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吊耳加强板零件冲压工艺与模具设计-拉深【9张CAD图纸+毕业答辩论文】【冲压模具】

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吊耳加强板零件冲压工艺与模具设计-拉深【全套CAD图纸+毕业答辩论文】【冲压模具】.rar

C015-吊耳加强板零件冲压工艺与模具设计

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关键词：: 加强零件冲压工艺模具设计全套 cad 图纸毕业答辩论文模具

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摘要：近年来，我国家电工业的高速发展对模具工业，尤其是冷冲模具提出了越来越高的要求，2004年，冷冲模具在整个模具行业中所占比例已大大上升，据有关专家预测，在未来几年中，中国冷冲模具工业还将持续保持年均增长速度达到15%左右的较高速度的发展。

冲压成型是金属成型的一种重要方法，它主要适用于材质较软的金属成型，可以一次成型形状复杂的精密制件。本课题就是将石化、化工、电力等行业的法兰密封结构中的垫片作为设计模型，将冷冲模具的相关知识作为依据，阐述冷冲模具的设计过程。

本设计对带法兰U型件进行的模具设计，利用Auto CAD软件对制件进行设计绘图。明确了设计思路，确定了冲压成型工艺过程并对各个具体部分进行了详细的计算和校核。如此设计出的结构可确保模具工作运用可靠，保证了与其他部件的配合。并绘制了模具的装配图和零件图。

本课题通过对工件的冲压模具设计，巩固和深化了所学知识，取得了比较满意的效果，达到了预期的设计意图。

关键词：冲压模具；冲压成型；模具设计

Abstract：In recent years, the rapid development of China's household electrical appliance industry of mold industry, especially Die with the increasing demands put forward in 2004, Die in the proportion of the entire mold industry has been greatly increased, experts predict, In the next few years, China will continue to maintain industrial Die average annual growth rate reached 15% of the high rate of development.

Stamping is an important method of metal forming, it is mainly applied to relatively soft metal forming, can be a molding of precision parts of complex shape. This topic is to petrochemical, chemical, electric power industries in the flange gasket sealing structure as a design model, Die related knowledge as a basis to explain the design process of Die.

The design of the U-piece with a flange to the mold design, the use of Auto CAD software to design parts drawing. Clear design ideas, determine the process of stamping and forming part of the various specific details of the calculation and verification. The structure of such a design die is used to ensure reliability, ensure coordination with other components. And the mapping of the mold assembly and part drawings.

The subject of the workpiece by stamping die design, consolidate and deepen the knowledge, and achieved satisfactory results, to achieve the desired design intent.

Keywords: stamping die; stamping molding; die design

1 绪论3

1.1 模具行业的发展现状及市场前景3

1.2 冲压工艺介绍3

1.3 冲压工艺的种类4

1.4 冲压行业阻力和障碍与突破4

2 工件的工艺分析7

2.1 工件材料7

2.2 工件结构形状7

2.3 工件尺寸精度7

2.4 工件展开长度计算8

3 工艺方案的确定11

4 模具结构形式的确定13

5 模具总体设计14

5.1 模具类型的选择14

5.2 操作方式14

5.3 卸料、出件方式14

5.4 确定导向方式14

6 模具设计计算15

6.1 弯曲力的计算15

6.2 顶件力的计算 15

6.3 压力中心的确定16

6.4 模具工作部分零件尺寸计算16

7 主要零部件设计20

7.1 工作零部件的结构设计20

8 校核模具闭合高度及压力机有关参数25

8.1 校核模具闭合高度25

8.2 冲压设备的选定25

9 设计并绘制模具总装图及选取标准件27

10 模具的安装调试28

10.1 模具的安装调试28

结论 29

参考文献 30

致谢 31

1 绪论

1.1 模具行业的发展现状及市场前景

现代模具工业有“不衰亡工业”之称。世界模具市场总体上供不应求，市场需求量维持在600亿至650亿美元，同时，我国的模具产业也迎来了新一轮的发展机遇。近几年，我国模具产业总产值保持13%的年增长率（据不完全统计，2004年国内模具进口总值达到600多亿，同时，有近200个亿的出口），到2005年模具产值预计为600亿元，模具及模具标准件出口将从现在的每年9000多万美元增长到2005年的2亿美元左右。单就汽车产业而言，一个型号的汽车所需模具达几千副，价值上亿元，而当汽车更换车型时约有80%的模具需要更换。2003年我国汽车产销量均突破400万辆，预计2004年产销量各突破500万辆，轿车产量将达到260万辆。另外，电子和通讯产品对模具的需求也非常大，在发达国家往往占到模具市场总量的20%之多。目前，中国17000多个模具生产厂点，从业人数约50多万。1999年中国模具工业总产值已达245亿元人民币。工业总产值中企业自产自用的约占三分之二，作为商品销售的约占三分之一。在模具工业的总产值中，冲压模具约占50%，塑料模具约占33%，压铸模具约占6%，其它各类模具约占11%。

1.2 冲压工艺介绍

冲压是靠压力机和模具对板材、带材、管材和型材等施加外力，使之产生塑性变形或分离，从而获得所需形状和尺寸的工件(冲压件)的成形加工方法。冲压和锻造同属塑性加工(或称压力加工)，合称锻压。冲压的坯料主要是热轧和冷轧的钢板和钢带。

全世界的钢材中，有60～70%是板材，其中大部分是经过冲压制成成品。汽车的车身、底盘、油箱、散热器片，锅炉的汽包、容器的壳体、电机、电器的铁芯硅钢片等都是冲压加工的。仪器仪表、家用电器、自行车、办公机械、生活器皿等产品中，也有大量冲压件。

冲压件与铸件、锻件相比，具有薄、匀、轻、强的特点。冲压可制出其他方法难于制造的带有加强筋、肋、起伏或翻边的工件，以提高其刚性。由于采用精密模具，工件精度可达微米级，且重复精度高、规格一致，可以冲压出孔、凸台等。

冷冲压件一般不再经切削加工，或仅需要少量的切削加工。热冲压件精度和表面状态低于冷冲压件，但仍优于铸件、锻件，切削加工量少。

冲压是高效的生产方法，采用复合模，尤其是多工位级进模，可在一台压力机上完成多道冲压工序，实现由带料开卷、矫平、冲裁到成形、精整的全自动生产。生产效率高，劳动条件好，生产成本低，一般每分钟可生产数百件。

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内容简介：: - 7 -Cost Savings for Mold Materials: Consider the DetailsWays to reduce costs that are not related to the price per pound of the mold material. By Patricia MillerChoosing the right tooling material for plastic molding is becoming ever more difficult. In light of intense competition, as well as the cost of raw materials, which is driving the price of materials for molds up, it becomes increasingly more important to be selective in the choice of mold materials. There are things that can be done to help the moldmaker make the best selections for the application at hand, and these things are not simply looking at the price per pound. But in order to do this, the moldmaker must consider other factors. This starts at the beginning of the moldmaking cycle, as the part to be manufactured is being proposed. The major areas to be considered in a mold design include: Size and complexity of the part or mold Production quantity required Type of plastic molding material required and its impact on the molding environment Mechanical requirements for the mold Physical property requirements for the mold (thermal conductivity, stiffness, thermal expansion) Stability requirement of mold during operation Assembly issues (mating material criteria, coatability) Design features (sharp corners, thin sections, sealing methods) Surface condition requirements (polishing, texturing demands) Manufacturing methods (electro dis-charge machining, hard milling) Cost savings can occur in all these areas, but for this discussion four areas of alloys will be addressed: 1. New high hardness matrix alloys 2. Thermally conductive alloys 3. Corrosion resistant materials 4. Prehardened alloys In each case, the cost of the mold material is significantly outweighed by the benefits these alloys bring. Figure 1. A mold for plastic injection molded electric motor rotors, made of 30 percent glass-filled Polyamide. Mold material has, to date, increased the life of the mold over 20 percent, eliminating mold repairs and refurbishment. Figures courtesy of Bohler-Uddeholm Corporation.1. High Hardness Matrix AlloysIn an exciting development for mold materials, there are now tool steel grades available that can replace S7, H13 and with coating replace A2, D2 and M2 types where wear resistance is required. But the advantage that these grades bring is that they can be used from 50 HRC up to 62 HRC, and are weldable, polishable to high levels, texturable and are coatable when even higher wear resistance is required. Figure 2. The relationship of highly conductive alloys, thermal conductivity versus hardness. The new Cu-Ni alloy, having hardness levels like that of P20, has higher thermal conductivity than other copper alloys and aluminum.Very tough grades, these materials also provide an added advantage that thermal conductivity exceeds that of H13, hence cycle times can be reduced. These grades replace past cold work grades that could only achieve their mechanical properties by low temperature tempers, which did not permit good weldability, nitriding or PVD coating above 400oF. Their high polishability and texturability is due to the excellent uniformity of the matrix from the use of high technology remelting processes.An example of this is shown in Figure 1. An injection mold insert made of Polyamide plus 30 percent glass fiber, was manufactured from a chromium-molybdenum-vanadium alloyed tool steel. At 54-56 HRC, it has been running for over 7,700 pieces and is still running well. Premium H13 at 50-52 HRC began to wear and plastically deform at 6,000 pieces. 2.Thermally Conductive AlloysCopper alloys have been available for several years to address the need for cycle time reduction and part reproducibility, and have been used particularly for cores where plastic residing times are highest. Copper-beryllium alloys are available in hardness ranges of 30-40 HRC. In addition, there is a copper-nickel alloy that can achieve hardness of 30 HRC, which is in the range of a typical P20. The advantage this grade brings is that its thermal conductivity exceeds that of other copper alloys in this hardness range, and also that of aluminum. This grade also is antigalling and corrosion resistant (see Figure 2).Figure 3. Rough milling of the cavity; premium H13, 45 HRC.3. Design and Stainless Alloys It is time to reconsider stainless alloys. There are new stainless alloys whose benefits are clear: high polishability, with toughness levels in the range of Premium H13, up to 50-52 HRC. The fact that these alloys will maintain their corrosion resistance with minimal need for rework or repolishing over the life of the mold, and still provide a durable, high mechanical strength mold, is worth careful consideration.Figure 4. Drilling of cooling channels; premium H13, 45 HRCOne area which has limited the life of stainless molds in the past has been the use of tapered pipe plugs. Heat treatment limitations, machining issues with devel-oping the threads, stresses generated in the threads following torquing, along with the corrosive conditions of dead zoneswhich create pitting attack on the stainlesscan lead to cracking in these regions. New stainless alloys can minimize susceptibility to this along with plug designs that are available to handle hydraulic sealing issues without machining threads into the mold material. 4. Prehardened Mold MaterialsLooking away from the steel cost to manufacturing technique, we now see the development of machining practices, which permit the customer to use grades that are prehardened to higher hardness ranges. It is now possible to machine grades like H13 at hardness levels in the range of 44-46 HRC, and in many cases even harder. The advantage this brings is that the steel can be prehardened, in a method that gives excellent properties because the cooling rates can be faster when less detail is in the mold, and cracking susceptibility is less. The integrity of the steel increases, while the need for rough machining, stress relieving and prefinish machining is eliminated. This saves time and money, when usually at the stage when heat treatment is performed, time constraints are high. With these time constraints, corners get cut and heat treatment is not always done to optimize the property of the steel. Tempers may not all get done, and cooling rates are slowed down to permit less stock to be left on, because the moldmaker has less time to remove the extra stock needed for the movement that will take place from a good, rapid quench. Figure 5. Finishing milling of cavity; premium H13, 45 HRC.Some examples of how to machine a hardened H13 are given in Figures 3, 4 and 5.ConclusionThere are many ways to reduce cost that are not related to the price per pound of the mold material. With the ultimate goal to provide the customer what they need in terms of part integrity and reliability, manufacturing a mold that will provide all of these things in a reasonable way requires a thorough review of the design criteria, manufacturing processes and production demands. New materials and methods are available that were not there the last time the mold was made, that can help minimize the overall cost of the mold.附录B专业外文翻译节省模具材料费用细则降低成本的方式涉及的不光是每磅模具材料的价格。作者：帕特丽夏米勒正确的选择塑料模具材料变得越来越重要，在竞争激烈的今天，原材料的成本升高使得模具的价格上涨，模具的材料的选择就本的日益重要。有些东西可以帮助模具制造者们最好的选择模具材料，并且这些东西不就简单的降低每磅模具材料的价格。但是为了节省成本，模具制造商们肯定也会考虑到其他因素。首先要考虑的是模具制造的周期，当要制造一个零件的时候，模具的主要设计的部分包括：l 模具尺寸和复杂的模具型腔l 产品质量要求l 塑料成型的类型和成型因素的影响l 模具制造机械设备的要求l 模具物理因素要求（传热性、硬度、热膨胀）l 生产过程中的稳定性装配问题（符合装配原则，防绣）l 设计原则（锐角转角、避免薄壁、密封性好）l 符合表面技术要求（抛光、粗糙度要求）l 制造方式（电镀、电火花加工、磨削加工）每个阶段都可以作到节省成本，但是有四个方面最为突出：1. 新型高硬度铋铅锡锑合金2. 热导性良好的合金3. 抗腐蚀材料4. 预硬合金无论以上那一种材料，作为模具材料，在节省成本方面的价值都是超过其他材料的方案。例1 电机转子注塑模添加了30的玻璃填充物聚酰胺，使得模具的寿命延长了20，减少模具修理和抛光工序。本例由Bohler-Uddeholm公司提供。1 高硬度铋铅锡锑合金模具材料的发展令人乐观，出现的许多新型的工具，钢取代了S7，H13并且表面处理钢代替了A2，D2，M2。这些新型的高级钢的优势在于他们的硬度达到HRC50HRC60，并且能够焊接、精密磨削，组织致密和良好的耐磨性。例2 高热导性钢的导热性与硬度的联系。新型的铜镍合金有着高硬度，达P20，比其他铜合金和铝合金有着更好的导热性。那些超硬的材料，他们的优势在于热导性超过H13。因此生产周期缩短。这些高级钢替代了过去冷作模具钢需要通过低温回火才能达到所需机械性能，而且冷作模具钢还不能焊接，挤压或者400oF的PVD表面处理。高硬材料的优良的表面特性来自于高技术的熔化处理得到的均匀的内部晶体结构。例1能够说明以上观点。注塑模加入30的聚酰胺玻璃纤维，被制造成铬钼钒合金工具钢。硬度在5456HRC，它能够工作7700次而毫物损伤，Premium H13的硬度在5052HRC，在6000次的工作之后，塑件开始发生变形。2 热导合金钢铜合金的使用已经有很多年了，一直以来都在努力缩短铜合金重新

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