Development of intermediate shaft manufacturing process (version 7)

1. Developing a Working Part Drawing

1.1 Selection of design, process and measurement bases

High accuracy of shafts is provided by processing in centers. In Table 2, select the dimensions of the center holes. Center hole A4 for shaft with diameter D = 30 mm. Total drill depth Ø4mm 5.0mm. The cone with an angle of 60 ° is countersunk to a depth of 3.90mm .

One of the bases will be a centerline. This base will be both design, process and measurement.

The base for linear dimensions is the end of the collar, until the pinion is pressed into the rest.

Manufacturing Process

2.2 Metal cutting machines, tools, cutting and measuring tools

Machining machines:

lathe - for treatment of external surfaces;

central - for making center holes;

vertical - milling - for keyway milling;

circular - grinding - for grinding surfaces D1 and D2.

The necessary devices are machine tools that provide machining of the shaft in centers, and prisms for installation of the part on a vertical milling machine for milling the key slot, therefore the necessary devices:

thrust center as per GOST 18259 - 72

rotating center as per GOST 8742 - 75

leash faceplate

clamping prisms

List of cutting tool required for shaft machining:

undercut cutter

pass cutter

groove cutter

chamfer cutter

centering

key cutter

abrasive circles

If the diameter of the workpiece lies in the range from 20mm to 100mm, then the technologist's handbook recommends tool holders with hard alloy plates and fast-cutting steels 16 × 25mm, 25 × 25mm, 25 × 40mm. For rough turning during continuous cutting, for cutting and turning grooves, hard alloy plates T15K6 are recommended. For precise turning during continuous cutting of carbon and alloyed steel, the material of hard alloy T30K4 is recommended.

To mill the keyway, select a keyway cutter (Table 9) with a cylindrical shank as per GOST 9140-78 with a diameter of the cutting part d = 12mm and a long cutting part of 16mm.

The shape and dimensions of the abrasive wheel are determined by the passport data of the selected grinding machine. For preliminary and final grinding of hardened steel surfaces (Ra = 2.50.63 μm), wheels with grains of 32 and 25 are recommended. Abrasive wheels 15A, 23A32 are used for circular external grinding in centers. To obtain the required roughness of Ra = 0.8 μm, it is recommended that the rotation speed of the wheel is 3045 m/s, and the rotation speed of the part is 2535 m/min.

Since the production of the shaft relates to single production, it is advisable to use universal measuring instruments for measurements. In preliminary shaft machining operations, diameter dimensions can be controlled by micrometer. The linear dimensions of the shaft can be measured by a caliper. The width of the keyway can be controlled by a slot gauge.

Diameters D1 and D2 must be processed with high precision. Therefore, at the stage of finishing grinding of these surfaces, it is advisable to use a special bracket with active control, i.e., one of the heels of the bracket is movable and its movement fixes an indicator of the hour type with a scale division price of 0.002 mm. The nominal size of the shaft between the heels of the bracket is set using plane-parallel end measures long .

Surface roughness can be evaluated by comparison with samples of roughness of cylindrical surfaces, which are produced according to GOST 9378-93.

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