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河南機(jī)電高等專科學(xué)校 畢業(yè)設(shè)計(jì)任務(wù)書 系 部 材 料 工 程 系 專 業(yè) 模具設(shè)計(jì)與制造 學(xué) 生 姓 名 金猛 學(xué) 號 061304523 設(shè)計(jì)題目 焊片沖壓成形工藝及模具設(shè)計(jì) 起迄日期 2009 年 3 月 11 日 5 月 20 日 指導(dǎo)教師 原紅玲 2009 年 3 月 11 日 1 中文 4900 字 沖壓變 形 沖壓變形工藝可完成多種工序 其基本工序可分為分離工序和變形工序兩 大類 分 離 工 序 是 使 坯 料 的 一 部 分 與 另 一 部 分 相 互 分 離 的 工 藝 方 法 主 要 有 落 料 沖孔 切邊 剖切 修整等 其中有以沖孔 落料應(yīng)用最廣 變形工序是使坯 料的一部分相對另一部分產(chǎn)生位移而不破裂的工藝方法 主要有拉深 彎曲 局部成形 脹形 翻邊 縮徑 校形 旋壓等 從本質(zhì)上看 沖壓成形就是毛坯的變形區(qū)在外力的作用下產(chǎn)生相應(yīng)的塑 性 變形 所以變形區(qū)的應(yīng)力狀態(tài)和變形性質(zhì)是決定沖壓成形性質(zhì)的基本因素 因 此 根據(jù)變形區(qū)應(yīng)力狀態(tài)和變形特點(diǎn)進(jìn)行的沖壓成形分類 可以把成形性 質(zhì)相 同的成形方法概括成同一個類型并進(jìn)行系統(tǒng)化的研究 絕大多數(shù)沖壓成形時(shí)毛坯變形區(qū)均處于平面應(yīng)力狀態(tài) 通常認(rèn)為在板材表面上 不受外力的作用 即使有外力作用 其數(shù)值也是較小的 所以可以認(rèn)為垂直于 板面方向的應(yīng)力為零 使板材毛坯產(chǎn)生塑性變形的是作用于板面方向上相互垂 直的兩個主應(yīng)力 由于板厚較小 通常都近似地認(rèn)為這兩個主應(yīng)力在厚度方向 上是均勻分布的 基于這樣的分析 可以把各種形式?jīng)_壓成形中的毛坯變形區(qū) 的 受 力 狀 態(tài) 與 變 形 特 點(diǎn) 在 平 面 應(yīng) 力 的 應(yīng) 力 坐 標(biāo) 系 中 沖 壓 應(yīng) 力 圖 與 相 應(yīng) 的 兩 向 應(yīng) 變 坐 標(biāo) 系 中 沖 壓 應(yīng) 變 圖 以 應(yīng) 力 與 應(yīng) 變 坐 標(biāo) 決 定 的 位 置 來 表 示 也 就 是 說 沖 壓 應(yīng) 力 圖 與 沖 壓 應(yīng) 變 圖 中 的 不 同 位 置 都 代 表 著 不 同 的 受 力 情 況 與 變 形 特 點(diǎn) 1 沖 壓 毛 坯 變 形 區(qū) 受 兩 向 拉 應(yīng) 力 作 用 時(shí) 可 以 分 為 兩 種 情 況 即 0 t 0 和 0 t 0 再這兩種情況下 絕對值最大的應(yīng)力都是拉應(yīng)力 以下 對這兩種情況進(jìn)行分析 1 當(dāng) 0 且 t 0 時(shí) 安全量理論可以寫出如下應(yīng)力與應(yīng)變的關(guān)系式 1 1 m m t t m k 式中 t 分別是軸對稱沖壓成形時(shí)的徑向主應(yīng)變 切向主應(yīng)變 和 厚度方向上的主應(yīng)變 t 分別是軸對稱沖壓成形時(shí)的徑向主應(yīng)力 切向主應(yīng)力和厚度 方向上的主應(yīng)力 m 平均應(yīng)力 m t 3 k 常數(shù) 在平面應(yīng)力狀態(tài) 式 1 1 具有如下形式 2 3 2 3 2 t 3 t t k 1 2 因 為 0 所以必定有 2 0 與 0 這 個 結(jié) 果 表 明 在 兩 向 拉 應(yīng) 力 的 平 面 應(yīng) 力 狀 態(tài) 時(shí) 如 果 絕 對 值 最 大 拉 應(yīng) 力 是 則 在 這 個 方 向 上 的 主 應(yīng)變一定是正應(yīng)變 即是伸長變形 又因?yàn)?0 所以必定有 t 0 與 t2 時(shí) 0 當(dāng) 0 的變化范圍是 0 在雙向等拉力狀態(tài)時(shí) 有 式 1 2 得 0 及 t 0 且 t 0 時(shí) 有式 1 2 可知 因?yàn)?0 所以 1 定有 2 0 與 0 這個結(jié)果表明 對于兩向拉應(yīng)力的平面應(yīng)力狀 態(tài) 當(dāng) 的絕對值最大時(shí) 則在這個方向上的應(yīng)變一定時(shí)正的 即一定是 伸長變形 又因?yàn)?0 所以必定有 t 0 與 t 0 當(dāng) 0 的變化范圍是 0 當(dāng) 時(shí) 0 也 就 是 在雙 向等拉力狀態(tài)下 在兩個拉應(yīng)力方向上產(chǎn)生數(shù)值相同的伸長變形 在受單 向 拉應(yīng)力狀態(tài)時(shí) 當(dāng) 0 時(shí) 2 也就是說 在受單向拉應(yīng)力狀態(tài) 下 其變形性質(zhì)與一般的簡單拉伸是完全一樣的 這種變形與受力情況 處于沖壓應(yīng)變圖中的 AOC 范圍內(nèi) 見圖 1 1 而 在沖壓應(yīng)力圖中則處于 AOH 范圍內(nèi) 見圖 1 2 上述兩種沖壓情況 僅在最大應(yīng)力的方向上不同 而兩個應(yīng)力的性質(zhì)以及 它們引起的變形都是一樣的 因此 對于各向同性的均質(zhì)材料 這兩種變形是 完全相同的 1 沖壓毛坯變形區(qū)受兩向壓應(yīng)力的作用 這種變形也分兩種情況分析 即 o t 0 和 0 t 0 1 當(dāng) 0 且 t 0 時(shí) 有 式 1 2 可 知 因 為 0 一定 3 有 2 0 與 0 這個結(jié)果表明 在兩向壓應(yīng)力的平面應(yīng)力狀態(tài)時(shí) 如果 4 絕對值最大拉應(yīng)力是 0 則 在 這 個 方 向 上 的 主 應(yīng) 變 一 定 是 負(fù) 應(yīng) 變 即 是 壓 縮變形 又因?yàn)?0 與 t 0 即在板料厚度 方 向上的應(yīng)變是正的 板料增厚 在 方向上的變形取決 于 與 的數(shù)值 當(dāng) 2 時(shí) 0 當(dāng) 2 時(shí) 0 當(dāng) 0 這時(shí) 的變化范圍是 與 0 之間 當(dāng) 時(shí) 是 雙 向 等 壓 力 狀 態(tài) 時(shí) 故有 0 當(dāng) 0 時(shí) 是受單向壓應(yīng)力狀態(tài) 所以 2 這種變形情況處于沖壓應(yīng)變圖中的 EOG 范 圍 內(nèi) 見 圖 1 1 而 在 沖 壓 應(yīng) 力 圖 中則處于 COD 范圍內(nèi) 見圖 1 2 2 當(dāng) 0 且 t 0 時(shí) 有 式 1 2 可 知 因 為 0 所 以 一定有 2 0 與 0 這個結(jié)果表明 對于兩向壓應(yīng)力的平面應(yīng) 力狀 態(tài) 如果絕對值最大是 則在這個方向上的應(yīng)變一定時(shí)負(fù)的 即一 定是壓 縮變形 又因?yàn)?0 與 t 0 即在板料厚度 方 向上的應(yīng)變是正的 即為壓縮變形 板厚增大 在 方向上的變形取決 于 與 的數(shù)值 當(dāng) 2 時(shí) 0 當(dāng) 2 0 當(dāng) 0 這時(shí) 的數(shù)值只能在 0 之間變化 當(dāng) 時(shí) 是雙 向 等壓力狀態(tài) 所以 0 這種變形與受力情況 處于沖壓應(yīng)變圖中的 GOL 范圍內(nèi) 見圖 1 1 而在沖壓應(yīng)力圖中則處于 DOE 范圍內(nèi) 見圖 1 2 1 沖 壓 毛 坯 變 形 區(qū) 受 兩 個 異 號 應(yīng) 力 的 作 用 而 且 拉 應(yīng) 力 的 絕 對 值 大 于 壓 應(yīng) 力的絕對 值 這種變形共有兩種情況 分別作如下分析 1 當(dāng) 0 時(shí) 由 式 1 2 可 知 因 為 0 所以一定有 2 0 及 0 這個結(jié)果表明 在異號 的 平面應(yīng)力狀態(tài)時(shí) 如果絕對值最大應(yīng)力是拉應(yīng)力 則在這個絕對值最大的 拉應(yīng) 力方向上應(yīng)變一定是正應(yīng)變 即是伸長變形 又因?yàn)?0 所 以 必 定 有 0 0 0 時(shí) 由式 1 2 可知 用與 前 項(xiàng) 相 同 的 方 法 分 析 可 得 0 即 在 異 號 應(yīng) 力 作 用 的 平 面 應(yīng) 力 狀 態(tài) 下 如 果 絕 對值最大應(yīng)力是拉應(yīng)力 則 在 這 個 方 向 上 的 應(yīng) 變 是 正 的 是 伸 長 變 形 而 在 壓應(yīng)力 方 向 上 的 應(yīng) 變 是 負(fù) 的 0 0 0 時(shí) 由式 1 2 可知 因?yàn)?0 所以一定有 2 0 及 0 0 必定有 2 0 即在拉應(yīng)力方向 上 的應(yīng)變是正的 是伸長變形 這時(shí) 的變化范圍只能在 與 0 的范圍內(nèi) 當(dāng) 時(shí) 0 0 0 時(shí) 由式 1 2 可知 用 與前 項(xiàng)相同的方法分析可得 0 0 AON GOH 伸長類雙向受拉 o 0 0 o AOC AOH 伸長類 o EOG COD 壓縮類雙向受壓 o 0 0 o MON FOG 伸長類異號應(yīng)力 o 0 LOM EOF 壓縮類 COD AOB 伸長類異號應(yīng)力 o 0 DOE BOC 壓縮類 表 1 2 伸長類成形與壓縮類成形的對比 項(xiàng)目 伸長類成形 壓縮類成形 9 變形區(qū)質(zhì)量問題的表 現(xiàn)形式 變形程度過大引起變形區(qū) 產(chǎn)生破裂現(xiàn)象 壓力作用下失穩(wěn)起皺 成形極限 1 主要取決于板材的塑 性 與厚度無關(guān) 2 可用伸長率及成形極 限 DLF 判斷 1 主要取決于傳力區(qū)的 承載能力 2 取決于抗失穩(wěn)能力 3 與板厚有關(guān) 變形區(qū)板厚的變化 減薄 增厚 提高成形極限的方法 1 改善板材塑性 2 使變形均勻化 降低局 部變形程度 3 工序間熱處理 1 采用多道工序成形 2 改變傳力區(qū)與變形區(qū) 的力學(xué)關(guān)系 3 采用防起皺措施 擴(kuò)口 圖 1 3 沖壓應(yīng)變圖 1 0 圖 1 3 體系化研究方法舉例 1 1 Categories of stamping forming Many deformation processes can be done by stamping the basic processes of the stamping can be divided into two kinds cutting and forming Cutting is a shearing process that one part of the blank is cut form the other It mainly includes blanking punching trimming parting and shaving where punching and blanking are the most widely used Forming is a process that one part of the blank has some displacement form the other It mainly includes deep drawing bending local forming bulging flanging necking sizing and spinning In substance stamping forming is such that the plastic deformation occurs in the deformation zone of the stamping blank caused by the external force The stress state and deformation characteristic of the deformation zone are the basic factors to decide the properties of the stamping forming Based on the stress state and deformation characteristics of the deformation zone the forming methods can be divided into several categories with the same forming properties and to be studied systematically The deformation zone in almost all types of stamping forming is in the plane stress state Usually there is no force or only small force applied on the blank surface When it is assumed that the stress perpendicular to the blank surface equal to zero two principal stresses perpendicular to each other and act on the blank surface produce the plastic deformation of the material Due to the small thickness of the blank it is assumed approximately that the two principal stresses distribute uniformly along the thickness direction Based on this analysis the stress state and 10 the deformation characteristics of the deformation zone in all kind of stamping forming can be denoted by the point in the coordinates of the plane princ ipal stress diagram of the stamping stress and the coordinates of the corresponding plane principal stains diagram of the stamping strain The different points in the figures of the stamping stress and strain possess different stress state and deformation characteristics 1 When the deformation zone of the stamping blank is subjected toplanetensile stresses it can be divided into two cases that is 0 t 0and 0 t 0 In both cases the stress with the maximum absolute value is always a tensile stress These two cases are analyzed respectively as follows 2 In the case that 0and t 0 according to the integral theory the relationships between stresses and strains are m m t t m k 1 1 where t are the principal strains of the radial tangential and thickness directions of the axial symmetrical stamping forming and tare the principal stresses of the radial tangential and thickness directions of the axial symmetrical stamping forming m is the average stress m t 3 k i s a constant In plane stress state Equation 1 1 3 2 3 2 t 3 t t k 1 2 Since 0 so 2 0 and 0 It indicates that in plane stress state with two axial tensile stresses if the tensile stress with the maximum absolute value is the principal strain in this direction must be positive that is the deformation belongs 11 to tensile forming In addition because 0 therefore t 0 and t2 0 and when 0 The range of is 0 In the equibiaxial tensile stress state according to Equation 1 2 0 and t 0 and t 0 according to Equation 1 2 2 0 and 0 This result shows that for the plane stress state with two tensile stresses when the absoluste value of is the strain in this direction must be positive that is it must be in the state of tensile forming Also because 0 therefore t 0 and t 0 and when 0 12 The range of is 0 When 0 that is in equibiaxial tensile stress state the tensile deformation with the same values occurs in the two tensile stress directions when 0 2 that is in uniaxial tensile stress state the deformation characteristic in this case is the same as that of the ordinary uniaxial tensile This kind of deformation is in the region AON of the diagram of the stamping strain see Fig 1 1 and in the region GOH of the diagram of the stamping stress see Fig 1 2 Between above two cases of stamping deformation the properties of and and the deformation caused by them are the same only the direction of the maximum stress is different These two deformations are same for isotropic homogeneous material 1 When the deformation zone of stamping blank is subjected to two compressive stresses and t 0 it can also be divided into two cases which are 0 t 0 and 0 t 0 1 When 0 and t 0 according to Equation 1 2 2 0 與 0 This result shows that in the plane stress state with two compressive stresses if the stress with the maximum absolute value is 0 the strain in this direction must be negative that is in the state of compressive forming Also because 0 and t 0 The strain in the thickness direction of the blank t is positive and the thickness increases The deformation condition in the tangential direction depends on the values 13 of and When 2 0 when 2 0 and when 0 The range of is 0 When it is in equibiaxial tensile stress state hence 0 when 0 it is in uniaxial tensile stress state hence 2 This kind of deformation condition is in the region EOG of the diagram of the stamping strain see Fig 1 1 and in the region COD of the diagram of the stamping stress see Fig 1 2 2 When 0and t 0 according to Equation 1 2 2 0 and 0 This result shows that in the plane stress state with two compressive stresses if the stress with the maximum absolute value is the strain in this direction must be negative that is in the state of compressive forming Also because 0 and t 0 The strain in the thickness direction of the blank t is positive and the thickness increases The deformation condition in the radial direction depends on the values of and When 2 0 when 2 0 and when 0 The range of is 0 When it is in equibiaxial tensile stress state hence 0 This kind of deformation is in the region GOL of the diagram of the stamping strain see Fig 1 1 and in the region DOE of the diagram of the stamping stress see Fig 1 2 3 The deformation zone of the stamping blank is subjected to two stresses with opposite signs and the absolute value of the tensile stress is larger than that of the compressive stress There exist two cases to be analyzed as follow 14 1 When 0 according to Equation 1 2 2 0 and 0 This result shows that in the plane stress state with opposite signs if the stress with the maximum absolute value is tensile the strain in the maximum stress direction is positive that is in the state of tensile forming Also because 0 therefore When then 0 0 0 according to Equation 1 2 by means of the same analysis mentioned above 0 that is the deformation zone is in the plane stress state with opposite signs If the stress with the maximum absolute value is tensile stress the strain in this direction is positive that is in the state of tensile forming The strain in the radial direction is negative When then 0 0 0 according to Equation 1 2 2 0 and 0 and 0 therefore 2 0 The strain in the tensile stress direction is positive or in the state of tensile forming The range of is 0 When then 0 0 0 according to Equation 1 2 and by means of the same analysis mentioned above When then 0 0 AON GOH TensileBiaxial tensile stress state 0 0 AOC AOH Tensile EOG COD Compress ive Biaxial compressive stress state 0 0 MON FOG TensileStateof stress with opposite signs 0 LOM EOF Compress ive COD AOB TensileState of stress with opposite signs 0 DOE BOC Compress ive 20 Table 1 2 Comparison between tensile and compressive forming Item Tensile forming Compressive forming Representation of the quality problem in the deformation zone Fracture in the deformation zone due to excessive deformation Instability wrinkle caused by compressive stress Forming limit 3 Mainly depends on the plasticity of the material and is irrelevant to the thickness 4 Can be estimated by extensibility or the forming limit DLF 4 Mainly depends on the loading capability in the force transferring zone 5 Depends on the anti instability capability 6 Has certain relationship to the blank thickness Variation of the blank thickness in the deformation zone Thinning Thickening Methods to improve forming limit 4 Improve the plasticity of the material 5 Decrease local 4 Adopt multi pass forming process 5 Change t he mechanics 21 deformation and increase deformation uniformity 6 Adopt a n intermediate heat treatment process relationship between the force transferring and deformation zones 6 Adopt anti wrinkle measures Fig 1 1 Diagram of stamping strain 4 4 expanding Fig 1 2 Diagram of stamping stress 22 Fig 1 3 Examples for systematic research methods 焊片沖壓成形工藝及模具設(shè)計(jì) 摘要 本設(shè)計(jì)題目為復(fù)合模具設(shè)計(jì) 體現(xiàn)了典型復(fù)合模具設(shè)計(jì)的要求 內(nèi) 容與方向 通過工藝分析 工藝方案的確定 確定了模具設(shè)計(jì)的方向 對 毛坯尺寸的確定 計(jì)算沖裁力 來計(jì)算壓力中心 選擇壓力機(jī)和壓力機(jī)的噸 位 復(fù)合模是指沖床在一次行程中 完成落料 沖孔等多個工序的一種模具 結(jié)構(gòu) 相對其他冷沖壓模具結(jié)構(gòu)而言 它具有以下一些優(yōu)點(diǎn) 工件同軸度 較好 表面平直 尺寸精度較高 生產(chǎn)效率高 受條料外形尺寸的精度 限制較小 但需考慮的問題是 模具零部件加工制造比較困難 成本較高 并且凸凹模容易受到最小壁厚的限制 本設(shè)計(jì)運(yùn)用了沖裁工藝及模具設(shè)計(jì)的基礎(chǔ)知識 首先 分析了板材的性能 要求 為選去模具的類型做了準(zhǔn)備 同時(shí) 也為凸 凹模的材料有了依據(jù) 后 分析沖裁件的特征 確定了模具設(shè)計(jì)參數(shù) 選擇其他零件及卸料裝置 也為凸 凹模尺寸的計(jì)算有了根據(jù) 還有零件的加工工藝 關(guān)鍵詞 復(fù)合模 工藝性能 凸凹模 模具制造 Soldering lug ramming superposable die design Abstract This design topic designs for The piercing die design of the dunnage backup plate body now typical model The piercing die design of request contents and direction Pass the craft analysis the craft project really settles making sure the direction of The piercing die design really settling to the blank product size computing to the blanking pressure compute the pressure center choose the tonnage of the pressure machine and the pressure machine The compound mold mean the punching machine is in a route of travel completing to fall to anticipate a kind of molding tool structure of several work prefaces of etc of blunt bore Opposite and other cold hurtle to press the molding tool structure but speeches it has following some advantageses The work piece is together the stalk degree is better the surface is straight and even the size accuracy is higher The produces the efficiency high be subjected to the anticipates the shape size of accuracy limit smaller But need the problem of the consideration is The molding tool zero partses process the manufacturing more difficulty the cost is higher and the convex and cave mold is subjected to the thick restrict of minimum wall easily This design made use of to hurtle foundation knowledge of blanking craft and The piercing die design First Analyzed the function request of the plank material did preparation for the type that chooses to the die is also convex in the meantime the material of punch and cavitydie had a basis Analyze to hurtle a characteristic of cut the piece behind make sure the molding tool design parameter choose other spare partses and unload to anticipate device Is also convex the calculation of the cave mold size had a basis Still there is spare parts to process a craft Keywords Compound mold craft function The convex and cave mold molding tool manufacturing 目 錄 1 緒論 1 1 1 沖壓的概念 特點(diǎn)及應(yīng)用 1 1 2 沖壓的基本工序及模具 2 1 3 沖壓技術(shù)的現(xiàn)狀及發(fā)展方向 3 2 制件的工藝性分析 7 2 1零件的工藝性分析 7 2 2沖裁件的精度與粗糙度 7 2 3沖裁件的材料 8 2 4確定工藝方案 8 3 沖壓模具總體結(jié)構(gòu)設(shè)計(jì) 9 3 1模具類型 9 3 2操作與定位方式 9 3 3卸料與出件方式 9 3 4模架類型及精度 9 4 沖壓模具工藝與設(shè)計(jì)計(jì)算 10 4 1排樣設(shè)計(jì)與計(jì)算 10 4 2設(shè)計(jì)沖壓力與壓力中心 初選壓力機(jī) 12 4 2 1沖裁力 12 4 2 2壓力中心 14 4 2 3計(jì)算凸凹模刃口尺寸及偏差 14 5 模具的總裝圖與零件圖 18 5 1根據(jù)前面的設(shè)計(jì)與分析 我們可以得出如級進(jìn)模具的總裝圖如附圖所示 18 5 2沖壓模具的零件圖 18 5 2 1凹模設(shè)計(jì) 18 5 2 2凸模設(shè)計(jì) 20 5 2 3選擇堅(jiān)固件及定位零件 23 5 2 4設(shè)計(jì)和選用卸料與出件零件 25 5 2 5選擇模架及其他模具零件 26 5 3 壓力機(jī)及閉合高度的校核 28 結(jié)論 29 致謝 30 參考文獻(xiàn) 31 河南機(jī)電高等?？茖W(xué)校 學(xué)生畢業(yè)設(shè)計(jì)中期檢查表 學(xué)生姓名 金猛 學(xué) 號 061304523 指導(dǎo)教師 原紅玲 課題名稱 焊片沖壓復(fù)合模設(shè)計(jì) 難易程度 偏難 適中 偏易選題情況 工作量 較大 合理 較小 任務(wù)書 有 無 開題報(bào)告 有 無符合規(guī)范化 的要求 外文翻譯質(zhì)量 優(yōu) 良 中 差 學(xué)習(xí)態(tài)度 出勤情況 好 一般 差 工作進(jìn)度 快 按計(jì)劃進(jìn)行 慢 中期工作匯 報(bào)及解答問 題情況 優(yōu) 良 中 差 中期成績評定 所在專業(yè)意見 負(fù)責(zé)人 年 月 日 1 沖壓變形 沖壓變形工藝可完成多種工序 其基本工序可分為分離工序和變形工序兩 大類 分離工序是使坯料的一部分與另一部分相互分離的工藝方法 主要有落料 沖孔 切邊 剖切 修整等 其中有以沖孔 落料應(yīng)用最廣 變形工序是使坯 料的一部分相對另一部分產(chǎn)生位移而不破裂的工藝方法 主要有拉深 彎曲 局部成形 脹形 翻邊 縮徑 校形 旋壓等 從本質(zhì)上看 沖壓成形就是毛坯的變形區(qū)在外力的作用下產(chǎn)生相應(yīng)的塑性 變形 所以變形區(qū)的應(yīng)力狀態(tài)和變形性質(zhì)是決定沖壓成形性質(zhì)的基本因素 因 此 根據(jù)變形區(qū)應(yīng)力狀態(tài)和變形特點(diǎn)進(jìn)行的沖壓成形分類 可以把成形性質(zhì)相 同的成形方法概括成同一個類型并進(jìn)行系統(tǒng)化的研究 絕大多數(shù)沖壓成形時(shí)毛坯變形區(qū)均處于平面應(yīng)力狀態(tài) 通常認(rèn)為在板材表面上 不受外力的作用 即使有外力作用 其數(shù)值也是較小的 所以可以認(rèn)為垂直于 板面方向的應(yīng)力為零 使板材毛坯產(chǎn)生塑性變形的是作用于板面方向上相互垂 直的兩個主應(yīng)力 由于板厚較小 通常都近似地認(rèn)為這兩個主應(yīng)力在厚度方向 上是均勻分布的 基于這樣的分析 可以把各種形式?jīng)_壓成形中的毛坯變形區(qū) 的受力狀態(tài)與變形特點(diǎn) 在平面應(yīng)力的應(yīng)力坐標(biāo)系中 沖壓應(yīng)力圖 與相應(yīng)的兩 向應(yīng)變坐標(biāo)系中 沖壓應(yīng)變圖 以應(yīng)力與 應(yīng)變坐標(biāo)決定的位置來表示 也就是說 沖壓 應(yīng)力圖與沖壓應(yīng)變圖中的不同位置都代表著不同的受力情況與變形特點(diǎn) 1 沖壓毛坯變形區(qū)受兩向拉應(yīng)力作用時(shí) 可以分為兩種情況 即 0 t 0 和 0 t 0 再這兩種情況下 絕對值最大的應(yīng)力都是拉應(yīng)力 以下 對這兩種情況進(jìn)行分析 1 當(dāng) 0且 t 0時(shí) 安全量理論可以寫出如下應(yīng)力與應(yīng)變的關(guān)系式 1 1 m m t t m k 式中 t 分 別 是 軸對稱沖壓 成 形時(shí) 的 徑向 主 應(yīng)變 切向主 應(yīng) 變 和厚度方向上的主 應(yīng)變 t 分 別 是 軸對稱沖壓 成 形時(shí) 的 徑向 主 應(yīng) 力 切向主 應(yīng) 力和厚度 方向上的主 應(yīng) 力 m 平均 應(yīng) 力 m t 3 k 常數(shù) 在平面 應(yīng) 力 狀態(tài) 式 1 1 具有如下形式 3 2 3 2 t 3 t t k 1 2 因?yàn)?0 所以必定有 2 0 與 0 這個結(jié) 果表明 在 兩向 2 拉應(yīng) 力的平面 應(yīng) 力 狀態(tài)時(shí) 如果 絕對 值 最大 拉應(yīng) 力是 則在這個方向上的主 應(yīng)變一定是正應(yīng)變 即是伸長變形 又因?yàn)?0 所以必定有 t 0 與 t2 時(shí) 0 當(dāng) 0 的變化范圍是 0 在雙向等拉力狀態(tài)時(shí) 有 式 1 2 得 0 及 t 0 且 t 0 時(shí) 有式 1 2 可知 因?yàn)?0 所以 1 定有 2 0 與 0 這個結(jié)果表明 對于兩向拉應(yīng)力的平面應(yīng)力狀 態(tài) 當(dāng) 的絕對值最大時(shí) 則在這個方向上的應(yīng)變一定時(shí)正的 即一定是 伸長變形 又因?yàn)?0 所以必定有 t 0 與 t 0 當(dāng) 0 的變化范圍是 0 當(dāng) 時(shí) 0 也就是 在 雙向等拉 力 狀態(tài)下 在 兩個拉應(yīng) 力方向 上產(chǎn) 生 數(shù) 值相同的伸 長變形 在受 單 向拉應(yīng) 力 狀態(tài)時(shí) 當(dāng) 0 時(shí) 2 也就是說 在受 單向拉應(yīng) 力 狀態(tài) 下 其 變形 性 質(zhì) 與一般的 簡單 拉伸是完全一 樣 的 這種變形與受力情況 處于沖壓應(yīng)變圖中的 AOC 范圍內(nèi) 見圖 1 1 而 在沖壓應(yīng)力圖中則處于 AOH 范圍內(nèi) 見圖 1 2 上述兩種沖壓情況 僅在最大應(yīng)力的方向上不同 而兩個應(yīng)力的性質(zhì)以及 它們引起的變形都是一樣的 因此 對于各向同性的均質(zhì)材料 這兩種變形是 完全相同的 1 沖壓毛坯變形區(qū)受兩向壓應(yīng)力的作用 這種變形也分兩種情況分析 即 t 0 和 0 t 0 1 當(dāng) 0 且 t 0 時(shí) 有式 1 2 可知 因 為 0 一定有 2 0 與 0 這個結(jié) 果表明 在 兩向壓應(yīng) 力的平面 應(yīng) 力 狀態(tài)時(shí) 如果 3 絕對 值最大 拉應(yīng) 力是 0 則在這個方向上的主應(yīng)變一定是負(fù)應(yīng)變 即是壓 縮變形 又因?yàn)?0 與 t 0 即在板料厚度方 向上的 應(yīng)變 是正的 板料增厚 在 方向上的變形取決于 與 的數(shù)值 當(dāng) 2 時(shí) 0 當(dāng) 2 時(shí) 0 當(dāng) 0 這時(shí) 的變化范圍是 與 0 之間 當(dāng) 時(shí) 是雙向等 壓 力狀態(tài) 時(shí) 故有 0 當(dāng) 0 時(shí) 是受 單 向 壓應(yīng) 力 狀態(tài) 所以 2 這種變形情況處于沖壓應(yīng)變圖中的 EOG 范圍內(nèi) 見圖 1 1 而在沖壓應(yīng)力圖 中則處于 COD 范圍內(nèi) 見圖 1 2 2 當(dāng) 0 且 t 0 時(shí) 有式 1 2 可知 因?yàn)?0 所以 一定有 2 0 與 0 這個結(jié)果表明 對于兩向 壓 應(yīng)力的平面應(yīng)力狀 態(tài) 如果絕對值最大是 則在這個方向上的應(yīng)變一定時(shí)負(fù)的 即一定是壓 縮變形 又因?yàn)?0 與 t 0 即在板料厚度方 向上的 應(yīng)變 是正的 即 為壓縮變形 板厚增大 在 方向上的變形取決于 與 的數(shù)值 當(dāng) 2 時(shí) 0 當(dāng) 2 0 當(dāng) 0 這時(shí) 的數(shù)值只能在 0 之間變化 當(dāng) 時(shí) 是 雙向 等壓力狀態(tài) 所以 0 這種變形與受力情況 處于沖壓應(yīng)變圖中的 GOL 范圍內(nèi) 見圖 1 1 而在沖壓應(yīng)力圖中則處于 DOE 范圍內(nèi) 見圖 1 2 1 沖壓毛坯變形區(qū)受兩個異號應(yīng)力的作用 而且拉應(yīng)力的絕對值大于壓應(yīng) 力的絕對 值 這種變形共有兩種情況 分別作如下分析 1 當(dāng) 0 時(shí) 由式 1 2 可知 因 為 0 所以一定 有 2 0 及 0 這個結(jié) 果表明 在異 號 的 平面 應(yīng) 力 狀態(tài)時(shí) 如果 絕對 值最大 應(yīng) 力是 拉應(yīng) 力 則在這個絕對值最大的拉應(yīng) 力方向上應(yīng)變一定是正應(yīng)變 即是伸長變形 又因?yàn)?0 所以必定有 0 0 0 時(shí) 由式 1 2 可知 用與前 項(xiàng)相同的方法分析可得 0 即在異 號應(yīng) 力作用的平面 應(yīng) 力 狀態(tài)下 如果 絕 對 值最大 應(yīng) 力是 拉應(yīng) 力 則在這個方向上的應(yīng)變是正的 是伸長變形 而在 壓應(yīng)力 方向上的應(yīng)變是負(fù)的 0 0 0 時(shí) 由式 1 2 可知 因 為 0 所以一定有 2 0 及 0 0 必定有 2 0 即在 拉應(yīng) 力方向上 的 應(yīng)變 是正的 是伸長變形 這時(shí) 的變化范圍只能在 與 0 的范圍內(nèi) 當(dāng) 時(shí) 0 0 0 時(shí) 由式 1 2 可知 用與前 項(xiàng)相同的方法分析可得 0 0 0 0 AON GOH 伸長類 AOC AOH 伸長類 雙向受壓 0 0 EOG COD 壓縮類 0 MON FOG 伸長 類 LOM EOF 壓縮類 異號應(yīng)力 0 COD AOB 伸長類 DOE BOC 壓縮類 7 變形區(qū)質(zhì)量問題的表 現(xiàn)形式 變形程度過大引起變形區(qū) 產(chǎn)生破裂現(xiàn)象 壓力作用下失穩(wěn)起皺 成形極限 1 主要取決于板材的塑 性 與厚度無關(guān) 2 可用伸長率及成形極 限 DLF 判斷 1 主要取決于傳力區(qū)的 承載能力 2 取決于抗失穩(wěn)能力 3 與板厚有關(guān) 變形區(qū)板厚的變化 減薄 增厚 提高成形極限的方法 1 改善板材塑性 2 使變形均勻化 降低局 部變形程度 3 工序間熱處理 1 采用多道工序成形 2 改變傳力區(qū)與變形區(qū) 的力學(xué)關(guān)系 3 采用防起皺措施 伸 長 類 成 形 脹 形 拉 深 翻 邊 壓 縮 類 成 形 壓 縮 類 成 形 擴(kuò) 口 拉 深 脹 形 伸 長 類 成 形 縮 口 縮 口 擴(kuò)口 4 4 翻 邊 圖 1 3 沖壓應(yīng)變圖 8 沖壓成形 極限 變形區(qū)的 成形極限 傳動區(qū)的 成形極限 伸長類 變 形 壓縮類 變 形 強(qiáng) 度 抗拉與抗壓 縮失衡能力 塑 性 抗縮頸 能 力 變形均 化與擴(kuò) 展能力 塑 性 抗起皺 能 力 變形力及 其 變 化 各向異性 值 硬化性能 變形抗力 化學(xué)成分 組 織 變形條件 硬化性能 應(yīng)力狀態(tài) 應(yīng)變梯度 硬化性能 模具狀態(tài) 力學(xué)性能 值與 值 相對厚度 化學(xué)成分 組 織 變形條件 圖 1 3 體系化研究方法舉例 9 Categories of stamping forming Many deformation processes can be done by stamping the basic processes of the stamping can be divided into two kinds cutting and forming Cutting is a shearing process that one part of the blank is cut form the other It mainly includes blanking punching trimming parting and shaving where punching and blanking are the most widely used Forming is a process that one part of the blank has some displacement form the other It mainly includes deep drawing bending local forming bulging flanging necking sizing and spinning In substance stamping forming is such that the plastic deformation occurs in the deformation zone of the stamping blank caused by the external force The stress state and deformation characteristic of the deformation zone are the basic factors to decide the properties of the stamping forming Based on the stress state and deformation characteristics of the deformation zone the forming methods can be divided into several categories with the same forming properties and to be studied systematically The deformation zone in almost all types of stamping forming is in the plane stress state Usually there is no force or only small force applied on the blank surface When it is assumed that the stress perpendicular to the blank surface equal to zero two principal stresses perpendicular to each other and act on the blank surface produce the plastic deformation of the material Due to the small thickness of the blank it is assumed approximately that the two principal stresses distribute uniformly along the thickness direction Based on this analysis the stress state and 10 the deformation characteristics of the deformation zone in all kind of stamping forming can be denoted by the point in the coordinates of the plane princ ipal stress diagram of the stamping stress and the coordinates of the corresponding plane principal stains diagram of the stamping strain The different points in the figures of the stamping stress and strain possess different stress state and deformation characteristics 1 When the deformation zone of the stamping blank is subjected toplanetensile stresses it can be divided into two cases that is 0 t 0and 0 t 0 In both cases the stress with the maximum absolute value is always a tensile stress These two cases are analyzed respectively as follows 2 In the case that 0and t 0 according to the integral theory the relationships between stresses and strains are m m t t m k 1 1 where t are the principal strains of the radial tangential and thickness directions of the axial symmetrical stamping forming and tare the principal stresses of the radial tangential and thickness directions of the axial symmetrical stamping forming m is the average stress m t 3 k is a constant In plane stress state Equation 1 1 3 2 3 2 t 3 t t k 1 2 Since 0 so 2 0 and 0 It indicates that in plane stress state with two axial tensile stresses if the tensile stress with the maximum absolute value is the principal strain in this direction must be positive that is the deformation belongs 11 to tensile forming In addition because 0 therefore t 0 and t2 0 and when 0 The range of is 0 In the equibiaxial tensile stress state according to Equation 1 2 0 and t 0 and t 0 according to Equation 1 2 2 0 and 0 This result shows that for the plane stress state with two tensile stresses when the absoluste value of is the strain in this direction must be positive that is it must be in the state of tensile forming Also because 0 therefore t 0 and t 0 and when 0 12 The range of is 0 When 0 that is in equibiaxial tensile stress state the tensile deformation with the same values occurs in the two tensile stress directions when 0 2 that is in uniaxial tensile stress state the deformation characteristic in this case is the same as that of the ordinary uniaxial tensile This kind of deformation is in the region AON of the diagram of the stamping strain see Fig 1 1 and in the region GOH of the diagram of the stamping stress see Fig 1 2 Between above two cases of stamping deformation the properties of and and the deformation caused by them are the same only the direction of the maximum stress is different These two deformations are same for isotropic homogeneous material 1 When the deformation zone of stamping blank is subjected to two compressive stresses and t 0 it can also be divided into two cases which are 0 t 0 and 0 t 0 1 When 0 and t 0 according to Equation 1 2 2 0 與 0 This result shows that in the plane stress state with two compressive stresses if the stress with the maximum absolute value is 0 the strain in this direction must be negative that is in the state of compressive forming Also because 0 and t 0 The strain in the thickness direction of the blank t is positive and the thickness increases The deformation condition in the tangential direction depends on the values 13 of and When 2 0 when 2 0 and when 0 The range of is 0 When it is in equibiaxial tensile stress state hence 0 when 0 it is in uniaxial tensile stress state hence 2 This kind of deformation condition is in the region EOG of the diagram of the stamping strain see Fig 1 1 and in the region COD of the diagram of the stamping stress see Fig 1 2 2 When 0and t 0 according to Equation 1 2 2 0 and 0 This result shows that in the plane stress state with two compressive stresses if the stress with the maximum absolute value is the strain in this direction must be negative that is in the state of compressive forming Also because 0 and t 0 The strain in the thickness direction of the blank t is positive and the thickness increases The deformation condition in the radial direction depends on the values of and When 2 0 when 2 0 and when 0 The range of is 0 When it is in equibiaxial tensile stress state hence 0 This kind of deformation is in the region GOL of the diagram of the stamping strain see Fig 1 1 and in the region DOE of the diagram of the stamping stress see Fig 1 2 3 The deformation zone of the stamping blank is subjected to two stresses with opposite signs and the absolute value of the tensile stress is larger than that of the compressive stress There exist two cases to be analyzed as follow 14 1 When 0 according to Equation 1 2 2 0 and 0 This result shows that in the plane stress state with opposite signs if the stress with the maximum absolute value is tensile the strain in the maximum stress direction is positive that is in the state of tensile forming Also because 0 therefore When then 0 0 0 according to Equation 1 2 by means of the same analysis mentioned above 0 that is the deformation zone is in the plane stress state with opposite signs If the stress with the maximum absolute value is tensile stress the strain in this direction is positive that is in the state of tensile forming The strain in the radial direction is negative When then 0 0 0 according to Equation 1 2 2 0 and 0 and 0 therefore 2 0 The strain in the tensile stress direction is positive or in the state of tensile forming The range of is 0 When then 0 0 0 according to Equation 1 2 and by means of the same analysis mentioned above When then 0 0 0 0 AON GOH Tensile AOC AOH Tensile Biaxial compressive stress state 0 0 EOG COD Compress ive 0 MON FOG Tensile LOM EOF Compress ive State of stress with opposite signs 0 COD AOB Tensile DOE BOC Compress ive 20 Table 1 2 Comparison between tensile and compressive forming Item Tensile forming Compressive forming Representation of the quality problem in the deformation zone Fracture in the deformation zone due to excessive deformation Instability wrinkle caused by compressive stress Forming limit 3 Mainly depends on the plasticity of the material and is irrelevant to the thickness 4 Can be estimated by extensibility or the forming limit DLF 4 Mainly depends on the loading capability in the force transferring zone 5 Depends on the anti instability capability 6 Has certain relationship to the blank thickness Variation of the blank thickness in the deformation zone Thinning Thickening Methods to improve forming limit 4 Improve the plasticity of the material 5 Decrease local 4 Adopt multi pass forming process 5 Change the mechanics 21 deformation and increase deformation uniformity 6 Adopt an intermediate heat treatment process relationship between the force transferring and deformation zones 6 Adopt anti wrinkle measures Fig 1 1 Diagram of stamping strain tensile forming bulging deep drawing flanging compressive forming compressive forming expanding deep drawing bulging tensile forming necking necking expanding 4 4 flanging Fig 1 2 Diagram of stamping stress 22 Ten sile for ming Com pres sion for ming St re ngth Cap abil ity of an ti w rinkle und er t he t ensi le and com pres sive st re sses Plasticity Cap abil ity of an ti n ecking Def orma tion uniformit y an d ex te nsion ca pa bility Pl as ticity Cap abil ity of an ti w rinkle Def orma tion for ce a nd i ts Ani sotr opy valu e of r Har deni ng c hara cter isti cs Deformation r es is ta nc e Che mist ry c ompo nent Str uctu re Deformation c on di ti on s Har deni ng c hara cter isti cs Sta te o f st ress Gradient of s tr ai n Har deni ng c hara cter isti cs Die sha pe Mechanical pr oe rt y The value of t he n a nd r Relative th ic kn es s Che mist ry c ompo nent Str uctu re Deformation c on di ti on s Fig 1 3 Examples for systematic research methods