Zhejiang Balford Mechatronics Co., ltd focus on difficult stamping & deep drawing. Main product: motor housing and difficult custom deep drawn stampings.
stamping is a general term that encompasses a broad range of metal forming capabilities and industrial uses. technology of deep drawing Parts produced by metal stamping can range from 0.25 inches in diameter or smaller, ...
Read More →
Stamping and tensioning is a commonly used part in drawing and is widely used in many industries. Stamping and drawing parts should be treated with rust prevention during the production process to effectively avoid corrosion during use. Let’s take a look at the anti-corrosion treatment method of stamping and drawing parts. What is the effect of multiple stretches?
1. Apply asphalt paint and preheat the stamping and drawing parts before spraying, which can improve the adhesion of asphalt paint and accelerate drying.
2. Coating a special coating in the cement mortar can improve the corrosion resistance of the lining of the punching piece.
3. Epoxy coal tar coating is a two-component coating with high adhesion and smooth surface.
4. Epoxy porcelain lining is a kind of anti-corrosion coating for stamping parts. Due to the difficulty of production and high cost, the use has certain restrictions, and it has high adhesion and smoothness.
5. Aluminate cement coating or salt cement coating, two kinds of special cement coatings are suitable for the anticorrosion of punching and pulling parts, and can improve the corrosion resistance.
6. Polyurethane coating is a new type of green special coating with good wear resistance and corrosion resistance.
Read More →
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.
Read More →
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) 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.
(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.
Read More →
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.
Read More →
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?
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.
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.
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.
Read More →
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.
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.
Read More →
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.
Read More →
When processing stainless steel sheet metal parts, in order to avoid debris from hurting people, the baffle should be lit in an appropriate position. When the surface of the workpiece needs to be polished with gauze, move the tool to a safe position and be careful not to let your hands and clothes touch the surface of the workpiece. When grinding the inner hole, don’t use your fingers to support the gauze, use a wooden stick instead, and don’t drive too fast.
Obstructs placing objects, fixtures or workpieces on the lathe bed and spindle gearbox. Be mindful when doing homework. Obstruct tired operation, chat operation, multi-person operation, drinking operation, smoking operation.
Adhere to the regularity of machine tools, tools, and operations, and do a good job of handover work. When cleaning the workplace after work, the power should be turned off, and various feed handles should be placed in a safe place. When turning workpieces with irregular shapes, a balance block should be installed, and the cutting should be carried out after trial rotation.
The tool clamping should be reliable, and the protruding part of the tool head should not exceed 1.5 times the height of the tool body. The shape and specification of the gasket under the tool should be consistent with the shape and specification of the cutter body, and the gasket should be as few and flat as possible.
In addition to installing measuring tools on the lathe that can be actively measured in operation, stop and move the tool holder to a safe position before measuring the workpiece. Ribbon chips and spiral long chips that occur during cutting should be removed with hooks in time to prevent hand pulling.
Wear work clothes, cuffs and safety glasses before work. Female workers should wear work caps, long hair in hair care caps, and operate with gloves.
When the chuck is loaded and unloaded on the spindle of the lathe, it must be carried out after the machine is stopped. The power of the motor must not be used to remove the chuck. Guards should be used for the protrusions of chucks, dials and core clamps that clamp the workpiece to avoid strangling clothing and other parts of the body. If there is no protective cover, care should be taken to adhere to the required interval during operation.
When clamping the workpiece with the top, it should be noted that the center of the tip is exactly the same as the center hole of the spindle. Sheet metal work must not use damaged or angled tips. Before use, the top should be cleaned, the center hole should be clean, and the tailstock tip should be firm. When cutting slender workpieces, in order to ensure operational safety and processing quality, a tracking tool rest or center rest should be selected, and a mobile protective cover and safety signs should be set.
Read More →
Today, we are going to talk about a very common bad situation in progressive die stamping — chip jumping and crushing. What are the reasons for this, and what effective solutions can be taken to avoid affecting the quality and production efficiency of metal stamping products and causing losses to stamping manufacturers.1. Reasons
(1) The clearance is too large;
(2) Improper feeding;
(3) Punching oil drops too fast, and the oil is sticky;
(4) The punch is worn and chips are pressed on the punch;
(5) The punch is too short, and the length of inserted die is insufficient;
(6) The mold is not demagnetized;
(7) Hard material, simple punching shape;
(8) Emergency measures.
2. Solutions
(1) Control the machining accuracy of punch and die or modify the design clearance;
(2) Trim the tape and clean the mold in time when it is sent to the proper position;
(3) Control the oil drop amount of stamping oil or change the oil type to reduce the viscosity;
(4) Studied the punch edge;
(5) Adjust the length of the punch edge into the die;
(6) Demagnetization is required after mold and research;
(7) Replace the material, modify the design, install ejecting or trim the inclined plane or arc (pay attention to the direction) on the end face of the punch edge, and reduce the fitting area between the end face of the punch edge and the scrap;
(8) Reduce the sharpness of the die edge, reduce the amount of research and study on the die edge, increase the roughness of the straight edge surface of the die, use a vacuum cleaner to absorb waste materials, reduce the impact speed, and slow down chip jumping.
Read More →
Metal stamping mainly uses metal or non-metal sheets, which are formed by stamping die pressing by the pressure of the press. It mainly has the following characteristics:
(1) The stamping parts are manufactured by stamping under the premise of low material consumption. The parts are light in weight and good in stiffness, and after the sheet material is plastically deformed, the internal structure of the metal is improved, and the strength of the stamping parts is improved. .
(2) The stamping parts have high dimensional accuracy, uniform size with the same modular parts, and good interchangeability. General assembly and use requirements are met without further machining.
(3) In the stamping process, since the surface of the material is not damaged, it has a good surface quality and a smooth and beautiful appearance, which provides convenient conditions for surface painting, electroplating, phosphating and other surface treatment.
We are a metal stamping company. We also have Carbon Steel Metal Stamping available for you. Contact us to learn more about stamping.
Read More →
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.
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.
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
Read More →
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.
Read More →
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.
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.
Read More →
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.
Read More →
China Balford Mechatronics Co.,Ltd. CONTACT US