鈑(ban)金加(jia)工(gong)(gong)(gong)(gong)被(bei)廣泛應(ying)用在各行(xing)各業(ye)，在中國(guo)機械類加(jia)工(gong)(gong)(gong)(gong)中占有重要地位。隨著(zhu)科學(xue)技(ji)術的飛速(su)發(fa)展(zhan)，鈑(ban)金加(jia)工(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)藝(yi)(yi)也日趨成熟，對其加(jia)工(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)藝(yi)(yi)水(shui)(shui)平也越(yue)來越(yue)高。但在鈑(ban)金加(jia)工(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)藝(yi)(yi)上仍存在許多問(wen)題，影響(xiang)鈑(ban)金加(jia)工(gong)(gong)(gong)(gong)效(xiao)率及(ji)零部件質量。研究掌握問(wen)題產生的根本原因，鈑(ban)金加(jia)工(gong)(gong)(gong)(gong)工(gong)(gong)(gong)(gong)藝(yi)(yi)水(shui)(shui)平才能實(shi)現技(ji)術性的突破(po)。對鈑(ban)金加(jia)工(gong)(gong)(gong)(gong)設計及(ji)工(gong)(gong)(gong)(gong)藝(yi)(yi)進行(xing)簡單介紹，并且提(ti)出(chu)鈑(ban)金加(jia)工(gong)(gong)(gong)(gong)中遇到的難(nan)點及(ji)改進方法，以供參考。

　　一、鈑金加工工藝流程

　　鈑(ban)(ban)金(jin)(jin)(jin)的(de)(de)加(jia)(jia)(jia)(jia)工(gong)(gong)工(gong)(gong)藝是(shi)(shi)將(jiang)金(jin)(jin)(jin)屬薄板件(jian)借助機械設(she)備(bei)的(de)(de)作(zuo)用，制成所要(yao)(yao)求的(de)(de)形狀和尺寸，或(huo)通(tong)(tong)過焊接或(huo)者機械加(jia)(jia)(jia)(jia)工(gong)(gong)，使(shi)其形成更加(jia)(jia)(jia)(jia)復雜(za)的(de)(de)形狀[]。鈑(ban)(ban)金(jin)(jin)(jin)加(jia)(jia)(jia)(jia)工(gong)(gong)方法(fa)主要(yao)(yao)有(you)：①通(tong)(tong)過數控設(she)備(bei)（激光切割機、剪板機、折彎(wan)機）對鈑(ban)(ban)金(jin)(jin)(jin)進(jin)(jin)行加(jia)(jia)(jia)(jia)工(gong)(gong)制作(zuo)，主要(yao)(yao)用在小批量(liang)生產(chan)的(de)(de)零件(jian)中，成本(ben)較高。②模(mo)具成型(xing)(xing)。通(tong)(tong)過模(mo)具加(jia)(jia)(jia)(jia)壓成型(xing)(xing)，進(jin)(jin)行修邊(bian)沖(chong)孔及整型(xing)(xing)，達(da)到零件(jian)要(yao)(yao)求，一般有(you)沖(chong)裁(cai)模(mo)、拉延模(mo)、整型(xing)(xing)模(mo)、修邊(bian)沖(chong)孔模(mo)，主要(yao)(yao)用于大(da)批量(liang)生產(chan)，成本(ben)較低。鈑(ban)(ban)金(jin)(jin)(jin)加(jia)(jia)(jia)(jia)工(gong)(gong)工(gong)(gong)藝大(da)致分為3個過程(cheng)：①下料過程(cheng)是(shi)(shi)對材料初(chu)加(jia)(jia)(jia)(jia)工(gong)(gong)的(de)(de)過程(cheng)；②使(shi)用折彎(wan)、焊接設(she)備(bei)或(huo)模(mo)具，使(shi)零件(jian)加(jia)(jia)(jia)(jia)工(gong)(gong)成型(xing)(xing)；③對產(chan)品表(biao)面進(jin)(jin)行處(chu)理(li)，延長其使(shi)用壽命(ming)。

　　二、鈑金設計要點及改進方法

　　1．沖(chong)裁、激光切割

　　合理(li)設計鈑(ban)金形狀，結(jie)構(gou)形狀要(yao)簡單(dan)對(dui)稱，減少(shao)排版時的(de)廢料(liao)(liao)(liao)，提高材(cai)料(liao)(liao)(liao)利用率。鈑(ban)金件(jian)外內部(bu)(bu)不(bu)(bu)(bu)要(yao)出(chu)(chu)現尖(jian)角(jiao)(jiao)，要(yao)有圓(yuan)弧瓜過(guo)(guo)渡連(lian)接，其(qi)(qi)要(yao)求(qiu)≥0.5t，其(qi)(qi)中為材(cai)料(liao)(liao)(liao)壁(bi)厚，避免(mian)尖(jian)角(jiao)(jiao)，沖(chong)(chong)裁(cai)件(jian)圓(yuan)角(jiao)(jiao)半(ban)徑的(de)最小(xiao)值(zhi)如圖所示。安(an)全因素：鈑(ban)金外部(bu)(bu)尖(jian)角(jiao)(jiao)鋒(feng)利，容易(yi)使操作人(ren)員或(huo)用戶劃傷手指。沖(chong)(chong)壓模(mo)具(ju)因素：鈑(ban)金的(de)尖(jian)角(jiao)(jiao)對(dui)應(ying)在模(mo)具(ju)上也是(shi)尖(jian)角(jiao)(jiao)，模(mo)具(ju)凹(ao)模(mo)上的(de)尖(jian)角(jiao)(jiao)加工困難，同時熱處理(li)時極(ji)易(yi)開裂(lie)，沖(chong)(chong)裁(cai)時尖(jian)角(jiao)(jiao)處容易(yi)萌(meng)刃和(he)過(guo)(guo)快磨損，造成模(mo)具(ju)壽(shou)命(ming)降低。沖(chong)(chong)孔間距與(yu)孔邊(bian)距要(yao)求(qiu)：零(ling)件(jian)沖(chong)(chong)孔距邊(bian)的(de)最小(xiao)距離隨零(ling)件(jian)與(yu)孔的(de)形狀不(bu)(bu)(bu)同而(er)變化。當沖(chong)(chong)孔邊(bian)緣與(yu)零(ling)件(jian)外形邊(bian)緣不(bu)(bu)(bu)平(ping)行時，其(qi)(qi)最小(xiao)距離應(ying)不(bu)(bu)(bu)小(xiao)于(yu)(yu)材(cai)料(liao)(liao)(liao)厚度(du)(du)；平(ping)行時，其(qi)(qi)最小(xiao)距離應(ying)不(bu)(bu)(bu)小(xiao)于(yu)(yu)1.5倍料(liao)(liao)(liao)厚。沖(chong)(chong)裁(cai)件(jian)的(de)凸出(chu)(chu)或(huo)凹(ao)入部(bu)(bu)分(fen)的(de)深(shen)度(du)(du)和(he)寬度(du)(du)，一般情況下，應(ying)不(bu)(bu)(bu)小(xiao)于(yu)(yu)1.5倍料(liao)(liao)(liao)厚，同時應(ying)該(gai)避免(mian)窄(zhai)長的(de)切(qie)口(kou)與(yu)和(he)過(guo)(guo)窄(zhai)的(de)切(qie)槽(cao)，以便增大模(mo)具(ju)相(xiang)應(ying)部(bu)(bu)位(wei)的(de)刃口(kou)強度(du)(du)。

　　2.折彎

　　拉伸件(jian)(jian)(jian)沖(chong)孔(kong)(kong)時(shi)(shi)，其孔(kong)(kong)壁(bi)與(yu)直壁(bi)之間應保(bao)持一(yi)定的(de)(de)(de)(de)距離(li)，防(fang)止孔(kong)(kong)變(bian)形，如(ru)圖(tu)所示。折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)件(jian)(jian)(jian)的(de)(de)(de)(de)高(gao)(gao)度(du)(du)：設(she)計時(shi)(shi)折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)件(jian)(jian)(jian)的(de)(de)(de)(de)高(gao)(gao)度(du)(du)不宜太小(xiao)，設(she)計最小(xiao)高(gao)(gao)度(du)(du)按要(yao)求(qiu)h>R+2t,即大(da)于(yu)2倍的(de)(de)(de)(de)料(liao)(liao)厚加(jia)(jia)(jia)內測(ce)折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)半徑(jing)R。彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)邊(bian)(bian)(bian)(bian)(bian)側(ce)邊(bian)(bian)(bian)(bian)(bian)帶有(you)斜角(jiao)(jiao)(jiao)的(de)(de)(de)(de)直邊(bian)(bian)(bian)(bian)(bian)高(gao)(gao)度(du)(du)：當彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)邊(bian)(bian)(bian)(bian)(bian)側(ce)邊(bian)(bian)(bian)(bian)(bian)帶有(you)斜角(jiao)(jiao)(jiao)的(de)(de)(de)(de)折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)件(jian)(jian)(jian)時(shi)(shi)，側(ce)面(mian)的(de)(de)(de)(de)最小(xiao)高(gao)(gao)度(du)(du)h=(2~4)t>3mm,即最小(xiao)高(gao)(gao)度(du)(du)等于(yu)2~3倍的(de)(de)(de)(de)料(liao)(liao)厚，必須大(da)于(yu)3m。折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)件(jian)(jian)(jian)的(de)(de)(de)(de)最小(xiao)子(zi)孔(kong)(kong)邊(bian)(bian)(bian)(bian)(bian)距：折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)件(jian)(jian)(jian)上的(de)(de)(de)(de)子(zi)孔(kong)(kong)加(jia)(jia)(jia)工方(fang)(fang)(fang)式有(you)2種，先折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)后沖(chong)孔(kong)(kong)邊(bian)(bian)(bian)(bian)(bian)距的(de)(de)(de)(de)設(she)計參(can)照拉伸件(jian)(jian)(jian)的(de)(de)(de)(de)要(yao)求(qiu)，先沖(chong)孔(kong)(kong)后折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)應讓孔(kong)(kong)處(chu)于(yu)變(bian)形區外側(ce)，否則造(zao)成孔(kong)(kong)的(de)(de)(de)(de)變(bian)形及(ji)開孔(kong)(kong)處(chu)易(yi)裂，按圖(tu)2的(de)(de)(de)(de)要(yao)求(qiu)進(jin)行設(she)計。局(ju)部折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)的(de)(de)(de)(de)工藝切(qie)口：折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)某一(yi)段(duan)邊(bian)(bian)(bian)(bian)(bian)緣時(shi)(shi)，為(wei)了防(fang)止尖(jian)角(jiao)(jiao)(jiao)處(chu)應力集中(zhong)產(chan)生裂紋，或者折(zhe)(zhe)(zhe)(zhe)不起來(lai)，可(ke)將折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)線移(yi)動一(yi)定距離(li)，以離(li)開尺寸突變(bian)處(chu)，或開工藝槽。防(fang)止圓角(jiao)(jiao)(jiao)在(zai)(zai)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)曲時(shi)(shi)受壓產(chan)生擠料(liao)(liao)后起皺，應預(yu)留切(qie)口。鈑金的(de)(de)(de)(de)折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)方(fang)(fang)(fang)向盡量垂(chui)直于(yu)材料(liao)(liao)的(de)(de)(de)(de)纖(xian)維方(fang)(fang)(fang)向。板(ban)材或卷料(liao)(liao)軋制(zhi)方(fang)(fang)(fang)向，一(yi)般指板(ban)材的(de)(de)(de)(de)長度(du)(du)方(fang)(fang)(fang)向，在(zai)(zai)下料(liao)(liao)時(shi)(shi)，可(ke)提(ti)前在(zai)(zai)板(ban)材標記纖(xian)維方(fang)(fang)(fang)向，防(fang)止折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)混淆。鈑金展開及(ji)折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)時(shi)(shi)，避(bi)免(mian)材料(liao)(liao)干涉。多重(zhong)折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)上的(de)(de)(de)(de)孔(kong)(kong)設(she)計要(yao)求(qiu)如(ru)圖(tu)3所示。提(ti)高(gao)(gao)鈑金件(jian)(jian)(jian)的(de)(de)(de)(de)強度(du)(du)設(she)計，避(bi)免(mian)平板(ban)。在(zai)(zai)產(chan)品表(biao)面(mian)上壓凹(ao)凸加(jia)(jia)(jia)強筋(jin)，有(you)助于(yu)增加(jia)(jia)(jia)產(chan)品結構的(de)(de)(de)(de)剛性和強度(du)(du)，減少變(bian)形。增加(jia)(jia)(jia)加(jia)(jia)(jia)強筋(jin)、折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)、翻(fan)邊(bian)(bian)(bian)(bian)(bian)、壓平（死邊(bian)(bian)(bian)(bian)(bian)）、三角(jiao)(jiao)(jiao)筋(jin)及(ji)孔(kong)(kong)翻(fan)邊(bian)(bian)(bian)(bian)(bian)等。零件(jian)(jian)(jian)避(bi)免(mian)復雜(za)的(de)(de)(de)(de)折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)，考慮折(zhe)(zhe)(zhe)(zhe)彎(wan)(wan)(wan)(wan)(wan)(wan)(wan)刀(dao)具、省料(liao)(liao)等方(fang)(fang)(fang)面(mian)進(jin)行設(she)計。

　　在鈑(ban)(ban)金設計時(shi)，應(ying)正確認識鈑(ban)(ban)金加工(gong)(gong)的(de)基本流程，立足于加工(gong)(gong)難點，采取(qu)有(you)效的(de)改進方法，不斷優化和(he)(he)創新(xin)，提高加工(gong)(gong)質(zhi)量和(he)(he)效率，最終實現(xian)加工(gong)(gong)技術性的(de)突破。