150T-2(HD)側(cè)板沖孔落料復(fù)合模設(shè)計【說明書+CAD+PROE】

150T-2(HD)側(cè)板沖孔落料復(fù)合模設(shè)計【說明書+CAD+PROE】,說明書+CAD+PROE,150T-2(HD)側(cè)板沖孔落料復(fù)合模設(shè)計【說明書+CAD+PROE】,hd,沖孔,復(fù)合,設(shè)計,說明書,仿單,cad,proe 江西農(nóng)大______學(xué)院(系)本科畢業(yè)論文(設(shè)計)完成情況登記卡 姓 名 性別 學(xué)號 院(系) 專業(yè) 班級 論文(設(shè)計)題 目 完成情況 完成提綱時間 完成初稿時間 成二稿時間 定 稿 時 間 所 用 主 要 參 考 資 料 索 引 畢 業(yè) 論 文 、 設(shè) 計 指 導(dǎo) 情 況 指導(dǎo)次數(shù) 指導(dǎo)日期 求教事項(xiàng) 指導(dǎo)內(nèi)容 指導(dǎo)教師簽名 150T-2(HD)側(cè)板沖孔落料復(fù)合模側(cè)板沖孔落料復(fù)合模 2009江西農(nóng)業(yè)大學(xué)畢業(yè)設(shè)計答辯答辯人：羅文 20055019專業(yè)班級：機(jī)制052班指導(dǎo)老師：曾一凡 緒緒 論論1.1.1.11.1沖壓的概念、特點(diǎn)及應(yīng)用沖壓的概念、特點(diǎn)及應(yīng)用 沖壓是利用安裝在沖壓設(shè)備（主要沖壓是利用安裝在沖壓設(shè)備（主要是壓力機(jī)）上的模具對材料施加壓力，是壓力機(jī)）上的模具對材料施加壓力，使其產(chǎn)生分離或塑性變形，從而獲得所使其產(chǎn)生分離或塑性變形，從而獲得所需零件（俗稱沖壓或沖壓件）的一種壓需零件（俗稱沖壓或沖壓件）的一種壓力加工方法。沖壓通常是在常溫下對材力加工方法。沖壓通常是在常溫下對材料進(jìn)行冷變形加工，且主要采用板料來料進(jìn)行冷變形加工，且主要采用板料來加工成所需零件，所以也叫冷沖壓或板加工成所需零件，所以也叫冷沖壓或板料沖壓。沖壓是材料壓力加工或塑性加料沖壓。沖壓是材料壓力加工或塑性加工的主要方法之一，隸屬于材料成型工工的主要方法之一，隸屬于材料成型工程術(shù)。程術(shù)。1.2 1.2 沖壓技術(shù)的現(xiàn)狀及發(fā)展方向沖壓技術(shù)的現(xiàn)狀及發(fā)展方向 隨著科學(xué)技術(shù)的不斷進(jìn)步和工業(yè)生產(chǎn)的迅速隨著科學(xué)技術(shù)的不斷進(jìn)步和工業(yè)生產(chǎn)的迅速發(fā)展，許多新技術(shù)、新工藝、新設(shè)備、新材料不發(fā)展，許多新技術(shù)、新工藝、新設(shè)備、新材料不斷涌現(xiàn)，因而促進(jìn)了沖壓技術(shù)的不斷革新和發(fā)展。斷涌現(xiàn)，因而促進(jìn)了沖壓技術(shù)的不斷革新和發(fā)展。其主要表現(xiàn)和發(fā)展方向如下。其主要表現(xiàn)和發(fā)展方向如下。沖壓成形理論的研究是提高沖壓技術(shù)的基礎(chǔ)。沖壓成形理論的研究是提高沖壓技術(shù)的基礎(chǔ)。國內(nèi)外對沖壓成形理論的研究非常重視，在材料國內(nèi)外對沖壓成形理論的研究非常重視，在材料沖壓性能研究、沖壓成形過程應(yīng)力應(yīng)變分析、板沖壓性能研究、沖壓成形過程應(yīng)力應(yīng)變分析、板料變形規(guī)律研究及坯料與模具之間的相互作用研料變形規(guī)律研究及坯料與模具之間的相互作用研究等方面均取得了較大的進(jìn)展。究等方面均取得了較大的進(jìn)展。精密連桿超高速沖床精密連桿超高速沖床 雙曲軸精密鋼架沖床雙曲軸精密鋼架沖床2.12.1設(shè)計任務(wù)書設(shè)計任務(wù)書 設(shè)計工件如下圖所示設(shè)計工件如下圖所示零件名稱：零件名稱：150150T-2T-2（HDHD）側(cè)板側(cè)板材料：材料：10#10#材料厚度：材料厚度：t=2mmt=2mm批量：大批量成產(chǎn)批量：大批量成產(chǎn) 由零件圖可知，沖裁完成此工件需要落料，由零件圖可知，沖裁完成此工件需要落料，沖孔兩道工序。其加工工藝方案可以分為以下三沖孔兩道工序。其加工工藝方案可以分為以下三種：種：第一種方案第一種方案:采用單工序逐步加工，此方案的特點(diǎn)：采用單工序逐步加工，此方案的特點(diǎn)：由于采用單工序模，模具制造簡單，維修方便。由于采用單工序模，模具制造簡單，維修方便。但生產(chǎn)效率低，不適合大批量生產(chǎn)。但生產(chǎn)效率低，不適合大批量生產(chǎn)。第二種方案第二種方案:采用復(fù)合模加工成型，即在模具同一采用復(fù)合模加工成型，即在模具同一位置同時完成落料，沖孔兩道工序。該方案的特位置同時完成落料，沖孔兩道工序。該方案的特點(diǎn)：生產(chǎn)效率高，工件精度高，但模具制造較為點(diǎn)：生產(chǎn)效率高，工件精度高，但模具制造較為復(fù)雜，調(diào)整維修較為麻煩，使用壽命低下等。復(fù)雜，調(diào)整維修較為麻煩，使用壽命低下等。2.22.2沖裁件沖壓工藝方案的確定沖裁件沖壓工藝方案的確定 第三種方案第三種方案:采用連續(xù)模加工成型。該方采用連續(xù)模加工成型。該方案的特點(diǎn)：生產(chǎn)效率高，便于實(shí)現(xiàn)機(jī)械案的特點(diǎn)：生產(chǎn)效率高，便于實(shí)現(xiàn)機(jī)械化，自動化，但模具制造復(fù)雜，調(diào)整維化，自動化，但模具制造復(fù)雜，調(diào)整維修麻煩，工件精度較低修麻煩，工件精度較低。根據(jù)本零件的設(shè)計要求，以及方案根據(jù)本零件的設(shè)計要求，以及方案的特點(diǎn)，故采用第二種方案，即復(fù)合模的特點(diǎn)，故采用第二種方案，即復(fù)合模具較為合理。具較為合理。2.32.3沖裁件沖模結(jié)構(gòu)的確定沖裁件沖模結(jié)構(gòu)的確定 2.3.12.3.1模具的的形式模具的的形式:根據(jù)凸凹模在模具種的位置及其工件和廢料清除根據(jù)凸凹模在模具種的位置及其工件和廢料清除裝置的特點(diǎn)裝置的特點(diǎn).正裝式正裝式 復(fù)合模復(fù)合模 倒裝式倒裝式 廢料都將落在凹模表面上，須加以清除后廢料都將落在凹模表面上，須加以清除后方能進(jìn)行下次沖裁。操作不便，對多孔工方能進(jìn)行下次沖裁。操作不便，對多孔工件不宜采用，但沖出的工件表面比較平直。件不宜采用，但沖出的工件表面比較平直。廢廢料料由由沖沖孔孔凸凸模模沖沖入入凹凹模模洞洞口口中中，積積聚聚到到一一定定數(shù)數(shù)量量，由由下下模模座座的的漏漏料料孔孔排排除除，不不必必清清除除廢廢料料，操操作作方方便便，但但工工件件表表面面平平直直度度較較差差，凹凹凸凸模模承承受受的的張張力力較較大大，因因此此凹凹凸凸模塊的壁厚應(yīng)嚴(yán)格控制，以免強(qiáng)度不足。模塊的壁厚應(yīng)嚴(yán)格控制，以免強(qiáng)度不足。正裝式復(fù)合模正裝式復(fù)合模 倒裝式復(fù)合模倒裝式復(fù)合模2.3.22.3.2定位裝置定位裝置 由于沖裁零件的尺寸較大，采用三個由于沖裁零件的尺寸較大，采用三個外六角螺栓，彈簧片，定位銷組成的伸縮外六角螺栓，彈簧片，定位銷組成的伸縮式擋料銷定位。安裝在凹模與退料板之間，式擋料銷定位。安裝在凹模與退料板之間，工作時，可隨凹模下行而壓入孔內(nèi)，工作工作時，可隨凹模下行而壓入孔內(nèi)，工作很方便。且對模具強(qiáng)度削落小。很方便。且對模具強(qiáng)度削落小。2.3.3 2.3.3 卸料裝置卸料裝置 (1)(1)條料的卸除，采用彈性退料板。因?yàn)槭降箺l料的卸除，采用彈性退料板。因?yàn)槭降寡b式復(fù)合模，所以退料板安裝在下模。裝式復(fù)合模，所以退料板安裝在下模。(2)(2)工件的工件的卸除，采用模具上部的卸料裝置將工件從上模落卸除，采用模具上部的卸料裝置將工件從上模落料凹模中推下，落在模具工作面上。料凹模中推下，落在模具工作面上。(3)(3)沖孔廢料沖孔廢料的卸除，采用下模座上漏料孔排出，沖孔廢料在的卸除，采用下模座上漏料孔排出，沖孔廢料在下模的凹凸模內(nèi)積聚到一定數(shù)量，便從下模座的下模的凹凸模內(nèi)積聚到一定數(shù)量，便從下模座的漏料孔中排出漏料孔中排出.2.3.42.3.4導(dǎo)向零件導(dǎo)向零件導(dǎo)向零件導(dǎo)向零件導(dǎo)板導(dǎo)向?qū)О鍖?dǎo)向 滾珠式導(dǎo)柱導(dǎo)套滾珠式導(dǎo)柱導(dǎo)套 滑動式導(dǎo)柱導(dǎo)套滑動式導(dǎo)柱導(dǎo)套 特點(diǎn)：在模具上安裝不便，且阻擋特點(diǎn)：在模具上安裝不便，且阻擋操作者的視線，故不采用。操作者的視線，故不采用。特點(diǎn)：導(dǎo)向精度高，壽特點(diǎn)：導(dǎo)向精度高，壽命長，但結(jié)構(gòu)較復(fù)雜，命長，但結(jié)構(gòu)較復(fù)雜，故也不采用。故也不采用。特點(diǎn)：使模具在壓力機(jī)特點(diǎn)：使模具在壓力機(jī)上的安裝較簡單，操作上的安裝較簡單，操作方便，還可以較低成本，方便，還可以較低成本，針對該零件的產(chǎn)品精度針對該零件的產(chǎn)品精度要求不高，故采用滑動要求不高，故采用滑動式導(dǎo)柱導(dǎo)套即可。式導(dǎo)柱導(dǎo)套即可。2.3.5 2.3.5 模架模架 模架模架 中間導(dǎo)柱模架中間導(dǎo)柱模架 對角導(dǎo)柱模架對角導(dǎo)柱模架 后側(cè)導(dǎo)柱模架后側(cè)導(dǎo)柱模架 特點(diǎn)：導(dǎo)柱對稱分布，受力平特點(diǎn)：導(dǎo)柱對稱分布，受力平衡，滑動平穩(wěn)，拔模方便，但衡，滑動平穩(wěn)，拔模方便，但只能一個方向送料只能一個方向送料 特點(diǎn)：受力平衡，滑動平穩(wěn)，特點(diǎn)：受力平衡，滑動平穩(wěn)，可以縱向或橫向送料?？梢钥v向或橫向送料。特點(diǎn)：可以三方送料，操作者特點(diǎn)：可以三方送料，操作者視線不被阻擋，結(jié)構(gòu)比較緊湊，視線不被阻擋，結(jié)構(gòu)比較緊湊，但模具受力不平衡，滑動不平但模具受力不平衡，滑動不平穩(wěn)。穩(wěn)。綜上考慮，選用對角模架。綜上考慮，選用對角模架。后導(dǎo)柱模架后導(dǎo)柱模架對角模架對角模架中間導(dǎo)柱模架中間導(dǎo)柱模架各式模架圖片各式模架圖片2.42.4沖裁件沖壓工藝計算沖裁件沖壓工藝計算 橫橫排排 a a 搭搭邊邊值值 查查冷冷沖沖壓壓模模具具手手冊冊如如下下圖圖，確定確定a,b.a,b.t=2t=2時，時，a=2.2 b=2.0a=2.2 b=2.0 c c 材料利用率材料利用率0 0=nFnF/LB/LB100%100%式中式中 n n板料上實(shí)際沖裁的零件數(shù)量板料上實(shí)際沖裁的零件數(shù)量 F F1 1零件的實(shí)際面積零件的實(shí)際面積 mmmm2 2 L L板料長度板料長度mm mm B B板料寬度板料寬度 mmmm 若取工件數(shù)量若取工件數(shù)量n=20n=20件則料長為件則料長為 L=20L=20633.53+19633.53+192 22 22 212712.3mm 12712.3mm 取取L=12713mm L=12713mm 所以條料規(guī)格為所以條料規(guī)格為 12713 12713137.2137.22 2零件的實(shí)際面積為：零件的實(shí)際面積為：F F1 1=2=2131.73131.73240.27240.2789.2389.2317.2517.25（52.2352.2372.23)/272.23)/259.2559.25 =73746.66 mm =73746.66 mm2 2所以材料的實(shí)際利用率為所以材料的實(shí)際利用率為 0 0=20=2073746.6673746.661271312713137.2 137.2 100%=84.6%100%=84.6%（1 1）豎排豎排 a a搭邊值搭邊值 同上同上 查手冊得查手冊得 搭邊值搭邊值 a=2.2 b=2.0 a=2.2 b=2.0 b b 條料寬度條料寬度 B-=(b+2a+Z)_ B-=(b+2a+Z)_ 同上同上 查手冊得查手冊得 Z=1mm =0.8 Z=1mm =0.8 所以所以 B B-=（633.53633.532 22.22.21 1）=638.93 =638.93 c c 材材料料利利用用率率0 0=nFnF/LB/LB100%100%若若取取工工件件數(shù)數(shù)量量n=20n=20件，則料長為件，則料長為 L=20L=20131.73131.7321212 22676.6mm 2676.6mm 取取L=2677mmL=2677mm 所以條料規(guī)格：所以條料規(guī)格：26772677638.9638.92 2 即：即：0 0=nFnF/LB/LB100%=20100%=2073746.6673746.6626772677638.9 638.9 100%100%=86.2%=86.2%綜上從材料的利用率分析可以綜上從材料的利用率分析可以知道，豎排排樣比橫排排樣節(jié)知道，豎排排樣比橫排排樣節(jié)省材料，材料利用率高，所以省材料，材料利用率高，所以確定豎排排樣。確定豎排排樣。2.52.5計算沖壓力計算沖壓力 2.5.12.5.1計算壓力中心計算壓力中心 雖雖然然落落料料件件形形狀狀是是關(guān)關(guān)于于x,yx,y軸軸對對稱稱，但但由由于于多多凸凸模模沖沖孔孔造造成成沖沖孔孔后后零零件件形形狀狀不不對對稱稱，故使用解析法確定該沖裁件的壓力中心。故使用解析法確定該沖裁件的壓力中心。分別以零件最外輪廓為分別以零件最外輪廓為x,yx,y軸建立坐軸建立坐標(biāo)系，如下圖標(biāo)系，如下圖 2.5.2 2.5.2 計算刃口尺寸計算刃口尺寸 因因?yàn)闉橥雇鼓Ｄ＃及寄Ｄ７址珠_開加加工工時時，具具有有互互換換性性，適適合合批批量量生生產(chǎn)產(chǎn)，所所以以本本例例中中選選用用凸凸凹凹模模分分開開加加工工方方法法制制造造凸凸凹模。凹模。1 1 落料凸凹模落料凸凹模 落料時間隙取在凸模上落料時間隙取在凸模上 凸模尺寸：凸模尺寸：凹模尺寸：凹模尺寸：所以所以 落料的凸凹模刃口尺寸結(jié)構(gòu)設(shè)計合理。落料的凸凹模刃口尺寸結(jié)構(gòu)設(shè)計合理。2 2 沖孔凸凹模沖孔凸凹模 沖孔時，間隙取在凹模上。沖孔時，間隙取在凹模上。2.5.32.5.3計算孔與孔間中心距計算孔與孔間中心距2.6 2.6 沖裁復(fù)合模主要零件的設(shè)計及其計算沖裁復(fù)合模主要零件的設(shè)計及其計算 2.6.1 2.6.1固定板的設(shè)計計算固定板的設(shè)計計算 卸料板固定卸料板固定卸料板 彈壓卸料板彈壓卸料板 固定卸料板裝在下模，具有固定卸料板裝在下模，具有卸料力大，工作可靠，模具卸料力大，工作可靠，模具安裝方便等優(yōu)點(diǎn)，但是沖裁安裝方便等優(yōu)點(diǎn)，但是沖裁時，卸料板壓不住材料，沖時，卸料板壓不住材料，沖出的工件平整度差出的工件平整度差.彈壓卸料板除了在沖裁后卸彈壓卸料板除了在沖裁后卸料外，還可以在沖裁前壓住料外，還可以在沖裁前壓住材料，使沖制的工件平整度材料，使沖制的工件平整度好，一般選用沖裁材料厚度好，一般選用沖裁材料厚度較小或較軟的工件較小或較軟的工件.本例中，選用彈性卸料和退料板。本例中，選用彈性卸料和退料板。2.6.2 2.6.2 卸料板及其退料板的設(shè)計計算卸料板及其退料板的設(shè)計計算2.6.32.6.3定位零件的設(shè)計計算定位零件的設(shè)計計算 條料的限位條料的限位 送進(jìn)導(dǎo)向送進(jìn)導(dǎo)向 送料定距送料定距 定義：與送料方向垂直的方向上定義：與送料方向垂直的方向上限位，保證條料沿正確的方向送限位，保證條料沿正確的方向送進(jìn)。進(jìn)。定位零件有：倒料銷，倒料板，定位零件有：倒料銷，倒料板，側(cè)壓板。側(cè)壓板。定義：在送料方向上的限位，定義：在送料方向上的限位，控制條料一次送進(jìn)的距離。控制條料一次送進(jìn)的距離。定位零件有：始用擋料銷，擋定位零件有：始用擋料銷，擋料銷，導(dǎo)正銷，側(cè)刃等。料銷，導(dǎo)正銷，側(cè)刃等。2.6.42.6.4沖孔凸模的設(shè)計計算沖孔凸模的設(shè)計計算 2.7 2.7 標(biāo)準(zhǔn)零件的設(shè)計計算及其選擇標(biāo)準(zhǔn)零件的設(shè)計計算及其選擇 2.7.1 模模座座的的設(shè)設(shè)計計 采采用用矩矩形形模模座座 自自行行設(shè)設(shè)計計時時,長長度度比比凹凹模模大大40704070mm,mm,寬寬度度與與凹凹模模的的寬寬度度相相同同或或稍稍微微寬寬一一些些.一一般般按按照照國國家家標(biāo)標(biāo)準(zhǔn)準(zhǔn)選選用用模模座座.(2).(2)模模座座的的厚厚度度 模模座座的的厚厚度度一一般般參參照照標(biāo)標(biāo)準(zhǔn)準(zhǔn)模模座座確確定定,也也可可以以根根據(jù)據(jù)凹凹模模厚厚度度來來定定,一一般般為凹模板厚度的為凹模板厚度的1.01.51.01.5倍倍.以保證由足夠的強(qiáng)度和剛度以保證由足夠的強(qiáng)度和剛度.2.7.2 模模柄柄的的設(shè)設(shè)計計 模模柄柄的的作作用用是是將將上上模模與與壓壓力力機(jī)機(jī)的的滑滑塊塊相相連連接接。在在安安裝裝模模具具時時應(yīng)應(yīng)該該注注意意模模柄柄直直徑徑與與壓壓力力機(jī)機(jī)模模柄柄孔孔徑徑要要一一致致，模模柄柄的的形形式式采采用用壓壓入入式式模模柄柄結(jié)結(jié)構(gòu)構(gòu)，此此模模柄柄與與上上模模座座的的連連接接，采采用用過過渡渡配配合合H7/m6H7/m6，沖沖模模的的工工作作端端為為非非圓圓形形時，需要在模柄與上模座的騎縫出加放轉(zhuǎn)銷。時，需要在模柄與上模座的騎縫出加放轉(zhuǎn)銷。選取標(biāo)準(zhǔn)模柄，代號選取標(biāo)準(zhǔn)模柄，代號GB2862.1-81 GB2862.1-81 基本尺寸為基本尺寸為606075.75.為防止模柄轉(zhuǎn)動，選取標(biāo)準(zhǔn)圓柱銷，代號為防止模柄轉(zhuǎn)動，選取標(biāo)準(zhǔn)圓柱銷，代號 GB119-76 GB119-76 基本尺寸為基本尺寸為6615 15 材料為材料為20#20#鋼。鋼。2.7.82.7.8墊板的設(shè)計計算墊板的設(shè)計計算墊墊板板的的作作用用式式直直接接承承受受凸凸模模的的壓壓力力，以以防防止止模模座座被被凸凸模模頭頭部部壓壓陷陷，從而影響凸模的正常工作。是否需要墊板，可以按下式校核：從而影響凸模的正常工作。是否需要墊板，可以按下式校核：2.7.92.7.9模具閉合高度的計算與校驗(yàn)?zāi)＞唛]合高度的計算與校驗(yàn) 則則 選取上模座：選取上模座：JB/T 7185.2 800JB/T 7185.2 8004004006363 選取下模座：選取下模座：JB/T 7184.2 800JB/T 7184.2 8004004008080 選取導(dǎo)柱：選取導(dǎo)柱：JB/T 7187.1 50 JB/T 7187.1 50 260260 選取導(dǎo)套：選取導(dǎo)套：JB/T 7187.3 50 JB/T 7187.3 50 1601606060 （1 1）下下模模座座與與下下墊墊板板之之間間用用兩兩個個圓圓柱柱銷銷定定位位 代代號號 GB119-76 GB119-76 尺寸為尺寸為10108080 用用1212個個內(nèi)內(nèi)六六角角螺螺栓栓進(jìn)進(jìn)行行夾夾緊緊。代代號號為為GB70-76 GB70-76 尺寸為尺寸為 M10M105050 （2 2）下下墊墊板板與與墊墊板板之之間間用用兩兩個個圓圓柱柱銷銷定定位位 代代號號 GB119-76 GB119-76 尺寸為尺寸為10103535 用用1010個個內(nèi)內(nèi)六六角角螺螺栓栓進(jìn)進(jìn)行行夾夾緊緊。代代號號為為GB70-76 GB70-76 尺尺寸為寸為 M10M103535 （3 3）凸凸凹凹模模與與墊墊板板之之間間用用兩兩個個圓圓柱柱銷銷定定位位 代代號號 GB119-76 GB119-76 尺寸為尺寸為10106060 用用1010個個內(nèi)內(nèi)六六角角螺螺栓栓進(jìn)進(jìn)行行夾夾緊緊。代代號號為為GB70-76 GB70-76 尺尺寸為寸為 M10M106060 （4 4）凹凹模模與與沖沖頭頭固固定定板板之之間間用用兩兩個個圓圓柱柱銷銷定定位位 代代號號 GB119-76 GB119-76 尺寸為尺寸為10107070 用用1010個個內(nèi)內(nèi)六六角角螺螺栓栓進(jìn)進(jìn)行行夾夾緊緊。代代號號為為GB70-76 GB70-76 尺尺寸為寸為 M10M106060 （5 5）上上墊墊板板，沖沖頭頭固固定定板板，與與上上模模座座之之間間用用兩兩個個圓圓柱柱銷定位銷定位 代號代號 GB119-76 GB119-76 尺寸為尺寸為10108080 用用1212個個內(nèi)內(nèi)六六角角螺螺栓栓進(jìn)進(jìn)行行夾夾緊緊。代代號號為為GB70-76 GB70-76 尺尺寸寸為為 M10M107070 通通過過大大學(xué)學(xué)的的學(xué)學(xué)習(xí)習(xí)，使使我我對對模模具具設(shè)設(shè)計計與與制制造造有有了了深深刻刻的的認(rèn)認(rèn)識識。面面臨臨畢畢業(yè)業(yè)期期間間，此此次次單單獨(dú)獨(dú)設(shè)設(shè)計計一一個個模模具具，讓讓我我了了解解了了很很多多的的模模具具結(jié)結(jié)構(gòu)構(gòu)、模模具具加加工工工工藝藝、模模具具的的用用途途。并并且且學(xué)學(xué)到到不不少少的的書書本本上上沒沒有有的的知知識識，例例如如，對對于于影影響響模模具具壽壽命命的的因因素素，主主要要是是模模具具的的加加工工精精度度和和材材料料的的剛剛度度，還還有有模模具具的的材材料料，模模具具生生產(chǎn)產(chǎn)批批量量，模模具具結(jié)結(jié)構(gòu)構(gòu)等等。影影響響模模具具的的產(chǎn)產(chǎn)品品質(zhì)質(zhì)量量的的主要因素也是模具的制造精度。主要因素也是模具的制造精度。通通過過這這次次畢畢業(yè)業(yè)設(shè)設(shè)計計，我我從從理理論論和和實(shí)實(shí)踐踐上上又又更更進(jìn)進(jìn)一一步步的的加加深深。模模具具結(jié)結(jié)構(gòu)構(gòu)設(shè)設(shè)計計的的好好壞壞直直接接影影響響產(chǎn)產(chǎn)品品質(zhì)質(zhì)量量和和經(jīng)經(jīng)濟(jì)濟(jì)。中中國國面面臨臨世世界界的的挑挑戰(zhàn)戰(zhàn)，在在模具行業(yè)這方面，我希望日后能在模具這一行有所貢獻(xiàn)。模具行業(yè)這方面，我希望日后能在模具這一行有所貢獻(xiàn)。在這里我要特別感謝我的導(dǎo)師曾一凡老師，他嚴(yán)謹(jǐn)細(xì)致、一絲不在這里我要特別感謝我的導(dǎo)師曾一凡老師，他嚴(yán)謹(jǐn)細(xì)致、一絲不茍的作風(fēng)一直是我工作、學(xué)習(xí)中的榜樣；他們循循善誘的教導(dǎo)和不拘茍的作風(fēng)一直是我工作、學(xué)習(xí)中的榜樣；他們循循善誘的教導(dǎo)和不拘一格的思路給予我無盡的啟迪。一格的思路給予我無盡的啟迪。感謝所有在此次設(shè)計中給予我?guī)徒M的老師，同學(xué)，朋友。讓我克感謝所有在此次設(shè)計中給予我?guī)徒M的老師，同學(xué)，朋友。讓我克服一個個困難終于完成了此篇畢業(yè)設(shè)計，當(dāng)然由于時間倉促以及能力服一個個困難終于完成了此篇畢業(yè)設(shè)計，當(dāng)然由于時間倉促以及能力所限，避免不了出現(xiàn)許多錯誤，望各位老師多加批評指正。所限，避免不了出現(xiàn)許多錯誤，望各位老師多加批評指正。Int J Adv Manuf Technol (2002) 19:253259 2002 Springer-Verlag London Limited An Analysis of Draw-Wall Wrinkling in a Stamping Die Design F.-K. Chen and Y.-C. Liao Department of Mechanical Engineering, National Taiwan University, Taipei, Taiwan Wrinkling that occurs in the stamping of tapered square cups and stepped rectangular cups is investigated. A common characteristic of these two types of wrinkling is that the wrinkles are found at the draw wall that is relatively unsup- ported. In the stamping of a tapered square cup, the effect of process parameters, such as the die gap and blank-holder force, on the occurrence of wrinkling is examined using finite- element simulations. The simulation results show that the larger the die gap, the more severe is the wrinkling, and such wrinkling cannot be suppressed by increasing the blank-holder force. In the analysis of wrinkling that occurred in the stamping of a stepped rectangular cup, an actual production part that has a similar type of geometry was examined. The wrinkles found at the draw wall are attributed to the unbalanced stretching of the sheet metal between the punch head and the step edge. An optimum die design for the purpose of eliminating the wrinkles is determined using finite-element analysis. The good agreement between the simulation results and those observed in the wrinkle-free production part validates the accuracy of the finite-element analysis, and demonstrates the advantage of using finite-element analysis for stamping die design. Keywords: Draw-wall wrinkle; Stamping die; Stepped rec- tangular cup; Tapered square cups 1. Introduction Wrinkling is one of the major defects that occur in the sheet metal forming process. For both functional and visual reasons, wrinkles are usually not acceptable in a finished part. There are three types of wrinkle which frequently occur in the sheet metal forming process: flange wrinkling, wall wrinkling, and elastic buckling of the undeformed area owing to residual elastic compressive stresses. In the forming operation of stamp- ing a complex shape, draw-wall wrinkling means the occurrence Correspondence and offprint requests to: Professor F.-K. Chen, Depart- ment of Mechanical Engineering, National Taiwan University, No. 1 Roosevelt Road, Sec. 4, Taipei, Taiwan 10617. E-mail: fkchenL50560 w3.me.ntu.edu.tw of wrinkles in the die cavity. Since the sheet metal in the wall area is relatively unsupported by the tool, the elimination of wall wrinkles is more difficult than the suppression of flange wrinkles. It is well known that additional stretching of the material in the unsupported wall area may prevent wrinkling, and this can be achieved in practice by increasing the blank- holder force; but the application of excessive tensile stresses leads to failure by tearing. Hence, the blank-holder force must lie within a narrow range, above that necessary to suppress wrinkles on the one hand, and below that which produces fracture on the other. This narrow range of blank-holder force is difficult to determine. For wrinkles occurring in the central area of a stamped part with a complex shape, a workable range of blank-holder force does not even exist. In order to examine the mechanics of the formation of wrinkles, Yoshida et al. 1 developed a test in which a thin plate was non-uniformly stretched along one of its diagonals. They also proposed an approximate theoretical model in which the onset of wrinkling is due to elastic buckling resulting from the compressive lateral stresses developed in the non-uniform stress field. Yu et al. 2,3 investigated the wrinkling problem both experimentally and analytically. They found that wrinkling could occur having two circumferential waves according to their theoretical analysis, whereas the experimental results indi- cated four to six wrinkles. Narayanasamy and Sowerby 4 examined the wrinkling of sheet metal when drawing it through a conical die using flat-bottomed and hemispherical-ended punches. They also attempted to rank the properties that appeared to suppress wrinkling. These efforts are focused on the wrinkling problems associa- ted with the forming operations of simple shapes only, such as a circular cup. In the early 1990s, the successful application of the 3D dynamic/explicit finite-element method to the sheet- metal forming process made it possible to analyse the wrinkling problem involved in stamping complex shapes. In the present study, the 3D finite-element method was employed to analyse the effects of the process parameters on the metal flow causing wrinkles at the draw wall in the stamping of a tapered square cup, and of a stepped rectangular part. A tapered square cup, as shown in Fig. 1(a), has an inclined draw wall on each side of the cup, similar to that existing in a conical cup. During the stamping process, the sheet metal on the draw wall is relatively unsupported, and is therefore 254 F.-K. Chen and Y.-C. Liao Fig. 1. Sketches of (a) a tapered square cup and (b) a stepped rectangular cup. prone to wrinkling. In the present study, the effect of various process parameters on the wrinkling was investigated. In the case of a stepped rectangular part, as shown in Fig. 1(b), another type of wrinkling is observed. In order to estimate the effectiveness of the analysis, an actual production part with stepped geometry was examined in the present study. The cause of the wrinkling was determined using finite-element analysis, and an optimum die design was proposed to eliminate the wrinkles. The die design obtained from finite-element analy- sis was validated by observations on an actual production part. 2. Finite-Element Model The tooling geometry, including the punch, die and blank- holder, were designed using the CAD program PRO/ ENGINEER. Both the 3-node and 4-node shell elements were adopted to generate the mesh systems for the above tooling using the same CAD program. For the finite-element simul- ation, the tooling is considered to be rigid, and the correspond- ing meshes are used only to define the tooling geometry and Fig. 2. Finite-element mesh. are not for stress analysis. The same CAD program using 4- node shell elements was employed to construct the mesh system for the sheet blank. Figure 2 shows the mesh system for the complete set of tooling and the sheet-blank used in the stamping of a tapered square cup. Owing to the symmetric conditions, only a quarter of the square cup is analysed. In the simulation, the sheet blank is put on the blank-holder and the die is moved down to clamp the sheet blank against the blank-holder. The punch is then moved up to draw the sheet metal into the die cavity. In order to perform an accurate finite-element analysis, the actual stressstrain relationship of the sheet metal is required as part of the input data. In the present study, sheet metal with deep-drawing quality is used in the simulations. A tensile test has been conducted for the specimens cut along planes coinciding with the rolling direction (0) and at angles of 45 and 90 to the rolling direction. The average flow stress H9268, calculated from the equation H9268H11005(H9268 0 H11001 2H9268 45 H11001H9268 90 )/4, for each measured true strain, as shown in Fig. 3, is used for the simulations for the stampings of the tapered square cup and also for the stepped rectangular cup. All the simulations performed in the present study were run on an SGI Indigo 2 workstation using the finite-element pro- gram PAMFSTAMP. To complete the set of input data required Fig. 3. The stressstrain relationship for the sheet metal. Draw-Wall Wrinkling in a Stamping Die Design 255 for the simulations, the punch speed is set to 10 m s H110021 and a coefficient of Coulomb friction equal to 0.1 is assumed. 3. Wrinkling in a Tapered Square Cup A sketch indicating some relevant dimensions of the tapered square cup is shown in Fig. 1(a). As seen in Fig. 1(a), the length of each side of the square punch head (2W p ), the die cavity opening (2W d ), and the drawing height (H) are con- sidered as the crucial dimensions that affect the wrinkling. Half of the difference between the dimensions of the die cavity opening and the punch head is termed the die gap (G) in the present study, i.e. G H11005 W d H11002 W p . The extent of the relatively unsupported sheet metal at the draw wall is presumably due to the die gap, and the wrinkles are supposed to be suppressed by increasing the blank-holder force. The effects of both the die gap and the blank-holder force in relation to the occurrence of wrinkling in the stamping of a tapered square cup are investigated in the following sections. 3.1 Effect of Die Gap In order to examine the effect of die gap on the wrinkling, the stamping of a tapered square cup with three different die gaps of 20 mm, 30 mm, and 50 mm was simulated. In each simulation, the die cavity opening is fixed at 200 mm, and the cup is drawn to the same height of 100 mm. The sheet metal used in all three simulations is a 380 mm H11003 380 mm square sheet with thickness of 0.7 mm, the stressstrain curve for the material is shown in Fig. 3. The simulation results show that wrinkling occurred in all three tapered square cups, and the simulated shape of the drawn cup for a die gap of 50 mm is shown in Fig. 4. It is seen in Fig. 4 that the wrinkling is distributed on the draw wall and is particularly obvious at the corner between adjacent walls. It is suggested that the wrinkling is due to the large unsupported area at the draw wall during the stamping process, also, the side length of the punch head and the die cavity Fig. 4. Wrinkling in a tapered square cup (G H11005 50 mm). opening are different owing to the die gap. The sheet metal stretched between the punch head and the die cavity shoulder becomes unstable owing to the presence of compressive trans- verse stresses. The unconstrained stretching of the sheet metal under compression seems to be the main cause for the wrink- ling at the draw wall. In order to compare the results for the three different die gaps, the ratio H9252 of the two principal strains is introduced, H9252 being H9280 min /H9280 max , where H9280 max and H9280 min are the major and the minor principal strains, respectively. Hosford and Caddell 5 have shown that if the absolute value of H9252 is greater than a critical value, wrinkling is supposed to occur, and the larger the absolute value of H9252, the greater is the possibility of wrinkling. The H9252 values along the cross-section MN at the same drawing height for the three simulated shapes with different die gaps, as marked in Fig. 4, are plotted in Fig. 5. It is noted from Fig. 5 that severe wrinkles are located close to the corner and fewer wrinkles occur in the middle of the draw wall for all three different die gaps. It is also noted that the bigger the die gap, the larger is the absolute value of H9252. Consequently, increasing the die gap will increase the possibility of wrinkling occurring at the draw wall of the tapered square cup. 3.2 Effect of the Blank-Holder Force It is well known that increasing the blank-holder force can help to eliminate wrinkling in the stamping process. In order to study the effectiveness of increased blank-holder force, the stamping of a tapered square cup with die gap of 50 mm, which is associated with severe wrinkling as stated above, was simulated with different values of blank-holder force. The blank-holder force was increased from 100 kN to 600 kN, which yielded a blank-holder pressure of 0.33 MPa and 1.98 MPa, respectively. The remaining simulation conditions are maintained the same as those specified in the previous section. An intermediate blank-holder force of 300 kN was also used in the simulation. The simulation results show that an increase in the blank- holder force does not help to eliminate the wrinkling that occurs at the draw wall. The H9252 values along the cross-section Fig. 5. H9252-value along the cross-section MN for different die gaps. 256 F.-K. Chen and Y.-C. Liao MN, as marked in Fig. 4, are compared with one another for the stamping processes with blank-holder force of 100 kN and 600 kN. The simulation results indicate that the H9252 values along the cross-section MN are almost identical in both cases. In order to examine the difference of the wrinkle shape for the two different blank-holder forces, five cross-sections of the draw wall at different heights from the bottom to the line M N, as marked in Fig. 4, are plotted in Fig. 6 for both cases. It is noted from Fig. 6 that the waviness of the cross-sections for both cases is similar. This indicates that the blank-holder force does not affect the occurrence of wrinkling in the stamp- ing of a tapered square cup, because the formation of wrinkles is mainly due to the large unsupported area at the draw wall where large compressive transverse stresses exist. The blank- holder force has no influence on the instability mode of the material between the punch head and the die cavity shoulder. 4. Stepped Rectangular Cup In the stamping of a stepped rectangular cup, wrinkling occurs at the draw wall even though the die gaps are not so significant. Figure 1(b) shows a sketch of a punch shape used for stamping a stepped rectangular cup in which the draw wall C is followed by a step DE. An actual production part that has this type of geometry was examined in the present study. The material used for this production part was 0.7 mm thick, and the stress strain relation obtained from tensile tests is shown in Fig. 3. The procedure in the press shop for the production of this stamping part consists of deep drawing followed by trimming. In the deep drawing process, no draw bead is employed on the die surface to facilitate the metal flow. However, owing to the small punch corner radius and complex geometry, a split occurred at the top edge of the punch and wrinkles were found to occur at the draw wall of the actual production part, as shown in Fig. 7. It is seen from Fig. 7 that wrinkles are distributed on the draw wall, but are more severe at the corner edges of the step, as marked by AD and BE in Fig. 1(b). The metal is torn apart along the whole top edge of the punch, as shown in Fig. 7, to form a split. In order to provide a further understanding of the defor- mation of the sheet-blank during the stamping process, a finite- element analysis was conducted. The finite-element simulation was first performed for the original design. The simulated shape of the part is shown from Fig. 8. It is noted from Fig. 8 that the mesh at the top edge of the part is stretched Fig. 6. Cross-section lines at different heights of the draw wall for different blank-holder forces. (a) 100 kN. (b) 600 kN. Fig. 7. Split and wrinkles in the production part. Fig. 8. Simulated shape for the production part with split and wrinkles. significantly, and that wrinkles are distributed at the draw wall, similar to those observed in the actual part. The small punch radius, such as the radius along the edge AB, and the radius of the punch corner A, as marked in Fig. 1(b), are considered to be the major reasons for the wall breakage. However, according to the results of the finite- element analysis, splitting can be avoided by increasing the above-mentioned radii. This concept was validated by the actual production part manufactured with larger corner radii. Several attempts were also made to eliminate the wrinkling. First, the blank-holder force was increased to twice the original value. However, just as for the results obtained in the previous section for the drawing of tapered square cup, the effect of blank-holder force on the elimination of wrinkling was not found to be significant. The same results are also obtained by increasing the friction or increasing the blank size. We conclude that this kind of wrinkling cannot be suppressed by increasing the stretching force. Since wrinkles are formed because of excessive metal flow in certain regions, where the sheet is subjected to large com- pressive stresses, a straightforward method of eliminating the wrinkles is to add drawbars in the wrinkled area to absorb the redundant material. The drawbars should be added parallel to the direction of the wrinkles so that the redundant metal can be absorbed effectively. Based on this concept, two drawbars are added to the adjacent walls, as shown in Fig. 9, to absorb the excessive material. The simulation results show that the Draw-Wall Wrinkling in a Stamping Die Design 257 Fig. 9. Drawbars added to the draw walls. wrinkles at the corner of the step are absorbed by the drawbars as expected, however some wrinkles still appear at the remain- ing wall. This indicates the need to put more drawbars at the draw wall to absorb all the excess material. This is, however, not permissible from considerations of the part design. One of the advantages of using finite-element analysis for the stamping process is that the deformed shape of the sheet blank can be monitored throughout the stamping process, which is not possible in the actual production process. A close look at the metal flow during the stamping process reveals that the sheet blank is first drawn into the die cavity by the punch head and the wrinkles are not formed until the sheet blank touches the step edge DE marked in Fig. 1(b). The wrinkled shape is shown in Fig. 10. This provides valuable information for a possible modification of die design. An initial surmise for the cause of the occurrence of wrink- ling is the uneven stretch of the sheet metal between the punch corner radius A and the step corner radius D, as indicated in Fig. 1(b). Therefore a modification of die design was carried out in which the step corner was cut off, as shown in Fig. 11, so that the stretch condition is changed favourably, which allows more stretch to be applied by increasing the step edges. However, wrinkles were still found at the draw wall of the cup. This result implies that wrinkles are introduced because of the uneven stretch between the whole punch head edge and the whole step edge, not merely between the punch corner and Fig. 10. Wrinkle formed when the sheet blank touches the stepped edge. Fig. 11. Cut-off of the stepped corner. the step corner. In order to verify this idea, two modifications of the die design were suggested: one is to cut the whole step off, and the other is to add one more drawing operation, that is, to draw the desired shape using two drawing operations. The simulated shape for the former method is shown in Fig. 12. Since the lower step is cut off, the drawing process is quite similar to that of a rectangular cup drawing, as shown in Fig. 12. It is seen in Fig. 12 that the wrinkles were eliminated. In the two-operation drawing process, the sheet blank was first drawn to the deeper step, as shown in Fig. 13(a). Sub- sequently, the lower step was formed in the second drawing operation, and the desired shape was then obtained, as shown in Fig. 13(b). It is seen clearly in Fig. 13(b) that the stepped rectangular cup can be manufactured without wrinkling, by a two-operation drawing process. It should also be noted that in the two-operation drawing process, if an opposite sequence is applied, that is, the lower step is formed first and is followed by the drawing of the deeper step, the edge of the deeper step, as shown by AB in Fig. 1(b), is prone to tearing because the metal cannot easily flow over the lower step into the die cavity. The finite-element simulations have indicated that the die design for stamping the desired stepped rectangular cup using one single draw operation is barely achieved. However, the manufacturing cost is expected to be much higher for the two- operation drawing process owing to the additional die cost and operation cost. In order to maintain a lower manufacturing cost, the part design engineer made suitable shape changes, and modified the die design according to the finite-element Fig. 12.