本文選題：沖裁 + 間隙　； 參考：《吉林大學(xué)》2015年碩士論文

【摘要】：近年來隨著國內(nèi)外軌道車輛制造行業(yè)的飛速發(fā)展，軌道車輛的車體制造技術(shù)和產(chǎn)品質(zhì)量也越來越受到國內(nèi)外制造行業(yè)的關(guān)注。考慮到車體的質(zhì)量和制造精度等問題，我國軌道車輛的車體大多為鋁合金車體和不銹鋼車體。其中，車體中一個(gè)重要的構(gòu)件就是調(diào)整墊，車體調(diào)整墊用來調(diào)節(jié)車體中機(jī)械器件的高度、零件間的間隙及各個(gè)構(gòu)件的連接，其質(zhì)量好壞直接影響軌道車輛的后序裝配工作。車體調(diào)整墊加工屬于沖孔類的沖裁加工工藝，因此對沖裁技術(shù)的研究是至關(guān)重要的。 現(xiàn)階段，經(jīng)沖裁工藝加工完的沖裁件依舊存在較多缺陷，主要有制件表面不平整、斷面質(zhì)量差、毛刺較大等問題，這些問題不僅降低了實(shí)際生產(chǎn)的效率，同時(shí)增加了后續(xù)工序；除了需要解決斷面質(zhì)量差、毛刺較大的問題之外，還需對調(diào)整墊通用沖模進(jìn)行開發(fā)研究，過度的更換模具是一種無辜的消耗，開發(fā)調(diào)整墊通用模具即降低成本又提高生產(chǎn)效率。本文對以上現(xiàn)實(shí)中存在的兩大難題應(yīng)用DEFORM-3D軟件進(jìn)行模擬研究，具體內(nèi)容如下： （1）首先對調(diào)整墊在沖裁過程中裂紋的產(chǎn)生、擴(kuò)展及斷裂過程進(jìn)行模擬分析；其次對板厚為2mm的鋁合金5083-O和不銹鋼301L-ST的U型調(diào)整墊沖裁過程進(jìn)行數(shù)值模擬研究，分析了凸凹模間隙對沖裁斷面質(zhì)量的影響，確定合理的凸凹模間隙范圍及最優(yōu)沖裁間隙值。2mm厚鋁合金5083-O的合理凸凹模間隙（雙邊間隙）范圍是3%t~5%t（0.06mm~0.1mm），最優(yōu)沖裁間隙值為3%t（0.06mm）；2mm厚不銹鋼301L-ST的合理凸凹模間隙范圍是5%t~7%t（0.1mm~0.14mm），最優(yōu)沖裁間隙值為5%t。同時(shí)將上述兩種材料的模擬結(jié)果做對比，研究材料性能對沖裁斷面各部分比例的影響。 （2）研究凸模與壓料板間隙對沖裁斷面質(zhì)量的影響，確定最優(yōu)凸模與壓料板的間隙值使沖裁斷面質(zhì)量最優(yōu)。2mm板厚的鋁合金5083-O調(diào)整墊，，在凸、凹間隙為0.06mm（3%t）、凸模與壓料板間隙為0.05mm時(shí)得到的沖裁件斷面質(zhì)量最優(yōu)。 （3）結(jié)合數(shù)值模擬技術(shù)，探究U型調(diào)整墊通用沖模開發(fā)的可行性；研究采用一種通用沖裁模具，在相同工藝參數(shù)下實(shí)現(xiàn)對不同板厚調(diào)整墊的沖裁加工。研究結(jié)果表明0.5mm和1mm的鋁合金5083-O板料可在沖裁間隙為0.02mm的同一套模具上進(jìn)行沖裁；板厚為1.5mm、2mm、2.5mm和3mm的鋁合金5083-O板料可在沖裁間隙為0.075mm的同一套模具上進(jìn)行沖裁；板厚為4mm和5mm的鋁合金5083-O板料可在沖裁間隙為0.36mm的同一套模具上進(jìn)行沖裁。此外，板厚為0.5mm和1mm的不銹鋼301L-ST板料可在沖裁間隙為0.02mm的同一套模具上進(jìn)行沖裁；板厚為1.5mm、2mm、2.5mm和3mm的不銹鋼301L-ST板料可在沖裁間隙為0.105mm的同一套模具上進(jìn)行沖裁；板厚為4mm和5mm的不銹鋼301L-ST板料可在沖裁間隙為0.36mm的同一套模具上進(jìn)行沖裁。 在上述數(shù)值模擬研究的基礎(chǔ)上，本文開展了車體U型調(diào)整墊沖裁實(shí)驗(yàn)研究，驗(yàn)證了最優(yōu)間隙選取值的準(zhǔn)確性和通用模具開發(fā)的可行性。 本文確定的凸凹模間隙最優(yōu)值和調(diào)整墊通用模具開發(fā)技術(shù)已應(yīng)用于長春軌道客車U型調(diào)整墊的生產(chǎn)中，反饋效果良好。
[Abstract]:In recent years, with the rapid development of the manufacturing industry of rail vehicles both at home and abroad, the manufacturing technology and product quality of rail vehicles are becoming more and more concerned about the manufacturing industry at home and abroad. Considering the quality and manufacturing precision of the car body, the body of our rail vehicles is mostly aluminum alloy car body and stainless steel car body. An important component is the adjustment pad, the body adjustment pad is used to adjust the height of the mechanical device in the body, the gap between parts and the connection of each component. Its quality directly affects the post sequence assembly work of the rail vehicle. The processing of the body adjustment pad belongs to the punching processing technology of the punching type. Therefore, the research on the cutting technology is of great importance. Yes.
At the present stage, there are still many defects in blanking parts processed by blanking process, such as uneven surface of the workpiece, poor quality of cross section, large burr, and so on. These problems not only reduce the efficiency of the actual production, but also increase the follow-up process. Besides the problems that need to solve the problem of poor cross section quality and large burr, the adjustment cushion is also needed. General die for the development and research, excessive replacement of the die is an innocent consumption, the development of the adjustment pad general mold is to reduce costs and improve production efficiency. This paper in the above two major problems existing in the application of DEFORM-3D software simulation research, the specific content as follows:
(1) first, the process of crack generation, expansion and fracture in the blanking process is simulated and analyzed. Secondly, the numerical simulation study on the blanking process of aluminum alloy 5083-O and stainless steel 301L-ST of 2mm plate thickness is carried out. The influence of the gap gap on the quality of the gap is analyzed, and the reasonable clearance range of the convex and concave die is determined. The reasonable gap (bilateral gap) range of.2mm thick aluminum alloy 5083-O is 3%t~5%t (0.06mm~0.1mm) and the optimal blanking gap is 3%t (0.06mm), and the reasonable gap range of 2mm thick stainless steel 301L-ST is 5%t~7%t (0.1mm~0.14mm), and the best blanking clearance value is the analog knot of the two kinds of materials. The effect of material properties on the proportion of each part of the cutting section is studied.
(2) study the influence of the gap between the punch and the blanking plate, and determine the gap between the best punch and the press plate to make the aluminum alloy 5083-O adjusting pad with the best.2mm plate thickness for the cutting section, and the gap is 0.06mm (3%t) in the convex, concave gap and the gap between the punch and the press plate is 0.05mm.
(3) combining with the numerical simulation technology, the feasibility of the development of the general punching die for the U type adjustment pad is explored. A general blanking die is used to realize the blanking processing of different plate thickness adjusting pads under the same process parameters. The results show that the aluminum alloy 5083-O plate of 0.5mm and 1mm can be washed on the same die with the blanking gap of 0.02mm. The aluminum alloy 5083-O sheet with plate thickness of 1.5mm, 2mm, 2.5mm and 3mm can be blanked on the same set of die with the blanking gap of 0.075mm, and the aluminum alloy 5083-O plate with the thickness of 4mm and 5mm can be blanked on the same die with the blanking gap of 0.36mm. In addition, the stainless steel plate with the thickness of 0.5mm and 1mm can be blanked in the blanking gap. In the same set of die for 0.02mm, the stainless steel 301L-ST board with a thickness of 1.5mm, 2mm, 2.5mm and 3mm can be blanked on the same die with the blanking gap of 0.105mm, and the stainless steel 301L-ST board with the thickness of 4mm and 5mm can be blanked on the same set of die with the blanking gap for 0.36mm.
On the basis of the above numerical simulation research, this paper has carried out the research on the U type adjustment pad blanking experiment of the car body, which verifies the accuracy of the optimal gap selection and the feasibility of the universal die development.
The optimal value of the gap between the die and the concave die and the development technology of the adjustment pad have been applied to the production of the U type adjustment pad of Changchun railway passenger car, and the feedback effect is good.
【學(xué)位授予單位】：吉林大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2015
【分類號】：TG386.2

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