Development of tools and technologies for the production of the "Shield" part

Contents

Introduction

1. Development of Sheet Part Stamping Technology

"Shield"

1.1 Part drawing, processability analysis

1.2 Discussion of possible versions of part manufacturing and selection of the most rational

1.3 Procurement Calculation (Drilldown)

1.4 Optimization of cutting (when stamping from sheet), determination of cutting coefficient, CMM and consumption rate

1.5 Content and Flow Definition

1.6 Calculation of process transitions

(tool forces and geometry)

1.6.1 Calculation of tool actuating dimensions

1.6.2 Calculation of forces

2. Stamp Design

2.1 Justification of design selection

2.2 Determination of dimensions of working parts, selection of standard die parts

2.2.1 Determination of die pressure center

2.2.2 Determination of dimensions of working parts of the die

2.3 Calculation of actuating dimensions of working parts of dies

2.4 Calculation for strength of main parts of dies

2.5 Calculation of buffer

2.6 Press Selection

2.7 Safety considerations in die design

List of literature

Application

Introduction

Sheet stamping is one of the types of metal forming carried out in dies installed on presses. Cold sheet stamping is one of the most advanced technological methods of production; it has a number of advantages over other types of metal processing, both technically and economically. Sheet stamping involves the use of a starting material in the form of a sheet, strip, tape, roll. As a rule, sheet stamping production is focused on the mass production of parts.

The development of mechanical engineering and metalworking requires further improvement of technological processes and organization of production, increase of its efficiency and increase of labor productivity based on automation of production processes.

Discuss possible manufacturing options for the part and choose the most rational

Combining several operations in one die (for example, bending and punching) would complicate the stamping process, operations would become more time consuming. Due to the fact that our annual output is 10,000 units, and this is a small-scale production, it makes no sense to make a complex stamp. This will be economically inefficient and more labour-intensive. It makes sense to make two stamps. Punching die and bending die.

As already mentioned, the "Shield" part has a complex configuration, so it can be manufactured as follows:

Punch holes and cut the contour of a part.

Bending in the second die with one transition.

Define Content and Flow

Based on the design considerations, the features of manufacturing the part, we will adopt a punching and cutting scheme in a sequential die, and bending in a simple die.

Stamp Design

You must use two stamps to obtain the Panel part. Sequential die for punching and cutting, and simple die for bending.

2.1 Substantiation of design selection.

For cutting stamp - punches:

1) The lower and upper plates have diagonal arrangement of guide elements (columns and bushings), since the upper and lower halves of the die are well centered;

2) The die is attached to the stamping plate by means of grips;

3) Guide bushings - stepped, guide columns - stepped, of different diameters for uniqueness of die assembly;

4) The overall dimensions of the bottom plate shall ensure that the lower part of the die can be fixed: the plate shall protrude beyond the package by a size sufficient for the installation of tacks.

5) Stamping occurs on failure.

6) A movable extractor is used in the die.

For bending die:

1) The lower and upper plates have a rear arrangement of guide elements (columns and bushings), since they facilitate access to the stamping zone and are convenient for maintenance;

2) The die is attached to the stamping plate by means of grips;

3) Guide bushings - stepped, guide columns - stepped;

4) The overall dimensions of the bottom plate shall ensure that the lower part of the die can be fixed: the plate shall protrude beyond the package by a size sufficient for the installation of tacks.

2.7 Accounting of safety precautions in the design of dies.

To protect the puncher, the following features are laid in the die structures:

A barrier shield is located along the perimeter of the die, which prevents the fingers of the puncher from entering the punching zone;

The length of the guide columns is selected so that a distance of 1015 mm remains between the upper end of the column and the lower plane of the press slider in the lower extreme position of the die;

Length of guide bushings is selected so that in extreme upper position of die column enters bushing by value not less than 10 mm;

Guide sleeves and guide columns use different diameters to uniquely assemble the die;

Guide bushings and guide columns have a complex heat treatment: columns and bushings are made of steel 20, then cemented and hardened. A hard outer layer for columns (inner for bushings) and a "soft" core are obtained, which prevents brittle destruction of the metal in an emergency.

The equipment is selected with two-handed actuation of the drive, also to prevent the puncher fingers from entering the stamping zone. When working on a bending die, the blanks are stacked and removed from the die using tweezers.