填料箱盖工艺课程设计说明书

目录工艺部分······················································································21.1有关零件的结构分析和功用·························································21.1.1零件的功用···········································································21.1.2零件的结构分析······································································21.2课题（提供的技术资料）····························································21.2.1生产纲领···············································································21.2.2技术资料···············································································31.3毛坯的种类··············································································31.3.1确定毛坯的种类······································································31.4定位基准的选择原则··································································31.4.1粗基准的选择原则···································································31.4.2精基准的选择原则···································································41.5工艺规程的拟定········································································41.5.1制定工艺规程的原则································································41.5.2拟定工艺路线·········································································41.6机械加工余量工序尺寸及毛坯尺寸的确定······································41.6.1确定加工余量和工序尺寸··························································41.6.2确定毛坯尺寸·········································································51.7确定切削余量···········································································61.7.1确定和计算切削用量································································61.8工时定额的确定········································································141.8.1计算工时定额·········································································15结论······························································································18致谢······························································································18参考文献························································································19工艺部分1.1有关零件的结构分析和功用:1.1.1零件的功用:题目所给的零件是ZW-6/7型空气压缩机的填料箱盖（见附图1）主要作用是保证与填料箱体联接后保证密封性，对内表面的加工精度要求比较高，对配合面的表面粗糙度要求也较高。1.1.2零件的结构分析:套类零件的主要加工表面有孔、外圆、和端面．其中孔既是装配基准又是设计基准，加工精度和表面粗糙度一般要求较高，内外圆之间的同轴度及端面与孔的垂直度也有一定的技术要求．题目所给填料箱盖有两处加工表面，其间有一定位置要求。分述如下：填料箱盖的零件图中规定了一系列技术要求：（查表1.4-28《机械制造工艺设计手册》）1.以ф65h5（0013.0）轴为中心的加工表面。包括：尺寸为ф65h5（0013.0）的轴，表面粗糙度为1.6，尺寸为ф80的与ф65h5（0013.0）相接的肩面,尺寸为ф100f8(036.0090.0)与ф65H5（0013.0）同轴度为0.025的面.尺寸为ф60H8(048.00)与ф65h5（0013.0）同轴度为0.025的孔。2.以ф60H8(048.00)孔为中心的加工表面。尺寸为78与ф60H8(048.00)垂直度为0.012的孔底面,表面粗糙度为0.4,须研磨。3.以ф60H8(048.00)孔为中心均匀分布的12孔,6-ф13.5,4-M10-6H深20孔深24及4-M10-6H。4.其它未注表面的粗糙度要求为6.3,粗加工可满足要求。1.2课题（提供的技术资料）1.2.1生产纲领：1000件/年1.2.2技术资料：（1）选用机床设备参数：卧式车床C620-1，转塔车床365L，摇臂钻床Z3025，C616，金刚镗床，X63，T60，M115B，研磨机。（2）选用机床刀具参数：YG6外圆车刀，切槽刀，φ25、φ13.5、φ8.5麻花钻，φ32扩孔钻，φ43锪孔钻，φ10丝锥，金刚石车刀，YG30、YG10镗刀，端面铣刀，内孔车刀，砂轮G36YA6N20X6X8，金刚玉微分。（3）选用机床夹具：三爪卡盘，专用夹具。（4）选用量具：卡板，卡尺，塞规，螺纹塞规，粗糙度仪。1.3毛坯的种类1.3.1确定毛坯的种类：零件材料为HT200，考虑到零件材料的综合性能及材料成本和加工成本,保证零件工作的可靠,采用铸造。由于年产量为1000件，属于中批生产的水平，而且零件轮廓尺寸不大，故可以采用铸造成型。1.4定位基准的选择原则1.4.1粗基准的选择原则：对于一般轴类零件而言，以外圆作为粗基准是完全合理的。按照有关的粗基准选择原则（保证某重要表面的加工余量均匀时，选该表面为粗基准。若工件每个表面都要求加工，为了保证各表面都有足够的余量，应选择加工余量最小的表面为粗基准）。1.4.2精基准的选择原则按照有关的精基准选择原则（基准重合原则；基准统一原则；可靠方便原则），对于本零件，有中心孔，可以以中心孔作为统一的基准，但是随便着孔的加工，大端的中心孔消失，必须重新建立外圆的加工基面，一般有如下三种方法：当中心孔直径较小时，可以直接在孔口倒出宽度不大于2MM的锥面来代替中心孔。若孔径较大，就用小端孔口和大端外圆作为定位基面，来保证定位精度。采用锥堵或锥套心轴。精加工外圆亦可用该外圆本身来定位，即安装工件时，以支承轴颈本身找正。1.5工艺规程的拟定1.5.1制定工艺规程的原则：按照先加工基准面，先面后孔、先粗后精的原则，布置工艺路线。1.5.2拟定工艺路线：工序Ⅰ车削左右两端面。工序Ⅱ粗车ф65，ф80，ф75，ф155外圆及倒角。工序Ⅲ钻ф30孔、扩ф32孔，扩ф47孔。工序Ⅳ精车ф65外圆及与ф80相接的端面.工序Ⅴ粗、精、细镗ф60H8（)046.00孔。工序Ⅵ铣ф60孔底面工序Ⅶ孔底面工序Ⅷ镗ф60孔底面沟槽。工序Ⅸ研磨ф60孔底面。工序Ⅹ钻6-ф13.5孔,2-M10-6H,4-M10-6H深20孔深24的孔及攻螺纹工序Ⅺ终检。1.6机械加工余量工序尺寸及毛坯尺寸的确定1.6.1确定加工余量和工序尺寸：（1）外圆表面(ф65、ф80、ф75、ф100、ф91、ф155)考虑到尺寸较多且相差不大，为简化铸造毛坯的外形，现直接按零件结构取为ф86、ф106、ф161的阶梯轴式结构，除ф65以外，其它尺寸外圆表面粗糙度值为Ra6.3um,只要粗车就可满足加工要求。（2）外圆表面沿轴线长度方向的加工余量及公差。查《机械制造工艺设计手册》,铸件轮廓尺寸(长度方向100～160mm,故长度方向偏差为5.2mm。长度方向的余量查表,其余量值规定为3.0～3.5mm.现取3.0mm。（3）4332、内孔。毛坯为实心。两内孔精度要求自由尺寸精度要求，Ra为6.3,钻——扩即可满足要求。（4）内孔ф60H8(048.00)。要求以外圆面ф65h5（0013.0）定位，铸出毛坯孔ф30。查表：粗镗ф59.52Z=4.5精镗ф59.92Z=0.4细镗ф60H8(046.00)2Z=0.1(5)ф60H8(046.00)孔底面加工.按照《工艺手册》表：1.研磨余量Z=0.010～0.014取Z=0.0102.磨削余量Z=0.2～0.3取Z=0.33.铣削余量Z=3.0-0.3-0.01=2.69(6)底面沟槽.采用镗削,经过底面研磨后镗可保证其精度.Z=0.5。(7)6—5.13孔及2—M10—6H孔、4—M10—6H深20孔。均为自由尺寸精度要求。1．6—5.13孔可一次性直接钻出。2．查《工艺手册》表，得攻螺纹前用麻花钻直径为ф8.5的孔。钻孔ф8.5攻螺纹M101.6.2确定毛坯尺寸（1）外圆表面(ф65、ф80、ф75、ф100、ф91、ф155)考虑到尺寸较多且相差不大，为简化铸造毛坯的外形，现直接按零件结构取为ф86、ф106、ф161的阶梯轴式结构。（2）外圆表面沿轴线长度方向的加工余量及公差，查表可取余量3.0mm。（3）4332、内孔。毛坯为实心。（4）内孔ф60H8(048.00)铸出毛坯孔ф54。1.7确定切削余量1.7.1确定和计算切削用工序Ⅰ：车削端面、外圆：本工序采用计算法确定切削用量工件材料：HT200，铸造。加工要求：粗车ф65、ф155端面及ф65、ф80、ф75、ф100，ф155外圆，表面粗糙度值Ra为6.3。机床：C620—1卧式车床。刀具：刀片材料为YG6，刀杆尺寸为16mm×25mm,kr=90°,r0=15°0=12·rR=0.5mm。计算切削用量：（1）粗车ф65、ф155两端面：确定端面最大加工余量：已知毛坯长度方向单边余量为325.1mm，则毛坯长度方向的最大加工余量为4.25mm,分两次加工,ap=2mm计。长度加工方向取IT12级，取04.0mm。确定进给量f:根据《切削用量简明手册》（第三版）表1.4,当刀杆16mm×25mm,ap≤2mm时,以及工件直径为ф160时。f=0.5～0.7mm/r按C620—1车床说明书（见《切削手册》表1.30）取f=0.5