Metal Stamping Die
Metal stamping die can also be referred to as stamped parts. Stamping is an advanced manufacturing technology that cannot be compared or replaced by other processing methods, used to produce various sheet metal parts with specific advantages.
Metal stamping tooling is used to cold deform metal materials at room temperature and process them into the applied parts. Stamping technology, stamping equipment, and stamping materials are the three main key elements of stamping processing.
The Bending Characteristics of Metal Stamping Tooling
The bending process of metal stamping die involves bending raw materials into a stamping forming technique with a certain shape, angle, and size, which is called bending. When using bending technology for manufacturing, the bending radius should play a very important role. The important parameter of carbide stamping die quality is the processing limit of bending deformation.
In manufacturing, bending technology is widely used, and many intermediate processes involve bending techniques such as deep drawing, bulging, flanging, and punching. Using different processing tools for bending deformation can result in different bending forms, and the bending process is often used in conjunction with other deformation methods.
The bending process of materials is very complex, mainly involving elastic deformation and plastic changes. In the rounded area, the inner layer fibers are compressed short, while the outer layer fibers are stretched deep. There is a layer of fibers between shortened and elongated fibers of the same length, which is called the neutral layer. During bending manufacturing, the main deformation zone is the rounded part where the curvature changes. The basis for calculating the size of bent blanks is the neutral layer, which is closely related to the thickness and relative bending radius of the sheet metal. The neutral layer will change with the variation of the thickness and relative bending radius. Each bending method of raw materials has a corresponding pattern during the bending process. The main bending methods include compression bending, rolling bending, bending, tension bending, etc.
Assembly Process of Metal Stamping Tooling
The assembly of metal stamping tooling is based on the structural characteristics and technical requirements of the metal stamping tooling assembly design, the design standard assembly sequence and method, the parts must meet the technical requirements of the drawing and a series of operations are carried out according to the assembly process steps, such as positioning, fitting, trimming, connection and fixation. The assembly process of assembling a stamping die that meets the usage requirements according to the steps is called the metal stamping die assembly process.
Metal stamping tooling assembly plays a crucial role in the manufacturing process of metal stamping tooling, as the quality of assembly has a significant impact on the quality of the product, the accuracy of the tooling, the usage time, and the lifespan of the tooling. The assembly process specification has two parts processes, including the general technical requirements for metal stamping tooling assembly and the assembly process specification for specified tooling.
Requirements for the assembly process
A reasonable and correct assembly process plays a crucial role in the quality of tooling assembly. Due to the different tooling structures and processing methods of tooling parts, the assembly process of metal stamping tooling will also be different. In general, tooling with integral structures is simpler than those with block splicing structures, and the assembly of progressive and composite tooling is more difficult, while the assembly of simple tooling is relatively simple. Therefore, the operator must be proficient in the assembly and processing requirements and operating steps of each stamping tooling. metal stamping tooling parts are processed with high precision, and the assembly quality of the tooling is ensured to meet the requirements through reasonable and correct assembly processes. Only through the above steps can qualified high-quality stamping tooling be manufactured. The assembly process is related to the metal stamping tooling structure and part processing technology, and the uniformity of the clearance between the convex and concave tooling also plays an important role.
The steps of the metal stamping tooling assembly process
1.Choose the Correct Assembly: When assembling reference parts, the first step is to choose the reference part. The dependency relationship of the main parts of the metal stamping tooling during processing determines which reference part to choose. Many reference components can be used for assembly, such as fixed plates, four tooling, guide plates, and convex tooling.
2.Component Assembly: Before the final assembly of the metal stamping tooling, the assembly work of assembling several parts into one component according to the specified standard requirements is called component assembly. The main assembly includes the assembly of various parts of the unloading mechanism and the pushing mechanism, the assembly of convex, concave, and fixed plates, and the assembly of the metal stamping tooling frame. To improve the assembly accuracy of the entire metal stamping tooling, these components are assembled according to the different functions of each part.
3.Overall Assembly: Overall assembly is the process of combining parts and components into a complete set of metal stamping tooling. The benchmark components for assembly should be selected, and the assembly sequence of the upper and lower tooling should be designed before the overall assembly can begin. If using a guide plate for assembly, use the guide plate to install the convex tooling into the fixed plate, and the next step is to assemble the lower tooling through the upper tooling. During the overall assembly, when the tooling parts are loaded into the lower template, the first step is to assemble the reference parts. Once there are no issues, tighten the screws and insert the pins. Each type of component is assembled according to the reference part, and the screws are not tightened first. Only after checking and adjusting the clearance and testing to meet the requirements, can they be tightened.
Defects in the Deep Drawing Process and Their Solutions
- Crack Area
Sometimes, when analyzing the crack area, the arc radius of the workpiece is too small at the corners and roots, resulting in sharp corners and excessive stress concentration, which can cause damage to the sheet metal. During the deep drawing process of the tooling, when the material ring presses against the sheet metal, the convex tooling is formed by deep drawing. The tension of the workpiece in the deformation zone is different, and the reason is that due to the resistance of the pressing ribs and the complex shape of the convex tooling, most of the area of the workpiece becomes thinner, ultimately leading to the phenomenon of tensile cracking. The external dimensions of raw materials may also cause the parts to crack.Solution for cracking area:
1.The process gap is increased at the entrance of the overall side drawing die.
2.Choose the correct press pressure according to the requirements of the workpiece.
3.Increase the transition radius of the crack-prone area within the specified range.
4.By changing the rounded corners and external dimensions of the reinforcing bars, the size and distribution of the resistance of the reinforcing bars can be changed. The speed and quantity of the sheet metal feeding into the concave tooling on the surface can be controlled, and the tension and distribution in each deformation zone of the workpiece can be adjusted reasonably. The deformation positions can be deformed according to the required types and degrees of deformation.
5.Make the surface of the metal stamping tooling smoother and apply a smooth treatment to the surface.
- Roughening Area
The reason for the roughening area is that the casting accuracy of the metal stamping tooling does not meet the requirements, and there are rough sand holes on the pressing surface, which can have a certain impact on the workpiece. If the workpiece is excessively roughened, it will cause the workpiece to be torn. One of the factors that lead to uneven pressure on the workpiece is the shape change caused by the large difference in surface softness and hardness during surface quenching and welding of the material reinforcement and pressure, which makes it easy to roughen the hard points.
Solution: During the production process of metal stamping tooling, technicians should check whether the surface quality of the pressing surface of the metal stamping tooling meets the requirements. If there are any problems, such as casting sand holes, they should be filled with welding promptly. Uniformly inspect the pressing surface, and if there is not much difference in hardness, there is no need for further processing. If there is a significant difference in hardness, perform surface quenching again until the hardness is uniform.
- Wrinkle Area
At the forming position, due to the bending moment, the forming area of the workpiece is raised, resulting in wrinkles on the surface of the workpiece. Another factor that causes wrinkles is the significant change in the shape of the cross-section during the forming process at locations with significant height differences in the tooling, resulting in material accumulation. After deep drawing and forming, areas with relatively large areas and insufficient deformation should be uniformly deformed, otherwise it will lead to a decrease in the rigidity of some parts of the covering part. Assembling a car with such workpieces can generate vibration during vehicle operation, reduce the service life of the workpieces, and have an impact on the car.
- Solution for Wrinkled Areas:
1.By adjusting the size and structure of the pressure bars, as well as the transition radius of the convex and concave tooling, the thickness of the drawn parts is uniform, achieving the required degree of deformation.
2.Properly increasing the thickness of the sheet metal is beneficial for improving the hardness of the workpiece and reducing shape changes during pressing. To solve the problem of wrinkling of the workpiece, the pressure of the pressing ring is increased, the quantity of materials is controlled, and the clearance accuracy of the convex and concave tooling is improved. To make the transition of the workpiece smooth, add pressure bars in the necessary areas.
3.The closure height of the convex tooling and the pressure ring should be within the standard range, to achieve sufficient deep drawing and forming during production.
The forming of metal stamping tooling is a very important processing method in the manufacturing industry. Using metal materials to produce various parts has various advantages, such as high efficiency in production. So metal stamping tooling is widely used in fields such as automobiles and aerospace.
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