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編 號 無錫太湖學院 畢 業(yè) 設 計 論 文 相 關 資 料 題目 電喇叭底座冷沖壓工藝及模具設計 信 機 系 機 械 工 程 及 自 動 化 專 業(yè) 學 號 0923219 學生姓名 王勇剛 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 電喇叭底座冷沖壓工藝及模具設計 信 機 系 機 械 工 程 及 自 動 化 專 業(yè) 學 號 0923219 學生姓名 王勇剛 指導教師 鐘建剛 職稱 副教授 職稱 2012 年 11 月 25 日 課題來源 來源于無錫金立有限公司 是電器產(chǎn)品上的一個零件 科學依據(jù) 包括課題的科學意義 國內(nèi)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 沖壓加工與其他加工方法相比 無論在技術方面 還是在經(jīng)濟方面 都具有許多 獨特的優(yōu)點 生產(chǎn)的制件所表現(xiàn)出來的高精度 高復雜程度 高一致性 高生產(chǎn)率和 低消耗 是其他加工制造方法所不能比擬的 但需要指出的是 由于進行沖壓成形加 工必須具備相應的模具 而模具是技術密集型產(chǎn)品 其制造屬單件小批量生產(chǎn) 具有 難加工 精度高 技術要求高 生產(chǎn)成本高 占產(chǎn)品成本的 10 30 等特點 所以 只有在沖壓零件生產(chǎn)批量大的情況下 沖壓成形加工的優(yōu)點才能充分體現(xiàn) 從而獲得 好的經(jīng)濟效益 在現(xiàn)代工業(yè)生產(chǎn)中 模具是重要的工藝裝備之一 它在鑄造 鍛造 沖壓 塑料 橡膠 玻璃 粉末冶金 陶瓷制品等生產(chǎn)行業(yè)中得到了廣泛應用 由于采用模具進行 生產(chǎn)能提高生產(chǎn)效率 節(jié)約原材料 降低成本 并保證一定的加工質(zhì)量要求 所以 汽車 飛機 拖拉機 電器 儀表 玩具和日常品等產(chǎn)品的零部件很多都采用模具進 行加工 據(jù)國際技術協(xié)會統(tǒng)計 2011 年產(chǎn)品零件粗加工的 80 精加工的 60 都由模 具加工完成 沖壓主要是按工藝分類 可分為分離工序和成形工序兩大類 分離工序 也稱沖裁 其目的是使沖壓件沿一定輪廓線從板料上分離 同時保證分離斷面的質(zhì)量 要求 成形工序的目的是使板料在不破坯的條件下發(fā)生塑性變形 制成所需形狀和尺 寸的工件 本課題旨在提供一種能有效消除底座引起膜片產(chǎn)生的破壞性共振 使電喇 叭的聲音清脆 工作電流小 工作電壓變化范圍寬 基頻高 聲壓大 使用壽命長的 電喇叭底座 2 研究狀況及其發(fā)展前景 模具工業(yè)作為現(xiàn)代社會的一種新興工業(yè) 它能夠節(jié)約能源 節(jié)約原材料以及較高 的生產(chǎn)效率 它能夠保證比較高的加工精度等特點 模具市場在世界上大部分都是供 不應求的 它的市場需求量大致 580 億至 660 億美元之間 與此同時 模具工業(yè)在我 國也迎來了一輪新的發(fā)展前景 模具工業(yè)在我國最近幾年總產(chǎn)值保持 12 5 的年增長 率 截止至 2006 年底模具產(chǎn)值預計超過 550 億元 目前沖壓行業(yè)形成封閉內(nèi)部配套 導致各企業(yè)的沖壓件種類多 生產(chǎn)集中度低 規(guī)模小 易造成低水平的重復建設 難以滿足專業(yè)化分工生產(chǎn) 市場競爭力弱 為改 變現(xiàn)狀應該按沖壓件的大 中 小分門別類 成立幾個大型的沖壓零部件制造供應中 心及幾十個小而專的零部件工廠 加速發(fā)展數(shù)字化柔性成形技術 液壓成形技術 高 精度復合化成形技術 用信息化技術改造模具企業(yè) 發(fā)展重點在于大力推廣 CAD CAM CAE 一體化技術 特別是成形過程的計算機模擬分析和優(yōu)化技術 CAE 通過專業(yè)化道路 才能把沖壓零部件做大做強 成為國際上有競爭實力的沖壓零部件 供應商 研究內(nèi)容 生產(chǎn)能有效消除底座引起膜片產(chǎn)生的破壞性共振 使電喇叭的聲音清脆 工作電 流小 工作電壓變化范圍寬 基頻高 聲壓大 使用壽命長的電喇叭底座 試設計相 應的模具及其主要的零部件 工件結構分析 工藝分析 模具方案的論證 進行總體 結構設計 制定主要件的工藝規(guī)程 必須的工藝計算 制造工藝以及一定的技術經(jīng)濟 分析等 擬采取的研究方法 技術路線 實驗方案及可行性分析 研究方法 本論文采用查文獻資料與實踐做相結合的研究方法來電喇叭底座冷沖 壓工藝和模具設計 技術路線 在指導老師的指導下 確定實驗方案 根據(jù)實驗方案進行實驗操作 實驗方案如下 1 了解目前冷沖壓行業(yè)的工藝發(fā)展狀況 2 深入實踐 進企業(yè)了 解沖壓模具的現(xiàn)狀以及具體制作內(nèi)容 3 結合文獻 研究電喇叭底座的適用環(huán)境并 對制作條件做出定位 4 計算模具使用數(shù)據(jù) 繪制工程圖 5 試生產(chǎn)電喇叭底座 對比較預期功能是否實現(xiàn) 6 總結分析 得出最終報告 可行性分析 本論文的技術路線和實驗方案切實可行 結合企業(yè)實際生產(chǎn) 積極 投入 在實際是生產(chǎn)中得到論證和總結 研究計劃及預期成果 研究計劃 2012 年 11 月 12 日 2012 年 11 月 12 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 11 月 26 日 2012 年 12 月 31 日 工作計劃 進度 2013 年 2 月 13 日 2013 年 2 月 26 日 查閱參考資料 學習并翻譯一篇與畢業(yè)設計相 關的英文材料 2013 年 2 月 27 日 2013 年 3 月 25 日 沖壓工藝設計 模具結構設計 刃口尺寸和主 要零件結構設計和尺寸計算 2013 年 3 月 26 日 2013 年 5 月 3 日 繪制模具裝配圖和零件圖 2013 年 5 月 4 日 2013 年 5 月 16 日 工藝文件 畢業(yè)論文撰寫和修改工作 2013 年 5 月 17 日 2013 年 5 月 20 日 遞交畢業(yè)設計資料 準備答辯材料 預期成果 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?qū)I(yè) 文獻 內(nèi)容要盡量結合課題 特色或創(chuàng)新之處 嚴謹?shù)慕Y構設計計算 效果明顯 方便生產(chǎn) 能夠快速實現(xiàn)產(chǎn)品量產(chǎn) 采用固定某些參量 改變某些參量來研究問題的方法 思路清晰 簡潔明了 行 之有效 已具備的條件和尚需解決的問題 已具備的條件 設計方案思路已經(jīng)非常明確 已經(jīng)具備使用 UG Autocad 模型處理的知識 尚需解決的問題 使用 UG 三維建模的能力尚需加強 模具實際結構存在誤差 如何提高精度尚需深入研究 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 improvements 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 t