![]() High-speed stamping technology is a high-tech that integrates various technologies such as equipment, molds, materials, and processes. Compared with ordinary stamping, the speed of high-speed stamping is hundreds of times to thousands of times per minute. Defining 'High Speed' High-speed stamping is a relative term. What is considered high speed varies depending on the size of the part? For an automotive fender, 100 parts per minute (PPM) would be very fast. In comparison, stamping a small, simple washer at 100 strokes per minute (spm) would be very slow. High-speed progressive stamping dies for forming very small, complex parts, such as electrical connectors, which can be designed so the parts can run at 1,200 to 1,500 SPM. High-speed stamping means compare with tradition stamping machines, their stroke operation speed much faster than normal. High-speed stamping is an operation that generates special needs due to fast operating speeds. These special requirements generally relate to stock control, slug control and excessive wear problems. Speed-related problems typically start when press speeds exceed 100 strokes per minute. High-speed stamping is one of the progressive die stampings. It has an auto-transfer feeding system. And it also special designed for lots of numbers of parts of production. From the internet videos or view stamping factory at first glance, high-speed stamping appears do not require a big force to punching or blank out parts. Components at most times are produced from thin, small and relatively soft metal sheet material. Because the component material is thin and small, It’s easy to stack up and jam in the workstation, die plate, or the matrix. If the punch lacks the necessary hardness of strength, it fails or wears at a short time. Two factors affect compressive strength: alloy content and punch material hardness. Alloy content generally speaking it is means you should choose what kind of materials. Most of the times it will affect the lifetime of the tooling. Alloy elements such as molybdenum and tungsten contribute a great deal to the compressive strength. Meanwhile, the hardness of steel also can improve the wear resistance. But the material content will limit the highest of hardness. Generally speaking, tungsten carbide punch and hardened steel bushings are more often used as die tools when stamping metal parts. Because carbide punch and carbide dies has the better hardness and wear resistance compared with steel punches or dies. When the punching load exceeds the part material tensile strength limit, the slug suddenly separates from the part. This sudden loading of pressure on the punch generates a reverse force that often leads to punch head breakage. The punch head must have good tensile strength. it was determined by the material alloy and hardness. When the punch force removed, the deformed high-speed stamping part partially restored. The dimension of the blanked component is not 100% according to the shape of stamping tooling, then it will out the range of tolerance of mold. Stamping not only generates plastic deformation, but it also generates elastic deformation. The art of high-speed stamping is a tool maker’s skill. The high-speed stamping tooling has designed a special system to release the slug out of the matrix to avoid jammed in the workstation. This is very important to get stable quality products with high-speed stamping. #carbidebushings #hardenedsteelbushings #punchanddie #carbidemoldcomponents #carbidepunch
0 Comments
![]() How to Run a Stamping Die at Maximum Speed with Minimal Breakage? Support Equipment Must Match Speed Before looking at the tool design for speed capability, you should first understand the speed capabilities of the press and supporting equipment that will run the die. The tool's speed capability is irrelevant if the press feeder, raw material payout, vision inspection, sensors, take-up reel, and conveyors cannot keep up. When determining the capability of some of this equipment, you need to convert a linear speed such as feet per minute (FPM) or inches per second (IPS) into strokes per minute. To calculate the maximum speed of the equipment in SPM, you must divide the linear speed by the progression. Balancing Speed and Breakage Two factors establish a stamping die's speed capability. The first is simply how fast the part can physically be produced. The second is at what speed the tooling fails (breakage). The strength of carrying features (carrier), how high the part must be lifted, and the mechanical limitations of the springs and side action cams (mandrels) physically limit how fast the part can be made. Although problems associated with these items can cause tool breakage, they do not originate from tool breakage. Design to Counter Physical Limits. In one way or another, each of the physical speed-limiting factors is dictated by the configuration, or design, of the part. When possible, it can be very helpful for you to work closely with the product designer to identify product compromises that make the part more "speed-friendly." 1. For example, a part may be currently designed with very few areas where it can be attached between progressions, making the carrier too weak to feed the parts at high speeds without collapsing. A minor design change that makes the carrier more robust than can increase speed capability. 2. Other design compromises can be made without compromising part quality. For example, if the product design can be altered to eliminate the need for or reduce the travel of side action cams, or reduce the distance that springs need to travel, valuable increases in speed can be achieved. 3. Reducing how high a part must be lifted within the progressive die can help attain higher speeds. The most common way of limiting lift is by using more forming stations. A high form can be redesigned with multiple stations using lower forms that require less lift Preventing Tool Failure Tool failure is also very challenging. The cost associated with tool breakage makes it a hot topic. Although applying commonsense practices of robust tooling design certainly is helpful, there is no substitute for experience when you are designing tooling to prevent breakage. Often, when you are stamping smaller, more intricate parts, addressing breakage is easier said than done. Not Just Thicker Parts. Designing dies to run at high speeds is not as simple as making a die component (including carbide punch, carbide bushings ) thicker in a specific area. In fact, sometimes that approach backfires, because it results in more reciprocating mass, therefore actually increase the potential for breakage. Careful analysis of the forming and blanking pressures and their effect on the tooling is critical. Using strengthening techniques, such as the strategic placement of radii and chamfers on the tooling, is more effective. Know the Breaking Point. To effectively stamp at high speeds, you must understand tool breakage and the point of diminishing returns. This is very tricky to balance. Because experience is crucial to establishing design practices that prevent breakage, you must first understand and balance between the long-term benefits of running faster and the short-term benefits of running slower. Because tool breakage is costly—downtime, design hours, and detail manufacturing—it is natural to feel compelled to reduce the speed so tooling breakage won't occur. Conversely, if breakage is carefully analyzed and redesigned, the knowledge attained can be used to improve the speed capability of future tools. It's common to hear frustrated toolmakers say, "Do you want to run the tool at 1,000 SPM all day with no problems, or do you want to run it at 1,200 SPM and have it break down every two hours?" The short-term benefit of running parts at slower, proven speeds is that you will not incur unplanned downtime and tooling costs caused by breakage. Of course, the disadvantage of running at slower speeds is that you will never learn the weak points in a tool and therefore never attain the knowledge needed to maximize the speed it can be run. If you never push the speed limit, how will you ever know what the highest attainable speed is? When All Is Said and Designed Die designers' thirst for knowledge can drive the push for higher speed limits. That having been said, stampers are in business to make a profit, and pursuing high stamping speeds at any cost is irresponsible. Working closely with the pressroom personnel to analyze breakages and improve tool designs is likely to net the best results. Whether you are stamping a large fender or a tiny electrical pin, effectively increasing the speed of your stamping tool will result in cost savings. Once you know the capability of the supporting equipment, you can begin focusing on what can be done within the tool design to increase stamping speeds. The combination of refining the product design so it is more speed-friendly and eliminating speed-related breakages are major steps in the process. It is also of utmost importance that everyone involved in the designing, building, and running of the stamping dies is on the same page. Each individual must understand where the company stands on the balance between short-term breakage costs and the long-term benefits of pursuing higher speeds. If anyone within the chain is pressured by others in the group to either run the tool too fast or slow, he or she ultimately will likely take the path of least resistance, whether or not it is in the company's best interests. #tungstencarbidedies #carbidedies #punchanddie #tungstencarbidedies ![]() Cemented carbide drawing dies are used in wire drawing industries for drawing of different materials like Mild Steel (M.S), High Carbon (H.C), Stainless Steel (S.S), Brass, Aluminum, etc. All major wire producers use tungsten carbide drawing dies. Carbide grades for drawing dies: WF20,WF30,KG7,CD65O, AF312 We can make suggestions for suitable grades for customers’ usage. Our types of cemented carbide drawing dies: 1. Dies for drawing metal wires 2. Dies for rods. 3. Dies for tubes. 4. Dies for plugs. 5.No-standard drawing dies 6.finished and semi-finished available. Application: Carbide drawing dies ( Carbide dies )application scope is very extensive, mainly used for drawing rods, wire, silk, pipe material, and so on. It is suitable for drawing process steel, copper, Tungsten, molybdenum, and alloy material. #cementedcarbidedies #cementedcarbidedrawingdies #carbidedies ![]() Tungsten Carbide Bushings are an ideal choice for steel wire and other large-size wire drawing applications. Each of our products is manufactured with expert technology and strict quality measurements. Our standard tungsten carbide dies and tools can be customized to your specifications. We also offer completely custom products based on your engineering drawings/requirements. Dongguan JLS Precision manufactures a vast array of tungsten carbide dies and tools. Although we have a lot of standard products that can be customized to your specifications, we also offer completely custom tooling based on your technical drawings. So, if you do not happen to find the product you are looking for, please contact our sales department to see if we can meet your tooling needs. We are committed to providing competitive and quality tungsten carbide bushings that meet or exceed our customer's requirements. We will meet these levels of quality through a total commitment both in management and our skilled workforce for continuous improvement. Cemented carbides have a relatively good balance of hardness and toughness, and have also abrasion resistance and heat resistance. Therefore, they are widely used in cutting tools, blasting nozzles, drawing or extrusion dies, seal rings, and a variety of wear-resistant structure parts, etc. In general, cemented carbides consist of a hard phase (primarily tungsten carbide WC) and a binder phase (primarily cobalt Co). The friction and wear behaviors of WC/Co cemented carbide tool materials with average WC grain sizes ranging from 0.6 to 2.2 μm were evaluated in ambient air at temperatures up to 600 °C using a ball-on-disk high-temperature tribometer. The friction coefficient and wear rate were measured. The microstructural changes and the wear surface features of the WC/Co cemented carbides were examined by scanning electron microscopy. Results showed that the friction coefficient of WC/Co cemented carbides decreased with the increase of test temperature. All the tested samples showed the highest friction coefficient when sliding at 200 °C, and exhibited the lowest friction coefficient in the case of 600 °C. The wear rate of WC/Co cemented carbides increased with the increase of test temperature. The cemented carbide with the smallest WC grain size showed improved wear resistance at temperature up to 600 °C, which corresponds to its higher value of hardness. The difference of the work surface features of the WC/Co cemented carbide after sliding at different temperatures is related to the chemical transformation during sliding wear tests. Abrasion and grain cracking seemed to be the main wear types at a temperature less than 200 °C, the wear owing to binder removal by plastic deformation and grain pull out were suggested to be the main wear mechanism at an intermediate temperature, while the mechanism of oxidative wear dominated at 600 °C. #tungstencarbidebushings #tungstencarbidedies #carbidedies #hardenedsteelbushings ![]() What is cemented carbide dies? Cemented carbide dies are mold components made from cemented carbide. Ok, what is cemented carbide then? Although cemented carbide already exists for more than 100 years, the material is still not well enough known. The exceptional properties of cemented carbide make it particularly suitable for many wear applications. Cemented carbide also called tungsten carbide or just carbide consists of exceptionally hard tungsten carbide particles in a ductile metallic binder mostly Cobalt (Co) or Nickel (Ni). This hybrid structure gives cemented carbide its unique feature of combining extremely high hardness with very high compressive strength and good toughness. Other properties of cemented carbide are high hot hardness and good corrosion resistance. By varying the carbide grain size and the metal binder composition and content, cemented carbide can be fine-tuned in order to obtain optimized properties like : Wear resistance Corrosion resistance Edge stability Resistance against galling Impact resistance Cemented carbide is a material that is produced by powder metallurgy starting from carbide particles and metal powder. The production process and the purity of the powders are decisive for the final quality of the finished part. Therefore it is very important to make to correct choice of cemented carbide for each application. JLS will use its year-long experience in carbide properties and applications to advise you in the right choice for your application. Properties of Cemented Carbide Hardness: up to 2200 HV30 (tool steel Compressive strength: up to 8500 MPa (higher than any steel) Transverse Rupture Strength: up to 4600 MPa (force needed to break carbide in three-point bending test) Corrosion resistance: very high when the correct binder metal is chosen Examples of cemented carbide applications Abrasive Wear Because of the very high hardness and corrosion resistance, carbide has exceptional resistance against dry and wet abrasion resistance. Some applications are: seats for ball, gate and trim valves pump plungers and mechanical seal rings oil and gas drilling tools, wear parts for tunnel boring wastewater and solid waste treatment Cutting The compressive strength and toughness make cemented carbide the preferred material to cut all types of material. Applications: Wood chipping Knives for metal scrap Hardened steel bushings for expanded metal punches for perforated metal Guillotine shears Rotary knives, slitter knives Bending, rolling, extrusion The high hardness of the carbide grains increases the galling resistance. Applications: Cold and hot rolling rolls for wire Tools for bending and forming presses Aluminum extrusion dies Shredding, grinding and mixing Cemented carbide is exceptionally suitable for shredding, grinding and mixing of different materials. Shredders for metal, plastic, wood, paper, cardboard, cellulose, … Hammer mills Wet and dry grinding mills Impact mills for metal and mineral powders #hardenedsteelbushings #tungstencarbidedies #cementedcarbidedies ![]() Tungsten carbide is one of the hardest and most wear-resistant materials available. It is often used for die components in high volume manufacturing situations. It is also used for machine parts that come in contact with very abrasive materials. Tungsten carbide is a combination of tungsten carbide powder and a binder metal, such as cobalt or nickel, which holds the tungsten carbide powder together. By adjusting the percentage of binder metal, tungsten carbide components can be made very wear-resistant but brittle or very durable but not as wear-resistant. Very smooth, polished finishes can be produced on tungsten carbide components ( carbide dies, hardened steel bushings, carbide punch ) which improves wear resistance of the component and aids significantly in metal forming applications. Cemented carbides used in press die are alloys of tungsten carbide (WC) and cobalt (Co). The main constituent of the material is tungsten carbide, and cobalt has the role of a binder (adhesive material). The amount of cobalt is in the range of 5 to 25%. The hardness of cemented carbide decreases as the number of cobalt increases. This material has been stipulated into the types of V10, V20, V30, V40, V50, and V60 in the standard 019 of the Japan Cemented Carbide Tool Manufacturer's Association. V10 has about 5% cobalt, V30 has about 12%, and V60 about 25%. The hardness is 89 HRA or more in the case of V10, 87 HRA or more in the case of V30, and 78 HRA or more in the case of V60. By the way, 85 HRA is converted to 67 HRC. Apart from the amount of cobalt, the hardness is also related to the size of WC particles. The hardness increases as the particle size become smaller. The particle size of ordinary cemented carbide is about 2.5 to 1.5 μm. Ultrafine particles have diameters in the range of 0.7 to 0.5 μm. When the material has ultrafine particles, it is possible to enhance the properties of both wear resistance and brittleness. Cemented carbide is a hard material but is also brittle. The material property is selected considering the balance between hardness and brittleness according to the intended application. V30 and V40 are about the standard for the press dies. In the case of blanking dies and punches, V30 is used for punches, and V40 is used for dies. For bending and drawing, a slightly harder V30 and V20 are used giving priority to wear resistance. A softer V50 and V60 are used in compression forming in order to prevent breakage. Even if the selection of the material is appropriate, if the surface roughness is bad, it may not be possible to satisfy the expected life even in the case of cemented carbide. Reducing the surface roughness by lapping is a very frequently used countermeasure in the case of cutting blades. However, when machining copper, nickel, and pure iron, the wear of cemented carbide may be fast. The reason for this is that the affinity between the cobalt present in cemented carbide and copper or nickel causes the wearing of the cemented carbide to progress faster. Although cemented carbide appears to be hard and versatile, caution should be exercised because it may not meet the expectations depending on how it is used. Although the standards of the Japan Cemented Carbide Tool Manufacturer's Association were used for the above explanations, the code used can be different for different manufacturers. Use the standards of JCCMA to compare and select the appropriate material. #tungstencarbidecomponents #carbidedies #carbidebushings |
AuthorAbby Zhang Archives
August 2021
Categories |