1、冷鐓工藝全面介紹-國外資料翻譯冷鐓工藝全面介紹-國外資料翻譯Contents of the Training 培訓內容Assembly and setup of COD & COK 剪刀/剪模組立Assembly and setup of main dies主模組立Assembly and setup of punches沖頭組立/失效分析Understand steel & carbide tools模具組立/材料/鎢鋼Understand tool surface & friction 模具表面/摩擦系數Understand the effect of preform預成形分析10 Jan

2、 2011冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK剪刀/剪模組立冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK1Types of Shearing 剪切類型Half Cutter COK / Complete COD半剪Complete COK / Complete COD全剪COK: Cut Off Knife 剪刀COD: Cut Off Die 剪體冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COKBasic Mechanism of Shearin

3、g剪切基礎知識What Happen During Shearing:-剪切過程產生：Elastic Deformation 彈性變形Roll-over 曲面Plastic shear 塑性剪切Initial Fracture 初始斷裂Final Fracture 最終斷裂Physical Separation 實際剪斷冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK2Basic Mechanism of ShearingQuality Problems:- 質量問題Oval Shape 橢圓形 Tilting 歪斜Poor shear 剪切面粗糙B

4、urr 毛刺Not Straight 不直Clearance Too Big間隙太大Optimum Clearance最佳間隙Clearance Too Small間隙太小Elastic Deformation 彈性變形Roll-over 曲面Plastic shear 塑性剪切Initial Fracture 初始斷裂Final Fracture 最終斷裂Physical Separation 實際剪斷冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK2Basic Mechanism of Shearing (Half Cut COK) 半剪No C

5、ontrol of Blank 落料無法控制 Different Shear Patterns 剪切方式不同Blank Not Straight 線材不直Big Roll-over 曲面較大 Low Cost 成本低廉Easy to Setup 安裝簡易Long Tool Life 模具壽命較長冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK2Basic Mechanism of ShearingNeed Relief Surfaces 需要表面退讓（退剪槽Careful Control of Clearance 間隙要求高Difficult COK

6、/COD Alignment 剪刀、剪體對齊困難Better Shear / Quality 較好的剪切質量Achieve Straight Blank 剪斷的線材較直Small Roll-over 曲面小(Complete Cut 全剪)冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COKCommon Blank Quality Issue常見的線材剪切質量問題Roll-over 曲面Plastic shear 塑性剪切Secondary Fracture / Tongue 二次斷裂 / 舌狀毛刺Burr 毛刺Straightness 直線性14432

7、34冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK4COD & COK Setting 安裝Relief表面退讓（退剪槽Small Radius小圓角 Relief表面退讓（退剪槽冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK5COD & COK Materials 材料Tool Steel模具鋼Carbide鎢鋼冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK6Main Process Parameters 主要參數Material Hardness 材料硬

8、度COK/COD Clearance 剪刀/ 剪體間隙COK/COD Diameters 剪刀/ 剪體內孔直徑COK Speed 剪刀速度Lubricants 潤滑Types of COK 剪刀類型Harder materials need bigger clearance, more tool relief & higher speed 當剪切較硬的線材時, 需要更多的間隙, 表面退讓(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/ 剪體的內孔直徑太大時, 會造

9、成線材彎曲, 線材末端縮小.Shearing without lubricants causes short tool life 無潤滑剪切會縮短模具壽命.冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK7Understand Defects 缺陷分析?Poor Sheared Surface: small clearance and no tool relief剪切面粗糙: 間隙太小/ 沒有表面退讓Burr: COK or/and COD worn off毛刺: 剪刀/ 剪體磨損Tongue: small clearance and no tool

10、 relief舌狀毛刺: 間隙太小/ 沒有表面退讓Bent Blank: COK/COD diameter too big線材彎曲: 剪刀/ 剪體內孔直徑太大Oval Shape: COK/COD diameter too big橢圓形: 剪刀/ 剪體內孔直徑太大Big Roll-over: clearance too big and Tool worn off曲面大: 間隙太小/ 模具磨損冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of COD & COK7Understand Defects 缺陷分析?硬材料間隙較小剪切面較好刀口易磨損鎢鋼易破損軟材料間隙較大剪切面

11、難控制要退讓曹材料易彎冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main dies主模組立冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesBasic of Cold Forming冷鍛的基礎知識Materials for Die Construction模具的材質Types of Die Design模具設計的類型Importance of Die Surface Finishing模具表面加工的重要性Compressive Stress壓應力Good Die Assembly正確安裝模具Defective Parts

12、 / Poor Die缺陷部件 / 劣質模具冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesBasic of Cold Forming正擠壓反擠壓打頭冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesBasic of Cold FormingA combination of discipline, skill, knowledge & continuous improvement.生產良好的冷鍛件， 操作者需要具備: 紀律, 技能, 知識和持之以恒的進取精神。冷鍛的基礎知識冷鐓工藝全面介紹-國外資料翻譯Ass

13、embly and setup of main diesMaterials for Die Construction 模具的材質Carbide Insert鎢鋼Hot Work Steel耐熱鋼High Speed Steel高速鋼冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesTypes of Die Design 模具設計的類型Solid Main Die 實心主模Step Solid Main Die 臺階實心主模 Die-Piece / Casing / Insert 套片整裝主模Step Die-Piece / Casing / Inser

14、t臺階套片整裝主模冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesTypes of Die Design 模具設計的類型Low Cost成本低廉Easy Assemble組裝簡易Long Tool Life模具壽命長久The REASON for different die designs不同模具設計的成因Normal Cost成本一般Easy Assemble組裝簡易Tool Life Shorter模具壽命較短Some Assembly Problem某些組裝問題Difficult to Alignment對齊困難Short Die-piece

15、Life套片壽命短High Cost成本昂貴Some Assembly Problem某些組裝問題Difficult to Alignment對齊困難Short Die-piece Life套片壽命短Very High Cost成本最昂貴冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesImportance of Die Surface Finishing模具表面加工的重要性Grinding marks promote cracks模具研磨紋路造成脆裂Rough surfaces promote galling粗糙的表面造成表面磨傷Poor inter

16、nal surface causes short KOP life粗糙的內孔面縮短頂針使用壽命Sharp radius causes die chip & fracture模具尖角太鋒利造成模具脆裂或破損冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesCompressive Stress 壓應力Proper compressive stress to reduce material breathing during forming適當的壓力可減少在冷鍛時材料的伸展Increase product dimension stability增加產品尺寸的穩

17、定性Extend tool life延長模具壽命0.5% hot-shrink-fit interference0.5% 預熱組合的過盈配合量0.5% cold press interference0.5% 冷裝組合過盈配合量0.5% taper press interference0.5% 斜角部分的過盈配合量冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesGood Die Assembly 正確組裝模具Positive step to ensure proper support of die piece by die insert有效間隙以保證給

18、予套片適當的支撐Positive step to ensure proper support of die insert有效臺階以保證給予組合套心適當的支撐Sufficient chamfer Proper installation of die piece適當安裝套片Sufficient Interference足夠的過盈量足夠的倒角冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesDefective Parts / Dies 缺陷部件 / 模具Die Piece Breaks: 套片破裂1Die piece and die case off cen

19、ters套片和主模套偏心2Rough surfaces / insufficient polishing表面粗糙 / 研磨,拋光不足3Poor matching of taper surfaces斜角部分配合不好4Insufficient compressive stress壓力不足5No proper support from die insert組合套心沒有給予套片恰當的支撐6Insufficient step radius臺階部分圓角太小 7Poor punch / die alignment沖件 / 主模沒有對齊8Blank over-length線材剪切太長9Punch Recess

20、 hitting 二沖竄傷10 High KO force (taper / over forged / rough surface)頂出力太大 (倒錐，太飽滿，表面粗糙）冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesDefective Parts / Dies 缺陷部件 / 模具Step Die Fractures: 臺階主模破損Hydraulic effect / too much oil/air & oil trap液壓影響 / 潤滑油太多/憋氣憋油Insufficient step radius臺階部分圓角太小Rough surfaces

21、/ insufficient polishing表面粗糙 / 研磨, 拋光不足Poor punch / die alignment沖件 / 主模沒有對齊Blank over-length線材剪切太長Poor hot-shrink-fit預熱組裝配合差Heavy knock out action頂針沖擊力過大Punch Recess hitting二沖竄傷High KO force (taper / over forged / rough surface)頂出力太大 (倒錐，太飽滿，表面粗糙）冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesDefect

22、ive Parts / Dies 缺陷部件 / 模具Main Die Chip off / Cracks: 主模脆裂Improper sitting of main die主模安裝位置不正確Insufficient step radius臺階部分圓角太小Rough surfaces / insufficient polishing表面粗糙 / 研磨, 拋光不足Poor punch / die alignment沖件 / 主模沒有對齊Blank over-length線材剪切太長Poor hot-shrink-fit預熱組裝配合不好Over knock out action頂針行程過大Punch

23、 Recess hitting二沖竄傷冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of main diesDefective Parts / Poor Dies缺陷部件 / 劣質模具Die wear: 模具磨損Poor hot-shrink-fit 預熱組裝配合不好Poor punch/ part / die alignment沖件 / 沖頭/ 主模沒有對齊Wrong carbide grades 選擇錯誤的鎢鋼等級Insufficient or wrong lubricant 潤滑不足或用錯潤滑油Parts Defects: 部件缺陷Galling due to mi

24、salignment / poor carbide 磨傷-模具沒有對齊 / 劣質鎢鋼Blank diameter over size due to poor hot-shrink fit 光桿直徑太大-預熱組裝配合差 Blank diameter under size due to wrong die diameter 光桿直徑太小-主模內徑錯誤Inconsistent blank diameter due to die diameter too big 光桿直徑不穩定-主模內徑太大 Rough surfaces due to poor die polishing 表面粗糙-模具研磨, 拋光不

25、足冷鐓工藝全面介紹-國外資料翻譯Assembly and setup of punches沖頭組立/失效分析冷鐓工藝全面介紹-國外資料翻譯Timing / Speed 時間/速度Friction 摩擦系數Alignment 對齊How Punches Fail 二沖如何損壞Common Punch Problems 常見二沖問題Common Product Problems 常見產品問題冷鐓工藝全面介紹-國外資料翻譯Timing / Speed 時間 / 速度4m/sec (4米/秒)1m/sec (1米/秒)(MH-10 Machine)(UI-10 Machine)冷鐓工藝全面介紹-國外資

26、料翻譯Friction 摩擦系數Tool Dimension (can check) 模具尺寸 (可以測量)Tool Surface Roughness (difficult to check) 模具表面粗糙度(較難測量)冷鐓工藝全面介紹-國外資料翻譯Friction 摩擦系數Changing Factors:- 影響因素Lubrication Oil 潤滑油Tool Surface Roughness 模具粗糙度Preform Setting 一沖成形設置Machine Speed 機器速度Changing Dimension:- 受影響尺寸Flatness 平直度Head Corner R

27、adii 頭部圓角Head Roundness 頭部圓度Head diameter 頭部直徑冷鐓工藝全面介紹-國外資料翻譯Alignment 對齊Premature Wear of RecessIncorrect Head ShapePremature Break of RecessOff-center Recess( 0.05mm )梅花部分磨損頭形錯誤梅花部分破裂梅花偏心 ( 0.05mm )冷鐓工藝全面介紹-國外資料翻譯How Punches Fail1. Wear offIncorrect Hardness (Above HRC 65)Insufficient LubricantInc

28、orrect 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 Fast3. Break offRecess Stripped offbending / MisalignmentPin and Insert

29、 MismatchIncorrect Preform (1st Punch Preparation)Speed too FastWrong / Instable ProcessHigh FrictionPoor Cut Off1121233冷鐓工藝全面介紹-國外資料翻譯二沖如何損壞1. 磨損硬度錯誤 (高于 HRC 65)潤滑不足二沖材質錯誤 (M2, M42, Carbide)沒有涂 層 (TiN, TiCN, TiAlN)一沖成形差 (1st Punch Preparation)自然磨損2. 破損沒有對齊安裝技術差表面粗糙二沖材質錯誤人為損壞震動機器速度太快3. 斷裂梅花破裂二沖棒彎曲 /

30、 沒有對齊二沖套和沖棒不配一沖成形錯誤(1st Punch Preparation)速度太快錯誤/不穩定生產程序摩擦系數太大線材剪斷不良1121233冷鐓工藝全面介紹-國外資料翻譯Common Punch ProblemsShort Tool LifeIncorrect Hardness (Above HRC 65)Insufficient LubricantIncorrect Punch Material (M2, M42, Carbide)Without Coating (TiN, TiCN, TiAlN)Poor Preform (1st Punch Preparation)Poor A

31、lignmentPoor Setup SkillPunch Material too Hard (Above HRC 68)MishandlingVibrationSpeed too FastWrong / Instable ProcessHigh FrictionDimension outPoor Tool SuppliersPoor ReworkTooling not matchOrder Wrong ToolPoor Tool Suppliers冷鐓工藝全面介紹-國外資料翻譯常見二沖問題壽命短硬度錯誤 (高于HRC 65 )潤滑不足二沖材質錯誤 (M2, M42, Carbide)沒有涂

32、層 (TiN, TiCN, TiAlN)一沖成形問題 (1st Punch Preparation)沒有對齊安裝技術差二沖材質太硬 (高于 HRC 68)人為損壞震動機器速度太快錯誤/不穩定生產程序摩擦系數太大尺寸錯誤模具供應商不佳模具修改誤差模具不能配合購買錯誤模具模具供應商不佳冷鐓工藝全面介紹-國外資料翻譯Common Product Problems 常見產品問題Incorrect Recess ProfileLubrication OilTool Surface RoughnessIncorrect Tool DimensionIncorrect Recess DepthRecess

33、WearRecess Chip offRecess Off-setPoor Punch AlignmentPoor PreformPoor Cut offBig ChamferLubrication OilIncorrect Tool DimensionIncorrect PreformUnusual Visual DefectsLubrication OilTool Surface RoughnessIncorrect Tool Dimension成形形狀不正確潤滑油模具表面粗糙度模具尺寸不正確成形深度不正確沖棒磨損沖棒破損成形偏心二沖沒有對齊一沖成形差線材剪斷不良斜角大潤滑油模具尺寸不正確

34、一沖成形不正確非正常的外觀缺陷潤滑油模具表面粗糙度模具尺寸不正確冷鐓工藝全面介紹-國外資料翻譯4. Understand steel & carbide tools冷鐓工藝全面介紹-國外資料翻譯Manufacturing of Fasteners and forging parts fall in the same family緊固件與冷鍛件的生產工藝冷鐓工藝全面介紹-國外資料翻譯Low carbon steelAnti-galling SUS 高耐磨不銹鋼Hot work steel 耐 熱鋼General tool steel 普通工具鋼High speed steel 高速鋼Coarse

35、 grain carbide 粗顆粒鎢鋼Fine grain carbide 細顆粒鎢鋼300 SUS400 SUS4000 Mpa兆帕3000 MPa2000 MPa1000 MPaHow Strong is Strong鋼的強度對照表1000 Mpa = 100kg/mm21000 兆帕 = 100 千克/毫米2低炭鋼300 系列不銹鋼400 系列不銹鋼冷鐓工藝全面介紹-國外資料翻譯Die Design模具設計螺紋鎖緊件套殼上套心下套心鎢鋼套心襯套給予軸向預先加壓冷鐓工藝全面介紹-國外資料翻譯123Good Die Assembly 正確組裝模具預先加壓卸載加載冷鐓工藝全面介紹-國外資料翻

36、譯phase 1cyclic loadingof the undamaged material材料受力而產生反復的脹縮變形phase 2initiation ofmicro cracksa 0.1 mm開始出現微小的裂痕phase 3merging of micro cracks to surface defects and larger cracks0.1 a 0.5 mm演變成更大的裂痕Carbide Insert鎢鋼Hot Work Steel耐熱鋼High Speed Steel高速鋼冷鐓工藝全面介紹-國外資料翻譯5. Understand tool surface & frictio

37、n冷鐓工藝全面介紹-國外資料翻譯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 摩擦力產生的影響?Practical considerations 應用時需考慮的因素?冷鐓工藝全面介紹-國外資料翻譯What is friction什么是摩擦力?Y Force拉力X Force 壓力Friction Coefficient m = X force / Y force摩擦系數m = X壓力/Y拉力 通常金屬表面磨擦系數 冷鐓工藝全面介紹-國外資料翻譯Effect of f

38、riction 摩擦力產生的因素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冷鐓工藝全面介紹-國外資料翻譯Effect of friction 摩擦系數產生的影響?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冷鐓工藝全面介紹-國外資料翻譯Effect of friction 摩擦系數所產生的影響Assume Low Tool Friction摩擦力 那一邊大小？?冷鐓工藝全面介紹-國外資料翻譯Practical con

39、siderations實際情況需考慮因素?冷鐓工藝全面介紹-國外資料翻譯Practical considerations實際情況考慮因素冷鐓工藝全面介紹-國外資料翻譯Understand the effect of preform了解預成型的影響冷鐓工藝全面介紹-國外資料翻譯Understand the effect of preform了解預成型的影響What is Preform什么是預成型What is an optimised preform什么是好的預成型The effect of preform預成型的影響What is an optimised process control什么

40、是好的預成型過程控制Can preform be always be the same預成型都是相同的嗎?Should we have a preform drawing我們需要預成型圖紙嗎冷鐓工藝全面介紹-國外資料翻譯What is Preform 什么是預成型?冷鐓工藝全面介紹-國外資料翻譯What is an optimised preform什么是好的預成型?Operational:-操作方面?Tool Life:-模具壽命方面?Product Quality:-產品質量方面?冷鐓工藝全面介紹-國外資料翻譯What is an optimised preform 什么是好的預成型Ope

41、rational:-操作方面Controllable可控制的Achievable能夠完成的Stable穩定的Maintainable可持續的Low cost低成本的Manufacturable可操作的Repeatable可重復的Independent不受制約的Tool Life:-模具壽命方面Low punch force低沖力Low punch stress低壓力Manufacturable可持續的Low cost低成本的Prolong Operation延長生產力Product Quality:-產品質量方面No / Minimum Defects無缺陷或缺陷最小Achieve consi

42、stent quality達到品質一致Achieve required dimension達到要求尺寸冷鐓工藝全面介紹-國外資料翻譯The effect of preform預成型的影響Operational:-操作方面Controllable可控制的Achievable可實現的Stable穩定的Maintainable可持續的Low cost低成本的Manufacturable可操作的Repeatable可重復的Independent不受約束的Tool Life:-模具壽命Low punch force低沖力Low punch stress低壓力Manufacturable可操作Low co

43、st低成本Prolong Operation延長生產力Product Quality:-產品質量No / Minimum Defects無/最小缺陷Achieve consistent quality達到質量一致Achieve required dimension達到要求尺寸Punch force沖力Punch stress壓力Tool wear 模具磨損Laps / Folds 褶皺Surface 表面條件Dimensions尺寸Tool life模具壽命Part quality部品質量冷鐓工藝全面介紹-國外資料翻譯The effect of preform預成型的影響Test 1:-試驗1

44、Wide Punch Chamfer Angle沖模倒角較大Test 2:-試驗2Small Punch Chamfer Angle沖模倒角較小Forming of fasteners using different Preform design(effect of preform on the final forming shape)采用不同預成型的產品的最后成型Using 5113 for Illustration以5113為例矮扁的預成形較高的預成形冷鐓工藝全面介紹-國外資料翻譯The effect of preform預成型的影響Higher forming pressure較高的成型壓力Lower forming pressure較低的成型壓力Fastener forming using flatter preform采用扁而平的預成型Fastener forming using taller preform采用較高的預成型矮扁的預成形較高的預成形冷鐓工藝全面介紹-國外資料翻譯The effect of preform預成型的影響Taller preform高預成型 Low punch force沖力小 Longer tool