阶梯轴锻压模具设计

锻造工艺及模具（CAD/CAE）设计姓名：你的名字课程名称：锻造工艺与模具设计指导教师：XXX2012年7月1说明1.因没有前人经验，本报告仅供本学校锻压专业学习交流之用。仅供同专业后来的同学参考。2.燕山大学，版权所有，仅供参考，严禁抄袭。3.能不能早点回家看你们的速度了，你懂得！！！2前言本次课程设计的研究项目是《锻造工艺与模具设计》学习的一个重要组成部分。在设计的过程中首先通过查找有关资料确定设计的主题方向，通过课本的案例进行逐步实际计算。由于没有实际的设计经验，这也使我再设计的过程中走了不少弯路。在整个设计过程中，从开始的计算，画冷热锻件图到确定加工工艺过程，再到最后的画锻模模具，每个过程都让我有很深的的感触。由于个人能力有限，本次的设计如存在错误之处，敬希望老师能够给予批评改正。XXX于燕山大学2012年7月3目录1阶梯轴锻件图·················································11.1分模位置·····················································11.2公差和余量···················································11.3机械加工余量··················································11.4段模斜度·····················································21.5圆角半径·····················································21.6技术条件·····················································22计算锻件的主要参数············································33锻锤吨位的确定·················································33.1.经验公式一···················································33.2.经验公式二···················································33.3.经验公式三（双作用锤）···········································44确定飞边槽的形式和尺寸········································45终锻模膛设计··················································45.1冷锻件图······················································55.2热锻件图······················································66绘制计算毛坯图················································76.1计算毛坯的用途·················································86.2相关参数的计算·················································86.3绘制·························································87确定皮料尺寸··················································98其他模膛设计··················································98.1滚压模膛设计··················································98.2切断模膛设计··················································109锻模机构设计··················································109.1模膛排布·····················································109.2模膛紧固方法··················································109.3确定模膛壁厚··················································109.4模块尺寸确定··················································1010模锻工艺流程·················································1111模具工程图··················································12总结···························································13致谢···························································13参考文献·······················································144前言本次课程设计的研究项目是《锻造工艺与模具设计》学习的一个重要组成部分。在设计的过程中首先通过查找有关资料确定设计的主题方向，通过课本的案例进行逐步实际计算。由于没有实际的设计经验，这也使我再设计的过程中走了不少弯路。在整个设计过程中，从开始的计算，画冷热锻件图到确定加工工艺过程，再到最后的画锻模模具，每个过程都让我有很深的的感触。由于个人能力有限，本次的设计如存在错误之处，敬希望老师能够给予批评改正。XXX于燕山大学2012年7月5阶梯轴锻压模具设计你的名字（燕山大学里仁学院）1阶梯轴锻件图1.1分模位置确定分模面位置基本的原则是保证锻件形状尽可能与零件形状相同，以及锻件容易从锻模模膛取出。锻件分模位置一般都选择在具有最大轮廓线的地方。1.2公差和余量估算锻件质量约为2.28kg。阶梯轴材料为45钢，即材质系数为M1。（锻件体积：289.8cm3密度：7.85g/cm3）锻件形状复杂系数S=Vb/Vd=289.8/500.284=0.579，S在0.32-0.63范围内，所以复杂系数为S2级。查《锻压手册》表3-1-3[GB12362-1990]【普通级】基本尺寸：0~3030~8080~120120~180公差：2.25.17.02.57.18.02.89.19.03.21.21.1错位公差：0.8残留飞边公差：0.81.3机械加工余量该零件的表面粗糙度为Ra=3.2μm，即加工精度为F1，查《锻压手册》表3-1-1[GB12362-1990]锻件内表面的加工余量查得：厚度方向:2.2~7.1mm水平方向:2.2~7.1mm1.4模锻斜度选择模锻斜度为7°。1.5圆角半径为保证锻件凸角处的最小余量，按下式计算：r=余量+零件的圆角半径取余量为：2mmr=2+0=2mm6R=2.5r+0.5=5.5mm1.6技术条件⑴未注模锻斜度7°。⑵未注圆角半径5mm。⑶允许的错差量0.8mm。⑷允许的残留飞边量0.8mm。⑸允许的表面缺陷深度0.5mm。⑹锻件调质热处理。图1零件图2计算锻件的主要参数⑴锻件的水平面上的投影面积为6700mm2⑵锻件的周边长度为400mm⑶锻件的体积为289.8cm3⑷锻件质量为2.28kg3锻锤吨位的确定3.1经验公式一双作用锤G=(3.5-6.3)KA总变形面积为锻件在水平面上的投影面积与飞边水平投影面积之和，按t2~1锤飞边槽尺寸（见表7-7）考虑，假定飞边平均宽度为25mm。总的变形面积:S=（6700+400×25）mm2=16700mm2。取钢种系数K=1，锻件和飞边（按飞边的50%容积计算）在水平的投影面积为A（单位cm2）7G=6.3KA=6.3×1×167=1052.1kg3.2经验公式二G=KA'K：钢种系数；A：包括连皮的锻件投影面积（单位cm2）查《中国模具设计大典》表24.2-23得K=4A'=SG=4×167=668kg3.3经验公式三（双作用锤）G0=(1-0.005D)(1.1+2/D)2(0.75+0.001D2)D=897.67kgG0:锻锤落下部分的质量（kg）D：锻件外径（cm）：终端材料的变形抗力（MPa）查得=60MPa综上三种方法选1t双作用模锻锤。4确定飞边槽的形式和尺寸选用图7-20中Ⅲ型飞边槽，其尺寸按表7-7确定。选定飞边槽的尺寸为h飞=1.6mm，h1=4mm，b=8mm，b1=25mm,r=1.5mm,F飞=126mm2飞边体积：V飞=400×0.7×126=35280mm35终锻模膛设计终锻模膛是按照热锻件图来制造和检验的，热锻件图尺寸一般是在冷锻件图尺寸的基础上考虑15%的冷缩率。根据生产实践经验，应考虑锻模使用后承击面下陷，模膛深度减小的因素，可适当调整尺寸。85.1冷锻图图2冷锻件图95.2热锻件图图3热锻件图10图4热锻件CAD图6绘制计算毛坯图根据阶梯轴的形状特点，共选取4个截面，分别计算S锻,S锻,d计。计算结果列于下表6-1：表1-6断面号1234S锻/mm21963.43848.32827.4706.81.4S飞/mm2176176176176S计=s锻+1.4S飞/mm22139.44024.33003.4882.8d计=1.13√S计/mm25.371.761.933.611修正S计/mm2----d计/mm----K1111H=Kd计mm25.371.761.933.6图36.1计算毛坯图的用途⑴长轴类锻件选择制坯工步的依据；⑵确定坯料尺寸的依据⑶设计制坯模膛的依据。6.2相关参数计算V体=V锻+V飞=289803+35280=325083mm3平均截面积：S均=V体/L计=325083/130=2500.63mm2均直径d均=/4S均=56.44mm6.3绘制S计=S锻+2ηS飞12S计-计算毛坯的断面积；S锻-模锻件的断面积；η-飞边充满系数；S飞-飞边槽的断面积。7确定坯料尺寸由于此锻件只有滚压制坯工步，所以可根据公式S坯=S滚=（1.2~1.05）S均确定坯料截面尺寸，取系数为1.1，则S坯=1.1S均=1.1×2500.63=2750.7mm2d坯=1.13坯S=1.13×2750.7=59.2mm实际取d坯=60mm坯料的体积V坯=V体（1+）=325083×（1+3%）=334835.5式中--烧损率。坯料长度为L坯=V坯/S坯=334835.5/（602×π/4）=118mm由于此锻件质量小，仅为2.28kg，所以采用一火三件，料长可取3L坯+L钳=（3×118+1.2×60）=426mm，考虑的实际锻造和切断情况，可适当加长到430mm。试锻后再根据实际生产情况适当调整。8其他模膛设计8.1滚压模膛设计具体设计如下：①模膛高度：h=K计d,计算结果如上表6-1，按各断面的高度值绘出滚压模膛纵剖面外形。参见下图阶梯轴的截面图各计算毛坯图中计算毛坯直径图的虚线，然后用圆弧和直线光滑连接并进行适当简化，最终尺寸见图。②模膛宽度：1.7d坯d≥B≥1.1mind，根据实际生产情况，模膛宽度取B=102mm。③模膛长度L等于计算毛坯的长度。8.2切断模膛设计由于采用一火三锻，需要设计切断模膛，切刀倾斜角度取15°，切刀宽度为6mm，切断模13膛的宽度，根