注塑模具设计与制造综合训练报告书设计.doc

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1、 设计题目： 注塑模具设计与制造 一、训练目的机械产品设计制造综合训练是专业教学计划中规定的重要实践教学环节，通过完成指定产品或机械装置的设计制造过程，巩固和深化学生综合运用所学机械设计、制造工艺及CAD/CAM技术等方面的基础理论、基本知识和基本技能，较全面地获得机械产品的生产实际知识和综合应用能力，以培养具备现代机械设计制造技术基础知识与应用能力，具有较强的工程实践能力和创新能力的应用型工程师。二、训练任务在四周时间内完成注塑模具的设计、零件加工及装配。2.1 指定注塑模具的设计1）产品功能分析及结构设计2）零件设计2.2 零件制造工艺设计1）机械加工工艺过程卡2）机械加工工序卡3）复杂零

2、件数控编程2.3 加工制造2.4 检验分析2.5 产品装配 2.6 综合训练说明书三、训练要求1）进行产品的结构设计，运用CAD技术完成零件三维建模和产品装配建模。2）绘制指定零件的工程图，按国标正确标注尺寸、形位公差及技术要求。3）对零件进行正确的工艺分析，按指定的格式填写加工工艺文件。分析产品零件图样，确定毛坯，拟订工艺路线，选择设备及工艺装备。根据机械加工工艺卡片，确定各工序的加工余量，计算工序尺寸及公差，详细地说明整个零件各个工序的要求。4）进行复杂零件的刀具路径与指定数控系统的数控程序生成。编制零件的加工工序卡，填写加工程序单，填写刀具调整单。5）完成零件加工制造。按照制定工艺文件，

3、在老师指导下，遵守机床设备操作规程，独立调整、操作相应机床，进行零件加工。6）零件加工质量检测。正确地选用检验方法及计量器具，对零件进行质量检测和分析。7）产品装配。根据结构设计要求，正确装配。8）撰写综合训练说明书（上交电子稿和打印稿）。说明书应涵盖整个训练内容，字数不少于3.5千字。9）加工制造过程必须做好安全防范工作。四、成绩评定成绩评定是对学生在实训过程的能力、态度表现情况综合给出成绩，具体考核包括以下内容：1）机械设计能力。包括结构设计正确、合理性，工程图质量，工艺参数选定等。（20分）2）CAD技术应用能力。利用CAD/CAM 软件系统完成设计、编程情况，包括零部件的设计和造型、自

4、动编程的刀位文件和 NC 程序。（15分）3）实际加工操作水平，所完成的零件质量以及装配质量。（40分）4）综合训练报告。（15分）5）平时成绩。（10分）目 录课程设计任务书10前言41. 注塑模具的设计42. 推板的工艺设计52.1 推板的加工工艺分析62.1.1 毛坯的选择62.1.2工艺分析62.1.3机床的选择62.2 确定推板加工工艺路线72.2.1 零件加工工工艺卡72.2.2零件加工工序卡92.2.3 加工程序单103.加工过程综述3631机床坐标系、工件坐标系的建立364 加工零件检测与分析 375样机的装配及调整38心得体会38参考文献39注塑模具设计与制造说明书0前言机械

5、设计制造综合训练是在我们完成的专业基础课和专业课之后，所进行的一种综合性的实践环节，目的是为了加强我们创新能力、工程能力和综合应用能力的培养。通过强化实践锻炼，让我们成为能够满足企业要求的应用型人才。通过训练加深对模具设计的学习。1 注塑模具的设计图1-1在UG软件中画出根据图1-1中的制件的三维图，利用注塑模向导设计一套注塑模具，设计步骤如下：设置工件选择分型线、分型面设置型芯、型腔选定模架、标准件、推杆、复位杆设置浇口、流道 ，最终设计出如图1-2注塑模具总装配图：1- 定模圈 2-交流衬套 3-定模座板 4-定模板 5-型芯 6-垫板 7-推出固定板8-动模座板 9-定模板 10-复位杆

6、 11-推杆 12-推板 13-坚固螺钉图1-22推板的工艺设计 推板的三维视图如图2-1：图2-12.1推板的加工工艺分析绘制好零件图后，对零件进行工艺分析，结果如下:2.1.1 毛坯的选择 由于对推板的综合性能要求不高，毛坯选用铝板，毛坯的总长为170mm，宽为125mm，高为20mm。2.1.2工艺分析 1）调质处理提高推板的综合性能，使其不容易变形，使硬度为HRC26-30。 1)上表面及侧面 考虑到上表面及侧面不参与配合，故粗糙度要求不高，只作粗加工即可。 2) 光孔 该孔与螺栓连接，要求粗糙度为3.2 3) 螺纹底孔该段无配合要求，表面粗糙度要求为3.2，采用粗-半精车即可。4)攻

7、螺纹 攻M4,螺距0.7的螺纹。4）下表面 该表面有配合要求，三次铣销：粗铣，半粗铣，粗糙度3.2。 2.1.3机床的选择 参考各机床参数以及结合实验楼设备的实际情况，机床型号选择如下: 铣床 XK7142.2 确定推板加工工艺路线 参照前述加工工艺分析，现将齿轮轴的加工工艺路线列述如下:下料-归方热处理-铣上表面-铣侧面-钻大、小孔-钻螺纹底孔攻螺纹铣下表面2.2.1零件加工工艺卡38表1.1 推板机械加工工艺过程卡湖南工程学院机械加工工艺过程卡产品名称注射模具零件名称推板共（1）页第（1 ）页材料牌号45毛坯种类45钢毛坯外型尺寸170*125*20每毛坯可制件数1每台件数1备注工序号工序

8、名称工序内容设备夹具刀具量具工时准备单件01下料氧割使工件尺寸170*125*20 锯床虎钳锯刀02归方保证工件尺寸170*118*20XK714虎钳50mm面铣刀游标卡尺03调质保证材料硬度HRC26-3004粗铣平面粗铣上表面，加工2mmXK714虎钳50mm面铣刀游标卡尺05挖槽修外形，保证工件长156mm,宽90mm，铣槽深10mmXK714虎钳10mm平底刀游标卡尺06钻小孔钻通孔，保证孔径9mm XK714虎钳9mm钻头游标卡尺07铣大孔孔径15mm,，孔深4mmXK714虎钳10mm平底刀游标卡尺08钻底孔孔径3.3mm，孔深7.2mmXK714虎钳3.3mm钻头游标卡尺09翻边

9、10粗铣平面粗铣下表面，加工7.3mm，切削余量为0.7mmXK714虎钳50mm面铣刀游标卡尺11精铣平面精铣下表面，精加工0.7mm，保证工件高度12mmXK714虎钳50mm面铣刀游标卡尺12攻螺纹攻M4的螺纹，深度6mmM4螺纹丝锥标记处数更改文件号签字日期标记处数更改文件号签字日期设计审核标准化会签日期2.2.2 零件加工工序卡选用通用虎钳，夹紧工件。采用试切法对刀，找正工件X、Y、Z轴零点。 推板加工工序卡湖南工程学院机械加工工序卡片产品名称零件名称零件图号注塑模具推板材料材料名称毛坯种类毛坯尺寸零件重每台件数卡片编号第 1页45钢170*125*201共 1页加工工序图工序号工序

10、名设 备XK714夹具工量具刃具工步工步内容及要求机床转速(r/min)进给率轴向进给量(mm/r)径向进给量(mm)走刀次数1粗铣上表面，高度余量5mm8008000.4222铣外形，保证长度157mm，宽90mm10006000.41.573钻孔9mm的孔，通孔8003000.42.314铣15mm台阶孔，深度余量8mm12006000.41.555钻3.3mm的螺纹底孔，保证深度7.2mm8003000.2216翻边7粗铣表面，保证高度12mm8008001.54工艺编制陈秀峰学号080530审 定会 签工时定额校 核执行时间批 准2.23 加工程序单 推板加工程序单O0030N100

11、G0 G17 G40 G49 G80 G90 铣外轮廓 N102 G91G28 Z0.N104 S1000 M3N106 G0 G90 G54 X89.893 Y59.251N108 Z50.N110 Z10.5N112 G1 Z-1. F400.N114 Y-55.749 F600.N116 X-90.107N118 Y59.251N120 X89.893N122 X85.893 Y54.751N124 X85.79 Y47.251N126 X83.211 Y50.751N128 X79.174 Y53.251N130 X77.433 Y53.751N132 X-77.433N134 X-8

12、1.995 Y51.751N136 X-85.243 Y48.251N138 X-86.107 Y46.751N140 Y54.751N142 X85.893N194 G1 Z-2.5 F400.N196 Y-55.749 F600.N198 X-90.107N200 Y59.251N202 X89.893N204 X85.893 Y54.751N206 X85.79 Y47.251N208 X83.211 Y50.751N210 X79.174 Y53.251N212 X77.433 Y53.751N214 X-77.433N216 X-81.995 Y51.751N218 X-85.243

13、 Y48.251N220 X-86.107 Y46.751N222 Y54.751N224 X85.893N226 Y-47.249N228 Y-51.749N230 X81.996N232 X85.244 Y-48.249N234 X85.893 Y-47.249N236 X80.918 Y-47.383N238 G2 X75. Y-50. R8.N240 G1 X-16.731N242 X-81.996 Y-51.749N244 X-86.107N246 X-86.02 Y-46.749N248 X-83.715 Y-50.249N250 X-81.996 Y-51.749N252 X-7

14、5. Y-50.N254 G2 X-83. Y-42. R8.N256 G1 Y42.N258 G2 X-75. Y50. R8.N260 G1 X75.N262 G2 X83. Y42. R8.N264 G1 Y-42.N266 G2 X75. Y-50. R8.N268 G1 X-75.N270 G0 Z50.N272 X89.893 Y59.251N274 Z7.5N276 G1 Z-4. F400.N278 Y-55.749 F600.N280 X-90.107N282 Y59.251N284 X89.893N286 X85.893 Y54.751N288 X85.79 Y47.251

15、N290 X83.211 Y50.751N292 X79.174 Y53.251N294 X77.433 Y53.751N296 X-77.433N298 X-81.995 Y51.751N300 X-85.243 Y48.251N302 X-86.107 Y46.751N304 Y54.751N306 X85.893N308 Y-47.249N310 Y-51.749N312 X81.996N314 X85.244 Y-48.249N316 X85.893 Y-47.249N318 X80.918 Y-47.383N320 G2 X75. Y-50. R8.N322 G1 X-16.731N

16、324 X-81.996 Y-51.749N326 X-86.107N328 X-86.02 Y-46.749N330 X-83.715 Y-50.249N332 X-81.996 Y-51.749N334 X-75. Y-50.N336 G2 X-83. Y-42. R8.N338 G1 Y42.N340 G2 X-75. Y50. R8.N342 G1 X75.N344 G2 X83. Y42. R8.N346 G1 Y-42.N348 G2 X75. Y-50. R8.N350 G1 X-75.N352 G0 Z50.N354 X89.893 Y59.251N356 Z6.N358 G1

17、 Z-5.5 F400.N360 Y-55.749 F600.N362 X-90.107N364 Y59.251N366 X89.893N368 X85.893 Y54.751N370 X85.79 Y47.251N372 X83.211 Y50.751N374 X79.174 Y53.251N376 X77.433 Y53.751N378 X-77.433N380 X-81.995 Y51.751N382 X-85.243 Y48.251N384 X-86.107 Y46.751N386 Y54.751N388 X85.893N390 Y-47.249N392 Y-51.749N394 X8

18、1.996N396 X85.244 Y-48.249N398 X85.893 Y-47.249N400 X80.918 Y-47.383N402 G2 X75. Y-50. R8.N404 G1 X-16.731N406 X-81.996 Y-51.749N408 X-86.107N410 X-86.02 Y-46.749N412 X-83.715 Y-50.249N414 X-81.996 Y-51.749N416 X-75. Y-50.N418 G2 X-83. Y-42. R8.N420 G1 Y42.N422 G2 X-75. Y50. R8.N424 G1 X75.N426 G2 X

19、83. Y42. R8.N428 G1 Y-42.N430 G2 X75. Y-50. R8.N432 G1 X-75.N434 G0 Z50.N436 X89.893 Y59.251N438 Z4.5N440 G1 Z-7. F400.N442 Y-55.749 F600.N444 X-90.107N446 Y59.251N448 X89.893N450 X85.893 Y54.751N452 X85.79 Y47.251N454 X83.211 Y50.751N456 X79.174 Y53.251N458 X77.433 Y53.751N460 X-77.433N462 X-81.995

20、 Y51.751N464 X-85.243 Y48.251N466 X-86.107 Y46.751N468 Y54.751N470 X85.893N472 Y-47.249N474 Y-51.749N476 X81.996N478 X85.244 Y-48.249N480 X85.893 Y-47.249N482 X80.918 Y-47.383N484 G2 X75. Y-50. R8.N486 G1 X-16.731N488 X-81.996 Y-51.749N490 X-86.107N492 X-86.02 Y-46.749N494 X-83.715 Y-50.249N496 X-81

21、.996 Y-51.749N498 X-75. Y-50.N500 G2 X-83. Y-42. R8.N502 G1 Y42.N504 G2 X-75. Y50. R8.N506 G1 X75.N508 G2 X83. Y42. R8.N510 G1 Y-42.N512 G2 X75. Y-50. R8.N514 G1 X-75.N516 G0 Z50.N518 X89.893 Y59.251N520 Z3.N522 G1 Z-8.5 F400.N524 Y-55.749 F600.N526 X-90.107N528 Y59.251N530 X89.893N532 X85.893 Y54.7

22、51N534 X85.79 Y47.251N536 X83.211 Y50.751N538 X79.174 Y53.251N540 X77.433 Y53.751N542 X-77.433N544 X-81.995 Y51.751N546 X-85.243 Y48.251N548 X-86.107 Y46.751N550 Y54.751N552 X85.893N554 Y-47.249N556 Y-51.749N558 X81.996N560 X85.244 Y-48.249N562 X85.893 Y-47.249N564 X80.918 Y-47.383N566 G2 X75. Y-50.

23、 R8.N568 G1 X-16.731N570 X-81.996 Y-51.749N572 X-86.107N574 X-86.02 Y-46.749N576 X-83.715 Y-50.249N578 X-81.996 Y-51.749N580 X-75. Y-50.N582 G2 X-83. Y-42. R8.N584 G1 Y42.N586 G2 X-75. Y50. R8.N588 G1 X75.N590 G2 X83. Y42. R8.N592 G1 Y-42.N594 G2 X75. Y-50. R8.N596 G1 X-75.N598 G0 Z50.N600 X89.893 Y

24、59.251N602 Z1.5N604 G1 Z-10. F400.N606 Y-55.749 F600.N608 X-90.107N610 Y59.251N612 X89.893N614 X85.893 Y54.751N616 X85.79 Y47.251N618 X83.211 Y50.751N620 X79.174 Y53.251N622 X77.433 Y53.751N624 X-77.433N626 X-81.995 Y51.751N628 X-85.243 Y48.251N630 X-86.107 Y46.751N632 Y54.751N634 X85.893N636 Y-47.2

25、49N638 Y-51.749N640 X81.996N642 X85.244 Y-48.249N644 X85.893 Y-47.249N646 X80.918 Y-47.383N648 G2 X75. Y-50. R8.N650 G1 X-16.731N652 X-81.996 Y-51.749N654 X-86.107N656 X-86.02 Y-46.749N658 X-83.715 Y-50.249N660 X-81.996 Y-51.749N662 X-75. Y-50.N664 G2 X-83. Y-42. R8.N666 G1 Y42.N668 G2 X-75. Y50. R8

26、.N670 G1 X75.N672 G2 X83. Y42. R8.N674 G1 Y-42.N676 G2 X75. Y-50. R8.N678 G1 X-75.N680 G0 Z50.N682 G91 G28 Z0.N684 G0 G90 G54 X-50. Y34. 钻9mm孔N686 S800 M3N688 Z10.N690 G99 G81 Z-25. R10. F300.N692 X50.N694 Y-34.N696 X-50.N698 G80N700 G91 G28 Z0.N702 G0 G90 G54 X-52.125 Y34. 铣15mm台阶孔N704 S1200 M3N706

27、 Z50.N708 Z10.5N710 G1 Z-1. F400.N712 G3 X-47.875 R2.125 F800.N714 X-52.125 R2.125N716 G1 Z-2.5 F400.N718 G3 X-47.875 R2.125 F800.N720 X-52.125 R2.125N722 G1 Z-4. F400.N724 G3 X-47.875 R2.125 F800.N726 X-52.125 R2.125N728 G1 Z-5.5 F400.N730 G3 X-47.875 R2.125 F800.N732 X-52.125 R2.125N734 G1 Z-7. F4

28、00.N736 G3 X-47.875 R2.125 F800.N738 X-52.125 R2.125N740 G1 Z-8.5 F400.N742 G3 X-47.875 R2.125 F800.N744 X-52.125 R2.125N746 G0 Z50.N748 X47.875N750 Z10.5N752 G1 Z-1. F400.N754 G3 X52.125 R2.125 F800.N756 X47.875 R2.125N758 G1 Z-2.5 F400.N760 G3 X52.125 R2.125 F800.N762 X47.875 R2.125N764 G1 Z-4. F4

29、00.N766 G3 X52.125 R2.125 F800.N768 X47.875 R2.125N770 G1 Z-5.5 F400.N772 G3 X52.125 R2.125 F800.N774 X47.875 R2.125N776 G1 Z-7. F400.N778 G3 X52.125 R2.125 F800.N780 X47.875 R2.125N782 G1 Z-8.5 F400.N784 G3 X52.125 R2.125 F800.N786 X47.875 R2.125N788 G0 Z50.N790 Y-34.N792 Z10.5N794 G1 Z-1. F400.N79

30、6 G3 X52.125 R2.125 F800.N798 X47.875 R2.125N800 G1 Z-2.5 F400.N802 G3 X52.125 R2.125 F800.N804 X47.875 R2.125N806 G1 Z-4. F400.N808 G3 X52.125 R2.125 F800.N810 X47.875 R2.125N812 G1 Z-5.5 F400.N814 G3 X52.125 R2.125 F800.N816 X47.875 R2.125N818 G1 Z-7. F400.N820 G3 X52.125 R2.125 F800.N822 X47.875

31、R2.125N824 G1 Z-8.5 F400.N826 G3 X52.125 R2.125 F800.N828 X47.875 R2.125N830 G0 Z50.N832 X-52.125N834 Z10.5N836 G1 Z-1. F400.N838 G3 X-47.875 R2.125 F800.N840 X-52.125 R2.125N842 G1 Z-2.5 F400.N844 G3 X-47.875 R2.125 F800.N846 X-52.125 R2.125N848 G1 Z-4. F400.N850 G3 X-47.875 R2.125 F800.N852 X-52.1

32、25 R2.125N854 G1 Z-5.5 F400.N856 G3 X-47.875 R2.125 F800.N858 X-52.125 R2.125N860 G1 Z-7. F400.N862 G3 X-47.875 R2.125 F800.N864 X-52.125 R2.125N866 G1 Z-8.5 F400.N868 G3 X-47.875 R2.125 F800.N870 X-52.125 R2.125N872 G0 Z50.N874 G91 G28 Z0.N876 G0 G90 G54 X-68. Y34. 钻3.3mm螺纹底孔N878 S800 M3N880 Z10.N8

33、82 G99 G81 Z-8.2 R10. F300.N884 Y-34.N886 X68.N888 Y34.N890 G80N892 G91 G28 Z0.翻边N894 G0 G90 G54 X89.893 Y59.251 铣外轮廓N896 S1000 M3N898 Z50.N900 Z10.5N902 G1 Z-.857 F400.N904 Y-55.749 F600.N906 X-90.107N908 Y59.251N910 X89.893N912 X85.893 Y54.751N914 X85.79 Y47.251N916 X83.211 Y50.751N918 X79.174 Y53

34、.251N920 X77.433 Y53.751N922 X-77.433N924 X-81.995 Y51.751N926 X-85.243 Y48.251N928 X-86.107 Y46.751N930 Y54.751N932 X85.893N934 Y-47.249N936 Y-51.749N938 X81.996N940 X85.244 Y-48.249N942 X85.893 Y-47.249N944 X80.918 Y-47.383N946 G2 X75. Y-50. R8.N948 G1 X-16.731N950 X-81.996 Y-51.749N952 X-86.107N9

35、54 X-86.02 Y-46.749N956 X-83.715 Y-50.249N958 X-81.996 Y-51.749N960 X-75. Y-50.N962 G2 X-83. Y-42. R8.N964 G1 Y42.N966 G2 X-75. Y50. R8.N968 G1 X75.N970 G2 X83. Y42. R8.N972 G1 Y-42.N974 G2 X75. Y-50. R8.N976 G1 X-75.N978 G0 Z50.N980 X89.893 Y59.251N982 Z9.143N984 G1 Z-2.214 F400.N986 Y-55.749 F600.

36、N988 X-90.107N990 Y59.251N992 X89.893N994 X85.893 Y54.751N996 X85.79 Y47.251N998 X83.211 Y50.751N1000 X79.174 Y53.251N1002 X77.433 Y53.751N1004 X-77.433N1006 X-81.995 Y51.751N1008 X-85.243 Y48.251N1010 X-86.107 Y46.751N1012 Y54.751N1014 X85.893N1016 Y-47.249N1018 Y-51.749N1020 X81.996N1022 X85.244 Y

37、-48.249N1024 X85.893 Y-47.249N1026 X80.918 Y-47.383N1028 G2 X75. Y-50. R8.N1030 G1 X-16.731N1032 X-81.996 Y-51.749N1034 X-86.107N1036 X-86.02 Y-46.749N1038 X-83.715 Y-50.249N1040 X-81.996 Y-51.749N1042 X-75. Y-50.N1044 G2 X-83. Y-42. R8.N1046 G1 Y42.N1048 G2 X-75. Y50. R8.N1050 G1 X75.N1052 G2 X83.

38、Y42. R8.N1054 G1 Y-42.N1056 G2 X75. Y-50. R8.N1058 G1 X-75.N1060 G0 Z50.N1062 X89.893 Y59.251N1064 Z7.786N1066 G1 Z-3.571 F400.N1068 Y-55.749 F600.N1070 X-90.107N1072 Y59.251N1074 X89.893N1076 X85.893 Y54.751N1078 X85.79 Y47.251N1080 X83.211 Y50.751N1082 X79.174 Y53.251N1084 X77.433 Y53.751N1086 X-7

39、7.433N1088 X-81.995 Y51.751N1090 X-85.243 Y48.251N1092 X-86.107 Y46.751N1094 Y54.751N1096 X85.893N1098 Y-47.249N1100 Y-51.749N1102 X81.996N1104 X85.244 Y-48.249N1106 X85.893 Y-47.249N1108 X80.918 Y-47.383N1110 G2 X75. Y-50. R8.N1112 G1 X-16.731N1114 X-81.996 Y-51.749N1116 X-86.107N1118 X-86.02 Y-46.

40、749N1120 X-83.715 Y-50.249N1122 X-81.996 Y-51.749N1124 X-75. Y-50.N1126 G2 X-83. Y-42. R8.N1128 G1 Y42.N1130 G2 X-75. Y50. R8.N1132 G1 X75.N1134 G2 X83. Y42. R8.N1136 G1 Y-42.N1138 G2 X75. Y-50. R8.N1140 G1 X-75.N1142 G0 Z50.N1144 X89.893 Y59.251N1146 Z6.429N1148 G1 Z-4.929 F400.N1150 Y-55.749 F600.

41、N1152 X-90.107N1154 Y59.251N1156 X89.893N1158 X85.893 Y54.751N1160 X85.79 Y47.251N1162 X83.211 Y50.751N1164 X79.174 Y53.251N1166 X77.433 Y53.751N1168 X-77.433N1170 X-81.995 Y51.751N1172 X-85.243 Y48.251N1174 X-86.107 Y46.751N1176 Y54.751N1178 X85.893N1180 Y-47.249N1182 Y-51.749N1184 X81.996N1186 X85.244 Y-48.249N1188 X85.893 Y-47.249N1190 X80.918 Y-47.383N1192 G2 X75. Y-50. R8.N1194 G1 X-16.731N1196 X-81.996 Y-51.749N1198 X-86.107N1200 X-86.02 Y-46.749N1202