弯链板双斜楔横向对冲冲孔模具设计

在某型号销合链弯链板自动化冲压级进模的研发中，由于冲孔工序涉及废料难以去除和工件不便取出的问题，使得该型号销合链弯链板的加工难以实现自动化。针对此问题，延续弯链板自动化冲压级进模的设计思路，提出一种双斜楔横向对冲冲孔模具设计方案，用于代替原有的悬架式竖直冲孔模具，并运用DEFORM-3D软件对横向对冲冲孔工艺方案进行仿真验证。在此基础上，开展冲裁间隙、凸凹模刃口尺寸和冲裁力等工艺参数计算，并对斜楔、冲孔装置、凹模、压料装置和顶料装置等关键零部件展开结构设计，运用SOLIDWORKS软件完成模具的三维设计。最后，研制模具样机并开展冲压试验验证。结果表明，所研制的双斜楔横向对冲冲孔模具能够较好地应用于弯链板自动化冲压级进模中。经抽样检测，冲孔加工后的工件全部合格，同时也有效地解决了冲孔废料难以去除和工件不便取出的问题，实现了弯链板的自动化生产，有效缩短了模具的研发时间与试模周期。     

配有机器人上下料系统的冲压生产线

配有机器人上下料系统的冲压生产线德国ＳＭＧ冲压公司开发的由机器人将６台压力机连接而成的冲压生产线，可满足小批量生产汽车的要求。该生产线包括自动交换模具系统和微处理器控制系统。一套柔性机器人系统完成各种工件的上下料工作。当变换工件时，机器人机械手上的工...     

冲压自动化机器人成套设备

针对国内汽车、家电、制冷、包装等行业中大量、广泛使用的中小型开式压力机,研制开发了高速上下料机器人、自动提升分层装置、二次定位对中工作台、工件翻转装置等自动化成套设备,该成套设备可以与单台压力机组成自动化生产单元,也可与多台压力机组成柔性自动化生产线,实现冲压生产过程的自动化。     

定位板冲孔-整孔-落料级进模设计

对定位板零件的冲压工艺进行了分析,改用冲孔-整孔-落料连续冲压工艺,可明显提高工件质量及生产率.简述了定位板冲模的排样图、冲压力及压力中心等工艺计算,设计了冲孔-整孔-落料级进模.     

落料线卷料矫直方法的探究

随着机械自动化的快速发展,自动化在冲压行业运用的越来越多,而冲压行业对于板料的平整度要求也越来越高。为了节约成本,很多汽车主机厂都开设了开卷落料线,那么如何在开卷落料线上将卷料矫直成一个高标准的板料就成了一个亟待解决的问题。本文根据矫直机的矫直原理进行理论分析和实际试验,最后给出内应力不均和线长度不均导致的各种卷料的调试方法。     

纵梁冲压自动化生产线设计及应用

介绍了为实现纵梁冲压自动化生产,从生产线布局、机器人选型、零件自动上下料、工装模具设计及纵梁自动化生产调试过程中所遇到的问题,提出解决方法。纵梁自动化生产线的研制成功不仅提高了生产产能,改善了工作环境,也降低了操作工的工作强度,是纵梁冲压技术的一次重大进步。     

自动化冲压线铝板料拆垛分张不良优化方法

自动化冲压线生产过程中,因铝板料没有磁性,板料在线首拆垛时存在分张不良现象,经现场调查研究,制定了控制板料残油、板料压窝、增加辅助分层装置等措施,解决了铝板料分张不良的问题。经生产验证,提出的方法有效,工艺合理,满足冲压线大批量生产的需求。     

基于超声波技术的冲压送料双板检测系统研究

双板料检测是板料冲压自动化过程中的一个关键环节.本文介绍了超声波以及超声波传感器技术,提出了基于超声波技术的冲压送料双板料检测原理及方法,建立了双板料检测系统的硬件结构,并以Visual Studio 2008为开发工具,开发了双板料检测控制系统.     

浅析纵梁冲压模具自动化设计

纵梁冲压自动化生产过程中,因制件细长,容易出现制件定位稳定性差、传感器不能稳定感应到制件、制件卡在下模及废料排出困难等问题。在模具设计过程中,通过在拉伸工艺补充面上设置筋条、设置传感器浮动机构及顶料浮动块等措施,解决了纵梁冲压自动化生产的问题。     

多工位级进模的半冲技术

<正> 在多工位级进模中,有一种被称为“冲裁后压回条料”的排样技术,分析其冲压材料被冲裁的工作原理,并不一定真正将冲裁工件再压回条料,对冲压材料是厚材料来讲,往往凸模只切入被冲压材料的一半,就完成了冲裁动作,冲压件有一半搭连在条料上;对冲压材料是薄材料来讲,外形轮廓只冲裁     

拉延速度对拉延件破裂的影响

讨论了压力机工作速度与板料拉延变形速度的关系以及拉延速度对板料塑性及变形抗力的影响,分析了曲柄压力机速度的变化规律,提出了深拉延件必须校核拉延过程中工件处于最大变形抗力位置时的压力机速度。     

单柱式油压机行程及压力检测系统改造设计

为了实现在油压机冲压过程中进行区间检测,并通过系统工作状态判断工件过盈量的大小,保证工件压装质量,设计改造了以位移传感器、位移变送器、模拟量输入模块及触摸屏显示为主要模块的压力检测系统。结果表明:系统能实时监控运行状态,并集监、管、控于一体。     

多连杆压力机三维实体建模及运动仿真

对多连杆压力机三维实体建模,生成装配体,对装配体干涉情况进行检验。运用虚拟样机技术得到滑块位移、速度、加速度曲线,从而分析出滑块的最大行程和较佳的工作区域,得到优质工件,有效保护模具。     

Adjustment of stochastic responses of typical cold forging systems

The stochastic nature of typical cold forging processes is assessed in this paper. Finite element computations have been applied to backward can extrusion, free upsetting, closed-die forging and forward rod extrusion in order to study the influence of scatter of the principal process input parameters on the dimensional accuracy of products and on the tool service life. Flow stress and mass of the workpiece have been varied in combination with tribological parameters to evaluate scatter of process responses for soft and stiff press. The results show that stochastic interactions differ radically for the four typical cold forging processes and that press stiffness has a significant influence on the stochastic relationships. For the closed-die upsetting it is demonstrated that statistical distributions of the input parameters can be adjusted in order to achieve reliable process. Here it is shown that bounds of operating windows defined by intersections between product tolerances and tool service life constraints are different for soft and stiff press. At the end of the paper an industrial example is provided to demonstrate how stochastic responses can be adjusted for production of the inner race.     

正列密集方形凸包件啮辊胀形数值模拟

通过提供单元凸、凹模的设计要点,使用Deform-3D软件对板料进行模拟分析,在长度为100 mm、宽度为130 mm、厚度为1 mm的塑性板料上,尝试模拟成形5列4排(纵横对正)、边长b=10 mm、高度h≤3.5 mm的正列密集方形凸包件.从啮辊胀形装置、凸包尺寸参数两个方面进行模拟研究,首先论证了压料框的必要性,...     

Comprehensive approach for process modeling and optimization in cold forging considering interactions between process,tool and press

In this paper a comprehensive approach is presented for the consideration of the interactions between process, tool and machine during the design of cold forging tools and processes by simulation. The interactions occur due to the high forming loads in cold forging and yield considerable deflections of press and tooling system. These, in turn, influence the workpiece dimensions. The entire approach comprises an efficient determination of the deflection characteristic of stroke-controlled press and tooling system and its condensed modeling in combination with the FE simulation of a cold forging process. Building on that, an analytic process model is developed that is based on a set of variant simulations. It permits an optimization of the values of influencing parameters to achieve high workpiece accuracy without subsequent adjusting effort. Initially, the analytic process model required a high number of variant simulations. By acquiring knowledge on the specific process behavior in an analysis of effects and interactions a considerable reduction of simulation runs by a factor of almost 12 was achieved in the case study on full forward extrusion. The approach is supplemented by an analytic model of the die load. In addition, scatter and uncertainties of target values depending on the ones of the influencing parameters can be estimated by applying the Monte Carlo method to the analytic process model.     

Optimization of multi-stage closed-die forging processes by coupled simulation of the machine and the forging processes

The use of finite element analysis in the development of closed-die forging processes is widely established in industry. However, the simulated and the real workpiece dimensions differ from each other in a significant way, as the interactions between the forging process and the production machine are not adequately considered in the simulation. As a result, multi-stage dies in particular often need to undergo an experimental time-consuming optimization process on the production machine. In this paper a method is presented that allows the coupling of the forging simulation with external machine tool simulation systems and nonlinear-elastic press models in order to consider the interactions between the process and the machine, and to improve the accuracy of the forging simulation. This method of coupled simulation was integrated into a software tool and may be used for single-stage as well as for multi-stage processes in closed-die forging operations. It allows simulation-aided optimization of the dies as early as the design stage as well as individual adaptation to the particular production press well in advance of the test phase of the dies on the press.     

管形件端头的浮动凹模修边冲孔模设计

介绍了管形件端头冲压加工技术,根据管形件端头的形状特点,设计了一种新型模具结构———浮动凹模修边冲孔模,将弯管端头上侧的修边废料作为下侧修边的凸模,将上侧修边、下侧修边和冲孔一次完成,解决了修边凹模强度问题。生产实验表明,所设计的浮动凹模修边冲孔模在实际生产中,能够保证产品质量,可使生产效率提高2倍以上,并且极大地降低了废品率。     

采用比例方向阀实现液压机底缸精确定位

此套控制系统采用可编程控制器根据磁致伸缩位移传感器反馈的位置信息实现对比例方向阀的控制,从而满足液压机底缸顶出位置的精确控制,确保制件批量制作的质量。通过触摸屏数据采样功能,可对每种工件的位置等实际参数进行存储,并可形成报表输出。