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卡环 冲孔 复合 设计

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卡环冲孔落料复合模设计,卡环,冲孔,复合,设计

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i外文资料与中文翻译外文资料：Analysis on The Factors of Impacting on The Life of Stamping DieREN Hai-dongYU LingAbstract：Stamping is a wide range of material processing methods，stamping die is equipment to achieve the important parts of theprocessing，whose life directly afects quality an d cost ofthe productThis article analyzes to its influencing factors，finding a method tosolveproblems，andimprovethelifeof stamping dieKeywords：Samping die；life；Infl uencing factoIs the use of stamping presses installed in the die pressure on the material to produce plastic deformation or separation in order to obtain the parts needed for a pressure processing method. In industrial production, especially in household appliances, automotive, aerospace and engineering fields such as instrumentation is widely available. The die is the realization of this important technology components and equipment for processing. Die as a result of a long cycle of production and processing, the use of the high cost of materials, manufacturing costs in product cost of production occupies a significant proportion, therefore, to improve the life of stamping dies is very important. Through the use of molds, for various reasons can not be a reproduction of the red pieces of qualified, could no longer be repaired, which is commonly referred to as die failure. Die life by various forms of limitations expired, common are: wear failure, failure deformation, fracture failure and failure, such as bite wounds. Stamping processes, as well as due to different working conditions of the different effects of stamping die failure are many factors, but the same factors may also bring some form of failure. In this paper, an analysis of its influencing factors, possible solutions to the problem in order to achieve the purpose of die life.1 Mold DesignMold design, including structural design and parts design. The structure of mold not only affects the quality of parts produced to determine the productivity of enterprises and processing methods, but also to improve the life of mold also has a key role. Therefore, before designers to make full preparations to meet the production tooling to optimize the structure at the same time.1.1 Parts of Product DesignReasonable product design will help improve the life of mold. If the product has a cusp, or fillet radius is too small, the design of the edge will die due to stress concentration and cracking. Without prejudice to the structure and function of products, we can change the design of some of its unreasonable.1.2 Die Structure DesignReasonable structure can improve the die life. For example, in Die, the direction to improve the convex and concave stamping die in the course of the relative stability, thus ensuring the mold space at a reasonable framework of blanking blanking. And the reasonableness of blanking clearance and stability to improve die life is an important measure. Accurate reduced-oriented relationship between the relative movement of the wear and tear of parts and components to avoid the convex, concave die as a result of unreasonable gap a bite injuries and other forms of failure. Particularly in the Fine Blanking Die, the high-precision mold-oriented institutions is to ensure that the structural design of an important guarantee for success. Therefore in order to improve the life of mold, the form must be the right choice and guide precision-oriented. The choice of orientation should be higher than the accuracy of convex and concave mold with precision. For more blanking punch, punch in a number of large difference in diameter, there is a difference and close the case that if a small and a long punch, then easily lead to instability or break. We can punch arranged in Figure 1 (a) ladder-style in order to increase its stiffness. Punching holes for the need to increase the punch guide in order to enhance the strength of punch, which is to ensure the normal work of stamping dies to the premise. Which can increase many-oriented approach, to be used in Figure 1 (b) shown in the front and the entire process-oriented and other-oriented.Figure 1 (a) ladder layout punch 1 (b) punch-orientedAccurate calculation of the process can also increase mold life. Such as discharge power and the calculation of stroke. If we are not allowed to easily spring fatigue fracture or failure. Die on a high degree of calculation, as well as the choice of press and reasonable manner and location-oriented institutions can effectively improve the die life. Modulus of continuity for the design and layout of the ride side of the calculation of size is also crucial.1.3 Die gapStamping dies when space is the convex, concave die size difference between the horizontal edge. Gap on the impact of a large die life is a stamping process and die design of an extremely important issue. Convex, concave die gap size of a direct impact on product quality and mold the life space is too large or too small will cause the edge passivation or wear and tear (as shown in Figure 2). Die materials drop to die later, punch to punch prevail, and these two dimensions has been the impact of space. The experimental results show that the thickness of the gap below 2 percent, prone punch damage, space for more than 6%, there had been errors in parts size. Gap in the thickness of 4% 5%, the effect of blanking good stability. Die gap, therefore the correct choice is to ensure that an important way to die life. At present, the choice of space data in addition to investigations, the most by the actual experience.(a) gap is too small (b) a reasonable gap (c) gap is too largeFigure 2 gap on the impact of stampings2 Die ManufacturingMold manufacturing process design is reasonable, to ensure that mold is an important way of life. Most of mold manufacturing parts of the process can be carried out in accordance with the normal, but there are special requirements for spare parts or spare parts for local processing, will need to have some special methods.2.1 Mechanical RoughMaterial machining accuracy of the assembly of the mold affects accuracy, it will directly affect the mold of parallelism, perpendicularity and coaxiality. In addition, the marks left rough, worn, are prone to stress concentration sites, but also occurred in the early fatigue cracks and the local.2.2 Heat TreatmentHeat Treatment in the manufacture of stamping die plays a very important role, in spite of different types and different structure of mold, the use of different steel products, or using different machining and processing of shape, but they need to use heat treatment process to obtain a higher hardness and wear resistance, as well as other mechanical properties required. In general, the die service life and quality of products produced to a large extent depends on the quality of heat treatment processing. Thus, in die manufacturing, and continuously improve the skill level of heat treatment, a reasonable template to improve the performance of internal organization and working methods, it is particularly important. Heat treatment time and temperature is an important factor, because of the time in different temperatures, heat treatment may constitute a different form, the main annealing, normalizing, quenching and tempering, and carburizing, nitriding, carbonitriding, etc. For example, in the blanking die, because people punch wedge material is the work of more serious wear and tear parts, so the hardness should be greater in general for the HRC 60 63, die for the HRC 57 60, this kind of hardness than the two , or die punch hardness is higher than the longer die life.3 Die Assembly and DebuggingAssembly is the key to mold production process. A direct impact on the quality of the die assembly of the quality of parts, dies and the life of the state of the technology. Die assembly includes two aspects: (1) good parts of each machining process in accordance with requirements of drawings assembled into a general assembly and assembly; (2) in the assembly process as part of the processing work. Die in the assembly as an example, the technical requirements is to ensure consistency blanking gap and ensure the accuracy of direction-oriented institutions, as well as the movement to ensure that all relevant pieces of die design in accordance with strict technical parameters. This is a debugging tool to ensure a successful and smooth conduct of the production protection, but also to ensure that an important factor in mold life. In recent years, with the development of the production, users are vulnerable to damage parts of the swap request, so that users die at the scene of the rapid replacement of damaged parts. Die before the test mode, it should also be designed in strict accordance with the technical parameters of the model to select press. It is closely related to the length of die life. Press the stiffness, precision, crucial parameters such as tonnage. Press one of the stiffness of stiffness by the bed, transmission stiffness and rigidity of three parts-oriented, if less stiffness, load and unloading end, the die gap, great changes will happen, it will affect the accuracy of stamping parts and mold life. Die after assembly, must be red and adjust the test can be used for production. In order to protect the mold, the first time in debugging, it is necessary to pay attention to the use of paper or aluminum, as well as cold-rolled plate red test. To ensure that edge punch die edge into the depth of the scope of a reasonable (usually for a material thickness). Stamping die so red when the level of stress and wear and tear will be minimal, and fully protect the convex and concave mold, increased die life. The purpose of debugging and the task is: to die out not only qualified stampings, security and stability but also put into production use. Should be based on examination of stamping defects, analysis of its causes and try to solve them. Some bending, deep drawing and flanging, etc. so that the deformation of sheet metal dies, stamping parts, when the shape of complex or high accuracy, it is difficult to accurately calculate the deformation of the former size and shape of the rough. For this type of stamping parts, although the relevant references are rough calculation methods and formulas, but the impact of plastic deformation as a result of many factors, calculated from the size and needs of different size. In the actual production in order to obtain more accurate size, often determined through experiments. Red in the test set to adjust the size of blank.4 ConclusionStamping die life impact of a number of factors, from the above analysis we can see from the mold design to the use of the entire process can improve the die life. Practice has proved that the rational design of die structure and the shape of the die using the appropriate manufacturing processes, heat treatment process, so that die in the normal conditions, can increase the mold life.References: 1 Weng its gold. Cold stamping technology M. Beijing: Mechanical Industry Press, 2007. 2 Liu, ZHANG Bao-zhong. Stamping die design and manufacture of M. Beijing: Higher Education Publishing Agency. 2006. 3Xiaopei.wang. Stamping Manual M. Beijing: Mechanical Industry Press, 2006.中文翻译：影响冲压模具寿命的因素分析任海东，于玲摘要：冲压成形是一种应用广泛的材料加工方法，冲压模具是实现零件加工的重要工艺装备，它的使用寿命直接影响到产品的质量和成本。对模具寿命的影响因素加以分析，找出解决问题的方法，从而达到提高模具寿命的目的。关键词：冲压模具：寿命；影响因素冲压是利用安装在压力机上的冲模对材料施加压力，使其产生分离或塑性变形，从而获得所需要的零件的一种压力加工方法。它在工业生产中，尤其是在家用电器、汽车、航空以及仪器仪表等工程领域获得广泛应用。而冲模就是实现这一零件加工的重要工艺装备。由于模具的生产加工周期长，使用的材料费用高，制造成本在产品生产成本中占有相当大的比例，因此，提高冲压模具的寿命是非常重要的。模具经过使用，由于种种原因不能再生产出合格的冲件，也不能再修复，这种情况一般称为模具失效。模具寿命受各种失效形式的限制，常见的有：磨损失效、变形失效、断裂失效及啃伤失效等。由于冲压工序不同以及工作条件的不同，影响冲压模具失效的因素很多，而同一种因素也可能带来几种失效形式。本文对其影响因素进行分析，找出解决问题的方法，从而达到提高模具寿命的目的。1 模具设计模具设计包括结构设计和零部件设计。模具的结构不仅能影响到所生产零件的质量，决定企业的生产效率和加工方式，而且对提高模具的使用寿命也具有关键的作用。因此设计者在设计之前，要做好充分的准备工作，在满足生产的同时尽可能优化模具结构。11 零件产品设计合理的产品设计有利于提高模具的寿命。如果产品具有尖角，或圆角半径太小，所设计的凹模刃口就会因应力集中而开裂。在不影响产品结构和功能的前提下，我们可以改变其一些不合理的设计。12 模具结构设计合理的结构可以提高模具的寿命。例如在冲裁模中，导向机构提高了凸、凹模在冲压过程中的相对稳定性，从而保证模具在合理的冲裁间隙范围内进行冲裁。而冲裁间隙的合理性及稳定性正是提高模具寿命的重要措施。精确的导向减少了有相对运动关系的零部件的磨损，避免了凸、凹模由于间隙不合理出现“啃伤”等失效形式。尤其在精密冲裁模中，高精度的导向机构是确保模具结构设计成功的重要保障。因而为了提高模具的寿命，必须正确选择导向形式和导向精度。导向精度的选择应高于凸、凹模的配合精度。对于多凸模冲裁，在几个凸模直径相差较大，相距又很近的情况下，如果小凸模细小而又较长，则容易造成失稳或折断。我们可以把凸模布置成如图1(a)阶梯式的，以增加其刚度。对于小孔冲裁，必须增加对凸模的导向，以提高凸模的强度，这是保证冲压模具能正常工作的前提。其中能增加导向的方法很多，可采用如图1(b)所示的前端导向和全程导向等。准确的工艺计算也可以提高模具的寿命。如卸料力及行程的计算。若计算不准，容易造成弹簧的疲劳断裂或失效。对合模高度的计算以及压力机的选择，合理的定位方式及导向机构等，都可以有效地提高模具的使用寿命。对于连续模排样的设计和搭边尺寸的计算也至关重要。13 模具间隙模具间隙是指冲压时凸、凹模刃口横向尺寸之差。间隙对模具寿命的影响很大，是冲压工艺与模具设计中的一个极其重要的问题。凸、凹模间隙的大小直接影响产品的质量和模具的使用寿命，间隙过大或过小都会使刃口钝化或磨损(如图2所示)。冲裁模中落料一般以凹模为准，冲孔以凸模为准，而这两个尺寸又受到间隙的影响。实验表明，间隙在板厚的2以下时，凸模容易发生损坏，间隙在6以上时，制件尺寸出现误差。间隙在板厚4 5时，冲裁稳定效果好。因此正确选择模具间隙，是保证模具寿命的重要途径。目前，间隙的选择除了查资料以外，大部分靠实际经验获得。2 模具制造模具制造工艺设计的合理性，也是保证模具寿命的重要途径。大部分模具零件的制造可以按正常的工艺进行，但对有特别要求的零件或零件局部加工，就需要有一定特殊的方法。21 机械粗加工材料的加工精度对模具的装配精度有很大的影响，将直接影响模具的平行度、垂直度和同轴度。另外，粗加工留下的刀痕、磨痕，都是容易产生应力集中的部位，也是早期产生裂纹和发生疲劳的地方。22 热处理热处理在冲压模具的制造中起着很重要的作用，尽管不同类型及不同的结构模具，使用不同的钢材，或采用不同的机械加工及加工成形，但都需要用热处理的加工方法，使其获得较高的硬度和耐磨性，以及其他所要求的力学性能。一般来说，冲模的使用寿命及生产出来的产品质量，在很大程度上取决于热处理加工质量因此，在冲模制造中，不断提高热处理的技术水平，合理的改进模板内部组织和性能的工作方法，就显得格外的重要。时间和温度是热处理的重要因素，由于时间温度的不同，可构成不同的热处理形式，其主要有退火、正火、淬火、回火和渗碳、渗氮、碳氮共渗等。比如在冲裁模中，由于凸模楔人材料，是磨损比较严重的工作零件，所以其硬度应大些，一般为HRC 6063，凹模为HRC 5760，这样比两者硬度样，或凹模硬度高于凸模的模具寿命更长一些。3 模具装配及调试装配是模具生产中的关键工序。冲模装配质量直接影响制件的质量、冲模的技术状态和使用寿命。冲模的装配工作包括两方面的内容：(1)将每个加工好的零件按图纸工艺要求装配成组合件及总体装配；(2)在装配过程中进行的一部分加工工作。以冲裁模的装配为例，其技术要求是保证冲裁间隙一致性，保证导向机构的导向精度，以及保证各相关运动件能够按照模具设计的技术参数严格进行。这是保证模具调试成功及生产能够顺利进行的保障，也是确保模具寿命的重要因素。近年来，随着生产的发展，用户对易损坏零件提出了互换要求，以便用户在现场对模具损坏零件的迅速更换。模具在试模前，还应该严格按照设计的技术参数来选择压力机的型号。它关系到模具使用寿命的长短。压力机的刚度、精度、吨位等参数至关重要。其中压力机的刚度是由床身刚度、传动刚度和导向刚度三部分组成，如果刚度较差，负载终了和卸载时，模具间隙会发生很大变化，将会影响到冲压件的精度和模具寿命。模具装配完后，必须经过试冲和调整，才能进行生产使用。为了保护模具，在第一次调试时，要注意利用纸片或铝片以及冷轧板进行试冲。保证凸模刃口进入到凹模刃口的深度在合理的范围内(一般为一个料厚)。这样模具冲压时的冲压力及磨损程度会最小，充分保护了凸、凹模，提高了模具寿命。调试的目的和任务是：使冲模不仅能冲出合格的冲压件，而且能安全稳定的投入生产使用。应根据试冲件中出现的缺陷，分析其产生的原因，设法加以解决。有些弯曲、拉深及翻边等使板料变形的冲模，当冲压件的形状复杂或精度较高时，很难精确计算出变形前的毛坯尺寸和形状。对于这一类冲压件，虽然相关参考资料都有计算毛坯的方法和公式，但由于影响塑性变形的因素非常多，计算出来的尺寸和实际的需要尺寸是有差别的。在实际的生产中为了得到较准确的尺寸，往往通过试验来确定即在试冲调整中确定毛坯的尺寸。4 结论影响冲压模具寿命的因素很多，从以上分析可以看出从模具设计到使用的全过程中，均能提高模具寿命。实践证明，合理设计模具结构及形状，采用恰当的冲模制造工艺、热处理工艺，使模具在正常的条件下工作，均能提高模具的寿命。参考文献：1翁其金冷冲压技术M北京：机械工业出版社，20072刘建超，张宝忠冲压模具设计与制造M北京：高等教育出版社。20063王孝培冲压手册M北京：机械工业出版社，200614 XX学院毕业设计课题名称卡环冲孔落料复合模设计 作 者 专 业 班级学号 班级 学号（七位数字）指导教师 * 摘要摘要 关于学校这次的毕业设计，我设计了零件的冲孔落料复合模一套经过毕业设计的整个课题精心制作，对我所学的模具设计与制造所有知识得到了一个全面的复习，经过查询我们的教材还有我们学校图书馆里的和我这次毕业设计课题有关的书本，根据模具设计的相关流程进行一步一步的不折不扣制作，把我这次毕业设计的整个设计过程给很清楚的写在这份说明书上了。 在这次设计零件同样先进行了工艺的分析，工艺的计算，确定压力机型号，再将各主要零部件的设计表达出来。 这次毕业设计零件设计说明书的第一个部分是对我这次毕业设计课题的第一套模具，零件坯料的冲孔落料复合模的工艺的分析，工艺的计算，主要零部件的设计。这次零件设计说明书的工艺计算，主要零件的设计。这都为选择冲压设备提供重要依据。也为本次模具设计的AutoCAD装配图，以及AutoCAD主要零件图绘制提供了依据。关键词：冲压模、定位块、冲压、模具设计 IIAbstractAbstractThe graduation design of the school, I designed parts punching blanking compound die a after graduation design the whole subject to elaborate, mould design and manufacture all I learned the knowledge obtained a comprehensive review, after a query our textbooks and our school library on the graduation and I design task book, step by step on hundred-percent making according to the related process of die design, the whole design process of this graduation design I to very clearly written in the instructions on.In the design of parts in the same first tested the process analysis, process calculation, determine press model, then express the design of main parts.The first part of the graduation design, parts design specification is on the graduation project of the first set of mold, part blank punching compound die material process analysis, process calculation, the main components of the design. Process calculation of the part design specification, the design of main parts. All these provide an important basis for the selection of stamping equipment. For the AutoCAD assembly drawing of this die design, and the map of part mainly provides the basis for the AutoCAD drawing.Keywords: stamping die, stamping, die design, the positioning block III - 4 - 目录一、概述- 1 -1.1毕业设计的目的- 1 -1.2 毕业设计的要求- 1 -1.3毕业设计的的注意事项- 1 -二、零件工艺设计- 2 -2.1 分析零件坯料的冲压工艺性- 2 -2.1.1零件坯料工艺分析- 2 -2.1.2确定零件坯料冲压工艺方案- 3 -2.1.3确定零件坯料冲孔落料复合模结构形式的确定- 3 -2.2工艺计算- 3 -三、零件坯料冲孔落料复合模工作部分零件设计- 10 -3.1零件坯料冲孔落料复合模，冲5mm孔凸模的设计- 10 -3.2零件坯料冲孔落料复合模落料凹模设计- 12 -3.3零件坯料冲孔落料复合模凸凹模设计- 12 -3.4 零件坯料冲孔落料复合模，凸模固定板设计- 13 -3.5零件坯料冲孔落料复合模，凸凹模固定板设计- 14 -3.6 零件坯料冲孔落料复合模，推件块设计- 15 -3.7零件坯料冲孔落料复合模，垫板设计- 16 -四、零件坯料冲孔落料复合模具结构设计- 17 -4.1零件坯料冲孔落料复合模模架的选择- 17 -4.2 零件坯料冲孔落料复合模压力中心计算- 18 -4.3零件坯料冲孔落料复合模模具装配图和零件的绘制- 18 -总 结- 19 -致谢- 20 -参考文献- 21 -IV一、概述1.1毕业设计的目的1、在这次毕业设计中通过对毕业设计的课题制作，对我们在学校老师所教的专业知识和我们自己所自学的专业知识进行一个巩固。2、在这次毕业设计中培养我们模具专业的学生在遇到问题时的分析能力和解决问题能力，还有能独立的完成对于模具设计的流程的熟练制作。3、在这次毕业设计中对我们模具设计与制造专业的学生工作作风以及责任心还有安全意识得到较大跨度的一个提升。1.2 毕业设计的要求1、毕业设计的图纸图幅量：一共要最少3张零号的图幅工作量（其中最少要有1张零号装配图，剩下的不做要求）。 2、图纸：最后答辩前上交的图纸必须用AutoCAD绘制，画图时要更具绘图标准去画，最后要交1份AutoCAD图纸和1份1：1打印出来的图纸。 3、毕业设计说明书的字数要求：不少于6000字。4、查看和毕业设计课题有关的各种资料，为顺利的完成毕业设计以及能顺利毕业做好充分的准备工作。5、要求计算准确、结构设计合理、图面整洁，图样及标注符合国家标准。6、要求编制的工艺规程符合生产实际。7、设计计算说明书要求文字通顺，书写工整。1.3毕业设计的的注意事项1、相关安全的事宜：在进行毕业设计的样品加工时一定要遵守各类加工机械的操作规范，确保人生安全，器械安全。2、服从命令听指挥:在进行任何加工都前都要听从老师的安排，认真负责，精心制作，保质保量完成模具加工任务。3、毕业设计的所有内容必须自己独立完成，可以请教同学或老师，但严禁抄袭，做，在模具加工时同样要独立完成。 - 12 -二、零件工艺设计2.1 分析零件坯料的冲压工艺性零件坯料如图2-1零件坯料图2-1零件坯料图2-2零件展开图2.1.1零件坯料工艺分析由图2-1可见,零件坯料的形状比较简单，结构成对称分布，零件尺寸通过一般的冲压能满足零件坯料的尺寸精度要求。尺寸的公差为自由公差，孔5mm的孔边距离外轮廓的距离远远大于凸、凹模所允许的最小壁厚，没有凸、凹模强度的困扰，所以可以采用冲压工序完成零件的生产。2.1.2确定零件坯料冲压工艺方案1、方案的种类 零件坯料需要冲孔落料2个基本的工序，我们用以下3种加工的工艺方案来进行加工：方案一：先把坯料冲下来，然后再利用另外的一套冲孔的模具进行孔的加工，用单个工序的模具来对零件坯料的制作。方案二：采用冲孔落料，级进冲压，采用级进模具来完成零件坯料的生产加工任务。方案三：采用落料和冲孔同时进行的复合模具完成零件坯料的生产任务。2、方案的比较 每种加工方案的特点以及方案比较如下。方案一：所需要的模具的结构不怎么复杂，在加工模具时比较容易，但要2个工序才能将加工中心坯料加工出来，用两个模具整个生产，这样生产的成本有点高，并且加工时的效率很低，最为重要的是这个方案加工不能保证零件坯料的尺寸精度。这个方案我们不要。方案二：虽然用级进模他的加工效率是比较高的。但是级进模具外形很大，制造模具时麻烦，这样他的成本代价太高，本身这种模具就不适合加工这种形状很小，结构还很简单的零件，因而这种案我们也不要。方案三：这个就要一个模具就行了，而且零件坯料的零件精度还有生产的速度要求都能够达到要求，关键成本也不太高。3、方案的最终确定 综上所诉，零件坯料冲压模具采用冲孔落料复合模具进行产品的加工。2.1.3确定零件坯料冲孔落料复合模结构形式的确定有正装复合模具还有倒装复合模具2种复合模。考虑到成型后拿料问题。最终确定我们用倒装式复合模具进行零件的冲压加工。2.2工艺计算2.2.1零件坯料零件的排样设计如图2-2排样图2-2排样1、搭边值的确定1冷冲压工艺及模具设计表2.10得出工件的搭边对于本次的设计，我们a1选取2mm，工件侧面a=2.5mm2、条料步距的确定 步距值：15mm+2mm=17mm 宽度177.7mm+2.5mm+2.5mm=182.7mm。根据三维软件进行测量得出，面积为2645.42平方毫米，周长401.46mm3、材料的利用率计算 =S工/S总=2645.42/17mm182.7100=85.72.2.2凸模和凹模的工作部分尺寸零件图上所注公差经查标准公差表1.2为IT14级，尺寸精度较低，普通冲裁完全可以满足要求。表1.2部分标准公差值（GB/T175.31998）公差等级IT6IT7IT8IT9IT10IT11IT12IT13IT14IT15基本尺寸/m /mm36812183048750.120.180.300.48610915223658900.150.220.361.58101811182743701100.180.270.430.70183013213352841300.210.331.520.843050162539621001600.250.390.621.005035519304674151900.300.460.741.53551522355487140250.351.540.871.40根据表1.2分析：该零件冲裁工艺性较好，适宜冲裁加工。查公差表得各尺寸公差：零件外形： 36mm零件内形：5mm1、 确定凸、凹模的间隙以及制造公差。2冷冲压模具毕业设计指导与范例表2-7可得凸、凹模的间隙最小值Zmin=0.132mm，凹模间隙最大值Zmax=0.240mm冲孔凸、凹模计算设冲孔尺寸为根据以上原则，冲孔时以凸模设计为基准，首先确定凸模刃口尺寸，使凸模基本尺寸接近或等于 工件孔的最大极限尺寸，再增大凹模尺寸以保证最小合理间隙Zmin。凸模制造偏差取负偏差，凹模取正偏差。其计算公式为：凸模 dp=(dx)0- p 凹模 dd=(Zmin)0+ d(dXZmin) 0+ d式中dd冲孔凹模基本尺寸(mm)； dp冲孔凸模基本尺寸(mm)； d冲孔件孔的最小极限尺寸(mm)； Ld同一工步中凹模孔距基本尺寸(mm)； Lmin制件孔距最小极限尺寸(mm)； 冲孔件孔径公差(mm)； Zmin凸、凹模最小初始双面间隙(mm)；X磨损系数，是为了使冲裁件的实际尺寸尽量接近冲裁件公差带的中间尺寸，与工件制造精度有关，可查表9.1取值：当工件精度IT10以上，取x=1；当工件精度IT11IT13，取x=0.75；当工件精度IT14，则取x=1.5。表9.1磨损系数X料厚t(mm)非圆形圆形10.751.50.751.5工件公差/mm1122440.161.50.240.300.170.350.210.410.250.490.311.590.360.421.500.600.161.50.240.300.161.50.240.30根据图1.1和表9.1查得磨损系数X取1.5，即X=0.75设凸、凹模分别按IT6和IT7级加工制造，所以凸模： dp =(d+X) 0- p=(5+0.750.12)=5.09凹模： dd=( dp +Zmin)=(6.09+0.04)=5.13二、落料凸、凹模计算凹模： Dd=(DX)凸模： Dp=( DdZmin)(DXZmin)式中Dd落料凹模基本尺寸(mm)；Dp落料凸模基本尺寸(mm)；D落料件最大极限尺寸(mm)；r落料件外径公差(mm)；Zmin凸、凹模最小初始双面间隙(mm)；X磨损系数，是为了使冲裁件的实际尺寸尽量接近冲裁件公差带的中间尺寸，与工件制造精度有关。表9.1取X=1.5。由公差表（1.2）查得：设凸、凹模分别按IT6和IT7级加工。所以凹模 177.7:Dd2=(D2-X)=(36-1.50.62)0+0.025 =177.390+0.025mm凸模 177.7:Dp2=(Dd2- Zmin)=(177.39-0.04)=35.65 mm式中，由已知条件零件为非圆形，材料的厚度是1.5mm，以及零件的公差大于0.42mm，查询冷冲压模具设计表2-9磨损系数X5得X=1.5，制件精度为IT14级时查询冲压模具毕业设计指导与范例6得=0.87mm。2、 零件坯料冲压模，冲压力计算计算冲裁力是为了选择合适的压力机，设计模具和检验模具的强度，压力机的吨位必须大于所计算的冲裁力，以适宜冲裁的要求，普通平刃冲裁模，其冲裁力一般可以按下式计算：Fp=Kp Lt =Lt （6.1）式中材料抗剪强度（MPa）；L冲裁周边总长（mm）；t材料厚度（mm）；系数Kp是考虑到冲裁模刃口的磨损，凸模与凹模间隙之波动，取Kp =1.3。2.1 冲裁力Fp的计算据图5.3可得一个零件内外周边之和L=401.46mm。查碳素结构钢的力学性能表知：钢板的抗剪强度=216Mpa304Mpa，取260Mpa，制件厚度t=2mm，则根据公式(6.1)： Fp= Kp Lt=1.31.5401.46260=25485.2(N)25.5（KN）2.2卸料力Fq1的计算Fq1=KxFp （6.2）式中Kx卸料力系数，查表6.1取Kx0.05。根据公式（6.2）： Fq1= KxFp=0.06525.5（KN）1.656(KN)表6.1卸料力、推件力和顶件力系数料厚t/mmKxktKd钢0.10.11.51.52.52.56.56.50.0650.0750.0450.0550.040.050.030.040.020.030.10.0630.0550.0450.0250.140.080.060.050.032.3顶件力Fq2的计算Fq2= KdFp （6.3）式中Kd顶件力系数。查表6.1得Kd0.06.根据公式（6.3）： Fq2= KdFp =0.1425.5（KN）3.57（KN）2.4总的冲压力F的计算根据模具结构总的冲压力F=FP+Fq1+Fq2=25.5+1.656+3.57=30.3556(KN)选用的压力机公称压力P（1.11.3）F，取系数为1.3，则： P1.3F=1.3x30.3556 (KN)=39.9438(KN)。从满足加工的工艺要求考虑，可拟选用J23-6.3查冲压模具毕业设计指导与范例表9-9开式双柱可倾压力机技术规格2J23-6.3参数：公称压力/KN ：63滑块行程次数/次min-1：160最大封闭高度/mm:170封闭高度调节量/mm: 40立柱距离/mm: 150工作台尺寸/mm：31550垫板尺寸/mm：厚度： 40模柄尺寸/mm：直径： 50深度： 70 三、零件坯料冲孔落料复合模工作部分零件设计3.1零件坯料冲孔落料复合模，冲5mm孔凸模的设计零件坯料冲孔落料复合模，冲5mm孔凸模材料选择：为保证模具的寿命以及零件的精度和材料供应问题我们选择Cr12MOV。零件坯料冲孔落料复合模，冲5mm孔凸模形式确定： 采用国家规定形式中的(GB2863.2-81)。 材料选择：为保证模具的寿命以及零件的精度和材料供应问题零件坯料冲孔落料复合模，冲5mm孔凸模的热处理： 5862HRC。零件坯料冲孔落料复合模。冲5mm凸模的冷处理： 加超深冷冷处理（零下400C）因为光靠热处理没法完全的去除材料的内应力。在材料刚刚经过热处理后接着进行材料的加超深冷冷处理。这样可以最大限度的去除材料的内应力。以增加模具的使用寿命。保证产品的尺寸精度稳定性。零件坯料冲孔落料复合模，冲5mm凸模的固定方式：采用压入式固定。零件坯料冲孔落料复合模，冲5mm凸模具体设计图纸如：图3-1冲孔凸模所示。图3-1冲孔凸模3.2零件坯料冲孔落料复合模落料凹模设计零件坯料冲孔落料复合模，落料凹模材料的选择： 同凸模的材料一样选择Cr12MoV。零件坯料冲孔落料复合模，落料凹模的热处理： 6064HRC。零件坯料冲孔落料复合模，落料凹模的冷处理： 加超深冷冷处理（零下400C应为光靠热处理没法完全的去除材料的内应力，在材料刚刚经过热处理后接着进行材料的加超深冷冷处理，这样可以最大限度的去除材料的内应力，以增加模具的使用寿命，保证产品的尺寸精度稳定性）。零件坯料冲孔落料复合模，落料凹模的具体设计图纸如：图2-4落料凹模所示。图3-2落料凹模