沈陽機械零件加工的幾種常用工藝：

一、材(cai)料去除制造工藝(yi)（⑽m ＜0）

材(cai)料(liao)(liao)去除制造工(gong)藝是按一定的(de)方(fang)式從工(gong)件(jian)上(shang)切(qie)除多余的(de)材(cai)料(liao)(liao)，得到所需形狀、尺(chi)寸的(de)零件(jian)。此類工(gong)藝要(yao)求工(gong)件(jian)表面有足夠的(de)多余材(cai)料(liao)(liao)。在材(cai)料(liao)(liao)的(de)去除過(guo)程中，工(gong)件(jian)逐漸逼近(jin)理(li)想零件(jian)的(de)形狀和尺(chi)寸。原材(cai)料(liao)(liao)或毛坯(pi)與(yu)零h的(de)形狀、尺(chi)寸相差越(yue)大，去除的(de)材(cai)料(liao)(liao)就越(yue)多，材(cai)料(liao)(liao)損耗(hao)(hao)就越(yue)大，加工(gong)過(guo)程消耗(hao)(hao)的(de)能源也越(yue)多。有時損耗(hao)(hao)的(de)材(cai)料(liao)(liao)體(ti)(ti)積甚至(zhi)超過(guo)零件(jian)自身的(de)體(ti)(ti)積。

雖然材(cai)(cai)(cai)(cai)料(liao)(liao)去(qu)除(chu)工(gong)(gong)(gong)(gong)藝(yi)的(de)材(cai)(cai)(cai)(cai)料(liao)(liao)利用(yong)率(lv)低(di)，但至今它依然是(shi)提(ti)高零件(jian)品質的(de)主要手段，同時也具有(you)很(hen)強的(de)加工(gong)(gong)(gong)(gong)適應(ying)性，是(shi)機制(zhi)造中應(ying)用(yong)廣(guang)泛的(de)加工(gong)(gong)(gong)(gong)方(fang)式。材(cai)(cai)(cai)(cai)料(liao)(liao)去(qu)除(chu)法工(gong)(gong)(gong)(gong)藝(yi)與材(cai)(cai)(cai)(cai)料(liao)(liao)成(cheng)形工(gong)(gong)(gong)(gong)藝(yi)相結合，可以大(da)大(da)降(jiang)低(di)原材(cai)(cai)(cai)(cai)料(liao)(liao)的(de)消耗。隨著少(shao)無切削加工(gong)(gong)(gong)(gong)技術(shu)（精(jing)密(mi)鑄造、精(jing)鍛造等）的(de)發展，可以進一步提(ti)高材(cai)(cai)(cai)(cai)料(liao)(liao)的(de)利用(yong)率(lv)。生產數(shu)量很(hen)少(shao)時，為(wei)了減少(shao)材(cai)(cai)(cai)(cai)料(liao)(liao)成(cheng)形工(gong)(gong)(gong)(gong)藝(yi)投資，單純采用(yong)材(cai)(cai)(cai)(cai)料(liao)(liao)去(qu)除(chu)工(gong)(gong)(gong)(gong)藝(yi)也是(shi)經(jing)濟合理的(de)。

材(cai)料去除工藝(yi)有很多加(jia)工形式，包括傳統的切削加(jia)工和特種(zhong)加(jia)工。

切(qie)削(xue)加(jia)(jia)工(gong)(gong)(gong)(gong)是用金屬(shu)切(qie)削(xue)刀(dao)具(ju)在(zai)機床上(shang)切(qie)除(chu)工(gong)(gong)(gong)(gong)件（毛坯）上(shang)多余(yu)的(de)(de)金屬(shu)，從而使工(gong)(gong)(gong)(gong)件的(de)(de)形(xing)狀、尺寸和表面質量符合設計要求(qiu)的(de)(de)工(gong)(gong)(gong)(gong)藝方法(fa)。切(qie)削(xue)過程中(zhong)，刀(dao)具(ju)和工(gong)(gong)(gong)(gong)件安裝在(zai)機床上(shang)，由機床帶動實現(xian)一(yi)定規(gui)律的(de)(de)相(xiang)對(dui)(dui)運(yun)動。在(zai)刀(dao)具(ju)與工(gong)(gong)(gong)(gong)件的(de)(de)相(xiang)對(dui)(dui)運(yun)動過程中(zhong)，多余(yu)的(de)(de)金屬(shu)被切(qie)除(chu)，形(xing)成(cheng)了工(gong)(gong)(gong)(gong)件的(de)(de)已加(jia)(jia)工(gong)(gong)(gong)(gong)表面。常見的(de)(de)金屬(shu)切(qie)削(xue)加(jia)(jia)工(gong)(gong)(gong)(gong)方式(shi)有車削(xue)、銑削(xue)、刨削(xue)、拉削(xue)、磨削(xue)等。金屬(shu)切(qie)削(xue)過程中(zhong)存(cun)在(zai)力(li)、熱、變形(xing)、振動、磨損等現(xian)象。對(dui)(dui)加(jia)(jia)工(gong)(gong)(gong)(gong)過程、加(jia)(jia)工(gong)(gong)(gong)(gong)質量都存(cun)在(zai)一(yi)定的(de)(de)影凇(song)Ｈ綰握確選擇加(jia)(jia)工(gong)(gong)(gong)(gong)方法(fa)、加(jia)(jia)工(gong)(gong)(gong)(gong)機床、刀(dao)具(ju)、夾(jia)具(ju)和切(qie)削(xue)參數，改善加(jia)(jia)工(gong)(gong)(gong)(gong)質量，提高(gao)加(jia)(jia)工(gong)(gong)(gong)(gong)效益(yi)將是本書的(de)(de)重點講述內容(rong)。

特種加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)是指利用電(dian)(dian)能(neng)、光能(neng)等(deng)對工(gong)(gong)(gong)(gong)(gong)(gong)件進(jin)行材(cai)料(liao)去(qu)除(chu)(chu)的(de)(de)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)方法。有(you)電(dian)(dian)火花加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)、電(dian)(dian)解加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)、激光加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)等(deng)。電(dian)(dian)火花加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)是利用工(gong)(gong)(gong)(gong)(gong)(gong)具(ju)電(dian)(dian)極與詡電(dian)(dian)極之(zhi)(zhi)間(jian)產生的(de)(de)脈沖放電(dian)(dian)現象蝕除(chu)(chu)工(gong)(gong)(gong)(gong)(gong)(gong)件材(cai)料(liao)達(da)到加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)目(mu)的(de)(de)。加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)時，工(gong)(gong)(gong)(gong)(gong)(gong)件電(dian)(dian)極與工(gong)(gong)(gong)(gong)(gong)(gong)具(ju)電(dian)(dian)極之(zhi)(zhi)間(jian)存在一(yi)定的(de)(de)放電(dian)(dian)間(jian)隙(xi)，而(er)不(bu)(bu)直接接觸，加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)中沒有(you)力的(de)(de)作用，可以(yi)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)任(ren)何力學性能(neng)的(de)(de)導電(dian)(dian)材(cai)料(liao)。在工(gong)(gong)(gong)(gong)(gong)(gong)藝上其(qi)主要(yao)優點是可以(yi)對復雜(za)形(xing)狀(zhuang)(zhuang)的(de)(de)內輪廓表面進(jin)行加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)，將其(qi)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)難度轉化為外輪廓（工(gong)(gong)(gong)(gong)(gong)(gong)詰緙）的(de)(de)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)，所以(yi)在模具(ju)制(zhi)造(zao)中有(you)特殊的(de)(de)作用。由于電(dian)(dian)火花加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)的(de)(de)金屬去(qu)除(chu)(chu)率(lv)低，一(yi)般(ban)不(bu)(bu)用于產品(pin)的(de)(de)形(xing)狀(zhuang)(zhuang)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)。激光加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)、離子束加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)多用于細微加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)。

隨著科學技術的(de)進步，在(zai)航天、計算機領域，有些加工精(jing)度和表(biao)面粗糙度要求(qiu)特別高的(de)零件，需要進行(xing)精(jing)密(mi)(mi)加工及(ji)超精(jing)加工。精(jing)密(mi)(mi)、超精(jing)密(mi)(mi)加工達(da)(da)到的(de)尺寸精(jing)度可以達(da)(da)亞微米乃至納米級。這些加工方法(fa)有超精(jing)密(mi)(mi)車削、超精(jing)密(mi)(mi)研磨等(deng)。

二、材料成形(xing)制造工藝（⑽m ＝0）

材(cai)料(liao)(liao)(liao)成形(xing)(xing)(xing)制(zhi)(zhi)造(zao)工藝(yi)多利(li)用(yong)模型使(shi)原材(cai)料(liao)(liao)(liao)形(xing)(xing)(xing)成零件或毛坯。材(cai)料(liao)(liao)(liao)成屑(xie)庸す程中，原材(cai)料(liao)(liao)(liao)的(de)形(xing)(xing)(xing)狀、尺寸、組織狀態，甚至(zhi)結合狀態都(dou)會改(gai)變。由于(yu)成形(xing)(xing)(xing)精(jing)度一(yi)般不(bu)高，材(cai)料(liao)(liao)(liao)成形(xing)(xing)(xing)制(zhi)(zhi)造(zao)工藝(yi)常(chang)用(yong)來制(zhi)(zhi)造(zao)毛坯。也(ye)可(ke)以用(yong)來制(zhi)(zhi)造(zao)形(xing)(xing)(xing)狀復(fu)雜但精(jing)度要求不(bu)太高的(de)零件。材(cai)料(liao)(liao)(liao)成形(xing)(xing)(xing)工藝(yi)的(de)生產(chan)效率較高。常(chang)用(yong)的(de)成形(xing)(xing)(xing)工藝(yi)有鑄造(zao)、鍛壓、粉末冶金等(deng)。

（一）鑄(zhu)

鑄(zhu)(zhu)(zhu)(zhu)造是將液態金屬澆注(zhu)到(dao)(dao)與零件的(de)形狀尺(chi)寸相適應的(de)鑄(zhu)(zhu)(zhu)(zhu)型型腔中去，冷卻凝固(gu)后獲得毛(mao)坯或零件的(de)工(gong)藝方法(fa)。基本(ben)工(gong)藝過程為造型、熔(rong)煉、澆注(zhu)、清理等。由(you)于(yu)合金鑄(zhu)(zhu)(zhu)(zhu)造時的(de)充型能力、收縮及其它(ta)因素影響，鑄(zhu)(zhu)(zhu)(zhu)件可能會存在組織不均勻、縮孔、熱應力、變形腥畢藎使鑄(zhu)(zhu)(zhu)(zhu)件的(de)精(jing)度、表面(mian)質量、力學(xue)性能不高。盡(jin)管如此，由(you)于(yu)適應性強，生產成本(ben)低，鑄(zhu)(zhu)(zhu)(zhu)造加工(gong)依然(ran)得到(dao)(dao)十分廣泛(fan)的(de)應用。形狀復雜(za)，尤其有(you)復雜(za)內腔零件的(de)毛(mao)坯常采用鑄(zhu)(zhu)(zhu)(zhu)造。

目前生產中常用的鑄(zhu)(zhu)造(zao)方(fang)法有普(pu)通砂型鑄(zhu)(zhu)造(zao)、熔模鑄(zhu)(zhu)造(zao)、金屬型鑄(zhu)(zhu)造(zao)、壓力鑄(zhu)(zhu)小⒌脫怪造(zao)、離心鑄(zhu)(zhu)造(zao)等。其(qi)中，普(pu)通砂型鑄(zhu)(zhu)造(zao)應用廣。

（二） 鍛壓

鍛(duan)造(zao)與板料沖壓統稱為鍛(duan)壓。鍛(duan)造(zao)是(shi)利(li)用(yong)鍛(duan)造(zao)設備對加熱后的(de)(de)金屬(shu)施加外力(li)進行塑性變形(xing)，形(xing)成具(ju)有(you)一定形(xing)狀(zhuang)、尺(chi)寸和組(zu)織(zhi)(zhi)性能的(de)(de)零件(jian)毛坯。經過(guo)鍛(duan)造(zao)的(de)(de)毛坯其內部組(zu)織(zhi)(zhi)致密均(jun)勻。金屬(shu)流(liu)線分(fen)布合理，提高了零件(jian)強度。因此，鍛(duan)造(zao)常用(yong)于制造(zao)綜合力(li)學性能要求高的(de)(de)零件(jian)的(de)(de)毛坯。

鍛造可分為自由鍛造、模型鍛造和(he)胎模鍛造。

自由鍛造是(shi)將金屬置于上下抵鐵之間進(jin)行金屬塑性變形，利用(yong)(yong)自由流(liu)動的(de)侶沙(sha)尚巍３尚渦率低(di)，精度低(di)。一般(ban)用(yong)(yong)于生(sheng)產批量較(jiao)小，形狀簡單的(de)鍛件。

模(mo)型鍛造(zao)是將金(jin)屬(shu)置于(yu)(yu)鍛模(mo)的(de)模(mo)膛(tang)中(zhong)變形(xing)，金(jin)屬(shu)的(de)塑性流(liu)動受到模(mo)膛(tang)的(de)限制，成形(xing)效率高(gao)，精度高(gao)，金(jin)屬(shu)流(liu)線分布更(geng)加合理(li)。但由(you)于(yu)(yu)模(mo)具制造(zao)費用(yong)(yong)很(hen)高(gao)，通常用(yong)(yong)于(yu)(yu)大(da)批量(liang)生產(chan)。與自由(you)略(lve)煜啾齲模(mo)型鍛造(zao)時需要的(de)鍛造(zao)力大(da)，不能用(yong)(yong)于(yu)(yu)大(da)型鍛件的(de)鍛造(zao)。

胎(tai)模(mo)(mo)鍛(duan)(duan)造是在自由鍛(duan)(duan)造的設備上(shang)利用胎(tai)模(mo)(mo)對金屬進行鍛(duan)(duan)造。胎(tai)模(mo)(mo)制造簡單，成本低，成形方便，但成形精度(du)(du)不高(gao)，常用來生產精度(du)(du)要求不高(gao)的小(xiao)鍛(duan)(duan)件。

板料(liao)沖(chong)(chong)壓(ya)略諮沽機上(shang)利用沖(chong)(chong)模(mo)將(jiang)板料(liao)沖(chong)(chong)壓(ya)成各(ge)種形狀和(he)尺寸(cun)的(de)制(zhi)(zhi)件。沖(chong)(chong)壓(ya)加工(gong)(gong)(gong)具有(you)很(hen)高(gao)的(de)生產(chan)(chan)(chan)率和(he)較高(gao)的(de)加工(gong)(gong)(gong)精度，其加工(gong)(gong)(gong)形式有(you)沖(chong)(chong)裁(cai)、彎曲、拉深、成形等。沖(chong)(chong)裁(cai)是將(jiang)板料(liao)沖(chong)(chong)壓(ya)成各(ge)種平面制(zhi)(zhi)件。彎曲、拉深等成形工(gong)(gong)(gong)序將(jiang)板料(liao)沖(chong)(chong)壓(ya)成各(ge)種立體(ti)制(zhi)(zhi)件。板料(liao)沖(chong)(chong)壓(ya)在(zai)電氣產(chan)(chan)(chan)品、輕(qing)工(gong)(gong)(gong)產(chan)(chan)(chan)品、汽車制(zhi)(zhi)造中有(you)著路止惴旱撓τ謾

（三）粉末冶金

粉(fen)末(mo)冶金是以金屬(shu)粉(fen)末(mo)或金屬(shu)與非金屬(shu)粉(fen)末(mo)的(de)(de)(de)(de)(de)混合物作為(wei)原(yuan)料(liao)，經模(mo)具(ju)壓制(zhi)、燒結等工(gong)序，制(zhi)造某些金屬(shu)制(zhi)品或金屬(shu)材料(liao)的(de)(de)(de)(de)(de)工(gong)藝(yi)方法。它(ta)既可以生產特(te)種金屬(shu)材料(liao)，又可以生產少(shao)無切削加工(gong)的(de)(de)(de)(de)(de)金屬(shu)零(ling)件(jian)(jian)。粉(fen)末(mo)冶輪破返(fan)牟牧(mu)俠(xia)用率能達到95 ％，可大(da)量(liang)減少(shao)切削加工(gong)的(de)(de)(de)(de)(de)投(tou)入，降低生產成本，因(yin)此(ci)在機(ji)械制(zhi)造中獲得日(ri)益廣泛的(de)(de)(de)(de)(de)應用。由于粉(fen)末(mo)冶金所用蹬粉(fen)末(mo)原(yuan)料(liao)價格高，成形時(shi)粉(fen)末(mo)的(de)(de)(de)(de)(de)流(liu)動(dong)性(xing)(xing)差，零(ling)件(jian)(jian)形狀的(de)(de)(de)(de)(de)和大(da)小受到一(yi)定(ding)的(de)(de)(de)(de)(de)限制(zhi)。粉(fen)末(mo)冶金制(zhi)件(jian)(jian)內部存(cun)在一(yi)定(ding)量(liang)的(de)(de)(de)(de)(de)微(wei)小孔(kong)隙(xi)，其強度比鑄件(jian)(jian)或鍛(duan)件(jian)(jian)約低20 ％～30 ％，且塑(su)性(xing)(xing)、韌(ren)性(xing)(xing)也較差。

粉末(mo)冶金生產的(de)工藝(yi)流(liu)程包括粉末(mo)制(zhi)備(bei)、混(hun)配料(liao)(liao)、壓制(zhi)成形、燒(shao)結、整形等(deng)。其中(zhong)粉末(mo)的(de)制(zhi)備(bei)與混(hun)配料(liao)(liao)工序通常由提供(gong)粉末(mo)的(de)廠商完成。

三、材料累(lei)積制造工藝 （⑽m ＞0 ）

材料累積(ji)制造工(gong)藝是將零(ling)件以微元疊加方(fang)式(shi)逐(zhu)漸累積(ji)生長出來的。在制造過程中(zhong)，將零(ling)件三維實體(ti)模型數據經(jing)計算機處理，控制材料的累積(ji)過程，形成所(suo)要的零(ling)件。此類(lei)工(gong)藝方(fang)法的優點是無需(xu)刀具、夾具等生產準備活動，就(jiu)可以成形任意(yi)復雜形狀的零(ling)件。

制(zhi)(zhi)造出(chu)采的(de)(de)(de)原型可供設計評估、投標或樣件(jian)展示。因此，這一工(gong)藝又稱(cheng)為快速成(cheng)形技(ji)術。快速成(cheng)形技(ji)術用于產(chan)品(pin)樣件(jian)的(de)(de)(de)制(zhi)(zhi)造、模(mo)具制(zhi)(zhi)造和(he)少量零件(jian)的(de)(de)(de)制(zhi)(zhi)造，成(cheng)為加速新產(chan)品(pin)開發及實現(xian)并行工(gong)程(cheng)的(de)(de)(de)有效技(ji)術，使企業的(de)(de)(de)產(chan)品(pin)能快速響應(ying)市(shi)場，提(ti)高企業的(de)(de)(de)競爭能力。

快速(su)成形(xing)技術的發展(zhan)十(shi)分迅速(su)，現在有幾種方法(fa)已 經 進(jin) 入(ru) 應 用 階 段， 主 要(yao) 有 光 固 化 法(fa) （SL ：Stereolithog －raphy）、層疊制造法(fa) （LO M ：LaminatedObject Manufacturing）、激光選區燒結法(fa) （SLS ：Selec－tive Laser Sintering）、熔化堆積造型法(fa) （FD M ：Fused Deposition Modeling），其中光固化法(fa)是(shi)很早投入(ru)商(shang)業應用的快速(su)成形(xing)技術。

光固(gu)(gu)化(hua)法(fa)以光敏樹(shu)脂(zhi)為原(yuan)料，將(jiang)計(ji)算(suan)機控(kong)制(zhi)的(de)紫(zi)外激光按預定零件分層(ceng)截面對液態(tai)樹(shu)脂(zhi)逐點(dian)掃(sao)(sao)描，使(shi)被(bei)掃(sao)(sao)描區域的(de)樹(shu)脂(zhi)薄層(ceng)產生(sheng)光聚(ju)合反應(ying)，從而形成零件一(yi)(yi)(yi)個薄層(ceng)截面。當一(yi)(yi)(yi)層(ceng)固(gu)(gu)化(hua)完畢后，托(tuo)盤下(xia)降一(yi)(yi)(yi)個薄層(ceng)高度。在原(yuan)先固(gu)(gu)化(hua)好的(de)樹(shu)脂(zhi)表面再(zai)敷(fu)上一(yi)(yi)(yi)層(ceng)新的(de)液態(tai)樹(shu)脂(zhi)以便下(xia)一(yi)(yi)(yi)次掃(sao)(sao)描固(gu)(gu)化(hua)。新固(gu)(gu)化(hua)的(de)一(yi)(yi)(yi)層(ceng)牢(lao)固(gu)(gu)地(di)與前一(yi)(yi)(yi)層(ceng)粘合，如此重復，直到整個零件原(yuan)型制(zhi)造完畢。

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