钣金工艺规范及折弯机模具手册1简介1.1钣金所用材料常用材料有:冷轧板SPCC、热轧板SPHC、电解板SECC、普通铝板及铝合金板AL1050、AL5052-H32,不锈钢板SUS304、覆铝锌钢板.1.2典型钣金件加工流程图面展开---编程---下料（剪、冲、割）----冲网孔----校平----拉丝----冲凸包----压铆----折弯-----焊接----立体拉丝----表处----组装2下料2.1数冲是用数控冲床加工，板材厚度加工范围为：冷扎板、热扎板小于或等于3.0mm；铝板小于或等于4.0mm；不锈钢小于2.0mm。
2.1.1 冲孔有最小尺寸要求冲孔最小尺寸与孔的形状、材料机械性能和材料厚度有关。
t为材料厚度，冲孔尺寸一般不小于1.5t。
如遇特殊情况，可参照下表：图2.1.1 冲孔形状示例* t为材料厚度，冲孔最小尺寸一般不小于1.2mm。
冲孔最小尺寸列表2.1.2 数冲的孔间距与孔边距零件的冲孔边缘离外形的最小距离随零件与孔的形状不同有一定的限制，见图2.1.2。
当冲应不小于1.5t。
2.1.3 折弯件及拉深件不可选用数冲下料，可选用二次激光切割。
2.1.4 螺钉、螺栓的过孔和沉头座螺钉、螺栓过孔和沉头座的结构尺寸按下表选取取。
对于沉头螺钉的沉头座，如果板材太薄难以同时保证过孔d2和沉孔D，应优先保证过孔d2。
用于螺钉、螺栓的过孔*要求钣材厚度t≥h。
用于沉头螺钉的沉头座及过孔*要求钣材厚度t≥h。
用于沉头铆钉的沉头座及过孔激光切割是用激光机飞行切割加工，板材厚度加工范围为冷扎板、热扎板小于或等于8.0mm；不锈钢小于或等于4.0mm ；铝板小于等于5.0mm。
其优点是加工板材厚度大，切割工件外形速度快，加工灵活.缺点是会产生热变型，网孔件不宜用此方式加工,加工成本高！折弯折弯件的最小弯曲半径材料弯曲时，其圆角区上，外层收到拉伸，内层则受到压缩。
当材料厚度一定时，内r越小，材料的拉伸和压缩就越严重；当外层圆角的拉伸应力超过材料的极限强度时，就会产生裂缝和折断，因此，弯曲零件的结构设计，应避免过小的弯曲圆角半径。
公司常用材料的最小弯曲半径等于0.5t。
(弯曲半径是指弯曲件的内侧半径,t是材料的壁厚)弯曲件的直边高度一般情况下的最小直边高度要求弯曲件的直边高度不宜太小，最小高度按（图3.2.1）要求：h＞2t>2.5mm。
特殊要求的直边高度如果设计需要弯曲件的直边高度h≤2t,，则首先要加大弯边高度，弯好后再加工到需要尺寸(可采用激光二次切割或者机加工)；或者在弯曲变形区内加工浅槽后，再折弯（如下图所示）。
线的位置割线，折弯后焊接磨平。
折弯件上的孔边距图3.5 带斜边的折弯边应避开变形区反折压死边的设计要求压死边的死边长度与材料的厚度有关。
如下图所示，一般死边最小长度L≥3t+R。
其中t为材料壁厚，R为打死边前道工序（如下图右所示）的最小内折弯半径。
图3.6 死边的最小长度L折弯4.1加强筋在板状金属零件上压筋，有助于增加结构刚性，加强筋结构及其尺寸选择参见表6。
加强筋结构及尺寸选择4.2 打凸间距和凸边距的极限尺寸打凸间距和凸边距的极限尺寸按下列公式计算。
当D≤16mm时：I-1/2D≥2tL-1/2D≥16mm当D≥16mm时：根据实际情况结合生产确定，可选用数冲或者简易冷冲模具加工4.3 百叶窗百叶窗通常用于各种罩壳或机壳上起通风散热作用，其成型方法是借凸模的一边刃口将材料切开，而凸模的其余部分将材料同时作拉伸变形，形成一边开口的起伏形状。
百叶窗的典型结构参见图4.3。
带螺纹孔的内孔翻边尺寸参数钣金连接钣金联接主要采用焊接、螺纹联接、铆接和粘接.我司采用的联接方式:焊接、螺纹联接和铆接.5.1焊接焊接是对焊件进行局部或整体加热或使焊件产生塑性变形，或加热与塑性变形同时进行,实现永久连接的工艺方法.可分为:手工电弧焊、气体保护电弧焊、激光焊、气焊、段焊和接触焊.我司主要采用气体保护焊和接触焊.5.1.1.1气体保护电弧焊在进行气体保护电弧焊时,电极电弧区及焊接熔池都处在保护气体的保护下.采用氩气保护焊缝表面没有氧化物及夹杂物.可以在任何空间位置施焊,可以用肉眼观察焊缝的成形过程并进行调整生产效率高.二氧气体保护焊则成本相当低.5.1.1.2接触焊接触焊是瞬时加热连接部位在熔化状态或非熔化状态下对被焊件加压形成焊接接头的焊接方法.它可分为对焊、点焊和缝焊.5.2 螺纹联接螺纹联接具有安装容易、拆卸方便、操作简单等优点,常用于可拆的钢结构连接.它可分为螺钉联接和螺栓联接.5.3铆接铆接是用铆钉将金属结构的零件或组合件连接在一起的方法，铆钉种类较多，我司常用的铆钉有封闭形圆头抽芯铆钉、封闭形沉头抽芯铆钉及开口型圆头抽芯铆钉、开口型沉头抽芯铆钉。
铆钉长度可根据以下公式计算：L=0.8d+1.1td:铆钉直径t：板厚5.4粘接用粘接剂将所需连接件粘接在一起的一种连接方法。
6 钣金表面处理方式1.拉丝2.喷砂3.烤漆、喷粉、主要技术指标：光泽度、膜厚和色差4.电镀：主要镀五彩锌、白锌、黑锌、镀铬、蓝白锌5.抛光6.氧化7 钣金加工主要设备1.下料设备：数控剪床、激光切割机、数控冲床2.成形设备：普通冲床和数控折床。
3.焊接设备：氩弧焊机、二氧化碳保护焊机、点焊机、机器人焊机。
4.表面处理设备：拉丝机、立体拉丝机、抛光机、烤漆线5.调形设备：校平机8 折弯机模具手册自由折弯的折弯压力对照表本表格中的数据是在90°折弯，材料抗拉强度δb=420MPa，折弯长度为1m基础上计算的结果。
V6810121618202432354050606380100120130140150160180190200230260 b 4.5578.51213151723252835434557718592100105115130135140160180 r1 1.2 1.62 2.5 2.83 3.55 5.5689.5101215.519212324.5262830323640 0.5 2.50.87 4.81.011861.212971.5151282.023*******.52.526222015113.030241614124.044312823185.0534*******6.0614536348.0886*******10110806047433912120907165585550 1614012511510595818071 181481351251101009580 2014013012011090内径R约等于凹模开口宽度V的16%材料厚度(t)0.5~2.5mm3~8mm9~10mm>12mm凹模开口宽度(V) 6 ×t8 ×t10 ×t12 ×t铝Aluδb=300 MPa F=F（表）×0.65F=F（chart）×0.65不锈钢S.Sδb=700 MPa F=F（表）×1.6F=F（chart）×1.6折弯压力吨位计算公式（参考值）F（表）= 65 × t2 / V （吨）普通斜楔夹紧重型斜楔夹紧实用于50t~220t之间欧式上模的安装实用于220t以上欧式上模的安装机械快速夹紧美式夹紧快夹可以方便欧式上模的快速安装适用于美式上模的安装过渡模柄夹紧过渡联接块适用于大行程机床的安装适用于滑块受重载的安装YAWEI上模液压夹紧 WILA上模液压夹紧式适用于上模的快速安装NSCL Ⅱwith Top with Safety Click1V插槽式 1V插槽式 2V可调式模具肩部受力模具底部受力下模口可前后调节2V快换式多V插槽分段式下模口可快速更换适用于分段多V下模多V工作台式下模插片式适用于整体多V下模模口可分级增大，适用于大吨位折弯机YAWEI下模液压夹紧液压夹紧工作台适用于1V下模快速安装NSCR Ⅱwith OZU bottom tool标准上模上模模柄结构标准欧式加强型欧式美式大吨位过渡模柄上刀标准分段方式10.100 10.101 10.102Max Tons:100t/m Max Tons:80t/m Max Tons:60t/m10.103 10.104 10.105Max Tons:80t/m Max Tons:100t/m Max Tons:80t/m10.106 10.107 10.108Max Tons:50t/m Max Tons:50t/m Max Tons:100t/m10.109 10.110 10.111Max Tons:80t/m Max Tons:40t/m Max Tons:80t/m10.112 10.113 10.114Max Tons:70t/m Max Tons:40t/m Max Tons:50t/m10.115 10.116 10.117Max Tons:100t/m Max Tons:60t/m Max Tons:45t/m10.118 10.119 10.120Max Tons:80t/m Max Tons:80t/m Max Tons:50t/m标准上模88°10.130 10.131 10.132Max Tons:100t/m Max Tons:80t/m Max Tons:60t/m10.133 10.134 10.135Max Tons:100t/m Max Tons:50t/m Max Tons:20t/m10.136 10.137 10.138 Max Tons:80t/m Max Tons:45t/m Max Tons:20t/m10.139 10.140 10.141 Max Tons:70t/m Max Tons:50t/m Max Tons:50t/m10.142 10.143 10.144 Max Tons:30t/m Max Tons:20t/m Max Tons:50t/m10.150 10.151 10.152 Max Tons:100t/m Max Tons:35t/m Max Tons:80t/m10.153 10.154 10.155 Max Tons:80t/m Max Tons:20t/m Max Tons:60t/m10.156 10.157 10.158 Max Tons:60t/m Max Tons:20t/m Max Tons:50t/m10.170 10.171 10.172Max Tons:80t/m Max Tons:80t/m Max Tons:70t/m10.173 10.174 10.175Max Tons:100t/m Max Tons:100t/m Max Tons:60t/m10.176 10.177 10.178Max Tons:160t/m Max Tons:60t/m Max Tons:40t/m10.190 10.191 10.192Max Tons:80t/m Max Tons:80t/m Max Tons:90t/m10.193 10.194 10.195Max Tons:70t/m Max Tons:100t/m Max Tons:100t/m10.196 10.197 10.198Max Tons:80t/m Max Tons:160t/m Max Tons:70t/m10.210 10.211 10.212Max Tons:100t/m Max Tons:100t/m Max Tons:80t/m10.213 10.214 10.215Max Tons:80t/m Max Tons:80t/m Max Tons:80t/m10.216 10.217 10.218Max Tons:80t/m Max Tons:80t/m Max Tons:80t/m10.21910.220 10.221Max Tons:80t/m Max Tons:80t/m Max Tons:80t/m10.222Max Tons:80t/m10.230Max Tons:80t/mRmm Rmm10.231R33R5.5 5.510.232R3.5 3.5R6610.233R44R6.5 6.510.234R4.5 4.5R7710.235R55R7.57.5标准圆模10.240 10.241Max Tons:100t/m Max Tons:100t/m分段方式Rmm Rmm10.242R88R202010.243R1010R252510.244R12.512.5R303010.245R1515R353510.246R17.517.5R404010.250+20.134 10.251+20.135 10.252+20.13610.250 Max Tons:A 80t/m B 100t/m 10.251 Max Tons:A 80t/m B 100t/m 10.252 Max Tons:A 80t/m B 100t/m 20.134 Max Tons:A 50t/m B 100t/m 20.135 Max Tons:A 50t/m B 100t/m 20.136 Max Tons:A 50t/m B 100t/mA Bs mm Amm450Mpat/m700Mpat/msmmAmm450Mpat/m700Mpat/m0.6 3.09150.6 1.223350.8 3.012200.8 1.632501.0 3.51525 1.02.04060 1.253.51726 1.25 2.550801.5 4.62238 1.5 3.063952.0 5.53050 2.0 4.08013010.260 10.261 10.262Max Tons:60t/m Max Tons:60t/m Max Tons:60t/m10.263 10.264 10.265Max Tons:40t/m Max Tons:100t/m Max Tons:100t/ms mm Amm450Mpat/m700Mpat/msmmAmm450Mpat/m700Mpat/m0.6 3.09150.6 1.223350.8 3.012200.8 1.632501.0 3.51525 1.02.04060 1.253.51726 1.25 2.550801.5 4.62238 1.5 3.063952.0 5.53050 2.0 4.0801302.5 6.555 2.5 5.0903.08.070 3.0 6.0100标准Z型模10.270 10.271 10.272 Max Tons:100t/m Max Tons:100t/m Max Tons:100t/mZ mm B°smaxmaxt/mZ-11160°0.5100 Z-1.5 1.5160°0.6100 Z-22150°0.8100 Z-2.5 2.5140° 1.0100 Z-3390° 1.0100 Z-3.5 3.590° 1.2100 Z-4490° 1.2100 Z-4.5 4.590° 1.5100 Z-5590° 1.5100 Z-5.5 5.590° 1.5100 Z-6690° 1.5100 Z-6.5 6.590° 1.5100 Z-7790°2100 Z-7.57.590°2100 Z-8890° 2.5100Z mm B°smaxmaxt/mZ-9990° 2.5100 Z-101090°3100 Z-111190°3100 Z-121290°310010.300 10.301 10.302Max Tons:100t/m10.303 10.304 10.305Max Tons:100t/m Max Tons:100t/m Max Tons:160t/m10.306 特殊折弯方式Max Tons:100t/m20.100 20.101 20.102Max Tons:40t/m Max Tons:40t/m Max Tons:50t/m20.103 20.104 20.105Max Tons:60t/m Max Tons:80t/m Max Tons:85t/m20.106 20.107 20.108Max Tons:90t/m Max Tons:100t/m Max Tons:100t/m20.109 20.110 20.111Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.112 20.120 20.121Max Tons:145t/m Max Tons:40t/m Max Tons:40t/m20.122 20.123 20.124Max Tons:55t/m Max Tons:55t/m Max Tons:60t/m20.125 20.126 20.127 Max Tons:40t/m Max Tons:40t/m Max Tons:40t/m20.128 20.129 20.130 Max Tons:40t/m Max Tons:55t/m Max Tons:55t/m20.131 20.132 20.133 Max Tons:60t/m Max Tons:50t/m Max Tons:50t/m20.140 20.141 20.142 Max Tons:95t/m Max Tons:95t/m Max Tons:95t/m20.143 20.144 20.145 Max Tons:95t/m Max Tons:95t/m Max Tons:95t/m20.146 20.147 20.148 Max Tons:95t/m Max Tons:95t/m Max Tons:95t/m20.160 20.161 20.163 Max Tons:60t/m Max Tons:65t/m Max Tons:70t/m20.164 20.165 20.166 Max Tons:70t/m Max Tons:70t/m Max Tons:70t/m20.167 20.168 20.169 Max Tons:70t/m Max Tons:65t/m Max Tons:70t/m20.170 20.171 20.172Max Tons:70t/m Max Tons:70t/m Max Tons:70t/m 分段方式特殊下模20.180Vmm Rmm Max Tons20.18135310020.18240410020.18350510020.18460610020.18580810020.186********20.220 20.221 20.222Max Tons:70t/m Max Tons:80t/m Max Tons:80t/m20.223 20.224 20.230Max Tons:80t/m Max Tons:80t/m Max Tons:60t/m20.231 20.232 20.233Max Tons:60t/m Max Tons:100t/m Max Tons:100t/m20.234 20.235 20.236Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.237 20.238 20.239Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.250 20.251 20.252Max Tons:80t/m Max Tons:80t/m Max Tons:80t/m20.300 20.301 20.302Max Tons:70t/m Max Tons:80t/m Max Tons:80t/m20.303 20.304 20.305Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.306 20.307 20.308Max Tons:60t/m Max Tons:60t/m Max Tons:100t/m20.320 20.321 20.322Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.323 20.324 20.325Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.340 20.341 20.342Max Tons:60t/m Max Tons:60t/m Max Tons:60t/m20.350/Tx 20.351/TxMax Tons:100t/m Max Tons:100t/mVmm Rmm Smm max t/mT660.414100T880.514100T10100.818100T1212 2.7518100T1616 2.7524100T2020330100T2525335100TR66 2.7514100TR88 2.7514100TR1010 2.751810020.352/TxMax Tons:60t/mVmm Rmm Smm max t/mT660.51460T880.81460T10100.81860T12120.81860T1616 2.752460T202033060T252533560TR66 1.51460TR88 1.51460TR1010 2.751860TR1212 2.75186020.353/Tx 20.354/Tx 20.355/TxVm Rm Sm max t/m Vm Rm Smm max t/m Vm Rm Smm max t/m T660.81450T660.81435T660.81620T8811850T8811635T8812020T110 1.21850T1010 1.22040T1010 1.22420T112 1.62450T1212 1.62240T1212 1.62620T116 2.752650T161633045T22033050T202033550T22533750T25253405020.356/Tx 20.357/TxMax Tons:100t/m Max Tons:100t/mVmm Rmm Smm max t/mT660.414100T880.514100T10100.818100T1212 2.7518100T1616 2.7524100T2020330100T2525335100TR66 2.7514100TR88 2.7514100TR1010 2.751810020.358/TxMax Tons:60t/mVmm Rmm Smm max t/mT660.51460T880.81460T10100.81860T12120.81860T1616 2.752460T202033060T252533560TR66 1.51460TR88 1.51460TR1010 2.751860TR1212 2.75186020.359/Tx 20.360/Tx 20.361/TxVm Rm Sm max t/m Vm Rm Smm max t/m Vm Rm Smm max t/m T660.81450T660.81435T660.81620T8811850T8811635T8812020T110 1.21850T1010 1.22040T1010 1.22420T112 1.62450T1212 1.62240T1212 1.62620T116 2.752650T161633045T22033050T202033550T22533750T25253405020.400 20.401 20.402Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.403 20.404 20.410Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.411 20.412 20.420Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.421 20.422 20.430Max Tons:100t/m Max Tons:100t/m Max Tons:100t/m20.431 20.440 20.441Max Tons:100t/m Max Tons:80t/m Max Tons:80t/m分段方式20.500 20.501 20.50220.503 20.504 20.50520.506 20.507 20.50820.509 20.510 20.51120.512 20.513 20.51420.515 20.516 20.51720.530 20.531 20.540Max Tons:80t/m Max Tons:80t/m Max Tons:60t/m20.541 20.550 20551Max Tons:100t/m组合凹模20.560 20.561Max Tons:100t/m Max Tons:100t/m20.600 20.601 20.60220.603 20.604 20.60520.606 20.607 20.60820.609 20.610 20.61120.612 20.613 20.61420.615 20.616 20.617。