Course Design (Mechanical Engineering Technology) - Engineering of Bearing Cover (Flange) Manufacturing Process

Contents

Introduction

1. Structural and technological analysis of the article

1.1. Gearbox service purpose

1.2. Classification of work surfaces

2. Development of gearbox assembly process

2.1. Gearbox Assembly Process

2.2. Process Development

2.3.Assembly Flow Sheet

3. Procurement Selection

3.1.Base procurement selection

3.2. Define Production Type

3.3. Process Requirements for Fabrication Analysis

gear shaft

3.4. Purpose of machining allowances

4. Design of routing technology of part manufacturing

4.1. Preparation of the gear shaft manufacturing route

4.2. Operating Technology Design

5. Mechanical Assembly Safety

General position

6. List of literature

Introduction

The goal of course design in mechanical engineering technology is to learn to correctly apply the theoretical knowledge gained in the process, to use practical experience at machine-building enterprises to solve technological and design problems.

The purpose of this course design is to design the manufacturing process of the bearing cover (flange), which is a typical part. To assign a part to a particular type, it is customary to divide them into classes. A class is a collection of products (machines, assemblies or parts) that have the proximity of a service purpose. The similarity of the service purpose of the products gives rise to the similarity of requirements that the machine, assembly unit or part must meet, the proximity of design shapes, sizes and other qualitative indicators. For example, lathes are divided, depending on the accuracy of the work performed on them, into high-precision, increased and normal accuracy, adding in each of the classes an additional division in size of the parts manufactured on them into small, medium and heavy machines intended for the manufacture of large-sized parts. In each class of machines, assemblies and parts, a typical machine, assembly unit or part is selected. A typical is called a part, assembly unit or machine that most fully represents the service purpose of a given class. Thus, a typical part should cover all structural elements inherent in a given class of parts, differ in the highest requirements for dimensional accuracy, be made of material that corresponds to the service purpose of parts of this class. In case none of the parts of this class fully meets the specified requirements, the design of the detail representative is developed, taking into account the peculiarities of all steels that make up the class.

Procurement Selection

3.3. Analysis of process requirements for gear shaft fabrication

The gear shaft manufactured shall meet the following accuracy parameters:

The limit deviations of the relative dimensions of the contact spot in length and height of the tooth in percentage terms are ± 10% for 4-7 degrees of accuracy.

The gear shaft shall be manufactured in accordance with the following accuracy criteria:

The limit deviations of the surfaces to be seated shall be h8.

HB surface hardness 265... 295.

Tolerance of parallel ends 0.05 mm.

Coaxiality tolerance of cylindrical surfaces 0.04 mm

Roughness Ra 1.25

Unspecified limit deviations of holes H14, shafts h14, steel dimensions - ± IT14/2 as per GOST 2567083.

3.4. Purpose of machining allowances

The allowance to the side is defined as the total allowance for machining.

Cylindrical surface of ∅ 16

Roughing - 1.5 mm

Finishing -0.45 mm

Grinding - 0.05 mm

Total allowance -2 mm

Cylindrical surface of ∅ 19

Roughing -1.5 mm

Finishing -0.45 mm

Grinding - 0.05 mm

Total allowance -2 mm

Conical surface

Roughing -2 mm

Finishing -0.45 mm

Grinding - 0.05 mm

Total allowance -1.5 mm

End surfaces

Roughing -2 mm

Finishing -1 mm

Total allowance -3 mm

The design size is considered by sequentially adding the design minimum allowance of each process transition to the design size. The largest limit dimensions are calculated by adding allowance to the rounded limit dimensions.

The smallest limit dimensions (dmin) are determined from the largest limit dimensions by subtracting the tolerances of the corresponding transitions.

Operating Technology Design

Transactions:

001. Incoming control.

Equipment: Ruler, caliper, hardener.

Inspection according to the requirements of the workpiece drawing. The material mark (by marking) is checked; dimensions (universal measuring means - ruler, caliper, etc.); availability of primary heat treatment (hardness meter); no superficial defects (visually)

005. End Milling and Centering

Equipment: Milling and Centering Machine

- Install, attach the workpiece.

- Trim the ends.

- Perform alignment.

- Remove the workpiece.

010. Pre-turning on one side.

Equipment: Hydrocopy semi-machine

- Install, attach the workpiece.

- Turn the conical surface.

- Turn Ø19.

- Remove the workpiece.

015. Pre-turning on the other side

Equipment: Turret semi-automatic

- Install, attach the workpiece.

- Turn Ø16mm.

- Remove the workpiece.

020. Heat treatment.

Equipment: Thermal workshop.

- Perform heat treatment.

025 Finishing turning on one side.

Equipment: Hydrocopy semi-machine

- Install, attach the workpiece.

- Turn the conical surface.

- Turn Ø19.

- Remove the workpiece.

030. Preliminary grinding of the base neck and end face to create a technological base for subsequent processing of the gear ring

Equipment: Circular grinding machine

- Install, attach the workpiece.

- Grind Ø16mm.

- Remove the workpiece.

035. Finish turning of conical and other surfaces for toothed rim

Equipment: High precision turret machine

- Install, attach the workpiece.

- Turn the conical and other surfaces under the toothed rim.

- Remove the workpiece.

040. Pre-milling of teeth for removal of base metal

Equipment: Semi-automatic toothfree machine

- Install, attach the workpiece.

- mill the teeth to remove the base metal.

- Remove the workpiece.

045. Preliminary toothing with allowance for subsequent processing

Equipment: Zubostrogal semi-automatic

- Install, attach the workpiece.

- perform toothing with an allowance for subsequent treatment of 0.55... 0.65 mm per tooth thickness.

- Remove the workpiece.

050. Finishing toothwork, 6th degree of accuracy

Equipment: Zubostrogal semi-automatic

- Install, attach the workpiece.

- carry out finishing toothfighting, of the 6th degree of accuracy (allowance for subsequent splicing 0.2... 0.3 mm per tooth thickness).

- Remove the workpiece.

055. Flushing.

Equipment: washing machine

060. Inspection (contact spot check)

Equipment: Control rolling machine

065. Polishing of base necks and end face

Equipment: Circular grinding machine

- Install, attach the workpiece.

- Grind Ø16mm.

- Grind Ø19mm.

- Remove the workpiece.

070. Groove Milling

Equipment: Vertical Milling Machine

- Install, attach the workpiece.

- Mill groove 5x5x20 Rz 20.

- Remove the workpiece.

075. Metalwork

Tools: file, cutter.

- Grind burrs.

080. Thread Cutting

Equipment: Turret semi-automatic

- Install, attach the workpiece.

- Thread M19x1,56g.

- Remove the workpiece.

085. Finish grinding of base necks and ends.

Equipment: High precision circular grinding machine

- Install, attach the workpiece.

- Grind Ø16mm Ra = 1.25 μm.

- Grind Ø19mm Ra = 1.25 μm.

- Grind ends Ra = 1.25 mcm.

- Remove the workpiece.

090. Grinding of cone, cylindrical and end surfaces of toothed rim.

Equipment: High precision circular grinding machine

- Install, attach the workpiece.

- Grind conical, cylindrical and end surfaces of the gear ring; permissible run-out on conical and cylindrical surfaces - not more than 0.02 mm, Ra = 1.25 mcm.

- Remove the workpiece.

095. Preliminary grinding of teeth.

Equipment: High-precision grinding machine

- Install, attach the workpiece.

- Before grinding the teeth, 1/3 of the total grinding allowance remains for final grinding.

- Remove the workpiece.

100. Final grinding of wheel teeth.

Equipment: High-precision grinding machine

- Install, attach the workpiece.

- Grinding of wheel teeth, Ra = 1.25 mcm.

- Remove the workpiece.

105. Flushing.

Equipment: washing machine

110. Final inspection, inspection of microcracks on flaw detector, matching of gears in pairs by contact spot

Equipment: Control rolling machine