圓形墊片沖孔落料復(fù)合模具設(shè)計(jì)
圓形墊片沖孔落料復(fù)合模具設(shè)計(jì),圓形,墊片,沖孔,復(fù)合,模具設(shè)計(jì)
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外文資料與中文翻譯
外文資料:
Analysis on The Factors of Impacting on The Life of Stamping Die
REN Hai-dong.YU Ling
Abstract:Stamping is a wide range of material processing methods,stamping die is equipment to achieve the important parts of theprocessing,whose life directly afects quality an d cost ofthe product.This article analyzes to its influencing factors,finding a method tosolveproblems,andimprovethelifeof stamping die.
Keywords:Samping die;life;Infl uencing facto
Is the use of stamping presses installed in the die pressure on the material to produce plastic deformation or separation in order to obtain the parts needed for a pressure processing method. In industrial production, especially in household appliances, automotive, aerospace and engineering fields such as instrumentation is widely available. The die is the realization of this important technology components and equipment for processing. Die as a result of a long cycle of production and processing, the use of the high cost of materials, manufacturing costs in product cost of production occupies a significant proportion, therefore, to improve the life of stamping dies is very important. Through the use of molds, for various reasons can not be a reproduction of the red pieces of qualified, could no longer be repaired, which is commonly referred to as die failure. Die life by various forms of limitations expired, common are: wear failure, failure deformation, fracture failure and failure, such as bite wounds. Stamping processes, as well as due to different working conditions of the different effects of stamping die failure are many factors, but the same factors may also bring some form of failure. In this paper, an analysis of its influencing factors, possible solutions to the problem in order to achieve the purpose of die life.
1 Mold Design
Mold design, including structural design and parts design. The structure of mold not only affects the quality of parts produced to determine the productivity of enterprises and processing methods, but also to improve the life of mold also has a key role. Therefore, before designers to make full preparations to meet the production tooling to optimize the structure at the same time.
1.1 Parts of Product Design
Reasonable product design will help improve the life of mold. If the product has a cusp, or fillet radius is too small, the design of the edge will die due to stress concentration and cracking. Without prejudice to the structure and function of products, we can change the design of some of its unreasonable.
1.2 Die Structure Design
Reasonable structure can improve the die life. For example, in Die, the direction to improve the convex and concave stamping die in the course of the relative stability, thus ensuring the mold space at a reasonable framework of blanking blanking. And the reasonableness of blanking clearance and stability to improve die life is an important measure. Accurate reduced-oriented relationship between the relative movement of the wear and tear of parts and components to avoid the convex, concave die as a result of unreasonable gap a "bite injuries" and other forms of failure. Particularly in the Fine Blanking Die, the high-precision mold-oriented institutions is to ensure that the structural design of an important guarantee for success. Therefore in order to improve the life of mold, the form must be the right choice and guide precision-oriented. The choice of orientation should be higher than the accuracy of convex and concave mold with precision. For more blanking punch, punch in a number of large difference in diameter, there is a difference and close the case that if a small and a long punch, then easily lead to instability or break. We can punch arranged in Figure 1 (a) ladder-style in order to increase its stiffness. Punching holes for the need to increase the punch guide in order to enhance the strength of punch, which is to ensure the normal work of stamping dies to the premise. Which can increase many-oriented approach, to be used in Figure 1 (b) shown in the front and the entire process-oriented and other-oriented.
Figure 1 (a) ladder layout punch 1 (b) punch-oriented
Accurate calculation of the process can also increase mold life. Such as discharge power and the calculation of stroke. If we are not allowed to easily spring fatigue fracture or failure. Die on a high degree of calculation, as well as the choice of press and reasonable manner and location-oriented institutions can effectively improve the die life. Modulus of continuity for the design and layout of the ride side of the calculation of size is also crucial.
1.3 Die gap
Stamping dies when space is the convex, concave die size difference between the horizontal edge. Gap on the impact of a large die life is a stamping process and die design of an extremely important issue. Convex, concave die gap size of a direct impact on product quality and mold the life space is too large or too small will cause the edge passivation or wear and tear (as shown in Figure 2). Die materials drop to die later, punch to punch prevail, and these two dimensions has been the impact of space. The experimental results show that the thickness of the gap below 2 percent, prone punch damage, space for more than 6%, there had been errors in parts size. Gap in the thickness of 4% ~ 5%, the effect of blanking good stability. Die gap, therefore the correct choice is to ensure that an important way to die life. At present, the choice of space data in addition to investigations, the most by the actual experience.
(a) gap is too small (b) a reasonable gap (c) gap is too large
Figure 2 gap on the impact of stampings
2 Die Manufacturing
Mold manufacturing process design is reasonable, to ensure that mold is an important way of life. Most of mold manufacturing parts of the process can be carried out in accordance with the normal, but there are special requirements for spare parts or spare parts for local processing, will need to have some special methods.
2.1 Mechanical Rough
Material machining accuracy of the assembly of the mold affects accuracy, it will directly affect the mold of parallelism, perpendicularity and coaxiality. In addition, the marks left rough, worn, are prone to stress concentration sites, but also occurred in the early fatigue cracks and the local.
2.2 Heat Treatment
Heat Treatment in the manufacture of stamping die plays a very important role, in spite of different types and different structure of mold, the use of different steel products, or using different machining and processing of shape, but they need to use heat treatment process to obtain a higher hardness and wear resistance, as well as other mechanical properties required. In general, the die service life and quality of products produced to a large extent depends on the quality of heat treatment processing. Thus, in die manufacturing, and continuously improve the skill level of heat treatment, a reasonable template to improve the performance of internal organization and working methods, it is particularly important. Heat treatment time and temperature is an important factor, because of the time in different temperatures, heat treatment may constitute a different form, the main annealing, normalizing, quenching and tempering, and carburizing, nitriding, carbonitriding, etc.. For example, in the blanking die, because people punch wedge material is the work of more serious wear and tear parts, so the hardness should be greater in general for the HRC 60 ~ 63, die for the HRC 57 ~ 60, this kind of hardness than the two , or die punch hardness is higher than the longer die life.
3 Die Assembly and Debugging
Assembly is the key to mold production process. A direct impact on the quality of the die assembly of the quality of parts, dies and the life of the state of the technology. Die assembly includes two aspects:
(1) good parts of each machining process in accordance with requirements of drawings assembled into a general assembly and assembly;
(2) in the assembly process as part of the processing work. Die in the assembly as an example, the technical requirements is to ensure consistency blanking gap and ensure the accuracy of direction-oriented institutions, as well as the movement to ensure that all relevant pieces of die design in accordance with strict technical parameters. This is a debugging tool to ensure a successful and smooth conduct of the production protection, but also to ensure that an important factor in mold life. In recent years, with the development of the production, users are vulnerable to damage parts of the swap request, so that users die at the scene of the rapid replacement of damaged parts. Die before the test mode, it should also be designed in strict accordance with the technical parameters of the model to select press. It is closely related to the length of die life. Press the stiffness, precision, crucial parameters such as tonnage. Press one of the stiffness of stiffness by the bed, transmission stiffness and rigidity of three parts-oriented, if less stiffness, load and unloading end, the die gap, great changes will happen, it will affect the accuracy of stamping parts and mold life. Die after assembly, must be red and adjust the test can be used for production. In order to protect the mold, the first time in debugging, it is necessary to pay attention to the use of paper or aluminum, as well as cold-rolled plate red test. To ensure that edge punch die edge into the depth of the scope of a reasonable (usually for a material thickness). Stamping die so red when the level of stress and wear and tear will be minimal, and fully protect the convex and concave mold, increased die life. The purpose of debugging and the task is: to die out not only qualified stampings, security and stability but also put into production use. Should be based on examination of stamping defects, analysis of its causes and try to solve them. Some bending, deep drawing and flanging, etc. so that the deformation of sheet metal dies, stamping parts, when the shape of complex or high accuracy, it is difficult to accurately calculate the deformation of the former size and shape of the rough. For this type of stamping parts, although the relevant references are rough calculation methods and formulas, but the impact of plastic deformation as a result of many factors, calculated from the size and needs of different size. In the actual production in order to obtain more accurate size, often determined through experiments. Red in the test set to adjust the size of blank.
4 Conclusion
Stamping die life impact of a number of factors, from the above analysis we can see from the mold design to the use of the entire process can improve the die life. Practice has proved that the rational design of die structure and the shape of the die using the appropriate manufacturing processes, heat treatment process, so that die in the normal conditions, can increase the mold life.
References:
[1] Weng its gold. Cold stamping technology [M]. Beijing: Mechanical Industry Press, 2007.
[2] Liu, ZHANG Bao-zhong. Stamping die design and manufacture of [M]. Beijing: Higher Education Publishing
Agency. 2006.
[3]Xiaopei.wang. Stamping Manual [M]. Beijing: Mechanical Industry Press, 2006.
中文翻譯:
影響沖壓模具壽命的因素分析
任海東,于玲
摘要:沖壓成形是一種應(yīng)用廣泛的材料加工方法,沖壓模具是實(shí)現(xiàn)零件加工的重要工藝裝備,它的使用壽命直接影響到產(chǎn)品的質(zhì)量和成本。對(duì)模具壽命的影響因素加以分析,找出解決問(wèn)題的方法,從而達(dá)到提高模具壽命的目的。
關(guān)鍵詞:沖壓模具:壽命;影響因素
沖壓是利用安裝在壓力機(jī)上的沖模對(duì)材料施加壓力,使其產(chǎn)生分離或塑性變形,從而獲得所需要的零件的一種壓力加工方法。它在工業(yè)生產(chǎn)中,尤其是在家用電器、汽車(chē)、航空以及儀器儀表等工程領(lǐng)域獲得廣泛應(yīng)用。而沖模就是實(shí)現(xiàn)這一零件加工的重要工藝裝備。由于模具的生產(chǎn)加工周期長(zhǎng),使用的材料費(fèi)用高,制造成本在產(chǎn)品生產(chǎn)成本中占有相當(dāng)大的比例,因此,提高沖壓模具的壽命是非常重要的。模具經(jīng)過(guò)使用,由于種種原因不能再生產(chǎn)出合格的沖件,也不能再修復(fù),這種情況一般稱(chēng)為模具失效。模具壽命受各種失效形式的限制,常見(jiàn)的有:磨損失效、變形失效、斷裂失效及啃傷失效等。由于沖壓工序不同以及工作條件的不同,影響沖壓模具失效的因素很多,而同一種因素也可能帶來(lái)幾種失效形式。本文對(duì)其影響因素進(jìn)行分析,找出解決問(wèn)題的方法,從而達(dá)到提高模具壽命的目的。
1 模具設(shè)計(jì)
模具設(shè)計(jì)包括結(jié)構(gòu)設(shè)計(jì)和零部件設(shè)計(jì)。模具的結(jié)構(gòu)不僅能影響到所生產(chǎn)零件的質(zhì)量,決定企業(yè)的生產(chǎn)效率和加工方式,而且對(duì)提高模具的使用壽命也具有關(guān)鍵的作用。因此設(shè)計(jì)者在設(shè)計(jì)之前,要做好充分的準(zhǔn)備工作,在滿足生產(chǎn)的同時(shí)盡可能優(yōu)化模具結(jié)構(gòu)。
1.1 零件產(chǎn)品設(shè)計(jì)
合理的產(chǎn)品設(shè)計(jì)有利于提高模具的壽命。如果產(chǎn)品具有尖角,或圓角半徑太小,所設(shè)計(jì)的凹模刃口就會(huì)因應(yīng)力集中而開(kāi)裂。在不影響產(chǎn)品結(jié)構(gòu)和功能的前提下,我們可以改變其一些不合理的設(shè)計(jì)。
1.2 模具結(jié)構(gòu)設(shè)計(jì)
合理的結(jié)構(gòu)可以提高模具的壽命。例如在沖裁模中,導(dǎo)向機(jī)構(gòu)提高了凸、凹模在沖壓過(guò)程中的相對(duì)穩(wěn)定性,從而保證模具在合理的沖裁間隙范圍內(nèi)進(jìn)行沖裁。而沖裁間隙的合理性及穩(wěn)定性正是提高模具壽命的重要措施。精確的導(dǎo)向減少了有相對(duì)運(yùn)動(dòng)關(guān)系的零部件的磨損,避免了凸、凹模由于間隙不合理出現(xiàn)“啃傷”等失效形式。尤其在精密沖裁模中,高精度的
導(dǎo)向機(jī)構(gòu)是確保模具結(jié)構(gòu)設(shè)計(jì)成功的重要保障。因而為了提高模具的壽命,必須正確選擇導(dǎo)向形式和導(dǎo)向精度。導(dǎo)向精度的選擇應(yīng)高于凸、凹模的配合精度。對(duì)于多凸模沖裁,在幾個(gè)凸模直徑相差較大,相距又很近的情況下,如果小凸模細(xì)小而又較長(zhǎng),則容易造成失穩(wěn)或折斷。我們可以把凸模布置成如圖1(a)階梯式的,以增加其剛度。對(duì)于小孔沖裁,必須增加對(duì)凸模的導(dǎo)向,以提高凸模的強(qiáng)度,這是保證沖壓模具能正常工作的前提。其中能增加導(dǎo)向的方法很多,可采用如圖1(b)所示的前端導(dǎo)向和全程導(dǎo)向等。
準(zhǔn)確的工藝計(jì)算也可以提高模具的壽命。如卸料力及行程的計(jì)算。若計(jì)算不準(zhǔn),容易造成彈簧的疲勞斷裂或失效。對(duì)合模高度的計(jì)算以及壓力機(jī)的選擇,合理的定位方式及導(dǎo)向機(jī)構(gòu)等,都可以有效地提高模具的使用壽命。對(duì)于連續(xù)模排樣的設(shè)計(jì)和搭邊尺寸的計(jì)算也至關(guān)重要。
1.3 模具間隙
模具間隙是指沖壓時(shí)凸、凹模刃口橫向尺寸之差。間隙對(duì)模具壽命的影響很大,是沖壓工藝與模具設(shè)計(jì)中的一個(gè)極其重要的問(wèn)題。凸、凹模間隙的大小直接影響產(chǎn)品的質(zhì)量和模具的使用壽命,間隙過(guò)大或過(guò)小都會(huì)使刃口鈍化或磨損(如圖2所示)。沖裁模中落料一般以凹模為準(zhǔn),沖孔以凸模為準(zhǔn),而這兩個(gè)尺寸又受到間隙的影響。實(shí)驗(yàn)表明,間隙在板厚的2%以下時(shí),凸模容易發(fā)生損壞,間隙在6%以上時(shí),制件尺寸出現(xiàn)誤差。間隙在板厚4% ~5%時(shí),沖裁穩(wěn)定效果好。因此正確選擇模具間隙,是保證模具壽命的重要途徑。目前,間隙的選擇除了查資料以外,大部分靠實(shí)際經(jīng)驗(yàn)獲得。
2 模具制造
模具制造工藝設(shè)計(jì)的合理性,也是保證模具壽命的重要途徑。大部分模具零件的制造可以按正常的工藝進(jìn)行,但對(duì)有特別要求的零件或零件局部加工,就需要有一定特殊的方法。
2.1 機(jī)械粗加工
材料的加工精度對(duì)模具的裝配精度有很大的影響,將直接影響模具的平行度、垂直度和同軸度。另外,粗加工留下的刀痕、磨痕,都是容易產(chǎn)生應(yīng)力集中的部位,也是早期產(chǎn)生裂紋和發(fā)生疲勞的地方。
2.2 熱處理
熱處理在沖壓模具的制造中起著很重要的作用,盡管不同類(lèi)型及不同的結(jié)構(gòu)模具,使用不同的鋼材,或采用不同的機(jī)械加工及加工成形,但都需要用熱處理的加工方法,使其獲得較高的硬度和耐磨性,以及其他所要求的力學(xué)性能。一般來(lái)說(shuō),沖模的使用壽命及生產(chǎn)出來(lái)的產(chǎn)品質(zhì)量,在很大程度上取決于熱處理加工質(zhì)量.因此,在沖模制造中,不斷提高熱處理的技術(shù)水平,合理的改進(jìn)模板內(nèi)部組織和性能的工作方法,就顯得格外的重要。時(shí)間和溫度是熱處理的重要因素,由于時(shí)間溫度的不同,可構(gòu)成不同的熱處理形式,其主要有退火、正火、淬火、回火和滲碳、滲氮、碳氮共滲等。比如在沖裁模中,由于凸模楔人材料,是磨損比較嚴(yán)重的工作零件,所以其硬度應(yīng)大些,一般為HRC 60~63,凹模為HRC 57~60,這樣比兩者硬度樣,或凹模硬度高于凸模的模具壽命更長(zhǎng)一些。
3 模具裝配及調(diào)試
裝配是模具生產(chǎn)中的關(guān)鍵工序。沖模裝配質(zhì)量直接影響制件的質(zhì)量、沖模的技術(shù)狀態(tài)和使用壽命。沖模的裝配工作包括兩方面的內(nèi)容:
(1)將每個(gè)加工好的零件按圖紙工藝要求裝配成組合件及總體裝配;
(2)在裝配過(guò)程中進(jìn)行的一部分加工工作。以沖裁模的裝配為例,其技術(shù)要求是保證沖裁間隙一致性,保證導(dǎo)向機(jī)構(gòu)的導(dǎo)向精度,以及保證各相關(guān)運(yùn)動(dòng)件能夠按照模具設(shè)計(jì)的技術(shù)參數(shù)嚴(yán)格進(jìn)行。這是保證模具調(diào)試成功及生產(chǎn)能夠順利進(jìn)行的保障,也是確保模具壽命的重要因素。近年來(lái),隨著生產(chǎn)的發(fā)展,用戶對(duì)易損壞零件提出了互換要求,以便用戶在現(xiàn)場(chǎng)對(duì)模具損壞零件的迅速更換。模具在試模前,還應(yīng)該嚴(yán)格按照設(shè)計(jì)的技術(shù)參數(shù)來(lái)選擇壓力機(jī)的型號(hào)。它關(guān)系到模具使用壽命的長(zhǎng)短。壓力機(jī)的剛度、精度、噸位等參數(shù)至關(guān)重要。其中壓力機(jī)的剛度是由床身剛度、傳動(dòng)剛度和導(dǎo)向剛度三部分組成,如果剛度較差,負(fù)載終了和卸載時(shí),模具間隙會(huì)發(fā)生很大變化,將會(huì)影響到?jīng)_壓件的精度和模具壽命。模具裝配完后,必須經(jīng)過(guò)試沖和調(diào)整,才能進(jìn)行生產(chǎn)使用。為了保護(hù)模具,在第一次調(diào)試時(shí),要注意利用紙片或鋁片以及冷軋板進(jìn)行試沖。保證凸模刃口進(jìn)入到凹模刃口的深度在合理的范圍內(nèi)(一般為一個(gè)料厚)。這樣模具沖壓時(shí)的沖壓力及磨損程度會(huì)最小,充分保護(hù)了凸、凹模,提高了模具壽命。調(diào)試的目的和任務(wù)是:使沖模不僅能沖出合格的沖壓件,而且能安全穩(wěn)定的投入生產(chǎn)使用。應(yīng)根據(jù)試沖件中出現(xiàn)的缺陷,分析其產(chǎn)生的原因,設(shè)法加以解決。有些彎曲、拉深及翻邊等使板料變形的沖模,當(dāng)沖壓件的形狀復(fù)雜或精度較高時(shí),很難精確計(jì)算出變形前的毛坯尺寸和形狀。對(duì)于這一類(lèi)沖壓件,雖然相關(guān)參考資料都有計(jì)算毛坯的方法和公式,但由于影響塑性變形的因素非常多,計(jì)算出來(lái)的尺寸和實(shí)際的需要尺寸是有差別的。在實(shí)際的生產(chǎn)中為了得到較準(zhǔn)確的尺寸,往往通過(guò)試驗(yàn)來(lái)確定.即在試沖調(diào)整中確定毛坯的尺寸。
4 結(jié)論
影響沖壓模具壽命的因素很多,從以上分析可以看出從模具設(shè)計(jì)到使用的全過(guò)程中,均能提高模具壽命。實(shí)踐證明,合理設(shè)計(jì)模具結(jié)構(gòu)及形狀,采用恰當(dāng)?shù)臎_模制造工藝、熱處理工藝,使模具在正常的條件下工作,均能提高模具的壽命。
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[3]王孝培.沖壓手冊(cè)[M].北京:機(jī)械工業(yè)出版社,2006.
14
學(xué)院
課程設(shè)計(jì)說(shuō)明書(shū)
課 題:沖孔落料復(fù)合模具設(shè)計(jì)
專(zhuān) 業(yè)
學(xué)生姓名
班 組
學(xué) 號(hào)
指導(dǎo)教師
完成日期
摘要
摘要
關(guān)于學(xué)校這次的課程設(shè)計(jì),我設(shè)計(jì)了零件的沖孔落料復(fù)合模一套經(jīng)過(guò)課程設(shè)計(jì)的整個(gè)課題精心制作,對(duì)我所學(xué)的模具設(shè)計(jì)與制造所有知識(shí)得到了一個(gè)全面的復(fù)習(xí),經(jīng)過(guò)查詢我們的教材還有我們學(xué)校圖書(shū)館里的和我這次課程設(shè)計(jì)課題有關(guān)的書(shū)本,根據(jù)模具設(shè)計(jì)的相關(guān)流程進(jìn)行一步一步的不折不扣制作,把我這次課程設(shè)計(jì)的整個(gè)設(shè)計(jì)過(guò)程給很清楚的寫(xiě)在這份說(shuō)明書(shū)上了。
在這次設(shè)計(jì)零件同樣先進(jìn)行了工藝的分析,工藝的計(jì)算,確定壓力機(jī)型號(hào),再將各主要零部件的設(shè)計(jì)表達(dá)出來(lái)。
這次課程設(shè)計(jì)零件設(shè)計(jì)說(shuō)明書(shū)的第一個(gè)部分是對(duì)我這次課程設(shè)計(jì)課題的第一套模具,零件坯料的沖孔落料復(fù)合模的工藝的分析,工藝的計(jì)算,主要零部件的設(shè)計(jì)。這次零件設(shè)計(jì)說(shuō)明書(shū)的工藝計(jì)算,主要零件的設(shè)計(jì)。這都為選擇沖壓設(shè)備提供重要依據(jù)。也為本次模具設(shè)計(jì)的AutoCAD裝配圖,以及AutoCAD主要零件圖繪制提供了依據(jù)。
關(guān)鍵詞:沖壓模、
Ⅰ
- 15 -
目錄
摘要··················································································································Ⅰ
Abstract···········································································································Ⅱ
第一張 概述····································································································4
1.1 課程設(shè)計(jì)的目的·························································································4
1.2 課程設(shè)計(jì)的要求·························································································4
1.3 課程設(shè)計(jì)的注意事項(xiàng)··················································································4
第二章 零件坯料工藝設(shè)計(jì)··············································································5
2.1分析零件坯料的工藝性···············································································5
2.1.1零件坯料工藝分析··················································································5
2.1.2確定零件坯料沖壓工藝方案····································································5
2.2 零件坯料的工藝計(jì)算·················································································6
第三章 零件坯料沖孔落料復(fù)合模模具零部件設(shè)計(jì)······································7
3.1零件坯料沖孔落料復(fù)合模,沖Φ6mm孔凸模的設(shè)計(jì)·······································7
3.2零件坯料沖孔落料復(fù)合模落料凹模設(shè)計(jì)·····················································8
3.3零件坯料沖孔落料復(fù)合模凸凹模設(shè)計(jì)·······················································8
3.4 零件坯料沖孔落料復(fù)合模,凸模固定板設(shè)計(jì)············································9
3.5零件坯料沖孔落料復(fù)合模,凸凹模固定板設(shè)計(jì)··········································10
3.6 零件坯料沖孔落料復(fù)合模,推件塊設(shè)計(jì)··················································11
3.7零件坯料沖孔落料復(fù)合模,墊板設(shè)計(jì)······················································12
第四章 零件坯料沖孔落料復(fù)合模具結(jié)構(gòu)設(shè)計(jì)·········································14
4.1 零件坯料沖孔落料復(fù)合模模架的選擇····················································14
4.2 零件坯料沖孔落料復(fù)合模壓力中心計(jì)算·················································14
4.3零件坯料沖孔落料復(fù)合模模具裝配圖和零件的繪制··································14
總結(jié)··················································································································22
致謝··················································································································23
參考文獻(xiàn)·········································································································24
第一章 概述
1.1課程設(shè)計(jì)的目的
1、在這次課程設(shè)計(jì)中通過(guò)對(duì)課程設(shè)計(jì)的課題制作,對(duì)我們?cè)趯W(xué)校老師所教的專(zhuān)業(yè)知識(shí)和我們自己所自學(xué)的專(zhuān)業(yè)知識(shí)進(jìn)行一個(gè)鞏固。
2、在這次課程設(shè)計(jì)中培養(yǎng)我們模具專(zhuān)業(yè)的學(xué)生在遇到問(wèn)題時(shí)的分析能力和解決問(wèn)題能力,還有能獨(dú)立的完成對(duì)于模具設(shè)計(jì)的流程的熟練制作。
3、在這次課程設(shè)計(jì)中對(duì)我們模具設(shè)計(jì)與制造專(zhuān)業(yè)的學(xué)生工作作風(fēng)以及責(zé)任心還有安全意識(shí)得到較大跨度的一個(gè)提升。
1.2 課程設(shè)計(jì)的要求
1、課程設(shè)計(jì)的圖紙圖幅量:一共要最少3張零號(hào)的圖幅工作量(其中最少要有1張零號(hào)裝配圖,剩下的不做要求)。
2、圖紙:最后答辯前上交的圖紙必須用AutoCAD繪制,畫(huà)圖時(shí)要更具繪圖標(biāo)準(zhǔn)去畫(huà),最后要交1份AutoCAD圖紙和1份1:1打印出來(lái)的圖紙。
3、課程設(shè)計(jì)說(shuō)明書(shū)的字?jǐn)?shù)要求:不少于6000字。
4、查看和課程設(shè)計(jì)課題有關(guān)的各種資料,為順利的完成課程設(shè)計(jì)以及能順利畢業(yè)做好充分的準(zhǔn)備工作。
5、要求計(jì)算準(zhǔn)確、結(jié)構(gòu)設(shè)計(jì)合理、圖面整潔,圖樣及標(biāo)注符合國(guó)家標(biāo)準(zhǔn)。
6、要求編制的工藝規(guī)程符合生產(chǎn)實(shí)際。
7、設(shè)計(jì)計(jì)算說(shuō)明書(shū)要求文字通順,書(shū)寫(xiě)工整。
1.3課程設(shè)計(jì)的的注意事項(xiàng)
1、相關(guān)安全的事宜:在進(jìn)行課程設(shè)計(jì)的樣品加工時(shí)一定要遵守各類(lèi)加工機(jī)械的操作規(guī)范,確保人生安全,器械安全。
2、服從命令聽(tīng)指揮:在進(jìn)行任何加工都前都要聽(tīng)從老師的安排,認(rèn)真負(fù)責(zé),精心制作,保質(zhì)保量完成模具加工任務(wù)。
3、課程設(shè)計(jì)的所有內(nèi)容必須自己獨(dú)立完成,可以請(qǐng)教同學(xué)或老師,但嚴(yán)禁抄襲,做,在模具加工時(shí)同樣要獨(dú)立完成。
第二章 零件工藝設(shè)計(jì)
2.1 分析零件坯料的沖壓工藝性
零件坯料如圖2-1零件坯料
圖2-1零件坯料
2.1.1零件坯料工藝分析
由圖2-1可見(jiàn),零件坯料的形狀比較簡(jiǎn)單,結(jié)構(gòu)成對(duì)稱(chēng)分布,零件尺寸通過(guò)一般的沖壓能滿足零件坯料的尺寸精度要求。尺寸的公差為自由公差,孔Φ6mm的孔邊距離外輪廓的距離遠(yuǎn)遠(yuǎn)大于凸、凹模所允許的最小壁厚,沒(méi)有凸、凹模強(qiáng)度的困擾,所以可以采用沖壓工序完成零件的生產(chǎn)。
2.1.2確定零件坯料沖壓工藝方案
1、方案的種類(lèi) 零件坯料需要沖孔落料2個(gè)基本的工序,我們用以下3種加工的工藝方案來(lái)進(jìn)行加工:
方案一:先把坯料沖下來(lái),然后再利用另外的一套沖孔的模具進(jìn)行孔的加工,用單個(gè)工序的模具來(lái)對(duì)零件坯料的制作。
方案二:采用沖孔落料,級(jí)進(jìn)沖壓,采用級(jí)進(jìn)模具來(lái)完成零件坯料的生產(chǎn)加工任務(wù)。
方案三:采用落料和沖孔同時(shí)進(jìn)行的復(fù)合模具完成零件坯料的生產(chǎn)任務(wù)。
2、方案的比較 每種加工方案的特點(diǎn)以及方案比較如下。
方案一:所需要的模具的結(jié)構(gòu)不怎么復(fù)雜,在加工模具時(shí)比較容易,但要2個(gè)工序才能將加工中心坯料加工出來(lái),用兩個(gè)模具整個(gè)生產(chǎn),這樣生產(chǎn)的成本有點(diǎn)高,并且加工時(shí)的效率很低,最為重要的是這個(gè)方案加工不能保證零件坯料的尺寸精度。這個(gè)方案我們不要。
方案二:雖然用級(jí)進(jìn)模他的加工效率是比較高的。但是級(jí)進(jìn)模具外形很大,制造模具時(shí)麻煩,這樣他的成本代價(jià)太高,本身這種模具就不適合加工這種形狀很小,結(jié)構(gòu)還很簡(jiǎn)單的零件,因而這種案我們也不要。
方案三:這個(gè)就要一個(gè)模具就行了,而且零件坯料的零件精度還有生產(chǎn)的速度要求都能夠達(dá)到要求,關(guān)鍵成本也不太高。
3、方案的最終確定 綜上所訴,零件坯料沖壓模具采用沖孔落料復(fù)合模具進(jìn)行產(chǎn)品的加工。
2.1.2確定零件坯料沖孔落料復(fù)合模結(jié)構(gòu)形式的確定
有正裝復(fù)合模具還有倒裝復(fù)合模具2種復(fù)合模??紤]到成型后拿料問(wèn)題。最終確定我們用倒裝式復(fù)合模具進(jìn)行零件的沖壓加工。
2.2 工藝計(jì)算
2.2.1零件坯料零件的排樣設(shè)計(jì)如圖2-2排樣
圖2-2排樣
1、搭邊值的確定[1]冷沖壓工藝及模具設(shè)計(jì)》表2.10得出工件的搭邊對(duì)于本次的設(shè)計(jì),我們a1選取2mm,工件側(cè)面a=2.5mm
2、條料步距的確定 步距值:33mm+2mm=35mm 寬度150mm+2.5mm+2.5mm=155mm。
根據(jù)三維軟件進(jìn)行測(cè)量得出,面積為961.35平方毫米,周長(zhǎng)150.8mm
3、材料的利用率計(jì)算 η=S工/S總=961.35/40mm×37.5×100%=64.09%
2.2.2凸模和凹模的工作部分尺寸
零件圖上所注公差經(jīng)查標(biāo)準(zhǔn)公差表1.2為IT14級(jí),尺寸精度較低,普通沖裁完全可以滿足要求。
表1.2部分標(biāo)準(zhǔn)公差值(GB/T1800.3—1998)
公差等級(jí)
IT6
IT7
IT8
IT9
IT10
IT11
IT12
IT13
IT14
IT15
基本尺寸
/μm /mm
>3~6
8
12
18
30
48
75
0.12
0.18
0.30
0.48
>6~10
9
15
22
36
58
90
0.15
0.22
0.36
0.58
>10~18
11
18
27
43
70
110
0.18
0.27
0.43
0.70
>18~30
13
21
33
52
84
130
0.21
0.33
0.52
0.84
>30~50
16
25
39
62
100
160
0.25
0.39
0.62
1.00
>50~80
19
30
46
74
120
190
0.30
0.46
0.74
1.20
>80~120
22
35
54
87
140
220
0.35
0.54
0.87
1.40
根據(jù)表1.2分析:該零件沖裁工藝性較好,適宜沖裁加工。查公差表得各尺寸公差:
零件外形: 36mm
零件內(nèi)形: 6mm
1、 確定凸、凹模的間隙以及制造公差。[2]冷沖壓模具課程設(shè)計(jì)指導(dǎo)與范例》表2-7可得凸、凹模的間隙最小值Zmin=0.040mm,凹模間隙最大值Zmax=0.060mm
沖孔凸、凹模計(jì)算
設(shè)沖孔尺寸為根據(jù)以上原則,沖孔時(shí)以凸模設(shè)計(jì)為基準(zhǔn),首先確定凸模刃口尺寸,使凸?;境叽缃咏虻扔诠ぜ椎淖畲髽O限尺寸,再增大凹模尺寸以保證最小合理間隙Zmin。凸模制造偏差取負(fù)偏差,凹模取正偏差。其計(jì)算公式為:
凸模 dp=(d+x△)0- δp
凹模 dd=(+Zmin)0+ δd=(d+X△+Zmin) 0+ δd
在同一工步中沖出制件兩個(gè)以上孔時(shí),凹模型孔中心距Ld按下式確定:
Ld=(Lmin+0.5△)±0.125△
式中dd——沖孔凹?;境叽?mm);
dp——沖孔凸?;境叽?mm);
d——沖孔件孔的最小極限尺寸(mm);
Ld——同一工步中凹??拙嗷境叽?mm);
Lmin——制件孔距最小極限尺寸(mm);
△——沖孔件孔徑公差(mm);
Zmin——凸、凹模最小初始雙面間隙(mm);
X——磨損系數(shù),是為了使沖裁件的實(shí)際尺寸盡量接近沖裁件公差帶的中間尺寸,與工件制造精度有關(guān),可查表9.1取值:當(dāng)工件精度IT10以上,取x=1;當(dāng)工件精度IT11~I(xiàn)T13,取x=0.75;當(dāng)工件精度IT14,則取x=0.5。
表9.1磨損系數(shù)X
料厚t(mm)
非圓形
圓形
1
0.75
0.5
0.75
0.5
工件公差△/mm
1
1~2
2~4
>4
<0.16
<0.20
<0.24
<0.30
0.17~0.35
0.21~0.41
0.25~0.49
0.31~0.59
≥0.36
≥0.42
≥0.50
≥0.60
<0.16
<0.20
<0.24
<0.30
≥0.16
≥0.20
≥0.24
≥0.30
根據(jù)圖1.1和表9.1查得磨損系數(shù)X取0.5,即X=0.75
設(shè)凸、凹模分別按IT6和IT7級(jí)加工制造,所以
凸模: dp =(d+X△) 0- δp
=(6+0.75×0.12)
=6.09
凹模: dd=( dp +Zmin)
=(6.09+0.04)
=6.13
二、落料凸、凹模計(jì)算
凹模: Dd=(D-X△)
凸模: Dp=( Dd-Zmin)=(D-X△-Zmin)
式中Dd——落料凹?;境叽?mm);
Dp——落料凸?;境叽?mm);
D——落料件最大極限尺寸(mm);
r——落料件外徑公差(mm);
Zmin——凸、凹模最小初始雙面間隙(mm);
X——磨損系數(shù),是為了使沖裁件的實(shí)際尺寸盡量接近沖裁件公差帶的中間尺寸,與工件制造精度有關(guān)。表9.1取X=0.5。
由公差表(1.2)查得:設(shè)凸、凹模分別按IT6和IT7級(jí)加工。
所以凹模
36:Dd2=(D2-X)
=(36-0.5×0.62)0+0.025
=35.690+0.025mm
凸模
36:Dp2=(Dd2- Zmin)
=(35.69-0.04)
=35.65 mm
式中,由已知條件零件為非圓形,材料的厚度是0.5mm,以及零件的公差大于0.42mm,查詢《冷沖壓模具設(shè)計(jì)》表2-9磨損系數(shù)X[5]得X=0.5,制件精度為IT14級(jí)時(shí)查詢《沖壓模具課程設(shè)計(jì)指導(dǎo)與范例》[6]得Δ=0.87mm。
零件坯料2孔中心距離的計(jì)算:由圖2-1可知當(dāng)制件精度取IT14級(jí)時(shí),中心距離:18±0.023m mm
C凹=C±σ凹=18±0.023mm
式中,σ凹=1/4×0.09mm=0.023mm
2、 零件坯料沖壓模,沖壓力計(jì)算
計(jì)算沖裁力是為了選擇合適的壓力機(jī),設(shè)計(jì)模具和檢驗(yàn)?zāi)>叩膹?qiáng)度,壓力機(jī)的噸位必須大于所計(jì)算的沖裁力,以適宜沖裁的要求,普通平刃沖裁模,其沖裁力一般可以按下式計(jì)算:
Fp=Kp Ltτ =Lt (6.1)
式中τ——材料抗剪強(qiáng)度(MPa);
L——沖裁周邊總長(zhǎng)(mm);
t——材料厚度(mm);
系數(shù)Kp是考慮到?jīng)_裁模刃口的磨損,凸模與凹模間隙之波動(dòng),取Kp =1.3。
2.1 沖裁力Fp的計(jì)算
據(jù)圖5.3可得一個(gè)零件內(nèi)外周邊之和L=150.8mm。
查碳素結(jié)構(gòu)鋼的力學(xué)性能表知:鋼板的抗剪強(qiáng)度τ=216Mpa~304Mpa,取260Mpa,制件厚度t=2mm,則
根據(jù)公式(6.1): Fp= Kp Ltτ
=1.3×0.5×150.8×260
=25485.2(N)
≈25.5(KN)
2.2卸料力Fq1的計(jì)算
Fq1=KxFp (6.2)
式中Kx——卸料力系數(shù),查表6.1取Kx=0.05。
根據(jù)公式(6.2): Fq1= KxFp
=0.065×25.5(KN)
≈1.656(KN)
表6.1卸料力、推件力和頂件力系數(shù)
料厚t/mm
Kx
kt
Kd
鋼
≤0.1
>0.1~0.5
>0.5~2.5
>2.5~6.5
>6.5
0.065~0.075
0.045~0.055
0.04~0.05
0.03~0.04
0.02~0.03
0.1
0.063
0.055
0.045
0.025
0.14
0.08
0.06
0.05
0.03
2.3頂件力Fq2的計(jì)算
Fq2= KdFp (6.3)
式中Kd——頂件力系數(shù)。
查表6.1得Kd=0.06.
根據(jù)公式(6.3): Fq2= KdFp
=0.14×25.5(KN)
≈3.57(KN)
2.4總的沖壓力F的計(jì)算
根據(jù)模具結(jié)構(gòu)總的沖壓力F=FP+Fq1+Fq2
=25.5+1.656+3.57
=30.726(KN)
選用的壓力機(jī)公稱(chēng)壓力P≥(1.1~1.3)F,取系數(shù)為1.3,則:
P≥1.3F=1.3x30.726 (KN)=39.9438(KN)。
從滿足加工的工藝要求考慮,可擬選用J23-6.3查《沖壓模具課程設(shè)計(jì)指導(dǎo)與范例》表9-9開(kāi)式雙柱可傾壓力機(jī)技術(shù)規(guī)格[2]
J23-6.3參數(shù):公稱(chēng)壓力/KN :63
滑塊行程次數(shù)/次?min-1 :160
最大封閉高度/mm:170
封閉高度調(diào)節(jié)量/mm: 40
立柱距離/mm: 150
工作臺(tái)尺寸/mm:315×200
墊板尺寸/mm:厚度: 40
模柄尺寸/mm:直徑: 50
深度: 70
第三章 零件坯料沖孔落料復(fù)合模工作部分零件設(shè)計(jì)
3.1零件坯料沖孔落料復(fù)合模,沖Φ6mm孔凸模的設(shè)計(jì)
零件坯料沖孔落料復(fù)合模,沖Φ6mm孔凸模材料選擇:為保證模具的壽命以及零件的精度和材料供應(yīng)問(wèn)題我們選擇Cr12MOV。
零件坯料沖孔落料復(fù)合模,沖Φ6mm孔凸模形式確定: 采用國(guó)家規(guī)定形式中的(GB2863.2-81)。 材料選擇:為保證模具的壽命以及零件的精度和材料供應(yīng)問(wèn)題零件坯料沖孔落料復(fù)合模,沖Φ6mm孔凸模的熱處理: 58—62HRC。
零件坯料沖孔落料復(fù)合模。沖Φ6mm凸模的冷處理: 加超深冷冷處理(零下400C°)因?yàn)楣饪繜崽幚頉](méi)法完全的去除材料的內(nèi)應(yīng)力。在材料剛剛經(jīng)過(guò)熱處理后接著進(jìn)行材料的加超深冷冷處理。這樣可以最大限度的去除材料的內(nèi)應(yīng)力。以增加模具的使用壽命。保證產(chǎn)品的尺寸精度穩(wěn)定性。
零件坯料沖孔落料復(fù)合模,沖Φ6mm凸模的固定方式:采用壓入式固定。
零件坯料沖孔落料復(fù)合模,沖6mm凸模具體設(shè)計(jì)圖紙如:圖3-1沖孔凸模所示。
圖3-1沖孔凸模
3.2零件坯料沖孔落料復(fù)合模落料凹模設(shè)計(jì)
零件坯料沖孔落料復(fù)合模,落料凹模材料的選擇: 同凸模的材料一樣選擇Cr12MoV。
零件坯料沖孔落料復(fù)合模,落料凹模的熱處理: 60—64HRC。
零件坯料沖孔落料復(fù)合模,落料凹模的冷處理: 加超深冷冷處理(零下400C°應(yīng)為光靠熱處理沒(méi)法完全的去除材料的內(nèi)應(yīng)力,在材料剛剛經(jīng)過(guò)熱處理后接著進(jìn)行材料的加超深冷冷處理,這樣可以最大限度的去除材料的內(nèi)應(yīng)力,以增加模具的使用壽命,保證產(chǎn)品的尺寸精度穩(wěn)定性)。
零件坯料沖孔落料復(fù)合模,落料凹模的具體設(shè)計(jì)圖紙如:圖2-4落料凹模所示。
圖3-2落料凹模
3.3零件坯料沖孔落料復(fù)合模凸凹模設(shè)計(jì)
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總 結(jié)
零件坯料沖孔落料復(fù)合模,凸凹模材料的選擇: 和凸模的材料一樣我們用Cr12MoV。
零件坯料沖孔落料復(fù)合模,凸凹模的熱處理: 58—62HRC。
零件坯料沖孔落料復(fù)合模,凸凹模的冷處理: 加超深冷冷處理(零下400C°應(yīng)為光靠熱處理沒(méi)法完全的去除材料的內(nèi)應(yīng)力,在材料剛剛經(jīng)過(guò)熱處理后接著進(jìn)行材料的加超深冷冷處理,這樣可以最大限度的去除材料的內(nèi)應(yīng)力,以增加模具的使用壽命,保證產(chǎn)品的尺寸精度穩(wěn)定性)。
零件坯料沖孔落料復(fù)合模,凸凹模設(shè)計(jì)圖紙如:圖2-5凸凹模所示。
圖3-3凸凹模
3.4 零件坯料沖孔落料復(fù)合模,凸模固定板設(shè)計(jì)
零件坯料沖孔落料復(fù)合模,凸模固定板材料選擇:45。
零件坯料沖孔落料復(fù)合模,凸模固定板熱處理要求:45—50HRC。
零件坯料沖孔落料復(fù)合模,凸模固定板設(shè)計(jì)如:圖2-6凸模固定板所示。
圖3-4凸模固定板
3.5零件坯料沖孔落料復(fù)合模,凸凹模固定板設(shè)計(jì)
零件坯料沖孔落料復(fù)合模,凸、凹模固定板材料選擇:45。
零件坯料沖孔落料復(fù)合模,凸、凹模固定板熱處理要求:45—50HRC。
零件坯料沖孔落料復(fù)合模,凸、凹模固定板設(shè)計(jì)圖紙如:圖2-7凸、凹模固定板所示。
圖3-5凸凹模固定板
3.6 零件坯料沖孔落料復(fù)合模,推件塊設(shè)計(jì)
零件坯料沖孔落料復(fù)合模,推件塊材料選擇:45。
零件坯料沖孔落料復(fù)合模,具體設(shè)計(jì)如:圖2-8推薦號(hào)。
圖3-6推件塊
3.7零件坯料沖孔落料復(fù)合模,墊板設(shè)計(jì)
零件坯料沖孔落料復(fù)合模,墊板材料選擇:45。
零件坯料沖孔落料復(fù)合模,墊板具體設(shè)計(jì)如:圖2-9所示。
圖3-7墊板
第四章 零件坯料沖孔落料復(fù)合模具結(jié)構(gòu)設(shè)計(jì)
4.1零件坯料沖孔落料復(fù)合模模架的選擇
模架形式的選用后側(cè)導(dǎo)動(dòng),結(jié)合設(shè)計(jì)的凹模等,先大概的確定一下模架的尺寸,最后再通過(guò)查詢資料選取標(biāo)準(zhǔn)模架。
上模座尺寸80mm×80mm×75mm,材料選用,HT250
下模座尺寸80mm×80mm×90mm,材料選用,HT250
4.2 零件坯料沖孔落料復(fù)合模壓力中心計(jì)算
由零件坯料圖就可以看出壓力中心,因?yàn)榱慵髁狭慵菍?duì)稱(chēng)的,沒(méi)有必要進(jìn)行壓力中心的計(jì)算。
4.3零件坯料沖孔落料復(fù)合模模具裝配圖和零件的繪制
見(jiàn)圖紙
總 結(jié)
將近1個(gè)多月的課程設(shè)計(jì)已近進(jìn)入尾聲,請(qǐng)各位老師對(duì)我的課程設(shè)計(jì)—零件做最后的檢查。
在我們目前的生活中絕大部分的用品都是利用模具做出來(lái),無(wú)論是精密零件還是普通精度的零件,用模具都能高效率的生產(chǎn)出來(lái),并且成本還很低,模具對(duì)我們影響的不單單是生活中的方方面面,也包括其它的各個(gè)行業(yè)。
我們國(guó)家的起步不是太早,所以目前一些比較大型的還有比較精密的大部分都是依靠國(guó)外進(jìn)口,就連好的材料和刀具也是依賴(lài)于進(jìn)口,不過(guò)根據(jù)目前我們國(guó)家的發(fā)展速度,在不久我們就能趕上與世界先進(jìn)水平的差距,我們就能獨(dú)立的做出先進(jìn)的模具。
所以我們學(xué)院安排的這次課程設(shè)計(jì)。對(duì)我們學(xué)生來(lái)說(shuō)意義非常的大??梢詫⑽覀兯鶎W(xué)的知識(shí)進(jìn)行一個(gè)完美的組合。同時(shí)還提高了我對(duì)于問(wèn)題的思考能力。對(duì)于問(wèn)題的解決能力。也讓我體會(huì)到了只要努力去做,付出了,“面包“總是會(huì)有的,只是時(shí)間問(wèn)題。
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致謝
致謝
這次我的課程設(shè)計(jì)課題零件能夠成功個(gè)完成,首先要感謝我的課程設(shè)計(jì)指導(dǎo)老師模具教研室的主任,老師不僅借給我?guī)妆娟P(guān)于本次零件課程設(shè)計(jì)非常好的資料,而且還幫我把控整個(gè)課程設(shè)計(jì)的方向。
在我遇到瓶頸時(shí)也耐心的輔導(dǎo)我,幫助我順利的完成我的零件課題設(shè)計(jì)。同時(shí)也感謝我們學(xué)院教過(guò)我的老師,在我AutuCAD工程繪圖時(shí)遇到不會(huì)時(shí)她耐心的教我如何用AutuCAD繪圖,這才使我的設(shè)計(jì)圖能夠順利的用繪圖軟件畫(huà)出來(lái),并在設(shè)計(jì)說(shuō)明書(shū)中插入部分圖紙,還有教我們模具設(shè)計(jì)在我的設(shè)計(jì)出現(xiàn)于實(shí)際生產(chǎn)不相符的時(shí)候及時(shí)的指導(dǎo)我,讓我設(shè)計(jì)的零件彎曲模和零件坯料沖孔落料復(fù)合模復(fù)合實(shí)際生產(chǎn)。
但是由于老師時(shí)間比較緊,不可能完全的將所有的問(wèn)題都找出了,加之我對(duì)于模具設(shè)計(jì)的各方面知識(shí)學(xué)得還不到位,有很多的東西還沒(méi)學(xué)好,無(wú)法避免的會(huì)出現(xiàn)一些不足之處,這點(diǎn)將在以后的工作中會(huì)進(jìn)一步完善。
這次零件課題的課程設(shè)計(jì)的設(shè)計(jì)過(guò)程中參考了很多書(shū)籍還有一些網(wǎng)站,并且我們宿舍的舍友和班級(jí)里面的同學(xué)都給與我了我很大的幫助,在此表示衷心的感謝。
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參考文獻(xiàn)
參考文獻(xiàn)
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