Zhejiang Balford Mechatronics Co., ltd focus on difficult stamping & deep drawing. Main product: motor housing and difficult custom deep drawn stampings.
Multiple progressive dies deep drawing is a classic sheet metal forming technique which is used mostly for producing large numbers of products. It is a process in which a sheet metal blank is radially drawn into a
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The opening size also plays a non-negligible role in the production test of the entire mold. Therefore, in most cases, when designing irregular deep-drawn parts, a cavity is often left for deep-drawn part design.
If the customer is not strict with the material requirements, and the repeated test model does not meet the requirements, you can replace the material with good tensile properties and try again. Good material is half the battle, and stretching cannot be ignored. The cold-rolled steel plate is mainly 08Al.08.08F.10.15.20 steel, and the amount used is 08 steel, which is divided into boiling steel and stable steel. The price of boiling steel is low and the surface quality is good, but the deviation is serious, and the phenomenon of strain aging is prone to occur. The foreign steel grade adopts Japanese SPCC-SD deep drawing steel, and its tensile properties are better than 08Al.
In deep drawing, especially stainless steel plate and aluminum plate are easy to produce drawing when deep drawing, and tensile fracture is serious.
The more wrinkled the die, the less the crack is our principle. High positioning accuracy and high precision. Under the same stretching conditions, when the rotating body is pulled out, the thickness of the blank will change, but its thickness is basically the same as the original thickness. According to the same principle, the blank area and the drawn area (if needed to adjust, trim the allowance). But wire drawing is more complex in shape and process, and sometimes becomes thinner. Now, there is a lot of software for 3D that can extend the calculation of materials.
Answer: Test data.
A product needs to go through several processes, usually one process is blanking. Through the calculation of the unfolded material, the shape and size of the blank have been fully understood, and the overall size of the droplet mold has been determined. After the mold design is completed, the convexity and concavity of the mold cannot be processed. The blank is first machined by wire cutting. If the blank is relatively large, it can be milled with a milling cutter and then clamped), and then the size of the blank is determined by repeated tests of the subsequent wire drawing process, and then the die punch is processed.
The above is the relevant content of mold design in drawing mold processing. Friendly advice. If the trial die is cracked, try applying lubricant (rapeseed oil, soapy water) to the lower die, or covering the die compound with a film wrap to get results. Proper antipyretic process can improve the plasticity of the material and reduce the multiple stretching of the parts. Hope the above will help readers.
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1. In the production process of electric vehicle stamping parts, due to the burrs of the stamping parts during blanking, it is necessary to study the cutting edge, and it is also necessary to pay attention to whether the blanking gap is reasonable. During bending, the instability of stamping parts is caused, mainly for U-shaped and V-shaped bending, for the guide position before bending, the guide position during the bending process, and the pressure during the bending process. Holding the material to prevent the stamping from slipping during bending is the key to solving the problem.
2. During production, the stress on the material increases, and the stamping parts tend to turn over and twist. When the material is turned over, the size of the punching hole will become smaller, and the strong pressure on the material will cause plastic deformation of the material, so the size of the punching hole will be larger. Thereby reducing the strong pressure, the punching size will be smaller.
3. In the production process of electric vehicle stamping parts, if the end is repaired with a slope or arc, due to the relief of the punching force, the stamping parts are easy to turn over and slander, so the stamping size will be larger. The convex end is flat, and the size of the punching hole is relatively small.
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In order to improve the precision of metal stampings, some stamping processes, such as refurbishment and refurbishment, are sometimes added during the production process of stamping parts. So, people who have just entered the industry will ask, what is the difference between the two?Shaping is to use the reshaping die to press the inaccurate parts of the bending or stretching parts into an accurate shape; Or for the stamping parts with surface flatness requirements, the flat stamping parts with arch bending and warping shall be flattened with the leveling die. That is to say, depending on the material flow, the shape and size of the process parts are changed a little to ensure the accuracy of the workpiece. It belongs to the forming process of stamping parts.
Trimming is to remove the allowance of the outer edge or inner hole of the blank with the trimming die to obtain a smooth section and accurate size. It is a blanking process applied to stamping parts and belongs to blanking process.
That is to say, shaping is used for the forming process of stamping parts to improve the shape quality and dimensional accuracy of finished metal stamping parts; The trimming is often used in the blanking process of stamping parts to obtain high-quality blank or inner hole of stamping parts and improve the dimensional accuracy.
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1. Materials: Good materials are half the battle. Stretching cannot be ignored. Cold rolled steel plate is mainly composed of 08Al.08.08F.10.15.20 steel, of which 08 steel is the most widely used, divided into boiling steel and killed steel. The price of boiling steel is low and the surface quality is good, but the segregation is serious and there is a tendency to adapt to aging. Not suitable for parts with high stamping performance and strict appearance requirements.
2. Determination of blank size: The blank diameter of a simple rotating body drawing part does not become thinner during the drawing process. Although the thickness of the material has changed, it is basically very close to the original thickness. It can be calculated according to the principle of the area of the blank and the area of the drawn part (if there is trimming, the trimming allowance must be increased. However, the shape and process of the deep-drawn part are often complicated, sometimes thinning and stretching. Although there are many three-dimensional The software can calculate the material, but its accuracy is less than 100%.
The solution: material testing. A product part should go through multiple processes, the first of which is usually the process of material transportation.
First perform material calculations to have a rough idea of the shape and size of the blank to determine the overall dimensions of the material delivery die. After the mold design is completed, do not deal with the convex and concave die dimensions of the material conveying die. First use wire cutting and machine the blanks (when the blanks are large, they can be milled with a milling machine and then repaired). After trial and error in the subsequent stretching process, half the size of the feed conveyor die was finally determined.
3. The drawing coefficient m is one of the main process parameters in the calculation of the drawing process, and is often used to determine the drawing sequence and drawing times. There are many factors that affect the elongation coefficient m, including the properties of the material. The relative thickness of the material. Drawing method (with or without a blank holder). number of stretches. stretching speed. Punch and concave die fillet radius. The calculation and selection principle of the tensile factor m is the focus of introduction in various stamping manuals, including calculation. View the form. calculation and many other methods.
The relative thickness of the material. Drawing method (with or without a blank holder). In the process of mold repair, the number of stretches is not easy to adjust, so be careful! When you choose the stretch factor m, it is better to find another colleague. Grease the concave die or place a film bag on the sheet.
4. When stretching and cracking, apply lubricating oil on the die (do not apply it on the punch), and cover the plastic film of 0.013-0.018 mm with the die.
5. During the stretching process, due to the cold plastic deformation, the parts are cold hardened, the plasticity is reduced, the deformation resistance and hardness are increased, the mold design is unreasonable, and intermediate annealing is required to soften the metal and restore the plasticity. Note: annealing is not necessary in the general process. After all, in order to increase the cost, choose to increase the process and increase the amount of annealing, and use it with caution! Annealing generally adopts low temperature annealing, that is, crystallization annealing.
Two points should be noted during the annealing process: carbon and oxidation. It’s mostly about oxidation. Oxidized skin has two hazards: thinning the effective thickness of the workpiece and increasing die wear. When the company’s conditions are not met, ordinary annealing is generally used. To reduce the production of oxidized skin, the furnace should be filled as much as possible during the annealing process. I also used the soil method: 1. The workpiece can be mixed with other workpieces (premise: the annealing process parameters should be basically the same) 2. The workpiece is put into the iron box for welding, and then the electric furnace is installed. To eliminate scale, the furnace should be filled as much as possible during the annealing process.
When the company conditions are met, nitrogen furnace annealing, that is, bright annealing, can be used. Don’t look closely, it’s almost the same color as it was before annealing. Add the intermediate annealing process when there is no other way to deal with cracks in cold-hardened metal or die tests.
The above is about the mold processing of the drawn parts. When judging the cause of cracks in the processing of tensile parts, it can be referred to: the cracks caused by poor material quality are mostly serrated or irregular in shape, and the cracks generated by the process mold are generally neat. To ensure wear resistance and prevent tensile scratches, punches and dies and blank holders must be hardened and, if necessary, plated with hard chrome. Hope the above content can be helpful to readers.
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1. The stretching material of the stretching die.
If the repeated test model does not meet the requirements, the material with good tensile properties can be replaced. Where there is quality, there is success. The commonly used specification is 08 steel, which is divided into boiling steel and stable steel. The price of boiling steel is low, the surface quality is good, but the angle is serious, it has a tendency of strain aging, and the appearance requirements are high.
In deep drawing, especially stainless steel plate and aluminum plate are easy to produce drawing when deep drawing, and tensile fracture is serious.
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In the process of shrinking, the metal stamping material at the shrinking end slides into the die under the pressure of the punch to reduce the diameter and increase the wall thickness and height. It can be approximated that the deformation region is in a state of plane stress under positive pressure in both tangential and radial directions, and the tangential pressure is the main force. The radial compressive strain is the maximum strain, while the thickness and length directions are elongation deformation, and the deformation amount in the thickness direction is more than that in the length direction.
Due to the action of tangential compressive stress, the billet is easily unstable and wrinkled during the shrinking process; at the same time, the wall of the non-deformed area is also prone to instability and deformation due to all the shrinking pressure. Therefore, preventing instability is shrinking. The main problem with the process.
The ultimate deformation degree of the necking is mainly limited by the buckling conditions. The degree of deformation of the necking depends on the necking coefficient of the material. It is expressed by the total shrinkage coefficient ms:
ms = d/D where
ms—total shrinkage coefficient, d—diameter after shrinkage; D—diameter before shrinkage.
The size of the shrinkage coefficient is related to the mechanical properties of the material, the thickness of the material, the form of the mold, the surface quality, the edge of the shrinkage end of the part and the lubrication conditions. The comprehensive mouth coefficient of various materials can be obtained through the relevant information table.
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In the industry, hardware is generally divided into large and small hardware. Big hardware refers to steel plate, steel bar, flat iron, universal angle steel, channel iron, I-beam and various types of steel materials, while small hardware mainly refers to construction hardware, white iron sheet, lock nails, iron wire, steel wire mesh, wire scissors , household hardware, various tools, etc. As far as the nature and use of hardware are concerned, it should be divided into eight categories: steel materials, non-ferrous metal materials, mechanical parts, transmission equipment, auxiliary tools, work tools, construction hardware, and home hardware. There are also many varieties of hardware products. Relatively speaking, the difference in specifications is relatively large. It plays an irreplaceable role in home decoration. Choosing a good hardware mold processing factory can increase the processing accuracy and improve the use process. safety, while also increasing the service life.
The stamping materials often used in precision metal stamping processing include beryllium copper BECU, steel plate SK, phosphor bronze PB, tinplate SPTE, aluminum AL, stainless steel plate SUS, white copper NS, hot-rolled steel plate SECC, cold-rolled steel plate SPCC, etc. Moreover, the material of stamping metal stamping has good plasticity, and the bright band of our stamping products will be larger and the fracture band will be smaller.
Precision metal stamping parts can also be divided into various types according to industry, use and process characteristics. Next, the types of precision metal stamping parts are introduced as follows:
1. Auto parts: mainly include automotive structural parts, automotive functional parts, automotive lathe parts, automotive relays, etc.
2. Electronic parts: mainly include connecting devices, connectors, brush parts, electrical terminals, elastic parts, etc.
3. Appliance parts: It mainly includes major appliance parts, such as color tube electron gun parts, as well as small appliance parts, various structural parts and functional parts.
4. IC integrated circuit lead frame: mainly includes discrete device lead frame and integrated circuit lead frame.
5. Motor core: mainly includes single-phase series motor core, single-phase household motor core, single-phase shaded-pole motor core, permanent magnet DC motor core, industrial motor core, plastic-encapsulated stator core, etc.
6. Electrical iron core: It mainly includes E-shaped transformer core, EI-shaped transformer core, I-shaped transformer core, and other transformer cores.
7. Heat exchanger fins: mainly include industrial heat exchanger fins, household heat exchanger fins, automotive heat exchanger fins, etc.
8. Other parts: mainly include instrumentation parts, IT parts, acoustic and camera parts, modern office parts, and daily hardware.
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1. What are the requirements for qualified metal stamping parts?
1. The basic performance of metal stamping parts processing products must be met. The assembly and maintenance of products need to be fast, convenient and trouble-free.
2. The products processed by metal stamping parts are simple in shape and reasonable in structure, which is conducive to the processing of molds, that is, the processing of the entire part is completed within the entire part time, and the mechanization and automation of production can be quickly realized to improve production efficiency.
3. The existing material equipment, process equipment and process flow should be processed with metal stamping parts as much as possible, and the service life of the stamping die can be guaranteed.
4. Under the condition of ensuring the normal use of metal stamping parts, the use size can be calculated reasonably, the dimensional accuracy level and surface roughness can be reduced, and the same size can be stamped together to reduce scrap and loss.
The above is the relevant content of “what requirements and conditions should qualified metal stamping parts have?” introduced by the editor of Zhejiang Baifudu Electromechanical. I hope that after reading the above content, it can be helpful to you.
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Why is the surface quality of metal stampings poor? There are many reasons for the surface quality problems of stamping parts. For example, the surface quality of coils, sheets and molds will affect the quality of the final stamping parts. The operation during the stamping process and the clamping, taking and unloading of station instruments may also damage the surface quality of the parts. Therefore, the details should be fully considered in each link of the entire manufacturing process to avoid quality problems and affect the final product appearance.
Common undesirable phenomena of coiled materials mainly include the following aspects:
1. There are foreign matters on the surface or inside of the steel plate;
2. The foreign body peels off, and the coiled material is in scar like state; Poor coiled material
3. The edges and corners of the coil are damaged;
4. The corner (20~30mm) is deformed or wrinkled due to uneven stress;
5. Scratches (caused by roller surface or foreign substances);
6. Caused by roller sliding;
7. Irregular edge damage;
8. After foreign matters enter, press out the bulge on the back of the coil (foreign matters will disappear if dropped);
9. Roller trace (caused by foreign matters attached to the roller);
10. Poor materials beyond the rules;
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The basic principles of metal stamping cutting edge size calculation:
The dimensional accuracy of the blanking part is mainly determined by the dimensional accuracy of the die edge, and the fair gap value of the die also depends on the die edge size and manufacturing accuracy. Correctly determining the size of the die edge and manufacturing tolerances is one of the main tasks in designing a blanking die. It can be found in production practice:
1. Because there is a gap between the convex and concave dies, the falling material or punched holes are tapered, and the large end size of the blanking part is the die size, and the small end size of the punching part is the die size.
2. In measurement and use, the blanking part is based on the large end size, and the diameter of the punching hole is based on the small end size.
3. When punching, the convex and concave dies must be in friction with the blanking part of the waste.
As an Auto Stamping Exporter, the following principles must be taken into account when determining die edge size and manufacturing tolerances:
1. The size of the blanking part is determined by the size of the die, and the size of the hole when punching is determined by the size of the punch. Therefore, when designing the blanking die, the concave die is used as the reference, and clearance is taken on the convex die; when designing the punching die, the convex die is used as the reference, and clearance is taken on the concave die.
2. When determining die manufacturing tolerances, account should be taken of the part’s tolerances. If the precision of the cutting edge is too high (that is, the manufacturing tolerance is too small), it will make the mold difficult, increase the cost, and prolong the production cycle. Parts may diverge, which will reduce the life of the mold. The relationship between the precision of the parts and the precision of the mold manufacturing is shown in Table 2-1. If the parts are not marked with tolerances, the non-circular parts are processed according to the national standard “Non-fitting tolerance value” IT14 level, and the die can be manufactured according to IT11 level; for round parts, the mold can generally be manufactured according to IT7 ~ 6 levels. The dimensional tolerances of stamping parts shall be marked as one-way tolerances according to the principle of “entry body”. The deviation on the blanking part is zero and the lower deviation is negative; the upper deviation of the punching part is positive and the lower deviation is zero.
3. Considering the wear of the convex and concave die in punching, when designing the blanking die, the basic size of the concave die should be the smaller size of the dimensional tolerance range; when designing the punching die, the basic size of the convex die should take the workpiece hole size tolerance range. Larger size inside. In this way, when the convex and concave molds are worn to a certain extent, the qualified parts can still be punched out. Clearances of convex and concave die are taken as the least fair clearance values. Our company also has Aluminum Stamping Lids on sale. Welcome to consult.
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Metal electric stamping is a manufacturing process by which a sheet metal is formed or cut into a preferred shape using a pre-cut die. Stamping includes a range of technologies, such as stamping, blanking, bending, stamping, flanging, and more. In order to achieve a certain precision stamping forming, the die design was carried out by using precision CAD(. Computer aided design. Application of software. Since stamping requires a specific amount of clearance, accurate measurement of the die is particularly important.
For more than 20 years, Balford Precision Stamping has been a leading manufacturer of precision stamping parts for electromechanical components and electrical contacts. Our ISO 9001 certified facilities, including advanced manufacturing tools, allow us to provide comprehensive configuration files for custom manufacturing of stamping contact parts and electromechanical stamping parts. Our experienced team has a wealth of knowledge to overcome the most serious difficulties.
Zhejiang Bailford Precision Stamping Co., Ltd. is pleased to provide electronic stamping for automotive equipment, household appliances, aerospace equipment, elevator control and other electromechanical equipment.
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1. How to remove burrs on metal stamping parts
1. Manual removal of burrs: If the number of stamped products is small, a more feasible method is to remove them manually. This kind of quality is better, but it is not suitable for high-volume processing removal.
2. Electrolytic deburring: This method is more efficient and has better quality, but the equipment cost is too high, and general small enterprises cannot afford it.
3. Vibration grinding to remove burrs (gear burrs), this method has high efficiency and good quality.
4. For the stamping parts after heat treatment, the burrs can be removed by shot peening, which can also eliminate the surface stress of the material;
5. Use air guns with various shapes of gun tips to remove burrs. This method is very effective and works more efficiently.
6. Use electrochemical deburring. If self-made equipment, the cost is not high, economical, efficient and practical.
1. Outer diameter: When performing metal stamping processing, chamfering is performed with a lathe.
2. Edge: Use file, oil stone, sandpaper, sharpening stone.
3. Welding slag: Vibrating welding slag tools can remove brittle burrs.
4. Holes: Use a chamfering knife or the front end of a drill with a larger diameter to deburr the holes of the metal stamping parts.
5. It can also be polished, polished, sandblasted, etc., depending on the workpiece.
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This series of TOOLOX materials is a new type of pre-hardened tool steel with high toughness, high wear resistance and basically no internal stress. And the purity is very high, the grain size is small, the content of S and P is very small, the content of precipitated carbide is very small, and it is very uniform. Due to the special composition design, this series of TOOLOX materials have excellent surface treatment performance. The surface hardness of TOOLOX44 after nitridation can reach HRC65, TOOLOX can reach 40, the surface hardness can reach HRC62 or above, and the surface hardness of TOOLOX33 can reach HRC58 or above, and the depth is up to 1.8mm.
The above characteristics of TOOLOX series materials make TOOLOX series materials have special advantages in some stamping dies:
1. Stamping and forming dies for thicker steel plates (a typical case of punching and shearing thickness of 35mm), stainless steel plates, and non-ferrous metal plates, typically air-conditioning fin dies.
2. Drawing die, stainless steel drawing die.
3. Cold extrusion die, cold extrusion 304 stainless steel, thickness above 0.5mm, replace DC53 and other materials, the effect is very good.
4. Large stamping templates that require high dimensional stability.
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The cutting process in sheet metal parts processing can not only change the style, but also deal with aspects such as thickness, so the effect of using it in different environments is also different. Therefore, cutting is the function of sheet metal parts changing their essence during processing, and we must know quite a few cutting methods.
Electric welding, plasma cutting, laser cutting and other methods are more common, and laser cutting is used in the sheet metal processing process. This is because the hardness of sheet metal is relatively hard, so choosing laser cutting is also a better choice when processing.
When using laser cutting, the section is relatively neat and clean. It will be simpler to dispose of in the later stage, and it will be more suitable when used. When using it, there will be no inconsistency in the environment, and the effect that can be exerted is quite large. Be very careful when cutting to avoid confusion on the cut side.
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