毕业设计--推拉窗中空光企铝型材挤压模具设计(含外文翻译）

推拉窗中空光企铝型材挤压模具设计摘要本次设计主要阐述地弹门光企的挤压模具结构设计过程。设计中分析了挤压模具及地弹门光企的基本结构特点，分析其加工工序，结合工件的产量和模具设计的复杂程度，确定了生产过程的各个详细的工艺参数及生产流程。设计重点阐述了模具的结构设计过程，选择800吨的挤压设备，选用4CR5MOSIV1作为模具材料，并确定采用平面分流模、模孔数为4、模孔为中心对称分布、模孔外形尺寸的修正及模孔工作带长度并对其进行了强度校核；考虑添加了模孔形状类似分流孔的导流模，计算了锭坯尺寸、挤压比和挤压力。最后对挤压工具进行了设计，根据全部零件的结构设计选用合适的磨具尺寸，其中涉及挤压筒的设计，挤压筒采用三层的结构形式；选择内外套的配合形式及各项尺寸，并进行强度校核；挤压轴的设计，主要有挤压轴的结构形式及具体尺寸；挤压垫片设计，主要有尺寸选取及强度校核。最后绘制出各部分图纸。关键词推拉窗中空光企、挤压模具，平面分流模，分流孔、导流模HOLDSTHEPIECETHEPUNCHHOLESTOFALLTHEMATERIALTHECURVINGRAMMINGMOLDDESIGNABSTRACTTHISDESIGNMAINLYEXPOUNDSTHETRANSITIONOFSTAMPINGMOULDDESIGNFIRST,ASIMPLEANALYSISOFTHEDESIGNOFTHEDEVELOPMENTOFSTAMPINGFORMINGPROCESSANDTHEMAINCHARACTERISTICSOFPUNCHFORMING,STAMPINGANDTHEMAINSTRUCTURECHARACTERISTICS,ANDTHENFROMTHETITLEOFBASICSTRUCTURE,THEAUTHORANALYZESTHEPROCESSINGPROCEDURECOMBINEDWITHPRODUCTIONANDDIEDESIGNOFWORKPIECE,DECIDEDTOADOPTTHECOMPLEXITYOFPUNCH,BLANKING,BENDADEPUTYMULTIPOSITIONPROGRESSIVE,ANDUSINGCAXA,CADDESIGNOFMOLDDESIGNANDDRAWINGTHEMOULDDESIGNFOCUSESONPROCESSOFSTRUCTURALDESIGNFIRSTTOMOULDPROCESSPARAMETER,THEMAINPARTOFTHEWORKRELATEDPICTURES,THEMAINPARTSOFMOULDSTRUCTUREDESIGN,INCLUDINGTHEWORKPIECEPARTS,COMPONENTSANDPARTS,THEDIRECTIONPOSITIONINGUNLOADERDEVICEETC,ACCORDINGTOTHEDESIGNOFSTRUCTUREDESIGNOFALLPARTSOFTHEMOULDSEATANDAPPROPRIATEDESIGN,MOULDHANDLEISBRIEFLYANALYZEDTHEBLANKSHAPE,SIZE,ANDLAYOUT,CUTTINGPLATEPUNCHINGPROCESSSCHEME,THENUMBEROFNATURE,ANDSEQUENCE,THEPROCESSOFTHEWORKFORCE,THECALCULATIONANDDESIGNANDTOLERANCEOFTHEMOULDPRESSINGEQUIPMENTSELECTIONKEYWORDSSTAMPING,PROGRESSIVEDIE,PUNCHING,BLANKING,BENDING目录前言1第一章挤压件结构工艺性分析311产品图及其分析312铝及铝合金的特点313挤压工艺的制定6131挤压工艺流程6132挤压工艺及工艺参数条件的确定6133铸锭的加热温度7134挤压筒预热9135模子预热9136挤压温度9137挤压速度9138工模具的润滑10139模具材料111310切压余121311淬火121312冷却121313切头尾121314时效121315表面处理1214挤压设备及坯料的选择13141坯料尺寸确定13142挤压力的计算14第二章导流模的设计16第三章平面分流模的设计1731平面分流模的结构及特点17311平面分流模的结构17312平面分流模的特点1832模组尺寸确定1933组合模相关参数的确定20331扇形面积的确定20332分流孔位置的确定21333分流孔的形状2234分流桥22341分流桥的形状23342分流桥高度的确定2335焊合室2436模子内形尺寸的确定2537模孔工作带2738模芯的设计28381上模凸台设计29382定位设计和螺钉的选择2939模子强度校核29第4章挤压工具设计3241挤压筒的结构设计32411挤压筒内径的选择32412挤压筒长度的选择32414挤压筒配合公盈之确定34415挤压筒的热装配3542挤压轴的设计35421挤压轴的结构形式35422挤压轴尺寸的确定36423挤压轴强度校核3843挤压垫片设计39431挤压垫材料选择39432垫片尺寸的确定3944挤压垫片强度校核4045其他挤压工具设计41451模支承41第5章装配图42结论43谢辞44参考文献45外文资料翻译46前言挤压是有色金属、钢铁材料生产与零件成型加工的主要方一，也是各种复合材料、粉末材料等先进材料制备与加工的重要方法。从大尺寸金属铸锭的热挤压开坯、大型管棒型材的热挤压加工至小型精密零件的冷挤压成型，从粉末、颗粒料为原料的复合材料直接固化成型到金属间化合物、超导材料等难加工材料，现代挤压技术得以广泛的应用。挤压加工的方法主要有正挤压，反挤压，侧向挤压，玻璃润滑挤压，静液挤压，连续挤压。挤压加工特点是处于强烈的三向压应力状态，这有利于提高金属的塑性变形能力，提高制品的质量，改善制品内部微观组织和性能。除此以外，挤压加工还具有应用范围广，生产灵活性大，工艺流程简单和设备投资少的特点。应用挤压加工工艺最多的材料是低熔点的有色合金，如铝及铝合金模具是利用其特定形状去成型具有一定的形状和尺寸制品的工具。在各种材料加工工业中广泛的使用着各种模具。例如金属铸造成型使用的砂型或压铸模具、金属压力加工使用的锻压模具、冷压模具等各种模具。对模具的全面要求是能生产出在尺寸精度、外观、物理性能等各方面都满足使用要求的公有制制品。以模具使用的角度，要求高效率、自动化操作简便；从模具制造的角度，要求结构合理、制造容易、成本低廉。模具影响着制品的质量。首先，模具型腔的形状、尺寸、表面光洁度、分型面、进浇口和排气槽位置以及脱模方式等对制件的尺寸精度和形状精度以及制件的物理性能、机械性能、电性能、内应力大小、各向同性性、外观质量、表面光洁度、气泡、凹痕、烧焦、银纹等都有十分重要的影响。其次，在加工过程中，模具结构对操作难以程度影响很大。在大批量生产塑料制品时，应尽量减少开模、合模的过程和取制件过程中的手工劳动，为此，常采用自动开合模自动顶出机构，在全自动生产时还要保证制品能自动从模具中脱落。另外模具对制品的成本也有影响。当批量不大时，模具的费用在制件上的成本所占的比例将会很大，这时应尽可能的采用结构合理而简单的模具，以降低成本。现代生产中，合理的加工工艺、高效的设备、先进的模具是必不可少是三项重要因素，尤其是模具对实现材料加工工艺要求、塑料制件的使用要求和造型设计起着重要的作用。高效的全自动设备也只有装上能自动化生产的模具才有可能发挥其作用，产品的生产和更新都是以模具的制造和更新为前提的。由于制件品种和产量需求很大，对模具也提出了越来越高的要求。因此促进模具的不断向前发展。模具主要类型有冲模、锻摸、塑料模、压铸模、粉末冶金模、玻璃模，橡胶模、陶瓷模等。除部分冲模以外的的上述各种模具都属于腔型模，因为他们一般都是依靠三维的模具形腔是材料成型。挤压模具所涉及的工艺繁多，包括机械设计制造，塑料，挤压加工，金属材料，铸造（凝固理论），塑性加工，玻璃等诸多学科和行业，是一个多学科的综合，其复杂程度显而易见。通过对模具专业的学习，掌握了常用材料在各种成型过程中对模具的工艺要求，各种模具的结构特点及设计计算的方法，以达到能够独立设计一般模具的要求。在模具制造方面，掌握一般机械加工的知识，金属材料的选择和热处理，了解模具结构的特点，根据不同情况选用模具加工新工艺。毕业设计能够对以上各方面的要求加以灵活运用，综合检验大学期间所学的知识。第一章挤压件结构工艺性分析11产品图及其分析本次设计的产品是推拉窗中空光企铝型材，其截面如下图所示图图11产品截面图表11所设计中空光企的相关尺寸名称型号壁厚单重（KG/M）光企760610MM048本材料是6060铝合金，截面是空心型材，给定的数据有壁厚1MM，52315及截面形状，其他根据实际情况自行拟定制品的截面积0481000/2717778MM2制F模孔外接圆直径608外D2253112铝及铝合金的特点铝及铝合金具有一系列特性，在金属材料的应用中仅次于钢材而居第二位。目前全世界铝材的消费量在1800万吨以上，其中用于交通运输（包括铁道车辆、汽车、摩托车、自行车、汽艇、快艇、飞机等）的铝材约占27，用于建筑装修的铝材约23，用于包装工业的铝材约占20。随着中国经济建设的高速发展，人民生活水平的不断提高，中国的建筑行业发展迅速，包括铝型材在内的建筑装饰材料不断增加。铝型材的应用已经扩展到了国民经济的各个领域和人民生活的各个层面。铝合金比纯铝具有更好的物理力学性能易加工、耐久性高、适用范围广、装饰效果好、花色丰富。铝合金分为防锈铝、硬铝、超硬铝等种类，各种类均有各自的使用范围，并有各自的代号，以供使用者选用。铝合金型材具有强度高、重量轻、稳定性强、耐腐蚀性强、可塑性好、变形量小、无污染、无毒、防火性强，使用寿命长（可达50100年），回收性好，可回炉重炼。多年来世界各国均采用6063铝合金（铝合金近百种）作为门窗框架。主要是为了该金属表面阳极氧化效果好，开始阳极氧化是白色，后进一步改变电解质才达到古铜色，这两种主体颜色在国内用了十多年表12铝合金化学成分CHEMICALCOMPOSITIONLIMITSWTGB/T31901996牌号SIFECUMNMGCRZNTI其他元素AL备注每种合计6063020603501010409010101005015余量LD316005060903501010406010101005015余量60610408071050401508120103025015005015余量LD3060820713050104100612020201005015余量本设计选用6063铝合金,由于其强度高，质量轻，加工性能好，在退火状态下，该合金有优良的耐蚀性及物理机械性能，是一种可以时效强化的ALMGSI系合金，广泛应用于基础性建筑行业以及一些机械制造业。6063合金中的主要合金元素为镁与硅，具有加工性能极佳、优良的可焊接性、挤出性及电镀性、良好的抗腐蚀性、韧性，易于抛光、上色膜，阳极氧化效果优良，是典型的挤压合金。广泛应用于建筑型材、灌溉管材、供车辆、台架、家具、升降机、栅栏等用的管、棒、型材。从表可以看出随着温度的升高抗拉强度和屈服强度逐渐变小，伸长率增大。表136063室温下的机械性能（MECHANICALMOLDPROCESSINGFIRST,FOREWORDINTHEMODERNMOLDPRODUCTION,ALONGWITHTOMODELSARTISTICANDTHEFUNCTIONMUSTOBTAINMOREANDMOREHIGH,MODELSTHEINTERNALSTRUCTURETODESIGNMOREANDMORECOMPLEX,THEMOLDCONTOURDESIGNDAYBYDAYISALSOCOMPLEX,THEFREECURVEDSURFACEACCOUNTSFORTHEPROPORTIONTOINCREASEUNCEASINGLY,THECORRESPONDINGMOLDSTRUCTUREALSODESIGNSMOREANDMORECOMPLEXTHESEALLSETAHIGHERREQUESTTOTHEMOLDPROCESSINGTECHNOLOGY,NOTONLYSHOULDGUARANTEETHEHIGHMANUFACTUREPRECISIONANDTHESURFACEQUALITY,MOREOVERMUSTPURSUETHEPROCESSINGSURFACEARTISTICALONGWITHISUNCEASINGLYTHOROUGHTOTHEHIGHSPEEDPROCESSINGENGINEERINGRESEARCH,ISPROCESSINGTHEENGINEBED,THENUMERICALCONTROLSYSTEM,THECUTTINGTOOLSYSTEM,CAD/ESPECIALLYCORRELATIONTECHNOLOGYANDSOONCAMSOFTWAREDEVELOPSUNCEASINGLYUNDERTHEIMPETUS,HIGHSPEEDPROCESSESTHETECHNOLOGYMOREANDMOREMANYTOAPPLYINTHEMOLDCAVITYPROCESSINGANDTHEMANUFACTURETHENUMERICALCONTROLHIGHSPEEDCUTTINGPROCESSINGTOOKINTHEMOLDMANUFACTUREAMOSTIMPORTANTADVANCEDMANUFACTURETECHNOLOGY,ISTHECOLLECTIONISHIGHLYEFFECTIVE,HIGHQUALITY,THELOWCONSUMPTIONINABODYADVANCEDMANUFACTURETECHNOLOGYISOPPOSITEINTHETRADITIONALMACHINING,ITSCUTTINGSPEED,ENTEREDTOTHESPEEDHADTHEVERYBIGENHANCEMENT,MOREOVERCUTTHEMECHANISMNOTTOBESAMETHEHIGHSPEEDCUTTINGCAUSEDTHEMACHININGTOHAVETHELEAP,ITSSPECIFICPOWERMETALEXCISIONRATEENHANCED3040,THECUTTINGFORCEREDUCED30,THECUTTINGTOOLWORKINGDURABILITYENHANCED70,REMAINEDHOTLYLARGESCALEREDUCESINTHEWORKPIECECUTTING,THELOWSTEPSHUDDERVANISHEDNEARLYALONGWITHTHECUTTINGSPEEDENHANCEMENT,UNITTIMESEMIFINISHEDMATERIALSMATERIALREMOVINGRATEINCREASED,THECUTTINGTIMEREDUCED,THEPROCESSINGEFFICIENCYENHANCED,THUSREDUCEDTHEPRODUCTMANUFACTURECYCLE,ENHANCEDTHEPRODUCTMARKETCOMPETITIVEPOWERATTHESAMETIME,THEHIGHSPEEDPROCESSINGSMALLAMOUNTENTEREDQUICKLYCAUSESTHECUTTINGFORCETOREDUCE,THESCRAPHIGHSPEEDDISCHARGEDREDUCEDTHEWORKPIECECUTTINGFORCEANDTHETHERMALLOADDISTORTS,ENHANCESTHERIGIDITYTOBEBADANDTHETHINWALLCOMPONENTSMACHININGPOSSIBILITYBECAUSECUTTINGFORCEREDUCING,THEROTATIONALSPEEDENHANCEMENTCAUSESTHECUTTINGSYSTEMTHEOPERATINGFREQUENCYTOBEFARAWAYTHEENGINEBEDTHELOWSTEPNATURALFREQUENCY,BUTTHEWORKPIECESURFACEROUGHNESSISMOSTSENSITIVETOTHELOWSTEPFREQUENCY,FROMTHISREDUCEDTHESURFACEROUGHNESSINMOLDHIGHHARDSTEELSTOCKHRC45HRC65INTHEPROCESSINGPROCESS,USESTHEHIGHSPEEDCUTTINGTOBEPOSSIBLETOSUBSTITUTEFORTHEWORKINGPROCEDUREWHICHTHEELECTRICALFINISHINGANDRUBSTRUNCATESPOLISHES,THUSHASAVOIDEDTHEELECTRODEMANUFACTUREANDTHETIMECONSUMINGELECTRICALFINISHING,LARGESCALEREDUCEDFITTERSPOLISHINGWITHTOTHROWTHELIGHTQUANTITYTHINWALLMOLDWORKPIECEMOREANDMORENEEDSWHICHREGARDINGSOMEMARKETSIN,THEHIGHSPEEDMILLINGALSOMAYSMOOTHLYCOMPLETE,MOREOVERINTHEHIGHSPEEDMILLINGCNCPROCESSINGCENTER,AMOLDATTIRECLAMPSMAYCOMPLETETHEMULTIPLEXSTEPOFPROCESSINGTHEHIGHSPEEDPROCESSINGTECHNOLOGYHASHADTHEHUGEINFLUENCETOTHEMOLDPROCESSINGCRAFT,CHANGEDTHETRADITIONALMOLDPROCESSINGTOUSE“THEANNEALINGMILLINGPROCESSINGHEATTREATMENTTORUBTRUNCATES“OR“THEELECTRICSPARKMACHININGMANUALLYPOLISHES,POLISHES“ANDSOONTHECOMPLEXLONGTECHNICALPROCESS,EVENMIGHTUSETHEHIGHSPEEDCUTTINGPROCESSINGSUBSTITUTIONORIGINALCOMPLETEWORKINGPROCEDURETHEHIGHSPEEDPROCESSINGTECHNOLOGYBESIDESMAYAPPLYINTHEHARDMOLDCAVITYDIRECTPROCESSINGINPARTICULARHALFPRECISIONWORKANDPRECISIONWORK,INEDMASPECTANDSOONELECTRODEPROCESSING,FASTTYPEMANUFACTUREALSOOBTAINEDTHEWIDESPREADAPPLICATIONTHEMASSPRODUCTIONSPRACTICEINDICATEDTHAT,THEAPPLICATIONHIGHSPEEDCUTTINGTECHNOLOGYMAYSAVEINTHEMOLDFOLLOWINGPROCESSING80HANDWORKTOGRINDTHETIMEAPPROXIMATELY,SAVESTHEPROCESSINGCOSTEXPENSENEARLY30,THEMOLDFACEWORKPRECISIONMAYREACH1M,THECUTTINGTOOLCUTTINGEFFICIENCYMAYENHANCEONETIMESECOND,HIGHSPEEDMILLINGPROCESSINGENGINEBEDTHEHIGHSPEEDCUTTINGTECHNOLOGYISONEOFMACHININGTECHNOLOGYMAINDEVELOPMENTDIRECTIONS,ITALONGWITHFOUNDATIONTECHNOLOGYTHEANDSOONCNCTECHNOLOGY,MICROELECTRONICTECHNOLOGY,NEWMATERIALANDNEWSTRUCTUREDEVELOPMENTBUTSTEPSAHIGHERSTAIRBECAUSETHEMOLDPROCESSESPARTICULARASWELLASHIGHSPEEDPROCESSINGTECHNOLOGYOWNCHARACTERISTIC,PROCESSEDENGINEBED,NUMERICALCONTROLSYSTEM,CUTTINGTOOLTOTHEMOLDHIGHSPEEDPROCESSINGRELATEDTECHNOLOGYANDTHECRAFTSYSTEMANDSOONPROPOSEDPROCESSEDAHIGHERREQUESTCOMPAREDTOTHETRADITIONALMOLD1HIGHSTABLEENGINEBEDSTRUTPARTTHEHIGHSPEEDCUTTINGENGINEBEDLATHEBEDANDSOONSUPPORTSTHEPARTTOBESUPPOSEDTOHAVEVERYWELLMOVES,THESTATICRIGIDITY,HOTRIGIDITYANDBESTDAMPINGCHARACTERISTICTHEMAJORITYOFENGINEBEDSALLUSEHIGHGRADE,THEHIGHRIGIDITYANDGAOKANGZHANGTHEGRAYIRONTOOKTHESTRUTPARTMATERIAL,SOMEENGINEBEDCOMPANIESALSOINCREASETHEHIGHDAMPINGCHARACTERISTICINTHEFOUNDATIONPOLYMERCONCRETE,BYINCREASESITSVIBRATIONPROOFANDTHETHERMOSTABILITY,THISNOTONLYMAYGUARANTEETHEENGINEBEDPRECISIONISSTABLE,ALSOMAYPREVENTWHENCUTTINGTHECUTTINGTOOLINSPIRESTREMBLESUSESTHEENCLOSEDLATHEBEDDESIGN,THEOVERALLCASTINGLATHEBED,THESYMMETRICALLATHEBEDSTRUCTUREANDHASTHEDENSELYCOVEREDSTIFFENERANDSOONALSOENHANCESTHEENGINEBEDSTABLEIMPORTANTMEASURESOMEENGINEBEDCOMPANIESRESEARCHANDDEVELOPMENTDEPARTMENTSINDESIGNPROCESS,BUTALSOUSESTHEMODALITYANALYSISANDTHEFINITEELEMENTSTRUCTURECOMPUTATIONANDSOON,OPTIMIZEDTHESTRUCTURE,STABLYCAUSESTHEENGINEBEDSTRUTPARTTOBERELIABLE2ENGINEBEDMAINAXLETHEHIGHSPEEDENGINEBEDMAINAXLEPERFORMANCEISTHEREALIZATIONHIGHSPEEDCUTTINGPROCESSINGIMPORTANTCONDITIONTHEHIGHSPEEDCUTTINGENGINEBEDMAINAXLEROTATIONALSPEEDSCOPEIS10000100000M/MIN,THEMAINAXLEPOWERISBIGGERTHAN15KWISNOTBIGGERTHAN0005MMTHROUGHTHEMAINAXLECOMPRESSEDAIROFORAXIALPLAYBETWEENTH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