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畢業(yè)設(shè)計（論文）中期檢查表（指導(dǎo)教師）
指導(dǎo)教師姓名：郭中玲 填表日期： 2014年 4 月 20 日
學(xué)生學(xué)號
1000110532
學(xué)生姓名
鄭波
題目名稱
充電器外殼注射模具設(shè)計
已完成內(nèi)容
開題并做調(diào)研，進(jìn)行翻譯；
確定其方案設(shè)計；
完成結(jié)構(gòu)設(shè)計；
繪制結(jié)構(gòu)草圖；
完成相關(guān)計算；
完成英文翻譯；
繪制裝配圖；
繪制零件圖；
撰寫論文；
完成畢業(yè)設(shè)計。
檢查日期：2014-4-20
完成情況
t全部完成
□按進(jìn)度完成
□滯后進(jìn)度安排
存在困難
解決辦法
查閱相關(guān)資料，并且與指導(dǎo)老師和同學(xué)們一起討論解決方案。
預(yù)期成績
□優(yōu) 秀
t良 好
□中 等
□及 格
□不及格
建
議
教師簽名：
教務(wù)處實(shí)踐教學(xué)科制表
說明：1、本表由檢查畢業(yè)設(shè)計的指導(dǎo)教師如實(shí)填寫；2、此表要放入畢業(yè)設(shè)計（論文）檔案袋中；
3、各院(系)分類匯總后報教務(wù)處實(shí)踐教學(xué)科備案
編號：
畢業(yè)設(shè)計(論文)任務(wù)書
題 目：充電器外殼注射模具設(shè)計
學(xué) 院： 國防生學(xué)院
專 業(yè)：機(jī)械設(shè)計制造及其自動化
學(xué)生姓名： 鄭波
學(xué) 號： 1000110532
指導(dǎo)教師單位： 機(jī)電工程學(xué)院
姓 名： 郭中玲
職 稱： 高級工程師
題目類型：¨理論研究 ¨實(shí)驗(yàn)研究 t工程設(shè)計 ¨工程技術(shù)研究 ¨軟件開發(fā)
2013年12月9日
一、 畢業(yè)設(shè)計（論文）的內(nèi)容
1.塑件的分析.
2.塑件材料的選用與性能分析.
3.擬定模具的結(jié)構(gòu)形式.
4.澆注系統(tǒng)的設(shè)計.
5.分流道的設(shè)計.
6.澆口的設(shè)計.
7.冷料穴和拉料桿的設(shè)計.
8.成型零件的設(shè)計.
9.脫模推出機(jī)構(gòu)的設(shè)計.
10.側(cè)向分型與抽芯機(jī)構(gòu)設(shè)計..
11排氣系統(tǒng)的設(shè)計.
12. 溫度調(diào)節(jié)系統(tǒng)的設(shè)計.
二、畢業(yè)設(shè)計（論文）的要求與數(shù)據(jù)
要求：
1.外型尺寸及配合精度必需標(biāo)注.
2.使用環(huán)境為-10°~40°.
3.電氣性能符合GB標(biāo)準(zhǔn).
4.外觀要求美觀牢固.
5.根據(jù)實(shí)際情況確定脫模斜度.
6.ABS主要技術(shù)指標(biāo)及工藝參數(shù).
7.設(shè)計中的計算.
8.安裝尺寸的校核.
三、畢業(yè)設(shè)計（論文）應(yīng)完成的工作
1、完成二萬字左右的畢業(yè)設(shè)計說明書（論文）；在畢業(yè)設(shè)計說明書（論文）中必須包括詳細(xì)的300-500個單詞的英文摘要；
2、獨(dú)立完成與課題相關(guān)，不少于四萬字符的指定英文資料翻譯（附英文原文）；
3、用AutoCAD軟件繪制系統(tǒng)設(shè)計圖紙，模具的裝配圖，零件圖和塑件圖打印圖紙折合0號圖紙1張以上。
對于機(jī)電結(jié)合類課題，必須完成繪圖工作量折合A0圖紙1張以上，其中必須包含兩張A3以上的計算機(jī)繪圖圖紙；
四、應(yīng)收集的資料及主要參考文獻(xiàn)
[1] 李學(xué)峰.塑料模設(shè)計及制造.[M].北京：機(jī)械工業(yè)出版社,2001
[2] 翁其金.塑料模塑成型技術(shù). [M].北京：機(jī)械工業(yè)出版社,2002..
[3] 馮炳堯等.模具設(shè)計與制造簡明手冊（第二版)[M]..上海科學(xué)技術(shù)出版社,2008.
[4] 錢泉森.塑料成型工藝及模具設(shè)計. [M].濟(jì)南：山東科學(xué)技術(shù)出版社,2004
[5] 《塑料模設(shè)計手冊》編著組.塑料設(shè)計手冊.北京：機(jī)械工業(yè)出版社,2002
[6] 陳劍鶴.模具設(shè)計基礎(chǔ). [M].北京：機(jī)械工業(yè)出版社,2004
[7] 王文廣等.塑料注塑模具設(shè)計技巧與實(shí)例.[M].北京：化學(xué)工業(yè)出版社,2004
[8] 章飛.型腔模具設(shè)計與制造. [M].北京：化學(xué)工業(yè)出版社,2003
[9] 田寶善等.塑料注射模設(shè)計實(shí)例及技巧. [M].北京：化學(xué)工業(yè)出版社,2009
[10] 朱光.塑料注塑模中小型模架及其技術(shù)條件.[M].北京：清華大學(xué)出版社,2003
[11] 宋滿倉等.注塑模具設(shè)計. [M].北京：電子工業(yè)出版社,2010
[12] 許鶴峰.注塑模設(shè)計要點(diǎn)與圖例. [M].北京：化學(xué)工業(yè)出版社,2003
[13] cunha,L,et.al.,performance of chromium nitride and titanium nitride coatings during platics injection moulding. Surface and coating Technology,2002.153(2-3):p.160-165.
五、試驗(yàn)、測試、試制加工所需主要儀器設(shè)備及條件
計算機(jī)(autoCAD,及pro/E,protel軟件)。
任務(wù)下達(dá)時間：
2013年12月9日
畢業(yè)設(shè)計開始與完成時間：
2013年12月9日至 2014年05 月4日
組織實(shí)施單位：
教研室主任意見：
簽字： 2013年12月14日
院領(lǐng)導(dǎo)小組意見：
簽字： 2013年12月16日
2014年機(jī)電工程學(xué)院畢業(yè)設(shè)計(論文)進(jìn)度計劃表
學(xué)生姓名： 學(xué)號：
序號
起止日期
計劃完成內(nèi)容
實(shí)際完成內(nèi)容
檢查日期
檢查人簽名
1
2013.12.9—12.15
教師填寫，下同
教師填寫，下同
2
2013.12.16—12.22
3
2013.12.23—12.29
4
2013.12.30-2014.1.5
5
2014.1.6-2014.1.12
6
2014.1.13-2014.1.19
7
2014.2.24-2014.3.2
8
2014.3.3-2014.3.9
(本表同時作為指導(dǎo)教師對學(xué)生的16次考勤記錄)
2014年機(jī)電工程學(xué)院畢業(yè)設(shè)計進(jìn)度計劃表（續(xù)）
學(xué)生姓名： 學(xué)號：
序號
起止日期
計劃完成內(nèi)容
實(shí)際完成內(nèi)容
檢查日期
檢查人簽名
9
2014.3.10-2014.3.16
教師填寫，下同
教師填寫，下同
10
2014.3.17-2014.3.23
11
2014.3.24-2014.3.30
12
2014.3.31-2014.4.6
13
2014.4.7-2014.4.13
14
2014.4.14-2014.4.20
15
2014.4.21-2014.4.27
16
2014.4.28-2014.5.4
任務(wù)下達(dá)時間：2013年12月9日 (本表同時作為指導(dǎo)教師對學(xué)生的16次考勤記錄)
編號：
畢業(yè)設(shè)計(論文)開題報告
題 目： 充電器外殼注射模具設(shè)計
院 （系）： 國防生學(xué)院
專 業(yè)： 機(jī)械設(shè)計制造及其自動化
學(xué)生姓名： 鄭波
學(xué) 號： 1000110532
指導(dǎo)教師單位： 機(jī)電工程學(xué)院
姓 名： 郭中玲
職 稱： 講 師
題目類型：¨理論研究 ¨實(shí)驗(yàn)研究 t工程設(shè)計 ¨工程技術(shù)研究 ¨軟件開發(fā)
2013年12月23日
1．畢業(yè)設(shè)計的主要內(nèi)容、重點(diǎn)和難點(diǎn)等
畢業(yè)設(shè)計的主要內(nèi)容：
畢業(yè)設(shè)計課題為時尚藝術(shù)塑料板凳注塑模具設(shè)計。近幾年，我國塑料模具工業(yè)有了很大的發(fā)展，塑料制品在我們的日常生活中扮演著越來越重要的角色，其種類也越來越多，制造加工也越來越精致美觀。在未來的模具市場中，塑料模具發(fā)展的速度將高于其它模具，在模具行業(yè)中的比例將逐步提高。并且隨著注塑模具技術(shù)的發(fā)展，在工程機(jī)械和工業(yè)機(jī)械、電子、汽車、家電、玩具等產(chǎn)品中，60%以上的零部件，可以依靠模具成型。?
隨著國內(nèi)經(jīng)濟(jì)發(fā)展，居民生活水平的提高，塑料板凳已經(jīng)成為日常生活中常備的用品。塑料板凳也出現(xiàn)了多種樣式，其中更多的板凳以其精美的外觀，低廉的價格，以及耐用的特點(diǎn)而受到企業(yè)和廣大消費(fèi)者的歡迎。塑料板凳雖然看似簡單，但是其注塑模具的設(shè)計制造所涉及的知識面和知識點(diǎn)比較多，能比較全面的反應(yīng)一些注塑模具設(shè)計的特點(diǎn)。本課題應(yīng)用性強(qiáng)，知識面覆蓋較廣，并且來自生活，所以容易激發(fā)我學(xué)習(xí)研究的興趣，所以選擇了這個課題,其主要內(nèi)容如下：
1、參觀調(diào)研，查閱資料。到模具制造相關(guān)企業(yè)調(diào)研，了解模具設(shè)計、生產(chǎn)、制造及加工情況。結(jié)合本次畢設(shè)課題，查閱模具相關(guān)資料；
2、 撰寫開題報告；
3、通過對產(chǎn)品的性能分析，完成相關(guān)的模具結(jié)構(gòu)與零件設(shè)計；
4、設(shè)計的模具結(jié)構(gòu)要求完整、合理；
5、合理選擇尺寸、公差、表面粗糙度和制件材料，繪制的產(chǎn)品圖樣完整；
6、認(rèn)真分析制件圖，確定模具型腔、模具結(jié)構(gòu)、分型面和進(jìn)料口形式，計算含收縮率的相關(guān)尺寸和模具的強(qiáng)度和剛度；
7、 翻譯專業(yè)外語文獻(xiàn)。
8、 撰寫畢業(yè)設(shè)計（論文）說明書；
9、 繪制模具總裝圖、零件圖；
畢業(yè)設(shè)計的重點(diǎn)難點(diǎn)：
1、脫模推出機(jī)構(gòu)和側(cè)抽芯機(jī)構(gòu)的設(shè)計；
2、塑件的合理性設(shè)計及結(jié)構(gòu)工藝性分析；
3、材料選擇及相關(guān)參數(shù)的計算；
4、模具型腔數(shù)的確定，模具結(jié)構(gòu)、分型面和進(jìn)料口形式的選擇；
5、保證塑件成型時無變形，注出的制件表面光滑，無氣泡和其它缺陷，無飛邊或少飛邊。
6、繪制模具總裝圖、零件圖及尺寸標(biāo)注。
2．準(zhǔn)備情況（查閱過的文獻(xiàn)資料及調(diào)研情況、現(xiàn)有設(shè)備、實(shí)驗(yàn)條件等）
1、模具技術(shù)的現(xiàn)狀
模具是汽車、電子、電器、航空、儀表、輕工、塑料、日用品等工業(yè)部門極其重要的工藝裝備。沒有模具、就沒有高質(zhì)量的產(chǎn)品。模具不是一般的工藝裝備，而是技術(shù)密集型的產(chǎn)品，工業(yè)發(fā)達(dá)國家把模具作為機(jī)械制造方面的高科技產(chǎn)品來對待。他們認(rèn)為：“模具是發(fā)展工業(yè)的一把鑰匙；模具是一個企業(yè)的心臟；模具是富裕社會的一種動力”。?
近年來,我國塑料模具業(yè)發(fā)展相當(dāng)快，目前，塑料模具在整個模具行業(yè)中約占30%左右，而在整個塑料模具市場以注塑模具需求量最大。隨著模具制造行業(yè)的發(fā)展，許多企業(yè)開始追求提高產(chǎn)品質(zhì)量及生產(chǎn)效率,縮短設(shè)計周期及制造周期,降低生產(chǎn)成本，最大限度地提高模具制造業(yè)的應(yīng)變能力等目標(biāo)。新興的模具CAD技術(shù)很大程度上實(shí)現(xiàn)了企業(yè)的愿望。近年來，CAD技術(shù)的應(yīng)用越來越普遍和深入,?大大縮短了模具設(shè)計周期,?提高了制模質(zhì)量和復(fù)雜模具的制造能力。?
目前，?美國、日本、德國等工業(yè)發(fā)達(dá)國家模具工業(yè)的產(chǎn)值均已超過機(jī)床工業(yè)總產(chǎn)值。美國模具年產(chǎn)值已超過100億美元；日本從1957年到1984年二十七年間，?模具工業(yè)增長100倍；1987年臺灣地區(qū)模具出口達(dá)一億二千萬美元。香港的模具年產(chǎn)值為30億港幣，我國的模具年產(chǎn)值為人民幣30億元。?
從整體來看，中國塑料模具無論是在數(shù)量上，還是在質(zhì)量、技術(shù)和能力等方面都有了很多進(jìn)步，但與國民經(jīng)濟(jì)發(fā)展的需求、世界先進(jìn)水平相比，差距仍然很大。主要缺陷明顯的表現(xiàn)在精度不高，技術(shù)含量低、復(fù)雜程度低等缺點(diǎn)。嚴(yán)重的阻礙著國內(nèi)模具業(yè)的發(fā)展。一些大型、精密、復(fù)雜、長壽命的中高檔塑料模具每年仍需大量進(jìn)口。在總量供不應(yīng)求的同時，一些低檔塑料模具卻供過于求，市場競爭激烈，還有一些技術(shù)含量不太高的中檔塑料模具也有供過于求的趨勢。因此中國塑料模具行業(yè)和國外先進(jìn)水平相比，主要存在一下問題：發(fā)展不平衡，產(chǎn)品總體水平較低；工藝裝備落后，組織協(xié)調(diào)能力差；大多數(shù)企業(yè)開發(fā)能力弱，創(chuàng)新能力明顯不足；供需矛盾短期難以緩解；體制和人才問題的解決尚需時日。這些都嚴(yán)重的阻礙著國內(nèi)電子業(yè)的發(fā)展。設(shè)計出好的產(chǎn)品卻無法做出是我模具業(yè)的最大不足。因此，注重科技含量，借助了國外的先進(jìn)理論技術(shù)則尤為重要。?
大型化、高精密度、節(jié)能復(fù)合型模具將是未來注塑模具的發(fā)展方向。隨著國際化，市場競爭越來越激烈，短周期、高質(zhì)量、長壽命的高檔塑料模具也會加大研制與開發(fā)。同時，注塑模具將與并行工程、精益生產(chǎn)、敏捷制造等多種生產(chǎn)模式密切結(jié)合，最終使塑料模具行業(yè)發(fā)生重大變革。在工業(yè)高速變革的時期，更新模具技術(shù)成了關(guān)鍵的課題。
2、注塑模簡介
注塑成型又稱注塑模具，是熱塑性塑料制件的一種主要成型方法，并且能夠成功地將某些熱固性塑料注塑成型。注塑成型可成型各種形狀的塑料制品，其優(yōu)點(diǎn)包括成型周期短，能一次成型外形復(fù)雜、尺寸精密、帶有嵌件的制品，且生產(chǎn)效率高易于實(shí)現(xiàn)自動化，因而廣泛應(yīng)用在塑料制品生產(chǎn)當(dāng)中。
3、注塑成型原理及特點(diǎn)
塑料的注塑成型過程，就是借助螺桿或柱塞的推力，將已塑化的塑料熔體以一定的壓力和速度注入模具型腔內(nèi)，經(jīng)過冷卻固化定型后開模而獲得制品。因此，可以說注塑成型在塑料裝配生產(chǎn)中具有重要地位。
4、注塑成型原理
注塑成型所用的模具即為注塑模（也稱為注射模），注塑成型的原理（以螺桿式注射機(jī)為例）。首先將顆?；蚍蹱畹乃芰霞尤肓隙?，然后輸送到側(cè)裝有電加熱的料筒中塑化。螺桿在料筒前端原地轉(zhuǎn)動，使被加熱預(yù)塑的塑料在螺桿的轉(zhuǎn)動作用下通過螺旋槽輸送至料筒前端的噴嘴附近。螺桿的轉(zhuǎn)動使塑料進(jìn)一步化，料溫在剪切摩擦熱的作用下進(jìn)一步提高并得以均勻化。當(dāng)料筒前端堆積的體對螺桿產(chǎn)生一定的壓力時（稱為螺桿的背壓），螺桿將轉(zhuǎn)動后退，直至整好的行程開關(guān)接觸，從而使螺母與螺桿鎖緊。具有模具一次注射量的塑料預(yù)塑和儲過程結(jié)束。
這時，馬達(dá)帶動氣缸前進(jìn)，與液壓缸活塞相連接的螺桿以一定的速度和壓力將熔料通過料筒前端的噴嘴注入溫度較低的閉合模具型腔中。熔體通過噴嘴注入閉合模具腔后，必須經(jīng)過一定時間的保壓，熔融塑料才能冷卻固化，保持模具型腔所賦予形狀和尺寸。當(dāng)合模機(jī)構(gòu)打開時，在推出機(jī)構(gòu)的作用下，即可頂出注塑成型的塑料制品。
5、充電器外殼注塑模具設(shè)計注塑模具設(shè)計的流程：
(1)思考與創(chuàng)新，繪制草圖，確定充電器外殼的外觀形式；
(2)實(shí)踐操作：通過Pro-e軟件畫出充電器外殼的三維模型；
（3)用Pro-e做出內(nèi)部的結(jié)構(gòu)，實(shí)現(xiàn)外觀要求；
(4)將Pro-e做的圖導(dǎo)入AutoCAD中；
(5)修改結(jié)構(gòu)圖，優(yōu)化結(jié)構(gòu)圖。
6、注射模具的設(shè)計過程
(1)對塑料零件的材料、形狀和功能進(jìn)行分析
(2)確定型腔的數(shù)目
確定型腔的數(shù)目條件有：最大注射量、鎖模力、產(chǎn)品的精度要求和經(jīng)濟(jì)性等。
(3)選擇分型面
分型面的選擇應(yīng)以模具結(jié)構(gòu)簡單、分型容易，且不破壞已成型的塑件為原則。
(4)型腔的布置方案
型腔的布置應(yīng)采用平衡式排列，以保證各型腔平衡進(jìn)料。型腔的布置還要注意
與冷卻管道、推桿布置的協(xié)調(diào)問題。
(5)確定澆注系統(tǒng)
澆注系統(tǒng)包括主流道、分流道、澆口和冷料穴。澆注系統(tǒng)的設(shè)計應(yīng)根據(jù)模具的類型、型腔的數(shù)目及布置方式、塑件的原料及尺寸等確定。
(6)確定脫模方式
脫模方式的設(shè)計應(yīng)根據(jù)塑件留在模具的部分而同。由于注射機(jī)的推出頂桿在動模部分，所以，脫模推出機(jī)構(gòu)一般都設(shè)計在模具的動模部分。因此，應(yīng)設(shè)計成使塑件能留在動模部分。設(shè)計中，除了將較長的型芯安排在動模部分以外，還常設(shè)計拉料桿，強(qiáng)制塑件留在動模部分。但也有些塑件的結(jié)構(gòu)要求塑件在分型時，留在定模部分，在定模一側(cè)設(shè)計出推出裝置。推出機(jī)構(gòu)的設(shè)計也應(yīng)根據(jù)塑件的不同結(jié)構(gòu)設(shè)計出不同的形式，有推桿、推管和推板等結(jié)構(gòu)。
(7)確定調(diào)溫系統(tǒng)結(jié)構(gòu)
模具的調(diào)溫系統(tǒng)主要由塑料種類決定。模具的大小、塑件的物理性能、外觀和尺寸精度都對模具的調(diào)溫系統(tǒng)有影響。
(8)確定凹模和型心的固定方式
當(dāng)凹?；蛐托牟捎描倝K結(jié)構(gòu)時，應(yīng)合理地劃分鐵塊并同時考慮鑲塊的強(qiáng)度、可加工性及安裝固定。
(9)確定排氣尺寸
一般注射模的排氣可以利用模具分型面和推桿與模具的間隙；而對于大型和高速成型的注射模，必須設(shè)計相應(yīng)的排氣裝置。
(10)確定注射模的主要尺寸
根據(jù)相應(yīng)的公式，計算成型零件的工作尺寸，以及決定模具型腔的側(cè)壁厚度、動模板的厚度、拼塊式型腔的型腔板的厚度及注射模的閉合高度。
(11)選用標(biāo)準(zhǔn)模架
根據(jù)設(shè)計、計算的注射模的主要尺寸，來選用注視模的標(biāo)準(zhǔn)模架，并盡量選擇標(biāo)準(zhǔn)模具零件。
(12)繪制模具的結(jié)構(gòu)草圖
在以上工作的基礎(chǔ)上，繪制注射模的完整的結(jié)構(gòu)草圖，繪制模具結(jié)構(gòu)圖是模具設(shè)計十分重要的工作，其步驟為先畫俯視圖（順序?yàn)椋寒嬆＜?、型腔、冷卻管道、支撐柱、推出機(jī)構(gòu)），再畫出主視圖。
(13)校核模具與注射機(jī)有關(guān)尺寸
對所使用的注射機(jī)的參數(shù)進(jìn)行校核：包括最大注射量、注射壓力、鎖模力及模
具的安裝部分的尺寸、開模行程和推出機(jī)構(gòu)的校核。
(14)注射模結(jié)構(gòu)設(shè)計的審查
對根據(jù)上述有關(guān)注視模結(jié)構(gòu)設(shè)計的各項要求設(shè)計出來的注射模，應(yīng)進(jìn)行注射模
結(jié)構(gòu)設(shè)計的初步審查，同時，也有必要對提出的要求加以確認(rèn)和修改。
(15)繪制模具的裝配圖
裝配圖是模具裝配的主要依據(jù)，因此應(yīng)清楚地表明注視模的各個零件的裝配關(guān)系、必要的尺寸（如外形尺寸、定位圈直徑、安裝尺寸、活動零件的極限尺寸等）、序號、明細(xì)表、標(biāo)題欄及技術(shù)要求。
(16)繪制模具的零件圖
由模具裝配圖拆繪零件圖的順序?yàn)椋合葍?nèi)后外，先復(fù)雜后簡單，先成型零件后結(jié)構(gòu)零件。
(17)復(fù)核設(shè)計圖樣
注射模具設(shè)計的最后是審核所設(shè)計的注射模，應(yīng)多關(guān)注零件的加工、性能。
7、已查閱的文獻(xiàn)資料
[1] 李學(xué)峰.塑料模設(shè)計及制造.[M].北京：機(jī)械工業(yè)出版社,2001
[2] 翁其金.塑料模塑成型技術(shù). [M].北京：機(jī)械工業(yè)出版社,2002..
[3] 馮炳堯等.模具設(shè)計與制造簡明手冊（第二版)[M]..上?？茖W(xué)技術(shù)出版社,2008.
[4] 錢泉森.塑料成型工藝及模具設(shè)計. [M].濟(jì)南：山東科學(xué)技術(shù)出版社,2004
[5] 《塑料模設(shè)計手冊》編著組.塑料設(shè)計手冊.北京：機(jī)械工業(yè)出版社,2002
[6] 陳劍鶴.模具設(shè)計基礎(chǔ). [M].北京：機(jī)械工業(yè)出版社,2004
[7] 王文廣等.塑料注塑模具設(shè)計技巧與實(shí).[M].北京：化學(xué)工業(yè)出版社,2004
[8] 章飛.型腔模具設(shè)計與制造. [M].北京：化學(xué)工業(yè)出版社,2003
[9] 田寶善等.塑料注射模設(shè)計實(shí)例及技巧. [M].北京：化學(xué)工業(yè)出版社,2009
[10] 朱光.塑料注塑模中小型模架及其技術(shù)條件.[M].北京：清華大學(xué)出版社,2003
[11] 宋滿倉等.注塑模具設(shè)計. [M].北京：電子工業(yè)出版社,2010
[12] 許鶴峰.注塑模設(shè)計要點(diǎn)與圖例. [M].北京：化學(xué)工業(yè)出版社,2003
[13] cunha,L,et.al.,performance of chromium nitride and titanium nitride coatings during platics injection moulding. Surface and coating Technology,2002.153(2-3):p.160-165.
現(xiàn)有設(shè)備及實(shí)驗(yàn)條件：計算機(jī)一臺，使用軟件為Pro/Engineer5.0及Auto CAD2008、Moldflow insight，以上實(shí)驗(yàn)條件可滿足本次畢業(yè)設(shè)計的要求。
3、 實(shí)施方案、進(jìn)度實(shí)施計劃及預(yù)期提交的畢業(yè)設(shè)計資料
一、2013年12月17日至2013年12月30日，理解消化畢設(shè)任務(wù)書要求并收集、分析、消化資料文獻(xiàn)，根據(jù)畢設(shè)內(nèi)容完成并交開題報告；
二、2013年1月6日至2014年1月13日，開展調(diào)研，了解塑件結(jié)構(gòu)，對原材料進(jìn)行分析，考慮塑件的成型工藝性、模具的總體結(jié)構(gòu)的形式，并完成部分英文摘要翻譯。
三、2014年3月4日至2013年3月31日，查閱資料，熟悉注射模的結(jié)構(gòu)及有關(guān)計算，擬定模具的方案設(shè)計、總體設(shè)計及主要零件設(shè)計，擬定成型工藝過程，查閱有關(guān)手冊確定適宜的工藝參數(shù)，注射機(jī)的選擇及確定注射設(shè)備及型號規(guī)格；
四、2014年4月1日至2014年4月21日，完成設(shè)計計算任務(wù)，總體結(jié)構(gòu)的設(shè)計和完成總裝配圖及零件圖的設(shè)計；
五、2014年4月22日至2014年5月1日，完成設(shè)計，圖紙繪制任務(wù)，工藝規(guī)程說明書的編寫；
六、2014年5月1日至2014年5月4日，完善設(shè)計并完成論文的撰寫；
七、2014年5月4日至2014年5月8日，修改并打印畢業(yè)論文及整理相關(guān)資料，交指導(dǎo)老師評閱，準(zhǔn)備論文答辯。
指導(dǎo)教師意見
指導(dǎo)教師（簽字）：
2013年12月 日
開題小組意見
開題小組組長（簽字）：
2014年1 月 日
院（系、部）意見
主管院長（系、部主任）簽字：
2014年1月 日
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桂林電子科技大學(xué)畢業(yè)設(shè)計（論文）報告用紙
編號：
畢業(yè)設(shè)計(論文)外文翻譯
（原文）
學(xué) 院： 國防生學(xué)院
專 業(yè)：機(jī)械設(shè)計制造及其自動化
學(xué)生姓名： 鄭 波
學(xué) 號： 1000110532
指導(dǎo)教師單位： 機(jī)電工程學(xué)院
姓 名： 郭中玲
職 稱： 高級工程師
2014年 1 月 12 日
EFFECTS OF CUTTING EDGE GEOMETRY,WORKPIECE HARDNESS, FEED RATE AND CUTTING SPEED ON SURFACE ROUGHNESS AND FORCES IN FINISH TURNING OF HARDENED AISI H13 STEEL
Tugrul ?zel, Tsu-Kong Hsu, Erol Zeren
Department of Industrial and Systems Engineering Rutgers, The State University of New Jersey, New Jersey 08854 USA
Abstract
In this study, effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI H13 steel were experimentally investigated. Cubic boron nitrite inserts with two distinct edge preparations and through-hardened AISI H-13 steel bars were used. Four factor (hardness, edge geometry, feed rate and cutting speed)- two level fractional experiments were conducted and statistical analysis of variance was performed. During hard turning experiments, three components of tool forces and roughness of the machined surface were measured. This study shows that the effects of workpiece hardness, cutting edge geometry, feed rate and cutting speed on surface roughness are statistically significant. The effects of two-factor interactions of the edge geometry and the workpiece hardness, the edge geometry and the feed rate, and the cutting speed and feed rate are also appeared to be important. Especially, small edge radius and lower workpiece surface hardness resulted in better surface roughness. Cutting edge geometry, workpiece hardness and cutting speed are found to be affecting force components. The lower workpiece surface hardness and small edge radius resulted in lower tangential and radial forces.
1. INTRODUCTION
Hard turning, machining ferrous metal parts that are hardened usually between 45-70 HRC, can be performed dry using polycrystalline cubic boron nitride (PCBN, commonly CBN) cutting tools as extensively reported in literature [1-8]. Research results in the literature concerning mechanism of serrated chip formation in order to relate process characteristics and stability of cutting to the chip shapes during hard turning [9-19]. Other research concerning with composition, temperatures and wear characteristics of CBN cutting tools [1,8,20,21,22,28] and effects of work material properties, tool geometry and cutting conditions on surface integrity of the finish machined parts [23-28] indicate challenges in hard turning and identifies various process, equipment and tooling related factors affecting surface quality, tool life and productivity. After reviewing the literature, factors affecting forces, tool wear/failure and roughness and integrity of the finished surfaces in hard turning using CBN cutting tools and their influences on each other are illustrated with a chart shown in Fig. 1. In this chart, the parameters above the horizontal dashed lines are considered as factors or inputs to the hard turning process and they can only be selected in the beginning except tool vibration. All other parameters, that are located below these dashed lines, considered as performance measures or outputs of the hard turning process. Review of the literature reveals that almost all of the factors given in this chart affect performance of the hard turning process. Those factors can be classified as follows:
1.1 Cutting tool geometry and material properties
Hard turning with CBN cutting tools demands prudent design of tool geometry. CBN cutting tools have lower toughness than other common tool materials, thus chipping ismore likely [2]. Therefore, a nose radius and proper edge preparation are essential to increase the strength of cutting edge and attain favorable surface characteristics on finished metal components [23]. CBN cutting tools designed for hard turning feature negative rake geometry and edge preparation (a chamfer or a hone, or even both). Specifications of the edge preparation design are often finalized after extensive experimentation. Fig. 2 shows the types of edge preparations common for CBN cutting tools. According to recent studies, it is evident that effect of edge geometry on surface quality is significant [23-28].
Fig. 1. A flow chart illustrating relationships of factors in hard turning.
Theile et al. [24, 25], presented research results of an experimental investigation of effects of cutting edge geometry and workpiece hardness on residual stresses in finish hard turning of AISI 52100 steel. They indicated that both factors are significant for the surface integrity of finish hard turned components. Specifically, they showed that large hone radius tools produce more compressive stresses, but also leave “white-layers”. ?zel [26] investigated the influence of edge geometry in CBN tools with respect to stress and temperature development through finite element simulations in hard turning. Chou et al. [28] experimentally investigated the influence of CBN content on surface quality and tool wear in hardened AISI 52100 steel tool. This study concluded that low content CBN tools produce better surface roughness with respect to higher content CBN tools and depth of cut has minor effect on tool wear rate.
Fig. 2. Type of edge preparations for CBN cutting tools.
1.2 Workpiece hardness
Due to the changes in properties of hardened workpiece material, basic shearing process and formation of chips differ in hard turning [5]. Prior research showed that workpiece hardness has a profound effect on the performance of the CBN tools [1,2,8] and also integrity of finish machined surfaces [23,25]. Matsumoto et al. [23] and Thiele et al. [25] studied the effect of workpiece hardness on residual stresses. In a recent study, Guo and Liu [27] investigated material properties of hardened AISI 52100 bearing steel using temperature controlled tensile tests and orthogonal cutting tests and demonstrated that hardness greatly influences the material properties accounting for high variation in flow stress properties.
1.3 Cutting speed, feed rate and depth of cut
Performance of CBN cutting tools is highly dependent on the cutting conditions i.e. cutting speed, feed, feed-rate, and depth of cut [7]. Especially cutting speed and depth of cut significantly influence tool life [22]. Increased cutting speed and depth of cut result in increased temperatures at the cutting zone. Since CBN is a ceramic material, at elevated temperatures chemical wear becomes a leading wear mechanism and often accelerates weakening of cutting edge, resulting in premature tool failure (chipping), namely edge breakage of the cutting tool. In addition, Thiele et al. [24] noticed that when feed rate is increased, residual stresses change from compressive to tensile.
1.4 Surface integrity, residual stresses and tool wear
In general, residual stresses become more compressive as workpiece hardness increases. The hardness and fracture toughness of CBN tools decrease with reduced CBN content [8]. Owing to ceramic binder phase, CBN-L tools have a lower thermal conductivity, which causes increasing temperatures of cutting edge during hard turning. Chou and Barash [9] reported that CBN-L tools are more suitable for finish turning of hardened steel. At low cutting speeds, tool life of CBN-L is superior to CBN-H, whereas at higher cutting speeds, the reverse is true, and also surface roughness is less favorable when using CBN-H tool [28]. Thiele et al. [24] reported that residual stresses generated by large edge hone tools are typically more compressive than stresses produced by small edge hone tools and they also leave white-layers. In addition, the effects of edge geometry play an important role in thermoplastic deformation of the workpiece. Koenig et al. [3] reported that an increase in feed rate raises the compressive residual stress maximal and deepens the affected zone. It was also suggested that the chamfer is unfavorable in terms of attainable surface finish when compared to honed or sharp edges.
1.5 Accuracy and rigidity of the machine tool
Another parameter that is often ignored is tool vibration. In order to reduce tool vibration it is necessary provide sufficiently rigid tool and workpiece fixtures. Assuring that there is minimal tool vibration is an easy way to improve surface roughness. It is also necessary that the tooling system be extremely rigid to withstand the immense cutting forces. It is well known that the radial force is the largest among force components during hard turning. Many researchers indicated that extremely rigid, high power, and high precision machine tools are required for hard turning because CBN tools are brittle and prone to chipping [3, 7, 8, 14, 23]. It is also suggested that having higher rigidity in machine tool-clamping-tooling system achieves better surface quality on the part. It is well known that vibration and chatter are important problems that degrade part quality and tool performance.
To improve the overall efficiency of finish hard turning, it is necessary to have a complete process understanding. To this end, a great deal of research has been performed in order to quantify the effect of various hard turning process parameters to surface quality. In order to gain a greater understanding of the hard turning process it is necessary to understand the impact of each of these variables, but also the interactions between them. It is impossible to find all of the variables that impact surface quality in finish hard turning. In addition, it is costly and time-consuming to discern the effect of every variable on the output.
2. EXPERIMENTAL PROCEDURE
2.1 Workpiece material
The workpiece material used in this study was AISI H13 hot work tool steel, which is used for high demand tooling. The cylindrical bar AISI H13 specimen that are utilized in this experiments had a diameter of 1.25 inches and length of 2 feet. The bar specimens were heat treated (through-hardened) at in-house heat treatment facility in order to obtain the desired hardness values of 50 and 55 HRC. However, the subsequent hardness tests by using Future Tech Rockwell type hardness tester revealed that the actual hardness of each specimen was 51.3±1.0 and 54.7±0.5 HRC. Henceforth, the hardness values are defined by the mean values of the measured workpiece hardness.
2.2 Tooling and edge geometry
CBN inserts with two distinct representative types of edge preparations were investigated in this study. These edge preparations include: a) “chamfered” (T-land) edges and b) “honed” edges as illustrated in Fig.2. Solid top CBN inserts (TNM-433 and GE Superabrasives BZN 8100 grade) inserts were used with a Kennametal DTGNR-124B right hand tool holder with 00 lead and –50 rake angles. Honed and chamfered insert edge geometry were measured in coordinated measurement machine with three replications using a high precision touch-trigger probe. For the honed inserts, an average radius of 10.5 ±4.0 μm was found. Chamfered insert edge geometry was found to have 200 chamfer angle and 0.1 ± 0.03 mm chamfer width using same instruments with three replications and was approximated to an equivalent hone radius of 101.6 ±5.1 μm.
2.3 Experimental design
A four factor – two level factorial design was used to determine the effects of the cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and resultant forces in the finish hard turning of AISI H 13 steel. The factors and factor levels are summarized in Table 1. These factor levels results in a total of 16 unique factor level combinations. Sixteen replications of each factor level combinations were conducted resulting in a total of 256 tests. Each replication represents 25.4 mm cutting length in axial direction. The response variables are the workpiece surface roughness and the cutting forces.
Longitudinal turning was conducted on a rigid, high-precision CNC lathe (Romi Centur 35E) at a constant depth of cut at 0.254 mm. The bar workpieces were held in the machine with a collet to minimize run-out and maximize rigidity. The length of cut for each test was 25.4 mm in the axial direction. Due to availability constraints, each insert were used for one factor level combination, which consisted of 16 replications. (A total of three honed and three chamfer inserts were available). In this manner each edge preparation was subject to the same number of tests and the same axial length of cut. Finally, surface roughness and tool wear measurements were conducted when the cutting length reached 203.2 mm (8 inches) and 406.4 mm (16 inches) during each factor level combination. The surface roughness was measured with a Taylor-Habson Surtronic 3+ profilometer and Mitutoyo SJ-digital surface analyzer, using a trace length of 4.8 mm, a cut-off length of 0.8 mm. The surface roughness values were recorded at eight equally spaced locations around the circumference every 25.4 mm distance from the edge of the specimen to obtain statistically meaningful data for each factor level combination. CBN inserts were examined using a tool-maker microscope to measure flank wear depth and detect undesirable features on the edge of the cutting tool by interrupting finish hard turning process.
2.4 Cutting force measurements
The cutting forces were measured with a three-component force dynamometer (Kistler Type 9121) mount on the turret disk of the CNC lathe via a custom designed turret adapter (Kistler type 9121) for the toolholder creating a very rigid tooling fixture. The charge signal generated at the dynamometer was amplified using charge amplifiers (Kistler Type 5814B1). The amplified signal is acquired and sampled by using data acquisition PCMCIA card and Kistler DyanoWare software on a laptop computer at a sampling frequency of 2000 Hz per channel. Time-series profiles of the acquired force data reveal that the forces are relatively constant over the length of cut and factors such as vibration and spindle run-out were negligible. Three components of the resultant force are shown schematically in Fig. 3.
Fig. 3. Measured cutting-force components.
3. RESULTS AND DISCUSSION
An analysis of variance (ANOVA) was conducted to identify statistically significant trends in the measured surface roughness and cutting force data. Separate ANOVA analyses were conducted for Ra surface roughness values and for each component of the cutting force i.e. axial (feed), radial (thrust), and tangential (cutting) forces. Additionally, plots of significant factors corresponding to each ANOVA analysis were constructed. These plots provide a more in-depth analysis of the significant factors related to the surface roughness and cutting forces in finish hard turning of AISI H13 steel using chamfered and honed CBN inserts.
3.1 ANOVA results
ANOVA tables for Ra surface roughness parameters are given in Table 2. In addition to degree of freedom (DF), mean square (MS) and F values (F) the table shows the P-values (P2) associate with each factor level and interaction. A low P-value indicates an indication of statistical significange for the source on the response. Table 2 show that the main effects of edge geometry, cutting speed and feed rate except hardness, interactions between edge geometry and hardness, feed rate, and cutting speed, the interactions between cutting speed and feed rate are significant to surface roughness. Feed rate is the dominant parameter associated with the surface roughness. This is expected because it is well known that the theoretical surface roughness is primarily a function of the feed for a given nose radius and varies as the square of the feed rate [8].
The radial force is usually the largest, tangential force is the middle and the axial (feed) force is the smallest in finish hard turning. In general, cutting force components are influences by cutting speed, edge geometry and feed rate. Tables 3-5 are ANOVA tables corresponding to the radial, axial (feed force) and tangential components of the cutting force, respectively. These tables show that the main effects of workpiece hardness, the edge geometry, cutting speed and feed rate (except for axial force) are all significant with respect to the forces in the radial, axial and tangential directions.
Table 3 shows that the main effects of the edge geometry, cutting speed, hardness and the interactions between edge geometry and hardness, cutting speed, feed rate are significant with respect to the forces in the axial (feed) direction. Axial (feed) force is not much influence by the change in feed rate.
Table 4 shows that the main effects of the edge geometry, cutting speed, hardness and only the interactions between edge geometry and cutting speed, feed rate are significant with respect to the forces in the radial direction.
Table 5 shows that the main effects of the edge geometry, cutting speed, hardness, feed and only the interactions between edge geometry and hardness, cutting speed, feed rate are significant with respect to the forces in the tangential direction.
3.2 Effect of feed rate and edge preparation on surface roughness
Graphs of Ra surface roughness parameters are shown in Figures 4 and 5. These figures have been constructed to illustrate the main effects of edge geometry and feed rate parameters on the surface roughness. Based on the previous analysis, the main effect of the interaction between edge geometry and feed rate are found to be statistically significant on surface roughness Ra. Fig. 4 shows the effect of edge geometry and feed rate on the Ra surface roughness parameter for 54.7 HRC, cutting speed 200 m/min and cutting length of 406.4 mm. Fig. 5 shows the effect of edge geometry and feed rate on the Ra surface roughness parameter for 51.3 HRC with cutting speed of 100 m/min and cutting length of 25.4 mm.
Fig. 4. Effect of cutting edge geometry and feed rate on surface roughness (high levels).
Fig. 5. Effect of cutting edge geometry and feed on surface roughness (low levels).
These two figures show that all edge preparations are confounded at the lowest feed rate (0.05mm/rev). However, the large edge radius resulted in better surface roughness when higher hardness and cutting speed selected, whereas it is the opposite when lower hardness and cutting speed selected. Finally, it should be noted that the main effect due to feed is readily apparent for each edge preparation. Specifically, the surface roughness increases as the feed rate increases as the surface roughness being proportional to the square of the feed rate.
3. 3 Effect of surface hardness and edge preparation on surface roughness
Fig. 6 is constructed to illustrate the main effects of edge geometry and surface hardness parameters on the surface roughness with cutting speed 200 m/min, feed rate 0.2 mm/rev and cutting length 406.4 mm. Based on the previous analysis, the main effect of the interaction between edge geometry and workpiece surface hardness are statistically significant to surface roughness Ra parameters. The figure shows that small edge radius and lower workpiece surface hardness resulted in better surface roughness.
Fig. 6. Effect of cutting edge geometry and hardness on surface roughness.
3.4 Effect of surface hardness and edge preparation on tangential, radial and axial (feed) forces
Graphs of the force components as functions of edge geometry and workpiece surface hardness are shown in Figs. 7-9. These figures show that chamfered edge geometry and higher workpiece surface hardness result in hig