The Importance of Stamping Parts for Automotive Pipe Supports

There are many kinds of automobile pipeline stamping parts, which are generally used in the transmission system and steering system of automobiles. Its advantages lie in the specification of materials, high precision and relatively low cost.

The cold stamping process technology is widely used in the production of stamping parts for automobile pipeline brackets, which is suitable for many types of stamping parts in the automobile industry and requires large-scale production. In medium and heavy-duty vehicles, most of the supporting parts, such as the frame and carriage of large vehicles, are automotive stamping parts.

The steel mainly used for cold stamping is steel plate and steel strip, which accounts for 80% of the steel consumption of the whole vehicle. The production of cold stamping materials and automobile stamping parts is very close.

Usually a relatively high-strength steel plate is selected. The quality of the selected material not only determines the performance of a good product, but also directly affects the process design of our later automotive stamping process, the service cycle of the mold and the impact of the production process. To the quality, cost, service life and production organization of the product, it is an important and complicated task to reasonably select materials that are conducive to product performance. This material is usually also designed and evaluated in the initial design, taking into account the performance and required characteristics of different types of automotive products to ensure vehicle quality and performance.

Causes and Solutions of Stamping Scrap

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

1. Reasons

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

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

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

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

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

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

2. Solutions

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

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

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

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

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

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

What is the reason for the wrinkling and cracking of automobile covering tensile parts?

The direct reason for the cracking of the workpiece is that the tensile deformation resistance is higher than the actual effective tensile strength of the material at the simple wall crack. The appropriate adjustment method to completely eliminate the breakage of the puller is as follows:

(1) Adjust the pressing material pressure and reduce the pressure.

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

(3) Adjust the radius of the mold fillet. If the radius of the mold fillet is too small, the parts are easy to crack. Increasing the die fillet radius can reduce the degree of pull cracking.

(4) Adjust the radius of the die fillet.

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

(6) The size of the blank is too large or the shape is incorrect, and the quality and lubrication of the plate may also cause the parts to crack. The size or shape of the blank should be changed, and the stamping process should be adjusted.

There are many reasons why parts can crack. When adjusting, carefully check the state and position of the crack, determine the stroke position of the crack, infer the cause of the crack according to the specific situation, and then work out a specific solution to the crack.

Some experience in solving trial wrinkling and cracking.

During the initial deep drawing of the drawing die, the drawn parts are generally wrinkled and cracked. At this time, it is necessary to carefully observe the condition of the pressing surface and analyze the various causes of wrinkles. If there are indentations on the pressing surface and cracks at the radius of the concave die, it means that feeding is difficult; if the pressing surface is corrugated, it is easy to feed. Later, due to the generation of material corrugations, it is difficult to flow, resulting in wrinkling and cracking, that is, the material is difficult to flow during the stretching process, which will cause wrinkling and cracking during the stretching process, so different situations should be solved by different methods.

Feeding difficulties are usually caused by excessive binder resistance. If the surface roughness of the binder surface and the die fillet is too high, or there is recoil forming and local stretching is too large, it is necessary to adjust the outer slider, reduce the blank holder force, and appropriately increase the die fillet. Reduce the surface convexity and appropriately increase the lacing clearance. If the local tensile deformation is too large and inversion occurs, it should be solved by adding process gaps or process holes.

The feeding is easy, mainly because the feeding resistance is too small, the contact of the pressing surface is poor, or the design process performance of the drawing part is poor. If it is a binder surface problem, the binder surface needs to be ground to ensure adequate contact. In addition, the outer slider can be adjusted to increase the blank holder force or increase the blank holder area. If the process performance of the stretched part is not good, it is necessary to redesign the stretched part to make it a qualified product.

The above only discusses how to prevent or solve the wrinkling problem of the cover from the aspects of technology, drawing die design and adjustment. There are many reasons for the wrinkling and cracking of the cover. But as long as the phenomenon is carefully studied and classified, different situations can be solved in different ways, resulting in a coating of good surface quality. Hope the above content can be helpful to readers.

What is the cause of the bending of the material during the mold processing?

In daily life, mold processing is easy to see. Many items and equipment require a tooling process to complete. Mold processing involves many industries, so the quality of mold processing is very important. During the customization process, a series of situations may arise. In fact, one of the phenomena we face is bending and deformation in mold processing. Then, throughout the machining process, the performance of the tooling and equipment should be considered in addition to the final requirements or installation. In this case, we need to consider the mold processing technology more. Why does the material bend during tooling?

1. Mould

In the mold customization process, if this happens, it is basically possible that the door is not positioned properly or the quantity is insufficient, or the position of the top product is inconsistent.

2. Technology

If the element has more technical aspects, for example a particularly high longitudinal line temperature can be considered during the molding process, or a special injection pressure can be considered during the molding process, as well as some other injection molding with shorter holding and cooling times. Good manufacturers basically give us more protection during processing. As it stands, if we really want to do custom processing, we have to consider additional processing issues. To the extent that this actual machining process requires more powerful handling systems and handling equipment, it can continue to be used.

3. Raw materials

In the actual processing process, all raw materials will affect the final cleanliness and will cause the deformation of the whole product. Due to the rework of raw materials, if it is not clean enough, or in the process of mold processing customization, its cleanliness will be different, and certain errors will occur during the processing process. Although the product is small, there are still a series of effects in the original processing process. Therefore, raw materials It is an important link in the cleaning and processing process, which must be paid attention to, because these small mistakes often determine the final success or failure of the entire mold processing.

Fourth, product design

Each product has its own unique design style in the mold design. This is due to its different processing requirements, so their product design requirements are different, but the product design is different due to different process requirements, so the processing thickness of the product or the overall partial design will be different. There are differences, so it is more reasonable to change the protrusion thickness, so in this case, the product structure needs to be considered.

In the process of mold processing, under the existing circumstances, if it is to be processed, it can be divided into different plastics for processing. Due to the different materials required for the required mold, the protective effect of the final treatment is also different. Of course, the mold is customized according to the working hours. Once the deformation is sufficient, it needs to be organized and reduced to a reasonable size before final processing to reduce the possibility of thermal decomposition.

Regarding the content of mold processing above, we consider the actual situation in the processing process. When bending and deforming, we must first adjust to achieve a reasonable processing state. Hope the above content can help readers.

Metal stamping continuous die layout technology

1. Design principles of continuous stamping layout drawing

Before blanking of flat blanking parts (including flat blanks of various forming stamping parts – the same below), in order to save materials, economical and reasonable arrangement is carried out on plates, strips, strips and coils to obtain the best samples and achieve the best possible results. Possible high material utilization. In the cold stamping process design and die design, this is an important and technical work; in the cold stamping die structure design, the stamping part drawing, stamping process and its sample drawing are the main basis.

In the known professional publications, the layout of single-station blanking dies and composite die-stamping parts is introduced in detail, and the layout of multi-station continuous die-stamping parts is not involved.

The layout drawing of multi-station continuous stamping parts should fully explain the stamping process and the sequence of stamping steps, and indicate the feeding distance, the specific data of edge extension and edge overlap, the feeding method between stations, and all stamping processes and deformations of stamping parts. and separation process.

Die selection, structural design, stamping material utilization η, stamping productivity are closely related to the production cost of stamping parts, but also affect the quality of stamping parts and die life. The layout should fully consider the material supply and the production conditions of the stamping equipment. On the basis of ensuring the stamping quality, efforts should be made to make the stamping die have better structure, better operational safety and die technology, and comprehensively analyze the various factors that affect the layout. Factors, compare multiple schemes, and choose the best layout.

Before the die stamping design begins, the die stamping drawing and layout drawing should be analyzed to understand its main technical requirements and stamping difficulties, and lay the foundation for the die stamping structure design according to the rationality of the die stamping process and possible problems.

Among the many single-process dies, only blanking dies and single-station composite dies need to design layout drawings. That is to say, when blanking (blanking) flat blanks and forming stampings to develop flat blanks, nesting is required. And most of them are conventional nesting methods with scrap blanking along the edge, and most of them can only achieve less scrap blanking. Regardless of the layout method used, the rationality and advantages and disadvantages of layout are generally measured by the material utilization rate.

The layout of continuous die-stamped parts is different from the above. Material utilization η is not the most important and only criterion for measuring the quality of nesting.

For the layout of continuous die stamping parts, it is necessary to analyze the stamping process, reasonably design the stamping process and the sequence of the stamping process, fully consider the characteristics of the continuous stamping process and the needs of the stamping structure design, and pay attention to the feeding and inter-station feeding methods. selection and design of positioning systems.

Therefore, the layout of continuous die stamping parts is based on the design of continuous stamping process steps, with the core of ensuring the quality of stamping parts and the accuracy of size and shape, and the sequence arrangement of stamping steps and the selection of the feeding method between stations are as follows: Pilot, for the purpose of die selection and structural design, the basic principles that should be followed are as follows: 

(1) It is beneficial to choose a simpler type and structure of punching die, and its operation is safe and the quality of punching parts is good.  

(2) The manufacturing process of the die is good, the grinding is convenient, the molding cycle is short, and the cost of molding and repairing is low.

(3) The plate utilization rate η value is high.  

(4) The mold life is longer.  

(5) The stamping efficiency is higher, and the production cost of stamping parts is lower.

Among the above five articles, article (1) is the primary one.

Sometimes it is impossible to have both, the user’s requirements and delivery time should be considered first, and other terms can be appropriately relaxed. In many cases, higher material utilization η tends to complicate the structure of the die, making the die more difficult, and even difficult to manufacture with the existing die-making equipment and technical level, no matter how good the layout and the higher the η value. , and must also be abandoned; some would rather reduce the utilization rate of the plate η to obtain better molding processability, shorter molding cycle, and higher mold life.

2. Selection of layout form and its relationship with die type and structure

For blanking dies and composite dies with only one station, the layout methods of flat blanking and various forming blanks on plates, strips, strips and coils are usually: single row, straight row, Single row oblique row; double row parallel row, double row head-to-head row, double row head-to-head oblique row; multi-row row, staggered row and mixed row, etc.

Different nesting methods obtain different material utilization rates, and the choice of different nesting methods should first consider the size and shape accuracy of the punching parts, and then decide to choose the appropriate type of punching die and its structure.

If the dimensional accuracy of punched parts is required to be above 1t10 level, the layout method with edge and overlap should be adopted; the dimensional accuracy of punched parts without overlap layout is poor, generally below 1t12 level, or even as low as 1t14 level. If the dimensional accuracy of the punching piece is as high as 1t9 or higher and the punching piece is required to be straight, a punching die with a sliding guide column die set with a spring-loaded stripper structure should be selected, and its layout should be given enough edge and overlap.

According to the German Industrial Standard din1543, the cold stamping steel plate is classified according to the thickness t: t<3mm is a thin plate.

In the production of products in the instrumentation and electronic industries, ultra-thin foil stamping parts with t≤0.3~0.1mm or even ≤0.1~0.05mm are often used, which brings many difficulties to stamping layout and die design.

Because the edge of the nesting, the width of the overlapping edge and the size of the blanking gap all increase or decrease with the thickness t of the blanking material.

When t≤0.5mm, the width of the lap and edge should be greater than t so as not to be pulled into the die hole during punching, and to make it have sufficient strength and ensure that the lap frame has a good feeding rigidity; t= 0.3mm low carbon steel plate, according to the class I gap stipulated by gb/t16743-1997 “Blanking Gap” Internationally, 3%t can be taken as the unilateral gap of punching die c=3%×0.3mm=0.009mm, t=0.1mm then c=0.003mm, which is 3μm. And gb/t2854-90 international grade I sliding guide guide column die set stipulates the guide column guide sleeve matching clearance is 0.010 ~ 0.016mm. Therefore, when the above-mentioned ultra-thin material is punched and continuously punched, special attention should be paid to selecting a suitable layout method and designing a reasonable and precise mold structure, otherwise it will be difficult to complete the punching of such punching parts, and it is impossible to meet the requirements. Dimensional and geometric accuracy.

For continuous stamping and forming of ultra-thin punching parts with t<0.5mm, the width of the overlapping edge and the edge of the layout can be the same, and it can be appropriately enlarged according to the needs of the die structure design. In terms of the selection of die structure type, it is recommended to select the guide column die frame elastic pressure unloading guide die, and it is best to install the elastic pressure guide plate on the guide column and install a small guide column on the discharge plate (guide plate) to ensure the elastic pressure discharge. The guide plate type punching die has precise guidance and improves the punching accuracy of the punching die; the coaxiality and position of the punching group holes put forward higher requirements on the accuracy of the layout and feeding distance and the feeding and positioning of the punching die. Special attention should be given to layout.

Ultra-thin punching parts with material thickness t≤0.1mm, especially complex-shaped punching parts formed by multiple stations and one die, should not use multiple rows of oblique rows, facing rows and turning punches, and it is even more unsuitable to use mixed rows. Otherwise, the frame will be easily deformed, broken, or even pulled into the die during feeding, which will affect production, increase scrap products, and damage the mold; for medium and heavy plate punching with a material thickness of t≥3mm, cutting and stacking layout is not recommended. , t ≥ 4.75mm, it is not recommended to use nesting and cutting layout. Otherwise, it will bring difficulties to the structural design of the mold.

For high-precision foil stampings with dimensional accuracy ≤±0.01mm and material thickness t≤0.1mm, especially for stampings with complex shapes with a precision higher than 1t9, it is recommended to use a ball-guide-pillar die-base elastic-pressure unloading guide-type die structure.

Layout drawing design points The layout drawing design of single-station blanking die and compound die is to expand the shape of flat blank according to flat blanking parts and three-dimensional forming parts, and repeatedly arrange them on strips and strips to ensure the quality of punching parts. In the case of production efficiency and process requirements, the die structure is simpler, the mold making is more convenient, and the highest possible material utilization rate is the criterion, and a better layout method is selected. Under normal circumstances, the shape and size structure of the blanking parts determine the type of layout, and most of them need to use the traditional layout method with edge and overlap to carry out blanking with waste.

According to many years of practical experience, for the design of the layout drawing of single-process blanking and composite punching and single-station integrated composite stamping, it can be considered as a single blanking of flat blanks and three-dimensional forming parts. Compared with single punching die, the layout of continuous die punching parts is much more complicated. The layout should ensure the smooth implementation of the continuous punching process and obtain the highest possible η value. The operation is safe, the efficiency is high, there are many influencing factors, and the requirements are high. The steps and key points are as follows:

(1) After a detailed process analysis of the stamping parts, the feasibility of continuous stamping and one-die forming of the stamping parts is studied, and a number of stamping process schemes are proposed for comparison, and the layout is implemented after selecting the best ones.

(2) The shape, size and accuracy of the stamping directly affect the continuous stamping process and the sequence of the steps. When laying out the layout, the manufacturability of the continuous stamping and the needs of the die structure design should be considered, and attention should be paid to the sequence of the steps and the arrangement of the stations. The following points:

a. The holes in the group of holes on the punching piece whose hole spacing accuracy is required to be above 1t10 or the hole spacing tolerance value is less than 0.01mm should be punched out in one or two adjacent stations;

b. If the hole wall and hole edge of the punched part are smaller than the material thickness t or less than 2mm, they should be punched out in two stations in steps to enhance the strength of the die and expand the installation position of the punch on its fixing plate;

c. For the coaxiality and position of the group holes, the requirements are very high, and the tolerance is less than 0.01mm. The relevant holes can be punched out at one time or in two adjacent stations. The parts that require smooth punching and punching should be concentrated. Implemented at one or two stations;

d. If the shape of the punched part and the size tolerance of the formed part are very strict, the overall blanking can be considered and then bent or deep drawn; if the size of the local boss or notch of the punched part is strict, it can be punched separately by multiple stations. post splicing;

e. For small and complex shaped stampings with large output, multi-station continuous stamping and one die should be used as much as possible to improve the quality and efficiency of stampings; 

f. The dimensional accuracy requires high-precision punching parts above 1t10. When laying out samples, the number of steps should be minimized to prevent the number of stations from being too large, the accumulation of feeding errors will be large, and the punching accuracy will be reduced. Partial fine punching, upsetting extrusion, flattening, etc. should be Arrange special work stations; 

h. For punching parts with complex multi-directional bending, lateral punching and incision that need to be punched with lateral force, consideration should be given to using wedge drive transverse punching to form after plane punching, incision or before blanking. Precision and Efficiency.

(3) Considering the requirements of the die structure design and the required position of the stamping deformation, set up the necessary neutral station, and increase the installation position of the punch on the fixed plate; Surface area, an empty station should also be added to increase the wall thickness of the die.

3. Layout type and method of continuous die stamping

According to the characteristics of the continuous die stamping process, the same feeding method of the station, whether the layout has overlapped edges, and the method of removing process waste, the layout of the continuous die stamping parts can be summarized into the following types and layout methods:

1. Slitting and combining layout

Each station punches and forms a part of the punching piece respectively. Each station is relatively independent and independent of each other. Its relative position is controlled by the die, and finally combined into a complete and qualified punching piece, see Figure 1a), b), f), j).

2. Piece and cut combination layout

The inner hole and shape of the punching piece, even a complete blanking line of any shape, are punched separately by several stations, and finally assembled into a complete punching piece. Although it is similar to the slitting combination, it is not the same. The combination of each station and the cutting edges are related to each other, and the interface parts must overlap, which increases the difficulty of mold making.

3. Cutting edge layout

The complex shape of the side of the punched piece is obtained by the method of punching along the edge, that is, the cutting edge layout. When the length l of the punching edge in the feeding direction is equal to the feeding distance s, that is, l=s, the punch can replace the side edge and undertake the task of cutting the edge of the fed raw material. This type of side punch is commonly referred to as a forming side edge. Because jb/t-76481-94 has few standard side edge varieties and limited size specifications, the maximum cutting edge length is only 40.2mm. When the feeding distance s>40.2mm, only non-standard side edges can be used.

Another disadvantage of using a standard side edge is that it is necessary to cut a certain width of material on the side of the raw material to form an incision with a length equal to the feeding distance. Positioning the feeding raw material increases the process waste and reduces the η value by 2% to 3%. %. Using the side punch to cut the edge can not only complete the blanking of any complex shape of the side profile of the punching piece, but also realize the limit of the feeding distance of the raw material, instead of the standard side edge, which serves multiple purposes.

4. Cut and overlap the layout

For slender and thin blanking parts, long blanking parts with complex contours to be blanked at the part connected to the lap edge, can obtain high-quality and high-yield effects by laying out the lap edge, which can avoid slender blanking parts Disadvantages such as distortion and difficult unloading. The more typical punching parts are instrument hands, watch second hands, etc. The above cutting edge layout is used, and the effect is very good. For the convenience of molding, sometimes the edge is enlarged to facilitate blanking, and the edge is left on the raw material as a punch. The pieces are finally cut and separated.

5. Combined punching and nesting along edge and overlapping edge

Step by step punching the edge and lap by sub-station, to obtain the layout of the formed punching blank and punching and forming, which is called the combined punching layout of the edge and the lap. The process wastes are washed away at each station, and the punched parts are left on the raw materials and gradually formed until the final station is separated. This type of layout can keep the stations on the same plane and arrange them in a straight line along the feeding direction. The raw materials are used to carry the workpieces into place between the stations. The mold structure is simple, and the operation is convenient and safe.

6. Nesting layout

Use the structural waste of the inner hole of the large-sized punching piece to punch the smaller-sized punching piece of the same material in the special station of the same set of continuous molds, that is, the nesting layout.

Under normal circumstances, the small-sized punching parts in the inner hole are punched first, and the large-sized punching parts are often punched out at the last station.

The nesting of gaskets with a single-station composite blanking die is a typical nesting layout that has been known for a long time. For the nesting layout of multi-station continuous blanking parts, because the upper and lower stations have no overlapping edges, the coaxiality is required to be high, and the feeding distance must be small to ensure the size and shape accuracy of the nesting blanking parts.

7. Layout layout

Using the process waste of the punched parts and the structural waste connected along the edge, the punching parts of the same material are spliced ​​and punched together, that is, the layout is cut out. The difference from nesting and layout is that stenciling is to make the best use of process waste or excess edge and overlap, as well as the outer edge structure waste generated due to the complex shape of the punched parts and the large difference between convex and concave. The punching material is the same. Various punching pieces. When laying out samples, make full use of the convex and concave parts of the shape of the punching parts, and insert forks into each other to make full use of the raw materials.

No lap layout and no-waste blanking Since most of the continuous die-stamping parts use edge and lap layout, only blanking with waste can be carried out. If the layout without edge and edge can be carried out, and the blanking part has no structural waste, it can be blanked without waste. Completely scrap-free blankings that truly achieve 100% or near 100% sheet utilization are rare. Any punching that can be used for layout without overlapping can be punched with less waste.

In order to implement the blanking of blanking parts with no waste and less waste, it is first necessary to carry out the layout of blanking parts without overlapping edges.

There are certain conditions and methods for the implementation of no-overlap nesting. In addition to the above-mentioned continuous die-punching parts, which can be used for layout without overlapping edges and blanking with no waste or less waste, single-process punching dies and single-station composite punching dies can also do the same.

4. Non-linear feeding continuous composite die-stamping method

The feeding direction of most continuous molds is carried out along a straight line on the same plane, and the feeding of each station is carried out by feeding raw materials. For this reason, the punched parts are always kept on the raw materials with lap edges for stamping processing at each station. The finished punching piece connected with the lap edge cannot be separated from the raw material until the processing is completed to the last station. For some punching parts with large flange heights, large drawing heights and complex shapes that require multi-directional force bending, it is often necessary to blank them as a whole and then form them on another set of punching dies.

Otherwise, the punched part can be taken out from the die cavity because the die needs to have a large opening height. If the conventional continuous die is used to arrange the stations in a straight line on the same plane along the feeding direction, it will be difficult to design the die structure.

This type of punching piece is formed by a multi-station continuous die, and its layout method is completely different from the above-mentioned conventional continuous die layout. The blanking blank is pushed to the forming station at a certain angle to the feeding direction of the raw material, and is bent or deep drawn. Make the stations of the die arranged in an L shape, and the stations are not on the same plane

With the rapid development of modern stamping technology, the continuous improvement of stamping mechanization and automation, and the improvement of stamping safety production requirements, continuous dies of this type of structure will be increasingly widely used.

The three-station continuous composite die for lifting ring punching parts, the first station punches rectangular holes, the second station is blanking, bending and compound punching, and the third station is a feeding system driven by the wedge of piece 8. After the curved workpiece at the second station is pushed into place along the bending core piece 12, the two sets of 13 cam drive mechanisms are used to exert force opposite and perpendicular to the feeding direction to push a pair of forming die pieces 17, and the stamping workpiece is finally formed. The die has both the action characteristics of a continuous die and the function of a composite die. Since the second to third stations are formed by separating the workpiece from the raw material, it is not realistic to call the progressive die;

Calling a continuous die ignores the function of the second station compound stamping and the separation and deformation of the entire die and the characteristics of the compound stamping, so it is more appropriate to name it a continuous compound die.

The continuous composite die adopts staggered double rows and straight rows. After the overall blanking, the unrolled blanks are pushed to both sides and bent at the third station. The production efficiency is high and the punching quality is good. This type of automatic or semi-automatic continuous compound die is safe to operate, and will be used more and more with the diversification of coil supply varieties and specifications.

How to reduce the concave and convex problem of metal stamping parts?

1. Five methods to reduce the concave and convex of stamping parts

1. Inspection and correction of drawing dies: Everyone should know that drawing dies need to be inspected and maintained regularly to avoid reducing the production of convex and concave and maintain a stable state. The usual practice is to use samples to check the bonding scratches of the blank holder and the condition of the machined surface (concave die fillet, punch die fillet).

2. Inspection and correction of the shearing die: The reason for the concave and convex after the shearing process is that iron powder is generated during the shearing process. The iron powder must be observed before stamping to avoid the occurrence of convex and concave.

3. Appropriate manipulator speed: For the production of semi-automatic drawing molds, when the drawing mold is in the lower mold position and the manipulator speed is fast, the burr will fall on the upper part of the punch, resulting in unevenness. In order to avoid this problem, we can carry out the part discharge test before production, and set the speed and discharge angle of the manipulator reasonably to avoid contact with the parts and the die.

4. Check the cut surface: When cutting the material, the wear and damage of the cut die will produce a large amount of small iron powder attached to the cutting edge. Therefore, before stamping production, it is necessary to check the secondary cut surface in the material area or stamping line, and clean the plate in time to remove burrs.

5. Inspection of the plate cleaning device: Before stamping production, it must be inspected and repaired at the same time to clean the plate more effectively. It is also necessary to pay attention to the quality of the roller gap and cleaning oil. The specific method is to apply red paint on the steel plate to make it cleaned and installed. At present, the cause of the removal of the red paint is checked. If the removal rate is not up to standard, it is necessary to check and repair the cleaning and installation. When the cleaning oil is lacking, it must be reduced in time.

What problems should be paid attention to when dealing with scrap metal stamping parts?

Generally speaking, in the production process of metal stamping parts, because metal stamping parts are produced in large quantities, there will be many wastes, and we all know that dealing with these metal stamping wastes is a very dangerous job, so Generally, we use automatic equipment for processing, but some scraps have to be processed manually. So what are the problems that need to be paid attention to when dealing with metal stamping scraps early? The following Zhejiang Baifudu Electromechanical editor will take you to understand!

First of all, we must be clear that metal stamping waste packaging processing is divided into two types, one is automatic processing, and the other is non-automatic processing.

1. Safety measures for automatic processing of waste metal stamping parts

1. When we use ordinary plates for stamping processing, the scrap of metal stamping parts will be conveyed by the conveyor belt, because the scrap shredder is cut short, and then pressed into squares by the press.

2. The waste is wound through the take-up reel. In fact, the appearance of the take-up reel is similar to that of the strip reel. The scrap after metal stamping can be used as material for other parts. Since the take-up reel motor is independently driven, it can also be driven by a press or a feeding mechanism.  

3. Set a cutter on the metal stamping die to cut off the waste, and then transport it to the briquetting block at the baler through the conveyor belt. When carrying out the press, be sure to separate a distance and cut it once.

2. Safety measures for non-automatic processing of scrap metal stamping parts

1. When the scraps of punching holes are discharged obliquely, the scraps should be automatically layered and crushed, and at least 100 scraps should be stored on the upper die or the lower die base. If two local wastes are grouped together, there should be enough space for stacking.

2. Try not to have sharp corners or burrs in waste disposal to prevent injury to people, and the size of waste should be appropriate to prevent operators from hurting operators when they are nearby.

3. When the waste passes through the pipeline, pay attention to the poor width and height on the straight line, which is easy to block, and try to prevent more than two kinds of waste on a pipeline from passing through.

4. The chute for removing waste must lead to the end of the backing plate and be aligned with the opening of the waste pit. When installing the chute, pay attention to whether the screws of the metal stamping die are tightened.

5. If the metal stamping waste cannot fall by its own weight, once it hangs at the cutting edge, it should be forced to fall by using throwing, ejecting and other falling aid equipment.

6. In order to ensure safety, a protective cover should be set up when non-automatic processing of metal stamping scraps nearby, and the scraps should not flow out or scatter near the operator during operation.

The above is a brief introduction to the issues that should be paid attention to when dealing with metal processing waste. It is also reminded that the personnel engaged in waste packaging must pay attention to safety and prevent the occurrence of dangerous events.

Problems easily occurred in drawing process of stamping parts

Due to the different shapes and sizes of products in the process of stamping, different stamping processes are required, and deep drawing is one of them. In the actual production of deep drawing, some problems are easy to occur, which affect the product quality and processing efficiency. Please refer to the following points for specific problems.

1. The wear of the die will cause the inner diameter of the stretching piece to be too large
2. Excessive jacking force will cause larger inner diameter; Insufficient will cause the inner diameter of the stretching piece to be smaller
3. The inner diameter of the stretching piece will be larger if the stretching material is too thin; Too thick will lead to smaller inner diameter
4. Too high temperature or oil leakage of the hydraulic oil used for deep drawing will cause the inner diameter of the stretching piece to be too small
5. The mouth of the stretch piece is easy to wrinkle
6. The stretching piece is strained
7. There are gouges and bruises on the appearance of the stretching piece
   
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solutions after Metal Stamping deformation

In the process of metal stamping, we often encounter the deformation of stamping parts. So how to avoid the deformation of stamping parts when the deformation of metal stamping parts occurs?

Main factors of deformation and scrap of metal stamping parts:

1. Due to the long shock and vibration time, the fastening part is loose, the installation position of the stamping die has changed relatively, and the operator’s negligence has not been carried out in accordance with the operating procedures.

2. Improper installation adjustment and use of a die.

3. Poor quality of raw materials.

4. Clearance and reaction forces do not produce moments on the line. The main reason is that the gap between punch and death is too large. The concave edge of the die has an inverted cone or the contact area between the ejector and the workpiece. 1. In the structure of the stamping die, the pressure plate should be connected to the pressure plate in contact with a certain pressure.

2. Reasonable selection of blank clearance.

3. When the blanking part has a complex shape and there are multiple internal holes, if the cutting force increases unevenly, press the strip or use a high-precision press before blanking, the cutting force is uneven, and the blanking force is determined by the blanking The complex shape and multiple inner holes are added.

4. If the edge of the die is found to have a reverse taper, the edge of the die must be properly trimmed;

5. Regularly clean the stolen goods in the mold cavity, lubricate the surface of the metal plate, and there are oil and gas passage holes in the mold structure.

6. Flatten the paper before punching. If warping is still not eliminated, the punching workpiece can be leveled again by leveling the mold;

We know that the output of aluminum alloy stamping parts in China is very large. In addition to the huge demand for automobiles and other industries, we are constantly expanding the field of use. It is understood that at present, the scale of China’s IT industry is very large, especially the production capacity of the IT industry is very strong. Its various types of mobile phones and other equipment must not only meet domestic demand, but must also be exported to a large number of foreign countries.

As mentioned earlier, stamping parts have huge performance advantages in areas such as automotive engines, and have become indispensable metal die castings in these areas. These benefits have been applied to the IT industry. Our company also sells Al Alloy Stamping Plates. Welcome to consult.

Advantages of Deep Drawing Stamping

Easy to use.

The drawing process is relatively simple, which is an ideal choice for companies that want to save labor costs. This type of stamping does not require as much expertise as some other methods, so your staff can easily learn how to operate the machine.

Adapt to complex designs.

As mentioned earlier, deep drawing can easily create complex parts without design constraints. This makes it a great choice for companies that need unique or customized metal parts without paying extra for a design.

Flexibility.

The advantage of deep drawing is the ability to use multiple material types. This is especially beneficial if you are trying to reduce costs or improve product quality by switching from one metal type to another.

Industry universality.

If you need help with mechanical problems or need more information about this manufacturing process, you can have the opportunity to contact more experts to help you, because deep drawing is applied in many industries.

volume production
Drawing can quickly and efficiently produce large quantities of high quality parts. This makes it an attractive choice for companies that need to create many products in a short time.

Easy to use.

The drawing process is relatively simple, which is an ideal choice for companies that want to save labor costs. This type of stamping does not require as much expertise as some other methods, so your staff can easily learn how to operate the machine.

Adapt to complex designs.

As mentioned earlier, deep drawing can easily create complex parts without design constraints. This makes it a great choice for companies that need unique or customized metal parts without paying extra for a design.

Flexibility.

The advantage of deep drawing is the ability to use multiple material types. This is especially beneficial if you are trying to reduce costs or improve product quality by switching from one metal type to another.

Industry universality.

If you need help with mechanical problems or need more information about this manufacturing process, you can have the opportunity to contact more experts to help you, because deep drawing is applied in many industries.

How to calculate the mold processing of metal drawing parts?

First, learn to stretch the expansion

The expansion of the stretched parts can be divided into two types: software expansion and manual expansion. For the expansion of general cylindrical parts, it is generally feasible to use software and manual expansion. For complex curved parts, irregular products, Then we can use software to expand, for example: one-step expansion of UG software, or expansion with AUTOFORM software is possible. Its principle is to assume that the material does not change in volume without thinning. principle.

Then the computer expansion is based on the finite element analysis and calculation to obtain an expansion result, which is usually the result under ideal conditions and has a great reference value. Manual expansion is the radius of expansion obtained by mathematical calculation, so manual expansion can only be a conventional method of mathematical calculation.

2. Learn to calculate the stretching parameters

The biggest problem that troubles us in the stretching calculation is how many times a piece can be pulled out, and how to determine the size of each time? Masters who have done stretching molds are generally confused about this piece. If you can calculate, it will be like clearing the clouds and seeing the sun. A very important parameter in the stretching parameters is the stretching coefficient M, which is a ratio to put it bluntly, and is an empirical parameter summed up by predecessors in long-term practice. Tensile coefficient M = finished product size d / blank size D, when this coefficient is less than the ultimate tensile coefficient of a certain material, then we assess that the product cannot be pulled out at one time, that is, there is a risk of rupture. Of course, the stretched parts are also closely related to the forming R of the product and the size of the blank holder. There are many parameters involved. For details, you can consult the relevant stretching data for details.

3. Process layout

The process design is to calculate the stretched size according to the result of the stretching calculation, but the calculation is quite complicated each time the height is stretched. In order to obtain the stretched height more intuitively and easily, the CAD software can be used for simulation calculation. Adjust the height value of the stretch a few times to determine the correct height value for each stretch, still following the principle of constant volume. Of course, expressing computation in words is a difficult process. It takes practice to really master it.

The last thing I want to tell you is that stretching is not as difficult as you think. Find experienced people to learn the method, then many problems will be solved easily.

The above is the relevant content about the calculation of mold processing for metal drawing parts. For those who are not familiar with the field, mold processing is more complicated, and the failure rate is high. People in the industry can be said to be at their fingertips. Hope the above content is helpful to readers

Resonant Rods RF Filters for 5G Technology

We explain how the new XBAR resonator technology is optimized to create filters for 5G and WiFi networks. “We are working with several RF module and filter suppliers for 4G and 5G filters and have recently achieved a major milestone that will lead to mass production of critical 5G RF filters,” said PAX.

The proliferation of 4G LTE networks, the deployment of new 5G networks, and the ubiquity of Wi-Fi have led to a dramatic increase in the number of radio frequency bands that smartphones and other mobile devices must support. RF filters are not new and our smartphones would not work without them. The first generation of smartphones had fewer than 10 filters because they didn’t have many RF signals. Today—using Wi-Fi, Bluetooth, GPS, and 2G, 3G, 4G, and now 5G—more than 100 filters are trying to prevent conflicting signals coming into your phone.

However, 5G networks are not ready for prime time. The challenge is that each 5G band must be isolated with filters to avoid interference that can drain battery life, reduce data rates, and cause dropped calls. Today, filter technology cannot deliver the performance these new networks promise.

We are now focusing on 5G communication accessories because the requirements have changed dramatically compared to 4G filters. If you look at the iPhone 13, there are nearly 100 sonic filters; in the iPhone 13, one filter is required for each frequency band that needs to be processed in the phone. As we look at 5G, higher frequencies, wider bandwidths and more complexities, it is clear that the market needs a different type of acoustic building blocks for these filters. That’s why we’ve developed technology to address new markets in the 5G and Wi-Fi bands 5 GHz and 6 GHz, and ultra-wideband (UWB) from 6 to 8 GHz.

What is the reason for the cracking of stamping parts?

1. Reasons for bending and cracking of stamping parts

1. The steel used has poor plasticity, including the low elongation of the steel, the uneven grain size, the continuous occurrence of harmful Widmanstler structures, the cold bending performance that does not meet the technical standards, and the poor surface quality of various kinds, etc. Problems may cause a drop in plasticity, resulting in the consequences of bending cracking.

2. When the angle between the bending line and the direction of the embossing of the sheet does not meet the layout regulations, the angle between the direction of the embossing of the bent sheet does not meet the process regulations.

3. The bending radius is too small, and the deformation degree of the outer metal during the bending process exceeds the deformation limit.

4. The quality of blank shearing and punching sections is poor, such as large burrs or cracks in the sheet at the bend.

5. The thickness of the material is seriously out of tolerance, which will cause difficulty in feeding and cracking.

6. Factors such as the wear of the mold fillet radius or the too small gap, the rough surface of the die or the improper design structure cause the feeding resistance to be large, and the stamping parts are easy to crack.

7. The quality of pickling is poor, and the pickling process of steel is carried out carelessly, resulting in over-pickling or hydrogen embrittlement, resulting in reduced plasticity and cracking.

8. Insufficient lubrication, high friction, easy to cause cracks.

Second, the solution to the bending and cracking of stamping parts

1. Improve the condition of the steel plate, mainly including the selection of steel with good plasticity (such as good cold bending performance), local annealing in the parts with large deformation, and improving the quality of the sheared blank section.

2. Improve the technical state of the working part of the mold, reduce the roughness of the working surface of the convex and concave mold, and adjust the reasonable gap.

3. Formulate the correct process plan, select the appropriate process plan, so that the flow resistance of the steel during the bending process is small and the deformation is easy.

4. Improve the manufacturability of the product structure, select a reasonable fillet radius, and increase the process incision at the local bending part to avoid root fracture.

5. Improve lubricating conditions, lubricate rationally, and use lubricating oil with good lubricating performance to reduce the resistance of steel flowing during the bending process.

Characteristics of stainless steel in sheet metal processing

　As a supplier of Stamping dies, let us share with you the technical characteristics of stainless steel in sheet metal processing.

Due to the high yield point and high hardness of stainless steel, the effect of cold work hardening is remarkable. The characteristics of the stainless steel sheet when drawing are as follows:

1Because thermal conductivity is worse than ordinary low carbon steel, the required deformation force is large;

2(3) The rebound is caused by the bending and reverse bending of the sheet at the corner of the deep drawing die, usually forming a concave deformation on the sidewall of the Sheet Metal Bending Parts, so that the product with higher dimensional accuracy and shape requirements needs to increase the shaping process.

Production requirements for precision metal drawing parts

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.

2. What are the technical requirements for the processing of metal drawing parts?

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.