DP engineering technology, part Cover

Contents

Contents

Introduction

1 General part

1.1 Service purpose of the part and technical requirements for

part as per drawing and operating conditions

1.2 Part Constructability Analysis

2 Process Design

2.1 Definition of production type

2.2 Justification of initial procurement selection

2.3 Development of routing technology for part processing

2.4 Determination of allowances by calculation-analytical method

2.5 Operating Technology Design

2.5.1 Calculation of cutting modes and their rationing

2.5.2 Selection of machines, tools, measuring instruments and

technological equipment

2.5.3 Selection of procurement basing scheme

3 Engineering of technological equipment

3.1 Description of the structure and operating principle of the accessory

3.2 Calculation of required force of blank clamping

3.3 Calculation of workpiece basing error

3.4 Calculation of the main parameters of the clamping mechanism

4 Organizational and Economic Section

4.1 Process Design Network Schedule

4.2 Calculation of process design costs

4.3 Process Efficiency Assessment

5 Life Safety

5.1 NC Machine Hazards and Hazards

5.2 Process section electrical safety equipment

5.3 Calculation of protective grounding

Conclusion

List of literature

Appendix A Process Documentation

Appendix B Specifications

Appendix B Automated Network Calculation Map

Paper

Explanatory note 185 sheets, 6 figures, 16 tables, 10 sheets of format A1, 17 sources, 3 annexes.

TECHNOLOGY, WORKPIECE, ARTIFICIAL AGING, ACCESSORY, CUTTING TOOL, PRIME COST, ELECTRICAL SAFETY

The object of development is the process of manufacturing the internal cover part.

The purpose of the work is to develop the technological process of manufacturing an internal cover part and its equipment: special devices and a cutting tool.

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 the Penzakompressorash enterprise were investigated.

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

Degree of implementation - completed developments are proposed as a diploma project for protection in specialty 151001.

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

Introduction

A combination of methods and techniques for manufacturing machines developed over a long period of time and used in a certain field of production constitutes the technology of this field. All such fields relate to engineering technology, covering all stages of the manufacturing process of machine-building products.

By "engineering technology" it is customary to mean a scientific discipline that studies mainly the processes of machining parts and assembling machines and simultaneously touches on the issues of choosing blanks and methods of their manufacture. In the process of machining machine parts, the greatest number of problematic issues arise related to the need to fulfill the technical requirements set by the designer before production. The machining process is associated with the operation of complex equipment - metal cutting machines; labour intensity and cost of machining are higher than at other stages of machine manufacturing process.

These circumstances explain the development of "engineering technology" as a scientific discipline, first of all, in the direction of studying the issues of machining and assembly technology that most affect the productive activities of the enterprise.

The goal of the "engineering technology" in practice is to develop a technological process for the manufacture of a part, without which more than one machine-building production cannot do. Roadmaps allow you to trace the entire path of a part from the start to the end operation. The operating cards describe all the actions of the worker necessary to process the part in this operation.

This work presents the development of the technological process for the manufacture of the part - the cover of the internal fuel pump of the diesel engine D49.

The quality of the finished part depends to a large extent on the design and accuracy of the workpiece. Technological, structural, economic and other factors should be taken into account at the first stage of the design development with close cooperation of designers, technologists, and machining.

1 General part

1.1 Service purpose of the part and technical requirements for the part as per drawing and operating conditions

The part is the internal cover of the fuel pump and serves for the final assembly of the diesel D49 product. The part has a flat shape. The shape of the part is explained on one side by the assembly conditions - on the surface of the part there are different holes for connecting the working parts of the pump; on the other hand, such a shape of the lid provides sufficiently high tightness and strength at nominal weight.

Diameters of holes for connection of various parts are selected from normal row of diameters.

When ensuring the strength of the cover, convenience of assembly and other basic requirements, its design is simplified as much as possible.

The cover is made of material cast iron of the A-HM-P78001-87I brand.

Cover structure comprises complex of smooth and threaded holes. They have the following functional purpose.

1. Openings of Ø82H7 and Ø45H9 serve for installation of responsible working details with high precision of positioning.

2. The five holes of M10-7H and the annular groove are designed to install the sealing ring and create tightness of the pump housing.

3. The combined openings of Ø15/M12-7H and Ø15/Ø17H14 are intended for interface of a cover to a pump enclosure.

After preliminary machining, the workpiece undergoes artificial aging.

The "inner cover" part belongs to the class of body parts and is processed mainly by milling, drilling and internal grinding methods.

The placement of the hole axes on the surface of the part is particularly stringent.

The part has cylindrical mounting surfaces with rigid requirements for processing accuracy (seventh quota).

Another structural feature of the cover is the presence on one of the flat surfaces of non-through slots of a complex geometric shape.

The most suitable form of billet is casting.

The technological bases of the workpiece are flat surfaces and accurately machined holes.

In addition to the requirements for dimensional accuracy, the part is subject to increased requirements for the accuracy of the shape and relative arrangement of surfaces. Their tolerance is 0.02-0.6 mm.

The workability of the part depends on the quality of the basic flat surface on which the presence of casting defects and their correction are not allowed. The required quality of the base surface is achieved by the stacking method.

2.5.2 Selection of machines, tools, measuring instruments and process equipment

The choice of the type of metal cutting machines for processing the cover is based on the typical structure of the technological route (see Table 2). Note the overall dimensions (268x176x66mm) of the workpiece and the specified machining accuracy. (7th quota).

Based on these considerations, we choose the following machines to perform a set of milling operations:

Vertical-milling 6H13P

Sizes of a working surface of a table, mm...............................400Õ1600

Highest table angle, deg.............................. ± 45

Spindle speed, min-1..................................... 31.5-1600

Motor power drive main motion, kW....... 11

Overall dimensions:

Length mm......................................................................... 2560

Width of mm.......................................................................2260

Height of mm........................................................................1770

Weight, kg......................................................................... 3800

NC Vertical Milling GF2171C3

Table working surface dimensions, mm........................... 500x1000

Highest table angle, deg.............................. ± 45

Spindle speed, min-1........................................ 20-1600

Motor power drive main motion, kW....... 8

Overall dimensions:

Length, mm......................................................................... 5000

Width, mm......................................................................... 3550

Height, mm........................................................................ 3180

Weight, kg..................................................................... 10490

To perform the set of grinding operations, we select the following machines:

Flat grinding 3D725

Sizes of a working surface of a table, mm.................................400Õ125

Workpiece size, max, mm.....................................................................................................................................................

Longitudinal movement of a table, mm................................... 500

Spindle speed, max, min-1................................. 1600

Motor power drive main motion, kW....... 4

Overall dimensions:

Length, mm......................................................................... 2560

Width, mm.......................................................................1980

Height, mm........................................................................ 1790

Weight, kg......................................................................... 2300

Flat grinding 3L722

Table working surface dimensions, mm................................. Ø400

Workpiece size, mm..................................................... 40-400

Longitudinal movement of the table, mm................................... 400

Spindle speed, min-1........................................ 1670

Motor power of main motion drive, kW...... 11

Overall dimensions:

Length, mm......................................................................... 2350

Width, mm....................................................................... 1970

Height, mm........................................................................ 2300

Weight, kg...................................................................... 5800

To process the holes, we select the following machines:

Radial drilling 2M55

Maximum drilling diameter in steel, mm........................ 50

Distance from spindle to working surface, mm................ 450

Spindle speed, min-1........................................ 20-2000

Giving of a spindle, mm / about................................................... 0.056-2.5

Motor power drive main motion, kW...... 5.5

Overall dimensions:

Length, mm..................................................................... 2665

Width, mm....................................................................... 1020

Height, mm........................................................................ 3430

Weight, kg.......................................................................... 4700

Turning and screw-cutting 1M63C101

The largest diameter of the workpiece to be processed, mm:

over the bed............................................................400

above caliper.......................................................... 220

Maximum length of workpiece to be processed.................. 1.000

Spindle speed, min-1................................. 12.5-2000

Highest caliper movement, mm:

longitudinal............................................................... 900

cross............................................................... 250

caliper feed (mm/min)

longitudinal................................................................... (3-1200)

transverse................................................................... (1.5-600)

Length, mm............................................................... 3360

Width, mm............................................................. 1710

Height, mm...............................................................1750

Weight, kg.................................................................. 4000

Diamond boring 2A716

Diameter of drained holes, mm............................ 8-350

Table working surface dimensions, mm.......................... 630x1250

Largest table movements, mm:

longitudinal............................................................... 400

cross............................................................... 400

Spindle speed, min-1.................................. 2000

Length, mm................................................................. 2000

Width, mm.......................................................... 1120

Height, mm...............................................................3820

Weight, kg.................................................................. 9000

When choosing different types of tools, we are guided by reference technical literature.

Operation 010 Milling

Machine Tool Universal

Mill 200 2214-0159 VK8 GOST 9473-80

ShtZ-I-125-0.1 rod-cylinder, GOST 166-89

Operation 015 Flat Grinding

Schlif. circle. 1-500х100х305 25A 40-P.C1.6K 40m/with B of 2 C. GOST 2424-83

Micrometer MK 75-1 GOST 6507-90

Diamond pencil 3908-0084 GOST 607-80

Operation 020 Layout

Center punch of 7843-0044 H12X1 GOST 7213-72

Hammer 0.5 7850-0118 GOST 2310-77

Rod-rail mass SR-250-0.05 GOST 164-90

Elbow ULP-0-250 GOST 3749-77

Operation 025 Drill

Mandrel 6039-0015, GOST 2682-86

Cartridge 16-B18 GOST 8522-79

Bushing 6100-0142 GOST 13598-85

Bushing 6100-0143, GOST 13598-85

Bushing 6100-0146, GOST 13598-85

Drill Ø15 2301-0050 GOST 10903-77

Drill Ø14 2301-0046 GOST 10903-77

Drill Ø10.2 2301-0030 GOST 10903-77

Drill Ø8.5 2300-0200 GOST 10902-77

Zenker Ø14.75 2320-2566 h8 GOST 12489-71

Sweep Ø14.97 2363-0196 u8 GOST 1672-80

Sweep Ø15.0 2363-0196 N7 GOST 1672-80

Plug 8133-0929 N7, GOST 14810-69

Shchtz-I-125-0.1 rod-cylinder, GOST 166-89

Operation 030 Turning

Special accessory

Cutter 2140-0059 VK8 GOST 18882-73

Nutromer 50-100 GOST 9244-75

Operation 040 Assembly and Locksmith

Shop support

Lining S = 0.4mm shop

Bracket SR 100 GOST 11098-75

Nutromer 50-100 GOST 9244-75

Shchtz-I-125-0.1 rod-cylinder, GOST 166-89

Shop lining

Operation 045 Locksmith

Drill Ø5 2300-6173 GOST 10902-77

Boss of 13-B16 GOST 8522-79

Mandrel KM4/B16 6039/0010 GOST 2682-86

ShtZ-I-125-0.1 rod-cylinder, GOST 166-89

Mark 2620-24853 GOST 326681

Mark 2620-24873 GOST 326681

Wrench 6910-0032 GOST 22399-77

Plug 8221-3030.7N, GOST 17758-72

Screwdriver 7810-0928 GOST 17199-88

Kerner 7843-0037 GOST 7213-72

Hammer 7850-0116 GOST 2310-77

Operation 050 Flat Grinding

Schlif. circle. 1-500х100х305 25A 40-P.C1.6K 65m/with B of 2 C. GOST 2424-83

ShtZ-I-125-0.1 rod-cylinder, GOST 166-89

Micrometer MK 75-1 GOST 6507-90

Diamond pencil 3908-0084 GOST 607-80

Operation 055 Current

Accessory for hole boring

Cutter 2140-0009 VK8 GOST 18882-73

Cutter T9315-218 VK8 GOST 18882-73

Cutter 2102-0059 VK8 GOST 18877-73

Nutromer 50-100 GOST 9244-75

Micrometer MK 75-1 GOST 6507-90

ShtZ-I-125-0.1 rod-cylinder, GOST 166-89

Operation 060 Diamond Bore

Special accessory

Cutter T9317-485-1 VK8 GOST 18882-73

Nutromer 50-100 GOST 9244-75

Cutter T9315-732 VK8 GOST 18882-73

Nutromer 2.5-50 GOST 9244-75

Operation 065 Milling NC

Special accessory

Cutter Ø12 (with R12) VK8 2235-0193 GOST 6396-78

Cutter Ø40 VK8 T9336-280

Cutter Ø50 VK8 2223-0105 GOST 17026-71

Drill Ø15 2301-0050 GOST 10903-77

Cartridge 6151-0022 MN 26-64

Cartridge 6251-0182 GOST 14077-83

Cartridge 6251-0182 GOST 14077-83

Collet Ø12 6113-0007 MN 27-64

Bushing KM 3/50 6130-0003 GOST 13790-68

Bushing KM 4/50 6130-0004 GOST 13790-68

Bushing 6100-0142 GOST 13598-85

Bushing 6120-0354 GOST 13409-83

ShtZ-I-125-0.1 rod-cylinder, GOST 166-89

Template

Operation 070 Drill

Shop support

Countersink 2353-0134 GOST 14953-80

Mark 2620-2595-3, GOST 3266-81

Mark 2620-1515-3, GOST 3266-81

Bushing 6120-0353 GOST 13409-83

Bushing 6100-0143, GOST 13598-85

Bushing 6100-0146, GOST 13598-85

Cartridge 6251-0181 GOST 14077-83

Plug 8221-3044 7N, GOST 17758-72

Plug 8221-3053.7N, GOST 17758-72

Operation 075 Drill

Shop bar

Drill Ø8 2300-0195, GOST 10902-77

Drill Ø5 2300-6173 GOST 10902-77

Drill Ø5 2300-0034, GOST 886-77

Bushing km 5/4 6100-0147 GOST 13598-85

Mandrel of km of 4/B16 6039-0010 GOST 2682-86

Cartridge 16-B18 GOST 8522-79

ShtZ-I-125-0.1 rod-cylinder, GOST 166-89

Operation 080 Drill

Drill Ø8.5 2301-0390 GOST 2092-77

Drill Ø17 2301-0057 GOST 10903-77

Zenker 2320-2555 GOST 12489-71

Countersink 2353-0134 GOST 14953-80

Scan 2363-0104 N8 GOST 1672-80

Scan 2363-0104 N7 GOST 1672-80

Bushing km 5/3 6100-0147 GOST 13598-85

Mandrel of km of 4/B16 6039-0010 GOST 2682-86

Cartridge 6251-0182 GOST 14077-83

ShtZ-I-125-0.1 rod-cylinder, GOST 166-89

Plug 8133-0922 N7 GOST 14810-69

Mandrel 6039-0010, GOST 2682-86

Bushing 6100-0142 GOST 13598-85

Bushing 6100-0143, GOST 13598-85

Bushing 6120-0354 GOST 13409-83

Operation 085 Locksmith

Vice

Superfile 2828-0074 GOST 1513-77

Kerner 7843-0036 GOST 7213-72

Hammer 7850-0116 GOST 2310-77

Shaber

Plate of 1-0-400х400 GOST 10905-86

SHP-1-400 line GOST 8026-92

Micrometer MK75-1 GOST 6507-90

3 Engineering of technological equipment

3.1 Description of the structure and operating principle of the accessory

The accessory is designed to secure the workpiece taking into account the possibility of its processing by three coordinates: x, y, z.

Billet is based on side surface and rear end face on fixed supports. Parallel installation is achieved by means of fixed supports. The part in the first position is fixed by means of two double-sided grips, pressed to the support on the side of the rear surface by a clamp, as well as by two screws to the supports and the clamp.

At the second fixing position, the blank is based on two mounting pins and support plates, fixed by means of a clamp and a double-sided rotary clamp through a pin-nut transmission.

In each case, the support and clamping elements have a minimum area of contact with the surface of the part, providing a minimum error in the installation of the part.

Supports are arranged so that required stiffness of part fixation and minimum error of spatial deviation after machining are provided. The accessory ensures accurate orientation, basing of the part and possibility of machining by three coordinates.

The use of double-sided fixation of the part on the elbow provides more complete use of the technical capabilities of the machine, eliminating errors during reinstallation and basing compared to a single-position installation on several devices.

To implement this scheme, a special fixture is used in the project.

This arrangement allows milling of the upper and lower plane of the cover in series.

To reduce the auxiliary time for installation and fixation of the workpiece, a set of installation devices of 2 pieces (package) is used. The workpiece is installed in the accessory and removed during the workpiece processing.

The accessory is based on the machine table along the central slot of the table.

Conclusion

The present work is a diploma project performed on the topic "Technological process of manufacturing of the internal cover and its equipment."

The cover internal is made of cast iron of the A-HM-P78001-87I brand. After preliminary machining, the workpiece undergoes artificial aging. The use of this material is due to the operating conditions of the inner cover.

The part has a flat shape. The shape of the part is explained on one side by the assembly conditions - on the surface of the part there are different holes for connecting the working parts of the pump; on the other hand, such a shape of the lid provides a sufficiently high tightness and strength with a minimum weight.

Cover structure comprises complex of smooth and threaded holes. The highest requirements are applied to holes Ø82N7 and Ø45N9, which serve for installation of critical working parts with high positioning accuracy.

Another structural feature of the cover is the presence on one of the flat surfaces of non-through slots of a complex geometric shape.

At the specified annual program (800 pcs), procurement - casting is selected. Feasibility study of such procurement selection is given in item 2.2 of this explanatory note.

The route of casting in medium-term production is detailed in Annex A of this Explanatory Note.

An analysis of the part design showed that it is not possible to maintain the unity of the bases due to the complexity of the part profile, so when processing on various operations, the bases change. The main bases of the part are flat surfaces and precisely machined holes.

Tools for machining on milling and boring machines are designed to install and secure the inner cover blank in the required position.

The device for perpendicular control is necessary for better and more timely control of the accuracy of the most critical surfaces of the part - holes made according to the 7th quota.

The large number of holes in the part makes it necessary to use conductors.

By comparing the obtained total error value (127 μm) with the size tolerance taken in calculating the processing allowance, which is 630 μm for roughing, it can be concluded that the required manufacturing accuracy under these processing conditions of the part is achieved.

As a result of the CNC lathe implementation the following positive results are obtained: reduction of labour intensity of part manufacturing, increase of labor productivity, reduction of number of units of used equipment and tooling, reduction of number of production workers, reduction of production areas, reduction of production cost of manufactured product.

Due to the above mentioned advantages, the economic effect of introducing new equipment into production will amount to 1,6063.95 thousand rubles.

The payback period of the project is 20.4 months.

The introduction of CNC machines in the manufacturing process of the part significantly reduces the number of manual machines, which makes it possible to use multi-stage maintenance; reduces the risk of injuries associated with transportation and installation of the part, since on one machine it becomes possible to perform seven machining transitions from one plant; releases additional production areas, which positively affects the illumination of the site, its dust content and gas content, as well as reduces the level of noise at the workplace.

In the life safety section, hazardous factors of machining of the designed part on CNC machines were analyzed and it was revealed that one of the most dangerous factors is electric shock.

The project considers many protective means in order to protect a person working on a CNC machine from electric shock.

Calculation of the most important device for ensuring electrical safety - protective grounding is carried out in item 5.3.

The design resistance of the grounding conductor was equal to 1.7 Ohm, which is less than permissible, therefore the workplace is not dangerous to human life and meets the standards of GOST 12.1.01979.