機(jī)械工藝夾具畢業(yè)設(shè)計(jì)113L

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3L-10/8空氣壓縮機(jī)曲軸零件的機(jī)械加工工藝及夾具設(shè)計(jì)

學(xué)生姓名：學(xué)生學(xué)號(hào)：

院院系）：機(jī)電工程學(xué)院年級(jí)專業(yè)：機(jī)械制造及自動(dòng)化1班指導(dǎo)教師：

目錄

目錄

摘要········································································································································IABSTRACT································································································································I1緒論···································································································································12零件分析·······························································································································2

2.1零件的作用·····················································································································2

2.2零件的工藝分析··············································································································22.3零件加工的主要問(wèn)題和工藝過(guò)程設(shè)計(jì)分析····································································2

3工藝規(guī)程設(shè)計(jì)······················································································································5

3.1確定毛坯的制造形式······································································································53.2基面的選擇·····················································································································5

3.2.1粗基準(zhǔn)選擇·········································································································53.2.2精基準(zhǔn)的選擇·····································································································53.3制定工藝路線·················································································································53.4機(jī)械加工余量、工序尺寸及毛坯尺寸的確定································································73.5確定切削用量及基本工時(shí)····························································································113.6時(shí)間定額計(jì)算及生產(chǎn)安排···························································································31

4專用夾具設(shè)計(jì)····················································································································40

4.1加工曲拐上端面油孔夾具設(shè)計(jì)·····················································································40

4.1.1定位基準(zhǔn)的選擇································································································404.1.2切削力的計(jì)算與夾緊力分析·············································································404.1.3夾緊元件及動(dòng)力裝置確定·················································································414.1.4鉆套、襯套及夾具體設(shè)計(jì)·················································································424.1.5夾具精度分析····································································································444.2加工曲拐上側(cè)面油孔夾具設(shè)計(jì)·····················································································45

4.2.1定位基準(zhǔn)的選擇································································································454.2.2切削力的計(jì)算與夾緊力分析·············································································454.2.3夾緊元件及動(dòng)力裝置確定·················································································464.2.4鉆套、襯套及夾具體設(shè)計(jì)·················································································474.2.5夾具精度分析····································································································484.3銑曲拐端面夾具設(shè)計(jì)····································································································49

4.3.1定位基準(zhǔn)的選擇································································································494.3.2定位元件的設(shè)計(jì)································································································494.3.3銑削力與夾緊力計(jì)算·························································································504.3.4對(duì)刀塊和塞尺設(shè)計(jì)·····························································································51

4結(jié)論·································································································································53

1零件分析

2零件分析

2.1零件的作用

題目所給定的零件是3L—10/8空氣壓縮機(jī)上的曲軸，它位于空氣壓縮機(jī)連桿處，曲軸產(chǎn)生旋轉(zhuǎn)運(yùn)動(dòng)，帶動(dòng)連桿使活塞產(chǎn)生往復(fù)運(yùn)動(dòng)，并將旋轉(zhuǎn)轉(zhuǎn)為直線運(yùn)動(dòng)，它在工作過(guò)程中將承受周期性的繁雜的交變載荷。其主要作用是傳遞轉(zhuǎn)矩，是連桿獲得所需的動(dòng)力。

2.2零件的工藝分析

由3L-10/8空氣壓縮機(jī)的曲軸零件圖可知，它的外表面上有多個(gè)平面需要進(jìn)行加工，此外各表面上還需加工一系列螺紋孔和鍵槽。因此可將其分為兩組加工表面，它們相互間有一定的位置要求它們之間有一定的位置要求.現(xiàn)分析如下:

2.2.1以拐徑為?95mm為中心的加工表面

0.036這一組加工表面包括:拐徑?95??0.071mm加工及其倒圓角,兩個(gè)?8的斜油孔,兩0.036個(gè)油孔孔口倒角，它的加工表面的位置要求是?95??0.071mm圓跳動(dòng)公差為0.01mm。

2.2.2以軸心線兩端軸為中心的加工表面

?0.052這一組加工表面：1：10錐度面的鍵槽240mm并左端倒角，端面?15mm0.025深16.8mm的中心孔,2個(gè)M12深24mm的螺紋孔，各軸的外圓表面,右端面?95??0.003?0.084mm的孔?300mm。

這組加工表面有一定的位置要求，主要是：

?0.052(1)鍵槽240mm×110mm與1：10錐度軸心線的對(duì)稱度公差為0.10mm。

(2)1：10錐度軸心線對(duì)A-B軸心線的的圓跳動(dòng)公差0.025mm；

0.22(3)?90??0.57mm軸表面的圓柱度公差為0.01mm

這兩組加工表面之間有著一定的位置要求，主要有：

0.036(1)曲軸拐徑?95??0.071mm軸心線與A-B軸心線的平行度公差?0.03mm

又以上分析可知，對(duì)于這兩組加工表面而言，可以先加工其中一組表面，然后借助于專用夾具加工另一組表面，并保證他們的位置精度要求。

2.3零件加工的主要問(wèn)題和工藝過(guò)程設(shè)計(jì)分析

0.025（1）曲軸在鑄造時(shí)，右端?95?鑄造?0.003mm要在直徑方向上留出工藝尺寸量，

尺寸為105mm，這樣為開拐前加工出工藝鍵槽準(zhǔn)備。該工藝鍵槽與開拐工裝協(xié)同傳遞扭轉(zhuǎn)。

（2）為保證加工精度，對(duì)所有加工的部位均應(yīng)采用粗、精加工分開的原則。

21零件分析

（3）曲軸加工應(yīng)充分考慮在切削時(shí)平衡裝置。1）車削拐徑用專用工裝及配重裝置。

110±0.1

圖2-1車削拐徑

2）粗、精車軸徑及粗、精磨軸徑都應(yīng)在曲軸拐徑的對(duì)面加裝配重。

圖2-2車、磨軸徑

（4）1：10錐度環(huán)規(guī)與塞規(guī)要求配套使用，環(huán)規(guī)檢測(cè)曲軸錐度，塞規(guī)檢測(cè)與之配套的電機(jī)轉(zhuǎn)子錐孔或聯(lián)軸器錐孔，以保證協(xié)同精度。

（5）曲軸偏心距110?將等高V形塊放在工作平?0.1mm的檢驗(yàn)方法如圖1-3。

0.025臺(tái)上，以曲軸兩軸徑?95??0.003mm作為測(cè)量基準(zhǔn)。將曲軸放在V形塊上。首先用百

分表將兩軸徑的最高點(diǎn)調(diào)整到等高（可用紙墊V形塊的方法），并同時(shí)用高度尺測(cè)出軸徑的最高點(diǎn)實(shí)際尺寸H2,H3(如兩軸徑均在公差范圍內(nèi)，這是H2和H3應(yīng)等高)。用百分表將曲軸拐徑調(diào)整到最高點(diǎn)位置上，同時(shí)用高度尺測(cè)出拐徑最高點(diǎn)實(shí)際尺寸H1。在用外徑千分尺測(cè)出拐徑?1和軸徑?2，?3的實(shí)際尺寸。這樣經(jīng)過(guò)計(jì)算可得出偏心距的實(shí)際尺寸。

31零件分析

H1

圖2-3曲軸偏心距檢測(cè)示意圖

偏心距=（H1-?1/2）-（H2-?2/2）

式中H1——曲軸拐徑最高點(diǎn)????????????式(1)

H2（H3）——曲軸軸徑最高點(diǎn)??????????式(2)

?1——曲軸拐徑實(shí)際尺寸???????????式(3)

?2（?3）——曲軸軸徑實(shí)際尺寸????????式(4)

（6）曲軸拐徑軸線與軸徑軸線平行度的檢查，可參照?qǐng)D1-3進(jìn)行。當(dāng)用百分表將兩軸徑的最高點(diǎn)，調(diào)整到等高后，可用百分表再測(cè)出拐徑?1最高點(diǎn)兩處之差（距離盡可能遠(yuǎn)些），然后通過(guò)計(jì)算可得出平行度值。

（7）曲軸拐徑、軸徑圓度測(cè)量，可在機(jī)床上用百分表測(cè)出。圓柱度的檢測(cè)，可以在每個(gè)軸上選取2~3個(gè)截面測(cè)量，通過(guò)計(jì)算可得出圓柱度值。

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攀枝花學(xué)院本科畢業(yè)設(shè)計(jì)2工藝規(guī)程設(shè)計(jì)

3工藝規(guī)程設(shè)計(jì)

3.1確定毛坯的制造形式

零件材料為球球墨鑄鐵，型號(hào)為QT600-3?？紤]到空氣壓縮機(jī)曲軸的零件較大，零件比較繁雜，應(yīng)采用鑄件。而且投資較少，成本較低，生產(chǎn)周期短。

3.2基面的選擇

基面選擇是工藝規(guī)程設(shè)計(jì)中的重要工作之一，基面選擇的正確與合理，可以使加工質(zhì)量得到保證，生產(chǎn)率得以提高，不盲目的選擇基面。否則，加工工藝過(guò)程中會(huì)問(wèn)題百出，更有甚者，還會(huì)造成零件的大批報(bào)廢，使生產(chǎn)無(wú)法正常進(jìn)行。

3.2.1粗基準(zhǔn)選擇

在小批生產(chǎn)的條件下，尋常都是采取劃線找正。所以曲軸加工的第一道工序是鉗工劃線，劃出主軸頸端面的十字中心線以及待加工表面的輪廓線，然后按劃線找正將曲軸安裝在機(jī)床上進(jìn)行加工。這樣兼顧了各部分的加工余量，以減少毛坯的廢品率。

3.2.2精基準(zhǔn)的選擇

加工曲軸的主軸頸止以及與主軸頸同旋轉(zhuǎn)軸心線的其它協(xié)同部分和曲柄外圓弧面、外端面時(shí)，同軸類零件外圓表面加工一樣，采用輔助精基準(zhǔn)－頂針孔。用頂針孔作為精基準(zhǔn)，符合基面同一的原則，從而可以保證一次安裝中加工的各表面的同軸度或垂直度。對(duì)于主軸頸較大而偏心距又較小的曲軸，可以在曲軸兩端面上分別各打出兩個(gè)頂針孔A及B，使用典型的一面兩孔定位方法，則可以滿足整個(gè)加工過(guò)程中基本上都采用統(tǒng)一的基準(zhǔn)定位的要求。

3.3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、尺寸精度等技術(shù)要求能得到合理的保證。除此之外，還應(yīng)當(dāng)考慮經(jīng)濟(jì)效果，以便使生產(chǎn)成本盡量下降。工藝路線方案（一）：

1）畫線，以毛坯外形找正，劃主要加工線，偏心距100?0.1mm及外形加工。2）劃軸兩端中心孔線，顧各部加工余量。

0.0253）工件平放在鏜床工作臺(tái)上，壓軸95??0.003mm兩處，鉆右端中心孔。0.0254）夾右端（1：10錐度一邊）頂右端中心孔，粗車左端外圓?95??0.003mm，粗

車左端所有軸徑，粗車拐徑外側(cè)左、右端面，保證拐徑外側(cè)的對(duì)稱性及尺寸，粗銑凸臺(tái)?25。

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攀枝花學(xué)院本科畢業(yè)設(shè)計(jì)2工藝規(guī)程設(shè)計(jì)

5）夾右端，左端上中心架車端面，去長(zhǎng)短保證總長(zhǎng)尺寸610mm，鉆左端中心孔，鉆左端?6的孔，深16.8mm，锪60°角，深7.8mm，再锪120°角，深1.8mm。

0.0366）粗車拐徑?95??0.071mm尺寸。0.0367）精車拐徑?95??0.071mm尺寸。

0.0258）夾左端，頂右端中心孔，精車右端軸徑?95??0.003mm，長(zhǎng)度尺寸至87mm，保

證曲拐端面60mm尺寸，精車右端軸徑?93至圖示長(zhǎng)度12mm。

0.0259）夾右端，頂左端中心孔，精車左端軸徑?95??0.003mm，長(zhǎng)度尺寸至85mm，保

曲拐端面60mm尺寸。

0.025?0.2210）以兩中心孔定位，磨左端軸徑?95?mm，磨左端軸徑?90?0.003?0.57mm。0.02511）以兩中心孔定位，倒頭裝夾，磨左端軸徑?95??0.003mm。

12）底面60mm×115mm，以兩側(cè)面定位并壓緊，保證距中心高70mm，總高236mm。13）以兩軸徑定位壓緊鉆、攻4—M20螺紋。

0.03614）以兩端中心孔定位，精磨拐徑?95??0.071mm至圖樣尺寸，磨圓角R6。0.02515）以兩端中心孔定位，精磨兩軸徑?95??0.003mm至圖樣尺寸，磨圓角R6，精0.22磨?90??0.57mm至圖樣尺寸，倒角2.5×45°。

16）夾右端，頂右端中心孔車1：10圓錐，留余量1.5mm。17）以兩端中心孔定位，磨1：10圓錐?86長(zhǎng)124mm，磨圓角R6。18）粉探傷各軸徑，拐徑。

0.02519）劃鍵槽線24mm×110mm，銑鍵槽，以兩軸徑?95??0.003mm定位，采用專用

工裝裝夾銑鍵槽24mm×110mm至圖樣尺寸。

0.520）銑右端軸徑?93mm的槽44??0.2mm至圖樣尺寸。

?0.08421）粗鏜、精鏜右端?300mm孔至圖樣尺寸，深75mm。锪60°角，深5.5mm，

再锪120°角，深2mm。。

0.03622）重新裝夾工件，采用專用工裝裝夾，鉆拐徑?95??0.071mm兩斜油孔?8mm。

27）鉗工，修油孔，倒角，清污垢。28）檢查。工藝路線方案（二）：

1）畫線，以毛坯外形找正，劃主要加工線，偏心距100?0.1mm及外形加工。2）劃軸兩端中心孔線，顧各部加工余量。

0.0253）工件平放在鏜床工作臺(tái)上，壓軸95??0.003mm兩處，鉆右端中心孔。0.0254）夾右端（1：10錐度一邊）頂右端中心孔，粗車左端外圓?95??0.003mm，粗

車左端所有軸徑，粗車拐徑外側(cè)左、右端面，保證拐徑外側(cè)的對(duì)稱性及尺寸，粗銑凸臺(tái)?25。

5）夾右端，左端上中心架車端面，去長(zhǎng)短保證總長(zhǎng)尺寸610mm，鉆左端中心

6

攀枝花學(xué)院本科畢業(yè)設(shè)計(jì)2工藝規(guī)程設(shè)計(jì)

按[3]表3.1-22可得，與500.8r/min相近的轉(zhuǎn)速為540r/min，則實(shí)際速度

?dn3.14?95?540V??0??161.1m/min。

100010005)計(jì)算切削工時(shí)：按[3]表2.5-3，取

被切削層長(zhǎng)度l：由毛坯尺寸可知L=123mm刀具切入長(zhǎng)度l1：L1=ap/tgkr+(2~3)主偏角kr=0,L1=2mm刀具切出長(zhǎng)度l2：取l2?0mm本工序機(jī)動(dòng)時(shí)間tm：

tm?l?l1?l2?l3123?2i?min?1.157min

nwf540?0.20.025工序7：精車右端軸徑?95??0.003mm

機(jī)床：CW6180B臥式車床刀具：YG61)被吃刀量ap：ap=0.6mm。

2)進(jìn)給量f：根據(jù)[3]表2.4-4，預(yù)估切削速度VC?1.33，取f?0.2mm/r。3)切削速度：

按[2]表1.27，切削速度計(jì)算公式（壽命選T=60min）。vc?cvkyvvmxvTapf式中：cv?189.8,xv?0.15,yv?0.2,m?0.2kv見(jiàn)[2]表1.28，即

kmv?1.44,ksv?0.8,kkv?1.04,kkrv?0.81,kbv?0.97所以：

189.8?01.44?0.8?1.04?0.81?0.97m/min?149.4m/minvc?0.20.15.3560?0.6?0.24)機(jī)床主軸轉(zhuǎn)速：ns?vc?切削速度

1000vc1000?149.4?r/min≈500.8r/min?dw??95dw?曲軸直徑

按機(jī)床說(shuō)明書，與500.8r/min相近的轉(zhuǎn)速為540r/min，則實(shí)際速度?dn3.14?95?540V??0??161.1m/min。

100010005)計(jì)算切削工時(shí)：按[3]表2.5-3，取

被切削層長(zhǎng)度l：由毛坯尺寸可知L=74mm刀具切入長(zhǎng)度l1：L1=ap/tgkr+(2~3)

17

攀枝花學(xué)院本科畢業(yè)設(shè)計(jì)2工藝規(guī)程設(shè)計(jì)

主偏角kr=0,L1=2mm刀具切出長(zhǎng)度l2：取l2?0mm

本工序機(jī)動(dòng)時(shí)間tm：

l?l1?l2?l374?2tm?i?min?0.70min

nwf540?0.2

工序8：精車右端軸徑?93mm

機(jī)床：CW6180B臥式車床刀具：YG61)被吃刀量ap：ap=0.6mm。

2)進(jìn)給量f：根據(jù)[3]表2.4-4，預(yù)估切削速度VC?1.33，取f?0.2mm/r。3)切削速度：

按[2]表1.27，切削速度計(jì)算公式（壽命選T=60min）。

vc?cvkyvvmxvTapf式中：cv?189.8,xv?0.15,yv?0.2,m?0.2kv見(jiàn)[2]表1.28，即

kmv?1.44,ksv?0.8,kkv?1.04,kkrv?0.81,kbv?0.97所以：

vc?189.82.15600.?0.60?0.2?01.44?0.8?1.04?0.81?0.97m/min?149.4m/min.354)機(jī)床主軸轉(zhuǎn)速：ns?1000vc1000?149.4?r/min≈511.6r/min?dw??93vc?切削速度dw?曲軸直徑

按[3]表3.1-22可得，與511.6r/min相近的轉(zhuǎn)速為540r/min，則實(shí)際速度?dn3.14?93?540V??0??157.6m/min。

100010005)計(jì)算切削工時(shí)：按[3]表2.5-3，取

被切削層長(zhǎng)度l：由毛坯尺寸可知L=12mm刀具切入長(zhǎng)度l1：L1=ap/tgkr+(2~3)主偏角kr=0,L1=2mm刀具切出長(zhǎng)度l2：取l2?0mm

本工序機(jī)動(dòng)時(shí)間tm：

l?l1?l2?l312?2tm?i?min?0.13min

nwf540?0.20.025工序9：精車左端軸徑?95??0.003mm

18

攀枝花學(xué)院本科畢業(yè)設(shè)計(jì)2工藝規(guī)程設(shè)計(jì)

機(jī)床：CW6180B臥式車床刀具：YG61)被吃刀量ap：ap=0.6mm。

2)進(jìn)給量f：根據(jù)[3]表2.4-4，預(yù)估切削速度VC?1.33，取f?0.2mm/r。3)切削速度：

按[2]表1.27，切削速度計(jì)算公式（壽命選T=60min）。vc?cvkyvvmxvTapf式中：cv?189.8,xv?0.15,yv?0.2,m?0.2kv見(jiàn)[2]表1.28，即

kmv?1.44,ksv?0.8,kkv?1.04,kkrv?0.81,kbv?0.97所以：

189.8?1.44?0.8?1.04?0.81?0.97m/min?149.4m/minvc?0.260?0.60.15?0.20.354)機(jī)床主軸轉(zhuǎn)速：ns?1000vc1000?149.4?r/min≈500.8r/min?dw??95vc?切削速度

dw?曲軸直徑

按[3]表3.1-22可得，與500.8r/min相近的轉(zhuǎn)速為540r/min，則實(shí)際速度

V???dwn1000?3.14?95?540?161.1m/min。

10005)計(jì)算切削工時(shí)：按[3]表2.5-3，取被切削層長(zhǎng)度l：由毛坯尺寸可知L=85mm刀具切入長(zhǎng)度l1：L1=ap/tgkr+(2~3)主偏角kr=0,L1=2mm刀具切出長(zhǎng)度l2：取l2?0mm本工序機(jī)動(dòng)時(shí)間tm：

tm?l?l1?l2?l385?2i?min?0.81min

nwf540?0.2工序10：精銑底面60mm×115mm機(jī)床：X62W銑床

刀具：硬質(zhì)合金端銑刀YG6dw?320mm，齒數(shù)Z?121)銑削深度ap：ap?1.5mm

2)每齒進(jìn)給量af：根據(jù)[3]表2.4-73，取af?0.15mm/Z3)銑削速度V：參照[3]表2.4-81，取V?3.5m/s機(jī)床主軸轉(zhuǎn)速n：n?1000V1000?3.5?60??209r/min，取n?235r/min?dw3.14?32023

攀枝花學(xué)院本科畢業(yè)設(shè)計(jì)2工藝規(guī)程設(shè)計(jì)

V?切削速度

dw?曲軸直徑實(shí)際銑削速度V?：V???dwn1000?3.14?320?235?3.94m/s

1000?604)給量Vf：Vf?afZn?0.15?12?200/60?6mm/s工作臺(tái)每分進(jìn)給量fm：fm?Vf?6mm/s?360mm/min5)刀具切入長(zhǎng)度l1：精銑時(shí)l1?D?320mm由工序3可知：l?118mml2?3mm走