現(xian)模模具(ju)是工業生產(chan)的(de)(de)主要(yao)工藝裝備。現(xian)代(dai)工業產(chan)品的(de)(de)發展(zhan)和技術(shu)水平的(de)(de)提高，很大程度上取決于(yu)模具(ju)工業的(de)(de)發展(zhan)水平。我國(guo)雖(sui)是模具(ju)生產(chan)大國(guo),卻過不是模具(ju)制造強國(guo)。對與(yu)于(yu)模具(ju)相配的(de)(de)彈簧，此細(xi)節卻也是成就(jiu)品質的(de)(de)關(guan)鍵。影響(xiang)整套模具(ju)的(de)(de)使(shi)用性能(neng)。彈簧表(biao)(biao)(biao)面采用各(ge)(ge)種(zhong)漆(qi)層來(lai)代(dai)作識(shi)別，如輕小荷重用黃色(se)漆(qi)表(biao)(biao)(biao)示(shi)(shi);輕荷重用藍色(se)漆(qi)表(biao)(biao)(biao)示(shi)(shi);中(zhong)荷重用紅色(se)漆(qi)表(biao)(biao)(biao)示(shi)(shi);極重荷重用咖啡色(se)漆(qi)表(biao)(biao)(biao)示(shi)(shi);性能(neng)分析:好的(de)(de)漆(qi)層來(lai)配套彈簧表(biao)(biao)(biao)面處理，可謂一舉兩得(de)，用顏色(se)來(lai)標識(shi)各(ge)(ge)種(zhong)技術(shu)參(can)數，方(fang)便(bian)工業生產(chan)操作，而且(qie)使(shi)彈簧表(biao)(biao)(biao)面的(de)(de)防腐性能(neng)得(de)以(yi)更好的(de)(de)保證。目前成功(gong)使(shi)用上述方(fang)式(shi)的(de)(de)主要(yao)廠家(jia)為國(guo)外廠家(jia)多，如日本東發公司等。

　　在(zai)國(guo)(guo)(guo)內，此還只有小(xiao)(xiao)部分(fen)廠(chang)家(jia)效(xiao)訪，目(mu)前主要(yao)是一(yi)些固(gu)定(ding)(ding)的(de)(de)技術要(yao)求，如(ru)采用進口材料而(er)達到國(guo)(guo)(guo)外(wai)(wai)水平(ping)外(wai)(wai)，但(dan)整(zheng)個彈(dan)(dan)(dan)簧(huang)(huang)表(biao)面(mian)處(chu)理效(xiao)果(guo)卻明顯存在(zai)差距。國(guo)(guo)(guo)內一(yi)般用人工噴漆(qi)，外(wai)(wai)觀會出現流(liu)掛、漏噴、結(jie)(jie)合不好(hao)，防(fang)銹能力差。本身的(de)(de)工藝局限性(xing)造成大量的(de)(de)產品要(yao)脫(tuo)(tuo)漆(qi)返工。國(guo)(guo)(guo)外(wai)(wai)采用的(de)(de)是電(dian)(dian)泳漆(qi)，在(zai)水溶性(xing)的(de)(de)漆(qi)槽內，把工件(jian)做陰極(ji)，施加(jia)一(yi)定(ding)(ding)的(de)(de)電(dian)(dian)壓和(he)時間(jian)，便可(ke)在(zai)彈(dan)(dan)(dan)簧(huang)(huang)的(de)(de)所(suo)有表(biao)面(mian)形成厚(hou)(hou)度均勻的(de)(de)漆(qi)層(ceng)，然后清(qing)洗(xi)烘干(gan)便可(ke)。其外(wai)(wai)觀清(qing)潔光(guang)亮(liang)，無顆(ke)粒，無露底現象，結(jie)(jie)合力好(hao)不易脫(tuo)(tuo)落，硬度好(hao)有3-4H，如(ru)果(guo)采用英國(guo)(guo)(guo)LVH公司聚氨(an)酯陰極(ji)電(dian)(dian)泳漆(qi)，則(ze)其柔軟性(xing)相當好(hao)。操作環境無濃的(de)(de)溶劑味，對空(kong)氣污(wu)染少(shao)，廢(fei)水處(chu)理排放流(liu)程簡易，只要(yao)調節PH沉降(jiang)電(dian)(dian)泳漆(qi)的(de)(de)樹脂，然后排放清(qing)水。我們為國(guo)(guo)(guo)內一(yi)廠(chang)家(jia)設計工藝流(liu)程:成形彈(dan)(dan)(dan)簧(huang)(huang)→噴丸→→上掛具(ju)→堿(jian)性(xing)除油→雙(shuang)(shuang)水洗(xi)→(微酸1%中和(he))磷(lin)化(hua)→雙(shuang)(shuang)水洗(xi)→雙(shuang)(shuang)去離子(zi)水洗(xi)→陰極(ji)系統(tong)聚氨(an)酯彩色電(dian)(dian)泳漆(qi)→回(hui)收→雙(shuang)(shuang)水洗(xi)→助洗(xi)→烘烤(kao)固(gu)化(hua)→下掛具(ju)。結(jie)(jie)果(guo):噴丸的(de)(de)粒子(zi)會夾在(zai)彈(dan)(dan)(dan)簧(huang)(huang)的(de)(de)兩頭的(de)(de)縫隙(xi)內。噴丸導致(zhi)(zhi)粗糙表(biao)面(mian)，漆(qi)層(ceng)也要(yao)相應(ying)地加(jia)厚(hou)(hou)，才有光(guang)亮(liang)平(ping)整(zheng)外(wai)(wai)觀，有10-20微米(mi)厚(hou)(hou)，這樣又導致(zhi)(zhi)彈(dan)(dan)(dan)簧(huang)(huang)的(de)(de)可(ke)收縮厚(hou)(hou)度變小(xiao)(xiao)。磷(lin)化(hua)會導致(zhi)(zhi)氫(qing)脆(cui)，減少(shao)彈(dan)(dan)(dan)簧(huang)(huang)的(de)(de)使用壽命。

　　改進流程(cheng):成形(xing)彈(dan)(dan)簧→堿液光飾除油→離心摔水→上(shang)(shang)掛→堿性(xing)除油→雙(shuang)(shuang)水洗(xi)→(微酸(suan)(suan)(suan)中和1%)磷化(hua)(hua)(hua)→雙(shuang)(shuang)水洗(xi)→雙(shuang)(shuang)去(qu)離子水洗(xi)→陰(yin)極系統(tong)聚(ju)氨酯彩(cai)色電泳(yong)漆(qi)(qi)(qi)(qi)→回收→雙(shuang)(shuang)水洗(xi)→助(zhu)洗(xi)→烘(hong)烤固化(hua)(hua)(hua)→下掛具。分析:光飾(整(zheng))工(gong)(gong)(gong)(gong)藝(yi)是(shi)(shi)將(jiang)彈(dan)(dan)簧直(zhi)接(jie)放(fang)入傾斜離心式(shi)或者螺旋振動(dong)式(shi)、渦(wo)流式(shi)等系列的(de)(de)(de)光飾機中，并(bing)加入適(shi)量(liang)的(de)(de)(de)研磨料、研磨劑和水，進行光整(zheng)加工(gong)(gong)(gong)(gong)。光飾后(hou)的(de)(de)(de)表面(mian)(mian)比(bi)噴(pen)丸(wan)(wan)的(de)(de)(de)表面(mian)(mian)更光潔。而且(qie)減少傳統(tong)工(gong)(gong)(gong)(gong)藝(yi)如(ru)如(ru)去(qu)油、清(qing)洗(xi)、酸(suan)(suan)(suan)洗(xi)、磷化(hua)(hua)(hua)、去(qu)氫等，生產(chan)工(gong)(gong)(gong)(gong)序簡化(hua)(hua)(hua)，彈(dan)(dan)簧在生產(chan)過程(cheng)的(de)(de)(de)銹蝕機會(hui)少，不(bu)(bu)用(yong)(yong)(yong)(yong)酸(suan)(suan)(suan)洗(xi)。在表面(mian)(mian)上(shang)(shang)漆(qi)(qi)(qi)(qi)的(de)(de)(de)厚度(du)就(jiu)可控制在10微米左(zuo)右。筆者采(cai)用(yong)(yong)(yong)(yong)浩(hao)金精細(xi)化(hua)(hua)(hua)工(gong)(gong)(gong)(gong)(上(shang)(shang)海)有(you)限公(gong)司的(de)(de)(de)吉利(li)隆陰(yin)極電泳(yong)漆(qi)(qi)(qi)(qi)作(zuo)實驗(yan)。其(qi)各方(fang)面(mian)(mian)性(xing)能較佳(jia)且(qie)涂覆率(lv):當涂層為10微米時，每公(gong)斤漆(qi)(qi)(qi)(qi)可涂覆45-50個平方(fang)米。鹽(yan)霧測試:500-1000H。但(dan)(dan)減去(qu)噴(pen)丸(wan)(wan)工(gong)(gong)(gong)(gong)序可能會(hui)使彈(dan)(dan)簧本(ben)身(shen)的(de)(de)(de)強度(du)降低，最(zui)好是(shi)(shi)根(gen)據不(bu)(bu)同彈(dan)(dan)簧規格，如(ru)間隙的(de)(de)(de)大小(xiao)，選擇合(he)適(shi)直(zhi)徑大小(xiao)的(de)(de)(de)鋼丸(wan)(wan)，避免(mian)鋼丸(wan)(wan)夾于彈(dan)(dan)簧縫隙。不(bu)(bu)合(he)格的(de)(de)(de)漆(qi)(qi)(qi)(qi)層退除方(fang)法:目前有(you)的(de)(de)(de)工(gong)(gong)(gong)(gong)廠采(cai)用(yong)(yong)(yong)(yong)油燒漆(qi)(qi)(qi)(qi)層，然后(hou)再用(yong)(yong)(yong)(yong)噴(pen)丸(wan)(wan)清(qing)潔表面(mian)(mian)，但(dan)(dan)操作(zuo)過程(cheng)造污染(ran)相(xiang)當大，而且(qie)人工(gong)(gong)(gong)(gong)操作(zuo)過程(cheng)中易出現火情(qing)。用(yong)(yong)(yong)(yong)濃硫酸(suan)(suan)(suan)碳(tan)化(hua)(hua)(hua)漆(qi)(qi)(qi)(qi)漆(qi)(qi)(qi)(qi)層，但(dan)(dan)強酸(suan)(suan)(suan)本(ben)身(shen)會(hui)導致氫脆，不(bu)(bu)適(shi)用(yong)(yong)(yong)(yong)彈(dan)(dan)簧。采(cai)用(yong)(yong)(yong)(yong)KRT脫(tuo)漆(qi)(qi)(qi)(qi)劑，用(yong)(yong)(yong)(yong)溶(rong)漲方(fang)法，剝(bo)離漆(qi)(qi)(qi)(qi)層，不(bu)(bu)傷彈(dan)(dan)簧基體，操作(zuo)簡單，是(shi)(shi)比(bi)較先進的(de)(de)(de)方(fang)法，但(dan)(dan)使用(yong)(yong)(yong)(yong)商品的(de)(de)(de)脫(tuo)漆(qi)(qi)(qi)(qi)劑可能會(hui)導致成本(ben)上(shang)(shang)升(sheng)，但(dan)(dan)如(ru)果減免(mian)了報廢(fei)率(lv)，總體成本(ben)倒不(bu)(bu)會(hui)上(shang)(shang)升(sheng)。