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 20111.Assembly and setup of COD
2、&COK剪刀/剪模组立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.P
3、lastic 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
4、间隙太小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
5、Roll-over 曲面较大 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/Quality 较好的剪切质量5.Achieve Straight Blank 剪断的线材较直
6、6.Small Roll-over 曲面小(Complete Cut 全剪)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 直线性1443234Assembly 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
7、剪槽Assembly and setup of COD&COK5COD&COK Materials 材料Tool Steel模具钢Carbide钨钢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
8、,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.Assembly and setup of COD&COK7Understand Defects 缺陷分析?1.Poor Sheared
9、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/剪体内孔直径太大6.Big Roll-over:clearance too big and
10、 Tool worn off曲面大:间隙太小/模具磨损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2.Assembly and setup of main dies主模组立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
11、 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 main diesBasic of Cold Forming正挤压反挤压打头Assembly and setup of main diesBasic of Cold FormingA combination of discipline,skill,knowledge&continuous improvement.生产良好的冷锻件，操作者
12、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Assembly and setup of 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/C
13、asing/Insert台阶套片整装主模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 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
14、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成本最昂贵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
15、short KOP life粗糙的内孔面缩短顶针使用寿命Sharp radius causes die chip&fracture模具尖角太锋利造成模具脆裂或破损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%ho
16、t-shrink-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有效间隙以保证给予套片适当的支撑Positive step to ensure proper support of d
17、ie 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Assembly and setup of main diesDefective Parts/Dies 缺陷部件/模具Die Piece Breaks: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
18、 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/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，
19、表面粗糙）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 much 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-sh
20、rink-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/rough surface)顶出力太大(倒锥，太饱满，表面粗糙）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 s
21、urfaces/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预热组装配合不好Over knock out action顶针行程过大Punch Recess hitting二冲窜伤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-shrink-fit 预热组装配合不好2.Poor punch
22、/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 diameter under size due to wrong die
23、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3.Assembly and setup of punches冲头组立/失效分析Timing/Speed 时间时间/速度速度Friction 摩擦系数摩擦系数Alignment 对齐对齐How Punches Fail 二冲如何损坏二冲如何损坏Common Punch Problems 常见二冲
24、问题常见二冲问题Common Product Problems 常见产品问题常见产品问题Timing/Speed 时间时间/速度速度4m/sec(4米/秒)1m/sec(1米/秒)(MH-10 Machine)(UI-10 Machine)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)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
25、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Alignment 对齐对齐Premature Wear of RecessIncorrect Head ShapePremature Break of RecessOff-center 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)How P
26、unches Fail1.Wear offIncorrect Hardness(Above HRC 65)Insufficient LubricantIncorrect Punch Material(M2,M42,Carbide)Without Coating(TiN,TiCN,TiAlN)Poor Preform(1st Punch Preparation)Nature Wear2.Chip OffPoor AlignmentPoor Setup SkillPoor surface Incorrect Punch MaterialMishandlingVibrationSpeed too F
27、ast3.Break offRecess Stripped offbending/MisalignmentPin and Insert MismatchIncorrect Preform(1st Punch Preparation)Speed too FastWrong/Instable ProcessHigh FrictionPoor Cut Off1121233二冲如何损坏二冲如何损坏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
28、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1121233Common Punch ProblemsShort Tool LifeIncorrect Hardness(Above HRC 65)Insufficient LubricantIncorrect Punch Material(M2,M42,Carbide)Without Coating(TiN,TiCN,TiAlN)Poor Preform(1st Punch
29、 Preparation)Poor AlignmentPoor Setup SkillPunch Material too Hard(Above HRC 68)MishandlingVibrationSpeed too FastWrong/Instable ProcessHigh FrictionDimension outPoor Tool SuppliersPoor ReworkTooling not matchOrder Wrong ToolPoor Tool Suppliers常见二冲问题常见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,Carbi
30、de)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错误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Common Product Problems 常见产品问题常见产品问题Incorrect Recess ProfileLubrication OilTool Surface RoughnessIncorrect Tool DimensionIncorrect Recess DepthReces
31、s 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
32、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观缺陷非正常的外观缺陷润滑油模具表面粗糙度模具尺寸不正确4.Understand steel&carbide toolsManufacturing of Fasteners and forging parts fall in the same family紧固件与冷锻件的生产工艺紧固件与冷锻件的生产工艺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 grai
33、n carbide 粗颗粒钨钢Fine grain carbide 细颗粒钨钢300 SUS400 SUS4000 Mpa兆帕3000 MPa2000 MPa1000 MPaHow Strong is Strong钢的强度对照表钢的强度对照表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strainstressprestressingloadingunloading123Good Die Assembly 正确组装模具预先加压卸载加载phase
34、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5.Understand tool surface&f
35、rictionUnderstand 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?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
36、.05 to 0.2Effect of friction 摩擦力产生的因素Assume High Tool Friction采用摩擦力大的模具Assume Low Tool Friction采用摩擦力小的模具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Effect of friction 摩擦系数所产生的影响Assume Low Tool Friction摩擦力 那一边大小？?Practical considerations实际情况需考虑因素?Pra
37、ctical considerations实际情况考虑因素6.Understand the effect of preform了解预成型的影响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
38、 a preform drawing我们需要预成型图纸吗What is Preform 什么是预成型?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?What is an optimised 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Manufactur
39、able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/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The effect of preform预成型的影响Oper
40、ational:-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Tool 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 qualit
41、y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 life模具寿命Part quality部品质量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 Pre
42、form design(effect of preform on the final forming shape)采用不同预成型的产品的最后成型Using 5113 for Illustration以5113为例矮扁的预成形较高的预成形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
43、成形较高的预成形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
44、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 surface 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
45、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What is an optimised process control什么是理想的过程控制A process that will robust enough withstand external 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Can pr
46、eform 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 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 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定位是不是太短间隙太大粗糙手工磨修裂纹波冲头折断冲头拉断粗糙横向平磨打得太死，包住冲头冲头折断冲头拉断间隙太大表面机加工纹粗糙裂纹波谢谢 谢！谢！放映结束 感谢各位的批评指导！让我们共同进步
