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
#12;
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
#12;
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························ 145
8.6　铣削加工基本方法
···················· 146
8.6.1　铣削水平面的方法和步骤 ······ 146
8.6.2　铣削斜面的方法和步骤 ········· 148
8.7　铣削加工安全操作规范
·············· 149
第
9章　磨削加工
·································151
9.1　概述 ······································ 151
9.2　磨削加工的种类及方法
·············· 152
9.2.1　平面磨削··························· 152
9.2.2　外圆磨削··························· 153
9.2.3　内圆磨削··························· 154
9.3　磨具 ······································ 155
9.4　磨削加工案例 ·························· 158
9.5　其他磨削工艺 ·························· 159
9.6　磨削加工安全操作规程
·············· 159
第
10章　钳工
·······································161
10.1　划线 ···································· 161
10.1.1　划线工具及使用 ················ 161
10.1.2　划线操作 ························· 163
10.2　锯削、锉削、錾削··················· 166
10.2.1　锯削 ······························· 166
10.2.2　锉削 ······························· 167
10.2.3　錾削 ······························· 170
10.3　钻孔、扩孔、锪孔、铰孔加工 ···· 171
10.3.1　钻孔加工设备 ··················· 171
10.3.2　钻孔与扩孔、锪孔、铰孔
#12;
操作 ······························· 175
10.4　攻螺纹和套螺纹······················ 176
10.4.1　攻螺纹和套螺纹工具··········· 177
10.4.2　攻螺纹和套螺纹操作··········· 178
10.5　刮削与研磨···························· 179
10.5.1　刮削用工具 ······················ 180
10.5.2　刮削操作 ························· 181
10.5.3　研具与研磨剂 ··················· 182
10.5.4　平面的研磨方法 ················ 183
10.6　钳工安全操作规程··················· 185
10.6.1　钻床安全操作规程 ············· 185
10.6.2　钳工常用工具安全操作
规程 ······························· 185
第
4篇　现代制造技术
第
11章　数控加工
·······························188
11.1　概述····································· 188
11.2　数控加工工艺基础
··················· 189
11.2.1　数控加工工艺过程·············· 189
11.2.2　数控加工工艺相关概念········ 189
11.2.3　工序划分原则 ··················· 190
11.2.4　进给路线 ························· 190
11.2.5　对刀点的选择 ··················· 191
11.2.6　切削用量 ························· 192
11.2.7　技术文件 ························· 192
11.2.8　工艺装备的选择················· 192
11.3　数控加工编程基础
··················· 193
11.3.1　数控程序编制的内容和步骤 ·· 193
11.3.2　数控程序格式 ··················· 194
11.3.3　数控程序基本代码·············· 194
11.4　数控车削加工························· 195
11.4.1　数控车床基本知识·············· 195
11.4.2　数控车床坐标系················· 198
11.4.3　数控车削加工中的装刀与
对刀 ······························· 199
11.4.4　数控车削加工编程指令········ 200
11.4.5　数控车削加工案例分析········ 202
11.5　数控铣削加工························· 204
11.5.1　数控铣床基本知识·············· 204
11.5.2　数控铣床坐标系················· 205
11.5.3　数控铣削加工对刀点··········· 206
11.5.4　数控铣削加工编程指令········ 207
11.5.5　数控铣削加工案例分析········ 208
11.6　数控加工安全操作规程 ············· 213
11.6.1　数控车削加工安全操作
规程 ······························· 213
11.6.2　数控铣削加工安全操作
规程 ······························· 214
第
12章　特种加工
·······························216
12.1　概述 ···································· 216
12.1.1　特种加工的特点及应用········ 216
12.1.2　特种加工的分类 ················ 216
12.2　电火花加工···························· 217
12.2.1　电火花加工原理 ················ 217
12.2.2　电火花加工的特点、应用
及分类 ···························· 219
12.2.3　电火花成形加工机床··········· 219
12.2.4　电火花成形加工机床的
操作 ······························· 221
12.3　电火花线切割加工··················· 223
12.3.1　电火花线切割加工概述········ 223
12.3.2　电火花线切割加工设备········ 224
12.3.3　电火花线切割机床控制
系统 ······························· 225
12.3.4　电火花线切割加工编程········ 227
12.4　激光加工······························· 230
12.4.1　激光加工概述 ··················· 230
12.4.2　激光加工设备 ··················· 232
12.4.3　激光加工机床控制系统········ 233
12.5　增材制造（3D打印）················ 235
12.5.1　增材制造概述 ··················· 235
#12;
12.5.2　增材制造工艺方法 ············· 236
12.6　电解加工······························· 238
12.6.1　电解加工原理 ··················· 238
12.6.2　电解加工特点与应用··········· 239
12.7　超声加工······························· 239
12.7.1　超声加工原理 ··················· 239
12.7.2　超声加工特点与应用··········· 240
12.8　电子束和离子束加工················ 240
12.8.1　电子束加工 ······················ 240
12.8.2　离子束加工 ······················ 241
12.9　特种加工安全操作规程
（电火花加工）························· 242
第
13章　智能制造
·······························243
13.1　概述 ···································· 243
13.1.1　国外智能制造背景 ············· 243
13.1.2　中国制造
2025 ··················· 244
13.2　智能制造的内涵······················ 244
13.3　智能制造发展现状··················· 245
13.4　智能制造发展目标··················· 245
13.5　智能制造系统构架··················· 246
13.5.1　生命周期 ························· 246
13.5.2　系统层级 ························· 246
13.5.3　智能功能 ························· 246
13.6　智能制造标准体系结构
············· 247
13.7　智能制造标准体系框架
············· 248
13.8　智能制造相关名词术语和
缩略语 ································· 248
13.9　工业
4.0体系下的智能制
造构架 ································· 250
13.9.1　智能工厂拓扑结构 ············· 250
13.9.2　智能工厂架构 ··················· 250
第
5篇　综合训练与创新
第
14章　机械加工质量与检测
············252
14.1　概述 ···································· 252
14.2　机械加工精度························· 252
14.3　机械加工表面质量··················· 253
14.3.1　加工表面的几何特征··········· 253
14.3.2　表面层金属的力学物理性能和化
学性能 ···························· 253
14.4　机械加工质量检测··················· 254
14.4.1　测量的基本要素 ················ 254
14.4.2　测量方法的分类 ················ 254
14.5　常用测量器具的使用、维护
及示例 ································· 255
14.5.1　游标卡尺 ························· 255
14.5.2　千分尺 ···························· 256
14.5.3　百分表及杠杆百分表··········· 257
14.5.4　内径指示表 ······················ 259
14.5.5　三坐标测量机 ··················· 260
14.6　三坐标测量案例······················ 261
14.6.1　测量准备工作 ··················· 261
14.6.2　3个面基准测量案例 ··········· 262
14.7　三坐标测量技能训练操作规程 ···· 263
第
15章　机械装配与拆卸
····················266
15.1　概述 ···································· 266
15.1.1　装配要求、方法和配合性质·· 266
15.1.2　装配流程 ························· 268
15.2　几种典型装配工作··················· 269
15.2.1常用连接件的装配················ 269
15.2.2　滑动轴承、滚动轴承的装配·· 272
15.2.3　齿轮的装配 ······················ 273
15.2.4　装配自动化 ······················ 274
15.3　装配示例······························· 275
15.4　机械的拆卸···························· 277
15.5　机械拆装安全操作规程
············· 277
第
16章　典型零件加工工艺
················280
16.1　概述 ···································· 280
16.2　工艺过程与生产类型················ 281
16.3　机械加工工艺规程··················· 282
#12;
16.4　典型表面的加工方法················ 285
16.4.1　外圆面的加工方法 ············· 285
16.4.2　内圆面的加工方法 ············· 286
16.4.3　平面的加工方法 ················ 287
16.5　拟订工艺路线························· 288
16.5.1　确定加工方案 ··················· 288
16.5.2　选择定位基准 ··················· 288
16.5.3　划分加工阶段 ··················· 290
16.5.4　安排加工顺序 ··················· 290
16.6　典型零件的加工工艺················ 291
16.6.1　典型轴类零件的加工工艺····· 292
16.6.2　典型盘套类零件的加工
工艺 ······························· 293
16.6.3　典型支架箱体类零件的加工
工艺 ······························· 296
参考文献
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