压圈冲压课程设计说明书.pdf

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1、eaintheaeaintheacciccidentidentinvestigation,managemenvestigation,manageme ntandrntandreportieporting,eang,eachpostchpostshoulshouldbedbedeveldevelopeopedunderthissystemspecialistschedunderthissystemspecialistsche ck,clck,cleartheexaminatieartheexaminati ons,time,cyons,time,cy clesaclesandotndotherr

2、elevaherrelevantregulations.Strentregulations.Stre ngthengtheningningsitesupervisisitesupervisionaonandexamindexamination,tnation,todeteodetectandinvestigateillctandinvestigateill egalcommaegalcomma nd,ind,illegaloperationsandviolllegaloperationsandviol ationsofoperatiationsofoperatingrules.Secondsa

3、fetyreferstothengrules.Secondsafetyreferstothe productiproductionsite,technologymanagonsite,technologymanag ement,eement,equiquipment,facilitiepment,facilities,andsooncas,andsoonca nleadtnleadtoaccidentsriskoaccidentsrisk sexist.1,asexist.1,accordiccordingtotheextengtotheextentofthesentofthesecurity

4、ricurityrisks,solvingisks,solvingisdivisdividedidedintoa,b,andclntoa,b,andclevelsofdifficulty;A-levelsofdifficulty;A-l evel:difficult,minievel:difficult,mini ngdifficultiengdifficulties,shallbereportedtothecompanysproblems.Bs,shallbereportedtothecompanysproblems.B-cla-class:difficulttoresolvedifss:d

5、ifficulttoresolvedif冲压工艺与模具设计冲压工艺与模具设计课程设计任务书题 目：压圈的设计内 容：（一）冲压件的工艺性分析（一）冲压件的工艺性分析 (二）确定工艺方案及模具机构形式二）确定工艺方案及模具机构形式(三三)模具设计计算模具设计计算（四（四)模具总体设计模具总体设计（五）模具主要零部件的结构设计（五）模具主要零部件的结构设计（六（六)冲压设备的选择冲压设备的选择(七）绘制模具总装图七）绘制模具总装图（八（八)拆画零件图拆画零件图（九（九)设计总结设计总结（十）参考文献（十）参考文献目目录录（一）。冲压件的工艺性分析4（二）.确定工艺方案模具机构形式4(三)。模具设计

6、计算5（1）排样方式的确定及其计算 (2)计算凸。凹模刃口尺寸（3）外形落料凸、凹模刃口尺寸的计算ficulties,shallficulties,shallconsistofminiconsistofminingorganizationstosolvengorganizationstosolve problproblems.Cems.C-cla-class:fromsegmentsass:fromsegmentsa ndbusinendbusinessriskstssrisksthatmustbeaddressehatmustbeaddresse dintdintheDeheDepartme

7、nt.2,openpartment.2,open-pitmine-pitmineunsafetypesiunsafetypesi nclncludeude:ele:electrical,transport,blastictrical,transport,blasti ng,fire,ang,fire,andotherslndotherslope.3,aope.3,accordingtccordingtothesevotheseverityofthehaerityofthehazardfillezardfilledinbyunittroubldinbyunittroubl eshootiesho

8、oting,registrang,registrationform(seeatttionform(seeatteaintheaeaintheacciccidentidentinvestigation,managemenvestigation,manageme ntandrntandreportieporting,eang,eachpostchpostshoulshouldbedbedeveldevelopeopedunderthissystemspecialistschedunderthissystemspecialistsche ck,clck,cleartheexaminatiearthe

9、examinati ons,time,cyons,time,cy clesaclesandotndotherrelevaherrelevantregulations.Strentregulations.Stre ngthengtheningningsitesupervisisitesupervisionaonandexamindexamination,tnation,todeteodetectandinvestigateillctandinvestigateill egalcommaegalcomma nd,ind,illegaloperationsandviolllegaloperation

10、sandviol ationsofoperatiationsofoperatingrules.Secondsafetyreferstothengrules.Secondsafetyreferstothe productiproductionsite,technologymanagonsite,technologymanag ement,eement,equiquipment,facilitiepment,facilities,andsooncas,andsoonca nleadtnleadtoaccidentsriskoaccidentsrisk sexist.1,asexist.1,acco

11、rdiccordingtotheextengtotheextentofthesentofthesecurityricurityrisks,solvingisks,solvingisdivisdividedidedintoa,b,andclntoa,b,andclevelsofdifficulty;A-levelsofdifficulty;A-l evel:difficult,minievel:difficult,mini ngdifficultiengdifficulties,shallbereportedtothecompanysproblems.B-clas,shallbereported

12、tothecompanysproblems.B-class:difficulttoresolvedifss:difficulttoresolvedif (4)冲压力的计算（5)压力中心的计算（四）。模具总体设计8（五）。模具主要零部件的结构设计9（1）落料凸、凹模的结构设计（2)弹性元件的设计计算（3）模架的设计（六）。冲压设备的选择12（七）。绘制模具总装图13（八）.拆画零件图13(九)。参考文献14ficulties,shallficulties,shallconsistofminiconsistofminingorganizationstosolvengorganizationstos

13、olve problproblems.Cems.C-cla-class:fromsegmentsass:fromsegmentsa ndbusinendbusinessriskstssrisksthatmustbeaddressehatmustbeaddresse dintdintheDeheDepartment.2,openpartment.2,open-pitmine-pitmineunsafetypesiunsafetypesi nclncludeude:ele:electrical,transport,blastictrical,transport,blasti ng,fire,ang

14、,fire,andndotherslotherslope.3,aope.3,accordingtccordingtothesevotheseverityofthehaerityofthehazardfillezardfilledinbyunittroubldinbyunittroubl eshootieshooting,registrang,registrationform(seeatttionform(seeatteaintheaeaintheacciccidentidentinvestigation,managemenvestigation,manageme ntandrntandrepo

15、rtieporting,eang,eachpostchpostshoulshouldbedbedeveldevelopeopedunderthissystemspecialistschedunderthissystemspecialistsche ck,clck,cleartheexaminatieartheexaminati ons,time,cyons,time,cy clesaclesandotndotherrelevaherrelevantregulations.Strentregulations.Stre ngthengtheningningsitesupervisisitesupe

16、rvisionaonandexamindexamination,tnation,todeteodetectandinvestigateillctandinvestigateill egalcommaegalcomma nd,ind,illegaloperationsandviolllegaloperationsandviol ationsofoperatiationsofoperatingrules.Secondsafetyreferstothengrules.Secondsafetyreferstothe productiproductionsite,technologymanagonsit

17、e,technologymanag ement,eement,equiquipment,facilitiepment,facilities,andsooncas,andsoonca nleadtnleadtoaccidentsriskoaccidentsrisk sexist.1,asexist.1,accordiccordingtotheextengtotheextentofthesentofthesecurityricurityrisks,solvingisks,solvingisdivisdividedidedintoa,b,andclntoa,b,andclevelsofdifficu

18、lty;Alevelsofdifficulty;Al evel:difficult,minievel:difficult,mini ngdifficultiengdifficulties,shallbereportedtothecompanysproblems.Bclas,shallbereportedtothecompanysproblems.Bclass:difficulttoresolvedifss:difficulttoresolvedif河南机专冲压课程设计说明书冲裁模具设计冲裁模具设计工件名称:压圈生产批量：大批量材料：Q235厚度：2mm工件简图：如右图所示(一一)冲压件的工艺性

19、分析冲压件的工艺性分析该零件形状简单、对称，是由圆弧和直线组成的.冲裁件内外形所能达到的经济精度为 IT11IT14.凡产品图样上没有标注公差等级或者公差的尺寸，其极限偏差数值通常按 IT14 级处理.将以上精度与零件的精度要求相比较，可以为该零件的精度要求能够在冲裁加工中得到保证，其他尺寸标注、生产批量等情况，也均符合冲裁的工艺要求，故决定采用冲压方式进行加工。经查公差表,各尺寸公差为：42-0.62mm2000+0.52mm 220+0。52mm 40+0。3mm（二（二)确定工艺方案及模具结构形式确定工艺方案及模具结构形式该工件所需的冲压工序包括落料、冲孔两个基本工序，可以拟定出以下三种

20、工艺方案：方案一:先落料，后冲孔，采用单工序模分两次加工。方案二：落料-冲孔复合冲压，采用复合模加工。方案三：落料冲孔级进冲压,采用级进模加工.方案一模具结构简单，但需两道工序两副模具，成本高而生产效率低，难以满足顾客的要求,而且工件的累积误差大，操作不方便.由于该工件大批量生产，所以方案二和方案三更具优越性。该零件20mm22mm 的孔与42mm 的最小距离为 9mm,大于此零件要求的最小壁厚（4.9mm)，可以采用冲孔、落料复合模或冲孔、落料级进模，复合模模具的形位精度和尺寸精度容易保证,且生产率也高，尽管模具结构比较复杂,但由于零件的几何形状简单对称，模具制ficulties,shall

21、ficulties,shallconsistofminiconsistofminingorganizationstosolvengorganizationstosolve problproblems.Cclaems.Ccla ss:fromsegmentsass:fromsegmentsa ndbusinendbusinessriskstssrisksthatmustbeaddressehatmustbeaddresse dintdintheDeheDepartment.2,openpartment.2,open pitminepitmine unsafetypesiunsafetypesi

22、nclncludeude:ele:electrical,transport,blastictrical,transport,blasti ng,fire,ang,fire,andotherslndotherslope.3,aope.3,accordingtccordingtothesevotheseverityofthehaerityofthehazardfillezardfilledinbyunittroubldinbyunittroubl eshootieshooting,registrang,registrationform(seeatttionform(seeatt-3-11eaint

23、heaeaintheacciccidentidentinvestigation,managemenvestigation,manageme ntandrntandreportieporting,eang,eachpostchpostshoulshouldbedbedeveldevelopeopedunderthissystemspecialistschedunderthissystemspecialistsche ck,clck,cleartheexaminatieartheexaminati ons,time,cyons,time,cy clesaclesandotndotherreleva

24、herrelevantregulations.Strentregulations.Stre ngthengtheningningsitesupervisisitesupervisionaonandexamindexamination,tnation,todeteodetectandinvestigateillctandinvestigateill egalcommaegalcomma nd,ind,illegaloperationsandviolllegaloperationsandviol ationsofoperatiationsofoperatingrules.Secondsafetyr

25、eferstothengrules.Secondsafetyreferstothe productiproductionsite,technologymanagonsite,technologymanag ement,eement,equiquipment,facilitiepment,facilities,andsooncas,andsoonca nleadtnleadtoaccidentsriskoaccidentsrisk sexist.1,asexist.1,accordiccordingtotheextengtotheextentofthesentofthesecurityricur

26、ityrisks,solvingisks,solvingisdivisdividedidedintoa,b,andclntoa,b,andclevelsofdifficulty;A-levelsofdifficulty;A-l evel:difficult,minievel:difficult,mini ngdifficultiengdifficulties,shallbereportedtothecompanysproblems.B-clas,shallbereportedtothecompanysproblems.B-class:difficulttoresolvedifss:diffic

27、ulttoresolvedif造并不困难。级进模虽生产率也高，但零件的冲裁精度稍差，欲保证冲压件的形位精度,需要在模具上设置导正销导正,故模具制造、安装较复合模复杂。通过对上述三种方案的分析比较,该零件的冲压生产采用方案二的复合模为佳。（三）（三）模具设计计算模具设计计算（1）排样方式的确定及其计算设计复合模时，首先要设计条料的排样图，因该零件外形为圆形，可采用有废料排样的直排比较合适。参考 冲压工艺与模具设计 表 2.8确定其排样方式为直排画出排样图排样图由于 R=2122 查表 2。9 最小搭边值可知：最小工艺搭边值a(侧面）=1.5mm a1（工件间）=1。2mm 分别取 a=2 a1=

28、2 计算条料的宽度：B=42+22=46mm步距：S=42+2=44mm材料利用率的计算:计算冲压件毛坯的面积：A=R2=212=1384。74mm 2一个步距的材料利用率:=1384.74/4644=68。4(2）计算凸、凹模刃口尺寸查冲压工艺与模具设计书中表2。4 得间隙值Zmin=0。246mm，Zmax=0.360mm。1)冲孔20mm22mm 凸、凹模刃口尺寸的计算由于制件结构简单,精度要求不高，所以采用凹模和凸模分开加工的方法制作凸、凹模.其凸、凹模刃口尺寸计算如下:查冲压工艺与模具设计书中表 2.5 得20mm 凸、凹模制造公差：凸=0。020mm凹=0.025mm校核：Zmax

29、Zmin=（0.3600。246)=0。114mm而凸+凹=（0.020+0.025）=0.045mm满足 ZmaxZmin凸+凹的条件ficulties,shallficulties,shallconsistofminiconsistofminingorganizationstosolvengorganizationstosolve problproblems.Cems.C-cla-class:fromsegmentsass:fromsegmentsa ndbusinendbusinessriskstssrisksthatmustbeaddressehatmustbeaddresse din

30、tdintheDeheDepartment.2,openpartment.2,open-pitmine-pitmineunsafetypesiunsafetypesi nclncludeude:ele:electrical,transport,blastictrical,transport,blasti ng,fire,ang,fire,andndotherslotherslope.3,aope.3,accordingtccordingtothesevotheseverityofthehaerityofthehazardfillezardfilledinbyunittroubldinbyuni

31、ttroubl eshootieshooting,registrang,registrationform(seeatttionform(seeatteaintheaeaintheacciccidentidentinvestigation,managemenvestigation,manageme ntandrntandreportieporting,eang,eachpostchpostshoulshouldbedbedeveldevelopeopedunderthissystemspecialistschedunderthissystemspecialistsche ck,clck,clea

32、rtheexaminatieartheexaminati ons,time,cyons,time,cy clesaclesandotndotherrelevaherrelevantregulations.Strentregulations.Stre ngthengtheningningsitesupervisisitesupervisionaonandexamindexamination,tnation,todeteodetectandinvestigateillctandinvestigateill egalcommaegalcomma nd,ind,illegaloperationsand

33、violllegaloperationsandviol ationsofoperatiationsofoperatingrules.Secondsafetyreferstothengrules.Secondsafetyreferstothe productiproductionsite,technologymanagonsite,technologymanag ement,eement,equiquipment,facilitiepment,facilities,andsooncas,andsoonca nleadtnleadtoaccidentsriskoaccidentsrisk sexi

34、st.1,asexist.1,accordiccordingtotheextengtotheextentofthesentofthesecurityricurityrisks,solvingisks,solvingisdivisdividedidedintoa,b,andclntoa,b,andclevelsofdifficulty;Alevelsofdifficulty;Al evel:difficult,minievel:difficult,mini ngdifficultiengdifficulties,shallbereportedtothecompanysproblems.Bclas

35、,shallbereportedtothecompanysproblems.Bclass:difficulttoresolvedifss:difficulttoresolvedif河南机专冲压课程设计说明书查冲压工艺与模具设计书中表2.6 得:IT14 级时标准公差=0。52，因为 0.520。20 所以磨损系数 X=0。5，按式（2.5）d凸=（20+0。50.52)00.020=mm D凹=mm查冲压工艺与模具设计书中表 2。5 得 2.2mm4mm 的矩形凸、凹模制造公差:凸=0。020mm凹=0。020mm凸+凹=0.020+0.020=0.040mm满足 ZmaxZmin凸+凹的条件

36、（3）外形落料凸、凹模刃口尺寸的计算由于外形形状简单，精度要求不高，所以采用凸模和凹模分开加工的方法制作凸、凹模。其凸、凹模刃口尺寸计算如下：查冲压工艺与模具设计书中表2。5 得凸、凹模制作公差凸=0。020mm凹=0。030mm校核：ZmaxZmin=0.3600。246=0.114mm而T+A=0.050mm满足 Zmax-Zmin凸+凹的条件查冲压工艺与模具设计书中表 2。6 得：IT14 级时磨损系数 X=0.5,按式(2。5）d凸=42.2600。020mm d凹=42.506+00.030mm（4）冲压力的计算落料力 F落=Ltb=（2R2450）N=118.692KN冲孔力 F冲

37、=Ltb=（336。910/180+4+22。2）2 450=60。453KN冲孔时的推件力 F推=n K推F孔由冲压工艺与模具设计书中表 2。21 得 h=6mm则 n=h/t=6mm/2=3个查冲压工艺与模具设计书中表 2.7 得 K推=0。05ficulties,shallficulties,shallconsistofminiconsistofminingorganizationstosolvengorganizationstosolve problproblems.Cclaems.Ccla ss:fromsegmentsass:fromsegmentsa ndbusinendbusi

38、nessriskstssrisksthatmustbeaddressehatmustbeaddresse dintdintheDeheDepartment.2,openpartment.2,open pitminepitmine unsafetypesiunsafetypesi nclncludeude:ele:electrical,transport,blastictrical,transport,blasti ng,fire,ang,fire,andotherslndotherslope.3,aope.3,accordingtccordingtothesevotheseverityofth

39、ehaerityofthehazardfillezardfilledinbyunittroubldinbyunittroubl eshootieshooting,registrang,registrationform(seeatttionform(seeatt-5-11eaintheaeaintheacciccidentidentinvestigation,managemenvestigation,manageme ntandrntandreportieporting,eang,eachpostchpostshoulshouldbedbedeveldevelopeopedunderthissy

40、stemspecialistschedunderthissystemspecialistsche ck,clck,cleartheexaminatieartheexaminati ons,time,cyons,time,cy clesaclesandotndotherrelevaherrelevantregulations.Strentregulations.Stre ngthengtheningningsitesupervisisitesupervisionaonandexamindexamination,tnation,todeteodetectandinvestigateillctand

41、investigateill egalcommaegalcomma nd,ind,illegaloperationsandviolllegaloperationsandviol ationsofoperatiationsofoperatingrules.Secondsafetyreferstothengrules.Secondsafetyreferstothe productiproductionsite,technologymanagonsite,technologymanag ement,eement,equiquipment,facilitiepment,facilities,andso

42、oncas,andsoonca nleadtnleadtoaccidentsriskoaccidentsrisk sexist.1,asexist.1,accordiccordingtotheextengtotheextentofthesentofthesecurityricurityrisks,solvingisks,solvingisdivisdividedidedintoa,b,andclntoa,b,andclevelsofdifficulty;A-levelsofdifficulty;A-l evel:difficult,minievel:difficult,mini ngdiffi

43、cultiengdifficulties,shallbereportedtothecompanysproblems.B-clas,shallbereportedtothecompanysproblems.B-class:difficulttoresolvedifss:difficulttoresolvedif F推=n K推F孔=30。0560.453=9.068KN落料时的卸料力 F卸=K卸F落查冲压工艺与模具设计书中表 2。7 取 K卸=0.04故 F卸=K卸F落=0。04118。692=4。748KN总冲压力为：F总=F落+F孔+F推+F卸=（118.692+60.453+9。068+4

44、。748）KN=192。961KN为了保证冲压力足够，一般冲裁时压力机吨位应比计算的冲F总=1。3F总=1。3192.961=250.8KN（5)压力中心的计算用解析法求模具的压力中心的坐标，建立如下图所示的坐标系 XOY.由图可知工件上下对称,将工件冲裁周边分成 L1、L2、L3、L4、L5基本线段，求出各段长度的重心位置：因工件相对 x 轴对称，所以 Yc=0,只需计算 XCL1=2r=131.88 X1=0L2=58.77mm X2=-0.68L3=L5=2。2mm X3=X5=10.9 L4=4mm X4=12 将以上数据代入压力中心坐标公式 X=(L1 X1+L2 X2+L5 X5)

45、/L1+L2+L5 X=131。880+58。77（-0。68)+2.210。9+412+2。210。9/（131。88+58。77+2.2+4+22.2)=0.28mm（四）（四）.模具的总体设计模具的总体设计根据上述分析，本零件的冲压包括冲压和落料两个工序，且孔边距较大，可采用倒装复合模，可直接利用压力机的打杆装置进行推件，卸ficulties,shallficulties,shallconsistofminiconsistofminingorganizationstosolvengorganizationstosolve problproblems.Cems.C-cla-class:fr

46、omsegmentsass:fromsegmentsa ndbusinendbusinessriskstssrisksthatmustbeaddressehatmustbeaddresse dintdintheDeheDepartment.2,openpartment.2,open-pitmine-pitmineunsafetypesiunsafetypesi nclncludeude:ele:electrical,transport,blastictrical,transport,blasti ng,fire,ang,fire,andndotherslotherslope.3,aope.3,

47、accordingtccordingtothesevotheseverityofthehaerityofthehazardfillezardfilledinbyunittroubldinbyunittroubl eshootieshooting,registrang,registrationform(seeatttionform(seeatteaintheaeaintheacciccidentidentinvestigation,managemenvestigation,manageme ntandrntandreportieporting,eang,eachpostchpostshoulsh

48、ouldbedbedeveldevelopeopedunderthissystemspecialistschedunderthissystemspecialistsche ck,clck,cleartheexaminatieartheexaminati ons,time,cyons,time,cy clesaclesandotndotherrelevaherrelevantregulations.Strentregulations.Stre ngthengtheningningsitesupervisisitesupervisionaonandexamindexamination,tnatio

49、n,todeteodetectandinvestigateillctandinvestigateill egalcommaegalcomma nd,ind,illegaloperationsandviolllegaloperationsandviol ationsofoperatiationsofoperatingrules.Secondsafetyreferstothengrules.Secondsafetyreferstothe productiproductionsite,technologymanagonsite,technologymanag ement,eement,equiqui

50、pment,facilitiepment,facilities,andsooncas,andsoonca nleadtnleadtoaccidentsriskoaccidentsrisk sexist.1,asexist.1,accordiccordingtotheextengtotheextentofthesentofthesecurityricurityrisks,solvingisks,solvingisdivisdividedidedintoa,b,andclntoa,b,andclevelsofdifficulty;Alevelsofdifficulty;Al evel:diffic