Single process design classification

1 blade design

Blade design classification:

A blanking-punching the material with a die, and the punched part is a punching sheet, and the size of the punching sheet is the same as that of the lower die.

B. Punching —— Punching the material with a die. The punched part is waste, and the aperture size is the same as that of the punch.

C, cutting stamping materials with a stamping die, wherein the stamping part comprises a stamping part and waste materials.

Notch-punch a notch in the blank. The cut portion is curved.

E trimming-cut off the edge of the workpiece.

B. Blade design type:

Ordinary blade (figure 1)

Suitable for blanking, punching, flash and so on. The size of the punched product is the same as that of the lower die, the punching size is the same as that of the punch, and the flash is similar to the punching.

B layered knife edge (Figure 2)

Suitable for high-speed mold or knife-edge tolerance mold.

Note: This blade should be equipped with a blade pressing device to prevent the blade from jumping up.

C Top-bottom knife edge (Figure 3)

Suitable for dies that need to ensure the flatness of stamping parts.

Note: This blade should be equipped with a blade pressing device to prevent the blade from jumping up.

D Single-edged blade (Figure 4)

Suitable for single-sided blanking die.

Note: In general, you should rely on a knife.

E upper and lower knife edges (Figure 5)

Suitable for compound mould.

F- continuous shearing machine with connecting blade (Figure 6)

The die suitable for punch that punching part of the continuous shear band comprise a continuous die and a compound die. (This method can also be used for circular drawing parts, provided that the side height is less than 5T. )

Note: both the upper die and the lower die need to have a material return device.

2 Molding design

1) Bend upward (Figure 1)

Precautions:

The lower die needs to be equipped with a floating block, which is laid flat on the lower molding insert, and the upper molding insert is installed on the stripper.

2) Bend downward (Figure 2)

Precautions:

Floating devices need to be installed around the lower die, and the upper molding insert is installed on the male splint.

3) Bending (Figure 3)

Note: Bend the upper die forming insert upward to install the stripper plate, and bend the upper die forming insert downward to install the male splint. Both the upper and lower dies need demoulding devices.

4. 1) Bending (Figure 4)

Note: Bend the upper die forming insert upward to install the stripper. Bend the upper die downward to form an insert and install the male splint. (This picture shows downward bending.)

4.2) Bending (Figure 5)

Note: Bend the upper die forming insert upward to install the stripper. Bend the upper die downward to form an insert and install the male splint. (This picture shows downward bending.)

4.3) Bending (Figure 6)

Note: Bend the upper die forming insert upward to install the stripper. Bend the upper die downward to form an insert and install the male splint. (This picture shows downward bending.)

5)V-bend

Suitable for single-punch forming dies, mostly used for large stamping parts such as chassis and machine plate. Note: The lower die angle is generally 2 degrees smaller than the product.

3. Line pressing design

1) purpose of line pressing

1. The pre-deformation of the material reduces the resistance in the bending process and makes the bending size more accurate.

2. Prevent deformation due to stretching when bending.

2) Position and size requirements of line pressing

1. The line pressing position should be selected between the inner and outer broken lines, at 1/2 of the compensation coefficient. As shown in figure (a)

2. The line pressing length should be less than 1mm or so, and adjusted to an integer. As shown in figure (a)

3. The cross-sectional shape of the line pressing insert is shown in Figure (b); Where 0.3 and 92 are constant dimensions.

4. Design of compression bar insert

1) The purpose of steel bar pressing

1. Reduce the springback during bending and make the bending dimension more accurate.

2. Reduce the tensile deformation during bending.

2) Size requirements of press bar insert

The sectional shape of the line pressing section is shown in the figure. The width of the rib pressing working part is 0.8~ 1.2. The height is 0.2~0.4. When the material thickness t is less than 0.8, the width of the compression bar is 0.8 mm; When the material thickness is 0.8 ≦ t < 1.2, the width of the pressing bar is1.0 mm ﹔; When the material thickness is T≧ 1.2, the width of the pressing rib is 1.2 mm (applicable to chassis molds).

5. Design of burr insert

1. Deburring action

When the product requires no burr on the cutting edge, burr pressing can remove the burr produced during stamping.

2. Classification and size requirements of stamping burr

Deburring can be divided into two ways: deburring the inner hole, as shown in Figure (a); The shape is pressed with burrs, as shown in Figure (b), and the specific dimensions are shown in Figures (a) and (b); When T≤ 1.0mm, the product shape deviates from the inside of the material by 0.4T, and when t >: when 1.0mm, the product shape deviates from the inside of the material by 0.5mm (that is, the shape of the insert). The insertion height is the template thickness plus 0.4 ~ 0.6 mm.

6 spring design

1). Selection principle:

1. The selection of spring length is generally guaranteed: the pre-shrinkage of the spring is generally 2~4mm when the mold is opened (in case of special circumstances, the compression value shall be determined as required); When the spring is compressed in the closed mode, it is less than or equal to the maximum compression amount (maximum compression amount LA= free length L of the spring * maximum compression ratio%).

2. The red spring is used for the outer stripper plate of the compound die, and the colored (brown) spring is used for the inner stripper plate.

3. Color recording or brown springs for stamping dies and forming dies

4. The movable locating pin generally adopts φ 8.0 ejector pin, φ 10.0 * φ 1.0 round spring and M 12.0* 1.5 stop screw.

5. The spring specification is preferred to φ 30.0; Other specifications (such as φ25.0, φ20.0, φ 18.0, etc.). ) in areas with small space, it should be considered.

2). Distribution principle:

1. When the springs are distributed, the distance from the center of the spring through hole to the edge of the template should be greater than the outer diameter d, and the distance from other through holes should be kept above 5mm in solid wall thickness.

2. The spring layout should first consider the stress key parts, and then consider the stress balance and stability of the whole die. The key parts of the stress are: the shape of the stripper plate and the periphery of the punch in the compound die; Around the punch of the stamping die; The bending edge of the molding die and the place where tooth extraction is formed.

3. Springs should also be evenly distributed around the inner guide post to ensure the normal movement of the mold.

3). Template processing hole:

1. The value of the spring hole on the template varies according to the outer diameter of the spring.

When the diameter is ≧ Φ 25.0, the via hole is single-sided 1.0mm, such as Φ 30.0 spring, and the via hole in the template is Φ 32.0.

When the diameter is less than φ25.0, one side of the through hole is 0.5mm larger, such as a spring with φ20.0, and the through hole in the template is φ2 1.0.

2. The position and size of the spring passing (sinking) hole need not be marked; Diameter dimensions are stated in the notes, accurate to one decimal place.

7 cutting and molding design

Job description:

1. After cutting, the cutting edge height is 1.0mm and the inclination is 1.5 degrees. The purpose is to reduce the contact surface between the punch and the notch, thus reducing the friction.

2. The bottom of the punching cut is 0.5~2mm straight, which is the edge of the punching cut. The bending height of the punch is 1.5T, which can ensure cutting first and then folding.

8. Type design of cutter.

Common forms of tool dependence

1. Single-sided punching depends on the cutting plane, and the cutting plate depends on the cutting surface, which is +0.0 1MM (thin material depends on the situation). The common forms are shown in the following figures (1) and (2), and the punching thickness is generally10 ~15 mm. (1) The height of the drawing tool is 5MM and the width is 3 ~ 5mm；; (2) The tool height in this drawing is 5 ~10 mm.

2. The gap between the forming punch and the forming edge bent on one side is the same material thickness, and the cutting plate on the cutting surface is+0.01mm.. See the figure below for common forms.

(3),(4),(5),(6) The thickness of the forming punch is generally10 ~15 mm. (3), (5) and (6) The width of the diagram is 3~5MM, (3) the height of the diagram is 5MM, and (4) the height of the diagram is 5. In (5) and (6), the tool height is H+ 1.5~2MM.

9 Da Salad Hole Design

The first method (the product has good appearance, high precision and good stability. But multi-engineering)

1. Classification of Salakong

Salad holes are generally divided into deep and shallow types according to the requirements of products. As shown in figure 1, when the product is riveted, the salad is formed by a light hole; As shown in Figure 2, salad is used for rivets and is formed by dark drawing. In the design process, according to the graphics, the salad shapes are distinguished and different molding methods are adopted.

The formation of salad holes is generally divided into three steps: the first step: bottoming holes; Step 2: punch a salad hole; Step 3: punch the salad hole. Because there are two forms of salad, there are special requirements for its molding process. According to this content, please refer to the following description.

Step 1: Make a bottom hole, as shown in Figure 3: Step 1: Make a bottom hole, with the punch diameter = d-0.4 mm

Step 2: punch a salad hole, as shown in Figure 4 and Figure 5:

Step 3: punch a salad hole, as shown in Figure 6 and Figure 7:

When drilling holes, the values of light drawing holes are different from those of dark drawing holes. (Inserts should be placed in the lower die first)

1. When the dark drawing hole is used to punch the salad hole, the blanking gap (one side) is fixed at 0.02 (punch diameter =D).

2. When pulling light holes and playing salad holes; The blanking gap (one side) is fixed at 0.02﹔ punch diameter = d.

The second method (saving engineering, the aperture size can be guaranteed. However, when the inclined plane is extruded, the punch is stressed heavily, and the upper pad is easy to sink)

1 When the project arrangement is tight, you can extrude the slope of the salad first, and then punch the salad hole.

The first step is to squeeze and beat the salad slope, as shown in Figures 8 and 9:

Step 2: punch the salad hole, as shown in figure 10 and figure 1 1.

When drilling holes, the values of light drawing holes are different from those of dark drawing holes. (Lower die parts should be used as inserts first)

3. When punching a through hole with a concealed drawing hole, the punching gap (one side) is fixed at 0.02﹔ punch diameter = d.

4. When pulling light holes and playing salad holes; The blanking gap (one side) is fixed at 0.02 ~ punch diameter =D 。

The third method (saving engineering. However, the extrusion inclined plane is easy to fluff, and the salad hole is not allowed)

1. When the project arrangement is tight, you can use pre-punched large holes (30% larger than the positive value drawn by the primary color holes) and then make a salad.

Step 1: Make a bottom hole, as shown in figure 12: punch diameter = (d+30% d) mm. 。

Step two, make a salad. As shown in figure 13 and figure 14.

Structural design of 10 slider

1) slider fixing form

Commonly used are as follows:

1. is suitable for small and medium-sized sliders and is limited by the vertical edge of the slider (as shown in figure 1).

2. It is suitable for the large slider processed in * * * mode, and the stopper is in the form of plug (as shown in Figure 2).

3. It is suitable for large and medium-sized sliders that need to be quickly assembled and disassembled, and is limited by the limit plate at the bottom of the slider (as shown in Figure 3).

4. It is suitable for situations where the slider needs to be reset before contacting the material. The slider is reset by the ejector pin in the slider. The ejector pin is usually 7 mm in length and 2.0mm higher than the end face, and the red sand flat wire spring is selected. (as shown in figure 4)

5. It is suitable for blocking that requires the middle vertical P to move up and down and the left and right sliders to move horizontally. The middle slider is guided by the inner guide post, and the left and right sliders are limited by the contour sleeve, and the length of the contour sleeve is the thickness of the splint plus 0.5 mm (as shown in Figure 5).

2) General structure and dimensions of the slider

1 The external angle between the large slider of the mating part and the template is usually r1.0%, and the internal angle is R0.8, as shown in Figure (9). The external angle between the small slider and the template is R0.5, and the internal angle is r0.3..

Figures (7) and (8) are common structural forms of sliders.

Figure (6) is suitable for the case that the size of the slider is too small to set the dovetail, or in the form of Figure (7)(8), when the dimensions of the template interfere in the direction of the slider W, the dimensions A, B, C and D in the figure are generally at least 3 mm

3 Fit clearance of slider (shaded part in the figure):

(1) When the material thickness is greater than or equal to 0.6, the unilateral amplification gap corresponding to the template is 0.03, and the slider does not put the gap.

(2) When the material thickness is less than 0.6, the unilateral amplification gap of the corresponding part of the template is 0.02, and the slider does not put the gap.

(3) When cutting large and medium-sized sliders, the designer only needs to draw the theoretical shape of the slider, and the step section and clearance of the slider are handled by the processing department. The clearance of the slider is generally 0.02.

4 when the inclination angle p of the slider is within 15 degrees, you can choose it at will; When it is greater than 15 degrees, only 30 degrees and 45 degrees can be selected, and the maximum inclination angle shall not exceed 45 degrees.

The slope of the slider is preferably 5? ﹐ 10? ﹐30? ﹐45? Several specifications

3) Matters needing attention in slider design

In general, the vertical motion stroke of the 1 slider should not exceed half of the slider thickness.

In order to ensure the reliable movement of the slider, an appropriate number of floating pins or springs should be set at the top of the slider.

3. The slider shall be machined into * * *, and the two sliders shall be machined by rotating 180 degrees around the center of the template. At this time, the designer does not need to rotate the pixels, and the adjustment is the responsibility of the processing department.

4 As shown in Figure (12), when there is a small slider in the middle of the template, if the inclination of the slider is less than or equal to 15 degrees, the guide groove can be directly cut on the template; If the inclination of the slider is greater than 15 degrees, the guide groove on the template should be changed into a block.

1 1 Folding block and roller design

1. function

Reduce bending edge damage

Reduce the wear of the folding block

2. Suitable for 90-degree bending

Step 3: manufacturing method

(1) roller

1. In general, the roller is φ 6.00, and in special cases, φ 4.00 can be selected.

2. If the roller is not allowed to be processed, drawing is not required.

(2) Folding block

1. The folding block is milled with a splint and fixed with a socket head cap screw (M 10).

2.H value is less than the thickness of the internal stripper. The internal grinding of 0. 1 on the upper part of the folding block is mainly to prevent the folding block from scratching the material.

3. The clearance between the folding block and the inner stripper plate is +0. 1 when there is an inner guide post, and 0.02 when there is no inner guide post.

4. Relationship table between specifications of folding block and thickness (x) and groove depth (s) of stripper:

(3) Detailed drawing of roller groove processing:

(4) In the bending die, when the bending height of the product is less than 5.0mm, or for other reasons, the product can be bent by rounding, and after the trial die is completed, hard chromium is plated at the R angle to ensure its strength. As shown in figure < a >

12 side positioning design

In the design of continuous die, in order to make the feeding accurate, pitch positioning is used to ensure the feeding step. Pitch positioning generally has two ways: tongue cutting and side positioning. Because the positioning size of the side is relatively stable, it is often used. The clearance between the side positioning and the punch is 0.0 1 mm ... Please refer to the standard "spacing positioning block" for the dimensions of the side positioning block. See (Figure 1) for details about the structure.

13 side positioning structure design

1. Suitable for positioning of side push forming (usually used for single punch forming)

2. Production method:

Floating positioning method is needed for external positioning during side push molding. The specific structure is shown in figure 1. Please select the fitting clearance of each component according to the standard clearance of each component. Please refer to the standard "inclined plane positioning block" for the size of the positioning block.

Design of 14 dual-purpose pin

Production method:

1. Select dual-purpose pin.

The choice of dual-purpose floating pin should consider not only the thickness of the material, but also the size of the die (the principle is to take the larger one first). Please refer to the standard "Dual-purpose Floating Pin" for specific dimensions.

2. Relevant dimensions of dual-purpose floating pin (as shown in the figure)

1. The abdication depth of the dual-purpose floating pin on the stripper plate directly affects the quality of the workpiece. For example, if the abdication is too deep or too shallow, the edge of the material will be crushed or even cut off. In order to reduce this phenomenon, according to the specifications of the standard dual-purpose pin, you can refer to the table in the figure to determine the unloading depth of the stripper.

2. When the mold is opened, if the floating height of the dual-purpose floating pin exceeds the guiding length of the inner guide pillar when the mold is opened, when the guide pillar leaves the lower mold, the head of the floating pin is still in the stripper. If the release gap of the floating pin is too small and the mold opening force is unbalanced, the floating pin will break, so the release edge of the floating pin is stipulated to be 2.0 mm However, if the material width is too small, please determine the release gap according to the actual situation.

3. The floating pin not only has the function of positioning and floating, but also can make the feeding smooth, so the gap between the material and the floating pin before shearing is 0.10 mm; The gap between the material and the floating pin after shearing is 0.05 mm.

Design of 15 guide pin device

1. Guide pin structure (mode 1)

In the continuous die, in order to ensure the product accuracy; The workpiece can be fed accurately and smoothly, and the guide pin will be used to meet the requirements.

1). As shown in the above figure, the guide pin is fixed on the upper stripper. When s is less than or equal to S≤0.3 and s is 0.5, t >, the effective guide length s is generally1.5t; At 0.3, s is1.5t.

2. Guide pin structure (mode 2):

1. The guide device shown in the figure below is suitable for materials with T≤0.5mm, and is fixed on the splint through guide punching.

2. The device needs to use a guide floating sleeve on the stripper with a floating height of 2.0mm, and the lower die is equipped with a guide floating pin; As shown in the above structure. In order to avoid imprinting on the product, the diameter D2 of the lower die guide positive floating pin should be larger than the diameter D4 of the upper die guide positive floating sleeve.

The elastic force of the upper die should be less than that of the lower die.

Structural design of 16 bump

In chassis products, bumps are often used for positioning, which are mainly divided into positioning bumps and contact bumps; Next, we introduce two bump design methods respectively.

1. Positioning projection

In die design, punching is usually used, and the height of the punch is based on the material (0.85~0.9)T to prevent the material from being punched through; The stripping device is consistent with tooth extraction stripping.

Positioning bumps can be divided into two forms: upward projection and downward projection.

1) protrudes upward, as shown in figure (1).

The male die is directly fixed in the lower template, and the upper die adopts a stripping device to ensure smooth stripping.

2) Convex downward, as shown in Figure 2.

The punch is fixed on the stripper plate or splint, and the fixing mode is reasonably selected as required; If you can't judge, ask the superior supervisor for instructions.

2. Contact bump:

For some bumps with small diameter and low height, the punch of the bump can be designed to be consistent with the hole of the lower die without gap, and the height of the bump is controlled by the spherical surface of the punch.

For bumps with a large bump diameter and a certain height, in order to make the appearance of bumps perfect, the bump punch can directly take the internal dimensions of bumps in product drawings, and the template hole takes the external dimensions of bumps.

Contact bumps can also be divided into upward and downward categories.

1. protrudes downward, as shown in Figure 3.

When the diameter of the bump is less than or equal to φ 2.0, the punch is directly fixed in the stripper.

When the diameter of the bump is less than φ 2.0, the punch should be fixed in the splint.

2. Raise upward, as shown in Figure 4.

The punch is directly fixed on the lower template.

17 folded flat design.

In mold design, there are generally two ways of reverse folding forming: upward pressing and lateral pushing.

1. Generally, pressing and flattening are designed in four steps to ensure the size of the product. The value of k in the extended graph is equal to 0.4T

2. The flanging process is shown in the following figure 1 (left):

Step 1: simultaneously forming R 1 arc by pressing lines, that is, punching 1/4 circumference.

Step 2: Bend 90 degrees and use the slider to form.

Step 3: flatten and shape.

3. The flanging process is shown in the following figure 1 (right).

Step 1: Bend 90 degrees, which can be peeled off directly.

Step 2: Fold 70 degrees.

Step 3: flatten and shape.

4. Press and flatten the punch shape.

The shape of the upper flattening punch is shown in Figure 2, and the selection of R value of the punch has a certain relationship with the material thickness. Generally, the following material thickness values are as follows

T=0.6mm，R = 1.5mm； T= 1.0mm, R = 2.2mmT = 1.2 mm, r = 2.5 mm, when the value of t is other, please discuss and decide.

C (straight section) > D+ 1mm, and C=B+2mm is appropriate in actual design.

The size of 2T in the drawing should be ensured according to the closing of the mold when designing.

When the reverse hem is high, it is formed by pushing sideways. The molding process is divided into three steps: 1. cutting; 2. Fold 90 degrees; 3. flatten sideways. See Figure 3 for details.

18 coiling design

Generally, there are two ways of rounding: upward pressure and lateral push. The forming process is shown in figure 1.

Structural design of 19 tooth extractor

Production standard of three-tooth extraction

1 The calculation principle of tooth extraction is the principle of constant volume. Generally, the height of the extraction hole H=3P(P is the tooth distance).

R = ef, ∫ t * ab = (h-ef) ef+π * ef/4, ∴ ab = {h * ef+(π/4- 1) ef * ef, ∴ precharging = ψ d-.

When t≤0.5, take ef = 100 t.

0.5<T< is 0.8 when ef = 70.

When t≥0.8, ef = 65 t.

2. The commonly used tapping parts size standard:

4. Several commonly used tooth extraction forms are shown in the following figure: (The punch for upward and downward tooth extraction has the same length, which is convenient for replacement.

Forming design of 20 convex hull

1. Product shape

Some convex hulls with higher height can often be seen on MB boards and other products, as shown in Figure (a).

2. Forming method

The convex hull height (h) of the product is relatively high, and it is easy to be torn during one convex molding. In order to avoid tearing and ensure the shape and size of the product after molding, it is generally formed in two steps.

Step 1: Draw an arc. As shown in (b) above, please pay attention to the following points:

(1). The perimeter L 1 (plus the length of three arcs) between C and D after the product is arced should be slightly larger than the perimeter L2 between A and B in the required section of the product (see Figure A for A and B), generally l1= L2+(0.2 ~ 0.8) mm.

(2) The linear distance between two points C and D of the lower die insert is equal to the linear distance D5 between two points A and B in the cross section required by the product.

(2) The overall dimensions of the initial product during bending:

& lt 1 & gt； As shown in figure (f), make a circle with three points (the tangent point of two r 1 arcs of the lower die hole and the lower die hole and the midpoint (g) of the convex bottom).

& lt2> After pruning, as shown in Figure (g), measure the total length L 1 of three arcs between point C and point D.

& lt3> If the total length L 1 of the three arcs is less than the circumference L2 between the two points A and B in the cross section required by the product, the center point G of the convex bottom will be moved down by a certain distance h(h can be 0.5mm as the first order) to obtain the point H, and then a circle will be made through the three points, as shown in Figure (h).

& lt4> Repeat step 3.2.2.2 and step 3.2.2.3 until L 1 = L2+(0.2 ~ 0.8) mm meets the requirements. By this method, the overall dimensions of the product when drawing an arc can be obtained.

3. Method for determining the radius of the ball at the end of the arc punch:

& lt 1 & gt； Offset the overall dimension of the product in the arc diagram determined in step 3.3.2 by a material thickness. As shown in figure (I)

The following two arcs with radius of r 1 in the inner hole of<2> die are offset by t * 0.6%. As shown in figure (I)

& lt3> Make a circle with three points, and draw a circle tangent to the three arcs determined in 3.3.3. 1 step and 3.3.3.2 step. The radius r of this circle is the radius r of the sphere at the end of the arc punch (take one place after the decimal point, but the size should be accurate to two decimal places). As shown in figure (j)

(4) determining the diameter of the arc punch body;

& lt 1 & gt； If the center of the sphere determined in (3) is above the upper surface of the product material (i.e., the contact surface between the upper stripper and the material) and the sphere intersects the upper surface of the product material, the cross section of the daughter of the arc portion can be obtained. As shown in fig. (k), D9 is the diameter of the arc-shaped punch body.

& lt2> If the center of the sphere determined in (3) is between the upper surface (that is, the contact surface between the upper stripper and the material) and the lower surface of the product material, let the figure diameter D9 of the arc-drawing punch be equal to the diameter of the sphere (that is, D9=2*R), and the end shape of the arc-drawing punch is a hemisphere. As shown in figure (I)

& lt3> If the spherical center determined in (3) is lower than the lower surface of the product material (i.e. the contact surface between the lower template and the material), it must be decided by the supervisor.

(5) Other precautions:

& lt2> Plastic punch is installed on the stripper plate, and it is not allowed to cross the splint.