冷镦模具设计培训资料.ppt

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 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? 1.0mm 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 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 Alignment 对齐 Premature Wear of Recess Incorrect Head Shape Premature Break of Recess Off-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 off Incorrect Hardness (Above HRC 65?) Insufficient Lubricant Incorrect Punch Material (M2, M42, Carbide) Without Coating (TiN, TiCN, TiAlN) Poor Preform (1st Punch Preparation) Nature Wear 2. Chip Off Poor Alignment Poor Setup Skill Poor surface Incorrect Punch Material Mishandling Vibration Speed too Fast 3. Break off Recess Stripped off bending / Misalignment Pin and Insert Mismatch Incorrect Preform (1st Punch Preparation) Speed too Fast Wrong / Instable Process High Friction Poor Cut Off 1 1 2 1 2 3 3 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 1 1 2 1 2 3 3 Common Punch Problems Short Tool Life Incorrect Hardness (Above HRC 65?) Insufficient Lubricant Incorrect Punch Material (M2, M42, Carbide) Without Coating (TiN, TiCN, TiAlN) Poor Preform (1st Punch Preparation) Poor Alignment Poor Setup Skill Punch Material too Hard (Above HRC 68?) Mi