Longsheng

Parts de automóviles y Componentes electrónicos . By optimizing mold design or adjusting pressure parameters, La eficiencia de producción se puede mejorar, los desechos de material se pueden reducir y la necesidad de se puede satisfacer la producción en masa .

¿Cómo elegir moldes de estampado de metal?

Cortes básicos para la selección de muelles de estampas metálicas Cortes básicos para la selección de la selección de estampas de metales < 1. rendimiento de materiales de moho

El material del estampador de metal afecta directamente la vida útil y la precisión de mecanizado de Stamper. carbide (steater) (stein) Adecuado para estampar materiales de alta dureza y aceros para herramientas (por ejemplo, CR12MOV) es adecuado para metales medianos a baja resistencia. " Ductilidad del metal procesado.

2. requisitos de proceso de estampado

El tipo de proceso de estampado de metal (como estampado, estiramiento, el bendición de la estructura de moho. ">"> ">" Moldens complejo requerir múltiples complejos que requiera que los moldes progresivos requieren que los moldes seguren de manera progresiva. Moldes, mientras que las piezas simples se pueden seleccionar de un solo proceso de moldes.

3. Bacches de producción y saldos de costos

Los moldes de alto costo y larga vida (como los moldes de carburo cementado) están preferidos para la producción en masa, mientras que los moldes de acero de herramientas con mejor valor por dinero están disponibles para .

3d escanear moldeos , para garantizar la rápida itereración de la itition y la itition de la rápida. Mantenimiento.

factores de consideración moho de aleación dura Molde de acero de herramientas molde de material de polímero materiales aplicables metales de alta enduría, como acero inoxidable y aleaciones de titanio. metales de resistencia baja a media, como aluminio y cobre. hoja de aluminio delgada, paneles compuestos de plástico. ciclo de vida (número de ciclos de estampado) 1,000,000+tiempos. 500,000-800,000 veces. dentro de 100,000 veces. costo alto (altos costos de material y procesamiento). Medium Low precisión de procesamiento ± 0.005 mm ( para componentes de precisión ). ± 0.01 mm ± 0.1 mm escenarios aplicables componentes del motor automotriz , conectores de precisión. conchas de electrodomésticos , disipador de calor. adornos pequeños, muestras temporales.

Elija sugerencias

• Requisitos de alta precisión: La prioridad debe darse a moldes de aleación dura, combinada con Tecnología de maquinamiento de cinco eje para garantizar la precisión detallada.
• Proyecto sensible a los costos: Balance de rendimiento y presupuesto de moldes de acero de herramientas, adecuado para una producción pequeña y mediana.
• verificación rápida: Los moldes de material de polímero pueden usarse para pruebas de prototipo , acortando el ciclo de desarrollo.

¿Cómo organizar la secuencia del proceso de estampado de metal?

"El proceso de estampado de metal es razonable. de partes.

• Propósito: láminas de metal de separación para obtener en blanco o contorno inicial.
• Operaciones: la compatibilidad se controla a ± 0.1 mm Uso de sello metálico de corte (e.g.t.dating dreing o puñetazos) para cortar el material.
• Puntos clave: la brecha entre los moldes debe coincidir con el grosor del material (por ejemplo, la brecha entre las placas de aluminio de 0.5 mm es equivalente a aproximadamente 8% de espesor).

Bending

• Objetivo: formar una curvatura específica o ángulo de curvatura a través de la formación de ángulo de la marca metálica.
• adoptar el moho de v-groove Para ajustar la carrera de golpe para evitar el rebote (si el acero inoxidable debe preinstalarse una compensación de 0.5 ° de grado).

• tasa de utilización del material: agujeros de golpe y bordes de corte para reducir la generación de residuos.
• Control de deformación: estirarse antes de doblar para evitar el rebote que afecta la precisión.
• Vida útil del moho: en las etapas posteriores de la producción de moho, se planea un proceso de desgaste de alto desgaste (como estiramiento profundo) para reducir el costo de desgaste del molde.

¿Cuáles son los efectos de la dureza del material en el estampado de metal?

Main Effect of Material Hardness on metal stamping

1.Mould wear rate

• High-hardness stamping metal (such as stainless steel and titanium alloys) accelerate mold wear, resulting in increased surface roughness (Ra value 0.5-1.0 μm).
• Alloy molds (such as tungsten steel) or surface coating techniques (such as TiN coating) are needed to extend service life.

2.Adjustment of stamping process parameters

• Harder materials require greater punching force (increasing the tonnage of the press by 20% to 30%) and lower punching speed to minimize the impact loss of the die.
• Low hardness materials (such as aluminum foil) is easy to wrinkle, need to adjust the edge pressure to increase the use of lubricating oil.

3.Quality of finished products and tolerance control

• When the hardness of stamping metal is greater than HRC 45, the tensile forming limit decreases decreases, cracks are easy to appear, and progressive stamping and additional annealing processes required.
• Low hardness materials suffer poor stability (±0.1mm fluctuation) and additional finishing processes are required to correct deformation.

4.Material Applicability Limitations

• Too much hardness (such as quenched steel) may cause mold blade breakage, so choose a composite mold structure (such as block mold).
• Ultra-low hardness materials (such as pure aluminum) require anti-adhesion treatment (such as nitrogenation of mold surfaces).

Comparison of stamping process of Different Hardness materials

• Material with high hardness: Priority should be given to alloy molds with slow stamping equipment (velocity ≤50spm) and annealing and softening should be added.
• Low hardness material: Optimize mold clearance (reduce by 5%-10%) and use polyurethane shock absorber to reduce rebound.
• General recommendation: Predicting process risk through material hardness testing (such as Rockwell hardness tester) and test pressure if necessary.

How to reduce the cost of metal stamping?

1.Improving accuracy and reducing waste

High-precision equipment and technology:

• Adopt ±0.005mm ultra precision machining technology (JS core technology) to reduce the scrap rate caused by size deviation and reduce secondary processing cost.
• The CAD/CAM system simulates stamping process, optimizes mold design and parameter setting in advance, and avoids material waste in actual production.

Automated production and intelligent detection: Automatic stamping equipment is combined with real-time quality control system to reduce manual intervention errors and improve yield rates.

2.Material management and selection strategy

Adaptability of a variety of materials: Use JS's metal material database of metal materials (such as stainless steel, aluminum alloy, copper alloy, etc.) to select the most cost-effective materials based on product performance and avoid overdesign.

Residual material recycling and nesting technology: Maximize board utilization (15%-20% increase in JS's material utilization rate) through intelligent typesetting algorithms, reduce corner material waste, and support the recycling of materials such as aluminum and steel.

3.Process efficiency and rapid response

Standardized and modular design: Provides a standardized metal punch library (connectors, casings, etc.) to shorten design lead times, and supports customers to customize quickly to existing templates to reduce development costs.

Agile production mode: Commit to 1-2 weeks of standard delivery time (including complex orders) and reduce additional costs for emergency orders through lean production management and priority scheduling.

4.Collaborative design and process collaboration

Early intervention in client design: The JS team provides pre-design review services to optimize the structural strength, tolerance fit, and assembly feasibility of metal punch to avoid additional costs associated with later modifications.

Mold sharing and lifecycle management: Provide long term maintenance and optimization services for high frequency order molds, extend the lifespan of molds (the average life of JS molds is 30% longer than industry standard), and dilute unit cost of individual products.

5.Sustainable production reduces costs and improves efficiency

Green manufacturing certification: Energy energy consumption has been reduced (JS energy consumption has been reduced by 15%) through the implementation of the ISO 14001 environmental management system and the introduction of energy-efficient stamping equipment and renewable lubricants.

Reduce process and logistics costs: Provide Design stamping surface processing one-stop service (JS integration capability covers the entire chain), eliminating intermediate costs.

How does JS company ensure the accuracy of metal stamping?

Cutting-edge equipment and precision machining technology

1.Ultra precision stamping equipment

• Equipped with a Germany/ Japan imported high-precision servo stamping machines with repeat positioning accuracy ±0.002mm and support tolerance ±0.005mm.
• Adopt ball screws, straight line guide rail and so on transmission systems, reduce mechanical error, guarantee the stability of shape and position tolerances of hardware punch.

2.Mold design and manufacture

• CAD integration software is used to simulate stamping process, optimize mold structure (such as convex die clearance, guidance accuracy), and reduce burrs and deformation risk.
• The mold material is made of SKD11. After heat treatment, the hardness reaches HRC60 or above, and the service life can reach millions of stamping cycles, ensuring consistency of mass production.

Intelligent process control systems

1.Real-time quality monitoring

• Integrated optical measurement system and automation equipment, real-time measurement of punch size, flatness, hole accuracy, automatic clearance of non-conforming products.
• Through statistical process control Analyze production data, dynamic adjustment of stamping parameters (pressure, speed, temperature) to prevent batch deviations.

2.Adjustment of material properties

Match the best material grade (e.g. Al6061) and thickness (0.1-5mm) to the application of metal punch (e.g. automotive sheet metal and electronic components) to avoid rebound or cracking due to insufficient material ductility.

Full-process quality management system

1.ISO 9001 and IATF 16949 certification

• Strictly in accordance with industry standards for auto parts, 100% of tests are performed from the time the raw materials are stored to the time the finished product is out of storage, with measurement accuracy of key dimensions reaching μ level (0.001mm).
• Provide production parts approval process documentation, including size reports, material certifications and performance testing data to ensure customer verification safety.

2.Reverse engineering and rapid feedback

For accuracy of customer feedback, the failure analysis is carried out using coordinate measuring machine, and the improvement scheme is provided within 48 hours to shorten the debugging cycle.

Resumen

Metal stamping is the core technology of modern industry, which can effectively transform metal sheets into high-precision metallic stamps. Process flow includes design optimization, material adaptation, mold manufacturing, stamping production and reprocessing, each step requiring strict tolerance and deformation control. The hardness of the material directly influences the wear and tear of the die, the selection of process adjustment parameters and the quality of the finished product.

With ultra-precision its ultra precision stamping equipment mold technology full process quality management system JS Company ensures that metal stamping tolerance is controlled to ±0.005mm and material utilization is increased to over 92%. At the same time, it reduces energy consumption and waste through sustainable manufacturing practices. Providing efficient, reliable and cost-effective solutions for manufacturing highlights the irreplaceable role of metal stamping in precision manufacturing.

descargo de responsabilidad

El contenido de esta página es solo para fines informativos. js series No hay representaciones o garantías de ningún tipo, expreso o implícito, se hacen en cuanto a la trampa, la integridad o la validez de la información. No se debe inferir que los parámetros de rendimiento, tolerancias geométricas, características de diseño específicas, calidad y tipo de material o mano de obra que el proveedor o fabricante de terceros proporcionará a través de la red Jusheng. Esta es la responsabilidad del comprador solicite una cotización para piezas para determinar los requisitos específicos para estas partes. Póngase en contacto con nosotros.

JS Team

JS es una empresa líder de la industria Enfoque en soluciones de fabricación personalizadas. Con más de 20 años de experiencia atendiendo a más de 5,000 clientes, nos centramos en la alta precisión CNC Meckining , Semátil href = "https://jsrpm.com/3d-printing"> 3d Impresión , moldura de inyección ,
Nuestra fábrica está equipada con más de 100 centros de mecanizado de 5 ejes de última generación y está certificada ISO 9001: 2015. Proporcionamos soluciones de fabricación rápidas, eficientes y de alta calidad a los clientes en más de 150 países de todo el mundo. Ya sea que se trate de una producción de bajo volumen o personalización masiva, podemos satisfacer sus necesidades con la entrega más rápida dentro de las 24 horas. Elija js tecnología Significa elegir eficiencia, calidad y profesionalismo.
Para aprender más, visite nuestro sitio web: jsrpm.com

Preguntas frecuentes

1.What tools are needed for metal stamping?

Includes high-precision die, press, tool, lubricant, clamping devices, quality inspection equipment, etc. Mould ensures accuracy of shape, press provides punch pressure, tool completes cutting, lubricant reduces friction, fixture fixed plate, test equipment ensures consistency of dimensions.

2.What materials are suitable for stamping?

Common materials include stainless steel, aluminum, copper, steel plates, etc. Thickness (0.1-5mm) and strength shall be selected according to the purpose of the product, taking into account ductility, corrosion resistance and cost requirements.

3.Do stamped parts need additional processing?

Stamped parts usually require burr removal, polishing, or surface treatment to improve appearance, rust resistance, or functional compatibility. Treatment depends on the product's purpose, for example, electronic components require high-precision polishing and automotive parts often require anticorrosive coatings.

4.What are the consequences of stamping metal too fast?

High speed stamping may cause material tearing or mold impact damage due to inertia. Normally, stainless steel stamping speed is controlled at 50-80 times perminute, while aluminum can be ramped up to 120 times perminute, depending on the malleability of the material.

recursos

Metalworking

Stamping press

Progressive stamping