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編號
無錫太湖學(xué)院
畢業(yè)設(shè)計（論文）
相關(guān)資料
題目： 啟動電機殼體冷沖壓工藝
及模具設(shè)計
信機 系 機械工程及自動化專業(yè)
學(xué) 號： 0923279
學(xué)生姓名： 李鵬飛
指導(dǎo)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(shè)計（論文）開題報告
二、畢業(yè)設(shè)計（論文）外文資料翻譯及原文
三、學(xué)生“畢業(yè)論文（論文）計劃、進(jìn)度、檢查及落實表”
四、實習(xí)鑒定表
無錫太湖學(xué)院
畢業(yè)設(shè)計（論文）
開題報告
題目： 啟動電機殼體冷沖壓工藝及模具設(shè)計
信機 系 機械工程及自動化 專業(yè)
學(xué) 號： 0923279
學(xué)生姓名： 李鵬飛
指導(dǎo)教師： 鐘建剛 （職稱：副教授）
（職稱： ）
2012年11月20日
課題來源
來源于無錫毅立模具有限公司，是電器產(chǎn)品上的一個零件。
課題來源于生產(chǎn)實際，探討沖壓加工中較常見零件的工藝方法和結(jié)構(gòu)設(shè)計。課題涉及知識面較廣，且設(shè)計要求較高，對學(xué)生的設(shè)計能力，特別是思考能力是一個很好的鍛煉。課題研究內(nèi)容包括機械工程學(xué)科的力學(xué)，材料學(xué)，機械原理，機械設(shè)計，公差與互換性，機械制造工藝等知識，特別鍛煉學(xué)生規(guī)范性設(shè)計的能力。使學(xué)生能得到全面的鍛煉。課題要求學(xué)生具備較強的機構(gòu)設(shè)計能力和創(chuàng)新能力，對學(xué)生是一個挑戰(zhàn)。課題為典型的機械設(shè)計類課題，涉及機械知識全面，與工程機械專業(yè)方向結(jié)合緊密。
科學(xué)依據(jù)（包括課題的科學(xué)意義；國內(nèi)外研究概況、水平和發(fā)展趨勢；應(yīng)用前景等）
（1）課題科學(xué)意義
沖壓模具作為一種生產(chǎn)工具已經(jīng)運用到各行各業(yè)，其發(fā)展快，模具需求量之多，是前所未有的。當(dāng)今，在國民經(jīng)濟的各個工業(yè)部門。都越來越多的依靠模具來進(jìn)行生產(chǎn)加工，模具已成為國民經(jīng)濟的基礎(chǔ)工業(yè)，已成為當(dāng)代工業(yè)的基本手段和工藝發(fā)展手段之一?，F(xiàn)代工業(yè)產(chǎn)品的品種和生產(chǎn)效益的提高，是高技術(shù)含量的社會產(chǎn)品，其價值和價格主要取決于模具材料、加工、外購件的勞動與消耗三項直接發(fā)生的費用和模具設(shè)計與試模等技術(shù)費用，后者是模具價值與市場價格的主要組成部分，其中一部分技術(shù)價值計入了市場價格，而更大的一部分價值，則是模具用戶和產(chǎn)品用戶受惠變?yōu)樯鐣б妗Ｈ珉娨暀C用模，其模具費用為產(chǎn)品價格的1/3000~1/5000，盡管模具的一次投資較大，但大批量生產(chǎn)后，其模具成本占很小的部分，甚至可以忽略不計，而實際上，很高的模具價格為社會所擁有，變成了社會財富。所以本模具設(shè)計擁有很高的現(xiàn)實意義。
（2）研究狀況及其發(fā)展前景
目前我國模具市場總體趨勢平穩(wěn)向上。目前，國內(nèi)市場對中高檔家電、汽車、塑料制品模具的需求量很大，但要求國產(chǎn)模具必須在質(zhì)量、交貨期等方面滿足用戶的需求。我國加入WTO后，伴隨著世界經(jīng)濟的一體化浪潮，全球制造業(yè)加速向中國大陸地區(qū)轉(zhuǎn)移已是大勢所趨，中國也將逐步發(fā)展成為世界級的制造業(yè)基地。中低檔的模具國際市場潛力十分巨大，只要國產(chǎn)模具的質(zhì)量能夠有提高，交貨期能夠保證，模具出口的前景是十分樂觀的。優(yōu)勢明顯的廣東特別是珠三角地區(qū)，將在十年之內(nèi)發(fā)展成為
世界模具生產(chǎn)中心。同時，由于近年來我國每年用近10億美元進(jìn)口模具，其中精密、大型、復(fù)雜、長壽命模具占多數(shù)，所以從減少進(jìn)口角度出發(fā)，這類高檔模具在市場的分額比例也將逐步增大?，F(xiàn)代模具其高技術(shù)、人才密集、高技術(shù)背景下的工藝密集型工業(yè)的特點，是在新型工業(yè)化道路上走在前面的產(chǎn)業(yè)，模具作為重要的制造裝備行業(yè)在為各行各業(yè)服務(wù)的同時，也直接為高新技術(shù)產(chǎn)業(yè)服務(wù)，模具在制造業(yè)產(chǎn)品研發(fā)、創(chuàng)新和生產(chǎn)中所具有的獨特的重要地位，使得模具制造能力和水平的高低也成為國家創(chuàng)新能力的重要標(biāo)志。
隨著電子、信息等高新技術(shù)的不斷發(fā)展，模具CAD/CAE/CAM正向集成化、三維化、智能化和網(wǎng)絡(luò)化方向發(fā)展。模具CAD/CAE/CAM技術(shù)是模具設(shè)計、制造技術(shù)的發(fā)展方向，模具和工件的檢測數(shù)字、模具軟件功能集成化、模具設(shè)計、分析及制造的三維化、模具產(chǎn)業(yè)的逆向工程以及模具軟件應(yīng)用的網(wǎng)絡(luò)化是主趨勢。
研究內(nèi)容
本課題研究的是啟動電機殼體沖壓模具設(shè)計，要求其材料08F鋼，采用大批量生產(chǎn)，精度要求高。通過合理的設(shè)計凸凹模，選擇合理的標(biāo)準(zhǔn)模架，制造出符合要求的制件。
（1）查閱有關(guān)模具設(shè)計方面的資料，翻譯與模具設(shè)計相關(guān)的英文文獻(xiàn)；
（2）對工件進(jìn)行沖壓成型工藝分析，選擇合理的設(shè)計方案；
（3）進(jìn)行必要的參數(shù)計算，確定出正確的設(shè)計參數(shù)；
（4）在計算正確的基礎(chǔ)上設(shè)計沖壓成型模具；
（5）撰寫出一份與自己設(shè)計相配套的設(shè)計說明書。
擬采取的研究方法、技術(shù)路線、實驗方案及可行性分析
1、分析沖壓件的工藝性，確定工藝方案。
根據(jù)設(shè)計題目，分析沖壓件成型的結(jié)構(gòu)工藝性，分析沖壓件的形狀特點、精度要求等。在分析了沖壓件的工藝性后，可以列出幾種不同的沖壓方案，然后從產(chǎn)品質(zhì)量、生產(chǎn)效率、設(shè)備占有情況、模具制造難易程度和模具壽命高低、工藝成本等，確定最經(jīng)濟合理的工藝方案。
2、確定毛坯形狀、尺寸和下料方式
在最經(jīng)濟的原則下，確定毛坯形狀、尺寸和下料方式，并確定材料的消耗量。
3、確定沖壓模類型及結(jié)構(gòu)形式
4、進(jìn)行必要的工藝計算
5、選擇壓力機。
6、繪制模具總圖和非標(biāo)準(zhǔn)零件圖。
7、編寫設(shè)計計算所明書。
研究計劃及預(yù)期成果
研究計劃：
2012年11月12日-2012年12月2日：按照任務(wù)書要求查閱論文相關(guān)參考資料，填寫畢業(yè)設(shè)計開題報告書。
2012年12月3日-2012年12月31日：工作計劃、進(jìn)度。
2013年3月4日-2013年3月15日：查閱參考資料，學(xué)習(xí)并翻譯一篇與畢業(yè)設(shè)計相關(guān)的英文材料。
2013年3月18日-2013年4月5日：沖壓工藝設(shè)計，模具結(jié)構(gòu)設(shè)計，刃口尺寸和主要零件結(jié)構(gòu)設(shè)計和尺寸計算。
2013年4月15日-2013年5月3日：繪制模具裝配圖和零件圖。
2013年5月6日-2013年5月25日：工藝文件、畢業(yè)論文撰寫和修改工作。
預(yù)期成果：
1．完成模具裝配圖：2張（A0或A1）；
2．零件圖：主要非標(biāo)準(zhǔn)件零件圖（不少于5張）；
3．冷沖壓工藝卡片：1張；
4．設(shè)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(guān)技術(shù)資料或?qū)I(yè)文獻(xiàn)，內(nèi)容要盡量結(jié)合課題。
特色或創(chuàng)新之處
模具技術(shù)的特色應(yīng)該為適應(yīng)模具產(chǎn)品“交貨期短”、“精度高”、“質(zhì)量好”，“價格低”的要求服務(wù)。
創(chuàng)新之處是通過研究各種新型材料及先進(jìn)表明處理技術(shù)，使模具拋光技術(shù)向自動化，智能化發(fā)展。
已具備的條件和尚需解決的問題
已具備的條件：
1、工件的尺寸；
2、工件的價格方法;
3、工件的制造流程，工藝卡
尚需解決的問題：
拉深工藝的確定，沖壓力的大小和壓力機選擇，模具結(jié)構(gòu)的確定，模具的裝配工藝等等。
指導(dǎo)教師意見
指導(dǎo)教師簽名：
年 月 日
教研室（學(xué)科組、研究所）意見
教研室主任簽名：
年 月 日
系意見
主管領(lǐng)導(dǎo)簽名：
年 月 日
英文原文
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 o