后神速解鍛模說(shuō)明書(shū)

1、沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)目錄1零件分析及工藝方案確定 ································1.1零件分析············&

2、#183;···················1.2 分析零件的材料特性 ····························

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5、;··········111111112233333344567888999910101112····························1.3 零件精度，表面粗糙度分析 ···

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10、····錘上模鍛件設(shè)計(jì) ································2.1選擇分模面···········&#

11、183;····················2.2 確定模鍛件余量及公差 ···························

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13、;···················22.2.1 確定鍛件重量及····························

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16、83;·······························2.2.2 計(jì)算形狀復(fù)雜系數(shù)················&

17、#183;···············2.2.3 確定鍛件公差和余量·······························

18、3;2.2.4 確定模鍛斜度。································2.2.5 計(jì)算鍛件基本數(shù)據(jù) ·············

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22、·······················2.32.42.52.63.13. 23.33.43.5確定鍛件模鍛斜度·····················

23、···········確定鍛件圓角半徑································確定模鍛件的技術(shù)要求····

24、····························繪制鍛件圖及計(jì)算鍛件基本數(shù)據(jù) ···················

25、83;············確定模鍛錘的噸位····································&

26、#183;·················································&

27、#183;············選擇飛邊槽································繪制計(jì)算毛坯圖···&

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31、#183;·················································&

32、#183;···························計(jì)算繁重系數(shù)，選擇制坯工步 ····················

33、;············確定坯料·····································&

34、#183;··························鍛前加熱，鍛后冷卻及熱處理要求的確定 ····················

35、············44.14.24.34.4確定加熱方式，及鍛造溫度范圍 ································確定加熱時(shí)間&#

36、183;·······························確定冷卻方式及規(guī)范·················

37、;···············確定鍛后熱處理方式及要求 ································

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41、3;錘上鍛模設(shè)計(jì) ················································

42、83;···············55.15.25.35.45.5終鍛型槽設(shè)計(jì)·······························

43、;·預(yù)鍛型槽設(shè)計(jì)································制坯型槽設(shè)計(jì)···············

44、;·················型槽布置方式及模塊結(jié)構(gòu)設(shè)計(jì) ······························

45、83;·確定模具材料及熱處理的要求 ··············································&

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48、#183;·········································參考文獻(xiàn)13I沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)1 零件分析及工藝方案確定1.1 零件分析本次設(shè)計(jì)的零件名

49、為后伸縮節(jié)，其工藝特點(diǎn)為：帶細(xì)長(zhǎng)桿的復(fù)雜叉形件，截面沿軸向的變化劇烈，叉形兩側(cè)與軸線完全對(duì)稱。為保證終鍛時(shí)充滿叉形又不產(chǎn)生折疊，預(yù)鍛時(shí)應(yīng)將坯料上端用劈料臺(tái)劈開(kāi)，且鍛件中間桿部的徑向變形小，可設(shè)計(jì)成一個(gè)長(zhǎng)軸桿件進(jìn)行鍛造，凹槽和齒輪鍛后進(jìn)行機(jī) 。1.2 分析零件的材料特性零件所用的材料為 40Cr,比熱容：461 (20)/J/(kg.k)始鍛溫度：1200 終鍛溫度：8001.3 零件精度，表面粗糙度分析因?yàn)榱慵^大，故零件基本精確到個(gè)位，其表面粗糙度為上叉部需要的表面為 Ra>1.6;桿部1.4 工藝方案的確定面粗糙度為 Ra=1.6,需要精。因設(shè)計(jì)批量為大批量；設(shè)計(jì)精度為普通級(jí)，初步確

50、定采用模鍛錘模鍛，鍛件步依次為拔長(zhǎng)，滾擠，預(yù)鍛，終鍛。工2錘上模鍛件設(shè)計(jì)2.1選擇分模面根據(jù)零件的形狀選擇分模面為零件側(cè)面的中線，且為平直的直線；表現(xiàn)在桿部即為使桿部上下對(duì)稱的軸線。2.2 確定模鍛件余量及公差2.2.1 確定鍛件重量及由零件圖估算鍛件的質(zhì)量。整個(gè)零件的質(zhì)量即為叉部質(zhì)量+中間部分質(zhì)量+桿部質(zhì)1沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)量。由 40Cr 的密度為 7.85(g/cm3 )，確定零件各部分體積即可估算其質(zhì)量。計(jì)算部叉體積?？砂巡娌靠醋鲀蓚€(gè)圓柱的體積,則V叉 = 2 ´p ´ 652 = 159198mm3 =4計(jì)算中間部分的體積，可把他看成是矩形的物體，則V法

51、= 長(zhǎng)´寬´高= 135 ´ 7計(jì)算桿部體積，桿部是由幾個(gè)直徑不同的圓柱，則V= 1 p ´ 642 ´180 + 1桿44則總體積 V=159+284+8721315cm3m = rV = 7.85 ´1315 = 10322.75估算零件質(zhì)量為 10.3 Kg.由零件質(zhì)量估算鍛件質(zhì)量為 10.3 Kg.2.2.2 計(jì)算形狀復(fù)雜系數(shù)由 S = Vd其中 Vd 為鍛件體積；Vb 為鍛件外包容體體積VbVd=1315cm3Vb = (324 + 40) ´140´ 75S = Vd =1315/3822=0.34Vb

52、零件的復(fù)雜程度為S2 級(jí)，復(fù)雜程度一般。2.2.3 確定鍛件公差和余量因?yàn)殄懠牧蠟?40Cr,即材質(zhì)系數(shù)為 M1，鍛件精度等級(jí)為普通級(jí)，鍛件形狀復(fù)雜系數(shù)為S2 級(jí)，鍛件質(zhì)量為 10.3 Kg，可查表得：鍛件長(zhǎng)度方向上的公差為+3 0-1 5鍛件寬度方向上的公差為+2 4-1 2鍛件高度方向上的公差為+1 9-0 9鍛件的單邊余量：厚度方向?yàn)?2.53.2，取為 3mm。水平方向?yàn)?2.53.2，2沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)取為 3mm。鍛件的錯(cuò)差公差以及殘留飛邊公差均為 1.4mm。2.2.4 確定模鍛斜度。由標(biāo)準(zhǔn)銑刀的決定鍛模斜度為7。，圓角半徑為R=2-3mm，未注圓角均為R=2-3mm

53、。2.2.5 計(jì)算鍛件基本數(shù)據(jù)鍛件投影面積 F=29147mm2鍛件周長(zhǎng) L 周=1093mm 鍛件長(zhǎng)度 L=366mm 鍛件體積 V=1315cm3 鍛件質(zhì)量 m=10.3kg2.3確定鍛件模鍛斜度為便于模鍛件從型槽中取出，必須將型槽壁做成一定的斜度，稱為模鍛斜度或出模角。由參考文獻(xiàn) 1 確定型槽的外斜度為 7°，內(nèi)斜度為 10°。2.4確定鍛件圓角半徑為了使金屬易于和充滿型槽，提高鍛件質(zhì)量并延長(zhǎng)鍛模，模鍛件上的所有轉(zhuǎn)接出圓弧連接。確定外圓角半徑 r 為 3mm，內(nèi)圓角半徑為 R=（23）r，所以內(nèi)圓角半徑為 2-5mm。2.5確定模鍛件的技術(shù)要求（1） ：未注明的模鍛斜

54、度為 7°；（2） ：未注明的圓角半徑為R3mm；（3）：的殘留量和殘留飛邊錯(cuò)移量為 1.4mm；（4）：鍛后熱處理的方法及硬度要求：調(diào)質(zhì)；（5）：表面方法：為便于檢查淬火裂紋，采用酸洗。2.6 繪制鍛件圖及計(jì)算鍛件基本數(shù)據(jù)冷熱鍛件圖見(jiàn)鍛件圖的畫(huà)法。利用 CAD 求出鍛件的基本數(shù)據(jù)如下：3沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)為 29147mm2;（1） 鍛件在平面上的投影面（2） 鍛件的周邊長(zhǎng)度 L周為 1093mm；（3） 鍛件的體積V 為 1315cm3；（4） 鍛件的長(zhǎng)度 L 為 366mm;3錘上模鍛工藝設(shè)計(jì)3.1確定模鍛錘的噸位利用經(jīng)驗(yàn)公式 G=（3.56.3）KF當(dāng)取 K=1，并假

55、定毛邊平均寬度 30mm,則F件 = 29147 + 1093 ´ 30 = 61937因鍛件為大批量生產(chǎn)，生產(chǎn)效率高，故取較大系數(shù) 6.3 G=6.3´ 619=3899.7 Kg確定選為 5 噸鍛錘。3.2選擇飛邊槽開(kāi)式模鍛的終鍛型槽周邊必須設(shè)計(jì)毛邊槽，其形式和對(duì)鍛件質(zhì)量影響很大。飛邊槽有幾種形式，本設(shè)計(jì)采用最廣泛的一種，其優(yōu)點(diǎn)是橋部設(shè)在上模塊，與坯料接觸時(shí)間短，吸收熱量少，因而度。，能減輕橋部磨損或避免壓塌，影響鍛件厚度的精確定飛邊槽的如下：有噸位法和計(jì)算法，本設(shè)計(jì)采用噸位法，查表，確定飛邊的h=3mm；h1=6mm；b=12mm；b1=40mm；R1=2mm；飛邊槽

56、的具體形狀如圖 3-1:4沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)圖 3-1 飛邊槽3.3繪制計(jì)算毛坯圖計(jì)算毛坯的依據(jù)是，假定軸類鍛件在模段平面應(yīng)變狀態(tài)，因而計(jì)算毛坯的長(zhǎng)度與鍛件長(zhǎng)度相等，而軸向個(gè)截面面積應(yīng)與鍛件上相應(yīng)截面面積和毛邊截面積之和相等， 即，F(xiàn) 計(jì)= Fi 鍛 + 2hFi毛F第 i 個(gè)截面的毛坯截面積(mm2)i計(jì)F鍛件上第 i 個(gè)截面面積(mm2)i鍛F鍛件上第 i 個(gè)截面出毛邊的截面積(mm2)i毛h 充滿系數(shù)，取 0.7繪出計(jì)算毛坯的截面圖和直徑圖，如下：表 3.1 連桿計(jì)算毛坯的計(jì)算數(shù)據(jù)5沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)=Fi計(jì)F´ 2d= 1.13修正 Fi計(jì)/mmF截修正i毛i

57、計(jì)計(jì)hi桿 = ka計(jì)/mmFi鍛/mm2hi計(jì) /mm2F+ F2d 計(jì)/mmk面i鍛i毛/mm2/mm號(hào)04776477668647878660467605524435044843720827515515515515515515515839839839827529152917379839371197275603951895323455932.582.282.297.1103.595.396.487.881.482.476.359.431.016.54105.82105.82109.67114.59117.39120.19121.84123.07119.62111.2799.9189.863

58、2.582.282.287.093.497.0100.3102.1100.391.573.651.131.016.6105.8105.8147.6167.9142.4145.5120.8103.8106.591.255.215.10.750.70.91.051.051.051.051.051.051.051.051.11.145598186971021081111071038858012345678910110755755123.4計(jì)算繁重系數(shù)，選擇制坯工步V =30´ 1093´ 4=131 cm3毛V =（V +V ）/ L =（1315+131）/36.6=41.98

59、cm3=4198mm2均鍛毛計(jì)d均 = 1.13 F均 = 73mma = dmax / d均=104/73=1.42b = L桿 /d 均=366/73=5.01根據(jù)公式：K = (d拐 - dmin ) / L桿 =(82-31)/366=0.14式中 a 金屬流向頭部的繁重系數(shù)；b 金屬沿軸向的繁重系數(shù)；6沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)K桿部斜率；dmax 計(jì)算毛坯的最大直徑；d min 計(jì)算毛坯的最小直徑；d拐 桿部與頭部轉(zhuǎn)接處的直徑，又稱為拐點(diǎn)處直徑 82（mm）；L桿 計(jì)算毛坯的桿部長(zhǎng)度 366（mm）；a 值越大，表明金屬流到頭部的金屬體積愈多；b 值愈大，則軸向的距離愈長(zhǎng)；K 值愈

60、大，表明桿部錐度大，小頭一端的為過(guò)剩；鍛件質(zhì)量 G 愈大，表明大，制坯更。因此繁重系數(shù)代表了制坯時(shí)需轉(zhuǎn)移的多少，金屬轉(zhuǎn)移時(shí)的難易程度，作為選擇制坯工步的依據(jù)。根據(jù)以上所算數(shù)據(jù)，查表確定制坯工長(zhǎng)，滾擠，模鍛工步為預(yù)鍛，終鍛。3.5確定坯料1. 根據(jù)公式拔長(zhǎng)加滾擠制坯時(shí)：F坯 =（0.75 - 0.9）FmaxF坯 毛坯截面積;計(jì)算毛坯頭部最大處截面積,8393mm2;FmaxF= 0.75´ F= 0.75´ 8393= 6302.4mm2坯max2.坯料長(zhǎng)度：坯料體積按下式計(jì)算：V=（V+ V + V ）(1 + d ) = (1315 + 131) ´ (1 +

61、 0.01) = 938694mm3毛坯件連其中V坯 坯料體積V毛 毛邊體積V件 鍛件體積V連 連皮體積, 為 0；d火耗；7沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)查表取d =1.0%。，在高頻加熱爐中加熱。D坯 = 1.13 F坯 = 89.7mm取標(biāo)準(zhǔn)直徑 D坯 =90mm所以坯料長(zhǎng)度 L坯 ：L鉗 =（11.5）× D坯 =120mmL= V / F , + L =350mm坯坯坯鉗F ，所選規(guī)格鋼坯的截面積；式中坯L鉗 鉗夾頭長(zhǎng)度；4鍛前加熱，鍛后冷卻及熱處理要求的確定4.1確定加熱方式，及鍛造溫度范圍在鍛造生產(chǎn)中，金屬坯料鍛前加熱的目的：提高金屬塑性，降低變形抗力，即增加金屬的可塑性，

62、從而使金屬易于成型，并使鍛件獲得良好的組織和力學(xué)性能。金屬坯料的加熱方法，按所采用的加熱源不同，可分為的形狀，材質(zhì)和體積，采用半連續(xù)爐加熱。加熱和電加熱兩大類。根據(jù)鍛件金屬的鍛造溫度范圍是指開(kāi)始鍛造溫度（始鍛溫度）和金屬鍛造溫度（終鍛溫度） 之間的一段溫度區(qū)間。確定鍛造溫度的原則是，應(yīng)能保證金屬在鍛造溫度范圍內(nèi)具有較高的塑性和較小的變形抗力。并能使制出的鍛件獲得所希望的組織和性能。查有關(guān)資料確定鍛件的始段鍛溫度為 1200，終鍛溫度為 800。4.2確定加熱時(shí)間加熱時(shí)間是坯料后從開(kāi)始加熱到出爐所需的時(shí)間，包括加熱個(gè)階段的升溫時(shí)間和保溫時(shí)間。在半連續(xù)爐中加熱，加熱時(shí)間可按下式計(jì)算：t = aD =0.13×9=1.17(h)D坯料直徑或厚度，9.0cm；式中a 鋼化學(xué)成分?jǐn)?shù)，取 0.13（h/cm）;8沈陽(yáng)理工大學(xué)課程設(shè)計(jì)說(shuō)明書(shū)4.3確定冷卻方式及規(guī)范按照冷卻速度的不同，鍛件的冷卻方法有 3 種：在空氣中冷卻，冷卻速度快；在灰沙中冷卻，冷