huán)填料組合的使用方法已開(kāi)始流行,并且取得了良好的效果。5結(jié)束語(yǔ)  綜上所述,在石化工業(yè)生產(chǎn)中調(diào)節(jié)閥門(mén)的泄漏是不容忽視的問(wèn)題,它對(duì)生產(chǎn)的經(jīng)濟(jì)性、安全性以及對(duì)環(huán)境都會(huì)帶來(lái)重大的影響。消除調(diào)節(jié)閥門(mén)泄漏的關(guān)鍵在于優(yōu)化調(diào)節(jié)閥門(mén)結(jié)構(gòu)的設(shè)

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