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無錫太湖學院 冷沖壓工藝卡片 零件名稱 支撐板 零件圖號 115015 材料牌號及規(guī)格 08F 2×34.4×L 毛坯種類 帶料 毛坯尺寸 34.4×L 每毛坯可制件數(shù) 1件/每20 工序號 工序名稱 工序內容 沖壓設備 工藝裝備 一次加工數(shù) 工 序 附 圖 10 沖裁 沖4個孔 J23-40 模具和自動送料機構 1 1.沖孔 2.導正落料 20 落料 導正落料 J23-40 模具和自動送料機構 1 30 檢驗 檢驗 班級 機械96 姓名 花喜 學號 0923255 日期 2013.5.17 批改 日期 編號 無錫太湖學院 畢業(yè)設計（論文） 相關資料 題目： 支撐板冷沖壓工藝及級進模設計 信機 系 機械工程及自動化專業(yè) 學 號： 　　　 0923255　　　　 學生姓名： 花喜 指導教師： 　 鐘建剛 （職稱：副教授 ） （職稱： ） 2013年5月25日 目 錄 一、畢業(yè)設計（論文）開題報告 二、畢業(yè)設計（論文）外文資料翻譯及原文 三、學生“畢業(yè)論文（論文）計劃、進度、檢查及落實表” 四、實習鑒定表 無錫太湖學院 畢業(yè)設計（論文） 開題報告 題目： 支撐板冷沖壓工藝及級進模設計 信機 系 機械工程及自動化 專業(yè) 學 號： 0923255 學生姓名： 花喜 指導教師： 鐘建剛 （職稱：副教授 ） （職稱： ） 2012年11月20日 課題來源 來源于無錫惠龍有限公司，是電器產(chǎn)品上的一個零件。 機械工程及其自動化專業(yè)的方向之一是模具，因此選擇模具設計作為畢業(yè)設計題目是完全符合本專業(yè)的要求，模具生產(chǎn)效率高，同時能有效保證產(chǎn)品一致性和可換性，具有很好的發(fā)展前途和應用價值。連續(xù)模在模具中技術含量高，制造、裝配難度大，因此本課題研究連續(xù)模的沖壓工藝、模具結構，并進行模具設計有著重要的意義。 科學依據(jù)（包括課題的科學意義；國內外研究概況、水平和發(fā)展趨勢；應用前景等） （1）課題科學意義 冷沖壓生產(chǎn)靠壓力機和模具完成加工過程，與其他加工方法相比，在技術與經(jīng)濟方面具有下列特點： 1）冷沖壓是少、無切屑加工方法之一，所獲得的沖壓件一般無需再加工。 2）普通壓力機每分鐘可生產(chǎn)幾十件，高速壓力機每分鐘可生產(chǎn)千件以上，是一種高效率的加工方法。 3）沖壓件的尺寸精度由模具保證，所以質量穩(wěn)定，互換性好。 4）冷沖壓可以加工壁薄、重量輕、剛性好、形狀復雜的零件，為其他加工方法所不能替代。 另外，冷沖壓加工不需加熱、無氧化皮，表面質量好，操作方便，費用較低。 由于具有上述突出特點，冷沖壓在生產(chǎn)中得到了廣泛的應用。全世界的鋼材中，有60％～70％是板材，其中大部分是經(jīng)過沖壓制成。汽車的車身、底盤、油箱、散熱器片，鍋爐的汽包、容器的殼體，電機、電器的鐵芯硅鋼片等都是沖壓加工的。儀器儀表、家用電器、自行車、辦公器械、生活器皿等產(chǎn)品中，也有大量沖壓件。冷沖壓可加工各種類型的產(chǎn)品，尺寸從小到鐘表的秒針，大到汽車的縱梁、覆蓋件；沖切厚度已達20 mm以上，加工尺寸幅度大，適應性強。 級進模（也叫連續(xù)模，據(jù)說連續(xù)模在標準術語已經(jīng)取消）由多個工位組成，各工位按順序關聯(lián)完成不同的加工，在沖床的一次行程中完成一系列的不同的沖壓加工。一次行程完成以后，由沖床送料機按照一個固定的步距將材料向前移動，這樣在一副模具上就可以完成多個工序，一般有沖孔，落料，折彎，切邊，拉伸等等 。 中國模具工業(yè)發(fā)展十分迅速。目前，國內已能生產(chǎn)精度達2微米的精密多工位級進模，工位數(shù)最多已達160個，壽命達到1～ 2億次。但許多方面與工業(yè)發(fā)達國家相比仍有較大差距。例如，精密加工設備在模具加工設備中的比重還比較低，CAD／CAE /CAM技術的普及率不高 ，許多先進的模具技術應用還不夠廣泛等等。特別在大型、精密、復雜和長壽命模具技術上存在明顯差距，這些類型模具的生產(chǎn)能力也不能滿足國內需求，因而需要大量從國外進口。許多模具企業(yè)十分重視技術進步，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。此外，許多研究機構和大專院校都開展模具技術的研究和開發(fā)。經(jīng)過多年的努力，在模具CAD／CAE／CAM技術、 模具的電加工和數(shù)控加工技術、快速成形與快速制模技術、新型模具材料等方面取得了顯著進步。雖然我國的模具工業(yè)和技術在過去的十多年得到了快速發(fā)展，但與國外工業(yè)發(fā)達國家相比仍存在較大差距，尚不能完全滿足國民經(jīng)濟高速發(fā)展的需求因而需 要大量從國外進口。許多模具企業(yè)十分重視技術進步，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。此外，許多研究機構和大專院校都開展模具技術的研究和開發(fā)。經(jīng)過多年的努力，在模具CAD／CAE／CAM技術、模具的電加工和數(shù)控加工技術、快速成形與快速制模技術、新型模具材料等方面取得了顯著進步。雖然我國的模具工業(yè)和技術在過去的十多年得到了快速發(fā)展，但與國外工業(yè)發(fā)達國家相比仍存在較大差距，尚不能完全滿足國民經(jīng)濟高速發(fā)展的需求。 （2）研究狀況及其發(fā)展前景 隨著國民經(jīng)濟的高速發(fā)展、沖壓技術的發(fā)展和新型模具材料的不斷研究開發(fā)，市場對模具的需求量不斷增長，模具的結構也發(fā)生了一定的變化，對模具的制造，裝配等都有了很大的影響。近年來，模具工業(yè)一直以15%左右的增長速度快速發(fā)展。模具是機械制造業(yè)中技術先進、影響深遠的重要工藝裝備,具有生產(chǎn)效率高、材料利用率高、制件質量優(yōu)良、工藝適應性好等特點,被廣泛應用于汽車、機械、航天、航空、輕工、電子、電器、儀表等行業(yè)。中國模具的“珠江三角洲、長江三角洲和以成都/重慶為代表的西部模具”三足鼎立局面已經(jīng)基本形成，然而與國際先進水平相比,中國的模具行業(yè)的差距不僅表現(xiàn)在精度差距大、交貨周期長等方面,模具壽命也只有國際先進水平的50%左右,大型、精密、技術含量高的轎車覆蓋件沖壓模具和精密沖裁模具,每年都需要花費大量資金進口。但我們相信，中國不會因此而停頓，中國模具的發(fā)展，不僅僅是要量上考慮，更應該要從質上考慮，中國模具行業(yè)大有發(fā)展的空間。 研究內容 冷沖壓加工。是在常溫下，利用沖壓設備和沖模，使各種不同規(guī)格的板料或配料在壓力的作用下發(fā)生永久變形或分離，制成所需要各種形狀零件的一種加工方法。 級進模又稱連續(xù)模，它將落料、彎曲、拉深、沖孔和切邊等多工序安排在一個模具的不同工位上，在沖壓過程中坯料依次通過多工位被連續(xù)沖壓成形，至最后工位成為制件。 綜合應用各種所學的專業(yè)知識，在規(guī)定的時間內對產(chǎn)品進行冷沖壓工藝分析，制訂完整的沖壓工藝方案，并完成其中的模具設計、數(shù)據(jù)計算和圖紙。 擬采取的研究方法、技術路線、實驗方案及可行性分析 我們可采用調查法，觀察法，實驗法，文獻研究法，經(jīng)驗總結法，思維方法，系統(tǒng)科學法來研究接觸片連續(xù)模。 方案設計：在工藝分析的基礎上，綜合考慮產(chǎn)品的產(chǎn)量和精度要求。所用材料的性能，工廠的技術力量，設備情況及模具制造情況，確定該工件的工藝規(guī)程和每道工序的沖模結構形式。 結構設計：在方案設計的基礎上，進一步設計模具各部分零件的具體結構尺寸。 1．沖裁的工藝分析：分析沖裁件的結構形狀，尺寸精度，材料是否符合，沖壓力工藝要求，從而確定沖裁的可能性。 2．確定沖裁工藝方案及模具結構形式：工序數(shù)目，工序性質，工序順序，工序組合及模具結構形式。 3．沖壓模具的設計計算。排樣，沖壓力，壓力中心，模具刃口尺寸計算，確定各主要零件的外形尺寸，計算模具的閉合高度，確定所用沖床。 4． 繪制沖?？傃b圖 5．繪制非標準零件圖 研究計劃及預期成果 研究計劃： 2012年11月12日-2011年12月2日：按照任務書要求查閱論文相關參考資料，填寫畢業(yè)設計開題報告書。 2012年12月3日-2013年1月20日：機械制造綜合實訓，機械零件加工方法和加工工藝的編制。 2013年1月21日-2013年3月1日：到企業(yè)進行崗位實習，了解本專業(yè)的實踐知識，掌握基本的設計生產(chǎn)模式。 2013年3月4日-2013年3月8日：查閱與設計有關的參考資料不少于10篇，其中外文不少于5篇。 2013年3月11日-2013年3月15日：翻譯外文資料（8000-10000字符）。 2013年3月18日-2013年3月22日：分析產(chǎn)品圖、分析沖壓工序、排樣方案，優(yōu)選確定模具沖壓工藝方案。 2013年3月25日-3月29日：確定模具結構。 2013年4月1日-4月5日：計算模具刃口所需的尺寸。 2013年4月8日-4月12日：主要零件結構設計和尺寸計算。 2013年4月15日-4月19日：初步繪制模具裝配圖。 2013年4月22日-4月26日：修改模具裝配圖。 2013年4月29日-5月3日：繪制模具主要零件的零件圖，不少于5個。 2013年5月6日-5月10日：填寫沖壓工藝卡片等。 2013年5月13日-5月17日：完成設計說明書（論文）、摘要和小結。 2013年5月20日-5月25日：整理所有資料，打印后上交指導教師，準備答辯。 1．完成模具裝配圖：2張（A0或A1）； 2．零件圖：主要非標準件零件圖（不少于5張）； 3．冷沖壓工藝卡片：1張； 4．設計說明書：1份； 5．翻譯8000以上外文印刷字符或譯出約5000左右漢字的有關技術資料或專業(yè)文獻，內容要盡量結合課題。 特色或創(chuàng)新之處 一副級進模上可對形狀十分復雜的沖壓件進行沖裁、彎曲、拉深成型等工序，故生產(chǎn)率高，便于實現(xiàn)機械化和自動化，適于大批量生產(chǎn)。由于采用帶料進行連續(xù)沖壓，所以操作方便安全。在本設計課題中，主要是解決沖半圓孔和關鍵部分尺寸精度，比如說支撐板的半圓孔的大小只有r1.5mm，厚度也只有1.6mm，還有該模具有兩個90度的彎角。但可以通過提高模具結構精度，改進模具零件結構來解決關鍵部分和孔等一系列尺寸精度問題。 已具備的條件和尚需解決的問題 已具備的條件：我們已經(jīng)知道此次設計的模是連續(xù)模，支撐板的尺寸也已經(jīng)告訴我們，現(xiàn)在所需要的是計算出模具的尺寸，選擇材料等。 尚需解決的問題：如何提高模具結構精度。（如導柱的設計，定位銷的設計）在大批量生產(chǎn)過程中如何保證零件不發(fā)生塑性變形。 指導教師意見 指導教師簽名： 年 月 日 教研室（學科組、研究所）意見 教研室主任簽名： 年 月 日 系意見 主管領導簽名： 年 月 日 英文原文 Die Life of cold stamping die and influence 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. Cold stamping mould convex, concave die size and distribution of the clearance degree directly affect the quality of the blanking pieces and the length of the service life of the die. In guarantee blanking pieces space is mould manufacturing assembly very important link, and assembly quality will directly influence the convex, concave die if the clearance between the uniform. Such as the process of convex, concave die size precision although already meet the requirements, but in assembling if adjustment is bad, can cause clearance does not even, rushed out of the spare parts of the raw edges. Even rushed out of unqualified parts. The mold assembly is key to control convex, concave die of relative positions, in order to ensure that the convex, concave die, uniform and the clearance between the right to rush out of qualified parts. 1. Die before assembly the problems that should be paid attention[2] Convex, concave die and mould parts itself is clearance of the precision, and the assembly of the assembly process is reasonable. In order to ensure that the position of the convex, concave die correctly and gaps even, mould design, processing to assembly from the whole link should pay attention to the following questions： （1）Convex, concave die design and manufacture of the right Design should be based on the above all when die cutting the section of a quality, service life of die factors such as the reasonable selection of convex, concave die clearance. And to consider the mould in the process of using that gap wear increases, general in the design the least reasonable clearance when mould. And in the manufacturing process can ensure the parts processing precision and quality, in the assembly process ensure convex, concave die gap even, this for processing complex shape is very key parts. （2）Assembly method the choice should be reasonable Die assembly method include roughly assembly method and direct with assembly method. Before the assembly must be carefully study mold assembly drawing, full consideration and analysis of the structure characteristics of punching die, die parts processing technology and processing accuracy etc, in order to choose convenient, accurate and reliable assembly method to ensure the quality of blanking pieces. 2. Convex, concave die gap between the control and adjustment of the method[3] Convex, concave die clearance control, should according to die structure, clearance size, blanking pieces of quality and practical assembly condition to selected. Convex, concave die gap between the control and adjustment method have the following kinds. （1）Pervious to light method Will convex, concave die after molmerged, shone a light on the underside, observe the convex, concave die around through light and distribution to judge the size of the clearance and uniformity. If not even, to adjust to evenly between fixed again, this method is suitable for small gap plate stamping die. （2）Feeler method Will convex, concave die after molmerged, convex, concave die into the thickness of unilateral clearance feeler convex, concave die gaps in each direction. Then tighten the screw on mode. Finally put paper to stamping and will last mould seat and fixed on board with drilling, reaming positioning pin hole, and at a pin location. （3）Gaskets DiaoZhengFa Gasket adjustment method is simple, convenient, clearance is used widely. As shown in figure 1 shows, the mat with good contour mat iron, will gaskets wrapped in the punch to the punch into the concave mould, observe the convex, concave die clearance condition. If clearance does not even, with striking the protruding models of fixed plate method clearance adjustment, then tighten the screw on mode. Finally put paper to stamping, observation on paper cutting around burr and even rate to judge whether clearance convex, concave die even, to adjust the gap until cutting burr uniform so far. Finally the mould seat and the plate with drilling, reaming positioning pin hole, and enter the pin location. This method widely used cutting materials focusing thick large clearance and bending stamping, deep drawing mould clearance control. (4) Chemical method When the convex, concave die complex shape, the use of the above several methods more difficult to adjust the gap, the chemical method can be used to control the gap, the plating method is used. Plating method is the punch in the work surface coated with copper or zinc instead of washers. The plating thickness and unilateral gap is same, blade people concave die hole, and check the move without block phenomenon can assembly tighten. Coating in use process will die fall off naturally, need not removed. This uniform coating, can improve the uniformity of assembling clearance. (5) Technology DiaoZhengFa measures The main technological measures to adjust the gap between two kinds of the mould method: 1. Size method Processing of the punch, will the punch front-end appropriate lengthen, extended period of section size and sunken model hole processing to the same size. Assembly, make the punch into female model hole, natural form the cutting clearance, and then to the punch with fixed together with the punch mould seat on board with the pin for fixed and will last longer period of the punch front can remove form even clearance. 2. Positioning hole method Process positioning hole method and the inside of the progressive die principle about. Processing, the punch in fixed board and concave die on the same position processing two positioning hole, can will locate hole and the mold cavity a cut out. Assembly, in the positioning hole insert pins to ensure that gap. (6) Standard model method According to the drawing wedm in advance in processing a standard model or the qualified stamping parts, to adjust the assembly put it in between convex, concave die, upper and lower die relative motion can be reasonable degree when appropriate. (7) Measurement method Measuring method of the measuring tool have feeler. A feeler method after the adjustment convex, concave die clearance good uniformity, it is the commonly used method. Assembly, the punch in the concave die in the hole, convex, concave die according to the size of the clearance choose different specifications of the feeler insert convex, concave die clearance, inspection concave die around the blade gap everywhere, and according to the measured results adjustment. If the adjustment of the punch fixed board knock until adjust good so far. (8) Adjustment method of repair match means Die in use after period of time, because the convex, concave die normal wear and tear. To working parts inspection, if products produce burr, convex, concave die dull and collapse the blade factors, it is because of the convex, concave die clearance for wear changed, namely bigger or not even. To make the convex, concave die restored to the original gap value out of parts can use the following method to qualified for repair match means. 1. Convex, concave die clearance greaten repair match means method General dies in use after period of time, because normal wear will make convex, concave die gap increase gradually, thus to make the work and so on a series of problems produced burr. This kind of circumstance, can use first thickness is equal to one of the KuaiGui insert gap between the convex, concave die, if convex, concave die clearance does not too big, the grinding work part of the blade continue to use, can improve the qual