Flange fabrication

Contents

Introduction

1.Technological section

1.1 Purpose and process requirements for the manufactured part design

1.2 Chemical composition, physical-mechanical and technological properties of mate-rial

1.3 Calculation of part weight

2. Definition of production type

3. Selection and description of the procurement method

3.1 Determination of machining allowances

4. Development of part manufacturing process

4.1 Structural diagram of the process

4.2. Selection and description of process equipment

4.3 Selection and Description of Cutting Tool

4.4 Measuring tool selection

5 Calculation of cutting modes

5.1 Turning operation

5.2 Grinding operation

List of literature

Appendix A. Part Manufacturing Process Roadmap

Appendix B. Operating cards

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" 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. 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 design is to develop the manufacturing process for the flange part. Cutting calculations will be performed in the course design, technological rationing will be provided, cutting and measuring tools equipment will be selected.

Process Section

Purpose and process requirements to the design of the manufactured part.

The flange is an integral part of the pipeline valves. The field of application of the flanges is extremely wide, the flanges are used as a connecting component of pipes, and the flange can also serve as a connection of rotating parts. In appearance, the flange represents a paired structure of a flat section of an annular or disk shape. Attachment of flanges is performed through diametrically arranged holes of one and the other flange by means of threaded connection. These are bolts or studs that tighten two flanges. The flanges differ in size, in versions of connecting the flanges to each other, in face shape and also in versions of seals between two connecting surfaces of the flange. The reliability of the flange in the pipeline connections from a vacuum of 1013 mbar to the options where the flanges connect the pipelines with a pressure of 200 bar makes the flanges a popular element of the connecting structures. According to GOST, flanges are produced in three types: steel flat flanges, collar flanges and free flanges on a ring fixed by welding. The flanges of the first kind serve as a connecting element of the pipeline between each other and with a similar flange of another element of the system. Flanges are attached to the pipe either on a threaded connection or on a welded one. Such flanges are capable of withstanding temperature conditions from 75 to 450 degrees, but it should be borne in mind that flanges have up to ten subspecies of gasket connections depending on the diameter of the pipe itself and the expected pressure values and regional operating conditions. Flat flanges are able to withstand an even greater temperature range, so they connect such flanges by welding, without using additional materials for gaskets between the flat flanges. Collar flanges are butt-mounted, flanges of this type are common for fixing various devices, by connecting with flanges of various fittings and branch pipes of additional equipment. Flanges of each type and view are provided with separate tables of characteristics.

Flanges are a connecting part of pipes, shafts, tanks. They are flat steel discs or rings with holes for studs or bolts. Flanges are used when connecting various fittings to main pipelines. In addition, they are used to attach separate sections of the pipeline to each other or to connect to equipment. The flange connection is capable of ensuring the strength, tightness of the structure, as well as simplifying the assembly and disassembly process. According to Belarusian standards, flanges produce steel threaded, mouth, as well as for devices and gasket vessels.

Surfaces Ø50 and length 63 mm determine the position of the flange in the mechanism, therefore it is the main one. Surface roughness Ø50 Ra = 1.25.

The surface Ø105 is free.

The surface Ø40 is auxiliary. It determines the position of all attachment parts relative to that part.

Surfaces Ø9, Ø15, Ø7.6, Ø44 are service surfaces.

Selection and description of the procurement method

In mass production, the grey cast iron part 15 is suitably made of casting. The most affordable method of producing casting is casting in sandy-clay forms.

Casting results from filling the mold cavity with liquid metal. After pouring, the liquid metal cools in the mold and solidifies to form a cast.

The model is a device for obtaining in the form of an imprint corresponding to the configuration and size of the casting. Models are made of wood, metal, gypsum, plastic and other materials.

The rod is part of the mold. It is made from rod mixture sealed in box. After removal from the box, the rod is dried in an oven. When assembling the mold, the dry rod is installed with rod marks in the corresponding mold sockets obtained using the model signs. Length of rod exceeds length of casting cavity by value of signs.

Mold for bushing is assembled from two semi-molds: upper and lower. The semi-molds are made of a moulding mixture sealed in cast iron or steel frames, which are called supports.

The process of making castings in single molds is widespread in foundry. It consists of various processes that are carried out in special workshops or departments of the foundry.

The casting process begins with the preparation of a model set: models or model plates, model boards, rod boxes, drying plates, templates for checking the size of the mold and rods, conductors to templates for checking the correct installation of rods in the mold, supports, pins, etc.

The model set is made in the model shop or model compartment of the foundry.

No less important part of the process chain is the preparation of materials for the manufacture of the mold. Molding materials are materials used to make single and semi-permanent molds. These are sands, binders and special additives. Initial moulding materials are stored in the warehouse of moulding materials in special containers and silos. When arriving at the warehouse, it is mandatory to check their quality compliance with the certificate. Quality control of molding materials is carried out in special laboratories.

The process of making molds is called molding. In foundry, manual and machine molding is used: in single and small-scale production - manual molding (molds are usually made using wooden models), in mass and mass production - machine (molds are made on machines using metal models).

Rods are obtained using boxes or templates. The finished rods are dried in special furnaces (dryers) to increase their strength, gas permeability, as well as reduce the gas-producing capacity. The rods are painted with paints consisting of refractory materials: graphite, pulverized quartz, zircon, etc., which is necessary to increase the purity of the casting surface.

The molten metal must be overheated in the furnace to a certain temperature so that it fills the mold well. After melting and overheating, the metal is drained from the furnace into various ladles and transported to the mold pouring section. The metal poured into the mold, giving heat to the mold, cools and solidifies.

After cooling the casting, the molds are broken (knocked out) and the castings are removed from the molds. Moulds are knocked out only after the casting has cooled to a certain temperature, since at high temperatures the alloys are not strong enough and the casting can break down. Moulds are knocked out on special installations located in the compartment or on the knock-out section.

Castings have runners, bulges, sometimes burrs and bays of metal, their surface can be contaminated with a moulding mixture burnt to it. Cutting or chopping of runners, evaporators, burrs, cleaning of casting surface is carried out in cleaning and chopping of castings by special tools, on shot blasting and blasting plants, in hydraulic, sand-hydraulic and cleaning drums.

After that, castings are sent to the technical control department (CTC). Castings are controlled here: their dimensions and tightness, the presence of internal and external defects (shrinkage shells, gas shells, cracks, etc.), mechanical properties and metal structure are checked. Castings with minor defects are corrected by various methods: gas and electric brewing, impregnation with various resins, application of putty, etc.