外文翻译原文.pdf

ORIGINAL ARTICLE Study on the correlated design method of plate holes for progressive dies based on functional feature Zhi Xin Jia 2 then the inserts punches dies and other forming parts are designed including positioning and locating holes and 3 based on the specific circumstances assistive devices are inserted such as pilot pins ejectors screws dowel pins springs standard parts etc The progressive die structure design usually costs about 2 3 design cycle time There are a lot of holes in a progressive die for mounting inserts assembles and standards and hole design is tedious time consuming and error prone This study is concentrated on the correlated design of holes on plates The developments of automated basic knowledge and intelligent design systems are studied by researchers all over the world Cheok and Nee presented a review of research and design before 1998 in the design automation of tools for metal stampings and proposed a framework for an integrated design system for progressive dies 1 Wang et al did some research of association technology in assembly design for precision progressive die on AutoCAD Z X Jia X C Zhang H B Wu Ningbo Institute of Technology Zhejiang University 1 Qianhu Road Ningbo 315100 People s Republic of China e mail jzx H L Li M C Fang School of Mechanical Engineering Ningbo University 818 Fenghua Road Ningbo 315211 People s Republic of China Int J Adv Manuf Technol 2010 49 1 12 DOI 10 1007 s00170 009 2371 6 2 Kumar et al developed an intelligent system for automatic modeling of progressive die 3 They also presented an expert system for automation of strip layout design process using the production rule based expert system approach of artificial intelligence on AutoCAD 4 Choi et al developed a system written in AutoLISP on the AutoCAD for strip layout and die layout and a tool kit on the SmartCAM software for modeling and postprocessing with a PC 5 7 Based on knowledge based rules Kim et al developed a system for electric product with bending and piecing operations written in AutoLISP on the AutoCAD with a PC 8 Tor et al investigated the suitability of using a blackboard framework for stamping process planning in progressive die design 9 Li et al adopted feature and rule based approach and developed an integrated modeling and process planning system for planning bending operations of progressive dies using C and ObjectARX of AutoCAD 10 Farsi and Arezoo described a two stage method to determine bending sequence in progressive dies 11 Chang et al established a genetic algorithm to solve the problems of ranking the working steps in progressive dies using AutoCAD as a drawing tool 12 Taking advantage of neural network and computer aided design CAD software Pilani et al proposed a method for automatically generating an optimal die face design based on die face formability parameters 13 Based on sheet metal operations Singh and Sekhou developed a punch machine selection expert system which was built in AutoCAD and used AutoLISP 14 Jiang et al proposed a flexible and complete insert representation scheme and analyzed the complex assembly relationships and constraints between inserts and components 15 Almost all the design systems mentioned above belong to 2D patterns As it is not easy to find defects check interference modify correlated drawings etc in 2D patterns the development of 3D software and PC technology which describes parts in solid modeling can dramatically help to resolve the above problems This technique has gradually become a mainstream tool in the design industry In recent years moreand moresystems weredeveloped on topof3Dsoftware Anautomatednestingandpilotingsystem for progressive die according to minimum scrap strategy on 3D SolidWorks was developed by Ghatrehnaby and Arezoo 16 Roh and Lee proposed a hull structural modeling system for ship design built on top of C and 3D CAD software 17 Chu et al developed a computer aided parametric design system for 3D tire mold production by in CATIA 18 Kong et al developed a Windows native 3D plastic injection mold design system based on SolidWorks with Visual C 19 Lin et al in National Kaohsiung First University of Science and Technology developed structural design systems for 3D drawing dies based on functional features in Pro E and CATIA software 20 21 Lin and Kuo also developed an integrated RE RP CAD CAE CAM system for magnesium alloy shell of mobile phone in 3D software 22 Comparedwiththe muchworkdoneinthe computer aided process planning lessworkinstructure designhas beendone Most of the work is concentrated in the computer aided process planning 1 4 7 13 16 19 Jia et al presented a relationship model of structural relevance in progressive dies 23 Wang et al discussed association technology in assembly design for precision progressive die on AutoCAD 2 Jiang et al discussed the inserts design automation 15 They proposed a representation scheme of inserts using an object oriented feature based approach Methods of standard part library construction and modeling methods of punches and dies were discussed in references on SolidWorks 24 25 Zhao et al in HuaZhong University of Science and Technology discussed correlated design of standardized parts and components in CAD system for progressive die on AutoCAD 26 For die structure design the designer can treat each function feature as a design unit 15 20 According to the design norm and standard part library of our partner who is a progressive die company this study describes a hole design system based on function feature in SolidWorks software There are several commercial progressive die design systems available in the market e g progressive die wizard on NX progressive die expert on Pro ENGINEER LOGPRESS on SolidWorks TopSolid Progress et al These packages can fulfill the holes design in condition that the users set up their own part library and make some customization As the die companies are mainly small and medium sized enterprises discussion with the local tool and die industry indicates that those systems are too expensive and beyond what they could afford to invest in In addition the commercial packages for progressive die contain generic design rules provided by die design textbooks course materials component manufacturer s catalogues etc while each die company concentrates on several classes of dies and has its own company s specific design rules parameters and tooling components Hence the development of hole design system is necessary especially for the companies which have their own specific component library and in house design rules In order to make die design more flexible and efficient with higher quality this paper proposes a computer aided structural design system of holes on the plates of progressive die based on functional feature according to a set of design rules of a local progressive die company Taking advantage of well organized die design knowledge base standard parts database hole feature library database and an integrated 3D CAD environment our system is able 2Int J Adv Manuf Technol 2010 49 1 12 to output hole structure correlated design for the main plates of a progressive die such as upper die shoe lower die shoe punch holding plate punch backing plate die holding plate and so on Upon user s input of strip layout selection of die set and design information of correlating parts the parts are inserted into the die assemble and correlated holes on the plates are constructed automatically A system has been implemented which is interfaced with a parametric and feature based CAD system SolidWorks through C An example is provided to demonstrate our approach and to show its effectiveness in progressive die design The rest of the paper is organized as follows Section 2 describes the design procedure for progressive die hole classification and the descriptive model for design of hole on plates for progressive dies Section 3 explains the architecture of the structural design system for holes on plates and deals with the process for constructing the holes design with the help of library feature in detail Section 4 demonstrates the hole designing of a progressive die for the motor core using the proposed system Conclusions are given in Section 5 2 Hole classification and the descriptive model for progressive dies The structure ofa progressdie usuallyconsistsofanupper die shoe a lower die shoe a punch holder plate upper backing plates a lower plate a punch backing plate a die backing plate and other die structure components required by each process station such as punches dies strip guide pins lifters guide posts and bushings et al as shown in Fig 1 Figure 1 shows the structure of a typical progressive die There are a lot of holes on the main parts such as upper die shoe lower die shoe punch holder plate upper backing plates die holder plate punch backing plate die backing plate etc which are used for connecting locating and installing The holes are different in structure function tolerance and fit Meanwhile holes on different plates have complex correlated relations for different kinds of correlating parts or assembles such as punches dies screws pilot pin assembles lifter pin assembles etc When the parameters or location is changed for the correlating parts the size or the location must also change to fit which cannot be defined and achieved by functions provided by general 3D CAD software Hence the relationship among the holes the correlating parts or assembles and the correlated plates must be studied on the basis of relevance So in this paper we first give classification for holes on plates by structure then analyze the relationship between the plate holes and associated parts and present a descriptive model 2 1 Hole classification by structure By studying the structure of the progressive dies six types of holes are summarized according to their structure They are through hole step hole blind hole screw hole figure hole and combined hole The characters of the different kinds of holes are listed below in detail 2 1 1 Through hole The hole goes through the plate The assemble of guideposts and bushes which are employed for aligning the die set associates with the upper die shoe the stripper holding plate and the bottom die shoe as shown in Fig 2 The holes on the stripperholdingplateandthebottomdieshoearethroughholes 2 1 2 Step hole The hole has one or two steps As shown in Fig 3 when screws and pins are employed to connect and locate two plates the step holes are usually adopted In Fig 1 the hole on upper die shoe is also a step hole for amounting the guide seat and the housing plate 2 1 3 Blind hole The hole is blind Figure 4 shows that a slot punch is amounted on the punch holding plate by a supporting plate and a screw A blind hole must be constructed on the stripper holding plate below in order to avoid colliding when the upper die set moves down to shear 2 1 4 Screw hole The screw hole is mainly used for screw As shown in Fig 3 a screw hole is constructed on the connected plate 2 1 5 Figure hole The figure hole is mainly for noncircular punches and dies As shown in Fig 4 the slot punch which is formed by wire electrical discharge machining goes through punch holding plate stripper holding plate and stripper plate The contour of figure holes on the three plates is as same as that of slot punch while the fits and tolerance are different In addition when the outside contour of the die inserts is noncircular the hole on die holding plate is also regarded as figure hole as shown in Fig 5 2 1 6 Composite hole The composite hole means that the geometric structure of the hole is complex and can be viewed as the combination Int J Adv Manuf Technol 2010 49 1 123 a A set of progressive die b Holes on bottom die shoe Hole for pilot pin components Upper die shoe Hole for guideposts and bushes Stripper backing plate Stoppers Bottom die shoe Hook screw Holes for hook screw Hole for pilot pin components Stripper plate Die inserts Bottom die shoe backing plate Fig 1 The structure of a typical progressive die a A set of progressive die b Holes on bottom die shoe Components for rolling ball guide post guide cushion etc Upper die shoe Stripper backing plate Bottom die shoe 1 guide post 2 guide bushes 3 guide bushes 4 guide seat 5 housing plate 6 inner hex screw 7 Helical coil spring 8 steel ball retainer 9 steel ball retainer 10 internal retaining rings Fig 2 Assembly for guide post and bushes and the plate holes 4Int J Adv Manuf Technol 2010 49 1 12 of several simple holes For example in order to facilitate the installation and lifting usually four hook screws are mounted on large plates such as upper die shoe bottom die shoe and stripper plate and the holes for hook screws are combined holes as shown in Fig 6 Usually on the progressive die typical components such as pilot pin assemble and lifter pin assemble are employed which are composed by plug screw spring cylinder pin pilot or lifter Figure 7 shows one pilot pin assemble and the holes on the correlated plates The hole on upper die shoe is a composite hole that consists of a through hole and a screw hole 2 2 Classification according to the relationship between the correlating parts and correlated plates From the points of relevance the above mentioned various holes associate the correlating parts or function assemble and the correlated plates The relationship between the correlating parts and correlated plates can be classified into three categories which are one to one one to many many to many as shown in Fig 8 2 2 1 One to one It means the one correlating part and the one correlated plate as shown in Fig 8a For example when the hook screw is mounted on the upper die shoe or the bottom die shoe or the stripper plate as shown in Fig 6 the hook screw is the correlating part while the upper die shoe or the bottom die shoe or the stripper plate is the correlated part The hook screw hole is the connector This kind of relation is simple 2 2 2 One to many It means the relation between one correlating part and a group of correlated plates as shown in Fig 8b This kind of relationship exists commonly such as a threaded fastener connected two or three plates and pins located two plates There are also many such examples in relevant punch and die structures In Fig 4 the slot punch is amounted by the supporting plate and screw The slot punch is the correlating part that associates the punch holding plate stripper holding plate and stripper plate and three holes with different fits on the corresponding plate In Fig 5 the die is the correlating part that results in three holes Composed dies Circular die Die insert Die holding plate Die backing plate Bottom die shoe Fig 5 Die insert and relevant holes Screw and pin Fig 3 Step hole screw hole and pin hole Punch 1 screw 2 suporting plate 3 slot punch Stripper backing plate Stripper plate Punch holding plate Punch backing plate Fig 4 Figure hole blind hole and screwed hole Int J Adv Manuf Technol 2010 49 1 125 respectively on die holding plate die backing plate and bottom die shoe The die is amounted on the die holding plate with an interference fit The diameter of the circular holes on the die backing plate and the bottom die shoe is increasingly larger than the maximum contour size of the scrap in order to let the scrap drop down smoothly 2 2 3 Many to many It indicates the relation between a group of correlating parts and several correlated plates as shown in Fig 8c In a set of progressive die assembles such as guideposts and bushes the pilot pins and lifter pins are common components which can be standardized In Fig 2 the assemble of guideposts and bushes composed of ten parts associates with the correlated three parts upper die shoe stripper backing plate and bottom die shoe In Fig 7 the pilot pin assemble consists of plug screw spring cylinder pin pilot and adjusting collar The correlated parts are upper die shoe punch backing plate punch holding plate stripper holding plate stripper plate and die holding plate 2 3 The descriptive model of plate holes and associated parts From the analysis of the relationship of the correlating parts and the correlated plates we can see that two conditions must be met in order to achieve the correlated structure design of holes on plates 1 The size of the hole s on the correlated part s will be determined by the correlating part s 2 Whenlocationofthecorrelatingpartsismovedorthesize ofthe correlatingparts isedited sotoodothe holesonthe correlated plates Hence we establish a descriptive model that views the correlating parts as controller The relationship model of associated holes is defined as follows Class associated holes Correlating part one part or a functional assemble Location points for the correlating part Correlated plates one or a group of parts Corresponding library features of holes one or a group 3 Construction process for correlated hole design system for progressive die Parameterized die design takes changeable sizes of die structure as parameters and then changes the die structure sizes by means of a relationship formula for the parameters so as to fulfill the design objectives But in the relevant hole design process for progressive die some portions of the die Hook screw Fig 6 Composite hole for hook screw Pilot pin assemble 1 plug screw 2 spring 3 cylinder pin 4 adjusting collar 5 pilot pin Punch backing plate Upper die shoe Punch holding plate Stripper backing plate Stripper plate Die holding plate Fig 7 Pilot pin assemble and relevant holes 6Int J Adv Manuf Technol 2010 49 1 12 structure suchasguides punches dies lifters andsupporting plates may be rather different in shape so it is impossible to meet the design requirements by simply changing the structure size alone Therefore in this document various structuresofthe main parts ofa progressive die are partitioned into functional features and the same functions are catego rized into a single identical functional module The resultin