柴油机活塞的加工工艺及夹具设计.doc

柴油机活塞的加工工艺及夹具设计 摘 要：柴油机活塞是在高温高压下作长时间连续变负荷的往复运动，它的负荷和工作环境很恶劣，在本设计中将对活塞的加工工艺进行设计，以保证活塞长久稳定的工作。现将设计中所做的工作简要介绍如下：通过对零件的作用及工艺方案分析，拟定毛坯的制造形式及工艺路线，通过分析、比较，最终确定比较合理的机械加工工艺路线。制定工艺路线时主要考虑粗、精加工安排、加工方法选择、工序集中与分散、加工顺序等方面的要求。接着确定加工余量、工序尺寸与公差。经过对工序特点的分析，恰当的选择相应加工设备和工艺装备。接下来经过计算查表确定活塞各主要工序的切削用量并绘制工序卡片，最后设计夹具。 关键词：活塞；加工工艺；夹具 The Design of Manufacture Process Technology and Machine Tongs of Piston Abstract: Diesel engine piston is a continuous variable load for a long time in the high temperature and pressure to make an reciprocating motion, it very bad about the load and working environment, and it will be make a design about the deep processing for this pistons, to ensure that the pistons long-term stable work in this design. In this design, the working schedule are briefly described as following: to analysis the role of parts and process programs, then development of the rough form of manufacturing and process route, and ultimately determine the reasonable mechanical processing line through analysis and comparison. The main consideration is thick, finishing arrangements, processing methods, processes of centralization and decentralization, the requirements of the processing sequence when formulating process line. Then determine the allowance, processes, dimensions and tolerances. Then to analysis the process characteristics, the appropriate choice of the appropriate processing equipment and process equipment. The next step is to determine the piston all the major processes of cutting parameters and draw process card through calculate and look-up the sheet. At last, design the fixture. Key words: Piston; Deep process; fixture 1 前言 活塞是内燃机上最关键的运动件，它在高温高压下承受反复交变载荷，被称为内燃机的心脏。它的工作情况直接关系到高速内燃机的工作可靠性和使用耐久性，同时直接影响到内燃机的排放性能。活塞的结构和所处的工作环境十分复杂， 在工作状态下受到高压燃气压力、高速往复运动产生的惯性力、侧向压力和摩擦力等周期性载荷作用，产生机械应力和机械变形。高压气体燃烧产生的高温使活 塞顶部乃至整个活塞温度很高，且温度分布很不均匀，导致活塞产生热应力和热变形。热负荷和机械负荷耦合将导致活塞产生裂纹、活塞环胶结以及拉缸等。因此，活塞设计在内燃机设计中十分关键。本设计以C6110型铝型活塞为例。 2 活塞的结构组成和技术要求 2.1 活塞的结构组成 活塞按部位不同，分为顶部，头部和裙部三部分.