基于Pro_E的盒體壓鑄模設(shè)計(jì)研究

1、壓力鑄特種鑄造及有色合金2007年第27卷第6期基于Pro/E 的盒體壓鑄模設(shè)計(jì)研究黃勇吉寧郝永平布國(guó)亮(沈陽(yáng)理工大學(xué)材料科學(xué)與工程學(xué)院摘要論述了應(yīng)用Pro/E 及其二次開(kāi)發(fā)工具Pro/TOOL KIT 等軟件對(duì)盒體類(lèi)壓鑄模設(shè)計(jì)的問(wèn)題, 介紹了基于Pro/E 的盒體壓鑄模設(shè)計(jì)系統(tǒng)的結(jié)構(gòu)及其組成部分。研究表明, 通過(guò)對(duì)Pro/E 的二次開(kāi)發(fā), 可以完成從三維圖形到二維圖形的轉(zhuǎn)化, 從而實(shí)現(xiàn)盒體類(lèi)壓鑄模的實(shí)體及平面圖的設(shè)計(jì)過(guò)程, 顯著地縮短了盒體類(lèi)壓鑄模的設(shè)計(jì)周期, 提高生產(chǎn)效率。關(guān)鍵詞Pro/E ; 二次開(kāi)發(fā); 盒體壓鑄模中圖分類(lèi)號(hào)T G 24911; TP311文獻(xiàn)標(biāo)志碼A 文章編號(hào)1001-

2、2249(2007 06-0451-03CAD/CAM 技術(shù)被認(rèn)為是現(xiàn)代模具設(shè)計(jì)的核心和重要的發(fā)展方向1。在對(duì)CAD 進(jìn)行二次開(kāi)發(fā)后,CAD 二維圖形向三維圖形的轉(zhuǎn)化已得到實(shí)現(xiàn)2,3。在Pro/E 三維造型軟件日益普及后, 三維造型已不再是模具設(shè)計(jì)的難點(diǎn), 但要高效地進(jìn)行產(chǎn)品設(shè)計(jì)以滿(mǎn)足更高層次的要求, 須借助其高級(jí)開(kāi)發(fā)工具包Pro/TOOL KIT 4?；赑ro/E , 方便設(shè)計(jì)。23壓鑄件逐漸向大型化和復(fù)雜化方向發(fā)展, 原來(lái)的模具設(shè)計(jì)依賴(lài)于手工, 僅憑設(shè)計(jì)者的經(jīng)驗(yàn), 設(shè)計(jì)周期長(zhǎng), 質(zhì)量較難滿(mǎn)足新產(chǎn)品壓鑄件的要求5, 為此, 開(kāi)發(fā)壓鑄模的設(shè)計(jì)計(jì)算系統(tǒng)。壓鑄模設(shè)計(jì)計(jì)算系統(tǒng)是為解決壓鑄模具工藝參

3、數(shù)、方案選擇等而提供的一套有效、合理、可靠的設(shè)計(jì)方案。這部分將采用VC +610編程軟件來(lái)完成, 利用該軟件設(shè)計(jì)計(jì)算壓鑄模具工藝參數(shù)、方案選擇等的計(jì)算程序, 通過(guò)輸入?yún)?shù)和選擇參數(shù)得出最后參數(shù), 并由計(jì)算程序保證參數(shù)計(jì)算的正確性, 最終將結(jié)果數(shù)據(jù)作為文件保存到數(shù)據(jù)庫(kù)里面。使用該系統(tǒng)時(shí), 用戶(hù)可以輸入設(shè)計(jì)的壓鑄件的種類(lèi), 然后系統(tǒng)將自動(dòng)進(jìn)入設(shè)計(jì), 用戶(hù)只需要輸入一些必要的參數(shù)協(xié)助系統(tǒng)完成設(shè)計(jì)。壓鑄模設(shè)計(jì)計(jì)算部分由壓鑄機(jī)選擇系統(tǒng)、澆注系統(tǒng)、推出機(jī)構(gòu)設(shè)計(jì)系統(tǒng)等幾部分組成, 其結(jié)構(gòu)流程圖見(jiàn)圖3。3. 1壓鑄機(jī)選擇1圖1所示的盒體壓鑄件, 結(jié)構(gòu)較復(fù)雜, 由4個(gè)側(cè)面與一個(gè)底面組成, 底面由直徑不均的孔和柱

4、體組成,4側(cè)是形狀不同的結(jié)構(gòu), 其中一個(gè)側(cè)面如同暖氣片的形狀, 另外兩個(gè)側(cè)面都由5個(gè)長(zhǎng)條形的凹槽構(gòu)成, 其余一面是一個(gè)空框。側(cè)面均需側(cè)向抽芯完成。盒體利用Pro/E 軟件的拉伸、倒角等命令對(duì)其進(jìn)行三維造型 。圖1盒體鑄件的三維圖2系統(tǒng)總體設(shè)計(jì)分析方盒體類(lèi)零件具有以下特點(diǎn):外部結(jié)構(gòu)都是由4個(gè)側(cè)面與一個(gè)底面組成, 側(cè)面都通過(guò)側(cè)向抽芯成型, 盒體底部用一個(gè)大鑲塊成型。找到這類(lèi)零件的相似之處, 解決這類(lèi)鑄件的壓鑄模設(shè)計(jì)問(wèn)題就容易了。本系統(tǒng)主要由3部分組成:壓鑄模設(shè)計(jì); 圖形處理; 數(shù)據(jù)庫(kù)。系統(tǒng)結(jié)構(gòu)見(jiàn)圖2。在進(jìn)行壓鑄模結(jié)構(gòu)設(shè)計(jì)之前, 必須首先選擇壓鑄機(jī)。壓鑄機(jī)的參數(shù)將影響到模具的各個(gè)方面, 比如模具最小

5、最大厚度、壓室直徑等。壓鑄模設(shè)計(jì)時(shí)需要考慮壓射比壓、鎖模力、開(kāi)模行程、合模行程和壓室直徑等方面的限制, 還要考慮模具與壓鑄機(jī)的裝配和配合問(wèn)題, 因此, 在設(shè)計(jì)壓鑄模時(shí)要對(duì)上述各方面進(jìn)行校核。這部分的人機(jī)對(duì)話(huà)要求更高, 圖形化用戶(hù)界面必須完善。鑒于這些原因, 單獨(dú)開(kāi)發(fā)了壓鑄機(jī)選擇模塊, 該模塊由多個(gè)收稿日期:2007203209hy195953163. com451 特種鑄造及有色合金2007年第27卷第6期圖6圖形處理部分結(jié)構(gòu)圖4. 1參數(shù)化部分Pro/E 軟件在提供強(qiáng)大的設(shè)計(jì)、分析、制造功能的圖3壓鑄模設(shè)計(jì)部分流程圖對(duì)話(huà)框組成, 壓鑄機(jī)選擇對(duì)話(huà)框見(jiàn)圖4。3. 2澆注系統(tǒng)設(shè)計(jì)分之一, , ,

6、排出等密切相關(guān), 、充填時(shí)間、型腔溫度等充型條件, 其設(shè)計(jì)是壓鑄模設(shè)計(jì)的重要環(huán)節(jié)6。傳統(tǒng)的壓鑄模澆注系統(tǒng)設(shè)計(jì)比較麻煩而且復(fù)雜, 設(shè)計(jì)者需要查閱大量的資料, 而且澆注系統(tǒng)的設(shè)計(jì)是一個(gè)返返復(fù)復(fù)的過(guò)程, 浪費(fèi)了設(shè)計(jì)者很多時(shí)間。本系統(tǒng)中澆注系統(tǒng)的設(shè)計(jì)采用VC +610編程實(shí)現(xiàn), 直接計(jì)算出澆注系統(tǒng)的尺寸, 其中包括對(duì)直澆道、橫澆道、內(nèi)澆道、溢流槽、排氣道的設(shè)計(jì)。橫澆道的一對(duì)話(huà)框見(jiàn)圖5 。同時(shí), 也為用戶(hù)提供了多種參數(shù)化設(shè)計(jì)開(kāi)發(fā)工具。壓鑄模的零件中既包含標(biāo)準(zhǔn)件, 。針對(duì)壓, 應(yīng)用KIT 進(jìn)行開(kāi)發(fā)。, 只是尺寸不同, 這些, 可先建立一個(gè)零件模型, 控制零件中所有尺寸的參數(shù), 通過(guò)改變各個(gè)參數(shù)的值生成所需

7、要尺寸的零件7。三維參數(shù)化的開(kāi)發(fā)方法可以利用Pro/E 軟件完成零件建模過(guò)程, 選取建模的零件尺寸參數(shù)必須保持完整齊全, 建立人機(jī)交互界面來(lái)控制尺寸參數(shù)改變, 完成零件的參數(shù)化造型。參數(shù)化造型過(guò)程見(jiàn)圖7 。圖7參數(shù)化造型過(guò)程4. 2平面圖生成部分傳統(tǒng)的壓鑄模設(shè)計(jì)完全采用人工繪圖, 由于Pro/E軟件不僅有三維建模的功能, 還有自動(dòng)生成二維圖形的功能, 而且生成的二維工程圖轉(zhuǎn)換成AutoCAD 平面圖, 再進(jìn)行修改, 這樣大大減輕了模具設(shè)計(jì)者的負(fù)擔(dān)。但針對(duì)某些模具零件的特殊性, 要生成合理的、修改少的圖形, 還需要對(duì)Pro/E 工程圖部分進(jìn)行二次開(kāi)發(fā)。Pro/E 系統(tǒng)的工程圖配置文件, 對(duì)于工程

8、圖的生成來(lái)說(shuō)是非常重要的, 它包含了諸如工程圖的文本字體類(lèi)型、字高、字寬; 尺寸箭頭的形式、長(zhǎng)度、寬度; 尺寸公差的顯示、格式等的設(shè)置8。由于Pro/E 系統(tǒng)提供的配置文件只滿(mǎn)足企業(yè)的部分要求, 所以, 有些參數(shù)需要經(jīng)過(guò)用戶(hù)另行配置才能生效。以下為配置文件示例:drawing_text_height3. 500000text_thickness 01000000text_width_factor01700000圖4 壓鑄機(jī)選擇對(duì)話(huà)框圖5橫澆道設(shè)計(jì)對(duì)話(huà)框4圖形處理壓鑄模設(shè)計(jì)系統(tǒng)的圖形處理部分將采用Pro/E 大型三維造型軟件及其二次開(kāi)發(fā)功能, 即以VC +610為編譯工具的Pro/TOOL KI

9、T 應(yīng)用程序進(jìn)行設(shè)計(jì)。首先對(duì)盒體壓鑄模的各個(gè)零件進(jìn)行三維造型, 然后進(jìn)行零件的參數(shù)化造型(即根據(jù)設(shè)計(jì)計(jì)算部分輸出參數(shù), 改變零件的大小 生成所需三維零件圖, 然后組裝裝配圖。三維零件圖與裝配圖生成后, 自動(dòng)生成二維工程圖, 最后進(jìn)入AutoCAD 中進(jìn)行修改, 結(jié)構(gòu)流程圖見(jiàn)圖6。本系統(tǒng)采用Pro/E 對(duì)其進(jìn)行二次開(kāi)發(fā)。在VC +610下編譯Pro/TOOL KIT 應(yīng)用程序, 系統(tǒng)將注冊(cè)一菜單, 下拉菜單中有工程圖生成命令。為了使系452壓力鑄特種鑄造及有色合金2007年第27卷第6期標(biāo)致汽車(chē)鋁輪缺陷防止方法陳利平(浙江新昌職業(yè)技術(shù)學(xué)校摘要對(duì)某鋁輪有限公司生產(chǎn)的標(biāo)致汽車(chē)鋁輪所產(chǎn)生的裂紋、疏松、

10、氣孔等的原因作了分析。通過(guò)改進(jìn)鑄件結(jié)構(gòu)、鑄型、合金和工藝、涂料后, 該產(chǎn)品的合格率從40%左右提高到87%90%。關(guān)鍵詞工藝結(jié)構(gòu); 熔煉; 涂料中圖分類(lèi)號(hào)T G 24912文獻(xiàn)標(biāo)志碼A 文章編號(hào)1001-2249(2007 06-0453-02整鑄鋁輪常采用重力鑄造, 其優(yōu)點(diǎn)是冷卻速度高, 晶粒細(xì)小, 鋁合金車(chē)輪力學(xué)性能高, 設(shè)備投資小, 其缺點(diǎn)是鑄件成品率不高, 產(chǎn)品質(zhì)量不夠穩(wěn)定。針對(duì)某公司生產(chǎn)的標(biāo)致汽車(chē)鋁輪的缺陷進(jìn)行分析, 對(duì)鑄件結(jié)構(gòu)、鑄型、合金和工藝、涂料等進(jìn)行改進(jìn), 產(chǎn)品的合格率大幅度提高, 取得明顯的經(jīng)濟(jì)效益。熱裂, 附近區(qū)域產(chǎn)生縮坑 。1熱裂紋1. 11. (1 鑄件結(jié)構(gòu)設(shè)計(jì)整鑄鋁

11、合金車(chē)輪要得到合格, 裂紋主要集中在輪輞和輻板的交接處, 見(jiàn)圖1中1處。從產(chǎn)生的位置來(lái)看, 輪輞和輻板交接處是一個(gè)熱點(diǎn), 使輪輞外模過(guò)熱, 而且往往由于輪輞和輻板壁厚相差太大, 使熱節(jié)點(diǎn)集中在輪輞與輻板交接處, 如果輻板比輪輞先凝固, 則輻板向中心收縮。在熱節(jié)得不到補(bǔ)縮條件下, 該處常常形成鑄件, 必須加以順序凝固控制, 即輪輞首先凝固, 輻板在壓力作用下補(bǔ)縮輪輞熱節(jié)點(diǎn), 然后輻板凝固, 輪轂部分補(bǔ)縮輻板, 輪轂最后凝固, 輪轂部分通過(guò)直澆道來(lái)補(bǔ)縮。這是整鑄輪圈鑄件結(jié)構(gòu)設(shè)計(jì)必須考慮的原則。由于輪輞壁厚設(shè)計(jì)尺寸為610mm , 單面加工余量為115mm , 而輻板厚度為510mm , 這樣輻板與

12、輪輞之收稿日期:2007204223作者簡(jiǎn)介:陳利平, 男,1964年出生, 工程師, 浙江新昌職業(yè)技術(shù)學(xué)校, 浙江新昌(312500 , 電話(huà)E -mail :zjxswp163. com統(tǒng)命令使用方便, 將所有命令集中于一個(gè)菜單, 方便用戶(hù)調(diào)用。點(diǎn)擊工程圖生成命令即生成工程圖 。由于工等命令。最后的裝配圖見(jiàn)圖8。5結(jié)語(yǔ)應(yīng)用Pro/E 軟件及其二次開(kāi)發(fā)工具對(duì)壓鑄模具進(jìn)行設(shè)計(jì), 縮短了模具設(shè)計(jì)周期, 減少人工操作時(shí)間, 同時(shí)也增加了模具的價(jià)值和市場(chǎng)競(jìng)爭(zhēng)力。通過(guò)盒體壓鑄模具設(shè)計(jì)實(shí)例, 說(shuō)明了基于Pro/E 的盒體類(lèi)壓鑄模設(shè)計(jì)的實(shí)現(xiàn)方法, 對(duì)其他盒體類(lèi)壓鑄模設(shè)計(jì)提供參考

13、。參考文獻(xiàn)1潘利波, 羅繼相, 潘欣. 基于Pro/E 二次開(kāi)發(fā)的壓鑄模CAD 研究J.金屬成形工藝,2003(1 :26230. 2孟憲嘉, 劉云生, 王承志, 等. 壓鑄模特征化實(shí)體建模技術(shù)的研究J.特種鑄造及有色合金,2004(3 :42244. 3代六玲, 孟憲嘉. 三角帶輪壓鑄模智能CAD 系統(tǒng)的研究J.特種鑄造及有色合金,2002(1 :18219.4李世國(guó). Pro/TOOL KIT 程序設(shè)計(jì)M .北京:機(jī)械工業(yè)出版社,2003. 5于彥東. 壓鑄模具設(shè)計(jì)及CADM .北京:電子工業(yè)出版社,2002. 6潘憲曾. 壓鑄模設(shè)計(jì)手冊(cè)(第3版 M .北京:機(jī)械工業(yè)出版社,2006. 7

14、何培英, 紀(jì)蓮清. PRO/E 參數(shù)化技術(shù)在沖壓模CAD 中的應(yīng)用J.2005(4 :64266. 8黃勇. 用CAXA 電子圖板和AutoCAD2000設(shè)計(jì)電刷端蓋壓鑄模(編輯:袁振國(guó) J.金屬成形工藝. 2002(9 :47252.圖8盒體壓鑄模裝配圖1. 滑塊2. 吊環(huán)螺釘3. 動(dòng)模套板4. 支撐板5. 動(dòng)模座板6. 固定板7. 推板8. 動(dòng)模鑲塊9. 型芯10. 推桿11. 復(fù)位桿12. 導(dǎo)套13. 導(dǎo)柱14. 定模鑲塊15. 澆口套16. 活塊17. 定模座板18. 定模套板程圖不僅僅包括圖形, 還包括尺寸、粗糙度、公差等, 針對(duì)上述問(wèn)題, 也開(kāi)發(fā)了工程圖圖框選擇、自動(dòng)標(biāo)注尺寸453

15、Abstract Cont rol equations of kinetics and dynamics a 2mong t he plunger , shot sleeve and liquid metal have been established to simulate t he 2D flow field of liquid metal in shot sleeve based on co nventional flow field simulation , in which t he boundary and initial condi 2tions among t he t hre

16、es are considered. The effect s of different velocities of plunger on t he ent rapped 2gas de 2fect s in liquid metal in shot sleeve have been ap 2proached , which p rovides a reference for t he selection of slow -injectio n velocity in practical die casting. K ey Words :Shot Sleeve , Flow Field , N

17、umerical Simu 2lationNumerical Simulation and Optimization of G ating Sys 2tem for Aluminum Alloy E ngine B racket Ha n J ieli , Cao Ha nxue , Lo ng Siyua n , Guo J ia n (Chongqing Engineering Research Center for Magnesium Alloys , Chongqing University , Chongqing , China 2007, 27(6 439441Abstract T

18、he filling p rocess was simulated to analyze local overheat in die resulting f rom irrational filling and cold shut occurred in far 2end in aluminum engine bracket. The result s t t are caused by irratio nal on analysis , t he have been optimized. t hat t he desir 2able filling can be in t he optimi

19、zed ingate , which plays t he uniform temperat ure dist ribution in t he die and eliminates t he cold shut in filling far 2end in t he bracket.K ey Words :Aluminum Alloy , Die C astings , Numerical Simulation , Ingate , Process OptimizationWC P article R einforced Steel/iron Matrix Wear R esist 2ant

20、 Composites Zeng Shaoli a n , Li Wei (Depart ment of Materials Science and Engineering , Jinan University , Guangzhou , China 2007,27(6 441444Abstract The p rocess used to p roduce t he WC particle reinforced steel/iron mat rix co mposites was reviewed including cast 2infilt ration met hod , powder

21、metallur 2gy , overlay welding , elect ro 2slag casting , and t he se 2lection of t ungsten carbide and t he steel/iron base , in 2terface reaction and bonding st rengt h , properties of application of t he compo sites. The effect s of parame 2ters , such as binder , additive , shape and size of WC

22、particle , po uring temperat ure , on t he composites fab 2ricated by cast 2infilt ration met hod have been paid at 2tention to. It is pointed out t hat t he cast 2infilt ration met hod is a p romising technique for fabricating t he WC particle reinforced steel/iron matrix compo sites , while t he c

23、ombination of SHS wit h cast 2infilt ration is a very potential app roach. It is a spotlight on cast 2in 2filt ration for fabricating t he composites wit h compo site layer of 10mm in t hickness and on stabilization of composites p rocess as well as t he key technology of in 2dust rialization. Surfa

24、ce wear resistant composites are more suitable for part s in t he co nditions of local wear and small angle erosion , and t he process and t he com 2posites sho uld be selected according to t he wear condi 2tions.K ey Words :Particle R einforced , Tungsten C arbide ,C ast 2nf iltration , Steel/iron

25、Matrix Composites , Wear Problems in E nvironmental Protection in Chinese Foundry Industry and Its Countermeasures Ya ng Li 2jun 1, Ti a n Shiji a ng 2,Liu Do ngmei 2(1. Shenyang Ar 2chitect ure University , Shenyang , China ; 2. Shenyang Research Instit ute of Foundry , Shenyang , China 2007,27(6 4

26、45447Abstract The ext reme ponderance for environmental p rotection and imminence of solving environmental p ro blems in t he China , especially austere environmen 2tal p roblems about foundry industries were reviewed. Aiming at t he existing problems , some countermeas 2ures were given.K ey Words :

27、Foundry Industries , E nvironmental Protec 2tion , E nvironmental PollutionPreparation of Semi 2solid Al 25Cu Alloy by U ltrasonic Stirring Li Y o ngjun , Cheng a , Hua ng X i ao mei , Zha ng ng , Mo e of Materials Science of Technology , 25Cu alloy was prepared by ul 2t The effect s of important pa

28、rameters , such as melt temperat ure , t he ult rasonic t reat ment time and outp ut power of ultrasonic stirrer , o n t he semi 2solid st ruct ure of t he alloy have been observed The result s show t hat finer primary p hase can be ob 2served wit h increasing t he melt temperat ure in t he range of

29、 610to 660. In addition , t he p rimary p hase in t he Al 25Cu alloy can be converted from coarse den 2drite into fine sp heroids wit h increasing t he outp ut power and time of ult rasonic stirrer at 660.K ey Words :Semi 2solid , U ltrasonic Stirring , Al 25Cu Al 2loy , MicrostructureDesign of Die C asting Die for Box Part System B ased on Pro/E Hua ng Y o ng , J i Ning , Hao Y o ngping , Bu Guoli a ng (School of Materials Science and Engineer 2ing , Shenyang University of Science and Technology