Several basic factors affecting die life

The related factors affecting the life of automobile stamping die are from design, use to maintenance. Only by doing every link well can the service life of the die be better extended.

Definition of stamping die life

Die life refers to the total number of parts that can be processed by the die under the premise of ensuring the quality of product parts, including the life after repeated die repair and replacement of wearing parts on the working face. Die life is generally divided into die design life and service life. In the die design stage, the total number of parts produced by the die should be made clear, that is, the design life of the die. Under normal circumstances, the service life of the die is longer than the design life of the die.

Basis of life design of stamping die
1. When making a strategy, each new automobile project will first define the production life of the automobile, which is the primary basis for the design life of the stamping die.

2. Other factors, such as the actual working state of the mold, need to be considered. For example, the production frequency per minute, the SPM (times of producing parts per minute) of different presses are different, and the loss of the mold is also different. The greater the production frequency, the greater the impact on the mold life, which needs to be considered when defining the mold design life.

Factors affecting the life of stamping die
Design quality of mould
1. Stamping manufacturability of parts.
When designing stamping process, the division of process content should be reasonable to avoid the design of too concentrated process content; The punching angle should be reasonable, so as to avoid sharp corners in the inserts of trimming dies; Molding dies try to make the material flow evenly and avoid wrinkling and stacking. Try to choose raw materials with good stamping technology to reduce stamping deformation force; Ensure the brand, thickness and surface quality of raw materials.

2. Rationality of die structure design.
Reasonable die structure is beneficial to improve the bearing capacity of the die and reduce the mechanical load level of the die. When designing the die structure, we should fully consider the stress situation and structural strength of each structural component, especially the key areas where the stress is concentrated, all trimming blocks, non-standard wedge structure and so on.
3. Selection of mold materials.
The material selection of the die is very important to the life of the die. The material division of each component needs to be based on the stress of each component and the comprehensive consideration of the region according to the chemical composition, microstructure, hardness and metallurgical quality of the material itself. There are two basic requirements for the materials of the working parts of stamping dies: the usability of the materials has high hardness and strength, high wear resistance and sufficient toughness, and the heat treatment deformation is small, and it has a certain degree of heat hardness; Good process performance. The manufacturing process of working parts of stamping dies is generally complicated, so it must adapt to various complex processes such as cutting and heat treatment. Usually, it is necessary to choose the die material with excellent performance according to the material characteristics, production batch and precision requirements of stamping parts, taking into account both manufacturability and economy.
4. Selection of the precision of the guiding mechanism.
The precision of the guide mechanism of the die is very important to the life of the die. In order to improve the life of the die, the correct guide form and the precision of the guide mechanism must be selected according to the nature of the process and the requirements of the precision of the parts. Accurate and reliable guide mechanism has a great influence on reducing the wear of working parts of the mold and avoiding the gnawing of the mold. In order to ensure the service life of the mold, the precision design and selection of the guide mechanism of the mold must be checked by a certified engineer.

Manufacturing quality of mould
1. Quality of castings and forgings.
The casting quality and forging quality directly affect the service life of the mold. The defects of casting forgings may directly lead to the scrapping of the mold. The sudden failure of hidden internal defects in the use process may cause irreparable safety accidents and have a great impact on production. Therefore, it is very important to check the quality of mold materials in the mold manufacturing stage.
2. Machining accuracy.

The quality of the machined surface of the die working parts has a significant impact on the wear resistance, anti-gluing ability and anti-fracture ability of the die, and directly affects the service life of the die, especially the surface roughness value has a great influence on the die. If the surface is too rough, stress concentration data will be generated in the work, which will easily lead to cracks and affect the durability of the stamping die. The machining accuracy of the reference area that needs to be guided and positioned should be strictly guaranteed. The machining accuracy of each component directly affects the overall accuracy of the mold. The poor accuracy will constantly generate friction stress during the use of the mold, which will affect the overall service life of the mold.

3. Assembly accuracy.

For all mounting surfaces/holes and datum surfaces/holes that need to be assembled, under the condition of ensuring machining accuracy, they must be assembled in accordance with reasonable assembly technology in the assembly process to ensure the quality of each process. Assembly accuracy directly affects product quality and die life. The better the process accuracy is guaranteed, the longer the die life will be.

4. Heat treatment.

The choice of heat treatment process and equipment has great influence on the quality and life of the die. A good heat treatment process can give full play to the properties of die steel materials and achieve the hardness, strength, toughness and wear resistance required for die work. Unreasonable heat treatment process will produce carbonization or insufficient hardness of the die body, thus accelerating the wear of the die and affecting the life of the die.

Use link of mould
1. Accuracy of stamping equipment.
The precision and rigidity of stamping equipment have great influence on the life of stamping die. The stamping equipment has high precision and good rigidity, and the life of stamping die will be greatly improved.
2. Mold clamping and mold inspection.

Before the mold is put into operation, it should be fully cleaned and maintained to ensure that the cavity of the mold is clean and free of sundries, the guide parts of the mold are well lubricated, and the working parts of the mold are free of defects such as cracks and unreasonable gaps. The mold is clamped to ensure that the machine is clean and free of other sundries. Correct use of molds is beneficial to the increase of mold life.

Maintenance of mould

Establish a hierarchical management system for molds: regularly carry out maintenance, daily cleaning, lubrication and inspection of molds; Carry out inspection of molds, inspect molds during and after production, discover and expose problems in time, and maintain molds in time; Maintain the molds quantitatively according to the production capacity. When the molds are produced in 1000 ~ 3000 sets, a small maintenance is needed. Check whether the guide parts, working parts, safety parts and cutting edges of the molds are damaged, whether the lubrication is good, and whether the punching and trimming wastes are blocked. Find the abnormalities in time and repair the defects in time. When the molds are produced in 5000 ~ 6000 sets, a big maintenance is needed. Disassemble all the working parts and wedge mechanism of the mold, and maintain the moving parts, working parts, safety parts, profile and cutting edge, elastic components, pneumatic components, discharging mechanisms and auxiliary mechanisms. In order to make the mold produce normally, improve the quality of stamping parts, reduce the cost and prolong the life of the mold, it is necessary to use the mold correctly and reasonably, and do a good job in the maintenance of the mold in time.

In short, in the process of design, manufacture, use and maintenance of stamping dies, we should use advanced die manufacturing technology and implement comprehensive die quality management, develop professional manufacturing mode, implement standardized operation procedures, and constantly improve the equipment and environment for die manufacturing and use, so as to better extend the service life of dies and ensure the production quality of parts.

 

 

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