Introduction

The main trend in the development of modern machine-building production is its automation in order to significantly increase labor productivity and the quality of products.

Automation of mechanical processing is carried out through the widespread use of equipment with CNC and the creation on its basis of HPS, controlled by a computer.

When developing technological processes for processing parts in automated areas, it is necessary to solve the following tasks:

improving the manufacturability of parts;

improving the accuracy and quality of workpieces; ensuring the stability of the stock; improvement of existing and creation of new methods for obtaining blanks that reduce their cost and metal consumption;

an increase in the degree of concentration of operations and the associated complication of the structures of technological systems of machines;

development of progressive technological processes and structural layout schemes of equipment, development of new types and designs cutting tool and devices that ensure high productivity and quality of processing;

development of the modular and modular principle of creating machine-tool systems, loading and transport devices, industrial robots, control systems.

Mechanization and automation of machining technological processes provides for the elimination or maximum reduction of manual labor associated with the transportation, loading, unloading and processing of parts at all stages of production, including control operations, changing and setting tools, as well as work on collecting and processing chips.

The development of low-waste production technology provides for a comprehensive solution to the problem of manufacturing blanks and machining with minimal allowances by radically re-equipping procurement and machining shops using the most advanced technological processes, creating automatic and complex-automated lines based on modern equipment.

In such production, a person is freed from direct participation in the manufacture of a product. The functions of preparation of the tooling, adjustment, programming, maintenance of computer equipment remain behind him. The proportion of mental labor increases and the proportion of physical labor is reduced to a minimum. The number of workers is decreasing. The requirements for the qualifications of workers serving automated production are increasing.

1. Calculation of the volume of output and determination of the type of production

Initial data for determining the type of production:

a) The volume of parts production per year: N = 6500 pcs / year;

b) Percentage of spare parts: c = 5%;

c) The percentage of inevitable technological losses b = 5%;

d) Total volume of parts production per year:

e) part mass: m = 3.15 kg.

The type of production is determined approximately according to table 1.1

Table 1.1 Organization of production by weight and volume of production

Part weight, kg Type of production <1,0<1010-20002000-7500075000-200000>2000001,0-2,5<1010-10001000-5000050000-100000>1000002,5-5,0<1010-500500-3500035000-75000>750005,0-10<1010-300300-2500025000-50000>50000>10<1010-200200-1000010000-25000>25000

In accordance with the table, the processing of parts will be carried out in the conditions of medium-scale production with an approach to small-scale production.

Serial production is characterized by the use of specialized equipment, as well as numerically controlled machine tools and automated lines and sections based on them. Attachments, cutting and measuring tools can be both special and universal. The scientific and methodological basis for organizing serial production is the introduction of group technology based on design and technological unification. Arrangement of equipment, as a rule, in the course of the technological process. Automatic trolleys are used as means of interoperational transportation.

In mass production, the number of parts in a batch for simultaneous launch can be determined in a simplified way:

where N is the annual program for the production of parts, pcs;

a - the number of days for which it is necessary to have a stock of parts (the frequency of launch - release, corresponding to the needs of the assembly);

F is the number of working days in a year.

2. General characteristics of the part

1 Service purpose of the part

"Adapter". The adapter works under static load conditions. Material - Steel 45 GOST 1050-88.

Presumably, this part does not work in difficult conditions - it serves to connect two flanges with different mounting holes. The part may be part of a pipeline that circulates gases or liquids. In this regard, rather high requirements are imposed on the roughness of most internal surfaces(Ra 1.6-3.2). They are justified, since low roughness reduces the possibility of creating additional foci of oxidative processes and contributes to the unimpeded flow of liquids, without strong friction and turbulent eddies. The end surfaces have a rough roughness, as most likely the connection will be made through a rubber gasket.

The main surfaces of the part are: cylindrical surfaces Æ 70h8; Æ 50H8 + 0.039, Æ 95H9; threaded holes М14х1.5-6Н.

2.2 Part type

The part refers to parts of the type of bodies of revolution, namely, a disk (Fig. 1). The main surfaces of the part are the outer and inner cylindrical surfaces, the outer and inner end surfaces, the inner threaded surfaces, that is, the surfaces that determine the configuration of the part and the main technological tasks for its manufacture. Various chamfers are referred to as non-basic surfaces. The classification of the treated surfaces is presented in table. 2.1

Rice. 1. Sketch of the detail

Table 2.1 Classification of surfaces

No. Executive size Specified parameters Ra, μmTf, μmTras, μm1NTP, IT = 12, Lus = 1012.5-2NCP Æ 70 h81.6-3NTP, IT = 12, Lus = 2512.5-0.14NTSP Æ 120 h1212.5-5NTP, IT = 12, Lus = 1412.5-6FP IT = 10, L = 16.3-7NTSP Æ 148 h1212.5-8FP IT = 10, L = 16.3-9 NTP, IT = 12, Lus = 26.512.5-10VCP Æ 12 Н106,3-11ВЦП Æ 95 N93.2-12VTP, IT = 12, Lus = 22.512.5-13VTSP Æ 50 N81.6-14VTSP Æ 36 N1212.5-15VTP, IT = 12, Lus = 1212.5-16VTSP Æ 12.50.01-17FP IT = 10, L = 1.56.3-18FP IT = 10, L = 0.56.3-19 VRP, M14x1.5 - 6H6.30.01-20VCP R = 9 H1212.5 - The characteristic features of the processing of this part are as follows:

the use of turning and grinding machines with CNC as the main group of equipment;

processing is carried out when installed in a cartridge or in a device;

the main processing methods are turning and grinding of external and internal cylindrical and end surfaces, tapping;

preparation of bases (trimming of ends) for of this type production is advisable to produce on lathe.

high requirements for roughness require the use of finishing methods of processing - grinding.

2.3Analysis of manufacturability of a part

The purpose of the analysis is to identify design flaws according to the information from the drawing of the part, as well as possible improvement in the design.

Part "Adapter" - has cylindrical surfaces, which leads to a reduction in equipment, tools and fixtures. During processing, the principle of constancy and unity of bases, which are the surface, is observed Æ 70 h8 and the butt end of the part.

all surfaces are easily accessible for processing and control;

metal removal is uniform and shock-free;

no deep holes;

it is possible to process and inspect all surfaces using standard cutting and measuring tools.

The part is rigid and does not require the use of additional devices during processing - lunettes - to increase the rigidity of the technological system. As non-technological, one can note the lack of unification of such elements as external and internal chamfers - ten chamfers have three standard sizes, which leads to an increase in the number of cutting and measuring tools.

2.4Norm control and metrological examination of a drawing of a part

2.4.1 Analysis of standards applied in the drawing

In accordance with the requirements of ESKD, the drawing must contain all the necessary information that gives a complete picture of the part, have all the necessary sections and technical requirements. Special areas of the form are highlighted separately. The original drawing meets these requirements completely. One groove is highlighted and referenced in the drawing. The textual requirements for shape tolerances are indicated conventions directly on the drawing, and not in the technical requirements. The leader is identified by a letter, not a Roman numeral. It should be noted the designation of the surface roughness, made taking into account change No. 3 of 2003, as well as unspecified tolerances of dimensions, shape and location. Limit deviations of sizes are stated mainly by qualifications and numerical values ​​of deviations, as is customary in medium-batch production, since control can be carried out by both special and universal measuring instruments. The inscription "Unspecified maximum deviations according to OST 37.001.246-82" in the technical requirements should be replaced with the inscription "Unspecified dimensions and maximum deviations of dimensions, shape and location of processed surfaces - according to GOST 30893.2-mK"

4.2 Checking the compliance of the specified maximum deviations with standard tolerance fields in accordance with GOST 25347

In the drawing there are maximum deviations of dimensions, which are indicated only by the numerical values ​​of the maximum deviations. Let's find the corresponding tolerance fields according to GOST 25347 (Table 2.2).

Table 2.2. Compliance of specified numerical deviations with standard tolerance fields

Size Tolerance js10 Æ H13

Analysis of table 2.2. shows that the absolute majority of sizes have maximum deviations that correspond to standard ones.

4.3 Determination of limit deviations of dimensions with unspecified tolerances

Table 2.3. Limit deviations of dimensions with unspecified tolerances

Size Tolerance range Limit deviations 57js12 5js12 Æ 36H12-0,1258js12 R9H12-0,1592js12 Æ 148h12 + 0.4 Æ 118H12-0.35 Æ120h12 + 0.418js12 62js12

2.4.4 Analysis of compliance of requirements for shape and roughness to size tolerance

Table 2.4. Compliance with shape and roughness requirements

No. Executive size Specified parameters Calculated parameters Ra, μmTf, μmTras, μmRa, μmTf ,. μm Tras, μm1NTP, IT = 12, Lus = 1012.5--3.2--2NCP Æ 70 h81.6-1.6-3NTP, IT = 12, Lus = 2512.5-0.11.6-0.14NTSP Æ 120 h1212.5-1.6-5NTP, IT = 12, Lus = 1412.5-1.6-6FP IT = 10, L = 16.3-6.3-7NTSP Æ 148 h1212.5-12.5-8FP IT = 10, L = 16.3-6.3-9 NTP, IT = 12, Lus = 26.5 12.5-3.2-10VCP Æ 12 H106.3-3.2-11VTSP Æ 95 N93.2-1.6-12VTP, IT = 12, Lus = 22.5 12.5-6.3-13VTSP Æ 50 N81.6-1.6-14VTSP Æ 36 N1212.5-12.5-15VTP, IT = 12, Lus = 1212.5-6.3-16VTSP Æ 12.50.01-250.01-17 FP IT = 10, L = 1.56.3-6.3-18 FP IT = 10, L = 0.56.3-6.3-19 GRP , М14х1.5 - 6Н6.30.01-6.30.01- 20VTSP R = 9 Н1212.5-6.3--

Conclusions to the table: the calculated roughness for a number of sizes is less than the specified one. Therefore, for free surfaces 5,10,12,15,16,20 we assign the calculated roughness as more appropriate. The calculated location tolerances for surface 3 are the same as those specified in the drawing. We make the appropriate corrections to the drawing.

2.4.5 Analysis of the correctness of the choice of bases and location tolerances

In the analyzed drawing, two position tolerances are set relative to the cylindrical surface and the right end: position and perpendicularity tolerances of threaded holes and flange holes 0.01 mm, as well as a tolerance of parallelism of the end face 0.1 mm. You should choose other bases, since these will be inconvenient to base the part in the fixture when machining radial holes. Change the base B to the axis of symmetry.

cutting lathe adapter workpiece

3. The choice of the type of workpiece and its justification

The method of obtaining a blank of a part is determined by its design, purpose, material, technical requirements for manufacturing and its cost-effectiveness, as well as the volume of production. The method of obtaining the workpiece, its type and accuracy directly determine the accuracy of machining, labor productivity and the cost of the finished product.

For a serial type of production, it is advisable to assign a blank - stamping, as close as possible to the configuration of the part.

Forging is one of the main methods of metal forming (PMD). Giving the metal the required shape, as close as possible to the configuration of the future part and obtained with the least labor costs; correction of defects in the cast structure; improving the quality of the metal by converting the cast structure into a deformed one and, finally, the very possibility of plastic deformation of metal-plastic alloys - the main arguments for the use of metal forming processes.

Thus, an improvement in the quality of the metal is achieved not only during its smelting, casting and subsequent heat treatment, but also in the process of metal casting. It is plastic deformation, by correcting defects in the cast metal, and by transforming the cast structure, which imparts the highest properties to it.

So, the use of metal forming processes in the machine-building industry allows not only to significantly save metal and increase the productivity of workpiece processing, but also makes it possible to increase the resource performance characteristics parts and structures.

The technological processes of low-waste production of blanks include: obtaining precision hot-stamped blanks with minimal waste in the flare, production of blanks by cold forging or with heating. Tables 3.1 and 3.2 show the mechanical properties and chemical composition of the workpiece material.

Table 3.1 - Chemical composition of the material Steel 45 GOST 1050-88

Chemical element% Silicon (Si) 0.17-0.37 Copper (Cu), no more than 0.25 Arsenic (As), no more than 0.08 Manganese (Mn) 0.50-0.80 Nickel (Ni), no more than 0.25 Phosphorus (P), no more than 0.035 Chromium (Cr ), no more than 0.25 Sulfur (S), no more than 0.04

Table 3.2 - Mechanical properties of the workpiece material

Steel grade Hard-worked state After annealing or high tempering uv, MPad,% w,% uv, MPad,% w,% Steel 456406305401340

A blank disc can be obtained in several ways.

Cold extrusion on presses. The cold extrusion process encompasses a combination of five types of deformation:

direct extrusion, reverse extrusion, upsetting, trimming and punching. For cold extrusion of workpieces, hydraulic presses are used, which automate the process. The establishment of the maximum force at any point in the stroke of the slide on hydraulic presses allows stamping parts of great length.

Forging on a horizontal forging machine (HCM), which is a horizontal mechanical press, in which, in addition to the main deforming slider, there is a clamping one, which grips the deformable part of the bar, ensuring its upset. The stops in the dies of the GCM are adjustable, which makes it possible to clarify the deformable volume during adjustment and obtain a forging without burst. Dimensional accuracy of steel forgings can reach 12-14 quality standards, the surface roughness parameter is Ra12.5-Ra25.

The determining factors for choosing a method for the production of blanks are:

the precision of the workpiece and the quality of its surface.

the closest approximation of the dimensions of the workpiece to the dimensions of the part.

The choice of the method for obtaining the workpiece was based on the analysis possible ways obtaining, the implementation of which can contribute to the improvement of technical and economic indicators, i.e. achieving maximum efficiency while ensuring the required product quality.

The obtained forgings are subjected to preliminary heat treatment.

The purpose of heat treatment is:

elimination of the negative effects of heating and pressure treatment (removal of residual stresses, evaporation of overheating);

improving the machinability of the workpiece material by cutting;

preparation of the metal structure for final maintenance.

After maintenance, the forgings are sent for surface cleaning. A sketch of the workpiece is presented in the graphic part of the diploma project.

As one of the options for obtaining a workpiece, we will take the manufacture of workpieces by the method of cold die forging. This method makes it possible to obtain stampings that are closer to the finished part in shape and dimensional accuracy than stampings obtained by other methods. In our case, if it is necessary to manufacture an exact part, the minimum surface roughness of which is equal to Ra1.6, obtaining a workpiece by cold forging will significantly reduce blade processing, reduce metal consumption and machine tool processing. The average metal utilization rate for cold die forging is 0.5-0.6.

4. Development of a route technological process of manufacturing a part

The determining factor in the development of a routing technological process is the type and organizational form of production. Taking into account the type of part and the type of surfaces to be processed, a rational group of machines is established for processing the main surfaces of the part, which increases productivity and reduces the processing time of the part.

In the general case, the processing sequence is determined by the accuracy, surface roughness and the accuracy of their mutual position.

When choosing a standard size and model of a machine, we take into account the dimensions of the part, its design features, the assigned bases, the number of positions in the installation, the number of potential positions and installations in the operation.

For processing the main surfaces of a group of specified parts, we will use equipment that has the property of quick changeover for processing any of the parts of the groups, i.e. having flexibility and, at the same time, high productivity, due to the possible concentration of operations, which leads to a reduction in the number of installations; the appointment of intensive cutting modes, due to the use of progressive tool materials, the possibility of full automation of the processing cycle, including auxiliary operations, such as installation and removal of parts, automatic control and replacement of cutting tools. These requirements are met by machine tools with numerical control and, built on their basis, flexible production complexes.

In the designed version, we will take the following technical solutions.

For the processing of external and internal cylindrical surfaces, we choose CNC lathes.

For each surface, a typical and individual plan for its processing is assigned, while choosing economically feasible methods and types of processing, when performing each technological transition in accordance with the adopted equipment.

The development of routing technology means the formation of the content of the operation and the sequence of their implementation is determined.

The main and non-main elementary and typical surfaces are identified, since the general sequence of processing a part, and the main content of the operation will be determined by the sequence of processing only the main surfaces, as well as the equipment used, typical for mass production and the type of workpiece obtained by hot forging.

For each elementary surface of the part, typical machining plans are assigned in accordance with the specified accuracy and roughness.

The stages of processing a part are determined by the plan for processing the most accurate surface. The assigned machining plan of the part is presented in table. 4.1. The processing of minor surfaces is carried out at a semi-finishing stage.

Table 4.1 Technological information on the workpiece

Surface no. Surface to be machined and its accuracy, ITRa, μm Variants Variants of plans for surface treatment of the final method and type of processing Type of treatment (stages) EchrEpchEpEotd1NTP, IT = 12, Lus = 103.2 Finish turning (milling, grinding) Tchr (Fcr) (Fcr) Tpch (Шпч) Тч (Фч) (Шч) 2НЦП Æ ( grinding, milling) of increased accuracy Tchr (Fchr) (Shchr) Tpch (Fpch) (Shpch) Tch (Fch) (Shch) Tp (Fp) (Shp) 4NTsP Æ 120 h121.6 Turning (grinding, milling) of increased accuracy Tchr (Fchr) (Shchr) Tpch (Fpch) (Shpch) Tch (Fch) (Shh) Tp (Fp) (Shp) 5NTP, IT = 12, Lus = 141.6 Turning ( grinding, milling) of increased accuracy Tchr (Fchr) (Shchr) Tpch (Fpch) (Shpch) Tch (Fch) (Shch) Tp (Fp) (Shp) 6FP IT = 10, L = 16.3 Semi-finishing turning (grinding, milling) Tchr (Фчр) (Шчр) Тпч (Фпч) (Шпч) 7НЦП Æ 148 h1212.5 Rough turning (grinding, milling) Tchr (Fchr) (Shchr) 8FP IT = 10, L = 16.3 Semi turning (grinding, milling) Tchr (Fchr) (Shchr) Tpch (FPch) (Shpch) 9 NTP, IT = 12, Lus = 26.5 3.2 Æ 12 Н106.3 Re-boring (semi-finishing drilling) UHCR (UHF) 11VTsP Æ 95 Н91.6 Growing (milling, grinding) of increased accuracy Рчр (Фчр) Рпч (Фпч) (Шпч) Рч (Фч) (Шч) Рп (Фп) (Шп) 12ВТП, IT = 12, Lus = 22.5 12.5 RoughRchr (Fchr) 13VTSP Æ 50 N81.6 Growing (milling, drilling, grinding) of increased accuracy Rchr (Fchr) (Svchr) Rpch (Fpch) (Shpch) (Svpch) Rch (Fch) (Shch) (Svch) Rp (FP) (Shp) (Svp) 14VTsP Æ 36 Н1212.5 Drilling (milling) roughingSvchr (Fchr) 15VTP, IT = 12, Lus = 1212.5 Countersinking (milling) Zchr (Fchr) 16VTsP Æ 12.5 Rough drillingSvchr17FP IT = 10, L = 1.56.3 Countersinking Z18FP IT = 10, L = 0.56.3 CountersinkingZ 19 GRP, M14x1.5 - 6N6.3 Finishing threading N 20VTsP R = 9 N1212.5 Rough milling Table 4.1 shows not only treatment plans, but several options for plans. All of the above options can take place in the processing of a given part, but not all of them are appropriate for use. The classic treatment plan, which is shown in the table without brackets, is universal option processing, in which there are all possible stages for each surface. This option is suitable for those cases when the production conditions, equipment, workpiece, etc. are unknown. Such a processing plan is common in obsolete production, when parts are manufactured on worn out equipment, on which it is difficult to maintain the required dimensions and ensure the accuracy and roughness parameters. We are faced with the task of developing a promising technological process. V modern production stages are not used in its classical sense. Nowadays, quite accurate equipment is being produced, processing on which is carried out in two stages: roughing and finishing. Exceptions are made in some cases, for example, when the part is not rigid, additional intermediate steps can be introduced to reduce the cutting pressure. Roughness parameters, as a rule, are provided by cutting conditions. The machining options shown in the table can be alternated, for example, after rough turning, go to semi-finishing milling or grinding. Considering that the workpiece is obtained by cold forging, which provides 9-10 quality levels, it is possible to exclude roughing, since the surface of the workpiece will initially be more accurate.

Table 4.2

Surface No. Worked surface and its accuracy, ITRa, μm Final method and type of processing Surface treatment plan Type of treatment (stages) EchrEpchEpEotd1NTP, IT = 12, Lus = 103.2 Finishing turning TpchTch2NTSP Æ 70 h81.6 Turning increased accuracy TpchTp3NTP, IT = 12, Lus = 251.6 Turning increased accuracy TpchTp4NTSP Æ 120 h121.6 Turning increased accuracy TpchTp5NTP, IT = 12, Lus = 141.6 Turning increased accuracy TpchTp6FP IT = 10, L = 16.3 Semi-circular turning Tpch7NTSP Æ 148 h1212.5 Rough turning Tchr8FP IT = 10, L = 16.3 Semi-circular turning Tpch9NTP, IT = 12, Lus = 26.53.2 Finish turning TpchTch10VTSP Æ 12 Н106.3 Semi-finishing drilling Æ 95 Н91.6 Expansion of increased accuracy RpchRp12VTP, IT = 12, Lus = 22.5 12.5 Expanding rough Æ 50 N81.6 Increased accuracy spreading RpchRp14VTSP Æ 36 Н1212.5 Rough milling Св15ВТП, IT = 12, Lus = 12 12.5 Milling Frch16ВЦП Æ 12.5 Rough drilling CW17FP IT = 10, L = 1.5 6.3 Countersinking Z18FP IT = 10, L = 0.56.3 CountersinkingZ 19 GRP, M14x1.5 - 6N6.3 Finishing threading N 20VTsP R = 9 N1212.5 Rough milling Fcr

Taking into account all of the above, a potential technical process can be formed.

After identifying the content of potential transition operations, their content is clarified by the number of installations and the content of transitions. The content of potential operations is shown in table. 4.3.

Table 4.3. Formation of a potential processing route

Stages of part processing Content of a potential operation Type of machine in a stage Number of potential installations Installation Operation EchrTchr7, Rchr12 CNC lathe, cl. N1A005Sv14, F15, Sv16, Fchr20Vertical milling, class H2A B010EpchTpch1, Tpch2, Tpch3, Tpch4, Tpch5, Tpch6, Tpch8, Tpch9, Rpch11, Rpch13 CNC lathe, cl. Н2А Б015Св10, З17, З18Vertical drilling machine, class N1A020EchTch1, Tch9 CNC lathe, class. H2A B025EpTp2, Tp3, Tp4, Tp5, Rp11, Rp13 CNC lathe, cl. P2A B030

The content of the operation of the technological route is formed according to the principle of maximum concentration when performing settings, positions and transitions, therefore, we replace the equipment assigned in the potential processing route with a CNC machining center, on which the part will be completely processed in 2 settings. OTs select a two-spindle, the change of settings is carried out by means of the machine automatically. The positioning of the part according to the location of the radial holes after installation is also provided by the means of the machine tool using the angular position sensors of the spindle.

Table 4.4. Formation of a real preliminary route for processing a part in a batch production

Operation No.Settings No. of position in the installationProcessing stagesBasesContents of the operationEquipment correction P II Rpch13IIIEchTch1IVEpTp2, Tp3, Tp4, Tp5 V Pp13VI EchrFchr20BIEchr1.4Tchr7 II Rchr12 III EpchTpch8, Tpch9 IV Ech Tch9 VEPch Rpch11, Rp11 VIEchrFchrSv14

After analyzing the data presented in Tables 4.5 and 4.6, we make a choice in favor of the variant of the technological process presented in Table 4.7. The chosen option is promising, modern equipment and a modern accurate method of obtaining a workpiece, which allows to reduce the amount of machining by cutting. Based on the generated real processing route, we will write down the route technological process in the route map.

Table 4.5. Route map technological process

the name of detail Adapter

Material Steel 45

Blank type: Stamping

No. oper.Name and a summary of the operationBasesType of equipment005Turning machine with CNC A. I. Sharpening 1,2,3,4,5,6 (EPCH) 7,9Turning and milling center machining duplex, class. P 1730-2M CNC lathe A. II. Bore 13 (EPCH) CNC Turning A. III. Turn 1 (Ech) CNC lathe A. IV. Grind 2,3,4,5 (EP) Turning with CNC A. V. Bore 13 (EP) Milling with CNC A. VI. To mill a cylindrical recess 20 (Echr) Turning with CNC B. I. Turn 7 (Echr) 1.4 Turning with CNC B. II. Bore 12 (Echr) CNC lathe B. III. Sharpen 8.9 (EPH) CNC lathe B. IV. To grind 9 (Ech) Turning with CNC B. V. To bore 11 (Ech, EP) Boring with CNC B. VI. Drilling 14 (ECHR) CNC milling B. VII. Milling 15 (ECHR) Drilling with CNC B. VIII. Drill 16 (ECHR) Drill with CNC B. IX. Drilling 10 (Epch) Milling with CNC B. X. Countersinking 17.18 (Epch) Tapping with CNC B. XI. Thread 19 (EPCH)

5. Development of an operational technological process

1 Equipment specification

The main type of equipment for processing parts such as bodies of revolution, in particular shafts, in the conditions of medium-scale production are turning and cylindrical grinding machines with numerical control (CNC). For threaded surfaces - thread rolling, for milling grooves and flats - milling machines.

For the processing of the main cylindrical and end surfaces, we leave the pre-selected machining center, turning and milling two-spindle 1730-2M, of increased accuracy class. The technological capabilities of such a machine include turning cylindrical, conical, shaped surfaces, processing center and radial holes, milling surfaces, cutting threads in small diameter holes. When installing the part, the locating scheme is taken into account, which determines the dimensioning. The characteristics of the accepted equipment are shown in Table 5.1.

Table 5.1. Technical parameters of the selected equipment

Machine name max, min-1Ndw, kW Tool magazine capacity, pcs Maximum part dimensions, mm Overall dimensions of the machine, mm Weight, kg Accuracy class of the machine 1730-2М350052-800х6002600x3200x39007800П

5.2Clarification of the installation scheme of the part

The installation diagrams selected in the formation of a real technological process of processing do not change after the equipment is refined, since with this basing scheme it is possible to realize rational sizing, taking into account the processing of the part on a CNC machine, and also these bases have the largest surface area, which provides the greatest stability of the part during processing. The part is completely processed on one machine in one operation, consisting of two installations. Thus, it is possible to minimize processing errors caused by the accumulation of errors during successive resetting from stage to stage.

5.3Appointment of cutting tools

Cutting tools are used to form the required shape and size of workpiece surfaces by cutting, cutting off relatively thin layers of material (chips). Despite the big difference certain types tools for their intended purpose and design, they have a lot in common:

working conditions, general structural elements and methods of their substantiation, calculation principles.

All cutting tools have a working and fastening part. The working part performs the main service purpose - cutting, removal of an excess layer of material. The fastening part is used to install, locate and fix the tool in the working position on the machine (technological equipment), it must perceive power load the cutting process, to ensure the vibration resistance of the cutting part of the tool.

The choice of the type of tool depends on the type of machine, the processing method, the material of the workpiece, its size and configuration, the required accuracy and roughness of processing, and the type of production.

The choice of the material of the cutting part of the tool is of great importance for increasing productivity and reducing the cost of processing and depends on the adopted processing method, the type of material being processed and working conditions.

Most designs of metal-cutting tools are made - the working part of the tool material, the fastening part - from ordinary structural steel 45. The working part of the tool - in the form of plates or rods - is connected to the fastening part by welding.

Hard alloys in the form of multifaceted carbide inserts are fixed with clamps, screws, wedges, etc.

Let's consider the use of the tool by operations.

In turning operations of processing a part, we use cutters (contour and boring) as a cutting tool.

On cutters, the use of multifaceted carbide non-regrowth inserts provides:

increased durability by 20-25% compared to brazed cutters;

the possibility of increasing cutting conditions due to the ease of restoring the cutting properties of multifaceted plates by turning them;

reduction: tool costs by 2-3 times; losses of tungsten and cobalt by 4-4.5 times; auxiliary time for the change and resharpening of the cutters;

simplification of tool management;

reduction of abrasive consumption.

As a material of replaceable cutter inserts for processing steel 45 for rough, semi-finishing turning, hard alloy T5K10 is used, for finishing turning - T30K4. The presence of chip breaking holes on the surface of the plate allows the resulting chips to be crushed during processing, which simplifies their disposal.

We choose the method of fastening the plate - a wedge with a tack for the rough and semi-finishing stage of processing and a two-arm tack for the finishing stage.

By accepted, a contour cutter with c = 93 ° with a triangular plate for the semi-finishing stage of processing and with c = 95 ° with a rhombic plate (e = 80 °) made of hard alloy (TU 2-035-892) for the finishing stage (Fig. 2.4 ). This cutter can be used when turning NCP, when trimming ends, when turning an inverse taper with a drop angle of up to 30 0, when processing radius and transition surfaces.

Figure 4. Sketch of the cutter

For drilling holes, spiral drills are used in accordance with GOST 10903-77 from high-speed steel R18.

For the processing of threaded surfaces - taps made of high-speed steel P18.

4 Calculation of operational dimensions and dimensions of the workpiece

A detailed calculation of the diametrical dimensions is given for the surface Æ 70h8 -0,046... For clarity, the calculation of diametrical operating dimensions is accompanied by the construction of a diagram of allowances and operating dimensions (Fig. 2).

Shaft blank - stamping. Technological route of surface treatment Æ 70h8 -0,046 consists of semi-finishing and high precision turning.

We calculate the diametrical dimensions in accordance with the diagram according to the formulas:

dpmax = dpov max + 2Z pov min + Tzag.

The minimum value of the 2Zimin stock when machining external and internal cylindrical surfaces is determined by:

2Z imin = 2 ((R Z + h) i-1 + ?D 2S i-1 + e 2 i ), (1)

where R Zi-1 - the height of the profile irregularities at the previous transition; h i-1 - the depth of the defective surface layer at the previous transition; ; D S i-1 - total deviations of the surface location (deviations from parallelism, perpendicularity, alignment, symmetry, axis intersections, positional) and, in some cases, deviations of the surface shape; c - the error in the installation of the workpiece on the ongoing transition;

R value Z and h, characterizing the surface quality of the stamped blanks, is 150 and 150 μm, respectively. R values Z and h, achieved after machining, are found from The total value of spatial deviations for workpieces of this type is determined by:

where is the general deviation of the location of the workpiece, mm; - deviation of the position of the workpiece when centering, mm.

The warpage of the workpiece is found by the formula:

where is the deviation of the axis of the part from straightness, μm per 1 mm (specific curvature of the workpiece); l is the distance from the section for which we determine the value of the deviation of the location to the place of fastening of the workpiece, mm;

where Tz = 0.8 mm is the tolerance for the diametral size of the base of the workpiece used for centering, mm.

μm = 0.058 mm;

For intermediate stages:

where Ku is the refinement factor:

semi-finishing turning K = 0.05;

turning of increased accuracy K = 0.03;

We get:

after semi-finishing:

r2 = 0.05 * 0.305 = 0.015 mm;

after turning with increased accuracy:

r2 = 0.03 * 0.305 = 0.009 mm.

The values ​​of the tolerances of each transition are taken according to the tables in accordance with the quality of the type of processing.

The values ​​of the installation error of the workpiece are determined according to the "Handbook of the Technologist-Mechanical Engineer" for the stamped workpiece. When installed in a three-jaw lathe chuck with a hydraulic power unit e i = 300 microns.

In the graph, the limiting dimensions dmin are obtained from the calculated dimensions, rounded to the accuracy of the tolerance of the corresponding transition. The largest limiting dimensions dmax are determined from the smallest limiting dimensions by adding the tolerances of the corresponding transitions.

Determine the size of the allowances:

Zminpch = 2 × ((150 + 150) + (3052 + 3002) 1/2) = 1210 μm = 1.21 mm

Zmin d.t. = 2 × ((10 + 15) + (152 + 3002) 1/2) = 80 μm = 0.08 mm

Determine Zmax for each processing stage using the formula:

Zmaxj = 2Zminj + Tj + Tj-1

Zmaxpch = 2Zmincher + Tzag + Tcher = 1.21 + 0.19 + 0.12 = 1.52 mm.

Zmax d.t. = 0.08 + 0.12 +0.046 = 0.246 mm.

All the results of the calculations are summarized in Table 5.2.

Table 5.2. The results of calculating allowances and limiting dimensions for technological transitions to processing Æ 70h8 -0,046

Technological transitions of surface treatment. Allowance elements, μm Design allowance 2Z min, μm Installation error e i, μm Start-up tolerance , mm Limit size, mm Limit values ​​of allowances, mm Execution size dRZT dmindmax Billet (stamping) 1501503053000.1971.4171.6--71.6-0.19 Semi-finishing turning 15015030512103000.1270.0870.21,211.5270.2-0.12 High precision turning 10159803000.04669.954700,080,24670-0,046

The diametrical dimensions for the remaining cylindrical surfaces are determined in a similar way. The final calculation results are given in Table 5.3.

Figure 2. Scheme of diametrical dimensions and allowances

Table 5.3. Operating diametrical dimensions

Surface to be machined Process transitions of processing Installation error e i, μm Minimum diameter Dmin, mm Maximum diameter Dmax, mm Minimum allowance Zmin, mm Tolerance T, mm Operating size, mm NCP Æ 118h12 Blank-punching Turning semi-finishing Turning increased accuracy 300 120.64 118.5 117.94120.86 18.64 118- 2 0.50.22 0.14 0.054120.86-0.22 118.64-0.14 118-0,054NTSP Æ 148h12 Blank-stamping Rough turning 0152 147.75 152.4 148- 40.4 0.25 152.4-0.4 148-0.25 VCP Æ 50H8 + 0.039 Blank-stamping Semi-finish boring Boring with increased accuracy 30047.34 49.39 50.03947.5 49.5 50- 2 0.50.16 0.1 0.03947.5-0.16 49.5-0, 1 50 + 0.039VCP Æ 95Н9 + 0.087 Blank-stamping Semi-finish boring Boring with increased accuracy 092.33 94.36 95.08792.5 94.5 95- 2 0.50.22 0.14 0.05492.5-0.22 94.5-0, 14 95 + 0.087

Calculation of linear operating dimensions

We give the sequence of the formation of linear dimensions in the form of table 5.4

Table 5.4. The sequence of forming linear dimensions

No. of oper.InstallationPositionContents of the operationEquipmentSketch of processing005АI Grind 1,2,3,4,5,6 (EPch), keeping the dimensions A1, A2, A3 Machining center turning and milling duplex, cl. P 1730-2M II Waste 13 (Epch) 005АIII Turn 1 (Ech), keeping the A4 size Center turning and milling two-spindle, cl. P 1730-2M IV Grind 2,3,4,5 (EP), keeping the size A5, A6 005AV Spread 13 (EP) Two-spindle turning-milling machining center, cl. P 1730-2M VI Mill a cylindrical groove 20 (Echr), keeping the A7 dimension 005BITchit 7 (ECHR) Two-spindle turning-milling machining center, cl. P 1730-2M II Spread 12 (Echr), keeping the size A8 005BIII Grind 8.9 (EPCH), keeping the size A9 Machining center turning and milling duplex, class. P 1730-2M IV Grind 9 (Eh), keeping the size a10 005BV To spread 11 (Epch, Ep) Two-spindle turning-milling machining center, cl. P 1730-2M VI Drill 14 (EHR), keeping size A11 005BVII Mill 15 (Echr), keeping the size A12 Two-spindle turning and milling machining center, class P 1730-2M VIII Drill 16 (ECHR) 005BIXDrill 10 (EPCH) Two-spindle turning-milling machining center, cl. P 1730-2M X Countersink 17 (Epch) 005BX Rebore 18 (Epch) Two-spindle turning-milling machining center, cl. P 1730-2M XI Cut threads 19 (EPCH)

The calculation of linear operating dimensions is accompanied by the construction of a diagram of allowances and operating dimensions in Fig. 3, drawing up the equations of dimensional chains, calculating them, and ends with the determination of all dimensions of the workpiece. The smallest allowances required for the calculation are taken by.

Let's compose the equations of dimensional chains:

D5 = A12- A4 + A6

Z A12 = A11- A12

Z A11 = A10- A11

Z A10 = A9- A10

Z A9 = A4- A9

Z A8 = A4 - A8 - Z4

Z A7 = A5- A7

Z A6 = A2- A6

Z A5 = A1- A5

Z A4 = A3- A4

Z A3 = З3- A3

Z A2 = Z2- A2

Z A1 = З1- A1

Let us give an example of calculating operating dimensions for equations with a closing link - design dimension and for three dimensional chains with a closing link - an allowance.

Let us write down the equations of dimensional chains with a closing link - design dimension.

D5 = A12 - A4 + A6

Before solving these equations, you need to make sure that the design tolerances are correct. To do this, the equation of the ratio of tolerances must be fulfilled:

Let us assign economically feasible tolerances to the operating dimensions:

for the high-precision stage - grade 6 each;

for the stage of increased accuracy - grade 7 each;

for the finishing stage - grade 10 each;

the length of the semi-finishing stage - 11 grade each;

For the rough stage - grade 13 each.

TA12 = 0.27mm

T A11 = 0.27 mm,

TA10 = 0.12 mm,

TA9 = 0.19 mm,

TA8 = 0.46 mm,

T A7 = 0.33 mm,

T A6 = 0.03 mm,

T A5 = 0.021 mm,

TA4 = 0.12 mm,

T A3 = 0.19 mm,

T A2 = 0.19 mm,

T A1 = 0.13 mm.

D5 = A12 - A4 + A6,

TD5 = 0.36 mm

36> 0.27 + 0.12 + 0.03 = 0.42 mm (the condition is not met), we tighten the tolerances on the constituent links within the technological capabilities of the machines.

Let's take: TA12 = 0.21 mm, TA4 = 0.12 mm.

360.21 + 0.12 + 0.03 - the condition is met.

We solve the equations for dimensional chains with a closing link - an allowance. Determine the operating dimensions required to calculate the above equations. Consider an example of calculating three equations with a closing link - an allowance limited by the minimum value.

) Z A12 = A11 - A12, (rough milling op.005).

Z A12 min = A 11 min - A 12 max .

Calculate Z A12 min ... Z A12 min determined by the errors that arise when milling a cylindrical recess at the roughing stage.

Assign Rz = 0.04 mm, h = 0.27 mm, = 0.01 mm, = 0 mm (installation in the cartridge). The value of the allowance is determined by the formula:

Z12 min = (RZ + h) i-1 + D2Si-1 + e 2i;

Z12 min = (0.04 + 0.27) + 0.012+ 02 = 0.32 mm.

then Z12 min = 0.32 mm.

32 = A11 min-10.5

А11 min = 0.32 + 10.5 = 10.82 mm

А11 max = 10.82 + 0.27 = 11.09mm

A11 = 11.09-0.27.

) ZA11 = A10 - A11, (rough drilling, operation 005).

ZА11 min = А10 min - А11 max.

The minimum allowance is taken taking into account the drilling depth ZA11 min = 48.29 mm.

29 = A10 min - 11.09

A10 min = 48.29 + 11.09 = 59.38mm

A10max = 59.38 + 0.12 = 59.5mm

) ZА10 = А9 - А10, (finishing turning, operation 005).

ZА10 min = А9 min - А10 max.

Let's calculate ZА10 min. ZА10 min is determined by the errors arising from finishing turning.

Assign Rz = 0.02 mm, h = 0.12 mm, = 0.01 mm, = 0 mm (installation in the chuck). The value of the allowance is determined by the formula:

ZA10 min = (RZ + h) i-1 + D2Si-1 + e 2i;

ZА10 min = (0.02 + 0.12) + 0.012+ 02 = 0.15 mm.

then ZА10 min = 0.15 mm.

15 = A9 min-59.5

A9 min = 0.15 + 59.5 = 59.65 mm

A9 max = 59.65 + 0.19 = 59.84mm

) D5 = A12 - A4 + A6

Let's write down the system of equations:

D5min = -A4max + A12min + A6min

D5max = -A4min + A12max + A6max

82 = -59.77 + 10.5 + A6 min

18 = -59.65 + 10.38+ A6 max

А6 min = 57.09 mm

А6 max = 57.45 mm

TA6 = 0.36 mm. We assign an admission according to an economically feasible quality. TA6 = 0.03 mm.

Let's finally write down:

A15 = 57.45h7 (-0.03)

The results of calculating the remaining technological dimensions obtained from the equations with a closing link - an allowance limited by the smallest value are presented in Table 5.5.

Table 5.5. Results of calculating linear operating dimensions

Equation No.EquationsUnknown operating size The smallest allowance Tolerance of the unknown operating size The value of the unknown operating size The accepted value of the operating size1D5 = A12 - A4 + A6 A12-0.2710.5-0.2710.5-0.272ZA12 = A11 - A12 09-0.273ZA11 = A10 - A11 A1040.1259.5-0.1259.5-0.124ZA10 = A9 - A10 A910.1959.84-0.1959.84-0.195ZA9 = A4 - A9 A420.1960.27- 0.1960.27-0.196ZA8 = A4 - A8 - Z4A840.3355.23-0.3355.23-0.337ZA7 = A5 - A7A540.02118.521-0.02118.52-0.0218ZA6 = A2 - A6 A20 , 50.1957.24-0.1957.24-0.199ZA5 = A1 - A5A10.50,1318.692-0.1318.69-0.1310ZA4 = A3 - A4A310,361.02-0.361.02-0.311ZA3 = Z3 - A3Z320.3061.62-0.3061.62-0.3012ZA2 = Z2 - A2Z220.3057.84-0.3057.84-0.3013ZA1 = Z1 - A1Z120,2119.232-0.2119.23-0.21

Selection of working attachments

Taking into account the accepted type and form of production organization based on the group processing method, it can be stated that it is advisable to use specialized, high-speed, automated readjustable devices. Self-centering chucks are used for turning operations. All devices must contain in their design basic part(common according to the locating scheme for all parts of the group) and replaceable adjustments or adjustable elements for quick changeover when switching to processing any of the parts of the group. In the processing of this part, the only device is a self-centering three-jaw lathe chuck.

Figure 3

5.5 Calculation of cutting conditions

5.1 Calculation of cutting conditions for turning operation 005 with CNC

Let's calculate cutting modes for semi-finishing of the part - trimming the ends, turning cylindrical surfaces (see the sketch of the graphic part).

For the semi-finishing stage of processing, we take: a cutting tool - a contour cutter with a triangular plate with an apex angle e = 60 0made of hard alloy, tool material - T15K6 fastening - wedge-clutch, with an angle in the plan c = 93 0, with an auxiliary angle in the plan - c1 =320 .

back angle q = 60;

rake angle - r = 100 ;

the shape of the front surface is flat with a chamfer;

radius of rounding of the cutting edge c = 0.03 mm;

radius of the tip of the cutter - rв = 1.0 mm.

For the semi-finishing stage of processing, the feed is selected according to S 0t = 0.16 mm / rev.

S 0= S 0T Ks and Ks p Ks d Ks h Ks l Ks n Ks c Ksj K m ,

Ks and =1.0 - coefficient depending on the tool material;

Ks p = 1.05 - from the method of mounting the plate;

Ks d = 1.0 - from the section of the tool holder;

Ks h = 1.0 - from the strength of the cutting part;

Ks l = 0.8 - from the workpiece installation scheme;

Ks n = 1.0 - from the state of the surface of the workpiece;

Ks c = 0.95 - from the geometric parameters of the cutter;

Ks j = 1.0 of the rigidity of the machine;

K sm = 1.0 - on the mechanical properties of the processed material.

S 0= 0.16 * 1.1 * 1.0 * 1.0 * 1.0 * 0.8 * 1.0 * 0.95 * 1.0 * 1.0 = 0.12 mm / rev

Vt = 187 m / min.

Finally, the cutting speed for the semi-finishing stage of processing is determined by the formula:

V = V T Kv and Kv with Kv O Kv j Kv m Kv cKv T Kv f

Kv and - coefficient depending on the tool material;

Kv with - from the group of workability of the material;

Kv O - from the type of processing;

Kv j - rigidity of the machine;

Kv m - on the mechanical properties of the processed material;

Kv c - on the geometric parameters of the cutter;

Kv T - from the period of durability of the cutting part;

Kv f - from the presence of cooling.

V = 187 * 1.05 * 0.9 * 1 * 1 * 1 * 1 * 1 * 1 = 176.7 m / min;

The rotational speed is calculated by the formula:

The calculation results are shown in table.

Checking calculation of cutting power Npez, kW

where N T . - tabular value of power, kN;

The power condition is met.

Table 5.6. Cutting data for operation 005. A. Position I. T01

Elements of the cutting mode Worked surfaces T. Æ 118/ Æ 148Æ 118T. Æ 70h8 / Æ 118Æ 70h8T. Æ 50h8 / Æ 70h8 Depth of cut t, mm 222222 Tabular feed Sfrom, mm / rev0,160,160,160,160,16 Accepted feed Sо, mm / rev0,120,120,120,120,12 Tabular cutting speed Vt, m / min 187187187187187 Corrected cutting speed V176,7176,717 Frequency spindle rotation nph, rpm 380.22476.89476.89803.91803.91 Accepted spindle speed nп, rpm 400 500 500 800 800 Actual cutting speed Vph, m / min 185.8185.26 185.26 175.84 175.84 Tabular cutting power NT, kW --- 3.8-Actual cutting power N, kW --- 3.4-Minute feed Sм, mm / min 648080128128

5.2 Let's perform an analytical calculation of the cutting mode according to the value of the accepted tool life for operation 005 (rough turning Æ 148)

Tool - a contour cutter with a replaceable multi-faceted plate made of T15K6 hard alloy.

The cutting speed for external longitudinal and transverse turning is calculated using the empirical formula:

where T is the average value of tool life, for single-tool processing it is taken 30-60 minutes, we choose the value T = 45 minutes;

Сv, m, x, y - tabular coefficients (Сv = 340; m = 0.20; x = 0.15; y = 0.45);

t - depth of cut (we take t = 4mm for rough turning);

s - feed (s = 1.3 mm / rev);

Kv = Kmv * Kpv * Kiv,

where Kmv is a coefficient that takes into account the influence of the workpiece material (Kmv = 1.0), Kpv is a coefficient that takes into account the effect of the surface state (Kpv = 1.0), Kpv is a coefficient that takes into account the effect of the tool material (Kpv = 1.0). Kv = 1.

5.3 Calculation of cutting conditions for operation 005 (drilling radial holes Æ36)

Tool - drill R6M5.

The calculation is carried out according to the method specified in Art. Determine the value of the drill feed per revolution from the table. So = 0.7 mm / rev.

Cutting speed when drilling:

where T is the average value of the tool life, according to the table we select the value T = 70 min;

WITH v , m, q, y - tabular coefficients (С v = 9.8; m = 0.20; q = 0.40; y = 0.50);

D - drill diameter (D = 36 mm);

s - feed (s = 0.7 mm / rev);

TO v = K mv * Kpv * K and v ,

where K mv - coefficient taking into account the influence of the workpiece material (K mv = 1.0), K pv is the coefficient taking into account the effect of the surface state (K pv = 1.0), K pv - coefficient taking into account the influence of the tool material (K nv = 1.0). TO v = 1.

6 Technical regulation

6.1 Determining the piece calculation times for a CNC turning operation 005

The unit time rate for CNC machines is determined by the formula:

where T Ts.A. - time automatic operation machine according to the program;

Auxiliary time.

0.1 min - auxiliary time for the installation and removal of the part;

The auxiliary time associated with the operation includes the time for turning the machine on and off, checking the return of the tool to set point after processing, installation and removal of a shield that protects against splashing with an emulsion:

The auxiliary time for control measurements contains five measurements with a caliper and five measurements with a bracket:

= (0.03 + 0.03 + 0.03 + 0.03 + 0.03) + (0.11 + 0.11 + 0.11 + 0.11 + 0.11) = 0.6 min.

0.1 + 0.18 + 0.6 = 0.88 min.

We accept that remote control is being carried out at the site.

The calculation of the time of automatic operation of the machine according to the program (Tts.a.) is presented in table 5.7.

Determination of the main time To is made according to the formula:

where L p.x. - the length of the working stroke;

Sм - feed.

Determination of idle time is calculated by the formula:

where L х.x. - idle length;

Sхх - idle speed feed.

Table 5.7. Time of automatic operation of the machine according to the program (setting A)

GCP coordinates Z-axis increment, DZ, mm X-axis increment, DX, mm Length of the i-th stroke, mm Minute feed per i-th section, Sм, mm / min The main time of automatic operation of the machine according to the program T0, min Machine-auxiliary time Tmv, min Tool T01 - Contour cutter SI0,010-1-81,31-2484,77100000,0081-20-16,7516,75480 , 342-338,55038,55600,643-40-24,1924,19600,44-53,7803,78960,0395-60-35,0535,05960,36 6-038,98 100107,32100000.01 Instrument T02 - Boring cutter SI0,010-7-37-75,2583,85100000,0087-8-61061960,638-90-22100000,00029-061061100000,006110-03777,2585,65100000,008 Tool T01 - Contour cutter SI0,010-11- 39,73-6475,32100000,007511-120-36361000,3612-039,98100107,69100000,0107 Tool T03 - Contour cutter 0-13-81,48-2585,22100000,008514-150-16161000,1615-1638,48038, 481000.38 16-17 0-24241000.24 17-18 4 041000.0418-0 39 6575.80100000.0075 Tool T04 - Boring cutter SI 0.010-19-39-7584.53100000.008419-20-600601000.620-210-22100000 , 0002 21-2260060100000.006 22-0 39 7786.31100000.0086 Tool T05 - End milling cutter SI0.010-23-40-129.5135.53100000.01723-24-420421000.002524-25420421000.0025 25-26024.52 4,5100000.0024 26-27-420421000,4227-28420421000,4228-29034,534,5100000,003429-30-420421000,4230-31420421000,4231-320-24,524,5100000,002432-33-420421000,4233-34420421000,4234 -04095103.07100000.0103 Total7.330.18 Automatic cycle time7.52

To set B: Tts.a = 10.21; = 0.1; = 0 min. Remote control.

Time for organizational and Maintenance workplace, rest and personal needs are given as a percentage of operational time [4, map 16]:

Finally, the piece time rate is:

Tsh = (7.52 + 10.21 + 0.1 + 0.1) * (1 + 0.08) = 19.35 min.

The rate of preparatory and final time for a CNC machine is determined by the formula:

Тпз = Тпз1 + Тпз2 + Тпз3,

where Тпз1 is the time norm for organizational training;

Тпз2 - the norm of time for setting up a machine tool, device, tool, software devices, min;

Tpz3 is the time standard for trial processing.

The calculation of the preparatory and final time is presented in table 5.8.

Table 5.8. The structure of the preparatory and final time

№ p / p Content of work Time, min 1. Organizational preparation 9.0 + 3.0 + 2.0 Total Тпз114,0 Adjustment of the machine, devices, tools, software devices 2. Set the initial modes of machine processing 0.3 * 3 = 0.93. Install the chuck 4, 04. Install cutting tools 1.0 * 2 = 2.05 Enter the program into the memory of the CNC system 1.0 Total Tpz210.96 Trial machining Part is accurate (semi-finishing), surfaces are processed according to grade 11 12 Total Tpz310 + tts Total preparatory and final time for the batch 36.3 parts: Tpz = Tpz1 + Tpz2 + Tpz3

Tsht.k = Tsht + Tpz = 19.35 + = 19.41min.

6. Metrological support of the technological process

In modern machine-building production, control of the geometric parameters of parts in the process of their production is mandatory. The costs of performing control operations significantly affect the cost of mechanical engineering products, and the accuracy of their assessment determines the quality of manufactured products. When performing technical control operations, the principle of uniformity of measurements must be ensured - the measurement results must be expressed in legal units and the measurement error must be known with the specified probability. Control must be objective and reliable.

Type of production - serial - determines the form of control - selective statistical control of the parameters specified by the drawing. The sample size is 1/10 of the lot size.

Universal remedies measurements find wide application in all types of production, due to their low cost.

Chamfering control is carried out with special measuring instruments: templates. The measurement method is passive, contact, direct, portable measuring instrument. We control the outer cylindrical surface with an indicator bracket on the SI-100 stand GOST 11098.

Inspection of the outer end surfaces at the rough and semi-finishing stages is performed by ШЦ-11 GOST 166, and at the finishing and high-precision stages with a special template.

Roughness control at the rough and semi-finishing stages is carried out according to the roughness samples GOST 9378. The measurement method is a passive contact comparative, portable measuring instrument. Roughness control on finishing stage conducted by the MII-10 interferometer. The measurement method is passive contact, portable measuring instrument.

The final control is carried out by the technical control department at the enterprise.

7. Safety of the technological system

1 General Provisions

Development of technological documentation, organization and implementation of technological processes must comply with the requirements of GOST 3.1102. The production equipment used in cutting must comply with the requirements of GOST 12.2.003 and GOST 12.2.009. Cutting devices must comply with the requirements of GOST 12.2.029. The maximum permissible concentration of substances formed during cutting should not exceed the values ​​established by GOST 12.1.005 and regulatory documents Ministry of Health of Russia.

2 Requirements for technological processes

Safety requirements for the cutting process should be set out in technological documents in accordance with GOST 3.1120. Installation of workpieces to be processed and removal of finished parts during operation of the equipment is allowed with the use of special positioning devices that ensure the safety of workers.

3 Requirements for storage and transportation of raw materials, workpieces, semi-finished products, coolant, finished parts, production waste and tools

Safety requirements for transportation, storage and operation of abrasive and elbor tools in accordance with GOST 12.3.028.

Containers for transportation and storage of parts, workpieces and production waste in accordance with GOST 14.861, GOST 19822 and GOST 12.3.020.

Loading and unloading of goods - in accordance with GOST 12.3.009, movement of goods - in accordance with GOST 12.3.020.

4 Monitoring compliance with safety requirements

The completeness of reflections of safety requirements should be controlled at all stages of the development of technological processes.

Control of noise parameters at workplaces - in accordance with GOST 12.1.050.

In this course project, the volume of output was calculated and the type of production was limited. Analyzed the correctness of the drawing from the point of view of compliance with the applicable standards. A route for processing a part has been designed, equipment, cutting tools and fixtures have been selected. The operating dimensions and the dimensions of the workpiece have been calculated. The cutting conditions and the time rate for a turning operation have been determined. The issues of metrological support and safety precautions are considered.

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14. Allowance calculation: Method. instructions for the implementation of practical work and sections in coursework and diploma projects for students of mechanical engineering specialties of all forms of education / NSTU; Compiled by: D.S. Pakhomov, N, Novgorod, 2001.24 p.
15. Metelev B.A., Kulikova E.A., Tudakova N.M. Mechanical engineering technology, Part 1.2: Complex of educational and methodological materials; Nizhny Novgorod State Technical University Nizhny Novgorod, 2007 -104s.

16. Metelev B.A. Basic provisions on the formation of processing on a metal-cutting machine: textbook / B.A. Metelev. - NSTU. Nizhny Novgorod, 1998

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Detail "Adapter"

ID: 92158
Upload Date: 24 February 2013
Salesman: Hautamyak ( Write if you have any questions)

Kind of work: Diploma and related
File formats: T-Flex CAD, Microsoft Word
Delivered at an educational institution: Ri (F) MGOU

Description:
Part “Adapter” is used in deep hole drilling machine RT 265, which is produced by JSC RSZ.
It is designed for attaching the cutting tool to the "Stem", which is a fixed axis fixed in the tailstock of the machine.
Structurally, the "Adapter" is a body of revolution and has a rectangular three-start internal thread for attaching the cutting tool, as well as a rectangular external thread for connection with the "Stalk". A through hole in the "Adapter" serves:
for removal of chips and coolant from the cutting zone when drilling blind holes;
for supplying coolant to the cutting zone when drilling through holes.
The use of, namely, a three-start thread is due to the fact that in the process of machining to quickly change the tool, it is necessary to quickly unscrew one tool and wrap the other into the body of the "Adapter".
The workpiece for the "Adapter" part is rolled steel made of AC45 TU14-1-3283-81 steel.

CONTENT
sheet
Introduction 5
1 Analytical part 6
1.1 Purpose and design of part 6
1.2 Processability analysis 7
1.3 Physical and mechanical properties of the material of the part 8
1.4 Analysis of the basic technological process 10
2 Technological part 11
2.1 Determining the type of production, calculating the size of the launch batch 11
2.2 Choosing a method of obtaining a workpiece 12
2.3 Calculation of minimum machining allowances 13
2.4 Calculation of the weighting accuracy factor 17
2.5 The business case for stock selection 18
2.6 Design version of the technological process 20
2.6.1 General 20
2.6.2 Order and sequence of TP 20
2.6.3 Route of a new technological process 20
2.6.4 Selection of equipment, description of technological capabilities
and technical characteristics of machines 21
2.7 Justification of the basing method 25
2.8 Selection of fasteners 25
2.9 Choice of cutting tools 26
2.10 Calculation of cutting conditions 27
2.11 Calculation of piece and piece - calculation time 31
2.12 Special issue on mechanical engineering technology 34
3 Design part 43
3.1 Description of the fastener 43
3.2 Calculation of the fixing device 44
3.3 Description of the cutting tool 45
3.4 Description of test fixture 48
4. Calculation of the mechanical shop 51
4.1 Calculation of the required equipment for shop 51
4.2 Determination of the production area of ​​the workshop 52
4.3 Determination of the required number of employees 54
4.4 Choosing a design solution industrial building 55
4.5 Design service premises 56
5. Safety and environmental friendliness of design solutions 58
5.1 Characteristics of the object of analysis 58
5.2 Analysis of the potential hazard of the projected area
mechanical workshop for workers and environment 59
5.2.1 Analysis of potential hazards and hazardous work
factors 59
5.2.2 Analysis of the impact of the workshop on the environment 61
5.2.3 Analysis of the possibility of occurrence
emergencies 62
5.3 Classification of premises and production 63
5.4 Ensuring safe and sanitary
hygienic working conditions in the shop 64
5.4.1 Safety measures and measures 64
5.4.1.1 Automation of production processes 64
5.4.1.2 Equipment location 64
5.4.1.3 Fencing of hazardous areas, prohibited,
safety and locking devices 65
5.4.1.4 Ensuring electrical safety 66
5.4.1.5 Waste disposal in workshop 66
5.4.2 Measures and means for production
sanitation 67
5.4.2.1 Microclimate, ventilation and heating 67
5.4.2.2 Industrial lighting 68
5.4.2.3 Protection against noise and vibration 69
5.4.2.4 Auxiliary sanitary - household
premises and their arrangement 70
5.4.2.5 Personal protective equipment 71
5.5 Measures and means to protect the environment
environment from the impact of the projected machine shop 72
5.5.1 Disposal of solid waste 72
5.5.2 Purification of exhaust gases 72
5.5.3 Waste water treatment 73
5.6 Measures and means to ensure
safety in emergencies 73
5.6.1 Fire safety 73
5.6.1.1 Fire prevention system 73
5.6.1.2 System fire protection 74
5.6.2 Providing lightning protection 76
5.7. Engineering development to ensure
labor safety and environmental protection 76
5.7.1 Calculation of the total illumination 76
5.7.2 Calculation of piece noise absorbers 78
5.7.3 Calculation of Cyclone 80
6. Organizational part 83
6.1 Description of the automated system
projected area 83
6.2 Description of automated transport and storage
systems of the projected area 84
7. Economic part 86
7.1 Background 86
7.2 Calculation of capital investments in fixed assets 87
7.3 Material costs 90
7.4 Designing the organizational structure of the shop floor 91
7.5 Calculation of the annual payroll of employees 92
7.6 Estimating indirect and shop floor costs 92
7.6.1 Estimated maintenance and operating costs
equipment 92
7.6.2 Estimated general workshop costs 99
7.6.3 Allocation of maintenance and operation costs
equipment and public costs for the cost of products 104
7.6.4 Estimated production costs 104
7.6.4.1 Kit Costing 104
7.6.4.2 Calculation of unit costs 105
7.7 Result Part 105
Conclusion 108
References 110
Applications

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1.1 Service purpose and technical characteristics of the part

To draw up a high-quality technological process for manufacturing a part, it is necessary to carefully study its design and purpose in the machine.

The part is a cylindrical axis. The highest requirements for shape and position accuracy, as well as roughness, are imposed on the surfaces of the axle journals intended for bearing seating. So the accuracy of the bearing journals must correspond to grade 7. The high requirements for the accuracy of the positioning of these journals relative to each other result from the operating conditions of the axle.

All axle journals are surfaces of revolution of relatively high precision. This determines the advisability of using turning operations only for their preliminary processing, and the final processing in order to ensure the specified dimensional accuracy and surface roughness should be carried out by grinding. To ensure high requirements for the accuracy of the position of the axle journals, their final processing must be carried out in one setup or, in extreme cases, on the same bases.

Axes of this design are widely used in mechanical engineering.

The axles are designed to transmit torques and mount various parts and mechanisms on them. They are a combination of smooth landing and non-landing surfaces, as well as transitional surfaces.

The technical requirements for the axles are characterized by the following data. The diametric dimensions of the landing journals are made according to IT7, IT6, and other journals according to IT10, IT11.

The axle design, its dimensions and rigidity, technical requirements, production program are the main factors that determine the manufacturing technology and the equipment used.

The part is a body of revolution and consists of simple structural elements presented in the form of bodies of revolution of a circular cross-section of various diameters and lengths. There is a thread on the axle. The axle length is 112 mm, the maximum diameter is 75 mm and the minimum diameter is 20 mm.

Based constructive purpose parts in the machine, all surfaces of this part can be divided into 2 groups:

main or work surfaces;

free or non-working surfaces.

Almost all surfaces of the axle belong to the main ones, because they mate with the corresponding surfaces of other machine parts or directly participate in the working process of the machine. This explains the rather high requirements for the accuracy of processing the part and the degree of roughness indicated in the drawing.

It can be noted that the design of the part fully meets its service purpose. But the principle of manufacturability of design is not only to meet the operational requirements, but also the requirements of the most rational and economical manufacture of the product.

The part has surfaces that are easily accessible for processing; sufficient rigidity of the part allows it to be processed on machines with the most productive cutting conditions. This part is technologically advanced, since it contains simple surface profiles, its processing does not require specially designed devices and machines. Axle surfaces are machined on a turning, drilling and grinding machine. The required dimensional accuracy and surface roughness are achieved with a relatively small set of simple operations, as well as a set of standard cutters and grinding wheels.

Manufacturing of a part is laborious, which is associated, first of all, with the provision of technical conditions for the work of the part, the required dimensional accuracy, and the roughness of the working surfaces.

So, the part is technologically advanced in terms of design and processing methods.

The axle material, steel 45, belongs to the group of medium-carbon structural steels. It is used for medium loaded parts operating at low speeds and medium specific pressures.

Chemical composition of this material let us summarize in table 1.1.

Table 1.1

7
WITH	Si	Mn	Cr	S	P	Cu	Ni	As
0,42-05	0,17-0,37	0,5-0,8	0,25	0,04	0,035	0,25	0,25	0,08

Let us dwell a little on the mechanical properties of rolled products and forgings required for further analysis, which we will also summarize in Table 1.2.

Table 1.2

Here are some of the technological properties.

The temperature of the beginning of forging is 1280 ° C, and the temperature of the end of forging is 750 ° C.

This steel has limited weldability

Workability by cutting - in the hot-rolled state at HB 144-156 and σ B = 510 MPa.

1.2 Determining the type of production and batch size of the part

In the assignment for the course project, the annual program for the release of the product in the amount of 7000 pieces is indicated. Using the source formula, we determine the annual program for the production of parts in pieces, taking into account spare parts and possible losses:

where P is the annual product release program, pcs;

P 1 - the annual program for the manufacture of parts, pcs. (we accept 8000 pcs.);

b - the number of additionally manufactured parts for spare parts and to compensate for possible losses, in percent. You can take b = 5-7;

m - the number of parts of this name in the product (we accept 1 piece).

PCS.

The size of the production program in physical quantitative terms determines the type of production and has a decisive influence on the nature of the construction of the technological process, on the choice of equipment and tooling, on the organization of production.

In mechanical engineering, there are three main types of production:

Single or individual production;

Mass production;

Mass production.

Based on the release program, we can come to the conclusion that in this case we have mass production. In serial production, the manufacture of products is carried out in batches, or in series, periodically repeated.

Depending on the size of batches or series, there are three types of batch production for medium-sized machines:

Small-scale production with the number of products in a series up to 25 pcs;

Medium batch production with the number of items in the series 25-200 pcs;

Large-scale production with more than 200 items in a batch;

A characteristic feature of batch production is that the production of products is carried out in batches. The number of parts in a batch for simultaneous launch can be determined using the following simplified formula:

where N is the number of blanks in the batch;

P is the annual program for the manufacture of parts, pcs.;

L is the number of days for which it is necessary to have a stock of parts in the warehouse to ensure assembly (we take L = 10);

F is the number of working days in a year. You can take F = 240.

PCS.

Knowing the annual volume of production of parts, we determine that this production belongs to large-scale production (5000 - 50,000 pcs.).

In serial production, each operation of the technological process is assigned to a specific workplace. In most workplaces, several operations are performed, periodically repeating.

1.3 Choosing a method of obtaining a workpiece

The method of obtaining the initial blanks of machine parts is determined by the design of the part, the volume of production and the production plan, as well as the economy of manufacture. Initially, from the whole variety of methods for obtaining initial blanks, several methods are selected that technologically provide the possibility of obtaining a blank of a given part and allow the configuration of the original blank to be as close as possible to the configuration of the finished part. To choose a workpiece means to choose a method of obtaining it, outline allowances for processing each surface, calculate dimensions and indicate tolerances for manufacturing inaccuracies.

The main thing when choosing a blank is to ensure the desired quality of the finished part at its minimum cost.

The correct solution to the issue of choosing blanks, if, from the point of view of technical requirements and capabilities, their various types are applicable, can be obtained only as a result of technical and economic calculations by comparing the options for the cost of the finished part with one or another type of blank. Technological processes for obtaining blanks are determined by the technological properties of the material, structural shapes and sizes of parts and the release program. Preference should be given to a workpiece with better metal utilization and lower cost.

Let's take two methods of obtaining blanks and having analyzed each, we will choose the desired method for obtaining blanks:

1) obtaining a billet from rolled products

2) obtaining a blank by stamping.

You should choose the most "successful" method of obtaining a workpiece by analytical calculation. Let's compare the options for the minimum value of the reduced costs for the manufacture of a part.

If the billet is made from rolled stock, then the cost of the blank is determined by the weight of the rolled stock required to manufacture the part and the weight of the chips. The cost of the billet obtained by rolling is determined by the following formula:

,

where Q is the mass of the workpiece, kg;

S - price of 1 kg of workpiece material, rubles;

q is the mass of the finished part, kg;

Q = 3.78 kg; S = 115 rubles; q = 0.8 kg; S ex = 14.4 kg.

Let's substitute the initial data into the formula:

Consider the option of obtaining a blank by stamping on the GCM. The cost of the procurement is determined by the expression:

Where C i is the price of one ton of stampings, rubles;

К Т - coefficient depending on the stamping accuracy class;

К С - coefficient depending on the group of stamping complexity;

K B - coefficient depending on the mass of the forgings;

K M - coefficient depending on the brand of stamping material;

К П - coefficient depending on the annual program of stampings production;

Q is the mass of the workpiece, kg;

q is the mass of the finished part, kg;

S waste - the price of 1 ton of waste, rub.

With i = 315 rubles; Q = 1.25 kg; K T = 1; K C = 0.84; K B = 1; K M = 1; K P = 1;

q = 0.8 kg; S ex = 14.4 kg.

The economic effect for comparing the methods of obtaining workpieces, in which the technological process of machining does not change, can be calculated by the formula:

,

where S E1, S E2 - the cost of the compared workpieces, rubles;

N - annual program, pcs.

We define:

From the results obtained, it can be seen that the option of obtaining a blank by stamping is economically viable.

Manufacturing of a blank by stamping on different types equipment is a progressive method, since it significantly reduces the allowances for machining in comparison with obtaining a billet from rolled products, and is also characterized by a higher degree of accuracy and higher productivity. In the process of stamping, the material is also compacted and the direction of the fiber of the material along the contour of the part is created.

Having solved the problem of choosing a method for obtaining a blank, you can proceed to the next stages of the course work, which will gradually lead us to the direct drawing up of the technological process of manufacturing a part, which is the main goal of the course work. The choice of the type of workpiece and the method of its production have the most direct and very significant effect on the nature of the construction of the technological process for manufacturing a part, since, depending on the selected method of obtaining a workpiece, the amount of allowance for processing a part can fluctuate within significant limits and, therefore, the set of methods does not change, used for surface treatment.

1.4 Purpose of methods and stages of processing

The choice of processing method is influenced by the following factors that must be taken into account:

shape and size of the part;

precision of processing and cleanliness of surfaces of parts;

economic feasibility of the selected processing method.

Guided by the above points, we will begin to identify a set of processing methods for each surface of the part.

Figure 1.1 Sketch of the part with the designation of the layers removed during machining

All axle surfaces have fairly high roughness requirements. We divide the turning of surfaces A, B, C, D, D, E, Z, I, K into two operations: rough (preliminary) and finishing (final) turning. For rough turning, remove most of the allowance; processing is done from great depth cutting and high feed. The scheme that provides the shortest processing time is the most beneficial. When finishing turning, we remove a small part of the allowance, and the order of surface processing is preserved.

When machining on a lathe, it is necessary to pay attention to the firm fixing of the workpiece and the cutter.

To obtain the specified roughness and the required quality of surfaces G and I, it is necessary to apply finishing grinding, in which the accuracy of processing the outer cylindrical surfaces reaches the third class, and the surface roughness is 6-10 classes.

For greater clarity, we schematically write down the selected processing methods on each surface of the part:

A: rough turning, finishing turning;

B: rough turning, finishing turning, threading;

B: rough turning, finishing turning;

D: rough turning, finishing turning, finishing grinding;

D: rough turning, finishing turning;

E: rough turning, finishing turning;

W: drilling, countersinking, reaming;

З: rough turning, finishing turning;

And: rough turning, finishing turning, finishing grinding;

K: rough turning, finishing turning;

L: drilling, countersinking;

M: drilling, countersinking;

Now you can proceed to the next stage of the course work, associated with the choice of technical bases.

1.5 Selection of bases and sequence of processing

The blank part in the process of processing must take and maintain during the entire processing time a certain position relative to the parts of the machine or fixture. To do this, it is necessary to exclude the possibility of three rectilinear movements of the workpiece in the direction of the selected coordinate axes and three rotational movements around these or parallel axes (i.e. to deprive the workpiece of a part of six degrees of freedom).

To determine the position of a rigid workpiece, six reference points are required. To place them, three coordinate surfaces are required (or three combinations of coordinate surfaces replacing them), depending on the shape and size of the workpiece, these points can be located on the coordinate surface in different ways.

It is recommended to choose design bases as technological bases in order to avoid recalculation of operational dimensions. The axis is a cylindrical part, the design bases of which are end surfaces. In most operations, the basing of the part is carried out according to the following schemes.

Figure 1.2 Installation diagram of the workpiece in a three-jaw chuck

In this case, when installing the workpiece in the chuck: 1, 2, 3, 4 - a double guide base, which takes away four degrees of freedom - movement about the OX and OZ axis and rotation around the OX and OZ axes; 5 - the support base deprives the workpiece of one degree of freedom - movement along the OY axis;

6 - support base, depriving the workpiece of one degree of freedom, namely, rotation around the OY axis;

Figure 1.3 Installation diagram of the workpiece in a vice

Taking into account the shape and size of the part, as well as the processing accuracy and surface finish, a set of processing methods were selected for each shaft surface. We can define the sequence of surface treatments.

Figure 1.4 Sketch of the part with the designation of surfaces

1. Turning operation. The workpiece is set on a surface 4 in

self-centering 3-jaw chuck with an emphasis on the end face 5 for rough turning of the end face 9, surface 8, end face 7, surface 6.

2. Turning operation. We turn the workpiece over and install it in a self-centering 3-jaw chuck along surface 8 with an emphasis on end face 7 for rough turning of end face 1, surface 2, end face 3, surface 4, end face 5.

3. Turning operation. The workpiece is set on a surface 4 in

self-centering 3-jaw chuck with an end stop 5 for finishing turning of end face 9, surface 8, end face 7, surface 6, chamfer 16 and groove 19.

4. Turning operation. We turn the workpiece over and install it in a self-centering 3-jaw chuck along surface 8 with an emphasis on end face 7 for finishing turning of end face 1, surface 2, end face 3, surface 4, end face 5, chamfers 14, 15 and grooves 17, 18.

5. Turning operation. We install the workpiece in a self-centering 3-jaw chuck along surface 8 with an emphasis on the end face 7 for drilling and countersinking surface 10, cutting threads on surface 2.

6. Drilling operation. The part is installed in a vice on surface 6 with an emphasis on the end 9 for drilling, countersinking and reaming surface 11, drilling and countersinking surfaces 12 and 13.

7. Grinding operation. The part is installed along surface 4 into a self-centering 3-jaw chuck with an emphasis on the end 5 for grinding surface 8.

8. Grinding operation. The part is installed along surface 8 in a self-centering 3-jaw chuck with an emphasis on the end 7 for grinding surface 4.

9. Remove the part from the fixture and send it for inspection.

The workpiece surfaces are machined in the following sequence:

surface 9 - rough turning;

surface 8 - rough turning;

surface 7 - rough turning;

surface 6 - rough turning;

surface 1 - rough turning;

surface 2 - rough turning;

surface 3 - rough turning;

surface 4 - rough turning;

surface 5 - rough turning;

surface 9 - finishing turning;

surface 8 - finishing turning;

surface 7 - finishing turning;

surface 6 - finishing turning;

surface 16 - chamfer;

surface 19 - sharpen a groove;

surface 1 - finishing turning;

surface 2 - finishing turning;

surface 3 - finishing turning;

surface 4 - finishing turning;

surface 5 - finishing turning;

surface 14 - chamfer;

surface 15 - chamfer;

surface 17 - sharpen the groove;

surface 18 - sharpen the groove;

surface 10 - drilling, countersinking;

surface 2 - threading;

surface 11 - drilling, countersinking, reaming;

surface 12, 13 - drilling, countersinking;

surface 8 - fine grinding;

surface 4 - fine grinding;

As you can see, the surface treatment of the workpiece is carried out in order from coarser to more precise methods. The last processing method in terms of accuracy and quality must comply with the requirements of the drawing.

1.6 Development of route technological process

The part represents an axis and refers to bodies of revolution. We process the workpiece obtained by stamping. When processing, we use the following operations.

010. Turning.

1. grind surface 8, cut end face 9;

2.Charge surface 6, cut end face 7

Cutter material: CT25.

Coolant brand: 5% emulsion.

015. Turning.

Processing is carried out on a 1P365 turret lathe.

1. grind surface 2, cut end face 1;

2. grind surface 4, cut end face 3;

3.cut the butt 5.

Cutter material: CT25.

Coolant brand: 5% emulsion.

The part is based in a three-jaw chuck.

We use a bracket as a measuring tool.

020. Turning.

Processing is carried out on a 1P365 turret lathe.

1. grind surfaces 8, 19, cut end face 9;

2. grind the surfaces 6, cut the butt end 7;

3.Remove chamfer 16.

Cutter material: CT25.

Coolant brand: 5% emulsion.

The part is based in a three-jaw chuck.

We use a bracket as a measuring tool.

025. Turning.

Processing is carried out on a 1P365 turret lathe.

1. grind surfaces 2, 17, cut end face 1;

2. grind surfaces 4, 18, cut end face 3;

3. trim the butt end 5;

4.Remove chamfer 15.

Cutter material: CT25.

Coolant brand: 5% emulsion.

The part is based in a three-jaw chuck.

We use a bracket as a measuring tool.

030. Turning.

Processing is carried out on a 1P365 turret lathe.

1. drill, countersink hole - surface 10;

2. cut threads - surface 2;

Drill material: CT25.

Coolant brand: 5% emulsion.

The part is based in a three-jaw chuck.

035. Drilling

Processing is carried out on a coordinate drilling machine 2550F2.

1. Drill, countersink 4 stepped holes Ø9 - surface 12 and Ø14 - surface 13;

2. drilling, countersinking, reaming Ø8 hole - surface 11;

Drill material: R6M5.

Coolant brand: 5% emulsion.

The part is based in a vice.

We use the caliber as a measuring tool.

040. Grinding

1.Grind the surface 8.

The part is based in a three-jaw chuck.

We use a bracket as a measuring tool.

045. Grinding

Processing is carried out on a 3T160 cylindrical grinding machine.

1.Grind the surface 4.

For processing, select the grinding wheel

PP 600 × 80 × 305 24А 25 Н СМ1 7 К5А 35 m / s. GOST 2424-83.

The part is based in a three-jaw chuck.

We use a bracket as a measuring tool.

050. Vibro-abrasive

Processing is carried out in a vibro-abrasive machine.

1.Dull sharp edges, remove burrs.

055. Flushing

Washing is done in the bathroom.

060. Control

They control all dimensions, check the roughness of surfaces, the absence of nicks, dullness of sharp edges. The control table is used.

1.7 Selection of equipment, tooling, cutting and measuring tools

axis workpiece cutting machining

The choice of machine tools is one of the most important tasks in the development of a technological process for machining a workpiece. The productivity of manufacturing a part, the economic use of production areas, mechanization and automation of manual labor, electricity and, as a result, the cost of the product depend on its correct choice.

Depending on the volume of production, machines are chosen according to the degree of specialization and high productivity, as well as machines with numerical control (CNC).

When developing a technological process for machining a workpiece, it is necessary to choose the right devices that should contribute to increasing labor productivity, processing accuracy, improving working conditions, eliminating preliminary marking of the workpiece and aligning them when installed on a machine.

The use of machine tools and auxiliary tools when processing workpieces gives a number of advantages:

improves the quality and accuracy of parts processing;

reduces the complexity of processing workpieces due to a sharp decrease in the time spent on installation, alignment and fastening;

expands the technological capabilities of machine tools;

creates the possibility of simultaneous processing of several workpieces fixed in a common fixture.

When developing a technological process for machining a workpiece, the choice of a cutting tool, its type, design and size is largely predetermined by the processing methods, the properties of the material being processed, the required processing accuracy and the quality of the workpiece surface being processed.

When choosing a cutting tool, it is necessary to strive to accept a standard tool, but, when appropriate, a special, combined, shaped tool should be used, allowing the processing of several surfaces to be combined.

Choosing the right cutting edge is essential for increasing productivity and reducing your machining cost.

When designing a technological process for machining a workpiece for interoperative and final control of the machined surfaces, it is necessary to use a standard measuring tool, taking into account the type of production, but at the same time, when appropriate, a special measuring tool or measuring device should be used.

The control method should help to increase the productivity of the controller and machine operator, create conditions for improving the quality of products and reducing its cost. In single and serial production, a universal measuring tool is usually used (vernier caliper, depth gauge, micrometer, goniometer, indicator, etc.)

In mass and large-scale production, it is recommended to use limiting calibers (staples, plugs, templates, etc.) and active control methods, which are widespread in many branches of mechanical engineering.

1.8 Calculation of operating dimensions

The operational dimension is understood as the dimension indicated on the operational sketch and characterizing the size of the surface to be machined or the relative position of the machined surfaces, lines or points of the part. The calculation of the operating dimensions is reduced to the problem of correctly determining the size of the operating allowance and the size of the operating tolerance, taking into account the peculiarities of the developed technology.

Long operating dimensions are understood as dimensions that characterize the processing of surfaces with a one-sided arrangement of the allowance, as well as dimensions between axes and lines. Calculation of long operating dimensions is carried out in the following sequence:

1. Preparation of initial data (based on the working drawing and operational maps).

2. Drawing up a processing scheme based on the initial data.

3. Building a graph of dimensional chains to determine allowances, drawing and operational dimensions.

4. Drawing up a statement of calculation of operating sizes.

On the processing diagram (Figure 1.5), we place a sketch of a part indicating all surfaces of a given geometric structure that are encountered during processing from the workpiece to the finished part. In the upper part of the sketch, all long drawing dimensions are indicated, drawing dimensions with tolerances (C), and below all operating allowances (1z2, 2z3,…, 13z14). Under the sketch in the processing table, there are dimension lines that characterize all the dimensions of the workpiece, oriented by one-sided arrows, so that no arrow approaches one of the surfaces of the workpiece, and only one arrow approaches the rest of the surfaces. The dimension lines below indicate the dimensions of the machining. The operating dimensions are oriented in the direction of the machined surfaces.

Figure 1.5 Part processing scheme

On the graph of the initial structures connecting surfaces 1 and 2 with wavy edges, characterizing the size of the allowance 1z2, surfaces 3 and 4 with additional ribs characterizing the size of the allowance 3z4, etc. And we also draw thick edges of drawing dimensions 2c13, 4c6, etc.

Figure 1.6 Graph of initial structures

The top of the graph. Characterizes the surface of a part. The number in the circle indicates the number of the surface on the machining diagram.

The edge of the graph. It characterizes the type of connections between surfaces.

"z" - Corresponds to the size of the operating allowance, and "c" - to the drawing dimension.

On the basis of the developed processing scheme, a graph of arbitrary structures is constructed. The construction of the derived tree begins from the surface of the workpiece, to which no arrows are drawn in the processing diagram. In Figure 1.5, such a surface is indicated by the number "1". From this surface we draw those edges of the graph that touch it. At the end of these edges, we indicate the arrows and the numbers of those surfaces to which the indicated dimensions are drawn. Similarly, we complete the graph according to the processing scheme.

Figure 1.7 Graph of derived structures

The top of the graph. Characterizes the surface of a part.

The edge of the graph. The constituent link of the dimensional chain corresponds to the operating size or the size of the workpiece.

The edge of the graph. The closing link of the dimensional chain corresponds to the drawing dimension.

The edge of the graph. The closing link of the dimensional chain corresponds to the operating allowance.

On all edges of the graph we put a sign ("+" or "-"), guided by the following rule: if an edge of the graph enters with its arrow into a vertex with a large number, then on this edge we put a sign “+”, if the edge of the graph enters the vertex with its arrow with a lower number, then on this edge we put a "-" sign (Figure 1.8). We take into account that we do not know the operating dimensions, and according to the processing scheme (Figure 1.5) we determine approximately the value of the operating size or the size of the workpiece, using for this purpose the drawing dimensions and the minimum operating allowances, which are the sum of the microroughness values ​​(Rz), the depth of the deformation layer (T) and spatial deviation (Δпр), obtained in the previous operation.

Column 1. In random order, rewrite all drawing dimensions and allowances.

Column 2. We indicate the numbers of operations in the sequence of their execution according to route technology.

Column 3. We indicate the name of the operations.

Column 4. We indicate the type of machine and its model.

Column 5. We place simplified sketches in one unchanged position for each operation, indicating the surfaces to be processed according to the route technology. Surfaces are numbered in accordance with the processing scheme (Figure 1.5).

Column 6. For each surface processed in this operation, indicate the operating size.

Column 7. We do not heat treatment of the part in this operation, therefore we leave the column blank.

Column 8. Filled in in exceptional cases when the choice of the measuring base is limited by the convenience of monitoring the operational size. In our case, the graph remains free.

Column 9. We indicate possible options for surfaces that can be used as technological bases, taking into account the recommendations given in Art.

The choice of surfaces used as technological and measuring bases, we begin with the last operation in the reverse order of the technological process. We write down the equations of dimensional chains according to the graph of initial structures.

After the selection of bases and operating dimensions, we proceed to the calculation of nominal values ​​and the selection of tolerances for operating dimensions.

The calculation of long operating dimensions is based on the results of work to optimize the structure of operating dimensions and is carried out in accordance with the sequence of works. The preparation of the initial data for calculating the operating sizes is done by filling in the columns

13-17 maps for choosing bases and calculating operational sizes.

Column 13. To close the links of dimensional chains, which are drawing dimensions, we write minimum values these sizes. To close the links, which are operational allowances, we indicate the value of the minimum allowance, which is determined by the formula:

z min = Rz + T,

where Rz is the height of the irregularities obtained in the previous operation;

T is the depth of the defective layer formed in the previous operation.

The Rz and T values ​​are determined from the tables.

Column 14. For the closing links of the dimensional chains, which are drawing dimensions, we write down the maximum values ​​of these dimensions. We do not put down the maximum values ​​of the allowances yet.

Columns 15, 16. If the tolerance for the required operational size has a "-" sign, then in column 15 we put the number 1, if "+", then in column 16 we put the number 2.

Column 17. We put down the approximate values ​​of the determined operating dimensions, we use the equations of the dimensional chains from column 11.

1.9A8 = 8c9 = 12 mm;

2.9A5 = 3s9 - 3s5 = 88 - 15 = 73 mm;

3.9A3 = 3s9 = 88 mm;

4.7A9 = 7z8 + 9A8 = 0.2 + 12 = 12mm;

5.7A12 = 3c12 + 7A9 - 9A3 = 112 + 12 - 88 = 36 mm;

6.10A7 = 7A9 + 9z10 = 12 + 0.2 = 12 mm;

7.10A4 = 10A7 - 7A9 + 9A5 + 4z5 = 12 - 12 + 73 + 0.2 = 73 mm;

8.10A2 = 10A7 - 7A9 + 9A3 + 2z3 = 12 - 12 + 88 + 0.2 = 88 mm;

9.6A10 = 10A7 + 6z7 = 12 + 0.2 = 12 mm;

10.6A13 = 6A10 - 10A7 + 7A12 + 12z13 = 12 - 12 + 36 + 0.2 = 36 mm;

11.1A6 = 10A2 - 6A10 + 1z2 = 88 - 12 + 0.5 = 77 mm;

12.1A11 = 10z11 + 1A6 + 6A10 = 0.2 + 77 + 12 = 89 mm;

13.1A14 = 13z14 + 1A6 + 6A13 = 0.5 + 77 + 36 = 114 mm.

Column 18. We put down the values ​​of tolerances for operating dimensions adopted according to accuracy table 7, taking into account the recommendations set out in Art. After setting the tolerances in column 18, you can determine the value of the maximum values ​​of the allowances and put them in column 14.

The value of ∆z is determined from the equations in column 11 as the sum of the tolerances for the operating dimensions that make up the dimensional chain.

Column 19. In this column it is necessary to put down the nominal values ​​of the operating dimensions.

The essence of the method for calculating the nominal values ​​of the operating dimensions is reduced to solving the equations of dimensional chains written in column 11.

1.8s9 = 9A89A8 =

2.3s9 = 9A39A3 =

3.3s5 = 3s9 - 9A5

9A5 = 3s9 - 3s5 =

We accept: 9A5 = 73 -0.74

3s5 =

4.9z10 = 10A7 - 7A9

10A7 = 7A9 + 9z10 =

We accept: 10A7 = 13.5 -0.43 (correction + 0.17)

9z10 =

5.4z5 = 10A4 - 10A7 + 7A9 - 9A5

10A4 = 10A7 - 7A9 + 9A5 + 4z5 =

We accept: 10A4 = 76.2 -0.74 (correction + 0.17)

4z5 =

6.2z3 = 10A2 - 10A7 + 7A9 - 9A3

10A2 = 10A7 - 7A9 + 9A3 + 2z3 =

Accept: 10A2 = 91.2 -0.87 (adjustment + 0.04)

2z3 =

7. 7z8 = 7A9 - 9A8

7A9 = 7z8 + 9A8 =

Accept: 7A9 = 12.7 -0.43 (adjustment: + 0.07)

7z8 =

8.3c12 = 7A12 - 7A9 + 9A3

7A12 = 3s12 + 7A9 - 9A3 =

We accept: 7A12 = 36.7 -0.62

3s12 =

9.6z7 = 6A10 - 10A7

6A10 = 10A7 + 6z7 =

Accept: 6A10 = 14.5 -0.43 (correction + 0.07)

6z7 =

10.12z13 = 6A13 - 6A10 + 10A7– 7A12

6A13 = 6A10 - 10A7 + 7A12 + 12z13 =

Accept: 6A13 = 39.9 -0.62 (adjustment + 0.09)

12z13 =

11.1z2 = 6A10 - 10A2 + 1A6

1A6 = 10A2 - 6A10 + 1z2 =

Accept: 1A6 = 78.4 -0.74 (correction + 0.03)

1z2 =

12.13z14 = 1A14 - 1A6 - 6A13

1A14 = 13z14 + 1A6 + 6A13 =

Accept: 1A14 = 119.7 -0.87 (adjustment + 0.03)

13z14 =

13.10z11 = 1A11 - 1A6 - 6A10

1A11 = 10z11 + 1A6 + 6A10 =

Accept: 1A11 = 94.3 -0.87 (adjustment + 0.03)

10z11 =

After calculating the nominal sizes, we enter them into column 19 of the base selection card and, with a processing tolerance, write them down in the “note” column of the Processing Schemes (Figure 1.5).

After we fill in column 20 and the column "approx.", The obtained values ​​of the operating dimensions with a tolerance are applied to the sketches of the route technological process. This completes the calculation of the nominal values ​​of the long operating dimensions.

Map for choosing bases and calculating operating sizes

Closing links

Operation No.

the name of the operation

Model equipment

processing

Operating

Base

Dimensional chain equations

Closing links of dimensional chains

Operating dimensions

Surfaces to be treated

Thermocontrol depth layer

Selected from the conditions of convenience of measurement

Technol options. bases

Accepted tech-nol. and measure. base

Designation

Limit sizes

Tolerance mark and approx. operating value

The magnitude

Nominal meaning

min

max

magnitude

5

Prepare.

GCM

13z14 = 1A14-1A-6A13 10z11 = 1A11-1A6-6A10 1z2 = 6А10-10А2 + 1А6

10

Lathe

1P365

6

6

12z13 = 6A13–6A10 + 10A7–7A12

Figure 1.9 Map of base selection and calculation of operational dimensions

Calculation of operating dimensions with a two-sided arrangement of the allowance

When processing surfaces with a two-sided arrangement of the allowance, it is advisable to calculate the operating dimensions using a statistical method for determining the size of the operating allowance, depending on the selected processing method and on the dimensions of the surfaces.

To determine the size of the operating allowance by the static method, depending on the processing method, we will use the source tables.

To calculate the operating dimensions with a two-sided arrangement of the allowance, for such surfaces we draw up the following calculation scheme:

Figure 1.10 Layout of operating allowances

Drawing up a statement of calculating diametrical operating dimensions.

Column 1: Indicates the numbers of operations according to the developed technology in which this surface is processed.

Column 2: Indicate the processing method in accordance with the operational chart.

Columns 3 and 4: Indicate the designation and the value of the nominal diametrical operating allowance, taken from the tables in accordance with the processing method and dimensions of the workpiece.

Column 5: Indicate the designation of the operating size.

Column 6: According to the adopted processing scheme, equations are drawn up to calculate the operating dimensions.

Filling out the sheet begins with the final operation.

Column 7: Indicate the accepted operating size with a tolerance. The estimated value of the required operational size is determined by solving the equation from column 6.

List of calculation of operating dimensions when processing the outer diameter of the axis Ø20k6 (Ø20)

	Name operations	Operational allowance		Operating size
		Designation	The magnitude	Designation	Calculation formulas	Approximate size
1	2	3	4	5	6	7
Zag	Stamping	Ø24
10	Turning (roughing)	D10	D10 = D20 + 2z20
20	Turning (finishing)	Z20	0,4	D20	D20 = D45 + 2z45
45	Grinding	Z45	0,06	D45	D45 = damn. rr

Statement of calculation of operating dimensions when processing the outer diameter of the axis Ø75 -0.12

1	2	3	4	5	6	7
Zag	Stamping	Ø79
10	Turning (roughing)	D10	D10 = D20 + 2z20	Ø75.8 -0.2
20	Turning (finishing)	Z20	0,4	D20	D20 = damn. rr

List of calculation of operating dimensions when processing the outer diameter of the axis Ø30k6 (Ø30)

List of calculation of operating dimensions when processing the outer diameter of the shaft Ø20h7 (Ø20 -0.021)

1	2	3	4	5	6	7
Zag	Stamping	Ø34
15	Turning (roughing)	D15	D15 = D25 + 2z25	Ø20.8 -0.2
25	Turning (finishing)	Z25	0,4	D25	D25 = damn. rr	Ø20 -0.021

Statement of calculation of operating dimensions when machining a hole Ø8H7 (Ø8 +0.015)

Statement of calculation of operating dimensions when machining a hole Ø12 +0.07

Statement of calculation of operating dimensions when machining a hole Ø14 +0.07

Statement of calculation of operating dimensions when machining a hole Ø9 +0.058

After calculating the diametrical operating dimensions, we will apply their values ​​to the sketches of the corresponding operations of the route description of the technological process.

1.9 Calculation of cutting conditions

When assigning cutting modes, the nature of processing, the type and size of the tool, the material of its cutting part, the material and condition of the workpiece, the type and condition of the equipment are taken into account.

When calculating cutting conditions, the depth of cut, the minute feed, and the cutting speed are set. Let's give an example of calculating cutting conditions for two operations. For the rest of the operations, the cutting conditions are assigned according to, vol. 2, p. 265-303.

010. Rough turning (Ø24)

Mill model 1P365, processed material - steel 45, tool material CT 25.

The cutter is equipped with a ST 25 carbide insert (Al 2 O 3 + TiCN + T15K6 + TiN). The use of a carbide insert, which does not need regrinding, reduces the time required for tool change, in addition, the basis of this material is improved T15K6, which significantly increases the wear resistance and temperature resistance of ST 25.

Cutting geometry.

We select all the parameters of the cutting part from the Through cutter source: α = 8 °, γ = 10 °, β = + 3 °, f = 45 °, f 1 = 5 °.

2. Coolant brand: 5% emulsion.

3. The depth of cut corresponds to the size of the allowance, since the allowance is removed in one pass.

4. The estimated feed is determined based on the roughness requirements (, page 266) and is specified according to the machine passport.

S = 0.5 rpm.

5. Fortitude, p. 268.

6. The design cutting speed is determined from the specified tool life, feed and depth of cut from, page 265.

where C v, x, m, y - coefficients [5], p. 269;

T - tool life, min;

S - feed, rev / mm;

t is the depth of cut, mm;

K v is a coefficient that takes into account the influence of the workpiece material.

K v = K m v ∙ K p v ∙ K and v,

K m v - coefficient that takes into account the effect of the properties of the processed material on the cutting speed;

K p v = 0.8 is a coefficient that takes into account the effect of the state of the workpiece surface on the cutting speed;

K and v = 1 is a coefficient that takes into account the influence of the tool material on the cutting speed.

K m v = K g ∙,

where K g is a coefficient characterizing a group of steel in terms of machinability.

K m v = 1 ∙

K v = 1.25 ∙ 0.8 ∙ 1 = 1,

7. Estimated speed.

where D is the processed diameter of the part, mm;

V Р - design cutting speed, m / min.

According to the passport of the machine, we take n = 1500 rpm.

8. Actual cutting speed.

where D is the processed diameter of the part, mm;

n - rotation frequency, rpm.

9. The tangential component of the cutting force Pz, H is determined by the formula of the source, p.271.

Р Z = 10 ∙ С р ∙ t х ∙ S у ∙ V n ∙ К р,

where P Z - cutting force, N;

С р, х, у, n - coefficients, page 273;

S - feed, mm / rev;

t is the depth of cut, mm;

V - cutting speed, rpm;

К р - correction factor (К р = К мр ∙ К j р ∙ К g р ∙ К l р, - the numerical values ​​of these coefficients from, pp. 264, 275).

K p = 0.846 ∙ 1 ∙ 1.1 ∙ 0.87 = 0.8096.

Р Z = 10 ∙ 300 ∙ 2.8 ∙ 0.5 0.75 ∙ 113 -0.15 ∙ 0.8096 = 1990 N.

10. Power from, p. 271.

,

where P Z - cutting force, N;

V - cutting speed, rpm.

.

The power of the electric motor of the 1P365 machine is 14 kW, so the drive power of the machine is sufficient:

N res.< N ст.

3.67 kW<14 кВт.

035. Drilling

Drilling a hole Ø8 mm.

Machine model 2550F2, processed material - steel 45, tool material P6M5. Processing is carried out in one pass.

1. Justification of the grade of material and geometry of the cutting part.

Material of the cutting part of the P6M5 tool.

Hardness 63 ... 65 HRCэ,

Ultimate bending strength s p = 3.0 GPa,

Tensile strength s in = 2.0 GPa,

Compressive strength s compress = 3.8 GPa,

Cutting part geometry: w = 10 ° - angle of inclination of the helical tooth;

f = 58 ° - entering angle,

a = 8 ° - back angle to be sharpened.

2. Depth of cut

t = 0.5 ∙ D = 0.5 ∙ 8 = 4 mm.

3. Estimated feed is determined based on the roughness requirements .s 266 and is specified according to the machine passport.

S = 0.15 rpm.

4. Persistence with. 270.

5. The design cutting speed is determined from the specified tool life, feed and depth of cut.

where C v, x, m, y are coefficients, p. 278.

T - tool life, min.

S - feed, rev / mm.

t - cutting depth, mm.

K V is a coefficient that takes into account the influence of the workpiece material, surface condition, tool material, etc.

6. Estimated speed.

where D is the workpiece diameter to be machined, mm.

V p - design cutting speed, m / min.

According to the passport of the machine, we take n = 1000 rpm.

7. Actual cutting speed.

where D is the processed diameter of the part, mm.

n- rotation frequency, rpm.

.

8. Torque

М cr = 10 ∙ С М ∙ D q ∙ S у ∙ К р.

S - feed, mm / rev.

D - drilling diameter, mm.

M cr = 10 ∙ 0.0345 ∙ 8 2 ∙ 0.15 0.8 ∙ 0.92 = 4.45 N ∙ m.

9. Axial force R about, N on, p. 277;

P about = 10 ∙ С Р · D q · S y · К Р,

where С Р, q, у, K р, - coefficients с.281.

P o = 10 ∙ 68 8 1 0.15 0.7 0.92 = 1326 N.

9. Cutting power.

where М cr - torque, N ∙ m.

V - cutting speed, rpm.

0.46 kW< 7 кВт. Мощность станка достаточна для заданных условий обработки.

040. Grinding

Machine model 3T160, processed material - steel 45, tool material - normal electrocorundum 14A.

Plunge grinding with the periphery of the wheel.

1. Grade of material, geometry of the cutting part.

Choosing a circle:

PP 600 × 80 × 305 24А 25 Н СМ1 7 К5А 35 m / s. GOST 2424-83.

2. Depth of cut

3. Radial feed S p, mm / rev is determined by the formula from the source, p. 301, tab. 55.

S P = 0.005 mm / rev.

4. The speed of the circle V K, m / s is determined by the formula from the source, p. 79:

where D K is the diameter of the circle, mm;

D K = 300 mm;

n К = 1250 rpm - rotation frequency of the grinding spindle.

5. The estimated frequency of rotation of the workpiece n z.r, rpm will be determined by the formula from the source, p.79.

where V З.Р - the selected workpiece speed, m / min;

V З.Р will be determined according to table. 55, p. 301. Let's take V З.Р = 40 m / min;

d З - workpiece diameter, mm;

6. The effective power N, kW is determined according to the recommendation in

source p. 300:

when plunge-cut grinding with the periphery of the wheel

where the coefficient C N and the exponents r, y, q, z are given in Table. 56, p. 302;

V З.Р - workpiece speed, m / min;

S P - radial feed, mm / rev;

d З - workpiece diameter, mm;

b - grinding width, mm is equal to the length of the workpiece to be ground;

The power of the electric motor of the 3T160 machine is 17 kW, so the drive power of the machine is sufficient:

N res< N шп

1.55 kW< 17 кВт.

1.10 Rationing of operations

Calculation and technological norms of time are determined by calculation.

There are the unit time rate T SHT and the calculation time rate. The calculation rate is determined by the formula on page 46:

where T pcs is the unit time rate, min;

T p.z. - preparatory and final time, min;

n is the number of parts in the batch, pcs.

T pc = t main + t pop + t service + t lane,

where t main is the main technological time, min;

t aux - auxiliary time, min;

t obsl - time of service of the workplace, min;

t lane - time of breaks and rest, min.

The main technological time for turning, drilling operations is determined by the formula on page 47,:

where L is the calculated processing length, mm;

Number of passes;

S min - minute tool feed;

a - the number of simultaneously processed parts.

The estimated processing length is determined by the formula:

L = L res + l 1 + l 2 + l 3.

where L cut - cutting length, mm;

l 1 is the length of the tool approach, mm;

l 2 is the cutting length of the tool, mm;

l 3 - tool overrun length, mm.

The service time of the workplace is determined by the formula:

t service = t technical service + t org.examination,

where t technical service - maintenance time, min;

t org.examination - organizational service time, min.

,

,

where is the coefficient determined according to the standards. We accept.

The time for a break and rest is determined by the formula:

,

where is the coefficient determined according to the standards. We accept.

Here is the calculation of the time norms for three different operations

010 Turning

Let's preliminarily determine the estimated length of processing. l 1, l 2, l 3 will be determined according to the data of Tables 3.31 and 3.32 on page 85.

L = 12 + 6 +2 = 20 mm.

Minute feed

S min = S about ∙ n, mm / min,

where S about - reverse feed, mm / about;

n is the number of revolutions, rpm.

S min = 0.5 ∙ 1500 = 750 mm / min.

min.

Auxiliary time consists of three components: for installation and removal of a part, for transition, for measurement. This time is determined by cards 51, 60, 64 on pages 132, 150, 160 by:

t mouth / removed = 1.2 min;

t transition = 0.03 min;

t meas = 0.12 min;

t flash = 1.2 + 0.03 + 0.12 = 1.35 min.

Maintenance time

min.

Organizational Service Time

min.

Break times

min.

Piece time per operation:

T pcs = 0.03 + 1.35 + 0.09 + 0.07 = 1.48 min.

035 Drilling

Drilling a hole Ø8 mm.

Determine the estimated processing length.

L = 12 + 10.5 + 5.5 = 28 mm.

Minute feed

S min = 0.15 ∙ 800 = 120 mm / min.

Main technological time:

min.

Processing is carried out on a CNC machine. The cycle time of automatic operation of the machine according to the program is determined by the formula:

T c.a = T o + T mv, min,

where T about - the main time of automatic operation of the machine, T about = t main;

T mv - machine-auxiliary time.

T mv = T mv.i + T mv.x, min,

where T mv.i - machine-auxiliary time for automatic tool change, min;

Т мв.х - machine-auxiliary time for the execution of automatic auxiliary moves, min.

T mv. And determined by Appendix 47,.

We accept T mv.x = T o / 20 = 0.0115 min.

T c.a = 0.23 + 0.05 + 0.0115 = 0.2915 min.

The piece time rate is determined by the formula:

where Т в - auxiliary time, min. Determined by card 7,;

and those, and org, and ex - time for service and rest, is determined by, card 16: and those + a org + a ex = 8%;

T in = 0.49 min.

040. Grinding

Determination of the main (technological) time:

where l is the length of the processed part;

l 1 - the value of the penetration and overrun of the tool on the card 43,;

i is the number of passes;

S - tool feed, mm.

min

For definition of auxiliary times see map 44,

T in = 0.14 + 0.1 + 0.06 + 0.03 = 0.33 min

Determination of time for maintenance of the workplace, rest and natural needs:

,

where a obs and a dep is the time for servicing the workplace, rest and natural needs as a percentage of the operational time according to the map 50,:

a obs = 2% and a obs = 4%.

Determination of the piece time norm:

T w = T about + T in + T obs + T dep = 3.52 + 0.33 + 0.231 = 4.081 min

1.11 Economic comparison of 2 options of operations

When developing a technological process for mechanical processing, the problem arises to choose from several processing options one that provides the most economical solution. Modern methods of mechanical processing and a wide variety of machine tools allow you to create various options for technology, ensuring the manufacture of products that fully meet all the requirements of the drawing.

In accordance with the provisions for assessing the economic efficiency of new technology, the most profitable is the option in which the sum of current and reduced capital costs per unit of production will be minimal. The number of addends of the sum of the reduced costs should include only those costs that change their value during the transition to a new version of the technological process.

The sum of these costs, referred to the hours of operation of the machine, can be called hourly adjusted costs.

Consider the following two options for performing a turning operation, in which processing is carried out on different machines:

1. according to the first option, rough turning of the outer surfaces of the part is carried out on a universal screw-cutting lathe model 1K62;

2. According to the second option, rough turning of the outer surfaces of the part is performed on a 1P365 turret lathe.

1. Operation 10 is performed on the 1K62 machine.

The value characterizes the efficiency of the equipment. A lower value for comparing machines with equal productivity indicates that the machine is more economical.

The value of the hourly reduced costs

where is the main and additional wages, as well as social insurance charges to the operator and the adjuster for the physical hour of operation of the serviced machines, kop / h;

The multi-station factor, taken according to the actual state in the considered section, is taken as M = 1;

Hourly costs for the operation of the workplace, cop / h;

Standard coefficient of economic efficiency of capital investments: for mechanical engineering = 2;

Specific hourly capital investments in the machine, cop / h;

Specific hourly capital investments in the building, cop / h.

The basic and additional wages, as well as social insurance contributions to the operator and the adjuster can be determined by the formula:

, cop / h,

where is the hourly wage rate of the machine operator of the corresponding category, cop / h;

1.53 is the total coefficient representing the product of the following partial coefficients:

1.3 - coefficient of compliance with the norms;

1.09 - the coefficient of additional wages;

1.077 - social insurance deduction ratio;

k - the coefficient taking into account the salary of the adjuster, we take k = 1.15.

The value of the hourly costs for the operation of the workplace in the event of a decrease

the load on the machine must be corrected by a factor if the machine cannot be reloaded. In this case, the adjusted hourly cost is:

, cop / h,

where are the hourly costs of operating the workplace, cop / h;

Correction factor:

,

The share of conditionally fixed costs in hourly costs at the workplace, we take;

Machine load factor.

where T SHT - piece time for the operation, T SHT = 2.54 min;

t B - release cycle, we take t B = 17.7 minutes;

m P - the accepted number of machines per operation, m P = 1.

;

,

where is the practical adjusted hourly costs at the base workplace, kopecks;

The machine factor, which shows how many times the costs associated with the operation of a given machine are greater than those of the base machine. We accept.

cop / h.

The capital investment in the machine and building can be determined by:

where C is the book value of the machine, we take C = 2200.

, cop / h,

Where F is the production area occupied by the machine, taking into account the passes:

where is the production area occupied by the machine, m 2;

Coefficient taking into account additional production area,.

cop / h.

cop / h.

The cost of machining for the operation under consideration:

, cop.

cop.

2. Operation 10 is performed on the 1P365 machine.

C = 3800 rubles.

T PC = 1.48 min.

cop / h.

cop / h.

cop / h.

cop.

Comparing the options for performing the turning operation on various machines, we come to the conclusion that turning the outer surfaces of the part should be carried out on a 1P365 turret lathe. Since the cost of machining a part is lower than if it is performed on a 1K62 machine.

2. Design of special machine tooling

2.1 Initial data for the design of machine tooling

In this course project, a machine tool has been developed for operation No. 35, in which drilling, countersinking and reaming of holes is performed using a CNC machine.

The type of production, the release program, as well as the time spent on the operation, which determine the level of speed of the device when installing and removing the part, influenced the decision to mechanize the device (the part is clamped in teaks due to the pneumatic cylinder).

The fixture is used to install only one part.

Consider the layout of the part in the fixture:

Figure 2.1 Installation diagram of a part in a vice

1, 2, 3 - installation base - deprives the workpiece of three degrees of freedom: movement along the OX axis and rotation around the OZ and OY axes; 4, 5 - double support base - deprives of two degrees of freedom: movement along the axes OY and OZ; 6 - support base - deprives rotation around the OX axis.

2.2 Schematic diagram of the machine tool

As a machine tool, we will use a machine vise equipped with a pneumatic drive. The pneumatic drive ensures the constant clamping force of the workpiece, as well as the quick fixing and detaching of the workpiece.

2.3 Description of design and principle of operation

Universal self-centering vice with two movable replaceable jaws is designed for fixing axle-type parts when drilling, countersinking and reaming holes. Consider the design and principle of operation of the device.

On the left end of the body 1 of the vice is fixed the adapter sleeve 2, and on it the pneumatic chamber 3. Between the two covers of the pneumatic chamber diaphragm 4 is clamped, which is rigidly fixed on the steel disk 5, in turn, fixed on the rod 6. The rod 6 of the pneumatic chamber 3 is connected through the rod 7 with a rolling pin 8, at the right end of which there is a rack 9. The rack 9 is in engagement with the gear wheel 10, and the gear wheel 10 - with the upper movable rack 11, on which the right movable jaw is installed and secured by means of two pins 23 and two bolts 17 12. The lower end of the pin 14 enters the circular groove on the left end of the rolling pin 8, its upper end is pressed into the hole of the left movable jaw 13. Replaceable clamping prisms 15 corresponding to the diameter of the axis to be machined are fixed with screws 19 on movable jaws 12 and 13. Pneumatic chamber 3 is attached to the adapter sleeve 2 using 4 bolts 18. In turn, the adapter sleeve 2 is attached to the body of the tool 1 using bolts 16.

When compressed air enters the left cavity of the pneumatic chamber 3, the diaphragm 4 bends and moves to the right the rod 6, the rod 7 and the rolling pin 8. The rolling pin 8 with the finger 14 moves the sponge 13 to the right, and with the left rack and pinion end, rotating the gear 10, moves the upper rack 11 with the sponge 12 to the left. Thus, the jaws 12 and 13, moving, clamp the workpiece. When compressed air enters the right cavity of the pneumatic chamber 3, the diaphragm 4 bends to the other side and the rod 6, the rod 7 and the rolling pin 8 are moved to the left; rolling pin 8 spreads jaws 12 and 13 with prisms 15.

2.4 Calculation of the machine tool

Force calculation of the device

Figure 2.2 Scheme for determining the clamping forces of the workpiece

To determine the clamping force, we will simplify the workpiece in the device and depict the moments from the cutting forces and the required required clamping force.

Figure 2.2:

M is the torque on the drill;

W is the required fastening force;

α is the angle of the prism.

The required clamping force of the workpiece is determined by the formula:

, H,

where M is the torque on the drill;

α is the angle of the prism, α = 90;

The coefficient of friction on the working surfaces of the prism, we take;

D is the diameter of the workpiece, D = 75 mm;

K is the safety factor.

K = k 0 ∙ k 1 ∙ k 2 ∙ k 3 ∙ k 4 ∙ k 5 ∙ k 6,

where k 0 is the guaranteed safety factor, for all cases of processing k 0 = 1.5

k 1 - coefficient taking into account the presence of random irregularities on the workpieces, which entails an increase in cutting forces, we take k 1 = 1;

k 2 - coefficient taking into account the increase in cutting forces from progressive bluntness of the cutting tool, k 2 = 1.2;

k 3 - coefficient taking into account the increase in cutting forces during interrupted cutting, k 3 = 1.1;

k 4 - coefficient taking into account the variability of the clamping force when using pneumatic lever systems, k 4 = 1;

k 5 - coefficient taking into account the ergonomics of hand clamping elements, we take k 5 = 1;

k 6 - coefficient taking into account the presence of moments tending to rotate the workpiece, we take k 6 = 1.

K = 1.5 ∙ 1 ∙ 1.2 ∙ 1.1 ∙ 1 ∙ 1 ∙ 1 = 1.98.

Torque

М = 10 ∙ С М ∙ D q ∙ S у ∙ К р.

where C M, q, y, K p, are the coefficients, p. 281.

S - feed, mm / rev.

D - drilling diameter, mm.

M = 10 ∙ 0.0345 ∙ 8 2 ∙ 0.15 0.8 ∙ 0.92 = 4.45 N ∙ m.

N.

Determine the force Q on the rod of the diaphragm pneumatic chamber. The force on the rod changes as it moves, since the diaphragm begins to resist in a certain area of ​​movement. The rational stroke length of the rod, at which there is no sharp change in the force Q, depends on the calculated diameter D, the thickness t, the material and design of the diaphragm, as well as on the diameter d of the supporting disk.

In our case, we take the diameter of the working part of the diaphragm D = 125 mm, the diameter of the supporting disk d = 0.7 ∙ D = 87.5 mm, the diaphragm is made of rubberized fabric, the thickness of the diaphragm is t = 3 mm.

Force in the initial position of the stem:

, H,

Where p is the pressure in the pneumatic chamber, we take p = 0.4 ∙ 10 6 Pa.

Rod force for 0.3D travel:

, N.

Calculation of the device for accuracy

Based on the accuracy of the maintained size of the workpiece, the following requirements are imposed on the corresponding dimensions of the fixture.

When calculating the accuracy of fixtures, the total error in processing the part should not exceed the tolerance value T of the size, i.e.

The total error of the device is calculated using the following formula:

where T is the tolerance of the size to be performed;

Positioning error, since in this case there is no deviation of the actually reached position of the part from the required one;

Fixing error,;

Installation error of the device on the machine,;

The error in the position of the part due to wear of the elements of the device;

The approximate wear of the installation elements can be determined by the formula:

,

where U 0 is the average wear of the mounting elements, U 0 = 115 microns;

k 1, k 2, k 3, k 4 are, respectively, coefficients that take into account the influence of the workpiece material, equipment, processing conditions and the number of workpiece installations.

k 1 = 0.97; k 2 = 1.25; k 3 = 0.94; k 4 = 1;

We accept microns;

Error from skewing or displacement of the tool, since there are no guiding elements in the fixture;

The coefficient taking into account the deviation of the scattering of the values ​​of the constituent quantities from the law of normal distribution,

Coefficient that takes into account the reduction of the limiting value of the positioning error when working on tuned machines,

Coefficient that takes into account the share of processing error in the total error caused by factors that do not depend on the device,

Economic precision of processing, = 90 microns.

3. Design of special control equipment

3.1 Initial data for the design of the test fixture

Control and measuring devices are used to check the compliance of the parameters of the manufactured part with the requirements of the technological documentation. Preference is given to devices that allow you to determine the spatial deviation of some surfaces in relation to others. This device meets these requirements, because measures the radial runout. The device has a simple device, easy to operate and does not require high qualifications of the controller.

Parts of the axle type in most cases transmit significant torques to the mechanisms. In order for them to work reliably for a long time, high accuracy of the main working surfaces of the axis in terms of diametric dimensions is of great importance.

The inspection process predominantly provides for a complete check of the radial runout of the outer surfaces of the axle, which can be carried out on a multidimensional inspection device.

3.2 Schematic diagram of the machine tool

Figure 3.1 Schematic diagram of the test fixture

Figure 3.1 shows a schematic diagram of a device for monitoring the radial runout of the outer surfaces of the axle part. The diagram shows the main parts of the device:

1 - device body;

2 - headstock;

3 - tailstock;

4 - rack;

5 - indicator heads;

6 - controlled detail.

3.3 Description of design and principle of operation

On the body 1 with the help of screws 13 and washers 26, a headstock 2 with a mandrel 20 and a tailstock 3 with a fixed return center 23 are fixed, on which the tested axis is installed. The axial position of the axle is fixed by a fixed reverse center 23. The axle is pressed against the latter by a spring 21, which is located in the central axial hole of the quill 5 and acts on the adapter 6. The quill 5 is mounted in the headstock 2 with the possibility of rotation about the longitudinal axis thanks to the bushings 4. at the left end quill 5, a handwheel 19 with a handle 22 is installed, which is secured with a washer 8 and a pin 28, the torque from the handwheel 19 is transmitted to the quill 5 using the key 27. To the adapter 6, the rotational movement during measurement is transmitted through the pin 29, which is pressed into the quill 5. In addition , at the other end of the adapter 6, a mandrel 20 with a conical working surface is inserted for precise, backlash-free positioning of the axis, since the latter has a cylindrical axial hole with a diameter of 12 mm. The taper of the mandrel depends on the tolerance T and the diameter of the axle hole and is determined by the formula:

mm.

In two racks 7, attached to the housing 1 with screws 16 and washers 25, there is a shaft 9, along which the brackets 12 move and are fixed with screws 14. On the brackets 12, rolling pins 10 are installed using screws 14, on which screws 15, nuts 17 and washers 24 fixed by IG 30.

Two IG 30 serve to check the radial runout of the outer surfaces of the axle, which is given one or two revolutions and the maximum readings of the IG 30, which determine the runout, are counted. The device ensures high productivity of the control process.

3.4 Calculation of the test fixture

The most important condition, which must be satisfied by control devices, is to ensure the required measurement accuracy. Accuracy largely depends on the adopted measurement method, on the degree of perfection of the circuit diagram and design of the device, as well as on the accuracy of its manufacture. An equally important factor influencing the accuracy is the accuracy of the surface fabrication, which is used as a measuring base for the parts to be inspected.

where is the error in the manufacture of the installation elements and their location on the device body, we take mm;

The error caused by the inaccuracy of the manufacturing of the transfer elements is taken as mm;

The systematic error, taking into account the deviations of the installation dimensions from the nominal ones, is taken as mm;

Basis error, we accept;

The error of displacement of the measuring base of the part from the given position, we take mm;

Fixing error, take mm;

The error from the gaps between the axes of the levers, we accept;

The error in the deviation of the installation elements from the correct geometric shape, we accept;

The error of the measurement method, we take mm.

The total error can be up to 30% of the tolerance of the controlled parameter: 0.3 ∙ T = 0.3 ∙ 0.1 = 0.03 mm.

0.03 mm ≥ 0.0034 mm.

3.5 Development of a setup card for operation No. 30

The development of a setup card allows you to understand the essence of setting up a CNC machine when performing an operation with an automatic method of obtaining a given accuracy.

As the adjustment dimensions, we take the dimensions corresponding to the middle of the tolerance field of the operating dimension. The value of the tolerance for the setting size is taken

T n = 0.2 * T op.

where T n is the tolerance for the setting size.

T op - tolerance for the operating size.

For example, in this operation we sharpen the surface Ø 32.5 -0.08, then the adjustment size will be equal to

32.5 - 32.42 = 32.46 mm.

T n = 0.2 * (-0.08) = - 0.016 mm.

Adjustment dimension Ø 32.46 -0.016.

The calculation of the remaining sizes is carried out in the same way.

Conclusions on the project

According to the assignment for the course project, a technological process for manufacturing a shaft was designed. The technological process contains 65 operations, for each of which cutting conditions, time rates, equipment and tooling are indicated. For the drilling operation, a special machine tool has been designed, which allows to ensure the necessary precision in the manufacture of the part, as well as the required clamping force.

When designing a technological process for manufacturing a shaft, a setup card for a turning operation No. 30 was developed, which makes it possible to understand the essence of setting up a CNC machine when performing an operation with an automatic method of obtaining a given accuracy.

During the implementation of the project, a settlement and explanatory note was drawn up, which describes in detail all the necessary calculations. Also, the settlement and explanatory note contains applications that include operational cards, as well as drawings.

Bibliography

1. Handbook of a mechanical engineer. In 2 volumes / ed. A.G. Kosilova and R.K. Meshcheryakova.-4th ed., Revised. and add. - M .: Mechanical Engineering, 1986 - 496 p.

2. G.I. Granovsky, V.G. Granovsky Cutting metals: Textbook for machine building. and instrument specialist. universities. _ M .: Higher. shk., 1985 - 304 p.

3. Marasinov M.A. Guidelines for calculating operating sizes. - Rybinsk. RGATA, 1971.

4. Marasinov M.A. Design of technological processes in mechanical engineering: Textbook.- Yaroslavl. 1975.-196 p.

5. Mechanical engineering technology: a textbook for the implementation of a course project / V.F. Languageless, V.D. Korneev, Yu.P. Chistyakov, M.N. Averyanov.- Rybinsk: RGATA, 2001.- 72 p.

6. General machine-building standards for the auxiliary, for the maintenance of the workplace and the preparatory - final for the technical standardization of machine work. Mass production. M, Mechanical Engineering. 1964.

7. Anserov M.A. Accessories for metal-cutting machine tools. 4th edition, revised. and additional L., mechanical engineering, 1975

Impossible without the use of various shaped parts.

Adapters are needed for the transition from plastic to metal, as well as for connecting pipe material of different diameters.

Pipe adapters are connection adapters that help to correctly and securely assemble a piping system. Such elements serve for the transition from plastic to metal (adapters), for connecting pipe material of different diameters, provide the required angle of rotation and branching of the pipeline. Structural details are also called the newfangled English term "fittings".

With the help of modern fittings, a pipeline system of any complexity can be assembled with a minimum of time and effort. Some adapters can be docked using only hands. This connection method is no less reliable than any other, and is used even for high pressure pipes.

Installation of adapters for plastic pipes

Plastic adapters for the pipeline must be selected based on the composition of the pipes. They may be:

• polyethylene;
• polypropylene;
• polyvinyl chloride.

Installation of plastic fittings-adapters is carried out in different ways. This does not require bulky equipment and a team of pipelines. The type of connection depends on the type of polymer, the diameter of the pipes and the purpose of the pipeline. Often there is a need to replace a piece of a pipeline that has rotted from time to time with a plastic pipe. Then a connection of a cast iron / steel and polymer pipe is required. Adapters come to the rescue. To connect you will need:

1. Combination adapter with metal threaded part (mostly brass) and plastic flare with rubber gasket.
2. Two adjustable wrenches.
3. Teflon tape (tow).

The installation of plastic pipes is carried out in the socket, thereby achieving a high-quality homogeneous seam.

The replacement of the old pipe is very fast. First, the clutch of the metal pipeline is unscrewed in the right place. To do this, use two adjustable wrenches. With one key, they take up the coupling, and with the other, the metal pipe. If the connection does not lend itself, then it should be lubricated with a special grease with an increased degree of penetration (Unisma-1, Molykote Multigliss).

At the next stage, when the old pipe is unscrewed, the threaded connections are sealed with Teflon tape in two to three turns. This little precaution helps to avoid further leaks. The final step is to install the adapter. Tighten the adapter carefully without over-tightening until resistance is felt.

Metal and polymer have different coefficients of expansion during temperature fluctuations, therefore it is not recommended to use adapters with plastic threads for metal elements. In hot water supply and heating systems, for connection with metal valves and meters, it is worth using transitional brass couplings with a plastic body and a sealing rubber.

Classification of adapter adapters

Adapters are:

• compression;
• electrowelded;
• flanged;
• threaded;
• reduction.

The type of connection depends on the type of polymer, the diameter of the pipes and the purpose of the pipeline.

The compression adapter is a crimp fitting for plastic water pipes. Also, such fittings are used for the distribution of the pipeline system. Plastic compression parts withstand pressures up to 16 atm. (up to 63 mm) and high temperature. They are not subject to lime deposits, decay and other biological and chemical influences. Manufactured in standard diameters. They have such components as a nut-cap, a polypropylene body, a polyoxymethylene clamping ring, a press-in sleeve.

Installing the compression adapter

1. Loosen union nut and remove.
2. Disassemble the fitting into its component parts and put them on the plastic pipe in the same order.
3. Push the pipe firmly into the fitting until it stops.
4. Tighten the adapter nut with the Allen wrench (a crimp wrench is usually sold with the fittings).

The modern plumbing market today offers non-collapsible ones, but it is still difficult to say which of them is better.

When installing a compression fitting, a crimping of the compression element is formed on the pipe, which creates a tight connection. The clamping ring - the main part of the fitting - allows the joint to withstand colossal axial loads and jerks. Spontaneous spinning caused by vibration of the water is prevented. Therefore, you do not have to constantly tighten the loose nut.

A threaded adapter is a collapsible and assembled pipeline element that is used repeatedly. Threaded fittings can be either male or female. Such fittings are installed in those places where some additional installation is required, disassembly of the pipeline system and other work that would be impossible if the system were non-separable.

Threaded adapters do not require special equipment during installation. At the same time, a sealed connection is created, preventing the leakage of water or gas from the plastic pipes. For more reliable sealing, an FUM tape is additionally used, which is wound on the thread in the direction of screwing the nut.

ZNE allow to quickly carry out the installation of polyethylene pipelines using cheaper welding equipment for electrofusion welding.

An electrowelded adapter (ZNE) is a connecting element with a built-in electric heater, designed for different diameters. A heating coil built into the adapter melts the plastic at the pipe joint and creates a monolithic joint.

Installation of an electrowelded adapter does not require any special skills. The quality of electrofusion welding depends little on the person performing the work, which cannot be said about hardware welding.

Installing an electrofusion adapter

The fastened parts are carefully aligned and docked in the required places. Electric current is passed through the embedded electric heaters. Under the influence of electricity, the spiral heats up and brings the plastic planes into a viscous state. The result is a monolithic compound at the molecular level.

When installing electrowelded adapters, general requirements should be observed:

• the elements to be welded must have an identical chemical composition;
• degreasing and thorough cleaning of surfaces;
• mechanical cleaning with tools;
• natural cooling.

On the advice of experts, it is better to use ZNE adapters with an open heating coil. Plastic pipes should go deep into the fitting, and the weld zone should be as long as possible.

Flange adapter or compression flange

This is a detachable connection element that provides constant access to a section of the pipeline. The joint is formed by two flanges and bolts that pull them together. For plastic pipes passing to metal elements, free-form flanges with a reference point on a straight shoulder or a universal wedge connection with shaped flanges are most often used.

Before installation, the flange part must be inspected and all nicks and burrs that can damage the polymer pipe are revealed. Then a phased connection is made:

• pipes are cut strictly at right angles;
• flanges of the required standard size are installed;
• a rubber gasket is put on (the gasket must not be allowed to go beyond the pipe cut more than 10 mm);
• both flange rings slide over the rubber gasket and are bolted together.

These flanges will ensure the tightness and strength of the pipeline structure. They are easy to manufacture and easy to install.

Reducing adapter is a connecting piece for. This fitting is threaded and is often installed in assemblies that connect the pipe to meters and other distribution equipment.

Plastic pipes cannot be assembled into a piping system without a large set of fittings. The variety of these structural elements is amazing. It's hard to figure out what's what right away. Therefore, before assembling the pipeline, you should scrupulously study the entire rich assortment and choose only what you need. Very often, an unlucky craftsman who decides to change pipes will end up with a bunch of unnecessary parts at home. It's time to open a plumbing store yourself!

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technological process construction detail

1. Design part

1.1 Description of the assembly unit

1.2 Description of the design of parts included in the design of the unit

1.3 Description of structural modifications proposed by the student

2. Technological part

2.1 Analysis of the manufacturability of the design of the part

2.2 Development of a route technological process for manufacturing a part

2.3 Selection of the applied technological equipment and tools

2.4 Development of basing schemes

1 . Design part

1 . 1 Description of the design of a subassembly or assembly unit

An adapter part, for which the manufacturing process will subsequently be designed, is an integral part of an assembly unit, such as a valve, which, in turn, is used in modern equipment (for example, an oil filter in a car). Oil filter - a device designed to clean engine oil from contaminating it during the operation of an internal combustion engine, mechanical particles, resins and other impurities. This means that the lubrication system of internal combustion engines cannot do without an oil filter.

Figure 1.1 - Valve BNTU 105081.28.00 SB

Parts: Spring (1), spool (2), adapter (3), tip (4), plug (5), washer 20 (6), ring (7), (8).

To assemble the "Valve" assembly, you must perform the following steps:

1. Before assembly, check the surfaces for cleanliness, as well as for the absence of abrasive substances and corrosion between the mating parts.

2. When installing, secure rubber rings (8) against distortions, twisting, mechanical damage.

3. When assembling grooves for rubber rings in parts (4), lubricate with Litol-24 GOST 21150-87 grease.

4. Observe the tightening standards in accordance with OST 37. 001. 050-73, as well as the technical requirements for tightening in accordance with OST 37. 001. 031-72.

5. The valve must be sealed when supplying oil to any cavity, with the second plugged, with a viscosity of 10 to 25 cSt under a pressure of 15 MPa, the appearance of separate drops at the connection of the tip (4) with the adapter (3) is not a rejection sign.

6. Comply with the rest of the technical requirements in accordance with STB 1022-96.

1 . 2 Part design description, included in the construction of the node (assembly unit)

A spring is an elastic element designed to accumulate or absorb mechanical energy. The spring can be made of any material with sufficiently high strength and elastic properties (steel, plastic, wood, plywood, even cardboard).

Steel springs for general use are made of high-carbon steels (U9A-U12A, 65, 70) alloyed with manganese, silicon, vanadium (65G, 60S2A, 65S2VA). For springs operating in aggressive environments, stainless steel (12X18H10T), beryllium bronze (BrB-2), silicon-manganese bronze (BrKMts3-1), tin-zinc bronze (BrOTs-4-3) are used. Small springs can be wound from ready-made wire, while powerful springs are made of annealed steel and are hardened after forming.

Washer - A fastener that is placed under another fastener to create a larger surface area, reduce damage to the surface of the part, prevent the fastener from self-loosening, and also to seal the connection with the gasket.

Our design uses a washer GOST 22355-77

Spool, spool valve - a device that directs the flow of liquid or gas by displacing the moving part relative to the windows in the surface on which it slides.

Our design uses a spool 4570-8607047

Spool material - Steel 40X

An adapter is a device, device or part designed to connect devices that do not have any other compatible connection method.

Figure 1. 2 Sketch of the "Adapter" part

Table 1.1

Summary table of the characteristics of the surface of the part (adapter).

Name surface	Accuracy (Quality)	Roughness,	Note
End (flat) (1)			End runout no more than 0. 1 relative to the axis.
Male threaded (2)
Groove (3)
Internal cylindrical (4)
Outer cylindrical (5)			Deviation from perpendicularity no more than 0.1 relative to (6)
End (flat) (6)
Internal thread (7)
Internal cylindrical (9)
Groove (8)
Internal cylindrical (10)

Table 1.2

Chemical composition of steel Steel 35 GOST 1050-88

The material that was chosen for the manufacture of the part in question is steel 35 GOST 1050-88. Steel 35 GOST1050-88 is a high-quality structural carbon steel. It is used for parts of low strength, experiencing small stresses: axles, cylinders, crankshafts, connecting rods, spindles, sprockets, rods, traverses, shafts, tires, discs and other parts.

1 . 3 Owriting modifications to the designs proposed by the student

The part of the adapter complies with all accepted norms, GOSTs, design standards, therefore, it does not need revision and improvements, since this will lead to an increase in the number of technological operations and equipment used, as a result of which to an increase in processing time, which will lead to an increase in the cost of a unit of production, which is not economically feasible.

2 . Technological part

2 . 1 Analysis of the manufacturability of the design of the part

The manufacturability of a part is understood as a set of properties that determine its adaptability to achieving optimal costs in production, operation and repair for given quality indicators, production volume and work performance. Analysis of the manufacturability of a part is one of the important stages in the process of developing a technological process and is carried out, as a rule, in two stages: qualitative and quantitative.

Qualitative analysis of the part The adapter for manufacturability showed that there is a sufficient number of sizes, types, tolerances, roughness for its manufacture, that there is a possibility of maximizing the approximation of the workpiece to the size and shape of the part, the ability to carry out processing with through cutters. Part material St35 GOST 1050-88, it is widely available and widespread. Part weight 0. 38kg, therefore there is no need to use additional equipment for its processing and transportation. All surfaces of the part are easily accessible for processing and their design and geometry allows processing with standard tools. All holes in the part are through, therefore there is no need for positioning the tool during machining.

All chamfers made at the same angle, therefore, can be performed with one tool, the same applies to the grooves (groove cutter), there are 2 grooves in the part for the tool to exit when cutting a thread, this is a sign of manufacturability. The part is rigid, since the ratio of length to diameter is 2. 8, therefore, it does not require additional fixtures to secure it.

Due to the simplicity of the design, small dimensions, low weight and a small number of machined surfaces, the part is quite technologically advanced and does not present any difficulties for machining. I determine the manufacturability of the part using quantitative indicators that are necessary to determine the accuracy coefficient. The data obtained are shown in Table 2.1.

Table 2.1

Number and accuracy of surfaces

The coefficient of manufacturability in terms of accuracy is 0.91> 0.75. This shows the small requirements for the accuracy of the surfaces of the adapter part and indicates its manufacturability.

To determine the roughness, all the necessary data are summarized in table 2.2.

Table 2.2

Number and roughness of surfaces

The coefficient of manufacturability in terms of roughness is 0.0165<0. 35, это свидетельствует о малых требованиях по шероховатости для данной детали, что говорит о её технологичности

Despite the presence of non-technological features, according to the qualitative and quantitative analysis, the adapter part is generally considered to be technologically advanced.

2 .2 Development of a route technological process for manufacturing a part

To obtain the required shape of the part, trim the ends "as clean" is used. We sharpen the surface Ш28. 4-0. 12 for a length of 50.2-0, 12, maintaining R0. 4max. Next, we sharpen the chamfer 2.5X30 °. We sharpen the groove "B", keeping the dimensions: 1. 4 + 0, 14; angle 60 °; Ш26. 5-0. 21; R0. 1; R1; 43 + 0. 1. Centers the end face. Let's drill a hole Ш17 to a depth of 46.2-0. 12. We bore the hole Ш14 to Ш17. 6 + 0. 12 to a depth of 46.2-0. 12. We grind Ш18. 95 + 0. 2 to a depth of 18.2-0. 12. We bore the groove "D", keeping the dimensions. We bore a chamfer 1.2X30 °. We cut the end to size 84. 2-0, 12. Drill the Ш11 hole up to the entrance to the Ш17 hole. 6 + 0. 12. Countersink a chamfer 2.5 × 60 ° in hole Ш11. Sharpen Ш31. 8-0, 13 to length 19 for thread М33Ч2-6g. Sharpen a chamfer 2.5X45 °. Sharpen groove "B". Cut the thread М33Ч2-6g. Sharpen the chamfer keeping the dimensions Ш46, angle 10 °. Cut the thread M20CH1-6H. Drill hole Ш9 through. Countersink a 0.3X45 ° chamfer in hole Ш9. Grind hole Ш18 + 0, 043 to Ra0. 32. Grind Ш28. 1-0. 03 to Ra0. 32 with right-hand side grinding in size 84. Grind W up to Ra0, 16.

Table 2.4

List of mechanical operations

Operation No.	Operation name
	CNC lathe
	CNC lathe
	Screw-cutting lathe.
	Vertical drilling
	Vertical drilling
	Internal grinding
	Cylindrical grinding
	Cylindrical grinding
	Screw-cutting lathe
	Control by the performer

2 .3 Selection of the applied technological equipment and tools

In the conditions of modern production, a cutting tool that is used in the processing of large batches of parts with the required accuracy acquires an important role. At the same time, such indicators as durability and the method of adjusting to size come out on top.

The choice of machines for the designed technological process is made after each operation has been previously developed. This means that the following have been selected and determined: the method of surface treatment, accuracy and roughness, cutting tool and type of production, overall dimensions of the workpiece.

For the manufacture of this part, the following equipment is used:

1. CNC lathe CNC16K20F3;

2. Screw-cutting lathe 16K20;

3. Vertical drilling machines 2H135;

4. Internal grinding machine 3K227V;

5. Semi-automatic circular grinding machine 3M162.

Lathe with CNC 16K20T1

Lathe with CNC model 16K20T1 is designed for fine processing of parts such as bodies of revolution in a closed semi-automatic cycle.

Figure 2.1 - Lathe with CNC 16K20T1

Table 2.5

Technical characteristics of a turning machine with CNC 16K20T1

Parameter	Meaning
The largest diameter of the workpiece to be processed, mm:
over bed
over support
The greatest length of the workpiece to be processed, mm
Center height, mm
The largest diameter of the bar, mm
Cut thread pitch: metric, mm;
Spindle bore diameter, mm
Internal taper of spindle Morse
Spindle speed, rpm
Feed, mm / rev. :
Longitudinal
Transverse
Taper hole pintles morse
Cutter section, mm
Chuck diameter (GOST 2675. 80), mm
Main drive motor power, kW
Numerical control device
Deviation from the flatness of the end surface of the sample, μm
Machine dimensions, mm

Figure 2.2 - Screw-cutting lathe 16K20

The machines are designed for a variety of turning operations and for cutting threads: metric, modular, inch, pitch. The designation of the machine model 16K20 acquires additional indices:

"B1", "B2", etc. - when changing the main technical characteristics;

"U" - when the machine is equipped with an apron with a built-in accelerated movement motor and a feed box, which provides the ability to cut threads of 11 and 19 threads per inch without replacing replaceable gears in the gearbox;

"C" - when equipping the machine with a drilling and milling device designed for drilling, milling and threading at different angles on parts installed on the machine support;

"B" - when ordering a machine with an increased largest diameter of the workpiece processing over the bed - 630mm and the support - 420mm;

"G" - when ordering a machine with a recess in the bed;

"D1" - when ordering a machine with an increased largest diameter of the bar passing through the hole in the spindle 89 mm;

"L" - when ordering a machine with a division value of the lateral movement dial of 0.02mm;

"M" - when ordering a machine with a mechanized drive of the upper part of the support;

"C" - when ordering a machine with a digital indexing device and linear displacement transducers;

"RC" - when ordering a machine with a digital indexing device and linear displacement transducers and with stepless spindle speed control;

Table 2.6

Technical characteristics of the screw-cutting lathe 16K20

Parameter name	Meaning
1 Indicators of the workpiece processed on the machine
1.1 The largest diameter of the workpiece to be processed: over bed, mm
1.2 The largest diameter of the workpiece to be processed over the slide, mm, not less
1.3 The greatest length of the workpiece to be installed (when installed in the centers), mm, not less over the groove in the bed, mm, not less
1.4 Height of centers over bed guides, mm
2 Indicators of the tool installed on the machine
2.1 The greatest height of the cutter installed in the tool holder, mm
3 Indicators of the main and auxiliary movements of the machine
3.1 Number of spindle speeds: direct rotation reverse rotation
3.2 Limits of spindle frequencies, rpm
3.3 Number of caliper feeds longitudinal transverse
3.4 Limits of the support feed, mm / rev longitudinal transverse
3.5 Limits of steps of the cut threads metric, mm modular, module inch, number of threads pitch, pitch
3.6 Speed ​​of rapid movements of the support, m / min: longitudinal transverse
4 Indicators of the power characteristics of the machine
4.1 The greatest torque on the spindle, kNm
4. 2
4.3 Power of the drive of fast movements, kW
4.4 Cooling drive power, kW
4.5 Total power installed on the machine electric motors, kW
4.6 Total power consumption of the machine, (maximum), kW
5 Indicators of the dimensions and weight of the machine
5.1 Overall dimensions of the machine, mm, no more:
5.2 Machine weight, kg, no more
6 Characteristics of electrical equipment
6.1 Kind of current of the supply network	Variable, three-phase
6.2 Current frequency, Hz
7 Corrected sound power level, dBa
8 Machine accuracy class according to GOST 8

Figure 2.3 - Vertical drilling machine 2T150

The machine is designed for: drilling, reaming, countersinking, reaming and threading. Vertical drilling machine with a table moving along a round column and a table rotating on it. The machine can handle small parts on a table, larger ones on a base plate. Manual and mechanical spindle feed. Tincture to the working depth with automatic feed cut-off. Tapping with manual and automatic spindle reversal at a given depth. Processing small parts on the table. Control of the spindle movement along the ruler. Built-in cooling.

Table 2.7

Technical characteristics of the machine of the Vertical drilling machine 2T150

The largest conditional drilling diameter, mm cast iron SCH20
The largest diameter of the thread to be cut, mm, in steel
Precision of holes after reaming
Spindle taper	Morse 5 AT6
The greatest movement of the spindle, mm
Distance from spindle end to table, mm
The greatest distance from the end of the spindle to the plate, mm
The greatest movement of the table, mm
Working surface size, mm
Number of spindle speeds
Spindle speed limits, rpm.
Number of spindle feeds
Amount of spindle feed, mm / rev.
The greatest torque on the spindle, Nm
The greatest feed force, N
Angle of rotation of the table around the column
Cutting off the feed when reaching the specified drilling depth	automatic
Mains current type	Three-phase variable
Voltage, V
Main drive power, kW
Total power of the electric motor, kW
Overall dimensions of the machine (LхBхH), mm, no more
Machine weight (net / gross), kg, no more
Overall dimensions of the package (LхWхH), mm, no more

Figure 2.4 - Internal grinding machine 3K228A

Internal grinding machine 3K228A is designed for grinding cylindrical and conical, blind and through holes. The 3K228A machine has a wide range of rotational speeds of grinding wheels, product spindle, cross feed values ​​and table movement speeds, which ensure processing of parts at optimal conditions.

Roller guides for the lateral movement of the grinding head together with the final link - a ball, screw pair, ensure minimal movements with high accuracy. The device for grinding the ends of products allows you to process holes and an end on the 3K228A machine in one installation of the product.

The accelerated set-up transverse movement of the grinding head reduces the auxiliary time during the changeover of the 3K228A machine.

To reduce the heating of the bed and eliminate the transmission of vibration to the machine, the hydraulic drive is installed separately from the machine and connected to it with a flexible hose.

The magnetic separator and filter conveyor ensure high quality cleaning of the coolant, which improves the quality of the treated surface.

Automatic interruption of cross feed after removal of the set allowance allows the operator to simultaneously control several machines.

Table 2.8

Technical characteristics of the internal grinding machine 3K228A

Characteristic
Grinding hole diameter largest, mm
Maximum length of grinding with the largest diameter of the hole to be ground, mm
The largest outer diameter of the installed product without a casing, mm
Greatest angle of the cone to be ground, degrees
Distance from the axis of the product spindle to the table mirror, mm
The greatest distance from the end of the new circle of the face grinding device to the support end of the product spindle, mm
Main drive power, kW
Total power of electric motors, kW
Machine dimensions: length * width * height, mm
Total floor area of ​​the machine with external equipment, m2
Weight 3K228A, kg
Precision index of processing a sample of the product:
constancy of diameter in longitudinal section, μm
roundness, μm
Roughness of the sample-product surface:
cylindrical internal Ra, μm
flat end

Figure 2.5 - Semi-automatic circular grinding 3M162

Table 2.9

Technical characteristics of the semi-automatic circular grinding 3M162

Characteristic	Name
The largest diameter of the workpiece, mm
The greatest length of the workpiece, mm
Grinding length, mm
Accuracy
Power
Dimensions (edit)

Tools used in the manufacture of the part.

1. Cutter (eng. Toolbit) - a cutting tool designed for processing parts of various sizes, shapes, accuracy and materials. It is the main tool used in turning, planing and slotting work (and on the corresponding machines). The cutter and the workpiece, rigidly fixed in the machine, contact each other as a result of relative movement, the cutting element of the cutter is cut into the material layer and then cut in the form of chips. With further advancement of the cutter, the chipping process is repeated and chips are formed from individual elements. The type of chips depends on the feed of the machine, the rotation speed of the workpiece, the material of the workpiece, the relative position of the cutter and the workpiece, the use of coolant, and other reasons. In the process of work, the cutters are subject to wear, therefore, they are regrind.

Figure 2.6, Cutter GOST 18879-73 2103-0057

Figure 2.7 Cutter GOST 18877-73 2102-0055

2. Drill - a cutting tool with a rotary cutting movement and an axial feed movement, designed to make holes in a continuous layer of material. Drills can also be used for reaming, that is, enlarging existing, pre-drilled holes, and for drilling, that is, obtaining non-through recesses.

Figure 2.8 - Drill GOST 10903-77 2301-0057 (material Р6М5К5)

Figure 2.9 - Cutter GOST 18873-73 2141-0551

3. Grinding wheels are designed for cleaning curved surfaces from scale and rust, for grinding and polishing products made of metals, wood, plastic and other materials.

Figure 2.10 - Grinding wheel GOST 2424-83

Control tool

Means of technical control: Caliper ШЦ-I-125-0, 1-2 GOST 166-89; Micrometer MK 25-1 GOST 6507-90; Internal gauge GOST 9244-75 18-50.

The caliper is designed for high-precision measurements, it is able to measure the outer and inner dimensions of parts, the depth of the hole. The caliper consists of a fixed part - a measuring ruler with a jaw and a moving part - a movable frame

Figure 2. 11 - Vernier caliper ШЦ-I-125-0, 1-2 GOST 166-89.

A bore gauge is a tool for measuring the inside diameter or distance between two surfaces. The accuracy of measurements with an internal gauge is the same as that of a micrometer - 0.01 mm

Figure 2.12 - Inside gauge GOST 9244-75 18-50

Micrometer - a universal instrument (device) designed for measuring linear dimensions by the absolute or relative contact method in the area of ​​small dimensions with a low error (from 2 μm to 50 μm, depending on the measured ranges and accuracy class), the conversion mechanism of which is a screw-nut micro-pair

Figure 2.13 - Micrometer smooth MK 25-1 GOST 6507-90

2 .4 Development of schemes for basing workpieces by operations and selection of devices

The basing and fastening scheme, technological bases, supporting and clamping elements and device devices should ensure a certain position of the workpiece relative to the cutting tools, the reliability of its fastening and the invariability of the basing during the entire processing process with a given installation. The surfaces of the workpiece, taken as bases, and their relative location should be such that the simplest and most reliable design of the device can be used, to ensure ease of installation of clamping, detachment and removal of the workpiece, the ability to apply clamping forces and supply of cutting tools in the right places.

When choosing bases, one should take into account the basic principles of basing. In the general case, a full cycle of processing a part from roughing to finishing is carried out with a sequential change of sets of bases. However, in order to reduce errors and increase the productivity of parts processing, one must strive to reduce the re-positioning of the workpiece during processing.

With high requirements for processing accuracy for basing workpieces, it is necessary to choose such a basing scheme that will provide the smallest positioning error;

It is advisable to observe the principle of constant bases. When changing the bases in the course of the technological process, the processing accuracy decreases due to the error in the relative position of the new and previously used base surfaces.

Figure 2.14 - Blank

At operation 005-020, 030, 045, the part is fixed in the centers and driven by a three-jaw chuck:

Figure 2.15 - Operation 005

Figure 2.16 - Operation 010

Figure 2.17 - Operation 015

Figure 2.18 - Operation 020

Figure 2.19 - Operation 030

Figure 2.20 - Operation 045

At step 025, the part is clamped in a vice.

Figure 2.21 - Operation 025

In operation 035-040, the part is secured at the centers.

Figure 2.22 - Operation 035

To fix the workpiece in operations, the following devices are used: three-jaw chuck, movable and stationary centers, stationary support, machine vice.

Figure 2.23- Three-jaw chuck GOST 2675-80

Machine vise - a device for clamping and holding workpieces or parts between two jaws (movable and fixed) during processing or assembly.

Figure 2.24- Machine vices GOST 21168-75

Center А-1-5-Н GOST 8742-75 - rotating machine center; Machine centers are a tool used to fix workpieces during their processing on metal-cutting machines.

Figure 2. 25- Center rotating GOST 8742-75

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