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冷镦工艺介绍-国外资料翻译ContentsoftheTraining培训内容•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模具表面/摩擦系数•Understandtheeffectofpreform预成形分析10Jan20111.AssemblyandsetupofCOD&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&COK2BasicMechanismofShearing剪切基础知识WhatHappenDuringShearing:-剪切过程产生：1.ElasticDeformation弹性变形2.Roll-over曲面3.Plasticshear塑性剪切4.InitialFracture初始断裂5.FinalFracture最终断裂6.PhysicalSeparation实际剪断AssemblyandsetupofCOD&COK2BasicMechanismofShearingQualityProblems:-质量问题1.OvalShape椭圆形2.Tilting歪斜3.Poorshear剪切面粗糙4.Burr毛刺5.NotStraight不直ClearanceTooBig间隙太大OptimumClearance最佳间隙ClearanceTooSmall间隙太小1.ElasticDeformation弹性变形2.Roll-over曲面3.Plasticshear塑性剪切4.InitialFracture初始断裂5.FinalFracture最终断裂6.PhysicalSeparation实际剪断AssemblyandsetupofCOD&COK2BasicMechanismofShearing(HalfCutCOK)半剪1.NoControlofBlank落料无法控制2.DifferentShearPatterns剪切方式不同3.BlankNotStraight线材不直4.BigRoll-over曲面较大5.LowCost成本低廉6.EasytoSetup安装简易7.LongToolLife模具寿命较长AssemblyandsetupofCOD&COK2BasicMechanismofShearing1.NeedReliefSurfaces需要表面退让（退剪槽〕2.CarefulControlofClearance间隙要求高3.DifficultCOK/CODAlignment剪刀、剪体对齐困难4.BetterShear/Quality较好的剪切质量5.AchieveStraightBlank剪断的线材较直6.SmallRoll-over曲面小(CompleteCut全剪)AssemblyandsetupofCOD&COK3CommonBlankQualityIssue常见的线材剪切质量问题1.Roll-over曲面2.Plasticshear塑性剪切3.SecondaryFracture/Tongue二次断裂/舌状毛刺4.Burr毛刺5.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1.MaterialHardness材料硬度2.COK/CODClearance剪刀/剪体间隙3.COK/CODDiameters剪刀/剪体内孔直径4.COKSpeed剪刀速度5.Lubricants润滑6.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?1.PoorShearedSurface:smallclearanceandnotoolrelief剪切面粗糙:间隙太小/没有表面退让2.Burr:COKor/andCODwornoff毛刺:剪刀/剪体磨损3.Tongue:smallclearanceandnotoolrelief舌状毛刺:间隙太小/没有表面退让4.BentBlank:COK/CODdiametertoobig线材弯曲:剪刀/剪体内孔直径太大5.OvalShape:COK/CODdiametertoobig椭圆形:剪刀/剪体内孔直径太大6.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2.Assemblyandsetupofmaindies主模组立Assemblyandsetupofmaindies•BasicofColdForming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Assemblyandsetupofmaindies•BasicofColdForming正挤压反挤压打头Assemblyandsetupofmaindies•BasicofColdFormingAcombinationofdiscipline,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Assemblyandsetupofmaindies•MaterialsforDieConstruction模具的材质CarbideInsert钨钢HotWorkSteel耐热钢HighSpeedSteel高速钢Assemblyandsetupofmaindies•TypesofDieDesign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Assemblyandsetupofmaindies•TypesofDieDesign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Assemblyandsetupofmaindies•ImportanceofDieSurfaceFinishing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Assemblyandsetupofmaindies•CompressiveStress压应力1.Propercompressivestresstoreducematerialbreathingduringforming适当的压力可减少在冷锻时材料的伸展1.Increaseproductdimensionstability增加产品尺寸的稳定性1.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Assemblyandsetupofmaindies•GoodDieAssembly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Assemblyandsetupofmaindies•DefectiveParts/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）Assemblyandsetupofmaindies•DefectiveParts/Dies缺陷部件/模具StepDieFractures:台阶主模破损•Hydr