鈑金工藝規(guī)范及折彎及模具手冊(cè)

1、坂金工藝規(guī)范及折彎?rùn)C(jī)模具手冊(cè)1簡(jiǎn)介1.1 鉞金所用材料常用材料有：冷軋板SPCC熱軋板SPHC電解板SECC普通鋁板及鋁合金板AL105OAL5052-H32,不銹鋼板SUS304覆鋁專鋼板.1.2 典型鉞金件加工流程圖面展開(kāi)-編程-下料（剪、沖、割）-沖網(wǎng)孔-校平-拉絲-沖凸包壓怫折彎焊接-立體拉絲-表處-組裝2下料2.1 數(shù)沖是用數(shù)控沖床加工，板材厚度加工范圍為：冷扎板、熱扎板小于或等于3.0mm鋁板小于或等于4.0mm不銹鋼小于2.0mm2.1.1 沖孔有最小尺寸要求沖孔最小尺寸與孔的形狀、材料機(jī)械性能和材料厚度有關(guān)。t為材料厚度，沖孔尺寸一般不小于1.5t。如遇特殊情況，可參照下表：圖

2、2.1.1沖孔形狀示例材料圓孔最小直徑b矩形孔短邊寬b不銹鋼1.3t1.0t冷扎板、熱扎板1.0t0.7t鋁、黃銅0.8t0.5t*t為材料厚度，沖孔最小尺寸一般不小于1.2mm）沖孔最小尺寸列表2.1.2 數(shù)沖的孔間距與孔邊距零件的沖孔邊緣離外形的最小距離隨零件與孔的形狀不同有一定的限制，見(jiàn)圖2.1.2。當(dāng)沖孔邊緣與零件外形邊緣不平行時(shí)，該最小距離應(yīng)不小于材料厚度t;平行時(shí)，應(yīng)不小于1.5t。（圖1.4）圖2.1.2沖裁件孔邊距、孔間距示意圖2.1.3 折彎件及拉深件不可選用數(shù)沖下料，可選用二次激光切割。2.1.4 螺釘、螺栓的過(guò)孔和沉頭座螺釘、螺栓過(guò)孔和沉頭座的結(jié)構(gòu)尺寸按下表選取取。對(duì)于沉

3、頭螺釘?shù)某令^座，如果板材太薄難以同時(shí)保證過(guò)孔d2和沉孔D,應(yīng)優(yōu)先保證過(guò)孔d201d1M2M2.5M3M4M5M6M8MIOJ一TAr力:d2-d202.202.8H504.505.506.501kO用于螺釘、螺栓的過(guò)孔'J匕d1M2M2.5M3M4M5rLNLd202.2屹8分5M5©5.5D04.0鈍.500.509,a01OQh期醺精尺寸1,2L51.652727Ja90,*要求鉞材厚度t>ho用于沉頭螺釘?shù)某令^座及過(guò)孔d102貶503045LV八d2紀(jì)102.603.1網(wǎng)105.1D04J05心07.2£9%-AftdUMlh11d1.2162a90&#

4、39;*要求鉞材厚度t>ho用于沉頭挪釘?shù)某令^座及過(guò)孔激光切割是用激光機(jī)飛行切割加工，板材厚度加工范圍為冷扎板、熱扎板小于或等于8.0mm不銹鋼小于或等于4.0mm;鋁板小于等于5.0mm其優(yōu)點(diǎn)是加工板材厚度大，切割工件外形速度快，加工靈活.缺點(diǎn)是會(huì)產(chǎn)生熱變型，網(wǎng)孔件不宜用此方式加工，加工成本高！折彎折彎件的最小彎曲半徑材料彎曲時(shí)，其圓角區(qū)上，外層收到拉伸，內(nèi)層則受到壓縮。當(dāng)材料厚度一定時(shí)，內(nèi)r越小，材料的拉伸和壓縮就越嚴(yán)重；當(dāng)外層圓角的拉伸應(yīng)力超過(guò)材料的極限強(qiáng)度時(shí)，就會(huì)產(chǎn)生裂縫和折斷，因此，彎曲零件的結(jié)構(gòu)設(shè)計(jì)，應(yīng)避免過(guò)小的彎曲圓角半徑。公司常用材料的最小彎曲半徑等于0.5t。（彎曲半徑

5、是指彎曲件的內(nèi)側(cè)半徑,t是材料的壁厚）彎曲件的直邊高度一般情況下的最小直邊高度要求彎曲件的直邊高度不宜太小，最小高度按（圖3.2.1）要求：h>2t>2.5mm。圖3.2.1彎曲件的直邊高度最小值特殊要求的直邊高度如果設(shè)計(jì)需要彎曲件的直邊高度hW2t,則首先要加大彎邊高度，彎好后再加工到需要尺寸（可采用激光二次切割或者機(jī)加工）；或者在彎曲變形區(qū)內(nèi)加工淺槽后，再折彎（如下圖所示）圖3.2.2特殊情況下的直邊高度要求彎邊側(cè)邊帶有斜角的直邊高度當(dāng)彎邊側(cè)邊帶有斜角的彎曲件時(shí)(圖3.2.3),側(cè)面的最小高度為：h=(24)t>2.5mm圖3.2.3彎邊側(cè)邊帶有斜角曲1%相度折彎件上的孔

6、邊距孔邊距：先沖孔后折彎，孔的位置應(yīng)處于彎曲變形區(qū)外，避免彎曲時(shí)孔會(huì)產(chǎn)生變形。孔壁至彎邊的距離見(jiàn)下表?；蛘咴诳淄队霸谡蹚澣缬鎏厥馇闆r，孔邊距小于下表尺寸，可采用先小孔，折彎后再鉆孔，線的位置割線，折彎后焊接磨平。折彎件上的孔邊距局部彎曲的工藝切口折彎件的彎曲線應(yīng)避開(kāi)尺寸突變的位置局部彎曲某一段邊緣時(shí)，為了防止尖角處應(yīng)力集中產(chǎn)生彎裂，可將彎曲線移動(dòng)一定距離，以離開(kāi)尺寸突變處（圖3.4.1.a）,或開(kāi)工藝槽（圖3.4.1.b）,或沖工藝孔（圖3.4.1.1.c）。注意圖中的尺寸要求：S>R；槽寬k>t;槽深L>t+R+k/2。圖3.4.1局部彎曲的豳處理3展當(dāng)孔位于折彎變形區(qū)內(nèi)，

7、所采取的切口形式當(dāng)孔在折彎變形區(qū)內(nèi)時(shí)，采用的切口形式示例（圖3.4.2）;或者在孔投影于彎曲線的位置圖3.4.2切口形式示例割線或者切口，折彎后可根據(jù)需要焊接磨平。（圖1.14）帶斜邊的折彎邊應(yīng)避開(kāi)變形區(qū)也可采用在變形區(qū)域?qū)?yīng)位置割線，折彎后可根據(jù)需要焊接磨平。圖3.5帶斜邊的折彎邊應(yīng)避開(kāi)變形區(qū)反折壓死邊的設(shè)計(jì)要求壓死邊的死邊長(zhǎng)度與材料的厚度有關(guān)。如下圖所示，一般死邊最小長(zhǎng)度L>3t+R。其中t為材料壁厚，R為打死邊前道工序（如下圖右所示）的最小內(nèi)折彎半徑。圖3.6死邊的最小長(zhǎng)度L折彎4.1加強(qiáng)筋4.2打凸間距和凸邊距的極限尺寸打凸間距和凸邊距的極限尺寸按F列公式計(jì)算。閻畫II%當(dāng)DW1

8、6m附：I-1/2D>2tL-1/2D>16mm當(dāng)D>16mmf：根據(jù)實(shí)際情況結(jié)合生產(chǎn)確定，可選用數(shù)沖或者簡(jiǎn)易冷沖模具加工加強(qiáng)筋結(jié)構(gòu)及尺寸選擇客稱筒圖RhH或Dra7廠宿C7-10)t打凸laC2TsM05r5H15-306。在板狀金屬零件上壓筋，有助于增加結(jié)構(gòu)剛性，加強(qiáng)筋結(jié)構(gòu)及其尺寸選擇參見(jiàn)表4.3百葉窗百葉窗通常用于各種罩殼或機(jī)殼上起通風(fēng)散熱作用，其成型方法是借凸模的一邊刃口將材料切開(kāi)，而凸模的其余部分將材料同時(shí)作拉伸變形，形成一邊開(kāi)口的起伏形狀。百葉窗的典型結(jié)構(gòu)參見(jiàn)圖4.3。圖4.3百葉懶11將5)百葉窗尺寸要求：a>4t;b>6t;h<5t;L>

9、;24t;r>0.5to具體尺寸要求以生產(chǎn)需要為準(zhǔn)，可選擇數(shù)沖或者普通冷沖加工。4.4孔翻邊孔翻邊型式較多，本規(guī)范只關(guān)注要加工螺紋的內(nèi)孔翻邊，如圖4.4所示。具體的翻邊孔尺寸的具體參數(shù)參看表6圖4.4帶螺紋孔I幽孔2®勾示意圖螺紋材料厚度t翻邊內(nèi)孔D翻邊外孔d2凸緣高度h預(yù)沖孔直徑D0凸緣圓角半徑RM30.82.553.381.61.90.613.251.62.20.53.381.81.93.5221.23.381.9220.63.52.161.51.53.52.41.70.75M413.354.4622.30.51.24.351.922.70.64.52.162.34.652

10、.41.51.54.462.42.50.754.652.71.824.562.22.41M51.24.255.62.430.61.55.462.42.50.755.62.735.7532.525.533.22.415.753.62.72.55.7543.11.25M61.55.17.033.60.7526.73.24.217.03.63.67.342.52.57.042.81.257.34.5337.04.83.41.5帶螺紋孔的內(nèi)孔翻邊尺寸參數(shù)鉞金連接鉞金聯(lián)接主要采用焊接、螺紋聯(lián)接、挪接和粘接.我司采用的聯(lián)接方式：焊接、螺紋聯(lián)接和挪接.5.1焊接焊接是對(duì)焊件進(jìn)行局部或整體加熱或使焊件產(chǎn)生塑性

11、變形，或加熱與塑性變形同時(shí)進(jìn)行，實(shí)現(xiàn)永久連接的工藝方法.可分為：手工電弧焊、氣體保護(hù)電弧焊、激光焊、氣焊、段焊和接觸焊.我司主要采用氣體保護(hù)焊和接觸焊.1.1 .1.1氣體保護(hù)電弧焊在進(jìn)行氣體保護(hù)電弧焊時(shí)，電極電弧區(qū)及焊接熔池都處在保護(hù)氣體的保護(hù)下.采用僦氣保護(hù)焊縫表面沒(méi)有氧化物及夾雜物.可以在任何空間位置施焊，可以用肉眼觀察焊縫的成形過(guò)程并進(jìn)行調(diào)整生產(chǎn)效率高.二氧氣體保護(hù)焊則成本相當(dāng)?shù)?1.2 .1.2接觸焊接觸焊是瞬時(shí)加熱連接部位在熔化狀態(tài)或非熔化狀態(tài)下對(duì)被焊件加壓形成焊接接頭的焊接方法.它可分為對(duì)焊、點(diǎn)焊和縫焊.1.3 螺紋聯(lián)接螺紋聯(lián)接具有安裝容易、拆卸方便、操作簡(jiǎn)單等優(yōu)點(diǎn)，常用于可拆的

12、鋼結(jié)構(gòu)連接.它可分為螺釘聯(lián)接和螺栓聯(lián)接.1.4 怫接娜接是用挪釘將金屬結(jié)構(gòu)的零件或組合件連接在一起的方法，挪釘種類較多，我司常用的挪釘有封閉形圓頭抽芯挪釘、封閉形沉頭抽芯挪釘及開(kāi)口型圓頭抽芯挪釘、開(kāi)口型沉頭抽芯挪釘。挪釘長(zhǎng)度可根據(jù)以下公式計(jì)算：L=0.8d+1.1td:挪釘直徑t:板厚1.5 粘接用粘接劑將所需連接件粘接在一起的一種連接方法。1.6 表面處理方式1 .拉絲2 .噴砂3 .烤漆、噴粉、主要技術(shù)指標(biāo)：光澤度、膜厚和色差4 .電鍍：主要鍍五彩鋅、白鋅、黑鋅、鍍銘、藍(lán)白鋅5.拋光6.氧化7鉞金加工主要設(shè)備1 .下料設(shè)備：數(shù)控剪床、激光切割機(jī)、數(shù)控沖床2 .成形設(shè)備：普通沖床和數(shù)控折床。

13、3 .焊接設(shè)備：僦弧焊機(jī)、二氧化碳保護(hù)焊機(jī)、點(diǎn)焊機(jī)、機(jī)器人焊機(jī)。4 .表面處理設(shè)備：拉絲機(jī)、立體拉絲機(jī)、拋光機(jī)、烤漆線5 .調(diào)形設(shè)備：校平機(jī)8折彎?rùn)C(jī)模具手冊(cè)自由折彎的折彎壓力對(duì)照表本表格中的數(shù)據(jù)是在90°折彎，材料抗拉強(qiáng)度8b=420MPa,折彎長(zhǎng)度為1m基礎(chǔ)上計(jì)算的結(jié)果。V6810121618202432354050606380100120130140150160180190200230260b4.5578.51213151723252835434557718592100105115130135140160180r11.21.622.52.833.555.5689.5101215.

14、519212324.52628303236400.52.50.874.81.011861.212971jifj1.5151282.0231613129.52.526222015113.03024161412un4.044312823185.05347433125*6.0614536348.088696547361011080604743391212090716558555016140125115105958180711814813512511010095802014013012011090內(nèi)徑R約等于凹模開(kāi)口寬度V的16%自由折彎建議凹模開(kāi)口寬度V材料厚度0.52.5mm38mm910mm&g

15、t;12mm凹模開(kāi)口寬度（V）6xt8xt10xt12xt折彎力鋁Alu8b=300MPaF=F(表)x0.65F=F(chart)x0.65不銹鋼S.S8b=700MPaF=F(表)x1.6F=F(chart)x1.6折彎壓力噸位計(jì)算公式（參考值）F（表）=65xt2/V（噸）普通斜楔夾緊8實(shí)用于50t220t之間歐式上模的安裝機(jī)械快速夾緊快火可以方便歐式上模的快速安裝適用于美式上模的安裝過(guò)渡聯(lián)接塊適用于大行程機(jī)床的安裝YAWE止模液壓夾緊WILA適用于滑塊受重載的安裝上模液壓夾緊式1V插槽式1V插槽式2V可調(diào)式模具肩部受力模具底部受力下?？诳汕昂笳{(diào)節(jié)2V快換式多V插槽分段式下?？诳煽焖俑鼡Q

16、適用于分段多V下模多V工作臺(tái)式下模插片式適用于整體多V下模YAWEIT模液壓夾緊?？诳煞旨?jí)增大，適用于大噸位折彎?rùn)C(jī)液壓夾緊工作臺(tái)標(biāo)準(zhǔn)上模上模模柄結(jié)構(gòu)大噸位過(guò)渡模柄標(biāo)準(zhǔn)歐式加強(qiáng)型歐式上刀標(biāo)準(zhǔn)分段方式10.100MaxTons:100t/m10.101MaxTons:80t/m10.102MaxTons:60t/m10.103MaxTons:80t/m10.104MaxTons:100t/m10.105MaxTons:80t/m10.10610.10710.10810.109MaxTons:80t/m10.110MaxTons:40t/m10.111MaxTons:80t/m10.112MaxTo

17、ns:70t/m10.113MaxTons:40t/m10.114MaxTons:50t/m10.11510.11610.117MaxTons:100t/m聃MaxTons:60t/mMaxTons:45t/m10.11810.11910.120標(biāo)準(zhǔn)上模8810.130MaxTons:100t/m10.131MaxTons:80t/m10.132MaxTons:60t/m10.135MaxTons:20t/m10.13610.13710.138MaxTons:80t/mMaxTons:20t/mMaxTons:45t/m10.139MaxTons:70t/m10.140MaxTons:50t/

18、m10.141MaxTons:50t/m10.142MaxTons:30t/m10.143MaxTons:20t/m10.144MaxTons:50t/m10.150MaxTons:100t/m10.151MaxTons:35t/m10.152MaxTons:80t/m10.153MaxTons:80t/m10.154MaxTons:20t/m10.155MaxTons:60t/m10.156MaxTons:60t/m10.157MaxTons:20t/m10.158MaxTons:50t/m10.170MaxTons:80t/m10.171MaxTons:80t/m10.172MaxTons

19、:70t/m10.173MaxTons:100t/m10.174MaxTons:100t/m10.175MaxTons:60t/m10.17610.17710.178MaxTons:160t/mMaxTons:60t/mMaxTons:40t/m10.19010.19110.192MaxTons:80t/mMaxTons:80t/mMaxTons:90t/m10.193MaxTons:70t/m10.19410.195MaxTons:100t/mMaxTons:100t/m10.196MaxTons:80t/m10.197MaxTons:160t/m10.198MaxTons:70t/m蒂上_

20、10.21010.211MaxTons:100t/mMaxTons:100t/m10.212MaxTons:80t/m10.21310.214MaxTons:80t/mMaxTons:80t/m10.215MaxTons:80t/m10.216MaxTons:80t/m10.217MaxTons:80t/m10.218MaxTons:80t/m1410.219MaxTons:80t/m10.220MaxTons:80t/m10.221MaxTons:80t/m10.222MaxTons:80t/m1410.230MaxTons:80t/mRmmRmm10.231R33R5.55.510.232

21、R3.53.5R6610.233R44R6.56.510.234R4.54.5R7710.235R55R7.57.5標(biāo)準(zhǔn)圓模10.240MaxTons:100t/m分段方式10.241MaxTons:100t/mi丁制，RmmRmm10.242R88R202010.243R1010R252510.244R12.512.5R303010.245R1515R353510.246R17.517.5R404010.250+20.13410.250MaxTons:A80t/mB100t/m20.134MaxTons:A50t/mB100t/m10.251+20.13510.251MaxTons:A80t

22、/mB100t/m20.135MaxTons:A50t/mB100t/m10.252+20.13610.252MaxTons:A80t/mB100t/m20.136MaxTons:A50t/mB100t/msmmAmm450Mpat/m700Mpat/msmmAmm450Mpat/m700Mpat/m0.63.019150.61.223350.83.012200.81.632501.03.515251.02.040601.253.5117261.252.550801.54.622381.53.063952.05.530502.04.08013010.26010.26110.262MaxTons

23、:60t/mMaxTons:60t/mMaxTons:60t/m10.26410.26510.263MaxTons:40t/mMaxTons:100t/mMaxTons:100t/msmmAmm450Mpat/m700Mpat/msmmAmm450Mpat/m700Mpat/m0.63.019150.611.223350.83.012200.81.632501.03.515251.02.040601.253.517261.252.550801.54.622381.53.063952.05.5；30502.0：4.0801302.56.5552.55.0903.08.0703.06.0100標(biāo)準(zhǔn)

24、Z型模10.270MaxTons:100t/m10.271MaxTons:100t/m10.272MaxTons:100t/mZmmB°smaxmaxt/mZ-11160°0.5100Z-1.51.5160°0.6100Z-22150°0.8100Z-2.52.5140°1.0100Z-3390°1.0100Z-3.53.590°1.2100Z-4490°1.2100Z-4.54.590°1.5100Z-5590°1.5100Z-5.55.590°1.5100Z-6690°1

25、.5100Z-6.56.590°1.5100Z-7790°2100Z-7.57.590°2100Z-8890°2.5100ZmmB°smaxmaxt/mZ-9990°2.5100Z-101090°3100Z-111190°3100Z-121290°3100上刀附件10.30010.30110.30210.30310.304MaxTons:100t/m10.306特殊折彎方式10.305MaxTons:100t/mMaxTons:160t/mMaxTons:100t/mMaxTons:100t/m20.10

26、0MaxTons:40t/m20.10120.102MaxTons:50t/m20.103MaxTons:60t/m20.104MaxTons:80t/m20.105MaxTons:85t/m20.106MaxTons:90t/m20.10720.108MaxTons:100t/mMaxTons:100t/m20.109MaxTons:100t/m20.11020.11120.112MaxTons:145t/m20.122MaxTons:55t/mMaxTons:100t/m20.120MaxTons:40t/m20.123MaxTons:55t/mMaxTons:100t/m20.121Ma

27、xTons:40t/m20.124MaxTons:60t/m20.12520.12620.127MaxTons:40t/mMaxTons:40t/mMaxTons:40t/m20.12820.12920.130MaxTons:40t/mMaxTons:55t/mMaxTons:55t/m2520.131MaxTons:60t/m20.132MaxTons:50t/m20.133MaxTons:50t/m20.140MaxTons:95t/m20.141MaxTons:95t/m20.142MaxTons:95t/m20.14320.144MaxTons:95t/m20.145MaxTons:9

28、5t/m20.146MaxTons:95t/m20.147MaxTons:95t/m20.148MaxTons:95t/m20.160MaxTons:60t/m20.163MaxTons:70t/m20.164MaxTons:70t/m20.165MaxTons:70t/m20.166MaxTons:70t/m20.167MaxTons:70t/m20.168MaxTons:65t/m20.169MaxTons:70t/m20.170MaxTons:70t/m20.172MaxTons:70t/m20.171MaxTons:70t/m分段方式特殊下模20.180VmmRmmMaxTons20.

2918240410020184606100201861001010020.220MaxTons:70t/m20.221MaxTons:80t/m20.222MaxTons:80t/m20.22320.22420.230MaxTons:80t/mMaxTons:80t/mMaxTons:60t/m20.23120.23220.233MaxTons:60t/mMaxTons:100t/mMaxTons:100t/m20.234MaxTons:100t/m20.23520.236MaxTons:100t/mMaxTons:10

30、0t/m20.237MaxTons:100t/m20.23820.239MaxTons:100t/mMaxTons:100t/m20.25020.251MaxTons:80t/m20.25220.30020.30120.302MaxTons:70t/mMaxTons:80t/mMaxTons:80t/m20.30320.30420.305MaxTons:100t/mMaxTons:100t/mMaxTons:100t/m20.306MaxTons:60t/m20.30720.308MaxTons:100t/m20.320MaxTons:100t/m20.32120.322MaxTons:100

31、t/mMaxTons:100t/m20.323MaxTons:100t/m20.32520.340MaxTons:60t/m20.34120.342MaxTons:60t/mMaxTons:60t/m5020.350/TxMaxTons:100t/mVmmRmmSmmmaxt/mT660.414rioOT880.514100T10100.818100T12122.7518100T16162.7524100T2020330100T2525335100TR662.7514rioOTR882.75141100TR10102.751810020.351/TxMaxTons:100t/m20.352/T

32、xMaxTons:60t/mVmmRmmSmmmaxt/mT660.514r60T880.81460T10100.81860T12120.818r60T16162.752460T2020330國(guó)T252533560TR661.51460TR881.51460TR10102.751860TR12122.75186020.353/Tx20.354/Tx20.355/TxVmRmSmmaxt/mVmRmSmmmaxt/mVmRmSmmmaxt/mT660.81450T660.81435T660.81620T8811850T8811635T8812020T1101.21850T10101.22040T10101.22420T1121.62450T12121.62240T12121.62620T1162.752650T161633045T22033050T202033550T22533750T252534050VmRmSmmaxt/mVmRmSmmmaxt/mVmRmSmmmaxt/mT660.81450T660.81435T660.81620T8811850T