变速器换挡叉地实用工艺设计
变速箱换挡叉的加工工艺及夹具设计(设计说明书)
毕业设计（论文）变速箱换挡叉的加工工艺及夹具设计摘 要本次设计内容涉及了机械制造工艺及机床夹具设计、金属切削机床、公差配合与测量等多方面的知识。
拨叉的加工工艺规程及其铣叉口面与钻mm 8.15Φ孔的夹具设计是包括零件加工的工艺设计、工序设计以及专用夹具的设计三部分。
铣叉口面以mm 8.15Φ孔及其端面作为来定位基准，以工件的另外一个端面作为辅助基准，实现工件的完全定位，夹紧则是通过调节螺母来实现；钻mm 8.15Φ孔以其端面作为定位基准，夹紧则是由快换垫圈、螺母、心轴等组成。
关键词：夹紧 定位 基准AbstractThe design of the content relates to the machinery manufacturing technology and machine tool fixture design, metal cutting machine tool, tolerance and measuring and other aspects of knowledge.Fork processing procedures and milling fork and drill mm 8.15Φ hole of fixture design is including machining process design, process design and fixture design in three parts. Milling fork with diameter mm 8.15Φ hole and end as to the locating datum to the workpiece, another end as auxiliary reference, realize the workpiece positioning, clamping is realized through adjusting nut; drill mm 8.15Φ hole and its face as a positioning reference, to achieve workpiece positioning, clamping is fast changing washer, nut, the mandrel.Key words: clamping positioning datum目录摘要 (i)Abstract..................................................... i i 1 绪论.. (1)1.1 课题的现状分析： (1)1.2 课题的研究目的及意义： (2)2 零件的分析 (4)2.1零件的作用 (4)2.2零件的工艺分析 (4)2.2.1零件的功用、结构及特点 (4)2.2.2该零件需要加工的表面大致分为 (5)2.2.3尺寸和粗糙度的要求 (5)2.2.4位置公差要求 (6)3 工艺规程设计 (7)3.1确定毛坯的制造形式 (7)3.2基面的选择 (7)3.3制定工艺路线 (8)3.4机械加工余量、工序尺寸及公差的确定 (9)3.4.1圆柱表面工序尺寸 (9)3.4.2平面工序尺寸 (9)3.4.3确定切削用量及时间定额： (9)4 夹具设计 (21)4.1问题的提出 (21)4.2夹具设计 (21)5 总结 (23)致谢 (24)参考文献 (25)1 绪论1.1 课题的现状分析：汽车变速器，是一套用于来协调发动机的转速和车轮的实际行驶速度的变速装置，用于发挥发动机的最佳性能，为满足现代人们对汽车适应节能、安全、舒适、高效、可靠方面不断提高的要求，变速器的性能及换挡叉的操作简便、舒适度就尤为重要。
变速器换挡叉加工工艺及夹具设计详解
目录1 前言 (1)1.1设计的意义 (1)1.2设计的目的 (1)1.3设计任务和要求 (2)2 零件的分析 (2)2.1零件的作用 (2)2.2零件的工艺分析 (2)3 工艺规程设计 (5)3.1确定毛坯的制造形式 (5)3.2确定毛坯的尺寸公差 (5)3.3锻件形状复杂系数与锻件材质系数的确定 (5)3.4锻件分模线形状与零件表面粗糙度 (5)3.5基面的选择 (5)3.6制定工艺路线 (6)3.7机械加工余量、工序尺寸及毛坯尺寸确定 (7)3.8确定切削余量及基本工时 (9)4 夹具设计 (18)4.1问题的提出 (18)4.2夹具设计 (19)4.3夹具设计及操作说明 (23)5 总结 (24)致谢 (24)参考文献 (25)附录:变速器换挡叉机械加工工序卡 (26)变速器换挡叉加工工艺及夹具设计机械设计制造及其自动化唐银旺指导教师陈洪军摘要：变速器换档叉位于主轴箱。
主要作用是传递扭矩，使变速器获得换档的动力。
优点是可以从一种变速直接变到另一种速度,而不需要经过中间的一系列,因此变速很方便;其缺点是比较复杂。
本课题拟使用机械制造技术理论对变速器换挡叉进行加工工艺以及夹具的优化设计。
通过使用AUTOCAD绘制装配图和零部件图，用PRO/E进行实体建模，同时生成能够用于实际生产的工程图纸，并与传统设计结果进行比较。
关键词：工艺规程夹具 PRO/E实体建模1 前言1.1 设计的意义毕业设计是培养学生综合运用所学的基础理论和专业理论知识，独立解决零件工艺和夹具设计问题的能力一个重要的实践性教学环节。
机械加工工艺是实现产品设计，保证产品质量、节约能源、降低成本的重要手段，是企业进行生产准备，计划调度、加工操作、生产安全、技术检测和健全劳动组织的重要依据，也是企业上品种、上质量、上水平，加速产品更新，提高经济效益的技术保证。
同时夹具作为机械制造系统中不可或缺的重要组成部分，在稳定保证工件加工精度、提高劳动生产率、扩大机床适用范围、改善操作者劳动条件、降低成本都具有十分突出的贡献。
变速箱换挡叉的加工工艺及夹具设计模板
变速箱换挡叉的加工工艺及夹具设计模板1毕业设计( 论文)变速箱换挡叉的加工工艺及夹具设计a摘要本次设计内容涉及了机械制造工艺及机床夹具设计、金属切削机床、公差配合与测量等多方面的知识。
拨叉的加工工艺规程及其铣叉口面与钻mmΦ孔的夹8.15具设计是包括零件加工的工艺设计、工序设计以及专用夹具的设计三部分。
铣叉口面以mmΦ孔及其端面作为来定位8.15基准, 以工件的另外一个端面作为辅助基准, 实现工件的完全定位, 夹紧则是经过调节螺母来实现; 钻mmΦ孔以其端面158.作为定位基准, 夹紧则是由快换垫圈、螺母、心轴等组成。
关键词: 夹紧定位基准iAbstractThe design of the content relates to the machinery manufacturing technology and machine tool fixture design, metal cutting machine tool, tolerance and measuring and other aspects of knowledge.Fork processing procedures and milling fork and drill Φ hole of fixture design is including machining 15mm8.process design, process design and fixture design in three parts. Milling fork with diameter mmΦ hole and end as to8.15the locating datum to the workpiece, another end as auxiliary reference, realize the workpiece positioning, clamping is realized through adjusting nut; drill mmΦ158. hole and its face as a positioning reference, to achieve workpiece positioning, clamping is fast changing washer, nut, the mandrel.Key words:clamping positioning datumii目录摘要..................................................................... 错误!未定义书签。
变速箱换挡叉地加工实用工艺及夹具设计(中英文文献)
毕业论文附件材料目录1 英文文献翻译 (1)1.1 Shift gearbox (1)1.2 变速箱的换挡方式 (12)1 英文文献翻译1.1 Shift gearboxClassification usually gearbox as follows:Manual transmissionThe general automatic gearbox / common automatic transmission with tiptronicCVT stepless gearbox with gear box of the /CVTDual clutch gearboxSequential gearbox(1) manual gearboxManual transmission, also known as manual gear, English name is manual transmission, referred to as MT, which push the shift lever to change gears meshing position inside the transmission, changing the transmission ratio, so as to achieve the purpose of speed. Step on the clutch, can move the shift lever.The working principle of a manual gearboxThe manual gear box is composed of different gear ratio of the gear group, its basic principle is through the gear group work in different, to realize the transformation of gear ratio. As the key link for power distribution, transmission must have the power input shaft and the output shaft of the big two, together constitute the transmission gear, is a manual transmission is the most basic component. The power input is connected with the clutch shaft clutch transmission, from the power to directly through the input shaft to the group, the gear set is composed of different diameter gear, gear power transmission effect of different proportion reached is completely different, the usual shift driving also refers to change gear ratio.Next, let us through a simple model to tell you, the principle of manual gearbox shift. Below is a simple structural model of 3 axis 2 speed gearbox.The input shaft (green) is also called the first shaft, connected by a clutch and engine, shaft and the gear is a hard connected components. Red is called the intermediate gear shaft. Enter the two gear shaft and intermediate shaft is in constant mesh state, so when the input shaft rotates will drive shaft rotation. Yellow is the output shaft, it is also called the second shafts and connected to the drive shaft (only for rear wheel drive, the precursor is generally two), and then through the differential drive vehicles.When the wheel rotates the same with spline shaft to rotate together, at this time, blue gear shaft can occur on the spline shaft relative free rotation. Therefore, the engine stops, and the wheel is rotated, the blue gear and shaft in the stationary state, and the spline shaft with wheels. The principle and the rear axle of the bicycle flywheel is similar. Blue gear and spline shaft is composed of a sleeve to connect, sleeve with spline shaft to rotate, but also can be free to slide on the spline shaftto gear.With these, the shifting process is very good understanding, when connecting sleeve and a blue gear, engine power will be transmitted to the output shaft through the shaft, at the same time, blue gear left in free rotation, but because there is no and sleeve engaged, so it does not affect the spline shaft. If the sleeve between the two blue gear, the gearbox in neutral position, the two blue gear on the spline shaft rotate freely, without mutual interference.Principle of a conventional 5 speed manual gearbox shift is the same, only the gearbox structure increased the number of sleeve and the gear sets, so that it has more gear. But the reverse is based on the intermediate shaft (red) and the output shaft (blue) is added between a gear to achieve. Due to the increase of a gear, the reverse gear will always rotate toward other gear in the opposite direction. The gear because only to change gear rotation direction function, so it is also called the idler.5 block two shaft transmission structure, the input shaft and the driving gear are integrated into a whole, simplifies the structure and saves spaceIn addition to the traditional three axis manual gearbox, the widespread use of cars is two axis manual transmission, its structure and the three shaft of the gearbox is similar, only the input shaft and intermediate shaft as a shaft, therefore has the advantages of simple structure, small size advantages, in addition, it also has the middle gear transmission high efficiency, and low noise characteristics, so it is more suitable to be the precursor home car general car transmission form, is currently the most widely used, its shortcomings is not set up direct gear, transmission and file than the design cannot be too high. While driving, three shaft gearbox used is still the traditional.Manual gearbox in general, is through the push rod is connected or cable to control the shift. Push rod shift control connection, more direct but vibration will be large; and the cable type although no vibration,but the shift is not very clear, it is each to have good and bad. In addition to shift the two pure mechanical control, in addition, and the use of electronic shift device of manual transmission, which can combine the merits of push and pull the shift between the good. This kind of gear box in the shift when the gear shift lever, shifting to the corresponding gear, the transmission will be motor drive the corresponding fork control sleeve and the gear is engaged, so that there is no gear is not clear, but the shift schedule can be controlled in the ideal range.So, a good manual transmission need to have what characteristic? The first transmission must have good gear handle, each gear position clear, have reasonable horizontal and vertical stroke, into the block resistance is small and with suction. What is more important is, the gear tooth between than arrangement must be reasonable. Because each gear position than distribution, directly affect the cohesion power vehicles moving in a smooth, usually require a low gear can effectively accelerate, high block to achieve high speed and efficient, and the distance between each block should be uniform, otherwise will be very easy to cause the channeling shift when the car.Analysis of the advantages and disadvantages of manual gearboxAdvantages Obviously, which is simple in structure, reliable performance, manufacturing and maintenance cost is low, and the transmission efficiency is high (theory will be more fuel-efficient), also, because it is pure mechanical control, shift reaction is fast, and can be more direct expression of driver's intention, and therefore more driving pleasure, these are the advantages of manual gearbox. But compared to automatic transmission, its operation is complicated, and frustration in gear switch when the obvious disadvantage is irreparable.(2) automatic gearboxAutomatic transmission AT, the full name of Auto Transmission, whichis composed of hydraulic torque converter, composed of planetary gear and hydraulic control system, through the hydraulic transmission and gear combination to achieve variable speed moment.Compared with the manual transmission, automatic transmission is very different in structure and usage. The manual is mainly regulated by different gear combination to change gear, and the automatic transmission is through the hydraulic transmission and gear combination to achieve the purpose of changing speed. Hydraulic torque converter is one of the most characteristic of the automatic gearbox parts, which is composed of a pump, turbine and guide wheel and other components, pump wheel and turbine is a combination of work, through the liquid pump wheel drives the turbine to rotate, and the wheel between the pump and turbine wheel through the reaction between the pump wheel and turbine implementation the speed difference and implementation of variable torque function, the driver, you only need to different intensity slam the pedal, the gearbox can automatically stop lifting. Since the torque converter automatic transmission torque range is not big enough, so in a later series several rows of planetary gear to improve efficiency, the hydraulic control system will change with the engine to manipulate the planetary gear, so as to realize the automatic transmission torque. In order to meet a variety of running process needs (such as parking, reversing), automatic transmission also has some manual shift lever position, like the P block (R block (anchor), after the block), block N (neutral), D (forward), block.From the performance that the more gear automatic gearbox, the car in the process of running more smoothly, acceleration is better, and more fuel-efficient. In addition to providing a comfortable driving feeling, automatic transmission also has insurmountable defects. Dynamic automatic transmission response is not directly, which makes it in the"driving pleasure" slightly shortage. In addition, because of the use of hydraulic transmission, the automatic transmission gearbox transmission power loss.Tiptronic automatic transmissionHands appeared gearbox is in order to improve the automatic gearbox and operating economy and increase the setting, let the original computer automatic shift time back into the hands of drivers. At the same time, if in the city traffic in, or you can always switch back to automatic.A tiptronic automatic transmission is actually automatic gearbox, first appeared in a Porsche 911, manual gearbox electronic control system through the simulation of the operation of a manual gearbox. It appears, giving the driver a greater degree of freedom in the operation, can block up the blocking or shift paddles on the steering wheel to choose their own gear and shift the timing right, thereby greatly improving the driving pleasure.(3) CTV non-polar transmissionCVT (Continuously Variable Transmission), direct translation is a continuously variable transmission, which is continuously variable transmission. We often say, just as its name implies is that there is no clear and specific file, which operate on similar automatic gearbox, gear jump process but the ratio change is different from the automatic gearbox, but a continuous, so the power transmission continues smooth.CVT transmission system, the traditional gear by a pair of pulleys and a steel belt is replaced, each block is V structure is composed of two intervertebral disk, engine shaft is connected through a small pulley, steel belt drive pulley. Mystery lies in this special pulley: drive pulley structures CVT strange activity, divided into halves, can be close to or separate relative. Cone disc can tighten or open the thrust hydraulic, extrusion sheet steel chain so as to adjust the V slot width. When thecone disc inside mobile tightened, steel chain in the extrusion cones to center outside of the direction of movement (centrifugal direction), but moving to the center of the circle. In this way, steel chain drives the disc diameter increases, the transmission ratio is changed.The CVT gearbox what are the advantages?1, because there is no general automatic transmission gear, there will be no shift process of automatic transmission, shift the resulting sense of frustration will disappear, so the power output of CVT gearbox is linear, in actual driving very smooth.Theory of transmission system of 2 CVT, the gear can be an unlimited number of gear set, more freedom, the traditional transmission gear ratio, speed ratio and performance, fuel consumption, exhaust emissions balance, are more likely to achieve.3, the mechanical efficiency of CVT transmission, the province is oily considerably better than the automatic transmission common, after manual gearbox, fuel economy is much better than.Since there are so many advantages, why not let all the cars using CVT gearbox? There are two factors:1, compared with the traditional automatic transmission, its cost is high; and the operation is undeserved word, the higher probability.2, CVT gearbox itself still has its shortcomings, is the transmission of the steel belt can withstand strength is limited, generally more than 2.8L capacity or power above 280N • M is its limit, but we also see that there are more and more cars such as Audi, or Nissan, has broken the limit, believe strip the problem will be solved gradually.(4) dual clutch gearboxDual clutch gearbox DCT, English name is Dual Clutch Transmission, because it has two clutches, so called "dual clutch transmission".Technology introducedDual clutch gearbox combines the advantages of manual transmission and automatic transmission, no torque converter, instead of using two sets of clutch, through two sets of clutch alternately work, to achieve seamless shift effect. Two clutches respectively control the odd block and even block, that is to say, in the shift before, DSG had the next gear meshing, after shifting instruction, DSG quickly sends instructions to the engine, the engine speed increases, the previous meshing gears quickly, while the first group of clutch fully liberalized, the completion of a rise to block the action time, action and so on.Because without the torque converter, so the power of the engine can be fully played out, while the two clutch alternately work, shift time making, dynamic fault engine may be very limited. As the driver is the feeling that we are the most direct, switch gear action very quickly and smoothly, dynamic transmission process of almost uninterrupted, vehicle dynamic performance can be fully play. Compared with the traditional automatic transmission with torque converter, the DSG shift more directly, the power loss is smaller, so the fuel consumption can be reduced by more than 10%.DeficienciesHowever, with the traditional automatic transmission ratio, DSG also has some inherent disadvantages, firstly it is because there is no use hydraulic torque converter, nor realize manual transmission "linkage" action, so for the small-displacement engine, low speed torque characteristic is not enough to be completely exposed; secondly, because the DSG transmission using computer control, belonging to an intelligent transmission, it needs to send electronic signals to the engine block in the process of falling in the L /, the engine after reply, and the engine to be completed with L / reduction gear. A large number of electronic components, but also increases the probability of its failure.The dual clutch common with Volkswagen's DSG, Ford Powershift, Mitsubishi SST and Porsche PDK.(5) sequential gearboxSequential gearbox (AMT) is improved on the traditional manual gear transmission based on; it combines hydromechatronics automatic transmission has the advantages of both AT and MT; AMT has the advantages of automatic transmission common automatic transmission, and the retention efficiency of the original manual transmission gear transmission, the high cost of low, simple structure, easy manufacture. It is the reform in the present manual transmission, retained most of the original assembly, only to change the shift lever manual operating system part, the production of succession, to transform the input costs less, is very easy to be manufacturers to accept.The driver through the accelerator pedal and joystick to the electronic control unit (ECU) control signal transmission; electronic control unit collects the engine speed sensor, the speed sensor signal, the time to master the running state of the vehicle; electronic control unit (ECU) based on the best program according to these signals stored therein, optimal shifting rules, clutch fuzzy control rules engine oil, adaptive control law, action and temporal separation of the engine, clutch and transmission shift binding, the three to achieve the best matching. In order to obtain the excellent fuel economy and power performance and ability to smooth start and rapid shift, in order to achieve the desired results.But the AMT transmission is not perfect, the biggest disadvantage of AMT gearbox is shifting comfort is poor, and generate power interruption in the process of shifting, the shift in the process of speed performance is not good.AMT mechanical gearbox, its basic structure and conventional manualgearbox consistent, generally only one input shaft and an output shaft (RWD usually a middle shaft), which generally is the input shaft 5 forward gear and output shaft gear is in constant mesh state, wherein the output shaft of the 1 gear and a reverse gear, 2 block and the 3 block, 4 block and 5 block were shared by the three shift fork. The mechanism of two adjacent gear with a shifting mechanism, when the shift action, fork need once upon a gear defect, through neutral to the next gear gear meshing, due to three actions is the order, even if each action will be the time to a minimum, is still very difficult to obtain the shift speed fast enough."Independent innovation shift fork"The ISR gearbox has a unique structure, the gear arrangement it is different with the traditional AMT gearbox, also different from the dual clutch gearbox. The use of four independent shift fork, two stalls adjacent to the gear shift fork is composed of different control. Four independent fork respectively control 1 gear and reverse gear; block 3 and block 5, block 2 and block 4, block 6 and block 7, that is to say, from 1 until 6 block, two adjacent stalls are composed of two independent fork to respectively control.Because of this design, the shifting process can be further shortened: when two adjacent gear to gear switch, a shift fork and the current gear gear detachment, another gear meshing has already started, and a shift fork action and activates the electronic clutch three, because the action is almost synchronously, so that the whole time shorten. Lamborghini is compared originally claimed, performance is very good before the generation of the E-gear sequential gearbox, shift speed upgrade 40%, shift speed of 50 milliseconds is close to F1 gearbox level.Gear shift mechanism of ISR is driven by the electric hydraulic pump, a maximum of 60 bar pressure ensures the necessary operating speed, 7hydraulic valve controls the gear shift mechanism of action, and the electric pump to provide power, double plate clutch tough also driven by hydraulic pressure, will be responsible for the torque of the 690Nm transmitted to the four wheels. Synchronizer gear ring is made from carbon fiber, not only wear but also reduce the overall quality of the gearbox.In the design process, the transmission is not only fast, shift quality is equally important, VOCIS design control procedure is also fully take into account the daily driving comfort. The gearbox can choose three kinds of work modes: Strada (Road) or full automatic mode can provide comfortable for shift operation oriented; Sport (motion) mode will postpone shifting node and provides a more rapid gear switch; Corsa (track) model can provide the best track shift strategy, the model can also provide the starting control, also is the ejection start function.1.2 变速箱的换挡方式通常变速箱的分类为以下几种：手动变速箱普通自动变速箱/普通自动变速箱带手自一体CVT无级变速箱/CVT带挡位的变速箱双离合变速箱序列变速箱(1) 手动变速箱手动变速器，也称手动挡，英文全称为manual transmission，简称MT，即用手拨动变速杆才能改变变速器的齿轮啮合位置，改变传动比，从而达到变速的目的。
变速器换挡叉的工艺过程及夹具设计
变速器换挡叉的工艺过程及夹具设计变速器换挡叉是一种重要的汽车零部件，它位于变速器内部，通过连接齿轮和离合器来实现换挡操作。
换挡叉的工艺过程主要包括原料准备、加工制造、热处理和组装等步骤，并伴随着夹具的设计和制造。
首先，原料准备是换挡叉工艺过程中的第一步。
根据产品设计要求，选择合适的材料，通常选用优质合金钢作为原料。
然后，根据产品的形状和尺寸要求，通过锻造或冷挤压等方式将原料加工成初型。
接下来是加工制造的步骤。
加工工艺通常包括车削、铣削、刨削和磨削等工序。
首先，使用车床或其他加工设备对原料进行车削，将其加工成近似形状的换挡叉毛坯。
然后，在铣床上对毛坯进行铣削，使其形状更加接近最终产品的要求。
接着，通过刨床进行刨削，使换挡叉的表面光滑。
最后，利用磨床对换挡叉进行磨削和修整，使其达到产品设计要求的尺寸和形状。
在加工制造完成后，还需要对换挡叉进行热处理。
热处理的目的是通过加热和冷却等过程，改变其晶粒结构和机械性能，提高产品的强度和硬度。
热处理的方法通常包括淬火、回火和渗碳等。
通过适当的热处理工艺，可以使换挡叉具有更好的耐磨性和抗断裂性能。
最后一步是组装。
根据产品的设计要求，将热处理后的换挡叉与其他零部件进行组装，如齿轮、离合器等。
组装过程需要使用夹具来固定和定位零部件。
夹具的设计通常基于产品的尺寸和形状要求，通过设计合理的夹具，可以提高工作效率和产品的质量。
总之，变速器换挡叉的工艺过程包括原料准备、加工制造、热处理和组装等步骤。
在这个过程中，夹具的设计和制造起着重要的作用，它能够提高工作效率、保证产品质量，并降低人工操作的难度和风险。
通过科学合理的工艺和优质的夹具配合，可以生产出高质量的换挡叉产品。
夹具设计是换挡叉制造过程中的关键环节之一。
夹具的设计不仅要符合产品的尺寸和形状要求，还要保证稳定的固定和定位，使得零部件能够准确地装配在一起。
下面将进一步介绍夹具设计的相关内容。
首先，夹具设计应考虑到产品的形状和尺寸要求。
机械制造技术课程设计-变速器换挡叉加工工艺及铣叉脚端面夹具设计(全套图纸)
机械制造工艺课程设计说明书题目：变速器换挡叉叉脚端面铣夹具设计目录一、零件分析 (3)1.1零件的作用 (3)1.2零件的工艺分析 (3)1.3尺寸和粗糙度的要求 (3)1.4位置公差要求 (4)二、毛坯的设计 (4)2.1选择毛坯 (4)2.2确定机加工余量、毛坯尺寸和公差 (4)2.3 确定机械加工加工余量 (4)2.4 确定毛坯 (5)2.5 确定毛坯尺寸公差 (4)2.6设计毛坯图 (4)三、选择加工方法，拟定工艺路线 (7)3.1基面的选择 (7)3.2粗基准的选择 (8)3.3精基准的选择 (14)3.4制定机械加工工艺路线··································15四、加工设备及道具、夹具、量具的选择 (15)五、确定切削用量 (18)六、基本时间的确定 (20)七、夹具设计 (25)八、总结 (29)一、零件分析1.1零件的作用题目所给定的零件是变速器换档叉（如下图2-1所示），它位于传动轴的端部。
主要作用是传递扭矩，使变速器获得换档的动力。
该零件是以15.88F∅孔套在轴上，并用M10×1-7H螺纹孔与轴定位，换挡叉脚卡在双联齿轮的轴中，变速操作机构通过换挡叉头部的操纵槽带动换挡叉与轴一起在变速箱中滑动，换挡叉脚拨动双联齿轮在花键轴上滑动，就可实现变速功能，从而实现变速器变速。
换挡叉的主要工作面为操纵槽换挡叉脚两端面，主要配合面为15.88∅孔，M10×1-7H螺纹孔和换挡叉F脚侧面.该零件属于特殊形状零件，但复杂程度一般。
变速器换挡叉加工工艺及夹具设计
加工精度：保 证夹具的加工 精度，以满足
加工要求
装配要求：夹 具的装配应符 合设计要求， 保证夹具的稳 定性和可靠性
维护保养：定 期对夹具进行 维护保养，以 保证其使用寿 命和加工精度
04
加工工艺与夹具设计的结合
夹具设计的工艺性分析
夹具设计需要满足加工工艺 的稳定性和可靠性，如夹具 的夹紧力、定位精度等
夹具设计的经济性分析
成本控制：选择合适的材料和加工方法，降低生产成本 效率提升：优化夹具设计，提高生产效率，降低生产时间 质量保证：保证产品质量，减少废品率，降低生产成本 维护方便：设计易于维护的夹具，降低维护成本 环保要求：符合环保要求，降低环保成本 安全性能：保证操作安全，降低安全事故成本
05
夹具设计需要考虑加工工艺 的要求，如加工精度、加工 效率等
夹具设计需要考虑加工工艺 的可操作性和安全性，如夹 具的操作方便性、安全性等
夹具设计需要考虑加工工艺 的经济性，如夹具的成本、
维护成本等
夹具在加工过程中的使用要求
夹具应具有足够的强度和刚度，以保证加工过程中的稳定性和精度
夹具应具有良好的定位精度和重复定位精度，以保证加工过程中的 一致性和稳定性 夹具应具有良好的耐磨性和耐腐蚀性，以保证加工过程中的使用寿命 和可靠性
工艺流程： 加热、保 温、冷却
时间： 根据材料 和工艺要 求确定
冷却方式： 空气冷却、 油冷却、 水冷却等
热处理后 的检验： 硬度、耐 磨性、疲 劳强度等
表面处理工艺
电镀：通过电解作用在工件表面形成一层金属或合金的薄膜，提高耐磨性、耐腐蚀性和 美观性
夹具的动力学性能分析
夹具的稳定性：保证加工过程中的稳定性，避免振动和变形 夹具的刚度：保证加工过程中的刚度，避免变形和磨损 夹具的精度：保证加工过程中的精度，避免误差和偏差 夹具的耐磨性：保证加工过程中的耐磨性，避免磨损和损坏
变速器换挡叉工艺工装设计概论
镇江高专ZHENJIANG COLLEGE 毕业设计（论文）变速器换挡叉工艺工装设计Transmission shift Forks tooling design 题目∶变速器换挡叉工艺工装设计系名：机械工程系专业班级：机电W072学生姓名：李婷学号：070108218指导教师姓名：张晶指导教师职称：副教授二○一二年六月十五日目录摘要 (3)引言 (4)第一章零件的分析 (5)第二章工艺规程的设计 (6)2.1确定毛坯的的制造形式 (6)2.2基准的选择 (6)2.3制订工艺路线 (6)2.4机械加工余量、工序尺寸及毛坯尺寸的确定 (8)2.5确定切削用量及基本工时 (9)第三章专用夹具的设计 (19)3.1钻、攻M10螺纹的夹具设计 (19)3.1.1问题提出 (19)3.1.2 定位基准的选择 (19)3.1.3定位元件的设计 (19)3.1.4切削力及夹紧力计算 (19)3.1.5 夹具设计及操作简要说明 (19)3.2铣拨叉宽51面的夹具设计 (21)3.2.1 问题的提出 (21)3.2.2 定位基准的选择 (21)3.2.3定位元件的设计 (21)3.2.4 切削力及夹紧力计算 (21)3.2.5 定向键与对刀装置设计 (23)3.2.6 夹具设计及操作简要说明 (25)总结 (26)致谢 (27)参考文献 (28)变速器换挡叉专业班级：机电W072 学生姓名：李婷指导教师：张晶职称：副教授摘要：本次设计内容涉及了机械制造工艺及机床夹具设计、金属切削机床、公差配合与测量等多方面的知识。
拨叉的加工工艺规程及其铣叉口面与钻M10螺纹的夹具设计是包括零件加工的工艺设计、工序设计以及专用夹具的设计三部分。
铣叉口面以Φ15.81F8孔及其端面作为来定位基准，以工件的另外一个端面作为辅助基准，实现工件的完全定位，夹紧则是通过调节螺母来实现；钻M10螺纹以Φ15.81F8孔及其端面作为定位基准，以一削边销作为辅助基准，实现工件的完全定位，夹紧则是由快换垫圈、螺母、心轴等组成。
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课程设计说明书题目变速器换挡叉的工艺设计目录机械自造工艺及夹具课程设计任务书 (3)序言 (4)零件的分析 (4)零件的工艺分析 (4)确定生产类型 (4)确定毛坯 (5)工艺规程设计 (5)选择定位基准 (5)制定工艺路线 (5)机械加工余量、工序尺寸及公差的确定 (6)夹具设计 (16)问题提出 (16)夹具设计 (16)参考文献 (17)机械制造工艺及夹具课程设计任务书设计题目：制定变速器换挡叉的加工工艺，设计钻φ15及2-M6孔的钻床夹具设计要求：中批量生产手动夹紧通用工艺装备设计时间：2009.6设计容：1、熟悉零件图；2、绘制零件图（一）；3、绘制毛坯图（一）；4、编写工艺过程卡片和工序卡片；5、绘制夹具总装图；6、绘制夹具零件图；7、说明书2009年06月序言机械制造装备设计课程设计是我们在学完了大学的全部基础课，专业基础课以及专业课后进行的。
这是我们在进行毕业设计之前对所学的各科课程一次深入的综合性总复习，也是一次理论联系实际的训练。
因此，他在我们的大学四年生活中占有重要的地位。
就我个人而言，我希望通过这次课程设计对自己未来将从事的工作进一步适应性的训练，希望自己在设计中能锻炼自己的分析问题、解决问题、查资料的能力，为以后的工作打下良好的基础。
由于能力有限，设计尚有很多不足之处，希望各位老师给予指导。
零件的分析题目所给的零件是变速器换档叉。
它位于汽车的变速机构上，主要起换档作用。
一．零件的工艺分析零件的材料为35钢，，为此以下是变速器换档叉需要加工的表面以及加工表面之间的位置要求：1、孔Φ15.8以及与此孔相通的、M10螺纹孔。
2、上下U型口及其两端面3、换档叉底面、下U型口两端面与孔Φ15.8中心线的垂直度误差为0.15mm。
由上面分析可知，可以粗加工Φ15的孔，然后以此作为基准采用专用夹具进行加工，并且保证位置精度要求。
再根据各加工方法的经济精度及机床所能达到的位置精度，选择以孔为基准加工的面作为孔加工的精基准。
最后，以精加工的孔为基准加工其他所有的面。
此变速器换档叉零件没有复杂的加工曲面，所以根据上述技术要求采用常规的加工工艺均可保证。
二、确定生产类型已知此换档叉零件的生产纲领为5000件/年，零件的质量是2.26Kg/个，查《机械制造工艺设计简明手册》第2页表1.1-2，可确定该换档叉生产类型为中批生产，所以初步确定工艺安排为：加工过程划分阶段；工序适当集中；加工设备以通用设备为主，大量采用专用工装。
三、确定毛坯1、确定毛坯种类：零件材料为35钢。
考虑零件在机床运行过程中所受冲击不大，零件结构又比较简单，生产类型为中批生产，故采用模锻件作为毛坯。
查《机械制造工艺设计简明手册》第41页表2.2-5,选用锻件尺寸公差等级为CT-12。
工艺规程设计(一)选择定位基准：1 粗基准的选择：以零件的圆柱面为主要的定位粗基准2 精基准的选择：考虑要保证零件的加工精度和装夹准确方便，依据“基准重合”原则和“基准统一”原则，以Φ15.8的孔表面为辅助的定位精基准。
(二)制定工艺路线:根据零件的几何形状、尺寸精度及位置精度等技术要求，以及加工方法所能达到的经济精度，在生产纲领已确定的情况下,可以考虑采用万能性机床配以专用工卡具,并尽量使工序集中来提高生产率。
除此之外，还应当考虑经济效果，以便使生产成本尽量下降。
查《机械制造工艺设计简明手册》第20页表1.4-7、1.4-8、1.4-11，选择零件的加工方法及工艺路线方案如下：工序01 粗铣Φ15上、下端面，以外圆为定位基准，采用X51立式铣床加专用夹具；工序02 铣16.5*42面，以外圆为定位基准，采用X51立式铣床加专用夹具；工序03 钻Φ15孔，以Φ15孔的上端面为定位基准，采用Z525立式钻床加专用夹具；工序04 扩Φ15.5孔，以Φ15上、下端面为定位基准，采用Z525立式钻床加专用夹具；工序05 粗铰Φ15.7孔，以Φ15上、下端面为定位基准，采用Z525立式钻床加专用夹具；工序06 精铰Φ15.8孔，以Φ15上、下端面为定位基准，采用Z518立式钻床加专用夹具；工序07 粗铣叉口前后两侧面，以Φ15.8孔为定位基准，采用X51立式铣床加专用夹具；工序08 粗铣16*56两侧面，以Φ15.8孔为定位基准，采用X51立式铣床加专用夹具；工序09 精铣16*56两侧面，以Φ15.8孔为定位基准，采用X51立式铣床加专用夹具；工序10 粗铣叉口19*5.9两侧面，以Φ15.8孔为定位基准，采用X51立式铣床加专用夹具；工序11 精铣叉口19*5.9两侧面，以Φ15.8孔为定位基准，采用X51立式铣床加专用夹具；工序12 粗铣14.2*9.65面、铣11*9.65面，以Φ15.8孔为定位基准，采用X51立式铣床加专用夹具；工序13 精铣16.5*42面，以Φ15.8孔为定位基准，采用X51立式铣床加专用夹具；工序14 钻Φ9孔，以Φ15.8孔为定位基准，采用Z525立式钻床并采用专用夹具；工序15 攻螺纹，以Φ15.8孔为定位基准，采用Z525立式钻床并采用专用夹具；工序16 去毛刺；工序17 终检。
（三）机械加工余量、工序尺寸及公差的确定:1、圆柱表面工序尺寸：前面根据资料已初步确定工件各面的总加工余量，现在确定各表面的各个加工工序的加工余量如下：2工序01 粗铣Φ15上、下端面，以外圆为定位基准，采用X51立式铣床加专用夹具刀具：YG6硬质合金端铣刀。
铣削宽度a e ≤90,深度a p ≤6,齿数z=12,故根据《机械制造工艺设计简明手册》（后简称《简明手册》）表3.1，取刀具直径d 0=125mm 。
根据《切削用量手册》（后简称《切削手册》）表3.16，选择刀具前角γ0＝0°后角α0＝8°，副后角α0’=10°，刃倾角：λs=－10°,主偏角Kr=60°,过渡刃Kr ε=30°,副偏角Kr ’=5°。
2. 切削用量 1）确定切削深度a p因为余量较小，故选择a p =4mm ，一次走刀即可完成。
2）确定每齿进给量f z采用对称端铣，以提高进给量提高加工效率。
根据《切削手册》表3.5，使用YG6硬质合金端铣刀加工，机床功率为4.5kw （据《简明手册》表4.2-35，X51立式铣床）时： f z =0.09~0.18mm/z 故选择：f z =0.18mm/z 。
3）确定刀具寿命及磨钝标准根据《切削手册》表3.7，铣刀刀齿后刀面最大磨损量为1.5mm ；由于铣刀直径d 0=125mm ，故刀具使用寿命T=180min （据《简明手册》表3.8）。
4）计算切削速度v c 和每分钟进给量v f根据《切削手册》表 3.16，当d 0=125mm ，Z=12，a p ≤7.5，f z ≤0.18mm/z 时，v t =98m/min,n t =250r/min,v ft =471mm/min 。
各修正系数为：k MV = 1.0，k SV = 0.8。
切削速度计算公式为：v pv e v z v p T vv c k z u a y f x a q d c v vm0=其中 mm a e 72=，mm a p 4=，245=v C ，2.0=q v ，15.0=x v ，35.0=y v ，8.08.00.1=⨯=⋅=k k k Sv Mv v ，2.0=u v ，0=p v ，32.0=m ，min 180=T ，z mm f z /18.0=，12=Z ，将以上数据代入公式：min/1428.0122.07235.008.015.041802.012524532.0m v c =⨯⨯⨯⨯⨯⨯⨯⨯⨯⨯=确定机床主轴转速： min /3611000r d v n wcs==π。
根据《简明手册》表4.2-36，选择n c =300r/min,v fc =390mm/min,因此，实际进给量和每分钟进给量为：v c =10000n d π=100030012514.3⨯⨯m/min=118m/min f zc =v fc /n c z=390/300×12 mm/z=0.1mm/z5)校验机床功率根据《切削手册》表3.24，近似为Pcc=3.3kw,根据机床使用说明书，主轴允许功率Pcm=4.5×0.75kw=3.375kw>Pcc 。
故校验合格。
最终确定:a p =4.0mm ，n c =300r/min ，v f =390mm/s ，v c =118m/min ，f z =0.1mm/z 。
6）计算基本工时t m ＝L/ v f ，L=l+ y+Δ，l=24mm.查《切削手册》表3. 26，入切量及超切量为：y+Δ=40mm ，则： t m ＝L/ V f =(24*2+40)/390=0.22min 。
工序02 铣16.5*42面，以外圆为定位基准，采用X51立式铣床加专用夹具；刀具：YG6硬质合金端铣刀； 机床：X51立式铣床；查《切削手册》表3.5，进给量为：min /0.1~5.0mm f z =，取为0.5mm/r参考有关手册，确定min /124m v =，采用YG6硬质合金端铣刀，12,125==z mm d w ，则：min /31612512410001000r d vn ws =⨯⨯==ππ现采用X51立式铣床，根据《简明手册》表4.2-36，取min /300r n w =，故实际切削速度：min /75.11710003001251000m n d vww =⨯⨯==ππ当min/300r n w =时，工作台每分钟进给量：min /1800300125.0mm n z f f w z m =⨯⨯=⋅⋅=，取为980mm/min本工序切削时间为：05.098042====f l t t m m min工序03 钻Φ15孔，以Φ15孔的上端面为定位基准，采用Z525立式钻床加专用夹具 1. 加工条件工件材料：35钢,σb =170~240MPa ，锻造;工件尺寸：a emax =72mm ，l=176mm; 加工要求：钻Φ15孔，加工余量0.8; 机床：Z525立式钻床；刀具：根据《切削手册》表2.1.2.2，选择高速钢麻花钻钻头，粗钻时d o =15mm ，钻头采用双锥后磨横刀，后角αo ＝12°，二重刃长度b ε=3.5mm,横刀长b=2mm,宽l=4mm,棱带长度mm l 5.11=，1002=ϕ°，30=β°2.选择切削用量 （1）确定进给量按加工要求确定进给量：查《切削手册》，r mm f /53.0~43.0=，367.11830<==dl，由《切削手册》表2.7,系数为0.5,则：r mm f /)265.0~215.0(5.0)53.0~43.0(=⨯=按钻头强度选择:查《切削手册》表2.8,钻头允许进给量为：r mm f /0.2=； 按机床进给机构强度选择：查《切削手册》表2.9，机床进给机构允许轴向力为8330N 时，进给量为r mm f /93.0=。