冷镦模具设计培训资料
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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
Assembly and setup of main dies • Basic of Cold Forming
正挤压
反挤压
打头
Assembly and setup of main dies • Basic of Cold Forming
冷锻的基础知识
A combination of discipline, skill, knowledge & continuous improvement.
Assembly and setup of main dies • Good Die Assembly 正确组装模具
Tool Life Shorter
模具寿命较短
Some Assembly Problem
某些组装问题
Some Assembly Problem
某些组装问题
Difficult to Alignment
对齐困难
Difficult to Alignment
对齐困难
Short Die-piece Life
套片寿命短
Half Cutter COK / Complete COD 半剪
Complete COK / Complete COD 全剪
Assembly and setup of COD & COK 2 Basic Mechanism of Shearing 剪切基础知识
What Happen During Shearing:剪切过程产生： 1. 2. 3. 4. 5. 6. Elastic Deformation Roll-over Plastic shear Initial Fracture Final Fracture Physical Separation 弹性变形 曲面 塑性剪切 初始断裂 最终断裂 实际剪断
Assembly and setup of COD & COK 2 Basic Mechanism of Shearing (Half Cut COK) 半剪
1. 2. 3. 4. 5. 6. 7.
No Control of Blank Different Shear Patterns Blank Not Straight Big Roll-over Low Cost Easy to Setup Long Tool Life
•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.
需要表面退让（退剪槽〕 间隙要求高 剪刀、剪体对齐困难 较好的剪切质量 剪断的线材较直 曲面小
Assembly and setup of COD & COK 3 Common Blank Quality Issue 常见的线材剪切质量问题
1
4 2 3 4 4 3
1. 2. 3. 4. 5.
Roll-over Plastic shear Secondary Fracture / Tongue Burr Straightness
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。
Assembly and setup of main dies • Materials for Die Construction 模具的材质
Hot Work Steel 耐热钢
High Speed Steel 高速钢 Carbide Insert 钨钢
落料无法控制 剪切方式不同 线材不直 曲面较大 成本低廉 安装简易 模具寿命较长
Assembly and setup of COD & COK 2 Basic Mechanism of Shearing (Complete Cut 全剪)
1. 2. 3. 4. 5. 6.
Need Relief Surfaces Careful Control of Clearance Difficult COK/COD Alignment Better Shear / Quality Achieve Straight Blank Small Roll-over
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% taper press interference 0.5% 斜角部分的过 盈配合量
0.5% cold press interference 0.5% 冷装组合过盈配合量
曲面 塑性剪切 二次断裂 / 舌状毛刺 毛刺 直线性
Assembly and setup of COD & COK 4 COD & 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 & COK 5 COD & COK Materials 材料
Assembly and setup of COD & COK 2
1. 2. 3. 4. 5. 6.
Basic Mechanism of Shearing
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 main dies • Types 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 dies • Types of Die Design 模具设计的类型
Low Cost
成本低廉
Normal Cost
成本一般
Easy Assemble
组装简易
Easy Assemble
组装简易
Long Tool Life
模具寿命长久
Clearance Too Big 间隙太大
Optimum Clearance 最佳间隙
Clearance Too Small 间隙太小
Quality 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
主模组立
Assembly and setup of main dies
• • • • • • •
Basic 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 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
2. Assembly and setup of main dies
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
1.
0.5% hot-shrinkfit interference 0.5% 预热组合的 过盈配合量
Proper compressive stress to reduce material breathing during forming
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 suwenku.baidu.comface causes short KOP life
粗糙的内孔面缩短顶针使用寿命
Sharp radius causes die chip & fracture
Short Die-piece Life
套片寿命短
High Cost
成本昂贵
Very High Cost
成本最昂贵
The REASON for different die designs 不同模具设计的成因
Assembly and setup of main dies • • • • • Importance of Die Surface Finishing
10 Jan 2011
1. Assembly and setup of COD & COK 剪刀/剪模组立
Assembly and setup of COD & COK 1 Types of Shearing 剪切类型
COK: Cut Off Knife 剪刀 COD: Cut Off Die 剪体
Tool Steel 模具钢 Carbide 钨钢
Assembly and setup of COD & COK 6
1. 2. 3. 4. 5. 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 Types of COK 剪刀类型
Assembly and setup of COD & COK 7 Understand Defects 缺陷分析
?
1. 2. 3. 4. 5. 6. 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 Shape: 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 main dies • Basic of Cold Forming
正挤压
反挤压
打头
Assembly and setup of main dies • Basic of Cold Forming
冷锻的基础知识
A combination of discipline, skill, knowledge & continuous improvement.
Assembly and setup of main dies • Good Die Assembly 正确组装模具
Tool Life Shorter
模具寿命较短
Some Assembly Problem
某些组装问题
Some Assembly Problem
某些组装问题
Difficult to Alignment
对齐困难
Difficult to Alignment
对齐困难
Short Die-piece Life
套片寿命短
Half Cutter COK / Complete COD 半剪
Complete COK / Complete COD 全剪
Assembly and setup of COD & COK 2 Basic Mechanism of Shearing 剪切基础知识
What Happen During Shearing:剪切过程产生： 1. 2. 3. 4. 5. 6. Elastic Deformation Roll-over Plastic shear Initial Fracture Final Fracture Physical Separation 弹性变形 曲面 塑性剪切 初始断裂 最终断裂 实际剪断
Assembly and setup of COD & COK 2 Basic Mechanism of Shearing (Half Cut COK) 半剪
1. 2. 3. 4. 5. 6. 7.
No Control of Blank Different Shear Patterns Blank Not Straight Big Roll-over Low Cost Easy to Setup Long Tool Life
•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.
需要表面退让（退剪槽〕 间隙要求高 剪刀、剪体对齐困难 较好的剪切质量 剪断的线材较直 曲面小
Assembly and setup of COD & COK 3 Common Blank Quality Issue 常见的线材剪切质量问题
1
4 2 3 4 4 3
1. 2. 3. 4. 5.
Roll-over Plastic shear Secondary Fracture / Tongue Burr Straightness
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。
Assembly and setup of main dies • Materials for Die Construction 模具的材质
Hot Work Steel 耐热钢
High Speed Steel 高速钢 Carbide Insert 钨钢
落料无法控制 剪切方式不同 线材不直 曲面较大 成本低廉 安装简易 模具寿命较长
Assembly and setup of COD & COK 2 Basic Mechanism of Shearing (Complete Cut 全剪)
1. 2. 3. 4. 5. 6.
Need Relief Surfaces Careful Control of Clearance Difficult COK/COD Alignment Better Shear / Quality Achieve Straight Blank Small Roll-over
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% taper press interference 0.5% 斜角部分的过 盈配合量
0.5% cold press interference 0.5% 冷装组合过盈配合量
曲面 塑性剪切 二次断裂 / 舌状毛刺 毛刺 直线性
Assembly and setup of COD & COK 4 COD & 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 & COK 5 COD & COK Materials 材料
Assembly and setup of COD & COK 2
1. 2. 3. 4. 5. 6.
Basic Mechanism of Shearing
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 main dies • Types 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 dies • Types of Die Design 模具设计的类型
Low Cost
成本低廉
Normal Cost
成本一般
Easy Assemble
组装简易
Easy Assemble
组装简易
Long Tool Life
模具寿命长久
Clearance Too Big 间隙太大
Optimum Clearance 最佳间隙
Clearance Too Small 间隙太小
Quality 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
主模组立
Assembly and setup of main dies
• • • • • • •
Basic 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 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
2. Assembly and setup of main dies
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
1.
0.5% hot-shrinkfit interference 0.5% 预热组合的 过盈配合量
Proper compressive stress to reduce material breathing during forming
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 suwenku.baidu.comface causes short KOP life
粗糙的内孔面缩短顶针使用寿命
Sharp radius causes die chip & fracture
Short Die-piece Life
套片寿命短
High Cost
成本昂贵
Very High Cost
成本最昂贵
The REASON for different die designs 不同模具设计的成因
Assembly and setup of main dies • • • • • Importance of Die Surface Finishing
10 Jan 2011
1. Assembly and setup of COD & COK 剪刀/剪模组立
Assembly and setup of COD & COK 1 Types of Shearing 剪切类型
COK: Cut Off Knife 剪刀 COD: Cut Off Die 剪体
Tool Steel 模具钢 Carbide 钨钢
Assembly and setup of COD & COK 6
1. 2. 3. 4. 5. 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 Types of COK 剪刀类型
Assembly and setup of COD & COK 7 Understand Defects 缺陷分析
?
1. 2. 3. 4. 5. 6. 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 Shape: 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