1. Material selection
- Mold materials: mold materials should have high hardness, wear resistance and toughness, commonly used materials include tool steel (such as Cr12, Cr12MoV), high-speed steel and cemented carbide.
- Workpiece material: according to the characteristics of the workpiece material (such as hardness, ductility) to choose the appropriate mold material and design parameters.
2. Mold structure design
- Design of upper and lower molds: The shape and size of the upper mold (punch) and lower mold (concave mold) should be accurately designed according to the bending angle and the shape of the workpiece to ensure the bending accuracy.
- Gap control: the gap between the upper and lower molds should be set reasonably according to the thickness and hardness of the material, too small a gap will lead to damage to the material, too large will affect the bending accuracy.
- Guiding mechanism: In order to ensure the alignment of the upper and lower molds, it is necessary to design a guiding mechanism (such as guide columns, guide bushings) to ensure the stability of the mold during the bending process.
3. Bending angle and springback compensation
- Bending angle: mold design needs to take into account the bending angle of the workpiece to ensure that a molding.
- Rebound compensation: metal bending will produce rebound, the design needs to be adjusted through the mold angle or increase the amount of compensation to control the rebound.
4. Mold strength and rigidity
- Strength calculation: the mold needs to withstand greater pressure, the design should be strength calculation to ensure that no deformation or fracture in the bending process.
- Rigidity design: the mold structure should have sufficient rigidity to avoid deformation due to uneven force, affecting the bending accuracy.
5. Surface treatment and lubrication
- Surface treatment: In order to improve the wear resistance and service life of the mold, surface treatment (such as quenching, nitriding, chrome plating, etc.).
- Lubrication: the design needs to consider the lubrication system to reduce the friction between the mold and the workpiece to extend the life of the mold and improve the surface quality of the workpiece.
6. Mold installation and commissioning
- Installation design: the mold should be easy to install and dismantle, the design needs to consider the interface with the bending machine and fixing methods.
- Commissioning: The design of the mold should be easy to debug to ensure that the bending angle and size meet the requirements.
7. Safety and maintenance
- Safety: mold design needs to consider the safety of operation, to avoid sharp corners or protruding parts cause injury.
- Maintenance: the mold should be easy to maintain and repair, the design needs to consider the replacement of wearing parts and routine maintenance.
8. Economy and productivity
- Economy: Under the premise of meeting the performance requirements, try to reduce the cost of mold manufacturing.
- Production efficiency: the mold design should improve production efficiency, reduce the time of mold change and debugging.