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模具設計報告 設計題目:墊圈倒裝復合模設計 專 業(yè) 名 稱: 班 級: 姓 名: 指 導 教 師: 時 間: 2009 年 12 月 20 日 - 目 錄 1. 沖材件工藝性分析.1 1.1 材料 1.2 工件結構形狀 1.3 尺寸精度 2.沖裁工藝方案的確定. 3.模具結構形式的確定. 4.模具總體設計. 4.1 模具類型的選擇 4.2 操作與定位方式 4.3 卸料、出件方式 4.4 確定送料方式 4.5 確定導向方式 5 模具設計計算. 5.1 排樣 計算條料寬度、確定步距、計算材料利用率 5.2 沖壓力的計算 5.3 模具壓力中心的確定 5.4 模具刃口尺寸的計算 5.5 卸料橡膠的設計 6.主要部零件設計. 6.1 工作零件的結構設計 6.2 卸料部件的設計 6.3 模架及其他零部件的選用 7 校核模具閉合高度及壓力機有關參數. 7.1 校核模具閉合高度 7. 2 沖壓設備的選定 參考文獻. - 1 沖裁件工藝性分析 工件名稱:六角墊圈 工件簡圖:如圖 1-1 所示 生產批量:大批量 材料:45 鋼 材料厚度:2mm 圖 1-1 1.1 材料 查沖壓手冊知:45 鋼為普通碳素結構鋼,具有良好的塑性、焊接性以及壓力加工 性,主要用于工程結構和受力較小的機械零件。綜合評比均適合沖裁加工。 1.2 工件結構形狀 工件結構形狀相對簡單,成中心對稱,只有一個 20 的孔,孔與邊緣之間的距離 也滿足要求,可以沖裁。 1.3 尺寸精度 零件圖上未注公差為 IT12 級,尺寸精度較低,普通沖裁完全可以滿足要求。 根據以上分析:該零件沖裁工藝性較好,適宜沖裁加工。 2 沖裁工藝方案的確定 方案一:先沖孔,后落料。單工序模生產。 - 方案二:沖孔落料復合沖壓。復合模生產。 方案三:沖孔落料級進沖壓。級進模生產。 結合所學模具設計知識分析知:方案一模具結構簡單,制造周期短,制造簡單, 但需要兩副模具,成本高而生產效率低,難以滿足大批量生產的要求。方案三只需一 副模具,生產效率高,操作方便,精度也能滿足要求,但模具輪廓尺寸較大,制造復 雜,成本較高。方案二也只需一副模具,制件精度和生產效率都較高,且工件最小壁 厚大于凸凹模許用最小壁厚模具強度也能滿足要求。沖裁件的內孔與邊緣的相對位置 精度較高,板料的定位精度比方案三低,模具輪廓尺寸較小,制造比方案三簡單。 通過對上述三種方案的分析比較,該工件的沖壓生產采用方案二為佳。 3 模具結構形式的確定 正裝式復合模和倒裝式結構比較: 正裝式復合模適用于沖制材質較軟或板料較薄的平直度要求較高的沖裁件,還可 以沖制孔邊距較小的沖裁件。 倒裝式復合模不宜沖制孔邊距較小的沖裁件,但倒裝式復合模結構簡單,又可以 直接利用壓力機的打桿裝置進行推件卸件可靠,便于操作,并為機械化出件提供了有 利條件,所以應用十分廣泛。 根據零件分析,制件的精度要求較低,孔邊距較大,為提高經濟效益和簡化模具 結構,適宜 采用倒裝復合模生產。 根據以上分析確定該制件的生產采用倒裝式復合模具生產 4 模具總體設計 4.1 模具類型的選擇 經分析,工件尺寸精度要求不高,形狀較簡單,但工件產量較大,根據材料厚度, 為保證沖模有較高的生產率,通過比較,決定實行工序集中的工藝方案,彈性卸料裝 置,自然漏料的倒裝復合結構方式。 4.2 操作與定位方式 4.2.1 操作方式 零件的生產批量較大,但合理安排生產可用手工送料方式,提高經濟效益。 4.2.2 定位方式 因為導料銷和固定擋料銷結構簡單,制造方便。且該模具采用的是條料,根據模 - 具具體結構兼顧經濟效益,控制條料的送進方向采用導料銷,控制送料步距采用固定 擋料。 4.3 卸料、出件方式 4.3.1 卸料方式 彈壓卸料板具有卸料和壓料的雙重作用,主要用于料厚小于或等于 2mm 的板料由 于有壓料作用,沖件比較平整。卸料板與凸模之間的單邊間隙選擇(0.10.2)t,若 彈壓卸料板還要起對凸模導向作用時,二者的配合間隙應小于沖裁間隙。常用作落料 模、沖孔模。工件平直度較高,料厚為 2mm 相對較薄,卸料力不大,由于彈壓卸料模 具比剛性卸料模具方便,操作者可以看見條料在模具中的送進動態(tài),且彈性卸料板對 工件施加的是柔性力,不會損傷工件表面,故可采用彈性卸料。 4.3.2 出件方式 因采用倒裝復合模生產,故采用下出件為佳。 4.4 確定送料方式 因選用的沖壓設備為開式壓力機,采用縱向送料方式,即由前向后送料。 4.5 確定導向方式 方案一:采用對角導柱模架。由于導柱安裝在模具壓力中心對稱的對角線上,所 以上模座在導柱上滑動平穩(wěn)。常用于橫向送料級進?;蚩v向送料的落料模、復合模。 方案二:采用后側導柱模架。由于前面和左、右不受限制,送料和操作比較方便。 因為導柱安裝在后側,工作時,偏心距會造成導套導柱單邊磨損,嚴重影響模具使用 壽命,且不能使用浮動模柄。 方案三:四導柱模架。具有導向平穩(wěn)、導向準確可靠、剛性好等優(yōu)點。常用于沖 壓件尺寸較大或精度要求較高的沖壓零件,以及大量生產用的自動沖壓模架。 方案四:中間導柱模架。導柱安裝在模具的對稱線上,導向平穩(wěn)、準確。單只能 一個方向送料。 根據以上方案比較并結合模具結構形式和送料方式,為提高模具壽命和工件質量, 采用后側導柱的導向方式,即方案四最佳。 5 模具設計計算 5.1 排樣 計算條料寬度、確定步距、計算材料利用率 5.1.1 排樣方式的選擇 - 方案一:有廢料排樣 沿沖件外形沖裁,在沖件周邊都留有搭邊。沖件尺寸完全 由沖模來保證,因此沖件精度高,模具壽命高,但材料利用率低。 方案二:少廢料排樣 因受剪切條料和定位誤差的影響,沖件質量差,模具壽命 較方案一低,但材料利用率稍高,沖模結構簡單。 方案三:無廢料排樣 沖件的質量和模具壽命更低一些,但材料利用率最高。 通過上述三種方案的分析比較,綜合考慮模具壽命和沖件質量,該沖件的排樣方 式選擇方案一為佳??紤]模具結構和制造成本有廢料排樣的具體形式選擇直排最佳。 5.1.2 計算條料寬度 搭邊的作用是補償定位誤差,保持條料有一定的剛度,以保證零件質量和送料方 便。搭邊過大,浪費材料。搭邊過小,沖裁時容易翹曲或被拉斷,不僅會增大沖件毛 刺,有時還有拉入凸、凹模間隙中損壞模具刃口,降低模具壽命。或影響送料工作。 搭邊值通常由經驗確定,表 4 所列搭邊值為普通沖裁時經驗數據之一。 根據零件形狀,查表 4 工件之間搭邊值 a=2.0mm, 工件與側邊之間搭邊值 a1=3mm, 條料是有板料裁剪下料而得,為保證送料順利,規(guī)定其上偏差為零,小偏差為負值 B=(Dmax2a) -0 (公式 5-1) 式中 Dmax條料寬度方向沖裁件的最大尺寸; a 沖裁件之間的搭邊值; 板料剪裁下的偏差(其值查表 5-2) ; B=(36.69 23) =45.690-0.5(mm) 所以條料寬度在 45.1945.69mm 表 5-1 搭邊值和側邊值的數值 圓件及 r2t 圓角 矩形邊長 l50 矩形邊長 l50 或圓角 r2 材料厚度 t 工件間 a1 側邊 a 工件間 a 側邊 a1 工件間 a1 側邊 a 0.25 以下 1.8 2.0 2.2 2.5 2.8 3.0 0.250.5 1.2 1.5 1.8 2.0 2.2 2.5 0.50.8 1.0 1.2 1.5 1.8 1.8 2.0 - 0.81.2 0.8 1.0 1.2 1.5 1.5 1.8 1.21.5 1.0 1.2 1.5 1.8 1.9 2.0 1.62.0 1.2 1.5 2.0 2.2 2.0 2.2 表 5-2 剪裁下的下偏差( mm) 條料寬度(mm) 條料厚度(mm) 50 50100 100200 200 0.5 0.5 0.7 1.0 0.5 1.0 1.0 1.0 3 1.0 1.0 1.0 1.5 4 1.0 1.0 1.0 2.0 5.1.3 確定步距 送料步距 S:條料在模具上每次送進的距離稱為送料步距,每個步距可沖一個或 多個零件。進距與排樣方式有關,是決定擋料銷位置的依據。條料寬度的確定與模具 的結構有關。 進距確定的原則是,最小條料寬度要保證沖裁時工件周邊有足夠的搭邊值;最大 條料寬度能在沖裁時順利的在導料板之間送進條料,并有一定的間隙。 送料步距 S S 17.32mm17.32mm 2mm 36.64(mm) 排樣圖如圖 5-2 所示。 - 圖 5-2 排樣圖 5.1.4 計算材料利用率 沖裁件的實際面積與所用板料面積的百分比叫材料的利用率,它是衡量合理利用 材料的重要指標。 一個步距內的材料利用率 /BS100% (公式 5-2) 式中A一個步距內沖裁件的實際面積; B條料寬度; S步距; =725 45.6936.64100% =45% 5.2 沖壓力的計算 5.2.1 沖裁力的計算 用平刃沖裁時,其沖裁力一般按下式計算: F=KLtb ( 公式 5-3) 式中F 沖裁力; L沖裁周邊長度; - t材料厚度; b材料抗剪強度; K系數,系數是考慮到實際生產中,模具間隙值的波動和不均勻,刃 口磨損、板料力學性能和厚度波動等原因的影響而給出修正系數,一般取=1.3。 計算沖裁件輪廓周長 L L=d6b (公式 5-4) 式中 d沖裁孔的直徑; b沖裁件邊長; L=3.1420619.24 =178.24(mm) 查表 2-1 取 b=350Mpa 所以 F=KLtb =1.3178.242350 =162200(N) 5.2.2 卸料力、推料力的計算 卸料力 FX FX=KXF (公式 5-5) 推料力 FT FT =nKTF (公式 5-6) n梗塞在凹模內的制件或廢料數量(n=h/t) ; h直刃口部分的高(mm); t 材料厚度(mm) FX=KXF =0.04162200 =6488(N) - (K X、K T 為卸料力、推件力系數,其值查表 5-3 可得) FT=nKTF =40.055162200 =35684(N) 所以總沖壓力 FZ=F+FX+FT =162200N+6488N+35684N =204372(N) 根據沖壓力計算結果擬選壓力機規(guī)格為 J2325。 5.3 模具壓力中心的確定 模具壓力中心是指沖壓時諸沖壓力合力的作用點位置。為了確保壓力機和模具正 常工作,應使模具的壓力中心與壓力機滑塊的中心相重合,否則,會使沖模和力機滑 塊產生偏心載荷,使滑塊和導軌之間產生過大的摩擦,模具導向零件加速磨損,降低 模具和壓力機的使用壽命。該零件為中心對稱圖形,其幾何中心即為壓力中心。 表 5-3 卸料力、推件力和頂件力系數 料厚 t/mm KX KT KD 鋼 0.1 0.10.5 0.52.5 2.56.5 6.5 0.0650.075 0.0450.055 0.040.05 0.030.04 0.020.03 0.1 0.063 0.055 0.045 0.025 0.14 0.08 0.06 0.05 0.03 鋁、鋁合金 純銅,黃銅 0.0250.08 0.020.06 0.030.07 0.030.09 5.4 工作零件刃口尺寸計算 5.4.1 落料凹、凸模刃口尺寸計算 該制件外形為一正六邊形,相對較復雜,適合采用凸凹模配作加工。配作法加工 的特點是模具的間隙由配做保證,工藝比較簡單,無需較核 T AZ maxZmin 的 條件,并且還可以放大基準件的制造公差,使制造容易,所以采用配作法加工。 落料凹模刃口磨損后,刃口尺寸只有一種變化,全部變大。其刃口尺寸一般按式 5-7 計算。 AA=(A max-x) 0+0.25 (式 5-7) 式中 Amax垂直于送料方向的凹模刃口間的最大距離; - x 凹模磨損系數; 刃口制造公差; 1)凹模刃口尺寸計算 基本尺寸 39.85、34.64,按 IT12 級將其轉化為 39.850-0.25、34.64 0-0.25。查表 5-4 得 x=0.75。 A1=(39.850.750.25) 0+0.250.25 =39.650+0.06(mm) A2 =(34.640.750.25) 0+0.250.25 =34.440+0.06(mm) 將 A1、A 2 轉化為整數尺寸: A1=40-0.29-0.35 A2=35-0.5-0.56 2)落料凸模刃口尺寸計算 制件精度不高,為 IT12 級,確定刃口間隙時主要考慮模具壽命,故應該取較大間 隙。查表得: Zmax=0.360mm Zmin=0.246mm 所以 Z=Z max=0.360mm 落料凸模刃口尺寸 B1=39.650-0.3 B2=34.440-0.3 將其轉換為整數尺寸: B1=40-65-0.35 B2=35-0.86-0.56 表 5-4 系數 X 非圓形 圓形 1 0.75 0.5 0.75 0.5料厚 t(mm) 工件公差/mm 1 12 24 0.16 0.20 0.24 0.170.35 0.210.41 0.250.49 0.36 0.42 0.50 0.16 0.20 0.24 0.16 0.20 0.24 - 4 0.30 0.310.59 0.60 0.30 0.30 5.4.2 沖孔凸模、凹模尺寸計算 該制件只有一個圓形的孔,適宜采用凸、凹模分開加工。其尺寸計算公式: dT=(dminx) 0-T (式 5-8) dA=( dTZ min)A 0 (式 5-9) 表 5-5 規(guī)則形狀沖裁時凸、凹模制造偏差(mm) 基本尺寸 凸模偏差 dT 凹模偏差 dA 18 0.020 0.020 1830 0.020 0.025 3080 0.020 0.030 80120 0.025 0.035 120180 0.030 0.040 180260 0.030 0.045 260360 0.035 0.050 360500 0.040 0.060 500 0.050 0.070 查表 5-4、5-5 得: A=0.020mm T=0.020mm X=0.75 校核: T A=0.040mmC maxC min,滿足 T A C maxC min 的條件。 將已知和查表所得的數據代入公式,即得: dT=(20+0.750.21) 0-0.20=20.160-0.20mm dA=(20+0.246)0+0.20=20.250+0.20mm 5.5 卸料橡膠的設計 5.5.1 卸料板工作行程 h h=h1+h2+t =1+2+2=5(mm) - h1 為凸凹模凹進卸料板的深度 1mm,h 2 為凸凹模沖裁后進入凹模的深度 2mm,t 為 材料厚度 2mm。 5.5.2 卸料橡膠工作行程 H H=h1+h0 =5+5=10(mm) h0 為凸凹模修磨量,取 5mm 5.5.3 卸料橡膠自由高度 H0 H0=4H =411=40(mm) 取 H 為 H0 的 25% 5.5.4 卸料橡膠的預壓縮量 H1 H1 =15%H0 =0.1540=6(mm) (一般取 H1=10%15%H0) 5.5.5 每個橡膠所承受的載荷 F1 根據模具安裝位置和模具結構,選取 4 個卸料橡膠。 F1=Fx/4 =6488/4=1622(N) 5.5.6 卸料橡膠的外徑 D D2=d2+1.27F1/P =1444mm 所以 D=36(mm) (取 P=1,d=13) 5.5.7 較核卸料橡膠自由高度 H0 X=H0/D =44/38=1.16 0.5H01.5 ,滿足要求 - 5.5.8 卸料橡膠安裝高度 H2 H2=H0-H1 =40-6=36(mm) 6 主要部零件設計 6.1 工作零件的結構設計 6.1.1 落料凹模 落料凹模采用整體凹模,采用線切割機床加工,安排凹模在模架上的位置時,要 依據計算壓力中心的數據,將壓力中心與模柄中心重合。其外形尺寸按相關公式計算: 凹模厚度 H=KB (公式 6-1) =0.539.85=19.925(mm) 取凹模厚度 H=20mm 凹模壁厚 c=(1.52)H =(3040)mm 取凹模壁厚 c=40mm 凹模寬度 B=b2c (公式 6-2) =39.85402 =119.85(mm) 取凹模寬度 B=120mm 凹模長度 L=S12S 2 (公式 6-3) =34.64236=108.64(mm) 取凹模長度 L=120mm 凹模整體輪廓尺寸 LBH=120mm120mm20mm 6.1.2 沖孔凸模 所沖孔為圓形孔,為方便裝配和滿足凸模強度將沖孔凸模設計成階梯式,采用數 - 控銑床、線切割加工。其總長按相關公式計算: Lh h 202058(mm) (h 為凹模厚度,h 為凸模固定板厚度。 ) 6.1.3 凸凹模 制件外形比較復雜,考慮加工和強度,把凸凹模設計成臺階式。采用用線切割機 床和數控銑床加工。其長度 L 可按式 6-4 計算: L=H 墊 H 卸 Y (公式 6-4) 式中 Y 凸凹模修磨量 L102034 64(mm) 6.2 卸料部件的設計 6.2.1 卸料板的設計 卸料板采用 45 鋼制造,淬火硬度 4045HRC,卸料板輪廓尺寸與落料凹模輪廓尺 寸相同,厚度為 15mm。 6.2.2 卸料螺釘的選用 卸料板上設置 4 個卸料螺釘,公稱直徑為 10mm,螺紋部分為 M810mm,卸料螺釘 尾部應留有足夠的行程空間,以保證卸料的正常運動。卸料螺釘擰緊后,應使卸料螺 板超出凹模端面 1mm,有誤差時通過在螺釘與卸料板之間安裝墊片來調整。 6.3 模架及其他零部件的選用 以凹模輪廓尺寸為依據,選擇模架規(guī)格。選一大一小兩組導套、導柱。導柱 d/mmL/mm 為 28mm180mm,導套 d/mmL/mmD/mm 為 28mm110mm 43mm;導柱 d/mmL/mm 為 32mm180mm ,導套 d/mmL/mmD/mm 為 32mm110mm 45mm。 上模座厚度 H1取 40mm,墊板厚度取 10mm,固定板厚度取 20mm,卸料板厚度取 15mm,凹模厚 20mm,下模坐厚度取 45mm。 模具閉合高度 H H4010406410452 - 207(mm) 7 校核模具閉合高度及壓力機有關參數 7.1 校核模具閉合高度 模具閉合高度 H 應該滿足 HminH 110HHmaxH 15(公式 7-1) 式中 Hmax壓力機最大閉合高度; Hmin壓力機最小閉合高度; H1墊板厚度。 根據擬選壓力機 J2325,查開式壓力機參數表(見附錄 2)得: Hmax=320mm, Hmin=180mm,H1=50mm 將以上數據帶入公式 7-1,得 140H265 經計算該模具閉合高度 H=207mm,在 140mm265mm 內,開式壓力機 J23 25,滿足要求。 7.2 沖壓設備的選定 通過校核,選擇開式雙柱可傾式壓力機 J2363 能滿足使用要求。其主要技 術參數如下: 公稱壓力:250KN 滑塊行程:65mm 最大閉合高度:270mm 最大裝模高度:220mm 工作臺尺寸(前后左右):370mm560mm 墊板尺寸(厚度直徑):50mm200mm 模柄孔尺寸:40mm60mm 最大傾斜角度:30 0 - 參考文獻 1閻其鳳主編.模具設計與制造.北京:機械工業(yè)出版社出版,2000. 2甄瑞麟主編.模具制造工藝學.北京:清華大學出版社出版,2005. 3王孝培主編.沖壓手冊.北京:機械工業(yè)出版社,2000 4 5 4翁其金主編.沖壓工藝與沖模設計.北京:機械工業(yè)出版社出版,1999. 5程俊偉、馮憲章、劉長紅主編.模具設計指導書
編號
無錫太湖學院
畢業(yè)設計(論文)
相關資料
題目: 啟動電機殼體冷沖壓工藝
及模具設計
信機 系 機械工程及自動化專業(yè)
學 號: 0923279
學生姓名: 李鵬飛
指導教師: 鐘建剛(職稱:副教授)
(職稱: )
2013年5月25日
目 錄
一、畢業(yè)設計(論文)開題報告
二、畢業(yè)設計(論文)外文資料翻譯及原文
三、學生“畢業(yè)論文(論文)計劃、進度、檢查及落實表”
四、實習鑒定表
無錫太湖學院
畢業(yè)設計(論文)
開題報告
題目: 啟動電機殼體冷沖壓工藝及模具設計
信機 系 機械工程及自動化 專業(yè)
學 號: 0923279
學生姓名: 李鵬飛
指導教師: 鐘建剛 (職稱:副教授)
(職稱: )
2012年11月20日
課題來源
來源于無錫毅立模具有限公司,是電器產品上的一個零件。
課題來源于生產實際,探討沖壓加工中較常見零件的工藝方法和結構設計。課題涉及知識面較廣,且設計要求較高,對學生的設計能力,特別是思考能力是一個很好的鍛煉。課題研究內容包括機械工程學科的力學,材料學,機械原理,機械設計,公差與互換性,機械制造工藝等知識,特別鍛煉學生規(guī)范性設計的能力。使學生能得到全面的鍛煉。課題要求學生具備較強的機構設計能力和創(chuàng)新能力,對學生是一個挑戰(zhàn)。課題為典型的機械設計類課題,涉及機械知識全面,與工程機械專業(yè)方向結合緊密。
科學依據(包括課題的科學意義;國內外研究概況、水平和發(fā)展趨勢;應用前景等)
(1)課題科學意義
沖壓模具作為一種生產工具已經運用到各行各業(yè),其發(fā)展快,模具需求量之多,是前所未有的。當今,在國民經濟的各個工業(yè)部門。都越來越多的依靠模具來進行生產加工,模具已成為國民經濟的基礎工業(yè),已成為當代工業(yè)的基本手段和工藝發(fā)展手段之一?,F代工業(yè)產品的品種和生產效益的提高,是高技術含量的社會產品,其價值和價格主要取決于模具材料、加工、外購件的勞動與消耗三項直接發(fā)生的費用和模具設計與試模等技術費用,后者是模具價值與市場價格的主要組成部分,其中一部分技術價值計入了市場價格,而更大的一部分價值,則是模具用戶和產品用戶受惠變?yōu)樯鐣б?。如電視機用模,其模具費用為產品價格的1/3000~1/5000,盡管模具的一次投資較大,但大批量生產后,其模具成本占很小的部分,甚至可以忽略不計,而實際上,很高的模具價格為社會所擁有,變成了社會財富。所以本模具設計擁有很高的現實意義。
(2)研究狀況及其發(fā)展前景
目前我國模具市場總體趨勢平穩(wěn)向上。目前,國內市場對中高檔家電、汽車、塑料制品模具的需求量很大,但要求國產模具必須在質量、交貨期等方面滿足用戶的需求。我國加入WTO后,伴隨著世界經濟的一體化浪潮,全球制造業(yè)加速向中國大陸地區(qū)轉移已是大勢所趨,中國也將逐步發(fā)展成為世界級的制造業(yè)基地。中低檔的模具國際市場潛力十分巨大,只要國產模具的質量能夠有提高,交貨期能夠保證,模具出口的前景是十分樂觀的。優(yōu)勢明顯的廣東特別是珠三角地區(qū),將在十年之內發(fā)展成為
世界模具生產中心。同時,由于近年來我國每年用近10億美元進口模具,其中精密、大型、復雜、長壽命模具占多數,所以從減少進口角度出發(fā),這類高檔模具在市場的分額比例也將逐步增大。現代模具其高技術、人才密集、高技術背景下的工藝密集型工業(yè)的特點,是在新型工業(yè)化道路上走在前面的產業(yè),模具作為重要的制造裝備行業(yè)在為各行各業(yè)服務的同時,也直接為高新技術產業(yè)服務,模具在制造業(yè)產品研發(fā)、創(chuàng)新和生產中所具有的獨特的重要地位,使得模具制造能力和水平的高低也成為國家創(chuàng)新能力的重要標志。
隨著電子、信息等高新技術的不斷發(fā)展,模具CAD/CAE/CAM正向集成化、三維化、智能化和網絡化方向發(fā)展。模具CAD/CAE/CAM技術是模具設計、制造技術的發(fā)展方向,模具和工件的檢測數字、模具軟件功能集成化、模具設計、分析及制造的三維化、模具產業(yè)的逆向工程以及模具軟件應用的網絡化是主趨勢。
研究內容
本課題研究的是啟動電機殼體沖壓模具設計,要求其材料08F鋼,采用大批量生產,精度要求高。通過合理的設計凸凹模,選擇合理的標準模架,制造出符合要求的制件。
(1)查閱有關模具設計方面的資料,翻譯與模具設計相關的英文文獻;
(2)對工件進行沖壓成型工藝分析,選擇合理的設計方案;
(3)進行必要的參數計算,確定出正確的設計參數;
(4)在計算正確的基礎上設計沖壓成型模具;
(5)撰寫出一份與自己設計相配套的設計說明書。
擬采取的研究方法、技術路線、實驗方案及可行性分析
1、分析沖壓件的工藝性,確定工藝方案。
根據設計題目,分析沖壓件成型的結構工藝性,分析沖壓件的形狀特點、精度要求等。在分析了沖壓件的工藝性后,可以列出幾種不同的沖壓方案,然后從產品質量、生產效率、設備占有情況、模具制造難易程度和模具壽命高低、工藝成本等,確定最經濟合理的工藝方案。
2、確定毛坯形狀、尺寸和下料方式
在最經濟的原則下,確定毛坯形狀、尺寸和下料方式,并確定材料的消耗量。
3、確定沖壓模類型及結構形式
4、進行必要的工藝計算
5、選擇壓力機。
6、繪制模具總圖和非標準零件圖。
7、編寫設計計算所明書。
研究計劃及預期成果
研究計劃:
2012年11月12日-2012年12月2日:按照任務書要求查閱論文相關參考資料,填寫畢業(yè)設計開題報告書。
2012年12月3日-2012年12月31日:工作計劃、進度。
2013年3月4日-2013年3月15日:查閱參考資料,學習并翻譯一篇與畢業(yè)設計相關的英文材料。
2013年3月18日-2013年4月5日:沖壓工藝設計,模具結構設計,刃口尺寸和主要零件結構設計和尺寸計算。
2013年4月15日-2013年5月3日:繪制模具裝配圖和零件圖。
2013年5月6日-2013年5月25日:工藝文件、畢業(yè)論文撰寫和修改工作。
預期成果:
1.完成模具裝配圖:2張(A0或A1);
2.零件圖:主要非標準件零件圖(不少于5張);
3.冷沖壓工藝卡片:1張;
4.設計說明書:1份;
5.翻譯8000以上外文印刷字符或譯出約5000左右漢字的有關技術資料或專業(yè)文獻,內容要盡量結合課題。
特色或創(chuàng)新之處
模具技術的特色應該為適應模具產品“交貨期短”、“精度高”、“質量好”,“價格低”的要求服務。
創(chuàng)新之處是通過研究各種新型材料及先進表明處理技術,使模具拋光技術向自動化,智能化發(fā)展。
已具備的條件和尚需解決的問題
已具備的條件:
1、工件的尺寸;
2、工件的價格方法;
3、工件的制造流程,工藝卡
尚需解決的問題:
拉深工藝的確定,沖壓力的大小和壓力機選擇,模具結構的確定,模具的裝配工藝等等。
指導教師意見
指導教師簽名:
年 月 日
教研室(學科組、研究所)意見
教研室主任簽名:
年 月 日
系意見
主管領導簽名:
年 月 日
英文原文
Overview of stamping die
Stamping Die - Stamping in the cold, the material (metal or non-metallic) processing into parts (or half) of a special technical equipment, called cold stamping die (commonly known as Die). Press - is at room temperature, using the die installed in the press to put pressure on the material to produce a separation or plastic deformation, and thus to obtain the necessary parts of a pressure processing method.
Stamping die in the form of many, the general categories according to the following main features:
1. According to the technical nature of
(1) Die along the closed or open contour the material are derived from mold. If blanking die, punch die, cut off the mold, cut mode, cutting mode, split mode, etc..
(2) bending mode to blank or blank sheet along a straight line (curved line) to bend, deform, and thus obtain a certain angle and shape of the workpiece in the mold.
(3) The drawing die is made of the blank sheet opening hollow, or hollow pieces of further changes to the shape and size of the mold.
(4) Die rough or semi-finished workpiece is convex according to plan, direct copy the shape of the die shape, the material itself, generate only local plastic deformation of the mold. Such as the bulging mode, reducing the die, expansion die, forming die rolling, flanging mold, plastic mold.
2. According to the degree classification process combination
(1) single process model in a press tour, just completed a die stamping process.
(2) composite model is only one station, in a press tour, at the same station at the same time to complete more than two or two die stamping process.
(3) Progressive Die (also known as the modulus of continuity) in the feeding direction, rough, with two or more of the station, at the press of a visit, work in different places on the completion of two or two successive Road over stamping die process.
Chong called cold stamping die Die-wide.
Cold stamping die is used in cold stamping die mold industry, and accessories required for high-performance structural ceramic materials, preparation methods, high-performance ceramic materials, molds and accessories from the zirconium oxide and yttrium aluminum powder increases, Pr element composition, Preparation is the solution of zirconia, yttria solution, praseodymium oxide solution, according to a certain percentage of alumina solution when mixed liquor, ammonium bicarbonate infusion, by co-precipitation synthesis of ceramic materials, molds and accessories needed for raw materials, reaction precipitate generated by the treatment, drying, calcining and accessories by high performance ceramic mold material superfine powder, and then after forming, sintering, finishing, they will have high-performance ceramic materials, molds and accessories. Advantages of this invention is the invention made of cold stamping dies and parts and long service life, the process does not appear in the press and its parts and stamping die bond generated the phenomenon of stamping surface is smooth, no glitches, can replace traditional high-speed steel, tungsten steel.
Die with the main parts
Die stamping tools is the main process equipment, stamping rely on the relative movement under the mold completed. Processing time because the upper and lower mold between the constant division and, if continued operation of the fingers of workers to enter or remain in the mold closed, there will certainly pose a serious threat to their personal safety.
(A) of the mold main parts, function and safety requirements
1. Working parts is a direct punch to blank forming the working parts, therefore, it is the key to mold parts. Punch not only sophisticated and complex, it should meet the following requirements:
(1) be of sufficient strength, can not be broken or destroyed during stamping.
(2) should be appropriate to its material and heat treatment requirements, to prevent too high hardness and brittle fracture.
2. Positioning parts positioning part is to determine the location of the parts installed blank, there are pins (board), gauge pin (plate), lead is sold, guide plate, knife set from the side, side pressure etc.. Design should be considered when positioning parts easy to operate and should not have had orientation, location to facilitate observation, preferably in the forward position, contouring to correct the pin location and positioning.
3. Binder, unloading and discharging parts binder components are blank holder, binder board.
Blank holder pressure can drawing blank holder force, thereby preventing billets under the action of the tangential pressure arch formed folds. The role of pressure plate to prevent movement and bounce blank. Top of the device, discharge board's role is to facilitate the pieces and clean up waste. Them by the spring, rubber and equipment, putting on the air-cushion support, can move up and down, knocking out pieces of the design should have enough top output, movement to the limited spaces. Stripper plate area should be minimized or closed position in the operating groove milling out empty-handed. Exposure of the stripper plate should have protection around the plate, to prevent finger inserted into or foreign objects inside, exposed surface edges should be blunt down.
4. Guide parts and guide sleeve guide pin is the most widely used part of a guide. Its role is to ensure punch the punching clearance when accurate match. Therefore, the guide posts, guide cover the gap should be less than the blanking clearance. Guide Post located next mold base, to ensure that the stroke bottom dead center, the lead column in the template on the face over the top for at least 5 to 10 mm. Guide columns should be arranged far away from the module and the pressure plate in the area, so the operator's arms do not get to take over the lead column material.
5. Supporting and clamping the upper and lower parts which includes templates, die handle, fixed plate punch, plate, stopper, etc..
Up and down the template is the basis of the cold die parts, other parts are respectively fixed at the top. Template plane size, especially around the direction to be compatible with the workpiece, too large or too small are not conducive to action.
Some molds (blanking, punching type mold) to the pieces of convenience, be set up under the mold plate. At this time the best and the template plate connected between the screw, the two plate thickness should be absolutely equal. Plate spacing out the pieces to be able to prevail, not too much, so as not to break the template.
6. Fastening parts which includes screws, nuts, springs, pins, washers, etc., are generally used standard parts. Die more with the amount of standard parts, design choice and flexibility should be tightened to ensure the top out of the need to avoid exposure to the surface fastener operating position, the staff and impede operation to prevent bumps.
Die with the development of
Since reform and opening, with the rapid development of the national economy, the market demand with the growing Die. In recent years, Die with the industry has been around 15% growth rate of the rapid development of industrial enterprises with ownership Die components also changed dramatically, in addition to the professional mold factory outside of state-owned, collective, joint ventures, wholly-owned and private has been a rapid development.
As with the accelerating pace of international integration, the increasing competition in the market, it has been increasingly recognized product quality, cost, and new product development capacities. The cold die manufacturing is the most basic elements of the chain, one of the cold die manufacturing technology to measure a country's manufacturing sector has become an important symbol of the level, and largely determine the viability of enterprises.
Die with enterprises to increase in recent years many technological advances for investment, technological progress will be seen as an important driving force for enterprise development. Some domestic enterprises have popularized the two-dimensional mold CAD, and gradually began to use UG, Pro / Engineer, I-DEAS, Euclid-IS and other international common software, individual manufacturers have also introduced Moldflow, C-Flow, DYNAFORM, Optris and MAGMASOFT etc. CAE software, and successfully applied in stamping die design.
A car cover mold as the representative of a large stamping die manufacturing technology has made great progress, Dongfeng Motor Corporation mold factory, mold manufacturers such as FAW mold center has been able to produce some car cover mold. In addition, many research institutions and universities to carry out technology research and development of mold. After years of effort, in the mold CAD / CAE / CAM technology has made remarkable progress; in improving quality and reducing mold die design and manufacturing cycle, and so contributed.
Although China Die with the industry over the past decade has made remarkable development, but in many ways compared with the industrialized countries there is still a large gap. For example, the precision machining equipment, processing equipment in Die with the relatively low proportion; CAD / CAE / CAM technology penetration is not high; many advanced mold technology not widely so, resulting in a considerable number of large, sophisticated, complex and long Die life with dependence on imports.
????With the continuous progress of science and technology, modern industrial production of increasingly complex and diverse, product performance and quality is ever increasing, thus the cold stamping technology put forward higher requirements. In order to adapt to the cold stamping technology industry needs, cold stamping technology itself also in innovation and development. cold stamping technology idea is to improve and expand as much as possible the advantages of the cold stamping process, to overcome its shortcomings. in the cold stamping technology development, should note the following aspects:
(1) cold stamping technology process parameters should be properly identified and Die with the work of some of the shape and size, to improve the quality of stamping parts and shorten the new product production cycle should be in strengthening the metal forming the basis of theoretical studies, to metal forming theory to practice can produce a direction, and gradually establish a close connection with the actual production of the advanced process of calculation. abroad have begun to use plastic finite element method, automobile parts forming process of the stress and strain analysis and computer simulation to predict the forming part of a process plan on the possibilities and potential problems.
(2) to accelerate product replacement, mold design to overcome the shortcomings of a long cycle. Should vigorously carry out computer-aided design and manufacture of molds (CAD / CAM) Research. In my country, paying particular attention to strengthening the multi-position progressive die CAD / CAM Technology.
(3) to meet the needs of mass production, and reduce labor intensity. Should strengthen cold stamping of mechanized and automated, so that the average, small pieces of high-speed presses in a multi-position progressive die production, production reached a high degree of automation to further improve stamping productivity.
(4) expand the scope of application of cold stamping production. So cold pressing both suitable for mass production, but also for small batch production; both the general accuracy of product production, but also can produce precision parts. Should pay attention to development such as fine blanking (especially thick material fine blanking), forming high-energy, soft mold forming, pressure and processing new superplastic forming process, but also promote the easy mode (soft mode and the low melting point alloy mold), Universal Hybrid model, the use of CNC punch press and other equipment.
In addition, the performance improvement of sheet metal stamping, mold new material, die development of new processing methods should be further strengthened.
Die with life and Countermeasures
Die with the life of the workpiece by punching out the number of terms. Many factors affect the life Die. There are die structure design, manufacture molds used in the punch and die materials, die quality and surface hardening heat treatment, precision die manufacturing parts and cold stamping materials selection. In addition, there are die installation, adjustment, use and maintenance.
1. Die Design on Life
(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.
(4) 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.
2. Die Die Life of
Die Die 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 o
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