外舌止动垫圈级进模具设计.doc

宜宾职业技术学院毕业论文（设计）题目：外舌止动垫圈级进模具设计系部现代制造工程系专业名称模具设计制造班级模具1074姓名陈鹏学号200710746指导教师罗宗平（工程师）赖啸2009年7月20日1摘要冲压模具在工业生产中应用广泛。冲压模具的设计充分利用了机械压力机的功用特点，在室温的条件下对坯件进行冲压成形，生产效率提高，经济效益显著。冲压模具的设计充分利用了机械压力机的功用特点，在室温的条件下对坯件进行冲压成形，生产效率提高，经济效益显著。本文的级进模具设计实例结构简单实用，使用方便可靠，对类似的两工位零件的大批量生产具有一定的参考作用。本设计还做了一些简化，比如没有单独用侧刃挡块，而是用导料板代替了侧刃挡块，减少了零件数量。在传统的工业生产中，工人生产的劳动强度大、劳动量大，严重影响生产效率的提高。随着当今科技的发展，工业生产中模具的使用已经越来越引起人们的重视，而被大量应用到工业生产中来。冲压模具的自动送料技术也投入到实际的生产中，冲压模具可以大大的提高劳动生产效率，减轻工人负担，具有重要的技术进步意义和经济价值。关键词：冷冲压、模具设计、模具制造、生产效率2目录1绪论·········································································································12零件工艺性分析····························································································23确定工艺方案································································································34排样设计······································································································44.1排样方法······························································································44.2搭边值的确定························································································44.3条料宽度的确定····················································································44.4材料利用率···························································································55计算总冲压力································································································65.1冲裁力的计算························································································65.2卸料力和推件力的计算···········································································76压力中心的计算····························································································87冲裁间隙·····································································································118凸、凹模刃口尺寸计算··················································································129主要零件的设计···························································································149.1凸模的设计··························································································149.1.1凸模结构形式的确定·····································································149.1.2凸模的固定方式···········································································149.1.3凸模长度设计···············································································159.1.4凸模的材料及热处理·····································································159.2凹模的设计··························································································159.2.1凹模洞口的选用···········································································159.2.2凹模结构和尺寸的设计··································································169.2.3凹模材料和热处理········································································179.3定位零件的设计···················································································179.4导料板的设计·······················································································1939.5卸料板的设计·······················································································209.6弹性元件的设计···················································································209.7凸模固定板和垫板的设计·······································································229.8模架、模柄、导柱和导套的选择·····························································229.9压力机的选择·······················································································249.10自动送料装置的选择···········································································259.11模具总装图························································································26总结···············································································································30致谢···············································································································31附表···············································································································32参考文献········································································································3711绪论根据考古发现，早在2000多年前，我国已有冲压模具被用于制造铜器，证明了中国古代冲压成型和冲压模具方面的成就在世界领先。1953年，长春第一汽车制造厂在中国首次建立了冲模车间，该厂于1958年开始制造汽车覆盖件模具。我国于20世纪60年代开始生产精冲模具。在走过了漫长的发展道路之后，目前我国已形成了300多亿元（未包括港、澳、台的统计数据）各类冲压模具的生产能力。我国冲压模具无论在数量上，还是在质量、技术和能力等方面都已有了很大发展，但与国民经济需求和世界先进水平相比，差距仍很大，一些大型、精密、复杂、长寿命的高档模具每年仍大量进口，特别是中高档轿车的覆盖件模具，目前仍主要依靠进口。一些低档次的简单冲模，已趋于供过于求，市场竞争激烈。改革开放以来，随着国民经济的高速发展，工业产品的品种和数量的不断增加，更新换代的不断加快，在现代制造业中，企业的生产一方面朝着多品种、小批量和多样式的方向发展，加快换型，采用柔性化加工，以适应不同用户的需要；另一方面朝着大批量，高效率生产的方向发展，以提高劳动生产率和生产规模来创造更多效益，生产上采取专用设备生产的方式。模具，做为高效率的生产工具的一种，是工业生产中使用极为广泛与重要的工艺装备。采用模具生产制品和零件，具有生产效率高，可实现高速大批量的生产。节约原材料，实现无切屑加工。产品质量稳定，具有良好的互换性。操作简单，对操作人员没有很高的技术要求。利用模具批量生产的零件加工费用低，所加工出的零件与制件可以一次成形，不需进行再加工，能制造出其它加工工艺方法难以加工、形状比较复杂的零件制品，容易实现生产的自动化的特点。22零件工艺性分析结构：零件大小适中，外形简单，对称。冲裁件外形为圆角，不需用过用镶拼模或分段冲裁，直接冲裁可获得，零件毛刺小，模具寿命高，孔的直径较小，适合冲裁加工。公差：尺寸公差除260-0.13、10+0.110为IT11级以外，其余尺寸公差均低于IT12级，亦无其他特殊要求，利用普通冲裁既可达到零件图纸要求。材料：Q235-A，卷料，抗剪强度=350MPa，抗拉强度b=400MPa,延伸率10=2125%。此材料具有高的弹性和良好的耐磨性，其冲裁加工性好。因受凸模强度和刚度的限制，冲裁件上的孔不宜太小，从附表5自由凸模冲孔的最小尺寸可知最小孔10.50.9t，所以用于冲孔的凸模不必使用凸模保护套。一般普通冲裁方式冲2mm以下的的金属板料时，其断面粗糙度可达12.53.2m，毛刺高度为0.010.05mm，从此零件的技术要求上看普通冲裁即可满足要求。综上所述，该零件有良好的冲裁性能，所以采用普通冲裁既可加工。图（2-1）零件图零件名称：外舌止动垫圈材料：Q235-A厚度：0.5mm生产批量：大批量未注公差：IT1433确定工艺方案该工件包括落料、冲孔、打弯三个工序，可有以下三种工艺方案：方案一：先冲孔，再切口，最后落料，单工序生产；方案二：冲孔切口落料复合模生产；方案三：冲孔切口落料级进冲压，采用级进模生产。方案一用单工序模。该模具结构简单，单副模具成本低，使用、维修方便，但需要三道工序三付模具，重复定位差，成本高而生产效率低，难以满足大批量生产要求和制件精度。方案二用复合模。只需一副模具，其结构紧凑，生产率高，制件精度高，特别是制件孔对外形的位置度容易保证，由于工件的设计，对模具零件精度要求较低，模具装配精度也较工件的精度及生产效率都较低。且模具强度差较小，制造难度较低，并且冲压后成品件不会留在模具上，在清理模具上的物料时也不会影响冲压速度，操作方便，大批量生产是很合适。方案三用级进模。整个制件的成形是在级进过程中逐步完成的。级进成形是属工序集中的工艺方法，可使切边、冲孔、打弯成形、落料等多种工序在一副模具上完成。级进模可分为普通级进模和多工位精密级进模。采用导正销或侧刃定位，板料厚度0.5mm比较薄，适合用侧刃定位，因为用导正销定位薄料易使零件产生翘曲。但是模具设计成本适中，且模具的定位简单。利于大批量生产。通过对上述三种方案的分析比较，从零件的生产批量和技术要求上看，该零件的冲压生产宜采用侧刃定位的普通级进模为最佳选择。