畢業(yè)設(shè)計(jì)CA6140車床法蘭盤加工工藝及鉆孔夾具設(shè)計(jì)附件

1、畢業(yè)設(shè)計(jì)附件題目：CA6140車床法蘭盤加工工藝及鉆孔夾具設(shè)計(jì)姓 名： 董震澤 學(xué) 號： 2012090371201 學(xué) 院： 機(jī)電學(xué)院 專 業(yè)： 機(jī)械工程及其自動(dòng)化 指 導(dǎo) 教 師： 付文宇 協(xié)助指導(dǎo)教師： 2016年5月28日畢業(yè)設(shè)計(jì)附件清單一、畢業(yè)設(shè)計(jì)任務(wù)書二、畢業(yè)設(shè)計(jì)開題報(bào)告三、畢業(yè)設(shè)計(jì)外文原文及譯文四、畢業(yè)設(shè)計(jì)圖紙北京聯(lián)合大學(xué)畢業(yè)設(shè)計(jì)（論文）任務(wù)書題目： CA6140車床法蘭盤加工工藝及夾具設(shè)計(jì) 專業(yè)： 機(jī)械工程及自動(dòng)化 指導(dǎo)教師： 付文宇 學(xué)院： 機(jī)電學(xué)院 學(xué)號： 2012090371201 班級： 1201B 姓名： 董震澤 一、主要內(nèi)容和基本要求CA6140車床法蘭盤的加工工藝

2、及鉆孔夾具設(shè)計(jì)的主要任務(wù)是： （1）搜集相關(guān)繪圖資料并繪制出零件的加工工件圖與Solid Works零件三維圖； （2）根據(jù)法蘭盤相應(yīng)的形狀要求、尺寸精度要求、表面粗糙度要求，制定出符合零件使用要求的加工工藝路線； （3）齒輪架的鉆孔夾具設(shè)計(jì)（繪制裝配圖及零件圖）。研究目的：本次法蘭盤機(jī)械制造工藝學(xué)課程設(shè)計(jì)的目的是旨在熟悉機(jī)械制造工藝學(xué)課程，需要我們綜合地運(yùn)用所學(xué)過的專業(yè)知識(shí)，針對實(shí)際零件進(jìn)行機(jī)械加工工藝規(guī)程制定及專用機(jī)床夾具設(shè)計(jì)，使我具備了制定機(jī)械加工工藝規(guī)程及設(shè)計(jì)專用機(jī)床夾具的能力，為以后所從事的機(jī)械工程工作打下基礎(chǔ)。就我個(gè)人方面而言，希望通過這次設(shè)計(jì)在各方面有不小的提高，能夠基本上掌握零

3、件機(jī)械加工工藝規(guī)程的設(shè)計(jì)。并學(xué)會(huì)了使用和查閱各種設(shè)計(jì)資料、手冊、和國家標(biāo)準(zhǔn)等。最重要的是綜合運(yùn)用所學(xué)理論知識(shí)，解決現(xiàn)代實(shí)際工藝設(shè)計(jì)問題，鞏固和加深了所學(xué)到的東西。并在設(shè)計(jì)過程中，學(xué)習(xí)更多在課堂上沒有學(xué)到的東西。在這個(gè)過程中，將使我對所學(xué)的知識(shí)有了進(jìn)一步的了解，也了解了一些零件設(shè)計(jì)工具書的用途，同時(shí)，也將鍛煉了協(xié)同工作能力。在以后的學(xué)習(xí)生活中，我將繼續(xù)刻苦努力，不斷提高自己。二、主要參考資料1李大磊，王棟主編 機(jī)械制造工藝學(xué)。北京：機(jī)械工業(yè)出版社，2014年。2孫建東，李春光主編 機(jī)械設(shè)計(jì)基礎(chǔ)。北京：清華大學(xué)出版社，2008年。3張建成，方新主編 數(shù)控機(jī)床與編程。北京：高等教育出版社，2013年

4、第二版。4湛迪強(qiáng)主編 Solid Works 2014快速入門、進(jìn)階與精通。北京：電子工業(yè)出版社，2014年4月。5張忠將主編 Solid Works 2014機(jī)械設(shè)計(jì)完全實(shí)例教程。北京：機(jī)械工業(yè)出版社，2015年1月。6王博平主編互換性與測量技術(shù)基礎(chǔ)。北京：機(jī)械工業(yè)出版社，2013年9月第四版。7張世昌，李旦，高航主編 機(jī)械制造技術(shù)基礎(chǔ)。北京：高等教育出版社，2007年5月第二版。8陳宏鈞主編實(shí)用機(jī)械加工工藝手冊(第3版) 。北京：機(jī)械工業(yè)出版社， 2009年3月。三、進(jìn)度要求時(shí)間工作內(nèi)容1-2周根據(jù)零件圖繪制三維零件圖3-5周通過力學(xué)計(jì)算設(shè)計(jì)工序以及工藝的流程6-8周設(shè)計(jì)法蘭盤的專用夾具9

5、-13周檢查問題，查漏補(bǔ)缺，最后完成畢業(yè)設(shè)計(jì)論文，準(zhǔn)備畢業(yè)答辯指 導(dǎo) 教 師： （簽字）專業(yè)負(fù)責(zé)人系主任： （簽字）北京聯(lián)合大學(xué)畢業(yè)設(shè)計(jì)開題報(bào)告題目： CA6140車床法蘭盤加工工藝及夾具設(shè)計(jì) 專業(yè)： 機(jī)械工程及自動(dòng)化 指導(dǎo)教師： 付文宇 學(xué)院： 機(jī)電學(xué)院 學(xué)號： 2012090371201 班級： 1201B 姓名： 董震澤 一、課題任務(wù)與目的CA6140車床法蘭盤的加工工藝及鉆孔夾具設(shè)計(jì)的主要任務(wù)是： （1）搜集相關(guān)繪圖資料并繪制出零件的加工工件圖與Solid Works零件三維圖； （2）根據(jù)法蘭盤相應(yīng)的形狀要求、尺寸精度要求、表面粗糙度要求，制定出符合零件使用要求的加工工藝路線； （3

6、）齒輪架的鉆孔夾具設(shè)計(jì)（繪制裝配圖及零件圖）。研究目的：本次法蘭盤機(jī)械制造工藝學(xué)課程設(shè)計(jì)的目的是旨在熟悉機(jī)械制造工藝學(xué)課程，需要我們綜合地運(yùn)用所學(xué)過的專業(yè)知識(shí)，針對實(shí)際零件進(jìn)行機(jī)械加工工藝規(guī)程制定及專用機(jī)床夾具設(shè)計(jì)，使我具備了制定機(jī)械加工工藝規(guī)程及設(shè)計(jì)專用機(jī)床夾具的能力，為以后所從事的機(jī)械工程工作打下基礎(chǔ)。就我個(gè)人方面而言，希望通過這次設(shè)計(jì)在各方面有不小的提高，能夠基本上掌握零件機(jī)械加工工藝規(guī)程的設(shè)計(jì)。并學(xué)會(huì)了使用和查閱各種設(shè)計(jì)資料、手冊、和國家標(biāo)準(zhǔn)等。最重要的是綜合運(yùn)用所學(xué)理論知識(shí)，解決現(xiàn)代實(shí)際工藝設(shè)計(jì)問題，鞏固和加深了所學(xué)到的東西。并在設(shè)計(jì)過程中，學(xué)習(xí)更多在課堂上沒有學(xué)到的東西。在這個(gè)過程

7、中，將使我對所學(xué)的知識(shí)有了進(jìn)一步的了解，也了解了一些零件設(shè)計(jì)工具書的用途，同時(shí)，也將鍛煉了協(xié)同工作能力。在以后的學(xué)習(xí)生活中，我將繼續(xù)刻苦努力，不斷提高自己。二、調(diào)研資料情況法蘭盤就是用于連接管道、管件或器材的零件，也有用于兩個(gè)設(shè)備之間的連接，如減速機(jī)法蘭盤。法蘭盤連接是由法蘭盤、墊片及螺栓三者相互連接為一組的可拆卸密封結(jié)構(gòu)，先各自固定在一個(gè)法蘭盤上，再墊上法蘭墊，用螺栓緊固在一起，這樣就完成了法蘭盤連接。法蘭盤主要用于連接緊固管道、管件等，并保持管道管件的密封性能；法蘭盤可拆卸，便于拆開檢查管道情況畢業(yè)設(shè)計(jì)所要求的CA6140臥式車床上的法蘭盤, 為盤類零件,存在于臥式車床上。車床的變速箱固定

8、在主軸箱上，依靠法蘭盤定心。法蘭盤內(nèi)孔與主軸的中間軸承外圓相配，外圓與變速箱體孔相配，為了保證主軸之上的三個(gè)軸承孔同心，使齒輪正確嚙合，從而保障了機(jī)床的精準(zhǔn)度。三、初步設(shè)計(jì)方法與實(shí)施方案初步設(shè)計(jì)方法：（1）構(gòu)思CA6140車床法蘭盤的三維造型；（2）法蘭盤的加工工藝路線設(shè)計(jì)；（3）正確填寫機(jī)械加工工藝過程卡和工序卡；（4）針對零件要求進(jìn)行鉆孔夾具的設(shè)計(jì)。實(shí)施方案：（1）繪制法蘭盤三維零件圖；（2）合理規(guī)劃工藝流程；（3）進(jìn)行夾具定位計(jì)算與力學(xué)分析；（4）繪制夾具裝配圖與三維爆炸圖。四、預(yù)期結(jié)果（1）法蘭盤三維造型； （2）法蘭盤加工工藝流程 ；（3）法蘭盤鉆孔工具夾具的設(shè)計(jì)；（4）法蘭盤鉆孔工

9、具夾具裝配圖，零件圖；（5）提交畢業(yè)論文一份。 五、進(jìn)度計(jì)劃時(shí)間工作內(nèi)容1-2周根據(jù)零件圖繪制三維零件圖3-5周通過力學(xué)計(jì)算設(shè)計(jì)工序以及工藝的流程6-8周設(shè)計(jì)法蘭盤的專用夾具9-13周檢查問題，查漏補(bǔ)缺，最后完成畢業(yè)設(shè)計(jì)論文，準(zhǔn)備畢業(yè)答辯北京聯(lián)合大學(xué)畢業(yè)設(shè)計(jì)（論文）外文原文及譯文題目： CA6140車床法蘭盤加工工藝及夾具設(shè)計(jì) 專業(yè)： 機(jī)械工程及自動(dòng)化 指導(dǎo)教師： 付文宇 學(xué)院： 機(jī)電學(xué)院 學(xué)號： 2012090371201 班級： 1201B 姓名： 董震澤 一、外文原文Research on selecting the optimal design of antivibrational l

10、athe tool using computer simulationABSTRACT: Computer simulation of machining processes can save cost, time, and lead to reach an effective predictive capability. In this paper, by using computer simulation, damping capability of the lathe tools under static and vibrational analysis at different too

11、l overhang conditions is studied. A novel predictive model of the cutting tool is developed, in which damping capability of the tool is improved by using composite material with high damping capability. Epoxy granites with normal, rigid, and plastic structures were used as composite materials in mod

12、ified model of tool holder. The all-metal model, model with holes in tool holder and the modified model filled up with the composite material, with the same geometryand dimensions are used.Keywords: Lathe tool, epoxy granite, tool life, overhang, vibration, frequency, damping capacityIntroductionOne

13、 of the methods of the machining process is turning, and in some cases finish cutting can complete a technological process of manufacturing of products. The aim in the turning process is to obtain the right quality of machined products by removing high volumes of material. 1,2 However, this success

14、in cutting process depends on the following factors: machine rigidity, fixing rigidity, tool rigidity, and good vibration damping capability. 3 During metal cutting, some problems occur such as deformation, chip formation, friction, wear of the cutting tool, and heat generation. Thus, efficiency and

15、 cost of machining, and quality of the processed surface of the product depend on static and dynamic characteristics of the closed loop system(the machinecutting processthe tool). 4Metal cutting is a dynamic process and during cutting vibrations occur, which can be divided into forced and chatter vi

16、brations. The effect of forced vibrations generated during a regular cutting process is small. It is difficult to avoid them completely due to the compliance of the machining system. 13 However, chatter vibrations negatively affect the stability of the system, which reduce the precision of the part

17、and quality of surface. 46 Cutting forces depend on the tool geometry, material properties, feed rate, and cut-ting speed. In an unstable process, the amplitude of vibrations may grow exponentially until they become as large as chip thickness. This unstable vibration creates large cutting forces, wh

18、ich can damage the machine, cutting tool, and the work piece; furthermore, it causes tool wear, tool breakage, unacceptable surface finish, and dimensional errors. Besides, vibration during cutting process causes noise that tires workers and reduces stability of the cutting tool leading to poor surf

19、ace finish. From the literature review of vibration induced by a machining process, clearly the majority of the work on vibration creation attempt to reduce vibration during a machining process owing to what productivity and machining accuracy decrease. Vela et al. 8 investigated the compliance betw

20、een the work piece and cutting tool in turning process and a multiple degree of freedom model for chatter prediction was proposed. Sortino et al. experimentally studied the influence of the material, geometry of the tool, and workpiece on process stability in internal finish turning. They founded th

21、at the ratio of boring bar overhang to bar external diameter is the main factor that affect the stability of the process. Tayloret. analytically presented the effect of tools edge condition and the relief angle on process damping inmachining process. They suggested that the process damping effect du

22、e to an edge radius reduces as the tool relief angle reduces. Mahdavinejad 11 analyzed the instability of the machining process by dynamic model of turning machine, consisted of tools structure, using finite element method. Kopac et al. 12 conducted an investigation on identification of the dynamic

23、instability in hard turning process based on the determination of natural frequencies of machine tool components on different positions in work area and position of resonance frequency determination.The results showed that if cutting instability and push-off effect do not have dominant influence it

24、is possible to achieve minimum roughnes on machined surface. An investigation carried out by Yusuke et al. on inprocessiden tification of process damping coefficient in turning process reported that process damping is effective when tool wear reaches a level that covers the vibration wave left on th

25、e surface.Rama and Srinivas 14 proposed a realistic analytical stability model of regenerative chatter in orthogonal turning operation. They reported that tool overhang and work cross-section are the main factors that affect the stability. Abuthakeer et al. 15 used a passive damping pad of viscoelas

26、tic material of neoprene in their investigation to predict and suppress the vibration level of cutting tool in Computer numerical control (CNC) lathe. Ramesh and Alwarsamy 16 suggested the impact dampers with different materials, such ascopper, cast iron, phosphor, structured steel, aluminum, brass,

27、 bronze, and gun metal, in boring tools in order to improve stiffness and damping capability of the tool and suppress the chatter. Arsecularatne et al. 17 used tool life to investigate the dominant wear mechanism of the cutting tools made of tungsten carbide (WC), Poly-crystalline cubic boron nitrid

28、e (PCBN), and Poly-crystalline diamond (PCD). Devin and Osadchii 18 proposed a new tool design with an increased vibration damping ability, whichincludes special elements made of damping materials. They investigated influence of damping properties of the proposed model on the Cubic boron nitride (cB

29、N) tool life, vibration amplitude, and machined surface roughness. Kanase and Jadhav 19 presented a passive vibration damping to absorb the vibrations in boring process. They also concluded that impact damping has improved the surface finish in boring operation. So to ensure precise and efficient ma

30、chining process, avoidance of vibrations is crucial. In modern manufacturing industry, cutting tool is the basic element of a technological process.Fundamental understanding of cutting tool behavior during machining is essential to determine tool life. During turning operation, cutting tool might fa

31、ce a hard spot on the metal surface and begin to oscillate, which causes a vibration of the cutting tool relative to the workpiece. As a result it may change many factors such as cutting force, thickness of the cut-off layer, and size and character of operating loads. It is essential while cutting o

32、f metals in microscales. The complexity of the machining process (very high temperatures, strains, and strain rates) and lack of suitable data impede to provide an adequate relation-ship between tool life and cutting conditions, tool geometrical parameters, and work and tool material properties. 202

33、2 However, cutting efficiency and tool life in high-speed machining of difficult-to-cut materials can be improved using new materials and newtechnology such as tool coatings and changing the machining conditions. 23,24 Thus, the key factor is the choice of the most effective design of cuttingtool. M

34、oreover, in advanced machining processes combined tool is usually used. The aim of vibration reduction is to increase the dynamic stiffness of the machining system or changing its main natural frequency or feedback-controlled actuators. 9 In order to reduce vibration in cutting process, there are th

35、ree methods, which are widely used: using the vibration damper, applying special coating on a cutting insert, and using tool holder made of material with high damping capability. 18 The precision of machine tools is directly related to the materials used in their construction. These materials in the

36、 tools construction dissipate the energy and by this way they reduce vibration, and we can achieve the required accuracy. 21,23 Therefore, materials, used in machine tools structure, must have high values of yield strength, elastic modulus, and also high vibrations damping capacity and reduced therm

37、al expansion coefficient. An extensive use of composite materials due to their higher specific properties of strength and stiffness in comparison with metals offers interestingopportunities for new product design. They have different chemical compounds but possess also a number of similar parameters

38、. These materials consist of a filling agent, or reinforcing particles, and filler. Reinforcing elements can have various orientations. 21One of such materials is epoxygranite, which is a combination of epoxy and granite. Recent investigations have pointed out the use of epoxygranite, replacing cast

39、 iron and granite for building machine basements, because of its high elastic modulus andmechanical resistance per unit weight and workability. Besides, products made of epoxygranite have better vibration damping capacity in comparison with steel and cast iron, which has been investigated by Antonio

40、 and Flam´nio 25 ; where samples of gray cast iron and epoxygranite were machined with the same geometry and dimensions. The result showed that the logarithmic decrement values of the epoxygranite samples are almost 3 times higher than those of cast iron, which indicates better damping effect o

41、f epoxygranite in comparison with gray cast iron, for the same volume of material. The study carried out by Selvakumar and Mohanram 26 on specimens modeled and manufactured with cast iron,steel, and epoxygranite materials showed that vibration is dampened out faster by epoxygranite in comparison wit

42、h steel and cast iron structures. Hence using epoxygranite in the cutting tools structure makes a possibility to improve damping capacity and tool life, and, therefore, increase machining accuracy class, which make epoxygranite more preferable material for precision machine tool structures.Experimen

43、tal studies are usually expensive and time consuming. Besides, their results are valid only for the experimental conditions and depend on the accuracy of calibration of the experimental equipment and apparatus used. The application of computer simulation of machining processes has grown in the last

44、years, because it potentially saves time and cost,which leads to reach an effective predictive capability. Thus, an alternative approach to study the machining processes is computer simulation. In this paper SolidWorks Simulation is used to perform the analysis. Therefore, the purpose of this work i

45、s to find the optimal design of the lathe tools filled up with composite material (epoxygranite) in the tool holder, and a new model of the lathe tools is proposed based on the computer analysis of the behavior of the tools during static and vibration analysis. In this study, three different cutting

46、 tools were used: the standard all-metal model, the model with horizontal holes arranged in a chessboard pattern, and the model with horizontal holes arranged in achessboard pattern and filled up with composite material (see Figure 1).Materials and method In the analysis, the lathe tools dimension i

47、s 150mm?27mm?27mm, and they are made of hardened steel (AISI 5140). Modeling of the tools was performed using SolidWorks Version 2012, where, at first stage, the sketches of the models were created and then their 3D models, as shown in Figure 1. Static and vibration analysis were performed using Sol

48、idWorks Simulation for next overhangs: 30, 35,38, 41, 44, 47, 50, 53, 56, 59, 62, and 65mm.In Figure 1(c) the holes of the tool holder of the modified model are filled up with epoxygranites with normal, rigid, and plastic structures, the physical andmechanical characteristics of which are provided i

49、n Table 1.Static analysis To perform static analysis using Solidworks Simulation it is necessary to assign the material of the tools and restrictions, set the external loads, assign the contact surfaces and contact characteristics, create a finite element mesh, and perform calculations. In static an

50、alysis, the lathe tools are affected by tool clamps force (15000N) and cutting force (2000N). Figure 2 shows finite element mesh and external loads on tool tip and tool holder of model filled up with composite material. static analysis, tool tip displacement was determined at different tool overhang

51、 condition. Figure 3 illustrates the relationship bet ween displacement of tool tip and overhang.In Figure 3, it can be clearly seen that, for allmodels, displacement of tool tip increases as tooloverhang increases. The holes in tool holder reducestiffness of the tool; therefore, tool tip displaceme

52、nt of the tool with holes in the tool holder is greater in comparison with all-metal model. Filling up the holes by epoxygranite has reduced displacement of tool tip in comparison with model with holes, which confirms high damping capability of epoxygranite. However, the result of static analysis in

53、dicates that stiffness of the all-metal model is greater than that of models with and without epoxygranite. The flexibility of the tool holder strongly affects the surfaceroughness in machining of materials. It is known that cutting tool with higher stiffness improves the surface roughness during ma

54、chining process. In this study all-metal model has the highest stiffness, therefore using this cutting tool in machining process givesbetter result in terms of surface finish.Natural frequency analysis of lathe tools The stability of cutting tool considerably depends on vibration. Frequency analysis

55、 of tools was conducted to examine mode in the first harmonic of the natural oscillations, as the maximum amplitude occurs on first harmonica. In frequency analysis of the models,external loads can be ignored, since their impact on the frequency is not significant. The models are fixed from the bott

56、om side. The overhang length is changed (30, 35, 38, 41, 44, 47, 50, 53, 56, 59, 62, and 65mm) to find the relationship between natural frequency andtool overhang. This relationship is shown in Figure 4, which illustrates that natural frequency decreases as overhang increases. As can be seen from Figure 4,cutting tool with holes decreased the natural frequency in comparison with all-metal model. This can be explained by the fact that the cutting tool with holes has the heterogeneous structure. Vibration waves pass through the m