高速精密级进冲压中的冲裁断面质量实验研究

运用正交实验方法,研究了冲裁间隙、模具表面粗糙度、冲压速度对高速精密级进冲压中的冲裁断面质量的影响,结果显示,模具表面粗糙度对冲裁断面质量的影响最大,模具表面精度越高,冲裁断面质量越好。因此,尽量采用先进的加工设备和加工工艺以获得尽量高的凸、凹模表面加工精度,对于保证高速精密级进冲压中的冲裁断面质量非常重要。     

接触端子精密级进模设计

基于接触端子外形、尺寸、精度特点及其高速冲压成形时的主要问题,详细叙述了接触端子精密级进模的排样、模具结构、模具主要零部件的设计过程,并简要介绍了级进模主要零部件的加工工艺。模具设计合理,结构可靠,制造精度高,维修方便,适应高速冲压生产要求。     

弧形簧片精密高速多工位级进模设计

基于弧形簧片外形、尺寸、精度特点及其高速冲压成形时的主要问题,叙述了工位设计、排样图设计、步距精度、模具结构及关键零件设计等关键技术.介绍了高速精密级进模主要零部件的加工工艺.模具结构紧凑合理,制程稳定性好,适应高速冲压生产要求.     

试谈精密级进模的寿命

<正> 制造精度高、间隙均匀和易损件具有互换性是精密级进模的主要特点之一,因而使模具寿命大大提高了,实现了高速自动精密冲压加工,使冲压件的质量、生产效率提     

电机定转子冲压控制系统的设计

传统的电机定转子冲压工艺落后。用精密加工机床作保证,以先进的自动控制技术为后盾,开发了电机定转子自动化生产线。采用高效率、高寿命多工位级进模具现代冲压技术,配合P2H-500高速精密机床,实现了电机带回转和扭斜定转子大批量自动化生产,以此保证各类电机各技术性能。     

多工位高速冲压级进模具错层模板结构

分析平行模板结构的级进模具,由于受到模板厚度的限制,模具凸模长度较长。当凸模截面尺寸小,且采用硬质合金材料时,凸模抗冲击性能差,冲裁中易发生折断。该类模具结构不适合采用高速精密级进冲模加工产品尺寸小、生产批量大的电子产品。文章提出一种新型错层模板模具结构,有效缩短冲裁凸模长度,提高了硬质合金凸模抗冲击性能,避免凸模在高速冲压条件由于振动发生折断。     

涂层技术在制造业中的应用

21世纪我国制造业正朝着高速、高效和高精密加工的方向发展。随着我国汽车、航空和模具等制造业的发展，以及高效数控加工设备的普及，各种高硬度、高韧性难加工材料对工、模具的表面涂层技术提出了更高的要求，涂层技术也将得到日益广泛的应用。     

提高冲模耐磨性的热处理方法

本文将探讨如何从热处理的角度提高以高速工具钢为基本材料的冲压模具的耐磨性。 1.冲模材料由于冷冲模工作时反复承受着摩擦、压缩、冲击等应力的作用,常被磨损。因磨损与硬度有关,常通过提高硬度去追求耐磨性。但硬度高则容易崩碎。因此选择材料和进行热处理不仅是为了得到高硬度,还要考虑韧性和寿命。冷冲模材料在摩擦热的不断作用下其硬度不应降低,应具有抗退火软化的性能。     

通过表面改性提高冲裁模的寿命

0前言提高冲裁模的寿命可以降低模具修理成本和冲床待机的生产损失,对提高冲压生产效率有很大的经济效果。因此,提高作为高价值生产资料之金属冲裁模的寿命乃是冲压技术的一个重要的研究领域。为此,正在不断地努力开发提高金属模具之耐磨性的技术。其具体的措施有:1)选择硬质的模具材料。2)确定模具材料的最佳热处理条件。3)在模具表面涂覆各种硬质膜,进行表面改性。但是,采取这些措施可能带来如下一些缺点:1)高硬度的模具材料容易发生裂纹和缺损。特别是局部刃口承受大负荷的冲裁模,这一危险性更高。而且,由于硬度高,切削性变差、加工费时,…     

高速冲压模具精密导向机构研究

研究不同模具导向方式对高速冲压模具定位精度的影响.通过对传统多工位级进模具导向机构分析,提出这种导向机构由于滑动导柱导套间的配合间隙使模具合模时存在定位误差.指出传统多工位级进模具导向机构不能满足冲裁间隙和步距精度在微米级的引线框架零件多工位精密级进模的设计精度要求.设计出一种无滑动导向件、无定位精度误差的精密级进模具的导向机构,满足了精密零件级进模具的冲裁加工要求.     

带超高实体凸台的薄板冲压件加工工艺研究

在金属板料成形过程中,由于夹在凸模与凹模之间的板料随着加工的进行变得越来越薄,导致板料向凹模腔内的流动阻力越来越大,从而阻碍材料流向凹模型腔,因此利用传统成形工艺无法在薄板上加工带超高凸台的冲压零件.本文研究了一带超高实体凸台的零件,并根据数值模拟及一系列工艺实验结果,研制了一套连续模,获得了超高凸台冲压零件.研究表明,利用弯曲、镦挤复合新工艺方法能够实现在薄板上加工带超高凸台冲压零件,而且与该零件的其它加工方法相比新工艺具有诸多优越性.     

汽车前翼子板整形翻边冲孔复合模设计

分析了前翼子板的工艺特性,设计了模具结构,论述了其工作过程。该模具的凸模部分由固定凸模和可伸缩的活动凸模组成,解决了零件成形后出件难的问题;翻边凹模设有让位槽,解决了其与冲孔凸模干涉的问题;使用了氮气缸来调节压料力,简化了模具结构,提高了生产效率。     

一种新型材质轿车前悬架横梁加强件冲压工艺

分析了一种新型材质轿车前悬架横梁加强件零件材质的特点,制定了其冲压工艺。设计了拉深模并对模具进行了调试。运用Dynaform软件,分别对料片拉深和落料后拉深的冲压成形过程进行数值模拟。对比模拟结果,确定合理的工艺方案,进一步优化工艺参数和模具结构。经生产实践验证,该模具工作状态良好,冲件质量稳定。     

汽车盘式制动衬片热压模设计

分析了汽车盘式制动嚣零件的工艺性，对其成形制造工艺、衬片模具结构及其设计、衬片模具的选材及主要零部件的制造加工要点、衬片模具的工作过程及使用情况等作了系统地介绍。     

圆柱直齿轮冷精锻模具工装设计

为将圆柱直齿轮冷精锻技术应用于实际生产,提出了齿腔分流工艺,并为该工艺设计了专用模具工装。通过有限元模拟校核了模具关键零件的强度,并采用20CrMnTi坯料进行实验研究,验证该工艺方案及模具结构的合理性。结果表明,齿腔分流工艺能很好地成形出20CrMnTi齿轮锻件;模具结构合理,满足生产强度要求,出模容易。     

底盖工艺分析及模具设计

系统分析了底盖翻边成形工艺,并介绍了传统的加工工艺方案。针对翻边成形特性,计算了翻边成形的材料长度,根据计算结果,采用了全新的加工方案,成功设计了翻边挤切落料复合模。由此,克服了传统工艺方案的不足;解泱了翻边、挤切、落料复合的工艺难点;提高了生产效率;保证了零件形状及精度要求。     

A new pore closure concept for the manufacturing of heavy rings

In order to avoid pores in heavy rings, a new forming concept is presented. The proposed manufacturing route is based on an analysis regarding the current manufacturing of a ring associated with serious pore closure problems. It is concluded that the present method results in small strains close to the outer surface of the ring. Thus, the likelihood for remaining pores in this region is considered to be high. This apprehension was confirmed both by ultrasonic testing and metallographic analysis. The forming route starts with heavy upsetting of a cylindrical billet followed by piercing in a closed die. The penetrating punch is furnished with an upper flat part that is used for upsetting at the end of the process, forcing the material to fill the cavity between the die and the upper tool. The remaining bottom disk is then sheared off in a separate tool. The new concept starts with a lighter upsetting, resulting in a higher “pan cake” of smaller diameter. This workpiece is then moved to a closed die of the same diameter as that of the material. The diameter of the piercing punch is not changed. Because of the small die diameter, the workpiece is, after piercing, considerably higher than in today’s production. The so-obtained workpiece is placed into a die equal to the original one with the exception of a bottom hole. A new mandrel, with a flat upper part and a lower part meant for shearing off the thin bottom disk, will be inserted to fit the recently generated cylindrical hole. At the beginning of the operation, the bottom disk is cut away as the punch moves through the bottom hole and after that, during the same stroke, the high ring will be heavily upset to its final geometry. During the upsetting the ring is supported by the mandrel. If the ring is too high during upsetting, there is a risk for the material to loose contact with the punch, which might result in instability and a fold. Applying the new concept, the strains close to the envelope surface became approximately 160% larger. The present analysis is carried out with an FE-code Q-form making it possible to trace different material elements of the initial billet throughout the different manufacturing steps. The results are presented in form of hydrostatic pressure as a function of the effective strain. Theoretically determined workpiece shapes, based on the conditions of today’s production are in good agreement with those obtained from full-scale experiments. The present work also includes comparisons with another analysis of similar character, published by the authors. In that work, the manufacturing of two other types of rings were analysed, one with pore closure problems and one without.     

Influences of material parameters on deep drawing of thin-walled hemispheric surface part

During deep drawing process, the material parameters of blank have a significant effect on the quality of the drawn part and the determination of process parameters. Here, a 3D finite element model is developed for the deep drawing process of a thin-walled hemispheric surface part. Then the influences of material parameters including hardening exponent n, yield stress σs and elastic modulus E on the process are investigated by simulation. The results show that the effects of n and σs on punch force, thickness variation and equivalent strain are more notable. The maximum equivalent plastic strain occurs outside the die corner. However, when the value of n is 0.03 or σs is smaller than 120 MPa, higher equivalent plastic strain occurs at ball top.     

不锈钢筒形件深拉深新工艺

传统工艺中,1Cr18Ni9Ti不锈钢板料需多次拉深加工,其生产周期长、产品成本高、生产效率低.通过实验探究,在合理地调整凹、凸模间隙,特别是采用新的润滑剂和润滑方法,同时取消或改变热处理方法的情况下,同样可以深拉深出表面质量理想的不锈钢筒形件.在整个生产工艺中,零件拉深成功的重要因素是合理选择和使用润滑剂,3种润滑剂的配合使用,保证了拉深过程的顺利完成.将该方法用于批量生产,模具寿命大大延长,并取得了很好的生产效益.     

模块横梁总成压入螺母模具设计

通过对模块横梁总成零件特点分析,介绍了零件冲压成形工艺方案的确定过程。为了满足制件要求,通过大量试验得出压入螺母的工艺参数,同时在制造过程中对模具结构进行优化,重点对压入螺母模具结构设计、制造优化过程进行了阐述。