Stamping Dies to Achieve Automation of Several Directions

The level of mold technology is an important symbol to measure the level of a country’s manufacturing industry, with the further development of China’s industry requires the mold industry to be large, precise, efficient and multi-functional direction, one of the important ways is to combine the mold with automation, this paper combines the experience in the field of cold stamping dies and automation technology, and discusses the development direction of stamping dies together.

Cold stamping die development status

The key to the development of stamping dies is die manufacturing technology, die materials and die talents. The development of mold technology is a key factor in the development of mold industry, and its development goal is to adapt to the requirements of short delivery time, high precision, good quality and low price of mold products, and one of the important directions is to vigorously develop mold automation. Stamping die-related automation development combines traditional die and optical electromechanical technology; the multi-process automation module is integrated into the die through electrical control to achieve full continuous die production to save a lot of machines and workforce, to achieve maximum efficiency, process optimization, and maximum benefit.

Advantages of stamping automation production

The stamping process is installing a die on a punching machine to deform, cut off, bend and shape the material by punching pressure when the plate material is passed between the dies.

The stamping process has an extremely wide application in the market because of its good interchangeability, material saving, thin wall, lightweight, rigidity, high surface quality and complex shape parts that are difficult to manufacture by other processing methods. Still, at present, the majority of stamping dies are produced manually way, which greatly restricts their development.

The problematic points of manual stamping processing are.

1.stamping processing is heavy physical work with a certain degree of danger, making it difficult for stamping enterprises to recruit workers.

2.Manual stamping requires a large working space and a large stock of semi-finished products. New stamping and die technologies are not introduced in time, resulting in low efficiency and high costs in actual production.

3.Manual stamping causes safety injury accidents due to equipment failure or personal factors, and automatic stamping production line largely makes up for the above deficiencies. With the advent of a small number of diverse electronic products, coupled with the influence of factors such as difficulty in recruiting and expensive labour, the development of automation in the field of cold stamping is an inevitable requirement.

Examples of stamping automatic production technology development

In-die riveting stud technology

(1) Traditional riveting stud technology: The studs are manually put into the product using continuous die feeding and then riveted by the workstation die. This production method requires more machines and a workforce, with high labour intensity and low efficiency.

(2) Innovative in-mold riveting stud technology: This technology uses a vibrating disc, and straight vibration to orderly arrange the studs into the front end of the dividing rod. The upper die-inserting knife drives the divining rod to guide 1PCS studs at a time, and the studs, after being divided, are sent to the riveting point inside the mold via the track under the action of gas and enter the state to be riveted. During the riveting process, the clamping slide clamps the stud first to precisely locate the stud. During the downward movement of the die, the riveting floating punch moves downward, the fork knife drives the side slider to both sides, and the clamping slide separates. After the floating punch is in place, the upper die continues to move downward, and the riveting punch drives the studs to finish riveting, realizing full continuous die production.

Riveting stud structure diagram

In-die servo tapping technology

(1)Conventional tapping technology: The product is tapped by continuous die feed and manually put into the table tapping machine. This production method requires more machines and a workforce, with high labour intensity and low efficiency.

(2) Innovative servo in-mold tapping technology: This technology adopts servo motor drive, high-precision gear drive, and universal joints to connect the gear shaft and tooth bar shaft. The lower die adopts a movable stripper structure, and the upper die presses the material first and then taps. The tooth bar is designed with a quick-change clamping mechanism, which can replace the tap quickly. The tapping module is compact and can be integrated into the lower die, making it quick and easy to disassemble and repair. Universal joint structure, tapping axis position can be adjusted at will, strong versatility. Up to 20PCS can be tapped simultaneously in the die, and the production capacity can reach 2000PCS/hour, which can realize full continuous die production.

Servo tapping structure diagram

In-mold riveting, adhesive integration technology

(1) Traditional riveting and glueing technology: The material is placed in the continuous die, and the studs are manually placed in the workstation die for riveting and then glued by hand. This production method requires more machines and a workforce, with high labour intensity and low efficiency.

(2) Innovative in-mold riveting and glueing integration technology: This technology firstly integrates the in-mold riveting stud module into the continuous mold, and the glueing module contains the feeding mechanism, peeling mechanism, glueing mechanism, laminating mechanism, receiving mechanism and electrical control. The whole die set is independent and quick to dismantle, which is convenient for maintenance. The loading mechanism is placed at the front of the mold, which is convenient for changing the material rolls. The power adopts servo control, stable and reliable operation. The laminating machine is designed with one die and three cavities, matching the capacity of the die to achieve full continuous production, with a capacity of up to 1800PCS/hour.

Integrated module structure diagram

Multi-material belt riveting technology

(1) Traditional multi-product riveting technology: Multi-product riveting usually starts with a few sets of molds to produce single pieces of products. Then, the products are combined manually and riveted with a workstation die. This production method requires more machines and a workforce, with high labour intensity and low efficiency.

(2) Innovative multi-material belt riveting technology: This technology integrates multiple products in one set of molds and is designed for parallel feeding and vertical feeding according to the product riveting method. The press does parallel feeding with its feeding machine. In contrast, vertical feeding is done by two sets of miniature pneumatic feeding mechanisms, with feeding mechanism 1 pulling the material at the front end and feeding mechanism 2 achieving precise feeding. The riveting product is sent to the riveting position by the material belt or conveying mechanism, and the upper die moves down to the riveting position. Finally, the product is cut off and discharged. This technology enables the production of multi-products in a continuous mode with a 2000 PCS/hour capacity.

Multi-belt riveting structure diagram

After years of practical exploration, the automatic production of stamping has achieved promising results and brought considerable economic benefits through product introduction; the industry is the foundation of a nation and a strong nation. And as the mother of industry, the importance of the status of the mold can be imagined. At present, the state vigorously implements to promote the upgrading of manufacturing development, mold in the direction of automation is the road to transformation, to mold on the wings of wisdom will significantly enhance the enterprise to enhance the core competitiveness in the industry.

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