后钢板弹簧吊耳工艺设计说明书(附工艺卡)

【课程设计说明书】[附工艺卡片]班号：0351001学生姓名：黄思翰指导老师：杨志兵贺鸣1目录一、零件的工艺分析及生产类型的确定1.零件的作用···········································································································22.零件的工艺分析···································································································23.零件的生产类型···································································································2二、选择毛坯、确定毛坯尺寸1.选择毛坯···············································································································32.确定机械加工余量、毛坯尺寸和公差·······························································33.确定机械加工余量·······························································································34.确定毛坯尺寸和尺寸公差···················································································4三、选择加工方法、制定工艺路线1.定位基准的选择·································································································42.零件表面加工方法的选择·················································································43.制定工艺路线·····································································································5四、工序设计1.机床设备的选用·································································································72.工艺装备的选用·································································································7五、确定切削用量及基本时间工序1：“粗铣φ37孔的两φ60端面至78”························································7工序2：“粗铣两φ30孔内侧端面距离至75”·····················································8工序3：“精铣两φ30孔内侧端面距离至〖77〗_0^(+0.07)”·····························9工序4：“粗铣两φ30孔外侧端面与内侧端面距离至22”································11工序5：“半精铣φ37孔的两φ60端面至〖76〗_(-0.6)^(-0.2)”·······················12工序6：“钻φ20孔···································································································13工序7：“扩钻φ35孔”·························································································14工序8：“扩φ35孔至φ36.75”············································································15工序9：“铰φ36.75孔至φ〖37〗_0^(+0.05)”···················································16工序10：“钻φ15孔”···························································································17工序11：“钻φ28孔”···························································································18工序12：“扩φ28孔至φ29.93”··········································································19工序13：“铰φ29.93孔至φ〖30〗_0^(+0.05)”·················································20工序14：“钻φ10.5孔”························································································21工序15：“粗铣4mm开口槽”··············································································22附录工序卡2课程设计题目：“板簧吊耳”零件工艺设计一、零件的工艺分析及生产类型的确定1.零件的作用后钢板弹簧吊耳的主要作用是在汽车载重之后，使得钢板能够自由延伸、伸展，起到正常的缓冲作用，故弹簧吊耳的加工质量会影响汽车的使用性能和寿命。吊耳的作用包括减震功能、阻尼缓冲功能以及导向功能。吊耳两端的卷耳用销子铰接在车架的支架上。这样，通过钢板弹簧将车桥与车身连接起来，起到缓冲、减振和传力作用。2.零件的工艺分析根据后钢板弹簧吊耳的零件图可知它为对称型零件，拥有两个相互垂直的对称面。它的加工面的数量较少，大部分外表面以及圆角都不进行加工，制作毛坯时一次制成。需要加工的表面包括一个φ37通孔和两个φ30通孔各有的两个端面、φ37通孔以及其的两个端面倒角、两φ30通孔和各有的一个倒角、两个分别与两个φ30通孔相交错的φ10.5的通孔、两分别对应两个φ30通孔的宽4mm的开口槽。根据对称关系将以上表面分为两组：1)顶部的φ37通孔及相关的加工面2)底部两对称的φ30通孔及相关的加工面（同时加工）3.零件的生产类型1)生产纲领产品的生产类型由生产纲领决定，生产纲领是企业根据市场需求和自身生产能力在计划期内对需要生产的产品产量划定，以此为依据设定生产进度计划。若计划期为一年，则计算得到的为年生产纲领。根据设计题目知：Q=330000台/年，n=1，备品率α=18%，废品率β=0.22%工作班次z=2。后钢板弹簧吊耳的年生产纲领N=Qn(1+α)(1+β)=330000×1×1.18×1.022=3902572)生产节拍生产节拍是根据生产纲领计算而得的生产速度衡量指标，节拍指批量生产或大量生产中生产连续两个产品之间的时间间隔。根据工作班次的不同有不同的年时基数T:一班生产为2350h，二班生产为4600h。后钢板弹簧吊耳的生产节拍𝜏=𝑇𝑁=4600∗3600s390257≈42.4s3)生产类型后钢板弹簧吊耳的质量为2.6kg，属于轻型零件，再根据计算得到的年生产纲领339025750000，查表2-1可知其生产类型属于大量生产。二、选择毛坯、确定毛坯尺寸1.选择毛坯该零件材料为35钢，年产量为350000，为大量生产，其结构形状呈Y形，且外表面有许多圆角加工要求，零件的轮廓尺寸不大，故应使用模锻成形。由于零件材料为钢，锻造时如果制作孔不方便，且可能对零件的机械性能有很大影响，故在锻造毛坯中不制造孔，在后续机械加工过程中再打孔。2.确定机械加工余量、毛坯尺寸和公差毛坯是钢质模锻件，根据GB/T12362-2003确定机械加工余量。1)锻件公差等级，根据零件的功用和技术要求，去锻件公差等级为普通级。2)锻件质量𝑚𝑓：根据零件成品质量2.6kg，估算其锻件质量为𝑚𝑓=3.3kg。3)锻件形状复杂系数S：该锻件为扁状弯杆组合，用长方体作外廓包容体，l≈170mm、b=120.5mm、h=60mm，钢密度ρ=7.85g/cm3，外廓包容体质量：𝑚𝑁=170∗120.5∗60∗7.85∗10−6kg=9.65kg故形状复杂系数S𝑆=𝑚𝑓𝑚𝑁=3.39.65≈0.34由于0.320.330.63，故形状复杂系数S属于S2级。4)锻件材质系数M：由于该零件材料为35钢，其碳的质量分数为0.32%~0.40%，小于0.65%，故该锻件的材质系数属M1级。5)零件表面粗糙度：由零件图可知，零件所有表面的Ra都大于或等于1.6μm。3.确定机械加工余量根据零件图判断需要加工的表面，汇总成表：后钢板弹簧吊耳加工面汇总表需要加工的表面加工面数加工得到表面数量相关尺寸Ra要求φ37孔11370+0.051.6φ37孔的两φ60端面2276−0.6−0.26.3两φ30孔内侧端面22770+0.0712.5两φ30孔22300+0.0512.5两φ30孔外侧端面222250两φ10.5孔2210.550两开口槽24450φ37孔两端的倒角221.5×30°50两φ30孔的外端面倒角221×45°504根据锻件质量、零件表面粗糙度、形状复杂系数，查表（GB/T12362-2003）得：零件厚度方向的单边余量为1.7~2.2mm，水平方向单边余量为1.7~2.2mm。取“φ37孔的两φ60端面间距离”的余量为2、“两φ30孔内侧端面距离”的余量为2、“φ30孔内外侧端面距离的余量”为2。4.确定毛坯尺寸和尺寸公差由于本零件的加工表面Ra＞1.6μm，φ37、φ30以及φ10.5的孔在后续工序中钻出，在毛坯中没有，其他加工表面的毛坯基本尺寸为零件图上的尺寸再加上所查得的加工余量毛坯尺寸公差根据锻件质量、材质系数、形状复杂系数从GB/T12362-2003查得，本零件中φ37孔两端面距离的毛坯尺寸为80mm，公差为−0.7+1.5；两φ30孔内侧端面距离毛坯尺寸为73，公差为−0.7+1.5。φ30孔内外侧端面距离尺寸为26，公差为−0.6+1.2。后钢板弹簧吊耳毛坯（锻件）尺寸及公差尺寸名称零件图尺寸单面加工余量锻件尺寸及公差φ37孔的两φ60端面间距离76−0.6−0.2280−0.7+1.5两φ30孔内侧端面距离770+0.07273−0.7+1.5φ30孔内外侧端面距离22226−0.6+1.2三、选择加工方法、制定工艺路线1.定位基准的选择本零件的毛坯主要有六个平面，除此之外基本都是无须加工的曲面，毛坯无孔。首次加工时要对毛坯的“φ37孔的两φ60端面”、“两φ30孔内侧端面”、“两φ30孔外侧端面”进行加工，粗基准可选择φ37孔和