花式立体冰激凌PLC系统设计【冰淇淋成型机】
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。具体请见文件预览,有不明白之处,可咨询QQ:12401814
南通大学本科生毕业设计(论文)开题报告学生姓名学 号专业机械工程及自动化课题名称立体花式冰淇淋成型机PLC控制系统设计阅读文献情 况国内文献 5 篇开题日期2011年3月25日国外文献 2 篇开题地点12-712一、文献综述与调研报告:(阐述课题研究的现状及发展趋势,本课题研究的意义和价值、参考文献)(一)研究的现状及发展趋势 冰激凌以其美观、冰凉、快乐与甜蜜的感受,自19世纪问世以来,越来越受到世界各地人们的喜爱。近十多年,随着有关机构大力倡导食用乳制品及更多的医疗保健专家的建议,中国的冰激凌产品已成为最普及的乳制消费品了。目前,人均年消费量是2升(相当于25到30支的冰激凌),未来20年有望上升到6升,中国也将成为世界上最大的冰激凌消费国。而这个潜力巨大的市场吸引了越来越多资本的追捧和关注,这一切也为中国冰淇淋工业的发展带来了广阔的市场前景。目前, 国内的冷饮机械, 特别是冰淇淋成形机的品种较少, 自动化程度低, 大多数食品厂生产的冰淇淋存在档次低和品种单一的问题! 在线运行的进口、国产设备(以平面异形线和花色雪线为主)都只能生产中、低档棒式或平面形冰淇淋、产品迫切需要升级换代以适应市场的需求。国外一些公司的软冰淇淋浆料在中国市场推广的过程中,遇到一个突出的问题就是:很多国产的软冰淇淋成型机不能与之配套。将他们公司生产的浆料在国产的冰淇淋成型机上操作,这些浆料的成型性不好、加工出的软冰淇淋产品很难站立起来。软冰淇淋浆料成型性不好的根本原因是国产的软冰淇淋成型机的制冷量不够,当浆料进入机器之后,由于机器内的温度过高,使软冰淇淋不能硬化、站不起来。国外冷饮业从80 年代初开始, 就把开发的重点放在设备的更新改造上, 力求以新的设备带出新的产品, 以不断满足冰淇淋产品升级换代的要求。成型机的性能不高,制约了我国高档软冰淇淋行业的发展。有关人士认为,应尽快开发性能良好、价格适合国情的国产软冰淇淋成型机。多年从事冰淇淋设备和技术开发的中国冷食技术研发中心主任钱献庆先生告诉记者,国内市场上有国产的和国外的软冰淇淋成型机,但都存在一定的问题:1.国产软冰淇淋成型机虽然便宜,但制冷量不够,不能将高品质的软冰淇淋浆料很好地成型。2.国外制造的软冰淇淋成型机虽然能够很好地将软冰淇淋浆料成型,但价格太高,国内的客户很少。钱献庆先生认为,要解决设备成型性能和价格之间的矛盾,一要在现有国产设备的基础上,加大软冰淇淋成型机的制冷量;二要采取其他配套措施,以系统的眼光来对待成型问题,需对国产软冰淇淋成型机的整体结构进行改进;三要降低高性能软冰淇淋成型机的制造成本,提高设备的市场竞争力。据悉,中国冷食技术研发中心正在和上海圆圆食品机械有限公司联合研制高性价比的软冰淇淋成型机。然而,在高速发展的今天,人们对食品种类、质量、品味等都有了更高的需求,这不仅促进了食品机械行业的发展,也对食品机械创新、技术升级提出了更高的要求。与发达国家相比,我国食品机械还处于弱势,不少企业存在低水平的重复建设。这种状况不但浪费了有限的资金、人力等重要资源,还造成了市场的无序混乱,阻碍了行业的健康发展。行业要发展,不仅要依靠老产品的销量增加,更需要新产品做技术支撑,现阶段行业调整产品结构、技术升级的压力日益加大。随着全球科技的进步,发达国家已经把核能技术、微电子技术、激光技术、生物技术和系统工程融入到传统的机械制造技术中。新的合金材料、高分子材料、复合材料、无机非金属材料等新材料也得到了推广应用,机械的集成化、智能化、网络化、柔性化将成为未来发展的主流。随着人们对食品的需求逐渐走向多样化、多层次化,为食品工业的发展提供了广阔的市场。食品机械行业也将提供多品种、高质量的产品以满足食品工业发展的需求。 总之,摒弃单一,追求多元化发展,顺应时代发展潮流,拓展食品机械发展之路,食品机械行业必将得到更快速的发展。(二)研究的意义和价值目前我国冰淇淋人均年消费水平约为公斤,与美国等发达国家的人均年消费量公斤差距甚远。随着我国国民经济的发展,人们生活质量提高,冰淇淋将成为老百姓的平常消费品。冰淇淋的消费目的将由过去的防暑降温转为不分季节的习惯性消费。地处中国南方,常年气候炎热的广东和近亿的常住、流动人口及较为成熟的市场基础、强劲的消费市力,形成对冷冻饮食的旺盛需求。近年来冷冻饮品在国内食品行业中发展迅猛,中国庞大的冷冻饮品市场招引了众多的淘金者的追逐。我国从90年代以来,被誉为“冷饮之王”的冰淇淋乳品生产每年以约的速度在递增。中国冷饮市场在10年内产量增长了近12倍,品种从几十种增加到3000多种。上海、广东、北京是冰淇淋销量最集中的三大区,约占全国总量的30左右。在未来的5-10年内行业收入仍然将保持20%以上的增长速度。有这么大的市场,但是我国生产冰激凌的设备还比较落后。我国冰激凌生产设备与国外还有一定的差距,主要表现在稳定性和可靠性,造型落后,外观粗糙,基本件与配套件寿命短,无故障运行时间和大修周期短,且绝大多数产品还没有制定可靠性标准。发达国家十分注重食品机械产品的内在质量、外观质量及整体效果,对每个零部件的质量都精益求精,把产品的外观质量看作整机质量的重要组成部分,对影响外观质量的模具及设备表面处理等都舍得投资研究。发达国家目前研制开发的食品机械新产品是集机、点、光、声、磁、化、美等一体上的高技术和高智能产品。先进技术水平体现在产品高度自动化、生产高效率化和食品资源高度综合利用化,不仅保持食品的营养风味,能生产出高品质的食品,而且可保护环境和节约能源。如日本食品机械自动化程度高,采用大量的光、计算机和伺服驱动系统等先进技术;许多设备的附加值高,具有自动检测、自动报警、自动纠错和补偿功能,可以达到无人化操作。因此,研究花式冰淇淋成型机PLC控制系统意义重大。争取早日克服我国现在冰激凌成型机的一些问题,实现冰激凌的高自动化生产,使我国冰激凌成型机设备赶超国外先进水平。生产出更物美价廉的冰激凌以满足我国巨大的市场需求。(三)参考文献:1 周国富. 食品工业现状和未来发展趋势的探讨. 广州食品工业科技. 2003,19(3):100102,992 黄圣明. 新世纪之初的中国食品工业发展趋势分析. 食品工业科技. 2000(1):583 盛国华. 国内外速冻食品的概况及发展趋势. 冷饮与速冻食品工业. 1999(2):42434 童军茂,施维新. 我国速冻食品的现状及发展对策. 冷饮与速冻食品工业. 2001,7(1):33345 黄圣明. 国内外冷冻食品生产现状与发展趋势. 食品与机械.1997(3): 45三、课题的研究方法、技术路线四、研究工作条件和基础五、进度计划起讫日期工作内容指导教师评语 导师签名: 年 月 日教研室意见 教研室主任签名: 年 月 日学院意见通过开题()开题不通过() 教学院长签名: 年 月 日南通大学毕业设计(论文)立题卡课题名称立体花式冰淇淋成型机PLC控制系统设计出题人课题表述(简述课题的背景、目的、意义、主要内容、完成课题的条件、成果形式等)冰淇淋是一种风味可口、富有情调的冷食产品,市场空间极大。但成型设备存在的缺陷,影响了我国高档软冰淇淋的生产。我国食品设备企业应加大创新力度,尽快研制出高性能的国产冰淇淋成型机,以推动冰淇淋行业的健康发展。本课题针对现有的冰淇生产设备进行改良设计,对其机械结构、控制系统进行全面改进设计。课题任务主要包括:成型机部分结构设计、PLC控制系统设计、气动系统设计等。完成课题的条件:PLC实验箱、气动试验系统、计算机等。成果形式:图纸、AUTOCAD图纸、毕业设计说明书等。课题来源科研课题类别毕业设计该课题对学生的要求 要求学生具备一定的机械工程及自动化专业知识,有较好的PLC编程能力和计算机应用能力。教研室意见 教研室主任签名:_ _年_月_日学院意见同意立题()不同意立题() 教学院长签名:_ _年_月_日注:1、此表一式三份,学院、教研室、学生档案各一份。 2、课题来源是指:1.科研,2.社会生产实际,3. 其他。3、课题类别是指:1.毕业论文,2.毕业设计。4、教研室意见:在组织专业指导委员会审核后,就该课题的工作量大小,难易程度及是否符合专业培养目标和要求等内容提出具体的意见和建议。5、学院可根据专业特点,可对该表格进行适当的修改。General all-steel punching dies punching accuracy Accuracy 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 accuracyFor 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 put nto 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 “he height of punching part”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 practiceal prove that the bur 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 manufacture the 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。
收藏