极品冷镦模具设计

ContentsoftheTraining培训内容AssemblyandsetupofCOD&COK剪刀/剪模组立Assemblyandsetupofmaindies主模组立Assemblyandsetupofpunches冲头组立/失效分析Understandsteel&carbidetools模具组立/材料/钨钢Understandtoolsurface&friction模具表面/摩擦系数Understandtheeffectofpreform预成形分析10Jan2011AssemblyandsetupofCOD&COK剪刀/剪模组立AssemblyandsetupofCOD&COK1 TypesofShearing剪切类型HalfCutterCOK/CompleteCOD半剪CompleteCOK/CompleteCOD全剪COK:CutOffKnife剪刀COD:CutOffDie剪体AssemblyandsetupofCOD&COKBasicMechanismofShearing剪切基础知识WhatHappenDuringShearing:-剪切过程产生：ElasticDeformation弹性变形Roll-over曲面Plasticshear塑性剪切InitialFracture初始断裂FinalFracture最终断裂PhysicalSeparation实际剪断AssemblyandsetupofCOD&COK2 BasicMechanismofShearingQualityProblems:-质量问题OvalShape

椭圆形Tilting

歪斜Poorshear

剪切面粗糙Burr

毛刺NotStraight不直ClearanceTooBig间隙太大OptimumClearance最佳间隙ClearanceTooSmall间隙太小ElasticDeformation弹性变形Roll-over曲面Plasticshear塑性剪切InitialFracture初始断裂FinalFracture最终断裂PhysicalSeparation实际剪断AssemblyandsetupofCOD&COK2 BasicMechanismofShearing(HalfCutCOK)半剪NoControlofBlank

落料无法控制DifferentShearPatterns

剪切方式不同BlankNotStraight

线材不直BigRoll-over

曲面较大LowCost

成本低廉EasytoSetup

安装简易LongToolLife

模具寿命较长AssemblyandsetupofCOD&COK2 BasicMechanismofShearingNeedReliefSurfaces

需要表面退让（退剪槽〕CarefulControlofClearance

间隙要求高DifficultCOK/CODAlignment

剪刀、剪体对齐困难BetterShear/Quality

较好的剪切质量AchieveStraightBlank

剪断的线材较直SmallRoll-over

曲面小(CompleteCut全剪)AssemblyandsetupofCOD&COKCommonBlankQualityIssue

常见的线材剪切质量问题Roll-over

曲面Plasticshear

塑性剪切SecondaryFracture/Tongue

二次断裂/舌状毛刺Burr

毛刺Straightness

直线性1443234AssemblyandsetupofCOD&COK4 COD&COKSetting 安装Relief表面退让（退剪槽〕SmallRadius小圆角Relief表面退让（退剪槽〕AssemblyandsetupofCOD&COK5 COD&COKMaterials材料ToolSteel模具钢Carbide钨钢AssemblyandsetupofCOD&COK6 MainProcessParameters主要参参数MaterialHardness材料硬度COK/CODClearance剪刀/剪剪体间隙COK/CODDiameters剪刀/剪剪体内孔直直径COKSpeed剪刀速度Lubricants润滑TypesofCOK剪刀类型Hardermaterialsneedbiggerclearance,moretoolrelief&higherspeed当剪切较硬硬的线材时时,需要要更多的间间隙,表表面退让(退剪槽)和更快的的速度.TooloosetheCOD/COKdiameterswillbendtheblankandcausetaperends剪刀/剪剪体的内孔孔直径太大大时,会会造成线材材弯曲,线线材末端端缩小.Shearingwithoutlubricantscausesshorttoollife无润滑剪切切会缩短模模具寿命.AssemblyandsetupofCOD&COK7 UnderstandDefects缺缺陷分析析?PoorShearedSurface:smallclearanceandnotoolrelief剪切面粗糙糙:间隙隙太小/没没有表面面退让Burr:COKor/andCODwornoff毛刺:剪剪刀/剪剪体磨损Tongue:smallclearanceandnotoolrelief舌状毛刺:间隙太太小/没没有表面退退让BentBlank:COK/CODdiametertoobig线材弯曲:剪刀/剪体内内孔直径太太大OvalShape:COK/CODdiametertoobig椭圆形:剪剪刀/剪剪体内孔孔直径太大大BigRoll-over:clearancetoobigandToolwornoff曲面大:间间隙太小小/模具具磨损AssemblyandsetupofCOD&COK7 UnderstandDefects缺缺陷分析析?硬材料间隙较小剪切面较好好刀口易磨损损钨钢易破损损软材料间隙较大剪切面难控控制要退让曹材料易弯Assemblyandsetupofmaindies主模组立AssemblyandsetupofmaindiesBasicofColdForming冷锻的基础础知识MaterialsforDieConstruction模具的材质质TypesofDieDesign模具设计的的类型ImportanceofDieSurfaceFinishing模具表面加加工的重要要性CompressiveStress压应力GoodDieAssembly正确安装模模具DefectiveParts/PoorDie缺陷部件/劣质质模具AssemblyandsetupofmaindiesBasicofColdForming正挤压反挤压打头AssemblyandsetupofmaindiesBasicofColdFormingAcombinationofdiscipline,skill,knowledge&continuousimprovement.生产良好的的冷锻件，，操作者者需要具备备:纪律律,技能能,知识识和持之以以恒的进取取精神。冷锻的基础础知识AssemblyandsetupofmaindiesMaterialsforDieConstruction模具的材质质CarbideInsert钨钢HotWorkSteel耐热钢HighSpeedSteel高速钢AssemblyandsetupofmaindiesTypesofDieDesign模具设计的的类型SolidMainDie实心主模StepSolidMainDie台阶实心主主模Die-Piece/Casing/Insert套片整装主主模StepDie-Piece/Casing/Insert台阶套片整整装主模AssemblyandsetupofmaindiesTypesofDieDesign模具设计的的类型LowCost成本低廉EasyAssemble组装简易LongToolLife模具寿命长长久TheREASONfordifferentdiedesigns不同模具设设计的成因因NormalCost成本一般EasyAssemble组装简易ToolLifeShorter模具寿命较较短SomeAssemblyProblem某些组装问问题DifficulttoAlignment对齐困难ShortDie-pieceLife套片寿命短短HighCost成本昂贵SomeAssemblyProblem某些组装问问题DifficulttoAlignment对齐困难ShortDie-pieceLife套片寿命短短VeryHighCost成本最昂贵贵AssemblyandsetupofmaindiesImportanceofDieSurfaceFinishing模具表面加加工的重要要性Grindingmarkspromotecracks模具研磨纹纹路造成脆脆裂Roughsurfacespromotegalling粗糙的表面面造成表面面磨伤PoorinternalsurfacecausesshortKOPlife粗糙的内孔孔面缩短顶顶针使用寿寿命Sharpradiuscausesdiechip&fracture模具尖角太太锋利造成成模具脆裂裂或破损AssemblyandsetupofmaindiesCompressiveStress压应力Propercompressivestresstoreducematerialbreathingduringforming适当的压力力可减少在在冷锻时材材料的伸展展Increaseproductdimensionstability增加产品尺尺寸的稳定定性Extendtoollife延长模具寿寿命0.5%hot-shrink-fitinterference0.5%预热组合的的过盈配合合量0.5%coldpressinterference0.5%冷装组合过过盈配合量量0.5%taperpressinterference0.5%斜角部分的的过盈配合合量AssemblyandsetupofmaindiesGoodDieAssembly正确组装模模具Positivesteptoensurepropersupportofdiepiecebydieinsert有效间隙以以保证给予予套片适当当的支撑Positivesteptoensurepropersupportofdieinsert有效台阶以以保证给予予组合套心心适当的支支撑SufficientchamferProperinstallationofdiepiece适当安装套套片SufficientInterference足够的过盈盈量足够的倒角角AssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具具DiePieceBreaks:套片破裂1 Diepieceanddiecaseoffcenters套片和主模模套偏心2 Roughsurfaces/insufficientpolishing表面粗糙/研磨磨,抛光不不足3 Poormatchingoftapersurfaces斜角部分配配合不好4 Insufficientcompressivestress压力不足5 Nopropersupportfromdieinsert组合套心没没有给予套套片恰当的的支撑6 Insufficientstepradius台阶部分圆圆角太小7 Poorpunch/diealignment冲件/主主模没有有对齐8 Blankover-length线材剪切太太长9 PunchRecesshitting二冲窜伤10HighKOforce(taper/overforged/roughsurface)顶出力太大大(倒锥，太饱饱满，表面面粗糙）AssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具具StepDieFractures:台阶主模破破损Hydrauliceffect/toomuchoil/air&oiltrap液压影响/润滑滑油太多/憋气憋油Insufficientstepradius台阶部分圆圆角太小Roughsurfaces/insufficientpolishing表面粗糙/研磨磨,抛光光不足Poorpunch/diealignment冲件/主主模没有有对齐Blankover-length线材剪切太太长Poorhot-shrink-fit预热组装配配合差Heavyknockoutaction顶针冲击力力过大PunchRecesshitting二冲窜伤HighKOforce(taper/overforged/roughsurface)顶出力太大大(倒锥，太饱饱满，表面面粗糙）AssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具具MainDieChipoff/Cracks:主模脆裂Impropersittingofmaindie主模安装位位置不正确确Insufficientstepradius台阶部分圆圆角太小Roughsurfaces/insufficientpolishing表面粗糙/研磨磨,抛光光不足Poorpunch/diealignment冲件/主主模没有有对齐Blankover-length线材剪切太太长Poorhot-shrink-fit预热组装配配合不好Overknockoutaction顶针行程过过大PunchRecesshitting二冲窜伤AssemblyandsetupofmaindiesDefectiveParts/PoorDies缺陷部件/劣质质模具Diewear:模具磨损Poorhot-shrink-fit预热组装配配合不好Poorpunch/part/diealignment冲件/冲冲头/主模没有对对齐Wrongcarbidegrades选择错误的的钨钢等级级Insufficientorwronglubricant润滑不足或或用错润滑滑油PartsDefects:部件缺陷Gallingduetomisalignment/poorcarbide磨伤--模模具没有对对齐/劣劣质钨钢钢Blankdiameteroversizeduetopoorhot-shrinkfit光杆直径太太大--预预热组装配配合差Blankdiameterundersizeduetowrongdiediameter光杆直径太太小--主主模内径错错误Inconsistentblankdiameterduetodiediametertoobig光杆直径不不稳定--主模内径径太大Roughsurfacesduetopoordiepolishing表面粗糙--模具研研磨,抛抛光不足Assemblyandsetupofpunches冲头组立/失效分析Timing/Speed时间/速度Friction摩擦系数Alignment对齐HowPunchesFail二冲如何损损坏CommonPunchProblems常见二冲问问题CommonProductProblems常见产品问问题Timing/Speed时间/速度4m/sec(4米/秒)1m/sec(1米/秒)(MH-10Machine)(UI-10Machine)Friction摩擦系数ToolDimension(cancheck)模具尺寸(可以测量)ToolSurfaceRoughness(difficulttocheck)模具表面粗粗糙度(较难测量)Friction摩擦系数ChangingFactors:-影响因素LubricationOil润滑油ToolSurfaceRoughness模具粗糙度度PreformSetting一冲成形设设置MachineSpeed机器速度ChangingDimension:-受影响尺寸寸Flatness平直度HeadCornerRadii头部圆角HeadRoundness头部圆度Headdiameter头部直径Alignment对齐PrematureWearofRecessIncorrectHeadShapePrematureBreakofRecessOff-centerRecess(<0.05mm)梅花部分磨磨损头形错误梅花部分破破裂梅花偏心(<0.05mm)HowPunchesFail1.WearoffIncorrectHardness(AboveHRC65)InsufficientLubricantIncorrectPunchMaterial(M2,M42,Carbide)WithoutCoating(TiN,TiCN,TiAlN)PoorPreform(1stPunchPreparation)NatureWear2.ChipOffPoorAlignmentPoorSetupSkillPoorsurfaceIncorrectPunchMaterialMishandlingVibrationSpeedtooFast3.BreakoffRecessStrippedoffbending/MisalignmentPinandInsertMismatchIncorrectPreform(1stPunchPreparation)SpeedtooFastWrong/InstableProcessHighFrictionPoorCutOff1121233二冲如何损损坏1.磨损硬度错误(高于HRC65)润滑不足二冲材质错错误(M2,M42,Carbide)没有涂层层(TiN,TiCN,TiAlN)一冲成形差差(1stPunchPreparation)自然磨损2.破损没有对齐安装技术差差表面粗糙二冲材质错错误人为损坏震动机器速度太太快3.断裂梅花破裂二冲棒弯曲曲/没有对齐二冲套和冲冲棒不配一冲成形错错误(1stPunchPreparation)速度太快错误/不稳定生产产程序摩擦系数太太大线材剪断不不良1121233CommonPunchProblemsShortToolLifeIncorrectHardness(AboveHRC65)InsufficientLubricantIncorrectPunchMaterial(M2,M42,Carbide)WithoutCoating(TiN,TiCN,TiAlN)PoorPreform(1stPunchPreparation)PoorAlignmentPoorSetupSkillPunchMaterialtooHard(AboveHRC68)MishandlingVibrationSpeedtooFastWrong/InstableProcessHighFrictionDimensionoutPoorToolSuppliersPoorReworkToolingnotmatchOrderWrongToolPoorToolSuppliers常见二冲问问题寿命短硬度错误(高于HRC65)润滑不足二冲材质错错误(M2,M42,Carbide)没有涂层(TiN,TiCN,TiAlN)一冲成形问问题(1stPunchPreparation)没有对齐安装技术差差二冲材质太太硬(高于HRC68)人为损坏震动机器速度太太快错误/不稳定生产产程序摩擦系数太太大尺寸错误模具供应商商不佳模具修改误误差模具不能配配合购买错误模模具模具供应商商不佳CommonProductProblems常见产品问问题IncorrectRecessProfileLubricationOilToolSurfaceRoughnessIncorrectToolDimensionIncorrectRecessDepthRecessWearRecessChipoffRecessOff-setPoorPunchAlignmentPoorPreformPoorCutoffBigChamferLubricationOilIncorrectToolDimensionIncorrectPreformUnusualVisualDefectsLubricationOilToolSurfaceRoughnessIncorrectToolDimension成形形状不不正确润滑油模具表面粗粗糙度模具尺寸不不正确成形深度不不正确冲棒磨损冲棒破损成形偏心二冲没有对对齐一冲成形差差线材剪断不不良斜角大润滑油模具尺寸不不正确一冲成形不不正确非正常的外外观缺陷润滑油模具表面粗粗糙度模具尺寸不不正确4.Understandsteel&carbidetoolsManufacturingofFastenersandforgingpartsfallinthesamefamily紧固件与冷冷锻件的生生产工艺LowcarbonsteelAnti-gallingSUS高耐磨不锈锈钢Hotworksteel耐热钢Generaltoolsteel普通工具钢钢Highspeedsteel高速钢Coarsegraincarbide粗颗粒钨钢钢Finegraincarbide细颗粒钨钢钢300SUS400SUS4000Mpa兆帕3000MPa2000MPa1000MPaHowStrongisStrong钢的强度对对照表1000Mpa=100kg/mm21000兆帕=100千克/毫米2低炭钢300系列不锈钢钢400系列不锈钢钢DieDesign模具设设计螺纹锁紧件件套壳上套心下套心钨钢套心衬套给予轴轴向预先加加压123GoodDieAssembly正确组组装模具预先加压卸载加载phase1cyclicloading

oftheundamagedmaterial材料受力而产生反复的胀缩变形phase2initiationof

microcracks

a<0.1mm开始出现微小的裂痕phase3mergingofmicrocrackstosurfacedefectsandlargercracks0.1<a<0.5mm微小的裂痕痕深入到表表面，使使裂纹加加深phase4growthoflargercracks

a>0.5mm演变成更大的裂痕CarbideInsert钨钢HotWorkSteel耐热钢HighSpeedSteel高速钢5.Understandtoolsurface&frictionUnderstandtoolsurface&friction理解模具表表面及摩擦擦力Whatisfriction什什么是摩摩擦力?Effectoffriction摩擦擦力产生的的影响?Practicalconsiderations应应用时需需考虑的因因素?Whatisfriction什么是摩擦擦力?YForce拉力XForce压力FrictionCoefficientm=Xforce/Yforce摩擦系数m=X压力/Y拉力NormalFrictionCoefficientformetalforming=0.05to0.2通常金属表表面磨擦系系数=0.05to0.2Effectoffriction摩擦擦力产生的的因素AssumeHighToolFriction采用摩擦力力大的模具具AssumeLowToolFriction采用摩擦力力小的模具具Effectoffriction摩擦擦系数产生生的影响?AssumeLowToolFriction采用摩擦力力小的模具具AssumeLowToolFriction采用摩擦力力小的模具具Effectoffriction摩擦擦系数所产产生的影响响AssumeLowToolFriction摩擦力那那一边大小小？?Practicalconsiderations实际情况需需考虑因素素??Practicalconsiderations实际情况考考虑因素Understandtheeffectofpreform了解预成型型的影响Understandtheeffectofpreform了解预成型型的影响WhatisPreform什么是预成成型Whatisanoptimisedpreform什么是好的的预成型Theeffectofpreform预成型的影影响Whatisanoptimisedprocesscontrol什么是好的的预成型过过程控制Canpreformbealwaysbethesame预成型都是是相同的吗吗?Shouldwehaveapreformdrawing我们需要预预成型图纸纸吗WhatisPreform什什么是预成成型?Whatisanoptimisedpreform什么是好的的预成型?Operational:-操作方面?ToolLife:-模具寿命方方面?ProductQuality:-产品质量方方面?Whatisanoptimisedpreform什么是好的的预成型Operational:-操作方面Controllable可控制的Achievable能够完成的的Stable稳定的Maintainable可持续的Lowcost低成本的Manufacturable可操作的Repeatable可重复的Independent不受制约的的ToolLife:-模具寿命方方面Lowpunchforce低冲力Lowpunchstress低压力Manufacturable可持续的Lowcost低成本的ProlongOperation延长生产力力ProductQuality:-产品质量方方面No/MinimumDefects无缺陷或缺缺陷最小Achieveconsistentquality达到品质一一致Achieverequireddimension达到要求尺尺寸Theeffectofpreform预成型的影影响Operational:-操作方面Controllable可控制的Achievable可实现的Stable稳定的Maintainable可持续的Lowcost低成本的Manufacturable可操作的Repeatable可重复的Independent不受约束的的ToolLife:-模具寿命Lowpunchforce低冲力Lowpunchstress低压力Manufacturable可操作Lowcost低成本ProlongOperation延长生产力力ProductQuality:-产品质量No/MinimumDefects无/最小缺缺陷Achieveconsistentquality达到质量一一致Achieverequireddimension达到要求尺尺寸Punchforce冲力Punchstress压力Toolwear模具磨损Laps/Folds褶皱Surface表面条件Dimensions尺寸Toollife模具寿命Partquality部品质量Theeffectofpreform预成型的影影响Test1:-试验1WidePunchChamferAngle冲模倒角较较大Test2:-试验2SmallPunchChamferAngle冲模倒角较较小FormingoffastenersusingdifferentPreformdesign(effectofpreformonthefinalformingshape)采用不同预预成型的产产品的最后后成型Using5113forIllustration以5113为例矮扁的预成成形较高的预成成形Theeffectofpreform预成型的影影响Higherformingpressure较高的成型型压力Lowerformingpressure较低的成型型压力Fastenerformingusingflatterpreform采用扁而平平的预成型型Fastenerformingusingtallerpreform采用较高的的预成型矮扁的预成成形较高的预成成形Theeffectofpreform预成型的影影响Tallerpreform高预成型Lowpunchforce冲力小Longertoollife模具寿命长长Stableprocess过程稳定MajorFolds较大褶皱LowerPreform低预成型Highpunchforce冲力大Shortertoollife模具寿命短短Minimumfolds褶皱最小Ringmark环状痕迹Theeffectofpreform预成型的影影响Thegeometryofpreformisdefinedby:预成型形状状具体取决决于:profile外形height高度diameter直径weight重量Thegeometryofpreformisaffectedby:影响预成型型形状的因因素:Tooltemperature模具的温度度Lubricationoil润滑油Machinestability机台的稳定定性Machinespeed机台速度Too