折彎作業(yè)指導書

1、株洲天勝機電設備有限作業(yè)指導書文件編號TS/QS06.04-2015文件版本A發(fā)放編號受控標識折彎通用作業(yè)指導書編 制日 期審 核日 期批 準日 期20150107發(fā)布 20110108實施折彎通用作業(yè)指導書TS/QS06.04-2015 版本狀態(tài)：A株洲天勝機電設備有限公司作業(yè)指導書一 適用范圍本公司鉗工工序所使用液壓折彎機、手動折彎機、以及手工使用錘子等工具折彎工件的工序二 作業(yè)前準備1使用液壓折彎機加工，必須熟悉折彎機操作規(guī)程，熟悉機床操作。2核對圖紙和所要加工工件相符合，包括尺寸、厚度、材質等，以及確認工藝單上所要求折彎前的工序如鉆（沉）孔、去毛刺等。3工作前確認機床正常，模具刀具無誤

2、。詳細參考折彎工藝規(guī)程。4. 對折彎印痕有嚴格要求的產(chǎn)品（例如：TE003銅排系列，TE6112不銹鋼系列等），在折彎時墊防壓痕保護膜保證產(chǎn)品外觀無折彎壓痕。三工作內容1使用靠模定位或者劃線、量尺定位。2試彎。保證精度符合公差要求。3自檢。確認靠模無誤。4按圖加工四工藝規(guī)程1彎曲過程:一般彎曲過程可分為二個階段:工件在外力作用下僅產(chǎn)生幾何變形的階段,稱之為自由彎曲.當外力超過材料的屈服極限,工件就開始產(chǎn)生塑性變形,一直到工件成型的這個階段,就稱為拉伸彎曲.2最小彎曲半徑與材料的纖維方向:不同的材料具有不同的最小彎曲半徑.見<表24>表24 各種材料的最小彎曲半徑表材 料退火的或正火

3、的冷作硬化的彎 曲 線 位 置垂直纖維平行纖維垂直纖維平行纖維0.8,100.1t0.4 t0.4 t0.8 t15,200.1t0.5 t0.5 t1 t25,300.2 t0.6 t0.6 t1.2 t35,400.3 t0.8 t0.8 t1.5 t45,500.5 t1 t1 t1.7 t55,600.7 t1.3 t1.3 t2 t磷銅1 t3 t半硬黃銅0.1 t0.35 t0.5 t1.2 t軟黃銅0.1 t0.35 t0.35 t0.8 t紫銅0.1 t0.35 t1 t2 t鋁0.1 t0.35 t0.5 t1.0 t注:當彎曲線與纖維方向成一定角度時,可采用垂直和平行纖維方

4、向二者的中間數(shù)值.中沖載或剪裁后沒有退火的毛料應作為硬化的金屬選用.彎曲時應使有毛刺的一邊處于彎角的內側.表中t為板料厚度.從上表可以看出同一種材料的不同纖維方向的最小彎曲半徑也不相同.因此折彎時(特別是小彎曲角時)要特別注意材料的纖維方向.3展開算料:展開算料是鉚工和從事展開下料工種的最基本要求的常知,一般展開算料的方法有以下幾種: 按薄板中性層位置的計算方法中性層彎曲半徑:Ro=r + Xo(1)式中Xo中性層位置系數(shù)。薄板厚度。R彎曲半徑。中性層位置系數(shù)Xo按t/查表25得出。表25 中性層位置系數(shù)表r/0.250.50.812345678101214Xo0.20.250.30.350.

5、370.40.410.430.440.450.460.470.480.50 薄板/4圓弧的展開長度Y=(r+Xo)/2(2)或Y=(R-+Xo)/2 (3)薄板/4圓弧的展開長度Y值可查表26得出。表26 薄板1/4圓弧展開長度表（y） mmrR(r)0.50.81.01.21.52.02.53.0內徑外徑內徑外徑內徑外徑內徑外徑內徑外徑內徑外徑內徑外徑內徑外徑11.872.012.122.1423.472.673.632.343.732.123.831.783.9835.064.265.303.955.343.735.413.515.625.856.1146.645.856.025.956.

6、945.347.055.117.214.837.467.723.537.9858.227.448.417.148.536.948.646.718.816.449.075.859.345.229.5869.809.0110.008.7310.128.5310.248.3110.408.0310.687.4610.947.1111.19711.3910.6011.5810.3111.7010.1211.829.9012.009.6312.279.0712.558.7212.807.98812.9612.1713.1611.8913.2911.7013.4111.4913.5911.2213.871

7、0.6814.1510.3314.419.58914.5313.7414.7413.7414.8713.2914.9913.0815.1712.8115.4612.2715.7411.7816.0211.191016.1015.3216.3415.0516.4514.8716.5014.6716.7614.4017.0613.8717.3413.3817.6112.801117.6716.8017.9116.6318.0316.4518.1616.2518.3615.9818.6515.4618.9314.9719.2114.411219.2418.4619.4818.2219.6018.03

8、19.7417.8319.9317.5220.2317.0620.5316.5620.8116.021320.8120.0921.0619.7921.2119.6021.3119.4121.5119.1521.8218.6522.1218.1622.3917.611422.3821.6022.6221.3622.7821.2122.0921.0023.0920.7323.4020.2323.7019.7523.9919.211523.9523.1724.1922.9824.3522.7824.5022.5724.6722.3124.9921.8225.3021.3425.5920.811625

9、.5324.7425.7624.9825.9224.3626.0024.1526.2523.8926.5723.4026.8822.9327.1722.391727.1026.3127.3326.0827.4925.9227.6525.7627.8325.4728.1624.9928.4624.5128.7623.991820.6727.8828.9027.6529.0627.4929.2227.3329.4127.0629.7426.5730.0526.1030.3525.591930.2429.4530.4729.2230.6329.0630.7928.9031.2028.6531.312

10、8.1631.7927.6831.9327.172031.8131.0232.0430.7932.2030.6332.3630.4732.5930.2433.0529.7433.2229.2733.5228.722133.3832.5933.6232.2633.7732.2033.9832.0434.1631.8134.6331.3134.8030.8836.2630.352234.9534.1635.1933.9335.3433.7735.5033.6235.7433.3836.2133.0536.3832.4436.8531.932336.5235.7436.7636.5036.9136.

11、3437.6736.1937.3134.9537.7834.6337.9634.0238.4433.522438.0037.3138.3037.0738.4836.9138.6436.7638.6036.5239.3636.2139.5436.5440.0235.262539.6638.8039.7038.6440.0638.4840.2138.3340.4538.0940.8437.7041.1237.3341.6036.852641.2340.4641.4770.2141.6340.0641.7339.9042.0239.6642.4139.3642.6938.9143.1838.4427

12、42.8042.0243.0441.7843.2041.6343.3341.4743.5941.2343.9840.8444.2740.4844.7640.022844.3843.5944.6143.3644.7043.2044.9243.6445.1642.8846.5542.4145.8541.9146.3441.602945.9545.1646.1844.9246.3444.7046.5044.6146.7344.3847.1243.9847.4343.4947.7643.183047.5246.7347.7546.5047.9146.3448.0746.1848.3045.9548.6

13、945.9549.0145.0749.3444.76注:內徑項值為按內徑r所查得的值:外徑項值為按外徑R值所查得的值.當彎曲半徑的尾數(shù)為0.5時,則應按查表系數(shù)加0.79. 按薄鈑折彎系數(shù)的計算方法:展開長度計算公式:Y=a+b+x(4)式中:x=薄鈑折彎系數(shù).可查表27得出.表27 薄鈑折彎系數(shù)表(x) mmrx0.10.20.30.40.50.811.21.522.534568100.30.1250.100.070.0350-0.125-0.21-0.3-0.42-0.64-0.85-1.05-1.5-1.9-2.34-3.2-4.070.40.100.150.120.080.05-0.0

14、6-0.14-0.22-0.35-0.56-0.78-1.0-1.4-1.84-2.35-3.1-4.00.50.220.200.180.150.120-1.07-0.36-0.28-0.48-0.7-0.9-1.34-1.79-2.2-3.0-3.90.80.370.350.330.310.200.100.110.04-0.07-0.3-0.5-0.7-1.12-1.57-1.96-2.8-3.661.00.460.450.430.410.380.30.230.150.05-0.14-0.35-0.57-0.96-1.38-1.82-2.66-3.51.20.560.550.530.510.

15、430.40.360.250.15-0.01-0.23-0.45-0.82-1.25-1.67-2.52-3.381.50.700.680.670.660.630.560.500.460.350.15-0.02-0.21-0.62-1.02-1.47-2.3-3.722.00.930.920.910.890.380.010.760.700.620.460.280.09-0.27-0.68-1.10-1.93-2.782.51.21.301.161.151.131.071.040.960.880.750.570.390.05-0.35-0.75-1.60-2.453.01.421.401.391

16、.381.361.321.261.201.131.00.870.690.35-0.02-0.4-1.25-2.2注:粗折線之左其值為正,粗折線之右其值為負.在其角折彎時,對于比較厚的鋼板和鋁板的伸長系數(shù)略有不同.鋼板折彎系數(shù)與鋁板折彎系數(shù)的對比:可參見表28.表28 鋼板和鋁板折彎系數(shù)對比表 mm厚度材料0.50.811.21.522.53鋼板0.120.180.230.250.350.460.570.69鋁板0.280.400.600.901.051.25 折彎零件展開長度計算公式表:見表29表29 折彎零件展開長度計算公式表序號零件彎曲程度草圖公式1一端變成90°角L=a+b+(

17、r+x)/22兩端變成90°角L=a+b+c+(r+x)3變成四個90°角L=2a+2b+c+(r1+x1)+(r2+x2)4折彎操作：正確選取凸凹模:根據(jù)工件的板厚,折彎角及折彎尺寸選取適當?shù)耐拱寄?此外還要遵守某些設備(如進口折彎機)對凸凹模使用的具體規(guī)定.凹模開口選擇普通折彎機標準為板厚的8倍數(shù)控標準為6倍。（薄板折彎大R時需按照展開料選擇凹模）定位:根據(jù)折彎尺寸定位.確定折彎順序:某些工件需折彎幾道,因此必須選取正確的折彎順序,才能折出每一道彎.試壓:根據(jù)工件有有板厚和寬度估算適當?shù)恼蹚潐毫?然后試壓.試壓后檢查工件尺寸.調整參數(shù):根據(jù)試壓的結果調整定位,折彎壓力等

18、參數(shù),直到折出合格的產(chǎn)品.整形:折彎后某些工件需要適當?shù)倪M行整形,如折彎角的垂直度等. 5凸凹模選取原則:凸模圓角半徑按圖紙規(guī)定選取.凹模開口尺寸S按<表30>選取:3 不銹鋼材料壓力計算P=650x（Sx1.5）²xL/V凹模選擇需盡量用大點以減少受力表30 凹模選擇表 V下模寬度R角度B最小尺寸板厚t0.50.81.01.21.51.822.5345678940.72.64010581.55.2205580115180101.76.5416595145210260122.7.85580120175215335162.710.46090130160250360203.4

19、1375105130200290520254.2168510516023041064030520N/mm2650xS²xL/V14019034054077035623170300460660407261502604005801030457.529230360520910508.5322103204808201230553004207501170折彎大R時盡量選擇開口寬一點的下模以減少壓力 下模槽口的選擇:數(shù)控折彎機V=Sx6，普通折彎機V=Sx8,文 件 更 改 記 錄更改單號更改標記更 改 項更改日期更 改 者折彎操作紅色折彎操作49.24楚德年提 出日 期審 核日 期批 準日 期

20、 折彎參考系數(shù)表 一.下表僅適用于本公司計算展開料用(適用材料:冷、熱軋板) 二.選擇刀片時應嚴格對照下表選相應的槽寬 三.計算展開長的方式 例: 5.0以上的板厚 畫圖測量 測量辦法：折彎內引邊板厚的0.4部分畫線，得展開周長 展開長=A+B-板厚*1.75 （3MM以下） 計算公式:A+B-C=展開長 折銳角多減一個料厚、折鈍角少減一個料厚 公式中C表示直接系數(shù),依照產(chǎn)品的板厚及R角,在下表中查找系數(shù)板厚 刀片T1T1.2T1.5T2.0T2.5T3.0 T4.0T5.0直接系數(shù)槽寬直接系數(shù)槽寬直接系數(shù)槽寬直接系數(shù)槽寬直接系數(shù)槽寬直接系數(shù)槽寬直接系數(shù)槽寬直接系數(shù)槽寬R0.51.7661.9862.6793.28114.3613