铁芯片无废料跳步模设计【E型垫片】【山字型垫板】【9张CAD图纸和文档全套】
购买设计请充值后下载,资源目录下的文件所见即所得,都可以点开预览,资料完整,充值下载可得到资源目录里的所有文件。【注】:dwg后缀为CAD图纸,doc,docx为WORD文档,原稿无水印,可编辑。带三维备注的都有三维源文件,由于部分三维子文件较多,店主做了压缩打包,都可以保证打开的,三维预览图都是店主用电脑打开后截图的,具体请见文件预览,有不明白之处,可咨询QQ:1304139763
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: 郑 圣 学 号: 0312149 设计(论文)题目:铁芯片无废料跳步模起 迄 日 期: 2006年 4月 3 日 5月 13 日指 导 教 师: 杨占尧 教授 发任务书日期: 2006 年 4 月 3 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:模具毕业设计是一个重要的专业教学环节,这个数学环节的目的: (1)帮助学生具体运用和巩固模具设计与制造课程及相关的理论知识,了解设计冲压模的一般程序。 (2)使学生能够熟练地运用有关技术资料,如冷冲模国家标准、模具设计与制造简明手册、冷冲压模具结构图册及其它有关规范等。 (3)训练学生初步设计冷冲压模具的能力,为以后的工作打下初步的基础。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):冲压模课程设计按以下内容进行。 (1)拟定冲压工序安排方案、画出冲压工序图、画出待设计模具的排样图(2)计算冲裁力、确定模具压力中心、计算凹模周界、确定待设计模具的有关结构要素、选用模具典型组合等,初选压力机吨位; (3)考虑工厂的实际情况;(4)确定压力机吨位;(5)模具模板与作用原理和公差;(6)冲裁间隙;(7)设计及绘制模具装配图; (8)设计及绘制模具零件图; (9)设计及绘制模具模板图;(10)按规定格式编制设计说明书; (11)课程设计面批后或答辩。 所在专业审查意见:负责人: 年 月 日系部意见:系领导: 年 月 日毕业设计说明书目录绪 论1第1章 设计内容及要求41.1 制件图、材料及要求4第2章、冲裁件的工艺分析5第3章 主要设计计算63.1 排样方式的确定63.2 毛胚的确定63.3 冲裁力的计算73.3.1冲裁力73.3.2 压力中心的确定及相关尺寸的计算83.4 工作零件刃口尺寸计算8第4章 模具总体设计及主要零部件设计114.1 模具结构的选择114.2 卸料弹簧的设计与计算114.3冲压设备的选择124.4送料机机型功能规格名称送料宽度送料厚度134.5 模具的总体设计154.5.1 模具类型的选择154.5.2 定位方式的选择154.5.3 导向方式的选择154.6 主要零部件的设计154.6. 工作零件的结构设计154.6.2 落料凸模的设计154.6.3 落料凹模的设计164.6.4 定位零件的设计164.7 卸料部件的设计164.7.1 卸料板的设计164.7.2 卸料螺钉的选用174.7.3 顶件装置174.7.4 快拆装置174.8冲孔模各模板零件的名称材质硬度及功能184.9 模具零件公差及间隙标准204.10 冲裁刃口要求及冲裁间隙标准204.11 模具总装图214.12模具工作零件的加工工艺22第5章 模具的装配和调整23毕业设计说明书目录5.1 主要组件的装配235.1.1 凸模的装配235.1.2 弹压卸料板的装配235.2 总装配235.3 冲裁模试冲的缺陷和调整245.4 模具设计要点265.4.1 送料265.4.2 出料275.4.3 精度27结 论28致 谢29参考文献30 铁芯片无废料跳步模 摘要冲压模具作为制造产品(或半产品)的一种工具,其作用是完成某种工艺。模具设计必须满足工艺要求,最终满足产品的形状、尺寸和精度的要求。因此冲压设计师必须掌握冲压工艺,包括冲压工艺的分类、各种工艺计算、工艺制订等基础知识,而后才可以选择模具的类型,进行模具设计,使模具的类型表面质量、尺寸精度结构及尺寸等满足工艺及产品的要求。冷冲压工艺大致分两类:分离工序和成型工序。分离工序的目的是在冲压过程中将冲压件与板料按一定的轮廓线进行分离:分离工序又可分为落料、冲孔和剪切等。成型工序的目的是使冲压毛胚在不破坏其完整性的条件下产生塑性变形,并转化成产品所需要的形状:成形工序又分为弯曲、拉深、翻边、翻孔、胀形、扩孔等。冷冲压模具是冲压生产的主要工艺设备。冲压件的表面质量、尺寸精度、生产率以及经济效益等,与模具结构及设计是否合理关系极大。关键词: 落料、塑性变形、工艺计算、工艺制订、表面质量、尺寸精度 Injection Mold for long Junction SummaryHurtle a kind of tool of press the molding tool conduct and actions manufacturing product( or the half product), its function is to complete a certain craft. Therefore hurtling to press designer must control to hurtle to press the craft, the classification, various craft calculation, craft that includes to hurtle to press the craft establishes etc. the foundation knowledge, just can choose the type of the molding tool and then, carry on the molding tool design, make the type, structure and size etc. of the molding tool satisfy the request of the craft and product.Cold hurtle to press the craft to divide mostly two type: Separate the work preface and model the work preface. Purpose that separates the work preface is at hurtle to ran over the distance lieutenant general to hurtle to press the piece and planks to anticipate to press certain outline line to carry on the separation: Separating the work preface can is divided in to fall to anticipate again, blunt bore and shear to slice etc. The purpose that models the work preface is to make hurtle to press the hair , the creation transforms under the condition of not break its integrity, and convert the shape that product need: Take shape the work preface and is divided into the flection and pull deep, turn over the side, turn over the bore, bulge form and expand the bore, etc. Cold hurtle to press the molding tool is main craft equipments that hurtles to press to produce. Hurtle the surface quantity, size accuracy, rate of production and the economy performance etc. of press the piece, with the molding tool structure and designs whether the reasonable relation is biggest.Keyword: Fall to anticipate, plastic deformation, the craft calculation, craft establish, surface quantity, size accuracy机械加工工艺过程卡机械加工工艺过程卡片产品型号零(部)件图号02产品名称凹模零(部)件名称凹模材料牌号Cr12MoV毛坯种类卷料毛坯外型尺寸273525备注凸模配制工序号工序名称工 序 内 容车间工段设备工 艺 装 备工时准终单件1下料140,长65mm金工普通锯床0.52锻造锻方形体,L210,B125 H65金工空气锤13退火消除锻造后的内应力,并改善其加工性能金工74刨(铣)刨成六面体,厚度留余量0.40.6mm金工25平磨磨上下两平面及相邻两侧面,对角尺达到Ra0.631.25金工16划线钳工按型孔及其他安装孔划线金工17钳工钻出穿丝孔金工0.58插(铣)金工9钳工加工螺孔金工210热处理淬火 回火 5862HRC金工711平磨磨上下两平面,表面粗糙度值应小于Ra0.8金工212电火花切割凹模按图样编制切割程序,并将程序打成纸带,将纸带输入计算机金工设计日期审核日期标准化日期会签日期13研光是工作表面光洁金工标记记数更改文件号签字日期标记处数更该文件号冲压成形与板材冲压 1 概述通过模具使板材产生塑性变形而获得成品零件的一次成形工艺方法叫做冲压。由于冲压通常在冷态下进行,因此也称为冷冲压。只有当板材厚度超过8100mm时,才采用热冲压。冲压加工的原材料一般为板材或带材,故也称板材冲压。某些非金属板材(如胶木板、云母片、石棉、皮革等)亦可采用冲压成形工艺进行加工。冲压广泛应用于金属制品各行业中,尤其在汽车、仪表、军工、家用电器等工业中占有极其重要的地位。冲压成形需研究工艺设备和模具三类基本问题。 板材冲压具有下列特点: (1)高的材料利用率。(2)可加工薄壁、形状复杂的零件。(3)冲压件在形状和尺寸方面的互换性好。(4)能获得质量轻而强度高、刚性好的零件。(5)生产率高,操作简单,容易实现机械化和自动化。冲压模具制作成本高,因此适合大批量生产。对于小批量、多品种生产,常采用简易冲模,同时引进冲压加工中心等新型设备,以满足市场求新求变的需求。板材冲压常用的金属材料有低碳钢、铜、铝、镁合金及高塑性的合金刚等。如前所述,材料形状有板材和带材。冲压生产设备有剪床和冲床。剪床是用来将板材剪切成具有一定宽度的条料,以供后续冲压工序使用,冲床可用于剪切及成形。 2 冲压成形的特点生产时间中所采用的冲压成形工艺方法有很多,具有多种形式饿名称,但塑性变形本质是相同的。冲压成形具有如下几个非常突出的特点。 (1)垂直于板面方向的单位面积上的压力,其数值不大便足以在板面方向上使板材产生塑性变形。由于垂直于板面方向上的单位面积上压力的素质远小于板面方向上的内应力,所以大多数的冲压变形都可以近似地当作平面应力状态来处理,使其变形力学的分析和工艺参数的计算大呢感工作都得到很大的简化。 (2)由于冲压成形用的板材毛胚的相对厚度很小,在压应力作用下的抗失稳能力也很差,所以在没有抗失稳装置(如压边圈等)的条件下,很难在自由状态下顺利地完成冲压成形过程。因此,以拉应力作用为主的伸长类冲压成形过程多于以压应力作用为主的压缩类成形过程。 (3)冲压成形时,板材毛胚内应力的数值等于或小于材料的屈服应力。在这一点上,冲压成形与体积成形的差别很大。因此,在冲压成形时变形区应力状态中的静水压力成分对成形极限与变形抗力的影响,已失去其在体积成形时的重要程度,有些情况下,甚至可以完全不予考虑,即使有必要考虑时,其处理方法也不相同。 (4)在冲压成形时,模具对板材毛胚作用力所形成的约束作用较轻,不像体积成形(如模锻)是靠与制件形状完全相同的型腔对毛胚进行全面接触而实现的强制成形。在冲压成形中,大多数情况下,板材毛胚都有某种程度的自由度,常常是只有一个表面与模具接触,甚至有时存在板材两侧表面都有于模具接触的变形部分。在这种情况下,这部分毛胚的变形是靠模具对其相邻部分施加的外力实现其控制作用的。例如,球面和锥面零件成形时的悬空部分和管胚端部的卷边成形都属这种情况。 由于冲压成形具有上述一些在变形与力学方面的特点,致使冲压技术也形成了一些与体积成形不同的特点。由于不需要在板材毛的表面施加很大的单位压力即可使其成形,所以在冲压技术中关于模具强度与刚度的研究并不十分重要,相反却发展了学多简易模具技术。由于相同原因,也促使靠气体或液体压力成形的工艺方法得以发展。因冲压成形时的平面应力状态或更为单纯的应变状态(与体积成形相比),当前对冲压成形汇中毛胚的变形与 力能参数方面的研究较为深入,有条件运用合理的科学方法进行冲压加工。借助于电子计算机与先进的测试手段,在对板材性能与冲压变形参数进行实时测量与分析基础上,实现冲压过程智能化控制的研究工作也在开展。人们在对冲压成形过程有离开较为深入的了解后,已经认识到冲压成型与原材料有十分密切的关系。所以,对板材冲压性能即成形性与形状稳定性的研究,目前已成为冲压技术的一个重要内容。对板材冲压性能的研究工作不仅是冲压技术发展的需要,而且也促进了钢铁工业生产技术的发展,为其提高板材的质量提供了一个可靠的基础与依据。 3冲压变形的分类 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。分离工序是使胚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。其中又以冲孔、落料应用最广。变形工序是使胚料的一部分相对于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,冲压成形就是毛胚的变形区在外力的作用下产生相应的塑性变形,所以变形区内的应力状态和变形特点景象的冲压成形分类,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体系化的研究。绝大多数冲压成形时毛胚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上的应力为零,使板材毛胚产生塑性变形的是作用于板面方向上相互的两个主应力。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型中的毛陪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与相应的两向应变坐标系中以应力与应变坐标决定的位置来表示。4.冲压用原材料 冲压加工用原材料有很多种,它们的性能也有很大的差别,所以必须根据原材料的性能与特点,采用不同的冲压成形方法、工艺参数和模具结构,才能达到冲压加工的目的。由于人们对冲压成形过程板材毛胚的变形行为有了较为深入的认识,已经相当清楚的建立了由原材料的化学成分、组织等因素所决定的材料性能与冲压成形之间的关系,这就使原材料生产部门不但按照冲压件的工作条件与使用要求进行原材料的设计工作,而且也根据冲压件加工过程对板材性能的要求进行新型材料的开发工作,这是冲压技术在原材料研究方面的一个重要方向。对冲压用原材料冲压性能方面的研究工作有(1)原材料冲压性能的含义。(2)判断原材料冲压性能的科学方法,确定可以确切反映材料冲压性能的参数,建立冲压性能的参数与实际冲压成形间的关系,以及冲压性能参数的测试方法等。 (3)建立原材料的化学成分、组织和制造过程与冲压性能之间的关系。冲压用原材料主要是各种金属与非金属板材。金属板材包括各种黑色技术和有色金属板材。虽然在冲压生产中所用金属板材的种类很多,但最多的原材料蛀牙是钢板、不锈钢板、铝合金板及各种复合金属板。5板材冲压性能及其鉴定方法 板材是指对冲压加工的适应能力。对板材冲压性能的研究具有飞行重要的意义。为了能够运用最科学与最经济合理的冲压工艺过程与工艺参数制造出冲压零件,必须对作为加工对象的板材的性能具有十分清楚的了解,这样才有可能充分地利用板材在加工方面的潜在能力。另一方面,为了能够依据冲压件的形状与尺寸特点及其所需的成形工艺等基本因素,正确、合理地选用板材,也必须对板材的冲压性能有一个科学的认识与正确的判断。评定板材冲压性能的方法有直接试验法与间接试验法。 实物冲压试验是最直接的板材冲压性能的评定方法。利用实际生产设备与模具,在与生产完全相同的条件下进行实际冲压零件的性能评定,当然能够的最可靠的结果。但是,这种评定方法不具有普遍意义,不能作为行业之间的通用标准进行信息的交流。 模拟试验是把生产中实际存在的冲压成形方法进行归纳与简单化处理,消除许多过于复杂的因素,利用轴对称的简化了的成形方法,在保证试验中板材的变形性质与应力状态都与实际冲压成形相同的条件下进行的冲压性能的评定工作。为了保证模拟试验结果的可靠性与通用性,规定了私分具体的关于试验用工具的几何形状与尺寸、毛胚的尺寸、试验条件(冲压速度、润滑方法、压边力等)。 间接试验法也叫做基础试验法。间接试验法的特点是:在对板材在塑性变形过程中所表现出的基本性质与规律进行分析与研究的基础上,进一步把它和具体的冲压成形中板材的塑性变形参数联系起来,建立间接试验结果(间接试验值)与具体的冲压成形性能(工艺参数)之间的相关性。由于间接试验时所用试件的形状与尺寸以及加载的方式等都不同于具体的冲压成形过程,所以它的变形性质和应力状态也不同于冲压变形。因此间接试验所得的结果(试验值)并不是冲压成形的工艺参数,而是可以用来表示板材冲压性能的基础性参数。Characteristics and Sheet Metal Forming1 The article overview Stamping is a kind of plastic forming process in which a part is produced by means of the plastic forming the material under the action of a die. Stamping is usually carried out under cold state, so it is also called stamping. Heat stamping is used only when the blank thickness is greater than 8100mm. The blank material for stamping is usually in the form of sheet or strip, and therefore it is also called sheet metal forming. Some non-metal sheets (such as plywood, mica sheet, asbestos, leather)can also be formed by stamping. Stamping is widely used in various fields of the metalworking industry, and it plays a crucial role in the industries for manufacturing automobiles, instruments, military parts and household electrical appliances, etc. The process, equipment and die are the three foundational problems that needed to be studied in stamping. The characteristics of the sheet metal forming are as follows: (1) High material utilization (2) Capacity to produce thin-walled parts of complex shape. (3) Good interchangeability between stamping parts due to precision in shapeand dimension. (4) Parts with lightweight, high-strength and fine rigidity can be obtained. (5) High productivity, easy to operate and to realize mechanization and automatization. The manufacture of the stamping die is costly, and therefore it only fits to mass production. For the manufacture of products in small batch and rich variety, the simple stamping die and the new equipment such as a stamping machining center, are usually adopted to meet the market demands. The materials for sheet metal stamping include mild steel, copper, aluminum, magnesium alloy and high-plasticity alloy-steel, etc.Stamping equipment includes plate shear punching press. The former shears plate into strips with a definite width, which would be pressed later. The later can be used both in shearing and forming. 2Characteristics of stamping forming There are various processes of stamping forming with different working patterns and names. But these processes are similar to each other in plastic deformation. There are following conspicuous characteristics in stamping: (1)The force per unit area perpendicular to the blank surface is not large but is enough to cause the material plastic deformation. It is much less than the inner stresses on the plate plane directions. In most cases stamping forming can be treated approximately as that of the plane stress state to simplify vastly the theoretical analysis and the calculation of the process parameters. (2)Due to the small relative thickness, the anti-instability capability of the blank is weak under compressive stress. As a result, the stamping process is difficult to proceed successfully without using the anti-instability device (such as blank holder). Therefore the varieties of the stamping processes dominated by tensile stress are more than dominated by compressive stress. (3)During stamping forming, the inner stress of the blank is equal to or sometimes less than the yield stress of the material. In this point, the stamping is different from the bulk forming. During stamping forming, the influence of the hydrostatic pressure of the stress state in the deformation zone to the forming limit and the deformation resistance is not so important as to the bulk forming. In some circumstances, such influence may be neglected. Even in the case when this influence should be considered, the treating method is also different from that of bulk forming. (4)In stamping forming, the restrain action of the die to the blank is not severs as in the case of the bulk forming (such as die forging). In bulk forming, the constraint forming is proceeded by the die with exactly the same shape of the part. Whereas in stamping, in most cases, the blank has a certain degree of freedom, only one surface of the blank contacts with the die. In some extra cases, such as the forming of the blank on the deforming zone contact with the die. The deformation in these regions are caused and controlled by the die applying an external force to its adjacent area. Due to the characteristics of stamping deformation and mechanics mentioned above, the stamping technique is different form the bulk metal forming: The importance or the strength and rigidity of the die in stamping forming is less than that in bulk forming because the blank can be formed without applying large pressure per unit area on its surface. Instead, the techniques of the simple die and the pneumatic and hydraulic forming are developed. Due to the plane stress or simple strain state in comparison with bulk forming, more research on deformation or force and power parameters has been done. Stamping forming can be performed by more reasonable scientific methods. Based on the real time measurement and analysis on the sheet metal properties and stamping parameters, by means of computer and some modern testing apparatus, research on the intellectualized control of stamping process is also in proceeding. It is shown that there is a close relationship between stamping forming and raw material. The research on the properties of the stamping forming, that is, forming ability and shape stability, has become a key point in stamping technology development, but also enhances the manufacturing technique of iron and steel industry, and provides a reliable foundation for increasing sheet metal quality. 3Categories of stamping forming Many 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 from 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 from 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 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 is assumed that the stress perpendicular to the blank surface equals 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 the two principal stresses distribute uniformly along the thickness direction. Based on this analysis, the stress state and the deformation characteristics of the deformation zone in all kinds of stamping forming can be denoted by the points in the coordinates of the plane principal stresses and the coordinates of the corresponding plane principal strains. 4Raw materials for stamping formingThere are a lot of raw materials used in stamping forming, and the properties of these materials may have large difference. The stamping forming can be succeeded only by determining the stamping method, the forming parameters and the die structures according to the properties and characteristics of the raw materials. The deformation of the blank during stamping forming has been investigated quite thoroughly. The relationships between the material properties decided by the chemistry component and structure of the material and the stamping forming has been established clearly. Not only the proper material can be selected based on the working condition and usage demand, but also the new material can be developed according to the demands of the blank properties during processing the stamping part. This is an important domain in stamping forming research. The research on the material properties for stamping forming is as follows: (1)Definition of the stamping property of the material. (2)Method to judge the stamping property of the material, find parameters to express the definitely material property of the stamping forming, establish the relationship between the property parameters and the practical stamping forming, and investigate the testing methods of the property parameters. (3)Establish the relationship among the chemical component, structure, manufacturing process and stamping property. The raw materials for stamping forming mainly include various metals and nonmetal plate. Sheet metal includes both ferrous and nonferrous metals. Although a lot of sheet metals are used in stamping forming, the most widely used materials are steel, stainless steel, aluminum alloy and various composite metal plates. 5Stamping forming property of sheet metal and its assessing methodThe stamping forming property of the sheet metal is the adaptation capability of the sheet metal to stamping forming. It has crucial meaning to the investigation of the stamping forming property of the sheet metal. In order to produce stamping forming parts with most scientific, economic and rational stamping forming process and forming parameters, it is necessary to understand clearly the properties of the sheet metal, so as to utilize the potential of the sheet metal fully in the production. On the other hand, to select plate material accurately and rationally in accordance with the characteristics of the shape and dimension of the stamping forming part and its forming technique is also necessary so that a scientific understanding and accurate judgment to the stamping forming properties of the sheet metal may be achieved. There are direct and indirect testing methods to assess the stamping property of the sheet metal.Practicality stamping test is the most direct method to assess stamping forming property of the sheet metal. This test is done exactly in the same condition as actual production by using the practical equipment and dies. Surely, this test result is most reliable. But this kind of assessing method is not comprehensively applicable, and cannot be shared as a commonly used standard between factories. The simulation test is a kind of assessing method that after simplifying and summing up actual stamping forming methods, as well as eliminating many trivial factors, the stamping properties of the sheet metal are assessed, based on simplified axial-symmetric forming method under the same deformation and stress states between the testing plate and the actual forming states. In order to guarantee the reliability and generality of simulation results, a lot of factors are regulated in detail, such as the shape and dimension of tools for test, blank dimension and testing conditions(stamping velocity, lubrication method and blank holding force, etc).Indirect testing method is also called basic testing method its characteristic is to connect analysis and research on fundamental property and principle of the sheet metal during plastic deformation, and with the plastic deformation parameters of the sheet metal in actual stamping forming, and then to establish the relationship between the indirect testing results(indirect testing value) and the actual stamping forming property (forming parameters). Because the shape and dimension of the specimen and the loading pattern of the indirect testing are different from the actual stamping forming, the deformation characteristics and stress states of the indirect test are different from those of the actual one. So, the results obtained form the indirect test are not the stamping forming parameters, but are the fundamental parameters that can be used to represent the stamping forming property of the sheet metal.
收藏