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畢業(yè)設計（論文）中期報告 題目：汽車零件牛桿調(diào)整臂的模具設計 系 別 機電信息系 專 業(yè) 機械制及其自動化 班 級 姓 名 學 號 導 師 20130年 3月 18日 一、論文總體概述 本次畢業(yè)設計的課題是：汽車零件牛桿調(diào)整臂的沖壓模具設計。 沖壓模具：由金屬盒其他剛性材料制成的用于沖壓成形的工具。其基本零部件包括凸模、凹模以及壓邊裝置。模具設計與制造技術水平的高低，是衡量一個國家產(chǎn)品制造水平高低的重要標志之一，在很大程度上決定著產(chǎn)品的質(zhì)量、效益和新產(chǎn)品的開發(fā)能力。 二、設計進展狀況 為了加深對本課題的認識，了解國外的技術層次，上網(wǎng)查詢了外文資料文獻，并做了部分摘要的翻譯，為畢業(yè)設計的成功做出了鋪墊。鑒于沖壓模具于我是一門新的學科，很多知識需要現(xiàn)學現(xiàn)做，所以我選擇了從基礎開始。 1.冷沖壓工序 冷沖壓工序按工作性質(zhì)分為分離工序和變形工序兩大類。 分離工序主要是沖裁。而變形工序包括了彎曲、拉深、成形、擠壓等步驟。 2.冷沖壓模具的基本呢結(jié)構(gòu)形式 （1）單工序沖模 （2）復合模 （3）連續(xù)模 3.冷沖模零件的分類 （1）沖模工藝零件 A.工作零件 B.定位零件 C.卸料、推件零件 （2）沖模輔助零件 A.導向零件 B.支持零件 C.緊固零件 D.供力零件 沖裁的部分。主要是了解認識了沖裁。 沖裁是利用模具使板料沿一定的輪廓形狀產(chǎn)生分離的一種沖壓工序，沖裁包括落料、沖孔、切口、切邊等工序。 其中沖裁間隙是沖裁中的一個重要部分。間隙的大小直接影響了沖裁力的大小，沖件精度和沖件斷面質(zhì)量。在沖裁過程有一個需要注意的地方，就是沖裁件毛刺的產(chǎn)生。沖裁間隙過大時出現(xiàn)拉斷毛刺，而間隙過小時則出現(xiàn)擠壓毛刺。同樣的沖裁模的刃口變鈍，也會產(chǎn)生毛刺。除了毛刺還有沖裁件的工藝性，排樣搭邊等需要注意的地方。 沖裁這一步驟需要的計算，主要有凸、凹模刃口尺寸計算，沖裁力計算。 ① 其中凸凹模刃口尺寸的計算有兩種方法。 第一種應用在凸模和凹模分開加工的情況。我選擇的是另一種方法，先按計算的尺寸制造凸?；虬寄Ｖ械囊患鳛榛鶞始?，然后按基準件實際尺寸配制另一件。這種方法有以下特點：1.加工基準價時，可適當放寬公差，使其加工簡單。2.模具間隙是在配作加工中保證，在計算中可以免去校核凸模與凹模的公差和小于等于最大間隙和最小間隙的差。3.尺寸標注簡單，只需在基準件上標注尺寸和公差，配制件僅注明按基準件留出間隙配制即可。 ② 沖裁力的計算 沖裁力的計算公式為：P0= Ltτ 式中：P0——沖裁力，N； L ——沖裁件沖切輪廓長度，mm； t ——沖壓材料厚度，mm； τ ——材料抗剪強度，MPa。 完成了沖裁部分后，緊接著又進行了彎曲部分的設計計算。 彎曲是指將材料彎成一定角度和形狀，其中V形彎曲是最基本的一種。彎曲時的彎曲半徑R越小，毛坯外表面變形程度就越大。如果彎曲半徑過小，毛坯外邊面變形可能會超過材料變形極限而產(chǎn)生裂紋，因此，彎曲工藝受到最小彎曲半徑的限制。 彎曲中也有很多的不確定因素， 比如彎曲時的回彈，偏移。 不過這些不確定因素，也是可以盡可能避免的。 例如材料的力學性能，相對彎曲半徑，彎曲方式等諸多因素可以有效的避免回彈。同樣偏移也可以采用壓料裝置，使毛坯在壓緊狀態(tài)下逐漸彎曲成型。 三、后期的工作安排 進一步完善前期的工作計算，編制沖壓工藝規(guī)程。完成總裝配圖和零件圖，制定模具加工工藝流程。進行畢業(yè)設計總結(jié)，整理畢業(yè)設計論文，為這次畢業(yè)設計答辯做好最終答辯準備，為自己的大學畫一個完整的句號。 指導教師簽字： 年 月 日 Modo development The current existence question and the disparity mainly display in following several aspects: (1) The total quantity falls short of demand Domestic mold assembling oneself rate only ,about 70%. Low-grade mold , center upscale mold assembling oneself rate only has 50% about . (2) The enterprise organizational structure, the product structure, the technical structure and the import and export structure does not gather Iin our country mold production factory to be most is from the labor mold workshop which produces assembles oneself (branch factory), from produces assembles oneself the proportion to reach as high as about 60%, but the overseas mold ultra 70% is the commodity mold. The specialized mold factory mostly is "large and complete", "small and entire" organization form, but overseas mostly is "small but", "is specially small and fine". Domestic large-scale, precise, complex, the long life mold accounts for the total quantity proportion to be insufficient 30%, but overseas in 50% above 2004 years, ratio of the mold import and export is 3.7:1, the import and export balances the after net import volume to amount to 1.32 billion US dollars, is world mold net import quantity biggest country . (3) The mold product level greatly is lower than the international standard The production cycle actually is higher than the international water broad product level low mainly to display in the mold precision, cavity aspect and so on surface roughness, life and structure . (4) Develops the ability badly, economic efficiency unsatisfactory our country mold enterprise technical personnel proportion low The level is lower, also does not take the product development, frequently is in the passive position in the market. (1) Layout design of layout methods and take the boundary value a great impact on the die life, too small to take the boundary value, often causing rapid wear and convex mold, die bite wounds on the. Starting from material savings, take the boundary value smaller the better, but take the edge is less than some value, the cut surface of the mold and the quality of life adversely. There will be left behind in the blanking die Q-gap were to produce spare parts glitch, or even damage the die edge, reduce die life. Therefore, consider increasing the material utilization of the same time, parts must yield, quality and life expectancy to determine the layout methods and take the boundary.(2) die structure prone to stress concentration on the cracking of the die structure, composite structure can be used or mosaic structure, and prestressed structure to enhance the mold life.(3) the impact of clearance when the gap is too small, compressed extrusion of interest, increased friction, increased wear, the wear side of aggravated discharge and push pieces after blanking time, materials and convex, the friction between die will cause wear and tear than the end edge on the side of the grinding much, but also easily lead to convex, concave mold temperature is high, the adsorption of metal debris in the side edge to form a metal tumor, so that male and female die chipping or expansion occurs crack phenomenon. Therefore, the gap is too small to Die Life very bad. Gap is too large will increase the punch and the die face the edge of the concentration of stress, resulting in a sharp increase in stress, so blade edge quickly lose angular yield deformation. Therefore, addition of blanking force, thereby enabling faster edge edge wear, reduce die life. But in order to reduce the male and female die wear, extending mold life, while ensuring quality of stamping pieces under the premise that larger space designed properly it is necessary. Die-oriented structure of the life of a reliable guide for the working parts reduce wear, prevent male and female die bite wound is very effective. In particular, non-small-Q gap Q gap or Die, compound die and multi-position progressive die even more important. To improve the die life, must be based on processes and the demand of precision, the correct choice-oriented form and orientation accuracy, the choice should be higher than the accuracy-oriented convex, concave mold with precision. (5) the impact of cold stamping materials, cold stamping materials selected should meet the design requirements of workpieces and stamping process requirements, or easy to mold damage and reduce mold life. Poor surface quality of cold stamping, punching, cracking when the workpiece is also easy to scratch mold. Bad cold stamping plastic materials, deformation is small, easy to press when the workpiece rupture, but also easy to scratch mold. In addition, the material thickness tolerances shall comply with national standards. Die because of a certain thickness of material suitable for forming, bending, flanging, drawing die of the male and female die structure gap is directly determined by the thickness of the material. Therefore, uneven thickness, will result in waste generation and mold damage. Life of a mold material properties, chemical composition, structure, hardness and comprehensive reflection of metallurgical quality. Among them, the material properties and heat treatment affect the quality of the most obvious. Mold material properties on the impact of die life is great. If the same workpiece, using a different mold material of the bending test, the test results: The 9Mn2V material, the life of 5 million; with Crl2MoV nitriding, the life of up to 40 million. Therefore, the choice of materials, the batch size should be based on workpiece, rational use of mold materials. The hardness of the die parts to Die Life a great impact. But not the higher hardness, longer die life. This is because the hardness and strength, toughness and abrasion resistance are closely related. Some die demands of high hardness, long life. Such as the use of T10 steel dies, hardness 54 ~ 58HRC, only washed thousands of times a burr on the workpiece great. If the hardness to 60 ~ 64HRC, the grinding life of up to 2 to 3 million. However, if continue to improve hardness, fracture occurs earlier. Some die hardness should not be too high, as the die manufacturing using Crl2MoV 58 ~ 62HRC hardness, the general life of 2-3 million, invalid form of chipping and cracking, and if the hardness down to 54 ~ 58HRC, life expectancy increased to 5 ~ 60 000, but decreased to 50 ~ 53HRC hardness appears easy to blunt the die edge phenomenon. Thus, mold hardness must be based on material properties and failure modes may be. Should enable the hardness, strength, toughness and wear resistance, resistance to fatigue strength needed to achieve a particular stamping process the best match. The surface of the mold heat treatment to strengthen the quality and The surface of the mold heat treatment to strengthen the quality and The surface of the mold heat treatment to strengthen the quality and The surface of the mold heat treatment to strengthen the quality and impact on life impact on life impact on life impact on life . Mold heat treatment the nature and quality of life of the mold a great impact. Practice shows that the die parts of the quenching distortion and cracking, early fracture during use, while the metallurgical and materials quality, forging quality, mold structure and process related, but related more to die of heat treatment. According to statistical analysis of failure causes of mold, heat treatment failure due to improper accounting for more than 50%. Practice shows that the mold material must be accompanied by high heat treatment process properly, can really play a material's potential. Parts surface hardening mold work purpose is to obtain the effect of external hard tough inside, so be hardness, wear resistance, toughness, good resistance to fatigue with. Many ways to die surface hardening, surface treatment technology of new technologies developed rapidly. In addition to Nitrocarburizing and ion nitride, boride, seepage niobium, vanadium permeability, hard chrome plated and spark strengthening, the chemical vapor deposition (CVD) and physical vapor deposition (PVD) has been gradually adopted. By CVD and PVD treatment, the mold surface covered with super-hard material, such as TiC, TiN, etc.. High hardness, wear resistance, corrosion resistance, adhesion is very good, can improve the die life several times to several times. 4. Manufacturing precision of the die parts of die lifeManufacturing precision of the die parts of die lifeManufacturing precision of the die parts of die lifeManufacturing precision of the die parts of die life Precision die manufacturing and life in it in particular, mold surface roughness on the mold a great impact. If using Crl2MoV steel blanking die, if the surface roughness value R = 1 m, its life span is about 30,000. Such as polished by the precision, surface roughness value R = 0.4 m, life can be increased to 4-5 million. Therefore, the working parts of the mold surface, the general must go through grinding, grinding, polishing and other finishing and fine processing. 5. Other aspects of the impact of die life Other aspects of the impact of die life Other aspects of the impact of die life Other aspects of the impact of die life. (1) Press the accuracy is not high, but also easy to make die damage. (2) die in the press or not installed properly and the operator's technical level, on the tool life is also greatly affected. (3) dies in the custody and maintenance of good and bad, and the use of lubricant condition also affects mold life. Cold die clearances between control and adjusting Cold die clearances between control and adjusting Cold die clearances between control and adjusting Cold die clearances between control and adjusting methodmethodmethodmethod.Cold stamping mould convex, concave die size and distribution of the clearance degree directly affect the quality of the blanking pieces and the length of the service life of the die. In guarantee blanking pieces space is mould manufacturing assembly very important link, and assembly quality will directly influence the convex, concave die if the clearance between the uniform. Such as the process of convex, concave die size precision although already meet the requirements, but in assembling if adjustment is bad, can cause clearance does not even, rushed out of the spare parts of the raw edges. Even rushed out of unqualified parts. The mold assembly is key to control convex, concave die of relative positions, in order to ensure that the convex, concave die, uniform and the clearance between the right to rush out of qualified parts. 1. Die before assembly the problems that should be paid attentionDie before assembly the problems that should be paid attentionDie before assembly the problems that should be paid attentionDie before assembly the problems that should be paid attention Convex, concave die and mould parts itself is clearance of the precision, and the assembly of the assembly process is reasonable. In order to ensure that the position of the convex, concave die correctly and gaps even, mould design, processing to assembly from the whole link should pay attention to the following questions:（1）Convex, concave die design and manufacture of the right Design should be based on the above all when die cutting the section of a quality, service life of die factors such as the reasonable selection of convex, concave die clearance. And to consider the mould in the process of using that gap wear increases, general in the design the least reasonable clearance when mould. And in the manufacturing process can ensure the parts processing precision and quality, in the assembly process ensure convex, concave die gap even, this for processing complex shape is very key parts. （2）Assembly method the choice should be reasonable Die assembly method include roughly assembly method and direct with assembly method. Before the assembly must be carefully study mold assembly drawing, full consideration and analysis of the structure characteristics of punching die, die parts processing technology and processing accuracy etc, in order to choose convenient, accurate and reliable assembly method to ensure the quality of blanking pieces. 2. Convex, concave die gap between the control and adConvex, concave die gap between the control and adConvex, concave die gap between the control and adConvex, concave die gap between the control and adjustment of the justment of the justment of the justment of the methodmethodmethodmethod Convex, concave die clearance control, should according to die structure, clearance size, blanking pieces of quality and practical assembly condition to selected. Convex, concave die gap between the control and adjustment method have the following kinds. （1）Pervious to light method Will convex, concave die after molmerged, shone a light on the underside, observe the convex, concave die around through light and distribution to judge the size of the clearance and uniformity. If not even, to adjust to evenly between fixed again, this method is suitable for small gap plate stamping die. （2）Feeler method Will convex, concave die after molmerged, convex, concave die into the thickness of unilateral clearance feeler convex, concave die gaps in each direction. Then tighten the screw on mode. Finally put paper to stamping and will last mould seat and fixed on board with drilling, reaming positioning pin hole, and at a pin location. （3）Gaskets DiaoZhengFa Gasket adjustment method is simple, convenient, clearance is used widely. As shown in figure 1 shows, the mat with good contour mat iron, will gaskets wrapped in the punch to the punch into the concave mould, observe the convex, concave die clearance condition. If clearance does not even, with striking the protruding models of fixed plate method clearance adjustment, then tighten the screw on mode. Finally put paper to stamping, observation on paper cutting around burr and even rate to judge whether clearance convex, concave die even, to adjust the gap until cutting burr uniform so far. Finally the mould seat and the plate with drilling, reaming positioning pin hole, and enter the pin location. This method widely used cutting materials focusing thick large clearance and bending stamping, deep drawing mould clearance control. (4) Chemical method When the convex, concave die complex shape, the use of the above several methods more difficult to adjust the gap, the chemical method can be used to control the gap, the plating method is used. Plating method is the punch in the work surface coated with copper or zinc instead of washers. The plating thickness and unilateral gap is same, blade people concave die hole, and check the move without block phenomenon can assembly tighten. Coating in use process will die fall off naturally, need not removed. This uniform coating, can improve the uniformity of assembling clearance. (5) Technology DiaoZhengFa measures The main technological measures to adjust the gap between two kinds of the mould method:.1. Size method Processing of the punch, will the punch front-end appropriate lengthen, extended period of section size and sunken model hole processing to the same size. Assembly, make the punch into female model hole, natural form the cutting clearance, and then to the punch with fixed together with the punch mould seat on board with the pin for fixed and will last longer period of the punch front can remove form even clearance. 2. Positioning hole method Process positioning hole method and the inside of the progressive die principle about. Processing, the punch in fixed board and concave die on the same position processing two positioning hole, can will locate hole and the mold cavity a cut out. Assembly, in the positioning hole insert pins to ensure that gap. (6) Standard model method According to the drawing wedm in advance in processing a standard model or the qualified stamping parts, to adjust the assembly put it in between convex, concave die, upper and lower die relative motion can be reasonable degree when appropriate. (7) Measurement method Measuring method of the measuring tool have feeler. A feeler method after the adjustment convex, concave die clearance good uniformity, it is the commonly used method. Assembly, the punch in the concave die in the hole, convex, concave die according to the size of the clearance choose different specifications of the feeler insert convex, concave die clearance, inspection concave die around the blade gap everywhere, and according to the measured results adjustment. If the adjustment of the punch fixed board knock until adjust good so far. (8) Adjustment method of repair match means Die in use after period of time, because the convex, concave die normal wear and tear. To working parts inspection, if products produce burr, convex, concave die dull and collapse the blade factors, it is because of the convex, concave die clearance for wear changed, namely bigger or not even. To make the convex, concave die restored to the original gap value out of parts can use the following method to qualified for repair match means. 1. Convex, concave die clearance greaten repair match means method General dies in use after period of time, because normal wear will make convex, concave die gap increase gradually, thus to make the work and so on a series of problems produced burr. This kind of circumstance, can use first thickness is equal to one of the KuaiGui insert gap between the convex, concave die, if convex, concave die clearance does not too big, the grinding work part of the blade continue to use, can improve the quality of stamping. When gap value too big when, the recoverable high temperature heat of local forging the modification methods female die size make it restored to the original gap value. Workpiece cooling followed by the pressure seal the law to file to trim gap value, and with the flame hardening method to improve the blade surface hardness. 2. Convex, concave die clearance does not even repair match means method Dies after a period of using, clearance does not even can make blunt a local produce burr or the blade was edge chewed. In normal wear punching die, because after wearing precision guide device that reduce convex, concave die happen relatively migration, respectively in the guide pin and a guide to cover on the plating chromium layer the restored to its original size, again through the pressure seal the law will remove file high. If it is due to the pins loosening lose positioning function and cause different convex, concave die heart, and cause convex, concave die clearance does not even. Should first will convex, concave die gap adjusting well, to match for taper pin.Due to historical reasons for the formation of closed, "big and complete" enterprise features, most enterprises in China are equipped with mold workshop, in factory matching status since the late 70s have a mold the concept of industrialization and specialization of production. Production efficiency is not high, poor economic returns. Mold production industry is small and scattered, cross-industry, capital-intensive, professional, commercial and technical management level are relatively . According to incomplete statistics, there are now specialized in manufacturing mold, the product supporting mold factory workshop (factory) near 17 000, about 600 000 employees, annual output value reached 20 billion yuan mold. However, the existing capacity of the mold and die industry can only meet the demand of 60%, still can not meet the needs of national economic development. At present, the domestic needs of large, sophisticated, complex and long life of the mold also rely mainly on imports. According to customs statistics, in 1997 630 million U.S. dollars worth of imports mold, not including the import of mold together with the equipment; in 1997 only 78 million U.S. dollars export mold. At present the technological level