Troubleshooting of mold design points and production
1 For stamping production, single-position mold structure is single, low production efficiency, and sheet metal parts cannot be too complex, otherwise multiple single-piece mold molds can be realized. These disadvantages can be changed if stamping is made by graded molding. The characteristics of grade molding are high production efficiency, short production cycle, and less operators, which is very suitable for mass production.
2 Mold design points and troubleshooting - level nodes design
2.1 Expands and Coordination of Products
After reading the product map, you must first develop, and the size of the product is generally obtained by the empirical formula, and some are calculated by software. No matter which method is used, it should be ensured that the calculation result is within the allowable range. Because once the size is discharged wrong, the last product is unqualified, and it will be troublesome again. Therefore, the results of the deployment calculation should be verified to ensure that the expansion size is accurate.
The process of designing the dramatic diagram is to determine the process of the mold structure, such as the stamps are determined, then the basic structure of the mold is determined. Therefore, in the design of the slime design, you must be detailed from the overall situation, you cannot be limited to local structure, but also pay more attention to details. For example, when allocating each step, not only which station is buzzled, which station bends, which station is formed, but also how each insert should be arranged, the arrangement is not enough. There is no interaction between each insert. For the punching, it should mainly consider how the punching is distributed uniform and uniform, and it is possible to ensure that complex punching should be appropriate. For stations such as bending and shaping, it should be considered whether it can be formed once, if not grasping, add a step formation or air step to facilitate mold adjustment. For products that are easy to form a warpage in high or forming of flatness, the leveling level should be increased to ensure a flatness.
At the order of the workload, you should pay attention to the upper and back on the upper and rear, otherwise it should be adjusted. For example, when the Z-shaped bending is performed, if the zigzag is bent, the punching is a strict tolerance requirement, then the Z-shaped bend should be performed first, then wear, so it guarantees punching. Location.
The final upper in the grade mold is an important station. Because it involves how the product is removed from the mold. The general outbound manner mainly includes blowing and falling, and some special products also require robotic pickup. Regardless of the way, it is necessary to cut off. The size and location of the cut-off is carefully considered, but they not only affect the discharge of the mold, but also affect whether the strip can be stable and smooth. If the ship is used, the burrs in the cutting direction is opposite to other locations, which is to be determined after discussing the product designer.
When designing the row, under the premise of ensuring the smooth delivery and stability production, it should minimize the cost of material width and steps to reduce the cost of sheet metal parts.
2.2 insert design
(1) punching the punching.
The shape of the punching is determined by the shape of the product, which can use a straight-up structure. The main methods are: hanging table fixed, pin fixing, screw fixation. The block is fixed, and the top wire is fixed. This is the safest and reliable, the pin is fixed, and the other three types of fixed methods are mainly quick to replace when repairing. Can be freely selected as needed.
The concave die cutting can be cut directly on the concave mode, but for a large product having a large amount of hardness, the concave mode insert should be designed to facilitate maintenance. The fixing method of the concave mode insert is: the mount fixed, the screw is fixed, and the block is fixed.
When designing a single-side twezy die insert, in order to prevent the waste of the waste, the squeezing tip should be increased, and the scrap is extruded, and the waste is not allowed to float.
(2) Bend insert.
Bending inserts can be fixed with a hanging table or secured by screws. The gap between the recess should be a thickness. The bending convex mold head should be designed as an arc R angle to avoid rubbing the product when bending. For the bending recess of the self-fulminated bending, it should be designed to create a corrected rib to produce plastic deformation at the root of the product, reduce the return, and ensure the 90 ° curved angle.
2.3 template design
Standard level input mold templates include: unloading plates, fixed plates, concave templates, upper molding, and lower die.
Unloading, fixed plates, concave templates are critical 3 templates, which are essential. The fixing plate functions as a fixed convex mode; the unloading plate mainly disengages 3 effects, orients with three effects; the concave mode can serve both both the concave die edge, and can be set on the concave pattern. The 3-piece template is guided by four small guide columns, and 4 small guide columns are fixed on the convex mode fixing plate, and 4 small guide columns are respectively arranged on the discharge plate and the concave template, precisely control the small guide post and The fitting precision between the small guide is to ensure the motion accuracy of the convex mode.
The design of the grade molding is also important, which is to design the design, generally bending or forming, etc., all subsequent stations such as bending, and is fully allowed, not only to consider static letters, but also Considering whether the dynamic needs to be bittened.
2.4 Other Parts Design
In grades, some auxiliary parts also play an important role in the smooth work of the mold.
Guide nail. In the grade molding, the guideline has a great influence on the accuracy of the product. It is generally rushed to 2 holes in the first station, and the subsequent station uses these two holes to carry out two holes, which can guarantee the product. Accuracy. When designing guidelines, you should pay attention to the length of the control guide. When the mold is guided in the free state, the length of the straight arm portion extends out of the unloading plate is less than the product, which can effectively avoid the belt. Phenomenon.
When it is determined, when designing is high, it should ensure that the stripe is in this height, and it is not hindered by the 块 or the rod. Floating feed nails can not only raise strips, but also the guidance effects. Its quantity and location should be determined accordingly based on the width and thickness of the bar.
The pickup block and the rod. When the strip is bent, cut the door, the stretching is formed, and the pouch is generated to block the stripping portion on the insert, which is not easy to demold. In order to ensure that the bargains are smoothly populated, the lifting block or the rod should be designed in place, relying on the top of the spring force. At the last station, the cut-off product is sometimes adhered to the mold due to the action of punching oil, so the lower mold should be designed to prevent a stack and damage the mold.
In addition, in order to prevent the improvators and waste on the scavenging injury molding, it can be designed to be designed to be alarming device on the measuring material and waste.
3 Mold design main points and troubleshooting - troubleshooting in production
In the production of grade molding, some faults sometimes occur, affecting the production, and the solutions to some common faults are described below.
3.1 Product burrs increase
When the mold is produced for a while, the increasing phenomenon of production parts will occur. At this time, the convex, concave die cut, if the blade is worn or produced, the blade is wrinkled, and the blade is rearward or concave. The corresponding thickness of the mold pad. When the concave mold is sharpened, it should be checked whether the straight wall of the blade has been grinded. If there is no bladed straight wall, if the concave pattern is no, the concave die cut is no wear, and the burr is unevenness on the part because the punching gap produces an offset, at this time, gap adjustment.
In stamping production, the waste float is a big problem, but it not only affects production, but even damages the mold. In general, the rule-shaped waste such as circular or square is prone to floating, while the shape of shaped waste is less than the upper floating.
Here are the causes and solutions of some waste.
The punching clearance is large. If the waste is floating frequently, the punching gap is too large. The dielectric die should be re-made and the punching gap should be reduced. If only the waste is occasionally generated, the roughness can be increased in the concave die cavity.
The surface of the convex mold is too smooth, and the waste is attached to the convex mold under atmospheric pressure, and the air hole can be increased on the convex mold.
Single-side punching generating waste floats, increasing the sharp-angled scrap in the unfair side.
The stamping speed should be considered to reduce the speed. If the production needs cannot be lowered, the rod can be increased on the convex mode, and the waste is turned on.
In addition, there are some artificial factors. If there is no sufficient demagnetization after the Edge Tang, there are too many punching oils when the god pressure is produced, and these should be avoided as much as possible.
3.3 stack phenomenon
In stamping production. After the last station completes the cut, the production part is provided in a timely blown mold, still left on the mold, and it is easy to produce a stack. The stack is very dangerous and it is easy to damage the mold. There are many factors that produce a laminate, and the wind is not enough, the adhesion of the fuel oil is hooked on the top rod. For these factors, a variety of measures can be taken to prevent the appearance of stacking. For example, in the stamping production to ensure that the wind is large enough, the top rod is added on the concave mode plate and the unloading plate when the mold is designed, wherein the rod on the concave template should be designed, at least more than the holes on the part. Big, or simply use the beam block structure to avoid the production of parts hooks on the top rod. When designing the concave mode, under the premise of ensuring the intensity of the punch, a wider slope should be designed at the end of the concave template so that the parts can smooth out the mold smoothly. In addition, in the design, it should be considered to extend the bullous parts to be cut to be cut to be cut or extended to the ramp, and try to rely on the self-weight of the production part.
3.4 leakage hole clogging
In stamping production, if there is a flood binder clogging and is not found in time, it is easy to damage the mold, resulting in a flushing and concave mobilization. To prevent leakage pores from clogging, ensure smooth leakage. Be sure to fine the size of the leakage hole. For some small high-out part, the size of the leakage bore is properly enlarged; and the leakage hole caused by the waste rolls, the leakage hole size is reduced. Take the mold design. The leakage hole should be given, and the concave mode pad is designed to be referred to when the concave mode plate is designed to ensure that the leakage profile of the concave mount plate is large, and the formwork is mainly used in the design of the concave mode pad. Reference. Push it in this class. Finally, to ensure that the installation board leakage hole is small, otherwise, the slope is to be opened on the mounting plate to ensure the final slide machine leakage bore of the waste.
In addition, excessive posts of the concave die cutting dam or punching oil will also cause leakage holes to block or reduce the replacement of fuel oil.
3.5 is not smooth
The feeding is not smooth, affecting production, and damage the mold. There are the following aspects:
If there is a difference in the step from the design and the design of the design, it should be adjusted to the feed step.
The pitch of the lifting staple is too large, and the number of lifting nails should be increased.
The high level is insufficient, and the strip is easy to hook on the lifting block or the top rod, and the strip should be increased.
The delivery gap is too small, and the strip is not smooth, and the gap should be properly enlarged.
The bargain is too wide, and it is easy to generate the backbone, and the lifting block should be increased in the middle of the strip.
The mold design is the source. Although the design only accounts for about 10% of the mold cost, it has determined 70% -80% of the entire mold cost, so the designer must consider the mold structure in design, consider increasing productivity, how to convenient Maintain. However, it is not fully dependent on the design, and the specific problems in actual production and the body analysis are also necessary according to the actual situation. It is also important to repair and maintenance in the production of molds. During the mold repair. It should pay more attention to details, find a fundamental reason, lead its maintenance. When the mold is disassembled, carefully carefully to prevent damage to the injury. Regular maintenance, maintenance can greatly improve the life of the mold.