What aspects determine the quality of advanced manufacturing technology for stamping toolings and injection molds?
The application of advanced mold manufacturing technology has changed the traditional molding technology that the mold quality depends on human factors and is difficult to control, making the mold quality dependent on physical and chemical factors, the overall level is easy to control, and the mold reproduction ability is strong.
1- High Speed Milling
Ordinary milling uses low feed speed and large cutting parameters, while high-speed milling uses high feed speed and small cutting parameters. Compared with ordinary milling, high-speed milling has the following characteristics:
(1)High-efficiency High-speed milling spindle speed is generally 15000r/min ~ 40000r/min, up to 100000r/min. When cutting steel, its cutting speed is about 400m/min, which is 5 to 10 times higher than that of traditional milling; when machining mold cavity, its efficiency is compared with that of traditional machining methods (traditional milling, EDM, etc.). Increase 4 to 5 times.
(2)High precision The machining accuracy of high-speed milling is generally 10 μm, and some are even higher.
(3)High surface quality Because the temperature rise of the workpiece is small (about 3°C) during high-speed milling, there is no metamorphic layer and micro-cracks on the surface, and the thermal deformation is also small. The best surface roughness Ra is less than 1μm, which reduces the workload of subsequent grinding and polishing.
(4)It can process high-hard materials. It can mill 50-54HRC steel, and the maximum hardness of milling can reach 60HRC.
In view of the above advantages of high-speed machining, high-speed machining is being widely used in mold manufacturing, and gradually replaces part of grinding and electrical machining.
2- EDM milling
EDM milling (also known as EDM) is a major development in EDM technology, a new technology that replaces the traditional machining of mold cavities with forming electrodes. Like CNC milling, EDM uses high-speed rotating rod electrodes to contour the workpiece in 2D or 3D without the need to manufacture complex, expensive shaped electrodes. The EDSCAN8E EDM machine tool launched by Japan's Mitsubishi Corporation is equipped with an electrode loss automatic compensation system, a CAD/CAM integrated system, an online automatic measurement system and a dynamic simulation system, which reflects the level of today's EDM machine tools.
3-Slow wire cutting technology
The development level of CNC wire cutting technology has been quite high, the function is quite complete, and the degree of automation has reached the level of unattended operation. The maximum cutting speed has reached 300mm2/min, the machining accuracy can reach ±1.5μm, and the machining surface roughness Ra0.1～0.2μm. The development of wire cutting technology with a diameter of 0.03~0.1mm can realize the one-time cutting of the concave and convex die, and can perform the cutting process of 0.04mm narrow groove and 0.02mm radius inner fillet. The taper cutting technology has been able to carry out precision machining with a taper of more than 30°.
4-Grinding and polishing technology
Grinding and polishing are widely used in precision mold processing due to their high precision, good surface quality, and low surface roughness values. Precision mold manufacturing widely uses advanced equipment and technologies such as CNC forming grinders, CNC optical curve grinders, CNC continuous trajectory coordinate grinders and automatic polishing machines.
5-CNC measurement
The complex product structure will inevitably lead to the complex shape of the mold parts. Traditional geometric detection methods have been unable to adapt to the production of molds. Modern mold manufacturing has widely used three-coordinate numerical control measuring machines to measure the geometric quantities of mold parts, and great progress has been made in the detection methods of mold processing. In addition to measuring the data of complex curved surfaces with high precision, the three-coordinate numerical control measuring machine has good temperature compensation device, reliable anti-vibration protection ability, strict dust removal measures and simple operation steps, which makes on-site automatic detection possible.
The difference between single die, continuous die and compound die in stamping die
Stamping dies can be divided into simple stamping dies,continuous stamping dies, and composite stamping dies according to the degree of process combination, but composite dies are relatively rare in the industry, so what is the difference between single punching dies, continuous dies and composite dies of stamping dies?
1-A simple stamping die is an open die
Single punch means that only one process of punching or blanking is completed in one punch. Simple stamping dies can be divided into:
(1) The unguided single-process model is simple in structure, light in weight, small in size, easy to manufacture and low in cost. However, the use and installation of the die is troublesome, the die life is low, the precision of the stamping parts is poor, and the operation is not safe. Simple die without guide is suitable for stamping parts with low precision requirements and simple shapes.
(2) The guide plate type simple stamping die has high die precision, long service life, installation frame and safe operation, but the manufacturing is more complicated. Generally, it is suitable for workpieces with simple shape and small size.
(3) The guide column type simple stamping die is accurate and reliable, which can ensure the uniform punching gap, the stamped workpiece has high precision, the die has a long service life, and it is easy to install and use on the punching machine, so the guide column type stamping die is the most suitable The widest variety of die, suitable for mass production.
2- Continuous stamping die
Definition of Progressive Die Press: According to a certain sequence of procedures, punching is completed at different positions of the die, also known as progressive die or skip die. The positioning principle of the Metal Stamping Tooling can be divided into: the positioning principle of the guide pin and the principle of the side blade spacing. Due to the large number of Metal Stamping Die stations, it is necessary to solve the problem of accurate positioning of the strip or strip material to punch parts with a Progressive Stamping. It is possible to ensure the quality of stamping parts.
3-Composite stamping die
The definition of composite stamping die: a stamping die that simultaneously completes the upper process of the inner hole and the outer shape at the same station of the Stamping Die Manufacturing. According to the structure, the composite stamping die can be divided into: a positive-loading composite die and a flip-chip composite die. The characteristics are: the production efficiency is doubled; the quality of the Sheet Metal Stamping Dies is improved; the mold manufacturing precision is high.
Summary of Custom Metal Stamping Dies:
The single-die structure is simple, the cost of a single die is low, the processing cycle is short, and the adjustment is convenient. It is used for products with complex product structure and small production output. The composite die has a compact structure and high one-time molding accuracy. It is suitable for relatively simple product structures. However, for products with high precision requirements, the Progressive Metal Stamping structure is complex, the production efficiency is high, and the cost is relatively high, Progressive Die Stamping is suitable for products with large output.
Contact Information:
Mr.Terry Young (Sales Manager)
Apollo Electronic Components (Xiamen) Co.,Ltd
Xiamen Apollo Stamping Welding Technology Co., Ltd
Add:225#,Jinshang Road,Huli District,Xiamen City,Fujian Province,China,361009
Tel&Fax: 0592-5765084, Mob/WhatsApp/WeChat: 0086-13859903038 ,QQ: 1260358661
Email: yfd@china-electronic-components.com
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