2269 薄壁墻板零件的工藝分析、專用夾具設(shè)計(jì)、數(shù)控加工

2269 薄壁墻板零件的工藝分析、專用夾具設(shè)計(jì)、數(shù)控加工,薄壁,零件,工藝,分析,專用,夾具,設(shè)計(jì),數(shù)控,加工 中原工學(xué)院畢 業(yè) 論 文 (設(shè) 計(jì) )開 題 報(bào) 告課題名稱：薄壁墻板零件的工藝分析、專用夾具設(shè)計(jì)、數(shù)控加工 畢業(yè)設(shè)計(jì)起止時(shí)間：2006 年 3 月 5 日 6 月 25 日(共 17 周)學(xué)生姓名： 學(xué)號(hào)：專 業(yè)： 班級(jí)： 指導(dǎo)教師： 報(bào)告日期： 1本課題所涉及的內(nèi)容國內(nèi)(外) 研究現(xiàn)狀綜述機(jī)器零件的尺寸、形狀、位置等精度要求按實(shí)際使用情況各有所側(cè)重，某些零件精度雖然要求不高，由于結(jié)構(gòu)形狀上的因素(形狀尺寸大、厚度薄、剛性差)，卻難以保證所要求的加工精度。例如紡織機(jī)械中的絡(luò)絲機(jī)、并絲機(jī)和捻絲機(jī)等薄壁墻板零件，加工工藝過程中出現(xiàn)的一些質(zhì)量問題，大致都屬于這種情況。而在薄壁墻板的加工工藝中的夾具選擇是一個(gè)在眾多生產(chǎn)問題中需要國內(nèi)外都急需解決的現(xiàn)狀。在機(jī)械加工的成組批量生產(chǎn)中選擇合適的夾具是機(jī)械加工中的一個(gè)關(guān)鍵問題，夾具選擇不合理，會(huì)導(dǎo)致夾具體出現(xiàn)體積大，精度差，輔助時(shí)間長，工序繁瑣等諸多問題，直接影響到生產(chǎn)效率，造成生產(chǎn)成本偏高。在現(xiàn)時(shí)的一些工廠中，采用普通設(shè)備加工零件時(shí)，有很多仍然采用手動(dòng)夾緊的方法，尤其在大尺寸零件的加工過程中存在夾具選擇不合理的問題。例如在生產(chǎn)梳棉機(jī)道夫圓墻板零件時(shí)，由于零件的整體外形尺寸較大，傳統(tǒng)的手動(dòng)夾緊夾具存在很明顯的輔助時(shí)間長的缺點(diǎn)。在薄壁墻板的生產(chǎn)中，大多也是采用手動(dòng)夾緊，然而在要求大批量生產(chǎn)工件時(shí)，需要頻繁的扳動(dòng)螺來夾緊或松開工件，同時(shí)還必須注意夾緊力的大小和工件的相對(duì)位置保證加工精度，可見傳統(tǒng)夾具體的手動(dòng)夾緊是很不合理的，不僅夾緊時(shí)費(fèi)力而且很難保證加工精度，而且存在安全隱患。傳統(tǒng)夾具生產(chǎn)效率低，主要是因?yàn)楣と嗽诩庸み^程中要同時(shí)對(duì)三個(gè)壓板都進(jìn)行夾緊操作，在夾緊中因?yàn)椴荒鼙ＷC三個(gè)壓板的壓緊力，在加工過程中工件容易發(fā)生震動(dòng)，影響加工精度 針對(duì)這一問題我們?cè)趥鹘y(tǒng)夾具的基礎(chǔ)上，嘗試引入鉸桿杠桿式壓板和汽缸組合元件，使用氣動(dòng)夾緊代替原來的手動(dòng)夾緊，以此來尋求提高生產(chǎn)效率的方法。在氣壓傳動(dòng)夾具中，活塞桿端作為壓緊力輸出裝置直接加壓于工件的情況極少在實(shí)際生產(chǎn)中，下列兩種夾緊方式比較常用：1） 通過杠桿式壓板夾緊工件；2）通過鉸桿杠桿式壓板夾緊工件。由于鉸桿杠桿式壓板屬于二次串聯(lián)曾力機(jī)構(gòu)，曾力效果要明顯高于杠桿式壓板，因而在加工過程中工件所需壓緊力一定的條件下，二次串聯(lián)曾力機(jī)構(gòu)能顯著減小汽缸的直徑引入鉸桿杠桿式壓板和汽缸元件。同時(shí)在生產(chǎn)薄壁墻板或者其他零件時(shí)都要求采用工序集中，減少工件裝夾次數(shù)，特別是當(dāng)該零件各加工表面有相互位置精度要求時(shí)，最適宜在一次裝夾中把各表面都加工出來，這樣既有利于保證這些表面的相互位置，又可以減少裝卸工件的輔助時(shí)間。因此，在薄壁墻板零件的生產(chǎn)中，要保證其加工精度的要求，我認(rèn)為目前需要在夾具的選擇以及夾具夾緊方面進(jìn)行改善，也就是用于薄壁墻板的的各個(gè)表面的加工或者是孔加工的夾具設(shè)計(jì)進(jìn)行探討。改進(jìn)生產(chǎn)是各大廠家提高生產(chǎn)效率主要攻堅(jiān)項(xiàng)目，機(jī)械加工效率是夾具系統(tǒng)合理性的綜合反映。在傳統(tǒng)薄壁墻板的加工夾具的基礎(chǔ)上提出改進(jìn)，這樣夾具在具有傳統(tǒng)夾具優(yōu)點(diǎn)的同時(shí)，具有了更強(qiáng)的靈活性和可靠性，大大提高了機(jī)械加工的效率完全滿足現(xiàn)代夾具高效。同時(shí)對(duì)于其他類型的零件的加工業(yè)可以基于同類原理進(jìn)行借鑒此類夾具系統(tǒng)。夾具作為工藝系統(tǒng)中重要的一部分還有很大的技術(shù)空間，也有很大的市場(chǎng)前景。但很多企業(yè)不是很重視這一道工序，對(duì)其投入不大，所以在設(shè)計(jì)過程中要盡量注重起制造成本。2本課題有待解決的主要關(guān)鍵問題經(jīng)過三個(gè)禮拜的畢業(yè)調(diào)研和查閱資料，我對(duì)本課題的主要意圖還是有一定的了解，大至了解了要完成的設(shè)計(jì)任務(wù)，綜合起來，我認(rèn)為最需要解決的主要問題有：根據(jù)選定機(jī)床及數(shù)控系統(tǒng)編制數(shù)控加工程序和根據(jù)數(shù)控加工工藝確定裝夾方案，設(shè)計(jì)專用夾具一套，加工過程中零件的裝夾。機(jī)床和數(shù)控系統(tǒng)的選定是根據(jù)給定的零件圖紙對(duì)零件進(jìn)行工藝分析，確定若干工藝方案，再對(duì)工藝方案進(jìn)行比較，確定最終方案。方案確定之后選擇數(shù)控加工設(shè)備、切削刀具、切削用量以及數(shù)控加工工藝設(shè)計(jì)。最后根據(jù)數(shù)控加工機(jī)床和零件工藝方案編制數(shù)控加工程序，根據(jù)數(shù)控加工工藝設(shè)計(jì)夾具。關(guān)鍵問題就在程序的編制和夾具的設(shè)計(jì)。3對(duì)課題要求及預(yù)期目標(biāo)的可行性分析 (包括解決關(guān)鍵問題技術(shù)和所需條件兩方面)上述已經(jīng)闡述了需要解決的關(guān)鍵問題是程序的編制和夾具的設(shè)計(jì)。程序的編制需要把以前學(xué)過的數(shù)控技術(shù)相關(guān)內(nèi)容進(jìn)行相應(yīng)的復(fù)習(xí)，重新去認(rèn)識(shí)數(shù)控機(jī)床上程序的編制，根據(jù)給定任務(wù)書的零件確定零件工藝方案，結(jié)合數(shù)控技術(shù)課本的 NC程序設(shè)計(jì)對(duì)零件的加工編制出數(shù)控程序。要解決這一方面問題必須要借助于相關(guān)的理論書籍，當(dāng)然這還遠(yuǎn)遠(yuǎn)不夠，雖然當(dāng)今的網(wǎng)絡(luò)共享很豐富，使我對(duì)數(shù)控程序編制的了解有幫助，但還是需要我的個(gè)人付出努力，畢竟網(wǎng)絡(luò)資源是有限的。因此這一問題的解決必須要多向?qū)熣?qǐng)教，有需要的話還要到廠去找相關(guān)的數(shù)據(jù)資料。 夾具結(jié)構(gòu)的選擇取決于加工后的表面狀況，如機(jī)械加工、電火花加工，磨加工等等。所以要解決這一問題不僅要對(duì)一般的夾具結(jié)構(gòu)有所了解，還要對(duì)零件的材料特性，加工前的表面狀況和加工后的表面要求有詳盡的了解。目前的數(shù)控夾具結(jié)構(gòu)有很多種，但是要找到一種適用薄壁墻板零件加工的方法對(duì)薄壁墻板的加工精度要求幾乎符合理論程度，還有待于對(duì)各種夾具方案的深入了解，通過相互比較，最后選擇一種加工效率高并經(jīng)濟(jì)效益好的裝夾方法。總之，完成這一項(xiàng)目需要多查閱相關(guān)的資料和自己不斷的思考創(chuàng)新。4完成本課題的工作計(jì)劃及進(jìn)度安排3.8-3.21 調(diào)研與實(shí)習(xí)，英文文獻(xiàn)翻譯及編寫實(shí)習(xí)報(bào)告。3.224.18 總體方案設(shè)計(jì)，工藝方案，裝夾方案設(shè)計(jì)。寫出方案論證報(bào)告。4.194.30 加工工藝草案，專用夾具草圖。5.16.9 數(shù)控加工方案設(shè)計(jì)，機(jī)床，刀具及切削用量選擇與計(jì)算。詳細(xì)設(shè)計(jì)（工藝，夾具，程序） ，整理設(shè)計(jì)任務(wù)書。6.116.16 定稿6.186.23 評(píng)審6.176.19 畢業(yè)答辯6.196.25 修改畢業(yè)設(shè)計(jì)5指導(dǎo)教師審閱意見指導(dǎo)教師(簽字)： 年 月 日6指導(dǎo)小組意見指導(dǎo)小組組長(簽字)： 年 月 日 說明：1. 本報(bào)告前 4 項(xiàng)內(nèi)容由承擔(dān)畢業(yè)論文(設(shè)計(jì)) 課題任務(wù)的學(xué)生獨(dú)立撰寫；2. 本報(bào)告必須在第八學(xué)期開學(xué)兩周內(nèi)交指導(dǎo)教師審閱并提出修改意見；3. 學(xué)生須在小組內(nèi)進(jìn)行報(bào)告，并進(jìn)行討論；4. 本報(bào)告作為指導(dǎo)教師、畢業(yè)論文(設(shè)計(jì)) 指導(dǎo)小組審查學(xué)生能否承擔(dān)該畢業(yè)設(shè)計(jì) (論文)課題和是否按時(shí)完成進(jìn)度的檢查依據(jù)，并接受學(xué)校的抽查。數(shù)控加工程序題目名稱：薄壁墻板零件的工藝分析、專用夾具設(shè)計(jì)、數(shù)控加工院系名稱：機(jī)電學(xué)院班 級(jí)： 學(xué) 號(hào)： 學(xué)生姓名： 指導(dǎo)教師： O001(粗銑上平面.cut)N08 G92 X0.000 Y0.000 Z200.000N10 T01 M06N12 G90 G00 G54 X-175.000 Y55.000 S298 Mo3 N14 G43 Z200.000 H01N16 G41 D01N20 G01 X-71.239 F596N28 G02 X71.239 Y55.000 I71.239 J-55.000N30 G01 X175.000N32 Z97.000 F596N34 G00 X-175.000 Y60.000N36 Z97.000N38 G01 Z97.000 F596N40 X-67.082 F596N42 G02 X67.082 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