模具设计任务书正文.doc

中州大学毕业设计一 、 工艺分析1. 工件的工艺分析 工件名称：托板 工件形状：如图所示生产批量：大批量材料：08F厚度：3mm此工件只有落料和冲孔两个工序。材料为08F，具有良好的冲压性能，适合冲裁。工件结构相对简单，有4个3.5的孔，孔与孔，孔与边缘之间的距离也满足要求，厚度要求为3mm，零件图上所有尺寸未标注尺寸公差，属于自由尺寸，可按IT14级确定工件尺寸精度，经查公差表，各尺寸公差为：58-0.74、38-0.62、30-0.52、16-0.44、140.22、170.22、3.5+0.3普通冲裁完全能满足要求。2. 冲裁工艺方案的确定该工件包括落料、冲孔两个基本工序，可有以下三种工艺方案：方案一：先落料，后冲孔。采用单工序模生产。方案二：落料冲孔复合冲模。采用复合模生产。方案三：冲孔落料级进冲模。采用级进模生产。方案一结构简单，但需要两道工序两副模具，成本高生产效率低，难以满足大批量生产的要求。方案二只需要一副模具，工件精度及生产效率都教高，工件最小壁厚为7MM模具强度较好。方案三也只需要一副模具，生产效率高，操作方便，但是制造精度不如复合模。工件尺寸精度要求不高，形状不大，但工件产量较大，根据材料较厚（2mm）的特点，为保证孔位精度，冲模有较高的生产率，通过对上述三种方案的分析比较，决定实行工序集中的工艺方案，采取利用导正钉进行定位、刚性卸料装置、自然漏料方式的级进冲裁模结构形式。综上该件的冲裁工艺采用方案三为佳，即级进模。二 模具设计1. 模具结构形式(1)模具类型设计由冲压工艺分析可知，采用级进模。(2)定位方式的选择该模具采用的是条料，控制条料送进方向采用导料板，无测压装置，控制条料的送进步距采用挡料销定距。(3)卸料方式的选择因为工件料厚为3MM，相对较薄，卸料力也较小，故采用刚性卸料。又因为是级进模，故采用下出料。(4)排样方式的确定及其计算 托板的形状为左右对称，下端水平，采用直对排效率较高。如图所示的排样方法。查（冲压工艺与模具设计表2.5.2 ）确定搭边值。根据零件形状，两工件间按矩形取搭边值b=2,侧边按圆形取搭边值a=2。连续模进料步距为32mm。条料宽度按相应的公式计算：B=(D+2a)- 查表 =0.6B=(58+22)-0.6=62-0.6画出排样图，如图 2. 模具主要零部件设计（1） 冲压力的计算 P0=P+PtP=P1+P2而式中 P1-落料时的冲裁力P2-冲孔时的冲裁力按推料力公式计算冲裁力：P1=KLt 查=300MPa=2.22（58-16）+2（30-16）+16*2*300/10000=12.6 (t)P2=2.2*4*3.5*2*300/10000 =3.4(t)按推料力公式计算推料力Pt：Pt=nKtP 取n=3，查表2-10，Kt=0.055Pt=3*0.055*(12.6+304)=2.65(t) 计算总冲压力PZ：PZ=P1+P2+Pt =12.6+3.4+2.65 =18.73(t)根据排样图分析，因为工件图形对称，故落料时P1的压力中心在O1上；冲孔时P2的压力中心在O2上。设冲模压力中心离O1点的距离为X，根据力矩平衡原理得：P1X=(32-X)P2由此算得X=7mm（2） 冲模刃口尺寸及公差的计算刃口尺寸计算方法及演算过程不再赘述，仅将计算结果列于下表中。冲裁性质工作尺寸凹模尺寸注法凸模尺寸注法落料58-0.7438-0.6230-0.5216-0.44R857.6+0.1837.7+0.1629.7+0.1316.8+0.11R7.9+0.06凸模尺寸按实际尺寸配置，保证双边间隙 0.250.36mm冲孔3.5+0.3凹模尺寸按凹模实际尺寸配置，保证双边间隙0.250.36mm3.65-0.08在计算模具中心距尺寸时，制造偏差值取工件公差的1/8据此，冲孔凹模和凸模固定板孔中心距的制造尺寸为：L14=140.44/8=140.055L17=170.44/8=170.055在冲模刃尺寸计算时需要注意：在计算工件外形落料时，应以凹模为基准，凸模尺寸按相应的凹模实际尺寸配制，保证双面间隙为0.250.36mm。为了保证R8与尺寸为16的轮廓线相切，R8的凹模尺寸，取16的凹模尺寸的一半，公差也取一半。在计算冲孔模刃口尺寸时，应以凸模为基准，凹模尺寸按凸模实际尺寸配制，保证双面间隙为0.250.36mm。（3）凹模外形尺寸的确定凸模厚度H的确定：H= P取总压力=184750NH=26mm凹模长度L的确定 W1=2.1H=31；工件b=58 L=b+2W1=58+2*31=120mm凹模宽度B的确定B= 步距+工件宽+2W2取：步距=32；工件=30；W2=1.5HB2=32+30+2*39 =140mm（4）凸模长度L1的确定凸模长度计算为：L1=h1+h2+h3+Y其中 导料板厚h1=8；卸料板厚h2=12；凸模固定板厚h3=18; 凸模修磨量Y=18则L1=8+12+18+18=56mm选用冲床的公称压力，应大于计算出的总压力P0=18.475t;最大闭合高度应大于冲模闭合高度+5mm;工作台台面尺寸应能满足模具的正确安装。按上述要求，结合工厂实际，可选用J23-25开式双柱可倾压力机。并需在工作台面上配备垫块，垫块实际尺寸可配制。（5）绘制非标准零件草图l 落料凸模如下图所示l 落料凹模如下图所示 l 凸模固定板如下图所示按已确定的模具形式及参数，从冷冲模标准中选取标准模架。绘制模具总装草图。如下图单排冲孔落料连续模。按模具标准，选取所需的标准件，查清标准件代号及标记，写在总图明细表内表2 零件明细表序号名 称数 量材 料热处理标准件代号备注页次1簧片165Mn2螺钉145HRC40453下模座11HT2004凹模1T10AHRC58625螺钉445HRC40456承导料1457导料板245HRC40458始用挡料销1459导柱220渗碳HRC566010导套220渗碳HRC586211挡料钉14512卸料板1Q235(A3)13上模座1HT20014凸模固定板14515落料凸模1T8AHRC566016冲孔凸模1T8AHRC566017垫板145HRC404518定位销145HRC404519导正销145HRC404520模柄1Q235(A5)21防转销145HRC404522内六角螺钉M12701045HRC404523圆柱销12n6100645HRC404524内六角螺钉M1270145HRC4045三 模具零件加工工艺1.落料凹模的加工工艺过程工序号工序名称工序主要内容设备刀具量具1下料锯床下料锯床锯条游标卡尺2锻造锻六方空气锤游标卡尺3热处理退火4粗铣铣六面至尺寸铣床铣刀游标卡尺5平磨磨六面，对90磨床砂轮游标卡尺6钳工划线，做螺纹铰孔，销钉孔，打穿丝孔游标卡尺7热处理淬火，回火5862HRC8平磨磨六面至尺寸磨床砂轮游标卡尺9线切割加工型孔尺寸线切割机床游标卡尺10铣铣型孔以为的尺寸铣床铣刀游标卡尺11研磨研磨内孔外形研具千分尺12检验2.落料凸模加工工艺过程工序号工序名称工序主要内容设备刀具量具1下料锯床下料锯床锯条游标卡尺2锻造锻六方空气锤游标卡尺3热处理退火4粗铣铣六面至尺寸铣床铣刀游标卡尺5平磨磨六面，对90磨床砂轮游标卡尺6钳工划线，去毛刺，打穿丝孔游标卡尺7热处理淬火，回火5862HRC8平磨磨六面至尺寸磨床砂轮游标卡尺9线切割线切割内孔线切割机床游标卡尺10研磨研磨内孔外形研具铣刀游标卡尺11钳作漏料孔千分尺12检验模具的装配根据复合模的装配要点，选凸凹模作为装配基准，先装下模，再装上模，并调整间隙。序号工序工艺说明1凸凹模预装a. 装配前仔细检查凸凹模的尺寸和形状，是否符合图纸要求尺寸精度，形状。b. 将各凸模与相应的凹模相配，检查期间隙是否加工均匀，不适合应从新修模或更换。2装配下模a. 在下模座上划中心线，按中心安装垫板，凸凹模，凸凹模固定板，打入销钉固定。b. 安装橡胶，卸料板，卸料螺钉，保证卸料螺钉比凸凹模高0.5mmc. 安装导料销，挡料销3装配上模a. 在上模座板上划中心线，装入星型顶板，安装垫板b. 按中心线安装凸模，安装凸模固定板，凹模板，装入螺钉c. 将顶杆装入推件块，将顶杆顶出星型顶板，在下模打入导柱，在上模打入导套，导柱装入导套内4试冲与调整装机试冲并根据试冲结果作相应调整。Die history1 Die position in industrial productio2Mold is a high-volume products with the shape tool, is the main process of industrial production equipment. 采用模具生产零部件，具有生产效率高、质量好、成本低、节约能源和原材料等一系列优点，用模具生产制件所具备的高精度、高复杂程度、高一致性、高生产率和低消耗，是其他加工制造方法所不能比 With mold components, with high efficiency, good quality, low cost, saving energy and raw materials and a series of advantages, with the mold workpieces possess high accuracy, high complexity, high consistency, high productivity and low consumption , other manufacturing methods can not match. 已成为当代工业生产的重要手段和工艺发展方向。 Have already become an important means of industrial production and technological development. 现代经济的基础工The basis of the modern industrial economy. 现代工业品的发展和技术水平的提高，很大程度上取决于模具工业的发展水平，因此模具工业对国民经济和社会发展将起越来越大的作用。The development of modern industrial and technological level depends largely on the level of industrial development die, so die industry to national economic and social development will play an increasing role. 1989 年 3 月国务院颁布的关于当前产业政策要点的决定中，把模具列为机械工业技术改造序列的第一位、生产和基本建设序列的第二位 ( 仅次于大型发电设备及相应的输变电设备 ) ，确立模具工业在国民经济中的重要地位。 March 1989 the State Council promulgated on the current industrial policy decision points in the mold as the machinery industry transformation sequence of the first, production and capital construction of the second sequence (after the large-scale power generation equipment and the corresponding power transmission equipment), establish tooling industry in an important position in the national economy. 1997 年以来，又相继把模具及其加工技术和设备列入了当前国家重点鼓励发展的产业、产品和技术目录和鼓励外商投资产业目录。 Since 1997, they have to mold and its processing technology and equipment included in the current national focus on encouraging the development of industries, products and technologies catalog and to encourage foreign investment industry directory. 经国务院批准，从 1997 年到 2000 年，对 80 多家国有专业模具厂实行增值税返还 70% 的优惠政策，以扶植模具工业的发展。 Approved by the State Council, from 1997 to 2000, more than 80 professional mold factory owned 70% VAT refund of preferential policies to support mold industry. 所有这些，都充分体现了国务院和国家有关部门对发展模具工业的重视和支持。 All these have fully demonstrated the development of the State Council and state departments tooling industry attention and support. 目前全世界模具年产值约为 600 亿美元，日、美等工业发达国家的模具工业产值已超过机床工业，从 1997 年开始，我国模具工业产值也超过了机床工业产值。 Mold around the world about the current annual output of 60 billion U.S. dollars, Japan, the United States and other industrialized countries die of industrial output value of more than machine tool industry, beginning in 1997, Chinas industrial output value has exceeded the mold machine tool industry output.据统计，在家电、玩具等轻工行业，近 90 的零件是综筷具生产的；在飞机、汽车、农机和无线电行业，这个比例也超过 60 。 According to statistics, home appliances, toys and other light industries, nearly 90% of the parts are integrated with production of chopsticks; in aircraft, automobiles, agricultural machinery and radio industries, the proportion exceeded 60%. 例如飞机制造业，某型战斗机模具使用量超过三万套，其中主机八千套、发动机二千套、辅机二万套。 Such as aircraft manufacturing, the use of a certain type of fighter dies more than 30,000 units, of which the host 8000 sets, 2000 sets of engines, auxiliary 20 000 sets. 从产值看， 80 年代以来，美、日等工业发达国家模具行业的产值已超过机床行业，并又有继续增长的趋势。 From the output of view, since the 80s, the United States, Japan and other industrialized countries die industry output value has exceeded the machine tool industry, and there are still rising. 据国际生产技术协会预测，到 2000 年，产品尽件粗加工的 75% 、精加工的 50 将由模具完成；金属、塑料、陶瓷、橡胶、建材等工业制品大部分将由模具完成， 50 以上的金属板材、 80 以上的塑料都特通过模具转化成制品。 Production technology, according to the International Association predicts that in 2000, the product best pieces of rough 75%, 50% will be finished mold completed; metals, plastics, ceramics, rubber, building materials and other industrial products, most of the mold will be completed in more than 50% metal plates, more than 80% of all plastic products, especially through the mold into.模具的历史发展 2 The historical development of mold模具的出现可以追溯到几千年前的陶器和青铜器铸造，但其大规模使用却是随着现代工业的掘起而发展起来的。 The emergence of mold can be traced back thousands of years ago, pottery and bronze foundry, but the large-scale use is with the rise of modern industry and developed.19 世纪，随着军火工业 ( 枪炮的弹壳 ) 、钟表工业、无线电工业的发展，冲模得到广泛使用。 The 19th century, with the arms industry (guns shell), watch industry, radio industry, dies are widely used. 二次大战后，随着世界经济的飞速发展，它又成了大量生产家用电器、汽车、电子仪器、照相机、钟表等零件的最佳方式。 After World War II, with the rapid development of world economy, it became a mass production of household appliances, automobiles, electronic equipment, cameras, watches and other parts the best way. 从世界范围看，当时美国的冲压技术走在前列许多模具先进技术，如简易模具、高效率模具、高寿命模具和冲压自动化技术，大多起源于美国；而瑞士的精冲、德国的冷挤压技术，苏联对塑性加工的研究也处于世界先进行列。 From a global perspective, when the United States in the forefront of stamping technology - many die of advanced technologies, such as simple mold, high efficiency, mold, die and stamping the high life automation, mostly originated in the United States; and Switzerland, fine blanking, cold in Germany extrusion technology, plastic processing of the Soviet Union are at the world advanced. 50 年代，模具行业工作重点是根据订户的要求，制作能满足产品要求的模具。 50s, mold industry focus is based on subscriber demand, production can meet the product requirements of the mold. 模具设计多凭经验，参考已有图纸和感性认识，对所设计模具零件的机能缺乏真切了解。 Multi-die design rule of thumb, reference has been drawing and perceptual knowledge, on the design of mold parts of a lack of real understanding of function. 从 1955 年到 1965 年，是压力加工的探索和开发时代对模具主要零部件的机能和受力状态进行了数学分桥，并把这些知识不断应用于现场实际，使得冲压技术在各方面有飞跃的发展。 From 1955 to 1965, is the pressure processing of exploration and development of the times - the main components of the mold and the stress state of the function of a mathematical sub-bridge, and to continue to apply to on-site practical knowledge to make stamping technology in all aspects of a leap in development. 其结果是归纳出模具设计原则，并使得压力机械、冲压材料、加工方法、梅具结构、模具材料、模具制造方法、自动化装置等领域面貌一新，并向实用化的方向推进，从而使冲压加工从仪能生产优良产品的第一阶段。 The result is summarized mold design principles, and makes the pressure machine, stamping materials, processing methods, plum with a structure, mold materials, mold manufacturing method, the field of automation devices, a new look to the practical direction of advance, so that pressing processing apparatus capable of producing quality products from the first stage.进入 70 年代向高速化、启动化、精密化、安全化发展的第二阶段。 Into the 70s to high speed, launch technology, precision, security, development of the second stage. 在这个过程中不断涌现各种高效率、商寿命、高精度助多功能自动校具。 Continue to emerge in this process a variety of high efficiency, business life, high-precision multi-functional automatic school to help with. 其代表是多达别多个工位的级进模和十几个工位的多工位传递模。 Represented by the number of working places as much as other progressive die and dozens of multi-station transfer station module. 在此基础上又发展出既有连续冲压工位又有多滑块成形工位的压力机弯曲机。 On this basis, has developed both a continuous pressing station there are more slide forming station of the press - bending machine. 在此期间，日本站到了世界最前列其模具加工精度进入了微米级，模具寿命，合金工具钢制造的模具达到了几千万次，硬质合金钢制造的模具达到了几亿次 p 每分钟冲压次数，小型压力机通常为 200 至 300 次，最高为 1200 次至 1500 次。 In the meantime, the Japanese stand to the worlds largest - the mold into the micron-level precision, die life, alloy tool steel mold has reached tens of millions of times, carbide steel mold to each of hundreds of millions of times p minutes for stamping the number of small presses usually 200 to 300, up to 1200 times to 1500 times. 在此期间，为了适应产品更新快、用期短 ( 如汽车改型、玩具翻新等 ) 的需要，各种经济型模具，如锌落合金模具、聚氨酯橡胶模具、钢皮冲模等也得到了很大发展。 In the meantime, in order to meet product updates quickly, with the short duration (such as cars modified, refurbished toys, etc.) need a variety of economic-type mold, such as zinc alloy die down, polyurethane rubber mold, die steel skin, also has been very great development.从 70 年代中期至今可以说是计算机辅助设计、辅助制造技术不断发展的时代。 From the mid-70s so far can be said that computer-aided design, supporting the continuous development of manufacturing technology of the times. 随着模具加工精度与复杂性不断提高，生产周期不断加快，模具业对设备和人员素质的要求也不断提高。 With the precision and complexity of mold rising, accelerating the production cycle, the mold industry, the quality of equipment and personnel are required to improve. 依靠普通加工设备，凭经验和手艺越来越不能满足模具生产的需要。 Rely on common processing equipment, their experience and skills can not meet the needs of mold. 90 年代以来，机械技术和电子技术紧密结合，发展了 NC 机床，如数控线切割机床、数控电火花机床、数控铣床、数控坐标磨床等。 Since the 90s, mechanical and electronic technologies in close connection with the development of NC machine tools, such as CNC wire cutting machine, CNC EDM, CNC milling, CNC coordinate grinding machine and so on. 而采用电子计算机自动编程、控制的 cNc 机床提高了数控机床的使用效率和范围。 The use of computer automatic programming, control CNC machine tools to improve the efficiency in the use and scope. 近年来又发展出由一台计算机以分时的方式直接管理和控制一群数控机床的 nNc 系统。 In recent years, has developed a computer to time-sharing by the way a group of direct management and control of CNC machine tools NNC system.随着计算机技术的发展，计算机也逐步进入模具生产的各个领域，包括设计、制造、管理等。 With the development of computer technology, computers have gradually into the mold in all areas, including design, manufacturing and management. 国际生产研究协会预测，到 2000 年，作为设计和制造之间联系手段的图纸将失去其主要作用。 International Association for the Study of production forecasts to 2000, as a means of links between design and manufacturing drawings will lose its primary role. 模具自动设计的最根本点是必须确立模具零件标准及设计标准。 Automatic Design of die most fundamental point is to establish the mold standard and design standards. 要摆脱过去以人的思考判断和实际经验为中心所组成的设计方法，就必须把过去的经验和思考方法，进行系列化、数值化、数式化，作为设计准则储存到计算机中。 To get rid of the people of the past, and practical experience to judge the composition of the design center, we must take past experiences and ways of thinking, for series, numerical value, the number of type-based, as the design criteria to the computer store. 因为模具构成元件也干差万别，要搞出一个能适应各种零件的设计软件几乎不可能。 Components are dry because of mold constitutes a million other differences, to come up with a can adapt to various parts of the design software almost impossible. 但是有些产品的零件形状变化不大，模具结构有一定的规律，放可总结归纳，为自动设计提供软件。 But some products do not change the shape of parts, mold structure has certain rules, can be summed up for the automatic design of software. 如日本某公司的 CDM 系统用于级进模设计与制造，其中包括零件图形输入、毛坯展开、条料排样、确定模板尺寸和标准、绘制装配图和零件图、输出 NC 程序 ( 为数控加工中心和线切割编程 ) 等，所用时间由手工的 20% 、工时减少到 35 小时；从 80 年代初日本就将三维的 cad cam 系统用于汽车覆盖件模具。 If a Japanese companys CDM system for progressive die design and manufacturing, including the importation of parts of the figure, rough start, strip layout, determine the size and standard templates, assembly drawing and parts, the output NC program (for CNC machining Center and line cutting program), etc., used in 20% of the time by hand, reduce their working hours to 35 hours; from Japan in the early 80s will be three-dimensional cad / cam system for automotive panel die. 目前，在实体件的扫描输入，图线和数据输入，几何造形、显示、绘图、标注以及对数据的自动编程，产生效控机床控制系统的后置处理文件等方面已达到较高水平；计算机仿真 (CAE) 技术也取得了一定成果。 Currently, the physical parts scanning input, map lines and data input, geometric form, display, graphics, annotations and the data is automatically programmed, resulting in effective control machine tool control system of post-processing documents have reached a high level; computer Simulation (CAE) technology has made some achievements. 在高层次上， CAD CAM CAE 集成的，即数据是统一的，可以互相直接传输信息 At high levels, CAD / CAM / CAE integration, that data is integrated, can transmit information directly with each other. 实现网络化。 Achieve network. 目前 Present. 国外仅有少数厂家能够做到。 Only a few foreign manufacturers can do it.3我国模具工业现状及发展趋势 Chinas mold industry and its development trend模具工业现状 Die & Mould Industry Status由于历史原因形成的封闭式、“ 大 而全” 的 企业特征，我国大部分企业均设有模具车间，处于本厂的配套地位，自 70 年代末才有了模具工业化和生产专业化这个概念。 Due to historical reasons for the formation of closed, big and complete enterprise features, most enterprises in China are equipped with mold workshop, in factory matching status since the late 70s have a mold the concept of industrialization and specialization of production. 生产效率不高，经济效益较差。 Production efficiency is not high, poor economic returns. 模具行业的生产小而散乱，跨行业、投资密集，专业化、商品化和技术管理水平都比较低。 Mold production industry is small and scattered, cross-industry, capital-intensive, professional, commercial and technical management level are relatively low.据不完全统计，全国现有模具专业生产厂、产品厂配套的模具车间（分厂）近17000家，约60万从业人员，年模具总产值达200亿元人民币。 According to incomplete statistics, there are now specialized in manufacturing mold, the product supporting mold factory workshop (factory) near 17 000, about 600 000 employees, annual output value reached 20 billion yuan mold. 但是，我国模具工业现有能力只能满足需求量的60左右，还不能适应国民经济发展的需要。 However, the existing capacity of the mold and die industry can only meet the demand of 60%, still can not meet the needs of national economic development. 目前，国内需要的大型、精密、复杂和长寿命的模具还主要依靠进口。 At present, the domestic needs of large, sophisticated, complex and long life of the mold also rely mainly on imports. 据海关统计，1997年进口模具价值6.3亿美元，这还不包括随设备一起进口的模具；1997年出口模具仅为7800万美元。 According to customs statistics, in 1997 630 million U.S. dollars worth of imports mold, not including the import of mold together with the equipment; in 1997 only 78 million U.S. dollars export mold. 目前我国模具工业的技术水平和制造能力，是我国国民经济建设中的薄弱环节和制约经济持续发展的瓶颈。 At present the technological level of China Die & Mould Industry and manufacturing capacity, Chinas national economy in t