J5600调温器工艺规程设计和系列夹具设计-调温器座3套夹具
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编号
无锡太湖学院
毕业设计（论文）
相关资料
题目： J5600调温器工艺规程设计和
系列夹具设计
信机 系 机械工程及其自动化 专业
学 号： 0923808
学生姓名： 张 燕
指导教师： 张大骏 （职称：高级工程师 ）
（职称： ）
2013年5月25日
目 录
一、毕业设计（论文）开题报告
二、毕业设计（论文）外文资料翻译及原文
三、学生“毕业论文（论文）计划、进度、检查及落实表”
四、实习鉴定表
无锡太湖学院
毕业设计（论文）
开题报告
题目： J5600调温器工艺规程设计和
系列夹具设计
信机系 机械工程及其自动化 专业
学 号： 0923808
学生姓名： 张 燕
指导教师： 张大骏 （职称：高级工程师 ）
（职称： ）
2012年11月25日
课题来源
本课题是广西玉林柴油机厂委托无锡市宏业机械配件厂加工的柴油机零件，此种发动机在载重汽车及客车上广泛使用。
科学依据（包括课题的科学意义；国内外研究概况、水平和发展趋势；应用前景等）
（1）课题科学意义
调温器研究报告主要是通过对调温器的主要内容和配套条件，如市场调查、资源供应、建设规模、工艺路线、设备选型、环境影响、资金筹措、盈利能力等，从技术 、经济、工程等方面进行调查研究和分析比较，并对项目建成以后可能取得的财务、经济效益及社会影响进行预测，从而提出该调温器项目是否值得投资和如何进行建设的咨询意见，为项目决策提供依据的一种综合性的分析方法。可行性研究具有预见性、公正性、可靠性、科学性的特点。调温器研究报告是确定建设项目前具有决定性意义的工作，是在调温器投资决策之前，对拟建项目进行全面技术经济分析论证的科学方法，在投资管理中，可行性研究是指对拟建项目有关的自然、社会、经济、技术等进行调研、分析比较以及预测建成后的社会经济效益。
（2）J5600调温器的研究状况及其发展前景
调温器行业趋势研究报告是通过对影响调温器行业市场运行的诸多因素所进行的调查分析，掌握调温器行业市场运行规律，从而对调温器行业的未来的发展趋势特点、市场容量、竞争趋势、细分下游市场需求趋势等进行预测。
调温器行业趋势研究报告主要分析要点包括：
1） 调温器行业发展趋势特点分析。通过对调温器行业发展影响因素分析，总结出未来调温器行业总体运行趋势特点；
2） 预测调温器行业生产发展及其变化趋势。对生产发展及其变化趋势的预测，这是对市场中商品供给量及其变化趋势的预测；
3） 预测调温器行业市场容量及变化。综合分析预测期内调温器行业生产技术、产品结构的调整，预测调温器行业的需求结构、数量及其变化趋势。
4）预测调温器行业市场价格的变化。企业生产中投入品的价格和产品的销售价格直接关系到企业盈利水平。在商品价格的预测中，要充分研究劳动生产率、生产成本、利润的变化，市场供求关系的发展趋势，货币价值和货币流通量变化以及国家经济政策对商品价格的影响。
调温器行业趋势研究报告主要依据了国家统计局、国家海关总署、国家发改委、国家商务部、国家工业和信息化部、行业协会、国内外相关刊物杂志等的基础信息，结合调温器行业历年供需关系变化规律，对调温器行业内的企业群体进行了深入的调查与研究，对调温器行业环境、调温器市场供需、调温器行业经济运行、调温器市场格局、调温器生产企业等的详尽分析。在对以上分析的基础上，对调温器行业未来发展趋势和市场前景进行科学、严谨的分析与预测。
研究内容
1、机械加工工艺规程的编制，结合具体工厂的条件和发展前景进行考虑。
2、同样结合具体工厂的现有生产条件和发展前景设计专用（不少于三副）。
拟采取的研究方法、技术路线、实验方案及可行性分析
采用组织分析零件的具体结构，加工精度要求，表面粗糙度要求，制造出初步的加工方案。然后组织学生下厂参观，实习，实地了解工厂现有的生产条件，发展展望及具体的生产水平。在此基础上编制工艺规程，填写工艺文件，设计专用夹具。待初步完成后再回工厂征集意见，加以改进，定稿。
研究计划及预期成果
研究计划：
2012年11月12日-2012年12月2日：按照任务书要求查阅论文相关参考资料，填写毕业设计开题报告书。
2012年12月3日-2013年1月20日：指导专业实训。
2013年1月21日-2013年3月1日：指导毕业实习。
2013年3月4日-2013年3月8日：填写实习报告。
2013年3月9日-2013年3月17日：学习并翻译一篇与毕业设计相关的英文材料。
2013年3月25日-2013年4月28日：工艺规程设计、工序卡和工艺卡。
2013年4月29日-2013年5月15日：夹具设计、装配图和说明书。
2013年5月16日-2013年5月25日：毕业论文撰写和修改工作。
预期成果：
工艺规程：工艺卡片，工序卡片，夹具总图及主要零件图，设计说明书
特色或创新之处
工艺规程可以适用于一般中小型工厂的普通通用机床，也能改进后用于专用机床，或加工中心，适用于范围较广。
已具备的条件和尚需解决的问题
现有广西玉柴机器的生产图样，委托加工工厂的现有生产条件及技术状况，特别是已有的生产经验。
目前缺少设计手册、资料等，对检测条件也不够清楚其它资料也缺乏。
指导教师意见
指导教师签名：
年 月 日
教研室（学科组、研究所）意见
教研室主任签名：
年 月 日
系意见
主管领导签名：
年 月 日
无锡太湖学院
毕业设计（论文）外文资料翻译
信机 系 机械工程及自动化 专业
院 （系）： 信 机 系
专 业： 机械工程及自动化
班 级： 机械97班
姓 名： 张 燕
学 号： 0923808
外文出处： 机械专业英语教程
附 件： 1.译文；2.原文；3.评分表
2013年3月17日
英文原文
Application and development
Of case based reasoning in fixture design
Abstract: Based on the case based designing (CBD) methodology, the fixture similarity is in two respects: the function and the structure information. Then, the computer aided fixture design system is created on case based reasoning (CBR),in which the attributes of the main features of workpiece and structure of fixture as case index code are designed for the retrieve of the similar cases, and the structure and hierarchical relation of case library are set up for store. Meanwhile, the algorithm based on the knowledge guided in the retrieve of the similar cases, the strategy of case adapt at ion and case storage in which the case ident if cat ion number is used to distinguish from similar cases are presented. The application of the system in some projects improves the design efficiency and gets a good result .
Keywords: case based reasoning ;fixture design; computer aided design(CAD)
Fixtures are devices that serve as the purpose of holding the workpiece securely and accurately, and maintaining a consistent relationship with respect to the tools while machining. Because the fixture structure depends on the feature of the product and the status of the process planning in the enterprise, its design is the bottleneck during manufacturing, which restrains to improve the efficiency and leadtime. And fixture design is a complicated process, based on experience that needs comprehensive qualitative knowledge about a number of design issues including workpiece configuration, manufacturing processes involved, and machining environment. This is also a very time consuming work when using traditional CAD tools (such as Unigraphics, CATIA or Pro/E), which are good at performing detailed design tasks, but provide few benefits for taking advantage of the previous design experience and resources, which are precisely the key factors in improving the efficiency. The methodology of case based reasoning (CBR) adapts the solution of a previously solved case to build a solution for a new problem with the following four steps: retrieve, reuse, revise, and retain [1]. This is a more useful method than the use of an expert system to simulate human thought because proposing a similar case and applying a few modifications seems to be self explanatory and more intuitive to humans .So various case based design support tools have been developed for numerous areas[2-4], such as in injection molding and design, architectural design, die casting die design, process planning, and also in fixture design. Sun used six digitals to compose the index code that included workpiece shape, machine portion, bushing, the 1st locating device, the 2nd locating device and clamping device[5]. But the system cannot be used for other fixture types except for drill fixtures, and cannot solve the problem of storage of the same index code that needs to be retained, which is very important in CBR[6].
1 Construction of a Case Index and Case Library
1.1 Case index
The case index should be composed of all features of the workpiece, which are distinguished from different fixtures. Using all of them would make the operation in convenient. Because the forms of the parts are diverse, and the technology requirements of manufacture in the enterprise also develop continuously, lots of features used as the case index will make the search rate slow, and the main feature unimportant, for the reason that the relative weight which is allotted to every feature must diminish. And on the other hand, it is hard to include all the features in the case index.
Therefore, considering the practicality and the demand of rapid design, the case index includes both the major feature of the workpiece and the structure of fixture. The case index code is made up of 16 digits: 13 digits for case features and 3 digits for case identification number.
The first 13 digits represent 13 features. Each digit is corresponding to an attribute of the feature, which may be one of“*”, “?”, “1”, “2”,…,“A”,“B”,…, “Z”,…, etc. In which, “*” means anyone, “?” uncertain, “0” nothing.
The system rules: fixture type, workpiece shape, locating model cannot be “*”or“?”. When the system is designed, the attribute information of the three items does not have these options, which means the certain attribute must be selected.
The last three digits are the case identification number, which means the 13 digits of the case feature are the same, and the number of these three digits is used for distinguishing them.
The system also rules: “000” is a prototype case, which is used for retrieval, and other cases are “001”,“002”,…, which are used for reference cases to be searched by designers. If occasionally one of them needs to be changed as the prototype case, first it must be required to apply to change the one to “000”, and the former is changed to referential case automatically.
The construction of the case index code is shown in Fig.1.
1.2 Case library
The case library consists of lots of predefined cases. Case representation is one of the most important issues in case based reasoning. So compounding with the index code,.
1.3 Hierarchical form of Case
The structure similarity of the fixture is represented as the whole fixture similarity, components similarity and component similarity. So the whole fixture case library, components case library, component case library of fixture are formed correspondingly. Usually design information of the whole fixture is composed of workpiece information and workpiece procedure information, which represent the fixture satisfying the specifically designing function demand. The whole fixture case is made up of function components, which are described by the function components’ names and numbers. The components case represents the members. (function component and other structure components,main driven parameter, the number, and their constrain relations.) The component case (the lowest layer of the fixture) is the structure of function component and other components. In the modern fixture design there are lots of parametric standard parts and common non standard parts. So the component case library should record the specification parameter and the way in which it keeps them.
2 Strategy of Case Retrieval
In the case based design of fixtures ,the most important thing is the retrieval of the similarity, which can help to obtain the most similar case, and to cut down the time of adaptation. According to the requirement of fixture design, the strategy of case retrieval combines the way of the nearest neighbor and knowledge guided. That is, first search on depth, then on breadth; the knowledge guided strategy means to search on the knowledge rule from root to the object, which is firstly searched by the fixture type, then by the shape of the workpiece, thirdly by the locating method. For example, if the case index code includes the milling fixture of fixture type, the search is just for all milling fixtures, then for box of workpiece shape, the third for 1plane+ 2pine of locating method. If there is no match of it, then the search stops on depth, and returns to the upper layer, and retrieves all the relative cases on breadth.
Retrieval algorithms:
1) According to the case index information of fixture case library, search the relevant case library;
2) Match the case index code with the code of each case of the case library, and calculate the value of the similarity measure;
3) Sort the order of similarity measure, the biggest value, which is the most analogical case.
Similarity between two cases is based on the similarity between the two cases. features. The calculation of similarity measure depends on the type of the feature. The value of similarity can be calculated for numerical values, for example, compareWorkpiece with the weight of 50kg and 20kg. The value can also be calculated between non numerical values, for example, now the first 13 digits index code is all non numerical values. The similarity measure of a fixture is calculated as follows:
where S is the similarity measure of current fixture, n is the number of the index feature, is the weight of each feature, is the similarity measure of the attribute of the i2th feature with the attributeof relative feature of the j-th case in the case library. At the same time, , the value counts as follows:
.
Where is the value of the index attribute of the i-th feature, and is the value of attribute of the relative i-th feature of the j-th case in case library.
So there are two methods to select the analogical fixture. One is to set the value. If the values of similarity measure of current cases were less than a given value, those cases would not be selected as analogical cases. When the case library is initially set up, and there are only a few cases, the value can be set smaller. If there are lots of analogical cases, the value should get larger. The other is just to set the number of the analogical cases (such as10), which is the largest value of similarity measure from the sorted order.
3 Case adaptation and Case Storage
3.1 Case adaptation
The modification of the analogical case in the fixture design includes the following three cases:
1) The substitution of components and the component;
2) Adjusting the dimension of components and the component while the form remains;
3) The redesign of the model.
If the components and component of the fixture are common objects, they can be edited, substituted and deleted with tools, which have been designed.
3.2 Case storage
Before saving a new fixture case in the case library, the designer must consider whether the saving is valuable. If the case does not increase the knowledge of the system, it is not necessary to store it in the case library. If it is valuable, then the designer must analyze it before saving it to see whether the case is stored as a prototype case or as reference case. A prototype case is a representation that can describe the main features of a case family. A case family consists of those cases whose index codes have the same first 13 digits and different last three digits in the case library. The last three digits of a prototype case are always “000”. A reference case belongs to the same family as the prototype case and is distinguished by the different last three digits.
From the concept that has been explained, the following strategies are adopted:
1) If a new case matches any existing case family, it has the same first 13 digits as an existing prototype case, so the case is not saved because it is represented well by the prototype case. Or is just saved as a reference case (the last 3 digits are not “000”, and not the same with others) in the case library.
2) If a new case matches any existing case family and is thought to be better at representing this case family than the previous prototype case, then the prototype case is substituted by this new case, and the previous prototype case is saved as a reference case.
3) If a new case does not match any existing case family, a new case family will be generated automatically and the case is stored as the prototype case in the case library.
4 Process of CBR in Fixture Design
According to the characteristics of fixture design, the basic information of the fixture design such as the name of fixture, part, product and the designer, etc. must be input first. Then the fixture file is set up automatically, in which all components of the fixture are put together. Then the model of the workpiece is input or designed. The detailed information about the workpiece is input, the case index code is set up, and then the CBR begins to search the analogical cases, relying on the similarity measure, and the most analogical case is selected out. If needed, the case is adapted to satisfy the current design, and restored into the case library. The flowchart of the process is shown in Fig.3.
5 Illustrating for Fixture Design by CBR
This is a workpiece (seeFig.4). Its material is 45# steel. Its name is seat. Its shape is block, and the product batch size is middle, etc. A fixture is turning fixture that serves to turn the hole, which needs to be designed.
The value of feature, attribute, case index code and weight of the workpiece is show n in Tab.2.
Through searching, and calculating the similarity, the case index code of the most similar case is 19325513321402000, and the detailed information is show n in Tab. 3.
The similarity is calculated as follows:
So the value of similarity measure of the fixture which needs to be designed with the most analogical case in case library is 0.806, and the structure of the most analogical case is shown in Fig.5.
After having been substituted the component, modified the locating model and clamp model, and adjusted the relative dimension, the new fixture is designed, and the figure is show n in Fig.6.
As there is not the analogical fixture in the case library, the new fixture is restored in to the case library. The case index code is 19325513311402000.
6 Conclusion
CBR, as a problem solving methodology, is a more efficient method than an expert system to simulate human thought, and has been developed in many domains where knowledge is difficult to acquire. The advantages of the CBR are as follows: it resembles human thought more closely; the building of a case library which has self learning ability by saving new cases is easier and faster than the building of a rule library; and it supports a better transfer and explanation of new knowledge that is more different than the rule library. A proposed fixture design framework on the CBR has been implemented by using Visual C ++, UG/Open API in U n graphics with Oracle as database support, which also has been integrated with the 32D parametric common component library, common components library and typical fixture library. The prototype system, developed here, is used for the aviation project, and aids the fixture designers to improve the design efficiency and reuse previous design resources.
中文译文
基于事例推理的夹具设计研究与应用
摘要:根据基于事例的设计方法,提出采用工序件的特征信息和夹具的结构特征信息来描述夹具的相似性,并建立了包括这2方面主要特征信息为基础的事例索引码,设计了事例库的结构形式,创建了层次化的事例组织方式；同时,提出了基于知识引导的夹具事例检索算法,以及事例的修改和采用同族事例码进行相似事例的存贮,形成了基于事例推理的夹具设计。所开发的原型系统在型号工程夹具设计等项目的设计过程中得到了应用,并取得了令人满意的使用效果。
关键词: 基于事例的推理 夹具设计 CAD
夹具是以确定工件安全定位准确为目的的装置，并在加工过程中保持工件与刀具或机床的位置一致不变。因为夹具的结构依赖于产品的特点和在企业规划中加工工序的地位,所以它的设计是制造过程中的瓶颈,制约着效率的提高。 夹具设计是一个复杂的过程,需要有从大量的设计论文中了解质量知识的经验，这些设计论文包括工件的结构设计、涉及加工工艺，和加工环境。当用这些擅长绘制详细设计图的传统的CAD工具（如Unigraphics、CATIA、Pro/E)时,这仍然是一项非常耗时的工作，但是利用以往的设计经验和资源也不能提供一些益处,而这正是提高效率的关键因素。 基于事例推理 (CBR) 的方法适应以往个案解决的办法,建立一个新问题的方法,主要有以下四步骤：检索、利用、修改,并保留。这是一个比用专业系统模仿人类思维有用的使用方法，因为提出一个类似的情况,和采用一些修改,似乎不言自明,而且比人类更直观。所以支持不同事例的设计工具已经在诸多领域中发展起来，如在注射成型及设计、建筑设计、模具设计投死, 规划过程中,还有夹具设计。 孙用六个数字组成代码参数,包括工件的形状、机械部分、轴衬,第一定位装置,第二定位装置和夹紧装置。 但这个系统不能用于除钻床夹具外的其他夹具类型,不能解决储存需要保留的同一参数代码的问题,这在CBR中是非常重要的。
1 事例参数和事例图书馆的建立
1.1 事例参数
事例参数应该由工件的所有的特征组成，来区别不同的夹具。 使用他们能够使操作方便. 因为零件的形状是多种多样的, 在生产企业中制造的技术要求也不断发展,许多特征作被用做事例参数将会使搜索速度降低,其主要特征是不重要的,因为分配给每个特征的比重必须减少。 另一方面,事例参数包含所有的特征是困难的。
因此,考虑到实际和快速设计的需求,事例参数要包含工件的主要特征和夹具的结构。事例参数代码由16位数组成：13位数是事例特征3位数是事例识别数字。
前13位数代表13个特征。 每个数字与特征的一个属性相一致,这可能是"*"、"?"、"1"、"2"，…，"A"、"B"，…，"Z"，…，等其中的一个。其中，"*"是指任何一个,"?"代表不确定,"0"代表没有。
系统规定:夹具的类型，工件的形状，位置模式不能是"*"和"?"。在设计系统时,三个项目的属性信息没有这些选择,这就意味着必须选择确定的属性。
最后三位数是事例识别号码,如果事例特征的13位数是一样的,这三个数字就用来区别他们。
该系统还规定:"000"是用于修正的一个典型事例,其他事例"001"、"002"、…,这些是用于设计师查找参考事例的。 如果其中一个偶尔需要改变成典型事例,首先它必须要求改成"000",前面的自动变成参考事例。
事例索引码的结构如图1所示。
1—夹具类型； 6—工件重量； 11—夹紧模型；
2—工件形状； 7—工件刚度； 12—夹具体；
3—工件材料； 8—加工内容； 13—其他；
4—批 量； 9—过程所有物； 14到16—事例识别码；
5—工件比例； 10—定位模型；
图1 事例索引码的结构
1.2 事例库
事例库由许多预定义的事例组成。事例的描述是基于事例推理的最重要的问题之一。所以由索引码复合。
1.3 事例的层次化
夹具的结构相似被认为是整个夹具，成分和内容相似。所以，整个夹具事例库，成分事例库，夹具的成分事例库形成相同。整个夹具的设计资料通常是由工件资料和工件加工资料组成,这就意味着夹具的设计应满足特别功能的需求。全部夹具事例是由功能成分组成，它是用功能成分的名字和数字来进行描述的。成分事例代表成员（成分功能和其他结构成分，主要驱动参数，数字，和它们的约束关系）。成分事例（夹具的最低层）是功能成分和和其他成分的结构。在现代夹具设计中有很多参数化准件和普通非标准件。所以成分事例图书馆应记录特殊参数和保持它们的方法。
2 事例修改的策略
在基于事例的夹具设计中，最重要的是相似点的修改，这样能有助于获得最相似的事例，以及缩短适应时间。根据夹具设计的需求，事例修改的策略使最接近的事例方法和知识指导结合起来。首先在深度上查找，然后在宽度上；知识指导策略意味着在来自客观事物根源的知识规则上查找，这就要首先查找固定类型，然后查找工件的形状，第三查找定位方法。例如，如果事例索引码包括夹具类型的磨削夹具，就只查找所有的磨削夹具，然后查找工件形状的盒子，第三查找一个平面两个销的定位方法。如果没有合适的，就查找深度标点，然后回到最上层，然后再找所有与宽度相关的事例。
修改方法：
1) 根据夹具事例库的事例索引信息，查找有关事例库。
2) 将事例索引码与事例库的每个事例码匹配，然后计算相似尺寸的价值。
3) 整理相似尺寸的次序，最大的架子是最类似的事例。
两个事例之间的相似点是基于两个事例特征之间的相似点。相似点尺寸的计算依靠特征的类型。相似点的价值可以通过数字化的价值来计算，例如比较重量分别是50kg 和 20kg的工件。非数字化的价值也能计算，例如，现在前13位索引码都是非数字化的价值。一个夹具的相似尺寸的计算公式如下：
其中S表示通用夹具的相似尺寸，n表示索引特性数，表示每个特性的重量，表示事例库中特性和相关夹具的特性的相似尺寸。同时， ，数值计算如下：
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