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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1. The reason for the instability and wrinkling of the flange of the stretched part: the blank holder force is too small, or the relative thickness of the blank is small, or the tensile coefficient is too small.
Solution: Increase the blank holder force or increase the number of stretches.
2. Reasons for surface strain of stamping and drawing parts: low heat treatment hardness, poor finish, improper material selection, excessive material thickness, wear of concave die fillet, poor surface quality of bending blank, unreasonable selection of process plan, insufficient lubrication, etc.
Solution: For stamping parts that need to be stretched many times, under the premise of ensuring the necessary appearance quality, there are traces that can occur during the stretching process. Choose suitable materials and process solutions, lubricate and reduce friction.
3. Reasons for the inconsistent shape and size of stamping and drawing parts: due to inaccurate positioning, in addition to taking measures to reduce springback, the reliability of blank positioning should also be improved.
Solution: The shape of stamping and drawing should be as simple and symmetrical as possible, and one-time stretching should be done as much as possible.
4. The reason for the cracking of the hole after the stretching of the tensile member with the hole: the hole diameter is too large, so that the material around the hole is subjected to a large tensile stress, which leads to fracture.
Solution: Change the sequence of forming process, stretch and form first, and then punch holes at the bottom.
5. The reason for the instability and wrinkling of the upper edge of the cylindrical drawing part: the radius of the concave die fillet is too large, which causes the gap between the concave die and the punch die to be too large, or the blank holder force is too small.
Solution: increase the blank holder force and reduce the radius of the die fillet.
In the drawing process, the cylindrical drawing part is a common metal drawing part, which is widely used. Some customers have special requirements for stretched parts, such as flanging, etc., which can meet the special requirements of the product. Drawing parts processing plants need to fully understand the knowledge of drawing parts flanging processing.
Cylindrical stretching parts with flanging include narrow flanging, cylindrical stretching parts and wide flanging cylindrical stretching parts; narrow flanging cylindrical punching and stretching parts are stretching parts with a small total flange width . When this type of parts is stretched many times, due to the narrow flanging, it can be stretched by punching the flanging cylinder first, and then the flanging process is performed to form the specified narrow flanging shape.
In order to make the flanging better, the conical concave die and the conical pressing ring can be selected for stretching in the last two processes of drawing, and the conical flanging can be vacated, so that the flanging area can be reduced when the part is formed. Radial tensile deformation is beneficial to avoid edge cracking.
When the wide-flanged cylindrical stretched piece needs to be stretched multiple times, for the first stretch, make sure that the flanging specification is equivalent to the flanging specification of the stretched piece. In the next stretching, the flanging specification No change, only the raw material in a certain part of the cylinder migrates to the stretch specification. Because in the subsequent stretching process, even a small deformation caused by a part of the flanging will cause a very large tensile stress in the force transmission area of the cylinder wall, thereby causing the bottom section to crack.
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1. Principles of selection of fine benchmarks
1. The principle of datum coincidence: The design datum of the machined surface should be selected as the precise datum as much as possible, which can avoid the positioning error caused by the misalignment of the datum.
2. The principle of mutual reference: when the positional accuracy between the two machined surfaces on the workpiece is relatively high, the method of repeated machining of the two machined surfaces as a reference to each other can be used.
3. Self-base principle: some surface finishing processes require small and uniform machining allowances, and the machined surface itself is often used as the fine base.
4. Unified datum principle: as many surfaces as possible on the workpiece should be machined with the same set of fine datums as much as possible to ensure the relative positional accuracy between the machined surfaces.
The above four principles for selecting rough benchmarks can sometimes not be taken into account at the same time, so the main decision should be made.
1. A rough benchmark should be used in one process of workpiece processing. Whether the rough benchmark is selected correctly or not is not only related to the processing of the first process, but also has a significant impact on the entire process of workpiece processing.
2. The principle of rationally allocating machining allowances: Considering ensuring that the machining allowances of important surfaces are uniform, important surfaces should be selected as rough benchmarks.
3. The principle that rough benchmarks should not be reused in general.
4. The principle of easy clamping: In order to stabilize the positioning of the workpiece and the clamping is reliable, the selected rough datum is required to be as smooth and clean as possible. Forging flashes, pouring riser cuts or other defects are not allowed, and there must be enough support area.
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In fact, the so-called performance is mainly worth the forming limit, moldability and shape freezing of stamping parts. Among them, the forming limit mainly refers to the maximum deformation degree of the raw material of the stamping part during the forming process, and on the premise of ensuring no cracking. In many cases, we consider the forming limit to be the fracture resistance of the material, that is, the better the fracture resistance of the stamped material, the higher the forming limit.
And mold fit and shape freezing refers to the ability of the material to obtain the shape of the mold during the stamping process and to obtain the shape in the mold. There are many influencing factors. Pay attention to all aspects and try to avoid the influence of the material properties by the impression concept stock, so that the shape error of the stamping parts is large.
The above is the key point in the forming process of stamping parts introduced by Zhejiang Baifudu Electromechanical Editor and everyone. Do you have more understanding of stamping parts after reading it? I hope that my friends can help you after reading the above content.
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Metal spring clips are usually made of stainless steel or manganese alloy after heat treatment and are important parts of electronic switches. The spring clamp plays an important role in the high-quality switch between the operator and the product. At the same time, stable toughness and long life performance will provide good tactile feedback for the operator.
Material Science
Generally, copper, carbon steel, stainless steel, manganese and other materials are used to manufacture metal spring clips. Factors such as heat resistance, quenching, corrosion resistance, fatigue strength and elastic limit should be considered comprehensively.
features
Metal spring clip is mainly used to control the movement of machinery, store and output energy, absorb vibration and impact energy, and is also a force measuring element.
application
Metal spring clips have been widely used in various fields, especially in the mechanical and electrical industry, mainly in electronics, electrical appliances, advertising, IT, communications, automobiles, buildings, furniture, bags, craft gifts, sports equipment, clothing, outdoor, etc.
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Precision stamping and ordinary stamping are completely different. The minimum value of the hole diameter and hole margin of precision stamping parts is smaller than that of ordinary stamping. Therefore, when designing precision stamping parts, there are certain requirements for the design of the structure.
When designing the structure of precision stamping parts, the shape of the workpiece and the inner hole should be rounded, and sharp corners are not allowed. However, the minimum allowable corner radius value is related to the material thickness. The punching diameter, slot width and edge distance of the workpiece should not be too small. When precision stamping gears, the pitch circle tooth width of the gear should not be less than 0.6T, and the top and root of the tooth shape should be a rounded transition, not a sharp transition. The contour shape of the outer edge of precision stamping parts should be as smooth as possible, and should not change suddenly. On the surface of the workpiece, design symbols or marks, and when pressing, the cutting depth should not exceed 0.25T.
In general, the production of precision stamped workpieces is mainly based on strong blanking and fine blanking. The geometry, dimensional tolerances, geometric tolerances and shear surface quality of fine blanked workpieces are much higher than those of ordinary blanked workpieces.
The most commonly used materials in the production of precision stampings are metallic materials (including ferrous and non-ferrous metals), but sometimes non-metallic materials are also used.
Among them, ferrous metals mainly include ordinary carbon structural steel, high-quality carbon structural steel, alloy structural steel, carbon tool steel, stainless steel, electrical silicon steel, etc.; non-ferrous metals mainly include pure copper, brass, bronze, aluminum, etc.; there are many Metal materials and models. How can we choose materials, not only to ensure the quality of the workpiece, but also save materials?
When manufacturers of precision stamping parts choose stamping materials for drawing parts, they generally have the following principles:
Metal materials must meet the performance requirements of the workpiece; stamping parts work normally in machines or parts and have a certain service life.
The selected material must have good process performance; for any kind of stamping part, the selected material should be able to meet the requirements of the stamping process.
The selected material should have good economy; under the premise of meeting the performance and stamping process requirements, the material should be low in price, convenient in source and economical to reduce the cost of stamping parts.
The above are the principles that manufacturers of precision metal stamping parts should follow when choosing metal stamping materials. Hope the above content is helpful to readers.
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The selection of suitable convex and concave die fillets for stainless steel wire drawing is closely related to the size and distribution of stress. If the radius of the fillet is large, the pressing area of the blank holder is insufficient, which will easily cause instability and wrinkling; if the fillet is too small, it increases the resistance of the material entering the die during deformation, making it difficult for the material to flow and transfer inward, thereby increasing the force transmission. area, which may cause cracking. Therefore, it is very important to choose a reasonable punch and concave die fillet radius. Under the effect of preventing cracks, the punch relative to the fillet radius rp/ is about 4. The degree of polar deformation of the die and punch will increase, and the relative fillet radius of the die will increase by 5mm~8mm, which helps prevent cracking.
4. Thin strip stretching is used for stainless steel stretching: previous testers have also confirmed that the thin strip stretching method can significantly reduce the maximum tangential residual stress of the stretched parts and effectively prevent longitudinal cracking. According to the degree of deformation and the thickness of the original plate, an appropriate thinning coefficient (usually 0.9t~0.95t) is selected. If the value is too small, the deformation stress of the deep-drawing part will increase sharply, resulting in the bottom cracking.
5. An intermediate annealing process is added to the deep drawing method for stainless steel drawing: after multiple deep drawing, an intermediate annealing process should be carried out, which can completely eliminate residual stress and restore the austenitic stainless steel structure. For high-strength steels, it is generally necessary to go through 1 to 2 stretching processes before moderate annealing. For example, 1Crl8Ni9Ti is usually heated at 1150~1170℃, heated for 30min, and then cooled in airflow or water. Moreover, whether it is the heat treatment between processes or the final heat treatment of the finished product, it should be carried out as soon as possible after stretching to avoid deformation or cracking of the workpiece due to internal stress due to long-term storage. However, both annealing and post-cleaning annealing increase product cycle time, which affects surface quality.
6. Use suitable lubricants for stainless steel drawing: using suitable lubricants has a significant effect on stainless steel deep drawing. The lubricant can form a film with certain toughness and ductility between the convex and concave dies, which is beneficial to the stretch forming of stainless steel. Due to the large deformation of stainless steel deep-drawing parts and the difficulty of forming, polyvinyl fluoride film can be used as a lubricant in actual production. PTFE membrane has good tear resistance, certain toughness and ductility, and is easy to clean. After coating the dry film, in the stretching process, the dry film can be deformed together with the blank, and can always separate the blank from the mold, and the film itself has a certain porosity and a large number of fiber cracks, so it can be stored in a certain amount. of lubricating oil.
The above-mentioned common defects and preventive measures of stainless steel drawing die, in the actual production process, the drawing die is prone to strain, and to solve this problem, the adhesive wear should be reduced by changing the characteristics of the contact pair. I hope the above can be helpful to readers.
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Our commitment is to provide you with tailored, high-quality, reliable parts, assemblies and sub-assemblies that meet co-built specifications. For this, we rely on our 30 manual and automatic presses from 6 to 350 tons, more than 12,000 molds and more than 2,000 square meters of workshop and storage space.
Stamping can handle the most demanding industries: agricultural equipment, aviation, railways, automotive, defense, machine building, electric motors, pumps, food processing, electronics, machinery subcontracting, nuclear power, energy, environment…
The pressing process makes it possible to design a wide variety of industrial parts.
Various shapes of parts: -drawings
Standard or special gasket on-lid-lid– the lid and surface of the gauge– many metal mechanical partsIndustrial products of various sizes:Standard, Standardized or Drawing. Thickness: between 0.2mm and 6mm (depending on material).
different materials Stamping:
– Cold Rolled Sheet, Hot Rolled Sheet, Galvanized Sheet
– Stainless Steel-
aluminum
– brass
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1. Washer method
The gasket method is to place the paper, metal plate or forming workpiece with uniform thickness and the same gap value around the edge of the female mold, then slowly close the mold, and place an equal-height cushion so that the male mold can enter the edge of the female mold, and observe the male mold. and the gap between the die. If the gap is not uniform, adjust the gap by tapping the punch fixing plate until it is uniform, then tighten the upper die fixing screw, then put the paper into the test punching hole, and observe the blanking of the paper until the gap is uniform. Finally, after clamping the upper mold base and the fixing plate, drill and ream the dowel pin holes together, and then punch the cylindrical pins. This method is widely used in small and medium punching dies, drawing dies, bending dies, etc. It is also suitable for controlling the wall thickness of plastic molds.
2. Copper plating method
For punching dies with complex shapes and a large number of punches, it is difficult to control the gap with the above method, so a layer of soft metal (such as copper plating) can be plated on the punch surface, and the coating thickness is equal to the punching gap value on one side , and then adjust, fix and position as above. There is no need to remove the coating after assembly, and it will fall off naturally during the cutting process.
The coating method is to apply a layer of enamel or amino acid paint on the surface of the punch. When painting, you should choose paints of different viscosity according to the size of the gap, or control the thickness by painting multiple times. After painting, the punch assembly should be baked in a 100120 oven for 0.5-1 hour until the thickness of the paint layer is equal to the blanking gap value, which should be uniform, and then adjusted, fixed and positioned according to the above method.
The light transmission method is to illuminate the bottom surface with light after the upper and lower molds are closed, observe the size of the light gap around the edge of the convex and concave mold, and judge whether the blanking gap is uniform. If the gap is not uniform, adjust, fix and position. This method is suitable for thin blanking dies that require high assembly fitters. For example, it is best to use a die gap gauge for inspection and adjustment.
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Mirror finish is used for pre-polishing and fine polishing. Pre-polishing uses a hard or harder buffing wheel to finish the finish of the stainless steel sheet metal finish and remove the roughness of the ground finish. Fine polishing uses soft to further process the pre-polished surface, remove the traces left by pre-polishing, and obtain a bright mirror surface.
The mercerizing effect is the process of using the brushing wheel installed on the grinding and polishing machine to process the surface of the stainless steel sheet metal to obtain decorative silk-grain brushing and satin finishing.
Sandblasting effect, using compressed air flow to spray sand or steel pellets, glass balls and other abrasives on the appearance of stainless steel sheet metal processing, so that it presents a beautiful, slightly rough sandy appearance.
In stainless steel operations, stainless steel is usually heated by coils, lashings, welding or fire on artificial surfaces to produce black scale. This gray-black scale is relatively strong and contains two EO4 components, NiCr2O4 and NiF. In the past, it was basically removed by strong etching with hydrofluoric and nitric acids. However, due to environmental pollution, harm to human body, high corrosion and high cost, the sheet metal processing industry gradually adopts chemical methods: non-polluting pickling passivation paste and non-toxic cleaning solution are used, and inorganic additives are added for leaching at room temperature.
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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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Considerations for Deep Drawing Stamping
When considering deep drawing stamping for your manufacturing needs, it is important to be aware of the following:
Reduced Material Waste: Deep drawing stamping uses a larger amount of base material than other metal forming processes for significantly reduced material waste.
Measurement is critical: not only is it important to ensure that die dimensions are accurate, it is equally essential to consider the material thickness and desired measurements. Incorrect measurements can result in thin walls and inaccurate dimensions.
Drafting and tapping: Due to the basic manufacturing process of deep drawing stamping, some drafting and tapping of the top of the component is unavoidable. This should be taken into account during the initial design phase.
Varied Material Thickness: Deep-drawn components will typically have different thicknesses with thinner walls and a thicker base. This can be mitigated by tooling after the drawing process is completed.
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In the processing industry, molds are indispensable equipment, and different processing industries choose different molds. Metal stamping dies and plastic processing dies are widely used in industrial production. As for the difference between them, many people will say that metal stamping dies are made of metal, and plastic processing dies are made of plastic. What is the essential difference between metal mold and plastic mold? What are their main areas of application? To understand the difference between the two, we must first understand what is a metal stamping die and what is a plastic die.
1. Metal molds refer to stamping parts processed by using various presses and special tools in industrial production to process metal materials according to the shape required by the finished product. This special tool is often called a metal mold.
2. Plastic mold is a combination of plastic molds, which can be used for compression molding, extrusion molding, injection molding, blow molding and low plastic, and can be used as mold punch, die and auxiliary molding system. A range of plastic products that can be processed in various shapes and sizes.
3. From the perspective of the role of the mold, the metal mold is a mass production tool for metal products. The materials used are generally iron or copper or aluminum, the plastic molds are plastic products, and the raw materials used are also plastic raw materials.
4. The most fundamental difference between metal molds and plastic molds is the structure of the molds. Plastic molds have cooling systems, but metal molds do not. The molding principle of the product is also different. The plastic mold is cooled and formed after injection molding, and the metal mold is punched into a standard thickness steel plate.
5. Hardware molds and plastic molds are made of steel. Stamping metal molds generally use cold steel. If it is a pressure injection mold, hot-working steel is required. The plastic mold is generally hot-working steel. The mold is more complicated. Mold) There is no gating system and cooling system, which can be understood as: plastic mold processing is to cool plastic flow into the cavity in a closed space for cooling and forming.
Due to the use of mold processing, metal stamping parts that cannot or are difficult to manufacture by other processing methods, are thin-walled, lightweight, have good rigidity, good surface quality and complex shapes can be obtained. The dimensional accuracy of the blanked parts is guaranteed by the mold, and the characteristics are exactly the same, so the general press can produce dozens of parts per minute, while the high-speed press can produce hundreds of parts per minute. Therefore, it is an efficient processing method.
Plastic molds have high tolerances, low repetitive labor costs, and can use a variety of materials. The waste loss is far less than that of metal molds, and there is no need to continue to improve parts after plastic molds are formed.
The above is the relevant content of metal stamping dies and plastic dies. These two molds are suitable for different industries and different processing requirements, so the production methods of the molds will also be different. I hope the above will be helpful to readers.
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During the processing of the drawing die, if the die clamping is not flexible enough, or there is a stuck situation, then the production should be stopped immediately, and the main reason for the stuck die should be found out and troubleshoot. Otherwise, it may expand the failure, resulting in mold damage.
The mold is poorly guided and tilted. And there are foreign objects in the template, so that the template cannot be flatly attached; there is a problem with the strength design of the mold or uneven force. It will lead to the deformation of the mold, such as the hardness and thickness of the mold base and the template are too small, and it is very easy to be deformed by external force; the mold position is not installed correctly, and the positioning error of the upper and lower molds is too poor. Or the precision of the press is too low, causing the mold to interfere; the strength of the punch is low, and the position of the large and small punches is too close, which makes the lateral force of the mold unbalanced. At this time, the strength of the punch should be increased, and the guidance and protection of the stripper plate should be strengthened.
The above has explained the reasons for the occurrence of card molds in the processing of drawing molds, and different reasons will have different solutions, so we need to solve the problems in a targeted manner.
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1. Some common problems and reasons in the processing of stamping parts
1. Roller printing: It is caused by foreign matter adhering to the cleaning roller or paper feeding roller (occurs at a fixed distance). Under normal circumstances, the foreign matter printed by the roller on the sheet can be removed.
2. Burrs: In the process of punching or chamfering, there is incomplete residual material, and burrs are generated in the part below the truncated surface of the steel plate. Based on the truncated surface, the iron powder generated here will damage the mold and produce Concave and convex.
3. The coil may be crushed or the edge is wrinkled: When the gap between the guide rollers on the die is small, the guide rollers of the uncoiler may be wrinkled, which is caused by the unyielding balance of the coil feed.
4. Concave and convex: The material is abnormally convex or concave due to foreign matter (iron filings, dust) mixed in the uncoiler.
5. Sliding mark: It is caused by the sliding of the roller, which occurs when it suddenly stops or accelerates.
When we design the mold, we must have reasonable clearance value, fillet radius and machining accuracy. When designing a bending die, effective measures should be taken to reduce the springback, and the springback should be subtracted from the die; reasonable rounded corners should be designed to prevent bending cracking. When deep drawing, use a blank holder to prevent wrinkling, and the pressure should be moderate; use appropriate lubrication to reduce the drawing resistance to prevent the die from sticking or the workpiece being pulled through.
There are many defects in metal stamping parts, such as scratches, cracks, raised dents, burrs, oxidation, etc. In the processing of metal stamping parts, we must pay attention to these details, so as to bring greater benefits. Spinning is a metal rotary machining process. During the processing, the blank is actively rotated with the spinning die or the spinning head is actively rotated around the blank and the spinning die. hollow revolving body parts.
Reshaping is the second reshaping of the product shape using the established tool shape. Mainly reflected in the pressing plane, spring feet, etc. In view of the elasticity of some materials, the quality of one-time forming cannot be guaranteed. Reprocessing is a basic stamping process that uses molds to separate materials. , forming and other stamping processes to prepare the blank, and can also cut and trim the formed stamping parts. Blanking is widely used in automobiles, home appliances, electronics, light industry, instrumentation, machinery, railways, communications, chemicals, textiles, aerospace and other industries. The blanking process accounts for about 50% to 60% of the entire stamping process.
Forming process:
(1) Bending: a plastic forming method that bends metal sheets, pipe fittings and profiles into a certain angle, curvature and shape. Bending is one of the main processes widely used in the production of stamping parts. The bending of metal materials is essentially an elastic-plastic deformation process. After unloading, the workpiece will produce elastic recovery deformation in the direction, which is called rebound. Springback affects the accuracy of the workpiece and is a technical key that must be considered in the bending process.
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