Diploma of Mechanical Processing of Part Val

Contents

Table of Contents:

Summary

Introduction

1.Analytic Overview

1. 2. Purpose and design features of the part:

2. Workability of the part

3 Procurement Type Selection:

3.1 Selection of procurement material

3.2 Characteristics of steel

3.3 Chemical composition in% steel

3.4 Calculation of processing allowances

4. Selecting How to Process a Part

4.1 Selection and justification of process bases diagrams

5. Manufacturing process of gear shaft

5.1 Development of the production process of the shaft-gear

5.2 Development of operation structure and selection of necessary tools and accessories in adjustment

5.3 Analytical calculation of cutting modes for main operations. Calculation of cutting modes by analytical method for drilling operation

Analytical calculation of cutting modes for a turning operation

5.5 Process rationing

5.6 Equipment selection. Characteristics

5.7 Selection of cutting tool

5.8 Selection of instrumentation

6. Description of fixture design:

6.1 Calculation of blank clamping forces:

7. Select Production Type

7.1 Justification of production type

8. Technical and economic indicators of the site

Define Production Areas

9. Environmental and safety issues at the enterprise

9.1. Safety in machining area

9.2. Safety precautions for NC machines

9.3. Fire protection

9.4. Development of the industrial lighting system for the machining area of parts

9.5 General Safety Requirements

9.6 Occupational Safety

9.3 Fire Safety

Conclusion

Literature

Summary

The following are considered in the work:

- General provisions of the metalworking industry, development prospects, the situation in this field;

- part processing technology;

- design section;

- justification of production type selection, development of site plan;

- Economic division;

- occupational safety section;

- conclusion.

Introduction

The leading role in accelerating scientific and technological progress is to play mechanical engineering, which as soon as possible needs to be raised to the highest technical level. In this regard, the development and mass production of modern electronic computing equipment is a primary task.

The immediate goal of machine builders is to change the structure of production, increase the quality characteristics of machines and equipment. New approaches will be required in investment and structural policies, in the development of science and technology.

Many economic experiments are aimed at overcoming the shortage of labor resources and increasing labor productivity, which are based on organizational, scientific, technical and economic solutions. Other scientific and technical programs are operating in the same direction. According to experts, they will not only create new devices, machines and mechanisms, progressive technological processes, but also save the labor of about 3 million people.

The word "technology" means the science systematizing set of methods and ways of processing of raw materials, materials, semi-finished products the corresponding instruments of production for receiving finished goods. The technology includes technical control of production. The most important indicators characterizing the technical and economic efficiency of the technological process: consumption of raw materials, semi-finished products and energy per unit of production; quantity and quality of finished products and products; productivity; process intensity; production costs; cost of products and products.

The subject of research and development in mechanical engineering technology are types of processing, selection of blanks, quality of machined surfaces, accuracy of processing and allowance for it, basing of blanks; methods of machining surfaces - flat, cylindrical, complex-profile, etc.; methods of manufacturing typical parts - housings, shafts, gears, etc.; assembly processes (nature of connection of parts and assemblies, principles of mechanization and automation of assembly works); design of devices.

The technology of mechanical engineering is constantly updated and changes as the technology develops. Improving technology is an important condition for accelerating technological progress.

The purpose of this work is to develop a section of mechanical processing of Valschestern, design technological processes for the production of typical, medium complexity of typical operations of parts of industrial engineering, modernization of a typical technological process to increase productivity and quality of production.

Analytical Overview

Modern machine-building production is characterized by a constant increase in requirements for the quality of products and a complication of the tasks to ensure it, an increase in flexibility, that is, a change in the range of products produced, which makes it necessary to reduce the time for technological preparation of production. Production tasks are complicated, the requirements for the quality of their solution increase, the timing of decisions is reduced, there is a need to make effective decisions in a minimum time.

The most important problem that arises in the development of technological processes and in their implementation in production is the choice of a rational technological solution. At the same time, a technological solution refers to any decision taken during the technological preparation of production or during the manufacture of products, relating directly to the determination or change of the state of the object of production and aimed at ensuring the production of products. The development of the technological process is based on two principles: technical and economic. In accordance with the first principle, the designed process should fully comply with the requirements of the working drawing and the technical conditions for acceptance of the product. According to the second principle, the production of the product should be carried out with minimum costs of energy and labor resources, which determine the costs of production .

Process design is a multivariable task. For the manufacture of the same part or assembly, various technological processes can be designed that differ in technical and economic indicators, primarily in productivity and manufacturing costs.

The technical and economic principles of the design of the technological process, reflecting various aspects of the manufacture of the machine, are sometimes in dialectical contradiction. Resolution of this contradiction is achieved by compromise and solution of process optimization problems. The technical principle must always be observed. Performance and cost trade-offs are most common. At equal performance of the compared processes, a process is selected that ensures minimum costs. At equal cost, a process is usually chosen that provides greater productivity. At different costs and performances, a process is chosen that provides a minimum of costs, provided that the performance of all compared options is not lower than the specified one. When producing particularly important products or under extreme conditions for a certain period of time, preference is given to a technological process that provides high productivity. Optimization can be performed at the operation level when the optimal processing method, structure and parameters of the operation (sequence of transitions and cutting modes) are selected, and at the level of the entire process, when the content of its main stages, their order and relationship (process structure) are determined. In the latter case, optimization is structural optimization. It has been proven that structural optimization is more efficient than parametric optimization and allows you to obtain more optimal solutions. For example, the efficiency of the part handling operation on automated equipment depends largely on the optimality of the composition and sequence of transitions and to a lesser extent on the optimization of cutting modes. Structural optimization is more complicated than parametric optimization.

Currently, most scientific research is devoted to solving certain scientific problems that ensure production efficiency and the specified quality of products. Such areas include: testing the design of parts for processability; optimization of cutting modes to ensure specified requirements for accuracy and quality parameters of the surface layer; Optimizing the structure of the individual operation and the part route substantiation of the production structure depending on the specified production conditions for the production of products.

The conditions of the market economy and intense competition in the production of mechanical engineering products lead to a transition from large-scale and mass production to mass production, often replaced production, which requires a clearer and more comprehensive approach to solving technological and organizational issues in the design of technological processes and, in the future, to the projects of production systems and the organization of their work.

At the same time, factors in substantiating the rationality of the technological solution are: ensuring the specified requirements for the quality of parts, including tolerances for geometric dimensions, surface roughness, special requirements for the quality of the working surfaces of the part;

- provision of the specified capacity determined by the annual demand of the parts in accordance with the specified terms of delivery of the parts for assembly of the products ;

- minimizing the resources required for manufacturing a part with specified characteristics; - minimizing the production cycle of manufacturing parts; Minimization of total production costs (part process cost).

The purpose of the work is to develop a methodology and working methodology for the integrated solution of technological and organizational problems in the development of technological processes and projects of production systems of machine-building plants for the conditions of small-scale production.

1. 2. Purpose and design features of the part:

Mechanical gears, various machine units contain a number of parts designed to support rotating machine elements - pulleys, sprockets, toothed and worm gears, etc. These parts are called wallpipes. Shafts are links of the mechanism that transmit torques and, in addition to bending, experience torsion.

The shafts always rotate during the operation of the mechanism. Rotation from gear wheel secured on shaft gear by means of key is transmitted through shaft-gear to gear. The pinion shaft rotates together with the gear wheels, resting on the housing through bearings .

Features for the classification of axes and shafts are their purpose, the shape of the geometric axis (only for shafts), structural features. By purpose, there are valshestern gears (gear, belt, chain, etc.) and indigenous valshestern machines carrying, in addition to gear parts, working organs of machines - engines or working machines. An example of indigenous valshesterniai is valshesterniai turbines on which turbine discs are fitted; shafts of electric motors carrying rotors.

According to the shape and structural features, valshestern of a constant cross section, for example, transmission valshestern, stepped-variable cross section, are distinguished (this shape has the vast majority of valshestern); shafts with flanges for connection of their separate sections or separate shafts. A special group is made up of valshesternyashesterny and valshesternyashervyaky (a gear or worm are made in conjunction with valshesterny).

The shafts may be solid or hollow. The shape of their cross section in most cases is a circle or circular ring, but individual sections may have a different section. For example, splined wallpipes are widespread, the shape of the section of the splined section is determined by the accepted profile of the splines; profile joints can be used, the type of which determines the shape of the cross-section of the valshestern in the corresponding section .

Conclusion

During the design process, the typical processing process of the Valshesternya part was analyzed; The production environment was assessed. The following deficiencies were noted during the analysis:

- production of the Valshestern part according to the proposed technological process requires the use of a large number of equipment, which occupies a large production area and requires high costs for technical preparation; low level of automation of part manufacturing.

2. To realize the established shortcomings in the thesis, a new technological process was calculated using modern CNC technological equipment. A part machining area plan has been developed for the machining route.

3. In the designed process version, compared to the basic process, the following was achieved:

- reduction of labour intensity of part manufacturing and increase of labor productivity due to application of CNC machines;

- reduction of part manufacturing cost;

- Reducing wage costs by reducing the number of employees;

- reduction of depreciation expenses. Energy costs by reducing the number of process equipment;

improved layout of part machining section due to better arrangement of equipment.

4. As a result of the above technical and economic calculations, it was established that the annual economic effect is 76556.3 rubles.