Design of manufacturing process of rod guide part

Contents

Introduction

1. General part

Service assignment of a part and conditions of its operation in an assembly unit

Part Material Characteristic

1.3 Structural Inspection of Part Drawing

1.4Parse Part Fabrication Specifications

1.5Assay the workability of a part design

1.5.1Quantity evaluation of workability of part design

1.5.2Qualification of processability

2. Process Part

Procurement Method

Procurement Selection Feasibility Study

Selection of bases and baselines

Routing and Process Design

Selection of process equipment

Selecting a Cutting Tool

2.6 Selection of measuring instruments

Calculation of machining allowances

Calculation and selection of cutting modes

2.9 Calculation and selection of time standards

3. Design Part

3.1. Design of special machine tool. Development of design diagram and power calculation of the accessory

3.2. Calculation of machine tool for accuracy

4. Organizational Part

4.1. Determination of the required quantity of machine equipment and its load factor

4.2. Determination of number of machine tools, auxiliary workers and ITR in the area

4.3. To Define a Parcel Area

5. Safety of life

5.1. Project Environmental Safety Engineering Justification

5.2. Production safety

5.2.1. Heating, exhaust, ventilation

5.2.2. Lighting

5.2.3. Calculation of artificial lighting in the workshop

5.2.4. Noise and vibration

5.2.5. Electrical safety

5.3. Fire safety

5.4. Emergency

5.5. Occupational Safety Instruction for the Worker

5.5.1. General Occupational Safety Requirements

6. Economic part

6.1. Calculation of economic effect from improvement of technological process of turning cam support manufacturing

6.1.1. Current Cost Calculation

6.1.2. Calculation of economic efficiency indicators

Conclusion

List of literature used

Introduction

Mechanical engineering is the most important industry. Its products - machines for various purposes are supplied to all branches of the national economy. The growth of industry, as well as the pace of re-equipment with their new technology and technology, largely depend on the level of development of engineering.

The state of mechanical engineering largely determines the development of other sectors of the national economy. Machines and mechanisms with worm-type parts are used in various fields of science and technology. These parts, based on high requirements for technical, economic and operational parameters of machines and mechanisms, should have high reliability, repairability, processability, minimum dimensions, convenience in operation. In many ways, these indicators are provided in the process of designing and manufacturing shafts.

The main tasks of mechanical engineering technology are the design of the entire complex of technological means that ensure the production of products of a given quality in a given amount and in a given time, as well as reducing the cost of production, improving quality, reducing the time spent on the production of the product, increasing the coefficient of material use, automation of technological processes.

The main tasks of mechanical engineering technology are: the use of automatic systems, adaptive control systems, GPS, the introduction of the latest technological equipment into production, the use of computers, the latest cutting, measuring tools and equipment.

Technological preparation of production is a decisive stage in the cycle of production of machines and mechanisms. One of the stages of technological preparation of production consists in the development of a technological process for the manufacture of machine parts.

The graduation work is devoted to the development of the gear manufacturing process. Such parts are made in large volumes and are used in various cars and mechanisms, machines, gearboxes, etc.

The main tasks that need to be solved when designing new technological processes are to increase the accuracy and quality of processing, stability and durability of parts and maximize the reduction of the cost of processing by improving technological processes. In the course project, these tasks will be solved by analyzing the design process, identifying its main shortcomings and methods for solving them.

The purpose of the graduation work is to consolidate the knowledge gained at lectures, practical exercises and acquire the skills to fulfill the main stages of the development of the technological process and independently search for the most optimal technical solutions based on the latest achievements of science and technology.

Procurement Selection

melt of aluminium or its alloy is sprayed with compressed gas with oxygen content up to 10% at pressure in nozzle 15-55 atm, melt temperature 700-800 ° C. The obtained pulverisate having a size of up to 1500 μm is classified by screening on a screen to separate a fraction with a size of less than 1000 μm, then using a screen with cells 005 to separate a fraction of 0-50 μm. Powder of said fraction is subjected to pressing with addition of aluminium and zinc stearate in amount of 0.5-3%. Described method makes it possible to reduce explosion hazard of powder feeding for pressing, improves technological properties of powder and provides for improvement of quality of sintered products. 1 Table

invention relates to powder metallurgy of aluminium and its alloys, in particular, to method of mass production of parts by cold pressing of powders with further sintering of blanks.

A method is known for producing sintered semifarcates and articles from metal, including aluminium powders by pressing and subsequent sintering of blanks [1].

This method includes the following processing steps: spraying melts with compressed gas (or any other method) to obtain a polydisperse powder; classifying (sizing) powders by size to obtain fractions of required size; feeding (transporting, loading, unloading, packing, etc.) the powder for pressing and pressing; sintering; calibration of semi-finished product or product.

This method in various modifications is widely used in the industry for mass sliming of parts on press machines, which provides its high productivity and economic efficiency.

There is known a method of producing sintered semi-finished products and products from aluminium powder with unregulated size less than 50 mcm [2].

The disadvantages of this method are the instability of the quality of the sintered material (strength and fluidity), the increased explosion hazard of the powder and its handling operations, the poor fluidity of the powder and its sticking to the walls of the molds, which does not allow automating the pressing process and requires frequent remaking of the molds.

Methods are known for producing sintered materials from aluminum powders and alloys thereof, which use powders with an unregulated size in the range of up to 1000 μm.

Disadvantages of these methods are poor quality of sintered materials and instability of their properties, considerable dusting when sprinkling polydisperse powders, which increases the risk of handling them, worsens working conditions, requires the use of large amounts of special lubricants to prevent metal sticking to the press tool.

The method closest to the claimed method involves spraying the melt with compressed gas (nitrogen with controlled oxygen content), classifying the powder to the specified size, feeding the powder for pressing, pressing and sintering. After spraying, the resulting powder, called pulverizate, has an unregulated size of up to 2.5 mm. A large fraction (larger than 1000 mcm) is separated from the pulverizate by sieve classification and the obtained powder is sent to compress the blanks, the latter are subjected to sintering.

The disadvantage of this method is the high explosion hazard of the process during its transportation, pouring and loading into press machines, as well as the low technological properties of the obtained powders and the mechanical properties of sintered products or semi-finished products.

The object of the invention is to improve the safety of the process, improve the technological properties of the powder and the quality of sintered products.

when producing sintered materials from aluminium powders and its alloys, powder with content of not more than 15 wt% of particle fraction with size of up to 50 mcm is subjected to pressing.

The tests carried out in the VAS established that when conducting the classification, which ensures the content in the powder with a particle size of 0... 1000 μm, the fraction of 0... 50 μm is not more than 15 wt%, the explosion hazard of subsequent operations of transporting, pouring, loading the powder, feeding it to pressing and the pressing operation itself is drastically reduced; these operations are becoming more technological and explosion-proof, working conditions are improving, and the quality of the sintered semi-products and articles is improved by removing the thinnest powder particles, which impair its fluidity, compressibility and sinterability.

A significant difference in our technical solution is the determination of a narrow link in the process chain of operations for the production of sintered materials - the classification of a powder with the removal of a fraction of 0... 50 μm from it to its specific (no more than 15 wt%) content. An increase in the content of the fraction 0... 50 μm in the powder reduces the NCCP, increases the maximum explosion pressure and its growth rate, that is, increases the danger of powder production and processing processes, and the limit of the content of 15 wt% ensures the explosion safety of the processes for handling such powders.

In a prior art solution, the fraction of 0... 100 μm in the range of 0 to 12 wt% is limited to increase safety in aluminum alloy powder. The proposed solution is more cost effective, as it reduces explosion hazard, but also increases the share of the business fraction used for production.

Limitation of content of fraction smaller than 50 mcm to 15 wt% simultaneously improves technological properties (fluidity) of powders, eliminates their stickiness to pressing tool, improves quality of sintered materials.

The best processing properties and properties of the sintered materials are obtained in the process of the present invention.

The method has significant advantages over the known one, since it ensures explosion safety of the process, improves working conditions, improves the quality of sintered materials and, eliminating sticking of powder on the pressing tool, increases the process productivity by 510%.

This method was tested during the production of parts of devices for video recorders.

Its application makes it possible to obtain significant economic effect due to increased output of parts of high quality and productivity of pressing process.

Part Manufacturing Process Design

2.4.1 Development of part processing route

The major surfaces of the revolution are machined in a NC lathe.

Heat treatment with this material is not used. Part inspection is performed during cutting operations and at the final stage of the process in a separate inspection operation.

The processing route will be as follows:

05 Procurement;

010 NC Turning;

015 Coordinate-bore;

020 Control.

2.4.2 Selection of equipment and process bases

The equipment is selected based on the type of processing, the dimensions of the workpiece and the part, the basing schemes, making maximum use of the technological characteristics of the machine. To perform turning, we use NC equipment. In other operations, due to the simple configurations of the machined surfaces, we use universal machines.

When designing process operations, special attention is paid to the selection of bases, since their correct selection depends on the accuracy of processing and the fulfillment of the technical requirements of the drawing.

One of the most complex and fundamental design sections of the machining process is the purpose of the process bases. The correct resolution of this issue depends to a large extent on:

- actual accuracy of the dimensions specified by the designer;

- correctness of mutual arrangement of machined surfaces;

- degree of complexity and design of necessary devices, cutting and measuring tools.

The principle of constancy of bases is that when developing a technological process, it is necessary to strive to use the same technological base, not allowing without the special need to change bases, not counting the change of the draft base.

The principle of base alignment provides that a surface that is a measurement base or design base should be used as a technological base whenever possible.

In our case, the main design base is cylindrical surfaces 6, 8 and end 1. The main measuring base is the axis of the centers. Thus, the basic basing principles are fulfilled.

2.4.3 Selection of process tooling, cutting tool and instrumentation

When selecting devices, we take into account the type of production and the formula of the clamped surface, the type of processing and the required accuracy. For large-scale production, we choose technological equipment that provides an increase in productivity compared to the basic version.

The selection of the auxiliary tool depends on the type of machine and the design of the cutting tool; selection is made according to directories and corresponding GOST. The design and dimensions of the cutting tool are predetermined by the type of machining, the dimensions of the surface to be machined, the properties of the workpiece material, the accuracy required, and the roughness of the machining.

Conclusion

During the graduation work, options for constructing a technological process were studied, taking into account the production program, the nature of the products, as well as the technical and economic conditions for the implementation of the production process. The developed technological process is mainly differentiated, i.e. divided into separate operations, which are assigned to individual machines. When using machines, universal devices, a universal cutting tool, a measuring tool were used to ensure the interchangeability of processed parts.

Content and sequence of process transitions, cutting modes are determined. Process Improvement

The use of CNC machines significantly reduces the auxiliary time for processing the part by reducing the auxiliary time for changing the tool, numerous reinstallations of the part and reducing the main time due to the possibility of increasing cutting modes.

The design part of the project contains the design issues of the fixture for all operations.

In the section, safety and environmental friendliness of the project, the following issues are considered: occupational safety during machining of materials by cutting; noise pollution of the environment, characteristics of noise sources in the designed workshop, noise rationing in the enterprise and in the residential area; ensuring stability of the designed area operation in emergency conditions.

When planning and organizing production, the following were determined: the form of organization of technological processes, the production structure of the site, the composition of the site. Based on the comparison, the most preferred layout of the workshop was chosen.