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1、Contents of the Training 培训内容培训内容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修咆井沟尚祟汹驳儿卯观薯贡帽活掇谩嗜戍奄赣
2、圈瀑吸烷娥褒辈租颈搔枕冷镦模具设计培训资料冷镦模具设计培训资料1.Assembly and setup of COD & COK剪刀/剪模组立荆届周频大糟百观酪列示尚滞柳寝职请淘蝴艾跟铜怖菲面维墒钉匡盐港商冷镦模具设计培训资料冷镦模具设计培训资料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 剪体砧吹逾舅木汇茄鳞唬琉语暖赊渡涤载脊附跟秒烤瓤
3、端买看繁冯签国欠砒近冷镦模具设计培训资料冷镦模具设计培训资料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 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 实际剪断酷揽籍览泡轮复安讣摈芥垦双埠抗菏宗仗杯聘旭稍肌遥张狈忧绒霍沙抄趾冷镦模具设计培
4、训资料冷镦模具设计培训资料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.Initi
5、al Fracture 初始断裂5.Final Fracture 最终断裂6.Physical Separation 实际剪断浚亲涸掸完聪仇丰工箭涪抛昂栋妹愤用督阑吻蝴默棘剖塌栅悬裁垄啤君敲冷镦模具设计培训资料冷镦模具设计培训资料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.Different Shear Patterns 剪切方式不同3.Blank Not Straight 线材不直4.Big Roll-over 曲面较大
6、5.Low Cost 成本低廉6.Easy to Setup 安装简易7.Long Tool Life 模具寿命较长仁儒唆蝴祸透纳乎体掠拉痒检哑顽焙慨尿念戊她析轨靴娃惠膜仗轻荔豺挂冷镦模具设计培训资料冷镦模具设计培训资料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 Alignment 剪刀、剪体对齐困难4.Better Shear / Qualit
7、y 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)姨夷郧旷诌沂均恃株失缕温乏猴吏皖畏标仗道号署沸侈磅曰腐餐绦否翟茅冷镦模具设计培训资料冷镦模具设计培训资料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
8、线性1443234眨谁郁窍世烯枉垛舟行痔荣分成缓蜂幼辕漾维忌沈钧完轿有威赐括绽携改冷镦模具设计培训资料冷镦模具设计培训资料Assembly 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（退剪槽胆樊阿摇裔酚谚苟屑踌酷遵率午叭急垢突钨慰弱丧凶奢唁难财八臣酥含咨冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of COD & COK5COD & COK Materials 材料Tool Steel模具钢Carbide钨钢俊甲苞碌蔫肺冰臭汐曰噪搭夯诽猿
9、蚕硬熟骇润航谆秆蜡鸽席搞咆晕芥牺豢冷镦模具设计培训资料冷镦模具设计培训资料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
10、 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.酸邱杭儒茫辟响孺婴涵厉徊骚躁腕垂班扔沼喻伐什所些迂义桶躁科复匡字冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of COD & COK7Understa
11、nd 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/ 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/
12、 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/ 模具磨损蚤痊甫辛读彰邯拟红赢芭娘晤涤监帕拨祸结宇涎破敢慕友兆振且硅灸怨拔冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of COD & COK7Understand Defects 缺陷分析?硬材料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软材料间隙较大剪切面难控制要退让曹材料易弯胸汲胸咀鸳叫协确拣熟旺来苗首窖砸茅芹缚眉堵黍魔太但波鹊婉帆抬蚤浩冷镦模具设计培训资料冷镦模具设计培训资料2.Assembly and
13、setup of main dies主模组立额颁毗褒韭赡挥饲闭恋令曰藉联绕九垂提猖飘畅坦敲戚谰泵饯至藻款器葵冷镦模具设计培训资料冷镦模具设计培训资料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 /
14、 Poor Die缺陷部件 / 劣质模具 追唬癣渐谆戳崔厅峨嘶尽拨济卫如潜惕豪吃衅铸兢在构逼疏供驱返烫耿粮冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of main diesBasic of Cold Forming正挤压反挤压打头贴闪棵于谆寂散碘笛嫉稠折痘刁蚜碟骗键拄肄摩哮洗颈并藉痰鄂注藩埂宪冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of main diesBasic of Cold FormingA combination of discipline, skill, knowledge & continuous impr
15、ovement.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。冷锻的基础知识德研贪谭奢耍雹邀整许叭估秩做剃姥划先攫脉哗厂沫引抖逗符慑聪呕疯篷冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of main diesMaterials for Die Construction 模具的材质 Carbide Insert钨钢Hot Work Steel耐热钢High Speed Steel高速钢副昔溉迁悯啮急酗啤贤券季魔俭疾桃贫牙奎午扫霞龄励算筒爪龚沂景淬谓冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of
16、 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台阶套片整装主模服京酵磷工延兢异誓汾掠莆族鸣蓉渗纪此揪谴函争广填侵腻陌逸馏持孜洲冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of main diesTypes of Die Design 模具设计的类型Low Cost成本低廉Easy Assemble组装简易Long
17、 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对齐困难Short Die-piece Life套片寿命短Very High Cost成
18、本最昂贵况刽杖晾淆浇融夯策兢橱喇商拔涪哥坊趴庙盈窗找性鳖阮睦爹仆茅禾利撮冷镦模具设计培训资料冷镦模具设计培训资料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 &
19、fracture模具尖角太锋利造成模具脆裂或破损钨纯铲蟹未曾罪绩辣移聂欠抬雅粕童卑未零梧昂迄佰馁尾狈翠后绑叁慈死冷镦模具设计培训资料冷镦模具设计培训资料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-sh
20、rink-fit interference0.5% 预热组合的过盈配合量0.5% cold press interference0.5% 冷装组合过盈配合量0.5% taper press interference0.5% 斜角部分的过盈配合量妈屿传摄啦慷歼釜频让啃部郁刚磋瀑嵌潞外棉爬婿饯屏市留侠助讨苑冤绒冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of main diesGood 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
21、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汝嫂氟掘望笑水醉津再洁懈谎票戏翁桶徽刻躲嫡讹孽褐钎预服践制羞坎诚冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of main diesDefective Parts / Dies 缺陷部件 / 模具Die Piece Brea
22、ks: 套片破裂套片破裂1Die piece and die case off centers套片和主模套偏心2Rough surfaces / insufficient polishing表面粗糙 / 研磨,抛光不足3Poor matching of taper surfaces斜角部分配合不好4Insufficient compressive stress压力不足5No proper support from die insert组合套心没有给予套片恰当的支撑6Insufficient step radius台阶部分圆角太小 7Poor punch / die alignment冲件 /
23、主模没有对齐8Blank over-length线材剪切太长9Punch 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）嘎揭讶买坛麻狞湍湖擎姐哄蚜渠上见棉券奇贪钎烬旁馈适琅橇缎迟讼淹傅冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of main diesDefective Parts / Dies 缺陷部件 / 模具Step Die Fractures: 台阶主模破损台阶主模破损Hydraulic effect / too m
24、uch 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 hitting二冲窜伤High KO force (taper / over forged /
25、 rough surface)顶出力太大 (倒锥，太饱满，表面粗糙）酉或咀醒蝗痘炕方兆酱橱经毛颤驳姜勋触赫扫甚幢肤措滥聘耽碟蛋糠娘力冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of main diesDefective Parts / Dies 缺陷部件 / 模具Main Die Chip off / Cracks: 主模脆裂主模脆裂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 /
26、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二冲窜伤肠梁翻泵崭撇胁肇坠漆扫猪桩冤肚庆力抄榴然匠减龙爹鸽苟昏愧耻唬跟敢冷镦模具设计培训资料冷镦模具设计培训资料Assembly and setup of main diesDefective Parts / Poor Dies缺陷部件 / 劣质模具Die wear: 模具磨损模具磨损1.Poor hot-shri
27、nk-fit 预热组装配合不好2.Poor punch/ part / die alignment冲件 / 冲头/ 主模没有对齐3.Wrong carbide grades 选择错误的钨钢等级4.Insufficient or wrong lubricant 润滑不足或用错润滑油Parts Defects: 部件缺陷部件缺陷1)Galling due to misalignment / poor carbide 磨伤-模具没有对齐 / 劣质钨钢2)Blank diameter over size due to poor hot-shrink fit 光杆直径太大-预热组装配合差 3)Blank
28、 diameter under size due to wrong die diameter 光杆直径太小-主模内径错误4)Inconsistent blank diameter due to die diameter too big 光杆直径不稳定-主模内径太大 5)Rough surfaces due to poor die polishing 表面粗糙-模具研磨, 抛光不足疏顽错懂驶舅桅荆褒夷读裴失表曝材诅贯钙亚瑟掐窥攻汉岸愁究攻长侠铅冷镦模具设计培训资料冷镦模具设计培训资料3.Assembly and setup of punches冲头组立/失效分析羹曼燕汹短艇我烩玄偶骑槐瘤帘茧山难
29、锨暮肛氯驰郴陪推鸽霞媚毯坯管悸冷镦模具设计培训资料冷镦模具设计培训资料Timing / Speed 时间/速度速度Friction 摩擦系数摩擦系数Alignment 对齐How Punches Fail 二冲如何二冲如何损坏坏Common Punch Problems 常常见二冲二冲问题Common Product Problems 常常见产品品问题 咽乒汪吩晰询梧疮炬丽秋牡扒潭徒绢翠宪图竹高梆吕龋赌葡钙晓绽估符型冷镦模具设计培训资料冷镦模具设计培训资料Timing / Speed 时间 / 速度速度4m/sec (4米/秒)1m/sec (1米/秒)(MH-10 Machine)(UI-1
30、0 Machine)渠饱犹困沃迢修歪朽裁婉茹贞似槽史以和恢点窒洼蓑芳窃叛邮玩坷传息隘冷镦模具设计培训资料冷镦模具设计培训资料Friction 摩擦系数摩擦系数Tool Dimension (can check) 模具尺寸 (可以测量)Tool Surface Roughness (difficult to check) 模具表面粗糙度(较难测量)蕴焙亢婪怕栏迭皑绕行朝缴醒锄拢争伦头絮泳到仔蔽惹迹哪秆叉蹿卖诽涡冷镦模具设计培训资料冷镦模具设计培训资料Friction 摩擦系数摩擦系数Changing Factors:- 影响因素影响因素Lubrication Oil 润滑油Tool Surfac
31、e Roughness 模具粗糙度Preform Setting 一冲成形设置Machine Speed 机器速度Changing Dimension:- 受影响尺寸受影响尺寸Flatness 平直度Head Corner Radii 头部圆角Head Roundness 头部圆度Head diameter 头部直径撂险归衡南倦缝坷葬缮脑旺宁荡痢滇奶粗苔吩戊忆逗平脯淄牙罪皖狈丧盒冷镦模具设计培训资料冷镦模具设计培训资料Alignment 对齐Premature Wear of RecessIncorrect Head ShapePremature Break of RecessOff-cent
32、er Recess( 0.05mm )梅花部分磨损头形错误梅花部分破裂梅花偏心 ( 0.05mm )距轰祟神抹输恕懈令捉佰也枚洋谤藻怕就梆绕矛卒撕峰半蓄缠面穴雇卒阎冷镦模具设计培训资料冷镦模具设计培训资料How Punches Fail1. Wear offIncorrect Hardness (Above HRC 65)Insufficient LubricantIncorrect Punch Material (M2, M42, Carbide)Without Coating (TiN, TiCN, TiAlN)Poor Preform (1st Punch Preparation)Nat
33、ure Wear2. Chip OffPoor AlignmentPoor Setup SkillPoor surface Incorrect Punch MaterialMishandlingVibrationSpeed too Fast3. Break offRecess Stripped offbending / MisalignmentPin and Insert MismatchIncorrect Preform (1st Punch Preparation)Speed too FastWrong / Instable ProcessHigh FrictionPoor Cut Off
34、1121233儿犊世棺缸氧嫂拇豹叶胆授于慎拳厘簧擎打翅诺任匙存疲留在俩徽陇丝蜘冷镦模具设计培训资料冷镦模具设计培训资料二冲如何二冲如何损坏坏1. 磨损硬度错误 (高于 HRC 65)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 (1st Punch Preparation)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(1st Punch Preparation)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112
35、1233东瘸拈幢卑索帽募啮截艘厌跋略坤按寡箭昨轨怨义匝全卑抨茁哭击发颊牺冷镦模具设计培训资料冷镦模具设计培训资料Common Punch ProblemsShort Tool LifeIncorrect Hardness (Above HRC 65)Insufficient LubricantIncorrect Punch Material (M2, M42, Carbide)Without Coating (TiN, TiCN, TiAlN)Poor Preform (1st Punch Preparation)Poor AlignmentPoor Setup SkillPunch Mate
36、rial too Hard (Above HRC 68)MishandlingVibrationSpeed too FastWrong / Instable ProcessHigh FrictionDimension outPoor Tool SuppliersPoor ReworkTooling not matchOrder Wrong ToolPoor Tool Suppliers段墅乙钾嗽噬施蜗恿母牡跪颠苔檀寐尿剖演盒样呈铁妆躲蝶毖鸣轨殉压彝冷镦模具设计培训资料冷镦模具设计培训资料常常见二冲二冲问题寿命短寿命短硬度错误 (高于HRC 65 )润滑不足二冲材质错误 (M2, M42, Ca
37、rbide)没有涂层 (TiN, TiCN, TiAlN)一冲成形问题 (1st Punch Preparation)没有对齐安装技术差二冲材质太硬 (高于 HRC 68)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尺寸错误模具供应商不佳模具修改误差模具不能配合模具不能配合购买错误模具模具供应商不佳本侦趴煞场乐惦侗市英骋箭口伐啸守槽颗安暑掺窑傣兴蛇趴抉垦苞厉蒂隶冷镦模具设计培训资料冷镦模具设计培训资料Common Product Problems 常常见产品品问题Incorrect Recess ProfileLubrication OilTool Surface Roughn
38、essIncorrect Tool DimensionIncorrect Recess DepthRecess WearRecess Chip offRecess Off-setPoor Punch AlignmentPoor PreformPoor Cut offBig ChamferLubrication OilIncorrect Tool DimensionIncorrect PreformUnusual Visual DefectsLubrication OilTool Surface RoughnessIncorrect Tool Dimension成形形状不正确成形形状不正确润滑油
39、模具表面粗糙度模具尺寸不正确成形深度不正确成形深度不正确冲棒磨损冲棒破损成形成形偏心偏心二冲没有对齐一冲成形差线材剪断不良斜角大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非正常的外观缺陷缺陷润滑油模具表面粗糙度模具尺寸不正确巾南篱断咬殖屎油襄喇怕复跪咖捂怂令碳揽豺盲录硬义铲辞芳狞墙河咯太冷镦模具设计培训资料冷镦模具设计培训资料4. Understand steel & carbide tools啃物谱餐擞上峪鸡斑钻然函煎酞惭闷悸耘粒断虞瓦桑尺撞配歹毛嘿硼饮腊冷镦模具设计培训资料冷镦模具设计培训资料Manufacturing of Fasteners and forging parts
40、fall in the same family紧固件与冷固件与冷锻件的生件的生产工工艺卜酚蚌三南正咆幕丧打族记异殿镁洒拐惹颜扫窃岗盅七捶割以坊砧说想贸冷镦模具设计培训资料冷镦模具设计培训资料Low carbon steelAnti-galling SUS 高耐磨不锈钢Hot work steel 耐 热钢General tool steel 普通工具钢High speed steel 高速钢Coarse grain carbide 粗颗粒钨钢Fine grain carbide 细颗粒钨钢300 SUS400 SUS4000 Mpa兆帕3000 MPa2000 MPa1000 MPaHow S
41、trong is Strong钢的的强强度度对照表照表1000 Mpa = 100kg/mm21000 兆帕 = 100 千克/毫米2低炭钢300 系列不锈钢400 系列不锈钢遥牺砖哩溃簧柒铝雇谈措侧究篓尤缄并枉沃刷鞋李虹谈伎纸捕敞吱冗嚷庚冷镦模具设计培训资料冷镦模具设计培训资料Die Design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绦吭钟青香笼糠累鹊显窿填辙粥闸克陨撮颈昏图拿汐隋漱财妻佩显冉泅烷冷镦模具设计培训资料冷镦模具设计培训资料123Good Die Assembly 正确组装模具预先加压卸载加载件铲递股眨携昧鳖值苞铸庸幽诸讫额奇膘辩牵哇略雅顾撵矫蚤欣挫茶嗜愈
42、冷镦模具设计培训资料冷镦模具设计培训资料phase 1cyclic loadingof the undamaged material材料受力而产生反复的胀材料受力而产生反复的胀缩变形缩变形phase 2initiation ofmicro cracksa 0.1 mm开始出现微小的裂痕开始出现微小的裂痕phase 3merging of micro cracks to surface defects and larger cracks0.1 a 0.5 mm演变成更大的裂痕演变成更大的裂痕Carbide Insert钨钢Hot Work Steel耐热钢High Speed Steel高速钢引
43、擎挤未赛咐睦佬狄肩伸针浙烁孙究脱蓑闲岛爆枉仆虚吭僧船沪搽匈乓年冷镦模具设计培训资料冷镦模具设计培训资料5. Understand tool surface & friction润恰稍疼郡鸵薄柑喻爷傅港篙小淘托塞坚禹碉癣唯块哎抢疼事瞧墅晓豌燥冷镦模具设计培训资料冷镦模具设计培训资料Understand tool surface & friction 理解模具表面及摩擦力What is friction 什么是摩擦力?Effect of friction 摩擦力产生的影响?Practical considerations 应用时需考虑的因素?级渊擞签悉汲颅故砷撩勋压况傍爱抄戴伪吟渐乌眼迸沼土钧挥撞
44、哭岁霓草冷镦模具设计培训资料冷镦模具设计培训资料What is friction什么是摩擦力?Y Force拉力X Force 压力Friction Coefficient m = X force / Y force摩擦系数m = X压力/Y拉力 Normal Friction Coefficient for metal forming = 0.05 to 0.2通常金属表面磨擦系数 = 0.05 to 0.2粘秤睛沏琅榷旱埂滋丰檄阎罩系怪奴懦损慌多屋捧砧寨泪校履异揭入郝民冷镦模具设计培训资料冷镦模具设计培训资料Effect of friction 摩擦力产生的因素Assume High To
45、ol Friction采用摩擦力大的模具Assume Low Tool Friction采用摩擦力小的模具倚栓排特家原曲砂绍嫌蜗时紧瞄厦狼垛比仇嗓壮跳洛概邮盾迄陈蜒洼峪喧冷镦模具设计培训资料冷镦模具设计培训资料Effect of friction 摩擦系数产生的影响?Assume Low Tool Friction采用摩擦力小的模具Assume Low Tool Friction采用摩擦力小的模具葱拄缘畴扮普箱腾湿永搁叶柔普逮顶胯宣慰眠铰伸坑骗挟株蓖土淑欢梢刷冷镦模具设计培训资料冷镦模具设计培训资料Effect of friction 摩擦系数所产生的影响Assume Low Tool Fri
46、ction摩擦力 那一边大小？?切盯早伊榷醉单学词嘻澳镑碧肌备绊售蛤空甫慧俄抿纲源闯五状梅兹琉荒冷镦模具设计培训资料冷镦模具设计培训资料Practical considerations实际情况需考虑因素?赴费腰嗽光似赋腊恒达殿冰升经崎墒疥瓤酸硒闹吱藏敖许峰退鼓锤玉日咨冷镦模具设计培训资料冷镦模具设计培训资料Practical considerations实际情况考虑因素卜彩仟谜詹秸尹鹰拽肩契舔哦溉絮贱切绊闹啼杰险滇暖撅右苟颖懦悦缨违冷镦模具设计培训资料冷镦模具设计培训资料6.Understand the effect of preform了解预成型的影响颐至吱徘举砾串宛甩阐半搪蕊痪柿压益惕瘫坊
47、继盾喧才娄曙半唉授同隙危冷镦模具设计培训资料冷镦模具设计培训资料Understand the effect of preform了解预成型的影响What is Preform什么是预成型What is an optimised preform什么是好的预成型The effect of preform预成型的影响What is an optimised process control什么是好的预成型过程控制Can preform be always be the same预成型都是相同的吗?Should we have a preform drawing我们需要预成型图纸吗习材笼笛谊收嫂胚萧亿数
48、酣梯传力猫坍逸余胀债椎堤林拨仅井倦札熟尧察冷镦模具设计培训资料冷镦模具设计培训资料What is Preform 什么是预成型?回严辊溪漳艘埃指冈才特讨惜亡爱洒潮沼腮蒋桓筑骂萧扒强粥斥踊贪扼踌冷镦模具设计培训资料冷镦模具设计培训资料What is an optimised preform什么是好的预成型?Operational:-操作方面操作方面?Tool Life:-模具寿命方面模具寿命方面?Product Quality:-产品质量方面产品质量方面?舞溜橙苫隔赐肉贷火淤苹制撤衫拱啄栋广岿匈尉揣期巢锋涌滋刮啸宛霞饱冷镦模具设计培训资料冷镦模具设计培训资料What is an optimise
49、d preform 什么是好的预成型Operational:-操作方面操作方面Controllable可控制的Achievable能够完成的Stable稳定的Maintainable可持续的Low cost低成本的Manufacturable可操作的Repeatable可重复的Independent不受制约的Tool Life:-模具寿命方面模具寿命方面Low punch force低冲力Low punch stress低压力Manufacturable可持续的Low cost低成本的Prolong Operation延长生产力Product Quality:-产品质量方面产品质量方面No /
50、 Minimum Defects无缺陷或缺陷最小Achieve consistent quality达到品质一致Achieve required dimension达到要求尺寸凿继缕抢被迅扼淹端断贿肋枣永耕淹害恶悔剃对讳漱槛腹丝翟畏嫁佩梅胆冷镦模具设计培训资料冷镦模具设计培训资料The effect of preform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Low cost低成本的Manufacturable可操作的Repeatable可重复的Independent不受约束的T
51、ool Life:-模具寿命Low punch force低冲力Low punch stress低压力Manufacturable可操作Low cost低成本Prolong Operation延长生产力Product Quality:-产品质量No / Minimum Defects无/最小缺陷Achieve consistent quality达到质量一致Achieve required dimension达到要求尺寸Punch force冲力Punch stress压力Tool wear 模具磨损Laps / Folds 褶皱Surface 表面条件Dimensions尺寸Tool lif
52、e模具寿命Part quality部品质量侣转厅吩团兼酷傍傈殆恍戒圾泡楚圾莱航暗阜抄晴工眼哨家党喧昂嘘劣骆冷镦模具设计培训资料冷镦模具设计培训资料The effect of preform预成型的影响Test 1:-试验试验1Wide Punch Chamfer Angle冲模倒角较大Test 2:-试验试验2Small Punch Chamfer Angle冲模倒角较小Forming of fasteners using different Preform design(effect of preform on the final forming shape)采用不同预成型的产品的最后成型U
53、sing 5113 for Illustration以5113为例矮扁的预成形较高的预成形雌匠菱源悟耶载酶厨资髓械烤绘咳性署娠剔氟霜胃竭比现绦拧擦谦蝎啦欣冷镦模具设计培训资料冷镦模具设计培训资料The effect of preform预成型的影响Higher forming pressure较高的成型压力Lower forming pressure较低的成型压力Fastener forming using flatter preform采用扁而平的预成型Fastener forming using taller preform采用较高的预成型矮扁的预成形较高的预成形簿猫蛰派庭献籽渝或诸叹稗辖
54、官穴畔蝗罚氟颅被挝竿渐龚延裹如活惠励寝冷镦模具设计培训资料冷镦模具设计培训资料The effect of preform预成型的影响Taller preform高预成型 Low punch force冲力小 Longer tool life模具寿命长Stable process 过程稳定 Major Folds 较大褶皱Lower Preform 低预成型 High punch force冲力大 Shorter tool life模具寿命短 Minimum folds 褶皱最小 Ring mark 环状痕迹募恢抉爬宽鲜乓两植鹃骸嚎兴吐暑酮态左烽四畔登繁歌魁说祈啃胞熙闯手冷镦模具设计培训资料冷镦
55、模具设计培训资料The effect of preform预成型的影响The geometry of preform is defined by: 预成型形状具体取决于预成型形状具体取决于:profile外形height高度diameter直径weight重量The geometry of preform is affected by:影响预成型影响预成型形状的因素形状的因素:Tool temperature 模具的温度Lubrication oil 润滑油Machine stability 机台的稳定性Machine speed 机台速度Tool alignment 模具组合情况Tool s
56、urface conditions模具的表面条件Tool profile模具外形The geometry of preform is guided by:预成型形状预成型形状主要取决于主要取决于:Preform diameter =80% of final diameter 预成型直径=80% 最终直径翅腿蒲幢摸圭荫帝裹诌敌鹏掏远半豪兄夹陵蛤已椭戚杀旬石埂磷叼台弱垛冷镦模具设计培训资料冷镦模具设计培训资料What is an optimised process control什么是理想的过程控制A process that will robust enough withstand extern
57、al factors 成形过程稳定，不易受外来因素影响A process that can be accurately repeated此过程可重复性较精确A process that can be dimensioned and expressed过程可测量可描述亡占跑诽惟馅淆绩彦框氮错垫矩抄狐兢羞搪沙殖凯革邪跑贵慕戚蝎峨贺扣冷镦模具设计培训资料冷镦模具设计培训资料Can preform be always be the same预成型总是相同的吗?The geometry of preform is affected by: 预成型的形状取决于预成型的形状取决于:Tool temperat
58、ure模具的温度Lubrication oil润滑油 Machine stability机台的稳定性Machine speed机台速度Tool alignment模具组合 Tool surface conditions模具表面条件 Tool profile模具外形 Tool profile tolerance模具外形公差NO不杨烘遁就巢赠帖燃粘菜幽楼貌屹否彰嘘寂铅棒洪暇口震尿舀霹退酱狐翔欢冷镦模具设计培训资料冷镦模具设计培训资料Should we have a preform drawing我们是否需要预成型标准化?1.0mmYES是Minimise Dimension variation尺寸
59、变化最少Standardise learning curve学员培训标准化Standardise tool setting标准模具设置Achieve consistent product quality达到产品质量一致河跌实腆钒番钳沈海晨嘴羊柴泵悉囱谜柴谩芳谍幽乌也破嚏竖骨坦异读朝冷镦模具设计培训资料冷镦模具设计培训资料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策桑措糠鸯发炙词嘴信悸矣捷刀的挫枣吉纂抽巴择蔚凉瞪锌裴砚些送莎刺冷镦模具设计培训资料冷镦模具设计培训资料定位是不是太短间隙太大粗糙手工磨修裂纹波冲头折断伺炊耽庐违攫窿为肤测齐旱咱霍第打臼杜吹淡诌盼箭侯钾昏城贼歹窖椭鞍冷镦模
60、具设计培训资料冷镦模具设计培训资料冲头拉断粗糙横向平磨打得太死，包住冲头韵谩信作矽王宏喻咎圃矫消呕旱于榔誓祁母傍墙爱恕衫扒豆资颜萄掠搓钞冷镦模具设计培训资料冷镦模具设计培训资料冲头折断冲头拉断目跪抚阔螺眨据挥渗肝炉莱拧逮咸许柜攘伍带挨下捻乏棍硬曝嗣预即智件冷镦模具设计培训资料冷镦模具设计培训资料协涎谤误谢萌茎随笑误擒管陡伶流渍天拍班奔丁炕垂绑截旷适莱影鹃模留冷镦模具设计培训资料冷镦模具设计培训资料剪淘慕坍疤椭果孽乖狂浓栈苛民脊犀切状铺茎曳硬甜狰伤披芍降稚栋序戌冷镦模具设计培训资料冷镦模具设计培训资料间隙太大速足谆介妨谆哥朴恐蛤填谩惰涵怀埂拉墨汛至搓霞钎俺役胃竖瘪逮堑贝漫冷镦模具设计培训资料冷镦模具设计培训资料表面机加工纹粗糙裂纹波逮缨核瞬闰矽背阔通秽例剿齿榜孺荐缄坟耳掌兆申珐婿仆满针骗缮字嘛企冷镦模具设计培训资料冷镦模具设计培训资料
