冲压件模具设计常用公式

1第三章常用公式及數據表第四節衝壓件模具設計常用公式一.衝裁間隙分類見表4-1表4-1衝裁間隙分類(JB/Z271-86)分類依據類別ⅠⅡⅢ制件剪切面質量剪切面特征t=材料厚度塌角深度a(4~7)%t(6~8)%t(8~10)%t光亮帶b(35~55)%t(25~40)%t(15~25)%t剪裂帶E小中大毛刺高度h一般小一般斜度β4°~7°7°~8°8°~11°制件精度撓角f稍小小較大尺寸精度落料件接近凹模尺寸稍小于凹模尺寸小于凹模尺寸沖孔件接近凸模尺寸稍小于凸模尺寸小于凸模尺寸模具壽命較低較高最高適用場合制件剪切面質量﹑尺寸精度要求高時采用,模具壽命較低制件剪切面質量﹑尺寸精度要求一般時采用,適用于繼續塑變的制件制件剪切面質量﹑尺寸精度要求不高時采用,以利提高模具壽命二.衝裁間隙選取(僅供參考)見表4-2(見下頁)2表4-2衝裁間隙比值(單邊間隙)(單位:%t)分類依據類別ⅠⅡⅢ低碳鋼08F﹑10F﹑10﹑20﹑A3﹑B23.0~7.07.0~10.010.0~12.5中碳鋼45不銹鋼1Cr18Ni9Ti、4Cr13可伐合金4J293.5~8.08.0~11.011.0~15.0高碳鋼T8A、T10A、65Mn8.0~12.012.0~15.015.0~18.0純鋁L2、L3、L4、L5鋁合金(軟態)LF21黃銅(軟態)H62紫銅(軟態)T1、T2、T32.0~4.04,5~6.06.5~9.0黃銅(硬態)鉛黃銅紫銅(硬態)3.0~5.05.5~8.08.5~11.0鋁合金(硬態)LY12錫磷青銅、鋁青銅鈹青銅3.5~6.07.0~10.011.0~13.0鎂合金1.5~2.5硅鋼2.5~5.05.0~9.0(注:1.本表適用于厚度為10mm以下的金屬材料,厚料間隙比值應取大些;2.凸,凹模的制造偏差和磨損均使間隙變大,故新模具應取最小間隙;3.硬質合金衝模間隙比鋼模大20%左右.)注:衝裁間隙選取應綜合考慮下列因素:1.衝床﹑模具的精度及剛性.2.產品的斷面品質﹑尺寸精度及平整度.3.模具壽命.4.跳屑.5.被加工材料的材質﹑硬度﹑供應狀態及厚度.6.廢料形狀.7.衝子﹑模仁材質﹑硬度及表面加工質量.三.衝裁力﹑卸(剝)料力﹑推件力﹑頂件力F衝=1.3*L*t*τ(N)(公式4-1)F卸=K卸*F衝(N)(公式4-2)F推=N*K推*K衝(N)(公式4-3)F頂=K頂*F衝(N)(公式4-4)其中:L――衝切線長度(mm)3t――材料厚度(mm)τ――材料抗剪強度(N/mm2)1.3――安全系數K卸――卸(剝)料力系數K推――推料力系數K頂――頂料力系數K卸K推K頂數值見表4-3表4-3卸料力﹑推件力和頂件力系數料厚K卸K推K頂鋼≦0.10.1~0.50.5~2.52.5~6.56.50.065~0.0750.045~0.0550.04~0.050.03~0.040.02~0.030.10.0630.0550.0450.0250.140.080.060.050.03鋁﹑鋁合金紫銅﹑黃銅0.025~0.080.02~0.060.03~0.070.03~0.09注:卸料力系數K卸在衝多孔﹑大搭邊和輪廓復雜時取上限值.四.中性層彎曲半徑R=r+x*t(mm)(公式4-5)其中:R――中性層彎曲半徑(mm)r――零件內側半徑(mm)x――中性層系數中性層系數見表4-4(僅供參考)4表4-4中性層系數x值r／t0.10.20.250.30.40.50.8X0.230.280.300.310.320.330.34r／t1.01.52.03.04.05.06.5X0.350.370.400.430.450.480.5注:彎曲件展開尺寸與下列因素有關:1.彎曲成形方式.2.彎曲間隙.3.有無壓料.4.材料硬度﹑延伸率﹑厚度.5.根据實際狀況精確修正.五.材料最小彎曲半徑,見表4-5表4-5最小彎曲半徑材料退火或正火冷作硬化彎曲線位置垂直于縴維平行于縴維垂直于縴維平行于縴維08﹑1015﹑2025﹑3035﹑4045﹑5055﹑6065Mn﹑T7Cr18Ni9軟杜拉鋁硬杜拉鋁磷銅半硬黃銅軟黃銅紫銅鋁錠0.1t0.1t0.2t0.3t0.5t0.7t1t1t1t2t—0.1t0.1t0.1t0.1t0.4t0.5t0.6t0.8t1.0t1.3t2t2t1.5t3t—0.35t0.35t0.35t0.35t0.4t0.5t0.6t0.8t1.0t1.3t2t3t1.5t3t1t0.5t0.35t1t0.5t0.8t1t1.2t1.5t1.7t2t3t4t2.5t4t3t1.2t0.8t2t1t鎂合金加熱到300~400℃冷彎MB1MB82t1.5t3t2t6t5t8t6t鈦合金BT1BT51.5t3t2t4t3t5t4t6t鉬合金t≦2mm加熱到400~500℃冷彎2t3t4t5t注:表列數据用于彎曲中心角≧90∘﹑斷面質量良好的情況.六﹑彎曲回彈半徑及回彈角5r凸=r0/(1+Kr0/t)(公式4-6)回彈角的數值為Δα=(180°-α0)(r0/r凸-1)(公式4-7)式中r凸――凸模的圓角半徑,[r凸]為mm;r0――工件的圓角半徑,[r0]為mm;α0――工件的彎曲角度,[α0]為(°);t――工件材料厚度,[t]為mm;K――簡化系數,見表4-6表4-6簡化系數k值名稱牌號狀態K名稱牌號狀態K鋁L4,L6退火0.0012磷青銅QSn65-0.1硬0.015冷硬0.0041鈹青銅Qbe2軟0.0064防銹鋁LF21退火0.0021硬0.0265冷硬0.0054鋁青銅QA15硬0.0047LF12軟0.0024碳鋼08,10,A20.0032硬鋁LY11軟0.006420,A30.005硬0.017530,35,A50.0068LY12軟0.007500.015硬0.026碳工鋼T8退火0.0076銅T1,T2,T3軟0.0019冷硬0.0035硬0.0088不銹鋼1Cr18Ni9Ti退火0.0044黃銅H62軟0.0033冷硬0.018半硬0.008彈簧鋼65Mn退火0.0076硬0.015冷硬0.015H68軟0.002660Si2MnA冷硬0.021硬0.0148七﹑彎曲力計算針對“v”型彎曲:F彎=0.6kbtσb/(R+t)(N)(公式4-8)其中:b―――彎曲線長度(mm)t―――材料厚度(mm)r―――內側半徑(mm)σb――材料極限強度(N/mm2)6k―――安全糸數,一般k=1.3八﹑拉深(抽引)系數m=d/D(公式4-9)其中:d――拉深(抽引)后工件直徑(mm)D――毛坯直徑(mm)1.無凸緣或有凸緣筒形件用壓邊圈拉深系數見表4-7表4-7無凸緣或有凸緣筒形件用壓邊圈拉深的拉深系數(適用08,10號鋼)t/d×100r1r/td凸/D1.51.00.60.30.1141251561872080.480.500.510.530.540.550.580.600.650.700.750.800.850.900.950.970.990.480.480.480.480.480.480.480.480.480.470.450.430.410.380.330.310.300.500.500.500.500.500.500.500.490.480.470.450.430.390.340.320.310.510.510.510.510.510.500.490.480.460.450.420.390.350.330.320.540.540.540.530.520.510.490.470.450.410.370.340.330.530.530.530.530.530.520.510.490.470.450.410.370.350.330.550.550.550.540.530.510.490.460.430.380.360.340.550.550.540.530.520.500.480.450.420.380.360.330.580.580.560.540.520.500.480.440.390.370.340.580.570.550.530.510.490.470.430.380.360.340.600.580.560.540.520.490.450.400.380.35以後各次拉深m2m3m4m50.730.760.780.800.750.780.800.820.750.780.800.820.760.790.810.840.760.790.810.830.780.800.820.850.780.800.820.840.790.810.830.850.790.810.830.850.800.820.840.86注:1)隨材料塑性高低,表中數值應酌情增減.2)――線上方為直筒件(d凸=d1).3)隨d凸/D數值增大,r/t值可相應減小,滿足2r1≦h1,保証筒部有直壁.4)查用時,可用插入法,也可用偏大值.5)多次拉深首次形成凸緣時,為考慮多拉入材料,m1增大0.02.2.帶凸緣筒形件第一次拉深系見表4-87表4-8帶凸緣筒形件第一次拉深時的拉深系數m1凸緣相對直徑d凸/d1毛坯相對厚度t/D×1000.06~0.20.2~0.50.5~1.01.0~1.51.5≦1.11.1~1.31.3~1.51.5~1.81.8~2.02.0~2.22.2~2.52.5~2.82.8~3.00.590.550.520.480.450.420.380.350.330.570.540.510.480.450.420.380.350.330.550.530.500.470.440.420.380.340.320.530.510.490.460.430.410.380.340.320.500.490.470.450.420.400.370.330.31注:適用于08﹑10號鋼3.無凸緣筒形件用壓邊圈拉深系數見表4-9表4-9無凸緣筒形件用壓邊圈時的拉深系數拉深系數毛坯相對厚度t/D×1002~1.51.5~1.01.0~0.60.6~0.30.3~0.150.15~0.08m1m2m3m4m50.48~0.500.73~0.750.76~0.780.78~0.800.80~0.820.50~0.550.75~0.760.78~0.790.80~0.810.82~0.840.53~0.550.76~0.780.79~0.800.81~0.820.84~0.850.55~0.580.78~0.790.80~0.810.82~0.830.85~0.860.58~0.600.79~0.800.81~0.820.83~0.850.86~0.870.60~0.630.80~0.820.82~0.840.85~0.860.87~0.88注:1.凹模圓角半徑大時(r凹=8~15t),拉深系數取小值,凹模圓角半徑小時(r凹=4~8t),拉深系數取大值.2.表中拉深系數適用于08﹑10S﹑15S鋼與軟黃銅H62﹑H68.當拉深塑性更大的金屬時(05﹑08Z及10Z鋼﹑鋁等),應比表中數值減小1.5-2%.而當拉深塑性較小的金屬時(20﹑25﹑A2﹑A3﹑酸洗鋼﹑硬鋁﹑硬黃銅等),應比表中數值增大1.5-2%(符號S為深拉深鋼,Z為最深拉深鋼).4.無凸緣筒形件不用壓邊圈拉深系數見表4-10表4-10無凸緣筒形件不用壓邊圈時的拉深系數8材料相對厚度t/D×100各次拉深系數m1m2m3M4m5m60.40.60.81.01.52.02.53.03以上0.900.850.800.750.650.600.550.530.500.920.900.880.850.800.750.750.750.70———0.900.840.800.800.800.75————0.870.840.840.840.78————0.900.870.870.870.82—————0.900.900.900.85注:適用于08﹑10以及15Mn等