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I. Product Material
1. Die Steel
The main body of the trimming die is usually made of high-quality die steel, such as Cr12MoV. This kind of steel has high hardness, high wear resistance and good hardenability. Its hardness can generally reach HRC 58 - 62, which enables it to withstand the high stress generated during the punching process and ensure the service life of the die.
In addition, some high-end products will choose powder metallurgy high-speed steel, such as ASP - 23. It has a more uniform carbide distribution, and its toughness and wear resistance are more excellent. It is suitable for the trimming processing of square head bolts with extremely high precision requirements in mass production.
2. Material of Auxiliary Components
For the guiding components in the die, such as guide pillars and guide bushes, GCr15 bearing steel is generally used. After quenching and tempering treatment, this kind of steel has high hardness, high precision and good wear resistance, which can ensure the guiding accuracy of the die during the working process and prevent the misalignment between the punch and the die cavity.
Springs are made of high-quality alloy spring steel, such as 60Si2Mn. It has a high elastic limit, high fatigue strength and sufficient toughness, and can provide stable and reliable elasticity during the opening and closing of the die to ensure the normal operation of the die.
II. Product Production Process
1. Design Stage
According to the size specifications, precision requirements and production batch of the square head bolt, design the overall structure of the trimming die. This includes determining the shapes and sizes of main components such as punches, die cavities and stripper plates, as well as considering the guiding method, stripping method and installation method of the die.
Use professional die design software to conduct 3D modeling and 2D drawing. Simulate the movement process of the die to check whether there is interference, and conduct a preliminary check on the strength and stiffness of the die.
2. Preparation of Raw Materials
Purchase suitable die steel and other auxiliary materials according to the design requirements. Inspect the chemical composition, hardness and metallographic structure of the purchased steel to see if they meet the standards.
Cut the steel so that its size is slightly larger than the final size of the die parts, leaving a margin for subsequent processing. The cutting methods usually include wire cutting or sawing.
3. Processing Stage
Rough Machining: Use milling machines, planing machines and other equipment to conduct rough machining on die parts to remove most of the allowance and make the shape and size of the parts close to the design requirements. During the rough machining process, it is necessary to leave a machining allowance of 0.5 - 1 mm for subsequent finishing.
Finishing: Use CNC machining centers (CNC) for finishing. Through programming, accurately machine the shapes and sizes of key components such as punches and die cavities. For some parts with particularly high precision requirements, such as the cutting edge of the punch, slow wire cutting or electrical discharge machining (EDM) may be needed to meet the final dimensional accuracy and surface roughness requirements.
Heat Treatment: Conduct heat treatment on the processed die parts to improve their hardness and wear resistance. For example, for Cr12MoV die steel, the general heat treatment process is quenching + tempering. The quenching temperature is 1020 - 1050 °C, and the tempering temperature is 180 - 220 °C. After heat treatment, the hardness of die parts will be significantly increased, but certain deformation may also occur, which requires subsequent grinding and polishing treatment.
Grinding and Polishing: Use surface grinders, cylindrical grinders and other equipment to grind die parts to eliminate the deformation caused by heat treatment and improve the dimensional accuracy and surface finish of the parts. For the cutting edge of the punch and the working surface of the die cavity, polishing treatment is also needed to make the surface roughness reach Ra 0.4 - Ra 0.8 μm, so as to reduce the friction during the punching process and improve the punching quality and service life of the die.
4. Assembly and Debugging Stage
Assemble the processed die parts, including installing punches, die cavities, guide pillars, guide bushes, springs and other components. During the assembly process, strictly follow the assembly process requirements to ensure the fitting accuracy between various components.
Debug the assembled die. Use trial punching materials (generally billets made of the same material as the square head bolt) for trial punching. Observe whether the punching process is smooth and whether the dimensional accuracy and trimming quality of the punched square head bolts meet the requirements. According to the trial punching results, adjust and optimize the die, such as correcting the clearance between the punch and the die cavity and adjusting the tightness of the stripper plate until the die can stably produce qualified products.
III. Product Processing Technology
1. Punching Technology
The core processing technology of the trimming die is punching. During the punching process, the punch moves downward at a certain speed and pressure under the action of the press to punch the excess material on the head of the square head bolt blank placed on the die cavity and form a square head shape that meets the dimensional requirements.
The clearance between the punch and the die cavity is a key factor affecting the punching quality. If the clearance is too small, the punching force will increase, the wear of the die will be aggravated, and even the punch may break or the die cavity may crack; if the clearance is too large, the trimming quality of the punched square head bolt will be poor, and burrs, tearing and other defects may appear. Generally speaking, the clearance between the punch and the die cavity is determined according to the material and thickness of the square head bolt, usually between 0.05 - 0.15 mm.
2. Cutting Edge Treatment Technology
The cutting edge of the punch needs special treatment to improve its wear resistance and punching performance. Common cutting edge treatment technologies include coating treatment and cutting edge blunting treatment.
Coating treatment is to coat a hard coating on the surface of the punch cutting edge, such as TiN (titanium nitride), TiC (titanium carbide), etc. These coatings have high hardness, low friction coefficient and good chemical stability, which can effectively reduce the wear of the punch during the punching process and improve the service life of the punch. The thickness of the coating is generally between 2 - 5 μm.
Cutting edge blunting treatment is to slightly blunt the cutting edge of the punch. The blunting radius is generally between 0.01 - 0.03 mm. This can avoid the chipping of the cutting edge of the punch in the early stage of punching because it is too sharp, and also help to improve the stability during the punching process.
3. Surface Treatment Technology
In addition to the treatment of the cutting edge, other surfaces of the die also need appropriate surface treatment to prevent rust and improve the overall performance of the die. For example, chrome plating treatment is carried out on the surface of the die. The chrome plating layer can improve the hardness and finish of the die surface and has good anti-rust performance. The thickness of the chrome plating layer is generally between 0.02 - 0.05 mm.
For some trimming dies used in humid environments or environments with corrosive media, chemical nickel-phosphorus alloy plating and other surface treatment technologies can also be adopted. The plating layer formed by this technology has excellent corrosion resistance and wear resistance.
IV. Application Scenarios
1. Machinery Manufacturing Industry
In the manufacturing process of various mechanical equipment, square head bolts are commonly used connecting parts. For example, in machine tools, construction machinery, agricultural machinery and other equipment, a large number of square head bolts are used to connect various parts. The trimming die is used to produce these square head bolts, which can ensure the dimensional accuracy and quality of the bolts and meet the assembly requirements of mechanical equipment.
2. Automobile Manufacturing Industry
Square head bolts are also widely used in the assembly of automobile engines, chassis, bodies and other components. The automobile industry has very high requirements for the quality and precision of bolts. The trimming die can produce square head bolts that meet the standards of the automobile industry and ensure the safety and reliability of automobiles during driving.
3. Construction Industry
In the connection of building steel structures, square head bolts are sometimes used to replace ordinary bolts to meet specific connection strength and aesthetic requirements. The square head bolts produced by the trimming die can be applied to the manufacturing of building steel structures, such as the connection of bridges, high-rise buildings and other steel structures.
V. Precautions for Use
1. Die Installation
When installing the trimming die on the press, make sure that the installation surface of the die is clean and flat to prevent foreign matters from affecting the installation accuracy of the die. Operate according to the installation manuals of the press and the die, and use appropriate bolts and locating pins to fix the die on the press.
Check whether the slide stroke, closing height and other parameters of the press match the die to avoid damage to the die or failure to work normally due to parameter mismatch.
2. Operation Process
Before the punching operation, preheat the die, especially in winter or when restarting after a long shutdown. The preheating temperature is generally between 150 - 200 °C, and the preheating time depends on the size and material of the die, generally 30 - 60 minutes. Preheating can reduce the thermal stress of the die in the early stage of punching and prevent cracks in the die.
Control the punching speed and pressure of the press to avoid damage to the die caused by too fast speed or too high pressure. Adjust the punching parameters reasonably according to the material and size of the square head bolt. Generally speaking, the punching speed should not exceed 50 - 80 times/minute, and the punching pressure should be within the rated pressure range of the die.
3. Die Maintenance
Regularly clean the die to remove waste materials, oil stains and other impurities generated during the punching process. Tools such as compressed air and brushes can be used for cleaning to keep the die clean.
Check the wear of key components such as punches, die cavities, guide pillars and guide bushes of the die. When it is found that the wear exceeds a certain limit (for example, when the wear of the cutting edge of the punch exceeds 0.1 - 0.2 mm), repair or replace them in time.
Regularly lubricate the die. Use appropriate lubricants to lubricate the moving parts of the die (such as guide pillars, guide bushes, sliders, etc.) to reduce friction and extend the service life of the die. Generally, lubrication operation is carried out every 8 - 12 working hours.
I. Product Material
1. Die Steel
The main body of the trimming die is usually made of high-quality die steel, such as Cr12MoV. This kind of steel has high hardness, high wear resistance and good hardenability. Its hardness can generally reach HRC 58 - 62, which enables it to withstand the high stress generated during the punching process and ensure the service life of the die.
In addition, some high-end products will choose powder metallurgy high-speed steel, such as ASP - 23. It has a more uniform carbide distribution, and its toughness and wear resistance are more excellent. It is suitable for the trimming processing of square head bolts with extremely high precision requirements in mass production.
2. Material of Auxiliary Components
For the guiding components in the die, such as guide pillars and guide bushes, GCr15 bearing steel is generally used. After quenching and tempering treatment, this kind of steel has high hardness, high precision and good wear resistance, which can ensure the guiding accuracy of the die during the working process and prevent the misalignment between the punch and the die cavity.
Springs are made of high-quality alloy spring steel, such as 60Si2Mn. It has a high elastic limit, high fatigue strength and sufficient toughness, and can provide stable and reliable elasticity during the opening and closing of the die to ensure the normal operation of the die.
II. Product Production Process
1. Design Stage
According to the size specifications, precision requirements and production batch of the square head bolt, design the overall structure of the trimming die. This includes determining the shapes and sizes of main components such as punches, die cavities and stripper plates, as well as considering the guiding method, stripping method and installation method of the die.
Use professional die design software to conduct 3D modeling and 2D drawing. Simulate the movement process of the die to check whether there is interference, and conduct a preliminary check on the strength and stiffness of the die.
2. Preparation of Raw Materials
Purchase suitable die steel and other auxiliary materials according to the design requirements. Inspect the chemical composition, hardness and metallographic structure of the purchased steel to see if they meet the standards.
Cut the steel so that its size is slightly larger than the final size of the die parts, leaving a margin for subsequent processing. The cutting methods usually include wire cutting or sawing.
3. Processing Stage
Rough Machining: Use milling machines, planing machines and other equipment to conduct rough machining on die parts to remove most of the allowance and make the shape and size of the parts close to the design requirements. During the rough machining process, it is necessary to leave a machining allowance of 0.5 - 1 mm for subsequent finishing.
Finishing: Use CNC machining centers (CNC) for finishing. Through programming, accurately machine the shapes and sizes of key components such as punches and die cavities. For some parts with particularly high precision requirements, such as the cutting edge of the punch, slow wire cutting or electrical discharge machining (EDM) may be needed to meet the final dimensional accuracy and surface roughness requirements.
Heat Treatment: Conduct heat treatment on the processed die parts to improve their hardness and wear resistance. For example, for Cr12MoV die steel, the general heat treatment process is quenching + tempering. The quenching temperature is 1020 - 1050 °C, and the tempering temperature is 180 - 220 °C. After heat treatment, the hardness of die parts will be significantly increased, but certain deformation may also occur, which requires subsequent grinding and polishing treatment.
Grinding and Polishing: Use surface grinders, cylindrical grinders and other equipment to grind die parts to eliminate the deformation caused by heat treatment and improve the dimensional accuracy and surface finish of the parts. For the cutting edge of the punch and the working surface of the die cavity, polishing treatment is also needed to make the surface roughness reach Ra 0.4 - Ra 0.8 μm, so as to reduce the friction during the punching process and improve the punching quality and service life of the die.
4. Assembly and Debugging Stage
Assemble the processed die parts, including installing punches, die cavities, guide pillars, guide bushes, springs and other components. During the assembly process, strictly follow the assembly process requirements to ensure the fitting accuracy between various components.
Debug the assembled die. Use trial punching materials (generally billets made of the same material as the square head bolt) for trial punching. Observe whether the punching process is smooth and whether the dimensional accuracy and trimming quality of the punched square head bolts meet the requirements. According to the trial punching results, adjust and optimize the die, such as correcting the clearance between the punch and the die cavity and adjusting the tightness of the stripper plate until the die can stably produce qualified products.
III. Product Processing Technology
1. Punching Technology
The core processing technology of the trimming die is punching. During the punching process, the punch moves downward at a certain speed and pressure under the action of the press to punch the excess material on the head of the square head bolt blank placed on the die cavity and form a square head shape that meets the dimensional requirements.
The clearance between the punch and the die cavity is a key factor affecting the punching quality. If the clearance is too small, the punching force will increase, the wear of the die will be aggravated, and even the punch may break or the die cavity may crack; if the clearance is too large, the trimming quality of the punched square head bolt will be poor, and burrs, tearing and other defects may appear. Generally speaking, the clearance between the punch and the die cavity is determined according to the material and thickness of the square head bolt, usually between 0.05 - 0.15 mm.
2. Cutting Edge Treatment Technology
The cutting edge of the punch needs special treatment to improve its wear resistance and punching performance. Common cutting edge treatment technologies include coating treatment and cutting edge blunting treatment.
Coating treatment is to coat a hard coating on the surface of the punch cutting edge, such as TiN (titanium nitride), TiC (titanium carbide), etc. These coatings have high hardness, low friction coefficient and good chemical stability, which can effectively reduce the wear of the punch during the punching process and improve the service life of the punch. The thickness of the coating is generally between 2 - 5 μm.
Cutting edge blunting treatment is to slightly blunt the cutting edge of the punch. The blunting radius is generally between 0.01 - 0.03 mm. This can avoid the chipping of the cutting edge of the punch in the early stage of punching because it is too sharp, and also help to improve the stability during the punching process.
3. Surface Treatment Technology
In addition to the treatment of the cutting edge, other surfaces of the die also need appropriate surface treatment to prevent rust and improve the overall performance of the die. For example, chrome plating treatment is carried out on the surface of the die. The chrome plating layer can improve the hardness and finish of the die surface and has good anti-rust performance. The thickness of the chrome plating layer is generally between 0.02 - 0.05 mm.
For some trimming dies used in humid environments or environments with corrosive media, chemical nickel-phosphorus alloy plating and other surface treatment technologies can also be adopted. The plating layer formed by this technology has excellent corrosion resistance and wear resistance.
IV. Application Scenarios
1. Machinery Manufacturing Industry
In the manufacturing process of various mechanical equipment, square head bolts are commonly used connecting parts. For example, in machine tools, construction machinery, agricultural machinery and other equipment, a large number of square head bolts are used to connect various parts. The trimming die is used to produce these square head bolts, which can ensure the dimensional accuracy and quality of the bolts and meet the assembly requirements of mechanical equipment.
2. Automobile Manufacturing Industry
Square head bolts are also widely used in the assembly of automobile engines, chassis, bodies and other components. The automobile industry has very high requirements for the quality and precision of bolts. The trimming die can produce square head bolts that meet the standards of the automobile industry and ensure the safety and reliability of automobiles during driving.
3. Construction Industry
In the connection of building steel structures, square head bolts are sometimes used to replace ordinary bolts to meet specific connection strength and aesthetic requirements. The square head bolts produced by the trimming die can be applied to the manufacturing of building steel structures, such as the connection of bridges, high-rise buildings and other steel structures.
V. Precautions for Use
1. Die Installation
When installing the trimming die on the press, make sure that the installation surface of the die is clean and flat to prevent foreign matters from affecting the installation accuracy of the die. Operate according to the installation manuals of the press and the die, and use appropriate bolts and locating pins to fix the die on the press.
Check whether the slide stroke, closing height and other parameters of the press match the die to avoid damage to the die or failure to work normally due to parameter mismatch.
2. Operation Process
Before the punching operation, preheat the die, especially in winter or when restarting after a long shutdown. The preheating temperature is generally between 150 - 200 °C, and the preheating time depends on the size and material of the die, generally 30 - 60 minutes. Preheating can reduce the thermal stress of the die in the early stage of punching and prevent cracks in the die.
Control the punching speed and pressure of the press to avoid damage to the die caused by too fast speed or too high pressure. Adjust the punching parameters reasonably according to the material and size of the square head bolt. Generally speaking, the punching speed should not exceed 50 - 80 times/minute, and the punching pressure should be within the rated pressure range of the die.
3. Die Maintenance
Regularly clean the die to remove waste materials, oil stains and other impurities generated during the punching process. Tools such as compressed air and brushes can be used for cleaning to keep the die clean.
Check the wear of key components such as punches, die cavities, guide pillars and guide bushes of the die. When it is found that the wear exceeds a certain limit (for example, when the wear of the cutting edge of the punch exceeds 0.1 - 0.2 mm), repair or replace them in time.
Regularly lubricate the die. Use appropriate lubricants to lubricate the moving parts of the die (such as guide pillars, guide bushes, sliders, etc.) to reduce friction and extend the service life of the die. Generally, lubrication operation is carried out every 8 - 12 working hours.
