Mechanical design technical requirements
First, stamping parts
1. Sharp edge deburring, stamping cut roughness 6.3.
2. Oxidation treatment of stamping surface: HY or (surface galvanized blunt color. Zn8.DC.).
3. The limit deviation of the unfilled tolerance dimension is in accordance with GB/T 1804-92 m class.
Second, castings
1. Castings must not have defects such as pores, slag inclusions, cracks, etc.
2. The casting inclination is not indicated as 1~2.5°.
3. Casting tolerance according to GB6414-86 CT6.
4. The casting fillet is not indicated as R1~R2.5.
5. The limit deviation of the unfilled tolerance dimension is in accordance with GB/T 1804-92 m class.
6. Unfilled position tolerance according to GB/T1184-96 H class.
7. Deburring, not chamfering 0.5x45°
Third, forgings
1. The radius of the fillet is not forged. R1~R2.
2. The unforged forging slope is 1~1.5°, and the forging tolerance is IT15.
3. The forging structure should be dense, and there should be no defects such as folding and cracking, and go to the flash.
4. Go to the sharp edge burr, blunt at the right angle.
5. The limit deviation of the unfilled tolerance dimension is in accordance with GB/T 1804-92 m class.
6. Unfilled position tolerance according to GB/T1184-96 H class.
Fourth, the piston parts
1. The limit deviation of the unfilled tolerance dimension is in accordance with GB/T 1804-92 m class.
2. Unfilled position tolerance according to GB/T1184-96 H class.
3. Deburring, not scoring 0.5x45°.
4. Surface phosphating.
Five, rubber parts
1. The surface of the part should be smooth and clean. (The surface roughness of the mold should be above Ra0.4) and no bubbles are allowed. Impurities and defects such as bumps and bumps.
2. The mold clamping joint is not allowed to be misplaced, and the thickness of the convex level of the mold clamping flash shall not exceed 0.02mm.
3. Shore A hardness 65%% P5.
4. Go to the net flash.
Six, plastic parts
1. The material should be preheated and dried before forming.
2. After forming, the parts should be smoothed without distortion.
3. The unfilled corner is R0.5.
4. The outer surface should be smooth, its roughness is not greater than Ra0.4. There must be no scratches, nicks and other defects.
5. Unfilled dimensional tolerance according to GB/T 1804-92 m class.
Seven, spring parts
1. Swirling: left-handed.
2. Total number of turns: no=12
3. Number of working circles: no=10
4. Steel wire hardness: HRC42~48.
5. Surface oxidation treatment: HY (commonly known as blackening)
6. Single end and tightly ground.
The basic technical requirements are summarized for reference (specific values, specific terms are determined by the designer according to the actual situation)
1. General technical requirements:
l Parts are descaled.
l There should be no scratches, scratches, etc. on the surface of the part to damage the surface of the part.
l Remove the burr flash.
2. Heat treatment requirements:
l After quenching and tempering treatment, HRC50～55.
l The parts are subjected to high-frequency quenching, tempered at 350-370 °C, and HRC 40-45.
l Carburizing depth is 0.3mm.
l Perform high temperature aging treatment.
3. Tolerance requirements:
l Unfilled shape tolerances shall comply with the requirements of GB1184-80.
l The deviation of the length of the unfilled length is ±0.5mm.
l The casting tolerance band is symmetrical to the basic size configuration of the blank casting.
4. Part corners:
l The fillet radius R5 is not marked.
l The uninterrupted angle is 2×45°.
l Sharp angle is blunt.
5. Assembly requirements:
l Each seal must be saturated with oil before assembly.
l The assembly of rolling bearings allows for hot charging with oil heating. The temperature of the oil must not exceed 100 °C.
l After the gearbox is assembled, the no-load test shall be carried out according to the design and process specifications. There should be no impact or noise during the test, and the temperature rise and leakage should not exceed the relevant standards.
l After gear assembly, the contact spots and side gaps of the tooth surface should meet the requirements of GB10095 and GB11365.
l Seal packing or sealant is allowed when assembling the hydraulic system, but should be prevented from entering the system.
l Parts and components (including purchased parts and external parts) that enter the assembly must have a certificate from the inspection department for assembly.
l Parts must be cleaned and cleaned prior to assembly without burrs, flash, scale, rust, chips, oil, colorants and dust.
l Before assembly, check the main fit dimensions of the parts and components, especially the interference fit size and related accuracy.
l Parts are not allowed to be scratched, bumped, scratched and rusted during assembly.
l When tightening screws, bolts and nuts, it is strictly forbidden to strike or use improper screwdrivers and wrenches. The screw groove, nut and screw, and the head of the bolt must not be damaged after tightening.
l Fasteners that specify tightening torque requirements must be torque wrenches and tightened to the specified tightening torque.
l When the same part is fastened with multiple screws (bolts), each screw (bolt) should be crossed, symmetrical, stepwise, and evenly tightened.
l When the tapered pin is assembled, the hole should be inspected with color. The contact rate should not be less than 60% of the length of the fit and should be evenly distributed.
l The flat key should be evenly contacted on both sides of the keyway on the shaft, and there should be no clearance on the mating surface.
l The number of flank contacts in the spline assembly is not less than 2/3, and the contact rate shall not be less than 50% in the length and height direction of the key teeth.
After the sliding flat key (or spline) is assembled, the phase accessories move freely without any unevenness.
l Remove excess adhesive from the adhesive after bonding.
l The outer ring of the bearing and the semi-circular hole of the open bearing housing and bearing cap are not allowed to jam.
l The outer ring of the bearing should be in good contact with the semi-circular hole of the open bearing seat and the bearing cap. When the color is checked, it should be evenly symmetrical with the bearing seat at 120° from the center line and 90° from the bearing cover in the symmetry to the center line. contact. When using a feeler gauge within the above range, a 0.03 mm feeler gauge shall not be inserted into 1/3 of the width of the outer ring.
l After the outer ring of the bearing is assembled, it should be in even contact with the end face of the bearing end of the positioning end.
l After the rolling bearing is installed, it should be flexible and stable by hand rotation.
l The joint surface of the upper and lower bearing bushes should be closely attached and inspected with a 0.05mm feeler gauge.
l When fixing the bearing bush with the positioning pin, the hinge and the pin should be drilled while ensuring that the opening and the end face of the mouth and the end of the relevant bearing hole are flush. Do not loosen after the pin is inserted.
l The bearing body and the bearing seat of the spherical bearing should be in uniform contact. Check by the coloring method, the contact should not be less than 70%.
l When the surface of the alloy bearing lining is yellow, it is not allowed to use. The nuclear separation phenomenon is not allowed within the specified contact angle. The area outside the contact angle shall not be greater than 10% of the total area of ​​the non-contact area.
l The reference end face of the gear (worm gear) and the shoulder (or the end face of the positioning sleeve) should be fitted together, and the 0.05 mm feeler gauge should not be used. The verticality requirement of the reference end face of the gear and the axis should be ensured.
l The joint surface of the gear box and the cover should be in good contact.
l Strictly check and remove the sharp corners, burrs and foreign objects remaining during the machining of the parts before assembly. Ensure that the seal is not scratched when it is installed.
6. Casting requirements:
l Cold insulation, cracks, shrinkage and penetrating defects and severe defects (such as under-casting, mechanical damage, etc.) are not allowed on the surface of the casting.
l The castings should be cleaned and free of burrs and burrs. Non-machining indicates that the pouring risers should be cleaned and flush with the surface of the casting.
l The casting and marking on the non-machined surface of the casting should be clearly identifiable, and the position and font should conform to the requirements of the drawing.
l The roughness of the non-machined surface of the casting, sand casting R, not more than 50μm.
l Castings should be cleaned of pouring risers, flying thorns, etc. The residual amount of the riser on the non-machined surface should be leveled and polished to meet the surface quality requirements.
l The molding sand, core sand and core bone on the casting should be cleaned.
l The casting has a slanted part, and its dimensional tolerance zone should be symmetrically arranged along the inclined surface.
l The molding sand, core sand, core bone, fleshy, sticky sand on the casting should be shoveled and cleaned.
l The wrong type, the boss casting, etc. should be corrected to achieve a smooth transition and ensure the appearance quality.
l Wrinkles on the non-machined surface of the casting, the depth is less than 2mm, and the spacing should be greater than 100mm.
l The non-machined surface of the machine product casting needs to be shot blasted or drum treated to achieve the cleanliness Sa2 1/2 level.
The casting must be water toughened.
l The surface of the casting should be flat, and the gate, burr, and sand should be removed.
l Castings are not allowed to have casting defects such as cold partitions, cracks, holes, etc. that are detrimental to use.
7. Painting requirements:
l All steel parts that need to be painted must be removed from rust, scale, grease, dust, dirt, salt and dirt before painting.
l Before removing rust, remove the grease and dirt on the surface of the steel parts with organic solvents, lye, emulsifiers, steam, etc.
l The time between the surface to be coated and the primer to be blasted or manually descaled shall not exceed 6h.
l The surfaces of the rivet joints that are in contact with each other must be coated with a 30 to 40 μm anti-rust paint before joining. The lap joints are closed with paint, putty or adhesive. Repaint due to processing or welding damaged primer.
8. Piping requirements:
l All tubes before assembly should be removed from the tube end, burrs and chamfered. Use compressed air or other methods to clear the debris and rust attached to the inner wall of the pipe.
l Prior to assembly, all steel pipes (including pre-formed pipes) are degreased, pickled, neutralized, washed, and rust-proof.
l When assembling, tighten the pipe clamps, supports, flanges and joints that are screwed to prevent looseness.
l The prefabricated pipe joints are subjected to a pressure test.
l When piping is replaced or transported, the pipe separation port must be sealed with tape or plastic pipe to prevent any debris from entering and smashing the label.
9. Repair weldment requirements:
l The defects must be completely removed before repair welding, and the groove surface should be smooth and smooth, and no sharp corners should exist.
l According to the defects of the steel castings, the defects in the repair welding zone can be removed by shovel, grinding, carbon arc gouging, gas cutting or mechanical processing.
l The sand, oil, water, rust and other dirt within 20mm around the repairing zone and the groove must be thoroughly cleaned.
l During the whole process of repair welding, the temperature of the preheating zone of the steel castings shall not be lower than 350 °C.
l Apply welding as much as possible to the horizontal position, if possible.
l When repairing the welding, the welding rod should not be subjected to excessive lateral oscillation.
l When the surface of the steel casting is welded, the overlap between the weld bead shall not be less than 1/3 of the width of the weld bead.
10. Forging requirements:
l The nozzle and riser of each ingot should have sufficient removal to ensure that the forging has no shrinkage holes and severe deflection.
l Forgings should be forged on a forging press with sufficient capacity to ensure full forging inside the forgings.
l Forgings are not allowed to have visible cracks, folds and other appearance defects that affect the use. Local defects can be removed, but the cleaning depth should not exceed 75% of the machining allowance. The defects on the non-machined surface of the forging should be cleaned and smoothed.
White spots, internal cracks and residual shrinkage cavities are not allowed in forgings.
11. Cutting processing requirements:
l Parts should be inspected and accepted according to the process. After passing the previous process inspection, they can be transferred to the next process.
l No burrs are allowed on the machined parts.
l After the finished parts are placed, they should not be placed directly on the ground. The necessary support and protection measures should be taken. The machined surface is not allowed to have rust and defects such as bumps and scratches that affect performance, life or appearance.
l Roll the finished surface without peeling after rolling.
l The parts after heat treatment in the final process should have no scale on the surface. The finished mating surface and tooth surface should not be annealed, blue, or discolored.
l The surface of the machined thread is not allowed to have defects such as black skin, bumps, clasps and burrs.
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