Assignment drawing of a part on the subject of mechanical engineering technology. Collection of practical problems in the discipline "technology of mechanical engineering. Name of training elements
Task 1.66 option 3.
Given: d (size of the base surface of the shaft) = 80-0.039 mm,
? (precision of the processing method) = 60 μm,
Life (permissible bushing wear) = 10 microns,
A2 = 50 ± 0.080 mm.
Determine the working dimension D of the centering sleeve, which ensures the specified accuracy of the A2 dimension when milling the groove.
Solution.
An analysis of the installation scheme shows that the accuracy of the hole diameter of the centering sleeve D affects the accuracy of the A2 dimension, given from the workpiece axis to the machined surface. It can be seen from the installation diagram that the fixing error (? S) for the A2 size is zero. Proceeding from this, as a starting point, we take that the accuracy of the A2 size: TA2 =? BA2 + Tizn. +?, where? бА2 = ТD + Smin + Td - the error of the A2 size basing. The components TD and Smin are unknown quantities.
Solving the equality with respect to these unknowns, we get:
(Smin + TD) = TA2 - (Td + Life +?) = 0.16 - (0.039 + 0.010 + 0.060) = 0.051 mm.
From the tables of GOST 25347-82, select the hole tolerance field so that the condition is met: Smin + TD? ES.
Comparing the calculated value (Smin + TD) = 0.051 with the tabular value of the upper hole deviation (ES), I take the tolerance field G7 (), which can be taken as the actuator dimensions of the sleeve:
D = 80G7.
Task 1.67 option 3.
Given: mandrel material - steel 20X,
workpiece material - bronze,
E 1 (steel) = 210 GPa
E 2 (bronze) = 100 GPa,
? 1 (steel) = 0.3
? 2 (bronze) = 0.33
f bronze on steel = 0.05
u? 1,2 (Rz1 + Rz2)
d = 30 + 0.013mm
L = 40 mm
d1 = 70 mm
K = 2.0
Rz (mandrels) - 1.6
Rz (blanks) - 3.2
Pz = 240 H
Life = 10 microns.
Solution.
The starting point for performing calculations is the condition KMres = Mtr,
where: Мres = Рz - cutting moment when turning the surface
Мтр = lfp - friction moment of the contact surface of the workpiece with the mandrel.
р = - contact pressure on the interface surface.
Required smallest preload: Ncal. min =
When using a solid mandrel: c1 = 1-? 1> c1 = 1-0.3 = 0.7
c2 = +? 2> + 0.33 = 1.78
Ncalc. min = = = 3.767
Taking into account the correction u for the height of the roughness crumpled during pressing, we find the value of the measured interference:
Nmeasure. min = Ncalc. min + u> 3.767 + 1.2 (1.6 + 3.2) = 3.767 + 5.76 = 9.5 μm;
From the tables of GOST 25347-82 we select the shaft tolerance field so that
(Td + Nmeasure min + Life)? Ei, where Life is the permissible wear of the mandrel.
In our case (13 + 9.5 + Life)? Ei.
For my version, the tolerance fields of the shaft (mandrels) can be taken
p5 () or p6 () with a permissible arbor wear of 3.5 μm.
Then the executive dimensions of the mandrel:
d = 30p5 () mm or d = 30p6 () mm.
Pressing force at the greatest interference, taking into account the safety factor K = 2: P = Kfp? Dl,
p => p = = = 15,
P = 2 · 0.05 · 15 · 3.14 · 30 · 40 = 5652H.
Task 1.57 option 1.
Given:? B = 0.05 mm,? Z = 0.01 mm,? S = 0.01 mm,? C = 0.012 mm,
Ng = 3000 pcs.,
Workpiece: material - non-hardened steel, hardness - HB 160, base surface - cylindrical, Тl = 0.2 mm.
Fixture: prism, Steel 20, hardness - HV 650, F = 36.1 mm2, Q = 10000H, L = 20 mm.
Processing method - milling with cooling,? (precision of the processing method) = 0.1 mm, tm = 1.95 min.
Determine the overhaul period of the device.
Solution.
Determine the permissible value [? And] by the equations:
? y = +>? y = + =
=0,051+
? y = Тl -?,> 0.051+ = Тl -?,> 0.051+ = 0.2-0.1>
> = 0.049> [? U] = = 0.04644 mm = 46.44 microns.
We find the permissible number of workpieces to be installed [N] until the limit wear of the installation elements of the device from the equation:
[N] =, from the reference book - we find m = 1818, m1 = 1014, m2 = 1309, wear resistance criterion P1 = 1.03, a correction factor that takes into account the processing conditions Ku = 0.9.
[N] = = = = 21716 pcs.
The overhaul period, which determines the need to replace or restore the installation elements of the device, is found from the equation:
PC = = = 73.8 months.
Target 1.43
Given: D1 = D2 = 50 + 0.039 mm, dts = dc = 50f7 mm,
ТL = 0.1 mm,? (precision of the processing method) = 0.050 mm.
Determine the accuracy of the size 70 of the connecting rod head and the possibility of processing the connecting rod surfaces with a set of cutters, observing the dimensional accuracy of 45 + 0.4 mm.
Solution.
Based on the installation scheme of the workpiece in the fixture, the positioning error when performing size 70 is determined by the equation:
? б70 = Smax = TD + Smin + Td = 0.039 + 0.025 + 0.025 = 0.089 mm,
Since the problem statement does not say anything about the fixing and position errors of the workpiece, then
T70 =? B70 +? = 0.089 + 0.05 = 0.139 mm.
For size 45, a tolerance is added to the size between the axes of the holes (it could also affect size 70 if the fingers did not have the same tolerance range):
? б45 = Smax = TD + Smin + Td + TL = 0.039 + 0.025 + 0.025 + 0.1 = 0.189 mm,
T45 =? B45 +? = 0.189 + 0.05 = 0.239 mm.
As you can see, the calculated tolerance is 0.239< 0,4 мм допуска заданного, следовательно, мы можем применить набор фрез для обработки головки шатуна.
Literature:
1. Machine tools. Directory. / Ed. B.N. Vardashkin et al. M., Mechanical Engineering, 1984.
2. The metalworker's handbook. / Ed. M.P. Novikova / M., Mechanical Engineering, 1977.
Solution provided practical tasks on all main sections of the discipline "Technology of mechanical engineering". Variants of individual tasks for practical work are given with a description of the methodology for their implementation on the example of solving one of the options for the task. The appendices contain the normative and reference materials necessary to carry out practical work.
The textbook can be used in the study of the general professional discipline "Technology of mechanical engineering" in accordance with the Federal State Educational Standard of the SPO for the specialty 151901 "Technology of mechanical engineering".
An electronic educational resource "Technology of Mechanical Engineering" has been released for this textbook.
For students of educational institutions of secondary vocational education.
DETERMINATION OF THE VALUE OF INCLUSIONS.
A workpiece is an object of production, the shape of which is close to the shape of a part, from which a part or an integral assembly unit is made by changing the shape and roughness of surfaces, their dimensions, as well as material properties. It is generally accepted that a workpiece enters for any operation, and a part leaves the operation.
The configuration of the workpiece is determined by the design of the part, its dimensions, material and working conditions of the part in the finished product, that is, all types of loads acting on the part during the operation of the finished product.
The original workpiece is the workpiece that arrives at the first operation. technological process.
The allowance is a layer of the workpiece material that is removed during its machining to obtain the required accuracy and parameters of the surface layer of the finished part.
An intermediate stock is a layer of material removed during one technological transition. It is defined as the difference between the size of the surface of the workpiece obtained in the previous operation and the size of the same surface of the part obtained when performing this transition on processing the surface of the workpiece in one operation.
TABLE OF CONTENTS
Foreword
Chapter 1. Fundamentals of mechanical engineering technology
1.1. Production and technological processes of a machine-building enterprise
Practical work No. 1.1. Study of the structure of the technological process
1.2. Determination of the size of the allowances
1.3. Calculation of the dimensions of the workpieces
1.4. Preliminary assessment of options for obtaining blanks
and their manufacturability
Practical work No. 1.2. Appointment of operating rooms
allowances for machining a part with a graphical representation of the location of allowances and tolerances for operating dimensions
1.5. The choice of bases when processing blanks
1.6. Sequence of operations
1.7. Selecting an installation base
1.8. Selecting a source base
Practical work No. 1.3. Basing workpieces in the processing area of the machine
1.9. Precision machining
1.10. Determination of the expected accuracy at automatic receipt coordinating size
Chapter 2. Technical regulation of technological operations
2.1. Piece time structure
2.2. Operations rationing
Practical work No. 2.1. Standardization of the turning operation of the technological process
Practical work №2.2. Standardization of the milling operation of the technological process
Practical work №2.3. Standardization of the grinding operation of the technological process
2.3. Development of operations
Practical work №2.4. Development of a cylindrical grinding operation of a technological process
Practical work No. 2.5. Development of surface grinding operation of the technological process
Chapter 3. Methods of surface treatment used in the manufacture of main parts
3.1. Manufacturing of shafts
3.2. Making discs
3.3. Gear making
3.4. Spur gear manufacturing
3.5. Bevel gear manufacturing
Chapter 4. Production of ring parts
Chapter 5. Manufacturing parts from sheet materials
Chapter 6. Selection of devices for basing (setting and fixing) workpieces
Chapter 7. Assembly of connections, mechanisms and assembly units
7.1. Route and assembly scheme development
7.2. Assembly Dimension Chains
7.3. Ensuring assembly accuracy
7.4. Control of assembly and technological parameters
7.5. Balancing parts and rotors
Chapter 8. Course design
8.1. The main provisions of the course project
8.2. General requirements to the design of the course project
8.3. General method of working on a project
8.4. Technological part
Applications
Annex 1. Sample form title page explanatory note
Appendix 2. An approximate form of the assignment for the course project
Appendix 3. Units of measurement of physical quantities
Appendix 4. Rules for the design of the graphic part of the course project
Appendix 5. Tolerances in the hole system for external dimensions according to ESDP (GOST 25347-82)
Appendix 6. Approximate routes for obtaining the parameters of the outer cylindrical surfaces
Appendix 7. Approximate routes for obtaining the parameters of internal cylindrical surfaces
Appendix 8. Operational allowances and tolerances
Appendix 9. Time indicators of technological operations
Appendix 10. Specifications technological equipment and materials
Appendix 11. Cutting parameters and processing modes
Appendix 12. Indicators of accuracy and surface quality
Appendix 13. Dependence of the type of production on the volume of output
Appendix 14. Approximate indicators for economic calculations
Appendix 15. Methods of surface treatment
Appendix 16. Values of coefficients and quantities
Appendix 17. Brief specifications metal cutting machines
Bibliography.
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Ministry of Education and Science of the Samara Region
GBOU SPO Togliatti Engineering College
Reviewed Approve
at a meeting of the MC Deputy. Director for NMR
specialty 151901 __________ Lutsenko T.N.
Protocol No. ______
"___" ___________ 2013 "___" ___________ 2013
MK Chairman
__________ / Bykovskaya A.V. /
Control and measuring materials
in the discipline "Technology of mechanical engineering"
specialties SPE: 151901 Mechanical engineering technology
for 4th year students
Developed by the teacher Ivanov A.S.
Specialty SPE: 151901 Mechanical Engineering Technology
Discipline: Engineering Technology
Section 1: Specification of Learning Items
№ p / p
Name of training elements
(Didactic units)
The purpose of training
must know
must know
must know
must know
must know
must know
must know
must know
must know
Technological setup diagrams
must know
must know
Time rate and its structure
must know
must know
must know
must know
must know
must know
must know
must know
Machine assembly technology.
must know
must know
must know
must know
Section 2 Test Items
Option 1
Block A
Assignment (question)
Sample answer
№ tasks
Possible answer
1
1-B, 2-A, 3-B
Set the correspondence between the name of the surface and the graphic image
1 - B;
2 - B;
3 - A;
4 - G.
IMAGE
Surfaces:
A) main
B) auxiliary
B) executive
D) free
Establish a correspondence between the name and the designation of the hotel
1 - G;
2 - D;
3 - A;
4 - B;
5 B.
Name
A) cylindricity
B) roundness
B) flatness
D) straightness
D) tolerance of the profile of the longitudinal section
Establish a correspondence, which varieties of directions of irregularities are indicated on the diagrams.
1 - B;
2 - D;
3 - G;
4 - A;
5 B.
Irregularities
parallel
crisscross
perpendicular
arbitrary
radial
Designation on the diagrams
A. G.
B. D.
The finished part of the technological process performed by the worker at one workplace is
operation
Serial production is characterized by
the number of products does not affect the type of production
The criterion for determining the type of production is
nomenclature of manufactured products and the coefficient of consolidation of operations
production cycle
3.qualification of workers
precision in metalworking can be achieved by methods
by the method of passes and measurements
on tuned machines
points 1 and 2
by measuring the treated surface
The minimum operating allowance for bodies of revolution is determined by the formula
the roughness of the surface, not undergoing treatment, IS DECLARED BY THE SIGN
1. 3.
2. 4.all of the above
The base used to determine the position of the workpiece in the manufacturing process is called
design base
technological base
main base
auxiliary base
The operational time is determined by the formula
T OP = T O + T B
T DOP = T SB + T OP
T SHT = T O + T B + T OB + T OT
T Sh-K = T ShT + T P-Z / N
The base that deprives the workpiece of three degrees of freedom is called
double support
installation
guide
The base of the workpiece, which appears as a real surface, is called
open
measuring
Determine the type of production, if the coefficient of consolidation of operationsTO Z =1
small batch production
medium batch production
large-scale production
mass production
The set of all irregularities on the surface under consideration is called
non-straightness of the surface of the part
surface waviness
non-parallelism of part surfaces
surface roughness
The set of dimensions that form a closed contour and related to one part is called
dimension line
dimensional chain
size group
dimensional link
Define the term - total stock
Basis errors occur if they do not match
design and technological bases
technological and measuring bases
design and measurement bases
When choosing finishing bases when processing in all operations, it is necessary to use
the principle of combining bases
principle of constant bases
only installation bases
installation and design bases
The ability of a structure and its elements to resist the effects of external loads without collapsing is called
rigidity
steadiness
strength
elasticity
Block B
Assignment (question)
Sample answer
The limited application of the principle of interchangeability and the use of fitting work is characteristic of ____________
single assembly production.
The main basing schemes in metalworking are _________________________________________________
basing of prismatic blanks, basing of long and short cylindrical blanks.
The degree of conformity of the part given dimensions and the form, called ________________________________
processing precision.
The amount of movement of the tool per revolution of the workpiece is called ___________________
By designation, the surfaces of parts are classified into __________________________________________________
for basic, auxiliary, executive, free
The working drawing of the part, the drawing of the workpiece, the technical conditions, and the assembly drawing of the part are the initial data for the design _____________________________
technological process.
To compensate for errors arising in the selection of blanks, __________________________________
machining allowance.
A set of periodically alternating rises and troughs with a ratio is called _____________________
surface waviness.
One of the sizes forming a dimensional chain is called ________________________________
dimensional link.
Assembly of blanks, component parts or products as a whole that are subject to subsequent disassembly is called _________________________
pre-assembly
Option- 2
Block A
Assignment (question)
Sample answer
Instructions for completing tasks No. 1-3: correlate the content of column 1 with the content of column 2. Write in the corresponding lines of the answer sheet the letter from column 2, indicating the correct answer to the questions in column 1. As a result, you will receive a sequence of letters. For example,
№ tasks
Possible answer
1
1-B, 2-A, 3-B
Match: these formulas are used to determine which parameters of the workability analysis of a part
1 - G;
2 - B;
3 - A;
4 - B
Coefficient
A. Coefficient of machining accuracy
B. Coefficient of surface roughness
B. Material utilization rate
D. Coefficient of unification of structural elements
Establish a correspondence between the graphic designation and the name of the support, clamp and installation device.
1 - B
2 - B
3 - A
4 - D
graphic designation
1. 3.
Name
A - collet mandrel
B - floating center
B - fixed support
Г - adjustable support
Set the correspondence between the processing sketch and its name
1 - B
2 - D
3 - A
4 - B
Name
A. Parallel multi-tool single.
B. Sequential multi-tool single.
B. Parallel-sequential multi-tool single.
D. Parallel single-tool single
Instructions for completing tasks number 4-20: Select the letter corresponding to correct option answer and write it down on the answer sheet.
- this is the formula for determining
piece time
main time
auxiliary time
technological standard of time
route map
process map
operating card
technological instruction
Machine tools, intended for the manufacture of products of the same name and different sizes
universal
specialized
special
mechanized
Determine the type of production, if the coefficient of consolidation of operations K Z = 8.5
small batch production
medium batch production
large-scale production
mass production
the surface roughness formed by the removal of a layer of material is indicated by the sign
2. 4.
Mass production is characterized by
narrow range of manufactured products
limited range of manufactured products
a wide range of manufactured products
various nomenclature of manufactured products
– this is the formula for determining
cutting speed
minute feed
spindle speed
cutting depth
An item or set of production items to be manufactured in an enterprise is called
assembly unit
product
4.set
Connections that can be disassembled without damaging mating or fasteners are called
mobile
detachable
one-piece
motionless
When planning the site in front of the machines, a working place is provided with a width
– this is the formula for determining
design tightness
tightness in conjunction
temperatures of mating parts
forces when pressing parts
Define the term - defective layer
metal layer intended to be removed in one operation
the minimum required metal layer thickness to perform the operation
the surface layer of a metal, which has a structure, chemical composition, the mechanical properties are different from the base metal
metal layer intended to be removed during all operations
When basing the workpiece in the device according to technological bases that are not related to measuring ones,
fixing errors
installation errors
processing errors
basing errors
Single, not regularly repeated deviations from the theoretical shape of the deviation surface are called
surface waviness
macrogeometric deviations
surface roughness
microgeometric deviations
The error that occurs before the application of the clamping force and during clamping is called
basing error
installation error
clamping error
fitting error
To ensure high hardness of the working surfaces of the teeth of the wheels, a type of heat treatment is used
carburizing followed by hardening
nitriding followed by quenching
cyanidation followed by quenching
oxidation followed by hardening
the property of a product that allows it to be manufactured and assembled at the lowest cost is called
repair manufacturability
production adaptability
operational adaptability
product manufacturability
Block B
Assignment (question)
Sample answer
Instructions for completing tasks No. 21-30: In the appropriate line of the answer sheet, write down the short answer to the question, the end of the sentence or the missing words.
For a clear illustration of the technological process, use ____________________
thumbnail map
Automated systems control of technological processes, in which the development of corrective actions on a controlled technological process occurs automatically, is called ________________________
managers
Surface irregularities formed as a result of the impact of the cutting edge of the tool on the machined surface are called _________________________
microgeometric deviations.
Deformation and wear of machine tools, wear cutting tool, clamping force, thermal deformations affect __________
processing precision
The product, the components of which are interconnected, are called ____________________________
assembly unit.
The technological process of manufacturing a group of products with common design and technological features is called ________________________
When processing the reference surfaces of body parts, _________________________ is taken as the primary base.
rough main holes
A part formed from a set of bushings joined by rods are called ______________________
Compliance with the exact compliance of the technological process of manufacturing or repairing the product with the requirements of the technological and design documentation, called _________
technological discipline
Products that are not connected at the manufacturing plant, which are a set of products of an auxiliary nature, are called ______________________________________
set
Section 3 Codification System
Name of the didactic unit
Option number
Question numbers
Technological processes of mechanical processing
4; 5; 6; 10, 14, 25
Precision machining.
Surface quality of machine parts
The choice of bases when processing blanks
3, 12, 13, 18, 19, 22
Machining allowances
Design principles, rules for the development of technological processes
The concept of technological discipline
Auxiliary and control operations in the technological process
Calculations for the design of machine operations
Technological setup diagrams
Requirements for the development of calculation and technological maps for CNC machines
Time rate and its structure
Standardization methods labor processes, standards for technical regulation
Organization of technical and regulatory work at a machine-building enterprise
Methods for processing the main surfaces of typical machine parts
Programming of machining of parts on machine tools different groups
Technological processes, production of standard parts for general machine-building applications
Technological processes for the manufacture of parts in a flexible production system(GPS), on automatic rotary lines (ARL).
Computer-aided design of technological processes
Machine assembly technology.
11; 12; 14; 25; 30
Methods of implementation, production debugging of technological processes, control over the observance of technological discipline
Defective products: analysis of reasons, their elimination
Parcel Design Basics mechanical workshops
Section 4 List of used literature
Averchenkov V.I. and etc. Engineering technology. Collection of tasks and exercises. - M .: INFRA-M, 2006.
B.M. Bazrov Fundamentals of mechanical engineering technology. - M .: Mechanical Engineering, 2005.
Balakshin B.S. Fundamentals of mechanical engineering technology - M .: Mechanical engineering, 1985.
Vinogradov V.M. Engineering technology. Introduction to the specialty. - M .: Mechanical Engineering, 2006.
Gorbatsevich A.F., Shkred V.A. Course design in mechanical engineering technology - Minsk: Higher school, 1983.
Danilevsky V.V.... Engineering technology. - M .: graduate School, 1984.
Dobrydnev I.S. Course design on the subject "Technology of mechanical engineering". - M .: Mechanical Engineering, 1985.
Klepikov V.V., Bodrov A.N. Engineering technology. - M .: FORUM - INFRA-M, 2004.
A.A. Matalin Mechanical engineering technology - L .: Mechanical engineering, 1985.
Mikhailov A.V., Rastorguev D.A., Skhirtladze A.G. - Basics of designing technological processes of mechanical assembly production. - T .: Togliatinsky State University, 2004.
Transcript
1 FEDERAL EDUCATION AGENCY State educational institution higher professional education "TOMSK POLYTECHNICAL UNIVERSITY" YURGINSKY TECHNOLOGICAL INSTITUTE А.А. Saprykin, V.L. Bibik COLLECTION OF PRACTICAL TASKS ON THE DISCIPLINE "TECHNOLOGY OF MACHINE BUILDING" Textbook Publishing House of Tomsk Polytechnic University 2008
2 BBK 34.5 y 73 UDC (076) S 19 S 19 Saprykin A.A. Collection of practical tasks for the discipline "Technology of mechanical engineering": tutorial/ A.A. Saprykin, V.L. Bibik. Tomsk: Publishing house of the Tomsk Polytechnic University, p. The manual contains examples and tasks with solutions. It will help to acquire skills in solving technological problems, identifying the improvement of existing and developing new technological processes. It is intended for practical work in the discipline "Technology of mechanical engineering" by students of higher educational institutions of the specialty "Technology of mechanical engineering". UDC (076) Reviewers Doctor technical sciences, TPU professor S.I. Petrushin Deputy Head of Shop 23, LLC Yurginsky Machine-Building Plant P.N. Bespalov Yurga Technological Institute (branch) of Tomsk Polytechnic University, 2008 Design. Tomsk Polytechnic University Publishing House,
3 CONTENTS CHAPTER 1. BASICS OF DESIGNING TECHNOLOGICAL PROJECTS PRODUCTION AND TECHNOLOGICAL PROCESSES.4 2. ACCURACY OF MECHANICAL PROCESSING BASE AND BASING PRINCIPLES TECHNOLOGY OF DESIGN START-UP ON MECHANICAL PROCESS. OPERATING DIMENSIONS AND THEIR TOLERANCES PROCEDURE FOR DESIGNING TECHNOLOGICAL PROCESSES PRODUCT QUALITY CONTROL METHODS OF BILLS INSTALLATION. 94 CHAPTER 2. METHODS OF PROCESSING OF THE MAIN SURFACES OF WORKPIECES TREATMENT OF EXTERNAL SURFACES OF BODIES OF ROTATION ... 62 CHAPTER 3. TECHNOLOGY OF ASSEMBLING MACHINES ... DESIGN WORKSHOP 3 DESIGN TECHNOLOGY PROCESSING ...
4 CHAPTER 1. BASES FOR DESIGNING TECHNOLOGICAL PROCESSES 1. PRODUCTION AND TECHNOLOGICAL PROCESSES When designing a technological process and its implementation and when designing technological documentation it is important to be able to determine the structure of the technological process and correctly formulate the name and content of its elements. This work is guided by GOST and An important stage in the development of a technological process is also the definition of the type of production. Roughly the type of production is established at the initial design stage. The main criterion in this case is the coefficient of consolidation of operations. This is the ratio of the number of all technological operations performed during a certain period, for example, months, on a mechanical section (O), and to the number of jobs (P) of this section: K z.o = O / R. (1.1) Types of machine-building industries are characterized by the following values of the coefficient of consolidation of operations:<1 массовое производство; 1<К з.о 10 крупносерийное производство; 10<К з.о 20 среднесерийное производство; 20<К з.о 40 мелкосерийное производство; К з.о не регламентируется единичное производство. Формулирование наименования и содержания операции Пример 1.1. Деталь (втулку) изготовляют в условиях серийного производства и из горячекатаного проката, разрезанного на штучные заготовки. Все поверхности обрабатываются однократно. Токарная операция выполняется согласно двум операционным эскизам по установкам (рис.1.1). 4
5 3 9 0 * Ç 8 0 Ç Å 5 6 Ç Å * ð Fig Operating sketches Required: to analyze operational sketches and other source data; establish the content of the operation and formulate its name and content; establish the sequence of processing the workpiece in this operation; describe the content of the transition operation. Solution. 1. Analyzing the initial data, we establish that in the operation under consideration, consisting of two installations, the processing of nine surfaces of the workpiece is carried out, for which it will be necessary to perform nine technological transitions sequentially. 2. To perform the operation, a lathe or screw-cutting lathe will be used, and the name of the operation will be "Turning" or "Screw-cutting lathe" (GOST). Using the same GOST, we determine the operation group number (14) and the operation number (63). To record the content of the operation in the presence of operational sketches, an abbreviated notation can be used: "Trim three ends", "Drill and bore a hole", "Bore one and sharpen two chamfers". 3. We establish a rational sequence of technological transitions for installations, guided by operational sketches. In the first installation, you need to trim 5
6 end face 4, sharpen surface 2 to form end 1, sharpen chamfer 3, drill hole 6 and bore chamfer 5. In the second setting, trim end face 9, sharpen surface 7 and chamfer 8. Table 1.1 Initial data View Contents of transition transition 1 PV Set and fix the workpiece 2 PT Trim the end face 4 Sharpen the surface 2 to form the end face 1 3 PT (when turning surface 2, 2 working strokes are performed) 4 PT Sharpen the chamfer 3 5 PT Drill the hole 6 6 PT Rebore the chamfer 5 7 PT Reinstall the workpiece 8 PT Trim butt end 9 9 ПТ Sharpen the surface 7 10 ПТ Sharpen the chamfer 8 11 PV Control of the dimensions of the parts 12 PV Remove the part and put in the container 4. The content of the operation in the technological documentation is recorded according to the transitions: technological (PT) and auxiliary (PV). When formulating the content of transitions, an abbreviated notation according to GOST is used. Table 1.1 shows the records of the example under consideration. Task 1.1. For the turning operation, an operational sketch was developed and the executive dimensions with tolerances and requirements for the roughness of the machined surfaces were set (Figure 1.2). One-time treatment of each surface. 6
7 3 I, VIR a Å Ç 2 5 H 1 2 II, VII 2 45 Å 3 2 ô à ê è Ç 9 4, 5 h 1 4 Ç 9 5 h 1 4 Ç 8 0 hjshhh 1 4 III, VIIIR a VI, IXR a 2 0 Ç 6 0 h 1 1 Ç 5 0 h 1 1 Ç 4 5 H 1 2 Ç 6 5 H 1 2 Ç H * 2 5 * * î ê 4 5 ± 0, ± 0, 3 3 V, XR a 1 0 Ç, 5 Ç 5 5 H 1 2 Ç hh ± 0.5 Fig Operating sketches 7
8 Required: set the type of machine; determine the configuration and dimensions of the workpiece; establish a basing scheme; number on the sketch all surfaces to be processed; formulate the name and content of the operation for recording in technological documents; write down the content of all technological transitions in the technological sequence in full and abbreviated forms. Establishing the name and structure of the operation and recording its content in the technological documentation Example 1.2. In Fig. 1.3, which is a fragment of the working drawing of the part, the structural element of the part is highlighted, which is to be processed in the conditions of mass production. R a 20 Ç 18 H 12 6 from t. Ç ± 0, 2 8 Ç * * a Fig Working drawing Required: to analyze the initial data; choose a method of processing a constructive type of production; choose the type of metal-cutting machine; set the name of the operation; record the contents of the transaction in full form; formulate a record of the content of the operation for technological transitions. Solution. 1. We establish that six holes in the body flange are to be machined, evenly spaced on a circle of Ø 280 mm. 2. Holes in solid material are made by drilling. 3. Select a radial drilling machine for processing. 4. The name of the operation (in accordance with the type of machine used) "Radial drilling". 5. Recording the content of the operation in full form looks like this: “Drill 6 through holes Ø18H12 sequentially, while maintaining
9 d = (280 ± 0.2) mm and surface roughness Ra = 20 µm, according to the drawing. 6. Recording the content of transitions in full form is as follows: 1st transition (auxiliary). Place the workpiece in the jig and fix it. 2, ..., 7th transitions (technological). Drill 6 holes Ø18H12, keeping the dimensions d = 280 ± 0.2; Ra20 in series on the conductor. 8th transition (auxiliary). Size control. 9th transition (auxiliary). Remove the workpiece and place in a container. Task 1.2. Establish the name and structure of the operation in the conditions of serial production for the processing of structural elements of the part (Fig. 1.4). Option numbers are indicated in the figure in Roman numerals. I, IIIII, IV 3 R a 5 R a Ç 3 4 h 1 0 M g V, VI 4 0 ± 1 VII, VIII Ç 6 0 H 1 2 R a 1 2, 5 R a 5 Ç 6 0 H ± 0 , 3 I Õ, X 1 5 H 1 0 Fig Operating sketches 9
10 Establishing the type of production at the site Example 1.3. The machine shop has 18 jobs. During the month, 154 different technological operations are performed on them. Required: to set the load factor of operations on the site; determine the type of production: state its definition in accordance with GOST Decision. 1. The coefficient of consolidation of operations is set according to the formula (1.1): K z.o = 154/18 = 8.56. In our case, this means that an average of 8.56 operations are assigned to each workplace at the site. 2. The type of production is determined according to GOST and Since 1<К з.о <10, тип производства крупносерийное. 3. Серийное производство характеризуется ограниченной номенклатурой изделий, сравнительно большим объемом их выпуска; изготовление ведется периодически повторяющимися партиями. Крупносерийное производство является одной из разновидностей серийного производства и по своим техническим, организационным и экономическим показателям близко к массовому производству. Задача 1.3. Известно количество рабочих мест участка (Р) и количество технологических операций, выполняемых на них в течение месяца (О). Варианты приведены в табл Требуется: определить тип производства. Таблица 1.2 Данные для расчета коэффициента закрепления операций варианта I II III IV V VI VII VIII IX X Количество рабочих мест (Р) Количество технологических операций (О)
11 2. ACCURACY OF MECHANICAL PROCESSING One of the main tasks of technologists and other production participants in machine shops is to ensure the required accuracy of the manufactured parts. Real machine parts made by means of machining have parameters that differ from ideal values, that is, they have errors, the sizes of errors should not exceed the permissible maximum deviations (tolerances). To ensure the specified processing accuracy, the technological process must be correctly designed taking into account the economic accuracy achieved by various processing methods. Average economic accuracy rates are given in the sources. It is important to take into account that each next transition should increase the accuracy for quality. In some cases, calculation methods are used to determine the possible value of the processing error. This is how the errors of turning are determined from the action of cutting forces arising from insufficient rigidity of the technological system. In some cases, the accuracy of processing a batch of parts is analyzed by methods of mathematical statistics. Determination of the economic accuracy achieved with various methods of processing the outer surfaces of revolution Example 2.1. The surface of a step of a 480 mm long steel shaft made from a forging is preliminarily processed on a lathe to a diameter of 91.2 mm (Fig. 2.1). R a 2 0 Ç 9 1, 2 Rice Stepped shaft Determine: economic accuracy of machining size 91.2; quality of precision of the processed surface and its roughness. eleven
12 Solution. To determine the economic accuracy, use the tables "Economic accuracy of machining", which are given in various reference books. In our case, after rough turning, the accuracy of the machined surface should be within the limits of the first grade (we accept the 13th grade). Taking into account that at l / d = 5.3, the processing errors increase by 1.5 ... 1.6 times, this corresponds to a decrease in accuracy by one grade. Finally, we accept the accuracy of the 14th grade. Since during rough turning the size of the workpiece is intermediate, this size is set for the outer surface with the tolerance field of the main part Ø91.2h14, or Ø91.2-0.37. Surface roughness Ra = µm (in the practice of factories, with well-made workpieces and normal production conditions, a higher machining accuracy is achieved). Task 2.1. One of the stages of the shaft is machined using one of the indicated methods. Option numbers are given in the table. Required: to establish the economic accuracy of processing; execute an operational sketch and indicate on it the size, accuracy grade, tolerance size and roughness. Assume that the surface of the considered shaft step has the tolerance field of the main part (h). version Initial data Table 2.1 Processing method and its nature Shaft length, mm I Lapping II Semi-finishing III Grinding fine IV Grinding once V Superfinishing Step diameter, mm VI Grinding preliminary VII Grinding fine VIII Grinding final IX Diamond smoothing X Grinding final
13 Determination of the accuracy of the shape of the surfaces of the part during processing Example 2.2. On the outer surface of the shaft (Fig. 2.2), a shape tolerance is specified, indicated by a conventional sign according to STSEV. The final processing of this surface is supposed to be performed by grinding on a circular grinding machine model ZM151. It is required: to establish the name and content of the symbol of the specified deviation; to establish the ability to withstand the requirement for the accuracy of the shape of this surface during the intended processing. 0, 01 Ç 7 0 Fig Shaft sketch Solution. 1. According to the sketch presented, the accuracy of the shape of the cylindrical surface is expressed by the roundness tolerance and is 10 microns. According to GOST, this tolerance corresponds to the 6th degree of shape accuracy. The term "Toughness tolerance" is understood to mean the maximum permissible value of the roundness deviation. Particular types of deviation from roundness are ovality, faceting, etc. 2. On a circular grinding machine model ZM151, workpieces with a maximum diameter of up to 200 mm and a length of up to 700 mm can be processed. Therefore, it is suitable for processing this workpiece. The roundness deviation during processing on this machine is 2.5 microns. Based on the foregoing, we conclude that it is possible to perform processing with a given accuracy. Task 2.2. In fig. 2.3 and in table. 2.2 shows surface options with permissible shape deviations. Required: to establish the name and content of the designation of the indicated deviations; to establish the ability to perform processing on the specified machine, observing the specified accuracy. The missing dimensions are set. 13
14 I 0, V, V I Ç, 0 5 Ç 5 0 I I, I I I 0.02 À 0.02 V I I 0, À I V 0, 0 2 V I I I 0, 1 5 I X, X 0, Fig Operational sketches 14
15 Initial data Table 2.2 options Surface form Machine type I Hole Internal grinding II Plane Surface grinding III Plane Surface grinding IV Face Circular grinding V, VI Hole Honing VII Cylinder Screw-cutting VIII Plane Planing IX Cylinder Turning multi-cutter X Cylinder during processing Example 2.3. The sketch (Fig. 2.4) indicates a technical requirement for the accuracy of the relative position of the surfaces of the part. The final processing of the upper plane is supposed to be performed by finishing milling on a vertical milling machine according to the operational sketch shown in Fig, 2 / x À 0, 2 / x À À Fig. Design requirements À Fig. Operational sketch Required: to state the name and content of the technical requirement; to establish, according to technological reference books, the accuracy of the relative position of the surfaces of the part, depending on the type of equipment; make a conclusion about the possibility of fulfilling the specified requirement. Solution. 1. The conventional sign in the working drawing shows the tolerance of parallelism of the upper plane relative to the lower plane, indicated by the letter A.
16 parallelism. In our case, the tolerance is 0.2 mm over an area of mm. 2. In the tables of technological reference books, for example, we find the maximum deviations of our case: they are equal to microns and microns at a length of 300 mm, which means that at a length of 150 mm they will be equal to 12, microns. Of all these data, we take the highest value of 100 μm for guarantee, i.e. 0.1 mm. 3. We draw a conclusion the required accuracy of the relative position of the machined plane relative to the base plane A will be ensured. Task 2.3. In fig. 2.6 shows the options for surface treatment. It is required: to decipher the designation of the content of the admission; develop technological measures to ensure the fulfillment of this requirement. À I, I I 0, À À I I I, I V 0, À V, V I V I I, V I I I 0, 1 5 À Á 0, 0 4 À Á I X, X 0, 0 5 À À Fig Surface treatment options 16
17 3. BASES AND PRINCIPLES OF BASING To carry out the processing of a workpiece on the machine, it must be fixed on it, having previously selected the bases. By basing it is meant giving the workpiece the required position relative to the machine and tool. The accuracy of processing depends on the correctness of the basing. When developing a basing scheme, the issues of selection and placement of control points are solved. In production conditions, there are always processing errors ε mouth, depending on the installation conditions, i.e. from the basing ε of the bases, the fixing ε of the closed workpiece, and from the inaccuracy of the device ε pr. The installation error is expressed by the formula: ε = ε + ε + ε. (3.1) mouth of bases To reduce these errors, it is important to observe the basing rules: the rule of "six points", the rule of "constant bases", the rule of "alignment of bases", etc. The error values can be determined by various methods. The tabular method allows you to determine the installation errors depending on the production conditions. The calculation method for determining the errors of basing, fixing and caused by inaccuracy of the adaptation is carried out using the formulas given in the literature. If the rule of "aligning bases" is not followed, it becomes necessary to recalculate the design dimensions into technological ones (Figure 3.1). The purpose of the recalculation is to determine the size error of the closing link and compare it with the design size tolerance. Á Ê closed pr H = 7 5 h 9 h = 3 0 H * À 1 Ò = À 2 À S Á Ò Fig Technological dimensional chain 17
18 The calculation of dimensional chains is carried out in accordance with GOST and one of the methods specified in them ("maximum minimum", probabilistic, etc.). In these calculations, the formulas for determining the nominal size of the closing link are used: h = H T, (3.2) where H is the size connecting the design and technological bases; T dimension connecting the technological base with the processed surface. The error in the size of the closing link ε h = ε Δ when solving by the "maximum minimum" method is determined by the formulas: ε = T + T; ε = T =, (3.3) h H T n h Σ T i 1 where Ti is the tolerance for the size of each link in the chain; T N tolerance for the size N set by the drawing; T T tolerance for the technological size, the value of which depends on the processing method and is established in accordance with the standard of average economic processing accuracy; n is the number of constituent links. When calculating by the probabilistic method, use the formulas T n 2 = t λiti, (3.4) i = 1 where t is the risk coefficient (t = 3); λi is the coefficient of relative scattering (for the normal distribution law λi = 1/9). When the distribution laws are unknown, take t = 3 and λi = 1/6, therefore n T i i = 1 2 T 1,2t. (3.5) = As a result of the calculation, the condition T h T Σ must be met. (3.6) 18
19 à Selection of the technological base taking into account the technical requirements for the part Example 3.1. In the technological process of manufacturing the body, an operation is provided for boring a hole with a diameter D (Fig. 3.2). When making a hole, dimension a and technical requirements regarding the correct relative position of the hole relative to other surfaces of the part must be observed. Â H 0, 1 À 6 Ã Á 6 Â D 4 5 4, 5 Á 0, 1 Â 22 0, 1 Á Fig Working drawing А А, Fig. 3.3. The basing scheme It is required: to select the technological base for the considered operation; develop a basing scheme. Solution. 1. One of the design bases is plane A of the base. It should be taken as a technological installation base, creating three reference points 1, 2 and 3 for its basing (Fig. 3.3). The technological guide base should be taken to plane B with two reference points 4 and 5. This base will allow you to machine the hole perpendicular to this plane. To ensure the symmetry of the hole location relative to the outer contour, surface B can be used as a technological base, but it is structurally easier to use the surface G of the half-cylinder for this and use a device with a movable prism for this purpose. Based on the foregoing, we will apply a technological base of three surfaces: A, B and D (Fig. 3.3). 2. The basing scheme, which is the location of the control points on the bases of the workpiece, is shown in Fig.
20 a Task 3.1. For a machining operation for processing the specified surface of a part, it is required to select a technological base and draw up a basing scheme. The options are shown in Fig. 3.4 and in Table d I, IIIII, IV, V à 0 0 d 1 dd 2 VI, VII, VIIIIX, X ahb 0, 1 A À D 1 Á d 1 0, 1 Á À d 2 Á d 1 d 2 0 , 1  0, 1 À 0, 1 Á Fig Operational sketches  option I Name and content of operations Name and content of operations Description of operation Content of operation Vertical drilling Drill a hole in the ball Table 3.1 II Turning Drilling a hole in the ball III Turning To sharpen the surfaces finally Grind the indicated IV, V Cylindrical grinding surface final VI, VII Horizontal milling Milling groove VIII Vertical milling Milling groove IX Vertical drilling Drilling 2 holes X Fine boring 2 holes 20
21 Determination of the technological base and drawing up a workpiece basing scheme Example 3.2. It is required: to consider the installation elements of the existing device (Fig. 3.5) and establish the workpiece surfaces that make up the technological base when fixing the workpiece in the device; to develop a scheme for basing the workpiece and conclude that the six-point rule is being followed. Decision. 1. In the device shown in the figure, we identify its mounting elements: the plane of the body 2, the mounting cylindrical pin and the mounting cut-off pin 3. The technological base of the workpiece is the following surfaces: the lower plane of the workpiece A and two holes located diagonally. 2. In accordance with the identified technological bases and the used installation elements, we develop a basing scheme (Fig. 3.6): for basing the plane (installation base), three reference points are formed (1, 2, 3); for locating along the first hole (with the help of a cylindrical pin), two more reference points (4, 5) are formed, and for locating along the second hole, a cut pin (6) forming the 6th locating point is used. 3. As can be seen from Figure 3.6 and the above reasoning, the rule of basing by six points is observed, the workpiece is deprived of six degrees of freedom À Fig Basing the workpiece 21
Fig. 22 Fig. Basing scheme 6 Task 3.2. In fig. 3.7 depicts a device for processing on a machine. It is necessary, using the figure, to identify the technological base adopted for basing the workpiece and present a scheme for basing the workpiece; make a conclusion about the correctness of the choice of control points by the number and their placement. The variant number is indicated in the figure with a Roman numeral. I, I I A - A I I I, I V, V À À V I, V I I V I I I, I X, X Fig Attachments 22
23 Calculation of a linear technological dimensional chain Example 3.3. On a tuned horizontal milling machine, which is working on set-up, the specified plane is finally machined. In this case, the coordinating dimension h = (70 ± 0.05) mm must be maintained (Fig. 3.8). Dimensional tolerance h = 0.1 mm. Required: to establish whether the specified dimensional accuracy will be maintained during processing. Á - h 8 (- 0,) À Σ = h = 7 0 ± 0, 0 5 À 1 = 8 5 h 8 (- 0,) А - те х н о л г г г и е с к а ÿ б а з а Fig Technological dimensional chain Solution. 1. From the conditions of the example and from the operational sketch, it can be seen that the lower plane A of the workpiece is taken as the technological base. The design and measurement bases for control of the size h is the upper plane B. Due to the fact that the bases do not coincide, it became necessary to recalculate the design dimensions to the technological ones. In this case, it is necessary to calculate the error with which the size h can be made, and compare it with the tolerance T h of this size, the condition ε h T h must be met. 2. The dimensional chain under consideration is linear and consists of three links: the size h = 70 mm of interest to us will be considered the closing link And the first component link size A 1 = 85h8 (85-0.04) between the previously processed planes is an increasing link; the second constituent link, the size A 2, is a technological one, which reduces, and its accuracy is determined by the norms of economic accuracy of processing on machines (see GOST). For our case, the error of this size is 0.06 mm. The nominal dimensions of this chain are related by Equation 23
24 A = A 1 A 2 = = 70 mm. 3. When calculating a linear dimensional chain (Fig. 3.8) by the method of complete interchangeability, i.e. using the maximum minimum method, determine the maximum deviations (processing error) of the initial (closing) link according to the formula (3.3): T n = Ti = (TA 1 + TA2) = (0.06) = 0, 114 mm Σ. i = 1 As follows from the solution, the tolerance according to the drawing T h = 0.1 mm is less than the possible error in processing T = ε h = 0.114 mm, which is completely unacceptable. Therefore, it is necessary to take measures to achieve the fulfillment of the condition ε h T h For this, firstly, one can pose a question to the designer about reducing the accuracy of the size h, i.e. on expanding the tolerance T h to a value of 0.12, then T = ε h = (0.06) T h. Secondly, apply fine milling or fine grinding as a finishing (finishing) treatment. The economic accuracy of these processes is higher and with them T A2 = 0.025 mm (GOST). Then T = (0.025) = 0.079 mm. Condition T T h is met. Thirdly, the constituent dimension A = 85h8 was obtained when processing planes A and B before the operation under consideration. If the previous processing is performed more precisely by one quality, then the size tolerance will be 85h7 (-0.035). Then the processing error T = (0.035 +0.06) = 0.095 mm. Condition is met T T h. Fourthly, when calculating the dimensional chain, you can use the probabilistic method according to the formula n T i i = 1 2 T 1,2t. 2 2 Then Т = 1,2 0,060 = 0, 097 mm and the condition T Th is met. Fifthly, the tolerance of the closing link is calculated using the theory of probability for the case of dispersion of errors of deviations according to the law of normal distribution according to the formula (3.5). In our case 2 2 TΣ = 0.060 = 0.08mm. Condition T T h is satisfied. Sixth, with a small volume of production of parts, that is, in a single or small-scale production, it is possible to work not on adjustment, but, for example, with the removal of test shavings. When processing each part, the dimension h is controlled. = 24
25 Task 3.3. In fig. 3.9 and in table. 3.2 options of operations are presented. It is required: to determine the possible error of dimension basing as a result of performing the specified processing. I, IIIII, IV 1 2 l V, VI l 2 l 1 lh 9 Ç Ç Ç l 1 l 2 VII, VIII h 9 1 l 2 l 1 2 Ç Ç Ç hhh 1 0 l 1 IX, X 1 2 l 2 Fig Options for calculating dimensional chains Initial data Table 3.2 options Content of operation Dimension l, mm I Planing plane 1 preliminarily l 1 = 150 + 0.2 II Planing plane 2 finally l 2 = 170 ± 0.1 III Trim end 1 preliminarily l 1 = 60 + 0.3 IV Trim end 2 finally l 2 = 30 + 0.1 V Trim end 1 preliminarily L 1 = 100 + 0.2 VI Trim end 2 finally l 2 = 50 + 0.1 25
26 Continuation of table 3.2 VII Pre-grind plane 1 l 1 = 75 + 0.1 VIII Grind plane 2 finally l 2 = 175 + 0.2 IX Mill plane 1 pre-l 1 = 70 + 0.4 X Mill plane 2 finally l 2 = 30 + 0.2 4. TECHNOLOGY OF DESIGN The successful solution of problems that are and will continue to face mechanical engineering is possible only when creating new and improving existing machines in order to achieve higher performance characteristics while reducing their weight, size and cost, increasing durability, ease of maintenance and reliability in work. At the same time, in mechanical engineering itself, it is necessary to improve the technological processes of manufacturing products, improve the use of all means of technological equipment, and introduce progressive methods of organizing production into production. One of the effective ways of solving these problems is the introduction of the principles of manufacturability of structures. This term is understood as such a design that, while observing all the performance characteristics, ensures the minimum labor intensity of manufacture, material consumption and cost, as well as the possibility of quickly mastering the production of products in a given volume using modern methods of processing and assembly. Manufacturability is the most important technical basis, which ensures the use of design and technological reserves to fulfill tasks to improve the technical and economic indicators of manufacturing and the quality of products. Work to improve manufacturability should be carried out at all stages of design and development in the production of manufactured products. When performing work related to manufacturability, one should be guided by a group of standards included in the Unified System for Technological Preparation of Production (ESTPP), namely GOST, as well as GOST "Technological control in design documentation". The manufacturability of the design of parts is determined by: a) a rational choice of initial blanks and materials; b) the manufacturability of the shape of the part; c) rational setting 26
27 sizes; d) the appointment of the optimal dimensional accuracy, shape and relative position of surfaces, roughness parameters and technical requirements. The manufacturability of the part depends on the type of production; the selected technological process, equipment and tooling; organization of production, as well as from the working conditions of the part and assembly unit in the product and the conditions of repair. Signs of the manufacturability of the design of a part, for example, a subclass of shafts, are the presence of small differences in the diameters of the steps in stepped shafts, the location of stepped surfaces with a decrease in diameter from the middle or from one of the ends, the availability of all machined surfaces for machining, the ability to use the original blank of a progressive type for the manufacture of the part , which in shape and dimensions is close to the shape and dimensions of the finished part, the ability to use high-performance processing methods. Improving the manufacturability of the original workpiece Example 4.1. Two variants of the design of the original workpiece obtained by casting were made for the manufacture of the support body (Fig. 4.1, a, b). It is required to establish which of the options has a more technologically advanced design of the original workpiece. Solution. The body (Fig. 4.1, a) has a tubular cavity in the lower part. To form it in a casting mold, you will have to use a cantilever rod, and this will complicate and increase the cost of making a casting. Smooth hole of considerable length at the top will complicate machining. The body (Fig. 4.1, b) in the lower part has a cruciform section, which has high strength and rigidity, and a rod is not needed for making the casting. This greatly facilitates the manufacture of casting molds. The casting is symmetrical about the vertical plane and will easily be molded in two flasks. The hole in the middle part has a recess and therefore the length of the surface of the hole to be machined is reduced, and this, in turn, greatly facilitates and reduces the cost of machining. Based on the above considerations, it can be concluded that the second option is more technological. 27
28 А А А - А a) b) Fig Variants of the casting shape Problem 4.1. When designing the initial workpiece or its elements, two designs were proposed (options are given in Table 4.1, in Fig. 4.2). Table 4.1 Initial data of the variant Name of the part Type of workpiece I; VI II; VII III; VIII IV; IX V; X Gear wheel Lever Cover Body throat Round body Forged die The same Cast Welded Cast I, V I I I, V I I I I I, V I I I I V, I X V, X Fig.
29 It is required to state considerations for assessing the manufacturability of the design of each of the options for the original workpiece and to establish a more technological one. Improving the manufacturability of parts and their elements Example 4.2. In order to improve the technical and economic indicators of the technological process, two options are proposed for the details of the elements in the structure of the body made of castings (Fig. 4.3, a, b). It is required to evaluate their manufacturability. Solution. The bosses and plates on the body of the part (Fig. 4.3, a) are located at different levels, and the processing of each boss has to be carried out according to individual adjustment. Insufficient rigidity of the upper part of the part does not allow the use of high-performance machining methods. In the construction in fig. 4.3, b all machined surfaces are located in the same plane and therefore can be machined on one machine, for example, on a vertical milling or longitudinal milling machine. a) b) Fig. Casting options The ribs added on the inner side of the part increase the rigidity of the body. During processing, this will help to reduce the deformation of the workpiece from cutting and clamping forces and will allow processing with high cutting conditions or simultaneously with several tools. This will increase the accuracy and quality of the processed surfaces. 29
30 The level of the part's non-machined surfaces is below the machined surfaces. This will allow for more productive processing "on the pass". Task 4.2. One and the same structural element of a machine part can be constructively solved in different ways. These solutions are presented in two sketches (options in Fig. 4.4). It is required to analyze the compared sketches of structures for manufacturability and to justify the choice of the structural element of the part. I, I I V I I, V I I I I I I, I V V, V I I X, X R Fig. Design options Determination of quantitative indicators of the manufacturability of the part design Example 4.3. The body with a mass of m D = 2 kg is made of cast iron grade SCH 20 GOST Method of obtaining the original workpiece casting in an earthen mold, according to the I class of accuracy (GOST); workpiece weight m 0 = 2.62 kg. thirty
31 Labor intensity of the machining of the part T and = 45 min with the basic labor intensity (analogue) = 58 min. Technological cost of the part C t = 2.1 rubles. at the base technological cost of the analogue C b.t = 2.45 rubles. The data of the design analysis of the part by surfaces are presented in Table 4.2 Initial data Name of the surface Number of surfaces Number of unified elements Main hole 1 1 Flange end 2 Chamfer 2 2 Threaded hole 8 8 Top of the base 2 Holes of the base 4 4 Bottom of the base 1 Total ... Q e = 20 Q u.e = 15 It is required to determine the indicators of manufacturability of the design of the part. Solution. 1. The main indicators of manufacturability of the design include: absolute technical and economic indicator labor intensity of manufacturing a part T and = 45 min; the level of manufacturability of the structure in terms of the labor intensity of manufacturing K U. T = T and / T b.i = 45/58 = 0.775. The part for this indicator is technologically advanced, since its labor intensity is 22.5% lower than its basic analogue; technological cost of the part C t = 2.1 rubles; the level of manufacturability of the structure at the technological cost K y. c = C t / C b.t = 2.1 / 2.45 = 0.857. The part is technologically advanced, since its cost compared to the base analogue has decreased by 14.3%. 2. Additional indicators: the coefficient of unification of structural elements of the part K y. e = Q y.e / Q e = 15/20 = 0.75. 31
32 According to this indicator, the part is technologically advanced, since K y. e> 0.6 mass of the part m D = 2 kg; the utilization factor of the material K and m = m d / m 0 = 2 / 2.62 = 0.76. For an initial workpiece of this type, this indicator indicates a satisfactory use of the material. Task 4.3. The part under consideration, its original workpiece and its basic analogue or prototype are known; basic data given in table. 4.3 for ten options. It is required to determine the indicators of manufacturability of the design of the part. Table 4.3 Initial data of the variant Number of surfaces of the part Qe Number of unified elements Qу.e Mass, kg Details md Initial workpiece m0 Labor intensity, min Details T and Basic analogue Tb. And Cost, rub. Details of St Basic analogue С6.г I; VI, 8 1.7 2.1 II; VII, 3 0.9 1.3 III; VIII, 1 3.4 4.1 IV; IX, 2 0.2 1.4 V; X, 8 5.8 5.3 5. STREAMS FOR MACHINING. OPERATING DIMENSIONS AND THEIR TOLERANCES When considering the elementary surface of the original workpiece and the corresponding surface of the finished part, the total allowance for machining is determined by comparing their sizes: this is the difference in the sizes of the corresponding surface on the original workpiece and the finished part. When considering the outer surface of rotation (on the left in Fig. 5.1), the total allowance: 2P total d = d 0 d D; (5.1) 32
33 at the inner surface of revolution (in the center in Fig. 5.1) the total allowance: 2П total d = D D D 0; (5.2) near a flat surface (on the right in Fig. 5.1) the total allowance on the side: P total h = h 0 h D, (5.3) where d 0, D 0, h 0 are the dimensions of the original workpiece; d D, D D, h D corresponding dimensions of the finished part; 2П totald and 2П totald general allowances for diameter, outer surface and holes; P total allowance on the side (butt, plane). The allowance for machining is usually removed sequentially in several transitions and therefore for surfaces of revolution and for flat surfaces 2P total d = 2P i; 2P total d = 2P i; P total h = 2P i, (5.4) where Pi are intermediate allowances performed during the i-th transition, and at each next transition the size of the intermediate allowance is less than at the previous one, and with each subsequent transition, the accuracy increases and the roughness of the machined surface decreases. Ï Ï d ä d 0 D ä D 0 h ä h 0 Ï Ï Ï Fig Types of allowance for machining processing technology of the part parameters intermediate dimensions of the workpiece, which appear in the technological documentation, depending on 33
34 from which performers select cutting and measuring tools. Intermediate allowances for each transition can be established by two methods: by the experimental-statistical method, using tables in GOSTs, in technological reference books, departmental guiding technological materials and other sources. These sources often lack tables for determining the operating allowances for the first rough cut. The operational allowance for the rough transition is determined by the calculation according to the formula P 1 = P total (P 2 + Pz P n), (5.5) where P total is the total allowance for machining, established during the design of the workpiece; P 1, P 2; ..., P n intermediate allowances for the 1st, 2nd, ..., nth transitions, respectively; by calculation and analytical method according to special formulas, taking into account many processing factors. When calculating using this method, the operating allowances are obtained less than those selected according to the tables, which allows you to save metal and reduce the cost of processing. This method is used in the design of technological processes for processing parts with a large annual output. In the technological documentation and in the practice of processing, intermediate nominal dimensions are used with permissible deviations. As can be seen in the diagram (Fig.5.2) of the location of allowances and tolerances during processing, the nominal intermediate dimensions depend on the nominal allowances, which are found by the formula П nomi = П min i + T i-1, (5.6) where T i-1 tolerance for intermediate size at the previous transition. For various surfaces, the following formulas are used: for surfaces of revolution, except for the case of processing in centers: 2P nomi = 2 (R zi-1 + h i Δ i 1 + ε) + T i-1; (5.7) 2 i for surfaces of revolution when machining in centers: 34
35 for flat surfaces 2P nomi = 2 (R zi-1 + h i-1 + Δ Σi-1) + T i-1; (5.8) P nomi = 2 (R zi-1 + h i-1 + Δ Σi-1 + ε i) + T i-1; (5.9) for two opposite flat surfaces with their simultaneous processing: П nomi = 2 (R zi-1 + h i-1 + Δ Σi-1 + ε i) + T i-1, (5.10) where R Zi-1 the height of microroughnesses on the surface after the previous transition; h i-1 thickness (depth) of the defective layer obtained at the previous adjacent transition, for example, a casting crust, decarburized or work-hardened layer (this term is not taken into account for cast iron parts, starting from the second transition, and for parts after heat treatment); Δ Σi-1 the total value of the spatial deviations of interconnected surfaces from the correct shape (warpage, eccentricity, etc.) remaining after the previous transition (the total value of the spatial deviations decreases with each subsequent transition: Δ Σi = 0.06 Δ Σ0; Δ Σ2 = 0.05 Δ Σ1; Δ Σ3 = 0.04 Δ Σ2 When non-rigid clamping of the workpiece or tool, for example, in oscillating or floating holders, Δ Σi-1 = 0); ε i is the error in setting the workpiece on the machine when the transition under consideration is performed: 2 bases 2 closed 35 2 adj ε = ε + ε + ε, (5.11) where ε bases, ε close centers ε i = 0, when processing on multi-position operations when changing position, the indexing error ε ind = 50 μm is taken into account according to the formula ε i = 0.06 ε i-1 + ε ind); T i-1 tolerance for the intermediate dimension (when determining the allowance for the first rough transition for the outer surfaces, only the minus part of T is taken into account, and for the inner 0 surfaces the plus part of the tolerance of the original workpiece). Intermediate dimensions when processing the outer surfaces of rotation (shafts) are set in the reverse order
36 technological process of processing this surface, i.e. from the size of the finished part to the size of the workpiece by sequentially adding allowances P nom4 to the largest limiting size of the finished surface of the part (initial calculated size); P number3; P nom2; P number 1. The tolerances of these dimensions are set according to the shaft system with a tolerance field h of the corresponding quality. The largest limiting size of the finished surface is taken as the initial calculated size. Rounding of intermediate dimensions is performed in the direction of increasing the intermediate allowance to the same sign as the tolerance of this dimension. The features of calculating intermediate allowances and dimensions for internal surfaces are as follows: a) tolerances of intermediate (interoperational) dimensions are set according to the hole system with a tolerance field H of the corresponding quality; b) nominal dimensions and nominal allowances, at all transitions, except for the first one, are connected by the dependence П nomi = П mini + T i-1, (5.12) and the nominal allowance for the first (rough) transition is determined by the formula where П nomi = П mini + T 0 +, (5.13) + T 0 plus part of the workpiece tolerance; c) intermediate dimensions are set in the reverse order of the technological process from the size of the finished hole to the size of the workpiece by subtracting from the smallest limiting size of the finished hole (original size) allowances P nom3; P nom2; P number 1. Their tolerances are set according to the hole system with a tolerance field H; d) the smallest limiting size of the finished hole is taken as the initial calculated size. The diagram of the tolerance fields of the outer surface of the part, workpieces at all stages of processing and the original workpiece and the total and intermediate allowance fields are shown in Fig.
37 + T 0 - d 0 í î ì = d 1 í î ì + 2 Ï 1 í î ì 2 Ï 1 í î ì T 1 d 1 í î ì = d 2 í î ì + 2 Ï 2 í î ì 2 Ï 2 - - T 2 d 2 î ì = d 3 í î ì + 2 Ï 3 í î ì 2 Ï 3 í î ì T 3 d 3 í î ì = d 4 í î ì + 2 Ï 4 í î ì 2 Ï 4 í î ì T 4 I I d I I I I I I I I I I III I do I do IV I do it Scheme of tolerance fields à Selection of intermediate allowances when machining a rolled shaft and calculation of intermediate dimensions Example 5.1. A stepped shaft with a length of L D = 480 mm (Fig. 5.3) is manufactured under conditions of small-scale production from steel round hot-rolled products of normal accuracy with a diameter of d 0 = 100 mm. The largest shaft step Ø90h10 (90-0.35) with a surface roughness of Ra5 (Rz20) is machined twice: preliminary and final turning. Required: to set the total allowance for machining diametrical dimensions; set intermediate allowances for both processing transitions using the statistical method; calculate the intermediate size. R a 5 Ç 9 0 h * Fig Stepped shaft 37
Solution 38. 1. The total allowance for machining for the diameter is determined by the formula 5.1: 2P total d = = 10 mm. 2. Intermediate diameter allowance for fine turning of the shaft. 2P 2 tabl = 1.2 mm. For a small-scale production, the allowance increases, for which the coefficient K = 1.3 is introduced, i.e. 2P 2calculated = 1.2 1.3 = 1.56 mm 1.6 mm. Since there are no indications regarding the size of the operating allowance for the diameter during rough turning in the technological manuals, we determine it by calculation using the formula (5.4): 2P 1 = 2P total d 2P 2calculated = 10 1.6 = 8.4 mm. So, the initial calculated size of the diameter (the largest limiting size) is equal to d and cx = 90 mm, the operating allowance for finishing turning 2P 2 = 1.6 mm. The diameter of the workpiece after rough turning is d 1 = d out + 2P 2 = 91.6; he is with a tolerance: d 1 = 91.6h12, or d 1 = 91.6-0.35; surface roughness Ra20. In the technological documentation, operational sketches are made for both transitions (Fig. 5.4, a, b) R a 20 Ç 9 1, 6 h 1 2 a) R a 5 Ç 9 0 h 1 0 b) Fig Operational sketches Task 5.1. For the manufacture of a stepped shaft (Fig.5.5), hot-rolled steel round steel of normal accuracy with a diameter d 0 was used as a workpiece.
39 twice with preliminary and final turning. Variants of the problem are given in the table d 0 d ä L ä Fig Workpiece circle Initial data Table 5.1 of variants I II III IV V VI VII VIII IX X d D mm 75h11 85a11 65b11 95a11 60d11 95d11 70a11 90h11 80d11 55h11 do mm L D mm Required: install using tables, total and intermediate allowances; calculate the intermediate dimension and perform operational sketches. Establishment by a statistical method (according to tables) of intermediate allowances for each transition and calculation of intermediate dimensions of the workpiece Example 5.2. A multistage shaft (Fig. 5.6) is made of high-precision stamped forgings (class I). The workpiece underwent milling and centering, as a result of which the ends were cut and center holes were created. 39
40 Ç 8 5 p 6 Ç 9 1, 2 + 0, 3-0, * Fig. Workpiece forging The outer cylindrical surface of one shaft step has a diameter d = 85p6 (85) * with a roughness of Ra1.25. Stage D of the original workpiece (see example P1.2) has a diameter d 0 = 91, and a roughness Rz250 (Ra60). The accepted sequence of processing the specified surface is given in the table Required: to analyze the initial data; to establish by a statistical method (according to tables) operational allowances for each transition; calculate intermediate dimensions for each technological transition. Solution. 1. The total machining allowance for the diameter is 6.2 mm. The coefficient of hardening of the size of the processed surface is K hardened p. = T 0 / T D = 2000/22 = 91. Table 5.2 Initial data Processing sequence (transition content) Pre-sharpen the surface Pre-grind the surface for grinding Pre-grind the surface Finish the surface Accuracy quality Roughness parameter Ra, μm 20.0 5.0 2 , 5 1.25 Note that the permissible deviation of the diameter of the original workpiece corresponds to approximately the 16th grade of accuracy (IT16), and the finished part corresponds to the 6th grade of accuracy (IT6). Thus, the accuracy during processing increases by about ten qualities. Such a difference in accuracy can be achieved in four processing stages, so 40
41 how each stage of processing increases the dimensional accuracy by an average of quality. 2. The selection of the operating allowances for the diameter is performed according to the tables. Total allowance 2P total = 6.2 mm. The tabular value of the operating allowance for the diameter during grinding is 0.5 mm, we distribute it for preliminary and final grinding (approximately in a ratio of 3: 1) and we obtain 2P 3 = 0.375 mm and 2P 4 = 0.125 mm. Roundedly we take 2P 3 = 0.4; 2P 4 = 0.1. Turning allowance for grinding 2P 2 = 1.2 mm. From here we find the allowance for rough turning: 2P 1 = 2P total 2P 2 2P 3 2P 4 = 4.5 mm. Surface parameters after machining for each transition are presented in table. 5.3, the following conclusions can be drawn: a) the total allowance is divided by transitions in the ratio of 72.5%, 19.5%, 6.5% and 1.5%, which corresponds to the rules of machining technology; b) after each transition, the accuracy increases in the following sequence (by quality): and, accordingly, the size tolerance decreases (there is a tightening of the tolerance) by 4.3; 3.8; 2.6 and 2.1 times; Table 5.3 Initial data of the transition Designation and size of the intermediate allowance for diameter 0 2P total = 6.2 mm Tolerance field IT 16 (I class according to GOST) 1 2P 1 = 4.5 mm h13 2 2P 2 = 1.2 mm h10 3 2P 3 = 0.4 mm h8 4 2P 4 = 0.1 mm р6 41 Size tolerance, mm +1.3 0.4 0 0.054 +0.059 +0.037 Surface roughness, μm Ra60 (Rz250) Ra20 Ra5.5 Ra2.5 Ra1.25
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