料斗移動(dòng)小車設(shè)計(jì)【含CAD圖紙、說明書】

【溫馨提示】壓縮包內(nèi)含CAD圖有下方大圖片預(yù)覽，下拉即可直觀呈現(xiàn)眼前查看、盡收眼底縱觀。打包內(nèi)容里dwg后綴的文件為CAD圖，可編輯，無水印，高清圖，壓縮包內(nèi)文檔可直接點(diǎn)開預(yù)覽，需要原稿請自助充值下載，所見才能所得，請見壓縮包內(nèi)的文件及下方預(yù)覽，請細(xì)心查看有疑問可以咨詢QQ：11970985或197216396 壓縮包內(nèi)含有CAD圖紙和說明書,咨詢Q 197216396 或 11970985摘 要 隨著時(shí)代不斷的發(fā)展鋼鐵行業(yè)向著高速、重載、運(yùn)載能力的跨越式發(fā)展。好多生產(chǎn)車間的工作量以及效率在不斷加大和提高，這樣對車間的物流速度要求也有了進(jìn)一步提升。先前靠單一的天車來搬動(dòng)工件已經(jīng)完全不能滿足現(xiàn)代高效率的生產(chǎn)要求，同時(shí)這種大馬拉小車的搬運(yùn)方式也成為了一種典型的浪費(fèi)。因此車間內(nèi)需要這種具有結(jié)構(gòu)簡易、承載能力大、使用方便、容易保養(yǎng)、使用壽命長得料斗小車來保證搬運(yùn)的暢通，我所設(shè)計(jì)的料斗移動(dòng)小車就完全適應(yīng)社會的需求。 我設(shè)計(jì)的料斗移動(dòng)小車又叫過跨電動(dòng)平車，在經(jīng)過大量閱讀料斗小車書本的基礎(chǔ)上，我從小車生產(chǎn)需求方面出發(fā)，設(shè)計(jì)了50T的電動(dòng)平板車樣機(jī)。 關(guān)鍵詞：平板車 強(qiáng)度 軌道車輪 壓縮包內(nèi)含有CAD圖紙和說明書,咨詢Q 197216396 或 11970985Abstract With the development of the era constantly steel industry towards high speed, overload, leapfrog development capacity. A lot of work and efficiency of production workshop in growing and improving, so logistics speed requirements of workshop has a further increase. Prior to move the workpiece by a single crown has been completely can not meet the requirement of the modern high efficient production, at the same time the large mara car handling way has also become a kind of typical waste. So the workshop need this has simple structure, convenient use, large carrying capacity, easy maintenance, long service life of the hopper electric flat car to ensure smooth handling of so I designed hopper electric car was completely adapt to the demand of the society.Ive designed hopper car is primarily a cross electric flat car, after extensive reading on the basis of related literature, I based on actual production demand, the 50 t electric flat car prototype design.I have mainly introduced the cross in the design of electric flat car overall design theory and design process, including a across the overall design of electric flat car running mechanism and transmission mechanism, across to the layout of the electric flat car body, car running mechanism calculation. Calculation in the design of shaft and bearing selection, the selection and design of the bearing, gear motor selection, the design of the shaft.Keywords：Flat carbstrength Rail wheels壓縮包內(nèi)含有CAD圖紙和說明書,咨詢Q 197216396 或 11970985目錄 摘 要IIIAbstractIV1緒 論12料斗移動(dòng)小車設(shè)計(jì)綜述22.1料斗移動(dòng)小車概況22.2料斗移動(dòng)小車的類型23料斗移動(dòng)小車的控制系統(tǒng)33.1PLC控制系統(tǒng)示意圖33.2開關(guān)量I/O模塊33.3元器件的選用33.4料斗移動(dòng)小車的工作流程44料斗移動(dòng)小車電氣控制系統(tǒng)設(shè)計(jì)64.1 I/O端口分配：64.2資源詳細(xì)分配：64.3變頻器的端子接線：74.4 PLC控制程序設(shè)計(jì)75料斗移動(dòng)小車車輪類型的選用115.1車輪的材料選用115.2車輪的結(jié)構(gòu)選用115.3車輪的直徑選則116料斗移動(dòng)小車傳動(dòng)系統(tǒng)結(jié)構(gòu)的設(shè)計(jì)與計(jì)算136.1設(shè)計(jì)參數(shù)：136.2電動(dòng)機(jī)的類型選用：136.3電動(dòng)機(jī)的功率選用136.4電動(dòng)機(jī)轉(zhuǎn)速的選用146.5電動(dòng)機(jī)型號的選用146.6 計(jì)算總傳動(dòng)比和分配各級傳動(dòng)比146.7計(jì)算傳動(dòng)裝置的運(yùn)動(dòng)和動(dòng)力參數(shù)156.8減速器的計(jì)算與選用157行走機(jī)構(gòu)的設(shè)計(jì)177.1主動(dòng)輪軸的設(shè)計(jì)177.2從動(dòng)輪軸的設(shè)計(jì)198車架的設(shè)計(jì)218.1材料選用218.2結(jié)構(gòu)選用219三維建模2210.結(jié)論24參考文獻(xiàn)25致 謝27VIII壓縮包內(nèi)含有CAD圖紙和說明書,咨詢Q 197216396 或 119709851緒 論我設(shè)計(jì)的料斗小車，它在使用過程中比較便利、整個(gè)機(jī)器的結(jié)構(gòu)比較簡單、使用以后的維修和維護(hù)既方便又容易、而且這個(gè)車不怕臟不怕砸、使用壽命比較長，而且它對提高生產(chǎn)能力，保證產(chǎn)品質(zhì)量，減輕勞動(dòng)強(qiáng)度，降低成本，提高運(yùn)輸效率，加快物資周轉(zhuǎn)、流通等方面有著重要影響，尤其能提高安全生產(chǎn)的能力，減小事故的發(fā)生，因此車具有的便利、耐實(shí)、經(jīng)濟(jì)、實(shí)用、好清理等優(yōu)點(diǎn)，因而在廠里應(yīng)用廣泛。 28壓縮包內(nèi)含有CAD圖紙和說明書,咨詢Q 197216396 或 119709852料斗移動(dòng)小車設(shè)計(jì)綜述2.1料斗移動(dòng)小車概況料斗移動(dòng)小車簡稱平車，是一種廠內(nèi)搬運(yùn)類型小車，通常情況下它的臺面平整而且是沒有箱蓋的，只有在特殊的情況下臺面是不平整但是沒有箱蓋，車體主要靠軌道前進(jìn)，后退和拐彎，它主要是通過電力作用進(jìn)行驅(qū)動(dòng)小車，靠減速電機(jī)自動(dòng)運(yùn)行，因?yàn)樗峭ㄟ^軌道運(yùn)行所以需要在地面上鋪設(shè)軌道，此次我采用工字型面接觸類型的軌道。2.2料斗移動(dòng)小車的類型低壓軌道供電式電動(dòng)平車：主要運(yùn)行的軌道當(dāng)做導(dǎo)電軌來使用，它是通過滑觸線連接軌道從而進(jìn)行供電，不用電纜，提高了安全性，對環(huán)境要求不高但是對軌道施工要求較高，必須保證軌道絕緣，所以成本較高。卷筒供電式電動(dòng)平車：主要是電纜提供380V的交流電，由于電纜是磁滯耦合式，所以電纜受力均勻，不容易拉壞掉，但是卷線筒長度不是無限長，所能行走的最大運(yùn)行距離要小于100m，受到限制。蓄電池供電式電平車:它無需電纜，所以安全性好，不怕砸，不怕燙，因而對軌道要求不高，軌道不需要絕緣，但是蓄電池供電式不能長時(shí)間連續(xù)工作，要是長時(shí)間工作，中間要充電，而且充電時(shí)間比較長，只適合在工作強(qiáng)度不高的環(huán)境下。拖鏈電纜供電式：它噪聲小，使用裝拆方便，可靠性高,維護(hù)少，節(jié)省空間，成本也比較低，還可以防止沖擊，主要適用于運(yùn)行速度高，往返運(yùn)行頻率高以及工作環(huán)境條件差的地方。所以本文中我所選的就是拖鏈電纜供電式。 料斗移動(dòng)小車的控制系統(tǒng)3料斗移動(dòng)小車的控制系統(tǒng)3.1PLC控制系統(tǒng)示意圖圖3.1 PLC控制系統(tǒng)示意圖3.2開關(guān)量I/O模塊開關(guān)量模塊的輸入輸出信號分為兩種，一種是接通，另外一種是斷開。電壓等級有交流110V，220V和直流5V，12V，24V，48V等。開關(guān)量I/O模塊可能4，8，16，32，64點(diǎn)。3.3元器件的選用3.3.1變頻器變頻器就是可以通過頻率和電壓固定不變的交流電從而轉(zhuǎn)化為頻率或者電壓可變的交流電。變頻器可以啟動(dòng)重載負(fù)荷，也可以達(dá)到節(jié)能調(diào)速的目的，另外變頻器還有的優(yōu)點(diǎn)就是過載保護(hù)、過壓、過流等其他的功能。它應(yīng)用了現(xiàn)代的技術(shù)，雖然內(nèi)部結(jié)構(gòu)復(fù)雜但是使用起來很方便，所以用途廣泛。3.3.2可編程控制器三菱生產(chǎn)的PLC 特別事FX2N系列在我國應(yīng)用很多，該系列PLC的運(yùn)算速度快，編程簡單，可以擴(kuò)展模塊，質(zhì)量可靠，價(jià)格也比較能讓人接受，所以我選擇FX2N系列繼電器輸出的PLC。3.3.3元器件選型表需要增加的元器件如表1所示。表3.7.1.元器件選型名稱品牌型號（規(guī)格）數(shù)量備注可編制控制器三菱FX2N-32MT1傳感器TRUCKAP6X-BI304變頻器ABBAC550-01-246A-41繼電器歐姆龍MY2J924V開關(guān)電源施耐德ABL2REM24150H124V其他一些元器件就保留利用原系統(tǒng)已有的，如交流接觸器，電流表，電壓表等，要做到物盡其用，節(jié)約成本的目的。3.4料斗移動(dòng)小車的工作流程料斗移動(dòng)小車裝滿貨物向目的地以30m/min的速度運(yùn)行，在離目的地還有3m處感應(yīng)到減速接近開關(guān)則電動(dòng)平車減速為10m/min運(yùn)行，當(dāng)電動(dòng)平車感應(yīng)到停車接近開關(guān)則電動(dòng)平車剎車，然后電動(dòng)平車停車，卸貨后的電動(dòng)平車空載以50m/min速度返回，在距啟運(yùn)地還有2m處感應(yīng)到減速接近開關(guān)則電動(dòng)平車減速為15m/min運(yùn)行，當(dāng)電動(dòng)平車感應(yīng)到停車接近開關(guān)則電動(dòng)平車剎車，電動(dòng)平車停車，裝貨，由此進(jìn)行一個(gè)裝貨與卸貨的循環(huán)。電動(dòng)平車運(yùn)行途中如遇緊急情況，按下急停按鈕，電動(dòng)平車在空載時(shí)立即變頻器與機(jī)械同時(shí)剎車停車，電動(dòng)平車在滿載時(shí)變頻器剎車2秒內(nèi)停車。變頻器內(nèi)的停車參數(shù)設(shè)為積分停車。對于容量比較大的交流電動(dòng)機(jī)，我們使用的是Y-降壓啟動(dòng)。它的工作流程如下：在電動(dòng)機(jī)開始啟動(dòng)時(shí)使用的是形連接，通過一定的時(shí)間后，它會自己切換到Y(jié)形連接，然后開始工作。Y-的轉(zhuǎn)換是通過兩個(gè)接觸器相互之間的切換來完成，它主要是由PLC的輸出點(diǎn)來控制。在正轉(zhuǎn)的時(shí)候，當(dāng)我們只有按下正轉(zhuǎn)開關(guān)的時(shí)候它才會有反應(yīng)，按下其他開關(guān)沒任何反應(yīng)，當(dāng)我們按下停止的開關(guān)時(shí)，電動(dòng)機(jī)停止工作，按下反轉(zhuǎn)按鈕，啟動(dòng)Y形連接，此時(shí)如果我們按下正轉(zhuǎn)按鈕的時(shí)候，系統(tǒng)是沒有任何反應(yīng)的，從而達(dá)到連鎖保護(hù)的作用。圖3.8.2 料斗電動(dòng)平車工作流程圖 料斗移動(dòng)小車電氣控制系統(tǒng)設(shè)計(jì)4料斗移動(dòng)小車電氣控制系統(tǒng)設(shè)計(jì)4.1 I/O端口分配：輸入端口如下表所示。表4.1.2輸入端口分配端口名稱序號端口名稱序號端口名稱序號急停按鈕X0復(fù)位按鈕X4返回到達(dá)接近開關(guān)X10啟動(dòng)按鈕X1前進(jìn)減速接近開關(guān)X5變頻器故障輸入X11前進(jìn)按鈕X2前進(jìn)到達(dá)接近開關(guān)X6卸料X12返回按鈕X3返回減速接近開關(guān)X7.輸出端口如下表所示。表4.1.3輸出端口分配端口名稱序號端口名稱序號端口名稱序號報(bào)警輸出Y0滿載轉(zhuǎn)速Y3空載減速Y6變頻器啟動(dòng)Y1空載轉(zhuǎn)速Y4剎車Y7前進(jìn)（返回）Y2滿載減速Y5卸料Y104.2資源詳細(xì)分配：如下表所示：表4.2.4資源分配4.3變頻器的端子接線：如圖3所示KA4KA6KA2KA124VGNDCOMMDI1DI2輔助電壓輸出+24V輔助電壓輸出公共端所有數(shù)字輸入公共端電動(dòng)平車得電啟動(dòng)電動(dòng)平車得電反轉(zhuǎn)U1V1W1PEU2V2W2L1L2L33 M變頻器接線端R03CR03AR03BCOMX11變頻器故障輸出KA3DI3DI4DI2電動(dòng)平車滿載速度電動(dòng)平車空載速度電動(dòng)平車滿載減速電動(dòng)平車空在減速DI2KA5圖4.3.3變頻器的端子接線圖程序控制：實(shí)現(xiàn)簡單的裝料向前，到達(dá)后卸料，然后再返回裝料。4.4 PLC控制程序設(shè)計(jì)裝料完成后（在不超重的情況下）按下X1啟動(dòng)按鈕，變頻器通電，按下X2前進(jìn)按鈕，復(fù)位Y2,Y2=0不輸出信號，變頻器為前進(jìn)狀態(tài)，置位M2，M2=1，變頻器以滿載速度運(yùn)行，小車以30m/min的速度前行。當(dāng)小車在前進(jìn)到達(dá)處3M感應(yīng)到前進(jìn)減速接近開關(guān)時(shí)，置位M4,M2,M4=1,M2=0則Y3=0,Y3常閉觸點(diǎn)閉合，Y5=1，變頻器減速，小車以10m/min的速度前行。當(dāng)小車感應(yīng)到前進(jìn)到達(dá)接近開關(guān)時(shí)，復(fù)位M4,M4=0,Y5=0,同時(shí)置M10,M10=1,小車剎車，按下卸料按鈕，小車開始卸料。卸料完成，按下復(fù)位按鈕SB4，小車剎車松開，準(zhǔn)備返回然后開始循環(huán)工作。 料斗移動(dòng)小車車輪類型的選用5料斗移動(dòng)小車車輪類型的選用料斗移動(dòng)小車通過車輪的旋轉(zhuǎn)來實(shí)現(xiàn)前后的移動(dòng)，因而車輪不僅僅支持了整個(gè)料斗小車的運(yùn)行，更加承受了料斗小車的自重和小車上物品的重量，車輪一般有有軌運(yùn)行的車輪和無軌運(yùn)行的車輪，本設(shè)計(jì)我采用的是有軌運(yùn)行的車輪。5.1車輪的材料選用我們一般根據(jù)驅(qū)動(dòng)方式和工作級別來確定車輪的材料。當(dāng)車輪用于機(jī)械驅(qū)動(dòng)且速度大于等于30m/min時(shí)，我們選擇中級及中級以上的工作類型，采用不低于ZG55的鑄鋼，并進(jìn)行表面淬火（高頻淬火或火焰淬火），硬度需大于等于HB=300-350，淬火深度不得小于5mm，這樣有助于提高車輪表面的耐磨性和延長它的使用壽命。當(dāng)車輪需要人力驅(qū)動(dòng)或機(jī)械驅(qū)動(dòng)，并且工作類型屬于輕級的時(shí)候，速度小于30m/min時(shí)，可采用鑄鐵車輪，表面硬度為HB=180-240。在我的這次設(shè)計(jì)中，通過翻閱起重機(jī)械設(shè)計(jì)手冊，我所涉及的料斗小車通過機(jī)械進(jìn)行驅(qū)動(dòng)，運(yùn)行速度為30m/min，工作級別為中級。所以本設(shè)計(jì)中，我采用的車輪材料為ZG55的鑄鋼，并且對他進(jìn)行表面淬火，淬火要求表面硬度HB=300-350，淬火深度不少于20mm（距離踏面20mm深處硬度不小于HB=180-240）。5.2車輪的結(jié)構(gòu)選用車輪按輪緣形式可分為雙緣的型式、單緣的型式的和無緣的型式。雙輪緣一般用于大車中，單輪緣一般用于小車中。輪緣的作用是導(dǎo)向和防止脫軌。車輪的踏面主要有圓錐的形式、圓柱的形式和鼓形，大多數(shù)的大型的起重機(jī)采用圓錐和圓柱形。因我設(shè)計(jì)的料斗小車的車輪組運(yùn)行速度不是很高，所以在設(shè)計(jì)中采用單輪緣式小車車輪,代號為DL這是為了降低成本，其結(jié)構(gòu)簡圖如圖5.2.4所示： 圖5.2.4單輪緣式 5.3車輪的直徑選則當(dāng)車輪直徑不能變大的時(shí)候，因?yàn)檩唹号c車輪數(shù)目成反比，所以我們通常采用增加車輪數(shù)目的方法來降低輪壓。為了使各輪的輪壓能夠均衡分布，我們在車輪數(shù)目超過四個(gè)時(shí)，設(shè)計(jì)時(shí)就采用鉸鏈均衡架裝置。 初步設(shè)置料斗小車自重為m=8T，車輪的數(shù)目n=4，據(jù)設(shè)計(jì)要求和載重量可得知輪壓最大值為：查8表6-1及表6-2得知，此料斗小車的車輪直徑D=500mm，車輪的數(shù)目n=4，踏面為圓柱形的單緣車輪。 料斗移動(dòng)小車傳動(dòng)系統(tǒng)結(jié)構(gòu)的設(shè)計(jì)與計(jì)算6料斗移動(dòng)小車傳動(dòng)系統(tǒng)結(jié)構(gòu)的設(shè)計(jì)與計(jì)算6.1設(shè)計(jì)參數(shù)：（1）運(yùn)輸重量：50t（2）軌距： 1436mm（3）滿載行走速度：30m/min,空載行走速度50m/min,行走距離：40m（4）臺面尺寸：5000mmX2000mm 6.2電動(dòng)機(jī)的類型選用：電動(dòng)機(jī)，顧名思義，是一種通過電力然后旋轉(zhuǎn)從而進(jìn)行工作的機(jī)器，它的作用是把電能轉(zhuǎn)變?yōu)闄C(jī)械能。一般用在冶金及起重行業(yè)的三相異步電動(dòng)機(jī)具有較高的機(jī)械強(qiáng)度和較大的過載能力,適用于頻繁啟動(dòng)和制動(dòng)、短時(shí)間或者斷續(xù)周期運(yùn)行的場合。此次設(shè)計(jì)我選擇YZR、YZ系列的冶金及起重用的三相異步電動(dòng)機(jī)。6.3電動(dòng)機(jī)的功率選用工作機(jī)所需電動(dòng)機(jī)輸出功率應(yīng)根據(jù)中間傳動(dòng)裝置的效率和工作機(jī)所需功率等確定。通過以下計(jì)算，可知公式中：S-表示為安全系數(shù)，等于1.1 -表示為摩擦系數(shù)，等于0.05 M-表示小車的承載重量，等于50T m-表示小車的自重，等于8T V-表示小車行走速度，等于30m/min= g-重力加速度（N/kg），等于9.8N/kgm電動(dòng)機(jī)的輸出功率為： 公式中：3-表示齒輪傳動(dòng)效率2-表示滾動(dòng)軸承效率1-表示帶傳動(dòng)效率翻閱書本1-7：=96.01=、=98.02=、=98.03=。查2表12-7得，電動(dòng)機(jī)額定功率為22W。6.4電動(dòng)機(jī)轉(zhuǎn)速的選用 根據(jù)負(fù)荷的性質(zhì)，電動(dòng)機(jī)常用的工作制:S2(短時(shí)工作制)、S3(斷續(xù)周期工作制)、S4（包括啟動(dòng)的斷續(xù)周期性工作制）、S5(包括電制動(dòng)的斷續(xù)周期工作制)。電動(dòng)機(jī)的額定工作制一般均為S3，每一工作的周期是10min，它就相當(dāng)于等效啟動(dòng)6次/h。電動(dòng)機(jī)的基準(zhǔn)負(fù)載持續(xù)率FC=40%，F(xiàn)C=工作時(shí)間/一個(gè)工作周期，工作時(shí)間包括起動(dòng)和制動(dòng)的時(shí)間。 因而我選擇的電動(dòng)機(jī)為S3(斷續(xù)周期工作制)即相當(dāng)于是等效啟動(dòng)6次/h，電動(dòng)機(jī)的基準(zhǔn)負(fù)載持續(xù)率FC=40%的轉(zhuǎn)速,大概等于715r/min。6.5電動(dòng)機(jī)型號的選用根據(jù)電動(dòng)機(jī)額定功率=18.76kw和轉(zhuǎn)速=715r/min，我們由2表12-7確定電動(dòng)機(jī)型號為：YZR225M-86.6 計(jì)算總傳動(dòng)比和分配各級傳動(dòng)比總傳動(dòng)比為，低速級齒輪傳動(dòng)的傳動(dòng)比為，高速級齒輪傳動(dòng)的傳動(dòng)比為，帶傳動(dòng)的傳動(dòng)比為。已知總傳動(dòng)比要求的時(shí)候，當(dāng)我們合理選擇和分配各級傳動(dòng)機(jī)構(gòu)的傳動(dòng)比時(shí)應(yīng)考慮以下幾點(diǎn)傳動(dòng)比。車輪轉(zhuǎn)速： 公式中：-車輪直徑D=5OOmm； -行走速度v=30m/min?？倐鲃?dòng)比：取帶傳動(dòng)的:=1.87則減速器低速級傳動(dòng)比:減速器高速級傳動(dòng)比:=1.4 =1.4x3.78=5.29 取=1。 公式中：-電動(dòng)機(jī)滿載轉(zhuǎn)速等于715r/min； -車輪轉(zhuǎn)速等于1.19r/min=。 6.7計(jì)算傳動(dòng)裝置的運(yùn)動(dòng)和動(dòng)力參數(shù)1各軸轉(zhuǎn)速軸：= 軸：=軸：2各軸功率軸：= 軸： 軸 ：3各軸轉(zhuǎn)矩：軸：= 軸：=軸：6.8減速器的計(jì)算與選用已知減速器總的傳動(dòng)比為20，查參考文獻(xiàn)7得，選用ZLY型標(biāo)準(zhǔn)減速器。減速器承載能力的大小受機(jī)械強(qiáng)度和熱平衡許用功率的影響。選用減速器考慮以下兩點(diǎn)：公稱輸入功率應(yīng)滿足通過查參考文獻(xiàn)7中的表15-2-8、表15-2-9、表15-2-10分別得工況系數(shù)，啟動(dòng)系數(shù)，可靠度系數(shù)。由以上可知，負(fù)載功率，機(jī)械強(qiáng)度功率。由此我選用ZLY180-20-II，公稱輸入功率，從而滿足要求。校核熱平衡許用功率的時(shí)候需保證。由表15-2-11和表15-2-13從而得到載荷率系數(shù)、環(huán)境溫度系數(shù)以及公稱功率利用系數(shù)。綜上有減速器的熱平衡功減速器ZLY180-20-II的，很明顯。因此可以選定ZLY180-20-II減速器。 行走機(jī)構(gòu)的設(shè)計(jì)7行走機(jī)構(gòu)的設(shè)計(jì)眾所周知，一輛料斗小車主要由車輪以及車輪軸組成從而實(shí)現(xiàn)車的移動(dòng)，此外，軸上還按裝軸承，軸套以及鍵等零件。我們在設(shè)計(jì)軸時(shí)不僅僅需要設(shè)計(jì)它的外形以及尺寸，而且還要始終滿足以下幾點(diǎn)：軸的方面就是使軸要具有良好的制造工藝性能，軸上零件應(yīng)便于安裝和拆卸，軸和裝在軸上的零件要有準(zhǔn)確的工作位置。7.1主動(dòng)輪軸的設(shè)計(jì)7.1.1確定主動(dòng)輪軸的結(jié)構(gòu)和尺寸設(shè)計(jì)由豎直方向力平衡得由 得 聯(lián)立式子,得,，則垂直面內(nèi)受力分析如下：圖7.1.12垂直面內(nèi)的受力情況由豎直方向力平衡得由得聯(lián)立式子有,總彎矩計(jì)算扭矩則根據(jù)計(jì)算結(jié)果我們制出了如下的幾張圖：圖7.1.13水平面彎矩圖 圖7.1.14垂直面彎矩圖 圖7.1.15扭矩圖判斷危險(xiǎn)截面截面D是危險(xiǎn)截面，按照彎扭合成強(qiáng)度校核軸的強(qiáng)度。我們在校核時(shí)只校核該軸承受最大彎矩和扭矩的截面，即校核危險(xiǎn)截面D的強(qiáng)度，其中扭轉(zhuǎn)切應(yīng)力是脈動(dòng)循環(huán)變應(yīng)力，而且也是對稱循環(huán)變應(yīng)力，由1P373知折合系數(shù)，從而算的軸的計(jì)算應(yīng)力查1表有.因此，故安全。7.2從動(dòng)輪軸的設(shè)計(jì)從動(dòng)輪軸上安裝有從動(dòng)輪組、支座。軸與從動(dòng)輪組通過鍵為連接，在從動(dòng)輪上與支座的連接為軸承連接，且軸承需要在軸向設(shè)置定位軸肩。輪組跨距為1436mm，車架寬度約為3000mm。從動(dòng)輪軸結(jié)構(gòu)如下圖：圖7.2.16從動(dòng)輪軸 從動(dòng)輪軸上裝有圓錐滾子軸承和軸套，選用的軸承型號為23022C/W33；軸與滾動(dòng)軸承為過渡配合,選軸的直徑尺寸公差為 m6；車輪和軸為間隙配合,采用 H7/h6 配合；為了使軸與車架安裝合理, 約束軸的總長為 1940mm，軸承各段的直徑值和長度如圖。段和段的鍵同主動(dòng)輪軸一樣。 車架的設(shè)計(jì)8車架的設(shè)計(jì)8.1材料選用料斗小車車體使用最常用的材料主要是鋼材，有的小車也采用鋁合金。但是因?yàn)殇X合金比鋼的延伸率大，比重小，彈性模量僅僅是鋼的三分之一，而且造價(jià)高，所以我為了節(jié)省成本，在料斗小車的車體設(shè)計(jì)中并未采用鋁合金，因鋼由于具有可焊性的特點(diǎn)，特別是普通碳素鋼Q235，Q235根據(jù)化學(xué)成分和脫氧方法的不同主要分為 、四個(gè)質(zhì)量等級，而B級它是制造料斗小車金屬結(jié)構(gòu)最常用的材料，同時(shí)料斗小車金屬結(jié)構(gòu)的主要承載構(gòu)件與Q235性能滿足，因其力學(xué)性能適中，所以采用Q235B。其具體的性能如下所示：表8.1.8 Q235B鋼的特性鋼號密度屈服強(qiáng)度抗拉強(qiáng)度沖擊功8.2結(jié)構(gòu)選用車架三種型式：鑄造，焊接和鉚接。鑄造優(yōu)點(diǎn)：架子堅(jiān)固、工作時(shí)軸承座不易移動(dòng)和變位。由于焊接的發(fā)展，現(xiàn)在已被焊接車架取代。焊接的車架一般是由型鋼和鋼板焊接而成，主要因?yàn)樾弯摰膭偠容^好。根據(jù)本次的設(shè)計(jì)要求，選用焊接的車架。它由型鋼和鋼板焊接而成。該種車架結(jié)構(gòu)簡單，自身輕便且加工方便。 三維建模9三維建模圖9.18制動(dòng)器圖9.19主動(dòng)輪軸裝配圖9.20從動(dòng)輪軸裝配圖9.21車架 結(jié)論10.結(jié)論隨著時(shí)代的不斷發(fā)展，生活水平的不斷提高，生活需求日益提高，產(chǎn)量的嚴(yán)重需求，這就要提高產(chǎn)品的生產(chǎn)效率，因而機(jī)械也向著自動(dòng)化，輕便化在發(fā)展，所以我們要活到老學(xué)到老，增加自己的創(chuàng)新意識，努力使用自己的大腦來幫助機(jī)械走向更快更好的自動(dòng)化發(fā)展，就像我設(shè)計(jì)的料斗移動(dòng)小車，由于人類的創(chuàng)新由原先的半自動(dòng)化齒輪傳動(dòng)，到現(xiàn)在的PLC程序自動(dòng)控制，不僅僅給人們帶來了許多便利，而且給廠家節(jié)約一大筆資源還提高了生產(chǎn)效率，大大加快了世界經(jīng)濟(jì)的發(fā)展。 參考文獻(xiàn)參考文獻(xiàn)1 濮良貴,紀(jì)名剛等.機(jī)械設(shè)計(jì).8版.北京：高等教育出版社,2006.5.2 吳宗澤,羅圣國.機(jī)械設(shè)計(jì)課程設(shè)計(jì)手冊.北京：高等教育出版社,2006.5.3 機(jī)械設(shè)計(jì)手冊編委會.機(jī)械設(shè)計(jì)手冊（單行本）滾動(dòng)軸承.北京：機(jī)械工業(yè)出版社,2007.3.4 機(jī)械設(shè)計(jì)手冊編委會.機(jī)械設(shè)計(jì)手冊（單行本）聯(lián)軸器、離合器與制動(dòng)器.北京：機(jī)械工業(yè)出版社,2007.2.5 機(jī)械設(shè)計(jì)手冊編委會.機(jī)械設(shè)計(jì)手冊（單行本）起重運(yùn)輸機(jī)械零部件、操作件和小五金.北京：機(jī)械工業(yè)出版社,2007.3.6 何銘新,錢可強(qiáng).機(jī)械設(shè)制圖.北京：高等教育出版社,2004.1.7 成大先.機(jī)械設(shè)計(jì)手冊（單行本）減（變）速器電機(jī)與電器.北京：化學(xué)工業(yè)出版社,2010.1.8 李錚.起重運(yùn)輸機(jī)械.北京：冶金工業(yè)出版社,1982.6.9 北京鋼鐵學(xué)院，陳道南，盛漢中.起重機(jī)課程設(shè)計(jì).北京：冶金工業(yè)出版社,1983.11.10 陳道南，盛漢中等.起重運(yùn)輸機(jī)械.北京：冶金工業(yè)出版社,1988.5.（2010.1重?。?1 北京科技大學(xué)，東北大學(xué).工程力學(xué).北京：高等教育出版社,2008.1（2009重?。?2 祝凌云，李斌.Pro/ENGINEER野火版3.0自學(xué)手冊機(jī)構(gòu)/動(dòng)畫/有限元篇.北京：人民郵電出版社,2008.9.12 張智明，李預(yù)斌.精通Pro/ENGINEER中文野火版零件設(shè)計(jì)篇.北京：中國出版社,2004.13 丁長紅.電動(dòng)平車供電方式.設(shè)備管理與維護(hù).2009.(6).4344.14 趙韓.機(jī)械系統(tǒng)設(shè)計(jì).高等教育出版社.2005.315 劉鴻文.材料力學(xué).高等教育出版社.2006.716 方新.機(jī)械CAD/CAM技術(shù).西安電子科技大學(xué)出版社.2004.217 劉巖.鋼鐵公司用200t專用平車的研制. 鐵道車輛 2010.48（5）：272918 賈濰.100t大型電動(dòng)平車設(shè)計(jì)19 梁志力.蓄電池直流電動(dòng)轉(zhuǎn)運(yùn)平車的設(shè)計(jì).叉車技術(shù).2001.（2）：131520 田建東.100t電動(dòng)平車無線遙控系統(tǒng)的應(yīng)用.一重技術(shù).2004.（4）：162021 張明忠.160t電動(dòng)平車設(shè)計(jì)探討.安徽冶金科技職業(yè)學(xué)院學(xué)報(bào).2010.20:899522 鄭祝斌.通用機(jī)械設(shè)備.機(jī)械工業(yè)出版社.201123 起重機(jī)設(shè)計(jì)手冊編寫組.起重機(jī)設(shè)計(jì)手冊.北京：機(jī)械工業(yè)出版社.1980. 致謝致 謝通過這幾個(gè)月的不懈努力終于完成了此次畢業(yè)論文的設(shè)計(jì)。在本論文設(shè)計(jì)的整個(gè)過程中，我得到了毛志偉老師的精心指導(dǎo)，在設(shè)計(jì)的過程中，對于我設(shè)計(jì)上面的錯(cuò)誤。毛老師能夠?qū)Ｐ牡奶嫖曳治觯粎捚錈┑臑槲抑v解，有些超出他專業(yè)方面的知識，他會去尋找書本，自己理解后在給我進(jìn)行分析，并且指導(dǎo)我論文的錯(cuò)誤之處，幫助我把一些錯(cuò)誤的觀念矯正過來，在完成初稿的過程中盡心盡力的為我講解一些錯(cuò)的地方，由于毛老師細(xì)心的指導(dǎo)和對我不斷的支持，我才能順利完成此次的設(shè)計(jì)，在此，我向毛志偉老師表示深深的感謝。在此感謝大學(xué)四年以來所有為我們傳播知識的老師們，是你們的教導(dǎo)讓我在這里學(xué)到更多，通過上課和實(shí)踐，真正做到了理論聯(lián)系實(shí)際，從而讓我們的專業(yè)知識扎根，牢固于心，為將來進(jìn)入社會，進(jìn)行工作打下了深深的基礎(chǔ)。本次的設(shè)計(jì)雖說已經(jīng)圓滿結(jié)束，但我知道還有很多不足的地方，通過這個(gè)答辯我懂得了更多的注意點(diǎn)，為進(jìn)入社會工作提供了良好的鋪墊。畢 業(yè) 設(shè) 計(jì)（論 文）任 務(wù) 書設(shè)計(jì)（論文）題目：料斗移動(dòng)小車設(shè)計(jì) 學(xué)生姓名： 學(xué) 號： 專 業(yè)： 所在學(xué)院： 指導(dǎo)教師： 職 稱： 20xx年 2月 27日任務(wù)書填寫要求1畢業(yè)設(shè)計(jì)（論文）任務(wù)書由指導(dǎo)教師根據(jù)各課題的具體情況填寫，經(jīng)學(xué)生所在專業(yè)的負(fù)責(zé)人審查、系（院）領(lǐng)導(dǎo)簽字后生效。此任務(wù)書應(yīng)在畢業(yè)設(shè)計(jì)（論文）開始前一周內(nèi)填好并發(fā)給學(xué)生。2任務(wù)書內(nèi)容必須用黑墨水筆工整書寫，不得涂改或潦草書寫；或者按教務(wù)處統(tǒng)一設(shè)計(jì)的電子文檔標(biāo)準(zhǔn)格式（可從教務(wù)處網(wǎng)頁上下載）打印，要求正文小4號宋體，1.5倍行距，禁止打印在其它紙上剪貼。3任務(wù)書內(nèi)填寫的內(nèi)容，必須和學(xué)生畢業(yè)設(shè)計(jì)（論文）完成的情況相一致，若有變更，應(yīng)當(dāng)經(jīng)過所在專業(yè)及系（院）主管領(lǐng)導(dǎo)審批后方可重新填寫。4任務(wù)書內(nèi)有關(guān)“學(xué)院”、“專業(yè)”等名稱的填寫，應(yīng)寫中文全稱，不能寫數(shù)字代碼。學(xué)生的“學(xué)號”要寫全號，不能只寫最后2位或1位數(shù)字。 5任務(wù)書內(nèi)“主要參考文獻(xiàn)”的填寫，應(yīng)按照金陵科技學(xué)院本科畢業(yè)設(shè)計(jì)（論文）撰寫規(guī)范的要求書寫。6有關(guān)年月日等日期的填寫，應(yīng)當(dāng)按照國標(biāo)GB/T 740894數(shù)據(jù)元和交換格式、信息交換、日期和時(shí)間表示法規(guī)定的要求，一律用阿拉伯?dāng)?shù)字書寫。如“2002年4月2日”或“2002-04-02”。畢 業(yè) 設(shè) 計(jì)（論 文）任 務(wù) 書1本畢業(yè)設(shè)計(jì)（論文）課題應(yīng)達(dá)到的目的： 通過畢業(yè)設(shè)計(jì)初步掌握機(jī)械設(shè)計(jì)的一般方法和步驟，同時(shí)提高查閱資料的能力；分析解決問題的能力。通過畢業(yè)設(shè)計(jì)可以學(xué)習(xí)新的知識。2本畢業(yè)設(shè)計(jì)（論文）課題任務(wù)的內(nèi)容和要求（包括原始數(shù)據(jù)、技術(shù)要求、工作要求等）： 主要技術(shù)參數(shù)： 料斗數(shù)量：2個(gè)料斗尺寸：3800mm*2000mm*2200mm載荷重量（含料斗）：50噸移動(dòng)速度：5-20m/min移動(dòng)距離;6m主要內(nèi)容：料斗移動(dòng)小車是一種電動(dòng)有軌廠內(nèi)運(yùn)輸車輛，解決廠內(nèi)跨度之間的產(chǎn)品運(yùn)輸。又稱臺車、電動(dòng)平車。它具有結(jié)構(gòu)簡單、使用方便、容易維護(hù)、承載能力大、污染少等優(yōu)點(diǎn)。廣泛用于機(jī)器制造和冶金工廠，作為車間內(nèi)部配合吊車運(yùn)輸重物過跨或者移動(dòng)之用，解決行車吊運(yùn)極限等很多局部問題。本小車用于料斗移動(dòng)，便于機(jī)組連續(xù)生產(chǎn)，主要運(yùn)輸物流為廢鋼板和污泥。小車載重大，啟動(dòng)力矩大，要求可靠，經(jīng)濟(jì)。電機(jī)驅(qū)動(dòng)，單輪驅(qū)動(dòng)，其余滾輪為被動(dòng)輪，軌道型號為重軌50kg.電機(jī)為交流電機(jī)三相380V，變頻驅(qū)動(dòng)，滾輪及軸為鍛件，框架材料采用Q235B，焊接結(jié)構(gòu)，軌道兩端設(shè)止擋。電機(jī)帶抱閘，接近開關(guān)定位。畢 業(yè) 設(shè) 計(jì)（論 文）任 務(wù) 書3對本畢業(yè)設(shè)計(jì)（論文）課題成果的要求包括圖表、實(shí)物等硬件要求： 一、設(shè)計(jì)總裝配圖及若干零件圖二、設(shè)計(jì)說明書一份三、英文資料翻譯4主要參考文獻(xiàn)： 1 成大先 主編.機(jī)械設(shè)計(jì)手冊（第二冊) 化學(xué)工業(yè)出版社 20082 成大先 主編.機(jī)械設(shè)計(jì)手冊(第四冊)化學(xué)工業(yè)出版社 20083 成大先 主編.機(jī)械設(shè)計(jì)手冊(第五冊)化學(xué)工業(yè)出版社 20084 哈爾濱工業(yè)大學(xué)理論力學(xué)教研組編. 理論力學(xué). 北京：高等教育出版社 19975 大連理工大學(xué)工程畫教研室編. 機(jī)械制圖. 北京：高等教育出版社 19936 孫 桓，陳作模主編. 機(jī)械原理. 北京：高等教育出版社 20007 高澤遠(yuǎn)，王 金主編. 機(jī)械設(shè)計(jì)基礎(chǔ)課程設(shè)計(jì).沈陽：東北工學(xué)院出版社 19878 喻子建，張磊、邵偉平、喻子建主編. 機(jī)械設(shè)計(jì)習(xí)題與解題分析.沈陽：東北大學(xué)出版社 20009 張 玉，劉 平主編. 幾何量公差與測量技術(shù) .沈陽：東北大學(xué)出版社 199910 成大先 主編.機(jī)械設(shè)計(jì)手冊（第一冊）化學(xué)工業(yè)出版社 200811 孫志禮，冷興聚，魏嚴(yán)剛等主編. 機(jī)械設(shè)計(jì). 沈陽：東北大學(xué)出版社 200012 鞏云鵬、田萬祿等主編. 機(jī)械設(shè)計(jì)課程設(shè)計(jì) . 沈陽：東北大學(xué)出版社 200013 劉鴻文主編. 材料力學(xué). 北京：高等教育出版社199114 機(jī)械零件課程設(shè)計(jì)，郭奇亮等主編，貴州人民出版社，1982.115 機(jī)械設(shè)計(jì)標(biāo)準(zhǔn)應(yīng)用手冊/第二卷，汪愷主編，北京：機(jī)械工業(yè)出版社， 1997.816 礦山提升機(jī)械設(shè)計(jì)，潘英編，徐州：中國礦業(yè)大學(xué)出版社，2000.1217 機(jī)械設(shè)計(jì)(第七版)，濮良貴、紀(jì)名剛主編，北京：高等教育出版社， 200118 極限配合與測量技術(shù)基礎(chǔ)，孔慶華、劉傳紹主編，上海：同濟(jì)大學(xué)出版社，2002.2畢 業(yè) 設(shè) 計(jì)（論 文）任 務(wù) 書5本畢業(yè)設(shè)計(jì)（論文）課題工作進(jìn)度計(jì)劃：20xx.12.16-20xx.1.10 領(lǐng)任務(wù)書、開題20xx.2.25-2.16.3.9 畢業(yè)實(shí)習(xí)調(diào)研，完成開題報(bào)告、中英文翻譯、論文大綱20xx.3.19-20xx.4.25 提交論文草稿，4月中旬中期檢查20xx.4.26-20xx.5.6 提交論文定稿20xx.5.6-20xx.5.13 準(zhǔn)備答辯20xx.5.13-20xx.5.26 答辯，成績評定，修改完成最終稿 所在專業(yè)審查意見：通過負(fù)責(zé)人： 年 月 日 畢 業(yè) 設(shè) 計(jì)（論 文）外 文 參 考 資 料 及 譯 文譯文題目： 微孔的加工方法 學(xué)生姓名： 學(xué) 號： 專 業(yè)： 所在學(xué)院： 指導(dǎo)教師： 職 稱： 20xx年 2月 27日說明：要求學(xué)生結(jié)合畢業(yè)設(shè)計(jì)（論文）課題參閱一篇以上的外文資料，并翻譯至少一萬印刷符（或譯出3千漢字）以上的譯文。譯文原則上要求打印（如手寫，一律用400字方格稿紙書寫），連同學(xué)校提供的統(tǒng)一封面及英文原文裝訂，于畢業(yè)設(shè)計(jì)（論文）工作開始后2周內(nèi)完成，作為成績考核的一部分。外文原文Options for micro-holemakingAs in the macroscale-machining world, holemaking is one of the most if not the mostfrequently performed operations for micromachining. Many options exist for how those holes are created. Each has its advantages and limitations, depending on the required hole diameter and depth, workpiece material and equipment requirements. This article covers holemaking with through-coolant drills and those without coolant holes, plunge milling, microdrilling using sinker EDMs and laser drilling. Helpful Holes Getting coolant to the drill tip while the tool is cutting helps reduce the amount of heat at the tool/workpiece interface and evacuate chips regardless of hole diameter. But through-coolant capability is especially helpful when deep-hole microdrilling because the tools are delicate and prone to failure when experiencing recutting of chips, chip packing and too much exposure to carbides worst enemyheat.When applying flood coolant, the drill itself blocks access to the cutting action. “Somewhere about 3 to 5 diameters deep, the coolant has trouble getting down to the tip,” said Jeff Davis, vice president of engineering for Harvey Tool Co., Rowley, Mass. “It becomes wise to use a coolant-fed drill at that point.” In addition, flood coolant can cause more harm than good when microholemaking. “The pressure from the flood coolant can sometimes snap fragile drills as they enter the part,” Davis said. The toolmaker offers a line of through-coolant drills with diameters from 0.039 to 0.125 that are able to produce holes up to 12 diameters deep, as well as microdrills without coolant holes from 0.002 to 0.020. Having through-coolant capacity isnt enough, though. Coolant needs to flow at a rate that enables it to clear the chips out of the hole. Davis recommends, at a minimum, 600 to 800 psi of coolant pressure. “It works much better if you have higher pressure than that,” he added. To prevent those tiny coolant holes from becoming clogged with debris, Davis also recommends a 5m or finer coolant filter. Another recommendation is to machine a pilot, or guide, hole to prevent the tool from wandering on top of the workpiece and aid in producing a straight hole. When applying a pilot drill, its important to select one with an included angle on its point thats equal to or larger than the included angle on the through-coolant drill that follows. The pilot drills diameter should also be slightly larger. For example, if the pilot drill has a 120 included angle and a smaller diameter than a through-coolant drill with a 140 included angle, “then youre catching the coolant-fed drills corners and knocking those corners off,” Davis said, which damages the drill. Although not mandatory, pecking is a good practice when microdrilling deep holes. Davis suggests a pecking cycle that is 30 to 50 percent of the diameter per peck depth, depending on the workpiece material. This clears the chips, preventing them from packing in the flute valleys.Lubricious ChillTo further aid chip evacuation, Davis recommends applying an oil-based metalworking fluid instead of a waterbased coolant because oil provides greater lubricity. But if a shop prefers using coolant, the fluid should include EP (extreme pressure) additives to increase lubricity and minimize foaming. “If youve got a lot of foam,” Davis noted, “the chips arent being pulled out the way they are supposed to be.” He added that another way to enhance a tools slipperiness while extending its life is with a coating, such as titanium aluminum nitride. TiAlN has a high hardness and is an effective coating for reducing heats impact when drilling difficult-to-machine materials, like stainless steel. David Burton, general manager of Performance Micro Tool, Janesville, Wis., disagrees with the idea of coating microtools on the smaller end of the spectrum. “Coatings on tools below 0.020 typically have a negative effect on every machining aspect, from the quality of the initial cut to tool life,” he said. Thats because coatings are not thin enough and negatively alter the rake and relief angles when applied to tiny tools. However, work continues on the development of thinner coatings, and Burton indicated that Performance Micro Tool, which produces microendmills and microrouters and resells microdrills, is working on a project with others to create a submicron-thickness coating. “Were probably 6 months to 1 year from testing it in the market,” Burton said. The microdrills Performance offers are basically circuit-board drills, which are also effective for cutting metal. All the tools are without through-coolant capability. “I had a customer drill a 0.004-dia. hole in stainless steel, and he was amazed he could do it with a circuit-board drill,” Burton noted, adding that pecking and running at a high spindle speed increase the drills effectiveness. The requirements for how fast microtools should rotate depend on the type of CNC machines a shop uses and the tool diameter, with higher speeds needed as the diameter decreases. (Note: The equation for cutting speed is sfm = tool diameter 0.26 spindle speed.) Although relatively low, 5,000 rpm has been used successfully by Burtons customers. “We recommend that our customers find the highest rpm at the lowest possible vibrationthe sweet spot,” he said. In addition to minimizing vibration, a constant and adequate chip load is required to penetrate the workpiece while exerting low cutting forces and to allow the rake to remove the appropriate amount of material. If the drill takes too light of a chip load, the rake face wears quickly, becoming negative, and tool life suffers. This approach is often tempting when drilling with delicate tools. “If the customer decides he wants to baby the tool, he takes a lighter chip load,” Burton said, “and, typically, the cutting edge wears much quicker and creates a radius where the land of that radius is wider than the chip being cut. He ends up using it as a grinding tool, trying to bump material away.” For tools larger than 0.001, Burton considers a chip load under 0.0001 to be “babying.” If the drill doesnt snap, premature wear can result in abysmal tool life. Too much runout can also be destructive, but how much is debatable. Burton pointed out that Performance purposely designed a machine to have 0.0003 TIR to conduct in-house, worst-case milling scenarios, adding that the company is still able to mill a 0.004-wide slot “day in and day out.” He added: “You would think with 0.0003 runout and a chip load a third that, say, 0.0001 to 0.00015, the tool would break immediately because one flute would be taking the entire load and then the back end of the flute would be rubbing. When drilling, he indicated that up to 0.0003 TIR should be acceptable because once the drill is inside the hole, the cutting edges on the end of the drill continue cutting while the noncutting lands on the OD guide the tool in the same direction. Minimizing run out becomes more critical as the depth-to-diameter ratio increases. This is because the flutes are not able to absorb as much deflection as they become more engaged in the workpiece. Ultimately, too much runout causes the tool shank to orbit around the tools center while the tool tip is held steady, creating a stress point where the tool will eventually break. Taking a Plunge Although standard microdrills arent generally available below 0.002, microendmills that can be used to “plunge” a hole are. “When people want to drill smaller than that, they use our endmills and are pretty successful,” Burton said. However, the holes cant be very deep because the tools dont have long aspect, or depth-to-diameter, ratios. Therefore, a 0.001-dia. endmill might be able to only make a hole up to 0.020 deep whereas a drill of the same size can go deeper because its designed to place the load on its tip when drilling. This transfers the pressure into the shank, which absorbs it. Performance offers endmills as small as 5 microns (0.0002) but isnt keen on increasing that lines sales. “When people try to buy them, I very seriously try to talk them out of it because we dont like making them,” Burton said. Part of the problem with tools that small is the carbide grains not only need to be submicron in size but the size also needs to be consistent, in part because such a tool is comprised of fewer grains. “The 5-micron endmill probably has 10 grains holding the core together,” Burton noted. He added that he has seen carbide powder containing 0.2-micron grains, which is about half the size of whats commercially available, but it also contained grains measuring 0.5 and 0.6 microns. “It just doesnt help to have small grains if theyre not uniform.”MicrovaporizationElectrical discharge machining using a sinker EDM is another micro-holemaking option. Unlike , which create small holes for threading wire through the workpiece when wire EDMing, EDMs for producing microholes are considerably more sophisticated, accurate and, of course, expensive. For producing deep microholes, a tube is applied as the electrode. For EDMing smaller but shallower holes, a solid electrode wire, or rod, is needed. “We try to use tubes as much as possible,” said Jeff Kiszonas, EDM product manager for Makino Inc., Auburn Hills, Mich. “But at some point, nobody can make a tube below a certain diameter.” He added that some suppliers offer tubes down to 0.003 in diameter for making holes as small as 0.0038. The tubes flushing hole enables creating a hole with a high depth-to-diameter ratio and helps to evacuate debris from the bottom of the hole during machining. One such sinker EDM for producing holes as small as 0.00044 (11m) is Makinos Edge2 sinker EDM with fine-hole option. In Japan, the machine tool builder recently produced eight such holes in 2 minutes and 40 seconds through 0.0010-thick tungsten carbide at the hole locations. The electrode was a silver-tungsten rod 0.00020 smaller than the hole being produced, to account for spark activity in the gap. When producing holes of that size, the rod, while rotating, is dressed with a charged EDM wire. The fine-hole option includes a W-axis attachment, which holds a die that guides the electrode, as well as a middle guide that prevents the electrode from bending or wobbling as it spins. With the option, the machine is appropriate for drilling hole diameters less than 0.005. Another sinker EDM for micro-holemaking is the Mitsubishi VA10 with a fine-hole jig attachment to chuck and guide the fine wire applied to erode the material. “Its a standard EDM, but with that attachment fixed to the machine, we can do microhole drilling,” said Dennis Powderly, sinker EDM product manager for MC Machinery Systems Inc., Wood Dale, Ill. He added that the EDM is also able to create holes down to 0.0004 using a wire that rotates at up to 2,000 rpm. Turn to Tungsten EDMing is typically a slow process, and that holds true when it is used for microdrilling. “Its very slow, and the finer the details, the slower it is,” said , president and owner of Optimation Inc. The Midvale, Utah, company builds Profile 24 Piezo EDMs for micromachining and also performs microEDMing on a contract-machining basis. Optimation produces tungsten electrodes using a reverse-polarity process and machines and ring-laps them to as small as 10m in diameter with 0.000020 roundness. Applying a 10m-dia. electrode produces a hole about 10.5m to 11m in diameter, and blind-holes are possible with the companys EDM. The workpiece thickness for the smallest holes is up to 0.002, and the thickness can be up to 0.04 for 50m holes. After working with lasers and then with a former EDM builder to find a better way to produce precise microholes, Jorgensen decided the best approach was DIY. “We literally started with a clean sheet of paper and did all the electronics, all the software and the whole machine from scratch,” he said. Including the software, the machine costs in the neighborhood of $180,000 to $200,000. Much of the companys contract work, which is provided at a shop rate of $100 per hour, involves microEDMing exotic metals, such as gold and platinum for X-ray apertures, stainless steel for optical applications and tantalum and tungsten for the electron-beam industry. Jorgensen said the process is also appropriate for EDMing partially electrically conductive materials, such as PCD.“The customer normally doesnt care too much about the cost,” he said. “Weve done parts where theres $20,000 in time and material involved, and you can put the whole job underneath a fingernail. We do everything under a microscope.”Light CuttingBesides carbide and tungsten, light is an appropriate “tool material” for micro-holemaking. Although most laser drilling is performed in the infrared spectrum, the SuperPulse technology from The Ex One Co., Irwin, Pa., uses a green laser beam, said Randy Gilmore, the companys director of laser technologies. Unlike the femtosecond variety, Super- Pulse is a nanosecond laser, and its green light operates at the 532-nanometer wavelength. The technology provides laser pulses of 4 to 5 nanoseconds in duration, and those pulses are sent in pairs with a delay of 50 to 100 nanoseconds between individual pulses. The benefits of this approach are twofold. “It greatly enhances material removal compared to other nanosecond lasers,” Gilmore said, “and greatly reduces the amount of thermal damage done to the workpiece material” because of the pulses short duration.The minimum diameter produced with the SuperPulse laser is 45 microns, but one of the most common applications is for producing 90m to 110m holes in diesel injector nozzles made of 1mm-thick H series steel. Gilmore noted that those holes will need to be in the 50m to 70m range as emission standards tighten because smaller holes in injector nozzles atomize diesel fuel better for more efficient burning. In addition, the technology can produce negatively tapered holes, with a smaller entrance than exit diameter, to promote better fuel flow. Another common application is drilling holes in aircraft turbine blades for cooling. Although the turbine material might only be 1.5mm to 2mm thick, Gilmore explained that the holes are drilled at a 25 entry angle so the air, as it comes out of the holes, hugs the airfoil surface and drags the heat away. That means the hole traverses up to 5mm of material. “Temperature is everything in a turbine” he said, “because in an aircraft engine, the hotter you can run the turbine, the better the fuel economy and the more thrust you get.”To further enhance the technologys competitiveness, Ex One developed a patent-pending material that is injected into a hollow-body component to block the laser beam and prevent back-wall strikes after it creates the needed hole. After laser machining, the end user removes the material without leaving remnants. “One of the bugaboos in getting lasers accepted in the diesel injector community is that light has a nasty habit of continuing to travel until it meets another object,” Gilmore said. “In a diesel injector nozzle, that damages the interior surface of the opposite wall.” Although the $650,000 to $800,000 price for a Super- Pulse laser is higher than a micro-holemaking EDM, Gilmore noted that laser drilling doesnt require electrodes. “A laser system is using light to make holes,” he said, “so it doesnt have a consumable.” Depending on the application, mechanical drilling and plunge milling, EDMing and laser machining all have their place in the expanding micromachining universe. “People want more packed into smaller spaces,” said Makinos Kiszonas.中文翻譯微孔的加工方法正如宏觀加工一樣，在微觀加工中孔的加工也許也是最常用的加工之一?？椎募庸し椒ㄓ泻芏喾N，每一種都有其優(yōu)點(diǎn)和缺陷，這主要取決于孔的直徑、深度、工件材料和設(shè)備要求。這篇文章主要介紹了內(nèi)冷卻鉆頭鉆孔、無冷卻鉆孔、插銑、電火花以及激光加工微孔的幾種方法。易于孔加工的操作無論孔有多大，在加工時(shí)將冷卻液導(dǎo)入到刀尖，這都有助于排屑并能降低刀具和工件表面產(chǎn)生的摩擦熱。尤其是在加工深細(xì)孔時(shí)，有無冷卻對加工的影響更大，因?yàn)樯罴?xì)孔加工的刀具比較脆弱，再加上刀具對切屑的二次切削和切屑的堆積會積累大量的熱，而熱量是碳化物刀具的主要“天敵”，它會加快刀具的失效速度。當(dāng)使用外冷卻液時(shí)，刀具本身會阻止切削液進(jìn)入切削加工位置?！耙簿褪堑?-5倍的直徑深度后切削液就會很難流入到刀尖?！?副哈維工具有限公的副總工程師杰夫戴維斯說，“這時(shí)，就應(yīng)該選用帶有內(nèi)冷的鉆頭?！绷硗?，在加工小孔時(shí)采用外冷卻液的冷卻方式產(chǎn)生的利要大于弊，“當(dāng)鉆頭進(jìn)入工件時(shí)，已經(jīng)流入孔的冷卻液產(chǎn)生的壓力有時(shí)會繳壞鉆頭。”戴維斯說。刀具生產(chǎn)商提供的標(biāo)準(zhǔn)鉆頭的直徑從0.039到0.125英寸，能加工深度小于12倍直徑的深孔，同時(shí)提供直徑從0.002到0.020英寸的不帶內(nèi)冷的鉆頭。盡管有內(nèi)冷能力，但還是不夠的，冷卻液還需要一定的流動(dòng)速度從而能夠?qū)⑶行记宄隹淄?。戴維斯強(qiáng)調(diào)，冷卻液的最低壓力應(yīng)為600-800磅/平方英寸，“加工狀況還會隨著所施壓力的增加而提高。”他補(bǔ)充道。為了防止這些冷卻液通口被雜物堵塞，戴維斯還推薦在鉆頭上加一5m孔徑或更加精密的冷卻液濾清器。另外，他還推薦在加工孔時(shí)有必要在工件的上方先加工一個(gè)定心或?qū)蚩?，以防止刀具偏斜，并有助于保證所加工孔的垂直度。當(dāng)選用定心鉆時(shí)，應(yīng)使選擇的定心鉆刀尖上的坡口角小于等于其后內(nèi)冷鉆的破口角。定心鉆的直徑還要稍微大一些。例如，如果定心鉆的坡口角為120，內(nèi)冷卻鉆頭的坡口角為140，并且定心鉆的直徑小于內(nèi)冷卻鉆的直徑，“在加工時(shí)內(nèi)冷卻鉆的拐角處會與定心孔干涉而容易脫落，”戴維斯說，“這將導(dǎo)致鉆頭損壞。”雖然沒加強(qiáng)調(diào)，但是加工細(xì)深孔時(shí)，啄式進(jìn)給是一種很好的加工方式。戴維斯建議，根據(jù)工件的材料的不同，每次啄式進(jìn)給的深度最好為孔徑的30%50%。這種加工方式便于排出切屑，使切屑不在加工的孔中堆積。潤滑及冷卻為了更加有助于排屑，戴維斯推薦在金屬加工中用油基金屬切削液代替水基冷卻液，因?yàn)橛途哂休^高的潤滑效果。但是如果車間更加青睞于使用水基冷卻液，液體中應(yīng)該包括EP（極壓）添加劑，增加潤滑和減少發(fā)泡?！叭绻a(chǎn)生很多泡沫，”戴維斯說，“切屑就不會按著預(yù)定的方式排出?！彼€補(bǔ)充到，另一種提高潤滑并且提高刀具壽命方法是刀具涂層，例如氮鋁化鈦（TiAlN）。TiAlN具有很高的硬度，當(dāng)鉆削像不銹鋼這樣的難加工金屬材料時(shí)，帶有TiAlN涂層的刀具能有效地減少熱量沖擊。威斯康星州簡斯維爾微型刀具公司的總經(jīng)理大衛(wèi)伯頓，對微加工刀具的小批量涂層有不同的看法，他說：“對直徑小于0.020英寸的刀具涂層，會對從刀具的加工質(zhì)量到刀具的壽命等每一加工方面都產(chǎn)生消極影響”。因?yàn)樾〉毒叩耐繉硬荒軌蜃龅米銐虮?，這樣涂層就會改變刀具的前角和后角，從而不利于加工。不過，更薄涂層的開發(fā)正在繼續(xù)，伯頓表示，現(xiàn)在微型刀具公司除了生產(chǎn)銷售微型銑刀、刨刀和微型鉆頭外，還在和其他公司合作致力于開發(fā)一種亞細(xì)微涂層。伯頓說：“我們計(jì)劃這種圖層刀具會在六個(gè)月到一年的時(shí)間內(nèi)上市?！蔽⑿豌@公司的產(chǎn)品主要是用于電路板加工的鉆頭，但也可用于有效的切削金屬。所有的刀具都沒帶有內(nèi)冷能力?！拔矣幸粋€(gè)客戶想要在不銹鋼上面鉆一個(gè)0.004英寸的孔，他當(dāng)時(shí)非常驚訝這能用一把加工電路板的鉆頭完成?！辈D還補(bǔ)充說，“采用啄式進(jìn)給并選擇高的主軸速度可以提高鉆頭的效率?！蔽⒓庸さ毒咭褂枚喔叩霓D(zhuǎn)速，這主要依賴于車間所使用的數(shù)控機(jī)床和刀具的直徑，所需的轉(zhuǎn)速隨刀具直徑的增加而加快（注：切削速度公式為 sfm=刀具直徑0.26主軸轉(zhuǎn)速）。雖然相對較低，但伯頓的客戶也成功地應(yīng)用過每分鐘5000轉(zhuǎn)的加工速度。伯頓說：“我們建議我們的用戶找到一個(gè)震動(dòng)最小的最高轉(zhuǎn)速最佳加工速度。”為了減少震動(dòng)，在用小的切削力通過刀具的前傾面去除適當(dāng)?shù)慕饘贂r(shí)，應(yīng)使?jié)B入到工件中的切削載荷連續(xù)而充足，如果鉆頭承受的切削載荷太輕，刀具前傾面的磨損速度就會加快，刀具變鈍，從而影響刀具的使用壽命。這在加工細(xì)孔時(shí)應(yīng)更加注意?！坝脩魝兂３Ｊ褂幂^輕的切削載荷來延長刀具的使用壽命，”伯頓說， “這恰恰會加快切削刃的磨損，并在刀刃寬出切屑的位置形成圓弧，刀具會變得像磨削工具一樣把材料強(qiáng)行除掉，只能成為報(bào)廢刀?！辈D認(rèn)為，直徑大于0.001英寸的刀具切削抗力小于0.0001時(shí)，切削力抗力就已經(jīng)太小了，即使刀具不會斷裂，過早的摩擦也會導(dǎo)致刀具壽命縮短。太多的跳動(dòng)也可能是破壞性的，但是影響有多少還值得商榷。伯頓指出，公司打算設(shè)計(jì)一臺具有0.0003英寸偏差的機(jī)器，用以建立室內(nèi)最壞情況下的銑削場景，還將能夠加工0.004英寸寬的槽，“這遲早會實(shí)現(xiàn)的”。他還補(bǔ)充：“你還可以試想一下0.0003英寸的跳動(dòng)和只有正常水平三分之一的切削載荷，也就是說0.0001到0.00015，刀具將會立即破壞，因?yàn)榈毒叩囊粋€(gè)排屑槽會承受所有的載荷，然后排屑槽的后面就會破壞。”他還指出，在鉆孔時(shí)，小于0.0003英寸的偏差是可接受的，因?yàn)楫?dāng)鉆頭深入孔內(nèi)時(shí)，鉆頭末端的切削刃在外圓柱非加工表面的引導(dǎo)下會繼續(xù)切削。偏差的最小值隨著深度和直徑比值的增加而迅速減少，這是因?yàn)楫?dāng)鉆頭越深入工件，排屑槽的吸震能力越差。最后強(qiáng)烈的跳動(dòng)導(dǎo)致刀柄繞著刀具的軸線轉(zhuǎn)動(dòng)，而刀尖還仍然保持穩(wěn)定，從而產(chǎn)生使刀具最終斷裂的集中應(yīng)力。插銑雖然通常沒有直徑小于0.002英寸的標(biāo)準(zhǔn)微型鉆頭，但可以用微型端銑刀來“沖”孔?！懊慨?dāng)人們想加工一個(gè)小于0.002英寸的孔時(shí)，他們可以選用端銑刀，效果也不錯(cuò)?！辈D說到。但是這樣加工的孔不能太深，因?yàn)榈毒唧w不長，沒有大的深度直徑比率。因此一把直徑為0.001英寸的端銑刀只能加工最深0.020英寸的孔，而同樣直徑的鉆頭可以加工得更深，因?yàn)殂@頭的設(shè)計(jì)使載荷全部作用在刀尖上，進(jìn)而傳到刀柄上被吸收。市面上能提供最小5微米（0.0002英寸）的端銑刀，但是并沒有大量銷售?！爱?dāng)人們想買這樣的刀具時(shí)，我非常嚴(yán)肅的試著說服他們不要買，因?yàn)槲覀儾幌矚g制作這樣的刀具?！辈D說到。這種刀具的主要問題是，不但這種刀具的硬質(zhì)合金齒處于亞細(xì)微尺寸，而且當(dāng)一把刀有多個(gè)齒時(shí)，每個(gè)齒的尺寸還要保持一致。伯頓道：“一把直徑5微米的端銑刀在其基體上就夾持大約10個(gè)刀齒?！彼€補(bǔ)充說，他曾經(jīng)看到過帶有0.2微米齒的粉末冶金硬質(zhì)合金刀具，這是商業(yè)上能提供齒的尺寸的一半，但它還包括0.5和0.6微米的小齒?！叭绻X的尺寸不統(tǒng)一，小齒是發(fā)揮不出作用的”。墜電火花加工應(yīng)用墜電火花的電火花加工是另一種微孔加工方式。這不同于將放電導(dǎo)線穿過工件的電火花加工方式，應(yīng)用墜電火花加工的微孔更加精密和精確，但同時(shí)花費(fèi)也會很高。墜電火花加工深細(xì)孔時(shí)，要用一個(gè)導(dǎo)電管作為電極。加工小而淺的孔時(shí)，需要用到一根導(dǎo)線或棒，“我們盡量用導(dǎo)管做電極，”位于密歇根州的牧野公司總經(jīng)理 Jeff Kiszonas說道，導(dǎo)管的排渣孔能使加工的孔有大的深度直徑比，并能夠在加工中將孔底的熔渣排除孔外。他又補(bǔ)充道“但是另一方面，沒人能制出小于一定直徑的導(dǎo)管。”一些供應(yīng)商能提供直徑小于0.003英寸的導(dǎo)管可以加工出0.0038英寸的孔?，F(xiàn)在Makino公司生產(chǎn)的雙邊墜電火花加工設(shè)備能夠加工出0.00044英寸（11微米）的微孔，這種設(shè)備主要用于孔的精加工。最近，在日本這種機(jī)床的開發(fā)人員用兩分鐘加工了八個(gè)這樣的孔，并用四十秒穿透了0.0010英寸厚的碳化鎢板。加工電極為一個(gè)銀鎢合金棒，由于電火花加工中在電極和工件間存在放電間隙，所以，所加工孔的直徑會比電極直徑大0.00020英寸。當(dāng)加工上述尺寸的孔時(shí)，旋轉(zhuǎn)的導(dǎo)棒上包裹著通電的放電導(dǎo)線。精加工時(shí)需要一個(gè)W軸附件，用來夾持電極導(dǎo)向的模具，另外還需要一個(gè)中間導(dǎo)向件，當(dāng)電極旋轉(zhuǎn)時(shí)用來來防止其彎曲和擺動(dòng)。應(yīng)用這種加工方式的機(jī)床適合于加工直徑小于0.005英寸的孔。另一種墜電電火花加工微型孔機(jī)床是三菱VA10機(jī)床，它用精加工孔的鉆模附件來裝卡和引導(dǎo)精制導(dǎo)線來腐蝕金屬。伊利諾伊州的MC機(jī)械系統(tǒng)公司產(chǎn)品加工經(jīng)理丹尼斯德利說：“這是一種標(biāo)準(zhǔn)的電火花加工，但是借助于安裝在機(jī)器上的附件，我們同樣可以加工細(xì)孔。”他還補(bǔ)充說在電火花加工中用2000轉(zhuǎn)/分的轉(zhuǎn)速旋轉(zhuǎn)的導(dǎo)線可以加工小于0.0004英寸的孔。鎢電極電火花加工