Profile processing
According to the traditional production method of stamping die, the surface processing is carried out: roughing → semi-finishing finishing → clearing root. After turning to the assembly, the fitter is usually sanded with a grinder, then polished with coarse stone, and finally polished with fine stone. This often leads to two problems. One is the problem that the profile is damaged. Normally, it is normal for the profile to cause an error of 0.1 to 0.2 mm due to grinding of the grinder. On the other hand, the fit assembly cycle of the fitter will be longer.
Cutting edge machining
The processing of the cutting edge of the punching die is usually done first, and the amount is quenched. Finally, the fitter repairs one by one, so that the assembly precision and cycle cannot be guaranteed. Dimensional accuracy also has certain discrepancies due to the reasons for the research, often resulting in uneven gaps and large trimming burrs.
Introduction of fine processing of profile and trimming edge
The fine processing technology has a great improvement on the basis of inheriting the traditional processing method, and the quality of the profile is greatly improved. The pressing member can be pressed without the need of research and analysis, and the clearance rate of the trimming edge is more than 75%. Reduce the assembly time of the fitter assembly by 30% to 40%, greatly improving quality and efficiency. Directly reduce the cost to 548 yuan / standard set (a standard door outer panel pull mold is a standard set).
Profile finishing
Profile refinement processing route: rough root 50 - rough processing 50 - semi-finishing root 32 - semi-finishing 32 - fine root 30 - finishing 30 - fine root 20 - fine Qing root 16 - fine root 12 - fine root 10 - fine root 8 - fine root 6 - fine root 4.
The profiled light after processing can be directly pressed without polishing.
Processing example
Machining workpiece name: car door outer panel drawing punch
Workpiece material: MoCr cast iron alloy
Hardness: about HRC28
Spindle speed: 6000 rpm
Cutting line speed: 400m/min
Feed rate: F=4000mm/min
Feed per tooth: Fz=0.5mm/rev
Cutting depth: Ap=0.2mm
Step distance: Ae (step) = 0.4mm
Cooling method: dry
Processing tool: é»›æ°é•œé¢çƒåˆ€
Tool diameter: φ30
Processing time: 12 hours
After 12 hours of processing, it can be seen that the surface roughness is very good, no need to connect the knife, the tool wear condition is only worn off by 0.015mm by inspection, and it is also very sharp, and the mold surface feels smooth, such as the user has no profile. Pushing light requirements, you can directly pull the parts without grinding, if the user has requirements, you can directly use 150# oil stone to push the light, the profile can achieve the mirror surface effect, and can save the fitter working time per standard set (one door outer plate drawing die) For a standard set, about 30 to 35 hours), and the surface accuracy is compared with the digital model, the maximum error is 0.06mm (test after pushing).
Fine processing of trimming die cutting edge
The clearance and dimensional accuracy of the trimming edge are very important, and the size of the gap is unreasonable, the dimensional accuracy is too bad, and the burr or the edge life is too short, which affects the dimensional accuracy. In this respect, the routing is such. : Trimming contour rough milling (STOCK=1mm left 10mm)→Trimming contour finishing (STOCK=0.3mm)→R angle clearing angle (STOCK=0.3mm)→Removing quenching→assembly→φ20 superhard knife machining→φ16 Clear angle → φ10 clear angle → φ8 clear angle (generally there is no special requirement for the process fillet to leave R4).
During the processing, after passing through this processing route, the pass rate of the trimming edge gap is 75% to 80%. If the angle design is reasonable, it can reach 100%, and the repair value of δ=0.8mm or more. The mold can reach 100%. In this respect, the choice of tool is very critical, the difficulty is the processing after quenching, which is a key part of the whole process, in this respect, there are several tools to choose from:
(1) superhard tools;
(2) Yanjie Dajet's solid carbide end mill;
(3) HITACHI overall super hard end mill + super hard coating.
In this example, we selected the HITACHI overall super-hard end mill. The parameters of this tool are as follows:
Speed: 1500rpm
Feed: 2500mm/min
Factors affecting dimensional accuracy and surface roughness of superfinishing
It should be said that for CNC machining, there are many factors that affect the machining accuracy, which come down to the following categories:
(1) Geometric accuracy and linear accuracy of the equipment, interpolation performance, etc.;
(2) the influence of the structure and rigidity of the machine tool on the machining;
(3) Thermal deformation during cutting;
(4) the size of the machining allowance;
(5) Selection of tool material and cutting parameters;
(6) The influence of environmental temperature changes;
(7) Fixing, secondary alignment, positioning, etc.;
(8) The responsibility of the operator.
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