Automation Metal Stamping Line
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Automation Metal Stamping Line
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Metal Stamping Line

Automation Metal Stamping Line

What Is Metal Stamping?

What Is Metal Stamping? Metal stamping is the use of punching and die to deform or break stainless steel, iron, aluminum, copper and other materials to achieve a certain shape and size.Metal stamping is sometimes referred to as sheet forming, but with a slight difference. The term "sheet forming" refers to the use of a sheet material, a thin-walled tube, a thin profile, or the like as a raw material. The forming method of plastic working is collectively referred to as sheet forming, and at this time, the deformation in the direction of the thick plate is generally not considered.Process classificationThe stamping process can be roughly divided into two categories: separation process and forming process (also divided into bending, deep drawing, and forming). The separation process is to separate the stamping parts and the blanks along a certain contour line in the stamping process, and the quality of the separated sections of the stamping parts also meets certain requirements; the forming process is to plastically deform the stamping blanks without breaking. And into the required shape of the finished product, but also meet the requirements of dimensional tolerances.According to the temperature conditions at the time of stamping, there are two methods of cold stamping and hot stamping. This depends on the strength, plasticity, thickness, degree of deformation, and equipment capabilities of the material, as well as the original heat treatment state and end use conditions of the material.1. Cold stamping metal processing at room temperature is generally suitable for blanks with a thickness of less than 4mm. The utility model has the advantages of no heating, no scale, good surface quality, convenient operation and low cost. The disadvantage is that there is work hardening, which causes the metal to lose further deformation ability. Cold stamping requires that the thickness of the blank is uniform and the fluctuation range is small, the surface is smooth, no spots, no scratches, and the like.2. Hot stamping A stamping process that heats the metal to a certain temperature range. The utility model has the advantages that the internal stress can be eliminated, the work hardening is avoided, the plasticity of the material is increased, the deformation resistance is reduced, and the power consumption of the device is reduced. (Source: China Machinery Network)1. Die structure: The die is a tool that separates or deforms the sheet. A typical die structure is shown in Figure 3-17, which consists of two parts, an upper die and a lower die. The mold shank of the upper mold is fixed on the slider of the punching machine, and the lower mold is fixed on the working table of the punching machine as the slider moves up and down.The punch and the die are the working portions of the die for deforming or separating the blank, and are fixed to the upper die plate and the lower die plate by press plates, respectively. The upper and lower templates are respectively provided with a guide sleeve and a guide post to guide the alignment of the punch and the die. The guide plate and the positioning pin are respectively used to control the feeding direction and the feeding length of the blank. The function of the stripper is to remove the workpiece or blank from the punch after stamping.2. Classification of dieThe die is an indispensable mold in stamping production. The die can be basically divided into three types: simple mode, continuous mode and composite mode.(1) Simple die A simple die is a die that performs only one process in one stroke of the press. Figure 3-17 is a simple die for blanking or punching. The assembly drawing of a simple die is shown in Figure 3-18. During operation, the strip is fed between the two guide plates 9 on the die and hits the positioning pin 10. When the punch is punched down, the punched part (or scrap) enters the die hole, and the strip clamps the punch and moves back up with the punch. When the strip hits the stripper 8 (fixed on the die), it is pushed down, so that the strip continues to feed between the guides. Repeat the above action and rush down the second part.(2) Continuous die In a single stroke of a punch press, a mold that performs several stamping processes simultaneously on different parts of the die is called a continuous die, as shown in Figure 3-19. During operation, the positioning pin 2 is aligned with the positioning hole which is punched out in advance, the upper die moves downward, the punch 1 performs blanking, and the punch 4 punches. When the upper die is returned, the discharge plate 6 pushes the waste from the punch. At this time, the blank 7 is fed forward again, and the second punching is performed. This cycle is performed, and each feed distance is controlled by the stopper pin.(3) Composite die In a single stroke, a mold that performs several stamping processes simultaneously on the same part of the mold is called a composite mold, as shown in Figure 3-20. The most important feature of the composite mold is that there is a convex and concave mold 1 in the mold. The outer circle of the convex and concave die is the blanking die edge, and the inner hole becomes the deep drawing die. When the slider moves downward with the male and female molds, the strip is first blanked in the male and female molds 1 and the blanking mold 4. The blanking member is held by the deep drawing punch 2 in the lower die, and when the slider continues to move downward, the female die is then moved downward to be deepened. The ejector 5 and the unloader 3 push the drawn member 9 out of the mold during the return stroke of the slider. The composite mold is suitable for stamping parts with large output and high precision.3. The main basic processes of stamping basic process stamping include blanking, punching, bending and drawing.(1) Blanking and punching blanking and punching are the steps of separating the blank, as shown in Figure 3-21 below.The process of blanking and punching is exactly the same, but the use is different. When blanking, the separated part is the finished product, and the remaining periphery is waste; the punching is to obtain the hole, the punched sheet is the finished product, and the separated part is the waste. Blanking and punching are collectively referred to as punching. Both the punch and the die of the blanking die have a sharp edge, and there is a gap of 5%-10% between the punch and the die to ensure that the cut is neat and less burr.(2) Bending and bending is to make the workpiece obtain various corners of different shapes. The working part of the bending die that bends the workpiece should have an appropriate fillet radius r to avoid cracking when the workpiece is bent, as shown in Figure 3-22.(3) Drawing: Drawing is a process in which a flat blank is formed into a cup or a box. The punch and die edges of the drawing die should be rounded to avoid cracking of the workpiece. There should be a slightly larger gap (typically 1.1-1.2 times the thickness of the plate) between the punch and the die to reduce friction. In order to prevent wrinkles, the edge of the blank needs to be pressed with a pressure plate (crimbing ring), as shown in Figure 3-23. The actual drawing process of the product will produce a cracking defect, please seeSheet metal stamping is a processing method that uses a die to separate or deform the sheet material. Because in most cases the sheet does not need to be heated, it is also called cold stamping, also referred to as cold stamping or stamping.Commonly used plates are low carbon steel, stainless steel, aluminum, copper and their alloys. They have high plasticity and low deformation resistance, and are suitable for cold stamping.Sheet metal stamping is easy to mechanize and automate, and the production efficiency is high; the stamping parts are accurate in size and interchangeable; the surface is smooth and free of mechanical processing; it is widely used in the manufacturing industries of automobiles, electrical appliances, instruments and aviation.Terminology1, drawing: a stamping process in which a straight wool or process member is turned into a hollow member, or the hollow member is further changed in shape and size. When drawing, the hollow member is mainly formed by flowing a material other than the bottom of the punch into the die.2, trimming: a stamping process that uses a metal stamping die to trim the edge of the forming process to have a certain diameter, a certain height, or a certain shape.3, punching: A stamping process that separates the waste material from the material or process piece along the closed contour to obtain the desired holes in the material or workpiece.4, flanging: a stamping process that turns into a side short edge along the contour curve.5, the flip hole: a stamping process of turning the material into a side up flange around the inner hole.6, blanking: a stamping process that separates the material along the closed contour. The separated material becomes a workpiece or a process component, most of which is planar.Seventh, shaping: a stamping process that relies on the flow of materials and changes the shape and size of the process pieces to ensure the accuracy of the workpiece.

What Is An Automation Metal Stamping Line?

The automatic metal stamping production line mainly includes: progressive die stamping, multi-station stamping, and tandem stamping. Due to their respective characteristics, they are used to produce different automotive sheet metal parts, with their unique advantages in automotive automation. The efficient production system plays a huge role.Here we will compare and analyze the characteristics of the three automated stamping production lines, and explain the selection of the production line according to its characteristics. Therefore, it is convenient for each business to select automatic production lines according to the characteristics of its own parts. With the rapid development of the automobile industry, the metal stamping industries have also flourished. In order to adapt to the ever-increasing output, various automated production lines have emerged, and with the characteristics of the products, the different production methods are given. Companies select different production methods according to the characteristics of its own products. The production lines are classified into: progressive die stamping, multi-station stamping, tandem stamping, and a brief analysis of the characteristics and selection methods of each production line. Selection factors for stamping automated production lines:Generally consider the following factors to select the type of press lines:(1) Product material: including material type, formability, hardness, etc., to measure the choice of coil or sheet forming.(2) Material thickness: Consider the thickness and materials together to select the tonnage of the press machine and the feeding machines.(3) Monthly production requirements: assess production capacity for the selection of automatic line types.(4) The volume and shape of the stamping product: Through the modeling complexity and product quality requirements, the mold design method and the corresponding stamping automation production method are comprehensively considered. Common stamping automation production line types:Progressive die stamping production line(1) Overview: The progressive die automatic stamping production line is a production line that uses progressive die stamping. It is generally composed of decoiler, straightener, feeder, punching machine, progressive die, and automatic cutting line to realize decoiling, straightening, feeding, oiling, stamping, blanking and collecting of the coil material.The important part is progressive die, which consists of multiple stations, and some can be as many as more than 20 stations. Each station is sequentially connected in order to complete different processing contents, such as punching, trimming and turning, edge, shaping, blanking process, etc. A series of different processing are completed in one stroke of the press. After the completion of one stroke, the feeder moves the strip in the forward direction according to a fixed step, so that multiple processes can be completed simultaneously in one punching, as shown in Fig. 1.(2) Features: The progressive production line is highly efficient, and can usually reach up to 30 s.p.m.A. High productivity. The progressive die is a multi-tasking die, which can include various processes such as punching, bending, and drawing in a pair of molds, and has high productivity. The progressive die placement process is shown in Figure 2. B. The line is easy to automate. Automated operation can be realized from loading, decoiling, straightening, feeding, stamping and blanking, thereby reducing labor costs, improving production efficiency, and preventing abnormalities caused by inconsistencies in manual operations.C. Can be produced using high speed presses. Depending on the product features, high speed presses can be considered for higher productivity.D. Safe operation. The progressive press equipment has safety gates that separate the work area from the personnel operation area to form a relatively closed work area, providing safety for high-speed production.E. Saves production space. Just one press machine is needed in the production line to complete the production of a metal product. It has a small footprint and also simplifies the transportation state detection of the bottom and semi-finished products, and has high safety.F. Material utilization is not high. In order to ensure the continuity of the material and the requirements, in order to ensure the stability of the feeding, it is generally necessary to ensure the even distribution of the contents of the process state, sometimes at the expense of wasting parts of the material, so that high material utilization cannot be achieved. Multi-station stamping automation production line(1) Overview: A multi-tonnage press table is equipped with multiple (usually 4~5 pairs of molds) independent working position mold production lines, using the unloading hand or the unwinding feeder to feed, using the automatic feeding rod for process parts transfer , use the automatic conveyor belt to collect the off-line products, as shown in Figure 3. (2) Features.A. The material can be a coil material or a sheet material, which has great flexibility and increases material utilization.B. Uses automatic rod feeding, which is slower than the progressive die production line and faster than the traditional tandem production line, which can achieve higher production efficiency.C. Can equip with the loading and unloading sensor, double material detection, pinch sensor, in-mold sensor, etc., to control the position and state detection of the material and the production parts, and is highly safe.D. There is a high requirement for the feeding height and the feeding direction of each station. In order to ensure the stability of the feeding, it is generally necessary to ensure the consistency of the process steps in each process. Tandem stamping automation production line(1) Overview: Arranged by multiple presses in series into an automated production line. Each presses is mounted with a pair of dies (ie, one step of the production process), and the loading is performed by an automatic robot arm. The transfer, blanking and packing work is shown in Figure 4.(2) Features.A. It has a wide application range and can be applied to the production of various stamping parts. It has no high requirements on the size, shape and thickness of stamping parts, and can be applied to the production of large-sized cover parts with high flexibility.B. Production efficiency is low, due to the use of mechanical arm feeding, the pressing speed can not be higher, compared with the progressive production line and multi-station production line, the production efficiency is lower.C. Is convenient for mold repair and debugging. Each pair of dies on each press are independent, thus the working parameters are independent, and the maintenance and debugging of each mold process can be carried out independently without affecting each other.D. Occupying a large production space, a traditional tandem production line generally includes 4 to 5 presses and covers a large area. Selection and application of stamping automation production lineProgressive Die Stamping Automated Production Line: Considering the process characteristics that various processes are distributed on a single continuous strip and the high efficiency in metal stamping, it can be applied to the production of small parts on the car body and can meet a high supply. Multi-station stamping automation production line: It can be applied to the rapid production of medium-sized parts, for example, the beam parts that are not easy to be deformed, the symmetrical parts with complex left and right common-mode shapes, and the products that can be clamped by the clips on the automatic rod. Tandem stamping automation production line: Because its various processes are independently distributed in each press, the production line has the highest flexibility and is suitable for large-sized coverings with complicated production processes, which is conducive to the commissioning and independent production of individual processes, and is convenient for quality control of products. The characteristics of the three production lines are shown in Table 1. The selection of each stamping automation line can be based on two main requirements: High-volume and high-flexibility parts require high-efficiency, high-volume automated production lines. If the parts are complex and require high production processes, a flexible production line can be selected. A simple illustration is shown in Figure 5. With its own characteristics, the stamping automation production lines have been applied to major automobile factories, providing a strong guarantee for the development of the automotive industry and the rapid growth of automobile production. The analysis and understanding of the stamping automation production line facilitates the selection of stamping parts production methods, making full use of the advantages of their respective automatic lines to serve the automotive field.