Process design problems and solutions
1. Problems in process design
Design review is the key link of mold process design, generally organize internal review after the completion of the process, verify the feasibility of the process plan in the company's production practice, and can carry out mold design and manufacturing. There are some problems in the process combined with the actual production through review, as follows.
(1) In addition to the shell R Angle in the forming process, the other dimensions are directly flanged for the wavy straight cylinder shape required by the design. The basic size of the shell is consistent with the design size of the product, the elastic deformation of the material, the gap between the die flanging, the direction of the steel plate fiber and other factors lead to the irregular rebound deformation of the diameter of the clutch cover after flanging, and the straight diameter of the shell is easy to fluctuate during the actual forming.
Clutch housing stamping parts process flow
(2) When the internal cavity and auxiliary positioning of the clutch cover are used as the benchmark for secondary shaping, punching the center hole, fine pressing and leveling processing, the clutch cover cannot be smoothly placed in the mold and cannot be accurately positioned. The clutch cover is pressed into the mold and automatically aligned with the shape when working through the mold, which is easy to cause difficulties in placing and retrieving parts. The clutch cover, die concave die and punch die are seriously strained, the die needs frequent polishing and maintenance, and the clutch cover roundness, diameter and wall thickness are different.
2. Process optimization solutions
After analyzing the audit opinions, process improvement, mold structure optimization, shorten the process route, reduce the processing error, and try to complete the key step by step. The main process optimization of the forming and shaping levelling two processes: ① improve the stamping process and die structure design, in the forming process of the steel sheet pre-flanged into a wave cone shape; ② In the shape leveling process through two flanging and internal upsetting leveling, stamping parts eventually into a wave straight cylinder shape.
3. Problem improvement effect
(1) stamping process: parts preforming flanging for the wave cone shape, fine press punching and shaping to the clutch cover cavity as the positioning basis, the use of the cone shape has the characteristics of self-positioning, coupled with the corresponding auxiliary positioning, so that the positioning, placing, taking parts more accurate and easy, reduce the clutch cover 2 positioning caused by stamping processing errors.
Comparison before and after stamping process improvement
(2) Shaping and levelling process: through 2 flanging and internal upsetting levelling, the clutch cover becomes a wave straight cylinder shape, and the key dimensions such as the diameter of the formed parts are formed once to meet the design requirements.
(3) The concave die and punch of the above two key processes adopt a split structure for maintenance and adjustment. The surface TD treatment technology is used to improve the strain of the parts and the wear of the die parts during flanging, and the coaxiality, dimensional accuracy and appearance quality of the parts are effectively improved.
