1. burr of stamping parts.
(1) Reason:
A, knife edge wear; B, the effect is not obvious after the gap is too large; C, knife edge collapse angle; D, the gap is unreasonable up and down offset or loose; E, the mold is staggered up and down.
(2) Countermeasures:
A, training knife edge; B, controlling the machining accuracy of the convex-concave die or modifying the design gap; C, training the knife edge; D, adjusting the blanking gap to confirm the wear of the template cavity or the machining accuracy of the molded part; E, replace the guide rail or reassemble the mold.
2. Jumping chip crush injury
(1) Reason:
A, the gap is too big; B, improper feeding; C, stamping oil droplets too fast, oil sticky; D, the mold does not demagnetize; E, the punch is worn, and debris is pressed on the punch; F, the punch is too short, and the length of the insert die is insufficient; G, the material is hard and the stamping shape is simple; Emergency measures.
(2) Countermeasures:
A. Control the machining accuracy of punch and die or modify the design gap; B, when it is delivered to a proper position, trim the material belt in time and clean the mold; C, controlling the oil quantity of the punched oil drop or changing the oil type to reduce the viscosity; D, demagnetization must be carried out after the training (pay more attention to strike while the iron is hot); E, researching the punch blade; F, adjust that length of the edge of the male die entering the female die; G. change materials and modify design. The edge of the punch is inserted into the end face to eject or trim the slope or arc (pay attention to the direction). Reduce the joint area between the end face of the punch blade and the chip; H, reduce the sharpness of the die cutting edge, reduce the grinding amount of the die cutting edge, increase the roughness (coating) of the surface of the straight edge of the die, and use a vacuum cleaner to absorb waste. Reduce the impact speed and chip bounce.
3. Debris blockage
(1) Reason:
A, the leakage hole is small; B, leakage hole is too large, debris rolling; C, blade wear, burr is bigger; D, stamping oil droplets too fast, oil sticky; E, the surface of the straight edge of the female die is rough, and powder crumbs are sintered and attached to the edge; F, the material is soft; Emergency measures.
(2) Countermeasures:
A, modifying the leakage hole; B. modify the leakage hole; C, trimming the knife edge; D, control the amount of oil dripping and change the types of oil; E, surface treatment, polishing, pay attention to reduce the surface roughness during processing; Change the material, f, modify the blanking gap; G, repair the end face of the punch blade into an inclined plane or an arc (pay attention to the direction), and use a vacuum cleaner to aerate the blanking hole of the backing plate.
4. The change of blanking offset size
(1) Reason:
A. The edge of the convex-concave die is worn, resulting in burrs (too large in shape and too small in inner hole); B, improper design size and clearance, poor machining accuracy; C, that punch and the die insert at the punch position are offset, and the gap is uneven; D, guide pin wear, pin diameter is insufficient; E, guide rail wear; F, feeder feeding distance, pressure, relax improper adjustment; G, improper adjustment of clamping height; H, the material level of the discharging insert is worn, and there is no material pressing (strong pressing) function (small punching caused by pulling and turning materials); First, the discharging insert is pressed too deeply and the punching hole is too big; J, mechanical properties variation of stamping materials (unstable strength elongation); K, punching, punching force on the material traction, resulting in dimensional changes.
(2) Countermeasures:
A, training knife edge; B, modify the design and control the machining accuracy; C, adjusting the position accuracy and punching the gap; D, replacing the guide pin; E, replace the guide post and guide sleeve; F. readjust the feeder; G, readjusting the clamping height; H, grinding or replacing the discharging insert, increasing the pressing function and adjusting the pressing material; Reduce the depth of strong pressure; J, refuelling, and controlling feed quality; K, the punch blade end face slope or arc repair (pay attention to the direction), to improve the stress situation during stamping. When allowed, the guide function is added to the unloading insert at the unloading position.
Step 5: filler
(1) Reason:
A. Improper adjustment of feeding distance, pressure and relaxation of the feeder; B, feed distance changes in production; C, feeder failure; D, the material is arc-shaped, with out-of-tolerance width and large burr; E, abnormal die stamping, resulting in sickle bending; F, the hole diameter of the guide material is insufficient, and the upper die pulls the material; G, stripping up and down at the bending or tearing cutting position; H, guide plate discharging function is set improperly, with material belt; Me, the material is thin and the middle is upturned; J, improper mold erection, the verticality deviation of the feeder is large.
(2) Countermeasures:
A. readjustment; B, readjust; C. adjustment and maintenance; D, changing raw materials and controlling feed quality; E, eliminating the sickle bend of the material belt; F, research and develop the punch and die for punching the positive hole; G, adjust the strength of the demoulding spring, etc. H, modify the guide plate, and take the material prevention belt; 1, adding upper and lower pressing materials between a feeder and a die, and adding an upper and lower extrusion safety switch; J, reset the mold.
This material is bent with a sickle.
(1) Reason:
A, punching burr (especially on the carrier); B, raw edges of materials, and no trimming of the mold; C, improper drilling depth (too deep or too shallow); D, the stamping parts are crushed, and there are wastes in the mold; E, local pressure material is too deep or pressure to local damage; F, mold design.
(2) Countermeasures:
A, research frontier; B, replacing materials and adding an edge trimming device on the die; C, readjusting the depth of the punching machine; D, cleaning the mold to solve the problem of chip jumping and breaking; E, check and adjust the correct height and size of each discharging and die insert, and study the damaged position; F, adopt the whole bending mechanism to adjust.
7. Punch fracture and edge collapse
(1) Reason:
A, chip jumping, chip blocking, die sticking, etc. ; B, improper feeding, cutting half material; C, insufficient punching power; D, the big punch and the small punch are too close, and the material is pulled when punching, which leads to the fracture of the small punch; E, punch and die local too sharp; F, the blanking gap is too small; G. There is no stamping oil or the used stamping oil is highly volatile; H, uneven offset of blanking gap, interference between punch and die; I. The precision of the discharging insert is poor or worn, and the precision guiding function is lost; J, mold guide is not allowed, wear; K. Improper material selection and hardness of convex and concave dies; I, guide (pin) wear; M, gasket added improperly.
(2) Countermeasures:
A. Solve the problems of sheet jumping, sheet blocking and die sticking; B, pay attention to feeding, trim the material belt in time, and clean the mold in time; C, modify the design, increase the overall strength of the punch, shorten the size of the straight edge of the female die, pay attention to the slope or arc of the edge end face of the punch, and the small part will be cut back; D, the length of the small punch is shortened by more than one material thickness relative to the large punch; E, modify the design; F. Control the machining accuracy of punch and die or modify the design clearance, and appropriately increase the stamping clearance of fine parts; G, adjusting the oil quantity of the stamping oil drop or replacing the oil type; H, check the accuracy of each molded part, and adjust or replace it to control the machining accuracy; I. training or replacement; J, replace the guide post and guide sleeve, and pay attention to daily maintenance; K, change the materials used and use appropriate hardness; I. replace the guide; M, correction, the number of gaskets should be as small as possible, and steel pads should be used. The gaskets under the female die should be placed under the block.
8. Dimensional change of bending deformation
(1) Reason:
A, guide pin wear, pin diameter is insufficient; B, bending guide part accuracy is poor, wear; C, bending punch wear (pressure loss); D, insufficient molds; E, the material slips, the bending punch and die have no guiding function, and no preloading is applied during bending; F, poor mold structure and design size; G, stamping parts burr lead to poor bending; H, more gaskets are added to the punch and die at the bend, resulting in unstable dimensions; I, material thickness size change; Mechanical shape and energy change of materials.
(2) Countermeasures:
A, replace the guide pin; B, re-grinding or replacement; C. regrinding or replacement; D, check and correct; E, modify the design, increase the guidance and preloading function; F, modify the design size, decompose bending, increase bending shaping, etc. G, researching the cutting edge of the blanking position; H, when adjusting, use the integral steel pad; First, change raw materials and control feed quality; J, change raw materials and control feed quality.
9. Stamping height (when multiple parts are in one mold)
(1) Reason:
A, burr of stamping parts; B, the stamping parts are crushed, and there is waste in the mold; C, punch, die (bending position) pressure loss or damage; D, turning materials when punching and shearing; E. Wear and pressure loss of relevant compression parts; F, related tearing and cutting positions are inconsistent in tearing and cutting dimensions, and the blade is worn; G. The pre-cutting depth of relevant fragile parts is inconsistent, and the convex and concave dies are worn or cracked; H, the convex and concave dies of the relevant protruding parts have broken edges or are seriously worn; First, mold design defects.
(2) Countermeasures:
A, researching the cutting edge of the blanking position; B, cleaning the mold to solve the floating problem of the chip; C. Re-study or replace new parts; D, learn the punching knife edge, and adjust or increase the pressing function; E, inspection, maintenance or replacement; F, maintenance or replacement, to ensure that the tearing and cutting conditions are consistent; G, check the state of the pre-cutting punch and die, and carry out maintenance or replacement; H, check the state of the punch and die, and implement maintenance or replacement; Modify the design, increase the height adjustment or increase the molding station.
10. Improper maintenance
(1) Reason:
A, the mold has no foolproof function, which leads to wrong direction and dislocation (referring to different stations) due to negligence in assembling the mold; B. Inserts that deviate from the gap are not restored.
(2) Countermeasures:
A, modify the mold, and increase the fool-proof function; B, mark the mold, etc. , and after assembling the mold, make necessary inspection and confirmation of the protective belt, and make a written record for inquiry.
In stamping production, the daily maintenance of the die is very important, that is, daily attention is paid to checking whether the punch and die are in normal state, such as refueling the supply guide rail of stamping oil. Many unexpected accidents can be avoided by checking the mold before it is put on the machine, checking the blade and confirming the locking of each part. You must think twice before you repair the mold, make records carefully and accumulate experience.