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河南机电高等专科学校学生毕业设计(论文)中期检查表学生姓名陈海峰学 号0412101指导教师原红玲选题情况课题名称硅钢片正装模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 日硅钢片正装模 摘要(中文) 本模具设计题目为落料合模,此零件需一道工序完成,体现了复杂零件的设计要求,内容及方向.具有一定的设计意义,通过对该零件模具的设计进一步加强了设计者冲压模具设计的基础知识,为设计更复杂的冲压模做好了铺垫和吸取了更深该的经验. 本设计运用冲压模具设计与制造工艺基础知识,首先分析了E形零件的外形,尺寸,精度要求,进行了工艺分析,考虑到此零件形位要求较高,采用单工序模工艺方案.然后根据零件的外形尺寸计算毛坯总体尺寸,设计排样图及计算材料利用率及压力中心最后计算出工作部分尺寸,模具总体尺寸,总体尺寸包括工作零部件的结构设计,卸料装置的设计以及固定零件的设计与运用.本模具的特点是推板在弹顶器,顶杆的作用下,处于最上位置,定位板固定坯料,上模部分下降,用凸凹模成零件,用顶料装置把工件顶出,开模时可使工件抬起,便于取件.关键词: 凸凹模 THE BENGDING DIE DESIGN This mold design topic for the bending die, falls the material, the punch holes superposable die, this components need three working procedures to complete. Has manifested the complex components design request, the content and the direction. Has certain design significance, through further strengthened the elementary knowledge to this components mold design which the designer ramming mold designs, for designed more complex flushes the die to complete the upholstery and to absorb a deeper this experience.This design utilization ramming mold design and the manufacture craft elementary knowledge, has first analyzed the end cover components contour, the size, the precision request, has carried on the craft analysis, considered this components are the circular components, is high to the proper alignment request, therefore uses the superposable die craft plan. Then the basis components external dimensions computation semifinished materials overall size, a design row of specimen map and the computation material use factor and the center of pressure last count is present at work makes the partial sizes, the mold overall size, the overall size including the work spare part structural design, the dumping device design as well as the fixed components design and the utilization. This mold characteristic is the small end cover drawing, falls the material, the punch holes superposable die.The formed push pedal goes against in the ball, under the roof bar function, is in on most the position, the nursery lives the semifinished materials, the top die part drops, the use convex-concave mold and the formed push pedal carry on the drawing and press the shape, the top die continue to drop, impel the formed push pedal to drop, this time by falls the material concave mold, the convex-concave mold carries on falls the material, then flushes the bottom hole. When formed push pedal and dead plate contact, then carries on the reshaping. Is loaded with 6 roof bars in the formed push pedal, operates when the mold may cause the work piece to lift, is advantageous for takes.Key words: The bending die Superposable die Falls the material convex-concave mold2河南机电高等专科学校毕业设计(论文)任务书系 部: 材料工程系 专 业: 模具设计与制造 学生姓名: 陈海峰 学 号: 0412101 设计(论文)题目: 硅钢片正装模 起 迄 日 期: 2007 年 3月20 日 6月20日 指 导 教 师: 原 红 玲 发任务书日期: 2007 年 3月 20 日毕 业 设 计(论 文)任 务 书1本毕业设计(论文)课题来源及应达到的目的: 1. 硅钢片零件的结构工艺分析;2. 硅钢片正装模设计,绘制模具总装图及全部的工作零件图;3. 编写设计说明书; 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):毕业设计任务书一份,图纸(各个零件图及装配图按1:1出图)设计说明书一份。所在专业审查意见:负责人: 年 月 日系部意见:系领导: 年 月 日【中文4900字】冲压变形冲压变形工艺可完成多种工序,其基本工序可分为分离工序和变形工序两 大类。分离工序是使坯料的一部分与另一部分相互分离的工艺方法,主要有落料、 冲孔、切边、剖切、修整等。其中有以冲孔、落料应用最广。变形工序是使坯 料的一部分相对另一部分产生位移而不破裂的工艺方法,主要有拉深、弯曲、 局部成形、胀形、翻边、缩径、校形、旋压等。从本质上看,冲压成形就是毛坯的变形区在外力的作用下产生相应的塑性 变形,所以变形区的应力状态和变形性质是决定冲压成形性质的基本因素。因 此,根据变形区应力状态和变形特点进行的冲压成形分类,可以把成形性质相 同的成形方法概括成同一个类型并进行系统化的研究。绝大多数冲压成形时毛坯变形区均处于平面应力状态。通常认为在板材表面上 不受外力的作用,即使有外力作用,其数值也是较小的,所以可以认为垂直于 板面方向的应力为零,使板材毛坯产生塑性变形的是作用于板面方向上相互垂 直的两个主应力。由于板厚较小,通常都近似地认为这两个主应力在厚度方向 上是均匀分布的。基于这样的分析,可以把各种形式冲压成形中的毛坯变形区 的受力状态与变形特点,在平面应力的应力坐标系中(冲压应力图)与相应的两 向应变坐标系中(冲压应变图)以应力与应变坐标决定的位置来表示。也就是说, 冲压应力图与冲压应变图中的不同位置都代表着不同的受力情况与变形特点 (1)冲压毛坯变形区受两向拉应力作用时,可以分为两种情况:即 0 t=0 和 0, t=0。再这两种情况下,绝对值最大的应力都是拉应力。以下 对这两种情况进行分析。1)当 0 且 t =0 时,安全量理论可以写出如下应力与应变的关系式:(1-1) /( - m)= /( - m)= t/( t - m)=k式中 , , t分别是轴对称冲压成形时的径向主应变、切向主应变 和厚度方向上的主应变; , , t分别是轴对称冲压成形时的径向主应力、切向主应力和厚度 方向上的主应力; m平均应力, m=( + + t)/3;k常数。在平面应力状态,式(11)具有如下形式:3 /(2 - )=3 /(2 - t)=3 t/-( t+ )=k (12) 因为 0,所以必定有 2 - 0 与 0。这个结果表明:在两向拉应力的平面应力状态时,如果绝对值最大拉应力是 ,则在这个方向上的主 应变一定是正应变,即是伸长变形。又因为 0,所以必定有-( t+ )0 与 t2 时, 0;当 0。 的变化范围是 = =0 。在双向等拉力状态时, = ,有 式(12)得 = 0 及 t 0 且 t=0 时,有式(12)可知:因为 0,所以 1)定有 2 0 与 0。这个结果表明:对于两向拉应力的平面应力状态,当 的绝对值最大时,则在这个方向上的应变一定时正的,即一定是 伸长变形。又因为 0,所以必定有-( t+ )0 与 t , 0;当 0。 的变化范围是 = =0 。当 = 时, = 0,也就是 在双向等拉力状态下,在两个拉应力方向上产生数值相同的伸长变形;在受单 向拉应力状态时,当 =0 时, =- /2,也就是说,在受单向拉应力状态 下其变形性质与一般的简单拉伸是完全一样的。这种变形与受力情况,处于冲压应变图中的 AOC 范围内(见图 11);而 在冲压应力图中则处于 AOH 范围内(见图 12)。上述两种冲压情况,仅在最大应力的方向上不同,而两个应力的性质以及 它们引起的变形都是一样的。因此,对于各向同性的均质材料,这两种变形是 完全相同的。(1)冲压毛坯变形区受两向压应力的作用,这种变形也分两种情况分析,即o t=0 和 0, t=0。1)当 0 且 t=0 时,有式(12)可知:因为 0,一定有2 - 0 与 0。这个结果表明:在两向压应力的平面应力状态时,如果11绝对值最大拉应力是 0,则在这个方向上的主应变一定是负应变,即是压 缩变形。又因为 0 与 t0,即在板料厚度方 向上的应变是正的,板料增厚。在 方向上的变形取决于 与 的数值:当 =2 时, =0;当 2 时, 0;当 0。这时 的变化范围是 与 0 之间 。当 = 时,是双向等压力状态 时,故有 = 0;当 =0 时,是受单向压应力状态,所以 =- /2。 这种变形情况处于冲压应变图中的 EOG 范围内(见图 11);而在冲压应力图 中则处于 COD 范围内(见图 12)。2) 当 0 且 t=0 时,有式(12)可知:因为 0,所以 一定有 2 0 与 0。这个结果表明:对于两向压应力的平面应力状 态,如果绝对值最大是 ,则在这个方向上的应变一定时负的,即一定是压 缩变形。又因为 0 与 t0,即在板料厚度方 向上的应变是正的,即为压缩变形,板厚增大。在 方向上的变形取决于 与 的数值:当 =2 时, =0;当 2 , 0;当 0。这时, 的数值只能在 = =0 之间变化。当 = 时,是双向 等压力状态,所以 = 0。这种变形与受力情况,处于冲压应变图中的 GOL 范围内(见图 11);而在冲压应力图中则处于 DOE 范围内(见图 12)。(1)冲压毛坯变形区受两个异号应力的作用,而且拉应力的绝对值大于压应 力的绝对值。这种变形共有两种情况,分别作如下分析。1)当 0, | |时,由式(12)可知:因为 0, | |,所以一定有 2 - 0 及 0。这个结果表明:在异号的 平面应力状态时,如果绝对值最大应力是拉应力,则在这个绝对值最大的拉应 力方向上应变一定是正应变,即是伸长变形。又因为 0, | |,所以必定有 0 0, 0, | |时,由式(12)可知:用与前 项相同的方法分析可得 0。即在异号应力作用的平面应力状态下,如果绝 对值最大应力是拉应力 ,则在这个方向上的应变是正的,是伸长变形;而在 压应力 方向上的应变是负的( 0, 0, 0, | |时,由式(12)可知:因为 0, | |,所以一定有 2 - 0 及 0, 0,必定有 2 - 0,即在拉应力方向上 的应变是正的,是伸长变形。这时 的变化范围只能在 =- 与 =0 的范围内 。当 =- 时, 0 0, 0, | |时,由式(12)可知:用与前 项相同的方法分析可得 0, 0, 0, 0o AONGOH+伸长类o AOCAOH+伸长类双向受压o 0, 0o EOGCOD压缩类o 0, | |MONFOG+伸长类| | |LOMEOF压缩类异号应力o 0, | |CODAOB+伸长类| | | |DOEBOC压缩类表 12伸长类成形与压缩类成形的对比项目伸长类成形压缩类成形变形区质量问题的表现形式变形程度过大引起变形区产生破裂现象压力作用下失稳起皱成形极限1主要取决于板材的塑性,与厚度无关2可用伸长率及成形极限 DLF 判断1主要取决于传力区的承载能力2取决于抗失稳能力3与板厚有关变形区板厚的变化减薄增厚提高成形极限的方法1改善板材塑性2使变形均匀化,降低局部变形程度3工序间热处理1采用多道工序成形2改变传力区与变形区的力学关系3采用防起皱措施+ + - +扩口- - 图 13 冲压应变图图 13体系化研究方法举例Categories of stamping formingMany deformation processes can be done by stamping, the basic processes of the stamping can be divided into two kinds: cutting and forming.Cutting is a shearing process that one part of the blank is cut form the other .It mainly includes blanking, punching, trimming, parting and shaving, where punching and blanking are the most widely used. Forming is a process that one part of the blank has some displacement form the other. It mainly includes deep drawing, bending, local forming, bulging, flanging, necking, sizing and spinning.In substance, stamping forming is such that the plastic deformation occurs in the deformation zone of the stamping blank caused by the external force. The stress state and deformation characteristic of the deformation zone are the basic factors to decide the properties of the stamping forming. Based on the stress state and deformation characteristics of the deformation zone, the forming methods can be divided into several categories with the same forming properties and to be studied systematically.The deformation zone in almost all types of stamping forming is in the plane stress state. Usually there is no force or only small force applied on the blank surface. When it is assumed that the stress perpendicular to the blank surface equal to zero, two principal stresses perpendicular to each other and act on the blank surface produce the plastic deformation of the material. Due to the small thickness of the blank, it is assumed approximately that the two principal stresses distribute uniformly along the thickness direction. Based on this analysis, the stress state andthe deformation characteristics of the deformation zone in all kind of stamping forming can be denoted by the point in the coordinates of the plane princ ipal stress(diagram of the stamping stress) and the coordinates of the corresponding plane principal stains (diagram of the stamping strain). The different points in the figures of the stamping stress and strain possess different stress state and deformation characteristics.(1) When the deformation zone of the stamping blank is subjected toplanetensile stresses, it can be divided into two cases, that is 0,t=0and 0,t=0.In both cases, the stress with the maximum absolute value is always a tensile stress. These two cases are analyzed respectively as follows.2)In the case that 0andt=0, according to the integral theory, the relationships between stresses and strains are:/(-m)=/(-m)=t/(t -m)=k1.1where, ,t are the principal strains of the radial, tangential and thickness directions of the axial symmetrical stamping forming; ,and tare the principal stresses of the radial, tangential and thickness directions of the axial symmetrical stamping forming;m is the average stress,m=(+t)/3; k is a constant.In plane stress state, Equation 1.13/(2-)=3/(2-t)=3t/-(t+)=k1.2Since 0,so 2-0 and 0.It indicates that in plane stress state with two axial tensile stresses, if the tensile stress with the maximum absolute value is , the principal strain in this direction must be positive, that is, the deformation belongs10to tensile forming.In addition, because 0,therefore -(t+)0 and t2,0;and when 0.The range of is =0 . In the equibiaxial tensile stress state = , according to Equation 1.2,=0 and t 0 and t=0, according to Equation 1.2 , 2 0 and 0,This result shows that for the plane stress state with two tensile stresses, when the absoluste value of is the strain in this direction must be positive, that is, it must be in the state of tensile forming.Also because0,therefore -(t+)0 and t,0;and when 0.14The range of is = =0 .When =,=0, that is, in equibiaxial tensile stress state, the tensile deformation with the same values occurs in the two tensile stress directions; when =0, =- /2, that is, in uniaxial tensile stress state, the deformation characteristic in this case is the same as that of the ordinary uniaxial tensile.This kind of deformation is in the region AON of the diagram of the stamping strain (see Fig.1.1), and in the region GOH of the diagram of the stamping stress (see Fig.1.2).Between above two cases of stamping deformation, the properties ofand, and the deformation caused by them are the same, only the direction of the maximum stress is different. These two deformations are same for isotropic homogeneous material.(1) When the deformation zone of stamping blank is subjected to two compressive stressesand(t=0), it can also be divided into two cases, which are 0,t=0 and 0,t=0.1)When 0 and t=0, according to Equation 1.2, 2-0 与 =0.Thisresult shows that in the plane stress state with two compressive stresses, if the stress with the maximum absolute value is 0, the strain in this direction must be negative, that is, in the state of compressive forming.Also because 0 and t0.The strain in the thicknessdirection of the blankt is positive, and the thickness increases.The deformation condition in the tangential direction depends on the valuesof and .When =2,=0;when 2,0;and when 0.The range of is 0.When =,it is in equibiaxial tensile stress state, hence=0; when =0,it is in uniaxial tensile stress state, hence =-/2.This kind of deformation condition is in the region EOG of the diagram of the stamping strain (see Fig.1.1), and in the region COD of the diagram of the stamping stress (see Fig.1.2).2)When 0and t=0, according to Equation 1.2,2- 0 and 0. Thisresult shows that in the plane stress state with two compressive stresses, if the stress with the maximum absolute value is , the strain in this direction must be negative, that is, in the state of compressive forming.Also because 0 and t0.The strain in thethickness direction of the blankt is positive, and the thickness increases.The deformation condition in the radial direction depends on the values of and . When =2, =0; when 2,0; and when 0.The range of is = =0 . When = , it is in equibiaxial tensile stress state, hence =0.This kind of deformation is in the region GOL of the diagram of the stamping strain (see Fig.1.1), and in the region DOE of the diagram of the stamping stress (see Fig.1.2).(3) The deformation zone of the stamping blank is subjected to two stresses with opposite signs, and the absolute value of the tensile stress is larger than that of the compressive stress. There exist two cases to be analyzed as follow:1) When 0, |, according to Equation 1.2, 2-0 and 0.This result shows that in the plane stress state with opposite signs, if the stress with the maximum absolute value is tensile, the strain in the maximum stress direction is positive, that is, in the state of tensile forming.Also because 0, |, therefore =-. When =-, then 0,0,0, |, according to Equation 1.2, bymeans of the same analysis mentioned above, 0, that is, the deformation zone is in the plane stress state with opposite signs. If the stress with the maximum absolute value is tensile stress , the strain in this direction is positive, that is, in the state of tensile forming. The strain in the radial direction is negative (=-. When =-, then 0, 0, 0,|, according to Equation 1.2, 2- 0 and 0 and 0, therefore 2- 0. The strain in the tensile stress direction is positive, or in the state of tensile forming.The range of is 0=-.When =-, then 0,0,0, |, according to Equation 1.2 and by means of the same analysis mentioned above,=-.When =-, then 0, 0, 0, and =-/2. Such deformation is in the region DOF of the15diagram of the stamping strain (see Fig.1.1), and in the region BOC of the diagram of the stamping stress (see Fig.1.2).The four deformation conditions are related to the corresponding stamping forming methods. Their relationships are labeled with letters in Fig.1.1 and Fig.1.2.The four deformation conditions analyzed above are applicable to all kinds of plane stress states, that is, the four deformation conditions can sum up all kinds of stamping forming in to two types, tensile and compressive. When the stress with the maximum absolute value in the deformation zone of the stamping blank is tensile, the deformation along this stress direction must be tensile. Such stamping deformation is called tensile forming. Based on above analysis, the tensile forming occupies five regions MON, AON, AOB, BOC and COD in the diagram of the stamping stain; and four regions FOG, GOH, AOH and AOB in the diagram of the stamping stress.When the stress with the maximum absolute value in the deformation zone of the stamping blank is compressive, the deformation along this stress direction must be compressive. Such stamping deformation is called compressive forming. Based on above analysis, the compressive forming occupies five regions LOM, HOL, GOH, FOG and DOF in the diagram of the stamping strain; and four regions EOF, DOE, COD and BOC in the diagram of the stamping stress.MD and FB are the boundaries of the two types of forming in the diagrams of the stamping strain and stress respectively. The tensile forming is located in the top right of the boundary, and the comp
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