设计说明书本次主要内容对4102连杆小头孔滚压装置

4102连杆小头孔滚压装置的设计，本设计装置的Thedesignofthemaincontentistheconnectingrodsmallendhole4102Rollingdevicedesign,themainpartofthedesigndevicesarerotarytabledevice,press-fitdevice,rollingdeviceandconnectingrodfixture.TablerotarydeviceismainlyusedtoachievetankroundIntermittentdialstopatthestationlocation,whiletheuseslewingbearingforcesontheturntabletounloadthetable,thismakesthespindledoesnotrequiretoomuchtobearaxialforce.Press-fitdeviceismainlydrivenbyhydrauliccylinderunderpressuremountedheaddowntoachievetheworkpieces.Rollingdeviceinthehydrauliccylinderdrivesplineshaftinthehollowshaftofthelift,whilethehollowshaftofthedrivensplineshaftrotates.Inthesplineshafthydrauliccylinderandthejunctiondesignarotaryvice,sothatsplineshaftinrotationwhenthehydrauliccylinderpistonrodwillnotfollowtherotation.Connectingrodfixturedesignistousetwoofftoonesideforworkpiecepositioning,clampingboltsThedesignunitisflexible,institutionalsimpleprocessingunitswithcommonplantworkerscomparedtosignificantlyreducethelaborintensity,reducedproductioncosts.Pressingthegeneralplantandrollingaretwodeviceswereprocessed,pressfitinthehandpressontheprocessingtime,rollinginthelegislaturewhenthedrillingmachineontheprocessing,butthisdesignwillbepress-fitandflowtogetherorganically,incanbedoneonamachinepressfit,androllingthetwofunctionsgreatlyenhancetheworkefficiency,whilethedesignofequipmentandrollingsomeofthepressureequipmentcanworkindependently.Keywords:connectingrod；press-fit；rolling；第1章绪 选题意 滚压技术的应 滚压技术现状及前 本文研究主要内 第2章总体方案设 制定工艺路 方案确 制定系统方案原理 总体布置方 第3章传动系统的设计计 电机与减速器的选 槽轮的设计计 齿轮传动的设计计 第4章执行系统设 液压缸的选 滚压装置主轴结构设 夹具结构设 压装头机构设 压装装置支架结构有限元分 第5章设备维护使用要 设备维护要 设备使用要 第6章结 参考文 致 附一：外文资 附二：中文翻 1种特征和市场形势发展的要求。发动机是给汽车提供动力的主要部件，是汽车度要求为Ra0.4～0.8µm，对同轴度、耐磨性要求严格。缸筒的基本特征是深孔滚压加工原理：它是一种压力光整加工，是利用金属在常温状态的冷塑性2、修正圆度，椭圆度可≤0.01mm123施加静压力，同时由冲击源引起钢球对工件表面施加一个较高频率的动压力。击滚压装置仅比一般的滚压装置增加了一个冲击部分。若取消这一冲击源，该731—冲击源2—传感器3—夹具4—钢球5—压头6—主轴7—工件8对比试验表明：冲击滚压比一般滚压更容易使零件表面产生较大的塑性变陷。对材料硬度达到2的高温合金，圆角尺寸为R=1.6mmNN为提高零件疲劳强度等目的的表面强化工艺，通常对表面质量要求都比较a0.2。零件表面强化作为新兴的表面工程学中一项重要技术，通过表面质量的改高强度螺栓硬度达到HRC48-52)。由于这类高强度，高硬度的零件抗塑性变形决上述问题。对前面提到的硬度达HRC48—52的高强度螺栓圆角滚压进行的对另一方面，冲击滚压还可以用于对平面和曲面等零件形面进行表面强化处2据任务书列出设计要求，如表2.1所示。2.1121、滚压头转速：200r/9、电源：AC380V/50Hz（三相四线3410567 很多，并且操作方便。设计费用约2万元左右，使用寿命可达10年。再对内孔进行滚压。根据上述条件绘制黑箱如图2.1所示。

凸轮间歇机构实现间歇运动，总体工艺路线如图1所示。能和间歇功能。本设计功能分解如图2.3所示。连杆小头孔能列出，装置实现每种功能都有多种功能方案，每种功能的方案见表2.1。2.112342.2小头孔挤压装置的形态学矩阵1234A（动力源求等方面加以考虑，采用评价法进行评价，如表2.3所示。2.3++++-++++号给液压缸，液压缸开始工作进行压装，如图2.4所示。1122.41—液压缸2443212.5滚压机构简图1—滚压头2—减速器3—电机4动力性能好。传动机构简图如图2.6所示。1223452.6输送机构简图1—夹具2—工位转盘3—从动轮4—主动轮5 2AAAA1—定位面2—连杆3—螺栓4—定位销5便工件的装卸，整体布局如图2.8所示。463721892.8整体布局图1—从动轮2—转盘3—滚压头4—滑移齿轮5—减速器67—夹具8—主动轮93传动装置总效率h＝h承2×h减=0.992×0.9=0.88深沟球轴承效率h=0.99减速器效率h电电机输出功率P 电h承2·h

=1.175由文献[4]15-2-1128145C电机直连减速器额定功率1.5kWJv

2

=2

n=12Z

41+

=

2

+l

+2

4l =

1++1++1+0.70722+24·0.707==11.47 = max330 1+l2-2l3

1+0.7072-2·0.707·cos11.47)=5.6·1.577·-0.25·0.273·

N

95=0.149由文献[4]15-2-1128095A电机直连减速器额定功率0.18kW。式中JV——所有从动件转化到槽轮轴上的等效转动惯量（Kg·m2（r/minqmax——由文献[5]13.6-4

2-2 -=90 180 z 槽间角2b

z

=4

=90R1asinb280·sin45198R与a的比值lR1sinbsin450.71 h132mm；00

d02a1dkRxR1r198-15183锁止凸弧张角g3602a36090270K<z-K

=2·4=44-动停比k z- =12z-(z-K

P11.5kw，转速n1200rmini=1N1=60n1jLh=60·200·1·10·300·8=2.88N2=N1=2.88由文献[6]表5-17得ZN1=ZN2=1.1,取 SHmin[δH]1=sHlim1SH

N1

[δH]2=sHlim2SH

N2

T=9.55·P1=9.55·1.5·1000=716251 1tk=KZ2=1.2，at22cos22cos200·sin取fa由文献[6]5-5，得ZEKTZZZ 1.2·71625189.8·2.49a‡(u 1 EHe = t

]2

2·0.35·1 取m

=2·280·0.978=3取ZZ z1=(u+1)=(1+1)=

i1-

z1=z2=i=z2 =

精确求

2·280 与暂取b12ZZ d=

=3·92=282.04d1=d2=282.04 v=60

=p·200·282.04=2.9560表 b=fa·a=0.25×280=70mm取b2=70mm，b1=75mm 按式5-4计算载荷系数da1d12m282.042·3288.04mmda1=da2=288.04aat1=arccos(db1/da1)=aat2=arccos(db2/da2=dH

HZE75·2822=113.4MPa<<[δH]1=638MPa查图5-15得YSa1=1.73、YSa2=1.73Ye=0.25+0.75=0.25+0.75= 查图5-15得YN1=YN2=1.0由式5-31计算许用弯曲应力： 75·282.04· ssYFa2YSa2£[sF]F

F1 d=

=3·92=282.04d2=d1=282.04da1=d1+2ham=276+2·1·3=282da2=282 =dcosa=276·cos20= db2=db1=259.36a=1(d+

)=1(276+276)=2762b175mm，b270mm已知条件da df di lf1.1—11被包容件ssi=560pfamax=assa=0.428·250=1075.2—27pfimax=cssi=0.48·560=268.85.2—27pfmax=107Ft=pfmaxpdflfm=107·p·38·45·0.2=11490533.4—5D

=23.4—7得D=100mm因此d=70mm取所需的最大重力为1200N33.4—5D

=0.62~23.4—7得D=100mm因此d=70mm 4.1升降，同时与空心轴同时旋转承受一定的转矩。材料为45号钢，总体长度为630mm，443mm4—82查得，该花键公称尺寸为8—50×46×9。花键轴在工作中承受一定的轴 4.1花键轴示意图出现转动现象。由文献[9]查得，莫氏锥度如表4.1所示，本设计选择型号3。4.1莫氏锥度型号表0123456712312364.2夹具示意图1—夹紧螺栓2—夹具体3—连杆4—定位销5—心轴6A1A12345A4.3压装头机构示意图1—小钢珠2—弹簧3—内六角螺钉4—压装头5

4.664102连杆小头孔滚压装置的设计，设计中参考了东风朝孔进行滚压。该连杆为东风朝柴4102柴油机缸体用连杆。250mm1.5Kw；回转转盘中电机额定功率0.18Kw；功率为12件/min。2002（4：1-百度百科莫氏锥度，2008，36（8：1～36张友德.内燃机连杆小头钢套拆装和镗铰装置.中国专利，黄压西.一种连杆衬套压装装置以及连杆衬套压装方法.中国专利，FundamentalsofMachineInmanycasesproductsfromtheprimaryformingprocessesmustundergofurtherrefinementsinsizeandsurfacefinishtomeettheirdesignspecifications.Tomeetsuchprecisetolerancetheremovalofsmallamountsofmaterialisneeded.Usuallymachinetoolsareusedforsuchoperation.IntheUnitedStatesmaterialremovalisabigbusiness—inexcessof＄36×109peryear,includingmaterial,labor,overhead,andmachine-toolsshipments,isspent.Since60percentofthemachanicalandindustrialengineeringandtechnologygraduatehavesomethingconnectionwiththemachiningindustryeitherthroughsale,design,oroperationofmachineshops,orworkinginrelatedindustry,itiswiseforanengineeringstudenttodevotesometimeinhiscurriculumtostudyingmaterialremovalandmachinetools.Amachinetoolprovidethemeansforcuttingtoolstoshapeaworkpiecetorequireddimensions;themachinesupportsthetoolandtheworkpieceinacontrolledrelationshipthroughthefunctioningofitsbasicmembers,whichareasfollows:Bed,StructureorFrame.Thisisthemainmemberwhichprovidesabasisfor,andaconnectionbetween,thespindlesandslides;thedistorionandvibrationunderloadmustbekepttoaminimum.SlidesandSlideways.Thetranslationofamachineelement(e.g.theslide)isnormallyachievedbystraight-linemotionundertheconstraintofaccurateguidingsurface(theslideways).SpindlesandBearings.Angulardisplacementtakeplaceaboutanaxisofrotation;thepositionofthisaxismustbeconstantwithinextremelyfinelimitsinmachinetools,andisensuredbytheprovisionofprecisionspindlesandbearings.PowerUnit.Theelectricmotoristheuniversallyadoptedpowerunitformachinetools.Bysuitablypositioningindividualmotors,beltandgeartransmissionsandreducedtoaminimum.TransmissionLinkage.Linkageisthegeneraltermusedtodenotethemechanical,hydraulic,pneumaticorelectricmechanismswhichconnectangularandlineardisplacementsindefinedrelationship.TherearetwobroaddivisionsofmachiningRoughing,forwhichthemetalremovalrate,andconsequentlythecuttingforce,ishigh,buttherequireddimensionalaccuracyrelativelylow.Finishing,forwhichthemetalremovalrate,andconsequentlythecuttingforce,islow,buttherequireddimensionalaccuracyandsurfacefinishrelativelyhigh.Itfollowsthatstaticloadsanddynamicloads,suchasresultfromanunbalancedgrindingwheel,arermoresignificantinfinishingoperationsthaninroughingoperations.Thedegreeofprecisionachievedinanymachiningprocesswillusuallybeinfluencedbythemagnitudeofthedeflections,whichoccurasaresultoftheMachinetoolframesaregenerallymadeincastiron,althoughsomemaybesteelcastingormild-steelfabrications.Castironischosenbecauseofitscheapness,rigidity,compressivestrengthandcapacityfordampingthevibrationsset-upinmachineoperations.Toavoidmassivesectionsincastings,carefullydesignedsystemsofribbingareusedtoofferthemaximumresistancetobendingandtorsionalstresses.Twobasictypesofribbingareboxanddiagonal.Theboxformationisconvenienttoproduce,aperturesinwallspermittingthepositioningandextractionofcores.Diagonalribbingprovidesgreatertorsionalstiffnessandyetpermitsswarftofallbetweenthesections;itisfrequentlyusedforlathebeds.Theslidesandslidewaysofamachinetoollocateandguidememberswhichmoverelativetoeachother,usuallychangingthepositionofthetoolrelativetotheworkpiece.Themovementgenenallytakestheformsoftranslationinastraightline,butissometimesangulairotation,e.g.tiltingthewheel-headofauniversalthread-grindingmachinetoananglecorrespondingwiththehelixangleoftheworkpiecethread.Thebasicgeometricelementsofslidesareflat,vee,dovetailandcylinder.Theseelementsmaybeusedseparatelyorcombinedinvariouswaysaccordingtotheapplications.Featuresofslidewaysareasfollows:AccuracyofMovement.Whereaslideistobedisplacedinastraightline,thislinemustlieintwomutuallyperpendicularplanesandtheremustbenosliderotation.Thegeneraltoleranceforstraightnessofmachinetoolslidewaysis0—0.02mmper1000mm;onhorizontalsurfacesthistolerancemaybedisposedsothataconvexsurfaceresults,thuscounteringtheeffectof“sag”oftheslideway.MeansofAdjustment.Tofacilitateassembly,maintainaccuracyandeliminate“play”betweenslideingmembersafterwearhastakenplace,astripissomethinginsertedintheslides.Thisiscalledagib-strip.Usually,thegribisretainedbysocket-headscrewpassingthroughelongatedslots;andisadjustedbygrub-screwssecuredbylocknuts.Lubrication.Slidewaysmaybelubricatedbyeitherofthefollowingsystems:1)Intermittentlythroughgreaseoroilnipples,amethodsuitablewheremovementsareinfrequentandspeed2)Continuously,e.g.bypumpingthroughameteringvalueandpipe-worktothepointofapplication;thefilmofoilintroducedbetweensurfacesbythesemeansmustbeextremelythintoavoidtheslide“floating”.Ifslidingsurfaceswereopticallyflatoilwouldbesqueezedout,resultinginthesurfacessticking.Henceinpracticeslidesurfacesareeithergroundusingtheedgeofacupwheel,orscraped.Bothprocessesproduceminutesurfacedepresssions,whichretain“pocket”ofoil,andcompleteseparationofthepartsmaynotoccuratallpoints;positivelocationoftheslidesisthusretained.Protection.Tomaintainslidewaysingoodorder,thefollowingconditionsmustbemet:Ingressofforeignmatter,e.g.swarf,mustbeprevented.Wherethisisnopossible,itisdesirabletohaveaformofslideway,whichdoesnotretainswarf,theinvertedvee.Lubricatingoilmustberetained.Theadhensivepropertyofoilforuseverticalorinclinedslidesurfaceisimportant;oilsareavailablewhichhavebeenspeciallydevelopedforthispurpose.Theadhesivenessofoilalsopreventsitbeingwashedawaybycuttingfluids.AccidentaldamagemustbepreventedbyprotectiveAmachinetoolperformsthreemajorfunctions:1)itrigidlysupportstheworkpieceoritsholderandthecuttingtool;2)itprovidesrelativemotionbetweentheworkpieceandthecuttingtool;3)itprovidesarangeoffeedsandspeeds.Machinesusedtoremovemetalintheformofchipsareclassifiedinfourgeneralgroups:thoseusingsingle-pointtools,thoseusingmultipointtools,thoseusingrandom-pointtools(abrasive),andthosethatconsideredspecial.Machinesusingbasicallythesingle-pointcuttingtoolsinclude:1)engine2)turretlathes,3)tracingandduplicatinglathes,4)single-spindleautomaticlathes,5)multi-singleautomaticlathes,6)shapersandplaners,7)boringmachines.Machinesusingmultipointcuttingtoolsinclude:1)drillingmachines,2)millingmachines,3)broachingmachines,4)sawingmachines,5)gear-cuttingmachines.Machinesusingrandom-pointcuttingtoolsinclude:1)cylindricalgrinder, include:1)chemicalmilling,2)electricaldischargemachining,3)ultrasonicmachining.Thelatheremovesmaterialbyrotatingtheworkpieceagainstacuttertoproduceexternalorinternalcylindricalorconicalsurfaces.Itisalsocommonlyusedfortheproductionofflatsurfacesbyfaing,inwhichtheworkpieceisrotatedwhilecuttingtoolismovedperpendicularlytotheaxisofTheenginelatheisthebasicturningmachinefromwhichotherturningmachineshavebeendeveloped.Thedrivemotorislocatedinthebaseanddrivesthespindlethroughacombinationofbeltsandgears,whichprovidesthespindlespeedsfrom25to1500rpm.Thespindleisasturdyhollowshaft,mountedbetweenheavy-dutybearings,withtheforwardendusedformountingadriveplatetoimpartpositivemotiontotheworkpiece.Thedriveplatemaybefastenedtothespindlebythreads,byacamlockmechanism,orbyathreadcollarandkey.Thelathebediscastironandprovidesaccuratelygroundslidingsurfaces(way)onwhichthecarriagerides.ThelathecarriageisaH-shapedcastingonwhichthecuttingtoolismountedinatoolholder.Theapronhangsfromthefrontofthecarriageandcontainsthedrivinggearsthatmovethetoolandcarriagealongoracrossthewaytoprovidethedesiredtoolmotion.Acompoundrest,locatedabovethecarriageprovidesforrotationofthetoolholderthroughanydesiredangle.Ahandwheelandfeedscrewareprovidedwithahandwheelandfeedscrewformovingthecompoundrestperpendiculartothelatheway.Ageartrainintheapronprovidespowerfeedforthecarriagebothalongandacrosstheway.Thefeedboxcontainsgearstoimpartmotiontothecarriageandcontroltherateatwhichthetoolmovesrelativetotheworkpiece.Onatypicallathefeedsrangefrom0.002to0.160in.perrevolutionofthespindle,inabout50steps.Sincethetransmissioninthefeedboxisdrivenfromthespindlegears,thefeedsaredirectlyrelatedtothespindlespeed.Thefeedboxgearingisalsousedinthreadcuttingandprovidesfrom4to224threadsperin.Theconnectingshaftbetweenthefeedboxandthelatheapronarethefeedrodandtheleadscrew.Manylathemanufacturerscombinethesetworodsinone,apracticethatreducesthecostofthemachineattheexpenseofaccuracy.Thefeedrodisusedtoprovidetoolmotionessentialforaccurateworkpieceandgoodsurfacefinishes.Theleadscrewisusedtoprovidetheaccurateleadnecessaryforthethreadcutting.Thefeedrodisdriventhroughafrictionclutchthatallowsslippageincasethetoolisoverloaded.Thissafetydeviceisnotprovidedintheleadscrew,sincethreadcuttingcannottolerateslippage.Sincethefulldepthofthethreadisseldomcutinonepass,achasingdialisprovidedtorealignthetoolforsubsequentpasses.Thelathetailtockisfittedwithanaccuratespindlethathasataperedholeformountingdrills,drillchucks,reamers,andlathecenters.Thetailstockcanbemovedalongthelathewaystoaccommodatevariouslengthsofworkpiecesaswellastoadvanceatoolintocontactwiththeworpiece.Thetailstockcanbeoffsetrelativetothelathewaystocuttapersorconicalsurfaces.Theturretlatheisbasicallyanenginelathewithcertainadditionalfeaturestoprovideforsemiautomaticoperationandtoreducetheopportunityforhumanerror.ThecarriageoftheturretlatheisprovidedwithT-slotsformountingatool-holdingdeviceonbothsidesofthelathewayswithtoolsproperlysetforcuttingwhenrotatedintoposition.Thecarriageisalsoequippedwithautomaticstopsthatcontrolthetooltravelandprovidegoodreproductionofcuts.Thetailstockoftheturretlatheisofhexagonaldesign,inwhichsixtoolscanbemounted.Althoghalargeamountoftimeisconsumedinsettingupthetoolsandstopsforoperation,theturretlathe,onceset,cancontinuetoduplicateoperationswithaminimumofoperatorskilluntilthetoolsbecomedulledandneedreplacing.Thus,theturretlatheiseconomicallyfeasibleonlyforproductionwork,wheretheamountoftimenecessarytopreparethemachineforoperationisjustifiableintermsofthenumberofparttobemade.Tracingandduplicatinglathesareequippedwithaduplicatingdevicetoautomaticallycontrolthelongitudinalandcrossfeedmotionsofthesingle-pointcuttingtoolandprovideafinishedpartofrequiredshapeandsizeinoneortwopassesofthetools.Thesingle-spindleautomaticlatheusesaverticalturretaswellastwocrossslids.Theworkisfedthroughthemachinespindleintothechuck,andthetoolsareoperatedautomaticallybycams.Themultispindleautomaticlatheisprovidedwithfour,five,six,oreightspindles,withoneworkpiecemountedineachspindle.Thespindlesindexaroundacentralshaft,withthemaintoolsslideaccessibletoallspindles.Eachspindlepositionisprovidedwithasidetool-slideoperatedindependently.Sincealloftheslidesareoperatedbycams,thepreparationofthismachinemaytakeseveraldays,andaproductionrunofatleast5000partsisneededtojustifyitsuse.Theprincipaladvantageofthismachineisthatalltoolsworksimultaneously,andoneoperatorcanhandleseveralmachines.Forrelativelysimpleparts,multispindleautomaticlathescanturnoutfinishedproductsattherateof1every5sec.Ashapersutilizesasingle-pointtoolinatoolholdermountedontheendoftheram.Cuttingisgenerallydoneontheforwardstroke.Thetoolisliftedslightlybytheclapperboxtopreventexcessivedragacrossthework,whichisfedunderthetoolduringthereturnstrokeinpreparationforthenextcut.Thecolumnhousetheoperatingmechanismsoftheshaperandalsoservesasamountingunitforthework-supportingtable.Thetablecanbemovedintwodirectionsmutuallyperpendiculartotheram.Thetoolslideisusedtocontrolthedepthofthecutandismanuallyfed.Itcanberotatedthrough90deg.Oneithersideofitsnormalverticalposition,whichallowsfeedingthetoolatanangletothesurfaceofthetable.TwotypesofthedrivingmechanismsforshapersareamodifiedWhitworthquick-returnmechanismandahydraulicdrive.FortheWhitworthmechanism,themotordrivesthebullgear,whichdrivesacrankarmwithanadjustablecrankpintocontrolthelengthofthestroke.Asthebullgearrotates,therockerarmisforcedtoreciprocate,impartingthismotiontotheshaperram.Themotoronahydraulicshaperisusedonlytodrivethehydraulicpump.Theremainderoftheshapermotionsarecontrolledbythedirectionoftheflowofthehydraulicoil.Thecuttingstrokeofthemechanicallydrivenshaperuses220deg.ofrotationofthebullgear,whilethereturnstrokeuses140deg.Thisgivesacuttingstroketoreturnstrokeratioof1.6to1.Thevelocitydiagramshowsthatthevelocityofthetoolduringthecuttingstrokeisneverconstant,whilethevelocitydiagramforahydraulicshapershowsthatformostofthecuttingstrokethecuttingspeedisconstant.Thehydraulicshaperhasanaddedadvantageofinfinitelyvariablecuttingspeeds.Theprincipaldisadvantageofthistypeofmachineisthelackofadefinitelimitattheendoftheramstroke,whichmayallowafewthousandthsofaninchvariationinstrokeAduplicatingdevicethatmakespossiblethereproductionofcontoursfromasheet-metaltemplateisavailable.Thesheetmetaltemplateisusedinconjunctionwithhydrauliccontrol.Uprightdrillingmachinesordrillpressesareavailableinavarietyofsizesandtypes,andareequippedwithasufficientrangeofspindlespeedsandautomaticfeedstofittheneedsofmostindustries.Speedrangesonatypicalmachinearefrom76to2025rpm.,withdrillfeedfrom0.002to0.20in.perrevolutionofthespindle.Radialdrillingmachinesareusedtodrillworkpiecesthataretoolargeorcumbersometoconvenientlymove.Thespindlewiththespeedandfeedchangingmechanismismountedontheradialarm;bycombingthemovementoftheradialarmaroundcolumnandthemovementofthespindleassemblyalongthearm,itispossibletoalignthespindleandthedrilltoanypositionwithinreachofthemachine.Forworkthatistoolargetoconvenientlysupportonthebase,thespindleassemblycanbeswungoutoverthefloorandtheworkpiecesetonthefloorbesidethemachine.Plainradialdrillingmachineprovideonlyforverticalmovementofthespindle;universalmachinesallowthespindletoswiveaboutanaxisnormaltotheradialarmandtheradialarmtorotateaboutahorizontalaxis,thuspermittingdrillingatanyAmutispindledrillingmachinehasoneormoreheadsthatdrivethespindlesthroughuniversaljointsandtelescopingsplinedshafts.Allspindlesareusu