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山 西 農 業(yè) 大 學 本科生畢業(yè)論文（設計）選題審批表 畢業(yè)論文（設計）題目 杯形件拉深模具的設計 指 導 教 師 邢澤炳 職 稱 副教授 學生具備條件 修完教學計劃要求課程內容及學時 選題完成形式 開題報告 內 容 簡 要：本論文應用本專業(yè)所學課程的理論和生產實際知識進行一次冷沖壓模具設計工作的實際訓練從而培養(yǎng)和提高獨立工作能力，鞏固與擴充了冷沖壓模具設計等課程所學的內容，掌握冷沖壓模具設計的方法和步驟，掌握冷沖壓模具設計的基本的模具技能懂得了怎樣分析零件的工藝性，怎樣確定工藝方案，了解了模具的基本結構，提高了計算能力，繪圖能力，熟悉了規(guī)范和標準，同時各科相關的課程都有了全面的復習，獨立思考的能力也有了提高。采用拉深模模具設計制造簡便易行。拉深效果好，能極大地提高生產效率。本設計共分5章，分別論述了產品工藝分析，工藝計算，模板及零件設計，模具組立等問題。了解產品用途，并進行沖壓件的工藝性及尺寸公差等級分析，對于一些沖壓件結構不合理或工藝性不好的進行改進并繪制模具總圖和非標準件零件圖。 系主任簽字： 年 月 日 院長簽字： 年 月 日 2 山西農業(yè)大學 本科生畢業(yè)論文(設計) 開題報告 題 目 杯形件拉深模具的設計 學 院 信息學院 專 業(yè) 機械設計制造及其自動化 年 級  機制信052 姓 名 田 陽 學 號 2005151211 指導教師  邢澤炳 職 稱  副教授 2009年06月15日 選題的依據及意義 隨著科學技術的發(fā)展需要，模具已成為現代化不可缺少的工藝裝備，模具設計是機械專業(yè)一個最重要的教學環(huán)節(jié),是一門實踐性很強的學科，是我們對所學知識的綜合運用，通過對專業(yè)知識的綜合運用，對模具從設計到制造的過程有個基本上的了解，為以后的工作及進一步學習深造打下了堅實的基礎。模具制造技術現代化是模具工業(yè)發(fā)展的基礎。計算機技術、信息技術、自動化技術等先進技術正在不斷向傳統制造技術滲透、交叉、融合形成了現代模具制造技術。其中高速銑削加工、電火花銑削加工、慢走絲切割加工、精密磨削及拋光技術、數控測量等代表了現代沖模制造的技術水平。高速銑削加工不但具有加工速度高以及良好的加工精度和表面質量（主軸轉速一般為15000~40000r/min）,加工精度一般可達10微米，最好的表面粗糙度Ra≤1微米），而且與傳統切削加工相比具有溫升低（工件只升高3攝氏度）、切削力小，因而可加工熱敏材料和剛性差的零件，合理選擇刀具和切削用量還可實現硬材料（60HRC）加工；電火花銑削加工（又稱電火花創(chuàng)成加工）是以高速旋轉的簡單管狀電極作三維或二維輪廓加工（像數控銑一樣），因此不再需要制造昂貴的成形電極，如日本三菱公司生產的EDSCAN8E電火花銑削加工機床，配置有電極損耗自動補償系統、CAD/CAM集成系統、在線自動測量系統和動態(tài)仿真系統，體現了當今電火花加工機床的技術水平；慢走絲線切割技術的發(fā)展水平已相當高，功能也相當完善，自動化程度已達到無人看管運行的程度，目前切割速度已達到300mm/min,加工精度可達±1.5微米，表面粗糙度達Ra=01~0.2微米;精度磨削及拋光已開始使用數控成形磨床、數控光學曲線磨床、數控連續(xù)軌跡坐標磨床及自動拋光等先進設備和技術;模具加工過程中的檢測技術也取得了很大的發(fā)展,現在三坐標測量機除了能高精度地測量復雜曲面的數據外,其良好的溫度補償裝置、可靠的抗振保護能力、嚴密的除塵措施及簡單操作步驟，使得現場自動化檢測成為可能。此外，激光快速成形技術（RPM）與樹脂澆注技術在快速經濟制模技術中得到了成功的應用。 本課題研究內容 本課題研究的是杯形件拉深模具的設計。拉深是主要的沖壓工序之一，應用很廣，象汽車、拖拉機的一些罩件、覆蓋件，電器儀表的殼體件及眾多的日用品等都是應用拉深成型的。本課題主要研究的是拉深的工藝性。包括分析零件的工藝性，確定工藝方案，了解了模具的基本結構、尺寸公差等級的確定以及拉深時毛坯起皺、斷裂等現象，并提出解決方案。 本課題研究方案 我國當前拉深技術發(fā)展受到限制，主要的問題表現在： （1）模具故障，模具故障是沖壓生產中最容易出現的問題，常常造成停產，影響產品生產周期。 　　 （2）模具損壞，模具損壞是指模具開裂、折斷、漲開等，處理模具損壞問題。 鑒于上述分析，本課題主要是從模具的設計、制造工藝和模具使用方面尋找原因。首先要審核模具的制造材料是否合適 ，相對應的熱處埋工藝是否合理。模具使用時，零件位置、方向等安裝錯誤或螺栓緊固不好。工作高度調整過低、導柱潤滑不足。送料設備有故障，壓力機異常等，都會造成模具的損壞。本課題針對以上缺陷提出了解決方案。 研究的創(chuàng)新之處 本課題的難點以及重點在于解決拉深時起皺現象。拉深過程中，凸緣材料由扇形擠壓成矩形。材料間產生很大的切向壓力，這一壓力猶如壓桿兩端受壓失穩(wěn)似的似凸緣材料失去穩(wěn)定而形成皺折，鑒于以上情況分析，我解決的方法是： （1）模具改進，在流量大的地方設加強筋 （2）改善材質，降低延伸率等 研究過程(含完成期限) 第一周與指導老師確定設計題目并制定詳細的設計要求； 第二周調查、收集、研究現有資料，根據課題的要求，明確整個論文的任務和方向； 第三周提出多種研究方案，通過分析對比，確定出最優(yōu)方案； 第四和第五周以確定的初步方案繪制出工作示意圖或機構運動簡圖，確定機構組成和各種參數計算； 第六和第七周詳細書寫論文正文內容及經濟效益分析 第八周交由指導老師批改； 第九周修改并完善論文。 指導教師意見 指導教師簽名： 年 月 日 教研室意見 教研室主任簽名： 年 月 日 院系意見 主管領導簽名： 年 月 日 畢業(yè)論文中文摘要 杯形件拉深模具的設計 摘要 本論文應用本專業(yè)所學課程的理論和生產實際知識進行一次冷沖壓模具設計工作的實際訓練從而培養(yǎng)和提高學生獨立工作能力，鞏固與擴充了冷沖壓模具設計等課程所學的內容，掌握冷沖壓模具設計的方法和步驟，掌握冷沖壓模具設計的基本的模具技能懂得了怎樣分析零件的工藝性，怎樣確定工藝方案，了解了模具的基本結構，提高了計算能力，繪圖能力，熟悉了規(guī)范和標準，同時各科相關的課程都有了全面的復習，獨立思考的能力也有了提高。。采用拉深模模具設計制造簡便易行。拉深效果好，能極大地提高生產效率。本設計共分5章，分別論述了產品工藝分析，工藝計算，模板及零件設計，模具組立等問題。了解產品用途，并進行沖壓件的工藝性及尺寸公差等級分析，對于一些沖壓件結構不合理或工藝性不好的進行改進并繪制模具總圖和非標準件零件圖。 關鍵詞 工藝分析 工藝設計 模具組立 畢業(yè)論文外文摘要 Cup form a deep drawing die design Abstract In this paper, the application of the professional courses of theoretical and practical knowledge of the production of a cold stamping die design of the practical training of students so as to nurture and enhance the ability to work independently, Consolidation and expansion of the cold stamping die design, the content of classroom teaching, master of cold stamping die design methods and steps. Cold stamping die design to master the basic skills to understand how to mold parts of the process of analysis and how to determine the technology program to understand the basic structure of the mold to enhance the computing power, graphics capability, familiar with the norms and standards, At the same time, there are various courses related to a comprehensive review, the ability to think independently improved. . The use of drawing die design and manufacture of simple mold. Drawing effective and can greatly improve the production efficiency. The design is divided into 5 chapters on analysis of the product technology, technical computing, design templates and components, mold legislation and other issues group.We should understand the product uses, and the process of stamping parts and dimension tolerance level analysis, some unreasonable or stamping process of the bad ones, and we need to mapping tool to improve the overall map and non-standard Parts items. Keywords Process Analysis Process Design Mold Group Characteristics and Sheet Metal Forming 'b FEhQ ? 1．The article overview 1pWz~3e)o ? 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 8~100mm. 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. )O 4~lE7/ ? ? 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. 2
E[?( ? ? The process, equipment and die are the three foundational problems that needed to be studied in stamping. o r]j&LW ? ? The characteristics of the sheet metal forming are as follows: #\A%}B, j` ? (1)? ? High material utilization Zm0Je1u.% ? (2)? ? Capacity to produce thin-walled parts of complex shape. hn R-Umy ? (3)? ? Good interchangeability between stamping parts due to precision in shape 8:Ho*jo ? and dimension. v$M_cO =c ? (4)? ? Parts with lightweight, high-strength and fine rigidity can be obtained. /b*( y@{ ? (5)? ? High productivity, easy to operate and to realize mechanization and? ? automatization. R;2r&r~ ? ? ? 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. O2QzX]t;W ? ? The materials for sheet metal stamping include mild steel, copper, aluminum, magnesium alloy and high-plasticity alloy-steel, etc. T3


NM ? ? 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. pb"8]LFUuH ? 2．Characteristics of stamping forming m{IkZ~%D ? 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: dl4jgw)% ? （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. '%%Q[o- ? （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. Km!HlKdy| ? （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. HvL
H
L? ? （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. E_J)wzM@ ? Due to the characteristics of stamping deformation and mechanics mentioned above, the stamping technique is different form the bulk metal forming: Is `A{Uw} ? （1）．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. ".k!Z$,X ? （2）．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. ZfpI>#? ? （3）．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. QeXUoR'VF2 ? 3．Categories of stamping forming (]U,<Z"
. ? ? ? Many deformation processes can be done by stamping, the basic processes of the stamping can be divided into two kinds: cutting and forming. N0y9=& ? ? ? 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. VmO=.1Wa ? 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. GHM7rWF~ ? ? 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. ONCSGa$` ? Wrinkling that occurs in the stamping of tapered square cups and stepped rectangular cups is investigated. A common characteristic of these two types of wrinkling is that the wrinkles are found at the draw wall that is relatively unsupported. In the stamping of a tapered square cup, the effect of process parameters, such as the die gap and blank-holder force, on the occurrence of wrinkling is examined using finiteelement simulations. The simulation results show that the larger the die gap, the more severe is the wrinkling, and such wrinkling cannot be suppressed by increasing the blank-holder force. In the analysis of wrinkling that occurred in the stamping of a stepped rectangular cup, an actual production part that has a similar type of geometry was examined. The wrinkles found at the draw wall are attributed to the unbalanced stretching of the sheet metal between the punch head and the step edge. An optimum die design for the purpose of eliminating the wrinkles is determined using finite-element analysis. The good agreement between the simulation results and those observed in the wrinkle-free production part validates the accuracy of the finite-element analysis, and demonstrates the advantage of using finite-element analysis for stamping die design. OpFyd^mlr ?Wrinkling is one of the major defects that occur in the sheet metal forming process. For both functional and visual reasons, wrinkles are usually not acceptable in a finished part. There are three types of wrinkle which frequently occur in the sheet metal forming process: flange wrinkling, wall wrinkling, and elastic buckling of the undeformed area owing to residual elastic compressive stresses. In the forming operation of stamping a complex shape, draw-wall wrinkling means the occurrence of wrinkles in the die cavity. Since the sheet metal in the wall area is relatively unsupported by the tool, the elimination of wall wrinkles is more difficult than the suppression of flange wrinkles. It is well known that additional stretching of the material in the unsupported wall area may prevent wrinkling, and this can be achieved in practice by increasing the blank-holder force; but the application of excessive tensile stresses leads to failure by tearing. Hence, the blank-holder force must lie within a narrow range, above that necessary to suppress wrinkles on the one hand, and below that which produces fracture on the other. This narrow range of blank-holder force is difficult to determine. For wrinkles occurring in the central area of a stamped part with a complex shape, a workable range of blank-holder force does not even exist.uXqw&+P(8d 沖壓成形與板材沖壓 x?Hv ? ? ? 分離工序是使胚料的一部分與另一部分相互分離的工藝方法，主要有落料、沖孔、切邊、剖切、修整等。其中又以沖孔、落料應用最廣。變形工序是使胚料的一部分相對于另一部分產生位移而不破裂的工藝方法，主要有拉深、彎曲、局部成形、脹形、翻邊、縮徑、校形、旋壓等。 0D}zj yoLX ? ? ? 從本質上看，沖壓成形就是毛胚的變形區(qū)在外力的作用下產生相應的塑性變形，所以變形區(qū)內的應力狀態(tài)和變形特點景象的沖壓成形分類，可以把成形性質相同的成形方法概括成同一個類型并進行體系化的研究。 WC]2(s~-w= ? ? ? 絕大多數沖壓成形時毛胚變形區(qū)均處于平面應力狀態(tài)。通常認為在板材表面上不受外力的作用，即使有外力作用，其數值也是較小的，所以可以認為垂直于板面方向上的應力為零，使板材毛胚產生塑性變形的是作用于板面方向上相互的兩個主應力。由于板厚較小，通常都近似地認為這兩個主應力在厚度方向上是均勻分布的?；谶@樣的分析，可以把各種形式沖壓成型中的毛陪變形區(qū)的受力狀態(tài)與變形特點，在平面應力的應力坐標系中與相應的兩向應變坐標系中以應力與應變坐標決定的位置來表示。 )qWKd9 ? 5．板材沖壓性能及其鑒定方法 n(|A1( ? ? ? 板材是指對沖壓加工的適應能力。對板材沖壓性能的研究具有飛行重要的意義。為了能夠運用最科學與最經濟合理的沖壓工藝過程與工藝參數制造出沖壓零件，必須對作為加工對象的板材的性能具有十分清楚的了解，這樣才有可能充分地利用板材在加工方面的潛在能力。另一方面，為了能夠依據沖壓件的形狀與尺寸特點及其所需的成形工藝等基本因素，正確、合理地選用板材，也必須對板材的沖壓性能有一個科學的認識與正確的判斷。 Km{H kJk ? ? ? 評定板材沖壓性能的方法有直接試驗法與間接試驗法。 q`{ MdF@ ? ? ? 實物沖壓試驗是最直接的板材沖壓性能的評定方法。利用實際生產設備與模具，在與生產完全相同的條件下進行實際沖壓零件的性能評定，當然能夠的最可靠的結果。但是，這種評定方法不具有普遍意義，不能作為行業(yè)之間的通用標準進行信息的交流。 ^27%[6 ? ? ? 模擬試驗是把生產中實際存在的沖壓成形方法進行歸納與簡單化處理，消除許多過于復雜的因素，利用軸對稱的簡化了的成形方法，在保證試驗中板材的變形性質與應力狀態(tài)都與實際沖壓成形相同的條件下進行的沖壓性能的評定工作。為了保證模擬試驗結果的可靠性與通用性，規(guī)定了私分具體的關于試驗用工具的幾何形狀與尺寸、毛胚的尺寸、試驗條件（沖壓速度、潤滑方法、壓邊力等）。 B']7Xb ? ? ? 間接試驗法也叫做基礎試驗法。間接試驗法的特點是：在對板材在塑性變形過程中所表現出的基本性質與規(guī)律進行分析與研究的基礎上，進一步把它和具體的沖壓成形中板材的塑性變形參數聯系起來，建立間接試驗結果（間接試驗值）與具體的沖壓成形性能（工藝參數）之間的相關性。由于間接試驗時所用試件的形狀與尺寸以及加載的方式等都不同于具體的沖壓成形過程，所以它的變形性質和應力狀態(tài)也不同于沖壓變形。因此間接試驗所得的結果（試驗值）并不是沖壓成形的工藝參數，而是可以用來表示板材沖壓性能的基礎性參數。 mJKl4\Q ? 在沖壓臺階方盒形件、錐形方盒形件中發(fā)生的褶皺現象（的原因）已經被調查出。兩種褶皺的共同特點是褶皺都出現在相對無支撐的拉延壁上。沖壓錐形方盒形件時，工藝參數如凸凹模間隙和壓邊力等對產生褶皺的影響可以用有限元分析檢查出來。（有限元分析的）模擬結果顯示凸凹模間隙越大,褶皺就越嚴重,并且這種褶皺不能通過增加壓邊力來消減.在對沖壓臺階方盒形件中產生的褶皺的分析中,對一個有相似結構(臺階結構)的實際生產中的零件進行檢查.在拉延壁上發(fā)現的褶皺歸因于在沖頭和臺階之間的金屬板材受到的拉伸力的不平衡.通過有限元分析能夠確定最合理的可以減小褶皺的模具的設計.模擬結果和對不發(fā)生褶皺產品的觀察結果的吻合驗證了有限元分析的精確性,并且證明了對沖壓模具設計進行有限元分析的優(yōu)勢所在. 起皺是金屬板料成型中常見的失效形式之一。 由于功能的和視覺效果的原因, 起皺通常不能為零件制品所接受。在金屬板料成型加工中通常存在三種類型的起皺現象：法蘭起皺，側壁起皺，和由于殘余壓應力在未變形區(qū)產生的彈性變形。在沖壓復雜形狀之間時，拉伸壁起皺就是在模具型腔中形成的起皺。由于金屬板