Manufacturing process of housing part

Summary

In this course project, a new technological process for the production of the Hull part (DB60.335.00.01), produced at OJSC Bryansk Machine-Building Plant in small-scale production conditions with an annual production program of 90 pcs, is being developed.

The designed technological process is less labor intensive due to the use of more advanced equipment (CNC machines).

Advanced tools and productive equipment are used for machining the part by cutting.

Introduction

In this course project, it is assumed that the student will make extensive use of theoretical knowledge in the design of technological processes using CNC machines, NCC machines, etc.

In addition to the design of a given process, the direct application of the knowledge obtained in the areas of tooling design, selection of the method of obtaining the workpiece, economic justification and functional-cost analysis of the process is implied.

During the analysis of the basic version of the process, characteristic features and disadvantages are identified, on the basis of which the process modernization is carried out, which means a revision of the equipment, tool, cutting modes in order to increase the productivity and accuracy of processing the part, as well as cost-effectiveness of production.

All introduced innovations must lead to the improvement of the manufacturing process of the part, which will affect the economic effect over the calculation period

The Russian economy and its leading industry - mechanical engineering have switched to a market economy.

The formation of market relations is the only means of creating high-performance production that is flexible and susceptible to achieving consumer-oriented scientific and technological progress. A market economy involves a variety of forms of ownership and management, direct linkages and competition.

All this leads to the complete economic independence of enterprises, the functioning of which is based on the principles of self-accounting, self-financing and self-reliance. In this regard, the responsibility of enterprise managers at all levels for the results of their work, for the production of competitive products, and for profitability increases. This requires some knowledge of production management.

The modern stage of the scientific and technical revolution has introduced significant new moments in the economic development of Russia. The country is experiencing a rapid growth of a complex of knowledge-intensive industries, caused by the needs of a large-scale modernization of the entire production apparatus in the national economy of countries. The saturation of solvent demand with mass standardized products, diversification and individualization of social needs differ. This dictates a significant acceleration of the renewal of the range of products produced, as well as the growth of the service sector, with a corresponding increase in its share in the national product. In such conditions, there should be much more flexibility than before of the economic mechanism, its ability to quickly and without loss respond to the change in directions of development of science and technology, to the structure of demand.

The scientific and technological potential of the country depends to a large extent on the scientific and production capacity of its national firms and enterprises, their ability to provide a high level and pace of NTP, their "survival" in a competitive environment. The scientific and technical potential of the country is created both by the efforts of national scientific and technical organizations and by the use of world achievements in science and technology. A potential approach to the concept of "new technology" for a particular production is to assess the ability to achieve the objectives of an enterprise or firm in a short time.

Therefore, for a particular production, it allows you to raise the productivity and quality of products to a higher level.

The design of the manufacturing processes of machine parts is aimed at establishing the most rational and economical method of processing, while the processing of parts on metal cutting machines should ensure the fulfillment of the requirements for accuracy and cleanliness of the treated surfaces, correctness of contours, shapes, etc.

Thus, the designed process of machining the parts should, when implemented, ensure that the requirements for the normal operation of the assembled machine are met.

The metal cutting equipment currently available is characterized by a rapid expansion of the CNC application using micro processing techniques.

At this stage of mechanical engineering development, when designing technological processes, they strive for the possible complete mechanization and automation, the use of low-waste methods for producing machining blanks without removing a metal layer, and a decrease in the labor intensity of manufacturing parts.

On the basis of the above principles, during the course of the diploma project, I designed the technological process for processing the part.

Part Service Assignment

Part "Hull" (DB60.335.00.01) is the drive housing of the ship diesel regulator. The regulator, which is installed on the cover of the drive compartment, serves for automatic adjustment of the crankshaft rotation speed due to rotation of the oil pump of the regulator and movement of the slide valve from divergent weights.

This case is made by casting from cast iron C4 TU24040110092, in the amount of 90 pcs per year. Accuracy of casting 1113 GOST 2664585 shall be ensured.

Development of machining route

The main area of ​ ​ reducing the cost of auxiliary time is the use of NC machines. Efficiency of application of these machines is expressed in increased accuracy and homogeneity of dimensions and shape of processed workpieces, in increased efficiency of processing associated with reduction of share of auxiliary time, in reduced cost of workpieces, in increased efficiency of processing associated with reduction of share of auxiliary time, in reduced cost of processing associated with increase of productivity, in reduced requirements for qualification of machine tool. Complex, expensive to manufacture and labor-intensive adjustment of cams, stops, conductors in CNC systems is not required, which significantly reduces and accelerates adjustment.

Therefore, CNC machines are fundamentally new automation tools for small-scale and mass production of mechanical engineering, combining the performance and accuracy of automatic machines with the flexibility of universal equipment.

In multi-purpose machines, a new approach to the construction of a technological process is expressed. It provides various types of tools with a comprehensive treatment of parts without reinstallation or with a minimum number of them.

New Part Routing Process Plan

005. The first operation of manufacturing the part "Housing" (DB60.335.00.01) accepts the vertical-milling operation. It is necessary to provide a process base (plane) for further processing of the part.

010. Drilling and drilling operations are required to mill the remaining part flanges, stretch the main hole, drill, countersink, unfold, and thread the remaining holes.

Selection of process equipment

Based on the accepted processing route "Hull," we select the machine equipment for each operation. When selecting, consider:

- part release program;

- type of production;

- dimensions and arrangement of machined surfaces;

- requirements for accuracy and surface roughness;

- cost of machine tools.

The specifications of the selected machines shall meet the following requirements:

1. machine working area (height of centers, dimensions between centers, table dimensions, etc.) shall correspond to the dimensions of the machined part;

2. power, rigidity and kinematic capabilities of the machine should allow to operate in optimal cutting modes;

3. machine capacity must correspond to the specified program of parts release.

It is useful to use NC multi-operation machines when machining body parts. At the same time, the expediency of their use is as follows.

1. The Housing part has several planar surfaces, and a main hole with high accuracy requirements. There are also holes on three sides of the part. All this requires the use of a large number of tools in processing. In addition, the share of auxiliary time is reduced, the main (process) time is reduced.

2. Processing time due to the assignment of higher cutting modes, the use of cutting tools equipped with hard alloy non-rolling plates with mechanical attachment.

Use of multipurpose machine IS500PMF4 allows to exclude operations of preliminary marking of treated holes, and also allows to process all flat surfaces in 3 planes.

Thus, on the basis of the above, we accept:

- for vertical-milling operation - universal machine 6M13P;

- for multipurpose machining of IS500PMF4 machine