ZL50裝載機總體及工作裝置設計

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冷沖模具使用壽命的影響及對策 沖壓模具概述 沖壓模具--在冷沖壓加工中，將材料（金屬或非金屬）加工成零件（或半成品）的一種特殊工藝裝備，稱為冷沖壓模具（俗稱冷沖模）。沖壓--是在室溫下，利用安裝在壓力機上的模具對材料施加壓力，使其產生分離或塑性變形，從而獲得所需零件的一種壓力加工方法。 沖壓模具的形式很多，一般可按以下幾個主要特征分類： １．根據(jù)工藝性質分類 　?。?）沖裁模 沿封閉或敞開的輪廓線使材料產生分離的模具。如落料模、沖孔模、切斷模、切口模、切邊模、剖切模等。 （2）彎曲模 使板料毛坯或其他坯料沿著直線（彎曲線）產生彎曲變形，從而獲得一定角度和形狀的工件的模具。 （3）拉深模 是把板料毛坯制成開口空心件，或使空心件進一步改變形狀和尺寸的模具。 　?。?）成形模 是將毛坯或半成品工件按圖凸、凹模的形狀直接復制成形，而材料本身僅產生局部塑性變形的模具。如脹形模、縮口模、擴口模、起伏成形模、翻邊模、整形模等。 ２．根據(jù)工序組合程度分類 （1）單工序模 在壓力機的一次行程中，只完成一道沖壓工序的模具。 （2）復合模 只有一個工位，在壓力機的一次行程中，在同一工位上同時完成兩道或兩道以上沖壓工序的模具。 （3）級進模（也稱連續(xù)模） 在毛坯的送進方向上，具有兩個或更多的工位，在壓力機的一次行程中，在不同的工位上逐次完成兩道或兩道以上沖壓工序的模具。 沖冷沖模全稱為冷沖壓模具。 冷沖壓模具是一種應用于模具行業(yè)冷沖壓模具及其配件所需高性能結構陶瓷材料的制備方法，高性能陶瓷模具及其配件材料由氧化鋯、氧化釔粉中加鋁、鐠元素構成，制備工藝是將氧化鋯溶液、氧化釔溶液、氧化鐠溶液、氧化鋁溶液按一定比例混合配成母液，滴入碳酸氫銨，采用共沉淀方法合成模具及其配件陶瓷材料所需的原材料，反應生成的沉淀經濾水、干燥，煅燒得到高性能陶瓷模具及其配件材料超微粉，再經過成型、燒結、精加工，便得到高性能陶瓷模具及其配件材料。本發(fā)明的優(yōu)點是本發(fā)明制成的冷沖壓模具及其配件使用壽命長，在沖壓過程中未出現(xiàn)模具及其配件與沖壓件產生粘結現(xiàn)象，沖壓件表面光滑、無毛刺，完全可以替代傳統(tǒng)高速鋼、鎢鋼材料。 冷沖模具主要零件 冷沖模具是沖壓加工的主要工藝裝備，沖壓制件就是靠上、下模具的相對運動來完成的。加工時由于上、下模具之間不斷地分合，如果操作工人的手指不斷進入或停留在模具閉合區(qū)，便會對其人身安全帶來嚴重威脅。 （一）模具的主要零件、作用及安全要求 1．工作零件凸凹模是直接使坯料成形的工作零件，因此，它是模具上的關鍵零件。凸凹模不但精密而且復雜，它應滿足如下要求： （1）應有足夠的強度，不能在沖壓過程中斷裂或破壞． 　?。?）對其材料及熱處理應有適當要求，防止硬度太高而脆裂。 2．定位零件定位零件是確定坯件安裝位置的零件，有定位銷（板）、擋料銷（板）、導正銷、導料板、定距側刀、側壓器等。設計定位零件時應考慮操作方便，不應有過定位，位置要便于觀察，最好采用前推定位、外廓定位和導正銷定位等。 3．壓料、卸料及出料零件壓料零件有壓邊圈、壓料板等。 　　壓邊圈可對拉延坯料加壓邊力，從而防止坯料在切向壓力的作用下拱起而形成皺褶。壓料板的作用是防止坯料移動和彈跳。頂出器、卸料板的作用是便于出件和清理廢料。它們由彈簧、橡膠和設備上的氣墊推桿支撐，可上下運動，頂出件設計時應具有足夠的頂出力，運動要有限位。卸料板應盡量縮小閉合區(qū)域或在操作位置上銑出空手槽。暴露的卸料板的四周應設有防護板，防止手指伸入或異物進入，外露表面棱角應倒鈍。 4．導向零件導柱和導套是應用最廣泛的一種導向零件。其作用是保證凸凹模在沖壓工作時有精確的配合間隙。因此，導柱、導套的間隙應小于沖裁間隙。導柱設在下模座，要保證在沖程下死點時，導柱的上端面在上模板頂面以上最少5至10毫米。導柱應安排在遠離模塊和壓料板的部位，使操作者的手臂不用越過導柱送取料。 5．支承及夾持零件它包括上下模板、模柄、凸凹模固定板、墊板、限位器等。 上下模板是冷沖模具的基礎零件，其他各種零件都分別安裝固定在上面。模板的平面尺寸，尤其是前后方向應與制件相適應，過大或過小均不利于操作。 　　有些模具（落料、沖孔類模具）為了出件方便，需在模架下設墊板。這時墊板最好與模板之間用螺釘連接在一起，兩墊板的厚度應絕對相等。墊板的間距以能出件為準，不要太大，以免模板斷裂。 6．緊固零件它包括螺釘、螺母、彈簧、柱銷、墊圈等，一般都采用標準件。冷沖模具的標準件用量較多，設計選用時應保證緊固和彈性頂出的需要，避免緊固件暴露在表面操作位置上，防止碰傷人手和妨礙操作。 冷沖模具的發(fā)展 改革開放以來，隨著國民經濟的高速發(fā)展，市場對冷沖模具的需求量不斷增長。近年來，冷沖模具工業(yè)一直以15%左右的增長速度快速發(fā)展，冷沖模具工業(yè)企業(yè)的所有制成分也發(fā)生了巨大變化，除了國有專業(yè)模具廠外，集體、合資、獨資和私營也得到了快速發(fā)展。 　　隨著與國際接軌的腳步不斷加快，市場競爭的日益加劇，人們已經越來越認識到產品質量、成本和新產品的開發(fā)能力的重要性。而冷沖模具制造是整個鏈條中最基礎的要素之一，冷沖模具制造技術現(xiàn)已成為衡量一個國家制造業(yè)水平高低的重要標志，并在很大程度上決定企業(yè)的生存空間。 　　近年許多冷沖模具企業(yè)加大了用于技術進步的投資力度，將技術進步視為企業(yè)發(fā)展的重要動力。一些國內模具企業(yè)已普及了二維CAD，并陸續(xù)開始使用UG、Pro/Engineer、I-DEAS、Euclid-IS等國際通用軟件，個別廠家還引進了Moldflow、C-Flow、DYNAFORM、Optris和MAGMASOFT等CAE軟件，并成功應用于沖壓模的設計中。 以汽車覆蓋件模具為代表的大型沖壓模具的制造技術已取得很大進步，東風汽車公司模具廠、一汽模具中心等模具廠家已能生產部分轎車覆蓋件模具。此外，許多研究機構和大專院校開展模具技術的研究和開發(fā)。經過多年的努力，在模具CAD/CAE/CAM技術方面取得了顯著進步；在提高模具質量和縮短模具設計制造周期等方面做出了貢獻。 雖然中國冷沖模具工業(yè)在過去十多年中取得了令人矚目的發(fā)展，但許多方面與工業(yè)發(fā)達國家相比仍有較大的差距。例如，精密加工設備在冷沖模具加工設備中的比重比較低；CAD/CAE/CAM技術的普及率不高；許多先進的模具技術應用不夠廣泛等等，致使相當一部分大型、精密、復雜和長壽命冷沖模具依賴進口。 隨著科學技術的不斷進步,現(xiàn)代工業(yè)產品的生產日益復雜與多樣化,產品性能和質量也在不斷提高,因而對冷沖壓技術提出了更高的要求.為了使冷沖壓技術能適應各工業(yè)部門的需要,冷沖壓技術自身也在不斷革新和發(fā)展.冷沖壓技術的發(fā)展思路就是盡可能地完善和擴充冷沖壓工藝的優(yōu)點,克服其缺點.在冷沖壓技術的發(fā)展過程中,應注意以下幾方面： (1)冷沖壓技術的發(fā)展過程中應正確地確定工藝參數(shù)及冷沖模具工作部分的形狀與尺寸,提高沖壓件的質量、縮短新產品試制周期,應在加強沖壓成形理論研究的基礎上,使沖壓成形理論達到能對生產實際起指導作用,逐步建立起一套密切結合生產實際的先進的工藝分析計算方法.國外已開始采用彈塑性有限元法對汽車覆蓋零件的成形過程進行應力應變分析和計算機模擬,以預測某一工藝方案對零件成形的可能性和可能出現(xiàn)的問題。 (2)加快產品更新?lián)Q代,克服模具設計周期長的缺點.應大力開展模具計算機輔助設計和制造(CAD/CAM)技術的研究.在我國,目前要特別注意加強多工位級進模CAD/CAM技術的研究。 (3)滿足大量生產需要以及減輕勞動強度.應加強冷沖壓生產的機械化和自動化研究,使一般中、小件能在高速壓力機上采用多工位級進模生產,達到生產高度自動化,進一步提高沖壓的生產率。 (4)擴大冷沖壓生產的運用范圍.使冷沖壓既適合大量生產,也適合小批量生產;既能生產一般精度的產品,也能生產精密零件.應注意開發(fā)如精密沖裁(特別是厚料精沖)、高能成形、軟模成形、施壓和超塑性加工等新成形工藝,還要推廣簡易模(軟模和低熔點合金模)、通用組合模、數(shù)控沖床等設備的運用。 此外,對沖壓板料性能的改進,模具新材料、模具新加工方法的開發(fā)也應進一步加強。 冷沖模具使用壽命的影響及對策 冷沖模具的使用壽命是以沖制出的工件數(shù)量來計算的。影響冷沖模壽命的因素很多。主要有模具結構設計、制造模具所用凸模和凹模的材料、模具的熱處理質量與表面強化、沖模零件的制造精度和冷沖壓材料的選取。除此之外，還有沖模的安裝、調整、使用以及維修等。 1．模具設計對壽命的影響 (1)排樣設計的影響排樣方法與搭邊值對模具壽命的影響很大，過小的搭邊值，往往是造成模具急劇磨損和凸、凹?？袀闹匾颉墓?jié)約材料出發(fā)，搭邊值愈小愈好，但搭邊值小于一定數(shù)值后，對模具壽命和剪切表面質量不利。在沖裁中有可能被拉人模具問隙中，使零件產生毛刺，甚至損壞模具刃口，降低模具壽命。因此，在考慮提高材料利用率的同時，必須根據(jù)零件產量、質量和壽命，確定排樣方法和搭邊值。 (2)凹模結構的影響對容易產生應力集中而開裂的凹模結構，可以采用組合結構或鑲拼結構，以及預應力結構，從而提高模具使用壽命。 (3)間隙的影響當間隙過小時，壓縮擠壓利害，摩擦力增大，磨損增大，側面的磨損加劇，沖裁后卸料和推件時，材料與凸、凹模之間的摩擦還將造成刃口側面的磨損比端面的磨大大，同時也容易造成凸、凹模溫度很高，把金屬碎屑吸附在刃口側面，形成金屬瘤，使凸、凹模出現(xiàn)崩刃或脹裂現(xiàn)象。因此，過小的間隙對模具壽命極為不利。間隙太大，會增加凸模與凹模端面邊緣的集中應力，致使壓應力急劇增加，于是刃口邊很快屈服變形而失去棱角。因此又增加了沖裁力，進而使刃口邊更快磨損，降低模具壽命。但為了減小凸、凹模的磨損，延長模具使用壽命，在保證沖裁件質量的前提下，設計時適當采用較大間隙是十分必要的。 (4)模具導向結構對壽命的影響可靠的導向對于減小工作零件的磨損，避免凸、凹?？袀欠浅Ｓ行У摹Ｌ貏e對無問隙或小問隙沖裁模、復合模和多工位級進模更為重要。為提高模具壽命，必須根據(jù)工序和零件精度要求，正確選擇導向形式和導向精度，所選擇導向精度應高于凸、凹模的配合精度。 (5)冷沖壓材料選取的影響冷沖壓材料應滿足制件的設計要求和沖壓工藝要求，否則容易損傷模具，降低模具使用壽命。冷沖壓材料表面質量不好，沖壓時制件易破裂，也易擦傷模具。冷沖壓材料塑性不好，變形量小，沖壓時制件易破裂，也易擦傷模具。另外，材料的厚度公差應符合國家標準。因為一副沖模適用于一定材料的厚度，成形、彎曲、翻邊、引伸模具的凸、凹模結構間隙是直接根據(jù)材料厚度來確定的。所以材料厚度不均勻，會導致廢品產生和模具損壞。 2．模具材料對模具壽命的影響 模具材料對模具壽命的影響是模具材料性質、化學成分、組織結構、硬度和冶金質量等的綜合反映。其中，材料性質和熱處理質量影響最為明顯。模具材料性質對模具壽命的影響是很大的。如將同一種工件，使用不同的模具材料做彎曲試驗，試驗結果：用9Mn2V材料，其壽命為5萬次；用Crl2MoV滲氮，其壽命可達40萬次。因此，在選用材料時，應根據(jù)制件的批量大小，合理選用模具材料。模具工作零件的硬度對模具壽命的影響也很大。但并不是硬度愈高、模具壽命愈長。這是因為硬度與強度、韌性及耐磨性等有密切的關系。有的沖模要求硬度高，壽命長。如采用T10鋼制造沖模，硬度為54～58HRC，只沖幾千次，制件毛刺就很大。如果將硬度提高到60～64HRC，則刃磨壽命可達2～3萬次。但如果繼續(xù)提高硬度，則會出現(xiàn)早期斷裂。有的沖模硬度不宜過高，如采用Crl2MoV制造凹模硬度為58～62HRC時，一般壽命為2—3萬件，失效形式是崩刃和開裂以及如果將硬度降到54～58HRC，壽命提高到5～6萬件，但硬度降低到50～53HRC會出現(xiàn)凹模刃口易磨鈍現(xiàn)象。由此可見，模具硬度必須根據(jù)材料性質和失效形式而定。應使硬度、強度、韌性及耐磨性、耐疲勞強度等達到特定沖壓工序所需要的最佳配合。 3．模具的熱處理質量與表面強化對壽命的影響 模具的熱處理質量對模具的性質與使用壽命影響很大。實踐證明，模具工作零件的淬火變形與開裂，使用過程中早期斷裂，雖然與材料的冶金質量、鍛造質量、模具結構及加工有關，但與模具的熱處理關系更大。根據(jù)模具失效原因的分析統(tǒng)計，熱處理不當引起的失效占50％ 以上。實踐證明，高級的模具材料必須配以正確的熱處理工藝，才能真正發(fā)揮材料的潛力。模具工作零件表面強化處理的目的，是獲得外硬內韌的效果，從而得到硬度、耐磨性、韌性、耐疲勞強度的良好配合。模具表面強化處理方法很多，表面處理的新技術工藝發(fā)展很快。除氮碳共滲和離子氮化、滲硼、滲鈮、滲釩、表面鍍硬鉻和電火花強化外，化學氣相沉積(CVD)和物理氣相沉積(PVD)已逐步采用。經CVD和PVD處理后，模具表面覆蓋一層超硬物質，如TiC、TiN等。硬度極高、耐磨性、耐蝕性、抗黏合性很好，可提高模具壽命幾倍到幾十倍。 4．沖模零件的制造精度對模具壽命的影響 沖模制造的精度與使用壽命關系很大，特別是模具表面粗糙度對模具影響很大。如用Crl2MoV鋼制造落料模，如果表面粗糙度值R =1．6 m時，其壽命為3萬件左右。如經精拋光，表面粗糙度值R =0．4 m，壽命可提高到4—5萬件。因此，對模具工作零件表面，一般都要經過磨削、研磨、拋光等精加工和精細加工。 5．其他方面對模具壽命的影響 (1)壓力機的精度不高，也易使沖模損壞。 (2)沖模在壓力機上安裝的正確與否及操作者的技術水平高低，對模具壽命也有很大影響。 (3)沖模的保管和維護好壞，以及使用潤滑劑的情況，也影響模具使用壽命。 6．結語 在實際生產中，對于薄板沖模使用，很少出現(xiàn)非正常磨損的情況。但對于厚板沖模時則發(fā)現(xiàn)易出現(xiàn)非正常磨損，我們總是針對出現(xiàn)的問題進行研究總結。因為一副冷沖模，從設計、加工制造、裝配、調試到安裝、使用，都耗費了眾多工時，同時沖模的凸、凹模使用的材料，大都是優(yōu)質合金鋼。因此，沖模的成本都是比較高的。所以在生產中了解影響沖模壽命的因素及采取相應的對策來指導生產，具有重大的現(xiàn)實意義。 冷沖壓工藝卡片 九江職業(yè)技術學院 冷沖壓工藝卡片 產品型號 零（部）件名稱 共1頁 產品名稱 零（部）件型號 第1頁 材料牌號及規(guī)格 材料技術要求 毛坯尺寸 每毛坯可制件數(shù) 毛坯 質量 輔助 材料 10鋼1500x600x1 條料６００Ｘ1 ５０萬件 工序號 工序 名稱 工序內容 加　工　簡　圖 設備 工藝 裝備 工　時 １ 下料 剪床上裁板600x90 Q11-6X2500 ２ 沖壓 沖孔、落料 J2325 沖孔級進模 ３ 檢驗 按產品圖紙檢驗 ４ ５ ６ ７ ８ ９ １０ 編制日期 審核日期 會 簽 日 期 標記 處數(shù) 更改文件號 簽字 日期 標記 處數(shù) 更改文件號 簽字 日期 目 錄 1． 目錄…………………………………1 2． 任務書………………………………2 3． 工藝分析……………………………3 4． 工藝方案的分析與確定……………4 排樣圖………………….4 材料利用率…………….5 計算沖壓力…………….6 沖裁力………………….6 卸料力………………….6 初定壓力機…………….7 壓力中心……………….7 模刃口尺寸…………….7 6．模具結構設計……………………….8 7．線切割編程………………………….9 8．參考文獻……………………………11 9．心得體會……………………………12 設計任務書 1） 目錄 2） 簡述設計任務及說明要求 3） 沖件的工藝分析 4） 工藝方案的制定及分析比較 5） 排樣設計及材料利用率計算，進行排樣與模具結構及生產率，操作安全和經濟性分析，然后確定排樣方案畫出排樣圖 6） 寫工藝規(guī)程卡 7） 模具結構設計的分析過程 8） 沖壓力，推件力，卸料力的計算過程 和典型結構選擇壓力中心的計算過程 9） 凹模輪廓尺寸計算過程和典型組合的選擇 10） 沖模的主要零件的結構形狀材料公 差的要求及技術要求說明 11） 凸凹模工作刃口尺寸計算過程 12） 其他計算過程及需要說明內容 13） 該設計的優(yōu)缺點及改進措施 14） 設計所用的參考資料 一：工藝分析 沖壓材料為Q235鋼，料厚t=3mm，沖件尺寸精度為IT12級，形狀并不復雜，尺寸大小為小型沖件，年產50萬件，屬于普通沖件， 此沖件在沖裁時應注意以下事項 1. φ20mm和φ8mm的孔較小，孔壁給模具設計和沖裁工藝帶來不便，特別注意材料的金屬流動情況，防止φ20mm和φ8mm凸模彎曲變形 2. φ20mm和φ8mm的周邊和孔壁均勻，模具設計時應妥善處理 3. 沖件較小，故必須考慮到工人的操作安全性 以上3點是此沖件沖壓時較為困難之處，要想得到合格沖件并適應50萬件生產數(shù)量的需要，提高模具壽命是必須處理好的問題 二：工藝方案的分析與確定 從工件的結構形狀可知，其基本工序有沖孔和落料兩種，但根據(jù)先后順序的不同排列，可設定以下方案 1. 沖孔→沖孔→落料。（級進沖壓） 2.沖孔→落料。 （單工序沖壓） 方案2屬于單工序沖壓，由于此沖壓件生產批量很大，沖件較小，為了提、高生產效率和材料的利用率故不宜采用。 方案1也屬于單工序沖壓，此方案較好，即解決了難點，也給模具裝備帶來了方便，沖件方便，排樣合理，沖件也平整，故方案合適。 三：模具結構形式的確定 因制件材料較薄，為保證制作平整，采用彈壓卸料裝置，他還可以對沖孔小凸模起導向作用和保護作用，為方便操作和取件，選用雙柱可傾壓力機橫向送料，因制件薄而窄，故采用側刃定位，生產效率高材料消耗也不大 工件圖 綜上所述，由模具設計指導表5-3 5-7選用彈壓卸料橫向送料典型組合形式，對角導柱滑動導向模架。 畫排樣圖 因由冷沖壓技術表3－14查的最小搭邊值，側邊a=2.0工件之間b=1.8,步距s=21.8由冷沖壓技術公式3－25和3－26和公式3－27的條料寬度，因由文獻側刃條料寬度尺寸B(mm)確定公式得條料寬度B B=1.5a+C+2F =2x1.5+8+2x2 =87mm 導料板間的距離 X=c+1.5 a +nF+z =8+1.5 x2+2 x2+0.5 =87.5 C－條料寬度的最大沖裁力 a－側搭邊值 F－側刃沖切的料邊寬度 n－側刃數(shù) z－沖裁前的條料寬度與板料間的間隙 如圖所示排樣圖,查模具設計指導書4-8選板料的規(guī)格1500 x 900 x 2 mm每塊可剪 47x 900mm的規(guī)格,條料剪切率77.2% 排樣圖 3）計算材料利用率η，由文獻[2]材料通用計算公式η=A。/Ax100% A。－得到制件的總面積 A－ 一個公步的條料面積 η=1256÷1755。6×％100 =71.5% 4）計算沖壓力。完成本制作所需的沖壓力，由沖裁力，卸料力，推件力組成 1． 沖裁力F沖=KLTτ或F沖=LTσ 式中K：系數(shù) K=1.3 L：沖裁周邊長度（mm） τ：材料抗剪強度（Mpa） σ: 材料抗拉強度（Mpa） 由書中表4-12得 σ=362。5（為計算方便取σ=80 Mpa） F沖＝80×2（2×8×3.14＋8×3.14+2×43.8） =210KN 2.卸料力和推件力F推—由文獻[2]卸料力和頂料力推件力的計算公式 F卸=K卸* F沖 F推=K推* F沖*n 式中K推，K卸—系數(shù)，查文獻[2]表2-16卸料力，推件力和頂件力的系數(shù)得K卸= F推=0.05 n：卡在凹模直壁洞口內的制件件數(shù)一般卡3-5件本題取n=4 F卸=K卸×F沖 = 0.05×210 = 10.5KN F推=nK推×F沖 =4×0.55×210 = 46KN F = F卸+ F推+ F沖 = 210 +10.5+46 =266.5KN 5） 初選壓力機，查文獻[2]表1-8開式雙柱可推壓力機部分參數(shù)，初選壓力機型號規(guī)格J23-25 6） 計算壓力中心，本例由于圖形排列規(guī)則，故可采用解析法求壓力中心較方便建立工件坐標系如圖所示 7）由于這圖形是對稱的，所以它的壓力中心在原點，為（0，0） 8）計算凸凹模刃口尺寸，本制件形狀簡單可按分別加工法計算刃口尺寸 1．沖孔 工件尺寸孔直徑8mm 由表3－5，3－6，3－7查得Z=0.246mm，Z=0.360mm =0.02mm，=0.02mm， 查表3-7得：x=0.75；； 校核間隙：因為Z－Z=0.360－0.246=0.114mm 0.114mm＞||+||=0.04mm 說明凸模公差能滿足||+||≤Z－Z的條件 將已知和查表的數(shù)據(jù)代入公式中去得： dT=8.075mm dA=8.321mm 2、落料： 工件尺寸直徑8mm 查表3-7得x=1,；， 校核間隙：Z－Z=0.36－0.246=0.114mm；||+||=0.05mm 0.114＞0.05mm 凸凹模公差能滿足||+||≤Z－Z的條件 將已知和查表得到的數(shù)據(jù)代入公式得 dA=39.99mm dT=39.744mm 四：模具結構設計 ( 1 ) 凹模設計，因制件形狀簡單，隨有三個公步，但總體積并不大，選用整體式矩形凹模較為合理，因生產批量為中批，由查模具設計指導3－5表選用10鋼為凹模材料。 1） 確定凹模的厚度值：由冷沖壓技術：凹模厚的確定3－5公式，確定厚度H值：K=0. 5（查資料）s=8mm H = K s= 0.5 X 8 =20 mm 2）確定凹模的周邊尺寸L X B，由模具設計指導3－43矩形凹模標準可以查到靠近凹模周界尺寸125mm ×100mm×20mm. 選擇模架及確定其他沖模零件尺寸，由凹模周界尺寸及模架閉和高度在一定的范圍之間，查書5-7選用對角導柱模架，標記為125×100×130(GB/T2851.1-1990),并可以根據(jù)此標準畫出模架圖，類似也可以查出其它零件參數(shù)，此時即可畫裝備圖 （ 2 ）校核壓力機安裝尺寸 模座外形尺寸為250×230閉合，高度為130，由為文選表1－2j23－25型壓力機工作尺寸370×560最大閉合為270，連桿調節(jié)長度為55mm，故在工作臺上加20－18mm墊板，模柄孔尺寸也本副模具所述模柄尺寸相符。 ( 3 )線切割編程： B B B2000 GY L2 B B 2000 B2000 GX SR1 B B B2000 GY L4 A B B B800 GY L2 B B800 B1600 GX SR1 B B B800 GY L4 A B B B800 GY L2 B B800 B16000 GX SR1 B B B800 GY L4 D 五：參 考 文 獻 1.冷沖壓技術 、翁其金、北京、機械工業(yè)出版社、2003 2.冷沖壓模具設計指導、王芳、北京、機械工業(yè)出版社、2003 3.模具制造工藝學、郭鐵良、北京、高等教育出版 心 得 體 會 為期一個月的畢業(yè)設計即將結束，也就意味著我的大學生活即將結束，在這期間里學到了很多知識和技能。 通過這次畢業(yè)設計使我掌握了做科學研究的基本方法和思路，為今后的工作打下了基礎，現(xiàn)將感受總結如下： 首先，我學會了對相關科技文獻的檢索，一切科學研究都是建立在前人研究的基礎之上的。因此，對于相關文獻資料的檢索顯得尤為重要。在現(xiàn)代社會中，隨著計算機的普及以及網絡技術的發(fā)展，，對于文獻的檢索已經從圖書館的紙質資料轉移到網絡平臺下的電子文檔。 其次，對于各種工具軟件的熟練使用也是科學研究中所必不可少的。在這次畢業(yè)設計中，我主要使用的是AUTO-CAD這一工具軟件，該軟件可用于圖形設計, 再次，通過這次畢業(yè)設計還使我了解了科技論文的寫作規(guī)范，熟悉了offic系列軟件在文字處理與排版等方面的使用。 總之，這次畢業(yè)設計不是簡簡單單的完成了一個課題，而是使我初步的掌握了科學研究的步驟與方法，鞏固了我的專業(yè)知識，練習了我的實際操作能力，鍛煉了我分析解決問題的能力，為今后的科研工作打下了堅實的基礎。 13 沖 模 件 機 械 加 工 工 藝 過 程 卡 校 名 模具工程學院 模具名稱 墊板沖壓連續(xù)模 共1頁 凹模 第1頁 材料 名稱 合金工具鋼 毛坯種類 毛坯尺寸 零件數(shù)量 件數(shù) 更改內容 牌號 Cr12MoV 鍛 坯 130×110×２０ 50萬件/年 1 序號 工 序 內 容 加工車間 設備名稱 工藝裝備 工時定額 1 下 料 140×110×２０ 備料車間 鋸床 2 鍛 造： 1500 x 900 x 20尺寸公差均為±２ 鍛造車間 空氣錘 3 退 　　 火 鍛造車間 加熱爐 4 校 　　 驗 鍛造車間 5 刨：粗精加工６個面，單面余量0.3∽0.4mm 模具車間 銑床或刨床 虎 鉗 6 磨：磨上下平面兩基準至圖樣尺寸 模具車間 磨床M7120A 7 劃線：劃中心線，各螺孔銷孔，型孔的輪廓 模具車間 畫線平臺 8 加工各孔：各螺釘，銷釘與下模座配鉆配鉸 模具車間 立銑Z525 平行夾頭 9 銑：銑出落料孔 模具車間 立銑X53K 虎 鉗 10 熱處理：檢驗硬度為60∽64HRC 熱處理車間 加熱爐油槽 11 磨：精磨上下面，表面Ra達圖樣要求 模具車間 M120A 12 劃線：各孔型孔，彎曲型槽 模具車間 畫線平臺 13 電加工：電火花線切割沖裁型孔 模具車間 電火花 工件墊板 14 修整：修整型腔 模具車間 電動拋光儀 15 檢驗：按圖樣檢驗 16 入　　　　　　庫 Die Life of cold stamping die and mprovements Overview of stamping die Stamping Die - Stamping in the cold, the material (metal or non-metallic) processing into parts (or half) of a special technical equipment, called cold stamping die (commonly known as Die). Press - is at room temperature, using the die installed in the press to put pressure on the material to produce a separation or plastic deformation, and thus to obtain the necessary parts of a pressure processing method. Stamping die in the form of many, the general categories according to the following main features: 1. According to the technical nature of (1) Die along the closed or open contour the material are derived from mold. If blanking die, punch die, cut off the mold, cut mode, cutting mode, split mode, etc.. (2) bending mode to blank or blank sheet along a straight line (curved line) to bend, deform, and thus obtain a certain angle and shape of the workpiece in the mold. (3) The drawing die is made of the blank sheet opening hollow, or hollow pieces of further changes to the shape and size of the mold. (4) Die rough or semi-finished workpiece is convex according to plan, direct copy the shape of the die shape, the material itself, generate only local plastic deformation of the mold. Such as the bulging mode, reducing the die, expansion die, forming die rolling, flanging mold, plastic mold. 2. According to the degree classification process combination (1) single process model in a press tour, just completed a die stamping process. (2) composite model is only one station, in a press tour, at the same station at the same time to complete more than two or two die stamping process. (3) Progressive Die (also known as the modulus of continuity) in the feeding direction, rough, with two or more of the station, at the press of a visit, work in different places on the completion of two or two successive Road over stamping die process. Chong called cold stamping die Die-wide. Cold stamping die is used in cold stamping die mold industry, and accessories required for high-performance structural ceramic materials, preparation methods, high-performance ceramic materials, molds and accessories from the zirconium oxide and yttrium aluminum powder increases, Pr element composition, Preparation is the solution of zirconia, yttria solution, praseodymium oxide solution, according to a certain percentage of alumina solution when mixed liquor, ammonium bicarbonate infusion, by co-precipitation synthesis of ceramic materials, molds and accessories needed for raw materials, reaction precipitate generated by the treatment, drying, calcining and accessories by high performance ceramic mold material superfine powder, and then after forming, sintering, finishing, they will have high-performance ceramic materials, molds and accessories. Advantages of this invention is the invention made of cold stamping dies and parts and long service life, the process does not appear in the press and its parts and stamping die bond generated the phenomenon of stamping surface is smooth, no glitches, can replace traditional high-speed steel, tungsten steel. Die with the main parts Die stamping tools is the main process equipment, stamping rely on the relative movement under the mold completed. Processing time because the upper and lower mold between the constant division and, if continued operation of the fingers of workers to enter or remain in the mold closed, there will certainly pose a serious threat to their personal safety. (A) of the mold main parts, function and safety requirements 1. Working parts is a direct punch to blank forming the working parts, therefore, it is the key to mold parts. Punch not only sophisticated and complex, it should meet the following requirements: (1) be of sufficient strength, can not be broken or destroyed during stamping. (2) should be appropriate to its material and heat treatment requirements, to prevent too high hardness and brittle fracture. 2. Positioning parts positioning part is to determine the location of the parts installed blank, there are pins (board), gauge pin (plate), lead is sold, guide plate, knife set from the side, side pressure etc.. Design should be considered when positioning parts easy to operate and should not have had orientation, location to facilitate observation, preferably in the forward position, contouring to correct the pin location and positioning. 3. Binder, unloading and discharging parts binder components are blank holder, binder board. Blank holder pressure can drawing blank holder force, thereby preventing billets under the action of the tangential pressure arch formed folds. The role of pressure plate to prevent movement and bounce blank. Top of the device, discharge board's role is to facilitate the pieces and clean up waste. Them by the spring, rubber and equipment, putting on the air-cushion support, can move up and down, knocking out pieces of the design should have enough top output, movement to the limited spaces. Stripper plate area should be minimized or closed position in the operating groove milling out empty-handed. Exposure of the stripper plate should have protection around the plate, to prevent finger inserted into or foreign objects inside, exposed surface edges should be blunt down. 4. Guide parts and guide sleeve guide pin is the most widely used part of a guide. Its role is to ensure punch the punching clearance when accurate match. Therefore, the guide posts, guide cover the gap should be less than the blanking clearance. Guide Post located next mold base, to ensure that the stroke bottom dead center, the lead column in the template on the face over the top for at least 5 to 10 mm. Guide columns should be arranged far away from the module and the pressure plate in the area, so the operator's arms do not get to take over the lead column material. 5. Supporting and clamping the upper and lower parts which includes templates, die handle, fixed plate punch, plate, stopper, etc.. Up and down the template is the basis of the cold die parts, other parts are respectively fixed at the top. Template plane size, especially around the direction to be compatible with the workpiece, too large or too small are not conducive to action. Some molds (blanking, punching type mold) to the pieces of convenience, be set up under the mold plate. At this time the best and the template plate connected between the screw, the two plate thickness should be absolutely equal. Plate spacing out the pieces to be able to prevail, not too much, so as not to break the template. 6. Fastening parts which includes screws, nuts, springs, pins, washers, etc., are generally used standard parts. Die more with the amount of standard parts, design choice and flexibility should be tightened to ensure the top out of the need to avoid exposure to the surface fastener operating position, the staff and impede operation to prevent bumps. Die with the development of Since reform and opening, with the rapid development of the national economy, the market demand with the growing Die. In recent years, Die with the industry has been around 15% growth rate of the rapid development of industrial enterprises with ownership Die components also changed dramatically, in addition to the professional mold factory outside of state-owned, collective, joint ventures, wholly-owned and private has been a rapid development. As with the accelerating pace of international integration, the increasing competition in the market, it has been increasingly recognized product quality, cost, and new product development capacities. The cold die manufacturing is the most basic elements of the chain, one of the cold die manufacturing technology to measure a country's manufacturing sector has become an important symbol of the level, and largely determine the viability of enterprises. Die with enterprises to increase in recent years many technological advances for investment, technological progress will be seen as an important driving force for enterprise development. Some domestic enterprises have popularized the two-dimensional mold CAD, and gradually began to use UG, Pro / Engineer, I-DEAS, Euclid-IS and other international common software, individual manufacturers have also introduced Moldflow, C-Flow, DYNAFORM, Optris and MAGMASOFT etc. CAE software, and successfully applied in stamping die design. A car cover mold as the representative of a large stamping die manufacturing technology has made great progress, Dongfeng Motor Corporation mold factory, mold manufacturers such as FAW mold center has been able to produce some car cover mold. In addition, many research institutions and universities to carry out technology research and development of mold. After years of effort, in the mold CAD / CAE / CAM technology has made remarkable progress; in improving quality and reducing mold die design and manufacturing cycle, and so contributed. Although China Die with the industry over the past decade has made remarkable development, but in many ways compared with the industrialized countries there is still a large gap. For example, the precision machining equipment, processing equipment in Die with the relatively low proportion; CAD / CAE / CAM technology penetration is not high; many advanced mold technology not widely so, resulting in a considerable number of large, sophisticated, complex and long Die life with dependence on imports. ????With the continuous progress of science and technology, modern industrial production of increasingly complex and diverse, product performance and quality is ever increasing, thus the cold stamping technology put forward higher requirements. In order to adapt to the cold stamping technology industry needs, cold stamping technology itself also in innovation and development. cold stamping technology idea is to improve and expand as much as possible the advantages of the cold stamping process, to overcome its shortcomings. in the cold stamping technology development, should note the following aspects: (1) cold stamping technology process parameters should be properly identified and Die with the work of some of the shape and size, to improve the quality of stamping parts and shorten the new product production cycle should be in strengthening the metal forming the basis of theoretical studies, to metal forming theory to practice can produce a direction, and gradually establish a close connection with the actual production of the advanced process of calculation. abroad have begun to use plastic finite element method, automobile parts forming process of the stress and strain analysis and computer simulation to predict the forming part of a process plan on the possibilities and potential problems. (2) to accelerate product replacement, mold design to overcome the shortcomings of a long cycle. Should vigorously carry out computer-aided design and manufacture of molds (CAD / CAM) Research. In my country, paying particular attention to strengthening the multi-position progressive die CAD / CAM Technology. (3) to meet the needs of mass production, and reduce labor intensity. Should strengthen cold stamping of mechanized and automated, so that the average, small pieces of high-speed presses in a multi-position progressive die production, production reached a high degree of automation to further improve stamping productivity. (4) expand the scope of application of cold stamping production. So cold pressing both suitable for mass production, but also for small batch production; both the general accuracy of product production, but also can produce precision parts. Should pay attention to development such as fine blanking (especially thick material fine blanking), forming high-energy, soft mold forming, pressure and processing new superplastic forming process, but also promote the easy mode (soft mode and the low melting point alloy mold), Universal Hybrid model, the use of CNC punch press and other equipment. In addition, the performance improvement of sheet metal stamping, mold new material, die development of new processing methods should be further strengthened. Die with life and Countermeasures Die with the life of the workpiece by punching out the number of terms. Many factors affect the life Die. There are die structure design, manufacture molds used in the punch and die materials, die quality and surface hardening heat treatment, precision die manufacturing parts and cold stamping materials selection. In addition, there are die installation, adjustment, use and maintenance. 1. Die Design on Life (1) Layout design of layout methods and take the boundary value a great impact on the die life, too small to take the boundary value, often causing rapid wear and convex mold, die bite wounds on the. Starting from material savings, take the boundary value smaller the better, but take the edge is less than some value, the cut surface of the mold and the quality of life adversely. There will be left behind in the blanking die Q-gap were to produce spare parts glitch, or even damage the die edge, reduce die life. Therefore, consider increasing the material utilization of the same time, parts must yield, quality and life expectancy to determine the layout methods and take the boundary. (2) die structure prone to stress concentration on the cracking of the die structure, composite structure can be used or mosaic structure, and prestressed structure to enhance the mold life. (3) the impact of clearance when the gap is too small, compressed extrusion of interest, increased friction, increased wear, the wear side of aggravated discharge and push pieces after blanking time, materials and convex, the friction between die will cause wear and tear than the end edge on the side of the grinding much, but also easily lead to convex, concave mold temperature is high, the adsorption of metal debris in the side edge to form a metal tumor, so that male and female die chipping or expansion occurs crack phenomenon. Therefore, the gap is too small to Die Life very bad. Gap is too large will increase the punch and the die face the edge of the concentration of stress, resulting in a sharp increase in stress, so blade edge quickly lose angular yield deformation. Therefore, addition of blanking force, thereby enabling faster edge edge wear, reduce die life. But in order to reduce the male and female die wear, extending mold life, while ensuring quality of stamping pieces under the premise that larger space designed properly it is necessary. (4) Die-oriented structure of the life of a reliable guide for the working parts reduce wear, prevent male and female die bite wound is very effective. In particular, non-small-Q gap Q gap or Die, compound die and multi-position progressive die even more important. To improve the die life, must be based on processes and the demand of precision, the correct choice-oriented form and orientation accuracy, the choice should be higher than the accuracy-oriented convex, concave mold with precision. (5) the impact of cold stamping materials, cold stamping materials selected should meet the design requirements of workpieces and stamping process requirements, or easy to mold damage and reduce mold life. Poor surface quality of cold stamping, punching, cracking when the workpiece is also easy to scratch mold. Bad cold stamping plastic materials, deformation is small, easy to press when the workpiece rupture, but also easy to scratch mold. In addition, the material thickness tolerances shall comply with national standards. Die because of a certain thickness of material suitable for forming, bending, flanging, drawing die of the male and female die structure gap is directly determined by the thickness of the material. Therefore, uneven thickness, will result in waste generation and mold damage. 2. Die Die Life of Die Die Life of a mold material properties, chemical composition, structure, hardness and comprehensive reflection of metallurgical quality. Among them, the material properties and heat treatment affect the quality of the most obvious. Mold material properties on the impact of die life is great. If the same workpiece, using a different mold material of the bending test, the test results: The 9Mn2V material, the life of 5 million; with Crl2MoV nitriding, the life of up to 40 million. Therefore, the choice of materials, the batch size should be based on workpiece, rational use of mold materials. The hardness of the die parts to Die Life a great impact. But not the higher hardness, longer die life. This is because the hardness and strength, toughness and abrasion resistance are closely related. Some die demands of high hardness, long life. Such as the use of T10 steel dies, hardness 54 ~ 58HRC, only washed thousands of times a burr on the workpiece great. If the hardness to 60 ~ 64HRC, the grinding life of up to 2 to 3 million. However, if continue to improve hardness, fracture occurs earlier. Some die hardness should not be too high, as the die manufacturing using Crl2MoV 58 ~ 62HRC hardness, the general life of 2-3 million, invalid form of chipping and cracking, and if the hardness down to 54 ~ 58HRC, life expectancy increased to 5 ~ 60 000, but decreased to 50 ~ 53HRC hardness appears easy to blunt the die edge phenomenon. Thus, mold hardness must be based on material properties and failure modes may be. Should enable the hardness, strength, toughness and wear resistance, resistance to fatigue strength needed to achieve a particular stamping process the best match. 3. The surface of the mold heat treatment to strengthen the quality and impact on life Mold heat treatment the nature and quality of life of the mold a great impact. Practice shows that the die parts of the quenching distortion and cracking, early fracture during use, while the metallurgical and materials quality, forging quality, mold structure and process related, but related more to die of heat treatment. According to statistical analysis of failure causes of mold, heat treatment failure due to improper accounting for more than 50%. Practice shows that the mold material must be accompanied by high heat treatment process properly, can really play a material's potential. Parts surface hardening mold work purpose is to obtain the effect of external hard tough inside, so be hardness, wear resistance, toughness, good resistance to fatigue with. Many ways to die surface hardening, surface treatment technology of new technologies developed rapidly. In addition to Nitrocarburizing and ion nitride, boride, seepage niobium, vanadium permeability, hard chrome plated and spark strengthening, the chemical vapor deposition (CVD) and physical vapor deposition (PVD) has been gradually adopted. By CVD and PVD treatment, the mold surface covered with super-hard material, such as TiC, TiN, etc.. High hardness, wear resistance, corrosion resistance, adhesion is very good, can improve the die life several times to several times. 4. Manufacturing precision of the die parts of die life Precision die manufacturing and life in it in particular, mold surface roughness on the mold a great impact. If using Crl2MoV steel blanking die, if the surface roughness value R = 1.6 m, its life span is about 30,000. Such as polished by the precision, surface roughness value R = 0.4 m, life can be increased to 4-5 million. Therefore, the working parts of the mold surface, the general must go through grinding, grinding, polishing and other finishing and fine processing. 5. Other aspects of the impact of die life (1) Press the accuracy is not high, but also easy to make die damage. (2) die in the press or not installed properly and the operator's technical level, on the tool life is also greatly affected. (3) dies in the custody and maintenance of good and bad, and the use of lubricant condition also affects mold life