1、美國公司的模具設計細節指導(中英文 I. Purpose 目的A. The purpose of this metal stamping die standard is to provide detailed instructions for use in the design, construction, and testing of all metal stamping dies supplied to the Su-dan Corporation本份模具標準是向所有提供給Su-dan公司的五金模具的設計、組立、試模提供細節指導。1. Su-dan requires die(s to pr

2、oduce finished parts that conform to:Su-dan要求模具制造的產品應與以下保證一致:a. The part drawing. 產品圖面b. Including geometric dimensioning and tolerancing.形狀尺寸及公差c. Requirements for first parts approval process.首件承認程序要求2. This standard and the specifications referenced herein are issued to:本標準是應用:a. Define the gener

3、al classifications of metal stamping dies for Su-dan. 定Su-dan五金模具分類b. Reduce the dies design and build costs by: 通過以下條款降低模具設計及組立成本(1 Standardization of design, which will decrease review time and expense.設計標準化將降低審圖時間及成本(2 Using commercially available die components. 使用標準件c. Assure the safety of Su-d

4、an personnel. 確保Su-dan員工安全d. Promote superior tool design and consistent die making practices.提升模具設計能力及協調模具制造習慣II. ScopeA. All metal stamping dies supplied to Su-dan will comply with the requirements specified herein and as stated in the die design and construction data sheets.所有供應給Su-dan的鐵件模具必須遵守這份

5、指定的及在模具設計及組裝表冊里規定的要求III. Die Classifications 模具級別A. All dies will be constructed for inter-changeability of perishable die blocks, punches, retainers, die buttons, and pilots.模具需保證易壞的鑲快、沖頭、固定器、引導沖組裝的易換性。B. Die material requirements: 模具材質要求Die Component Description模具組件名稱 Die Material Type材質種類Die stee

6、l 模板D2 or betterFiller steel 導料板HRS/CRSButtons 鑲件 M-2Pilots 引導沖 M-2Punches 沖頭 M-2Buttons & punch retainers 鑲件及沖頭固定裝置A2, 6150,- 4140 steel - hardenedPressure pads 壓料墊板 6150 or 4140 steel-hardened (See p.17, S-16Stripper windows 脫料板快拆窗口6150, 4140 or 0-1 steel hardened- (See p. 17, S-16Form steel 成

7、型 D2 or betterIn any application where Su-dan is stamping a high strength or high carbon material the use of CPM-4, CPM10V, and CRU-Wear material with a surface coating should be discussed. 在Su-dan沖壓高強度及高碳材質的地方,如應用表面強化需討論IV. Metal Stamping Dies - General Requirements: 五金模具一般要求A. Die design and const

8、ruction data sheet: 模具設計與組立數據表1. The Su-dan Engineer shall complete and submit data sheet with each die proposal request (Including shut height, feed levels,parallels, etc.Su-dan工程師應填寫及提供每一套模具方案要求的資料表(包括閉模高度、送料高度、墊腳等 2. Data sheet will be updated at final die design review, including the Project Eng

9、ineer and the vendors recommendations, which will become part of the gen eral die specifications.資料表在最終模具審核時應該更新,項目工程師及供應商的建議都將成為普通模具規范的一部分。B. Die design approval: 模具設計審核1. A strip layout is required on all parts before formal design is started. The strip layout is to reflect the stock width, the pr

10、ogression, and the tonnage required to produce the stamping. Strip layouts should be developed so that scrap pieces are not left in the die.在正式設計之前必須提供料帶排布,料帶包含料帶寬,步距,沖床噸位,料帶應保證廢料不停留在模具上.2. To conserve material, the edge of the part may be the edge of the coil material wherever the part design will

11、permit. Using edge of coilmaterial as part entity will require written approval from the Tool Engineer.為了節約料,產品邊可使用材料邊,如使用卷料邊,需要模具工程師的書面批準!3. The strip should be developed to maintain maximum strip strength for the greatest possible distance through the die.料帶應該強化到最大強度以通過最大的模板距離4. A die should be de

12、signed to minimize any strip distortion which would tend to change the distance between pilot holes (alter the progression.模具設計應保證最少的任何改變料帶步距的料帶扭曲.5. All die designs will include part number, stamped on the part if indicated on the part print and a Su-Dan ID. stamp if required.如果產品圖面指示或Su-Dan 有號碼要求所

13、有模具設計應包含部件號碼并刻印在零件上.6. All die designs that involve both single and/or double progressive dies that produce the following:在一出一及一出二的連續模設計中,產品應該符合以下標準:a. A right and left hand part, if symetrically opposite, will be equipped with either “R” and “Lidentification on each part.左右對稱相反的零件,必須在每個零件上刻上字符L 及R

14、b. If parts are not symmetrically opposite a 1/8” letter “T” identification should be used on one of the parts.如果左右不是對稱相反的零件,在其中的一個零件必須加上1/8” 高的T加以區別。c. In some cases, a part number destination will be an dated by the part print or requested by the Project Manager.在有些案例中,根據圖面或項目工程師的要求,零件料號將有一個日期區別d.

15、 Julian date stamps (interchangable will be required on all safety parts.7. All die capable of producing multiple level designs from that die, must be equipped with a provision for interchangable part identification to distinguish all variations capable of being produced from that die. Consult with

16、Project Manager for specific identification.在共用模具設計中,必須預先對快換入子提供一個可區別的方法,可以與制定標準的項目經理商量8. All die drawing numbers plus special die drawings will be supplied at preliminary review.在初級設計中所有模具圖紙必須完全提供。9. Provision for loading and unloading of raw materials for all dies, as well as part ejection and scr

17、ap removal will be covered during the die design.在所有模具設計中,必須提供未加工和已加工的工序圖,以及產品頂出及廢料脫落方式。10. Designs will avoid excessive use of lubrication to produce stampings。在模具設計中應該避免過多的使用潤滑油去制造產品。11. If stock does not start against a pitch notch (positive stop a start mark for first hit will be necessary.如果條料沒

18、有步距開口槽(正極停止送進,首次沖壓條料送到位置的標記是有必要的。12. Full scale preliminary drawings must be reviewed on site between Project Manager and Vendor. Drawings must be approved by Project Manager prior to the start of construction.在項目經理與供應商規定的時間必須對全尺寸的初級設計進行審核,在組裝開始之前圖面必須得到項目經理的承認。13. The die supplier will furnish in wr

19、iting the developed blank size along with the preliminary tool drawing(s.在提交初級設計的同時供應商應提供下料尺寸。14. All die designs are to be originated and dimensioned using inch standards.所有的模具設計用英制原點標注。15. Dies are to be designed so they can be maintained in the press using inserts in forms and cut off sections. A

20、ll forming inserts must be adjustable to accommodate stock thickness variance.設計時應考慮使用成形入子及刀口入子,所有的成形入子應該可以根據料厚的變化可以調整。16. Wear points of the die sections must be inserted for economical maintenance, replacement cost, and adjustability for stock variance.所有模具入子耐磨的地方必須使用鑲嵌以方便經濟的維修,置換以及根據料厚的變化調整能力。17.

21、 Die should contain a minimum of one idle station to accommodate future design considerations. i.e. restrike, cam pierce, etc.摸具應至少包含一個空站以適應未來的設計變更,回整,凸輪,沖孔等。18. The position of the ball seat and key flats must be noted on stock list when not in standard position on oblong and rectangular punches an

22、d buttons.當橢圓形,矩形的沖頭及入子沒有在標準的位置時,球鎖的位置及扁平鍵應該標在料表清單上。19. Die designs should include the provisions for sensors. A minimum of two sensors-SeeSection K1.模具設計中至少使用兩種感應器。20.In addition the die design drawing will show: 此外,模具設計圖面應顯示:a. Strip layout (full scale if possible. 料帶(只要可能的話必須全尺寸b. Plan view (top

23、and bottom section assembly. 平面圖(上下部分的剖視組裝圖c. Sectional views (right and left and/or front and back as required to show construction.剖視圖(前后左右的反映結構的視圖d. Cross-sectional views (for timing, punch length, and travel of springs.橫斷面視圖(剪邊,沖頭長度以及彈簧的行程e. Detail drawing(s of all perishable trim and form secti

24、ons with material identified. Detail drawing(s will be on 8.5” x 11” paper with Su-dan title block provided in a binder and/or Cad data.所有的易磨損的沖頭以及成形塊必須用細部圖表示并注明材料,細部圖將使用Su-dan 用文件夾或Cad提供的8.5” x 11”標題框。20. Die progress reports are to be submitted twice a month to the Su-dan Project Manager. 每個月應向Su-

25、dan項目工程師提交兩次的模具進度報告。21. P aper is to be 34” x 22” with the standard Su-dan title block.圖紙應為34” x 22”大并使用Su-dan的標準圖框。22. If roll sized drawings are supplied they will be folded to 34” x 22” size with the title block located in the lower right hand corner.如果提供的為卷紙圖紙,應該折疊成34” x 22”大并使標題框位于右下角落。23. Comp

26、leted die designs are to be reviewed and approved before die construction begins. 在模具組裝開始之前完整的模具圖紙必須被審核及承認。C. Die design ownership: 模具設計所有權1. The die design supplied to Su-dan under a design and build purchase agreement will become the property of Su-dan. Therefore, no restrictions will be placed on

27、 the die design drawings and diskettes by the vendor.根據設計及組裝購買合同,Su-dan對應給Su-dan的模具設計具有所有權。因此,供應商應無保留的供應所有的圖紙及相關磁片。D. Die noise: 模具噪音1. During the die design and build, consideration will be given to the following:在模具設計及組裝中,應考慮以下幾點:a. Grind shear. 修模刀口b. Stagger punches. 沖頭防呆c. Minimize pressure at

28、die shut height. 在閉模時壓力應該最小。F. Die design responsibility: 模具設計責任1. The die design, construction, function, and ability of the die to produce acceptable repetitive production parts will be the sole responsibility of the die supplier.供應商對模具設計、組裝、功能以及反復制造產品的能力負主要責任。2. Any errors found in the dies durin

29、g tryout and final acceptance test will be corrected bythe die supplier at no additional cost to Su-dan.任何在模具試模及接受過程中發現的錯誤應由供應商更正,任何相關費用與Su-dan無關。G.Die performance: 模具性能1. All dies to be designed and constructed considering optimal production rates as designated by the Porject Manager. The Goal is t

30、o explore innovative techniques to increase the press Speed at which these dies will operate. This in turn translates Into higher production capacities, in a shorter period of time.在模具設計及組裝中應考慮由項目經理提出的最佳生產速率,這個目的就是研究更新的技術去增加模具生產沖床的速率。這將轉換為在更短的時間內獲得更高的制造能力2. All new dies will produce Su-dan productio

31、n parts to meet first parts approval and part run rate before final acceptance.在模具最終接受前,所有生產Su-dan產品的模具必須獲得首件承認以及產品生產速率V. Die Design Criteria 模具設計標準A. Preferred components: 首選的零件1. All metal stamping die(s supplied to Su-dan will be constructed using the preferred components already identified.所有供應給

32、Su-dan的五金模具都應使用已經證明的首選零件組裝。B. Production part materials - Die design relationship : 產品的材料(與模具設計有關1. The production material thickness will be used when calculating the die design dimensions-check with Project Manager for exact tolerances.當計算模具設計尺寸(由項目經理做精確公差的檢查將使用材料的厚度。2. To optimize material usage,

33、 flat blank nominal material thickness will be used along with the minimum inside form radii to calculate material used.為提高材料的利用率,將使用最小的內側半徑及平的材料厚度來計算材料的用量。C. Calculating operation tonnage of die: 計算模具工作噸位1. The calculated operating tonnage of the die will include stripping pressure.計算出的模具工作噸位應包含脫料力

34、。2. The stripping pressure for the press tonnage will be calculated with the die closed.沖床噸位中的脫料力應為模具閉合時的壓力。D. General die life and construction: 模具壽命與組裝1. All dies will be provided with a minimum of 4 steel “set blocks,” or stop blocks positioned over the parallels. 所有的模具應包含至少四個位于墊腳上的限位塊或者限位柱a. Siz

35、e of set blocks to be determined by: 限位塊的尺寸由以下條件決定(1 Die area 250 square inches or less, use 2 inch diameter round or comparablearea-rectangular set blocks.當模具尺寸小于或等于250平方英寸,使用直徑位2英寸的限位柱或同等面積的限位塊。(2 Die are over 250 square inches, use 3 inch diameter set blocks.當模具尺寸大于250平方英寸時,使用3英寸直徑的限位塊。b. Set blo

36、cks will have a .050” deep by .250” wide slot for soft lead coining at shut height. Set block to be stamped, or die shoe to be stamped “.050” near set block.限位塊將有一條.050”深.250”款的槽,在限位塊上或者模座上刻上“.050”3. Die sections will have staggered hole patterns for one-way assembly.為方便組模模具入子應使用防呆孔方式3. Die section(

37、s will be a minimum of 1.5” thick. 模具刀口入子至少有1.5英寸厚。a. There must be a .375-.500” cutting land with all wire burned sections or holes for all parts. These sections must be undercut at 1½° taper to provide the desired cutting land.所有線割的刀口入子必須有.375-.500”的刀口直深并有1½°的落料錐度。b. Dies shoul

38、d be designed for use of wire E.D.M. on die sections, trim and notch punches where applicable. Traditional die making practice must be used so each section can be worked during the repair process. All large wire burned sections should be segmented when possible.有切口及開槽的地方,模具刀口入子都應設計成線割,傳統的模具制造方法可以利用這

39、樣每一個入子在維修中都能夠工作,所有大的線割部件只要可能都應該分段。4. Cutting sections will be ground or finished by E.D.M. to remove decarb. All die sections will have a ground seating surface.所有的沖裁入子都應該研磨或者用E.D.M.精加工除去,所有的模具入子都應有一個研磨放置面。5. All pierce die holes will be buttoned unless otherwise specified.除非其他說明,所有的下模沖孔都應使用入子。6. Sc

40、rew holes will be counterbored in the die section . Screw heads will be a minimum of 3/8” plus die cutting land below the die section surface, and screw threads must enter no less than 1.5 times diameter.在入子上的螺絲孔必須沉頭,螺絲頭必須沉入模具入子下表面3/8”加上刀口直深,螺絲至少鎖入1.5倍螺絲直徑。7. Where possible, screws will be hex socke

41、t head cap screws. Other types of screws, such as set screws, will be hex socket.只要空間允許,都使用內六角沉頭螺絲,其它種類的螺絲,譬如固定螺絲,必須是內六角的8. Refer to company press information to determine the proper shut height, die size, and parallel size needed. 根據公司沖床情況決定適當的閉模高,模具尺寸以及需要的墊腳尺寸。a. Parallels are to be ground both to

42、p and bottom. 墊腳應該研磨上下兩個面。b. Parallel mounting screws will be 2 different sizes from one end to the other.兩端墊腳固定螺絲必須為不同的尺寸c. The 2 outer and center parallel on both top and bottom shoe if present are to:上模及下模的兩個最外端的和中間的墊腳如果有的話必須為:(1 E xtend 3” from the side of the die.從模具側向外延伸3英寸(2 Are to be cut int

43、o a clamping foot with a maximum height of 2” with a 1” slot for clamping.應該切割成帶有2” 高及1” 固定槽的固定墊腳d. The upper shoe if no p arallels are present will have 1” clearance slots for fastening.如果沒有上墊腳應該開1” 的固定槽。e. Die handling holes of ¾” or 1” are required on both sides of the top and bottom shoes.在

44、上下模座兩側應該有¾” 或者1”的起吊孔。f. All parallels with integral feet should be located on 6” J.I.C. centers.所有整數尺寸的墊腳應該位于6” J.I.C.中心。g. Provide adequate clearance for slug removal. 提供足夠的落料間隙。g. Proper clearance for Hi-Lo forks between the bottom parallels to provide safe balance when lifting. Slot s must b

45、e a minimum of 6” and maximum of 28” apart, and equal distance from the center of the die.在下墊腳之間應該提供足夠的Hi-Lo叉車搬運間隙并保持平衡,間隙最小為6”最大為28”,到模具的中心距離應該相等。h. A keyway slot must be on parallels for centering die on bolster. 1.020” wide and 1” deep.在墊腳上應提供將模具定位在臺面上鍵槽(1.020”寬1” 深8. Large weldments in die struc

46、ture will be machined on the mating surfaces, screwed together, welded, and normalized before final machining.模具中的大型燒焊件必須在配合面上進行加工并用螺絲所在一起,在最終加工前必須焊接及處理。9. Welding on trim steels to make corrections or modifications is acceptable only to complete tryout and first piece approval. Welded trim steel se

47、ctions must be remade and retried before die is shipped. Welded form steels must be approved by Project Manager.對剪斷入子進行更正和變更所做的燒焊僅用于試模及首件承認,在模具船運之前燒焊的入子必須重制并再次試模,對成型的部件進行燒焊必須經過項目經理的同意。10. All overhung items, gages, hoses, valves, electrical wires or boxes will be protected with heavy duty guarding,

48、from lift truck mast.所有懸掛物體,量側器,軟管,閥門,電子線及包裝都必須很好的保護,避免碰到插車天線11. Dies with thrust characteristics must be properly heeled and keyed.帶沖刺特征的模具必須有適當的跟刀及鍵塊a. Heel blocks to have a minimum of 1/8” heeling before work is started.在工作之前跟刀必須有1/8”長度導正。b. Heel blocks should have screws located on the side of t

49、he block toward the thrust.跟刀靠向沖頭一側應該有螺絲定位。12. Use D2 steel or better on all cutting and forming sections with heavy usage. Provide kicker pins in punch sections and spring plungers in the stripper when necessary for positive strip removal. Each section is to be doweled separately.對重載荷的沖裁及成型入子使用D2或更

50、好的鋼,當有必要正面移出時在沖頭入子中提供推出銷,在脫料板中提供彈簧定位銷,每個入子都應該單獨用銷子結合。14. Eject parts toward front side of the die and press. 推出的產品應該面對模具及沖床的前側。a. Parts and scrap cannot be mixed. 產品及廢料不能混合。b. On dies where multiple parts are made, parts must be kept seperate.在生產多個產品的模具中,每個產品必須分開。c. In two-out dies the back part mus

51、t be marked with a 1/8” T stamp as required by part print or Project Managers direction.在一出二模具中,根據圖面要求或項目經理的指示在后面的不見刻上一個1/8”高的T。15. Flattening and restrike sections are to be provided, as dictated by part configuration and part print specification. Flattening, forming, and coining steels will go thr

52、ough the stripper in lieu of using the stripper to perform above listed die functions.根據產品功能以及產品圖面指示,應提供整平以及回壓入子,在使用脫料板的地方,整平,成型,壓印沖子應穿過脫料板執行以上功能。16. All dies containing a restrike station should have a parallel under restrike station. Pararllel should have a minimum width to cover entire restrike a

53、rea.在有回整工步的地方,必須有一個墊腳支撐,墊腳最小寬度應該覆蓋回整區域。17. All dies containing coining stations shall have a minimum .750” hardened plate under each station for support.在有壓印工步的地方,至少有一塊.750”厚的熱處理板支撐。18. In dies using shave applications, it is best to use a two-out die configuration. This is used to balance cutting f

54、orces shave punches must be heeled. Shave area to be outboard of strip stock. Use double pilots to locate parts. Use pilots that are located in lower die half. Use two shave stations as follows:在剪邊模具中,最好使用一出二的結構,這有助于平衡沖裁力,剪切沖頭必須有靠刀,剪切靠向料帶的外側,用雙倍的導正銷導正產品。使用位于下模的定位銷。如下使用兩個剪切工步:a. All shave application

55、s must be reviewed for die clearance accuracy.所有應用剪切的地方必須對模具間隙精度進行評估。19. Carrier design must be developed in one of three ways to avoid match cuts and the burrs that are associated with them (no burrs are exceptable in these areas.為避免重復過切以及由此產生的毛刺必須使用以下三種之一的過切設計。(在這些區域毛邊是不可接受的a. Cutting carrier or c

56、utting of part leaving a male tab on the parts.過切在產品上切除一個小凸塊。b. Cutting carrier or cutting of part leaving a recess on the parts.過切在產品上留一個凹槽。c. Match cut on an angle to a radius.在原角處做一個相切的角度。20. A die must have sufficient pilots to control the strip adequately in order to produce consistent parts.在模

57、具中為制造穩定的產品必須使用充足的導正銷充分導正料帶。a. Pilots are to be .004” diameter smaller than pierce punches.導正沖頭直徑比沖到導正孔沖頭直徑小.004”。21. The following tolerance standards should be adhered to when detailing a progressive die:當設計連續模具時必須遵守以下公差標準。a. 4 place decimal +/- (小數點后四位 . . . . . . . . . . .0005”3 place decimal +/-

58、 (小數點后三位 . . . . . . . . . . .001”2 place decimal +/- (小數點后兩位. . . . . . . . . .010”1 place decimal +/- (小數點后一位. . . . . . . . .020”b. Linear dimensions in the direction of progression must not be stacked.連續模送料方向上的尺寸不能累加。22. Extrusion punches must be coated to prevent galling.為防止磨損拉伸沖頭必須做鍍層處理。23. A minimum of two safety switches must be installed on all progressive dies to probe forproper strip advancement and part out detection.在所有連續模中至少安裝兩個安全檢測開關去