Product Design

1. Board selection

On the premise of meeting the strength requirements of the entire vehicle, enterprises should try to adopt more common and mature technologies in the market. For example, our company uses Swedish cutting edge material DOCO860 for the inner panel of a front anti-collision beam. Due to the high strength of the board, the opening rebound of the mld developed according to general processes reaches 8MM, and the arc rebound reaches 15MM after forming. For these problems, we can only conduct multiple tests through rebound compensation, which not only has a long cycle but also causes serious material waste.

2. Product Structure

When developing multiple vehicle models, it is important to consider the universality of the product. In addition, the product should simplify its structure to avoid increasing the number of mold processes or complicating the mold structure.

3. Application of synchronous engineering

Stamping Synchronous Engineering (SE) is a process in which stamping engineers intervene in the product design phase to conduct process analysis, eliminate errors and defects in the design phase, and shorten the development cycle of molds. From the figure, it can be seen that the use of synchronous engineering eliminates a process step, allowing tooling manufacturing to begin in the shortest possible time and providing sufficient time for manufacturing.

Production process

There are currently two types of production lines used by enterprises: manual production lines and automatic production lines. As for the automatic line, in order to ensure the automatic sliding of production waste, the angle between the slide plate and the worktable must be greater than 20 °. In addition, the feeding height of the automatic line mold must be consistent. Finally, to ensure that the waste can slide freely, the height of all molds must be increased. However, for the entire vehicle, reducing the height of the mold is an effective way to save mold development costs. Using a manual production line eliminates the issues mentioned above. Each enterprise can choose its production method and equipment according to its own situation, ultimately achieving small input and large output. Aluminum plate spot welding machine

Mold manufacturing

1. Mold process

(1) Firstly, consider the cutting process, and then consider the drawing process. With the application of high-strength steel plates in automotive production, in order to ensure that high-strength plates can be formed, the success rate of using the post cutting forming method is higher. Compared with drawing, there is no edge ring for cutting, and the material utilization rate is greatly improved. However, the drawing process is easy to ensure product quality, and the debugging cycle can be shortened. So both should be considered together to develop the optimal process.

(2) The waste generated from the cutting process of some parts can be reused to produce small components of the same material.

(3) The maximum requirement is to realize the mode of left and right parts clamping or the first mock examination with multiple cavities. Almost all the products we develop are left and right symmetrical. If the left and right parts clamping production only needs to increase the size of symmetrical parts on the width (length) of the single mold, it is the mold outline size of the new process. Compared to others, it can save a set of guiding mechanisms and reduce the overall weight of the mold. For narrow and long parts, it is recommended to use the first mock examination with multiple cavities for production.

2. Mold Design

In mold structure design, some structures are redundant. For example, in order to ensure smooth pick-up, pneumatic top feeding devices are often retained on the mold, which are almost not used in actual production.