電腦輔助冷沖壓連續沖模設計之研究

1960年代後由於工業快速發展，產品需求趨向於大量生產及自動化，使沖壓製程發展出連續沖壓模具。由於連續沖模具有高精度、高效率、壽命長等特性，且便於操作和實現生產自動化，成為現代製造業主要的模具類型。保證連續沖模維持正常工作，必須具有高精度的導向和準確的定距系統，故連續沖模在設計過程上比一般單工程模具要複雜許多，成本也連帶提高。現代模具設計廣泛應用電腦輔助設計(Computer-Aided Design，CAD)技術，該技術將電腦快速準確的運算能力，和模具設計人員的設計經驗與綜合分析能力結合起來，有效縮短設計週期和簡化設計過程。本研究在文獻探討的部分，大致分為沖模設計理論和電腦輔助模具設計原理兩個部分。首先在沖模設計理論中探討沖剪、彎曲、引伸等三種主要的沖壓加工相關原理。討論沖壓件結構設計的各方面影響因素，對於連續沖模設計原理(料帶佈置設計、沖壓件加工性分析、加工方案分析與確定)，提出在連續沖模之設計過程中需要注意的問題。在電腦輔助模具設計原理的部分，說明連續沖模設計系統的組成架構由應用系統、資料系統、輔助系統及圖形系統所組成。描述電腦輔助連續模具設計的相關流程，主要分為繪製成品圖、料帶設計、組立圖設計、成品圖完成。以及介紹目前市面上幾種常見的連續沖模設計軟體。本研究使用VISI連續沖模設計軟體，首先介紹VISI軟體之操作介面環境，並利用實例示範VISI軟體中有關於2D草圖繪製工具、3D實體建構工具、製品胚料展開、料帶排列設計、模具總體建構、沖頭設計、插入沖模標準件等功能。利用詳細的操作過程，說明VISI軟體內建之各種專為連續沖模設計的模組化功能。本研究以一大樓外牆之固定錨件為例，使用沖模設計理論以及VISI軟體，建構出用來生產錨件之連續沖壓模具。首先利用沖模設計理論，對沖壓件進行結構加工性分析，接著設計幾種不同的沖壓加工方案進行比較，選出最適合的加工方案。再選定中立線折彎係數值以VISI計算出胚料的展開長度，以及計算沖壓過程中所需要的沖壓力。以沖壓力為依據選擇適合之沖壓設備後，進行模具總體結構設計，最後加工為實體進行沖壓試驗，以驗證模具設計的合理性。結果顯示，利用電腦輔助連續沖模設計軟體進行模具設計，可快速、有效率的完成連續沖模設計，縮短模具開發時程，增加模具設計的競爭力。

關鍵字

沖模設計理論； CAD ；連續沖模； VISI

並列摘要

After the 1960s due to rapid industrial development, product demand tends to mass production and automation, so that the stamping process to develop the progressive stamping dies. The progressive die with high precision, high efficiency, long life and other characteristics, and ease of operation and production automation, modern manufacturing mold type. Ensure continuous die to maintain normal work, you must have a high-precision-oriented and accurate distance system, it is continuous die in the design process on many complex than the general single project mold, also contributed to increased costs. Modern mold design widely used computer-aided design (Computer-Aided Design, CAD) technology, the technology is a computer quickly and accurately computing power and experience in the design of the mold design staff, and comprehensive analysis capabilities combine to effectively shorten the design cycle and simplify the design process. In this study, part of the literature, divided into two parts of the die design theory and computer-aided mold design principles. First in the die design theory to explore the three main punching, bending, extension and other stamping processing principle. Stampings structural design of influencing factors for progressive die design principles (the strip layout design, stamping parts processing, analysis and processing program analysis and determination), raised issues that need attention in progressive die design process. Part of the computer-aided mold design principles, indicating that the composition of progressive die design system composed by the application systems, information systems, auxiliary systems and graphics system. Description of computer-assisted continuous mold design process, divided into the main draw of the finished map, strip layout, assembly drawing design, completion of the finished map. As well as the introduction of the market at present several common progressive die design software. In this study, using VISI continuous die design software, first introduced VISI software user interface environment, and use an example from VISI software 2D sketching tools, 3D entities construct tools, products billet to commence strip arrangement design, mold overall constructpunch design, insert die standard parts and functions. The details of the operation, the module features built-in VISI software designed for continuous die design. In this study, the anchors of a building's exterior walls, for example, die design theory and VISI software to construct the stamping dies used to produce anchors. First use of die design theory, structural stampings processing analysis, then design several different punching processing program, choose the most appropriate processing program. Selected neutral line bending coefficient calculated to VISI expand the length of the billet, and calculate the impulse pressure in the stamping process. Mold the overall structural design of the blast pressure is the basis for the stamping equipment, and final processing entity stamping test, to verify the rationality of the mold design. The results show that the use of computer-assisted continuous mold design and die design software, for quick, efficient completion of progressive die design, shorten the mold development process and increase the mold design competitiveness.