1, Raw material preparation
The first step in the stamping process is the preparation of raw materials. This includes material preparation and cutting. The raw materials are usually metal sheets, such as steel plates, aluminum plates, etc. When preparing materials, the required material specifications and quantities should be determined based on the product design drawings, and then cut to the size and shape suitable for stamping. Cutting can be done using equipment such as shearing machines or laser cutting machines to ensure the accuracy and surface quality of the material.
2, Heating of raw materials (if necessary)
In order to improve the cutting performance of metals, it is sometimes necessary to heat the blank. The heating temperature should be determined based on the specific properties of the material and the type of blank. However, the heating temperature should not be too high to avoid tempering brittleness, which may affect the mechanical properties of the material and the quality of the stamped parts.
3, Forming process
The forming process is the core of the stamping process, which involves plastic deformation of materials through molds to achieve various shapes and accuracies required by the drawings. Common forming processes include flanging, rounding, expanding, shrinking, punching, bulging, etc.
Flanging: Turning the inner hole of the stamped part outward to obtain a certain height of the side edge.
Curling: Curling the shape of a product into a circle, commonly used in manufacturing cylindrical parts.
Expansion: Expand the end or part of a tubular component outward to form a trumpet shape.
Shrinking: In contrast to expanding, reducing the end or a certain point of a tubular component inward.
Punching: Separate the material from the cutting edge using a punch to obtain the desired hole shape and size.
Embossing: Creating a protrusion on a flat material to meet usage requirements.
4, Punching process
The punching process is to punch holes or grooves of the desired shape on the sheet metal through a punching die. Punching is the general term for separation processes such as blocking, dropping, punching, punching, grooving, cutting, chiseling, edge cutting, tongue cutting, and cutting. These processes play a crucial role in the stamping process, ensuring the shape and dimensional accuracy of the product.
Dropping: Separating materials along a closed contour to obtain workpieces or process parts of the desired shape.
Edge trimming: Using a die to trim the edges of a molded part to achieve the desired diameter, height, or shape.
Tongue cutting: Separate the material along the open contour, but not completely. The partially separated material has the required orientation of the workpiece.
Cutting: Dividing the forming process into several parts, commonly used for manufacturing complex shaped parts.
5, Finishing process
The finishing process involves shaping, trimming, precision cutting, acid washing, and other treatments on stamped parts to improve the surface quality and dimensional accuracy of the product. This process is crucial for ensuring the final quality of the product.
Plastic surgery: By making small changes to the shape and size of the workpiece, the precision of the workpiece is ensured.
Trimming: Further trimming to remove excess burrs and burrs.
Precision cutting: Precise cutting of key parts of the product to ensure dimensional accuracy.
Acid washing: removes oxide scale and stains generated during the stamping process, improving the surface quality of the product.
6, Selection and Manufacturing of Molds
Mold is a key equipment in the stamping process, and its quality and performance directly affect the quality and production efficiency of the product. The selection of molds should be determined based on factors such as the shape, size, material, and production batch of the product. Common types of molds include engineering molds, composite molds, and progressive molds.
Engineering mold: Only one stamping process can be completed in one set of molds.
Composite mold: One stamping process in a set of molds can complete two or more different stamping processes.
Progressive die: feeding by material belt, arranging two or more processes in sequence, and feeding them in sequence with the stamping process to achieve qualified products.
The manufacturing of molds requires the use of high-precision machining equipment and processes, such as CNC milling machines, grinders, electrical discharge machining, etc. At the same time, in order to improve the service life and performance of the mold, it is necessary to carry out reasonable heat treatment processes, such as annealing, quenching and tempering, carburizing, high-frequency quenching, etc.
7, Stamping equipment
Stamping equipment is the executing mechanism of the stamping process, and its performance directly affects the production efficiency and quality of the product. Common stamping equipment includes ordinary punching machines and precision punching machines.
Ordinary punch press: suitable for producing large batches and simple shaped parts.
Precision punch press: suitable for producing parts with small batch sizes, complex shapes, and high precision requirements.
Stamping equipment should have sufficient rigidity and accuracy to ensure stability and accuracy during the stamping process. At the same time, suitable feeding devices and control systems need to be equipped to achieve automated production.
8, Application of Stamping Technology
Stamping technology is widely used in the automotive industry, and almost all metal parts used in the automotive manufacturing industry are manufactured using stamping technology. The body frame, doors, trunk lid, body beam, and bogie on the car are all manufactured from thick steel plates through a series of stamping and forming processes. In addition, many auxiliary parts on cars, such as ventilation ducts, fenders, backrests, etc., are also manufactured using stamping technology.
In addition to the automotive industry, stamping technology is also widely used in fields such as electronics, aerospace, and medical equipment. With the development of new materials and technologies, the application scope of stamping technology is constantly expanding.
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