公司承接(jie)的(de)(de)箱體(ti)結(jie)構件已(yi)研制定形，進(jin)入批(pi)量生產階段，對嵌焊(han)接(jie)螺(luo)母的(de)(de)需(xu)求量也隨之增加，原有的(de)(de)工藝(yi)手段已(yi)不能滿足生產需(xu)要。必須考慮利用更精良的(de)(de)設(she)備(bei)和工裝提(ti)高加工效(xiao)率和加工質(zhi)量。

　　１.設(she)計思路要實(shi)現(xian)高(gao)效、快(kuai)捷的加工(gong)，首(shou)先考慮(lv)到設(she)計適(shi)于沖床加工(gong)的精密模具。該模具要求必須工(gong)作(zuo)可靠(kao)，使用壽(shou)命高(gao)，維修方便，模具零件(jian)更換容易(yi)，整體結構通用性強。通過沖壓模具和沖床實(shi)現(xian)雙(shuang)層牙螺絲毛坯零件(jian)的精確(que)定(ding)位，快(kuai)速成形、自動卸(xie)件(jian)。

　　２.雙層牙(ya)螺絲模(mo)具(ju)(ju)(ju)(ju)結(jie)構如下圖(tu)所示(shi)，采(cai)用(yong)了正(zheng)擠壓成形工藝，整個(ge)模(mo)具(ju)(ju)(ju)(ju)采(cai)用(yong)了柔性化(hua)設(she)計(ji)，通過此模(mo)具(ju)(ju)(ju)(ju)可完成嵌螺母零(ling)件(jian)(jian)系(xi)列(lie)化(hua)的(de)生產(chan)制造(zao)。關鍵模(mo)具(ju)(ju)(ju)(ju)零(ling)件(jian)(jian)凸(tu)模(mo)１９、限位(wei)套１７、凹(ao)模(mo)鑲(xiang)件(jian)(jian)８、頂件(jian)(jian)器６、定(ding)位(wei)鑲(xiang)件(jian)(jian)４及主要模(mo)板(ban)固定(ding)板(ban)２０、彈壓板(ban)１５、凹(ao)模(mo)板(ban)１４的(de)安裝(zhuang)定(ding)位(wei)均符(fu)合(he)標(biao)準件(jian)(jian)設(she)計(ji)要求，使模(mo)具(ju)(ju)(ju)(ju)核心部件(jian)(jian)具(ju)(ju)(ju)(ju)有良好(hao)的(de)可互換(huan)性，提高模(mo)具(ju)(ju)(ju)(ju)整體使用(yong)壽命，節約(yue)了此類嵌螺母零(ling)件(jian)(jian)的(de)制造(zao)成本(ben)。

雙層牙螺絲模具結構圖

　　３.工作(zuo)機理如上(shang)(shang)(shang)(shang)圖所示，模(mo)(mo)具處于(yu)自然狀態。工作(zuo)時(shi)，上(shang)(shang)(shang)(shang)模(mo)(mo)下(xia)(xia)行(xing)，同時(shi)壓(ya)(ya)(ya)迫彈壓(ya)(ya)(ya)板１５下(xia)(xia)壓(ya)(ya)(ya)，則凸(tu)模(mo)(mo)１９將毛(mao)(mao)坯(pi)５頂入凹模(mo)(mo)鑲件(jian)８，與頂件(jian)器(qi)６同步上(shang)(shang)(shang)(shang)移，至(zhi)頂件(jian)器(qi)與上(shang)(shang)(shang)(shang)模(mo)(mo)墊板１３接觸，隨后頂件(jian)器(qi)下(xia)(xia)壓(ya)(ya)(ya)毛(mao)(mao)坯(pi)，直至(zhi)墊板１６與限位套(tao)１７接觸，齒(chi)在凹模(mo)(mo)鑲件(jian)內壓(ya)(ya)(ya)制(zhi)成形(xing)。開模(mo)(mo)時(shi)，毛(mao)(mao)坯(pi)與凸(tu)模(mo)(mo)分離，滯留于(yu)凹模(mo)(mo)鑲件(jian)內，隨同上(shang)(shang)(shang)(shang)模(mo)(mo)上(shang)(shang)(shang)(shang)行(xing)，直至(zhi)打桿１０與沖床上(shang)(shang)(shang)(shang)橫杠(gang)剛性撞擊(ji)，作(zuo)用(yong)力(li)傳遞(di)于(yu)頂件(jian)器(qi)，將毛(mao)(mao)坯(pi)頂出凹模(mo)(mo)鑲件(jian)，工作(zuo)結束。準備下(xia)(xia)一(yi)個循環(huan)。

　　４.可靠性保障

　　本模(mo)(mo)具(ju)中模(mo)(mo)座上(shang)(shang)安(an)裝有精確(que)定(ding)(ding)(ding)位(wei)(wei)(wei)導向(xiang)的(de)(de)(de)導柱(zhu)、導套，可保證凹模(mo)(mo)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)與(yu)凸(tu)(tu)模(mo)(mo)的(de)(de)(de)同(tong)軸(zhou)度不大于０.０２ｍｍ；彈(dan)(dan)壓(ya)板(ban)與(yu)凸(tu)(tu)模(mo)(mo)固定(ding)(ding)(ding)板(ban)之間(jian)雖然設計(ji)有小導柱(zhu)，但(dan)由于彈(dan)(dan)壓(ya)板(ban)為活動(dong)件(jian)(jian)(jian)(jian)(jian)而裝在其上(shang)(shang)的(de)(de)(de)定(ding)(ding)(ding)位(wei)(wei)(wei)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)４也隨之上(shang)(shang)下(xia)(xia)運(yun)動(dong)，按常規方法設計(ji)除了對(dui)(dui)(dui)彈(dan)(dan)壓(ya)板(ban)上(shang)(shang)的(de)(de)(de)定(ding)(ding)(ding)位(wei)(wei)(wei)型孔與(yu)其配(pei)合實體(ti)的(de)(de)(de)定(ding)(ding)(ding)位(wei)(wei)(wei)精度，以(yi)及(ji)對(dui)(dui)(dui)互(hu)(hu)換部(bu)件(jian)(jian)(jian)(jian)(jian)（定(ding)(ding)(ding)位(wei)(wei)(wei)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)）裝配(pei)時(shi)(shi)也有較高要(yao)求外，還必須保證彈(dan)(dan)壓(ya)板(ban)上(shang)(shang)下(xia)(xia)運(yun)動(dong)時(shi)(shi)具(ju)有極強(qiang)的(de)(de)(de)平穩度。為降低制作精度和裝配(pei)難度，設計(ji)上(shang)(shang)考(kao)慮：如下(xia)(xia)圖(tu)所示，凸(tu)(tu)模(mo)(mo)伸入(ru)定(ding)(ding)(ding)位(wei)(wei)(wei)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)６～７ｍｍ，并(bing)與(yu)定(ding)(ding)(ding)位(wei)(wei)(wei)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)配(pei)合間(jian)隙雙面０.０１ｍｍ，定(ding)(ding)(ding)位(wei)(wei)(wei)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)與(yu)彈(dan)(dan)壓(ya)板(ban)對(dui)(dui)(dui)應(ying)安(an)裝孔配(pei)合間(jian)隙雙面０.１ｍｍ，則(ze)定(ding)(ding)(ding)位(wei)(wei)(wei)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)通(tong)過凸(tu)(tu)模(mo)(mo)精確(que)導向(xiang)，避免定(ding)(ding)(ding)位(wei)(wei)(wei)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)通(tong)過彈(dan)(dan)壓(ya)板(ban)精確(que)定(ding)(ding)(ding)位(wei)(wei)(wei)并(bing)與(yu)凸(tu)(tu)模(mo)(mo)精密(mi)配(pei)合不能同(tong)時(shi)(shi)滿(man)足時(shi)(shi)，發生干涉，不能保證毛坯、凹模(mo)(mo)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)與(yu)凸(tu)(tu)模(mo)(mo)位(wei)(wei)(wei)置(zhi)的(de)(de)(de)同(tong)軸(zhou)度。對(dui)(dui)(dui)于相對(dui)(dui)(dui)靜態模(mo)(mo)具(ju)核心零件(jian)(jian)(jian)(jian)(jian)凸(tu)(tu)模(mo)(mo)１９、凹模(mo)(mo)鑲(xiang)(xiang)件(jian)(jian)(jian)(jian)(jian)８固定(ding)(ding)(ding)部(bu)位(wei)(wei)(wei)對(dui)(dui)(dui)應(ying)安(an)裝軸(zhou)孔間(jian)隙配(pei)合H７／js6，可實現備件(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)精確(que)互(hu)(hu)換，不影(ying)響模(mo)(mo)具(ju)裝配(pei)精度。

雙層牙螺絲的(de)凸模、定位鑲件、毛坯、彈壓板裝配(pei)簡圖