嵌件板級進(jìn)模設(shè)計(jì)-沖壓模具
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編號
無錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
相關(guān)資料
題目： 嵌件板級進(jìn)模設(shè)計(jì)
信機(jī) 系 機(jī)械工程及自動(dòng)化專業(yè)
學(xué) 號： 0923079
學(xué)生姓名： 徐 敏
指導(dǎo)教師： 林承德（職稱：教授）
（職稱： ）
2013年5月25日
目 錄
一、畢業(yè)設(shè)計(jì)（論文）開題報(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
無錫太湖學(xué)院
畢業(yè)設(shè)計(jì)（論文）
開題報(bào)告
題目： 嵌件板級進(jìn)模設(shè)計(jì)
信機(jī) 系 機(jī)械工程及自動(dòng)化 專業(yè)
學(xué) 號： 0923079
學(xué)生姓名： 徐 敏
指導(dǎo)教師： 林承德（職稱：教授 ）
（職稱： ）
2012年11月25日
課題來源
本課題來源于工程生產(chǎn)實(shí)際。該零件是電度表上的沖壓件。該零件的材料為純鐵DT4，該件的設(shè)計(jì)特點(diǎn)是壓窩120度后，平面度要求高，底孔不能變形而且尺寸精度高。該件原工藝采用單工序沖裁一壓120度。錐窩分開加工，結(jié)果零件外形脹，尺寸超差大，卸料困難，M2.2孔與外形不對稱而且生產(chǎn)效率低。基于以上問題，只有采用級進(jìn)模才能保證零件質(zhì)量又能提高生產(chǎn)效率。
科學(xué)依據(jù)（包括課題的科學(xué)意義；國內(nèi)外研究概況、水平和發(fā)展趨勢；應(yīng)用前景等）
在工業(yè)生產(chǎn)中許多機(jī)器零件普遍采用模具沖壓成形的工藝方法，有效的保證了產(chǎn)品的質(zhì)量和勞動(dòng)生產(chǎn)率，并使操作技術(shù)簡單化，而且還能省料，節(jié)能，可以獲得顯著的經(jīng)濟(jì)效益。
由于種種原因，我國模具工業(yè)和當(dāng)前工業(yè)發(fā)展還很不適應(yīng)。無論是在設(shè)計(jì)制造技術(shù)和生產(chǎn)能力方面，還是在管理水品方面，模具工業(yè)都遠(yuǎn)遠(yuǎn)不能滿足需求，它嚴(yán)重影響工業(yè)產(chǎn)品品種，質(zhì)量和生產(chǎn)周期，削弱了其在國際市場上的競爭力。今年來，我國模具進(jìn)口幅度呈大幅下降的趨勢，并有超億元的出口額。大型，復(fù)雜，精密，高效和長壽命模具也逐漸上了新的臺(tái)階，體現(xiàn)高水品制造技術(shù)的多工位級進(jìn)模也越來越多，沖壓自動(dòng)線，自動(dòng)沖技術(shù)也得到廣泛應(yīng)用。我國模具行業(yè)的技術(shù)水品迅速提高，模具國產(chǎn)化已經(jīng)取得十分可喜的成績，這將對我國在國際市場的競爭能力和綜合國力的提高起到有力的促進(jìn)作用。
研究內(nèi)容
⑴ 能夠熟練檢索相關(guān)產(chǎn)品的設(shè)計(jì)資料，查閱相關(guān)產(chǎn)品的外文資料，并翻譯不少于8000英文字符的外文資料；
⑵ 熟悉級進(jìn)模具的開發(fā)設(shè)計(jì)流程，能夠熟練應(yīng)用CAD集成軟件完成結(jié)構(gòu)設(shè)計(jì)和裝配工作；
⑶ 進(jìn)行零件的沖壓加工工藝分析，確定加工方案，進(jìn)行排樣圖設(shè)計(jì)；
⑷ 完成級進(jìn)模的設(shè)計(jì)工作，并繪制完整的工程裝配圖紙及其零部件圖紙一套；（要求：完成不少于四張0號圖紙的設(shè)計(jì)工作量，圖紙符合國家標(biāo)準(zhǔn)，各種標(biāo)注正確無誤）
⑸ 完成不少于30頁的畢業(yè)設(shè)計(jì)說明書一份。（要求：格式規(guī)范，符合學(xué)校標(biāo)準(zhǔn)，設(shè)計(jì)計(jì)算準(zhǔn)確，圖文并茂）
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
根據(jù)企業(yè)提出的設(shè)計(jì)要求和模具生產(chǎn)行業(yè)的標(biāo)準(zhǔn)
根據(jù)生產(chǎn)效率和產(chǎn)品質(zhì)量，決定用級進(jìn)模生產(chǎn)該零件，采用帥孔→導(dǎo)正→壓窩→修孔→空位→落外形兼校形等工序。
經(jīng)過各方面的資料查證分析，以上加工流程完全可以達(dá)到預(yù)期的生產(chǎn)效率和產(chǎn)品質(zhì)量的要求，此方案可行。
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25日：按照任務(wù)書要求查閱論文相關(guān)參考資料，填寫畢業(yè)設(shè)計(jì)開題報(bào)告書。
2013年1月11日-2013年3月5日：填寫畢業(yè)實(shí)習(xí)報(bào)告。
2013年3月8日-2013年3月14日：按照要求修改畢業(yè)設(shè)計(jì)開題報(bào)告。
2013年3月15日-2013年3月21日：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22日-2013年4月11日：繪制級進(jìn)模裝配圖及零件圖。
2013年4月12日-2013年4月25日：修改圖紙。
2013年4月26日-2013年5月21日：畢業(yè)論文撰寫和修改工作。
預(yù)期成果：所設(shè)計(jì)的級進(jìn)模符合企業(yè)提出的設(shè)計(jì)要求和模具生產(chǎn)行業(yè)的標(biāo)準(zhǔn)，可以達(dá)到預(yù)期的生產(chǎn)效率和產(chǎn)品質(zhì)量的要求。
特色或創(chuàng)新之處
多工位級進(jìn)模主要用于細(xì)小復(fù)雜沖壓零件的批量生產(chǎn)，其工位數(shù)多、精度高、壽命要求長，模具細(xì)小零件和鑲塊多，板類零件孔位精度高、尺寸協(xié)調(diào)多，因此，多工位級進(jìn)模與常規(guī)沖模相比，雖然加工和裝配方法相似，但要求提高了，需要協(xié)調(diào)的地方多了，因而加工和裝配更加復(fù)雜和困難。在模具設(shè)計(jì)合理的前提下，要制造出合格的多工位級進(jìn)模，必須具備先進(jìn)的模具加工設(shè)備和測量手段以及合理的模具制造工藝規(guī)范。
已具備的條件和尚需解決的問題
已具備的條件：
1．各種和課題相關(guān)的書籍和參考資料。
2．各個(gè)階段的任務(wù)和目標(biāo)。
3．畢業(yè)設(shè)計(jì)的專用教室和電腦。
4．老師的指導(dǎo)。
尚解決的問題：
1．模具總結(jié)構(gòu)的設(shè)計(jì)。
2．排樣圖和步局的設(shè)計(jì)。
3．主要零部件的設(shè)計(jì)。
4．零件圖和裝配圖。
5．設(shè)計(jì)說明書。
指導(dǎo)教師意見
指導(dǎo)教師簽名：
年 月 日
教研室（學(xué)科組、研究所）意見
教研室主任簽名：
年 月 日
系意見
主管領(lǐng)導(dǎo)簽名：
年 月 日
Die Life of cold stamping die and improvements
Overview of stamping die
Stamping Die - Stamping in the cold, the material (metal or non-metallic) processing into parts (or half) of a special technical equipment, called cold stamping die (commonly known as Die). Press - is at room temperature, using the die installed in the press to put pressure on the material to produce a separation or plastic deformation, and thus to obtain the necessary parts of a pressure processing method.
Stamping die in the form of many, the general categories according to the following main features:
1. According to the technical nature of
(1) Die along the closed or open contour the material are derived from mold. If blanking die, punch die, cut off the mold, cut mode, cutting mode, split mode, etc..
(2) bending mode to blank or blank sheet along a straight line (curved line) to bend, deform, and thus obtain a certain angle and shape of the workpiece in the mold.
(3) The drawing die is made of the blank sheet opening hollow, or hollow pieces of further changes to the shape and size of the mold.
(4) Die rough or semi-finished workpiece is convex according to plan, direct copy the shape of the die shape, the material itself, generate only local plastic deformation of the mold. Such as the bulging mode, reducing the die, expansion die, forming die rolling, flanging mold, plastic mold.
2. According to the degree classification process combination
(1) single process model in a press tour, just completed a die stamping process.
(2) composite model is only one station, in a press tour, at the same station at the same time to complete more than two or two die stamping process.
(3) Progressive Die (also known as the modulus of continuity) in the feeding direction, rough, with two or more of the station, at the press of a visit, work in different places on the completion of two or two successive Road over stamping die process.
Chong called cold stamping die Die-wide.
Cold stamping die is used in cold stamping die mold industry, and accessories required for high-performance structural ceramic materials, preparation methods, high-performance ceramic materials, molds and accessories from the zirconium oxide and yttrium aluminum powder increases, Pr element composition, Preparation is the solution of zirconia, yttria solution, praseodymium oxide solution, according to a certain percentage of alumina solution when mixed liquor, ammonium bicarbonate infusion, by co-precipitation synthesis of ceramic materials, molds and accessories needed for raw materials, reaction precipitate generated by the treatment, drying, calcining and accessories by high performance ceramic mold material superfine powder, and then after forming, sintering, finishing, they will have high-performance ceramic materials, molds and accessories. Advantages of this invention is the invention made of cold stamping dies and parts and long service life, the process does not appear in the press and its parts and stamping die bond generated the phenomenon of stamping surface is smooth, no glitches, can replace traditional high-speed steel, tungsten steel.Die with the main parts
Die stamping tools is the main process equipment, stamping rely on the relative movement under the mold completed. Processing time because the upper and lower mold between the constant division and, if continued operation of the fingers of workers to enter or remain in the mold closed, there will certainly pose a serious threat to their personal safety.
(A) of the mold main parts, function and safety requirements
1. Working parts is a direct punch to blank forming the working parts, therefore, it is the key to mold parts. Punch not only sophisticated and complex, it should meet the following requirements:
(1) be of sufficient strength, can not be broken or destroyed during stamping.
(2) should be appropriate to its material and heat treatment requirements, to prevent too high hardness and brittle fracture.
2. Positioning parts positioning part is to determine the location of the parts installed blank, there are pins (board), gauge pin (plate), lead is sold, guide plate, knife set from the side, side pressure etc.. Design should be considered when positioning parts easy to operate and should not have had orientation, location to facilitate observation, preferably in the forward position, contouring to correct the pin location and positioning.
3. Binder, unloading and discharging parts binder components are blank holder, binder board.
Blank holder pressure can drawing blank holder force, thereby preventing billets under the action of the tangential pressure arch formed folds. The role of pressure plate to prevent movement and bounce blank. Top of the device, discharge board's role is to facilitate the pieces and clean up waste. Them by the spring, rubber and equipment, putting on the air-cushion support, can move up and down, knocking out pieces of the design should have enough top output, movement to the limited spaces. Stripper plate area should be minimized or closed position in the operating groove milling out empty-handed. Exposure of the stripper plate should have protection around the plate, to prevent finger inserted into or foreign objects inside, exposed surface edges should be blunt down.
4. Guide parts and guide sleeve guide pin is the most widely used part of a guide. Its role is to ensure punch the punching clearance when accurate match. Therefore, the guide posts, guide cover the gap should be less than the blanking clearance. Guide Post located next mold base, to ensure that the stroke bottom dead center, the lead column in the template on the face over the top for at least 5 to 10 mm. Guide columns should be arranged far away from the module and the pressure plate in the area, so the operator's arms do not get to take over the lead column material.
5. Supporting and clamping the upper and lower parts which includes templates, die handle, fixed plate punch, plate, stopper, etc..Up and down the template is the basis of the cold die parts, other parts are respectively fixed at the top. Template plane size, especially around the direction to be compatible with the workpiece, too large or too small are not conducive to action.
Some molds (blanking, punching type mold) to the pieces of convenience, be set up under the mold plate. At this time the best and the template plate connected between the screw, the two plate thickness should be absolutely equal. Plate spacing out the pieces to be able to prevail, not too much, so as not to break the template.
6. Fastening parts which includes screws, nuts, springs, pins, washers, etc., are generally used standard parts. Die more with the amount of standard parts, design choice and flexibility should be tightened to ensure the top out of the need to avoid exposure to the surface fastener operating position, the staff and impede operation to prevent bumps.
Die with the development of
Since reform and opening, with the rapid development of the national economy, the market demand with the growing Die. In recent years, Die with the industry has been around 15% growth rate of the rapid development of industrial enterprises with ownership Die components also changed dramatically, in addition to the professional mold factory outside of state-owned, collective, joint ventures, wholly-owned and private has been a rapid development.
As with the accelerating pace of international integration, the increasing competition in the market, it has been increasingly recognized product quality, cost, and new product development capacities. The cold die manufacturing is the most basic elements of the chain, one of the cold die manufacturing technology to measure a country's manufacturing sector has become an important symbol of the level, and largely determine the viability of enterprises.
Die with enterprises to increase in recent years many technological advances for investment, technological progress will be seen as an important driving force for enterprise development. Some domestic enterprises have popularized the two-dimensional mold CAD, and gradually began to use UG, Pro / Engineer, I-DEAS, Euclid-IS and other international common software, individual manufacturers have also introduced Moldflow, C-Flow, DYNAFORM, Optris and MAGMASOFT etc. CAE software, and successfully applied in stamping die design.
A car cover mold as the representative of a large stamping die manufacturing technology has made great progress, Dongfeng Motor Corporation mold factory, mold manufacturers such as FAW mold center has been able to produce some car cover mold. In addition, many research institutions and universities to carry out technology research and development of mold. After years of effort, in the mold CAD / CAE / CAM technology has made remarkable progress; in improving quality and reducing mold die design and manufacturing cycle, and so contributed.Although China Die with the industry over the past decade has made remarkable development, but in many ways compared with the industrialized countries there is still a large gap. For example, the precision machining equipment, processing equipment in Die with the relatively low proportion; CAD / CAE / CAM technology penetration is not high; many advanced mold technology not widely so, resulting in a considerable number of large, sophisticated, complex and long Die life with dependence on imports.
With the continuous progress of science and technology, modern industrial production of increasingly complex and diverse, product performance and quality is ever increasing, thus the cold stamping technology put forward higher requirements. In order to adapt to the cold stamping technology industry needs, cold stamping technology itself also in innovation and development. cold stamping technology idea is to improve and expand as much as possible the advantages of the cold stamping process, to overcome its shortcomings. in the cold stamping technology development, should note the following aspects:
(1) cold stamping technology process parameters should be properly identified and Die with the work of some of the shape and size, to improve the quality of stamping parts and shorten the new product production cycle should be in strengthening the metal forming the basis of theoretical studies, to metal forming theory to practice can produce a direction, and gradually establish a close connection with the actual production of the advanced process of calculation. abroad have begun to use plastic finite element method, automobile parts forming process of the stress and strain analysis and computer simulation to predict the forming part of a process plan on the possibilities and potential problems.
(2) to accelerate product replacement, mold design to overcome the shortcomings of a long cycle. Should vigorously carry out computer-aided design and manufacture of molds (CAD / CAM) Research. In my country, paying particular attention to strengthening the multi-position progressive die CAD / CAM Technology.
(3) to meet the needs of mass production, and reduce labor intensity. Should strengthen cold stamping of mechanized and automated, so that the average, small pieces of high-speed presses in a multi-position progressive die production, production reached a high degree of automation to further improve stamping productivity.
(4) expand the scope of application of cold stamping production. So cold pressing both suitable for mass production, but also for small batch production; both the general accuracy of product production, but also can produce precision parts. Should pay attention to development such as fine blanking (especially thick material fine blanking), forming high-energy, soft mold forming, pressure and processing new superplastic forming process, but also promote the easy mode (soft mode and the low melting point alloy mold) , Universal Hybrid model, the use of CNC punch press and other equipment.In addition, the performance improvement of sheet metal stamping, mold new material, die development of new processing methods should be further strengthened.
Die with life and Countermeasures
Die with the life of the workpiece by punching out the number of terms. Many factors affect the life Die. There are die structure design, manufacture molds used in the punch and die materials, die quality and surface hardening heat treatment, precision die manufacturing parts and cold stamping materials selection. In addition, there are die installation, adjustment, use and maintenance.
1. Die Design on Life
(1) Layout design of layout methods and take the boundary value a great impact on the die life, too small to take the boundary value, often causing rapid wear and convex mold, die bite wounds on the. Starting from material savings, take the boundary value smaller the better, but take the edge is less than some value, the cut surface of the mold and the quality of life adversely. There will be left behind in the blanking die Q-gap were to produce spare parts glitch, or even damage the die edge, reduce die life. Therefore, consider increasing the material utilization of the same time, parts must yield, quality and life expectancy to determine the layout methods and take the boundary.
(2) die structure prone to stress concentration on the cracking of the die structure, composite structure can be used or mosaic structure, and prestressed structure to enhance the mold life.
(3) the impact of clearance when the gap is too small, compressed extrusion of interest, increased friction, increased wear, the wear side of aggravated discharge and push pieces after blanking time, materials and convex, the friction between die will cause wear and tear than the end edge on the side of the grinding much, but also easily lead to convex, concave mold temperature is high, the adsorption of metal debris in the side edge to form a metal tumor, so that male and female die chipping or expansion occurs crack phenomenon. Therefore, the gap is too small to Die Life very bad. Gap is too large will increase the punch and the die face the edge of the concentration of stress, resulting in a sharp increase in stress, so blade edge quickly lose angular yield deformation. Therefore, addition of blanking force, thereby enabling faster edge edge wear, reduce die life. But in order to reduce the male and female die wear, extending mold life, while ensuring quality of stamping pieces under the premise that larger space designed properly it is necessary.
(4) Die-oriented structure of the life of a reliable guide for the working parts reduce wear, prevent male and female die bite wound is very effective. In particular, non-small-Q gap Q gap or Die, compound die and multi-position progressive die even more important. To improve the die life, must be based on processes and the demand of precision, the correct choice-oriented form and orientation accuracy, the choice should be higher than the accuracy-oriented convex, concave mold with precision.(5) the impact of cold stamping materials, cold stamping materials selected should meet the design requirements of workpieces and stamping process requirements, or easy to mold damage and reduce mold life. Poor surface quality of cold stamping, punching, cracking when the workpiece is also easy to scratch mold. Bad cold stamping plastic materials, deformation is small, easy to press when the workpiece rupture, but also easy to scratch mold. In addition, the material thickness tolerances shall comply with national standards. Die because of a certain thickness of material suitable for forming, bending, flanging, drawing die of the male and female die structure gap is directly determined by the thickness of the material. Therefore, uneven thickness, will result in waste generation and mold damage.
2. Die Die Life of
Die Die Life of a mold material properties, chemical composition, structure, hardness and comprehensive reflection of metallurgical quality. Among them, the material properties and heat treatment affect the quality of the most obvious. Mold material properties on the impact of die life is great. If the same workpiece, using a different mold material of the bending test, the test results: The 9Mn2V material, the life of 5 million; with Crl2MoV nitriding, the life of up to 40 million. Therefore, the choice of materials, the batch size should be based on workpiece, rational use of mold materials. The hardness of the die parts to Die Life a great impact. But not the higher hardness, longer die life. This is because the hardness and strength, toughness and abrasion resistance are closely related. Some die demands of high hardness, long life. Such as the use of T10 steel dies, hardness 54 ~ 58HRC, only washed thousands of times a burr on the workpiece great. If the hardness to 60 ~ 64HRC, the grinding life of up to 2 to 3 million. However, if continue to improve hardness, fracture occurs earlier. Some die hardness should not be too high, as the die manufacturing using Crl2MoV 58 ~ 62HRC hardness, the general life of 2-3 million, invalid form of chipping and cracking, and if the har
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