Automobile panel moulds are the main stamping moulds for car production. Syca Limited independently develops and manufactures automobile stamping dies within 4 meters. Over the years, it has accumulated rich experience in automobile mold design, development, and processing and manufacturing. Now take the car cover automobile mold as an example, and introduce from the following aspects Its design and manufacturing ideas:

Design principles of automotive stamping die

Combining with the many years of experience in mold design and manufacturing of Syca Company, the design of car panel automobile molds should follow the following basic principles:

(1) It is very important to determine a reasonable stamping direction based on the product shape of the part and the product testing standard. Whether the stamping direction design of the car cover is reasonable or not determines whether a satisfactory cover product can be stretched, and it directly affects the number of process supplements, the shape of the pressing surface, and the hardness and service life of the automobile mold.

(2) The shape of the profiling pressing surface of the mold must be effective. The shape of the blanking surface of the covering member stretched and formed is the primary condition to ensure that the material does not break and smoothly formed during the stretching process. In order to achieve this goal, the blanking surface should be formed with a certain inclination angle to reduce the drawing depth, and a flat blanking surface should be formed to achieve the best blanking effect. It is also necessary to maintain a certain geometric relationship between the pressing ring and the shape of the punch, so that the material is always in a tight state during the stretching process, and it can be firmly attached to the punch, no excess material is allowed to produce wrinkles, and the best pressing effect is maintained . In order to ensure that the pressing surface is smooth and smooth so that the wool flows into the cavity of the concave mold, the pressing surface must not have local bulges, pits and sinks. If the pressing surface is the flange of the stretched part itself and there are protrusions and depressions on it, the shaping process should be added. When the angle between the pressing surface and the stamping direction is greater than 90°, the feeding resistance will increase, so it is not desirable.

(3) The supplementary surface of the stamping process must be fully determined. The process supplement surface is not only a condition to achieve stretching, but also a necessary supplement to increase the degree of deformation and increase the stiffness of the part. It will directly affect the stretching forming and subsequent trimming, shaping, flanging and other processes.

(4) Automobile mold design must be planned as a whole. The design of the deep-drawing die for car panels must be combined with future processes and a reasonable overall plan. The design scheme of multiple progressive die should be adopted to reduce the number of progressions under the premise of ensuring product deformation rebound and surface quality as much as possible. , To help companies reduce mold manufacturing costs, maintenance costs, and improve production beats.

The design of car cover parts and automobile molds must also pay attention to these points:

(1) The rounded corners and linear design of the stretched parts. When the stretched part has rounded corners and straight parts, set the stretch ribs on the straight part to balance the feeding speed; if the stretched ribs are set in the shallow part of the straight part of the stretched part, then the deep straight part There is no need to set stretch ribs.

Syca Limited specializes in the development and manufacture of stamping dies, which can design and process automotive dies and hardware stamping dies for household appliances within 4 meters.

(2) Design of inner and outer ring of automobile mould. The rounded corners and straight parts of the shallow stretched parts should be set with stretch ribs, but the rounded corners can only be set with one stretch rib, and the straight part can be set with 1-3 stretch ribs; if there are multiple stretch ribs When the time, it should be "outer loose and inner tight", that is, the tensile ribs of the outer ring of the mold are "loose", and the tensile ribs of the inner ring of the mold are "tighter". This can be achieved by changing the height of the tensile ribs.

(3) The profile of the stretch ribs should be convex and concave. Width stretch ribs should be set in the convex curve part. Stretching ribs may not be set in the concave curve part; the stretching ribs or the stretching threshold should be as close as possible to the round corners of the stretching rib mold, which can increase the material utilization rate and reduce the mold outline size, but consider not to affect the trimming mold Strength of.

Manufacturing steps

The manufacturing of automobile stamping die for car cover parts mainly includes the following steps:

(1) Conceptual design of automobile mould. The car body is a complex collection of free-form surfaces. The conceptual design of the cover is generally realized by using CAD three-dimensional modeling software, abstracting and generalizing the required analysis data and their relationships, and establishing a basic model after computer data processing. Conceptual design is also a data abstraction of objective entities, which reflects the specific attributes of the entity and the relationship between the entities, thereby abstracting the specific entity into the data model. Therefore, the relationship between each cover entity and its attributes can be determined through conceptual design. Specific to the design of the drawing die for car panels, the entity is the object that the drawing die plays a decisive role in the design process, and it is the data model established from different aspects of the entity.

 (2) Entity design of automobile mould. The physical design of the cover is generally realized by CAE finite element analysis and simulation software. The application of CAE technology must pay attention to these points: first, you should fully understand the material designation, material specification, material elongation and maximum expansion area of the processed cover. , And correctly predict the wrinkles, cracks, surface quality, springback and other defects that may occur during the physical stamping of the cover. Secondly, we should fully consider the material properties selected in the physical design of the car cover stamping die, such as material specifications, material grades and material strength, and correctly grasp the requirements of the connection method and connection size of the stamping die and the stamping equipment. Finally, you should fully understand the attributes of the stamping equipment, such as stamping equipment model, overload protection pressure, clutch pressure, air cushion ejection pressure, mobile working pressure, press stroke distance, etc.

 (3) Compliance verification of automobile molds. Mold conformity verification is to verify whether the mold installation dimensions, mold hardness, positioning pins and positioning block positions, mold cavity dimensions, etc. meet the requirements of the design drawings, and verify whether the mold meets the requirements of the assembly adjustment technical requirements specified in the design drawings after assembly. That is, the static verification that the mold has not been installed to the equipment used.

(4) Applicability verification of automobile molds. Mold applicability verification is to install the assembled mold to the specified equipment after the mold meets the compliance verification, and verify the specified process parameters and the specified mass production capacity according to the specified product. The purpose of applicability verification is to verify whether the mold processed product meets the product drawing requirements and product assembly performance requirements. Therefore, the applicability verification conclusion should be confirmed by the main user.

Production organization of car panels

 Taking the top of the main parts of car panels as an example, the organization of the stamping production line of car body panels is introduced.

 Auto stamping die finishing

 As car cover molds must never allow unclean and defects on the surface of the mold, so the finishing of the car cover molds is very important, and it is necessary to consider the determination of the finishing requirements such as mold cleaning and mold repair.

 (1) Cleaning the cover mold. When the car cover mold is processed to the specified batch, the unclean surface of the mold must be eliminated to avoid affecting the surface quality of the cover. For mold surface cleaning, the water pressure and cleaning fluid formula must be controlled.

(2) Inspection of the surface quality of the cover mold. When processing defects such as burrs, napping, slip marks, wrinkles, pitting, etc. are found, the surface quality of the mold must be inspected immediately, and the surface of the mold must be cleaned with fine gauze of 200 mesh or more. The mold must be cleaned with special Train personnel and strictly control the number of yarn skins used for surface cleaning, and strictly inspect the surface quality of car cover mold cleaning.

 (3) Cycle appraisal of cover moulds. When the cover mold is used in a certain batch, the cover mold should be periodically evaluated, and the focus of the inspection is the limit size of the vulnerable parts of the mold. If the limit size of the wearing parts has reached the specified amount, the replacement of the wearing parts must be considered. It must be noted: After the replacement of the wearing parts of the mold, the full-size verification of the car cover mold should be carried out.

Quality control of car panels

The quality control of car stamping covers is the process of measuring different car covers according to the quality characteristics of different cover products and according to different measurement methods. The quality control methods are as follows:

(1) Verification of the quality characteristics of raw materials for car panels. Car cover products generally have to be stretched many times during the forming process, so special items that affect the forming and stretching of automobile stamping parts must be verified. Raw material conformity verification is to verify the shape, size, mechanical properties, chemical composition and other items of the raw materials used. These verifications are carried out in accordance with the specified items, methods, frequency and material standard determination criteria in the inspection guide.

(2) Dimension verification of car covering parts. The stamping dimensions of covering parts of products such as four doors and two covers of cars are generally sampled with standard sample racks to determine whether the dimensions of these covering parts meet the regulations. The standard sample racks are designed and manufactured according to the overall dimensions and assembly requirements of car covering products such as four doors and two covers. In order to ensure the stamping size of car covering products such as four doors and two covers, the measurement points of these standard sample racks must be checked regularly. Standard samples are also used to calibrate the measurement points every day. The relevant personnel shall record and analyze the dimensional stability of the test results of the standard sample rack size, the verification results of the sample rack measurement points and the calibration results of the sample rack measurement points.

(3) Dimension verification of the assembly position of car cover products. The size verification of the assembly position of the four-door, two-cover, left and right side panels and the body stamping parts of the car is generally tested with a flexible inspection tool and a cantilever three-coordinate measuring instrument, and the three-coordinate testing room regularly controls the stability of these testing instruments And analyze these test data. The appearance of these covering parts is complicated, and it is difficult to manufacture and use standard sample frames. Therefore, automobile companies generally use flexible inspection tools to detect the size of these parts. At present, foreign car companies have widely adopted laser measuring instruments to perform 100% online measurement of manufactured car bodies. The online measurement system is currently a measurement system widely used by mainstream automobile manufacturers in the world. It uses laser probes and cameras mounted on robots to measure Sampling and measurement of surfaces, holes and slots on the car body has a greater improvement in the quality level of the car body than the three-coordinate measurement used for sampling. The online measurement system has the advantages of short measurement time, 100% measurement, real-time deviation detection, and real-time alarm. By complementing the advantages of the online measurement system and the three-coordinate measurement, the size status of the car body can be better grasped, and help to improve the size and quality of the car body. It must be noted that the data collected for the various assembly inspections of each batch of car covers should be completed under the same production process conditions, and the production batch number of each batch of car cover assemblies should be maintained. All types of cover assemblies that have passed the inspection shall establish release records according to the batch number for retrospective inspection. Where defective products of various assemblies are found during the inspection, inspection records and summary analysis must be made according to the production batch number, and at the same time, the relevant departments shall formulate corrective measures and carry out quality improvements.