剎車保持架沖壓成形工藝及模具設(shè)計(jì)外文翻譯

英文BrakemaintainsastampingformingtechnologyanddiedesignBrakecage,partiallywrappedallorpartoftherollbody,andwiththemovementofthebearingparts,usedtoisolaterollingbody,usuallyalsoguideandkeepitwithinthebearingroller.Retainersmaterial:rollingbearingatwork,heatandwearcausedbyslidingfrictionbearing,especiallyundertheconditionofhightemperatureoperation,inertialcentrifugalforceroleexacerbatedthefriction,wearandheat,bracketwillbecausedseriousburnsorrupture,thebearingcanworknormally.Requestretainersmaterial,therefore,besideshaveacertainstrength,mustalsohavegoodthermalconductivity,smallfrictioncoefficient,goodwearresistance,impacttoughness,densityissmallandlinearexpansioncoefficientandphaseclosetotheroller.Inaddition,thepresscageneedtoundergocomplicatedstampingdeformation,alsorequiresamaterialhasgoodprocessingperformance.First，F(xiàn)unctionandclassificationofbearingcageKeepbearingframeisoneofthemainparts,keeptheaircraftintherollingbearinghasfourbasicfunctions:1.Separationroller;2.Willkeeprollingelementitselforkeepitwitharingtogether;3.Guidanceontherighttrackrollerrolling;4.Theorientationofrollingbody,reducethefriction.Accordingtothemanufacturingprocessandmaterialsusedincagecanbedividedinto:stampingatlowandmediumcarbonsteelasthematerialofthecage;Withhighstrengthcopperalloy(leadbrass,nickel,siliconbronze,etc.),zincalloy,ductilecastironasthematerialofthealloysolidcage;Polyamideresinasmaterialofengineeringplasticcage;Phenoliclaminatedclothtubeasmaterialentitiesphenolicbakeliteretainer.Includingpunchingcagewithhighproductionefficiency,qualitativelight,intensityisgood,widecoverageandwidelyused.Retainersarebasicrequirementsofthedesigninacertainspaceandstructurestrengthmaximumload-bearingloadandmeetthebearingontherotatingprecisionandspeedrequirements,accordingtotheworkingconditionoftheuseofbearingsonthehostandguideclearancerequirements,determinetheinnerandouterdiameterorrollerguideway,andthendeterminethestructureandmainparameters.Rollingbearingatwork,heatandwearcausedbyslidingfrictionbearing,especiallyundertheconditionofhighspeed,duetotheroleofcentrifugalforce,inertiaforce,speeduptheinternalrollingelementbearings,innerandouterringandcagecollision,frictionandwearwithfever,bracketwillbecausedseriousburnsandfracture,thebearingcan'tnormaluse,keeptheframedamageinmakeupalargeproportionofbearingfailureforms,andinthecageinthecauseofthedamage,thecagematerialqualityisoneofthemainreasons.Therefore,bearingretainersrequirementsshouldhavegoodmechanicalstrength;Thestabilityofsize;Goodplasticityandmachinabilityaspectsofperformance.Becausemaintainsauniquewayofmachiningprocessorofthelimitations,andconsideringtheforcebearing,lubrication,thespeed,temperatureandsoonvariousaspectsfactorandtheinfluenceofthemarketforbearinghighspeed,highprecision,overload,longlifeandlownoiserequirements,bearingcagetechnologycontinuousimprovementanddevelopmenthasbecomeinevitable.Second,theevolvementanddevelopmentofpunchingcagestructureInherentstructureimprovementofrollingbearing,inadditiontoincreasethenumberandsizeroller,mostlyduetothebearingcagestructureimprovement.Punchingcage,forexample,therearedozensoftypesofstructures.Itscommonorgenericinthepressingcagestructuretypeandstructureevolvementanddevelopmentoftheintroductionisasfollows:1.Deepgrooveballbearingcage;Itscagetypewithleadguardribboncage;\"S\"shapecage;Ribboncage;Crownretainer;Withclawribboncage;One-wayclearanceribboncage;DoublewaveformcageKvalues.Thetopfivekindsofstructureareoldtypecagestructure.One-waywaveclearanceformcageandthedoubleKvalueofthewaveformcage,greasegrooveribboncagealldevelopmentortoreducenoise,exploreanewtypeofcagestructure,atthesametimecanimprovethelubricatingabilityofcage,areofgreathelptoimprovethespeedofthebearing.Abroadcentripetalballbearingcagepocketholewitharoundoroval,rotationalflexibilitygood,clearancerange13to25microns,tendtowidenthecagestructure,(widthratioofballdiameterof0.45to0.48),highstrength,goodrigidity,ballpocketholeRlightbeltround,full,platformparalleldifferencebetweensmall,USEStherivetwithtaperedinterference,highpositioningaccuracy,suitableforhighefficiencyautomaticassembly,aftertheriveting,rotationalflexibilityisgood,lownoise.2.Self-aligningballbearingcage,itsstructureischrysanthemumformcage;Kwaiformcage;Elephantnosecage.Thestampingmaintainsabasicnotmuchchangeinthestructure,butthestampingmouldmanufacturingcomplex,productsizeisdifficulttoguaranteeandinspection,astheengineeringplasticcagestrengthandthecontinuousimprovementofhightemperatureresistantperformance,hasbeenthetrendofgraduallyreplaced.Third，thenatureofthecageandfunction1:onthebasisofguaranteethestrength,canmaketherollingelementbearingshaveincreasedinquantityorgeometrysize,inordertoimprovethebearingcapacityandservicelife.2:havehastheabilitytoimprovetheselflubricatingbearing,atthesametimecanreducethenoise.Meettherequirementsofbearingtoimprovespeedandreducenoise.3:havesaverawmaterialsandreducetheimpactonthesurroundingenvironment.ImprovematerialutilizationandsaverawmaterialisthetrendofTheTimes,especiallywhenlimitedresourcesincreasinglytenseofcoppermaterial,withsteelandcopper,plasticgenerationthatistokeeptheframestructureplayedasignificantroleinimprovingandalternative.Intermsofenvironment,reducepollution,increasinglybecomethefocusofenterprisesandsociety.4:improvethesurfacehardnessandretainerslubricatingabilitywillbecomethedevelopmentdirectionofnewcagestructure.Punchingcageatpresent,undertheconditionofenvironmentalprotectionofsurfaceshotblasting,finishing,blueandotherphysical,chemicalprocessing,toreducestressincage,improvethesurfaceroughness,lubricationabilityhasplayedapositiverole.Partstructure,suchasshortconical,cylindricalandsphericalrollerbearings,needlerollerbearingcagesurfacecarburizing,carbonitriding,orbracketwillbesoftnitridingtreatmentistoimprovethemechanicalstrengthandresistancetowear,prolongingthelifeofthecageplayakeyrole.Anynewthinghasitsoccurrenceanddevelopmentprocess,structureimprovementandadvancementofthecageisnotexceptionalalso,technologyprogressanddevelopmentistheeternalthemeinbearingindustry.Stampingmaintainsaproductionandprocessingofthenewstructurenotonlyhavetechnicaldifficulties,thereisalsohaveabilitytoacceptthemarketproblem.However,improvingthestructureofthecageaslongasmeettheincreasedspeed,load,bearinglifeandreducenoise,saverawmaterials,havedemonstratedthedevelopmentoftheabsolutetruth,thereisthesurvivalanddevelopmentspace,itwillbeacceptedbythemarket,soastooccupythemarket,bringmorerichlyrewardedforenterprisesandusers.Fourth，maintainsaworkefficiencyandapplicationpunchingcagemanufacturecraftandtheequipmentabroadwavetypedeepgrooveballbearingcageismorespecializedandautomaticproduction,accordingtothesizeofthecagetherearetwomainmodeofproduction:tinycageusingcoilonthesimplexpresscompoundonprogressivedie,moldingprocessfortheprecisiononthecoilstep5-7station,inturngraduallyundertheexpected,thecuttingring,forming,shaping,cutting,etc.Smallandmedium-sizedcageusingcoiledmaterialinhigh-speedtransferstampingpressesthewavetypecage,directlydowntheringmaterialfirst,andthenbyclampsteppingintomechanicalarmonbothsidesofeachstation,incompleteforming,punching,processessuchasplasticrivethole.Thecharacteristicsofthetwowaysarecomplexmould,manufacturingofhighprecision,longlife,safeandreliable,highproductionefficiency,suitableforlittlevarietyandmassproduction.Domesticseatypecageinthepastwithasinglepunchlistprocessproduction,andacageneed4-5unitspunch,dieandforthestaffoftheoperationtocomplete,simplemouldefficiencyislow,productioncostsarehigh.Inordertoimprovethequalityandefficiency,luoyangretainerfactorytooktheleadintheindustryinthedevelopmentofthemechanicalarmtypemulti-stationpunch,butduetothemoldandcontrolelementisnotpass,themachineprice,hasbeencannotgetagoodpromotionanduse.Shandongliaochengregionofsomecompanies,suchasgoldemperor,andonthisbasistodotheimprovement,withasinglepunchcoilautomaticflushring,onsinglearmupintothemouldagaintocompletetheotherprocessapproachtomakethemouldandmachinecostsbecomesimple,andcangreatlyimproveproductionefficiency,thusinliaochengmaintainsspecializingintheproductionareatogetapromotionandpopularization.Zhejiang,longinthe90stointroduceJapan'scoilautomaticproductionlineproducetinycage,throughtotheequipmentandmoldconstantlydigestionandabsorption,innovation,improvement,hasgreatlyreducedthecostofmouldandequipmentused,becomeoutstandingminiaturecageproduction.WuxiAnFengalsobyimitatingandexploration,successfullydevelopedhighspeedautomaticsteppingmodevolumes,isusedintheproductionoftheminiaturecage.Domesticmostoftheneedlerollerbearingcageproductionforsingleprocessofpunchingholeandpunchingandflanging,way,suchasplasticprecisionmoldandautoindustryisfarfrommeetingtherequirementofmassproductionefficiencyofformacompletesetofrequirements.Nowsuzhoushaftbearingfactoryco.,LTD.,duct,changzhouGuangYangrespectivelyintroducedtheTorringtonNTNcorporationandJapanneedlerollerbearingmanufacturingtechnology,makeitshavetheworld'smostadvancedprofessionalneedlerollerbearingprocessingequipment,suchas:theSwissSAFEDcompany'sheattreatmentfurnace;SwedishLIDOINGcompanycenterlessgrindingmachine;BritishPLATARGtransferpress;GermanyBilhercompanymaintainsautomaticweldingmachineandsoon,eachoftheautomaticlinewithcoil,multi-stationcoldgrindingformingstepdiepunching,automaticrollforming,plasticweldingprocessessuchasmassproductionwithhighefficiency,canproduce50000setsofleftandrightsideskeepineveryline.Othertypesofcage,suchasbasketshape,bowl,anddrumstructureandlimitsofproduction,large-scaleautomatedproductionisdifficulttoachieve,themorecommonlyusedsinglebisectedautomaticblanking,punchingholemachine,punching,pressuregradientandplastictocomplete.Basketshapedcagealsocanuseawholepunchingmoldingprocess,mouldmanufacturingcomplex,highcost.Tosumup,ourcountryofrollingbearingretainerandprocessingquality,technologyandmanufacturingequipmentlevelsalsohastheverybigdisparitycomparedwithforeignadvancedlevel,speedupthedevelopmentofnewhighspeed,efficient,stampingequipment,improvetheprecisionofcomplexcompositemembrane,continuousprogressivediemold,moldmanufacturinglevel,toadapttothebearingcageneedsofindustryspecializationandautomation,massproductionisstillourfuturelong-termeffortsandstrivingdirectionandgoals.譯文剎車保持架沖壓成型工藝及模具設(shè)計(jì)剎車保持架，部分地包裹全部或部分滾動(dòng)體，并隨之運(yùn)動(dòng)的軸承零件，用以隔離滾動(dòng)體，通常還引導(dǎo)滾動(dòng)體并將其保持在軸承內(nèi)。保持架的材料：滾動(dòng)軸承在工作時(shí)，由于滑動(dòng)摩擦而造成軸承發(fā)熱和磨損，特別在高溫運(yùn)轉(zhuǎn)條件下，慣性離心力的作用加劇了摩擦、磨損與發(fā)熱，嚴(yán)重時(shí)會(huì)造成保持架燒傷或斷裂，致使軸承不能正常工作。因此，要求保持架的材料除具有一定強(qiáng)度外，還必須導(dǎo)熱性好、摩擦因數(shù)小、耐磨性好、沖擊韌性強(qiáng)、密度較小且線脹系數(shù)與滾動(dòng)體相接近。此外，沖壓保持架需經(jīng)受較復(fù)雜的沖壓變形，還要求材料具有良好的加工性能。一、剎車保持架的作用和分類保持架是軸承的主要零件之一，保持架在滾動(dòng)軸承中有四個(gè)基本作用：1．分離滾動(dòng)體；2．將滾動(dòng)體本身保持住或使其與一個(gè)套圈保持在一起；3．引導(dǎo)滾動(dòng)體在正確的軌道上滾動(dòng)；4.對滾動(dòng)體定向、減少摩擦力。按其制造工藝和所使用的材料保持架可分為：以低、中碳鋼為材質(zhì)的沖壓保持架；以高強(qiáng)度銅合金（鉛黃銅、鎳、硅青銅等）、鋅鋁合金、球墨鑄鐵等為材質(zhì)的合金實(shí)體保持架；以聚酰胺樹脂為材質(zhì)的工程塑料保持架；以酚醛層壓布管為材質(zhì)的酚醛膠木實(shí)體保持架。其中沖壓保持架以其生產(chǎn)效率高，材質(zhì)輕，強(qiáng)度好，覆蓋范圍廣而得到廣泛的應(yīng)用。保持架設(shè)計(jì)的基本要求是在一定的空間和結(jié)構(gòu)強(qiáng)度上滿足軸承的最大承載載荷和旋轉(zhuǎn)精度和速度的要求，可根據(jù)軸承在主機(jī)中的使用工況及引導(dǎo)間隙的要求，確定內(nèi)、外徑或滾動(dòng)體的引導(dǎo)方式，進(jìn)而確定結(jié)構(gòu)和主參數(shù)。滾動(dòng)軸承在工作時(shí)，由于滑動(dòng)摩擦而造成軸承發(fā)熱和磨損，特別是在高速運(yùn)轉(zhuǎn)的條件下，由于離心力、慣性力的作用，加速了軸承內(nèi)部滾動(dòng)體、內(nèi)外圈與保持架的碰撞、摩擦磨損與發(fā)熱，嚴(yán)重時(shí)會(huì)造成保持架燒傷和斷裂，致使軸承不能正常使用，保持架損壞在軸承失效形式中占很大的比例，而在保持架損壞的原因中，保持架材質(zhì)好壞又是主要原因之一。因此，要求軸承保持架的材質(zhì)應(yīng)具有良好的機(jī)械強(qiáng)度；尺寸的穩(wěn)定性；良好的可塑性和可加工性等多方面性能。由于保持架特有的加工方式或工藝難度的局限，并考慮其受力、潤滑、速度、溫度等各方面因素的影響以及市場對軸承高速、高精、重載、長壽命、低噪音的要求，軸承保持架技術(shù)的不斷改進(jìn)和發(fā)展已成為必然。二、沖壓保持架結(jié)構(gòu)的衍變和發(fā)展固有滾動(dòng)軸承的結(jié)構(gòu)改進(jìn)，除了增加滾動(dòng)體數(shù)量和尺寸外，大多出于對軸承保持架結(jié)構(gòu)的改進(jìn)上。以沖壓保持架為例，就有數(shù)十種結(jié)構(gòu)類型。在此就其常見或通用的沖壓保持架結(jié)構(gòu)類型以及結(jié)構(gòu)的衍變和發(fā)展介紹如下：1．深溝球軸承用保持架；其保持架類型有帶引導(dǎo)擋邊的浪形保持架；“S”形保持架；浪形保持架；冠形保持架；帶爪浪形保持架；單向游隙浪形保持架；雙K值浪形保持架。其中前五種結(jié)構(gòu)均為老結(jié)構(gòu)類型保持架。單向游隙浪形保持架和雙K值浪形保持架、帶油槽浪形保持架均為降低噪音而發(fā)展或探索出的新型結(jié)構(gòu)保持架，同時(shí)可以提高保持架的潤滑能力，對提高軸承的轉(zhuǎn)速有很大幫助。國外向心球軸承保持架球兜孔采用正圓形或橢圓形，旋轉(zhuǎn)靈活性好，游隙變化范圍為13-25微米，保持架結(jié)構(gòu)趨向于加寬，（寬度比為球徑的0.45-0.48），強(qiáng)度高，剛性好，球兜孔R(shí)的光亮帶圓滑，飽滿，平臺(tái)間相互平行差小，采用帶錐形過盈鉚釘，定位精度高，適于高效率自動(dòng)裝配，鉚合后，旋轉(zhuǎn)靈活性好，噪音低。2．調(diào)心球軸承保持架，其結(jié)構(gòu)有菊形保持架；葵形保持架；象鼻形保持架。該類沖壓保持架在結(jié)構(gòu)上基本沒有多大變化，但沖壓模具制造復(fù)雜，產(chǎn)品尺寸難以保證和檢驗(yàn)，隨著工程塑料保持架強(qiáng)度和耐高溫性能的不斷提高，有被其逐步替代的趨勢。三、保持架的性質(zhì)與作用1：在保證強(qiáng)度的基礎(chǔ)上，能夠使軸承滾動(dòng)體在數(shù)量或幾何尺寸上得到增加，以提高軸承的承載能力和使用壽命。2：具備有提高軸承的自潤滑的能力，同時(shí)可以降低噪音。滿足軸承提高轉(zhuǎn)速和減少噪音的要求。3：具備有節(jié)約原材料和減少對周邊環(huán)境的影響。提高材料利用率和節(jié)約原材料是大勢所趨，尤其是銅材料的有限資源日益緊張，以鋼代銅，以塑代銅都對保持架的結(jié)構(gòu)改進(jìn)和替代起到了促進(jìn)作用。在環(huán)境方面，減少污染日益成為企業(yè)和社會(huì)關(guān)注的重點(diǎn)。4.：提高保持架的表面硬度及潤滑能力將成為新結(jié)構(gòu)保持架的發(fā)展方向。當(dāng)前，在環(huán)保條件下對沖壓保持架表面所進(jìn)行的拋丸、光飾、發(fā)藍(lán)等物理、化學(xué)處理，都為降低保持架內(nèi)應(yīng)力，改善表面粗糙度及潤滑能力起到了積極的作用。部分結(jié)構(gòu)如圓錐、短圓柱及調(diào)心滾子軸承、滾針軸承保持架的表面滲碳、碳氮共滲或軟氮化處理都對提高保持架的機(jī)械強(qiáng)度和耐磨性，延長保持架的壽命起到關(guān)鍵性的作用。任何新生事物的發(fā)生和發(fā)展都有其過程，保持架的結(jié)構(gòu)改進(jìn)與進(jìn)步也不例外，技術(shù)進(jìn)步和發(fā)展一直是軸承行業(yè)永恒的主題。新結(jié)構(gòu)沖壓保持架的生產(chǎn)與加工不但存在有技術(shù)困難，還存在有市場的接受能力的問題。但是，改進(jìn)結(jié)構(gòu)的保持架只要滿足了提高軸承轉(zhuǎn)速、載荷、壽命及降低了噪音，節(jié)約了原材料，就具備了發(fā)展的硬道理，就有生存和發(fā)展的空間，就必將為市場接受，從而占領(lǐng)市場，為企業(yè)和用戶帶來更加豐厚的回報(bào)。四、保持架的工作效率與應(yīng)用沖壓保持架制造工藝及其裝備國外深溝球軸承浪型保持架多為專業(yè)化、自動(dòng)化生產(chǎn)，根據(jù)保持架的大小有兩種主要生產(chǎn)方式：微型保持架采用卷料在高速單工位壓力機(jī)的復(fù)合級進(jìn)模上完成，成型工藝為在卷料上精密步進(jìn)5—7個(gè)工位，依次逐步下料，裁環(huán)，成型、整形、切邊等工序。中小型保持架采用卷料在高速多工位壓力機(jī)上沖壓浪型保持架，先直接沖下環(huán)料，然后靠兩邊機(jī)械臂夾住步進(jìn)送入各個(gè)工位，依次完成成型、沖鉚釘孔、整形等工序。兩種方式的特點(diǎn)都是模具復(fù)雜、制造精度高、壽命長、安全可靠、生產(chǎn)效率高，適合少品種、大批量生產(chǎn)。國內(nèi)浪型保持架過去多采用單臺(tái)沖床單工序生產(chǎn)，一副保持架需4-5臺(tái)沖床、模具和為其操作的員工才能完成，模具簡單效率低，生產(chǎn)成本高。為提高質(zhì)量和效率，洛軸保持器廠率先在行業(yè)中開發(fā)了機(jī)械臂式多工位沖床，但由于模具和自控元件不過關(guān)、機(jī)床價(jià)格等原因，一直得不到很好的推廣和使用。山東聊城地區(qū)的一些企業(yè)如金帝、人和等在此基礎(chǔ)上做了改進(jìn)，采用單臺(tái)沖床卷料自動(dòng)沖環(huán)，再放到單臺(tái)步進(jìn)模機(jī)械臂上完成其他工序的方法使得模具和機(jī)床成本變得簡單易行，又能大幅提高生產(chǎn)效率，因而在聊城的保持架專業(yè)生產(chǎn)地區(qū)得到推廣和普及。浙江利隆于90年代起引進(jìn)日本的卷料自動(dòng)生產(chǎn)線生產(chǎn)微型保持架，通過對設(shè)備和模具的不斷地消化吸收、創(chuàng)新改進(jìn)，已大幅降低了模具和設(shè)備的使用成本，成為微型保持架生產(chǎn)的佼佼者。無錫安風(fēng)也通過模仿和探索，成功地開發(fā)了卷料高速自動(dòng)步進(jìn)模，用于微型保持架的生產(chǎn)。國內(nèi)大部分滾針軸承保持架生產(chǎn)為單工序的沖窗孔機(jī)和沖孔、彎邊、整形等方式，模具精度和生產(chǎn)效率遠(yuǎn)不能滿足汽車工業(yè)大批量的配套要求。目前蘇州軸承廠有限公司、襄軸、常州光洋分別引進(jìn)了美國Torrington和日本ＮＴＮ公司的滾針軸承制造技術(shù)，使其擁有世界上最先進(jìn)的滾針軸承專業(yè)工藝設(shè)備，如：瑞士SAFED公司的熱處理爐；瑞典LID?ING公司的無心磨床；英國PLATARG公司的多工位壓力機(jī)；德國Bilher公司的保持架自動(dòng)卷焊機(jī)等等，每條自動(dòng)線采用卷料冷碾成形、多工位步進(jìn)模具沖孔、自動(dòng)卷焊成型、整形等工序高效率大規(guī)模生產(chǎn)，每條線可班產(chǎn)5萬套左右保持架。其他類型的保持架如筐形、碗形和鼓形受結(jié)構(gòu)和產(chǎn)量的限制，大規(guī)模自動(dòng)化生產(chǎn)較難實(shí)現(xiàn)，一般多采用單工序的下料、自動(dòng)等分沖窗孔機(jī)沖孔、壓坡、整形來完成?？鹦伪３旨芤部刹捎谜w一次沖孔成型工藝加工，但模具制造復(fù)雜，成本高?？傊?，我國滾動(dòng)軸承保持架的加工質(zhì)量、工藝和制造設(shè)備水平與國外先進(jìn)水平相比還有很大差距，加快發(fā)展新型高速、高效沖壓設(shè)備，提高精密復(fù)雜復(fù)合膜、連續(xù)模、級進(jìn)模模具制造水平，適應(yīng)軸承保持架行業(yè)專業(yè)化、自動(dòng)化、大規(guī)模生產(chǎn)的需要，依然是我們今后長期努力和奮斗的方向和目標(biāo)。目錄TOC\o"1-2"\p""\h\z\u第一章總論 11.1項(xiàng)目概況 11.2研究依據(jù)及范圍 21.3結(jié)論 31.4建議 4第二章項(xiàng)目建設(shè)的背景和必要性 52.1項(xiàng)目建設(shè)的背景 62.2項(xiàng)目建設(shè)的必要性 7第三章項(xiàng)目服務(wù)需求分析 9第四章項(xiàng)目選址與建設(shè)條件 114.1選址原則 114.2項(xiàng)目選址 114.3建設(shè)條件 12第五章建設(shè)方案與設(shè)計(jì) 125.1建設(shè)規(guī)模與