Custom Stamping Die
Custom stamping dies are workpieces formed by placing metal materials into stamping machines. Stamping molds involve many metal manufacturing processes, such as stamping, cutting, and bending using a press.
Progressive Die Service
Progressive die service is very extensive. This type of die is composed of multiple workstations, each with its function, and each workstation is processed in a specified order. In each stroke of the press, a stamping die that achieves two or more stamping processes step by step at different workstations is called a progressive die service. This type of die is also called a continuous die.
The most efficient stamping die is the progressive die service. Manufacturing stamping parts that have undergone multiple processes such as punching, bending, and deep drawing, can be stamped on a multi-station progressive die. Progressive die is a multi-process custom stamping die, which has higher labor productivity than composite die and can also manufacture more difficult stamping parts.
The Benefits of Progressive Die Service
1.High Efficiency
This type of die can meet the requirements of stamping, flanging, bending, deep drawing, three-dimensional forming, and assembly processes for complex parts, without increasing intermediate transportation and repeated positioning work. Even if the number of workstations is increased, it will not affect production efficiency. It can stamp large quantities of parts and also meet the requirements of punching small-volume high-precision parts. Progressive die achieves automation, enabling automatic feeding, output, and stacking.
2.Long Usage Time
Complex internal and external shapes can be decomposed into simple convex and concave shapes, with each section being punched separately and each workstation having corresponding processing steps that need to be completed. Vacancies can also be set in areas with concentrated processing steps to prevent unnecessary trouble, such as the problem of small wall thickness of convex and concave dies. Changing the stress situation of convex and concave dies, can help increase the strength of the die. To improve the service time of the progressive die, the progressive die service uses a discharge plate as the convex die guide plate.
3.High Quality
Progressive die service has extremely high quality and can be used as a routine process for stamping products on a multi-station progressive die. Compared with simple dies, progressive die service is easier to operate and have smaller errors, which greatly helps to improve the quality of components. Carefully designed stamping dies serve to meet high-quality and precise dimensions in large-scale manufacturing, ensuring the reliable performance of stamping dies.
4.Security
During progressive die stamping, due to the safety detection device installed inside the mold, technicians do not need to put their hands inside the equipment, so it will not pose a danger to operators.
Problems in Progressive Die Service
During the progressive die stamping process, there may be some problems that need to be addressed through effective methods. Only when these problems are resolved promptly can stamping manufacturing proceed smoothly. The following are the problems in progressive die service, their causes, and solutions.
1.Improper Maintenance
Due to incorrect assembly of the die during assembly by the operator, or factors such as the insert that has already deviated from the gap not being restored to its shape.
In the process of progressive die manufacturing, operators should take the maintenance of the die seriously and regularly inspect the stamping equipment for any damage. The cutting edge of the die and before installation should be carefully inspected to reduce the occurrence of accidents. If the equipment malfunctions, it should be repaired promptly and the cause should be recorded to prevent such a situation from happening again in the future.
2.Chipping and Crushing Injury
Reducing the pressure damage caused by chip jumping can be achieved through several measures: modifying the cutting edge of the convex die and the length of the convex die edge into the concave die; Reducing the sharpness of the concave die edge and making the surface roughness of the straight edge of the concave die rougher.
3.Material Blockage
Factor: The edge of the knife is damaged and the burrs are relatively large; Due to the large size of the hole for placing debris, it may cause blockage of the debris.
The operator should adjust the size of the leakage hole to be smaller and polish the surface to make it smoother. If the end face of the blade is trimmed to a slope, use a vacuum cleaner to blow air into the discharge hole.
4.Rough Edges of Punched Parts
Unreasonable positional deviation of the gap or the effect of adjusting the large gap is not very obvious, or the position of the upper and lower parts changes, all of these factors can cause the problem of burrs in the punched parts. Method: Improve the precision of convex and concave die manufacturing and effectively adjust the clearance.
5.Deviation of the Cutting Position
Reason: Poor machining precision; Design dimensions have errors; Some components have been damaged; When using equipment for punching, the material will be attracted by the punching force, which will change the size. Operators can increase the precision of machining by adjusting the design; Adjusting the position of components and the size of gaps; and Adjusting the guide sleeve, guide pillar, and guide pin; Improving the quality of materials, using high-quality materials will increase the quality of components.
6.Material Jamming
The feeder has malfunctioned, the feeder has not been adjusted properly, or it has been damaged during the stamping process of the die; The width of the material is not very complete, and the burrs are not very small.
Components in the wrong position should be adjusted to the correct position, and faulty components should be repaired. Replace low-quality materials with high-quality ones.
7.Changes in Bending Shape
Reason: The raw materials slipped, and the concave and convex dies did not have a positioning effect; The structure of the stamping die is unstable; The thickness of the material has undergone deformation. The operator needs to modify or replace the guide pin, change the design size, and disassemble and bend.
Commonly Used Progressive Die Service Materials
Due to the specific requirements for producing workpieces, progressive dies will have various stamping materials. According to the different requirements for durability and corrosion resistance of each workpiece, corresponding materials should be selected. The following are the main materials applied:
1.Plastic
Plastic materials are mainly divided into two types: thermoplastic materials and thermosetting materials, both of which are beneficial for strengthening stamping operations. Mainly used in the production of electronic products, including small components, insulators, etc.
2.Steel Alloy
The most widely used steel alloys are cold-rolled steel and stainless steel. Both materials have their characteristics. Cold-rolled steel has good durability. Stainless steel is also a widely used material in production, which has corrosion resistance and can manufacture workpieces even in harsh environments.
3.Aluminum Alloy
This material has corrosion resistance and can be used to manufacture different progressive die workpieces. Aluminum alloy also has the characteristic of high strength.
4.Rare Alloy
Rare alloys play a significant role in progressive die service, and these materials are generally used in the aerospace industry. The use of rare alloys has the characteristics of high-temperature resistance and good corrosion resistance to manufacture high-quality components.
Design of Progressive Die Service
1.Design of Components
The operator first designs the die for the progressive die service design components that meet the requirements and minimizes the number of materials in the design plan to avoid certain material losses. The design of this component must be feasible.
2.Ingredients
Ensure that high-quality materials are provided to the equipment and stably delivered into the die. Straightening the material can help avoid encountering thick coils inside the material.
3.Take lubrication Measures
Taking some lubrication is helpful for the friction between the material and the die, which can reduce the friction between them. Proper cooling helps to reduce the heat generated by the progressive die service during the stamping process.
4.Protection Methods
Designing a protection system in the design of progressive dies helps to protect the die and equipment. Check if there are any issues with the materials and listen for further damage to the equipment.
5.Equipment
During the stamping process of progressive die, suitable stamping equipment should be selected to ensure that the specifications and dimensions of the produced workpiece meet the requirements.
6.Quality
During the stamping process, it is essential to attach great importance to the quality of the product and conduct a comprehensive inspection to identify areas that require improvement.
7.Master the Operation
Operators should be proficient in the use of equipment and relevant measures to solve some problems, to prevent special situations from occurring. Technical personnel should be able to solve problems promptly.
8.Disposal of Waste Materials
In every die design, some waste is generated. Technicians try to design a suitable amount of materials to prevent a lot of material waste and ensure the utilization rate of materials.
9.Placement Location
When placing the equipment, the BOOLING progressive die service should be placed in a suitable position to reduce the impact on the environment during the stamping process.
Progressive die service provides various benefits, and to achieve high efficiency and high-quality components, it is very important to process them according to different design requirements.
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