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編號
無錫太湖學院
畢業(yè)設計（論文）
相關資料
題目： 電池柜冷藏箱DC-tall之箱體主
要零件部件的計算設計
信機 系 機械工程及自動化專業(yè)
學 號： 0923244
學生姓名： 楊理剛
指導教師： 陳偉明（職稱：教授 ）
（職稱： ）
2013年5月25日
目 錄
一、畢業(yè)設計（論文）開題報告
二、畢業(yè)設計（論文）外文資料翻譯及原文
三、學生“畢業(yè)論文（論文）計劃、進度、檢查及落實表”
四、實習鑒定表
無錫太湖學院
畢業(yè)設計（論文）
開題報告
題目： 電池柜冷藏箱DC-tall之主要
零件部件的設計計算
信機 系 機械工程及自動化 專業(yè)
學 號： 0923244
學生姓名： 楊理剛
指導教師： 陳偉明 （職稱：教授 ）
（職稱： ）
2012年11月12日
課題來源
DC tall是該廠根據市場需求開發(fā)研制的電池柜冷藏箱。電池柜冷藏箱（DC tall）的主要結構采用的是鈑金材料，本產品的主要研究目的：將電池保持一定的溫度，使得電池延長使用壽命。裝電池后產品重量達1.42t吊起時頂部的四個螺絲每個都必須能承受220kg的拉力。保持電池柜內部溫度251，并保持內部溫度的均勻性
科學依據（包括課題的科學意義；國內外研究概況、水平和發(fā)展趨勢；應用前景等）
電池柜冷藏箱DC Tall之箱體主要零件部件的計算設計研究的意義將電池保持一定的溫度，使得電池延長使用壽命，節(jié)能減排、綠色成本、節(jié)約成本。
模具工業(yè)是國民經濟的基礎產業(yè)，據統(tǒng)計，金屬零件粗加工的75%、精加工的50%和塑料零件的90%是用模具加工完成的。被譽為“工業(yè)之母”、“皇冠工業(yè)”的模具制造業(yè)是高技術密集型產業(yè)，模具工業(yè)一稱為先進制造技術的重要組成部分。模具工業(yè)的發(fā)展水平標志著一個國家工業(yè)水平及產品開發(fā)能力。
其中，沖壓是模具工業(yè)中最重要的加工方法之一。沖壓的應用范圍十分廣泛，據統(tǒng)計在電子產品中，沖壓件（包括鈑金件）的數量約占零件總數的85%，在全世界的鋼材中，有60%-70%是板材，其中大部分是經過沖壓制成成品。沖壓加工在汽車、拖拉機、點擊、儀器儀表、家用電器、自行車、辦公機械等機械工業(yè)和國防工業(yè)以及日常生活用品的生產方面，占據著十分重要的地位。
本課題要求對自己選定的零件進行沖壓模設計。通過對零件進行詳細的工藝分析確定零件的沖壓工藝方案并制定部分零件的制造工藝。通過本課題，可以培養(yǎng)我們綜合運用所學的基礎理論、基本知識和基本技能來分析、解決實際問題的能力和初步進行科學研究的；培養(yǎng)我們獨立工作的能力、創(chuàng)新能力以及理論聯系實際和嚴謹求實的工作作風的重要途徑。
我國沖壓模具產品的質量和生產工藝水平，總體上比國際先進水平低許多，而模具生產周期卻要比國際先進水平長許多。產品質量水平低主要表現在精度、表面粗糙度、壽命及模具的復雜程度上；生產工藝水平低則主要表現在加工工藝、加工裝備等方面。模具壽命也只有國際先進水平的50%左右，大型、精密、技術含量高的轎車覆蓋件沖壓模具和精密沖裁模具，每年都要花費大量資金進口。但現在一汽模具公司、東汽模具公司、上海大眾模具公司等中國沖壓模具業(yè)的龍頭企業(yè)可部分生產此類模具。但是在一些低檔次的簡單沖模，則已供過于求，市場競爭非常激烈。
發(fā)展趨勢
模具技術的發(fā)展是模具工業(yè)發(fā)展最關鍵的一個因素，其發(fā)展方向應該為適應模具產品“交貨期短”、“精度高”、“質量好”和“價格低”的要求服務。未來，我國模具工業(yè)和技術 2 主要發(fā)展方向將主要集中在以下幾個方面：
（1）模具CAD/CAE/CAM正向集成化、三維化、智能化和網絡化服務
（2）模具檢測、加工設備向精密、高效和多功能方向發(fā)展
（3）快速經濟制造技術的廣泛引用
（4）開發(fā)優(yōu)質模具材料和先進的表面處理技術
（5）模具研磨拋光將向自動化、智能化方向發(fā)展
（6）模具標準件的應用日漸廣泛
（7）模具工業(yè)新工藝、新理念和新模式的發(fā)展
研究內容
1.工藝性分析
電池柜冷藏箱上頂蓋，和簧片是多種沖壓件。
1）分析零件的尺寸、形狀，加工要求，表面粗糙度等。分析零件的材料以及材料的性能 和制件的用途；
2）分析工藝資料及件的變形方式 ，成型可能性分析等；
3）分析材料是否滿足強度要求，是否滿足材料性能的成形性關系等。
4）了解工件的生產批量（決定模具的形式、結構、材料等）
5）了解工件原材料的規(guī)格與毛坯情況；
6）分析沖壓車間的設備資料或情況；
7）分析車間制造模具的技術能力和設備條件以及可采用的模具標準件情況；
2.運用UG，CAD繪制零件圖，分析零件的成型原理，選擇成型設備
1）學習UG，CAD軟件，運用UG，CAD的鈑金模塊進行繪制零件圖，然后運用其中的折彎命令對相應的部位進行折彎。
2）根據零件的成形特點及成形原理分析，以及工藝性分析的結果，再根據現有設備選出適合的成形設備。
3.確定具體的工藝方案
1）根據連接件本身結構特點，選擇零件件沖壓成形基本工序，如沖孔、落料、彎曲、成型等。
2）根據零件結構的工藝性，并根據零件測繪出的彎曲件圖，確定最合理的方案，確定總工序數、工序順序、各工序的加工內容、沖壓方向等。根據彎曲件的結構、形狀尺寸，選擇合適的毛坯。對彎曲件展開，初步確定毛坯的形狀和外形尺寸，制定材料消耗定額。選定各個工序的模具結構形式，選定毛坯和各工序制件的送、卸料方 3 向和方法。
4.模具主要結構的計算和設計
1）電池柜冷藏箱上頂蓋，和簧片等零件主要有：沖孔凸、凹模刃口尺寸和落料凸、凹模刃口尺寸以及彎曲凸、凹模刃口尺寸的計算。根據冷藏箱連接件結構形式對模具主要零件尺寸進行計算，并繪制出相應的模具的結構。
2）選擇定位裝置的形式及位置，選擇卸料和推件裝置，選擇導向零件，如選用導柱、導套導向或者導板導向等。選擇安裝、緊固零件，如模柄、上下模座的結構形式?？紤]各個零件的安裝位置。
5.利用UG，CAD進行模具各個主要結構的繪制以及最終的裝配。
擬采取的研究方法、技術路線、實驗方案及可行性分析
研究的基本內容，擬解決的主要問題
本課題研究的是墊圈沖壓模具設計，要求其材料軟黃銅H62，采用大批量生產，精度要求高。通過合理的設計凸凹模，選擇合理的標準模架，制造出符合要求的制件。 （1）查閱有關模具設計方面的資料，翻譯與模具設計相關的英文文獻；
（2）對工件進行沖壓成型工藝分析，選擇合理的設計方案；
（3）進行必要的參數計算，確定出正確的設計參數；
（4）在計算正確的基礎上設計沖壓成型模具；
（5）撰寫出一份與自己設計相配套的設計說明書
可能存在的問題
（1）沖孔時要保證斷面質量、尺寸精度和形狀誤差。
（2）合理的安排工序的先后順序及一模多腔的位置分布。
（3）沖裁間隙值對沖裁件質量、沖裁力及模具壽命有很大影響，是沖裁工藝及沖裁模具設計的重要工藝參數。間隙大小合適則可得到好的斷面質量；同時刃口銳利也可得到好的斷面質量。得到的沖裁件精度質量高，即零件的實際尺寸和沖裁模工作部分的尺寸之間的偏差少。
（4） 凸凹模刃口會有磨損，這樣會影響斷面質量，應及時更換刃口。
（5） 設計前后工序的關聯性以及模具的關聯性，合理安排工序，盡量是模具的結構緊密，同時在模具的設計過程中環(huán)要考慮到所設計的零件的可加工性，要盡量多的選用標準間，達到規(guī)范設計的要求成為此次畢業(yè)設計的難點
研究計劃及預期成果
1分析沖壓件的工藝性，確定工藝方案。
根據設計題目，分析沖壓件成型的結構工藝性，分析沖壓件的形狀特點、精度要求等。在分析了沖壓件的工藝性后，可以列出幾種不同的沖壓方案，然后從產品質量、生產效率、設備占有情況、模具制造難易程度和模具壽命高低、工藝成本等，確定最經濟合理的工藝方案
2確定毛坯形狀、尺寸和下料方式 在最經濟的原則下，確定毛坯形狀、尺寸和下料方式，并確定材料的消耗量
3確定沖壓模類型及結構形式
4進行必要的工藝計算 a 計算毛坯尺寸，以便在最經濟的原則下進行拍樣和合理使用材料 b計算沖壓力（包括沖裁力、卸料力、推件壓邊力等），以便選擇壓力機 c確定模具的壓力中心防止模具銀收偏心負荷作用影響模具壽命。 d計算或估算模具各主要零件的外型尺寸 e確定凸凹模的間隙，計算凸凹模工作部分中尺寸。
5選擇壓力機
6繪制模具總圖和非標準零件圖
7編寫設計計算所明書
特色或創(chuàng)新之處
① 使用CAD設計及繪畫，效果明顯，方便改變參量，能夠直觀判斷實驗結果。
② 我的設計會按照要求，既注重實用性和安全性；同時性價比高，成本低。
已具備的條件和尚需解決的問題
已具備的條件：
設計過程中所需的各種軟硬件資源和相關產品實物照片。
尚需解決的問題：
1.防水性要求：背部拼接達到IP65等級即：浸水一米以內不漏水； 其余拼接部分IP55級即要求能夠防雨。
2.門和箱體的防腐蝕性
3.整個機器的保溫性及隔熱性能。
防止能量損失小于整體的35%。在環(huán)境溫度35℃時，壓縮機輸入功率170W，制冷功率280W。保持內部室溫25℃,以及內部溫度的均勻性±1℃。
指導教師意見
指導教師簽名：
年 月 日
教研室（學科組、研究所）意見
教研室主任簽名：
年 月 日
系意見
主管領導簽名：
年 月 日
英文原文
Design Of Tool Machine Prop
Research significance
The original knife machine control procedures are designed individually, not used tool management system, features a single comparison, the knife only has to find the tool knife, knife positioning the shortest path, axis tool change, but does not support large-scale tool.
Automatic knife in the knife election, in the computer memory knife-election on the basis of using the Siemens 840 D features, and the election procedures knife more concise, and complete the space Daotao View. ATC use the knife rapid completion of STEP-7 programming, and have been tested in practice. In the positioning of the knife, PLC controlled modular design method, which future production of similar machines will be very beneficial, it is easy to use its other machine. Automatic tool change systems will be faster growth, reduced tool change time, increase the positioning accuracy tool is an important means to help NC technology development.
Tool and inventory components of modern production is an important link in the management, especially for large workshop management. The traditional way of account management, and low efficiency, high error rate, and not sharing information and data, tools and the use of state can not track the life cycle, are unable to meet the current information management needs. With actual production, we have to establish a workshop tool for the three-dimensional tool storage system to meet the knife workshop with auxiliary storage and management needs.
The system uses optimization technology, a large number of computer storage inventory information, timely, accurate, and comprehensive tool to reflect the inventory situation. The entire system uses a graphical interface, man-machine dialogue tips from the Chinese menu, select various functions can be realized and the importation of all kinds of information. Management system using online help function. Through the workshop management, network management and sharing of information. Have automated inventory management, warehousing management tool, a tool for the management and statistical functions.
1.System components and control structure
The entire system, including the structure and electrical machinery control systems.
1.1.1Mechanical structure and working principle
Tool from the stent, drive, drive system, Turret, shielding, control system, and electrical components. Support from the column, beam, the upper and lower guide Central track, and track support component.
1) Drive for the system chosen VVVF method. Cone used brake motors, with VVVF by Cycloid reducer through sprocket drive.
2) Drag a variable frequency drive system and control technology. VVVF adopted, will speed drive shaft in the normal range adjustment to control the speed rotary turret to 5 ~ 30mm in, the drive shaft into two, two under through sprocket, the two profiled rollers Chain driven rotating shelves. Expansion chain adopted by the thread tight regulation swelling, swelling the regular way. - Conditioned, under the same chain-of-conditioning, so that the chain of uniform.
3) Turret and shields the entire total of 14 independent Turret. 13 of them as a socket-Turret, as a drawer-Turret, each Turret back through the pin and, under the conveyor chain link chain plate, installed at the bottom roller, chain driven rotating turret rotation along the track. Outlet-Turret and BT50-BT40 Turret Turret two kinds of forms. To strengthen management, security, landscaping modeling, shelf peripherals and shields. Turret-drawer drawer placed at six other Des Voeux a knife, can be categorized with some of knife auxiliary equipment, such as bits, such as turning tools.
1.1.2.Electrical Control System
This tool storage systems is the main electrical control their shelves for operational control and position control. Operational control equipment, including operation of the start of braking control. Position Control is the main location and address of the shelves for testing. Control system as shown in Figure 1.
圖 1 Tool Control System for the
1) Electric Transmission horizontal rotary tool storage systems are the mechanical movements are repeated short-term work system. And the run-time system needs some speed, speed transmission needs, the system will use VVVF method can be used simple structure, reliable operation of the motor and frequency inverter.
2) Control of the system is divided into two kinds of manual control and automatic control, manual control as a general reserve and debugging methods of work; ways to the system control computer (IPC) and the control unit (inverter contactor , etc.) consisting of a control system.
3) location and positioning accuracy of the system automatically identify the site and location using a detection device as proximity switches, relays through the plate-point isolation and the number plate recorded close to the switching signal acquisition and operation of Hutchison with a Optimal Path addressable identify the current location and shelves of the purpose of the shelf location. In order to enable a more accurate positioning system, adopted two photoelectric switches, to detect the two shelves of the two films.
1.2.The functions of the knife
knife The is the role of reserves a certain number of tools, machine tool spindle in hand to achieve the fungibility a disc cutter knife is the type of library, the chain knives, and other means, in the form of the knife and capacity according to the Machine Tool to determine the scope of the process.
1.3.Common types
The knife is a tool storage devices, the common knife mainly in the following forms:
(1) the turret knife
Including the first level turret vertical turret and the first two, see Figure 2.6 a) and b):
(2) the disc cutter
Disc knife in the library with discoid knife, cutting tool along See how vertical arrangement (including radial and axial from knife from knife), along See how radial array into acute or arranged in the form of the knife. Simple, compact, more applications, but are ring-cutter, low utilization of space. Figure 2.7 a) to c). If the knife storage capacity must be increased to increase the diameter of the knife, then the moment of inertia also increased correspondingly, the election campaign long knife. Tool number not more than 32 general. Cutter was multi-loop order of the space utilization knife, but inevitably given the knife from complex institutions, applicable to the restricted space Machine Tool storage capacity and more occasions. Two-disc structure is two smaller capacity knife on both sides of the sub-spindle place, more compact layout, the number of certificates corresponding increase knife, apply to small and medium-sized processing center.
(3) the chain knife
? Including single-and multi-ring chain ring chain, chain link can take many forms change, see Figure 2.8 a) to c), the basic structure shown in Figure 2. 8 do
Features: knife apply to the larger capacity of the occasion, the space of the small number of generally applicable to the tool in the 30-120. Only increase the length of the chain tool will increase the number should not be increased circumferential speed of its moment of inertia of the knife does not increase the disc as large.
(4) linear combination knife and the knife library
The linear knife simple structure in Figure 2.9, tool single order, the capacity of small knife, used for CNC lathe and drill press on. Because the location of fixed knife, ATC completed action by the spindle without manipulator. The cutter knife is generally the turret combination turret with a combination of the disc cutter knife and the chain combination. Every single knife the knife certificates of smaller, faster tool change. There are also some intensive drum wheel, and the lattice-type magazine for the knife, the knife-intensive though. Small footprint, but because of structural constraints, basically not used for single processing center, the concentration used for FMS for the knife system.
1.4 Tool storage capacity
Tool storage capacity of the first to consider the needs of processing, from the use of point of view, generally 10 to 40 knives, knife will be the utilization of the high, and the structure is compact.
1.5 Tool options
(1) choose to order processing tool according to the order, followed Add to the knife every knife in the Block. Each tool change, the order of rotation of a cutter knife on location, and remove the need knives, has been used by the cutter knife can be returned to the original Block, can also order Add Block, a knife. However, as the knife in the tool in different processes can not be repeated use of the knife must increase the capacity and lower utilization rate.
(2) most of the arbitrary choice of the current system of using arbitrary NC election knives, divided into Daotao coding, coding and memory-cutter, three. Daotao coding tool code or knives or Daotao need to install the code used to identify, in accordance with the general principle of binary coding coding. Tool knife election coding method uses a special knife handle structure, and each of the coding tool. Each of the tool has its own code, thereby cutting tool can be in different processes repeatedly used, not to replace the tool back at the original knife, the knife capacity can be reduced accordingly. Memory-election this paper knife, in this way can knives and knife in the position corresponding to the Daotao memory of the PLC in the NC system, no matter which tool on the Inner knife, tool information is always there in mind, PLC . On the knife with position detection devices, will be the location of each Daotao. This tool can be removed and sent back to arbitrary. On the knife is also a mechanical origin, every election, the nearest knife selection.
1.6. Control of the knife
? (1) the knife as a system to control the positioning axis. In the ladder diagram in accordance with the instructions for computing T code comparison of the output angle and speed of instructions to the knife the knife servo drive servo motor. Tool storage capacity, rotation speed, and / deceleration time, and other system parameters can be set in such a manner free from any outside influence positioning accurate and reliable but the cost is higher.
? (2) knife from the hydraulic motor drives, fast / slow the points, with proximity switches count and positioning. In comparison ladder diagram of the current storage system knife (knife spindle) and goals knife (pre-knife) and computing, then output rotation instructions, judging by the shortest path rotation in place. This approach requires sufficient hydraulic power and electromagnetic valve knife the rotational speed can be adjusted through the throttle. But over time may be oily hydraulic, oil temperature and environmental factors impact the change in velocity and accuracy. Not generally used in large and medium-sized machine tool change frequently.
? (3) the knife from AC asynchronous motor driven cam mechanism (Markov institutions), with proximity switches count, which means stable operation, and generally accurate and reliable positioning cam used in conjunction with a mechanical hand, ATC fast-positioning.
2. ATC, the main types, characteristics, and the scope of application
2.1 Auto Rotary Tool
Rotary Tool automatically on the use of CNC machine tool is a simple installation of automatic tool change, the Quartet and 47.60 Turret Tool various forms, such as rotary turret were installed on four, six or more of the Tool , NC instructions by ATC. Rotary Tool has two vertical and horizontal, relatively simple structure, applicable to economic CNC lathe.
Rotary Tool in the structure must have good strength and stiffness, resistance to bear rough Cutting Tool in the cutting force and reduce the role of deformation and improve processing accuracy. Rotating Tool to choose reliable positioning programme structure and reasonable position, in order to ensure that each rotary turret to a higher position after repeated positioning accuracy (typically 0.001 to 0.005mm). Figure 2.1 shows the spiral movements of the Quartet Turret.
Auto Rotary Tool in the simplest of ATC, is 180 o rotary ATC devices, as shown in Figure 2.2 ATC instructions received, the machine control system put ATC spindle control to the designated location at the same time, the tool movement to the appropriate location, ATC, with the rotary axis and at the same time, the knives matching tool; drawbars from Spindle Cutting Tools rip, ATC, will be the tool from their position removed; ATC, 180 o rotary tool spindle and the tool and tool away; ATC, the Rotary At the same time, the tool refocusing its position to accept Spindle removed from the cutting tool; Next, ATC, will be replaced with the cutter knives were unloaded into the spindle and tool: Finally, back to the original ATC, "standby" position. At this point, ATC completed procedures to continue to run. This ATC, the main advantage of simple structure, the less movement, fast tool change. The main disadvantage is that knives must be kept in parallel with the axis of the plane, and after the home side compared to the tool, chip and liquid-cutting knife into the folder, it is necessary to the tool plus protection. Cone knife folder on the chip will cause ATC error, or even damage knife folders, and the possibility of spindle. Some processing centre at the transfer, and the tool side. When the ATC command is called, the transfer-cutter knives will be removed, the machine go forward, and positioning with the ATC, in line with the position. 180 o "Rotary ATC devices can be used horizontal machine, can also be used for vertical machining centers.
2. 2 ATC head-turret installed
With rotating CNC machine tool often used such ATC devices, with a few turret head spindle, each with a spindle on both knives, the first tower interim process can be automatic tool change-realization. The advantage is simple structure, tool change time is short, only about 2 s. However, due to spatial constraints, the number of spindle can not be too much, usually only apply to processes less, not to high precision machine tools, such as the NC drill, such as CNC milling machine. In recent years there has been a mechanical hand and the turret head with a knife for the automatic tool change ATC devices, as shown in Figure 2.3. It is in fact a turret head ATC, and the knife-ATC device combination. The principle is as follows:
5 turret on the first two tool spindle 3 and 4, when using the tool spindle 4 processing tool, the manipulator 2 will be the next step to the need for the tool does not work on the tool spindle 3 until after the completion of this process , the first rotary turret 180 o, ATC completed. ATC most of their time and processing time coincidence, the only real tool change time turret transposition of the first time, this approach mainly used for ATC and NC NC drilling file bed.
2. 3.Daidao system for the automatic tool change
Figure 2.4 shows the knife and the whole machine tool CNC machine tools for the appearance of Fig.
? Figure 2.5 shows the knife and split-type machine to the appearance of CNC machine tool plans.
At this point, knife storage capacity, a heavier tool can, and often additional transport unit to complete the knife between the spindle and cutting tool transport.