Honda S2000 ringrajale kohandatud tagakäänmiku tootmistehnoloogia

Lõputöö eesmärgiks oli luua tootmistehnoloogia ja vajalik rakistus Honda S2000 tagakäänmiku tootmiseks ettevõttes Wisefab OÜ. Käänmik on vedrustuse detail, mis ühendab rattavõlli või rattarummu teiste vedrustuse komponentidega. Töötlemistehnoloogia määramisel hinnati algul valmistatava toote materjali ja kuju ning sellele tuginedes valiti sobivad tööriistad ja režiimid. Kasutatavate tööriistade tootjad on Eestis hästi esindatud ja instrumentide tarneaeg on lühike. Seeläbi välditakse võimalikke seisakuid tootmises. Töö käigus selgus, et antud käänmikku on kõige optimaalsem valmistada neljas paigalduses. Tolereeritud mõõduga rummuava töötlemine teostatakse viimases paigalduses, et vältida materjali sisepingetest ja kinnitusjõududest tekkivaid deformatsioone. Käänmike valmistamiseks projekteeriti kaks spetsiaalset rakist. Arvutati detaili positsioneerimistäpsus ja kinnituselementide poolt rakendatav vajalik jõud. Leiti, et antud rakised tagavad piisava täpsuse ja kinnitusjõu. Lõputöö võib lugeda edukaks, sest saavutati töö algul püstitatud eesmärgid. Ühe toote valmistamisajaks saadi 1 tund ja 56 minutit ja täisomahinnaks 361€.

The purpose of this thesis is to develope production technology and to design necessary jigs for manufacturing Honda S2000 rear knuckles. It is needed to decrease companys dependence on subconctractors. Knuckle is component of car suspension, which connects hub or shaft to other suspension parts. Production output will be about 100 knuckles a year, which will be manufactured in five series, 20 units in each. It is required that under these conditions manufacturing one knuckle takes less than 2 hours and costs less than 400 €. The first two chapters of present thesis describe the knuckle to be manufactured and company where given knuckle was designed. Manufacturing will take palce in small company named Wisefab OÜ. It was established in 2011. Wisefab OÜ is specialized in designing and producing suspension setups for drifting, circuit racing and rallying. About 95% of its production is exported. Knuckle will be machined from EN AW 7075-T6 billet sized 90 x 323 x 252 mm, weighing 20,5 kg. Final product weighs 2,08 kg. Third and fouth chapers give an overview of tools, equipment and general measurements used for machining and present step-by-step development of billet to finished product. Possible issues that may occur during machining due to materials properties are pointed out. Machining is carried out in four operations. Based on detailed machining sequence that contains every tool and cutting parameters used, total machining time is calculated. Calculations describing jigs are carried out in chapter five. Based on estimated cutting forces, necessary clamping forces for fixing elements are calculated. For every operation, mounting deviation is calculated also. Sixth chapter gives an overview of manufacturing costs and estimated net cost of the knuckle, which is 361 €.