冷镦模具设计培训资料

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模具外表/摩擦系数Understandtheeffectofpreform预成形分析10Jan2021精选pptAssemblyandsetupofCOD&COK剪刀/剪模组立精选pptAssemblyandsetupofCOD&COK1 TypesofShearing

剪切类型HalfCutterCOK/CompleteCOD半剪CompleteCOK/CompleteCOD全剪COK:CutOffKnife

剪刀COD:CutOffDie

剪体精选pptAssemblyandsetupofCOD&COKBasicMechanismofShearing剪切根底知识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实际剪断精选pptAssemblyandsetupofCOD&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最正确间隙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实际剪断精选pptAssemblyandsetupofCOD&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 本钱低廉EasytoSetup 安装简易LongToolLife 模具寿命较长精选pptAssemblyandsetupofCOD&COK2 BasicMechanismofShearingNeedReliefSurfaces 需要外表退让〔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)精选pptAssemblyandsetupofCOD&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1443234精选pptAssemblyandsetupofCOD&COK4 COD&COKSetting

安装Relief外表退让〔退剪槽〕SmallRadius小圆角Relief外表退让〔退剪槽〕精选pptAssemblyandsetupofCOD&COK5 COD&COKMaterials材料ToolSteel模具钢Carbide钨钢精选pptAssemblyandsetupofCOD&COK6

MainProcessParameters主要参数MaterialHardness

材料硬度COK/CODClearance剪刀/剪体间隙COK/CODDiameters剪刀/剪体内孔直径COKSpeed

剪刀速度Lubricants

润滑TypesofCOK

剪刀类型Hardermaterialsneedbiggerclearance,moretoolrelief&higherspeed当剪切较硬的线材时,需要更多的间隙,外表退让(退剪槽)和更快的速度.TooloosetheCOD/COKdiameterswillbendtheblankandcausetaperends剪刀/剪体的内孔直径太大时,会造成线材弯曲,线材末端缩小.Shearingwithoutlubricantscausesshorttoollife无润滑剪切会缩短模具寿命.精选pptAssemblyandsetupofCOD&COK7 UnderstandDefects缺陷分析?PoorShearedSurface:smallclearanceandnotoolrelief 剪切面粗糙:间隙太小/没有外表退让Burr:COKor/andCODwornoff 毛刺:剪刀/剪体磨损Tongue:smallclearanceandnotoolrelief 舌状毛刺:间隙太小/没有外表退让BentBlank:COK/CODdiametertoobig 线材弯曲:剪刀/剪体内孔直径太大OvalShape:COK/CODdiametertoobig 椭圆形:剪刀/剪体内孔直径太大BigRoll-over:clearancetoobigandToolwornoff 曲面大:间隙太小/模具磨损精选pptAssemblyandsetupofCOD&COK7 UnderstandDefects缺陷分析?硬材料间隙较小剪切面较好刀口易磨损钨钢易破损软材料间隙较大剪切面难控制要退让曹材料易弯精选pptAssemblyandsetupofmaindies主模组立精选pptAssemblyandsetupofmaindiesBasicofColdForming 冷锻的根底知识MaterialsforDieConstruction 模具的材质TypesofDieDesign 模具设计的类型ImportanceofDieSurfaceFinishing 模具外表加工的重要性CompressiveStress 压应力GoodDieAssembly 正确安装模具DefectiveParts/PoorDie 缺陷部件/劣质模具

精选pptAssemblyandsetupofmaindiesBasicofColdForming正挤压反挤压打头精选pptAssemblyandsetupofmaindiesBasicofColdFormingAcombinationofdiscipline,skill,knowledge&continuousimprovement.生产良好的冷锻件，操作者需要具备:纪律,技能,知识和持之以恒的进取精神。冷锻的根底知识精选pptAssemblyandsetupofmaindiesMaterialsforDieConstruction模具的材质

CarbideInsert钨钢HotWorkSteel耐热钢HighSpeedSteel高速钢精选pptAssemblyandsetupofmaindiesTypesofDieDesign模具设计的类型SolidMainDie实心主模StepSolidMainDie台阶实心主模

Die-Piece/Casing/Insert套片整装主模StepDie-Piece/Casing/Insert台阶套片整装主模精选pptAssemblyandsetupofmaindiesTypesofDieDesign模具设计的类型LowCost本钱低廉EasyAssemble组装简易LongToolLife模具寿命长久TheREASONfordifferentdiedesigns不同模具设计的成因NormalCost本钱一般EasyAssemble组装简易ToolLifeShorter模具寿命较短SomeAssemblyProblem某些组装问题DifficulttoAlignment对齐困难ShortDie-pieceLife套片寿命短HighCost本钱昂贵SomeAssemblyProblem某些组装问题DifficulttoAlignment对齐困难ShortDie-pieceLife套片寿命短VeryHighCost本钱最昂贵精选pptAssemblyandsetupofmaindiesImportanceofDieSurfaceFinishing 模具外表加工的重要性Grindingmarkspromotecracks 模具研磨纹路造成脆裂Roughsurfacespromotegalling 粗糙的外表造成外表磨伤PoorinternalsurfacecausesshortKOPlife 粗糙的内孔面缩短顶针使用寿命Sharpradiuscausesdiechip&fracture 模具尖角太锋利造成模具脆裂或破损精选pptAssemblyandsetupofmaindiesCompressiveStress压应力Propercompressivestresstoreducematerialbreathingduringforming

适当的压力可减少在冷锻时材料的伸展Increaseproductdimensionstability

增加产品尺寸的稳定性Extendtoollife

延长模具寿命0.5%hot-shrink-fitinterference0.5%预热组合的过盈配合量0.5%coldpressinterference0.5%冷装组合过盈配合量0.5%taperpressinterference0.5%斜角局部的过盈配合量精选pptAssemblyandsetupofmaindiesGoodDieAssembly正确组装模具Positivesteptoensurepropersupportofdiepiecebydieinsert有效间隙以保证给予套片适当的支撑Positivesteptoensurepropersupportofdieinsert有效台阶以保证给予组合套心适当的支撑SufficientchamferProperinstallationofdiepiece适当安装套片SufficientInterference足够的过盈量足够的倒角精选pptAssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具DiePieceBreaks:套片破裂1 Diepieceanddiecaseoffcenters 套片和主模套偏心2 Roughsurfaces/insufficientpolishing 外表粗糙/研磨,抛光缺乏3 Poormatchingoftapersurfaces 斜角局部配合不好4 Insufficientcompressivestress 压力缺乏5 Nopropersupportfromdieinsert 组合套心没有给予套片恰当的支撑6 Insufficientstepradius 台阶局部圆角太小7 Poorpunch/diealignment 冲件/主模没有对齐8 Blankover-length 线材剪切太长9 PunchRecesshitting 二冲窜伤10 HighKOforce(taper/overforged/roughsurface) 顶出力太大(倒锥，太饱满，外表粗糙〕精选pptAssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具StepDieFractures:台阶主模破损Hydrauliceffect/toomuchoil/air&oiltrap 液压影响/润滑油太多/憋气憋油Insufficientstepradius 台阶局部圆角太小Roughsurfaces/insufficientpolishing 外表粗糙/研磨,抛光缺乏Poorpunch/diealignment 冲件/主模没有对齐Blankover-length 线材剪切太长Poorhot-shrink-fit 预热组装配合差Heavyknockoutaction 顶针冲击力过大PunchRecesshitting 二冲窜伤HighKOforce(taper/overforged/roughsurface)顶出力太大(倒锥，太饱满，外表粗糙〕精选pptAssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具MainDieChipoff/Cracks:主模脆裂Impropersittingofmaindie 主模安装位置不正确Insufficientstepradius 台阶局部圆角太小Roughsurfaces/insufficientpolishing 外表粗糙/研磨,抛光缺乏Poorpunch/diealignment 冲件/主模没有对齐Blankover-length 线材剪切太长Poorhot-shrink-fit 预热组装配合不好Overknockoutaction 顶针行程过大PunchRecesshitting 二冲窜伤精选pptAssemblyandsetupofmaindiesDefectiveParts/PoorDies 缺陷部件/劣质模具Diewear:模具磨损Poorhot-shrink-fit预热组装配合不好Poorpunch/part/diealignment冲件/冲头/主模没有对齐Wrongcarbidegrades选择错误的钨钢等级Insufficientorwronglubricant润滑缺乏或用错润滑油PartsDefects:部件缺陷Gallingduetomisalignment/poorcarbide磨伤--模具没有对齐/劣质钨钢Blankdiameteroversizeduetopoorhot-shrinkfit光杆直径太大--预热组装配合差Blankdiameterundersizeduetowrongdiediameter光杆直径太小--主模内径错误Inconsistentblankdiameterduetodiediametertoobig光杆直径不稳定--主模内径太大Roughsurfacesduetopoordiepolishing外表粗糙--模具研磨,抛光缺乏精选pptAssemblyandsetupofpunches冲头组立/失效分析精选pptTiming/Speed时间/速度Friction摩擦系数Alignment对齐HowPunchesFail二冲如何损坏CommonPunchProblems常见二冲问题CommonProductProblems常见产品问题

精选pptTiming/Speed时间/速度4m/sec(4米/秒)1m/sec(1米/秒)(MH-10Machine)(UI-10Machine)精选pptFriction摩擦系数ToolDimension(cancheck)模具尺寸(可以测量)ToolSurfaceRoughness(difficulttocheck)模具外表粗糙度(较难测量)精选pptFriction摩擦系数ChangingFactors:-影响因素LubricationOil润滑油ToolSurfaceRoughness模具粗糙度PreformSetting一冲成形设置MachineSpeed机器速度ChangingDimension:-受影响尺寸Flatness平直度HeadCornerRadii头部圆角HeadRoundness头部圆度Headdiameter头部直径精选pptAlignment对齐PrematureWearofRecessIncorrectHeadShapePrematureBreakofRecessOff-centerRecess(<0.05mm

)梅花局部磨损头形错误梅花局部破裂梅花偏心(<0.05mm)精选pptHowPunchesFail1.WearoffIncorrectHardness(AboveHRC65)InsufficientLubricantIncorrectPunchMaterial(M2,M42,Carbide)WithoutCoating(TiN,TiCN,TiAlN)PoorPreform(1stPunchPreparation)NatureWear2.ChipOffPoorAlignmentPoorSetupSkillPoorsurfaceIncorrectPunchMaterialMishandlingVibrationSpeedtooFast3.BreakoffRecessStrippedoffbending/MisalignmentPinandInsertMismatchIncorrectPreform(1stPunchPreparation)SpeedtooFastWrong/InstableProcessHighFrictionPoorCutOff1121233精选ppt二冲如何损坏1.磨损硬度错误(高于HRC65)润滑缺乏二冲材质错误(M2,M42,Carbide)没有涂层(TiN,TiCN,TiAlN)一冲成形差(1stPunchPreparation)自然磨损2.破损没有对齐安装技术差外表粗糙二冲材质错误人为损坏震动机器速度太快3.断裂梅花破裂二冲棒弯曲/没有对齐二冲套和冲棒不配一冲成形错误(1stPunchPreparation)速度太快错误/不稳定生产程序摩擦系数太大线材剪断不良1121233精选pptCommonPunchProblemsShortToolLifeIncorrectHardness(AboveHRC65

)InsufficientLubricantIncorrectPunchMaterial(M2,M42,Carbide)WithoutCoating(TiN,TiCN,TiAlN)PoorPreform(1stPunchPreparation)PoorAlignmentPoorSetupSkillPunchMaterialtooHard(AboveHRC68

)MishandlingVibrationSpeedtooFastWrong/InstableProcessHighFrictionDimensionoutPoorToolSuppliersPoorReworkToolingnotmatchOrderWrongToolPoorToolSuppliers精选ppt常见二冲问题寿命短硬度错误(高于HRC65)润滑缺乏二冲材质错误(M2,M42,Carbide)没有涂层(TiN,TiCN,TiAlN)一冲成形问题(1stPunchPreparation)没有对齐安装技术差二冲材质太硬(高于HRC68)人为损坏震动机器速度太快错误/不稳定生产程序摩擦系数太大尺寸错误模具供给商不佳模具修改误差模具不能配合购置错误模具模具供给商不佳精选pptCommonProductProblems常见产品问题IncorrectRecessProfileLubricationOilToolSurfaceRoughnessIncorrectToolDimensionIncorrectRecessDepthRecessWearRecessChipoffRecessOff-setPoorPunchAlignmentPoorPreformPoorCutoffBigChamferLubricationOilIncorrectToolDimensionIncorrectPreformUnusualVisualDefectsLubricationOilToolSurfaceRoughnessIncorrectToolDimension成形形状不正确润滑油模具外表粗糙度模具尺寸不正确成形深度不正确冲棒磨损冲棒破损成形偏心二冲没有对齐一冲成形差线材剪断不良斜角大润滑油模具尺寸不正确一冲成形不正确非正常的外观缺陷润滑油模具外表粗糙度模具尺寸不正确精选ppt4.Understandsteel&carbidetools精选pptManufacturingofFastenersandforgingpartsfallinthesamefamily紧固件与冷锻件的生产工艺精选pptLowcarbonsteelAnti-gallingSUS

高耐磨不锈钢Hotworksteel

耐热钢Generaltoolsteel

普通工具钢Highspeedsteel

高速钢Coarsegraincarbide

粗颗粒钨钢Finegraincarbide

细颗粒钨钢300SUS400SUS4000Mpa兆帕3000MPa2000MPa1000MPaHowStrongisStrong钢的强度对照表1000Mpa=100kg/mm21000

兆帕=100千克/毫米2低炭钢300系列不锈钢400系列不锈钢精选pptDieDesign模具设计螺纹锁紧件套壳上套心下套心钨钢套心衬套给予轴向预先加压精选ppt123GoodDieAssembly正确组装模具预先加压卸载加载精选pptphase1cyclicloading

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phase3mergingofmicrocrackstosurfacedefectsandlargercracks

0.1<a<0.5mm微小的裂痕深入到外表，使裂纹加深phase4growthoflargercracks

a>0.5mm演变成更大的裂痕CarbideInsert钨钢HotWorkSteel耐热钢HighSpeedSteel高速钢精选ppt5.Understandtoolsurface&friction精选pptUnderstandtoolsurface&friction理解模具外表及摩擦力Whatisfriction什么是摩擦力?Effectoffriction摩擦力产生的影响?Practicalconsiderations应用时需考虑的因素?精选pptWhatisfriction什么是摩擦力?YForce拉力XForce压力FrictionCoefficientm=Xforce/Yforce摩擦系数m=X压力/Y拉力NormalFrictionCoefficientformetalforming=0.05to0.2通常金属外表磨擦系数=0.05to0.2精选pptEffectoffriction摩擦力产生的因素AssumeHighToolFriction采用摩擦力大的模具AssumeLowToolFriction采用摩擦力小的模具精选pptEffectoffriction摩擦系数产生的影响?AssumeLowToolFriction采用摩擦力小的模具AssumeLowToolFriction采用摩擦力小的模具精选pptEffectoffriction摩擦系数所产生的影响AssumeLowToolFriction摩擦力那一边大小？?精选pptPracticalconsiderations实际情况需考虑因素??精选pptPracticalconsiderations实际情况考虑因素精选pptUnderstandtheeffectofpreform了解预成型的影响精选pptUnderstandtheeffectofpreform了解预成型的影响WhatisPreform什么是预成型Whatisanoptimisedpreform什么是好的预成型Theeffectofpreform预成型的影响Whatisanoptimisedprocesscontrol什么是好的预成型过程控制Canpreformbealwaysbethesame预成型都是相同的吗?Shouldwehaveapreformdrawing我们需要预成型图纸吗精选pptWhatisPreform什么是预成型?精选pptWhatisanoptimisedpreform什么是好的预成型?Operational:-操作方面?ToolLife:-模具寿命方面?ProductQuality:-产品质量方面?精选pptWhatisanoptimisedpreform什么是好的预成型Operational:-操作方面Controllable可控制的Achievable能够完成的Stable稳定的Maintainable可持续的Lowcost低本钱的Manufacturable可操作的Repeatable可重复的Independent不受制约的ToolLife:-模具寿命方面Lowpunchforce低冲力Lowpunchstress低压力Manufacturable可持续的Lowcost低本钱的ProlongOperation延长生产力ProductQuality:-产品质量方面No/MinimumDefects无缺陷或缺陷最小Achieveconsistentquality到达品质一致Achieverequireddimension到达要求尺寸精选pptTheeffectofpreform预成型的影响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低本钱的Manufacturable可操作的Repeatable可重复的Independent不受约束的ToolLife:-模具寿命Lowpunchforce低冲力Lowpunchstress低压力Manufacturable可操作Lowcost低本钱ProlongOperation延长生产力ProductQuality:-产品质量No/MinimumDefects无/最小缺陷Achieveconsistentquality到达质量一致Achieverequireddimension到达要求尺寸Punchforce冲力Punchstress压力Toolwear模具磨损Laps/Folds褶皱Surface外表条件Dimensions尺寸Toollife模具寿命Partquality部品质量精选pptTheeffectofpreform预成型的影响Test1:-试验1WidePunchChamferAngle冲模倒角较大Test2:-试验2SmallPunchChamferAngle冲模倒角较小FormingoffastenersusingdifferentPreformdesign(effectofpreformonthefinalformingshape)采用不同预成型的产品的最后成型Using5113forIllustration以5113为例矮扁的预成形较高的预成形精选pptTheeffectofpreform预成型的影响Higherformingpressure较高的成型压力Lowerformingpressure较低的成型压力Fastenerformingusingflatterpreform采用扁而平的预成型Fastenerformingusingtallerpreform采用较高的预成型矮扁的预成形较高的预成形精选pptTheeffectofpreform预成型的影响Tallerpreform高预成型Lowpunchforce冲力小Longertoollife模具寿命长Stableprocess过程稳定