引线片冲裁件冲裁工艺及模具设计【冲孔落料级进模】
引线片冲裁件冲裁工艺及模具设计【冲孔落料级进模】,冲孔落料级进模,引线片冲裁件冲裁工艺及模具设计【冲孔落料级进模】,引线,片冲裁件冲裁,工艺,模具设计,冲孔,落料级进模
中期检查表学生姓名 学 号 指导教师 选题情况课题名称引线片冲裁件冲裁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: 年 月 日 机 械 加 工 工 艺 过 程 卡 模具号零件号零 件 名 称01-01凹模XYZ-003牌 号硬 度Cr1260-62HRC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110 mm100 mm25mm蒸汽锤直尺03粗铣六面达尺寸100mm90 mm21mm立式铣床虎钳20面铣刀, 游标卡尺04磨上下表面及一直角面平面磨床磁力夹具、精密平口钳砂轮游标卡尺,刀口尺05钳工划线去毛刺做螺纹孔立式钻床虎钳钻头、铰刀、丝锥高度尺、游标卡尺06热处理(淬火、回火)保证硬度60-62HRC热处理炉硬度仪,游标卡尺07磨削上下面及一直角面平面磨床磁力夹具、精密平口钳砂轮游标卡尺,刀口尺08线切割各个型孔留余量0.02mm线切割慢走丝机床复式支撑0.2mm黄铜丝千分表,游标卡尺09检验游标卡尺 编制 校对 审核 批准 说明书 设计题目:引线片冲裁件冲裁工艺及模具设计系 部 专 业 班 级 学生姓名 学 号 指导教师 任务书系 部: 专 业: 学生姓名: 学 号: 设计题目 : 引线片冲裁件冲裁工艺及模具设计 起迄日期: 指 导 教 师: .任 务 书1本课题来源及应达到的目的:本设计题目为引线片冲裁工艺及模具设计,体现了典型冲裁模的设计要求、内容及方向,有一定的设计意义。通过对该零件模具的设计,进一步加强了冲压模设计的基础知识,为设计更复杂的冲压模具做好了铺垫和吸取了更深刻的经验2本毕业设计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、 原始数据名称:引线片冲裁件;生产批量:大批量生产;材料:Q235,t=1.5mm;2、其技术要求为: 1毛刺小于0.15; 2制件要求平整; 3未注明公差等级按IT14选取;所在专业审查意见: 负责人: 年 月 日系部意见:系领导: 年 月 日 机 械 加 工 工 艺 过 程 卡 模具号零件号零 件 名 称00-04凸模XYZ-003牌 号硬 度Cr12MoV58-62HRC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45mm25 mm70mm蒸汽锤直尺03粗铣六面达尺寸40mm20mm60mm立式铣床虎钳10面铣刀, 游标卡尺04磨上下表面及一直角面平面磨床磁力夹具、精密平口钳砂轮游标卡尺,刀口尺05钳工划线去毛刺做螺纹孔立式钻床虎钳钻头、铰刀、丝锥高度尺、游标卡尺06热处理(淬火、回火)保证硬度48-52HRC热处理炉硬度仪,游标卡尺07磨削上下面及一直角面平面磨床磁力夹具、精密平口钳砂轮游标卡尺,刀口尺08线切割各个型孔留余量0.02mm线切割慢走丝机床复式支撑0.2mm黄铜丝千分表,游标卡尺09检验游标卡尺编制 校对 审核 批准 摘 要本设计题目为引线片冲裁模,体现了典型冲裁模的设计要求、内容及方向,有一定的设计意义。通过对该模具的设计,加强了设计者对冲裁模设计基础知识的理解和运用,为设计更复杂的冲裁模具做好了铺垫。本设计运用冲裁工艺及模具设计的基础知识,首先分析了板材的性能要求,为选取模具的类型做好了准备;然后计算了冲裁件的冲裁力,便于选取压力机吨位及确定压力机型号;最后分析了冲裁件的特征,便于确定模具的设计参数、设计要点及卸件装置。本设计采用了冲孔落料级进模成形引线片。成形原理可划分为两个阶段:首先冲孔凸模与凹模共同作用先冲出两个1.85mm和两个6.5mm的孔,而后利用第一步冲出的两个1.85mm和两个6.5mm的孔做精确定位使外形凸模与凹模共同作用使工件落料成形。关键词 冲孔落料级进模,冲孔凸模,凹模,压力机吨位 AbstractThe topic for the design is gasket blanking die design,It has manifested the typical blanking dies design request, the content and the direction, has certain design significance.Through the design of the component mold, strengthens the designers understand and utilize to the blanking die design basical knowledge,has prepareed for designing more complex blanking die.The design has utilize blanking craft and the basical knowledge of the mold design, has first analyzed the property requirement of the plate , has prepared for selecting the mold type;then has calculated the blanking strength,has advantaged to select the press tonnage and determine press model; Finally has analyzed the characteristic of the products, has advantaged to finite the mold design variable,the design main point and shedder. This design used piercing and blanking progressive die to form the products.The forming principle can be divided to two stages: First, piercing punch and die affect together and pierce two holes of1.85mm and two holes of6.5mm,then use the three holes as pinpoint to make the product formed.Key word Piercing and blanking progressive die Piercing punch Press Tonnage 目 录 1 绪 论12 零件工艺性分析32.1 零件要求32.2 材料分析423 结构分析42.4 精度分析43 工艺方案及工艺计算53.1工艺方案确定53.2工艺计算5(1)排样设计5(2)冲裁工艺力的计算73.3初选压力机84 模具的总体设计94.1 模具类型的选择94.2 操作方式94.3 卸料、出件方式9(1)卸料方式9(2)出件方式94.4确定送料方式94.5确定导向方式105 模具零件设计及标准件的选择115.1 工作零件设计11(1)模具间隙11(2)落料凹模和冲孔凸模刃口的制造公差11(3)冲孔凸模12(4)凹模采用整体式结构145.2 其他板类零件的设计145.3 橡胶的选用15(1)根据卸料力求橡胶的横截面积15(2)橡胶的高度尺寸15(3)校核165.4 模柄的选用165.5 导柱与导套的选择165.6 紧固零件的选择165.7 所选设备的校核166 模具总装图177 模具零件加工工艺198 模具的装配22设 计 总 结24致 谢25参考文献26IV 评语学生姓名: 班级: 学号: 题 目: 引线片冲裁件冲裁工艺及模具设计 综合成绩: 优秀 指导者评语:1)该同学工作态度认真,能按质按量较好的完成毕业设计任务;2)该同学查阅了国内有关冲压模具设计与制造方面的大量资料,制订出了较合理的冲压成形工艺及模具结构,设计中基本不存在创新;3)设计说明书内容完整,计算正确,格式规范;4)该同学装配图、零件图设计合理,图纸问题较少,质量较高;5)建议该同学成绩评定:优秀;6)可以提交答辩。 指导者(签字): 年 月 日 评语评阅者评语:该同学设计题目来源于生产实践,能较好的完成毕业设计任务;工作态度较认真;装配图、零件图设计合理,视图表达存在细节错误;设计说明书内容完整,计算正确,格式规范。建议该同学成绩评定:优秀。;可以提交答辩。 评阅者(签字): 年 月 日答辩委员会(小组)评语: 答辩委员会(小组)负责人(签字): 年 月 日引线片冲裁件冲裁工艺及模具设计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。大学三年的学习即将结束,毕业设计是在完成大学三年的课程学习和课程、生产实习其中最后一个实践环节,是对以前所学的知识及所掌握的技能的综合运用和检验。在学校的近三年学习中,已完成了模具专业教学计划中所要求的理论课程。在毕业前夕,通过毕业设计的实践环节,进行已学知识的全面总结和应用,提高综合能力的培训及扩大模具领域的新知识。毕业设计其目的在于巩固所学知识,熟悉有关资料,树立正确的设计思想,掌握设计方法,培养实际工作能力。通过设计,使我在工艺性分析、工艺方案论证、工艺计算、零件结构设计、编写技术文件和阅读技术文献等方面受到一次综合训练。毕业设计要达到的具体要求是:1.系统总结,巩固过去所学的基础知识和专业课知识。2. 运用所学知识解决模具技术领域内的实际工程问题,以此进行综合知识的训练。3.通过某项具体工程设计和实验研究,达到多种综合能力的培养,掌握设计和科研的基本过程和基本方法。4.提高和运用与工程技术有关的人文科学,价值工程和技术经济的综合知识。改革开放以来,随着国民经济的高速发展,市场对模具的需求量不断增长。近年来,模具工业一直以15左右的增长速度快速发展,模具工业企业的所有制成分也发生了巨大的变化,除了国有专业模具厂外,集体、合资、独资和私营也得到了快速的发展。浙江宁波和黄岩地区的模具之乡;广东一些大集团公司和迅速崛起的乡镇企业,科龙、美的、康佳等集团纷纷建立了自己的模具制造中心;中外合资和外商独资的模具企业现已有几千家。随着我国经济的迅速发展,采用模具的生产技术得到愈来愈广泛的应用。近年来,随着我国经济的腾飞和产品制造业的蓬勃发展,模具制造业也相应进入了高速发展的时期。据中国模具工业协会统计,1995年我国模具工业总产值约为145亿,而2003年已达450亿左右,年均增长14%。另据统计,我国(不含台湾、香港、澳门地区)现有模具生产厂点已超过20000家,从业人员有60万人,模具年产值在一亿以上的企业已达十多家。可以预见,我国经济的高速发展将对模具提出更为大量、更为迫切的需求,特别需要发展大型、精密、复杂、长寿命的模具。同时要求模具设计、制造和生产周期达到全新的水平。我国模具制造业面临着发展的机遇,无疑也面临着更大的挑战。我做的是冷冲压模具设计,冷冲压是利用安装在压力机上的冲模对材料施加压力,使其产生分离或塑性变形,从而获得需要零件(俗称冲压件或冲件)的一种压力加工方法。因为它通常是在室温下进行加工,所以称为冷冲压。冷冲压与其他加工方法相比,具有独到的特点,所以在工业生产中,尤其在大批量生产中应用十分广泛。相当多的工业部门越来越多地采用冷冲压加工产品零部件,如汽车、拖拉机、电器、仪表、电子、国防以及日用品等行业。在这些工业部门中,冲压件所占的比重相当大。不少过去有铸造、锻造、切削加工方法制造的零件,现在已经被质量轻、刚度好的冲压件所代替。通过冲压加工制造,大大提高了生产效率,降低了成本。可以说如果在生产中不广泛采用冲压工艺,许多工业部门的产品要提高生产率,提高质量,降低成本,进行产品的更新换代是难以实现的。在大学三年的课程学习和课程、生产实习,我熟练地掌握了机械制图、机械设计、机械原理等专业基础课和专业课方面的知识,对机械制造、加工的工艺有了一个系统、全面的理解,达到了学习的目的于模具设计这个实践性非常强的设计课题,我们进行了大量的实习。经过在新飞电器有限公司、洛阳中国一拖的生产实习,我对于模具特别是冲压模具的设计步骤有了一个全新的认识,丰富了各种模具的结构和动作过程方面的知识,而对于模具的制造工艺更是有了零的突破。在指导老师的协助下和在工厂师傅的讲解下,同时在现场查阅了很多相关资料并亲手拆装了一些典型的模具实体,明确了模具的一般工作原理、制造、加工工艺。并在图书馆借阅了许多相关手册和书籍,设计中,充分利用和查阅各种资料,并与同学进行充分讨论,尽了最大努力做毕业设计。在设计的过程中,虽然有一定的困难,但在指导老师的细心指导、同学间的讨论和自己的努力下,自信会完满的完成毕业设计任务。由于我的水平有限,而且缺乏经验,设计中难免会出现疏漏和不妥之处,敬请各位老师指正。2 零件工艺性分析2.1 零件要求制件如下图1所示:图1该制件名称为引线片冲裁件,其技术要求为:1、毛刺小于0.15;2、制件要求平整;3、大批量生产;4、材料:Q235,t=1.5mm;5、未注明公差等级按IT14选取;设计任务:完成引线片冲裁工艺及模具设计。2.2 材料分析该制件材料为Q235,属于普通碳素结构钢,由于这种材料含碳量较低,综合性能较好,强度、塑性和焊接等性能得到很好地配合,用途广泛。化学成分():C0.20,Si0.35,Mn1.4,S0.045, P0.045;力学性能:抗剪强度为304373MPa,抗拉强度b432461 MPa,屈服强度s为235MPa,伸长率2125%。23 结构分析该零件结构不复杂,形状对称,零件局部宽度小于料厚,可以直接冲出来,因此零件满足冲裁要求。2.4 精度分析图示零件未标注尺寸公差按IT14选取,即普通冲裁可以达到零件的精度要求。由以上分析可知,该零件的冲裁性能好,冲裁加工能够达到设计要求。3 工艺方案及工艺计算3.1工艺方案确定该零件需要落料和冲孔两道工序完成,可采用的方案有三种:方案一:单工序冲裁,先落料后冲孔;方案二:复合冲裁,落料冲孔同时完成;方案三:级进冲裁,先冲孔在落料;由于是大批量生产,因此方案一不满足生产效率的要求,方案二和方案三都具有较高的生产效率,虽然方案二比方案三操作方便,制件不但要求得到较高的精度和平整度,而且被冲裁板料较薄并不允许产生翘曲,而且冲裁件部分厚度小于料厚,因此采取方案三比较容易冲裁得到,即采用级进冲裁,此方案为先冲出四个孔(两个大孔和两个小孔)和两个相同的矩形,接着进一个工位在冲裁出零件的外轮廓,即落料得到所需要的制件。3.2工艺计算(1)排样设计根据工件形状,这里选用有废料的直对排排样类型,查表3-32得搭边值a1=2mm,侧搭边值a=2.5mm,每个零件的面积经计算得99.9605mm2,根据排样的方案可以得到两种方案: 方案一:条料的宽度B=29+2*2=33mm,进距S=13.72+1.5=15.22mm,查表3-4得,裁板误差=0.5mm,于是得到如图所示的排样图2根据GB/T708-2006可知,这里选用的钢板规格为18001180mm,采用横裁法,则可裁的宽度为33mm的条料54条,每条条料可冲出77个零件;采用纵裁法,则可裁的宽度为33mm的条料35条,每条条料可冲出118个零件。 两者比较得,采用横截法利用率比较高些。方案二: 条料的宽度B=11.51+2*2=15.51mm,进距S=30+1.5=31.5mm,查表3-4得,裁板误差=0.5mm,于是得到如图所示的排样图3根据GB/T708-2006可知,这里选用的钢板规格为18001180mm,采用横裁法,则可裁的宽度为15.51mm的条料116条,每条条料可冲出37个零件;采用纵裁法,则可裁的宽度为15.51mm的条料76条,每条条料可冲出57个零件。;两者比较得,采用横截法利用率比较高些。总和比较上边两种方案可以得出,方案二的利用率稍微高些,但是方案二的送进距离过大,给操作者带来很大的不便,且性价比不高,故而选取方案一作为排样方式。(2)冲裁工艺力的计算 由于采用级进模冲裁,则总的冲裁力为落料力和冲孔力之和, 其中: =Ktt=1.3354.62711.5450=47935N; =Kt=1.3326.2191.5450=23007N;则总冲裁力: =2(+)=2(47.935+23.007)=141.884KN;由表3-8查得: =O.045; = F=0.045247.935=4.31KN;由表3-30查得凹模刃口直壁高度为6mm,则n=4。3.3初选压力机由前述计算出冲裁工艺力,可得总的冲压力 =+=141.884+4.31=146194N则选择J23-25开式压力机,主要参数如:公称压力:250000N;最大闭合高度:270mm, 最大装模高度:220mm;闭合高度调节量:55mm;工作台尺寸:370560mm;垫板尺寸:20050mm;模柄孔尺寸:R4060;4 模具的总体设计4.1 模具类型的选择由冲压工艺分析可知,采用级进模冲裁,所以模具类型为级进模。4.2 操作方式零件的生产批量为大批量,但合理安排生产可用手动送料方式,既能满足生产要求,又可以降低生产成本,提高经济效益。4.3 卸料、出件方式(1)卸料方式卸料力分为两种,为刚性卸料和弹性卸料。由于刚性卸料是采用固定卸料板结构。常用于较硬、较厚且精度要求不高的工件冲裁后卸料。当卸料板只起卸料作用时与凸模的间隙随材料厚度的增加而增大,单边间隙取(0.20.5)t。当固定卸料板还要起到对凸模的导向作用时卸料板与 凸模的配合间隙应该小于冲裁间隙。此时要求凸模卸料时不能完全脱离卸料板。主要用于卸料力较大、材料厚度大于2mm且模具结构为倒装的场合。弹压卸料板具有卸料和压料的双重作用,主要用于料厚小于或等于2mm的板料由于有压料作用,冲件比较平整。卸料板与凸模之间的单边间隙选择(0.10.2)t,若弹压卸料板还要起对凸模导向作用时,二者的配合间隙应小于冲裁间隙。常用作落料模、冲孔模、正装复合模的卸料装置。 工件平直度较高,料厚为1.5mm相对较薄,卸料力较小,弹压卸料模具比刚性卸料模具方便,操作者可以看见条料在模具中的送进动态,且弹性卸料板对工件施加的是柔性力,不会损伤工件表面,所以采用弹性卸料。(2)出件方式因采用级进模生产,故采用向下落料出件。4.4确定送料方式因选用的冲压设备为开式压力机且垂直于送料方向的凹模宽度B小于送料方向的凹模长度L故采用横向送料方式,即由前向后送料。4.5确定导向方式方案一:采用对角导柱模架。由于导柱安装在模具压力中心对称的对角线上,所以上模座在导柱上滑动平稳。但上下配合度不好。方案二:采用后侧导柱模架。由于前面和左、右不受限制,送料和操作比较方便。因为导柱安装在后侧,工作时,偏心距会造成导套导柱单边磨损,严重影响模具使用寿命,且不能使用浮动模柄。方案三:四导柱模架。具有导向平稳、导向准确可靠、刚性好等优点。常用于冲压件尺寸较大或精度要求较高的冲压零件,以及大量生产用的自动冲压模架。方案四:中间导柱模架。导柱安装在模具的对称线上,导向平稳、准确。常用于纵向送料的落料模、复合模。根据以上方案比较并结合模具结构形式和送料方式,为提高模具寿命和工件质量,该级进模采用中间导柱模架的导向方式,即方案四最佳。5 模具零件设计及标准件的选择5.1 工作零件设计 工作零件包括凹模、凸模,由于零件外形不规则,其模具采用配合加工制作制造,即落料时以凹模为基准,只需计算凹模刃口尺寸和公差;冲孔以凸模为基础,只需计算凸模刃口尺寸及公差。(1)模具间隙 由于零件有平面度的要求,这里选用类冲裁间隙,有表3-202查得C=(37)t,即=0.031.5=0.045mm,=0.071.5=0.105mm(2)落料凹模和冲孔凸模刃口的制造公差落料凹模和冲孔凸模刃口的制造公差都按IT7级4选取,公差值由GB/T1800.3-796查得,则尺寸9.8、13.3、4.2、R1.85由冲压件尺寸公差按IT14精度查表3-85查得偏差值,其具体值见下表1。零件尺寸R1.8515398磨损系数查表0.750.750.75111模具制造偏差GB/1800.3-796 0.0150.0150.0150.250.010.0120.010.450.43表1落料凹模刃口尺寸计算如下:凹模磨损后,变大的尺寸有9.4、3.7、15.3、1.5刃口尺寸计算公式: ; ; ; ; ;凹模磨损后,变小的尺寸有3.25刃口尺寸计算公式:; ;凹模磨损后,无变化的尺寸有R1.85 =(C+0.5 )0.5 =(1.85+0.50.048) 0.50.250.048mm =(1.8740.006)mm凸模的刃口尺寸按凹模尺寸配作,保证双面间隙在0.045mm0.105mm之间。冲孔凸模刃口尺寸计算如下:;(3)冲孔凸模由于凸模为圆形和矩形,且圆形凸模径向尺寸较小,因此采用凸模固定板固定,凸模与固定板采用H7/m6的过渡配合,并通过台阶D压紧在固定板的台阶孔上,防止凸模被顶出,其工作部分采用表2-27查得:1.85的凸模: 1.85()5(D)50(L); 6.5的凸模: 6.581150;矩形凸模: 1.651.850;如下图4所示:图4凸模压应力校核:圆形凸模的校核 1.44 非圆形凸模压应力校核 =31.957:凸模材料的许用压应力;带有导向装置的凸模弯曲应力校核:圆形凸模: 6.12非圆形凸模:I: 凸模最小横截面积的惯性矩;F: 冲裁力N;D: 凸模的最小直径mm;: 允许的凸模最大自由度mm;综上所述凸模的压应力和弯曲应力都合适。(4)凹模采用整体式结构凹模采用整体式结构,外形为矩形,计算凹模的尺寸如下: 凹模的厚度H: H=Kb=O.4233=13.86,取H=15,查表3-292得K=0.42; 凹模的壁厚C: C=(1.52)H=22.530,取C=30; 凹模的长度L: L=33+230=93; 凹模的宽度B: B=152230=90;根据凹模外形尺寸的计算,则可查得标准凹模外形为10090167,落料凹模Cr12MoV,热处理6065HRC。5.2 其他板类零件的设计当凹模的外形尺寸确定后,可根据凹模的外形尺寸查阅有关标准的凸模固定板、垫板、卸料板和模座的外形尺寸:卸料板:其厚度为凹模厚度的0.81倍8,得1009016,材料为45钢;垫板:查JB/T7643.3得,垫板100908,材料为45钢;凸模固定板:查JB/T580-94得,凸模固定板1009016,材料为45钢;模座:查GB/T2855.2-2008得,滑动导向下模座16010030,材料为HT200;查GB/T2855.1-2008得,滑动导向上模座16010040,材料为HT200;5.3 橡胶的选用根据模具的总体设计可以得到,选用橡胶作为弹性卸料装置(1)根据卸料力求橡胶的横截面积F=212.826F:橡胶横截面积; :橡胶所产生的弹性压力,设计时取大于或等于卸料力N;: 与橡胶压缩量有关的单位MPa,查表8-787压缩量取30%,p取1.52;(2)橡胶的高度尺寸使用橡胶时,不应使最大相对压缩量过大,避免橡胶过早失去弹性而损坏,其允许最大压缩量应不超过自由高度的45%,一般取=(0.350.45)工作行程计算式,可得自由高度=(3.54):卸料板或者推件板压边工作行程与磨具修边量或者调整量46mm之和再加1mm经计算得=12mm(3)校核橡胶的自由高度h与直径D之比满足大于0.5小于1.5的要求,故而选用的橡胶合理5.4 模柄的选用根据初选设备J23-25模柄孔的尺寸,查得JB/T7646.1-2008得:压入式模柄4060,材料为Q235钢;5.5 导柱与导套的选择 查GB/T2861.1-2008和 GB/2861.3-2008得: 导柱:20*130,材料为20钢,表面用渗碳处理; 导套:20*70*28,材料为20钢,表面用渗碳处理;5.6 紧固零件的选择 模具上常用的紧固零件是螺钉和销钉,螺钉和销钉都是标准件,根据凹模的厚度而选择,凹模的厚度为16mm,即螺钉选择M6*40,销钉选择公称直径为5*40。5.7 所选设备的校核由标记为“下模座 中间导柱 160*100*40GB/T2885.1-2008”可知,下模座平面的最大外形尺寸为:294*259mm,长度方向单边小于压力机工作台面尺寸(500-194)mm/2=103mm,下模座的平面尺寸单边大于压力机工作台孔尺寸(294-220)mm/2=37mm,故而满足模具的安装要求。模具的闭合高度为:30mm+8mm+16mm+12mm+16mm+16mm+40mm=138mm,小于压力机的最小闭合高度,因此选用的设备合适。6 模具总装图通过以上设计,可得到如图5所示的模具总装图。模具上模部分主要由上模座、垫板、凸模(8个)、凸模固定板及卸料板等组成。卸料方式采用弹性卸料,以橡胶为弹性元件。下模部分由下模座、凹模板、导料板等组成。冲孔废料和成品件均由漏料孔漏出。 图5-引线片级进模装配图1、 凹模 2、螺钉 3、导料板 4、弹性橡胶体 5、导套 6、螺钉7、下模座 8、模柄 9、止转销 10、销钉 11、垫板 12、导柱 13、凸模固定板 14.凸模 15、螺钉 16、卸料板 17、侧刃切刀 18、销钉 19、螺钉 20、下模座 7 模具零件加工工艺本副冲裁模,模具零件加工的关键在工作零件、固定板以及卸料板,若采用线切割加工技术,这些零件的加工就变得相对简单。落料凸模的加工工艺过程如下表(2)所示:表(2)-落料凸模的加工工艺过程工序号工序名称工 序 内 容工序简图(示意图)1备 料将毛坯锻造成长方体201555mm2热 处 理退 火3刨刨6面,互为直角,留单边余量0.54热 处 理调 质5磨 平 面磨6面,互为直角6钳工划线划出各孔位置线7加工螺钉孔、安装孔及穿丝孔按位置加工螺纹孔、销钉孔及穿丝孔等8热 处 理按热处理工艺,淬火回火达到58-62HRC9磨 平 面精磨上、下平面10线 切 割按图线切割,轮廓达到尺寸要求11钳工精修全面达到设计要求12检 验按产品零件图检验图7所示凹模的加工工艺过程如下表(3)所示:表(3)-凹模加工工艺过程 工序号工序名称工 序 内 容工序简图(示意图)1备 料将毛坯锻成长方体11010025mm2热 处 理退 火3粗 刨刨六面达到1039321mm,互为直角4热 处 理调 质5磨 平 面磨六面,互为直角6钳工划线划出各孔位置线7铣漏料孔达到设计要求8加工螺钉孔、销钉孔及穿丝孔按位置加工螺钉孔、销钉孔及穿丝孔9热 处 理按热处理工艺,淬火回火达到60-62HRC10磨 平 面精磨上、下平面11线 切 割按图切割型孔达到尺寸要求12钳工精修全面达到设计要求13检 验按产品零件图检验8 模具的装配根据级进模装配要点,选凹模作为装配基准件,先装下模,再装上模,并调整间隙、试冲、返修。具体装配见下表(4)所示:表(4)-引线片级进模的装配序号工 序工 艺 说 明1凸、凹模预配1) 装配前仔细检查各凸模形状及尺寸以及凹模形孔,是否符合图纸要求尺寸精度、形状。2) 将各凸模分别与相应的凹模孔相配,检查其间隙是否加工均匀。不合适者应重新修磨或更换。2凸模装配以凹模孔定位,将各凸模分别压入凸模固定板的形孔中,并挤紧牢固。3装配下模1) 在下模座上划中心线,按中心预装凹模、导料板;2) 在下模座、导料板上,用已加工好的凹模分别确定其螺孔位置,并分别钻孔,攻丝;3) 将下模座、导料板、凹模、固定挡料销装在一起,并用螺钉紧固,打入销钉。4装配上模1) 在已装好的下模上放等高垫铁,再在凹模中放入0.12的纸片,然后将凸模与固定板组合装入凹模;2) 预装上模座,划出与凸模固定板相应螺孔、销孔位置并钻铰螺孔、销孔;3) 用螺钉将固定板组合、垫板15、上模座连在一起,但不要拧紧;4) 将卸料板套装在已装入固定板的凸模上,装上橡胶和卸料螺钉,并调节橡胶的预压量,使卸料板高出凸模下端约1mm; 5) 复查凸、凹模间隙并调整合适后,紧固螺钉;6) 安装导正销、承料板;7) 切纸检查,合适后打入销钉。设 计 总 结本毕业设计是我进行完了三年的模具设计与制造专业课程后进行的,它是对我们三年来所学课程的又一次深入、系统的综合性的复习,也是一次理论联系实践的训练。它可以说又是一次对专业知识的学习的深入和系统掌握。通过这次毕业设计使我从新系统的复习了所学专业知识,同时也巩固了先前学到的知识,同时感触最深刻的是:所学知识只有在应用中才能更深刻理解和长时间记忆。对一些原来一知半解的理论也有了进一步的的认识。特别是原来所学的一些专业基础课:如机械制图、模具材料、公差配合与技术测量、冷冲模具设计与制造等有了更深刻的理解,使我进一步的了解了怎样将这些知识运用到实际的设计中。同时还使我更清楚了模具设计过程中要考虑的问题,如怎样使制造的模具既能满足使用要求又不浪费材料,保证工件的经济性、加工工艺的合理性。 在设计的过程中通过冲压模具设计手册、模具制造简明手册、模具标准应用手册等对所要设计的问题进行查询,通过更多的途径去了解我要做的设计,使设计更具合理性。也使我学会了设计过程中对资料的查询和运用。通过这次设计,我更加深入地学习了冷冲压技术工作设计的内容。冷冲压技术工作设计的内容包括冷冲压工艺设计、模具设计及冲模制造三方面内容,尽管三者的工作内容不同,但三者之间存在着相互渗透、相互补充、相互依存的关系。冷冲压工艺设计是针对给定的产品图样,根据其生产批量的大小、冲压设备的类型规格、模具制造能力及工人技术水平等具体生产条件,从对产品零件图的冲压工艺性分析入手经过必要的工艺计算,制定出合理的工艺方案,最后编写冲压工艺卡的一个综合分析、计算、设计过程。冲压工艺方案的确定包括工序性质、数量的确定,工序顺序的安排,工序组合方式及工序定位方式的确定等内容。冲压模具设计则是依据制定的冲压工艺规程,在认真考虑毛坯的定位、出件、废料排出诸问题以及模具的制造维修方便、操作安全可靠等因素后,设计计算并构思出与冲压设备想适应的模具总体结构,然后绘制出模具总装图和所有非标准零件图的整个设计绘图过程。历经近三个月的毕业设计即将结束,在这次毕业设计中通过参考、查阅各种有关模具方面的资料,请教指导老师有关模具方面的问题,并且和同学的探讨模具设计在实际中可能遇到的具体问题,使我在这短暂的时间里,对模具的认识有了一个质的飞跃。从陌生到开始接触,从了解到熟悉,这是每个人认识事物所必经的一般过程,我对模具的认识过程亦是如此。经过近三个月的努力,我相信这次毕业设计一定能为三年的大学生涯划上一个圆满的句号,为将来走上工作岗位奠定坚实的基础。致 谢首先感谢本人的导师翟德梅老师,她仔细审阅了本文的全部内容并对我的毕业设计内容提出了许多建设性建议。翟德梅老师渊博的知识,诚恳的为人,使我受益匪浅,在毕业设计的过程中,特别是遇到困难时,她给了我鼓励和帮助,在这里我向她表示真诚的感谢!感谢母校河南机电高等专科学校的辛勤培育之恩!感谢材料工程系给我提供的良好学习及实践环境,使我学到了许多新的知识,掌握了一定的操作技能。感谢各位老师在三年之中的教导和在做设计的过程中对我的帮助。使我在大学三年里不但学到了更多知识,而且学到了怎么做人、怎么做事。我非常庆幸在三年的的学习、生活中认识了很多可敬的老师和可亲的同学,并感激师友的教诲和帮助。毕业之后,我一定会努力工作的,不辜负各位老师对我们的深切期望,在这里向你们道一声:老师你们辛苦了!最后深深地祝愿祝各位老师,身体健康、万事如意!参考文献1 肖祥芷 中国模具设计大典 M 江西:江西科学技术出版社2003 2 何旭贵 张荣清 冲压工艺和模具设计 M 北京:机械工业出版社 20123 王孝培 冲压手册M 北京:机械工业出版社,20124 蔡兰 机械零件工艺手册M 北京:机械工业出版社,19955 许毓潮 何祚蒨 机械手册M 北京:水利电力出版社,19886 何祖舜 蔡君亮 机械设计与工艺手册M 宁夏:宁夏人民出版社,19897 陈炎嗣 冲压模设计手册(多工位级进模)M 北京:化学工业出版社,20138曹立文、王冬、丁海娟、郭士清 新编实用冲压模具设计手册M 北京:人民邮电出版社,20079原红玲 冲压工艺与模具设计M 北京: 机械工业出版社,200710 翟德梅、段维峰 模具制造技术M北京:化学工业出版社,200925Journal of Materials Processing Technology 151 (2004) 237241 Recent developments in sheet hydroforming technology S.H. Zhang a, , Z.R. Wang b ,Y.Xu a , Z.T. Wang a , L.X. Zhou a a Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China b School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China Abstract In this paper, recent developments in sheet hydroforming technology are summarized, several key technical problems to be solved for the development of sheet hydroforming technology are analyzed, and varied sheet hydroforming technologies are discussed. Compound deformation by drawing and bulging is the main direction for the development of sheet hydroforming technology, in which it is advantageous to increase the feeding of materials, and the ratio of drawing deformation (drawing in of the blank flange) to bulging, enabling the forming limit of a sheet blank to be increased. It is also advantageous to increase the local deformation capacity for sheet hydroforming, to increase the range of application of the process. Press capacity is one of the important factors restraining the range of applications. As one of the flexible forming technologies that is still under development, it has much potential for innovative applications. Its applications have been increasing remarkably, recently in automotive companies. A breakthrough in the technology will be obtained by the development of novel equipment. A new sheet hydroforming technology using a movable die is proposed in this paper, which has been developed recently by the authors. 2004 Elsevier B.V. All rights reserved. Keywords: Sheet hydroforming; Drawing in; Bulging; Flexible forming; Forming limit 1. Introduction Compared with conventional deep drawing, sheet hydro- forming technology possesses many remarkable advantages, such as a higher drawing ratio, better surface quality, less springback, better dimensional freezing and the capability of forming complicated-shaped sheet metal parts. For exam- ple a multi-pass forming process may be decreased to one pass for the forming parabolic parts. Sheet hydroforming technology has been applied to industries for the forming of automotive panels and aircraft skins 1. It is a soft-tool forming technology and as the development of this technol- ogy is imperfect compared with other rigid forming tech- nologies, there are more extensive demands and space for it to be improved with the development of modern industry. There are many demands for hydrofoming technology for use with some new materials, such as forming of magnesium alloy sheets, composite material sheets and sandwich sheets. Some new hydroforming processes have entered this area, such as viscous pressure forming technology, warm sheet hydroforming, the hydroforming of sheet metal pairs and the hydroforming of tailor-welded blanks. Through long-term Corresponding author. Tel.: +86-24-8397-8266/8721; fax: +86-24-2390-6831. E-mail address: (S.H. Zhang). investigation by the AP namely, the compound deformation of bulging and drawing due to the draw-in of blank flange area (blank feeding of the blank flange area), which compensates the materials for the stretch of the bulging area and avoids excessive thinning resulting from the increase of the blank area, thus assuring material strength and rigidity in the bulging area. It is very diffi- cult to realize the uniform distribution of thinning, the large local deformation of sheet the metal and the increasing of the forming limit of the blank without blank feeding and supplementation. Thus the advantages for the hydroforming of complicated-shaped parts from sheet cannot be revealed fully, although the breakthrough for tube hydroforming has been realized. A tubular component can be hydroformed if dealing with a high-pressure forming process with the simul- taneous feeding of the tube end 3, which increases the tube area and thus reduces little thinning. The requirements for the pressure of the tool in tube hydroforming are small. The internal pressure for the tube is closed and self-restrained, and the closing force involved is small. The material feeding of the tube end can be enforced without difficulty for this technology, compared with the difficulties of the feeding in of the material in hydroforming. As in tube hydroforming, a closing force is required for sheet hydroforming, but a difficulty is that the closing force for sheet hydroforming is far greater than that in tube hydro- forming, and requires a high press tonnage: this is an impor- tant factor restraining the application of sheet hydroforming. The closing pressure can be supplied by a hydraulic press, but the pressure for sheet hydroforming is no limits and not self-restrained. 2.1. Hydroforming with a rubber diaphragm A rubber membrane was employed as the diaphragm of the hydraulic chamber and the blankholder in the early form of sheet hydroforming. This process has been applied to small batch production of automotive panels and aircraft skins (Fig. 1). There are many advantages for this process: better surface quality and the forming of more complicated workpieces. It is suitable for small batch production. How- ever, it also has some disadvantages, such as low process efficiency and the requirement of heavy presses. In addition, it is easy to destroy the rubber membrane and difficult to control wrinkling. 2.2. The hydromechanical deep drawing process and the hydro-rim deep drawing process The hydromechanical deep drawing process has been de- veloped on the basis of rubber membrane hydroforming (Fig. 2(a). The pressure can be produced by the downwards movement of the punch into the fluid chamber, or supplied by a hydraulic system, because a rubber membrane is not used. Thus, it is very easy to obtain hydraulic pressure. The tool device is similar to a conventional tool. All these param- eters lead to high efficiency. The shape of the workpieces may be very complicated, and the drawing ratio may be in- creased, from 1.8 to 2.7, compared with that for conven- tional drawing processes. There are many applications for this process 1315. More local deformation and forming of complicated parts are realized by using this process. Forced feeding is difficult to practice in current sheet hy- droforming processes. To some extent, the radial hydrome- S.H. Zhang et al. / Journal of Materials Processing Technology 151 (2004) 237241 239 Fig. 1. Sheet hydroforming with a rubber membrane: (a) the process; (b) a hydroformed workpiece. chanical deep drawing (hydro-rim) process can realize some forced radial feeding (Fig. 2(b), which can significantly in- crease the forming limit of the sheet metal. According to the research results in 2, the drawing ratio can be increased, from 2.6 to 3.2, compared with that for the common hy- dromechanical deep drawing process. 2.3. Hydroforming of sheet metal pairs A special case is the hydroforming of welded-closing sheet metal pairs (Fig. 3(a). The hydroforming technology of sheet metal pairs was developed by Kleiner et al at. Dort- mund University in the early 1990s 46. In the first scheme the periphery of the sheet metal can be welded using laser welding. Then a liquid medium can be filled between the blanks, and pressurization can be effected by a hydraulic sys- tem. Plastic deformation starts in the blank under the pres- sure and then further deformation occurs sequentially in the zone contacting with the die. However, it is very difficult to realize radial feeding using this method, as it is essentially a pure bulging deformation. The advantage is that the pres- sure is a kind of self-restraining pressure. There is a low re- quirement for the closing force. A stainless steel automotive model was formed with the new press of 100,000 kN with hydroforming technology. To some extent, this technology is similar to tube hydroforming, however, it is very difficult to realize the radial feeding of the blank. Fig. 2. Showing: (a) hydromechanical deep drawing; (b) hydro-rim deep drawing. Another variation was proposed by Dortmund University (Fig. 3(b). The principle is that the tool system is made up of an upper and lower die and an intermediate plate. The intermediate plate can be applied on its own or together with the upper and lower blank, for hydroforming. The pressure pipeline may be connected or disconnected. Generally, the shape of the upper and lower workpieces is symmetrical when the pressure pipeline is connected, whilst the shapes of the upper and lower workpieces are independent when the pressure pipeline is not connected: infact, they may deform separately. This tool is for the realization of the compound deformation of drawing and bulging. 2.4. The compound deformation of drawing and bulging Sheet hydroforming with compound drawing and bulging has been investigated for many years. Since the early 1980s, the theory of hydroforming with draw-in has been studied by Shang at Singapore National University 7. He studied the reasonable match of draw-in and bulging, but it is still in the research stage and has not been applied. 2.5. The dieless integral hydro-bulge forming (IHBF) of spherical shells Another special case is the integral hydro-bulge forming (IHBF) of spherical shells. IHBF is a new dieless forming 240 S.H. Zhang et al. / Journal of Materials Processing Technology 151 (2004) 237241 Fig. 3. The hydroforming of sheet metal pairs with an intermediate plate. technology for sphere-inner-scribing polyhedral shell, that means, all the side inter-sections of the polyhedral shell sides are on the sphere; which was invented by Wang 8 at Harbin Institute of Technology in 1985. It realized the dieless IHBF of flat sheets. In fact, this technology is a pure bulging process as it is impossible to obtain the supplementation of materials. Moreover, it is a non-uniform bulging forming. The hydroforming of single curvature shells and the dieless IHBF of double spherical vessels, oblate spheroid shells, ellipsoidal shells and pairs of pressure vessel heads were developed later, which resulted in the full development of the dieless IHBF technology and secured wide applications. 3. A new sheet hydroforming technology: hydroforming with a movable die A sheet hydroforming technology with a movable female die was proposed by authors in 2001 (see Fig. 4) 11,12. Some hydroformed workpieces of stainless steel and magne- sium alloys are shown in Fig. 5. For sheet hydroforming with a movable die, a combined die is used, which consists of a fixed part and a movable part. As the technology can realize the compound deformation of drawing and bulging, it is suit- able for forming complicated-shaped parts and low-plasticity difficult-to-form materials. That part of the blank in the flange area is drawn in during the process, which may real- ize the compound deformation of deep drawing and bulging. Fig. 5. Some hydroformed workpieces of stainless steel and magnesium alloy. Blankholder plate Movable die Combination die Bolster plate O-ring sealing Blank Dies Fig. 4. Schematic of the new set-up for sheet hydroforming using a movable die. The movable die component keeps in touch with the blank during the early stage. Plastic deformation and then defor- mation of the blank in the die-contacting area take place. The movable die remains in contact with the blank under the friction force, which makes the deformation area spread to the non-contacting area. Preliminary research shows that the thinning of the sheet metal can be alleviated remark- ably if this innovative process is adopted 12 (see Fig. 6). The forming limit of the sheet metal is increased. This pro- cess is suitable for the forming of complicated-shaped parts such as aluminum alloy sheets, as well as low-plasticity and light-weight materials such as aluminum lithium alloy and magnesium alloys. S.H. Zhang et al. / Journal of Materials Processing Technology 151 (2004) 237241 241 Fig. 6. Comparison of the thinning ratio between hydroforming with and without a movable die. It is difficult for the tool to be damaged or worn because of the use of hydraulic pressure, so the tool life is improved. Moreover, it is very easy to modify the product because the blankholder has versatility and the punch is not required to be changed: it is only required to change the die for the form- ing of different parts. It can be shown that this process has many advantages over conventional processes: it makes the dies contact well, which results in better shape, dimensional accuracy, less springback and higher precision, remarkably lower tools cost and obviously shorter production periods for small batch production. This process is especially suit- able for the production of large-scale sheet metal parts with complicated shape, varied size and of small batch. It makes the production of complicated shape parts simple and flex- ible and realizes the quick production of workpieces. It is especially suitable for the development of new products in the aerospace industry and prototypes in the automotive in- dustry. If the deformation methods of conventional tools are adopted, because the production batch is not great, the de- sign cycle is long and the manufacturing cost is high, whilst if the presently described process is adopted, the cost for the tool will be decreased and the production periods and development cycle will be shortened. It is expected to apply this technology to many other area of manufacture, such as the production of prototype workpieces, which may save the cost of development, shorten the development cycle for the development of new models and improve competitive power for the business. 4. Conclusions In this paper, recent developments of sheet hydroforming technology are discussed systematically. With the realization of the compound deformation of drawing and bulging for further development of sheet hydroforming, more draw-in of blank flange (drawing deformation) and more capacity of local deformation, can be achieved. The forming limit of sheet metal can be significantly increased, and a wider range of part shape can be formed. Moreover, the multi-pass form- ing process for conventional complicated sheet parts can be decreased to one or two passes. Thus higher efficiency and lower costs can be achieved, which compensates for the low efficiency of the single pass procedure of hydroforming. The pre-requisite to the application for this process is a large tonnage for the equipment and high automation. The com- pound deformation of drawing and bulging can be realized if hydroforming with movable dies is adopted. Moreover, the distribution of wall thickness can be controlled. Thin- ning can be decreased and the forming limit of sheet metal can be increased. There are wide prospects for this technol- ogy, and the process can meet the developing direction of production requirements. References 1 S.H. Zhang, Developments in hydroforming, J. Mater. Process. Tech- nol. 91 (1991) 236244. 2 S.H. Zhang, J. 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