上盖压铸模设计.rar

上盖压铸模设计

机械设计专业相关的毕业设计，里面有详细的图纸，ppt,说明书，外文翻译


目录
  
目  录．．....................................................................1
上盖压铸模设计说明书．．．．．．．.................................................3
DESIGN INSTRUCTION．.........................................................5
1.前 言．．...................................................................8
1.1选题依据．................................................................8
1.2国内外研究现状及发展趋势...............................................9
1.3主要研究内容及可行性分析...............................................9
2.压铸件的结构工艺分析．．...................................................10
2压铸件实物图............................................................10
2铸件的结构工艺性分析....................................................11
3.压铸机的选用．．...........................................................11
3.1确定压铸机的锁模力....................................................12
3.2压室容量的估算........................................................15
4.分型面的设计．．...........................................................16
4.1分型面的类型..........................................................17
4.2分型面的选择要点......................................................17
4.3上盖分型面的确定......................................................17
5.浇注系统和溢流、排气系统设计．．............................................18
5.1浇注系统的设计........................................................18
5.2溢流槽的设计..........................................................24
5.3排气槽的设计..........................................................26
6.成型零件的设计．..........................................................27
6.1成型零部件的设计......................................................27
6.2成型尺寸的计算........................................................27 
7.抽芯机构的设计．..........................................................33
7.1抽芯机构的组成与分类..................................................33
7.2抽芯力和抽芯机构......................................................34
7.3斜销的设计............................................................37
8.推出机构的设计．．．........................................................39
8.1推出机构的组成和分类..................................................40
8.2推出机构的设计........................................................40
8.3推杆推出机构的设计....................................................41
8.4推出机构的复位与预复位机构............................................45

9.冷却装置 .................................................................45
10压铸模的技术要求及选材．..................................................46
10.1压铸模的技术要求.....................................................46
10.2压铸模材料的选择.....................................................50
11.1金属注射量校核.......................................................50
11.2压铸机锁模力校核.....................................................50
11.3动模座板行程校核.....................................................50
结 论 .................................................................... 51
致 谢 .................................................................... 52
参考文献  ．...............................................................53

设计总说明

   本课题是由广东宏图压铸厂的实际生产课题，配件是重要的制造产业，其中压铸的铝合金配件制造是一个技术性很强的行业。本题目正是研究工程机械里面一个上盖零件的铝合金压铸模具设计。
本设计依据国家相关技术标准和广东宏图压铸厂的技术标准、规范进行相关设计。上盖零件毛坯图材料为YZAlSi9Cu4，合金代号YL112；压铸件外形尺寸：长186mm，宽105.5mm，高52mm，具体尺寸见毛坯图，压铸件未注尺寸精度等级GB/T6414—1999 7级，质量为0.32kg。
（1）铸件的结构工艺性分析  上盖压铸件材料为铝合金，最小壁厚3mm，且平均壁厚在3-5mm，压铸件尺寸精度等级为GB/T6414—1999 7级，符合压铸件的工艺要求；为便于金属液流畅，气体的排出，并避免因锐角而产生裂纹，需要采用铸造圆角R=1mm；表面粗糙度Ra3.2均在压铸工艺能力的范围内，因此上盖满足压铸工艺要求。
（2）分型面的选择 根据上盖零件的结构，综合考虑抽芯及浇注系统的设定，分型面设在上盖零件毛坯图的Ⅰ-Ⅰ面上。
（3）浇注系统的确定 由于上盖零件在两个尺寸为 5.5×3mm孔的一端需要抽芯。平均壁厚又较薄。为使合金的流程较短，防止冷隔和保证模具热平衡，浇注系统从上盖零件尺寸为32mm处两侧同时流入，浇口采用侧浇口，在合金流入处设有集渣包以及排气槽。直浇道选用Ø60H9浇口套。横浇道形式为V形，与两个内浇口相连。
（4）压铸模具的总装图设计  由于一侧有两个两个尺寸为Ø5.5×3mm孔和3mm凹下部分。故该面需要设计滑块机构侧抽芯。由于滑块较宽，故采用双斜销抽芯机构。考虑浇注系统的流向，该模具采用上抽芯，开模时由两根弹簧固定滑块。为了防止铸件错边，在动、定模的定位方式上，本模具采用导柱导套间隙配合定位。为了节省降低模具费用，该模具与金属液接触的型腔部分如动、定模镶块采用3Cr2W8V材料。模具外框部分如：动、定模套板和座板采用45钢制造。 动模镶块、定模镶块和动模套板、定模套板采用凸台定位，靠套板和座板用螺钉连接压紧后固定。在推杆设计方面，由于该零件壳薄，无法设计圆推杆，故在零件壁厚处设计了8根扁推杆，以增加顶出面积，其余处在平面上设有不同直径的圆推杆，以保证铸件顺利推出。为了使零件顶出平衡，模具在动模座板上装有推板导柱，与推板固定板的推板导套配合，保证其顶出平衡。考虑到压铸模具安装方便，模具在定模、动模均设有25mm厚，25mm宽的压板位置以便装模，另外在定模和动模上设计了吊环螺钉孔。
(5) 压铸模具的零件图  定模套板，定模座板，动模套板、动模座板用，四个均采用45钢并进行调质处理，硬度要求在28～32HRC。
定模型腔部分的设计采用了定模镶块材料为3Cr2W8V，淬火后硬度44～48HRC。动模型腔部分的设计上，采用了动模镶块与动模型芯镶配组合，解决模具加工问题又保证模具内腔尺寸精度。侧型芯抽芯滑块的设计考虑到强度采用了整体结构，材料仍用3Cr2W8V，淬火后硬度44～48HRC。
动、定模定位采用导套Ø32H8和导柱Ø32e7配合定位，导套和导柱均采用T10A材料，并进行淬火处理，处理后硬度50～55HRC。为了合模时顺畅 ，在导柱前段设计长8mm、锥度30 º的导向段，动、定模的导套和导柱安装孔进行组合加工，以确保其四个孔的一致性，为了压铸时取件，一般情况下导柱安装于定模上，导套安装于动模上。
推出机构推板，推杆固定板均采用45钢并进行调质处理，硬度要求在28～32 HRC。由于铸件壁厚小，故采用扁推杆推出，推杆用直径12mm的圆推杆加工制成，在尾部60mm尺寸段用圆形不变，这样既便于推杆本身的加工，而且也方便了推杆在动模支承板组装孔的加工。
推板导柱与推板导套均采用T10A材料，并进行淬火处理，处理后硬度50～55HRC，推板导柱与动模支承板的配合为H7/m6，推板导柱与推板导套的配合为H9/e9，由于推板导柱与推板导套在模具使用过程中只是相对滑动，不会脱出，所以在推板导柱与推板导套的配合的端部设计C2的导向即可，导向段不必过长，反之顶出部分受力条件不好，易磨损。
（6）压铸机的选用 上盖压铸件材料为铝合金，故选用常用的卧式压铸机。根据压铸件及浇注与排溢系统在分型面的投影面积（200～230cm2）计算和生产实际情况，选用J1113C型压铸机生产。该压铸机的锁模力为1250kN,充头直径为60mm时的最大静压力为44Mpa,最大金属流量8.9L/s。
本设计主要参考了《潘宪曾.压铸模设计手册（第2版）.北京：机械工业出版社，1998.10.》、《齐卫东.压铸工艺与模具设计.北京:北京理工大学出版社，2007.9.》、《 杨裕国.压铸工艺与模具设计.北京：机械工业出版社，2009.9.》等资料。
关键词：压铸模；压铸机；压铸工艺

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