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零件名
壓料板
序號
10
材料
45
數(shù)量
1
工序號
工序名稱
工序內(nèi)容
所選設(shè)備
1
備料
鍛造毛坯，尺寸206mmX166mmX20mm
2
刨削
刨削六面，成尺200mmX160mmX15.5mm
刨床
3
磨削
磨削尺寸15mm兩端面至圖紙要求
磨床
4
鉆孔
按圖樣劃全部孔線
平板、高度尺、鋼板尺等
5
鉆孔
4XM12螺紋底孔，并攻螺紋
鉆孔3XΦ12mm
鉆床
6
線切割
割型腔至圖紙要求
線切割機(jī)床
加工工藝過程卡片
零件名稱
序號
毛坯規(guī)格
毛坯材料
數(shù)量
打桿
1
Φ16mmX106mm
45
1
模柄
2
Φ55mmX106mm
Q235
1
上模座
3
200mmX160mmX45mm
HT200
1
上模座墊板
5
206mmX166mmX12mm
45
1
上模固定板
7
206mmX166mmX32mm
45
1
蓋板
8
206mmX166mmX12mm
45
1
壓料板
10
206mmX166mmX18mm
45
1
落料凹模
11
206mmX166mmX74mm
Cr12MoV
1
下模固定板
13
206mmX166mmX16mm
45
1
下模座
14
200mmX160mmX45mm
HT200
1
頂桿
16
Φ26mmX87mm
45
1
沖孔凸模
18
Φ15mmX82mm
Cr12MoV
2
拉深凹模
20
94mmX64mmX20mm
Cr12MoV
1
凸凹模
22
件1 94mmX64mmX15mm
件2 72mmX44mmX50mm
Cr12MoV
1
導(dǎo)柱
23
Φ32mmX205mm
20
2
推桿
24
Φ8mmX76mm
45
1
拉深凸模
25
Φ36mmx66mm
Cr12MoV
1
拉深凸模墊板
26
91mmX63mmX12mm
45
1
推板
27
68mmX24mmX10mm
45
1
導(dǎo)套
28
Φ50mmX105mm
20
2
備料清單
零件名
導(dǎo)套
序號
28
材料
20
數(shù)量
1
工序號
工序名稱
工序內(nèi)容
所選設(shè)備
1
備料
毛坯尺寸Φ50 mm X 105mm
2
車削
車端面保持長度102mm,鉆孔Φ28mm留鏜量
車Φ42mm外圓留磨量并倒角
切3mmX0.5mm的槽至尺寸
鏜孔Φ28mm的孔至Φ27.6mm鏜油槽,鏜Φ29的孔至圖紙要求，
車床
3
車削
車Φ45的外圓至圖紙要求，車端面保證長度100mm倒內(nèi)圓角
車床
5
熱處理
按熱處理工藝進(jìn)行，保證滲碳層深度0.8-1.2mm硬度 HRC 58-62
4
磨削
磨Φ42mm外圓至圖樣要求
磨Φ28mm內(nèi)孔留研磨量0.01mm
萬能外圓磨床
5
研磨內(nèi)孔
研磨Φ28mm的孔至圖紙要求，研磨的內(nèi)圓角
車床
加工工藝過程卡片
零件名
導(dǎo)柱
序號
23
材料
20
數(shù)量
1
工序號
工序名稱
工序內(nèi)容
所選設(shè)備
1
備料
毛坯尺寸Φ32 mm X205mm
2
車削
車端面保持長度202.5mm、打中心孔
調(diào)頭車端面保持長度200mm、打中心孔
車外圓至Φ28.4mm
切10mmX0.5mm槽至圖紙要求
調(diào)頭車外圓至Φ28.4mm、端部倒圓角
車床
3
熱處理
按熱處理工藝進(jìn)行，保證滲碳層深度0.8-1.2mm，硬度HRC58-62
4
研中心孔
研中心孔
調(diào)頭研另一端中心孔
車床
5
磨削
磨mm外圓長148mm留研磨量0.01m
調(diào)頭磨mm外圓長42mm至圖紙要求尺寸
外圓磨床
6
研磨
研磨mm 至圖紙要求，
車床
加工工藝過程卡片
零件名
打 桿
序號
1
材料
45
數(shù)量
1
工序號
工序名稱
工序內(nèi)容
所選設(shè)備
1
備料
毛坯尺寸Φ16mm X 106mm
2
車削
車削Φ12.5mm外圓
車床
3
熱處理
淬火達(dá)到HRC43-48
加工工藝過程卡片
序號
零件名稱
零件規(guī)格
材料
數(shù)量
標(biāo)準(zhǔn)代號
4
內(nèi)六角
螺釘
M12X65
35
4
GB70-76
12
M12X80
35
4
6
圓柱銷
Φ12mmX65mm
45
2
GB119.1-2000
17
Φ12mmX80mm
45
2
30
Φ6mmx32mm
45
1
29
卸料螺釘
M 12mmX100mm
45
4
JB/T7650.5-1994
23
導(dǎo)柱
28mmX200mm
20
2
GB2861.1-1990-
28
導(dǎo)套
28mmX110mmX42mm
20
2
GB2861.6-1990
21
擋料銷
Φ4mmX13mm
45
3
JB/T7649.10-1994
19
碟彈簧
A 35.5-1
65Mn
6
GB/T 1972-1992
9
橡膠
Φ45mmx32mm
4
JB/T7649.10-1994
15
Φ25mmx20
1
標(biāo)準(zhǔn)件清單
零件名
模 柄
序號
2
材料
Q235
數(shù)量
1
工序號
工序名稱
工序內(nèi)容
所選設(shè)備
1
備料
毛坯尺寸Φ55 mm X 106 mm
2
熱處理
調(diào)質(zhì) HRC28-32
3
車削
車削Φ50mm、Φ42mm、Φ40mm外圓
Φ42mm、Φ40mm并留磨削余量
鉆孔Φ13mm并倒角
車床
5
磨削
磨外圓至圖樣要求（外圓磨）
模柄與上模座裝配后磨平面（平磨）
磨床
6
鉗工鉆孔
Φ6mm孔與上模座配鉆
鉆床
加工工藝過程卡片
零件名
蓋板
序號
8
材料
45
數(shù)量
1
工序號
工序名稱
工序內(nèi)容
所選設(shè)備
1
備料
鍛造毛坯，尺寸206mmX166mmX12mm
2
刨削
刨削六面，成尺寸200mmX160mmX8.5mm
3
磨削
磨削尺寸8mm兩端面至圖紙要求
磨床
4
鉗工劃線
按圖樣劃全部孔線
平板、高度尺、鋼板尺等
5
鉆孔
與蓋板配鉆4XM12螺紋底孔，并攻螺紋
鉆孔4XΦ17mm
鉆床
6
線切割
割型腔至圖紙要求
線切割機(jī)床
7
加工銷孔
Φ12H7mm銷孔，在試沖、調(diào)整后，與上模座、上模座墊板及上模固定板配鉆、擴(kuò)、鉸加工至圖面要求
鉆床
加工工藝過程卡片
零件名
落料凹模
序號
11
材料
Cr12MoV
數(shù)量
1
工序號
工序名稱
工序內(nèi)容
所選設(shè)備
1
備料
鍛造毛坯，尺寸206mmX166mmX74mm
2
刨削加工
刨削六面，成尺200mmX160mmX70.5mm
刨床
3
鉗工劃線
按圖樣劃全部孔線
平板、高度尺、鋼板尺等
4
鉆孔
4XM12螺紋底孔，并攻螺紋
鉆孔4XΦ4mm
鉆床
5
鉸孔
3-Φ4H7mm鉸削至圖面要求精度
鉆床
6
銑削加工
加工尺寸81mmX50mmX60mm至圖紙要求
銑床
7
熱處理
對刃口部分進(jìn)行局部淬火，達(dá)到HRC60-64
8
線切割
割刃口形狀至圖紙要求
線切割機(jī)床
9
鉗工修整
鉗工精修刃口形狀
10
磨削
磨削尺寸70mm兩端面至圖紙要求
磨床
11
加工銷孔
Φ12H7mm銷孔，要在裝配、試沖及調(diào)整后，與下固定板、下模座配鉆、擴(kuò)、鉸至圖面要求
鉆床
加工工藝過程卡片
General all-steel punching die’s punching accuracy
Author：John J. Craig
Accuracy of panel punching part is display the press accuracy of the die exactly. But the accuracy of any punching parts’ linear dimension and positional accuracy almost depend on the blanking and blanking accuracy,. So that the compound mould of compound punching’s accuracy, is typicalness and representation in the majority.
Analyse of the die’s accuracy
For the analyse of pracyicable inaccuracy during production of dies to inactivation, we could get the tendency when it is augmentation in most time. From this we could analyse the elements. When the new punch dies pt into production to the first cutter grinding, the inaccuracy produced called initial error; if the die grinding more than twenty times, until it’s discard, the inaccuracy called conventional error; and before the dies discard, the largest error of the last batch permit, called limiting error. at job site, the evidence to confirm life of sharpening is the higher of the blanking, punched hole or punched parts. Because all finished parts had been blanked ,so it is especially for the compound dies. Therefore, the analyse of burr and measurement is especially important when do them as enterprise standardization or checked with <
>.
The initial error usually is the minimal through the whole life of die. Its magnitude depend on the accuracy of manufacture, quality, measure of the punching part, thickness of panel, magnitude of gap and degree of homogeneity. The accuracy of manufacture depend on the manufacture process. For the 1 mm thicked compound punching part made in medium steel, the experimental result and productive practice all prove that the burr of dies which produced by spark cutting are higher 25%~~30% than produced by grinder ,NC or CNC. The reason is that not only the latter have more exact machining accuracy but also the value of roughness Ra is less one order than the formmer, it can be reached 0.025μm. Therefore, the die’s initial blanked accuracy depends on the accuracy of manufacture, quality and so on.
The normal error of the punch die is the practicable error when the fist cutter grinding and the last cutter grinding before the die produce the last qualified product. As the increase of cutter grinding, caused the measure the nature wear of the dies are gradual increasing, the error of punching part increase also, so the parts are blew proof. And the die will be unused. The hole on the part and inner because the measure of wear will be small and small gradually, and its outside form will be lager in the same reason. Therefore, the hole and inner form in the part will be made mould according to one-way positive deviation or nearly equal to the limit max measure. In like manner, the punching part’s appearance will be made mould according to one-way negative deviation or nearly equal to limit mini measure. For this will be broaden the normal error, and the cutter grinding times will be increased, the life will be long.
The limit error in punching parts are the max dimension error which practicable allowed in the parts with limit error. This kind of parts usually are the last qualified products before the die discard.
For the all classes of dies, if we analyse the fluctuate, tendency of increase and decrease and law which appeared in the die’s whole life, we will find that the master of the error are changeless; the error that because the abrade of the cutter and impression will be as the cutter grinding times increased at the same time. And that will cause the error oversize gradually; and also have another part error are unconventional , unforeseen. Therefore, every die’ s error are composed of fixed error, system error, accident error and so on.
At the whole process when the New punching die between just input production to discard, the changeless master error that in qualified part are called fixed error. It’s magnitude is the deviation when the die production qualified products before the first cutter grinding. Also is the initial error, but the die have initial punching accuracy at this time. Because of the abrade of parts, the die after grinding will be change the dimension error. And the increment of deviation will oversize as the times of cutter grinding. So the punching accuracy after cutter grinding also called “grinding accuracy” and lower tan initial accuracy. The fixed error depend on the elements factor as followed :
1. the material , sorts, structure, (form) dimension, and thick of panel
the magnitude of punching gap and degree of homogeneity are have a important effect for the dimension accuracy. Different punching process, material, thick of panel, have completely different gap and punching accuracy. A gear H62 which made in yellow brass with the same mode number m=0.34, 2mm thick and had a center hole, when the gap get C=0.5%t (single edge) , and punched with compound punching die, and the dimension accuracy reached IT7, the part have a flat surface ,the verticality of tangent plane reached 89.5°, its roughness Ra magnitude are 12.5μm, height of burr are 0.10mm; and the punching part are punched with progressive die, the gap C=7%t (single edge) , initial accuracy are IT11, and have an more rough surface, even can see the gap with eyes. In the usual situation, flushes a material and its thickness t is theselection punching gap main basis. Once the designation gap haddetermined flushes the plane size the fixed error main body; Flushesthe structure rigidity and the three-dimensional shape affects itsshape position precision.
2. punching craft and molder structure type
Uses the different ramming craft, flushes a precision and the fixederror difference is really big. Except that the above piece gearexample showed, the essence flushes the craft and ordinary punching flushes a precision and the fixed error differs outside a magnitude,even if in ordinary punching center, uses the different gap punching, thefixed error difference very is also big. For example material thickt=1.5mm H62 brass punching, selects C <= the 40%t unilateral I kind ofsmall gap punching compared to select C <= 8%t (unilaterally) III kindof big gap punching, will flush a fixed error to enlarge 40% ~ 60%, theprecision at least will fall a level. Side in addition, whether thereis picks builds a row of type side, flushes a error to have far to bebigger than has builds a row of type to flush. Side not builds a rowof type to flush. Side not builds a row of type to flush a precisionto be lower than the IT12 level side, but most has builds a row oftype to flush a precision in IT11 between ~ IT9 level, material thickt > 4mm flushes, the size precision can lower some. Different die’s structure type, because is suitable the rammingmaterial to be thick and the manufacture precision difference, causesto flush a fixed error to have leaves. Compound die center, multi-locations continuous type compound die because flushes continuously toduplicate the localization to add on the pattern making error to bebigger, therefore it flushes a fixed error compound punching die to wantcompared to the single location Big 1 ~ 2 levels
3. the craft of punching die’s manufacture
the main work of punching die namely are raised, the concave moldprocessing procedure, to operates on the specification not to behigh, can time form a more complex cavity. But its processing surfaceapproximately is thick > 0.03 ~ 0.05mm is the high temperatureablation remaining furcated austenite organization, degree ofhardness may reach as high as HRC67 ~ 70, has the micro crack, easilywhen punching appears broke the cutter or flaking. The Italian CorradaCorporation''s related memoir called "the line cut the processing contruction to have the disadvantageous influence to the superficialgold, in fact already changed the gold contruction. We must use theJin''gang stone powder to grind or the numerical control continual pathcoordinates rub truncate (cut to line) to make the precision work ". In recent years country and so on Switzerland and Japan, has conductedthe thorough research to the electrical finishing equipment and abigger improvement, makes function complete high accuracy NC and theCNC line cutter, the processing precision may reach ±0.005 ~ 0.001mm,even is smaller. The processing surface roughness Ra value can achieve0.4 mu m. According to the recent years to the domestic 12 productionlines cutter factory investigation and study, the domesticallyproduced line cutter processing precision different factory differentmodel line cutter might reach ±0.008 ~ ±0.005mm, generally all in±0.01mm or bigger somewhat, was individual also can achieve±0.005mm, the processing surface roughness Ra value was bigger than1.6μm. However, the electrical finishing ablation metal surface thus the change and the damage machined surface mental structure character can not change, only if with rubs truncates or other ways removes this harmful level. Therefore, merely uses electricity machining, including the spark cutting and the electricity perforation, achieves with difficulty punching, especially high accuracy, high life punching die to size precision and work components surface roughness Ra value request.
With precisely rubs truncates the law manufacture punching die, specially makes the high accuracy, the high life punching die, such as: Thin material small gap compound punching die, multi- locations continuous type compound die and so on, has the size precision high, the work component smachined surface roughness Ra value is small, the mold life higher characteristic. Its processing craft at present changed the electrical fire by the past ordinary engine bed rough machining spark cutting or the electricity puncher rough machining, finally precisely rubs truncates, also from takes shape rubs, optics curve rubs, the manual grid reference rubs gradually filters the continual path grid reference to rub and NC and the CNC continual path grid reference rubs, Processing coarseness may reach ±0.001 ~ 0.0005mm, the processing surface roughness Ra value may reach 0.1 ~ 0.025 mu m. Therefore, with this craft manufacture the die , regardless of the size precision, the work components surface roughness, all can satisfy die, each kind of compound request, the die is especially higher than the electrical finishing craft manufacture scale.
4. gap size and degree of homogeneity
the flange and other sheet forming sgene rally all must first punching (fall material) the plate to launch the semi finished materials, after also has the forming to fall the material, the incision obtains the single end product to flush. Therefore punching the work, including is commonly used punching hole, the margin, cut side and so on, regarding each kind of sheet pressing partall is necessary. Therefore punching the gap to flushes a out form in chprecision to have the decisive influence. punching the gap small and is even, may cause punching the size gain high accuracy. Regarding drawability, is curving and so on mould, the gap greatly will decide increases flushes the oral area size error and the snapping back. The gapnon-uniformity can cause to flush a burr enlarges and incurs cutting edge the non-uniform attrition.
5. ramming equipment elastic deformation In the ramming process
After the punch press load bearing can have the certain elastic deformation. Although this kind of distortion quantity according to flushes the pressure the size to change also to have the obvious directivity, but on the pressing part, mainly is to has the volume ramming archery target stamping, embosses, the equalization, the pressure is raised, the wave, flushes crowds, the shape, the flange, hits flatly, thinly changes draw ability and so on the craft work punching forming flushes, has the significant influence to its ramming aspect size precision
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