某款鎖扣板沖裁彎曲復(fù)合模具設(shè)計(jì)【2套】【說(shuō)明書(shū)+CAD】
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本科畢業(yè)設(shè)計(jì)(論文)說(shuō)明書(shū)某款鎖扣板沖裁彎曲復(fù)合模具設(shè)計(jì)學(xué) 院 專(zhuān)業(yè)班級(jí) 學(xué)生姓名 學(xué)生學(xué)號(hào) 指導(dǎo)教師 提交日期 年 月 日 學(xué)位論文原創(chuàng)性聲明本人鄭重聲明:所呈交的論文是本人在導(dǎo)師的指導(dǎo)下獨(dú)立進(jìn)行研究所取得的研究成果。除了文中特別加以標(biāo)注引用的內(nèi)容外,本論文不包含任何其他個(gè)人或集體已經(jīng)發(fā)表或撰寫(xiě)的成果作品。對(duì)本文的研究做出重要貢獻(xiàn)的個(gè)人和集體,均已在文中以明確方式標(biāo)明。本人完全意識(shí)到本聲明的法律后果由本人承擔(dān)。作者簽名: 日期: 年 月 日學(xué)位論文版權(quán)使用授權(quán)書(shū)本學(xué)位論文作者完全了解學(xué)校有關(guān)保留、使用學(xué)位論文的規(guī)定,同意學(xué)校保留并向國(guó)家有關(guān)部門(mén)或機(jī)構(gòu)送交論文的復(fù)印件和電子版,允許論文被查閱和借閱。本人授權(quán)華南理工大學(xué)廣州學(xué)院可以將本學(xué)位論文的全部或部分內(nèi)容編入有關(guān)數(shù)據(jù)庫(kù)進(jìn)行檢索,可以采用影印、縮印或掃描等復(fù)制手段保存和匯編本學(xué)位論文。 保密,在 年解密后適用本授權(quán)書(shū)。本學(xué)位論文屬于 不保密。(請(qǐng)?jiān)谝陨戏娇騼?nèi)打“”)學(xué)位論文作者簽名: 日期: 年 月 日指導(dǎo)教師簽名: 日期: 年 月 日畢 業(yè) 設(shè) 計(jì) (論文) 任 務(wù) 書(shū)茲發(fā)給 機(jī)械工程及自動(dòng)化 專(zhuān) 班學(xué)生 畢業(yè)設(shè)計(jì)(論文)任務(wù)書(shū),內(nèi)容如下: 1.畢業(yè)設(shè)計(jì)(論文)題目: 某款鎖扣板沖裁彎曲復(fù)合模具設(shè)計(jì) 2.應(yīng)完成的項(xiàng)目(論文提綱): (1)查找、閱讀有關(guān)沖壓工藝方面的書(shū)籍、論文資料4篇以上(要求外文資料閱讀量不少于3萬(wàn)印刷字符),撰寫(xiě)一份不少于3000字的開(kāi)題報(bào)告。 (2)根據(jù)提供的某款鎖扣板零件,分析零件的沖壓工藝性,確定模具總體方案;設(shè)計(jì)計(jì)算毛坯排樣尺寸;設(shè)計(jì)模具零件及裝配結(jié)構(gòu);利用平面CAD軟件繪制模具總裝圖和零件圖。要求總圖量不少于3張A0圖紙。 (3)撰寫(xiě)成一份1萬(wàn)漢字以上的畢業(yè)設(shè)計(jì)說(shuō)明書(shū); (4)翻譯一份與畢業(yè)設(shè)計(jì)相關(guān)的外文文獻(xiàn)資料,字?jǐn)?shù)要求3000漢字左右(或1.2萬(wàn)印刷字符)。 3.參考資料以及說(shuō)明: 1 王孝培. 沖壓手冊(cè)(第2版)M. 北京:機(jī)械工業(yè)出版社,2004. 2 夏琴香. 沖壓成形工藝及模具設(shè)計(jì)M. 廣州:華南理工大學(xué)出版社,2005. 3 王新華. 沖模設(shè)計(jì)與制造實(shí)用計(jì)算手冊(cè)M. 北京:機(jī)械工業(yè)出版社,2003. 4 王芳. 冷沖壓模具設(shè)計(jì)指導(dǎo)M. 北京:機(jī)械工業(yè)出版社,2005. 5 薛啟翔. 沖壓模具設(shè)計(jì)結(jié)構(gòu)圖冊(cè)M. 北京:化學(xué)工業(yè)出版社,2005. 6 陳錦昌. 計(jì)算機(jī)工程制圖(第3版)M. 廣州:華南理工大學(xué)出版社,2003. 4.本畢業(yè)設(shè)計(jì)(論文)任務(wù)書(shū)于 2012 年 12 月 20 日發(fā)出,應(yīng)于 2013 年 5 月 18 日前完成,然后提交畢業(yè)設(shè)計(jì)(論文)答辯委員會(huì)進(jìn)行答辯。 專(zhuān)業(yè)教研組(系)負(fù)責(zé)人 審核 年 月 日 指導(dǎo)教師(導(dǎo)師組負(fù)責(zé)人) 簽發(fā) 年 月 日畢業(yè)設(shè)計(jì)(論文)評(píng)語(yǔ): 畢業(yè)設(shè)計(jì)(論文)總評(píng)成績(jī): 畢業(yè)設(shè)計(jì)(論文)答辯小組負(fù)責(zé)人簽字: 年 月 日摘 要排樣是沖壓模具設(shè)計(jì)中的一個(gè)重要工藝。材料成本是板料沖壓中最重要的成本之一,因此最大限度減小廢料是節(jié)省材料的本質(zhì)所在,這不僅僅體現(xiàn)在板料沖壓過(guò)程中,而且在整個(gè)生產(chǎn)過(guò)程中也應(yīng)該注意。本文主要是討論用AutoCAD的ObjectARX開(kāi)發(fā)工具為沖壓模具開(kāi)發(fā)一個(gè)切實(shí)可行的排樣優(yōu)化系統(tǒng)。這個(gè)排樣優(yōu)化系統(tǒng)的基本原理還是首次被描述,并且也提出了這個(gè)系統(tǒng)的一般結(jié)構(gòu)。這個(gè)系統(tǒng)不僅僅是一個(gè)排樣算法的計(jì)算問(wèn)題而且還要考慮到工業(yè)實(shí)際要求和用戶(hù)操作的問(wèn)題。在最后,以一個(gè)毛坯形狀補(bǔ)償法去解決補(bǔ)償曲面的自交問(wèn)題,并且這種方法是對(duì)傳統(tǒng)的“一步轉(zhuǎn)換”法的一種改良,它可以消除排樣過(guò)程中高效性和精確性之間的沖突。關(guān)鍵詞:排樣;優(yōu)化;沖壓模具AbstractBlank layout is one of the most important processes in stamping die design. As the major cost in sheet metal stamping is the material cost, any efforts to minimise the scrap may result in substantial savings not only in strip material, but also in overall production. This paper is mainly targeted at establishing a practical blank layout optimisation system for stamping die by using AutoCADs ObjectARX toolkit. The basic principles of blank layout optimisation are first described, and then the general structure of the system is proposed. Not only a suitable algorithm for layout calculation, but also the manufacturing requirements and user operation are fully considered in this system. Finally, an algorithm for blank shape offsetting is proposed to solve the problem of selfintersection in offset curves, and the traditional 1-step translation algorithm for the calculation of layout parameters is improved to eliminate the conflict between precision and efficiency in the layout optimisation.Keywords: Blank layout; Optimization; Stamping die目 錄摘 要IAbstractII第一章 緒論11.1 冷沖壓與模具技術(shù)現(xiàn)狀11.2畢業(yè)設(shè)計(jì)的意義與目的21.3 本章小結(jié)3第二章 沖壓件工藝性分析及沖裁方案的確定42.1 材料分析42.2 沖裁件的結(jié)構(gòu)工藝性42.3 展開(kāi)尺寸的計(jì)算42.4 沖裁件尺寸精度和表面粗糙度要求52.5沖裁方案的確定52.6 本章小結(jié)6第三章 排樣圖的設(shè)計(jì)及材料利用率的計(jì)算73.1 排樣的設(shè)計(jì)73.2 搭邊的選取83.3 材料利用率的計(jì)算93.4 本章小結(jié)9第四章 沖裁工藝力的計(jì)算104.1 沖裁力的計(jì)算104.1.1沖裁力的計(jì)算公式104.2 卸料力、推件力、和頂件力的計(jì)算114.3 彎曲力的計(jì)算124.4 沖壓壓力中心計(jì)算124.5 本章小結(jié)14第五章 沖壓設(shè)備的選擇155.1 沖壓設(shè)備類(lèi)型的選擇155.3 本章小結(jié)15第六章 沖裁模工作部分設(shè)計(jì)計(jì)算166.1 沖裁間隙166.2 模具刃口尺寸的計(jì)算166.2.1落料部分刃口設(shè)計(jì)計(jì)算186.2.2沖孔部分刃口設(shè)計(jì)計(jì)算196.2.3 彎曲凸模,凹模設(shè)計(jì)計(jì)算196.3 本章小結(jié)21第七章 模具總體設(shè)計(jì)227.1模具類(lèi)型的選擇227.2確定送料方式227.3定位方式的選擇227.4卸料、出件方式的選擇227.5 本章小結(jié)23第八章 卸料零件計(jì)算238.1 卸料樹(shù)脂的選擇23第九章 主要零部件設(shè)計(jì)249.1模具材料的選擇249.1.1模具材料的性能與熱處理249.2落料凹模設(shè)計(jì)249.2.1落料凹模外形和尺寸的確定249.2.2落料凹模的結(jié)構(gòu)形式259.3凸凹模設(shè)計(jì)259.3.1模具的結(jié)構(gòu)形式和固定方法259.3.2凸凹模長(zhǎng)度的確定259.3.3凸凹模結(jié)構(gòu)設(shè)計(jì)269.4沖孔凸模269.4.1沖孔凸模的固定形式269.4.2凸模強(qiáng)度校核269.4.3 沖孔凸模的結(jié)構(gòu)269.5 彎曲凸模設(shè)計(jì)269.5.1模具的結(jié)構(gòu)形式和固定方法269.5.2凸模強(qiáng)度的較核279.6 彎曲凹模設(shè)計(jì)279.6.1模具的結(jié)構(gòu)形式和固定方法279.6.2凹模強(qiáng)度的較核279.7 本章小結(jié)27第十章 標(biāo)準(zhǔn)件的選擇2810.1模架及模柄的選擇2810.2凸模固定板及墊板的選擇2810.3模具閉合高度的校核2810.4卸料螺釘2910.5螺釘及銷(xiāo)釘?shù)倪x擇2910.6 本章小結(jié)29第十一章 模具裝配3011.1模具的總裝配(以彎曲模為例)30參考文獻(xiàn)33致 謝34附錄35 III 第一章 緒論第一章 緒論1.1 冷沖壓與模具技術(shù)現(xiàn)狀 我國(guó)考古發(fā)現(xiàn),早在2000多年前,我國(guó)已有沖壓模具被用于制造銅器,證明了中國(guó)古代沖壓成型和沖壓模具方面的成就就在世界領(lǐng)先。1953年,長(zhǎng)春第一汽車(chē)制造廠在中國(guó)首次建立了沖模車(chē)間,該廠于1958年開(kāi)始制造汽車(chē)覆蓋件模具。我國(guó)于20世紀(jì)60年代開(kāi)始生產(chǎn)精沖模具。在走過(guò)了漫長(zhǎng)的發(fā)展道路之后,目前我國(guó)已形成了300多億元(未包括港、澳、臺(tái)的統(tǒng)計(jì)數(shù)字,下同。)各類(lèi)沖壓模具生產(chǎn)能力。改革開(kāi)放以來(lái),隨著國(guó)民經(jīng)濟(jì)的高速發(fā)展,市場(chǎng)對(duì)模具的需求量不斷增長(zhǎng)。近年來(lái),模具工業(yè)一直以15%左右的增長(zhǎng)速度快速發(fā)展,模具工業(yè)企業(yè)的所有制成分也發(fā)生了巨大變化,除了國(guó)有專(zhuān)業(yè)模具廠外,集體、合資、獨(dú)資和私營(yíng)也得到了快速發(fā)展。浙江寧波和黃巖地區(qū)的“模具之鄉(xiāng)”;廣東一些大集團(tuán)公司和迅速崛起的鄉(xiāng)鎮(zhèn)企業(yè),科龍、美的、康佳等集團(tuán)紛紛建立了自己的模具制造中心;中外合資和外商獨(dú)資的模具企業(yè)現(xiàn)已有幾千家。近年來(lái),我國(guó)沖壓模具水平已有很大提高。大型沖壓模具已能生產(chǎn)單套重量達(dá)50多噸的模具。為中檔轎車(chē)配套的覆蓋件模具內(nèi)也能生產(chǎn)了。精度達(dá)到12m,壽命2億次左右的多工位級(jí)進(jìn)模國(guó)內(nèi)已有多家企業(yè)能夠生產(chǎn)。表面粗糙度達(dá)到Ra1.5m的精沖模,大尺寸(300mm)精沖模及中厚板精沖模國(guó)內(nèi)也已達(dá)到相當(dāng)高的水平。沖壓加工在汽車(chē)、拖拉機(jī)、電機(jī)、電器、儀器、儀表、各種民用輕工產(chǎn)品以及航空、航天和兵工等的生產(chǎn)方面占據(jù)十分重要的地位。現(xiàn)代各種先進(jìn)工業(yè)化國(guó)家的沖壓生產(chǎn)都是十分發(fā)達(dá)的。在我國(guó)的現(xiàn)代化建設(shè)進(jìn)程中,沖壓生產(chǎn)占有重要的地位。沖壓工藝是塑性加工的基本加工方法之一。它主要用于加工板料零件,所以有時(shí)也叫板料沖壓。沖壓不僅可以加工金屬板料,而且也可以加工非金屬板料。沖壓加工時(shí),板料在模具的作用下,于其內(nèi)部產(chǎn)生使之變形的內(nèi)力。當(dāng)內(nèi)力的作用達(dá)到一定程度時(shí),板料毛坯或毛坯的某個(gè)部位便會(huì)產(chǎn)生與內(nèi)力的作用性質(zhì)相對(duì)應(yīng)的變形,從而獲得一定的形狀、尺寸和性能的零件。 沖壓生產(chǎn)靠模具與設(shè)備完成加工過(guò)程,所以它的生產(chǎn)率高,而且由于操作簡(jiǎn)便,也便于實(shí)現(xiàn)機(jī)械化和自動(dòng)化。 利用模具加工,可以獲得其它加工方法所不能或難以制造的、形狀復(fù)雜的零件。 沖壓產(chǎn)品的尺寸精度是由模具保證的,所以質(zhì)量穩(wěn)定,一般不需要再經(jīng)過(guò)機(jī)械加工便可以使用。 沖壓加工一般不需要加熱毛坯,也不像切削加工那樣大量的切削材料,所以它不但節(jié)能,而且節(jié)約材料。沖壓產(chǎn)品的表面質(zhì)量較好,使用的原材料是冶金工廠大量生產(chǎn)的軋制板料或帶料,在沖壓過(guò)程中材料表面不受破壞。 因此,沖壓工藝是一種產(chǎn)品質(zhì)量好而且成本低的加工工藝。用它生產(chǎn)的產(chǎn)品一般還具有重量輕且剛性好的特點(diǎn)。沖壓加工在汽車(chē)、拖拉機(jī)、電機(jī)、電器、儀器、儀表、各種民用輕工產(chǎn)品以及航空、航天和兵工等的生產(chǎn)方面占據(jù)十分重要的地位?,F(xiàn)代各種先進(jìn)工業(yè)化國(guó)家的沖壓生產(chǎn)都是十分發(fā)達(dá)的。在我國(guó)的現(xiàn)代化建設(shè)進(jìn)程中,沖壓生產(chǎn)占有重要的地位。 當(dāng)今,隨著科學(xué)技術(shù)的發(fā)展,沖壓工藝技術(shù)也在不斷革新和發(fā)展,這些革新和發(fā)展主要表現(xiàn)在以下幾個(gè)方面:(1)工藝分析計(jì)算方法的現(xiàn)代化(2)模具設(shè)計(jì)及制造技術(shù)的現(xiàn)代化(3)沖壓生產(chǎn)的機(jī)械化和自動(dòng)化(4)新的成型工藝以及技術(shù)的出現(xiàn)(5)不斷改進(jìn)板料的性能,以提高其成型能力和使用效果。1.2畢業(yè)設(shè)計(jì)的意義與目的畢業(yè)設(shè)計(jì)是一種綜合性的訓(xùn)練,也是一個(gè)重要的專(zhuān)業(yè)實(shí)訓(xùn)環(huán)節(jié),它綜合性強(qiáng),應(yīng)用知識(shí)面寬。隨著社會(huì)主義市場(chǎng)經(jīng)濟(jì)的不斷發(fā)展,工業(yè)產(chǎn)品增多,產(chǎn)品更新?lián)Q代加快,市場(chǎng)競(jìng)爭(zhēng)激烈。模具作為一種工具已廣泛地應(yīng)用在各行各業(yè)之中。模具是現(xiàn)代化工業(yè)生產(chǎn)的重要工藝裝備。在國(guó)民經(jīng)濟(jì)的各個(gè)工業(yè)部門(mén)都越來(lái)越多地依靠模具來(lái)進(jìn)行生產(chǎn)加工。模具已成為國(guó)民經(jīng)濟(jì)的基礎(chǔ)工業(yè)。模具已成為當(dāng)代工業(yè)的重要手段和工藝發(fā)展方向之一?,F(xiàn)代工業(yè)產(chǎn)品的品種和生產(chǎn)效益的提高,在很大程度上取決于模具的發(fā)展和技術(shù)經(jīng)濟(jì)水平。為了更進(jìn)一步加強(qiáng)我們的設(shè)計(jì)能力,鞏固所學(xué)的專(zhuān)業(yè)知識(shí),在畢業(yè)之際,特安排了此次的畢業(yè)設(shè)計(jì)。畢業(yè)計(jì)也是我們專(zhuān)業(yè)在學(xué)完基礎(chǔ)理論課,技術(shù)基礎(chǔ)課和專(zhuān)業(yè)課的基礎(chǔ)上,所設(shè)置的一個(gè)重要的實(shí)踐性教學(xué)環(huán)節(jié)。本次設(shè)計(jì)的目的:一、綜合運(yùn)用本專(zhuān)業(yè)所學(xué)的理論與生產(chǎn)實(shí)際知識(shí),進(jìn)行一次沖壓模設(shè)計(jì)的實(shí)際訓(xùn)練,從而提高我們獨(dú)立工作能力。二、鞏固復(fù)習(xí)三年以來(lái)所學(xué)的各門(mén)學(xué)科的知識(shí),以致能融貫通,進(jìn)一步了解從模具設(shè)計(jì)到模具制造整個(gè)工藝流程。三、掌握模具設(shè)計(jì)的基本技能,如計(jì)算、繪圖、查閱設(shè)計(jì)資料和手冊(cè),熟悉標(biāo)準(zhǔn)和規(guī)范等。由于本人設(shè)計(jì)水平有限,經(jīng)驗(yàn)不足,錯(cuò)誤難免,敬請(qǐng)老師批評(píng)、指導(dǎo),不勝感激。1.3 本章小結(jié)本章從國(guó)內(nèi)外當(dāng)今模具的發(fā)展?fàn)顩r這個(gè)角度介紹了課題的研究意義,在此基礎(chǔ)上提出課題設(shè)計(jì)的任務(wù)。并分析了產(chǎn)品工藝,進(jìn)行了比較,選擇最佳方案。5第二章 沖壓件工藝性分析及沖裁方案的確定第二章 沖壓件工藝性分析及沖裁方案的確定2.1 材料分析沖裁材料為Q235,查文獻(xiàn)屬于普通碳素鋼,屈服點(diǎn)s=240MPa,抗拉強(qiáng)度440-470 MPa,延伸率不小于21-25,抗剪強(qiáng)度310-380 MPa塑性好,焊接性好,適合沖裁。2.2 沖裁件的結(jié)構(gòu)工藝性沖裁件的結(jié)構(gòu)形狀應(yīng)盡可能簡(jiǎn)單、對(duì)稱(chēng)、避免復(fù)雜形狀的曲線,在許可的情況下,把沖裁件設(shè)計(jì)成少、無(wú)廢料排樣的形狀,以減少?gòu)U料,矩形孔兩端宜用圓弧連接,以利于模具加工。沖裁件凸出或凹進(jìn)的部分不能太窄,盡可能避免過(guò)長(zhǎng)的懸臂和窄槽,如圖2-2所示。最小寬度b一般不小于1.5t,若沖裁材料為高碳鋼,b2t, ,當(dāng)材料厚度t0.10.50.52.52.56.5 6.50.0650.0750.0450.0550.040.050.030.040.020.060.10.0630.0550.0450.0250.140.080.060.050.03鋁 鋁合金紫銅 黃銅0.0250.080.020.060.030.070.030.09 注:表4-1引自文獻(xiàn)2。卸料力系數(shù)K卸在沖多孔、大搭邊和輪廓復(fù)雜時(shí)取上限值。 沖裁時(shí),所需沖壓力為沖裁力、卸料力和推件力之和,這些力在選擇壓力機(jī)時(shí)是否要考慮進(jìn)去,應(yīng)根據(jù)不同的模具結(jié)構(gòu)區(qū)別對(duì)待。采用剛性卸料裝置和下出料的沖裁模的總壓力為 (4-4)采用彈性卸料裝置和下出料的總壓力為 (4-5)采用彈性卸料裝置和上出料方式的的總壓力為 (4-6)式(4-5)、(4-6)、(4-7)引自文獻(xiàn)2P52。因?yàn)楣ぜ?.5mm,相對(duì)較薄,卸料力也比較小,故采用彈性卸料裝置上出料方式,總沖壓力F總:F總=F沖+F卸+F頂=162.27+8.11+8.92=179.3KN4.3 彎曲力的計(jì)算本產(chǎn)品屬于V形彎曲,由于彎曲雖然是一副模具,但需要彎曲兩次,定位做成可調(diào)接的,所以在計(jì)算彎曲力時(shí),需要計(jì)算兩次,V形彎曲的計(jì)算公式如下第一次彎曲,彎曲力計(jì)算F=0.6KBtt/(R+t) (4-7) F=0.61.3141.01.0470/(1.0+1.0)=2566.2N =8.69KN第一次彎曲,彎曲力計(jì)算F=0.6KBtt/(R+t) (4-8) F=0.61.3281.01.0470/(1.0+1.0)=5132.4N 式中 F彎曲力(N);B產(chǎn)品的彎曲的寬度(mm);材料抗拉強(qiáng)度(MPa);(440-470 MPa)t材料厚度;(mm)K系數(shù),通常K=1.3;彎曲力用理論計(jì)算很復(fù)雜,一般采用經(jīng)驗(yàn)計(jì)算方法, K值的大小取決于彎曲件的形狀及變形方式。其數(shù)值由實(shí)驗(yàn)確定。 由于彎曲時(shí)兩邊對(duì)稱(chēng)彎曲,所以計(jì)算彎曲力時(shí),兩側(cè)彎曲力等同。由于本設(shè)計(jì)中,上模和下模剛性碰撞,成型。所以總的彎曲力F總=F=2.565.13=7.69KN 4.4 沖壓壓力中心計(jì)算沖裁時(shí)的合力作用或多工序模各工序沖壓力的合力作用點(diǎn),稱(chēng)為模具壓力中心。如果模具壓力中心與滑塊的壓力中心不一致,沖壓時(shí)會(huì)產(chǎn)生偏載,導(dǎo)致模具以及滑塊與導(dǎo)軌的急劇磨損,降低模具壽命和壓力機(jī)的使用壽命。計(jì)算壓力中心時(shí),如圖4-2所示。為了減少計(jì)算,坐標(biāo)設(shè)在和上,此時(shí)=0,=0,可少算兩個(gè)數(shù)。將xoy坐標(biāo)系建立在圖示的對(duì)稱(chēng)中心上,將沖裁輪廓線按集合圖形分解為10段基本線段。若選用J23-40T沖床,模柄孔40,壓力中心點(diǎn)仍在壓力機(jī)模柄孔投影面積范圍內(nèi),滿(mǎn)足要求。有關(guān)計(jì)算如表4-1。落料沖孔模如下:F1沖6孔力 F1=3801.33.1461.0=9.31KN,得F1=9.31KNF2沖6孔力 F2=3801.33.1461.0=9.31KN,得F2=9.31KNF3沖方孔力 F3=3801.395.31.0=47.08KN,得F3=47.08KNF4落料力 F4=3801.3195.51.0=96577KN, 得F4=96.57KNY1F1到X軸的力臂 Y1=-5.1X1F1到Y(jié)軸的力臂 X1=-23.5Y2F2到X軸的力臂 Y2=-5.1X2F2到Y(jié)軸的力臂 X2=23.5Y3F3到X軸的力臂 Y3=0X3F3到Y(jié)軸的力臂 X3=-4.1Y4F4到X軸的力臂 Y4=0X4F4到Y(jié)軸的力臂 X4=0根據(jù)合力距定理:YG = (Y1F1+Y2F2+Y3F3)/(F1+ F2+ F3)YGF沖壓力到X軸的力臂;YG =-5.85XG = (X1F1+X2F2+X3F3)/(F1+ F2+ F3)XGF沖壓力到Y(jié)軸的力臂;XG =-1.19彎曲模計(jì)算公式如上,式中 x1、x2xn各圖形沖裁力的x軸坐標(biāo)(mm); y1、y2yn各圖形沖裁力的y軸坐標(biāo)(mm); 、各圖形沖裁周邊長(zhǎng)度(mm)。由于本設(shè)計(jì)中產(chǎn)品對(duì)稱(chēng),所以模具的壓力中心為零,即在產(chǎn)品中心。4.5 本章小結(jié)本章分析了加工該零件沖壓工序的安排,計(jì)算沖壓力,為選擇合理的模具結(jié)構(gòu)和壓力機(jī)打下基礎(chǔ)。11第五章 沖壓設(shè)備的選擇第五章 沖壓設(shè)備的選擇5.1 沖壓設(shè)備類(lèi)型的選擇根據(jù)所要完成的沖壓工藝的性質(zhì)、生產(chǎn)批量的大小、沖壓件的幾何尺寸和精度要求來(lái)選定設(shè)備類(lèi)型。開(kāi)式曲柄壓力機(jī)雖然剛度差,降低了模具壽命。但是它成本低,且有三個(gè)方向可以操作的優(yōu)點(diǎn)廣泛適用于中小型沖裁件、彎曲件或拉深件的生產(chǎn)中。閉式曲柄壓力機(jī)剛度好、精度高,只能兩個(gè)方向操作,適用于大型復(fù)雜沖壓件的生產(chǎn)。雙動(dòng)曲柄壓力機(jī)有兩個(gè)滑塊,壓邊可靠易調(diào),適用于較復(fù)雜的大中型拉深件的生產(chǎn)。高速壓力機(jī)或多工位自動(dòng)壓力機(jī)適用于大批量生產(chǎn)。液壓機(jī)沒(méi)有固定的工作行程,不會(huì)因板厚超差而過(guò)載,全行程中壓力恒定,但是壓力機(jī)的速度低、生產(chǎn)效率低。適用于小批量,尤其是大型厚板沖壓件的生產(chǎn)。摩擦壓力機(jī)結(jié)構(gòu)簡(jiǎn)單、造價(jià)低、不易發(fā)生超負(fù)荷損壞。在小批量生產(chǎn)中用來(lái)完成彎曲、成型等沖壓工作??紤]到以上的因素,選用開(kāi)式壓力機(jī)比較合適。5.2 選擇壓力機(jī)考慮到制件的精度要求,參考文獻(xiàn)2P49初選J23-40壓力機(jī),其主要技術(shù)參數(shù)如下: 公稱(chēng)壓力:400KN 標(biāo)稱(chēng)壓力行程:7mm 滑塊行程:100mm 最大封閉高度:300mm 封閉高度調(diào)節(jié)量:80mm 工作臺(tái)孔徑(前后左右):420mm630mm 模柄孔尺寸(直徑深度):50mm70mm5.3 本章小結(jié)本章分析了壓力機(jī)的選擇方法,根據(jù)零件的特點(diǎn)以及廠里的要求,選擇合理的沖床來(lái)調(diào)試模具。第六章 沖裁模工作部分設(shè)計(jì)計(jì)算第六章 沖裁模工作部分設(shè)計(jì)計(jì)算6.1 沖裁間隙沖裁間隙是沖裁模的凸模和凹模刃口之間的間隙。沖裁間隙分為單邊間隙和雙邊間隙單邊間隙用C表示,雙邊間隙用Z表示。間隙值的大小對(duì)沖裁件質(zhì)量、模具壽命、沖裁力的影響很大,是沖裁工藝與模具設(shè)計(jì)中一個(gè)極其重要的工藝參數(shù)。確定合理間隙的方法主要有理論計(jì)算法和查表選取法兩種。一般直接采取查表的方法,直接明了。間隙的選取主要與材料的種類(lèi)、厚度有關(guān),但由于各種沖壓件對(duì)其斷面質(zhì)量和尺寸精度的要求不同,以及生產(chǎn)條件的差異,在生產(chǎn)實(shí)踐中就很難有一種統(tǒng)一的間隙數(shù)值,各種資料中給的間隙值并不相同,有的相差較大,選用時(shí)應(yīng)按使用要求分別選取。對(duì)于斷面質(zhì)量和尺寸精度要求高的工件,應(yīng)選用小的間隙值,而對(duì)于精度要求不高的工件,則應(yīng)盡可能采用大間隙,以利于提高模具壽命、降低沖裁力。同時(shí)還必須結(jié)合生產(chǎn)條件,根據(jù)沖裁件尺寸和形狀、模具材料和加工方法、沖壓方法及生產(chǎn)率等,靈活掌握、斟情增減。本模具所沖裁的材料為Q235,材料厚度為1.0mm,查表得:=0.03mm,=0.05mm.6.2 模具刃口尺寸的計(jì)算沖裁件的尺寸精度主要決定于模具刃口的尺寸精度,合理的間隙的數(shù)值也必須依靠模具刃口尺寸來(lái)保證。因此,正確確定模具刃口尺寸及其公差是設(shè)計(jì)沖裁模的主要任務(wù)之一。(一)計(jì)算原則由于凸、凹模之間存在間隙,所以沖裁件斷面都是帶有錐度的,且落料件的大端尺寸等于凹模尺寸,沖裁件的小端尺寸等于凸模尺寸。在測(cè)量與使用過(guò)程中,落料件是以大端尺寸為 基準(zhǔn),沖孔件孔徑是以小端尺寸為基準(zhǔn)。沖裁過(guò)程中,凸、凹模要與沖裁零件或廢料發(fā)生摩擦,凸模越磨越小,凹模越磨越大,結(jié)果使間隙越用越大。因此,在確定凸、凹模刃口尺寸時(shí),必須遵循下述原則:(1)落料模先確定凹模尺寸,其標(biāo)稱(chēng)尺寸應(yīng)取接近或者等于制件的最小極限尺寸,以保證凹模磨損到一定尺寸范圍內(nèi),也能沖出合格制件,凸模刃口的標(biāo)稱(chēng)尺寸比凹模小一個(gè)最小合理間隙。(2)沖孔模先確定凸模刃口尺寸,其標(biāo)稱(chēng)尺寸應(yīng)接近或者等于制件的最大極限尺寸,以保證凸模磨損到一定尺寸范圍內(nèi),也能沖出合格的孔。凹模刃口的標(biāo)稱(chēng)尺寸應(yīng)比凸模大一個(gè)最小合理間隙。(二)計(jì)算方法模具工作部分尺寸及公差的計(jì)算方法與加工方法有關(guān),基本上可分為兩類(lèi)。1.凸模與凹模分開(kāi)加工 凸、凹模分開(kāi)加工,是指凸模和凹模分別按圖樣加工至尺寸。此種方法適用于圓形或形狀簡(jiǎn)單的工件,為了保證凸、凹模間隙小于最大合理間隙,不僅凸、凹模分別標(biāo)注公差(凸模,凹模),而且要求有較高的制造精度,以滿(mǎn)足如下條件 (6-2)或取 (6-3) 也就是說(shuō),新制造的模具應(yīng)該是,如圖6-5所示。否則制造的模具間隙已超過(guò)允許的變動(dòng)范圍,影響模具的使用壽命。2.凸模與凹模配合加工 對(duì)于沖制件形狀復(fù)雜或薄板制件的模具,其凸、凹模往往采用配合加工的方法。此方法是先加工好凸模(或凹模)作為基準(zhǔn)件,然后根據(jù)此基準(zhǔn)件的實(shí)際尺寸,配作凹模(或凸模),使他們保持一定距離。因此,只需在基準(zhǔn)件上標(biāo)注尺寸及公差,另一件只標(biāo)注標(biāo)稱(chēng)尺寸,并注明“尺寸按凸模(或凹模)配作,保證雙面間隙”。這樣??煞糯蠡鶞?zhǔn)件的制造公差。其公差不再受凸、凹模間隙大小的限制,制造容易,并容易保證凸、凹模間的間隙。由于復(fù)雜形狀工件各部分尺寸性質(zhì)不同,凸模和凹模磨損后,尺寸變化趨勢(shì)不同,所以基準(zhǔn)件的刃口尺寸計(jì)算方法也不相同。6.2.1落料部分刃口設(shè)計(jì)計(jì)算應(yīng)以凹模為基準(zhǔn)件,然后配做凸模。圖示為落料件,先做凹模,凹模磨損后,(圖6-6右圖的點(diǎn)畫(huà)線位置),刃口尺寸的變化有增大、減小、不變?nèi)N情況。因此凹模尺寸應(yīng)按不同情況分別計(jì)算。 凹模磨損后尺寸變大(圖中A類(lèi))。 計(jì)算這類(lèi)尺寸,先把工件圖尺寸化為A0-,再按落料凹模公式計(jì)算: (6-4)上式引自文獻(xiàn)2P64式(2-11)。式中Ad凹模刃口尺寸(mm); A工件標(biāo)稱(chēng)尺寸(mm);工件公差(mm);d 凹模制造偏差(mm);d=/4。落料凹模尺寸:Aj1=(Amax-X)+ =65-0.50.04=64.98+0.02; Aj2=(Amax-X)+ =36.2-0.50.04=36.18+0.02;Aj3=(Amax-X)+ =28-0.50.02=27.99+0.02;Aj4=(Amax-X)+ =26-0.50.02=25.99+0.02;Aj5=(Amax-X)+ =2-0.50.02=1.99+0.02;該零件落料時(shí)凸模刃口各部分尺寸按上述凹模的相應(yīng)部分尺寸配制,保證雙面間隙值=0.040.08 mm。本設(shè)計(jì)中取0.06。落料凸模尺寸:Aj1=(Amax-2Z)+ =65-20.04=64.92+0.02; Aj2=(Amax-2Z)+ =36.2-20.04=36.12+0.02; Aj3=(Amax-2Z)+ =28-20.04=27.92+0.02; Aj4=(Amax-2Z)+ =26-20.04=25.92+0.02;Aj5=(Amax-Z)+ =2-0.04=1.96+0.02;6.2.2沖孔部分刃口設(shè)計(jì)計(jì)算 由于沖出的孔形狀簡(jiǎn)單,所以凸模與凹模分開(kāi)加工。由文獻(xiàn)2P58表2-5查得=0.03mm =0.05mm -=(0.05-0.03)mm=0.04 mm 由文獻(xiàn)2P58表2-10查得凸、凹模的制造公差: =0.02 mm, =0.02 mm/2=(0.0+0.02)/2mm=0.02 mm- 工件尺寸11mm未標(biāo)注尺寸公差,按照IT10級(jí)精度處理,x=0.5,,工件公差=0.04,沖孔凸模尺寸:Bj1=(Amin+X)+ /4 =6+0.50.02=6.01+0.02Bj2=(Amin+X)+ /4 =26+0.50.02=26.01+0.02Bj3=(Amin+X)+ /4 =18+0.50.02=18.01+0.02Bj4=(Amin+X)+ /4 =2+0.50.02=2.01+0.02沖孔凹模尺寸:Bh1=(Amin+2Z)- /4 =6+20.04=6.08-0.02Bh2=(Amin+2Z)- /4 =26+20.04=26.08-0.02 Bh3=(Amin+2Z)- /4 =18+20.04=18.08-0.02Bh4=(Amin+Z)- /4 =2+0.04=2.04-0.026.2.3 彎曲凸模,凹模設(shè)計(jì)計(jì)算毛坯經(jīng)凹模圓角進(jìn)入凹模時(shí),受彎曲和摩擦作用,若凹模圓角半徑過(guò)小,因徑向拉力增大,易使拉伸件表面劃傷或產(chǎn)生斷裂;若過(guò)大,則壓邊面積小,由于懸空增大,易起內(nèi)皺。因此,合理的選擇凹模圓角半徑很重要。具體數(shù)值查表可得。彎曲模間隙是單面間隙,即凹模和凸模直徑之差的一半。本次設(shè)計(jì)的模具結(jié)構(gòu)比較簡(jiǎn)單,在選擇間隙時(shí)可以直接查表,所以查表可知間隙為(1-1.1t),t為材料厚度。由于產(chǎn)品圓角較大,所以間隙不能大,否則產(chǎn)品有錐度,精度差,不符合要求,間隙太小,模具壽命短,所以取間隙為t。凸、凹模工作部分尺寸的確定,主要考慮模具的磨損和產(chǎn)品的回彈。1)、制件標(biāo)注外形尺寸 凹模尺寸為L(zhǎng) d=(Lmax 0.75)凸模尺寸為L(zhǎng) p=(Ld0.75Z)(2)、制件標(biāo)注內(nèi)尺寸凸模尺寸為L(zhǎng) p=(Lmin +0.4) 凹模尺寸為L(zhǎng) d=(Lp+0.4+Z) 其中 L產(chǎn)品件的外形或內(nèi)尺寸產(chǎn)品件的尺寸偏差L d產(chǎn)品凹模的基本尺寸L p產(chǎn)品凸模的基本尺寸Z凸凹模雙面間隙具體計(jì)算如下,制件標(biāo)注內(nèi)尺寸,按此公式計(jì)算彎曲凸模尺寸為L(zhǎng) p1=(Lmin +0.4) =16L p1=(Lmin +0.4) =30凹模尺寸為L(zhǎng) d1=(Lp1+0.4+Z) =17L d1=(Lp1+0.4-Z) =29凸、凹模工作表面粗造度要求:凹模工作表面和型腔表面粗造度應(yīng)達(dá)到0.8;圓角處的表面粗造度一般要求0.4;凸模工作部分表面粗造度一般要求0.8-1.6。6.3 本章小結(jié)本章的難點(diǎn),設(shè)計(jì)計(jì)算并確定模具各零件尺寸,完成了模具總體設(shè)計(jì),繪制出模具裝配圖。本章重點(diǎn)與難點(diǎn)是工藝方案,模具結(jié)構(gòu)的確定以及凸模,凹模尺寸的計(jì)算,因?yàn)樗鼘⒅苯佑绊懥慵馁|(zhì)量和模具的合理性。第七章 模具總體設(shè)計(jì)第七章 模具總體設(shè)計(jì)7.1模具類(lèi)型的選擇由沖壓工藝分析可知,采用落料沖孔復(fù)合模,彎曲模沖壓,所以模具類(lèi)型為復(fù)合模具。7.2確定送料方式 模具相對(duì)于模架是采用從前往后的縱向送料方式,還是采用從右往左的橫向送料方式,這主要取決于凹模的周界尺寸。如L(送料方向的凹模長(zhǎng)度)B(垂直于送料方向的凹模寬度)時(shí),采用縱向送料方式;LB時(shí),則采用橫向送料方式;L=B時(shí),縱向或橫向均可。就本模具而言,其送料方式應(yīng)采用縱向送料。7.3定位方式的選擇由于該模具采用的是條料,控制條料送進(jìn)方向采用定位銷(xiāo)側(cè)向定位??刂茥l料送進(jìn)步距采用擋料銷(xiāo)(也叫定位銷(xiāo))。彎曲成型模采用外形定位。具體見(jiàn)CAD圖紙。7.4卸料、出件方式的選擇模具是采用彈壓卸料板,還是采用固定卸料板,取決于卸料力的大小,其中材料料厚是主要考慮因素。由于彈壓卸料模具操作時(shí)比固定卸料模具方便,操作者可以看見(jiàn)條料在模具中的送進(jìn)動(dòng)作,且彈壓卸料板卸料時(shí)對(duì)條料施加的是柔性力,不會(huì)損傷工件表面,因此實(shí)際設(shè)計(jì)中盡量采彈壓卸料板,而只有在彈壓卸料板卸料力不足時(shí),才改用固定卸料板。隨著模具用彈性元件彈力的增強(qiáng)(如采用矩形彈簧),彈壓卸料板的卸料力大大增強(qiáng)。根據(jù)目前情況,當(dāng)材料料厚約在2mm以下時(shí)采用彈壓卸料板,大于2mm時(shí)采用固定卸料板較為貼近實(shí)際。本模具所沖材料的料厚為1.0mm,因此可采用彈壓卸料板。由于采用的是倒裝復(fù)合模具,所以采用下出件便于操作和提高生產(chǎn)效率。彎曲模采用彈簧頂料,上模采用打料裝置。7.5 本章小結(jié)本章分析了模具結(jié)構(gòu)的設(shè)計(jì),分析并確定模具的合理性。第八章 卸料零件計(jì)算第八章 卸料零件計(jì)算8.1 卸料樹(shù)脂的選擇因?yàn)楣ぜ虾駷?.0mm,相對(duì)較薄,卸料力也比較小,故落料沖孔模采用彈性卸料。根據(jù)卸料力8110N采用6個(gè)樹(shù)脂,此時(shí)每個(gè)彈簧擔(dān)負(fù)的卸料力為約1351N。沖裁時(shí)卸料板的工作行程h2= t+1=2.5mm ;考慮凸模的修模余量h3=3mm,樹(shù)脂的預(yù)壓量為h1;故樹(shù)脂總壓縮量為 H總=h1+h2+h3=6.0 mm考慮卸料的可靠性,取樹(shù)脂在預(yù)壓量為h1時(shí)就有應(yīng)力1351.1N的壓力。初選樹(shù)脂直徑d=20mm,工作極限負(fù)荷800N;自由高度h0=20 mm,工作極限載荷下彈簧的變形量hj=6.3 mm。第九章 主要零部件設(shè)計(jì)第九章 主要零部件設(shè)計(jì)9.1模具材料的選擇9.1.1模具材料的性能與熱處理Cr12MoV 鋼C含量0.9%1.05%,Mn含量0.8%1.1%,Si含量0.15%0.35%,Cr含量0.9%1.2%,淬火溫度820840,HRC不低于62,回火溫度140160,HRC6265文獻(xiàn)。具有高淬透性、高硬度和耐磨性,淬火尺寸穩(wěn)定性好,變形小,并有效好的韌性。由于鎢形成碳化物,這種鋼在淬火和低溫回火編號(hào)無(wú)錫太湖學(xué)院畢業(yè)設(shè)計(jì)(論文)相關(guān)資料題目: 啟動(dòng)電機(jī)殼體冷沖壓工藝 及模具設(shè)計(jì) 信機(jī) 系 機(jī)械工程及自動(dòng)化專(zhuān)業(yè)學(xué) 號(hào): 0923279學(xué)生姓名: 李鵬飛 指導(dǎo)教師: 鐘建剛(職稱(chēng):副教授) (職稱(chēng): )2013年5月25日目 錄一、畢業(yè)設(shè)計(jì)(論文)開(kāi)題報(bào)告二、畢業(yè)設(shè)計(jì)(論文)外文資料翻譯及原文三、學(xué)生“畢業(yè)論文(論文)計(jì)劃、進(jìn)度、檢查及落實(shí)表”四、實(shí)習(xí)鑒定表無(wú)錫太湖學(xué)院畢業(yè)設(shè)計(jì)(論文)開(kāi)題報(bào)告題目: 啟動(dòng)電機(jī)殼體冷沖壓工藝及模具設(shè)計(jì) 信機(jī) 系 機(jī)械工程及自動(dòng)化 專(zhuān)業(yè)學(xué) 號(hào): 0923279 學(xué)生姓名: 李鵬飛 指導(dǎo)教師: 鐘建剛 (職稱(chēng):副教授) (職稱(chēng): )2012年11月20日課題來(lái)源來(lái)源于無(wú)錫毅立模具有限公司,是電器產(chǎn)品上的一個(gè)零件。課題來(lái)源于生產(chǎn)實(shí)際,探討沖壓加工中較常見(jiàn)零件的工藝方法和結(jié)構(gòu)設(shè)計(jì)。課題涉及知識(shí)面較廣,且設(shè)計(jì)要求較高,對(duì)學(xué)生的設(shè)計(jì)能力,特別是思考能力是一個(gè)很好的鍛煉。課題研究?jī)?nèi)容包括機(jī)械工程學(xué)科的力學(xué),材料學(xué),機(jī)械原理,機(jī)械設(shè)計(jì),公差與互換性,機(jī)械制造工藝等知識(shí),特別鍛煉學(xué)生規(guī)范性設(shè)計(jì)的能力。使學(xué)生能得到全面的鍛煉。課題要求學(xué)生具備較強(qiáng)的機(jī)構(gòu)設(shè)計(jì)能力和創(chuàng)新能力,對(duì)學(xué)生是一個(gè)挑戰(zhàn)。課題為典型的機(jī)械設(shè)計(jì)類(lèi)課題,涉及機(jī)械知識(shí)全面,與工程機(jī)械專(zhuān)業(yè)方向結(jié)合緊密??茖W(xué)依據(jù)(包括課題的科學(xué)意義;國(guó)內(nèi)外研究概況、水平和發(fā)展趨勢(shì);應(yīng)用前景等)(1)課題科學(xué)意義沖壓模具作為一種生產(chǎn)工具已經(jīng)運(yùn)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(dāng)今,在國(guó)民經(jīng)濟(jì)的各個(gè)工業(yè)部門(mén)。都越來(lái)越多的依靠模具來(lái)進(jìn)行生產(chǎn)加工,模具已成為國(guó)民經(jīng)濟(jì)的基礎(chǔ)工業(yè),已成為當(dāng)代工業(yè)的基本手段和工藝發(fā)展手段之一?,F(xiàn)代工業(yè)產(chǎn)品的品種和生產(chǎn)效益的提高,是高技術(shù)含量的社會(huì)產(chǎn)品,其價(jià)值和價(jià)格主要取決于模具材料、加工、外購(gòu)件的勞動(dòng)與消耗三項(xiàng)直接發(fā)生的費(fèi)用和模具設(shè)計(jì)與試模等技術(shù)費(fèi)用,后者是模具價(jià)值與市場(chǎng)價(jià)格的主要組成部分,其中一部分技術(shù)價(jià)值計(jì)入了市場(chǎng)價(jià)格,而更大的一部分價(jià)值,則是模具用戶(hù)和產(chǎn)品用戶(hù)受惠變?yōu)樯鐣?huì)效益。如電視機(jī)用模,其模具費(fèi)用為產(chǎn)品價(jià)格的1/30001/5000,盡管模具的一次投資較大,但大批量生產(chǎn)后,其模具成本占很小的部分,甚至可以忽略不計(jì),而實(shí)際上,很高的模具價(jià)格為社會(huì)所擁有,變成了社會(huì)財(cái)富。所以本模具設(shè)計(jì)擁有很高的現(xiàn)實(shí)意義。(2)研究狀況及其發(fā)展前景目前我國(guó)模具市場(chǎng)總體趨勢(shì)平穩(wěn)向上。目前,國(guó)內(nèi)市場(chǎng)對(duì)中高檔家電、汽車(chē)、塑料制品模具的需求量很大,但要求國(guó)產(chǎn)模具必須在質(zhì)量、交貨期等方面滿(mǎn)足用戶(hù)的需求。我國(guó)加入WTO后,伴隨著世界經(jīng)濟(jì)的一體化浪潮,全球制造業(yè)加速向中國(guó)大陸地區(qū)轉(zhuǎn)移已是大勢(shì)所趨,中國(guó)也將逐步發(fā)展成為世界級(jí)的制造業(yè)基地。中低檔的模具國(guó)際市場(chǎng)潛力十分巨大,只要國(guó)產(chǎn)模具的質(zhì)量能夠有提高,交貨期能夠保證,模具出口的前景是十分樂(lè)觀的。優(yōu)勢(shì)明顯的廣東特別是珠三角地區(qū),將在十年之內(nèi)發(fā)展成為世界模具生產(chǎn)中心。同時(shí),由于近年來(lái)我國(guó)每年用近10億美元進(jìn)口模具,其中精密、大型、復(fù)雜、長(zhǎng)壽命模具占多數(shù),所以從減少進(jìn)口角度出發(fā),這類(lèi)高檔模具在市場(chǎng)的分額比例也將逐步增大?,F(xiàn)代模具其高技術(shù)、人才密集、高技術(shù)背景下的工藝密集型工業(yè)的特點(diǎn),是在新型工業(yè)化道路上走在前面的產(chǎn)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(wù)的同時(shí),也直接為高新技術(shù)產(chǎn)業(yè)服務(wù),模具在制造業(yè)產(chǎn)品研發(fā)、創(chuàng)新和生產(chǎn)中所具有的獨(dú)特的重要地位,使得模具制造能力和水平的高低也成為國(guó)家創(chuàng)新能力的重要標(biāo)志。隨著電子、信息等高新技術(shù)的不斷發(fā)展,模具CAD/CAE/CAM正向集成化、三維化、智能化和網(wǎng)絡(luò)化方向發(fā)展。模具CAD/CAE/CAM技術(shù)是模具設(shè)計(jì)、制造技術(shù)的發(fā)展方向,模具和工件的檢測(cè)數(shù)字、模具軟件功能集成化、模具設(shè)計(jì)、分析及制造的三維化、模具產(chǎn)業(yè)的逆向工程以及模具軟件應(yīng)用的網(wǎng)絡(luò)化是主趨勢(shì)。研究?jī)?nèi)容本課題研究的是啟動(dòng)電機(jī)殼體沖壓模具設(shè)計(jì),要求其材料08F鋼,采用大批量生產(chǎn),精度要求高。通過(guò)合理的設(shè)計(jì)凸凹模,選擇合理的標(biāo)準(zhǔn)模架,制造出符合要求的制件。(1)查閱有關(guān)模具設(shè)計(jì)方面的資料,翻譯與模具設(shè)計(jì)相關(guān)的英文文獻(xiàn);(2)對(duì)工件進(jìn)行沖壓成型工藝分析,選擇合理的設(shè)計(jì)方案;(3)進(jìn)行必要的參數(shù)計(jì)算,確定出正確的設(shè)計(jì)參數(shù);(4)在計(jì)算正確的基礎(chǔ)上設(shè)計(jì)沖壓成型模具;(5)撰寫(xiě)出一份與自己設(shè)計(jì)相配套的設(shè)計(jì)說(shuō)明書(shū)。擬采取的研究方法、技術(shù)路線、實(shí)驗(yàn)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(jù)設(shè)計(jì)題目,分析沖壓件成型的結(jié)構(gòu)工藝性,分析沖壓件的形狀特點(diǎn)、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(chǎn)品質(zhì)量、生產(chǎn)效率、設(shè)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(jīng)濟(jì)合理的工藝方案。2、確定毛坯形狀、尺寸和下料方式在最經(jīng)濟(jì)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(lèi)型及結(jié)構(gòu)形式4、進(jìn)行必要的工藝計(jì)算5、選擇壓力機(jī)。6、繪制模具總圖和非標(biāo)準(zhǔn)零件圖。7、編寫(xiě)設(shè)計(jì)計(jì)算所明書(shū)。研究計(jì)劃及預(yù)期成果研究計(jì)劃:2012年11月12日-2012年12月2日:按照任務(wù)書(shū)要求查閱論文相關(guān)參考資料,填寫(xiě)畢業(yè)設(shè)計(jì)開(kāi)題報(bào)告書(shū)。2012年12月3日-2012年12月31日:工作計(jì)劃、進(jìn)度。2013年3月4日-2013年3月15日:查閱參考資料,學(xué)習(xí)并翻譯一篇與畢業(yè)設(shè)計(jì)相關(guān)的英文材料。2013年3月18日-2013年4月5日:沖壓工藝設(shè)計(jì),模具結(jié)構(gòu)設(shè)計(jì),刃口尺寸和主要零件結(jié)構(gòu)設(shè)計(jì)和尺寸計(jì)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(xiě)和修改工作。預(yù)期成果:1完成模具裝配圖:2張(A0或A1);2零件圖:主要非標(biāo)準(zhǔn)件零件圖(不少于5張);3冷沖壓工藝卡片:1張;4設(shè)計(jì)說(shuō)明書(shū):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(guān)技術(shù)資料或?qū)I(yè)文獻(xiàn),內(nèi)容要盡量結(jié)合課題。特色或創(chuàng)新之處模具技術(shù)的特色應(yīng)該為適應(yīng)模具產(chǎn)品“交貨期短”、“精度高”、“質(zhì)量好”,“價(jià)格低”的要求服務(wù)。創(chuàng)新之處是通過(guò)研究各種新型材料及先進(jìn)表明處理技術(shù),使模具拋光技術(shù)向自動(dòng)化,智能化發(fā)展。已具備的條件和尚需解決的問(wèn)題已具備的條件:1、工件的尺寸;2、工件的價(jià)格方法;3、工件的制造流程,工藝卡尚需解決的問(wèn)題:拉深工藝的確定,沖壓力的大小和壓力機(jī)選擇,模具結(jié)構(gòu)的確定,模具的裝配工藝等等。指導(dǎo)教師意見(jiàn) 指導(dǎo)教師簽名:年 月 日教研室(學(xué)科組、研究所)意見(jiàn) 教研室主任簽名: 年 月 日系意見(jiàn) 主管領(lǐng)導(dǎo)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 boards 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 operators 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 countrys 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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