1. Scrap Jumping Hole
a. If the punch length is insufficient, cut into the concave die with a punch edge, adding 1mm to the material thickness, and replace the punch.
b. If the gap between the concave die is too large, reduce the gap by inserting a shim or use a coating machine to decrease the gap.
c. If the punch or template is magnetized, demagnetize them using a demagnetizer.
2. Scrap Blocking Hole
a. If the blanking hole is small or misaligned, increase the size of the blanking hole to ensure smooth blanking.
b. If there are chamfers in the blanking hole, enlarge the blanking hole to remove the chamfers.
c. If the cutting edge does not have a tapered line, cut a taper or reduce the length of the straight wall by expanding the hole on the opposite side.
d. If the straight wall of the cutting edge is too long, drill a hole on the opposite side to shorten the straight wall.
e. If the cutting edge is broken, causing excessive burr, regrind the cutting edge to remove the burr.
3. Poor Burr
a. If the cutting edge is broken, causing excessive burr, regrind the cutting edge to remove the burr.
b. If the gap between the punch and the concave die is too large, insert a shim to reduce the gap.
c. If the cutting edge of the concave die has poor smoothness, polish the cutting edge's straight wall.
d. If the gap between the punch and the concave die is too small, re-grind the punch or adjust the gap.
e. If the blanking force is too large, causing excessive burr, replace the spring to reduce the blanking force.
4. Uneven Trimming
a. Adjust the positioning if there is a deviation.
b. If there is unilateral forming, increase the pressure force during material feeding and adjust the positioning.
c. If there is a design error causing uneven blade contact, re-cut the edge and add a block.
d. Adjust the feeding device if the feeding is inaccurate.
e. Recalculate the step distance and redefine the blade position if there is an error in the step calculation.
5. Punch Breakage
a. Adjust the closing height if the closing height is too low and the punch enters the cutting edge for too long.
b. Improper material positioning causing the punch to cut only one side, adjust the positioning or the feeding device to prevent uneven force and fracture.
c. If the lower die scrap blocks the cutting edge, causing the punch to break, drill a larger blanking hole to ensure smooth blanking.
d. Repair or recut the fixed part (clamp plate) and guide part of the punch to ensure smooth movement and prevent deviation.
e. Poor guide of the clamp plate causing uneven force on the punch, readjust the gap of the clamp plate.
f. If the punch edge is too short and interferes with the clamp plate, replace the punch and increase the length of the cutting edge.
g. If the punch is not properly fixed and moves up and down, re-fix the punch to prevent upward and downward movement.
h. Regrind the cutting edge if it is not sharp.
i. If the punch surface is scratched and uneven force occurs during stripping, replace the punch.
j. If the punch is too thin or too long and lacks strength, replace it with a different type of punch.
k. If the punch hardness is too high or the punch material is incorrect, replace the punch material and adjust the heat treatment hardness.
6. Iron Chips
a. Misalignment of rib pressing. Recalculate the position of the rib pressing or bending.
b. Insufficient bending clearance, resulting in extrusion of iron chips. Readjust the clearance, grind the forming block, or grind the forming punch.
c. The bending punch is too sharp. Repair the R corner.
d. Insufficient material for the blade joint. Reconnect the blade joint.
e. The rib pressing is too narrow. Regrind the rib pressing.
7. Poor Sprouting
a. The center of the sprouting bottom hole does not coincide with the center of the sprouting punch. Determine the correct center position, or move the sprouting punch position, or adjust the position of the pre-punch hole, or adjust the positioning.
b. Uneven gap in the concave die, resulting in sprouting-high-side-low-side. Repair the sprouting gap or even cause fracture.
c. The sprouting bottom hole does not meet the requirements, resulting in sprouting height and fracture. Recalculate the bottom hole diameter, increase or decrease the diameter deviation of the pre-punch hole, or even cause fracture.
8. Poor Forming
a. The forming punch is too sharp, causing material tearing. Round the forming punch, and appropriately round the blade edge.
b. The forming punch is not long enough, resulting in incomplete forming. Calculate the correct length of the punch and adjust the actual length of the punch to meet the forming requirements.
c. The forming punch is too long, causing material deformation at the forming area, or even fracture. Determine the correct length of the punch, adjust the actual length of the punch, until the punch breaks.
d. Insufficient material at the forming area, causing tearing. Calculate the unfolded material, round the edge, or reduce the forming height.
e. Poor positioning, resulting in poor forming. Adjust the positioning or feeding device.
f. The forming clearance is too small, causing tearing or deformation. Adjust the clearance.
9. Bending Dimensions
a. Improper mold positioning causing angle errors, resulting in dimensional deviations. Adjust the closing height or angle difference.
b. Insufficient elasticity causing angle errors, resulting in dimensional deviations. Replace the spring.
c. Material does not meet the requirements causing angle errors, resulting in dimensional deviations. Replace the material or readjust the gap deviation.
d. Thickness deviation of the material causing angle errors, resulting in dimensional deviations. Determine the material thickness, replace the material, or readjust the gap deviation.
e. Improper positioning causing dimensional deviations. Adjust the positioning to ensure proper dimensions.
f. Design or processing errors causing gaps between bending blocks. Grind and eliminate the gaps between the blocks, paying attention to the smaller bending dimensions.
g. The forming block does not have an R corner. Under normal angle conditions and other circumstances, the forming block needs to be rounded to increase the bending height.
h. Both sides of the bending have larger dimensions. Add rib pressing.
i. Unilateral bending causing unstable dimensions. Increase the spring force and adjust the positioning.
j. Unreasonable gap causing angle errors and dimensional deviations. Adjust the gap.
k. Insufficient height of the bending blade, the forming punch is too short. Increase the height of the bending blade to allow the forming punch to fit into the bending blade as much as possible, causing slight angle errors.
l. Too fast bending speed causing deformation at the root of the bend. Adjust the speed ratio control and select a reasonable speed.
m. Unreasonable structure, the bending blade is not embedded in the fixed template. Remill the groove and embed the bending blade into the template. During stamping, the gap becomes larger.
n. Insufficient heat treatment hardness of the forming block, causing line collapse. Repair or remake the forming block to flatten the line collapse.
10. Failure to Unload Material
a. Improper positioning or improper feeding. Adjust the positioning or feeding device.
b. Insufficient avoidance causing interference. Grind the avoidance.
c. Damage to the inner guide post, causing poor movement of the clamp plate. Replace the inner guide post.
d. Scratches or rough surface of the punch. Replace the punch.
e. Improper arrangement of the material ejector pin. Rearrange the position of the material ejector pin.
f. Insufficient ejecting force or insufficient stripping force. Replace the ejector spring or stripping spring.
g. Poor coordination between the punch and the clamp plate. Repair the clamp plate and the punch to ensure proper coordination.
h. Poor fit between the forming slide and the guide groove. Adjust the slide and the guide groove to ensure proper fit.
i. Improper heat treatment of the clamp plate, causing deformation after a period of stamping. Regrind the clamp plate to correct the deformation.
j. The punch is too long or the length of the material ejector pin is insufficient. Increase the length of the material ejector pin or replace it with a punch of suitable length.
k. Punch breakage. Replace the punch.
l. The template is magnetized, causing the workpiece to stick to the template. Demagnetize the template.
11. Poor Feeding
a. Improper mold alignment, causing the material strip, feeding device, and mold not to be on the same straight line. Remount the mold or adjust the feeding device.
b. Uneven material strip causing feeding. Adjust the leveling machine or replace the material.
c. Failure to unload material causing poor feeding. Refer to the solution for failure to unload material.
d. Too tight positioning. Adjust the positioning.
e. The guide pin is too tight or the straight wall is too long. Adjust the guide pin.
f. Poor fixation of the punch or the punch is too long, causing interference with the material strip. Replace the punch with a suitable length and re-fix it.
g. The material ejector pin is too short, causing interference between the material strip and the forming block. Adjust the length of the material ejector pin to avoid interference.
h. Improper arrangement of the floating block causing poor feeding. Adjust the position of the floating block.
12. Poor Riveting
a. Improper mold closing height, resulting in inadequate riveting. Adjust the closing height.
b. Workpiece not properly positioned, causing positioning deviation. Adjust the positioning.
c. Defective workpiece before riveting. Check the sprouting hole and refer to the solution for sprouting hole defects. Confirm if the riveting hole is chamfered, and if not, add a chamfer.
d. Insufficient length of the riveting punch. Replace it with a punch of suitable length.
e. The riveting punch does not meet the requirements. Confirm and use a riveting punch that meets the requirements.
13. Missing or Incorrect Assembly
a. Carelessly assembled, causing incorrect punches. Pay attention to careful assembly.
b. Punches without directional markings. Mark the punches with directional indications.
14. Incorrect Screw Installation
a. Unaware of the thickness of the template. Understand the thickness of the template, whether it is too long or too short.
b. Lack of attention and insufficient experience. Select appropriate screws.
15. Mold Disassembly and Assembly
a. Failure to clean the dowel pin holes. Clean the dowel holes and dowel pins. When disassembling the mold, first remove the positioning pins to avoid damage. When assembling the mold, use screw guidance first, and then install the positioning pins.
b. Incorrect procedures for mold assembly and disassembly. When knocking out the dowel pins, avoid damaging the dowel pin holes.
16. Positioning Pins
a. Rough hole walls or scratches causing tight fit during mold assembly. Carefully check if the dowel pin holes have rough walls. If so, ream the holes that cannot be punched out.
b. Misaligned dowel pin holes or lack of escape holes below. Add positioning pins and escape holes.
17. Springs Too Long
a. Failure to pay attention to the depth of the spring holes. Measure the depth of the spring holes accurately and calculate the compression amount of the spring. Choose a spring that can be compressed to the bottom.
b. Lack of attention and insufficient experience. Use an appropriate spring that reaches the dead point.
