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

  • Start cooperation with Unimotor (Canada)

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    Congratulations! Junhao Stampings Company, one division of Balford Mechatronics Co.,Ltd.  got order for motor housing from Unimotor in 2014, which means starting the long-term cooperation with this world's first-class automobile motor provider. Unimotor, a Four Seasons company and ...

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  • Surface Finishing

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    China Balford's expertise in surface finishing dates back to the company's introduction of electroplating in the 1998's. Since then, the company has leveraged its knowledge in operating these types of unique processes to expand its offering to include decorative and functional coatings. Painting ...

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  • What are the parts of the design and processing of metal stamping parts?

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    1. Stamping parts must meet the requirements of product use and technical performance, and be easy to assemble and maintain.

    2. Where permitted, stamped parts must help improve material utilization, reduce material types and specifications, and use low-cost materials.

    3. In order to simplify the mold structure and optimize the number of processes, the stamping parts must be simple, and there is a simple punching step, that is, to complete the processing of all parts. Try not to use other processing methods that are conducive to stamping operations, easy to organize, and achieve mechanized and automatic production to improve labor productivity.

    4. The dimensional accuracy and surface roughness of sleeve pressing parts should be minimized.

    5. The design of stamping parts should be processed with existing equipment, process equipment and process flow as much as possible to improve the service life of stamping dies.

    Due to the wide application of metal stamping dies, the popularity of stamping parts and changes in processing technology, there are many factors affecting the performance of metal stamping dies. The production process of metal stamping dies mainly includes:

    1. The production process of metal stamping dies includes

    (1), raw materials

    (2), mold

    (3), punch

    There are many kinds of stamping materials, and stainless steel is the most widely used. Most stamped products are made from steel sheet materials through stamping dies. Stamping hardware products can be seen everywhere in our lives.

    2. What are the metal stamping dies?

    1. Furniture hardware accessories

    2. Home appliance stamping parts

    3. Home kitchen supplies

    4. Automobile stamping parts

    5. Body

    6. Chassis

    7. Auto booster

    8. Car brake pads

    9. Radiator

    The above molds are all made by stamping. The material requirements for stamping parts are high, such as hardness, strength, tensile, corrosion resistance, surface quality and plasticity, and the accurate thickness is considered.

    With the rapid development of the industry, the variety of molds continues to increase, and the mold design is more and more accurate and complex. The qualification rate of stamping parts is closely related to whether the mold design is reasonable. The forming, surface quality, dimensional tolerance and product qualification rate of stamping parts are related to the design of the die process structure. Simply put, the process technology of a product is usually a single process. Multiple process, progressive or compound tooling is available if product processing license is available.

    Stamping equipment is the most widely used hydraulic press in the factory. Punch is divided into ordinary punch and high-speed punch. Generally speaking, if most of the processes can solve production problems with high-speed punching or multiple processes, the key factors in making qualified products are advanced stamping equipment and die technology.

    The above is the relevant content of the design and processing of metal stamping parts. Under the premise of ensuring factors, the correct use and maintenance of metal stamping dies is also to improve the quality of stamping dies. Because metal stamping dies will shorten the service life of stamping dies if they are used and maintained improperly, regular inspection of abrasive tools can make the processing of stamping parts more accurate. I hope the above will help readers.

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  • What are the layout methods of precision stamping parts?

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    1. Sampling of waste

    Refers to other plates other than workpieces during the blanking process of precision stamping parts, including process waste and structural waste. All material contour lines are blanked, and there are process residuals between workpieces and workpieces and between workpieces and strips. Due to the blanking along the closed contour of the blanked part, the quality and die life of the blanked part will be relatively high.

    2. Sampling with less waste

    Precision stampings are cut or stamped along the contours of parts of the workpiece and have laps between the workpiece and the workpiece, and between the workpiece and the sides of the strip. The blanking of this method is only a part of the contour of the workpiece, which is affected by the quality of the cut strip, the positioning accuracy and the error. The quality of the blanking parts is slightly poor, but the material utilization rate can reach 70%~90%.

    3. No waste layout

    Precision stamping parts have no overlap between the blanking parts and the blanking parts, and between the blanking parts and the sides of the strip. In fact, the blanking parts are obtained by cutting the strip, and the material utilization rate can reach 85%-90%. However, this layout method will make the quality of the blanking parts slightly worse.

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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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  • 9th China International Sheet Metal Stamping and Metal Forming Exhibition 2015

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    This industry event in the global attention is prestigious, the annual Sheet Metal,stamping & Metal forming Expo had been successfully completed in 2014 June. The 2015 Organizing Committee will move the event to Shanghai New International Expo Center. This event will ...

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  • How to solve the strain in the process of drawing die processing?

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    By changing the characteristics of the contacts, the adhesive wear should be reduced to achieve the best results when solving the above problems. Let’s briefly analyze it below.

    1. In terms of raw materials for forming workpieces, through surface treatment of the raw materials, such as phosphating, spraying or other surface treatments, a layer of non-metallic molds is formed on the surface of the forming materials, which can greatly reduce or eliminate the strain on the workpiece. This method is costly and requires additional production equipment and increased production processes. Although this method sometimes produces some effects, it is rarely used in actual production.

    2. Adding a layer of film such as workpiece and mold PVC between the mold and the molding material can sometimes solve the problem of deep drawing.

    For the assembly line passing mechanism, continuous film supply can be achieved. For the periodic production of stamping equipment, each production needs to add a layer of film, which affects the production efficiency. This method is generally more expensive and will generate a large amount of waste. For the production of small batches , Large-sized workpiece, it is best to use this method. For some smaller molding loads, solutions such as adding lubricants or adding EP additive lubricants can be used.

    3. The contact characteristics of the stretched materials such as the convex and concave molds are changed by changing the surface treatment of the convex and concave mold materials or the surface treatment of the convex mold and the concave mold, or by selecting the appropriate mold material. Practical applications show that this is a cost-effective way to solve stretching problems.

    In short, there are many ways to solve the problem of pulling on the surface of the die and the die. The specific situation should be determined according to the size of the workpiece, the amount of force, the production batch and the type of processing material.

    Between the telescopic part and the mold, adding a layer of PVC and other films between the mold and the forming material can sometimes solve the problem of deep drawing.

    For the assembly line passing mechanism, continuous film supply can be realized. For stamping equipment with periodic production, a layer of film needs to be added every time a workpiece is produced, which affects the production efficiency. This method is generally more expensive and generates a large amount of waste. For the production of small batches, large size workpieces, this method is best.

    In terms of raw materials for forming workpieces, through surface treatment of raw materials such as phosphating, spraying or other surface treatment, a layer of non-metallic molds is formed on the surface of the forming materials, which can greatly reduce or eliminate the strain of the workpiece. This method is expensive, but also It is necessary to add additional production equipment and increase the production process. Although this method sometimes produces some effects, it is rarely used in actual production.

    By changing the punch and die material or the surface treatment methods of punch and die, or by selecting appropriate die materials, the contact characteristics of the stretched material such as punch and die can be changed.

    Practical applications show that this is a cost-effective solution to stretching problems.

    Tie rod cracking remedy

    (1), adjust the pressure of the pressing material and reduce the pressure.

    (2) Adjust the stretching gap to make the gap larger and make the gap more uniform.

    (3), adjust the radius of the die fillet. The corner radius of the die is too small, and the parts are easy to crack. Increasing the corner radius of the die can reduce the degree of cracking.

    (4), adjust the punch radius.

    (5), adjust the relative position of punch and die.

    The above is about the content of the drawing die. The drawing die used is called the drawing die, abbreviated as the die. A drawing die is a special tool required for mass production. The deep drawing die is a very important die, and it is difficult to draw in batches without a qualified die. Advanced drawing processes do not require advanced dies and are therefore not possible. The tension process and the mold, the tension device and the tension material constitute the three elements of the tension process. Only when they are combined with each other can the tension be obtained. I hope the above can be helpful to readers.

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  • How to deal with mold deformation?

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    First, the treatment method of mold deformation

    1. Reasonable selection of materials. For sophisticated and complex molds, micro-deformation mold steel with good material (such as air-quenched steel) should be selected. For die steel with serious carbide segregation, reasonable forging and quenching and tempering heat treatment should be carried out. For larger and unforgeable die steels, a solution double refinement heat treatment is performed.

    2. The mold structure design should be reasonable, the thickness should not be too great, and the shape should be symmetrical. For large deformation molds, the deformation law should be mastered, and machining allowance should be reserved. For large, sophisticated and complex molds, a combined structure can be used.

    3. Precise and complex molds should be pre-heated to eliminate residual stress during processing.

    4. Reasonable selection of heating temperature and control of heating speed. For sophisticated and complex molds, balanced heating methods such as slow heating and preheating can be used to reduce heat treatment deformation of the mold.

    5. On the premise of ensuring the hardness of the mold, try to use pre-cooling, graded cooling quenching or warm quenching process.

    6. For sophisticated and complex molds, vacuum heating and quenching and cryogenic treatment after quenching should be used as much as possible.

    7. For some sophisticated and complex molds, pre-heat treatment, aging heat treatment, and quenching and tempering nitriding heat treatment can be used to control the accuracy of the mold.

    8. When repairing defects such as mold blisters, pores, and wear, use repair equipment with small thermal shocks such as cold welding machines to avoid deformation during the repair process.

    In addition, correct heat treatment process operations (such as hole plugging, tying holes, mechanical fixing, appropriate heating methods, correct selection of the cooling direction of the mold and the direction of movement in the cooling medium, etc.) and reasonable tempering heat treatment process also reduce accuracy and Effective measures for complex mold deformation.

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  • What are the characteristics, design and material advantages of stamping parts?

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    When designing metal stamping parts, not only should the structure meet the requirements of use, but also the process requirements of the metal stamping part structure should be considered, that is, the metal stamping part structure should be adapted to the stamping process. Metal stamping parts with good structural technology can reduce or avoid stamping defects, easily ensure the quality of stamping parts, simplify the stamping process, improve productivity and reduce production costs. The main factors affecting the process performance of metal stamping parts are shape, size, precision and material.

    Stamping parts are parts that can be processed by means of stamping, bending, stretching, etc. Metal stamping parts are widely used in various fields of our life, including some electronic devices, auto parts, decorative materials and so on. The structure of metal stamping parts is as follows: 

    Stamping parts are mainly made of metal or non-metallic plates under the pressure of a press through a stamping die, which has the following advantages:

    1. Stamping parts are stamped and manufactured under the premise of low material consumption. Its parts are lightweight and rigid. After the plastic deformation of the plate, the internal structure of the metal is improved, and the strength of the stamping part is improved.

    2. The stamping parts have high dimensional accuracy, uniform size with the die, and good interchangeability. Meets general assembly and use requirements without further machining.

    3. The surface quality of stamping parts is good, the appearance is smooth and beautiful, which provides convenient conditions for surface coating, electroplating, phosphating and other surface treatments.  

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  • What are the common sheet metal processing materials?

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    2. Stainless steel

    Stainless steel refers to steel that is resistant to weak corrosive media such as air, steam, and water, and chemically corrosive media such as acid, alkali, and salt. It is also called stainless acid-resistant steel. In practice, steel that is resistant to weak corrosive media is often called stainless steel, and steel that is resistant to chemical media is called acid-resistant steel. At present, the market of stainless steel is very large, and the application range is also relatively wide.

    3. Aluminum plate

    Aluminum is a light metal junction material with good corrosion resistance, electrical and thermal conductivity. Under the same weight, the conductivity of aluminum is 2 times higher than that of copper, and the strength of pure aluminum is very low, so it cannot be used as a structural material. Generally, aluminum alloy plates are used for sheet metal processing.

    4. Copper plate

    Commonly used are copper, brass, bronze and beryllium copper. The appearance of red copper is purple, and it has excellent electrical conductivity, thermal conductivity, ductility and corrosion resistance. However, it is more expensive. It is mainly used as a conductive and thermally conductive material, and is generally used in power supplies that need to carry large currents. Due to its low strength, copper cannot be used as a structural member.

    Brass has good ductility and punchability, and has good resistance to seawater and atmospheric corrosion when used for electroplating.

    Bronze has better wear resistance than pure copper and brass: good machinability and corrosion resistance. Beryllium copper refers to a copper alloy containing beryllium (Be), which is mostly used as an electromagnetic shielding material.

    5. Hot dip galvanized steel sheet

    Electroplating or hot-dip galvanizing steel plate with a layer of about 5-12 microns metal zinc, which can prevent corrosion and is widely used in construction, home appliances, automobiles, etc. At present, the performance of hot-dip galvanized steel sheet is very good. First, it has excellent corrosion resistance, paintability, decorative properties and good formability.

    The above materials are common materials in sheet metal processing at present. With the continuous improvement of sheet metal processing technology, more and more types of materials will be processed.

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    Hardware stamping parts are metal stamping parts produced and processed by using a punch and a stamping die. Obviously, the stamping die is very important in the stamping process. Today, our stamping parts manufacturer will talk about the knowledge that the stamping die does not peel off. What are the specific reasons? There may be insufficient avoidance at the forming place;

    The forming slider does not fit smoothly;

    Improper positioning or feeding;

    The inner part of the mold is strained, resulting in the unsmooth stamping activity;

    The layout of ejector pin is unreasonable;

    Insufficient ejection or stripping force;

    Punch bar is strained or the surface is not smooth;

    The uneven force on the striking plate causes the tilting of the striking plate;

    The punch does not fit well with the punching part

    The punch is too long or the ejector pin is not long enough;

    The cutting edges of the male die and female die of the die are worn, the rear angle of the female die is too small, and there is too much material in the cavity of the female die;

    The template is not demagnetized, and the workpiece is brought up;

    The late deformation is caused by improper heat treatment.

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  • different types of Auto Stamping Parts?

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    Auto Stamping Parts, as the name suggests, are metal stampings that make up automotive parts. In automotive stamping parts, some of them are directly transformed into auto parts after being stamped, and the other part is subjected to welding, machining, or painting after being stamped to become auto parts. There are many kinds of automobile stamping parts, such as automobile shock absorber stamping spring tray, spring seat, spring bracket, end cover, cover, compression valve cover, compression valve sleeve, oil seal seat, bottom cover, dust cover, impeller, oil cartridges, lugs, brackets, etc. These are all automotive stampings. In Auto Stamping Parts China, stamping is sometimes referred to as sheet forming, but with a slight difference. The term “sheet forming” refers to the use of sheet material, a thin-walled tube, a thin profile, or the like as raw material. The method of forming plastic work is collectively referred to as sheet forming, and at this time, deformation in the direction of the thick plate is generally not considered. First, the application range of metal stamping parts:

    1. Special stamping enterprises. Such as the stamping of aviation parts, etc. belong to such enterprises, but these craft factories are also owned by some large factories.

    2. Stamping of parts and components in the automotive industry. Mainly punching and forming. Many of the companies in this sector belong to scale factories, and there are also some independent stamping plants. At present, there are many such small factories near some automobile factories or tractor factories.

    3The stamping factory of daily necessities. Do some crafts, tableware, etc. These factories have also grown significantly in recent years.

    4. Stamping in the automotive industry. Mainly drawing. In this part of China, we mainly focus on large factories such as automobile factories, tractor factories, and aircraft manufacturers. Independent large scale stamping and deep drawing plants have not been seen.

    5. Electric stamping plant. This type of factory is a new industry that has developed along with the development of electrical appliances, which are mainly concentrated in the south.

    6. Household appliance parts stamping plant. These factories only emerged after the development of household appliances in China, and most of them are distributed to household appliances enterprises.

    Second, the detection of metal stamping parts:

    The hardness of metal stamping parts is measured by a Rockwell hardness tester. Small, complex-shaped stampings can be used to test small planes that cannot be tested on ordinary Rockwell benchtop hardness testers. Stamping parts processing includes punching, bending, drawing, forming, finishing and other processes. The materials processed by stamping parts are mainly hot-rolled or cold-rolled (mainly cold-rolled) metal strip materials, such as carbon steel sheets, alloy steel sheets, spring steel sheets, galvanized sheets, tin-plated sheets, stainless steel sheets, copper and copper alloys. Plate, aluminum and aluminum alloy plates, etc.

    Rockwell’s PHP series of portable surface hardness testers are ideal for testing the hardness of these stamped parts. Alloy stampings are commonly used in metal processing and mechanical manufacturing. Stamping is a process that uses a Stamping Mould to separate or form a metal strip. Its application range is very broad.

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  • Types of Deep Drawing Processing

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    Generally speaking, a metal stamping manufacturer will divide the deep drawing process into four parts: deep drawing,’re drawing, reverse drawing and thinning&deep drawing.

    Drawing process: use the punching force of the flat plate device and the punch to pull part or all of the flat plate into the cavity of the female die to form a bottomed container.

    Re-drawing: In order to increase the depth of the forming container, it is necessary to re-draw the finished products after drawing.

    Reverse drawing process: reverse drawing the workpiece drawn in the previous process, then the inner part of the workpiece becomes the outer part, and the outer diameter becomes smaller.

    Thinning and deep drawing: extrude the formed container into a concave cavity slightly smaller than the outer diameter of the container with a punch, so that the outer diameter of the container and the bottom becomes smaller.

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  • Stamping die design method and operation steps are introduced in detail

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    1. Analysis of stamping process of stamping parts

    Stamping parts must have excellent stamping process, so that qualified stamping parts can be produced in the simplest and most economical way, and the process analysis of stamping can be completed according to the following methods:

    1. Be able to read the part drawing: In addition to the shape and size of the part, the key points are to understand the requirements of the part accuracy and surface roughness.

    2. Analyze whether the structure and shape of the parts are suitable for stamping processing.

    3. Analyze whether the benchmark selection and size marking of parts are reasonable, and whether the accuracy of size, orientation and shape is suitable for stamping processing.

    4. Whether the rough surface requirements of the blanking section are too high.

    5. Whether there is a strong enough production batch.

    If the craftsmanship of the part is too poor, the planner should be communicated and a plan to revise the plan should be proposed. Assuming the production batch size, other production methods should be considered for processing.

    2. Stamping process planning and best process design.

    1. According to the shape and size of the stamping parts, start to judge the nature of the stamping process, such as punching, bending, deep drawing, bulging, reaming and other stamping die planning methods and processes.

    2. Calculate the degree of deformation of each stamping method. If the degree of deformation exceeds the limit deformation degree, the number of punches for the process should be calculated.

    3. According to the deformation characteristics and quality requirements of each process, organize a reasonable stamping sequence. Care should be taken to ensure that the deformation area of ​​each process is a weak area, and the formed parts (including punched holes or shapes) must not participate in deformation in subsequent processes. Polygonal zigzag parts should be bent first and then bent inward, and necessary auxiliary processes and processes such as shaping, leveling, and heat treatment should be organized.

    4. On the premise of ensuring the accuracy of the parts, according to the production batch and the blank positioning and unloading requirements, determine a reasonable process combination method.

    5. More than two process plans should be planned, and the best process plan should be selected from the aspects of quality, cost, productivity, mold sharpening and repair, mold life, operation safety, etc.

    6. Start to judge the stamping equipment of each process.

    3. Blank planning and layout drawing design of stamping parts

    1. According to the performance scale of stamping parts, calculate the blank size and make a blank drawing

    2. According to the roughness scale, plan the layout drawing and calculate the data utilization rate. To plan a variety of nesting plans, choose the best plan by comparison.

    Fourth, die design

    1. Determine the die structure method of each process of stamping processing, and make a schematic diagram of the die.

    2. Carry out specific structural planning for the 1-2 processes specified by the mold, and make the mold operation diagram. The planning method is as follows:

    (1) Determine the type of mold: whether it is a simple mold, a continuous mold or a composite mold.

    (2) Design of mold working parts: Calculate the size of the edge of the convex and concave molds and the length of the convex and concave molds, and determine the structure and connection and fixing methods of the convex and concave molds.

    (3) Determine the positioning and spacing method of the blank, and plan the corresponding positioning and spacing parts.

    (4) Determine the pressing, unloading, ejecting and pushing methods, and plan the corresponding pressing plates, unloading plates, and pushing blocks.

    (5) Formwork design: It includes the design of upper and lower die bases and guiding methods, and standard formwork can also be selected.

    (6) On the basis of completing the above operations, make a mold operation diagram according to the scale. First make blanks with double-dot-dash lines, then make parts, then make positioning and spaced parts, connect the above parts with connecting parts, and finally make pressing and unloading parts in the proper position. According to the specific conditions of the mold, the above order can also be adjusted appropriately.

    (7) The outer contour size of the mold, the closed height of the mold, the cooperation size, and the design method and process mold design of the cooperation type stamping die should be marked on the work map. The job drawing should indicate the requirements of the production accuracy and skill conditions of the mold. The job drawing should be made according to the national drawing standards, with a standardized title bar and detailed table. If it is a blanking die, make a layout drawing on the upper left corner of the work drawing.

    (8) Calculate the pressure center of the mold and check whether the pressure center coincides with the center line of the mold handle. If they do not coincide, make corresponding corrections to the mold results.

    (9) Calculate the punching force, finally select the punching equipment, and check the relevant dimensions of the die and the punching equipment (closed height, work surface, die handle device dimensions, etc.).

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  • What aspects should metal stamping parts processing plants pay attention to in the design?

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    Generally speaking, the process of producing auto parts in metal stamping parts processing plants includes: stamping, cleaning, welding, degreasing, cleaning, electrophoresis, etc.

    1. When designing the structure and shape of auto parts, it is best to adopt a simple and reasonable structure, and at the same time minimize the number of machined surfaces and processing area.

    2. The materials used in automotive metal stamping parts must not only meet the technical requirements of product design, but also meet the stamping process requirements of stamping parts processing plants, as well as the processing requirements of cutting, electroplating, cleaning and other processes after stamping.

    3. In the forming process, in order to facilitate the improvement of stamping deformation and the quality of the parts, the material should have good plasticity, a large plate thickness direction coefficient, a small plate plane direction coefficient, and a small yield strength and elastic modulus ratio of the material. Regarding the separation process, the material does not need to have good plasticity, but it should have a certain plasticity. The better the plasticity of the material, the easier the separation will be.

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