工序余量切实实在定45790[资料]

工序余量切实实在定45790[资料]4.3工序余量的确定4.3.1轴的加工余量(见表4-38,表4-43)表4-38轴的折算长度(确定半精车及磨削加工余量)注:轴类零件的加工中受力变形与其长度和装夹方式(顶尖或卡盘)有关。轴的折算长度可分为表中五中情形。(1)、(2)、(3)轴件装在顶尖间或装在卡盘与顶尖，相当二支梁。其种(2)为加工轴的中段。(3)为加工轴的边缘(靠近端部的两段)，轴的折算长度L是轴的端面到加工部分最远一端距离的2倍。(4)、(5)轴件仅一端夹紧在卡盘内，相当于悬臂梁，其折算长度是卡盘端面到加工部分最远一端之间距离的2倍。表4-39粗车及半精车外圆加工余量及偏差mm直径余量直径偏差半精车经或未经热处理零件基本零件的粗车未经热处理经热处理荒车粗车尺寸(h14)(h12,h13)折算长度?>200,?>200,?>200,2004002004002004003~60.50.8-0.30————-0.12,-0.18>6~101.51.70.81.01.01.3-0.36-0.15,-0.22>10~181.51.71.01.31.31.5-0.43-0.18,-0.27>18~302.02.21.31.31.31.5-0.52-0.21,-0.33>30~502.02.21.41.51.51.9-0.62-0.25,-0.39>50~802.32.51.51.81.82.0-0.74-0.30,-0.54>80~1202.52.81.51.81.82.0-0.87-035,-0.54>120~1802.52.81.82.02.02.3-1.00-0.40,-0.63>180~2502.83.02.02.32.32.5-1.15-0.46,-0.72>250~3153.03.32.02.32.32.5-1.30-0.52,-0.81注:加工带凸台的零件时，其加工余量要根据零件的最大直径来确定。表4-40半精车后磨外圆加工余量及偏差mm直径余量直径偏差第一种第二种第三种第一种磨削前热处理后第二种经或未经热处热处理前粗热处理后零件基本半精车粗磨理零件的终磨磨半精磨尺寸粗磨半精磨或第三(h8~h9种粗磨)折算长度(h10~h11)>200~>200>200~4>200~4>200?????400~4000000~400200200200200200-0.048,-0.018,3~60.150.200.100.120.050.08————-0.075-0.030-0.058,-0.022,>6~100.200.300.120.200.080.100.120.200.200.30-0.090-0.036-0.070,-0.027,>10~180.200.300.120.200.080.100.120.200.200.30-0.110-0.043-0.084,-0.033,>18~300.200.300.120.200.080.100.120.200.200.30-0.130-0.052-0.100,-0.039,>30~500.300.400.200.250.100.150.200.250.300.40-0.160-0.062-0.120,-0.064,>50~800.400.500.250.300.150.200.250.300.400.50-0.190-0.074-0.140,-0.054,>80~1200.400.500.250.300.150.200.250.300.400.50-0.220-0.087-0.160,-0.063,>120~1800.500.800.300.500.200.300.300.500.500.80-0.250-0.100-0.185,-0.072,>180~2500.500.800.300.500.200.300.300.500.500.80-0.290-0.115-0.210,-0.081,>250~3150.500.800.300.500.200.300.300.500.500.80-0.320-0.130表4-41用金钢石刀精车外圆加工余量及偏差mm零件材料零件基本尺寸直径加工余量?1000.3轻合金0.5,100?1000.3青铜及铸铁0.4,100?1000.2钢0.3,100表4-42半精车轴端面加工余量及偏差mm端面最大余量粗车端面尺寸零件长度?30>30,120>120,260>260,500>500偏差(全长)(IT12-IT13)端面余量-0.15,-0.22?100.50.61.01.21.4-0.18,-0.27>10,180.50.71.01.21.4-0.21,-0.33>18,300.61.01.21.31.5-0.25,-0.39>30,500.61.01.21.31.5>50,800.71.01.31.51.7-0.30,-0.46-0.35,-0.54>80,1201.01.01.31.51.7-0.40,-0.63>12,1801.01.31.51.71.8>18,2501.01.31.51.71.8-0.46,-0.72>25,5001.21.41.51.71.8-0.52,-0.97>5001.41.51.71.82.0-0.70,-1.10注:1.加工有台阶的轴时，每台阶的加工余量应根据该台阶的直径及零件全长分别选用。2.表面余量指单边余量，偏差指长度偏差。3.加工余量及偏差使用于经热处理及未经热处理的零件。表4-43磨轴端面加工加工余量及偏差mm端面最大余量半精车车端面零件长度?30>30,120>120,260>260,500>500尺寸偏差(IT11)端面余量-0.09?100.20.20.30.40.6-0.11>10,180.20.30.30.40.6>18,300.20.30.30.40.6-0.13>30,500.20.30.30.40.6-0.16>50,800.30.30.40.50.6-0.19-0.22>80,1200.30.30.50.50.6-0.25>120,1800.30.40.50.60.7>180,2500.30.40.50.60.7-0.29>250,5000.40.50.60.70.8-0.40>5000.50.60.70.70.8-0.44注:1.加工有台阶的轴时，每台阶的加工余量应根据该台阶的直径及零件全长分别选用。2.表中余量指单边余量，差指长度偏差。3.工余量及偏差使用于经热处理及未经热处理的零件。见表4-44,表4-48)4.3.2孔、槽的加工余量(表4-44基孔制7、8级精度(H7、8)孔的加工mm直径直径加加精铰工用车用车精铰工扩孔(H7、孔扩孔钻刀镗粗铰钻刀镗粗铰(H7、孔钻H8、H9)的钻以后以后H8、H9)的孔孔径径第第第第一二一二次次次次32.9———————3H73015.02829.829.829.9330H743.9———————4H73215.030.031.731.7531.9332H754.8———————5H73520.033.034.734.7534.9335H765.8———————6H73820.036.037.737.7537.9338H787.8—————7.968H74025.038.039.739.7539.9340H7109.8—————9.9610H74225.040.041.741.7541.9342H71211.0———11.8511.9512H74525.043.044.744.7544.9345H71312.0———12.8512.9513H74825.046.047.747.7547.9348H71413.0———13.8513.9514H75025.048.049.749.7549.9350H71514.0———14.8514.9515H7603055.059.559.559.960H71615.0———15.8515.9516H7703065.069.569.569.970H71817.0———17.8517.9418H7803075.079.579.579.980H72018.0—19.819.819.9420H7903080.089.5——89.990H72220—21.821.821.9422H71003080.099.3——99.8100H72422—23.822.823.9424H71203080.0119.3——119.8120H72523—24.824.824.9425H71403080.0139.3——139.8140H72624—25.825.825.9426H71603080.0159.3——159.8160H72826—27.827.827.9428H71803080.0179.3——179.8180H7注:1.在铸铁上加工直径小于15mm的孔时，不用扩孔钻和镗孔。2.在铸铁上加工直径为30与32mm的孔时，仅用直径为28与30mm的钻头各钻一次。3.如仅用一次铰孔，则铰孔的加工余量为本表中与精铰的加工余量之和。4.钻头直径大于75mm时采用环孔钻。表4-45按照7级或8级精度的加工预先铸出或冲出的孔加工粗镗精镗孔的粗铰精铰第一次第二次镗以后的直径按照H11公差孔径30—2829.7，0.1329.933035,3334.7，0.1634.933540,3839.7，0.1639.934045,4344.7，0.1644.934550454849.7，0.1649.935055515354.5，0.1954.925560565859.5，0.1959.926065616364.5，0.1964.926570666869.5，0.1969.907075717374.5，0.1974.907580757879.5，0.1979.908085808384.3，0.2284.858590858889.3，0.2289.759095909394.3，0.2294.8595100959899.3，0.2299.85100注:1.如仅用一次铰孔时，则铰孔的加工余量为粗铰与精铰加工余量之和。2.如铸出的孔有最大加工余量时，则第一次粗镗可以分成两次或多次进行表4-46半精镗后磨圆孔加工余量及偏差直径余量直径第一种第二种第三种终磨前半精镗基本尺寸经或未经热处理或第三种粗磨热处理前热处理后半热处理零(H10)粗磨精磨粗磨半径磨件的终磨6~100.2—————>10~180.30.20.10.20.3+0.07>18~300.30.20.10.20.3+0.084>30~500.30.20.10.30.4+0.10>50~800.40.30.10.30.4+0.12>80~1200.50.30.20.30.5+0.14>120~1800.50.30.20.50.5+0.16表4-47花键孔拉削余量/mm花键规格定心方式键数Z外径D外径定心内径定心635~420.4~0.50.7~0.8645~500.5~0.60.8~0.9655~900.6~0.70.9~1.01030~420.4~0.50.7~0.810450.5~0.60.8~0.916380.4~0.50.7~0.816500.5~0.60.8~0.9表4-48凹槽加工余量及偏差/mm凹槽尺寸宽度余量宽度偏差粗铣后半精铣粗铣半精铣长深宽半精铣后磨(IT12,13)(IT11)>3,61.50.5+0.12,+0.18+0.075>6,102.00.7+0.15,+0.22+0.09>10,183.01.0+0.18,+0.27+0.11?80?60>18,303.01.0+0.21,+0.33+0.13>30,503.01.0+0.25,+0.39+0.16>50,804.01.0+0.30,+0.46+0.19>80,1204.01.0+0.35,+0.54+0.224.3.3平面加工余量(见表4-49,表4-53)表4-49平面粗加工余量/mm毛坯制造方法铸件平面最大尺寸热冲压冷冲压锻造灰铸铁青铜可煅铸铁?501.0,1.51.0,1.30.8,1.00.8,1.10.6,0.81.0,1.4>50,1201.5,2.01.3,1.71.0,1.41.3,1.80.8,1.11.4,1.8>120,2602.0,2.71.7,2.21.4,1.81.5,1.81.0,1.41.5,2.5>260,5002.7,3.52.2,3.02.0,2.51.8,3.21.3,1.82.2,3.0>5004.0,6.03.5,4.53.0,4.02.4,3.02.0,2.63.5,4.5表4-50平面粗刨后精铣加工余量mm平面宽度平面长度?100>100,200>200?1000.6,0.7-------->100,2500.6,0.80.7,0.9---->250,5000.7,1.00.75,1.00.8,1.1>5000.8,1.00.9,1.20.9,1.2表4-51铣平面加工余量mm荒铣后粗铣粗铣后半精铣宽度?200宽度>200,400宽度?200宽度>200,400零件平面长度厚>250>100>250>100>250>100>250>100,?度?100,?100,,?100,,,,250100400250400250400250400>6,1.01.21.51.21.51.70.71.01.01.01.01.030>30,1.01.51.71.51.52.01.01.01.21.01.21.2501.51.72.01.72.02.51.01.31.51.31.51.5>50表4-51磨平面加工余量mm表4-53铣及磨平面时的厚度偏差零件厚度荒铣(IT14)粗铣(IT12,13)半精铣(IT11)精磨(IT8,IT9)>3,6-1.30-0.12,-0.18-0.075-0.018,-0.030>6,10-0.36-0.15,-0.22-0.09-0.022,-0.036>10,18-0.43-0.18,-0.27-0.11-0.027,-0.043>18,30-0.52-0.21,-0.33-0.13-0.033,-0.052>30,50-0.62-0.25,-0.39-0.16-0.039,-0.062>50,80-0.73-0.30,-0.46-0.19-0.046,-0.074>80,120-0.87-0.35,-0.54-0.22-0.054,-0.087>120,180-1.00-0.43,-0.63-0.25-0.063,-0.1004.3.4齿轮及花键加工(见表5-54,表5-56)表5-54齿轮精加工余量模数23456789101112精滚齿或精插齿0.60.750.91.051.21.351.51.71.92.12.2磨齿0.150.20.230.260.290.320.350.380.40.450.5?500.080.090.10.110.12剃D,50,1000.090.10.110.120.14齿,100,2000.120.130.140.150.16表4-55精铣花键的加工余量花键长度?100>100,200>200,350>350,500花键轴基本尺寸花键厚度及直径的加工余量------------?10,180.4,0.60.5,0.7-----,18,300.5,0.70.6,0.80.7,0.9----,30,500.6,0.80.7,0.90.8,1.0,500.7,0.90.8,1.00.9,1.21.2,1.5表4-56磨花键的加工余量花键长度花键轴基本尺寸?100>100,200>200,350>350,500花键厚度及直径的加工余量?10,180.1,0.20.2,0.3------------------->18,300.1,0.20.2,0.30.2,0.4------>30,500.2,0.30.2,0.40.3,0.5----------->500.2,0.40.3,0.50.3,0.50.4,0.6