Flange fabrication technology

INTRODUCTION In the process of machining machine parts, a large number of problematic issues arise that are related to the need to fulfill the technical requirements set by designers before production. Also, the machining process is associated with the operation of complex equipment - metal cutting machines, so the labor intensity and cost of machining is greater than at other stages of manufacturing machine parts. The reappraisal of the available design methods was caused by such factors as the complex mechanization and automation of production processes, the re-equipment of machine-building enterprises with modern Machines typification and standardization of technological processes, and the widespread introduction of electronic computers into the practice of technological design. So, modern technological design is a complex system of interaction of tools and methods, which lead to the creation of high-quality technological documentation based on the wide use of standard technological solutions. A feature of automation in small-scale production is the need to create flexible production systems that are able to automatically switch from machining parts of one type to another. CNC machines and multipurpose machines play a leading role in these tasks. After all, the use of one such machine allows you to replace several milling, drilling and boring machines, while significantly increasing productivity (in 2... 3 times) due to reduced auxiliary time (as a result of automation of the processing cycle and automatic replacement of the tool). Under the conditions of real enterprises, in the manufacture of parts, overestimated allowance values may be assigned to reduce possible scrap at individual operations. First of all, this is explained by the use of outdated equipment. The consequence is an increase in the cost of workpieces, as well as an increase in the cost of machining. Therefore, in developing the process in this course project, an attempt was made to use modern processing methods and high-performance equipment. Decisions were made taking into account the recommendations of GOST. As a result of the course project, practical knowledge and skills were obtained, which are necessary not only when performing a diploma project, but also when working in production. The purpose of this course project on mechanical engineering technology is to develop the technological process of machining the part "gear wheel." 1 Part processing technology 1.1 Process calculations of cutting modes 1. To manufacture the bushing, we take a steel blank - coarse section rolled stock a) material - Steel 40X; b) diameter - Æ200 mm; c) width - l = 32 mm; 2. Manufacturing steps: a) Turning 1 stage: 1. draft; 2.chistovaya. 1.2 Turning 1.2.1 Rough turning End of workpiece surface by size of 30 mm with diameter of 200 mm. a) feeding task S = 0.5 mm; b) cutting rate at this feed for steels with sur = 90... 100 kg/mm2 and hardness HB = 201... 226 is equal to J = 95 m/min. c) billet rotation speed: rpm, g) feed per minute mm/min, e) time required to end sec = 0.0628 min, End face of billet by size 28 mm with diameter 200 mm. a) feeding task S = 0.5 mm; b) cutting rate at this feed for steels with sur = 90... 100 kg/mm2 and hardness HB = 201... 226 is equal to J = 95 m/min. c) preparation rotation speed: rpm, d) giving a minute of mm/min., e) time necessary for a sec. tortsevaniye = 0.0628 min., Processing of Æ of 100 mm at the length of 4 mm a) speed of cutting of m/min b) time necessary for processing of sec. = 0.012 min. Processing of a facet with = 4'45 ° on diameter of 100 mm.a) required part rotation speed n = 270 rpm, b) supply S = 0.15 mm, c) cutting depth t = 4 mm, d) cutting speed mm/min d) time required for processing sec = 0.1 min. Treatment of diameter 195 mm by length 28 mm. a) feeding S = 0.5 mm b) cutting speed J = 40 m/min c) billet rotation speed rpm, g) feeding per minute mm/v, e) time required for processing sec = 0.86 min, drilling of center hole. a) diameter d = 65 mm, b) depth h = 28 mm, c) are accepted according to the table for steel with swr < 100 kg/mm2 and drill-bit A 65 mm feed S = 0.06 mm/rpm, g) we determine the cutting speed mm/min, e) the time required to drill the center hole sec = 0.2 min, Drilling four holes at a radius of 75 mm. a) diameter d = 20 mm, b) depth h = 24 mm, c) determine cutting speed mm/min, d) time required for drilling of four holes sec = 2.34 min, Time required for rough turning of bushing 1.3 Finishing treatment 1.3.1 Grinding of flange surfaces Method of grinding: round, external, internal with longitudinal feed. The grinding wheel is flat with a straight profile of PCB type, 40 mm wide. From the table we take the longitudinal minute feed for grinding diameter up to 40 mm Sm = 5200 mm/min. Transverse feed at this longitudinal feed and accuracy of processing according to 5... 7 with the quota t = 0,003 mm. Grinding allowance 0.4 mm per diameter. Thickness of detachable layer h = 0.2 mm. Number of wheel passes at each section of sanding of passage surface. Grinding of diameter 195 on length 24 mm a) length of longitudinal stroke of wheel mm, b) time spent on grinding sec = 0.3 min. Grinding of diameter 65 at length 28 mm a) length of longitudinal stroke of wheel mm b) time spent for grinding sec = 0.36 min. Grinding of diameter 195 on length 24 mm a) length of wheel longitudinal stroke mm, b) time spent for grinding sec = 0.3 min. Grinding of end surfaces on length 130 mm a) length of longitudinal stroke of wheel mm b) time spent for grinding sec = 1.67 min. Time required for grinding min. 2T3 is taken because there are two machined surfaces on the flange. 3.2 Technical normalization of working time 3.2.1 Turning Preparation - final time (Tp.Z.). Upon receipt of the task and familiarization with the drawing - 5 min. Preparation of the workstation - 5 min. Selection of the workpiece - 3 min. Selection and preparation of the tool, accessories and measuring tool - 30 min. Adjustment of the machine - 10 min. Removal of tools and accessories after completion of work - 3 min. Handover of work to OTC - 2 min. Total Tp.z. - 58 min Main time - machine - manual Draft turning - 3.63 min Final turning - 4 min Total Tosn - 7.63 min Auxiliary time (Tssp) Part installation - 2 min Part fixing - 1 min Part reinstallation - 5 min Machine control, tool and measuring devices rearrangement - 15 min.Total Tvsp - 23 min. Maintenance time (Tt.o.) Time spent on replacement of the dull tool - 5 min. Time spent on adjustment and cleaning of the machine during operation - 5 min. Total TT.o - 10 min. Time of organized maintenance of the workplace (To.o.) Time spent on tool rolling and cleaning at the beginning and end of work - 3 min. Time spent on machine cleaning and lubrication at the end of shift - 15 min. Total To.o. - 18 min. Break time for rest and personal needs To - 10 min. Piece time (Tsh.) In total, CONCLUSION was spent on processing the part on the lathe. According to the initial data, the part is machined. On the basis of the calculations of the course work, the types of machines that are necessary for the production of parts in accordance with this version were selected. For all machine types, the feed, cutting speed, spindle speed and main time are calculated. In accordance with the calculations, a table was compiled with the calculation of the time for each operation. In accordance with the design of the part, an analysis of possible defects was carried out and restoration methods were proposed. LIST OF USED LITERATURE 1 Handbook of the technologist - machine engineer. In 2 t. C74 T.1/Ed. A.G. Kosilova and R.K. Meshcheryakova. - 4th ed., Redesign. and supplement - M.: Mechanical Engineering, 1986, 656 p. 2 Course design according to the technology of mechanical engineering ./Gorbatsevich A.F., Shkred V.A. - 4th ed., Conversion. and additional - Mn.: Vysh. shk., 1983. - 256 p. 3 Design and production of blanks in mechanical engineering: Textbook/P.A. Rudenko, Yu.A. Kharlamov, V.M. Pleskach; Under the general. Ed. V.M. Pleskacha. - K.: Higher school, 1991. – 247 pages. 4 Metal cutting modes. Handbook ./Ed. Yu.V. Baranovsky - 3rd ed., Rev. and supplement - M., "Mechanical Engineering," 1972. – 363 pages.