Swivel Cam Support - Part Manufacturing Technology Design

Contents

Introduction

1. General part

Service assignment of a part and conditions of its operation in an assembly unit

Part Material Characteristic

1.3 Structural Inspection of Part Drawing

1.4Parse Part Fabrication Specifications

1.5Assay the workability of a part design

1.5.1Quantity evaluation of workability of part design

1.5.2Qualification of processability

2. Process Part

Procurement Method

Procurement Selection Feasibility Study

Selection of bases and baselines

Routing and Process Design

Selection of process equipment

Selecting a Cutting Tool

2.6 Selection of measuring instruments

Calculation of machining allowances

Calculation and selection of cutting modes

2.9 Calculation and selection of time standards

3. Design Part

3.1. Design of special machine tool. Development of design diagram and power calculation of the accessory

3.2. Calculation of machine tool for accuracy

4. Organizational Part

4.1. Determination of the required quantity of machine equipment and its load factor

4.2. Determination of number of machine tools, auxiliary workers and ITR in the area

4.3. To Define a Parcel Area

5. Safety of life

5.1. Project Environmental Safety Engineering Justification

5.2. Production safety

5.2.1. Heating, exhaust, ventilation

5.2.2. Lighting

5.2.3. Calculation of artificial lighting in the workshop

5.2.4. Noise and vibration

5.2.5. Electrical safety

5.3. Fire safety

5.4. Emergency

5.5. Occupational Safety Instruction for the Worker

5.5.1. General Occupational Safety Requirements

6. Economic part

6.1. Calculation of economic effect from improvement of technological process of turning cam support manufacturing

6.1.1. Current Cost Calculation

6.1.2. Calculation of economic efficiency indicators

Conclusion

List of literature used

Introduction

Mechanical engineering is the most important industry. Its products - machines for various purposes are supplied to all branches of the national economy. The growth of industry, as well as the pace of re-equipment with their new technology and technology, largely depend on the level of development of engineering.

The state of mechanical engineering largely determines the development of other sectors of the national economy. Machines and mechanisms with worm-type parts are used in various fields of science and technology. These parts, based on high requirements for technical, economic and operational parameters of machines and mechanisms, should have high reliability, repairability, processability, minimum dimensions, convenience in operation. In many ways, these indicators are provided in the process of designing and manufacturing shafts.

The main tasks of mechanical engineering technology are the design of the entire complex of technological means that ensure the production of products of a given quality in a given amount and in a given time, as well as reducing the cost of production, improving quality, reducing the time spent on the production of the product, increasing the coefficient of material use, automation of technological processes.

The main tasks of mechanical engineering technology are: the use of automatic systems, adaptive control systems, GPS, the introduction of the latest technological equipment into production, the use of computers, the latest cutting, measuring tools and equipment.

Technological preparation of production is a decisive stage in the cycle of production of machines and mechanisms. One of the stages of technological preparation of production consists in the development of a technological process for the manufacture of machine parts.

The graduation work is devoted to the development of the gear manufacturing process. Such parts are made in large volumes and are used in various cars and mechanisms, machines, gearboxes, etc.

The main tasks that need to be solved when designing new technological processes are to increase the accuracy and quality of processing, stability and durability of parts and maximize the reduction of the cost of processing by improving technological processes. In the course project, these tasks will be solved by analyzing the design process, identifying its main shortcomings and methods for solving them.

The purpose of the graduation work is to consolidate the knowledge gained at lectures, practical exercises and acquire the skills to fulfill the main stages of the development of the technological process and independently search for the most optimal technical solutions based on the latest achievements of science and technology.

Part Constructability Analysis

One of the main tasks solved in the process of designing the technological processes of assembly works and preparation of production is to evaluate and ensure the processability of the product.

The support of the KamAZ car swivel fist is a complex and responsible unit of the car. The quality of its assembly and further work depends on the safety of traffic on the road.

The product suspension consists of a large number of units and parts.

In order to allow parallel assembly, the product is divided into separate parts.

The design and workability of the product requires the assembly of parts and assemblies by a method of complete interchangeability, without additional mechanical fitting. In this case, intermediate assemblies and disassembles are excluded. The design does not have ladder dimension chains. In the design of the units there are no parts of low strength and cruelty and parts of easily deformable materials, which eliminates the possibility of their deformation during assembly.

Assembly design provides free access of tools, controls and working bodies of technical devices to assembly places.

All parts and assemblies are selected with the required wear characteristics, which provide the specified service life of the intermediate shaft, and, accordingly, the entire gearbox.

Assembly units included in the unit are kinematically closed, that is, during transportation from position to position they do not fall into component parts.

The workability of the design depends on how the parts in the assembly are connected.

Workability of the part - a set of properties and indicators,

determining the possibility of its manufacture with the least cost when achieving the accuracy requirements specified in the drawing. The workability of the part can be pre-evaluated by comparing the part with the available analogues. The final decision on the processability of the part can be made after the development of the technical and economic calculations.

The support of the swivel cam is a basic part. When testing for processability of the shaft structure, it is necessary to make an assessment according to qualitative and quantitative indicators. Requirements to workability of part design are given in GOST 14.20473. They are:

The part design must consist of standard and unified features or be standard;

parts shall be manufactured from standard and unified workpieces produced in a rational manner;

dimensions and surfaces of the part shall have an optimal degree of accuracy and roughness, respectively;

physicochemical and mechanical actions of the material, stiffness of the part, its shape and dimensions must comply with the requirements of the manufacturing technology;

parameters of the base surface of the part (accuracy, roughness) should ensure accuracy of installation, processing and control;

part design shall provide the possibility of application of standard and standard technological processes of its manufacturing.

When evaluating the workability of a part design, it is necessary to:

Calculate parameters of constructability;

Develop recommendations for improving technicality;

ensure the workability of the part design by making changes.

There are two general estimates of processability: 1) qualitative assessment of processability, 2) quantitative assessment of processability.

Qualitative evaluation of processability

Advantages:

1. The part has easy-to-configure machining surfaces on a milling machine and does not have hard-to-reach machining locations and surfaces;

2. The diameter differences in most surfaces are small, which allows you to obtain a workpiece close to the shape of the finished part;

3. Symmetrical about the axis;

4. The part allows you to process several surfaces in one installation (on an NC machine);

5. The design of the part provides free supply and withdrawal of the tool and LPG to and from the cutting zone, and removal of chips;

6. The part has reliable installation bases, i.e. the principle of constancy and alignment of bases is observed;

7. The design of the part is quite rigid;

8. Tolerances on the dimensions of precise surfaces do not complicate production technology.

Disadvantages: The part is not a body of revolution.

Thus, having carried out calculations for processability and having studied the external features of the shaft structure, having considered qualitative and quantitative characteristics, we conclude that the design of the rotary cam support is technological, since it meets most technological requirements.

Process Part

2.1 Definition of type of blanks and methods of their manufacture

Various methods are used in the manufacture of shaft blanks. The best method is the one by which the blanks are most economical, provide the lowest allowance for machining and have the required quality. The technology of low-waste production of blanks contributes to reduction of metal rolling, improvement of quality and productivity in their manufacture. These methods are widely used in large-scale and mass production.

The selection of the procurement method is largely determined by the size of the program task and the technological capabilities of the procurement workshops of the enterprise. The use of progressive initial blanks with a small allowance for mechanical processing in all cases reduces the labor intensity and cost of the latter, however, the additional costs of equipping the procurement workshops pay off only with sufficient size of the program task.

However, it should be borne in mind that the cost of the product is determined by the sum of the costs of the original workpiece and its machining, so it is ultimately important to reduce the entire amount rather than one of its components. Taking into account the additional savings in machining of progressive raw materials with a small allowance, the limits of economic application of these methods will shift towards a decrease in the cost of the whole product.

Creating part designs that allow machining to be replaced by stamping or planting always leads to a significant reduction in labor and metal consumption. In cold-seating of initial workpieces of parts, for example bolts, metal wastes are 25 times less than in metal-cutting machines. For critical parts at present, raw materials obtained by hot stamping and casting are often used.

The part is a shaft. Therefore, the shaft blank can be obtained by stamping on the HPCS to form separate surfaces.

2.5 Selection of process equipment

When selecting equipment, consider the following factors:

-the size of the working area of the machine, which must correspond to the dimensions of the machined part or several machined parts ,

- possibility to achieve the required accuracy and surface roughness during processing,

-conformance of power, rigidity and kinematic data of the equipment to advantageous operation modes,

- provision of required performance in accordance with the specified program of parts release,

- compliance of equipment with safety and industrial sanitation requirements,

-conformance of the equipment to the specified program according to the criterion of part manufacturing cost.

When selecting equipment in the current production conditions, you have to focus on the equipment available in the workshop and it is mandatory to take into account the degree of actual load of individual groups.

The following machines specified in Table 2.1 shall be used to manufacture the differential satellite.

2.6 Cutting Tool Selection

The selection of the cutting tool must be oriented to the standard tool. To perform individual operations, especially in large-scale production and mass production, it is advisable to use a special tool.

The cutting tool must have a high cutting ability, capable of high cutting modes, high dimensional resistance, ensuring the stability of the processing process, be quickly and conveniently replaced, adjusted and lifted during processing, stably form transportable chips and withdraw it without disrupting the normal operation of the equipment.

For the cutting part of the tool, hard alloys and fast-cutting steels of new grades, for example, P6M5 instead of P18, are widely used.

Cutting tool costs are included as a separate item in the cost of production.

To make the part, we use the following tool: cutters from SANDVIK COROMANT, bore heads; grinding wheel for grinding end face, drill for machining holes.

2.7 Selection of measuring instruments

The selection of measuring means is made in accordance with the accuracy characteristics of the tool, the accuracy of the size performed, the type of the measured surface, as well as the scale of the release of parts. In large-scale production, automatic controls are used. It is necessary to strive for the time spent on control to be overlapped by machine time.

In our particular case, to control the accuracy of the part elements, we will use as universal measuring instruments: micrometer MCC 175200 GOST 650790, caliper ShTSI 0-125-0.05 GOST 16689, micrometer MCC 75100 GOST 650790, caliper ShTSKI1250.02 GOST 16689, SKTzRZU s-0-S0, and bar-S0-Ss

Design Part

3.2. Development of calculation scheme and determination of fixing force.

The required machining accuracy is ensured by a certain position of the workpiece relative to the cutting tool. Under the basis of machining of workpieces on machines, it is considered to give the workpiece the required position relative to the machine elements that determine the trajectories of the feeding of the processing element .

To completely eliminate the mobility of a solid in space, you must deprive it of six degrees of freedom. This is achieved by overlapping the links. By links are meant the positional constraints imposed on the movements of the points of the body in question. In the devices, each of the links is implemented as a point of contact of the base surface with the support element. The location of the contact points on the base surfaces of the workpiece is a basing scheme.

The following basing scheme can be used for short cylindrical blanks. The main base in this case is the inner cylindrical surface of the workpiece, on which two reference points are located. They deprive the billet of 2 degrees of freedom (movements along two axes). Links located on the end surface of the workpiece deprive it of 3 degrees of freedom (movement along the axis and rotation relative to the other two axes).

Conclusion

During the graduation work, options for constructing a technological process were studied, taking into account the production program, the nature of the products, as well as the technical and economic conditions for the implementation of the production process. The developed technological process is mainly differentiated, i.e. divided into separate operations, which are assigned to individual machines. When using machines, universal devices, a universal cutting tool, a measuring tool were used to ensure the interchangeability of processed parts.

Content and sequence of process transitions, cutting modes are determined. Process Improvement

The use of CNC machines significantly reduces the auxiliary time for processing the part by reducing the auxiliary time for changing the tool, numerous reinstallations of the part and reducing the main time due to the possibility of increasing cutting modes.

The design part of the project contains the design issues of the fixture for all operations.

In the section, safety and environmental friendliness of the project, the following issues are considered: occupational safety during machining of materials by cutting; noise pollution of the environment, characteristics of noise sources in the designed workshop, noise rationing in the enterprise and in the residential area; ensuring stability of the designed area operation in emergency conditions.

When planning and organizing production, the following were determined: the form of organization of technological processes, the production structure of the site, the composition of the site. Based on the comparison, the most preferred layout of the workshop was chosen.