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存檔編碼：無(wú)無(wú)錫錫太太湖湖學(xué)學(xué)院院 2013 屆屆畢畢業(yè)業(yè)作作業(yè)業(yè)周周次次進(jìn)進(jìn)度度計(jì)計(jì)劃劃、檢檢查查落落實(shí)實(shí)表表 系別：信機(jī)系 班級(jí)：機(jī)械91 學(xué)生姓名：季婷婷 課題（設(shè)計(jì)）名稱：缸頭兩面鉆孔專機(jī)設(shè)計(jì) 開始日期：2012年11月12日周次起止日期工作計(jì)劃、進(jìn)度每周主要完成內(nèi)容存在問(wèn)題、改進(jìn)方法指導(dǎo)教師意見(jiàn)并簽字備 注1-32012年11月12日-2012年12月2日教師下達(dá)畢業(yè)設(shè)計(jì)任務(wù)，學(xué)生初步閱讀資料，完成畢業(yè)設(shè)計(jì)開題報(bào)告。按照任務(wù)書要求查閱論文相關(guān)參考資料，填寫畢業(yè)設(shè)計(jì)開題報(bào)告書參考資料不太詳細(xì)，論文中相關(guān)的設(shè)計(jì)結(jié)構(gòu)比較分散，要將各論文中設(shè)計(jì)的部件整合起來(lái)一起研究分析4-102012年12月3日-1月20日指導(dǎo)專業(yè)實(shí)訓(xùn)專業(yè)實(shí)訓(xùn)初次進(jìn)入工廠實(shí)習(xí)，對(duì)生產(chǎn)結(jié)構(gòu)不太熟悉，要多動(dòng)手做，加強(qiáng)熟悉工作流程11-122013年1月21日-3月1日指導(dǎo)畢業(yè)實(shí)習(xí),完成英文翻譯畢業(yè)實(shí)習(xí)，英文翻譯翻譯中遇到很多專業(yè)術(shù)語(yǔ)，翻譯語(yǔ)句不通順，加強(qiáng)英語(yǔ)練習(xí)，通順語(yǔ)句132012年3月4日-3月8日專用機(jī)床總體方案設(shè)計(jì)專用機(jī)床總體方案設(shè)計(jì)設(shè)計(jì)思路不夠明確，對(duì)于所要完成的任務(wù)還不是十分清楚，要明確目標(biāo)，設(shè)定計(jì)劃142013年3月11日-3月15日專用機(jī)床總體方案設(shè)計(jì)專用機(jī)床總體方案設(shè)計(jì)對(duì)于各部件的裝配關(guān)系不太清楚，要理清各部件間的裝配152013年3月18日-3月22日繪制零件加工工序圖繪制零件加工工序圖部分圖紙尺寸不全，多查找相關(guān)資料，估算尺寸162013年3月25日-3月29日繪制零件加工示意圖繪制零件加工示意圖CAD繪圖技能有待提高，要加強(qiáng)練習(xí)172013年4月1日-4月5日繪制機(jī)床聯(lián)系尺寸圖繪制機(jī)床聯(lián)系尺寸圖部分圖紙尺寸不全，多查找相關(guān)資料，查找尺寸182013年4月8日-4月12日繪制機(jī)床聯(lián)系尺寸圖；填生產(chǎn)率計(jì)算卡繪制機(jī)床聯(lián)系尺寸圖；填生產(chǎn)率計(jì)算卡CAD繪圖技能有待提高，要加強(qiáng)練習(xí)192013年4月15日-4月19日專用夾具設(shè)計(jì)專用夾具設(shè)計(jì)設(shè)計(jì)計(jì)算比較生疏，查閱書籍，按照書上步驟一步一步設(shè)計(jì)計(jì)算202013年4月22日-4月26日專用夾具設(shè)計(jì)專用夾具設(shè)計(jì)繪制圖紙，修改212013年4月29日-5月3日多軸箱設(shè)計(jì)多軸箱設(shè)計(jì)設(shè)計(jì)計(jì)算比較生疏，查閱書籍，按照書上步驟一步一步設(shè)計(jì)計(jì)算222013年5月6日-5月10日多軸箱設(shè)計(jì)多軸箱設(shè)計(jì)繪制圖紙，修改232013年5月13日-5月17日檢查、修改、完善、撰寫設(shè)計(jì)說(shuō)明書檢查、修改、完善、撰寫設(shè)計(jì)說(shuō)明書論文格式嚴(yán)格按照學(xué)校的規(guī)范進(jìn)行修改,完善242013年5月20日-5月25日資料整理、裝訂、準(zhǔn)備答辯資料整理、裝訂、準(zhǔn)備答辯存在很多細(xì)節(jié)方面的錯(cuò)誤，應(yīng)認(rèn)真檢查并及時(shí)改正 說(shuō)明：1、“工作計(jì)劃、進(jìn)度”、“指導(dǎo)教師意見(jiàn)并簽字”由指導(dǎo)教師填寫，“每周主要完成內(nèi)容”，“存在問(wèn)題、改進(jìn)方法”由學(xué)生填寫。2、本表由各系妥善歸檔，保存?zhèn)洳?。周次起止日期工作?jì)劃、進(jìn)度每周主要完成內(nèi)容存在問(wèn)題、改進(jìn)方法指導(dǎo)教師意見(jiàn)并簽字備 注編號(hào)
無(wú)錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
相關(guān)資料
題目： 缸頭兩面鉆孔專機(jī)設(shè)計(jì)
信機(jī) 系 機(jī)械工程及自動(dòng)化專業(yè)
學(xué) 號(hào)： 0923003
學(xué)生姓名： 季婷婷
指導(dǎo)教師： 劉新佳（職稱：副教授）
（職稱： ）
2013年5月25日
無(wú)錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
開題報(bào)告
題目： 缸頭兩面鉆孔專機(jī)設(shè)計(jì)
信機(jī) 系 機(jī)械工程及自動(dòng)化 專業(yè)
學(xué) 號(hào)： 0923003
學(xué)生姓名： 季婷婷
指導(dǎo)教師： 劉新佳 （職稱：副教授）
（職稱： ）
2012年11月25日
課題來(lái)源
自擬題目
科學(xué)依據(jù)（包括課題的科學(xué)意義；國(guó)內(nèi)外研究概況、水平和發(fā)展趨勢(shì)；應(yīng)用前景等）
（1）課題科學(xué)意義
專用機(jī)床相對(duì)于通用機(jī)床造價(jià)昂貴，設(shè)計(jì)、制造周期長(zhǎng)，在一定程度上阻礙著產(chǎn)品的更新?lián)Q代。為了解決通用機(jī)床與專用機(jī)床之間的矛盾，同時(shí)盡可能地兼顧通用機(jī)床與專用機(jī)床的優(yōu)越性，于是，組合機(jī)床便在通用機(jī)床與專用機(jī)床的夾縫中悄然興起，并得到了越來(lái)越廣泛的應(yīng)用。本課題主要是對(duì)缸頭兩面鉆孔組合機(jī)床進(jìn)行設(shè)計(jì)。
（2）國(guó)內(nèi)外研究概況、水平和發(fā)展趨勢(shì)
組合機(jī)床出現(xiàn)在世界上只有50多年的歷史。我國(guó)從1956年開始自行設(shè)計(jì)、制造了組合機(jī)床并得到很大發(fā)展。目前，我國(guó)大多數(shù)省、市、自治區(qū)都能設(shè)計(jì)并制造組合機(jī)床及自動(dòng)線，產(chǎn)量，質(zhì)量和技術(shù)水平都在不斷提高。組合機(jī)床在汽車、拖拉機(jī)、柴油機(jī)等部門已獲得廣泛的應(yīng)用。由于組合機(jī)床具有的一系列優(yōu)點(diǎn)，因此在我國(guó)機(jī)械加工工業(yè)中廣泛使用組合機(jī)床已成為多、快、好、省地發(fā)展我國(guó)機(jī)械加工工業(yè)的一條重要途徑，繼續(xù)發(fā)展和提高組合機(jī)床及自動(dòng)線技術(shù)水平，是當(dāng)前機(jī)械加工工業(yè)的一項(xiàng)重要任務(wù)。
組合機(jī)床行業(yè)雖然取得了較大的進(jìn)步與發(fā)展，但是，在制造技術(shù)高速發(fā)展的今天，由于基礎(chǔ)薄弱，從整體上看，與國(guó)外先進(jìn)水平還存在著一定的差距。國(guó)外組合機(jī)床技術(shù)在滿足精度和效率要求的基礎(chǔ)上，正朝著綜合成套和具備柔性的方向發(fā)展，實(shí)現(xiàn)了機(jī)床工作程序軟件化，工序高度集中，高效短節(jié)拍和多種功能的自動(dòng)監(jiān)控。
（3）應(yīng)用前景
縱觀世界四大機(jī)床展覽會(huì)的概況我們可以從中看到未來(lái)機(jī)床的發(fā)展動(dòng)向有以下特點(diǎn)：
（1） 從開發(fā)FA/CIM等制造系統(tǒng)轉(zhuǎn)變到積極深入開發(fā)單機(jī)與環(huán)節(jié)技術(shù)，提高其先進(jìn)性、可靠性、實(shí)用性和性能價(jià)格比，力求價(jià)廉，且實(shí)用于生產(chǎn)，產(chǎn)業(yè)經(jīng)濟(jì)效果。這是當(dāng)前世界機(jī)床技術(shù)發(fā)展的主流。
（2） 進(jìn)一步提高和開發(fā)高精度、高效率、高自動(dòng)化及多樣性、成套性、綜合性的單機(jī)與環(huán)節(jié)。這是目前世界機(jī)床技術(shù)發(fā)展的根本趨勢(shì)。
（3） 進(jìn)一步發(fā)展不同程度的低、中、高檔機(jī)電一體化的各類單機(jī)與環(huán)節(jié)產(chǎn)品，提高加工精度、效率、自動(dòng)化，全面提高制造技術(shù)水平，有利的長(zhǎng)遠(yuǎn)發(fā)展趨勢(shì)。
研究?jī)?nèi)容
① 熟悉組合機(jī)床的發(fā)展歷程，特別是從1956年我國(guó)開始自行設(shè)計(jì)制造并得到很大發(fā)展的歷史；
② 熟悉組合機(jī)床通用部件和專用部件的選用；
③ 完成組合機(jī)床的總體設(shè)計(jì)、多軸箱設(shè)計(jì)和夾具設(shè)計(jì)；
④ 熟練運(yùn)用CAD等制圖軟件；
擬采取的研究方法、技術(shù)路線、實(shí)驗(yàn)方案及可行性分析
（1）方案
查閱資料，調(diào)查研究；進(jìn)行零件的工藝分析，選擇加工方案；確定切削用量，切削功率；確定組合機(jī)床的配置形式和結(jié)構(gòu)方案；編制“三圖一卡”； 多軸箱的設(shè)計(jì)（含必要的計(jì)算）；夾具設(shè)計(jì)。
（2）研究方法
① 組合機(jī)床的總體設(shè)計(jì)。
② 多軸箱設(shè)計(jì)。
③ 夾具的設(shè)計(jì)。
研究計(jì)劃及預(yù)期成果
研究計(jì)劃：
2012年12月 3日-2013年 1月 20日：專業(yè)實(shí)訓(xùn)。
2013年 1月21日-2013年3月 1日：畢業(yè)實(shí)習(xí)；完成英文資料翻譯。
2013年 3月 4日-2013年 3月15日：專用機(jī)床總體方案設(shè)計(jì)。
2013年 3月18日-2013年 3月29日：繪制零件加工工序圖。
2013年 4月 1日-2013年 4月12日：繪制機(jī)床聯(lián)系尺寸圖；填生產(chǎn)率計(jì)算卡。
2013年 4月15日-2013年 4月26日：專用夾具設(shè)計(jì)。
2013年 4月29日-2013年 5月10日：多軸箱設(shè)計(jì)。
2013年 5月13日-2013年 5月17日：檢查、修改、完善、撰寫設(shè)計(jì)說(shuō)明書。
2013年 5月20日-2013年 5月25日：資料整理、裝訂、準(zhǔn)備答辯。
預(yù)期成果：
圖紙一套和說(shuō)明書一份。
特色或創(chuàng)新之處
①配置靈活，加工精度穩(wěn)定。
②研制周期短，便于設(shè)計(jì)、制造和使用維護(hù)，成本低。
③自動(dòng)化程度高，勞動(dòng)強(qiáng)度低，生產(chǎn)率高。
已具備的條件和尚需解決的問(wèn)題
① 經(jīng)過(guò)專業(yè)課程設(shè)計(jì)等的訓(xùn)練以及畢業(yè)實(shí)習(xí)，前期調(diào)研，相關(guān)資料等的搜集，已做好進(jìn)行技術(shù)設(shè)計(jì)的相關(guān)準(zhǔn)備工作，設(shè)計(jì)思路及方案已基本明確。
② AUTO CAD熟練程度尚待加強(qiáng)。
指導(dǎo)教師意見(jiàn)
指導(dǎo)教師簽名：
年 月 日
教研室（學(xué)科組、研究所）意見(jiàn)
教研室主任簽名：
年 月 日
系意見(jiàn)
主管領(lǐng)導(dǎo)簽名：
年 月 日
中文譯文
缸體機(jī)械加工工藝設(shè)計(jì)
發(fā)動(dòng)機(jī)缸體是發(fā)動(dòng)機(jī)零件中結(jié)構(gòu)較為復(fù)雜的箱體零件，其精度要求高，加工工藝復(fù)雜，且加工質(zhì)量的好壞直接影響發(fā)動(dòng)機(jī)整機(jī)性能，因此，它成為各發(fā)動(dòng)機(jī)生產(chǎn)廠家所關(guān)注的重點(diǎn)零件之一。
1．發(fā)動(dòng)機(jī)缸體的工藝特點(diǎn)
發(fā)動(dòng)機(jī)缸體是發(fā)動(dòng)機(jī)的基礎(chǔ)零件和骨架，同時(shí)又是發(fā)動(dòng)機(jī)總裝配時(shí)的基準(zhǔn)零件。缸體的作用是支承和保證活塞、連桿、曲軸等運(yùn)動(dòng)部件工作時(shí)的準(zhǔn)確位置；保證發(fā)動(dòng)機(jī)的換氣、冷卻和潤(rùn)滑；提供各種輔助系統(tǒng)、部件及發(fā)動(dòng)機(jī)的安裝。
1.1 工藝特點(diǎn)
缸體為一整體鑄造結(jié)構(gòu)，其上部有4個(gè)缸套安裝孔；缸體的水平隔板將缸體分成上下兩部分；缸體的前端面從前到后排列有三個(gè)同軸線的凸輪軸安裝孔和惰輪軸孔。
缸體的工藝特點(diǎn)是:結(jié)構(gòu)、形狀復(fù)雜；加工的平面、孔多；壁厚不均，剛度低；加工精度要求高，屬于典型的箱體類加工零件。缸體的主要加工表面有頂面、主軸承座側(cè)面、缸孔、主軸承孔及凸輪軸孔等，它們的加工精度將直接影響發(fā)動(dòng)機(jī)的裝配精度和工作性能，主要依靠設(shè)備精度、工夾具的可靠性和加工工藝的合理性來(lái)保證。
2．發(fā)動(dòng)機(jī)缸體工藝方案設(shè)計(jì)原則和依據(jù)
工藝方案是工藝準(zhǔn)備工作的總綱，是工藝規(guī)程設(shè)計(jì)和關(guān)鍵工藝裝備設(shè)計(jì)的指導(dǎo)文件。正確的工藝方案設(shè)計(jì)，有助于系統(tǒng)地運(yùn)用新的科學(xué)技術(shù)成果和先進(jìn)的生產(chǎn)經(jīng)驗(yàn)，保證產(chǎn)品質(zhì)量，改善勞動(dòng)條件，提高工藝技術(shù)和工藝管理水平。
2.1 工藝方案設(shè)計(jì)的原則
設(shè)計(jì)工藝方案應(yīng)在保證產(chǎn)品質(zhì)量的同時(shí)，充分考慮生產(chǎn)周期、成本和環(huán)境保護(hù)；根據(jù)本企業(yè)能力，積極采用國(guó)內(nèi)外先進(jìn)的工藝技術(shù)和裝備，不斷提高企業(yè)工藝水平。發(fā)動(dòng)機(jī)缸體機(jī)械加工工藝設(shè)計(jì)應(yīng)遵循以下基本原則:
(1) 加工設(shè)備選型原則 加工設(shè)備選型采用剛?cè)峤Y(jié)合的原則，加工設(shè)各以臥式加工中心為主，少量工序采用立式加工中心，關(guān)鍵工序一曲軸孔、缸孔、平衡軸孔加工采用高精度高速臥式加工中心，非關(guān)鍵工藝一上下前后四個(gè)平面的粗銑采用高效并有一定調(diào)整范圍的專用機(jī)床加工；
(2) 集中工序原則 關(guān)鍵工序一機(jī)體缸孔、曲軸孔、平衡軸孔的精加工及缸蓋結(jié)合面的精銑，采用集中在一道工序一次裝夾完成全部加工內(nèi)容的方案，以確保產(chǎn)品精度滿足缸體關(guān)鍵品質(zhì)的工藝能力和有關(guān)技術(shù)要求；
(3) 全部夾具均采用液壓夾具，夾緊元件、液壓泵及液壓控制元件采用德國(guó)或美國(guó)產(chǎn)優(yōu)質(zhì)可靠元器件；
(4) 整線全部采用濕式加工，采用單機(jī)獨(dú)立排屑，高精度關(guān)鍵加工工序的臥式加工中心采用恒溫冷卻并加裝高精度高壓雙回路帶旁通精過(guò)濾系統(tǒng)，加工中心全部帶有高壓內(nèi)冷。
根據(jù)汽車發(fā)動(dòng)機(jī)缸體的工藝特點(diǎn)和生產(chǎn)任務(wù)要求，發(fā)動(dòng)機(jī)缸體機(jī)械加工自動(dòng)生產(chǎn)線由臥式加工中心CWK500和CWK500D加工中心、專用銑/鏜床、立式加工中心matec-30L等設(shè)備組成。
(1) 頂?shù)酌婕巴呱w止口面粗銑組合機(jī)床 本機(jī)床為雙面臥式專用銑床，采用移動(dòng)工作臺(tái)帶動(dòng)工件，機(jī)床采用進(jìn)口西門子S7-200PLC系統(tǒng)控制，機(jī)床設(shè)獨(dú)立電控柜，切削過(guò)程自動(dòng)化完成，有自動(dòng)和調(diào)整兩種狀態(tài)；
(2) 高速臥式加工中心CWK500 該加工中心可實(shí)現(xiàn)最大流量的濕加工，但由于設(shè)備自動(dòng)排屑處理系統(tǒng)是通過(guò)位于托盤下的內(nèi)置寬式排屑器而完成，該加工中心可以進(jìn)行干加工；機(jī)床主軸轉(zhuǎn)速6000r/min，快速進(jìn)給速度38m/min；
(3) 前后端面粗銑組合機(jī)床 機(jī)床采用液壓傳動(dòng)；控制系統(tǒng)采用進(jìn)口西門子S7-200PLC系統(tǒng)控制，機(jī)床具有一定的柔性；
(4) 專用機(jī)床TXK1500 本機(jī)床由立式加工中心改造而成型，具備立式加工中心的特點(diǎn)及性能，該機(jī)床具有高強(qiáng)度、高耐磨度、高穩(wěn)定性、高精度、高配置等優(yōu)點(diǎn)；
(5) 高速立式加工中心matec-30L 該加工中心主軸最高轉(zhuǎn)速9000r/min?？刂葡到y(tǒng)采用西門子公司SINUMERIK840D控制系統(tǒng)；
(6) 高速臥式加工中心CWK500D 主軸最高轉(zhuǎn)速15000r/min。
2.2 工藝方案設(shè)計(jì)的依據(jù)
影響發(fā)動(dòng)機(jī)缸體零件的工藝方案設(shè)計(jì)因素是多方面的。具體地說(shuō)，可以從以下幾個(gè)方面理解。
(1) 產(chǎn)品對(duì)象、產(chǎn)品圖樣和有關(guān)技術(shù)文件根據(jù)發(fā)動(dòng)機(jī)缸體的復(fù)雜程度、精度要求等采取相應(yīng)的工藝措施。生產(chǎn)對(duì)象為四缸汽車發(fā)動(dòng)機(jī)缸體；
(2) 產(chǎn)品的生產(chǎn)綱領(lǐng)、生產(chǎn)性質(zhì)和生產(chǎn)類型該發(fā)動(dòng)機(jī)缸體年生產(chǎn)綱領(lǐng)為40000萬(wàn)件；
(3) 工作制度設(shè)備年有效工作日為320天，平均設(shè)備負(fù)荷率為80%,兩班制，16小時(shí)/天。
3．發(fā)動(dòng)機(jī)缸體機(jī)械加工工藝設(shè)計(jì)的主要內(nèi)容
發(fā)動(dòng)機(jī)缸體結(jié)構(gòu)復(fù)雜，精度要求高，尺寸較大，是薄壁零件，有若干精度要求較高的平面和孔。發(fā)動(dòng)機(jī)缸體機(jī)械加工的工藝特點(diǎn)是:主要是平面和孔的加工，加工平面一般采用刨、銑削等方法加工，加工孔主要采用鏜削，加工小孔多用鉆削。由于缸體結(jié)構(gòu)復(fù)雜，因此如何保證各表面的相互位置精度是加工中的一個(gè)重要問(wèn)題。
3.1 毛坯的選擇
發(fā)動(dòng)機(jī)缸體采用的材料一般是灰鑄鐵HT150、HT200、HT250，也有采用鑄鋁或鋼板的，此發(fā)動(dòng)機(jī)缸體采用高強(qiáng)度合金鑄鐵。缸體在加工前進(jìn)行時(shí)效處理，以消除鑄件內(nèi)應(yīng)力和改善毛坯的力學(xué)性能。
提高毛坯精度，減少加工余量，是提高自動(dòng)生產(chǎn)線系統(tǒng)生產(chǎn)率及加工質(zhì)量的重要措施。由于國(guó)外箱體類零件毛坯質(zhì)量和精度較高，其生產(chǎn)線系統(tǒng)己實(shí)現(xiàn)了毛坯直接上線，既省去了毛坯檢查裝置，也節(jié)省了由于毛坯質(zhì)量問(wèn)題而浪費(fèi)的加工工時(shí)，提高了綜合效益。因此，精化毛坯是提高生產(chǎn)率最有潛力的出路。對(duì)于發(fā)動(dòng)機(jī)缸體生產(chǎn)線，可在零件上線前粗銑六個(gè)面，去除大部分余量，便于零件直接上線。
3.2 機(jī)械加工工藝基準(zhǔn)的選擇與加工
選擇合理的加工工藝基準(zhǔn)，直接關(guān)系到能否保證零件的加工質(zhì)量。一般地說(shuō)，工藝基準(zhǔn)可分為粗基準(zhǔn)和精基準(zhǔn)。
(1) 粗基準(zhǔn)對(duì)于上線的毛坯，其粗基準(zhǔn)的選擇尤為重要，如果粗基準(zhǔn)選擇不合理，會(huì)使加工余量分布不均勻，加工面偏移，造成廢品。在缸體生產(chǎn)線中，我們采用側(cè)面為粗基準(zhǔn)；
(2) 精基準(zhǔn)對(duì)于發(fā)動(dòng)機(jī)缸體這種箱體零件來(lái)說(shuō)，一般采用“一面兩銷”為全線的統(tǒng)一基準(zhǔn)。對(duì)于較長(zhǎng)的自動(dòng)生產(chǎn)線系統(tǒng)，由于定位銷孔在使用過(guò)程中的磨損造成定位不準(zhǔn)確，因此，將定位銷孔分為2-3段使用。在缸體定位銷孔的加工中，我們采用了以側(cè)面、底面和主軸孔定位，在加工中心上加工。
3.3 機(jī)械加工加工階段的劃分和工序的安排
一個(gè)零件往往有許多表面需要加工，當(dāng)然表面的加工精度是不同的。加工精度較高的表面，往往要經(jīng)過(guò)多次加工；而對(duì)于加工精度低的表面，只需要經(jīng)過(guò)一兩次就行了。因此，擬訂工藝順序時(shí)，要抓住“加工精度高的表面”這個(gè)矛盾，合理安排工序和合理劃分加工階段。安排工藝順序的原則是:先粗后精，先面后孔，先基準(zhǔn)后其它。在發(fā)動(dòng)機(jī)缸體的機(jī)械加工中，同樣應(yīng)遵循這一原則。
(1) 粗加工階段 在發(fā)動(dòng)機(jī)缸體的機(jī)械加工過(guò)程中，安排粗加工工序，對(duì)毛坯全面進(jìn)行粗加工，切去大部分余量，以保證生產(chǎn)效率；
(2) 半精加工階段 在發(fā)動(dòng)機(jī)缸體的機(jī)械加工中，為了保證一些重要表面的加工精度，安排一些半精加工工序，將精度和表面粗糙度要求中等的一些表面加工完成，而對(duì)要求高的表面進(jìn)行半精加工，為以后的精加工做準(zhǔn)備；
(3) 精加工階段 對(duì)精度和表面粗糙度要求高的表面進(jìn)行加工；
(4) 次要小表面的加工 如螺紋孔，可以在精加工主要表面后進(jìn)行，一方面加工時(shí)對(duì)工件變形影響不大，同時(shí)廢品率也降低；另外，如果主要表面出廢品后，這些小表面就不必再加工了，從而避免浪費(fèi)工時(shí)。但是，如果小表面的加工很容易碰傷主要表面時(shí)，就應(yīng)該把小表面加工放在主要表面的精加工之前；
(5) 輔助工序也要妥善安排 如檢驗(yàn)工序，在零件粗加工階段之后，關(guān)鍵工序加工前后，零件全部加工完畢后，都要適當(dāng)安排。
對(duì)加工階段進(jìn)行劃分，具有以下好處:首先，可以在粗加工后采取措施消除工件內(nèi)應(yīng)力，保證精度；其次，精加工放在后面，不至于在運(yùn)輸過(guò)程中損壞工件己加工表面；再次，先粗加工各面，可以及早發(fā)現(xiàn)毛坯缺陷并及時(shí)處理，不會(huì)浪費(fèi)工時(shí)。不過(guò)對(duì)于一般小工件就不要分得很細(xì)。
3.4 缸體的主要加工表面和輔助工序
缸體主要加工表面和輔助工序有:
(1) 平面加工 目前，銑削是發(fā)動(dòng)機(jī)缸體平面加工的主要手段，國(guó)內(nèi)銑削進(jìn)給量一般為300-400mm/min，與國(guó)外銑削進(jìn)給量2000-4000mm/min相比，相差甚遠(yuǎn)，有待于提高，因此，提高銑削進(jìn)給量，縮短輔助時(shí)間，是提高生產(chǎn)效率的主要途徑，發(fā)動(dòng)機(jī)缸體精加工一些平面時(shí)的銑削進(jìn)給量達(dá)到2399 mm /min，大大提高了效率；
頂面的銑削是缸體加工中的一個(gè)關(guān)鍵工序，其平面度要求為0.02/145mm，表面粗糙度為Ra1.6um。在缸體的加工中，采用側(cè)面和主軸軸承孔定位，頂面、底面和中間瓦蓋止口面同時(shí)加工，在加工中采用線外對(duì)刀裝置，能較好地滿足發(fā)動(dòng)機(jī)缸體加工精度要求；
(2) 一般孔系的加工 一般孔系的加工仍采用傳統(tǒng)的鉆、擴(kuò)、鏜、鉸、攻絲等工藝方法。課題在設(shè)計(jì)具體的工藝方案時(shí)，采用涂層刀具、內(nèi)冷卻刀具等先進(jìn)刀具，并采用大流量冷卻系統(tǒng)，大大提高了切削速度，提高了生產(chǎn)率；
(3) 深油孔加工 傳統(tǒng)的加工方法是采用麻花鉆進(jìn)行分級(jí)進(jìn)給，其生產(chǎn)效率低，加工質(zhì)量差。在發(fā)動(dòng)機(jī)缸體深油孔的加工中，采用槍鉆工藝；
(4) 三軸孔的加工 三軸孔的加工為缸體孔系加工中精度要求高，工時(shí)長(zhǎng)的限制性工序。因此，工序安排、加工方法、刀具等都應(yīng)特別注意。合蓋前加工，即缸體半圓孔和主軸承蓋的荒加工，其主要目的是去除毛坯余量、釋放應(yīng)力，為后序加工做準(zhǔn)備；在加工中心上加工曲軸孔時(shí)，采用雙面鏜孔，先在曲軸孔一端鏜孔到1/2長(zhǎng)度時(shí)，然后工作臺(tái)回轉(zhuǎn)180度，從另外一端再鏜另一1/2長(zhǎng)。
(5) 缸孔的加工 缸孔的加工是缸體機(jī)械加工中的關(guān)鍵工序之一，一般情況下，其加工工藝過(guò)程為粗鏜、半精鏜、精鏜和珩磨。為及早發(fā)現(xiàn)缸孔內(nèi)壁的鑄造缺陷，消除應(yīng)力，應(yīng)盡量提前粗鏜缸孔；由于缸孔的結(jié)構(gòu)特點(diǎn)不同，需采用珩磨工藝，以提高缸孔表面質(zhì)量。在大批量生產(chǎn)中，缸孔的珩磨一般采用多軸珩磨機(jī)或珩磨自動(dòng)線。在此我們采用珩磨自動(dòng)線，由粗珩.精珩和檢測(cè)三臺(tái)設(shè)備組成；
(6) 清洗 清洗分為濕式清洗和干式清洗。缸體機(jī)械加工自動(dòng)生產(chǎn)線采用大流量濕式清洗；
(7) 檢測(cè) 檢測(cè)分在線檢測(cè)和線外檢測(cè)兩種。在發(fā)動(dòng)機(jī)缸體的質(zhì)量檢測(cè)中，根據(jù)實(shí)際情況采用線外檢測(cè)，主要采用三坐標(biāo)測(cè)量機(jī)對(duì)缸體進(jìn)行綜合測(cè)量，每200件抽查1-5件，每班抽查一件。
3.5 缸體加工切削用量的選擇
發(fā)動(dòng)機(jī)缸體切削用量的選擇包括切削速度、進(jìn)給量和進(jìn)給速度的選擇。由于加工中所使用的設(shè)備都是具有較高精度和剛度的機(jī)床和高速加工中心，為保證切削加工的效率，可以適當(dāng)選擇較大的切削用量。發(fā)動(dòng)機(jī)缸體的主要加工表面為平面和軸承孔、缸孔等孔的加工，而平面和軸承孔、缸孔的加工方式主要是銑削和鏜削，因此這里討論的切削用量的選擇主要是銑削和鏜削切削用量的選擇。
(1) 銑削量的選擇 銑削用量的選擇直接關(guān)系到銑削效果的好壞。一般地說(shuō)，銑削用量的選擇原則是:端面銑刀銑削時(shí)首先應(yīng)盡可能取較大的銑削深度和銑削寬度，然后盡可能選取較大的銑削速度。在具體選擇銑削用量時(shí)所涉及的因素很多，但總的來(lái)說(shuō)，粗銑時(shí)工件余量大，加工要求低，主要考慮銑刀的耐用度；精銑時(shí)余量小，加工精度要求高，主要考慮加工質(zhì)量的提高；
在發(fā)動(dòng)機(jī)缸體的銑削加工中，選用的機(jī)床為具有高剛度的高速機(jī)床，功率大，剛性好，因而選擇了比較大的切削用量。
(2) 鏜削用量的選擇 鏜削用量的選擇根據(jù)粗、精加工工藝的不同而不同。粗加工時(shí)，選用較大的切削深度，精加工時(shí)，選用較小的切削深度。切削深度確定以后，盡可能選用較大的切削用量。在切削深度和進(jìn)給量選定以后，可在保證刀具合理耐用度的條件下，用計(jì)算或查表的方法來(lái)確定切削速度。一般地，粗加工時(shí)，選擇較低的切削速度，精加工時(shí)，選用較高的切削速度。
在發(fā)動(dòng)機(jī)缸體的鏜削加工中，選用的機(jī)床為具有高剛度的高速機(jī)床，功率大，剛性好；刀具為國(guó)外先進(jìn)的刀具，質(zhì)量高，剛性好，因而選擇了比較大的切削用量。
4．小結(jié)
通過(guò)對(duì)發(fā)動(dòng)機(jī)缸體的結(jié)構(gòu)和工藝特點(diǎn)進(jìn)行分析，論述了發(fā)動(dòng)機(jī)缸體機(jī)械加工工藝方案設(shè)計(jì)的原則和依據(jù)以及切削用量的選擇，并以高速銑削和調(diào)頭鏜孔為例，設(shè)計(jì)、分析了發(fā)動(dòng)機(jī)缸體的高速銑削和調(diào)頭鏜孔工藝過(guò)程，及在加工中需要注意的問(wèn)題。
英文原文
Cylinder block machining process design
Engine parts in the engine block is a more complex structure of spare parts box, its high precision, processing, complex process, and the processing quality will affect the overall performance engine, so it has become the engine manufacturer's focus parts one.
1. Technical Characteristics of the engine cylinder block
Engine block is the basic engine parts and skeleton, while the engine when the general assembly of the base components. Cylinder's role is supporting and ensuring the piston, connecting rod, crankshaft and other moving parts work, the exact location; to ensure the engine ventilation, cooling and lubrication; to provide a variety of auxiliary systems, components and engine installation.
1.1 Technical Characteristics
Cylinder cast for a whole structure, and its upper part 4 cylinder mounting hole; cylinder standard cylinder is divided into upper and lower divisions into two parts; cylinder to the rear of the front-side arrangement of the previous three coaxial mounting hole of the camshaft and the idler axle hole.
Cylinder process features are: the structure of complex shape; processing plane, more than holes; uneven wall thickness and stiffness is low; processing of high precision typical of box-type processing part. The main processing of the surface of cylinder block top surface, the main bearing side, cylinder bore, the main and camshaft bearing bore holes and so on, they will directly affect the machining accuracy of the engine assembly precision and performance, mainly rely on precision equipment, industrial fixtures reliability and processing technology to ensure the reasonableness.
2. Engine block process design principles and the basis for
Technology program is the preparation of the master process is to process planning and key process equipment design guidance documents. The correct process of program design, facilitate the systematic application of new scientific and technological achievements and advanced production experience, to ensure product quality, improve working conditions, and improve process technology and process management level.
2.1 Process design principles
Design Technology program should be to ensure product quality at the same time, give full consideration to the production cycle, cost and environmental protection; based on the enterprises ability to actively adopt advanced process technology and equipment, and constantly enhance their level of technology. Engine block machining process design should follow the following basic principles:
(1) The selection of processing equipment, processing equipment, the principle of selection adopted the principle of combining rigid-flexible, processing each horizontal machining center is located mainly small operations with vertical machining center, the key process a crank hole, cylinder hole, balancer shaft hole High-speed processing of high-precision horizontal machining center, an upper and lower non-critical processes before and after the four-dimensional high-efficiency rough milling and have a certain adjustment range of special machine processing;
(2) focus on a key process in principle process the body cylinder bore, crankshaft hole, Balance Shaft hole surface finishing and the combination of precision milling cylinder head, using a process focused on a setup program to complete all processing elements in order to ensure product accuracy The key quality processes to meet the cylinder capacity and the relevant technical requirements;
(3) All fixtures are used hydraulic clamp, clamping components, hydraulic pumps and hydraulic control components used in Germany or the United States producing high quality and reliable components;
(4) The whole line used in all wet processing, using standalone BTA, high-precision machining processes critical horizontal machining center with constant cooling and to install high-precision high-voltage double-circuit band-pass fine filtration system, all with high-pressure processing center in the cold.
According to the technological characteristics of automobile engine cylinder block and the production mandate, the engine block machining automatic production line is composed of horizontal machining center CWK500 and CWK500D machining centers, special milling / boring machine, vertical machining centers matec-30L and other appliances.
(1) top and bottom, and tile covered only the combination of aperture rough milling machine dedicated to this machine to double-sided horizontal milling machine, using moving table driven parts, machine tools imported Siemens S7-200PLC system control, machine control cabinet set up an independent, cutting automate the process is completed and two kinds of automatic and adjust the state;
(2) high-speed horizontal machining center machining center can be realized CWK500 the maximum flow of wet processing, but because of equipment, automatic BTA treatment system through the built-in tray under the wide-type chip conveyor and the completion of the machining center can be dry processing; machine tool spindle speed 6000r/min, rapid feeding speed 38m/min;
(3) The combination of front and rear face rough milling machine tool using hydraulic transmission; control system imported Siemens S7-200PLC system control, machine tools have a certain flexibility;
(4) The special machine TXK1500 this machine vertical machining center by the modification of shape, with vertical machining center features and performance, this machine has high strength, high wear-resistant, high stability, high accuracy, high-profile etc.;
(5) high-speed vertical machining center matec-30L of the machining center spindle high speed 9000r/min. Control system uses Siemens SINUMERIK840D control system;
(6) high-speed horizontal machining center spindle CWK500D highest speed 15000r/min.
2.2 Process design basis
Affect the engine block part of the process design factors are manifold. Specifically, can be understood from the following aspects.
(1) product object, product drawings and technical documents related to the complexity of the engine block under the precision requirements of the process to take corresponding measures. Production targets for the four-cylinder automobile engine cylinder block;
(2) the production program, the production of the nature and type of production of the engine block the production program of 400 million;
(3) The annual effective system of work equipment, working for 320 days, with an average equipment loading rate of 80%, two shifts, 16 hours / day.
3. Engine block machining process design the main content
Engine block complex structure, high precision, large size, is thin-walled parts, there are a number of high precision plane and holes. Engine block machining process characteristics: mainly flat and the hole processing, processing of flat generally use planing, milling methods such as processing, processing of hole used mainly boring, processing and multi-purpose drilling holes. As the cylinder complex structure, so how to ensure that the mutual position of the surface processing precision is an important issue.
3.1 The selection of blank
Engine block on the materials used are generally gray cast iron HT150, HT200, HT250, there is also cast aluminum or steel plate, this engine block using high-strength alloy cast iron. Cylinder in the processing prior to aging treatment in order to eliminate stress and improve the rough casting mechanical properties.
Improve the rough accuracy, reduction of machining allowance, is to improve the automated production line system productivity and processing quality of the important measures. As the foreign box-type parts of rough quality and high precision, and its production-line system has been implemented directly on the blank line, not only eliminating the need for blank check device also saves the rough quality problems due to waste of machining time, increase overall efficiency. Therefore, the refinement of rough is to improve the productivity of the most promising way out. For the engine block production line, can be rough in parts on-line pre-milling six face, removing most of the margin, to facilitate direct on-line parts.
3.2 machining process selection and processing of the benchmark
Choose the right processing technology base is directly related to the processing quality can ensure the parts. Generally speaking, process benchmarking can be divided into coarse and fine reference base.
(1) The baseline for the on-line thick rough, which is particularly important the choice of benchmark crude, if crude benchmark choice unreasonable, will the uneven distribution of machining allowance, processing and surface offsets, resulting in waste. In the cylinder production line, we have adopted for the coarse side of the base;
(2) refined the base of this box for the engine block parts, the general use of “side two sales” for a full range of uniform benchmarks. For the longer automated production line system, due to pin holes in the course of the wear and tear caused by inaccurate positioning, therefore, will be divided into 2-3 segment pin holes used. In the cylinder pin hole of the process, we have adopted to the side, bottom and the spindle hole positioning, in the processing center on the process.
3.3 Machining Processing Stages and processes of the arrangements
Often a part of many apparent need for processing, of course, the surface machining accuracy are different. Processing of high precision surface, often after repeated processing; As for the processing of the surface of low precision, only need to go through one or two on the list. Thus, when the development process in order to seize the “processing high precision surface,”this conflict, the reasonable arrangement processes and rational division stage of processing. Arrange the order of the principle of process is: after the first coarse refined, the first surface after the hole, the first benchmark other. In the engine block machining, the same should follow this principle.
(1) roughing stage engine block machining process, the arrangements for roughing process, to fully carry out rough rough, trim most of the margin in order to ensure production efficiency;
(2) semi-finishing phase of the engine block machining, in order to ensure the accuracy of some important surface processing, and arrange some semi-finishing operations, will be required accuracy and surface roughness of the surface of the middle of some processing to complete, while demanding the surface of semi-finished, to prepare for future finishing;
(3) The finishing stage of requiring high accuracy and surface roughness of the surface processing;
(4) secondary processing, such as small surface screw holes, you can finish of the major surface after the one hand, when the workpiece deformation process little impact at the same time also reduced the rejection rate; In addition, if the main surface of a waste, these small the surface will not have to be processed, thus avoiding a waste of man-hours. However, if the processing is very easy for a small surface bumps the main surface, it should be placed on a small surface finish prior to the main surface finishing;
(5) should make proper arrangements for secondary processes such as product inspection process, in part roughing stage, the key process before and after processing, spare parts all the processing has been completed, should be appropriate arrangements.
Stage of processing division, has the following advantages: First, it can take measures to eliminate the rough workpiece after the stress, to ensure accuracy; second, finishing on the back, and will not damage during transport the surface of the workpiece has been processed; again, first roughing the surface defects can be detected early and promptly deal with rough, do not waste working hours. But most small parts, do not sub very thin.
3.4 cylinder surface of the main processing and secondary processes
Cylinder surface and support the main processing operations are:
(1) plane processing At present, the milling of engine blocks is the primary means of planar processing, domestic milling feed rate is generally 300-400mm/min, and foreign 2000-4000mm/min milling feed rate compared to far cry, to be on increasing, therefore, improve the milling feed rate, reduce overhead time is to improve the productivity of the major means of finishing a number of plane engine block when the milling feed rate to reach 2399 mm / min, greatly improved efficiency;
Top surface of the cylinder milling is a key process in the process, the flatness requirements for 0.02/145mm, the surface roughness of Ra1.6um. Processing in the cylinder, the use of side and spindle bearing bore positioning, top, bottom and middle vagay only aperture while processing used in the processing line outside of the knife device can better meet the engine block machining accuracy ;
(2) General holes machining holes in general are still using the traditional processing of drilling, expansion, boring, reaming, tapping and other craft approach. Issues in the design process of specific programs, use of coated cutting tools, cutting tools and other advanced tools within the cooling, and using a large flow of cooling systems, greatly improving the cutting speed, improved productivity;
(3) deep hole processing of the traditional processing method is used to grade twist drill feed, low efficiency of their production, processing and quality is poor. The deep hole in the engine block processing, the use of gun drilling process;
(4) The three-axis machining holes for the cylinder-axis machining holes holes of high precision, long working hours of the restrictive process. Thus, work arrangements, processing methods, tools and so on should be special attention. All cover pre-processing, that is, semi-circular hole and the cylinder block main bearing cap of the shortage of processing, its main purpose is to remove blank margin, release stress, to prepare for the post-order processing; in crankshaft machining processing center hole, using double-sided Boring, boring the first holes in the crankshaft hole at one end to 1 / 2 length, and then turn 180 degrees workbench, from the other end and then bore another 1 / 2 length.
(5) The cylinder bore machining cylinder hole cylinder machining processing is a key process in the one, under normal circumstances, the machining process as a rough boring, semi-fine boring, precision boring and honing. Cylinder bore wall for the early detection of casting defects, eliminate stress, should be thick cylinder boring holes in advance; due to the structural characteristics of the different cylinder bore, must be in honing process to improve the cylinder bore surface quality. In the high-volume production, the cylinder bore honing generally use the multi-axis grinding machine or honing Automatic Line. Here we use honing automatic lines, from the coarse-heng. Fine-heng and testing equipment, composed of three;
(6) Cleaning Cleaning is divided into wet cleaning and dry cleaning. Machining cylinder automatic production line using a large flow of wet cleaning;
(7) Detect points outside the line detection and line detection of two kinds. Quality inspection in the engine block, according to the actual situation with lines outside the detection, the main use of coordinate measuring machine integrated measurements of the cylinder, each 200 samples 1-5 pieces, each class random one.
3.5 cylinder processing the choice of cutting parameters
Engine block choice of cutting parameters including cutting speed, feed rate and feed rate option. As the processing equipment is used in high precision and rigidity of machine tools and high-speed machining centers in order to ensure the efficiency of cutting may be the appropriate choice of cutting a larger amount. The main processing engine block surface plane and bearing bore, cylinder bore holes such as the processing, while the plane and bearing bore, cylinder bore of the processing method is mainly milling and boring, so the discussion here, the choice of cutting parameters are mainly milling and Boring choice of cutting parameters.
(1) milling the choice of the amount of usage the choice of milling milling effect is directly related to good or bad. Generally speaking, the choice of dosage milling principles: Face milling cutter should be as much as possible when you first take a larger milling depth and width of milling, and then select the larger milling rate of as much as possible. Milling in a specific amount of choice when many factors involved, but in general, rough milling large margin when the workpiece, processing requirements low, the main consideration of the durability of cutter; Fine Milling margin is small, high precision machining, improvement in the quality processing of primary consideration;
In the engine block of the milling process, the use of machine tools as having a high stiffness, high-speed machine tools, big power, rigidity is good, so has chosen the relatively large amount of cutting.
(2) boring dosage amount of choice options under the rough finishing process varies. Rough, the selection of a larger depth of cut, finish, the selection of a smaller depth of cut. Depth of cut determined later, as cutting a large amount of use. In the cutting depth and feed rate after the selection can be a reasonable tool to ensure durability under the conditions of use calculations or look-up table method to determine the cutting speed. In general, the rough, choose a lower cutting speed, finishing, the selection of a higher cutting speed.
In the engine block boring process, the selection of machine tools as having a high stiffness, high-speed machine tools, big power, good rigidity; tool for foreign advanced tools, high quality, rigidity is good, so has chosen the relatively large amount of cutting.
4. Summary
Through the engine block of the structure and process characteristics of the analysis, discusses the engine block machining process design principles and basis of the choice of cutting parameters, and U-turn at high speed milling and boring, for example, design, analysis of the engine cylinder body of high-speed milling and turnover boring process, and in the processing need to pay attention to.