What are the common faults of metal stamping parts?

According to the practical experience of quality management in our company’s stamping plant, the reasons and countermeasures for common problems in the production process of metal stamping parts are summarized, hoping to provide a useful reference for improving the quality of parts in the stamping plant.

1. Why do metal stamping parts appear twisted?

The stamping part is formed by punching the remaining material around the stamping part in the progressive die to form the shape of the stamping part. The main reason for flanging and twisting of stamping parts is the influence of blanking force. During punching, due to the existence of the punching gap, the material is stretched on the die side (the material is warped upward) and compressed on the die side. When using a stripper, press the material with the stripper to prevent the material on the die side from warping upwards. At this time, the stress state of the material also changes accordingly. As the stripper pressure increases, the material on the punch side is stretched (the pressure tends to decrease), while the material on the die surface is compressed (the tension tends to decrease). The reversal of the stamping is caused by the stretching of the material on the die surface. Therefore, when punching, pressing the material is the key to preventing the punch from flipping and twisting. Causes and countermeasures of flanging and twisting when stamping parts are bent.

It is caused by the burrs of the blanking parts during blanking. It is necessary to study the punching edge, and pay attention to check whether the punching gap is reasonable.

During the blanking process, flanging and deformation of the blanking parts occur, resulting in poor forming after bending, which needs to be solved from the blanking and blanking station.

Stamping parts are unstable during bending and are mainly used for U-shaped and V-shaped bending. In response to this problem, the key to solving the problem is to guide the position before bending, guide during the bending process, and press the material during the bending process to prevent the stamping parts from slipping during the bending process.

How to reduce the concave and convex problem of metal stamping parts?

1. Five methods to reduce the concave and convex of stamping parts

1. Inspection and correction of drawing dies: Everyone should know that drawing dies need to be inspected and maintained regularly to avoid reducing the production of convex and concave and maintain a stable state. The usual practice is to use samples to check the bonding scratches of the blank holder and the condition of the machined surface (concave die fillet, punch die fillet).

2. Inspection and correction of the shearing die: The reason for the concave and convex after the shearing process is that iron powder is generated during the shearing process. The iron powder must be observed before stamping to avoid the occurrence of convex and concave.

3. Appropriate manipulator speed: For the production of semi-automatic drawing molds, when the drawing mold is in the lower mold position and the manipulator speed is fast, the burr will fall on the upper part of the punch, resulting in unevenness. In order to avoid this problem, we can carry out the part discharge test before production, and set the speed and discharge angle of the manipulator reasonably to avoid contact with the parts and the die.

4. Check the cut surface: When cutting the material, the wear and damage of the cut die will produce a large amount of small iron powder attached to the cutting edge. Therefore, before stamping production, it is necessary to check the secondary cut surface in the material area or stamping line, and clean the plate in time to remove burrs.

5. Inspection of the plate cleaning device: Before stamping production, it must be inspected and repaired at the same time to clean the plate more effectively. It is also necessary to pay attention to the quality of the roller gap and cleaning oil. The specific method is to apply red paint on the steel plate to make it cleaned and installed. At present, the cause of the removal of the red paint is checked. If the removal rate is not up to standard, it is necessary to check and repair the cleaning and installation. When the cleaning oil is lacking, it must be reduced in time.

How to choose a metal stamping press?

1. Whether the type and working form of stamping equipment are suitable for the process to be completed, and whether it meets the requirements of safe production and environmental protection. For the blanking process, open crank presses are often used for medium and small blanking parts; closed crank presses are generally used for large, medium and precision blanking parts; special dynamic presses or hydraulic presses are used for fine blanking. Formwork press. The hydraulic press is generally not used in the blanking process due to its slow speed, low efficiency, and sudden unloading at the end of blanking will produce shock vibration;

2. Whether the pressure and power of the stamping equipment meet the requirements of the completed process.

3. Whether the die installation height, table size, stroke, etc. of the stamping equipment are suitable for the die used to complete the process.

4. Whether the number of strokes of the stamping equipment meets the requirements of production efficiency.

1. How to choose a stamping part processing press

1. Small and medium-sized blanking parts, bending parts, drawing parts, forming parts and other stamping parts that do not require high precision generally use “open single-column presses”.

2. “Double-action presses” are generally used for medium-sized tensile parts.

3. For large and medium-sized stamping parts with high precision requirements, “closed presses” or “multi-point presses” are mostly used.

4. For the production of large batches of stamping parts, “high-speed presses” or “multi-station presses” are generally used.

5. The extrusion process should use a special “cold extrusion machine”.

6. The precision stamping process should use a special “precision stamping press”.

7. Stamping processes such as leveling, correction, and bending should choose a “double-column or four-column press”, a spiral friction press or a hydraulic press with good rigidity.

8. For the processing of porous stamping parts, CNC punching die rotary head press is used.

9. For the die that requires the punch to be unable to leave the spring-pressed discharge plate during the stamping process, a press with an adjustable stroke should be used.

What are the common materials for precision metal stamping dies?

In the industry, hardware is generally divided into large and small hardware. Big hardware refers to steel plate, steel bar, flat iron, universal angle steel, channel iron, I-beam and various types of steel materials, while small hardware mainly refers to construction hardware, white iron sheet, lock nails, iron wire, steel wire mesh, wire scissors , household hardware, various tools, etc. As far as the nature and use of hardware are concerned, it should be divided into eight categories: steel materials, non-ferrous metal materials, mechanical parts, transmission equipment, auxiliary tools, work tools, construction hardware, and home hardware. There are also many varieties of hardware products. Relatively speaking, the difference in specifications is relatively large. It plays an irreplaceable role in home decoration. Choosing a good hardware mold processing factory can increase the processing accuracy and improve the use process. safety, while also increasing the service life.

The stamping materials often used in precision metal stamping processing include beryllium copper BECU, steel plate SK, phosphor bronze PB, tinplate SPTE, aluminum AL, stainless steel plate SUS, white copper NS, hot-rolled steel plate SECC, cold-rolled steel plate SPCC, etc. Moreover, the material of stamping metal stamping has good plasticity, and the bright band of our stamping products will be larger and the fracture band will be smaller.

Precision metal stamping parts can also be divided into various types according to industry, use and process characteristics. Next, the types of precision metal stamping parts are introduced as follows:

1. Auto parts: mainly include automotive structural parts, automotive functional parts, automotive lathe parts, automotive relays, etc.

2. Electronic parts: mainly include connecting devices, connectors, brush parts, electrical terminals, elastic parts, etc.

3. Appliance parts: It mainly includes major appliance parts, such as color tube electron gun parts, as well as small appliance parts, various structural parts and functional parts.

4. IC integrated circuit lead frame: mainly includes discrete device lead frame and integrated circuit lead frame.

5. Motor core: mainly includes single-phase series motor core, single-phase household motor core, single-phase shaded-pole motor core, permanent magnet DC motor core, industrial motor core, plastic-encapsulated stator core, etc.

6. Electrical iron core: It mainly includes E-shaped transformer core, EI-shaped transformer core, I-shaped transformer core, and other transformer cores.

7. Heat exchanger fins: mainly include industrial heat exchanger fins, household heat exchanger fins, automotive heat exchanger fins, etc.

8. Other parts: mainly include instrumentation parts, IT parts, acoustic and camera parts, modern office parts, and daily hardware.

New energy power battery pole, friction welding pole

New energy power battery pole, friction welding pole

1. Manufacturing process: copper-aluminum composite, stamping processing

2. Scope of application: New energy copper-aluminum composite battery negative pole, power battery top cover pole can be customized

3. Stamping material: copper-aluminum composite

4. Surface treatment: stainless steel brightener

5. Dimensions: Outer diameter 22, height 3.8, and other dimensions can be customized according to your company’s requirements, and the unit price is negotiable with our company.

6. Product features: no burrs on the end face, flat head chamfering, parallel and vertical cut surfaces, bright appearance

7. Quality: Strictly control the production quality, the products are fully inspected before they are shipped, and the products must be inspected before leaving the factory to ensure that every process meets the requirements and quality problems.

Quality comes from details, confidence comes from customers’ evaluation of our evaluation, in order to let you buy better products , strive to perfect every detail, from accessories to craftsmanship, are devoted to the pursuit of quality by Balford people.

New energy copper-aluminum composite battery anode column

New energy copper-aluminum composite battery anode column
1. Manufacturing process: copper-aluminum composite, stamping processing

2. Scope of application: New energy copper-aluminum composite battery negative pole, power battery top cover pole can be customized

3. Stamping material: copper-aluminum composite

4. Surface treatment: stainless steel brightener

5. Dimensions: Outer diameter 22, height 3.8, and other dimensions can be customized according to your company’s requirements, and the unit price is negotiable with our company.

6. Product features: no burrs on the end face, flat head chamfering, parallel and vertical cut surfaces, bright appearance

7. Quality: Strictly control the production quality, the products are fully inspected before they are shipped, and the products must be inspected before leaving the factory to ensure that every process meets the requirements and quality problems.

Quality comes from details, and confidence comes from customers’ evaluation of us. In order to let you buy better products, we strive to improve every detail. From accessories to craftsmanship, we are devoted to the pursuit of quality by Balford people.

Photovoltaic elevator automation power semiconductor module copper substrate

Photovoltaic elevator automation power semiconductor module copper substrate
1. Manufacturing process: t2y2 copper, blanking, fine blanking

2. Scope of application: New energy electric vehicle power semiconductor module copper base plate

3. Stamping material: t2y2 copper, Vickers hardness 80-100

4. Surface treatment: nickel sulfamate plating

5. Size specifications: width 62, material thickness 3, length 122, other dimensions can be customized according to your company’s requirements, the unit price is negotiable with our company.

6. Product features: no burrs on the end face, flat head chamfering, parallel and vertical cut surfaces, bright appearance

7. Quality: Strictly control the production quality, the products are fully inspected before they are shipped, and the products must be inspected before leaving the factory to ensure that every process meets the requirements and quality problems.

Quality comes from details, and confidence comes from customers’ evaluation of us. In order to let you buy better products, we strive to improve every detail. From accessories to craftsmanship, we are devoted to the pursuit of quality by Balford people.

What are the methods of hardness testing of metal stamping parts?

First, the method of hardness testing of metal stamping parts

The hardness test of metal metal stamping parts adopts Rockwell hardness tester. Small stampings with complex shapes can be used for small test surfaces, which cannot be tested on ordinary benchtop Rockwell hardness testers.

The processing of metal stamping parts includes blanking, bending, deep drawing, forming, finishing and other processes. The processing materials of metal stamping parts are mainly hot-rolled or cold-rolled (mainly cold-rolled) metal sheets and strips, such as carbon steel sheets, alloy steel sheets, spring steel sheets, galvanized sheets, tin-plated sheets, stainless steel sheets, copper and copper. Alloy plate, aluminum and aluminum alloy plate, etc.

The PHP Series Portable Surface Rockwell Hardness Testers are ideal for testing the hardness of these stampings. Alloy stampings are the most commonly used parts in the fields of metal processing and machine manufacturing. Stamping is a processing method that uses a die to separate or form a sheet metal strip. Its application range is very wide.

The main purpose of the stamping material hardness test is to determine whether the annealing degree of the purchased metal sheet is suitable for the subsequent stamping processing. The same type of stamping process requires sheets of different hardness levels. Aluminum alloy plates used for stamping parts can be tested with Webster hardness tester. When the thickness of the material is greater than 13mm, it can be replaced by a barcol hardness tester, and a barcol hardness tester should be used for pure aluminum plates or low-hardness aluminum alloy plates.

In the stamping industry, stamping is sometimes also called sheet forming, but it is slightly different. The so-called plate forming refers to a forming method in which a plate, a thin-walled tube, a thin profile, etc. are used as raw materials for plastic processing. At this time, the preparation of the thick plate direction is generally not considered.

Well, the above is the relevant content about the hardness testing method of metal stamping parts, I hope the above content can help readers.

What are the precautions for metal stamping?

1. What are the preventive measures that should be taken during metal stamping processing?

1. We should regularly check the punch turntable and the die mounting seat of the stamping part to better ensure the coaxial accuracy of the upper and lower turntables.

2. Metal stamping parts need to be strictly inspected before installation and use, and the dirt should be removed. The guide bushes of stamping parts and die casting dies should be carefully checked for good lubrication.

3. In order to ensure the service life of the stretched and compressed parts, the spring of the die should also be replaced regularly to prevent the fatigue damage of the spring from affecting the use of the stretched stamping parts.

4. When installing the mold, the stamping personnel should use soft metal manufacturing tools to prevent the stamping parts from being damaged by impact and extrusion during the installation process.

5. The wear of the convex and concave die edges of the stamping parts should be stopped and polished in time, otherwise the wear degree of the die edge will expand rapidly, the die edge wear will be accelerated, and the stamping quality and die life will be reduced

What are the preventive measures for metal stamping processing above? I hope the above content can help readers!

What are the common problems in mold design and processing?

1. Why does the mold turn over less frequently?

In the process of making the mold, too much silicone oil is added, and the silicone oil destroys the molecular weight of the silicone, so the number of times the mold is turned over is small and not durable. If it is said that small products with complex patterns are used to open the mold with silicone with high hardness, there will be a phenomenon that the number of mold turning is less, because the time when the silicone is too hard will be very brittle and easy to break. On the contrary, if the mold is made of silicone with less hardness, the result is not satisfactory. Since the silicone is too soft, its tension and tear strength will decrease, and the mold will deform, so the number of flips will decrease. The quality of the mold glue itself is very good, and the silicone is not good or bad, only suitable or not. This does not happen when we make molds with silicone that is suitable for the hardness of the product.

2. Why does the mold burn out?

Since the unsaturated resin and resin products are added with peroxide curing agent, the resin reaction will generate a lot of heat. The resin curing time is generally 3 minutes, and the mold is released as soon as possible after 3 minutes to prevent the phenomenon of silicone mold burning.

3. The method of filling the mold and the production method of the slicing mold

The operation method of the slicing mold or the slicing mold: brush or pour the vacuum silica gel for construction. If you are making a sheet mold or a split mold and using the brushing method, apply a layer of release agent or release agent to the product or model to be replicated before painting, then apply silicone to the product and wait 30 minutes. Apply a layer of gauze or fiberglass cloth to the surface for strength, then apply a second layer of silicone. After the silica gel is dried, the outer mold is made. The outer mold can be made of materials such as plaster or resin.

The operation method of the pouring or pouring mold: the pouring or pouring mold is used for smooth or simple products, that is, the product or model to be copied is surrounded by a plastic or glass plate, and the vacuum silicone is directly poured into the product. After the silica gel is dried and formed, the product is taken out and the mold is formed. The above is the whole process of mold use and operation.

4. Why does the mold appear dry on the outside and not dry on the inside?

The mold is a condensed silicone that cures by absorbing moisture from the air. Silica gel evaporates water during the production process, and this happens without adding an appropriate amount of water.

5. Why does the mold have poor tensile force?

Because in the process of making the mold, in order to reduce the viscosity of the silica gel and make the silica gel easy to handle, a large amount of silicone oil is added to the silica gel to make the silica gel very soft, resulting in the phenomenon of intolerance, reduced tear strength, and poor tensile force. , resulting in the phenomenon that the mold is not durable, the service life is short, and the number of mold turnovers is small.

6. Why does the mold appear oily?

The mold itself will not emit oil, because the complex silicone oil (silicone oil and white mineral oil complex) is added during the operation, because the white mineral oil is a petrochemical product, not a silicone oil.

7. Why does the mold made by the mold have traces, streaks, and unevenness on the surface?

This phenomenon occurs why the product or model to be reproduced is not ground or polished. Because in fact, the model or product itself is not smooth or perfect, if the product or model to be reproduced is not sanded or polished, no matter how good the mold made of silicone, it will not be beautiful and smooth. Another situation is that when removing the mold, uneven brushing can also cause the mold to be uneven.  

Silicone mold production process and common problems

First, the choice of mold

The selection of the mold opening form and the selection of the mold line are very important. First, it is convenient to take the mold. Second, the mold line does not affect the overall effect of the product. Third, it does not affect the product quality. If there are too many materials, product cracking is prone to occur; the fourth is to reduce the process operation process, such as opening half of the mold.

Second, the mold processing

1. In order to prevent the silicone from flowing around, fix the mold with a wooden square or a wooden board within the specified range. When opening the mold, use a wooden board and sludge to separate the first part. It is required that there is no gap between the sludge and the mold, and the surface of the sludge is smooth and flat. .

2. Apply petroleum jelly or spray release agent on the plaster mold or mold. Smooth products need to apply Vaseline evenly with a clean cotton cloth, keep it for 30 minutes, so that the mold can fully absorb the Vaseline, and then wipe the surface of the mold with a clean cotton cloth, the surface is required to be bright; for textured products, just apply Vaseline evenly. , the silicone is adjusted according to the formula.

3. The silica gel should be stirred in an irregular direction, so that the curing agent and the silica gel are fully mixed, and the air mixed into the glue should be minimized.

3. Matters needing attention

After the mold is made, it is necessary to make a plaster or glass fiber reinforced plastic jacket to support the silicone soft mold. Note:

1. Mold line selection: choose the position that does not affect the appearance of the product; the position that is easy to process after grouting; the position that the mold itself is easy to disassemble; the position that the product is not easily deformed.

2. Do not blindly increase the amount of hardener to catch up with the production schedule, otherwise the service life of the silicone mold will be greatly reduced.  

What is the reason for the failure of stamping and drawing dies in processing and casting?

1. The process of stamping and drawing die

Punching die is a method of casting liquid die forging, a process completed on a special die-casting die forging machine. The basic process is: the molten metal is first cast into the mold cavity at a low speed or high speed, and the mold has a movable cavity surface. With the cooling process of the metal liquid, pressure forging not only eliminates the shrinkage defect of the blank, but also makes the internal structure of the blank reach forging. Broken grains.

2. The main reasons for the failure of stamping and drawing dies are as follows:

1. Thermal fatigue crack damage failure

During die-casting production, the mold is repeatedly subjected to the action of cold and heat, the forming surface and its interior will be deformed, and they will be pulled together to generate repeated thermal stress, which will cause damage to the structure and loss of toughness, which will lead to the occurrence of micro-cracks and continue to expand. , once the crack expands, the molten metal is continuously squeezed in, coupled with repeated mechanical stress, the crack accelerates the expansion rate. Therefore, the mold must be fully preheated at the beginning of die casting. In addition, during the production process of die casting, the mold must be kept in a moderate working temperature range to prevent early cracking failure. At the same time, it should be ensured that there are no problems with internal factors before the mold is put into production and during production. Because in actual production, most mold failures are failures caused by thermal fatigue cracks.

2. Fragmentation failure

Under the action of pressure, the mold will crack at the weak place, especially if the scribe marks or electrical machining marks on the molding surface of the mold are not polished, or the clear corners of the molding will appear micro cracks first. When there is a brittle phase or coarse grains in the boundary, it is easy to fracture. However, the cracks expand rapidly during brittle fracture, which is a very dangerous factor for the chipping failure of the mold. For this reason, on the one hand, all scratches and electrical machining marks on the mold surface must be polished, even if it is in the gating system part, it must be polished. In addition, the mold materials used are required to have high strength, good plasticity, good impact toughness and fracture toughness.  

3. Dissolution failure

Commonly used die-casting alloys include zinc alloy, aluminum alloy, magnesium alloy and copper alloy, as well as pure aluminum die-casting. Zn, Al, and Mg are more active metal elements, and they have a good affinity with mold materials. When the hardness of the mold is higher, the corrosion resistance is better, and if there are soft spots on the molding surface, the corrosion resistance is unfavorable.  

New energy electric vehicle power semiconductor module copper base plate

New energy electric vehicle power semiconductor module copper base plate

1. Manufacturing process: t2y2 copper, blanking, fine blanking

2. Scope of application: New energy electric vehicle power semiconductor module copper base plate

3. Stamping material: t2y2 copper, Vickers hardness 80-100

4. Surface treatment: nickel sulfamate plating

5. Size specifications: width 37.95, material thickness 3, length 104, and other dimensions can be customized according to your company’s requirements, the unit price is negotiable with our company.

6. Product features: no burrs on the end face, flat head chamfering, parallel and vertical cut surfaces, bright appearance

7. Quality: Strictly control the production quality, the products are fully inspected before they are shipped, and the products must be inspected before leaving the factory to ensure that every process meets the requirements and quality problems.

Quality comes from details, confidence comes from customers’ evaluation of our evaluation, in order to let you buy better products , strive to perfect every detail, from accessories to craftsmanship, are devoted to the pursuit of quality by Balford people.

Auto brake spring positioning base porous stamping

Auto brake spring positioning base porous stamping.jpg
Auto brake spring positioning base porous stamping
1. Manufacturing process: cold-rolled sheet coils, porous stamping parts, punching, turning holes,

2. Scope of application: stamping parts of auto parts, flange positioning connection parts

3. Stamping material: cold rolled sheet

4. Surface treatment: galvanized

5. Size specifications: The size can be customized according to your company’s requirements, and the unit price is negotiable with our company.

6. Product features: no burrs on the end face, flat head chamfering, parallel and vertical cut surfaces, bright appearance

7. Quality: The production quality is strictly controlled, and the products are fully inspected before they are shipped. The products must be inspected before leaving the factory to ensure that every process meets the requirements and quality problems.

Quality comes from details, and confidence comes from customers’ evaluation of us. In order to let you buy better products, we strive to improve every detail. From accessories to craftsmanship, we are devoted to the pursuit of quality by Balford people.

Solenoid valve gasket

Solenoid valve gasket.jpg
Solenoid valve gasket
1. Manufacturing process: cold-rolled sheet coil, fine blanking

2. Scope of application: Solenoid valve gasket, solenoid valve gasket

3. Stamping material: cold rolled sheet

4. Surface treatment: galvanized

5. Size specifications: The outer diameter is 17*6.25*2, and other sizes can be customized according to your company’s requirements, and the unit price is negotiable.

6. Product features: no burrs on the end face, flat head chamfering, parallel and vertical cut surfaces, bright appearance

7. Quality: The production quality is strictly controlled, and the products are fully inspected before they are shipped. The products must be inspected before leaving the factory to ensure that every process meets the requirements and quality problems.

Quality comes from details, and confidence comes from customers’ evaluation of us. In order to let you buy better products, we strive to improve every detail. From accessories to craftsmanship, we are devoted to the pursuit of quality by Balford people.