Custom Stamping Die
Custom die stamping has the characteristics of complex shape, high precision, and light weight. There are many types of precision mold stamping, mainly including metal stamping molds, plastic stamping molds, and powder stamping molds.
Progressive Bending Die
Progressive bending dies are commonly used for large batches and small sizes of workpieces. Operators use custom stamping die for multi-station punching, bending, and cutting continuous processes, which help improve productivity, simplify operation, and ensure high product quality. Stamping Die, as an efficient production tool, is a widely used and important process equipment in industrial production. Using dies to produce products and parts has high production efficiency, can achieve high-speed and large-scale production, saves raw materials, and minimizes material waste. High-quality processing helps to ensure stable product quality and good interchangeability. The steps of this operation are not very complicated, and there are no high technical requirements for technicians. The processed parts and components can be formed in one go without the need for multiple processing steps. This process will produce some products with more complex shapes.
Bending is a basic process in cold stamping manufacturing, which is the plastic forming process of making flat materials into parts with specified angle and size requirements. There are many types of bending processes, and due to the various shapes of processing materials and equipment used, they can be divided into many methods, such as tension bending, compression bending, bending, torsion bending, etc.
Design of Progressive Bending die
- Stamping Bending Direction
In the progressive bending die, if the product is required to be bent in multiple directions, the operator will cause some trouble during the progressive processing. There are two types of bending directions, one is upward and the other is downward. If the bending direction is different, the die structure design will also be different. If bending upwards, it is required to design a stamping direction conversion mechanism in the lower die, such as sliders, swing blocks, etc; Another scenario is to bend downwards, although the bending direction is not changed, it is necessary to ensure smooth feeding after bending. If there is any obstruction in the process, a lifting device must be installed. If multiple curling or bending are carried out, to avoid this situation, it is necessary to pay attention to setting sufficient empty workstations on the die, to help leave room for movement and installation space for the sliding module.
- Bending Forming Steps
Feeding Stage: During the feeding stage, the raw materials are placed at the entrance of the progressive bending die. The purpose of this stage is to ensure the safe entry of raw materials into the die and prepare for the next processing steps. Technicians need to ensure that the materials are intact and undamaged in this step and that the feeding speed and position are carried out as required and meet the manufacturing requirements of the die.
Pressing Stage: The pressing stage plays a major role in the working process of the progressive bending die. In this step, it is important to secure the material to ensure that the die does not change position or shape during the bending process. The magnitude and direction of the pressure generated by the material pressing machine need to be controlled according to the requirements of extremely high precision to prevent instability of the material during the bending process.
Bending Stage: The bending stage plays a core role in the operation of the progressive bending die. At this stage, the pressure material passing through the equipment is bent into the desired shape. The design of the die should meet the requirements of avoiding excessive stress or strain during the bending process of the material, otherwise, material fracture or deformation may occur. Many important factors affect the quality of bending, such as bending speed and temperature.
Detection Stage: The inspection stage is the stage where the workpiece will be adjusted in shape after the product is bent. At this stage, employees need to ensure that the workpiece meets the design requirements. If it does not meet the requirements, employees need to make necessary adjustments to the defective areas. The main purpose of detecting this step is to eliminate the stress generated during the bending process, ensuring that the workpiece achieves the specified accuracy and high quality.
Unloading Stage: The unloading stage is the final step in the manufacturing of the progressive bending die process. In this step, the tested product is taken out of the die and subjected to quality inspection to ensure that the product meets the specified quality requirements. The operator needs to take out the workpiece from the die and must handle it gently to avoid causing damage to the workpiece.
- Slippage of the Billet during Bending
If the material is bent and curled, there may be a change in the position of the material during the forming process, resulting in part errors. To solve this situation, technicians first guide and position the processed material, and press the discharge plate, material, and concave die tightly, and finally take a bending action.
Key Points of Layout for Progressive Bending Dies
The layout of progressive bending dies is different from that of ordinary punching dies, and is more complex because there are more things to consider and more issues to pay attention to. When designing this type of die, it is generally necessary to first draw a layout diagram, which needs to be carried out by standard requirements.
- First, design a blank sample for stamping parts, preferably no more than 5. Repeat the trial layout on the drawing. If the plan is established, design a separation station at the beginning of the layout, such as punching, cutting, and cutting waste. Design the forming station in sequence towards the other end, and finally separate the components and carrier. When designing a workstation, it is important to avoid punching small holes as much as possible. If a small hole is punched, it may cause uneven stress on the convex die and result in breakage.
- The first workstation generally arranges punching and punching process guide holes. The second workstation is designed with a guide pin to guide the belt material. In future workstations, guide pins can be set according to the number of workstations and those prone to movement. In future workstations, guide pins can also be set every 2-3 workstations. The third station can place an error detection device for checking the feeding step distance based on the positioning accuracy of the stamping strip.
- When there are a large number of holes on the stamped part and the positions of the holes are too close, they can be punched out at different workstations, but the holes cannot be deformed due to the influence of subsequent forming processes. For porous materials with relative positional accuracy requirements, synchronous punching should be considered. When the die strength is limited and cannot be simultaneously punched out, measures should be taken to ensure their relative positional accuracy. Complex-shaped holes can be decomposed into several simple-shaped holes that are punched out in steps.
- There are two choices for the forming direction: one is upward and the other is downward. It should be conducive to the design and manufacturing of dies, and facilitate smooth material delivery. If the forming direction is different from the stamping direction, mechanisms such as inclined sliders, levers, and swing blocks can be used to convert the forming direction.
- To improve the strength of the concave die insert, discharge plate, and fixing plate, and ensure that the installation positions of each formed part do not interfere, empty workstations can be set in the layout, and the number of empty workstations is determined according to the requirements of the progressive bending die structure.
- For bending and deep drawing formed parts, only a small amount of deformation is required for each workstation. If the degree of deformation is large, stamped parts can be formed in several stages. This not only helps to improve quality but also facilitates die debugging and repair. The shaping station is mainly used for forming parts with high precision requirements. To avoid stretching the material in the deformation zone of U-shaped bending parts, the selected method is to first bend 45 degrees and then bend to 90 degrees.
- In progressive deep drawing layout, some techniques are used to achieve material flow, such as pre-drawing notches, grooves, etc.
8.When there are local reinforcement bars, they should generally be arranged before punching to avoid deformation of the hole caused by reinforcement bars. If a protrusion occurs and the hole appears in the center of the protrusion, to facilitate the flow of the material, a small hole can be punched first, pressed, and then punched to the required aperture.
9.When the number of progressive forming stations is small, if the high-precision requirements of the workpiece are met, the “reset” technology can be used. That is, before the forming station, the workpiece blank is first punched along its specified shape, but the material cannot be separated. When the convex die cuts into one-fifth of the material, the reverse force will be passed through the reset mechanism in the die to press the cut workpiece back into the strip material and then sent to the subsequent processing station for forming.
Grinding Machine Processing of Progressive Bending Dies
There are many types of grinders, which can generally be divided into inner or outer cylindrical grinders, surface grinders, forming grinders, tool edge grinders, tool grinders, coordinate grinders, and many specialized grinders. They are machine tools that use manufacturing tools such as grinding wheels, oilstones, abrasives, and abrasive belts to cut and process product components.
The gradual development of grinding machines is due to the need for precision machining and hard surface machining, and currently, there are also a few high-efficiency grinding machines used for rough machining. Grinding machines can manufacture various surfaces, including inner and outer cylindrical and conical surfaces, flat surfaces, involute tooth profiles, helical surfaces, and various forming surfaces. They can also sharpen cutting tools and perform cutting. The manufacturing process of grinding machines is applied to many products.
Progressive bending die meets the surface, workpiece shape, and manufacturing requirements of various components for grinding die components. The processing range of various grinding machines commonly used for grinding die components may also vary.
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