钣金工艺规范及折弯及模具手册

1、钣金工艺规范及折弯机模具手册1简介1.1钣金所用材料常用材料有：冷轧板SPCC热轧板SPHC电解板SECC普通铝板及铝合金板AL1O50AL5052-H32，不锈钢板SUS304覆铝锌钢板.1.2典型钣金件加工流程图面展开-编程-下料（剪、冲、害【J）-冲网孔-校平-拉丝-冲凸包-压铆-折弯焊接-立体拉丝-表处-组装2下料2.1数冲是用数控冲床加工，板材厚度加工范围为：冷扎板、热扎板小于或等于3.0mm铝板小于或等于4.0mm不锈钢小于2.0mm2.1.1冲孔有最小尺寸要求冲孔最小尺寸与孔的形状、材料机械性能和材料厚度有关。t为材料厚度，冲孔尺寸一般不小于1.5t。如遇特殊情况，可参照下表：图

2、2.1.1冲孔形状示例材料圆孔最小直径b矩形孔短边宽b不锈钢1.3t1.0t冷扎板、热扎板1.0t0.7t铝、黄铜n0.8t0.5tt为材料厚度，冲孔最小尺寸一般不小于1.2mm。冲孔最小尺寸列表2.1.2数冲的孔间距与孔边距零件的冲孔边缘离外形的最小距离随零件与孔的形状不同有一定的限制，见图2.1.2。当冲孔边缘与零件外形边缘不平行时，该最小距离应不小于材料厚度t;平行时，应不小于1.5to图2.1.2冲裁件孔边距、孔间距示意图2.1.3折弯件及拉深件不可选用数冲下料，可选用二次激光切割。2.1.4螺钉、螺栓的过孔和沉头座螺钉、螺栓过孔和沉头座的结构尺寸按下表选取取。对于沉头螺钉的沉头座，如

3、果板材太薄难以同时保证过孔d2和沉孔D，应优先保证过孔d2o用于螺钉、螺栓的过孔*要求钣材厚度t>ho用于沉头螺钉的沉头座及过孔*要求钣材厚度t>ho用于沉头铆钉的沉头座及过孔激光切割是用激光机飞行切割加工，板材厚度加工范围为冷扎板、热扎板小于或等于8.0mm不锈钢小于或等于4.0mm;铝板小于等于5.0mm其优点是加工板材厚度大，切割工件外形速度快，加工灵活缺点是会产生热变型，网孔件不宜用此方式加工，加工成本高！折弯折弯件的最小弯曲半径材料弯曲时，其圆角区上，外层收到拉伸，内层则受到压缩。当材料厚度一定时，内r越小，材料的拉伸和压缩就越严重；当外层圆角的拉伸应力超过材料的极限强度

4、时，就会产生裂缝和折断，因此，弯曲零件的结构设计，应避免过小的弯曲圆角半径。公司常用材料的最小弯曲半径等于0.5t。（弯曲半径是指弯曲件的内侧半径,t是材料的壁厚）弯曲件的直边高度一般情况下的最小直边高度要求弯曲件的直边高度不宜太小，最小高度按（图321）要求：h>2t>2.5mm图3.2.1弯曲件的直边高度最小值特殊要求的直边高度如果设计需要弯曲件的直边高度h<2t,，则首先要加大弯边高度，弯好后再加工到需要尺寸（可采用激光二次切割或者机加工）；或者在弯曲变形区内加工浅槽后，再折弯（如下图所示）。图3.2.2特殊情况下的直边高度要求弯边侧边带有斜角的直边高度当弯边侧边带有斜

5、角的弯曲件时（图3.2.3），侧面的最小高度为：h=（24）t>2.5mm图3.2.3弯边侧边带有斜角的直边高度折弯件上的孔边距孔边距：先冲孔后折弯，孔的位置应处于弯曲变形区外，避免弯曲时孔会产生变形。孔壁至弯边的距离见下表。如遇特殊情况，孔边距小于下表尺寸，可采用先小孔，折弯后再钻孔，或者在孔投影在折弯线的位置割线，折弯后焊接磨平。ifri沁少t+r>2L&t+r>2550>50s>2.5t+r折弯件上的孔边距局部弯曲的工艺切口折弯件的弯曲线应避开尺寸突变的位置局部弯曲某一段边缘时，为了防止尖角处应力集中产生弯裂，可将弯曲线移动一定距离，以离开尺寸突变处

6、（图a），或开工艺槽（图b），或冲工艺孔（图c）。注意图中的尺寸要求：S>R;槽宽k>t;槽深L>t+R+k/2。当孔在折弯变形区内时，采用的切口形式示例（图342）;或者在孔投影于弯曲线的位置割线或者切口，折弯后可根据需要焊接磨平。图3.4.2切口形式示例带斜边的折弯边应避开变形区也可采用在变形区域对应位置割线，折弯后可根据需要焊接磨平。图3.5带斜边的折弯边应避开变形区反折压死边的设计要求压死边的死边长度与材料的厚度有关。如下图所示，一般死边最小长度L3t+Ro其中t为材料壁厚，R为打死边前道工序（如下图右所示）的最小内折弯半径。图3.6死边的最小长度L折弯4.1加强筋在

7、板状金属零件上压筋，有助于增加结构刚性，加强筋结构及其尺寸选择参见表6o加强筋结构及尺寸选择4.2打凸间距和凸边距的极限尺寸打凸间距和凸边距的极限尺寸按下列公式计算当D<16mm寸:I-1/2D>2tL-1/2D>16mm当D>16mnl寸：4.3百叶窗百叶窗通常用于各种罩壳或机根据实际情况结合生产确定，可选用数冲或者简易冷冲模具加工壳上起通风散热作用，其成型方法是借凸模的一边刃口将材料切开，而凸模的其余部分将材料同时作拉伸变形，形成一边开口的起伏形状。百叶窗的典型结构参见图4.3图4.3百叶窗的结构6t;h<5t;L>24t;r>0.5t。普通冷冲加

8、工。百叶窗尺寸要求：a>4t;b>具体尺寸要求以生产需要为准，可选择数冲或者4.4孔翻边孔翻边型式较多，本规范只关注要加工螺纹的内孔翻边，如图4.4所示。具体的翻边孔尺寸的具体参数参看表6图4.4带螺纹孔的内孔翻边结构示意图螺纹材料厚度翻边内孔D翻边外孔d2凸缘高度h预冲孔直径凸缘圆角半径M30.8I.12.5513.381.6D.9R.613.251.62.20.53.381.81.93.5221.23.381.9220.63.52.161.51.53.52.41.70.75M413.354.4622.30.51.24.351.922.70.64.52.162.34.652.41

9、.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带螺纹孔的内孔翻边尺寸参数钣金连接钣金联接主要采用焊接、螺纹联接、铆接和粘接我司采用的联接方式：焊接、螺纹联接和铆接5.1焊接焊接是对焊件进行局部或整体加热或使焊件产生塑性变形，或加

10、热与塑性变形同时进行，实现永久连接的工艺方法.可分为：手工电弧焊、气体保护电弧焊、激光焊、气焊、段焊和接触焊.我司主要采用气体保护焊和接触焊.5.1.1.1气体保护电弧焊？?？在进行气体保护电弧焊时，电极电弧区及焊接熔池都处在保护气体的保护下.采用氩气保护焊缝表面没有氧化物及夹杂物.可以在任何空间位置施焊，可以用肉眼观察焊缝的成形过程并进行调整生产效率高.二氧气体保护焊则成本相当低.5.1.1.2接触焊接触焊是瞬时加热连接部位在熔化状态或非熔化状态下对被焊件加压形成焊接接头的焊接方法.它可分为对焊、点焊和缝焊.5.2螺纹联接螺纹联接具有安装容易、拆卸方便、操作简单等优点，常用于可拆的钢结构连接

11、.它可分为螺钉联接和螺栓联接.5.3铆接铆接是用铆钉将金属结构的零件或组合件连接在一起的方法，铆钉种类较多，我司常用的铆钉有封闭形圆头抽芯铆钉、封闭形沉头抽芯铆钉及开口型圆头抽芯铆钉、开口型沉头抽芯铆钉。?铆钉长度可根据以下公式计算：L=0.8d+1.1td:铆钉直径t:板厚5.4粘接用粘接剂将所需连接件粘接在一起的一种连接方法。6钣金表面处理方式1. 拉丝2喷砂3. 烤漆、喷粉、主要技术指标：光泽度、膜厚和色差4. 电镀：主要镀五彩锌、白锌、黑锌、镀铬、蓝白锌5. 抛光6. 氧化7钣金加工主要设备1. 下料设备：数控剪床、激光切割机、数控冲床2. 成形设备：普通冲床和数控折床。3. 焊接设备

12、：氩弧焊机、二氧化碳保护焊机、点焊机、机器人焊机。4. 表面处理设备：拉丝机、立体拉丝机、抛光机、烤漆线5. 调形设备：校平机8折弯机模具手册自由折弯的折弯压力对照表本表格中的数据是在90°折弯，材料抗拉强度Sb=420MPa，折弯长度为1m基础上计算的结果。V6810121618202432354050606380100120130140150160180190200230260b4.5578.51213151723252835434557718592100105115130135140160180r11.21.622.52.833.555.5689.5101215.5192123

13、24.52628303236400.52.50.874.81.011861.212971.5151282.0231613129.52.52622201511一;,F3.030241614124.044312823185.053474331256.0614536348.088696547361011080604743391212090716558555016140125115105958180711814813512511010095802014013012011090内径R约等于凹模开口宽度V的16%自由折弯建议凹模开口宽度V材料厚度0.52.5mm38mm910mm>12mm凹模开口宽

14、度（V）6xt8xt10xt12xt折弯力铝AluSb=300MPa''|F=F(表)x0.65F=F(chart)x0.65不锈钢S.S|：-Sb=700MPaF=F(表)x1.6F=F(chart)x1.6折弯压力吨位计算公式（参考值）2F（表）=65xt/V（吨）常见上模夹紧形式普通斜楔夹紧重型斜楔夹紧实用于50t220t之间欧式上模的安装机械快速夹紧快夹可以方便欧式上模的快速安装实用于220t以上欧式上模的安装美式夹紧适用于美式上模的安装过渡模柄夹紧适用于大行程机床的安装YAWE上模液压夹紧适用于上模的快速安装WILA常见上模夹紧形式过渡联接块适用于滑块受重载的安装上模

15、液压夹紧式NSCLnwithTopwithSafetyClick常见下模夹紧形式1V插槽式模具肩部受力2V快换式下模口可快速更换常见下模夹紧形式1V插槽式模具底部受力2V可调式下模口可前后调节多V插槽分段式适用于分段多V下模多V工作台式适用于整体多V下模YAWE下模液压夹紧适用于1V下模快速安装下模插片式模口可分级增大，适用于大吨位折弯机液压夹紧工作台NSCRnwithOZUbottomtool标准上模上模模柄结构标准欧式美式上刀标准分段方式标准上模85°10.100MaxTons:100t/m10.103MaxTons:80t/m10.106MaxTons:50t/m标准上模85&

16、#176;10.109MaxTons:80t/m10.112MaxTons:70t/m10.115MaxTons:100t/m标准上模85°10.118MaxTons:80t/m标准上模88°10.130MaxTons:100t/m10.133MaxTons:100t/m加强型欧式大吨位过渡模柄10.101MaxTons:80t/m10.104MaxTons:100t/m10.107MaxTons:50t/m10.102MaxTons:60t/m10.105MaxTons:80t/m10.108MaxTons:100t/m10.110MaxTons:40t/m10.113M

17、axTons:40t/m10.116MaxTons:60t/m10.111MaxTons:80t/m10.114MaxTons:50t/m10.117MaxTons:45t/m10.119MaxTons:80t/m10.120MaxTons:50t/m10.131MaxTons:80t/m10.134MaxTons:50t/m10.132MaxTons:60t/m10.135MaxTons:20t/m标准上模8810.13610.13710.138MaxTons:80t/mMaxTons:45t/mMaxTons:20t/m10.13910.14010.141MaxTons:70t/mMaxT

18、ons:50t/mMaxTons:50t/m10.14210.14310.144MaxTons:30t/mMaxTons:20t/mMaxTons:50t/m标准上模9010.15010.15110.152MaxTons:100t/mMaxTons:35t/mMaxTons:80t/m10.15310.15410.155MaxTons:80t/mMaxTons:20t/mMaxTons:60t/mZ10.15610.15710.158MaxTons:60t/mMaxTons:20t/mMaxTons:50t/m标准上模60°10.17010.17110.172MaxTons:80t/

19、mMaxTons:80t/mMaxTons:70t/m10.17310.17410.175MaxTons:100t/mMaxTons:100t/mMaxTons:60t/m10.17610.17710.178MaxTons:160t/mMaxTons:60t/mMaxTons:40t/m标准上模3010.19010.19110.192MaxTons:80t/mMaxTons:80t/mMaxTons:90t/m10.19310.19410.195MaxTons:70t/m1L|MaxTons:100t/mMaxTons:100t/m10.19610.19710.198MaxTons:80t/m

20、MaxTons:160t/mMaxTons:70t/m标准R型圆模10.21010.21110.212MaxTons:100t/mMaxTons:100t/mMaxTons:80t/m10.21310.21410.215MaxTons:80t/mMaxTons:80t/mMaxTons:80t/m10.21610.21710.218MaxTons:80t/mMaxTons:80t/mMaxTons:80t/m标准R型圆模10.21910.22010.221MaxTons:80t/mMaxTons:80t/mMaxTons:80t/m10.222MaxTons:80t/m10.230MaxTon

21、s:80t/m标准圆模10.24010.241MaxTons:100t/mMaxTons:100t/m分段方式复平模具10.250+20.13410.250MaxTons:A80t/mB100t/m20.134MaxTons:A50t/mB100t/mRmmRmm10.231R33R5.55.510.232R3.53.5R6610.233R44R6.56.510.234R4.54.5R7710.235R55R7.57.5RmmRmm10.242:R88R202010.243:R1010R252510.244R12.512.5R303010.245R1515R353510.246R17.517.

22、5R404010.251+20.13510.251MaxTons:A80t/mB100t/m20.135MaxTons:A50t/mB100t/mABsmmAmm450Mpat/m700Mpat/msmmAmm450Mpat/m700Mpat/m0.63.09150.61.223350.83.0112200.8:1.632501.03.515251.02.040601.253.517261.252.550801.54.6122381.513.063r952.05.530502.04.08013010.252+20.13610.252MaxTons:A80t/mB100t/m20.136MaxT

23、ons:A50t/mB100t/m复平模具10.260MaxTons:60t/m10.26310.26410.265MaxTons:100t/mMaxTons:100t/m10.261MaxTons:60t/m10.262MaxTons:60t/mMaxTons:40t/msmmAmm450Mpat/m700Mpat/msmmAmm450Mpat/m700Mpat/m0.63.09150.61.223350.83.012200.81.632501.03.5151.012.040601.253.517261.252.550801.54.622381.53.063952.05.530：502.04

24、.0801302.56.5552.55.0903.08.0703.06.0100标准Z型模10.270MaxTons: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°

25、;1.5100Z-6.56.590°1.5100Z-7790°2100Z-7.57.590°2100Z-8890°2.5100ZB°smaxmmmaxt/mZ-9990°2.5100Z-101090°3100Z-111190°3100Z-121290°310010.271MaxTons:100t/m10.272MaxTons:100t/m上刀附件10.30010.303MaxTons:100t/m10.306MaxTons:100t/m10.30110.302MaxTons:100t/m10.30410.

26、305MaxTons:100t/mMaxTons:160t/m特殊折弯方式1V下刀20.10020.10120.102MaxTons:40t/mMaxTons:40t/mMaxTons:50t/m20.10320.10420.105MaxTons:60t/mMaxTons:80t/mMaxTons:85t/m20.10620.10720.108MaxTons:90t/mMaxTons:100t/mMaxTons:100t/m1V下刀20.10920.11020.111MaxTons:100t/mMaxTons:100t/mMaxTons:100t/m20.11220.12020.121MaxT

27、ons:145t/mMaxTons:40t/mMaxTons:40t/m20.12220.12320.124MaxTons:55t/mMaxTons:55t/mMaxTons:60t/m1V下刀20.12520.12620.127MaxTons:40t/mMaxTons:40t/mMaxTons:40t/m20.12820.12920.130MaxTons:40t/mMaxTons:55t/mMaxTons:55t/m20.13120.13220.133MaxTons:60t/mMaxTons:50t/mMaxTons:50t/m1V下刀-i二.20.14020.14120.142MaxTon

28、s:95t/mMaxTons:95t/mMaxTons:95t/m20.14320.14420.145MaxTons:95t/mMaxTons:95t/mMaxTons:95t/m20.14620.14720.148MaxTons:95t/mMaxTons:95t/mMaxTons:95t/m1V下刀20.16020.16120.163MaxTons:60t/m1MaxTons:65t/mMaxTons:70t/m20.1641*'20.16520.166MaxTons:70t/mMaxTons:70t/mMaxTons:70t/m20.16720.16820.169MaxTons:7

29、0t/mMaxTons:65t/mMaxTons:70t/m1V下刀20.17020.17120.172MaxTons:70t/mMaxTons:70t/mMaxTons:70t/m分段方式特殊下模20.180VmmRmmMaxTons2018240410020.1835051002V下刀2018580810020.22020.22120.1861001010020.222MaxTons:70t/mMaxTons:80t/mMaxTons:80t/m20.22320.22420.230MaxTons:80t/mMaxTons:80t/mMax

30、Tons:60t/m20.23120.23220.233MaxTons:60t/mMaxTons:100t/mMaxTons:100t/m2V下刀20.23420.23520.236MaxTons:100t/mMaxTons:100t/mMaxTons:100t/m20.23720.23820.239MaxTons:100t/mMaxTons:100t/mMaxTons:100t/m20.25020.25120.252MaxTons:80t/mMaxTons:80t/mMaxTons:80t/m2V下刀20.30020.30120.302MaxTons:70t/mMaxTons:80t/mMa

31、xTons:80t/m20.30320.304'：':20.305MaxTons:100t/mMaxTons:100t/mMaxTons:100t/m20.30620.30720.308MaxTons:60t/mMaxTons:60t/mMaxTons:100t/m2V下刀20.32020.32120.322MaxTons:100t/mMaxTons:100t/mMaxTons:100t/m20.32320.32420.325MaxTons:100t/m|MaxTons:100t/mMaxTons:100t/m20.34020.34120.342MaxTons:60t/mMax

32、Tons:60t/mMaxTons:60t/m1V下刀20.350/TxMaxTons:100t/m20.351/TxMaxTons:100t/mVmmRmmSmmmaxt/mT660.414100T880.514100T10100.818100T12122.7518100T16162.7524100T2020330100T2525335100VmRmSmmaxt/mVmRmSmmmaxt/mVmRmSmmmaxt/mT660.81450T660.81435T660.81620T8811850T8811635T8812020T1101.21850T10101.22040T10101.22420

33、T1121.62450T12121.62240T12121.62620T1162.752650T161633045T22033050T202033550T22533750T252534050TR662.7514100TR882.7514100TR10102.751810020.352/TxMaxTons:60t/mVmmRmmSmmmaxt/mT660.51460T880.8r1460T10100.81860T12120.81860T16162.75：2460T202033060T252533560TR661.51460TR881.5(1460TR10102.751860TR12122.75186020.353/Tx20.354/Tx20.355/Tx1V下刀20.356/TxMaxTons:100t/m20.357/TxMaxTons:100t/mVmmRmmSmmmaxt/mT660.4_j14100T880514100T10100.818100T121227518100T161627524100T2020330