DP technology of mechanical engineering, part of gate valve housing

Contents

Contents

Paper

Introduction

1 General part

1.1 Brief description of the part

1.2 Critical analysis and justification of process selection

1.3 Design Objectives and Objectives

2 Process Design

2.1 Definition of production type

2.2 Procurement Selection

2.3 Definition of process structure and processing methods

2.4 Calculation of allowances and interoperative dimensions

2.5 Equipment and Process Tooling Selection

2.6 Calculation of cutting modes

2.7 Calculation of technical time standards

3 Process Equipment Design

3.1 Description of the device for cutting the root of the seam for X-rays

3.1.1 Calculation of cutting forces

3.1.2 Calculation of the accessory for accuracy

3.1.3 Strength calculation

3.2 Description of the device for treatment of the hull with plates

3.2.1 Calculation of cutting forces

3.2.2 Calculation of accessory for accuracy

3.2.3 Strength calculation

3.3 Description of drilling device (conductor)

3.3.1 Calculation of cutting forces

3.3.2 Calculation of the accessory for accuracy

3.3.3 Accuracy calculation

3.4 Design of cutting and measuring tools

3.4.1 Calculation of the cutter for strength and stiffness

3.4.2 Caliber calculation

4 Ensuring Life Safety

4.1 Process Analysis by Hazardous and Harmful Factors

4.2 Requirements for lifting mechanisms

5 Technical - Economic Calculations

5.1 Process Design Network Schedule

5.2 Calculation of process design costs

5.3 Process Cost Effectiveness Assessment

Conclusion

Literature

Applications

Application

Application

Application

Application

Application

Application

Application

Application

Application

Application

Application

Paper

The diploma project was completed on the topic: "The technological process of manufacturing the case and its equipment."

Calculated - explanatory note of sheets, figures, tables, 10 sheets of A1 format, sources, annexes.

The object of development is the ball valve housing.

The purpose of the work is to develop a technological process for the manufacture of the ball crane housing and its equipment in relation to the conditions of OJSC Tyazhpromarmatura.

As a result of the work, a technological process was developed for the manufacture of the part "ball valve housing" and technological equipment that allow mastering the production of this product at an industrial enterprise.

In the process part of the project, the justification for the selection of the type of workpiece was given, the structure of the technological processing route was proposed, the necessary equipment and equipment were selected, calculations of cutting modes and time standards were given.

Three accessories have been developed in the design part:

1.Adjustment for pneumatic seam cutting.

2. Device for treatment of the housing with air-operated plates.

3. Hole drilling device (conductor).

In the economic part of the project, capital costs were calculated for the implementation of the proposed project and the economic efficiency of the technological process for the manufacture of the housing was estimated.

In the BJD section, a process analysis was carried out on hazardous and harmful factors. The second issue considers the requirements for lifting mechanisms.

The developed means of technological equipment can be used in the manufacture of ball crane housings of other modifications and models.

2 Engineering of processing process.

5 Selection of equipment, tooling, cutting and measuring tools

Operation 055. Turning - carousel

The lathe-carousel 1M553 is used to perform this operation.

Technical characteristics of lathe-carousel 1M553.

Maximum diameter of workpiece, mm 5300

Maximum height of workpiece, mm 3200

Plate diameter, mm 5300

Maximum horizontal displacement of caliper, mm 3425

Main motion motor power, kW 180

Overall dimensions, mm:

length 8200

width 4200

height 9800

Weight, kg 233 000

Service life, years 12

Treatment of seam No. 1 on the outer surface for X-rays

Cutting tool:

- special VK8 cutter

Measuring tool:

- ShTsIII 320-1000 rod cylinder GOST 16680;

- ruler 150 GOST 42775.

Snap-in:

- special supports for cams;

- special machining cams.

Operation 070. Turning - carousel

The lathe-carousel 1M553 is used to perform this operation.

Cutting tool:

- boring cutter D = 32 mm, L = 340 mm, n = 25 mm GOST 1888173;

- cutter for cutting of seam root VK8.

Measuring tool:

- shtangenreysmas GOST 16480 ShR6300,05;

- ruler 150 GOST 427-75

- nutrometer NM 1250 GOST 1088;

- radial template RSH1 GOST 412682.

Snap-in:

- special supports for cams;

- special machining cams.

Operation 085. Turning - carousel

The lathe-carousel 1M553 is used to perform this operation.

Cutting tool:

- special VK8 cutter (shaped);

- special cutter.

Measuring tool:

- caliper of ShTsIII4000,1 of GOST 16680;

- ruler 150 GOST 427-75

- nutrometer NM 175 GOST 1088;

- radial template RSH1 GOST 412682;

- special template.

Snap-in:

- accessory for seam treatment in the housing.

Operation 130. Turning - NC Carousel

To perform this operation, a Dorris NC carousel is used. VC 2400/200V.

Technical characteristics of the turret and carousel of the company "Dorris" mod. VC 2400/200V.

Main motion motor power, kW 69

Maximum diameter of workpiece, mm 2400

Plate diameter, mm 2000

Maximum height of workpiece, mm 2600

Traverse travel, mm 1400

Table Speed:

Stage I, rpm 1.25-50

II stage, rpm 5-200

Traverse speed, mm/min 425

Accelerated Stroke Working Feeds:

- working feed, mm/min 0.1-6000

speed, mm/v 0.01-50

- slow motion:

I stage, mm/min 2

II stage, mm/min 40

III stage, mm/min 400

- accelerated stroke, mm/min 6000

Dip diameter (slider with cutter holder), mm 430

Cam clamp diameters:

Bmax, mm 1835

Bmin, mm 370

Cmax, mm 1970

Cmin, mm 500

Dmax, mm 1690

Dmin, mm 260

Overall dimensions, mm:

length 5100

width 6200

height 5630

Cutting tool:

- cutter for contour turning LH 21030734 h = 40mm, b = 32mm, h1 = 40mm, h2 = 44mm, b1 = 40mm, L = 200mm GOST 2087280;

- cutter for contour turning LH 21010676 h = 40mm, b = 32mm, h1 = 40mm, h2 = 47mm, b1 = 40mm, L = 200mm GOST 2087280;

- milling cutter 22350018 equipped with hard alloy plates, GOST 914078 D = 32mm, d = 23.5 mm, L = 150mm, l = 50mm, Morse cone 3;

- special drill;

- special counterbore;

- special cutter h = 40mm, b = 32mm, L = 250mm, l = 40mm;

- end cutter (Ø28mm) 22230305 GOST 1702671 L = 147mm, l = 45mm, z = 5, Morse cone 3;

- special drill;

- mark 2680012 GOST 622780;

- mark 26800007 GOST 622780.

Measuring tool:

- special template for welding preparation control;

- special template for control of the mustache of the main flange;

- shtangenreysmas GOST 16480 ShR6300,05;

- ruler 150 GOST 427-75

- nutrometer NM 1250 GOST 1088;

- conical plug GOST 648569;

- conical plug GOST 648569;

Snap-in:

- special supports for cams;

- special machining cams;

- boss 6B12 of GOST 852279;

- special mandrel;

- glasses O GOST 12.401385;

- round filler 28220054 GOST 146580.

Operation 155. Turning - NC Carousel

To perform this operation, a Dorris NC carousel is used. VC 2400/200V.

Cutting tool:

- cutter for contour turning LH 21030734 GOST 2087280 h = 40mm, b = 32mm, h1 = 40mm, h2 = 44mm, b1 = 40mm, L = 200mm;

- special cutter;

- left boring cutter 21410562 GOST 1887373 h = 25mm, b = 25mm, l = 100mm, l1 = 35mm, d = 35mm, m = 19mm, L = 240mm;

- drill 23010086 GOST 1090377;

- drill 23010070;

- a countersink of D=25mm, L=190mm, l=22mm, d=15mm industry standard I22 - 80 with a conic shaft;

- a countersink of D=30mm, L=190mm, l=22mm, d=20mm industry standard I22 - 80 with a conic shaft;

- flat pattern 23632156 GOST 1117580;

- special countersink drill;

- special countersink drill;

- tap (M107H) of 26211435 GOST 326681;

- mark 2680012 GOST 622780;

- special countersink drill;

- mark 2680012 GOST 622780;

- LH boring cutter 21410010 GOST 1888373 h = 25mm, b = 25mm, L = 240mm, l = 100mm, m = 19mm;

- end cutter (Ø25mm) 22230050 GOST 1702671 L = 147mm, l = 45mm, z = 5, Morse cone 3.

Measuring tool:

- plug gauge (Ø25) 81331026 GOST 1481169;

- plug gauge (Ø162N8) 81400116 PR GOST 1482269;

- plug gauge (Ø162N8) 81400116 NOT GOST 1482269;

- plug gauge (Ø25N10) 81330939 GOST 1482269;

- stopper (M106H) of 82213044 GOST 1775872;

- special template for control of welding edge preparation;

- nutrometer NM 600 GOST 1088;

- probe depth meter SHG 250 GOST 16290;

- plug gauge (Ø170N9) 81400117 PR GOST 1482269;

- plug gauge (Ø170N9) 81400117 NOT GOST 1482269;

- special template for control of welding edge preparation;

- caliper ShTs III4000.1 GOST 16690;

- caliper ShTs I1250.1 GOST 16690;

- conical plug GOST 648569;

- conical plug GOST 648569;

Snap-in:

- special mandrel;

- special supports for cams;

- special machining cams;

- boss 6B12 of GOST 852279;

- special mandrel;

- glasses O GOST 12.401385;

- file 82200026 GOST 146580;

- accessory for treatment of housing with plates.

Operation 230. Radial - Drill

To perform this operation, a radial mod drilling machine is used. 2A55.

Technical characteristics of radial drilling machine 2A55.

Maximum drilling diameter, mm 500

Drill head movement, mm 1225

Distance from spindle end to plate surface, mm 450-1600

Angle of rotation, deg 360

Feed limit, mm/v 0.56-2

Speed limit, rpm 20-2000

Main motion motor power, kW 5.5

Overall dimensions, mm:

length 2665

width 1030

height 3430

Weight, kg 4700

Service life, years 10

Cutting tool:

- drill (Ø23) 23010079 GOST 1090377;

- drill (Ø14) 23010046 GOST 1090377;

- tap (M166H) of 82213067 GOST 326681.

Measuring tool:

- plug gauge (Ø23) 81330035 GOST 1481169;

- plug gauge (Ø14) 81330535 GOST 1481169;

- stopper (M166H) of 82213067 GOST 1775872.

Snap-in:

- conductor;

- special adapter bushings.

Conclusion

In this thesis, a new technological process for the manufacture of the ball crane housing was designed, in which labor-intensive operations (lathe semi-automatic) were replaced with lathe-carousel operations with CNC. Highly specialized machines for more advanced ones, as a result of which the piece time for the manufacture of a part was reduced. New improved devices are proposed. A special cutting and measuring tool has been developed, with the help of which the piece time for the operation is reduced.

Technical and economic calculations have shown the feasibility of using this technological process.

The BJD section contains analysis on hazardous and harmful factors, the load capacity of the mechanisms is calculated.