Stamped parts are common products in the metal processing industry, especially in fields such as automotive, household appliances, and aerospace manufacturing. Bending is a critical step in the stamping process, but sometimes stamped parts can have size discrepancies after bending. These dimensional errors not only affect the quality of the product but can also lead to increased costs and decreased production efficiency. Here are several main reasons for the bending size discrepancy:
1. Bending process
The complexity of the bending process directly affects the accuracy of stamped parts. With an increase in processes, small deviations in each process can accumulate into large errors. The arrangement order of different processes also has an important impact on the dimensional stability of the final product. For example, if a small bend is made first followed by a complex bending process, it may result in the material's stress state and spring-back effect affecting the final size.
2. Stamping raw materials
The quality of raw materials is crucial for the bending size of stamped parts. The material's mechanical properties such as elastic modulus, yield strength, and uniformity will affect material flow during bending and the final shape. Additionally, uneven material thickness can cause uneven deformation during bending, resulting in inconsistent finished sizes. For example, thicker sections may not bend as tightly as thinner sections.
3. Process operations
Human factors in the operation process should not be overlooked. The accuracy of mold installation, proper adjustment, and the skills and experience of operators can all affect bending quality. Even minor installation errors or improper operation can lead to significant deviations in finished product sizes.
4. Stamping dies
The die is one of the key factors determining the quality of stamped parts. The design, manufacturing accuracy, and maintenance of the die are directly related to the shape and dimensional accuracy of the bent part. Worn, damaged, or improperly designed dies can all lead to size discrepancies in stamped parts. Additionally, the heat treatment and material selection of the die are also important factors affecting its lifespan and performance.
5. Press machine
The type of press machine used also affects the accuracy of bending sizes. Press machines of different models and tonnages have different accuracy in force output and speed control, which directly affects the stress state and deformation degree of the material during bending. High-performance press machines can usually provide more stable and precise force control, thus improving the consistency of bending sizes.
6. Characteristics of the bent part itself
The design of the bent part is also an important factor affecting dimensional accuracy. For example, asymmetrical bent parts are more likely to produce uneven stress distribution during processing, leading to size discrepancies. Larger or more complex shaped bent parts are also more prone to errors during processing.
Solutions and preventive measures
To address the above issues, the following measures can significantly improve the accuracy of bending sizes and product quality:
- Optimize process design: Determine the optimal process flow and sequence through simulation and testing.
- Choose high-quality materials: Use materials with uniformity and stable mechanical properties.
- Improve operational accuracy: Provide professional training for operators to ensure precise installation and adjustment of molds.
- Maintain and upgrade equipment: Regularly maintain press machines and dies, and upgrade when necessary to maintain high performance.
- Design review: Conduct a detailed review of the design before production to ensure design feasibility and process rationality.
Through these measures, dimensional errors in production can be effectively reduced, and the quality and competitiveness of the products can be improved.
