板料成型工艺及模具设计【冲孔落料复合模】【说明书+CAD】
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外文翻译专 业 名 称 机械设计制造及其自动化班 级 学 号 078105232学 生 姓 名 冼 振 源指 导 教 师 陈 为 国填 表 日 期 2011 年 1 月 17 日General all-steel punching dies punching accuracyAccuracy of panel punching part is display the press accuracy of the die exactly. But the accuracy of any punching parts linear dimension and positional accuracy almost depend on the blanking and blanking accuracy,. So that the compound mould of compound punchings accuracy, is typicalness and representation in the majority.Analyse of the dies accuracy For the analyse of pracyicable inaccuracy during production of dies to inactivation, we could get the tendency when it is augmentation in most time. From this we could analyse the elements. When the new punch dies pt into production to the first cutter grinding, the inaccuracy produced called initial error; if the die grinding more than twenty times, until its discard, the inaccuracy called conventional error; and before the dies discard, the largest error of the last batch permit, called limiting error. at job site, the evidence to confirm life of sharpening is the higher of the blanking, punched hole or punched parts. Because all finished parts had been blanked ,so it is especially for the compound dies. Therefore, the analyse of burr and measurement is especially important when do them as enterprise standardization or checked with .The initial error usually is the minimal through the whole life of die. Its magnitude depend on the accuracy of manufacture, quality, measure of the punching part, thickness of panel, magnitude of gap and degree of homogeneity. The accuracy of manufacture depend on the manufacture process. For the 1 mm thicked compound punching part made in medium steel, the experimental result and productive practice all prove that the burr of dies which produced by spark cutting are higher 25%30% than produced by grinder ,NC or CNC. The reason is that not only the latter have more exact machining accuracy but also the value of roughness Ra is less one order than the formmer, it can be reached 0.025m. Therefore, the dies initial blanked accuracy depends on the accuracy of manufacture, quality and so on. The normal error of the punch die is the practicable error when the fist cutter grinding and the last cutter grinding before the die produce the last qualified product. As the increase of cutter grinding, caused the measure the nature wear of the dies are gradual increasing, the error of punching part increase also, so the parts are blew proof. And the die will be unused. The hole on the part and inner because the measure of wear will be small and small gradually, and its outside form will be lager in the same reason. Therefore, the hole and inner form in the part will be made mould according to one-way positive deviation or nearly equal to the limit max measure. In like manner, the punching parts appearance will be made mould according to one-way negative deviation or nearly equal to limit mini measure. For this will be broaden the normal error, and the cutter grinding times will be increased, the life will be long. The limit error in punching parts are the max dimension error which practicable allowed in the parts with limit error. This kind of parts usually are the last qualified products before the die discard.For the all classes of dies, if we analyse the fluctuate, tendency of increase and decrease and law which appeared in the dies whole life, we will find that the master of the error are changeless; the error that because the abrade of the cutter and impression will be as the cutter grinding times increased at the same time. And that will cause the error oversize gradually; and also have another part error are unconventional , unforeseen. Therefore, every die s error are composed of fixed error, system error, accident error and so on. 1. fixed error At the whole process when the New punching die between just input production to discard, the changeless master error that in qualified part are called fixed error. Its magnitude is the deviation when the die production qualified products before the first cutter grinding. Also is the initial error, but the die have initial punching accuracy at this time. Because of the abrade of parts, the die after grinding will be change the dimension error. And the increment of deviation will oversize as the times of cutter grinding. So the punching accuracy after cutter grinding also called “grinding accuracy” and lower tan initial accuracy. The fixed error depend on the elements factor as followed :(1) the material , sorts, structure, (form) dimension, and thick of panelthe magnitude of punching gap and degree of homogeneity are have a important effect for the dimension accuracy. Different punching process, material, thick of panel, have completely different gap and punching accuracy. A gear H62 which made in yellow brass with the same mode number m=0.34, 2mm thick and had a center hole, when the gap get C=0.5%t (single edge) , and punched with compound punching die, and the dimension accuracy reached IT7, the part have a flat surface ,the verticality of tangent plane reached 89.5, its roughness Ra magnitude are 12.5m, height of burr are 0.10mm; and the punching part are punched with progressive die, the gap C=7%t (single edge) , initial accuracy are IT11, and have an more rough surface, even can see the gap with eyes. In the usual situation, flushes a material and its thickness t is theselection punching gap main basis. Once the designation gap haddetermined flushes the plane size the fixed error main body; Flushesthe structure rigidity and the three-dimensional shape affects itsshape position precision.(2) punching craft and molder structure typeUses the different ramming craft, flushes a precision and the fixederror difference is really big. Except that the above piece gearexample showed, the essence flushes the craft and ordinary punching flushes a precision and the fixed error differs outside a magnitude,even if in ordinary punching center, uses the different gap punching, thefixed error difference very is also big. For example material thickt=1.5mm H62 brass punching, selects C = the 40%t unilateral I kind ofsmall gap punching compared to select C 4mm flushes, the size precision can lower some. Different dies structure type, because is suitable the rammingmaterial to be thick and the manufacture precision difference, causesto flush a fixed error to have leaves. Compound die center, multi-locations continuous type compound die because flushes continuously toduplicate the localization to add on the pattern making error to bebigger, therefore it flushes a fixed error compound punching die to wantcompared to the single location Big 1 2 levels (3) the craft of punching dies manufacturethe main work of punching die namely are raised, the concave moldprocessing procedure, to operates on the specification not to behigh, can time form a more complex cavity. But its processing surfaceapproximately is thick 0.03 0.05mm is the high temperatureablation remaining furcated austenite organization, degree ofhardness may reach as high as HRC67 70, has the micro crack, easilywhen punching appears broke the cutter or flaking. The Italian CorradaCorporations related memoir called the line cut the processing contruction to have the disadvantageous influence to the superficialgold, in fact already changed the gold contruction. We must use theJingang stone powder to grind or the numerical control continual pathcoordinates rub truncate (cut to line) to make the precision work . In recent years country and so on Switzerland and Japan, has conductedthe thorough research to the electrical finishing equipment and abigger improvement, makes function complete high accuracy NC and theCNC line cutter, the processing precision may reach 0.005 0.001mm,even is smaller. The processing surface roughness Ra value can achieve0.4 mu m. According to the recent years to the domestic 12 productionlines cutter factory investigation and study, the domesticallyproduced line cutter processing precision different factory differentmodel line cutter might reach 0.008 0.005mm, generally all in0.01mm or bigger somewhat, was individual also can achieve0.005mm, the processing surface roughness Ra value was bigger than1.6m. However, the electrical finishing ablation metal surface thus the change and the damage machined surface mental structure character can not change, only if with rubs truncates or other ways removes this harmful level. Therefore, merely uses electricity machining, including the spark cutting and the electricity perforation, achieves with difficulty punching, especially high accuracy, high life punching die to size precision and work components surface roughness Ra value request. With precisely rubs truncates the law manufacture punching die, specially makes the high accuracy, the high life punching die, such as: Thin material small gap compound punching die, multi- locations continuous type compound die and so on, has the size precision high, the work component smachined surface roughness Ra value is small, the mold life higher characteristic. Its processing craft at present changed the electrical fire by the past ordinary engine bed rough machining spark cutting or the electricity puncher rough machining, finally precisely rubs truncates, also from takes shape rubs, optics curve rubs, the manual grid reference rubs gradually filters the continual path grid reference to rub and NC and the CNC continual path grid reference rubs, Processing coarseness may reach 0.001 0.0005mm, the processing surface roughness Ra value may reach 0.1 0.025 mu m. Therefore, with this craft manufacture the die , regardless of the size precision, the work components surface roughness, all can satisfy die, each kind of compound request, the die is especially higher than the electrical finishing craft manufacture scale.(4) gap size and degree of homogeneity the flange and other sheet forming sgene rally all must first punching (fall material) the plate to launch the semi finished materials, after also has the forming to fall the material, the incision obtains the single end product to flush. Therefore punching the work, including is commonly used punching hole, the margin, cut side and so on, regarding each kind of sheet pressing partall is necessary. Therefore punching the gap to flushes a out form in chprecision to have the decisive influence. punching the gap small and is even, may cause punching the size gain high accuracy. Regarding drawability, is curving and so on mould, the gap greatly will decide increases flushes the oral area size error and the snapping back. The gapnon-uniformity can cause to flush a burr enlarges and incurs cutting edge the non-uniform attrition. (5) ramming equipment elastic deformation In the ramming process After the punch press load bearing can have the certain elastic deformation. Although this kind of distortion quantity according to flushes the pressure the size to change also to have the obvious directivity, but on the pressing part, mainly is to has the volume ramming archery target stamping, embosses, the equalization, the pressure is raised, the wave, flushes crowds, the shape, the flange, hits flatly, thinly changes draw ability and so on the craft work punching forming flushes, has the significant influence to its ramming aspect size precision普通全钢冲模的冲压精度分析板料冲压件的精度准确显示出其冲模的冲压精度。而任何冲件的线性尺寸精度与形位精度主要取决于冲模冲裁和立体成形冲压件展开平毛坯的落料精度。因此,多工步复合冲压的单工位复合模、多工位连续模的冲压精度,在普通冲压的众多种类与不同结构的冲模中,最具典型性和代表性。冲模的冲压精度分析对冲模投产至失效报废各个时期冲件的实际误差分析,可以看出其增大的时期及趋向,从而分析其增大的因素。新冲模投产至第一次刃磨前冲制冲件的误差即所谓的初始误差;冲模经过20次左右刃磨至失效报废前冲制的冲件误差称之为常规误差;而冲模失效报废前冲制的最后一批合格冲件的允许最大误差称之为极限误差。在现场,确定冲模刃磨寿命的依据是冲件冲孔与落料的毛刺高度。由于任何成形件都具有冲裁作业(毛坯落料或冲孔),对于复合模尤为如此。所以,冲件毛刺高度的触模检查和测量并按企业标准或JB4129-85冲压件毛刺高度对照检测就显得十分重要。冲模的初始误差通常是冲模整个寿命中冲件误差最小的。其大小主要取决于冲模的制造精度与质量及冲件尺寸、料厚以及间隙值大小与均匀度。冲模的制造精度及质量又取决于制模工艺。对于料厚t1mm的中碳钢复合冲裁模冲件,实验结果与生产实践都证明,电火花线切割制造的冲模冲件毛刺高度比用成型磨或NC与CNC连续轨迹座标磨即精密磨削工艺制造的冲模冲件要高25%30%。这是因为后者不仅加工精度高,而且加工面粗糙度Ra值要比前者小一个数量级,可达到0.025m。因此,冲模的制造精度与质量等因素决定了冲模的初始冲压精度,也造就了冲件的初始误差。冲件的常规误差是冲模经第一次刃磨到最后一次刃磨后冲出最后一个合格冲件为止,冲件实际具有的误差。随着刃磨次数的增加,刃口的自然磨损而造成的尺寸增量逐渐加大,冲件的误差也随之加大。当其误差超过极限偏差时,冲件就不合格,冲模也就失效报废。/冲件上孔与内形因凸模磨损尺寸会逐渐变小;其外形落料尺寸会因凹模磨损而逐渐增大。所以,冲件上孔与内形按单向正偏差标允差并依接近或几乎等于极限最大尺寸制模。同理,冲件外形落料按单向负偏差标注允差并依接近或几乎等于极限最小尺寸制模。这样就使冲件的常规误差范围扩大,冲模可刃磨次数增加,模具寿命提高。冲件的极限误差是具有极限偏差的冲件所具有的实际允许的最大尺寸误差。这类冲件通常是在冲模失效报废前冲制的最后一批合格冲件。对各类冲模冲件误差在冲模整个寿命中出现的波动、增减趋向及规律等进行全面分析便可发现:冲件误差的主导部分是不变的;因刃口或型腔的自然磨损而出现的误差增量随冲模刃磨冲数增加而使这部分误差逐渐加大;还有部分误差的增量是非常规的、不可预见的。所以,各类冲模冲件误差是由因定误差、渐增误差、系统误差及偶发误差等几部分综合构成。1、固定误差新冲模在指定的冲压设备上投入使用至失效报废的整个(总)寿命过程中,其合格冲件误差的主导部分固定不变即所谓固定误差。其大小就是新冲模第一次刃磨前冲制的合格冲件的偏差,也即冲模的初始误差,而此时的冲模具有初始冲压精度。刃磨后的冲模,因其工作零件(凸、凹模)磨损而改变尺寸误差,使冲件识差增量随刃磨次数增加而逐渐加大,故冲模刃磨后的冲压精度亦称“刃磨精度”比其初始精度要低。冲模冲件的固定误差取决于以下各要素:(1)冲件的材料种类、结构(形状)尺寸及料厚冲裁间隙的大小及其均匀度对冲裁件的尺寸精度有决定性的影响。不同冲裁工艺、不同材料种类与不等料厚,间隙相差悬殊,冲压精度差异很大。同一种模数m=0.34的2mm的料厚、中心有孔的H62黄铜材料片齿轮复合模冲件,当取间隙C=0.5%t(单边),用复合精冲模冲制,冲件尺寸精度达到IT7级,冲件平直无拱弯,冲切面垂直度可达89.5,其表面粗糙Ra值为0.2m;而用普通复合模冲制,间隙C=5%t(单边),冲件初始误差亦即冲模的初始冲压精度为1T9级,冲切面粗糙度Ra值为12.5m,毛刺高度为0.10mm;还是这个冲件用连续模冲制,间隙C=7%t(单边),初始冲件精度为IT11级,冲切面更粗糙,甚至有肉眼可见的台阶。通常情况下,冲件材料及其厚度t是选取冲裁间隙的主要依据。一旦选定间隙就确定了冲件的平面尺寸的固定误差的主体;冲件结构刚度及立体形状则影响其形位精度。(2)冲压工艺及冲模结构类型采用不同的冲压工艺,冲件的精度及固定误差相差甚大。除上述片齿轮实例说明,精冲工艺与普通冲裁的冲件精度与固定误差相差一个数量级之外,即便在普通冲裁中,采用不同间隙冲裁,固定误差相差也很大。例如料厚t=1.5mm的H62黄铜冲裁件,选用C40%t单边类小间隙冲裁比选用C8%t(单边)类大间隙冲裁,冲件固定误差将加大40%60%,精度至少降一级。此外,采有无搭边排样,冲件的误差要远大于有搭边排样冲件。无搭边排样冲件。无搭边排样冲件的精度低于IT12级,而多数有搭边排样的冲件精度在IT11IT9级之间,料厚t4mm的冲件,尺寸精度会更低一些。不同冲模结构类型,由于适用冲压料厚及制造精度的差异,导致冲件的固定误差有别。复合模中,多工位连续式复合模由于冲件连续重复定位加上制模误差较大,故其冲件的固定误差比单工位复合冲裁模要 大12级。(3)冲模制造工艺冲模主要工作零件即凸、凹模的加工程序,对操作上的技术要求不高,能够一次成形较复杂的模腔。但其加工表面约厚0.030.05mm为高温烧蚀的残余树枝状奥氏体组织,硬度可高达HRC6770,有显微裂纹,容易在冲裁时出现崩刃或剥落。意大利Corrada公司的有关研究报告称“线切割加工对表面金相结构产生不利的影响,实际上已经改变了金相结构。我们必须用金刚石粉研磨或数控连续轨迹坐标磨削(对线切割件)作精加工”。近年来瑞士和日本等国,对电加工设备进行了深入的研究和较大的改进,制造出功能齐全的高精度NC和CNC线切割机,加工精度可达0.0050.001mm,甚至更小。加工表面粗糙度Ra值能达到0.4m。根据近年对国内12家生产线切割机工厂的调研,国产线切割机加工精度各别厂家的各别型号线切割机可达0.0080.005mm,一般都在0.01mm或更大一些,个别也能达到0.005mm,加工表面粗糙度Ra值均大于1.6m。然而,电加工烧蚀金属表面从而改变和损坏加工面金相结构的特性不会改变,除非用磨削或其他加工法去除这一有害层。所以,仅仅用电加工法,包括电火花线切割与电穿孔,难以达到冲模,尤其高精度、高寿命冲模对尺寸精度与工作零件表面粗糙度Ra值要求。用精密磨削法制造冲模,特别是制造高精度、高寿命冲模,诸如:薄料小间隙复合冲裁模、多工位连续式复合模等,具有尺寸精度高、工作零件加工面粗糙度Ra值小、模具寿命高等特点。其加工工艺目前已由过去的普通机床粗加工改为电火花线切割或电穿孔机粗加工,最后精密磨削,也由成型磨、光学曲线磨、手动座标磨逐步过滤到连续轨迹座标磨及NC与CNC连续轨迹座标磨,加工粗度可达0.0010.0005mm,加工表面粗糙度Ra值可达0.10.025m。所以,用该工艺制造的冲模,无论尺寸精度、工作零件表面粗糙度,都能满足冲模,尤其各种复合模的要求,比电加工工艺制造的冲模高一个档次。(4)间隙的大小与均匀度拉深、弯曲、翻边及其他板料成形件一般都要先冲裁(落料)出平板展开毛坯,也有成形后落料、切开得到单个成品冲件。故冲裁作业,包括常用的冲孔、切口、切边等,对于每种板料冲压件都是必要的。所以冲裁间隙对冲件的外廓尺寸精度有决定性的影响。冲裁间隙小而均匀,可使冲裁尺寸获取更高精度。对于拉深、弯曲等成形模,间隙大定将增大冲件口部尺寸误差及回弹。间隙不均匀会使冲件毛刺加大并招致刃口的不均匀磨损。(5)冲压设备的弹性变形在冲压过程中,冲床承载后会产生一定的弹性变形。虽然这种变形量依冲压力的大小变化且具有明显的方向性,但就冲压件,主要是对具有体积冲压性质的压印、压花、校平、压凸、起波、冲挤、镦形、翻边、镦粗、打扁、变薄拉深等工艺作业冲制成形的冲件,对其冲压方面的尺寸精度有重大影响。板料成型工艺及模具设计课程设计指导书2013年9月15日一、 板金模设计的目的板金模课程设计是在理论教学之后进行的实践性教学环节,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,培养学生的实际工作能力。通过设计,使学生在冲压工艺性分析、冲压工艺方案论证、冲压工艺计算、冲模零件结构设计、编写技术文件和查阅技术文献等方面受到一次综合训练。二、 板金模设计的内容1 设计课题一般为单工序或较为简单的级进模和冲孔落料复合模。2 设计内容设计内容包括冲压工艺性分析,工艺方案制定,排样图设计,总的冲压力计算和压力中心计算,刃口尺寸计算,弹簧、橡皮的计算和选用,凸模、凹模或凸凹模的结构设计以及其它冲模零件的设计,绘制模具装配图和工作零件图,编写设计说明书,填写冲压工艺卡。3 设计工作量设计工作量:冲压工艺卡1份,冲模装配图1张,工作零件图4张,设计说明书1份。三、 板金模设计的要求1 板金模装配图板金模装配图用以表明冲模结构、工作原理组成冲模的全部零件及其相互位置和装配关系。一般情况下,板金模装配图用主视图和俯视图表示,若还不能表达清楚时,再增加其它视图。一般按1:1的比例绘制。板金模装配图上要标明必要的尺寸和技术要求。(1) 主视图 主视图放在图样的上面偏左,按冲模正对操作者方向绘制,采取剖面画法,一般按模具闭合状态绘制,在上、下模间有一完成的冲压件,断面涂红或涂黑。主视图是模具装配图的主体,应尽量在主视图上将结构表达清楚,力求将凸、凹模的形状画完整。(2) 俯视图 通过俯视图可以了解冲模零件的平面布置、排样方法、以及凹模的轮廓形状等。习惯将上模部分拿去,只反映模具的下模俯视可见部分;或将上模的左半部分去掉,只画下模,而右半部分保留上模画俯视图。俯视图上,制件图和排样图的轮廓用双点划线表示。图上应标注必要的尺寸,如模具闭合高度、模架外形尺寸、模柄直径等,不标配合尺寸和形位公差。(3) 制件图和排样图 制件图和排样图通常画在图样的右上角,要注明制件的材料、规格以及制件的尺寸、公差等。若图面位置不够可另立一页。对于多工序成形的制件,除绘制本工序的模具装配图,还应绘出排样图,排样图布置在制件图的左边。此外,对于有落料工序的模具装配图,还应绘出排样图,排样图布置在制件图的下方,并注明条料宽度及公差、步距和搭边值。制件图和排样图应按比例绘出,若不一致,必须用箭头指明冲压方向。(4) 标题栏与明细表 标题栏与明细表布置在图样的右下角,并按机械制图国家标准填写。零件明细表应包括件号、名称、数量、材料、热处理、标准零件代号及规格、备注等内容。模具图中的所有零件都应详细填写在明细表中。(5) 技术要求 装配图和技术要求布置在图纸的下部的适当位置。其内容包括:凸、凹模间隙,模具闭合高度,该模具的特殊要求,其它,按本行业国标或厂标执行。2 冲模零件图零件图的绘制和标注应符合机械制图国家标准的规定,要注明全部尺寸、公差配合、形位公差、表面粗糙度、材料、热处理要求及其它技术要求。冲模零件在图样上的方向应尽量按该零件在装配图中的方位画出,不要随意旋转或颠倒,以防画错,影响装配。对凸、凹模配合加工,其配制尺寸可不标公差,仅在该标称尺寸右上角注上符号“*”,并在技术条件中说明:注“*”尺寸按凸(凹)模配作,保证间隙若干即可。3 冲压工艺卡(这个可以略)按标准工艺卡片进行填写4 设计说明书设计者除了用工艺文件和图样表达自己的设计结果外,还必须编写设计说明书,用以阐明自己的设计观点、方案的优劣、依据和过程。其内容包括:(1) 目录(2) 设计任务书及产品图(3) 序言(4) 制件的工艺性分析(5) 冲压工艺方案的制定(6) 模具结构形式的论证及确定(7) 排样图设计及材料利用率计算(8) 工序压力计算及压力中心确定(9) 冲压设备的选择及校核(10) 模具零件的选用、设计及必要的计算(11) 模具工作零件刃口尺寸及公差的计算(12) 其它需要说明的问题(13) 主要参考书目录说明书中应附有冲模结构等必要的简图。所选参数及所用公式应注明出处,并说明式中各符号所代表的意义及单位。说明书最后(即内容13)应附有参考文献目录,包括书刊名称、作者、出版社、出版年份。在说明书中引用所列参考资料时,只需在方括号里注明其序号及页数,如:见文献7P211。四、 板金模设计的步骤与方法1 明确设计任务,收集有关资料学生拿到设计任务书后,首先明确自己的设计课题要求,并仔细阅读设计指导书,了解冲模设计的目的、内容、要求和步骤。然后在指导老师的指导下拟定工作进度计划,查阅有关图册、手册等资料。若有条件,应深入到有关工厂了解所设计零件的用途、结构、性能,在整个产品中的装配关系、技术要求,生产的批量,采用的冲压设备型号和规格,模具制造的设备型号和规格,标准化等情况。2 冲压工艺分析及工艺方案的确定(1) 冲压工艺性分析 在明确了设计任务、收集了有关资料的基础上,分析制品的技术要求、结构工艺性及经济性是否符合冲压工艺要求。若不合适,应提出修改意见,经指导教师同意修改后或更换设计任务书。(2) 制定工艺方案,填写工艺卡片 首先在工艺分析的基础上,确定冲压件的总体工艺方案,然后确定冲压加工工艺方案,它是制定冲压件工艺过程的核心。在确定冲压工艺方案时,先决定所需的基本工序性质、数目、顺序,再将其排列组合成若干种方案,最后对各种可能性的方案进行比较分析,综合其优缺点,选出一种最佳方案,将其内容填入冲压工艺卡中。3 冲压工艺计算及设计(1) 排样及材料利用率的计算 就设计冲裁模而言,排样图设计是进行工艺设计的第一步。每个制件都有自己的特点,每种工艺方案考虑问题的出发点也不尽相同,因而同一制件也可能有多种不同的排样方法。在设计排样图时,必须考虑制件精度、模具结构、材料利用率、生产效率、工人操作习惯等诸多因素。制件外形简单、规则、可采取直排单排排样,排样图设计较为简单,只需查出搭边值即可求出条料宽度,画出排样图。若制件外形复杂,或为节约材料、提高生产率而采取斜排、对排、套排等排样方法时,设计排样图则较困难。当没有条件用计算机辅助排样时,可用纸板按比例做若干个样板。利用实物排样,往往可以达到事半功倍的效果。在设计排样图时往往要同时对多种不同排样方案计算材料利用率,比较各种方案的优劣,选择最佳排样方案。(2) 刃口尺寸的计算 刃口尺寸的计算较为简单,当确定了凸凹模加工方法后而可按相关公式进行计算。一般冲模计算结果精确到小数点后两位,采用成形磨、线切割等加工方法时,计算结果精确到小数点后三位。若制件为弯曲件或拉深件,需先计算展开尺寸,再计算刃口尺寸。(3) 冲压力的计算、压力中心的确定、冲压设备的初选 根据排样图和所选模具结构形式,可以方便地算出所需总压力。用解析法求出压力中心,以便确定模具的外形尺寸。根据算出的总压力,初选冲压设备的型号和规格,待模具总图设计好后,校核该设备的装模尺寸(如闭合高度、工作台板尺寸、漏料孔尺寸等)是否合要求,最终确定压力机型号和规格。4 冲模结构设计(1) 确定凹模尺寸 先计算出凹模厚度,再根据厚度确定凹模周界大小,在确定凹模周界尺寸时,一定要注意三个问题,第一:要考虑凹模上螺孔、销孔的布置,第二,压力中心一般与凹模的几何中心重合,第三,凹模外形尺寸尽量按国家标准选取。(2) 选择模架并确定其它冲模零件的主要参数 根据凹模周界大小,从板金模国家标准(板金模典型组合)中即可确定模架规格及主要冲模零件的规格参数,再查阅冲模标准中有关零部件图表,就可以画装配图了。(3) 画冲模装配图 先画出冲模结构草图,经指导老师审阅后再画正式图。先画主视图,再画俯视图。最好从凸、凹模结合面开始,同时往上、下两个方向画较为方便,且不容易出错。(4) 画冲模零件图 装配图画好后,即可画零件图。一般选择凹模的右侧和下侧平面(俯视图)为设计的尺寸基准。(5) 编写技术文件 板金模课程设计编写的技术文件有:说明书,冲压工艺卡。按要求认真编写。五、 时间安排时间一般为二周,其进度及时间安排大致如下:熟悉设计题目,查阅资料,作准备工作:1天进行工艺方案分析,确定工艺方案1天工艺设计和工艺计算1.5天画装配图草图1.5天画正式图1.5天画零件图2天编写技术文件1.5天附件:板料成型工艺及模具设计课程设计是一个重要的专业教学环节,这个教学环节的目的: (1)帮助学生具体运用和巩固板料成型工艺及模具设计课程及相关的理论知识,了解设计冲压模的一般程序。 (2)是使学生能够熟练地运用有关技术资料,如板金模国家标准、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。 1 、冲压模设计的准备工作 根据课程设计目的,设计课题由指导教师用“设计任务书”的形式下达,课题难度以轻度复杂如冲孔落料复合模为宜。设计工作量根据课程设计时间安排情况,由指导教师酌定。 1.1 研究设计任务 学生应充分研究设计任务书,了解产品用途,并进行冲压件的工艺性及尺寸公差等级分析,对于一些冲压件结构不合理或工艺性不好的,必须征询指导教师的意见后进行改进。在初步明确设计要求的基础上,可按以下步骤进行冲压总体方案的论证。 第一步,酝酿冲压工序安排的初步方案,并画出各步的冲压工序草图; 第二步,通过工序安排计算及冷冲压模具结构图册等技术资料,验证各步的冲压成型方案是否可行,构画该道工序的模具结构草图。 第三步,构画其它模具的结构草图,进一步推敲上述冲压工序安排方案是否合理可行。 第四步,冲压工序安排方案经指导教师过目后,即可正式绘制各步的冲压工序图,并着手按照“设计任务书”上的要求进行课程设计。 1.2 资料及工具准备 课程设计开始前必须预先准备好板金模国家标准、模具设计与制造简明手册、冷冲压模具结构图册等技术资料,及图板、图纸、绘图仪器等工具。也可将课程设计大部分工作安排在计算机上用AutoCAD等软件来完成。 2、设计步骤 冲压模课程设计按以下几个步骤进行: (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(阶段考核比例为15%) (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(25%); (3)确定压力机吨位(5%); (4)设计及绘制模具装配图(25%); (5)设计及绘制模具零件图(25%); (6)按规定格式编制设计说明书(5%)。 3、 明确考核要求 根据以上6个阶段应该形成的阶段设计成果实施各阶段的质量及考核,从而形成各阶段的考核成绩。其中课程设计面批或答辩不仅有助与当面指出学生的各类设计错例,也是课程设计考核的重要手段。最终的考核成绩在6个阶段考核成绩的基础上,由指导教师结合考勤记录及面批或答辩记录对总成绩在10%左右的范围内适度调整。4、课程设计任务:1)制订冲压工艺方案,工艺卡一张2)模具总装图1张,凸模及凹模零件图2张,另加其它零件图3)设计说明书1份,20页左右5、设计要求:1、 图纸可以手绘或CAD绘制,CAD绘制者必须交纸质图及磁盘2、 本任务书应与说明书、图纸一同装订成册,并加封面,装入资料袋中,否则不接受作业3、 作业统一由各班班长收齐,于 按时交至任课教师4、 设计必须认真仔细,允许讨论,但严禁抄袭、复制或复印6、参考资料:比如板料成型工艺及模具设计翁其金主编,模具设计与制造简明手册、板金模图册、板金模设计指导、中国模具设计大典第一个课程设计(冲孔、落料,选择复合模或级进模,每人尺寸互商变化) 蔡美军陈雪梅陈专单小菁第二个课程设计(落料模,每人尺寸互商变化): T=1mm 材料为Q235范昆伦冯宏博付馨雪郭海第三个课程设计(冲孔落料模,每人尺寸互商变化): T=2.0mm 材料为 Q235胡涛胡晓剑李旺来李潇第四个课程设计(落料、冲孔、弯曲模,每人尺寸互商变化): T=2.0mm Q235钢李真廖灿廖晓航刘灿军刘程第五个课程设计(冲孔落料模,每人尺寸互商变化): T=2.0mm Q235钢姓名刘娜刘奇刘远铭栾懿第六个课程设计(冲孔落料模,每人尺寸互商变化): T=2.0mm Q235钢姓名罗钧文罗焱垚罗远明马春艳欧阳朝霞第七个课程设计(冲孔落料模,每人尺寸互商变化): T=1.0mm Q235钢姓名彭晓林彭震冉智睿任宇第八个课程设计(冲孔落料模,每人尺寸互商变化): T=1.0mm Q235钢姓名上官志强石正荣史红覃伟滨第九个课程设计(冲孔落料模,每人尺寸互商变化): T=1.0mm Q235钢姓名唐任涛屠洪江汪雨驰王任明第十个课程设计(落料冲孔拉伸修边模,每人尺寸互商变化):其中C1=15,C2=20 ,C3=10, T=1.0mm Q235钢王旭王跃琦翁奖键武山林第十一个课程设计(冲孔落料、拉伸翻孔模,每人尺寸互商变化):注:以上材料都是中大批生产。尧创业张小川张玉龙张蕴华19
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