Hinge stamping process and crimping die design_Hinge knowledge_Tallsen

HingeIt is a versatile daily-use hardware product that is widely used and consumed. It comes in a variety of specifications and has a strong decorative effect, especially with its mandrel sleeve formed by curling. The key to this product is ensuring a tight and flexible connection between two pieces, allowing the mandrel to rotate freely without any noise. Most manufacturers produce HingeIt in large quantities all year round using ordinary low-carbon steel plates and all-steel dies. After the hinge pieces are punched, they undergo cleaning and electroplating before being assembled into hinges.

There are two commonly used forming processes for cold stamping the sheet metal of the hinge: curling and rounding. Curling involves rolling the sheet up or down at one end and forming a 3/4 cylinder with a required diameter. The straight edge is then connected to the tangent point of the curling circle, resulting in a partial circle. On the other hand, sheet metal curling involves rolling the sheet into a full circle at the end, with the straight edge aligned with the diameter line or parallel to it. These forming processes are essential in producing hinges.

The crimping of the hinge mandrel sleeve and the combination of the two pieces are crucial to the product's functionality. The crimping circle's inner diameter is usually formed by pushing and rolling when it is between 0.6 and 3.5 times the thickness of the material. The hinge pieces are formed using this method.

For the stamping parts of the cover, which are the shell parts of a high-precision temperature control instrument, blanking and embossing processes are used. The process also involves pre-bending at both ends and curling forming, which is completed with four sets of single dies. This process can meet the production needs when the output is low. However, when the production output increases, the original process and die become inadequate.

To address this issue, a continuous composite one-mold forming solution is proposed. The stamping parts can be punched from coil material using a multi-station continuous compound die. A horizontal row layout is adopted, with grooves cut at the crimping parts on both ends. The middle lap carries the workpiece for feeding, and cutting and separation are performed after embossing, pre-bending, and crimping. This solution allows for higher production output and efficiency.

In terms of practical implementation, the factory's actual consumption does not justify using a multi-station continuous composite mold forming punching solution. Instead, an improved single-step process is used, where a pair of multi-station continuous molds completes the semi-finished blank with curling at both ends. The process involves cutting strips from plates, grooving, embossing, pre-bending, cutting, and separation on the multi-station continuous die. The pre-bent blank is then crimped using a separate crimping die. This practical process meets the current material production and supply status, and satisfies efficiency and production requirements.

The crimping die for the HingeIt product adopts a dual-roll method, where both ends of the pre-bent blank are rolled simultaneously. The die uses a guide structure with spring pressure unloading plates and double-acting inclined wedges to drive the wedge sliders. The die also incorporates a curling die that is pushed by the wedges to form the curling. A spring pressing plate provides accurate guidance and support for the forming briquetting block and withstands the curling and impact loads.

The design of the crimping die's working part ensures that the pre-bent blank matches the radius of the inner circle of the curling. The pre-bending is carried out to guarantee proper forming when rolling. The die's structure and surface roughness values are designed with these considerations in mind.

To produce the hinge plate, a five-station continuous composite mold structure is used in conjunction with a universal roller feeding device. The die incorporates a slide-guided rear guide column mold base, an elastic pressure unloading plate, and an inclined wedge transmission mechanism for lateral stamping of the crimping. The die also features a thickened rod for punching small holes and a unilateral punching cutting punch with a blanking punch stopper to balance the load.

As a leading manufacturer in the industry, Tallsen aims to provide high-quality products that meet customer needs. The visit from the client discussed in this article is important as it allows the company to gain a better understanding of the client's requirements and build trust. Tallsen has earned a good brand reputation and attracts many foreign customers. With its standardized production processes and international approval, Tallsen stands out in the global hardware market.