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What are the methods to improve the stability of progressive molds

ouzhong — Wed, 06 Dec 2023 00:38:48 +0000

The production of molds plays an important role in our industrial production. Nowadays, due to the needs of our industrial production, various types of molds have also emerged around us. The production of molds is very strict, because even a small error can cause the products we produce to be unqualified. The same is true in our mold production. Progressive molds are one of the commonly used molds, and their production is also extremely strict, How to improve the performance of our progressive molds is a common problem that all mold workers want to solve. Let’s learn how to improve the performance of progressive molds together. We know that any small error can affect the accuracy of processing data parameters, which in turn affects the performance of progressive mold products. Processing accuracy refers to the degree to which the actual dimensions, shape, and position of the machined part surface meet the ideal geometric parameters required by the drawing. The ideal geometric parameters, in terms of size, are uniform dimensions; For surface geometric shapes, they are absolute circles, cylinders, planes, cones, and straight lines, etc; For the mutual position between surfaces, it means absolute parallelism, verticality, coaxiality, symmetry, etc. The deviation between the actual geometric parameters of the part and the ideal geometric parameters is called machining error. Both machining accuracy and machining error are terms used to evaluate the geometric parameters of machining surfaces. The machining accuracy is measured by tolerance level, and the lower the level value, the more accurate it is. The higher the accuracy, the machining error is represented by numerical values, and the larger the numerical value, the greater the error. High machining accuracy means small machining errors, and vice versa.
The main reasons that affect the stability of molds and stamping are as follows: horizontal to the strength of a mold material and progressive die structure, the stability performance of progressive die stamping materials, the characteristics of waves, the thickness of progressive die materials in the progressive die stamping process, because each urgent plate has its own chemical composition, mechanical properties, and stamping performance characteristic values closely related, the stamping material performance is unstable, and the stamping material thickness fluctuates, The changes in stamping materials not only directly affect the accuracy and quality of the stamping process, but may also lead to damage to the progressive die. The stamping technology and progressive die design process must consider the magnitude of tensile resistance, decorate the range of tensile steel bars and determine the form of tensile steel bars based on the edge holding force, so that each area can complete the forming deformation mode and degree as needed. We believe that there are too many factors that affect the stability of progressive molds, so we are all using them. We also need to pay more attention to these operations to improve the stability of progressive molds and ensure the quality of processed products. In recent years, progressive molds have been increasingly used around us, and the performance requirements of our stamping dies are also high. We need to maintain them as progressive molds to extend their service life.
Precautions for designing progressive molds: Causes of faults during the stamping process of progressive molds:
1. Edge wear; 2. The difference is too large, and the cutting effect is not significant after reaching the destination; 3. Cutting edge cutting, unreasonable gaps, deviations, looseness, and misalignment. The method to improve the stability of progressive dies: level up to the strength of a mold material and progressive die structure, the stability performance of progressive die stamping materials, the characteristics of waves, the thickness of progressive die materials in the progressive die stamping process, because each urgent plate has its own chemical composition, mechanical properties, and stamping performance characteristic values closely related, the stamping material performance is unstable, the stamping material thickness fluctuates, and the stamping material changes, Not only does it directly affect the accuracy and quality of the stamping process, but it may also lead to damage to the progressive die. The stamping technology and progressive die design process must consider the magnitude of tensile resistance, decorate the range of tensile steel bars and determine the form of tensile steel bars based on the edge holding force, so that each area can complete the forming deformation mode and degree as needed. Notes on progressive die design: From the perspective of progressive die design systems, the role of practical experience should be highly valued in determining the large-scale systems that make up stamping and mold manufacturing, as well as the structure of progressive dies for parts. Realistically, establish practical mold solutions while considering existing mold manufacturing and stamping production conditions. The structure of progressive molds is complex, difficult to design, with high manufacturing costs and long cycles. Therefore, the design should adhere to scientific, rigorous, pragmatic, careful analysis and detailed planning, make reasonable designs, facilitate production and meet requirements, fully understand the requirements and usage conditions of product parts processing and mold manufacturing.

Classification of Stamping Dies

ouzhong — Wed, 06 Dec 2023 00:36:15 +0000

There are many forms of stamping molds, which can generally be classified according to the following main characteristics:
1. Classification based on process properties
(1) A die that separates materials along a closed or open contour line. Such as material cutting die, punching die, cutting die, cutting die, edge cutting die, cutting die, etc.
(2) A bending die is a mold that causes the blank or other blank to bend and deform along a straight line (bending curve), thereby obtaining a workpiece with a certain angle and shape.
(3) A deep drawing die is a mold that turns a blank sheet into an open hollow part, or further changes the shape and size of the hollow part.
(4) A forming die is a mold that directly replicates a rough or semi-finished workpiece into a convex or concave shape according to the drawing, while the material itself only produces local plastic deformation. Such as bulging molds, necking molds, expanding molds, undulating forming molds, flanging molds, shaping molds, etc.
2. Classification based on the degree of process combination
(1) A single process mold is a mold that completes only one stamping process in one stroke of a press.
(2) A composite mold has only one workstation, and in one stroke of the press, it is a mold that completes two or more stamping processes simultaneously on the same workstation.
(3) Progressive die (also known as continuous die) has two or more workstations in the direction of raw material feeding. It is a mold that completes two or more stamping processes on different workstations in one stroke of the press.

How is the stamping mold installed?

ouzhong — Wed, 06 Dec 2023 00:34:01 +0000

Installation of punching machine molds
1) Confirm whether the feeding holes of the mold and the cushion block are consistent.
2) After assembling the upper and lower molds, place them on the lower table, ensuring that the reference plane of the punching machine is parallel to the reference plane of the mold.
3) The lower mold should be completely fixed, and the upper mold should also be lightly fixed in advance.
4) Test punching the slider on the punching machine 20-30 times, confirm that the upper and lower molds are in a completely matching state, and then tighten the upper mold.
5) The biting component of the punch press’s convex and concave molds is combined with the lower mold stop block of the mold to adjust the height of the slider on the punch press.
6) Use the trial punching of the sealing paper to confirm its cutting condition. If it is uneven, confirm the installation status of the mold again. If consistency cannot be achieved, it is necessary to confirm the parallelism between the punch slide and the lower table of the punch.
7) Adjust the material feed length and feed time. (If there is a waste cutting blade attached, the length of the cut waste can be used to confirm the feed length of the material)
8) After a comprehensive operation of 3-5 minutes, fill the gap between the guide pillar and the lining with oil and confirm if there is any abnormal heat.
9) Try on the selected processed material and confirm that there are no obstacles during insertion.
10) After the above work is completed, processing can be carried out. Firstly, press the first material positioning rod set on the side of the lower mold, and feed the material until it touches the positioning rod. After insertion, first perform a trial punch using a manual feed until the final process is completed.
11) After confirming that there are no abnormalities with the manual feed, close the switch of the punching machine feeding device. At this point, the feed work needs to be carried out completely in the completed position.
12) The punching die utilizes a single punch motion to confirm whether the feed rate is appropriate.

The difference between progressive die and composite die

ouzhong — Wed, 06 Dec 2023 00:31:59 +0000

1、 Different properties
1. Composite mold: A mold structure in which a punching machine completes multiple processes such as material cutting and punching in one stroke.
2. Progressive die: composed of multiple workstations, each of which is sequentially associated to complete different processing tasks. A series of different stamping processes are completed in one stroke of the punching machine.
2、 Different characteristics
1. Composite mold:
(1) The workpiece has good coaxiality, a flat surface, and high dimensional accuracy.
(2) High production efficiency, not limited by the accuracy of plate shape and size. Sometimes waste corners can also be used for replication.
(3) The processing and manufacturing of mold parts is difficult and costly. Stamping and concave molds are easily limited by the minimum wall thickness and are not suitable for certain lower parts with small inner hole spacing and inner hole and edge spacing.
2. Progressive mold:
(1) Progressive die is a type of multi task continuous punching die. In a mold, it can include many processes such as cutting, bending, and drawing, with high productivity.
(2) Progressive mold operation safety.
(3) Easy to automate;
(4) High speed punching machines can be used for production.
(5) It can reduce the area of stamping machines and sites, as well as the transportation of semi-finished products and warehouse occupancy.
(6) Parts with high size requirements should not be produced using progressive molds.