Diploma of the Faculty of Mechanical Engineering - Development of the technological process of manufacturing the TAD-3 motor stator pressure ring

Contents

INTRODUCTION

PROCESS PART

1.1 Definition of production type

1.2 Part Constructability Analysis

1.3 Selection of procurement method

1.4 Development and justification of proposed process options

1.4.1 Analysis of existing process

1.4.2 Development of a new process

1.4.3 Part Processing Route Assignment

1.5 Equipment Characteristics

1.6 Purpose and calculation of machining allowances

1.6.1 Analytical calculation of allowances

1.6.2 Determination of design allowance value

1.7 Basing and fixing of the workpiece

1.8 Consolidated Process Analysis

1.8.1 Selection of process equipment

1.9 Calculation of cutting modes

1.9.1 Calculation of cutting modes by operations

1.9.2 Design cutting modes

1.10 Calculation and assignment of time standards

1.10.1 Calculation of unit time

DESIGN PART

2.1 Description of machine tools

2.1.1 Description of adapter device for key slot pulling

2.1.2 Description of apparatus for milling operation

2.1.3 Description of the device and operating principle of the rotor assembly accessory

2.1.4 Description of TAD engine

TECHNO-ECONOMIC PART

3.1 Technical and economic analysis of basic and new technological processes

3.2 Determination of capital investments by options

3.2.1 Capital investments in equipment

3.2.2 Capital investments in the building

3.2.3 Capital investments in tooling

3.3 Calculation of pressure ring processing cost

3.3.1 Cost of the product on wages by options

3.3.2 Equipment operation costs by options

3.3.2.1 Equipment depreciation costs by options

3.3.2.2 Equipment repair costs by options

3.3.2.3 Power costs by options

3.3.3 Equipment operation costs

3.3.3.1 Fixture Costs

3.3.3.2 Cutting Tool Costs

3.3.3.3 Metering tool costs

3.3.4 Room maintenance costs by options

3.4 Calculation of economic efficiency indicators

3.4.1 Cost Savings

3.4.2 Additional capital investments

3.4.3 Cost Savings

3.4.4 Reduction of labour intensity of manufacturing of one part

3.4.5 Productivity Growth

SAFETY OF LIFE

4.1 Characteristics of the designed process

4.2 Production sanitation

4.2.1 Air environment

4.2.2 Production lighting

4.2.3 Production Vibration and Noise

4.3 Electrical Safety

4.3.1 Electrical equipment used

4.3.2 Mechanical section of the process

4.3.3 Statistics

4.3.4 Measures to protect workers from electric shock

4.4 Process Safety Requirements

4.5 Fire and Explosion Hazard

4.6 Workplace Organization

CONCLUSION

Literature

APPLICATIONS

1. Process 1 Variant

2. Process 2 options

3. Specification of die for cutting of 36 slots

4. Specification of device for assembly and pressing of stator package

5. Mill Fixture Specification

Introduction

The purpose of this diploma project is to improve

process of part manufacturing and comparison of versions of part manufacturing - pressure ring and design of required technological equipment.

This part is manufactured at the PEMZ plant.

The pressure ring enters the stator of TAD3 motor and is designed to compress and maintain the stator package in the compressed state in the engine

1.1 Definition of production type.

The type of production is previously determined by the given volume of production of products and weight, with the annual volume of production of parts of one name from 101 to 500 pieces, weighing up to 30 kg. Small-scale production takes place. Part weight - 6.8 kg

The plant is planned to produce 120-180 parts per year. There are all signs of small-scale production: the part is made in small batches; equipment is located not along the process, but in sections; jobs specialize in multiple operations; parts processing is carried out on both universal and specialized equipment; High-skill and medium-skilled workers; The tool is normalized and specialized; universal, readjustable and specialized devices are used.

1.2 Analysis of workability of part design.

The part - the pressure ring - is made at the factory from a sheet of 12 × 480 × 480.

Part material - steel St 3 GOST 1463789. This is carbon steel of ordinary quality, general purpose. Steel of group A, which is characterized only by mechanical properties. Chemical composition is not regulated, but is indicated in the certificate

From the point of view of machining, the part has the following disadvantages with respect to processability.

Obtaining a part from a sheet requires a lot of labor, that is, additional preliminary operations to give the blank a shape close to the part (gas-oxygen cutting according to a template).

The part is quite technological. There are reliable technological bases and places for fixing. High-performance processing modes are allowed, taking into account the material of the part. Machined surfaces in terms of accuracy and roughness do not pose technological difficulties in the use of multi-operation equipment, allow for processing without the use of a special tool.

The part has convenient base surfaces.

Dimensional accuracy requirements:

linear dimensions: 5 ± 0.3. 43 ± 0.2. 30. 18 + 1. 12. 100 ± 2 "30" - correspond to 7 - 14 quotas of accuracy.

diametrical dimensions: 4720.2. 326 ± 0.3. 386 ± 0.2, R2, R9- correspond to 7 - 14 accuracy .

Surface layer quality is regulated by roughness of the main surfaces of the part as per Rz40 - 80, 472 Rz25

1.3 Selection of procurement method.

Obtaining a blank from a sheet, as is done in the plant, is undesirable

also, since with such a method of obtaining blanks, a very low material utilization factor, large allowances for mechanical

machining and billet are less close in shape to finished part.

The preform of the pressure ring is undesirable to cast, since castings, as a rule, have casting defects and also large allowances for machining

It is most convenient to obtain a blank for a press-cut ring by sheet stamping. With this method of obtaining the workpiece, the highest material utilization factor, the workpiece is closer in shape to the finished part and small allowances for machining. Selecting this method will reduce processing time and metal consumption.

1.4 Development and justification of proposed options

Process.

1.4.1 Analysis of existing process.

The part is a pressure ring, manufactured at the factory in small-scale production, on universal equipment using mainly standard tooling and tools.

The process consists of the following machining operations:

After the procurement operation, processing is carried out on a turning-carousel machine 1512: they are diluted, having previously held dimensions 326.

Control operation.

Turning operation on machine 16K25: sharpens 472.

Control operation.

Turning operation on machine 16K25: pre-cut and final end 472/326 in size 13.5 mm.

Control operation.

Lathe operation on machine 16K25:: pre-cut and finally end 472/326 in size 12 mm, turn angle 12 ° ± 2 °.

Control operation.

Milling operation on the FSS400 machine: milling 36 slots in size 18 × 30.

Control operation.

Locating operation: grind burrs after milling and remove sharp edges.

Washing operation for cleaning the part of dirt and oils.

Check operation on the QC table: check the finished part for compliance with the dimensions and requirements of the drawing, absence of burrs, sharp edges, compliance with the surface roughness in the drawing.

1.4.2 Development of a new process.

The proposed improved process does not significantly change the order of part surfaces processing, it is carried out in the same sequence.

Technological features and high requirements for the accuracy of the part do not allow to fully process the part in the machining center. In the new process, it is proposed to obtain a blank by stamping, which leads to a significant reduction in metal consumption and labor input of manufacture.

After obtaining the workpiece, on lathe 16K25 the external one 4720.2 is rough and finished, the end face 472/326 is cut to the size of 13.5 mm.

Further, on the same machine 16K25, a bore of the inner diameter 326 is made, the end face is carefully and cleanly cut: 472/326 in the size of 12 mm.

Then the angle of 12 ° ± 2 ° blunts the sharp edges.

The following two options are developed: 1) On a milling machine with NC SVM1F4, 36 slots are milled according to the program, bearing the dimensions 18 + 1. 30. Angle 100 ± 2 "30," radii R2, R9 are provided by the control program. Countersink the chamfers 1.5 × 45 ° according to the program.

2). Press 36 slots using the stamping method, keeping all dimensions.

4.2.3. Production vibration and noise.

- When working on metal cutting machines, there is a general vibration.

As per GOST 12.1.01290, SSBT "Vibration Safety":

Vibration occurs during operation, motors, drive elements and fans.

Local vibration occurs when the machine is in contact with the machine controls. The maximum allowable pressure force of equipment working on parts subject to vibration = up to 20 kg is normalized (at optimal shape of handles and coefficient of thermal conductivity not more than 0.15 to cal/m ²)

- Vibration isolating elastic gaskets are used to protect the workers, separating the pressure of the floor from the floor.

The handles of the machine controls are isolated by vibration-reflecting materials.

- When rationing noise according to GOST12.1.00396 SSBT "Noise. General safety requirements, "we use the method of normalizing the sound level in Dc .

As a method of combating noise, we use sound-insulating fences in the form of casings and screens.

-To combat vibration and noise, perform:

• timely repair and maintenance of machines

• fulfillment of maintenance rules for machines and units

• forced lubrication of machine gear gears

4.3.2.Mechanical section of the process.

-Mechanical section where production of pressure ring takes place is located according to layout in heated room with air temperature:

in winter = 18-20, in summer = 2123, since this is required by the operating instructions of the machines.

Indoor humidity shall be within 50%

-The site is located indoors. Therefore, the release of chemically active and organic dust, which is destructive for insulation, released in other areas of the enterprise, does not penetrate into this area.

The floor on the site is non-conductive, therefore, wooden flooring is provided at the workplace.

From all the characteristics of the parcel, it follows that the space belongs to the class

"without increased danger."

4.3.3. Statistics.

-At the enterprise where the pressure ring is manufactured (OJSC "PEMZ"),

over the past 10 years, 1 case of electric shock has been recorded. This happened during maintenance of the SW by the duty electrician. A factor in this case is a violation of the occupational safety instruction.

This case is uncharacteristic for this enterprise, because here all conditions are created for compliance with safety precautions, training and certification of maintenance personnel and ITR, availability of personal protective equipment. Process electrical equipment, grounding are in good condition.

4.3.4. Measures to protect workers from damage

electric current.

-Technical methods to ensure electrical safety include the following protective measures:

• grounding of non-current-carrying parts

(electric machine housings; bodies of transformers, devices, lamps; drives of electric devices, secondary windings of measuring transformers; frames of distribution boards, control boards, boards and cabinets; steel structure) is made of steel strip with a section of 24mm ² and a thickness of 3 mm.

The movable parts (metal sleeve, etc.) are grounded with a bare copper wire with an open lining with a section of 4 mm ².

Disconnection of machines and other electrical equipment in case of short circuit is carried out at the expense of automatic machines and fuses located in an accessible place.

• Inaccessibility of current-carrying parts is ensured by arrangement of motors, relay equipment, transformers, etc., in machine beds in closed cabinets.

Power to the machines comes through a busbar located at a height of 2 m.

From the bus to the machines, the cable is insulated with double insulation (pipes, armored langs)

The operator's control panel, control and control equipment, are powered by low-voltage alternating current of 42 V, which eliminates the danger of electric current damage.

Protective means are used for safe operation:

rubber gloves, galoshi, rubber mats, wooden flooring, glasses, etc.

Individual protective equipment is tested at least 1 times a year, using increased voltage.

From short circuits and large overloads, electric protective means are used:

- protectors designed for currents up to 2.5; 4.5; 10; 60 A

-heat relays built into starters and protecting the electric motor from overloads

-automata designed for currents up to 5; 10; 100A

Persons serving electrical installations must be trained and certified for knowledge of PUE, CTEEP (safety rules for operation of electrical installations of consumers) with assignment of a qualification group (IIV). Re-attestation is carried out at least 1 times a year.

4.4. Process safety requirements.

-In accordance with GOST 12.3.02596 SSBT "Metal cutting. Safety Requirements "safety regulations include requirements for equipment, tool, general rules:

• handles and buttons of the machine control must move in the direction of actuators movement

• part cannot be measured during spindle rotation

• To accelerate the rotation stop, the machine shall be equipped with a braking device.

• before works start, reliability of part attachment must be checked

• it is necessary to eliminate the possibility of removing the part during spindle rotation

• machine tool is allowed to work after passing the instruction

Safety Instructions

• The tool produced by the plant must be thoroughly checked.

• tools shall be stored in storage rooms on racks and shelves.

-In accordance with GOST 12.2.00996 SSBT "Metalworking machines.

General safety requirements "requirements are as follows:

• equipment is installed on a strong foundation

• operation on faulty equipment is prohibited

• press operation for double-handed actuation is provided

• individual mechanisms shall be provided with strong fencing

• cleaning of chips and dust shall be carried out by a machine tool working regularly on this machine.

• all parts of the equipment must be lubricated systematically

• drive lubrication is prohibited during operation

• The composition and use of LPG shall be consistent with sanitary supervision

• shields and choppers shall be installed in blind metal casings locked with the inscriptions on the applied voltage.

• repair of electrical equipment is carried out only by a special electrician.