Techniques

Zhejiang Balford Mechatronics Co., ltd focus on difficult stamping & deep drawing. Main product: motor housing and difficult custom deep drawn stampings.

  • Characteristics of stainless steel in sheet metal processing

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     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.

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  • different types of Auto Stamping Parts

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    Auto Stamping Parts, as the name suggests, are metal stampings that make up automotive parts. In automotive stamping parts, some of them are directly transformed into auto parts after being stamped, and the other part is subjected to welding, machining, or painting after being stamped to become auto parts. There are many kinds of automobile stamping parts, such as automobile shock absorber stamping spring tray, spring seat, spring bracket, end cover, cover, compression valve cover, compression valve sleeve, oil seal seat, bottom cover, dust cover, impeller, oil cartridges, lugs, brackets, etc. These are all automotive stampings. In Auto Stamping Parts China, stamping is sometimes referred to as sheet forming, but with a slight difference. The term “sheet forming” refers to the use of sheet material, a thin-walled tube, a thin profile, or the like as raw material. The method of forming plastic work is collectively referred to as sheet forming, and at this time, deformation in the direction of the thick plate is generally not considered.

    First, the application range of metal stamping parts:

    1. Special stamping enterprises. Such as the stamping of aviation parts, etc. belong to such enterprises, but these craft factories are also owned by some large factories.

    2. Stamping of parts and components in the automotive industry. Mainly punching and forming. Many of the companies in this sector belong to scale factories, and there are also some independent stamping plants. At present, there are many such small factories near some automobile factories or tractor factories.

    3The stamping factory of daily necessities. Do some crafts, tableware, etc. These factories have also grown significantly in recent years.

    4. Stamping in the automotive industry. Mainly drawing. In this part of China, we mainly focus on large factories such as automobile factories, tractor factories, and aircraft manufacturers. Independent large scale stamping and deep drawing plants have not been seen.

    5. Electric stamping plant. This type of factory is a new industry that has developed along with the development of electrical appliances, which are mainly concentrated in the south.

    6. Household appliance parts stamping plant. These factories only emerged after the development of household appliances in China, and most of them are distributed to household appliances enterprises.

    Second, the detection of metal stamping parts:

    The hardness of metal stamping parts is measured by a Rockwell hardness tester. Small, complex-shaped stampings can be used to test small planes that cannot be tested on ordinary Rockwell benchtop hardness testers. Stamping parts processing includes punching, bending, drawing, forming, finishing and other processes. The materials processed by stamping parts are mainly hot-rolled or cold-rolled (mainly cold-rolled) metal strip materials, such as carbon steel sheets, alloy steel sheets, spring steel sheets, galvanized sheets, tin-plated sheets, stainless steel sheets, copper and copper alloys. Plate, aluminum and aluminum alloy plates, etc.

    Rockwell’s PHP series of portable surface hardness testers are ideal for testing the hardness of these stamped parts. Alloy stampings are commonly used in metal processing and mechanical manufacturing. Stamping is a process that uses a Stamping Mould to separate or form a metal strip. Its application range is very broad.

    First, the application range of metal stamping parts:

    1. Special stamping enterprises. Such as the stamping of aviation parts, etc. belong to such enterprises, but these craft factories are also owned by some large factories.

    2. Stamping of parts and components in the automotive industry. Mainly punching and forming. Many of the companies in this sector belong to scale factories, and there are also some independent stamping plants. At present, there are many such small factories near some automobile factories or tractor factories.

    3The stamping factory of daily necessities. Do some crafts, tableware, etc. These factories have also grown significantly in recent years.

    4. Stamping in the automotive industry. Mainly drawing. In this part of China, we mainly focus on large factories such as automobile factories, tractor factories, and aircraft manufacturers. Independent large scale stamping and deep drawing plants have not been seen.

    5. Electric stamping plant. This type of factory is a new industry that has developed along with the development of electrical appliances, which are mainly concentrated in the south.

    6. Household appliance parts stamping plant. These factories only emerged after the development of household appliances in China, and most of them are distributed to household appliances enterprises.

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  • Sheet Metal Fabrication

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    Technical aspects: During Sheet Metal Fabrication, in order to achieve the purpose of reducing investment, workers are required to strictly follow the consumption standards to complete the work process. Before each processing, the application must stop reviewing the application status of the data. Ability to stop processing at will. Many of the processing industry’s costs are due to the lack of good data before processing, so staff must first understand the types of processing data, check data specifications and models, and make good preparations to prevent errors during processing. It can also reduce the amount of waste, and workers should pay attention to these issues during processing.

    To measure the quality of a sheet metal processing plant, first, look at the incomplete equipment; second, look at the skills of its operators; third, look at the order of the processes.

    First, TOX riveting

    The connected piece is pressed into the female die through a simple male die. Under further pressure, the data in the die is “moved” outward. The result is a round joint with no sharp edges and no burrs, and it will not affect its corrosion resistance. Even externally plated or spray painted plates can also retain the original rust and corrosion resistance characteristics. The paint layer also deforms with it. The material is squeezed to both ends, into the plate on the side of the die, and then forms a TOX connection point.

    Rivet riveting

    This type of rivet is often called rivet, and riveting two plates together is called rivet.

    Third, hole riveting

    One part in the middle is a drawing hole, and the other part is a counterbore. After being riveted, it becomes an inseparable joint. Superiority: The sinkhole with which the hole is matched has the positioning function itself. The riveting strength is high, and the riveting efficiency through the mold is also higher.

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  • Precision Stamping

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    Over 20000+ sets of precision stamping parts production experience, stamping accuracy up to ± 0.01mm.
    To achieve a high-quality international level, ISO 9001, ISO 14001, and IATF 16949 certifications promise high-quality precision stamping parts.
    Supporting you through all processes of your project, working with you to develop the ideal, competitive stamping solution. From our engineering services to tool manufacturing and parts production.

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  • Metal Stamping Parts

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    HULK Metal has provided excellent metal stamping services for more than 20 industries such as automobiles, home appliances, machinery, and other manufacturing or construction industries. Our factory strictly implements the ISO9001 quality management system and is equipped with more than 20 stamping machines with different pressures to manufacture metal stamping parts with a thickness of 0.1mm~10mm. Our products can pass CE, GB, and SGS certifications.

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  • Electronic Stampings Parts

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    The surface and intrinsic properties of electronic stamping materials have a great influence on the quality of stamped products. The thickness of stamping material is required to be precise and uniform; the surface is smooth, no spots, no flaws, no scratches, no surface cracks, etc.; Uniform yield strength, no obvious directionality; high uniform elongation; low yield ratio; low work hardening.

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  • Influence of Necking Process in Stamping

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    Influence of Necking Process in StampingDuring necking processing, the metal stamping material at the necking end slides into the female die under the pressure of the punch, the diameter decreases, the wall thickness and height increase, and when the wall thickness of the workpiece is not large, it can be approximately considered that the deformation area is in the plane stress state of tangential and radial compression, mainly tangential pressure. The radial compressive strain is the large strain of zui, while the thickness and length directions are elongation, and the deformation in the thickness direction is greater than that in the length direction.

    Due to the effect of tangential compressive stress, the billet is prone to instability and wrinkling during necking; At the same time, the cylinder wall in the non deformation area is prone to instability and deformation due to bearing all necking pressure, so preventing instability is the main problem of necking process.

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  • Factors influencing the dimensional accuracy of metal stamping parts

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    Different metal stamping products have different requirements for accuracy. As long as we meet the accuracy requirements of customers and comprehensively consider production costs, we can produce qualified stamping parts. The factors that affect the dimensional accuracy of metal stampings must be known by everyone. Let’s have a look together.The dimensional accuracy of metal stamping parts refers to the difference between the actual size of stamping parts and the basic size. The smaller the difference, the higher the dimensional accuracy of metal stamping parts.

    The influencing factors are as follows:

    1. Manufacturing precision of metal stamping die.

    2. Gap between male and female dies.

    3. Elastic recovery of materials after stamping.

    4. Accidental factors in the production process, such as inaccurate positioning, unstable material performance, etc.

    It can be divided into precision level and ordinary level. The ordinary level is the precision that can be achieved by more economic means, while the precision level is the precision that can be achieved by stamping technology.

    The surface quality of metal stampings shall not be higher than that of raw materials, otherwise, subsequent processing is required to achieve it, increasing production costs.

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  • Factors influencing the dimensional accuracy of metal stamping parts

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    Different metal stamping products have different requirements for accuracy. As long as we meet the accuracy requirements of customers and comprehensively consider production costs, we can produce qualified stamping parts. The factors that affect the dimensional accuracy of metal stampings must be known by everyone. Let’s have a look together.The dimensional accuracy of metal stamping parts refers to the difference between the actual size of stamping parts and the basic size. The smaller the difference, the higher the dimensional accuracy of metal stamping parts.

    The influencing factors are as follows:

    1. Manufacturing precision of metal stamping die.

    2. Gap between male and female dies.

    3. Elastic recovery of materials after stamping.

    4. Accidental factors in the production process, such as inaccurate positioning, unstable material performance, etc.

    It can be divided into precision level and ordinary level. The ordinary level is the precision that can be achieved by more economic means, while the precision level is the precision that can be achieved by stamping technology.

    The surface quality of metal stampings shall not be higher than that of raw materials, otherwise, subsequent processing is required to achieve it, increasing production costs.

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  • Influence of Die Clearance on Stamping Parts

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    As stamping parts manufacturers know, stamping requires reasonable blanking clearance, which can achieve better section quality, higher dimensional accuracy, smaller blanking force and higher die life. Now let’s understand the influence of die clearance.The relationship between the customized die clearance and blanking force of stamping parts. The smaller the clearance, the greater the blanking force. On the contrary, increasing the clearance can reduce the blanking force. When the clearance is reasonable, the upper and lower cracks coincide, and the large z blanking force will be smaller;

    The accuracy of stamping parts refers to the error value between the actual size and the basic size. The smaller the difference, the higher the accuracy. When the gap is large, the material will be larger under the tensile action. After stamping, the material will have elastic recovery, and the size of the blanking part will be smaller than the die size. When the gap is small, the elastic recovery of the material will make the size of the blanking part larger and the hole diameter smaller;

    During the processing and customization of stamping parts, the pressure on the die edge is very large, which causes local adhesion and wear when it contacts with materials. When the gap is small, the contact pressure becomes larger and the distance is longer, leading to accelerated wear of the die. When the gap is large, the material tension increases relatively, and the positive pressure on the end face of the die edge increases, which is easy to cause tool breakage or deformation, leading to die wear.

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  • Pay attention to 9 major issues when designing precision stamping dies

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    As an important tool in the process of stamping production, stamping die has its own characteristics. When designing stamping dies, stamping processing plants need to consider from a scientific and reasonable perspective to improve the service life, durability, production efficiency, reduce production costs and ensure product quality. Baifudu Precision Stamping – With 20 years of experience in customized processing of stamping parts, various complex precision stamping products can be customized according to customer needs. Then, what should we pay attention to when designing the mold? Baifudu Precision Stamping will tell you next.1. In mold design, the selection of mold materials, heat treatment and surface treatment.

    2. Strip design is the analysis of the product forming process, which basically determines the success of the die.

    Before designing the material belt, we need to know the tolerance requirements, material properties, punching tonnage, punching table, SPM (times of punching per minute), feeding direction, feeding height, die thickness requirements, material utilization rate and die service life of the parts. When designing the tape, CAE analysis should be carried out at the same time, mainly considering the material thinning rate, and more communication with customers.

    3. When testing the mold, make sure to slowly close the upper mold. During the stretching process, make sure to use the fuse to test the material layer thickness. When the material level gap reaches the material thickness, try the die again, and the blade must be aligned first. For drawbead, use a movable insert to adjust the height of the drawbead. After the mold is matched, the datum hole and datum plane must be measured on the fixture, or sent to CMM for 3D report.

    4. For parts with more bending, the bending shall be adjusted step by step according to the process during die adjustment.

    5. When adjusting the forming angle, you can reduce the R angle or move the polyline reference during the bending process to reach the forming angle.

    6. During die adjustment, the gasket is mainly used to adjust the height of the forming punch, or move the forming punch from left to left. Washers are usually stainless steel hardware.

    7. For trimming line affected by forming, cutting shall be selected after forming, and special position can be realized by cross cutting.

    8. For multiple datum hole locations, the method of one-time punching forming shall be adopted to avoid affecting the accuracy after step-by-step punching.

    9. For product fracture, a variety of methods can be used, such as adding packaging, extruding, and increasing the forming area of plate bar and opening in the late stretching process. CAE analysis shall be carried out after mold modification.

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  • Causes and Solutions of Stamping Scrap

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    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.

    1. 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.

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  • Differences between forming and finishing of stamping parts

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    In order to improve the precision of metal stampings, some stamping processes, such as refurbishment and refurbishment, are sometimes added during the production process of stamping parts. So, people who have just entered the industry will ask, what is the difference between the two?Shaping is to use the reshaping die to press the inaccurate parts of the bending or stretching parts into an accurate shape; Or for the stamping parts with surface flatness requirements, the flat stamping parts with arch bending and warping shall be flattened with the leveling die. That is to say, depending on the material flow, the shape and size of the process parts are changed a little to ensure the accuracy of the workpiece. It belongs to the forming process of stamping parts.

    Trimming is to remove the allowance of the outer edge or inner hole of the blank with the trimming die to obtain a smooth section and accurate size. It is a blanking process applied to stamping parts and belongs to blanking process.

    That is to say, shaping is used for the forming process of stamping parts to improve the shape quality and dimensional accuracy of finished metal stamping parts; The trimming is often used in the blanking process of stamping parts to obtain high-quality blank or inner hole of stamping parts and improve the dimensional accuracy.

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  • The Method of Punching Small Holes for Stamping Parts

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    In this paper, we will introduce the method and points for attention of punching small holes in the processing of stamping parts. With the development of science and technology and society, the previously commonly used machining method of micro holes has gradually been replaced by the stamping method. By making the punch firm and stable, improving the punch strength, preventing punch fracture and changing the stress state of the blank during punching, etc.The ratio d/t of the punching diameter to the material thickness in stamping can reach the following values: 0.4 for hard steel, 0.35 for mild steel and brass, and 0.3 for aluminum.

    When punching a small hole on a sheet, when the material thickness is greater than the punch diameter, the punching process is not a shearing process, but a process of extruding the material into the die through the punch. At the beginning of extrusion, part of the washed waste is compressed and squeezed into the area around the hole, so the thickness of the washed waste is generally less than the thickness of the raw material.

    When punching small holes in stamping parts, due to the small diameter of punch punch, if common blanking method is used, the small punch is easy to break, so try to improve punch strength to prevent it from breaking and bending. The methods and precautions are as follows:

    1. The stripper serves as a guide plate.

    2. The guide plate and the fixed working plate are connected by a small guide post guide sleeve or directly with a large guide post guide sleeve.

    3. The punch shall be retracted into the guide plate, and the distance between the guide plate and the punch fixing plate shall not be too large.

    4. The bilateral clearance between punch and guide plate is less than the unilateral clearance between punch and die.

    5. The pressing force is 1.5~2 times greater than that of simple stripping.

    6. The guide plate shall be made of or inlaid with high hardness materials, and the thickness shall be 20%~30% compared with the normal situation.

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  • Measures for Uneven Stripes on the Surface of Metal Stamping Parts

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    In the process of stamping, uneven stripes will appear on the surface of metal stamping parts, which will affect the surface quality and overall strength of stamping parts, and even scrap the products in serious cases. That is why this problem occurs, and what measures can be taken to effectively control and avoid it? Let’s get to know.It is mainly to improve the friction characteristics between metal stamping parts and tools, improve the stiffness of the whole system, increase the damping of the system, and reduce the cutting load. Specific measures are as follows for your reference:

    1. Use appropriate tools and stamping raw materials, and select appropriate tools for different metal stamping materials, so that the mutual friction system between tools and workpieces and the difference between dynamic and static friction coefficients of tools and workpieces are as small as possible.

    2. Adding cutting fluid with good performance can better improve the friction characteristics of tools and precision parts.

    3. Improve the stiffness of the system: increase the stiffness of the whole process, which can effectively reduce the occurrence of this phenomenon.

    4. Reduce the length of the tool extending out of the tool rest, thicken the tool handle, and improve the rigidity of the tool rest.

    5. To increase the damping of the system, materials with large internal damping can be selected as the supporting parts, or high damping materials can be added to the components or damping links can be used to reduce the occurrence of vibration.

    6. Reduce the length diameter ratio of stamping parts, and use intermediate supports such as center frame to increase the rigidity of the workpiece.

    7. Properly thicken the diameter of the transmission lead screw in the feed mechanism, shorten the length of the lead screw, etc., improve the transmission stiffness of the feed mechanism, try to eliminate the gap between the transmission components in the feed mechanism, give the transmission of the feed mechanism, and improve the stiffness of the machine tool transmission system.

    8. The ball screw is used to replace the ordinary thread screw, the liquid friction is used to replace the boundary or dry friction, and special lubricating oil is used to improve the sensitivity of the feed system by improving the friction performance of the machine tool transmission system, so as to reduce the occurrence of the vibration of the metal stamping parts.

    9. In the process of metal stamping, when the feed speed is low and there is vibration, it is necessary to stop the machine immediately, analyze the causes of the phenomenon, and take targeted effective measures to eliminate the phenomenon, so as to ensure the normal metal stamping process.

    10. Reduce the load of cutting and improve the vibration of metal precision stamping parts during cutting by reducing the amount of back cutting and reducing the weight of each transmission component.

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