模具設(shè)計(jì)與制造畢業(yè)設(shè)計(jì)說明書

1、摘要本說明書共分為三章。第一章，主要敘述了模具工業(yè)的發(fā)展史。首先介紹模具工業(yè)在經(jīng)濟(jì)發(fā)展中的重要性，再從三個(gè)方面闡述了模具工業(yè)的發(fā)展史。簡單介紹了如何分析沖裁零件。 第二章，電極板沖孔模設(shè)計(jì)部分。這部分介紹了電極板的結(jié)構(gòu)工藝性分析，沖孔、落料的模具結(jié)構(gòu)。并結(jié)合設(shè)計(jì)零件的實(shí)際結(jié)構(gòu)、功能與用途，經(jīng)過理論計(jì)算確定了比較合理的零件加工工藝，設(shè)計(jì)出了主要零件圖。此次設(shè)計(jì)是對以前所血理論知識的一次比較系統(tǒng)的實(shí)際演練。第三章，注塑模部分設(shè)計(jì)。這部分主要是隱形眼鏡清洗盒的模具設(shè)計(jì),通過對塑件進(jìn)行工藝性的分析和比較,最終設(shè)計(jì)出一副塑料注塑模。本設(shè)計(jì)從產(chǎn)品的結(jié)構(gòu)工藝性、具體模具結(jié)構(gòu)出發(fā)，對模具的澆注系統(tǒng)、注塑機(jī)的選

2、擇及有關(guān)參數(shù)的校核、模具成型部分的結(jié)構(gòu)設(shè)計(jì)和計(jì)算、脫模推出機(jī)構(gòu)等都有詳細(xì)的設(shè)計(jì)。針對清洗盒的具體結(jié)構(gòu)，并考慮經(jīng)濟(jì)性設(shè)計(jì)出這套注塑模。其優(yōu)點(diǎn)是機(jī)構(gòu)簡單，模具外形小，生產(chǎn)效率高，模具的制造成本低。通過模具設(shè)計(jì)表明該模具能達(dá)到清洗盒的質(zhì)量和加工工藝要求。關(guān)鍵詞：模具歷史；沖壓模；注塑模Abstractspecifications is three chapters together mark. The first chapters , the phylogeny having narrated mould industry's mainly. Introduce mould industry

3、 phylogeny having set forth mould industry again from three aspect in significance in economic growth first. How analyse according to cutting a part that the simplicity has been introduced. Second chapters , electrode board punched hole models design a part. This part has introduced unnatural electr

4、ode structure manufacturability analysis, punched hole , the blank mould structure. And link structure , function designing the part reality with use, by that theory calculates picture having ascertained the comparatively rational part processing handicraft , having designed out the main part. Desig

5、n a comparatively systematic reality being institute blood theory knowledge to the previously this time drilling.Third chapters, produce plastic articles by injection moulding the model part designs that. This part is that the haptic lens washes the box design for die and mould mainly , pass to anal

6、ysis and comparison moulding the manufacturability being in progress piece, model designing that a set of plastic produces plastic articles by injection moulding out ultimately. Design that structure sets off from product structure manufacturability , concrete mould originally, both the physical des

7、ign to mould choice pouring system , the injection machine and school core , mould about parameter molding part and secretly scheming against , demould debuting organization and so on have detailed design. Specifically for the structure cleaning the box concre, and think that economy designs that th

8、is produces plastic articles by injection moulding set out model. Whose merit is that organization is simple , mould external form is small , the efficacy is high, the mould cost of manufacture is low. Can reach the mass cleaning a box's and process technological requirements by the fact that de

9、sign for die and mould indicates that mould. Keywords: Mold history , the stamping model, produce plastic articles by injection moulding mold目錄第一章 綜述 ·························

10、·······························1 概述··················&#

11、183;······································2 如何分析沖裁零件·········

12、3;·····································第二章 電極板沖孔模的設(shè)計(jì)··········

13、83;································1 產(chǎn)品簡介················

14、83;······································2 電極板沖孔模設(shè)計(jì)的前期準(zhǔn)備·········

15、····························2.1研究設(shè)計(jì)任務(wù)····················

16、83;··························2.1.1閱讀沖裁件產(chǎn)品零件圖·····················

17、···············2.1.2分析沖裁件零件·································

18、········2.1.3沖裁加工的經(jīng)濟(jì)性分析···································3 電極板沖孔模總體方案的確定··

19、···································3.1電極板沖孔模類型的確定············

20、3;························3.1.1三種方案························&

21、#183;·······················3.1.2分析論證························

22、3;·······················3.2結(jié)構(gòu)形式的確定·························

23、····················3.2.1操作方式選擇····························&

24、#183;···············3.2.2等位方式的選擇································&

25、#183;·········3.2.3卸料方式······································

26、3;·········4 電極板沖孔工藝計(jì)算·······································

27、;·····4.1凸凹模刃口尺寸計(jì)算········································4.1.1凸凹模刃口尺寸計(jì)算原則&

28、#183;·································4.1.2簡單形狀凸凹模刃口尺寸的計(jì)算·············

29、···············4.2沖壓里的計(jì)算·································

30、83;············4.2.1計(jì)算沖裁力····································

31、;··········4.2.2計(jì)算卸料力、推件力·····································

32、83;4.2.3計(jì)算沖壓力總和··········································4.3初選壓力機(jī)····&

33、#183;···········································4.3.1壓力機(jī)類型的選擇····

34、····································4.3.2壓力機(jī)規(guī)格的選擇············

35、;····························4.4壓力中心的計(jì)算····················&

36、#183;························4.4.1簡單形狀壓力中心·······················

37、·················4.4.2多凸模的壓力中心·······························

38、;·········5電極板沖孔模主要零部件設(shè)計(jì)計(jì)算·································5.1凹模的設(shè)計(jì)計(jì)算···

39、83;·········································5.1.1凹?？卓诘脑O(shè)計(jì)······

40、83;···································5.1.2凹模外型結(jié)構(gòu)的設(shè)計(jì)············&

41、#183;·························5.1.3凹模凹模外型尺寸的計(jì)算·····················

42、83;············5.1.4凹模的固定方法···································

43、83;······5.2固定板的實(shí)際計(jì)算·········································

44、3;·5.2.1凹模固定板的設(shè)計(jì)·······································5.2.2凸模固定板的設(shè)計(jì)·····&#

45、183;··································5.3卸料板的設(shè)計(jì)計(jì)算·············

46、83;·····························5.3.1卸料板的類型選擇··················&#

47、183;·····················5.3.2卸料板的尺寸··························

48、83;·················5.4定位零件的設(shè)計(jì)計(jì)算······························

49、83;··········5.4.1定位板的結(jié)構(gòu)·····································

50、3;······5.4.2定位板尺寸的計(jì)算········································5.5彈性元件設(shè)計(jì)

51、計(jì)算···········································5.5.1橡膠墊的自有高度····

52、83;···································5.5.2橡膠墊的直徑············

53、3;·······························5.6凸模的設(shè)計(jì)計(jì)算·················

54、····························5.6.1凸模的結(jié)構(gòu)設(shè)計(jì)····················

55、······················5.6.2凸模尺寸的計(jì)算··························

56、················5.7電極板沖孔模其他零件的設(shè)計(jì)和選擇···························5.7.1模座的設(shè)計(jì)··&

57、#183;···········································5.7.2模柄的設(shè)計(jì)····

58、83;·········································5.8電極板沖孔模閉合高度的計(jì)算······

59、;···························5.9壓力機(jī)的選擇·····················&#

60、183;·························第三章 隱形眼睛清洗盒注塑模的設(shè)計(jì) ·····················&#

61、183;············1 擬定模具的結(jié)構(gòu)形式···································

62、83;·········1.1塑件成型工藝分析······································

63、3;····1.2分型面位置的確定···········································1.3確定

64、型腔數(shù)量和排列方式·····································1.3.1型腔數(shù)量的確定·········

65、83;································1.3.2型腔排列形式的確定···············&

66、#183;······················1.4模具結(jié)構(gòu)形式的確定·························&

67、#183;···············1.5注射機(jī)型號的選定································&#

68、183;··········1.5.1注射量的計(jì)算·····································

69、83;······1.5.2投影面積及所需鎖模力的計(jì)算······························1.5.3選擇注射機(jī)·········

70、;·····································1.5.4注射機(jī)有關(guān)參數(shù)的校核··········&#

71、183;·························2澆注系統(tǒng)的設(shè)計(jì)·······················

72、··························2.1主流道設(shè)計(jì)······················

73、3;··························2.1.1主流道尺寸······················

74、························2.1.2主流道襯套形式························

75、··················2.1.3主流道凝料體積······························

76、············2.1.4主流道剪切速率校核···································

77、3;··2.2分流道設(shè)計(jì)··············································&#

78、183;··2.2.1分流道布置形式··········································2.2.2分流道尺寸長度·&#

79、183;········································2.2.3分流道的形狀、截面尺寸及凝料體積······

80、;··················2.2.4分流道剪切速率校核·····························

81、83;········2.2.5分流道表面粗糙度·······································&#

82、183;2.3澆口的設(shè)計(jì)················································

83、·2.3.1潛伏式澆口尺寸的確定····································2.3.2澆口剪切速率的校核········&

84、#183;·····························2.4冷料穴的設(shè)計(jì)··················

85、3;····························2.4.1主流道冷料穴····················

86、;························2.4.2分流道冷料穴························

87、····················3成型零件的設(shè)計(jì)····························

88、3;····················3.1成型零件的結(jié)構(gòu)設(shè)計(jì)···························

89、3;·············3.1.1凹模設(shè)計(jì)···································&

90、#183;············3.1.2型芯設(shè)計(jì)···································

91、3;············3.2成型零件鋼材的選用···································

92、3;·····3.3成型零件工作尺寸的計(jì)算·····································3.3.1型腔徑向尺寸···

93、83;········································3.3.2型芯徑向尺寸·······

94、3;····································3.4成型零件強(qiáng)度及支承板厚度計(jì)算···········

95、;····················3.4.1型腔側(cè)壁的厚度····························

96、;·············3.4.2支承板的厚度···································

97、········4 模架的確定·········································

98、;············4.1各模板尺寸的確定····································

99、·······5 排氣槽的設(shè)計(jì)·········································

100、3;·········6 脫模推出機(jī)構(gòu)的設(shè)計(jì)·······································

101、;······7 溫度調(diào)節(jié)系統(tǒng)的設(shè)計(jì)··········································

102、···7.1冷卻水的體積流量···········································7.2冷卻水管道直徑

103、83;············································7.3冷卻水在管道內(nèi)的流速···&#

104、183;···································7.4冷卻管道孔壁與冷卻水之間的傳熱膜系數(shù)···········

105、;············7.5冷卻管道的總傳熱面積···································

106、3;···7.6模具上應(yīng)開設(shè)的冷卻水孔數(shù)···································參考文獻(xiàn) ········&#

107、183;·················································&#

108、183;文獻(xiàn)翻譯 ················································

109、83;···········致謝······································&

110、#183;··························第一章 綜述1 概述工、模具材料是工模具加工業(yè)的基礎(chǔ)。隨著我國國民經(jīng)濟(jì)發(fā)展和人民生活水平的提高， 人們對產(chǎn)品的審美觀，價(jià)值觀也不斷提高，從而對各類工、模具產(chǎn)品，無論是內(nèi)在質(zhì)量還是外表美觀等方面均要求日益精臻，困此勢必對工模具材料在數(shù)量上、系列上和質(zhì)量上提出更 高的要求。中國的模

111、具材料從無到有，從小到大，從少到多，直到現(xiàn)在，無論是從鋼種還是從規(guī)格、標(biāo)準(zhǔn)化、系列化等方面，都是伴隨著模具制造發(fā)展而發(fā)展的。五十七十年代（空白階段） 在這三十年中，由于我國推行計(jì)劃經(jīng)濟(jì)的模式和產(chǎn)業(yè)結(jié)構(gòu)上依照前蘇聯(lián)的生產(chǎn)方式，模具制造純屬依附于企業(yè)的一個(gè)配件加工車間。再則由于工業(yè)發(fā)展的緩慢和經(jīng)濟(jì)封閉，以及人民的生活水平處于很低的消費(fèi)水平等諸多因素，抑制了模具制造的產(chǎn)業(yè)化、社會化和商品化。由此而帶來了模具制造業(yè)對其所采用的材料要求不高甚至沒有要求，供需關(guān)系處于有什么用什么的不合理的混亂狀態(tài)。八十年代（發(fā)展階段） 隨著改革開放和國民經(jīng)濟(jì)的增長，很大程度上推動了模具制造業(yè)的發(fā)展。模具制造業(yè)已走出企業(yè)禁

112、錮的狀態(tài)，十年中，我國的仿制國外新鋼種的同時(shí)，還在高校、科研院所和各鋼廠的配合下，自行研制開發(fā)了一批適合我國國情的模具新鋼種。不僅改善了加工性能，而且還大大提高了模具的使用壽命。仿制D2鋼代替Cr12MoV制造沖壓模，用P20鋼代替45號鋼制造塑料模型芯、型腔，使模具的光潔度和壽命都有了較大的提高。用H13鋼代替國外已淘汰的3CW8V制造鍛模和壓鑄模。在冷作模具鋼方面，自行開發(fā)了65Nb、O12A、CG-2、LM1-2、LD、GD、GM、DS鋼等品種。其中65Nb、LD、GD及DS鋼因具有良好的抗沖擊性而更適合于作冷墩及原料沖裁凸模。GM鋼因有良好的耐磨性特別適合于作螺紋滾絲輪，與Cr12Mo

113、V相比，壽命可提高十多倍。除上述合金鋼外，還開發(fā)了GT35及DT等牌號的鋼結(jié)硬質(zhì)合金和YG系列的鎢鈷類硬硬合金以滿足高壽命的要求，制造高速沖床用的模具。在塑料模具鋼方面，自行開發(fā)了易切削類的5NiCa、06Ni、SM1、SM2以及PMS、CPR、PCY等鋼，都是一些具有良好加工、使用性能的優(yōu)良鋼種，并在使用上得到用戶的認(rèn)可。在熱作模具鋼方面Y4、Y10、HM-1、GR、ER8等新品種的開發(fā)和應(yīng)用徹底改變了熱作模具幾十年來由3Cr2W8V一統(tǒng)天下的局面。 九十年代(競爭階段) 隨著我國國民經(jīng)濟(jì)的發(fā)展和產(chǎn)品的更新?lián)Q代，我國已成為模具和模具材料的生產(chǎn)大國。據(jù)1997年統(tǒng)計(jì)，我國年耗模具材料13萬噸，

114、其中普鋼4.5噸。這說明模具這個(gè)特殊的產(chǎn)品在近十年中從計(jì)劃經(jīng)濟(jì)條件下的備件逐步發(fā)展成市場經(jīng)濟(jì)條件下的商品，并日益被模具制造商在其質(zhì)量和品牌上得到重視。而作為一個(gè)工業(yè)日趨發(fā)展，產(chǎn)品交替更新節(jié)奏很快的國家，其對模具的發(fā)展也更進(jìn)一步地被產(chǎn)品生產(chǎn)商重視。因此，一批過去已被研制成功的系列的能適應(yīng)不同工況條件和產(chǎn)品制造要求的模具材料的開發(fā)、試制和生產(chǎn)成為各大特鋼廠競爭相推出和競爭的市場熱點(diǎn)。但是，模具材料由于其規(guī)格繁多，同規(guī)格單次需求量少，市場即時(shí)采購等特點(diǎn)，使得各大鋼廠規(guī)模性生產(chǎn)裝備無法適應(yīng)。因此紛紛尋找合適的代理商以求得規(guī)模效應(yīng)。可是，眾多的代理商雖然手中握有厚資，但是對于模具工況條件，材料特性以及相

115、關(guān)熱處理等問題的了解不夠，都停留于普鋼類方面的激列競爭。另外，國外的資深代理機(jī)構(gòu)和各著名鋼廠近幾年來組織重兵力圖擠入中國的模具材料市場。如：瑞典的NUDDEHOLM、ASSAB，以及德國的蒂森、薩斯特，日本的大同等公司都在上海乃至全國各地樹起了優(yōu)特鋼的旗幟，但由于他們的價(jià)格過高，已逐漸顯得無法展開規(guī)模銷售，就連目前在國內(nèi)較有名氣的外資公司都在中國尋找價(jià)格低廉，品質(zhì)優(yōu)良的模具材料。2 如何分析沖裁零件沖裁件的工藝性是指零件在加工中的難易程度，在技術(shù)方面主要分析零件形狀特點(diǎn)、尺寸大小、精度要求和材料性能等因素是否符合沖裁工藝的要求。良好的工藝性應(yīng)保證材料消耗少、工序數(shù)目少、模具結(jié)構(gòu)簡單且壽命長，產(chǎn)

116、品質(zhì)量穩(wěn)定、操作簡單、方便等。在一般情況下對沖裁件工藝性影響最大的是沖裁結(jié)構(gòu)尺寸和精度要求，如果發(fā)現(xiàn)零件工藝性不好，則應(yīng)在不影響產(chǎn)品使用要求的前提下向產(chǎn)品開發(fā)部門提出修改意見，或在設(shè)計(jì)時(shí)采用相應(yīng)的工藝方法，避免由于工藝性差而容易產(chǎn)生的問題。 另外，分析沖裁件零件圖還要明確沖裁零件的難點(diǎn)所在，對于零件圖上的極限尺寸、設(shè)計(jì)基準(zhǔn)以及翹曲、毛刺大小和方向要求的要特別注意。因?yàn)檫@些因素對所需工序性質(zhì)的確定、對工件定位方式、模具制造精度結(jié)構(gòu)形式的選擇都有較大影響。分析沖裁件工藝主要有以下幾個(gè)方面：結(jié)構(gòu)形狀、尺寸大?。?a、沖裁件結(jié)構(gòu)形狀是否簡單、對稱？ b、沖裁件的外形或內(nèi)孔的轉(zhuǎn)角處是否有尖銳的清角。 c

117、、沖裁件上是否有過小孔徑。 d、沖裁件上是否有細(xì)長的懸臂和狹槽。 e、沖裁件上最大尺寸是多少？屬于大型、中型或小型。 f、沖裁件的孔與孔之間，孔與邊緣之間距離是否過小。尺寸精度、粗糙度、位置精度。 a、產(chǎn)品的最高尺寸精度是多少?b、產(chǎn)品的最高粗糙度時(shí)多少？c、產(chǎn)品的最高位置精度是多少？ 沖裁件材料的性能，分析產(chǎn)品的材料是否滿足以下要求。 a、技術(shù)要求：材料性能是否滿足使用要求，是否適應(yīng)工作條件。 b、沖壓工藝要求：材料的沖壓性能如何，表面質(zhì)量怎樣，材料的厚度公差是否符合國家標(biāo)準(zhǔn)。（3）沖壓加工的經(jīng)濟(jì)性分析產(chǎn)品的生產(chǎn)綱領(lǐng) 經(jīng)濟(jì)性 沖壓加工方法是一種先進(jìn)的工藝方法，因其產(chǎn)品質(zhì)量穩(wěn)定，材料利用率高，

118、操作簡單，生產(chǎn)率高等諸多優(yōu)點(diǎn)而被廣泛使用。由于模具制造成本高，沖壓加工的單件成本主要取決于生產(chǎn)批量的大小，它對沖壓加工的經(jīng)濟(jì)性起著決定性作用。批量越大，產(chǎn)品的單件成本就越低。批量小時(shí)，沖壓加工的優(yōu)越性就不明顯。所以，要根據(jù)沖壓件的生產(chǎn)綱領(lǐng)，進(jìn)行沖壓加工的經(jīng)濟(jì)性分析。通過工藝分析，如果發(fā)現(xiàn)沖裁件的工藝性差，應(yīng)在不影響其使用性能的條件下，對零件的形狀和尺寸做必要的、合理的修改，或說明在設(shè)計(jì)時(shí)如何注意容易產(chǎn)生的問題。良好的沖壓性能表現(xiàn)在材料消耗少，沖壓時(shí)不必采取特殊的控制手段，工藝過程簡單，模具結(jié)構(gòu)簡單、壽命較長，產(chǎn)品質(zhì)量穩(wěn)定、操作方便等。第二章 電極板沖孔模的設(shè)計(jì)1 產(chǎn)品簡介：零件名稱：電極板生產(chǎn)

119、批量：4000件/年材料：紫銅(硬)料厚：5mm產(chǎn)品零件圖： 毛坯 零件圖2 電極板沖孔模設(shè)計(jì)的前期準(zhǔn)備前期準(zhǔn)備工作主要包括閱讀產(chǎn)品零件圖，收集查閱有關(guān)設(shè)計(jì)資料，根據(jù)產(chǎn)品的原始數(shù)據(jù)研究設(shè)計(jì)任務(wù)，分析產(chǎn)品實(shí)施冷沖壓加工的可能性、經(jīng)濟(jì)性。2.1 研究設(shè)計(jì)任務(wù)2.1.1 閱讀沖裁件產(chǎn)品零件圖產(chǎn)品零件圖是制定沖壓工藝方案和模具設(shè)計(jì)的重要依據(jù)，在沖裁模設(shè)計(jì)之前，首先要仔細(xì)閱讀沖裁件產(chǎn)品零件圖，從產(chǎn)品的零件圖入手，進(jìn)行沖裁件工藝性分析和經(jīng)濟(jì)性分析。從電極板沖孔零件圖可知，它是由半成品毛坯經(jīng)沖孔得到的零件。2.1.2 分析沖裁件零件沖裁件的工藝性是指零件在加工中的難易程度，在技術(shù)方面主要分析零件形狀特點(diǎn)、尺

120、寸大小、精度要求和材料性能等因素是否符合沖裁工藝的要求。良好的工藝性應(yīng)保證材料消耗少、工序數(shù)目少、模具結(jié)構(gòu)簡單且壽命長，產(chǎn)品質(zhì)量穩(wěn)定、操作簡單、方便等。在一般情況下對沖裁件工藝性影響最大的是沖裁結(jié)構(gòu)尺寸和精度要求，如果發(fā)現(xiàn)零件工藝性不好，則應(yīng)在不影響產(chǎn)品使用要求的前提下向產(chǎn)品開發(fā)部門提出修改意見，或在設(shè)計(jì)時(shí)采用相應(yīng)的工藝方法，避免由于工藝性差而容易產(chǎn)生的問題。另外，分析沖裁件零件圖還要明確沖裁零件的難點(diǎn)所在，對于零件圖上的極限尺寸、設(shè)計(jì)基準(zhǔn)以及翹曲、毛刺大小和方向要求的要特別注意。因?yàn)檫@些因素對所需工序性質(zhì)的確定、對工件定位方式、模具制造精度結(jié)構(gòu)形式的選擇都有較大影響。分析沖裁件工藝主要有以下

121、幾個(gè)方面：結(jié)構(gòu)形狀、尺寸大小： a、沖裁件結(jié)構(gòu)形狀是否簡單、對稱？ b、沖裁件的外形或內(nèi)孔的轉(zhuǎn)角處是否有尖銳的清角。 c、沖裁件上是否有過小孔徑。 d、沖裁件上是否有細(xì)長的懸臂和狹槽。 e、沖裁件上最大尺寸是多少？屬于大型、中型或小型。 f、沖裁件的孔與孔之間，孔與邊緣之間距離是否過小。 此電極板是一個(gè)軸對稱的簡單沖孔件，內(nèi)孔為園孔，無尖銳的清角，無細(xì)長的懸臂和狹槽。小孔Ø8.33mm與邊緣之間的距離為20mm，大孔Ø14.3mm與邊緣之間的距離為5.65mm。其兩孔之間的距離為129.8mm，均滿足最小壁厚要求。其中最大尺寸為162.6mm，屬于中小型零件。最小尺寸為&#

122、216;8.33mm，不小于沖孔的最小孔徑（1.0t=5mm）,所以電極板尺寸設(shè)計(jì)合理，滿足工藝要求。尺寸精度、粗糙度、位置精度。 a、產(chǎn)品的最高尺寸精度是多少?b、產(chǎn)品的最高粗糙度時(shí)多少？c、產(chǎn)品的最高位置精度是多少？ 零件圖中兩沖孔尺寸均未標(biāo)注尺寸精度和位置精度，粗糙度也無要求。設(shè)計(jì)時(shí)一般按IT14級選取公差值，普通沖裁的沖孔精度一般在IT11IT12級以下，所以精度能夠保證。 沖裁件材料的性能，分析產(chǎn)品的材料是否滿足以下要求。 a、技術(shù)要求：材料性能是否滿足使用要求，是否適應(yīng)工作條件。 b、沖壓工藝要求：材料的沖壓性能如何，表面質(zhì)量怎樣，材料的厚度公差是否符合國家標(biāo)準(zhǔn)。紫銅（硬）具有良好

123、的導(dǎo)電性，滿足電極板導(dǎo)電的使用要求。利用設(shè)計(jì)手冊查處其抗剪強(qiáng)度t為240MPa抗拉強(qiáng)度6b為300MPa。具有良好的沖壓性能，滿足沖壓工藝要求。2.1.3 沖壓加工的經(jīng)濟(jì)性分析2.1.3.1 產(chǎn)品的生產(chǎn)綱領(lǐng) 年產(chǎn)量：4000件/年 屬于小批量生產(chǎn)。2.1.3.2 經(jīng)濟(jì)性 沖壓加工方法是一種先進(jìn)的工藝方法，因其產(chǎn)品質(zhì)量穩(wěn)定，材料利用率高，操作簡單，生產(chǎn)率高等諸多優(yōu)點(diǎn)而被廣泛使用。由于模具制造成本高，沖壓加工的單件成本主要取決于生產(chǎn)批量的大小，它對沖壓加工的經(jīng)濟(jì)性起著決定性作用。批量越大，產(chǎn)品的單件成本就越低。批量小時(shí)，沖壓加工的優(yōu)越性就不明顯。所以，要根據(jù)沖壓件的生產(chǎn)綱領(lǐng)，進(jìn)行沖壓加工的經(jīng)濟(jì)性分

124、析。此零件精度要求低，生產(chǎn)批量小，所以采用無導(dǎo)向簡單沖裁模進(jìn)行沖壓生產(chǎn)，就能保證產(chǎn)品的質(zhì)量，滿足生產(chǎn)要求，還能降低模具制造難度，降低生產(chǎn)成本。通過工藝分析，如果發(fā)現(xiàn)沖裁件的工藝性差，應(yīng)在不影響其使用性能的條件下，對零件的形狀和尺寸做必要的、合理的修改，或說明在設(shè)計(jì)時(shí)如何注意容易產(chǎn)生的問題。良好的沖壓性能表現(xiàn)在材料消耗少，沖壓時(shí)不必采取特殊的控制手段，工藝過程簡單，模具結(jié)構(gòu)簡單、壽命較長，產(chǎn)品質(zhì)量穩(wěn)定、操作方便等。3 總體方案的確定 確定工藝方案，主要是確定模具類型，包括確定沖壓工序、工序的組合和工序順序等。應(yīng)在工藝分析的基礎(chǔ)上，根據(jù)沖裁件的生產(chǎn)批量、尺寸精度的高低、尺寸大小、形狀復(fù)雜程度、材料

125、的厚薄、沖模制造條件與沖壓設(shè)備條件等多方面因素，擬定多種沖壓工藝，然后選出一種最佳方案。3.1 電極板沖孔模類型的確定3.1.1 一般沖裁?？梢圆捎靡韵氯N方案 方案一：采用無導(dǎo)向簡單沖裁模 方案二：采用導(dǎo)板導(dǎo)向簡單沖裁模 方案三：采用導(dǎo)柱導(dǎo)向簡單沖裁模3.1.2 分析論證方案一：無導(dǎo)向簡單沖裁模結(jié)構(gòu)簡單、尺寸小、質(zhì)量輕、模具制造容易、成本低，但沖模在使用安裝時(shí)麻煩，需要調(diào)試間隙的均勻性，沖裁精度低且模具壽命低。它適用于精度要求低、形狀簡單、批量小或試制的沖裁件。方案二：導(dǎo)板導(dǎo)向簡單沖裁模比無導(dǎo)向簡單沖裁模高、使用壽命較長、單模具制造較復(fù)雜、沖裁時(shí)視線不好。不適合單個(gè)毛坯的送料、沖裁。方案三：

126、導(dǎo)柱導(dǎo)向簡單沖裁模導(dǎo)向準(zhǔn)確、可靠，能保證沖裁間隙均勻、穩(wěn)定，因此沖裁精度比導(dǎo)板模高，使用壽命長。但比前兩種模具成本高。由于電極板批量小、精度低，故采用無導(dǎo)向簡單沖裁模就能滿足工藝要求，并能縮短模具的制造周期，降低模具的制造成本。所以本設(shè)計(jì)采用一模兩件的無導(dǎo)向簡單沖裁模。3.2 結(jié)構(gòu)形式的確定3.2.1 操作方式選擇 選擇手工送料（單個(gè)毛坯）操作方式。3.2.2 定位方式的選擇 工件在模具中的定位主要考慮定位基準(zhǔn)、上料方式、操作安全可靠等因素。 選擇定位基準(zhǔn)時(shí)應(yīng)盡可能與設(shè)計(jì)基準(zhǔn)重合，如果不重合，就需要根據(jù)尺寸鏈計(jì)算，重新分配公差，把設(shè)計(jì)尺寸換成工藝尺寸，但是這樣會使零件的加工精度要求提高。當(dāng)零件

127、采用多工序分別在不同模具上沖壓時(shí)，應(yīng)盡量使各工序采用同一基準(zhǔn)。為使定位可靠，應(yīng)選擇精度高、沖壓時(shí)不發(fā)生變形和移動的表面作為定位表面。沖壓件上能夠作用定位的表面隨零件的形狀不同而不同。 本設(shè)計(jì)采用定位板定位方式，見下圖。3.2.3 卸料方式由于此設(shè)計(jì)采用單個(gè)毛坯，手動操作送進(jìn)和定位，并且材料不是太硬，所以選擇彈性卸料方式比較方便、合理。4 工藝計(jì)算4.1 凸、凹刃口尺寸計(jì)算4.1.1 凸、凹模刃口尺寸計(jì)算的原則 設(shè)計(jì)基準(zhǔn)：落料以凹模為設(shè)計(jì)基準(zhǔn)，間隙取在凸模上；沖孔以凸模為設(shè)計(jì)基準(zhǔn)，間隙取在凹模上。設(shè)計(jì)時(shí)間隙一律采用最小合理間隙值Z。刃口尺寸的制造偏差方向：單向注入實(shí)體內(nèi)部。即磨損后，凸、凹模刃口尺寸變大的取+;磨損后凸、凹模刃口尺寸變小的取。刃口尺寸制造偏差的大小：簡單形狀，按IT6IT7取值；復(fù)雜形狀，取；磨損后尺寸無變化，取。加工方法：簡單形狀，分別加工；復(fù)雜形狀，配合加工。4.1.2 簡單形狀凸、凹模刃口尺寸的計(jì)算檢驗(yàn)。由分別加工的互換性要求采用較小的模具制造公差