减速箱箱体制造工艺设计

第0页共24页毕业设计2013年11月1日课题名称减速箱箱体制造工艺设计分院/专业机械工程系/机电一体化班级学号学生姓名指导教师：第1页共24页摘要箱体是机器的重要基础件，它将机器和部件中的轴、套、齿轮等有关零件连接成一个整体，并使之保持正确的位置，以传递转矩或改变转速来完成规定的运动。在各类生产加工中起着无可替代的作用，例如，它是减速机的重要组成部件，也是传动零件的基座，另外,在机车制造行业,箱体类铸件应用也十分广泛,特别是机车柴油机的主轴承座，因此一般都具有足够的强度和刚度。然而如今的很多箱体并不能达到预期的要求。1GF.02-05箱体是一种特殊结构的箱体，与其他箱体相比，它具有抗压能力强、稳定性高等优点。图纸上要求加工的部位多，加工精度高，加工难度大，因而其加工质量直接影响机器性能、精度和寿命。从而对此类箱体零件制造工艺的设计至关重要。本设计是对1GF.02-05箱体零件的加工工艺规程和及一些工序的专用夹具设计。1GF.02-05箱体零件的主要加工表面是平面和孔系，一般来说，保证平面的加工精度要比保证孔系的加工精度容易。因此，本设计遵循先面后孔的原则，并将孔与平面的加工明确划分成粗加工和精加工阶段，以保证孔系加工精度。基准选择以变速箱箱体的输入轴和输出轴的支承作为粗基准，以顶面与两个工艺孔作为精基准。主要加工工序安排是先以支承孔系定位加工出顶平面，再以顶平面与支承孔系定位加工出工艺孔，在后续工序中除个别工序外均用顶平面和工艺孔定位加工其他孔系平面。支承孔系的加工采用的是坐标法镗孔,整个加工过程均选用组合机床，夹具选用专用夹具，夹紧方式多选用气动夹紧，夹紧可靠，机构可以不必自锁。因此生产效率较高，适用于大批量、流水线上加工，能满足设计要求。关键词：箱体，制造工艺，夹具设计第2页共24页AbstractBoxisthebaseofthemachine,itconnectmachinesandpartsofshaft,sets,gearandrelatedpartsintoawhole,andkeepthemincorrectpositiontotransmittorqueorchangethespeedtocompletethemovement.Itplaysanirreplaceableroleinallkindsofproductionandprocessing.Forexample,Itisoneofthemostimportantcomponentsofreducers,what’smore,itisalsothebaseofthetransmissionparts.Inaddition,inthelocomotivemanufacturingindustry,castingpartsboxbodyisalsoverywidelyused,especiallyinthemainbearingoflocomotivedieselengine.therefore,theygenerallyhavesufficientstrengthandrigidity.However,nowadays,manyofthebodyandcannotachievethedesiredrequirements.1GF.02-05boxisaspecialkindofstructureofthebox,Comparedwiththeotherbox,ithasmorecompressiveability,higherstability,etc.Therearesomanyrequirementsinthedrawings.Andmostareofhighmachiningprecisionandmachiningdifficulty.Sotheprocessingqualitydirectlyaffectthemachineperformance,accuracyandlife.Tothiskindofcase,accessoriesmanufacturingprocessdesignisofprimeimportance.Thisdesignisfor1GF.02-05caseaccessoriesandprocessingproceduresandsomespecialfixturedesignprocess.1GF.02-05themainprocessingofpartsofthesurfaceisflatandhole,Ingeneral,guaranteetheaccuracyofplanethantoguaranteetheaccuracyofholeiseasy.Therefore,thisdesignfollowtheprincipleofsurfacebeforehole,andtheholeandtheplaneprocessingclearlydividedintoroughmachiningandfinishmachiningstage,toensuretheholemachiningaccuracy.Benchmarkchoiceforgear-boxinputshaftandoutputshaftbearingascrudebenchmark,withtopsurfaceandtwoholeasabenchmark.MainprocessingprocessistofastenwithbearingholepositioningprocessingChuDingplane,tothetopplaneandborebearingispositioningprocessingtechnology,Subsequentprocessinadditiontotheindividualprocessesaremadeoftopsurfaceandholepositioningprocessingotherhole.Departmentofbearingholeprocessingboringiscoordinatemethod,thewholeprocessselectsthemodularmachinetool,choosespecialfixturefixture,clampingwaychoosepneumaticclamping,morereliableclamping,organizationscannotself-locking.Sotheproductionefficiencyishigherandsuitableforthemass,assemblylineprocessing,whichcanmeetthedesignrequirements.Keywords:box,Manufacturingprocess,fixturedesign第3页共24页目录第1章1GF.02-05箱体的介绍············································41.1箱体零件的结构特点··············································51.2箱体零件的主要技术要求··········································51.3箱体零件的结构工艺性············································7第2章1GF.02-05箱体的加工工艺规程···································82.1箱体的工艺分析··················································92.2选定定位基准····················································92.3拟定零件的机械加工工艺路线······································92.4···································9第3章1GF.02-05箱体的方案参数及设计························73.1参数设计·······················································73.2方案设计························································73.3机床及各类工具具的选择·································3第4章钻床夹具设计····················································104.1有关夹具方案和元件的设计········································4.2钻套的选择与设计················································4.3钻床夹具的装配说明··············································第5章加工后箱体的检测及质量分析······································5.11GF.02-05箱体零件的检测········································5.21GF.02-05箱体的加工质量分析·····································5.3箱体的内应力与热变形对加工精度的影响·····························第6章总结···························································21致谢··································································22参考文献·······························································23附录··································································24第4页共24页第1章1GF.02-05箱体的介绍箱体的种类很多，按其功用可分为：主轴箱、变速箱、操纵箱、进给箱等。1GF.02-05箱体即是其中的一种变速箱体。箱体类零件由于其内部要安装其他各类零件,因而形状较为复杂。它的总体特点是由薄壁围成不同形状的空腔,以容纳运动零件及油、汽等介质。多数由铸造成毛坯，经必要的机械加工而成，具有加强肋、凹坑、铸造圆角等常见结构。箱体类零件由于结构、形状比较复杂，加工位置变化较多，通常以自然安放位置或工位位置，最能反映形状特征及相对位置的一面作为主视图的投影方向，一般需要用三个或三个以上的基本视图，并可根据具体零件的需要选择合适的视图、剖视图和剖面图来表达其复杂的内外结构。如图1.1所示即为1GF.02-05箱体零件图，详见附录1。图1.11GF.02-05箱体零件图第5页共24页1.1箱体零件的结构特点一般箱体具有以下结构特点：1.1.1形状复杂箱体的的作用是用来支撑和固定轴承部件并确保在外载荷作用下能正常工作，因此箱体要求有足够的刚度，从而箱体设计有复杂的截面形状和加强筋。在箱体上安装的零部件愈多，箱体形状就越复杂，这样才能满足各种定位面、定位孔和固定用的螺钉孔的安装需要；此外为储存润滑油箱体设有一定形状的空腔，还要有观察孔、放油孔等；为吊装方便还设有吊钩、凸耳等。1.1.2壁薄易变形为减少箱体整体质量，箱体型腔一般设计为薄壁结构，因此在铸造、焊接和切削加工过程中往往会产生较大的内应力，同时由于搬运方法不当等因素都会造成箱体变形。1