High-strength sheet stamping process and mold manufacturing (2)
3. Determination of the processing data of punching die profile
After the drawing process and the trimming and punching die surface processing data before the flanging finishing process, the final drawing of the finalized drawing must be taken, and the number of draws that have been subjected to springback compensation after CAE analysis cannot be used. The model data shall prevail. This requires reverse modeling of the final drawn part, and then the data of the reverse modeling is used as the mathematical basis for the processing of the trimming and punching die.
Figure 5: Lateral rebound compensation of the outer beam of the front anti-collision beam
4. Analysis of digital model of flanging shaping
CAE analysis and springback compensation are also applied to the processing digital model of the flanging shaping, and this is used as the processing basis for this process. The springback compensation of the flanging process of this part is shown in Figure 6.
Figure 6 Springback compensation for the outer beam shaping process of the front impact beam
5. Other attention issues
In addition to the above problems, the staff should determine the material of the working parts according to the characteristics of the parts, and determine which pieces need special heat treatment.
Mold making
Although the current computer technology is very advanced, the objective conditions when using CAE analysis by computer are not exactly the same as the actual environment when the mold is working. It is necessary to recompensate according to the actual situation of debugging during production debugging. Therefore, the compensation method must be taken into consideration when manufacturing the mold. The main precautions are as follows:
Drawing die
For the drawing type mold, if the mold adopts the casting structure, the molding surface should have more margin when the foam is actually cast, so that it can be rectified later. If the mold has an insert structure, at least 2 sets of materials are required.
2. Trimming and punching molds
For the repairing die before the drawing process and before the trimming, the profile data of the die must be based on the final drawn drawing.
3. Flanging plastic mold
For the flanging shaping mold, since the working part of the mold is mostly inlaid, at least two sets of materials are required.
4. Experience accumulation
Record each adjustment data in detail and accumulate relevant experience in stamping such materials.
Conclusion
The above content introduces the stamping process design and mold manufacturing precautions of high-strength sheet in automotive panels, and fully applies these precautions to the example of this article—the development of the front impact beam outer panel mold has been very successful. It not only satisfies the requirements of customers to shorten the production cycle and improve the quality of products, but also accumulates valuable experience for the development of high-strength sheet metal molds in our factory, which has raised the level of the overall stamping technology of our factory to a new level.
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