1、1第第2章章 冲裁模结构与设计冲裁模结构与设计 Chapter Twoblanking dies structure and design 2 使板料分离的冲压工艺称为冲裁。使板料分离的冲压工艺称为冲裁。 The stamping technique to divide the sheet matal is called blanking. There are various kinds of it.such as, cut down, punch,pierce, trim, incise, dissect and so on. 冲裁工艺的种类很多，常用的有切断、落料、冲孔、冲裁工艺的种类很多
2、，常用的有切断、落料、冲孔、切边、切口、剖切等。切边、切口、剖切等。 冲裁是冲压工艺的最基本工序之一。冲裁是冲压工艺的最基本工序之一。blanking is one basic procedure of stamping technique。在冲在冲压加工中应用极广。它既可以直接冲出成品零件，压加工中应用极广。它既可以直接冲出成品零件，也可以作为弯曲、拉深和挤压等其它工序的坯料，也可以作为弯曲、拉深和挤压等其它工序的坯料，还可以在已成形的工件上进行再加工（切边、切还可以在已成形的工件上进行再加工（切边、切口、冲孔等工序）。口、冲孔等工序）。 3本章要点本章要点: important point
3、s of this chapter l 冲裁工艺。冲裁工艺。 Blanking technique. l 典型冲裁模结构。典型冲裁模结构。 Typical blanking dies constructer l 冲裁模主要零部件的结构分析与标准冲裁模主要零部件的结构分析与标准的选用。的选用。The constructer analysis and standards selection of blanking dies important components l 冲裁模设计要点冲裁模设计要点the important points of blanking dies design4本章难点：本
4、章难点：difficulties of this chapter l 冲裁工艺。冲裁工艺。 Blanking technique. l 冲裁模设计要点冲裁模设计要点the important points of blanking dies design52 21 1 冲裁工艺冲裁工艺 Blanking technique.211 冲裁基本知识冲裁基本知识the basic knowledge of Blanking 在冲裁工艺中，以落料、冲孔应用最多。在冲裁工艺中，以落料、冲孔应用最多。The most use of it is punching and piercing. 从板料上冲下所需形
5、状的工件（或毛坯）称为落料。从板料上冲下所需形状的工件（或毛坯）称为落料。Run into the required types workpiece from the sheet matal (or roughcast) is punching. 在工件上冲出所需形状的孔（冲去的为废料）称为冲孔。在工件上冲出所需形状的孔（冲去的为废料）称为冲孔。Run into the required forms workpiece ( the washed thing washed thing is scrap ) is is scrap ) is pierce 落料和冲孔的变形性质完全相同，但在进行模具
6、工作部分落料和冲孔的变形性质完全相同，但在进行模具工作部分设计时，要分开加以考虑。设计时，要分开加以考虑。Punching and pierce have the same distortion feature , but when doing the model work design , we should distinguish them to consider them. , we should distinguish them to consider them.6211 冲裁基本知识冲裁基本知识 the basic knowledge of Blanking7211 冲裁基本知识冲裁
7、基本知识the basic knowledge of Blanking 根据冲裁变形机理的不同，冲裁工艺可以分为普通冲裁和精密冲裁根据冲裁变形机理的不同，冲裁工艺可以分为普通冲裁和精密冲裁两大类。两大类。According to the different distortion mechanism, blanking technique has two types are common blanking and exact blanking .普通冲裁普通冲裁: common blanking 是由凸、凹模刃口之间产生是由凸、凹模刃口之间产生剪裂缝剪裂缝的形式实现板料分离。的形式实现板料分离。
8、To make the edge of the male die and female die produce the shearing cranny to separate the sheet matal .精密冲裁精密冲裁: exact blanking 是以是以变形变形的形式实现板料的分离的形式实现板料的分离 。Through the distortion form to finish the sheet matal . 前者冲出的工件断面比较粗糙，精度较低。后者冲出的工件不但断面前者冲出的工件断面比较粗糙，精度较低。后者冲出的工件不但断面比较光洁而且精度也较高，但需要有专门的精冲设备及
9、精冲模具。比较光洁而且精度也较高，但需要有专门的精冲设备及精冲模具。The formers workpieces shearing surface is more rough, and the latter is more glabrous and the precision is higher, but it needs special precise equipment and model.8212 冲裁过程分析冲裁过程分析 the procedure analysis of blanking 凸模凸模1与凹模与凹模2具有与工具有与工件 轮 廓 一 样 的 刃 口 。件 轮 廓 一 样 的
10、 刃 口 。Male die 1 and female die 2 have the same edge with work profile. 凸、凸、凹模之间存在一定的间凹模之间存在一定的间隙。隙。Male die and female die must existence gap.当压力机滑块把凸模推当压力机滑块把凸模推下时，便将放在凸、凹下时，便将放在凸、凹模中间的板料冲裁成所模中间的板料冲裁成所需的工件。需的工件。9212 冲裁过程分析冲裁过程分析the procedure analysis of blanking 当模具间隙正常时，金属板料的冲裁变形当模具间隙正常时，金属板料的冲裁变
11、形过程大致可分为三个变形阶段过程大致可分为三个变形阶段. When the mould gap is normal,the metal sheet matals blanking distortion procedure has 3 phases. （1）弹性变形阶段）弹性变形阶段 elastic distortion phase （2）塑性变形阶段）塑性变形阶段 plastic distortion phase （3）剪裂阶段）剪裂阶段 shearing crack phase 如下图如下图:1011（1）弹性变形阶段）弹性变形阶段elastic distortion phase 当凸模开始
12、接触板料并下压时，当凸模开始接触板料并下压时，凸模与凹模刃口周围的板料产生应力凸模与凹模刃口周围的板料产生应力集中现象，使材料产生弹性压缩、弯集中现象，使材料产生弹性压缩、弯曲、拉伸等复杂的变形。曲、拉伸等复杂的变形。When the male die starts to touch with sheet matal and press it lowly,the sheet matal which around the male die and female dies edge produce the stress central phenomena, make the material pr
13、oduce the elastic compression ,bend, extend and so on these complex distortion. 板料略有挤入凹模洞口的板料略有挤入凹模洞口的现象。此时，凸模下的材料略有弯曲，现象。此时，凸模下的材料略有弯曲，凹模上的材料则向上翘。间隙愈大，凹模上的材料则向上翘。间隙愈大，弯曲和上翘愈严重。随着凸模继续压弯曲和上翘愈严重。随着凸模继续压入，直到材料内的应力达到弹性极限。入，直到材料内的应力达到弹性极限。12（2）塑性变形阶段）塑性变形阶段 plastic distortion phase当凸模继续压入，板料内的应力达到屈服点，当凸模
14、继续压入，板料内的应力达到屈服点，板料与凸模和凹模的接触处产生塑性剪切变板料与凸模和凹模的接触处产生塑性剪切变形。形。When the male die is gone on When the male die is gone on pressfitting, the stress in the sheet pressfitting, the stress in the sheet metal will get to the yield point, and metal will get to the yield point, and the tangency place of sheet m
15、etal and the tangency place of sheet metal and male die with cavity plate will have male die with cavity plate will have plastic sheer deformation.plastic sheer deformation.随着凸模的下压，应力不断加大，直到分离随着凸模的下压，应力不断加大，直到分离变形区的应力达到抗剪强度，塑性变形阶段变形区的应力达到抗剪强度，塑性变形阶段结束。结束。 With the male die being pressed down, the st
16、ress goes on aggrandizing. The plastic sheer deformation place wont be finished with separate deformed zone of stress gets to the shearing strength.13（3）剪裂阶段）剪裂阶段shearing crack phase当板料的应力达到抗剪强度后，凸模再向下压，当板料的应力达到抗剪强度后，凸模再向下压，则在板料与凸模和凹模的刃口接触处分别产生则在板料与凸模和凹模的刃口接触处分别产生裂纹。裂纹。After sheet matal stress gets
17、to the shearing intension, the male die is gone on being pressed down and the fissure will be begot at the tangency place of sheet metal and male dies with cavity plates blade mouth apart . 随着凸模下压，裂纹逐渐扩大并向材料随着凸模下压，裂纹逐渐扩大并向材料内延伸。内延伸。With the male die being pressed down, fissure is come to enlarge and
18、 extended to the inside of materials. 当上、下裂纹重合时，板料便被分离。当上、下裂纹重合时，板料便被分离。When surfissrue and lay-fissure coinage, sheet matal will be asundered . 凸模再下压，将已分离的材料克服摩擦阻力从凸模再下压，将已分离的材料克服摩擦阻力从板料中推出，完成冲裁过程板料中推出，完成冲裁过程。And with male die being frictional ressistance and will be pushed out of the sheet matal a
19、nd then the blanking course will be finished.14212 冲裁过程分析冲裁过程分析the procedure analysis of blanking 在正常的冲裁工作条件下，由凸模刃口出发的剪裂缝在正常的冲裁工作条件下，由凸模刃口出发的剪裂缝与由凹模刃口出发的剪裂缝是重合的与由凹模刃口出发的剪裂缝是重合的。这时可以得到这时可以得到如图如图2.4所示的冲裁件断面，它具有明显的四个特征区。所示的冲裁件断面，它具有明显的四个特征区。At the normal conditions of blanking work, the At the normal c
20、onditions of blanking work, the shear fracture slots are coinage, which start shear fracture slots are coinage, which start off the male die and cavity plate blade off the male die and cavity plate blade mouth.Now, the blanking pieces sever panel is mouth.Now, the blanking pieces sever panel is bein
21、g being obtaindeobtainde.Look at the picture 2-4.It has .Look at the picture 2-4.It has four evident earmark zones.four evident earmark zones. （1 1）圆角带）圆角带；circle angle zone（2）光亮带光亮带 ；euphotic zone （3）断裂带断裂带 ；fracture zone （4）毛刺。毛刺。burrburr1516212 冲裁过程分析冲裁过程分析 the procedure analysis of blanking 圆角带圆
22、角带1又称塌角又称塌角 circle angle zone 1,has an alternate name fallen angle. . 材料塑性愈好，凸、凹模之间间隙愈大，形成的塌角也材料塑性愈好，凸、凹模之间间隙愈大，形成的塌角也就愈大。就愈大。The plastic of material is better,and the gap between male die and cavity plate is bigger,the fallen down angle will be bigger. 光亮带光亮带2 2 euphotic zone 2 光亮带垂直于底面。材料塑性愈好，凸模和凹
23、模之间的光亮带垂直于底面。材料塑性愈好，凸模和凹模之间的间隙（图中间隙（图中Z Z2 2为单边间隙）愈小，光亮带的高度愈高。为单边间隙）愈小，光亮带的高度愈高。The euphotic zone and the botton side are uprightness.The material plastic is better,the gap (the gap in z/2 is a single side one)between male die and cavity plate is smaller,and the hight of euphotic zone will be higher
24、.17212 冲裁过程分析冲裁过程分析the procedure analysis of blanking 断裂带断裂带3 3 fractured zone 3 断裂带表面粗糙，并带有斜度。凸模和凹模的间断裂带表面粗糙，并带有斜度。凸模和凹模的间隙愈大，则断裂带高度愈大且斜度也增大。隙愈大，则断裂带高度愈大且斜度也增大。Fractured zone has a crudity surface with a pitch.The gap between male die and cavity plate is bigger, the height of fractured zone will be
25、 higher and the pitch will be bigger . 毛刺毛刺4 4 burr 4burr 4 紧挨着剪裂带的边缘，是由于裂纹的产生不是正紧挨着剪裂带的边缘，是由于裂纹的产生不是正对着凸模和凹模的刃口而是在靠近刃口的侧面。对着凸模和凹模的刃口而是在靠近刃口的侧面。That That next to the edge of shear fracture zone, is next to the edge of shear fracture zone, is causef causef by fissure generation,which is closed up by
26、fissure generation,which is closed up the flank of blade mouth but not against the the flank of blade mouth but not against the male dies and cavitys blade mouth. male dies and cavitys blade mouth. 18计算凸模和凹模尺寸的依据：计算凸模和凹模尺寸的依据：the gist of calculation male die and female dies size 对于冲孔件的孔，决定与轴类零件配合性质的
27、是它的最小尺对于冲孔件的孔，决定与轴类零件配合性质的是它的最小尺寸，即其光亮柱体部分尺寸；对于落料件，决定与孔类零件寸，即其光亮柱体部分尺寸；对于落料件，决定与孔类零件配合性质的是它的最大尺寸，也是它的光亮柱体部分尺寸。配合性质的是它的最大尺寸，也是它的光亮柱体部分尺寸。As for the hole of the rush vent piece, its least As for the hole of the rush vent piece, its least size depends on the coordination cy of the axle size depends on
28、the coordination cy of the axle genus details, that is the dimension of lustre pole genus details, that is the dimension of lustre pole part; As for blanking piece,its macrosize depends on part; As for blanking piece,its macrosize depends on the coordination cy of vent genus details, that is the coo
29、rdination cy of vent genus details, that is the dimension of lustre pole,too. the dimension of lustre pole,too. 于是，可以得出如下重要的关系式于是，可以得出如下重要的关系式 : : 落料尺寸落料尺寸 = = 凹模尺寸凹模尺寸 punching size=female die punching size=female die sizesize 冲孔尺寸冲孔尺寸 = = 凸模尺寸凸模尺寸 pierce size=male die size pierce size=male die siz
30、e 19213 冲裁件的质量分析冲裁件的质量分析 blanking pieces quality analysis 1 1尺寸精度；尺寸精度；size precision 2 2断面质量；断面质量；breaking surfaces quality 3毛刺毛刺。burrburr201尺寸精度尺寸精度size precision 冲裁件的尺寸精度与许多因素有关，如冲模冲裁件的尺寸精度与许多因素有关，如冲模的制造精度、材料性质、冲裁间隙和冲裁件的的制造精度、材料性质、冲裁间隙和冲裁件的形状等。形状等。The size precision of blanking piece is in relati
31、on to lots of factors, for example: （1 1）冲模的制造精度；）冲模的制造精度；dies constructive precision （2 2）材料性质；）材料性质；material quality （3 3）冲裁间隙；）冲裁间隙；blanking gap （4 4）冲裁件的形状。）冲裁件的形状。blanking pieces shape21（1 1）冲模的制造精度）冲模的制造精度 dies constructive precision 冲模的制造精度对冲裁件的尺寸精度冲模的制造精度对冲裁件的尺寸精度有直接影响。冲模的精度愈高，冲裁件有直接影响。冲模的精度
32、愈高，冲裁件的精度亦愈高。的精度亦愈高。The dies constructive precision has effect on blanking pieces size precision directly. 22（2 2）材料性质）材料性质material quality 对于比较软的材料，弹性变形量较对于比较软的材料，弹性变形量较小，冲裁后的回弹值也少，因而零件精小，冲裁后的回弹值也少，因而零件精度较高。而硬的材料，情况正好与此相度较高。而硬的材料，情况正好与此相反。反。To the softer material, elastic distortion quantity is sma
33、ller, and the re-flip value is small, so the component precision is higher.23（3 3）冲裁间隙）冲裁间隙blanking gap 如间隙过大，对于落料件，其尺寸将会小于凹模如间隙过大，对于落料件，其尺寸将会小于凹模尺寸，对于冲孔件，其尺寸将会大于凸模尺寸。尺寸，对于冲孔件，其尺寸将会大于凸模尺寸。If the gap is too bigger as for fallen material piece ,its side will be smaller than cavity size; as for rush ve
34、nt piece,its side will greater than male dies. 如间隙过小，对于落料件，其尺寸将会大于凹模如间隙过小，对于落料件，其尺寸将会大于凹模尺寸，对于冲孔件，其尺寸将会小于凸模尺寸。尺寸，对于冲孔件，其尺寸将会小于凸模尺寸。 If the gap is too smaller, as for fallen material piec, its side will be greater than cavity size; as for rush vent piece, its side will smaller than male dies.24（4 4）冲
35、裁件的形状）冲裁件的形状blanking pieces shape 冲裁件的形状越简单其精度越高。冲裁件的形状越简单其精度越高。The easier the shape is, the higher the precision is.252 2断面质量断面质量breaking surface quality 对于断面质量，起决定作用的是冲裁间隙。对于断面质量，起决定作用的是冲裁间隙。 To it , its up to the blanking gap.To it , its up to the blanking gap. 在具有合理间隙的冲裁条件下裂纹重合。在具有合理间隙的冲裁条件下裂纹重合
36、。Under the condition of the proper gaps Under the condition of the proper gaps blanking , the crack will be superposition. blanking , the crack will be superposition. 所得冲裁件断面有一个微小的塌角（所得冲裁件断面有一个微小的塌角（the angle the angle of dentof dent），），并有正常的既光亮又与板平面垂直并有正常的既光亮又与板平面垂直的光亮带的光亮带( (euphotic zone ) )，其断裂带
37、虽然粗糙但，其断裂带虽然粗糙但比较平坦，虽有斜度但并不大，所产生的毛刺也比较平坦，虽有斜度但并不大，所产生的毛刺也是不明显的。是不明显的。 26 2 2断面质量断面质量breaking surface quality27 2 2断面质量断面质量breaking surface quality 当间隙过大或过小时，就会使上、下裂纹不能重当间隙过大或过小时，就会使上、下裂纹不能重合。合。When the gap is too big or small, it will stop the upper and lower crack from superposition. . （1 1）间隙过大：）间
38、隙过大： the gap is too big 凸模产生的裂纹相对于凹模产生的裂纹向里移动一个凸模产生的裂纹相对于凹模产生的裂纹向里移动一个距离。距离。 the male dies gap opposite female dies gap move one distance outward. 板料受拉伸、弯曲的作用加大，使剪切断面塌角加大，板料受拉伸、弯曲的作用加大，使剪切断面塌角加大，光亮带的高度缩短，断裂带的高度增加，锥度也加大，光亮带的高度缩短，断裂带的高度增加，锥度也加大，有明显的拉断毛刺，冲裁件平面可能产生穹弯现象。有明显的拉断毛刺，冲裁件平面可能产生穹弯现象。 28 2 2断面质量
39、断面质量breaking surface quality （2 2）间隙过小：）间隙过小： the gap is too small the gap is too small 会使凸模产生的裂纹向外移动一个距离。会使凸模产生的裂纹向外移动一个距离。It will make the male dies gap move one It will make the male dies gap move one distance.distance.上、下裂纹不重合，产生第二次剪切，上、下裂纹不重合，产生第二次剪切，由凸模和凹模刃口所产生的裂从而在剪切面上由凸模和凹模刃口所产生的裂从而在剪切面上形成了略
40、带倒锥的第二个光亮带。在第二个光形成了略带倒锥的第二个光亮带。在第二个光亮带下面存在着潜伏的裂纹。由于间隙过小，亮带下面存在着潜伏的裂纹。由于间隙过小，板料与模具的挤压作用加大，在最后被分离时，板料与模具的挤压作用加大，在最后被分离时，冲裁件上有较尖锐的挤出毛刺。冲裁件上有较尖锐的挤出毛刺。 293毛刺毛刺burrburr 冲裁过程的分析可知，冲裁件产生微小的毛刺是不可避冲裁过程的分析可知，冲裁件产生微小的毛刺是不可避免的。免的。According to the blanking procedure, it According to the blanking procedure, it can
41、t avoid the blanking piece produce burr.cant avoid the blanking piece produce burr.若产品若产品要求不允许存在微小毛刺，则在冲裁后应增加去除毛刺的要求不允许存在微小毛刺，则在冲裁后应增加去除毛刺的辅助工序。正常冲裁中允许的毛刺高度见表辅助工序。正常冲裁中允许的毛刺高度见表2.2。 If the products requirement is not allowed to exist the small burr, so we should add the assistant working procedure t
42、o remove the burr. The height of burr of the usual blanking is in the table 2.2.303毛刺毛刺burrburr 若冲裁过程不正常，毛刺就会明显增大，这是不允若冲裁过程不正常，毛刺就会明显增大，这是不允许的。产生毛刺的原因主要有两个，其一是冲裁间许的。产生毛刺的原因主要有两个，其一是冲裁间隙不合理。隙不合理。If the procedure is not normal, If the procedure is not normal, the burr will become bigger, its not the b
43、urr will become bigger, its not permitted. There are 2 reasons of causing permitted. There are 2 reasons of causing burr,one of it is the improper blanking gap.burr,one of it is the improper blanking gap. （1 1）间隙过大，会产生明显的拉断毛刺。）间隙过大，会产生明显的拉断毛刺。 （2 2）间隙过小，会产生尖锐的挤出毛刺。）间隙过小，会产生尖锐的挤出毛刺。 (1)(1)The gap is
44、too big that will snap the The gap is too big that will snap the burr obviously; burr obviously; (2) its too small that will pile out the (2) its too small that will pile out the burr stridentlyburr stridently. .313毛刺毛刺burrburr 产生毛刺的原因其二是凸模或凹模磨钝后，其刃口产生毛刺的原因其二是凸模或凹模磨钝后，其刃口处形成圆角，这是产生毛刺的主要原因。处形成圆角，这是产生
45、毛刺的主要原因。The The second reason is that produce the circle second reason is that produce the circle angle at the edge after abraded the male die angle at the edge after abraded the male die and the female die. And this is the main and the female die. And this is the main reason.reason. 当凸模和凹模刃口带有圆角后，冲
46、裁时材料中就减当凸模和凹模刃口带有圆角后，冲裁时材料中就减少了应力集中现象而增大了变形区域，产生的裂纹少了应力集中现象而增大了变形区域，产生的裂纹偏离刃口，凸模和凹模间金属在剪切断裂前有很大偏离刃口，凸模和凹模间金属在剪切断裂前有很大的拉伸，这就使冲裁断面上产生了明显的毛刺。的拉伸，这就使冲裁断面上产生了明显的毛刺。 32213 冲裁件的质量分析冲裁件的质量分析blanking pieces quality analysis 综上所述用普通冲裁方法所能得到的冲裁件，综上所述用普通冲裁方法所能得到的冲裁件，其尺寸精度与断面质量都不太高。金属冲裁件所能其尺寸精度与断面质量都不太高。金属冲裁件所能达
47、到的经济精度为达到的经济精度为ITl4 ITl0级，要求高的可达到级，要求高的可达到ITl0 IT8级。厚料比薄料更差。若要进一步提高冲裁件级。厚料比薄料更差。若要进一步提高冲裁件的质量，则要在冲裁后加整修工序或采用精密冲裁的质量，则要在冲裁后加整修工序或采用精密冲裁法。法。To sum up the above arguments, use common blanking method gained blanking ware,its size precision and cut surface quality are all not very. Metal blanking wares e
48、conomy accuracy are certainly attainable IT14-IT10. 33214 冲裁间隙冲裁间隙blanking gapblanking gap 冲裁间隙是指冲裁凸模和凹模之间冲裁间隙是指冲裁凸模和凹模之间工作部分的尺寸之差。如图工作部分的尺寸之差。如图2.6所示，所示，即即 b l a n k i n g g a p i s t h e b l a n k i n g g a p i s t h e difference size between the difference size between the male die and female die
49、s male die and female dies w o r k p a r t . L o o k a t t h e w o r k p a r t . L o o k a t t h e picture2.6.picture2.6. Z D凹凹 一一D凸凸 如无特殊说明，冲裁间隙一般是指如无特殊说明，冲裁间隙一般是指双边间隙。双边间隙。If it has not other If it has not other special illustration, blanking special illustration, blanking gap is the bilateral gap
50、.gap is the bilateral gap.34214 冲裁间隙冲裁间隙blanking gapblanking gap 冲裁间隙对冲裁过程有着很大冲裁间隙对冲裁过程有着很大的影响。甚至可以说间隙对冲的影响。甚至可以说间隙对冲裁件的质量起着决定性的作用。裁件的质量起着决定性的作用。 blanking gap has great blanking gap has great effect on the blanking effect on the blanking procedure. And we can say procedure. And we can say that the g
