工程训练

前言 第 1篇 概论 第 1章 课程概述 ···································· 1 1.1 制造业的过去、现在和未来 ··········· 1 1.2 课程性质、目的与教学内容 ··········· 2 1.2.1 课程性质与目的 ····················· 2 1.2.2 课程的教学内容 ····················· 3 1.3 课程学习方法及安全要求 ·············· 4 第 2章 机械工程材料及热处理 ············· 5 2.1 机械工程材料的分类及应用 ··········· 5 2.1.1 机械工程材料的分类 ··············· 5 2.1.2 机械工程材料的应用 ··············· 5 2.2 常用钢铁材料简介 ······················· 6 2.2.1 钢······································· 6 2.2.2 铸铁···································· 7 2.3 钢铁材料现场鉴别方法 ················· 8 2.3.1 火花鉴别······························ 8 2.3.2 色标鉴别······························ 9 2.3.3 断口鉴别·····························10 2.3.4 音响鉴别·····························10 2.4 非铁金属简介 ····························10 2.4.1 铝及铝合金··························10 2.4.2 铜及铜合金··························11 2.5 金属材料的力学性能 ···················11 2.5.1 强度···································12 2.5.2 塑性···································12 2.5.3 硬度···································12 2.5.4 冲击韧度·····························13 2.5.5 疲劳强度·····························13 2.6 金属材料热处理 ·························13 2.6.1 退火与正火··························14 2.6.2 淬火与回火··························15 2.6.3 表面热处理··························16 2.6.4 金属表面改性·······················17 2.7 金相基础 ··································19 2.7.1 金相取样的原则 ····················20 2.7.2 金相试样的制备 ····················20 2.7.3 铁碳平衡组织的金相观察 ········24 2.8 热处理安全操作规程 ···················24 第 2篇 材料成形 第 3章 铸造成形 ···································26 3.1 概述 ········································26 3.2 砂型铸造 ··································27 3.2.1 造型材料性能及组成 ··············27 3.2.2 常用造型方法·······················28 3.2.3 浇注系统及其设置 ·················33 3.2.4 型芯的结构及制作 ·················34 3.2.5 砂型制作案例·······················35 3.3 铸造合金的熔炼及浇注工艺 ··········37 3.3.1 铸铁的熔炼··························37  3.3.2 铸钢的熔炼··························39 3.3.3 非铁金属的熔炼 ····················40 3.3.4 铝合金熔炼案例 ····················40 3.4 特种铸造方法及应用 ···················42 3.4.1 熔模铸造·····························42 3.4.2 金属型铸造··························43 3.4.3 离心铸造·····························43 3.4.4 压力铸造·····························44 3.4.5 低压铸造·····························44 3.4.6 实型铸造·····························44 3.5 铸造缺陷及其分析 ······················45 3.6 铸造安全操作规程 ······················46 第 4章 锻压成形 ···································48 4.1 概述 ········································48 4.1.1 常用压力加工方法 ·················48 4.1.2 坯料的加热和锻件的冷却 ········49 4.2 自由锻 ·····································52 4.2.1 自由锻设备··························52 4.2.2 自由锻工具··························53 4.2.3 自由锻工序··························53 4.2.4 自由锻工艺规程 ····················56 4.2.5 自由锻案例··························57 4.3 模锻和胎模锻 ····························59 4.3.1 模锻···································59 4.3.2 胎模锻································60 4.4 板料冲压 ··································61 4.4.1 冲压设备·····························61 4.4.2 冲压工序·····························62 4.4.3 冲模···································63 4.4.4 冲压模具拆装案例 ·················64 4.5 锻造安全操作规程 ······················65 4.6 冲压安全操作规程 ······················66 第 5章 焊接成形 ···································67 5.1 概述 ········································67 5.2 焊条电弧焊 ·······························68 5.2.1 焊接设备·····························70 5.2.2 焊钳及其他辅助工具 ··············72 5.2.3 焊条···································72 5.2.4 焊条电弧焊焊接工艺 ··············74 5.2.5 焊条电弧焊操作 ····················77 5.3 气焊与切割 ·······························80 5.3.1 气焊···································80 5.3.2 切割···································83 5.4 其他焊接方法及焊接机器人 ··········85 5.4.1 气体保护焊··························85 5.4.2 埋弧焊································87 5.4.3 压焊···································88 5.4.4 钎焊···································90 5.4.5 激光焊································90 5.4.6 焊接机器人··························90 5.5 焊接缺陷与焊接变形 ···················92 5.5.1 焊接缺陷与检验 ····················92 5.5.2 焊接变形·····························93 5.6 焊接安全操作规程 ······················94 5.6.1 焊条电弧焊安全操作规程 ········94 5.6.2 气焊气割安全操作规程 ···········94 第 6章 陶艺 ···········································96 6.1 概述 ········································96 6.1.1 陶瓷的发展历史 ····················96 6.1.2 陶艺制作常用泥料 ·················97 6.1.3 陶艺制作常用设备及工具 ········97 6.2 陶艺基本成型方法 ······················97 6.3 陶艺装饰方法 ····························99 6.4 陶艺烧成工艺 ·························· 100 6.5 安全操作规程 ·························· 100 第 3篇 常规切削加工 第 7章 车削加工 ·································102 7.2 卧式车床 ································ 103 7.1 车工概述 ································ 102 7.2.1 卧式车床的编号 ·················· 103  7.2.2 卧式车床主要部分的名称 和用途······························ 103 7.2.3 卧式车床主要附件的名称和 用途································· 104 7.2.4 卧式车床的传动系统 ············ 105 7.3 车刀的结构及安装 ···················· 107 7.3.1 车刀的种类与应用 ··············· 107 7.3.2 车刀的结构························ 108 7.3.3 车刀的刃磨························ 110 7.3.4 车刀的安装························ 111 7.4 工件的安装 ····························· 111 7.5 车床操作要点 ·························· 114 7.5.1 切削用量及对切削的影响 ······ 114 7.5.2 切削液的作用及其选择 ········· 116 7.5.3 刀架极限位置检查 ··············· 116 7.5.4 刻度盘及其正确使用 ············ 117 7.5.5 对刀和试切、试量 ··············· 117 7.6 车削加工的基本方式 ················· 118 7.6.1 车外圆······························ 118 7.6.2 车端面和台阶····················· 119 7.6.3 切槽和切断························ 120 7.6.4 钻孔、镗孔························ 121 7.6.5 车锥面······························ 124 7.6.6 车成形面··························· 126 7.6.7 车螺纹······························ 127 7.6.8 滚花································· 130 7.7 典型零件车削工艺简介 ·············· 131 7.7.1 零件图样分析····················· 131 7.7.2 连杆螺钉机械加工工艺过 程卡································· 131 7.7.3 工艺分析··························· 132 7.8 车削加工安全操作规范 ·············· 134 第 8章 铣削加工 ·································136 8.1 铣削加工概述 ·························· 136 8.2 铣床种类 ································ 137 8.2.1 卧式万能升降台式铣床 ········· 137 8.2.2 立式升降台铣床 ·················· 138 8.2.3 龙门铣床··························· 138 8.3 铣刀 ······································ 139 8.3.1 铣刀种类··························· 139 8.3.2 铣刀的安装························ 140 8.4 铣削加工 ································ 141 8.4.1 铣削运动··························· 141 8.4.2 铣削用量··························· 141 8.4.3 铣削方式··························· 142 8.5 铣床附件 ································ 144 8.5.1 机用虎钳··························· 144 8.5.2 万能铣头··························· 145 8.5.3 回转工作台························ 145 8.5.4 万能分度头···············