芯子隔套(带凸缘筒形件)冲压成形工艺及模具设计
芯子隔套(带凸缘筒形件)冲压成形工艺及模具设计,芯子隔套(带凸缘筒形件)冲压成形工艺及模具设计,芯子,凸缘,筒形件,冲压,成形,工艺,模具设计
中期检查表学生姓名 学 号 指导教师 选题情况课题名称芯子隔套冲压成形工艺及模具设计难易程度偏难适中偏易工作量较大合理较小符合规范化的要求任务书有无开题报告有无外文翻译质量优良中差学习态度、出勤情况好一般差工作进度快按计划进行慢中期工作汇报及解答问题情况优良中差中期成绩评定:所在专业意见: 负责人: 设计任务书系 部: 专 业: 学生姓名: 学 号: 设计(论文)题目: 芯子隔套冲压成形工艺 及模具设计 起 迄 日 期: 指 导 教 师: 任 务 书1本 课题来源及应达到的目的:本设计题目为有凸缘圆筒形件冲压成形工艺及模具设计,通过设计,应对冲压工艺生产较为熟悉,能熟练使用相关设计手册,独立完成一套模具的设计及模具工作零件加工工艺的编制。并且能够运用模具设计软件完成模具装配图及零件图的绘制。2本毕业设计(论文)课题任务的内容和要求(包括原始数据、技术要求、工作要求等):(1)了解目前国内外冲压模具的发展现状;(2)分析筒形件的成形工艺并确定其工艺方案;(3)模具主要设计计算;(4)绘制模具总装图,并绘制零件图;(5)得出设计结论。设计题目:有凸缘圆筒形件冲压成形工艺及模具设计材料:08钢料厚:1.0mm产量:大批量所在专业审查意见:负责人: 年 月 日系部意见:系领导: 年 月 日 说明书 设计题目:芯子隔套冲压成形工艺及模具设计系 部 专 业 班 级 学生姓名 学 号 指导教师 插图清单图2-1制件图3图2-2总工艺方案图 5图2-3 工序图6图2-4 压边结构示意图6图3-1刃口计算示意图12图3-2拉深刃口尺寸13图3-3拉深凸模15图4-1凹模固定板18图4-2定位板18图4-3凸模固定板18图4-4压边圈19图4-5总装图15附表清单表2-1拉深直径计算表7表3-1零件结构尺寸11表4-1模架尺寸简表17表4-2 所选择压力机的相关参数20机械加工工艺过程卡121机械加工工艺过程卡222 芯子隔套冲压成型工艺与模具设计 摘 要:本论文介绍了拉深的成形方法和条件,拉深是利用拉深模在压力机的压力作用下,将平板坯料或空心工序件制成开口空心件的加工方法。旋转体拉深时的应力应变分析,还有拉深过程中的 起皱和拉裂。拉深件毛坯的尺寸计算,和工艺计算,以及拉深次数的计算。 拉深模结构相对较简单。根据拉深模使用的压力机类型不同,拉深模可分为单动压力机用拉深模和双动压力机拉深模;根据拉深顺序分为首次拉深和以后各次拉深;根据工序组合可分为单工序拉深、复合工序拉深和连续工序拉深;根据压料情况可分为有压边装置和无压边装置拉深。从模具设计到零部件的加工工艺以及装配工艺等进行详细的阐述,并应用CAD进行各重要零件的设计。关键词:工艺分析 拉深成型 模具装配 模具结构The core sleeve of stamping forming process and die design Abstract:The paper introduced to pull to take shape method and condition deeply, pulling is the pressure function that the exploitation pulls a deep mold in the pressure machine deeply under, anticipate flat panel or the hollow work preface piece make in to open mouth a hollow piece to process a method.Revolving the body pulls deep hour of should dint contingency analysis, also have already pulled deep process in of shrivel and pull crack.Pull a deep piece the size calculation of the semi-finished product, and the craft compute, and pull the calculation of deep number of times. Pull deep mold structure opposite more simple.According to pull the pressure machine type dissimilarity that the deep mold uses, pulling the deep mold can is divided into a list to move pressure machine to use to pull deep mold and double to move pressure machine to pull a deep mold;According to pull deeply in proper order is divided into for the very first time pull deeply with later each one pull deeply;According to the work preface combination can is divided into a single work preface to pull deeply, compound the work preface pull to deeply pull with continuous work preface deeply;According to pressing to anticipate a circumstance can is divided in to press side device and dont press side device to pull deeply.Design to zero partses to process a craft and assemble crafts etc. to carry on to elaborate in detail from the molding tool, and the design applied CAD to carry on each important spare parts.Keywords: Craft analysis,Pull to model deeply,The molding tool assembles; Molding tool structure 目 录 1 绪 论 .1 1.1 概述 .1 1.2 冲压模具的特点 .1 1.3 拉深工艺特点 .2 1.4 有凸缘筒形件拉深模具设计与制造方面 .2 2 有凸缘筒形件冲压模设计 .3 2.1 工艺分析 .3 2.1.1 计算毛坯尺寸 .3 2.1.2 拉深次数的确定 .4 2.2 工艺方案确定 .5 2.3 必要的工艺计算 .5 2.3.1 坯料分析 .5 2.3.2 确定是否用压边圈 .6 2.3.3 实际拉深直径 .6 2.3.4 拉深凸模与凹模的圆角半径 .7 2.3.5 计算校核拉深高度 .8 2.3.6 压力中心计算 .8 2.3.8 卸料力的计算 .8 2.3.9 拉深力的计算 .9 2.3.10 压边力的计算 .9 3 模具工作部分设计 .11 3.1 工件零件结构尺寸的确定 .11 3.1.2 凹模板长度 L 的计算 .11 3.1.3 其他零件结构尺寸 .11 3.2 工件刃口尺寸的计算 .12 3.2.2 拉深凸模与凹模的尺寸计算 .12 4 模具的总体结构设计 .16 4.1 模具零件的结构设计 .16 4.1.1 导柱、导套 .16 4.1.2 模柄 .16 4.1.3 模具工作部分的计算 .16 4.1.4 模具的闭合高度 .17 4.2 模具总装图 .19 4.3 压力机的类型选定 .20 4.4 机械加工工艺过程卡 .21 结论 .23 致谢 .24 参考文献 .25 心子隔套冲压工艺及模具设计1 绪 论目前,我国冲压技术与工业发达国家相比还相当的落后,主要原因是我国在冲压基础理论及成形工艺、模具标准化、模具设计、模具制造工艺及设备等方面与工业发达的国家尚有相当大的差距,导致我国模具在寿命、效率、加工精度、生产周期等方面与工业发达国家的模具相比差距相当大。1.1概述古人云:没有规矩不成方圆。模具行业是工业的基础行业,工业的各个领域都广泛地使用模具。在电子、汽车、电机、电器、仪器、仪表、家电和通讯等产品中,60%一8%0的零部件都要依靠模具成形。用模具生产零件所表现出来的高精度、高复杂程度、高一致性、高生产率和低消耗,是其他加工制造方法所不能比拟的。模具又是“效益放大器”,用模具生产的最终产品的价值,往往是模具自身价值的几十倍、上百倍。模具生产技术水平的高低,在很大程度上决定着产品的质量、效益和新产品的开发能力,并且己成为衡量一个国家产品制造水平高低的重要标志。模具作为工业生产的基础工艺装备,在国民经济中占有重要的地位。近10年来,模具CAD技术发展很快,应用范围日益扩大。模具CAD技术给模具的设计和制造提供了一个高效、经济而且快速的方法,大幅度地提高了模具的质量,缩短了模具的设计和制造周期,降低了模具成本。1.2冲压模具的特点冷冲压生产靠压力机和模具完成加工过程,与其他加工方法相比,在技术与经济方面具有下列特点:(1)冷冲压是少、无切屑加工方法之一,所获得的冲压件一般无需再加工。(2)普通压力机每分钟可生产几十件,高速压力机每分钟可生产千件以上,是一种高效率的加工方法。(3)冲压件的尺寸精度由模具保证,所以质量稳定,互换性好。(4)冷冲压可以加工壁薄、重量轻、刚性好、形状复杂的零件,为其他加工方法所不能替代。另外,冷冲压加工不需加热、无氧化皮,表面质量好,操作方便,费用较低。由于具有上述突出特点,冷冲压在生产中得到了广泛的应用。全世界的钢材中,有6070是板材,其中大部分是经过冲压制成。汽车的车身、底盘、油箱、散热器片,锅炉的汽包、容器的壳体,电机、电器的铁芯硅钢片等都是冲压加工的。仪器仪表、家用电器、自行车、办公器械、生活器皿等产品中,也有大量冲压件。冷冲压可加工各种类型的产品,尺寸从小到钟表的秒针,大到汽车的纵梁、覆盖件;冲切厚度已达20 mm以上,加工尺寸幅度大,适应性强。1.3拉深工艺特点拉深是利用拉深模具将平板毛坯压制成各种开口的空心工件,或将已制成的开口空心件加工成其他形状空心件的一种冲压加工方法。其形变过程是:随着凸模的不断下行,留在凹模端面上的毛坯外径不断缩小,圆形毛坯逐渐被拉进凸、凹模间的间隙中形成直壁,而处于凸模下面的材料则成为拉深件的底,当板料全部进入凸、凹模间的间隙里是拉深过程结束,平面毛坯就变成具有一定的直径和高度的杯形件。与冲裁模相比,拉深凸、凹模的工作部分不应有锋利的刃口,而具有一定的圆角,凸、凹模间的单边间隙稍大于料厚。用拉深工艺可以制得筒形、阶梯型、球形、锥形、抛物线型等旋转体零件1.4有凸缘筒形件拉深模具设计与制造方面拉深是冲压基本工序之一,它是利用拉深模在压力机作用下,将平板坯料或空心工序件制成开口空心零件的加工方法。它不仅可以加工旋转体零件,还可以加工盒形零件及其他形状复杂的薄壁零件,但是,加工出来的制件的精度都很低。一般情况下,拉深件的尺寸精度应在IT13级以下,不宜高于IT11级。只有加强拉深变形基础理论的研究,才能提供更加准确、实用、方便的计算方法,才能正确地确定拉深工艺参数和模具工作部分的几何形状与尺寸,解决拉深变形中出现的各种实际问题,从而,进一步提高制件质量。有凸缘圆筒形件冲压成形工艺及模具设计是典型的拉深件,其工作过程很简单,先落料再拉深,根据计算确定它可以五次拉深成功。2 有凸缘筒形件冲压模设计2.1工艺分析图2-1 制件图25原始资料:如图所示 生产批量:大批量 材 料: 08钢厚 度: 1.0mm 此工件为带凸缘筒形件,要求外形尺寸,没有厚度不变的要求。公差等级为 IT13级。工件底部圆角半径4mm,外形尺寸为75mm查得其公差为0.54mm,内形尺寸为56mm,其公差为0.46mm属于小型零件。工件高度60mm,其公差为0.46mm可在拉深后采用修边达到要求。 2.1.1计算毛坯尺寸根据附图所示,D=dt=75mm,d=(56-1)=55mm。由凸缘的相对直径dt/d=75mm/55mm=1.36,查表4.10得,h=3.5mm. 由表4-7序号4中得有凸缘圆筒形件的毛坯直径为: Dp= dt2-1.72(r1+r2)d-0.56(r22-r12)+4dH 1/2将dt=75, r1=r2=3+t/2=(3+1/2) mm=3.5mm, d=(56-1)=55mm, H=(60-1) mm=59mm代入上式中,得毛坯的直径为: Dp= 752-1.72(3.5+3.5)55+45559 1/2mm =153mm2.1.2拉深次数的确定(1)判断能否一次拉成工件总的拉深系数m总=dD=55 mm153 mm =0.36 ,工件总的拉深相对高度Hd=59 mm55mm =1.07。 由dtd=75mm55mm=1.36,tD100=1mm153mm100=0.65,查表4.3得,有凸缘圆筒形件第一次拉深的极限拉深系数m 1=0.55;由表4.5查得,有凸缘圆筒形件首次拉深的极限相对高度h 1d1=0.67,由于m总m 1,Hdh 1d 1,故此工件不能一次拉出。(2)试制订首次拉深系数取首次d凸d 1=0.94,查表4.3得m 1=0.55,而第一次拉深系数m 1= d 1D,则第一次拉深的半成品直径为d 1= m 1 D=0.55153mm=84.15mm。第一次拉深的凹模圆角半径用式计算 r凹1=0.8将D=153mm, d1=84.15mm,t=1mm代入上式得,凹模的圆角半径r凹1=6.6mm,则r 1= r凹1+t2=(6.6+12)mm=7mm,并取r凸1= r凹1,则r 2= r 1=7mm,根据工件圆角重新调整凸、凹模的圆角,取为r凸1= r凹1=7-12=6.5 mm.工件的第一次相对高度(H 1d 1)工件=60 mm84.15 mm=0.71(3)确定拉深次数 因为tD100=0.61.5,m 1=0.550.6,由表4.4.4查得需要用压料装置。 由于有凸缘圆筒形件在以后各次拉深中的拉深系数可由表4.3选取,且取值应略大些。 根据毛坯的相对高度(tD)100=(1mm153 mm) 100=0.6,由表4.3【2】可取值为m 2=0.78,m 3=0.80。各次拉深时半成品的直径为:1530.55=84.1584.150.78=64.54(调整为64mm)640.8=51.2选定d 3为工件的直径65 mm。查冲压工艺与模具设计表4-15可得n=3,初步确定需要三次拉成。2.2工艺方案确定拉深件的工艺计算是拉深工艺设计中的一个环节,本制件的工艺计算属于最简单的。其主要的内容包括计算毛坯直径、决定拉深次数及确定工序件的尺寸等。第一步是落料,然后进行两次拉深。由于本工件每次拉深都有余料返回凸缘,为了去掉筒壁上的压痕和凸缘上的波纹,须加一次整形工序,最后是修边。图2-2 总工艺方案图本说明书针对第二次拉深进行设计。2.3必要的工艺计算2.3.1坯料分析在工序二中拉深工序的毛坯为直径96.276mm的杯形件,手工送料放到定位圈,再由压边圈进行精定位。图2-3 工序图2.3.2确定是否用压边圈相对厚度T/D%=1/153%=0.65%,查表1-4得,需要采用压边圈。一般采用平面压边装置。首次拉深时一般采用平面压边装置。再次拉深时,采用筒形压边圈。一般来说再次拉深所需要的压边力较小,而提供压边力的弹性力却随着行程而增加,所以要用限位装置。 首次拉深 再次拉深图2-4 压边结构示意图2.3.3实际拉深直径调整各次拉深系数,使其各次拉深变形程度分配合理。表2-1 拉深直径计算表各次极限拉深系数mn各次实际拉深系数mn拉深系数差m= mnmn各次拉深直径dnm1=0.53m1=0.625+0.095d1=m1 D=0.625153=95.5调整为整数m2=0.76m2=0.85+0.09d2=m2 d2=0.8595.58=81.2482m3=0.79m3=0.80+0.01d3=m3 d3=0.8082=652.3.4拉深凸模与凹模的圆角半径凸模、凹模的选用在制件拉深过程中有着很大的作用。凸模圆角半径的选用可以大些,这样会减低板料绕凸模的弯曲拉应力,工件不易被拉裂,极限拉深因数会变小些;凹模的圆角半径也可以选大些,这样沿凹模圆角部分的流动阻力就会小些,拉深力也会减小,极限拉深因数也会相应减小。但是凸、凹模的圆角半径也不易过大,过大的圆角半径,就会减少板料与凸模和凹模端面的接触面积及压边圈的压料面积,板料悬空面积增大,容易产生失稳起皱采用压边圈,考虑到实际采用的拉深系数均接近其极值,凹模圆角半径: 公式表4.58手册参考文献4计算拉深凸模和凹模的圆角半径并化整。将D=153mm,=96mm,t=1.0mm代入上式得,凹模的圆角半径:=0.8mm=6.04mm 则= +t/2=(6.04+1.02)mm=6.54,取=6.5mm,根据工件圆角重新调整凸、凹模的圆角,取为=6.5-1.0/2=6mm。由冲压工艺与模具设计式(4-49)和式(4-50)即: r=(0.70.8) r和r=(0.70.8)r 计算各次拉深凹模与凸模的圆角半径,分别为: R凹1=6mm R凸1=5mmR凹2=5mm R凸2=4mmR凹3=4mm R凸3=3mm 2.3.5 计算校核拉深高度并由式(19.4-10)5,第一次拉深高度 所以51.75mm 许可最大相对高度=0.50.6=0.43所以安全同样可以计算出第二、三次拉深高度 h2=52.72mm、h3=70mm2.3.6压力中心计算因为本制件是轴对称零件,所以压力中心为其轴对称中心。2.3.8卸料力的计算 F卸1=K卸F落F卸1=K卸F拉2式中:K卸卸料力因数。其值由表2.32【1】查得K卸=0.040.05卸料力为: F卸1=0.05562.25=28.26KNF卸1=0.0522=1.1 KN2.3.9拉深力的计算首次拉深时拉深力= 二次拉深时拉深力=1.3(d1-d2)tb 式中:为首次拉深与二次拉深时工件的直径; 为材料抗拉强度(MPa); 为修正系数。 查冲压工艺与模具设计表4-1可知:=1;=0.85首次拉深力:= =119.9 KN二次拉深力:=1.3(d1-d2)tb =22KN2.3.10压边力 FQ=AP 式中:A压边圈面积mm2P单位压边力。由表4-163查得P=3.0Mpa A=D坯料的直径,mm; 首次拉伸直径,mm;拉伸凹模圆角半径,mm;A1=9219.8mm A2=187.4mm压边力则为: FQ1=9219.83.0=27.66KNFQ2=187.43.0=0.56KN(1)则复合模总的冲压力为:F总=F落+F卸+F压+F拉 =565.25+28.26+27.66+119.9=741.07KN(2)二次拉深模的冲压力为:F总=F卸+F拉 =1.1+22+0.56=23.66KN(3)初选压力机根据上述公称压力的计算,复合模选用公称压力是800KN的压力机就行了。所以我们可以选择型号为JH21-80的开式可倾压力机。二次拉深模选用公称压力30KN的压力机。在此初选J23-3.15的开式可倾压力机。 3 模具工作部分设计3.1、工件零件结构尺寸的确定3.1.2凹模板长度L的计算 L=D+2C查表2.42【1】可知:C取40mm故: L=D+2C =85+240=210由于凹模固定在凹模固定板上,故L=210+223=256250故确定凹模板外形尺寸为:25025052 (mm)。 凸模板尺寸按配作法计算。3.1.3其他零件结构尺寸表3-1 零件结构尺寸序号 名称长宽厚(mm)材料数量1定位板2562045钢12凸模固定板2203545钢13凹模固定板2566045钢14压边圈2204545钢13.2工件刃口尺寸的计算刃口尺寸按凹模实际尺寸配作,用配作法,因此凸模基本尺寸与凹模尺寸相同,保证单边间隙(mm) 图3-1 刃口计算示意图3.2.2拉深凸模与凹模的尺寸计算(1)第一次拉深第一次拉深模,由于其毛坯尺寸与公差没有必要予以严格的限制,这时凸模和凹模尺寸只要取等于毛坯的过渡尺寸即可,以凸模为基准.取公差等级为IT10=0.12mm.根据公式 凸模尺寸 dp=(d+0.4)-p0凹模尺寸 dd=(d+0.4+Zmin)0+ 式中: Dd Dp落料凹模和凸模的刃口尺寸,mmdd dp拉深凹模和凸模的刃口尺寸,mmZmin双面间隙,mm查表2.4【2】单边间隙Z/2=0.05。工件公差,mm凸模和凹模的制造公差,mm凸、凹模的制造公差由表4.56【1】得凹=0.05mm 凸= 0.08mm。 计算出以下尺寸为:拉深凸模尺寸dp =(d+0.4)-p0= 96.056 拉深凹模尺寸dd=(d+0.4+Zmin)0+= 96.276其工作部分结构尺寸如图所示图3-2 拉深刃口尺寸(2)第二次拉深模凸模根据工件外形并考虑加工,将凸模设计成带肩台阶式圆凸凹模,一方面加工简单,另一方面又便于装配与修模,采用车床加工,与凸模固定板的配合按H7/m6。凸模长度 L=H1+H2+Y式中 H1凸模固定板厚度H2定位板高度H3压边圈高度Y附加长度,包括凸模刃口修磨量,凸模进入凹模的深度52.8mm,因此凸模长度L=35+20+52.8+21+15=143.8mm。具体结构可参见下图9所示。凹模凹模采用整体凹模,各冲裁的凹模孔均采用线切割机床加工,安排凹模在模架上的位置时,要依据计算压力中心的数据,将压力中心与模柄中心重合。取凹模轮廓尺寸为200mm70mm,结构如下图10所示。拉深凸模和凹模工作部分的尺寸及其制造公差:查表得凸凹的制造公差为:凸=0.025mm 凹=0.035mm查表2.6【2】,磨损系数x=0.5,当工件要求内形尺寸:凸模尺寸: d凸=(dmin+0.5)-0凸=(82+0.50.54)0-0.025mm=82.270-0.025 mm凹模尺寸: d凹=( dmin+0.5+2Z) 0+凹 =(82+0.50.54+20.1)0+0.035=82.47 0+0.035mm图3-3 拉深凸模图3-4 拉深凹模4 模具的总体结构设计1)正倒装结构:根据上述分析,本零件为拉深工序,采用正装结构。2)送料方式:因是大批量生产,采用手工送料方式。3)定位装置:本工件在复合模中尺寸是较小的,又是大批量生产,采用固定挡料销定位。首冲时利用条料毛边抵住挡料销定位,送料时废料孔与固定挡料销作为定位,依此保证条料送进的精度。4)导向方式:为确保零件的质量及稳定性,选用导柱、导套导向。由于已经采用了手工送料方式,为了提高开敞性,采用后侧导柱模架。5)卸料方式:本模具采用正装结构,工件因重力从凹模经由模座上的落料孔掉落。工件厚度为1.0mm,为了简化模具结构和达到可靠的卸料力,选用刚性卸料板来卸下条料。4.1模具零件的结构设计4.1.1导柱、导套对于生产批量大、要求模具寿命高的模具,一般采用导柱、导套来保证上、下模的导向精度。导柱、导套在模具中主要起导向作用。导柱与导套之间采用间隙配合。根据冲压工序性质、冲压的精度及材料厚度等的不同,其配合间隙也稍微不同。因为本制件的厚度为1.0mm,所以采用H7/f7。4.1.2模柄 对于小型的冲裁模直接利用模 柄与压力机固定。 4.1.3模具工作部分的计算(1) 拉深模的间隙本模具的拉深间隙查参考文献8得出:有压料圈拉深时单边间隙值查得,Z 12= Z 22= Z 32=1.2t=1.21mm=1.2 mm,Z 42=1.1 t=1.11mm=1.1mm,Z 52=1.05 t=1.051mm=1.05mm。因此各次拉深间隙为:Z 1=2.4mm,Z 2=2.4mm,Z 3=2.4mm,Z 4=2.2mm,Z 5=2.1mm。(2)选用模架、确定闭合高度及总体尺寸选用后侧导柱模架,其两导柱、导套分别装在上下模座后侧,凹模面积是导套前的有效区域。可用于冲压较宽条料,送料及操作方便,可纵向横向送料。再按其标准选择具体结构尺寸见表15.215.4【1】。表4-1 模架尺寸简表名称尺寸材料热处理上模座25025050HT200下模座25025065HT200导柱3523020渗碳5862导套4812520渗碳58624.1.4模具的闭合高度H闭=H上+H凸模固+H凸模固+H定位板+H压边圈+H下 =60+35+20+70+90+15=290mm式中:H凹模固凹模固定板厚度,H凸模固=60mm; H凸模固凸模固定板厚度,H凸模固=35mm; H定位板定位板厚度,H定位板=20mm; H压边圈定位板厚度,H压边圈=15mm;H上上模座的厚度,H上70mm; H下下模座的厚度,H下90mm;根据表格15.215.4【1】选择GB/T2855.5,GB/T2855.6,符合要求。 凹模固定板厚度取60mm,即H凹模固=60mm,如图所示: 图4-1 凹模固定板定位板板厚度取20mm,即H定位板=20mm,如图所示:图4-2 定位板凸模固定板板厚度取35mm,即H凸模固=35mm,如图所示: 图4-3 凸模固定板压边圈板厚度取35mm,即H压边圈=15mm,如图所示:图4-4 压边圈4.2模具总装图由以上设计,可得到模具的总装图,其工作过程是:将maopei坯料放入定位板中, 压力机滑块带着上模下行,凸模下表面压住坯料内底进行拉深拉深;当拉深结束后上模回程,拉深后的工件由凹模突出部分从凸模上卸下,掉落。图4-5 总装图1、 下模座 2、螺钉 3、导柱 4、导套 5、压边圈 6、上模座 7、螺钉 8、弹簧 9、模柄 10、螺钉 11、凸模 12、螺钉 13、凸模固定板 14、定位板 15、凹模 16、凹模固定板 17、螺钉 18、销钉模柄9固定在压力计滑块上,上模座6随压力机上行,将杯形坯料人工放置到定位板14中,压边圈5、凸模11随滑块下行,压边圈5进入坯料精定位,在弹簧8作用下将坯料压紧在凹模15上,凸模下行接触到坯料,继续下行,坯料开始变形。坯料被凸模11压成制件后,凸模上行,制件由于凹模凸出部分的作用,从凸模上脱落。4.3压力机的类型选定压力机的工作行程需要考虑工件的成形和方便取件。工作行程根据拉深力的计算结果和工件的高度,选择压力机: 查参考文献6开式可倾压力机参数初选压力机型号为J23-3.15开式固定台压力机,对比后发现虽然公称压力该型号压力机满足要求,但封闭高度、柱间距、工作台尺寸均小于要求,J23-40开式固定台压力机,选择见下表:表4-2 所选择压力机的相关参数公称压力/KN400滑块行程/mm80行程次数(次/min)55(最大闭合高度)固定台和可倾/mm330闭合高度调节量/mm65(标准型)滑块中心到机身距离(吼深)/mm250 (标准型)工作台尺寸(左右前后)/mm460700模柄孔尺寸(直径深度)/mm5070电动机功率/kW5.54.4机械加工工艺过程卡 机 械 加 工 工 艺 过 程 卡 1 模具号零件号零 件 名 称00-07凹模ZYD-01牌 号硬 度Cr12MoV58-64HRC工序号工 序 名 称设 备夹 具刀 具量 具工 时名 称型 号名 称规 格名 称规 格名 称规 格01下料02锻造达尺寸17047mm蒸汽锤直尺03粗车端面和外缘面达尺寸160.545.5mm车床游标卡尺04磨上下表面平面磨床磁力夹具砂轮游标卡尺刀口尺05精车端面和外缘面达尺寸16045mm车床高度尺、游标卡尺06车82.47孔,车床07热处理58-64HRC热处理炉硬度仪,游标卡尺09钳工研磨各型孔达尺寸要求游标卡尺10检验游标卡尺编制 校对 审核 批准 机 械 加 工 工 艺 过 程 卡 2 模具号零件号零 件 名 称00-04凸模ZYD-01牌 号硬 度T10A58-60HRC工序号工 序 名 称设 备夹 具刀 具量 具工 时名 称型 号名 称规 格名 称规 格名 称规 格01下料02锻造达尺寸100145mm蒸汽锤直尺03粗车端面和外缘面达尺寸94.5144mm,粗车阶梯车床游标卡尺04磨上下表面平面磨床磁力夹具砂轮游标卡尺刀口尺05精车端面和外缘面达尺寸94143.8mm,精车阶梯车床高度尺、游标卡尺06钻5孔钻床07热处理58-60HRC热处理炉硬度仪游标卡尺09钳工研磨达尺寸要求游标卡尺10检验游标卡尺编制 校对 审核 批准 结论带凸缘筒形件属于简单拉深件,分析其工艺性,并确定工艺方案。本设计主要是计算拉深时的间隙、工作零件的圆角半径、尺寸和公差,并且还需要确定模具的总体尺寸和模具零件的结构,然后根据上面的设计绘出模具的总装图。 由于在零件制造前进行了预测,分析了制件在生产过程中可能出现的缺陷,采取了相应的工艺措施。因此,模具在生产零件的时候才可以减少废品的产生。 带凸缘筒形件的形状结构较为简单,模具工作零件的结构也较为简单,它可以相应的简化了模具结构。以便以后的操作、调整和维护。带凸缘筒形件模具的设计,是理论知识与实践有机的结合,更加系统地对理论知识做了更深切贴实的阐述。也使我认识到,要想作为一名合格的模具设计人员,必须要有扎实的专业基础,并不断学习新知识新技术,树立终身学习的观念,把理论知识应用到实践中去,并坚持科学、严谨、求实的精神,大胆创新,突破新技术,为国民经济的腾飞做出应有的贡献。致谢时光如电,岁月如梭,大学三年一晃而过,而我也即将离开我们尊敬的老师、友好的同学和熟悉的校园走进社会。在这毕业之际,作为一名工科的学生,毕业设计是一件必不可少的事。毕业设计涉及的知识广泛,很多都是我门的教科书上没有的,这就需要自己到图书馆查找所需的资料。在设计中,涉及很多计算的问题,必须通过所学知识、相关的资料及自己的不断努力才能解决。在学校中,我们所学的主要是理论性知识,实践性比较欠缺,而毕业设计就相当于实战前的一次演练。通过毕业设计,可以把我们以前学的专业知识系统地联系起来,使我们既温故又学到更多新的知识;这不但提高了我们解决问题的能力,开阔了我们的视野,在一定程度上弥补我们实践经验的不足,为以后的工作打下坚实的基础。由于资质有限,很多知识掌握的不是很牢固,在设计的过程中难免要遇到很多问题,但经过课程设计,使我们有了一定的设计的经验;同时在老师的悉心指导及同学的热心帮助下,我克服了一个又一个的困难,使我的毕业设计不断完善。在此,我在设计中不断思考问题,研究问题,咨询问题,汲取了更系统的专业知识,使自己的能力得到很大程度的提高。最后,再次感谢翟德梅教授等在这一段时间给予无私的指导和帮助,并向你们致以深深的敬意!在以后的工作上,不辜负你们对我们寄予的厚望!参考文献1 郝滨海主编.冲压模具简明设计手册M.北京:化学工业出版社,20042 原红玲主编.冲压工艺与模具设计M.北京:机械工业出版社,20103 翟德梅主编.模具制造技术M.北京:化学工业出版社,20054 王孝培主编.冲压手册M.北京:机械工业出版社,19905 李学锋主编.模具设计与制造实训教程M.北京:化学工业出版社,20047 马宵.互换性与技术测量M.南京:南京大学出版社, 20058 寇世瑶主编.机械制图M.北京:高等教育出版社,2007* , Taiwan, of punch top Our use drawing dies for trunk lid outer panels and engine hood outer panels as concrete examples to showcase the power of our system. Experimental results show that our system can improve the design quality and reduce the design time and cost. expectation. Die design is part of the critical path of the entire development process. There are three categories of the die in design, which fundamentally reduced design time. However, most 3D CAD software only provides users with oped an expert system based on a configuration design method. This system allows users to design mechanical Solid Works using Visual C+. Chu, Song, and Luo (2006) developed a Computer aided parametric design sys- tem for 3D tire mold production in CATIA using CAA. In the stamping die design area, Cheok and Nee (1998) developed a knowledge based strip layout design system in AutoCAD. Taking advantage of neural network and CAD * Corresponding author. Tel.: +886 76 6011000; fax: +886 7 6011066. E-mail addresses: bt_linccms.nkfust.edu.tw (B.-T. Lin), u9314805 ccms.nkfust.edu.tw (S.-H. Hsu). Available online at Expert Systems with Applications stamping dies, based on their functionalities: drawing dies, trimming dies, and bending dies. Since most stamping dies for automotive sheet metals are big and complex, the stamping die design process is very time-consuming. Recently, as a result of the fast development of com- puter technology and of 3D CAD software, 3D CAD soft- ware has been widely used in designing drawing dies. A solid model oers users an intuitive and concrete view of products in a 3D environment. Roh and Lee (2006) pro- posed a hull structural modeling system for ship design, which was developed using C+ and built on top of 3D CAD software. Lee, Hsu, and Su (1999) developed a para- metric computer-aided die design system for cold forging using Auto-LISP. In order to make the modeling process more ecient, Kong et al. (2003) developed a Windows- native 3D plastic injection mold design system based on C211 2007 Elsevier Ltd. All rights reserved. Keywords: Drawing dies; Design system; CAD; Knowledge base; Parametric modeling 1. Introduction Press parts, such as frames, bodies, and doors, are widely used in the automotive industry. In order for a man- ufacturer to survive in todays competitive market, the development process of a vehicle needs to be carried out in an ecient and eective way in order to meet customers geometric modeling functions for constructing a solid model, but fails to oer a powerful design knowledge base, which is essential to assist engineers in accomplishing the design task. As a result, the developments of automated, knowledge base and intelligent design systems are studied by research- ers from around the world. Myung and Han (2001) devel- Automated design system Bor-Tsuen Lin Dept. of Mechanical and Automation Engineering, National Kaohsiung 824, Abstract This paper describes an automated design system for drawing dies. base, this system is able to output designs of the main components upon users input of design information of blank lines, die faces, hooks, guides, and stopper seats. This die design system is built on Part Design, Automation and Scripting, and Knowledge Advisor. 0957-4174/$ - see front matter C211 2007 Elsevier Ltd. All rights reserved. doi:10.1016/j.eswa.2007.01.024 for drawing dies Shih-Hsin Hsu Kaohsiung First University of Science and Technology, ROC Taking advantage of pre-built design knowledge base and data- a drawing die, such as upper dies, lower dies and blank holders, open lines, press data, and types of subcomponents such as of CATIA V5, and makes use of its built-in modules, including system also includes an inference engine, and user interfaces. We 34 (2008) 15861598 Expert Systems with Applications software, Pilani, Narasiman, Maiti, Singh, and Date (2004) proposed a method for automatically generating an optimal die face design based on die face formability parameters. Ismail, Chen, and Hon (1996) developed a fea- ture-based progressive press tool using cheap CAD soft- ware. Based on sheet metal operations, Singh and Sekhou (1999) developed a punch machine selection expert system, which was built in AutoCAD and used AutoLISP. Tisza (1995) developed an expert system for detail process plan- ning of metal forming in AutoCAD. Though the design process of drawing dies is extremely complex and requires a great deal of professional knowl- edge, the purpose of this paper is to develop an automated design system for drawing dies. Taking advantage of well- organized die design knowledge base and database and an integrated 3D CAD environment, our system is able to out- put designs of the main components of a drawing die, such as upper dies, lower dies and blank holders, upon users input of design information of blank lines, die faces, punch open lines (POL), press data, and types of subcomponents U-groove Triangle Rib Guide Stopper Seat Hook Auxiliary Plate Dieface Thickness Lower Die Size Hook Guide Cushion Pin Seat Stopper Seat Blank Holder Size Panel Guide Seat Avoid Structure Safety Area Avoid Structure B.-T. Lin, S.-H. Hsu / Expert Systems with Applications 34 (2008) 15861598 1587 U-groove Key-groove Auxiliary Plate Triangle Rib Lower Die Size Fig. 1. Structure of main components for a drawing die. Guide Safety Area Cushion Pin Hole Stopper Seat Hook Dieface Thickness (a) Upper die. (b) Blank holder. (c) Lower die. such as hooks, guides, and stopper seats. Experimental results show that our system can generate high quality design of main components of a drawing die in an ecient way. 2. Drawing die design 2.1. Drawing die configuration Drawing is a process of cold-forming a flat precut metal blankintoahollowvesselwithoutexcessivewrinkling,thin- ning, or fracturing (Wick, Benedict, 33 categories subcomponents with 42 dierent types are listed inoursystem.Theunderstandingoftherelationshipamong various subcomponents is vital to obtain an appropriate design process for each of the subcomponents. Detailed modeling processes for each subcomponent, as well as geo- metricoperationsusedinsuchprocesses,areavailableinthe knowledge base. Also, design guidelines and 3D diagrams with design parameters, itemized text, and formulas are stored as e-books for training, debugging, and reference purposes. 3.4. The design database The design database oers subcomponent specifications and press machine specifications. The subcomponent spec- ifications specify the sizes of each of the subcomponents, while the press machine specifications specify size of the bolster, maximum and minimum of the die height, maxi- mum die width, positions and sizes of T grooves and cush- ion pin holes, and cushion pin strokes. The design database has 44 types of subcomponent design specifications, which fall into 33 categories. The design specifications for each of the subcomponents are illustrated in 2D diagrams. In addition, each diagram is accompanied by a table that summarizes the related shape parameters and standard sizes. The design database oers four sets of press machine specifications, which are pre- sented in 2D diagrams. All information in the design data- base is stored as e-books for easy access. 3.5. CAD software Our system is developed based on CATIA V5 CAD soft- ware in the Windows XP operating system. This system is designed to be used in a PC, and is developed using the CATIA softwares built-in modules. The Part Design mod- ule is responsible for controlling and executing the process of constructing 3D models. Therefore, this module is used to build the inference coordinator. The Knowledge Advisor 1592 B.-T. Lin, S.-H. Hsu / Expert Systems with Applications 34 (2008) 15861598 Fig. 8. The layer tree of drawing die. module allows users to embed related knowledge into the design, which increases the productivity of design engi- neers. The subcomponent selector takes advantage of the Formula Editor and Rule Editor functions, while the shape calculator uses the Design Table function. The Automation and Scripting module oers a user-customized interface for CAD software. The model generator makes use of Visual Basic for Application (VBA) to develop programs for gen- erating solid models. The user interface also uses VBA to construct alphanumeric and graphic input interfaces. 4. Modeling process of the automated design system This system is built on top of the CATIA CAD system, and takes advantage of various CATIA built-in modules. Upon users input of the design information, our system Fig. 9. Sample die. B.-T. Lin, S.-H. Hsu / Expert Systems with Applications 34 (2008) 15861598 1593 Fig. 10. Program design. is able to automatically generate the solid model design of main components of a drawing die in an ecient and flexi- bleway.Fig.5showsthemodelingprocess.Eachstepofthe modeling process is detailed in the following sections. 1594 B.-T. Lin, S.-H. Hsu / Expert Systems with Applications 34 (2008) 15861598 Fig. 11. Interface for replace procedure of graphic data. (a) Load a graphic data. (b) Active replace window. (c) Ready for update. the design process, which makes programs more concise. Therefore, appropriate number of parameters is vital to the entire design process. All of the changeable dimensions are treated as parameters, whose values can be changed based on design requirements. Since the values of the dimension parameters cannot be non-positive, all possible situations should be taken into consideration to avoid any potential problems, especially when there are cause-and- eect relationships among the various subcomponents. 4.4. Parameter settings There are hundreds of parameters in our automatic design system, which demands a systematic naming schema so that parameters can be well managed to facilitate coding and debugging. The name of a parameter used in our sys- tem consists of two parts: the name of the part to which the parameter belongs, and the name of the dimension. Based on the parameters functionality, they can be divided into shape parameters and position parameters. Shape parameters can be further classified as dependent parameters and independent parameters. Independent with Applications 34 (2008) 15861598 1595 4.1. Die structure analysis Drawing dies for the automotive industry are very large, and have very complicated structures. Moreover, each sub- component has its own functionality. Therefore, before developing the design system, we collected various struc- tures of drawing dies for automotive sheet metals, and ana- lyzed their architectures and functions. Fig. 6 shows a classification of the subcomponents of a typical drawing die based on their functionality. The parameterized die design system treats the change- able dimensions of a die as parameters, and generates the final design by assigning appropriate values to each of the parameters based on design formulas, constraints and tables derived from the design guidelines and specifications. However, certain data and subcomponents, such as press machines, hooks, guides, and stopper seats, cannot be designed simply by changing the design parameters because of the diversity of their structures. Therefore, we pre-build the interfaces and structures of a sample die for all subcom- ponents that share the same functionality based on design guidelines and specifications. 4.2. Design process standardization The purpose of design process standardization is to pro- vide a systematic way of designing dies. Since the CAD sys- tem has its own modeling process, the size and position of design subcomponents cannot be determined until the size and position of certain subcomponents are fixed. A stan- dardized design process, as shown in Fig. 7, is generated based on the design guidelines and specifications of each of the subcomponents, as well as the cause-and-eect rela- tionships among these subcomponents. This standardized process is used to guide the design of main components of sample dies, such as their structures and initial sizes, as well as the initial sizes and positions of each subcompo- nent on a main component. 4.3. Sample die construction Once a standardized design process is obtained, a fea- ture layer tree and sample dies are developed based on the design process, as shown in Figs. 8 and 9. A typical die face consists of thousands of surfaces. In order to ensure the stability of a sample die, simple die faces are used to construct sample dies. Since various subcompo- nents of a drawing die can share a common functionality, all possible subcomponent structures of a function must be pre-constructed when constructing sample dies. When constructing a solid model of a die, only the selected sub- components should be activated. All unselected subcompo- nents should be deactivated. When constructing sample dies, design engineers should make use of all available parameters and pre-set sizes. The B.-T. Lin, S.-H. Hsu / Expert Systems numberofparametershasadirectimpactonthedesignflex- ibility.Inmostcases,thenumberofparametersdecreasesin Fig. 12. Alphanumeric data interface. parameters only need to meet the design guidelines, while dependent parameters are determined by both the design specifications and any relevant independent parameters. Taking the bolt type hook shown in Fig. 3 as an example, the diameter of the hook bolt, d, is an independent param- eter, while the other measures, such as Y, X, r, t, l, and R, are dependent parameters. 4.5. Programming Once the parameters have been identified, the relation- ships among various parameters need to be formulated based on design guidelines and specifications. These rela- tionships are further converted into programs. Programs are divided into three levels in order to facilitate the design process. Taking the bolt type hook as an example, the purpose of the first level is to select subcomponents based on design guidelines. This level of program takes advantage of two built-in modules of CATIA V5, Rule Editor and Formula Editor, to convert design guidelines into constraints and formulas respectively, which are used to determine the quantity, position and size of subcomponents, as shown in Fig. 10a and b. The second level of the program is responsible for calcu- lating the values of shape parameters of the die. This level takes advantage of the built-in modules of CATIA V5 to construct the design table of the die based on the design specifications of each subcomponent, so that this level of the program can use the design table and related indepen- dent to determine dependent parameters, as shown in Fig. 10c. The third level of the program is used to construct of the model. Written by VBA, this level of program is used to provide a modeling procedure of subcomponents based on determined the type and size of aforementioned two lev- els, as shown in Fig. 10d. 4.6. User interfaces User interfaces allow users to accomplish the design process in an intuitive and interactive way. The user inter- faces used in our system can be classified into two categories. 1596 B.-T. Lin, S.-H. Hsu / Expert Systems with Applications 34 (2008) 15861598 Fig. 13. Design process of the proposal system. (a) Sample die. (b) Graphic data outer panel. interface. (c) Alphanumeric data interface. (d) Drawing die for trunk lid ns with The first category is used to input graphic information, suchasblanklines,diefacesandPOLs.Thissetofinterfaces is using Replace, which is a built-in function of CATIA V5. Following are the procedures for replacing sample graphic information. First, start the automated design system, and Fig. 14. Compariso B.-T. Lin, S.-H. Hsu / Expert Systems load the desired graphic information into the design envi- ronment. Click on the layer tree representation of the sam- ple graphic information, as shown in Fig. 11a, and open theReplacewindow,asshowninFig.11b.Selectthedesired graphic information of the die and click OK. The color of the die turns to red when it is being updated, as shown in Fig. 11c. The second category is used to input alphanumeric information, such as types of press data, guide mechanism, and hooks and stopper seats, as shown in Fig. 12. Imple- mented using VBA, a drop-down menu allow users to select the appropriate types of subcomponents for the die. Design engineers only need to select the desired press machine and types of subcomponents, and click OK; the system is able to automatically complete the design. 5. Case study We use the design of drawing dies for a trunk lid outer panel as a concrete example to showcase the power of our system. A standard structure diagram of sample dies is dis- played when the system starts, as shown in Fig. 13a. Upon receiving graphic information from the user, our system uses CATIAs built-in Replace function to replace the gra- phic information using the layer tree of the sample die, as shown in Fig. 13b. Then, users begin to input alphanumeric information, such as the types of press machines, guide mechanism, hooks, and stopper seats, as shown in Fig. 13c. After users click OK, our system begins to gener- ate the design based on the design processes, guidelines and specifications. The final design of the drawing die is shown of die structures. Applications 34 (2008) 15861598 1597 in Fig. 13d. Fig. 14 presents a comparison of two dierent drawing dies, a drawing die for trunk lid outer panels and a drawing die for engine hood outer panels, to show that our system can handle a wide range of designs. 6. Conclusions and future works This paper presents an automated design system for drawing dies, which is built on top of CATIA CAD soft- ware. Upon receiving the initial design information from design engineers, such as blank lines, die faces, POLs, and press data, as well as the types of hooks, guide mech- anism, and stopper seats, the system is able to automati- cally generate the final design of main components of the die, such as upper dies, lower dies, and blank holders. Design formulas and geometric operations of modeling processes are generated by the system using the built-in modules of CATIA V5, such as Part Design, Automation and Scripting, and Knowledge Advisor. Experimental results show that our system has successfully reduced the design time from several working days to within one hour when designing a drawing die for trunk lid outer panels and engine hood outer panels, which saves a great deal of development time and cost and achieves high product quality and design flexibility. In the future, an optimization module can be introduced into our system, which will enable it to output an optimal design. Moreover, since our system can only handle draw- ing dies at this time, we would like to extend our system to be able to design trimming dies and bending dies. References Cheok, B. T., & Nee, A. Y. C. (1998). Trends and developments in the automation of design and manufacture of tools for metal stampings. Journal of Materials Processing Technology, 75, 240252. Chu, C. H., Song, M. C., & Luo, C. S. (2006). Computer aided parametric design for 3D tire mold production. Computers in Industry, 57, 1125. Ismail, H. S., Chen, S. T., & Hon, K. K. B. (1996). Feature-based design of progressive press tools. International Journal of Machine Tools and Manufacture, 36, 367378. Kong, L., Fuh, J. Y. H., Lee, K. S., Liu, X. L., Ling, L. S., Zhang, Y. F., et al. (2003). A windows-native 3D plastic injection mold design system. Journal of Materials Processing Technology, 139, 8189. Lee, R. S., Hsu, Q. C., & Su, S. L. (1999). Development of a parametric computer-aided die design system for cold forging. Journal of Materials Processing Technology, 91, 8089. Myung, S., & Han, S. (2001). Knowledge-based parametric design of mechanical products based on configuration design method. Expert Systems with Applications, 21, 99107. Pilani, R., Narasiman, K., Maiti, S. K., Singh, U. P., & Date, P. P. (2004). A hybrid intelligent system approach for die design in sheet metal f
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