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Do You Know About Metal Stamping Problems And Solutions


 During the product stamping process, even with superb stamping technology and advanced production equipment, it is inevitable that a few products will have problems such as wrinkles, uneven edges, and burrs. Fortuna, as a highly qualified and

 experienced hardware stamping manufacturer, extremely skilled at handling these simple product issues. For Fortuna, the requirements for each product are extremely strict, and our quality control requirements are - 0 PPM. The following is a brief

 introduction to common problems that products may cause and solutions to them.

Causes of wrinkles and wall cracks in metal stamping parts

1. Wrinkle

Since the material of metal stamping parts is relatively thin, the flange holder force of the product design is too small and cannot resist excessive tangential compressive stress; this causes tangential deformation, resulting in loss of stability and the formation of wrinkles.

Improvement method: This requires the metal stamping parts processing factory to improve by increasing the blank holder force of the blank holder and appropriately increasing the thickness of the material.

2. The wall is torn apart

The reason why the wall is cracked is that the radial tensile stress the material bears during deep drawing is too large; the die fillet radius is too small; deep drawing lubrication is poor; and the raw material has poor plasticity.

Improvement methods: Operators should reduce the blank holder force; increase the die fillet radius; use lubricants correctly; select materials with better properties or increase the inter-work annealing process.

The reason why the edges of stamped and drawn parts are uneven during processing

1. Reasons for uneven edges

The midpoint between the blank and the convex and concave molds does not match or the material thickness is uneven, as well as the concave mold fillet radius and the gap between the convex and concave molds are uneven (the concave mold fillet

 radius is too large, and the blank holder breaks away from the blank holder in the final stage of drawing, causing the mold not to cross the circle. The corner material is pulled into the die to form edge wrinkles after it cannot be wrinkled by the edge ring.

2. Solutions

Reposition the punch die, correct the fillet radius of the die and the gap between the convex and concave dies to make them even in size before putting them into production (wrinkles can be eliminated by reducing the fillet radius of the die or using an arc-shaped edge ring device).

Reasons why surface scratches often occur in metal stamping.

1. When soft materials such as copper and aluminum alloy are continuously pressed and bent, metal particles or debris tend to adhere to the surface of the working part, causing large abrasions and scratches on the workpiece;

2. When the direction is parallel to the rolling direction of the material, cracks will occur on the surface of the workpiece, which will reduce the surface quality of the workpiece. When bending at more than two locations, try to ensure that the bending direction has a certain angle with the rolling direction;

3. The radius of the die fillet is too small, and impact marks appear on the bending part. Polish the concave mold and increase the radius of the concave mold to avoid scratches on the bent parts;

4. The gap between the convex and concave molds should not be too small. If the gap is too small, it will cause thinning and scratches. During the stamping process, always check the changes in the gap of the mold;

5. If the depth of the punch entering the concave mold is too large, the surface of the part will be scratched. Therefore, the depth of the punch entering the concave mold should be appropriately reduced while ensuring that it is not affected by springback;

6. The surface of the raw materials provided by the supplier is improperly protected, resulting in inconspicuous scratches and abrasions, which makes the products produced extremely prone to surface abrasions.

How to deal with the burr problem of precision stamping parts?

There are several ways to remove burrs from precision stamping parts:

1. Edge: If there are burrs on the edge of the product, tools such as a knife, sandpaper, whetstone, and whetstone should be used to deal with them;

2. Hole: If there are burrs in the hole diameter, use the front end of a twist drill with a larger diameter or use a chamfering knife;

3. Diameter: During the production and processing process, CNC lathes need to be used for chamfering;

4. Welding slag: Welding slag removal equipment can also remove relatively fragile burrs;

5. Polishing, sandblasting, and grinding can be carried out, but it also depends on the type of workpiece and the product requirements.

How to deal with the burr problem of precision stamping parts?

1. Use tools to remove burrs from stamping parts

(1). Hole: Use a chamfering knife or a drill bit with a large diameter;

(2). Edge: Use a knife, whetstone, and sandpaper;

(3). Welding penetration: Special tools for vibrating welding penetration removal can also remove brittle burrs;

(4). Diameter: During the production process, the lathe is used to guide the angle;

(5). There are also polishing, grinding, and sandblasting treatments, depending on the product workpiece and product regulations;

2. The process of removing burrs

(1). Use photoelectrocatalytic deburring. If you make your own machinery and equipment, the cost is not high and the efficiency is high;

(2). Vibration grinding removes burrs (transmission gear burrs), the efficiency is quite high, and the quality is acceptable;

(3). The heat treatment process can also remove burrs through shot blasting and can also remove stress on the surface;

(4). Using a hot air gun with a gun nozzle of various shapes has better deburring effects and is more efficient.

Fortuna has experienced methods for dealing with problems such as wrinkles, scratches, abrasions, and burrs on products. It can fully deal with sudden problems that arise on products. It can also consider problems from the customer's perspective and ensure the quality of the product. Allow defective products to flow out and achieve zero-defect product management.

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