Zhejiang Balford Mechatronics Co., ltd focus on difficult stamping & deep drawing. Main product: motor housing and difficult custom deep drawn stampings.
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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By means of the deep drawing processes, carbon steel and stainless steel products are developed by China Balford . Any metal product shape belonging to several sectors can be provided. Thanks to the cold deformation, through the deep drawing process, ...
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1. Analysis of the causes of wrinkling of tensile parts
The way to avoid wrinkling is to ensure that the mold can hold down the material during the stretching process and to ensure a reasonable speed of movement of the sheet. If the sheet moves too fast when the product is stretched, it will cause wrinkling; on the other hand, if the sheet moves too slowly, it will cause the stamping to crack.
1. Select reasonable pressing equipment
When selecting the pressing equipment, the pressing equipment compresses the deformed part of the blank, and has a significant effect on the pressing material to avoid the flange part from arching and wrinkling. Press material should be appropriate. The pressing equipment is divided into two types: elastic pressing and rigid pressing. Elastic equipment is suitable for shallow drawing and rigid equipment is suitable for deep drawing.
2. Reasonable selection of drawbeads
Setting drawbeads on the binder surface is a useful method to control deformation resistance. The drawbead can well adjust the movement of the material, so that the material movement resistance of each part in the drawing process is uniform, so that the amount of material flowing into the cavity meets the needs of the appropriate parts, and avoids wrinkling and cracking. For curved stretched parts with messy shapes, especially those with small flanges, drawbeads should be set to increase the radial tensile stress of stretching and control wrinkling; the setting direction of the drawbeads is in the radial direction. The part with less stress, that is, the part where the sheet is easy to move. For parts with smaller flanges, some materials (process supplementary materials) can be appropriately added in order to set tensile ribs, and this part can be removed when trimming. For drawn parts with large difference in drawing depth, the draw bead should be set in the part with less material feed, so that too much material in this part can be arranged to be pulled into the cavity of the die to avoid wrinkling.
There are many reasons for the wrinkling of the stretched parts during the stretching process, the main reasons are as follows:
1. The drawing depth of the stamping part is too deep, which causes the sheet to move too fast during the feeding process, causing wrinkles.
2. The R angle of the die of the stamping part is too large during the stretching process, which leads to the fact that the punch cannot press the material during the stretching process, resulting in the sheet material moving too fast and causing wrinkles.
3. The pressing ribs of stamping parts are unreasonable, the pressing ribs are too small, and the direction is incorrect, which cannot effectively prevent the sheet material from moving too fast, causing wrinkling.
4. The pressure of the ejector is too small, so that the stamping parts are not formed completely and wrinkle is formed.
The above is the relevant content about the reasons for the wrinkling of stamping products. Of course, the wrinkling of products may also be due to problems with the parameters in the production process, and the parameters need to be redesigned. There are many reasons for product wrinkling. To prevent the cause of wrinkling, we can also check the origin.
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1. What are the main points of hardware accessories processing?
1. The machining accuracy of the parts changes due to internal force. Skilled workers know that during machining, the part is clamped by the three jaws of the lathe to ensure that the forces the part is subjected to during machining are stable over time. It will loosen the lathe chuck, reduce the force on the part and cause deformation.
2. Deformation easily occurs during heat treatment. When machining some thin and small parts, it is usually necessary to heat treat them first. At this time, if the professional knowledge of the technicians is not solid and the structural performance of these parts is not well understood, it is easy to cause the parts to bend.
3. The parts are elastically deformed under the action of external force. When machining parts, lathes and fixtures are often used. When the two are not uniform, the uneven force on the fixed parts will occur, and the deformation will occur when the force is small.
1. After the parts are heat treated and deformed naturally, they are trimmed with professional cutting tools to ensure the perfection of the parts.
2. Carry out technical transformation to improve the rigidity of components.
Technicians need to improve the process, increase innovation, select the appropriate heat treatment method, change the stiffness of the parts, so that the parts are not easily deformed.
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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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What should be paid attention to when producing precision stretched parts?
1. The shape of the precision stretched product should be as simple as possible, and it should be stretched as much as possible in one processing.
2. For parts with complex appearance that need to be stretched many times, on the premise of ensuring the quality, the appearance should be allowed to have traces that may be produced during the processing.
3. Under the premise of ensuring the assembly requirements of the drawing die, the side wall of the drawing part should be allowed to have a certain slope.
4. The distance from the edge of the hole on the bottom or flange to the side wall of the precision stretch is appropriate.
In daily life, you can see many metal stretch products, such as stainless steel thermos cups, stainless steel bottle caps, stainless steel basins for kitchens, stainless steel small bowls, etc., all of which are stainless steel stretch products.
Compared with the metal stretching process, the shape of the stretched part is related to the simplicity and complexity of the stretching process. Simple shapes will be stretched into shape at a time. If the process of stretching the product is complicated, it needs to be stretched several times. Of course, under the premise of ensuring product quality, the number of deep drawing should be increased as much as possible, and the interval time of the drawing process should be extended. During the stretching process, stretch marks may appear on the surface of the product. Under the premise that the product is qualified, there is a certain slope on the side after stretching to ensure that the product size, whether it is internal or external, can achieve better stretching quality.
Another important aspect of hardware stretching is choosing the right lubricant.
The mold used for metal drawing parts is generally composed of punch, die and blank holder. The gap between the punch and the die is greater than the thickness of the sheet metal. Since the diameter of the die is smaller than the diameter of the blank, the material undergoes plastic flow during stamping and drawing. One part increases the height of the part, and the other part increases the thickness of the barrel wall. The stretching process is due to the internal interaction of the metal caused by the force of the material, resulting in internal stress between the elements in the metal. Under the action of internal stress, a strain state occurs, which causes the material to undergo plastic deformation, and is pulled into the die from time to time to become a cylindrical workpiece. The modification point of the stamping and drawing process is the transformation from a large section of the material to a cylindrical workpiece with a small section. In this process, the surface of the material and the surface of the die must be in contact to generate friction. In order to reduce the friction coefficient and reduce the extrusion force, a stretching oil with good performance must be used. The complex stretching process and lubricants also play a very important role. effect.
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1. Processing characteristics of wire drawing dies
1. Protruding, the gap between the concave molds should be uniformly produced. For a drawing die without a guide device, the same piece should be placed so that the punch can be adjusted and the position of the die is correct; for a guided drawing die, it is also necessary to ensure that the gap between the punches is uniform.
2. The material has good compactness and elastic deformation when stretched and deformed. Before the convex and concave dies are hardened, test punching and trimming should be carried out. It is easy to process and has good wear resistance. After the deep drawing test die is qualified, press The blanking die is manufactured in the state of the die trial.
3. For the drawing die without guiding equipment, it is required to place the same piece, adjust the punch, and the position of the die is correct; for the drawing die with guidance, it is necessary to ensure that the gap between the punches is uniform when assembling.
4. The processing of drawing dies is generally to make drawing dies first, and after passing the deep drawing test, make blanking dies according to the test conditions, the processability of die parts and the convenience of die maintenance, all of which should be considered in design. .
5. The processing quality of deep drawing dies has been paid more and more attention, so processing the drawing dies into parts is also an important factor to improve the quality of the dies.
1. The concept of stretching.
(1) Stretching: Press the sheet into a hollow piece (almost no change).
(2) Stretching process: The material is transferred to the side wall of the cylinder (box) through a plane (flange), so that the overall dimensions of the plane will change significantly.
(3) Tensile coefficient: the ratio of the tensile diameter to the diameter of the blank (the degree of deformation from the blank to the workpiece).
2. Main influencing factors of tensile coefficient:
(1) Mechanical properties of the material (reduced strength – elastic deformation; tensile strength – plastic deformation; elongation coefficient; section shrinkage).
(2), relative material thickness.
(3), the number of stretches.
(4), stretching method.
(5), convex and concave die fillet radius.
(6) The drawing surface is clean, lubricated, clearance, etc.
(7), expansion rate.
1. Parts whose drawing depth is less than the diameter: the height of the cylinder can be increased by reducing the diameter of the cylinder, so that the angular radius can be gradually reduced.
2. Material parts with equal thickness and diameter: The height can be kept constant to reduce the radius of the fillet, if it is to gradually reduce the diameter of the small cylinder.
3. The flange is large and the circle radius is extremely small: it should be obtained by multiple forming.
4. The flange is too large: if necessary, use the expansion molding method.
In order to reflect the principle of “unchanged convex edge”, the flange formed by one stretch does not participate in all subsequent stretching deformation, while the wide flange stretching reduces the material that first enters the die (that is, the material that forms the wall and the bottom). ) 3~10% more than the final stretched material.
Note: The number of upper bounds for multiple times is taken from the lower bounds of multiple times within the zone. The excess material will be returned to the flange in the subsequent multiple drawing steps, which will thicken the flange without pulling and can be repaired by reshaping. Therefore, each stretch height should be strictly controlled when stretching.
The above introduces the relevant content in the design of the drawing part processing mold. During the drawing process, there is friction between the material and the die, so there should be a special drawing lubricant. High friction will not only increase the tensile coefficient, but also increase the pulling force, which is detrimental to the scratches on the mold and workpiece surface. I hope the above will be helpful to readers.
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1. Attention should be paid to processing metal stamping parts
1. Cracking at the bottom of the part: The main reason for the cracking at the bottom of the part is that the plasticity of the material is poor or the blank holder of the mold is pressed too tightly. The preventive measure is to replace the material with better shaping or loosen the blank holder.
2. Wrinkles on the side walls of the parts: The main reasons for the wrinkles on the side walls of the parts are the insufficient thickness of the material (thinner than the small allowable thickness) or the eccentricity when the upper and lower molds are installed, resulting in a gap on one side If it is too large, the gap on the other side is too small. The preventive measure is to replace the material in time and readjust the mold.
3. Scratches on stamping parts: The main reason for scratches on parts is that there are sharp scars on the mold or metal dust falls into the mold. The preventive measures are to grind the scars on the mold and clean the metal dust.
2. Employees should pay attention to their own operating procedures in the process of stamping parts processing
1. It is strictly forbidden to wear slippers when going to work, so as not to hit the feet with molds and iron blocks in the workshop. Squad leaders, fitters and mold repairers must wear safety shoes when going to work.
2. At work, first check whether the equipment is running abnormally, such as single, unclear continuous flushing, poor operation or electrical failure, immediately stop the machine, and promptly find a technician on duty to deal with it.
3. Check the equipment according to the inspection content on the equipment inspection card, pay special attention to whether the guide and braking device of the punch press are in normal operation, and the functions of single punch and continuous punch are clear.
4. It is strictly forbidden for operators and mold maintenance personnel to put their hands into the mold for operation.
5. Any flammable and explosive items cannot be stored under the switch.
6. When installing the suction fan, the operator is strictly forbidden to put his hand on the motor to clean up the waste.
7. Cut off the power supply, clean and scrub the work surface, remove the mold for maintenance and storage, and check the oil in the lubrication system at certain times every week.
8. Male operators are strictly prohibited from having long hair, and female operators should roll up their long hair to prevent the hair from getting caught in the flywheel.
9. It is strictly forbidden to wear gloves when drilling and milling machines; when using the grinding machine, wear masks and goggles to protect yourself.
10. Pay attention to fire prevention of other oils such as white oil, alcohol, cleaning agent, etc.
11. When there is oil, clean it up in time to avoid slipping.
12. Special tools (pliers, hooks) must be used when laying out or manually feeding and taking out blanks individually. It is strictly forbidden to feed and take blanks by hand. One switch will hurt your hand, you need a double switch. The machine must not leak oil, otherwise it will fall off. Do not expose the power supply, it is dangerous.
13. Gloves should be worn when packing materials, leftovers and molds to avoid scratching hands.
14. Pay attention to dragging the mold to prevent it from falling on the ground (the flatbed truck must be lowered to pull the mold).
15. The operator needs to wear earplugs.
16. When a new employee goes to work on the first day, the team leader must explain the safety operation rules to him, and learn the safety operation rules once a week.
17. It is strictly forbidden to blow the air gun at people, it is easy to hurt the eyes.
18. When adjusting the machine, the machine must be adjusted to single action, and it is strictly forbidden to move the discharge belt.
19. Operators are strictly prohibited from chasing and beating in the workshop, so as to avoid falling, knocking over the product or hurting themselves.
20. When installing the mold on the small punch, first loosen the locking device of the guide rail, install the upper and lower molds, and then adjust the stroke of the guide rail until the requirements are met and the fastening device is locked. In addition, a single stroke must be performed when the high punch is set up in the mold. After locking the upper mold, the oil pressure locks the mold and then locks the lower mold, and check again before production.
21. It is strictly forbidden for non-electricians to connect and repair the machine.
22. Wear gloves and pay attention when stamping iron sheets, otherwise it will hurt your hands.
23. It is strictly forbidden to use the foot switch on the punch, and all the original equipment of the machine are removed.
24. When the machine is found to be abnormal, turn off the power first, and then find the technician on duty to deal with it in time.
25. When cleaning and checking the equipment, the power must be cut off before operation.
26. Check whether various equipment and materials are ready.
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2. How to solve the problem of warping of stainless steel tensile parts?
For stainless steel tensile parts, if there is a problem of warping, the solution is to anneal. If not, then use the right material. In order to prevent the sticking phenomenon, the brightness of the mold should be improved, and the above purpose can be achieved by using the appropriate stretching oil and the correct stretching coefficient.
Tensile parts, when using materials, if the materials are different, the elongation will be different. Moreover, after stretching, the force on the material will also change, which is affected.
Sandblasting for surface preparation cannot be used to relieve internal stresses in tensioned parts. From another point of view, in the sandblasting process, there will be some effects. Then, over time, it may reduce the internal stress of the tension member, so this is not correct.
Well, the above is the relevant content about “how to solve the problem of warping of stainless steel tensile parts?”, I hope the above content can help readers!
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When processing stainless steel sheet metal parts, in order to avoid debris from hurting people, the baffle should be lit in an appropriate position. When the surface of the workpiece needs to be polished with gauze, move the tool to a safe position and be careful not to let your hands and clothes touch the surface of the workpiece. When grinding the inner hole, don’t use your fingers to support the gauze, use a wooden stick instead, and don’t drive too fast.
Obstructs placing objects, fixtures or workpieces on the lathe bed and spindle gearbox. Be mindful when doing homework. Obstruct tired operation, chat operation, multi-person operation, drinking operation, smoking operation.
Adhere to the regularity of machine tools, tools, and operations, and do a good job of handover work. When cleaning the workplace after work, the power should be turned off, and various feed handles should be placed in a safe place. When turning workpieces with irregular shapes, a balance block should be installed, and the cutting should be carried out after trial rotation.
The tool clamping should be reliable, and the protruding part of the tool head should not exceed 1.5 times the height of the tool body. The shape and specification of the gasket under the tool should be consistent with the shape and specification of the cutter body, and the gasket should be as few and flat as possible.
In addition to installing measuring tools on the lathe that can be actively measured in operation, stop and move the tool holder to a safe position before measuring the workpiece. Ribbon chips and spiral long chips that occur during cutting should be removed with hooks in time to prevent hand pulling.
Wear work clothes, cuffs and safety glasses before work. Female workers should wear work caps, long hair in hair care caps, and operate with gloves.
When the chuck is loaded and unloaded on the spindle of the lathe, it must be carried out after the machine is stopped. The power of the motor must not be used to remove the chuck. Guards should be used for the protrusions of chucks, dials and core clamps that clamp the workpiece to avoid strangling clothing and other parts of the body. If there is no protective cover, care should be taken to adhere to the required interval during operation.
When clamping the workpiece with the top, it should be noted that the center of the tip is exactly the same as the center hole of the spindle. Sheet metal work must not use damaged or angled tips. Before use, the top should be cleaned, the center hole should be clean, and the tailstock tip should be firm. When cutting slender workpieces, in order to ensure operational safety and processing quality, a tracking tool rest or center rest should be selected, and a mobile protective cover and safety signs should be set.
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Today, we are going to talk about a very common bad situation in progressive die stamping — chip jumping and crushing. What are the reasons for this, and what effective solutions can be taken to avoid affecting the quality and production efficiency of metal stamping products and causing losses to stamping manufacturers.1. Reasons
(1) The clearance is too large;
(2) Improper feeding;
(3) Punching oil drops too fast, and the oil is sticky;
(4) The punch is worn and chips are pressed on the punch;
(5) The punch is too short, and the length of inserted die is insufficient;
(6) The mold is not demagnetized;
(7) Hard material, simple punching shape;
(8) Emergency measures.
2. Solutions
(1) Control the machining accuracy of punch and die or modify the design clearance;
(2) Trim the tape and clean the mold in time when it is sent to the proper position;
(3) Control the oil drop amount of stamping oil or change the oil type to reduce the viscosity;
(4) Studied the punch edge;
(5) Adjust the length of the punch edge into the die;
(6) Demagnetization is required after mold and research;
(7) Replace the material, modify the design, install ejecting or trim the inclined plane or arc (pay attention to the direction) on the end face of the punch edge, and reduce the fitting area between the end face of the punch edge and the scrap;
(8) Reduce the sharpness of the die edge, reduce the amount of research and study on the die edge, increase the roughness of the straight edge surface of the die, use a vacuum cleaner to absorb waste materials, reduce the impact speed, and slow down chip jumping.
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1. Stainless steel stamping and drawing parts
Stainless steel tensile parts have the characteristics of high strength, light weight, good wear resistance, and high corrosion resistance. The tensile parts of this material do not require electroplating protection. It is suitable for heat treatment and is often used in fuel systems, braking systems, exhaust systems, oxidation sensors and decorative parts in automobile manufacturing.
Low carbon steel has the characteristics of excellent formability, stable forming dimensions, high strength, and light weight (see material grade for details). It is often used in various parts in automobile manufacturing, especially high-strength mechanism parts.
The characteristics of aluminum alloy tensile parts are: light weight (almost 1/3 of low carbon steel), high strength, non-magnetic, stainless rust, anodized anti-corrosion, suitable for heat treatment, etc., and are often used in bulk in automobile manufacturing and other industries. devices, energy storage devices, beverage containers and the pharmaceutical industry.
Copper alloy drawing parts have the characteristics of stable forming dimensions, corrosion resistance, good ductility, and easy welding. The disadvantage is that they are easy to oxidize. Due to the high price of copper alloy materials, waste needs to be reduced and recycled if necessary.
The above is related to the processing materials of stamping and drawing parts. In general, the machining methods for machining parts from different materials will vary. Material properties and processing characteristics should be considered to avoid losses. Hope the above content is helpful to readers.
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1. Design principles of precision die structure
1. According to the production batch of stamping parts, determine whether to use a simple die structure or a complex die structure. Generally speaking, a simple die structure has a short life and low cost, and a complex die structure has a long life and high cost. Therefore, if the number of stamping parts is small, it is more suitable to use a simple die structure. Larger quantities are more suitable for conventional die structures with longer service life.
2. The accuracy level of the stamping die is determined according to the size requirements of the stamping parts. If the dimensional accuracy and section quality of the stamping parts are high, the precision stamping structure should be used, and the stamping parts with general precision requirements can use the ordinary stamping structure.
3. Select the type of stamping die according to the capability of the existing equipment. For example, when drawing workpieces, a double-action die structure is much better than a single-action die structure.
4. The type of unloading device in the die structure is selected according to the thickness of the stamping plate. For example, when blanking thick plate workpieces, if the requirements for surface straightness and sharpness are not high, a fixed unloading device can be selected. Suitable for selection.
5. Select the mold type according to the technical conditions and economy of mold manufacturing. For example, when the technical requirements of die manufacturing are low, a simple die stamping structure should be designed as much as possible. When the variety of mold equipment is complete and the machining accuracy is high, in order to improve the service life of the mold and achieve mass production, a more complex precision mold stamping structure should be selected.
Designers should consider a variety of factors when choosing a die structure. Because simple stamping dies and general traditional stamping dies have their own advantages and limitations. This requires analysis and comparison to make the selected stamping die structure mode as reasonable and reliable as possible.
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All kinds of stamping parts can be seen everywhere in our daily life. Many domestic manufacturers have clearly seen the huge potential of the stamping market, and continue to increase their investment in the stamping market, which has effectively improved the quality of my country’s stamping products, so that they can meet the needs of the market. In the face of products produced by many manufacturers, how to choose is a headache for consumers, and which is better for high-quality stamping parts processing is a topic of concern.
When evaluating which manufacturer of metal stamping parts has better quality, the first thing to look at is the quality of the manufacturer’s products. Whether the manufacturer can produce in accordance with the relevant regulations in the production process, whether the product quality meets the relevant regulations and other related issues are all important evidences for measuring a manufacturer. When selecting, professional manufacturers let us consider the first time.
All kinds of stamping parts can be seen everywhere in our daily life. Many domestic manufacturers have clearly seen the huge potential of the stamping market, and continue to increase their investment in the stamping market, which has effectively improved the quality of my country’s stamping products, so that they can meet the needs of the market. In the face of products produced by many manufacturers, how to choose is a headache for consumers, and which is better for high-quality stamping parts processing is a topic of concern.
When evaluating which manufacturer of metal stamping parts has better quality, the first thing to look at is the quality of the manufacturer’s products. Whether the manufacturer can produce in accordance with the relevant regulations in the production process, whether the product quality meets the relevant regulations and other related issues are all important evidences for measuring a manufacturer. When selecting, professional manufacturers let us consider the first time.
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May 1 to May 4, 2014, Mr. Mustafa and Mr. Bashir went to Yongkang Balford Mechatronics Co.,Ltd.. Shawn, Balford's CMO, shown them around our company . They visited several stampings, sheet metals and deep drawings workshops in ...
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