Zhejiang Balford Mechatronics Co., ltd focus on difficult stamping & deep drawing. Main product: motor housing and difficult custom deep drawn stampings.

  • Causes of deformation in metal stamping

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    Hardware stamping processes include blanking, bending, stretching, forming, etc. Common processing materials include stainless steel, iron, aluminum, copper and other metal materials. Hardware stamping manufacturers will encounter some quality problems during stamping, such as deformation. Next, Xiaobian will explain the reasons for the deformation of metal stamping.1. Stereo pressing: redistribute the volume and transfer the material to change the blank shape or height thickness.

    2. Bending: turn the flat sheet into a bending part, further change the shape of the bending part, including bending, curling, twisting, etc.

    3. Rolling: Punch the flat blank into the hollow part of the required shape, or further change the size of the hollow part.

    4. Cutting and blanking: unclosed or unclosed to separate part of the material from another part, including blanking, punching, trimming, cutting, sectioning, cutting, etc.

    5. Forming: change the shape of the workpiece or blank with local deformation of various properties. The forming deformation includes undulating forming, flanging, necking, protruding belly, rolling and shaping.

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  • Influence of Necking Process in Stamping

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    Influence of Necking Process in StampingDuring necking processing, the metal stamping material at the necking end slides into the female die under the pressure of the punch, the diameter decreases, the wall thickness and height increase, and when the wall thickness of the workpiece is not large, it can be approximately considered that the deformation area is in the plane stress state of tangential and radial compression, mainly tangential pressure. The radial compressive strain is the large strain of zui, while the thickness and length directions are elongation, and the deformation in the thickness direction is greater than that in the length direction.

    Due to the effect of tangential compressive stress, the billet is prone to instability and wrinkling during necking; At the same time, the cylinder wall in the non deformation area is prone to instability and deformation due to bearing all necking pressure, so preventing instability is the main problem of necking process.

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  • Factors influencing the dimensional accuracy of metal stamping parts

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    Different metal stamping products have different requirements for accuracy. As long as we meet the accuracy requirements of customers and comprehensively consider production costs, we can produce qualified stamping parts. The factors that affect the dimensional accuracy of metal stampings must be known by everyone. Let’s have a look together.The dimensional accuracy of metal stamping parts refers to the difference between the actual size of stamping parts and the basic size. The smaller the difference, the higher the dimensional accuracy of metal stamping parts.

    The influencing factors are as follows:

    1. Manufacturing precision of metal stamping die.

    2. Gap between male and female dies.

    3. Elastic recovery of materials after stamping.

    4. Accidental factors in the production process, such as inaccurate positioning, unstable material performance, etc.

    It can be divided into precision level and ordinary level. The ordinary level is the precision that can be achieved by more economic means, while the precision level is the precision that can be achieved by stamping technology.

    The surface quality of metal stampings shall not be higher than that of raw materials, otherwise, subsequent processing is required to achieve it, increasing production costs.

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  • Factors influencing the dimensional accuracy of metal stamping parts

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    Different metal stamping products have different requirements for accuracy. As long as we meet the accuracy requirements of customers and comprehensively consider production costs, we can produce qualified stamping parts. The factors that affect the dimensional accuracy of metal stampings must be known by everyone. Let’s have a look together.The dimensional accuracy of metal stamping parts refers to the difference between the actual size of stamping parts and the basic size. The smaller the difference, the higher the dimensional accuracy of metal stamping parts.

    The influencing factors are as follows:

    1. Manufacturing precision of metal stamping die.

    2. Gap between male and female dies.

    3. Elastic recovery of materials after stamping.

    4. Accidental factors in the production process, such as inaccurate positioning, unstable material performance, etc.

    It can be divided into precision level and ordinary level. The ordinary level is the precision that can be achieved by more economic means, while the precision level is the precision that can be achieved by stamping technology.

    The surface quality of metal stampings shall not be higher than that of raw materials, otherwise, subsequent processing is required to achieve it, increasing production costs.

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  • Deep drawing

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    Deep drawing is a sheet metal forming process in which a sheet metal blank is radially drawn into a forming die by the mechanical action of a punch. It is thus a shape transformation process with material retention.

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  • How to deal with the rebound of metal stamping parts

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    When the metal stamping parts spring back, which is commonly referred to as springback, elastic deformation occurs due to insufficient plastic deformation during the stamping process. Once this problem occurs, it should be corrected in time, otherwise the shape and size of the stamping parts produced by processing will have a large error, which does not meet the requirements of the stamping process. Here are some solutions.1. Improve some structures in the workpiece design to reduce the rebound angle;

    2. Consider reducing springback in mold design;

    3. Adopt stretch bending process;

    4. Use other process methods.

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  • Influence of Die Clearance on Stamping Parts

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    As stamping parts manufacturers know, stamping requires reasonable blanking clearance, which can achieve better section quality, higher dimensional accuracy, smaller blanking force and higher die life. Now let’s understand the influence of die clearance.The relationship between the customized die clearance and blanking force of stamping parts. The smaller the clearance, the greater the blanking force. On the contrary, increasing the clearance can reduce the blanking force. When the clearance is reasonable, the upper and lower cracks coincide, and the large z blanking force will be smaller;

    The accuracy of stamping parts refers to the error value between the actual size and the basic size. The smaller the difference, the higher the accuracy. When the gap is large, the material will be larger under the tensile action. After stamping, the material will have elastic recovery, and the size of the blanking part will be smaller than the die size. When the gap is small, the elastic recovery of the material will make the size of the blanking part larger and the hole diameter smaller;

    During the processing and customization of stamping parts, the pressure on the die edge is very large, which causes local adhesion and wear when it contacts with materials. When the gap is small, the contact pressure becomes larger and the distance is longer, leading to accelerated wear of the die. When the gap is large, the material tension increases relatively, and the positive pressure on the end face of the die edge increases, which is easy to cause tool breakage or deformation, leading to die wear.

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  • Pay attention to 9 major issues when designing precision stamping dies

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    As an important tool in the process of stamping production, stamping die has its own characteristics. When designing stamping dies, stamping processing plants need to consider from a scientific and reasonable perspective to improve the service life, durability, production efficiency, reduce production costs and ensure product quality. Baifudu Precision Stamping – With 20 years of experience in customized processing of stamping parts, various complex precision stamping products can be customized according to customer needs. Then, what should we pay attention to when designing the mold? Baifudu Precision Stamping will tell you next.1. In mold design, the selection of mold materials, heat treatment and surface treatment.

    2. Strip design is the analysis of the product forming process, which basically determines the success of the die.

    Before designing the material belt, we need to know the tolerance requirements, material properties, punching tonnage, punching table, SPM (times of punching per minute), feeding direction, feeding height, die thickness requirements, material utilization rate and die service life of the parts. When designing the tape, CAE analysis should be carried out at the same time, mainly considering the material thinning rate, and more communication with customers.

    3. When testing the mold, make sure to slowly close the upper mold. During the stretching process, make sure to use the fuse to test the material layer thickness. When the material level gap reaches the material thickness, try the die again, and the blade must be aligned first. For drawbead, use a movable insert to adjust the height of the drawbead. After the mold is matched, the datum hole and datum plane must be measured on the fixture, or sent to CMM for 3D report.

    4. For parts with more bending, the bending shall be adjusted step by step according to the process during die adjustment.

    5. When adjusting the forming angle, you can reduce the R angle or move the polyline reference during the bending process to reach the forming angle.

    6. During die adjustment, the gasket is mainly used to adjust the height of the forming punch, or move the forming punch from left to left. Washers are usually stainless steel hardware.

    7. For trimming line affected by forming, cutting shall be selected after forming, and special position can be realized by cross cutting.

    8. For multiple datum hole locations, the method of one-time punching forming shall be adopted to avoid affecting the accuracy after step-by-step punching.

    9. For product fracture, a variety of methods can be used, such as adding packaging, extruding, and increasing the forming area of plate bar and opening in the late stretching process. CAE analysis shall be carried out after mold modification.

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  • Causes and Solutions of Stamping Scrap

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    There will be stamping scrap during the stamping process of metal stamping parts, especially in the case of mass production, the production of scrap will increase costs, affect production efficiency and reduce the durability of molds. In this paper, we will introduce the possible causes of stamping scrap and the corresponding solutions.

    1. Reasons

    (1) The quality of the steel purchased does not meet the national standards, such as unstable materials, out of tolerance dimensions, and unqualified surface accuracy.

    (2) The stamping die is not installed and used correctly.

    (3) After the die is used for a long time, the gap becomes larger or the die accessories are worn, leading to waste products.

    (4) During the stamping process, the mold needs to withstand a huge impact force, resulting in the loosening of bolts or other accessories, which affects the normal production of the entire mold.

    (5) In the process of operation, the puncher did not strictly install the positioning device for feeding.

    (6) The stamping worker did not produce according to the operation manual formulated by the company.

    1. Solutions

    (1) When purchasing raw materials, it is necessary to strictly install the standard of Guo. Try to choose regular steel dealers or products from large steel plants; Test the composition, surface roughness and dimensional accuracy of steel or obtain the material report from the supplier.

    (2) The punches and stamping dies used in the factory shall always be in a stable running state, and they shall be regularly maintained and overhauled.

    (3) During stamping, the die shall be kept clean, and the workpieces and raw materials in the workshop shall be placed in order.

    (4) Proper tools must be used for feeding and picking up to avoid scratching the products.

    (5) After the stamping process is designed, the stamping workers shall operate in strict accordance with the process rules. Each stamping product has a different stamping process, and the management shall formulate the corresponding process rules before processing the product.

    (6) Formulate perfect quality inspection regulations. The first batch of products must be completely inspected before formal production, and regular sampling inspection shall be conducted during production.

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  • Differences between forming and finishing of stamping parts

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    In order to improve the precision of metal stampings, some stamping processes, such as refurbishment and refurbishment, are sometimes added during the production process of stamping parts. So, people who have just entered the industry will ask, what is the difference between the two?Shaping is to use the reshaping die to press the inaccurate parts of the bending or stretching parts into an accurate shape; Or for the stamping parts with surface flatness requirements, the flat stamping parts with arch bending and warping shall be flattened with the leveling die. That is to say, depending on the material flow, the shape and size of the process parts are changed a little to ensure the accuracy of the workpiece. It belongs to the forming process of stamping parts.

    Trimming is to remove the allowance of the outer edge or inner hole of the blank with the trimming die to obtain a smooth section and accurate size. It is a blanking process applied to stamping parts and belongs to blanking process.

    That is to say, shaping is used for the forming process of stamping parts to improve the shape quality and dimensional accuracy of finished metal stamping parts; The trimming is often used in the blanking process of stamping parts to obtain high-quality blank or inner hole of stamping parts and improve the dimensional accuracy.

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  • Introduction of Hardware Stamping Die Blank Holder

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    The blank holder of the metal stamping die is a pressing device mainly used to prevent the wrinkling of the stamping and drawing products in the drawing process. Variable blank holder control through blank holder can greatly reduce the cost and has strong practicability. The following is a brief introduction to the blank holder by the hardware stamping parts manufacturer.1. The blank holder is a kind of pressing part on the die used for metal stamping and drawing, which is used to prevent the wrinkling of the workpiece wall or flange during the drawing.

    2. Structure

    It mainly includes the upper layer, small top pillar and lower layer. The upper layer is elastic material, the upper layer is in contact with the flange area of the slab blank, and the lower layer is connected with the top bar. A number of small top pillars are embedded between the upper layer and the lower layer through the sink. There is a small length difference between the small top pillars, generally 0.1mm. According to the actual needs, different numbers and lengths of small top pillars are embedded in different areas.

    3. Two kinds of common blank holder

    (1) Elastic blank holder is divided into spring pad, rubber pad and air cushion blank holder of the press itself, which is used for processing shallow drawing parts;

    (2) The rigid blank holder is applicable to the stretching or forming of large pieces with large height.

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  • The difference between steel stamping and copper aluminum stamping

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    Zhejiang Baifudu Precision, a manufacturer of precision metal stamping, stretching and precision overtime, high-quality raw materials, good product quality, rich customization experience and timely delivery. The processing materials we use include stainless steel, aluminum, copper, nonferrous metals and some alloys, which are commonly used by stamping manufacturers. Here is a brief introduction to the difference between steel stamping and copper aluminum stamping.The commonly used steel plates are carbon steel and stainless steel, and the non-ferrous metal plates include aluminum, copper and their alloys. They have high plasticity and low deformation resistance, and are suitable for cold stamping.

    (1) Copper aluminum and its alloys are widely used as components of electrical equipment because of their good ductility and excellent conductivity.

    (2) The stamping process of carbon steel and stainless steel is often used to manufacture equipment shells, structural parts, boxes, etc., but because of its strong stiffness, stamping oil is usually used to improve the process.

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  • The Method of Punching Small Holes for Stamping Parts

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    In this paper, we will introduce the method and points for attention of punching small holes in the processing of stamping parts. With the development of science and technology and society, the previously commonly used machining method of micro holes has gradually been replaced by the stamping method. By making the punch firm and stable, improving the punch strength, preventing punch fracture and changing the stress state of the blank during punching, etc.The ratio d/t of the punching diameter to the material thickness in stamping can reach the following values: 0.4 for hard steel, 0.35 for mild steel and brass, and 0.3 for aluminum.

    When punching a small hole on a sheet, when the material thickness is greater than the punch diameter, the punching process is not a shearing process, but a process of extruding the material into the die through the punch. At the beginning of extrusion, part of the washed waste is compressed and squeezed into the area around the hole, so the thickness of the washed waste is generally less than the thickness of the raw material.

    When punching small holes in stamping parts, due to the small diameter of punch punch, if common blanking method is used, the small punch is easy to break, so try to improve punch strength to prevent it from breaking and bending. The methods and precautions are as follows:

    1. The stripper serves as a guide plate.

    2. The guide plate and the fixed working plate are connected by a small guide post guide sleeve or directly with a large guide post guide sleeve.

    3. The punch shall be retracted into the guide plate, and the distance between the guide plate and the punch fixing plate shall not be too large.

    4. The bilateral clearance between punch and guide plate is less than the unilateral clearance between punch and die.

    5. The pressing force is 1.5~2 times greater than that of simple stripping.

    6. The guide plate shall be made of or inlaid with high hardness materials, and the thickness shall be 20%~30% compared with the normal situation.

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  • Introduction to 6 Stripping Methods of Stamping Bending Die

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    There are 6kinds of stripping methods of bending die for stamping, and the stamping parts processing manufacturer will introduce them to you. Balford Precision Stamping, a manufacturer of precision stamping, stretch forming and precision machining for 20 years, provides one-stop services for mold development and design, stamping, deep drawing and automatic assembly. With rich experience, you are welcome to consult and customize.There are 8 kinds of stripping methods of bending die for stamping, and the stamping parts processing manufacturer will introduce them to you. Baifudu Precision Stamping, a manufacturer of precision stamping, stretch forming and precision machining for 20 years, provides one-stop services for mold development and design, stamping, deep drawing and automatic assembly. With rich experience, you are welcome to consult and customize.

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  • Measures for Uneven Stripes on the Surface of Metal Stamping Parts

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    In the process of stamping, uneven stripes will appear on the surface of metal stamping parts, which will affect the surface quality and overall strength of stamping parts, and even scrap the products in serious cases. That is why this problem occurs, and what measures can be taken to effectively control and avoid it? Let’s get to know.It is mainly to improve the friction characteristics between metal stamping parts and tools, improve the stiffness of the whole system, increase the damping of the system, and reduce the cutting load. Specific measures are as follows for your reference:

    1. Use appropriate tools and stamping raw materials, and select appropriate tools for different metal stamping materials, so that the mutual friction system between tools and workpieces and the difference between dynamic and static friction coefficients of tools and workpieces are as small as possible.

    2. Adding cutting fluid with good performance can better improve the friction characteristics of tools and precision parts.

    3. Improve the stiffness of the system: increase the stiffness of the whole process, which can effectively reduce the occurrence of this phenomenon.

    4. Reduce the length of the tool extending out of the tool rest, thicken the tool handle, and improve the rigidity of the tool rest.

    5. To increase the damping of the system, materials with large internal damping can be selected as the supporting parts, or high damping materials can be added to the components or damping links can be used to reduce the occurrence of vibration.

    6. Reduce the length diameter ratio of stamping parts, and use intermediate supports such as center frame to increase the rigidity of the workpiece.

    7. Properly thicken the diameter of the transmission lead screw in the feed mechanism, shorten the length of the lead screw, etc., improve the transmission stiffness of the feed mechanism, try to eliminate the gap between the transmission components in the feed mechanism, give the transmission of the feed mechanism, and improve the stiffness of the machine tool transmission system.

    8. The ball screw is used to replace the ordinary thread screw, the liquid friction is used to replace the boundary or dry friction, and special lubricating oil is used to improve the sensitivity of the feed system by improving the friction performance of the machine tool transmission system, so as to reduce the occurrence of the vibration of the metal stamping parts.

    9. In the process of metal stamping, when the feed speed is low and there is vibration, it is necessary to stop the machine immediately, analyze the causes of the phenomenon, and take targeted effective measures to eliminate the phenomenon, so as to ensure the normal metal stamping process.

    10. Reduce the load of cutting and improve the vibration of metal precision stamping parts during cutting by reducing the amount of back cutting and reducing the weight of each transmission component.

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