Xiaochong mold manufacturing process

A, clear angle (usually 1~2 feet smaller than the original). When clearing the angle, the grinding wheel or the grinding head and the black steel knife should not be cut too deep and uneven. B. Polish the engraving marks. When grinding, be careful that the direction of the grinding wheel with the handle should be the same as the direction of the engraving or at a certain angle. The lower point should be light, hard forming. 1. Determine the reference mode according to the drawing requirements or the sample (usually Based on the harder to polish)
A, clear angle (usually 1~2 feet smaller than the original). When clearing the angle, the grinding wheel or the grinding head and the black steel knife should not be cut too deep and uneven.
B. Polish the engraving marks. When grinding, pay attention to the direction of the grinding wheel with the handle should be the same as the direction of the engraving or at a certain angle of intersection. The lower point should be light, slowly and forcefully, and stretch the trace as much as possible.
Note: The grinding wheel with handle should be flattened frequently, so that the grinding effect will be better.
2, clamping
1. The reference mold is coated with red dan (Red Dan can't be too thin), it can't be painted too thick, and it should be thin.
2. Use a copper rod to tap the middle part of the mold. The force should be appropriate (the size of the force can be determined according to the size of the mold).
3. Don't blindly polish according to the situation of red dan. In the process of clamping, you should use the height gauge to measure whether the parallelism of the mold has gone away (remember).
4. Red Dan eats tightly (black spots appear). The spots, faces, corners, and areas that are not easily found are ground first.
5, the research and development rate of the upper and lower mold red Dan can be more than 85%.
6. Before the machine is in the machine, firstly buckle the material thickness. Generally, the material thickness is first milled? x70%~80%.
7, the benchmark model pushes the stone, sanding cloth.
3. Pay attention to the following problems when assembling the mold:
1. When assembling the mold, lock the screws and pin nails from the front as much as possible. This design should also meet this requirement as much as possible, so that it is convenient to install and disassemble the mold, and the workload is greatly reduced.
2. If the weight of the convex and concave molds is heavier and the size is larger, the screw holes of the hooks should be drilled to facilitate the assembly and disassembly.
3, pay attention to the direction, the mark should be marked.
4, the guide column, guide sleeve should pay attention to anti-reverse.
4, the machine platform buckle material thickness, test mode
1. When the machine is deducted, first go empty once, and after confirming that there is no problem, use 0.5→0.8→1.0→1.2→1.5→2.0 to buckle the material thickness in turn, and do not allow the design thickness board to be used from the beginning. Press to pressure, so as not to cause the mold to be stuck (remember).
2. When the machine is closed, it is generally not allowed to re-ground the reference mode.
3. When trying to grasp the edge of the material, the waste of the sheet should be minimized.
4. When making the positioning, try to make it easy to discharge and reclaim, and do not cause over-positioning.
Soft Forming (involved with springs or rams) Parts that use soft forming dies are generally parts that are complex in shape, have a large drop in profile height, or are partially wrinkled.
Advantages: stable part forming, simple unloading and convenient positioning.
Disadvantages: cumbersome production and high cost.
1. Consider the height, coefficient and pressing force of the ejector and spring.
2. Others are the same as hard forming.
Drawing die 1, whether it is the convex flower ruler angle or the concave flower ruler angle. After grinding and clearing the corners, the flank angle should be smooth and round, and the concave and convex convexity phenomenon is never allowed, and the hardness after quenching treatment should be >50HRC.
2, the height of the ejector should be consistent, the deviation 3, the ejector hole can not be too large, generally the diameter of the ejector? +1mm.
4, the pressure plate must have a guide, and the gap should be reasonable (0.02 ~ 0.03), such as large drawing force, thick sheet material, the pressure plate should be heat treated, and the hardness must meet certain requirements.
5. The drawing of the drawbead should be reasonable, round and without corners, and the hardness should meet certain requirements.
6. The standard size of the drawbead can be adjusted according to the actual situation, but it should not be too small, otherwise it will not work.
7. Pay attention to whether the size of the material is suitable. If the material is too small, the drawing member will be wrinkled. If the material is too large, the drawing member will be broken.
8, the host pressure, buffer pressure will affect the drawing parts: (1) wrinkling; (2) rupture. If the drawing member is broken and wrinkled, the flow direction of the sheet material must be considered, and it is also considered whether the material is broken too quickly and then caused to wrinkle.
9. The material of the material used has a certain influence on the test mode effect. The more complicated the shape of the drawing piece, the higher the material requirements.
10. If the drawing piece is broken and the angle is enlarged, it must be based on the drawings (there are plastic parts or scrap areas that may not be in accordance with the drawings).
11. In general, the following three conditions and causes occur in the rupture of the drawing piece: 1→the lower die angle is too small or not smooth; 2→the flow of the material is insufficient; 3→the upper die angle is too small or not smooth.
The blanking punching die 1, the cutting edge of the wire, generally have to gently rub the traces off, and then push the oil stone (be careful not to push the knife edge into a flank), which can reduce the friction between the blade and the sheet, increase Knife life.
2, the blanking die should be designed to avoid sharp corners when designing, so as to avoid excessive stress and the blade edge strength is too small, resulting in a decrease in the life of the blade.
3, the hardness of the knife edge should reach HRC56 ~ 62.
4, the cutting edge of the wire, generally have to check whether the verticality meets the requirements, the longitudinal cutting blade section must be vertical, the verticality of the knife edge should be no more than 0.01mm, no inverted cone is allowed.
5. The gap between the upper and lower molds can be divided according to the thickness of the sheet:
6. Before the group punch, first determine whether the bottom of the punch seat and the punch are flat. If it is not flat, first level the work plane and only sand the bottom of the punch.
7. When group punching, first consider the placement of the punch seat, then insert the punch into the hole 3~5mm (preferably use plastic film to cover the punch, so that the punch is centered), press the flat bottom surface by hand. Apply instant glue. When the main unit is opened, hold the punch with your hand and pay attention to whether it is moving. If there is any change, you need to regroup.
8. Before selling the nails, generally remove the AB glue or instant glue glued to the group punches, reassemble the punches, and lock the screws to lock the positioning pins.
9. The waste hole discharge waste must be smooth, so it is best to rush one waste once. As shown:
10. The positioning of the blanking punching die should be accurate, and it is better to save the material as much as possible.
11. If the sheet material is thicker and more punches, the punch is preferably 1~1.5 mm shorter than the knife edge during design, which is easier to discharge.
12, the spring distribution must be reasonable, in the design should consider the thickness of the sheet, the size of the punch, how much, you can increase the spring.
13. When the pressure plate is locked, it is generally higher than the thickness of the plate. Generally, the spring should be pre-pressed 3~5mm.
14. If the mold cavity is small, the punch is more difficult, the material is difficult to discharge, and the large spring or rubber cannot be installed, the rod device can be considered. If it is not possible, you can use a double rod device. This method can be used to reduce the number of processes during design to reduce costs.
15. Basic identification method for the section of the plate: (50% of the bright band and the cracked zone are the best)
16. Basic identification methods for burrs:
(All are bright bands, but not black) Cause: The gap is too large or the upper die edge is not vertical, not sharp
(All are bright, black, shiny) Cause: The gap is too small or the knife edge is not vertical (the knife edge is easy to break and becomes a ruler)
Plastic mold + side punching 1. The shaping die is generally in the end, otherwise the mold set is to be determined.
2. Based on the shaping of the mold, determine the mold closing height and measure the limit block (note the material thickness).
3, group side punch cam seat
1. Take out the cam spring and determine the cam stroke, generally 3mm (retaining 3mm margin).
2. Insert the punch into the die sleeve about 3~5mm. Determine the position of the cam seat according to the tightness of the punch seat and the cam. After fixing the cam seat and the punch, turn the module into the knife.
3. When the group is inserted into the knife, the knife will be placed against the back of the cam. If it will stand out, it is necessary to process the insert seat.
4, group side punching cam seat
1, the same as above.
2. Insert the punch into the die sleeve about 3mm. According to the position of the punch seat and the cam, determine the position of the cam seat, fix the cam seat, insert the knife into the module, and then put the spring group punch. If it is an O° suspension side punch cam, the cam seat and the punch can be combined at the same time.
5, the forced pull back hook should be appropriate with the corresponding institutions, not tight or not, check with red Dan, should show a thin layer of red Dan.
6. Insert the knife and the cam slider, the contact area should be even, can not only touch the single side, the group should consider the active trajectory of the forced pull back when inserting the knife.
Note: For actuators involving springs, it is important to consider the stroke of the actuator and the safety of the spring.
7. There should be no gap between the plastic knife block and the back support. If there is a gap, it should be padded with copper.
8. The hardness of the plastic knife block should be sufficient.
Precautions for the flanging die 1. The gap between the edge of the hem is less than the thickness of the material. For example, the thickness of the material is 0.8 mm, and the gap can be set to 0. 7 mm.
2. The pressure plate should be pressed out of the knife edge by 10mm, and the pressure should be sufficient to prevent the material from protruding.
3. When the corner of the part is cracked, the side of the material should be considered, or the shape of the drawing die should be added, but the edge of the knife edge and the side of the material should be considered first. When the corner is wrinkled, the gap between the edges should be considered too much. To reduce the edge (according to the drawing).
4. If the parts after folding are scratched and pulled, it proves that the hardness of the mold folding knife is not enough. It can be heat treated or repaired by steel welding rod, smoothed, pushed stone and polished.
5. The parts where the mold is generally subjected to heat treatment include: drawing die angle, drawbead, trimming die, and shaping die.
Need to pay attention to the following problems when loading and trying
1. Mold closing height h1: Before the mold is moved on the machine, the height of the bottom dead center from the work surface is determined first. When h2h1, it can be installed.
2. It is not allowed to use jog when loading the mold. Use the iron rod to turn the flywheel to lower the main unit, so as not to cause the main unit to die, damage the mold or cause a safety accident.
3. Determine whether the machine is suitable for each condition of the mold, whether there is a ejector, whether the width, height and weight meet the requirements.
4. When the mold is debugged, the host cannot be lowered at once. It should be adjusted slowly so as not to cause the top of the machine to die, the safety block to be damaged or the mold to be crushed.
5, the guide column, guide sleeve should be cleaned with lubricating oil, mold can not have dust, iron filings and so on. The drawing die is generally required to be oiled.
Common problems and treatment methods of molds 1. Drawing die
The plate is unstable, easy to pull, wrinkle, crack, and there is a dark injury at the R corner.
Countermeasures: Check whether the ejector is highly consistent, whether there is any scratch on the surface of the pressure plate and the upper mold (hardness is insufficient), whether there is a sand hole, whether the flank angle is smooth or too small, and whether the main engine or the ejection pressure is abnormal. Whether the material and size of the sheet change.
2, forming die
The plate is unstable, there is a dark injury at the R corner, and the unloading is not smooth.
Countermeasures: Check if the positioning is loose, smooth or enlarge the R angle, and whether the ejector spring is deformed or smaller.
3, blanking punching die
If the burr is too large, the plate is not easy to unload, the waste can not be discharged, and there is a material at the edge of the knife edge.
Countermeasures: Check whether the knife edge and punch are sharp and vertical, whether the gap is too large or too small, whether the waste hole meets the requirements, whether the pressure plate and the knife edge are too small, whether the spring is deformed or too small, and whether the knife edge is eaten Too deep or too big.
4, side punch, hanging mold
The burr is too large, the punch is easy to collapse, the cam is difficult to return, and the waste cannot be discharged.
Countermeasures: Check if the punch is too deep (suspension is generally 2mm), whether the cam is loose, whether the stroke is too long, whether the spring is deformed or too small, whether the gap between the cam platen and the slider is too small, waste Whether the hole is satisfactory.
5, flanging die
The flange is uneven, the corner is wrinkled, the hair is pulled, and the width of the flange is unstable.
Countermeasures: Check whether the gap between the edge knife and the press material is too large (generally half of the material thickness), whether the gap between the upper and lower mold blocks is too large or too small, whether the hardness meets the requirements, whether the edge of the corner is too long, and the pressure plate Is it too low or the spring pressure is too small.
Note: Before the mold is started, it is necessary to chamfer the periphery of the mold and the edge of the upper and lower template. This is the most neglected work. Http://news.chinawj.com.cn Editor: (Hardware Business Network Information Center) http://news.chinawj.com.cn

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