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关键词：: 冲压拉伸复合模具设计优秀优良 15 cad 图纸模具全套毕业设计

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设计说明书.doc[18000字，46页]

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，近些年，冷冲模具在整个模具行业中所占比例已上升到50%左右，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10%以上的较高速度的发展。国内冷冲模具市场以冷冲模具需求量最大，其中发展重点为工程冷冲模具。

冲裁成型是冷冲成型的一种重要方法，它主要适用于金属材料的成型，可以一次成型形状复杂的精密零件。本课题就是将锁壳冷冲压模作为设计模型，将冲裁模具的相关知识作为依据，阐述冷冲压模具的设计过程。

本设计对锁壳冷冲压模进行的冷冲压模的设计，对工件结构进行了工艺分析。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。最后用autoCAD绘制了一套模具装配图和零件图。

本课题通过对锁壳冷冲压模的冷冲压模具设计，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；冲裁成型；模具设计

Abstract

In recent years, China's household electrical appliance industry in the development of high-speed tooling industry, in particular, have raised Die growing demands in recent years, the entire Die in a proportion of trade has risen to around 50 percent, according to the relevant Experts predict that in the next few years, China will continue to Die with industry to maintain an average annual growth rate reached over 10 percent of high speed development. Die with the domestic market to Die with the greatest demand, which focus on the development of a project Die.

Blanking is forming a cold-forming an important method, which apply mainly to the forming of metal materials, forming a complex shape of the precision components. The issue is to lock shell cold stamping die as a design model, will be punching die of related knowledge as the basis on cold stamping die design process.

The design of the lock shell of the cold stamping die of cold stamping die design, the structure of the workpiece Technology Analysis. Defined the design, determine the process of stamping and forming part of the specific details of the calculation and verification. So the structure can be designed to ensure that the use of reliable mold work to ensure that the co-ordination with other components. Finally, autoCAD drawing a mold assembly and parts plans.

The subject of the lock through the shell cold stamping die of cold stamping die design, consolidated and deepened by knowledge, has been relatively satisfied with the results, achieved the expected design intent.

Keywords :stamping die; blanking molding; die design

前言15

1 工艺分析工艺方案的确定19

1.1 冲裁件的工艺性分析19

1.2 综合技术经济效益观念19

1.3 零件材料性能分析及工件工艺性分析19

1.4零件工艺性的分析21

1.5重视模具材料和结构的选择，保证有一定的模具寿命。21

1.6 确定工艺方案及模具结构形式22

2 工艺计算及排样方案24

2.1尺寸的确定24

2.2确定排样方式和计算材料利用率27

2.3搭边值的确定28

2.4冲压设备的选择29

3 工作零件设计31

3.1凹模的设计31

3.2凸模的设计33

3.3凸凹模具的设计34

3.4卸料板的设计35

3.5打杆的长度35

3.6压边装置的设计36

3.7顶杆的长度36

3.8根据国标选用导向机构36

3.9导柱加工工艺过程卡38

3.10橡皮垫的设计39

3.11模具的选择40

4 工作原理及装配图41

参考文献42

致谢44

参考文献

[1]肖景容，姜奎华编的《冲压工艺学》北京：机械加工出版社会性， 1999。

XiaoJingRong, JiangKuiHua compiled the stamping technology of Beijing: mechanical processing publishing sociality 1999.

[2]王孝培.主编《冲压手册》第二版北京机械工业出版社。2004

WangXiaoPei. (Ed.), the stamping manual "second edition Beijing machinery industry press 2004

[3]王芳.主编《冷冲压模具设计手册》北京机械工业出版社。1999

Wang fang. (Ed.), the cold stamping mould design manual "Beijing machinery industry press 1999

[4]黄毅宏、李明辉。主编模具制造工艺.北京：机械工业出版社，1999.6。

HuangYiHong, LiMingHui. Editor mould manufacturing process. Beijing: machinery industry press 1999

[5]李绍林，马长福。主编.实用模具技术手册.上海：上海科学技术文献出版社，2000.6。

LiShaoLin, MaChangFu. Editor. Practical mould technology handbook. Shanghai: Shanghai science and technology literature press 2000

[6] 华北航天工业学院，钟斌主编《冲压工艺与模具设计》。北京：机械工业出版社，2000.5。

North China aerospace industry institute, clock, ".bin stamping process and mold design ". Beijing: machinery industry press 2000

[7]模具实用技术丛书编委会.冲模设计应用实例[M].北京:机械工业出版社,2005,1。

Mould practical technology series. Die design application examples editorial [M].beijing: machinery industry press, 2005,1.

[8]郑家贤.冲压工艺模具设计实用技术[M].北京:机械工业出版社,2005,1.

ZhengjiaXian. Stamping process mold design and practical technology [M].beijing: machinery industry press, 2005,1.

[9]梁炳文.实用板金冲压工艺图集[M].北京:机械工业出版社，2003,8.

LiangBingWen. Practical sheet metal stamping process atlas [M].beijing: machinery industry press, lei. 2003,8.

[10]冲模设计手册编写组.冲模设计手册[M].北京:机械工业版社,2007,3.

Editorial stamping die design manual design manual. [M].beijing: machinery industry edition clubs,.res social admi pharm. 2007,3.

[11]王立人,张辉.冲压模设计指导[M]. 北京:北京理工大学出版社, 2009,8.

WangLiRen, zhang hui punch mould design guidelines. [M].beijing: Beijing university of science and technology press, 2009,8.

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内容简介：: ofMgLiInstitute110016,December11ofstrengthenreserved.extrusion), cannot make the ultimate tensile strength(UTS) of MgLi alloys exceed 200 MPa.Zn/Y ratio was above a certain value (4.38), withincreasing Y content, more I-phase would be formedin the Mg matrix.Zn1.2% Y and Mg8% Li9% Zn1.8% Y, were pre-pared. By investigating the mechanical properties ofcopy (SEM; XL30-FEG-ESEM). Tensile bars with agauge length of 25 mm and 5 mm in diameter were ma-chined from the alloys. The axial direction of the tensilespecimens was parallel to the extruded direction. Tensileexperiments were conducted on an MTS (858.01 M)testing machine with a constant strain rate of 1 10C03sC01at room temperature. SEM (XL30-FEG-ESEM)*Corresponding author. E-mail: ehhanScripta Materialia 57 (2007) 285288On the other hand, it has been reported that MgZnY alloys containing I-phase (Mg3Zn6Y, icosahedralquasicrystal structure) as a secondary phase exhibitgood mechanical properties at both room temperatureand elevated temperature 3. Depending on the volumefraction of I-phase, MgZnYZr alloys can have yieldstrength from 150 to 450 MPa at room temperature 4.Previous studies 59 indicated that the existence of I-phase in MgZnY or MgZnYZr alloys was closelydependent on the Zn/Y weight ratio. Literature 7 sug-gested that when the Zn/Y ratio exceeded 4.38, elementY would exist almost completely as I-phase. When thethe alloys, the two questions will be answered.The materials used in this study were as-extrudedMgLiZnY magnesium alloys with dierent Zn andY contents, which were prepared using specific techno-logy in the Magnesium Alloy Research Department ofIMR, China. Using inductively coupled plasma atomicemission spectrum apparatus, the chemical composi-tions of alloys IIII were determined, and these are listedin Table 2. The extrusion ratio was 10:1.Phase analysis was determined with a D/Max 2400 X-ray diractometer (XRD). Microstructures of the as-castalloys IIII were examined by scanning electron micros-Alloying magnesium with lithium of extremely lowdensity (0.534 g cmC03) can further reduce the weight ofMg alloys. However, based on the previous results listedin Table 1, the strength of MgLi alloys is very low 1,2.Generally, previous strengthening methods, such asadding Zn or Al alloying elements and severe plasticdeformation (hot extrusion or equal channel angularBased on the analysis of these two alloy systemsmentioned above, two questions can be asked: (i) canI-phase be introduced into MgLi alloys? (ii) If I-phasecan be introduced, will the mechanical properties ofMgLi alloys be greatly improved? Therefore, in thiswork, three alloys (with Zn/Y ratios higher than 5),namely Mg8% Li3% Zn0.6% Y, Mg8% Li6%The strengthening eectas-extrudedD.K. Xu,a,bL. Liu,aY.B.aShenyang National Laboratory for Materials Science,ShenyangbEnvironmental Corrosion Center, Institute of Metal Research,Received 31 October 2006; revised 30Available onlineThrough investigating the mechanical properties of three kindsI-phase (Mg3Zn6Y, icosahedral quasicrystal structure) in the matrixonstrated. The tensile results indicate that I-phase can eectivelybeen explained by microstructure changes.C211 2007 Acta Materialia Inc. Published by Elsevier Ltd. All rightsKeywords: I-phase; MgLi alloy; Mechanical properties1359-6462/$ - see front matter C211 2007 Acta Materialia Inc. Published by Elsevierdoi:10.1016/j.scriptamat.2007.03.017icosahedral phase onalloysXuaand E.H. Hanb,*of Metal Research, Chinese Academy of Sciences,ChinaChinese Academy of Sciences, Shenyang 110016, China2006; accepted 7 March 2007May 2007MgLiZnY alloys, a strengthening method, i.e. introducingof MgLi alloys, for as-extruded MgLi alloys has been dem-the alloys. The substantial enhancement of strength /locate/scriptamatLtd. All rights reserved.ntsTable 1. Summary of the mechanical properties of the dierent MgLi alloysCondition As-extruded stater0.2(MPa) UTS (MPa)Mg11% Li1% Zn 1 96 133Mg9% Li1% Zn 1 100 141Mg9% Li1% Zn0.2% Mn 1 90 130Mg9% Li1% Zn1% Al0.2% Mn 1 105 150Mg9% Li1% Zn3% Al0.2% Mn 1 110 161Mg3.3% Li 2 69 160Table 2. Chemical composition and the mechanical properties of the as-extrudedNormal alloys Chemical composition (wt.%) Zn/YMg Zn Y LiAlloy I Bal 3.12 0.61 8.04 7286 D. K. Xu et al. / Scripta Materialiaobservations using either secondary electron imaging orbackscattered electron imaging were made to determinethe fracture characteristics and cracked I-phase on thefracture surfaces.XRD analysis is shown in Figure 1. It reveals that foralloys IIII, the main phases are a-Mg, b-Li, LiMgZnand I-phase. Meanwhile, with the increase in Zn andY content, the diraction peak of W-phase will be grad-ually intensified. In addition, it has been reported3,6,10 that I-phase could form interdendritic eutecticpockets with a-Mg. Therefore, an easy way to determineI-phase is by its morphology.The microstructure observations of as-cast alloysIIII are shown in Figure 2. The figure shows thatI-phase/a-Mg eutectic pockets preferentially form atthe a-Mg/b-Li phase interfaces. With increasing Znand Y contents, I-phase/a-Mg eutectic pockets can notonly coarsen at the a-Mg/b-Li phase interfaces but alsogradually form in the a-Mg matrix. Since element Yexists almost entirely in the form of I-phase, the quantityof I-phase for alloys is depended on Y content. There-Alloy II Bal 6.47 1.26 7.86Alloy III Bal 9.25 1.79 7.67fore, based on the variation of Y content, it can bededuced that the quantity of I-phase for alloy III is 3and two times as much as that of alloys I and II, respec-Figure 1. X-ray diraction patterns of as-extruded MgLiZnYalloys. The arrows in the figure indicate the intensifying tendency ofW-phase diraction peak.tively. In addition, with increasing Zn content, especiallyfor alloy III, many lamellar LiMgZn phases can beobserved in the a-Mg matrix, as shown in Figure 2(d).The stressstrain curves are shown in Figure 3. To de-scribe and compare these conveniently, the mechanicalproperties of 0.2% proof yield stress (r0.2), UTS andelongation to failure for the alloys are listed in Table2. It can be seen that the quantity of I-phase can eec-tively improve the yield strength and UTS of alloys.Comparing alloys I and III, with the quantity of I-phaseincreasing approximately 3-fold, the yield strength andUTS increase from 148 and 222 MPa to 166 and247 MPa, respectively. Meanwhile, the plasticity of alloyIII decreases greatly.Previous research of MgZnYZr alloys indicated5,7,9 that with the quantity of W-phase increasing,the strength of alloys decreased. X-ray analysis indicatesthat for alloy II, W-phase can hardly be detected. There-fore, it can eectively avoid the influence of W-phase.To indicate the eect of I-phase on the mechanical prop-erties of alloys, only the fracture of alloy II has been(tested at room temperature)Equal channel angular extrusionElongation (%) r0.2(MPa) UTS (MPa) Elongation (%)60 150 175 3556 160 182 3170 140 165 2260 145 180 2450 130 180 2718 113 200 33MgLiZnY alloysratio Mechanical propertiesr0.2(MPa) UTS (MPa) Elongation (%)148 222 30.7159 239 20.4166 247 17.157 (2007) 285288chosen to be observed. Figure 4 shows the secondaryand backscattered SEM images of the fracture surfaces.The figure reveals that micro-cracks can form in theinterior of big bulk I-phases.Based on the MgLiZn ternary phase diagram 11,when Li content is between 6.0 and 9.5 wt.%, a-Mg andb-Li coexist and the Zn content in the solid solutionscannot exceed 2 wt.%. With decreasing solidificationtemperature, the solid solubility of Zn decreases gradu-ally. Meanwhile, the MgLiY ternary phase diagramreveals 12 that the Y content in the solid solutions isvery tiny. In addition, due to the interaction of elementsZn and Y, the solid solubility of Zn and Y is greatly de-creased 13. In this study, Li content of alloys IIII isabout 8 wt.%. Therefore, as the solidification processcontinues, redundant Zn and Y (with a Zn/Y ratio high-er than 4.38) will exist between a-Mg and b-Li phasesand preferentially form I-phase at the a-Mg/b-Li phaseinterface. Certainly, I-phase can also form in the interiorof a-Mg and b-Li matrix, as shown in Figure 2ac. Ithas been reported that the melting temperature ofI-phase eutectic pockets is about 450 C176C 3,8,14,15.ntsD. K. Xu et al. / Scripta Materialia 57 (2007) 285288 287Therefore, when the temperature is lower than 450 C176C,the forming of I-phase will retard the further diusionof Zn and Y. Especially for alloys II and III, more I-phase can form during solidification process, which willFigure 2. The microstructure of the as-cast MgLiZnY alloys: (a) alloy I,location squared in image (c).0 5 10 15 20 25 30 35050100150200250300Tensile strength (MPa)Strain (%)1 Alloy I2 Alloy II3 Alloy III123Figure 3. The stressstrain curves of the as-extruded MgLiZnYalloys.Figure 4. The SEM observation of cracked I-phase on the fracture surface foreasily lead to the formation of areas with higher andlower Zn/Y ratios in the liquid phase. Therefore, thearea (with lower Zn/Y ratio) cannot fully meet therequirement of forming I-phase and W-phase will beformed, whereas the area (with higher Zn/Y ratio) cansuccessfully form I-phase and the redundant Zn willform a supersaturated solid solution in the a-Mg matrix.When the alloys are cooled down to room temperature,lamellar LiMgZn phases precipitate from the supersatu-(b) alloy II, (c) alloy III and (d) high-magnification observation of theration solid solution, as shown in Figure 2(d). Previousresearch reported 16 that after T6 temper treatment(solid solution for 2.5 h at 500 C176C plus 15 h of artificialageing at 180 C176C), MgZnY phases (I-phase and W-phase) disappeared and rod-like MgZn0precipitatedfrom the supersaturated solid solution. In addition, theMgLiZn ternary phase diagram 11 indicates thatwhen the contents of Mg and Zn are higher than about40 at.%, Li will preferentially form LiMgZn phase withZn and Mg. Therefore, the formation of LiMgZn canbe divided into two steps: (i) the formation of anarea of higher Zn content caused by rod-like MgZn0;and (ii) the diusion of Li and the formation ofLiMgZn. Based on the discussion above, I-phase canalloy II: (a) secondary and (b) backscattered SEM observation.ntsbe successfully introduced into the matrix of MgLi al-loys, which clearly answers the first question. Whether I-phase can eectively strengthen MgLi alloys or not willbe discussed below.It has been reported 3 that the interface layer ofa-Mg, 35 nm thick, still preserved the orientationrelationship with I-phase, and the coherency betweenI-phase and a-Mg could be achieved by introducingsteps and ledges periodically along the interface. There-fore, the atomic bonding between I-phase and the hex-agonal structure was rigid enough to be retainedBased on experimental results, two main factors influ-encing the strength of alloys can be determined: thequantity of existing W-phase and the size of I-phase.Therefore, it can be predicted that by controlling thesetwo factors, the potential strength of MgLi alloys canbe further improved.This work was supported by National Science Fundof China (NSFC) project under Grant No. 50431020.288 D. K. Xu et al. / Scripta Materialia 57 (2007) 285288during severe plastic deformation. A study of as-castMgZnYZr alloys 5 suggested that the a-Mg/I-phase eutectic pockets could retard the basal slip andthat no cracks could be observed at the a-Mg/I-phaseinterfaces. Compared with the tensile properties listedin Tables 1 and 2, this clearly suggests that introducingI-phase into the Mg matrix can eectively improve thestrength of MgLi alloy. However, the stressstraincurves reveal that with the quantity of I-phase increas-ing, the dierence in UTS between the alloys decreasesgreatly, as shown in Figure 3. The figure reveals thatthe dierence of UTS between alloys I and II is abouttwice as great as that between alloys II and III, whichcan be ascribed to two main reasons. First, based onX-ray phase analysis (in Fig. 1) and the discussion ofthe phase-forming mechanism, the quantity of W-phaseincreases with increasing Zn and Y content, which de-grades the strength of alloys, especially for alloy III. Sec-ondly, due to the higher content of Zn and Y for alloysII and III, I-phase formed at the a-Mg/b-Li interfaceswill be coarsened, leading to a large bulk I-phase afterhot-extrusion processing. During the tensile testing,the higher stress concentration will occur around thelarge bulk I-phase, which degrades the strength of al-loys. Figure 4 shows that at a certain stress level, mi-cro-cracks will be formed in the interior of the largebulk I-phase to relieve the deformation incompatibilitybetween I-phase and a-Mg matrix. This provides furtherevidence that a-Mg/I-phase interfaces are very strong.Furthermore, it also indicates that the size of thecracked I-phase is larger than 10 lm. Therefore, to fullyexploit the potential strength of MgLi alloys, the quan-tity of existing W-phase and the size of I-phase must bestrictly controlled.By investigating three kinds of MgLi alloys, astrengthening method, i.e. introducing I-phase in thealloy matrix, has been demonstrated. The maximumUTS of the new exploited alloys can reach 250 MPa.1 Tien-Chan Chang, Jian-Yih Wang, Chun-Len Chu,Shyong Lee, Mater. Lett. 60 (2006) 32723276.2 T. Liu, Y.D. Wang, S.D. Wu, R. Lin Peng, C.X. Huang,C.B. Jiang, S.X. Li, Scripta Mater. 51 (2004) 1057106

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