In the production process of metal molds, the stability of bending dimensions is a key factor determining product quality. Unstable bending dimensions can lead to non-conforming products, affecting production efficiency and costs. This article will analyze common reasons for unstable bending dimensions and provide detailed repair strategies to help technicians improve the bending accuracy and production efficiency of molds.
I. Analysis of Causes for Unstable Bending Dimensions
1. Classification of Angle Deviation
In the bending process of molds, common occurrences of unstable dimensions mainly include internal angle deviation and external angle deviation. Internal angle deviation is less common and typically occurs during the trial production of new molds, while external angle deviation is a more common issue in production.
2. Causes and Strategies for Internal Angle Deviation
Internal angle deviation usually occurs when the pressure on the bending block is too high, causing uneven stress on the material. Strategies to address this issue include:
- Reduce the height of the bending block: Adjust the pressure on the bending die to prevent it from being too high, reducing non-uniform pressure on the material.
- Decrease contact area: Adjust the contact area between the punch and the material to reduce contact and minimize the impact of internal forces.
- Increase bending clearance: Appropriately increase the clearance between the mold and the material to allow free movement during bending, reducing internal pressure.
- Adjust mold closing height: Ensure the mold closes at an appropriate height to avoid excessive material compression.
- Increase press speed: Increase the press speed appropriately to reduce material deformation caused by prolonged stress.
3. Causes and Strategies for External Angle Deviation
External angle deviation occurs when the mold does not fully close or when there is insufficient pressure. Methods to address this issue include:
- Ensure complete mold closure: Check the mold closure status to ensure it fully closes.
- Increase the height of the bending block: Adjust the height of the bending block to allow for more effective material compression.
- Refine the radius: If the radius is affecting dimensions due to wear, trim or sharpen worn angles to maintain the correct bending angle.
- Increase punch height: Raise the punch height to increase the contact area with the material and improve bending accuracy.
- Reduce bending clearance: Check and adjust the bending clearance, especially when using old molds, consider replacing worn bending punches.
- Decrease press speed: Lowering the operating speed of the press can increase bending accuracy and reduce material spring-back caused by rapid bending.
II. Analysis of Practical Cases
By analyzing specific production cases, we can better understand how to diagnose and adjust molds to address issues of unstable dimensions. For example, in a production batch where a significant number of products exhibited external angle deviation, it was discovered through inspection that this was due to worn punches and incomplete mold closure. By replacing the worn punch and adjusting the mold closure mechanism, the issue was successfully resolved, significantly improving product conformity.
III. Preventive Measures and Maintenance Strategies
To prevent unstable bending dimensions, it is recommended to take the following measures:
- Regular mold inspections: Conduct regular mold inspections and maintenance, especially checking for wear on bending blocks and punches.
- Mold trials: New molds or modified molds should undergo thorough trials to ensure all parameters are properly adjusted.
- Operator training: Enhance training for operators to ensure they understand the correct use and maintenance of molds.
- Record and analysis: Record defective products and adjustments made during the production process, conduct data analysis to identify potential issues and improvement measures.
The stability of bending dimensions in metal molds is crucial for ensuring product quality. By understanding and applying the above fault analysis and repair strategies, production personnel can effectively improve the accuracy and stability of mold bending, thereby enhancing the efficiency and quality of the entire production line. Regular maintenance and proper operation are the best strategies to prevent unstable bending dimensions.
I. Analysis of Causes for Unstable Bending Dimensions
1. Classification of Angle Deviation
In the bending process of molds, common occurrences of unstable dimensions mainly include internal angle deviation and external angle deviation. Internal angle deviation is less common and typically occurs during the trial production of new molds, while external angle deviation is a more common issue in production.
2. Causes and Strategies for Internal Angle Deviation
Internal angle deviation usually occurs when the pressure on the bending block is too high, causing uneven stress on the material. Strategies to address this issue include:
- Reduce the height of the bending block: Adjust the pressure on the bending die to prevent it from being too high, reducing non-uniform pressure on the material.
- Decrease contact area: Adjust the contact area between the punch and the material to reduce contact and minimize the impact of internal forces.
- Increase bending clearance: Appropriately increase the clearance between the mold and the material to allow free movement during bending, reducing internal pressure.
- Adjust mold closing height: Ensure the mold closes at an appropriate height to avoid excessive material compression.
- Increase press speed: Increase the press speed appropriately to reduce material deformation caused by prolonged stress.
3. Causes and Strategies for External Angle Deviation
External angle deviation occurs when the mold does not fully close or when there is insufficient pressure. Methods to address this issue include:
- Ensure complete mold closure: Check the mold closure status to ensure it fully closes.
- Increase the height of the bending block: Adjust the height of the bending block to allow for more effective material compression.
- Refine the radius: If the radius is affecting dimensions due to wear, trim or sharpen worn angles to maintain the correct bending angle.
- Increase punch height: Raise the punch height to increase the contact area with the material and improve bending accuracy.
- Reduce bending clearance: Check and adjust the bending clearance, especially when using old molds, consider replacing worn bending punches.
- Decrease press speed: Lowering the operating speed of the press can increase bending accuracy and reduce material spring-back caused by rapid bending.
II. Analysis of Practical Cases
By analyzing specific production cases, we can better understand how to diagnose and adjust molds to address issues of unstable dimensions. For example, in a production batch where a significant number of products exhibited external angle deviation, it was discovered through inspection that this was due to worn punches and incomplete mold closure. By replacing the worn punch and adjusting the mold closure mechanism, the issue was successfully resolved, significantly improving product conformity.
III. Preventive Measures and Maintenance Strategies
To prevent unstable bending dimensions, it is recommended to take the following measures:
- Regular mold inspections: Conduct regular mold inspections and maintenance, especially checking for wear on bending blocks and punches.
- Mold trials: New molds or modified molds should undergo thorough trials to ensure all parameters are properly adjusted.
- Operator training: Enhance training for operators to ensure they understand the correct use and maintenance of molds.
- Record and analysis: Record defective products and adjustments made during the production process, conduct data analysis to identify potential issues and improvement measures.
The stability of bending dimensions in metal molds is crucial for ensuring product quality. By understanding and applying the above fault analysis and repair strategies, production personnel can effectively improve the accuracy and stability of mold bending, thereby enhancing the efficiency and quality of the entire production line. Regular maintenance and proper operation are the best strategies to prevent unstable bending dimensions.
