“垫板”零件冲压工艺及模具设计

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JIU JIANG UNIVERSITY

课程设计

题目 “垫板”零件冲压工艺及模具设计

院系机械与材料工程学院姓名 XXX 年级 XXX 指导教师 XXX

专业模具设计与制造

2014年 4 月

前言·····························································1 第一章冲压件···················································3 1.1 形状与尺寸··················································3 第二章零件的工艺性分析·········································4 2.1 零件的工艺性分析············································4 2.2 确定冲裁件的工艺方案········································4 第三章冲压模具总体结构设计·····································5 3.1 模具类型····················································5 3.2 导向与定位方式··············································5 3.3 卸料与出件方式··············································5 3.4 模架类型及精度··············································5 3.5 凸模设计····················································5 第四章工艺设计计算·············································6 4.1 排样设计计算················································6 4.2 计算压力与压力中心、初选压力机······························7

4.3 计算凸凹模刃口尺寸及公差····································8 第五章设计选用零件、部件绘制模具总装草图·······················9 5.1 凹模设计····················································9 5.2 凸模设计····················································10 5.2.1 凸模形式与固定方法·············································10 5.2.2 凸模长度计算···················································10 5.2.3 凸模强度、刚度校核·············································11 5.2.4 凸模材料和技术条件·············································11 5.3 凸凹模设计··················································12 5.3.1 凸凹模结构形式与固定方法·······································12 5.3.2 校核凸凹模的强度···············································13 5.4 定位零件····················································13 5.5 卸料与出件装置··············································14 5.6 模架及其他零件的选用········································15 5.6.1 模柄···························································15 5.6.2 模座···························································16 5.6.3 垫板···························································16 5.6.4 冲压设备的选择·················································18 5.6.5 紧固件的选用…………………………………………………………..18 第六章压力机的校核·············································19 6.1 公称压力····················································19 6.2 工作台面尺寸················································19 第七章模具主要加工工艺规程的编制·······························20 7.1 冲压模具制造技术要求········································20 7.2 总装工艺····················································20 7.3 加工要求····················································22 7.4 主要零件加工工艺············································22 7.4.1 垫板的加工工艺·················································22 7.4.2 凸模固定板的加工工艺···········································22 7.4.3 冲孔凸模的加工工艺·············································23

7.4.4 卸料板的加工工艺···············································23 7.4.5 落料凹模加工工艺···············································23 7.4.6 凸凹模的加工工艺···············································24 7.4.7 凸凹模固定板的加工工艺·········································24 第八章总结·····················································25 参考文献·························································26

前言

冲压是利用安装在冲压设备（主要是压力机）上的模具对材料施加压力，使其产生分离或塑性变形，从而获得所需零件（俗称冲压或冲压件）的一种压力加工方法。冲压通常是在常温下对材料进行变形加工，且主要采用板料来加工成所需零件，所以也叫冷冲压或板料冲压。冲压是材料压力加工或塑性加工的主要方法之一，隶属于材料成型工程。

冲压所使用的模具称为冲压模具，简称冲模。冲模是将材料（金属或非金属）批量加工成所需冲件的专用工具。冲模在冲压中至关重要，没有符合要求的冲模，批量冲压生产就难以进行；没有先进的冲模，先进的冲压工艺就无法实现。冲压工艺与模具、冲压设备和冲压材料构成冲压加工的三要素，只有它们相互结合才能得出冲压件。与机械加工及塑件加工的其它方法相比，冲压加工无论在技术方面还是经济方面都具有许多独特的优点。主要表现如下。

(1)冲压加工的生产效率高，且操作方便，易于实现机械化和自动化。 (2)冲压时由于模具保证了冲压件的尺寸与形状精度，且一般不压件的表面质量，而模具的寿命一般较长，所以冲压的质量稳定，互换性好，具有“一模一样”的特征。

(3)冲压可加工出尺寸范围较大、形状较复杂的零件，如小到钟表的秒表，大到汽车纵梁、覆盖件等，加工冲压时材料的冷变形硬化效应，冲压的强度和刚度均较高。

(4)冲压一般没有切屑碎料生成，材料的消耗较少，且不需要其它加热设备，因为是一种省料，节能的加工方法，冲压件的成本较低。

由于冲压加工的零件种类繁多，各类零件的形状、尺寸和精度要求又各不相同，因而生产中采用的冲压工艺方法也是各种各样的。概括起来，可分为分离工

序和成形工序两大类：分离工序是指将坯料沿一定的轮廓线分离而获得一定形状、尺寸和断面质量的冲压（俗称冲压件）的工序；成形工序是指使坯料在不破坏的条件下产生塑性变形而获得一定形状和尺寸的冲压件的工序。

上述两类工序，按基本变形方式不同又可分为冲裁、弯曲、拉伸和成形四种基本工序，每种基本工序还包括有多种单一工序。

在实际生产中，当冲压件的生产批量较大、尺寸较少而公差要求较小时，若用分散的单一工序来冲压是不经济甚至难于达到要求。这时在工艺上多采用集中的方案，即把两种或两种以上的单一工序集中在一副模具内完成，称为组合的方法不同。

复合冲压—在压力机的一次工作行程中，在模具的同一个工位上同时完成两种或两种以上不同单一工序的一种组合方式。

级进冲压—在压力机上的一次工作行程中，按照一定的顺序在同一模具的不同工位上完成两种或两种以上不同单一工序的一种组合方式。

复合-级进—在一副冲模上包括复合和级进两种方式的组合工序。冲模的结构类型也很多。通常按工序性质可分为冲裁模、弯曲模、拉伸模和成形模等；按工序的组合方式可分为单工序模、复合模和级进模等。但不论何种类型的冲模，都可看成是由上模和下模两部分组成，上模被固定在压力机工作台或垫板上，是冲模的固定部分。工作时，坯料在下模面上通过定位零件定位，压力机滑块带动上模下压，在模具工作零件（即凸模、凹模）的作用下坯料便产生分离或塑性变形，从而获得所需形状与尺寸的冲件。上模回升时，模具的卸料与出件装置将冲件或废料从凸、凹模上卸下或推、顶出来，以便进行下一次冲压循环。

此设计针对所给的零件进行了一套冷冲压模具的设计，其中设计内容为分析零件的冲裁工艺性（材料、工件结构形状、尺寸精度），拟定零件的冲压工艺方案及模具结构，排样，裁板，计算冲压工序压力，选用压力机及确定压力中心，计算凸凹模刃口尺寸，主要零部件设计和加工工艺编制，压力机的校核。

第一章冲压件

1.1 形状与尺寸

“垫板”零件冲压工艺及模具设计

名称：垫板批量：大批量材料：08F

厚度：2mm冲裁件的尺寸要求：外形尺寸均未标注尺寸公差，属于自由尺寸，可按IT14级确定工件的尺寸公差，经查表得，各尺寸公差分别为：

00038308 零件外形：580mm，mm，mm，?0.74?0.62?0.52?0.36mm

?0.30零件内形：?60mm

孔心距：18?0.215mm

第二章零件的工艺性分析

2.1零件的工艺性分析

该零件结构简单，形状对称。08F，属于碳素结构钢，查《冷冲压工艺及模具设计》附表1可知抗剪强度??260MPa,断后伸长率=32%。此材料具有良好的塑性和较高的弹性，其冲裁加工性能好。