Hard drive adapters. Coursework: Designing the technological process for manufacturing the part "Axis" Detail adapter in mechanical engineering drawing

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Introduction

1. Technological part

1.3 Description of the technological operation

1.4 Equipment used

2. Settlement part

2.1 Calculation of processing modes

2.2 Calculation of clamping force

2.3 Drive calculation

3. Design part

3.1 Description of fixture design

3.2 Description of device operation

3.3 Development of technical requirements for the fixture drawing

Conclusion

Bibliography

Application (assembly drawing specification)

Introduction

The technological basis is the most important factor in the successful implementation of technical progress in mechanical engineering. At the present stage of development of mechanical engineering, it is necessary to ensure the rapid growth in the output of new types of products, the acceleration of their renewal, and the reduction of the duration of their stay in production. The task of increasing labor productivity in mechanical engineering cannot be solved only by putting even the most advanced equipment into operation. The use of technological equipment contributes to an increase in labor productivity in mechanical engineering and orients production towards intensive methods of its conduct.

The main group of technological equipment is made up of fixtures for mechanical assembly production. Devices in mechanical engineering are called auxiliary devices for technological equipment used in processing, assembly and control operations.

The use of devices allows you to: eliminate the marking of workpieces before processing, increase its accuracy, increase labor productivity in operations, reduce the cost of production, facilitate working conditions and ensure its safety, expand the technological capabilities of equipment, organize multi-machine maintenance, apply technically sound time standards, reduce the number of workers required for production.

Effective methods that speed up and reduce the cost of designing and manufacturing fixtures are unification, normalization and standardization. Normalization and standardization provide an economic effect at all stages of the creation and use of devices.

1. Technological part

1.1 Purpose and description of the part

The “Adapter” part is designed to connect the electric motor to the gearbox housing and protect the junction of the motor shaft with the gearbox shaft from possible mechanical damage.

The adapter is installed in the hole of the gearbox housing with a smooth cylindrical surface with a diameter of 62h9 and fastened with four bolts through holes with a diameter of 10 + 0.36. A cuff is installed in hole 42H9, and four holes with a diameter of 3 + 0.25 serve, if necessary, for its dismantling. A hole with a diameter of 130H9 is intended for locating the connecting flange of the electric motor, and a groove with a diameter of 125-1 is for installing a union flange connecting the electric motor with an adapter. Couplings are located in a hole with a diameter of 60 + 0.3, and two grooves 30x70 mm are designed for fastening and adjusting the couplings on the shafts.

The adapter part is made of Steel 20, which has the following properties: Steel 20 - carbon, structural, high-quality, carbon? 0.20%, the rest is iron (in more detail the chemical composition of steel 20 is given in table 1, and the mechanical and physical properties in table 2)

Table 1. Chemical composition of carbon structural steel 20 GOST 1050 - 88

In addition to carbon, silicon, manganese, sulfur and phosphorus are always present in carbon steel, which have a different effect on the properties of steel.

Permanent impurities of steel are usually contained within the following limits (%): silicon up to 0.5; sulfur up to 0.05; manganese up to 0.7; phosphorus up to 0.05.

b With an increase in the content of silicon and manganese, the hardness and strength of steel increases.

l Sulfur is a harmful impurity, it makes steel brittle, reduces ductility, strength and corrosion resistance.

Phosphorus gives steel cold brittleness (brittleness at normal and low temperatures)

Table 2. Mechanical and physical properties of steel 20 GOST 1050-88

у вр - temporary tensile strength (tensile strength

stretching);

y t - yield strength;

d 5 - elongation;

a n - impact strength;

w - relative narrowing;

HB - Brinell hardness;

g - density;

l - thermal conductivity;

b - coefficient of linear expansion

1.2 Technological process of manufacturing a part (route)

The part is processed in operations:

010 Turning operation;

020 Turning operation;

030 Turning operation;

040 Milling operation;

050 Drilling operation.

1.3 Description of the technological operation

030 Turning operation

Sharpen the surface clean

1.4 Equipment used

Machine 12K20F3.

Machine parameters:

1. The largest diameter of the processed workpiece:

over bed: 400;

over caliper: 220;

2. The largest diameter of the bar passing through the spindle holes: 20;

3. The greatest length of the processed workpiece: 1000;

4. Thread pitch:

metric up to 20;

inch, number of threads per inch: - ;

modular, module: - ;

5. Thread pitch:

pitch, pitch: - ;

6. Spindle speed, rpm: 12.5 - 2000;

7. Number of spindle speeds: 22;

8. The largest movement of the caliper:

longitudinal: 900;

transverse: 250;

9. Caliper feed, mm/rev (mm/min):

longitudinal: (3 - 1200);

transverse: (1.5 - 600);

10. Number of feed steps: B/s;

11. Speed of fast movement of a support, mm/min:

longitudinal: 4800;

transverse: 2400;

12. Power of the electric motor of the main drive, kW: 10;

13.Overall dimensions (without CNC):

length: 3360;

width: 1710;

height: 1750;

14. Mass, kg: 4000;

1.5 Scheme of basing the workpiece on the operation

Figure 1. - detail basing scheme

surface A - mounting with three reference points: 1,2,3;

surface B - double guide with two reference points: 4.5.

2. Settlement part

2.1 Calculation of processing modes

Processing modes are determined by two methods:

1. Statistical (according to the table)

2. Analytical method according to empirical formulas

The elements of cutting conditions include:

1. Depth of cut - t, mm

where di1 is the surface diameter obtained at the previous transition, mm;

di-diameter of the surface at a given transition, mm;

where Zmax is the maximum machining allowance.

t when cutting and grooving is equal to the width of the cutter t=H

2. Feed - S, mm/rev.

3. Cutting speed-V, m/min.

4. Spindle speed, n, rpm;

Determine the processing modes for turning the finishing operation of external turning of the surface O62h9 -0.074, determine the cutting force Pz, the main processing time To, and the possibility of performing this operation on a given machine.

Initial data:

1. Machine 16K20F3

2. Received parameters: O62h9 -0.074; Lobr \u003d 18 + 0.18; roughness

3.Tool: thrust cutter, c = 90?; c1 = 3?; r = 1 mm; L=170;

H?B = 20?16; T15K6; resistance T 60 min.

4. Material: steel 20 GOST 1050-88 (dvr = 410MPa);

Working process

1. Determine the depth of cut: ;

where Zmax - maximum allowance for processing; mm;

2. The feed is selected according to the tables, directories: ; (roughing).

Stab = 0.63, taking into account the correction factor: Ks = 0.48;

(t. to dvr \u003d 410 MPa);

S = Stab? Ks; S \u003d 0.63? 0.45 \u003d 0.3 mm / rev;

3. Cutting speed.

where C v - coefficient; x, y, m - exponents. .

C v = 420; m = 0.20; x = 0.15; y=0.20;

T - tool life; T = 60 min;

t - depth of cut; t = 0.75 mm;

S - feed; S = 0.3 mm/rev;

where K V is a correction factor that takes into account specific processing conditions.

K V \u003d K mv? To nv? K and v ? To mv ;

where K mv is a coefficient that takes into account the influence of the physical and mechanical properties of the material being processed on the cutting speed.

For steel

K mv \u003d K r? n v ;

n v = 1.0; K r = 1.0; K mv \u003d 1? = 1.82;

K nv - coefficient taking into account the influence of the state of the surface of the workpiece; .

K and v - coefficient taking into account the influence of the material tool on the cutting speed. .

K V \u003d 1.82? 1.0? 1.0 = 1.82;

V = 247? 1.82? 450 m/min;

4. The spindle speed is determined by the formula:

N = ; n = rpm

To increase tool life, we take n = 1000 rpm.

5. Determine the actual cutting speed:

V f = ; V f = = 195 m/min;

6. The cutting force is determined:

P z according to the formula; .

P z = 10? Cp? t x ? S y ?Vf n ? K p ;

where C p is a constant;

x, y, n - exponents; .

t - cutting depth, mm;

S - feed, mm/rev;

V - actual cutting speed, m/min;

C p = 300; x = 1.0; y=0.75; n=-0.15;

K p \u003d 10? 300? 0.75? 0.41? 0.44? K p \u003d 406? K p ;

K p - correction factor; .

K p \u003d K mr? K c r? K g r? K l r? K rr;

where K mr is a coefficient that takes into account the influence of the quality of the material being processed on the force dependences. .

K mr =; n=0.75; K mp =;

K c p; K g p; K l r; K rr; - correction factors that take into account the influence of the geometric parameters of the cutting part of the tool on the components of the cutting force

K c p = 0.89; K g p = 1.0; K l p = 1.0; Krr = 0.93;

K p \u003d 0.85? 0.89? 1.0? 1.0? 0.93 = 0.7;

Pz = 406? 0.7 = 284 H;

7. Check the cutting conditions for power on the machine spindle, for this, the cutting power is determined by the formula:

where Pz is the cutting force; m;

V - actual cutting speed; m/min;

60?1200 - conversion factor;

Kz = 406?0.7 = 284 N;

We determine N on the machine spindle, taking into account the efficiency; efficiency (h);

N sp. = N dv. ?h;

where N w - power on the spindle; kW;

N dv - the power of the electric motor of the machine; kW;

N dv 16K20F3 = 10kW;

Z - for metal-cutting machines; 0.7/0.8;

N w = 10? 0.7 = 7 kW;

Conclusion

Because condition N res< N шп; соблюдается (0,9 < 7) ,то выбранные режимы обработки осуществимы на станке 16К20Ф3;

9. Determine the main time according to the formula:

where L calc. - estimated processing length; mm;

Which is calculated by the formula:

L calc. \u003d lbr + l 1 + l 2 + l 3;

where lbr is the length of the treated surface; mm; (lobr = 18mm);

l 1 +l 2 - the value of the infeed and the value of the overrun of the tool; mm; (equal to an average of 5mm);

l 3 - additional length for taking test chips. (because the processing is in automatic mode, then l 3 = 0);

i - number of passes;

T o = = 0.07 min;

We summarize all the results obtained above in a table;

Table 1 - Machining parameters for turning operation

2.2 Calculation of clamping force

The design scheme of the fixture is a diagram that depicts all the forces acting on the workpiece: cutting force, torque, clamping force. The design scheme of the fixture is shown in Figure 2.

Figure 2

The design diagram of the device is a simplified image of the device, with its main elements.

The forces applied to the workpiece must prevent possible separation of the workpiece, shift or rotation under the action of cutting forces and ensure reliable fastening of the workpiece during the entire processing time.

The clamping force of the workpiece with this method of fastening is determined by the following formula:

where n is the number of sticks.

f - coefficient of friction on the working surface of the clamp f=0.25

Рz - cutting force Рz =284 N

K - safety factor, which is determined by the formula:

where K0 - guaranteed safety factor, K0=1.5;

K1 - correction factor taking into account

part surface view, K1=1;

K2 - correction factor that takes into account the increase in cutting force when the cutting tool becomes dull, K2 = 1.4;

K3 - correction factor that takes into account the increase in cutting force when machining intermittent surfaces of the part (in this case, absent);

K4 - correction factor, taking into account the inconsistency of the clamping force, distinguished by the power drive of the device K4=1;

K5 - correction factor taking into account the degree of convenience of the location of the handle in manual clamping devices (in this case, absent);

K6 is a correction factor that takes into account the uncertainty of the place of contact between the workpiece and supporting elements with a large supporting surface, K6 = 1.5.

Since the value of the coefficient K is less than 2.5, then the resulting value of 3.15 is accepted.

2.3 Power drive calculation

Since the clamping of the workpiece is carried out without an intermediate link, the force on the rod will be equal to the clamping force of the workpiece, that is

The diameter of a double-acting pneumatic cylinder when air is supplied without a rod is determined by the following formula:

where p - compressed air pressure, p=0.4 MPa;

d - rod diameter.

The diameter of the pneumatic cylinder is assumed to be 150 mm.

The stem diameter will be 30 mm.

Actual force on the rod:

3. Design part

3.1 Description of the design and operation of the device

The drawing shows the design of a pneumatic device for axial clamping of a thin-walled flanged bushing. The sleeve is centered in the undercut of the disk 7 attached to the body 1, and is clamped along the axis by three levers 6 mounted on the axis 5. The levers are actuated by a rod connected to the screw 2, when moving which it moves by the rocker arm 4 together with the levers 6, clamping the workpiece to be processed . When the thrust moves from left to right, the screw 2 moves the rocker 4 with the levers 6 to the side by means of the nut 3. The fingers on which the levers 6 are mounted slide along the oblique grooves of the disk 7 and thus, when the processed workpiece is unfastened, they rise slightly, allowing the processed part to be released and a new workpiece to be installed .

Conclusion

A fixture is a technological tool designed to install or guide an object of labor or a tool during a technological operation.

The use of devices helps to increase the accuracy and productivity of processing, control of parts and assembly of products, provides mechanization and automation of technological processes, lowering the qualifications of work, expanding the technological capabilities of equipment and increasing work safety. The use of fixtures can significantly reduce set-up time and thereby increase process productivity where the set-up time of the object is commensurate with the main process time.

Reducing the time for processing a part, increasing labor productivity was ensured by the development of a special machine tool - a chuck with a pneumatic clamp.

Bibliography

1. Filonov, I.P. Design of technological processes in mechanical engineering: Textbook for universities / I.P. Filonov, G.Ya. Belyaev, L.M. Kozhuro and others; Under total ed. I.P. Filonova.- +SF.-Mn.: "Technoprint", 2003.- 910 p.

2. Pavlov, V.V. The main tasks of technological design: Study guide / V.V. Pavlov, M.V.

3. Reference technologist-machine builder. T. 1 / Ed. A. M. Dalsky, Kosilova A. G., Meshcheryakova R. K., Suslova A. G., - 5th ed., revised. and additional .- M .: Mashinostroenie -1, 2001.- 912s., ill.

4. Reference technologist-machine builder. T.2 / Ed. Dalsky A.M., Suslova A.G., Kosilova A.G., Meshcheryakova R.K. - 5th ed., revised. and additional -M.: Mashinostroenie-1, 2001.- 944s .. ill.

5. Suslov, A.G. Mechanical engineering technology: A textbook for students of engineering specialties of universities. - M .: Mashinostroenie, 2004. - 400 p.

6. Zhukov, E.L. Engineering Technology: Textbook for High Schools / E.L. Zhukov, I.I. Kozar, S.L. Murashkin and others; Ed. S.L. Murashkin. - M.: Higher school, 2003.

Book 1: Fundamentals of mechanical engineering technology. - 278 p.

Book. 2. Production of machine parts. - 248 p.

7. Skhirtladze, A.G. Technological equipment of machine-building industries / A.G. Skhirtladze, V.Yu. Novikov; Ed. Yu.M. Solomentsev. - 2nd ed., revised. and additional - M.: Higher School, 2001. - 407 p.

9. General machine-building standards for time and cutting conditions for the regulation of work performed on universal and multi-purpose machines with numerical control. part 2. Standards for cutting modes. - M .: Economics, 1990.

8. Skhirtladze, A. G. A general machine operator: A textbook for prof. studies, institutions / A. G. Skhirtladze, Novikov V. Yu. - 3rd ed., ster. - M.: Higher School, 2001. - 464 p.

11. Pris, N. M. Basing and bases in mechanical engineering: Methodological instructions for the implementation of practical exercises on the course "Fundamentals of Mechanical Engineering Technology" for students of daytime and evening departments of special. 120100 "Technology of mechanical engineering" / N. M. Pris. - N.Novgorod.: NSTU, 1998. - 39 p.

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technological process construction detail

1. Design part

1.1 Assembly unit description

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

1.3 Description of design modifications proposed by the student

2. Technological part

2.1 Manufacturability analysis of the part design

2.2 Development of a route technological process for manufacturing a part

2.3 Selection of used technological equipment and tools

2.4 Development of basing schemes

1 . Design part

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

The 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). An oil filter is a device designed to purify engine oil from mechanical particles, resins and other impurities polluting it during the operation of an internal combustion engine. This means that the lubrication system of internal combustion engines cannot do without an oil filter.

Figure 1. 1 - Valve BNTU 105081. 28. 00 Sat

Details: 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 the absence of abrasive substances and corrosion between mating parts.

2. During installation, protect the rubber rings (8) from warping, twisting, and mechanical damage.

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

4. Follow 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 tight when oil is supplied to any cavity, with the second one plugged, with a viscosity of 10 to 25 cSt under a pressure of 15 MPa, the appearance of individual drops at the connection of the tip (4) with the adapter (3) is not a defective sign.

6. Follow other technical requirements according to STB 1022-96.

1 . 2 Description of the part design, included in the design 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).

General-purpose steel springs are made from 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 finished wire, while powerful springs are made from annealed steel and tempered after forming.

A washer is a fastener placed under another fastener to create a larger bearing surface area, reduce surface damage to the part, prevent the fastener from self-loosening, and also to seal the joint 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 shifting the movable part relative to the windows in the surface on which it slides.

Our design uses spool 4570-8607047

Spool material - Steel 40X

Adapter - a device, device or part designed to connect devices that do not have a compatible method of connection.

Figure 1. 2 Sketch of the part “Adapter”

Table 1. 1

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

Name surfaces	Accuracy (Quality)	Roughness,	Note
End (flat) (1)			Face runout is not more than 0. 1 relative to the axis.
External threaded (2)
Groove (3)
Internal cylindrical (4)
External cylindrical (5)			Deviation from perpendicularity no more than 0. 1 relative to (6)
End (flat) (6)
Internal threaded (7)
Internal cylindrical (9)
Groove (8)
Internal cylindrical (10)

Table 1.2

Chemical composition of steel Steel 35GOST 1050-88

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

1 . 3 Owriting modifications of designs proposed by the student

The adapter part complies with all accepted norms, state standards, design standards, therefore, it does not need to be finalized and improved, since this will lead to an increase in the number of technological operations and equipment used, as a result of which 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 Manufacturability analysis of the part design

Manufacturability of a part is understood as a set of properties that determine its adaptability to achieve optimal costs in production, operation and repair for given quality indicators, output 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 usually carried out in two stages: qualitative and quantitative.

Qualitative analysis of the part The adaptor for manufacturability showed that it contains a sufficient number of sizes, types, tolerances, roughness for its manufacture, that there is the possibility of the workpiece being as close as possible to the dimensions and shape of the part, and the possibility of machining with through cutters. The material of the part is St35GOST 1050-88, it is widely available and widespread. The mass of the part is 0.38 kg, 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 allow processing with a standard tool. All holes in the part are through, so there is no need to position the tool during machining.

All chamfers made at the same angle can therefore be performed with one tool, the same applies to grooves (grooving cutter), there are 2 grooves in the part for the tool to exit when threading, 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 fix it.

Due to the simplicity of 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 factor. The data obtained are shown in Table 2. 1.

Table 2.1

Number and accuracy of surfaces

The manufacturability coefficient for accuracy is 0.91>0.75. This shows the low 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

Roughness manufacturability coefficient 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 part of the adapter 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, trimming the ends "as clean" is used. We sharpen the surface Ш28. 4-0. 12 to length 50. 2-0, 12, holding R0. 4max. Next, we sharpen the chamfer 2. 5x30 °. We sharpen the groove "B", maintaining the dimensions: 1. 4 + 0, 14; angle 60°; Sh26. 5-0. 21; R0. one; R1; 43+0. 1. Centers the butt. We drill a hole Ш17 to a depth of 46. 2-0. 12. We bore the hole Ш14 to Ш17. 6+0. 12 to depth 46. 2-0. 12. We bore Sh18. 95+0. 2 to a depth of 18. 2-0. 12. We bore the groove "D", maintaining the dimensions. We bore the chamfer 1. 2×30 °. We cut the end in size 84. 2-0, 12. We drill a hole Ш11 to the entrance to the hole Ш17. 6+0. 12. Countersink chamfer 2. 5x60° in hole Ш11. Sharpen Sh31. 8-0, 13 for length 19 for M33Ch2-6g thread. Sharpen chamfer 2.5x45°. Sharpen groove "B". Cut the thread M33Ch2-6g. To sharpen a chamfer maintaining dimensions Ш46, an angle of 10 °. Cut thread M20Ch1-6H. Drill hole Ш9 through. Countersink chamfer 0.3×45° in hole Ш9. Grind hole Ш18+0.043 to Ra0. 32. Grind Sh28. 1-0. 03 to Ra0. 32 with right end sanded to size 84. Sand W to Ra0.16.

Table 2.4

List of mechanical operations

operation number	Operation name
	CNC lathe
	CNC lathe
	Screw-cutting.
	Vertical drilling
	Vertical drilling
	Internal grinding
	Cylindrical grinding
	Cylindrical grinding
	Screw-cutting
	Control by the performer

2 .3 Selection of used technological equipment and tools

In the conditions of modern production, a cutting tool, 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 to the fore.

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

For the manufacture of this part, equipment is used:

1. CNC lathe ChPU16K20F3;

2. Screw-cutting lathe 16K20;

3. Vertical drilling machines 2H135;

4. Internal grinding machine 3K227V;

5. Semi-automatic circular grinding machine 3M162.

CNC lathe 16K20T1

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

Figure 2. 1 - CNC lathe 16K20T1

Table 2.5

Technical characteristics of the lathe with CNC 16K20T1

Parameter	Meaning
The largest diameter of the processed workpiece, mm:
above bed
above the caliper
The greatest length of the processed workpiece, mm
Center height, mm
The largest diameter of the bar, mm
Thread pitch: metric, mm;
Spindle hole diameter, mm
Inner spindle taper Morse
Spindle speed, rpm.
Submission, mm/rev. :
Longitudinal
transverse
Morse quill hole taper
Cutter section, mm
Chuck diameter (GOST 2675. 80), mm
Main drive electric motor power, kW
Numerical control device
Deviation from the flatness of the end surface of the sample, microns
Machine dimensions, mm

Figure 2. 2 - 16K20 screw-cutting lathe

The machines are designed to perform a variety of turning operations and threading: 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 equipping the machine with an apron with a built-in fast-moving motor and a feed box that provides the ability to thread 11 and 19 threads per inch without replacing change gears in the gearbox;

"C" - when equipping the machine with a drilling and milling fixture designed to perform drilling, milling and threading at different angles on parts mounted on the machine support;

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

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

"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 the price of dividing the limb of the transverse movement of 0.02 mm;

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

"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 converters and with stepless regulation of the spindle speed;

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: above bed, mm
1. 2 The largest diameter of the workpiece to be processed above the support, mm, not less than
1. 3 The greatest length of the installed workpiece (when installed in the centers), mm, not less than above the recess in the frame, mm, not less than
1. 4 Height of centers above bed rails, 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 Spindle frequency limits, rpm
3. 3 Caliper feeds longitudinal transverse
3. 4 Caliper feed limits, mm/rev longitudinal transverse
3. 5 Limits of pitches of threads to be cut metric, mm modular, module inch, number of threads pitch, pitch
3. 6 Speed of fast movements of the caliper, m / min: longitudinal transverse
4 Indicators of the power characteristics of the machine
4. 1 Maximum torque on the spindle, kNm
4. 2
4. 3 Drive power of rapid 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 Dimensions and weight of the machine
5. 1 Overall dimensions of the machine, mm, not more than:
5. 2 Mass of the machine, kg, no more
6 Characteristics of electrical equipment
6. 1 Type of mains current	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 turning on it. On the machine, you can process small parts on the table, larger ones on the foundation plate. Manual and mechanical spindle feed. Depth adjustment with automatic feed cut-off. Threading with manual and automatic spindle reversal at a given depth. Processing small parts on the table. Control of spindle movement along the ruler. Built-in cooling.

Table 2.7

Technical characteristics of the machine Vertical drilling machine 2T150

The largest nominal drilling diameter, mm cast iron SCh20
The largest diameter of the cut thread, mm, in steel
Hole accuracy after reaming
Spindle taper	Morse 5 AT6
The greatest movement of the spindle, mm
Distance from spindle nose 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
Spindle feed rate, mm/rev.
Maximum torque on the spindle, Nm
Maximum feed force, N
The angle of rotation of the table around the column
Feed cut-off when the set drilling depth is reached	automatic
Type of supply current	Three-phase variable
Voltage, V
Main drive power, kW
Total motor power, kW
Overall dimensions of the machine (LхBхH), mm, no more
Machine weight (net/gross), kg, max
Overall dimensions of the package (LxBxH), 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 and table movement speeds, which ensure the processing of parts in optimal conditions.

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

The accelerated adjustment transverse movement of the grinding headstock reduces the auxiliary time during the changeover of the 3K228A machine.

To reduce the heating of the frame 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 provide high quality coolant cleaning, which improves the quality of the machined surface.

Automatic termination of the cross feed after removing 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
The greatest 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

The greatest angle of the ground cone, hail.
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: lengthwidthheight, mm
The total floor area of the machine with remote equipment, m2
Weight 3K228A, kg
The indicator of the accuracy of processing a product sample:
constancy of diameter in the longitudinal section, microns
roundness, microns
Surface roughness of the sample-product:
cylindrical internal Ra, µm
flat end

Figure 2. 5 - Semi-automatic circular grinding 3M162

Table 2.9

Technical characteristics of 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

Tools used in the manufacture of the part.

1. Cutter (English 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 grooving work (and on related machines). Rigidly fixed in the machine, the cutter and the workpiece contact each other as a result of relative movement, the working element of the cutter cuts into the material layer and is subsequently cut off 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 machine feed, workpiece rotation speed, workpiece material, the relative position of the cutter and workpiece, the use of coolant, and other reasons. In the process of work, the cutters are subject to wear, so they are regrinded.

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 rotational cutting movement and an axial feed movement, designed to make holes in a continuous layer of material. Drills can also be used for reaming, i.e. enlarging existing, pre-drilled holes, and pre-drilling, i.e. making recesses that are not through.

Figure 2. 8 - Drill GOST 10903-77 2301-0057 (material R6M5K5)

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; Nutromer gost 9244-75 18-50.

The caliper is designed for high-precision measurements, capable of measuring the external and internal dimensions of parts, the depth of the hole. The caliper consists of a fixed part - a measuring ruler with a sponge and a movable part - a movable frame

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

Nutromer - a tool for measuring the inner diameter or distance between two surfaces. The accuracy of measurements with a caliper is the same as with a micrometer - 0.01 mm

Figure 2. 12 - Nutromer gost 9244-75 18-50

A micrometer is a universal instrument (device) designed to measure linear dimensions by the absolute or relative contact method in the area of small sizes with a low error (from 2 microns to 50 microns, depending on the measured ranges and accuracy class), the converting mechanism of which is a screw-nut micropair

Figure 2. 13- Smooth micrometer MK 25-1 GOST 6507-90

2 .4 Development of workpiece basing schemes for operations and selection of fixtures

The locating and fastening scheme, technological bases, supporting and clamping elements and fixture devices must ensure a certain position of the workpiece relative to the cutting tools, the reliability of its fastening and the invariability of the basing throughout the entire processing process with this installation. The surfaces of the workpiece taken as bases and their relative position should be such that it is possible to use the simplest and most reliable design of the fixture, to ensure the convenience of mounting, detaching and removing the workpiece, the possibility of applying clamping forces in the right places and supplying cutting tools.

When choosing bases, the basic principles of basing should be taken into account. In the general case, a complete cycle of processing a part from a roughing operation to a finishing operation is carried out with a successive change of sets of bases. However, in order to reduce errors and increase the productivity of part processing, it is necessary to strive to reduce workpiece resets during processing.

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

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

Figure 2. 14 - Workpiece

At operations 005-020, 030, 045, the part is fixed in the centers and actuated using 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 operation 025, the part is fixed in a vise.

Figure 2. 21 - Operation 025

In operation 035-040, the part is fixed in the centers.

Figure 2. 22 - Operation 035

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

Figure 2. 23- Three-jaw chuck GOST 2675-80

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

Figure 2. 24- Machine vise GOST 21168-75

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

Figure 2. 25- Rotating center GOST 8742-75

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(3000 )

Detail "Adapter"

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

The type of work: Diploma and related
File formats: T-Flex CAD, Microsoft Word
Rented in an educational institution: Ri(F)MGOU

Description:
The “Adapter” part is used in the deep drilling machine RT 265, which is produced by OJSC RSZ.
It is designed for fastening 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 fastening the cutting tool, as well as a rectangular external thread for connection with the "Stem". The 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 processing for a quick tool change 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 ATs45 TU14-1-3283-81.

CONTENT
sheet
Introduction 5
1 Analytical part 6
1.1 Purpose and design of the part 6
1.2 Manufacturability 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 start-up lot 11
2.2 Selecting how to obtain the workpiece 12
2.3 Calculation of minimum machining allowances 13
2.4 Calculation of the weight accuracy factor 17
2.5 Economic justification for the choice of workpiece 18
2.6 Process design 20
2.6.1 General provisions 20
2.6.2 Order and sequence of TP 20 execution
2.6.3 Route of the new technological process 20
2.6.4 Selection of equipment, description of technological possibilities
and technical characteristics of machines 21
2.7 Justification of the basing method 25
2.8 Choice of fasteners 25
2.9 Choice of cutting tools 26
2.10 Cutting Data Calculation 27
2.11 Calculation of piece and piece - calculation time 31
2.12 Special question on engineering technology 34
3 Design part 43
3.1 Description of the fastener 43
3.2 Fastener calculation 44
3.3 Description of the cutting tool 45
3.4 Description of the control device 48
4. Calculation of the machine shop 51
4.1 Calculation of the required equipment of the workshop 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 constructive solution for an industrial building 55
4.5 Design of service rooms 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 project site
machine shop for workers and the environment 59
5.2.1 Analysis of potential hazards and harmful production
factors 59
5.2.2 Environmental impact analysis of the workshop 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 workshop 64
5.4.1 Measures and measures for safety 64
5.4.1.1 Automation of production processes 64
5.4.1.2 Equipment location 64
5.4.1.3 Enclosure of hazardous areas, prohibited,
safety and blocking devices 65
5.4.1.4 Ensuring electrical safety 66
5.4.1.5 Disposal of waste in the shop 66
5.4.2 Measures and means for the production
sanitation 67
5.4.2.1 Microclimate, ventilation and heating 67
5.4.2.2 Industrial lighting 68
5.4.2.3 Noise and vibration protection 69
5.4.2.4 Ancillary sanitary facilities
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 designed machine shop 72
5.5.1 Solid waste management 72
5.5.2 Purification of exhaust gases 72
5.5.3 Wastewater treatment 73
5.6 Measures and means to ensure
safety in emergency situations 73
5.6.1 Fire safety 73
5.6.1.1 Fire prevention system 73
5.6.1.2 Fire protection system 74
5.6.2 Providing lightning protection 76
5.7. Engineering development to ensure
labor safety and environmental protection 76
5.7.1 Total illumination calculation 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
site under design 83
6.2 Description of automated transport and storage
systems of the designed site 84
7. Economic part 86
7.1 Initial data 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 management 91
7.5 Calculation of the annual wage fund of employees 92
7.6 Estimating indirect and workshop costs 92
7.6.1 Estimated maintenance and operation costs
equipment 92
7.6.2 Estimate of general shop expenses 99
7.6.3 Allocation of costs for maintenance and operation
equipment and public spending on the cost of products 104
7.6.4 Production cost estimate 104
7.6.4.1 Kit costing 104
7.6.4.2 Unit costing 105
7.7 Result 105
Conclusion 108
References 110
Applications

File size: 2,1 MB
File: (.rar)
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note that teachers often rearrange the options and change the source data!
If you want the work to match exactly, with check the source data. If they are not available, contact

Along with the task, technological documentation arrives at the workplace: technological, route, operational maps, sketches, drawings. Not fulfilling the requirements means a violation of technological discipline, this is unacceptable, because. this leads to a decrease in the quality of products.

The initial data for the construction of the technological process is the drawing of the part and the technical requirements for its manufacture.

Route map (MK) - contains a description of the technological process of manufacturing or repairing a product for all operations of various types in a technological sequence, indicating data on equipment, tooling, materials, etc.

Forms and rules for issuing route maps are regulated in accordance with GOST 3.1118-82 (Forms and rules for issuing route maps)

Operational card (OK) - contains a description of the operations of the technological process of manufacturing a product with a division of operations into transitions, indicating processing modes, design standards and labor standards.

Forms and rules for issuing transaction cards are regulated in accordance with GOST 3.1702-79 (Forms and rules for issuing transaction cards)

Working drawings of parts must be made in accordance with ESKD (GOST 2.101-68), the drawing contains all the information for manufacturing the part: the shape and dimensions of surfaces, workpiece material, technical requirements for manufacturing, shape accuracy, dimensions, etc.

In this report, I examined the adapter part, analyzed the brand of material from which the part was made.

The part, the adapter, experiences axial and radial stresses, as well as variable stresses from vibration loads and minor thermal loads.

The adapter is made of alloyed design steel 12X18H10T. It is a high quality steel containing 0.12% carbon,18% chromium, 10% nickel and little content titanium, not exceeding 1.5%.

Steel 12X18H10T is excellent for the manufacture of parts operating under high shock loads. This type of metal is ideal for use in conditions of low negative temperatures, down to -110 °C. Another very useful property of steels of this type, when used in structures, is good weldability.

Detail drawing is presented in Appendix 1.

The development of the technological process begins after clarifying and determining the choice of the workpiece, clarifying its dimensions for further processing, then the drawing is studied, the plan for sequential processing of the part by operation, the tool is selected.

The technological process is presented in Appendix 2.

TECHNOLOGY FOR MANUFACTURING THE BLANK. SUBSTANTIATION OF THE CHOICE OF THE OPTION OF THE TECHNOLOGICAL PROCESS FOR OBTAINING THE BLANK FROM THE POINT OF VIEW OF THE HIGH QUALITY OF THE METAL, THE VALUE OF THE ALLOWANCES, INCREASING THE CIM

The part is made of the material 12X18H10T GOST5632-72 and a more appropriate method for obtaining a workpiece is casting, but for comparison, consider obtaining a workpiece - stamping.

Stamping on hydraulic presses is used where, as a rule, a hammer cannot be used, namely:

When stamping low-plastic alloys that do not allow high strain rates;

For various types of stamping by extrusion;

Where a very large stroke is required, such as deep piercing or broaching of pierced workpieces.

Currently, GOST 26645-85 "Castings from metals and alloys. Dimensional tolerances, masses and machining allowances" is in force in mechanical engineering, with amendment No. 1 to replace the canceled standards GOST 1855-55 and GOST 2009-55. The standard applies to castings from ferrous and non-ferrous metals and alloys, manufactured by various casting methods, and complies with the international standard ISO 8062-84

There are the following types of casting: earth casting, die casting, pressure casting, squeeze casting, shell molding, centrifugal casting, suction casting, vacuum casting.

For the manufacture of this casting, the following casting methods can be used: in a chill mold, according to investment patterns, in shell molds, in plaster molds, in sand molds and in gasified models.

Die casting. Die casting is a labor- and material-saving, low-operational and low-waste technological process. It improves working conditions in foundries and reduces environmental impact. The disadvantages of chill casting include the high cost of the mold, the difficulty of obtaining thin-walled castings due to the rapid removal of heat from the melt by metal mold, a relatively small number of castings in the manufacture of steel castings in it.

Since the cast part is manufactured in series, and the resistance of the mold when poured into it is low, I consider it not advisable to use this type of casting.

Casting on gasified models. LGM - allows you to get castings equal in accuracy to investment casting at a cost level comparable to casting in PF. The cost of organizing the production of LGM includes the design and manufacture of molds. The LGM technology makes it possible to obtain castings weighing from 10 grams to 2000 kilograms with a surface finish of Rz40, dimensional and weight accuracy up to class 7 (GOST 26645-85) .

Based on the serial production, as well as expensive equipment, the use of this type of casting for the manufacture of castings is not advisable.

Low pressure casting. LND - allows you to get thick-walled and thin-walled castings of variable cross section. Reduced cost of casting due to automation and mechanization of the casting process. Ultimately, LND gives a high economic effect. Limited use of high Tm alloys.

Sand casting. Casting in sand molds is the most widespread (up to 75-80% by weight of castings produced in the world) type of casting. By casting in PF, castings of any configuration of 1 ... 6 complexity groups are obtained. Dimensional accuracy corresponds to 6 ... 14 groups. Roughness parameter Rz=630…80 µm. It is possible to produce castings weighing up to 250 tons. with wall thickness over 3 mm.

Based on the analysis of possible types of casting to obtain our casting, we can conclude that it is expedient to use casting in PF, because. it is more economical for our production.

The main indicators that make it possible to assess the manufacturability of the design of blanks is the metal utilization factor (KIM)

The degrees of accuracy of the workpiece are:

1. Rough, KIM<0,5;

2. Reduced accuracy 0.5≤KIM<0,75;

3. Accurate 0.75≤KIM≤0.95;

4. Increased accuracy, for which KIM>0.95.

CMM (metal utilization ratio) is the ratio of the mass of the part to the mass of the workpiece.

Metal Utilization Factor (KIM) calculated according to the following formula:

where Q det is the mass of the part, kg;

Q ex. – billet weight, kg;