2406 沖壓模具畢業(yè)設計

2406 沖壓模具畢業(yè)設計,沖壓,模具,畢業(yè)設計 目錄1.緒論1.1 沖壓的概念、特點及應用1.2 沖壓的基本工序及模具1.3 沖壓技術的現(xiàn)狀及發(fā)展方向2 .零件的工藝性分析.2.1 零件的工藝性分析2.2 沖裁件的精度與粗糙度2.3 沖裁件的材料2.4 確定工藝方案3. 沖壓模具總體結構設計3.1 模具類型3.2 操作與定位方式33 卸料與出件方式34 模架類型及精度4 沖壓模具工藝與設計計算41 排樣設計與計算4.2 設計沖壓力與壓力中心,初選壓力機5. 模具的總張圖與零件圖5.1 根據(jù)前面的設計與分析,我們可以得出如級進模具的總張圖5.2 沖壓模具的零件圖5.3 壓力機的校核6.沖壓模具零件加工工藝的編制 6.1 凹模加工工藝過程 如表 6-1 所示1.緒論1.1 沖壓的概念、特點及應用沖壓是利用安裝在沖壓設備（主要是壓力機）上的模具對材料施加壓力，使其產(chǎn)生分離或塑性變形，從而獲得所需零件（俗稱沖壓或沖壓件）的一種壓力加工方法。沖壓通常是在常溫下對材料進行冷變形加工，且主要采用板料來加工成所需零件，所以也叫冷沖壓或板料沖壓。沖壓是材料壓力加工或塑性加工的主要方法之一，隸屬于材料成型工程術。沖壓所使用的模具稱為沖壓模具，簡稱沖模。沖模是將材料（金屬或非金屬）批量加工成所需沖件的專用工具。沖模在沖壓中至關重要，沒有符合要求的沖模，批量沖壓生產(chǎn)就難以進行；沒有先進的沖模，先進的沖壓工藝就無法實現(xiàn)。沖壓工藝與模具、沖壓設備和沖壓材料構成沖壓加工的三要素，只有它們相互結合才能得出沖壓件。與機械加工及塑性加工的其它方法相比，沖壓加工無論在技術方面還是經(jīng)濟方面都具有許多獨特的優(yōu)點。主要表現(xiàn)如下。(1) 沖壓加工的生產(chǎn)效率高，且操作方便，易于實現(xiàn)機械化與自動化。這是因為沖壓是依靠沖模和沖壓設備來完成加工，普通壓力機的行程次數(shù)為每分鐘可達幾十次，高速壓力要每分鐘可達數(shù)百次甚至千次以上，而且每次沖壓行程就可能得到一個沖件。（2）沖壓時由于模具保證了沖壓件的尺寸與形狀精度，且一般不破壞沖壓件的表面質(zhì)量,而模具的壽命一般較長,所以沖壓的質(zhì)量穩(wěn)定,互換性好,具有“一模一樣”的特征。（3）沖壓可加工出尺寸范圍較大、形狀較復雜的零件，如小到鐘表的秒表，大到汽車縱梁、覆蓋件等，加上沖壓時材料的冷變形硬化效應，沖壓的強度和剛度均較高。（4）沖壓一般沒有切屑碎料生成，材料的消耗較少，且不需其它加熱設備，因而是一種省料，節(jié)能的加工方法，沖壓件的成本較低。但是，沖壓加工所使用的模具一般具有專用性，有時一個復雜零件需要數(shù)套模具才能加工成形，且模具 制造的精度高，技術要求高，是技術密集形產(chǎn)品。所以，只有在沖壓件生產(chǎn)批量較大的情況下，沖壓加工的優(yōu)點才能充分體現(xiàn)，從而獲得較好的經(jīng)濟效益。沖壓地、在現(xiàn)代工業(yè)生產(chǎn)中，尤其是大批量生產(chǎn)中應用十分廣泛。相當多的工業(yè)部門越來越多地采用沖壓法加工產(chǎn)品零部件，如汽車、農(nóng)機、儀器、儀表、電子、航空、航天、家電及輕工等行業(yè)。在這些工業(yè)部門中，沖壓件所占的比重都相當?shù)拇?，少則 60%以上，多則 90%以上。不少過去用鍛造=鑄造和切削加工方法制造的零件，現(xiàn)在大多數(shù)也被質(zhì)量輕、剛度好的沖壓件所代替。因此可以說，如果生產(chǎn)中不諒采用沖壓工藝，許多工業(yè)部門要提高生產(chǎn)效率和產(chǎn)品質(zhì)量、降低生產(chǎn)成本、快速進行產(chǎn)品更新?lián)Q代等都是難以實現(xiàn) 的。1.2 沖壓的基本工序及模具由于沖壓加工的零件種類繁多，各類零件的形狀、尺寸和精度要求又各不相同，因而生產(chǎn)中采用的沖壓工藝方法也是多種多樣的。概括起來，可分為分離工序和成形工序兩大類；分離工序是指使坯料沿一定的輪廓線分離而獲得一定形狀、尺寸和斷面質(zhì)量的沖壓（俗稱沖裁件）的工序；成形工序是指使坯料在不破裂的條件下產(chǎn)生塑性變形而獲得一定形狀和尺寸的沖壓件的工序。上述兩類工序，按基本變形方式不同又可分為沖裁、彎曲、拉深和成形四種基本工序，每種基本工序還包含有多種單一工序。在實際生產(chǎn)中，當沖壓件的生產(chǎn)批量較大、尺寸較少而公差要求較小時，若用分散的單一工序來沖壓是不經(jīng)濟甚至難于達到要求。這時在工藝上多采用集中的方案，即把兩種或兩種以上的單一工序集中在一副模具內(nèi)完成，稱為組合的方法不同，又可將其分為復合-級進和復合-級進三種組合方式。復合沖壓在壓力機的一次工作行程中，在模具的同一工位上同時完成兩種或兩種以上不同單一工序的一種組合方法式。級進沖壓在壓力機上的一次工作行程中，按照一定的順序在同一模具的不同工位上完面兩種或兩種以上不同單一工序的一種組合方式。復合-級進在一副沖模上包含復合和級進兩種方式的組合工序。沖模的結構類型也很多。通常按工序性質(zhì)可分為沖裁模、彎曲模、拉深模和成形模等；按工序的組合方式可分為單工序模、復合模和級進模等。但不論何種類型的沖模，都可看成是由上模和下模兩部分組成，上模被固定在壓力機工作臺或墊板上，是沖模的固定部分。工作時，坯料在下模面上通過定位零件定位，壓力機滑塊帶動上模下壓，在模具工作零件（即凸模、凹模）的作用下坯料便產(chǎn)生分離或塑性變形，從而獲得所需形狀與尺寸的沖件。上模回升時，模具的卸料與出件裝置將沖件或廢料從凸、凹模上卸下或推、頂出來，以便進行下一次沖壓循環(huán)。1.3 沖壓技術的現(xiàn)狀及發(fā)展方向隨著科學技術的不斷進步和工業(yè)生產(chǎn)的迅速發(fā)展，許多新技術、新工藝、新設備、新材料不斷涌現(xiàn)，因而促進了沖壓技術的不斷革新和發(fā)展。其主要表現(xiàn)和發(fā)展方向如下。(1).沖壓成形理論及沖壓工藝方面沖壓成形理論的研究是提高沖壓技術的基礎。目前，國內(nèi)外對沖壓成形理論的研究非常重視，在材料沖壓性能研究、沖壓成形過程應力應變分析、板料變形規(guī)律研究及坯料與模具之間的相互作用研究等方面均取得了較大的進展。特別是隨著計算機技術的飛躍發(fā)展和塑性變形理論的進一步完善，近年來國內(nèi)外已開始應用塑性成形過程的計算機模擬技術，即利用有限元（FEM）等有值分析方法模擬金屬的塑性成形過程，根據(jù)分析結果，設計人員可預測某一工藝方案成形的可行性及可能出現(xiàn)的質(zhì)量問題，并通過在計算機上選擇修改相關參數(shù)，可實現(xiàn)工藝及模具的優(yōu)化設計。這樣既節(jié)省了昂貴的試模費用，也縮短了制模具周期。研究推廣能提高生產(chǎn)率及產(chǎn)品質(zhì)量、降低成本和擴大沖壓工藝應用范圍的各種壓新工藝，也是沖壓技術的發(fā)展方向之一。目前，國內(nèi)外相繼涌現(xiàn)出精密沖壓工藝、軟模成形工藝、高能高速成形工藝及無模多點成形工藝等精密、高效、經(jīng)濟的沖壓新工藝。其中，精密沖裁是提高沖裁件質(zhì)量的有效方法，它擴大了沖壓加工范圍，目前精密沖裁加工零件的厚度可達 25mm，精度可達 IT1617 級；用液體、橡膠、聚氨酯等作柔性凸?；虬寄５能浤３尚喂に嚕芗庸こ鲇闷胀庸し椒y以加工的材料和復雜形狀的零件，在特定生產(chǎn)條件下具有明顯的經(jīng)濟效果；采用爆炸等高能效成形方法對于加工各種尺寸在、形狀復雜、批量小、強度高和精度要求較高的板料零件，具有很重要的實用意義；利用金屬材料的超塑性進行超塑成形，可以用一次成形代替多道普通的沖壓成形工序，這對于加工形狀復雜和大型板料零件具有突出的優(yōu)越性；無模多點成形工序是用高度可調(diào)的凸模群體代替?zhèn)鹘y(tǒng)模具進行板料曲面成形的一種先進技術，我國已自主設計制造了具有國際領先水平的無模多點成形設備，解決了多點壓機成形法，從而可隨意改變變形路徑與受力狀態(tài)，提高了材料的成形極限，同時利用反復成形技術可消除材料內(nèi)殘余應力，實現(xiàn)無回彈成形。無模多點成形系統(tǒng)以 CAD/CAM/CAE 技術為主要手段，能快速經(jīng)濟地實現(xiàn)三維曲面的自動化成形。(2.)沖模是實現(xiàn)沖壓生產(chǎn)的基本條件.在沖模的設計制造上,目前正朝著以下兩方面發(fā)展:一方面,為了適應高速、自動、精密、安全等大批量現(xiàn)代生產(chǎn)的需要，沖模正向高效率、高精度、高壽命及多工位、多功能方向發(fā)展，與此相比適應的新型模具材料及其熱處理技術，各種高效、精密、數(shù)控自動化的模具加工機床和檢測設備以及模具CAD/CAM 技術也在迅速發(fā)展；另一方面，為了適應產(chǎn)品更新?lián)Q代和試制或小批量生產(chǎn)的需要，鋅基合金沖模、聚氨酯橡膠沖模、薄板沖模、鋼帶沖模、組合沖模等各種簡易沖模及其制造技術也得到了迅速發(fā)展。 精密、高效的多工位及多功能級進模和大型復雜的汽車覆蓋件沖模代表了現(xiàn)代沖模的技術水平。目前，50 個工位以上的級進模進距精度可達到 2 微米，多功能級進模不僅可以完成沖壓全過程，還可完成焊接、裝配等工序。我國已能自行設計制造出達到國際水平的精度達 2 5 微米，進距精度 23 微米，總壽命達 1 億次。我國主要汽車模具企業(yè)，已能生產(chǎn)成套轎車覆蓋件模具，在設計制造方法、手段方面已基本達到了國際水平，但在制造方法手段方面已基本達到了國際水平，模具結構、功能方面也接近國際水平，但在制造質(zhì)量、精度、制造周期和成本方面與國外相比還存在一定差距。模具制造技術現(xiàn)代化是模具工業(yè)發(fā)展的基礎。計算機技術、信息技術、自動化技術等先進技術正在不斷向傳統(tǒng)制造技術滲透、交叉、融合形成了現(xiàn)代模具制造技術。其中高速銑削加工、電火花銑削加工、慢走絲切割加工、精密磨削及拋光技術、數(shù)控測量等代表了現(xiàn)代沖模制造的技術水平。高速銑削加工不但具有加工速度高以及良好的加工精度和表面質(zhì)量（主軸轉(zhuǎn)速一般為 1500040000r/min）,加工精度一般可達 10 微米，最好的表面粗糙度 Ra1 微米） ，而且與傳統(tǒng)切削加工相比具有溫升低（工件只升高 3 攝氏度） 、切削力小，因而可加工熱敏材料和剛性差的零件，合理選擇刀具和切削用量還可實現(xiàn)硬材料（60HRC）加工；電火花銑削加工（又稱電火花創(chuàng)成加工）是以高速旋轉(zhuǎn)的簡單管狀電極作三維或二維輪廓加工（像數(shù)控銑一樣） ，因此不再需要制造昂貴的成形電極，如日本三菱公司生產(chǎn)的 EDSCAN8E 電火花銑削加工機床，配置有電極損耗自動補償系統(tǒng)、CAD/CAM 集成系統(tǒng)、在線自動測量系統(tǒng)和動態(tài)仿真系統(tǒng)，體現(xiàn)了當今電火花加工機床的技術水平；慢走絲線切割技術的發(fā)展水平已相當高，功能也相當完善，自動化程度已達到無人看管運行的程度，目前切割速度已達到 300mm /min,加工精度可達1.5 微米，2表面粗糙度達 Ra=010.2 微米;精度磨削及拋光已開始使用數(shù)控成形磨床、數(shù)控光學曲線磨床、數(shù)控連續(xù)軌跡坐標磨床及自動拋光等先進設備和技術;模具加工過程中的檢測技術也取得了很大的發(fā)展,現(xiàn)在三坐標測量機除了能高精度地測量復雜曲面的數(shù)據(jù)外,其良好的溫度補償裝置、可靠的抗振保護能力、嚴密的除塵措施及簡單操作步驟，使得現(xiàn)場自動化檢測成為可能。此外，激光快速成形技術（RPM）與樹脂澆注技術在快速經(jīng)濟制模技術中得到了成功的應用。利用RPM 技術快速成形三維原型后，通過陶瓷精鑄、電弧涂噴、消失模、熔模等技術可快速制造各種成形模。如清華大學開發(fā)研制的“M-RPMS-型多功能快速原型制造系統(tǒng)”是我國自主知識產(chǎn)權的世界惟一擁有兩種快速成形工藝（分層實體制造 SSM 和熔融擠壓成形MEM）的系統(tǒng)，它基于“模塊化技術集成”之概念而設計和制造，具有較好的價格性能比。一汽模具制造公司在以 CAD/CAM 加工的主模型為基礎，采用瑞士汽巴精化的高強度樹脂澆注成形的樹脂沖模應用在國產(chǎn)轎車試制和小批量生產(chǎn)開辟了新的途徑。(3) 沖壓設備和沖壓生產(chǎn)自動化方面性能良好的沖壓設備是提高沖壓生產(chǎn)技術水平的基本條件，高精度、高壽命、高效率的沖模需要高精度、高自動化的沖壓設備相匹配。為了滿足大批量高速生產(chǎn)的需要，目前沖壓設備也由單工位、單功能、低速壓力機朝著多工位、多功能、高速和數(shù)控方向發(fā)展，加之機械乃至機器人的大量使用，使沖壓生產(chǎn)效率得到大幅度提高，各式各樣的沖壓自動線和高速自動壓力機紛紛投入使用。如在數(shù)控四邊折彎機中送入板料毛坯后，在計算機程序控制下便可依次完成四邊彎曲，從而大幅度提高精度和生產(chǎn)率；在高速自動壓力機上沖壓電機定轉(zhuǎn)子沖片時，一分鐘可沖幾百片，并能自動疊成定、轉(zhuǎn)子鐵芯，生產(chǎn)效率比普通壓力機提高幾十倍，材料利用率高達 97%；公稱壓力為 250KN 的高速壓力機的滑塊行程次數(shù)已達 2000 次/min以上。在多功能壓力機方面，日本田公司生產(chǎn)的 2000KN“沖壓中心”采用 CNC 控制，只需 5min 時間就可完成自動換模、換料和調(diào)整工藝參數(shù)等工作；美國惠特尼公司生產(chǎn)的 CNC 金屬板材加工中心，在相同的時間內(nèi)，加工沖壓件的數(shù)量為普通壓力機的 410 倍，并能進行沖孔、分段沖裁、彎曲和拉深等多種作業(yè)。近年來，為了適應市場的激烈競爭，對產(chǎn)品質(zhì)量的要求越來越高，且其更新?lián)Q代的周期大為縮短。沖壓生產(chǎn)為適應這一新的要求，開發(fā)了多種適合不同批量生產(chǎn)的工藝、設備和模具。其中，無需設計專用模具、性能先進的轉(zhuǎn)塔數(shù)控多工位壓力機、激光切割和成形機、CNC 萬能折彎機等新設備已投入使用。特別是近幾年來在國外已經(jīng)發(fā)展起來、國內(nèi)亦開始使用的沖壓柔性制造單元（FMC）和沖壓柔性制造系統(tǒng)（FMS ）代表了沖壓生產(chǎn)新的發(fā)展趨勢。FMS 系統(tǒng)以數(shù)控沖壓設備為主體，包括板料、模具、沖壓件分類存放系統(tǒng)、自動上料與下料系統(tǒng)，生產(chǎn)過程完全由計算機控制，車間實現(xiàn) 24 小時無人控制生產(chǎn)。同時，根據(jù)不同使用要求，可以完成各種沖壓工序，甚至焊接、裝配等工序，更換新產(chǎn)品方便迅速，沖壓件精度也高。(4)沖壓標準化及專業(yè)化生產(chǎn)方面模具的標準化及專業(yè)化生產(chǎn)，已得到模具行業(yè)和廣泛重視。因為沖模屬單件小批量生產(chǎn)，沖模零件既具的一定的復雜性和精密性，又具有一定的結構典型性。因此，只有實現(xiàn)了沖模的標準化，才能使沖模和沖模零件的生產(chǎn)實現(xiàn)專業(yè)化、商品化，從而降低模具的成本，提高模具的質(zhì)量和縮短制造周期。目前，國外先進工業(yè)國家模具標準化生產(chǎn)程度已達 70%80%，模具廠只需設計制造工作零件，大部分模具零件均從標準件廠購買，使生產(chǎn)率大幅度提高。模具制造廠專業(yè)化程度越不定期越高，分工越來越細，如目前有模架廠、頂桿廠、熱處理廠等，甚至某些模具廠僅專業(yè)化制造某類產(chǎn)品的沖裁模或彎曲模，這樣更有利于制造水平的提高和制造周期的縮短。我國沖模標準化與專業(yè)化生產(chǎn)近年來也有較大發(fā)展，除反映在標準件專業(yè)化生產(chǎn)廠家有較多增加外，標準件品種也有擴展，精度亦有提高。但總體情況還滿足不了模具工業(yè)發(fā)展的要求，主要體現(xiàn)在標準化程度還不高（一般在 40%以下） ，標準件的品種和規(guī)格較少，大多數(shù)標準件廠家未形成規(guī)?；a(chǎn)，標準件質(zhì)量也還存在較多問題。另外，標準件生產(chǎn)的銷售、供貨、服務等都還有待于進一步提高。設計要求:設計該零件的沖裁模 沖壓件圖如下圖所示:120.5+0.2.15+0.25+0.32.53.289-.0-.43沖壓技術要求:1. 材料:H622. 材料厚度:4mm3. 生產(chǎn)批量:中批量4. 未注公差:按 IT14 級確定.2 .零件的工藝性分析.2.1 零件的工藝性分析 該零件材料為 H62(黃銅)結構簡單,形狀對稱,凹模寬度 B=121.2t(t 為材料厚度) ,沖孔時有尺寸為6.5 5.2 根據(jù)課本 P86 頁知沖孔時,因受凸模強度的2.015.0限制,孔的尺寸不應太小.沖孔的最小尺寸取決于材料性能,凸模的強度和模具結構等.根據(jù)表 3-3 可查得圓形孔最小值得d=0.9t=0.9X4=3.6mm(1.52)t 所以由沖件圖可知C1=12-5.2/2-6.5/2=6.151X4=4, C2=88.9-21-29.4-31.5-2-2.5=2.5682.74,所以壓力得以校核;(2).滑塊行程 滑塊行程應保證坯料能順利地放入模具和沖壓能順利地從模具中取出.這里只是材料的厚度 t=4,導料板的厚度 H=12 及凸模沖入凹模的最大深度 14,即 S1=4+12+14=30S=130,所以得以校核.(3).行和次數(shù) 行程次數(shù)為 45/min.因為生產(chǎn)批量為中批量,又是手工送料,不能太快,因此是得以校核.(4)工作臺面的尺寸 根據(jù)下模座 LXB=370X270,且每邊留出 60100,即 L1XB1=470X370,而壓力機的工作臺面 L2XB2=800X540,沖壓件和廢料從下模漏出, 漏料尺寸 95X50,而壓力機的孔尺寸為 360X23,故符合要求,得以校核;(5) 滑塊模柄孔尺寸 滑塊上模柄孔的直徑為 60,模柄孔深度為 80,而所選的模柄夾持部分直徑為 60,長度為 70 故符合要求,得以校核;(6).閉合高度 由壓力機型號知 Hmax=380 M=90 H1=100Hmin=HmaxM=380-90=290(M 為閉合高度調(diào)節(jié)量/mm,H1 為墊板厚度/mm)由式(1-24):( HmaxH1)-5H( HminH1)+10,得(380100)-5262(290100)+10即 275262200 ,所以所選壓力機合適,即壓力機得以校核.6.沖壓模具零件加工工藝的編制 6.1 凹模加工工藝過程 如表 6-1 所示表 6-1 凹模加工工藝過程工序號 工序名稱 工序內(nèi)容 設備1 備料 將毛坯鍛成 135mm110mm30mm2 熱處理 退火3 銑 銑六面,厚度留單邊磨量 0.20.3mm 銑床4 平磨 磨厚度到上限尺寸,磨側(cè)基面保證互相垂直 平面磨床5 鉗工 劃各型孔,螺孔,銷孔位置劃漏孔輪廓線6 鉗工 加工好凸模,配作沖孔凹模達要求7 銑 銑漏料孔達要求 銑床8 鉗工 鉆鉸 610 ,鉆攻 4XM12015. 鉆床9 熱處理 淬火,回火,保證 HRC606210 平磨 磨厚度及基面達到要求 平面磨床11 線切割 按圖切割各型孔,留 0.0050.01 單邊研量 線切割機 床12 鉗工 研光各型孔達要求13 檢驗6.2 凸模加工工藝過程 如表 6-2-1,6-2-2,6-2-3 所示表 6-2-1 落料凸模加工工藝過程工序號 工序名稱 工序內(nèi)容 設備1 備料 將毛坯鍛成 110mmX100mmX35mm2 熱處理 退火3 銑 銑六面,厚度留單邊磨量 0.20.3mm 銑床4 平磨 磨厚度到上限尺寸,磨側(cè)基面保證互相垂直 平面磨床5 鉗工 劃刃口輪廓尺寸及孔位置尺寸6 鉗工 加工好凹模,配作落料凸模達要求7 鉗工 鉆 10.5, 12.5 鉆鉸 7.5 ,鉆鉸 9015.015.鉆床8 熱處理 淬火,回火,保證 HRC60649 鉗工 磨各配合面達要求10 檢驗表 6-2-2 沖孔凸模加工工藝過程工序號 工序名稱 工序內(nèi)容 設備1 備料 備料 12mmX105mm2 熱處理 退火3 車外圓 車外圓達配合尺寸 車床4 車工作尺寸 車工作尺寸達要求 車床5 倒角 倒角達要求 車床6 鉗工 拋光達表面要求7 熱處理 淬火,回火,保證 HRC58628 鉗工 磨平上下表面達要求9 檢驗說明:凸模 6.65 ,5.313 都按表 6-2-2 加工.05.038.表 6-2-3 沖孔凸模加工工藝過程工序號 工序名稱 工序內(nèi)容 設備1 備料 備料 35mmX20mmX105mm2 熱處理 退火3 線切割 按圖切割外形,留 0.0050.01 單邊研量 線切割機 床4 銑 銑工作尺寸留 0.01 銑床5 鉗工 倒角達要求6 鉗工 拋光達表面要求7 熱處理 淬火,回火,保證 HRC58628 鉗工 磨平上下表面達要求9 檢驗說明:余下三個沖孔凸模按表 6-2-3 同理加工6.3 卸料板加工工藝過程 如表 6-3 所示表 6-3 卸料板加工工藝過程工序號 工序名稱 工序內(nèi)容 設備1 備料 將毛坯鍛成 205mmX165mmX48mm2 熱處理 退火3 銑 銑六面,厚度留單邊磨量 0.20.3mm 銑床4 平磨 磨厚度到上限尺寸,磨側(cè)基面保證互相垂直 平面磨床5 鉗工 劃各型孔,螺孔,銷孔位置劃漏孔輪廓線6 線切割 按圖切割各型孔,保證雙面間隙 0.5mm 線切割機 床7 鉗工 鉆鉸 2X10 ,鉆沉孔015. 鉆床8 平磨 磨厚度及基面見光 平面磨床9 鉗工 研光各型孔達要求10 檢驗6.4 凸模固定板加工工藝過程 如表 6-4 所示表 6-4 凸模固定板加工工藝過程工序號 工序名稱 工序內(nèi)容 設備1 備料 將毛坯鍛成 205mmX165mmX35mm2 熱處理 退火3 銑 銑六面,厚度留單邊磨量 0.20.3mm 銑床4 平磨 磨厚度到上限尺寸,磨側(cè)基面保證互相垂直 平面磨床5 鉗工 劃各型孔,螺孔,銷孔位置劃漏孔輪廓線6 線切割 按圖切割各型孔,保證配合尺寸 線切割機 床7 鉗工 鉆鉸 2X10 ,鉆攻 4XM12015. 鉆床8 鉗工 鉚接處倒角9 平磨 磨厚度及基面見光 平面磨床10 鉗工 研光各型孔達要求11 檢驗6.5 上模座加工工藝過程 如表 6-5 所示表 6-5 上模座加工工藝過程工序號 工序名稱 工序內(nèi)容 設備1 備料 取標準上模座2 熱處理 退火4 平磨 平磨上下平面達要求 平面磨床5 鉗工 劃螺孔,銷孔位置劃模柄孔輪廓線6 線切割 按圖切割各型孔,保證配合尺寸 線切割機 床7 鉗工 鉆鉸 2X10 ,鉆攻 4XM12,配鉆模柄防轉(zhuǎn)孔015. 鉆床8 鉗工 研光各型孔達要求9 檢驗6.6 下模座加工工藝過程 如表 6-6 所示表 6-6 下模座加工工藝過程工序號 工序名稱 工序內(nèi)容 設備1 備料 取標準上模座2 熱處理 退火4 平磨 平磨上下平面達要求 平面磨床5 鉗工 劃螺孔,銷孔位置劃模柄孔輪廓線6 線切割 按圖切割各型孔 線切割機 床7 鉗工 鉆鉸 2X10 ,鉆沉孔015. 鉆床8 鉗工 研光各型孔達要求9 檢驗6.7 導料板加工工藝過程 如表 6-7 所示表 6-7 導料板加工工藝過程工序號 工序名稱 工序內(nèi)容 設備1 備料 取標準導料板2 熱處理 退火3 鉗工 劃螺孔,銷孔位置4 鉗工 鉆鉸 4X10 ,鉆攻 4XM12,2XM5015. 鉆床5 鉗工 按圖加工與始用擋料銷的配合處達要求6 檢驗參考文獻1 編輯委員會 ,運輸機械設計選用手冊M,化學工業(yè)出版社,19992 青島運輸設備制造廠編,DDJ 型大傾角擋邊帶式輸送機選用手冊,19953 蔣瓊珠主編 ,連續(xù)運輸機M,人民交通出版社,1986 4 龔溎義主編 ,機械設計課程設計指導書M,高等教育出版社,20055 濮良貴、紀名剛主編,西北工業(yè)大學機械原理及機械零件教研室編著,機械設計M, 第七版,高等教育出版社,20006 徐克晉主編,金屬結構,第二版,機械工業(yè)出版社,19907 機械設計手冊編委會編,機械設計手冊M,機械工業(yè)出版社,20048 劉鴻文主編 ,材料力學M,第四版,高等教育出版社,20039 F.kesser.J.Paelke,Vertical Conveyous for Bulk MaterialsThe Economic Solution J,Bulk Solids Handling,1998,18（3）：443-44810 Zhou Manshan Analysis On Dynamic Propertics Of Belt Conveyor ICMH/ICFP 99 shanghai china11 Zhang Yuan ,Computer Simulation on Continuous Model of Belt Conveyor Dynamic Analysis,Proceedings of the First International Conference on Mechanical Engineering. 2000.shanghai china致謝在本次畢業(yè)設計結束之時，我要衷心地感謝我的指導老師劉曉玲老師，本次設計正是在劉老師的悉心指導下完成的，從論文選題、理論研究、帶式輸送機的設計，到最后的論文撰寫、修改，整個過程都得到了劉老師精心的指導和全力幫助。尤其是老師嚴謹?shù)目茖W研究精神，惜時如金的工作態(tài)度深深影響了本人，使本人受益匪淺。在此表示衷心感謝，并致以崇高的敬意。在青島理工大學學習和生活的四年中，我得到了眾多老師的指導以及很多同學的幫助，這使我在大學中學到了豐富的基礎知識和專業(yè)之時，為本次設計以及今后的工作生活打下了堅實的基礎，在此，對青島理工大學以及機電工程學院的各位領導和老師表示衷心感謝并致以崇高的敬意。最后，由衷地向所有關心和幫助過我的人表示感謝！ Research backgroundCasting, without pressure or under a little pressure, the liquid monomer, resin or mixtures thereof into the mold and make it a method of solid-state products. Casting plastic molding is similar to the metal casting, it is the preparation of a good liquid material poured into the mold cavity after curing obtained with a similar shape and size of plastic parts, this method is called casting plastic molding plastic.Divided into static casting casting, inlay casting, centrifugal casting, slush molding, rotational casting, rotational molding and casting casting and so on. In modern industry, the automation of the production process has become a prominent theme. Increasingly high level of automation in all walks of life, modern processing plant, often with a mechanical hand. Bed in the red robot used to replace manual feeding feeding has become the most effective in preventing injury incidents safety measures. Robot can not only security operations but also improved product quality and production efficiency and reduce the rejection rate. Robot is used in the automation of a production process and moving piece features a crawl automation devices, it is in the mechanization and automation of the production process developed a new type of device. In recent years, electronic technology, especially with the extensive use of computer, the robots development and production of high-tech fields has become a rapidly developed a new technology, it is more to promote the development of the manipulator, the robot hand can be better achieved with the combination of mechanization and automation. Robot can replace humans completed the risk of duplication of boring, and reduce human labor intensity and improve labor productivity. Manipulator has been applied more widely, in the machinery industry it can be used for parts assembly, workpiece handling, loading and unloading, particularly in the automation of CNC machine tools, machine tool use is more common. Currently, the mechanical hand developed into a flexible manufacturing system, FMS, and flexible manufacturing cell An important part of the FMC. The machine tools and robots together to form a flexible manufacturing system or flexible manufacturing cell, it was adapted, the small batch production, can save huge conveyor parts, compact, and adaptable. When the workpiece is changed, the flexible production system is very easy to change, help enterprises to continuously update the marketable variety, improve product quality, and better adapt to market competition. At present, Chinas industrial robot technology and its application level and there is a certain distance than abroad, application size and low level of industrialization, research and development of robot directly affect the higher level of automation, from the economic, technical considerations are essential. Therefore, the Manipulator design is very meaningful. 1.1 Classification of robot Many different types of industrial manipulator on the classification, at present there is no uniform standard in the country, in this current application more Zanan two aspects of classification. 1.1.1 according to the classification of carrying the weight of the workpiece 1. Small - arm strength 1 kg; 2. Medium - the arm strength of 1-30 kg or less; 3. Large - the arm strength of 30 kg. Most industrial robots handling a number of its medium. 1.1.2 Classification by Function 1) Simple general manipulator There are two fixed program and variable process. Fixed program or the cam drum by the control block to a given program. This mechanical sub-mostly pneumatic or hydraulic drive, simple structure, low cost long to change the process easier. Procedures apply only to relatively simple position control, to achieve a repeatable stand-alone service operating as a general handling work fully enough. The largest number of the current sub-machine. 2) general teaching and playback type robot Under this mechanical device that artificially brought by moving all the way to teach children or given a first operating temperature, known as teaching. It consists of the drum (or disk-shaped core) since the program recorded automatically by the robot to carry out the memory of the program repeats the cycle action. 3) has the vision, the sense of touch in general machinery The manipulator controlled by computer, equipped with a TV camera tube and the sensor which has the vision, thermal. Tactile and so on. The robot is still in development stage in China. 1.1.3 The design of hand 1. Hand should be sufficient clamping force. In addition to the gravity of the workpiece, but also to not to loose parts in the course of transmission or loss; 2. Clamping range compatible with the workpiece. Gripper for opening and closing angle (gripper open or closed position when the two extreme point of the swing) should be able to adapt to the larger diameter clamping; 3. Holding higher precision. Require both accurate positioning within the workpiece in the gripper, not a bad clip surface. General election to be based on the shape of the workpiece gripper stick in the appropriate structure: such as the cylindrical workpiece should be used with a v-shaped grooves to position the gripper; for high surface finish should be set in the gripper on the copper, cloth bakelite or other soft pads, etc. 4. Clamping action should be fast and flexible; 5. Hand playing simple and compact structure, good rigidity, light weight, easy to wear at the change should be easy to install in the wrist or arm to be easy to quickly change. 1.2 The composition of the manipulator The structure of industrial machinery in a simple but also complex. However, structure analysis, the main executive body drive system, position detection device and control system components. Figure l-1 is the schematic. Figure 1-1 Schematic diagram of manipulator1 actuator It includes the hand, wrist, arm, columns and other basic structure: 1. Hand - is the workpiece component. Its claws and clamps the two parts. There gripper clamping and release action. Clamp-type gripper means in the form similar to human murderer. There are also vacuum and electromagnetic disk (equivalent to gripper), a smooth surface to absorb the zero-41: or sheet. Some of the gripper can grip some special tools, such as gun, wrenches, welding tools. 2. Wrist - is the connection to the Department and the arm of the components, from the paper support the role of the hand. It can tilt, turn left and right advise and the three sports. Special circumstances can increase a lateral move. Some machinery was no wrist action. 3. Arm - is the text stays the hand, wrist components. Mechanical hip is replaced in the arm of one study design, but it does not reach a human being nimble and adapt capabilities dense. Therefore, only the simplified structure, the trajectory is divided into reciprocating motion along the coordinate axis and rotation around the coordinate axis. He usually hands back and forth again, left turn, or bobbing up and down movements, and several other sports. Optional according to need one, two or three sports. 4. Set to - is the support arm and other components. General machinery in the legislation to the stationary, and some because of work established for the horizontal shift to the hole, said movable column of this. 5. Travel agencies - in the more remote manipulator required to complete the operation, increase the wheel, walking track, etc. Institutions. 2 drive system Drive system is the driving arm, wrist, hand power sink. It has air, forms a straight line from the cylinder, rotary cylinder, a variety of valves, pipes and pipe fittings and other components. Pressure-driven advantages are: easy access to fast motion, the robot can use normal compressed air per plant has, so simple and low cost; air is not as sensitive to heat as oil and flammable; maintenance; and jet control are particularly easily used in combination. The disadvantages are: air pressure is low, output is small, a large volume of the implementing agencies; compression is high, the buffer effect of the damping is poor, difficult to achieve the middle of the stop, if the requirements of high accuracy, the buffer must be added complex, positioning mechanism. In a hydraulic driven robot is the most way. Use of tanks, motor oil, and rack and pinion to achieve linear motion, the use of rotating cylinders, motor oil and the rack and pinion or sprocket chain to achieve rotary motion. 3 Control System Control system is an important part of the robot, which is the dominant mechanical hand according to prescribed procedures, stroke and speed of movement of the device. It must be saved or memory instructions that people give the robot information (such as movements in order to reach the location and time information.) Work robot manipulator based on this information the executive body to issue control instructions according to the procedure, when necessary, the mechanical hand movements to monitor machine error when action or failure to issue management reports signal. 4 stroke position detection device The role of stroke position detection device is to control the robot movement position of each movement, or position feedback about the motor system control system, and then adjusted by the control system so the robot to achieve location accuracy. 5 assist device 1. Matrix - is a fundamental part of the robot base, it play supporting role. 2. Fuel tank - to keep independence and oil installations, and to heat the oil and impurities precipitated3. Gas evasion - the storage of compressed air.1.3 The significance of mechanical hand With the development of science and technology, mechanical hand, more and more is applied. In the machinery industry, casting, welding, riveting, punching, pressing, heat treatment, machining, assembly, verification and other types of work are examples of applications. Other departments, such as light industry, construction, defense industry, etc. are also applied. In the machinery industry, the significance of mechanical hand can be summarized as follows: (1) to improve the automation of the production process Conducive to the realization of mechanical hand-delivery of materials, parts handling, machine tool replacement and automation of the assembly, etc., which can increase labor productivity and reduce production costs. (2) to improve working conditions, to avoid personal injury At high temperature, high pressure, low temperature, low pressure, dust, noise, odor, radioactive or other toxic pollution, and work space in the narrow places, direct manipulation by hand is dangerous or impossible, and applications to be part of the robot or all of the safety instead of homework is to improve working conditions. In some simple, repetitive, especially the more cumbersome operation, the robot instead of people working to prevent the operation of fatigue or personal accident caused by negligence. (3) can reduce manpower, and facilitate the production of rhythmic Application of robot instead of people, and this is one aspect of a direct reduction of manpower, and because of mechanical hand can be a continuous work, which is another side to reduce manpower. Therefore, a comprehensive automated processing automatic machine line, currently almost no mechanical hand, to reduce the human and more accurate control of the production of beat, rhythm, to facilitate the conduct of production work. In summary, the effective application of robot is the inevitable trend of development of machinery industry. 2 overall technology plan and system components 2.1 Raw Data Uses: cast aluminum alloy cold chamber die casting machine solution. Specifications: Ladle maximum capacity: 8 kg Degrees of freedom: 3 Coordinate form: similar to the spherical coordinates Arm motion parameters: Rotary (&): 110 Pitch (): 54 Ladle the maximum tilt angle (1): 70 Driving type: hydraulic Control: Fixed program control relay 2.2 The work needs Casting manipulator (ie, ladle 1) the initial position, stopping the crucible 2 in the holding furnace above the metal surface, in which the heat, waiting for casting. When 630 tons die casting machine mold slow, the die-casting machine control device sent a letter to the robot lift cylinder 6 moves, ladle, and immersed in liquid metal begin to decline within the contact with the metal surface until the electrode B, the voltage following the Electric 2XJ letters, ladle stopped declining, and with time relay control ladle has been filled with liquid metal, and then ladle rise in the excess metal will enhance the process of pouring the solution from the overflow tailgate package, direct Holding furnace to the ladle bottom of the crucible than the highest point, hit the limit switch 1XW, improve end. Meanwhile, the mechanical hand-arm casting 3 slow rotation (5 driven by a rotating cylinder), when the collision limit switch 5XWK, the arm into a quick turn. When confronted with a limit switch 6XWK after he transformed into a slow rotation, until after the collision to stop turning the limit switch 3XWK. At this time, 630 tons die casting machine mold together Yan, 4 cylinder manipulator dumping action, pulling the rope through the dumping of bodies, led flip pouring ladle, the delay, the control of dumping fuel tank reset, and to reverse the arm rotation, when after hitting the limit switch 4XWK reverse end of the arm, while lifting cylinder piston up, ladle down until contact with the metal surface electrode A, the voltage relay 1XJ sent a letter to lift cylinder moves to stop, ladle on stop at a certain distance on the surface of molten metal at the heat, preparing for a second action cycle. 2.3 The work needs The main arm of the robot arm rotating frame, dump bodies, ladle, dumping fuel tank, rotary cylinder, base, lift cylinder and other components. 2.4 Motion Analysis Arm 1 is a parallelogram mechanism, it has pitch and rotational movement. Pitching arm movement is supported by hinges to achieve the lift cylinder 10, making the body parallelogram linkage E (which led ladle) for plane parallel to the movement, that is, ladle with lifting and sliding movement. Arm of the rotary motion is rotary cylinder 8 to achieve. Installed on the arm a spring 6, by rope and pulley connection with the dumping of bodies 3, used to reset the dumping of bodies, but also have a dampening effect. Die casting machine to meet different allowance parts or control the needs of the best parts, casting ladle capacity of the robot can be adjusted. For large capacity is adjusted by means ladle exchange, release the screws 5 (a total of four), will be able to replace the ladle. For small-capacity adjustment, adjustable electrode B and the distance between the metal surface. Alternatively, you can adjust the screw 5, the ladle was to trace the different tilt angle adjustment. 630 tons die casting machine casting machine hand equipment 4,6,8 kg capacity, ladle three of their structure the same, but sizes vary. 2.5 overall technical program The purpose of graduation is to take what we learned together just scattered, and the flexible use. Now the trend is mechanical and electrical integration, so we graduated design is to machine, electricity, medium among themselves. Machine means machinery, the process of hand movements can be divided into five parts, namely, the rise and fall robot, robot up, dumping, have to rely on rotating machinery to complete. 3 Hand Mechanism Design 3.1 The body design of hand 1. Hand should be sufficient clamping force. In addition to the gravity of the workpiece, but also to not to loose parts in the course of transmission or loss; 2. Clamping range compatible with the workpiece. Gripper for opening and closing angle (open or closed at the claws of two extreme positions during the swing angle) should be able to adapt to the larger diameter clamping; 3. Holding higher precision. Require both the workpiece is positioned within the claw, not a bad clip surface. The general election fast stick in the shape of the workpiece corresponding gripper structure: as per live-shaped piece with a v-shaped grid should be used to locate the gripper; the workpiece surface finish of high carbon, should be set in the gripper on the copper, the central distribution bakelite or other soft pads, etc.; 4. Clamping action should be fast and flexible; 5. Hand playing simple and compact structure, good rigidity, light weight, easy to wear Department should be easy to replace, installed in the wrist or hip to be easy to quickly change. 3.2 Structural Classification of hand Gripper divided into the following three types: 1. Clamp-type gripper: According to the gripper of the power for transformation and translation can be classified into the type; according to the number of fingers can be divided into two-finger and multi-finger style; according to the method of clamping the workpiece can be divided into outer and inner card Expanding the two. 2. Adsorption on the melon; into the vacuum suction type and electromagnetic sucker two. Vacuum suction-type vacuum pump type and meaning into burning compression air. Suction cup is made of rubber or plastic cup, the suction cup inside edge, with 2-3 fold concentric element to ensure the reliability of the adsorption.