Automobile stamping parts have a wide variety of products and complex shapes. During stamping production, some undesirable phenomena often occur. How to avoid problems?
The middle protective surface bracket is the key load-bearing connection part of the integral instrument Panel assembly of the automobile cab, and is an important part to ensure the stable and reliable use of various instruments of the automobile. Because the high-speed rotation of the high-power engine and the poor driving conditions of the vehicle are likely to cause strong vibration and turbulence to the cab, which will cause the instrument circuit in the front control panel and some functions to be disconnected or malfunctioning.
Therefore, the middle shield bracket must be able to withstand impact, bending fatigue load and torque, so it must have sufficient bending strength, shear strength and good toughness. In addition, if the part exceeds the allowable stress during forming, or the microcracks expand to a certain extent, causing tearing or skewing, this will not only waste material, but also put the mold in eccentric load operation and accelerate mold aging. The middle protective surface bracket is torn during the forming process, and the tearing parts are mainly distributed at the hole pattern of the workpiece, the corner of the side wall and the junction of the R arc and the wall neck, etc., due to the difference in the forming and production process conditions of the stamping parts. The proportion of the fractured part is different.
After careful analysis, we believe that the main reason is that the die is not stable in the forming direction of the die during the operation, the gap between the die and the die cannot be adjusted after long-term wear, and the mold structure is not properly designed. Common forms of tearing and skewing. The punching process of the middle protective surface bracket is: blanking and punching-punching incision-flanging forming-incision-flanging.
There are various forms of tearing and skew during the forming process of the middle protective surface bracket. The tearing parts are mainly distributed at the hole pattern of the workpiece, and the R arc at the corner of the side wall and the junction of the wall neck, etc., due to the forming of the stamping parts The production process conditions are different, and the proportion of each fractured part is different. The tear can be a one-time forming tear, or a tear caused by the development of fatigue cracks, that is, the development of invisible cracks. According to the actual situation of the site, by checking the tearing position, fracture shape and degree of crushing of the part, it is considered that the part is caused to tear. The cracking and skewing behavior is mainly reflected in the flanging forming process, and the reasons for this process are as follows:
1. Defects in the design of the flanging forming die
This mold is shared for the left and right parts of a mold with two cavities. Because the content of this process is not only the flanging, but also the shape forming content, and the part is particularly complex, the curved surface is narrow, and the forming requires that the concave die press material core matches the forming surface, etc. As a result, the mold structure condition has a large forming stroke and a small pressing area. In the initial mold design, the designer only considered the feature of small blanking surface, but ignored the guiding slip stroke of blanking core.
2. There is an error between mold processing parts and drawing design
Since the blanking core is a complex surface, the guide surface is machined after the casting is formed, which results in a gap error after the machining surface and the guiding surface of the die are slidingly matched. The blanking core left/right appears during the normal operation of the mold. swing. Since the guiding gap of this structure is the adjustment sliding gap, once it is damaged, there will be no more effective adjustment means, which will affect the forming quality of the part for a long time and bring potential safety hazards. Moreover, instead of using a special guide slide at the guiding part, it adopts a mutual guiding structure of the processing profile. There is a defect that the gap cannot be adjusted after the gap is too large, resulting in tearing and skewing of the parts.
3. The forming process parameters are not in place
In the process of forming parts, the process requires that the die, the blanking core and the two parts must be tightly attached together, and the sheet material is forced to plastically deform when the machine tool slides down to realize the forming. However, due to the shortcomings of the pressed parts such as unstable quality, it shows that the pressure of the machine tool is in a state of unbalanced pressure fluctuation during the production process. The main reason is that the processing technicians did not adjust the pressure of the machine tool at this stage in time according to the requirements of the process designation, or did not communicate with each other about the pressure stability information of the machine tool during the handover of each shift, resulting in poor quality of the parts. Stablize.
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