Exchange rate "Cover"

Introduction

A set 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. In this regard, concepts arose: casting technology, pressure processing technology, welding technology, machining technology, machine assembly technology. All these areas of production relate to the technology of mechanical engineering, covering all stages of the manufacturing process, machine-building products.

By "engineering technology" is understood to mean

scientific discipline, which mainly studies the processes of mechanical processing of parts and assembly of machines and simultaneously touches on the issues of selection of blanks and methods of their manufacture. This is because in mechanical engineering, the desired shapes of parts with the required accuracy and quality of their surfaces are achieved mainly by machining, since other machining methods cannot always meet these technical requirements. 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 production activities of the enterprise.

The complexity of the process and the physical nature of the phenomena associated with mechanical processing caused the difficulty of studying the entire range of issues within the same technological discipline and caused the formation of several such disciplines. So, the phenomena that occur when removing metal layers with a cutting and abrasive tool are studied in the discipline "Metal Cutting"; study of the designs of cutting tools and materials for their manufacture refers to the discipline "Cutting tools."

These specialized technological disciplines were formed earlier than the comprehensive discipline "Engineering Technology."

The Engineering Technologies comprehensively studies the interaction of the machine, accessory, cutting tool and machined part; ways to build the most rational, that is, the most productive and economic, technological processes for processing machine parts, including the selection of equipment and technological equipment; methods of rational construction of machine assembly processes.

Thus, the discipline "Engineering Technology" studies the basics and methods of machine production, which are common to various branches of mechanical engineering.

The purpose of this course project is to develop the manufacturing process of the "cover" part. Cutting calculations will be performed in the course design, technological rationing will be provided, cutting and measuring tools equipment will be selected.

Characteristics of the specified production type

Depending on the breadth of the nomenclature, regularity, stability and volume of production of products, modern production is divided into the following types: single, serial, mass. The nature of the process and its construction largely depend on the type of production.

Based on the handbook, based on the mass of the part M = 1kg and the assigned production program of 10000 pcs, we determine the production type - serial.

Serial production is characterized by the production of a limited range of products in batches (series), repeated at certain intervals. Depending on the size of the series, small-scale, medium-scale and large-scale production are distinguished. The peculiarities of the organization of mass production are that it is possible to specialize jobs for several such technological operations, along with the universal use of special equipment and technological equipment, to widely use the work of medium-skilled workers, to effectively use equipment and production areas, to reduce the cost of wages compared to single production.

Part Processability Analysis

In its design, the part "Cover" is a body of revolution with a through axial hole and a radial through hole for conical thread. On the flange "Cover" there are 8 holes with a diameter of 24mm for attachment of the housing to the device along the tail part "Cover." Threads M72 and M52 are made on its outer and inner surfaces, respectively. In general, the part should be recognized as technological, since:

1. all surfaces of the part are either straight or in the form of a solid of revolution;

2. the hole in the part is through, which provides free passage of the tool;

3. the surfaces of the part are designed so that its basing and fixation in the equipment does not require the use of special devices;

4. all surfaces, including threaded surfaces, have free access to a standard tool;

5. process radii, chamfers and rounds can be made with a gated tool;

6. surface roughness and accuracy classes do not require the use of special equipment, not traditional processing methods, tools and technological equipment.

It is necessary to carry it to shortcomings of technological effectiveness of a detail of production from stainless steel 38XA that forces to use as the cutting tool, the tool which is provided with plates of solid alloy or metal ceramics.

Lathe model 16k20fs5 with cnu

The lathe of the model 16K20FZS5 with CNC is designed to treat the outer surfaces of the bodies of revolution (with a stepped and curved profile of various complexity) over one or more passes in a closed semi-automatic cycle, as well as for cutting threads. Installation of blanks is carried out mainly in centers.

The tool translation program and auxiliary commands are recorded on the punch tape in one of the standard codes. Accuracy class of machine "P." The NC system H22 1m, which is equipped with a machine, provides movement of the caliper in two coordinates, automatic switching of spindle speeds in one of three ranges, indexing of the tool head in any of six positions, as well as execution of a number of auxiliary commands.

The kinematic circuit of the machine model 16K20FZS5 provides three ranges of spindle rotation speeds manually switched. The first spindle speed range (12.5-200 rpm) is obtained by turning the handle to the right; rotation from shaft V is transmitted through pair 2 = 45 and 45 to shaft VII, then through pair 2 = 18 and 72 to shaft VIII, then through pair 2 = 30 and 60 to shaft IV. The second range (50 - 800 rpm) is obtained by turning the handle to the left to the middle position: rotation from shaft V is transmitted to shaft IV through pair 2 = 60 and 48. The third range (125,2000 rpm) is obtained by turning the handle to the left until stop: rotation from shaft V is transmitted to shaft IV through a pair of 2 = 30 - 60.

The transverse feed drive is mounted on the rear side of the carriage; it consists of a stepper motor, torque booster, gear pair 2 = 74 and 100, transmission screw - rolling nut with a pitch of 5 mm.

Rotary cutter holder with horizontal axis of rotation is installed on transverse support. In the tool head, six cutting inserts are attached, which are pre-adjusted to the rear dimension outside the machine using an optical device.

Adjustment of position of track cams on longitudinal and transverse rulers is provided with two slots for installation of cams of emergency disconnection of supply and control of initial (zero) position of caliper. Cams act on units of track electric switches mounted on machine carriage.

At the same time, the NC system and the machine are not disconnected and information about the position of the caliper, which comes from feedback sensors, is stored in the communication memory.

Lubrication is essential for the normal operation and perpetuity of the machine and is carried out strictly in accordance with the lubrication map (operating manual of the machine) and the lubrication diagram of the spindle head.

The hydraulic drive of the machine consists of a hydraulic station, which includes an oil tank and an adjustable pump with a drive motor, devices for filtration and cooling of working fluid, and control equipment.

Actuation of hydraulic drive is performed by pressing "Start" button of hydraulic unit. Operation of hydraulic unit is performed in accordance with supply of electrical commands from control panel with step-by-step engine of hydraulic amplifiers.

Hydraulic drive maintenance. In the fine filter, when moving the filter clogging indicator to the red mark, it is necessary to notice the filter bag. During the operation of the hydraulic drive, noise and shocks can occur, accompanying the pressure fluctuation in the system and foaming of the oil. Possible reasons are air suction due to non-tightness of the suction line connection or lowering of the oil level in the tank; method of elimination - tighten the suction pipeline and add oil to the tank to the oil indicator reference mark.

Conclusion

As a result of the course project on mechanical engineering technology, the technological process of machining the part "Cover" was developed, which includes turning, drilling, grinding operations. On the most accurate surface, inter-operation allowances were calculated, which resulted in the design of the workpiece. For part of the machining operations, he determined the cutting modes by analytical calculation, and for the rest they were assigned according to general engineering standards. Technological rationing of machining operations was carried out, in the structural part of the course design the design and principle of operation of the turning-screw mill of model 16K20, measuring and cutting tools were considered and described.

The following package is presented in the attachment of the course project:

1) Appendix - Process Album;

2) Appendix - graphic part (part drawing, process adjustment, tool drawing).