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With the widespread application of metal accessories, products made by continuous stamping dies can well establish low-cost, high-efficiency automated stamping production lines. Continuous stamping dies require precision and complex components, and the issues that need to be paid attention to during design are more sophisticated.
1 When punching more holes, the length of the small punch should not be too large
For multi-punch stamping dies, punches of different heights can be made according to the size of the punches to form a stepped style, which can avoid the maximum punching pressure of each punch being generated at the same time and can effectively reduce the punching pressure of the die and reduce the load of the punch press. For stepped punches, in order to ensure that the punches have sufficient strength, the small punches should be made shorter and the large ones longer, with a height difference of the sheet thickness between the two, so that the large holes are punched first and the small holes are punched later during stamping.
2. Try to add stoppers, side blades, and other step positioning devices to the continuous die.
When punching workpieces with a continuous die, the problem of accurate positioning of the strip must be solved to ensure that the step of the continuous die is consistent, so that qualified parts can be punched out. In the continuous die, the commonly used positioning devices include fixed stopper pins, guide pins, guide plates, side blades, and other forms. When punching, use the fixed stopper pins for preliminary positioning, and use the guide pins installed in the mold to ensure the correct positioning of the strip when blanking. The side blade is used to control the distance of each step of the strip feeding. The length of the side blade should be equal to the step length plus 0.05-0.5mm, which is determined by the thickness of the material.
3 The guide pin (guide needle) of the continuous die should not be too long
In order to control the feeding step, the continuous die must have a better positioning device. Common positioning devices include guide pins, initial stop pins, side blades, guide pins, etc. Among them, the guide pin is a widely used precision positioning method in the continuous die. In high-precision continuous stamping dies, it is common to pre-punch holes, and then use guide pins to guide the feeding in each step. At this time, the diameter of the guide pin used is usually ∮1.2~6mm. It must be noted that the length of the guide pin cannot be too large, and the length entering the guide hole cannot be too large, otherwise, it will cause poor feeding of the mold, material carrying, etc. For this reason, the straight length of the guide pin of the continuous stamping die should be: the thickness of the guide pin fixed template + 1 material thickness.
4 It is not suitable to use urethane rubber or polyurethane rubber as demolding material components in automatic punching dies such as continuous dies
For high-efficiency production dies such as continuous dies, their lifespan is often more than 500,000 to 5 million strokes, and the punching speed is more than 40 times/min. In order to ensure the reliable and normal operation of the continuous die and reduce maintenance, a long-life spring should generally be used as a discharge component.
5. Complex or slender shapes in continuous stamping dies should not be punched out at one time. Complex and slender shapes in continuous dies should not be punched out at one time. If the process allows, they should be split into several punches and stamped in steps. This will make the die hole easier to process and extend its service life, facilitate the repair of the die, and improve production efficiency.
6. Design reserved empty steps to facilitate debugging and mold modification
When designing continuous deep drawing parts or products with unstable forming dimensions, the design of empty stations cannot be ignored. For such molds, when designing the layout drawing, one or two empty stations are often left after the first deep drawing and forming, leaving some room so that appropriate changes and adjustments can be made after the mold trial. Leaving an empty station between the shaping step and the final blanking step is convenient for the installation of the die and the stripper plate, and improves the strength of the die.
7 Anti-chip jumping design
The continuous die is a process of continuous stamping of a product. Especially when there are many punching holes and cutting edges, in order to avoid product crushing and the stability of the die during the stamping process, an anti-chip jumping structure is usually required. The punch is made into a special shape to increase the adhesion of the waste on the blade; the punch has a blowing hole; the blade is made into a V-shaped or dovetail clamping form; the blanking gap is reasonably placed to reduce chip jumping; there is a waste suction device in the mold.
8 The carrier of the continuous die cannot be deformed
The workpieces of each process in the continuous die are transferred by the overlapped surplus material of the strip material. The workpiece is generally separated from the strip material in the final blanking process. Since the continuous die has high requirements for step accuracy, in order to ensure the dimensional accuracy of the step and improve the stability of the continuous die, the carrier cannot be deformed. Therefore, the design of the carrier is an important aspect of the continuous die design. In order to ensure that the carrier has sufficient strength and rigidity, it is often adopted to appropriately increase the overlap size; when the strength of the single-sided carrier is insufficient, a double-sided carrier and an intermediate carrier can be designed; a process cut is punched out between the carrier and the workpiece to separate the carrier and the workpiece, and the deformation of the workpiece will not affect the deformation of the carrier.
9 Quick-release parts and parts fool-proofing
In the design of continuous molds, quick-release parts/standard parts fool-proofing is particularly important. Because the purpose of rapid mold repair is to achieve, the entire mold is rarely removed from the machine when the continuous mold is repaired. Instead, the parts and templates that need to be repaired are removed separately when the machine is stopped, so a quick-release structure needs to be designed.
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