压铸件零件设计的注意事项

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<P 0cm 0cm 0pt"><B normal">压铸件零件设计的注意事项</B><B normal"><p></p></B></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 36.8pt; mso-char-indent-count: 2.3; mso-char-indent-size: 16.0pt; tab-stops: 27.0pt">一、压铸件的设计涉及四个方面的内容：<FONT face="Times New Roman">a</FONT>、即压力铸造对零件形状结构的要求；<FONT face="Times New Roman">b</FONT>、压铸件的工艺性能；<FONT face="Times New Roman">c</FONT>、压铸件的尺寸精度及表面要求；<FONT face="Times New Roman">d</FONT>、压铸件分型面的确定；<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 45pt; mso-char-indent-count: 3.0; mso-char-indent-size: 15.0pt; tab-stops: 27.0pt">压铸件的零件设计是压铸生产技术中的重要部分，设计时必须考虑以下问题：模具分型面的选择、浇口的开设、顶杆位置的选择、铸件的收缩、铸件的尺寸精度保证、铸件内部缺陷的防范、铸孔的有关要求、收缩变形的有关要求以及加工余量的大小等方面；<p></p></P>
<P 0cm 0cm 0pt"><FONT face="Times New Roman">      </FONT>二、压铸件的设计原则是：<FONT face="Times New Roman">a</FONT>、正确选择压铸件的材料，<FONT face="Times New Roman">b</FONT>、合理确定压铸件的尺寸精度；<FONT face="Times New Roman">c</FONT>、尽量使壁厚分布均匀；<FONT face="Times New Roman">d</FONT>、各转角处增加工艺园角，避免尖角。<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 15pt; mso-char-indent-count: 1.0; mso-char-indent-size: 15.0pt"><FONT face="Times New Roman">    </FONT>三、压铸件按使用要求可分为两大类，一类承受较大载荷的零件或有较高相对运动速度的零件，检查的项目有尺寸、表面质量、化学成分、力学性能（抗拉强度、伸长率、硬度）；另一类为其它零件，检查的项目有尺寸、表面质量及化学成分。<p></p></P>
<P 0cm 0cm 0pt; TEXT-ALIGN: left" align=left>在设计压铸件时，还应该注意零件应满足压铸的工艺要求。压铸的工艺性从分型面的位置、顶面推杆的位置、铸孔的有关要求、收缩变形的有关要求以及加工余量的大小等方面考虑。合理确定压铸面的分型面，不但能简化压铸型的结构，还能保证铸件的质量。<p></p></P>
<P 0cm 0cm 0pt"><B normal"><FONT face="Times New Roman"> <p></p></FONT></B></P>
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<P 0cm 0cm 0pt; TEXT-INDENT: -24.75pt; mso-char-indent-count: -1.12; mso-char-indent-size: 22.05pt"><B normal">压铸件零件设计的要求</B><B normal"><p></p></B></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 37.65pt; mso-char-indent-count: 2.5; mso-char-indent-size: 15.05pt"><B normal">一、<U>压铸件的形状结构要求</U></B>：<FONT face="Times New Roman">a</FONT>、消除内部侧凹；<FONT face="Times New Roman">b</FONT>、避免或减少抽芯部位；<FONT face="Times New Roman">c</FONT>、避免型芯交叉；<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 45pt; mso-char-indent-count: 3.0; mso-char-indent-size: 15.0pt">合理的压铸件结构不仅能简化压铸型的结构，降低制造成本，同时也改善铸件质量，<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 45.2pt; mso-char-indent-count: 3.0; mso-char-indent-size: 15.05pt"><B normal">二、<U>铸件设计的壁厚要求</U>：</B><FONT face="Times New Roman">  </FONT>压铸件壁厚度（通常称壁厚）是压铸工艺中一个具有特殊意义的因素，壁厚与整个工艺规范有着密切关系，如填充时间的计算、内浇口速度的选择、凝固时间的计算、模具温度梯度的分析、压力（最终比压）的作用、留模时间的长短、铸件顶出温度的高低及操作效率；<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 45pt; mso-char-indent-count: 3.0; mso-char-indent-size: 15.0pt"><FONT face="Times New Roman">a</FONT>、零件壁厚偏厚会使压铸件的力学性能明显下降，薄壁铸件致密性好，相对提高了铸件强度及耐压性；<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 45pt; mso-char-indent-count: 3.0; mso-char-indent-size: 15.0pt"><FONT face="Times New Roman">b</FONT>、铸件壁厚不能太薄，太薄会造成铝液填充不良，成型困难，使铝合金熔接不好，铸件表面易产生冷隔等缺陷，并给压铸工艺带来困难；<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 45pt; mso-char-indent-count: 3.0; mso-char-indent-size: 15.0pt">压铸件随壁厚的增加，其内部气孔、缩孔等缺陷增加，故在保证铸件有足够强度和刚度的前提下，应尽量减小铸件壁厚并保持截面的厚薄均匀一致，为了避免缩松等缺陷，对铸件的厚壁处应减厚（减料），增加筋；对于大面积的平板类厚壁铸件<FONT face="Times New Roman">,</FONT>设置筋以减少铸件壁厚；<p></p></P>
<P 0cm 0cm 0pt"><FONT face="Times New Roman">     </FONT>根据压铸件的表面积，铝合金压铸件的合理壁厚如下：<p></p></P>
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<TR 21.35pt">
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<P 0cm 0cm 0pt; LINE-HEIGHT: 15pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center>压铸件表面积<FONT face="Times New Roman">/mm<SUP>2<p></p></SUP></FONT></P></TD>
<TD windowtext 0.5pt solid; PADDING-RIGHT: 5.4pt; BORDER-TOP: windowtext 0.5pt solid; PADDING-LEFT: 5.4pt; PADDING-BOTTOM: 0cm; BORDER-LEFT: #d4d0c8; WIDTH: 253.95pt; PADDING-TOP: 0cm; BORDER-BOTTOM: windowtext 0.5pt solid; HEIGHT: 21.35pt; BACKGROUND-COLOR: transparent; mso-border-left-alt: solid windowtext .5pt" width=339>
<P 0cm 0cm 0pt; LINE-HEIGHT: 15pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center>壁厚<FONT face="Times New Roman">S/mm<p></p></FONT></P></TD></TR>
<TR 22.75pt">
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<P 0cm 0cm 0pt; TEXT-INDENT: 82.5pt; LINE-HEIGHT: 19pt; mso-char-indent-count: 5.5; mso-char-indent-size: 15.0pt; mso-line-height-rule: exactly">≤<FONT face="Times New Roman">25<p></p></FONT></P></TD>
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<P 0cm 0cm 0pt; LINE-HEIGHT: 19pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center><FONT face="Times New Roman">1.0</FONT>～<FONT face="Times New Roman">3.0<p></p></FONT></P></TD></TR>
<TR 23.05pt">
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<P 0cm 0cm 0pt; LINE-HEIGHT: 19pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center><FONT face="Times New Roman"> </FONT>＞<FONT face="Times New Roman">25~100<p></p></FONT></P></TD>
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<P 0cm 0cm 0pt; LINE-HEIGHT: 19pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center><FONT face="Times New Roman">1.5</FONT>～<FONT face="Times New Roman">4.5<p></p></FONT></P></TD></TR>
<TR 23.3pt">
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<P 0cm 0cm 0pt; LINE-HEIGHT: 19pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center><FONT face="Times New Roman"> </FONT>＞<FONT face="Times New Roman">100~400<p></p></FONT></P></TD>
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<P 0cm 0cm 0pt; LINE-HEIGHT: 19pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center><FONT face="Times New Roman">2.5</FONT>～<FONT face="Times New Roman">5.0<p></p></FONT></P></TD></TR>
<TR 22.9pt">
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<P 0cm 0cm 0pt; TEXT-INDENT: 82.5pt; LINE-HEIGHT: 19pt; mso-char-indent-count: 5.5; mso-char-indent-size: 15.0pt; mso-line-height-rule: exactly">＞<FONT face="Times New Roman">400<p></p></FONT></P></TD>
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<P 0cm 0cm 0pt; LINE-HEIGHT: 19pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center><FONT face="Times New Roman">3.5</FONT>～<FONT face="Times New Roman">6.0<p></p></FONT></P></TD></TR></TABLE>
<P 0cm 0cm 0pt; TEXT-INDENT: 37.2pt; mso-char-indent-count: 2.47; mso-char-indent-size: 15.05pt"><B normal">三、<U>铸件设计筋的要求</U>：</B><B normal"><p></p></B></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 51.9pt; mso-char-indent-count: 3.46; mso-char-indent-size: 15.0pt">筋的作用是壁厚改薄后，用以提高零件的强度和刚性，防止减少铸件收缩变形，以及避免工件从模具内顶出时发生变形，填充时用以作用辅助回路（金属流动的通路），压铸件筋的厚度应小于所在壁的厚度，一般取该处的厚度的<FONT face="Times New Roman">2/3~3/4</FONT>；<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 52.1pt; mso-char-indent-count: 3.46; mso-char-indent-size: 15.05pt"><B normal">四、<U>铸件设计的圆角要求</U>：</B><B normal"><p></p></B></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 52.05pt; mso-char-indent-count: 3.47; mso-char-indent-size: 15.0pt">压铸件上凡是壁与壁的连接，不论直角、锐角或钝角、盲孔和凹槽的根部，都应设计成圆角，只有当预计确定为分型面的部位上，才不采用圆角连接，其余部位一般必须为圆角，圆角不宜过大或过小，过小压铸件易产生裂纹，过大易产生疏松缩孔，压铸件圆角一般取：<FONT face="Times New Roman">1/2</FONT>壁厚≤<FONT face="Times New Roman">R</FONT>≤壁厚；<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 45pt; mso-char-indent-count: 3.0; mso-char-indent-size: 15.0pt">圆角的作用是有助于金属的流动，减少涡流或湍流；避免零件上因有圆角的存在而产生应力集中而导致开裂；当零件要进行电镀或涂覆时，圆角可获得均匀镀层，防止尖角处沉积；可以延长压铸模的使用寿命，不致因模具型腔尖角的存在而导致崩角或开裂；<p></p></P>
<P 0cm 0cm 0pt; TEXT-INDENT: 30.1pt; TEXT-ALIGN: left; mso-char-indent-count: 2.0; mso-char-indent-size: 15.05pt" align=left><B normal">五、压<U>铸件设计的铸造斜度要求</U>：</B><B normal"><p></p></B></P>
<P 0cm 0cm 0pt 15pt; TEXT-ALIGN: left" align=left><FONT face="Times New Roman">       </FONT>斜度作用是减少铸件与模具型腔的摩擦，容易取出铸件；保证铸件表面不拉伤；延长压铸模使用寿命，铝合金压铸件一般最小铸造斜度如下：<p></p></P>
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<TR 31pt">
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<P 0cm 0cm 0pt; LINE-HEIGHT: 22pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center>铝合金压铸件最小的铸造斜度<p></p></P></TD></TR>
<TR 15pt">
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<P 0cm 0cm 0pt; LINE-HEIGHT: 22pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center>外表面<p></p></P></TD>
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<P 0cm 0cm 0pt 3.3pt; TEXT-INDENT: -3.3pt; LINE-HEIGHT: 22pt; TEXT-ALIGN: center; mso-char-indent-count: -.22; mso-char-indent-size: 15.0pt; mso-line-height-rule: exactly" align=center>内表面<p></p></P></TD>
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<P 0cm 0cm 0pt; LINE-HEIGHT: 22pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center>型芯孔（单边）<p></p></P></TD></TR>
<TR 30.45pt">
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<P 0cm 0cm 0pt; LINE-HEIGHT: 22pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center><FONT face="Times New Roman">1</FONT>°<p></p></P></TD>
<TD windowtext 0.5pt solid; PADDING-RIGHT: 5.4pt; BORDER-TOP: #d4d0c8; PADDING-LEFT: 5.4pt; PADDING-BOTTOM: 0cm; BORDER-LEFT: #d4d0c8; WIDTH: 144pt; PADDING-TOP: 0cm; BORDER-BOTTOM: windowtext 0.5pt solid; HEIGHT: 30.45pt; BACKGROUND-COLOR: transparent; mso-border-left-alt: solid windowtext .5pt; mso-border-top-alt: solid windowtext .5pt" width=192>
<P 0cm 0cm 0pt; LINE-HEIGHT: 22pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center><FONT face="Times New Roman">1</FONT>°<FONT face="Times New Roman">30</FONT>′<p></p></P></TD>
<TD windowtext 0.5pt solid; PADDING-RIGHT: 5.4pt; BORDER-TOP: #d4d0c8; PADDING-LEFT: 5.4pt; PADDING-BOTTOM: 0cm; BORDER-LEFT: #d4d0c8; WIDTH: 167.1pt; PADDING-TOP: 0cm; BORDER-BOTTOM: windowtext 0.5pt solid; HEIGHT: 30.45pt; BACKGROUND-COLOR: transparent; mso-border-left-alt: solid windowtext .5pt; mso-border-top-alt: solid windowtext .5pt" width=223>
<P 0cm 0cm 0pt; LINE-HEIGHT: 22pt; TEXT-ALIGN: center; mso-line-height-rule: exactly" align=center><FONT face="Times New Roman">2</FONT>°<p></p></P></TD></TR></TABLE>

vhxcqd

是否先考虑零件在使用上的结构及性能要求呢？

verygoodluck

楼主的压铸资料值的大家学习[em17][em17][em17]

yuhuo1954

<DIV class=quote><B>以下是引用<I>verygoodluck</I>在2005-12-3 8:06:18的发言：</B><BR>楼主的压铸资料值的大家学习[em17][em17][em17]</DIV>
<br>

jojo_wj1107

谢谢楼主，受益致用，就是有英语的更好了

sysy308

顶二楼的 替大家省钱了