蜗轮蜗杆减速器箱体设计毕业设计

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绪论
1.1 涡轮减速器箱体简介 涡轮减速器箱体零件是机器及其部件的基础零件， 它将机器及其部件中的轴、 轴承、 套、 和齿轮等零件按一定的相互位置关系装配成一个整体，并按预定传动关系协调其运动。在机 械设备中，涡轮减速器箱体零件是一种主要的零件，其加工质量对机器的精度、性能和寿命 有重要影响。涡轮减速器箱体的具体结构、尺寸虽不相同，但有许多共同特点。其结构一般 都比较复杂，壁薄且不均匀，内部型腔复杂，箱壁上既有许多孔要加工，又有许多面要加工， 加工部位多，加工难度大。 1.2 涡轮减速器箱体类零件的结构特点和技术要求 箱体结构较复杂，加工表面主要为平面和孔系。箱体的设计基准为平面，一般要求较高 的平面度和表面质量。箱体上有空间距和同轴度要求的一些列孔，零件的组孔用于安装轴承。 孔的尺寸精度一般较高，空间距精度要求高。粗基准的选择影响到余量的分配和工件的装夹 方式，一般选用轴孔为粗基准。精基准主要是满足精度要求，可以根据基准重合原则，选择 设计基准作为精基准。
箱体加工的顺序原则为：先加工平面，后加工内孔。 “先面后空”原则是涡轮减速器箱 体零件加工的一般规律；粗精分开，先粗后精。由于涡轮减速器箱体类零件结构复杂，主要 表面的精度要求高，为减少粗加工时产生的切削力、夹紧力和切削热对加工精度的影响，一 般尽可能把粗精加工分开，并分别在不同的机床上进行。至于要求不高的平面，可将粗精两 次进给安排在一个工序内完成，以缩短工艺过程，缩短时效；先加工主要孔，后加工次要孔。 孔系可以采用数控加工。由于加工的孔精度高，加工量大，传统上采用加工自动线。目前在 生产中，为了提高生产的柔性，多采用加工中心。零件的加工可以采用卧式加工中心，工序 集中，完成钻、扩、铰、镗、攻螺纹等工作，可以保证位置精度。涡轮加速器箱体的主要加 工表面为平面和轴承支承孔。涡轮减速器箱体平面的粗加工和半精加工，主要采用刨削和铣 削。铣削的生产率比刨削高，在成批和大量生产中，多采用铣削。涡轮减速器箱体平面的精 加工多用磨削。涡轮减速器箱体上的轴承支承孔，一般采用钻—扩—粗铰—精铰或镗—半精 镗—精镗的加工方案进行加工。 2 零件的分析 2.1 零件的结构特点 箱体是机器和部件的基础零件，由它将机器和部件中许多零件连接成个整体，并使之保 持正确的相互位置，彼此能协调地运动。常见的箱体零件有：各种形式的机床主轴箱，减速 箱和变速箱等。各种箱体类零件由于功用不同，形状结构差别较大，但结构上也存在着相同 的特点，如尺寸较大、形状复杂、精度较高、有许多紧固螺钉定位孔等。 2.2 零件的图样分析 （1）Φ 180 0 （2）Φ 180 （3） Φ 90
摘要：箱体零件是机器或部件的基础零件，轴、轴承、齿轮等有关零件按照规定的技术要求装配到箱体上， 连接成部件或机器，使其按规定的要求工作。在机械设备中，涡轮减速器箱体零件是一种主要的零件，其 加工质量对机器的精度、性能和寿命有重要影响。本文是在理论学习和实践实习的基础上，充分运用所学 知识对小型涡轮减速器箱体进行加工工艺规程的设计和夹具的设计，根据零件的加工要求制定出可行的工 艺路线和合理的夹具方案，以确保零件的质量。 在设计涡轮减速器箱体零件加工工艺过程中，要通过查表法准确的确定各表面的总余量及余量公差， 合理选择机床加工设备以及相应的加工刀具、进给量、切削速度、功率、夹紧力等用以提高加工精度，保 证其加工质量。加工过程中用夹具装夹工件方便，还可提高劳动生产率，尤其是在批量生产中，大大降低
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mm 和Φ 90 0 mm 和Φ 90
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mm 两孔的垂直度 0.06mm 要求，由 T68 机床分度在保证。 mm 两孔孔距 100±0.12mm，可采用装心轴的方法检测。
3 零件的工艺规程设计 3.1 毛坯的选择 箱体材料是 HT200， 材料抗拉强度为 200N/mm^2,抗弯强度为 400N/mm^2， 硬度为 HB170-241. 箱体结构复杂，箱壁薄，故选用铸造方法制造毛怌；因生产类型为大量生产，可采用沙箱机 器造型，内腔安放型芯。铸件需要人工实效处理。 3.2 机械加工工艺设计 3.2.1 基面的选择 基准：基准是用来确定生产对象上几何要素的几何关系所依据的那些点、线、面。基准 根据其功用的不同可分别为设计基准和工艺基准。 在工件工序图中，用来确定本工序 加工表面位置 的基准，加工表面与工序基准之间， 一般有两次核对位置要求：一是加工表面对工序基准的距离要求，即工序尺寸要求；二是加 工表面对工序基准的形状位置要求，如平行度，垂直度等。 工件定位时，用以确定工件在夹具中位置的表面、点、或线称为定位基准，定位基准的 选择，一般应本着基准重合原则，尽可能选用工序基准作为定位基准，工件在定位时，每个 工件的夹具中的位置是不确定的，一般是限制工件的六个自由度，分别指：沿三坐标轴的移 动自由度和绕三坐标轴转动的自由度。 基面选择是工艺规程设计中的重要设计之一，基面的选择正确与合理，可以使加工质量 得到保证，生产率得到提高。否则，加工工艺过程会问题百出，更有甚者，还会造成零件大 批报废，使生产无法进行. 3.2.2 粗基面的选择 对一般的轴类零件来说，以外圆作为基准是合理的，按照有关零件的粗基准的选择原则： 当零件有不加工表面时，应选择这些不加工的表面作为粗基准，当零件有很多个不加工表面 的时候，则应当选择与加工表面要求相对位置精度较高大的不加工表面作为粗基准。 箱体粗基准选择要求： （1）在保证各加工表面均有加工余量的前提下，使主要孔加工余量均匀。 （2）若工件每个表面都有加工要求，为了保证各表面都有足够的加工余量，应选择加工 量较少的表面为粗基准。 （3）若工件必须保证每个加工表面与加工表面之间的尺寸或位置要求，则应选择某个加 工面为粗基准。 （4）选择基准的表面应尽可能平整，没有铸造飞边，浇口，冒口或其他缺陷。粗基准一 般只允许使用一次。 （5）装入箱体内的旋转零件应与箱体内壁有足够的间隙。 （6）应保证定位、夹紧可靠。 为了满足上述要求，一般选箱体的主要孔的毛坯孔作为粗基准。减速器加工的第一个面 是盖或底座的结合面，由于分离式箱体轴承孔的毛坯孔分布在盖和底座两个不同的部分上很 不规则，因而在加工盖和底座的结合面时无法用主要孔的毛坯作粗基准，而是用顶面与底座
了生产成本。 关键词：箱体零件 切削加工 工艺 夹具 Abstract: The box parts are parts of the machine or basic components, shaft, bearings, gears and other related parts in accordance with the technical requirements of assembly on the box body to be component or machine and then work according to the requirements. In a mechanical device, a turbine reducer box part is one of the main parts, the quality of its processing has an important influence on precision of the machine, the performance and service life. The article is to make full use of the knowledge to design the small turbine reducer box processing technological process and fixture, according to the components processing request to make a feasible technical route and reasonable fixture scheme for ensuring the quality of parts after the study of theory and practice. In the process of the design of the turbine speed reducer box body parts machining, we should accurately determine the surface total allowance and allowance tolerance, rational selection of machining equipment and the corresponding processing tools, feed rate, cutting speed, power, clamping force is used to improve the accuracy of processing, ensure the machining quality through the method of look-up table. During the processing it is not only convenient to use clamping fixture, but also can improve labor productivity, especially in batch production and greatly reduced the cost of production. Key word: box part machine work process fixture
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mm 孔轴心线对基准轴心线 B 的垂直度公差为 0.06mm mm 两孔同轴度公差为Φ 0.06mm mm 两孔同轴度公差为Φ 0.05mm
（4）箱体内部做煤油渗漏检验 （5）铸件人工时效处理 （6）非加工表面涂防锈漆 （7）铸件不能有沙眼、疏松等缺陷 （8）材料 HT200 2.3 零件的工艺分析 分离的涡轮减速器箱体的主要加工部位有：轴承支承孔、接合面、端面、底座、上平面、 螺栓孔、螺纹孔等。加工部位的技术要求有： （1）为了保证工件壁厚均匀，并及时发现铸件的缺陷，在加工前安排画线工艺。 （2）该工件体积小，壁薄，加工时应注意夹紧力的大小，防止变形。 （3）Φ 180 0 （4）Φ 180
目录 摘要„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 关键词„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 第一章 绪论 „„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„
1.1 涡轮减速器箱体简介„„„„„„„„„„„„„„„„„„„„„„„„„„„ 1.2 涡轮减速器箱体类零件的结构特点和技术要求„„„„„„„„„„„„„„„„ 第二章 零件的分析„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 2.1 零件的结构特点„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 2.2 零件的图样分析„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 2.3 零件的工艺分析„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 第三章 零件的工艺规程设计„„„„„„„„„„„„„„„„„„„„„„„„„ 3.1 毛坯的选择„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3.2 机械加工工艺设计„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3.2.1 基面的选择„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3.2.2 粗基面的选择„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3.2.3 精基面的选择„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3.3 确定工艺方案„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3.4 加工设备、刀具及量具的选择„„„„„„„„„„„„„„„„„„„„„„„ 3．4.1 加工设备与工艺设备„„„„„„„„„„„„„„„„„„„„„„„„„„ 3.4.2 刀具的选择„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 3.4.3 量具的选择„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„ 第四章 切削用量及加工工时的计算„„„„„„„„„„„„„„„„„„„„„„ 4.1 工序 4 的切削用量及工时„„„„„„„„„„„„„„„„„„„„„„„„„ 4.2 工序 9 的切削用量及工时„„„„„„„„„„„„„„„„„„„„„„„„„ 4.3 工序 11 的切削用量及工时„„„„„„„„„„„„„„„„„„„„„„„„„ 第五章 夹具设计„„„„„„„„„„„„„„„„„„„„„„„„„„„„„„