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目 錄 摘 要 ...........................................................................................................................................III Abstract .........................................................................................................................................IV 目 錄 ............................................................................................................................................V 1 緒 論 .........................................................................................................................................1 1.1 課題研究的目的和意義 .......................................................................................................1 1.2 國內(nèi)外的發(fā)展概況 ...............................................................................................................2 1.3 本課題應(yīng)達(dá)到的要求 ...........................................................................................................5 2 沖壓工藝設(shè)計(jì) .............................................................................................................................6 2.1 沖壓件簡介 ...........................................................................................................................6 2.2 沖壓的工藝性分析 ...............................................................................................................6 2.3 沖壓工藝方案的確定 ...........................................................................................................8 2.3.1 沖壓模具類型 ................................................................................................................8 2.3.2 沖壓工藝分析和計(jì)算 ....................................................................................................8 3 側(cè)彎支架連續(xù)模設(shè)計(jì) ...............................................................................................................10 3.1 模具結(jié)構(gòu) .............................................................................................................................10 3.2 確定其搭邊值 .....................................................................................................................11 3.3 確定排樣圖 .........................................................................................................................11 3.3.1 送料步距與帶料寬度 ..................................................................................................11 3.3.2 排樣方案 ......................................................................................................................13 3.4 材料利用率計(jì)算 .................................................................................................................13 3.5 凸、凹模等刃口尺寸的確定 .............................................................................................14 3.5.1 沖孔凸、凹模刃口尺寸計(jì)算 ......................................................................................14 3.5.2 成形側(cè)刃凸、凹模刃口尺寸計(jì)算 ..............................................................................16 3.5.3 小凸形凸、凹模刃口尺寸計(jì)算 ..................................................................................18 3.5.4 大凸形凸、凹模刃口尺寸計(jì)算 ..................................................................................19 3.5.5 凹形凸、凹模刃口尺寸計(jì)算 ......................................................................................20 3.5.6 長矩形凸、凹模刃口尺寸計(jì)算 ..................................................................................21 3.5.7 短矩形凸、凹模刃口尺寸計(jì)算 ..................................................................................22 3.5.8 切斷凸、凹模刃口尺寸計(jì)算 ......................................................................................23 3.5.9 前彎曲凸、凹模刃口尺寸計(jì)算 ..................................................................................24 3.5.10 后彎曲凸、凹模刃口尺寸計(jì)算 ................................................................................25 3.5.11 左右彎曲凸、凹模刃口尺寸計(jì)算 ............................................................................25 3.5.12 中間切舌凸、凹模刃口尺寸計(jì)算 ............................................................................26 3.6 沖壓力計(jì)算 .........................................................................................................................26 3.6.1 沖孔部分沖壓力 ..........................................................................................................27 3.6.2 成形側(cè)刃沖壓力 ..........................................................................................................28 3.6.3 切廢料部分沖壓力 ......................................................................................................28 I 3.6.4 彎曲部分沖壓力 ..........................................................................................................29 3.6.5 切舌彎曲部分沖壓力 ..................................................................................................29 3.6.6 切斷部分沖壓力 ..........................................................................................................30 3.6.7 總沖壓力 ......................................................................................................................30 3.7 壓力機(jī)選用 .........................................................................................................................31 3.8 壓力中心計(jì)算 .....................................................................................................................31 3.9 模具主要零部件的結(jié)構(gòu)設(shè)計(jì) .............................................................................................32 3.9.1 凹模結(jié)構(gòu)及設(shè)計(jì) ..........................................................................................................32 3.9.2 圓凸模 1 的結(jié)構(gòu)設(shè)計(jì) ..................................................................................................34 3.9.3 圓凸模 2 的結(jié)構(gòu)設(shè)計(jì) ..................................................................................................34 3.9.4 方形凸模的結(jié)構(gòu)設(shè)計(jì) ..................................................................................................35 3.9.5 成形側(cè)刃的結(jié)構(gòu)設(shè)計(jì) ..................................................................................................36 3.9.6 小凸形凸模的結(jié)構(gòu)設(shè)計(jì) ..............................................................................................36 3.9.7 大凸形凸模的結(jié)構(gòu)設(shè)計(jì) ..............................................................................................37 3.9.8 凹形凸模的結(jié)構(gòu)設(shè)計(jì) ..................................................................................................38 3.9.9 長矩形凸模的結(jié)構(gòu)設(shè)計(jì) ..............................................................................................38 3.9.10 短矩形凸模的結(jié)構(gòu)設(shè)計(jì) ............................................................................................39 3.9.11 前彎曲凹模鑲塊的結(jié)構(gòu)設(shè)計(jì) ....................................................................................40 3.9.12 前彎曲凸模的結(jié)構(gòu)設(shè)計(jì) ............................................................................................40 3.9.13 U 型彎曲半凹模的結(jié)構(gòu)設(shè)計(jì) .....................................................................................41 3.9.14 彎曲切斷組合凸模的結(jié)構(gòu)設(shè)計(jì) ................................................................................42 3.9.15 切舌彎曲凸模的結(jié)構(gòu)設(shè)計(jì) ........................................................................................42 3.9.16 切斷彎曲凸凹模的結(jié)構(gòu)設(shè)計(jì) ....................................................................................43 3.9.17 卸料板設(shè)計(jì) ................................................................................................................44 3.9.18 凸模固定板設(shè)計(jì) ........................................................................................................44 3.9.19 凸模墊板設(shè)計(jì) ............................................................................................................45 3.9.20 凹模墊板設(shè)計(jì) ............................................................................................................46 3.9.21 擋塊設(shè)計(jì) ....................................................................................................................46 3.10 標(biāo)準(zhǔn)件確定 .......................................................................................................................47 3.10.1 模架確定 ....................................................................................................................47 3.10.2 上模螺釘確定 ............................................................................................................47 3.10.3 上模銷確定 ................................................................................................................47 3.10.4 下模螺釘確定 ............................................................................................................47 3.10.5 下模銷確定 ................................................................................................................47 3.10.6 卸料螺釘確定 ............................................................................................................48 3.10.7 卸料彈簧設(shè)計(jì) ............................................................................................................48 3.10.8 U 型彎曲頂件彈簧設(shè)計(jì) .............................................................................................48 3.10.9 U 型彎曲推件彈簧設(shè)計(jì) .............................................................................................48 3.10.10 切舌彎曲頂件彈簧設(shè)計(jì) ..........................................................................................48 3.10.11 U 型彎曲凸模固定螺釘確定 ...................................................................................49 3.10.12 大凸形凸模固定螺釘確定 ......................................................................................49 3.10.13 擋塊固定螺釘確定 ..................................................................................................49 3.10.14 小導(dǎo)柱確定 ..............................................................................................................49 3.10.15 凹模上小導(dǎo)套 2 確定 ..............................................................................................49 3.10.16 卸料板上小導(dǎo)套 1 確定 ..........................................................................................49 3.10.17 抬料銷確定 ..............................................................................................................49 3.10.19 抬料銷彈簧設(shè)計(jì) ......................................................................................................50 3.10.20 擋塊銷確定 ..............................................................................................................50 3.11 模具閉合高度、校驗(yàn)壓力機(jī) ...........................................................................................50 4 結(jié)論與展望 ...............................................................................................................................51 4.1 結(jié)論 .....................................................................................................................................51 4.2 不足之處及未來展望 .........................................................................................................51 致 謝 ...........................................................................................................................................52 參考文獻(xiàn) .......................................................................................................................................53 3 1 緒 論 1.1 課題研究的目的和意義 沖壓是指靠壓力機(jī)和模具對板材、帶材、管材和型材等施加外力，使之產(chǎn)生塑性變 形或分離，從而獲得所需形狀和尺寸的工件（沖壓件）的成形加工方法。冷沖壓是在常 溫下，利用沖壓模在壓力機(jī)上對板料或熱料施加壓力，使其產(chǎn)生塑性變形或分離從而獲 得所需形狀和尺寸的另件的一種壓力加工方法。 沖壓是高效的生產(chǎn)方法，采用復(fù)合模，尤其是多工位級進(jìn)模，可在一臺壓力機(jī)（單 工位或多工位的）上完成多道沖壓工序，實(shí)現(xiàn)由帶料開卷、矯平、沖裁到成形、精整的 全自動生產(chǎn)。生產(chǎn)效率高，勞動條件好，生產(chǎn)成本低，一般每分鐘可生產(chǎn)數(shù)百件。與機(jī) 械加工及塑性加工的其它方法相比，沖壓加工無論在技術(shù)方面還是經(jīng)濟(jì)方面都具有許多 獨(dú)特的優(yōu)點(diǎn)。主要表現(xiàn)如下。 （1）沖壓加工的生產(chǎn)效率高，且操作方便，易于實(shí)現(xiàn)機(jī)械化與自動化。這是因?yàn)闆_ 壓是依靠沖模和沖壓設(shè)備來完成加工，普通壓力機(jī)的行程次數(shù)為每分鐘可達(dá)幾十次，高 速壓力要每分鐘可達(dá)數(shù)百次甚至千次以上，而且每次沖壓行程就可能得到一個沖件。 （2）沖壓時由于模具保證了沖壓件的尺寸與形狀精度，且一般不破壞沖壓件的表面 質(zhì)量，而模具的壽命一般較長，所以沖壓的質(zhì)量穩(wěn)定，互換性好，具有“一模一樣”的 特征。