Diploma project Val 1K62-07-111

Contents

INTRODUCTION. P

1. PROCESS SECTION

1.1. Characteristics of machined part

1.2. Preselection of Production Type

1.3. Procurement Selection

1.4. Selection of process bases

1.5. Development of routing process

1.6. NC Machine Selection Justification

1.7. Calculation of allowances

1.8. Calculation of cutting modes

1.9. Calculation of time standards

1.10.Recalculated calculation of production type

1.11. Determination of required quantity of equipment

1.12.Development of control program for CNC machines

2. DESIGN SECTION

2.1. Selection of the workpiece installation scheme in the accessory

2.2. Calculation of workpiece clamping force in the accessory

2.3. Description of operation of accessory

3. NC MACHINE SETUP

3.1. Calculating the Dimension Setting

3.2. Adjusting CNC Machines for Part Handling

3.3. Control and maintenance of CNC machine units

4. GENERAL SECTION

4.1. Occupational and environmental protection

5. ECONOMIC DIVISION

5.1 Determination of time norm for part batch processing and number of workers

5.2 Calculation of fixed assets and depreciation and material costs

5.3 Calculation of the wage fund and overhead costs

5.4 Determination of cost of part lot processing by basic and projected versions

5.5 Calculation of economic efficiency indicators

CONCLUSION

LIST OF LITERATURE

Introduction

The purpose of diploma design is to learn how to correctly apply the theoretical knowledge gained during the study process, to use his practical experience at machine-building enterprises to solve professional technological and design problems.

To measures for the development of new progressive technological

process automation, high-performance process equipment is designed on its basis.

Work and support processes without direct human involvement.

Accordingly, the following tasks are being achieved:

Expansion, deepening, systematization and consolidation of theoretical knowledge and its application to the design of progressive technological processes of assembly of products and manufacture of parts, including the design of technological equipment.

Development and consolidation of skills in conducting independent creative engineering work.

Mastering the methodology of theoretical and experimental studies of technological processes of mechanical assembly production.

The diploma project should show savings in labor, material, energy. The solution of these issues is possible based on the fullest use of the capabilities of progressive technological equipment and equipment, the creation of flexible technologies.

The result of the work of workers, engineers, technologists of workers of all services of the plant is a finished product assembled from parts processed by machines.

From this, it becomes obvious what responsible task the machine installer solves in each factory team, the work of which primarily depends on the productivity of metal cutting equipment and the quality of the parts manufactured on it.

It is important to set up CNC machines, which combine the properties of both traditional semiautomatic machines used in mass and mass production, and universal manual machines used in machine building and single-unit production. As well as semi-automatic CNC machines after adjustment, they repeat all necessary movements on the program, without requiring operator intervention. The latter only change the workpiece and periodically check the dimensions of the processed part, if necessary prepare the machine, monitor the process.

Usually, the installer begins processing the first part with an accelerated check of the control program, spending some time, the installer is convinced that it contains no defects. Use the Preset Tool Size Setting to speed NC machining.

NC Machine Selection Justification

CNC machines are one of the most effective means of increasing productivity in serial, small-scale and single-unit production. When using them, the production preparation time is reduced by 5075%, the total processing cycle duration is reduced by 5060%, and the cost of designing and manufacturing technological equipment is reduced by 3085%. Along with this, locksmithing, marking and other works are sharply reduced or generally excluded. The extensive processing capabilities of CNC machines make it possible to fully process parts on one machine in one or more installations, which reduces the setup time and costs for inter-machine transportation of parts; Improves the accuracy and identity of part handling and, as a result, reduces scrap and racing during assembly; provides saving of shop areas intended for storage of parts, accessories, tools during production; reduces the volume of control operations and the staff of TCO supervisors. Modern CNC machines have the power of electric motors sufficient to perform both roughing and finishing.

The auxiliary time when working on a CNC machine is divided into the time of actions performed by the operator (installation, fixation of workpieces and removal of processed parts, start of the cycle, check of dimensions) and the time of auxiliary actions performed by the machine (mutual entrances and retractions of tools and workpieces, changes of tools).

On lathes, in order to reduce the time for installing the workpiece - removing the processed part, fast-acting equipment is used: clamping cartridges, driving inertial cartridges and driving cartridges with end knives complete with floating centers. In CNC machines, compared to manual machines, the driving power of the main movement is 2-3 times more. This makes it possible to conduct processing both at great depth and at a cutting speed of up to 400600 m/min.

The main (machine) time on CNC machines is reduced by performing cutting with high and optimal cutting modes (cutting speed, depth, supply).

On CNC machines working with a blade tool, finishing operations can be carried out, which before that were carried out less efficiently by grinding.

Currently, a significant range of CNC machines has been developed and is being produced.

In the course design, the technological process of processing the shaft KTNB 0098.515.003 using a lathe cartridge-center machine with CNC 16K20T1 was developed.

Technical characteristics of machine 16K20T1.

Largest diameter of workpiece to be processed, mm

- above the frame 400

- above caliper 215

The largest diameter of the rod to be treated, mm. 1000

Number of operating speeds of spindle 22

Spindle speed limits, 10... 2000

Caliper supply, mm/v

- longitudinal 0.01... 2.8

- transverse 0,005... 1.4

Cutter section, mm 25 * 25

Number of turret positions 6

Speed of quick movement of caliper, mm/min

- longitudinal 6000

- cross 5000

Number of simultaneously controlled coordinates 2

NC Device "NTs-31 Electronics"

Main motion motor power, kW 10

Overall dimensions, mm

- length 4000

- width 2700

- height 1700

Weight, kg 3800

Description of operation of accessory

The principle of operation of this cartridge can be simplified as follows: under the influence of compressed air, the wedge moves and acts as a cone part on the cam, which, in turn, moves radially. As a result of this movement of all three cams, the blank is clamped/expanded.

The chuck is mounted on the front end of the spindle of lathe 16K20T1 by means of a transition flange. It is based on a conical ledge and is attached by six M12 screws to the spindle flange. Machine has built-in pneumatic cylinder located on rear end of spindle. Through through hole in spindle the rod of pneumatic cylinder is connected to coupling having wedge bevels. Along these bevels, three main cams are connected to the clutch, on which replaceable cams are fixed by means of two screws M8. By removing the screws, you can reposition the replaceable cams on the main ones depending on the diameter of the workpiece being processed.

When the piston of the pneumatic cylinder moves, and therefore the clutch to the right, the cams will move radially from the center and the blank will open. Moving to the left clamps the workpiece.

Set Up Cnpu Machine

3.1. Calculates the dimension setting.

The machine is equipped with ECU model "Electronics NC31." For this ECC, the dimension setting is not performed, it is replaced by a tool reference. Use the tool dimension snap mode when you want to snap a cutting tool to an NC device measuring system. Before you snap the tool, you must call the tool to the work position, that is, dial the Tool Number T even if the machine does not automatically change the tool. The tool dimension snapping mode is performed in the following sequence:

1. Spindle is turned on and tool is brought to blank in manual mode.

2. In the mode of operation from the flywheel, the workpiece is rammed along its generatrix.

3. The spindle is stopped and the machining diameter (e.g. 152, 45 mm) is measured.

4. The device is put into the tool dimension binding mode by pressing the key (see Table 20.1, para. 15) and the measured diameter is entered into the device memory (for example, XI 5245), while the address and number indicator goes off.

5. Spindle is turned on and tool is brought to billet end face in manual mode and its end face is turned around.

6. Cutting tool is retracted along X axis and spindle is stopped; distance from billet end face to cartridge clamping cams is measured. From the measured value, the allowance is subtracted at the discretion of the operator (37 mm). For example, 3.37 mm was subtracted from the measured size of 98.37 mm to obtain 95 mm.

7. The device is put into the tool dimension binding mode by pressing the key (see Table 20.1, para. 18), after which the measured value is entered into the device memory (for example, 29500). The start of processing is programmed relative to this point. The processing start point is selected taking into account the workpiece installation error.

Conclusion

During the diploma project, the technological process of processing the Roller part in serial production was developed. In the project, the workpiece was re-calculated and selected, which led to a decrease in its mass, the technological process, tightened cutting modes and time standards for some operations compared to the basic version of the technological process. Part processing was transferred from manual control machines to machines with numerical software control systems. In addition to the above advantages, this translation allows you to more automate part of the auxiliary operations due to the use of a mechanized device for fastening the workpiece, reduce the labor intensity of the performed operations and the labor intensity of the racing work performed during assembly, since parts made according to one program are almost completely interchangeable, reduce the number of highly qualified workers, increase their general education level. In the turning operation developed in detail in the design, the unit processing time is significantly reduced, the accuracy of the part is increased, the safety of the worker is ensured, since the working area on its side is completely enclosed and located further from the worker than on manual machines.

From the point of view of production, transferring the production of the Roller part to CNC machines is advantageous.