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汽車沖壓模具設(shè)計與成形工藝
1、在設(shè)計料帶前，一定要了解零件的公差要求，材料性能、沖床噸位、沖床臺面、SPM（每分鐘沖次）、送料方向、送料高度、模厚要求、材料利用率、模具使用壽命。
2、在設(shè)計料帶時，要同時進行CAE分析，主要考慮材料的變薄率，一般要 在25%以下。特別深拉不銹鋼材料，可以在預(yù)拉伸后再進行退火，用高頻退火機，變薄率可以接受至40%，在設(shè)計料帶時，一定要和客戶多加溝通，最好要客戶提供之前的模具照片或結(jié)構(gòu)圖來參考，空步也是非常重要的，在模具長度允許的情況下，適當(dāng)留出空步對于試模后的改模幫助是很大的。
3、料帶設(shè)計是對制品成型工藝的分析，基本上決定了模具是否成功。
4、在連續(xù)模具設(shè)計時，抬料設(shè)計非常重要，如果升料桿不能將整個料帶升起，就無法進行自動化連續(xù)生產(chǎn)。
5、在模具設(shè)計中，模具材料的選擇和熱處理以及表面處理（如TD，TICN， TD時間需要3-4天），特別是拉伸件，如果沒有TD，模具表面會很容易就拉燒起毛。
6、在模具設(shè)計中，對于孔位或公差要求較小的面，盡可能做可調(diào)鑲件，便于在試模及生產(chǎn)時調(diào)節(jié)，以便容易達到，零件的尺寸要求，要上下模具同時時做可調(diào)鑲件。對于字嘜，要求在沖床上可拆，不需要下模再拆而浪費時間。
7、設(shè)計氮氣彈簧時，根據(jù)CAE分析的壓力來設(shè)計，不要設(shè)計過大的氮氣彈簧，防止產(chǎn)品破裂。通常情況是：壓力小，產(chǎn)品起皺，壓力大，產(chǎn)品破裂。解決產(chǎn)品起皺，可以采用局部增加拉延筋的方法，先用拉延筋固定位片材，再拉伸，來減少起皺。
8、第一次試模時，一定要慢慢將上模合下，對于有拉伸工序時，一定要用 保險絲試料位厚度，料位間隙達到材料厚度后再試模，刀口一定要先對好。拉延筋請使用活動鑲件，以便于調(diào)節(jié)拉延筋的高度。
9、試模時，基準孔、基準面一定要模具配好后再將產(chǎn)品放在檢具上測量， 或送去CMM做3D報告，否則沒有意義。
10、紅丹一定要配好，貼合率達到80%以上，才可以開剪口，做CMM報告， 或者是基準孔基準面已配好，產(chǎn)品已非常穩(wěn)密，貼合率可以適當(dāng)降低。配紅丹是非常重要的事項，否則產(chǎn)品不穩(wěn)定，無法進行后期的改模判斷，零件尺寸將達不到客戶要求。
11、客戶樣辦要求：一般先是鐳射辦→剪口辦→100%OK辦，在鐳射辦階段就 要把紅丹配好，送料調(diào)好，解決破裂起皺、尺寸公差問題，在開剪口辦時基本上改好主要問題，后面是微調(diào)（模具局部改良）。
12、在客人一定要剪口辦但是工藝條件不成熟的情況下，可以考慮開軟料刀口（就是直接用45鋼開刀口，改剪口時直接燒焊，等尺寸OK后再開正式硬料刀口）。
13、對于3D復(fù)雜的產(chǎn)品，可以采用3D鐳射的方法去鐳射，在3D鐳射前一定 要做好3D圖形，用CNC打好基準點位后再送去3D鐳射，3D鐳射還要做定位砂型。
14、對于高強度鋼板，刀口材料要采用A88或V4等硬質(zhì)合金材料。
15、在試模時，為試拉伸效果，可以在材料上不同位置上墊砂紙來試效果，確 定效果后在相應(yīng)位置在活動的拉延筋或活動的麻點陣（就是將一塊鍍件磨成麻點），用來起磨擦阻礙走料。
16、折彎較多的零件，調(diào)模時要按工序一步一步來調(diào)折彎。
17、調(diào)成型角度時，可以收小折彎時的R角或移動折線基準來實現(xiàn)達到成型角度的目的。
18、調(diào)模時多數(shù)采用墊片來調(diào)節(jié)成型公的高低，或者左右前后移動成型公件， 墊片一般使用不銹鋼硬片。（如是客戶不準用墊片，就等模具調(diào)好后再做新的工件給客戶）
19、不銹鋼材料的模具成型件，不能使用TD，要使用（TICN）或稱PVD。
20、要確定客人正式材料什么時候到，在試模時，節(jié)約使用材料，避免材料不 夠的現(xiàn)象發(fā)生。
21、連續(xù)模的感應(yīng)器（Sensor）有兩種，一種是步距感應(yīng)器，另一種是落料感 應(yīng)器。
22、廢料漏斗的斜度不少于30度，對于低角度的廢料盒（Scope box）,可以采 用安裝氣動震動器（Pneumatic Vibration）來解決。
23、對于受到成型后影響的剪邊線，要選擇在成型后再剪切，特別位置可以采 用橫切的方式來實現(xiàn)。
24、對于多個基準孔位，最好采用一次沖孔成型的方法，避免分步?jīng)_切后影響 精度。
25、對于試模分析，一定要對試模后的料帶進行分析逐個工步進行分析，并且 要附上紅丹料帶。
26、對于產(chǎn)品破裂，可以采取在前期拉伸時加包、擠料、增加片桿成型面積， 開孔等多種方式進行，在改模之前要進行CAE分析。
27、產(chǎn)品材料分為卷料coil和板料sheet兩種，有些卷料到廠后需要再次分條至料帶寬度，通常在分條時尺寸為負公差（負0.5mm）,并且卷料內(nèi)徑要符合送料架的尺寸,避免太大或太小及太重。
28、模具加工時，通常以線割的銷釘孔作為碰數(shù)基準，而CNC在編程后，需要 操機員將兩個孔的坐標給到編程員，由編程員求角度后，將程序擺一個角度后再加工。通常在初次加工模板時是碰邊加工不需要求角度。
29、精沖的概念就是不留沖裁間隙（或只留0.5%）。一般沖裁間隙為材料厚度 的10%，材料越厚，間隙比例越大。
PP(polypropylene
Purpose: Other
Characteristics Note: High Modulus PP
IMPORTANT PARAMETERS: MELT FLOW RATE: 6 g/10 min DENSITY: 1.15 g/cm 3 NOTCH IMPACT STRENGTH: 50 TENSILE STRENGTH: 30 MPa FRACTURE EXTENSION: 50% BENDING STRENGTH: 50 MPa BENDING MODULUS: 2500 MPa THERMAL DEFORMATION TEMPERATURE: 125
Manufacturer: Yuyao Hongli Plastic Co., Ltd.
PP (Polypropylene
Purpose: Other
Characteristics Note: By grafting modification of basic PP and surface treatment of glass fiber, the compatibility of glass fiber and PP was effectively improved, and the modified PP special material with good dimensional stability, high quality and high heat resistance was obtained.
IMPORTANT PARAMETERS: MELT FLOW RATE: 5 g/10 min DENSITY: 1.05 g/cm3 NOTCH IMPACT STRENGTH: 50 TENSILE STRENGTH: 60 MPa FRACTURE EXTENSION: 10% BENDING STRENGTH: 70 MPa BENDING MODULUS: 3100 MPa THERMAL: 150 C
Manufacturer: Cixi Fuda Plastic Co., Ltd.
PP (polypropylene
Purpose: Other
Characteristics Note: By grafting modification of basic PP and surface treatment of glass fiber, the compatibility of glass fiber and PP was effectively improved, and the modified PP special material with good dimensional stability, high quality and high heat resistance was obtained.
IMPORTANT PARAMETERS: MELT FLOW RATE: 5 g/10 min DENSITY: 1.14 g/cm 3 NOTCH IMPACT STRENGTH: 50 TENSILE STRENGTH: 70 MPa FRACTURE ELongation: 5% BENDING STRENGTH: 90 MPa BENDING MODULUS: 400 MPa THERMAL DEFORMATION TEMPERATURE: 150
Manufacturer: Cixi Fuda Plastic Co., Ltd.
PP (Polypropylene
Purpose: Other
Characteristics Note: By grafting modification of basic PP and surface treatment of glass fiber, the compatibility of glass fiber and PP was effectively improved, and the modified PP special material with good dimensional stability, high quality and high heat resistance was obtained.
IMPORTANT PARAMETERS: MELT FLOW RATE: 5 g/10 min DENSITY: 1.17 g/cm 3 NOTCH IMPACT STRENGTH: 100 TENSILE STRENGTH: 60 MPa FRACTURE ELongation: 5% BENDING STRENGTH: 80 MPa BENDING MODULUS: 2400 MPa THERMAL DEFORMATION TEMPERATURE: 145
Manufacturer: Cixi Fuda Plastic Co., Ltd.
PP(polypropylene
Purpose: Other
Characteristics Note: By grafting modification of basic PP and surface treatment of glass fiber, the compatibility of glass fiber and PP was effectively improved, and the modified PP special material with good dimensional stability, high quality and high heat resistance was obtained.
IMPORTANT PARAMETERS: MELT FLOW RATE: 3 g/10 min DENSITY: 0.985 g/cm3 NOTCH IMPACT STRENGTH: 40 TENSILE STRENGTH: 35 MPa FRACTURE EXTENSION: 50% BENDING STRENGTH: 50 MPa BENDING MODULUS: 2400 MPa THERMAL DEFORMATION TEMPERATURE: 14
Manufacturer: Cixi Fuda Plastic Co., Ltd.
PP (Polypropylene
Usage: Household appliances
Characteristics Note: Characteristics: Rising Transparent PP is a breakthrough in PP modification technology. While improving the heat resistance, glossiness, rigidity and toughness of PP, the transparency and glossiness of PP are improved, and the processability of PP is improved: the crystallization speed is fast, the injection processing cycle is shortened, and the injection defects such as shrinkage mark and flying edge are reduced.
IMPORTANT PARAMETERS: MELT FLOW RATE: 8 g/10 min DENSITY: 0.91 g/cm3 SHRINKAGE: 1.5% NOTCH IMPACT STRENGTH: 30 TENSILE STRENGTH: 40 MPa BENDING STRENGTH: 58 MPa BENDING MODULUS: 1700 MPa THERMAL DEFORMATION TEMPERATURE: 127
Manufacturer: Shanghai Rizhisheng New Technology Development Co., Ltd.
PP(PP
Purpose: Other
Important parameters: melt flow rate: 12 g/10 min
Manufacturer: American MDI Company
PP(polypropylene
Purpose: Other
Important parameters: melt flow rate: 12 g/10 min
Manufacturer: American MDI Company
PP (Polypropylene
Purpose: Other
Important parameters: melt flow rate: 12 g/10 min
Manufacturer: American MDI Company
PP(polypropylene
Purpose: Other
Characteristics Note: Properties: toughened PP, heat and weather resistance, impact resistance, aging resistance with PP-01PP-02
IMPORTANT PARAMETERS: MELT FLOW RATE: 3.5 g/10 min DENSITY: 0.91 g/cm3 SHRINKAGE: 1.65% NOTCH IMPACT STRENGTH: 67 TENSILE STRENGTH: 35 MPa BENDING STRENGTH: 38 MPa THERMAL DEFORMATION TEMPERATURE: 120 DEGREE
Manufacturer: Yuyao Zhongcheng Engineering Plastics Co., Ltd.
PP(polypropylene
Purpose: Other
Important parameters:
Manufacturer: Yuyao Shengjie Plastic Co., Ltd.
PP (Polypropylene Paste | Soft Gum)/PP-930/American MDI
Purpose: Other
Important parameters: melt flow rate: 20 g/10 min
Manufacturer: American MDI Company
PP (PP?
Purpose: Other
Characteristics Note: Extrusion and Injection Molding
Important parameters: melt flow rate: 12 g/10 min
Manufacturer: American MDI Company
PP(PP
Purpose: Other
IMPORTANT PARAMETERS: MELT FLOW RATE: 7g/10min DENSITY: 0.9g/cm3 NOTCH IMPACT STRENGTH: 4 FRACTURE ELongation: 20% BENDING MODULUS: 1225 MPa HARDNESS: 87 VICCA SOFTENING POINT: 150 DEGREE TEMPERATURE: 105 DEGREE
Manufacturer: Korea Dalin Company
PP(polypropylene
Purpose: Other
Notes on Characteristics:
IMPORTANT PARAMETERS: MELT FLOW RATE: 2.8 g/10 min DENSITY: 0.912 g/cm3 TENSILE STRENGTH: 55 MPa HARDNESS: 73
Manufacturer: Nordic Chemical Co., Ltd.
PP (PP # Paste | Soft Gum)/PP-124/Dalin, Korea
Purpose: Other
IMPORTANT PARAMETERS: MELT FLOW RATE: 3 g/10 min DENSITY: 0.9 g/cm 3 NOTCH IMPACT STRENGTH: 5 TENSILE STRENGTH: 36 MPa FRACTURE EXTENSION
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