《冷镦模具设计培训资料》由会员分享，可在线阅读，更多相关《冷镦模具设计培训资料（73页珍藏版）》请在金锄头文库上搜索。
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 20111. Assembly and setu
2、p of COD & COK 剪刀/剪模组立Assembly and setup of COD & COK1Types 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 & COK2Basic Mechanism of Shearing 剪切基础知识What Happen During Shearing:- 剪切过程产生：1. Elastic Deform
3、ation 弹性变形 2. Roll-over 曲面 3. Plastic shear 塑性剪切 4. Initial Fracture 初始断裂 5. Final Fracture 最终断裂 6. Physical Separation 实际剪断Assembly and setup of COD & COK2Basic Mechanism of ShearingQuality Problems:- 质量问题 1.Oval Shape 椭圆形 2.Tilting 歪斜 3.Poor shear 剪切面粗糙 4.Burr 毛刺 5.Not Straight 不直Clearance Too Big
4、 间隙太大Optimum Clearance 最佳间隙Clearance Too Small 间隙太小1.Elastic Deformation 弹性变形 2.Roll-over 曲面 3.Plastic shear 塑性剪切 4.Initial Fracture 初始断裂 5.Final Fracture 最终断裂 6.Physical Separation 实际剪断Assembly and setup of COD & COK2Basic Mechanism of Shearing (Half Cut COK) 半剪1. No Control of Blank 落料无法控制 2. Diff
5、erent Shear Patterns 剪切方式不同 3. Blank Not Straight 线材不直 4. Big Roll-over 曲面较大 5. Low Cost 成本低廉 6. Easy to Setup 安装简易 7. Long Tool Life 模具寿命较长Assembly and setup of COD & COK2Basic Mechanism of Shearing1. Need Relief Surfaces 需要表面退让（退剪槽 2. Careful Control of Clearance 间隙要求高 3. Difficult COK/COD Alignme
6、nt 剪刀、剪体对齐困难 4. Better Shear / Quality 较好的剪切质量 5. Achieve Straight Blank 剪断的线材较直 6. Small Roll-over 曲面小(Complete Cut 全剪)Assembly and setup of COD & COK3Common Blank Quality Issue 常见的线材剪切质量问题1. Roll-over 曲面 2. Plastic shear 塑性剪切 3. Secondary Fracture / Tongue 二次断裂 / 舌状毛刺 4. Burr 毛刺 5. Straightness 直线
7、性1443234Assembly and setup of COD & COK4COD & COK Setting 安装Relief 表面退让 （退剪槽Small Radius 小圆角 Relief 表面退让 （退剪槽Assembly and setup of COD & COK5COD & COK Materials 材料Tool Steel 模具钢Carbide 钨钢Assembly and setup of COD & COK6Main Process Parameters 主要参数1.Material Hardness 材料硬度 2.COK/COD Clearance 剪刀/ 剪体间隙
8、 3.COK/COD Diameters 剪刀/ 剪体内孔直径 4.COK Speed 剪刀速度 5.Lubricants 润滑 6.Types 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. S
9、hearing without lubricants causes short tool life无润滑剪切会缩短模具寿命.Assembly and setup of COD & COK7Understand Defects 缺陷分析 ?1.Poor Sheared Surface: small clearance and no tool relief 剪切面粗糙: 间隙太小/ 没有表面退让 2.Burr: COK or/and COD worn off 毛刺: 剪刀/ 剪体磨损 3.Tongue: small clearance and no tool relief 舌状毛刺: 间隙太小/
10、没有表面退让 4.Bent Blank: COK/COD diameter too big 线材弯曲: 剪刀/ 剪体内孔直径太大 5.Oval Shape: COK/COD diameter too big 椭圆形: 剪刀/ 剪体内孔直径太大 6.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 & COK7Understand 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2.
11、Assembly and setup of main dies 主模组立Assembly and setup of main diesBasic 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Assem
12、bly and setup of main diesBasic of Cold Forming正挤压反挤压打头Assembly and setup of main diesBasic of Cold FormingA 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 diesMaterials for Die Construction 模具的材质Carbi
13、de Insert 钨钢Hot Work Steel 耐热钢High Speed Steel 高速钢Assembly and setup of main diesTypes of Die Design 模具设计的类型Solid Main 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 diesTypes of Die Design 模具设计的类型Low Cost 成本低廉
14、 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 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
15、难 Short Die-piece Life 套片寿命短 Very High Cost 成本最昂贵Assembly and setup of main diesImportance of Die Surface 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 diesCompressive Stress 压应力1.Proper compressive stress to reduce material breathing during forming适当的压力可减少在冷锻时材料的伸展 1.Increase product dimension stability增加产品尺寸的稳定性 1.Extend tool life延长模具寿命0.5% hot-shrink- fit interference 0.5%
