[China Aluminum Network] The daily maintenance and management of cold stamping die is crucial to improve the technical status of the die, ensure the quality of the parts and ensure the smooth production. Therefore, we must do a good job of this work.
One, die maintenance and management content
The contents of routine maintenance and management of cold die include the following aspects:
1) Identification of die technology;
2) Die maintenance repair
3) maintenance of the die;
4) Die technology file management;
5) The storage and release of the die;
6) The method of keeping the die;
7) Die scrap processing;
8) Preparation of vulnerable parts of the die.
Second, the identification of die state
(a) The necessity of qualification of die technology
During the use of the cold die, the main components of the die will lose their original use performance and accuracy due to the natural wear of the die parts, unreasonable die manufacturing process, improper installation or use of the die on the machine tool, and failure of the equipment. . As a result, the state of die technology is getting worse, affecting the normal production and efficiency of production and the quality of products. Therefore, in the management of the die, it is necessary to actively grasp the changes of these technical states of the die and carefully handle it so that the die can always work in a good technical state.
In addition, the die repair technology status identification results, together with the number of defects in the production of the product, the quality of the content, the degree of wear of the die, the cause of die damage, etc. can be made out of the die repair program and maintenance methods, which to extend the life of the die, reduce production The cost as well as the improvement of die quality and technical manufacturing level are all very necessary.
(II) Method of stamping technical appraisal
The identification of the technical status of the die is generally carried out in two ways: After the new die is made and the die is repaired, the die's technical status is identified by the trial die. The identification of die technology in use is mainly carried out through the inspection of the quality of the parts and the working status of the die. Now we will introduce a method for identification of the die during and after use, for reference when identifying.
1. Die performance check
During the use of the die or after use, a detailed inspection of the performance of the die and its working condition shall be carried out. The main methods of inspection are as follows:
(1) Inspection of Forming Parts for Die Work
During the work of dies or after work, the convex and concave dies are inspected according to the quality of the parts, that is, whether the convex and concave dies are cracked, damaged and seriously worn, and whether the clearance of the convex dies is uniform and whether the size is appropriate. Whether the mouth is sharp (blank die) and so on. For example, when a burr is found on the blank, the convex and concave die edges must become blunt and the gap must be uneven. At this time, necessary trimming and handling must be done.
(2) Inspection of guides
Check whether the guiding column, guide sleeve and guide plate of the guiding device have serious wear. If the clearance is too large, install it on the template to see if it is loose.
(3) Inspection of discharging device
Check whether the pushing parts of the die and the unloading device are sensitive and reliable. Whether the top piece rod is bent or broken, the size of the rubber used for the discharging and the elasticity of the spring, and whether the work is stable and there is no serious wear and deformation.
(4) Inspection of positioning device
Check whether the positioning device is reliable, and whether the positioning pin and the positioning plate are loose and have serious wear. In case of inspection of combined parts, if the shape and hole position of the product changes and the quality is not satisfactory, the positioning device is defective and it should be strictly inspected.
(5) Inspection of safety guards
In some of the dies, in order to make the work safe and reliable, generally there are safety protection devices, such as protective plates and other facilities. Inspection should focus on checking the reliability of its use, whether it is sensitive and safe.
(6) Inspection of automatic system
In some automatic dies, the parts of the automatic system should be inspected for damage, whether the movements are coordinated, and whether normal feeding and returning can be done automatically.
2. Quality inspection of parts
The die's technical state is good or bad, directly reflected in the quality and accuracy of the parts. Therefore, the quality inspection of the parts is an important means to identify the state of the stamping technology.
(1) Content of Quality Inspection of Parts
1) There are obvious defects and deficiencies in the shape and surface quality of the parts.
2) Whether or not the dimensional accuracy of various parts of the parts has been reduced, and whether it meets the requirements of the drawings.
3) Whether the punched burr exceeds the specified requirements, there is no obvious change. Whether the side wall of the drawing piece is pulled or not, there is no obvious change in bending angle of the bending piece.
(2) Identification method
When doing the stamping technology appraisal, the inspection of the quality of the parts should be carried out in three stages:
1) The first inspection of the part. The first inspection of the part shall be performed when the die is installed on the press and after the trial trial is completed. Several parts that are to be punched out for the first time are examined in detail for their shape and dimensional accuracy, and compared with the measured values ​​at the previous die inspection to check whether the dies are installed and used correctly.
2) Inspection of die use. During the use of the die, the quality of the part should be checked at any time, and the working status of the die during use should be known and understood. The main inspection methods are: measurement of size, hole position, shape accuracy; observation of glitch conditions. Through inspection, the wear and performance of the die can be grasped at any time.
3) Check the last item. After the die is used, the following parts should be checked in detail to check the quality. During the inspection, according to the nature of the process, such as blanking parts mainly inspect the external dimensions, hole position changes and burr changes; drawing parts mainly check deep drawing shape, surface quality and dimensional change; bending parts mainly check the curved fillet, Shape position change status. Through the quality of the final inspection and the number of pieces, to determine the wear of the die or the need for repair of the die. To prevent accidents or interruption of production at the next use.
After the die is used and inspected, the main purpose is to ensure the accuracy of the die, which can ensure normal production under a good working condition, extend the service life of the die to a greater extent, and prevent defects from causing defective products.
Through the two inspection results of the performance of the die and the quality of the parts, the analysis can basically determine the technical state of the die, and use it as the main basis to decide the die repair and scrapped opinions.
When doing the stamping technology status appraisal, a technical appraisal file should be established for each die, and the registration card, processing advice, and technical status should be filled out for each inspection result. In order to facilitate the correct and reasonable use of the die in the future.
Third, cold die random maintenance repair
During the use of cold die, there will always be failures and minor glitches. At this time, it is not necessary to remove the die from the press, and the maintenance can be directly performed on the press so that it can normally resume work and the production can be performed normally.
(A) die maintenance and repair content
Die random maintenance repair, including the following:
1) Make use of the spare parts of the spare parts of the die and replace the parts that have been damaged in the working process of the die, such as the stoppers in the continuous die, the composite die, the bending pins, the positioning pins in the drawing die, and the positioning plate.
2) Using whetstone to sharpen the convex and concave die edges that are worn and blunt, making them sharp.
3) Temporary polishing of working parts such as drawing die and cold extrusion die is performed by polishing to eliminate the influence of the worn surface quality due to frequent use.
4) Tighten the loosened fixing screws and other parts of the die.
5) Replace the discharge spring and rubber pad.
6) Adjust the gap between the male and female molds and the positioning device that have become larger due to wear.
7) Replace the damaged top and top bars.
8) Replace the die with other fragile auxiliary parts.
(II) Random Maintenance Repair Methods for Dies
The random maintenance repair of the die is mainly to perform maintenance trimming on the temporary faults of the die under the production site environment, temporarily replacing some relatively simple wearing parts or making temporary adjustments. No complicated adjustments, research and development are required. test. The method is as follows.
1. Replace new parts
During the use of the die, it is easy to damage the parts that need to be replaced mainly include two kinds: one is the common standard parts, such as hexagon screws, pins, die handles, springs, rubber pads and so on. The other is the vulnerable parts of the die, such as punches, dies and positioning device parts.
2. Refining the working surface of the working part
1) When the degree of wear of the edge of the convex and concave die in the blanking die is not large, in order to reduce the die removal and affect the matching precision of the positioning pin and the pin hole and the gap between the convex and concave die, it is generally not necessary to disassemble the convex and concave die. Under the press, you can use several sets of different specifications of oil stone kerosene on the press machine to sharpen the knife edge in one direction along the cutting edge until the cutting edge is smooth and sharp.
2) For the working surface of deep drawing and bending die, metal particles often adhere to the surface due to wear, resulting in scratches on the work surface and seriously affecting the surface quality of the product. At this time, the arc surface of the female mold can be first polished with a curved oilstone or a fine sandpaper, and then polished with chromium oxide. In the process of lighting and polishing, the hole of the die must be smoothed everywhere. In the connection between the arc surface and the cylindrical surface of the cavity and the end surface of the die, smooth transition is required without any edge. If the corner of the die becomes larger after grinding, the die can be removed and re-plated with hard chrome and then polished until it is suitable.
3. Repair damaged and deformed parts
Due to the long-term use of the die, some parts are easily deformed or even damaged due to the punching force and the shock and impact of the strip. Such as drawing die in the pressure plate of the material. Long-term contact with the sheet material and pressure will lose the surface of the flatness, affect the quality of stamping, then it should be polished. For example, in the progressive die, after the long-term use of the lead plate, the lead plate can be easily deformed by the wear of the strip. At this time, it can be unloaded, and the surface of the contact strip can be flattened by a surface grinder. Then expand the screw holes and pin holes and reassemble them to restore the original accuracy. If it is a local wear, it can be repaired by welding and it can be used after grinding.
4. Fasten the loose parts on the die
During the use of the die, due to the violent impact of the pressure of the press, some parts such as the fixing plate, the guide plate, and the screws on the stripper plate are loosened by the vibration and cause the position of these parts to change and affect the accuracy and work performance of the die. The die will be damaged, reducing die life. Therefore, during the working of the die, it should be observed at any time. If it is found that the screw is loose, it must be tightened before use.
5. Grind the damaged edge
During the operation of the die, if the edge of the punching die has chipped or cracked, and the chipping and cracking is not severe, and the precision of the die is not high enough, the edge can be grinded with a whetstone or pneumatic grinding wheel. When grinding with an air-moving grinding wheel, the irregular section of the chipping or cracking section can be first ground to a smooth transitional section with an air-dynamic grinding wheel, and then sharply ground with oilstone to form a sharp edge.
6. Make up the lubricant
Because of the permanent work of the die, after working for a period of time, it is necessary to add lubricating oil to the guide site to reduce wear and increase die life.
Random maintenance of the die is an important measure to maintain and maintain the die and improve die usage and life. Therefore, it must be carefully operated to ensure quality, and careful inspection should be performed after maintenance to ensure the use effect after maintenance.
Fourth, the maintenance of cold die
Cold die is a relatively sophisticated and complex process equipment. It has a long manufacturing cycle, a high cost, and a complete set of production. Therefore, in order to ensure the normal production operation, improve the quality of parts, reduce the cost of parts, extend the service life of the die, improve the technical state of the die, the die must be carefully maintained. The maintenance and maintenance of the die should be carried through through the use of the die, the repair of the die and the storage of the die.
The maintenance of cold die mainly includes the following aspects:
(a) Inspection before using the die
1) Before using the cold die, check it against the process file. Whether the die used is correct. Is the specification and model consistent with the process documentation?
2) The operator should be aware of the use of die performance, structural characteristics and role of principle, and be familiar with the use of operating methods.
3) Check whether the die used is in good condition. Whether the stamping material used meets the requirements of the process pattern and prevent damage to the die due to poor quality of the raw material.
4) Check whether the equipment used is reasonable, such as whether the press stroke, press tonnage, and leak hole size are compatible with the used die.
5) Check whether the die is properly installed on the press and whether the upper and lower plates are fastened to the press.
(B) Inspection during use of the die
1) Before adjusting the boot, we must check whether there are any foreign objects inside or outside the die, and whether the blanks and sheet material washed are clean and tidy.
2) The operation site must be clean and the work pieces must be neatly arranged.
3) The first few pieces of the die after the trial punch should be carefully inspected according to the pattern, and then go into normal mass production after passing the test to prevent the die from starting to work.
4) In the use of the die, it is necessary to obey the rules of operation to prevent indiscriminate placement, disorderly movement, and chaos.
5) During the work, it is necessary to check the operation of the die at any time, and to find out the anomalies should be maintained at any time.
6) The surfaces of the workpieces and the movable components of the die must be surface-lubricated on a regular basis.
(III) Inspection after use of die
1) After the die is used, the die must be properly removed from the press according to the operating instructions. Do not disassemble or disassemble the die so that the die can be damaged.
2) After removing the die, wipe it clean and apply oil to prevent rust.
3) The lifting of the die should be steady, slow, slow.
4) Select several parts after the die is to be stopped and conduct a thorough inspection to determine whether it is overhauled or not.
5) Check the technical status of the die after use. For example, tighten the screws and send them to the designated place for storage.
(d) Maintenance and repair of dies
1) The cold die should be regularly overhauled according to the state of the die technology to maintain and improve the accuracy of the die, and the work performance is always in good condition.
2) During the inspection and repair - it must be carried out according to the inspection and repair process. After the inspection, adjustments, trials, and technical status assessments shall be carried out.
(five) storage of die
1) Carefully and carefully check the dies when they are in storage, and do a good job in the characterization of die dies.
2) When keeping the die, it must be classified and stored to establish a sound storage file.
3) The used die is better kept by a person.
4) The place where the die is stored or the warehouse must be dry and well ventilated.
5) Dies that are not used regularly must be wiped regularly and oiled to prevent rust.
Fifth, the cold die custody
(A) cold die management method
Cold die management method should be: account, object, card match, classification management.
1 mold management card
Die management card refers to the record card that records the number and name of the die, the date of manufacture, the unit of manufacture, the name of the product, the figure number of the product, the type and specification of the material, the sketch of the part, the equipment used, the condition of the use of the die, the number of parts processed by the die, and the quality of the die. Some of them also record the results of the identification of mold technology status, mold repairs, and improvements. The mold management card is generally hung on the mold and requires one mold and one card. After the die is used, it is necessary to immediately fill in related matters such as work date, quantity of parts and quality, and submit it to the warehouse for storage. Die management cards—usually stored in plastic bags to prevent long-term damage.
2 mold management account
The mold management account is for the total registration and management of all the molds in the inventory. The mold number and the storage and storage location of the molds are mainly recorded so that they can be accessed in time for use.
3 mold management
The classification management of the mold means that the mold should be stored according to its type and the machine tool classification. There are also classified according to the category of items, which are generally grouped by items. Such as a stamping product, respectively, through the punching, deep drawing, forming three processes can be completed, so that the use of these three processes can be blanked (blank) mold, pull probe (multiple deep drawing) mold, forming mold And so on - the series of punches are put together in a piece of management and preservation, so that in use, it is very convenient to access the molds, and according to the conditions of the parts, it is easy to maintain and maintain.
In the cold stamping production, according to the above methods, the inventory stamps should be checked frequently to make sure that the objects, accounts, and cards are consistent. If problems are found, they should be dealt with in time to prevent the normal production from being affected. The management of molds is critical to improving the state of mold technology, ensuring product quality and ensuring the smooth production of stamping. Therefore, we must do a good job of this work. It is also an important part of production and operation management.
(II) Management Measures for the Deposit of Dies
The storage of the mold should always make the mold ready for use. To this end, the following points should be made for the storage and release of molds:
1) New molds for storage must have a certificate of inspection, and must have a few pieces of qualified products after the trial mold or after use.
2) If the used mold needs to be stored for re-storage, it must have a technical status identification statement to confirm whether it can continue to be used next time.
3) After repairing and maintaining the mold of the technical state, the self-test and mutual inspection shall be the molds that can be used to confirm the qualification.
4) After the repaired mold, the mold shall be tested and qualified by the inspector.
Dies that do not meet the above requirements must not be allowed to be stored in the warehouse in order to avoid confusion and prevent the mould from causing undue losses during the next use. The issuance of stamps shall be issued in accordance with the production instruction, ie, the production notice, and the product name, drawing number, and mold number shall be used. If a certain factory is subject to the production plan, it is difficult to prepare ahead of time. Then the custodian will issue a “subpena subpena†to the dispatcher (foreman), indicating that this model already has production conditions. The foreman then uses the (installation) personnel of the die to release the die installation task, and the installer then picks up the die specified in the subpena for installation and use. This is because, because of the mass production conditions, there are many daily copies and repair dies. If they are not controlled, misused, and randomly distributed, the result is that several sets of replica molds will be repaired every day. Maintenance and production are all passive, affecting production. Therefore, this requires the mold management personnel to have a strong sense of responsibility and sense of responsibility, to be aware of the mold kept, to grasp the state of each mold technology status at all times, in order to ensure the normal production.
(c) Mold storage methods
When keeping the mold, pay attention to the following points:
1) The mold library where the mold is stored should be well ventilated, protected from moisture, and easily stored and removed.
2) When storing molds, they should be stored in categories and placed neatly.
3) For small molds should be placed on the shelf for storage, large and medium-sized molds should be placed on the bottom of the rack or at the entrance. The bottom should be cushioned with a sleeper and flattened.
4) Before the mold is stored, it should be wiped clean, and in the oil storage hole at the top of the guide post, inject oil and cover with a piece of paper to prevent dust and debris from falling into the guide sleeve to affect the guiding accuracy.
5) At the cutting edge and cavity of the punch and die, the contact surface of the guide bushing is coated with anti-rust oil to prevent rust after long-term storage.
6) When the mold is stored, it should be placed between the upper and lower molds to limit the block (especially large and medium-sized molds), in order to avoid failure of the discharge device long-term pressure.
7) The upper mold and the lower mold should be stored after being assembled as a whole and must not be opened for storage so as not to damage the working parts.
8) For molds that are not used for a long period of time, they should always be inspected for good preservation. If rust or dust is found, it should be treated in a timely manner.
(4) Management Measures for Die Retirement
The management of mold scrap should be carried out as follows:
1) For those molds that are naturally worn and cannot be repaired, the scraps should be written off by the technical appraisal department, and the reasons and changes in the size of wear should be indicated. After the production department signs the contract, the mold scrapping procedures will be processed.
2) Where the damaged mold is worn, the responsible person shall fill in the rejection form, indicate the reason, and go through the approval procedure after being approved by the production department.
3) If the mold is scrapped due to revision or modification of the design, the design department shall fill out the scrapped list, and indicate the figure number and reason after the revision. After the signing of the craft department, scrapping shall be performed according to natural wear.
4) After the new mold is tried or failed to be repaired, it must be analyzed by the technical department after the technicians, mold design, and manufacturer jointly identify the cause of discontinuation and the improvement measures before discarding.
(five) management of wearing parts inventory
After long-term use of the die, it will always wear out and damage the working parts and auxiliary parts. Therefore, in order to restore the original state of the art after the die is damaged, the repair cycle is shortened, and the spare part is stored in the factory spare part. A certain number of wearing parts are reserved. It is absolutely necessary, but stocks should not be too large. If a certain amount of wearing parts is consumed, analyze the reasons and take various measures. Do not blindly expand stocks.
For the commonly used wearing parts, in addition to a certain number of stocks to be replaced in time, but also must take various measures to make it adapt to production needs. For parts that are easily damaged, mold materials with particularly high toughness should be used. For parts that are easily worn, wear-resistant high-quality alloy steel and hard alloy materials should be used.
In addition, in order to avoid production stoppages due to poor management of spare parts or due to untimely supply, the type of wearing parts shall be determined for each pair of molds, and at least 2-3 spare parts shall be provided in the library. Ensure that production can proceed normally.
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