The course project is Teh. plastic deformation processes and equipment

Contents

Introduction

1. Define workpiece dimensions

2. Development of part manufacturing technology

3. Definition of technological forces, moments and operations

4. Selection of forging and pressing equipment

5. Selecting Materials for Die Parts

6. Calculating Die Features

7. Developing a Stamp Assembly Drawing

Literature

Introduction

One of the main types of metal forming is sheet stamping, or stamping from sheet blanks. Cold sheet stamping differs from other methods in that one of the dimensions of the processed blanks (thickness) is significantly smaller than the other two - length and width.

The sheet blank may be metallic or non-metallic and obtained by rolling, pressing or other methods.

The range of products produced by this method is very numerous and diverse and includes both flat and spatial details of various sizes (from hundredths to a dozen millimeters). This makes it possible to create lightweight structures of high rigidity and strength. In addition, during the stamping process, the material is hardened (glued), which makes it possible to obtain products of higher strength relative to the initial blank.

Depending on the weight and thickness of the workpiece, cold or hot sheet stamping is used. In the first case, billets with thickness not exceeding 10-15 mm are stamped. Preforms of greater thickness are generally heated prior to stamping.

The need and desirability of using cold sheet stamping for relatively thin preforms is due to a number of reasons. First, it is difficult to maintain a constant preform temperature; second, cold forging produces parts with good surface quality (no scale) and high accuracy (no thermal deformation); third, it is possible to obtain parts of complex spatial configuration, which allows to create lightweight structures of given strength and rigidity;

fourth, the use of cold stamping allows a sharp reduction or elimination of cutting treatment, which increases the utilization rate of the material; in fifths, cold sheet stamping is characterized by high productivity.

Cold sheet stamping is one of the most advanced production methods and has a number of advantages over other types of metal processing.

Selection of forging and pressing equipment

Based on the calculations, we previously select one crank open simple action press of KI 2128A model. The press is designed to perform cold stamping operations: cutting, punching, bending, shallow drawing. Presses of one crank of simple action, opened with mechanized adjustment of closed height, not inclined are representatives of the range of one crank presses and are of the type of high-speed.

In the design of presses, their use is provided in the composition of robotic technological complexes and lines.

Partial mechanization of the press adjustment process when changing the stamp allows reducing auxiliary time, improving the safety of the operator and the adjuster, improving working conditions by reducing the proportion of manual labor.

Press operation modes: single, automatic and adjustment moves.

The drive is single-sided, single-stage.

Coupling-brake - rigidly locked, multi-disc, friction with pneumatic actuation, mounted on a flywheel.

Slider is equipped with overload protector and pneumatic counterbalancers.

Lubrication of presses is centralized, impulse, liquid from pump with electric drive, individual.

The control of the press is electro-pneumatic, two-armed from buttons or pedals.

The electrical interlock ensures reliable operation and safe maintenance of the press.

Main technical characteristics of the press:

rated press force, kN 630

adjustable slide stroke, mm

smallest 10

largest 100

number of slider strokes per minute 125

table dimensions, mm:

left to right 710

front - back 480

table hole dimensions, mm

left to right 360

front - back 240

diameter 300

distance from slider axis to frame (departure), mm 260

largest distance between table and slider

in its lower position at highest travel, mm 340

distance in light between stand posts, mm 340

adjustment of distance between table and slider, mm 80

understand plate thickness, mm 85

slider dimensions, mm

from left to right 370

front - back 310

dimensions of hole in the shank slide, mm

diameter 50 H9

depth 75

greatest ejector stroke in the slider, mm 50

highest number of slider strokes per minute in single mode, 45

table height above floor, mm 840

compressed air flow rate per one press start, l 1.6

overall dimensions of the press, mm

from left to right 1500

duration of IR actuation = 40%

M101 execution form

vibration class C1

Developing a Stamp Assembly Drawing

The assembly drawing is executed on a standard layout sheet in accordance with the requirements of the ESKD and usually at a scale of 1:1. The specification is attached to the calculation explanatory note.

In the design of a die having working elements made of hard alloys or hard alloy inserts, ball guide units must be used to ensure the reliability of the die.

Punches and dies shall be supported on hardened backing plates if the pressure transmitted by the support surfaces of punches and dies to the plates exceeds the allowable stress on their crushing.

Extractors and clamps shall be designed to re-sharpen the cutting edges without removing the package. The possibility of incorrect assembly of the upper and lower parts of the dies should be completely excluded.

Working parts of dies of complex configuration are made sectional. The length of the sections is determined by the manufacturer's technological capabilities (but not more than 300 mm). Attachment of sections shall prevent their displacement. The sections are fixed with pins, tie-in to the plates, assembled in cages, etc. At the joints of the sections, a gap is not allowed.

The length of the mounting part for pins in parts having a thickness of more than two pin diameters must be no more than two diameters. The diameter of the rest of the hole should be at least 1 mm larger than the diameter of the pin.

In parts fixed by means of cylindrical pins, where holes for pins are not through, it is necessary to provide threaded holes for their pressing out using screws.

Unspecified casting radii depending on the overall dimensions of the die part blanks shall be in the range of 2 to 40 mm. Unspecified molding slopes are assigned by the manufacturer. Chamfers can be used instead of cast slopes.

The deviation of the die height in the closed state from the size indicated in the drawing shall not exceed: ± 3.0 mm for dies with a closed height up to 250 mm; ± 5.0 mm - with a closed height over 250 to 630 mm; ± 10.0 mm - with a closed height over 630 mm.

If the die is attached to the press by means of a shank, the shank should be placed so that its axis coincides with the center of pressure of the die, that is, with the point to which all forces acting in a direction parallel to the axis of the shank are applied. If the die is attached without a shank, its installation on the press shall be such that the center of pressure of the die coincides with the vertical axis of the press.

Guide units should be arranged symmetrically relative to the die pressure center.