Metal Stamping Die
The precision and quality of each component produced by metal stamping dies will have the same characteristics. Satisfy the demand for small batch production in a short period of time, suitable for most types of production needs.
Sheet Metal Press Tool Design
Sheet metal press tool design is the use of commonly used cold forming techniques in the manufacturing of metal sheets, with the help of pressure and specified tools to convert metal coils or sheets into specified geometric shapes. Stamping die is a pre-designed tool that allow for large-scale production of sheet metal stamping die design parts with excellent repeatability. Operators utilize optimized processes, systems, and tools to make carbide stamping die more industrialized. There are three important components in the stamping process, namely the punch, press tool, and press. Various parts require the use of corresponding tools, which are then fed into metal materials to form shapes in a press.
The metal plate has an advantage in the stamping process of the tool, which is that it will not produce the required shape and waste. Through mold feeding and pressing, metal sheet parts are transferred and manufactured into other shaped parts, such as V-shaped parts, without generating excess waste. Each component has corresponding steps, and their complexity varies. Manufacturing each component may require many steps, such as flipping and bending, punching, cutting, and embossing. Stamping is suitable for metal components, and commonly used materials for sheet metal press tool design include iron parts, aluminum, copper, etc.
Sheet Metal Press Tool Design for Deep Drawing
Structural Design of Concave Tools：There are two types of structures: ordinary flat-end concave tool and conical concave tool. The structure of a regular flat-end concave tool is relatively simple. The conical tool structure reduces the drawing force required for deep drawing using a conical tool, which allows for greater shape changes in the material and a smaller drawing coefficient. At the same time, the concave tool cone surface enhances the ability of components to resist instability and wrinkling during the deep drawing process. Therefore, the parts mainly used for deep drawing have the characteristic of relatively small thickness, and another advantage is that they are not prone to wrinkling.
Structural Design of Convex Tools：When drawing medium cylindrical or large cylindrical parts with a diameter greater than 100 millimeters, or workpieces that are not cylindrical in shape, a convex tool structure with an inclined angle is commonly used. This structure has many characteristics, such as conical tool deep drawing and reducing repeated material bending and deformation of deep drawn parts, which helps to improve the quality of component sidewalls. When using this form of convex mold, it is necessary to make the subsequent processes the same, mainly including the concave mold cone angle and the convex mold bevel angle of the previous process. The diameter of the concave tool in the subsequent process must be greater than the diameter of the convex tool cone in the previous process, to reduce the shape deformation caused by repeated bending during deep drawing and improve the quality of the workpiece. But for the final deep drawing, to ensure a flat bottom of the workpiece, technicians need to improve the design of the bottom structure.
Sheet Metal Press Tool Design for Punching
- Fixed Plate Design
Regarding sheet metal press tool design, the design of fixing plates can be divided into two types: one is the convex tool fixing plate, also known as the fixing plate. Another type is the mold fixing plate, also known as the lower plate. The convex mold fixing plate not only installs and fixes each convex mold, but also installs other components in the fixed position, such as guide pins, slants, small guide pillars, and spring-loaded unloading components.
The function of the concave mold fixing plate is to mainly install components, such as concave mold inserts, inner guide plates, top rods, etc. The fixed plate in multi-station progressive tools requires higher rigidity and strength. There are many types of materials in general, and tool steels that are not easily deformed are commonly used, such as using micro deformation alloy tool steels such as 45 steel and 40Cr for manufacturing. The minimum hardness for heat treatment is 43-48HRC, and the heat treatment cannot exceed 58HRC. 45 steel can be used in large multi-station progressive tools, which has the advantage of not requiring quenching treatment.
The shape of the fixing plate is generally the same as that of the discharge plate and the concave mold fixing plate. Stamping tools are commonly integrated and have a simple structure. Large and medium-sized multi-station progressive tools generally use integrally fixed plates for segmented assembly, but this external dimension may be large and not easy to process.
- Pad Design
The cushion plate can be designed into three types: the first type is fixed plate cushion plate, also known as convex mold cushion plate. The second one is the discharge plate cushion plate. The third one is the lower template pad, also known as the concave template pad. There are many functions of fixed plates and pads, mainly to withstand the force of the convex mold, and to ensure that the spring has sufficient compression stroke. The function of the lower template pad is to bear the force of the concave mold or the concave mold insert; The function of the discharge plate pad is to withstand the impact force of the discharge component and the discharge plate insert.
If the allowable pressure of the material is calculated to be greater than the allowable pressure of the mold seat material, that is, the unit pressure at the contact between the convex or concave mold and the cast iron mold seat is less than 100MPa. If the unit pressure at the contact between the convex or concave mold and the steel mold seat is less than 200MPa, a cushion plate should be added behind the convex or concave mold and quenched.
In general, in the Sheet metal press tool design, for safety reasons, a mold structure with a backing plate is usually designed. If segmented pads are used, the thickness dimensions should be the same. The thickness of the cushion plate generally exceeds 8 millimeters but will not exceed 18 millimeters.
- Design of Concave-convex Tool
The convex and concave molds are the working parts in the mold, which are responsible for stamping and determining the size, shape, and quality of the components on the stamping mold. So it plays a crucial role, as each component has a corresponding function.
There must be a reasonable gap and a unified benchmark between the convex and concave tools. The convex and concave tools must have sufficient strength, stiffness, and hardness. The convex and concave tool structures should be simple reliable, and easy to manufacture, measure, and assist operators in installation. The convex and concave tools should be designed to be easy to disassemble, convenient for operators to replace parts, and have reliable fixation characteristics.
Requirements for the Sheet Metal Press Tool Design
In general, the design steps of the sheet metal press tool design refer to the sequence of various tasks carried out by the employees who design stamping molds from receiving design tasks to issuing mold drawings. Due to the advanced technology nowadays, designers mostly use advanced auxiliary software for design, such as CAD, UG, etc. Therefore, designers generally do not use manual drawing of patterns. There are many design methods, but no matter what method is used, each method aims to achieve the same goal and result. The main design requirements for designing the best quality, economical, and practical stamping molds in a shorter period are as follows:
- The design of sheet metal press tool design plays an important role in ensuring the quality of components before manufacturing and is widely used in various industries such as automobiles and aerospace. The main products produced include instruments and meters, household appliances, electronic machinery, communication, toys, daily necessities, etc., which play an important role in these products. Stamped parts must meet the requirements of extremely high technology and good quality control, which also puts forward extremely high requirements for the design of sheet metal press tool. Mold designers should not only have professional knowledge in mold design when designing sheet metal press tool, but also proficiently master knowledge about sheet metal design, stamping processes, metal materials used, heat treatment, and stamping machines.
- There are many types of stamping molds, and the types of stamping molds used may vary depending on their structural form, design requirements, and considerations. The molds produced by different products and machines also have different structural characteristics; Different sheet metal stamping tools with different usages lead to different structures. Therefore, when designing sheet metal press tool, designers must design them according to specified requirements.
- The sheet metal press tool design should ensure that the punched product meets the specified shape and size requirements, while also simplifying the structure as much as possible, making it easy to operate and having a long usage time. The installation of mold components should be firm, and the work should be safe and reliable.
- Sheet metal press tool designshould ensure that three basic principles are met, mainly including Safety performance, advanced performance, and economy. At the same time, taking into account the actual situation of existing machines, technological level, and processing equipment conditions, it is helpful to design stamping molds that meet structural requirements and high quality, ensuring that the punched products meet the specified shape and size requirements.
Related News
Applied’s expertise in modifying materials at atomic levels and on an ihdustrial scaleenables our customers to transform possibilities into reality.
