Development of cover part

Contents

CONTENTS

Introduction

General Section

2 

Process Section

Part Assignment and Design Analysis

Development of machining process, selection of equipment and controls 

Procurement Selection

Calculation of allowances

Calculation of cutting modes

Calculation of the time norm

Define Production Type

Design Section

Calculation and design of machine tool structure

Cutting Tool Calculation and Design

Calculation and design of measuring tool

Organization of production

TP analysis of machining of the same type of parts for loading of equipment of the section

Definition of shop structure and composition of services

Calculation of the quantity of the main equipment and the number of workers in the workshop

Selection of vehicles and measures to reduce environmental hazards

Parameters of auxiliary areas of the workshop

Definition of areas and services of the workshop

Occupational safety

Economic section

Conclusion

List of literature

Appendix A: Mechanical Processing PD Package

Appendix B: Specifications 

Introduction

Modern mechanical engineering is characterized by great technicality and scientific capacity, that is, the development of this industry is associated with the need to strengthen science and education. For example, if earlier in the 20th century, mechanical engineering was associated with huge factories, conveyor production, required the attraction of a large number of workers, now modern mechanical engineering is focused on robotic production with a minimum of personnel, who are entrusted mainly with management and engineering functions.

Engineering is divided into a number of sub-sectors:

General engineering (for example, the production of vehicles, agricultural machines, production equipment).

Heavy engineering (for example, the production of metallurgical, mining equipment).

Secondary engineering (divided into automotive, machine tools, etc.).

Precision mechanical engineering (instrument engineering, radio engineering and electronic industry), etc.

Engineering of Kazakhstan. The sustainable development and reliable functioning of mechanical engineering largely determine the energy intensity and material intensity of the economy, labor productivity, the level of environmental safety of industrial production and, ultimately, the economic security of the country. Today in Kazakhstan engineering there are systemic problems associated with insufficient level of investment attractiveness of the industry, low level of competitiveness of products in domestic and foreign markets, shortage of qualified personnel.

Kazakhstan mechanical engineering is the most important industry, providing in the economy of the country both the transition to new technological ways, and the development of the already widespread fourth way. However, engineering will be able to fulfill this role subject to the rapid modernization and technical re-equipment of its production apparatus, which today is seriously worn out and is little competitive. Kazakhstan machine building as the basic system-forming industry is most affected by crisis phenomena. So, in 2008, the engineering sector suffered the worst due to the crisis, which was primarily due to the investment nature of demand for engineering products. The key factors in the growth of demand for engineering products in recent years have been the growth of investments in the oil and gas industry and the large-scale development of construction. With the onset of the crisis, consumer companies primarily abandon large-scale investments in expanding production and modernization, concentrating on maintaining operational efficiency. At the same time, the financial crisis leads to a decrease in the availability of credit resources for the population, which also affects the reduction of demand, for example, for the automotive industry.

Today, the structure of machine-building production of Kazakhstan is dominated by mining, agricultural, oil and gas, military and transport production. Share of the machine-building complex in the overall structure of the manufacturing industry of the Republic of Kazakhstan in 2011. amounted to 11.18%, in the structure of industrial production - 3.4%, in the structure of GDP - about 2%. Also, engineering products account for 3.4% of total exports and 40.6% of imports. The share of Kazakhstani products in the domestic market of machine-building products is about 13%, the remaining 87% of the country's needs are covered by foreign (mainly Russian) supplies.

Increasing the competitiveness and export potential of domestic engineering is impossible without attracting large investments into the industry, and in turn it is problematic to attract them at the current level of investment attractiveness of enterprises of the engineering complex. Unfortunately, the profitability of the engineering sub-sectors of 10.0% today does not interest either foreign or national investors to invest their capital, since they will receive a return only about no earlier than in 10 years. The investment of the oil sector with a profitability of 3580% pays off in about 3 years.

Today, the state has an important task - to choose the most important and promising technological areas, because in Kazakhstan, with its large territories and a small number of people, it is impossible to develop all branches of mechanical engineering at an equally high level. Therefore, the priority priorities for the development of engineering in Kazakhstan should include:

oil;

agricultural;

mining and metallurgical;

transport;

production of electrical equipment.

General Section

A reduction gear is called a unit containing engagement gears and designed to increase torque and reduce angular speed of the engine. This reducer is cylindrical, two-stage. Rotation from motor shaft is transmitted by wedge belt to pulley 12 secured on shaft 13 by key 23. Integral with the shaft 13 is a gear wheel which meshes with the gear wheel 5 and transmits rotation to the shaft 3 with the gear wheel. Further, rotation is transmitted through the gear 4 to the output shaft 2. Ball bearings installed in housing 1 and cover 7 serve as shaft supports. Collars 31 and 32 protect bearings from contamination. Oil for lubrication of engagement is poured into housing 1 through hole closed by plug 8.

Cylindrical reduction gears are one of the most widespread types of reduction mechanisms. The main advantage of a cylindrical gearbox is high efficiency, depending on the design and number of gears, it can reach 98%. These gearboxes are characterized by high kinematic accuracy, reliability, durability and unpretentiousness in operation. They successfully operate under constant and variable loads, making them universal industrial equipment. Systems of this category are capable of transmitting the highest power without noticeable losses. To this is worth adding a minor play of the output shafts. Therefore, the kinetic accuracy of travel in cylindrical gearboxes is significantly higher compared to mechanisms in which worm gear is used. The gearbox used has a vertical circuit. The choice of horizontal or vertical circuit for all types of reduction gears is due to the convenience of the overall arrangement of the drive (relative arrangement of the engine and the working shaft of the driven machine, etc.).

Design disadvantages

High noise level during operation. One, two and three-stage cylindrical reduction gear produces significantly more noise than the noises that are present during the operation of worm gear systems.

Lack of reversibility effect - self-braking. This function is an obvious disadvantage only if there is no need to rotate the output shafts when there is an external load.

Scope of Application

Cylindrical three-stage, one and two-stage reduction gears are actively used in the agricultural and construction fields. Also, gearboxes of this type are widely used in the field of mechanical engineering.

Cylindrical reducers are equipped with grinders, stirrers, all kinds of extruders, equipment for metal cutting. In general, cylindrical gearboxes become indispensable with extremely limited working area and therefore act as the optimal solution for performing the most numerous tasks.

Conclusion

Part - cover is made of material SCh 18 GOST141285, material substitute - SCh 20 GOST 141285. The cover is a part of the reduction gear unit and together with collars serves to prevent oil leaking and to protect bearings from clogging with mechanical particles. This reducer is cylindrical, two-stage. The part material assumes only casting as a workpiece, structurally the part is not a body of revolution and requires special machines in processing to achieve the necessary manufacturing accuracy.

During the development of the diploma project, a technological process of machining for a part was developed, a detailed analysis of the technological process for machining was made, modern equipment and tools were introduced, and outdated standards for new ones were replaced.

The part as a whole is processable for parts of this type, the outer contour of the part can be obtained by casting and the processing of the holes does not cause special difficulties, however, there are some elements whose processing causes certain difficulties, for example, for finishing the holes for bearings, it is assumed to use thin or diamond turning. The processing of these holes requires the manufacture of special technological equipment, since the installation of the part in this position without it is difficult and the equipment - a diamond boring machine. Also, holes for pins and screws require the manufacture of a drill tool - conductor. Otherwise, the part allows the use of high-performance machining modes and has good base surfaces for initial operations and is quite simple in design.

The workpiece is selected and calculated taking into account the purpose and design of the part, material, technical requirements, scale and serial quality of production, as well as cost-effectiveness of production .

Calculation of cutting modes and time standards was carried out. A milling tool, a measuring tool and a cutting tool have been developed. Economic justification and calculations for occupational safety, fire and electrical safety .

The total text part of the course project is -

Graphic part - sheets A1.