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High-Grade Die Steel: The primary material for the die body is often high-quality die steels such as Cr12MoV, SKD11, or DC53. Cr12MoV die steel is renowned for its excellent wear resistance, high hardness, and good hardenability. It can withstand the intense forces and friction during stamping and drawing operations, making it suitable for producing parts with complex shapes. SKD11, a popular choice in the industry, offers a balance of hardness, toughness, and wear resistance, enabling it to handle a wide range of materials. DC53, with its improved toughness compared to traditional die steels, reduces the risk of cracking and chipping, ensuring longer die life even under heavy loads.
Carbide Inserts: In areas of the die that experience extreme wear and require high precision, carbide inserts are used. Tungsten carbide inserts, for example, possess exceptional hardness and wear resistance. They are ideal for applications where the die comes into contact with hard or abrasive materials during the stamping or drawing process, such as working with stainless steel or high-strength alloys.
Alloy Steel for Supporting Components: For supporting components of the die, such as guide posts, bushes, and fastening elements, alloy steels are commonly selected. These steels offer good strength, toughness, and fatigue resistance, ensuring the stability and reliability of the die during operation.
Design and Customization:
Requirement Analysis: Our engineering team starts by thoroughly understanding the customer's specific needs, including the shape, size, material, and production volume of the target metal components.
CAD Modeling: Using advanced Computer-Aided Design (CAD) software, detailed 3D models of the stamping and drawing die are created. The design takes into account factors such as the stamping or drawing sequence, the flow of the metal material, and the necessary clearances to ensure smooth operation.
Simulation and Optimization: Through simulation tools, the die design is tested to predict its performance during the stamping and drawing processes. Any potential issues, such as uneven metal flow or excessive stress concentrations, are identified and addressed, and the design is optimized accordingly.
Material Preparation:
Cutting and Shaping: The selected die steel and other materials are cut to the appropriate size and shape according to the design specifications. This may involve processes like sawing, shearing, or machining with precision cutting tools.
Heat Treatment: To enhance the mechanical properties of the materials, heat treatment processes such as quenching and tempering are carried out. Quenching hardens the steel by rapidly cooling it, while tempering relieves internal stresses and adjusts the hardness and toughness to the desired levels.
Machining:
CNC Machining: High-precision Computer Numerical Control (CNC) machining centers are used to perform various operations on the die components, including milling, turning, drilling, and EDM (Electrical Discharge Machining). EDM is particularly useful for creating complex shapes and fine details that are difficult to achieve with traditional machining methods.
Grinding and Polishing: After machining, the die surfaces are ground and polished to achieve the required surface finish and dimensional accuracy. This step is crucial for reducing friction during the stamping and drawing processes and ensuring the quality of the final products.
Assembly and Inspection:
Assembly: The individual die components are carefully assembled, with precise alignment of the various parts. Guide posts, bushes, and other components are installed to ensure smooth movement and proper positioning during operation.
Quality Inspection: The completed die is thoroughly inspected using advanced measuring instruments, such as coordinate measuring machines (CMMs) and optical comparators. Dimensional accuracy, surface finish, and the functionality of the die are carefully checked to ensure that it meets the strict quality standards.
Installation:
Proper Alignment: When installing the die on the stamping or drawing press, ensure that it is accurately aligned with the press components. Misalignment can lead to uneven force distribution, resulting in poor product quality and potential damage to the die.
Secure Mounting: The die must be securely fastened to the press bed and ram to prevent any movement during operation. Use the appropriate bolts, nuts, and other fastening devices and ensure they are tightened to the specified torque.
Operation:
Material Selection and Preparation: Use only the materials that are suitable for the die and have been properly prepared. Ensure that the metal sheets or blanks are clean, free of defects, and of the correct thickness and size.
Operating Parameters: Follow the recommended operating parameters, such as the stamping or drawing speed, force, and stroke. Excessive speed or force can cause premature wear of the die, while improper stroke settings can lead to incomplete forming or damage to the parts.
Lubrication: Apply the appropriate lubricant to the die surfaces and the metal materials during the stamping or drawing process. Lubrication reduces friction, heat generation, and wear, and helps to ensure smooth metal flow and a better surface finish on the products.
Maintenance:
Regular Cleaning: After each production cycle, clean the die thoroughly to remove any metal chips, debris, and lubricant residues. Use suitable cleaning agents and tools to avoid scratching or damaging the die surfaces.
Inspection and Repair: Regularly inspect the die for signs of wear, damage, or cracks. Check the critical components, such as the cutting edges, forming surfaces, and guide elements. If any issues are found, repair or replace the damaged parts promptly to prevent further damage and maintain the die's performance.
Storage: When the die is not in use, store it in a clean, dry, and protected environment. Use protective covers or coatings to prevent corrosion and damage to the die surfaces.
High-Grade Die Steel: The primary material for the die body is often high-quality die steels such as Cr12MoV, SKD11, or DC53. Cr12MoV die steel is renowned for its excellent wear resistance, high hardness, and good hardenability. It can withstand the intense forces and friction during stamping and drawing operations, making it suitable for producing parts with complex shapes. SKD11, a popular choice in the industry, offers a balance of hardness, toughness, and wear resistance, enabling it to handle a wide range of materials. DC53, with its improved toughness compared to traditional die steels, reduces the risk of cracking and chipping, ensuring longer die life even under heavy loads.
Carbide Inserts: In areas of the die that experience extreme wear and require high precision, carbide inserts are used. Tungsten carbide inserts, for example, possess exceptional hardness and wear resistance. They are ideal for applications where the die comes into contact with hard or abrasive materials during the stamping or drawing process, such as working with stainless steel or high-strength alloys.
Alloy Steel for Supporting Components: For supporting components of the die, such as guide posts, bushes, and fastening elements, alloy steels are commonly selected. These steels offer good strength, toughness, and fatigue resistance, ensuring the stability and reliability of the die during operation.
Design and Customization:
Requirement Analysis: Our engineering team starts by thoroughly understanding the customer's specific needs, including the shape, size, material, and production volume of the target metal components.
CAD Modeling: Using advanced Computer-Aided Design (CAD) software, detailed 3D models of the stamping and drawing die are created. The design takes into account factors such as the stamping or drawing sequence, the flow of the metal material, and the necessary clearances to ensure smooth operation.
Simulation and Optimization: Through simulation tools, the die design is tested to predict its performance during the stamping and drawing processes. Any potential issues, such as uneven metal flow or excessive stress concentrations, are identified and addressed, and the design is optimized accordingly.
Material Preparation:
Cutting and Shaping: The selected die steel and other materials are cut to the appropriate size and shape according to the design specifications. This may involve processes like sawing, shearing, or machining with precision cutting tools.
Heat Treatment: To enhance the mechanical properties of the materials, heat treatment processes such as quenching and tempering are carried out. Quenching hardens the steel by rapidly cooling it, while tempering relieves internal stresses and adjusts the hardness and toughness to the desired levels.
Machining:
CNC Machining: High-precision Computer Numerical Control (CNC) machining centers are used to perform various operations on the die components, including milling, turning, drilling, and EDM (Electrical Discharge Machining). EDM is particularly useful for creating complex shapes and fine details that are difficult to achieve with traditional machining methods.
Grinding and Polishing: After machining, the die surfaces are ground and polished to achieve the required surface finish and dimensional accuracy. This step is crucial for reducing friction during the stamping and drawing processes and ensuring the quality of the final products.
Assembly and Inspection:
Assembly: The individual die components are carefully assembled, with precise alignment of the various parts. Guide posts, bushes, and other components are installed to ensure smooth movement and proper positioning during operation.
Quality Inspection: The completed die is thoroughly inspected using advanced measuring instruments, such as coordinate measuring machines (CMMs) and optical comparators. Dimensional accuracy, surface finish, and the functionality of the die are carefully checked to ensure that it meets the strict quality standards.
Installation:
Proper Alignment: When installing the die on the stamping or drawing press, ensure that it is accurately aligned with the press components. Misalignment can lead to uneven force distribution, resulting in poor product quality and potential damage to the die.
Secure Mounting: The die must be securely fastened to the press bed and ram to prevent any movement during operation. Use the appropriate bolts, nuts, and other fastening devices and ensure they are tightened to the specified torque.
Operation:
Material Selection and Preparation: Use only the materials that are suitable for the die and have been properly prepared. Ensure that the metal sheets or blanks are clean, free of defects, and of the correct thickness and size.
Operating Parameters: Follow the recommended operating parameters, such as the stamping or drawing speed, force, and stroke. Excessive speed or force can cause premature wear of the die, while improper stroke settings can lead to incomplete forming or damage to the parts.
Lubrication: Apply the appropriate lubricant to the die surfaces and the metal materials during the stamping or drawing process. Lubrication reduces friction, heat generation, and wear, and helps to ensure smooth metal flow and a better surface finish on the products.
Maintenance:
Regular Cleaning: After each production cycle, clean the die thoroughly to remove any metal chips, debris, and lubricant residues. Use suitable cleaning agents and tools to avoid scratching or damaging the die surfaces.
Inspection and Repair: Regularly inspect the die for signs of wear, damage, or cracks. Check the critical components, such as the cutting edges, forming surfaces, and guide elements. If any issues are found, repair or replace the damaged parts promptly to prevent further damage and maintain the die's performance.
Storage: When the die is not in use, store it in a clean, dry, and protected environment. Use protective covers or coatings to prevent corrosion and damage to the die surfaces.
