Custom Stamping Die
During the processing of the equipment, the metal material in the custom stamping die will undergo shape changes. There are many types of stamping dies based on their functions, including deep drawing dies, stamping dies, bending dies, riveting dies, etc.
Precision Die Stamping
Precision die stamping originates from ordinary stamping die. If there is a high precision requirement for the cross-sectional smoothness of stamped parts, and ordinary stamped parts cannot meet the high cross-sectional accuracy requirements, the stamping method of controlling cross-sectional accuracy is adopted, which is precision punching. Simply put, precision stamping is equivalent to stamping plus cold extrusion. Under the same quality and efficiency, custom stamping die is a low-cost alternative to machining, powder metallurgy, and other processes due to its high processing efficiency.
The carbide stamping die structure and performance are different. Design corresponding dies according to the characteristics and needs of different products. Each carbide stamping die structure has its function, and the products produced are also different, ranging from simple products to complex products. Even if its structure is complex, its basic structure will not change.
Die stamping is part that uses stamping technology and specialized equipment to process and shape sheets, strips, pipes, and other materials. Precision die stamping has complex shapes, and high precision, and lightweight, and is applied in many fields such as electronics, automobiles, and aerospace. According to the different materials, precision die stamping mainly includes metal stamping dies, plastic stamping dies, and powder stamping dies. Among them, the vast majority are metal stamping dies. Precision die stamping uses high pressure applied inside the die to stamp metal sheets into specific shaped parts.
The Benefits and Advantages of Precision Die Stamping
Precision stamping is a part processing method that uses dies to apply pressure or tension to sheets, strips, or profiles, resulting in plastic forming of the sheets. Sometimes, shear force is applied to the sheets to separate them, thus obtaining a certain size, shape, and performance. Precision stamping processing has the following advantages:
This type of processing has efficient production and facilitates operation, facilitating mechanization and automation.
Precision stamping is characterized by stable stamping quality and good interchangeability because the die is designed to achieve dimensional and shape accuracy of the stamped parts, and generally does not damage the surface quality of the stamped parts. The die has a longer lifespan.
This technology can produce large-sized and complex-shaped parts, such as stopwatches as small as clocks, longitudinal beams of large cars, covers, etc., and the cold deformation hardening effect of materials during stamping, high stamping, and high-strength stiffness.
This is a material-saving and energy-saving processing method with lower stamping costs. Because precision stamping generally does not produce chips and debris, material consumption is not significant, and other heating equipment is not needed.
The Process of Precision Die Stamping
Stamping is classified by process, and there are two main categories: separation process and forming process. The separation process, also known as punching, is to separate the stamped part from the sheet metal along a certain contour line and to meet the quality requirements of the separation section. The forming process produces workpieces of specific shapes and sizes to achieve plastic deformation of the sheet metal without breaking the billet. In actual production, it is often a combination of multiple processes applied to a workpiece. The main stamping processes include punching, bending, shearing, deep drawing, bulging, spinning, and straightening.
- Separation Process
A basic stamping process for using dies to separate materials is the separation process, which can directly produce flat parts or prepare blanks for other stamping processes such as bending, drawing, forming, etc. It can also perform cutting, trimming, etc. on formed stamping parts.
- Forming Process
1.Bending: A plastic forming method that bends metal sheets, fittings, and profiles into a certain angle, curvature, and shape. One of the main processes widely used in stamping production is bending. The bending of metal materials is essentially an elastic-plastic deformation process. After unloading, the workpiece will restore the elastic deformation in the direction, known as rebound. Rebound is a technical key that must be considered in the bending process, as it can affect the accuracy of the workpiece.
2.Deep Drawing: Deep drawing, also known as drawing or rolling, is a stamping method that uses a die to turn the flat blank obtained after punching into an open hollow part. It can be made into thin-walled parts with cylindrical, stepped, conical, spherical, box-shaped, and other irregular shapes. In conjunction with other stamping processes, complex-shaped parts can also be produced. In stamping production, there are many types of deep-drawn parts. According to the different geometric characteristics, the position of the deformation zone, the nature of deformation, the distribution of deformation, and the stress state and distribution law of various parts of the billet will also have different uses, even fundamentally different. Therefore, the methods for determining process parameters, the number and sequence of processes, and the principles and methods of die design are not the same.
3.Spinning is a Metal Rotary Machining Process. In the process of processing, the billet automatically rotates with the spinning die or the spinning head rotates around the billet and the spinning die. The spinning head moves relative to the core die and billet in a feed motion, to produce continuous local deformation of the billet and obtain the specified hollow rotating body part.
4.Flanging is a Plastic Processing Method.It bends the material in the narrow band area of the edge or pre-drilled hole on the thin plate blank along a curve or straight line into a vertical edge. Flipping is generally suitable for strengthening the edges of parts, removing cut edges, and making three-dimensional parts that are assembled and connected with other parts or have very complex shapes and reasonable space on the parts while increasing the stiffness of the parts. In the case of large-scale sheet metal forming, it can also be seen as a means of controlling cracking or wrinkling. Therefore, it is widely used in industrial sectors such as automobiles, aviation, aerospace, electronics, and household appliances.
Application and Industry of Precision Die Stamping
Precision die stamping plays a crucial role in metal parts with high precision and quality characteristics. Precision die stamping is widely used in various industries, mainly including the following areas:
1.Automotive Industry
This is mainly used for producing various metal parts, such as automotive body parts, chassis parts, engine parts, etc.
2.Electronics Industry
Widely used in the electronics industry, it is generally suitable for producing electronic components such as casings, connectors, and heat sinks.
3.Home Appliance Industry
The shells and components of household appliances such as refrigerators, washing machines, microwaves, etc. are often manufactured through precision die stamping.
4.Aerospace Industry
precision die stamping is suitable for manufacturing high-precision and complex-shaped metal parts such as aircraft components and spacecraft components in the aerospace field.
Material Requirements for Precision Die Stamping
The surface and intrinsic properties of stamping plates have a significant impact on the quality of stamped products. The requirements for stamping materials are:
1.Accurate and Uniform Thickness. The stamping die should be precise and the gap should not be too large. The thickness of the sheet metal should not be too large, as it will increase the deformation force and cause material jamming, and even the concave die will expand and crack; The sheet metal cannot be too thin, as it can affect the quality of the finished product and cause cracking during deep drawing.
2.The Surface is Smooth, Without Spots, Scars, Scratches, Surface Cracks, etc. All surface defects will remain on the surface of the finished workpiece, and crack-like defects may expand to a wider range during bending, deep drawing, forming, and other processes, resulting in the production of scrap.
3.The Yield Strength is Uniform and Cannot have Obvious Directionality. Anisotropy refers to the phenomenon where plastic deformation occurs in sheet metal during stamping processes such as deep drawing, flanging, and bulging. Due to the sequential occurrence of anisotropic yielding and different plastic deformation amounts, uneven deformation can be produced, resulting in incorrect forming and the production of defective or scrap products.
4.High Uniform Elongation. In tensile testing, the elongation before the occurrence of the necking phenomenon in the specimen is called uniform elongation. In the case of deep drawing, if the deformation of each area of the sheet exceeds the uniform extension range of the material, uneven deformation will occur. Therefore, the deformation of each area of the sheet cannot exceed the uniform extension range of the material.
5.The Flexural Strength Ratio is Low. The yield strength ratio is the ratio of the yield limit to the strength limit of a material. A low yield-to-strength ratio can reduce deformation resistance, as well as the tendency for wrinkling during deep drawing, reduce rebound after bending, and increase the accuracy of bent parts.
6.Low Work Hardening Properties. The work hardening that occurs after cold deformation will enhance the deformation resistance of the material. To continue the deformation difficulty, low-hardening index plates are commonly used. However, materials with a high hardening index have the characteristic of good plastic deformation stability and rarely experience localized tensile cracking.
Maintenance Methods for Precision Die Stamping
During the use of precision die stamping, there may be phenomena such as punch breaking, bending, and gnawing. The punch sleeve is generally gnawed, and the same standard parts are used to replace the punch and punch sleeve damage.
The design of precision hardware stamping dies requires attention to many factors, including the usability and safety of the structure of precision, die stamping, the selection of hardware stamping die materials, the machinability of precision die stamping parts, and the convenience of precision die stamping maintenance.
Surface strengthening of the main formed components of customized die stamping can increase the wear resistance of the surface of precision die stamping, thus helping to increase the quality of precision die stamping.
The manufacturing process of precision die stamping also plays a very important role in enhancing the quality of precision die stamping. The processing methods and precision in the manufacturing process of precision die stamping also have a certain impact on the service life of precision die stamping.
The correct use and maintenance of precision die stamping are also important factors in improving the quality of hardware stamping dies. Improper use and maintenance may reduce the service life of hardware stamping dies.
In the process of precision die stamping, dies play a very important role. However, due to various reasons, the die may be damaged. In customized stamping processing, attention should be paid to avoiding the influence of these factors to ensure the normal operation and service life of the die.
Unreasonable design of customized metal stamping die stamping:The design of customized die stamping should fully consider factors such as material properties, processing requirements, and the service life of the dies. If the design is unreasonable, it will generally cause some problems to be found during the use of the die, such as overload, overheating, etc., which can lead to die damage.
Manufacturing quality of precision die stamping:The manufacturing process of customized die stamping involves multiple stages, including material selection and control of processing technology. If quality problems occur in these processes, it may lead to substandard performance such as strength and hardness of the die, thereby affecting the service life of the die.
Improper use and maintenance of customized die stamping:When using precision die stamping, attention should be paid to controlling processing parameters to prevent overloading and overheating. Additionally, regular inspections and maintenance of the dies are necessary to immediately identify and resolve any potential hazards.
Unreasonable design of precision stamping die stamping:Precision die stamping has multiple processes such as punching, bending, and stretching, each with specific requirements and limitations. If the process is unreasonable, it may cause the die to withstand excessive pressure and temperature, thereby affecting the service life of the die. Therefore, in the design of the stamping process, it is necessary to first pay full attention to the bearing capacity and service life of the die, and reasonably select process parameters and processes.
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