Diploma design of grinding chamber rotor

Contents

Introduction of _____________________________________________

1. Assigning and analyzing part conditions _____________

2. Analysis of workability of parts ______________________

2.1. Process check of gearbox housing drawing ________

2.2. Process analysis of gearbox housing design _____

2.3. Process check of low-speed gear shaft drawing

2.4. Process analysis of low-speed gear shaft design ____________________________________________

3. Select how to restore ________________________

3.1. Selection of method of reduction of low-speed shaft of reduction gear box ____

3.2. Selection of method of reduction gear box housing restoration __________

4. Process sequence selection ____________

4.1. Restoration of surfaces under bearings of a wave of DP T 03.02. 40.00.002 P ____________________________________________

4.2. Restoration of surfaces under building T bearings 03.02. 40.00.003 RSF _____________________________________________

4.3. Manufacture of half-bullets ______________________________

5. Calculation of processing allowances ________________________

5.1. Calculation of surface handling allowances for shaft bearings ______________________________________________________

5.2. Calculation of surface handling allowances for housing bearings ___________________________________________________

6. Calculation of cutting modes during machining _____

6.1. Calculation of cutting modes at turning of surfaces for shaft bearings __________________________________________

6.2. Calculation of cutting modes during grinding of surfaces for shaft bearings __________________________________________

6.3. Calculation of cutting modes when surfaces are swept under housing bearings _______________________________________

7. Calculation of surfacing modes _____________________________

8. Calculation of technical time standards _____________________

8.1. Calculation of technical time standards for operations of shaft recovery process _______________

8.2. Calculation of technical time standards for the operations of the process of repairing the housing ____________

8.3. Calculation of technical time standards for operations

manufacturing processes of semi-modules ___________

9. Design of device for fixation of half-beams

9.1. Calculation of the accessory for accuracy ________________________

9.2. Description of operation of the accessory __________________________

10. Design of accessory for reinforcement rolling of surfaces for bearings of DP shaft T03.02. 40.00.002 P _______________________________________________

10.1. Description of operation of the accessory _________________________

11. Stamp Design _______________________________

11.1. General information and calculations _______________________________

11.2. Description of the stamp design ___________________________

12. Development of section plan for restoration of quick-wear parts of Ts2U-400N gearboxes ____________________________________________________

13. Calculation of technical and economic parameters of the section for restoration of quick-wear parts of Ts2U-400N reduction gear _______________________________________________

13.1. Brief description of the production object

and developed technological processes ______________

13.2. Justification of production type _________________________

13.3. Calculates the basic parameters of a parcel ______________________

14.3.1. Calculation of the required quantity of equipment ____________________

14.3.2. Calculation of lot size and start-release period of parts __

14.3.3. Calculation of production cycle duration

manufacturing a batch of parts __________________________________

14.3.4. Determine the amount of backlog _________________________________

14.4. Calculation of the value of fixed assets

and depreciation charges __________________________

13.5. Calculation of labor indicators ______________________________

14.5.1. Calculation of the number of production workers __________________

14.5.2. Payroll calculation ________________________________

13.6. Material Cost Calculation ______________________________

13.7. Costing _____________________________

13.8. Working capital standard _____________________________

13.9. Technical and economic indicators of the site ________________

13.10. Selling price calculation ______________________________

13.11. Justification of cost-effectiveness of the project _

14. Occupational safety ______________________________________

14.1. Introduction of ________________________________________

14.2. Industrial sanitation ___________________________

14.3. Safety of works performance ________________________

14.4. Fire safety ______________________________

15. Civil defense _______________________________

17.1. Calculation of parameters of a civil defense shelter with a capacity of 380 people _________________________________

Conclusion of the ___________________________________________

List of literature _____________________________________

Introduction

The engineering industries occupy a leading place in the economy of the Republic of Belarus, which provide the material basis for the technical progress of all sectors of the national economy. Engineering produces over a quarter of the country's industrial products.

Technology largely determines the state and development of production. Its level depends on labor productivity, economical consumption of materials and energy resources, quality of products and other indicators. For the further accelerated development of the machine-building industry, as the basis of the entire national economy of the country, it is necessary to develop new technological processes, constantly improve traditional ones and search for more efficient methods of processing and strengthening machine parts and assembling them into products.

In solving the problems of accelerating scientific and technological progress, moving the economy to an intensive path of development and more rational use of the country's productive potential, saving all types of resources and improving the quality of work, a significant place is occupied by accelerating scientific and technological progress based on the technical re-equipment of production, creation and production of high-performance machines and equipment of high single capacity, introduction of new equipment and materials, advanced technology and machine systems for integrated mechanization and automation of production. In this regard, great attention is paid to the development, development and implementation of new high-efficiency technological processes, new materials, including non-metallic ones, reducing metal consumption of products, saving fuel and energy resources, mechanization and automation of production processes, improving the reliability and durability of products that correspond (or exceed) in their technical level and quality to the best domestic and foreign analogues.

The advanced development of mechanical engineering and metalworking in conditions of growing shortage of labor and energy resources and metal is envisaged with simultaneous increase of output of mechanical engineering products by at least 1.4 times with progressive trends both in increasing the range of products and updating its structure.

A distinctive feature of mechanical engineering technology at the present stage is an integrated approach to the creation, improvement and use of strengthening and restoration processes, which provide increased productivity, energy and resource conservation, environmental cleanliness of production.

As a result, the main trends and prospects of recovery technologies are aimed at achieving a sustainable rate of increase in production, improving the efficiency and competitiveness of products in foreign and domestic markets.

Currently, the following basic methods are used to repair worn out surfaces of parts:

numerous types of material application (surfacing, spraying, electrocontact welding of metal coating, electrolytic deposition of metals and composite coatings);

installation and attachment of additional repair parts by pressing, welding, soldering, gluing;

The moral aging of mechanical engineering products often comes much faster than their physical aging, while the time for sustainable mass or mass production of products has been reduced to date from 10... 15 to 3... 5 years, and for putting new ones into production

for each thousand parts it is required to develop more than 15 thousand units of various technical documentation and to manufacture up to 5 thousand different types of technological equipment. All this requires further improvement of the scientific and technical level and quality of products, comprehensive

Improvement of technology and methods of organization and management of production processes.

1. Assigning and Analyzing Part Conditions

Initially, by analyzing the utility of the part, we will give a description of its design and working conditions in the node or mechanism.

Grinding chamber rotor is composed of 20 parts interconnected by press, rivet and threaded joints. Designed for grinding sand in the grinding chamber.

The rotor operates under conditions of constant abrasive wear, especially the so-called beats (pos.13), which directly participate in the grinding of sand, and rings designed to protect the riveted joints of the holders, are subjected to wear. In addition to abrasive wear, these parts can, due to ingress of foreign objects into the grinding chamber, be subjected to mechanical damage.

During sand grinding the rotor rotates with frequency up to 1000 rpm. In this regard, during operation, the rotor is strongly influenced by cyclic periodic loads, which leads to weakening of connections and, further, to disruption of balancing.

Special requirements shall be made for rotor assembly. Since the speed of its rotation is high, it is necessary that the radial run-out be minimal. The enterprise uses dynamic balancing, which often does not provide sufficient accuracy. The part, accordingly, fails faster.

Most often, the rotor fails due to the wear of the beat or due to a mechanical breakdown of the holders. Thus, the enterprise most often needs to manufacture these parts.

The beads directly involved in grinding shall have increased hardness and abrasive resistance of the surfaces. In the conditions of PolotskGlotlofokno OJSC, surface hardening is provided by the surfacing electrode T590EN.

All parts are made of cheap St3 steel, since there is no need for a more expensive material. This steel provides all the necessary requirements for the part: easy cutting, good weldability, compliance with the requirements for the unit. It was proposed to make billets from bleached cast iron, but this entails difficulties in manufacturing and insufficient properties during operation, since the beat with high abrasive resistance turned out to be brittle and insufficiently resistant to dynamic loads.

Thus, the improvement of the process should go in the direction of improving the manufacturing process itself and in the search for new materials and methods for strengthening the surface.

In the diploma project, a version of the production of the billboard holder is proposed that allows reducing the cost of materials by 30% due to the more complete use of high-grade rolled stock. In addition, due to the increase in the thickness of the plate of the holder, its service life is increased. Proposed method of hardening by method of freezing is characterised by high efficiency (about 5-7 times higher compared to manual arc surfacing), improved surface properties. In addition, this method makes it possible to build up various surfaces without labor-intensive re-installation of equipment.

2.1. Process inspection of grinding chamber rotor drawing

The drawing of the grinding chamber rotor is made in accordance with the requirements of the ESKD.

The comments on the drawing are as follows.

1. Left disk and right disk (pos. 1 and 2) do not correspond to the dimensions indicated in the drawings in the detail (different thicknesses). Also, the inner and outer diameters of the protective rings do not correspond.

2. Tolerances and fits are given in the old OST system.

3. The nut (pos.9) in the main view does not correspond to the drawing in detail, the method of attachment of the nut and ring (pos.8) is not clear.

4. Lock nut position 10 is not specified.

The views shown in the drawing are sufficient for the assembly drawing.

4. Process Sequence Selection

The choice of the processing sequence consists in setting the order of various operations (mechanical, thermal, etc.), ensuring the fulfillment of the specified requirements (accuracy of dimensions, shape, mutual arrangement and roughness of surfaces, etc.), presented to the finished product.

To make a billholder, perform the following operations:

Manufacture of necessary parts;

Welding operations;

Locksmith and assembly.

Therefore, we accept the following manufacturing process sequence.

To manufacture the rotor beat, perform the following operations:

- Obtaining the workpiece;

- Machining;

- Heat treatment.

Therefore, we accept the following process sequence for manufacturing the rotor beat

4.1 Manufacture of transverse plate

005 Procurement

Cutting of blank from sheet into dimensions: B = 90 ± 1 mm, L = 180 ± 1 mm.

010 QC monitoring.

015 Drilling.

Install the part on the table, attach, drill through the conductor two holes with diameter Ø25 mm .

020 Drilling.

Install the part on the table, attach, drill through the conductor two holes with diameter Ø23 mm.

025 QC monitoring.

4.2. Manufacture of longitudinal plate

005 Procurement

Cutting of blank from sheet into dimensions: B = 90 ± 1 mm, L = 260 ± 1 mm.

010 QC monitoring.

015 Drilling.

Install the part on the table, attach, drill through the conductor two holes with diameter Ø23 mm .

020 QC monitoring.

025 Milling

Install part on table, attach, mill surface to depth 18 mm and length 90 ± 1.5 mm

035 QC monitoring.

4.3. Making bila

005 Procurement

Cutting of blank from sheet into dimensions: B = 100 ± 1 mm, L = 200 ± 1 mm.

010 QC monitoring.

015 Drilling.

Install the part on the table, attach, drill through the conductor two holes with diameter Ø25 mm .

020 Drilling.

Install the part on the table, attach, countersink the holes Ø25 mm to the depth of 22 mm.

025 Surfacing

Install the bolts in the holes, apply the weld.

030 QC monitoring.

4.4. Assembly of the biblier

005 Locksmith

Perform edge preparation on the cut-off surface.

010 Welding

Install the parts in the accessory, perform welding.

015 QC monitoring.

020 Assembly

Assemble the part according to the drawing.