嵌件板級(jí)進(jìn)模設(shè)計(jì)【電度表上的沖壓件零件】【說(shuō)明書(shū)+CAD】

購(gòu)買(mǎi)設(shè)計(jì)請(qǐng)充值后下載，資源目錄下的文件所見(jiàn)即所得，都可以點(diǎn)開(kāi)預(yù)覽，資料完整，充值下載可得到資源目錄里的所有文件?！咀ⅰ浚篸wg后綴為CAD圖紙，doc,docx為WORD文檔，原稿無(wú)水印，可編輯。具體請(qǐng)見(jiàn)文件預(yù)覽，有不明白之處，可咨詢(xún)QQ:12401814 編號(hào)無(wú)錫太湖學(xué)院畢業(yè)設(shè)計(jì)（論文）題目： 嵌件板級(jí)進(jìn)模設(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)： 學(xué)生姓名： 指導(dǎo)教師： （職稱(chēng)：教授 ） （職稱(chēng)： ）2013年5月25日II無(wú)錫太湖學(xué)院本科畢業(yè)設(shè)計(jì)（論文）誠(chéng) 信 承 諾 書(shū)本人鄭重聲明：所呈交的畢業(yè)設(shè)計(jì)（論文） 嵌件板級(jí)進(jìn)模設(shè)計(jì) 是本人在導(dǎo)師的指導(dǎo)下獨(dú)立進(jìn)行研究所取得的成果，其內(nèi)容除了在畢業(yè)設(shè)計(jì)（論文）中特別加以標(biāo)注引用，表示致謝的內(nèi)容外，本畢業(yè)設(shè)計(jì)（論文）不包含任何其他個(gè)人、集體已發(fā)表或撰寫(xiě)的成果作品。 班 級(jí)： 學(xué) 號(hào)： 作者姓名： 2013 年 5 月 25 日無(wú)錫太湖學(xué)院系 專(zhuān)業(yè)畢 業(yè) 設(shè) 計(jì)論 文 任 務(wù) 書(shū)一、題目及專(zhuān)題：1、題目 嵌件板級(jí)進(jìn)模設(shè)計(jì) 2、專(zhuān)題 二、課題來(lái)源及選題依據(jù)本課題來(lái)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(kāi)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(duì)稱(chēng)而且生產(chǎn)效率低基于以上問(wèn)題，只有采用級(jí)進(jìn)模才能保證零件質(zhì)量又能提高生產(chǎn)效率。通過(guò)該模具的設(shè)計(jì)，使學(xué)生了解模具行業(yè)的先進(jìn)設(shè)計(jì)制造技術(shù)，掌握級(jí)進(jìn)模具的設(shè)計(jì)制造知識(shí)；熟悉機(jī)械產(chǎn)品的開(kāi)發(fā)設(shè)計(jì)流程，能夠熟練應(yīng)用CAD集成軟件完成設(shè)計(jì)工作。三、本設(shè)計(jì)（論文或其他）應(yīng)達(dá)到的要求： 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； 熟悉級(jí)進(jìn)模具的開(kāi)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；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)；完成級(jí)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(hào)圖紙的設(shè)計(jì)工作量，圖紙符合國(guó)家標(biāo)準(zhǔn)，各種標(biāo)注正確無(wú)誤） 完成不少于30頁(yè)的畢業(yè)設(shè)計(jì)說(shuō)明書(shū)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）四、接受任務(wù)學(xué)生： 班 姓名 五、開(kāi)始及完成日期：自2012年11月12日 至2013年5月25日六、設(shè)計(jì)（論文）指導(dǎo)（或顧問(wèn)）：指導(dǎo)教師簽名 簽名 簽名教研室主任學(xué)科組組長(zhǎng)研究所所長(zhǎng)簽名 系主任 簽名2012年11月12日III摘 要近年來(lái)，隨著我國(guó)汽車(chē)、家電工業(yè)的高速發(fā)展，對(duì)于模具工業(yè)，尤其是冷沖模具提出了越來(lái)越高、越來(lái)越科學(xué)的要求。多工位級(jí)進(jìn)模是在普通級(jí)進(jìn)模的基礎(chǔ)上發(fā)展起來(lái)的一種高精度、高效率、長(zhǎng)壽命的模具，是技術(shù)密集型模具的重要代表，是沖模發(fā)展方向之一。一副級(jí)進(jìn)模在一次沖壓動(dòng)作中可在模具不同工位進(jìn)行不同的沖壓操作。這些在通過(guò)模具的帶料上同時(shí)進(jìn)行的沖壓動(dòng)作制造出零件。每個(gè)工位可進(jìn)行一個(gè)或多個(gè)操作，但要生產(chǎn)出完整的零件條料必須經(jīng)過(guò)每一個(gè)工位。而零件依靠零件之間的載體輸送到各個(gè)工位，并在最后一個(gè)工位進(jìn)行切除。本設(shè)計(jì)對(duì)嵌件板進(jìn)行的級(jí)進(jìn)模設(shè)計(jì)，通過(guò)對(duì)級(jí)進(jìn)模沖壓成型的工作原理，以及根據(jù)級(jí)進(jìn)模定位零件的特征對(duì)鐵片進(jìn)行加工。同時(shí)利用Auto CAD 軟件對(duì)制件進(jìn)行設(shè)計(jì)繪圖。明確了設(shè)計(jì)思路，確定了沖壓成型工藝過(guò)程并對(duì)各個(gè)具體部分進(jìn)行了詳細(xì)的計(jì)算。并繪制了模具的裝配圖和零件圖。關(guān)鍵詞：級(jí)進(jìn)模；沖壓；AutoCADAbstractIn recent years, as Chinas automobile, hose-appliance industry, the rapid development of the mold industry, especially Die with higher and higher, more scientific requirements.Multi-position into modules are o-level into mode in the developed on the basis of a kind of high precision, high efficiency, long life mold, is an important representative of technology-intensive mould, is one of stamping development direction.A progressive die performs a series of fundamental sheet metal operations at two or more stations in the die during each press stroke. These simultaneous operations produce a part from a strip of material that moves through the die. Each working station performs one or more die operations, but the strip must move from the first station through each succeeding station to produce a complete part. Carriers, consisting of one or more strips of material left between the parts, provide movement of the parts from one die station to the next. These carrier strips are separated from the parts in the last die station.The design of the Insert plate of the progressive die design, through the progressive die stamping works, and locate parts progressive die based on the characteristics of the Iron tablets for processing. While using Auto CAD software to design parts drawing. Clear design ideas, determine the process of stamping and forming part of the various specific details of the calculation.And the mapping of the mold assembly and part drawings.Key words: progressive die; press; AutoCADVII目 錄摘 要IIIAbstractIV目 錄V1 緒論11.1 本課題的研究意義11.2 我國(guó)級(jí)進(jìn)模的發(fā)展現(xiàn)狀12 沖壓工件的工藝分析及排樣圖設(shè)計(jì)22.1 工藝分析22.2 排樣圖設(shè)計(jì)22.3 壓力中心的計(jì)算43 設(shè)計(jì)過(guò)程中的主要計(jì)算53.1 步距及條料標(biāo)稱(chēng)寬度的計(jì)算53.2 沖4-1.9mm孔53.2.1 沖裁力，卸料力，推件力計(jì)算53.2.2 沖裁間隙及凹模，凸模刃口尺寸公差計(jì)算63.3 以?xún)蓚€(gè)1.9mm的孔導(dǎo)正切邊63.3.1 沖裁力，卸料力，推件力計(jì)算63.3.2 沖裁間隙及凹模，凸模刃口尺寸公差計(jì)算73.4 以導(dǎo)正孔導(dǎo)正壓錐角83.4.1 壓印力，卸料力，推件力計(jì)算83.4.2 凹模，凸模刃口尺寸公差計(jì)算93.5 沖外型、落料93.5.1 沖裁力，卸料力，推件力計(jì)算93.5.2 沖裁間隙及凹模，凸模刃口尺寸公差計(jì)算93.6 側(cè)刃103.6.1 沖裁力，卸料力，推件力計(jì)算103.7 導(dǎo)正銷(xiāo)尺寸113.7.1 導(dǎo)正銷(xiāo)工作部分直徑113.8 空位114 模具結(jié)構(gòu)總體設(shè)計(jì)125 模具主要零件設(shè)計(jì)135.1 定位裝置135.2 卸料裝置：135.2.1 彈性元件135.2.2 卸料板155.2.3 卸料螺釘155.3 固定機(jī)構(gòu)的設(shè)計(jì)155.3.1 板類(lèi)零件的定位連接155.4 凸,凹模的設(shè)計(jì)165.4.1 凹模165.4.2 凸模185.5 固定零件245.5.1 模柄245.5.2 固定板與墊板245.5.3 模架245.6 導(dǎo)向零件245.7 壓力機(jī)的選擇256 模具材料的選取266.1 凸凹模材料的選擇266.2 其它主要零件材料的選取見(jiàn)下表26設(shè)計(jì)總結(jié)27致謝28參考文獻(xiàn)29嵌件板級(jí)進(jìn)模設(shè)計(jì)1 緒論1.1 本課題的研究意義在工業(yè)生產(chǎn)中許多機(jī)器零件都普遍地采用了模具沖壓成形的工藝方法，這就有效的保證了所得產(chǎn)品的質(zhì)量和勞動(dòng)生產(chǎn)率，不但使操作技術(shù)更簡(jiǎn)單化，還能省料，節(jié)能，從而獲得更顯著的經(jīng)濟(jì)效益。據(jù)不完全統(tǒng)計(jì)，在汽車(chē)、農(nóng)業(yè)機(jī)械產(chǎn)品中沖壓件占7580，在電子產(chǎn)品中沖壓件占8085，在輕工業(yè)產(chǎn)品中沖壓件占90以上，而在航天航空工業(yè)中沖壓件也占很大的比例。尤其是人類(lèi)生活越來(lái)越富裕的今天，工廠自動(dòng)化、辦公自動(dòng)化、家庭自動(dòng)化已走進(jìn)我們的生活。想要推動(dòng)新的產(chǎn)業(yè)革命往更深入、更高階段發(fā)展，那沖壓成形工藝和模具就是不可缺少的極重要的推動(dòng)力之一。由此可知，沖壓成形工藝和模具在國(guó)民經(jīng)濟(jì)中所具有的作用和意義是非常重要的。級(jí)進(jìn)模得到了很廣泛的應(yīng)用，在各類(lèi)的冷沖模具中，級(jí)進(jìn)模所占的比例為271。級(jí)進(jìn)模的概念：級(jí)進(jìn)模又稱(chēng)連續(xù)?；蛱侥?。級(jí)進(jìn)模有兩個(gè)或兩個(gè)以上的工位，在沖床的一次行程中，在模具的各個(gè)工位上同時(shí)完成兩個(gè)或兩個(gè)以上不同的加工。條料在模具內(nèi)向前送進(jìn)過(guò)程中，經(jīng)各工位逐步?jīng)_切，至最終工位形成產(chǎn)品零件。在壓力機(jī)的每次沖程中，級(jí)進(jìn)模至少?zèng)_出一個(gè)零件2。級(jí)進(jìn)模的功能：一般零件的成形由多個(gè)工序組成，級(jí)進(jìn)模設(shè)計(jì)中首先應(yīng)將零件的成形工序分解，然后對(duì)工序內(nèi)容進(jìn)行組合排序，分別將確定的加工內(nèi)容安排在若干個(gè)等距離的工位上，每個(gè)工位完成零件的一部分加工，從而將一個(gè)復(fù)雜零件的加工變?yōu)槎鄠€(gè)簡(jiǎn)單工序組的合成。沖壓加工過(guò)程中，隨著沖床的連續(xù)工作，被加工材料（一般為條料或帶料）在級(jí)進(jìn)模內(nèi)逐次向前送進(jìn)，經(jīng)過(guò)多個(gè)工位逐步?jīng)_切后獲得一個(gè)完整的沖壓產(chǎn)品。一個(gè)復(fù)雜的零件用一副級(jí)進(jìn)模即可完成沖制。在沖床的每次行程中，要從模具中沖出一個(gè)或數(shù)個(gè)產(chǎn)品零件（或半成品），模具是實(shí)現(xiàn)沖壓加工的載體。模具完成沖壓任務(wù)所必需的功能分為基本功能和輔助功能3。1.2 我國(guó)級(jí)進(jìn)模的發(fā)展現(xiàn)狀由于種種原因，我國(guó)模具工業(yè)和當(dāng)前工業(yè)發(fā)展還很不適應(yīng)。無(wú)論是在設(shè)計(jì)制造技術(shù)和生產(chǎn)能力方面，還是在管理水平方面，模具工業(yè)都遠(yuǎn)遠(yuǎn)不能滿(mǎn)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(guó)際市場(chǎng)上的競(jìng)爭(zhēng)力。今年來(lái)，我國(guó)模具進(jìn)口幅度呈大幅下降的趨勢(shì)，并有超億元的出口額。大型，復(fù)雜，精密，高效和長(zhǎng)壽命模具也逐漸上了新的臺(tái)階，體現(xiàn)高水平制造技術(shù)的多工位級(jí)進(jìn)模也越來(lái)越多，沖壓自動(dòng)線，自動(dòng)沖壓技術(shù)也得到廣泛應(yīng)用。我國(guó)模具行業(yè)的技術(shù)水平迅速提高，模具國(guó)產(chǎn)化已經(jīng)取得十分可喜的成績(jī)，這將對(duì)我國(guó)在國(guó)際市場(chǎng)的競(jìng)爭(zhēng)能力和綜合國(guó)力的提高起到有力的促進(jìn)作用5。12 沖壓工件的工藝分析及排樣圖設(shè)計(jì)2.1 工藝分析圖2.1 產(chǎn)品圖圖2.1嵌件板是電度表上的一個(gè)沖壓件。該零件的材料為純鐵DT4，由于其表上的特殊性，該零件的設(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與壓120度錐窩分開(kāi)加工，結(jié)果零件外形脹，尺寸超差大，卸料困難，M2.2mm孔與形不對(duì)稱(chēng)而且產(chǎn)效率低?；谝陨蠁?wèn)題，決定用級(jí)進(jìn)模生產(chǎn)該零件，采用沖孔導(dǎo)正切邊導(dǎo)正修孔空位落外形兼校形等工序，這樣既保證了零件質(zhì)量又提高生產(chǎn)效率。2.2 排樣圖設(shè)計(jì) 多工位級(jí)進(jìn)模設(shè)計(jì)中，排樣圖的合理正確與否，直接影響到制件精度及能否順利進(jìn)行沖壓生產(chǎn)，并且關(guān)系到材料的利用率。因此，排樣圖是多工位級(jí)進(jìn)模設(shè)計(jì)的依據(jù)，也是關(guān)鍵工作之一。在確定排樣方案時(shí)，要綜合分析工件的沖壓方向，變形次序與相應(yīng)的變形程度，并保證沖壓的可能性與加工工藝性。設(shè)計(jì)排樣圖時(shí)需注意的一些問(wèn)題6：（1） 盡可能的減少工位數(shù)目，避免累積定位誤差；（2） 排樣圖上增設(shè)空位是解決模具強(qiáng)度和要求有一定空間設(shè)置裝置的好方法；（3） 包含的切邊，沖孔，切外形，切舌,彎曲，切斷彎曲等工序時(shí)，切斷彎曲工序應(yīng)放在最后。其余應(yīng)遵循先沖平面形狀后沖立體形狀的原則，這樣對(duì)沖壓時(shí)的進(jìn)距有利；（4） 排樣時(shí)應(yīng)注意增設(shè)工藝孔，例如切外形方孔先沖圓孔定位，切斷彎曲前先校形等均有利于成形；（5） 防止小凸模早期損壞或變鈍；（6） 設(shè)計(jì)排樣圖時(shí)應(yīng)注意模具中心與壓力中心相一致；（7） 推桿位置應(yīng)對(duì)稱(chēng)布置，注意防止材料變形引起導(dǎo)正銷(xiāo)孔的位置變化，這點(diǎn)對(duì)薄料尤為重要?；谏鲜鲈瓌t，對(duì)此工件的排樣圖作如下分析：零件屬于中心型沖壓件。根據(jù)毛坯的形狀和尺寸，毛坯的排樣采用雙列排，這樣可以提高生產(chǎn)效率和材料利用率，模具體積也不會(huì)太大，采用標(biāo)準(zhǔn)模架。同時(shí)在正常情況下，即使采用手工送料，一副模具每日一班也足夠滿(mǎn)足生產(chǎn)的需要。材料利用率：K=naA=244.09204.16=43%模具的定距方式采用側(cè)刃和導(dǎo)正釘配合定距，因此在調(diào)料兩邊要有一定寬度的載體來(lái)滿(mǎn)足側(cè)刃的沖切。通過(guò)實(shí)用模具技術(shù)手冊(cè)，中心搭邊值取1.5mm，側(cè)搭邊值取2mm，雙側(cè)載體的單側(cè)寬度取4mm，這樣條料寬度為37.6mm，沖壓步距為6.6mm。經(jīng)分析得出以下排樣圖設(shè)計(jì)的方案：方案一：排樣圖如圖2.2所示，共有5個(gè)工位。圖2.2 排樣圖第1工位：沖4個(gè)1.9mm的孔。第2工位：用2個(gè)1.9mm的孔做導(dǎo)正孔導(dǎo)正沖外型。第3工位：用兩個(gè)導(dǎo)正孔導(dǎo)正壓120度錐角并修孔。第4工位：空工位。 第5工位：沖外型兼落料。方案二：排樣圖如圖2.3所示，一共6個(gè)工位 圖2.3 排樣圖第1工位：沖4個(gè)1.9mm的孔。第2工位：用2個(gè)1.9mm的孔做導(dǎo)正孔導(dǎo)正切邊。第3工位：用兩個(gè)導(dǎo)正孔導(dǎo)正壓120度錐角。第4工位：由于壓角引起孔徑邊小，因此用導(dǎo)正孔導(dǎo)正修孔。 第5工位：空工位。第6工位：沖外型兼落料。分析比較方案一，方案二，可以看出方案一與方案二，方案二將方案一的公位分解了，考慮到模具尺寸的設(shè)計(jì)大小，在滿(mǎn)足設(shè)計(jì)要求的情況下應(yīng)選擇較小的尺寸設(shè)計(jì)，所以此模具的排樣圖采用方案一較佳。2.3 壓力中心的計(jì)算 由于該零件是軸對(duì)稱(chēng)零件，所以其重心在對(duì)稱(chēng)中心線上。計(jì)算壓力中心時(shí)，僅考慮圖9示x方向的值。以條料邊緣與沖外型邊緣的延長(zhǎng)線交線為坐標(biāo)的原點(diǎn)。以下式中x,l,L分別表示壓力中心距離原點(diǎn)的坐標(biāo)，單工序中圖形的輪廓線，工序中輪廓線的長(zhǎng)度的總和。由沖模設(shè)計(jì)與制造實(shí)用計(jì)算手冊(cè)可得各種沖壓力的壓力中心為：X0=p1x1+p2x2+pnxnp1+p2+pna53 設(shè)計(jì)過(guò)程中的主要計(jì)算3.1 步距及條料標(biāo)稱(chēng)寬度的計(jì)算由沖壓工藝與模具設(shè)計(jì)中的公式可計(jì)算步距及條料寬度7。步距： A=L+b式中L零件的總長(zhǎng)度 b延送進(jìn)方向的搭邊值A(chǔ)=5.1+1.5=6.6mm條料寬度： B=D+2a式中 D零件的最大寬度(mm)a側(cè)搭邊(mm) B=10.82+24+42=37.6mm3.2 沖4-1.9mm孔3.2.1 沖裁力，卸料力，推件力計(jì)算由實(shí)用模具技術(shù)手冊(cè)表1-1查得電工用純鐵DT4的=177Mpa8L=4D式中：L沖裁件周邊長(zhǎng)度(mm)D沖裁件的直徑(mm)L=3.1441.9=23.9mm由實(shí)用模具設(shè)計(jì)手冊(cè)表3-14計(jì)算沖裁力為F沖=KLt式中：K系數(shù)，一般取1.3 材料抗剪強(qiáng)度Mpa t材料厚度=1.5(mm) F沖=1.323.91.5177=8249N卸料力： F卸=K卸F沖由實(shí)用模具設(shè)計(jì)手冊(cè)表3-15，查得K卸=0.12則F卸=K卸F沖=0.128249=990N推件力：由實(shí)用模具設(shè)計(jì)手冊(cè)表3-16，查得K推=0.05，n=1F推=K推F沖n=0.0518249=412N總沖壓力：F總=F沖+F卸+F推=8249+990+412=9651N3.2.2 沖裁間隙及凹模，凸模刃口尺寸公差計(jì)算 由沖模設(shè)計(jì)應(yīng)用實(shí)例附錄D查得沖裁件未注公差尺寸的極限偏差為9： 3.050+0.16mm，30+0.12mm 由實(shí)用模具技術(shù)手冊(cè)表3-17查得， Zmin=0.10mm，Zmax=0.14mm 由實(shí)用模具技術(shù)手冊(cè)表3-11查得， p=0.020mm，d=0.020mmp+d=0.020+0.020=0.040mmZmax-Zmin=0.14-0.10=0.04mm滿(mǎn)足： Zmax-Zminp+d 故凸，凹模采取分開(kāi)加工的方法制造 沖1.9mm的孔： 由實(shí)用模具技術(shù)手冊(cè)表3-12查得， x=0.75d凸=（d+x）-p0=(1.9+0.750.1)-0.020=1.975-0.020mmd凹=（d+x+Zmin）0+凹=（1.95+0.75+0.10）0+0.020=2.0750+0.02mm3.3 以?xún)蓚€(gè)1.9mm的孔導(dǎo)正切邊3.3.1 沖裁力，卸料力，推件力計(jì)算由實(shí)用模具技術(shù)手冊(cè)表1-1查得電工用純鐵DT4的=177MpaL=20.3+15.2+15.2=50.7mm由實(shí)用模具設(shè)計(jì)手冊(cè)表3-14計(jì)算沖裁力為F沖=KLtF沖=1.350.71.5177=17499N卸料力： F卸=K卸F沖由實(shí)用模具設(shè)計(jì)手冊(cè)表3-15，查得K卸=0.12則F卸=K卸F沖=0.1217499=2100N推件力：由實(shí)用模具設(shè)計(jì)手冊(cè)表3-16，查得K推=0.05,n=1F推=K推F沖n=0.05117499=848N總沖壓力：F總=F沖+F卸+F推=17499+2100+848=20447N3.3.2 沖裁間隙及凹模，凸模刃口尺寸公差計(jì)算 由于凸凹模形狀復(fù)雜，因此凸凹模采用配合加工，先加工好凸模作為基準(zhǔn)件，根據(jù)凸模的實(shí)際尺寸配合加工凹模。使它們保持一定間隙。由實(shí)用模具技術(shù)手冊(cè)表3-12查得，非圓形x=1凸模1磨損后，刃口尺寸AB，DE，GH，JK變小，其中AB=HG，DE=JK；刃口尺寸BC=FG=HI=LA和CD=EF=IJ=KL變大。由此LAB=LHG=(L+x)-p0=(3.1+10.08)-0.020=3.18-0.020mmLDE=LJK=(L+x)-p0=(4+10.08)-0.020=4.08-0.020mmLBC=LFG=LHI=LLA=L-+p2=0.99-+0.01mmLCD=LEF=LIJ=LKL=L-+p2=0.3-+0.01mm以凸模為基準(zhǔn)件配做凹模，對(duì)應(yīng)凹模尺寸為L(zhǎng)AB=LHG=L+x+Zmin0+=3.280+0.02mmLDE=LJK=(L+X+Zmin)0+=4.1800.02mmLBC=LFG=LHI=LLA=L-+p2+Zmin=1.09-+0.01mmLCD=LEF=LIJ=LKL=L-+p2+Zmin=0.4-+0.01mm凸模2磨損后，刃口尺寸AB，DE，F(xiàn)E，F(xiàn)G變??；BC=HA，CD=GH尺寸LAB=(L+x)-p0=(3.1+10.08)-0.020=3.18-0.020mmLDE=LFG=(L+x)-p0=(2+10.08)-0.020=2.08-0.020mmLEF=(L+x)-p0=(5.1+10.08)-0.020=5.18-0.020mmLBC=LHA=L-+p2=0.99-+0.01mmLCD=LGH=L-+p2=0.3-+0.01mm以凸模為基準(zhǔn)配作凹模，對(duì)應(yīng)凹模尺寸為L(zhǎng)AB=LAB凸+Zmin=3.280+0.02mmLDE=LFG=L凸+Zmin=2.180+0.02mmLEF=L凸+Zmin=5.280+0.02mmLBC=LHA=L-+p2+Zmin=1.09-+0.01mmLCD=LGH=L-+p2+Zmin=0.4-+0.01mm3.4 以導(dǎo)正孔導(dǎo)正壓錐角3.4.1 壓印力，卸料力，推件力計(jì)算由模具設(shè)計(jì)與制造實(shí)用計(jì)算手冊(cè)表1-76查得，純鐵的單位擠壓力為 p=1400P/MPa(1MP=1N)。壓角邊延長(zhǎng)可以得到兩個(gè)圓錐，因此壓角部分的面積S=RL-rl。式中 R 壓角后孔的半徑r 壓角前孔的半徑L大圓錐的母線長(zhǎng)l小圓錐的母線長(zhǎng)經(jīng)計(jì)算， R=1.1；r=0.95；L=0.64；l=0.39。S=RL-rl=3.141.10.64-3.140.950.39 =1.34mm2 總壓力 P=sp=1.341400=1848N推件力：由實(shí)用模具設(shè)計(jì)手冊(cè)表3-16，查得K推=0.05,n=1F推=K推F沖n=0.0511848=92.4N總沖壓力： F總=4F沖+F卸+F推=44158=16632N3.4.2 凹模，凸模刃口尺寸公差計(jì)算 由于有導(dǎo)正釘對(duì)條料進(jìn)行精定位，因此會(huì)使第一個(gè)工序沖孔變形，而且壓角會(huì)使孔距變小，因此凸模刃口段是對(duì)沖孔進(jìn)行修正并導(dǎo)正，尺寸和沖孔一樣，刃口段上方設(shè)計(jì)120度的錐角對(duì)孔進(jìn)行壓塌。凹模刃口尺寸和沖孔凹模尺寸一樣。3.5 沖外型、落料3.5.1 沖裁力，卸料力，推件力計(jì)算由實(shí)用模具技術(shù)手冊(cè)表1-1查得電工用純鐵DT4的=177MPa L=5.125.6=130.56mm由實(shí)用模具設(shè)計(jì)手冊(cè)表3-14計(jì)算沖裁力為 F沖=KLt F沖=1.3130.561.5177=45062.8N卸料力： F卸=K卸F沖由實(shí)用模具設(shè)計(jì)手冊(cè)表3-15，查得K卸=0.12 則 F卸=K卸F沖=0.1245062.8=5408N推件力：由實(shí)用模具設(shè)計(jì)手冊(cè)表3-16，查得K推=0.05，n=1F推=K推F沖n=0.05145062.8=2253N總沖壓力：F總=F沖+F卸+F推=45062.8+5408+2253=52723N3.5.2 沖裁間隙及凹模，凸模刃口尺寸公差計(jì)算 由實(shí)用模具技術(shù)手冊(cè)表3-17查得，Zmin=0.10mm，Zmax=0.14mm 由實(shí)用模具技術(shù)手冊(cè)表3-11查得，p=0.020mm，d=0.020mmp+d=0.020+0.020=0.040mmZmax-Zmin=0.14-0.10=0.04mm滿(mǎn)足：Zmax-Zminp+d 故凸，凹模采取分開(kāi)加工的方法制造 ：由實(shí)用模具技術(shù)手冊(cè)表3-12查得，非圓形x=1。由于是落料件，因此應(yīng)根據(jù)凹模尺寸來(lái)確定凸模的尺寸。凹模尺寸LAB=LCD=(L-x)0+凹=(5.1-10.08)0+0.02=5.0920+0.02mmLBC=LDA=(L-x)0+=(25.6-10.08)0+0.02=25.5920+0.02mm 凸模尺寸LAB=LCD=(L-x-Zmin)-凸0凹=4.992-0.020mmLBC=LDA=(L-x-Zmin)-凸0凹=25.492-0.020mm 3.6 側(cè)刃3.6.1 沖裁力，卸料力，推件力計(jì)算由實(shí)用模具技術(shù)手冊(cè)表1-1查得電工用純鐵DT4的=177MPaL=2+1.2+0.7+3.2+0.7+1.2+2=11mm由實(shí)用模具設(shè)計(jì)手冊(cè)表3-14計(jì)算沖裁力為F沖=KLtF沖=1.3111.5177=3796.7N卸料力：F卸=K卸F沖由實(shí)用模具設(shè)計(jì)手冊(cè)表3-15，查得F卸=0.12則 F卸=K卸F沖=0.123796.7=456N推件力：由實(shí)用模具設(shè)計(jì)手冊(cè)表3-16，查得K推=0.05，n=1F推=K推F沖n=0.0514556=228N總沖壓力：F總=F沖+F卸+F推=3796.7+456+228=4480N3.7 導(dǎo)正銷(xiāo)尺寸3.7.1 導(dǎo)正銷(xiāo)工作部分直徑根據(jù)實(shí)用模具技術(shù)手冊(cè)，d導(dǎo)=d導(dǎo)凸-t0.02=1.945mm導(dǎo)正銷(xiāo)的制造偏差為1.945-0.0060mm（按GB2864.1-84制造）導(dǎo)正銷(xiāo)直壁部分進(jìn)入條料長(zhǎng)度M=H+(0.5-1)t (mm)其中H為卸料板活動(dòng)量，H=L+t (mm)，L為凸模工作長(zhǎng)度，L=2.5mm則H=4帶入公式M=H+(0.5-1)t (mm)得M=5.5mm3.8 空位為了保證模具有足夠的強(qiáng)度，確保模具的使用壽命和產(chǎn)品質(zhì)量，在級(jí)進(jìn)模中適當(dāng)?shù)脑黾涌展の弧ＴO(shè)置空工位是應(yīng)考慮以下幾條原則10：1步距較大時(shí)不應(yīng)多設(shè)空工位。2精度高，形狀復(fù)雜的零件沖壓不應(yīng)多設(shè)置空工位，以減少總工位數(shù)。3用導(dǎo)正銷(xiāo)精定位時(shí)可以適當(dāng)多設(shè)置空位。根據(jù)以上原則，該模具在第四工位設(shè)置空工位。114 模具結(jié)構(gòu)總體設(shè)計(jì) 通過(guò)上述的工藝分析和一些初步的計(jì)算，采用了正裝式上模彈性卸料的五工位級(jí)進(jìn)模具。考慮到對(duì)角導(dǎo)柱模架可以?xún)煞较蛩土?，?dǎo)柱與導(dǎo)套滑動(dòng)平穩(wěn)，所以框架選用GB2851.1-81對(duì)角導(dǎo)程標(biāo)準(zhǔn)模架11，其模具結(jié)構(gòu)如下圖所示。 圖4.0 模具結(jié)構(gòu)圖 板料采用自動(dòng)送料裝置送進(jìn)，用導(dǎo)料板導(dǎo)向，先用側(cè)刃粗定位，后用導(dǎo)正銷(xiāo)進(jìn)行精確定位，在第1工位沖出導(dǎo)正孔后,在第2至第5工位間設(shè)置2對(duì)導(dǎo)正銷(xiāo)導(dǎo)正，從根本上保證了沖壓工件的穩(wěn)定性和精確性12。模具上部分由上模座，墊板，凸模固定板，卸料板和各個(gè)凸模組成。各板料之間采用圓柱頭內(nèi)六角螺釘連接。為了對(duì)卸料板精確導(dǎo)向，使用了4個(gè)12mm的小導(dǎo)柱，采用4個(gè)滑動(dòng)導(dǎo)向的導(dǎo)柱。導(dǎo)柱固定在凹模上，導(dǎo)套固定在卸料板上，導(dǎo)柱與導(dǎo)套采用小間隙配合。在上模座和卸料板之間采用6個(gè)8mm的卸料螺釘連接。 模具下模部分由凹模、墊板和導(dǎo)料板等組成?？紤]到節(jié)約材料和便于維修，凹模采用整體加部分鑲件結(jié)構(gòu)。在壓窩處，由于成型力大，凸模采用高韌性合金工具鋼。135 模具主要零件設(shè)計(jì) 模具的結(jié)構(gòu)圖如后所附的模具裝配圖所示，主要由上下模座，各工位的凸凹模，卸料裝置，固定裝置，定位裝置，斜鍥機(jī)構(gòu)等等13。5.1 定位裝置 條料在初始時(shí)采用了導(dǎo)料板導(dǎo)向，保證送進(jìn)方向。導(dǎo)料板與卸料板分開(kāi)制造，導(dǎo)料板用內(nèi)六角螺釘固定在整體凹模上面。為了使條料順利通過(guò)，導(dǎo)料板相互之間的距離應(yīng)該等于條料的最大寬度加上雙邊間隙值。一般導(dǎo)料板的間距和厚度為：W=B+（0.05-0.2） H0=h+0.5-2t+(1-5) 式中 W導(dǎo)料板間距B條料寬度 h工件最大成型高度 t 條料厚度 經(jīng)計(jì)算，取導(dǎo)料板間距為37.8，根據(jù)經(jīng)驗(yàn)公式導(dǎo)料板厚度取4.5mm，長(zhǎng)度和寬度按凹模尺寸配合制造。導(dǎo)料板的外形尺寸按GB2865.5-81選取。由于該模具用側(cè)刃定距，第一個(gè)工位需要在調(diào)料邊緣沖切一個(gè)與步距相同尺寸的定位槽，因此在導(dǎo)料板上需留出側(cè)刃的位置?？紤]到凹式側(cè)刃的定位精度比較高，因此模具選用凹式側(cè)刃。側(cè)刃的尺寸參照冷沖模國(guó)家標(biāo)準(zhǔn)。條料在第一工位沖出導(dǎo)正銷(xiāo)孔后，在其后的工位中用導(dǎo)正銷(xiāo)精確定位。導(dǎo)正銷(xiāo)導(dǎo)正銷(xiāo)共設(shè)4個(gè)，分別在第2，3工位，考慮到步距比較小，凸模固定板上孔的間距較小，因此直接把導(dǎo)正銷(xiāo)裝在卸料板上，與卸料板的配合公差為H7h6，與凹模的配合公差為H7k6，其長(zhǎng)度總長(zhǎng)為15mm。制造卸料板時(shí)，與導(dǎo)正銷(xiāo)的位置偏差不應(yīng)大于0.005mm。5.2 卸料裝置：5.2.1 彈性元件卸料裝置初定6根彈簧，每根彈簧分擔(dān)的卸料力為：F卸n=990+2100+5048+4566=1432N 這樣每根彈簧分擔(dān)的卸料力比較大，在彈簧的選取上有困難，因此考慮用承受負(fù)荷較大的橡膠進(jìn)行卸料。橡膠卸料還有安裝調(diào)整方便，價(jià)格不貴等優(yōu)點(diǎn)。 橡膠所能產(chǎn)生的壓力為： F=AP 式中 F橡膠所能產(chǎn)生的壓力（N） A橡膠的橫截面積（mm2） P與橡膠壓縮量有關(guān)的單位壓力（MPa） 由于卸料總力為990+2100+5048+456=8594N，所以橡膠產(chǎn)生的壓力F=8594N，根據(jù)使用沖壓技術(shù)手冊(cè)中表11-34 選取橡膠壓縮量為35%，所產(chǎn)生的單位壓力為2.10/MPa。則橡膠的斷面面積為4092mm2。 為了保證橡膠的正常使用，不至于過(guò)早損壞，應(yīng)控制其最大的壓縮量S總為自由高度H自由的35%45%。而橡膠的預(yù)壓縮量S預(yù)，一般取H自由的10%15%。則橡膠的工作行程為：S工作=S總-S預(yù)=(0.25-0.3)H自由 所以橡膠的自由高度為：H自由=S工作(0.25-0.3)=(3.5-4,0)S工作 式中S工作卸料板或推件塊，壓邊圈等的工作行程與模具修磨量或調(diào)量（46mm）之和再加1。 該模具卸料板的工作行程為4mm,則S工作=4+5+1=10mm。橡膠的自由高度為H自由=35mm.橡膠的高度H與直徑D之比必須在（0.51.5）的范圍內(nèi) 根據(jù)H自由計(jì)算橡膠的裝備高度H裝配 由實(shí)用沖壓技術(shù)手冊(cè)式（11-23）得H裝配=(0.85-0.9)H自由 H裝配=32mm 5.2.2 卸料板圖5.2 卸料板卸料板的設(shè)計(jì)如圖所示參照實(shí)用沖壓技術(shù)手冊(cè)中有關(guān)卸料板厚度的計(jì)算公式：H=(0.81.0)Hd式中： H卸料板厚度(mm) Hd凹模厚度(mm) 則取H = 20mm，根據(jù)結(jié)構(gòu)選用160mm125mm20mm的標(biāo)準(zhǔn)模板。因?yàn)橛脤?dǎo)料板導(dǎo)料，把卸料板14設(shè)計(jì)為凸臺(tái)式，便于壓料面把凹模上的條料壓住。凸臺(tái)的高度：H=h+(0.30.5)式中h(導(dǎo)料板板料厚度)=4.5-1.5=3因此凸臺(tái)高度取3.5mm此外卸料板對(duì)凸模進(jìn)行導(dǎo)向，取單邊間隙C=0.01mm，卸料板開(kāi)口處的間隙取0.5mm。5.2.3 卸料螺釘按GB2867.681選d = 8mm的圓柱頭內(nèi)六角卸料螺釘，螺柱長(zhǎng)度根據(jù)窩深，凸模尺寸和卸料板的配合高度確定為70，其它具體尺寸參照冷沖模國(guó)家標(biāo)準(zhǔn)。卸料螺釘?shù)母C深應(yīng)滿(mǎn)足：h卸料板行程+螺釘頭高度+修磨量+安全間隙 = 4 + 8 + 6 + 4 = 22mm卸料螺釘安裝在上模座上，則：卸料螺釘?shù)母C深h = 27mm故滿(mǎn)足要求。 5.3 固定機(jī)構(gòu)的設(shè)計(jì)5.3.1 板類(lèi)零件的定位連接 模座固定板和墊板之間采用銷(xiāo)釘定位，內(nèi)六角螺釘連接。銷(xiāo)釘用兩顆，直徑為D=6mm，分別用8顆直徑為6mm的內(nèi)六角螺釘連接上下模座和各模板。在上模座，上模固定板和墊板之間采用分層連接，在墊板和固定板之間采用直徑為4mm的內(nèi)六角螺釘連接。 5.4 凸,凹模的設(shè)計(jì)5.4.1 凹模（1） 凹模結(jié)構(gòu)和固定形式凹模的結(jié)構(gòu)如圖5.2所示：圖5.3 凹模該模具采用了整體與鑲件相結(jié)合的組合方式。沖空凸模，切邊凸模和落料凸模通過(guò)凸臺(tái)設(shè)計(jì)鑲嵌與凹模固定板內(nèi)，這樣不僅方便維修而且也減少了昂貴的凹模制造成本。沖孔凹模和落料凹模與凸模分開(kāi)制造，因此凹模刃口尺寸根據(jù)公式求得，而切邊凹模由于其外型復(fù)雜采用與凸模配合制造。凹模采用臺(tái)階式落料孔，該形狀的好處在于刃口強(qiáng)度較好，刃口尺寸不隨修磨人口而增大，但是易積聚沖裁件或廢料，孔壁磨損和壓力較大，修磨時(shí)刃口磨去的尺寸較多。因此應(yīng)用與向下頂出零件或廢料，形狀復(fù)雜或精度較高的零件。如下圖5.1所示，查實(shí)用沖壓技術(shù)手冊(cè)表11-22，得工作刃口高度h=7m,臺(tái)肩突出的寬度為a=0.5mm。 凹模的外形尺寸的確定依據(jù)經(jīng)驗(yàn)公式：凹模高度：H=Kb(15mm) 式中：b沖裁件最大外形尺寸(mm) K系數(shù)?？紤]坯料厚度影響的系數(shù)，其值可參考實(shí)用沖壓技術(shù)手冊(cè)表7-4 由上式計(jì)算，取凹模的厚度為H=20mm。 由于該模具為級(jí)進(jìn)模，且送料步距比較小，因此凹模的壁厚根據(jù)具體情況而定。（2） 凹模強(qiáng)度校核1） 沖孔凹模強(qiáng)度校核 根據(jù)沖模設(shè)計(jì)與制造實(shí)用計(jì)算手冊(cè)，矩形凹模強(qiáng)度計(jì)算公式：Hmin=3P彎ba1+b2a2彎=3PH2ba1+b2a2彎式中 P沖裁力（N） 彎凹模材料的許用彎曲應(yīng)力（Cr12M0V的彎曲應(yīng)力為294490） Hmin=凹模最小厚度(mm)Hmin=3842949027.891+27.8292=3.9mm彎=3PH2ba1+b2a2=293彎 故符合標(biāo)準(zhǔn)。2） 切邊凹模強(qiáng)度校核 根據(jù)沖模設(shè)計(jì)與制造實(shí)用計(jì)算手冊(cè)，矩形凹模強(qiáng)度計(jì)算公式：Hmin=3P彎ba1+b2a2彎=3PH2ba1+b2a2彎式中 P沖裁力（N） 彎凹模材料的許用彎曲應(yīng)力（Cr12M0V的彎曲應(yīng)力為294490） Hmin=凹模最小厚度(mm)則 Hmin=31749949038.691+38.6292=4.96mm彎=3174996238.691+38.6292=321彎 符合強(qiáng)度要求3） 落料凹模強(qiáng)度校核根據(jù)沖模設(shè)計(jì)與制造實(shí)用計(jì)算手冊(cè)，矩形凹模強(qiáng)度計(jì)算公式：Hmin=3P彎ba1+b2a2彎=3PH2ba1+b2a2彎式中 P沖裁力（N） 彎凹模材料的許用彎曲應(yīng)力（Cr12M0V的彎曲應(yīng)力為294490） Hmin=凹模最小厚度(mm)則Hmin=34506349046181+462182=9.755mm 經(jīng)校核滿(mǎn)足要求。2) 切邊凸模1的校核圖5.5 切邊凸模切邊凸模如圖5.5所示承載能力的校核沖裁時(shí)，凸模承受的壓應(yīng)力c必須小于凸模材料允許的壓應(yīng)力c根據(jù)實(shí)用模具技術(shù)手冊(cè)式11-1c=FAminc c凸模最小壓應(yīng)力（MPa）; F凸模壓力（N） Amin凸模最小截面積 (mm2) c凸模材料的許用壓應(yīng)力(MPa)，它的大小取決于材料種類(lèi)，熱處理和凸模的結(jié)構(gòu)與工作條件。 c=5246N12.9mm2=407MPa56.5mm3) 切邊凸模2的校核切邊凸模2的結(jié)構(gòu)尺寸如下圖5.6所示。圖5.6 切邊凸模2承載能力的校核沖裁時(shí)，凸模承受的壓應(yīng)力c必須小于凸模材料允許的壓應(yīng)力c根據(jù)實(shí)用模具技術(shù)手冊(cè)式11-1c=FAminc c 凸模最小壓應(yīng)力（MPa）; F凸模壓力（N） Amin凸模最小截面積(mm2) c 凸模材料的許用壓應(yīng)力(MPa)，它的大小取決于材料種類(lèi)，熱處理和凸模的結(jié)構(gòu)與工作條件。 c=7006N25.8mm2=272MPa56.5mm4) 落料凸模的校核圖5.7 落料凸模承載能力的校核沖裁時(shí)，凸模承受的壓應(yīng)力c必須小于凸模材料允許的壓應(yīng)力c根據(jù)實(shí)用模具技術(shù)手冊(cè)式11-1c=FAminc c 凸模最小壓應(yīng)力(MPa); F凸模壓力（N） Amin凸模最小截面積(mm2) c凸模材料的許用壓應(yīng)力(MPa)，它的大小取決于材料種類(lèi)，熱處理和凸模的結(jié)構(gòu)與工作條件。c=45062.8N127.5mm2=353MPa56.5mm 5.5 固定零件5.5.1 模柄考慮到模具的結(jié)構(gòu)并非很大，在這里采用裝卸方便的旋入式模柄。其標(biāo)準(zhǔn)對(duì)照GB2862.181。主要尺寸H = 78mm，h = 30mm 5.5.2 固定板與墊板參照有關(guān)凸模固定板厚度的經(jīng)驗(yàn)計(jì)算公式：H=（0.30.4）L 式中L凸模長(zhǎng)度 則取H = 20mm，其長(zhǎng)度與寬度與卸料板相同，與凸模配合高度H1 1.5D D凸模直徑 經(jīng)檢驗(yàn)符合要求。 凹模固定板的高度根據(jù)經(jīng)驗(yàn)表取20mm，尺寸為16012520 凸凹模墊板采用整體式，其厚度參照經(jīng)驗(yàn)表各為8mm。5.5.3 模架通過(guò)前面的計(jì)算，確定了凹模的外形尺寸和彈簧尺寸，參加實(shí)用模具技術(shù)手冊(cè)表11-4，選擇滑動(dòng)對(duì)角導(dǎo)柱模架 (GB/T2851.1-1990)。其主要規(guī)格為： L=160mm，B=125mm，Hmax=140mm，Hmin=170mmh1=35mm，h2=40mm5.6 導(dǎo)向零件該模具有3種規(guī)格的導(dǎo)柱導(dǎo)套，由于要防止模具在安裝的時(shí)候造成的錯(cuò)位,所以連接模架中的上模座和下模座的兩副導(dǎo)柱導(dǎo)套的大小規(guī)格是不相同的，查標(biāo)準(zhǔn)模架表可知,其規(guī)格為： 導(dǎo)柱： 25m130mm 材質(zhì)為20鋼 導(dǎo)套： 25m85mm33mm 材質(zhì)為20鋼 導(dǎo)柱： 28mm130mm 材質(zhì)為20鋼 導(dǎo)套： 28mm85mm33mm 材質(zhì)為20鋼小導(dǎo)柱導(dǎo)套主要連接凸模固定板，卸料板。主要起保證加工精度和保護(hù)細(xì)小凸模的作用，其規(guī)格為： 導(dǎo)柱：12h560mm 材質(zhì)為20鋼 導(dǎo)套： 18mm16mm 材質(zhì)為20鋼導(dǎo)柱導(dǎo)套滲碳深度為0.81.2mm，硬度為（5862）HRC，經(jīng)滲碳淬火處理，既耐磨又有足夠的韌度。5.7 壓力機(jī)的選擇總壓力的計(jì)算：F總=9651+20447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： 嵌件板級(jí)進(jìn)模設(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)： 0923079學(xué)生姓名： 徐 敏 指導(dǎo)教師： 林承德（職稱(chēng)：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： 嵌件板級(jí)進(jìn)模設(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)： 0923079學(xué)生姓名： 徐 敏 指導(dǎo)教師： 林承德（職稱(chēng)：教授 ） （職稱(chēng)： ）2012年11月25日 課題來(lái)源本課題來(lái)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(kāi)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(duì)稱(chēng)而且生產(chǎn)效率低。基于以上問(wèn)題，只有采用級(jí)進(jìn)模才能保證零件質(zhì)量又能提高生產(chǎn)效率?？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）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(jiǎn)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(guó)模具工業(yè)和當(dāng)前工業(yè)發(fā)展還很不適應(yīng)。無(wú)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(mǎn)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(guó)際市場(chǎng)上的競(jìng)爭(zhēng)力。今年來(lái)，我國(guó)模具進(jìn)口幅度呈大幅下降的趨勢(shì)，并有超億元的出口額。大型，復(fù)雜，精密，高效和長(zhǎng)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(jí)進(jìn)模也越來(lái)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(guó)模具行業(yè)的技術(shù)水品迅速提高，模具國(guó)產(chǎn)化已經(jīng)取得十分可喜的成績(jī)，這將對(duì)我國(guó)在國(guó)際市場(chǎng)的競(jìng)爭(zhēng)能力和綜合國(guó)力的提高起到有力的促進(jìn)作用。研究?jī)?nèi)容 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； 熟悉級(jí)進(jìn)模具的開(kāi)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； 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)； 完成級(jí)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(hào)圖紙的設(shè)計(jì)工作量，圖紙符合國(guó)家標(biāo)準(zhǔn)，各種標(biāo)注正確無(wú)誤） 完成不少于30頁(yè)的畢業(yè)設(shè)計(jì)說(shuō)明書(shū)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(jí)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(guò)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(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)。2013年1月11日-2013年3月5日：填寫(xiě)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(kāi)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(jí)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(xiě)和修改工作。預(yù)期成果：所設(shè)計(jì)的級(jí)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(jí)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(zhǎng)，模具細(xì)小零件和鑲塊多，板類(lèi)零件孔位精度高、尺寸協(xié)調(diào)多，因此，多工位級(jí)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(jí)進(jìn)模，必須具備先進(jìn)的模具加工設(shè)備和測(cè)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(wèn)題已具備的條件：1各種和課題相關(guān)的書(shū)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(zhuān)用教室和電腦。4老師的指導(dǎo)。尚解決的問(wèn)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(shuō)明書(shū)。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Die Life of cold stamping die and improvementsOverview of stamping dieStamping 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 partsDie 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 requirements1. 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 ofSince 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 CountermeasuresDie 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 ofDie 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