Aluminum alloy is a kind of non-ferrous metal material most widely used in industry, which has the advantages of low density, high specific strength, good plasticity, etc. In addition, it also has strong electrical conductivity, thermal conductivity and corrosion resistance, and it is an indispensable and important raw material for the industries of aviation, aerospace, automobile, machinery manufacturing, shipbuilding and chemical industry. For the aluminum alloy material in the mold manufacturing and stamping processing and workshop management problems that are likely to occur, put forward some suggestions for your reference.
Problems to be noted in mold manufacturing and stamping
Aluminum alloy stamping because the material relative to iron, the hardness is small, easy to break and expensive, therefore, to aluminum alloy material to make molds, should pay attention to the following issues:
The first one is that the punching process should be lined up at the back as much as possible without affecting the number of processes, and even for the molds with a large number of punching holes, the punching process should be lined up at the end even if it is preferable to increase one process.
The second is due to the soft hardness of the aluminum material, and the mold is easy to block the material, so in the design of the mold gap, should leave the size of the bilateral material thickness of 10% of the gap, the straight depth of the cutter to 2 mm is more appropriate, the taper is in the 0.8 to 1 degree between.
The third is in the bending molding, aluminum raw materials need to paste PE film, this is because the aluminum material in the bending is easy to produce aluminum chips, these aluminum chips will cause damage to the workpiece, the emergence of point and indentation and other processing defects. The presence of PE film can reduce the damage to the workpiece. In the case of rollers and plating, the molding block is better to be polished and plated with hard chrome.
Fourthly, for the subsequent stamping parts to be anodized, the flattening and flattening process can not be completely pressed together, otherwise the phenomenon of acid spitting will occur in the anodizing process, and it is necessary to leave a 0.2 to 0.3 mm gap so that the acid can be smoothly and timely outflow. Therefore, this process must be done on the limit block, and the mold on the mold height.
Fifthly, because the aluminum alloy material is brittle and easy to crack, especially in the case of reverse folded edges, so try not to do the crimping, even if you have to do it, you should make the crimping wider and the depth of the crimping shall be shallower.
The sixth is that all aluminum alloy workpiece knife edge are required to use slow-feed wire cutting processing, which can prevent the emergence of burrs and falling material is not smooth phenomenon. Aluminum parts are prone to high temperature, so the punch should be used at least in the hardness of SKD11 material above the material, can not use ordinary poor quality convex die.
Aluminum alloy processing workshop management should pay attention to the problem
First of all, in order to do a good job of stamping aluminum parts and reduce the defective rate, the first thing to do is to do a good job of workshop 6S management, especially clean molds, punch press table, assembly line and packaging materials, must be free of sharp debris and dirt. To regularly clean and tidy up the mold, mold up and down must be cleaned up, no debris.
Secondly, when the product is found to have more burrs, the mold must be repaired in time to improve the quality of the mold in order to reduce the chances of burrs.
Then, because the aluminum alloy workpiece is easy to heat, and accumulate together to make the workpiece hard, so when punching down the material surface needs to be coated with a little pressure wrench oil and then stamping, which can play a role in heat dissipation, but also can be smooth to unclog the drop material.
Next, for punching more products, need to do not punch a hole, must be on the mold surface for a cleanup to achieve the mold and the product to keep clean and free of debris, which can reduce the top of the workpiece injury. If you find the top injury, you must find out the problem of mold top injury, solve the problem before continuing production.
Lastly, the push flat die pusher block will produce aluminum chips, so the pusher block must be cleaned of aluminum chips under the pusher block after every day's production.
Punch in the punch is very easy to bring aluminum chips into the plate, and produce high temperature will punch wear or even soften, so the production of 3-7 days must be regularly cleaned punch or punching knife edge light grinding, really need to be replaced in a timely manner.
For 180 ° bending and flattening products, must not have 10-30 pieces of the folded edge will be torn PE film to see whether there is no rupture, because the aluminum material in the discharge will have uneven composition phenomenon, especially for the replacement of the manufacturer stamping materials need to do a rigorous first piece of inspection.