Custom Stamping Die
The assembly technology of custom stamping dies has played an important role in ensuring the accuracy of stamping molds. The assembly requirement is mainly to ensure the uniformity of stamping clearance, which is the key to meeting the assembly standards of stamping molds.
Automotive Stamping Dies
Automotive stamping dies are a widely used and highly important processing method in the modern automotive industry. They have the advantages of high efficiency, high hardness, and high strength. Therefore, their use in the manufacturing and production of automobiles facilitates the implementation of mechanical automation and batch production goals. Moreover, the high production efficiency of magnesium stamping die is an advanced automotive manufacturing technology that cannot be replaced by other sheet metal forming methods. After decades of exploration in die design and manufacturing, the focus of automotive stamping die technology has shifted to the research and development of cover panel dies and multifunctional precision stamping dies, effectively linking technological development with characteristics such as informatization and intelligence. In the process of developing methods, it is necessary to combine digital manufacturing of dies, computer processing, and integration of die systems to achieve the goal of integrating production and sales.
Automotive stamping dies play an important role in industrial production, using various presses and specialized tools installed on them. Automotive stamping dies are parts or products made of metal or non-metal materials into the desired shape through pressure, and these specialized tools are collectively referred to as dies. Custom stamping die: In cold stamping processing, a specific process equipment for manufacturing materials (metal or non-metal) into parts (or semi-finished products) is called a cold stamping die. Stamping is a forming and processing method that relies on a press and die to apply external forces to sheets, strips, pipes, and profiles, causing plastic deformation or separation, to obtain the required shape and size of the workpiece. The workpiece here is the stamped part. Stamping dies are one of the key tools for achieving production stamping processing.
Types of Automotive Stamping Dies
There are multiple categories of automotive stamping dies, and specific die types can be selected based on detailed production processes and technical requirements. According to different classification standards, it can be divided into three categories based on the degree of process combination: simple punching dies, continuous punching dies, and composite punching dies.
A simple punching die, also known as an open die, refers to a process where only punching or cutting is completed in each punching process.Simple punching dies can be divided into:
- The characteristics of an unguided single process die are simple structure, lightweight, small size, easy die manufacturing, and low cost. However it is troublesome to use and install the stamping die, the accuracy of the stamped parts is poor, and the operation is not safe. Non-guided simple stamping dies are suitable for stamping parts with low precision requirements and simple shapes.
- The guide plate type simple punching die has high accuracy, long usage time, and installation frame, but its manufacturing is relatively complex. Generally applicable to workpieces with simple shapes and small sizes.
- The guide pillar type simple punching die is a widely used punching die in industrial production due to its accuracy and reliability, uniform punching clearance, high precision of the punched workpiece, long service life of the die, and quick installation on the punching machine. Therefore, the guide pillar-type punching die is suitable for large-scale production.
1.Continuous Punching Die
According to the corresponding sequence of procedures, the punching die, also known as the feed die or skip die, is used to perform punching and material feeding on the slider of the punching machine, from one to the middle, and at multiple positions on the die. There are two positioning principles: the guide pin positioning principle and the side edge spacing principle.
2.Composite Punching Die
In one stroke of the bed slider, the punching die completes both the inner hole and outer shape of the upper process on the same workstation of the punching die. It can be divided into formal composite die and inverted composite die according to its structure.
Automotive Stamping Dies Technology
The automotive stamping process generally focuses on the drawing process, bending process, and punching process. Mastering the requirements of these three typical stamping processes is to propose improvement requirements for product design at the beginning of the stamping process design.
1.Drawing Process
The fillet radius R between the flange and sidewall of the drawn part, as well as the fillet radius R between the bottom and sidewall, should be enlarged as much as possible. The fillet radius should be large to facilitate the easy drawing and forming of the parts; Use drawing parts that correspond as much as possible or adopt symmetrical drawing parts on both sides; To be stretched in pairs and then cut into two pieces.
2.Bending Process
When bending, deformation of the hole should be avoided, and there should be an appropriate distance between the hole edge and the bending point to prevent deformation of the hole. Otherwise, the hole should be bent first and then punched; The length of the curved edge is not easily too small; Bending parts should pay attention to the positioning of process holes and forming double pressure domes as much as possible to change the stress situation.
3.Punching Process
The shape should be as convenient as possible for reasonable material layout and reduce waste; There should be appropriate rounded corners at the connection of straight or curved lines, which is conducive to the manufacturing, maintenance, and use of dies; Avoid excessively long and narrow shapes, and the aperture and spacing should meet the minimum size requirements.
Design and Manufacturing of Automotive Stamping Dies
1.Design and Manufacturing Requirements
Automotive stamping dies have the characteristic of high frequency of application, with a general usage frequency of up to 700000 times. If the quality of the die is good, it can reach up to 800000 times, and it is necessary to pay more attention to die design because it can improve the quality of the die. In detail, it is not only necessary to pay attention to the process structure issues but also to master and manage the die machining, installation, debugging, transportation process, and other aspects to ensure that the designed die has high directionality and structure. At the same time, pay attention to the issue of whether the safety of the die is easy to repair, to improve the design quality.
2.Die Material Selection
Before designing a stamping die, it is necessary to fully consider the production conditions and quantity of the die. Before designing a stamping die, it is necessary to fully consider the production conditions and quantity of the die, whether the strength, hardness, and other properties of the die material can meet the service life requirements, and select suitable die materials on this basis. After determining the materials for multiple components of the die, it is necessary to conduct tensile tests, and hardness tests, and analyze the material composition. However, during the die design proofreading stage, it is necessary to clarify the die materials and conduct a performance comparison of the die during the pre-acceptance stage. During the acceptance stage, it is necessary to conduct ultrasonic inspection on the surface of dies with high requirements such as drawing dies, to check for micro-cracks in the dies and ensure that the die material meets quality requirements. The production goal of the produced parts is to achieve large quantities and high punching times.
3.Punching Component Design
When designing punching dies, in addition to using guide plates for guidance, it is also necessary to use guide pillars to ensure uniform gaps between the punching convex and concave dies, as well as the dimensional accuracy of the punching parts. In addition, for stamping parts, in addition to ensuring the accuracy of the parts, special attention should also be paid to the discharge of stamping waste. If the wall thickness of the discharge hole of the die is too deep, it is easy to accumulate waste. If it is too thin, it can simply reduce the strength of the parts, and even cause cracking of the punching die, greatly shortening the service life of the die. Therefore, in the specific design and processing process, it is necessary to apply a graded punching method, and it is also necessary to fix it with a fixing plate to make the punching structure of the die more stable. In addition, doing a good job in die positioning can effectively improve the dimensional accuracy of parts in the punching and material-cutting process.
4.Die Structure Design
When designing edge trimming and punching dies, designers not only need to consider positioning accuracy and direction but also pay attention to the structure of inserts and waste disposal issues. When designing flanging and shaping dies, it is necessary to divide the flanging dies into two categories based on various flanging directions, such as horizontal and vertical. Design a reasonable flanging structure for better flipping of materials, this is an important part of the design analysis of covering parts. Moreover, to prevent the deformation of the parts, it is necessary to consider the ejection device of the pressed parts during design, to facilitate the extraction of the parts after the flanging process [4]. In addition, in the design process of automotive stamping dies, simulation is a commonly used pre-process analysis technique. Operators should conduct a formability analysis of the parts in the early stage of manufacturing, and optimize the shape or reasonably design the shape and size of the stretching ribs for difficult forming parts and simple areas that may cause potential quality problems. When encountering difficulties in the simulation process, it is necessary to propose design changes or possible die-design solutions to support product evaluation.
The Benefits and Advantages of Automotive Stamping Dies
Automotive stamping dies ensure the dimensional accuracy of stamped parts and have the same characteristics, so the quality is stable and the interchangeability is good.
Due to the use of dies for processing, parts with thin walls, lightweight, good rigidity, high surface quality, and complex shapes that cannot or are difficult to manufacture by other processing methods can be obtained.
Stamping processing generally does not require heating the blank and does not produce a large amount of cutting metal, so it can save both energy and metal.
Ordinary presses can produce dozens of pieces per minute, while high-speed presses can
Maintenance Methods for Automotive Stamping Dies
Automotive stamping dies are an important equipment used for stamping production and processing of components such as car bodies, engines, and chassis. The lifespan and performance of dies have a crucial impact on product quality and production efficiency. Therefore, the important task of production and quality assurance is to repair and maintain dies. Automotive stamping parts are produced through automotive stamping dies, and for stamping factories, the most important thing is the maintenance of automotive stamping dies. The following are maintenance methods for automotive stamping dies:
1.Maintenance and Upkeep During Die Installation
Before installing the die, it is necessary to clean the left and right surfaces of the die to ensure that the installation surface of the die and the cabinet countertop are not damaged by force during the operation of the press, and to ensure the flatness of the left and right installation surfaces of the die during production and manufacturing.
After the die is installed, open the die and clean each part of the die, especially the guiding structure. For surface die parts, clean the die surface to ensure the high quality of the product. Apply lubricating grease to the various drag parts of the lubrication die. Inspection of various parts of the die. Including side pins, screws, punching machine waste channels, etc.
2.Maintenance and Upkeep in Production and Manufacturing
Apply oil to the relative part of the car die on time during production and manufacturing. For example, the stripping ring and arc of the deep drawing die; The wound location of the trimming die; Part of the flipping tool, etc. Timely clean up the small circular hole waste channel of the edge punching machine die.
3.Maintenance and Upkeep after Production and Manufacturing
After the production and manufacturing are completed, a comprehensive inspection of the die should be carried out. Comprehensive cleaning of dies to ensure their cleanliness. Clean up the waste inside the die and ensure that there is no waste in the waste box.
4.Die Positioning
The positioning of stamping dies is a very important part, which not only involves the stable use of dies but also relates to the service life of dies. When using stamping die positioning, attention should be paid to the following details:Timely position and mark the die according to its usage status. After the die is damaged, it should be repositioned on time when reusing, and the positioning point should be set at the flat and smooth part of the die. Place the die on the machining platform and adjust its precise position. When there is no error, tighten it.
5.Knife Repair
The damage to the cutting edge of the stamping die is often a frequent fault, and if it causes damage to the cutting edge, it will directly affect the manufacturing accuracy of the stamping part. At this point, blade repair is required. Knife repair mainly includes the following steps:
- Check the position of the damaged blade.
- Remove the material from the damaged or worn area of the blade.
- Repair the surface of erosion, scratches, etc.
- Based on the characteristics and requirements of the die blade, the blade should be polished again.
6.Ground Knife Maintenance
The machining accuracy of automotive stamping dies is closely related to the ground-cutting tool.During the citation process, it is inevitable that the ground knife may be damaged or deformed. At this point, maintenance and repair of the ground knife need to be implemented. The maintenance of the ground knife mainly pays attention to the following steps：Check if the ground knife is deformed. If it is, use tools such as a red light gauge to correct it. And check the cutting edge of the ground knife. If there are cuts and cracks, they need to be polished or replaced.
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