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What are the methods to improve the stability of progressive molds

ouzhong — Wed, 06 Dec 2023 00:38:48 +0000

The production of molds plays an important role in our industrial production. Nowadays, due to the needs of our industrial production, various types of molds have also emerged around us. The production of molds is very strict, because even a small error can cause the products we produce to be unqualified. The same is true in our mold production. Progressive molds are one of the commonly used molds, and their production is also extremely strict, How to improve the performance of our progressive molds is a common problem that all mold workers want to solve. Let’s learn how to improve the performance of progressive molds together. We know that any small error can affect the accuracy of processing data parameters, which in turn affects the performance of progressive mold products. Processing accuracy refers to the degree to which the actual dimensions, shape, and position of the machined part surface meet the ideal geometric parameters required by the drawing. The ideal geometric parameters, in terms of size, are uniform dimensions; For surface geometric shapes, they are absolute circles, cylinders, planes, cones, and straight lines, etc; For the mutual position between surfaces, it means absolute parallelism, verticality, coaxiality, symmetry, etc. The deviation between the actual geometric parameters of the part and the ideal geometric parameters is called machining error. Both machining accuracy and machining error are terms used to evaluate the geometric parameters of machining surfaces. The machining accuracy is measured by tolerance level, and the lower the level value, the more accurate it is. The higher the accuracy, the machining error is represented by numerical values, and the larger the numerical value, the greater the error. High machining accuracy means small machining errors, and vice versa.
The main reasons that affect the stability of molds and stamping are as follows: horizontal to the strength of a mold material and progressive die structure, the stability performance of progressive die stamping materials, the characteristics of waves, the thickness of progressive die materials in the progressive die stamping process, because each urgent plate has its own chemical composition, mechanical properties, and stamping performance characteristic values closely related, the stamping material performance is unstable, and the stamping material thickness fluctuates, The changes in stamping materials not only directly affect the accuracy and quality of the stamping process, but may also lead to damage to the progressive die. The stamping technology and progressive die design process must consider the magnitude of tensile resistance, decorate the range of tensile steel bars and determine the form of tensile steel bars based on the edge holding force, so that each area can complete the forming deformation mode and degree as needed. We believe that there are too many factors that affect the stability of progressive molds, so we are all using them. We also need to pay more attention to these operations to improve the stability of progressive molds and ensure the quality of processed products. In recent years, progressive molds have been increasingly used around us, and the performance requirements of our stamping dies are also high. We need to maintain them as progressive molds to extend their service life.
Precautions for designing progressive molds: Causes of faults during the stamping process of progressive molds:
1. Edge wear; 2. The difference is too large, and the cutting effect is not significant after reaching the destination; 3. Cutting edge cutting, unreasonable gaps, deviations, looseness, and misalignment. The method to improve the stability of progressive dies: level up to the strength of a mold material and progressive die structure, the stability performance of progressive die stamping materials, the characteristics of waves, the thickness of progressive die materials in the progressive die stamping process, because each urgent plate has its own chemical composition, mechanical properties, and stamping performance characteristic values closely related, the stamping material performance is unstable, the stamping material thickness fluctuates, and the stamping material changes, Not only does it directly affect the accuracy and quality of the stamping process, but it may also lead to damage to the progressive die. The stamping technology and progressive die design process must consider the magnitude of tensile resistance, decorate the range of tensile steel bars and determine the form of tensile steel bars based on the edge holding force, so that each area can complete the forming deformation mode and degree as needed. Notes on progressive die design: From the perspective of progressive die design systems, the role of practical experience should be highly valued in determining the large-scale systems that make up stamping and mold manufacturing, as well as the structure of progressive dies for parts. Realistically, establish practical mold solutions while considering existing mold manufacturing and stamping production conditions. The structure of progressive molds is complex, difficult to design, with high manufacturing costs and long cycles. Therefore, the design should adhere to scientific, rigorous, pragmatic, careful analysis and detailed planning, make reasonable designs, facilitate production and meet requirements, fully understand the requirements and usage conditions of product parts processing and mold manufacturing.

What are the selection techniques for stamping materials?

ouzhong — Wed, 06 Dec 2023 00:37:27 +0000

What are the selection techniques for stamping materials? Today, European and Chinese automotive molds will tell you
Stamping processing includes processes such as punching, bending, deep drawing, forming, and finishing. The materials used for stamping processing are mainly hot-rolled or cold-rolled (mainly cold-rolled) metal sheet and strip materials, such as carbon steel plate, galvanized plate, tinplate, copper and copper alloy plate, aluminum and aluminum alloy plate, etc.
Due to the fact that the operation of the spring-loaded unloading mold is more convenient than that of a fixed unloading mold, the operator can see the feeding action of the strip in the mold, and the spring-loaded unloading plate applies a flexible force to the strip during unloading, which will not damage the surface of the workpiece. Therefore, in actual design, it is recommended to use a spring-loaded unloading plate as much as possible, and only when the unloading force of the spring-loaded unloading plate is insufficient, a fixed unloading plate is used instead. Whether the mold used for stamping parts adopts a spring-loaded discharge plate or a fixed discharge plate depends on the size of the discharge force, with material thickness being the main consideration factor.
The main purpose of hardness testing for stamping materials is to determine whether the annealing degree of the purchased metal sheet is suitable for the subsequent stamping processing. Different types of stamping processing processes require different hardness levels of sheets. Aluminum alloy plates used for stamping parts can be tested using a Vickers hardness tester. When the material thickness is greater than 13mm, a Babbitt hardness tester can be used. Pure aluminum plates or low hardness aluminum alloy plates should use a Babbitt hardness tester.

Classification of Stamping Dies

ouzhong — Wed, 06 Dec 2023 00:36:15 +0000

There are many forms of stamping molds, which can generally be classified according to the following main characteristics:
1. Classification based on process properties
(1) A die that separates materials along a closed or open contour line. Such as material cutting die, punching die, cutting die, cutting die, edge cutting die, cutting die, etc.
(2) A bending die is a mold that causes the blank or other blank to bend and deform along a straight line (bending curve), thereby obtaining a workpiece with a certain angle and shape.
(3) A deep drawing die is a mold that turns a blank sheet into an open hollow part, or further changes the shape and size of the hollow part.
(4) A forming die is a mold that directly replicates a rough or semi-finished workpiece into a convex or concave shape according to the drawing, while the material itself only produces local plastic deformation. Such as bulging molds, necking molds, expanding molds, undulating forming molds, flanging molds, shaping molds, etc.
2. Classification based on the degree of process combination
(1) A single process mold is a mold that completes only one stamping process in one stroke of a press.
(2) A composite mold has only one workstation, and in one stroke of the press, it is a mold that completes two or more stamping processes simultaneously on the same workstation.
(3) Progressive die (also known as continuous die) has two or more workstations in the direction of raw material feeding. It is a mold that completes two or more stamping processes on different workstations in one stroke of the press.

Design Points for Continuous Mold Manufacturing

ouzhong — Wed, 06 Dec 2023 00:35:07 +0000

Sharing an article with everyone about continuous mold manufacturing design is mainly about connecting stamped products to the strip, and sending semi-finished products to various engineering stations for stamping through equidistant feeding. There are many ways to connect stamped products to the strip, and continuous mold manufacturers introduce that the connection method also needs to be determined based on the characteristics of stamped products and stamping direction. Continuous mold manufacturing mainly involves conveying semi-finished products with additional materials, so the material utilization rate of continuous molds may be lower than that of engineering molds, but the production efficiency is much higher than that of engineering molds.
1. Stamped products detach from the strip and drop directly: the finished product is directly punched down at the end of the stamping die, and the stamped product is separated from the strip. This type of stamping product is directly stamped, and vibration grinding and cleaning are semi-finished products. This design is widely used in motor terminals, hardware parts, LCD parts, hard drive components, and other similar applications.
2. Stamped products are still attached to the material belt: Stamped products are connected to the material belt and leave the mold together. Stamped products are connected to the material belt, and there is a receiving machine behind the stamping mold to collect the stamped products connected to the material belt using a fixture. This type of stamped product generally requires post-processing such as electroplating, threading, etc., so it needs to be connected to the strip for other processes. This approach is mostly applied to terminal products.
3. Stamped products are attached to the strip, but can be peeled off directly by hand: Stamped products are connected to the strip and leave the mold, while stamped products are connected to the strip. The difference from terminals is that they can be peeled off by hand. This type of product also needs to undergo post-processing treatments such as electroplating, so it is necessary to connect the stamped product to the strip. During assembly, only the stamped product needs to be manually peeled off from the strip or other fixtures, simple molds, etc. After being assembled with the plastic part, it is peeled off to form a semi-finished product. This method is generally used for materials such as shrapnel, USB connectors, and connector shells.

How is the stamping mold installed?

ouzhong — Wed, 06 Dec 2023 00:34:01 +0000

Installation of punching machine molds
1) Confirm whether the feeding holes of the mold and the cushion block are consistent.
2) After assembling the upper and lower molds, place them on the lower table, ensuring that the reference plane of the punching machine is parallel to the reference plane of the mold.
3) The lower mold should be completely fixed, and the upper mold should also be lightly fixed in advance.
4) Test punching the slider on the punching machine 20-30 times, confirm that the upper and lower molds are in a completely matching state, and then tighten the upper mold.
5) The biting component of the punch press’s convex and concave molds is combined with the lower mold stop block of the mold to adjust the height of the slider on the punch press.
6) Use the trial punching of the sealing paper to confirm its cutting condition. If it is uneven, confirm the installation status of the mold again. If consistency cannot be achieved, it is necessary to confirm the parallelism between the punch slide and the lower table of the punch.
7) Adjust the material feed length and feed time. (If there is a waste cutting blade attached, the length of the cut waste can be used to confirm the feed length of the material)
8) After a comprehensive operation of 3-5 minutes, fill the gap between the guide pillar and the lining with oil and confirm if there is any abnormal heat.
9) Try on the selected processed material and confirm that there are no obstacles during insertion.
10) After the above work is completed, processing can be carried out. Firstly, press the first material positioning rod set on the side of the lower mold, and feed the material until it touches the positioning rod. After insertion, first perform a trial punch using a manual feed until the final process is completed.
11) After confirming that there are no abnormalities with the manual feed, close the switch of the punching machine feeding device. At this point, the feed work needs to be carried out completely in the completed position.
12) The punching die utilizes a single punch motion to confirm whether the feed rate is appropriate.

What steel is used for stamping molds

ouzhong — Wed, 06 Dec 2023 00:32:54 +0000

The materials used for stamping molds include steel, hard alloys, steel bonded hard alloys, zinc based alloys, low melting point alloys, aluminum bronze, polymer materials, and so on.
At present, the majority of materials used for manufacturing stamping molds are steel. The commonly used types of mold working parts materials include: carbon tool steel, low alloy tool steel, high carbon high chromium or medium chromium tool steel, medium carbon alloy steel, high-speed steel, matrix steel, as well as hard alloys, steel bonded hard alloys, and so on.
1. Carbon tool steel
Carbon tool steels commonly used in molds are T8A, T10A, etc., which have the advantages of good processing performance and low cost. But the hardenability and red hardness are poor, the heat treatment deformation is large, and the bearing capacity is low.
2. Low alloy tool steel
Low alloy tool steel is made by adding an appropriate amount of alloying elements on the basis of carbon tool steel. Compared with carbon tool steel, it reduces quenching deformation and cracking tendency, improves the hardenability of the steel, and also has better wear resistance. Low alloy steels used for mold manufacturing include CrWMn, 9Mn2V, 7CrSiMnMoV (code CH-1), 6CrNiSiMnMoV (code GD), etc.
3. High carbon and high chromium tool steel
The commonly used high carbon and high chromium tool steels include Cr12, Cr12MoV, and Cr12Mo1V1 (code D2), which have good hardenability, hardenability, and wear resistance. They have minimal heat treatment deformation and are high wear-resistant micro deformation mold steels, with a load-bearing capacity second only to high-speed steel. However, severe segregation of carbides requires repeated upsetting and drawing (axial and radial) to reduce the unevenness of carbides and improve their performance.
4. High carbon medium chromium tool steel
High carbon medium chromium tool steels used for molds include Cr4W2MoV, Cr6WV, Cr5MoV, etc. They have low chromium content, fewer eutectic carbides, uniform distribution of carbides, small heat treatment deformation, good hardenability and dimensional stability. Compared with high carbon and high chromium steel with relatively severe carbide segregation, the performance has been improved.
5. High speed steel
High speed steel has the highest hardness, wear resistance, and compressive strength among mold steels, and has a high load-bearing capacity. Commonly used in molds are W18Cr4V (code 8-4-1) and W6Mo5 Cr4V2 (code 6-5-4-2, US grade M2) with low tungsten content, as well as the low-carbon and vanadium reducing high-speed steel 6W6Mo5 Cr4V (code 6W6 or low-carbon M2) developed to improve toughness. High speed steel also needs to be forged to improve its carbide distribution.
6. Matrix steel
Add a small amount of other elements to the basic composition of high-speed steel, and appropriately increase or decrease the carbon content to improve the performance of the steel. This type of steel is collectively referred to as base steel. They not only have the characteristics of high-speed steel, but also have certain wear resistance and hardness, and their fatigue strength and toughness are better than those of high-speed steel. They are high-strength and toughness cold work mold steel, but their material cost is lower than that of high-speed steel. The commonly used matrix steels in molds include 6Cr4W3Mo2VNb (code 65Nb), 7Cr7Mo2V2Si (code LD), 5Cr4Mo3SiMnVAL (code 012AL), etc.
7. Hard alloys and steel bonded hard alloys
Hard alloy has higher hardness and wear resistance than any other type of mold steel, but poor bending strength and toughness. The hard alloy used for molds is tungsten cobalt type. For molds with low impact resistance and high wear resistance requirements, hard alloys with lower cobalt content can be selected. For molds with high impact, hard alloys with higher cobalt content can be selected.
Steel bonded hard alloy is made by sintering iron powder with a small amount of alloy element powder (such as chromium, molybdenum, tungsten, vanadium, etc.) as the binder, titanium carbide or tungsten carbide as the hard phase, using powder metallurgy method. The matrix of steel bonded hard alloy is steel, which overcomes the disadvantages of poor toughness and processing difficulties of hard alloy. It can be cut, welded, forged, and heat treated. Steel bonded hard alloys contain a large amount of carbides. Although their hardness and wear resistance are lower than those of hard alloys, they are still higher than other types of steel. After quenching and tempering, their hardness can reach 68-73HRC.

The difference between progressive die and composite die

ouzhong — Wed, 06 Dec 2023 00:31:59 +0000

1、 Different properties
1. Composite mold: A mold structure in which a punching machine completes multiple processes such as material cutting and punching in one stroke.
2. Progressive die: composed of multiple workstations, each of which is sequentially associated to complete different processing tasks. A series of different stamping processes are completed in one stroke of the punching machine.
2、 Different characteristics
1. Composite mold:
(1) The workpiece has good coaxiality, a flat surface, and high dimensional accuracy.
(2) High production efficiency, not limited by the accuracy of plate shape and size. Sometimes waste corners can also be used for replication.
(3) The processing and manufacturing of mold parts is difficult and costly. Stamping and concave molds are easily limited by the minimum wall thickness and are not suitable for certain lower parts with small inner hole spacing and inner hole and edge spacing.
2. Progressive mold:
(1) Progressive die is a type of multi task continuous punching die. In a mold, it can include many processes such as cutting, bending, and drawing, with high productivity.
(2) Progressive mold operation safety.
(3) Easy to automate;
(4) High speed punching machines can be used for production.
(5) It can reduce the area of stamping machines and sites, as well as the transportation of semi-finished products and warehouse occupancy.
(6) Parts with high size requirements should not be produced using progressive molds.

Four maintenance precautions for continuous metal stamping dies

ouzhong — Tue, 05 Dec 2023 09:29:34 +0000

1. Maintenance and upkeep of convex and concave molds.
When disassembling convex and concave molds, attention should be paid to the initial condition of the mold, which is beneficial for the repair of subsequent molds; If there are washers or offsets, the thickness of the washers should be engraved on the parts and noted.
When disassembling and replacing the convex mold, check whether the concave mold of the material removal block is smooth, and whether the gap between the trial insertion and the concave mold is uniform; When disassembling and replacing the concave mold, is the gap between the trial insertion and the punching needle uniform.
In order to better reduce the reduction of protrusions, it is necessary to lift the gasket to achieve the required length, and it should be checked whether the reasonable length of the protrusions is sufficient. Replace the cracked convex mold, investigate the cause, and check if the opposite concave mold has collapsed edges and if cutting edges is necessary.
When assembling the convex mold, check if the gap between the convex mold and the fixed fixed block or fixed plate is sufficient. If there is steel cutting, check if there is thematic activity capacity. The assembled concave mold should be placed horizontally, then a flat steel block should be placed on the surface of the concave mold, and lightly tapped with an aluminum rod in a timely manner. There is no need to tilt or strike forcefully. The bottom of the concave mold should be rounded. After installation, check if the concave mold surface is flush with the mold surface.
After assembling the convex and concave molds and mold cores, it is necessary to check the medical belt, whether each component is installed incorrectly or in the opposite direction, whether the concave mold and concave mold gasket are installed in the opposite direction, whether the feeding hole is blocked, whether new parts must be stolen, whether they are sufficient, and whether the mold must be tightened.
Pay attention to ensuring that the screws on the discharge plate are securely fastened. When locking, the force should be evenly applied from the inside out and clamped in a cross pattern. It is not necessary to lock one screw first, and then lock another screw to prevent the stripping plate from tilting, causing the convex mold to break or the mold accuracy to decrease.
2. Maintenance of the discharge plate.
When disassembling the stripper board, you can use two drivers to evenly smash it open, and then use both hands to balance the bar and remove it. When it is difficult to disassemble and assemble, check whether the mold is clean and tidy, whether the clamping screws are all disassembled and assembled, and whether the mold caused by the clamping material is damaged. After identifying the cause, carry out corresponding solutions, and do not blindly follow the trend to solve the problem.
When assembling the stripper board, first clean the convex mold and stripper board, add lubricating grease between the positioning pin and the convex mold guide, and successfully insert them. Then, press them in time with both hands and repeat several times. If it is too tight, the cause should be investigated (whether the positioning pin and guide pillar are all normal, whether each component is damaged, whether the new punch can pass through the stripper plate, and whether the position is appropriate), and then the corresponding solution should be completed.
If there is steel cutting on the fixed fixed plate, check if the seat on the side plate of the material removal is sufficient. The contact area between the stripper plate and the raw material in the concave mold is caused by long-term stamping and processing, resulting in imprinting. When the indentation is severe, it will affect the control accuracy of the raw materials, causing abnormal and unstable product specifications. The discharge plate and discharge plate must be repaired or ground again.
The specifications of the contour sleeve should be checked for accuracy. Different heights can cause the stripping plate to tilt, and its accuracy guidance and stable elastic compression will be damaged. It is necessary to maintain and maintain it.
3. Adjustment of mold clearance.
The positioning hole of the mold core is damaged due to damage to the mold core, resulting in excessive gap (loose after assembly) or uneven gap (positioning error) after assembly, resulting in poor cross-sectional appearance, easy breakage of the convex mold, burrs, etc. after laser cutting. Proper gap adjustment can be carried out based on the inspection of the cross-sectional situation after laser cutting.
When the gap is small, the cross-section is small, but when the gap is large, the cross-section is large and the burrs are large. Effective gaps can be obtained by moving. After adjustment, record as much as possible or at the edge of the concave mold for easy maintenance and practical operation.
In daily production and manufacturing, attention should be paid to collecting and storing the material strips of the original molds. If the subsequent work is unsuccessful or there is a genetic mutation in the mold, it can be used as a reference for mold maintenance and upkeep.
In addition, if the auxiliary system software such as the top material pin is damaged, can it be used to top the material, and if the guide pins and shaft sleeves are damaged, regular inspection and maintenance should be paid attention to.
4. Check the directional position.
It is necessary to check the clearance between the positioning pins and guide pillars, whether there are any burns or damage marks, and whether the oil supply for the mold’s guidance is normal.
The damage and precision degradation of directional components reduce the accuracy of the mold, and every part of the mold will have problems. It is necessary to carry out appropriate maintenance and regular replacement. Check the accuracy of electrical conductor components. If the guide pin is damaged, it is necessary to replace the accuracy and function of the electrical conductor. Check the condition of the detachment torsion spring and the top material spring to see if they are broken or have been used for a long time. Although it did not rupture, it was already tired and lost its original compressive strength. Be sure to maintain and replace the mold, otherwise it may cause damage or poor manufacturing.
In the production and manufacturing of stamping molds, everyone’s mold staff must be meticulous and careful to improve the service life of the molds, increase productivity, and save costs for the mold company.

魔天记 忘语 小说,已完本玄幻小说排行榜