冷镦模具设计培训资料.ppt
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1、Contents of the Training 培训内容 Assembly and setup of COD & COK 剪刀/剪模组立 Assembly and setup of main dies主模组立 Assembly and setup of punches冲头组立/失效分析 Understand steel & carbide tools模具组立/材料/钨钢 Understand tool surface & friction 模具表面/摩擦系数 Understand the effect of preform预成形分析,10 Jan 2011,Assembly and setu
2、p of COD & COK 剪刀/剪模组立,Assembly and setup of COD & COK,1 Types of Shearing 剪切类型,Half Cutter COK / Complete COD 半剪,Complete COK / Complete COD 全剪,COK: Cut Off Knife 剪刀 COD: Cut Off Die 剪体,Assembly and setup of COD & COK,Basic Mechanism of Shearing 剪切基础知识,What Happen During Shearing:- 剪切过程产生: Elastic
3、Deformation 弹性变形 Roll-over 曲面 Plastic shear 塑性剪切 Initial Fracture 初始断裂 Final Fracture 最终断裂 Physical Separation 实际剪断,Assembly and setup of COD & COK,2 Basic Mechanism of Shearing,Quality Problems:- 质量问题 Oval Shape 椭圆形 Tilting 歪斜 Poor shear 剪切面粗糙 Burr 毛刺 Not Straight 不直,Clearance Too Big 间隙太大,Optimum
4、Clearance 最佳间隙,Clearance Too Small 间隙太小,Elastic Deformation 弹性变形 Roll-over 曲面 Plastic shear 塑性剪切 Initial Fracture 初始断裂 Final Fracture 最终断裂 Physical Separation 实际剪断,Assembly and setup of COD & COK,2 Basic Mechanism of Shearing (Half Cut COK) 半剪,No Control of Blank 落料无法控制 Different Shear Patterns 剪切方式
5、不同 Blank Not Straight 线材不直 Big Roll-over 曲面较大 Low Cost 成本低廉 Easy to Setup 安装简易 Long Tool Life 模具寿命较长,Assembly and setup of COD & COK,2 Basic Mechanism of Shearing,Need Relief Surfaces 需要表面退让(退剪槽 Careful Control of Clearance 间隙要求高 Difficult COK/COD Alignment 剪刀、剪体对齐困难 Better Shear / Quality 较好的剪切质量 A
6、chieve Straight Blank 剪断的线材较直 Small Roll-over 曲面小,(Complete Cut 全剪),Assembly and setup of COD & COK,Common Blank Quality Issue 常见的线材剪切质量问题,Roll-over 曲面 Plastic shear 塑性剪切 Secondary Fracture / Tongue 二次断裂 / 舌状毛刺 Burr 毛刺 Straightness 直线性,Assembly and setup of COD & COK,4 COD & COK Setting 安装,Relief 表面
7、退让 (退剪槽,Small Radius 小圆角,Relief 表面退让 (退剪槽,Assembly and setup of COD & COK,5 COD & COK Materials 材料,Tool Steel 模具钢 Carbide 钨钢,Assembly and setup of COD & COK,6 Main Process Parameters 主要参数,Material Hardness 材料硬度 COK/COD Clearance 剪刀/ 剪体间隙 COK/COD Diameters 剪刀/ 剪体内孔直径 COK Speed 剪刀速度 Lubricants 润滑 Type
8、s of COK 剪刀类型,Harder materials need bigger clearance, more tool relief & higher speed 当剪切较硬的线材时, 需要更多的间隙, 表面退让(退剪槽)和更快的速度. Too loose the COD / COK diameters will bend the blank and cause taper ends 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. Shearing without lubricants causes short tool life 无润滑剪切会缩短模具寿命.,Asse
9、mbly and setup of COD & COK,7 Understand Defects 缺陷分析,Poor Sheared Surface: small clearance and no tool relief 剪切面粗糙: 间隙太小/ 没有表面退让 Burr: COK or/and COD worn off 毛刺: 剪刀/ 剪体磨损 Tongue: small clearance and no tool relief 舌状毛刺: 间隙太小/ 没有表面退让 Bent Blank: COK/COD diameter too big 线材弯曲: 剪刀/ 剪体内孔直径太大 Oval Sha
10、pe: COK/COD diameter too big 椭圆形: 剪刀/ 剪体内孔直径太大 Big Roll-over: clearance too big and Tool worn off 曲面大: 间隙太小/ 模具磨损,Assembly and setup of COD & COK,7 Understand Defects 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,Assembly and setup of main dies 主模组立,Assembly and setup of main dies,Basic
11、of Cold Forming 冷锻的基础知识 Materials for Die Construction 模具的材质 Types of Die Design 模具设计的类型 Importance of Die Surface Finishing 模具表面加工的重要性 Compressive Stress 压应力 Good Die Assembly 正确安装模具 Defective Parts / Poor Die 缺陷部件 / 劣质模具,Assembly and setup of main dies,Basic of Cold Forming,正挤压,反挤压,打头,Assembly and
12、 setup of main dies,Basic of Cold Forming,A combination of discipline, skill, knowledge & continuous improvement. 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。,冷锻的基础知识,Assembly and setup of main dies,Materials for Die Construction 模具的材质,Assembly and setup of main dies,Types of Die Design 模具设计的类型,Solid Ma
13、in Die 实心主模,Step Solid Main Die 台阶实心主模,Die-Piece / Casing / Insert 套片整装主模,Step Die-Piece / Casing / Insert 台阶套片整装主模,Assembly and setup of main dies,Types of Die Design 模具设计的类型,Low Cost 成本低廉 Easy Assemble 组装简易 Long Tool Life 模具寿命长久,The REASON for different die designs 不同模具设计的成因,Normal Cost 成本一般 Easy
14、Assemble 组装简易 Tool Life Shorter 模具寿命较短,Some Assembly Problem 某些组装问题 Difficult to Alignment 对齐困难 Short Die-piece Life 套片寿命短 High Cost 成本昂贵,Some Assembly Problem 某些组装问题 Difficult to Alignment 对齐困难 Short Die-piece Life 套片寿命短 Very High Cost 成本最昂贵,Assembly and setup of main dies,Importance of Die Surface
15、 Finishing 模具表面加工的重要性,Grinding marks promote cracks 模具研磨纹路造成脆裂 Rough surfaces promote galling 粗糙的表面造成表面磨伤 Poor internal surface causes short KOP life 粗糙的内孔面缩短顶针使用寿命 Sharp radius causes die chip & fracture 模具尖角太锋利造成模具脆裂或破损,Assembly and setup of main dies,Compressive Stress 压应力,Proper compressive stre
16、ss to reduce material breathing during forming 适当的压力可减少在冷锻时材料的伸展 Increase product dimension stability 增加产品尺寸的稳定性 Extend tool life 延长模具寿命,0.5% hot-shrink-fit interference 0.5% 预热组合的过盈配合量,0.5% cold press interference 0.5% 冷装组合过盈配合量,0.5% taper press interference 0.5% 斜角部分的过盈配合量,Assembly and setup of ma
17、in dies,Good Die Assembly 正确组装模具,Positive step to ensure proper support of die piece by die insert 有效间隙以保证给予套片适当的支撑,Positive step to ensure proper support of die insert 有效台阶以保证给予组合套心适当的支撑,Sufficient chamfer,Proper installation of die piece 适当安装套片,Sufficient Interference 足够的过盈量,足够的倒角,Assembly and set
18、up of main dies,Defective Parts / Dies 缺陷部件 / 模具,Die Piece Breaks: 套片破裂 1 Die piece and die case off centers 套片和主模套偏心 2 Rough surfaces / insufficient polishing 表面粗糙 / 研磨,抛光不足 3 Poor matching of taper surfaces 斜角部分配合不好 4 Insufficient compressive stress 压力不足 5 No proper support from die insert 组合套心没有给
19、予套片恰当的支撑 6 Insufficient step radius 台阶部分圆角太小 7 Poor punch / die alignment 冲件 / 主模没有对齐 8 Blank over-length 线材剪切太长 9 Punch Recess hitting 二冲窜伤 10 High KO force (taper / over forged / rough surface) 顶出力太大 (倒锥,太饱满,表面粗糙),Assembly and setup of main dies,Defective Parts / Dies 缺陷部件 / 模具,Step Die Fractures:
20、 台阶主模破损 Hydraulic effect / too much oil/air & oil trap 液压影响 / 润滑油太多/憋气憋油 Insufficient step radius 台阶部分圆角太小 Rough surfaces / insufficient polishing 表面粗糙 / 研磨, 抛光不足 Poor punch / die alignment 冲件 / 主模没有对齐 Blank over-length 线材剪切太长 Poor hot-shrink-fit 预热组装配合差 Heavy knock out action 顶针冲击力过大 Punch Recess h
21、itting 二冲窜伤 High KO force (taper / over forged / rough surface) 顶出力太大 (倒锥,太饱满,表面粗糙),Assembly and setup of main dies,Defective Parts / Dies 缺陷部件 / 模具,Main Die Chip off / Cracks: 主模脆裂 Improper sitting of main die 主模安装位置不正确 Insufficient step radius 台阶部分圆角太小 Rough surfaces / insufficient polishing 表面粗糙
22、/ 研磨, 抛光不足 Poor punch / die alignment 冲件 / 主模没有对齐 Blank over-length 线材剪切太长 Poor hot-shrink-fit 预热组装配合不好 Over knock out action 顶针行程过大 Punch Recess hitting 二冲窜伤,Assembly and setup of main dies,Defective Parts / Poor Dies 缺陷部件 / 劣质模具,Die wear: 模具磨损 Poor hot-shrink-fit 预热组装配合不好 Poor punch/ part / die al
23、ignment冲件 / 冲头/ 主模没有对齐 Wrong carbide grades 选择错误的钨钢等级 Insufficient or wrong lubricant 润滑不足或用错润滑油 Parts Defects: 部件缺陷 Galling due to misalignment / poor carbide 磨伤-模具没有对齐 / 劣质钨钢 Blank diameter over size due to poor hot-shrink fit 光杆直径太大-预热组装配合差 Blank diameter under size due to wrong die diameter 光杆直径
24、太小-主模内径错误 Inconsistent blank diameter due to die diameter too big 光杆直径不稳定-主模内径太大 Rough surfaces due to poor die polishing 表面粗糙-模具研磨, 抛光不足,Assembly and setup of punches 冲头组立/失效分析,Timing / Speed 时间/速度 Friction 摩擦系数 Alignment 对齐 How Punches Fail 二冲如何损坏 Common Punch Problems 常见二冲问题 Common Product Proble
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