Mold burst reason
1 mold material is not easy to break in the follow-up processing
2. Heat Treatment: Improper deformation due to quenching and tempering
3 mold grinding flatness is not enough to produce deflection deformation
4. Design process: the strength of the die is not enough, the gap between blades is too close, the die structure is irrational, and the number of template plates is not enough.
5. Improper wire cutting: Pulling the wire to cut, the gap is not correct, no clearance
6. Selection of punching equipment: punch tonnage, punching force is not enough, mold adjustment is too deep
7. The material is not smooth: there is no demagnetization treatment before production, there is no feed tip; in the production there is a broken spring and other cards
8. The material is not smooth: When the mold is assembled, there is no leakage, or the roller is blocked.
9. Production awareness: laminated stamping, positioning is not in place, air blow guns are not used, cracks in the template still continue to produce
Die failure form
The failure modes of the die are mainly wear failure, deformation failure, fracture failure, and failure of a bruising. However, due to different stamping processes and different working conditions, the factors that affect die life are many. In the following, the impact factors of the die life are analyzed comprehensively in terms of the design, manufacture and use of the die, and corresponding improvement measures are taken.
1 stamping equipment
The precision and rigidity of the stamping equipment (such as the press) have an extremely important effect on the die life. The stamping equipment has high precision and rigidity, and the life of the die is greatly improved. For example, the complex silicon steel die material is Crl2MoV, which is used on ordinary open presses and has an average regrinding life of 1 to 30,000 times. However, on the new precision presses, the resurfacing life of dies can reach 6 to 120,000 times. In particular, small gaps or gapless dies, hard alloy dies, and precision dies must be selected with high precision and good rigidity. Otherwise, the life of the dies will be reduced, and in serious cases, the chess can be damaged.
2 mold design
(1) The accuracy of the guide mechanism of the mold. Accurate and reliable guidance is more effective in reducing the wear of mould working parts and avoiding the great influence of convex and concave die bruising. In particular, gapless and small clearance blanking die, compound die and multi-position progressive die are more effective. In order to improve the life of the mold, the guide type and the accuracy of the guide mechanism must be correctly selected according to the requirements of the nature of the process and the accuracy of the parts. Under normal circumstances, the accuracy of the guide mechanism should be higher than the convex and concave mold fitting.
(2) Die (convex, concave die) edge geometry. The shape of the convex and concave molds, the fit clearance, and the radius of the fillet not only have a greater impact on the stamping part, but also have a great influence on the wear and life of the mold. For example, the clearance of the mold directly affects the blanking quality and die life. If the accuracy is higher, a smaller clearance value should be selected; otherwise, the clearance can be increased to improve the life of the mold.
3 stamping process
(1) Raw materials for stamping parts.
In actual production, due to the excessive thickness tolerance of raw materials for external pressure parts, fluctuations in material properties, poor surface quality (such as rust), or unclean (such as oil stains), etc., wear of the mold working parts will be aggravated, and easy to chipping. as a result of. To this end, it should be noted: 1 as far as possible the use of stamping process of good raw materials, in order to reduce the stamping deformation force; 2 stamping should strictly check the brand of raw materials, thickness and surface quality, etc., and wipe clean raw materials, if necessary, should remove the surface Oxide and rust; 3 According to the stamping process and the type of raw materials, if necessary, softening treatment and surface treatment can be arranged, and appropriate lubricants and lubrication procedures can be selected.
(2) layout and take the edge.
Unreasonable reciprocating feed layout methods and excessively small bridging values ​​often result in rapid tool wear or convex or concave die damage. Therefore, in consideration of improving the use of materials, it is necessary to reasonably select the method of layout and the margin value in accordance with the processing volume, quality requirements of the parts, and the clearances for the mold assembly, so as to increase the life of the mold.
4 mold materials
The impact of mold materials on the life of the mold is a comprehensive reflection of Gango Soo, such as material type, chemical composition, structure, hardness, and metallurgical quality. Die life of different materials is often different. To this end, two basic requirements are put forward for the working part material of the die: 1 The performance of the material should have high hardness (58~64HRC) and high strength, and have high wear resistance and sufficient toughness, heat treatment deformation is small, there is a certain Hardness; 2 process performance is good. Die processing parts manufacturing process is generally more complicated. Therefore, it must have adaptability to various processing technologies such as malleability, machinability, hardenability, hardenability, quench cracking sensitivity, and grinding processability. Generally, according to the material characteristics, production volume, and precision requirements of the stamping parts, mold materials with excellent properties are selected, taking into consideration the processability and economy.
1 mold material is not easy to break in the follow-up processing
2. Heat Treatment: Improper deformation due to quenching and tempering
3 mold grinding flatness is not enough to produce deflection deformation
4. Design process: the strength of the die is not enough, the gap between blades is too close, the die structure is irrational, and the number of template plates is not enough.
5. Improper wire cutting: Pulling the wire to cut, the gap is not correct, no clearance
6. Selection of punching equipment: punch tonnage, punching force is not enough, mold adjustment is too deep
7. The material is not smooth: there is no demagnetization treatment before production, there is no feed tip; in the production there is a broken spring and other cards
8. The material is not smooth: When the mold is assembled, there is no leakage, or the roller is blocked.
9. Production awareness: laminated stamping, positioning is not in place, air blow guns are not used, cracks in the template still continue to produce
Die failure form
The failure modes of the die are mainly wear failure, deformation failure, fracture failure, and failure of a bruising. However, due to different stamping processes and different working conditions, the factors that affect die life are many. In the following, the impact factors of the die life are analyzed comprehensively in terms of the design, manufacture and use of the die, and corresponding improvement measures are taken.
1 stamping equipment
The precision and rigidity of the stamping equipment (such as the press) have an extremely important effect on the die life. The stamping equipment has high precision and rigidity, and the life of the die is greatly improved. For example, the complex silicon steel die material is Crl2MoV, which is used on ordinary open presses and has an average regrinding life of 1 to 30,000 times. However, on the new precision presses, the resurfacing life of dies can reach 6 to 120,000 times. In particular, small gaps or gapless dies, hard alloy dies, and precision dies must be selected with high precision and good rigidity. Otherwise, the life of the dies will be reduced, and in serious cases, the chess can be damaged.
2 mold design
(1) The accuracy of the guide mechanism of the mold. Accurate and reliable guidance is more effective in reducing the wear of mould working parts and avoiding the great influence of convex and concave die bruising. In particular, gapless and small clearance blanking die, compound die and multi-position progressive die are more effective. In order to improve the life of the mold, the guide type and the accuracy of the guide mechanism must be correctly selected according to the requirements of the nature of the process and the accuracy of the parts. Under normal circumstances, the accuracy of the guide mechanism should be higher than the convex and concave mold fitting.
(2) Die (convex, concave die) edge geometry. The shape of the convex and concave molds, the fit clearance, and the radius of the fillet not only have a greater impact on the stamping part, but also have a great influence on the wear and life of the mold. For example, the clearance of the mold directly affects the blanking quality and die life. If the accuracy is higher, a smaller clearance value should be selected; otherwise, the clearance can be increased to improve the life of the mold.
3 stamping process
(1) Raw materials for stamping parts.
In actual production, due to the excessive thickness tolerance of raw materials for external pressure parts, fluctuations in material properties, poor surface quality (such as rust), or unclean (such as oil stains), etc., wear of the mold working parts will be aggravated, and easy to chipping. as a result of. To this end, it should be noted: 1 as far as possible the use of stamping process of good raw materials, in order to reduce the stamping deformation force; 2 stamping should strictly check the brand of raw materials, thickness and surface quality, etc., and wipe clean raw materials, if necessary, should remove the surface Oxide and rust; 3 According to the stamping process and the type of raw materials, if necessary, softening treatment and surface treatment can be arranged, and appropriate lubricants and lubrication procedures can be selected.
(2) layout and take the edge.
Unreasonable reciprocating feed layout methods and excessively small bridging values ​​often result in rapid tool wear or convex or concave die damage. Therefore, in consideration of improving the use of materials, it is necessary to reasonably select the method of layout and the margin value in accordance with the processing volume, quality requirements of the parts, and the clearances for the mold assembly, so as to increase the life of the mold.
4 mold materials
The impact of mold materials on the life of the mold is a comprehensive reflection of Gango Soo, such as material type, chemical composition, structure, hardness, and metallurgical quality. Die life of different materials is often different. To this end, two basic requirements are put forward for the working part material of the die: 1 The performance of the material should have high hardness (58~64HRC) and high strength, and have high wear resistance and sufficient toughness, heat treatment deformation is small, there is a certain Hardness; 2 process performance is good. Die processing parts manufacturing process is generally more complicated. Therefore, it must have adaptability to various processing technologies such as malleability, machinability, hardenability, hardenability, quench cracking sensitivity, and grinding processability. Generally, according to the material characteristics, production volume, and precision requirements of the stamping parts, mold materials with excellent properties are selected, taking into consideration the processability and economy.
Dongguan City Risen Medical Products Co., Ltd. , https://www.risenppe.com