圆形垫片落料、冲孔复合模设计[冲压模具]【10张CAD图纸+PDF图】
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落料 冲孔复合模设计,设计人: 韦斯 专业： 机制052班 指导老师: 樊十全,模具结构图,目录,1:前言 2: 冲压工艺分析 3:冲压工艺方案的确定 4:冲模结构的确定 5: 冲压工艺的计算 6:复合模主要零件的设计计算 7：模座的设计 8：其他零件的选用 9：模具的动态分析 10：致谢,1:前言,随着我国经济的发展，模具对于现代工业来说是十分重要的，尤其是冲压技术的应用.在国民经济各部门中,几乎都有冲压加工生产,它不仅与整个机械行业密切有关,而且与人民的生活相关. 由于冲压工艺具有生产效率高、质量稳定、成本低以及可加工复杂形状工件等一系列优点，在机械、汽车、轻工、国防、电机电器、家用电器，以及日常生活用品等行业应用非常广泛，占有十分重要的地位。随着工业产品的不断发展和生产技术水平的不断提高，冲压模具作为个部门的重要基础工艺装备将起到越来越大的作用,2: 冲压工艺分析,2.1产品结构形状分析 由零件图可知，产品为圆片落料，圆片冲孔。产品形状简单，对称，无狭槽，尖角。孔于孔之间，孔于零件边缘之间最小距离C满足C1.5t要求 2.2 产品尺寸、精度、粗糙度、断面质量分析 1：尺寸精度 查模具设计与制造简明手册得所有的尺寸都是IT13. 普通冲裁尺寸精度低于IT13级，现有产品的设计精度低于IT13级，所以尺寸精度满足设计要求,2:冲压工艺分析,2：产品材料分析 对于冲压材料一般要求的力学性能是强度低 、塑性高、表面质量和厚度公差符合国家标准。本设计是45钢，属于优质碳素结构钢。其力学性能是强度、硬度和塑性指标适中。经退火后，冲裁的加工方法是完全可以成形的。另外，产品对于表面质量没有严格要求，所以尽量采用国家标准的板材，其冲裁出的产品的表面质量和厚度公差就可以保证。 经上述分析产品的材料性能符合冲压加工要求。 3：产量 200万件/年 由产品的生产纲领200万/年。可知，产量批量为大批量。很适合采用冲压加工的方法。最好采用复合模或连续模。若能加上自动送料装置，会大大的提高生产率，降低成本,3:冲压工艺方案的确定,完成此工件需要冲孔、落料两道工序。其加工的工艺方案分为以下3种 第一种方案：采用单工序逐步加工 1：冲孔、落料单工序模。工序简图见图1-1 2：落料、冲孔单工序模。工序简图见图1-2 特点：由于采用单工序模，模具制造简单，维修方便但生产率低，工件精度低，很不适合大批量生产,3:冲压工艺方案的确定,第二种方案：采用复合模加工成形，工序图见图1-3 特点：生产率高，工件精度高，但模具制造较复杂，调整维修较麻烦,使用寿命低. 第三种方案：采用连续模加工成形。工序图见图1-4 特点：生产率高，便于实现机械化，自动化，但模具制造复杂，调整维修麻烦，工件精度低。 根据本零件的设计要求，以及各种方案的特点，决定采用第二种方案比较合理,4:冲模结构的确定,4.1 模具的形式 复合模又可以分为正装式复合模和倒装式复合模。 经分析，此工件有两个孔。若采用正装式复合模，操作很不方便。另外，此工件不要求有较高的平直度，工件精度要求低。所以，从操作方便，模具结构制造简单等方面考虑，决定采用倒装式复合模。 4.2 定位装置 采用伸缩式挡料销纵向定位，安装在下模座和活动卸料板之间。工作时，可随凹模下行而压入孔内。工作很方便。 采用导料螺栓横向定位。因此它的结构简单，使用方便，对模具的强度削弱小 4.3 卸料装置,4:冲模结构的确定,1：条料的卸除。采用弹性卸料板，因为是倒装式复合模，所以卸料板安装在下模。 2：工件的卸除。采用打料装置将工件从上模落料凹模中推下落在模具工作面上。 3：冲孔废料的卸除。采用下模内积聚到一定的数量，便从下模座的漏孔中派出。 4.4 导向零件 采用滑动式导柱导套进行导向即可.而且模具在压力机上的安装比较简单，操作又方便，还可以降低成本. 4.5 模架 采用中间导柱模架，则导柱对称分布，受力平衡，滑动平稳，拔模方便 综合上述特点和本零件的特点，本设计决定采用中间导柱模架,5: 冲压工艺的计算,5.1 排样 单排排样图,5: 冲压工艺的计算,根据 计算得.单排的材料利用率为0.76.而双排得材料利用率为0.82.所以,本设计采用双排.条料：钢板 . 5.2 计算冲压力 1:冲孔冲裁力 取 2:落料冲裁力 取 3:卸料力 4:推料力 5:顶件力 6:模具总压力 5.3 计算模具的压力中心 由于该零件完全对称于相互垂直的两条对称线，所以模具的压力中心在几何图形的中心点上,5: 冲压工艺的计算,冲孔凸模刃口尺寸 冲孔凹模刃口尺寸 其中 落料凹模刃口尺寸 落料凸模刃口尺寸 其中,6:复合模主要零件的设计计算,6.1 落料凹模 1：厚度 2：长度和宽度L,B L=B=400 6.2：冲孔凸模长度 L=81mm 6.3 卸料装置 采用橡胶弹簧卸料，橡胶弹簧的安装高度H=54mm 6.4 凸凹模长度确定 L=98mm,7：模座的设计,8.1 模座的材料 本设计中从降低模具成本考虑，选用铸铁HT250材料 8.2 上模座 H=60mm ,h=40mm, L1=410mm, B1=410mm, L2=560mm, B2=490mm, S=475mm, R=65mm, l2=100mm, d2=M20-6H mm, T=40mm, S2=360mm,7：模座的设计,8.3 下模座 H=75mm, h=45mm, L1=410mm, B1=410mm, L2=560mm, B2=490mm, S=475mm, R=65mm, l2=100mm， d2=M20-6H mm，t=40mm,S2=360mm,8：模具的动态分析,冲裁时，凸凹模固定不动，条料由正面送进，放置在凸凹模。压力机通过模柄带动上模座、落料凹模和冲孔凸模下行。通过导柱和导套的导向作用同时完成冲孔和落料。弹性卸料板一方面顶住条料起校平作用，同时在落料凹模推压下向后退让。上模回程时，弹性卸料板被橡胶弹簧顶出。将条料从凹凸模上卸下，冲孔废料则直接由凹凸模孔中漏到压力机台面下。在上模回程到上止点之前，打杆受到压力机横杆的推动，通过推件块将冲裁件从落料凹模中推出,9：模具的动态分析,心得与体会,通过本次毕业设计，在理论知识的指导下，结合认识实习和生产实习中所获得的实践经验，在老师和同学的帮助下，认真独立地完成了本次毕业设计。在本次设计的过程中，通过自己实际的操作计算，我对以前所学过的专业知识有了更进一步、更深刻的认识，同时也认识到了自己的不足之处。到此时才深刻体会到，以前所学的专业知识还是有用的，而且都是模具设计与制造最基础、最根本的知识。 本次毕业设计历时两个月左右，从最初的领会毕业设计的要求，到对拿到自己手上的冲压件的冲压性能的分析计算，诸如对冲压件结构的分析，对形状的分析等，不断地分析计算，对要进行设计的冲压件有了一个比较全面深刻的认识，并在此基础上综合考虑生产中的各种实际因素，最后确定本次毕业设计的工艺方案。然后是对排样方式的计算，直到模具总装配图的绘制，历时近一个月左右。在这段时间里，我进行了大量的计算：从材料利用率的计算，到工序压力的计算，再工作部分刃口尺寸及公差的计算，到各种零件结构尺寸的计算以及主要零部件强度刚度的核算。其间在图书馆翻阅了许多相关书籍和各种设计资料。因此从某种意义上讲，通过本次毕业设计的训练，也培养和锻炼了一种自己查阅资料，获取有价值信息的能力,10：致谢,在经过两个月的忙碌和工作，本次毕业设计已经接近尾声，作为一个本科生的毕业设计，由于经验的匮乏，难免有许多考虑不周全的地方，如果没有导师的督促指导，以及一起工作的同学们的支持，想要完成这个设计是难以想象的。 在这里首先要感谢我的导师樊十全老师。樊十全平日里工作繁多，但在我做毕业设计的每个阶段，从外出实习到查阅资料，设计草案的确定和修改，中期检查，后期详细设计，装配草图等整个过程中都给予了我悉心的指导。我的设计虽不复杂烦琐，但是樊老师仍然细心地纠正图纸中的错误。除了敬佩樊老师的专业水平外，他的治学严谨和科学研究的精神也是我永远学习的榜样，并将积极影响我今后的学习和工作。 还要感谢大学四年来所有的老师，为我们打下机械专业知识的基础；同时还要感谢所有的同学们，正是因为有了你们的支持和鼓励。此次毕业设计才会顺利完成。 最后感谢工学院和我的母校江西农业大学四年来对我的大力栽培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
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