Diploma in Mechanical Engineering Technology: Technological Process of Coupling Manufacturing and Equipment

Contents

Contents

Introduction

1. General part

1.1 Brief technical characteristics of the part

1.2 Part Material

1.3 Overview and critical analysis of existing process

1.4 Design Tasks

2 Process Design

2.1 Part processability analysis

2.2 Definition of production type

2.3 Justification of procurement selection

2.4 Routing Process Design

2.5 Selection of metal cutting equipment

2.6 Cutting Tool Selection

2.7 Selection of methods and means of control

2.8 Selection of process bases

2.9 Calculation of allowances

2.10 Calculation of cutting modes

2.11 Determination of cutting power

2.12 Calculation of technical time standards

3 Engineering of technological equipment

3.1 Design of fixture for vertical milling operation

3.2 Design of accessory for vertical drilling operation

3.3 Calculation of splined drawing

3.4 Calculation of caliber-bracket

4 Mechanical Shop Area Design

4.1 Determination of equipment quantity

4.2 Development of the general layout of the workshop area

5 Ensuring Life Safety

5.1 Process Analysis by Hazardous and Harmful Factors

5.2 Calculation of the noise level of the production area

5.3 Workplace Noise Reduction Measures

6 Organizational and Economic Section

6.1 Calculation of capital investments

6.2 Calculation of process cost

6.3 Calculation of basic parameters and operational planning of the serial production area

Conclusion

Literature

Appendix A. Process documentation

Appendix B. Specifications

THESIS ASSIGNMENT

Project Theme

Manufacturing process of coupling and its equipment

6. Technical assignment for the project (purpose of the device, conditions of use, external impacts, special requirements, etc.)

Source Data: 1. Part Work Drawing

2. Product release program 25000 pcs

3. Basic Process Variant

Special requirements: 1. Analyze coupling processing options and develop

technological process of its processing.

2. Use NC turning and drilling machines

and toothfree semiautomata.

3. Design Pneumatic Tools for Milling

two bald holes and treatment of radial holes.

5. Apply special tools: splined drawing, caliber -

splined plug and caliber-brace.

7. Scope and content of the main part of the project

7.1. Explanatory note (list of issues to be developed, calculations, justifications, descriptions)

Paper

Introduction

1. Common part. Analysis of processability of the coupling design. Basic analysis

process. Rationale for the task.

2. Process design. Define the production type. Analysis

Procurement selection. Substantiation of process structure and processing methods.

Define interoperative allowances. Justification of equipment selection, cutting

tools and measuring instruments. Calculation of cutting modes. Calculation of technical time standards.

3. Design of process equipment.

4. Ensuring life safety.

5. Technical and economic calculations.

7.2. Graphic part (list and contents of drawings, posters)

1. Part and workpiece - 1 l.

2. Adjustment cards - 3 liters.

3. Device for treatment of radial holes - 1 l.

4. Device for milling of two balds - 1 l.

5. Tools (splined link, splined plug caliber and brace caliber) - 2 liters.

6. The site plan is 1 liter.

7. Economic indicators - 1 liter.

Paper

The diploma project was carried out on the topic: "The technological process of manufacturing the coupling and its equipment."

Calculation and explanatory note of sheets, figures, tables, 10 sheets A1, literary sources 25, appendix 2.

KEYWORDS: PROCESS, ALLOWANCE, FEED, CUTTING SPEED, CUTTING TOOL, ACCESSORY, ECONOMIC EFFICIENCY.

The object of development is the technological process of manufacturing the coupling and its equipment.

The purpose of the work is to develop the technological process of manufacturing the coupling and its equipment, special devices, cutting and measuring tools that ensure production efficiency.

During the work, the existing technological processes for manufacturing parts of this type were studied, the necessary information was analyzed and selected, and the existing technological capabilities of enterprises were investigated.

As a result of the work done, a technological process for manufacturing the coupling was created, which has minimal costs for manufacturing and preparing production for given conditions, and designs of devices and tools were created.

Degree of implementation - development is proposed as a diploma project for protection in the specialty 151001.

The efficiency of this process is determined by the possibility of obtaining high-quality products in the conditions of serial production.

Introduction

The most important element of the country's economy is engineering. The state of this industry can be judged by the economic power and well-being of the state. It is mechanical engineering that determines the economic potential of industry. According to this, there is a need for the development of industry, and first of all such areas as machine tools, automotive, engine and other areas.

Any industry is based on production, and the main element of production is the technological process. It determines the properties of the obtained products, quality, competitiveness, cost.

The thesis on improving the quality of products is well known, but it is not enough to design a part or product with given properties. The main task in this field is to solve the problems of realising the quality of the product in the process of its manufacture. This can only ensure a full, properly organized technological process that meets all the parameters and requirements of a particular production.

The most important in the direction of developing promising technologies is: the development of new procurement technologies, the organization of precision machining processes, the creation of new technologies for pressure treatment, and freeze-free machining methods.

Modern production conditions impose slightly different requirements on technological processes than before. First of all, modern technologies must be flexible, that is, ready for a quick change in the range of manufactured products. They should be suitable for the manufacture of a variety of products, since many products do not have mass demand, then their manufacture should be carried out on such equipment and tools so that it is easy, without great costs, it is possible to switch to the production of new, better products and at the same time maintain the right quality.

1 General part

1.1 Brief technical characteristics of the part

The coupling is selected as the object of study for the diploma. The part in question is part of the speed box of the metal cutting machine.

The working drawing of the machined part contains all the necessary information that gives a complete idea of ​ ​ this part, that is, all dimensions and sections clearly clearly explain its configuration and possible methods of obtaining a workpiece. The drawing shows all dimensions with the required tolerances, surface roughness, allowable deviations from geometric shapes, and surface interposition.

The main working surfaces of the bushing are:

1. Surfaces with diameters 52h9 and 40h7 - serve to install a speed switching mechanism.

2. Cam Surface-Meshes with another part.

3. Splined central hole is intended for installation on splined shaft.

4. Gear engagement is intended for transmission of rotational motion.

5. Key slot is used for installation of key.

6. Two holes M10x1 are intended for installation of lubricants, which are intended for lubrication of splined joint.

On the drawings of the coupling and its workpiece there are all the necessary technical requirements, including:

1. Dimension accuracy is defined.

2. Surface roughness is defined.

3. The required heat treatment has been determined.

4. Unspecified fillet radii have been defined.

5. Defined coating of internal and external surfaces

1.2 Part Material

The part is made of steel 45 according to GOST 105088.

Steel is applied to production: shafts, valovshesteren, gear wheels, cylinders, cams and others of the details subjected to surface heat treatment and from which the increased durability is required.

The steel consists of the following chemical elements: carbon, C - 0.420.5%; silicon, Si - 0.20.52%; manganese, Mn - 0.50.8%; sulphur, S - not more than 0.25%; phosphorus, P - not more than 0.025%; chromium, Cr - not more than 0.25%; nickel, Ni - not more than 0.25%; copper, Cu - not more than 0.25%.

Mechanical properties of steel:

Ultimate strength............ 800MPa.

Yield strength.............. 550MPa.

Endurance limit........ 274MPa.

Impact, KSU............ 24 J/cm.

Process Properties:

Temperature of forging, wasps - the beginning 1250, the end 700. With a section of up to 400 mm, it is cooled in the air.

Weldability is hard to weld. Welding methods: RDS and CTS. Heating and subsequent heat treatment are required.

Machinability by cutting is good.

The tendency to vacation fragility is not prone.

1.3 Overview and critical analysis of existing process

Comparing the routing process with the typical process to the same type of parts, there are no significant differences. Therefore, a change in the order of technological operations can be considered inappropriate. But considering the level of progressiveness of processing methods, it follows that they are not quite productive.

By analyzing the process, you can recommend:

Replace turning-screw and boring operations with NC turning operations, which will significantly reduce processing time (by reducing auxiliary and preparation-final time) and increase processing accuracy.

By analyzing the level of mechanization and automation of the process, it can be concluded that it practically does not use special devices.

Based on this, it is recommended to develop several devices. In particular, a device for securing a blank in a milling operation with a pneumatic clamp should be developed. It is also necessary to develop a pneumatic device for clamping the blank in a vertical drilling operation. Both of these devices will reduce the auxiliary and preparatory and final processing time of the part.

By evaluating the methods and measuring instruments used in the existing process, it can be found that linear dimensions in most operations are usually controlled by the rod-cylinder, but in the case of more accurate and responsible dimensions, special splined plugs are used. Having analyzed the methods and measuring instruments used in the existing process, it can be concluded that they provide the necessary control accuracy.

1.4 Design Tasks

The purpose of the diploma project is to develop the technological process for manufacturing a part using CNC machines.

This process will significantly reduce production areas, reduce machining time, increase machining accuracy by reducing machining transitions, which will ultimately reduce the cost of the part, as well as the quality of production.

A further design objective is to provide dedicated air clamp devices for machining operations, thereby reducing the time required to install, secure and detach the part and in turn reducing the machining time.

The versatility of technological processes, i.e. the creation of group and standard technological processes, is also important requirements.

2 Process Design

2.1 Part processability analysis

The "Coupling" part is made of steel 45 by stamping, so obtaining the contour of the part is not difficult.

Considering the design of a part, you can draw several conclusions:

1. The part is sufficiently rigid to provide the required precision and roughness parameters.

2. All machined surfaces have good access to the cutting tool.

3. The part has a stepped structure, which makes it possible to treat surfaces with thrust through cutters.

4. The inner surface has a simple shape, which makes it possible to process for passage.

5. The part has good enough technological bases for initial and further technological operations.

Based on the above, it can be concluded that the part is quite technological, allows the use of high-performance processing modes and is quite simple in design.

the maximum drilling diameter is 35 mm.

The working surface of the table is 400x710 mm.

Spindle speed - 45... 2000.

Power - 3.7 kW.

Dimensions 1800x2170x2700 mm.

Operation 050 Splinter

A horizontally extended semi-automatic mode.7B55.

Nominal traction force - 100 kN.

The size of the working surface of the base plate is 450x450 mm.

The speed of the working stroke is 1.5... 11.5.

Power - 18.5 kW.

Dimensions - 6340x2090x1910 mm.

Operation 065 Vertical Milling

The vertical milling machine mod.6P11 is accepted.

Table working surface dimensions - 250x1000 mm.

The purity of the spindle rotation is 50... 160.

The number of spindle speeds is 16.

Power - 5.5 kW.

Dimensions - 1480x1990x2360 mm.

Operation 070 Horizontal Milling

The horizontal milling machine mod.6H81D is accepted.

Table working surface dimensions - 1000x250 mm.

Spindle speed - 63... 1900.

Power - 4 kW.

Dimensions - 2160x1780 1630 mm.

Operation 085 Dental

The zubofrezerny machine of fashion.53A10 is accepted.

The maximum diameter of the treatment is 125 mm.

Maximum dimensions of external wheels:

module - 2.5 mm,

tooth length - 140 mm.

The purity of the spindle rotation is 40... 900.

The number of operations is 9.

Power - 3.8 kW.

Dimensions 1370x980x1660 mm.

Operation 100, 105 Vertical Drilling

Vertical mod drilling machine is accepted. 2H118.

The maximum drilling diameter is 18 mm.

The working surface of the table is 320x360 mm.

Spindle speed - 180... 2800.

The number of speeds is 9.

Power - 1.5 kW.

Dimensions - 870x590x2080 mm.

Operation 125 Round Grinding

The circular grinding machine of fashion.3A151 is accepted.

Smallest dimensions of machined part:

diameter - 200 mm,

length - 750 mm.

The diameter of the grinding wheel is 450, 600 mm.

Grinding head spindle rotation speed - 1080, 1240.

Power - 7.5 kW.

Dimensions - 3100x2100x2000 mm.

Operation 130 Tooth Grinding

The gear grinding machine mod.5B830 is accepted.

The diameter of the machined wheel is 50... 125 mm.

The machined wheel module is 1.5 mm.

The number of teeth of the wheel to be processed is 12... 160.

Grinding wheel speed - 1500.

Power - 3 kW.

Dimensions - 1950x2000x1810 mm.

2.6 Cutting Tool Selection

According to the machining process and the parameters that are presented to the machined surfaces, the following cutting tools are defined.

Operation 015 NC Turning

1. Pass cutter K014229000 GOST 2115175 (T5K10),

2. Pass cutter K014229000 GOST 2115175 (T3OK4),

3. Groove cutter K014115000 (T15K6).

Operation 020 NC Turning

1. Pass cutter K014229000 GOST 2115175 (T5K10),

2. Pass cutter K014229000 GOST 2115175 (T3OK4),

3. Boring cutter MN 61964 (T15K6).

Operation 035 NC Drill

1. Drill spiral 23013244 GOST 1212177 (∅15, P6M5),

2. Drill spiral 23013284 GOST 1212177 (∅25, P6M5),

3. Special boring cutter (T30K4),

4. Special chamfer cutter (T15K6),

5. Sweep as per GOST 167280.

Operation 050 Splinter

Splined special link made of fast-cutting steel P6M5.

Operation 065 Vertical Milling

End cutter GOST 2053975 ∅16, z = 4.

Operation 070 Horizontal Milling

The milling cutter is special.

Mill diameter 16 mm, number of teeth z = 16, cutting part material - solid alloy T15K6.

Operation 085 Dental

Worm cutter GOST 932480.

Cutter diameter is 100 mm, number of teeth z = 14, material of cutting part is hard alloy T15K6.

Operation 100 Vertical Drill

For drilling holes with chamfer - two-stage spiral drill (P6M5),

For cutting of M10x1 thread - GOST 160471 (P6M5) tap 26000109.

Operation 105 Vertical Drill

Spiral drill 23013162 GOST 1212177.

Operation 125 Round Grinding

Circle grinding PP450h50h50 25A SM5 of K1 of GOST 242483.

Operation 130 Tooth Grinding

The grinding wheel is special.

2.7 Selection of methods and means of control

The shafts are monitored both during the most critical operations of the process and after the final processing of the part. At the same time, the accuracy of dimensions, the relative location of surfaces, the accuracy of the geometric shape, surface roughness, etc. are controlled.

In repetitive production conditions, control is carried out using universal and special measuring means. The accuracy of dimensions and geometrical shapes are controlled by means of a caliper, calibers, end measures and various templates. Micrometric and indicator devices are used to control surfaces and geometrical shape.

Based on the design of the shaft, the accuracy of the dimensions required, the roughness parameters and the accuracy of the surfaces, the following measurement tools are selected.

Are applied to control of the linear sizes: GOST 16689 ShTsII350 caliper (measurement range - up to 350 mm, counting size - 0.05 mm, blundered - ±0.05 mm) and GOST 16689 ShTsI125 caliper (measurement range - up to 125 mm, counting size - 0.05 mm, blundered - ±0.05 mm).

For depth control it is used - probe depth meter ShG1 GOST 16289: measuring range - up to 250 mm, reference value - 0.05 mm, permissible error - ± 0.05 mm.

For diameter control clamps GOST 1836093 and plugs GOST 1481069 are used.

To control the parameters of the splined hole, a special splined plug is used.

The stopper of M10x17H PR NOT of GOST 1775872 is applied to control of a carving.

To control radial run-out, an indicator of the hourly type 1MIGP GOST 369682 is used: the fission price is 0.01 mm; measuring range - 0... 1 mm.

6 Organizational and economic section.

The purpose of this diploma project is to develop the technological process of manufacturing the "coupling" part.

The purpose of this part of the diploma project is:

- calculation of capital investments in the technological process;

- calculation of the shaft process cost;

- organization and planning of the site operation.