冷镦模具设计介绍

会计学冷镦模具设计介绍ContentsoftheTraining 培训 焊锡培训资料ppt免费下载焊接培训教程 ppt 下载特设培训下载班长管理培训下载培训时间表下载 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 关于同志近三年现实表现材料材料类招标技术评分表图表与交易pdf视力表打印pdf用图表说话 pdf 面/摩擦系数Understandtheeffectofpreform预成形分析10Jan2011AssemblyandsetupofCOD&COK剪刀/剪模组立AssemblyandsetupofCOD&COK1TypesofShearing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&COK2BasicMechanismofShearingQualityProblems:-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&COK2BasicMechanismofShearing(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&COK2BasicMechanismofShearingNeedReliefSurfaces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&COK4COD&COKSetting安装Relief表面退让（退剪槽〕SmallRadius小圆角Relief表面退让（退剪槽〕AssemblyandsetupofCOD&COK5COD&COKMaterials材料ToolSteel模具钢Carbide钨钢AssemblyandsetupofCOD&COK6MainProcessParameters主要 参数 转速和进给参数表a氧化沟运行参数高温蒸汽处理医疗废物pid参数自整定算法口腔医院集中消毒供应 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,表面退让(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.AssemblyandsetupofCOD&COK7UnderstandDefects缺陷分析?PoorShearedSurface:smallclearanceandnotoolrelief剪切面粗糙:间隙太小/没有表面退让Burr:COKor/andCODwornoff毛刺:剪刀/剪体磨损Tongue:smallclearanceandnotoolrelief舌状毛刺:间隙太小/没有表面退让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AssemblyandsetupofCOD&COK7UnderstandDefects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Assemblyandsetupofmaindies主模组立AssemblyandsetupofmaindiesBasicofColdForming冷锻的基础知识MaterialsforDieConstruction模具的材质TypesofDieDesign模具设计的类型ImportanceofDieSurfaceFinishing模具表面加工的重要性CompressiveStress压应力GoodDieAssembly正确安装模具DefectiveParts/PoorDie缺陷部件/劣质模具AssemblyandsetupofmaindiesBasicofColdForming正挤压反挤压打头AssemblyandsetupofmaindiesBasicofColdFormingAcombinationofdiscipline,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。冷锻的基础知识AssemblyandsetupofmaindiesMaterialsforDieConstruction模具的材质CarbideInsert钨钢HotWorkSteel耐热钢HighSpeedSteel高速钢AssemblyandsetupofmaindiesTypesofDieDesign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AssemblyandsetupofmaindiesTypesofDieDesign模具设计的类型LowCost成本低廉EasyAssemble组装简易LongToolLife模具寿命长久TheREASONfordifferentdiedesigns不同模具设计的成因NormalCost成本一般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成本昂贵SomeAssemblyProblem某些组装问题DifficulttoAlignment对齐困难ShortDie-pieceLife套片寿命短VeryHighCost成本最昂贵AssemblyandsetupofmaindiesImportanceofDieSurfaceFinishing模具表面加工的重要性Grindingmarkspromotecracks模具研磨纹路造成脆裂Roughsurfacespromotegalling粗糙的表面造成表面磨伤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AssemblyandsetupofmaindiesCompressiveStress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%斜角部分的过盈配合量AssemblyandsetupofmaindiesGoodDieAssembly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AssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具DiePieceBreaks:套片破裂1Diepieceanddiecaseoffcenters套片和主模套偏心2Roughsurfaces/insufficientpolishing表面粗糙/研磨,抛光不足3Poormatchingoftapersurfaces斜角部分配合不好4Insufficientcompressivestress压力不足5Nopropersupportfromdieinsert组合套心没有给予套片恰当的支撑6Insufficientstepradius台阶部分圆角太小7Poorpunch/diealignment冲件/主模没有对齐8Blankover-length线材剪切太长9PunchRecesshitting二冲窜伤10HighKOforce(taper/overforged/roughsurface)顶出力太大(倒锥，太饱满，表面粗糙）AssemblyandsetupofmaindiesDefectiveParts/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台阶部分圆角太小Roughsurfaces/insufficientpolishing表面粗糙/研磨,抛光不足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，表面粗糙）AssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具MainDieChipoff/Cracks:主模脆裂Impropersittingofmaindie主模安装位置不正确Insufficientstepradius台阶部分圆角太小Roughsurfaces/insufficientpolishing表面粗糙/研磨,抛光不足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AssemblyandsetupofmaindiesDefectiveParts/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润滑不足或用错润滑油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表面粗糙--模具研磨,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二冲如何损坏CommonPunchProblems常见二冲问题CommonProductProblems常见产品问题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Alignment对齐PrematureWearofRecessIncorrectHeadShapePrematureBreakofRecessOff-centerRecess(<0.05mm)梅花部分磨损头形错误梅花部分破裂梅花偏心(<0.05mm)HowPunchesFail1.WearoffIncorrectHardness(AboveHRC65)InsufficientLubricantIncorrectPunchMaterial(M2,M42,Carbide)WithoutCoating(TiN,TiCN,TiAlN)PoorPreform(1stPunchPreparation)NatureWear2.ChipOffPoorAlignmentPoorSetupSkillPoorsurfaceIncorrectPunchMaterialMishandlingVibrationSpeedtooFast3.BreakoffRecessStrippedoffbending/MisalignmentPinandInsertMismatchIncorrectPreform(1stPunchPreparation)SpeedtooFastWrong/InstableProcessHighFrictionPoorCutOff1121233二冲如何损坏1.磨损硬度错误(高于HRC65)润滑不足二冲材质错误(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表面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1121233CommonPunchProblemsShortToolLifeIncorrectHardness(AboveHRC65)InsufficientLubricantIncorrectPunchMaterial(M2,M42,Carbide)WithoutCoating(TiN,TiCN,TiAlN)PoorPreform(1stPunchPreparation)PoorAlignmentPoorSetupSkillPunchMaterialtooHard(AboveHRC68)MishandlingVibrationSpeedtooFastWrong/InstableProcessHighFrictionDimensionoutPoorToolSuppliersPoorReworkToolingnotmatchOrderWrongToolPoorToolSuppliers常见二冲问题寿命短硬度错误(高于HRC65)润滑不足二冲材质错误(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应商不佳模具修改误差模具不能配合购买错误模具模具供应商不佳CommonProductProblems常见产品问题IncorrectRecessProfileLubricationOilToolSurfaceRoughnessIncorrectToolDimensionIncorrectRecessDepthRecessWearRecessChipoffRecessOff-setPoorPunchAlignmentPoorPreformPoorCutoffBigChamferLubricationOilIncorrectToolDimensionIncorrectPreformUnusualVisualDefectsLubricationOilToolSurfaceRoughnessIncorrectToolDimension成形形状不正确润滑油模具表面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表面粗糙度模具尺寸不正确4.Understandsteel&carbidetoolsManufacturingofFastenersandforgingpartsfallinthesamefamily紧固件与冷锻件的生产工艺LowcarbonsteelAnti-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DieDesign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123GoodDieAssembly正确组装模具预先加压卸载加载phase1cyclicloadingoftheundamagedmaterial材料受力而产生反复的胀缩变形phase2initiationofmicrocracksa<0.1mm开始出现微小的裂痕phase3mergingofmicrocrackstosurfacedefectsandlargercracks0.1<a<0.5mm微小的裂痕深入到表面，使裂纹加深phase4growthoflargercracksa>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理解模具表面及摩擦力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?Whatisfriction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通常金属表面磨擦系数=0.05to0.2Effectoffriction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Effectoffriction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Effectoffriction摩擦系数所产生的影响AssumeLowToolFriction摩擦力那一边大小？?Practicalconsiderations实际情况需考虑因素??Practicalconsiderations实际情况考虑因素Understandtheeffectofpreform了解预成型的影响Understandtheeffectofpreform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WhatisPreform什么是预成型?Whatisanoptimisedpreform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?Whatisanoptimisedpreform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低成本的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低成本的ProlongOperation延长生产力ProductQuality:-产品质量方面No/MinimumDefects无缺陷或缺陷最小Achieveconsistentquality达到品质一致Achieverequireddimension达到要求尺寸Theeffectofpreform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低成本的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低成本ProlongOperation延长生产力ProductQuality:-产品质量No/MinimumDefects无/最小缺陷Achieveconsistentquality达到质量一致Achieverequireddimension达到要求尺寸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Theeffectofpreform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Theeffectofpreform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MajorFolds较大褶皱LowerPreform低预成型Highpunchforce冲力大Shortertoollife模具寿命短Minimumfolds褶皱最小Ringmark环状痕迹Theeffectofpreform预成型的影响Thegeometryofpreformisdefinedby:预成型形状具体取决于:profile外形height高度diameter直径weight重量Thegeometryofpreformisaffectedby:影响预成型形状的因素:Tooltemperature模具的温度Lubricationoil润滑油Machinestability机台的稳定性Machinespeed机台速度Toolalignment模具组合情况Toolsurfaceconditions模具的表面条件Toolprofile模具外形Thegeometryofpreformisguidedby:预成型形状主要取决于:Preformdiameter=80%offinaldiameter预成型直径=80%最终直径Whatisanoptimisedprocesscontrol什么是理想的过程控制Aprocessthatwillrobustenoughwithstandexternalfactors成形过程稳定，不易受外来因素影响Aprocessthatcanbeaccuratelyrepeated此过程可重复性较精确Aprocessthatcanbedimensionedandexpressed过程可测量可描述Canpreformbealwaysbethesame预成型总是相同的吗?Thegeometryofpreformisaffectedby:预成型的形状取决于:Tooltemperature模具的温度Lubricationoil润滑油Machinestability机台的稳定性Machinespeed机台速度Toolalignment模具组合Toolsurfaceconditions模具表面条件Toolprofile模具外形Toolprofiletolerance模具外形公差NO不Shouldwehaveapreformdrawing我们是否需要预成型 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化?1.0mmYES是MinimiseDimensionvariation尺寸变化最少Standardiselearningcurve学员培训标准化Standardisetoolsetting标准模具设置Achieveconsistentproductquality达到产品质量一致定位是不是太短表面机加工纹粗糙间隙太大粗糙横向平磨裂纹波定位是不是太短间隙太大粗糙手工磨修裂纹波冲头折断冲头拉断粗糙横向平磨打得太死，包住冲头冲头折断冲头拉断间隙太大表面机加工纹粗糙裂纹波以上资料仅供参考完！AssemblyandsetupofmaindiesBasicofColdFormingAcombinationofdiscipline,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。冷锻的基础知识AssemblyandsetupofmaindiesDefectiveParts/Dies缺陷部件/模具DiePieceBreaks:套片破裂1Diepieceanddiecaseoffcenters套片和主模套偏心2Roughsurfaces/insufficientpolishing表面粗糙/研磨,抛光不足3Poormatchingoftapersurfaces斜角部分配合不好4Insufficientcompressivestress压力不足5Nopropersupportfromdieinsert组合套心没有给予套片恰当的支撑6Insufficientstepradius台阶部分圆角太小7Poorpunch/diealignment冲件/主模没有对齐8Blankover-length线材剪切太长9PunchRecesshitting二冲窜伤10HighKOforce(taper/overforged/roughsurface)顶出力太大(倒锥，太饱满，表面粗糙）AssemblyandsetupofmaindiesDefectiveParts/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润滑不足或用错润滑油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表面粗糙--模具研磨,抛光不足Assemblyandsetupofpunches冲头组立/失效分析phase1cyclicloadingoftheundamagedmaterial材料受力而产生反复的胀缩变形phase2initiationofmicrocracksa<0.1mm开始出现微小的裂痕phase3mergingofmicrocrackstosurfacedefectsandlargercracks0.1<a<0.5mm微小的裂痕深入到表面，使裂纹加深phase4growthoflargercracksa>0.5mm演变成更大的裂痕CarbideInsert钨钢HotWorkSteel耐热钢HighSpeedSteel高速钢Effectoffriction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Understandtheeffectofpreform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Shouldwehaveapreformdrawing我们是否需要预成型标准化?1.0mmYES是MinimiseDimensionvariation尺寸变化最少Standardiselearningcurve学员培训标准化Standardisetoolsetting标准模具设置Achieveconsistentproductquality达到产品质量一致