多工位级进模设计方案文献综述

1、1多工位级进模的研究现状及发展趋势1.1多工位级进模的研究现状多工位级进模是在普通级进模的基础上发展起来的一种高精度、高效率、长寿命的模具，是技术密集型模具的重要代表，是冲模发展方向之一。这种模具除 进行冲孔落料工作外，还可根据零件结构的特点和成形性质，完成压筋、冲窝、 弯曲、拉深等成形工序，甚至还可以在模具中完成装配工序 1-3。冲压时，将带 料或条料由模具入口端送进后，在严格控制步距精度的条件下，按照成形工艺安 排的顺序，通过各工位的连续冲压，在最后工位经冲裁或切断后，便可冲制出符 合产品要求的冲压件。为保证多工位级进模的正常工作，模具必须具有高精度的 导向和准确的定距系统，配备有自动送料

2、、自动出件、安全检测等装置。所以多 工位级进模与普通冲模相比要复杂，具有如下特点：（1）在一副模具中，可以完成包括冲裁，弯曲，拉深和成形等多道冲压工 序；减少了使用多副模具的周转和重复定位过程， 显著提高了劳动生产率和设备 利用率。（2）由于在级进模中工序可以分散在不同的工位上， 故不存在复合模的“最 小壁厚”问题，设计时还可根据模具强度和模具的装配需要留出空工位， 从而保 证模具的强度和装配空间4,5。（3）多工位级进模通常具有高精度的内、外导向（除模架导向精度要求高 外，还必须对细小凸模实施内导向保护） 和准确的定距系统，以保证产品零件的 加工精度和模具寿命。（4）多工位级进模常采用高速冲

3、床生产冲压件，模具采用了自动送料、自 动出件、安全检测等自动化装置，操作安全，具有较高的生产效率。目前，世界上最先进的多工位级进模工位数多达 50多个，冲压速度达1000次/分以上。（5）多工位级进模结构复杂，镶块较多，模具制造精度要求很高，给模具的制造、调试及维修带来一定的难度。同时要求模具零件具有互换性，在模具零 件磨损或损坏后要求更换迅速，方便，可靠。所以模具工作零件选材必须好（常 采用高强度的高合金工具钢、高速钢或硬质合金等材料），必须应用慢走丝线切割加工、成型磨削、坐标镗、坐标磨等先进加工方法制造模具。（6）多工位级进模主要用于冲制厚度较薄（一般不超过 2mm、产量大，形 状复杂、精

4、度要求较高的中、小型零件。用这种模具冲制的零件，精度可达IT10 级。1.2多工位级进模的发展趋势随着与国际接轨的脚步不断加快，市场竞争的日益加剧，人们已经越来越认 识到产品质量、成本和新产品的开发能力的重要性。 近年来许多模具企业因此加 大了用于技术进步的投资力度，一些国内模具企业已普及了二维CAD并陆续开始使用UG Pro/Engineer、I-DEAS等国际通用软件，个别厂家还引进了 Moldf随 着与国际接轨的脚步不断加快，市场竞争的日益加剧，人们已经越来越认识到产 品质量、成本和新产品的开发能力的重要性 。近年来许多模具企业因此加大了 用于技术进步的投资力度，一些国内模具企业已普及了

5、二维CAD并陆续开始使用UG Pro/Engineer、I-DEAS等国际通用软件，个别厂家还引进了 Moldflow等CAE 软件，并成功应用于多工位级进模的设计中。目前，以汽车覆盖件模具为代表的大型冲压模具的制造技术已取得很大进 步，东风汽车公司模具厂、一汽模具中心等模具厂家已能生产部分轿车覆盖件模 具。此外，许多研究机构和大专院校开展模具技术的研究和开发，在模具 CAD/CAE/CA技术方面取得了显著进步。例如，吉林大学汽车覆盖件成型技术所 独立研制的汽车覆盖件冲压成型分析 KMA软件，华中理工大学模具技术国家重点 实验室开发的注塑模、汽车覆盖件模具和级进模 CAD/CAE/CA软件，上

6、海交通大 学模具CADI家工程研究中心开发的冷冲模和精冲研究中心开发的冷冲模和精冲 模CA软件等8,9。而多工位级进模技术的发展应该为适应模具产品“交货期短”、“精度 高”、“质量好”、“价格低”的要求服务。专家认为，未来多工位级进模具制 造技术有以下几大发展趋势：（1）全面推广CAD/CAM/CA技术模具CAD/CAM/CA技术是模具设计制造的发展方向。随着微机软件的发展和 进步，普及CAD/CAM/CAE术的条件已基本成熟，各企业将加大CAD/CA技术培训 和技术服务的力度；进一步扩大CA技术的应用范围10。计算机和网络的发展正 使CAD/CAM/CA技术跨地区、跨企业、跨院所地在整个行业

7、中推广成为可能，实 现技术资源的重新整合，使虚拟制造成为可能。(2) 高速铣削加工国外近年来发展的高速铣削加工，大幅度提高了加工效率，并可获得极高的 表面光洁度。另外，还可加工高硬度模块，还具有温升低、热变形小等优点11 O高速铣削加工技术的发展，对汽车、家电行业中大型型腔模具制造注入了新的活 力。目前它已向更高的敏捷化、智能化、集成化方向发展。(3) 模具扫描及数字化系统高速扫描机和模具扫描系统提供了从模型或实物扫描到加工出期望的模型所需的诸多功能，大大缩短了模具的在研制制造周期。 有些快速扫描系统，可快 速安装在已有的数控铣床及加工中心上， 实现快速数据采集、自动生成各种不同 数控系统的加

8、工程序、不同格式的CA数据，用于模具制造业的“逆向工程”。模具扫描系统已在汽车、摩托车、家电等行业得到成功应用，相信在“十五”期 间将发挥更大的作用。(4) 电火花铣削加工电火花铣削加工技术也称为电火花创成加工技术，这是一种替代传统的用成型电极加工型腔的新技术，它是有高速旋转的简单的管状电极作三维或二维轮廓 加工(像数控铣一样)，因此不再需要制造复杂的成型电极， 这显然是电火花成形 加工领域的重大发展12。国外已有使用这种技术的机床在模具加工中应用。预 计这一技术将得到发展。(5) 提高模具标准化程度我国模具标准化程度正在不断提高，估计目前我国模具标准件使用覆盖率已 达到30%左右。国外发达国

9、家一般为80%左右。(6) 优质材料及先进表面处理技术选用优质钢材和应用相应的表面处理技术来提高模具的寿命就显得十分必要。模具热处理和表面处理是否能充分发挥模具钢材料性能的关键环节。模具热处理的发展方向是采用真空热处理。模具表面处理除完善应发展工艺先进的气相沉积(TiN、TiC等)、等离子喷涂等技术。(7) 模具研磨抛光将自动化、智能化模具表面的质量对模具使用寿命、制件外观质量等方面均有较大的影响，研 究自动化、智能化的研磨与抛光方法替代现有手工操作，以提高模具表面质量是重要的发展趋势。(8) 模具自动加工系统的发展这是我国长远发展的目标。模具自动加工系统应有多台机床合理组合； 配有 随行定位

10、夹具或定位盘；有完整的机具、刀具数控库；有完整的数控柔性同步系 统；有质量监测控制系统。2我国多工位级进模发展中的几个问题级进模的设计与制造，近几年来在许多企业里无论是数量还是质量水平上，都已经有了一个较快的发展。但在此同时，与之相适应的冲压机床种类，对冲压 料的要求，以及级进模选用的结构类型和制造工艺等都必须更加引起我们的高重 视和认真对待，因为这是先进的级进模技术赖以采用，并得以充分发挥效益的基 础。2.1级进模对中压设备的要求我国生产的大部分100吨以下的中小型机械压力机，几十年来结构上没有大 的变化。多数采用转键或拨销式剐性离合器， 偏心凸轮式皮带动器，不仅机床噪 声大，震动大，而且不

11、能实现滑块的寸琐行程和瞬时紧急制动。滑块导向精度偏 低，对侧向力承受能力差，行程多数也不可调节。这对于用级进模生产是不够理 想的。主要体现在下几个方面：(1) 级进模不可避免地存在着不同程度的侧向力和压力中心的偏移，因此不 仅希望压力机精度好，刚强，而且滑块要能长期承受较大的侧向力。(2) 级进模在连续生产中，为了避免因零件材料朱送到位，或发生较大的位置偏移，以及模具的局部故障等造成不正常冲压时的模具损坏，一般希望在模具 上设置有自动保护及安全检测装置。 一旦出现上述各类故障，机床能在极短暂的 一瞬问(通常在100200毫秒)停止运动。这要求压力机具有急停功能。以图1所示为例，当条料没有送到正

12、确的位置时，测杆便不能进入条料上已 冲出的孔内。于是测杆被条料顶住，克服上面弹簧的压力而上移，利用其顶端斜 面，迅速地推动微型开关而接通电路，从而对压力机控制箱给出一个要求紧急停 止的电信号。对于每分钟速度为100冲次左右的压力机，只要检测杆部分精度可 靠，参数合适，便完全可以在该冲次之内，即模具闭合之前，使滑块停止。图1么徴动开关3 压力机控制箱类似的送料步距失误检测结构还有电接触式等几种，在引进的模具上常见， 都属于比较成熟的结构，技术上一般没有什么困难。有些复杂的级进模，往往还 同时装有几种检测装置，包括凸模损坏等各种不正常情况的检测，以保护模具。(3) 级进摸生产均需配备自动送料器，对

13、于厚料，还要有相应的开卷、校平 机。但我国目前的机械压力机，大多不进行这项配套13。若想选择精度好，可靠性高，价格又适宜的送料器，则更是一件不易之事。根据我们的体会，若配上 好的自动送料器，同样一副模具的刃磨寿命可提高310倍。(4)现在多数压力机行程偏大，且不可调节。这对级进模非常不利。级进模固其本身结构上的需要， 通常希望在冲压时导柱、导套不分离，以保证安全。对于行程次数在200次/分 以下的压力机一般要求5080mm勺行程，最好还可以根据模具要求进行调节。 目前国产的压力机产品中，能满足这一要求的品种还不多。一些新研制的高冲次 的机床又行程过小，有的仅30mm。2.2对金属材料在规格、精

14、度方面的要求级进摸冲制是一个多道工序连续进行的过程，模具在送进方向上尺寸较长。 因此对于冲压材料的尺寸规范租精度、状态等提出了一些相对严格的质量要求。 反映在这样几个方面：(1) 希望材料是较长的卷料，裁剪后的宽度公差通常小于0.2mm且不能有明显的毛刺等缺陷。(2) 为了能保证零件在尺寸和形位误差方面有较好的一致性，要求材料有较 高的厚度精度和较为均匀的机械性能。 尤其对于有压弯和成形的零件，如果材料 厚度误差大，材料的软硬状态从料头到料尾、 边缘和中间都不均匀，相对轧制方 向的各向异性较大，则弯曲成型后角疲误差，弯曲边长度误差等都会很大。而且 许多零件由于排样上的困难，不得不将压弯线与轧制

15、方向平行，从而在压弯线上容易出现裂纹。2.3级进模结构对模具加工设备的要求级进模由于加工精度要求较高国外大都采用坐标磨床， 慢走丝线切割机床等 加工，国内大多数厂家并不具备这些先进的高精度加工及检测设各 14。在这样情 况下，我们认为，一方面要呼吁有厂家积极研制生产精度较高、适用(不终是最先进的)、价格适中的坐标磨床，模具磨床等精密加工机床，另一方面，模具的 设计、制造者应立足于现有普通设备条件， 积极实行生产匝芑概念上的转变， 努 力发展级进模生产。在目前的阶段，在结构设计上应注意加工工艺性方面的选择。凸模形式的选择比较简单，通常可以尽量采用直通形式，避免根部用凸缘固 定，这样有利于采用线切

16、割方式加工， 便于用投影仪检查精度。必要时还可以用 工具磨进行精密修磨。对于凹模，这个问题较为复杂。在通常的设计规范上，级进模的凹模结构类型可分为整体式、镶套式、分段拼合式、综合拼合式等多种。从高精度等结构先 进性角度来看，分段或综合拼合式自然具有无可争辨的优越性。但此类凹模要能 够成功并发挥其优越性，有一基本条件便是必须要用坐标磨床或高精度成型磨削 工艺进行加工。参考文献1 王哲英，马明旭，扬远龙基于Pro/E的液晶显示器支架的冲压工艺与模具设计黑龙江省：沈阳工业大学；2009.022 卢野.级进模结构设计中的几个问题贵州省：贵阳市华阳电工厂；1992.093 王信培我国级进模发展中的几个问

17、题福建省：厦门宏发电声有限公司；1992.074 彭广威.基于PDX的电器接线卡多工位级进模具设计湖南省：株洲职业技术学院；2009.045 陈永兴，葛正浩.基于PRO/E2PDX勺支架连续模设计陕西省：陕西理工学院；2009.096 Zone-Ching Lin , Chun-Yao Hsu . An Investigation of an Expert System for ShearingCut Progressive Die Desig n .Taiwa n:Nati onalTaiwa nIn stituteofTechno logy,1996.117 李光华.多工位级进模高速冲压时

18、存在的问题及其对策.广西桂林：桂林电器科学研究所；1999.118 曾霞文，胡彦辉.介绍一种多工位级进模的设计.湖南：湖南省工业职业技术学院；2003.019 宋欣，傅旻，刘雅洪.嵌入式插销冲压模具设计.天津：天津科技大学；2005.0310 王俊彪.多工位级进模设计.西北工业大学出版社；1999.0111 姜伯军.多工位级进模工艺零件的结构设计.江苏：常州继电器总厂；2001.0112 胡国骏.基于Pro/E的电机转子片与定子片多工位级进模设计.湖南：湖南工程学院；2005.0513 罗正斌.Pro /E技术在冲压设计上的应用.湖南省：娄底职业技术学院；2008.0114 J.Y.Li,A.

19、Y.C.Nee, B.T.Cheok .In tegrated Feature-Based Modelli ngand ProcessNatio nalPlanning of Bending Operations in Progressive Die Design . Singapore: University of Singapore , 2002.0815 R.D.Jiang ， B.T.Lauw , A.Y.C.Nee . Insert design automation for progressive dies . Sin gapore:In stitute of High Perfo

20、rma nee Comput ing ,2004.061 Station level in many of the research anddevelopment trend of the status quo1.1 Many station level in the course ofMany station level in the course is normal to be set up on the basisof a kind of high-precisionand efficiency,long service life of the moldand tech no logy

21、inten sive die of a developme nt directi on of progressive metal stamping tooling。This stencil off for a hole in the work, butaccord ing to the parts of the structure of the characteristics and properties, forming dow n and washed, bent, deep and con crete step, and even in the process of assembling

22、 the machine mold。The ram, with material or section of the mold into the entrance to the end, and to strictly control step from the conditions in accordanee with the concrete process of order, through various station of the ram, in the final cut down or station fnx, it will be charged with the produ

23、ct requireme nts pitch out the matter。To ensure more station level of the normal work in high precision tool must be oriented and accurate it is equipped with automatic system, material and automatically send out, the security device detecti on and。So many station level in the course of the ordinary

24、 classes of punches more. compared with the followi ng special features:（1）In a tool that can be completed, including at the deep and shape, and more stamp out the operation less ； use more than vice die turnover and positi oning process, sig nifica nt in crease their productivity andequipme nt util

25、izati on some 。（2）As in the process can be dispersed into the course in differentstation, it is not a composite of the "issue" mwminimumwall design molds is adjustable to stre ngth and molds assembly n eeds to leave vaca nt工位 to en sure that the stre ngth of the mold and assemble space。（3）

26、Many station level in the course usually have a high accuracyin addition,external oriented（ be a guide for high precision,it mustbe impleme nted in a tiny ） and correct guida nee to protect it from the system to en sure the products of the part of precisi on and ste ncil process ing life。（4）Stati on

27、 level in more ofte n used at very high speed up product ion of the ram, mold adopted to automatically, a detect ion and automatio n,security and safety of operation,high efficiency 。At present, the world'sadva need level in the course of many stati on, stati on for more tha n 50 multiple to sta

28、mp out the speed of time in more。（5）Station level in more complicated in structure, of course, together with the dema nding, mold manu facture, debug and maintain acertain degree of difficulty 。To mold both parts of exchange. on mold parts worn or damaged after ask ing for cha nge rapidly and conven

29、ient and reliable mould tool. therefore, work must be parts timber assortme nt（often used of high strength of steel, alloy steel tool with or exhibitions and other materials） , we must take care of applicationprocess ing and pelletized thread cutt ing, grinding and coord in ate, coordi nates worn fo

30、r the chamber process manu facture of mould adva need。（6）Many station level is primarily used to be rushed into thethickness of a thin （ do not usually exceed 2mm ） , production big and shaped complex and require a high precisi on, small parts. this tool at the parts and comp onents for it10 level.1

31、.2 Station level in many of the development trendAs to the internationalrulv the pace has been accelerated and marketcompetition increasing, it has been increasinglyrecognized the quality,costs and the new product developing ability of the importanee of。 Inrece nt years many machi ne mold is up for

32、the tech no logicalprogress, someof the mold bus in ess has bee n popular two-dime nsional cad, and bega n to start using ug, pro deas engineer, i wait for international use of software, in dividual manu facturers also imported moldf as to the intern ati onal rulv the pace has bee n accelerated and

33、market competiti on in creas in g, it has bee n in creas in gly recog ni zed the quality, costs and the new product developing ability of the importanee of。In recent years many machi ne mold is up for thetech no logical progress, someof the moldbus in ess has bee n popular two-dime nsional cad, and

34、bega n to start using ug, pro deas engineer, i wait for international use of software, in dividual manu facturers also imported moldflow, cae software, and more successful applicati on in modal stati on level in the desig n of。At prese nt, the car covered with mould of a large stamp out the mach ine

35、 mold manu facture has made great progress and the mould factory car company, faw's mold center and mould factory had to part with a mold car product ion 。 In additi on, many studies and tertiary in stituti ons in mold tech no logicalresearch and developme nt in die cad, cae camtech no logyhas m

36、ade remarkable progress 。 For example, and jilin university car covered with a core tech no logy and in depe ndent developme nt of the car with a stamp out of shape kmas software an alysis, cen tral uni versity of sculptural tech niq ues of the developme nt of key state laboratory injection mould, t

37、he car with a mold and the level of the module into cad cae, cam software sha nghai uni versity die cad the state engin eeri ng research centres the development of the cold and was a progressive metal stamp ing tooli ng up research cen ter of the cold developed progressive metal stamping tooling and

38、 a progressive metal stamping tooling cad software 。More stati on level in tech no logical developme nt should be to mold a short delivery of products "" and "high precision，”and "quality", "low"services. experts believe that the future more工位 togethertech no logic

39、al level in the follow ing major trend(1) Comprehe nsive promotio n of cad cam cae tech no logyDie cad cam cae tech no logy is a tool desig ned and manu factured inthe directi on of developme nt. as computer software developme nt and progress, cad cam cae tech ni cal terms is ripe, and all en terpri

40、ses will expand cad cam technical training and technical service of； furtherexpand the scope of applicationcae。Computer and network development isthat the cad, cae the cam tech no logy and across en terprisesin stitute inthe industry to make it possible to implement technical resources in the reshap

41、 ing, making a virtual 。(2) High speed milling for sliding guideAbroad in rece nt years to develop high-speed milli ng mach ine, achance to the efficiency and to the surface finish is very high. inadditi on, it is also high stre ngth for process ing module and a low heatdeforms temperature rise, the

42、 advantages of °A processing speed innovation of tech no logy, auto, household applia nces in dustry in large type of mold manu facture a new vitality in to. now it has to be quick, directi on, in tegratio n。(3) Tool scans and digital systemsHigh-speed "sca nners and ste ncil sca ns provid

43、e a model or sca n towork out in the model of the manyfunctions,has greatly narrowed the moldson the development of manufacturing cycle。Somerapidly scan system, but the rapid installationof the existing digit control machine tool millingmach ine and process ing cen ter, achiev ing rapid data collect

44、i on and automatically gen erate various digit con trol machi ne tool systems the process ing procedures, the cad, to mold manu facture of the "reverse engineering" 。Tool scans the system has been in cars, motorcycles and electrical household appliances industry was successfully applied in

45、 thefive-year period will play a greater role。(4) Research on electro-discharge milling with tilting shaftElectrical sparkle a process ing tech no logy inno vatio n is also called 电火花 in the process ing tech no logy, as it is a substitute for traditi onal with cen terl ine electrode fabricati on a n

46、ew tech no logy, it is a fast rotati ng colum n of simple tubular electrode make a two-dime nsional or three-dimensionalin processing (like digit control machine tool milling),so as to produce a complicated mold ing electrode, this is obviously electrical sparkle concrete process of the important de

47、velopment。Abroad have bee n using the tech no logy of machi ne tools in a ste ncil process ing of applicati on s. it is expected that this tech no logy will develop。(5) Mold degree of standardizationThe country level is to improve their sta ndards together, oursta ndards of the mold using coverage h

48、as reached 30% or so foreig n coun tries. in gen eral, about 80%。(6) High quality material and adva need surface treatme nt tech no logyUse high-quality steel and application of the surface treatmenttech no logy for improvi ng the life of the machi ne mold is n ecessary to mold and surface treatment

49、. treatment is full of mold steel material performa nee of the key link。Mold heat treatme nt is developme nt directi on of the treatment a vacuum. mold surface treatment should be developed in the process of the sedimentary (tin, for the tic), plasma spray applicati on for。(7) Mold lapping will be a

50、utomated, intellectualizedMold surface to mold the quality of life, a look of the quality asa greater impact and automation, intellectualizedabrasive and polishingway substitute for existi ng hand to improve the quality of the machi ne mold is an importa nt trend。(8) Stencil processing system of aut

51、omaticThis is our Ion g-term developme nt objectives. ste ncil an automaticprocess ing system should be more reas on able the comb in ati on； machi newith a means or location of the corporation, a complete； tool digitcontrol machine tool ； a whole library system digit control machine tool the synchr

52、oni zati on； quality mon itori ng and con trol systems。2 More station level in our country also developing a fewquesti onsLevel in the design and manufacture of mould, in recent years in many bus in esses in both the qua ntity or quality, we also have a relatively rapid growth. but at the same time,

53、 to meet the types of mach ine stamp out the material requireme nts, and steps into the course of con structi on and manufacturing process, we must be more high value and seriously, because this is the adva need level in tech ni cal can be adopted and its econo mic performa nee.2.1 Level in the cour

54、se of the equipme nt required formedium pressure (m.p.)Production of 100 tons of small and mediumpressures and mechanical decades structure no big cha nge. most of the cha nge butt on or the market in the clutch and the sexual bias 剐 轮式 leather machine tools, not only the no ise and vibrati on, and

55、could not achieve the slider inch of the journey and transient emergency brake. sliders guidanee precision is low, the ability to withstand the force, the majority or adjustable for use.this level in the course of product ion is not an ideal。Mainly embodiedin the n ext several areas :(1) Level in th

56、e course will inevitably there are different levelsof stress and to the force center is not only wish to stress that theaccuracy, strong, and the slider to long withsta nd the big to force。(2) In successive steps in the course of production, in order to avoidparts of the material to, or a larger pla

57、ce, and partial offset the machine mold is abno rmal for a stamp out of the mold damage, whe n the tool set on the protect ion and safety in spect ion unit 。 If all the above-me nti on ed, the mach ine can turn on a brief mome nt to ask (usually in the 100200ms) stop movement. this requires the pres

58、sure of a corporation has stopped fun cti oning.As shown in figure 1, for example, when the material was sent to the correct locati on, this club, he can't en ter the secti on had bee n rushed out of the hole. the n the measuri ng rod was the material aga in st a nd overcome stress on the up ramp, the use of the top and promote the switch and is made, and thereby the pressure of the control box to a request for urge nt up electrical sig nal. for the rate of