沖壓類外文翻譯、中英文翻譯沖壓模具設(shè)計(jì)講解學(xué)習(xí)

1、附件1:外文資料翻譯譯文沖壓模具設(shè)計(jì)對于汽車行業(yè)與電子行業(yè)，各種各樣的板料零件都是有各種不同的成型工藝所 生產(chǎn)出來的，這些均可以列入一般種類“板料成形”的范疇。板料成形（也稱為沖 壓或壓力成形）經(jīng)常在廠區(qū)面積非常大的公司中進(jìn)行。如果自己沒有去這些大公司訪問，沒有站在巨大的機(jī)器旁，沒有感受到地面的 震顫，沒有看巨大型的機(jī)器人的手臂吧零件從一個(gè)機(jī)器移動(dòng)到另一個(gè)機(jī)器，那么廠 區(qū)的范圍與價(jià)值真是難以想象的。當(dāng)然，一盤錄像帶或一部電視專題片不能反映出 汽車沖壓流水線的宏大規(guī)模。站在這樣的流水線旁觀看的另一個(gè)因素是觀看大量的 汽車板類零件被進(jìn)行不同類型的板料成形加工。落料是簡單的剪切完成的，然后進(jìn) 行不同

2、類型的加工，諸如：彎曲、拉深、拉延、切斷、剪切等，每一種情況均要求 特殊的、專門的模具。描述而且還有大量后續(xù)的加工工藝，在每一種情況下，均可以通過諸如拉深、拉延 與彎曲等工藝不同的成形方法得到所希望的得到的形狀。根據(jù)板料平面的各種各樣 的受應(yīng)力狀態(tài)的小板單元體所可以考慮到的變形情形描述三種成形，原理圖 1 的是一個(gè)簡單的從圓坯料拉深成一個(gè)圓柱水杯的成形過程。沖圖1板料成形一個(gè)簡單的水杯拉深是從凸緣型坯料考慮的，即通過模具上沖頭的向下作用使材料被水平拉 深。一個(gè)凸緣板料上的單元體在半徑方向上被限定，而板厚保持幾乎不變。板料成 形的原理如圖2所示。拉延通常是用來描述在板料平面上的兩個(gè)互相垂直的方向

3、被拉長的板料的單 元體的變形原理的術(shù)語。拉延的一種特殊形式，可以在大多數(shù)成形加工中遇到，即 平面張力拉延。在這種情況下，一個(gè)板料的單元體僅在一個(gè)方向上進(jìn)行拉延，在拉 長的方向上寬度沒有發(fā)生變化，但是在厚度上有明確的變化，即變薄。圖2板料成形原理彎曲時(shí)當(dāng)板料經(jīng)過沖模，即沖頭半徑加工成形時(shí)所觀察到的變形原理，因此在 定向的方向上受到改變，這種變形式一個(gè)平面張力拉長與收縮的典型實(shí)例。在一個(gè)壓力機(jī)沖程中用于在一塊板料上沖出一個(gè)或多個(gè)孔的一個(gè)完整的沖壓 模具可以歸類即制造商標(biāo)準(zhǔn)化為一個(gè)單工序沖孔模具，如圖3所示。圖3典型的單工序沖孔模具1 下模座2、5導(dǎo)套3 凹模4 導(dǎo)桿6彈壓卸料板7 凸模8 托板9

4、凸模護(hù)套10 扇形塊11 固定板12 凸模固定板13 墊塊15 階梯螺釘16 上模座17 模柄 任何一個(gè)完整的沖壓模具都是有一副（或多副的組合）用于沖制工作的（沖壓） 零件組成，包括：所有的支撐件部分與模具的工作部分零件，即構(gòu)成一副沖模。沖 壓（術(shù)語）通常將完整壓制工具的凹模（母模）部分定義為模具。導(dǎo)桿，或?qū)е?，是安裝在下模座上的。上模座則安裝有用于導(dǎo)桿滑動(dòng)的導(dǎo)套， 分別裝有導(dǎo)套與導(dǎo)桿的上模座與下模座組合成為木架。模架有許多規(guī)格與結(jié)構(gòu)設(shè)計(jì) 用于商業(yè)銷售。安裝在上模座上的凸模固定裝置固定兩個(gè)凸模（模具中的突出部分），這兩個(gè)圓形凸模則通過插入在卸料板上的導(dǎo)套進(jìn)行導(dǎo)向。套筒，或凸模護(hù)套，是用來保護(hù)

5、沖頭，以免在沖壓過程中被卡住。在沖穿工件材料后，兩個(gè)沖頭便進(jìn)入到凹模一定 距離。凹模（母模）部分，即凹模，通常是由插入模具體內(nèi)的兩個(gè)模具導(dǎo)套組成的。因?yàn)闆_頭的直徑是被沖孔的直徑所要求的，所以有一定間隙的凹模直徑是大于沖頭 直徑的。由于工件材料坯料或工件在沖制回程時(shí)與沖頭附連在一起，所以把材料從沖頭上剝離是必需的。彈壓卸料板則保持沖頭在沖制工件回程時(shí)縮回，使工件與工件剝 離。一個(gè)沖制的工件通常是留在漏料槽內(nèi)的，漏料槽是由包含整個(gè)零件外輪廓的平板組成。模座是由銷釘支撐板以及其他的滑塊下行程時(shí)定位的擋料塊等定位的。彎曲時(shí)一種最常見的成形工序。當(dāng)我們僅將目光移至汽車或電器上的部件，或一個(gè)剪紙機(jī)或檔案柜

6、上時(shí),就會(huì)發(fā)現(xiàn)許多零件都是由彎曲成形的。彎曲不僅可以用來成形法蘭、接頭、波紋,也可以提高零件的強(qiáng)度（通過增加零件的慣性矩）彎曲容許范也疔曲角材料縮進(jìn)1圖4彎曲術(shù)語疔曲彎曲中所用的術(shù)語，如圖4所示，應(yīng)該注意的是，在彎曲中材料的外纖維是處 于拉應(yīng)力狀態(tài)，而材料的內(nèi)纖維則處于壓應(yīng)力狀態(tài)。由于泊松比原因，在外部區(qū)域 的零件（彎曲長度L ）是小于原始寬度，處于內(nèi)部區(qū)域的則比原始寬度大。這種現(xiàn) 象可在彎曲一個(gè)矩形的橡膠板擦?xí)r容易觀察到的。最小彎曲半徑對于不同的金屬是變化的。一般而言，各種退火的金屬板在沒有斷裂或變?nèi)醯那疤嵯?，可以彎曲成一個(gè)等同金屬板厚的半徑。隨著R/T比值的減少（彎曲半徑對厚度的比值變?。?/p>

7、，外纖維的拉應(yīng)力增加，材料最終斷裂（參見圖 5）。疋縱気：1 h >圖5泊松效應(yīng)不同材料的最小彎曲半徑參考表 1他通常是按照不同板厚來表示的，諸如:2T, 3T, 4T 等。表1在室溫狀態(tài)下各種材料的最小彎曲半徑材料狀態(tài)軟硬鋁合金06T釹青銅合金，釹合金04T黃銅，低鉛02T鎂5T13T鋼奧氏體不銹鋼0.5T6T低碳鋼，低合金鋼，高強(qiáng)度鉛合金0.5T4T鈦0.7T3T鈦合金2.6T4T注：T材料厚度。彎曲容許范圍，是指彎曲中的中性線（層）的長度，用來確定彎曲零件的坯料 長度。然而，中性線（層）的位置是喲彎曲角度（正如在材料力學(xué)課本中所描述） 來決定的。彎曲容許范圍（Lb）的近似的公式為：

8、Lb= aR+kT）式中：Lb彎曲容許范圍，毫米；a彎曲角度（弧度），度；T金屬板厚，毫米；R彎曲內(nèi)層半徑，毫米；k當(dāng)半徑Rv 2T時(shí)為0.33,當(dāng)半徑 R>2T時(shí)為0.50。彎曲方式通常用于沖壓模具。金屬鋼板或帶料，由V形支撐，參見圖6 （a）在楔形沖頭的沖壓力作用下進(jìn)入 V形模具內(nèi)彈簧加載壓花銷和零件之間的摩擦將 會(huì)防止或減少零件在彎曲期間的邊緣滑移。棱邊彎曲，參見圖6 （b）是懸臂橫梁式加載方式，彎曲沖頭對相對支撐的凹模 上的金屬施加彎曲力。彎曲軸線是與彎曲模具的棱邊相平行的。在沖頭接觸工件之 前，為了防止沖頭向下行程的位移，工件則被一個(gè)彈性加載墊片加緊模具體上。.rDll（a&l

9、t; +形模卩 b）滑觸式模具圖6彎曲方式彎曲力的大小是可以通過對一根矩形橫梁的簡單彎曲的工藝過程的確定來估算。在此情況下的彎曲力是材料強(qiáng)度的函數(shù)，此彎曲力的計(jì)算式為：p=klsT/w式中：P彎曲力，噸（對于米制使用單位，噸乘以8.896數(shù)值以得到千牛頓單位）；K模具開啟系數(shù)：16倍材料厚度（16T）時(shí)的開啟系數(shù)為1.20，8倍 材料厚度（8T）時(shí)的開啟系數(shù)為1.33;L零件長度，英寸；S極限張力強(qiáng)度，噸/平方英寸；WV或U形模具的寬度，英寸；T材料厚度，英寸。對于U形彎曲（槽形彎曲），彎曲力大約是V形彎曲所需要的彎曲壓力的兩倍， 棱邊彎曲則大約是V形彎曲所需要的彎曲壓力的1/2。回彈。所有金

10、屬材料均有一個(gè)固定的彈性模量，隨之而來的是塑性變形，當(dāng)施 加在材料上的彎曲力消除時(shí)就會(huì)有一些彈性恢復(fù)（見圖7）。在彎曲過程中這種恢復(fù)稱為回彈。一般而言，這樣的回彈在0.5。5°之間變化，取決于固定的彈性模量、 彎曲方式、模具間隙等。磷青銅的回彈則在10°15°之間。圖7彎曲中的回彈減少或消除在彎曲工序中回彈方法可以根據(jù)下列工藝方法進(jìn)行，如圖8所示,在彎曲模具中產(chǎn)生的零件也可以通過等同回彈角度彎曲模上挖凹?；驈椥跃彌_式 彎曲模而被過度彎曲來減少或消除回彈。p* LfiiUlllLT圖8減少或消除回彈的方法從應(yīng)用角度來說，有許多類型的壓力機(jī)，諸如：閉式雙點(diǎn)偏心軸單動(dòng)機(jī)

11、械壓力 機(jī)，沖壓成形機(jī)，液壓成形壓力機(jī)，液壓機(jī)，彎板機(jī)，三動(dòng)式壓力機(jī)，沖?；剞D(zhuǎn)壓 力機(jī)，雙點(diǎn)壓力機(jī)，雙邊齒輪驅(qū)動(dòng)壓力機(jī)，雙點(diǎn)單動(dòng)壓力機(jī)，臺(tái)式壓力機(jī)，切邊壓 力機(jī)，閉式單動(dòng)（曲柄）壓力機(jī)，肘桿式壓力機(jī)，單點(diǎn)單動(dòng)壓力機(jī)，開式雙柱可傾 壓力機(jī)，開式壓力機(jī)，四點(diǎn)式壓力機(jī)，四曲柄壓力機(jī)，飛輪式螺旋壓力機(jī)，摩擦傳 動(dòng)螺旋壓力機(jī)，閉式雙點(diǎn)單動(dòng)雙曲柄壓力機(jī)，搖臂式壓力機(jī)螺旋式壓力機(jī)和上傳動(dòng) 板料沖壓自動(dòng)壓力機(jī)等。附件2:外文原文Stampi ng Die Desig nThe wide variety of sheet metal parts for both the automobile and elect

12、ronic in dustries is produced by nu merous forming processes that fall into the gen eric category of "sheet-metal forming". Sheet-metal forming ( also called stamping or pressing )is often carried out in large facilities hundreds of yards long.It is hard to imagine the scope and cost of th

13、ese facilities without visiting an automobile factory, standing next to the gigantic machines, feeling the floor vibrate, and watch ing heavy duty robotic man ipulators move the parts from one machi ne to ano ther. Certa inly, a videotape or televisi on special cannot convey the scale of today's

14、 automobile stamp ing lin es. Ano ther factor that one sees sta nding n ext to such lines is the nu mber of differe nt sheet-formi ng operati ons that automobile pan els go through. Bla nks are created by simple shearing, but from then on a wide variety of bending, drawing, stretching, cropp ing , a

15、nd trim ming takes place, each requiri ng a special, custom-made die.Despite this wide variety of sub-processes,in each case the desired shapes are achieved by the modes of deformati on known as draw ing, stretchi ng, and bending. The three modes can be illustrated by considering the deformation of

16、small sheet elements subjected to various states of stress in the pla ne of the sheet. Figure 1 con siders a simple forming process in which a cyli ndrical cup is produced from a circular bla nk.Figure 1 Sheet forming a simple cupDraw ing is observed in the bla nk flange as it is being draw n horiz

17、on tally through the die by the dow nward action of the pun ch. A sheet eleme nt in the flange is made to elon gate in the radial directi on and con tract in the circumfere ntial direct ion, the sheet thick ness remai ning approximately con sta nt Modes of sheet formi ng are show n in Figure 2.Figur

18、e2 Modes of sheet formingStretching is the term usually used to describe the deformation in which an element of sheet material is made to elon gate in two perpe ndicular direct ions in the sheet pla ne. A special form of stretching, which is encountered in most forming operations, is plane strain st

19、retchi ng. In this case, a sheet eleme nt is made to stretch in one directi on on ly, with no cha nge in dime nsion in the direct ion no rmal to the direct ion of elon gati on but a definite change in thickness, that is, thinning.Bending is the mode of deformation observed when the sheet material is

20、 made to go over a die or punch radius, thus suffering a change in orientation. The deformation is an example of pla ne stra in elon gati on and con tract ionA complete press tool for cutting a hole or multi-holes in sheet material at one stroke of the press as classified and standardized by a large

21、 manufacturer as a single-station pierc ing die is show n in Figure3.Any complete press tool, con sisti ng of a pair( or a comb in ati on of pars ) of mat ing member for produc ing pressworked (stmped parts, in cludi ng all support ing and actuat ing eleme nts of the tool, is a die. Pressworki ng te

22、rm ino logy com mon ly defi nes the female part of any complete press tool as a die.The guide pins, or posts, are moun ted in the lower shoe. The upper shoe contains bush ings which slide on the guide pins. The assembly of the lower and upper shoes with guide pins and bushi ngs is a die set. Die set

23、s in many sizes and desig ns are commercially available. The guide pins are show n in Figure 3.Figure3 Typical sin gle-stati on die for pierci ng hole1 Lower shoe 2,5 Guide bushi ngs 3 Cavity plate 4 Guid pin 6 Sprin g-loaded stripper 7 Punch 8 Support plate 9 Punch bush ing 10 Fan-shaped block 1 Fi

24、xed plate 12 Pun ch-holder plate 13- Backi ng plate 14 Spri ng 15 Steppi ng bolts16 Upper shoe 17- Sha nkA punch holder moun ted to the upper shoe holds two round pun ches (male members of the die) which are guided by bushings inserted in the stripper. A sleeve, or quill, en closes one punch to prev

25、e nt its buckli ng un der pressure from the ram of the press. After pen etrati on of the work material, the two pun ches en ter the die bush ings for a slight dista nee.The female member, or die, con sists of two die bush ings in serted in the die block. Si nee this press tool pun ches holes to the

26、diameters required, the diameters of the die bush ings are larger tha n those of the pun ches by the amount of cleara nee.Si nee the work material stock or workpiece can cling to a punch on the upstroke, it may be n ecessary to strip the material from the pun ch. Sprin g-loaded strippers hold the wo

27、rk material aga inst the die block un til the pun ches are withdraw n from the pun ched holes. A workpiece to be pierced is commonly held and located in a nest (Figure 2-3) composed of flat plates shaped to en circle the outside part con tours. Stock is positi oned in dies by pins, blocks, or other

28、types of stops for locat ing before the dow nstroke of the ram.Bending is one of the most com mon formi ng operati ons. We merely have to look at the comp onents in an automobile or an applia nce-or at a paper clip or a file cab in et-to appreciate how many parts are shaped by bending. Bending is us

29、ed not only to form flanges, seams, and corrugations but also to impart stiffness to the part ( by increasing its mome nt of in ertia ).The terminology used in bending is shown in Figure 4. Note that, in bending, the outer fibers of the material are in tension, while the inner fibers are in compress

30、i on. Because of the Poiss on's ratio, the width of the part (be nd len gth, L) in the outer regi on is smaller, and in the inner regi on is larger tha n the orig inal width. This phe nomenon may easily be observed by bending a recta ngular rubber eraser.Mi nimum bend radii vary for differe nt m

31、etals, gen erally, differe nt ann ealed metals can be bent to a radius equal to the thickness of the metal without cracking or weakening. As R/T decreases(the ratio of the bend radius to the thickness becomes smaller), the ten sile strain at the outer fiber in creases, and the material eve ntually c

32、racks(Figure 5).BendangleBend allowance Length of bend, £Setback7Bc el ansleFigure 4 Bending term ino logya | radius,/?Rolling directionElongated inclusions(stringers)Rolling directionNo cracks(a) Parallel with bending direction (b) Vertical with bending directionFigure5 Poiss on effectThe mini

33、mum bend radius for various materials is given in Table 1 and it is usually expressed in terms of the thick ness. such as 2 T, 3 T, 4T.Table 1 Minimum bend radius for various materials at room temperatureMaterialCon diti onSoftHardAlumi num alloys06TBeryllium copper04TBrass,low-leaded02TMagn esium5T

34、13TSteelsAuste nitic sta nl ess0.5T6TLow-carbo n,lowalloy,HSLA0.5T4TTitan ium0.7T3TTitanium alloys2.6T4TNote :Tthick ness of materialBend allowa nee as show n in Figure 4 is the len gth of the n eutral axis in the bend and is used to determine the blank length for a bent part. However, the position

35、of the n eutral axis depe nds on the radius and an gle of bend (as described in texts on meeha nics of materials).An approximate formula for the bend allowanee, Lb is given byLb=a (R十 kT)Where Lbbend allowa nee, in (mm).abend an gle, (radia ns) (deg).Tsheet thick ness, in (mm).Rin side radius of ben

36、d, in (mm).k0.33 whe n R is less than 2T and 0.50 whe n JR is more than 2T.Bend methods arc com monly used in press tool. Metal sheet or strip, supported by-V bockFigure 6(a),is forced by a wedge-shaped punch into the block. This method, termed V bending, produces a bend hav ing an in cluded an gle

37、which may be acute, obtuse, or 90°.Fricti on betwee n a spri ng-loaded kn urled pin in the vee die and the part will preve nt or reduce side creep of the part duri ng its bending.Edge bending Figure 6(b) is can tilever load ing of a beam. The bending punchforces the metal against the supporting

38、 die. The bend axis is parallel to the edge of the die. The workpiece is clamped to the die block by a spri ng-loaded pad before the punch con tacts the workpiece to preve nt its moveme nt duri ng dow nward travel of the pun ch.Diei'丨11V1Punch(a) V die(b) Wiping dieFigure 6 Bending methodsBendin

39、g Force can be estimated by assu ming the process of simple bending of a rectangular beam. The bending force in that case is a function of the strength of the material. The calculation of bending force is as follows:2p=klst2/wWhere P-bending force, tons (for metric usage, multiply number of tons by

40、8.896 to obta in kil on ewt on s).Kdie ope ning factor: 1.20 for a die ope ning of 16 times metal thick ness,1.33 for an ope ning of 8 times metal thick ness.Llen gth of part, in.Sultimate ten sile stre ngth, tons per square in.Wwidth of V or U die, i n.Tmetal thick ness, in.For U bending (channel b

41、ending) pressureswill be approximately twice those required for V bending, edge bending requires about one-half those needed for V bending.Springback in that all materials have a finite modulus of elasticity, plastic deformation is followed, when bending pressure on metal is removed, by some elastic recovery