毕业设计CA6140车床法兰盘加工工艺及钻孔夹具设计附件

1、毕业设计附件题目：CA6140车床法兰盘加工工艺及钻孔夹具设计姓 名： 董震泽 学 号： 2012090371201 学 院： 机电学院 专 业： 机械工程及其自动化 指 导 教 师： 付文宇 协助指导教师： 2016年5月28日毕业设计附件清单一、毕业设计任务书二、毕业设计开题报告三、毕业设计外文原文及译文四、毕业设计图纸北京联合大学毕业设计（论文）任务书题目： CA6140车床法兰盘加工工艺及夹具设计 专业： 机械工程及自动化 指导教师： 付文宇 学院： 机电学院 学号： 2012090371201 班级： 1201B 姓名： 董震泽 一、主要内容和基本要求CA6140车床法兰盘的加工工艺

2、及钻孔夹具设计的主要任务是： （1）搜集相关绘图资料并绘制出零件的加工工件图与Solid Works零件三维图； （2）根据法兰盘相应的形状要求、尺寸精度要求、表面粗糙度要求，制定出符合零件使用要求的加工工艺路线； （3）齿轮架的钻孔夹具设计（绘制装配图及零件图）。研究目的：本次法兰盘机械制造工艺学课程设计的目的是旨在熟悉机械制造工艺学课程，需要我们综合地运用所学过的专业知识，针对实际零件进行机械加工工艺规程制定及专用机床夹具设计，使我具备了制定机械加工工艺规程及设计专用机床夹具的能力，为以后所从事的机械工程工作打下基础。就我个人方面而言，希望通过这次设计在各方面有不小的提高，能够基本上掌握零

3、件机械加工工艺规程的设计。并学会了使用和查阅各种设计资料、手册、和国家标准等。最重要的是综合运用所学理论知识，解决现代实际工艺设计问题，巩固和加深了所学到的东西。并在设计过程中，学习更多在课堂上没有学到的东西。在这个过程中，将使我对所学的知识有了进一步的了解，也了解了一些零件设计工具书的用途，同时，也将锻炼了协同工作能力。在以后的学习生活中，我将继续刻苦努力，不断提高自己。二、主要参考资料1李大磊，王栋主编 机械制造工艺学。北京：机械工业出版社，2014年。2孙建东，李春光主编 机械设计基础。北京：清华大学出版社，2008年。3张建成，方新主编 数控机床与编程。北京：高等教育出版社，2013年

4、第二版。4湛迪强主编 Solid Works 2014快速入门、进阶与精通。北京：电子工业出版社，2014年4月。5张忠将主编 Solid Works 2014机械设计完全实例教程。北京：机械工业出版社，2015年1月。6王博平主编互换性与测量技术基础。北京：机械工业出版社，2013年9月第四版。7张世昌，李旦，高航主编 机械制造技术基础。北京：高等教育出版社，2007年5月第二版。8陈宏钧主编实用机械加工工艺手册(第3版) 。北京：机械工业出版社， 2009年3月。三、进度要求时间工作内容1-2周根据零件图绘制三维零件图3-5周通过力学计算设计工序以及工艺的流程6-8周设计法兰盘的专用夹具9

5、-13周检查问题，查漏补缺，最后完成毕业设计论文，准备毕业答辩指 导 教 师： （签字）专业负责人系主任： （签字）北京联合大学毕业设计开题报告题目： CA6140车床法兰盘加工工艺及夹具设计 专业： 机械工程及自动化 指导教师： 付文宇 学院： 机电学院 学号： 2012090371201 班级： 1201B 姓名： 董震泽 一、课题任务与目的CA6140车床法兰盘的加工工艺及钻孔夹具设计的主要任务是： （1）搜集相关绘图资料并绘制出零件的加工工件图与Solid Works零件三维图； （2）根据法兰盘相应的形状要求、尺寸精度要求、表面粗糙度要求，制定出符合零件使用要求的加工工艺路线； （3

6、）齿轮架的钻孔夹具设计（绘制装配图及零件图）。研究目的：本次法兰盘机械制造工艺学课程设计的目的是旨在熟悉机械制造工艺学课程，需要我们综合地运用所学过的专业知识，针对实际零件进行机械加工工艺规程制定及专用机床夹具设计，使我具备了制定机械加工工艺规程及设计专用机床夹具的能力，为以后所从事的机械工程工作打下基础。就我个人方面而言，希望通过这次设计在各方面有不小的提高，能够基本上掌握零件机械加工工艺规程的设计。并学会了使用和查阅各种设计资料、手册、和国家标准等。最重要的是综合运用所学理论知识，解决现代实际工艺设计问题，巩固和加深了所学到的东西。并在设计过程中，学习更多在课堂上没有学到的东西。在这个过程

7、中，将使我对所学的知识有了进一步的了解，也了解了一些零件设计工具书的用途，同时，也将锻炼了协同工作能力。在以后的学习生活中，我将继续刻苦努力，不断提高自己。二、调研资料情况法兰盘就是用于连接管道、管件或器材的零件，也有用于两个设备之间的连接，如减速机法兰盘。法兰盘连接是由法兰盘、垫片及螺栓三者相互连接为一组的可拆卸密封结构，先各自固定在一个法兰盘上，再垫上法兰垫，用螺栓紧固在一起，这样就完成了法兰盘连接。法兰盘主要用于连接紧固管道、管件等，并保持管道管件的密封性能；法兰盘可拆卸，便于拆开检查管道情况毕业设计所要求的CA6140卧式车床上的法兰盘, 为盘类零件,存在于卧式车床上。车床的变速箱固定

8、在主轴箱上，依靠法兰盘定心。法兰盘内孔与主轴的中间轴承外圆相配，外圆与变速箱体孔相配，为了保证主轴之上的三个轴承孔同心，使齿轮正确啮合，从而保障了机床的精准度。三、初步设计方法与实施方案初步设计方法：（1）构思CA6140车床法兰盘的三维造型；（2）法兰盘的加工工艺路线设计；（3）正确填写机械加工工艺过程卡和工序卡；（4）针对零件要求进行钻孔夹具的设计。实施方案：（1）绘制法兰盘三维零件图；（2）合理规划工艺流程；（3）进行夹具定位计算与力学分析；（4）绘制夹具装配图与三维爆炸图。四、预期结果（1）法兰盘三维造型； （2）法兰盘加工工艺流程 ；（3）法兰盘钻孔工具夹具的设计；（4）法兰盘钻孔工

9、具夹具装配图，零件图；（5）提交毕业论文一份。 五、进度计划时间工作内容1-2周根据零件图绘制三维零件图3-5周通过力学计算设计工序以及工艺的流程6-8周设计法兰盘的专用夹具9-13周检查问题，查漏补缺，最后完成毕业设计论文，准备毕业答辩北京联合大学毕业设计（论文）外文原文及译文题目： CA6140车床法兰盘加工工艺及夹具设计 专业： 机械工程及自动化 指导教师： 付文宇 学院： 机电学院 学号： 2012090371201 班级： 1201B 姓名： 董震泽 一、外文原文Research on selecting the optimal design of antivibrational l

10、athe tool using computer simulationABSTRACT: Computer simulation of machining processes can save cost, time, and lead to reach an effective predictive capability. In this paper, by using computer simulation, damping capability of the lathe tools under static and vibrational analysis at different too

11、l overhang conditions is studied. A novel predictive model of the cutting tool is developed, in which damping capability of the tool is improved by using composite material with high damping capability. Epoxy granites with normal, rigid, and plastic structures were used as composite materials in mod

12、ified model of tool holder. The all-metal model, model with holes in tool holder and the modified model filled up with the composite material, with the same geometryand dimensions are used.Keywords: Lathe tool, epoxy granite, tool life, overhang, vibration, frequency, damping capacityIntroductionOne

13、 of the methods of the machining process is turning, and in some cases finish cutting can complete a technological process of manufacturing of products. The aim in the turning process is to obtain the right quality of machined products by removing high volumes of material. 1,2 However, this success

14、in cutting process depends on the following factors: machine rigidity, fixing rigidity, tool rigidity, and good vibration damping capability. 3 During metal cutting, some problems occur such as deformation, chip formation, friction, wear of the cutting tool, and heat generation. Thus, efficiency and

15、 cost of machining, and quality of the processed surface of the product depend on static and dynamic characteristics of the closed loop system(the machinecutting processthe tool). 4Metal cutting is a dynamic process and during cutting vibrations occur, which can be divided into forced and chatter vi

16、brations. The effect of forced vibrations generated during a regular cutting process is small. It is difficult to avoid them completely due to the compliance of the machining system. 13 However, chatter vibrations negatively affect the stability of the system, which reduce the precision of the part

17、and quality of surface. 46 Cutting forces depend on the tool geometry, material properties, feed rate, and cut-ting speed. In an unstable process, the amplitude of vibrations may grow exponentially until they become as large as chip thickness. This unstable vibration creates large cutting forces, wh

18、ich can damage the machine, cutting tool, and the work piece; furthermore, it causes tool wear, tool breakage, unacceptable surface finish, and dimensional errors. Besides, vibration during cutting process causes noise that tires workers and reduces stability of the cutting tool leading to poor surf

19、ace finish. From the literature review of vibration induced by a machining process, clearly the majority of the work on vibration creation attempt to reduce vibration during a machining process owing to what productivity and machining accuracy decrease. Vela et al. 8 investigated the compliance betw

20、een the work piece and cutting tool in turning process and a multiple degree of freedom model for chatter prediction was proposed. Sortino et al. experimentally studied the influence of the material, geometry of the tool, and workpiece on process stability in internal finish turning. They founded th

21、at the ratio of boring bar overhang to bar external diameter is the main factor that affect the stability of the process. Tayloret. analytically presented the effect of tools edge condition and the relief angle on process damping inmachining process. They suggested that the process damping effect du

22、e to an edge radius reduces as the tool relief angle reduces. Mahdavinejad 11 analyzed the instability of the machining process by dynamic model of turning machine, consisted of tools structure, using finite element method. Kopac et al. 12 conducted an investigation on identification of the dynamic

23、instability in hard turning process based on the determination of natural frequencies of machine tool components on different positions in work area and position of resonance frequency determination.The results showed that if cutting instability and push-off effect do not have dominant influence it

24、is possible to achieve minimum roughnes on machined surface. An investigation carried out by Yusuke et al. on inprocessiden tification of process damping coefficient in turning process reported that process damping is effective when tool wear reaches a level that covers the vibration wave left on th

25、e surface.Rama and Srinivas 14 proposed a realistic analytical stability model of regenerative chatter in orthogonal turning operation. They reported that tool overhang and work cross-section are the main factors that affect the stability. Abuthakeer et al. 15 used a passive damping pad of viscoelas

26、tic material of neoprene in their investigation to predict and suppress the vibration level of cutting tool in Computer numerical control (CNC) lathe. Ramesh and Alwarsamy 16 suggested the impact dampers with different materials, such ascopper, cast iron, phosphor, structured steel, aluminum, brass,

27、 bronze, and gun metal, in boring tools in order to improve stiffness and damping capability of the tool and suppress the chatter. Arsecularatne et al. 17 used tool life to investigate the dominant wear mechanism of the cutting tools made of tungsten carbide (WC), Poly-crystalline cubic boron nitrid

28、e (PCBN), and Poly-crystalline diamond (PCD). Devin and Osadchii 18 proposed a new tool design with an increased vibration damping ability, whichincludes special elements made of damping materials. They investigated influence of damping properties of the proposed model on the Cubic boron nitride (cB

29、N) tool life, vibration amplitude, and machined surface roughness. Kanase and Jadhav 19 presented a passive vibration damping to absorb the vibrations in boring process. They also concluded that impact damping has improved the surface finish in boring operation. So to ensure precise and efficient ma

30、chining process, avoidance of vibrations is crucial. In modern manufacturing industry, cutting tool is the basic element of a technological process.Fundamental understanding of cutting tool behavior during machining is essential to determine tool life. During turning operation, cutting tool might fa

31、ce a hard spot on the metal surface and begin to oscillate, which causes a vibration of the cutting tool relative to the workpiece. As a result it may change many factors such as cutting force, thickness of the cut-off layer, and size and character of operating loads. It is essential while cutting o

32、f metals in microscales. The complexity of the machining process (very high temperatures, strains, and strain rates) and lack of suitable data impede to provide an adequate relation-ship between tool life and cutting conditions, tool geometrical parameters, and work and tool material properties. 202

33、2 However, cutting efficiency and tool life in high-speed machining of difficult-to-cut materials can be improved using new materials and newtechnology such as tool coatings and changing the machining conditions. 23,24 Thus, the key factor is the choice of the most effective design of cuttingtool. M

34、oreover, in advanced machining processes combined tool is usually used. The aim of vibration reduction is to increase the dynamic stiffness of the machining system or changing its main natural frequency or feedback-controlled actuators. 9 In order to reduce vibration in cutting process, there are th

35、ree methods, which are widely used: using the vibration damper, applying special coating on a cutting insert, and using tool holder made of material with high damping capability. 18 The precision of machine tools is directly related to the materials used in their construction. These materials in the

36、 tools construction dissipate the energy and by this way they reduce vibration, and we can achieve the required accuracy. 21,23 Therefore, materials, used in machine tools structure, must have high values of yield strength, elastic modulus, and also high vibrations damping capacity and reduced therm

37、al expansion coefficient. An extensive use of composite materials due to their higher specific properties of strength and stiffness in comparison with metals offers interestingopportunities for new product design. They have different chemical compounds but possess also a number of similar parameters

38、. These materials consist of a filling agent, or reinforcing particles, and filler. Reinforcing elements can have various orientations. 21One of such materials is epoxygranite, which is a combination of epoxy and granite. Recent investigations have pointed out the use of epoxygranite, replacing cast

39、 iron and granite for building machine basements, because of its high elastic modulus andmechanical resistance per unit weight and workability. Besides, products made of epoxygranite have better vibration damping capacity in comparison with steel and cast iron, which has been investigated by Antonio

40、 and Flam´nio 25 ; where samples of gray cast iron and epoxygranite were machined with the same geometry and dimensions. The result showed that the logarithmic decrement values of the epoxygranite samples are almost 3 times higher than those of cast iron, which indicates better damping effect o

41、f epoxygranite in comparison with gray cast iron, for the same volume of material. The study carried out by Selvakumar and Mohanram 26 on specimens modeled and manufactured with cast iron,steel, and epoxygranite materials showed that vibration is dampened out faster by epoxygranite in comparison wit

42、h steel and cast iron structures. Hence using epoxygranite in the cutting tools structure makes a possibility to improve damping capacity and tool life, and, therefore, increase machining accuracy class, which make epoxygranite more preferable material for precision machine tool structures.Experimen

43、tal studies are usually expensive and time consuming. Besides, their results are valid only for the experimental conditions and depend on the accuracy of calibration of the experimental equipment and apparatus used. The application of computer simulation of machining processes has grown in the last

44、years, because it potentially saves time and cost,which leads to reach an effective predictive capability. Thus, an alternative approach to study the machining processes is computer simulation. In this paper SolidWorks Simulation is used to perform the analysis. Therefore, the purpose of this work i

45、s to find the optimal design of the lathe tools filled up with composite material (epoxygranite) in the tool holder, and a new model of the lathe tools is proposed based on the computer analysis of the behavior of the tools during static and vibration analysis. In this study, three different cutting

46、 tools were used: the standard all-metal model, the model with horizontal holes arranged in a chessboard pattern, and the model with horizontal holes arranged in achessboard pattern and filled up with composite material (see Figure 1).Materials and method In the analysis, the lathe tools dimension i

47、s 150mm?27mm?27mm, and they are made of hardened steel (AISI 5140). Modeling of the tools was performed using SolidWorks Version 2012, where, at first stage, the sketches of the models were created and then their 3D models, as shown in Figure 1. Static and vibration analysis were performed using Sol

48、idWorks Simulation for next overhangs: 30, 35,38, 41, 44, 47, 50, 53, 56, 59, 62, and 65mm.In Figure 1(c) the holes of the tool holder of the modified model are filled up with epoxygranites with normal, rigid, and plastic structures, the physical andmechanical characteristics of which are provided i

49、n Table 1.Static analysis To perform static analysis using Solidworks Simulation it is necessary to assign the material of the tools and restrictions, set the external loads, assign the contact surfaces and contact characteristics, create a finite element mesh, and perform calculations. In static an

50、alysis, the lathe tools are affected by tool clamps force (15000N) and cutting force (2000N). Figure 2 shows finite element mesh and external loads on tool tip and tool holder of model filled up with composite material. static analysis, tool tip displacement was determined at different tool overhang

51、 condition. Figure 3 illustrates the relationship bet ween displacement of tool tip and overhang.In Figure 3, it can be clearly seen that, for allmodels, displacement of tool tip increases as tooloverhang increases. The holes in tool holder reducestiffness of the tool; therefore, tool tip displaceme

52、nt of the tool with holes in the tool holder is greater in comparison with all-metal model. Filling up the holes by epoxygranite has reduced displacement of tool tip in comparison with model with holes, which confirms high damping capability of epoxygranite. However, the result of static analysis in

53、dicates that stiffness of the all-metal model is greater than that of models with and without epoxygranite. The flexibility of the tool holder strongly affects the surfaceroughness in machining of materials. It is known that cutting tool with higher stiffness improves the surface roughness during ma

54、chining process. In this study all-metal model has the highest stiffness, therefore using this cutting tool in machining process givesbetter result in terms of surface finish.Natural frequency analysis of lathe tools The stability of cutting tool considerably depends on vibration. Frequency analysis

55、 of tools was conducted to examine mode in the first harmonic of the natural oscillations, as the maximum amplitude occurs on first harmonica. In frequency analysis of the models,external loads can be ignored, since their impact on the frequency is not significant. The models are fixed from the bott

56、om side. The overhang length is changed (30, 35, 38, 41, 44, 47, 50, 53, 56, 59, 62, and 65mm) to find the relationship between natural frequency andtool overhang. This relationship is shown in Figure 4, which illustrates that natural frequency decreases as overhang increases. As can be seen from Figure 4,cutting tool with holes decreased the natural frequency in comparison with all-metal model. This can be explained by the fact that the cutting tool with holes has the heterogeneous structure. Vibration waves pass through the m