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I. Materials
Customized stamping dies are made of various high-quality materials to meet the specific needs of different customers. The main die base materials are high-strength alloy tool steels, such as D2 steel or Cr12MoV steel. These steel materials possess excellent hardness, wear resistance, and fatigue resistance, ensuring that the stamping dies can maintain stable shape and dimensional accuracy during long-term and high-intensity stamping operations. To further enhance the performance of the stamping dies, hard alloy materials, such as tungsten-cobalt hard alloys (YG series) or tungsten-titanium-cobalt hard alloys (YT series), are used in key parts like punch heads and die cutting edges. Hard alloys have extremely high hardness and wear resistance, which significantly extend the service life of the stamping dies and also ensure the edge quality of the stamped products, making them smoother and flatter and reducing the need for subsequent processing procedures.
II. Manufacturing Processes
1. Design Stage
Advanced computer-aided design (CAD) software is used to conduct three-dimensional modeling design of the stamping dies according to the product drawings provided by customers and detailed stamping process requirements. During the design process, factors such as the shape of the product, dimensional accuracy, material thickness, and deformation laws during the stamping process are fully considered to optimize the structure of the stamping dies. Through simulating the stamping process, the stress distribution and deformation of the dies under stress are analyzed, and potential design defects are identified in advance for targeted improvements.
Computer-aided manufacturing (CAM) technology is adopted to directly convert the designed die model into numerical control machining codes, providing accurate instructions for subsequent high-precision machining.
2. Machining and Manufacturing Stage
High-precision numerical control machining equipment, such as five-axis linkage machining centers, CNC electrical discharge machines, and CNC wire-cutting machines, is used to perform fine machining on die components according to the machining codes generated by CAM. During the machining process, machining parameters such as cutting speed, feed rate, and cutting depth are strictly controlled to ensure the dimensional accuracy and surface quality of the components. For die components with complex shapes, multi-axis linkage machining technology is employed, which can complete the machining of multiple surfaces at one time, avoiding errors caused by multiple clamping and significantly improving machining accuracy and efficiency.
After the die components are machined, strict quality inspections are carried out. High-precision inspection equipment such as coordinate measuring machines and optical projectors is used to comprehensively inspect the dimensional accuracy, shape accuracy, and surface roughness of the components to ensure that each component meets the design requirements. Components that fail the inspection are adjusted or reworked in a timely manner.
3. Heat Treatment Process:
To improve the comprehensive performance of the dies, heat treatment is carried out on the machined die components. Based on different steel materials and performance requirements, scientific and reasonable heat treatment process plans, including quenching, tempering, and annealing procedures, are formulated. During the quenching process, the heating temperature, holding time, and quenching medium are precisely controlled to ensure that the die components obtain a uniform microstructure and high hardness. Tempering treatment is used to eliminate quenching internal stress and improve the toughness and stability of the dies. By optimizing the heat treatment process, the dies can maintain good toughness while having high hardness and wear resistance, effectively preventing fractures or deformations during use.
4. Assembly and Debugging:
Experienced die assembly workers assemble the dies according to the assembly drawings. During the assembly process, special assembly tools and measuring instruments are used to accurately position and install each component of the die, ensuring that the clearance between the punch head and the die is uniform and appropriate and that the opening and closing movements of the die are smooth. After assembly, strict debugging work is carried out. By trial stamping specimens of different thicknesses and materials, the stamping effect of the die and the quality of the products are observed, and the stamping parameters of the die, such as pressure, stroke, and speed, are adjusted and optimized until the stamped products fully meet the customer's quality standards and technical requirements.
III. Key and Difficult Points in the Machining Process
1. Accuracy Control:
Customized stamping dies have extremely high requirements for accuracy, especially in aspects such as the between the punch head and the die, the dimensional accuracy, and the shape accuracy of die components. For example, for some stamping dies for precision electronic components, the clearance between the punch head and the die needs to be controlled within ±0.005mm. During the machining process, factors such as machine tool accuracy, tool wear, and machining thermal deformation can easily lead to accuracy deviations. To overcome these problems, we use high-precision machining equipment and regularly maintain and calibrate the equipment; select high-quality tools and replace them in a timely manner according to the machining situation; adopt advanced cooling and lubrication technologies during the machining process to reduce machining thermal deformation; and increase the frequency of inspections during the machining process to detect and correct accuracy deviations in a timely manner.
2. Complex Structure Machining:
Some customized stamping dies have complex internal structures, such as deep holes, narrow slots, and special-shaped cavities, which are difficult to machine. For example, when machining deep holes, problems such as difficult chip removal, easy breakage of tools, and difficulty in ensuring the straightness and cylindricity of the holes are likely to occur. To address these issues, we use specialized deep hole machining equipment, such as gun drill machines, and equip them with high-pressure cooling systems to ensure smooth chip removal and tool cooling. When machining narrow slots, appropriate tool shapes and sizes are selected, and the slow wire-cutting process is adopted to accurately control the width and shape of the slots. For the machining of special-shaped cavities, multi-axis linkage machining centers are used, and the tool paths and cutting parameters are reasonably planned to achieve precise machining of complex shapes.
3. Material Heat Treatment Deformation Control:
Heat treatment is a key link in the manufacturing process of customized stamping dies, but it is prone to causing deformation of die components during the heat treatment process. Different steel materials and heat treatment processes have different impacts on deformation. To control heat treatment deformation, we conduct pre-machining on die components before heat treatment, reserve a certain amount of machining allowance for finishing correction after heat treatment; use appropriate heat treatment fixtures to effectively position and support die components and reduce deformation during heat treatment; and optimize heat treatment process parameters, such as adopting stepped quenching and isothermal quenching processes, to reduce heat treatment stress and thus control the amount of deformation.
IV. Application Scenarios
Customized stamping dies are widely used in numerous industrial fields. In the automotive manufacturing industry, they are used to stamp various parts of automobile bodies, such as engine hoods, doors, trunk lids, and body frames. The stamping processing of automotive parts requires stamping dies to have high precision, high reliability, and a long service life to meet the needs of large-scale and high-efficiency production. In the electronics and electrical appliance industry, stamping dies are used to produce precision parts such as mobile phone casings, computer motherboards, and electrical connectors. These parts have extremely high requirements for dimensional accuracy and surface quality, and customized stamping dies can ensure the consistency and high quality of the products. In the aerospace industry, stamping dies are used to manufacture key components such as aircraft wings, fuselage structural parts, and engine blades. Aerospace parts usually adopt high-strength and lightweight materials, such as aluminum alloys and titanium alloys, which impose higher requirements on the materials and processes of stamping dies. Customized stamping dies can meet these special requirements and ensure the performance and quality of the parts. In addition, customized stamping dies also play an important role in industries such as hardware products, medical devices, and machinery manufacturing, and are used to produce metal parts of various shapes and specifications.
V. Precautions During Use
1. Installation and Debugging:
Before installing the stamping die, it is necessary to ensure that the worktable surface of the punch press is clean, flat, free of debris and oil stains. Check whether the slide stroke, closing height, and other parameters of the punch press match the stamping die.
When installing the stamping die, the correct installation sequence should be followed, and appropriate installation tools should be used to ensure that the die is firmly installed and accurately positioned. After installation, preliminary debugging should be carried out to check whether the opening and closing movements of the die are smooth and whether there is interference between the punch head and the die.
During the debugging process, the stamping parameters of the punch press, such as pressure, stroke, and speed, should be adjusted step by step, starting from small values and gradually increasing. At the same time, the quality of the stamped products and the operation of the die should be observed. Based on the debugging results, the parameters of the punch press should be optimized and adjusted until the stamped products meet the quality requirements.
2. Operation Specifications:
Operators must undergo professional training, be familiar with the operation process and safety regulations of the stamping die, and those who have not received training are strictly prohibited from operating the die without permission.
During the stamping process, operators should strictly abide by the operation procedures and are strictly prohibited from putting their hands or other body parts into the working area of the die. Appropriate safety protection devices, such as safety light curtains and hand protection devices, should be used to ensure the personal safety of operators.
The stamping speed and frequency should be controlled to avoid excessive stamping speed that may lead to increased wear of the die or malfunctions. At the same time, attention should be paid to observing the operation of the die. If abnormal sounds, vibrations, or jamming phenomena are found, the stamping operation should be immediately stopped for inspection and repair.
3. Maintenance and Care:
Regular maintenance and care should be carried out on the stamping die to keep the die surface clean and promptly remove oil stains, iron filings, and other debris on the die surface. Special die cleaning agents and cleaning tools can be used for cleaning, and hard tools or materials with high hardness should be avoided to scrape the die surface to prevent damage to the die.
Check whether the components of the die are loose, worn, or deformed, especially key parts such as punch heads, dies, guide posts, and guide sleeves. For loose components, they should be tightened in a timely manner. For worn or deformed components, they should be repaired or replaced according to the degree of wear.
Regularly check and maintain the lubrication system of the stamping die to ensure that the die is well lubricated during the stamping process. According to the usage of the die, select appropriate lubricants and lubricate according to the specified lubrication cycle and method. Good lubrication can reduce the friction and wear between die components and extend the service life of the die.
Regularly conduct precision inspections on the stamping die using high-precision inspection equipment such as coordinate measuring machines to detect parameters such as the dimensional accuracy, shape accuracy, and fit clearance of the die. Based on the inspection results, timely adjustments and repairs should be made to ensure that the stamping accuracy of the die is always in good condition.
4. Storage and Preservation:
When the stamping die is not used for a long time, it should be properly stored and preserved. First, the die should be comprehensively cleaned and maintained, and anti-rust oil should be applied to prevent rusting.
The die should be stored in a dry and well-ventilated warehouse or storage area to avoid damage to the die caused by environmental factors such as humidity and corrosive gases. Special die storage racks or storage boxes can be used to classify and store the dies and mark and record them for easy search and management.
During storage, the dies should be regularly inspected to check whether there are problems such as rusting and deformation. If any problems are found, timely measures should be taken to deal with them to ensure that the dies remain in good condition during storage and can be put into use at any time.
I. Materials
Customized stamping dies are made of various high-quality materials to meet the specific needs of different customers. The main die base materials are high-strength alloy tool steels, such as D2 steel or Cr12MoV steel. These steel materials possess excellent hardness, wear resistance, and fatigue resistance, ensuring that the stamping dies can maintain stable shape and dimensional accuracy during long-term and high-intensity stamping operations. To further enhance the performance of the stamping dies, hard alloy materials, such as tungsten-cobalt hard alloys (YG series) or tungsten-titanium-cobalt hard alloys (YT series), are used in key parts like punch heads and die cutting edges. Hard alloys have extremely high hardness and wear resistance, which significantly extend the service life of the stamping dies and also ensure the edge quality of the stamped products, making them smoother and flatter and reducing the need for subsequent processing procedures.
II. Manufacturing Processes
1. Design Stage
Advanced computer-aided design (CAD) software is used to conduct three-dimensional modeling design of the stamping dies according to the product drawings provided by customers and detailed stamping process requirements. During the design process, factors such as the shape of the product, dimensional accuracy, material thickness, and deformation laws during the stamping process are fully considered to optimize the structure of the stamping dies. Through simulating the stamping process, the stress distribution and deformation of the dies under stress are analyzed, and potential design defects are identified in advance for targeted improvements.
Computer-aided manufacturing (CAM) technology is adopted to directly convert the designed die model into numerical control machining codes, providing accurate instructions for subsequent high-precision machining.
2. Machining and Manufacturing Stage
High-precision numerical control machining equipment, such as five-axis linkage machining centers, CNC electrical discharge machines, and CNC wire-cutting machines, is used to perform fine machining on die components according to the machining codes generated by CAM. During the machining process, machining parameters such as cutting speed, feed rate, and cutting depth are strictly controlled to ensure the dimensional accuracy and surface quality of the components. For die components with complex shapes, multi-axis linkage machining technology is employed, which can complete the machining of multiple surfaces at one time, avoiding errors caused by multiple clamping and significantly improving machining accuracy and efficiency.
After the die components are machined, strict quality inspections are carried out. High-precision inspection equipment such as coordinate measuring machines and optical projectors is used to comprehensively inspect the dimensional accuracy, shape accuracy, and surface roughness of the components to ensure that each component meets the design requirements. Components that fail the inspection are adjusted or reworked in a timely manner.
3. Heat Treatment Process:
To improve the comprehensive performance of the dies, heat treatment is carried out on the machined die components. Based on different steel materials and performance requirements, scientific and reasonable heat treatment process plans, including quenching, tempering, and annealing procedures, are formulated. During the quenching process, the heating temperature, holding time, and quenching medium are precisely controlled to ensure that the die components obtain a uniform microstructure and high hardness. Tempering treatment is used to eliminate quenching internal stress and improve the toughness and stability of the dies. By optimizing the heat treatment process, the dies can maintain good toughness while having high hardness and wear resistance, effectively preventing fractures or deformations during use.
4. Assembly and Debugging:
Experienced die assembly workers assemble the dies according to the assembly drawings. During the assembly process, special assembly tools and measuring instruments are used to accurately position and install each component of the die, ensuring that the clearance between the punch head and the die is uniform and appropriate and that the opening and closing movements of the die are smooth. After assembly, strict debugging work is carried out. By trial stamping specimens of different thicknesses and materials, the stamping effect of the die and the quality of the products are observed, and the stamping parameters of the die, such as pressure, stroke, and speed, are adjusted and optimized until the stamped products fully meet the customer's quality standards and technical requirements.
III. Key and Difficult Points in the Machining Process
1. Accuracy Control:
Customized stamping dies have extremely high requirements for accuracy, especially in aspects such as the between the punch head and the die, the dimensional accuracy, and the shape accuracy of die components. For example, for some stamping dies for precision electronic components, the clearance between the punch head and the die needs to be controlled within ±0.005mm. During the machining process, factors such as machine tool accuracy, tool wear, and machining thermal deformation can easily lead to accuracy deviations. To overcome these problems, we use high-precision machining equipment and regularly maintain and calibrate the equipment; select high-quality tools and replace them in a timely manner according to the machining situation; adopt advanced cooling and lubrication technologies during the machining process to reduce machining thermal deformation; and increase the frequency of inspections during the machining process to detect and correct accuracy deviations in a timely manner.
2. Complex Structure Machining:
Some customized stamping dies have complex internal structures, such as deep holes, narrow slots, and special-shaped cavities, which are difficult to machine. For example, when machining deep holes, problems such as difficult chip removal, easy breakage of tools, and difficulty in ensuring the straightness and cylindricity of the holes are likely to occur. To address these issues, we use specialized deep hole machining equipment, such as gun drill machines, and equip them with high-pressure cooling systems to ensure smooth chip removal and tool cooling. When machining narrow slots, appropriate tool shapes and sizes are selected, and the slow wire-cutting process is adopted to accurately control the width and shape of the slots. For the machining of special-shaped cavities, multi-axis linkage machining centers are used, and the tool paths and cutting parameters are reasonably planned to achieve precise machining of complex shapes.
3. Material Heat Treatment Deformation Control:
Heat treatment is a key link in the manufacturing process of customized stamping dies, but it is prone to causing deformation of die components during the heat treatment process. Different steel materials and heat treatment processes have different impacts on deformation. To control heat treatment deformation, we conduct pre-machining on die components before heat treatment, reserve a certain amount of machining allowance for finishing correction after heat treatment; use appropriate heat treatment fixtures to effectively position and support die components and reduce deformation during heat treatment; and optimize heat treatment process parameters, such as adopting stepped quenching and isothermal quenching processes, to reduce heat treatment stress and thus control the amount of deformation.
IV. Application Scenarios
Customized stamping dies are widely used in numerous industrial fields. In the automotive manufacturing industry, they are used to stamp various parts of automobile bodies, such as engine hoods, doors, trunk lids, and body frames. The stamping processing of automotive parts requires stamping dies to have high precision, high reliability, and a long service life to meet the needs of large-scale and high-efficiency production. In the electronics and electrical appliance industry, stamping dies are used to produce precision parts such as mobile phone casings, computer motherboards, and electrical connectors. These parts have extremely high requirements for dimensional accuracy and surface quality, and customized stamping dies can ensure the consistency and high quality of the products. In the aerospace industry, stamping dies are used to manufacture key components such as aircraft wings, fuselage structural parts, and engine blades. Aerospace parts usually adopt high-strength and lightweight materials, such as aluminum alloys and titanium alloys, which impose higher requirements on the materials and processes of stamping dies. Customized stamping dies can meet these special requirements and ensure the performance and quality of the parts. In addition, customized stamping dies also play an important role in industries such as hardware products, medical devices, and machinery manufacturing, and are used to produce metal parts of various shapes and specifications.
V. Precautions During Use
1. Installation and Debugging:
Before installing the stamping die, it is necessary to ensure that the worktable surface of the punch press is clean, flat, free of debris and oil stains. Check whether the slide stroke, closing height, and other parameters of the punch press match the stamping die.
When installing the stamping die, the correct installation sequence should be followed, and appropriate installation tools should be used to ensure that the die is firmly installed and accurately positioned. After installation, preliminary debugging should be carried out to check whether the opening and closing movements of the die are smooth and whether there is interference between the punch head and the die.
During the debugging process, the stamping parameters of the punch press, such as pressure, stroke, and speed, should be adjusted step by step, starting from small values and gradually increasing. At the same time, the quality of the stamped products and the operation of the die should be observed. Based on the debugging results, the parameters of the punch press should be optimized and adjusted until the stamped products meet the quality requirements.
2. Operation Specifications:
Operators must undergo professional training, be familiar with the operation process and safety regulations of the stamping die, and those who have not received training are strictly prohibited from operating the die without permission.
During the stamping process, operators should strictly abide by the operation procedures and are strictly prohibited from putting their hands or other body parts into the working area of the die. Appropriate safety protection devices, such as safety light curtains and hand protection devices, should be used to ensure the personal safety of operators.
The stamping speed and frequency should be controlled to avoid excessive stamping speed that may lead to increased wear of the die or malfunctions. At the same time, attention should be paid to observing the operation of the die. If abnormal sounds, vibrations, or jamming phenomena are found, the stamping operation should be immediately stopped for inspection and repair.
3. Maintenance and Care:
Regular maintenance and care should be carried out on the stamping die to keep the die surface clean and promptly remove oil stains, iron filings, and other debris on the die surface. Special die cleaning agents and cleaning tools can be used for cleaning, and hard tools or materials with high hardness should be avoided to scrape the die surface to prevent damage to the die.
Check whether the components of the die are loose, worn, or deformed, especially key parts such as punch heads, dies, guide posts, and guide sleeves. For loose components, they should be tightened in a timely manner. For worn or deformed components, they should be repaired or replaced according to the degree of wear.
Regularly check and maintain the lubrication system of the stamping die to ensure that the die is well lubricated during the stamping process. According to the usage of the die, select appropriate lubricants and lubricate according to the specified lubrication cycle and method. Good lubrication can reduce the friction and wear between die components and extend the service life of the die.
Regularly conduct precision inspections on the stamping die using high-precision inspection equipment such as coordinate measuring machines to detect parameters such as the dimensional accuracy, shape accuracy, and fit clearance of the die. Based on the inspection results, timely adjustments and repairs should be made to ensure that the stamping accuracy of the die is always in good condition.
4. Storage and Preservation:
When the stamping die is not used for a long time, it should be properly stored and preserved. First, the die should be comprehensively cleaned and maintained, and anti-rust oil should be applied to prevent rusting.
The die should be stored in a dry and well-ventilated warehouse or storage area to avoid damage to the die caused by environmental factors such as humidity and corrosive gases. Special die storage racks or storage boxes can be used to classify and store the dies and mark and record them for easy search and management.
During storage, the dies should be regularly inspected to check whether there are problems such as rusting and deformation. If any problems are found, timely measures should be taken to deal with them to ensure that the dies remain in good condition during storage and can be put into use at any time.
