Longsheng

1. تأثير سرعة الختم على الجودة

2.JS Company High-Tech Technology Solutions

التحكم في السرعة الذكية للختم:

نستخدم نظام الصحافة المؤازرة الذكية مع قدرة آلية على تغيير سرعة الختم حسب حالة المواد ، مع نطاق قابل للتعديل 100-1200 مرة/دقيقة. بمثال تصنيع مكونات السيارات ، سيقوم النظام تلقائيًا بتنفيذ تعويض الضغط الديناميكي تلقائيًا عند ختم السيارة بسرعة عالية 800 مرة في الدقيقة ، مع الحفاظ على معدل انتعاش المنتج بنسبة 0.3 ٪.

تقنية العفن الدقيقة:

يتميز القالب الخاص بنا ببنية قناة تبريد مدمجة مع قنوات تبريد مدمجة خاصة ، تتحكم بشكل فعال في الحرارة الناتجة عن المعدن عالي السرعة ، جعل عمر العفن أطول 30 ٪ من متوسط ​​الصناعة . وفي الوقت نفسه ، لا يقلل تقنية طلاء الكربون الشبيهة بالماس (DLC) من معامل الاحتكاك فحسب ، بل يتيح أيضًا سطح أجزاء ختم المعادن لتحقيق نعومة مستوى الميكرومتر.

تقنية محاكاة تكوين المواد:

من خلال محاكاة تحليل العناصر المحدودة (FEA) ، يمكننا التنبؤ بدقة ظروف تدفق المواد في سرعات ختم مختلفة وبالتالي تعديل معلمات العملية. على سبيل المثال ، بالنسبة لمواد سبيكة الألمنيوم ، يوصي النظام بالتحكم في سرعة الختم في غضون 600 مرة في الدقيقة. ستوفر منصتنا الرقمية اقتراحات ضبط العملية في الوقت الفعلي ، والتي ستقلل من تكلفة صب التجربة بشكل كبير.

نظام فحص الجودة lntelligent:

مع ماسح الضوئي الأزرق عالي الدقة ، يمكنه فحص دقة الأبعاد على الإنترنت لأجزاء الختم عالية السرعة (دقة اكتشاف 0.005 مم) ، ورفض المنتجات المعيبة تلقائيًا. من خلال تقنية التفتيش المرئي AI ، يمكن للنظام تحديد الخدوش السطحية والشقوق والعيوب الأخرى في الوقت الفعلي و زيادة معدل تأهيل المنتج إلى 99.5 ٪ .

3. Suggestions لاختيار السرعة في سيناريوهات التطبيق المختلفة

ما إذا كان إنتاج الدُفعات الصغيرة يتطلب معالجة دقيقة أو أوامر الدُفعة الكبيرة تتطلب توصيل سريع ، ودقة البعد واستقرار الجودة للمعادن.

كيفية اختيار معدات مناسبة لختم الهندسة؟

The logical selection of stamping machines is an essential consideration in ensuring production efficiency, cost control, and product quality guarantee. With regard to the requirement for metallic stamp parts in production, the following analysis will be conducted based on the major dimensions:

1.Correlating material properties with equipment tonnage

For light metal materials such as copper and aluminum, low to mid-tonnage punching machines weighing 50-200 tons should be used. This configuration is capable of addressing the needs of molding without causing waste created by material over-deformation.

While dealing with high-strength steel or alloy materials, the heavy-duty stamping machines should weigh more than 800 tons. Sufficient pressure is required to ensure that the material will undergo sufficient plastic deformation during the process of stamping.

For very thin sheets whose thickness is less than 0.2mm, servo presses or hydraulic presses are recommended. Such machinery can provide high speeds so that the stamping process may be controlled accurately and the tearing risk of material minimized effectively.

2.Production efficiency in batches and equipment

3.Accuracy requirement and equipment performance

• Tolerance sensitive parts: Use closed-loop control system equipment (e.g. servo presses), real-time stamping error compensation
• High surface quality: Magnetic levitation stamping is prioritized to reduce vibration-induced burr and distortion.
• Deep stretching process: Multiple intake molds and high rigidity body are required to avoid wrinkling or cracking.

4.Mold design and equipment compatibility

• Mold size limit: Equipment workbench ≥ the mold external size +50mm to ensure installation stability.
• Closed-type height adjustment: Hydraulic or servo presses allow adaptive mold height adjustment, reducing debugging time.
• Automated integration: Automatic feed, test and waste discharge between mold sensors and equipment.

5.Cost-benefit analysis

JS company uses intelligent control system to manage production process. They use precision molds to ensure product quality. At the same time, automated testing equipment will detect product conformity in real time.

This production method can meet different needs. We can guarantee the precise size and stable quality of the metallic stamp, whether for small-scale scale production requiring fine processing or for large scale orders requiring quick delivery.

What are the surface treatment methods for metal stamping?

1.Electroplating

• The rust resistance and electrical conductivity of stamp metal surface are improved by electrolysis to deposit metal layer such as zinc or nickel plating on stamping metal surface.
• JS technology association: Cyanide free electroplating process, 100% wastewater treatment compliance with EU RoHS standards, while maintaining coating uniformity (±0.01μm).

2.Chemical conversion coating

• Protective film (like phosphating and passivation) is formed by chemical reaction and generally is used for aluminum stamping part anti-corrosion pretreatment.
• JS Technology Association: Independently developed chromium-free passivation technology, zero VOC emission, and 50% improved corrosion resistance of the film layer, and it has been applied on battery trays for new energy vehicles.

3.Anodic oxidation

Oxide film is formed on the metal surface of aluminum stamp metal to improve hardness and abrasion resistance, and can be dyed to achieve a personalized appearance.

JS technology association: Provides hard anodizing (film thickness up to 50 μm) combined with sandblasting technology to meet military grade wear resistance (e.g. aerospace fasteners).

4.Spraying and powder coating

polymer coating is sprayed with electrostatic adsorption. It has the characteristics of heat preservation and weatherresistance, and is suitable for decoration parts such as home appliance panel.

JS technology association: Fully automated spraying lines with color difference ΔE≤1.5 were used to support special effects such as matte and high gloss with 99.8% rate.

How much longer is the lifespan of JS molds compared to other suppliers?

1.Core advantage of JS mold lifespan

• High precision machining technology: The precision of die processing reaches ±0.005mm by using the German import five-axis machining center, which reduces friction loss during stamping process.
• Surface strengthening technology: Innovative application of diamond coating and nitride treatment, so that the mold surface hardness of the mold increased threefold, anti-adhesion wear effect is remarkable.

2.Mould lifespan of JS compared to other suppliers

Value to customers of JS's mold usage time:

Automotive industry: 1.2 million vehicle service life, support a production line for 8 months in a row, reduce mold changes downtime.

Electronics industry: Mass production stamping metal parts with micrometer level precision and long life in accordance with 0.02mm tolerances.

Cost effectiveness: Based on a customer's annual output of 5 million pieces, we can save over $2 million annually by extending the service life of JS mold life.

ملخص

In the process of metal stamping design and engineering practice, material selection, mold design and equipment configuration are the most important contents to ensure the quality of finished products. Material directly affects the durability of product. High precision die design ensures dimension tolerance and surface integrity. Combining with the adaptability of advanced equipment and technology, the production efficiency can be greatly improved and the defect rates can be reduced.

By optimizing these critical processes, engineers can accelerate product iteration while ensuring product quality, putting the product in an advantageous position in a competitive market.

Disclaimer

The content on this page is for general reference only. JS Series makes no express or implied warranties regarding the accuracy, timeliness, or applicability of the information provided. Users should not assume that the product specifications, technical parameters, performance indicators, or quality commitments of third-party suppliers are completely consistent with the content displayed on this platform. The specific design feature, material standards, and process requirements of the product should be based on the actual order agreement. It is recommended that the purchaser proactively request a formal quotation and verify product details before the transaction. For further confirmation, please contact our customer service team for professional support.

JS Team

JS is an industry leading provider of customized manufacturing services, dedicated to providing customers with high-precision and high-efficiency one-stop manufacturing solutions. With over 20 years of industry experience, we have successfully provided professional CNC machining, sheet metal manufacturing, 3D printing, injection molding, metal stamping and other services to more than 5000 enterprises, covering multiple fields such as aerospace, medical, automotive, electronics, etc.

We have a modern factory certified with ISO 9001:2015, equipped with over 100 advanced five axis machining centers to ensure that every product meets the highest quality standards. Our service network covers over 150 countries worldwide, providing 24-hour rapid response for both small-scale trial production and large-scale production, ensuring efficient progress of your project.

Choosing JS Team means choosing manufacturing partners with excellent quality, precise delivery, and trustworthiness.
For more information, please visit the official website: jsrpm.com

FAQs

1.What defects can be caused by excessive stamping speed?

Will cause uneven material flow, burr and burr. Mold impact exacerbates wear and tear, easy to crack. Sudden increases in temperature can cause material to harden, increasing the risk of rebound.

2.How can surface treatment of molds reduce wear and tear?

DLC coating, nitriding and chrome plating are used to reduce friction coefficient, enhance adhesion and wear resistance, reduce the damage of stamping friction to the die, and significantly prolong its service life.

3.How to prevent surface oxidation of stamped parts?

Choose antioxidant material (such as galvanized steel plates), chrome plating or nitride treatment on the surface of the die, spray anti oxidation lubricants during stamping process, control mold temperature, avoid high-temperature oxidation, and timely passivation or oil treatment of the finished product.

4.How does material thickness affect the accuracy of stamped parts?

The design of mold clearance and rebound quantity is directly affected. Excessive thickness leads to impact wear and deformation of the die, while excess thickness leads to tearing or size fluctuation. mold clearance and stamping parameters need to be matched to control accuracy.

Resources

Engineering design process

Progressive stamping

Deep drawing