階梯圓筒的落料拉深復(fù)合模具設(shè)計(jì)【沖壓模具】
階梯圓筒的落料拉深復(fù)合模具設(shè)計(jì)【沖壓模具】,沖壓模具,階梯圓筒的落料拉深復(fù)合模具設(shè)計(jì)【沖壓模具】,階梯,圓筒,落料拉深,復(fù)合,模具設(shè)計(jì),沖壓,模具
畢業(yè)設(shè)計(jì)(論文)設(shè)計(jì)(論文)題 目 階梯圓桶落料拉深復(fù)合模具設(shè)計(jì)學(xué) 生 姓 名 指 導(dǎo) 教 師 20XX年 1 月 4 日 學(xué)院(系) 數(shù)控技術(shù) 專業(yè)畢 業(yè) 設(shè) 計(jì)論 文 任 務(wù) 書一、題目及專題:1、題目 沖壓模具設(shè)計(jì) 2、專題 階梯圓筒落料拉深模具設(shè)計(jì) 二、課題來源及選題依據(jù)課題來源:企業(yè)開發(fā)研制產(chǎn)品需要。 選題依據(jù):根據(jù)學(xué)生所學(xué)專業(yè)及教學(xué)大綱要求,結(jié)合相關(guān)企業(yè)實(shí)際生產(chǎn)需要及設(shè)計(jì)模式,促使學(xué)生將所學(xué)專業(yè)基礎(chǔ)知識及專業(yè)知識具體應(yīng)用到實(shí)踐中,培養(yǎng)其理論聯(lián)系實(shí)際的能力。 三、本設(shè)計(jì)(論文或其他)應(yīng)達(dá)到的要求:1根據(jù)零件的使用條件、技術(shù)要求、形狀和尺寸,確定該零件的冷沖壓工藝方案(包括排樣圖); 2選擇各工序沖壓設(shè)備,填寫沖壓工藝過程卡; 3設(shè)計(jì)本工序的工裝設(shè)備(模具); 4繪制全套模具圖(工序圖、排樣圖、裝配圖和零件圖); 5撰寫設(shè)計(jì)計(jì)算說明書一份,字?jǐn)?shù)約10000字符。 四、接受任務(wù)學(xué)生: 班 姓名 五、開始及完成日期:自20 年 11 月 05 至 20 年1月04日六、設(shè)計(jì)(論文)指導(dǎo)(或顧問):指導(dǎo)教師簽名 簽名 教研室主任學(xué)科組組長研究所所長簽名 院長(系主任) 簽名 年 月 日摘要此次畢業(yè)設(shè)計(jì)是由XX老師親自指導(dǎo),設(shè)計(jì)一副簡單的復(fù)合模具,經(jīng)過數(shù)個月的設(shè)計(jì),基本完成此次設(shè)計(jì)的任務(wù)。此副模具主要是階梯圓筒形零件的設(shè)計(jì),采用落料拉深兩道工序相結(jié)合的復(fù)合模,本人經(jīng)查閱相關(guān)書籍資料以隊(duì)此副模具所用到的相關(guān)公式數(shù)據(jù)做出了一個準(zhǔn)確的依據(jù)。此副模具的設(shè)計(jì)一共分為四章,和其他模具的設(shè)計(jì)一樣,首先第一章是對零件進(jìn)行了工藝分析,接著對工藝方案進(jìn)行了比較,最終確定采用先落料拉深后切邊的工藝方案,然后畫工序圖經(jīng)過計(jì)算選擇沖壓設(shè)備。第二章是選擇沖模類型以及結(jié)構(gòu)形式,接著是一些模具設(shè)計(jì)的相關(guān)數(shù)據(jù)計(jì)算。第三章是對模具凸模凹模加工工藝過程以及加工工藝方案的確定,最后填寫凸凹模加工工藝規(guī)程卡以及編制凸模數(shù)控加工程序。第四章是設(shè)計(jì)總結(jié)謝辭以及參考文獻(xiàn)。本人在設(shè)計(jì)過程中得到了其他同學(xué)的大力支持,并有XX老師的息心指導(dǎo),在此表示誠懇的感謝。由于本人水平有限,此次設(shè)計(jì)難免還存在一些缺點(diǎn)和錯誤,懇請閱讀者批評指正。 目 錄第1章 沖壓工藝設(shè)計(jì)11.1 零件的工藝分析11.2 制定沖壓工藝方案31.3 畫工序圖41.4 初選沖壓設(shè)備61.5編制沖壓工藝卡8第2章 沖壓模具設(shè)計(jì)102.1 沖模類型及結(jié)構(gòu)形式102.2 模具設(shè)計(jì)計(jì)算10第3章 模具主要零件加工工藝設(shè)計(jì)14 3.1 制定凸凹模加工工藝過程143.2 填寫凸凹模加工工藝規(guī)程卡16 3.3 編制凸?;虬寄?shù)控加工程序19第4章 設(shè)計(jì)總結(jié)21致謝22參考文獻(xiàn)23 第 23 頁 第1章 沖壓工藝設(shè)計(jì)1.1 零件的工藝分析此零件形狀為階梯圓筒形件,需要采用落料,拉深,切邊三道工序,通過計(jì)算確定拉深次數(shù)。零件材料為10鋼,根據(jù)參考文獻(xiàn)1表1.4.1得:10鋼的抗剪強(qiáng)度=210MPa。由此可見,其塑性較好,有較高的強(qiáng)度,適合于成形加工。=260440MPa、抗拉強(qiáng)度b=300440MPa伸長率10=29%、屈服強(qiáng)度=210MPa。由此可見,其塑性較好,有較高的強(qiáng)度,適合與成形加工。此零件毛坯形狀為圓形,故采用沖裁工藝中的落料工序。首先計(jì)算出毛坯的尺寸,根據(jù)毛坯尺寸要求計(jì)算出凸凹模的尺寸,但要注意落料見的尺寸應(yīng)增加修邊余量,以保證零件的高度。后面還有拉深等其它工序,最重要的是毛坯外形尺寸精度要保證下一道工序的完成。拉深見工藝性的好壞,直接影響到該零件能否用拉深方法生產(chǎn)出來,不僅能滿足產(chǎn)品的使用要求,同時(shí)也能夠用最簡單,最經(jīng)濟(jì)和最快的方法生產(chǎn)出來。拉深見外形尺寸的要求應(yīng)根據(jù)零件的高度以及厚度等選擇一次拉深還是多次拉深。1.計(jì)算落料毛坯尺寸:t=0.5mm2t=1mm,即滿足R1t,R2t ,所以拉深可以順利進(jìn)行,不需要增加整形工序,零件產(chǎn)品尺寸為、精度為IT10IT11級、,精度為IT14級,其中、 由拉深工序保證。拉深成形后切除零件多余外邊,保證零件最后的外形尺寸公差,故由切邊工序保證。1.2 制定沖壓工藝方案1.2.1 工藝方案分析比較此零件外殼形狀表明它為拉深件,所以拉深為基本工序,其毛坯可用落料工序完成。根據(jù)前面的計(jì)算,只需要一次拉深,故根據(jù)該零件所需基本沖壓工序,做出一個合格的零件,可以有三種工藝方案:第一種方案是把落料、拉深、二道工序做一個簡單復(fù)合模,然后再以切邊工序做一個單工序切邊模。第二種方案是以落料、拉深、切邊工序分開,各做一副單工序模。第三種方案是把落料、拉深、切邊三道工序并在一起,做一副多工位的級進(jìn)模。三種方案的比較:第一種方案:落料、拉深是一個簡單復(fù)合模,設(shè)計(jì)簡便,制造也不難生產(chǎn)效率高,裝夾方便,切邊工序作為單工序模,只要保證一個尺寸精度要求,方便、簡單。第二種方案:三道工序分開,分布鮮明,有序進(jìn)行,看得懂,弄得請,但效率不高,占用設(shè)備多,若單用一個設(shè)備,則需拆下來,裝上去次數(shù)多,比較麻煩。第三種方案:三道工序一起進(jìn)行,效率比較高,但是制造麻煩,周期長,成本高,只有大批量生產(chǎn)中才適合。1.2.2 工藝方案確定根據(jù)工藝方案的比較:方案一:落料拉深復(fù)合切邊方案二:落料拉深切邊方案三:落料、拉深、切邊級進(jìn)模綜合所有因素,此零件選用方案一。1.3 畫工序圖1.工序1:落料拉深(1)毛坯圖圖1-1(2)工序圖圖1-2 (3)排樣圖 a.計(jì)算開料寬度及步距由參考文獻(xiàn)1表2.5.2 取搭邊值=1.5mm =1.2mm由表2.5.3得 減料公差=0.4mm 導(dǎo)料間隙C=0.1mm考慮落料后需自然卸下條料 單惻需沖開0.5mm深缺口則開料寬度 B=(D-0.5+2+C) =(40-0.5+1.5+20.4+0.1) =41.9mm 取B=41.9mm 步距A=D+=40+1.2=41.2mm. 取A=42mmb.畫排樣圖圖1-3 2.工序2:切邊圖1-41.4 初選沖壓設(shè)備(1)計(jì)算拉深工藝力,相對厚度=1.25%1.5%t=0.5mm 根據(jù)參考文獻(xiàn)1表4.5.2 拉深時(shí)需采用壓邊圈。在該模具中可利用凸凹模與成型頂塊進(jìn)行壓邊。由于該零件只一次拉深 因此拉深時(shí)需兼整形。拉深工藝力應(yīng)按整形力計(jì)算。參考彎曲校正力進(jìn)行計(jì)算。查參考文獻(xiàn)1表3.3.3。取單位校正力q=40MPa則 (2)計(jì)算沖裁工藝力F沖=Ltb=400.5440=27632N由參考文獻(xiàn)1取頂件力系數(shù)K頂=0.08則 F頂=K頂F沖=0.0827632=2210.6NF總2=F沖+F頂=27632+2210.6=29842.6N(3)計(jì)算沖壓工藝力F總=F總1+F總2=47759.4+29842.6=77602N按F總=77602N,以及F總(0.70.8)F公 得 F公97002.5110860N查參考文獻(xiàn)2表8-10 初選壓力機(jī)為J23-161.5 編制沖壓工藝卡表1-1 沖壓工藝過程卡無錫技師學(xué)院沖壓工藝過程卡產(chǎn)品型號C003零(部)件名稱共1 頁產(chǎn)品名稱階梯圓筒零(部)件型號第 1 頁材料牌號及規(guī)格材料技術(shù)要求毛 坯 尺 寸每個毛坯可制件數(shù)毛坯重量輔助材料10鋼0.5481000工序號工序名稱工 序 內(nèi) 容加 工 簡 圖設(shè) 備工藝裝備備注0下料剪床上裁板481000材料厚度為0.5mm1落料拉深落料與拉深復(fù)合模J23-10落料拉深落料與拉深復(fù)合模編制(日期)審核(日期)會簽(日期)標(biāo)記處數(shù)更該文件號簽字日期標(biāo)記處數(shù)更該文件號簽字日期續(xù)表1-1無錫技師學(xué)院沖壓工藝過程卡產(chǎn)品型號C003零(部)件名稱共 1 頁產(chǎn)品名稱階梯圓筒零(部)件型號第 1 頁材料牌號及規(guī)格材料技術(shù)要求毛 坯 尺 寸每個毛坯可制件數(shù)毛坯重量輔助材料10鋼0.5481000工序號工序名稱工 序 內(nèi) 容加 工 簡 圖設(shè) 備工藝裝備備注2切邊切除凸圓邊達(dá)尺寸要求J23-10切邊模表示沖壓方向3檢驗(yàn)檢驗(yàn)所有尺寸編制(日期)審核(日期)會簽(日期)標(biāo)記處數(shù)更該文件號簽字日期標(biāo)記處數(shù)更該文件號簽字日期第2章 沖壓模具設(shè)計(jì)2.1 沖模類型及結(jié)構(gòu)形式此零件形狀為階梯圓筒形件,分為落料拉深(C003-1)、切邊(C003-2)兩副模具,本人設(shè)計(jì)C003-1模具,即落料拉深復(fù)合模,采用正裝式。利用擋料釘定距,模具本身利用M8螺釘固定及8銷釘定位,本模具采用彈頂器以及打桿作為卸料裝置。2.2 模具設(shè)計(jì)計(jì)算1壓力中心此零件為階梯圓筒形件,即屬于旋轉(zhuǎn)體件,結(jié)構(gòu)對稱,所以壓力中心應(yīng)該在其幾何中心。2各主要零件外形尺寸(1)落料凹模外形尺寸 由參考文獻(xiàn)1式(2.8.8)H=Kb查表2.8.2 K取0.3 b=40mmH1=Kb=0.340=12mm 按要求需滿足H115mm因?yàn)槭菑?fù)合模,另有拉深工序,零件高度為6mm,材料厚度為0.5mm,加之有凸模進(jìn)入凹模的深度,綜上所述,查參考文獻(xiàn)2,H=25mm由式(2.8.9)凹模壁厚C=(1.5-2)H1=(1.52)15=22.530mm 按要求需滿足C3040mm 故取 C=30mm為便于加工模板取圓形則D=230+40=100(2)固定板外形尺寸直徑D與凹模相同 為100mm厚度H2=(0.60.8)H1(0.60.8)25 =(1520)mm 取H2=20mm(3)墊板外形尺寸 直徑D=100mm厚度H3=(612)mm取H3=8mm各模板采用8與M8螺釘定位與連接根據(jù)參考文獻(xiàn)4 孔距取76mm(4)凸凹模、凸凹模型芯、成形頂塊、拉深凸模外形尺寸根據(jù)成型要求凸凹模、凸凹模型芯、成形頂塊以及拉深凸凹模長度分別為41mm、35.5mm、18.5和42.5mm。綜上所述,歸納所得 (單位:mm)落料凹模10025 GB2858.4-81上、下固定板10020 GB2858.5-81上、下墊板1008 GB2858.5-81凸凹模:4640凸凹模型芯:935.5成形頂塊:4018.5拉深凸模:1442.5聯(lián)接螺釘:M8 GB70-85定位銷釘:8 GB119-86孔距763.凸凹模間隙及凸凹模工作部分尺寸(1)落料凸凹模尺寸及公差 因?yàn)槊鞒叽鏒=40mm,無公差要求 根據(jù)參考文獻(xiàn)1,落料尺寸以凹模為基準(zhǔn),凸模采用配合加工,由于該零件最后需要切邊保證最終尺寸,故落料凹模尺寸直接采用計(jì)算尺寸40,另外制造公差取0.02mm。凸模與凹模配制,雙面間隙0.040.06mm(參考文獻(xiàn)1表2.2.3)。凸、凹模尺寸要求參考零件圖。(2)拉深凸、凹模尺寸及公差由零件圖知,工件外形尺寸及公差有要求,故以拉深凹模為基準(zhǔn),其值為:D=(28-0.750.52)=27.6D=27.7D=(9-0.750.36)D=(D-2c)=(8.7-20.5)=7.7mm注:以上凸、凹模制造公差取0.03mm4.選用模架 因?yàn)榘寄V芙鐬?00,根據(jù)參考文獻(xiàn)3,采用冷沖模滑動導(dǎo)向中間導(dǎo)柱模架,根據(jù)各項(xiàng)指標(biāo),選用模架為:模架100130150 GB2851.6-81.HT20-40 上、下模板厚度分別為H=25mm. H=30mm5.校核壓力機(jī)(1)閉合高度校核模具閉合高度H=H+ H+HtH+H+H =25+8+35.5+0.5+42.5+8+30=149.5mm由2表8-10得 壓力機(jī)最大裝模高度H=220-40=180mm由2表8-10得 壓力機(jī)最小裝模高度H=180-45=135mm 滿足H-5HH+10(2)公稱壓力F校核F=160KNF=77.6KN所以F合格。(3)滑塊行程校核根據(jù)參考文獻(xiàn)2表8-10得滑塊行程H=55模具工作行程H=(22.5)H=(22.5)6=(1215)mmHH 滿足使用要求(4)工作臺尺寸校核由參考文獻(xiàn)2. 工作臺前后尺寸為300mm,左右為450模架型號100130150 由參考文獻(xiàn)3. 模架左右為260,前后為170,滿足工作臺尺寸每邊大于模具5070mm的要求因?yàn)楣ぷ髋_孔尺寸直徑為210,能容納下彈頂器,所以滿足要求。第3章 模具主要零件加工工藝設(shè)計(jì)3.1 制定凸凹模加工工藝過程3.1.1 加工工藝過程方案分析(1)凸凹模(落料凸模兼拉深凹模)根據(jù)凸模加工方法,可以制定出的凸模加工工藝過程有很多種,現(xiàn)選兩種方案進(jìn)行比較:方案一:備料(下料、鍛造)去應(yīng)力退火毛坯外形加工(普通車床)數(shù)控車削粗加工(外形)數(shù)控車削半精加工數(shù)控車削精加工內(nèi)輪廓粗加工(數(shù)控加工中心加工)精加工鉗工精修淬火、回火研磨(拋光)。方案二:備料(下料、鍛造)去應(yīng)力退火毛坯外形加工(普通車床)數(shù)控內(nèi)輪廓粗加工精加工數(shù)控車削外形粗加工半精加工精加工鉗工精修淬火、回火研磨(拋光)。方案一的工藝過程占用設(shè)備多,拆、裝麻煩,影響工件精度,效率較低。方案二的工藝過程有序進(jìn)行,能消除熱處理變形對凸模精度的影響,加工精度較高。圖3-1* 尺寸與凹模配制雙面間隙0.040.06(2)落料凹模根據(jù)凹模形狀以及要求,可以制定出的凹模加工工藝過程有很多種?,F(xiàn)選兩種方案進(jìn)行比較:方案一:備料(下料、鍛造)去應(yīng)力退火毛坯外形加工(普通車床車削) 數(shù)控車削內(nèi)輪廓粗加工半精加工精加工鉆削粗加工精加工鉗工精修淬火、回火研磨。 方案二:備料(下料、鍛造)去應(yīng)力退火毛坯外形加工(普通車床車削)數(shù)控加工中心鉆半精加工精加工鉗工精修淬火、回火研磨。方案一的工藝過程:設(shè)備占用多,以至于影響工件精度,且效率偏低。方案二的工藝過程:加工精度高,成本較大,但效率高,加工方便。圖3-23.1.2.確定加工工藝過程凸凹模的加工工藝過程:選方案二:備料(下料、鍛造)去應(yīng)力退火毛坯外形加工(普通車床)數(shù)控內(nèi)輪廓粗加工精加工數(shù)控車削外形粗加工半精加工精加工鉗工精修淬火、回火研磨(拋光)。凹模加工工藝過程:選方案二:備料(下料、鍛造)去應(yīng)力退火毛坯外形加工(普通車床車削)數(shù)控加工中心鉆半精加工精加工鉗工精修淬火、回火研磨。3.2 填寫凸凹模加工工藝規(guī)程卡表3-1 機(jī)械加工工藝規(guī)程無錫技師學(xué)院機(jī)械加工工藝過程卡產(chǎn)品型號產(chǎn)品名稱C003階梯圓筒零件名稱零件材料毛坯種類毛坯尺寸凈重備注凸凹模Cr12MoV圓件5860工序號工序名稱工序內(nèi)容設(shè)備1備料(鍛造)備制尺寸5860圓形件,進(jìn)行鍛造2熱處理退火(改善切削加工性能)3毛坯粗加工車床車削(光一刀,去處表面氧化層)普通車床4內(nèi)輪廓粗加工內(nèi)輪廓尺寸留有余量為0.1mm數(shù)控車床5精加工達(dá)到尺寸要求,留拋光余量為0.1mm數(shù)控車床6外形粗加工車出外形,余量為1mm數(shù)控車床7半精加工按照尺寸要求,余量為0.4mm數(shù)控車床8精加工達(dá)到尺寸要求,外形留有磨削余量0.15mm-0.20mm數(shù)控車床9淬火、回火提高硬度10鉗工去除毛刺,打光內(nèi)輪廓銼刀、油石11外圓磨磨削外形至尺寸要求外圓磨床12檢驗(yàn)檢驗(yàn)所有尺寸編制審核批準(zhǔn)年月日第頁表3-2 數(shù)控加工工序卡片單位名稱無錫技師學(xué)院產(chǎn)品名稱或代號零件名稱零件圖號階梯圓筒凸凹模C003-1-13工序號程序編號夾具名稱使用設(shè)備車間工步號工步內(nèi)容刀具號刀具規(guī)格主軸轉(zhuǎn)速進(jìn)給速度背/側(cè)吃刀量備注1鉆9H7孔T01中心鉆500r/min0.32鉆9H7孔至55T028.9鉆頭500r/min0.33忽9H7孔T03100r/min0.34粗車內(nèi)輪廓27.8,斜角60度,深2mmT04鏜刀500r/min0.35粗車27.8,斜角60度T04鏜刀500r/min0.36粗車外形555,5315(退刀槽0.51.5倒角)4130T05粗車刀500r/min0.3編制審核批準(zhǔn)年月日第頁續(xù)表3-2單位名稱無錫技師學(xué)院產(chǎn)品名稱或代號零件名稱零件圖號階梯圓筒凸凹模C003-1-13工序號程序編號夾具名稱使用設(shè)備車間工步號工步內(nèi)容刀具號刀具規(guī)格主軸轉(zhuǎn)速進(jìn)給速度背/側(cè)吃刀量備注7半精車555,52.515(退刀槽0.51.5倒角)40.0530T05粗車刀500r/min0.38精車555,5215(退刀槽0.51.5倒角)4030T06精車刀500r/min0.39鉸9H7的孔T079絞刀100r/min0.3編制審核批準(zhǔn)年月日第頁3.3 編制凸?;虬寄?shù)控加工程序凸凹模數(shù)控加工程序(車削)O0001G43 G80 M03 T0101 S500G00 X25 Z2G73 U0 W2 R2G73 P5 Q10 U0.1 W01 F0.3N5 G0 X19.3G1 Z0 F0.1G2 X13.55 Z-0.2 R1.5G1 X10.78 Z-1.8G3 X0.03 Z-2 R1.5G1 X8N10G0 Z2G00 X100 Z100S800 T0101G0 X25 Z2G70 P5 Q10G00 X100 Z100T0202 S500G0 X62 Z2 G71 V1 R1 G71 P15 Q20 V0.5 W01 F0.3 N15 G0 X50.1 G1 Z0 F01 G1 Z-30 G1 X52.2 Z-31 Z-45 X55 N20 Z-50 G00 X100 Z100 S1000 T0202 G00 X62 Z2 G70 D15 Q20 G00 X100 Z100 M05 M30 刀具:T1 鏜孔刀 T2 外圓刀 第4章 設(shè)計(jì)總結(jié)數(shù)月的畢業(yè)設(shè)計(jì)即將結(jié)束,希望老師對我的設(shè)計(jì)過程作最后的審閱,最全面的指正。在這次課程設(shè)計(jì)中我通過參考及查閱各種有關(guān)模具設(shè)計(jì)方面的資料,請蔡昀老師指導(dǎo)有關(guān)模具方面的問題,特別是采用標(biāo)準(zhǔn)件時(shí)所遇到的困擾,老師給予我們想要的解答,使我在著短短的時(shí)間里對模具結(jié)構(gòu)及動作過程等有了更深一步的了解。其中在設(shè)計(jì)過程中,起初設(shè)計(jì)目標(biāo)與最終所想有些矛盾,但通過查閱相關(guān)書籍都得到了解決,從開始的無從下手到現(xiàn)在的得心應(yīng)手,至少了解了簡單模具設(shè)計(jì)。這些都是通過自己的努力與老師的指導(dǎo)才得到了現(xiàn)在的水準(zhǔn)。 經(jīng)過這幾個月的設(shè)計(jì),我深信這次課程設(shè)計(jì)能為我以后的畢業(yè)設(shè)計(jì)做一個很好的基礎(chǔ),甚至對以后的踏上社會也有許多幫助。致謝在這次設(shè)計(jì)過程中得到了蔡昀老師的幫助,從一開始,課題的選擇到后來的設(shè)計(jì)過程中,蔡老師給了我很大的幫助,幫我選擇課題和尋找相關(guān)的資料,特別是老師的悉心知道,使我受益良多,謝謝! 致此,感謝蔡老師在我設(shè)計(jì)過程中給予我的幫助。 謝謝!參考文獻(xiàn)1成虹,沖壓工藝與模具設(shè)計(jì),北京,高等教育出版社,20022王芳,冷沖壓模具設(shè)計(jì)指導(dǎo),北京,機(jī)械工業(yè)出版社,19993中華人民共和國國家標(biāo)準(zhǔn)GB2851-2875-81冷沖模,中國標(biāo)準(zhǔn)出版社4劉力,機(jī)械制圖,北京,高等教育出版社,20025郭鐵良,模具制造工藝學(xué),高等教育出版社,19996陳于萍,高曉康編著,互換性與測量技術(shù),北京高等教育出版社,20027吳宗澤,機(jī)械零件設(shè)計(jì)手冊,北京,機(jī)械工業(yè)出版社,19928許發(fā)越,實(shí)用模具設(shè)計(jì)與制造手冊,北京,機(jī)械工業(yè)出版社,19929朱傳禮,林蒲生,高等學(xué)校畢業(yè)設(shè)計(jì)論文指導(dǎo)手冊機(jī)械卷,北京高等教育出版社 經(jīng)濟(jì)日報(bào)出版社,199810王之鑠,機(jī)械設(shè)計(jì)綜合課程設(shè)計(jì),北京機(jī)械工業(yè)出版社,2003 南京工程學(xué)院繼續(xù)教育學(xué)院畢業(yè)設(shè)計(jì)專用紙汽車開發(fā)周期從40個月縮短到4個月。一、1、模具在工業(yè)發(fā)展中的地位采用模具生產(chǎn)零部件,具有生產(chǎn)效率高、質(zhì)量好、成本低、節(jié)約能源和原材料等一系列優(yōu)點(diǎn),用模具生產(chǎn)制件所具備的高精度、高復(fù)雜程度、高一致性、高生產(chǎn)率和低消耗,是其他加工制造方法所不能比擬的。已成為當(dāng)代工業(yè)生產(chǎn)的重要手段和工藝發(fā)展方向。現(xiàn)代經(jīng)濟(jì)的基礎(chǔ)工業(yè)?,F(xiàn)代工業(yè)品的發(fā)展和技術(shù)水平的提高,很大程度上取決于模具工業(yè)的發(fā)展水平,因此模具工業(yè)對國民經(jīng)濟(jì)和社會發(fā)展將起越來越大的作用。1989年3月國務(wù)院頒布的關(guān)于當(dāng)前產(chǎn)業(yè)政策要點(diǎn)的決定中,把模具列為機(jī)械工業(yè)技術(shù)改造序列的第一位、生產(chǎn)和基本建設(shè)序列的第二位(僅次于大型發(fā)電設(shè)備及相應(yīng)的輸變電設(shè)備),確立模具工業(yè)在國民經(jīng)濟(jì)中的重要地位。1997年以來,又相繼把模具及其加工技術(shù)和設(shè)備列入了當(dāng)前國家重點(diǎn)鼓勵發(fā)展的產(chǎn)業(yè)、產(chǎn)品和技術(shù)目錄和鼓勵外商投資產(chǎn)業(yè)目錄。經(jīng)國務(wù)院批準(zhǔn),從1997年到2000年,對80多家國有專業(yè)模具廠實(shí)行增值稅返還70%的優(yōu)惠政策,以扶植模具工業(yè)的發(fā)展。所有這些,都充分體現(xiàn)了國務(wù)院和國家有關(guān)部門對發(fā)展模具工業(yè)的重視和支持。目前全世界模具年產(chǎn)值約為600億美元,日、美等工業(yè)發(fā)達(dá)國家的模具工業(yè)產(chǎn)值已超過機(jī)床工業(yè),從1997年開始,我國模具工業(yè)產(chǎn)值也超過了機(jī)床工業(yè)產(chǎn)值。模具是大批量生產(chǎn)同形產(chǎn)品的工具,是工業(yè)生產(chǎn)的主要工藝裝備。據(jù)統(tǒng)計(jì),在家電、玩具等輕工行業(yè),近90的零件是綜筷具生產(chǎn)的;在飛機(jī)、汽車、農(nóng)機(jī)和無線電行業(yè),這個比例也超過60。例如飛機(jī)制造業(yè),某型戰(zhàn)斗機(jī)模具使用量超過三萬套,其中主機(jī)八千套、發(fā)動機(jī)二千套、輔機(jī)二萬套。從產(chǎn)值看,80年代以來,美、日等工業(yè)發(fā)達(dá)國家模具行業(yè)的產(chǎn)值已超過機(jī)床行業(yè),并又有繼續(xù)增長的趨勢。據(jù)國際生產(chǎn)技術(shù)協(xié)會預(yù)測,到2000年,產(chǎn)品盡件粗加工的75%、精加工的50將由模具完成;金屬、塑料、陶瓷、橡膠、建材等工業(yè)制品大部分將由模具完成,50以上的金屬板材、80以上的塑料都特通過模具轉(zhuǎn)化成制品。2、模具的歷史發(fā)展模具的出現(xiàn)可以追溯到幾千年前的陶器和青銅器鑄造,但其大規(guī)模使用卻是隨著現(xiàn)代工業(yè)的掘起而發(fā)展起來的。19世紀(jì),隨著軍火工業(yè)(槍炮的彈殼)、鐘表工業(yè)、無線電工業(yè)的發(fā)展,沖模得到廣泛使用。二次大戰(zhàn)后,隨著世界經(jīng)濟(jì)的飛速發(fā)展,它又成了大量生產(chǎn)家用電器、汽車、電子儀器、照相機(jī)、鐘表等零件的最佳方式。從世界范圍看,當(dāng)時(shí)美國的沖壓技術(shù)走在前列許多模具先進(jìn)技術(shù),如簡易模具、高效率模具、高壽命模具和沖壓自動化技術(shù),大多起源于美國;而瑞士的精沖、德國的冷擠壓技術(shù),蘇聯(lián)對塑性加工的研究也處于世界先進(jìn)行列。50年代,模具行業(yè)工作重點(diǎn)是根據(jù)訂戶的要求,制作能滿足產(chǎn)品要求的模具。模具設(shè)計(jì)多憑經(jīng)驗(yàn),參考已有圖紙和感性認(rèn)識,對所設(shè)計(jì)模具零件的機(jī)能缺乏真切了解。從1955年到1965年,是壓力加工的探索和開發(fā)時(shí)代對模具主要零部件的機(jī)能和受力狀態(tài)進(jìn)行了數(shù)學(xué)分橋,并把這些知識不斷應(yīng)用于現(xiàn)場實(shí)際,使得沖壓技術(shù)在各方面有飛躍的發(fā)展。其結(jié)果是歸納出模具設(shè)計(jì)原則,并使得壓力機(jī)械、沖壓材料、加工方法、梅具結(jié)構(gòu)、模具材料、模具制造方法、自動化裝置等領(lǐng)域面貌一新,并向?qū)嵱没姆较蛲七M(jìn),從而使沖壓加工從儀能生產(chǎn)優(yōu)良產(chǎn)品的第一階段。進(jìn)入70年代向高速化、啟動化、精密化、安全化發(fā)展的第二階段。在這個過程中不斷涌現(xiàn)各種高效率、商壽命、高精度助多功能自動校具。其代表是多達(dá)別多個工位的級進(jìn)模和十幾個工位的多工位傳遞模。在此基礎(chǔ)上又發(fā)展出既有連續(xù)沖壓工位又有多滑塊成形工位的壓力機(jī)彎曲機(jī)。在此期間,日本站到了世界最前列其模具加工精度進(jìn)入了微米級,模具壽命,合金工具鋼制造的模具達(dá)到了幾千萬次,硬質(zhì)合金鋼制造的模具達(dá)到了幾億次p每分鐘沖壓次數(shù),小型壓力機(jī)通常為200至300次,最高為1200次至1500次。在此期間,為了適應(yīng)產(chǎn)品更新快、用期短(如汽車改型、玩具翻新等)的需要,各種經(jīng)濟(jì)型模具,如鋅落合金模具、聚氨酯橡膠模具、鋼皮沖模等也得到了很大發(fā)展。從70年代中期至今可以說是計(jì)算機(jī)輔助設(shè)計(jì)、輔助制造技術(shù)不斷發(fā)展的時(shí)代。隨著模具加工精度與復(fù)雜性不斷提高,生產(chǎn)周期不斷加快,模具業(yè)對設(shè)備和人員素質(zhì)的要求也不斷提高。依靠普通加工設(shè)備,憑經(jīng)驗(yàn)和手藝越來越不能滿足模具生產(chǎn)的需要。90年代以來,機(jī)械技術(shù)和電子技術(shù)緊密結(jié)合,發(fā)展了NC機(jī)床,如數(shù)控線切割機(jī)床、數(shù)控電火花機(jī)床、數(shù)控銑床、數(shù)控坐標(biāo)磨床等。而采用電子計(jì)算機(jī)自動編程、控制的CNC機(jī)床提高了數(shù)控機(jī)床的使用效率和范圍。近年來又發(fā)展出由一臺計(jì)算機(jī)以分時(shí)的方式直接管理和控制一群數(shù)控機(jī)床的NNC系統(tǒng)。隨著計(jì)算機(jī)技術(shù)的發(fā)展,計(jì)算機(jī)也逐步進(jìn)入模具生產(chǎn)的各個領(lǐng)域,包括設(shè)計(jì)、制造、管理等。國際生產(chǎn)研究協(xié)會預(yù)測,到2000年,作為設(shè)計(jì)和制造之間聯(lián)系手段的圖紙將失去其主要作用。模具自動設(shè)計(jì)的最根本點(diǎn)是必須確立模具零件標(biāo)準(zhǔn)及設(shè)計(jì)標(biāo)準(zhǔn)。要擺脫過去以人的思考判斷和實(shí)際經(jīng)驗(yàn)為中心所組成的設(shè)計(jì)方法,就必須把過去的經(jīng)驗(yàn)和思考方法,進(jìn)行系列化、數(shù)值化、數(shù)式化,作為設(shè)計(jì)準(zhǔn)則儲存到計(jì)算機(jī)中。因?yàn)槟>邩?gòu)成元件也干差萬別,要搞出一個能適應(yīng)各種零件的設(shè)計(jì)軟件幾乎不可能。但是有些產(chǎn)品的零件形狀變化不大,模具結(jié)構(gòu)有一定的規(guī)律,放可總結(jié)歸納,為自動設(shè)計(jì)提供軟件。如日本某公司的CDM系統(tǒng)用于級進(jìn)模設(shè)計(jì)與制造,其中包括零件圖形輸入、毛坯展開、條料排樣、確定模板尺寸和標(biāo)準(zhǔn)、繪制裝配圖和零件圖、輸出NC程序(為數(shù)控加工中心和線切割編程)等,所用時(shí)間由手工的20%、工時(shí)減少到35小時(shí);從80年代初日本就將三維的CADCAM系統(tǒng)用于汽車覆蓋件模具。目前,在實(shí)體件的掃描輸入,圖線和數(shù)據(jù)輸入,幾何造形、顯示、繪圖、標(biāo)注以及對數(shù)據(jù)的自動編程,產(chǎn)生效控機(jī)床控制系統(tǒng)的后置處理文件等方面已達(dá)到較高水平;計(jì)算機(jī)仿真(CAE)技術(shù)也取得了一定成果。在高層次上,CADCAMCAE集成的,即數(shù)據(jù)是統(tǒng)一的,可以互相直接傳輸信息實(shí)現(xiàn)網(wǎng)絡(luò)化。目前國外僅有少數(shù)廠家能夠做到。3、模具的發(fā)展趨勢(1)模具軟件功能集成化模具軟件功能的集成化要求軟件的功能模塊比較齊全,同時(shí)各功能模塊采用同一數(shù)據(jù)模型,以實(shí)現(xiàn)信息的綜合管理與共享,從而支持模具設(shè)計(jì)、制造、裝配、檢驗(yàn)、測試及生產(chǎn)管理的全過程,達(dá)到實(shí)現(xiàn)最佳效益的目的。如英國Delcam公司的系列化軟件就包括了曲面/實(shí)體幾何造型、復(fù)雜形體工程制圖、工業(yè)設(shè)計(jì)高級渲染、塑料模設(shè)計(jì)專家系統(tǒng)、復(fù)雜形體CAM、藝術(shù)造型及雕刻自動編程系統(tǒng)、逆向工程系統(tǒng)及復(fù)雜形體在線測量系統(tǒng)等。集成化程度較高的軟件另外還包括:Pro/ENGINEER、UG和CATIA等。國內(nèi)有上海交通大學(xué)金屬塑性成型有限元分析系統(tǒng)和沖裁模CAD/CAM系統(tǒng);北京北航海爾軟件有限公司的CAXA系列軟件;吉林金網(wǎng)格模具工程研究中心的沖壓模CAD/CAE/CAM系統(tǒng)等。(2)模具設(shè)計(jì)、分析及制造的三維化傳統(tǒng)的二維模具結(jié)構(gòu)設(shè)計(jì)已越來越不適應(yīng)現(xiàn)代化生產(chǎn)和集成化技術(shù)要求。模具設(shè)計(jì)、分析、制造的三維化、無紙化要求新一代模具軟件以立體的、直觀的感覺來設(shè)計(jì)模具,所采用的三維數(shù)字化模型能方便地用于產(chǎn)品結(jié)構(gòu)的CAE分析、模具可制造性評價(jià)和數(shù)控加工、成形過程模擬及信息的管理與共享。舉個例子如Pro/ENGINEER、UG和CATIA等軟件具備參數(shù)化、基于特征、全相關(guān)等特點(diǎn),從而使模具并行工程成為可能。另外,Cimatran公司的Moldexpert,Delcam公司的Ps-mold及日立造船的Space-E/mold均是3D專業(yè)注塑模設(shè)計(jì)軟件,可進(jìn)行交互式3D型腔、型芯設(shè)計(jì)、模架配置及典型結(jié)構(gòu)設(shè)計(jì)。澳大利亞Moldflow公司的三維真實(shí)感流動模擬軟件MoldflowAdvisers已經(jīng)受到用戶廣泛的好評和應(yīng)用。國內(nèi)有華中理工大學(xué)研制的同類軟件HSC3D4.5F及鄭州工業(yè)大學(xué)的Z-mold軟件。面向制造、基于知識的智能化功能是衡量模具軟件先進(jìn)性和實(shí)用性的重要標(biāo)志之一。如Cimatron公司的注塑模專家軟件能根據(jù)脫模方向自動產(chǎn)生分型線和分型面,生成與制品相對應(yīng)的型芯和型腔,實(shí)現(xiàn)模架零件的全相關(guān),自動產(chǎn)生材料明細(xì)表和供NC加工的鉆孔表格,并能進(jìn)行智能化加工參數(shù)設(shè)定、加工結(jié)果校驗(yàn)等。(3)模具軟件應(yīng)用的網(wǎng)絡(luò)化趨勢隨著模具在企業(yè)競爭、合作、生產(chǎn)和管理等方面的全球化、國際化,以及計(jì)算機(jī)軟硬件技術(shù)的迅速發(fā)展,網(wǎng)絡(luò)使得在模具行業(yè)應(yīng)用虛擬設(shè)計(jì)、敏捷制造技術(shù)既有必要,也有可能。美國在其21世紀(jì)制造企業(yè)戰(zhàn)略中指出,到2006年要實(shí)現(xiàn)汽車工業(yè)敏捷生產(chǎn)/虛擬工程方案,使汽車開發(fā)周期從40個月縮短到4個月。AA二、The injection and Compression MoldingInjection molding si principally used for the production of the thermoplastic parts, although some progress has been made in developing a method for injection molding some thermosetting materials. The problem of injecting a melted plastic into a mold cavity form a reservoir of melted material has been extremely difficult to solve for thermosetting plastics which cure and harden under such conditions within a few minutes. The principle of injection molding is quite similar to that of die-casting. The process consists of feeding a plastic compound in powdered or granular form from a hopper through metering and melting stages and then injecting it into a mold. After a brief coolling period, the mold is opened and the solidified part ejected. Injection-molding machines can be arranged for manual operation, automatic single-cucle operation, and full automatic operation. The advantage of injection molding are:(i) a high molding speed adapted for mass production is possible;(ii) there is a wide choice of thermoplastic materials providing a variety of usefull properties;(iii) it is possible to mold threads, undercuts, side holes, and large thin sections. Several methods are used to force or inject the melted plastic into the mold. The most commonly used system in the larger machines is the in-line reciprocating screw.The screw acts as a combination and plasticizing unit.As the plastic is fed to the rotating screw,it passes through three zones as shown: feed,compression, and metering. After the feed zone, the screw-flight depth is gradually reduced,forcing the plastic to compress. The work is converted to heat by shearing the plastic, making it a semifluid mass. In the metering zone, additional heat is applied by conduction from the barrel surface. As the chamber in front of the screw becomes filled, it forces the screw back, tripping a limit switch that activates a hydraulic cylinder that forces the screw forward and injects the fluid plastic into the closed mold.An antiflowback valve prevents plastic under pressure from escaping back into the screw flights.The clamping force that a machine is capable of exerting is part of the size designation and is measured in tons. A rule-of-thumb can be used to determine the tonnage required for a particular job. It is based on two tons of clamp force per square inch of projected area. If the flow pattern is difficult and the parts are thin,this may have to go to three or four tons.Many reciprocating - screw machines are capable of handing thermosetting plastic materials.Previously these materials were handled by compression or transfer molding.Thermosetting materials cure or polymerize in the mold and are ejected hot in the range of 375410.Thermoplastic parts must be allowed to cool in the mold in order to remove them without distortion.Thus thermosetting cycles can be faster.Of course the mold must be heated rather than chilled,as with thermoplastics.The importance of Injecting the mold are :、Plastics have the density small, the quality light, the specific tenacity big, the insulating property good, the dielectric loss low, the chemical stability strong, the formation productivity high and the price inexpensive and so on the merits, obtained day by day the widespread application in the national economy and peoples daily life each domain, as early as in the beginning of 1990s, the plastic annual output already surpassed the steel and iron and the non-ferrous metal annual output sum total according to the volume computation.In mechanical and electrical (for example so-called black electrical appliances), domains and so on measuring appliance, chemical, the automobile and astronautics aviation, the plastic has become the metal the good substitution material, had the metal material plastic tendency.、Take the automobile industry as the example , as a result of the automobile lightweight, the low energy consumption development request, the automobile spare part material constitution occurred obviously has modelled the band steel the change, at present our country automobile plastic accounts for 5% which the automobile was self-possessed to 6%, but overseas has reached 13%, forecast according to the expert, the automobile plastic bicycle amount used will also be able further to increase.On modern vehicles, regardless of is outside installs the assorted items, the internal installation assorted items, the function and the structural element, all may use the plastic material, outside installs the assorted items to have the bumper, the fender, the wheel hub cap, the air deflector and so on; After the internal installation assorted items have in the display board, the vehicle door the board, the vice-display board, the sundry goods box lid, the chair, the guard shield and so on; The function and the structural element have the fuel tank, the radiator header, the spatial filter hood, the fan blade and so on.Statistics have indicated, our country in 2000 automobile output more than 200 ten thousand, the vehicle amounted to 1,380,000 tons with the plastic.Looked from the domestic and foreign automobile plastic application situation that, the automobile plastic amount used already became one of weight automobile production technical level symbols.、Injection of a molding formation as plastic workpiece most effective formation methods because may by one time take shape each kind of structure complex, the size precise and has the metal to inlay a product, and the formation cycle is short, may by mold multi-cavities, the productivity be high, when mass productions the cost isvery inexpensive, easy to realize the automated production, therefore holds the extremely important status in the plastic processing profession.Statistics have indicated, plastic mold composition all molds (including metal pattern) 38.2%, the plastic product gross weight about 32% is uses in injecting the formation, 80% above engineering plastics product all must use the injection formation way production. 4. counts according to the customs, our country in 2000 altogether imported mold 977,000,000 US dollars, in which plastic molding forms altogether 550,000,000 US dollars, occupied for 56.3%,2001 years altogether to import mold 1,112,000,000 US dollars, in which plastic molding forms altogether 616,000,000 US dollars, accounted for 55.4%.From the variety, the import volume biggest is the plastic molding forms.、Counts according to the customs, our country in 2000 altogether imported mold 977,000,000 US dollars, in which plastic molding forms altogether 550,000,000 US dollars, occupied for 56.3%, 2001 years altogether to import mold 1,112,000,000 US dollars, in which plastic molding forms altogether 616,000,000 US dollars, accounted for 55.4%.From the variety, the import volume biggest is the plastic molding forms. In compression molding the palstic material as powder or preforms is placed into a heated steel mold cavity,Since the parting surface is in a horizontal plane ,the upper half of the mold descends vertically.It closes the mold cavity and pressures for a predetermined period.A pressure of from 2 to 3 tons square inch and a temperaure at approximately 350F converts the plastic to a semiliquid which flows to all parts of the mold cavity.Usually from 1 to 15 minutes is required for curing,altough a recently developed alkyd plastic will cure in less than 25 secends. The mold is then opended and the molded part removed.If metal insers are desired in the parts,they should be placed in the mold cavity on pins or in the holes before the plastic is loaded.Also, the preforms should be preheated before loading into the mold cavity to eliminate gases,inprove flow,and decrease curing time.Dieletric heating is a convenient method of heating the preforms.Since the plastic material is placed directly into the mold cavity,the mold itself can be simpler than those used for other molding precesses.Gates and sprues are unnecessary.This also results in a saving in material,because trimmed-off gates and sprues would be a complete loss of the thermosetting plastic.The press require the full attention of one operator.However,several smaller presses can be operated by one operator. The presses are conveniently located so the operator can easilymove from one to the next.By the time he gets around to a particular press again,that mold will be ready to open.the thermosetting plastics which harden under heat and pressure are suitable for compression molding and transfer molding.It is not practical to moid shermoplastic materials by these methods,since the molds would have to be alternately heated and cooled.In order to harden and eject thermoplastic parts form the mold,cooling would be necessary.Types of molds for compression molding.The molds used for compression molding are classified into four basic types, namely ,positive molds,landed positive mold,flash-type molds,and semipositive molds.In a positive mold the plunger on the upper mold enters the lower mold cavity.since there are no lands or stops on the lower die ,the plunger completely trap the plastic material and descends with full pressure on the charge.A dense part with good electrical and physical properties is produced.The amount of plastic placed in the die cavity must be accurately measured,since it determines the thickness of the part .A landed positive mold is similar to a positive mold except that lands are added to stop the travel of the plunger at predetermined point.In this case,the lands absorb some of the pressure that should be exerted on the parts.The thickness of the parts will be accurately controlled,but the density may vary cansideraby.In a flash-type mold,flash redges are added ti the top and bottom molds.As the upper mold exerts pressure on the plastic,excess material is forced out between the flash ridges where it forms flash.This flash is further compressed.becomes hardened,and finally stops the downard thavel of the upper mold.A slight excess of the plastic material is always chared to ensure sufficient pressurs to produce a dense molded part.This type of mold is widely used because it is comparatively easy to construct and it controls thickness and density within colse limits.The semipositive mold is a combination od the flash type and landed posive molds.In addition to the flash ridges,a land is employed to restrict the travel of the upper mold.
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