DP mechanical engineering technology, part Supercharger housing

Contents

Contents

Paper

Introduction

1 Analysis of source data

1.1 Service purpose of the part

1.2 Technical Requirements for Part Fabrication

1.3 Technical characteristics of the material

1.4 Analysis of existing machining technology

water pump housing

1.5 Design Tasks

2 Process Design

2.1 Constructability Analysis

2.2 Definition of production type

2.3 Justification of procurement selection

2.4 Process Structure

2.5 Justification of process bases selection

2.6 Justification of equipment selection

2.7 Justification of cutting tool selection

2.8 Definition of interoperative allowances

2.9 Calculation of cutting modes

2.10 Calculation of technological time standards

3 Process tooling design

3.1 Design of End Mill Tool

3.2 Power Calculation of End Mill Tool

3.3 Description of the design and operating principle of the accessory for

End Mill

3.4 Description of the design and operating principle of the accessory

for lever milling

3.5 Cutting Tool Calculation

3.6 Calculation of measuring tool

4 Ensuring Life Safety

4.1 Process characteristics by hazardous and

harmful factors

4.2 Ensuring Electrical Safety

4.3 Calculation of protective grounding

5 Technical and economic calculations

5.1 Process Efficiency Assessment

Calculation of capital investments

Calculation of process cost

5.2 Organization of repair facilities

Conclusion

List of literature

Appendix A. Process documentation

Appendix B. Specifications

Paper

Explanatory note contains sheets, 4 figures, 31 tables,

10 sheets of A1 format, 14 sources, 2 appendices.

HOUSING, PROCESSABILITY, PROCESS, PRODUCTION TYPE, CUTTING MODES, ALLOWANCE, ACCESSORIES.

The object of development is the enclosure.

The purpose of the work is to develop a technological process for the manufacture of the housing of the D50 diesel water pump and its equipment in relation to the conditions of machine-building production.

During the work, a standard manufacturing process was studied, analysis and selection of the necessary information from the reference literature.

As a result of the work done, the technological process of manufacturing the housing of the D50 diesel water pump was developed in relation to the conditions of machine-building production, and designs of specialized devices and cutting tools were created.

The degree of implementation - the technological process of machining the pusher lever can be used at any machine-building enterprise, including Penzadizelmash OJSC.

Introduction

The modern stage of the development of mechanical engineering is characterized by an increase in economic and scientific and technical requirements for production. The economic factor has come first, among the requirements for production in a market economy, that is, production, in order to maintain the competitiveness of production, must be carried out with the most rational use of various types of resources. This requires a reduction in non-production costs, a reduction in material consumption and labor consumption of production, an improvement in the use of financial resources and a reduction in the return on investment period. Carrying out all the above measures should not affect the quality of the products produced, but on the contrary, the requirement of competitiveness for production sets the task of improving the quality of the products produced, while reducing its cost .

The real solution of the set of tasks can be increased automation of production and the use of more modern technologies and equipment.

The part considered in this project, the water pump housing, is one of the typical examples of modern products made using universal metal cutting equipment. This is a high-precision part of the D50 diesel engine with complex stepped surfaces.

All these tasks were solved in the current production using inefficient equipment.

All the technological solutions taken as a result of the analysis have a feasibility study in this project, which is confirmed by their effectiveness.

Analysis of source data

Part Service Assignment

The part we are developing - the water pump housing, is an integral part of the centrifugal water pump of diesel D50.

The water pump is a responsible and complex unit of the D50 diesel engine and is designed to circulate water in the engine under the pressure created by the pump itself.

Water pump is detachable and consists of housing and frame connected to each other by six bolts. Suction branch pipe is attached to pump housing. A bronze impeller rotates inside the body. Impeller and gear are installed on prismatic keys and fixed on shaft by nuts, shaft is installed in bed on bearings.

Water cavity is sealed with packing gland and replaceable bushing. The gland is pressed by two nuts through the pressure bushing.

For normal operation of the gland seal, it is allowed to leak water through it from 10 to 60 drops per minute. The water leaked through the gland is discarded by the shaft collar and drained through the connector. Labyrinth seal prevents ingress into oil cavity. The pump is attached to the engine by means of four flanges: side (suction pipe), upper (pressure pipe), and lower - to the cylinder block, and by means of a flange on the bed - to the gear drive housing.

Part fabrication specifications

The body of the water pump is the responsible body part of the engine cooling system, therefore, taking into account the service purpose, the following requirements are imposed on its manufacture:

1. 170.. 229 NV. Check on surface P. After checking hardness of hole edge grind.

2. Casting accuracy 10009 GOST 26645-85

3. Casting slopes as per GOST 3212-92

4. Unspecified casting radii 3.. 5 mm.

5. Unspecified limit deviations of H14, h14 dimensions

6. Run-out relative to Y surface axis:

a) surfaces K, L, H not more than 0.05 mm;

b) T&C surfaces not more than 0.2 mm;

c) F surface not more than 0.05 mm on F210 mm;

d) surface M not more than 0.2 mm on F230 mm;

e) P surface not more than 0.2 mm on F145 mm;

f) surfaces AND not more than 0.08 mm on F300 mm;

7. Surfaces of C and Highway have to lie in one plane, a deviation no more than 0.05 mm.

8. The admission of perpendicularity of planes Sh and Ts concerning a surface axis At no more than 0.05 mm on length of 100 mm.

9. Position admission of axes of openings of E,Yu no more than F 0.2 mm.

10. Countersink the threaded holes at an angle of 120 to the external diameter of the thread.

11. On the surfaces of Highway and C separate risks are allowed.

12. On treated and untreated surfaces, shells of non-group location with the largest measurement of 5 mm, a depth of not more than 1/3 of the wall thickness in this place, in the amount of up to five pieces per surface, which do not give leaks during hydraulic tests and do not violate joint seals, are allowed.

13. Shells are allowed in threaded holes, which affect not more than two thread threads and do not come to the external surface, in the amount of 1 piece per hole.

14. Correction of casting defects is allowed.

15. Pressurize the water cavity with water at pressure of 0.3 MPa (3 kgf/cm) for 3 minutes. Leak and sweating are not allowed.

16. Bays up to 2 mm high are allowed.

17. Material substitute SCh 20 GOST 1412-85

Design Tasks

Based on the analysis of the existing process, the manufacture of the water pump housing, the following design tasks are set.

Design a progressive process using high-performance CNC machines, while processing the internal surfaces of the water pump housing, to improve production efficiency.

Develop fast-acting, overhauling mechanized equipment to reduce the labor intensity of production and increase the exact parameters of the part.

Based on the technical decisions taken, calculate the cost of manufacturing the part, the cost-effectiveness from the implementation of this technology and analyze the investment of the project.

Taking into account the developed technology of water pump casing manufacturing, analyze safe and trouble-free operation of the used equipment and technological equipment and develop appropriate measures.

All the design tasks set in the complex are reduced to a single goal: quickly and efficiently, with the least cost, ensure the manufacture of the water pump housing.

Process Design

Constructability Analysis

Workability refers to the property of a structure, the manufacture of which requires minimal labor, time and means, taking into account the provision of specified characteristics.

Processability is the convenience of manufacturing, repair of the product.

By performing a process control of the part drawing, it can be noted that the part is a cast iron slab with complex shaped surfaces. The dimensional tolerances have both external sealing surfaces and internal holes for basing the pump shaft bearing. The remaining dimensions are free, which fully corresponds to the service purpose of this part.

Convenient and reliable basing surfaces are provided for installation of the workpiece during its processing. It is possible to easily and reliably fix the part on the machine. The configuration of the part is quite rigid, which contributes to the perception of cutting and fixing forces without noticeable deformations. This allows you to do without special, installation devices. Convenient supply of high-performance cutting tool to machined surfaces is provided. Convenient and efficient process control is provided for the workpiece using a standard measuring tool.

The workability of the part is estimated by technological and non-technological indicators. Non-process parameters include: large diameter differences, large length of machined surfaces, the presence of right and left threads on one part. In this part there are no technological parameters except for long length of machined surfaces.

Evaluating the part by process indicators, we note the following:

The part configuration is a combination of simple shapes of the outer surfaces, with a slight size difference. A smooth transition from one size to another, with a relatively small width of the stages, allows for a highly productive method of carousel processing.

The given quotas of accuracy and roughness of surfaces are strictly justified by the service purpose. Based on the above described, it can be concluded that the part as a whole is technologically constructed and manufactured.

Process Tooling Design

3.1 Design of End Mill Tool

An installation tool has been designed to mill the sealing plane of the water pump housing and drill the mounting holes performed in complex operation No. 025 on the NC horizontal milling machine of model MCHFD80 (see drawing

PGTA 1.151001.037.001 SS). The device is represented by the following structural elements: three clamping devices, a mounting box, two installations, a housing and other parts .

The workpiece is installed on the box with its inner hole and plane. And with flanges rests against adjustable supports. This determines the position of the workpiece in the axial and longitudinal directions.

Clamping force is transmitted through nut to clamp cross mounted on central pin. The cross is clamped, fixes two blanks at the end.

3.3 Description of the design and operating principle of the accessory

for end milling

Milling accessory (refer to drawing PGTA 1.151001.037.001 SS) is designed for basing and fixing the part for milling the sealing plane of the housing on the horizontal milling machine with NC model MCHFD80.

Milling device consists of plate - pos. 1, on which in longitudinal direction on the strut there fixed is a mounting box - pos. 18, in the center of which a stud is screwed into the plate - pos. 20, on which in turn a cross is installed - pos. 38, upper end of which is pressed by nut - pos. 21. The spider serves as the main clamp of the part.

On both sides of the landing box on the plate - pos. 1, three posts are fixed - pos. 2, 3 and 11 with two round installations - pos. 6 and underwater bell-crank - pos. 31, which serve for exhibition and fixation of the housing.

Housing with internal hole Ø235 is installed on the unit - pos. 18, and underwater bell-crank rests against inner side of flanges. 31, fixing the part in the transverse direction, while also the installations - pos. 2 and 3, fixing the part in the longitudinal direction. Then to the stud - pos. 20 detachable cross is installed - pos. 38 with hinged washer - pos. 37 and using nut - pos. 21 and the wrench are attached to the part manually.

To fill and carry the accessory, two cargo screws are screwed into the plate - pos. 25, and for basing and fixing the accessory on the machine table there are two keys - pos. 26 and four bolts and nuts - pos. 34 and 35 installed in the slots of the machine table and accessories, respectively.

3.4 Description of the design and operating principle of the grinding device

For grinding the sealing plane of the water pump housing, the design of a special accessory installed on the table of the flat grinding machine 3B724 has been developed (see drawing PGTA 1.151001.037.002 SS).

Grinding accessory consists of welded housing - pos. 1, on the vertical strut of which the centerpiece is fixed - pos. 5, in the center of which a stud is screwed into the plate - pos. 23, on which in turn a removable washer is installed - pos. 21, upper end of which is pressed by nut - pos. 14. The nut serves as the main clamp of the part.

On the other side on the vertical rack of the housing - pos. 1 ring is fixed - pos. 4 for mounting the mating part of the housing.

Housing with internal hole Ø235 and plane is installed on centering point - pos. 5, and hole Ø10.2 on the finger - pos. 17, which serves to prevent rotation of the part during installation. Then to the stud - pos. 23 detachable washer is installed - pos. 21 and using nut - pos. 14 and the wrench are manually secured to the part.

For alignment on the size in the upper part of the housing rack - pos. 1 plate is fixed - pos. 6.

On the machine table, the accessory is fixed with bolts and nuts, centering on the table slots using keys.

Technical and economic calculations

The purpose of the diploma project is to improve the technological process of manufacturing the body part. The relevance of the proposed topic of the diploma project is explained by the following shortcomings of the existing technological processes of parts of this type:

significant amount of piece time in process operations;

low productivity of machine tools;

high process cost of the part;

a significant number of items of equipment used;

high energy costs.

In this process, a part treatment option is offered using high-performance equipment and special equipment, which will reduce the main processing time of the part.

Instead of turning-carousel machines of model 1541, it is proposed to use turning-carousel with NC of model 1A512MC3, in addition, the horizontal-milling operation and part of radial-drilling are proposed to be performed on the machining center of the MCFHD80 model. Such an approach will make it possible to gain from the following

The result is the following:

increasing the productivity of machine tools;

reduction of total unit time of part processing;

reduction of the share of wages and social contributions in the cost of the part;

reduced number of machines with simultaneous reduction of energy costs and production space.

To justify the intended effect, a number of organizational and economic calculations must be carried out. The purpose of this part of the diploma project is:

Assessment of the cost-effectiveness of the process;

organization and planning of repair facilities.

Conclusion

The goal of the diploma project was: the development of the technological process of machining the hull and its equipment.

As a result of the work, a technological process was developed on using an CNC milling machine of the MCFHD80 model.

The explanatory note contains all the necessary technological calculations: cutting modes, interoperative allowances, technical rationing, etc.

To equip the process, milling and grinding devices are designed for appropriate operations. Technological adjustments, as well as a cutting and measuring tool with the necessary strength, accuracy and power calculations were designed.

In addition, measures have been developed to ensure the safety of life at work.

Investments in this project are economically profitable, the project is viable and can be put into production on the basis of a mechanical workshop of a machine-building enterprise.

In general, the project was completed in accordance with the task.