Machining process flow: blank warehousing-blank processing-finishing-semi-finished product inspection-installation-finished product inspection-packaging-logistics aluminum extrusion hardware stamping, wire drawing, grinding, sandblasting, anodizing, screen printing, slotting, extrusion die design and manufacturing, and die nitriding.
The technological process of electroplating is as follows: ① cleaning metal objects; (2) soaking in dilute hydrochloric acid; ③ washing; (4) immerse in plating solution; ⑤ Adjust electroplating current; (6) taking out from the plating solution; ⑦ washing; 8. Boil deionized water; Pet-name ruby drying.
Stamping includes blanking, bending, stretching, forming, finishing and other processes. Stamping materials are mainly hot-rolled or cold-rolled (mainly cold-rolled) metal strips, such as carbon steel plates, alloy steel plates, spring steel plates, galvanized plates, tinned plates, stainless steel plates, copper and copper alloy plates, aluminum and aluminum alloy plates, etc.
Stamping process flow: coil approach-uncoiling-shearing and blanking-blanking/blanking (no profile skipping)-stretching/pressing/bending (generally in the first step of stamping process)-trimming/punching/shaping/flanging/hole turning/(generally in the subsequent stamping process). Renovation/leveling of the inner and outer edges-the above is a common process in stamping-followed by later-stage surface treatment, such as electroplating, bluing, shot blasting, polishing, spraying and some heat treatment.
Processing flow: blank warehousing-blank processing-finishing-semi-finished product inspection-installation-finished product inspection-packaging-logistics.
External processing process: raw material procurement = > qualified warehousing after inspection = > system issuing = > outsourcing factory picking, confirmed quantity = > processed into parts = > delivery = > qualified warehousing = > raw material quantity deducted to 1) ESI (early participation in early supplier evolution): This stage is mainly a technical discussion between customers and suppliers on product design and mold development, and the main purpose is to let suppliers clearly understand product designers.
2) Quotation: including mold price, mold life and mold delivery date.
3) Purchase orders: the issuance of customer orders and deposits and the acceptance of supplier orders.
4) Mold production plan and schedule: At this stage, the specific delivery date of the customer's mold needs to be replied.
5) Mold design: The possible design software includes Pro/Engineer, UG, Solidworks, AutoCAD, etc.
6) Purchasing materials
7) Machining: The processes involved include turning, gong (milling), heat treatment, grinding, computer gong (CNC), electric spark (EDM), wire cutting (WEDM), fixture grinding, laser lettering and polishing.
8) mold assembly
9) Trial operation of the mold
10) sample evaluation report (SER)
1 1) sample evaluation report (approved by SER) cutting: front mold material, back mold material, insert material, discharging material and inclined ejector material;
Mold opening frame: front mold frame and back mold frame;
Mold opening: mold cavity before mold opening, mold cavity after mold opening and mold parting line;
Copper male: front mold copper male, back mold copper male, and corner clearing copper male of parting line;
Wire cutting: insert parting line, copper pin and inclined top pillow;
Computer gong: fine gong parting line, fine gong back mold core;
EDM: the front die is thick, the copper needle and the needle and thread angle are clear, and the bone position and pillow position of the back die;
Drilling, pinhole, thimble;
Line position, line position voltage;
lean-to
Composite thimble with thimble;
Others: ① water pump, mold pit, garbage nail (limit nail); ② flight model; (3) nozzle, supporting head, spring and water;
Die-saving, polishing and bone position of anterior and posterior dies;
Fine water structure, pull rod screw hook, spring
Quenching and surface nitriding;
Molding and lettering. Drawing approval-material preparation-processing-mold base processing-mold core processing-electrode processing-mold parts processing-inspection-assembly-flying mold-mold trial production.
A: Mold base processing: 1 serial number, 2 A/B plates, 3 panels, 4 ejector pin fixing plates and 5 bottom plates.
B: Mold core machining: 1 flash, 2 rough grinding, 3 milling machine machining, 4 locksmith machining, 5CNC rough machining, 6 heat treatment, 7 fine grinding, 8CNC fine machining, 9 EDM, 10 die saving.
C: mold parts processing: 1 slider processing, 2 briquetting processing, 3 split cone sprue sleeve processing, and 4 insert processing.
Machining details of mould base
1, the number should be unified, and the mold core should also be numbered, which should be consistent with the number on the mold base and in the same direction, so that it is not easy to make mistakes when assembling.
2.A/B plate processing (that is, moving and fixed die set processing), A: A/B plate processing should ensure the parallelism and verticality of the die set of 0.02mm, B: Milling machine processing: screw holes, water holes, pin holes, machine nozzle holes, chamfering C: fitter processing: tapping and trimming burrs.
3. Panel processing: the milling machine processes the nozzle hole of the boring machine or the nozzle hole of the processing material.
4. Processing of the ejector pin fixing plate: milling machine processing: the ejector pin plate and the B plate are connected by a return pin, and the B plate faces upwards, and the ejector pin hole is drilled from top to bottom. The thimble countersunk head needs to turn over the thimble plate, correct it, roughen it with a drill, and then finish it with a milling cutter and chamfer it.
5. Bottom plate processing: milling machine processing: marking, correcting, drilling and chamfering.
(Note: If some molds need to be forced to push and pull, the strong push-pull mechanism should be strengthened, such as drilling screw holes on the ejector plate. )
Mould core processing details
1) rough machining of flash hexagon: machining on milling machine to ensure verticality and parallelism, with a grinding allowance of1.2 mm.
2) Rough grinding: for large-scale water mill processing, the large surface should be ground first, and the small surface should be clamped by the batch company to ensure the verticality and parallelism of 0.05mm, with a margin of 0.6-0.8mm on both sides.
3) Milling machine processing: firstly, correct the milling machine head to ensure that it is within 0.02mm, correct and compact the workpiece, first, process the screw hole, pin hole, threaded hole, needle insert countersunk head, chamfering machine nozzle or feed nozzle hole, then make the water delivery hole and mill the R angle.
4) Fitter machining: Knock, knock and code.
5) CNC rough machining
6) External heat treatment HRC48-52
7) fine grinding; Large-scale water mill processing is 0.04mm less than that of formwork, ensuring parallelism and verticality within 0.02 mm.
8) CNC finishing
9) EDM
10) Save the mold, ensure the smoothness and control the cavity size.
1 1) is processed into a gate, and the gate is vented. Generally, the zinc alloy gate is 0.3-0.5 mm, the vent is 0.06-0. 1.0 mm, and the aluminum alloy gate is 0.5- 1.2 mm, and the vent is 0. 1-0.2 mm.
Oil removal → rust removal →→→→→→→ purification → drying.
└ Alkaline zinc plating ┌ Immersion dehydration antirust oil
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Dry ...
Degreasing → derusting → blackening at room temperature → soaking in soap solution → soaking in spindle oil or engine oil.
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└ Soak sealing agent 1, polish parts → remove wax → hot dip degreasing → electrolytic degreasing → acid etching → electroless plating.
2. Non-polished parts → hot dip degreasing → electrolytic degreasing → acid etching → other electroplating dewaxing → hot dip degreasing → cathode electrolytic degreasing → acid leaching → alkaline bright copper → copper pyrophosphate (selective) → acidic bright copper → bright nickel → chromium plating (12) electric frame and dyeing process.
Pretreatment or electroplating → pure water washing (2-3 times) → pre-dipping → electric frame → recovery → pure water washing (2-3 times) → drying → finished metal core mold: degreasing → weak etching → preparation of separation layer (for multi-purpose core mold) → coating dense layer → coating dense layer → electroforming → machining → reinforcement → demoulding.
Non-metallic core mold: coated waterproof layer (used for materials with easy water absorption) → degreasing → plating conductive layer → electroforming of dense layer with coating → processing → reinforcement → demoulding → heat treatment (used for electroforming layer with large internal stress and need to improve plasticity). Pickling → water washing → pre-degreasing → degreasing → water washing → phosphating → water washing → ultrasonic cleaning → pure water cleaning → electrophoresis → spray cleaning → water washing → pure water cleaning → air drying → drying.