止轉墊板冷沖壓工藝及其連續(xù)模設計-沖壓模具【含14張圖紙】

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無錫太湖學院 冷沖壓工藝卡片 零件名稱 止轉墊板 零件圖號 115010 材料牌號及規(guī)格 10鋼 0.7×25.4×L 毛坯種類 帶料 毛坯尺寸 25.4×L 每毛坯可制件數(shù) 1件/每22.52 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2個孔、側刃 J23-10 模具和自動送料機構 1 20 沖裁 沖內孔 J23-10 模具和自動送料機構 1 30 沖裁 落料 J23-10 模具和自動送料機構 1 40 沖裁 側刃 J23-10 模具和自動送料機構 1 50 檢驗 檢驗 班級 機械96 姓名 劉奎 學號 0923278 日期 2013.5.16 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： 止轉墊板冷沖壓工藝及連續(xù)模設計 信機 系 機械工程及自動化專業(yè) 學 號： 　　　0923278　　　　 學生姓名： 劉 奎 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：止轉墊板冷沖壓工藝及連續(xù)模設計 信機 系 機械工程及自動化 專業(yè) 學 號： 0923278 學生姓名： 劉奎 指導教師： 鐘建剛 （職稱：副教授） （職稱： ） 2012年11月20日 課題來源 來源于無錫海諾有限公司，是電器產(chǎn)品上的一個零件。 科學依據(jù) （1）課題科學意義 隨著當今科技的發(fā)展，?工業(yè)生產(chǎn)中模具的使用已經(jīng)越來越引起人們的重視，而被大量應用到工業(yè)生產(chǎn)中來。沖壓模具的自動送料技術也投入到實際的生產(chǎn)中，沖壓模具可以大大的提高勞動生產(chǎn)效率，減輕工人負擔，具有重要的技術進步意義和經(jīng)濟價值。 現(xiàn)在模具生產(chǎn)采用了一系列高新技術，如CAD/CAE/CAM/CAPP等技術、計算機網(wǎng)絡技術、激光技術、逆向工程和并行工程、快速成形技術及敏捷制造技術、高速加工及超精加工、微細加工、復合加工、表面處理技術等等。因此，模具工業(yè)已成為高新技術產(chǎn)業(yè)的一個重要組成部分。模具技術水平在很大程度上決定于人才的整體水平，而模具技術水平的高低，又決定著產(chǎn)品的質量、效益和新產(chǎn)品的開發(fā)能力，因此模具技術已成為衡量一個國家產(chǎn)品制造水平高低的重要標志！ 如今汽車、電子、電器、航空、儀表、輕工、塑料、日用品等工業(yè)部門極其依賴模具。沒有模具，就沒有高質量的產(chǎn)品。模具不是一般的工藝裝備，而是技術密集型的產(chǎn)品，工業(yè)發(fā)達國家把模具作為機械制造方面的高科技產(chǎn)品來對待他們認為：“模具是發(fā)展工業(yè)的一把鑰匙”；“模具是一個企業(yè)的心臟”；“模具是富裕社會的一種動力”。 工業(yè)發(fā)展水平的不斷提高，工業(yè)產(chǎn)品更新速度加快，對模具的要求越來越高，盡管改革開放以來，模具工業(yè)有了較大發(fā)展，但無論是數(shù)量還是質量仍滿足不了國內市場的需要，因此，要使國民經(jīng)濟各個部門獲得高速發(fā)展，加速實現(xiàn)社會主義四個現(xiàn)代化，就必須盡快將模具工業(yè)搞上去，從而充分發(fā)揮模具工業(yè)在國民經(jīng)濟中的關鍵作用。 （2）研究狀況及其發(fā)展前景 我國沖壓模具無論在數(shù)量上，還是在質量、技術和能力等方面都已有了很大發(fā)展，但與國外經(jīng)濟需求和世界先進水平相比，差距仍很大，一些大型、精度、復雜、長壽命的高檔模具每年仍大量進口。近年許多模具企業(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。我國的模具正向著高新產(chǎn)業(yè)逐步邁進。 今后模具技術的發(fā)展應該為適應模具產(chǎn)品“交貨期短”、“精度高”、“質量好”、“價格低”的要求服務。 一方面是制品使用周期短，品種更新快，另一方面制品的花樣變化頻繁，均要求模具的生產(chǎn)周期越快越好。因此，開發(fā)快速經(jīng)濟具越來越引起人們的重視，另外，采用計算機控制和機械手操作的快速換模裝置、快速試模技術也要得到發(fā)展和提高。在未來的模具設計制造中更要全面推廣CAD/CAM/CAE技術并將CAD/CAM/CAE向集成化、智能化和網(wǎng)絡化發(fā)展。隨著微機軟件的發(fā)展和進步，技術培訓工作也日趨簡化，在普及推廣模具CAD/CAM技術的過程中，應抓住機遇，重點扶持國產(chǎn)模具軟件的開發(fā)和應用。在競爭如此激勵的今天，抓住模具市場日益全球化的機遇將模具產(chǎn)品向大型化、精密化、多功能復合模具進一步發(fā)展。 研究內容 本課題要求對給定零件止板墊片進行落料、沖孔、成形連續(xù)模設計，通過對零件進行詳細的沖壓工藝、排樣方案、模具結構分析確定零件的沖壓工藝方案并制定部分零件的制造工藝，如：凸模、凹模、凸凹模、凸模固定板、墊板、凹模固定板、卸料板、導尺、擋料銷、導正銷等。通過該課題能夠讓學生掌握中等復雜程度零件沖壓連續(xù)模設計與制造的一般方法，對零件沖壓連續(xù)模工藝方案的制定、工藝計算及連續(xù)模具設計有了更深層次的認識。 擬采取的研究方法、技術路線、實驗方案及可行性分析 1、到圖書館或網(wǎng)上查閱相關資料，查找相關書籍。對連續(xù)模深入了解 2、工藝性分析，包括結構、尺寸、基準的分析計算 3、工藝方案的確定，包括工序的性質、順序及其種類組合，確定沖壓設備編寫沖壓工藝過程卡片。 4、通過對零件、排樣圖等具體的計算分析，檢查設計是否合理。 5、總裝圖的繪制，編制技術文件。 課題完全由計算數(shù)據(jù)決定整套模具裝配圖及其零件圖，通過對實際情況的了解，以數(shù)據(jù)為依據(jù)進行設計分析，具體的設計計算也完全可以通過查表或者書籍獲得，加上對于整套設計有完整的設計思路，完全有可行性。 研究計劃及預期成果 研究計劃： 2012年11月12日-2012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：機械制造實訓 2013年1月21日-2013年3月1日：到企業(yè)實習，了解本專業(yè)實踐知識 2013年3月4日-2013年3月8日：查閱與設計相關的資料不少于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 預期成果： 1．完成模具裝配圖：1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 1、 使用caxa，繪圖方便快捷，方便改變參量，能夠直接觀察成形的凸凹模。 2、在設計時通過三維軟件進行模擬，真實的知道設計里存在的不足 3、連續(xù)模相對復合模具有效率高、壽命高等優(yōu)點 已具備的條件和尚需解決的問題 已具備的條件： ① 設計方案思路已經(jīng)非常明確，已初步具備設計基礎，工程制圖與AutoCAD，機械制造工藝學，工程材料及熱處理等知識，完全含蓋了設計所涉及的各個方面。 ② 能夠使用相關三維軟件繪制裝配圖及其零件圖。 尚需解決的問題： 初次涉及連續(xù)模，所以對設計的每個環(huán)節(jié)考慮不是很周全。在設計連續(xù)模時，要準確掌握加工速度、沖材材質、沖壓力、工位數(shù)、模具間隙等各種因素。對于模具里的標準件使用需也要相當注意。 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 Cutting Technology and Machining Operations Basically, in metal cutting, a sharpened wedge-shaped tool removes a rather narrow strip of metal from the surface of a ductile workpiece in the form of a severely deformed chip. The chip is a waste product that is considerably shorter than the workpiece from which it came but with a corresponding increase in thickness of the uncut chip. The geometrical shape of workpiece depends on the shape of the tool and its path during the machining operation. Most machining operations produce parts of differing geometry. If a rough cylindrical workpiece revolves about a central axis and the tool penetrates beneath its surface and travels parallel to the center of rotation, a surface of revolution is produced, and the operation is called turning. If a hollow tube is machined on the inside in a similar manner, the operation is called boring. Producing an external conical surface uniformly varying diameter is called taper turning, if the tool point travels in a path of varying radius, a contoured surface like that of a bowling pin can be produced; or, if the piece is short enough and the support is sufficiently rigid, a contoured surface could be produced by feeding a shaped tool normal to the axis of rotation. Short tapered or cylindrical surfaces could also be contour formed. Multiple-edged tools can also be used. Drilling uses a twin-edged fluted tool for holes with depths up to 5 to 10 times the drill diameter. Whether the drill turns or the workpiece rotates, relative motion between the cutting edge and the workpiece is the important factor. In milling operations a rotary cutter with a number of cutting edges engages the workpiece. Which moves slowly with respect to the cutter. Plane or contoured surfaces may be produced, depending on the geometry of the cutter and the type of feed. Horizontal or vertical axes of rotation may be used, and the feed of the workpiece may be in any of the three coordinate directions. Speeds, feeds, and depth of cut are the three major variables for economical machining. Other variables are the work and tool materials, coolant and geometry of the cutting tool. The rate of metal removal and power required for machining depend upon these variables. The depth of cut, feed, and cutting speed are machine settings that must be established in any metal-cutting operation. They all affect the forces, the power, and the rate of metal removal. They can be defined by comparing them to the needle and record of a phonograph. The cutting speed (V) is represented by the velocity of- the record surface relative to the needle in the tone arm at any instant. Feed is represented by the advance of the needle radially inward per revolution, or is the difference in position between two adjacent grooves. The depth of cut is the penetration of the needle into the record or the depth of the grooves. The basic operations performed on an engine lathe are illustrated. Those operations performed on external surfaces with a single point cutting tool are called turning. Except for drilling, reaming, and lapping, the operations on internal surfaces are also performed by a single point cutting tool. All machining operations, including turning and boring, can be classified as roughing, finishing, or semi-finishing. The objective of a roughing operation is to remove the bulk of the material as rapidly and as efficiently as possible, while leaving a small amount of material on the work-piece for the finishing operation. Finishing operations are performed to obtain the final size, shape, and surface finish on the workpiece. Sometimes a semi-finishing operation will precede the finishing operation to leave a small predetermined and uniform amount of stock on the work-piece to be removed by the finishing operation. Generally, longer workpieces are turned while supported on one or two lathe centers. Cone shaped holes, called center holes, which fit the lathe centers are drilled in the ends of the workpiece-usually along the axis of the cylindrical part. The end of the workpiece adjacent to the tailstock is always supported by a tailstock center, while the end near the headstock may be supported by a headstock center or held in a chuck. The headstock end of the workpiece may be held in a four-jaw chuck, or in a type chuck. This method holds the workpiece firmly and transfers the power to the workpiece smoothly; the additional support to the workpiece provided by the chuck lessens the tendency for chatter to occur when cutting. Precise results can be obtained with this method if care is taken to hold the workpiece accurately in the chuck. Very precise results can be obtained by supporting the workpiece between two centers. A lathe dog is clamped to the workpiece; together they are driven by a driver plate mounted on the spindle nose. One end of the Workpiece is mecained;then the workpiece can be turned around in the lathe to machine the other end. The center holes in the workpiece serve as precise locating surfaces as well as bearing surfaces to carry the weight of the workpiece ?and to resist the cutting forces. After the workpiece has been removed from the lathe for any reason, the center holes will accurately align the workpiece back in the lathe or in another lathe, or in a cylindrical grinding machine. The workpiece must never be held at the headstock end by both a chuck and a lathe center. While at first thought this seems like a quick method of aligning the workpiece in the chuck, this must not be done because it is not possible to press evenly with the jaws against the workpiece while it is also supported by the center. The alignment provided by the center will not be maintained and the pressure of the jaws may damage the center hole, the lathe center, and perhaps even the lathe spindle. Compensating or floating jaw chucks used almost exclusively on high production work provide an exception to the statements made above. These chucks are really work drivers and cannot be used for the same purpose as ordinary three or four-jaw chucks. While very large diameter workpieces are sometimes mounted on two centers, they are preferably held at the headstock end by faceplate jaws to obtain the smooth power transmission; moreover, large lathe dogs that are adequate to transmit the power not generally available, although they can be made as a special. Faceplate jaws are like chuck jaws except that they are mounted on a faceplate, which has less overhang from the spindle bearings than a large chuck would have. Machining as a shape-producing method is the most universally used and the most important of all manufacturing processes. Machining is a shape-producing process in which a power-driven device causes material to be removed in chip form. Most machining is done with equipment that supports both the work piece and cutting tool although in some cases portable equipment is used with unsupported workpiece. Close accuracies, good finishes. The second application for machining is based on the high accuracies and surface finishes possible. Many of the parts machined in low quantities would be produced with lower but acceptable tolerances if produced in high quantities by some other process. On the other hand, many parts are given their general shapes by some high quantity deformation process and machined only on selected surfaces where high accuracies are needed. Internal threads, for example, are seldom produced by any means other than machining and small holes in press worked parts may be machined following the press working operations. The basic tool-work relationship in cutting is adequately described by means of four factors: tool geometry, cutting speed, feed, and depth of cut. The cutting tool must be made of an appropriate material; it must be strong, tough, hard, and wear resistant. The tool s geometry characterized by planes and angles, must be correct for each cutting operation. Cutting speed is the rate at which the work surface passes by the cutting edge. It may be expressed in feet per minute. For efficient machining the cutting speed must be of a magnitude appropriate to the particular work-tool combination. In general, the harder the work material, the slower the speed. Feed is the rate at which the cutting tool advances into the workpiece. "Where the workpiece or the tool rotates, feed is measured in inches per revolution. When the tool or the work reciprocates, feed is measured in inches per stroke, Generally, feed varies inversely with cutting speed for otherwise similar conditions. The depth of cut, measured inches is the distance the tool is set into the work. It is the width of the chip in turning or the thickness of the chip in a rectilinear cut. In roughing operations, the depth of cut can be larger than for finishing operations. In metal cutting operations heat is generated in the primary and secondary deformation zones and these results in a complex temperature distribution throughout the tool, workpiece and chip. A typical set of isotherms is shown in figure where it can be seen that, as could be expected, there is a very large temperature gradient throughout the width of the chip as the workpiece material is sheared in primary deformation and there is a further large temperature in the chip adjacent to the face as the chip is sheared in secondary deformation. This leads to a maximum cutting temperature a short distance up the face from the cutting edge and a small distance into the chip. Since virtually all the work done in metal cutting is converted into heat, it could be expected that factors which increase the power consumed per unit volume of metal removed will increase the cutting temperature. Thus an increase in the rake angle, all other parameters remaining constant, will reduce the power per unit volume of metal removed and the cutting temperatures will reduce. When considering increase in unreformed chip thickness and cutting speed the situation is more complex. An increase in undeformed chip thickness tends to be a scale effect where the amounts of heat which pass to the workpiece, the tool and chip remain in fixed proportions and the changes in cutting temperature tend to be small. Increase in cutting speed; however, reduce the amount of heat which passes into the workpiece and this increase the temperature rise of the chip m primary deformation. Further, the secondary deformation zone tends to be smaller and this has the effect of increasing the temperatures in this zone. Other changes in cutting parameters have virtually no effect on the power consumed per unit volume of metal removed and consequently have virtually no effect on the cutting temperatures. Since it has been shown that even small changes in cutting temperature have a significant effect on tool wear rate it is appropriate to indicate how cutting temperatures can be assessed from cutting data. The most direct and accurate method for measuring temperatures in high -speed-steel cutting tools is that of Wright &. Trent which also yields detailed information on temperature distributions in high-speed-steel cutting tools. The technique is based on the metallographic examination of sectioned high-speed-steel tools which relates microstructure changes to thermal history. Trent has described measurements of cutting temperatures and temperature ?distributions for high-speed-steel tools when machining a wide range of workpiece materials. This technique has been further developed by using scanning electron ?microscopy to study fine-scale microstructure changes arising from over tempering of the tempered martens tic matrix of various high-speed-steels. This technique has also been used to study temperature distributions in both high-speed -steel single point turning tools and twist drills. Discounting brittle fracture and edge chipping, which have already been dealt with, tool wear is basically of three types. Flank wear, crater wear, and notch wear. Flank wear occurs on both the major and the minor cutting edges. On the major cutting edge, which is responsible for bulk metal removal, these results in increased cutting forces and higher temperatures which if left unchecked can lead to vibration of the tool and workpiece and a condition where efficient cutting can no longer take place. On the minor cutting edge, which determines workpiece size and surface finish, flank wear can result in an oversized product which has poor surface finish. Under most practical cutting conditions, the tool will fail due to major flank wear before the minor flank wear is sufficiently large to result in the manufacture of an unacceptable component. Because of the stress distribution on the tool face, the frictional stress in the region of sliding contact between the chip and the face is at a maximum at the start of the sliding contact region and is zero at the end. Thus abrasive wear takes place in this region with more wear taking place adjacent to the seizure region than adjacent to the point at which the chip loses contact with the face. This result in localized pitting of the tool face some distance up the face which is usually referred to as catering and which normally has a section in the form of a circular arc. In many respects and for practical cutting conditions, crater wear is a less severe form of wear than flank wear and consequently flank wear is a more common tool failure criterion. However, since various authors have shown that the temperature on the face increases more rapidly with increasing cutting speed than the temperature on the flank, and since the rate of wear of any type is significantly affected by changes in temperature, crater wear usually occurs at high cutting speeds. At the end of the major flank wear land where the tool is in contact with the uncut workpiece surface it is common for the flank wear to be more pronounced than along the rest of the wear land. This is because of localised effects such as a hardened layer on the uncut surface caused by work hardening introduced by a previous cut, an oxide scale, and localised high temperatures resulting from the edge effect. This localised wear is usually referred to as notch wear and occasionally is very severe. Although the presence of the notch will not significantly affect the cutting properties of the tool, the notch is often relatively deep and if cutting were to continue there would be a good chance that the tool would fracture. If any form of progressive wear allowed to continue, dramatically and the tool would fail catastrophically, i. e. the tool would be no longer capable of cutting and, at best, the workpiece would be scrapped whilst, at worst, damage could be caused to the machine tool. For carbide cutting tools and for all types of wear, the tool is said to have reached the end of its useful life long before the onset of catastrophic failure. For high-speed-steel cutting tools, however, where the wear tends to be non-uniform it has been found that the most meaningful and reproducible results can be obtained when the wear is allowed to continue to the onset of catastrophic failure even though, of course, in practice a cutting time far less than that to failure would be used. The onset of catastrophic failure is characterized by one of several phenomena, the most common being a sudden increase in cutting force, the presence of burnished rings on the workpiece, and a significant increase in the noise level. There are basically five mechanisms which contribute to the production of a surface which have been machined. These are: (l) The basic geometry of the cutting process. (2) The efficiency of the cutting operation. (3) The stability of the machine tool. (4)The effectiveness of removing swarf. (5)The effective clearance angle on the cutting tool. Machine parts are manufactured so they are interchangeable. In other words, each part of a machine or mechanism is made to a certain size and shape so will fit into any other machine or mechanism of the same type. To make the part interchangeable, each individual part must be made to a size that wi