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长安福特马自达汽车有限公司模具设计标准


Q/CAF
长安 福特马 自达 汽车 有 限公 司企业 标准
Q/CAF 87-2008

冲压模具设计标准

2008-01-31 发布

2008-01-31 实施

2012-10-30 更新

长安福特马自达汽车有限公司

发布

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Q/CAF 87-2008





? 本标准由长安福特马自达汽车有限公司技术开发中心 STA 白车 身组提出。 ? 本标准由长安福特马自达汽车有限公司技术开发中心归口管 理。 ? 本标准由长安福特马自达汽车有限公司技术开发中心 STA 白车 身组和法规部门共同负责起草。

本标准主要起草人: Fu Yuanyu /傅苑渝 Hollander Paul

本标准批准人:高



CHANGAN FORD MAZDA AUTO CO DIE DESIGN STANDARD 长安福特马自达冲压模具设计标准
October 2012 Q/CAF 87-2008

TABLE OF CONTENTS 1 GENERAL GUIDE 总体标准 ............................................................................................. 1
1.1 GENERAL NOTES 概述 ................................................................................................................................ 1 1.2 DIMENSIONING SYSTEM 图面尺寸标注....................................................................................................... 4 1.3 CODE LETTERS FOR DIE COMPONENTS 模具组件代码................................................................................. 5 1.4 DIE KEY WAYS 模具定位键槽 ................................................................................................................... 6 1.5 TOOLING HOLES 基准销 ............................................................................................................................. 7 1.6 START DIMENSIONS, TIPPING POINTS & WORKLINES 基准点,旋转点和工作中心 ..................................... 8 1.7 SAFETY 安全 .............................................................................................................................................10 1.8 CASTING REQUIREMENTS GENERAL NOTES 铸件要求概述 .........................................................................11 1.9 GENERAL CASTING CONSTRUCTION 铸件结构............................................................................................12 1.10 DRAW DIE MATERIAL SELECTION 拉延模模具材料选用 .........................................................................13 1.11 TRIM / FLANGE MATERIAL SELECTION 切边模和翻边模模具材料选用 ....................................................14 1.12 PAD MATERIAL SELECTION 压料器材料选用 ...........................................................................................15 1.13 RIB CONSTRUCTION 加强筋结构 .............................................................................................................16 1.14 BACK UP FOR INSERTS 镶块背靠 .............................................................................................................18 1.15 CASTING RELIEF 铸件逃料 .......................................................................................................................19 1.16 DIE HOOK SETTING CONSTRUCTION 吊耳结构 .........................................................................................21 1.17 DIE HOOK BAR 吊棒 ................................................................................................................................22 1.18 DIE HOOK BUSHING 吊耳衬套 .................................................................................................................23 1.19 LOCKED HOOK A ND HOOK BAR 自锁吊耳和吊棒 ....................................................................................24 1.20 DIE HANDLING – EYE BOLT SELECTION 吊环 ...........................................................................................25 1.21 HEEL GUIDE CLASSIFICATION 导板分类...................................................................................................26 1.22 TOP AND BOTTOM TOOL GUIDING 上下模具导向 ....................................................................................27 1.23 WEAR PLATE APPLICATION 耐磨板 ..........................................................................................................28 1.24 SCREW & DOWEL 销和螺钉.....................................................................................................................29 1.25 PAD RETAINERS APPLICATION 压料器侧销 ..............................................................................................33 1.26 PAD RETAINERS - SAFETY PAD RETAINER PINS 侧销 - 安全螺钉 ..............................................................35 1.27 LOWER PAD RETAINER APPLICATION 下压料器限位螺钉 ........................................................................37 1.28 SPRING INSTALLATION 弹簧 .....................................................................................................................39 1.29 PANEL EJECTION FROM UPPER TOOLING 上模卸料 ...................................................................................41 1.30 H TYPE PANEL LIFTER H 式卸料 ..............................................................................................................42 1.31 AIR OPERATED PANEL EJECTOR 气动卸料 ...............................................................................................43 Version 1.0 Printed Copies are uncontrolled

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October 2012 Q/CAF 87-2008

1.32 GAS SPRING SYSTEMS 氮气缸系统 ..........................................................................................................44 1.33 NAMEPLATE 铭牌 ....................................................................................................................................47 1.34 DIE PAINTING 颜色喷涂 ..........................................................................................................................48 1.35 PRODUCTION INFORMATION 生产信息 .....................................................................................................50

2 DRAW DIES 拉延模 ......................................................................................................... 51
2.1 GENERAL NOTES 概要 ...............................................................................................................................51 2.2 TONNAGE FORMULA 吨位计算 ..................................................................................................................52 2.3 DIE SIZE REDUCTION 模具尺寸设定 ..........................................................................................................53 2.4 BLANK HOLDER FACE 压边圈面尺寸 ........................................................................................................54 2.5 BLANK HOLDER BOTTOMING SITUATION 压边圈到底条件 .........................................................................54 2.6 BOTTOM FIT STROKE STOPPER INSTALLATION 限位块 ................................................................................55 2.7 BOTTOM MARKER 到位标记......................................................................................................................56 2.8 BALANCING BLOCKS 平衡块 .....................................................................................................................57 2.9 DRAW BEAD APPLICATION 拉延筋.............................................................................................................58 2.10 BEAD LOCATION 拉延筋位置 ..................................................................................................................59 2.11 DRAW DIE BEADS TYPE 拉延筋类型 .......................................................................................................60 2.12 AIR RELIEF AND DRAW COMPOUND DRAIN HOLES 排气孔 .......................................................................61 2.13 DIE CO-ORDINATING HOLES C/H 孔 .........................................................................................................63 2.14 BLANK HOLDER RETAINER 压边圈安全压板 ...........................................................................................65 2.15 DRAW DIE POP UP GAUGES 活动挡料销 ..................................................................................................66 2.16 DRAW DIE FIXED GAUGES 固定挡料销 ....................................................................................................67 2.17 MACHINED CLEARANCE FOR LOCATIONS 挡料销间隙 ..............................................................................70

3 CUTTING DIES 冲裁模 ................................................................................................... 71
3.1 STRIPPING AND CUTTING FORCES 冲裁力和卸料力计算............................................................................71 3.3 TRIM DIE GENERAL NOTES 切边模概要.....................................................................................................73 3.2 SPRINGS APPLICATION 弹簧运用 ...............................................................................................................74 3.4 STEEL FASTENING 钢块固定 ......................................................................................................................75 3.5 CAST TRIM STEEL 铸造切边刀块 ..............................................................................................................76 3.6 BLADE TYPE STEELS & CUTTING ANGLES 镶块刀口和切边角度 ...............................................................77 3.7 COMPOSITE TYPE STEELS & CUTTING ANGLES 整体式刀块和切边角度.....................................................78 3.8 SCRAP CUTTERS AND PAD TRAVEL 废料刀和压料器行程 .........................................................................79 3.9 SCRAP LAYOUT 废料分布..........................................................................................................................80 Version 1.0 Printed Copies are uncontrolled

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October 2012 Q/CAF 87-2008

3.10 APPLICATIONS FOR SCRAP CUTTERS & SCRAP CHUTES 废料刀和废料滑槽 ..............................................81 3.11 APPLICATIONS FOR SCRAP CHUTES 废料滑槽 ..........................................................................................82 3.12 APPLICATIONS OF VIBRATEING SCRAP CHUTES 震动废料滑槽 .................................................................83 3.13 SCRAP / PART CHUTES HINGE APPLICATION 二级滑道固定链运用 ...........................................................84 3.14 PIERCE DIE GENERAL NOTES 冲孔模概述 ................................................................................................85 3.15 PIERCE PUNCH DESIGN 冲头设计.............................................................................................................86 3.16 PIERCE HOLE SPACING 冲孔间隔 .............................................................................................................88 3.17 VERTICAL C UTTING 垂直切边 .................................................................................................................89 3.18 PUNCH DEVELOPMENT 异性冲头 .............................................................................................................90 3.19 DIE BUTTON HOLE TOLERANCING 模钮孔公差 ........................................................................................92 3.20 PUNCH ACCESS APPLICATIONS 冲头固定 .................................................................................................93 3.21 APPLICATION OF POP ON STRIPPERS 卸料器运用 .....................................................................................94 3.22 ANGULAR PIERCING 非圆形冲裁 .............................................................................................................95

4 FORM DIES 成型模 .......................................................................................................... 98
4.1 GENERAL NOTES 概要 ...............................................................................................................................98 4.2 FORM DIE CALCULATIONS 成型模冲压力计算 ..........................................................................................99 4.3 METAL BENDING ALLOWANCE 弯曲预留量 ............................................................................................. 102 4.4 SPRING BACK 回弹 .................................................................................................................................. 104 4.5 APPLICATION FOR RESTRIKE DIES 整形.................................................................................................... 105 4.6 GENERAL FLANGING APPLICATIONS 翻边................................................................................................. 106 4.7 FLANGING APPLICATION AND FLAME HARDENING REQUIREMENTS 翻边模表面硬度要求 ........................ 107 4.8 HOLDING AREAS PROPORTIONS 压边区域 ................................................................................................ 108 4.9 PAD BOTTOMING 压料器到底.................................................................................................................. 109 4.10 FLANGING STEELS ON C URVED SURFACES 在弯曲表面上的翻边镶块 ................................................... 110 4.11 FLANGING STEEL JOINT LINE 翻边镶块拼接 .......................................................................................... 111 4.12 METHOD OF USING STEEL SECTIONS 镶块拼接方式............................................................................... 112 4.13 FLANGING APPLICATION USING BRACE 翻边镶块使用支撑 ................................................................... 113 4.14 HORIZONTAL & VERTICAL FLANGING STEELS ON SOLID RAILS 水平和垂直的翻边镶块的固定背靠 ..... 114 4.15 FLANGING STEELS AND LOOSE RAILS 翻边镶块和活动背靠 .................................................................. 115 4.16 LOOSE RAIL WITH HEEL & SERRATED PART GRIPPER 带导板的活动背靠和锯齿压料 .......................... 116 4.17 HEIGHT OF FLANGE STEELS 翻边镶块高度 ............................................................................................ 117 4.18 OPPOSING FLANGES & SHORT FLANGES 负角度翻边和短翻边 ............................................................... 118 4.19 FIXED STRIPPERS 固定卸料器................................................................................................................ 119 Version 1.0 Printed Copies are uncontrolled

CHANGAN FORD MAZDA AUTO CO DIE DESIGN STANDARD 长安福特马自达冲压模具设计标准
October 2012 Q/CAF 87-2008

4.20 FLANGE STRIPPER / LIFTER 翻边卸料器 ................................................................................................. 120

5 CAM DIES 斜楔模 .......................................................................................................... 121
5.1 GENERAL NOTES 概要 ............................................................................................................................. 121 5.2 SLIDE AND DRIVER ANGLES 滑块和驱动块的角度 ................................................................................... 122 5.3 GIB AND WEAR PLATE 耐磨板 ................................................................................................................ 123 5.4 MACHINING DIMENSION REQUIREMENTS FOR CAM SURFACES 斜楔的加工尺寸要求 .............................. 125 5.5 CAM PIERCE 侧冲 ................................................................................................................................... 127 5.6 CAM TRIMMING 侧切 ............................................................................................................................. 129 5.7 JEKTOLE CAM PIERCE PUNCH 冲头 – 带顶销............................................................................................ 130 5.8 DOUBLE CAM SLIDE 互动斜楔 ............................................................................................................... 131 5.9 AERIAL CAM SLIDES 吊楔 ...................................................................................................................... 133 5.10 CAM SLIDE RETRACTION 回程 .............................................................................................................. 135

6 BLANK DIES 落料模 ..................................................................................................... 141
6.1 GENERAL NOTES 概要 ............................................................................................................................. 141 6.2 APPLICATION OF SHEAR FOR BLANK DIES 剪边下料模运用 .................................................................... 142 6.3 BLANK NESTING 落料排样 ...................................................................................................................... 143

7 HIGH STRENGTH STEEL DIES 高张力钢板材料模具 .............................................. 144
7.1 GENERAL NOTES 概要 ............................................................................................................................. 144 7.2 CASTING THICKNESS 铸件厚度 ................................................................................................................ 145 7.3 MATERIAL SELECTION 模具材料选用 ...................................................................................................... 146 7.4 DRAW BEADS 拉延筋 .............................................................................................................................. 147 7.5 SETTING BEADS APPLICATION 工艺胀形筋运用....................................................................................... 148 7.6 POST FORM STRETCHING APPLICATION 下台阶式拉延 ............................................................................. 150 7.7 CUTTING CLEARANCES 切边间隙 ............................................................................................................ 151 7.8 TRIM CONDITIONS 切边条件 ................................................................................................................... 152

8 HIGH VOLUME DIE DESIGN 高寿命模具设计 .......................................................... 154 9 ATTACHMENT 附件 ..................................................................................................... 155
附件一:SIGNATURE 发布文件签署 ............................................................................................................. 155 附件二:HIGH VOLUME DIE DESIGN POINTS 高寿命模具设计框架 ............................................................... 156 GENERAL NOTES 概述 ................................................................................................................................... 156 Version 1.0 Printed Copies are uncontrolled

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October 2012 Q/CAF 87-2008

DRAW DIE MATERIAL SELECTION 拉延模具材料选择 ................................................................................... 157 TRIM DIE MATERIAL SELECTION 切边模具材料选择 ..................................................................................... 158 FLANGE / RE-STRIKE DIE MATERIAL SELECTION 翻边/整形模具材料选择 ..................................................... 159

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1 General Guide 总体标准 1.1 General Notes 概述 The following information has been found to be necessay on die drawing for clarity and ease of pattern making, tool build, and for die function. 以下信息是模具设计图纸中必要的,以便澄清保模制作,模具制造和模具功能。 It is required that this information be carefully studied. Upon completion of a die desing, it is essential that each item be checked for inclusion on the drawing. 以下信息需要仔细阅读。设计完成后,必须检查每一项都包含在设计图纸中。

1. All views and sections to be third angle projection.
所有视图和截面图采用三角投影画法。

2. All parts must be fully dimensioned and marked with the appropriate machining symbols.
所有零件必须使用适当的机加符号全尺寸标注和标识。

3. All dimensions must be to scale. Not to scale dimensions must not be used without Changan Ford
Mazda (CFMA) supervisory approval. 所有尺寸标注都必须有比例标注。没有比例标注的尺寸标注,在没有长安福特马自达认可 前不能使用。

4. Dimension casting completely. Also show casting heights, tool steels, and composite sections in
plan views. Ensure that positions of screw holes are dimensioned. 铸件要完整尺寸标注。在图纸中,应该显示铸件高度,钢块和截面等信息,并确保螺钉的 位置有尺寸标注。

5. All machined faces should be dimensioned to centreline of die.
所有加工面标注到模具中心线

6. Show reference, and datums for all punch and die shoes, with the exception of blank dies.
除落料模外,需要显示模具的参考平面和基准。

7. No deviations from process are to be made without CFMA supervisory approval.
没有长安福特马自达的认可,不允许任何背离工艺的设计。

8. Dies to be designed to fit main and alternative press.
模具设计必须符合压力机。

9. Deign dies to standard shut heights, as per press standards. The shut height may be increased to
facilitate scrap removal etc. on a case by case basis with CFMA approval. 根据压力机的标准设计模具的闭合高度标准。增加闭合高度有利于去废料,但需要长安福 特马自达的认可。
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October 2012 Q/CAF 87-2008

10. Label front of press and die on plan of die and punch.
模具标识需要在模具的前面。

11. All die fastening slots and holes to be shown.
所有模具的固定槽和孔需要标识。

12. Die location holes or slots to be provided.
模具中必须有快速定位或键槽。

13. Pressure pin layout to be shown on face sheet.
顶杆分布图需要被显示。

14. Provide balance pins when cushion is out of balance.
下压不平衡时需要提供平衡顶杆。

15. Add note for spring back if required.
如果需要,对回弹作上注释。

16. Show start dimensions in plan of die and section.
在模具图中标识开始点和截面。

17. Show work and car lines in all views and sections.
在所有视图和截面中标识工作坐标和车身坐标。

18. Show views of part as it comes from previous operation and position in next operation. Lable
previous position, finish position etc. 显示零件在上工序和下工序的视图,并标识。

19. Use symmetrically opposite note if applicable.
如果合适,使用对称表识。

20. Panel to be shown in all views.
所有视图中需要显示板件。

21. Show and lable centrelines of die, press, and stages in all views.
在所有视图中表识模具中心线和冲压中心。

22. Section planes to be shown on plan of both punch and die.
截面图需要同时显示上模和下模。

23. Show die and sheet number in title block.
在明细表中显示模具和图表编号。

24. Sheet numbers to be shown next to section letters indicating where section can be found or is
taken from. 在截面图旁应该有页码说明截面图的位置。

25. On plan and sections, item balloons should appear outside of die.
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在平面图和截面中,各项需要在模具外标识。

26. Casting balloon should appear in main section.
铸件标识在主截面图中。

27. Where more than one scale is used, note scale on each view.
如果采用多个放缩比例,注意每个视图中的比例。

28. Heel or guide post entrance to be 25mm minimum before any contact.
导板或导柱需要在其它部件接触前至少 25mm 开始导向。

29. Show in section 10mm × 45° chamfer on upper & lower die base.
上模座和下模座截面要 10mm × 45°的断面线。

30. Safety block area and stop blocks to be provided above supported part of die.
需要提供安全块区域和限位块。

31. Air vent grooves above guide post to be rough ground as required.
在导柱上方的排气孔只需要粗糙表面。

32. Show Screws and dowels for all details. Minimum screw size to be M12 and minimum dowel
size to be diam. 12mm unless approved by CFMA. 所有模具的螺钉和销需要标识。最小螺钉尺寸为 M12,销的直径不小于 12mm,如果低于 该标准需要长安福特马自达工程师批准。

33. Machine allowance on all bolsters to be 10mm.
所有模座的加工余量留 10mm。

34. Heat treatment hardness to be shown in stock list.
热处理硬度要求需要在明细表中说明。

35. Allow 3-5mm machining all over on tool steel blocks.
所有钢块需要 3-5mm 的加工余量。

36. Provide suitable loading chutes.
提供适当的送料托架。

37. Casting weights to be noted on face sheet.
铸件重量需要在表面标识。

38. All blank and trim dies running in major press line must have four guide pin etc.
所有下料模和切边模必须有 4 个导柱。

39. Provide sufficient clearance on die for automation equipment.
提供足够的空间给模具自动化设备。

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October 2012 Q/CAF 87-2008

1.2 Dimensioning System 图面尺寸标注

* Use orthodox dimensioning system 采用传统标注

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October 2012 Q/CAF 87-2008

1.3 Code Letters For Die Components 模具组件代码 Code No. A B C G M P S W D Components 组件 Air pins 顶杆 Bottoming blocks 限位块 Cam side plates 斜楔 Guide post sets 导柱 Mounting holes for air cylinders 气缸安装孔 Safety pad retainers or spools 安全侧销 Spring pocket 弹簧套 Wear plates 耐磨板 Balance blocks 平衡块

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October 2012 Q/CAF 87-2008

1.4 Die Key Ways 模具定位键槽 模具定位键槽

Supplier 供应商 Lianwei 联伟 Xingqiao 星乔 BND Push 百能达普什 Zhixin 至信 Changan Lingyu 长安凌云

X 28 28 28 28

Y 20 25 30 25

Z 80 80 80 80

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CHANGAN FORD MAZDA AUTO CO DIE DESIGN STANDARD 长安福特马自达冲压模具设计标准
October 2012 Q/CAF 87-2008

1.5 Tooling Holes 基准销

Note 注释: 1. 2 areas to be provided on top surface aproximately 50 × 50. 需要 2 个大致 50 × 50 的区域。 2. The 2 areas are to be machined flat and must be parallel with the base. 这 2 个区域需要加工平整并平行于底面。 3. A diameter 10mm × 20mm deep hole is to be machined in each surface parallel with the "X". 在表面上加工 10mm × 20mm 的孔,并平行于“X”。 4. The hole position can be different for upper and lower die castings. 上下模孔的位置可以不一致。 5. Stamp on X, Y, Z dimmensions adjustment to each hole to indicate distance from die worklines. 标识每个孔从工作坐标开始的 X, Y, Z 的尺寸。

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CHANGAN FORD MAZDA AUTO CO DIE DESIGN STANDARD 长安福特马自达冲压模具设计标准
October 2012 Q/CAF 87-2008

1.6 Start Dimensions, Tipping Points & Worklines 基准点, 基准点,旋转点和工作中心

Note 注释: 1. Nominate datum lines & worklines for multiple parts. 对多零件指定基准线和工作坐标。 2. Nominate start point(s) on all plan views. 所有平面图中指定开始点。 3. Nominate tipping points for single or mulitipe parts as requried. 指定旋转点,如果需要。 4. Nominate center-line of press and nominate ref dimension back to datum lines X & Y if required. 指定冲压中心线和参考尺寸。 5. Nominate front of press. 指定冲压前方。 6. Nominate direction of part flow. 指定送料方向。
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Note 注释: 1. Nominate bodylines / worklines & tipping angle from tip point. 指定车身坐标 / 工作坐标和旋转角度 2. Show ref dimensions from start point to tipping point if required. 标识参考尺寸从开始点到旋转点。 3. Nominate centre line of press 指定压机的中心线。

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1.7 Safety 安全 Operator safety must be considered by tool design personnel at all times. 在任何时候在模具设计中都必须考虑操作者的安全。 Trapping points created by any parts of the die or accessories other than is necessary to carry out the operation on the part shall be eliminated wherever possible. 应尽可能的消除在操作中由模具组件或附件引起的任何可能出现的安全隐患。

Safe positioning of guide posts and stop blocks 导柱和限位块的安全位置 Position guide posts and stop blocks as close to the centre line of the die as possible, away from safety block area and not less than 200mm from edge of press bolster. 在安全方面考虑,导柱和限位块的位置应尽可能的靠近模具的中心,并远离安全块区域,离模座 的边缘最小距离不小于 200mm。 Never position guide posts and stop blocks forward of where the operator's hand will be when loading and unloading panels or removing scrap. This requirement also applies to the positioning of heels and cams. 导柱和限位块的位置一定不能在操作工人在上件,取件或取废料时手能涉及到的区域的前方。对 斜楔和导根也有同样的要求。

Safety guard 安全护板 The aera will create trapping points like the space between pad and lower or upper die, should mount safety guard to prevent opeartors hand in when press machine moving. 在可能出现安全隐患的区域,如压料器与上模之间,压边圈于下摸之间需要安装安全护板,防止 压机工作时,操作工人手进入该区域。

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1.8 Casting Requirements General Notes 铸件要求概述 The design of castings should be guided at the following considerations: 铸件的设计必须考虑以下方面: 1. Walls should be of sufficient thickness. However, excessive and unnecessary metal thickness should be avoided。 外壁应该有足够的厚度。但是,过大或没有必要的厚度应该避免。 2. Walls and ribs should be of uniform thickness wherever the design permits: abrupt changes in section area should be avoided. 外壁和加强筋应该有一致的厚度,如果设计允许。陡然的厚度改变应该避免。 3. Adequate fillets should be provided at all adjoining walls and intersections: sharp corners should be avoided. 在外壁连接处或交叉处应有适当的倒角,尖角应该避免。 4. Small holes should be drilled rather than cored. (Min 30mm) 较小的孔应该采用钻孔加工。(最小 30mm) 5. Deep pockets and small recesses that complicate molding should be avoided. 较深的袋状和较小的凹状的复杂造型应该避免。 6. Castings shall be ribbed sufficiently to provide the required strength and rigidity. 铸件应该有足够的加强筋保证需要的强度。 7. A "U" shaped section is preferable to an "I" shaped one. As the mold is simpler. "U"型截面好于"I"型。模型更简单。 8. Ample clearance shall be allowed between unfinished castings surfaces and moving components and between unfinished surfaces of two different castings. 在不需要加工的铸件平面和可动组件间,和两个不同的不需要加工的铸件平面之间需要有 足够的间隙。 9. Finished pads and bosses should extend 3 to 10mm from the unfinished surfaces of castings according to the size of the casting. 根据不同尺寸的铸件,凸台需要留有 3 到 10mm 的高度。 10. Cast 40mm dia water / oil drainage holes in base of all castings. 所有铸件需要有直径为 40mm 的排水(油)槽。

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1.9 General Casting Construction 铸件结构 When designing dies requiring patterns the following standard thickness of polystyrene are available 30, 40, 50, 60, 70, 100, 150, & 300. Allow 10 to 15mm for machining depend on area. 模具设计时,泡沫的厚度应采用 30, 40, 50, 60, 70, 100, 150, & 300 的标准。不同的区域允许 10 到 15 的加工余量。

Note 注释: 1. Raise pads or bosses for finished surfaces. Avoid machining into the casting. This applies to safety block areas, mounting surfaces etc. 加工平面需要铸造凸台。避免铸件中加工槽。如安全块区域,安装平面要铸造加工凸台。 2. Max. size of core to be 450× 450,Min to be 150. Core depth shall not exceed 2 times the core width. Make cores the same size whenever possible. 减轻孔的大小最大为 450× 450,最小 150。减轻孔深度不要超过宽度的两倍。尽量保证每 个减轻孔大小一致。 3. Die pattern to be inspected and signed off by STA engineer prior to shipiment to foundary. 在做铸件以前,保利龙需要 STA 工程师签字确认。 4. For all other casting details refer to appropriate standards relating to specific die types. 特定的模具类型的铸件详细信息应参考相应的标准。

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1.10 Draw Die Material Selection 拉延模模具材料 拉延模模具材料选用 材料选用 Case 条件 t < 1.4 mm & material flow is < 40 mm t < 1.4 mm & Draw 拉延模 material flow is ≥ 40 mm t ≥ 1.4 mm & material flow is < 40 mm t ≥ 1.4 mm & material flow is ≥ 40 mm Note 注释: 1. Draw bead or former radii in expected scoring areas to be better grade casting. 拉延筋或成形 R 角如果是可能出现拉伤的区域,铸件等级需要提高。 2. Top and bottom bolsters should use HT300. 上下模座选用 HT300。 3. SKD-11 should be bought from following company: ASSAB (XW-42), BOHLER (K110) and HITACHI (SLD) 上述表中提到的 SKD-11 材料必须购买一胜百(对应 XW-42)和百禄(对应 K110)或日 立(SLD)三家公司的材料。 4. Above info is about normal material. When using high strength steel, refer to chapter 7. 上述标准仅适用于普通材料。如果为高张力材料钢板,模具材料选用参看第 7 章。 Blank holder 压边圈 Blank holder 压边圈 Punch 凸模 Former 凹模 SKD-11 Former 凹模 Blank holder 压边圈 Punch 凸模 Former 凹模 Blank holder 压边圈 Punch 凸模 Die item 模具项 Punch 凸模 Former 凹模 Material 模具材料 FCD600 MoCr GM241 Hardness requirement 热处理硬度要求 42 - 46 HRC 42 - 46 HRC 42 - 46 HRC 表面镀 Cr 表面镀 Cr 表面镀 Cr 42 - 46 HRC 58 - 62 HRC

FCD600 MoCr GM241 MoCr Cr12MoV SKD-11 Cr12MoV SKD-11

58 - 62 HRC 渗 N 或 TD 处理 渗 N 或 TD 处理 渗 N 或 TD 处理

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1.11 Trim/ Flange Material Selection 切边模和翻边模模具材料 切边模和翻边模模具材料选用 材料选用 Tool 模具 Case 条件 t < 1.0 mm Die item 模具项 Punch Die Punch Die Punch Trim 切边 1.4 mm ≤ t < 4.0 mm Die t < 1.4 mm Scrap cutters 废料刀 t ≥ 1.4 mm Scrap cutters 废料刀 t < 1.4 mm Top Punch Die Punch t ≥ 1.4 mm Die SKD-11 ICD5 ICD5 Cr12MoV SKD-11 Cr12MoV SKD-11 58 – 62 HRC 52 - 56 HRC Top Lower ICD5 SKD-11 58 – 62 HRC Lower SKD-11 ICD5 52 - 56 HRC Material 刀块材料 ICD-5 ICD-5 Cr12MoV Cr12MoV SKD-11 58 – 62 HRC Hardness requirement 热处理硬度要求 52 - 56 HRC

1.0 mm ≤ t < 1.4 mm

58 - 62 HRC

Flange/ restrike 翻边和 整形

Note 注释: 1. Top and bottom bolsters should use HT300. 上下模座选用 HT300。 2. Tooling steel selection refers to above table. 刀块材料选用参看上表。 3. Pad material selection refers to following pages 1.12. 压料器材料选用参看后续页 1.12。 5. SKD-11 should be bought from following company: ASSAB (XW-42), BOHLER (K110) and HITACHI (SLD) 上述表中提到的 SKD-11 材料必须购买一胜百(对应 XW-42)和百禄(对应 K110)或日 立(SLD)三家公司的材料。
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1.12 Pad Material Selection 压料器材料选用 Case 情况 General 普通情况 Material 材料选用 FCD300

FCD600 / MoCr Structurally Insufficient Strength 局部强度不够 Casting Steel Inserts ICD-5 or ZG-45 铸钢镶块 ICD-5 或 ZG-45

FCD300

Pad Material For Angular Applications 带角度的情况 FCD600 / MoCr

Casting Steel Inserts ICD-5 or ZG-45 铸钢镶块 ICD-5 或 ZG-45

Note 注释: 1. When shaping by restrike with pad, use Cr12MoV and flame hardening tool steel. 如果需要压边圈整形,采用 Cr12MoV,并热处理镶块。 2. This standard shall serve only as a reference. Material will be instructed during process schedule according to each part and shape. 该标准只作为参考。材料的选用应根据不同零件及形状由工艺来指导。

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1.13 Rib Construction 加强筋结构 Draw die 拉延模

Note 注释: 1. The distance between two ribs Maximum 300mm. 加强筋之间的间距不能超过 300mm。 2. All internal ribs 30mm 所有内部加强筋 30mm。 3. All exterior ribs 40mm. 所有外部加强筋 40mm。 4. ? All support ribs 40mm. ? 所有支撑的加强筋 40mm。 5. * To suit production press type. * 根据生产压机类型。

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Trim dies 切边模

Flange & restrike dies 翻边模和整形模

Note 注释: 1. The distance between two ribs Maximum is 300mm. 加强筋之间的间距不能超过 300mm。
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2. All internal ribs 30mm. 所有内部加强筋 30mm。 3. All exterior walls 40mm. 所有外部加强筋 40mm。 4. ? When pad bottoms out 35mm. 当压料器到底 35mm。 When pad does not bottom out 30mm. 压料器不到底 30mm。 5. * To suit production press type * 根据生产压机类型。

1.14 Back Up For Inserts 镶块背靠 镶块背靠

Case 条件 Blank Holder (inserts) 压边圈(镶块) Draw die top tool (inserts) 拉延模上模(镶块) Trim steel – Material thickness < 1.2mm 切边刀块 – 材料厚度小于 1.2mm Trim steel – Material thickness > 1.2mm 切边刀块 – 材料厚度大于 1.2mm Scrap cutter – Material thickness < 1.2mm 废料刀 – 材料厚度小于 1.2mm Scrap cutter – Material thickness > 1.2mm 废料刀 – 材料厚度大于 1.2mm Wipe and form steels 翻边和成型镶块

Requirement 要求 Required 需要 Required 需要 Not required 不需要 Required 需要 Not required 不需要 Required 需要 Required 需要

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1.15 Casting Relief 铸件逃料 铸件逃料

Male steels 凸镶块

Adaptor walls for male steels under 400mm apart should be rough cast 5mm short of the trim or flange line. 凸模镶块基座宽度小于 400mm 时,刀口下的侧壁应让开切边线或翻边线 5mm。

Adaptor walls for male steels over 400mm apart should be finished 5mm short of the trim or flange line for a height of 50mm and relieved 10mm for the remainder. 凸模镶块基座宽度大于 400mm 时,刀口下的侧壁应让开切边线或翻边线 5mm,基座相对机加面 让开 10mm,并保证机加 50mm 的高度。

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Cast walls for flanging should be finished for a height of 60mm for normal conditions & relieved 10mm for the remainder. 铸件翻边刀口应保证机加 60mm 高度,下部比翻边线让开 10mm。 Female steels 凹镶块

Adaptor walls for females steels under 400mm apart should be rough cast 10mm outside the trim or flange line.
凹模镶块基座宽度小于 400mm 时,基座下的侧壁应让开切边线或翻边线 10mm。

Adaptor walls for female steels over 400mm apart should be rough cast 10mm outside the trim or flange line for a height of 50mm and relieved 10mm for the remainder. 凹模镶块基座宽度大于 400mm 时,基座下的侧壁应让开切边线或翻边线 10mm,并且基座相对机 加面再让开 10mm,保证机加 50mm 的高度。

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1.16 Die Hook Setting Construction 吊耳结构

Allowable load ton/pce 1.5 3.0 5.0 7.0 10.0 13.0 Note 注释:

Z 30 40 40 50 50 50

d 25 35 45 55 64.3 74.3

x 65 70 75 80 85 110

y 105 110 125 125 135 190

r 50 70 85 100 120 140

t 40 60 70 80 85 100

I 50 60 70 80 85 100

L 130 180 210 240 255 300

R 15 20 25 25 30 30

1. This standard shows setting construction of die hook bar and hook bushing. 该标准描述了吊耳棒及衬套的结构尺寸。 2. 4 hooks of the same size must be used for each upper and lower dies, and 4 bars for each die. 根据上述要求,每个上模和下模需要 4 个同尺寸的吊耳,每副模具需要 4 个吊耳棒。 3. Size of hook should be decided on presumption that die is to be suspended by 2 hooks. 吊耳的尺寸因该是假设只有两个吊耳的情况下来决定。 4. Marked area on die hook bushing should be cut after being cast. 吊耳衬套由标识的区域在铸件后需要切掉。 5. Die hook bar should not protrude from die external shape. 吊耳棒不要超出模具的外部形状。
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1.17 Die Hook Bar 吊棒

Item 1 2 3 4 Nominal 1.5 3.0 5.0 7.0 10.0 13.0

Material A.I.S.I 4140 M.S M.S EN25 Load KN/PC 15.0 30.0 50.0 70.0 100.0 130.0 Ton/PC 1.5 3.0 5.0 7.0 10.0 13.0 ?D 24 34 44 54 63 73

Finish Heat Treat (Temper) HRC 27—33

Tolerance

±0.2

L 185 245 275 305 310 355

M 160 220 250 280 285 330

Mass Kg 0.7 1.8 3.4 5.7 7.8 11.7

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1.18 Die Hook Bushing 吊耳衬套

Nominal 1.5 3.0 5.0 7.0 10.0 13.0

Load KN/PC Ton/PC 15.0 30.0 50.0 70.0 100.0 130.0 1.5 3.0 5.0 7.0 10.0 13.0

?D ?D1 28 38 48 58 68 78 34 45 57.1 65.1 76.3 88.9

A 2 24 34 44 49

T 40 60 70 80 85

Y±1 30 30 30 30 30 30

Z

L

Mass Kg 0.6 1.2 2.0 2.2 3.2 5.4

38 190 38 240 38 270 38 300 38 315 38 360

64 100

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1.19 Locked Hook And Hook Bar 自锁吊耳和吊棒

Note 注释: 1. Above construction should be as primary choice for hook and hook bar whenever possible. 上述吊耳和吊棒结构应尽可能作为首选设计。 2. Dimension for these constrcution refer to normal one. 上述结构的尺寸要求参看普通吊耳和吊棒的尺寸。

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1.20 Die Handling – Eye Bolt Selection 吊环 To calculate sling angles and weight (Kg) use proportions shown below: 按下面所示选用吊索角度和重量(Kg):

Single Eye Bolt 单吊环

Pair Of Eye Bolts 多吊环

Size Of Eye Bolt 吊环尺寸

M12 M16 M20 M24

320 630 1250 2000

80 160 310 500

160 320 630 1000

400 790 1600 2500

260 500 1000 1600

160 320 630 1000

Note 注释: 1. The included angle, between the legs of every two leg sling connected to a load by a pair of eyebolts should not exceed 90 degrees. 两个起吊拉线之间的角度不能超过 90 度。 2. To ensure the correct eyebolt is used check weight and angle of lift and thread size. 确保使用正确的吊环,检查重量,角度和拉线大小。 3. A ring or shackle must be used with each eyebolt. 每个起吊环须有锁紧扣。 4. Each eyebolt must be tight on surface. Add washers if necessary. 每个吊环必须拧紧并紧贴表面。如果需要可以加垫片。 5. When 4 eyebolts are used, calculations must be made considering only 2 being effective at one time while lifting. 当使用 4 个吊环时,只能用 2 个作为有效重量计算。

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1.21 Heel Guide Classification 导板分类 A Type A 类:

A X × Y (cm2 ) < 8100 > 8100 Value of "L" to be 0.6 "Y" at minimum. L 最小为 Y 的 0.6 倍。 B Type B 类: Monoblock Construction 整体结构 100 Min 150 Separte Construction 分离结构 75 100

X × Y (cm2) < 8100 > 8100 Note 注释: 1. A type layout shall be standard. A 类的结构应该是标准。

A 100 Min 150

2. B type is used when cleaning of punch face of outer panel draw die is in consideration. 当需要清洁的下模表面时,如外板的拉延模,就需要考虑使用 B 类

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1.22 Top And Bottom Tool Guiding 上下模具导向 To select tooling guiding method should as following shown: 上下模模具导向方式的选用参看下表格: Tool 模具 Guide Preference 导向方式 Commnets 注释 If thrust guide is < 400mm, only 3 guide surfaces required. Draw die 拉延模 Thrust heel guide at both ends of die (Refer – 1.16) 两侧使用导板(参看 1.16) If thrust guide is > 400mm, only 4 guide surfaces required. 如果插入面小于 400mm,只需要 3 个导向面 如果插入面大于 400mm,需要 4 个导向面 For normal size tools, 4 off guide posts are required. Trim die 切边模 Guide posts 导柱 2 guide posts can be used for narrow tools. 普通大小的模具,需要 4 个导柱。如果是小模 具,需要 2 个导柱 Trim, flange and restrike 切边 翻边 整形模 If no thrust – Guide post with optional thrust Restrike and Flange 整形 翻边模 If thrust is present – Thrust heel guide with optional guide post. 如果有冲力-使用导根,选用导柱 heel guide. 如果没有冲力-使用导柱,选用导根 For normal size tools, 4 off guide posts are required. 2 guide posts can be used for narrow tools. 普通大小的模具,需要 4 个导柱。如果是小模 具,需要 2 个导柱 Guide posts and thrust heel guides 导柱和导板 For normal size tools, 4 off guide posts are required. 2 guide posts can be used for narrow tools. Thrust heel guides must be used to offset any thrust. 普通大小的模具,需要 4 个导柱。如果是小模 具,需要 2 个导柱 如果有冲力必须用导根来抵消冲力

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1.23 Wear Plate Application 耐磨板

Note 注释: 1.All the wear plate must have support under them. 所有耐磨板下部必须有支撑。 2.When die closed, the wear plate must engage more than 2/3 of the height of the wear plate. 最大行程处耐磨板接触必须大于耐磨板高度的 2/3。 3. When die opened, the inside wear plate must engage at least 1/3 of the height of the wear plate. 模具打开状态,内滑块必须接触耐磨板的 1/3。

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1.24 Screw & Dowel 销和螺钉

Mild Steel 低碳钢 Dowel dia X 销直径

Tool Steel 工具钢 2 × Dowel dia 2 倍销直径 30mm Min 最小 30mm

Screw head dia Y 螺钉头直径

Note 注释: 1. Holes near the edge of tool steel should be located so that the wall between the hole and the edge is greater than 10mm. 离边较近的孔需要保证孔离边的距离大于 10mm。 2. Adjacent holes in tool steel should be located so that the wall between the holes is greater than the thickness of the tool steel. 临近的孔必须固定位置,保证两孔之间的壁厚必须大于钢块的厚度。 3. Show positions of screws and dowels on die degisn, on plan views only & indicate thread size. 在平面设计图中标识螺钉和销的位置和大小。 4. Maintain counterbore depth for each application. 每个沉头孔的深度保持一致。 5. Use available standard screw and dowel sizes whenever possible.
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螺钉和销需要用标准件。 6. Use M16 screws and 16mm dia dowels in all cases except extremely small details. 除了特别小的位置,其他位置都用 M16 的螺钉和直径为 16mm 的销。 7. Top of screw head must be recessed 10mm Min. 上边面的螺钉必须下沉最少 10mm。 8. Thread screw into steel. Avoid threading into cast iron whenever possible. 螺钉拧入在钢块中,避免拧入铸件里。 9. Provide tapped holes in steel sections (cutting or forming) to facilitate lifting the steels off the dowel pins or out of a pocket. 较大的钢块需要有有螺纹的起吊孔方便吊起钢块。 10. Dowels & tapped holes must be properly spaced to prevent breakage in hardening. 销和螺纹孔必须合理的分布位置,避免热处理时破损。

Screw thread codes 螺钉符号

Thread 尺寸 M6 M8 M10 M12 M16 M20 M24

Symbol 符号

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Number of bolts can follow below;and about dowels always install 2. 螺钉数量的选择参看下图;销一般选用 2 个。 Size Of Steel 镶块尺寸 Number Of Bolts Per Steel 每块镶块的螺钉数 Figure 图示

L < 200mm

2

200mm ≤ L < 400mm

3

400mm ≤ L < 500mm

5

Typical screw and dowel layout: 典型的螺钉和销分布图:

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1.25 Pad Retainers Application 压料器侧销 Pad retainer application upper pads cast construction 上压料器侧销

Pad size 压料器尺寸 Small 小型 Medium 中型 Med – Large 中-大型 Large 大型

Hole dia 孔径 B C D

E Cast iron 铸铁 20 75 28 30

E Steel 钢块 20

25

35

25

85

40

45

30

50

30

100

56

60

40

65

35

120

70

80

50

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Pad retainer application upper pads cast construction – Alternative construction 上压料器侧销 – 可选结构

Note 注释: 1. Position retainer pins at front and rear of die if practical. 在模具的前后都标识侧销的位置。 2. Provide 6 pad retainer pins in upper pads. For pads > 1500 × 600mm. 如果压料器大于 1500 × 600mm,上模需要 6 个压料器侧销。 3. Dies with pads < 1500 × 600mm, use 4 off appropriate size retainer pins. 如果压料器小于 1500 × 600mm,上模需要 4 个压料器侧销。
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October 2012 Q/CAF 87-2008

1.26 Pad Retainers - Safety Pad Retainer Pins 侧销 - 安全螺钉 Safety pad retainer pin application upper pads – cast construction 上压料器安全螺钉 – 铸件结构

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Pad size 压料器尺寸 Small 小型 Medium 中型 Med – Large 中-大型 Large 大型

A Hole dia 孔径 30 20 75 33 B C D

E Cast iron 铸铁 30

E Steel 钢块 20

40

25

85

45

45

30

55

30

100

60

60

40

70

35

120

76

80

50

Note 注释: 1. Provide 4 safety pins for pads > 1500 × 600mm. Position safety pad retainer pins at front & rear of die if practical. 如果压料器大于 1500 × 600mm,需要 4 个安全螺钉。在模具的前后都标识安全螺钉的位 置。 2. Dies with Pads < 1500 × 600mm, use 2 appropriate sized safety pad retainer pins. 如果压料器小于 1500 × 600mm,需要 2 个安全螺钉。

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1.27 Lower Pad Retainer Application 下压料器限位螺钉 Small, medium & Large pads preferred method 大,中和小型压料器首选方案

Small & Medium cast pads and steel pad dies alternative method 中,小型压料器可选方案

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Casting construction for large dies 大型模具的铸件结构

Small dies – Use only when other methods shown are not practical 小型模具 – 下图所示结构仅适用于其它方案不能适用时备用

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1.28 Spring Installation 弹簧

Spring guards are to be used when pad bottoms out or comes to within 12mm or less of bottoming. Spring guards must enter 12mm Min. with die in open position. Keep guard within die area whenever possible. 弹簧保护用于压料器到底,或到达形成后,到底距离小于 12mm。弹簧保护必须在模具开启状态 时,高出至少 12mm。 尽量保证弹簧保护在模具中。

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Large pads – Spring installation 大型压料器 – 弹簧安装

Note 注释: Maintain 25mm Min, between springs to avoid weakening pad or punch shoe. Use 50mm dia springs whenever possible. 在弹簧之间最小保持 25mm,避免弱化压料器和下模。尽可能使用直径为 50mm 的弹簧。

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1.29 Panel Ejection From Upper Tooling 上模卸料 上模卸料 Spring plunger pins are to be provided in upper tool to prevent part sticking in top tool. Minimum stroke = 20 mm. 上模需要安装弹顶销避免零件卡在上模。最小长度为 20mm。 Spring plugers can also be used on lower tool of draw die to aid panel ejection. 弹顶销也可以用在下模,辅助拉延模取件。

Note 注释: 1. Ensure full casting around spring pin, and ensure pin is bottomed. Hole to be 0.5mm deeper than pin length. 弹顶销需要四周分布,并需要安装到底。孔需要比销的长度深 0.5mm。 2. If draw tool or parrellel side walls on panel, heavy duty shedder pins and oval wire springs are to be used. 如果是拉延模或两侧侧壁平行的零件,需要用高负荷卸料销或线圈弹簧。 3. Above mentioned, use only for light pressure. If more pressure required use die spring & pin. 上述弹顶销只适用于于小压力。如果需要更大的压力,使用弹簧。

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1.30 H type Panel Lifter H 式卸料 Make sure air cylinder and lifter to be accessible when die is in press. Provide 25mm clearance around lifter frames for toolmaker & operator safety. Use standard commercial lifters. 确保模具在压力机上气缸和卸料器可用。在卸料器周围需要 25mm 的间隙,保证模具制作和操作 者安全。卸料器需要使用标准件。

Note 注释: 1. For R & L hand parts running in one die use separate air cylinder and lifter to direct lift each part. 对左右件共模的零件,需要用独立的气缸顶出每个零件。 2. Flow control valve required on up stroke of lifter. 需要有流量控制阀控制卸料力的大小。

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1.31 Air Operated Panel Ejector 气动卸料

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1.32 Gas Spring Systems 氮气弹簧 氮气弹簧系统 弹簧系统 The following points should be considered by designers: 在设计时需要考虑下述要点: 1. When a gas spring is installed in the tool, there should be a stroke reserve of approximately 10% of the length of stroke. In no case must the stroke reserve be less than 5mm. 当氮气弹簧安装后,受压以后应该保留大约 10%的冲程。并且保留冲程不能小于 5mm。 2. Gas spring must be mounted square to mounting surface; 90° ± 3° dimension to appear on design. 氮气弹簧安装时应该与安装表面垂直,设计公差为 90° ± 3°. 3. Gas spring pockets to have 1.5mm minmum clearance per side. 氮气弹簧与安装孔单边需要最小 1.5mm 的间隙。 4. Gas spring selection should be from only Dadco or Kaller. Others need be approved by CFMA. 氮气弹簧可以选择 Dadco 与 Kaller 两个品牌,如果选用其它需要 CFMA 批准。

Typical nitrogen application built on top of die 典型上模氮气缸运用

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Gas spring syetems layout 氮气缸系统布局 (1)In series 串联

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(2)Parallel connection 并联

Note 注释: Parallel connection is preferred method for gas spring syetem layout. 并联方式是氮气缸系统布局的首选方式。

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1.33 Nameplate 铭牌

1. Material: Al, 1.5mm 材料:铝,1.5mm 2. Position: Front – Right 位置:模具前方右下角 3. Size and contend of the nameplate as following shown:

4. Air pin layout should be shown as following 拉延模的顶杆分布图也必须在铭牌上标识,如下图所示

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1.34 Die Painting 颜色喷涂

Code 序号 1

Item 项目 Overall painting 主体喷涂

Description 描述 Generally cast surfaces of die 模具主要的铸件表面 1).Material flow direction, tool No. and individual mass to be stencilled on both upper and lower tools. Total mass to be stencilled on upper tool. (Both ends 40mm high) 送料方向,模具号和重量分别标识在上下模。总 的重量标识在上模。(高度 40mm)

Colour code 颜色 Suppliers decided 冲压供应商选择

2

Notes 注释

2).Cast "F" on upper and lower tools to be painted in front of the tool. 在上模和下模前部都须喷涂“F”字体 3). Cast model, part number, operation name on upper and lower tools 在上下模前部都必须喷涂车型号,件号,工序名

Black 黑色

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Depends on 3 Model identify 车型识别 Die Hook 吊耳 differnt models 不同车型选用不 同颜色 1). Safety guards & blank holders. 安全区域和压边圈 2). Spring, cyliner & urethane covers. 弹簧,气缸和缓冲器安全罩 3). Lifter & stroke stoppers. 卸料器和限位块 Caution colour 4 警告颜色 4). Saftety bolt head & back surface of guide. 安全螺栓头和导向机构的后表面 5). Side retainer head & side pin plate. 侧销头 6). Front side of scrap box. 废料盒的前侧 7). Non-sliding surface of scrap chute and fittings. 废料滑道的反面 5 Hazard colour 危险颜色 Safety block area 安全块区域 Red 红色 Yellow 黄色

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1.35 Production Information 生产信息

Year 年

Stamping Marker 冲压件标识

Day 天

Shift 班次

1. Every part should be stamped on production information as above shown. 每个冲压件都需要在零件上标明生产信息,如上图所示。 2. Production information consists of produce year, day, shift and stamping marker. 生产信息由生产年,日,班次和冲压符号组成。 3. The location of this information should be easy to find after assembling 当冲压件焊接为总成后,生产信息在零件上的位置应该很容易被找到。

Example

8

S

023

A

8 – Production year is 2008. 生产年份为 2008。 S -- This is stamping products mark. 冲压零件标识。 23 – Production day is 23rd day of 2008. 生产日期为 2008 年的第 23 天。 A – Shift A. (Everyday can be divided to A, B and C shift) A 班生产。(每天分为 A,B 和 C 班)

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2 Draw Dies 拉延模 2.1 General Notes 概要 1. Show all views and sections necessary to construct patterns and to build tools. Ensure all critical areas are shown clearly. 显示保模和模具制造所需的所有视图和截面图。确保所有关键区域都清楚地显示。 2. Show trim lines and finished positions in red in all views and sections. 切边线和完成时位置以红色在所有视图和截面图中显示。 3. Ensure panel tip and start dimensions are in line with Cad data and "A" layout. 确保零件的旋转,开始点符合数模和工法图。 4. Provide bolt down slots or holes to fit both the production and alternative presses. 保证模具装夹压板的选择符合压力机。 5. Die build up information for production and alternative presses to be recorded on the face sheets, process and the process control plan sheet. 模具制造和压力机选择信息需要记录在工艺及工艺控制计划表中。 6. Add all necessary drain and vent holes. 加入所有有必要的排油和排气孔。 7. Refer to press specifications for Min distance between shut height of the blank holder and the inner ram. 参考压力机的规格,设计模具闭合时压边圈和模具装夹台面的最小距离。 8. All draw dies must have lifting lugs. 所有拉延模必须有吊耳。 9. Establish split lines on punch and blank holder. 设定下模和压边圈的分模线。 10. Show actual bead condition and soakers in all sections and views. 在所有视图中显示拉延筋和工艺造型。 11. Guard all pads. 所有压料器和其它部件之间如果有安全隐患区域都需要增加安全保护。 12. Flame harden all draw beads male radius and die mouth. 入模口和拉延凸筋需要热处理。

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2.2 Tonnage Formula 吨位计算 吨位计算 Calculate drawing force (D.F) & add it to the blank holder force (B.H.F) 计算拉延力(D.F),加上压边圈力(B.H.F) (F1) D.F (kN) = Perimeter(mm) × Material thickness (mm) × Yield strength (MPa) / 1000 D.F (kN) = 周长(mm) × 材料厚度 (mm) × 屈服强度 (MPa) / 1000 (F2) B.H.F refer to following fig for % of D.F B.H.F 参考下图表中 D.F 的百分比 (F3) Total tonnage = D.F + B.H.F

总压力 = 拉延力 + 压边圈力

Material 材料 HRC HRD HR340 HRC1012 HRS1070 CRC CRD CR310 CRS1070

Yield Strength MPa 屈服强度 MPa 310 310 450 310 620 260 230 380 480

Material thickness (mm) 材料厚度 (mm) 0.8 1.0 1.2 1.6 2.0 2.5 3.0 3.5 4.0

% of D.F 35 30 26 22 20 18 16 15 14

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2.3 Die Size Reduction 模具尺寸设定 Guiding around the punch 凸模周边导向

Guiding around the guide heel 导根周边导向 Heel strength H × W and machinability should be considered in following case. 应该考虑导根的长度和宽度及加工能力,如下图所示。

Note 注释: Blank holder guiding is dependant on part profile. Decision should be based on complexity of part profile. 压边圈导向由零件轮廓决定。

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2.4 Blank Holder Face 压边圈面尺寸 Material flow which is 30mm or more, use blank size +20mm on one side. 材料流入量大于 30mm,压边圈面尺寸比坯料每边增加 20mm。 Material flow which is less than 30mm, use blank size +10mm on one side. 材料流入量小于 30mm,压边圈面尺寸比坯料每边增加 10mm。

2.5 Blank Holder Bottoming Situation 压边圈到底条件 压边圈到底条件 Blank holder of draw die to be bottomed if 下列情况拉延模的压边圈需要到底 1. The trim line is on the blank holder. 切边线在压边圈上。 2. The part shape is on the blank holder. 零件形状在压边圈上。 But blank holder does not require bottoming if trim line is on the punch. 如果切边线在凸模上,压边圈不要到底。

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2.6 Bottom Fit Stroke Stopper Installation 限位块 1. Draw die 拉延模

Ensure stroke stoppers are positioned under main working area close as possible to punch. 确保限位块的位置设定在工作区域下方,并尽可能的靠近凸模。 2. Pressure pad 压料器

This standard sets a reference for installation of stroke stoppers in a die that bottoms. 该标准对需要到底的模具的限位块的安装提供了参考。
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2.7 Bottom Marker 到位标记

Harden & temper to 56-58 HRC 硬度 56-58 HRC

Note 注释: Bottoming markers to be placed in upper die cavity on all draw & stretch form dies also in all dies that bottom, restrike and or flange. This enables checking that the full depth of form / flange is obtained. This position of the bottoming markers should be as follows: 在所有需要到底模具如拉延模,整形模,翻边模的上模模腔内加入到位标记。有助于检查成型深 度及翻边是否达到。到位标记的位置应如下诉所示: 1. That it marks the panel in a place not visable after assembly. 该标记在片件上装配以后应该不可见。 2. That the mark is not completely cut out in later operations. 该标记在后工序不要完全被切掉。

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2.8 Balancing Blocks 平衡块

Note 注释: 1. All draw dies to have balance blocks, and size shown as below. 所有拉延模需要平衡块,尺寸见下表。 Die size 模具尺寸 模具长度 Y < 1600mm 模具长度 Y > 1600mm Balance block size 平衡块尺寸 80mm 100mm

2. Quantity depends on die size with a minimum of 4 for small tools, up to 8 on large tools. 平衡块的数量由模具大小决定,如小模具最少需要 4 个,大模具最少需要 8 个或更多。 3. A full and complete support must be maintained under each balance block, such as bottoming blocks. Provide riser supports under all balance blocks. 所有对应的平衡块下需要有限位块。并且在平衡块下部需要有铸件加强筋。 4. It is necessary that balance blocks do not interfer with blank loading or panel unloading. 确保上料或取件时,平衡块一定不能和板料干涉。 5. For the outer panel draw die, the taper shape balance blocks can be as an option. 外板件的拉延模,可以选用锥形的平衡块。

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2.9 Draw Bead Application 拉延筋

1. Die designs must show the draw bead pattern in plan view. 模具设计必须在平面图中显示拉延筋样式。 2. Secondary beads when required to be approximately 40mm shorter than the main bead as shown. 如果需要两条拉延筋时,如上图所示辅助筋会比主作用筋短大约 40mm。 3. Beads on the end of concave binder surfaces will be 3mm deeper than beads on the top surfaces. 尾部的拉延筋因该比两侧的拉延筋的深度深 3mm。

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2.10 Bead Location 拉延筋位置

Note 注释: 1. An Enlarged section and notes must be shown next to each section where the trim line falls on the binder surface. 压边圈上切边线出必须有放大的截面图显示拉延筋。 2. Beads on ends of concave binder surfaces will be 3mm deeper than beads on the top surface. Second and third bead requirements and location is to be determined by the construction vender during preliminary tryout and concurred by the CFMA STA engineer. 压边圈上尾部筋的槽深度比上模筋的高度多 3mm。如果需要第二,或第三条拉延筋,需 要 在首次试模以后,并于长安福特马自达 STA 工程师一起决定。
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2.11 Draw Die Beads Type 拉延筋类型 拉延筋类型

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2.12 Air Relief And Draw Compound Drain Holes 排气孔

Skin panel surfaces use 4mm air relief holes in a staggered hole pattern or 200mm spacing in reverse areas or air traps such as flat surfaces use 6mm air relief holes outside of any trim areas, spaced 250mm apart. 外板件采用直径为 4mm 的排气孔,200mm 的间距分布在凹面。切边外的区域采用直径为 6mm 的 排气孔,250mm 间距分布。 All other die surfaces use 6mm air relief holes no pattern required locate in reverses, air traps or area that will be trimmed out, spacing of 200mm, amount and spacings to suit volume of air trapped. 内结构件采用直径为 6mm 的排气孔,没有间距要求分布在凹面。切边外的区域,以 200mm 的间 距分布,但排气孔的数量和间距需要满足排气的量。
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Note 注释: 3. 6mm dia vent holes must be 90° to surface contour. 6mm 直径的排气孔应该和表面轮廓成 90°。 4. Steel tubes used to stop debris from falling back in die. 钢管防止残渣掉入模具。

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2.13 Die Co-Ordinating Holes C/H 孔 1. Provide co-ordinating holes with all tooling line ups which require draw or stretch form dies, on compound curves, skin or structural panels. 在复杂曲面,外板或结构件的拉延,成型模具上提供 C/H 孔。 2. Position co-ordinating holes preferably on body lines or intersection of body lines as far apart as practical on a surface as near to horizontal as possible for piercing. C/H 孔的位置适宜在车身线或车身线的交叉处,尽量远离实际需要冲孔的位置。 3. Position of co-ordinating holes to be determined by die design and shown on die layout. C/H 孔的位置由模具设计决定并标识在工法图中。 4. Punches and location pins are to be removed after tryout. 试模完成后冲头和定位销需要除去。

Draw die 拉延模 Create co-ordinating holes in die, positioned from die layout. 在模具中加入 C/H 孔,位置见工法图。

Following operations 后工序 The angle of co-ordinating holes must be the same in relation to the panel as in the draw die. If the panel is tipped the holes will be inclined requiring a larger clearance hole in the top tool. C/H 孔的角度必须和零件在拉延模中一致。如果零件有旋转,上模中需要更大的过孔。

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Draw die only 拉延模

Subsequent dies 后序模具

Note 注释: When panel is tipped in subsequent dies and co-ordinating hole centre line is 5° or greater, holes must be drilled normal to surface also X, Y, Z and angle dimmension specified on design. 如果零件在后工序中旋转,并且 C/H 孔的中心线偏移大于 5°时,角度尺寸需要在设计中指出。

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2.14 Blank Holder Retainer 压边圈安全压板

Note 注释: The size and position of blank holder retainer to be determined at die design. 压边圈安全压板的位置和尺寸在设计时决定。

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2.15 Draw Die Pop Up Gauges 活动挡料销 活动挡料销

Note 注释: 1. Pop up gauge should be used whenever possible, if it is manual operation. 如果是手动冲压线,应尽可能选用活动挡料销。 2. Quantity and setting position must be taken into consideration at die design and decided after tryout. 挡料销的数量和位置应在模具设计时考虑,但最后根据试模结果来决定。

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2.16 Draw Die Fixed Gauges 固定挡料销 固定挡料销 Front gauges for draw dies 拉延模的前侧挡料销

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Side gauges for draw dies 拉延模的两侧挡料销

Note 注释: A & B dimensions to be in 25mm increments, if material is mild steel. 当材料选用低碳钢,A 和 B 的尺寸需要 25mm 的增量。

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Side gauges for draw dies – robot press line 拉延模两侧挡料销 – 自动线

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2.17 Machined Clearance For Locations 挡料销间隙 1. Clearance for loacations to be 1mm to 3mm (preferred 1mm). 如下图所示挡料销间隙为 1mm 到 3mm。(1mm 最好) 2. Locations to be machined after tryout. 试模完成后,确定了坯料最终尺寸再加工。

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3 Cutting Dies 冲裁模 3.1 Stripping And Cutting Forces 冲裁力和卸料力 冲裁力和卸料力计算 和卸料力计算 The force in newtons (N) required for blanking, trimming & piercing is calculated using the following formula: 用下述公式以牛顿(N)计算下料模,切边冲孔模所需的冲压力: Cutting force F = L × T × Su × 0.8 Where L = Length of cut in (mm) 切边的长度 T = Thickness of stock in (mm) 板料厚度 Su = Tensile strength of material in (MPa) 材料的抗拉强度 The force for stripping in newtons (N) varies with the complexity of its shape. A thin uniform pierce of scrap requires less stripping force than an irregular pierce. 卸料力随着零件形状的不同而改变。如薄的,规则的废料比不规则的废料所用的力小。 Stripping force F = L × T × P Where L = Length of cut in (mm) T = Thickness of stock in (mm) P = Stripping factor in (N/mm2)

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Force In "N" Per 1mm Cut Or Break Line Stock Thickness "T" P = 12 0.7 0.75 0.8 0.85 0.95 1.2 1.4 1.8 1.9 2.2 2.5 3.0 3.2 3.5 4.0 4.5 4.8 5.0 8.4 9.0 9.6 10.2 11.4 14.4 16.8 21.6 22.8 26.4 30 36 38.4 42 48 54 57.6 60 Stripping Force In "N" Per 1mm Run For Stripping Factor Flange Straight Line F 36 38.7 41.3 43.9 49.1 62 72.3 93 98.2 113.7 129.2 155 165.3 180.9 206.7 232.5 248 258.3 Forming Curved Line F 217 232.5 248 263.5 294.5 372 434 558 589 682 775 930 992 1085 1240 1395 1488 1550

Blanking

Restrike

P = 16 11.2 12 12.8 13.6 15.2 19.2 22.4 28.8 30.4 35.2 40 48 51.2 56 64 72 76.8 80

P = 20 14 15 16 17 19 24 28 36 38 44 50 60 64 70 80 90 96 100

P = 24 16.8 18 19.2 20.4 22.8 28.8 33.6 43.2 45.6 52.8 60 72 76.8 84 96 108 115.2 120

F 273 292.5 312 331.5 370.5 468 546 702 741 858 975 1170 1248 1365 1560 1755 1872 1950

F 385 412.5 440 467.5 522.5 660 770 990 1045 1210 1375 1650 1750 1925 2200 2475 2640 2750

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3.3 Trim Die General Notes 切边模概要 1. Show trim lines in plan views and sections, and specify whether rough / finished trim or lance, etc. 在平面图和截面图中指定粗切边线和最终切边线等。 2. Show scrap in sections. 显示废料的界面。 3. Show binder line in plan views and sections. 在平面图和截面图中显示拉延件外形线。 4. Draw full plan views to show position of scrap cutters. 在平面图中显示废料刀的位置。 5. Maximum scrap length to be 600mm. Minimum shed angle to be 25°. Shed angle less than 25° requires a vibrated chute to be connected (Min shed angle of 10° with vibrator). 最大废料尺寸不能超过 600mm。最小的废料滑落斜度不能小于 25°。如果斜度小于 25°, 需要使用震动斜道(使用震动器的斜度也不能小于 10°)。 6. Scrap to be shed over edge of press bolster. 废料需要滑落出冲床台面。 7. Scrap chutes to be a minimum of 10% wider than diagonal length of scrap is falling through the die. 废料滑道的宽度至少要比废料对角线的长度宽 10%。 8. Pad travel to be great enough to precede scrap cutters. (ie. 25mm Min) 压料器需要有足够的行程,并领先于废料刀。(最小 25mm) 9. Use pad retainers. 压料器使用侧销。 10. Use safety pad retainers on all upper pads. 所有上压料器要使用安全螺钉。 11. Use traps and guide posts for unbalanced trim conditions. 在切边不平衡的情况下需要用复合导向。 12. Height and width ratio of trim steels to be 1:1.5 Min. 切边刀块的高度与宽度比例最小为 1:1.5。 13. Forces required for trimming and stripping to be calculated, ensuring selected press has capacity for specified operation. 切边和卸料所需的力的计算需要确保选择的压力机能满足生产能力。 14. Key or heel all trim sections. 所有切边镶块必须有背靠。 15. All trim corners to have 3mm Min where practicable.
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如果可行,切边转角大于 3mm。 16. Shear must be shown on die designs where possible. 剪边在模具设计中必须显示。 17. Provide inserts if piercings are to close to trim edge. 如果冲孔接近切边边缘使用镶块。 18. Machine base of pad – required for N/C set up. 加工压料器基座,需要设立加工中心。 19. All trimmed edges on panels must not be less than 70° included angle. 所有剪切的边必须小于 70°的斜角。 20. Avoid sharp pointed scrap wherever possible. 避免锋利尖角的废料。

3.2 Springs Application 弹簧运用 Springs application for cutting dies as below shown. 弹簧在切边模的运用如下图所示。

Springs to be compressed 3mm minimum in die open postion. Pad must advance cutting steel by 3mm minimum. Polyurethane springs do not requrie 3mm pre-compression. 弹簧在模具打开状态需要压缩最少 3mm。压料器比切边刀块最小要提前 3mm。 聚氨酯弹簧不需要预压缩 3mm。 Stripping pressure to be calculated at die closed position. Do not over compress springs. 卸料力需要在模具闭合位置计算。但不要过压缩弹簧。

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3.4 Steel Fastening 钢块固定 钢块固定 All tool steel & cast trim composites are to follow the gird pattern as specified below for manufacture 所有的镶块都需要按下图所示固定方案制造

Note 注释: 1. Every steel need at least 2 dowels. 每块镶块至少需要 2 个销钉。 2. Screw number depends on the steel size (ref to 1.23). 螺钉的数量取决于镶块的大小(参看 1.23) 3. Screw position prefer to be on 25 grid pattern when possible. 螺钉分布尽可能以 25mm 网格分布。

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3.5 Cast Trim Steel 铸造切边刀块

1. Height of section to be 40mm Min. Width of base to be approx 1.5 times that of the height. 高度最小 40mm。基座的宽度大约是高度的 1.5 倍。 2. Use ICD5 for dies cutting up to 1.5mm thick material flame harden cutting edge. 材料厚度小于 1.5mm 的材料,刀块使用 ICD5,并热处理刀口。 3. Provide tapped eyebolt holes for lifting. (ie. M16) 起吊使用有螺纹的起吊孔。(如 M16) 4. Use one piece die composite up to length 500mm Max. 每个刀块长度最大不超过 500mm。 5. All cutting steel over 70mm height must be ribbed and rib to be 12mm thick. 所有切边刀块高度超过 70mm,必须有 12mm 厚度的加强筋。

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3.6 Blade Type Steels & Cutting Angles 镶块刀口和切边角度 镶块刀口和切边角度

Blade type steels should be screwed & dowelled horizontally as shown whenever possible. Screw from the top only when horizontal screws would not be accessible with the die in the press. 刀块应尽可能水平地用销定位及用螺钉固定。只有当模具结构不能采用水平固定时,才使用从上 部固定。 Do not exceed maximum angles shown on any cutting section. 不要超过最大的切边角度如上图所示。

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3.7 Composite Type Steels & Cutting Angles 整体式刀块和切边角度

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3.8 Scrap Cutters And Pad Travel 废料刀和压料器行程

Note 注释: 1. Show a true view of all scrap cutters. 显示废料刀正确视图。 2. Pad travel on trim dies with scrap cutters to be 25mm Min. 切边模上有废料刀的压料器行程最小需要 25mm。

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3.9 Scrap Layout 废料分布

Note 注释: 1. Draw full plan view on all trim dies to show position of scrap cutters. 所有切边模需要显示所有废料刀的位置。 2. Provide sufficient height on scrap cutters to all for good scrap disposal. 需要足够的废料刀高度来保证废料顺利滑落。 3. Scrap cutter angle Maximum 9°. 废料刀最大倾斜角度为 9°。

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3.10 Applications For Scrap Cutters & Scrap Chutes 废料刀和废料滑槽

Note 注释: 1. When scrap chutes can not be 10% wider than diagonal dimension of scrap, the scrap chute clearance and casting wall must not allow scrap to get caught. 如果滑道的宽度不能大于废料对角线尺寸 10%,滑道两端的间隙需要确保废料不被卡住。 2. Make scrap chutes in one piece when practical. 滑道尽量是一块整体。
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3.11 Applications For Scrap Chutes 废料滑槽 1. For chute angle not less than 25° as standard。 废料滑道的倾斜角度应不小于 25°。 2. For chute angle less than 25° design & build with dimple plate & vibrator. Ensure a flow control valve fitted to vibrator. 如果滑道倾斜角度小于 25°时,应考虑设计震动器和波纹板。而且要保证流量控制阀适合 震动器。

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3.12 Applications Of Vibrateing Scrap Chutes 震动废料滑槽

Note 注释: 1. If angles less than 25° requires vibrators to be designed & fitted. 如果滑道角度小于 25°,需要震动器。 2. Ensure all vibrators have flow control valves fitted. 所有震动器都需要流量控制阀。

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3.13 Scrap / Part Chutes Hinge Application 二级滑道固定链运用

Note 注释: * Min. 10mm * Max. 50mm for chute on heavy press lines. 如果是大吨位压机,最大需要 50mm。

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3.14 Pierce Die General Notes 冲孔模概述 1. Forces for piercing and stripping to be calculated. 切边冲孔的力需要计算。 2. Piercing punches should be removable without removing the pressure pad. 在未拆卸压料器的情况下,冲头可以被拆卸。 3. On all outer panels and specified inner panels use removable inserts in stripper. 所有的外板零件和特定的内板零件,压料器使用可拆卸的镶块。 4. When piercing with cam slides, removal of punches in retracted position must be allowed for. 侧冲模需考虑在回收位置拆取冲头。 5. Use light duty ball lock punch, button and retainers up to 3mm material. Use heavy duty ball lock punch, buttons and retainers for all H.S.S material and material over 3mm thick. All pierce punches to be 80mm length. If the punches used which is not 80mm, it must be approved by CFMA engineer. 材料厚度小于 3mm,使用轻载荷快换冲头。材料厚度大于 3mm 或高张力材料,使用重载 荷快换冲头。所有冲头长度以 80mm 为标准。如果使用非 80mm 长度冲头,需要长安福特 马自达工程师批准认可。 6. On close hole spacing when individual retainers can not be fitted, use a special retainer for a group of punches. 当单个冲头固定座空间不够时,一组冲头使用一个特殊的冲头固定座。 7. Check for removal of die buttons. Replaceable die buttons to be used wherever possible. If not feasible, use a small replacement tool steel section. 尽可能使用可拆卸模钮。如果不能安装模钮的情况,采用小型可更换的镶块。 8. Avoid drilling slug clearance holes at angle. 避免有角度的废料滑出孔。 9. Minimum slug shed angle through die onto scrap chute -50°. 冲孔废料从模具到废料滑槽的最小斜度为-50°。 10. All pierced slugs to be shed off press bolster minimum scrap chute angle 25°, or use vibrated scrap chute minimum angle 10°. 所有冲孔废料需要滑出压机台面,最小的废料滑道斜度为 25°,或者用震动废料滑道,最 小斜度为 10°。 11. All the punch in the same the operation, must be same travel. 在同一工序中的冲头的行程必须一致。 12. Piercing with select retainer units, centreline of pierce punch is to align with centreline of unit. 如果冲头使用冲头基座,冲头的中心线必须和基座的中心线对齐。
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3.15 Pierce Punch Design 冲头设计 I. Limit of working direction 冲裁角度 Case 条件 Angle 角度 Figure 图示

d < 10mm

θ=d

10mm < d ≤ 15mm

θ ≤ 10°

d ≥ 15mm

θ ≤ 20°

II. Punch 冲头

Pierce punch to be 80mm long. 冲头需要 80mm 长。

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October 2012 Q/CAF 87-2008

Piercing infomation 冲裁信息 1. Forces required for blanking & stripping can be calculated using the formula shown before. 下料或切边所需要的力用之前所提到的公式计算。 2. Preferred, press fit centre dowel regular punches with retianers. 带有冲头固定座中心销标准冲头为首选。 3. Preferred punch length is 80mm. Optional 63mm. 冲头长度首选 80mm。63mm 长度可以作为备选。 4. Jektole punches to be used on: 带顶销的冲头用在: 1) All cam dies. 所有侧冲模。 2) All parts using H.S.S material. 所有选用高张力材料的零件。 5. Die cutting clearance: 切边间隙: 1) Normal sheet metal as per 6% per side. 一般情况间隙为单边 6%的料厚。 2) H.S.S sheet metal 10% per side. 高张力材料间隙为单边 10%的料厚。 6. Specify punch point diameter on plan-lower die. 在下模平面图中指定冲头直径。 7. Pierce punch penetration, see below. 冲孔深度如下图所示

Material thickness 材料厚度 Penetration 深度 ≤ 1.0mm > 1.0mm 3 – 4mm 5 – 6mm

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October 2012 Q/CAF 87-2008

3.16 Pierce Hole Spacing 冲孔间隔 Round hole to round hole 圆孔和圆孔的间隔

Pierce hole to trim line 冲孔和切边的间隔

Pierce bushing to trim line 冲孔衬套和切边间隔

Note 注释: 1. Specified above is to be applicable up to 0.8mm plate thickness. For thicker material distance must be greater than specified. 上诉规格只适用于 0.8mm 厚度的材料。对于更厚的零件,距离应该更大。 2. Spacing specified by "Pierce bushing to trim line" is for die made of carbon tool steel. For ICD5 die, it is to be doubled and for FCD die, it is to be tripled. 上诉 冲孔衬套和切边间隔的规格适用于碳素工具钢。对 ICD5 材料,距离需要加倍,对 FCD 材料,距离需要上述的 3 倍。
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CHANGAN FORD MAZDA AUTO CO DIE DESIGN STANDARD 长安福特马自达冲压模具设计标准
October 2012 Q/CAF 87-2008

3.17 Vertical Cutting 垂直切边

Angle (θ°) of vertical cutting section to be the value indicated below or more, including scrap cutter. 垂直切边的角度(θ°),如下表所示。这样同样适用于废料刀。 t (mm) θ° (Min.) 0.6 0.7 0.8 0.9 1.0 1.2 1.4 1.6 1.8 2.0 5.7° 8.0° 9.2° 10.3° 11.5° 13.9° 16.2° 18.6° 21.1° 23.5°

Zero cutting like following shown, should be except R area 0 度切边如下图所示,应该避免切到 R 角处。

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October 2012 Q/CAF 87-2008

3.18 Punch Development 异性冲头 Burst Extrude 刺破双翻边

Method in determining extruded hole punch sizes where flange height must be held. 决定刺破双翻边冲头的尺寸需要考虑法兰边的高度。 B = 1.571 × (0.25T + R) Use R = 0.5mm unless part print specifies radius. 如果图纸中没有给出特定半径,R 等于 0.5mm。 W = C – 2 × (B + F) If "W" is less than 1.5T, use a pointed extruding punch. 如果 W 小于 T 的 1.5 倍,采用尖形冲头。 P = High limit of part print hole size P 等于零件孔尺寸的上公差。 E = 4T or W, which ever is less E 等于 4T 和 W 的小值。 P + 2T = Inside Dia of button P + 2T 等于模钮的内径。

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October 2012 Q/CAF 87-2008

Lance Tab 刺破单翻边

Method in determining trim tab punch size. 冲头尺寸的计算方法。 Subtract 2 times stock thickness from part print Dimension. (When dimension is given to outside of stock), then add 0.12mm when stock thickness is less than 1.5mm. Or add 0.24mm when stock thickness is 1.5mm to 3mm. 零件图纸尺寸先减去 2 倍材料厚度的(如果图纸给出的尺寸是材料的外缘)。当材料厚度小于 1.5mm 时,再加上 0.12mm,或材料厚度大于 1.5mm,小于 3mm 时,加上 0.24mm。 When part print dimension is given to inside of stock subtract one stock thickness only. 如果图纸给出的尺寸是材料的内缘,只减去 1 倍材料厚度。

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October 2012 Q/CAF 87-2008

3.19 Die Button Hole Tolerancing 模钮孔公差 Slide fit (H6 hole tolerance) Dimeter (mm) 13 16 20 25 32 38 Upper +0.011 +0.011 +0.013 +0.013 +0.016 +0.016 Lower -0.0 -0.0 -0.0 -0.0 -0.0 -0.0 Press fit (H7 hole tolerance) Upper +0.018 +0.018 +0.021 +0.021 +0.025 +0.025 Lower -0.0 -0.0 -0.0 -0.0 -0.0 -0.0

Note 注释: 1. All buttons to be slide fit (H6 hole tolerance) when inserted into: 模钮嵌入到以下材料时需过渡配合: 1) tool steel 模具钢 2) Any steel or casting & on an angular surface 任何钢块或铸件有角度的表面 2. All buttons to be press fit (H7 hole tolerance) when inserted into: 模钮嵌入到以下材料时需过盈配合 1) Mild steel & on a flat surface 低碳钢,并且在平的表面 2) Cast iron & on a flat surface 铸铁,并且在平的表面

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October 2012 Q/CAF 87-2008

3.20 Punch Access Applications 冲头固定 冲头固定 All punches must have accessibility for punch replacement in the press. 所有冲头在压机上必须有很好的可更换性。

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October 2012 Q/CAF 87-2008

3.21 Application Of Pop On Strippers 卸料器运用

1) Standard punch 标准冲头 2) Urethane stripper 卸料器 3) Urethane retainer 卸料器基座

Note 注释: 1. This method use only on flat surfaces. 上述方法仅适用于平面 2. This method can be used for stripping light material, which thickness is up to 1.2mm

该卸料方式仅适合较轻的材料,如料厚小于 1.2mm。

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CHANGAN FORD MAZDA AUTO CO DIE DESIGN STANDARD 长安福特马自达冲压模具设计标准
October 2012 Q/CAF 87-2008

3.22 Angular Piercing 非圆形冲裁 Angular piercing method punch size development for angular piercing 下图所示非圆形冲裁设计时冲头大小的计算方法

Note 注释: The above method of developing should be used to determine the approximate radii for a punch piercing a hole at a given angle and requiring that the hole is round on the face of the metal. 上面的计算方法,在给出了冲压角度和孔在平面上的圆度的情况下,大致计算冲头的尺寸。
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October 2012 Q/CAF 87-2008

Angular piercing layout 带角度冲裁:

Use stanard round punches for angular piercing whenever possible. Use special developed punches to compensate for angular piercing deviation only when the part is of such nature as to require a round hole on the face of the metal. 尽可能在带角度冲裁时使用标准的冲头。只有在零件的特性要求在零件表面上的孔必须是圆孔 时,使用异性冲头来补偿非圆形冲裁的偏移量。

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October 2012 Q/CAF 87-2008

Angular piercing & calculation example 非圆形冲裁计算实例

Formula for determining large radius "R" and small radius "r" when drawing an ellipse are: 公式计算椭圆的长轴半径和短轴半径: R = 0.683H – 0.183W R=W–r W = Major axis H = Minor axis Example c = a × cosB = 12 × 0.93969 = 11.276mm b = a × sinB = 0.8 × 0.34202 = 0.274mm 11.276 + 0.274 = 11.55 = Minor axis of punch

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October 2012 Q/CAF 87-2008

4 Form Dies 成型模 4.1 General Notes 概要 1. Spring back and overbend must be allowed for and dimensioned on "A" layout & die designs. 回弹和过弯在公法图和模具设计中需要被考虑,并尺寸化。 2. Show previous and finished position in plan view and sections. 在平面图和截面图中显示初始和最终位置。 3. Flange lines on outer panels to be kept as sharp as possible for clinching. 外板件的需要扣合边的翻边线的 R 角应尽可能的小。 4. Pad travel to be great enough to fully wipe flange when curved horizontally and vertically. 在垂直和水平弯曲时,压料器的行程必须足够满足翻边。 5. Use pad retainer pins whenever possible. On smaller pads where pad retainer pin can not be installed, use pad retainer spools. 尽可能使用压料器侧销。如果较小的压料器不能安装侧销,使用限位螺钉。 6. Flange steels must be removabl. Provide access plates to facilitate steel removal as required. 翻边钢块必须是可拆卸的。如果有必要使用压板以便钢块拆卸。 7. Back up or key all flange steels regardless of metal thickness. 任何材料厚度,翻边镶块必须使用背靠。 8. Use flange strippers when panel is flanged all around or locked in. Use commercial stripper units. 当四周的翻边或被卡住,使用法兰边卸料器。尽可能使用标准的卸料器。 9. Show pressure pin layout if press cushion is to be used for lower pad. 如果下压料器使用顶杆,需要显示顶杆分布。 10. Forces for flanging, forming and bottoming to be calculated. Ensure selected press has capacity to perform operation specified, in particular when bottoming is required. 翻边,成型或到底所需的压力需要计算。确保选择的压力机有能力完成工序。 11. All pads required to bottom out should use standard bottoming blocks. 需要到底的压料器需要使用标准的限位块。 12. Guard all pads. 所有压料器和其它部件之间如果有安全隐患区域都需要增加安全保护。 13. All pads are to be made from tool steel or flame hardening cast iron and heat treated. 所有压料器需要使用钢块或热处理的铸铁。 14. All flanging, forming and restrike operations to have bottoming markers. 所有翻边,成型和整形工序必须有到位标记。

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October 2012 Q/CAF 87-2008

4.2 Form Die Calculations 成型模冲压力计算 Forces required for bending, flanging, and forming are dependant on a number of factors. These include the type of sheet metal, thickness, temper, part profile, length, and the amount of bottoming required. Hence, precise calculation of the forces required is difficult. 弯曲,翻边和成型所需的冲压力取决于许多因素。这包括材料的种类,厚度,零件形状,长度和 所需到底的程度。所以精确的计算冲压力很困难。 However, it is possible to determine, by calculation, estimates of at least the upper limit of the force required for a particular operation. 但是,可以通过估计特殊工序所需的最小上压力来计算冲压力。 The total force for an operation consists of: 冲压力有几部分组成: 1. Forming force or bottoming force, which ever is greater. 成型力和到底压力,选择大的一个。 2. Die friction. 模具摩擦力。 3. Pad force. 压料器所需压力。 Forces, in newtons (N), is calculated using the formula presented on the following pages symbols used include: 下述冲压力计算公式设计的符号: L = Length of bend or break (mm) 弯曲或翻边的长度 (mm) T = Stock thickness (mm) 材料厚度 (mm) S = Span between radial centres (mm) 半径中心之间的距离(mm) B = Width of bead (mm) 筋的宽度 Su = Ultimate tensile strength (MPa) 抗拉强度 (MPa) Sc = Compressive strength (MPa) 抗压强度 (MPa) Some conversion factors are: 单位换算: 1 N = 0.224809 lbf 1 kN = 0.100361 tons force

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October 2012 Q/CAF 87-2008

Vee bend force "F" = 1.33 × L × T2 × Su / S

Pad force "PF" = 50% of "F" Die friction = 20% of "F" Flange force "F" (straight breaks) = L × T × Su / 6 Flange force "F" (curved breaks) = L × T × Su The result of these calculations must be compared with the bottoming forces required. 计算的结果必须和所需的到底力比较。

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Die friction = 50% "F" W = Average width of pad 压料器平均宽度 Pad force "PF" (straight breaks) = 0.67L × T2 × Su / W Pad force "PF" (curved breaks) = L × T × Su / 10 Forming Force "F" (straight breaks) = L × T × Su / 6 Forming Force "F"(curved breaks) = L × T × Su Note 注释: For multiple breaks calculate total length of break line by adding 50% to break line length inicated as 1.5 breaks. 如果多处成型,计算成型边长度需要多加 50%。

Restrike force "F" = L × T × Sc

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October 2012 Q/CAF 87-2008

Bottoming force "F" = L × B × Sc Note 注释: 1. According to force calculation result, check press capacity at various stroke positions to avoid overloading. 根据冲压力的计算结果,确保选择者的压机有足够的能力生产零件,避免超过负载. 2. To overcome spring back, the bend area is often placed under high compressive stress to set the metal. It is accomplished by placing a projection or bead on the punch steel or by fitting flange steels around the bend radii 为克服回弹,弯曲区域往往在高压力位置。通常在凸模上设置凸点或墩死法兰边的 R 角。

4.3 Metal Bending Allowance 弯曲预留量

This chart shows values of "L" in mm for 90° bend assuming the neutral axis to be 0.35T 下面图表显示,假设 90°弯曲时,中心轴为 0.35 的料厚,L 的值。 Bending allowance other than 90° 当弯曲预留量大于 90°时 L = Value in chart × θ / 90

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Value of "L" for any bend angle radii and metal thickness 当弯曲为任何角度和料厚时 L = (R + 0.35T) × 2Π × θ / 360
Bend Radii "R" 0.7 0.75 0.8 0.85 0.95 1.0 1.2 1.4 1.5 1.8 1.9 2.0 2.2 2.5 3.0 3.5 4.0 4.5 5.0 Metal Thickness "T" In mm 0.7 1.48 1.56 1.64 1.72 1.88 1.96 2.27 2.58 2.74 3.21 3.37 3.53 3.84 4.31 5.10 5.88 6.67 7.45 8.24 0.75 1.51 1.59 1.67 1.75 1.90 1.96 2.30 2.61 2.77 3.24 3.40 3.55 3.67 4.34 5.12 5.91 6.69 7.48 8.26 0.8 1.54 1.62 1.70 1.77 1.93 2.01 2.32 2.64 2.80 3.27 3.42 3.58 3.90 4.37 5.15 5.94 6.72 7.51 8.29 0.85 1.57 1.65 1.72 1.80 1.96 2.04 2.35 2.67 2.82 3.29 3.45 3.61 3.92 4.39 5.18 5.96 6.75 7.54 8.32 0.95 1.62 1.70 1.78 1.86 2.01 2.09 2.41 2.72 2.88 3.35 3.51 3.66 3.98 4.45 5.23 6.02 6.80 7.59 8.38 1.2 1.76 1.84 1.92 1.99 2.15 2.23 2.54 2.86 3.02 3.49 3.64 3.80 4.11 4.59 5.37 6.16 6.94 7.73 8.51 1.4 1.87 1.95 2.03 2.10 2.26 2.34 2.65 2.97 3.13 3.60 3.75 3.91 4.23 4.70 5.48 6.27 7.05 7.64 8.62 1.5 1.92 2.00 2.08 2.16 2.32 2.40 2.71 3.02 3.18 3.65 3.61 3.97 4.28 4.75 5.54 6.32 7.11 7.89 8.68 1.8 2.09 2.17 2.25 2.32 2.48 2.56 2.87 3.19 3.35 3.82 3.97 4.13 4.45 4.92 5.70 6.49 7.27 8.06 8.84 1.9 2.14 2.22 2.30 2.38 2.54 2.62 2.93 3.24 3.40 3.87 4.03 4.19 4.50 4.97 5.76 6.54 7.33 8.11 8.90 2.2 2.31 2.39 2.47 2.54 2.70 2.78 3.09 3.41 3.56 4.04 4.19 4.35 4.66 5.14 5.92 6.71 7.49 8.28 9.06 2.5 2.47 2.55 2.63 2.71 2.87 2.96 3.26 3.57 3.73 4.20 4.36 4.52 4.83 5.30 6.09 6.87 7.66 8.44 9.23 3.0 2.75 2.83 2.91 2.98 3.14 3.22 3.53 3.85 4.00 4.48 4.63 4.79 5.10 5.58 6.36 7.15 7.93 8.72 9.50 3.2 2.86 2.94 3.02 3.09 3.25 3.33 3.64 3.96 4.12 4.59 4.74 4.90 5.21 5.69 6.47 7.26 8.04 8.83 9.61

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4.4 Spring Back 回弹 Spring overbend must be dimensioned on die design. 过弯控制回弹必须在模具设计中尺寸化。 To determine correct spring back allowance, contact CFMA STA engineer. 对给与回弹余量可以和长安福特马自达 STA 工程师一起讨论。

Note 注释: 1. Start points must be located on points not affected by spring back. 开始点的位置应该在不受回弹影响的位置。 2. It is the responsiblity of the design source to show the amount of spring back in the design cross section of the specific die. Spring back must be dimensioned and specified clearly even if it is not called for on the process sheets. 在模具设计时需要指出回弹,即使在公法图中为没有要求,需要在图纸中清楚地标识尺 寸。

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4.5 Application For Restrike Dies 整形 Material under 1.5mm thick 材料厚度小于 1.5mm 情况

Material over 1.5mm thick or H.S.S 材料厚度大于 1.5mm 或高张力板材料情况

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4.6 General Flanging Applications 翻边 Diagram below does not show coining of radii. Coining of skin panel straight line breaks is not prefered. 下图所示没有墩死 R 角。外板件翻边不能墩死 R 角。

Diagram below shows coining of radii. Non skin panel straight line breaks to be coined on radii with flange steel is acceptable. 下图所示墩死 R 角。非外板件翻边墩死 R 角可以接受。

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4.7 Flanging Application And Flame Hardening Requirements 翻边模表面硬度 翻边模表面硬度要求

Note 注释: 3. Fully heat treat steel inserts. 镶块需要全部热处理。 4. Inserts must be removable when die is in the press. 当模具在压力机上,镶块是可拆卸的。 5. Use SKD-11 or equivalent. 使用 SKD-11 或同等材料作镶块。 6. After hert treatment, hardness of the steel should be about 58 ~ 62 HRC. 热处理后,镶块硬度应该为 58 ~ 62 HRC。

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4.8 Holding Areas Proportions 压边区域 Holding areas 60mm -- Straight flanges 直翻边 80mm -- Curved flanges 曲面翻边 90mm -- Large panels 大零件

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4.9 Pad Bottoming 压料器到底

Note 注释: 1. Where pad bottoms out provide one front and one rear inspection opening. Core openings in casting. Machine same type in steel dies. This is to aid in checking if pad actually bottoms out. 如果压料器需要到底,需要在前部和后部提供观察孔。铸模在铸造时铸出观察孔。钢板模 需要机加出观察孔。这有助于检查压料器是否到底。 2. Each flange steel should have a minimum of one M10 tapped hole on an accessible surface to permit steel removal. This infomation should be noted on a typical section. 每个翻边钢块需要提供最小 M10 的螺孔,并在容易接近的表面,以便钢块拆卸。该信息 应该在截面图中表明。

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4.10 Flanging Steels On Curved Surfaces 在弯曲表面上的翻边镶块

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4.11 Flanging Steel Joint Line 翻边镶块拼接 When the flanging angle at the steel joint line is 30° or less in relation to the steel seat, the joint line should be square with the seat. 当翻边镶块在拼接处与镶块底座的角度小于 30°时,拼接线应该与底座垂直。

When the flanging angle at the steel joint line is greater than 30° in relation to the steel seat, the joint line should be square to the flange. 当翻边镶块在拼接处与镶块底座的角度大于 30°时,拼接线应该与翻边面垂直。

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4.12 Method Of Using Steel Sections 镶块拼接方式

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4.13 Flanging Application Using Brace 翻边镶 翻边镶块使用支撑 使用支撑

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4.14 Horizontal & Vertical Flanging Steels On Solid Rails 水平和垂直的翻边镶块的固定背靠

Note 注释: Flange steels must be backed up or keyed regardless of metal thickness. 任何材料厚度的翻边镶块都必须有背靠。

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4.15 Flanging Steels And Loose Rails 翻边镶块和活动背靠 Rails with vertical steel inserts, backed by keys may be used for flange breakline with a mild sweep in the plan view. 当翻边线在平面图是曲率较小的曲线时,使用垂直翻边镶块,并加上活动的背靠和键固定。

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4.16 Loose Rail With Heel & Serrated Part Gripper 带导板的活动 带导板的活动背靠和锯齿压料 活动背靠和锯齿压料 Serrated part grippers shall be used on applications where the part tends to slip when flanging. Serrated part grippers may be used on any class 3 surface. Use on class 2 surfaces must be approved by CFMA engineers. 当翻边时如果零件有滑动的趋势,可以在压料器上使用带有锯齿的部件。这可以用在内部结构件 的非外观表面,如果需要用在结构件的外观表面需要长安福特马自达工程师批准。

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4.17 Height Of Flange Steels 翻边镶块 翻边镶块高度 镶块高度 Coin all break lines straight in plan & elevation view. (except skin panel surface) 翻边线是直线的情况需要墩死 R 角,如下图。(外板件除外)

Break line curved in plan or elevation view 翻边线是曲线的情况,如下图。

Note 注释: 1. Previous position and finished position should be shown. 零件的初始和最终位置需要显示。 2. Provide adequate flange strippers. 需要足够的翻边卸料器。
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4.18 Opposing Flanges & Short Flanges 负角度翻边和短翻边 Opposing flanges should have a taper on the male steels and the radius should be spanked with the female steels to allow flanges to over bend and spring back. 负角度翻边时,凸模镶块应该有一定锥度,并且墩死 R 角,以便克服法兰边回弹。

Flanging steels should extend around and spank the flange radius for shor flanges of double metal thickness height or less. 当法兰边高度小于料厚的 2 倍时,翻边钢块应该应高于法兰边高度,并墩死 R 角。

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4.19 Fixed Strippers 固定卸料器

Note 注释: Show screws and dowels on plan and in section. 在平面图和截面图中显示螺钉和销。

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4.20 Flange Stripper / Lifter 翻边卸料器

Note 注释: Travel = Clearance + Flange length 行程 = 间隙 + 翻边高度 Clearance between flange stripper and flange to be equal to upper pad travel +3mm Min. to prevent stripper from deforming the flange. 法兰边和卸料器之间的间隙等于上压料器的行程 + 最小 3mm,以避免卸料器使法兰边变形。

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5 CAM Dies 斜楔模 5.1 General Notes 概要 1. Use commercial cam units where possible. 斜楔尽可能使用标准件。 2. Height to length ratio cam of slides to be 1 to 1.5 Min. and 1 to 2 Max. 滑块的高长比最小为 1.5,最大为 2。 3. Driver angle to be 36° maximum for horizontal cam slides and 25° minimum. 滑块最大角度不能超过 36°,最小 25°。 4. Double wear plates to be provided for all cam cutting and cam piercing. 所有的侧切和侧冲模需要双耐磨板。 5. Show slides and drives in open position. 在设计图中显示模具打开时滑块和驱动块的位置。 6. When determining slide travel, the distance between the edge of the panel and the front of the slide must be adequate for loading and unloading and the removal or replacement of steel or piercing punches. 当决定滑块行程时,滑块的前端到零件边的距离必须足够,满足上件和取件,满足更换镶 块和冲头。 7. Aerial cams to be retracted sufficient to clear pad for removal. 吊楔回程后,应有足够空间拆取压料器。 8. All aerial cams must have positive returns fitted. 所有上模斜楔必须有强制回程钩。

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5.2 Slide and driver angles 滑块和驱动块的 滑块和驱动块的角度 和驱动块的角度

Drivers are to be heeled whenever possible. When driver can not be heeled directly, key driver to die set. 所有驱动块应尽可能加背靠。如果不采用背靠,可以用键固定驱动块。
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5.3 Gib And Wear Plate 耐磨板 Small cams 小型斜楔

Medium cams 中型斜楔

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Large cams 大型斜楔

Double cam slides 互动斜楔

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5.4 Machining Dimension Requirements For CAM Surfaces 斜楔的加工尺寸要求 斜楔的加工尺寸要求

Note:注释 1. Datum point A, B & C are on centre line of cam or wear plates. 基准 A, B & C 是斜楔或耐磨板的中心线。 2. All dimensions marked "*" are to appear on design. 上图所有尺寸标识“ *”的位置都必须在设计图中显示。

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Machining Dimension Requirements For AERIAL CAM 吊楔的加工尺寸要求

Note:注释 1. Datum point A, B & C are on centre line of cam or wear plates. 基准 A, B & C 是斜楔或耐磨板的中心线。 2. All dimensions marked "*" are to appear on design. 上图所有尺寸标识“*”的位置都必须在设计图中显示。

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5.5 CAM Pierce 侧冲 General application for cam piercing 侧冲模的运用

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Cam piercing with cast iron slide & tool steel insert as shown below 下图所示铸铁滑块和镶块的侧冲模

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5.6 CAM Trimming 侧切

Designer to review points listed below, prior to establishing the 10mm Min. Clear of maximum draw binder scrap, and heads of cam punch trim steel hold down screws. 设计者在设计中应注意以下几点:

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1. Blank shape. 坯料形状。 2. Draw bead position. 拉延筋位置。 3. Cam travel is sufficient to allow panel to be loaded with draw binder scrap at maximum. Also allow for pad travel if a spring pad is used. 斜楔的行程一定要足够满足装卸零件。如果使用侧压料器,还需要满足侧压料器的行程。 4. Scrap chute width must be sufficient to clear maximum trimmed scrap. 废料滑槽的宽度必须足够滑落最大的废料。

Note 注释: If aerial cam trimming is used, then full consideration must be given in regards to scrap disposal and scrap falling back onto lower wear surface. 如果使用吊楔,必须考虑废料的处理和废料滑出问题。

5.7 Jektole Cam Pierce Punch 冲头 – 带顶销 When pierce angle is 30 degrees or less, as shown in below figture, use headed jektole punch with Centre Location Dowel. (Punch with small spring pin on working face) 当侧冲的角度为 30 度或小于 30 度时,如下图所示,使用带顶销的中心销定位冲头。

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5.8 Double CAM Slide 互动斜楔 Double cam slide incorporating air cylinder return, also with spring assist as shown below。 下图所示互动斜楔由气缸和弹簧组合回程。

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Double cam slide operated from two sides 双边互动斜楔

Gas Spring Use on Pads 侧压料器使用氮气缸

Use cam pad with gas springs when forming undercut areas on Fender and Quarter panel dies. 翼子板和 1/4 内板等零件需要使用带氮气缸的压料器。

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5.9 Aerial CAM Slides 吊楔 Aerial cam slides general application shown as below 如下图所示吊楔的运用

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Aerial cam slide safety bolting 吊楔安全螺钉

Note 注释: Minimum requirement – 2 per gib plate 最低需要 – 2 个螺钉

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5.10 CAM Slide Retraction 回程 Retraction by spring 弹簧回程 For cam slides with smaller than 70mm travel, less than 30° approach and with a length equal to or greater than width, use spring. Initial compression force, must equal or exceed retraction force. 对斜楔滑块小于 70mm 的行程,角度小于 30°,长度等于或大于宽度时,使用弹簧回程。初始的 压缩力必须等于或大于回程力。

To calculate the amount of springs required, divide the retraction force from the cam slide retraction table or formula on following pages by the Newtons(N) obtained from one spring at initial compression. 为了计算所需的弹簧数量,回程力可以从后续页的公式和表格中得到。

Return by air cylinder 气缸回程 For cam slides with travel of 70mm or over, or an approach angle of 30° or over,or having a width greater than their length use air cylinders. 对斜楔滑块大于 70mm 的行程,角度大于 30°,宽度大于长度时,使用气缸回程。

The full stroke of the air cylinder must be 20mm Min. larger than the required travel of the cam slide. 气缸的行程至少应大于侧滑所需行程 20mm。
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Slide return with springs mounted on side as shown below 下图所示安装弹簧的滑块回程

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Slide return with air cylinders mounted on side as shown below 下图所示安装气缸的滑块回程

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Cam slide return method – Optional to method with exposed springs, and is intended for use where space is limited 当空间不够时,可选用非隐蔽式弹簧回程的方式。

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Positive slide return method 强制回程

Note 注释: All cams must have positive returns fitted. 所有斜楔必须有强制回程

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Cam slide retraction – Calculation table 斜楔回程力计算表 Cam angle 斜楔角度 ? 0 5 10 15 20 25 30 35 40 45 50 125 245 453 461 559 657 735 824 903 981 1040 1099 250 490 706 912 1108 1404 1471 1647 1805 1961 2079 2186 375 735 1059 1373 1667 1961 2206 2471 2706 2942 3118 3285 Mass of slide in kg 滑块重量 500 981 1412 1825 2216 2608 2942 3295 3608 3922 4157 4373 625 1226 1766 2284 2775 3265 3677 4118 4510 4903 5197 5471 750 1471 2118 2735 3324 3913 4412 4942 5413 5884 6237 6560 1000 1961 2824 3648 4432 5219 5884 6590 7218 7844 8314 8747

The above table is calculated from the following formula 上表数据由以下公式计算 For horizontal cams: retraction force = mass × ? × 9.81 水平斜楔:回程力 = 重量 × ? × 9.81 For angle cams: retraction force = mass (sin ? + ?cos ?) × 9.81 有角度斜楔:回程力 = 重量 (sin ? + ?cos ?) × 9.81 Coefficient of friction ? = 0.2 摩擦系数 ? = 0.2 Mass of slide in kg 滑块重量(kg) Retraction force required in newtons (N) 所需回程力(N) Note 注释: 1. For cam slides where width is greater than length add 50% to mass of slide before determining force required. 当宽度大于长度的斜楔,在计算所需回程力前,增加滑块 50%的重量。 2. The force shown in the above table must be provided in the returned position. 上表所示回程力必须提供回程的位置。
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6 Blank Dies 落料模 6.1 General Notes 概要 1. Forces required for blanking and stripping to be calculated and shown on design. Ensure selected press has capacity for specified operation. 下料和卸料所需的力需要计算并显示在设计中。确保选择的压力机有足够的能力完成该工 序。 2. Stock guides and supports to be as long as possible. (All stock guides to be case hardened) 坯料导向应尽肯能的长。(所有导向应硬化处理) 3. Multi stage dies must have pilots. 多工位模具必须有定位销。 4. Coil widths to be set equal distance about die & C-line of press. 料卷的中心线应与模具和压机的中心线一致。 5. Feed length to be stamped on coil feed dies to 0.1mm 在模具上应标识步距,精确到 0.1mm。 6. All blanks to have maximum of 3mm radii on sharp corners where practicable. 所有坯料在尖角处最大有 3mm 的半径。 7. Shear must be called up on all blanking die designs for material up to 2mm thick, for material greater than 2mm thick angular shear may be required. 材料厚度达 2mm,需要用剪边。如果厚度大于 2mm,需要斜刃剪边。 8. Key / heel all cutting sections for thrust. 所有切边镶块需要背靠防止测向力。 9. Use M2 type heavy duty punches (high speed steel) when piercing H.S.S material. 高张力材料使用 M2 型的高负载冲头(高速钢)。

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6.2 Application Of Shear For Blank Dies 剪边下料模运用 For drop through panels the shearing angle is machined on the die half to prevent the blanks being bent. 如果下料后零件下落,剪切角度加工在半边下模上,避免零件被弯曲。

When the blank remains on the die the shearing angle is machined on the punch. 如果下料后零件留在模具上,剪切角度加工在上模。

Relationship of panel thickness to shear H 材料厚度和高度 H 的对应关系 Panel thickness 零件厚度 Shear H 高度 2mm 4 mm 5 mm 7 mm Up to 1.6mm 4.5 mm 6 mm 8 mm

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6.3 Blank Nesting 落料排样 Single blanking with one pass through the die 单片落料

Double blanking with one pass through the die 双片落料

Develop blanks accurately. Arrange in several positions to determine best nesting whereby the least number of mm2 will be required for a given number of blanks. 落料的排样需要精确的计算。零件可以排列多个位置取得最大的材料利用率。
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7 High Strength Steel Dies 高张力钢板材料模具 7.1 General Notes 概要 1. The material of which tensile strength is more than 330MPa is defined as H.S.S material in this die design standard. 在该标准中所提到的材料抗拉强度大于 330MPa,定义为高张力钢板材料。 2. Draw dies need to be of modular construction to allow for recutting to improve spring back without significant rework. 拉延模需要有较好的结构可以满足以后雕刻来改进回弹。 3. Casting wall thickness will be increased to 50mm to increase strength. 铸件侧壁厚度需要增加到 50mm,以保证强度。 4. Premium trim dies are required for H.S.S due to the very high loads created and the need for quality trim edges. 由于高张力材料冲裁需要高载荷,为了得到高质量的切边,需要高质量切边模。 5. Cutting clearances are increased to reduce tool wear and edge chipping. (Refer table on following pages) 切边间隙需要增加来减少模具的磨损和刀口损伤。(参考表见后续页) 6. Ejector punches are required for all piercing (jektole type punch's). 所有冲裁都需要带顶销冲头。 7. Heavy duty punches and buttons are required. 高张力材料冲裁需要高载荷的冲头和模钮。 8. Tool design must ensure that die clearance is maintained at all times. This is critical when trimming H.S.S. 模具设计时必须保证所有切边模的间隙要保持一致。这对高张力材料切边很重要。 9. Trim steels (SKD-11) need to be fully hardened (58~62 HRC) to maintain cutting edges. 切边刀块(SKD-11)需要全热处理(58~62 HRC)保持刀口强度。 10. Tonnages requiring for all operations is significantly increased for H.S.S. 高张力材料零件所有工序所需的吨位都需要增加。

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7.2 Casting Thickness 铸件厚度 Minimum casting wall thickness for use on stretch form dies as below shown. 成型模的铸件最小壁厚如下图。

Minimum casting wall thickness for use on trim and flange dies as below shown. 切边模和翻边模的铸件最小壁厚如下图。

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October 2012 Q/CAF 87-2008

7.3 Material Selection 模具材料 模具材料选用 材料选用 Tooling material selection for H.S.S sheet metal refers to following table. 高张力材料的模具材料选择参看下表。 Heat treatment Tool 模具 Case 条件 Die item 模具项 Tooling material 模 具材料 hardness reqirement 热处理硬度要求 Punch 凸模镶块

Cr12MoV Cr12MoV Cr12MoV SKD-11 SKD-11 SKD-11 ASSAB88 / K340 ASSAB88 / K340 ASSAB88 / K340 Cr12MoV Cr12MoV MoCr / FCD600 SKD-11 SKD-11 MoCr / FCD600

58 – 62 HRC 58 – 62 HRC 58 – 62 HRC 58 – 62 HRC 58 – 62 HRC 58 – 62 HRC 表面 TD 处理 表面 TD 处理 58 – 62 HRC 58 – 62 HRC 58 – 62 HRC

Tensile Strength < 440 MPa 440 MPa ≤ Tensile Strength ≤ 600 MPa Tensile Strength ≥ 800 MPa

Former 凹模镶块 Blank holder 压边圈 Punch 凸模镶块 Former 凹模镶块 Blank holder 压边圈 Punch 凸模镶块 Former 凹模镶块 Blank holder 压边圈 Lower Insert 下模镶块

Draw 拉延模

Trim 切边模 Flange 翻边模

t < 1.2 mm

Upper Insert 上模镶块 Pad 压料器 Lower Insert 下模镶块

56 – 62 HRC 56 – 62 HRC

t ≥ 1.2 mm

Upper Insert 上模镶块 Pad 压料器

Note 注释:
1. Top and bottom bolsters should use HT300. 上下模座选用 HT300。 1. SKD-11 should be bought from following company: ASSAB (XW-42), BOHLER (K110) and HITACHI (SLD) 上述表中提到的 SKD-11 材料必须购买一胜百(对应 XW-42)和百禄(对应 K110)或日 立(SLD)三家公司的材料。

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7.4 Draw Beads 拉延筋 Material thickness up to 1.6mm 材料厚度小于 1.6mm

Material thickness over 1.6mm 材料厚度大于 1.6mm

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7.5 Setting Beads Application 工艺胀形筋运用 For use on H.S.S rail type parts greater than 600 MPa. (Eg. DP600 & DP780) Not applicable for complex shape parts 工艺胀形筋用于采用抗拉强度大于 600MPa 高张力板的长条形零件。(如 DP600,DP780) Setting beads structure as following figures shown 工艺胀形筋的结构和成型过程如下图所示

Note:注释

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Setting bead height can be adjust by using shims. 工艺胀形筋的高度可以通过调整垫片调节,从而到达调整反拉力的大小。 Forming process 成型过程 Stage #1 Tool in open position 第一步,模具开放位置

Stage #2 Blank holder closed and part starting to form around the punch. 第二步,上模与压边圈接触,零件开始成形

Stage #3 Tool fully closed with setting bead engaed stretching the flange and side walls reducing springback 第三步,模具完全闭合,工艺胀形筋拉住法兰边,减小侧壁和法兰边的回弹

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October 2012 Q/CAF 87-2008

7.6 Post Form Stretching Application 下台阶式拉延 For use on H.S.S. parts with complex geometry where springback is a major concern. 下台阶式拉延运用于采用高张力材料,复杂形面,而且有严重回弹问题的零件。

Some parts with more complex geometry and or unequal length side walls will require a post stretch type draw die operation as shown above. The binder pressure is regulated by the press air cushion. This process uses a rough blank that will require a trimming operation to remove the binder scrap. The material is given a final stretch as the binder passes the step on the punch which will reduce the amount of sidewall curl and springback in the flange.

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当选用高张力材料的零件形面复杂或侧壁不等长时,需要下台阶式的拉延模,如上图所示。压边 圈的压力由顶杆力控制。这种工艺运用在当压边圈处的废料能被后续切边模切除的情况。这种工 艺的好处在于,当压边圈低于凸模的台阶后,材料能被拉紧,减少侧壁不平整和法兰边的回弹。

7.7 Cutting Clearances 切边间隙 Piercing 冲孔

Trimming 切边

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October 2012 Q/CAF 87-2008

Percentage of clearance per side Material Thickness (t) 0.6-0.9 0.9-1.2 1.2-1.8 1.8-3.0 H.S.S 440-600 MPa 10% 10% 10% 12% H.S.S 600 Mpa or over 13% 14% 15% 15%

7.8 Trim Conditions 切边条件 Maximum angle for trimming on angle pointing downwards from base as below 有角度的向下切边角度如下图

Maximum angle for trimming on angle pointing upwards from base as below 有角度的向上切边角度如下图

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8 High Volume Die Design 高寿命模具设计 1. 该章节的内容为只针对高寿命模具独有的要求,模具寿命要求大于 60 万适用。 2. 目前该章节具体类容正在编制中,框架内容见附件 2,可用于高寿命模具报价招标。

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9 Attachment 附件 附件一: 附件一: Signature 发布文件签署 发布文件签署

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附件二 附件二:High Volume Die Design Points 高寿命模具设计框架 General Notes 概述 1.该章节的内容为只针对高寿命模具独有的要求,模具寿命要求大于 70 万适用。 2.模具工艺设计时应尽量选用铸件模具结构,或级进模具。避免设计钢板模,以提高模具寿命。 3.所有零件必须制作 C/H 孔,便于后工序模具没有开发完成前检查零件。 4.模具开发制造过程中避免修补焊接模具。可采用延后开发切边类模具,或加厚拉延模具镶块尺 寸(10-30mm),便于后续调试加工等方式。 5.保养周期必须满足高张力和厚板零件不低于 5000 冲次保养,其它零件 8000 冲次保养的模具保 养频次。 6.所有模具弹性元件全部选用氮气弹簧。 7.整型模应尽量选用串联氮气缸系统,满足压力平衡需求。 8.结构设计必须满足铸件受力均衡,受力位置底部避免出现减轻孔。 9.侧向力必须尽量抵消,避免侧向力对模具寿命产生影响。 10.铸件质量必须满足要求,铸件厂必须得到长安福特马自达的认可。 11.铸件加强筋的选择至少选用 40,50,60mm 的厚度。 12.优化背靠的强度设计,高度和厚度加强。 13. 压料器强度不足时,选用压料器封闭导向方式 14. 导柱设计单侧双导柱形式,直径 60mm。若空间不够情况,其它结构需要 CFMA 批准。 15. 侧销与压料器之间必须选用缓冲标准件;限位螺钉与压料器之间也必须选用缓冲标准件。 16.优化压料器结构设计,注意侧销上部最小的尺寸要求(最小 70mm)以及整个压料器强度。 17.水平切边必须满足向下不大于 15 度,向上不大于 10 度的要求。 18.冲孔大于 15 度必须选择侧冲工艺。 19. 模具工艺设计时,孔与孔,孔与边的距离如果小于 5 倍料厚,必须分开工序,避免造成模具强 度不足。 20.冲切类标准件应尽量选用重载,并增加备件数量。 21.斜楔应尽量选用重载。 22.对于自制斜楔回程必须选用氮气弹簧。 23. 斜楔基体必须满足 MoCr / FCD600 等级以上的材料。 24.镶块的材料选择按零件材料分类选择更高等级的材料。参考材料选择表。 25.材料流入量过大(大于 50mm)或零件抗拉强度大于 600MPa 的零件必须选用 TD 表面处理。

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Draw Die Material Selection 拉延模具材料选择 下面模具材料选择使适用于拉延及成型类模具 Tensile Thickness Die Items Strengh 材料厚度 模具项 抗拉强度 Punch 凸模 t < 1.2mm Former 凹模 Blank holder 压边圈 Punch 凸模 Ts < 320 MPa 1.2 ≤ t <1.6mm Former 凹模 Blank holder 压边圈 Punch 凸模 t ≥ 1.6mm Former 凹模 Blank holder 压边圈 Punch 凸模 t < 1.2mm 320MPa ≤ Ts < 600MPa t ≥ 1.2mm Former 凹模 Blank holder 压边圈 Punch 凸模 Former 凹模 Blank holder 压边圈 Punch 凸模 All the thickness Ts ≥ 600MPa 所有料厚材料 Former 凹模 Blank holder 压边圈

Tooling Material 模具材料 MoCr / FCD600 MoCr / FCD600 MoCr / FCD600 MoCr / FCD600 Cr12MoV Cr12MoV SKD-11 SKD-11 SKD-11 SKD-11 SKD-11 SKD-11 ASSAB88 / K340 ASSAB88 / K340 ASSAB88 / K340 ASSAB88 / K340 ASSAB88 / K340 ASSAB88 / K340

Coating 表面处理

TD TD

TD TD

TD TD

注释: 1. 2. 模座选用 HT300 或更高级铸件材料。 Cr12MoV 选择国内钢厂的材料;SKD-11 选择国外钢厂的材料(仅限一胜百 XW-42、百禄 K110、日立 SLD)。 3. ASSAB88 / K340 是改良型 SKD-11,性能优于普通 SKD-11,ASSAB88 属于一胜百钢厂钢种 牌号,K340 属于百禄钢厂钢种牌号。 4. 5. 压边圈基体选用 MoCr / FCD600 或更高等级材料。 材料流动量超过 50mm,部分镶拼, TD。
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Trim Die Material Selection 切边模具材料选择 下面模具材料选择适用于切边,翻边,整形类模具 Tensile Thickness Die Items Strengh 材料厚度 模具项 抗拉强度 Lower Insert 下模镶块 t < 1.2mm Ts < 320 MPa t ≥ 1.2mm Upper Insert 上模镶块 Pad 压料器 Lower Insert 下模镶块 Upper Insert 上模镶块 Pad 压料器 Lower Insert 下模镶块 t < 1.4mm 320MPa ≤ Ts ≤ 800MPa t ≥ 1.4mm Upper Insert 上模镶块 Pad 压料器 Lower Insert 下模镶块 Upper Insert 上模镶块 Pad 压料器 Lower Insert 下模镶块 Ts ≥ 800 MPa All the thickness 所有料厚材料 Upper Insert 上模镶块 Pad 压料器

Tooling Material 模具材料 ICD5 / Cr12MoV ICD5 / Cr12MoV ZG45 / FCD600 SKD-11 SKD-11 ZG45 / FCD600 SKD-11 SKD-11 ZG45 / FCD600 Caldie / K340 ISODUR Caldie / K340 ISODUR ZG45 / FCD600 V4E V4E ZG45 / FCD600

Coating 表面处理

注释: 1. 2. 模座选用 HT300 或更高级铸件材料。 Cr12MoV 选择国内钢厂的材料;SKD-11 选择国外钢厂的材料(仅限一胜百 XW-42、百禄 K110、日立 SLD)。 3. Caldie / K340 ISODUR 是电渣重溶钢种,Caldie 属于一胜百钢厂钢种牌号,K340 ISODUR 属 于百禄钢厂钢种牌号。 4. 5. V4E 是粉末冶金钢种,V4E 属于一胜百钢厂钢种牌号。 压料器基体选用 ZG45 / FCD600 或更高等级材料。

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Flange / Re-Strike Die Material Selection 翻边/整形模具材料选择 下面模具材料选择适用于切边,翻边,整形类模具 Tensile Thickness Die Items Strengh 材料厚度 模具项 抗拉强度 Lower Insert 下模镶块 t < 1.2mm Ts < 320 MPa t ≥ 1.2mm Upper Insert 上模镶块 Pad 压料器 Lower Insert 下模镶块 Upper Insert 上模镶块 Pad 压料器 320MPa ≤ Ts < 600MPa All the thickness Ts ≥ 600 MPa 所有料厚材料 Lower Insert 下模镶块 All the thickness 所有料厚材料 Upper Insert 上模镶块 Pad 压料器 Lower Insert 下模镶块 Upper Insert 上模镶块 Pad 压料器

Tooling Material 模具材料 ICD5 / Cr12MoV ICD5 / Cr12MoV ZG45 / FCD600 SKD-11 SKD-11 ZG45 / FCD600 SKD-11 SKD-11 ZG45 / FCD600 ASSAB88 / K340 ASSAB88 / K340 ZG45 / FCD600

Coating 表面处理

注释: 1. 2. 模座选用 HT300 或更高级铸件材料。 Cr12MoV 选择国内钢厂的材料;SKD-11 选择国外钢厂的材料(仅限一胜百 XW-42、百禄 K110、高周波 KD11S、日立 SLD)。 3. ASSAB88 / K340 是改良型 SKD-11,性能优于普通 SKD-11,ASSAB88 属于一胜百钢厂钢种 牌号,K340 属于百禄钢厂钢种牌号。 4. 压料器基体选用 ZG45 / FCD600 或更高等级材料。

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Die Component Selection 模具标准件选择

斜楔: Sankyo(三协)、Punch(盘起)、Misumi(三住)。 冲切部件:Dayton、Punch(盘起)、Misumi(三住)、Jouder(优德)。
导向部件:Punch(盘起)、Misumi(三住)、Jouder(优德)。 气缸及气路:SMC、Festo。 氮气弹簧:Dadco、Kaller、Pascal。

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