Do you understand the steps involved in stamping process design? Based on our actual production experience combined with insights shared online, we will provide a detailed introduction below. This includes the collection and analysis of preliminary raw data, the analysis and review of the stamping process, and the formulation of the stamping process plan.
- Collect and analyze raw data related to the design.
(1) Product drawings and technical specifications of the stamped parts.
(2) Dimensions, properties, and supply conditions of the raw materials.
(3) Production batch size of the product.
(4) Existing stamping equipment conditions in the factory.
(5) Current die manufacturing capabilities and technical expertise within the factory.
(6) Other technical documentation, etc. - Analysis and review of the stamping process for product components.
Stamping processability refers to the adaptability of a stamped part to the stamping process, i.e., whether the structural shape, dimensions, precision requirements, and materials used for the stamped part meet the process requirements of stamping operations. - Formulate the stamping process plan.
Through analysis and calculation, determine the nature, quantity, sequence, combination, and positioning of the stamping processes. Determine the shape and dimensions of each process part. Arrange other non-stamping auxiliary operations, etc.
(1) Determine the nature of the process.
The process nature of a stamped part refers to the type of stamping process required for the part.
The nature of the stamping process should be determined based on the structural shape, dimensions, and precision requirements of the stamped part, the deformation laws of each operation, and certain specific condition constraints.
a. In general, the nature of the process can be determined directly from the part drawing.
b. After calculation, analysis, and comparison of the part drawing, determine the nature of the process.
c. To improve stamping deformation conditions or facilitate process positioning, additional operations may need to be added.
d. Sometimes, to save material, this can also influence the determination of the process nature.
(2) Determination of the number of operations.
a. The size of the production batch.
b. The precision requirements of the part.
The trimming process is an essential process to ensure the precision of the workpiece.
c. The existing forming conditions and stamping equipment of our factory.
d. Process stability.
Appropriately reduce the degree of deformation during the stamping process to avoid stamping deformation parameters approaching the limits.
(3) Arrangement of process sequence.
The arrangement of the stamping process sequence is mainly determined by the stamping deformation laws and the quality requirements of the part, followed by ease of operation, reliable blank positioning, and simple dies.
a. Deformation must first be applied to the weak areas, and the areas that have been deformed are then the weak areas.
b. Parts that meet the requirements of the part drawing obtained after the forming process must not be deformed in subsequent processes.
c. Principles for arranging hole processes.
① All holes, as long as their shape and dimensions are not affected by subsequent processes, should be punched in the flat blank.
② Holes whose positions will be affected by deformation in a subsequent process should generally be punched after the relevant process is completed.
③ Holes with high precision requirements and holes with high positional requirements should be punched after forming; other holes can be punched earlier depending on the situation.
④ If a large hole on the part is close to a small hole, the large hole should be punched first.
⑤ Punch first, then pierce.
6. Holes in the outer edge of drawn parts and the vertical sections of flanged parts should be punched after deep drawing and flanging.
d. Principles for arranging the process sequence of bending parts.
Generally, the outer corner is bent first, followed by the inner corner.
e. When punching at different positions, the process sequence should be determined based on the interaction between deformation zones, die structure, positioning, and ease of operation.
(4) Selection of process combination methods.
Whether process combination can be achieved and the degree of combination mainly depend on the production batch, shape, dimensions, quality, and precision requirements of the part, as well as considerations of die structure and die strength, die manufacturing and maintenance, and on-site equipment capabilities.
a. Consider the possibility of process combination from the aspects of part shape, dimensions, precision, die structure, and strength.
b. Consider the feasibility of process combination from the aspects of die manufacturing and maintenance capabilities, and on-site equipment capabilities.
(5) Selection of process locating datum and locating methods.
a. Selection of locating datum.
1. Principle of datum coincidence—make the locating datum coincide with the part design datum as much as possible.
② Principle of datum unification.
When multiple operations are used for separate stamping with different dies, the same locating datum should be used for each operation as much as possible.
③ Principle of datum reliability.
b. Selection of positioning method.
There are three basic positioning methods: hole positioning, surface positioning, and shape positioning.
(6) Determine the shape and dimensions of the process part.
a. The dimensions of the process part should be determined based on the limiting deformation parameters of the stamping process.
b. The dimensions of the process part should ensure the reasonable distribution and transfer of metal during the stamping deformation process.
① Already formed parts must not be altered in subsequent operations.
② For internal and external parts to be formed that are separated by the formed part, it is necessary to ensure that in each subsequent operation, the material is distributed and transferred within its respective range.
c. The shape and dimensions of the process part should be conducive to the stamping and forming of the next operation.
d. The shape and dimensions of the process part should be conducive to ensuring the surface quality of the stamped part.
1. The fillet radius of process parts that have been drawn multiple times should not be too small.
② Using the method of stepped conical surface forming or one-time conical surface forming can achieve better forming results.
e. The shape and dimensions of the process parts should meet the strength requirements of the die.