Abstract: Bending machine dies are the most common and widely used components in sheet metal processing factories. The performance of these dies directly affects the bending results and efficiency. The lifespan of bending machine dies is a significant concern for both manufacturers and users. This article introduces the factors that affect the lifespan of bending machine dies and provides maintenance tips for these dies.
I. Factors Affecting the Lifespan of Bending Machine Dies
1. Die Structure: Rationalizing the die structure improves its load-bearing capacity and reduces the level of thermal and mechanical stress it experiences. For example, a well-designed guiding system helps prevent damage between the punch and die. Cold heading and cold extrusion dies that withstand high-intensity loads are particularly sensitive to stress concentration, which can lead to cracking if the cross-sectional dimensions are not properly handled.
2. Die Material: The quality of the die material can affect the processing defects and load-bearing capacity during operation. Necessary measures should be taken to compensate for any metallurgical deficiencies and improve the die's lifespan.
3. Die Processing Quality: Defects in the workpiece during processing, as well as pre-treatment, forging, quenching, and surface treatment, significantly impact the die's wear resistance, anti-seizure ability, and fracture resistance. Surface roughness, residual tool marks, micro-cracks from electrical discharge machining, and defects such as surface carburization and decarburization during heat treatment can all affect the die's load-bearing capacity and lifespan.
4. Die Working Conditions: The precision and rigidity of the equipment used, lubrication conditions, pre-treatment of the processed material, and preheating and cooling conditions of the die all influence the die's lifespan. For example, precision stamping of thin materials is highly sensitive to the accuracy and rigidity of the press, requiring high-precision and high-rigidity presses to achieve good results.
5. Condition of the Workpiece: The surface quality, material hardness, elongation, and dimensional accuracy of the workpiece being processed directly affect the die's lifespan. For instance, when forming special alloys with a nickel content of 80%, strong adhesion between the workpiece material and the die surface can occur, leading to surface galling and directly affecting the die's normal operation.
II. Maintenance of Bending Machine Dies
1. Corrosion and Rust Prevention in Production: Statistics show that the losses caused by corrosion in bending machine dies account for approximately 7.2% of the total production value of manufacturing enterprises. The direct and indirect impacts of metal corrosion cannot be ignored. Implementing corrosion and rust prevention measures in the production of bending machine dies is essential. Specific requirements for protection and rust prevention in sheet metal processing production should be considered. Bending machine dies are essential technical products in sheet metal processing, and the improvement of the sheet metal processing industry requires high-quality bending machine dies.
2. Maintenance of Hydraulic Oil Circuit on the Bending Machine: Regularly check the oil level in the tank every week. Normal oil levels ensure the proper operation of the machine. If the oil level drops, it should be promptly replenished. When replacing the hydraulic oil, it should be done after cooling.
The hydraulic oil should be replaced approximately every 2,000 hours, initially, and then every 5,000 hours thereafter. Properly clean the oil tank each time the oil is changed to avoid the presence of foreign particles.
3. Maintenance of Filters: When changing the oil, the filters should be replaced. If not replaced, they should be cleaned. Each bending machine is equipped with an alarm device that alerts when the oil quality is not clean, indicating a problem with the filters, which should be replaced.
The air filters used in bending machine dies should be inspected and cleaned every three months, and replaced after approximately one year of use.
