Stamping die is a special process equipment used in cold stamping processing to process materials into parts (or semi-finished products), called cold stamping die (commonly known as cold stamping die). Stamping is a pressure processing method that uses a mold installed on a press machine to apply pressure to materials at room temperature, causing them to separate or undergo plastic deformation, in order to obtain the desired parts.
Stamping is one of the practical processes for mass production of parts. In the stamping production process, the mold has the most problems and is the most important factor in the entire stamping production process. Directly affecting production efficiency and costs. Affects the delivery cycle of the product. Mold problems mainly focus on mold damage, product quality defects, and mold grinding, which have long plagued industry production. Only by correctly handling these key points. Stamping production can proceed smoothly.
Mold failure is the most common problem in stamping production, often causing production downtime and affecting the product production cycle. Therefore, it is necessary to quickly identify the cause of the mold malfunction and carry out reasonable repairs.
1. Mold damage refers to the cracking, breakage, and expansion of the mold. To deal with mold damage, it is necessary to find the cause from the design, manufacturing process, and use of the mold. Firstly, it is necessary to review whether the manufacturing materials of the mold are suitable and whether the corresponding hot burial process is reasonable. Usually, the heat treatment process of mold materials has a significant impact on them. If the quenching temperature of the mold is too high, the quenching method and time are unreasonable, and the tempering frequency, temperature, and elbow spacing are not selected properly, it will all lead to damage of the mold after entering the stamping production. Insufficient size or depth design of the feeding hole can easily block the slot and cause damage to the feeding plate. If the spring force design is too small or the height of the sleeve is not equal, it will cause the spring to break, the material dropping plate to tilt, resulting in overlapping impact and damage to the parts.
Improper fixation of the punch or insufficient screw strength can cause the punch to fall or break.
When using the mold, there may be installation errors in the position and direction of the parts or poor bolt tightening. The working height adjustment is too low and the guide column lubrication is insufficient. Malfunctions in the feeding equipment and abnormalities in the press can cause damage to the mold. If foreign objects enter the mold, parts overlap, waste blockages, and other situations are not dealt with in a timely manner and continue processing and production, it is easy to damage the falling plate, punch, lower template, and guide column of the mold.
2. During the stamping process of the card mold, if the mold is not flexible or even stuck, production must be stopped immediately to identify the cause of the card mold and eliminate the fault. Otherwise, it will escalate the malfunction and cause damage to the mold.
The main reasons for mold jamming are poor mold orientation and tilting. Or there may be foreign objects between the templates, making it impossible to stick them flat; Insufficient mold strength design or uneven force distribution. Causing deformation of the mold, such as the hardness and thickness design of the mold seat and template being too small, making them susceptible to external impact and deformation; The installation of the mold position is inaccurate, and the positioning error of the upper and lower molds exceeds the tolerance. Or the accuracy of the press is too poor, causing interference in the mold; The strength of the punch is insufficient, and the position of the punch is too close, resulting in an imbalance of lateral force on the mold. At this point, the strength of the punch should be increased to enhance the guidance and protection of the discharge plate.
3. The cost of mold damage and maintenance in stamping production is high. Typically, mold costs account for 1/5-1/4 of the total cost of the component. This is because, in addition to the difficulty and high cost of mold manufacturing. The cost of mold repair and blade grinding maintenance after production is also high, and the original cost of the mold only accounts for about 40% of the total mold cost. Therefore, timely maintenance of molds to prevent mold damage can greatly reduce the cost of stamping production molds.
Generally speaking, after a mold is damaged, there is a choice between repair and scrapping. Non natural wear and tear failure of stamping dies, such as damage to non critical components. As well as faults such as small punch breakage, punch upsetting becoming shorter, concave template cracking, and punching blade cracking, most of them can be fully restored to normal state through maintenance methods and put back into stamping production. But. When the key components of the mold are severely damaged, sometimes both the convex and concave molds are damaged at the same time. The one-time repair cost exceeds 70% of the original cost of the stamping die, or the mold life is approaching. The significance of maintenance is not significant, and in this case, scrapped molds should be considered: except for large molds and continuous molds with complex structures. When the mold maintenance technology is too complex, the cost of repairing the mold is too high, and the difficulty is too great, it will inevitably lead to a long maintenance cycle, seriously affecting the normal production of stamping. Therefore, early failure and scrapping should be chosen, and the mold should be remanufactured.
The efficiency and cost of stamping production are highly dependent on molds. For mold failures that occur during the production process, specific problems should be analyzed and correct maintenance plans should be developed. Promptly resolve issues such as mold damage, mold jamming, blade grinding, and product quality defects. Only by properly handling the relationship between mold maintenance and scrapping can we reduce downtime for mold repair, shorten production cycles, and ensure the normal operation of stamping production.
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