CN113042627B - Multi-step stamping forming method for reducing part defects - Google Patents
Multi-step stamping forming method for reducing part defects Download PDFInfo
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- CN113042627B CN113042627B CN202110278292.5A CN202110278292A CN113042627B CN 113042627 B CN113042627 B CN 113042627B CN 202110278292 A CN202110278292 A CN 202110278292A CN 113042627 B CN113042627 B CN 113042627B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/10—Die sets; Pillar guides
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
- B21D22/02—Stamping using rigid devices or tools
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Abstract
The invention provides a multi-step punch forming method for reducing part defects, and relates to the field of punch forming, wherein a first through hole and a second blind hole which are different in radial sectional area are arranged to be communicated to form a stepped hole cavity, and a first gasket is placed at the bottom of the second blind hole; placing materials in the cavity, punching the materials by the first punch in cooperation with the first through hole, and enabling the materials to deform and attach to the top surface of the first gasket; taking out the material and replacing a second gasket, punching the material by a second punch and extending into a second blind hole, deforming the material and attaching the material to the top surface of the second gasket, replacing the second gasket with different thickness and repeating the punching process; removing the second gasket, punching the material by a second punch and extending into the second blind hole, and deforming the material and attaching the material to the bottom surface of the blind hole; the micro-part is processed in multiple steps, a mode that a gasket bears progressive stamping is adopted in the blind hole processing process with a longer stamping path, the wrinkle defect caused by single-feature one-step forming is overcome, and the influence of irregular metal flow on the surface of the micro-part is reduced.
Description
Technical Field
The disclosure relates to the field of punch forming, in particular to a multi-step punch forming method for reducing part defects.
Background
The statements in this section merely provide background information related to the present disclosure and may not necessarily constitute prior art.
With the development trend of miniaturization and miniaturization of global products, medium-scale non-axisymmetric parts (medium-scale parts refer to two parts with the size ranging from 1 to 10 millimeters) are widely used in the fields of electronic products, household appliances, automobiles and the like. In the forming process of metal parts, wrinkle defects often exist in medium-scale parts due to irregular flowing of metal, and the defects are not easy to find due to small characteristic sizes of the parts, so that sudden failure of a machine is often caused, and serious personnel injury and property loss are caused.
The inventor finds that the wrinkle defect is caused by irregular material flow, the forming sequence and the process technology have important influence on the flow direction of the material, at present, a special-shaped die is mostly adopted for the punch forming of the micro-part to match with a special-shaped punch head, the blank is subjected to one-time punch forming, only the blank with good ductility can be processed, and for some blanks with common ductility or even poor ductility, the wrinkle defect is easily caused by the one-time punch forming mode, even the blank is broken, and the requirement on the precision of the micro-part is difficult to meet; for some processing procedures of step-by-step forming, step-by-step forming is carried out corresponding to different processing characteristics, and during the processing of a single characteristic in the forming process, the wrinkle defect is still generated due to irregular flowing of metal, so that the precision requirement is difficult to meet.
Disclosure of Invention
The purpose of the disclosure is to provide a multi-step stamping forming method for reducing part defects and a micro part aiming at the defects in the prior art, the micro part is processed in multiple steps, a blind hole with a longer stamping path is processed, a mode that a gasket bears step-by-step stamping is adopted, the wrinkle defect caused by one-step forming with single characteristic is overcome, the influence of irregular metal flow on the surface of the micro part is reduced, and the processing precision of the micro part is ensured through multi-step stamping forming.
The first purpose of the present disclosure is to provide a multi-step punch forming method for reducing part defects, which adopts the following technical scheme:
the method comprises the following steps:
arranging a first through hole with different radial sectional areas to be communicated with a second blind hole to form a stepped hole cavity, and placing a first gasket at the bottom of the second blind hole;
placing materials in the cavity, punching the materials by the first punch in cooperation with the first through hole, and enabling the materials to deform and attach to the top surface of the first gasket;
taking out the material and replacing a second gasket, punching the material by a second punch and extending into a second blind hole, deforming the material and attaching the material to the top surface of the second gasket, replacing the second gasket with different thickness and repeating the punching process;
and removing the second gasket, punching the material by using a second punch and probing into the second blind hole, and enabling the material to deform and attach to the bottom surface of the blind hole.
Further, the first through hole is arranged on the first die, the second blind hole is arranged on the second die, and the bottom surface of the first die is attached to the top surface of the second die.
Furthermore, the radial sectional area of the first through hole is larger than that of the second blind hole, and one end of the first through hole is communicated with the second blind hole to form a stepped hole.
Furthermore, the first punch slides axially along the first through hole, the volume of the cavity is changed, the end part of the first punch contacts and extrudes the material to deform the material, and the cavity between the first punch and the first gasket is filled.
Furthermore, the second punch moves axially along the second blind hole, the end part of the second punch contacts and extrudes the material to deform the material, and the material is filled between the second punch and the second gasket and between the side surface of the second punch and the circumferential side wall of the second blind hole.
Furthermore, the radial cross section of the first gasket and the radial cross section of the second gasket are the same as the radial cross section of the second blind hole, and the first gasket and the second gasket are matched with the second blind hole to change the axial length of the second blind hole.
Further, the axial length of the first gasket is greater than that of the second gasket, and the axial lengths of the second gaskets are different.
Further, when the second punch punches the material, the thicknesses of the different replaced second gaskets are reduced in sequence.
Further, the first punch punches the materials to enable the materials to form a stepped structure, and the second punch punches the materials to enable the materials to form a blind hole structure.
Furthermore, after the first gasket or the second gasket is replaced by taking out the material, the material is placed to the original position in the cavity again.
A second object of the present disclosure is to provide a micro part fabricated using the multi-step press forming method for reducing defects of the part as described above.
Compared with the prior art, the utility model has the advantages and positive effects that:
(1) the micro-part is processed in multiple steps, a mode that a gasket bears progressive stamping is adopted in the blind hole processing process with a longer stamping path, the wrinkle defect caused by single-characteristic one-step forming is overcome, the influence of irregular metal flow on the surface of the micro-part is reduced, and the processing precision of the micro-part is ensured through multi-step stamping forming;
(2) when the thin-wall blind hole features are formed, a multi-step mode is adopted for stamping, a supporting gasket is arranged below a material, the deformation range of the material is controlled in the stamping process, the irregular flow of the material is limited, and the deformation quantity of each stamping step is controlled, so that the wrinkle defect caused by the irregular flow is reduced, the forming precision is improved, and the controllability of the deformation range in the forming process is ensured;
(3) the characteristic forming process is controlled by replacing the gasket, the stamping distance of each process step is controlled by adjusting the thickness of the arranged gasket according to requirements, the forming precision and the yield are improved, a forming die and a stamping head are not required to be replaced, the gasket is replaced to control the stamping process, and the wrinkle defect caused by one-time forming is avoided.
Drawings
The accompanying drawings, which are included to provide a further understanding of the disclosure, illustrate embodiments of the disclosure and together with the description serve to explain the disclosure and are not to limit the disclosure.
Fig. 1 is a schematic view of a first punch mating die in embodiments 1, 2 of the present disclosure;
fig. 2 is a schematic view of a second punch mating die in embodiments 1, 2 of the present disclosure;
fig. 3 is a schematic diagram of a second punch mating mold after replacing a second gasket in embodiments 1 and 2 of the present disclosure;
fig. 4 is a schematic structural diagram of the first punch and the first through hole in the embodiments 1 and 2 of the disclosure;
fig. 5 is a schematic structural diagram of a first gasket in embodiments 1 and 2 of the present disclosure;
FIG. 6 is a schematic view of the materials placed in the cavities in the embodiments 1 and 2 of the disclosure;
fig. 7 is a schematic structural diagram of a first punch for punching materials in embodiments 1 and 2 of the disclosure;
fig. 8 is a schematic structural diagram of a material punched by a first punch in embodiments 1 and 2 of the disclosure;
fig. 9 is a schematic structural diagram of a second punch pressing a material in embodiments 1 and 2 of the disclosure;
fig. 10 is a schematic structural view of a second punch in embodiments 1, 2 of the present disclosure;
fig. 11 is a schematic structural diagram of the second punch for punching the material in the embodiments 1 and 2 of the disclosure;
fig. 12 is a schematic structural diagram of a material punched by a second punch in embodiments 1 and 2 of the disclosure;
fig. 13 is a schematic structural diagram of the second punch pressing the material after the second gasket is replaced in embodiments 1 and 2 of the present disclosure;
fig. 14 is a schematic structural diagram of the second punch punching the material after replacing the second gasket in the embodiments 1 and 2 of the disclosure;
fig. 15 is a schematic structural diagram of a material punched by the second punch after the second gasket is replaced in embodiments 1 and 2 of the disclosure;
fig. 16 is a schematic structural diagram of the second punch pressing the material after the second gasket is removed in embodiments 1 and 2 of the present disclosure;
fig. 17 is a schematic structural diagram of the second punch punching the material after the second gasket is removed in embodiments 1 and 2 of the present disclosure;
FIG. 18 is a sectional view of the final structure of the materials after punch forming in the embodiments 1 and 2 of the present disclosure;
fig. 19 is an appearance structure diagram of the micro component obtained in examples 1 and 2 of the present disclosure.
In the figure, 1, a first punch, 2, a first gasket, 3, a second punch, 4, a second gasket, 5, a first die, 6, a second die, 7, a first through hole, 8, a second blind hole, 9, a cavity, 10 and a material.
Detailed Description
It should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present disclosure. As used herein, the singular forms "a", "an", and/or "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof;
for convenience of description, the words "up", "down", "left" and "right" in this disclosure, if any, merely indicate that the directions of movement are consistent with those of the figures themselves, and are not limiting in structure, but merely facilitate the description of the invention and simplify the description, rather than indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and thus should not be construed as limiting the present disclosure.
As introduced in the background art, in the prior art, the blank is subjected to one-time stamping forming, only the blank with good ductility can be processed, and for some blanks with common or even poor ductility, the one-time stamping forming mode easily causes wrinkle defects; in view of the above problems, the present disclosure provides a multi-step press forming method and a micro component for reducing defects of the component.
Example 1
In an exemplary embodiment of the present disclosure, a multi-step press forming method that reduces part defects is provided, as shown in fig. 1-19.
The method comprises the following steps:
constructing a forming die and a stamping mechanism;
a die cavity is arranged in the forming die, and materials are put into the die cavity and formed under the action of a stamping mechanism;
the stamping mechanism comprises a stamping output element and a stamping head, the stamping head moves under the action of the stamping output element, the end part of the stamping head acts on the material to enable the material to deform and be formed under the restraint of a die cavity, and the stamping head comprises a first stamping head 1 and a second stamping head 3;
arranging a first through hole and a second blind hole which have different radial sectional areas and are communicated with each other to form a stepped hole cavity 9, and placing a first gasket 2 at the bottom of the second blind hole;
placing a material 10 in the cavity, punching the material by a first punch matched with the first through hole, and enabling the material to deform and attach to the top surface of the first gasket;
taking out the material and replacing the second gasket 4, punching the material by the second punch and extending into the second blind hole, deforming the material and attaching the top surface of the second gasket, replacing the second gasket with different thickness and repeating the punching process;
in the process of replacing second gaskets with different thicknesses, the thickness of the second gasket is gradually reduced, and the stamping path of the second punch is gradually increased, so that the material is gradually formed;
removing the second gasket, punching the material by a second punch and extending into the second blind hole, and deforming the material and attaching the material to the bottom surface of the blind hole;
and taking out the materials to obtain the required micro-parts.
Further, for the construction of the mold cavity, two molds are combined to form the mold cavity, a first through hole 7 is formed in the first mold 5, a second blind hole 8 is formed in the second mold 6, the first through hole is communicated with the second blind hole to form a stepped hole, and the stepped hole serves as a molding cavity of a material.
It can be understood that, in order to guarantee the precision among the forming process, reduce defect structures such as burr, arch that produce among the stamping process, first mould bottom surface and the laminating of second mould top surface avoid among the material deformation process to extend to the clearance of first mould and second mould in produce defect structures such as burr, improve the shaping precision.
It needs to point out very much, adopt the integrated configuration of first mould and second mould, can make things convenient for the gasket to change, especially to the great little part characteristic structure of some axial length, the first mould of split and second mould when changing the gasket for half fashioned material is located the first through-hole of first mould, and the second blind hole of second mould can break away from the material, thereby conveniently takes out and relocates the gasket.
The radial sectional area of the first through hole is larger than that of the second blind hole, and one end of the first through hole is communicated with the second blind hole to form a stepped hole;
in this embodiment, the radial cross-sectional shape of first through-hole is circular, and the part that the first drift tip end that corresponds contacted the material also is the cylinder structure, and the extrusion material promotes the material and produces deformation, makes the material top form required cylindric structure.
Of course, it is understood that the radial cross-sectional shape of the first through hole may be other shapes, such as a rectangle, a triangle, etc., and the corresponding first punch is a compliant cube, a triangular prism, etc., and the end of the first punch can be adapted to fit with the first through hole to obtain the desired configuration.
In this embodiment, the radial cross sectional shape of second blind hole is the round corner star structure, and under the effect of drift, the lower half section that receives the drift extrusion material forms the star prism structure who adapts to the second blind hole, especially to the round corner star structure in this embodiment, can make the material flow gradually and form complicated characteristic through the multi-step stamping process, guarantees the abundant flow of material, reduces the fold defect.
Of course, it can be understood that the radial cross-sectional shape of the second blind hole may also be other shapes, such as star, ellipse, triangle, etc., and the material controls the flow process under the action of the gasket and the punch, so as to improve the forming accuracy.
For the second punch, the second punch is used to form a blind hole structure on the material, in this embodiment, a star-shaped inner blind hole is taken as an example to punch the material.
The first punch slides axially along the first through hole to change the volume of the cavity, the end part of the first punch contacts and extrudes the material to deform the material, and the cavity between the first punch and the first gasket is filled;
the second punch moves axially along the second blind hole, the end part of the second punch is contacted with and extrudes the material to deform the material, and the material is filled between the second punch and the second gasket and between the side surface of the second punch and the circumferential side wall of the second blind hole to form a thin-wall blind hole structure.
When the thin-wall blind hole features are formed, a multi-step mode is adopted for stamping, a supporting gasket is arranged below a material, the deformation range of the material is controlled in the stamping process, the irregular flowing of the material is limited, and the deformation amount of each stamping step is controlled, so that the wrinkle defect caused by the irregular flowing is reduced, the forming precision is improved, and the controllability of the deformation range in the forming process is ensured.
The micro-part is processed in multiple steps, a mode that a gasket bears progressive stamping is adopted in the blind hole processing process with a longer stamping path, the wrinkle defect caused by single-characteristic one-step forming is overcome, the influence of irregular metal flow on the surface of the micro-part is reduced, and the processing precision of the micro-part is ensured through multi-step stamping forming.
Similarly, in order to avoid the defects of burrs, bulges and the like generated in the forming process, the radial cross section of the first gasket and the radial cross section of the second gasket are the same as the radial cross section of the second blind hole, and the first gasket and the second gasket are matched with the second blind hole to change the axial length of the second blind hole.
In the forming process, the axial length of the first gasket is greater than that of the second gasket, and the axial lengths of the second gaskets are different;
the first gasket is matched with the first punch to punch materials, and the materials form a stepped structure.
When the second punch punches the material, the thicknesses of different replaced second gaskets are reduced in sequence;
the second punch punches the material to enable the material to form a blind hole structure.
And after the material is taken out and the first gasket or the second gasket is replaced, the material is placed to the original position in the cavity again.
The forming device has the advantages that the defect of folds caused by irregular flowing of materials in the original forming method is effectively overcome, the forming device does not need to be additionally replaced, only the gasket needs to be added, simplicity and convenience are realized, the operation is simple, and only the punching distance of the punch needs to be controlled and the gasket needs to be replaced.
Example 2
In another exemplary embodiment of the present disclosure, a multi-step press forming method for reducing part defects is provided as shown in fig. 1-19.
With reference to example 1, the method specifically includes the following steps:
the method comprises the following steps: the blank is first stamped by a circular first punch with the diameter phi 5 to form part of the star-shaped outer profile and flange features to form a stepped structure.
A 1.25 mm thick star-shaped first shim was used, the first punch was displaced 1.25 mm and the axial length of the blank within the second blind hole was 0.75 mm.
Step two: a star-shaped hole feature is formed using a second punch having a star-shaped profile.
At this time, a 0.75 mm star-shaped second gasket is used instead, the second punch is displaced by 1 mm, the axial length of the blank positioned in the second blind hole is 1.25 mm, and the star-shaped hole formed by the second punch is 1 mm deep.
Step three: and continuously using a star-shaped profile second punch, replacing a 0.25 mm star-shaped second gasket, continuously displacing the second punch by 1 mm, wherein the axial length of the blank in the second blind hole is 1.75 mm, and the depth of the star-shaped hole formed by the second punch is 2 mm.
Step four: still using the second punch with star-shaped profile without spacer, the second punch is displaced by 0.5 mm, the axial length of the blank in the second blind hole is 2 mm, and the star-shaped hole formed by the second punch is 2.5 mm deep, resulting in the final formed part shown in fig. 18 and 19.
The characteristic forming process is controlled by replacing the gasket, the stamping distance of each process step is controlled by adjusting the thickness of the arranged gasket according to requirements, the forming precision and the yield are improved, a forming die and a stamping head are not required to be replaced, the gasket is replaced to control the stamping process, and the wrinkle defect caused by one-time forming is avoided.
Example 3
In another embodiment of the present disclosure, a micro component is provided, which is manufactured by the multi-step press forming method for reducing the defects of the component according to embodiment 1 or 2.
The structure is shown in fig. 18 and 19.
The above description is only a preferred embodiment of the present disclosure and is not intended to limit the present disclosure, and various modifications and changes may be made to the present disclosure by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present disclosure should be included in the protection scope of the present disclosure.
Claims (10)
1. A multi-step stamping forming method for reducing part defects is characterized by comprising the following steps:
arranging a first through hole to be communicated with a second blind hole to form a stepped hole cavity, and placing a first gasket at the bottom of the second blind hole; placing materials in the cavity, punching the materials by the first punch in cooperation with the first through hole, and enabling the materials to deform and attach to the top surface of the first gasket;
taking out the material, replacing the first gasket with a second gasket, punching the material by a second punch and extending into a second blind hole, deforming the material and attaching the top surface of the second gasket, replacing the second gasket with different thickness and repeating the punching process;
and removing the second gasket, punching the material by using a second punch and probing into the second blind hole, and enabling the material to deform and attach to the bottom surface of the blind hole.
2. The multi-step press forming method for reducing defects of parts according to claim 1, wherein the first through hole is disposed on a first die, the second blind hole is disposed on a second die, and the bottom surface of the first die is attached to the top surface of the second die.
3. The multi-step press forming method for reducing defects of parts according to claim 1, wherein a radial cross-sectional area of the first through hole is larger than a radial cross-sectional area of the second blind hole, and one end of the first through hole is communicated with the second blind hole to form a stepped hole.
4. The multi-step press forming method for reducing part defects of claim 1, wherein the first punch slides axially along the first through hole to change the volume of the cavity, and the end of the first punch contacts and presses the material to deform the material to fill the cavity between the first punch and the first spacer.
5. The multi-step press forming method for reducing part defects of claim 1 wherein the second punch is moved axially along the second blind hole, the end portion contacts and presses the material to deform the material to fill the space between the second punch and the second spacer and the space between the side surface of the second punch and the circumferential sidewall of the second blind hole.
6. The multi-step press forming method for reducing defects of parts according to claim 1, wherein the radial cross section of the first gasket and the radial cross section of the second gasket are the same as the radial cross section of the second blind hole, and the first gasket and the second gasket are matched with the second blind hole to change the axial length of the second blind hole.
7. The multi-step press forming method for reducing part defects of claim 6, wherein the axial length of the first shim is greater than the axial length of the second shim, and the axial lengths of the second shims are all different; when the second punch punches the material, the thickness of the second gasket is changed to be reduced in sequence.
8. The multi-step press forming method for reducing defects in parts according to claim 1, wherein the first punch punches the material to form a stepped structure and the second punch punches the material to form a blind structure.
9. The method of multi-step press forming with reduced part defects of claim 7 wherein the material is removed to replace the first shim with a second shim or to replace the second shim with a second shim having a smaller thickness before the material is replaced in the cavity.
10. A micro component produced by a multi-step press forming method for reducing defects in a component according to any one of claims 1 to 9.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US4509356A (en) * | 1982-08-13 | 1985-04-09 | Verson Allsteel Press Co. | Method and apparatus for drawing heavy wall shells |
| CN105196483A (en) * | 2015-11-16 | 2015-12-30 | 重庆持恒模具有限公司 | Die with adjusting device |
| CN108672557A (en) * | 2018-06-28 | 2018-10-19 | 苏州汇程精密模具有限公司 | A kind of step-feeding diel |
| CN109604414B (en) * | 2018-12-14 | 2019-12-31 | 安徽工业大学 | Method and device for forming stepped cylindrical part through laser shock |
| CN110238260A (en) * | 2019-05-17 | 2019-09-17 | 长沙理工大学 | A kind of sheet metal multistage cylinder drawing and forming device and technique |
| CN110883122B (en) * | 2019-11-28 | 2021-01-01 | 中北大学 | Short-process large-deformation blank making method for large-size large-height-diameter-ratio magnesium alloy cast rod |
| CN212190851U (en) * | 2019-12-27 | 2020-12-22 | 山东大学 | Mold for micro-part machining |
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