Custom Stamping Die
There are various types of custom metal stamping dies, each with highly complex shapes and high precision. Stamping has the advantages of achieving high speed and continuity in the production process, which helps to improve production efficiency.
Progressive Die Design
Progressive die design is quite complex, and the manufacturing of stamping die has the characteristic of high precision. There are many key points to consider in the design, and attention should be paid to the design of the strip layout diagram of the progressive die. The structure of each custom stamping die needs to be considered, and so on, which are very important. The most commonly used type of progressive die design is the multi-station progressive die, mainly used in high-speed punching machines to meet the requirements of high-speed automation and help improve processing efficiency. It has important significance in improving quality and achieving stamping automation.
Magnesium stamping die design can be used on various complex-shaped workpieces. Even for some stamping parts with very complex shapes, multiple processing methods can be used, mainly including punching, bending, deep drawing, and forming. Multi-station progressive die design is mainly used for stamping components produced in large quantities. No matter how complex the shape of the stamped parts is or how many stamping workers there are, a multi-station progressive die design can be used to complete the stamping process.
In general, for stamping parts made with simple dies, the stamping process includes punching (punching, cutting, or dropping), bending, deep drawing, forming, and other processes, requiring a set of dies. Several sets of dies are needed to complete a relatively complex stamping part. Therefore, the production efficiency of this simple die will not be too high. For standardized products produced in large quantities, simple dies are rarely used for processing.
Design of Progressive Die Structure
The characteristics and current situation of the progressive die design. the progressive die design is a die that completes multiple processes in one stroke of a press. They have significant characteristics of safe operation, high die strength, and long service life. The use of a progressive die facilitates the automation of stamping production and can be produced using high-speed presses. Progressive die design is difficult to ensure consistency in the relative positions of the inner and outer parts.
- Design of Layout Drawings
In the process of progressive die design, the strip layout diagram plays a crucial role. Therefore, when designing the layout diagram, technicians mainly need to consider the following factors:
- Feeding method: The multi-station progressive die for high-speed stamping will use an automatic feeding mechanism for feeding, and precise spacing is achieved through the use of guide pins. However, manual feeding often uses side blades for rough spacing and guide nails for spacing.
- Specific structure and processing technology of the die: While designing the strip layout diagram, attention should be paid to the specific structure of the die. The assembly relationship and sequence of each link and specific part, as well as the processing plan for each part, should be comprehensively considered. In this way, the designed strip layout diagram will be helpful for die design. Regarding the processed materials, the quality of the processed materials is very strict for multi-station progressive diedesign. Technicians need to consider various aspects of materials when designing layout diagrams, such as feeding status, material performance, material shape, strip width and material grain direction, material shape, etc.
- The side edge hole and guide nail hole should be in the correct position, as the arrangement of the guide nail hole and guide nail position plays a crucial role in the precise positioning of the multi-station progressive diedesign.
- When cutting in sections, there are many ways to connect the shape of the workpiece. The layout diagram for segmented cutting of multi-station progressive die design can be divided into three types of connection methods: lap joint, flat joint, and cut joint. The strip carrier can be divided into three basic forms: bilateral carrier, unilateral carrier, and intermediate carrier. Lapping can increase the connection quality of punched parts, so the vast majority of segmented cutting processes use lap connections. Carrier: Strip carrier refers to the material that is continuously punched and cut during the feeding process, and is connected to the stamping parts inside the strip to carry forward. This part of the material is called a strip carrier.
- Shape analysis of stamped parts: The characteristics of each stamped part are different, so when designing a strip layout, these characteristics must be analyzed and studied.
- Determination of workstations and vacant workstations: When dividing workstations, due to the high precision requirements of some parts, it is better to complete the stamping in one workstation, which helps to reduce step error and avoid affecting the accuracy of the product. When there are dimensional accuracy requirements for the two curved parts of a part, the curved parts should also be processed and formed at the same workstation in one go. The purpose is to help ensure dimensional accuracy and accurately maintain the same quality of the workpiece after processing. The purpose of adding vacant workstations in the layout diagram is to ensure that the die has sufficient strength. Increase the usage time of the die or facilitate the setting of special structures for the die.
- The sequence principle of various stamping processes in strip layout design: In general cold stamping die design, each stamping process has its process. However, in the process of continuous stamping with a multi-station progressive diedesign, it is essential to master the sequence and individual characteristics when designing the strip layout diagram, to complete the design and manufacturing of the die with the highest efficiency, help the die smoothly punch and ensure the quality of the stamped parts. In manufacturing, the multi-station progressive die design for punching and bending should first cut off the excess material of the hole and bent part before bending.
Design of Concave Die Structure for Progressive Die
The design of the concave die for multi-station progressive die design is quite complex. There are many things that technicians need to pay attention to, such as the shape and precision of the working holes in each part, and also paying attention to whether the positions of each hole are correct, determining the reference and coordinate relationship between each hole; Simple operation steps and usage time, among other factors. Moreover, there are many types of multi-station progressive die mechanisms, and the classification of dies includes segmented assembly dies, integral dies, nested dies, and assembled hole dies. The usage scenarios and advantages and disadvantages of these dies are as follows:
1.Segmented Assembly of Concave Dies: In progressive die, there may be errors in the spacing between the holes at each workstation. The common design method for segmented assembly of concave dies is to divide the die into several sections, with different numbers of holes in each section. Then, the joint surface of these sections of concave dies is fitted into the concave die frame, which helps to form a complete concave die.
The advantages of segmented and assembled concave dies are more than those of integral concave dies. It is characterized by processing the working holes of each segment of the concave die, and then using the inner hole as the standard production shape size. Generally, the distance from the hole to the coordinate reference is controlled by the final grinding process after grinding, and the distance from the concave die hole will not exceed 0.01 millimeters.
2.Integrated Die: For a multi-station progressive die design, the number of holes or complexity of the die varies, and the die designed as a whole is called an integrated die.
3.Inlay Type Concave Die: For the convenience of processing and easy replacement of the working hole and blade die for certain pins, it is a type of embedding a set concave die in the local hole position of the overall concave die or other forms of concave die.
4.Assembly-type Hole Concave Die: This type of die has the characteristic of high machining accuracy for concave holes. Assembly-type hole concave dies are often used in some difficult-to-machine concave holes.
Progressive Die Design and Assembly
The overall assembly of multi-station progressive die is mostly completed on the die assembly machine, including fixation, adjustment, and trial punching. The assembly of dies has several steps, mainly including the following processes:
1.Before assembling the progressive die, perform a pre-assembly inspection on externally purchased or self-made die frames. To avoid unnecessary trouble caused by technical indicators not meeting the specified requirements.
2.Take the center of the guide pillar of the lower die base and the reference plane of the concave die fixing plate as the reference, align the position of the lower die, fix the lower die on the die base, recheck it correctly, drill, hinge, and pinholes, and insert the positioning pin.
3.Assemble the upper mold section. The first step is to install the convex mold and guide pin into the fixed plate, and then load and unload the material plate. The assembly sequence should not be wrong. When installing guide pins, the effective length of the diameter of each guide pin should be strictly consistent, and the error must be less than 0.05m to avoid material jamming or a decrease in the guide effect. Then, the guide sleeve hole and guide pin on the mold base is used as the reference plane, and the position size and step size of the concave model hole play a crucial role. The corresponding position size with the convex mold is measured, and each component is tightened according to the correct position size and step size in a fixed order.
4.Loading and unloading of material plates, springs, and other parts. Install limit pillars on the upper and lower die seats. The height of the limit pillar should ensure that the convex die does not enter the concave die’s hole after the die is closed. During the trial die, remove some of the limit pillar gaskets, and the convex die can enter the concave die. The degree of the removed gasket ensures the depth of the convex die entering the concave die.
5.Test punching. Use the produced strips for trial punching on the die assembly machine. Step-by-step punching first, make sure that the punching clearance at each step is the same, and the quality of the end face must meet the standards. The parts that need to be modified need to be adjusted promptly. The next step is to drill and twist the pin holes and insert the positioning pins. If the trial punching of the progressive die design is qualified, install the waste cutting tool and safety automatic detection system.
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