Development of part manufacturing process Spline bushing

Contents

Table of 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.

Process Part

2.1 Definition of type of blanks and methods of their manufacture

Various methods are used in the manufacture of shaft blanks. The best method is the one by which the blanks are most economical, provide the lowest allowance for machining and have the required quality. The technology of low-waste production of blanks contributes to reduction of metal rolling, improvement of quality and productivity in their manufacture. These methods are widely used in large-scale and mass production.

The selection of the procurement method is largely determined by the size of the program task and the technological capabilities of the procurement workshops of the enterprise. The use of progressive initial blanks with a small allowance for mechanical processing in all cases reduces the labor intensity and cost of the latter, however, the additional costs of equipping the procurement workshops pay off only with sufficient size of the program task.

However, it should be understood that the cost of the product is determined by the sum of the costs of the original workpiece and its machining, so it is ultimately important to ensure that the entire amount is reduced, not one of its components. Taking into account the additional savings in machining of progressive raw materials with a small allowance, the limits of economic application of these methods will shift towards a decrease in the cost of the whole product.

Creating part designs that allow machining to be replaced by stamping or planting always leads to a significant reduction in labor and metal consumption. In cold-seating of initial workpieces of parts, for example bolts, metal wastes are 25 times less than in metal-cutting machines. For critical parts at present, raw materials obtained by hot stamping and casting are often used.

The part is a shaft. Therefore, the shaft blank can be obtained by stamping on the HPCS to form separate surfaces.

2.5 Selection of process equipment

When selecting equipment, consider the following factors:

-the size of the working area of the machine, which must correspond to the dimensions of the machined part or several machined parts ,

- possibility to achieve the required accuracy and surface roughness during processing,

-conformance of power, rigidity and kinematic data of the equipment to advantageous operation modes,

- provision of required performance in accordance with the specified program of parts release,

- compliance of equipment with safety and industrial sanitation requirements,

-conformance of the equipment to the specified program according to the criterion of part manufacturing cost.

When selecting equipment in the current production conditions, you have to focus on the equipment available in the workshop and it is mandatory to take into account the degree of actual load of individual groups.

The following machines specified in Table 2.1 shall be used to manufacture the splined bushing.

2.6 Cutting Tool Selection

The selection of the cutting tool must be oriented to the standard tool. To perform individual operations, especially in large-scale production and mass production, it is advisable to use a special tool.

The cutting tool must have a high cutting ability, capable of high cutting modes, high dimensional resistance, ensuring the stability of the processing process, be quickly and conveniently replaced, adjusted and lifted during processing, stably form transportable chips and withdraw it without disrupting the normal operation of the equipment.

For the cutting part of the tool, hard alloys and fast-cutting steels of new grades, for example, P6M5 instead of P18, are widely used.

Cutting tool costs are included as a separate item in the cost of production.

To make the part, we use the following tool: SANDVIK COROMANT milling cutters, boring heads, crown drill, drill for processing holes, grinding wheels, grinding wheel for processing splines, electrodes for burning the slot, filler for grinding burrs.

2.7 Selection of measuring instruments

The selection of measuring means is made in accordance with the accuracy characteristics of the tool, the accuracy of the size performed, the type of the measured surface, as well as the scale of the release of parts. In large-scale production, automatic controls are used. It is necessary to strive for the time spent on control to be overlapped by machine time.

In our specific case we will use universal measuring devices to control of accuracy of production of elements of a detail: micrometer of MKC 175200 GOST 650790, caliper of ShTsI 0-125-0.05 GOST 16689, micrometer of MKC 75100 GOST 650790, caliper of ShTsKI1250.02 GOST16689, caliper of ShTsTsI 0-125 GOST 16689, nutromer 501001 GOST 86882 (1); 1MIG0 indicator GOST 969682 (1), nutrometer NI 100160 GOST 86882, roughness samples GOST 937899.

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.