Metal Stamping Die
Metal stamping die is a precision tool used in the stamping process, which involve applying tremendous force to deform and shape the metal plate into the desired geometric shape. These molds are typically composed of multiple components, each of which has a specific purpose in stamping operations.
Custom Metal Stamping Dies
Custom metal stamping dies are key special process equipments in the manufacturing industry, playing an important role in cold stamping processing, processing metal or non-metallic materials into parts or semi-finished products. At room temperature, using a die installed on a press to apply pressure to the material, the material can be separated or plastically deformed, thereby achieving a pressure processing method for the required parts. This method can be efficiently and accurately applied to various complex shaped components.
Metal stamping die is an indispensable and important tools in various industries, which can achieve large-scale production and ensure consistent product quality. For example, stamping die is widely used in industries such as automobiles, household appliances, and electronic products. In addition, to ensure the production of high-quality parts, it is necessary to select suitable metal materials, design reasonable die structures, and optimize stamping process parameters. There are many forms of stamping dies, such as classification based on the nature of work, die construction, and die materials.
In the field of metal manufacturing, custom stamping die plays a crucial role in shaping and transforming raw materials into complex functional components. Custom metal stamping dies play an important role in many industries due to their high efficiency in production, stable product quality, good interchangeability, energy conservation, and environmental protection.
Types of Custom Metal Stamping Dies
There are many categories for customizing metal stamping dies, and relevant die types can be selected based on specific production processes and technical requirements. According to different classification standards, key types include:
Classified by the degree of process combination:
1.Single-process Stamping Die
A single-process die refers to a die that requires one process to be carried out within one stroke of a press. It mainly includes a punching die, a bending die, a stretching die, a flipping die, and a shaping die. This type of die has a simple structure, low manufacturing cost, is suitable for small production batches, and makes die manufacturing simple and maintenance convenient.
2.Composite Die
Composite die is a special die structure that can complete multiple stamping processes, such as material cutting, punching, etc., in each stroke of the punching machine. The composite die structure can significantly improve production efficiency, while also ensuring the accuracy and quality of the product.
3.Continuous Die
Continuous die, also known as progressive die, is a type of die used in the stamping process. It is crucial in the cold stamping process of metal manufacturing. In a continuous die, the press utilizes strip stamping raw materials in one stamping stroke and completes different stamping processes on a set of dies using multiple different workstations in sequence. Continuous dies are widely used in the production of components in industries such as automobiles, home appliances, and electronics, and are crucial equipment.
Classified by process nature:
4.Punching Die
Punching die is a specialized process equipment that plays an extremely important role in cold stamping processing, and processing materials into parts. In stamping production, the die used for punching is called a punching die.
5.Bending Die
A bending die is a die that causes a blank or other blank to bend and deform along a straight line, thereby obtaining a certain angle and shape of the workpiece.
6.Deep Drawing Die
A deep drawing die is a process of stamping a specific shaped flat blank into open hollow parts of different shapes through a drawing die or using an open hollow part as the blank to further change the shape and size of the hollow part through stretching. Stretching has a wide range of applications in manufacturing various open hollow parts, such as automotive body components.
Application and Industry of Custom Metal Stamping Dies
Custom metal stamping dies have a wide range of applications in many industries, and stamping dies are important tools in various industries. Specifically, it includes:
- The Automotive Industry
The automotive industry is one of the largest consumers of custom metal stamping dies, using stamping dies to produce various components. Used for manufacturing automotive components and body structures, such as doors, roofs, seats, and engine hoods.
- Home Appliance Industry
Used to manufacture casings and components for various household appliances, such as TV casings, refrigerator doors, washing machine barrels, etc.
- Electronics Industry
The electronics industry also relies on stamping dies. Used for manufacturing electronic product casings, including various connectors sockets, and other components.
- Construction Industry
The construction industry relies on custom metal stamping dies to manufacture various metal components, and uses dies to manufacture various metal components such as doors, windows, and sunrooms.
- Aerospace Industry
The aerospace industry utilizes stamping dies to manufacture precision components for aircraft, spacecraft, and related equipment, ensuring strict tolerances and high-quality standards.
Materials and Manufacturing of Custom Metal Stamping Dies
Stamping dies are generally made of high-quality tool steel or some durable materials that can withstand the enormous forces and wear associated with the stamping process. The common materials used in die manufacturing include:
- Alloy Steel
A commonly used stamping die material with the advantages of good strength and toughness, suitable for making high-precision dies, and excellent heat treatment performance.
- High-speed Steel
It has high hardness, wear resistance, strength, and toughness, and is suitable for producing large quantities of small and medium-sized parts.Cr12MoV steel. A common die steel with the main advantages of high hardness, strength, and toughness, suitable for producing high-quality dies.
- Low Alloy Tool Steel
Based on carbon tool steel, the application of appropriate alloying elements reduces the tendency for cracking and quenching deformation and increases hardenability and wear resistance.
- Carbon Tool Steel
Such as T8A, T10A, etc., have good processing performance and affordable prices, but have poor hardenability and red hardness.
- Hard Alloys and Steel-bonded Hard Alloys
Has extremely high hardness and wear resistance, suitable for dies with low impact.
- Matrix Steel
Combining the benefits of the aforementioned materials, it is widely used in high-precision and complex dies.
The Benefits and Advantages of Custom Metal Stamping Dies
The use of stamping dies in the metal forming process has brought many benefits and advantages, mainly including:
- High Production Efficiency
Metal stamping is mainly completed by dies and stamping equipment. Custom metal stamping dies can quickly manufacture materials into the desired shape and size of products, and each stamping stroke can be perforated, resulting in products with high efficiency.
- Good Quality
The die ensures the dimensional and shape accuracy of precision metal stamped parts, and the surface quality of stamped parts is usually not damaged. The die has a long service life, so precision metal stamped parts have stable quality.
- High Strength
Metal stamping parts can be processed into parts with larger size ranges and more complex shapes, and the cold deformation hardening effect of the material during stamping makes the strength and extremely high stiffness of the stamped parts.
- Low Cost
The production of metal stamping parts does not require other heating equipment, consumes little material, and stamping generally does not generate chips or debris. It is a processing method that saves materials and energy, and the cost of stamping parts is relatively low.
- Facilitate Mechanization and Automation
Custom metal stamping dies are easy to operate and are used for large-scale production, making it easy to achieve mechanization and automation.
- Flexibly Applicable to Different Materials
The materials used to manufacture stamping dies, such as steel, hard alloys, and steel bonded hard alloys, have good wear resistance, corrosion resistance, and high-temperature resistance, meeting the production needs of a variety of products, and have applied the durability and applicability of dies.
Maintenance Methods for Custom Metal Stamping Dies
Understanding the various wear and failure mechanisms that may occur during the stamping process is crucial. By selecting appropriate die steel materials and hardness, these measures can help reduce wear during the stamping process and improve the service life and quality of dies and stamped parts. These mechanisms can be mainly divided into the following categories:
- Failure Mechanisms
- Blade Wear
This may lead to burrs, and solutions include repairing the cutting edge and controlling the machining accuracy of the convex and concave dies.
- The Gap Between the Punch and the Die is too Large or too Small
This may cause material deviation and size variation, which should be solved by adjusting the punching clearance or modifying the design.
- The Surface of the Straight Edge of the Concave Die is Rough
This may create debris blockage, which needs to be optimized through surface treatment and polishing.
- Improper Use of Stamping Oil
If the viscosity of the oil is too high, it may cause chip jumping and crushing, and the oil should be dropped or replaced.
- The Die has not been Demagnetized
This may have an impact on stamping performance, and all steel should be returned after stamping.
- Punch Wear
This may cause chips to adhere to the convex die, and the convex die blade should be studied and repaired.
- The Convex Die is too Short
The length of the inserted concave die is too short, and it is necessary to change the length of the convex die edge into the concave die.
- Hard Material or Simple Punching Shape
This may cause the blade to crack and require re-grinding of the blade.
- Daily Inspection and Maintenance
Before, during, and after each use of the die, the operator should inspect and maintain it, including checking the identification of the die, the convex and concave die, screws, cutting edges, upper and lower templates, the lubrication between the workbench, guide pillars, and sleeves, as well as the installation of the machine tool and die. Operators can follow the following steps:
- First Level Maintenance
Before installing the die, the upper and lower surfaces of the die should be cleaned to ensure that the installation surface and the working table of the press are not damaged. During the production process, timely apply oil to all parts of the die. At the end of production, conduct a comprehensive inspection and cleaning of the die to ensure that there is no waste residue.
- Regular Inspection and Maintenance
It is crucial to regularly check the wear of the die and replace severely worn components. It is essential to keep the die clean at the same time to prevent impurities and rust from causing damage to the die. Develop a lubrication plan based on the frequency of die usage and the characteristics of the processing materials.
- Setting Maintenance Benchmarks and Plans
Determine the maintenance cycle based on the die structure and production cycle, as the usage of different types of dies also varies. For low-production models, additional maintenance benchmarks can be considered, with die maintenance scheduled every six months. Develop annual or monthly maintenance plans based on die maintenance benchmarks and production plans.
- Maintenance Requirements
Adopt the “cross operation” method, which includes “cleaning, lubrication, adjustment, tightening, and anti-corrosion”. The inside and outside of the die need to be kept clean, and all structural surfaces and external oil stains should be cleaned and cleaned.
By consistently and efficiently providing high-quality products, manufacturers can have a competitive advantage and enhance overall profitability. Implementing the above measures can efficiently maintain the status of custom metal stamping dies, promote production efficiency, and reduce production costs. To accurately evaluate the return on investment of stamping die maintenance plans, manufacturers need to consider factors such as die replacement costs, output, scrap rates, downtime costs, and the potential to improve productivity and customer satisfaction. According to the above maintenance methods, the service life and performance of custom metal stamping dies can be effectively extended, bringing long-term benefits and competitive advantages to enterprises.
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