The mold repair program is free for you
1. Punch should be used before using
1. Clean the punch with a clean rag.
2. Check if the surface has scratches or dents. If yes, remove with oilstone.
3, timely oil rust.
4. When installing the punch, be careful not to have any tilt. Use a soft material tool such as a nylon hammer to gently knock it, and tighten the bolt only after the punch is properly positioned.
2. Die installation and debugging
Installation and adjustment of the punch must be especially careful. Because the die is especially large and medium-sized die, not only is the manufacturing cost high, but also the weight is too large and small to move, and the personal safety should always be placed first. The die of the infinite position device shall be provided with a pad of wood between the upper and lower molds. After the punching table is cleaned, the mold to be tested in the mold clamping state is placed in a suitable position on the table top.
The stroke of the press slider selected according to the process document and die design requirements is adjusted to the bottom dead point in front of the die plate and is 10~15mm larger than the die closing height. The slider link is adjusted and the die is moved to ensure the pair of die handles. Quasi-die shank hole and reach proper die height. Generally, the punching die is fixed to the lower die first (without tightening) and then the upper die is tightened (tightened). The T-bolts on the presser plate are preferably tightened with a suitable torque wrench (lower die) to ensure consistent and ideal pre-clamping for the same bolt. force. It can effectively prevent the manual tightening thread from being deformed due to physical force, gender, and touch error caused by excessive or small pre-tightening force and the same thread pre-tightening force, which causes misalignment of the upper and lower molds, gap change, and peeling edge during punching. Faults such as mouths occur.
Before the mold test, the mold is fully lubricated and the normal production materials are prepared. After the empty stroke is started, the mold is started 3 to 5 times to confirm that the mold operation is normal and then the test is performed. Adjust and control the depth of penetration of the punch into the die, check and verify the performance and operational flexibility of the die guide, feeding, unloading, side pressure, and snapping mechanisms and devices, and then make appropriate adjustments to achieve the optimal state of the technology. Three, five, and ten trials were carried out on large, medium, and small sized dies for the initial inspection of the shutdown, and 10, 15, and 30 retries were tested for retesting. After the line inspection, punching surface and burr inspection, all dimensions and shape accuracy are in line with the requirements of the drawings in order to be delivered.
3. Punching burrs
1, mold gap is too large or uneven, re-adjust the mold gap.
2, mold material and improper heat treatment, resulting in concave mold inverted cone or edge is not sharp, should be a reasonable selection, mold work part of the material with carbide, heat treatment is reasonable.
3, stamping wear, grinding punch or inserts.
4. The punch enters the die too deep and adjusts the depth of the punch into the die.
5, the guide structure is not precise or improper operation, inspection guide guide bushing guide and punch press precision, standard press operation.
4. Jump waste
Large mold gap, short punch, material effect (hard, brittle), high stamping speed, adhesion of stamping oil or adhesion caused by oil droplets too quickly, stamping vibration produces chip divergence, vacuum adsorption and core Insufficient demagnetization can cause debris to be carried onto the die surface.
1, the sharpness of the edge. The larger the radius of the edge, the more likely it is to cause a rebound of the scrap. For the relatively thin material such as stainless steel, an inclined edge can be used.
2. For more regular scrap, increase the complexity of the scrap or add a urethane rod on the punch to prevent skipping. Add scratches on the die edge side.
3, whether the mold gap is reasonable. Unreasonable mold gaps can easily cause the waste to rebound. For small-diameter holes, the clearance is reduced by 10%, the diameter is greater than 50.00 mm, and the gap is enlarged.
4, increase the depth of the mold. When the stamping of each station die, the requirement of the modulus is certain, and the entering modulus is small, which may cause the waste to rebound.
5. Whether the surface of the processed material is oily.
6, adjust the stamping speed, stamping oil concentration.
7, using vacuum adsorption.
8, the punch, inserts, materials demagnetization.
5. Crushing, scratching
1, the material or mold with oil, waste debris, resulting in pressure injury, need to wipe the oil and install automatic air gun to remove waste.
2, the mold surface is not smooth, should improve the mold surface finish.
3, the surface hardness of parts is not enough, the surface needs to be chrome-plated, carburized, boronized and other treatment.
4, the material strain and instability, reduce lubrication, increase the compressive stress, adjust the spring force.
5. When the product is scraped into the mold or other places causing scratches during operation, the position of the mold needs to be modified or reduced, and the education operator can take care when carrying out the work.
6. The outer surface of the workpiece after bending
1, the raw material surface is not smooth, clean, school plain material.
2, forming a block into the waste, remove the debris into the block. .
3, the forming block is not smooth, the forming block is plated and polished to improve the roughness of the convex and concave molds.
4. The radius of curvature R of the punch is too small to increase the bending radius of the punch.
5, mold bending gap is too small, adjust the upper and lower mold bending fit clearance.
6, the addition of roller molding forming die block.
7. Leakage hole
In the case of leakage punching, there are generally no punch breaks, missing punches, punch subsidences, etc. after mold repair. After the mold is repaired, the first part is confirmed and compared with the sample to check for any omissions. As the head sinks, the hardness of the upper die pad should be improved.
8. The material is not normal
1. When the stripper plate and the punch die are over-tightened, the stripper plate is tilted, the height of the height screw is not uniform, or other parts of the stripper are not properly installed, the stripper should be trimmed. The stripper screw is combined with the sleeve and the hexagon socket screw. form.
2. The clearance of the die is too small. The punch needs a large releasing force when it is separated from the material, causing the punch to be bitten by the material, and the gap of the lower die needs to be increased.
3, the die has inverted cone, trim die.
4. The die blanking hole is not aligned with the lower die set drain hole, and the drain hole is trimmed.
5, check the status of processing materials. Dirty material adheres to the mold, so that the punch is bitten by the material and cannot be processed. After the warped and deformed material is punched, the punch is clamped and the warped and deformed material is found. The warped and deformed material needs to be flattened and then processed.
6. Punching of the punch and lower die must be sharpened in time. The sharp cutting edge tool can produce a beautiful cut surface. If the cutting edge is blunt, additional punching pressure is required, and the workpiece has a rough section and a great resistance, resulting in the punch being bitten by the material.
7, the use of oblique edge punch.
8. Minimize wear, improve lubrication conditions, lubricate plates and punches.
9, spring or rubber elastic enough or fatigue loss, replace the spring.
10. The gap between the guide post and the guide bush is too large. Repair or replace the guide post bushing.
â—Ž Accumulation of parallelism error, re-grinding assembly.
â—Ž, the hole in the push block is not vertical, so that the small punch deviation, repair or replace the push piece.
â—Ž, punch or guide post installation is not vertical, re-assembled to ensure the verticality.
9. The bending edge is not straight and the dimensions are not stable
1. Increase the pressure or pre-bending process
2. The material pressing force is not enough to increase the pressing force
3. Asymmetry of convex and concave die wear or uneven bending force. Adjust the gap between convex and concave die to make it uniform and polish the convex die corners.
4 height size can not be less than the minimum limit size
10. Curved surface extrusion material becomes thinner
1. The die radius is too small, increase the corner radius of the die
2. The clearance between convex and concave die is too small to correct the gap between convex and concave dies.
11. The bottom of the concave is uneven
1. The material itself is not even, need to level the material
2. The contact area between the top plate and the material is small or the top material force is not enough. The top material device needs to be adjusted to increase the top material force.
3. No die feeding device in the die, should increase the top feeder device or correction
4. Add plastic surgery
12. Stainless steel flange deformation
Applying a good quality forming lubricant to the material prior to making the burring allows the material to better separate from the mold and smoothly move on the surface of the lower mold during forming. This gives the material a better chance to distribute the stresses that are created when it is bent and stretched, preventing the deformation that occurs on the edges of the formed flanging hole and the wear on the bottom of the flanging hole.
13. Material distortion
Punching a large number of holes in the material results in poor flatness of the material, which may be due to cumulative stamping stress. When a hole is punched, the material around the hole is pulled downward, so that the tensile stress on the upper surface of the plate increases, and the undershoot motion also causes the compressive stress on the lower surface of the plate to increase. For a small number of holes, the result is not obvious, but as the number of punches increases, the tensile and compressive stresses increase exponentially until the material is deformed.
One way to eliminate this distortion is to punch every other hole and return to punching the remaining holes. Although this produces the same stress on the sheet, it collapses as a tensile stress/compression stress build-up occurs due to punching one after the other in the same direction. This also allows the first batch to share the deformation effect of the second batch of holes.
14. Serious wear of mold
1. Replace worn mold guide components and punches in time.
2, check whether the mold gap is not reasonable (small), increase the gap between the lower mold.
3. Minimize wear, improve lubrication conditions, lubricate plates and punches. The amount of oil and the number of injections depend on the conditions of the material being processed. Cold-rolled steel plates, corrosion-resistant steel plates and other non-rust materials should be filled with oil. The injection points are guide bushes, oil injection ports, and lower molds. Light oil for oil. In the case of rusted materials, the rust fine powder will inhale between the punch and the guide sleeve during processing, causing dirt, so that the punch cannot slide freely in the guide sleeve. In this case, if oiled, it will make the rust more likely to be stained. Therefore, when rushing this kind of material, on the contrary, the oil must be wiped clean and decomposed once a month. The dirt from the punch and the lower mold should be removed with steam (chai) oil and wiped clean before reassembly. This will ensure that the mold has good lubrication properties.
4. Inappropriate sharpening methods cause annealing of the mold and exacerbate wear. Soft abrasive wheels should be used. Small amount of knife should be used. A sufficient amount of coolant should be used to clean the grinding wheel.
15. Preventing punching noise
Punch is the most critical necessary equipment for the sheet metal processing industry. The punch press produces mechanical transmission noise, stamping noise and aerodynamic noise. The maximum value of this noise is 125dB (A), which greatly exceeds the national standard requirements of 85dB (A) and the following noise index requirements. And the surrounding environment (such as offices, residential areas, conference rooms, etc.) caused extremely serious injuries and pollution. Effectively managing this noise has become an urgent problem to be solved. In particular, the implementation of China’s first “Noise Law†has led to an increase in the scale of environmental protection industrialization, which has accelerated the urgency of this noise control.
Starting from the noise source and die structure of the punch press, the following points must be noted to reduce the noise:
1, pay attention to mold maintenance, cleaning, and keep sharp edges.
2. The shape, quantity, material and punching line length of the die edge, the contact surface between the die edge and the part should not be too big, and the punch should be made with oblique edge step punching, so that the depth of the die cutting in different positions is different, and the whole process realizes real The cut off, not the simultaneous squeeze.
3, the mold edge must be perpendicular to the mounting surface, and the convex and concave die edge clearance should be reasonable, when the difficulty of unloading can increase the gap between the lower mold, increase the discharge force, the use of soft surface stripper plate and other methods.
4, the matching accuracy between the various working templates, processing some exhaust slots.
5. The baffle plate was changed into small pieces, and the stripper plate and the lower plate were replaced by inserts to reduce the slamming area.
6. The source of the stripper plate dome is changed to a T-type ejector pin. The spring is mounted on the upper mold holder. The contour sleeve and the ejector pin are used. In the open state, the stripper plate still has a certain amount of free movement.
7, to maintain good lubrication, mold without interference, smooth.
8, the upper and lower mold seat surface cushion aluminum cushion to do the impact buffer.
9. After the mold is debugged, install acoustic enclosures or sponge plates on the punching bed for soundproofing.
10. Improve the precision of punch press and reduce the structural noise. A buffered, shock-absorbing and noise-reducing cylinder is installed on the workbench. The gears are provided with helical gears to enhance lubrication and gear covers. A muffler is installed in the pneumatic system.
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