Hinge Stamping Die Processing Tips_Hinge knowledge_Tallsen

In the process of mold manufacturing and production, there are often challenges encountered when working with thicker plates. This requires a more suitable scheme and structure in the formulation of the stamping process and mold design and manufacture.

One specific example is the production of a middle hinge accessory for a refrigerator. This part is made of Q235 material with a thickness of 3mm, and the annual output is 1.5 million pieces. It is important that there are no sharp burrs or edges on the part after processing, and the surface should be smooth with no unevenness greater than 0.2mm.

The middle hinge plays a crucial role in the refrigerator as it supports the weight of the upper door, fixes the lower door, and ensures the flexibility of opening and closing. Therefore, it is essential that the manufacturing process does not reduce the thickness of the part and maintains its verticality.

Hinge Stamping Die Processing Tips_Hinge knowledge_Tallsen

The traditional process for this part involves three steps: blanking, punching, and bending. However, there are several problems that arise during production using this process:

1) Cracks and large burrs often occur during the punching process due to unbalanced force and thin blanking punch. This is caused by the small size and asymmetrical shape of the unfolded part.

2) Displacement of parts and unevenness at the bend occur during the bending process, affecting the appearance and verticality of the part.

3) The need for a shaping process to ensure the verticality of the parts increases the production cost and can lead to operational errors.

4) The use of four processes, including shaping, to complete this part can result in production delays when changing molds.

Hinge Stamping Die Processing Tips_Hinge knowledge_Tallsen

To address these issues, a new processing process is proposed. The process involves the combination of blanking and punching using a flip-chip composite mold and a bending process using a structure of one bend and two parts. This new process eliminates many of the problems encountered in the traditional process.

The combination of blanking and punching in a flip-chip composite mold ensures a more balanced force and reduces the occurrence of cracks and large burrs. The bending process with one bend and two parts helps maintain the verticality of the part by using the four U-shaped holes as positioning points. The lower unloading plate ensures the flatness of the part's bottom surface and eliminates displacement issues.

This new process also eliminates the need for a shaping process, reducing production costs and the potential for operational errors. With one mold producing two pieces, the production time is reduced, resulting in significant cost savings.

In conclusion, by analyzing the problems in the traditional process and implementing a new processing process, significant improvements have been made in the production of the middle hinge accessory. The new process has resulted in better quality parts, reduced production costs, and improved production efficiency.

This experience highlights the importance of continuous learning and innovation in the ever-changing field of mold manufacturing. By implementing new knowledge and skills, we can achieve better results, contribute to the industry, and ultimately benefit society as a whole.

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