大学方案外文翻译冲压模具方案成型方面Word格式文档下载.docx
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大学方案外文翻译冲压模具方案成型方面Word格式文档下载.docx
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Duringthedesignphase,thenecessarymanufacturingmethodsaswellasthesequenceandnumberofproductionstepsareestablishedinaprocessingplan(Fig.4.1.1>
.Inthisplan,theavailabilityofmachines,theplannedproductionvolumesofthepartandotherboundaryconditionsaretakenintoaccount.
Theaimistominimizethenumberofdiestobeusedwhilekeepingupahighlevelofoperationalreliability.ThepartsaregreatlysimplifiedrightfromtheirdesignstagebyclosecollaborationbetweenthePartDesignandProductionDepartmentsinordertoenableseveralformingandrelatedblankingprocessestobecarriedoutinoneformingstation.
Obviously,themoreoperationswhichareintegratedintoasingledie,themorecomplexthestructureofthediebecomes.Theconsequencesarehighercosts,adecreaseinoutputandalowerreliability.
Fig.4.1.1Productionstepsforthemanufactureofanoilsump
Typesofdies
Thetypeofdieandthecloselyrelatedtransportationofthepartbetweendiesisdeterminedinaccordancewiththeformingprocedure,thesizeofthepartinquestionandtheproductionvolumeofpartstobeproduced.
Theproductionoflargesheetmetalpartsiscarriedoutalmostexclusivelyusingsinglesetsofdies.Typicalpartscanbefoundinautomotivemanufacture,thedomesticapplianceindustryandradiatorproduction.Suitabletransfersystems,forexamplevacuumsuctionsystems,allowtheinstallationofdouble-actiondiesinasufficientlylargemountingarea.Inthisway,forexample,therightandleftdoorsofacarcanbeformedjointlyinoneworkingstroke(cf.Fig.4.4.34>
Largesizesinglediesareinstalledinlargepresses.Thetransportationofthepartsfromoneformingstationtoanotheriscarriedoutmechanically.Inapresslinewithsinglepressesinstalledonebehindtheother,feedersorrobotscanbeused(cf.Fig.4.4.20to4.4.22>
whilstinlarge-paneltransferpresses,systemsequippedwithgripperrails(cf.Fig.4.4.29>
orcrossbarsuctionsystems(cf.Fig.4.4.34>
areusedtotransfertheparts.
Transferdiesareusedfortheproductionofhighvolumesofsmallerandmediumsizeparts(Fig.4.1.2>
.Theyconsistofseveralsingledies,whicharemountedonacommonbaseplate.Thesheetmetalisfedthroughmostlyinblankformandalsotransportedindividuallyfromdietodie.Ifthisparttransportationisautomated,thepressiscalledatransferpress.Thelargesttransferdiesareusedtogetherwithsinglediesinlarge-paneltransferpresses(cf.Fig.4.4.32>
Inprogressivedies,alsoknownasprogressiveblankingdies,sheetmetalpartsareblankedinseveralstages。
generallyspeakingnoactualformingoperationtakesplace.Thesheetmetalisfedfromacoilorintheformofmetalstrips.Usinganappropriatearrangementoftheblankswithintheavailablewidthofthesheetmetal,anoptimalmaterialusageisensured(cf.Fig.4.5.2to4.5.5>
.Theworkpieceremainsfixedtothestripskeletonupuntilthela
Fig.4.1.2Transferdiesetfortheproductionofanautomatictransmissionforanautomotiveapplication
-stoperation.Thepartsaretransferredwhentheentirestripisshiftedfurtherintheworkflowdirectionaftertheblankingoperation.Thelengthoftheshiftisequaltothecenterlinespacingofthediesanditisalsocalledthestepwidth.Sideshears,veryprecisefeedingdevicesorpilotpinsensurefeed-relatedpartaccuracy.Inthefinalproductionoperation,thefinishedpart,i.e.thelastpartinthesequence,isdisconnectedfromtheskeleton.Afieldofapplicationforprogressiveblankingtoolsis,forexample,intheproductionofmetalrotorsorstatorblanksforelectricmotors(cf.Fig.4.6.11and4.6.20>
Inprogressivecompounddiessmallerformedpartsareproducedinseveralsequentialoperations.Incontrasttoprogressivedies,notonlyblankingbutalsoformingoperationsareperformed.However,theworkpiecealsoremainsintheskeletonuptothelastoperation(Fig.4.1.3andcf.Fig.4.7.2>
.Duetotheheightoftheparts,themetalstripmustberaisedup,generallyusingliftingedgesorsimilarliftingdevicesinordertoallowthestripmetaltobetransportedmechanically.Pressedmetalpartswhichcannotbeproducedwithinametalstripbecauseoftheirgeometricaldimensionsarealternativelyproducedontransfersets.
Fig.4.1.3Reinforcingpartofacarproducedinastripbyacompounddieset
Nexttothediesalreadymentioned,aseriesofspecialdiesareavailableforspecialindividualapplications.Thesediesare,asarule,usedseparately.Specialoperationsmakeitpossible,however,forspecialdiestobeintegratedintoanoperationalSequence.Thus,forexample,inflangingdiesseveralmetalpartscanbejoinedtogetherpositivelythroughthebendingofcertainmetalsections(Fig.4.1.4andcf.Fig.2.1.34>
.Duringthisoperationreinforcingparts,glueorothercomponentscanbeintroduced.
Otherspecialdieslocatespecialconnectingelementsdirectlyintothepress.Sortingandpositioningelements,forexample,bringstampingnutssynchronisedwiththepresscyclesintothecorrectpositionsothatthepunchheadscanjointhemwiththesheetmetalpart(Fig.4.1.5>
.Ifthereissufficientspaceavailable,formingandblankingoperationscanbecarriedoutonthesamedie.
Furtherexamplesincludebending,collar-forming,stamping,fineblanking,wobbleblankingandweldingoperations(cf.Fig.4.7.14and4.7.15>
Fig.4.1.4Ahemmingdie
Fig.4.1.5Apressedpartwithanintegratedpunchednut
4.1.2Diedevelopment
Traditionallythebusinessofdieengineeringhasbeeninfluencedbytheautomotiveindustry.Thefollowingobservationsaboutthediedevelopmentaremostlyrelatedtobodypaneldieconstruction.Essentialstatementsare,however,madeinafundamentalcontext,sothattheyareapplicabletoallareasinvolvedwiththeproductionofsheet-metalformingandblankingdies.
Timingcycleforamassproducedcarbodypanel
Untiltheendofthe1980ssomecarmodelswerestillbeingproducedforsixtoeightyearsmoreorlessunchangedorinslightlymodifiedform.Today,however,productiontimecyclesaresetforonlyfiveyearsorless(Fig.4.1.6>
.Followingthenewdifferentmodelpolicy,thedemandsondiemakershavealsochangedfundamentally.ComprehensivecontractsofmuchgreaterscopesuchasSimultaneousEngineering(SE>
contractsarebecomingincreasinglycommon.Asaresult,thediemakerisofteninvolvedattheinitialdevelopmentphaseofthemetalpartaswellasintheplanningphasefortheproductionprocess.Therefore,amuchbroaderinvolvementisestablishedwellbeforetheactualdiedevelopmentisinitiated.
Fig.4.1.6Timescheduleforamassproducedcarbodypanel
ThetimetableofanSEproject
Withinthecontextoftheproductionprocessforcarbodypanels,onlyaminimalamountoftimeisallocatedtoallowforthemanufactureofthedies.Withlargescalediesthereisarun-upperiodofabout10monthsinwhichdesignanddietry-outareincluded.IncomplexSEprojects,whichhavetobecompletedin1.5to2years,paralleltasksmustbecarriedout.Furthermore,additionalresourcesmustbeprovidedbeforeandafterdeliveryofthedies.Theseshortperiodscallforpre-ciseplanning,specificknow-how,availablecapacityandtheuseofthelatesttechnologicalandcommunicationssystems.Thetimetableshowstheindividualactivitiesduringthemanufacturingofthediesfortheproductionofthesheetmetalparts(Fig.4.1.7>
.Thetimephasesforlargescalediesaremoreorlesssimilarsothatthistimetablecanbeconsideredtobevalidingeneral.
Datarecordandpartdrawing
Thedatarecordandthepartdrawingserveasthebasisforallsubsequentprocessingsteps.Theydescribeallthedetailsofthepartstobeproduced.Theinformationgiveninthe
Fig.4.1.7TimetableforanSEproject
partdrawingincludes:
partidentification,partnumbering,sheetmetalthickness,sheetmetalquality,tolerancesofthefinishedpartetc.(cf.Fig.4.7.17>
Toavoidtheproductionofphysicalmodels(masterpatterns>
theCADdatashoulddescribethegeometryofthepartcompletelybymeansofline,surfaceorvolumemodels.Asageneralrule,highqualitysurfacedatawithacompletelyfilletedandclosedsurfacegeometrymustbemadeavailabletoalltheparticipantsinaprojectasearlyaspossible.
Processplananddrawdevelopment
Theprocessplan,whichmeanstheoperationalsequencetobefollowedintheproductionofthesheetmetalcomponent,isdevelopedfromthedatarecordofthefinishedpart(cf.Fig.4.1.1>
.Alreadyatthispointintime,variousboundaryconditionsmustbetakenintoaccount:
thesheetmetalmaterial,thepresstobeused,transferofthepartsintothepress,thetransportationofscrapmaterials,theundercutsaswellasthe
slidingpininstallationsandtheiradjustment.
Thedrawdevelopment,i.e.thecomputeraideddesignandlayoutoftheblankholderareaofthepartinthefirstformingstage–ifneedbealsothesecondstage–,requiresaprocessplannerwithconsiderableexperience(Fig.4.1.8>
.Inordertorecognizeandavoidproblemsinareaswhicharedifficulttodraw,itisnecessarytomanufactureaphysicalanalysismodelofthedrawdevelopment.Withthismodel,
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