微型玉米剝皮機(jī)設(shè)計(jì)【說(shuō)明書+CAD】

微型玉米剝皮機(jī)設(shè)計(jì)【說(shuō)明書+CAD】,說(shuō)明書+CAD,微型玉米剝皮機(jī)設(shè)計(jì)【說(shuō)明書+CAD】,微型,玉米,剝皮,設(shè)計(jì),說(shuō)明書,仿單,cad 摘要 在玉米分段收獲時(shí)，玉米剝皮工序勞動(dòng)強(qiáng)度大，費(fèi)工時(shí)和誤農(nóng)時(shí)，且影響玉米的質(zhì)量和質(zhì)量等問(wèn)題，針對(duì)我國(guó)玉米收獲后剝皮這個(gè)重要環(huán)節(jié)，設(shè)計(jì)出場(chǎng)上玉米剝皮機(jī)，并對(duì)其結(jié)構(gòu)及技術(shù)參數(shù)予以設(shè)計(jì)。微型玉米剝皮機(jī)是收獲玉米穗外表皮的一種機(jī)具，本機(jī)為4輥機(jī)型，可滿足單戶、聯(lián)戶和種糧大戶使用。它代替了傳統(tǒng)人工剝皮的緊張勞動(dòng)，減輕了人們的勞動(dòng)強(qiáng)度，提高了勞動(dòng)效率，有效地防止了因剝皮不及時(shí)而造成的玉米霉?fàn)€損失，該機(jī)結(jié)構(gòu)簡(jiǎn)單，調(diào)整方便性能可靠，生產(chǎn)效率高，可采用電動(dòng)機(jī)、柴油機(jī)或三輪農(nóng)用運(yùn)輸車發(fā)動(dòng)機(jī)作動(dòng)力，本機(jī)采用單相交流電動(dòng)機(jī)作動(dòng)力。剝皮裝置中剝皮輥一般有螺旋鐵棍和橡膠輥組成，鐵棍對(duì)籽粒有嚴(yán)重?fù)p傷，所以本機(jī)要求采用全橡膠輥。在滿足剝凈率95%以上。工作效率達(dá)到1500kg/h，動(dòng)力源3kw的設(shè)計(jì)要求的前提下進(jìn)行設(shè)計(jì)。為達(dá)到設(shè)計(jì)要求，主要?jiǎng)兤ぱb置采用全橡膠的玉米剝皮輥，并且兩輥高低設(shè)置，且可以根據(jù)玉米棒的大小不同調(diào)節(jié)兩輥間的距離。這避免了傳統(tǒng)設(shè)計(jì)方法中采用鑄鐵輥對(duì)玉米籽粒的損壞，而且在結(jié)構(gòu)上比傳統(tǒng)設(shè)計(jì)方法更為合理。經(jīng)計(jì)算、校核，該機(jī)符合設(shè)計(jì)要求，并且在剝皮裝置與傳統(tǒng)方式上較傳統(tǒng)設(shè)計(jì)有所改進(jìn)，更適于在廣大農(nóng)村的推廣應(yīng)用?！娟P(guān)鍵詞】 玉米剝皮機(jī) 剝皮輥 傳動(dòng)系統(tǒng) 動(dòng)力源 1Title: Corns Clothes Takes-Off Machine Abstract At the devided harvest time, the labor force of corns clothes take-off by hard is to strong. It wastes time and decreases the quantity of the corn. To solve the problem of corns clothes take-off in our country, we designed the corns clothes take-off machine including the structure and the technical parameter design. It is a machine that take off the corns clothes. It has four types, respectively for single, union of several and big harvest. The machine instead of the traditional handed labor, reduce the peoples labor strength, raise the efficiency and prevent the corns damage. The structure of the machine is simple. The machine is easily adopted, reiable and efficiency. The power of the machine can use electric motor、diesel engine and the power of agricultural car.This machine adoption list mutually the alternate current motive makes the motive. Peel to equip to win to peel the son of to have the spiral iron casting son of and the rubber son of to constitute generally, cast iron the son of to have severity to the seed grain to hurt, so this machine adoption the whole rubber son of. Designed under premise that must be get go 95% of take-off rate and efficiency required no less than 1500kg/h, power no more than or equality 3kw. For get to these requirements, main take-off part makes use of rubber cylinder, and they are installed up-down. It is more reasonable than orthodox way. The transmission system makes use of binary level decreasing velocity. Via computed and checked, the machine is right. Specially, it is better than forming designing. Worthwhile, it is widely applied in rural.Key words: Corns clothes、 Take-off Machine、 Cylinder、 transmission system、 Power resource 長(zhǎng)春工業(yè)大學(xué)本科畢業(yè)論文 微型玉米剝皮機(jī)設(shè)計(jì) 摘要 在玉米分段收獲時(shí)，玉米剝皮工序勞動(dòng)強(qiáng)度大，費(fèi)工時(shí)和誤農(nóng)時(shí)，且影響玉米的質(zhì)量和質(zhì)量等問(wèn)題，針對(duì)我國(guó)玉米收獲后剝皮這個(gè)重要環(huán)節(jié)，設(shè)計(jì)出場(chǎng)上玉米剝皮機(jī)，并對(duì)其結(jié)構(gòu)及技術(shù)參數(shù)予以設(shè)計(jì)。微型玉米剝皮機(jī)是收獲玉米穗外表皮的一種機(jī)具，本機(jī)為4輥機(jī)型，可滿足單戶、聯(lián)戶和種糧大戶使用。它代替了傳統(tǒng)人工剝皮的緊張勞動(dòng)，減輕了人們的勞動(dòng)強(qiáng)度，提高了勞動(dòng)效率，有效地防止了因剝皮不及時(shí)而造成的玉米霉?fàn)€損失，該機(jī)結(jié)構(gòu)簡(jiǎn)單，調(diào)整方便性能可靠，生產(chǎn)效率高，可采用電動(dòng)機(jī)、柴油機(jī)或三輪農(nóng)用運(yùn)輸車發(fā)動(dòng)機(jī)作動(dòng)力，本機(jī)采用單相交流電動(dòng)機(jī)作動(dòng)力。剝皮裝置中剝皮輥一般有螺旋鐵棍和橡膠輥組成，鐵棍對(duì)籽粒有嚴(yán)重?fù)p傷，所以本機(jī)要求采用全橡膠輥。在滿足剝凈率95%以上。工作效率達(dá)到1500kg/h，動(dòng)力源3kw的設(shè)計(jì)要求的前提下進(jìn)行設(shè)計(jì)。為達(dá)到設(shè)計(jì)要求，主要?jiǎng)兤ぱb置采用全橡膠的玉米剝皮輥，并且兩輥高低設(shè)置，且可以根據(jù)玉米棒的大小不同調(diào)節(jié)兩輥間的距離。這避免了傳統(tǒng)設(shè)計(jì)方法中采用鑄鐵輥對(duì)玉米籽粒的損壞，而且在結(jié)構(gòu)上比傳統(tǒng)設(shè)計(jì)方法更為合理。經(jīng)計(jì)算、校核，該機(jī)符合設(shè)計(jì)要求，并且在剝皮裝置與傳統(tǒng)方式上較傳統(tǒng)設(shè)計(jì)有所改進(jìn)，更適于在廣大農(nóng)村的推廣應(yīng)用。【關(guān)鍵詞】 玉米剝皮機(jī) 剝皮輥 傳動(dòng)系統(tǒng) 動(dòng)力源 1Title: Corns Clothes Takes-Off Machine Abstract At the devided harvest time, the labor force of corns clothes take-off by hard is to strong. It wastes time and decreases the quantity of the corn. To solve the problem of corns clothes take-off in our country, we designed the corns clothes take-off machine including the structure and the technical parameter design. It is a machine that take off the corns clothes. It has four types, respectively for single, union of several and big harvest. The machine instead of the traditional handed labor, reduce the peoples labor strength, raise the efficiency and prevent the corns damage. The structure of the machine is simple. The machine is easily adopted, reiable and efficiency. The power of the machine can use electric motor、diesel engine and the power of agricultural car.This machine adoption list mutually the alternate current motive makes the motive. Peel to equip to win to peel the son of to have the spiral iron casting son of and the rubber son of to constitute generally, cast iron the son of to have severity to the seed grain to hurt, so this machine adoption the whole rubber son of. Designed under premise that must be get go 95% of take-off rate and efficiency required no less than 1500kg/h, power no more than or equality 3kw. For get to these requirements, main take-off part makes use of rubber cylinder, and they are installed up-down. It is more reasonable than orthodox way. The transmission system makes use of binary level decreasing velocity. Via computed and checked, the machine is right. Specially, it is better than forming designing. Worthwhile, it is widely applied in rural.Key words: Corns clothes、 Take-off Machine、 Cylinder、 transmission system、 Power resource 目錄摘要-1Abstract-2引 言-11 題目來(lái)源及技術(shù)要求-11.1 任務(wù)來(lái)源-11.2 剝皮機(jī)的設(shè)計(jì)要求如下-21.3 玉米剝皮機(jī)結(jié)構(gòu)簡(jiǎn)介-22 總體方案的分析-32.1 剝皮的工藝過(guò)程-32.2 方案的選擇-32.3 主要工作部件形式的選擇-33 總體配置的確定-43.1 機(jī)架的配置-43.2 傳動(dòng)系統(tǒng)配置-54 剝皮裝置的確定-6 4.1 剝皮輥長(zhǎng)度確定-6 4.2 剝皮輥生產(chǎn)能力的確定-6 4.3 剝皮部件的設(shè)計(jì)-75 執(zhí)行部件及機(jī)架設(shè)計(jì)-8 5.1 果穗料斗的設(shè)計(jì)-8 5.2機(jī)架、連接架的設(shè)計(jì)-96 傳動(dòng)部分設(shè)計(jì)-10 6.1 玉米果穗在剝皮輥間的受力分析-10 6.2 皮帶傳動(dòng)的設(shè)計(jì)計(jì)算及校核-11 6.3 齒輪的設(shè)計(jì)-13 6.4 軸的強(qiáng)度校核與設(shè)計(jì)計(jì)算-20 6.5 鍵的選擇-22 6.6 軸承的選擇-22 6.7 電動(dòng)機(jī)的選擇-227 6YBJ4型玉米剝皮機(jī)的保養(yǎng)、使用、調(diào)整及修復(fù)-23 7.1 每日技術(shù)保養(yǎng)-23 7.2 傳動(dòng)裝置的使用和調(diào)整-23 7.3 機(jī)器的保管-24 7.4 工作部件損壞的修復(fù)和調(diào)整-24總結(jié)-25參考文獻(xiàn)-26表1-27表2-28表3-29表4-30 引言國(guó)內(nèi)外玉米剝皮機(jī)的概況：（1）前蘇聯(lián)玉米剝皮機(jī)的概況 前蘇聯(lián)的玉米種植面積達(dá)1200萬(wàn)hm2,僅次于美國(guó)的種植面積。由于生產(chǎn)需要，研制了O-4B型玉米剝皮機(jī)。隨著農(nóng)業(yè)機(jī)械化的發(fā)展，又研制了O -5、O-15、O-15C、O-15 和O-5等多種剝皮機(jī)。（2）美國(guó)玉米剝皮機(jī)的概況 美國(guó)玉米種植面積占全世界玉米種植面積的37%，由于生產(chǎn)過(guò)程對(duì)機(jī)械化得迫切要求，在1885年就研制成功了場(chǎng)上作業(yè)的玉米剝皮機(jī)；1908年又研制了田間摘穗剝皮機(jī)；現(xiàn)在已經(jīng)向聯(lián)合自走的方向發(fā)展。（3）我國(guó)玉米剝皮機(jī)研制現(xiàn)狀 從20世紀(jì)50年代開始，我國(guó)進(jìn)行玉米剝皮機(jī)的研制工作。如豐收2臥、豐收2立和4YBJ2型的田間玉米摘穗剝皮機(jī)。60年代，中國(guó)農(nóng)機(jī)院與黑龍江農(nóng)業(yè)機(jī)械化研究所協(xié)作設(shè)計(jì)了YD3型玉米剝皮機(jī)。70年代，黑龍江省紅興隆國(guó)營(yíng)農(nóng)場(chǎng)管理局設(shè)計(jì)了場(chǎng)上玉米剝皮機(jī)。1979年，遼寧省農(nóng)業(yè)機(jī)械化研究所研制的4YB2型玉米收獲機(jī)及吉林農(nóng)業(yè)機(jī)械化研究所研制的4QY2型玉米收獲機(jī)都配置了剝皮機(jī)構(gòu)。根據(jù)設(shè)計(jì)任務(wù)書的要求，微型玉米剝皮機(jī)是一種專玉米表皮的專用機(jī)械。這種機(jī)械主要針對(duì)農(nóng)村的廣大農(nóng)民用戶使用，所以此機(jī)械必須具有如下特點(diǎn)：（1）操作簡(jiǎn)單，便于廣大農(nóng)村用戶的使用，零部件盡量采用標(biāo)準(zhǔn)件，便于安裝和維修。（2）整機(jī)安裝，結(jié)構(gòu)簡(jiǎn)單，成本低而且動(dòng)力的選擇要符合農(nóng)村的實(shí)際情況，因此動(dòng)力盡量安裝電動(dòng)機(jī)或者柴油機(jī)。（3）本機(jī)還要有較高的生產(chǎn)率，較低的籽粒破碎率，較高剝凈率。因此，本機(jī)的設(shè)計(jì)根據(jù)農(nóng)村不同用戶的使用要求，設(shè)計(jì)了不同的類型。在動(dòng)力選擇上，采用電動(dòng)機(jī)與柴油機(jī)互相通用的形式，但不同的是由于小四輪的本身特點(diǎn)，在是喲個(gè)柴油機(jī)作動(dòng)力時(shí)要有一個(gè)轉(zhuǎn)向節(jié)連接，而使用電動(dòng)機(jī)則可直接安裝在機(jī)架上。在生產(chǎn)率方面，根據(jù)不同用戶的使用要求，現(xiàn)已有2對(duì)輥、4對(duì)輥兩種不同生產(chǎn)率的機(jī)型。本機(jī)為4輥機(jī)型，可滿足單戶、聯(lián)戶和種糧大戶使用。它替代了傳統(tǒng)人工剝皮的緊張勞動(dòng)，減輕了人們的勞動(dòng)強(qiáng)度，提高了勞動(dòng)效率，有效地防止了因剝皮不及時(shí)而造成的玉米霉?fàn)€損失，該機(jī)結(jié)構(gòu)簡(jiǎn)單，調(diào)整方便，性能可靠，生產(chǎn)效率高。此種機(jī)械的研制成功，大大減輕了農(nóng)民的勞動(dòng)負(fù)擔(dān)，為了廣大農(nóng)民 節(jié)省大量時(shí)間，降低了勞動(dòng)強(qiáng)度，也 成為農(nóng)民致富的途徑之一。 1、題目來(lái)源及技術(shù)要求：1.1任務(wù)來(lái)源：根據(jù)農(nóng)村當(dāng)前的生產(chǎn)實(shí)際情況，農(nóng)業(yè)機(jī)械的使用還沒(méi)有普遍推廣，尤其是在像東北這樣的產(chǎn)糧大區(qū)，農(nóng)民收獲的糧食由于不能及時(shí)得到農(nóng)業(yè)機(jī) 1械的支援，而只能用傳統(tǒng)的手工勞作，這樣使得農(nóng)民在秋季可謂苦不堪言。特別是對(duì)于玉米這一高產(chǎn)穩(wěn)產(chǎn)的作物，在東北地區(qū)特別是我省由于有大量的播種面積，而這種作物的本身又是一種勞動(dòng)含量較高的作物，因此，對(duì)于各種玉米所用的農(nóng)業(yè)機(jī)械已迫在眉睫，而玉米生產(chǎn)過(guò)程中的播種、耕管機(jī)械已基本解決，而收獲機(jī)械卻仍是一個(gè)空白，農(nóng)民收獲季節(jié)由于都是用傳統(tǒng)的手工勞動(dòng)，所以強(qiáng)度特別高，特別是玉米的剝皮，不但時(shí)間長(zhǎng)，且占用勞動(dòng)力多，工作效率又不高，如不及時(shí)剝皮，還易使玉米發(fā)霉、變質(zhì)。所以，玉米剝皮機(jī)不但具有廣泛市場(chǎng)，而且極易推廣，又能解決農(nóng)民的當(dāng)務(wù)之急，使農(nóng)民在玉米的收獲季節(jié)不再為玉米剝皮而犯難了。1.2剝皮機(jī)的設(shè)計(jì)要求如下： 1、玉米穗喂入時(shí)，其軸線的方向應(yīng)與剝皮輥軸線的方向一致。為此，在喂入裝置與剝皮輥之間需設(shè)置導(dǎo)槽。 2、剝皮輥軸線與水平面得傾角直接影響玉米穗的下滑速度。在裝有壓送 器的情況下，常用=1012。3、剝皮輥表面與壓送器頂端間的配置間隙應(yīng)略小于玉米穗的直徑，并可以調(diào)節(jié)。 4、配套動(dòng)力主要以電動(dòng)機(jī)為主，也可以與農(nóng)村廣泛使用的小四輪拖拉機(jī)配套，主要不同點(diǎn)是與小四輪配套有一個(gè)特殊的傳動(dòng)總成。 5、性能指標(biāo)要求：苞葉剝凈率要求達(dá)到95%以上，而在剝皮過(guò)程中脫凈率 低端傳動(dòng)比，初定高端傳動(dòng)比i高=2.4i總=i高i低 i低=1.83.3.3傳動(dòng)系統(tǒng)簡(jiǎn)圖 i帶=D2D1=240100=2.4 i齒=14480=1.8所以 總降速比 i=2.41.8=4.32所以 直軸的轉(zhuǎn)速為 n=n電動(dòng)機(jī)i總=14404.32=333.33n/min 由于依實(shí)驗(yàn)數(shù)據(jù)得出結(jié)論，剝皮輥?zhàn)罴艳D(zhuǎn)速范圍為n=300350n/min所以這一轉(zhuǎn)數(shù)符合要求。 這二級(jí)減速及傳動(dòng)系統(tǒng)各部件的尺寸如下： 主動(dòng)帶輪基準(zhǔn)直徑： D1=100mm 從動(dòng)帶輪基準(zhǔn)直徑： D2=240mm 齒輪1的分度圓直徑：d1=80mm 齒輪2的分度圓直徑：d2=144mm 齒輪3、4的分度圓直徑：d3=d4=90mm 齒輪5、6、7、8的分度圓直徑：d5=d6=d7=d8=67.5mm 動(dòng)力由電動(dòng)機(jī)傳到完成一級(jí)減速，再由皮帶傳到1軸上，1軸上有一與皮帶輪同轉(zhuǎn)速的齒輪1，齒輪1與齒輪2嚙合完成二級(jí)減速。2軸為主動(dòng)軸，在其上有三個(gè)齒輪。齒輪2與齒輪1嚙合完成降速；齒輪3與齒輪4嚙合實(shí)現(xiàn)傳動(dòng)比為1的傳動(dòng)；4軸的齒輪7與5軸的齒輪8嚙合實(shí)現(xiàn)同速傳動(dòng)來(lái)實(shí)現(xiàn)最終的剝皮過(guò)程；2軸上的齒輪6與3軸上的齒輪5嚙合實(shí)現(xiàn)同速傳動(dòng)。2、3、4、5軸的最終轉(zhuǎn)速為333.3r/min. 4、剝皮裝置的確定 5 剝皮裝置是由一對(duì)相向轉(zhuǎn)動(dòng)的剝皮輥?zhàn)ト『蛣兂衩姿氲陌~。剝皮輥與苞葉間的摩擦力必須大于苞葉與穗輥間的鏈接力，為了使苞葉剝凈，在玉米穗沿剝皮輥下滑的同時(shí)，自身應(yīng)能轉(zhuǎn)動(dòng)。在剝皮輥的上方設(shè)有壓送器，使果穗對(duì)剝皮輥穩(wěn)定地接觸而避免跳動(dòng)。4.1剝皮輥長(zhǎng)度確定： 傳統(tǒng)式玉米剝皮輥長(zhǎng)度為1.70mm，美國(guó)甜玉米剝皮機(jī)滾長(zhǎng)為1500mm，根據(jù)實(shí)驗(yàn)得出玉米在剝皮輥上的剝凈率在開始400mm內(nèi)剝凈率為85%，在600mm內(nèi)剝凈率為93%，因此輥長(zhǎng)定為1000mm可使苞葉的剝凈率在93%以上。剝皮輥的長(zhǎng)度是影響剝凈率的主要參數(shù)，為保證剝凈苞葉，剝皮輥應(yīng)有足夠的長(zhǎng)度，但過(guò)長(zhǎng)會(huì)引起籽粒脫落和破碎，剝皮輥的直徑應(yīng)不使最小直徑的果穗收擠壓和被抓取為準(zhǔn)。4.2剝皮輥生產(chǎn)能力的確定： 單對(duì)剝皮輥生產(chǎn)能力：Q剝=3600qL+lugkg/h - ug=sn600000f - 其中：q-剝凈率果穗質(zhì)量平均為0.4Kg L-果穗長(zhǎng)度最大為250mm ug-果穗沿剝皮輥移動(dòng)速度m/s S-剝皮輥螺距s=900mm N-剝皮輥轉(zhuǎn)速333.3r/min f-滑動(dòng)綜合系數(shù)試驗(yàn)得f=0.05 l-50mm 帶入：Q剝=3600qL+lsn600000f =6100qsnfL+l =61000.49003000.05250+50 =1066Kg/h所以 兩對(duì)輥計(jì)算生產(chǎn)率為2132Kg/h 設(shè)計(jì)要求為1500kg/h,2132kg/h1500kg/h符合設(shè)計(jì)要求。 6 由于此機(jī)是由人手式喂入，故實(shí)際生產(chǎn)能力大約在每對(duì)輥的生產(chǎn)率1500Kg/h左右，這是經(jīng)過(guò)實(shí)驗(yàn)后得出結(jié)論。4.3剝皮部件的配置： 本機(jī)剝皮裝置直接利用新型剝皮裝置專利技術(shù)，其剝皮輥為高苯橡膠面，有數(shù)條螺旋相互嚙合，高低配置成對(duì)使用，每?jī)蓪?duì)輥組成一槽型，每個(gè)輥軸上有每節(jié)250mm的四節(jié)膠輥串接而成螺旋首尾相接，局部磨損后便于更換，下輥2、5為固定輥，上輥1、3可繞鉸接點(diǎn)轉(zhuǎn)動(dòng)，既兩輥嚙合間隙時(shí)可調(diào)的。保證果柄可以通過(guò)，兩輥可以調(diào)節(jié)螺栓6來(lái)調(diào)節(jié)，所以可以根據(jù)不同的品種來(lái)適當(dāng)調(diào)節(jié)螺栓，使果穗順利通過(guò)。 玉米在兩輥所形成的槽型中，輥面的凸棱對(duì)苞葉有撕裂作用，由于兩輥的螺旋相互嚙合，使玉米苞葉在自轉(zhuǎn)過(guò)程中被嵌入凹槽中，此時(shí)由于兩輥的轉(zhuǎn)動(dòng)使苞葉被扯掉，玉米的自轉(zhuǎn)主要由于兩輥對(duì)玉米摩擦力大小不同，雖然兩輥的材料不同，但卻由于兩輥與玉米之間的壓力角不同而產(chǎn)生不等的摩擦力F1、F2且F1F2，而使得玉米能夠產(chǎn)生自轉(zhuǎn)。 兩輥中心距a=67.5mm，當(dāng)果穗直徑為60時(shí)果穗重力N與下輥壓力方向角a2=5與上輥方向壓力角a1=67.28，其相應(yīng)摩擦力： F1=N1fcos67.28=0.386Nf由于F1F2且方向相反，因此果穗在剝皮過(guò)程中產(chǎn)生轉(zhuǎn)動(dòng)，可加速剝皮過(guò)程，為加速果穗下移速度，剝皮輥還要有一定傾角，傾角小，下滑速度慢，生產(chǎn)率低傾角大，剝凈率低，本機(jī)通過(guò)部件試驗(yàn)，確定剝皮輥傾角為12。果穗通過(guò)間隙，根據(jù)實(shí)測(cè)果穗直徑最大不超過(guò)65，為防止過(guò)大的果穗卡滯現(xiàn)象通過(guò)70mm，可使果穗繞自身軸線自由轉(zhuǎn)動(dòng)，為防止在剝皮過(guò)程中產(chǎn)生果穗治理造成脫粒，在剝皮輥上方設(shè)有壓穗板，壓穗板通過(guò)間隙為70mm.5、執(zhí)行部件及機(jī)架設(shè)計(jì)5.1果穗料斗的設(shè)計(jì)： 果穗料斗不但呀有暫存果穗的能力，而且嗬喲能夠使果穗沿剝皮輥的軸向方向上進(jìn)入兩輥所形成的槽型中，在配置上與剝皮輥的傾角相同，均與水平面成12角，在長(zhǎng)度上按展開1000mm設(shè)計(jì)，因?yàn)榭紤]到玉米進(jìn)入到剝皮輥時(shí)的方向性，所以將出口處的滑板設(shè)計(jì)成與剝皮輥組數(shù)相等的槽型， 7盡可能保證每次只能通過(guò)一穗玉米。進(jìn)料斗是送入玉米的裝置，由于本機(jī)采用兩對(duì)剝皮輥工作，所以進(jìn)料斗必須設(shè)計(jì)成雙出口的結(jié)構(gòu)。玉米需自動(dòng)滑到剝皮輥的方向上進(jìn)入兩輥形成的槽型中進(jìn)行剝皮，這就要求料斗具有一定得傾斜度，經(jīng)參考實(shí)驗(yàn)數(shù)據(jù)選傾斜度為12。為保證玉米滑向剝皮輥時(shí)每次只能通過(guò)一穗玉米，可將出口設(shè)計(jì)成與剝皮輥組數(shù)相同的槽型（如下圖5）。同時(shí)為保證玉米在剝皮過(guò)程中受切向力的擠壓導(dǎo)致彈出，在剝皮輥上方增加兩個(gè)壓穗板，以防止果穗彈出。下料斗是在玉米剝皮結(jié)束后，果穗畫出的裝置，它可以設(shè)計(jì)成任何方便的形狀。5.2機(jī)架、連接架的設(shè)計(jì)： 機(jī)架和連接架均由角鋼焊接而成，兩種機(jī)型結(jié)構(gòu)相同，僅寬度不同。在滿足要求的前提下具有一定得抗壓能力既可，主要目的是便于組織生產(chǎn)，提高通用程度，因此物特別要求。6、傳動(dòng)部分設(shè)計(jì)6.1玉米果穗在剝皮輥間的受力分析兩輥對(duì)玉米產(chǎn)生的兩個(gè)摩擦力F1、F2分別為： Fb=Nbf Fa=NaF X=0Y=0 = Nbsin+Fbcos-Nasin-Facos=0Nacos+Nacos-Fbsin-Fasin=0 H=23R=22.5 8 cos=0.943 =19.47 cos=0.545 =56.94 =90-=13.59 =180-2-=52.53 =180-=113.88 所以： Na=Qsinsin=0.868Q Nb=Qsinsin=0.257Q 所以： Fa=Naf=0.868Q0.87=0.76Q=4.55N Fb=Nbf=0.2570.87Q=0.208Q=1.69N 由實(shí)驗(yàn)可知，撕破苞葉的抓取力F1大約為 F1=20.05N 同時(shí)在自轉(zhuǎn)過(guò)程中撕扯力 F2=F1f2=20.250.35=7.02 根據(jù)實(shí)驗(yàn)可知，扯斷苞葉所需力F3 F3=102N 故F=F1+F2+F3=129.07N 此時(shí)每個(gè)軸所承受的力不僅有F，而且還要有Fa與Fb。每對(duì)剝皮輥消耗的功率：N=F*V=1.5855kw因此兩對(duì)輥消耗的總功率：N總=21.2855=0.462105Nmm與皮帶輪同軸的齒輪所需扭矩為（d=144mm） 9T=95.5105p3001000=1.85105Nmm6.2皮帶傳動(dòng)的設(shè)計(jì)計(jì)算及校核： 已知：電動(dòng)機(jī)轉(zhuǎn)速n=1440r/min i=2.4 A型帶 P=3kw 1、確定計(jì)算功率Pca： 工作情況系數(shù)KA=1.1，故Pca=KAp=1.13kw=3.3kw 2、選取窄V帶帶型： 根據(jù)Pca、n電由機(jī)械設(shè)計(jì)P152圖89確定選用SPA型帶。3、確定帶輪的基準(zhǔn)直徑： 由機(jī)械設(shè)計(jì)P145表83和P153表87取主動(dòng)輪直徑 dd1=100mm。根據(jù)式i=n1n2=dd2dd1，從動(dòng)帶輪直徑dd2=idd1=2.4100=240mm根據(jù)機(jī)械設(shè)計(jì)P153表87，取dd2=250mm。驗(yàn)算帶的速度：V=dd1n電601000=1001440601000=7.536ms35ms所以：帶的速度合適。 4、確定窄V帶的基準(zhǔn)長(zhǎng)度和傳動(dòng)中心距： 根據(jù)0.7dd1+dd2a0120 主動(dòng)輪上的包角合適。 6、計(jì)算窄V帶的根數(shù)z： z=pca(P0+P0)kak1 由n電=1440rmin，dd1=100mm，i=2.4查表4和5得： P0=1.6kw P0=0.23kw 查機(jī)械設(shè)計(jì)P154表88得k=0.96,查P142表82得： kL=0.89，則z=3.3(1.6+0.23)0.960.892 取z=2根。 由于此機(jī)器在高速、強(qiáng)沖、強(qiáng)振動(dòng)下工作，為了使皮帶能夠安全工作，而且有時(shí)可能會(huì)有玉米卡入兩對(duì)剝皮輥中，所以取z=2。 7、計(jì)算預(yù)緊力F0： F0=500PcaVz2.5k-1+qV2 查表7得：q=0.07kg/m,故 F0=5003.322.50.96-1+0.077.532N=225.25N 8、計(jì)算作用在軸上的壓軸力Fp: Fp=2zsin2=22sin159.71/2N=301.93N 9、帶輪結(jié)構(gòu)設(shè)計(jì) (1)帶輪的材料選為鑄鐵選HT250 （2）結(jié)構(gòu)選擇：大小帶輪都選用腹板式的帶輪。 10、皮帶采用自動(dòng)張緊或定期張緊。6.3齒輪的設(shè)計(jì)6.3.1 對(duì)于d=67.5mm的齒輪模數(shù)的選?。?根據(jù)式m32KT1dz12YFaYSaF 式中： T=0.462105Nmm Kt=1.3 d=0.4 11 YFa=2.3 YSa=1.1 F=KFNS=0.96801.4=437.14Mpa 由上式對(duì)齒數(shù)進(jìn)行試選：選取Z=13 則m32KT1dz12YFaYSaF=321.30.4620.41322.31.1105437.14=4.7mm 所以m4.7mm m圓整取m=5 幾何尺寸：因?yàn)榉侄葓A直徑d=67.5mm，模數(shù)m=5 所以可知此齒為一變位齒輪Z=13 Z1=Z2=13 a=67.5mm m=5 ha*=1 c*=0.25 =20 d1=d2=mz1=65mm 未變?yōu)橹行木啵篴=12(d1+d2)=1265+65=65mm 中心距變位系數(shù)：y=a-am0.5 YZ=a-aa=y2z1+z2=0.5226=0.03864 分度圓壓力角：=20 嚙合角：cos=cos=6567.5cos20=0.963cos20=0.9049 =25.186 總變位系數(shù)： X=Z1+Z22taninv-inv=262tan20inv25.186-inv20 =0.030935-0.014904262tan20=1.1466 根據(jù)齒數(shù)比u=1 按線圖分配變位系數(shù)得x1=x2=0.57 齒輪變動(dòng)系數(shù)：y=x-y=0.9049-0.5=0.4049 齒頂圓直徑：dm=d+2mha*+x1-g=78mm da1=da2=78mm df1=d1-2mha*+c-x1=55mm df2=df1=55mm6.3.2對(duì)于d=67.5mm的齒輪分別進(jìn)行校核： a.選定齒輪類型、精度、材料及齒數(shù) （1）按傳動(dòng)方案，選用直齒輪傳動(dòng)。 （2）剝皮機(jī)為一般工作，速度不高，故選用7級(jí)精度傳動(dòng)（GB10095-8） （3）材料選擇。由機(jī)械設(shè)計(jì)P189表101考慮此齒輪振動(dòng)沖擊較大，選大小齒輪材料為40Cr(調(diào)質(zhì))硬度為240HBS，表面淬火，齒形變形不大，不需磨削。 （4）選齒數(shù)z2=13 z1=z2=13 12 b.按接觸強(qiáng)度設(shè)計(jì)和校核： 根據(jù)式：dt2.32KtT1du+1u(zEH)2mm (1)確定公式內(nèi)的各種計(jì)算數(shù)值 載荷系數(shù)：kt=1.3 計(jì)算每個(gè)齒輪傳遞扭矩：T1=95.5105PN=0.462105Nmm 由機(jī)械設(shè)計(jì)P201表107選取齒輪寬系數(shù)d=0.5 由機(jī)械設(shè)計(jì)P198表106可查得材料的彈性影響系數(shù)： ZE=189.8Mpa12 由機(jī)械設(shè)計(jì)P207圖1021d按齒面硬度中間值52HRC查得齒輪接觸疲勞極限 Hlim1=Hlim2=1170Mpa 由機(jī)械設(shè)計(jì)P203圖1019查得疲勞壽命系數(shù)kHN1=0.88 計(jì)算應(yīng)力循環(huán)次數(shù)： N1=60n1jLh=6096012830015=4.147109計(jì)算接觸疲勞強(qiáng)度需用應(yīng)力 取失效概率1%，安全系數(shù)S=1 H1=kHN1Hlim1s=1030Mpa (2) 計(jì)算 試計(jì)算小齒輪分度圓直徑d1t ,代入H中較小的值 d1t2.323KtT1du+1u(zEH)2=2.3231.30.4621050.41+11(189.81030)2=61.36mm 計(jì)算圓周速度V： V=67.5333.3601000=1.18m/s 計(jì)算齒寬b b=dd1t=0.561.36=30.68mm 計(jì)算齒寬與齒高之比b/h 模數(shù) mt=d1tz1=61.3613=4.72mm 齒高 h=2.25mt=2.254.72=10.62 bh=30.6810.62=2.89 計(jì)算載荷系數(shù) 由機(jī)械設(shè)計(jì)P192圖108查得系數(shù)：kv=1.12 直齒輪kAFtb100Nmm 由機(jī)械設(shè)計(jì)P193圖103查得kH=kF=1.1 由機(jī)械設(shè)計(jì)P190圖102查得使用系數(shù)kA=1由機(jī)械設(shè)計(jì)P194圖104查得kH=1.43 由機(jī)械設(shè)計(jì)P195圖1013查得kF=1.37 13 k=kAkVkkH=11.121.11.43=1.72 按實(shí)際載荷系數(shù)校正算得分度圓直徑： d1=d1t3kkt=61.3631.721.3=67.5 計(jì)算模數(shù)m m=d1z1=67.513=5.19mm 取整m=5mm c.按齒根彎曲疲勞強(qiáng)度設(shè)計(jì)： 彎曲強(qiáng)度的設(shè)計(jì)公式為：m32KT1dz12YFaYSaF (1)確定公式內(nèi)的各計(jì)算數(shù)值 由機(jī)械設(shè)計(jì)P204圖1020c查得齒輪的彎曲疲勞強(qiáng)度極限 FE=450Mpa 彎曲疲勞壽命系數(shù)YF=2.3 計(jì)算彎曲疲勞許用應(yīng)力 取彎曲疲勞安全系數(shù)S=1.4 F=kFNS=0.96801.4=437.14Mpa 計(jì)算載荷系數(shù)K k=kAkVkkF=11.121.12.3=2.83 查取應(yīng)力校正系數(shù) 由機(jī)械設(shè)計(jì)P197表105可查得 YS=1.1 T=0.462105Nmm a=0.4 z=13 (2)設(shè)計(jì)計(jì)算 m32KT1dz12YFaYSaF=4.7 對(duì)此計(jì)算結(jié)果，由齒面接觸疲勞強(qiáng)度計(jì)算的模數(shù)，由于齒輪模m 的大小主要取決于彎曲強(qiáng)度所決定的承載能力，而齒面接觸疲勞強(qiáng)度 所決定承載能力，僅與齒輪直徑有關(guān)，可取由彎曲強(qiáng)度算得模數(shù)4.7， 就近圓整m=5mm，算得分度圓直徑d1=67.5mm.6.3.3 對(duì)于d=90mm齒輪的計(jì)算及校核：（d=90mm初定） a.選定齒輪類型、精度等級(jí)、材料及齒數(shù) （1）按傳動(dòng)方案選用直齒輪傳動(dòng)。 （2）考慮齒輪較大，故大小齒輪都選用硬齒面。由機(jī)械設(shè)計(jì)P189 101選得大小齒輪材料均為40Cr（調(diào)質(zhì)），并經(jīng)調(diào)質(zhì)表面淬火，齒面硬度240HBS。 （3）選取精度等級(jí)，因采用表面淬火，輪齒變形不大，不需磨削，故初 14選7級(jí)精度。 （4）選齒數(shù)z1=18,z2=18 b.按齒面接觸強(qiáng)度設(shè)計(jì)： 由設(shè)計(jì)計(jì)算公式進(jìn)行計(jì)算，即：d1t2.32KtT1du+1u(zEH)2(1) 確定公式內(nèi)的各計(jì)算數(shù)值試選取載荷系數(shù)：kt=1.3 計(jì)算齒輪的扭矩： T1=95.5105P1n1=95.51050.161333=0.924105Nmm 由機(jī)械設(shè)計(jì)P201表107選取齒寬系數(shù)：d=0.4 由機(jī)械設(shè)計(jì)P198表106查得材料彈性系數(shù) zE=189.8Mpa12 由機(jī)械設(shè)計(jì)P207表1021d按齒面硬度中間值52HRC，查得齒輪接觸疲勞強(qiáng)度極限Hlim1=Hlim21170Mpa 計(jì)算應(yīng)力循環(huán)次數(shù)： N1=60 n1jLh=6096012830015=4.147109 由機(jī)械設(shè)計(jì)P203圖1019查得接觸疲勞強(qiáng)度壽命系數(shù)： kHN1=kHN2=0.90 計(jì)算接觸疲勞許用應(yīng)力： 取失效概率1%，安全系數(shù)S=1 H1=H2=kHN1lim1S=1030Mpa （2）計(jì)算 計(jì)算齒輪分度圓直徑d1t ，代入H中較小的值 d1t2.323KtT1du+1u(zEH)2=2.3231.30.9241050.41+11(189.81030)2 =84.112mm 計(jì)算圓周速度V：V=d1n1601000=84.112333.360100=1.47m/s 計(jì)算齒寬b b=dd1t=0.484.112=33.64mm 計(jì)算齒寬與齒高之比b/h 模數(shù) mt1=d1tz1=64.11218=4.67mm 齒高 h=2.25mt=2.25英文技術(shù)資料及中文翻譯中文翻譯 機(jī)械設(shè)計(jì)及最優(yōu)設(shè)計(jì) 機(jī)械設(shè)計(jì)是一門通過(guò)設(shè)計(jì)新產(chǎn)品或者改進(jìn)老產(chǎn)品，滿足人類需求的應(yīng)用技術(shù)科學(xué)。它涉及工程技術(shù)各個(gè)領(lǐng)域，主要研究產(chǎn)品的尺寸、形狀和詳細(xì)結(jié)構(gòu)的基本構(gòu)思，還要研究產(chǎn)品在制造、銷售和使用等方面的問(wèn)題。進(jìn)行各種機(jī)械設(shè)計(jì)工作的人員通常被稱為設(shè)計(jì)人員或者設(shè)計(jì)工程師。機(jī)械設(shè)計(jì)是一門創(chuàng)造性的工作。設(shè)計(jì)工程師不僅在工作上面有創(chuàng)新性，還必須在機(jī)械制圖、運(yùn)動(dòng)學(xué)、運(yùn)力學(xué)、工程材料、材料力學(xué)和機(jī)械制造工藝等方面有深厚的基礎(chǔ)知識(shí)。如前面所述，機(jī)械設(shè)計(jì)的目的是生產(chǎn)滿足人類的需求的產(chǎn)品。發(fā)明、發(fā)現(xiàn)和科學(xué)知識(shí)本身并不一定能給人類帶來(lái)好處，只有當(dāng)它們被用在產(chǎn)品上才能產(chǎn)生效益。因而，應(yīng)該認(rèn)識(shí)到在一個(gè)特定產(chǎn)品進(jìn)行設(shè)計(jì)之前，必須先確定人們是否需要這種產(chǎn)品。應(yīng)當(dāng)把機(jī)械設(shè)計(jì)看成是設(shè)計(jì)人員運(yùn)用創(chuàng)造性的才能進(jìn)行產(chǎn)品設(shè)計(jì)、系統(tǒng)分析和制訂產(chǎn)品的制造工藝的一個(gè)良機(jī)。掌握工程基礎(chǔ)知識(shí)要比熟記一些數(shù)據(jù)和公式更為重要。僅僅使用數(shù)據(jù)和公式是不足在一個(gè)好的設(shè)計(jì)中做出所需的全部決定的。另一方面，應(yīng)該認(rèn)真精確地進(jìn)行所有的運(yùn)算。例如，即使將一個(gè)小數(shù)點(diǎn)的位置放錯(cuò)，也會(huì)是正確的設(shè)計(jì)變成錯(cuò)誤的。一個(gè)好的設(shè)計(jì)人員應(yīng)該勇于提出新的想法，而且愿意承擔(dān)一定的風(fēng)險(xiǎn)；但新的方法不使用時(shí)，就恢復(fù)采用原來(lái)的方法。因此，設(shè)計(jì)人員必須要有耐心，因?yàn)樗ㄙM(fèi)的時(shí)間和努力并不能保證帶來(lái)成功。一個(gè)全新的設(shè)計(jì)，要摒棄許多許多陳舊的的，為人們所熟知的方法。由于許多人易于墨守陳規(guī)，這樣做并不是件容易的事情。一位設(shè)計(jì)過(guò)程師應(yīng)該不斷地探索改進(jìn)現(xiàn)有產(chǎn)品的方法，在此過(guò)程中應(yīng)該認(rèn)真選擇原有的、經(jīng)過(guò)驗(yàn)證的設(shè)計(jì)原理，將其與未經(jīng)過(guò)驗(yàn)證的新觀念結(jié)合起來(lái)。新設(shè)計(jì)本身會(huì)有許多缺陷和未能預(yù)料的問(wèn)題發(fā)生，只有當(dāng)這些缺陷和問(wèn)題被解決之后，才能體現(xiàn)出新產(chǎn)品的優(yōu)越性。因此，一個(gè)性能優(yōu)越的產(chǎn)品誕生的同時(shí)，也伴隨著較高的風(fēng)險(xiǎn)。應(yīng)該強(qiáng)調(diào)的是，如果設(shè)計(jì)本身不要求采用全新的方法，就沒(méi)必要僅僅為了變革的目的而采用新的方法。在設(shè)計(jì)的在設(shè)計(jì)的初始階段，應(yīng)該允許設(shè)計(jì)人員充分發(fā)揮創(chuàng)造性，不受各種約束。即使產(chǎn)生了許多不切實(shí)際的想法，也會(huì)在設(shè)計(jì)的早期，即繪制圖紙之前被改正掉。只有這樣，才不致于堵塞創(chuàng)新的思路。通常，要提出幾套設(shè)計(jì)方案，然后加以比較。很有可能在最后選定的方案中，采用了某些未被接受的方案中的一些想法。心理學(xué)家經(jīng)常談?wù)撊绾问谷藗冞m應(yīng)他們所操作的機(jī)器。設(shè)計(jì)人員的基本職責(zé)是努力使機(jī)器來(lái)適應(yīng)人們。這并不是一項(xiàng)容易的工作，因?yàn)閷?shí)際上并不存在著一個(gè)對(duì)所有人來(lái)說(shuō)都是最優(yōu)的操作范圍和操作過(guò)程。另一個(gè)重要問(wèn)題，設(shè)計(jì)工程師必須能夠同其他有關(guān)人員進(jìn)行交流和磋商。在開始階段，設(shè)計(jì)人員必須就初步設(shè)計(jì)同管理人員進(jìn)行交流和磋商，并得到批準(zhǔn)。這一般是通過(guò)口頭討論，草圖和文字材料進(jìn)行的。為了進(jìn)行有效的交流 ，需要解決下列問(wèn)題：（1） 所設(shè)計(jì)的這個(gè)產(chǎn)品是否真正為人們所需要？（2） 此產(chǎn)品與其他公司的現(xiàn)有同類產(chǎn)品相比有無(wú)競(jìng)爭(zhēng)能力？（3） 生產(chǎn)這種產(chǎn)品是否經(jīng)濟(jì)？（4） 產(chǎn)品的維修是否方便？（5） 產(chǎn)品有無(wú)銷路？是否可以盈利？ 只有時(shí)間能對(duì)上述問(wèn)題給出正確答案。但是， 產(chǎn)品的設(shè)計(jì)、制造和銷售只能在對(duì)上述問(wèn)題的初步肯定答案的基礎(chǔ)上進(jìn)行。設(shè)計(jì)工程師還應(yīng)該通過(guò)零件圖和裝配圖，與制造部門一起對(duì)最終設(shè)計(jì)方案進(jìn)行磋商。通常 ，在制造過(guò)程中會(huì)出現(xiàn)某個(gè)問(wèn)題?？赡軙?huì)要求對(duì)某個(gè)零件尺寸或公差作一些更改，使零件的生產(chǎn)變得容易。但是，工程上的更改必須要經(jīng)過(guò)設(shè)計(jì)人員批準(zhǔn)，以保證不會(huì)損傷產(chǎn)品的功能。有時(shí)，在產(chǎn)品的裝配時(shí)或者裝箱外運(yùn)前的試驗(yàn)中才發(fā)現(xiàn)設(shè)計(jì)中的某種缺陷。這些事例恰好說(shuō)明了設(shè)計(jì)是一個(gè)動(dòng)態(tài)過(guò)程?？偸谴嬖谥玫姆椒▉?lái)完成設(shè)計(jì)工作，設(shè)計(jì)人員應(yīng)該不斷努力，尋找這些更好的方法。近些年來(lái)，工程材料的選擇已經(jīng)顯得重要。此外，選擇過(guò)程應(yīng)該是一個(gè)對(duì)材料的連續(xù)不斷的重新評(píng)價(jià)過(guò)程。新材料不斷出現(xiàn)，而一些原有的材料的能夠獲得的數(shù)量可能會(huì)減少。環(huán)境污染、材料的回收利用、工人的健康及安全等方面經(jīng)常會(huì)對(duì)材料選擇附加新的限制條件。為了減輕重量或者節(jié)約能源，可能會(huì)要求使用不同的材料。來(lái)自國(guó)內(nèi)和國(guó)際競(jìng)爭(zhēng)、對(duì)產(chǎn)品維修保養(yǎng)方便性要求的提高和顧客的反饋等方面的壓力，都會(huì)促使人們對(duì)材料進(jìn)行重新評(píng)價(jià)。由于材料選用不當(dāng)造成的產(chǎn)品責(zé)任訴訟，已經(jīng)產(chǎn)生了深刻的影響。此外，材料與材料加工之間的相互依賴關(guān)系已經(jīng)被人們認(rèn)識(shí)得更清楚。因此，為了能在合理的成本和確保質(zhì)量的前提下獲得滿意的結(jié)果，設(shè)計(jì)工程師的制造工程師都必須認(rèn)真仔細(xì)地選擇、確定和使用材料。制造任何產(chǎn)品的第一步工作都是設(shè)計(jì)。設(shè)計(jì)通?？梢苑譃閹讉€(gè)明確的階段：（a）初步設(shè)計(jì)；（b）功能設(shè)計(jì)；（c）生產(chǎn)設(shè)計(jì)。在初步設(shè)計(jì)階段，設(shè)計(jì)者著重考慮產(chǎn)品應(yīng)該具有的功能。通常要設(shè)想和考慮幾個(gè)方案，然后決定這種思想是否可行；如果可行，則應(yīng)該對(duì)其中一個(gè)或幾個(gè)方案作進(jìn)一步的改進(jìn)。在此階段，關(guān)于材料選擇唯一要考慮的問(wèn)題是：是否有性能符合要求的材料可供選擇；如果沒(méi)有的話，是否有較大的把握在成本和時(shí)間都允許的限度內(nèi)研制出一種新材料。在功能設(shè)計(jì)和工程設(shè)計(jì)階段，要做出一個(gè)切實(shí)可行的設(shè)計(jì)。在這個(gè)階段要繪制出相當(dāng)完整的圖紙，選擇并確定各種零件的材料。通常要制造出樣機(jī)或者實(shí)物模型，并對(duì)其進(jìn)行試驗(yàn)，評(píng)價(jià)產(chǎn)品的功能、可靠性、外觀和維修保養(yǎng)性等。雖然這種試驗(yàn)可能會(huì)表明，在產(chǎn)品進(jìn)入到生產(chǎn)階段之前，應(yīng)該更換某些材料，但是，絕對(duì)不能將這一點(diǎn)作為不認(rèn)真選擇材料的借口。應(yīng)該結(jié)合產(chǎn)品的功能，認(rèn)真仔細(xì)地考慮產(chǎn)品的外觀、成本和可靠性。一個(gè)很有成就的公司在制造所有的樣機(jī)時(shí)，所選用的材料應(yīng)該和其生產(chǎn)中使用的材料相同，并盡可能使用同樣的制造技術(shù)。這樣對(duì)公司是很有好處的。功能完備的樣機(jī)如果不能根據(jù)預(yù)期的銷售量經(jīng)濟(jì)地制造出來(lái)，或者是樣機(jī)與正式生產(chǎn)的裝置在質(zhì)量和可靠性方面有很大不同，則這種樣機(jī)就沒(méi)有多大的價(jià)值。設(shè)計(jì)工程師最好能在這一階段完全完成材料的分析、選擇和確定工作，而不是將其留到生產(chǎn)設(shè)計(jì)階段去做。因?yàn)?，在生產(chǎn)設(shè)計(jì)階段材料的更換是由其他人進(jìn)行的，這些人對(duì)產(chǎn)品的所有功能的了解不如設(shè)計(jì)工程師。在生產(chǎn)設(shè)計(jì)階段中，與材料有關(guān)的主要問(wèn)題是應(yīng)該把材料完全確定下來(lái)，使它們與現(xiàn)有的設(shè)備相適應(yīng)，能夠利用現(xiàn)有設(shè)備經(jīng)濟(jì)地進(jìn)行加工，而且材料的數(shù)量能夠比較容易保證供應(yīng)。在制造過(guò)程中，不可避免地會(huì)出現(xiàn)對(duì)使用中的材料做一些更改的情況。經(jīng)驗(yàn)表明，可采用某些便宜材料作為替代品。然而，在大多數(shù)情況下，在進(jìn)行生產(chǎn)以后改換材料要比在開始生產(chǎn)前改換材料所花費(fèi)的代價(jià)要高。在設(shè)計(jì)階段做好材料選擇工作，可以避免多數(shù)這樣的情況。在生產(chǎn)制造開始后出現(xiàn)了可供使用的新材料是更換材料的最常見(jiàn)的原因。當(dāng)然，這些新材料可能降低成本、改進(jìn)產(chǎn)品的性能。但是，必須對(duì)新材料進(jìn)行認(rèn)真的評(píng)價(jià)，以確保其所有性能都滿足要求。應(yīng)當(dāng)記住，新材料的性能和可靠性很少像現(xiàn)有材料那樣為人們所了解。大部分的產(chǎn)品失效和產(chǎn)品責(zé)任事故案件是由于在選用新材料作為替代材料之前，沒(méi)有真正了解它們的長(zhǎng)期使用性能而引起的。產(chǎn)品的責(zé)任訴訟迫使設(shè)計(jì)人員和公司在選擇材料時(shí)，采用最好的程序。在材料過(guò)程中，五個(gè)最常見(jiàn)的問(wèn)題為：（a）不了解或者不會(huì)使用關(guān)于材料應(yīng)用方面的最新最好的信息資料；(b)未能預(yù)見(jiàn)和考慮擦黑年品可能的合理用途（如有可能，設(shè)計(jì)人員還應(yīng)進(jìn)一步預(yù)測(cè)和考慮由于產(chǎn)品使用方法不當(dāng)造成的后果。在近年來(lái)的許多產(chǎn)品責(zé)任訴訟案件中，由于錯(cuò)誤地使用產(chǎn)品而受到傷害的原告控告生產(chǎn)廠家，并且贏得判決）；(c)所使用的材料的數(shù)據(jù)不全或是有些數(shù)據(jù)不確定，尤其是當(dāng)其長(zhǎng)期性能數(shù)據(jù)是如此的時(shí)候；(d)質(zhì)量控制方法不適當(dāng)和未經(jīng)驗(yàn)證；(e)由一些完全不稱職的人員選擇材料。通過(guò)對(duì)上述五個(gè)問(wèn)題的分析，可以得出這些問(wèn)題是沒(méi)有充分理由存在的結(jié)論。對(duì)這些問(wèn)題的研究分析可以為避免這些問(wèn)題的出現(xiàn)指明方向。盡管采用最好的材料選擇方法也不能避免發(fā)生產(chǎn)品責(zé)任訴訟，設(shè)計(jì)人員和工業(yè)界按照適當(dāng)?shù)某绦蜻M(jìn)行材料選擇，可以大大減少訴訟的數(shù)量。從以上的討論可以看出，選擇材料的人們應(yīng)該對(duì)材料的性質(zhì)，特點(diǎn)和加工方法有一個(gè)全面而基本的了解。當(dāng)加工鋁時(shí)，我們主要關(guān)心的是：鋁粘住加工切削邊緣的傾向；保證有好的碎片排屑形成切削邊緣；和保證工具有足夠的中心強(qiáng)度來(lái)承受切削力而不被破壞。技術(shù)發(fā)展，比如：Makino MAG系列，已經(jīng)使工具商重新考慮任何工藝水平的機(jī)器技術(shù)。用正確的加工和編程思路是很重要的。材料，涂料和幾何形狀是與減小我們所關(guān)注問(wèn)題相關(guān)系的工具設(shè)計(jì)的三個(gè)因素。如果這些因素不能一起很好的配合，成功的調(diào)整磨削是不可能的。為了成功進(jìn)行高速鋁加工，理解這三個(gè)因素是很必要的。使組合邊緣最小化當(dāng)加工鋁時(shí)，一個(gè)失敗的切削工具模式是，被加工的材料粘住工具切削邊緣。這種情況會(huì)很快削弱工具的切削能力。由粘著的鋁形成的組合邊緣會(huì)導(dǎo)致工具變鈍，以至不能切削材料。工具材料選擇和工具涂料選擇是被工具設(shè)計(jì)者用來(lái)減小組合邊緣出現(xiàn)的主要工藝。亞微米微粒碳化物材料要求很高的鈷濃度來(lái)獲得良好的微粒結(jié)構(gòu)和材料強(qiáng)度屬性。隨著溫度的升高，鈷與鋁發(fā)生反應(yīng)，鈷使鋁與暴露的工具材料碳化物相粘合。一旦鋁開始粘住工具，鋁會(huì)在快速的在工具上形成組合邊緣，使工具不可用。在切削的進(jìn)程中，減小鋁粘合著的工具的暴露碳化物的秘訣就是找到正確的碳化物的平衡來(lái)提供足夠的材料強(qiáng)度。在加工鋁時(shí)，為了減小粘附，使用能提供足夠硬度的紋理粗糙的碳化物來(lái)獲得平衡，來(lái)使變鈍變慢。工具涂料當(dāng)嘗試減小組合邊緣時(shí)，第二個(gè)應(yīng)該考慮的工具設(shè)計(jì)因素是工具涂料。工具涂料的選擇包括：TiN, TiAIN, AITiN，鉻氮化物，鋯氮化物，鉆石和鉆石般的涂料（DLC）。擁有這么多的選擇，航空航天磨削商店需要知道在鋁的高速加工應(yīng)用中哪一種工作最有效。TiN, TiCN, TiAIN, 和 AITiN工具的PVD涂裝應(yīng)用進(jìn)程使這些選項(xiàng)不合適鋁的應(yīng)用。PVD涂裝進(jìn)程建立了兩個(gè)使鋁粘住工具的模式-表面的粗糙程度和鋁與工具涂料之間的化學(xué)反應(yīng)。PVD進(jìn)程形成了一個(gè)表面，這表面是比底層材料更粗糙的。由這個(gè)進(jìn)程形成的表面“凹凸”使工具中的鋁在凹處快速集結(jié)。由于涂料有金屬晶體和鐵晶體特征，PVD涂料是可以和鋁發(fā)生化學(xué)反應(yīng)的。一種TiAIN涂料通常是包含鋁的，這鋁很容易和相同材料的切削表面粘合。表面粗糙度和化學(xué)反應(yīng)特性將會(huì)導(dǎo)致工具和工作片體粘在一起，以致形成組合表面。OSG Tap and Die主導(dǎo)的試驗(yàn)中，人們發(fā)現(xiàn)在高速加工鋁時(shí)，一個(gè)沒(méi)有涂染過(guò)紋理粗糙的碳化物的工具的表面優(yōu)于用TiN, Ticn, TiAIN, 或者ALTiN涂染過(guò)的工具。這個(gè)試驗(yàn)不意味著所有工具涂料將減小工具的表現(xiàn)。鉆石和DLC涂料可生成一個(gè)非常光滑的化學(xué)惰性的表面。在切削鋁材料時(shí)，這些涂料很認(rèn)為是能非常有效的提高工具的壽命。鉆石涂料被認(rèn)為是表現(xiàn)最佳的涂料，但這種涂料要一個(gè)很可觀的成本。對(duì)于表現(xiàn)價(jià)值，DLC涂料提供最佳成本，增加大約20%-25%的總工具成本，而壽命相對(duì)于未涂染過(guò)紋理粗糙的碳化物的工具來(lái)是，是增長(zhǎng)得很明顯的。幾何形狀高速鋁加工工具設(shè)計(jì)的拇指定律就是使微粒排屑空間最大化。這是因?yàn)殇X是一種非常柔軟的材料。Federate通常是可以增長(zhǎng)的，它生成更多更大的微粒。Makino MAG-Series航空航天磨削機(jī)器，比如MAG4,要求額外關(guān)注工具幾何休和工具強(qiáng)度。擁有強(qiáng)大的80-hp的心軸的 MAG-Series機(jī)器將折斷工具如果他們不是用足夠的中心強(qiáng)度設(shè)計(jì)的?？偟膩?lái)說(shuō)，鋒利的切削邊緣一直都可以用來(lái)避免鋁的延伸。一個(gè)鋒利的切削邊緣將形成高剪切和高表面清潔，形成一個(gè)更好的表面和使表面振動(dòng)最小化。結(jié)果是用優(yōu)良的紋理碳化物材料比紋理粗糙的碳化物材料更有可能獲得一個(gè)鋒利的切削邊緣。但由于鋁能粘住紋理好的材料，長(zhǎng)久保持這各邊緣是不太可能的。粗略的折衷方案紋理粗糙的材料是最好的折衷。那是一種很強(qiáng)大的材料，它能擁有一個(gè)可觀的切削邊緣。試驗(yàn)結(jié)果表明；在獲得長(zhǎng)的工具壽命的同時(shí)擁有好的表面的可以的。通過(guò)工具來(lái)進(jìn)行油霧冷卻是可以改進(jìn)切削邊緣的保持的。霧化逐漸使工具冷卻，消除溫度急增的問(wèn)題。螺旋角度是一個(gè)額外的工具幾何考慮因素。傳統(tǒng)上來(lái)說(shuō)，當(dāng)加工鋁時(shí)，帶有高螺旋角度的工具已經(jīng)被運(yùn)用。高螺旋角度可以使微粒更快地從部分脫離，但卻增加力和熱，這是由切削運(yùn)動(dòng)導(dǎo)致的。一個(gè)高螺旋角被用在工具上，并且很大數(shù)量的凹槽可以使微粒排泄。當(dāng)以非常高的速度加工鋁時(shí)，由增加的力形成的熱量可能會(huì)引起微粒與工具焊接在一起。此外，一個(gè)有很高螺旋角的切削表面將比低角度的更快產(chǎn)生微粒。僅僅利用兩個(gè)凹槽工具設(shè)計(jì)使低螺旋角和足夠微粒排泄區(qū)域成為可能。由OSG主導(dǎo)的延伸性試驗(yàn)中，當(dāng)發(fā)展新工具流水線時(shí)，這被證明是最成功的方法。英文技術(shù)資料Mechanical Design and Optimum DesignMechanical design is the application of science and technology to devise new or improved products for the purpose of satisfying human needs. It is a vast field of engineering technology which not only concerns itself with the original conception of the product in terms of its size, shape and construction details, but also consideration the various factors involved in the manufacture and use of the product.People who perform the various function of mechanical design are typically called designers, or design engineers. Mechanical design is basically a creative activity. However, in addition to being innovative, a design engineer must also have a solid background in the areas of mechanical drawing, kinematics, dynamics, material engineering, strength of materials and manufacturing processes.As stated previously, the purpose of mechanical design is to product which will serve a need for man. Invention, discoveries and scientific knowledge by themselves do not necessarily benefit people; only if they are incorporated into a designed product will a benefit be derived. It should be recognized, therefore, that a human need must be identified before a particular product is designed.Mechanical design should be considered to be an opportunity to use innovation talents to envision a design of a product, to analyze the system and then make sound judgments on how the product is to be manufacture. It is important to understand the fundamentals of engineering rather than memorize mere facts and equations. There are no facts or equations which alone can be used to provide all the correct decisions required to produce a good design. On the other hand, any calculations made must be done with the utmost care and precision. For example, if a decimal point is misplaced, an otherwise acceptable design may not function.Good designs require trying new ideas and being willing to take a certain amount of risk, knowing that if the new idea does not work the existing method can be reinstated. Thus a designer must have patience, since there is no assurance of success for the time and effort expended. Creating a completely new design generally requires that many old and well-established methods be thrust aside. This is not easy since many people cling to familiar ideas, techniques and attitudes. A design engineer should constantly search for ways to improve an existing product and must decide what old, proven concepts should be used and what new, untried ideas should be incorporated.New designs generally have “bugs” or unforeseen problem which must be worked out before the superior characteristics of the new designs can be enjoyed. Thus there is a chance for a superior product, but only at higher risk. It should be emphasized that, if a design dose not warrant radical new methods, such methods should not be applied merely for the sake of change. During the beginning stage of design, creativity should be allowed to flourish to without a great number of constraints. Even thought many impractical ideas may arise, it is usually easy to eliminate them in the early stages of design before firm details are required by manufacturing. In this way, innovative ideas are not inhibited. Quite often, more than one design is developed, up to point where they can be compared against each other. It is entirely possible that the design which is ultimately accepted will use ideas existing in one of the rejected design that did not show as much overall promise.Psychologists frequently talk about trying to fit people to the machines they operate. It is essentially the responsibility of the design engineer to fit machines to people. This is not an easy task, since there is really no person for which certain operating dimension and procedures are optimum.Another important point which should be recognized is that a design engineer must be able to communicate ideas to other people if they are to be incorporated. Communicating the design to others is the final, vital step in the design process. Undoubtedly many great designs, inventions, and creative works have been lost to mankind simply because the originator were unable or unwilling to explain their accomplishments to others. Presentation is a selling job. The engineer, when presenting a new solution to administrative, management, or supervisory persons, is attempting to sell or to prove to them that this solution is a better one. Unless this can be done successfully, the time and effort spent on obtaining the solution have been largely wasted.Basically, there are only three means of communicate available to us. There are the written, the oral, and the graphical form. Therefore the successful engineer will be technically competent and versatile in all three forms of communication. A technically competent person who lacks ability in any one of these forms is severely handicapped. If ability in all three forms is lacking, no one will ever know how competent that person is!The competent engineer should not be afraid of the possible of not succeeding in a presentation. In fact, occasional failure should be expected because failure or criticism seems to a company every really creative idea. There is a great deal to be learned from a failure, and the greatest gains are obtained by those willing to risk defeat. In the final analysis, the real failure would lie in deciding not to make the presentation at all. To communicate effectively, the fowling questions must be answered:Dose the design really sever a human need?Will it be competitive with existing products of rival companies?Is it economical to produce?Can it be readily maintained?Will it sell and make a profit?Only time will provide the true answers to the preceding question, but the product should be design, manufactured and marketed only with initial affirmative answer. The design engineer also must communicate the finalized design to manufacturing through the use of detail and assembly drawings.Quite often, a problem will occur during the manufacturing cycle. It may be that a change is required in the dimensioning or tolerance of a part so that it can be more readily produced. This fall in the category of engineering changes which must be approved by the design engineer so that the product function will not be adversely affected. In other case, a deficiency in the design may appear during assembly or testing just prior to shipping. These realities simply bear out the fact that design is a living process. There is always a better way to do it and the designer should constantly strive towards findings that better way.The primary tooling concerns when machining aluminum are: minimizing the tendency of aluminum to stick to the tool cutting edges; ensuring there is good chip evacuation form the cutting edge; and ensuring the core strength of the tools is sufficient to withstand the cutting forces without breaking.Technological developments such as the Makino MAG-Series machines have made tooling vendors rethink the any state-of-the-art machine technology. It is vital to apply the right tooling and programming concepts.Materials coatings and geometry are the three elements in tool design that interrelate to minimize these concerns. If these three elements do not work together, successful high-speed milling is not possible. It is imperative to understand all three of these elements in order to be successful in the high-speed machining of aluminum.Minimize Built-Up Eagled. The surface peaks and valleys” created by this process causes aluminum to rapidly collect in the valleys on the tool. In addition, the PVD coating is chemically reactive to the aluminum due to its metallic crystal and ionic crystal features. A TiAIN coating actually contains aluminum, which easily bonds with a cutting surface of the same material. The surface roughness and chemical reactivity attributes will cause the tool and work piece to stick together, thus creating the built-up edge.In testing performed by OSG Tap and Die, it was discovered that when machining aluminum at very high speeds, the performance of an uncoated coarse-grained carbide tool was superior to that of one coated with TiN, Ticn, TiAIN, or ALTiN. This testing does not mean that all tool coatings will reduce the tool performance. The diamond and DLC coatings result in a very smooth chemically inert surface. These coatings have been found to significantly improve tool life when cutting aluminum materials.The diamond coatings were found to be the best performing coatings, but there is a considerable cost related to this type of coating. The DLC coatings provide the best cost for performance value, adding about 20%-25%to the total tool cost. But, this coating extends the tool life significantly as compared to an uncoated coarse-grained carbide tool.GeometryThe rule of thumb for high-speed aluminum machining tooling designs is to maximize space for chip evacuation. This is because aluminum is a very soft material, and the federate is usually increased which creates more and bigger chips.The Makino MAG-Series aerospace milling machines, such as the MAG4, require an additional consideration for tool geometry-tool strength. The MAG-Series machines with their powerful 80-hp spindles will snap the tools if they are not designed with sufficient core strength.In general, sharp cutting edges should always be used to avoid aluminum elongation. A sharp cutting edge will create high shearing and also high surface clearance, creating a better surface finish and finish and minimizing chatter or surface vibration. The issue is that it is possible to achieve a sharper cutting edge with the fine-grained carbide material than the coarse grained material. But due to aluminum adherence to the fine-grained material, it is not possible to maintain that edge for very long.Coarse compromiseThe coarse grained material appears to be the best compromise. It is a strong material that can have a reasonable cutting edge. Test results show it is able to achieve a very long tool life with good surface finish. The maintenance of the cutting edge is improved using an oil mist coolant through the tool. Misting gradually cools down the tools, eliminating thermal shock problems.The helix angle is an additional tool geometry consideration. Traditionally when machining aluminum a fool with a high helix angle has been used. A high helix angle lifts the chip away from the paWhen machining aluminum, one of the major failure modes of cutting tools the material being machined adheres to the tool cutting edge. This condition rapidly degrades the cutting ability of the tool. The built-up edge that is generated by the adhering aluminum dulls the tool so it can no longer cut through the material. Tool material selection and tool coating selection are the two primary techniques used by tool designers to reduce occurrence of the built-up edge.The sub-micron grain carbide material requires a high cobalt concentration to achieve the fine grain structure and the materials strength properties. Cobalt reacts with aluminum at elevated temperatures, which causes the aluminum to chemically bond to the exposed cobalt of the tool material. Once the aluminum starts to adhere to the tool, it quickly forms a built-up edge on the tool rendering it ineffective.The secret is to find the right balance of cobalt to provide adequate material strength, while minimizing the exposed cobalt in the tools for aluminum adherence during the cutting process. This balance is achieved using coarse-grained carbide that provides a tool of sufficient hardness so as to not dull quickly when machining aluminum while minimizing adherence.Tool coatingsThe second tool design element that must be considered when trying to minimize the built-up edge is the tool coating. Tool coating choices include TiN, TiAIN, AITiN, chrome nitrides, zirconium nitrides, diamond, and diamond-like coatings(DLC). With so many choices, aerospace milling shops need to know which one works best in an aluminum high-speed machining application.The Physical Vapor Deposition (PVD) coating application process on TiN, TiCN, TiAIN, and AITiN tools makes them unsuitable for an aluminum application. The PVD coating process creates two modes for aluminum to bond to the tools ：the surface roughness and the chemical reactivity between the aluminum and the tool coating.The PVD process results in surface that is rougher that the substrate material to which it is app rt more quickly, but increases the friction and heat generated as result of the cutting action. A high helix angle is typically used on a tool with a higher number of flutes to quickly evacuate the chip from the part.When machining aluminum at very high speeds the heat created by the increased friction may cause the chips to weld to the tool. In addition, a cutting surface with a high helix angle will chip more rapidly that a tool with a low helix angle. A tool design that utilizes only two flutes enables both a low helix angle and sufficient chip evacuation area. This is the approach that has proven to be the most successful in extensive testing performed by OSG when developing the new tooling line, the MAX AL.- 13 -