Development of the technological process of mechanical processing of the detail "Adapter. Adapters for metal and plastic pipes Calculation of operational sizes

Course project on mechanical engineering technology
Project Topic: Development technological process Mechanical processing details "Adapter".

Applications: Sketch cards Turn-milling drilling, operational card of combined parts processing operations on CNC metal cutting machines, control program (005, a) (in the FANUC system), adapter drawings, parts processing schemes, technological sketches, drawing of the workpiece.

In this course project, the volume of release was calculated and the type of production was determined. Analyzed the correctness of the performance of the drawing from the point of view of compliance with the current standards. Detail processing route is designed, equipment, cutting tools and fixtures. Operating dimensions and size of the workpiece are calculated. Cutting modes and time rate on the turning operation are defined. Considered issues of metrological support and safety.

The most important tasks of this term paper are: practical understanding of the basic concepts and provisions of mechanical engineering technology on the example of the design of the technological process of processing the detail "adapter", mastering the existing nomenclature technological equipment and accessories in the conditions of production, their technological capabilities, the rational area of \u200b\u200btheir use.

In the process of analyzing the technological process were considered next questions: Consideration of the design of the design details, the rationale for the choice of technological process, mechanization and automation, the use of high-performance machines and equipment, streaming and group methods of production, strict compliance with the machine-building standards and the series of preference, the validity of the use on specific operations of technological equipment, cutting tools, work devices, measurement tools, identifying the structures of technological operations, their critical assessment, fixing the elements of technological operations.

Content
1. Task
Introduction
2. Calculation of the volume of release and determination of the type of production
3. general characteristics Details
3.1 Official purpose Details
3.2 Detail type
3.3 Technological details
3.4 Normocontrol and metrological examination Drawing Details
4. Choosing a type of preparation and its justification
5. Development of the route technological process of manufacturing part
6. Development of the operational technological process of manufacturing part
6.1 Refinement of selected technological equipment
6.2 Refinement Installation Scheme Details
6.3 Appointment of cutting tools
7. Processing sketches
8. Development of the management program
8.1 Performing a technological sketch indicating the structure of operations
8.2 Calculation of the coordinates of the reference points
8.3 Development of the Management Program
9. Calculation of operating size and size of the workpiece
10. Calculation of cutting modes and technical rationing
11. Metrological support of the technological process
12. Safety of the technological system
13. Filling technological maps
14. Conclusions
15. Bibliographic list

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technological process Design Detail

1. Design part

1.1 Description of the assembly unit

1.2 Description of the design details included in the design of the node

1.3 Description of the design modifications proposed by the student

2. Technological part

2.1 Detail Design Technology Analysis

2.2 Development of the Routed Technological Process Manufacturing Details

2.3 Selection of used technological equipment and tools

2.4 Development of basic schemes

1 . Design part

1 . 1 Description of the design of a node or assembly unit

Detail - adapter for which the technological process of manufacture will later be designed, is part of Assembly node, such as a valve, which, in turn, is used in modern equipment (for example, an oil filter in a car). Oil filter - device designed to clean engine oil from polluting in the process of operation of the engine of the internal combustion of mechanical particles, resins and other impurities. This means that without an oil filter, the lubrication system of internal combustion engines cannot do.

Figure 1. 1 - Valve BNTU 105081. 28. 00 Sat

Details: Spring (1), spool (2), adapter (3), tip (4), plug (5), washer 20 (6), ring (7), (8).

To build a node "Valve", you must perform the following steps:

1. Before assembling, check the surfaces for purity, as well as on the absence of abrasive substances and corrosion between the mating details.

2. When installing rubber rings (8) to protect from distortion, twisting, mechanical damage.

3. When assembling grooves for rubber rings in the part (4), lubricate Litol-24 GOST 21150-87 with lubrication.

4. Observe the tightening standards according to OST 37. 001. 050-73, as well as technical requirements Tightening on OST 37. 001. 031-72.

5. The valve must be sealed at an oil supply to any cavity, with a mounted second, viscosity from 10 to 25 CR under pressure of 15 MPa, the appearance of individual drops by connecting the tip (4) with an adapter (3) is not a brave sign.

6. The remaining technical requirements are observed on STB 1022-96.

1 . 2 Description Design Details, included in the design of the node (assembly unit)

Spring-elastic element designed to accumulate or absorb mechanical energy. The spring can be made of any material having sufficiently high-influence and elastic properties (steel, plastic, wood, plywood, even cardboard).

Steel springs general purpose Move from high carbon steels (U9a-U12A, 65, 70) doped with manganese, silicon, vanadium (65g, 60c2a, 65С2A). For springs working in aggressive environments, stainless steel (12x18n10t), beryllium bronze (BRB-2), silmarchant bronze (BRCMC3-1), tin-zinc bronze (Brotz-4-3). Small springs can be poured out of the finished wire, while powerful are made from the rejected steel after the formation.

The washer is the fastener, placed under the other fastening product to create a larger area of \u200b\u200bthe supporting surface, reduce the damage to the surface of the part, prevent self-ejecting the fastening part, as well as to compact the connection with the gasket.

In our design is used by the washer GOST 22355-77

A spool, the spool valve is a device that guides the flow of liquid or gas by offsetting the movable part relative to the windows in the surface on which it slides.

In our design used spool 4570-8607047

Slot material - steel 40x

Compact adapter, or ordeal device, designed to connect devices that do not have a different compatible connection method.

Figure 1. 2 Sketch Details "Adapter"

Table 1. 1.

Summary table of characteristics of the surface of the part (adapter).

Name surface	Accuracy (Quality)	Roughness,	Note
Facial (flat) (1)			Facial beating of no more than 0. 1 relative to the axis.
Outdoor threaded (2)
Gallock (3)
Internal cylindrical (4)
Outdoor cylindrical (5)			Deviation from perpendicularity not more than 0. 1 relative to (6)
Facial (flat) (6)
Internal threaded (7)
Internal cylindrical (9)
Gallock (8)
Internal cylindrical (10)

Table 1. 2.

Chemical composition steel 35Gost 1050-88

The material that was selected for the manufacture of the part under consideration - steel 35Gost 1050-88. Steel 35 GOST1050-88 is a structural carbon high-quality. It is used for details of low strengths experiencing small stresses: axes, cylinders, crankshafts, rods, spindles, sprockets, traverses, traverses, shafts, bandages, discs and other details.

1 . 3 ABOUTscripture of modifications of the structures of the proposed student

The detail of the adapter corresponds to all accepted standards, gestures, design standards, therefore does not need to be improved and improved. This will lead to an increase in the number of technological operations and the equipment used, as a result of what to increase the processing time, which will lead to an increase in the cost of a unit of products, What is economically not appropriate.

2 . Technological part

2 . 1 Detail design techniques analysis

Under the technologicality of the details means a set of properties that determine its adaptability to achieve optimal costs in production, operation and repair for the specified quality indicators, the volume of production and work. The technological analysis of the part is one of the important stages in the process of developing a technological process and is carried out, as a rule, in two stages: high-quality and quantitative.

A qualitative analysis of the details of the adapter for manufacturability showed that there is a sufficient amount of sizes, types, tolerances, roughness for its manufacture, which exists the possibility of maximum billet approximation to the size and form of the part, the ability to process passage cutters. The material of the ST35GOST 1050-88, it is widely available and widespread. Mass of the part 0. 38kg, therefore there is no need to apply additional equipment for its processing and transportation. All surfaces of the part are easily accessible for processing and their design and geometry makes it necessary to process the standard tool. All holes in the details of the cross-cutting there is no need for the positioning of the tool when processing.

All chamfering performed at one angle can be performed by one tool, the same applies to the grooves (groove cutter), there are 2 grooves for the output of the tool when cutting the thread. This is a sign of technological. The part is rigid, since the ratio length to the diameter is 2. 8, so it does not require additional fixtures to secure it.

By virtue of the simplicity of design, small dimensions, minor mass and small number Processing surfaces, the part is quite technologically and does not represent the difficulties for machining. I define the manufacturability of the part using the quantitative indicators that are necessary to determine the accuracy coefficient. The data obtained are shown in Table 2. 1.

Table 2. 1.

Number and accuracy of surfaces

The efficiency coefficient is equal to 0, 91\u003e 0, 75. This shows the small requirements for the accuracy of the surfaces of the adapter details and indicates its technologicality.

To determine the roughness, all the necessary data is reduced to Table 2. 2.

Table 2. 2.

Number and roughness of surfaces

The coefficient of coefficient of roughness is 0. 0165<0. 35, это свидетельствует о малых требованиях по шероховатости для данной детали, что говорит о её технологичности

Despite the presence of non-technological features, according to high-quality and quantitative analysis, the detail of the adapter is generally considered to be technological.

2 .2 Development of a route technological process manufacturing part

For the necessary form of details, cutting the ends "as pure" are used. Preact the surface sh28. 4-0. 12Na length 50. 2-0, 12, withstanding R0. 4max. Next, the first chamfer 2. 5h30 °. Preact the groove "b", withstanding dimensions: 1. 4 + 0, 14; angle 60 °; Sh26. 5-0. 21; R0. one; R1; 43 + 0. 1. Center meters. Drills holes17 to depth 46. 2-0. 12. Clean the hole sh14 to sh17. 6 + 0. 12 to depth 46. 2-0. 12. Rarsing Sh18. 95 + 0. 2 at a depth of 18. 2-0. 12. Missing the groove "D", withstanding the dimensions. Restach the face 1. 2h30 °. Cut the end to size 84. 2-0, 12. Drills the hole sh11 before entering the hole sh17. 6 + 0. 12. SEND FACE 2. 5H60 ° in Hole sh11. To sharpen sh31. 8-0, 13 for a length 19 under the thread M33CH2-6G. Sharpe a chamfer 2. 5h45 °. To sharpen the groove "B". Cut the thread M33Ч2-6G. To accurately withstand the sizes sh46, angle 10 °. Cut the M20CH1-6H thread. Drill the hole sh9 output. Celebrate the champions 0. 3h45 ° in the hole sh9. Grind the hole sh18 + 0, 043 to RA0. 32. Grind sh28. 1-0. 03 to RA0. 32 with subwinding of the right end in size 84. Grind sh to RA0, 16.

Table 2. 4.

List of mechanical operations

Operation No	Name of operation
	Turning with CNC
	Turning with CNC
	Turn-screw.
	Vertically drilling
	Vertically drilling
	Intrahelifoval
	Kruglochlifoval
	Kruglochlifoval
	Tokar-screwing
	Control performer

2 .3 Selection of used technological equipment and tools

Under the conditions of modern production, a greater role acquires a cutting tool used in the processing of large parties of parts with the necessary accuracy. At the same time, such indicators are in the first place as durability and the method of size setting.

Selecting machines for the projected technological process We produce after each operation has previously been developed. This means that the method of surface treatment, accuracy and roughness, cutting tool and production type, overall dimensions of the workpiece are selected and defined.

For the manufacture of this part, equipment is used:

1. Turning machine with CNC CNC16K20F3;

2. Turning-screw machine 16K20;

3. Vertical drilling machines 2N135;

4. Machine intraslipheal 3K227V;

5. Machine semi-automatic circular slophing 3m162.

CNC lathe 16k20t1

The CNC clock with CNC model 16k20t1 is designed for fine processing of parts of the type of rotation bodies in a closed semi-automatic cycle.

Figure 2. 1 - CNC lathe 16K20T1

Table 2. 5.

TECHNICAL SPECIFICATIONS Turning machine with CNC 16K20T1

Parameter	Value
The largest diameter of the processed workpiece, mm:
over Stanna
over caliper
The greatest length of the processed workpiece, mm
The height of the location of the centers, mm
The largest diameter of the rod, mm
Step cut by carving: metric, mm;
The diameter of the spindle hole, mm
Inner Morse Spindle Cone
Spindle speed, rpm.
Feed, mm / about. :
Longitian
Transverse
Morse Pinoli Hole Cone
Cutter cross section, mm
Patron diameter (GOST 2675. 80), mm
Power of the motor drive of the main movement, kW
Numerical software control device
Deviation from the flatness of the end surface of the sample, microns
Machine dimensions, mm

Figure 2. 2 - Turning and screwing machine 16K20

Machines are designed to perform a variety of turning works and for cutting threads: metric, modular, inch, pitch. The designation of the machine model 16K20 acquires additional indices:

"B1", "B2", etc. - when changing the main technical characteristics;

"U" - when equipping the machine apron with an integrated accelerated movement engine and a box of feeding, ensuring the ability to cut a thread 11 and 19 threads on an inch without replacing the shift gears in the gearbox;

"C" - when equipped with a machine with a drilling-milling device, intended for you-complete drilling, milling work and cutting a thread at different angles on the parts mounted on the machine caliper;

"B" - when ordering a machine with an increased largest diameter of the processing of the workpiece over the bed - 630mm and the caliper - 420mm;

"G" - when ordering a machine with a recess in the bed;

"D1" - when ordering a machine with an increased largest diameter of the rod passing through a spindle in the spindle of 89 mm;

"L" - when ordering the machine with the price of dividing the Limb of the transverse movement 0, 02mm;

"M" - when ordering a machine with a mechanized drive of the upper part of the caliper;

"C" - when ordering a machine with a digital indexing device and linear rebuilding converters;

"RC" - when ordering a machine with a device for digital indexing and transducers of linear perars and with stepless adjustment of the spindle speed;

Table 2. 6.

TECHNICAL CHARACTERISTICS OF THE MACHINE OF LACKANCE-CHANGE 16K20

Name of parameter	Value
1 Expansion of the workpiece processed on the machine
1. 1 The largest diameter of the processed workpiece: above the bed, mm
1. 2 The largest diameter of the processed workpiece over the caliper, mm, not less
1. 3 The greatest length of the installed workpiece (when installed in the centers), mm, not less above the removal in the bed, mm, not less
1. 4 Height of the centers over the guides of the beds, mm
2 Tool indicators installed on the machine
2. 1 The highest height of the cutter installed in the mass holder, mm
3 Indicators of the main and auxiliary movements of the machine
3. 1 Number of spindle speeds: direct rotation reverse rotation
3. 2 Spindle frequency limits, rpm
3. 3 Caliper feed longitudinal transverse
3. 4 Caliper feed limits, mm / about longitudinal transverse
3. 5 Power Deferences Sliced \u200b\u200bThreads metric, mm. modular, module inch, number of threads pitchev, Pitch.
3. 6 Speed \u200b\u200bof fast caliper movements, m / min: longitudinal transverse
4 Indicators of the power characteristics of the machine
4. 1 The greatest torque on the spindle, KNM
4. 2
4. 3 Power Drive Fast Movements, kW
4. 4 Cooling Drive Power, kW
4. 5 Total power installed on the machine electric motors, kW
4. 6 Total power consumption machine, (largest), kW
5 Indicators of the size and mass of the machine
5. 1 overall dimensions of the machine, mm, not more:
5. 2 Machine Machine, kg, no more
6 Characteristics of electrical equipment
6. 1 generation of the supply network	Variable, three-phase
6. 2 Current frequency, Hz



7 Corrected sound power level, dBA
8 class of accuracy machine according to GOST 8

Figure 2. 3 - Vertical drilling machine 2T150

The machine is designed for: drilling, drilling, centers, deployment of thread cutting. A vertically drilling machine with a round column and turning on it with a table. On the machine you can handle small parts on the table, larger ones on the foundation plate. Manual and mechanical spindle feed. Tincture to the depth of processing with automatic shutdown of feed. Cutting threads with manual and automatic spindle reversal at a given depth. Processing small details on the table. Control of the movement of the spindle in the ruler. Built-in cooling.

Table 2. 7.

Technical characteristics of the machine vertically drilling machine 2T150

The greatest conditional diameter of drilling, mm cast iron sch20.
The greatest diameter of the cut thread, mm, in steel
Accuracy of holes after deployment
Cone spindle	Morse 5 AT6
The greatest movement of the spindle, mm
Distance from the end of the spindle to the table, mm
The greatest distance from the end of the spindle to the plate, mm
The greatest movement of the table, mm
Working surface size, mm
Number of spindle speeds
Spindle speed limits, rpm.
Number of spindle feed
The magnitude of the spindle feed, mm / about.
The greatest torque on the spindle, nm
The greatest effort of feeding, n
Turn angle around the column
Turning off the feed when the preceded drilling depth is reached	automatic
Ring current supply	Three phase variables
Voltage, B.
Main traffic drive power, kW
Total power of the electric motor, kW
Overall dimensions of the machine (LCBHH), mm, no more
Machine machine (net / gross), kg, no more
Dimensions of packaging (LCBHH), mm, no more

Figure 2. 4 - Machine Intrahelipheal 3K228A

The machine is intra-gland 3k228a is designed for grinding cylindrical and conical, deaf and through holes. The 3K228A machine has extensive range of rotational frequencies of grinding circles, the spindle of the product, the magnitude of the transverse feed and the velocity of the displacement of the table to process the parts on the optimal modes.

Roller guides for transverse movement of grinding grandmother along with the final link - ball, screw pair provide minimal movements with high accuracy. Fixture for grinding the ends of the product allows you to process on the machine 3k228A holes and end in one installation of the product.

The accelerated adjusting transverse movement of the grinding grandmother reduces the auxiliary time when the machine is reflected 3k228a.

To reduce the heating of the bed and exclusion transmission of vibration, the hydraulic drive machine is installed separately from the machine and connected to it the flexible hose.

The magnetic separator and filter conveyor provide high quality cleaning of the coolant, which improves the quality of the treated surface.

Automatic termination of the transverse feed after removing the installed allowance allows the operator to simultaneously control multiple machines.

Table 2. 8.

TECHNICAL SPECIFICATIONS OF THE MACHINE OF INTERISLIFICAL 3K228A

Characteristic
The diameter of the grinded hole is the largest, mm
The greatest length of grinding with the largest diameter of the grinded hole, mm

The largest outer diameter of the installed product without casing, mm

The largest angle of the grinding cone, hail.
Distance from the spindle axis products to the mirror of the table, mm
The greatest distance from the end of the new circle of the torchlife device to the spindle of the spindle of the product, mm
Main traffic drive power, kW
Total power of electric motors, kW
Machine dimensions: Length * Width * Height, mm
Total floor area machine with remote equipment, m2
Mass 3k228a, kg
Sample Processing Accuracy Indicator:
constancy of diameter in the longitudinal section, microns
rise, μm
Roughness surface of the sample product:
cylindrical internal RA, μm
flat torment

Figure 2. 5 - semiautomatic circular sloping 3m162

Table 2. 9.

The technical characteristics of the semiautomate of the circular slophing 3M162

Characteristic	Name

The largest diameter of the workpiece, mm
The greatest length of the processed part, mm
Grinding length, mm




Accuracy
Power
Gabarits.

Tools used in the manufacture of details.

1. Cutter (English Toolbit) - a cutting tool, designed to handle parts of various sizes, shapes, accuracy and materials. It is the main tool used in turning, planing and dragging works (and on the corresponding machines). The cutter and the billet are tightly fixed in the machine as a result of the relative movement in contact with each other, it occurs in the working element of the cutter in the material layer and its subsequent cutting in the form of chips. With the further promotion of the cutter, the rope process is repeated and chips are formed from individual elements. The type of chips depends on the supply of the machine, the speed of rotation of the workpiece, the material of the workpiece, the relative location of the cutter and the workpiece, the use of coolant and other reasons. In the process of operation, the cutters are susceptible to wear therefore carry out their flow.

Figure 2. 6, Cutter GOST 18879-73 2103-0057

Figure 2. 7 Cutter GOST 18877-73 2102-0055

2. Drill - cutting tool with rotational cutting movement and axial feed movement designed to perform holes in a solid layer of material. The roller can also be used for drilling, that is, an increase in existing, pre-drilled holes, and deploying, that is, not through recesses.

Figure 2. 8 - Drill GOST 10903-77 2301-0057 (material P6M5K5)

Figure 2. 9 - Cutter GOST 18873-73 2141-0551

3. Grinding wheels are designed for stripping curvilinear surfaces from scale and rust, for grinding and polishing products from metals, wood, plastics, and other materials.

Figure 2. 10 - Grinding Circle GOST 2424-83

Control tool

Technical monitoring tools: SCC-I-125-0 caliper, 1-2 GOST 166-89; Micrometer MK 25-1 GOST 6507-90; Nutrometer GOST 9244-75 18-50.

The caliper is designed for high accuracy measurements, the external and internal dimensions of the parts can be measured, the depth of the hole. The caliper consists of a fixed part - a measuring ruler with a sponge and moving part - a movable frame

Figure 2. 11 - CC-I-125-0 caliper, 1-2 GOST 166-89.

Nutromer - tool for measuring the inner diameter or distance between two surfaces. The accuracy of measurements by a chute meter is the same as the micrometer - 0, 01 mm

Figure 2. 12 - Nutrometer GOST 9244-75 18-50

The micrometer is a universal tool (device) designed to measure linear dimensions with an absolute or relative contact method in small size with a low error (from 2 microns to 50 microns, depending on the measured ranges and the accuracy class), the transducery mechanism of which is a micropara screw - Nut

Figure 2. 13- Micrometer Smooth MK 25-1 GOST 6507-90

2 .4 Development of blocking schemes for operations and selection of devices

The content and consolidation scheme, technological databases, support and clamping elements and devices must provide a certain position of the workpiece relative to the cutting tools, the reliability of its fixing and the invariance of the basing during the entire processing process at this installation. The surface of the workpiece adopted as the bases and their relative location should be such that it is possible to use the simplest and most reliable design of the device, to ensure the convenience of installing consolidation, disintegration and removal of the workpiece, the possibility of the application in the right places of the clamp forces and the supply of cutting tools.

When choosing the databases, basic basic principles should be taken into account. In general, the full cycle of processing the parts from the draft operation to the finishing is made with a consistent change of bases of the bases. However, in order to reduce errors and increase the productivity of parts, it is necessary to strive to reduce the reinstalling of the workpiece during processing.

With high requirements for the accuracy of processing for the preparation of blanks, it is necessary to choose such a software scheme that will ensure the smallest bazing error;

It is advisable to comply with the principle of constancy of the base. With the database change during the technological process, the processing accuracy is reduced due to the error of the mutual location of the new and previously used base surfaces.

Figure 2. 14 - Preparation

On operations 005-020, 030, 045, the part is fixed in the centers and operates with a three-tie cartridge:

Figure 2. 15 - Operation 005

Figure 2. 16 - Operation 010

Figure 2. 17 - Operation 015

Figure 2. 18 - Operation 020

Figure 2. 19 - Operation 030

Figure 2. 20 - Operation 045

On operation 025, the part is fixed in the vice.

Figure 2. 21 - Operation 025

Operations 035-040Deal is fixed in centers.

Figure 2. 22 - Operation 035

To secure the workpiece on operations, the following fixtures are used: three-tech, movable and fixed-road cartridge, fixed support, machine vice.

Figure 2. 23- three-tie cartridge GOST 2675-80

Machine vice is a device for clamping and holding billets or parts between two sponges (movable and fixed) during processing or assembly.

Figure 2. 24- Visits Machine GOST 21168-75

Center A-1-5-N GOST 8742-75 - Machine Rotating Center; Machine centers - a tool used to fix the billets when they are processed on metal cutting machines.

Figure 2. 25- Center Rotating GOST 8742-75

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Installation of adapters for plastic pipes

Plastic adapters for the pipeline must be chosen based on the composition of the pipes. They can be:

polyethylene;
polypropylene;
polyvinyl chloride.

Installation of plastic fittings adapters produce in different ways. It does not require cumbersome equipment and brigade of pipelines. The type of compound depends on the type of polymer, the diameter of the pipes and the purpose of the pipeline. Often the need arises to replace the segment of the pipeline rotting on the plastic tube. Then the compound of the cast iron / steel and polymer pipe will be required. Adapters come to the rescue. To connect, it will be necessary:

Combined adapter with a threaded part of a metal (mainly it is brass) and a polymer fulable with a rubber seal.
Two divorce keys.
Teflon tape (panel).

The installation of plastic pipes is performed in the fool, due to which high-quality homogeneous seam is achieved.

Replacing the old pipe occurs very quickly. First, the clutch of the metal pipeline is unscrewed in the right place. For this use two divorce keys. One key is taken behind the coupling, and the other is for the metal pipe. If the connection is not amenable, it should be lubricated with a special lubricant with an increased degree of penetration (UNISMA-1, Molykote Multigliss).

At the next stage, when the old pipe is unscrewed, the threaded compounds are compacted by teflon ribbon in two or three turns. Such a small precautionary measure helps to avoid further leaks. The final stage is the installation of an adapter. Tighten the adapter should be carefully without dragging, until resistance is feeling.

Metal and polymer have different extension coefficients at temperature fluctuations, so it is not recommended to use adapters with plastic threads to metal elements. In hot water and heating systems for compounding with metal valves and meters, you should use transient brass clutches with plastic housing and sealing rubber.

Adapter Adapter Classification

Adapters are:

compression;
electric welded;
flange;
threaded;
reducing.

The type of compound depends on the type of polymer, the diameter of the pipes and the purpose of the pipeline.

The compression adapter is a crimp member of the compound for plastic water pipes. Also, such fittings are also used to wiring the pipeline system. Plastic compression details withstand pressure up to 16 atm. (up to 63 mm) and high temperature. They are not subject to lime deposits, rotting and other biological and chemical influence. Standard diameter are manufactured. There are components such as a nut lid, a polypropylene case, a polyoxymethylene clamping ring, a pressing sleeve.

Installation of a compression adapter

Loosen the cape nut and remove it.
Disassemble the fitting on the components and put them on the plastic tube in the same order.
Tightly enter the pipe until a complete stop in the fitting.
Tighten the adapter nut with a universal key (the crimp key is usually sold along with fittings).

The modern Plumbing market today offers unsaturable, but it is still difficult to say which of them better.

When installing a compression fitting, crimp the crimping element on the pipe is formed, which creates a hermetic connection. The clamping ring is the main part of the fitting - it allows you to withstand the connective node with a colossal axial load and jerk. Prevents spontaneous spinning, created by vibration of water. Therefore, you do not have to constantly twist the scrambled nut.

The threaded adapter is the collapsible element of the pipeline, which is used repeatedly. Threaded fittings can be both with external and internal threads. These fittings are installed in those places where some additional installation, disassembling the pipeline system and other work that would be impossible in the event that the system was unintended.

Threaded adapters during installation do not require special equipment. At the same time, create a hermetic compound, preventing the leakage of water or gas from plastic pipelines. For more reliable sealing, a fum-tape is additionally used, which is wound on the thread in the direction of screwing the nut.

ZNE allows you to quickly implement the installation of polyethylene pipelines using cheaper welding equipment for electrical welding.

The electrical welded adapter (ZNE) is a connecting element with a mortgage heater, designed for different diameters. The heating spiral embedded in the adapter melts plastic at the junction of the pipes and creates a monolithic connection.

Installation of the electric welded adapter does not require special skills. The quality of electrical welding is little dependent on a person acting, which cannot be said about hardware welding.

Installation of an electric welded adapter

Fastened parts are thoroughly aligned and docked in the necessary places. Electric current is passed through mortgage steamers. Under the action of electricity, the helix is \u200b\u200bheated and plastic planes in a viscous state. The monolithic connection is obtained at the molecular level.

When installing electric welded adapters, general requirements should be followed:

the welded elements must have an identical chemical composition;
degreasing and careful cleansing of surfaces;
mechanical cleaning tools;
natural cooling.

According to the advice of specialists, it is better to use ZNE adapters with an open heating spiral. Plastic pipes should be deeply entering the fitting, and the welding zone is to be maximum length.

Flange adapter or crimping flange

This is an element of a detachable connection that provides permanent access to the pipeline. The connecting node is formed using two flanges and bolts, which are tightened. For plastic pipes, moving to metal elements, the flanges of a free view with a support point on a straight bourge or universal wedge compound with figure flanges are used.

Before installing the flange item be sure to inspect and detect all the jar and burrs that can damage the polymer pipe. Then the phased connection is made:

pipes are trimmed strictly at right angles;
the flanges of the desired size are installed;
a rubber gasket is put on (it is impossible to access the pads for the pipe cut more than 10 mm);
both flange rings come to the rubber gasket and bolted bolted.

Such flanges will provide the tightness and strength of the pipeline design. They are easy to manufacture and comfortable when installing.

The reduction adapter is a connecting element for. Such a fitting is equipped with a thread and is often installed in the nodes connecting the pipe with the meters and other distribution equipment.

Plastic pipes cannot be collected in the pipeline system without a large set of fittings. A variety of these structural elements amazing imagination. It is immediately difficult to figure out what. Therefore, before assembling the pipeline, you should scrupulously study the entire rich assortment and choose only what you need. Very often at the unlucky craftsman, who decided to change the pipes, a bunch of unnecessary details is formed at home. It is good to open the store plumbing!

1.1 Office and Specifications Details

To compile a high-quality technological process of manufacturing the part, it is necessary to carefully examine its design and purpose in the machine.

The item is a cylindrical axis. The highest requirements for the accuracy of the form and location, as well as roughness are presented to the surfaces of the axis necks intended for planting bearings. So the accuracy of the necks for bearings should correspond to 7 qualifications. The high requirements for the accuracy of these necks of the axis relative to each other leak out of the operating conditions of the axis.

All axis cervix are the surface of rotation relative to high accuracy. This determines the feasibility of applying turning operations only for their pre-treatment, and the final processing in order to ensure the specified accuracy of the size and roughness of the surfaces should be performed by grinding. To ensure high demands for the accuracy of the axis necks, their final processing must be carried out in one installation or, in the extreme case on the same bases.

The axes of such a design are used in mechanical engineering quite wide.

The axes are designed to transmit torque and mounting on them different parts and mechanisms. They are a combination of smooth landing and non-private, as well as transitional surfaces.

The technical requirements for axes are characterized by the following data. The diametrical sizes of the planting necks are performed by IT7, IT6, other sheek according to IT10, IT11.

The design of the axis, its size and rigidity, technical requirements, the release program are the main factors that determine the manufacturing technology and the equipment used.

The part is the body of rotation and consists of simple structural elements represented as the bodies of rotation of the circular cross section of different diameters and length. The axis has a carving. The axis length is 112 mm, the maximum diameter is 75 mm, and the minimum is 20 mm.

Based on the constructive purpose of the part in the machine, all the surfaces of this part can be divided into 2 groups:

basic or work surfaces;

free or non-working surfaces.

Almost all axis surfaces refer to the main, because they are conjugate with the corresponding surfaces of other parts of the machines or directly participate in the working machine process. This explains sufficiently high demands on the accuracy of the part and the degree of roughness indicated in the drawing.

It can be noted that the design of the part fully meets its official purpose. But the principle of the design of the structure consists not only in satisfying operational requirements, but also the requirements of the most rational and economical manufacturing of the product.

The part has surfaces are easily accessible for processing; A sufficient hardness of the part allows it to handle it on machines with the most productive cutting modes. This part is technological, as it contains simple surface profiles, its processing does not require specially designed devices and machines. The surfaces of the axis are processed on turning, drilling and grinding machines. The required accuracy of the sizes and roughness of the surfaces are achieved with a relatively small set of simple operations, as well as a set of standard cutters and grinding circles.

The manufacture of the part is characterized by the complexity, which is due, first of all, with the maintenance of the work of the part, the necessary accuracy of the size, the roughness of the working surfaces.

So, the item is technological in terms of design and processing methods.

The material from which the axis is made, steel 45 refers to a group of medium carbon structural steels. It is used for medium-generated parts operating at low speeds and medium specific pressures.

The chemical composition of this material will be reduced to Table 1.1.

Table 1.1.

7
FROM	SI	MN.	CR	S.	P.	Cu.	Ni.	As
0,42-05	0,17-0,37	0,5-0,8	0,25	0,04	0,035	0,25	0,25	0,08

Let's slightly focus on the mechanical properties of the rolled and forgings necessary for further analysis, which also reduce to Table 1.2.

Table 1.2.

We present some technological properties.

The temperature of the start of forging 1280 C °, the end of the forging 750 s °.

This steel has limited weldability.

Cutting processability - in a hot-rolled state at HB 144-156 and σ B \u003d 510 MPa.

1.2 Definition of the type of production and size part of the Part

In the task of the course project indicates the annual product output program in the amount of 7000 pieces. By the source formula, we determine the annual program of the output of parts in pieces, taking into account spare parts and possible losses:

where n is the annual product output program, pcs.;

P 1 - Annual Production Program for Parts, Piece. (take 8000 pcs.);

b - the number of additionally manufactured parts for spare parts and to replenish possible losses, as a percentage. You can take B \u003d 5-7;

m is the number of details of this name in the product (accept 1 pc.).

PC.

The size of the production program in physical quantitative terms determines the type of production and has a decisive effect on the nature of the construction of the technological process, to choose equipment and equipment, on the organization of production.

In mechanical engineering distinguish three main types of production:

Single, or individual production;

Mass production;

Mass production.

Based on the release program, you can come to the conclusion that in this case we have serial production. With serial production, the manufacture of products is carried out by parties, or series, periodically repeated.

Depending on the size of parties or episodes, there are three types of mass production for medium cars:

Small-sector production with the number of products in a series of up to 25 pcs.;

Medium-term production with the number of products in the series 25-200 pcs;

Large production with the number of products in a series of more than 200 pieces;

A characteristic feature of mass production is that the manufacture of products is carried out by parties. The number of parts in the batch for simultaneous starts is allowed to be determined by the following simplified formula:

where n is the number of billets in the party;

P - annual product manufacturing program, pcs.;

L - the number of days to which it is necessary to have a stock of details in stock to ensure the assembly (accept L \u003d 10);

F - the number of working days a year. You can take f \u003d 240.

PC.

Knowing annual output of parts, we define that this production refers to a large-scale (5000 - 50000 pcs.).

With serial production, each technological process is fixed in a specific workplace. Most jobs are performed several operations periodically repeated.

1.3 Choosing a method of obtaining a blank

The method of obtaining the initial billets of machine parts is determined by the design of the part, the volume of production and the production plan, as well as the cost-effectiveness of the manufacture. Initially, from the variety of methods for obtaining source billets, several methods are chosen, which technologically provide the possibility of obtaining the workpiece of this part and allow you to simply bring the configuration of the original workpiece to the configuration of the finished part. Select the workpiece - it means to choose a method for obtaining it, outline inputs for the processing of each surface, calculate the dimensions and specify the tolerances for the inaccuracy of manufacture.

The main thing when choosing a workpiece is to ensure the predetermined quality of the finished part at its minimum cost.

The correct solution of the issue of choosing the workpieces, if different types of technical requirements and capabilities are applicable, can be obtained only as a result of technical and economic calculations by comparing the cost of the cost of the finished part at the same form or other form of the workpiece. Technological processes of obtaining blanks are determined by the technological properties of the material, constructive forms and dimensions of the parts and the release program. Preference should be given a billet characterized by the best use of metal and less cost.

Take two methods of obtaining billets and analyzing each one choose the desired method of obtaining billets:

1) Getting a workpiece from the rental

2) Obtaining a billet with stamping.

You should choose the most "successful" method of obtaining a workpiece by analytical calculation. Compare options for the minimum value of the present costs of the part.

If the workpiece is made from the rolled, then the cost of the workpiece is determined by the weight of the rolled product required for the manufacture of the part, and the weight of the chips. The cost of the workpiece obtained by the rental is determined by the following formula:

whereQ is the mass of the workpiece, kg;

S - price of 1 kg of material billets, rub.;

q is the mass of the finished part, kg;

Q \u003d 3.78 kg; S \u003d 115 rubles; q \u003d 0.8 kg; S q \u003d 14.4 kg.

Substitute the source data in the formula:

Consider the option of obtaining the workpiece with stamping on the GKM. The cost of the workpiece is determined by the expression:

Where with i is the price of one ton of stamping, rub.;

K T - coefficient depending on the accuracy class of stamping;

To C - coefficient depending on the complexity of the complexity of stamping;

To in - coefficient depending on the mass of stamping;

To M - coefficient depending on the stamp material brand;

To P - coefficient depending on the annual program of the release of stamping;

Q - weight of the workpiece, kg;

q is the mass of the finished part, kg;

S ots - price 1 ton of waste, rub.

With i \u003d 315 rubles; Q \u003d 1.25 kg; K T \u003d 1; To C \u003d 0.84; K \u003d 1; To m \u003d 1; To n \u003d 1;

q \u003d 0.8 kg; S q \u003d 14.4 kg.

The economic effect for comparing the methods of obtaining billets under which the technological process of mechanical processing does not change, can be calculated by the formula:

wheres e1, s e2 - the cost of compaled blanks, rubles;

N - annual program, pcs.

Determine:

From the results obtained, it can be seen that the option of obtaining a stamping workpiece is economically beneficial.

The manufacture of the preparation method of stamping on various types of equipment is a progressive method, since significantly reduces the allowances for mechanical processing in comparison with the preparation of the workpiece from the rolled, and is also characterized by a higher degree of accuracy and higher performance. In the process of stamping, the material is also compacted and the direction of the fiber material on the contour of the part is created.

Deciding the task of choosing the method of obtaining the workpiece, you can begin to perform the following steps of the course work, which will gradually bring us to the direct preparation of the technological process of manufacturing the part, which is the main purpose of the course work. The choice of the type of workpiece and the method of obtaining it has the most direct and very significant effect on the nature of building the technological process of manufacturing the part, since, depending on the selected method of obtaining the workpiece, the value of the part processing and, therefore, changes the method of methods, and, therefore, not a set of methods, used for surface treatment.

1.4 Purpose of methods and processing stages

The following factors that need to be considered are influenced by the choice of processing method:

form and size of the part;

the accuracy of the processing and cleanliness of the surfaces of parts;

economic feasibility of the selected method of processing.

Guided by the above items, we will begin to identify the set of processing methods on each surface of the part.

Figure 1.1 Sketch of parts with the designation of layers removed during machining

All surfaces of the axis have sufficiently high requirements for roughness. Calculation of surfaces A, B, B, G, D, E, Z, and, to divide into two operations: black (preliminary) and piston (final) scrap. With rough scrapping, we remove most of the allowance; Processing is made with great cutting depth and large feed. The scheme ensures the smallest processing time is most beneficial. With chistoching, remove a small part of the allowance, and the order of surface treatment is preserved.

When processing on the lathe, you must pay attention to the durable fixation of the part and the cutter.

To obtain the specified roughness and the required quality of the surfaces of r and, it is necessary to apply a clean grinding, at which the accuracy of the treatment of external cylindrical surfaces reaches the third class, and the surface roughness of 6-10 classes.

For greater visibility, we schematically write the selected methods for processing each surface of the part:

A: draft sharpness, finishing stitch;

B: black sharpening, cleaning sharpening, threading;

Q: roughing, picker sharpening;

G: draft sharpness, finishing sharpening, chisty grinding;

D: draft sharpening, finite sharpening;

E: draft sharpness, finite sharpening;

W: drilling, cenching, deployment;

S: draft sharpening, finishing sharpening;

And: roughing, stem-in sharpening, grinding clean;

To: roughing, pickest sharpening;

L: drilling, coinening;

M: drilling, zenkering;

Now you can go to the next step of the course of the course work associated with the choice of technical bases.

1.5 Database selection and processing sequence

The workpiece DETAILS During the processing process, it should take and save during the entire processing time a certain position relative to the machine components or device. To do this, it is necessary to exclude the possibility of three straight-line movements of the workpiece in the direction of the selected coordinate axes and three rotational movements around these, or the axes parallel to them (that is, to deprive the workpiece of the six degrees of freedom).

To determine the position of the rigid blank, it is necessary to have six reference points. For their placement, three coordinate surfaces are required (or replacing their three combinations of coordinate surfaces), depending on the shape and size of the workpiece, these points may be located on the coordinate surface in various ways.

As technological databases, it is recommended to choose design bases to avoid recalculation of operational sizes. The axis is a detail of a cylindrical form, the design bases of which are the end surfaces. In most operations, the support is carried out according to the following schemes.

Figure 1.2 Scheme of the installation of the workpiece in a three-tech cartridge

In this case, when installing the workpiece in the cartridge: 1, 2, 3, 4 - the double guide base, which takes four degrees of freedom - displacement relative to the OX axis and the axis of the turn around the axes of Ox and OZ; 5 - the support base deprives the workpiece of one degree of freedom - moving along the Oy axis;

6 - the support base that depriving the workpiece of one degree of freedom, namely, rotation around the Oy axis;

Figure 1.3 Installation scheme of workpiece in vice

Considering the form and dimensions of the part, as well as the accuracy of processing and cleanliness of the surface, sets of processing methods for each surface of the shaft were selected. We can determine the surface treatment sequence.

Figure 1.4 Sketch Details with designation surfaces

1. Turning operation. The workpiece is installed on the surface 4 in

self-centered 3 cam cartridge with focusing in end 5 for rough end of the end 9, surface 8, end 7, surface 6.

2. Turning operation. We turn over the workpiece and set it into the self-centering 3 cam cartridge on the surface 8 with the stop in the end for the black turning of the end 1, surface 2, end 3, surface 4, end 5.

3. Turning operation. The workpiece is installed on the surface 4 in

self-centered 3 cam cartridge with focusing in the end 5 for finishing end of the end 9, surface 8, end 7, surfaces 6, chamfer 16 and groove 19.

4. Turning operation. We turn over the workpiece and set it into the self-centering 3 cam cartridge on the surface 8 with the stop in the end 7 for the finishing of the end of the end 1, surface 2, end 3, surfaces 4, end 5, champers 14, 15 and grooves 17, 18.

5. Turning operation. The workpiece is installed in the self-centering 3 cam cartridge on the surface 8 with a stop in the end for drilling and the coinage of the surface 10, cutting the thread on the surface 2.

6. Drill operation. The part is set in vice on the surface 6 with the stop in the end 9 for drilling, the coinening and deployment of the surface 11, drilling and cencing surfaces 12 and 13.

7. Grinding operation. The part is mounted on the surface 4 in the self-centering 3 cam cartridge with an emphasis in the end 5 for surface grinding 8.

8. Grinding operation. The part is mounted on the surface 8 to the self-centering 3 cam cartridge with a focus to the end 7 for surface grinding 4.

9. Remove the item from the device and send to control.

The surface of the workpiece is processed in the following sequence:

surface 9 - roughing;

surface 8 - roughing;

surface 7 - roughing;

surface 6 - roughing;

surface 1 - roughing;

surface 2 - roughing;

surface 3 - roughing;

surface 4 - roughing;

surface 5 - roughing;

surface 9 - piston sharpening;

surface 8 - piston sharpening;

surface 7 - piston sharpening;

surface 6 - piston sharpening;

surface 16 - remove the chamfer;

surface 19 - to sharpen the groove;

surface 1 - piston sharpening;

surface 2 - piston sharpening;

surface 3 - piston sharpening;

surface 4 - piston sharpening;

surface 5 - piston sharpening;

surface 14 - remove the chamfer;

surface 15 - remove the chamfer;

surface 17 - to sharpen the groove;

surface 18 - to sharpen the groove;

surface 10 - drilling, coinening;

surface 2 - threading;

surface 11 - drilling, coinening, deployment;

surface 12, 13 - drilling, coinening;

surface 8 - 18 grinding;

surface 4 - 18 grinding;

As can be seen, the processing of surfaces of the workpiece is carried out in order from more coarse methods to more accurate. The last method of processing according to the parameters of accuracy and quality must comply with the requirements of the drawing.

1.6 Development of the route process

The part is the axis and refers to the bodies of rotation. We produce the processing of the workpiece obtained by stamping. When processing, we use the following operations.

010. Turning.

1. Soak out the surface 8, cut the end 9;

2. Purify the surface 6, trim 7

Cutter material: ST25.

Coolant brand: 5% emulsion.

015. Turning.

Processing is carried out on a turn-revolving machine model 1P365.

1. Purify the surface 2, cut the end 1;

2. Soak out the surface 4, cut the end 3;

3. Cut the end 5.

Cutter material: ST25.

Coolant brand: 5% emulsion.

Detail is based in three-tech cartridge.

As a measuring instrument, we use the bracket.

020. Turning.

Processing is carried out on a turn-revolving machine model 1P365.

1. Soak out the surface 8, 19, cut the end 9;

2. Soak out the surface 6, cut the end 7;

3. Remove the chamfer 16.

Cutter material: ST25.

Coolant brand: 5% emulsion.

Detail is based in three-tech cartridge.

As a measuring instrument, we use the bracket.

025. Turning.

Processing is carried out on a turn-revolving machine model 1P365.

1. Soak out the surface 2, 17, trim the end 1;

2. Soak out the surface 4, 18, cut the end 3;

3. Cut the end 5;

4. Remove the chamfer 15.

Cutter material: ST25.

Coolant brand: 5% emulsion.

Detail is based in three-tech cartridge.

As a measuring instrument, we use the bracket.

030. Turning.

Processing is carried out on a turn-revolving machine model 1P365.

1. Drill, zenkering hole - surface 10;

2. Cut the thread - surface 2;

Drill material: ST25.

Coolant brand: 5% emulsion.

Detail is based in three-tech cartridge.

035. Drilling

Processing is carried out on a coordinate-drilling machine 2550f2.

1. Drill, zenkering 4 stepped holes Ø9 - surface 12 and Ø14 - surface 13;

2. Drill, zenkering, deploy a hole Ø8 - surface 11;

Drill material: P6M5.

Coolant brand: 5% emulsion.

Detail is based in vice.

As a measuring instrument, we use the caliber.

040. Grinding

1. Grind the surface 8.

Detail is based in three-tech cartridge.

As a measuring instrument, we use the bracket.

045. Grinding

Processing is conducted on a circular grinding machine 3T160.

1. Grind the surface 4.

For processing, choose a grinding wheel

PP 600 × 80 × 305 24a 25 H cm1 7 K5A 35 m / s. GOST 2424-83.

Detail is based in three-tech cartridge.

As a measuring instrument, we use the bracket.

050. Vibro Abrasive

Processing is conducted in the vibrationabrasive car.

1. Fuck sharp edges, remove burrs.

055. Washing

Flushing is made in the bathroom.

060. Control

Control all the sizes, check the surface roughness, the absence of cavering, pointing sharp edges. The control table is used.

1.7 Choose equipment, equipment, cutting and measuring instruments

axis harvest cutting processing

The selection of machinery is one of the most important tasks in the development of the technological process of mechanical processing of the workpiece. It depends on the proper choice of the productivity of the part, the economic use of production areas, mechanization and automation of manual labor, electricity and in the end of the cost of the product.

Depending on the volume of product release, machines are chosen according to the degree of specialization and high performance, as well as machine tools with numeric software control (CNC).

When developing the technological process of mechanical processing of the workpiece, it is necessary to correctly select devices that should help increase productivity, processing accuracy, improve working conditions, eliminate the preliminary markup of the workpiece and reconcile them when installing on the machine.

The use of machine tools and auxiliary tools when processing billets gives a number of advantages:

improves the quality and accuracy of the processing of parts;

reduces the labor intensity of processing of blanks due to a sharp decrease in time spent on the installation, reconciliation and fixing;

expands the technological capabilities of machines;

creates the ability to simultaneously process several blanks fixed in a general device.

When developing a technological process of mechanical processing of the workpiece, the choice of the cutting tool, its species, design and size is largely predetermined by the processing methods, the properties of the material being processed, the desired accuracy of processing and quality of the workpiece treated surface.

When choosing a cutting tool, it is necessary to strive to take a standard tool, but when it is advisable, a special, combined, shaped tool should be applied to combine the processing of several surfaces.

The right choice of the cutting part of the tool is of great importance for increasing productivity and reduce the cost of processing.

When designing the technological process of mechanical processing of the workpiece for the inter-operative and final control of the surfaces, it is necessary to use a standard measuring instrument, given the type of production, but at the same time, when it is advisable, a special control and measuring instrument should be applied or a control and measuring device.

The control method should contribute to improving the labor productivity of the controller and the machine man, create conditions for improving the quality of products and reduce its cost. In single and serial production, a universal measuring instrument is usually applied (caliper, calorienguineer, micrometer, coupling, indicator, etc.)

In mass and large-scale production, it is recommended to use limit calibers (brackets, traffic jams, patterns, etc.) and active control methods that have been widespread in many industrial construction industries.

1.8 Operating Size Calculation

Under the operating system is understood as the size affixed on the operating sketch and characterizing the value of the surface treated or the mutual location of the treated surfaces, lines or points of the part. The operational size calculation is reduced to the problem of properly determining the operational allowance and the size of the operational admission, taking into account the characteristics of the developed technology.

Under long operating dimensions are sizes characterizing the processing of surfaces with one-sided location of the transmission, as well as dimensions between axes and lines. The calculation of long operating dimensions is carried out in the following sequence:

1. Preparation of source data (based on working drawing and operating cards).

2. Drawing up the processing scheme based on the source data.

3. Constructing a graph of size chains to determine the allowance, drawing and operating dimensions.

4. Drawing up a statement of the calculation of operating dimensions.

On the processing scheme (Figure 1.5), we place the detail sketch with the indication of all surfaces of this geometric structure, occurring during the processing process from the workpiece to the finished part. At the top of the sketch, all long drawing sizes are drawing dimensions with tolerances (C), and from the bottom of the operational allowance (1Z2, 2Z3, ..., 13Z14). Under the sketch in the processing table, dimensional lines are indicated, characterizing all the dimensions of the workpiece oriented by one-sided arrows, so that not the same arrow approached one of the surfaces of the workpiece, and only one arrow approached the rest of the surfaces. The following are dimensional lines characterizing the dimensions of machining. Operating dimensions are oriented towards the surfaces of the surfaces.

Figure 1.5 Detail processing scheme

At the column of the initial structures of the connecting surfaces 1 and 2, wavy ribs characterizing the value of 1Z2, surfaces 3 and 4 with additional ribs characterizing the value of the allowance 3Z4, etc. and also carry out thick edges of the drawing dimensions 2c13, 4c6 and so on.

Figure 1.6 Count of source structures

Top graph. Characterizes the surface of the part. The digit in the circle indicates the surface number on the processing scheme.

Edge graph. It characterizes the type of connections between the surfaces.

"Z" - corresponds to the size of the operational allowance, and "C" - drawing size.

Based on the developed processing scheme, a graph of arbitrary structures is built. The construction of the derivative of the tree begins on the surface of the workpiece, to which, in the processing scheme, not the same arrow is supplied. Figure 1.5, such a surface is indicated by the number "1". From this surface, we carry out those edges of the graph that relate to it. At the end of these ribs, you specify the arrows and numbers of those surfaces to which the specified sizes are carried out. Similarly, the graph according to the processing scheme.

Figure 1.7 Count of derived structures

Top graph. Characterizes the surface of the part.

Edge graph. The component of the size of the size chain corresponds to the operating size or size of the workpiece.

Edge graph. The closing link of the size chain corresponds to the drawing size.

Edge graph. The closing link of the size chain corresponds to an operating allowance.

On all the edges of the graph, they put the sign ("+" or "-"), guided by the following rule: if the edge of the graph enters his arrow to the top with a large number, then on this edge put the sign "+", if the edge of the graph enters its arrow to the vertex With a smaller number, then on this edge set the sign "-" (Figure 1.8). We take into account that the operational dimensions are unknown, and according to the processing scheme (Figure 1.5), we determine approximately the size of the operational size or size of the workpiece using the drawing dimensions and minimum operating points for this purpose, which are made of micronether (RZ), the depth of the deformation layer (T) and spatial deviation (ΔPR), which have been preceding.

Count 1. In an arbitrary sequence, rewrite all drawing sizes and allowances.

Count 2. Indicate the operations of operations in the sequence of their implementation on the route technology.

Count 3. Indicate the name of operations.

Count 4. Indicate the type of machine and its model.

Count 5. We place simplified sketches in one unchanged position for each operation with an indication of the treated surfaces according to the route technology. Surface numbering is performed in accordance with the processing scheme (Figure 1.5).

Count 6. For each surface being processed on this operation, we indicate the operational size.

Count 7. We do not produce a heat treatment on this operation, therefore, the count is not filled.

Count 8. Filled in exceptional cases when the selection of the measuring base is limited to the conditions for the convenience of controlling the operational size. In our case, the graph remains free.

Count 9. We indicate possible surface options that can be used as technological databases, taking into account the recommendations given in.

The choice of surfaces used as technological and measuring bases, begin with the last operation in the order, reverse the process of the technological process. The equations of size chains are recorded according to the graph of the source structures.

After selecting the databases and operating sizes, we proceed to calculate the nominal values \u200b\u200band the choice of tolerances for operational dimensions.

The calculation of long operating dimensions is based on the results of working on optimizing the structure of operational sizes and is made in accordance with the sequence of work. Preparing the source data to calculate operating dimensions is made by filling the graph

13-17 Database selection cards and operating size calculation.

Count 13. To close the dimension chains, which are drawing sizes, write down the minimum values \u200b\u200bof these sizes. To close the links, which are operating points, indicate the value of the minimum allowance, which is determined by the formula:

z min \u003d rz + t,

wherer - the height of the irregularities obtained on the previous operation;

T is the depth of the defective layer formed on the previous operation.

RZ values \u200b\u200band T are determined by tables.

Count 14. For closing dimension chains that are drawing sizes, write the maximum values \u200b\u200bof these sizes. The maximum values \u200b\u200bof the allowances are not yet affixed.

Counts 15, 16. If the admission to the desired operational size will have a sign "-", then in column 15 put the number 1, if "+", then in column 16 put the number 2 in column 16.

Count 17. We put approximately the values \u200b\u200bof the operating dimensions of the sizes, we use the equations of dimensional chains from the graph 11.

1. 9A8 \u003d 8c9 \u003d 12 mm;

2. 9A5 \u003d 3C9 - 3C5 \u003d 88 - 15 \u003d 73 mm;

3. 9A3 \u003d 3C9 \u003d 88 mm;

4. 7A9 \u003d 7z8 + 9A8 \u003d 0.2 + 12 \u003d 12mm;

5. 7A12 \u003d 3C12 + 7A9 - 9A3 \u003d 112 + 12 - 88 \u003d 36 mm;

6. 10A7 \u003d 7A9 + 9Z10 \u003d 12 + 0.2 \u003d 12 mm;

7. 10A4 \u003d 10A7 - 7A9 + 9A5 + 4Z5 \u003d 12 - 12 + 73 + 0.2 \u003d 73 mm;

8. 10A2 \u003d 10A7 - 7A9 + 9A3 + 2Z3 \u003d 12 - 12 + 88 + 0.2 \u003d 88 mm;

9. 6A10 \u003d 10A7 + 6Z7 \u003d 12 + 0.2 \u003d 12 mm;

10. 6A13 \u003d 6A10 - 10A7 + 7A12 + 12Z13 \u003d 12 - 12 + 36 + 0.2 \u003d 36 mm;

11. 1A6 \u003d 10A2 - 6A10 + 1Z2 \u003d 88 - 12 + 0.5 \u003d 77 mm;

12. 1A11 \u003d 10Z11 + 1A6 + 6A10 \u003d 0.2 + 77 + 12 \u003d 89 mm;

13. 1A14 \u003d 13Z14 + 1A6 + 6A13 \u003d 0.5 + 77 + 36 \u003d 114 mm.

Count 18. We are putting up on the table of accuracy 7 values \u200b\u200bof tolerances to operating dimensions, given the recommendations set forth in. After putting the tolerances in column 18, it is possible to determine the maximum allowance values \u200b\u200band put them in column 14.

The value of Δz is determined from the equations in column 11 as the amount of tolerances to the components of the size chain of operational dimensions.

Count 19. In this graph, you need to smear the nominal values \u200b\u200bof operating dimensions.

The essence of the method of calculating the nominal values \u200b\u200bof operating dimensions is reduced to solving the dimension chains recorded in column 11.

1. 8c9 \u003d 9A89A8 \u003d

2. 3C9 \u003d 9A39A3 \u003d

3. 3C5 \u003d 3C9 - 9A5

9A5 \u003d 3C9 - 3C5 \u003d

Take: 9A5 \u003d 73 -0.74

3С5 \u003d.

4. 9Z10 \u003d 10A7 - 7A9

10A7 \u003d 7A9 + 9Z10 \u003d

Take: 10A7 \u003d 13.5 -0.43 (adjustment + 0.17)

9Z10 \u003d.

5. 4Z5 \u003d 10A4 - 10A7 + 7A9 - 9A5

10A4 \u003d 10A7 - 7A9 + 9A5 + 4Z5 \u003d

Take: 10A4 \u003d 76,2 -0.74 (adjustment + 0.17)

4Z5 \u003d.

6. 2Z3 \u003d 10A2 - 10A7 + 7A9 - 9A3

10A2 \u003d 10A7 - 7A9 + 9A3 + 2Z3 \u003d

Take: 10a2 \u003d 91.2 -0.87 (adjustment + 0.04)

2Z3 \u003d.

7. 7z8 \u003d 7A9 - 9A8

7A9 \u003d 7Z8 + 9A8 \u003d

Take: 7A9 \u003d 12.7 -0.43 (Adjustment: + 0.07)

7Z8 \u003d.

8. 3C12 \u003d 7A12 - 7A9 + 9A3

7A12 \u003d 3C12 + 7A9 - 9A3 \u003d

Take: 7A12 \u003d 36.7 -0.62

3C12 \u003d.

9. 6Z7 \u003d 6A10 - 10A7

6A10 \u003d 10A7 + 6Z7 \u003d

Take: 6A10 \u003d 14.5 -0.43 (adjustment + 0.07)

6Z7 \u003d.

10. 12Z13 \u003d 6A13 - 6A10 + 10A7- 7A12

6A13 \u003d 6A10 - 10A7 + 7A12 + 12Z13 \u003d

Take: 6A13 \u003d 39,9 -0.62 (adjustment + 0.09)

12Z13 \u003d.

11. 1Z2 \u003d 6A10 - 10A2 + 1A6

1A6 \u003d 10A2 - 6A10 + 1Z2 \u003d

Take: 1A6 \u003d 78,4 -0.74 (adjustment + 0.03)

1Z2 \u003d.

12. 13Z14 \u003d 1A14 - 1A6 - 6A13

1A14 \u003d 13Z14 + 1A6 + 6A13 \u003d

Take: 1A14 \u003d 119,7 -0.87 (adjustment + 0.03)

13Z14 \u003d.

13. 10Z11 \u003d 1A11 - 1A6 - 6A10

1A11 \u003d 10Z11 + 1A6 + 6A10 \u003d

Take: 1A11 \u003d 94.3 -0.87 (adjustment + 0.03)

10Z11 \u003d.

After calculating the nominal values \u200b\u200bof the sizes, entering them in the Count 19 of the base selection card and with a processing tolerance are recorded in the Count "Note" of the processing scheme (Figure 1.5).

After filling in the Count 20 and the Count "Note", the obtained values \u200b\u200bof operating dimensions are applied to the sketches of the route process. On this, the calculation of the nominal values \u200b\u200bof long operating dimensions is completed.

Card selecting the databases and calculation of operational sizes

Closing links

Operation No

the name of the operation

Motor equipment

processing

Operational

Base

Size chains

Circuit links of dimensional chains

Operating dimensions

Processed surfaces

The depth of the thermoproop. layers

Selected Conditions

Options Tehnol. Baz

Adopted technical nol. and measure. Base

Designation

Limit dimensions

Admission sign and approx.

operational value

Value

Nominal

value

mIN.

max

value

Prepared.

GKM.

13Z14 \u003d 1A14-1A-6A13

10Z11 \u003d 1A11-1A6-6A10.

1Z2 \u003d 6A10-10A2 + 1A6

Tokar

1P365

12Z13 \u003d 6A13-6A10 + 10A7-7A12

Figure 1.9 Card selecting the databases and calculating operating dimensions

Calculation of operating sizes with a bilateral allowance

When processing surfaces with a bilateral allowance, the calculation, operating dimensions should be carried out using the statistical method for determining the size of the operational allowance depending on the selected processing method and the size of the surfaces.

To determine the size of the operational allowance by the static method, depending on the processing method, we will use the source tables.

To calculate operating dimensions with a double-sided beabide location, for such surfaces, we compile the following calculation scheme:

Figure 1.10 Scheme of operational allowance

Drawing up a statement of calculating diametral operating sizes.

Count 1: Specifies the operations of operations according to the developed technology in which this surface is processed.

Count 2: The processing method is specified in accordance with the operating card.

Count 3 and 4: indicates the designation and the magnitude of the nominal diametrical operation taken by tables in accordance with the processing method and the size of the processed part.

Count 5: Indicates the designation of the operational size.

Count 6: According to the accepted processing scheme, equations are made to calculate operating dimensions.

Filling the statement begins with the final operation.

Count 7: Indicated operational size with admission. The calculated value of the desired operational size is determined by the solution of the equation from the graph 6.

The statement of the calculation of operating dimensions in the processing of the outer diameter of the Ø20k6 axis (Ø20)

	Name operations	Operational allowance		Operating size
	Name operations	Design.	Value	Design.	Formulas for calculation	Approximate size
1	2	3	4	5	6	7
Zag.	Stamping	Ø24.
10	Turning (rough)	D10	D10 \u003d D20 + 2Z20
20	Turning (pure)	Z20	0,4	D20	D20 \u003d D45 + 2Z45
45	Grinding	Z45	0,06	D45.	D45 \u003d Damn. R-R.

The statement of calculating operating dimensions in the processing of the outer diameter of the Ø75 -0.12 axis

1	2	3	4	5	6	7
Zag.	Stamping	Ø79.
10	Turning (rough)	D10	D10 \u003d D20 + 2Z20	Ø75,8 -0.2
20	Turning (pure)	Z20	0,4	D20	D20 \u003d Damn. R-R.

The statement of the calculation of operating dimensions in the processing of the outer diameter of the Ø30k6 axis (Ø30)

The statement of the calculation of operating dimensions in the processing of the outer diameter of the Ø20H7 shaft (Ø20 -0.021)

1	2	3	4	5	6	7
Zag.	Stamping	Ø34.
15	Turning (rough)	D15	D15 \u003d D25 + 2Z25	Ø20,8 -0.2
25	Turning (pure)	Z25	0,4	D25	D25 \u003d Damn. R-R.	Ø20 -0.021

The statement of calculating operating dimensions when processing the hole Ø8N7 (Ø8 +0.015)

The statement of calculating operating dimensions when processing hole Ø12 +0.07

The statement of calculating operating sizes when processing hole Ø14 +0.07

The statement of calculating operating dimensions when processing hole Ø9 +0.058

After calculating the diametrical operating dimensions, we assign them to the sketches of the corresponding operations of the route description of the technological process.

1.9 Calculation of cutting modes

When prescribing cutting modes, the nature of the processing, type and size of the tool, the material of its cutting part, the material and state of the workpiece, type and condition of the equipment are taken into account.

When calculating cutting modes, set the depth of cutting, minute submission, cutting speed. We give an example of calculating cutting modes for two operations. For other operations, cutting modes are prescribed according to, T.2, p. 265-303.

010. Strike roughing (Ø24)

Model 1P365, processed material - steel 45, tool material Art 25.

The cutter is equipped with a carbide plate Article 25 (Al 2 O 3 + TiCn + T15K6 + TIN). The use of a carbide plate that does not need a bulk reduces the time spent on the tool change, in addition, the basis of this material is an improved T15K6, which significantly increases the wear resistance and the temperature resistance of Article 25.

Geometry cutting part.

All parameters of the cutting part are chosen from the source a passage cutter: α \u003d 8 °, γ \u003d 10 °, β \u003d + 3º, f \u003d 45 °, F 1 \u003d 5 °.

2. Coolant brand: 5% emulsion.

3. Cutting depth corresponds to the size of the allowance, as the allowance is removed in one trip.

4. The calculated feed is determined on the basis of roughness requirements (, p.266) and is specified by the passport of the machine.

S \u003d 0.5 rpm.

5. Resistance, p.268.

6. The calculated cutting speed is determined from the specified durability, feeding and depth of cutting from, p.265.

where with V, x, m, y - coefficients [5], p.269;

T - the resistance of the tool, min;

S - feed, v / mm;

t - cutting depth, mm;

To V is a coefficient that takes into account the influence of the material of the workpiece.

To V \u003d K M V ∙ K n V ∙ K and V,

K M V is a coefficient that takes into account the influence of the properties of the material being processed to the cutting speed;

To n v \u003d 0.8 - the coefficient that takes into account the effect of the condition of the surface of the billet on the cutting speed;

K and V \u003d 1 is a coefficient that takes into account the effect of instrumental material for cutting speed.

K m v \u003d k g ∙,

where k g is a coefficient characterizing a group of steelmaking.

K M V \u003d 1 ∙

To V \u003d 1.25 ∙ 0.8 ∙ 1 \u003d 1,

7. Settlement rate of rotation.

where D is the processed diameter of the part, mm;

V p - estimated cutting speed, m / min.

According to the passport, the machine is taking N \u003d 1500 rpm.

8. Actual cutting speed.

where D-processed parts diameter, mm;

n is the speed of rotation, rpm.

9. The tangential component of the PZ, H cutting force is determined by the formula of the source, p.271.

P z \u003d 10 ∙ s p ∙ t x ∙ S y ∙ v n ∙ to r,

gder z - cutting force, n;

With p, x, y, n - coefficients, p.273;

S - Feed, mm / OB;

t - cutting depth, mm;

V - cutting speed, rpm;

To P is a correction coefficient (to p \u003d to MR ∙ K j p ∙ K g p ∙ to L p, the numerical values \u200b\u200bof these coefficients from, p.264, 275).

K p \u003d 0.846 ∙ 1 ∙ 1.1 ∙ 0.87 \u003d 0.8096.

P z \u003d 10 ∙ 300 ∙ 2.8 ∙ 0.5 0.75 ∙ 113 -0.15 ∙ 0.8096 \u003d 1990 N.

10. Power out, p.271.

where r z is the force of cutting, n;

V - cutting speed, rpm.

The power of the electric motor 1P365 is 14 kW, so the power drive power is sufficient:

N res.< N ст.

3.67 kW<14 кВт.

035. Drilling

Drilling hole Ø8 mm.

Machine model 2550f2, processed material - steel 45, material of the R6M5 tool. Processing is conducted in one pass.

1. Justification of the material brand and geometry of the cutting part.

Material cutting part of the R6M5 instrument.

Hardness 63 ... 65 HRCE,

The tensile strength of the bend s n \u003d 3.0 GPa,

Tensile strength S B \u003d 2.0 GPa,

Limit strength to compression S SZh \u003d 3.8 GPa,

Geometry of the cutting part: W \u003d 10 ° - the angle of inclination of the screw tooth;

f \u003d 58 ° - the main angle in the plan

a \u003d 8 ° - rear styled corner.

2. Cutting depth

t \u003d 0.5 ∙ d \u003d 0.5 ∙ 8 \u003d 4 mm.

3. The calculated feed is determined on the basis of the requirements of roughness. With 266 and is specified by the passport of the machine.

S \u003d 0.15 rpm.

4. Resistance s. 270.

5. The estimated cutting speed is determined from the specified durability, feed and depth of cutting.

where with V, x, m, y coefficients, p.278.

T - the resistance of the tool, min.

S - Feed, r / mm.

t - cutting depth, mm.

To V - coefficient, taking into account the effect of material of the workpiece, condition of the surface, tool material, etc.

6. Settlement rate of rotation.

where D is the processed detail diameter, mm.

V p - estimated cutting speed, m / min.

According to the passport, the machine is taking n \u003d 1000 rpm.

7. Actual cutting speed.

where D-processed the diameter of the part, mm.

n- Rotation frequency, rpm.

8. Torque

M k \u003d 10 ∙ s m ∙ d q ∙ s ∙ to r.

S - Feed, mm / about.

D - drilling diameter, mm.

M k \u003d 10 ∙ 0,0345 ∙ 8 2 ∙ 0.15 0.8 ∙ 0.92 \u003d 4.45 N ∙ m.

9. Axial force R O, N software, p. 277;

P o \u003d 10 ∙ s p · d q · s y · to p,

where with p, q, y, k r, - coefficients p.281.

R o \u003d 10 ∙ 68 · 8 1 · 0.15 0.7 · 0.92 \u003d 1326 N.

9. Cutting power.

gDEM KR - torque, n ∙ m.

V - cutting speed, rpm.

0.46 kW< 7 кВт. Мощность станка достаточна для заданных условий обработки.

040. Grinding

Machine model 3T160, processed material - steel 45, tool material - Normal electrocorundant 14A.

Curling grinding of the periphery of the circle.

1. Material brand, cutting part geometry.

Choose a circle:

PP 600 × 80 × 305 24a 25 H cm1 7 K5A 35 m / s. GOST 2424-83.

2. Cutting depth

3. Radial supply S p, mm / We define according to the formula from the source, p. 301, Table. 55.

S p \u003d 0.005 mm / about.

4. Circle speed V to, m / s Determine by the formula from the source, p. 79:

where D K is the diameter of the circle, mm;

D k \u003d 300 mm;

n K \u003d 1250 rpm - frequency of rotation of the grinding spindle.

5. The estimated frequency of rotation of the workpiece N z.r, rpm We define the formula from the source, p.79.

where V z.r - the selected speed of the workpiece, m / min;

V z. I will define the table. 55, p. 301. We will accept V z.r \u003d 40 m / min;

d h - the diameter of the workpiece, mm;

6. Effective power N, kW We define on the recommendation in

source p. 300:

with a mortise grinding of the periphery of the circle

where the coefficient C n and the indicators of the degrees R, Y, Q, Z are given in, Table. 56, p. 302;

V z.r - the speed of the workpiece, m / min;

S P - radial feed, mm / OB;

d h - the diameter of the workpiece, mm;

b - grinding width, mm is equal to the length of the grinding section of the workpiece;

The power of the motor 3T160 machine is 17 kW, so the power drive power is sufficient:

N cut< N шп

1.55 kW< 17 кВт.

1.10 Operational rationing

The calculated and technological standards of time are determined by the calculation.

There are norms of piece-time TPC and the rate of time calculation. The calculation rate is determined by the formula on page 46,:

where T pcs is the norm of pieces, min;

T P.Z. - preparatory and final time, min;

n - number of parts in the party, pcs.

T pieces \u003d t OSN + T VSP + T OKLL + T per

where T is the main technological time, min;

t VSP - auxiliary time, min;

t OBL - time maintenance time, min;

t PER - Time of breaks and recreation, min.

The main technological time for turning, drilling operations is determined by the formula on page 47,:

wherel is the estimated length of processing, mm;

Number of passes;

S min - minute tool feed;

a - the number of simultaneously processed parts.

The calculated processing length is determined by the formula:

L \u003d L cut + L 1 + L 2 + L 3.

wherel cut - cutting length, mm;

l 1 - the length of the tool, mm;

l 2 - the length of the insertion of the tool, mm;

l 3 - Length of the hitch of the tool, mm.

The workplace service time is determined by the formula:

t ORL \u003d T tech boss + t Org.Obl,

wheret tehn.OBSL - maintenance time, min;

t Org.Ocl - the time of organizational service, min.

where - the coefficient determined by the standards. We accept.

Time for a break and rest is determined by the formula:

where - the coefficient determined by the standards. We accept.

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Drilling hole Ø8 mm.

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040. Grinding

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D - drilling diameter, mm.

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Development of the technological process of mechanical processing of the detail "Adapter. Adapters for metal and plastic pipes Calculation of operational sizes

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1.1 Office and Specifications Details

1.2 Definition of the type of production and size part of the Part

1.3 Choosing a method of obtaining a blank

1.4 Purpose of methods and processing stages

1.7 Choose equipment, equipment, cutting and measuring instruments

1.8 Operating Size Calculation

1.9 Calculation of cutting modes

1.10 Operational rationing

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