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1、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,10 Jan 2011,Assembly and setup of COD&COK
2、剪刀/剪模组立,Assembly and setup of COD&COK,1Types 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&COK,Basic Mechanism of Shearing剪切基础知识,What Happen During Shearing:-剪切过程产生：Elastic Deformation 弹性变形Roll-over 曲面Plas
3、tic 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 COD&COK,2Basic Mechanism of Shearing,Quality Problems:-质量问题Oval Shape 椭圆形 Tilting 歪斜Poor shear 剪切面粗糙Burr 毛刺Not Straight 不直,Clearance Too Big间隙太大,Optimum Clearance最佳间隙,Clearance Too Small间隙太小,Elastic
4、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 COD&COK,2Basic Mechanism of Shearing(Half Cut COK)半剪,No Control of Blank 落料无法控制 Different Shear Patterns 剪切方式不同Blank Not Straight 线材不直Big Roll-over 曲面较大 Low Cost 成本低廉E
5、asy to Setup 安装简易Long Tool Life 模具寿命较长,Assembly and setup of COD&COK,2Basic Mechanism of Shearing,Need Relief Surfaces 需要表面退让（退剪槽Careful Control of Clearance 间隙要求高Difficult COK/COD Alignment 剪刀、剪体对齐困难Better Shear/Quality 较好的剪切质量Achieve Straight Blank 剪断的线材较直Small Roll-over 曲面小,(Complete Cut 全剪),Asse
6、mbly and setup of COD&COK,Common Blank Quality Issue常见的线材剪切质量问题,Roll-over 曲面Plastic shear 塑性剪切Secondary Fracture/Tongue 二次断裂/舌状毛刺Burr 毛刺Straightness 直线性,Assembly and setup of COD&COK,4COD&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,5COD&COK Materials 材料
7、,Tool Steel模具钢Carbide钨钢,Assembly and setup of COD&COK,6Main 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,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
8、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&COK,7Understand Defects 缺陷分析,Poor Sheared Surface:small clearance and no tool relief剪切面粗糙:间隙太小/没有表面退让
9、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 COD&COK,7Understand
10、 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,Assembly and setup of main dies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
11、确安装模具Defective Parts/Poor Die缺陷部件/劣质模具,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,A combination of discipline,skill,knowledge&continuous improvement.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,Assembly and setup of main die
12、s,Materials for Die Construction 模具的材质,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Easy Assemble组
13、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
14、 High Cost成本最昂贵,Assembly and setup of main dies,Importance 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 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 se
15、tup of main dies,Compressive Stress 压应力,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Increase product dimension stability增加产品尺寸的稳定性Extend tool life延长模具寿命,0.5%hot-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 in
16、terference0.5%斜角部分的过盈配合量,Assembly and setup of main dies,Good 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 die 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,Suffici
17、ent Interference足够的过盈量,足够的倒角,Assembly and setup of main dies,Defective Parts/Dies 缺陷部件/模具,Die Piece Breaks: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 matching of taper surfaces斜角部分配合不好4Insufficient compressive stress压力不足5No proper support f
18、rom 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，表面粗糙）,Assembly and setup of main dies,Defective Parts/Dies 缺陷部件/模具,Step Die Fractures:台阶主模破
19、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-shrink-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 f
20、orged/rough surface)顶出力太大(倒锥，太饱满，表面粗糙）,Assembly and setup of main dies,Defective Parts/Dies 缺陷部件/模具,Main Die Chip off/Cracks: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 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
21、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 dies,Defective Parts/Poor Dies缺陷部件/劣质模具,Die wear:模具磨损Poor hot-shrink-fit 预热组装配合不好Poor punch/part/die alignment冲件/冲头/主模没有对齐Wrong carbide grades 选择错误的钨钢等级Insufficient or wrong lubricant 润滑不足或用错
22、润滑油Parts Defects:部件缺陷Galling due to misalignment/poor carbide 磨伤-模具没有对齐/劣质钨钢Blank diameter over size due to poor hot-shrink fit 光杆直径太大-预热组装配合差 Blank diameter under size due to wrong die diameter 光杆直径太小-主模内径错误Inconsistent blank diameter due to die diameter too big 光杆直径不稳定-主模内径太大 Rough surfaces due to
23、 poor die polishing 表面粗糙-模具研磨,抛光不足,Assembly and setup of punches冲头组立/失效分析,Timing/Speed 时间/速度Friction 摩擦系数Alignment 对齐How Punches Fail 二冲如何损坏Common Punch Problems 常见二冲问题Common Product Problems 常见产品问题,Timing/Speed 时间/速度,4m/sec(4米/秒),1m/sec(1米/秒),(MH-10 Machine),(UI-10 Machine),Friction 摩擦系数,Tool Dimen
24、sion(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,Changing Factors:-影响因素Lubrication Oil 润滑油Tool Surface 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Flatness 平直度Head Corner Radii 头部圆角Head Roundness 头部圆度Head diameter 头部直径
25、,Alignment 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 Punches Fail,1.Wear offIncorrect Hardness(Above HRC 65)Insufficient LubricantIncorrect Punch Material(M2,M42,Carbide)Without Coating(TiN,TiCN,TiAlN)Poor Prefo
26、rm(1st Punch Preparation)Nature Wear2.Chip OffPoor AlignmentPoor Setup SkillPoor surface Incorrect Punch MaterialMishandlingVibrationSpeed too Fast3.Break offRecess Stripped offbending/MisalignmentPin and Insert MismatchIncorrect Preform(1st Punch Preparation)Speed too FastWrong/Instable ProcessHigh
27、 FrictionPoor Cut Off,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,Common Punch Problems,Short Tool LifeIncorrect Hardness(
28、Above HRC 65)Insufficient LubricantIncorrect Punch Material(M2,M42,Carbide)Without Coating(TiN,TiCN,TiAlN)Poor Preform(1st Punch Preparation)Poor AlignmentPoor Setup SkillPunch Material too Hard(Above HRC 68)MishandlingVibrationSpeed too FastWrong/Instable ProcessHigh FrictionDimension outPoor Tool
29、SuppliersPoor ReworkTooling not matchOrder Wrong ToolPoor Tool Suppliers,常见二冲问题,寿命短硬度错误(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模具供应商不佳模具修改误差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,Incorr
30、ect Recess ProfileLubrication OilTool Surface RoughnessIncorrect Tool DimensionIncorrect Recess DepthRecess WearRecess Chip offRecess Off-setPoor Punch AlignmentPoor PreformPoor Cut offBig ChamferLubrication OilIncorrect Tool DimensionIncorrect PreformUnusual Visual DefectsLubrication OilTool Surfac
31、e RoughnessIncorrect Tool Dimension,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冲棒磨损冲棒破损成形偏心二冲没有对齐一冲成形差线材剪断不良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润滑油模具表面粗糙度模具尺寸不正确,4.Understand steel&carbide tools,Manufacturing of Fasteners and forging parts fall in the same family紧固件与冷锻件的生产工艺,Low carbon steel,Anti-galling SUS 高耐磨不锈钢,Hot
32、 work steel 耐 热钢,General tool steel 普通工具钢,High speed steel 高速钢,Coarse grain carbide 粗颗粒钨钢,Fine grain carbide 细颗粒钨钢,300 SUS,400 SUS,4000 Mpa兆帕,3000 MPa,2000 MPa,1000 MPa,How Strong is Strong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
33、向预先加压,1,2,3,Good Die Assembly 正确组装模具,预先加压,卸载,加载,merging of micro cracks to surface defects and larger cracks0.1 a 0.5 mm微小的裂痕深入到表面，使裂纹加深,5.Understand tool surface&friction,Understand 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
34、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=0.05 to 0.2,Effect 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
35、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?,?,Practical considerations实际情况考虑因素,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
36、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 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?,Tool L
37、ife:-模具寿命方面?,Product Quality:-产品质量方面?,What is an optimised preform 什么是好的预成型,Operational:-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Manufacturable可操作的Repeatable可重复的Independent不受制约的,Tool Life:-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Prolon
38、g Operation延长生产力,Product Quality:-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,Operational:-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 Lif
39、e:-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 quality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,P
40、art quality部品质量,The effect of preform预成型的影响,Test 1:-试验1Wide Punch Chamfer Angle冲模倒角较大,Test 2:-试验2Small Punch Chamfer Angle冲模倒角较小,Forming of fasteners using different Preform 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 effec
41、t 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
42、 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:profile外形height高度diameter直径weight重量,The geometry of preform is affected by:影响预成型形状的因素:Tool temperature 模具的温度Lubrica
43、tion 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 enou
44、gh 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 preform 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:Tool temperature模具的温度Lubrication oil润滑油 Machine stabil
45、ity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?,YES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,
