In progressive die stamping production, for stamping undesirable phenomena we must do a detailed analysis, take effective treatment measures to solve the problems occurred fundamentally, so that it can reduce production costs and achieve smooth production. Reasons and Measures on the production of the following common stamping undesirable phenomena which produce are analyzed as follows, for mold maintenance officers.
1. Stamping burrs.
(1) Cause: A, edge wear; ineffective after B, the gap is too large training blade; C, edge chipping; D, the vertical offset or gap unreasonable loose; E, the upper and lower dislocation.
(2) Countermeasures: A, training blade; B, control precision punch or modify the design of space; C, training blade; D, adjust the blanking clearance confirmation template hole bore wear or precision molded parts and other issues; E, replace guide member or group to re-mold.
2. Jump crumbs crushed
(1) Cause: A, the gap is too large; B, improper feeding; C, stamping droplets too fast, oil viscosity; D, mold not demagnetization; E, punch wear, scrap material is pressed against the upper punch; F, punch is too short, less than the length of the die insert; G, hard material, cutting shape simple; H, emergency measures.
(2) Countermeasures: A, precision punch control or to modify the design gap; B, when the trim strip to the appropriate location and promptly clean up mold; C, control stamping oil droplets, or replace oil types to reduce the viscosity; D mold must demagnetization after training (red iron materials also should be noted); E, training punch blade; F, adjust the punch into the die edge length; G, replacement of materials, design modifications. Loaded into the end face of the punch blade ejection or repair a ramp or arcing (note the direction). Reduce the bonding area of the end face of the punch blade portion of the debris material; H, reducing the die edge sharpness, reducing the die edge of the amount of training, increasing the roughness of the die surface of the straight edge portion (covered), using vacuum cleaner waste. Chong reduce speed, slow jump crumbs.
3. Debris blocking material
(1) Cause: A, small leak orifice; B, the drain hole is too large material, scrap material roll; C, edge wear, larger flash; D, stamping droplets too fast, oil viscosity; E, die straight edge surfaces rough sintering fines attached to the blade portion; F, soft material; G, emergency measures.
(2) Countermeasures: A, modify leakage orifice; B, modify leakage orifice; C, repair knife edge; D, to control the amount of drip, replace oil types; E, surface treatment, polishing, pay attention to reduce the surface roughness when machining ; change material, F, modify blanking clearance; G, the end face of the punch blade repair a slope or curved (note the direction), use a vacuum cleaner, in the blanking plate hole plus blow.
4. Partial cutting slot size variation
(1) Cause: A ,. punch blade wear, burrs (the shape is too large, the hole is too small); B, design size and improper gap, machining accuracy is poor; C, lower material level punch and die inserts and other deviation, uneven gaps; D, the guide pin being worn, inadequate pin diameter; E, guides wear; F, sent from the feeder, binder, relax improperly adjusted; inappropriate G, mold shut height adjustment; H, Strippers binder insert bit wear, no binder (extreme pressure) function (material traction stacker initiator small punching); I, insert Forced discharging too, punching too large; J, stamping mechanical property variation ( strength elongation unstable); K, when punching, punching power of traction material, causing variation in size.
(2) Countermeasures: A, training blade; B, to modify the design, control precision; C, adjust its position accuracy, blanking clearance; D, replace the guide pins positive; E, replace the guide post, guide sleeve; F, readjust feeder; G, readjust the height of the closed mold; H, grinding or replacement stripper inserts, increased extreme pressure function, adjust binder; I, reduced Forced depth; J, replacement materials, feed quality control; K, punch stress condition when the end face of the blade repair a slope or curved (note the direction), in order to improve punching. Nowadays plus license provided the material is located on the discharge guide Bit insert.
5. Card stock
(1) Cause: A, sent from the feeder, binder, relax improperly adjusted; B, the production of feed produced from the variation; C, feeder fault; D, curved material, width tolerance, burr larger; E, die stamping exception camber initiator; insufficient F, derivative material aperture, the upper mold pull material; G, bend or tear cut bit up and down the stripper ring true; H, guide plate of the stripper function is set incorrectly, the material with tape ; I, thin material, feeding the warp; J, mold set up properly, and vertical deviation larger feeder.
(2) Countermeasures: A, readjust; B, readjust; C, adjustment and maintenance; D, replace materials, control of feed quality; E, to eliminate the strip camber; F, training punching pilot hole convex and concave mold ; G, adjust the stripper spring force, etc; H, modify derivative material, anti-material tape belt; inter-I, the feeder and the die set upper and lower binder plus, plus set up and down crowded material safety switch; J, re-erected mold.
6. Strip Camber
(1) Cause: A, stamping burrs (especially carrier); B, the material edges, no mold trimming; improper C, punch depth (deep or shallow); D, crushed pieces, there is debris in the mold material; E, local press nip is too dark or partial damage to the unit; F, mold design.
(2) Countermeasures: A, under the training material knife; B, replacement of materials, mold processing is provided trimming means; C, resetting punch depth; D, clean up the mold, crumbs and crushed hop solve problems; E, you check and adjust off materials and die inserts the correct height dimension, an injury site training; F, using the whole bending restructuring.
7. Punches chipping fracture
(1) Cause: A, jump dust, debris blocking material, card die as a result; B, improper feeding, cut in half material; insufficient C, punch strength; D, the size of the punch too close, when punching materials traction, small punch triggered off; E, the local punch and die too sharp; F, blanking gap is too small; G, or use the free press oil press oil more volatile; H, blanking gap uneven, partial shift, convex and concave mold interfere; I, the stripper inserts poor accuracy or wear, loss of precision guiding function; J, mold guide are not allowed wear; improper K, convex and concave mold material selection, improper hardness; I, lead materials and parts (pin) wear; m, plus gasket set properly.
(2) Countermeasures: A ,. solve hop cuttings, scrap material blocking the card mode and other issues; B, note feeding, timely trim strip, clean the mold; C, to modify the design to increase the punch overall strength, shorten die straight edge portion size, pay attention to the end face of the punch blade repair a slope or curved, small portions after cutting; D, small punch length wear short punch a relatively large material thickness above; E, to modify the design; F, control punch mold machining accuracy or modify the design of space, fine blanking gap portion due to increase; G, adjust or replace the oil stamping oil droplets species; H, to check the accuracy of each forming member, and subjected to adjustment or replacement, control precision; I , training or replacement; J, replace the guide post, guide sleeve, pay attention to routine maintenance; K, replace the use of materials, use of appropriate hardness; I, replace the guide materials and parts; m, amended several spacer small as possible, and use steel pad , die under the pad in the pad in the pad below.
8. Bending deformation size variation
(1) Cause: A, the guide pin being worn, inadequate pin diameter; B, bending guide portion bit accuracy, wear and tear; C, bending convex and concave mold wear (pressure drop); D, mold gave way inadequate; E, material slip, bending convex and concave mold-free lead-bit function, when not subjected to pre-press bending; bad F, mold structure and design size; G, stamping burrs, causing adverse bending; H, bending parts of the punch die set plus more pads, causing dimensional instability; I, material thickness dimension variation; J, the material can be mechanically shaped variation.
(1) Countermeasures: A, replace the guide alignment pins; B, reground or replaced; C, reground or replaced; D, inspection, amendment; E, design modifications, additional lead-bit and pre-press functions; F, modify the design size decomposition bending, bending increase shaping; G, training cutting edge position; H, adjustment, the overall steel pad; I, replace materials, feed quality control; J, replacement materials, feed quality control.
9. Stamping height (when more than one module)
(1) Cause: A, stamping burrs; B, there are pieces crushed, there is scrap material within the mold; C, convex, concave die (bending bits) pressure loss or damage; D, when punching stacker; E related binder parts wear, pressure loss; F, associated tear cut bit torn cut size is inconsistent, edge wear; G, the relevant frangible bit pre-cut depth inconsistent punch wear or chipping; H, related embossed site Bump norm chipping or wear more serious; I, mold design flaws.
(2) Countermeasures: A, training cutting edge position; B, clean up the mold, to solve the problem of debris floating material; C, re-training or replacement parts; D, training punching blade, extreme pressure adjustment or additional function; E, inspection, perform maintenance or replacement; F, repaired or replaced, ensure tear-cut situation consistent; G, check the pre-cut male and female die situation, the implementation of maintenance or replacement; H, check convex, concave die situation, the implementation of maintenance or replacement; I, modification designing, installing additional height adjustment or shaping station.
10. Improper maintenance
(1) Cause: A, mold no foolproof function, set the mold negligence installed in the opposite direction, dislocation (refers to the different stations) and so on; B, has been offset inserts a gap of failure to recover the status quo.
(2) Countermeasures: A, modify the mold, by fool-proof function; marking on B, mining mold, etc., and in the latter group to take care of the mold with do the necessary checks, validation, and make a written record for future retrieval.
In stamping, the mold is essential routine maintenance work, that is the daily attention to check whether the punch and die in a normal state, such as the fuel supply guide portion press oil. Check the mold machine before checking the blade portion of each part of the locking confirmation, so can avoid many unexpected fatalities. When the repair mode must first think twice, and do a good job recording experience.
