电接插件方针产品多向送料模内装配工艺开发
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摘要
电接插件是支撑IT产品在这个信息社会更有效地发挥其主导性作用的基础零件。由于种种原因,高性能电接插件方针产品在常规生产中存在许多问题,严重地制约电接插件的产能的扩张,这些问题主要包括:旧的电接插件方针产品生产工艺不能生产符合高端产品质量的产品;旧生产工艺需要两套模具,固定投资成本高,终端产品生产流程长;旧的生产加工系统不能满足企业进一步节约能源、原材料、降低成本的要求。
因此,本论文开发生产电接插件方针产品的多向送料模内装配冲压工艺,以取代旧式的生产工艺。本论文主要工作及研究结论如下:
(1)结合经典赫兹接触理论,对电接插件方针产品过盈装配过程进行接触分析。
(2)提出了受力分析的弹片模型,对电接插件方针产品的装配过程进行了受力分析。该过程得到分析结果可以用于计算在赫兹接触过程中的接触面半径、压缩量和单位接触应力峰值。
(3)建立了基于ABAQUS的电接插件方针产品过盈装配的有限元模拟模型。此外,通过仿真正交试验,对装配结构进行了优化,并找出了最佳组合结构。
(4)提出了多向送料模内装配冲压工艺的概念,并对这一作了深入的阐述。此外还首次提出了单工序模内装配和步进式模内装配。
(5)开发了用于生产电接插件方针产品的C1B4两向送料模内装配工艺。
Electronic Connectors are basic parts that support IT products more effectively play its leading role in this information society. For various reasons, there are many problems in manufacturing high-performance electronic connector products in the conventional approach, which seriously constrained the expansion of production capacity. These problems are: First, the old process of producing electronic connectors cannot meet the requirement of high quality. Moreover, the old production process requires two sets of molds and dies, which requires higher fixed investment costs, and prolongs the product production process. Besides, the old system can not meet the standard to save energy, raw materials and reduce the cost further.
In response, this thesis is to develop a kind of new process, namely, stamping process of square needle parts of electronic connectors with multi-way parallel co-feeding to replace the old process. Work undertaken and finished in this thesis includes:
Initially, combined with the classical Hertz contact theory, the contact existing in electronic connector interference assembly process is analyzed in this thesis. Moreover, this thesis puts forward the shrapnel model of mechanical analysis on electronic connectors’assembly. The result from the analysis can be used to calculate the radius of Hertz contact in the contact surface, the compression and the peak contact stress. Thirdly, the thesis establishes a FEM model based on ABAQUS simulation, together with an orthogonal simulation test, which is used to optimize the assembly structure. Fourth, the concept of multi-way parallel co-feeding metal stamping process, was proposed and explained in this thesis in depth. Besides, it is the first time the concept of single-step in-mold assembly (IMA) and progressive IMA are prompted. Lastly, a new guideline, namely C1B4, which feeds in two directions is developed for the production of electronic connectors.
因此,本论文开发生产电接插件方针产品的多向送料模内装配冲压工艺,以取代旧式的生产工艺。本论文主要工作及研究结论如下:
(1)结合经典赫兹接触理论,对电接插件方针产品过盈装配过程进行接触分析。
(2)提出了受力分析的弹片模型,对电接插件方针产品的装配过程进行了受力分析。该过程得到分析结果可以用于计算在赫兹接触过程中的接触面半径、压缩量和单位接触应力峰值。
(3)建立了基于ABAQUS的电接插件方针产品过盈装配的有限元模拟模型。此外,通过仿真正交试验,对装配结构进行了优化,并找出了最佳组合结构。
(4)提出了多向送料模内装配冲压工艺的概念,并对这一作了深入的阐述。此外还首次提出了单工序模内装配和步进式模内装配。
(5)开发了用于生产电接插件方针产品的C1B4两向送料模内装配工艺。
Electronic Connectors are basic parts that support IT products more effectively play its leading role in this information society. For various reasons, there are many problems in manufacturing high-performance electronic connector products in the conventional approach, which seriously constrained the expansion of production capacity. These problems are: First, the old process of producing electronic connectors cannot meet the requirement of high quality. Moreover, the old production process requires two sets of molds and dies, which requires higher fixed investment costs, and prolongs the product production process. Besides, the old system can not meet the standard to save energy, raw materials and reduce the cost further.
In response, this thesis is to develop a kind of new process, namely, stamping process of square needle parts of electronic connectors with multi-way parallel co-feeding to replace the old process. Work undertaken and finished in this thesis includes:
Initially, combined with the classical Hertz contact theory, the contact existing in electronic connector interference assembly process is analyzed in this thesis. Moreover, this thesis puts forward the shrapnel model of mechanical analysis on electronic connectors’assembly. The result from the analysis can be used to calculate the radius of Hertz contact in the contact surface, the compression and the peak contact stress. Thirdly, the thesis establishes a FEM model based on ABAQUS simulation, together with an orthogonal simulation test, which is used to optimize the assembly structure. Fourth, the concept of multi-way parallel co-feeding metal stamping process, was proposed and explained in this thesis in depth. Besides, it is the first time the concept of single-step in-mold assembly (IMA) and progressive IMA are prompted. Lastly, a new guideline, namely C1B4, which feeds in two directions is developed for the production of electronic connectors.
引文
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【22】戴源德,卢险峰,王鹏.级进模两步法冲裁降低工艺噪声的试验研究[J].噪声与振动控制. 2006, 26(6): 104-106.
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【2】黄珍媛,阮锋等.IT制件精密级进冲压模具关键技术的现状与发展[J].锻压技术,2005,(5):98-100
【3】邓明,贾进周.电接插件冲压成形级进冲压模具设计[J].锻压装备与制造技术,2004,(6):70-72.
【4】吴兴华.端盖板高速连续级进冲压模具设计[J].电加工与模具,2006,(5):44-48
【5】欧阳波仪,李洋,石宗金.精密连接端子级进冲压模具设计[J].模具工业,2006,(10):16-20.
【6】硬质合金级进模电加工反拷贝制造工艺[J].低压电器,1973,(1).
【7】冷挤压加工及无废料级进模[J].低压电器,1973,(1).
【8】多工序级进模[J].低压电器,1973,(1).
【9】点火线圈支架级进模[J].低压电器,1973,(1).
【10】弹性夹脚多道弯曲级进模[J].低压电器,1973,(1).
【11】RTO熔断器级进模的改进[J].低压电器,1973,(1)
【12】灭弧罩脚级进模[J].低压电器,1973,(1).
【13】双件排料三工序级进模[J].低压电器,1973,(1).
【14】徐飞腾.锁舌片五合一级进模[J].锻压技术. 1990, 15(3): 39-40.
【15】李建军,温建勇.基于特征的智能化级进模条料排样[J].塑性工程学报. 1997, 4(1): 26-30.
【16】辛勇,王鹭.引线框架冲裁级进模工步排样CAD系统[J].中国机械工程. 1997, 8(5): 75-77.
【17】沈新民.电机铁心冲片高速级进冲工艺[J].中小型电机. 1998, 25(1): 19-21.
【18】朱坚民,孙金花.轿车离合器轴承套圈级进冲压工艺参数自寻优[J].洛阳工学院学报. 1999, 20(3): 73-76.
【19】赵震,彭颖红.基于知识的级进冲模工步排样CAD技术的发展与展望[J].机械设计与制造. 2002(4): 96-97.
【20】王义林,李建军,李志刚等.级进模CAD冲压特征工序设计自动化的研究[J].中国机械工程. 2002, 13(22): 1955-1957.
【21】王可胜,董定福,李文胜.压力臂扭曲成形新工艺及其级进模的设计[J].锻压技术. 2005, 30(3): 71-73.
【22】戴源德,卢险峰,王鹏.级进模两步法冲裁降低工艺噪声的试验研究[J].噪声与振动控制. 2006, 26(6): 104-106.
【23】罗晓晔.不锈钢骨架多工位级进精密模具设计[J].制造技术与机床. 2007(7):32-36.
【24】曹立生.正极片冲压工艺分析与多工位级进模具设计[J].锻压技术. 2008, 33(3): 23-25.
【25】王哲英,马明旭,杨远龙.基于Pro/E的液晶显示器支架的冲压工艺与模具设计术[J].机械设计与制造. 2009(2): 257-258.
【26】黄珍媛,郭雷,阮锋.听筒T铁级进模冷锻工艺研究[J].锻压技术. 2009, 34(5): 80-84.
【27】赵战峰,康俊远,关余杰.电机转子、定子冲压工艺分析及级进模具设计[J].锻压技术. 2010(1): 106-109.
【28】辛勇,王鹭,阮雪榆.智能多工位冲裁级进冲压模具工步排样计算机优化设计方法及其应用[J].上海大学学报,1996,30(3):138-143
【29】袁国华,赵震,彭颖红等.级进冲压模具工步排样中的组合优化问题研究[J].机械科学与技术,2000,(11):947-949
【30】上海工程技术大学.集成电路封装模具三维CAD/CAM系统[J].集成电路应用,2003,(1):80-82
【31】肖祥芷,盛自强,李建军,等.基于特征设计的级进冲压模具CAD/CAM系统[J].模具工业1998,(4).
【32】王波,周驰,罗聪.区间法在冲压件嵌套排样中的应用[J].模具工业,2006,(4):28-31.
【33】罗聪.基于KBE技术的精密高速级进模设计系统的研究与开发[D].广州:华南理工大学,2007.
【34】N. Hatanaka, K. Yamaguchi,N. Takakura. Finite element simulation of the shearing mechanism in the blanking of sheet metal. Journal of Materials Processing Technology. 121–125(2003): 64-70.
【35】F.Faura, A.Garcia, M.Estrems.Finite element analysis of optimμm clearance in the blanking process[J].Materials Processing Technology, 1998,(80):121-125
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