Papers by Keyword: Die Insert

Abstract: In this paper, a change of die roll height according to the die chamfer shape and V-ring distance of a fine blanking tool was studied by experiments on a special part with various corner shapes. Three guide plate inserts with different V-ring positions and three die inserts with different die chamfers were machined, and then a fine blanking tool was manufactured for the fine blanking experiments. Nine experiments were conducted on a 650-ton fine blanking press. Each die roll height was measured and analyzed. It would be noticed that the die roll heights on the corner shapes of the fine blanked parts increased with increasing V-ring distance and die chamfer angle, but it decreased with increasing corner radius and angle. The results in this study can be used to minimize the die roll height of fine blanked parts with corner shapes when designing the V-ring and die chamfer of a fine blanking tool.

Abstract: In this paper, the relation between die roll height and V-ring distance of a fine blanking tool was studied by experimenting on a special designed seat recliner holder with various corner shapes. Three guide plate inserts with different V-ring distances and a die insert with constant die chamfer were machined, and a fine blanking tool was manufactured for the experiments. Three experiments were conducted on a 650-ton fine blanking press. Each die roll height on the sample from the experiments was measured and analyzed. It should be noticed that the die roll heights on the corner shapes of fine blanked parts increase with increasing the distance between the V-ring distance, and decrease with increasing corner radius and angle. These results can be used to minimize the die roll height of fine blanking parts with corner shapes when designing the V-ring of a fine blanking tool.

Abstract: In this paper, the relation between die roll height and V-ring position of a fine blanking tool was studied by experimenting on a special part with various corner shapes. Three guide plate inserts with different V-ring positions and a die insert with constant die chamfer were machined, and a fine blanking tool was manufactured for the fine blanking experiments. Three experiments were conducted on a 650-ton fine blanking press. Each die roll height was measured and analyzed. We found the tendency of the die roll heights on the corner shapes of fine blanked parts to increase with increasing the distance between the V-ring position and the contour of the special part, and to decrease with increasing corner radius and angle. These results can be used to minimize the die roll height of fine blanking parts with corner shapes when designing the V-ring of a fine blanking tool.

Abstract: In this paper, the relation between die roll height and V-ring position was studied by fine blanking experiments for imaginary special automobile seat recliner gear. The three die inserts and three guide plate inserts with different V-ring positions were machined, and fine blanking tool was manufactured. Using the fine blanking tool, three experiments were conducted on the 650 ton fine blanking press. Each die roll height was measured, analyzed and we found the tendency of die roll heights on imaginary special gear to increase with increasing the distance between V-ring position and contour of gear. This result can be used to minimize the die roll height of fine blanking gear parts when designing V-ring of fine blanking tool.

Abstract: In this paper, the effect of die chamfer shape on the die roll height was studied by fine blanking experiments for imaginary special automobile seat recliner gear. The three die inserts with different die chamfer shapes were machined, and fine blanking tool was manufactured. Using the fine blanking tool, three experiments were conducted on the 650 ton fine blanking press. Each die roll height was measured, analyzed and we found the tendency of die roll heights on imaginary special automobile seat recliner gear to increase with increasing die chamfer angle, with the horizontal distance of die chamfer being constant. This result can be used to minimize the die roll height of fine blanking gear parts when designing die chamfer of fine blanking tool.

Abstract: The manifolds of airbag inflator were used to be produced by sheet-metal forming. It comprised at least eleven forming stages to achieve its final shape. Uneven wall thickness and poor dimensional accuracy were the common defects because the planar anisotropy of sheet-metal caused earing on the cup rim. In this study, the cup-shape workpiece is obtained from backward-extrusion of billets, followed by two stages of end-forming of tube and three stages of hole-piercing. During the end-forming production, the tool life of the first forming stage was the most severe because it applies close-die forging to increase its rim thickness. Therefore, in addition to the design of prestressed die insert, special attendance is paid to the partition of the die insert to further alleviate the stress level. The optimization of die insert was aided by the finite element analysis of DEFORM software. The results show that by lowering the parting line, the stress level can be minimized. The tool life can therefore be improved.

Abstract: In this paper, the relation between die roll height and die chamfer shape was studied by fine blanking experiments for imaginary special gear. The three die inserts with different die chamfer shapes were machined, and fine blanking tool was manufactured. Using the fine blanking tool, three experiments were conducted on the 650 ton fine blanking press. Each die roll height was measured, analyzed and we found the tendency of die roll heights on imaginary special gear to increase with increasing die chamfer angle, with the horizontal distance of die chamfer being constant. This result can be used to minimize the die roll height of fine blanking gear parts when designing die chamfer of fine blanking tool.

Abstract: It’s a simple technology to manufacture big trimming die by hardfacing on the die insert of cast iron. Here, the chemical composition, microstructure, micro-hardness, wear resistance and wear mechanism of the hardfacing layer with a newly developed electrode have been studied. The experimental results indicate that the hardfacing technology has much more advantages and cheaper than that of traditional process. The chemical composition, microstructure, micro-hardness of the hardfacing metal are all satisfied for manufacturing the big trimming die by welding on die insert of cast iron. The wear resistant test of hardfacing layers were carried out by using M2000 type tester with two different electrodes. The wear resistance of new electrode hardfacing layer is higher than that of normal hardfacing electrode D322. The wear mechanism of hardfacing layer belongs to abrasive wear model. The service life of hardfacing die insert is as long as tool steel insert which was fully heat-treated. More than 25000 workpieces can be carried out by using the hardfacing die insert. The life of repaired cold die with new kind of hardfacing electrode bar can be raised up to 30~50% than that with the electrode D322 under the same condition.

Abstract: It’s simple technology to manufacture big trimming die by hardfacing on the die insert of steel. In this paper, a kind of surface hardfacing technology which deposited by using D322 on 42CrMo steel were studied instead of traditional manufacturing process. The effect of hardfacing parameters on microstructure, hardness and wear resistance are tested and analyzed. The key points of manufacturing trimming die by using hardfacing method was given out. There are no defects in the hardfacing layer. The average hardfacing layer is higher than 57.5HRC. The hardfacing surface has good figurations and hardfacing layer has good wear resistance. The hardfacing for real product of trimming die is completed successfully and their properties reach or exceed those of dies made with traditional technology. This technology is also an effective approach of repairing other cold working dies. The experimental results indicate that the hardfacing technology has much more advantages, cheaper than that of traditional process. The wear resistant test of hardfacing layers were carried out by using different welding current. The best welding current for hadfacing 42CrMo steel is 110 Ampere. The wear mechanism of hardfacing layer is belongs to abrasive wear model.