上蓋壓鑄模設計

機械設計專業(yè)相關的畢業(yè)設計，里面有詳細的圖紙，ppt,說明書，外文翻譯


目錄
  
目  錄．．....................................................................1
上蓋壓鑄模設計說明書．．．．．．．.................................................3
DESIGN INSTRUCTION．.........................................................5
1.前 言．．...................................................................8
1.1選題依據(jù)．................................................................8
1.2國內(nèi)外研究現(xiàn)狀及發(fā)展趨勢...............................................9
1.3主要研究內(nèi)容及可行性分析...............................................9
2.壓鑄件的結構工藝分析．．...................................................10
2壓鑄件實物圖............................................................10
2鑄件的結構工藝性分析....................................................11
3.壓鑄機的選用．．...........................................................11
3.1確定壓鑄機的鎖模力....................................................12
3.2壓室容量的估算........................................................15
4.分型面的設計．．...........................................................16
4.1分型面的類型..........................................................17
4.2分型面的選擇要點......................................................17
4.3上蓋分型面的確定......................................................17
5.澆注系統(tǒng)和溢流、排氣系統(tǒng)設計．．............................................18
5.1澆注系統(tǒng)的設計........................................................18
5.2溢流槽的設計..........................................................24
5.3排氣槽的設計..........................................................26
6.成型零件的設計．..........................................................27
6.1成型零部件的設計......................................................27
6.2成型尺寸的計算........................................................27 
7.抽芯機構的設計．..........................................................33
7.1抽芯機構的組成與分類..................................................33
7.2抽芯力和抽芯機構......................................................34
7.3斜銷的設計............................................................37
8.推出機構的設計．．．........................................................39
8.1推出機構的組成和分類..................................................40
8.2推出機構的設計........................................................40
8.3推桿推出機構的設計....................................................41
8.4推出機構的復位與預復位機構............................................45

9.冷卻裝置 .................................................................45
10壓鑄模的技術要求及選材．..................................................46
10.1壓鑄模的技術要求.....................................................46
10.2壓鑄模材料的選擇.....................................................50
11.1金屬注射量校核.......................................................50
11.2壓鑄機鎖模力校核.....................................................50
11.3動模座板行程校核.....................................................50
結 論 .................................................................... 51
致 謝 .................................................................... 52
參考文獻  ．...............................................................53

設計總說明

   本課題是由廣東宏圖壓鑄廠的實際生產(chǎn)課題，配件是重要的制造產(chǎn)業(yè)，其中壓鑄的鋁合金配件制造是一個技術性很強的行業(yè)。本題目正是研究工程機械里面一個上蓋零件的鋁合金壓鑄模具設計。
本設計依據(jù)國家相關技術標準和廣東宏圖壓鑄廠的技術標準、規(guī)范進行相關設計。上蓋零件毛坯圖材料為YZAlSi9Cu4，合金代號YL112；壓鑄件外形尺寸：長186mm，寬105.5mm，高52mm，具體尺寸見毛坯圖，壓鑄件未注尺寸精度等級GB/T6414—1999 7級，質(zhì)量為0.32kg。
（1）鑄件的結構工藝性分析  上蓋壓鑄件材料為鋁合金，最小壁厚3mm，且平均壁厚在3-5mm，壓鑄件尺寸精度等級為GB/T6414—1999 7級，符合壓鑄件的工藝要求；為便于金屬液流暢，氣體的排出，并避免因銳角而產(chǎn)生裂紋，需要采用鑄造圓角R=1mm；表面粗糙度Ra3.2均在壓鑄工藝能力的范圍內(nèi)，因此上蓋滿足壓鑄工藝要求。
（2）分型面的選擇 根據(jù)上蓋零件的結構，綜合考慮抽芯及澆注系統(tǒng)的設定，分型面設在上蓋零件毛坯圖的Ⅰ-Ⅰ面上。
（3）澆注系統(tǒng)的確定 由于上蓋零件在兩個尺寸為 5.5×3mm孔的一端需要抽芯。平均壁厚又較薄。為使合金的流程較短，防止冷隔和保證模具熱平衡，澆注系統(tǒng)從上蓋零件尺寸為32mm處兩側同時流入，澆口采用側澆口，在合金流入處設有集渣包以及排氣槽。直澆道選用Ø60H9澆口套。橫澆道形式為V形，與兩個內(nèi)澆口相連。
（4）壓鑄模具的總裝圖設計  由于一側有兩個兩個尺寸為Ø5.5×3mm孔和3mm凹下部分。故該面需要設計滑塊機構側抽芯。由于滑塊較寬，故采用雙斜銷抽芯機構?？紤]澆注系統(tǒng)的流向，該模具采用上抽芯，開模時由兩根彈簧固定滑塊。為了防止鑄件錯邊，在動、定模的定位方式上，本模具采用導柱導套間隙配合定位。為了節(jié)省降低模具費用，該模具與金屬液接觸的型腔部分如動、定模鑲塊采用3Cr2W8V材料。模具外框部分如：動、定模套板和座板采用45鋼制造。 動模鑲塊、定模鑲塊和動模套板、定模套板采用凸臺定位，靠套板和座板用螺釘連接壓緊后固定。在推桿設計方面，由于該零件殼薄，無法設計圓推桿，故在零件壁厚處設計了8根扁推桿，以增加頂出面積，其余處在平面上設有不同直徑的圓推桿，以保證鑄件順利推出。為了使零件頂出平衡，模具在動模座板上裝有推板導柱，與推板固定板的推板導套配合，保證其頂出平衡?？紤]到壓鑄模具安裝方便，模具在定模、動模均設有25mm厚，25mm寬的壓板位置以便裝模，另外在定模和動模上設計了吊環(huán)螺釘孔。
(5) 壓鑄模具的零件圖  定模套板，定模座板，動模套板、動模座板用，四個均采用45鋼并進行調(diào)質(zhì)處理，硬度要求在28～32HRC。
定模型腔部分的設計采用了定模鑲塊材料為3Cr2W8V，淬火后硬度44～48HRC。動模型腔部分的設計上，采用了動模鑲塊與動模型芯鑲配組合，解決模具加工問題又保證模具內(nèi)腔尺寸精度。側型芯抽芯滑塊的設計考慮到強度采用了整體結構，材料仍用3Cr2W8V，淬火后硬度44～48HRC。
動、定模定位采用導套Ø32H8和導柱Ø32e7配合定位，導套和導柱均采用T10A材料，并進行淬火處理，處理后硬度50～55HRC。為了合模時順暢 ，在導柱前段設計長8mm、錐度30 º的導向段，動、定模的導套和導柱安裝孔進行組合加工，以確保其四個孔的一致性，為了壓鑄時取件，一般情況下導柱安裝于定模上，導套安裝于動模上。
推出機構推板，推桿固定板均采用45鋼并進行調(diào)質(zhì)處理，硬度要求在28～32 HRC。由于鑄件壁厚小，故采用扁推桿推出，推桿用直徑12mm的圓推桿加工制成，在尾部60mm尺寸段用圓形不變，這樣既便于推桿本身的加工，而且也方便了推桿在動模支承板組裝孔的加工。
推板導柱與推板導套均采用T10A材料，并進行淬火處理，處理后硬度50～55HRC，推板導柱與動模支承板的配合為H7/m6，推板導柱與推板導套的配合為H9/e9，由于推板導柱與推板導套在模具使用過程中只是相對滑動，不會脫出，所以在推板導柱與推板導套的配合的端部設計C2的導向即可，導向段不必過長，反之頂出部分受力條件不好，易磨損。
（6）壓鑄機的選用 上蓋壓鑄件材料為鋁合金，故選用常用的臥式壓鑄機。根據(jù)壓鑄件及澆注與排溢系統(tǒng)在分型面的投影面積（200～230cm2）計算和生產(chǎn)實際情況，選用J1113C型壓鑄機生產(chǎn)。該壓鑄機的鎖模力為1250kN,充頭直徑為60mm時的最大靜壓力為44Mpa,最大金屬流量8.9L/s。
本設計主要參考了《潘憲曾.壓鑄模設計手冊（第2版）.北京：機械工業(yè)出版社，1998.10.》、《齊衛(wèi)東.壓鑄工藝與模具設計.北京:北京理工大學出版社，2007.9.》、《 楊裕國.壓鑄工藝與模具設計.北京：機械工業(yè)出版社，2009.9.》等資料。
關鍵詞：壓鑄模；壓鑄機；壓鑄工藝

DESIGN INSTRUCTION

The issue’s source is the actual production issues of the ambitious project die-casting plant in Guang Dong,the parts is important in the manufacture industry, and the manufacture of die casting aluminium alloy parts is a industry,which technical is high.the subject is the study of a  aluminium alloy part of the design of die-casting mould for up cover in the engineering machinery.
The design is according to the relevant technical standards of the national and the technical standards and the norms of the Guang Dong ambitious project die-casting plant to do relevant design.the blank picture of the up cover part’s material is YZAlSi9Cu4,the alloy code is YL112;the die casting overall dimension is:the length is 186mm,the wide is 105.5mm,and the high is52mm,we can see it in the specific dimension in the blank picture,and if die casting has no size accuracy class,which class is GB/T6414-1999 6,and the quality is 032kg.
(1) The structure manufacturability analysis of die casting  The up cover die casting’s material is aluminium alloy, the minimum wall thickness is 2mm,and the average wall thickness is between 3-5mm,the die casting’s size accuracy class is GB/T6414-1999 6,which is accord with the technological requirements of the die casting;in order to convenient for the metal liquid to flow and the gassy to eliminate,and to avoid acute angle to produce flaw,we need take curving of castings R=1mm;and the surface roughness is Ra3.2,which are in the scope of the ability of the die-casting processes,so the up cover is accord with the die casting technological requirements.                         
(2) The choice of parting face  According to structure of the up cover part to comprehensive consider the setting of the loose core and the running gate system,we set it on the face of theⅠ-Ⅰ of the up cover part’s blank picture.
(3) Confirm the running gate structure  As the up cover part has two hole,and the dimension is  5.5×3mm,which head face need loose core,and the average wall thickness is quite thin.in order to make the flow path to be shorter,avoid cold shut and ensure mould to be heat balance, the running gate system can flow into the cavity through the two side of the dimension which is 32mm at the same time,and the running gate could setted to be the side running gate,and could set the gather scrap material and exhausttrough in the inflow gate.in the choice of running gate knot,we can take the straight irrigate road ,which dimension is Ø60H9.and the irrigate road’s shape is “V”,which is connected with the inner running gate.
(4) Design the general assembly drawing of the die-casting mould  As to one side has two holes ，its dimension is Ø5.5×5.5mm,and the other is the sunken part ,its dimension is 3mm.so it needs design the slide block mechanism on the side to side cores.as the slide block is quite wide,we need need two taper pin core puller.considering to the flow direction if the running gate system,we use the up loose core,the two spring attachment the slide block while the mould is opened.in order to avoid the casting has misalignment,so we use guide pins and bushings with clearance fit to locate the position in the positioning way of the moveing die and the cover half .in order to save the cost of the mould,for example ,we use 3Cr2W8V in the moveing die insert and the cover half insert in the cavity tangent part of the mould with the metal liquid. In the outline border of the mould part,for example ,the moving die lag、the cover half lag and the riser plate are taken the 45 steel to manufacture.and use the boss to position in the moving die insert、cover half insert and the moving die lag、the cover lag, the lag and the base plate fixed with screws after connecting pressed.in the design of the push rod, In putter design, since the thin shell of the part, can not design a round putter, it was designed in part wall thickness at 8 flat putt, to increase the top of the area, the rest of the plane has a different diameter in round push lever to ensure the smooth introduction of casting. To make the top part out of balance, moving the mold with mold base plate push plate guide column, and the push plate push plate fixed plate with the guide sleeve to ensure that the top of the balance. Easy installation, taking into account the die casting, die in the fixed mode and dynamic model are equipped with 25mm thick, 25mm wide plate location to put on. Modelling and dynamic simulation in the design of the rings on the screw holes.
     (5) Die casting parts diagram scheduled to die Taoban, scheduled to die base plate, dynamic model Taoban, dynamic mold base boards, and four are used for quenched and tempered 45 steel, the hardness required 28 ~ 32HRC.
Cavity part of the design given by the fixed mold insert material 3Cr2W8V, after quenching hardness 44 ~ 48HRC. Cavity moving part of the design, using a dynamic model and dynamic model of the core inserts set the combinations to address the mold problem and to ensure dimensional accuracy of the mold cavity. Pulling the slider side core design of strength by taking into account the overall structure, material still used 3Cr2W8V, after quenching hardness 44 ~ 48HRC. Dynamic model
Move, scheduled to die by positioning guide sleeve and guide post Ø32e9 Ø32H9 with positioning, guide sleeve and the guide column T10A materials are used, and the quenching treatment, the treated hardness 50 ~ 55HRC. When the mold to smooth the design in the front pillar length 8mm, 30 º taper the guide section, move, scheduled to die in the guide sleeve and the guide post mounting hole combination process to ensure the consistency of the four holes, in order to die when the pickup, general guidance on the column installed in the fixed mold, guide sleeve mounted on a dynamic model.

Introduced organizations push plate, putting the fixed plate are made of 45 steel and quenching and tempering treatment, the hardness required 28 ~ 32 HRC. The casting wall thickness is small, so the use of flat putter launched, putting the round putting with a diameter of 12mm processed in the tail section of 60mm Circular same size, so both for putting their own processing, but also facilitates Putting in the moving die supporting plate assembly Hole.
Push plate and push plate guide post bushing materials are used T10A, and the quenching treatment, the treated hardness 50 ~ 55HRC, push plate guide column bearing plate and dynamic mode with the H7/m6, push plate and push plate guide pillar Sets with the H9/e9, the push plate and push plate guide pillar die sets in the course of just sliding, will not emerge, so the push plate and push plate guide pillar sets designed with the end of the C2 Orientation can be, not too long oriented segments, whereas the top part of the force out poor condition, easy to wear.
      (6) the selection of die-casting machine cover material for aluminum die casting, so use common horizontal die casting machine. According to casting and casting and scheduling system in the sub-surface excess of the projected area (200 ~ 230cm2) calculation and the actual situation of production, use J1113C die casting machine production. The die-casting machine clamping force 1250kn, when the filling head diameter of 60mm maximum static pressure 44Mpa, the maximum metal flow 8.9L / s.
       It main reference to the "Pan constitution had. Die Casting Die Design Handbook (2nd edition). Beijing: China Machine Press, 1998.10. ", "Qi Weidong. casting process and die design. Beijing: Beijing Institute of Technology Press, 2007.9 . ", " Yang Yuguo. casting process and die design. Beijing: China Machine Press, 2009.9. ", etc.in the design.
 [Keywords]  Die-casting Machine；Die Casting Mold；Die Casting Process