五金配件模具設計：（模具的靈魂）

　　1：首先(xian)產(chan)品(pin)圖或產(chan)品(pin)的(de)(de)(de)分析，找出(chu)(chu)產(chan)品(pin)的(de)(de)(de)難點(dian)，在沖壓過程中會出(chu)(chu)現影響產(chan)品(pin)的(de)(de)(de)尺寸，穩定性因素(su)，成(cheng)型的(de)(de)(de)困(kun)難性，零件的(de)(de)(de)易損(sun)性，外觀損(sun)傷(shang)等等。

　　2：產品圖檔的(de)處理，原(yuan)始圖檔或抄數圖，3D（3D轉2D），2D（注意圖檔的(de)視(shi)圖的(de)角(jiao)法）。

　　3：確(que)定好(hao)后進行產(chan)品數據(ju)的(de)公(gong)差處理(li)，這(zhe)步沒有處理(li)好(hao)是會影響后續模具(ju)調整(zheng)尺寸的(de)關鍵，會增加模具(ju)修(xiu)改和制造成(cheng)本。

　　4：根據(ju)經(jing)驗處理展開，工程步數圖（成型折彎(wan)方(fang)式）

　　5：結合產品的(de)(de)結構，提出(chu)我(wo)們(men)的(de)(de)難(nan)點(dian)，問題點(dian)，申請公差，毛邊，帶料點(dian)要(yao)求等等。

　　6：開始工程排樣(yang)(yang)，設(she)(she)計(ji)(ji)(ji)料帶（如果上(shang)述的(de)(de)(de)幾個問題都解決了(le)(le)，這(zhe)一(yi)步(bu)做(zuo)起來就很(hen)快(kuai)）我們一(yi)般要(yao)把產品的(de)(de)(de)材(cai)質，厚(hou)度(du)(du)(du)，料寬，步(bu)距。沖床高度(du)(du)(du)，大(da)小(xiao)。材(cai)料利用(yong)率，浮升高度(du)(du)(du)，注明。模具(ju)基本(ben)的(de)(de)(de)要(yao)素(su)都搞定了(le)(le)，剩下(xia) 的(de)(de)(de)就是按我們與(yu)客戶的(de)(de)(de)設(she)(she)計(ji)(ji)(ji)標(biao)(biao)準，和對(dui)五金模具(ju)的(de)(de)(de)了(le)(le)解畫(hua)圖了(le)(le)。（模具(ju)的(de)(de)(de)設(she)(she)計(ji)(ji)(ji)標(biao)(biao)準，希望(wang)我們每(mei)個設(she)(she)計(ji)(ji)(ji)人員有自己的(de)(de)(de)一(yi)個畫(hua)圖標(biao)(biao)準，這(zhe)樣(yang)(yang)畫(hua)圖和加(jia)工都比較(jiao)快(kuai)速(su)(su)，除了(le)(le)客戶要(yao)求的(de)(de)(de)標(biao)(biao)準以外(wai)。但是前提是要(yao)模具(ju)的(de)(de)(de)一(yi)般功能性保證后盡量簡單(dan)，成型拆換(huan)快(kuai)速(su)(su)，減少成本(ben)，方便維(wei)修。）

模具精加工的過程控制：

　　模具五金配(pei)件(jian)的(de)(de)加(jia)(jia)工(gong)，一(yi)(yi)個總的(de)(de)指導思(si)想是(shi)針(zhen)對(dui)不(bu)同的(de)(de)材質，不(bu)同的(de)(de)形狀，不(bu)同的(de)(de)技術要(yao)求進行適(shi)應性加(jia)(jia)工(gong)，它具有一(yi)(yi)定的(de)(de)可(ke)塑(su)性，可(ke)通過對(dui)加(jia)(jia)工(gong)的(de)(de)控制，達到(dao)好的(de)(de)加(jia)(jia)工(gong)效果。

　　根(gen)據配件(jian)(jian)的外(wai)觀形(xing)狀不同，大致可把(ba)配件(jian)(jian)分(fen)三類：軸類、板類與異型配件(jian)(jian)，其共(gong)同的工(gong)(gong)藝過程大致為：粗加(jia)工(gong)(gong)——熱處理(淬火、調質(zhi))——精磨——電加(jia)工(gong)(gong)——鉗工(gong)(gong)(表面(mian)處理)——組(zu)配加(jia)工(gong)(gong)。

五金模具配件電加工控制：

　　慢走絲(si)線切(qie)割加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)精度(du)可(ke)達±0.003mm，粗糙度(du)Ra=0.2μm。加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)開始時，要先(xian)檢(jian)查(cha)機床的(de)狀(zhuang)況，查(cha)看水的(de)去離子度(du)，水溫，絲(si)的(de)垂直度(du)，張力等各個因(yin)素，確保良好的(de)加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)狀(zhuang)態。線切(qie)割加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)是在(zai)一整塊材料上去除加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)，它破壞了工(gong)(gong)(gong)(gong)(gong)(gong)件原有的(de)應(ying)(ying)力平衡，很容(rong)易引起應(ying)(ying)力集中，特(te)別(bie)(bie)是在(zai)拐角處，因(yin)此(ci)當R＜0.2(特(te)別(bie)(bie)是尖角)時，應(ying)(ying)向(xiang)設計(ji)部門(men)提(ti)出改(gai)善(shan)建議。加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)中處理(li)應(ying)(ying)力集中的(de)方法，可(ke)運(yun)用矢(shi)量(liang)(liang)平移原理(li)，精加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)前(qian)先(xian)留余量(liang)(liang)1mm左右，預加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)出大致形狀(zhuang)，然后(hou)再進行熱(re)(re)處理(li)，讓(rang)加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)應(ying)(ying)力在(zai)精加(jia)(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)(gong)前(qian)先(xian)行釋(shi)放(fang)，保證熱(re)(re)穩定(ding)性。

　　加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)凸(tu)模時(shi)，絲的(de)(de)切入(ru)位置及路(lu)(lu)徑的(de)(de)選(xuan)擇要仔細考(kao)慮。工(gong)(gong)(gong)(gong)(gong)件左端夾(jia)持，加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)時(shi)選(xuan)擇路(lu)(lu)線(xian)(xian)(xian)①比(bi)路(lu)(lu)線(xian)(xian)(xian)②要好，因為路(lu)(lu)線(xian)(xian)(xian)①工(gong)(gong)(gong)(gong)(gong)件與材(cai)料的(de)(de)夾(jia)持部位聯(lian)接緊密，加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)穩定，若采(cai)用路(lu)(lu)線(xian)(xian)(xian)②，第(di)一遍進刀后，工(gong)(gong)(gong)(gong)(gong)件成懸壁狀，受力差，影響后續幾遍加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)。路(lu)(lu)線(xian)(xian)(xian)③，采(cai)用打孔穿絲加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)，效果(guo)最佳。高精(jing)線(xian)(xian)(xian)切割加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)，通常切割遍數為四次，可以保證配件質量。當加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)帶(dai)有(you)錐度(du)的(de)(de)凹模時(shi)，本著(zhu)快速高效的(de)(de)立場，第(di)一遍粗加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)直(zhi)邊(bian)，第(di)二邊(bian)錐度(du)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)，接著(zhu)再精(jing)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)直(zhi)邊(bian)，這(zhe)樣(yang)可不需進行X段垂直(zhi)向精(jing)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)，只(zhi)精(jing)加(jia)(jia)(jia)工(gong)(gong)(gong)(gong)(gong)刃口段直(zhi)邊(bian)，既節約時(shi)間又節約成本。

　　電(dian)(dian)(dian)(dian)火(huo)花加(jia)(jia)工(gong)(gong)(gong)先要(yao)制(zhi)(zhi)作電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)，電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)有粗、精之分。精加(jia)(jia)工(gong)(gong)(gong)電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)要(yao)求形(xing)狀(zhuang)符合(he)(he)(he)性好，建議用(yong)CNC數控機床加(jia)(jia)工(gong)(gong)(gong)完(wan)成。電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)的(de)材(cai)質選(xuan)擇上，紫銅電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)主要(yao)用(yong)于一(yi)般(ban)鋼件加(jia)(jia)工(gong)(gong)(gong)。Cu-W合(he)(he)(he)金電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)，綜合(he)(he)(he)性能(neng)好，特別是(shi)加(jia)(jia)工(gong)(gong)(gong)過程中消耗量(liang)明顯比(bi)紫銅小，配合(he)(he)(he)足(zu)量(liang)的(de)沖(chong)刷液(ye)(ye)，很適合(he)(he)(he)難加(jia)(jia)工(gong)(gong)(gong)材(cai)料(liao)加(jia)(jia)工(gong)(gong)(gong)及(ji)(ji)截面形(xing)狀(zhuang)復雜件精加(jia)(jia)工(gong)(gong)(gong)。Ag-W合(he)(he)(he)金電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)比(bi)Cu-W合(he)(he)(he)金電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)性能(neng)更優，但其價(jia)格(ge)高，資源少，一(yi)般(ban)較少采用(yong)。制(zhi)(zhi)作電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)時，需要(yao)計算電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)的(de)間(jian)隙量(liang)及(ji)(ji)電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)數量(liang)，當進行(xing)大面積或重(zhong)電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)加(jia)(jia)工(gong)(gong)(gong)時，工(gong)(gong)(gong)件和電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)裝夾要(yao)牢固，保證(zheng)具有足(zu)夠的(de)強度，防止加(jia)(jia)工(gong)(gong)(gong)松動。進行(xing)深臺階加(jia)(jia)工(gong)(gong)(gong)時，對電(dian)(dian)(dian)(dian)極(ji)(ji)(ji)各處的(de)損耗及(ji)(ji)因(yin)排液(ye)(ye)不(bu)暢引(yin)起的(de)電(dian)(dian)(dian)(dian)弧放電(dian)(dian)(dian)(dian)，要(yao)予以注(zhu)意。

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