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Contents and steps of stamping process and die design
Release time:
2018-07-05
Source:
Stamping process and die design is an important technical preparation for stamping production. Stamping process and mold design should be combined with the actual situation of the factory equipment, personnel, etc., from the quality of parts, production efficiency, production costs, labor intensity, environmental protection and production safety of all aspects of comprehensive consideration, selection and design of advanced technology, reasonable economy, safe and reliable use of process programs and mold structure, in order to make the production of stamping parts to ensure that the design drawings on the basis of the proposed technical requirements, as far as possible to reduce the cost of stamping process and ensure safe production. Generally speaking, the main contents and steps of the design package
Stamping process and die design is an important technical preparation for stamping production. Stamping process and mold design should be combined with the actual situation of the factory equipment, personnel, etc., from the quality of parts, production efficiency, production costs, labor intensity, environmental protection and production safety of all aspects of comprehensive consideration, selection and design of advanced technology, reasonable economy, safe and reliable use of process programs and mold structure, in order to make the production of stamping parts to ensure that the design drawings on the basis of the proposed technical requirements, as far as possible to reduce the cost of stamping process and ensure safe production.
Generally speaking, the main contents and steps of the design include:
1. Process design
(1) Parts and Stamping Process Analysis According to the stamping parts product diagram, analyze the shape characteristics, size, precision requirements, raw material size specifications and mechanical properties of stamping parts, and combine the available stamping equipment specifications and mold manufacturing conditions, production batch and other factors, analyze the stamping process of parts. Good stamping process should ensure that the material consumption is small, the number of processes is small, the number of equipment occupied is small, the mold structure is simple and the life is high, the product quality is stable, the operation is simple.
(2) Determine the process plan, the main process parameters are calculated on the basis of stamping process analysis, find out the characteristics and difficulties of process and mold design, and put forward various possible stamping process plans according to the actual situation, including the nature of the process, the number of processes, the sequence of processes and the combination method. Sometimes the same kind of stamping parts may also exist multiple feasible stamping process scheme, usually each scheme has its advantages and disadvantages, from the product quality, production efficiency, equipment occupation, mold manufacturing difficulty and life level, production cost, convenient operation and safety degree of comprehensive analysis, comparison, to determine the best scheme suitable for the existing production conditions. In addition, understanding the role of parts and the use of the requirements of the stamping process and mold design is helpful to the process parameters refer to the development of the process plan based on the data, such as various forming coefficients (drawing coefficient, bulging coefficient, etc.), parts expansion size and blanking force, forming force. There are two cases of calculation,
The first is that the process parameters can be calculated more accurately, such as the material utilization rate of part layout, the center of blanking pressure, the area of the workpiece, etc;
The second is that the process parameters can only be calculated approximately, such as general bending or drawing forming force, complex parts blank unfolding size, etc., to determine this kind of process parameters is generally based on empirical formulas or charts for rough calculation, some need to be adjusted through tests; sometimes even no empirical formula can be applied, or because the calculation is too complicated to be carried out, for example, the rigidity or strength of complex mold parts is checked, and the forming force calculation of complex stamping parts is generally estimated only by experience.
(3) Select stamping equipment According to the nature of the stamping process to be completed and the force and energy characteristics of various stamping equipment, consider the main factors such as the deformation force required for stamping processing, deformation work, mold closing height and contour size, and combine the existing equipment in the factory to reasonably select the equipment type and tonnage. Commonly used stamping equipment are crank presses, hydraulic presses, etc., of which crank presses are the most widely used. Blanking type stamping process is mostly carried out on the crank press, generally without hydraulic press; and forming type stamping process can be carried out on the crank press or hydraulic press.
2. Mold design Mold design includes the selection and design of mold structure, the calculation of mold structure parameters, and the drawing of mold drawings.
(1) the selection and design of die structure form according to the proposed process plan, considering the shape characteristics of stamping parts, part size, precision requirements, production batch, mold processing conditions, convenient operation and safety requirements, etc.
(2) After the mold structure parameters are calculated to determine the mold structure form, relevant parameters on the mold structure shall be calculated or checked, such as the geometric dimensions of the working parts of the mold (convex and concave molds, etc.), the strength and rigidity of the mold parts, the motion parameters of the mold moving parts, the installation dimensions between the mold and the equipment, the selection and accounting of elastic elements, etc.
(3) Drawing the mold drawing is the final embodiment of the stamping process and mold design results. A complete set of mold drawing should include complete information about the mold and the use of the mold. The drawing of the mold drawing should conform to the drawing standards formulated by the state, and at the same time consider the special requirements and habits of the mold industry. The mold drawing consists of the assembly drawing and the part drawing of non-standard parts. The general assembly drawing mainly reflects the assembly relationship between the various parts of the whole mold. The projection drawing explaining the mold structure should be drawn correspondingly, mainly the front view and the top view, the necessary section and section view, and the main structural dimensions, such as closing height, contour dimensions, etc. Traditionally, the top view is obtained by projecting the lower mold part. At the same time, the workpiece drawing and layout drawing are drawn in the upper right corner of the drawing, and the detailed list of mold parts is listed in the lower right corner, indicating the technical requirements, etc. The part drawing is generally mapped according to the general assembly drawing of the mold, and there should also be sufficient projection of all necessary sections and sectional views to clearly express the part structure. In addition, all structural dimensions, tolerances, surface roughness, heat treatment and other technical requirements required for part processing shall be marked. For a complete production process, stamping process and mold design are inseparable, the two are interrelated and influence each other, so the aforementioned supervision may need to be crossed and repeated. If the scheme is changed, the design calculation shall be carried out again.
3. Preparation of process documents and design calculation instructions In order to standardize production and strengthen management, corresponding process documents (such as process cards) shall be written for the production of each stamping product. Stamping process for parts and die design should be written design calculation instructions for future reference. The design calculation specification should include the process analysis of the stamping parts and the main content of the mold design. Stamping die is the main process equipment of stamping processing, stamping parts is to rely on the relative movement of the upper and lower mold to complete. Due to the continuous separation between the upper and lower molds during processing, if the fingers of the operators continue to enter or stay in the mold closing area, it will pose a serious threat to their personal safety.
Main Parts, Function and Safety Requirements of (I) Die
1. The convex and concave mold of the working part is the working part that directly shapes the blank, so it is the key part on the mold. The male and female die is not only precise and complex, it should meet the following requirements:
(1) It should have sufficient strength and cannot be broken or damaged during the stamping process;
(2) The material and heat treatment should have appropriate requirements to prevent the hardness is too high and brittle.
2. Positioning parts Positioning parts are parts that determine the installation position of blanks, including positioning pins (plates), stop pins (plates), guide pins, guide plates, fixed distance side knives, side presses, etc. When designing positioning parts, it should be considered that the operation is convenient. There should be no over-positioning. The position should be easy to observe. It is better to use forward positioning, outer contour positioning and positive pin positioning.
3. Presentation, unloading and discharging parts Presentation parts include blanking ring, pressing plate, etc. The blank holder can press the edge force on the drawn blank, thus preventing the blank from arching under the action of tangential pressure and forming wrinkles. The function of the pressing plate is to prevent the blank from moving and bouncing. The function of the ejector and the discharge plate is to facilitate the discharge of parts and the cleaning of waste materials. They are supported by springs, rubber and air cushion push rods on the equipment, and can move up and down. The ejection parts should be designed with sufficient ejection force, and the movement should be limited. The stripper plate shall minimize the closed area or mill free hand slots in the operating position. The exposed discharge plate shall be provided with protective plates around to prevent fingers from entering or foreign matter entering, and the edges and corners of the exposed surface shall be obtuse.
4. Guide parts Guide posts and guide sleeves are the most widely used guide parts. Its function is to ensure that the male and female dies have accurate matching clearance during stamping work. Therefore, the clearance of the guide column and the guide sleeve should be less than the blanking clearance. The guide post is arranged in the lower die base to ensure that the upper end surface of the guide post is at least 5 to 10mm above the top surface of the upper die plate at the bottom dead center of the stroke. The guide post should be arranged away from the module and the pressing plate, so that the operator's arm does not need to cross the guide post to feed and take materials.
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