第一部分(fen)：齒輪、軸類零(ling)件
1.齒輪(lun)加工工藝流程(cheng)
根據不同結構要求(qiu)，齒(chi)輪零件(jian)加工主要工藝流程采用的(de)是(shi)鍛造(zao)制坯(pi)→正火→精車加工→插齒(chi)→倒尖角→滾齒(chi)→剃齒(chi)→（焊接）→熱(re)處理(li)→磨(mo)加工→對(dui)嚙(nie)修(xiu)整。
熱后齒(chi)部一般不再加工，除了主減從齒(chi)或顧客(ke)要(yao)求磨齒(chi)的零件。
2.軸類工藝流程
輸入(ru)軸：鍛(duan)造制坯→正(zheng)火→精車加(jia)工→搓齒(chi)→鉆(zhan)孔→插齒(chi)→倒尖(jian)角→滾齒(chi)→剃齒(chi)→熱(re)處(chu)理→磨加(jia)工→對(dui)嚙(nie)修整。
輸出軸(zhou)：鍛造制坯→正(zheng)火→精車加(jia)工→搓齒滾(gun)齒→剃齒→熱處理→磨(mo)加(jia)工→對嚙修(xiu)整。
3.具體工藝流程
(1)鍛(duan)(duan)造(zao)制坯：熱模鍛(duan)(duan)是汽車齒輪件廣泛使用的(de)(de)毛坯鍛(duan)(duan)造(zao)工(gong)藝。以前較廣泛采用的(de)(de)是熱鍛(duan)(duan)和冷(leng)擠壓(ya)的(de)(de)毛坯，近(jin)年來，楔橫軋(ya)技(ji)術在軸(zhou)(zhou)類加工(gong)上(shang)得到了大量(liang)推廣。這項技(ji)術特別適合為比較復雜的(de)(de)階梯軸(zhou)(zhou)類制坯，它(ta)不僅精度較高、后序加工(gong)余(yu)量(liang)小(xiao)而且生產(chan)效率高。
(2)正(zheng)(zheng)火(huo)：這一(yi)工(gong)(gong)藝的(de)(de)目的(de)(de)是獲得適(shi)合后序(xu)齒輪切削(xue)加(jia)工(gong)(gong)的(de)(de)硬度(du)和為最(zui)終熱處(chu)理(li)做組(zu)織準備，以有效(xiao)地(di)減少(shao)熱處(chu)理(li)變(bian)形。一(yi)般(ban)的(de)(de)正(zheng)(zheng)火(huo)由于受人員、設備和環境的(de)(de)影響比較(jiao)(jiao)大，使得工(gong)(gong)件冷(leng)卻速(su)度(du)和冷(leng)卻的(de)(de)均勻(yun)性(xing)難以控制，造成硬度(du)散差(cha)大，金相(xiang)組(zu)織不(bu)均勻(yun)，直(zhi)接影響機(ji)加(jia)工(gong)(gong)和最(zui)終熱處(chu)理(li)；使得熱變(bian)形大而無規律，零件質(zhi)量無法控制，對刀具(ju)的(de)(de)磨損也(ye)較(jiao)(jiao)大，尤其對搓齒這種(zhong)受力大的(de)(de)工(gong)(gong)序(xu)更是明顯。為此(ci)，采用(yong)等(deng)(deng)溫(wen)正(zheng)(zheng)火(huo)工(gong)(gong)藝。實踐(jian)證明，采用(yong)這種(zhong)等(deng)(deng)溫(wen)正(zheng)(zheng)火(huo)有效(xiao)地(di)改變(bian)了一(yi)般(ban)正(zheng)(zheng)火(huo)的(de)(de)弊端，產品質(zhi)量穩(wen)定可靠。
(3)精(jing)車加(jia)工(gong)(gong)：為了(le)滿(man)足高(gao)(gao)精(jing)度齒(chi)(chi)(chi)(chi)輪加(jia)工(gong)(gong)的定位(wei)要求.齒(chi)(chi)(chi)(chi)坯(pi)的精(jing)車加(jia)工(gong)(gong)全部采用數(shu)控車床(chuang).齒(chi)(chi)(chi)(chi)輪先(xian)進行內(nei)孔和定位(wei)端(duan)面的加(jia)工(gong)(gong)，然后(hou)另一(yi)端(duan)面及外(wai)徑(jing)加(jia)工(gong)(gong)同步完成。既保證了(le)內(nei)孔與(yu)定位(wei)端(duan)面的垂直度要求，又保證了(le)大批(pi)量齒(chi)(chi)(chi)(chi)坯(pi)生產(chan)的尺寸離散(san)小。從而提高(gao)(gao)了(le)齒(chi)(chi)(chi)(chi)坯(pi)精(jing)度，確保了(le)后(hou)序(xu)齒(chi)(chi)(chi)(chi)輪的加(jia)工(gong)(gong)質量。另外(wai)，數(shu)控車床(chuang)加(jia)工(gong)(gong)的高(gao)(gao)效率(lv)還(huan)大大減少了(le)設備數(shu)量，經濟性好(hao)。
軸(zhou)類零(ling)件加工(gong)(gong)(gong)的(de)定位基準和(he)裝夾主(zhu)要(yao)有以下三種方式：○1 以工(gong)(gong)(gong)件的(de)中心(xin)孔定位：在軸(zhou)的(de)加工(gong)(gong)(gong)中，零(ling)件各(ge)外圓表面(mian)、端(duan)面(mian)的(de)同軸(zhou)度，端(duan)面(mian)對旋(xuan)轉軸(zhou)線的(de)垂直度是其相互位置精度的(de)主(zhu)要(yao)項(xiang)目，這些(xie)表面(mian)的(de)設計基準一般都是軸(zhou)的(de)中心(xin)線，若用兩中心(xin)孔定位，符(fu)合(he)基準重合(he)的(de)原則。
中(zhong)心(xin)孔(kong)不僅是車削(xue)時(shi)的(de)(de)定(ding)為(wei)(wei)基(ji)(ji)(ji)(ji)(ji)(ji)準，也(ye)是其他加(jia)工(gong)(gong)工(gong)(gong)序的(de)(de)定(ding)位(wei)(wei)基(ji)(ji)(ji)(ji)(ji)(ji)準和(he)檢驗基(ji)(ji)(ji)(ji)(ji)(ji)準，又(you)符合基(ji)(ji)(ji)(ji)(ji)(ji)準統一(yi)(yi)原(yuan)則。當(dang)采(cai)(cai)用(yong)(yong)兩中(zhong)心(xin)孔(kong)定(ding)位(wei)(wei)時(shi)，還能夠最(zui)大限度(du)地在一(yi)(yi)次裝(zhuang)夾中(zhong)加(jia)工(gong)(gong)出(chu)多個外(wai)(wai)(wai)圓(yuan)和(he)端面(mian)(mian)。○2 以外(wai)(wai)(wai)圓(yuan)和(he)中(zhong)心(xin)孔(kong)作(zuo)(zuo)(zuo)為(wei)(wei)定(ding)位(wei)(wei)基(ji)(ji)(ji)(ji)(ji)(ji)準（一(yi)(yi)夾一(yi)(yi)頂）：用(yong)(yong)兩中(zhong)心(xin)孔(kong)定(ding)位(wei)(wei)雖然定(ding)心(xin)精度(du)高(gao)，但(dan)剛性差，尤其是加(jia)工(gong)(gong)較重的(de)(de)工(gong)(gong)件(jian)(jian)時(shi)不夠穩固(gu)，切削(xue)用(yong)(yong)量也(ye)不能太大。粗加(jia)工(gong)(gong)時(shi)，為(wei)(wei)了提高(gao)零件(jian)(jian)的(de)(de)剛度(du)，可采(cai)(cai)用(yong)(yong)軸(zhou)(zhou)的(de)(de)外(wai)(wai)(wai)圓(yuan)表(biao)面(mian)(mian)和(he)一(yi)(yi)中(zhong)心(xin)孔(kong)作(zuo)(zuo)(zuo)為(wei)(wei)定(ding)位(wei)(wei)基(ji)(ji)(ji)(ji)(ji)(ji)準來加(jia)工(gong)(gong)。這種(zhong)定(ding)位(wei)(wei)方法(fa)能承受較大的(de)(de)切削(xue)力矩，是軸(zhou)(zhou)類零件(jian)(jian)最(zui)常見(jian)的(de)(de)一(yi)(yi)種(zhong)定(ding)位(wei)(wei)方法(fa)。 ○3 以兩外(wai)(wai)(wai)圓(yuan)表(biao)面(mian)(mian)作(zuo)(zuo)(zuo)為(wei)(wei)定(ding)位(wei)(wei)基(ji)(ji)(ji)(ji)(ji)(ji)準：在加(jia)工(gong)(gong)空心(xin)軸(zhou)(zhou)的(de)(de)內孔(kong)時(shi)，（例如：機床(chuang)上(shang)莫氏(shi)錐度(du)的(de)(de)內孔(kong)加(jia)工(gong)(gong)），不能采(cai)(cai)用(yong)(yong)中(zhong)心(xin)孔(kong)作(zuo)(zuo)(zuo)為(wei)(wei)定(ding)位(wei)(wei)基(ji)(ji)(ji)(ji)(ji)(ji)準，可用(yong)(yong)軸(zhou)(zhou)的(de)(de)兩外(wai)(wai)(wai)圓(yuan)表(biao)面(mian)(mian)作(zuo)(zuo)(zuo)為(wei)(wei)定(ding)位(wei)(wei)基(ji)(ji)(ji)(ji)(ji)(ji)準。當(dang)工(gong)(gong)件(jian)(jian)是機床(chuang)主軸(zhou)(zhou)時(shi)，常以兩支撐軸(zhou)(zhou)頸(jing)(jing)（裝(zhuang)配基(ji)(ji)(ji)(ji)(ji)(ji)準）為(wei)(wei)定(ding)位(wei)(wei)基(ji)(ji)(ji)(ji)(ji)(ji)準，可保(bao)證錐孔(kong)相對支撐軸(zhou)(zhou)頸(jing)(jing)的(de)(de)同軸(zhou)(zhou)度(du)要(yao)求，消除(chu)基(ji)(ji)(ji)(ji)(ji)(ji)準不重合而引起的(de)(de)誤差。
(4)搓/滾(gun)/插齒(chi)：加(jia)工(gong)齒(chi)部所(suo)用設(she)備仍大量采用普通滾(gun)齒(chi)機和(he)插齒(chi)機，雖然調(diao)整維(wei)護(hu)方便，但生產(chan)效(xiao)率較(jiao)低，若完成(cheng)較(jiao)大產(chan)能需要多機同時生產(chan)。隨著涂層技術的發展，滾(gun)刀(dao)(dao)、插刀(dao)(dao)刃磨后(hou)的再次涂鍍可方便地進(jin)行。經過涂鍍的刀(dao)(dao)具能夠明顯地提(ti)(ti)高耐用度，一(yi)般能提(ti)(ti)高90%以(yi)上，有效(xiao)地減少了換刀(dao)(dao)次數(shu)和(he)刃磨時間(jian)，效(xiao)益顯著。
對于花鍵的(de)(de)加工(gong)，為(wei)解決插(cha)齒(chi)(chi)(chi)效(xiao)(xiao)率(lv)低的(de)(de)問題，可以采用搓齒(chi)(chi)(chi)進行加工(gong)，效(xiao)(xiao)率(lv)大(da)(da)大(da)(da)提高，加工(gong)一檔花鍵需要(yao) 10～30s的(de)(de)時間(jian)。加工(gong)的(de)(de)插(cha)齒(chi)(chi)(chi)設(she)(she)備主要(yao)有(you)德國Gleason-Pfauter插(cha)齒(chi)(chi)(chi)機(ji)(ji)(ji)、南京YS5120CNC等，滾齒(chi)(chi)(chi)設(she)(she)備主要(yao)有(you)日本KASHIFUJI 數控滾齒(chi)(chi)(chi)機(ji)(ji)(ji)、重慶YS3118五(wu)軸數控滾齒(chi)(chi)(chi)機(ji)(ji)(ji)、YKX3132 數控滾齒(chi)(chi)(chi)機(ji)(ji)(ji)等，滾齒(chi)(chi)(chi)設(she)(she)備主要(yao)有(you)德國EXCELLO搓齒(chi)(chi)(chi)機(ji)(ji)(ji)和日本KASHIFUJI搓齒(chi)(chi)(chi)機(ji)(ji)(ji)等。
(5)剃(ti)(ti)齒(chi)(chi)：徑向剃(ti)(ti)齒(chi)(chi)技(ji)術(shu)以其效率高(gao)，設計(ji)齒(chi)(chi)形(xing)(xing)、齒(chi)(chi)向的(de)修形(xing)(xing)要求易于(yu)實現(xian)的(de)優勢被廣泛應用(yong)于(yu)大(da)批量汽(qi)車齒(chi)(chi)輪生產中(zhong)。齒(chi)(chi)形(xing)(xing)、齒(chi)(chi)向對(dui)汽(qi)車的(de)噪(zao)(zao)聲影(ying)響是較大(da)的(de)，通過(guo)對(dui)其修形(xing)(xing)和(he)反扭曲修正可(ke)降低變速(su)器的(de)傳動噪(zao)(zao)聲。
(6)熱(re)處(chu)理：汽車(che)齒(chi)輪要求(qiu)滲(shen)碳淬(cui)火.以保(bao)證其設計要求(qiu)的(de)(de)良好機(ji)械性能。對于熱(re)后(hou)不再進行磨(mo)齒(chi)加工的(de)(de)產(chan)品，穩定(ding)可靠(kao)的(de)(de)熱(re)處(chu)理設備(bei)是必不可缺的(de)(de)。
(7)磨(mo)(mo)(mo)加工(gong)：金(jin)屬(shu)(shu)磨(mo)(mo)(mo)削(xue)(xue)的(de)(de)(de)(de)實質是(shi)工(gong)件(jian)被磨(mo)(mo)(mo)削(xue)(xue)的(de)(de)(de)(de)金(jin)屬(shu)(shu)表層，在無數磨(mo)(mo)(mo)粒(li)瞬間的(de)(de)(de)(de)擠壓，摩(mo)擦作用(yong)下生產變形，而后轉(zhuan)為磨(mo)(mo)(mo)屑，并形成光潔(jie)表示的(de)(de)(de)(de)過程。主(zhu)要(yao)是(shi)對(dui)經過熱(re)處理的(de)(de)(de)(de)齒輪內孔。端面(mian)(mian)、軸的(de)(de)(de)(de)外徑等(deng)部(bu)分的(de)(de)(de)(de)精加工(gong)，以提高(gao)尺寸精度和形位精度。齒輪加工(gong)采用(yong)節(jie)圓夾具(ju)定位夾緊，能有效(xiao)保證齒部(bu)與安裝基準的(de)(de)(de)(de)加工(gong)精度，獲(huo)得滿(man)意的(de)(de)(de)(de)產品質量。磨(mo)(mo)(mo)削(xue)(xue)精度通常達到(dao) IT6～IT7 公(gong)差等(deng)級，表面(mian)(mian)粗(cu)糙(cao)度可達Ra1.25～0.16um。主(zhu)要(yao)的(de)(de)(de)(de)磨(mo)(mo)(mo)加工(gong)設備有德(de)國BUDERUS、意大利 MORARA、瑞士STUDER、北京(jing)數控磨(mo)(mo)(mo)床等(deng)。
(8) 磨(mo)(mo)(mo)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)：采用(yong)(yong)磨(mo)(mo)(mo)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)加(jia)(jia)工(gong)(gong)(gong)(gong)的齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)具有(you)低傳動(dong)噪音(yin)、高傳動(dong)效率和(he)長使用(yong)(yong)壽命(ming)的優點。現(xian)在(zai)(zai)，隨著磨(mo)(mo)(mo)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)機的效率的逐漸提高，砂輪(lun)性能(neng)也更好(hao)，高額成(cheng)(cheng)本得以大幅下降。由此，磨(mo)(mo)(mo)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)加(jia)(jia)工(gong)(gong)(gong)(gong)已開始大規模應(ying)用(yong)(yong)于汽(qi)車齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)加(jia)(jia)工(gong)(gong)(gong)(gong)中，而且已達到普(pu)遍應(ying)用(yong)(yong)的程度。而且由于磨(mo)(mo)(mo)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)加(jia)(jia)工(gong)(gong)(gong)(gong)能(neng)去掉熱處理畸變，因此許多齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)箱均(jun)使用(yong)(yong)磨(mo)(mo)(mo)削齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)，以更好(hao)地(di)控(kong)制傳動(dong)空程和(he)噪音(yin)。磨(mo)(mo)(mo)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)加(jia)(jia)工(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)藝在(zai)(zai)整個(ge)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)行(xing)業中已基本成(cheng)(cheng)熟并(bing)在(zai)(zai)快(kuai)速增長。主要的磨(mo)(mo)(mo)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)加(jia)(jia)工(gong)(gong)(gong)(gong)設備(bei)有(you)美國(guo)Gleason-245TWG、德國(guo)KAPP300X 等。
(9)對嚙(nie)修(xiu)整：這是(shi)變速驅動(dong)橋齒(chi)輪裝配(pei)前(qian)對齒(chi)部進行(xing)磕(ke)碰毛(mao)刺的(de)檢(jian)查(cha)清理，以消除(chu)它們在裝配(pei)后(hou)引(yin)起的(de)噪(zao)聲異(yi)響。通過(guo)單對嚙(nie)合聽聲音或在綜合檢(jian)查(cha)儀上觀察嚙(nie)合偏差來完(wan)成。也(ye)多采用的(de)是(shi)自動(dong)對嚙(nie)儀來檢(jian)查(cha)毛(mao)刺、中心距(ju)、跳動(dong)。
第二(er)部分：殼體類零件
（1）工(gong)(gong)(gong)(gong)藝(yi)(yi)流(liu)程：箱體(ti)類工(gong)(gong)(gong)(gong)件(jian)具有以(yi)下幾個特點：一是(shi)加(jia)工(gong)(gong)(gong)(gong)內容多，需頻繁更(geng)換機(ji)(ji)床(chuang)、刀(dao)具；二是(shi)加(jia)工(gong)(gong)(gong)(gong)精度(du)(du)要(yao)求高(gao)，采(cai)用普通機(ji)(ji)床(chuang)加(jia)工(gong)(gong)(gong)(gong)質量難以(yi)保證(zheng)，且由工(gong)(gong)(gong)(gong)藝(yi)(yi)流(liu)程長，周轉次(ci)數多，生產效率難以(yi)提高(gao)；三是(shi)形狀(zhuang)復雜(za)，且大(da)部(bu)分為(wei)薄壁殼體(ti)，工(gong)(gong)(gong)(gong)件(jian)剛度(du)(du)差，較(jiao)難裝夾。以(yi)離合器殼體(ti)為(wei)例，一般(ban)(ban)具有軸承孔、倒檔軸孔及二個大(da)平面(mian)(mian)(mian)、定位(wei)銷孔和(he)合箱螺孔等，加(jia)工(gong)(gong)(gong)(gong)尺寸上百個，精度(du)(du)高(gao)的一般(ban)(ban)都在(zai)IT6-IT9 級(ji)，表面(mian)(mian)(mian)粗糙度(du)(du)為(wei)Ra0.8～3.2um，平面(mian)(mian)(mian)度(du)(du)、平行(xing)度(du)(du)為(wei) 0.05～0.1mm,垂直度(du)(du)0.01～0.02mm，同(tong)軸度(du)(du)、位(wei)置度(du)(du) 0.05mm 等。一般(ban)(ban)工(gong)(gong)(gong)(gong)藝(yi)(yi)流(liu)程是(shi)銑結合面(mian)(mian)(mian)→加(jia)工(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)藝(yi)(yi)
孔和連接孔→粗鏜軸承(cheng)孔→精鏜軸承(cheng)孔和定位銷孔→清洗→泄漏試驗檢測(ce)。
（2）加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)設(she)備：殼體類零(ling)(ling)件的(de)(de)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)設(she)備主(zhu)要(yao)分(fen)為(wei)兩大類：組(zu)合(he)(he)(he)機(ji)床和加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)中心(xin)。傳統的(de)(de)殼體加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)生產(chan)線(xian)(xian)往往由組(zu)合(he)(he)(he)機(ji)床構成的(de)(de)，為(wei)了(le)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)一個(ge)零(ling)(ling)件需要(yao)20多(duo)道(dao)工(gong)(gong)(gong)序，大量(liang)的(de)(de)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)設(she)備只是為(wei)了(le)保(bao)證(zheng)有限的(de)(de)產(chan)品(pin)種(zhong)類，這種(zhong)情況適合(he)(he)(he)于(yu)單一品(pin)種(zhong)大批量(liang)的(de)(de)殼體生產(chan)。針對目前汽車市場需求的(de)(de)逐漸(jian)多(duo)樣化和產(chan)品(pin)更(geng)新換代(dai)的(de)(de)特點，組(zu)合(he)(he)(he)機(ji)床生產(chan)線(xian)(xian)已經不能滿(man)足要(yao)求，取而代(dai)之(zhi)的(de)(de)將是以加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)中心(xin)為(wei)主(zhu)的(de)(de)柔性(xing)生產(chan)線(xian)(xian)。加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)中心(xin)有加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)精度高、加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)范圍廣以及一次裝(zhuang)夾能完成多(duo)面(mian)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)的(de)(de)特性(xing)，已被大量(liang)采用。加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)中心(xin)分(fen)為(wei)立式(shi)和臥(wo)式(shi)兩種(zhong)。立式(shi)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)中心(xin)適宜加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)內容(rong)集(ji)中在同(tong)一個(ge)方向(xiang)上(shang)的(de)(de)零(ling)(ling)件，臥(wo)式(shi)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)中心(xin)適合(he)(he)(he)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)內容(rong)在不同(tong)方向(xiang)上(shang)的(de)(de)零(ling)(ling)件，特別(bie)是需圍轉加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)且同(tong)軸度較高的(de)(de)零(ling)(ling)件，兩者的(de)(de)加(jia)(jia)(jia)(jia)(jia)工(gong)(gong)(gong)費用基本在 1：2 左右。
（3）控制方法：夾(jia)(jia)具方面：變(bian)速(su)器殼體(ti)的(de)加(jia)工(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)序(xu)以采(cai)用“立式加(jia)工(gong)(gong)(gong)(gong)中(zhong)(zhong)心加(jia)工(gong)(gong)(gong)(gong)。10#工(gong)(gong)(gong)(gong)序(xu)+立式式加(jia)工(gong)(gong)(gong)(gong)中(zhong)(zhong)心加(jia)工(gong)(gong)(gong)(gong) 20#工(gong)(gong)(gong)(gong)序(xu)+臥式加(jia)工(gong)(gong)(gong)(gong)中(zhong)(zhong)心加(jia)工(gong)(gong)(gong)(gong) 30#工(gong)(gong)(gong)(gong)序(xu)”為例(li)，需要(yao)三(san)套加(jia)工(gong)(gong)(gong)(gong)中(zhong)(zhong)心夾(jia)(jia)具，其中(zhong)(zhong) 10#采(cai)用毛坯(pi)定位(wei)(wei)和支撐，20#、30#一(yi)般采(cai)用一(yi)面兩銷定位(wei)(wei)。壓鑄鋁殼體(ti)的(de)加(jia)工(gong)(gong)(gong)(gong)余量不大，一(yi)般為 0.8～1.2mm，在夾(jia)(jia)具設計過(guo)程中(zhong)(zhong)首先要(yao)考(kao)慮定位(wei)(wei)的(de)準確(que)性，其次是夾(jia)(jia)緊(jin)的(de)位(wei)(wei)置(zhi)必須是支撐的(de)對(dui)應位(wei)(wei)置(zhi)，避免工(gong)(gong)(gong)(gong)件(jian)的(de)夾(jia)(jia)緊(jin)變(bian)形，還要(yao)考(kao)慮刀具干涉、操作靈活、多件(jian)一(yi)夾(jia)(jia)、快速(su)切換等(deng)因素(su)。
刀(dao)(dao)具(ju)方面：在汽車零部(bu)件制造成(cheng)本(ben)中，刀(dao)(dao)具(ju)成(cheng)本(ben)占總成(cheng)本(ben)的(de)3%～5%，但是能夠通過(guo)提高加工(gong)效(xiao)(xiao)率來達到影響總成(cheng)本(ben)的(de)20%～30%。模塊式結(jie)構的(de)復合(he)刀(dao)(dao)具(ju)具(ju)有精度(du)較高，刀(dao)(dao)柄可(ke)重(zhong)復使用，庫存(cun)量(liang)(liang)少等特點，被廣泛采用，它可(ke)以大幅度(du)縮短加工(gong)時(shi)間，提高勞動效(xiao)(xiao)率。因(yin)此，在精度(du)要(yao)求(qiu)(qiu)不高、標(biao)準(zhun)刀(dao)(dao)具(ju)能夠達到比較好的(de)加工(gong)效(xiao)(xiao)果時(shi)盡量(liang)(liang)采用標(biao)準(zhun)刀(dao)(dao)具(ju)，降低庫存(cun)，提高互(hu)換性。同時(shi)，對(dui)于大批量(liang)(liang)生產(chan)的(de)零件，精度(du)要(yao)求(qiu)(qiu)又高的(de)零件采用先進的(de)非非標(biao)復合(he)刀(dao)(dao)具(ju)更能提高加工(gong)精度(du)和(he)生產(chan)效(xiao)(xiao)率。