皮帶輪落料拉深復(fù)合模設(shè)計(jì)【說(shuō)明書(shū)+CAD】
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外文翻譯專 業(yè) 名 稱 機(jī)械設(shè)計(jì)制造及其自動(dòng)化班 級(jí) 學(xué) 號(hào) 078105232學(xué) 生 姓 名 冼 振 源指 導(dǎo) 教 師 陳 為 國(guó)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普通全鋼沖模的沖壓精度分析板料沖壓件的精度準(zhǔn)確顯示出其沖模的沖壓精度。而任何沖件的線性尺寸精度與形位精度主要取決于沖模沖裁和立體成形沖壓件展開(kāi)平毛坯的落料精度。因此,多工步復(fù)合沖壓的單工位復(fù)合模、多工位連續(xù)模的沖壓精度,在普通沖壓的眾多種類與不同結(jié)構(gòu)的沖模中,最具典型性和代表性。沖模的沖壓精度分析對(duì)沖模投產(chǎn)至失效報(bào)廢各個(gè)時(shí)期沖件的實(shí)際誤差分析,可以看出其增大的時(shí)期及趨向,從而分析其增大的因素。新沖模投產(chǎn)至第一次刃磨前沖制沖件的誤差即所謂的初始誤差;沖模經(jīng)過(guò)20次左右刃磨至失效報(bào)廢前沖制的沖件誤差稱之為常規(guī)誤差;而沖模失效報(bào)廢前沖制的最后一批合格沖件的允許最大誤差稱之為極限誤差。在現(xiàn)場(chǎng),確定沖模刃磨壽命的依據(jù)是沖件沖孔與落料的毛刺高度。由于任何成形件都具有沖裁作業(yè)(毛坯落料或沖孔),對(duì)于復(fù)合模尤為如此。所以,沖件毛刺高度的觸模檢查和測(cè)量并按企業(yè)標(biāo)準(zhǔn)或JB4129-85沖壓件毛刺高度對(duì)照檢測(cè)就顯得十分重要。沖模的初始誤差通常是沖模整個(gè)壽命中沖件誤差最小的。其大小主要取決于沖模的制造精度與質(zhì)量及沖件尺寸、料厚以及間隙值大小與均勻度。沖模的制造精度及質(zhì)量又取決于制模工藝。對(duì)于料厚t1mm的中碳鋼復(fù)合沖裁模沖件,實(shí)驗(yàn)結(jié)果與生產(chǎn)實(shí)踐都證明,電火花線切割制造的沖模沖件毛刺高度比用成型磨或NC與CNC連續(xù)軌跡座標(biāo)磨即精密磨削工藝制造的沖模沖件要高25%30%。這是因?yàn)楹笳卟粌H加工精度高,而且加工面粗糙度Ra值要比前者小一個(gè)數(shù)量級(jí),可達(dá)到0.025m。因此,沖模的制造精度與質(zhì)量等因素決定了沖模的初始沖壓精度,也造就了沖件的初始誤差。沖件的常規(guī)誤差是沖模經(jīng)第一次刃磨到最后一次刃磨后沖出最后一個(gè)合格沖件為止,沖件實(shí)際具有的誤差。隨著刃磨次數(shù)的增加,刃口的自然磨損而造成的尺寸增量逐漸加大,沖件的誤差也隨之加大。當(dāng)其誤差超過(guò)極限偏差時(shí),沖件就不合格,沖模也就失效報(bào)廢。/沖件上孔與內(nèi)形因凸模磨損尺寸會(huì)逐漸變小;其外形落料尺寸會(huì)因凹模磨損而逐漸增大。所以,沖件上孔與內(nèi)形按單向正偏差標(biāo)允差并依接近或幾乎等于極限最大尺寸制模。同理,沖件外形落料按單向負(fù)偏差標(biāo)注允差并依接近或幾乎等于極限最小尺寸制模。這樣就使沖件的常規(guī)誤差范圍擴(kuò)大,沖??扇心ゴ螖?shù)增加,模具壽命提高。沖件的極限誤差是具有極限偏差的沖件所具有的實(shí)際允許的最大尺寸誤差。這類沖件通常是在沖模失效報(bào)廢前沖制的最后一批合格沖件。對(duì)各類沖模沖件誤差在沖模整個(gè)壽命中出現(xiàn)的波動(dòng)、增減趨向及規(guī)律等進(jìn)行全面分析便可發(fā)現(xiàn):沖件誤差的主導(dǎo)部分是不變的;因刃口或型腔的自然磨損而出現(xiàn)的誤差增量隨沖模刃磨沖數(shù)增加而使這部分誤差逐漸加大;還有部分誤差的增量是非常規(guī)的、不可預(yù)見(jiàn)的。所以,各類沖模沖件誤差是由因定誤差、漸增誤差、系統(tǒng)誤差及偶發(fā)誤差等幾部分綜合構(gòu)成。1、固定誤差新沖模在指定的沖壓設(shè)備上投入使用至失效報(bào)廢的整個(gè)(總)壽命過(guò)程中,其合格沖件誤差的主導(dǎo)部分固定不變即所謂固定誤差。其大小就是新沖模第一次刃磨前沖制的合格沖件的偏差,也即沖模的初始誤差,而此時(shí)的沖模具有初始沖壓精度。刃磨后的沖模,因其工作零件(凸、凹模)磨損而改變尺寸誤差,使沖件識(shí)差增量隨刃磨次數(shù)增加而逐漸加大,故沖模刃磨后的沖壓精度亦稱“刃磨精度”比其初始精度要低。沖模沖件的固定誤差取決于以下各要素:(1)沖件的材料種類、結(jié)構(gòu)(形狀)尺寸及料厚沖裁間隙的大小及其均勻度對(duì)沖裁件的尺寸精度有決定性的影響。不同沖裁工藝、不同材料種類與不等料厚,間隙相差懸殊,沖壓精度差異很大。同一種模數(shù)m=0.34的2mm的料厚、中心有孔的H62黃銅材料片齒輪復(fù)合模沖件,當(dāng)取間隙C=0.5%t(單邊),用復(fù)合精沖模沖制,沖件尺寸精度達(dá)到IT7級(jí),沖件平直無(wú)拱彎,沖切面垂直度可達(dá)89.5,其表面粗糙Ra值為0.2m;而用普通復(fù)合模沖制,間隙C=5%t(單邊),沖件初始誤差亦即沖模的初始沖壓精度為1T9級(jí),沖切面粗糙度Ra值為12.5m,毛刺高度為0.10mm;還是這個(gè)沖件用連續(xù)模沖制,間隙C=7%t(單邊),初始沖件精度為IT11級(jí),沖切面更粗糙,甚至有肉眼可見(jiàn)的臺(tái)階。通常情況下,沖件材料及其厚度t是選取沖裁間隙的主要依據(jù)。一旦選定間隙就確定了沖件的平面尺寸的固定誤差的主體;沖件結(jié)構(gòu)剛度及立體形狀則影響其形位精度。(2)沖壓工藝及沖模結(jié)構(gòu)類型采用不同的沖壓工藝,沖件的精度及固定誤差相差甚大。除上述片齒輪實(shí)例說(shuō)明,精沖工藝與普通沖裁的沖件精度與固定誤差相差一個(gè)數(shù)量級(jí)之外,即便在普通沖裁中,采用不同間隙沖裁,固定誤差相差也很大。例如料厚t=1.5mm的H62黃銅沖裁件,選用C40%t單邊類小間隙沖裁比選用C8%t(單邊)類大間隙沖裁,沖件固定誤差將加大40%60%,精度至少降一級(jí)。此外,采有無(wú)搭邊排樣,沖件的誤差要遠(yuǎn)大于有搭邊排樣沖件。無(wú)搭邊排樣沖件。無(wú)搭邊排樣沖件的精度低于IT12級(jí),而多數(shù)有搭邊排樣的沖件精度在IT11IT9級(jí)之間,料厚t4mm的沖件,尺寸精度會(huì)更低一些。不同沖模結(jié)構(gòu)類型,由于適用沖壓料厚及制造精度的差異,導(dǎo)致沖件的固定誤差有別。復(fù)合模中,多工位連續(xù)式復(fù)合模由于沖件連續(xù)重復(fù)定位加上制模誤差較大,故其沖件的固定誤差比單工位復(fù)合沖裁模要 大12級(jí)。(3)沖模制造工藝沖模主要工作零件即凸、凹模的加工程序,對(duì)操作上的技術(shù)要求不高,能夠一次成形較復(fù)雜的模腔。但其加工表面約厚0.030.05mm為高溫?zé)g的殘余樹(shù)枝狀?yuàn)W氏體組織,硬度可高達(dá)HRC6770,有顯微裂紋,容易在沖裁時(shí)出現(xiàn)崩刃或剝落。意大利Corrada公司的有關(guān)研究報(bào)告稱“線切割加工對(duì)表面金相結(jié)構(gòu)產(chǎn)生不利的影響,實(shí)際上已經(jīng)改變了金相結(jié)構(gòu)。我們必須用金剛石粉研磨或數(shù)控連續(xù)軌跡坐標(biāo)磨削(對(duì)線切割件)作精加工”。近年來(lái)瑞士和日本等國(guó),對(duì)電加工設(shè)備進(jìn)行了深入的研究和較大的改進(jìn),制造出功能齊全的高精度NC和CNC線切割機(jī),加工精度可達(dá)0.0050.001mm,甚至更小。加工表面粗糙度Ra值能達(dá)到0.4m。根據(jù)近年對(duì)國(guó)內(nèi)12家生產(chǎn)線切割機(jī)工廠的調(diào)研,國(guó)產(chǎn)線切割機(jī)加工精度各別廠家的各別型號(hào)線切割機(jī)可達(dá)0.0080.005mm,一般都在0.01mm或更大一些,個(gè)別也能達(dá)到0.005mm,加工表面粗糙度Ra值均大于1.6m。然而,電加工燒蝕金屬表面從而改變和損壞加工面金相結(jié)構(gòu)的特性不會(huì)改變,除非用磨削或其他加工法去除這一有害層。所以,僅僅用電加工法,包括電火花線切割與電穿孔,難以達(dá)到?jīng)_模,尤其高精度、高壽命沖模對(duì)尺寸精度與工作零件表面粗糙度Ra值要求。用精密磨削法制造沖模,特別是制造高精度、高壽命沖模,諸如:薄料小間隙復(fù)合沖裁模、多工位連續(xù)式復(fù)合模等,具有尺寸精度高、工作零件加工面粗糙度Ra值小、模具壽命高等特點(diǎn)。其加工工藝目前已由過(guò)去的普通機(jī)床粗加工改為電火花線切割或電穿孔機(jī)粗加工,最后精密磨削,也由成型磨、光學(xué)曲線磨、手動(dòng)座標(biāo)磨逐步過(guò)濾到連續(xù)軌跡座標(biāo)磨及NC與CNC連續(xù)軌跡座標(biāo)磨,加工粗度可達(dá)0.0010.0005mm,加工表面粗糙度Ra值可達(dá)0.10.025m。所以,用該工藝制造的沖模,無(wú)論尺寸精度、工作零件表面粗糙度,都能滿足沖模,尤其各種復(fù)合模的要求,比電加工工藝制造的沖模高一個(gè)檔次。(4)間隙的大小與均勻度拉深、彎曲、翻邊及其他板料成形件一般都要先沖裁(落料)出平板展開(kāi)毛坯,也有成形后落料、切開(kāi)得到單個(gè)成品沖件。故沖裁作業(yè),包括常用的沖孔、切口、切邊等,對(duì)于每種板料沖壓件都是必要的。所以沖裁間隙對(duì)沖件的外廓尺寸精度有決定性的影響。沖裁間隙小而均勻,可使沖裁尺寸獲取更高精度。對(duì)于拉深、彎曲等成形模,間隙大定將增大沖件口部尺寸誤差及回彈。間隙不均勻會(huì)使沖件毛刺加大并招致刃口的不均勻磨損。(5)沖壓設(shè)備的彈性變形在沖壓過(guò)程中,沖床承載后會(huì)產(chǎn)生一定的彈性變形。雖然這種變形量依沖壓力的大小變化且具有明顯的方向性,但就沖壓件,主要是對(duì)具有體積沖壓性質(zhì)的壓印、壓花、校平、壓凸、起波、沖擠、鐓形、翻邊、鐓粗、打扁、變薄拉深等工藝作業(yè)沖制成形的沖件,對(duì)其沖壓方面的尺寸精度有重大影響。XXXX大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)題 目: 皮帶輪落料拉深復(fù)合模設(shè)計(jì) 學(xué) 院: 機(jī)械工程學(xué)院 專 業(yè): 材料成型及控制工程學(xué) 號(hào): 姓 名: 指導(dǎo)教師: 完成日期: 目 錄目錄.1第一章 零件的工藝性分析.2第二章 毛坯尺寸展開(kāi)計(jì)算.3第三章 拉深工序次數(shù)及拉深系數(shù)確定.5第四章 沖裁力與拉深力的計(jì)算.11第五章 凸、凹模的設(shè)計(jì).7 1、 落料凸、凹模尺寸計(jì)算.7 2、 拉深凸、凹模尺寸計(jì)算.8 3、 粗糙度的確定.9第六章 模具基本結(jié)構(gòu)的確定.13第七章 模具主要零件的強(qiáng)度校核.15第八章 沖壓設(shè)備的選擇.16 1、初選設(shè)備.16 2、設(shè)備的校核.18主要參考文獻(xiàn)附錄 第一章 零件的工藝性分析1、零件的形狀、尺寸及一般要求 該零件為厚度2mm,大筒直徑為86.8mm,小筒直徑為47mm的皮帶輪,零件材料T8,尺寸精度按圖紙要求。2、工藝方案的分析及確定 工件由落料、拉深、反拉深三道工序成型,工件形狀較簡(jiǎn)單。 根據(jù)計(jì)算可知,拉深工序需要進(jìn)行多次拉深才能完成,如果完全采用連續(xù)模,則模具結(jié)構(gòu)比較復(fù)雜會(huì)增加沖壓件的生產(chǎn)成本。所以可先采用復(fù)合模進(jìn)行落料和第一步拉深,然后采用連續(xù)模直至拉深完成,再采用單工序模進(jìn)行反拉深。 本次主要設(shè)計(jì)其第一道工序,即落料和第一步拉深。第二章 毛坯尺寸展開(kāi)計(jì)算 旋轉(zhuǎn)體零件采用圓形毛坯,在不變薄拉深中,材料厚度雖有變化,但其平均值與毛坯原始厚度十分接近。因此,其直徑按面積相等的原則計(jì)算,即毛坯面積與拉深件面積(加上修邊余量)相等。1、確定修邊余量 在拉深的過(guò)程中,常因材料機(jī)械性能的方向性、模具間隙不均、板厚變化、摩擦阻力不等及定位不準(zhǔn)等影響,而使拉深件口部周邊不齊,必須進(jìn)行修邊,故在計(jì)算毛坯尺寸時(shí)應(yīng)按加上修邊余量后的零件尺寸進(jìn)行展開(kāi)計(jì)算。 修邊余量的數(shù)值可查文獻(xiàn)實(shí)用模具技術(shù)手冊(cè)表5-7. 由于工件凸緣的相對(duì)直徑 d凸/d = 1.1013 查表可得修邊余量=3.5mm。2、毛坯尺寸計(jì)算 根據(jù)工件的形狀,可將其分成F1-F8這幾個(gè)部分。則可計(jì)算出各部分的展開(kāi)面積如下:F1 =/42(4+t/2)(90.8-t)+4.56(4+t/2) =/42588.8+4.565 =222+28.5F2 =(d-t)(h-r1-r2-t) =(90.8-2)(34-4-2-2) =2308.8F3 =/42(2+t/2)(90.8-t-22-t)+8(2+t/2) =/4(2382.8+72) =124.2+18F4 =/4(90.8-2t-22)-/4(47+2t+22) =/482.8-/455 =957.71F5 =/42(2+t/2)(47+t)+4.56(2+t/2) =/4(2349+4.563) =73.5+10.26F6 =(20-2t-22)(47+t) =588F7 =/42(2+t/2)(47-22)+8(2+t/2) =/4(2343+83) =64.5+18F8 =/4(47-22) =462.25得:/4D=222+28.5+2308.8+124.2+18+957.71+73.5 +10.26+588+64.5+18+462.25 D=1936.8+17566.08=23647.632所以經(jīng)計(jì)算求得毛坯直徑D=154mm3、確定是否使用壓邊圈 由于D-d22t,則要使用壓邊圈。 壓邊力的計(jì)算: 因?yàn)閗=D/d=154/(47+4)=3 Fmax=dt(k-1)b =3.145122329=210.7 kN 所以F=0.11-18k/(k-1)kFmax =0.11-(183)/(3-1)3210.7 =0.10.659210.7 =123.4kN第三章 拉深工序次數(shù)及拉深系數(shù)確定 在制定拉深件的工藝過(guò)程和設(shè)計(jì)拉深模具時(shí),必須預(yù)先確定是否可以一道工序完成,或者是經(jīng)過(guò)幾道工序才能制成。在確定拉深工序次數(shù)時(shí),必須做到使毛坯內(nèi)部的應(yīng)力既不超過(guò)材料的強(qiáng)度極限,而且還能充分利用材料的塑性。也就是說(shuō)每一次拉深工序,應(yīng)在毛坯側(cè)壁強(qiáng)度允許的條件下,采用最大可能的變形程度。 制訂拉深工藝時(shí),為了減少拉深次數(shù),希望采用小的拉深系數(shù)(大的拉伸比)。有力學(xué)分析可知,拉深系數(shù)過(guò)小,將會(huì)在危險(xiǎn)斷面產(chǎn)生破裂。因此,要保證拉深順利進(jìn)行,每次拉深系數(shù)應(yīng)大于極限拉深系數(shù)。 該零件的拉深系數(shù),即拉深后圓筒件直徑與拉深前毛坯直徑的比值,為 m=d/D=(47+4)/154=0.33 有凸緣的圓筒件在拉深時(shí)還要考慮拉深的相對(duì)高度是否大于極限相對(duì)高度。計(jì)算可得拉深的相對(duì)高度為: h/d=20/(47+4)=0.392 極限拉伸系數(shù)與板料成形性能、毛坯相對(duì)厚度、凸凹模間隙及其圓角半徑有關(guān)。 通過(guò)計(jì)算可得: /4dF-756.25+73.5+10.26+588+64.5+18 +462.25=484.2 +4391.52 dF=143.6 所以:法蘭相對(duì)直徑dF/d=143.6/(47+2)=2.93 毛坯的相對(duì)厚度t/D100=2/154100=1.3 依文獻(xiàn)沖壓工藝學(xué),查表4-10,查得零件的極限拉深系數(shù) m=0.32 依文獻(xiàn)實(shí)用模具技術(shù)手冊(cè),查表5-16,查得第一次拉深的最大相對(duì)高度h/d=0.18 可知拉深系數(shù)大于極限拉深系數(shù),拉深的相對(duì)高度大于極限相對(duì)高度,所以不能一次拉深成形。 由于本設(shè)計(jì)只進(jìn)行第一次拉深的設(shè)計(jì),所以對(duì)以后的多次拉深不進(jìn)行計(jì)算。第四章 沖裁力與拉深力的計(jì)算1、沖裁力的計(jì)算 計(jì)算沖裁力的目的是為了合理地選用壓床和設(shè)計(jì)模具。壓床的噸位必須大于所計(jì)算的沖裁力,以適應(yīng)沖裁的要求。 平刃模具沖裁時(shí),其沖裁力F0可按下式計(jì)算: F0=Lt 式中 t材料厚度,t為mm 材料抗剪強(qiáng)度,為MPa L沖裁周長(zhǎng),L為mm 考慮到模具刃口的磨損,凸、凹模間隙的波動(dòng),材料機(jī)械性能的變化,材料厚度偏差等因素,實(shí)際所需沖裁力還須增加30%,即 F=1.3F0=1.3Lt 所以沖裁力F=1.32154/22260=326.89 kN 因?yàn)槟>卟捎脛傂孕读涎b置,所以不用計(jì)算卸料力。 而F頂件力=K2F=0.06326.89=19.62 kN (依文獻(xiàn)沖壓工藝學(xué)查表2-10得K2=0.06) 所以總沖裁力為: F0=326.89+19.62=346.51 kN2、拉深力的計(jì)算 在確定拉伸件所需的壓力機(jī)噸位時(shí),必須先求的拉深力。在拉深帶法蘭的圓筒件的生產(chǎn)中常用如下經(jīng)驗(yàn)公式計(jì)算: F = d1tbK 式中 t料厚; d1第一次拉深半成品圓筒直徑; b抗拉強(qiáng)度 由于零件材料為T(mén)8鋼,查得其抗拉強(qiáng)度 為329MPa; K系數(shù),依文獻(xiàn)沖壓工藝學(xué)查表4-11 查得K =1; 由上求得拉深力 F = 103.3 kN ;第五章 凸、凹模設(shè)計(jì)1、落料凸、凹模尺寸計(jì)算 因?yàn)槁淞闲螤顬閳A形,形狀簡(jiǎn)單,所以采用凸、凹模分開(kāi)加工的方法。 查文獻(xiàn)沖壓工藝學(xué)表2-3可知 沖裁模的雙面間隙為:Zmin=0.12mm, Zmax=0.16mm 則凸模和凹模的制造公差分別為: p=0.4(Zmax-Zmin)=0.4(0.16-0.12)=0.016 d=0.6(Zmax-Zmin)=0.6(0.16-0.12)=0.024 設(shè)工件尺寸為D-。落料時(shí)首先確定凹模尺寸,使凹模公稱尺寸接近或等于工件輪廓的最小極限尺寸,再減小凸模尺寸以保證最小合理間隙Zmin。則凸、凹模的尺寸計(jì)算公式如下: Dd=(D-x)+d DP=(Dd-Zmin)-p=(D-x-Zmin)-p 式中 Dd、DP落料凹、凸模尺寸,Dd與DP為mm 工件制造公差,為mm Zmin最小合理間隙(雙面),Zmin為mm p、d凸、凹模的制造公差,pd為mm x磨損量,其中系數(shù)x是為了使沖裁件的實(shí)際尺寸 盡量接近沖裁件公差帶的中間尺寸 查文獻(xiàn)沖壓工藝學(xué)表2-7,可知x=0.75.2、拉深凸、凹模尺寸計(jì)算 一、凹模圓角半徑rd rd與毛坯厚度、零件的形狀尺寸和拉深方法有關(guān) 因?yàn)镈-dd(凹模內(nèi)徑)30時(shí),應(yīng)取較大的rd值 查文獻(xiàn)沖壓工藝學(xué)表4-6,可得 rd=9mm 二、凸模圓角半徑rp 一般可取rp =rd。最后一道拉深時(shí)rp等于零件的圓角半徑. 所以取 rp =rd = 9mm. 三、凸、凹模間隙c 決定凸、凹模間隙時(shí),不僅要考慮材質(zhì)和板厚,還要考慮工件的尺寸精度和表面質(zhì)量要求。 由于該拉深要使用壓邊圈,則 C = tmax+kt ;取C=2mm 式中 tmax材料最大厚度; k間隙系數(shù)。 由于零件的尺寸標(biāo)注在內(nèi)徑上,則依凸模為準(zhǔn),間隙取在凹模上,即增大凹模尺寸得到間隙。四、凸、凹模尺寸及制造公差 最后一道拉深模的尺寸公差決定了零件的尺寸精度,故其尺寸、公差應(yīng)按零件要求來(lái)確定。 對(duì)于多次拉深的第一次拉深和中間工序的毛坯尺寸公差沒(méi)有必要限制,此時(shí),可取模具尺寸等于毛坯過(guò)渡尺寸。若取凸模為基準(zhǔn),則 凸模尺寸 DP=D-p 凹模尺寸 Dd=(D+2c)+d 根據(jù)拉深系數(shù)m=0.32,即d/154=0.32,d=50則,D=50-2t=46 凸、凹模的制造公差依文獻(xiàn)沖壓工藝學(xué)查表4-7,依工件的厚度和拉深直徑,查得 d=0.08, p=0.05 則:DP=46-0.05 ; Dd=50+0.083、粗糙度的確定 凸凹模的刃口部位要求較高,粗糙度選用0.4,凸模及凹模鑲塊用于固定的部位選用0.8,對(duì)于固定板上的孔,由于加工較困難,可選用1.6,其它不太重要的部位選用6.3。第六章 模具基本結(jié)構(gòu)的確定模具的基本結(jié)構(gòu)和組成如下所示:1、凸、凹模的結(jié)構(gòu)形式 一、落料凸模與拉深凹模 采用凸緣形式,用螺栓與上模板緊固。 模具結(jié)構(gòu)如下圖所示 二、落料凹模 模具結(jié)構(gòu)如下圖所示 三、拉深凸模 采用嵌入式結(jié)構(gòu),用螺釘與下模板緊固。 模具結(jié)構(gòu)如下圖所示:2、模具其他部分的作用與選材如下:上模座:上模座的作用是通過(guò)模柄與壓力機(jī)相連接,將模具的上模部分安裝在壓力機(jī)上。材料選用HT200。因?yàn)樯夏W谀>吖ぷ髦兄怀惺軟_擊力,要求材料具有較好的強(qiáng)度和韌性。上模座尺寸選用315mm 200mm45mm上模墊板 上模墊板在模具工作過(guò)程中,承受卸料組件、沖頭傳遞過(guò)來(lái)的較大的沖擊載荷。因此要求材料有較好的強(qiáng)度、硬度和一定的韌性。選用45,調(diào)質(zhì)到HRC3843。卸料板 本模具選用固定卸料板,用螺栓和銷釘固定在下模上,能承受的卸料力較大,常用于厚板沖壓件的卸料。厚度為6mm,材料選用45鋼,調(diào)質(zhì)HRC3843。定位板 定位板在過(guò)程中起到保證單個(gè)毛坯在拉深過(guò)程中有正確位置的作用,以保證拉深出合格的制件。通過(guò)螺釘與凹模固定板連接,以毛坯外形進(jìn)行定位。厚度為5mm,材料選用45鋼,調(diào)質(zhì)HRC3843。拉深凸模固定板 該固定板在模具中不僅起穩(wěn)定拉深凸模的作用,還通過(guò)其與下模板之間的彈簧的作用起到壓邊圈的作用。在工作過(guò)程中要承受來(lái)自落料凸模的沖擊,因此要求材料有較好的強(qiáng)度、硬度和一定的韌性。選用45,調(diào)質(zhì)到HRC3843。下模固定板 承受很大的沖擊載荷。需要有較好的韌性和強(qiáng)度。選用45鋼。下模座其作用與上模座相似,選用HT200。尺寸選用315mm 200mm55mm。2、模架 選定模具的基本形式后,開(kāi)始選擇模架。依凹模尺寸及壓力機(jī) 工作臺(tái)尺寸選取。根據(jù)文獻(xiàn)實(shí)用模具技術(shù)手冊(cè),選用后側(cè)導(dǎo)柱模架,選用HT200。其各尺寸參數(shù)如下: 凹模周界 D=200 mm B=200mm, L=315mm 閉合高度 190230mm 導(dǎo)套 32mm160mm 導(dǎo)柱 32mm43mm110mm其結(jié)構(gòu)形式如下圖:本模具采用人工送料。第七章 模具主要零件的強(qiáng)度校核 1、 壓力中心的確定 為了保證壓力機(jī)和模具正常的工作,必須使沖模的壓力中心與壓力機(jī)滑塊中心線相重合。否則在沖壓時(shí)會(huì)使沖模與壓力機(jī)滑塊歪斜,引起凸、凹模間隙不均和導(dǎo)向零件加速磨損,造成刃口和其它零件的損壞,甚至還會(huì)引起壓力機(jī)導(dǎo)軌磨損,影響壓力機(jī)精度。本制件為圓形,壓力中心在圓心。 2、模具主要零件強(qiáng)度設(shè)計(jì) 凸、凹模 凸模長(zhǎng)度確定以后,一般不作強(qiáng)度計(jì)算,且該凸模直徑較大,不會(huì)造成縱向失穩(wěn)或折彎,故可不進(jìn)行校核。 同理,凹模外形尺寸確定以后,可以保證凹模具有足夠的強(qiáng)度和剛度,也不做強(qiáng)度校核。 墊板 墊板的作用是為了平均分布模板所受到的壓力,可根據(jù)凸模傳給的壓力來(lái)決定墊板是否合格。第八章 沖壓設(shè)備的選擇 沖壓設(shè)備的選擇直接關(guān)系到設(shè)備的合理使用、安全、產(chǎn)品質(zhì)量、模具壽命、生產(chǎn)效率和成本等一系列問(wèn)題。1、初選設(shè)備 沖壓生產(chǎn)中主要應(yīng)用的是曲柄壓力機(jī)和液壓機(jī)。由于本零件的成型屬于落料淺拉深,且根據(jù)其幾何尺寸和精度要求,選用具有C形床身的開(kāi)式曲柄壓力機(jī)。雖然開(kāi)式壓力機(jī)的剛度差,并且由于床身變形而破壞了沖模的間隙分布,降低了沖模的壽命和制件的質(zhì)量。但是,它卻具有操作空間三面敞開(kāi),操作方便,容易安裝機(jī)械化的附屬設(shè)備和成本低廉等優(yōu)點(diǎn)。 在壓力機(jī)的類型選定以后,應(yīng)進(jìn)一步根據(jù)變形力的大小,沖壓件的尺寸和模具尺寸來(lái)確定設(shè)備的規(guī)格。 由于沖裁工序與拉深工序不是同時(shí)進(jìn)行,所以只需考慮兩工序中所需壓力較大的工序。 沖裁力為 F = 346.51 kN,依沖壓力的計(jì)算圖與沖壓設(shè)備需要負(fù)荷圖對(duì)比,故可選用公稱壓力為 450 kN的壓力機(jī)。根據(jù)國(guó)標(biāo) JB/T 9965-1999 ,初選壓力機(jī)的型號(hào)為 J21-45。 依文獻(xiàn)沖壓模具簡(jiǎn)明設(shè)計(jì)手冊(cè)表13.10,可查得該壓力機(jī)個(gè)技術(shù)參數(shù)如下: 標(biāo)稱壓力/kN 450 標(biāo)稱行程/mm 3.2 滑塊行程/mm 120 行程次數(shù)/次min-1 80 最大閉合高度/mm 270 封閉高度調(diào)節(jié)/mm 60 滑塊中心線到機(jī)身距離/mm 225 工作臺(tái)尺寸 左右/mm 810 前后/mm 440 工作臺(tái)孔尺寸/mm 150 模柄孔尺寸 直徑/mm 50 深度/mm 60 電動(dòng)機(jī)功率/kW 5.52、設(shè)備校核 裝模高度校核 為使模具正常工作,模具閉合高度必須與壓力機(jī)閉合高度相適應(yīng),應(yīng)介于壓力機(jī)最大和最小閉合高度之間,一般按如下關(guān)系確定: h最大-5mm = h模 = h最小+10mm 所設(shè)計(jì)模具的閉合高度為 220mm ,而壓力機(jī)的閉合高度為 210mm 270mm,在可調(diào)范圍之內(nèi)。 滑塊行程校核 在拉深中為了便于安放毛坯和取出工件,其行程一般大于拉深件高度的2.5倍。工件高度為9mm,而壓力機(jī)行程為 60mm,故該壓力機(jī)行程符合規(guī)定。 模具安裝空間尺寸校核 包括工作臺(tái)面的大小和模柄孔尺寸。經(jīng)校核比較該模具可在壓力機(jī)工作上正確安裝和定位。且臺(tái)面上的漏料孔與所選工藝相適應(yīng)。主 要 參 考 文 獻(xiàn) 主要參考文獻(xiàn)1 王孝培,沖壓手冊(cè)(修訂本).機(jī)械工業(yè)出版社.19882 薛啟翔.冷沖壓實(shí)用技術(shù).北京:機(jī)械工業(yè)出版社.20063 鄭家賢.沖壓工藝與模具設(shè)計(jì)實(shí)用技術(shù).北京:機(jī)械工業(yè)出 版社.20054 郝濱海.實(shí)用模具技術(shù)手冊(cè).北京:化學(xué)工業(yè)出版社.20045 周良德,朱泗芳等.現(xiàn)代工程圖學(xué).湖南:湖南科學(xué)技術(shù)出版社.20006 肖景容,姜奎華.沖壓工藝學(xué).北京:機(jī)械工業(yè)出版社.20047 陳錫棟、周小玉,實(shí)用模具技術(shù)手冊(cè)。北京:機(jī)械工業(yè)出版社.20058 模具實(shí)用技術(shù)叢書(shū)編委會(huì).沖模設(shè)計(jì)應(yīng)用實(shí)例.北京:機(jī)械工業(yè)出版社.20009 高為國(guó).模具材料.北京:機(jī)械工業(yè)出版社.200510 王衛(wèi)衛(wèi).材料成形設(shè)備.北京:機(jī)械工業(yè)出版社.200511 俞漢清,陳金德.金屬塑性成形原理.北京:機(jī)械工業(yè)出版社.200312 廖念釗,莫雨松,李碩根,楊興駿等.互換性與技術(shù)測(cè)量.北京:中國(guó)計(jì)量出版社.200313 楊可楨,程光蘊(yùn).機(jī)械設(shè)計(jì)基礎(chǔ)(第四版).北京:高等教育出版社.199920
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