Mill Design

Contents

Introduction

I. Process part

1.1 Tool material and its properties

1.2 Basic version of part processing process

1.3 Proposed Process Version

1.4 Definition of production type

1.5 Selection of procurement type and method

1.6 Equipment Selection

1.7 Calculation and assignment of processing modes

II. Design part

2. Keying Design

III. Economic part

Conclusion

List of used literature

Application

Summary

The topic of the course work is the development of the technological process for the manufacture of a shaped cutter for processing the Wormyak part (drawing DB 18180.00.31).

The course project consists of technological and design sections.

The production type and procurement method are selected in the process section. A routing technology for manufacturing this tool is being developed, with an analysis of ensuring the requirements of the drawing, the quality of the surface layer and the functional purpose of the part.

The selection of cutting tools, technological tooling used in the process under development, as well as calculation and assignment of processing modes are performed.

The design section discusses the second-order tool and the auxiliary tool.

Drawings of operational sketches of machining and process documentation shall be executed.

Introduction

Metal cutting tools are one of the main tools of production, and the design of metal cutting tools is the main one of the disciplines in the training of engineers in the specialty 151003 "Instrumental systems of machine-building industries."

The quality, reliability and operability of cutting tools used in mechanical engineering largely depend on the quality and accuracy of the obtained parts, the performance and efficiency of the processing process.

When designing cutting tools, you need knowledge of the theoretical foundations of the design and calculation of tools obtained during the study of the discipline "Cutting Tool Technology."

The development of technological processes for the production of metal cutting tools is based on the general principles and laws of machine building technology studied in the courses "Fundamentals of Machine Building Technology" and "Cutting Tool Technology." At the same time, in the production technology of metal cutting tools, there are specific features associated with the use of expensive and scarce tool materials, with the treatment of workpieces of high hardness and strength, with the treatment of complex surfaces, with high requirements for dimensional accuracy, geometric shape and surface roughness, with especially high requirements for the physical and mechanical properties of the material of the finished metal cutting tool.

The main requirements for cutting tools are determined by their service purpose: ensuring the operable state of the tool, that is, the state in which it is able to perform cutting processing, obtaining the required shape, size and quality of the treated surface of the blanks, the highest efficiency of the processing process with the lowest costs (economic efficiency); in addition, it is necessary to fulfill the following additional requirements: possibility and processability of manufacturing and restoration of cutting properties during operation, saving or minimum consumption of scarce materials. Cutting machining capabilities are provided by the material of the cutting part of the tool, its physical and mechanical properties, if necessary - thermal treatment, as well as geometric parameters. Obtaining the required shape, dimensions and quality of the machined surfaces of the part is ensured by the design of the tool, the shape of its cutting edges. In this regard, when designing a metal cutting tool, its design should provide for the possibility and processability of its restoration (sharpening and rework) or re-installation.

The performance of the processing process depends on the cutting modes (speed, depth, feed), and therefore on the material of the cutting part of the tool, its design, the geometric parameters of the tool blades, the method of removing heat from the cutting edges, and other structural parameters and processing conditions.

Process Part

1.1 Tool material and its properties

The cutter body is made of 40X steel GOST 454371. Napkin plates are made of T15K6 alloy GOST 2540490.

Mechanical properties of 40X steel in delivery state:

- strength at stretching σв = 981 MPas;

- hardness HRC = 52. [1, page 329]

in hardened state:

- strength at stretching σв = 2410 MPas;

Chemical composition of this steel :

- carbon (C) - 0.36... 0.44%;

- chromium (Cr) - 0.8... 1.1%;

- nickel (N) - up to 0.3%;

- silicon (Si) - 0.17... 0.37%;

- copper (Cu) - up to 0.3%;

The 40X steel has high hardness, wear resistance, redness resistance, strength and viscosity, which ensures the high operability of the tool made from them, its ability to withstand large power and thermal loads. In tungsten molybdenum steels, part of tungsten is replaced by molybdenum, which somewhat reduces their redness. Grade 40X steel is used for the manufacture of all types of cutting tools designed for the treatment of carbonaceous and medium-alloyed structural steels, as well as tooth-cutting and threaded tools.

Some technological properties of 40X steel:

Grindability:

The hardness of carbides in tool steels is close to the hardness of abrasive materials, which impairs grinding performance.

During grinding, at significant residual stresses and a large amount of residual austenite (more than 10%), grinding cracks are formed. The size of the carbides and their distribution determine the quality of the ground surface (large carbides can be painted). A significant increase in grinding temperature can lead to the tempering of martensite, a decrease in hardness and wear resistance.

Weldability:

Steel is poorly welded and practically not used for welded structures.

Equipment selection

1. Operation Number and Name: Procurement Operation 005

Equipment used: mod belt machine. WPB420A

Technical characteristics of the machine:

Material Dimensions:

Round material..................................................... ø420mm

4-sided material................................................. 420x420mm

Sizes of a tape cloth................................... 6280kh41kh1,3mm

Drive power:

Saw belt motor.............................................. 5.5kW

Hydraulics engine.................................................. 1, 5kW

Giving engine Sozh....................................................0.12 kW

Clean the engine. brushes............................................... 0.18 kW

Overall dimensions....................................... 2310kh3060kh2150mm

Cutting speed.................................................... 15-105m/min

Material Capture Progress (2poz).............................................................................................................................................................................................................................................................................................................................

Weight................................................................................. 2500 kg

2. Operation Number and Name: NC Lattice Operation 020

Equipment used: mod lathe. SK 3665 c NC

Technical characteristics of the machine:

CNC System..................................................... Siemens 820C

Diameter of machined part above the frame, mm...................... 360

Travel along axis X, mm...................................................................... 220

Z-axis travel, mm...................................................................... 660

The greatest length of processing of a detail, mm...................................650

Spindle cone.............................................................................. A2-6

Cartridge diameter, mm..................................................................... 200

Spindle cone............................................................................. M6

Bore diameter in spindle, mm.....................................................................................................................................................................

Spindle speed limits Min/Max, RPM........ 200/3000

Engine power, kW......................................................... 5.5

Rapid X/Z movement, m/min................................ 3,8/7,7

Repeatability accuracy of the turret, mm..................... 0.007

Tool change time, sec. 1.5

Cutter cross-section, mm. 20x20

Diameter pintles of the back grandma, mm..............................................60

Tailstock Pinol Stroke, mm.................................................................................................................................................................................................

Pinoli cone of the tailstock............................................... Morse 4

Machine weight, kg...................................................................... 1810

Surface roughness.................................................... Ra 1.6

3. Operation Number and Name: Operation 025 Milling

Equipment used: Vertical machining center mod.500VB

Technical characteristics of the machine:

Table Settings:

Plate diameter, mm.......................................................... 200

Diameter of central hole, mm................................. 60H7

Width of central slot, mm...................................... 12H11

Number of T-grooves...................................................... 8

Maximum distance from spindle end to table, mm............. 450

The largest mass of the processed detail, kg............................300

Spindle:

Spindle cone (DIN 69871)................................................. SK 40

Spindle RPM Limits............................ 0-12000

Rated spindle torque, Nm........................ 76

Moves:

Greatest Axially Displacements:

- longitudinal movement of X-sled (X), mm........................... 900

- transverse movement of Y-sled (Y), mm............................ 500

- vertical movement of spindle head (W), mm............ 450

- turn of the shpindelny grandma (B), hail....................................±30

Operating feed range by coordinates, mm/min................. 1-15000

Turn of table (A), deg................................................................................................. 360

X, Y, W, mm positioning accuracy................... 0.01

Accelerated travel along axes X, Y, W, m/min.......................... 15... 30

Highest speed of rotation along axis B, RPM.............................................................................................................................................................................................................................................................................

Rated rotation torque of axis B, Nm.................. 2940

Tool Store:

Tool magazine capacity, pcs................................... 16

Tool change time, sec. 12

The largest diameter of the tool installed in the magazine [without skipping the sockets], mm................................................................................................................................................................................................................................................................................................................................................................................................................................................... [... [... [[... [... [125] [80]

The longest length of tool installed in the machine spindle is mm............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 250

Maximum weight of mandrel installed in the magazine, kg......... 10

Characteristics of electrical equipment:

Main drive motor power, kW............................. 22.5

Rated RPM.................................. 2800

Maximum RPM............................... 12000

Total power of electric motors installed on the machine, kW............................................................................................................................................................................................................................................................................................................................................................................................................................................... 49

CNC System.................................................. SIEMENS 840D

Other characteristics:

Overall dimensions, mm.................................. 2350x3165x3000

The total area of the machine in the plan, sq.m., not more than (taking into account the open doors of the cabinet)................................................................................................................................................................................................................................................................................................................................................................................................................ 15.7

Weight, kg........................................................................ 7000

4. Transaction Number and Name: Operation 030 Long

Equipment used: Horizontal extension semi-automatic mode.7B56

Technical characteristics of the machine:

Nominal traction force, Nanometer...............................................200

The greatest length of a sled, mm.............................................1600

Support Plate Work Surface Size:

length, mm.................................................................. 450

width, mm................................................................ 450

Hole Diameter:

in the base plate for the chuck, mm....................................... 200

in the faceplate, mm...............................................................160

Working stroke speed, m/min............................. 1.5-13

Recommended retraction speed, m/min......... 20-25

Electric motor power, kW................................................. 30

Overall dimensions:

length, mm.................................................................... 7200

width, mm............................................................... 2135

height, mm................................................................ 1910

Weight, kg........................................................................ 7450

5. Operation Number and Name: Operation 040 Grinding

Equipment used: in-grinding machine mod. 3K227B

Technical characteristics of the machine:

Largest diameter:

of the workpiece to be installed, mm....................................... 400

of the workpiece to be installed in the casing, mm........................... 250

Longest length:

of the workpiece to be installed, mm....................................... 125

at largest diameter of grinding hole, mm......... 125

The greatest course of a table, mm....................................................450

Greatest adjustment cross movement:

grinding head:

forward, mm................................................................. 50

back, mm.............................................................. 10

workpieces:

forward, mm........................................................ 120

back, mm...............................................................30

Maximum billet head rotation angle, °.............................. 45

Largest diameter and height of grinding wheel, mm............ 80x50

Spindle RPM:

in-grinding................................. 9000, 12000,18000

workpiece head........................................................ 60-120

end grinding fixture.............................. 5600

Drive motor power

grinding wheel, kW................................................................. 4

Overall dimensions, mm

length........................................................................2815

width................................................................. 1900

height......................................................................1750

Weight, kg.......................................................................... 4300

6. Operation Number and Name: Operation 045 Grinding

Equipment used: flat grinding machine. 3E711V-1

Technical characteristics of the machine:

Table working surface dimensions, mm:

length...................................................................... 400

width........................................................................ 200

Largest dimensions of workpieces, mm:

length...................................................................... 400

width........................................................................200

height........................................................................ 320

Weight of workpieces, kg, not more than................................ 150

Maximum distance from spindle axis to table mirror, mm......... 445

Largest movement of table and grinding head, mm:

longitudinal.................................................................. 490

transverse.............................................................. 255

Grinding wheel dimensions, mm:

outer diameter........................................................250

height..................................................................... 40

internal diameter.......................................................76

Grinding wheel spindle speed, rpm............. 35

Table longitudinal displacement speed, m/min....................... 2-35

Main motor power, kW........................ 4

Overall dimensions, mm:

length................................................................... 2380

width................................................................. 1955

height................................................................. 1915

Weight, kg...................................................................... 3380

7. Operation Number and Name: Operation 050 Grinding

Equipment used: round grinding machine mod.8G622

Technical characteristics of the machine:

Maximum dimensions of the billet to be installed, mm:

diameter..................................................................... 280

length.................................................................. 700

Recommended grinding diameter, mm:

external........................................................ 20-280

internal.......................................................... 30-100

Largest grinding length, mm:

external............................................................... 130

internal.............................................................. 125

Height of centers above table, mm............................................. 160

Maximum longitudinal displacement of the table, mm....................... 700

Table rotation angle, °:

clockwise............................................................ 1

counterclockwise.................................................. 1

Table automatic displacement speed, m/min.............. 0.05-5

Spindle RPM.................................. 50620

The largest dimensions of the grinding wheel, mm:

outer diameter....................................................750

height....................................................................130

Grinding wheel speed, rpm during grinding:

external.............................................................. 1250

internal........................................................... 16000

Overall dimensions, mm:

length....................................................................3754

width............................................................. 4675

height...................................................................2245

Weight, kg.................................................................... 8110

8. Operation Number and Name: Operation 055 Refinement

Equipment used: sharpener mod.3M642

Technical characteristics of the machine

The largest dimensions of the workpiece to be processed,

installed in centers, mm:

diameter.....................................................................250

length........................................................................500

Table working surface dimensions, mm:

length................................................................... 140

width.....................................................................800

Longitudinal displacement of table, mm........................................ 400

Table rotation angle in horizontal plane, °................... ± 45

Grinding head movement, mm:

vertical............................................................ 250

cross............................................................... 230

Grinding wheel diameter, mm........................................ 200

Spindle RPM.............................. 2240-6300

Automatic longitudinal speed

table movements, m/min................................................ 0.2-8

Power of the PGD electric motor, kW....................................1.5

Overall dimensions, mm:

length....................................................................1650

width.................................................................. 1470

height....................................................................1625

Weight, kg........................................................................ 1400

Conclusion

During this course project, the technological process for the manufacture of the tool "Shaped Cutter" was developed. The development of routing technology for the manufacture of this tool and the development of operational technology and sketch maps was also carried out.

In the graphic part of the work, operational sketches of machining of the Profiled Cutter tool (2 sheets of A1 format) were developed, as well as a second-order tool (1 sheet of A1 format) and an auxiliary tool (1 sheet of A2 format).

Having developed a course project in the discipline "Cutting tool technology," we learned to develop the entire set of technological documentation, calculate the cost of the designed tool.