Guide to Shop Non-self-closing Door Hinge in Tallsen
Tallsen Hardware improves the performance of Non-self-closing door hinge through various methods. Made from raw materials of high purity, the product is expected to have more stable performance. It is found to conform to the requirements of ISO 9001. The product is subject to adjustments in manufacturing process so as to meet higher market requirements.
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Structural Optimization of Progressive Die for Upper Hinge Screw Mounting Plate_Hinge Knowledge_Tall
Fig. 1 showcases the upper hinge screw mounting plate made of DCOI, a material with 10% carbon content, a tensile strength of 270 MPa, a yield strength range of 130-260 MPa, and 28% elongation after fracture. The original forming process had several issues such as operational hazards, low work efficiency, high machine tool occupancy rate, and unstable part quality. In order to address these problems, an optimized forming process was developed, utilizing a three-position progressive die design to ensure safe production, improve efficiency, and reduce costs. This article will provide an expanded analysis of the parts forming process, layout design, mold structure, and key mold part design in detail.
Parts Forming Process Analysis:
The upper hinge screw mounting plate has a simple and symmetrical shape, involving three processes: blanking, punching, and bending. The tolerance grades of the 90.15mm holes and center distance of 2 holes (820.12mm) are ITIO and IT12 respectively, while the rest of the dimensions do not require specific tolerances and can be achieved through ordinary stamping. The material's thickness of 3mm ensures better plasticity, and the height of the straight edge to be bent is 9mm. Controlling springback during bending is crucial. To achieve this, the mold design must ensure the bending line is perpendicular to the fiber direction, with the burr surface on the inner edge of the bending compression.
Layout Design:
The expanded dimensions of the part are 110mm x 48mm, with the longitudinal dimension being relatively large. To simplify mold manufacturing and reduce costs, a single-row method is employed. Several factors were considered during the layout design:
1. Accurate and reliable positioning: Two 90.15mm holes are utilized as the second and third positioning and guiding process holes to minimize cumulative errors.
2. Simplification of mold structure: The part's shape is punched out in two steps to facilitate manufacturing and enhance mold service life.
3. Sturdy material feeding: A double-sided carrier layout design with sufficient strength and rigidity ensures safe and stable feeding of parts during the manufacturing process.
4. Reduction of cumulative error: The number of stations is minimized while maintaining die strength. Only three necessary stations for punching, forming cutting, and bending are arranged to enhance precision.
Based on the analysis, a compact single-row arrangement with a double-sided carrier is adopted, as shown in Fig. 3. The strip width is 126mm, with a 7mm edge. The step distance is set at 55mm. The process includes punching two 90.15mm holes, die-cutting shape waste, and bending and punching both sides of the carrier.
Mold Structure Design:
The mold structure, as depicted in Fig. 4, possesses several key features:
1. Sliding intermediate guide post precision formwork: The mold operates under dual guidance, improving accuracy, relative position, and facilitating assembly and maintenance.
2. Use of limit columns: These columns ensure consistent positioning of the upper die, maintaining stability, and parallelism between the unloading plate and upper and lower die bases.
3. Feeding guide: A single-side material guide plate and material guide block facilitate safe feeding of process parts, with precise positioning using rear straight edge and positioning pins.
4. Simplified structure and reduced material usage: Bending-forming and cutting carriers are designed at the same station, with rounded and sharp edge structures separating the carrier.
5. Integration of elastic unloading and top piece devices: These devices allow for compressed state separation and formation of strips, controlling springback, and ensuring part quality.
Design and Manufacture of Key Mold Parts:
The mold's key parts, including the die, punching punch, shape punching punch, bending-separating punch, and other templates, have high precision requirements. The die adopts an integral structure with Cr12moV material and HRC hardness between 60-64. Wire cutting is employed to achieve dimensional tolerance, and the unilateral matching gap between the punch and die is controlled at 0.12mm. The punching punch employs a step fixing form, while the shape punching punch and bending-separating punch adopt straight-through structures. High precision is maintained in all parts.
After more than a year of practice, the optimized progressive die for the upper hinge screw mounting plate has proven to be effective in ensuring stable part quality, simple and safe operation, high production efficiency, and convenient maintenance. The mold structure exhibits high accuracy and repeated assembly precision, meeting the requirements of mass production. Tallsen's manufacturing process incorporates advanced production concepts and fine technology, ensuring excellent performance, durability, safety, and convenience in their products.
Parts Forming Process Analysis:
The upper hinge screw mounting plate has a simple and symmetrical shape, involving three processes: blanking, punching, and bending. The tolerance grades of the 90.15mm holes and center distance of 2 holes (820.12mm) are ITIO and IT12 respectively, while the rest of the dimensions do not require specific tolerances and can be achieved through ordinary stamping. The material's thickness of 3mm ensures better plasticity, and the height of the straight edge to be bent is 9mm. Controlling springback during bending is crucial. To achieve this, the mold design must ensure the bending line is perpendicular to the fiber direction, with the burr surface on the inner edge of the bending compression.
Layout Design:
The expanded dimensions of the part are 110mm x 48mm, with the longitudinal dimension being relatively large. To simplify mold manufacturing and reduce costs, a single-row method is employed. Several factors were considered during the layout design:
1. Accurate and reliable positioning: Two 90.15mm holes are utilized as the second and third positioning and guiding process holes to minimize cumulative errors.
2. Simplification of mold structure: The part's shape is punched out in two steps to facilitate manufacturing and enhance mold service life.
3. Sturdy material feeding: A double-sided carrier layout design with sufficient strength and rigidity ensures safe and stable feeding of parts during the manufacturing process.
4. Reduction of cumulative error: The number of stations is minimized while maintaining die strength. Only three necessary stations for punching, forming cutting, and bending are arranged to enhance precision.
Based on the analysis, a compact single-row arrangement with a double-sided carrier is adopted, as shown in Fig. 3. The strip width is 126mm, with a 7mm edge. The step distance is set at 55mm. The process includes punching two 90.15mm holes, die-cutting shape waste, and bending and punching both sides of the carrier.
Mold Structure Design:
The mold structure, as depicted in Fig. 4, possesses several key features:
1. Sliding intermediate guide post precision formwork: The mold operates under dual guidance, improving accuracy, relative position, and facilitating assembly and maintenance.
2. Use of limit columns: These columns ensure consistent positioning of the upper die, maintaining stability, and parallelism between the unloading plate and upper and lower die bases.
3. Feeding guide: A single-side material guide plate and material guide block facilitate safe feeding of process parts, with precise positioning using rear straight edge and positioning pins.
4. Simplified structure and reduced material usage: Bending-forming and cutting carriers are designed at the same station, with rounded and sharp edge structures separating the carrier.
5. Integration of elastic unloading and top piece devices: These devices allow for compressed state separation and formation of strips, controlling springback, and ensuring part quality.
Design and Manufacture of Key Mold Parts:
The mold's key parts, including the die, punching punch, shape punching punch, bending-separating punch, and other templates, have high precision requirements. The die adopts an integral structure with Cr12moV material and HRC hardness between 60-64. Wire cutting is employed to achieve dimensional tolerance, and the unilateral matching gap between the punch and die is controlled at 0.12mm. The punching punch employs a step fixing form, while the shape punching punch and bending-separating punch adopt straight-through structures. High precision is maintained in all parts.
After more than a year of practice, the optimized progressive die for the upper hinge screw mounting plate has proven to be effective in ensuring stable part quality, simple and safe operation, high production efficiency, and convenient maintenance. The mold structure exhibits high accuracy and repeated assembly precision, meeting the requirements of mass production. Tallsen's manufacturing process incorporates advanced production concepts and fine technology, ensuring excellent performance, durability, safety, and convenience in their products.
In recent years, the automobile industry in my country has experienced rapid development, particularly with the addition of self-owned brands and joint venture brands. This has led to a reduction in automobile prices and a flood of tens of thousands of cars entering the consumer market annually. As the times progress and people's incomes improve, owning a car has become a common means of transportation in thousands of households, contributing to increased production efficiency and improved quality of life.
However, the frequent occurrence of car recalls due to design problems in the automotive industry serves as a reminder that when developing new products, attention should not only be given to development cycles and costs, but also to product quality and user needs. To ensure better quality and satisfaction for consumers, the "Three Guarantees Act" for automotive products sets stricter requirements, including a minimum validity period of 2 years or 40,000 km, and a minimum validity period of 3 years or 60,000 km. Therefore, it is crucial to focus on the early stages of product development, optimize the design structure, and avoid the need to "make up for" any shortcomings later on.
One specific area of concern in the automotive industry is the occurrence of cracking in the inner panel at the hinge of the liftgate hinge reinforcement plate. This problem was encountered during road tests of actual vehicles, leading to the need to investigate how to reduce the sheet metal stress value in the hinge area. The aim is to optimize the structure of the hinge reinforcement plate and achieve the optimal state to reduce stress values and enhance the performance of the liftgate system. Using computer-aided engineering (CAE) tools for structural optimization can improve the quality of design, shorten the design cycle, and save testing and production costs.
The analysis of the cracking problem in the inner panel at the liftgate hinge revealed that the boundary at the hinge installation surface and the upper boundary of the hinge reinforcement plate were staggered, causing the inner panel to be under a single-layer stress state, which did not provide adequate protection to the inner plate. This resulted in a cut in the upper boundary of the hinge installation surface, leading to increased cracking. Furthermore, stress concentration at the lower end of the hinge mounting surface exceeded the yield strength of the plate, posing a risk of cracking.
To address these issues, various structural optimization schemes were proposed and analyzed through CAE calculations. Four different schemes were designed, and the stress values of the inner plates were calculated and compared. The results showed that all optimization measures were effective in reducing stress values, with scheme 4 achieving the greatest reduction. However, implementing scheme 4 would require significant changes to the manufacturing process, leading to high mold repair costs and a long renovation period. Scheme 2, which achieved a 35% reduction in stress values compared to the original scheme, was deemed the most feasible and cost-effective solution.
To validate the effectiveness of the chosen scheme, manual samples of the modified parts were created, and vehicle manufacturing and reliability road tests were conducted. The results showed that scheme 3 and scheme 4 were successful, while scheme 1 failed. Based on these findings, the optimal improved structural design scheme (Scheme 4) of the hinge reinforcement plate was determined. However, to address issues of process convenience and perceived quality, further improvements were made to the structure of Scheme 4, resulting in a final design that eliminated boundary staggering, improved process operation, and ensured consistent application of sealant.
In conclusion, the analysis, optimization, and validation of the hinge reinforcement plate structure demonstrated that the reduction of stress values in the inner plate at the hinge is closely related to the design of the hinge reinforcement plate. While increasing sheet metal or using special processes can achieve some reduction in stress values, these approaches often complicate the process and increase costs. Therefore, it is crucial to carefully design and optimize the structure of the hinge reinforcement plate from the early stages of product development to achieve the best results in terms of stress reduction. Continuous improvement in product design and manufacturing processes is essential to meet the increasing demands for quality and reliability in the automotive industry.
However, the frequent occurrence of car recalls due to design problems in the automotive industry serves as a reminder that when developing new products, attention should not only be given to development cycles and costs, but also to product quality and user needs. To ensure better quality and satisfaction for consumers, the "Three Guarantees Act" for automotive products sets stricter requirements, including a minimum validity period of 2 years or 40,000 km, and a minimum validity period of 3 years or 60,000 km. Therefore, it is crucial to focus on the early stages of product development, optimize the design structure, and avoid the need to "make up for" any shortcomings later on.
One specific area of concern in the automotive industry is the occurrence of cracking in the inner panel at the hinge of the liftgate hinge reinforcement plate. This problem was encountered during road tests of actual vehicles, leading to the need to investigate how to reduce the sheet metal stress value in the hinge area. The aim is to optimize the structure of the hinge reinforcement plate and achieve the optimal state to reduce stress values and enhance the performance of the liftgate system. Using computer-aided engineering (CAE) tools for structural optimization can improve the quality of design, shorten the design cycle, and save testing and production costs.
The analysis of the cracking problem in the inner panel at the liftgate hinge revealed that the boundary at the hinge installation surface and the upper boundary of the hinge reinforcement plate were staggered, causing the inner panel to be under a single-layer stress state, which did not provide adequate protection to the inner plate. This resulted in a cut in the upper boundary of the hinge installation surface, leading to increased cracking. Furthermore, stress concentration at the lower end of the hinge mounting surface exceeded the yield strength of the plate, posing a risk of cracking.
To address these issues, various structural optimization schemes were proposed and analyzed through CAE calculations. Four different schemes were designed, and the stress values of the inner plates were calculated and compared. The results showed that all optimization measures were effective in reducing stress values, with scheme 4 achieving the greatest reduction. However, implementing scheme 4 would require significant changes to the manufacturing process, leading to high mold repair costs and a long renovation period. Scheme 2, which achieved a 35% reduction in stress values compared to the original scheme, was deemed the most feasible and cost-effective solution.
To validate the effectiveness of the chosen scheme, manual samples of the modified parts were created, and vehicle manufacturing and reliability road tests were conducted. The results showed that scheme 3 and scheme 4 were successful, while scheme 1 failed. Based on these findings, the optimal improved structural design scheme (Scheme 4) of the hinge reinforcement plate was determined. However, to address issues of process convenience and perceived quality, further improvements were made to the structure of Scheme 4, resulting in a final design that eliminated boundary staggering, improved process operation, and ensured consistent application of sealant.
In conclusion, the analysis, optimization, and validation of the hinge reinforcement plate structure demonstrated that the reduction of stress values in the inner plate at the hinge is closely related to the design of the hinge reinforcement plate. While increasing sheet metal or using special processes can achieve some reduction in stress values, these approaches often complicate the process and increase costs. Therefore, it is crucial to carefully design and optimize the structure of the hinge reinforcement plate from the early stages of product development to achieve the best results in terms of stress reduction. Continuous improvement in product design and manufacturing processes is essential to meet the increasing demands for quality and reliability in the automotive industry.
Expanding on the topic of glass hydraulic hinges, it is important to note the different hinge styles available. The full cover door hinge (G359H) provides complete coverage for the door, ensuring a neat and seamless appearance. The half cover door hinge (G358H) partially covers the door, allowing for a more minimalist look. The built-in door hinge (G357H) is installed inside the door frame, making it virtually invisible from the outside.
Glass hydraulic hinges are also known as mirror door hinges or buffer door hinges, as they provide a smooth and controlled closing action. Made from cold rolled steel plate, these hinges are highly durable and resistant to rust. The surface treatment involves copper base plating with nickel, further enhancing their anti-rust properties.
With a cup hole size of 35mm, these hinges are suitable for various applications in civil furniture, office furniture, and cabinet doors. They offer stability and ease of use, maintaining the integrity of the furniture or cabinetry. Their versatility makes them ideal for use in both residential and commercial settings.
Moving on to aluminum frame door hydraulic buffer hinges, there are three styles to choose from. The full cover door hinge (K509H) provides complete coverage for the door, while the half cover door hinge (K508H) only partially covers the door. The inline door hinge (K507H) is installed within the door frame, similar to the built-in door hinge mentioned earlier.
These hinges are also referred to as damping hinges or buffer door hinges due to their ability to provide a controlled and quiet closing action. Made from cold rolled steel plate, they offer excellent durability and resistance to rust. The surface treatment involves copper base plating with nickel, ensuring a strong anti-rust capability.
With a cup hole size of 14mm and a distance of 28mm between the two holes, these hinges are suitable for use in various civil furniture, office furniture, and cabinet applications. They provide a reliable and smooth closing mechanism for aluminum frame doors, enhancing the overall functionality of the furniture or cabinetry.
Moving on to the 90-degree swing door buffer hinge, also known as the S90H hinge, it provides a 90-degree swing motion for the door. It is also referred to as a 180-degree damping hinge, indicating its ability to control the door's swing movement.
Made from cold rolled steel plate, these hinges are highly durable and resistant to rust. The surface treatment involves copper base plating with nickel, ensuring a strong anti-rust capability. With a cup hole size of 35mm and a distance of 48mm between the two holes, these hinges are suitable for civilian furniture, office furniture, and cabinet doors.
The drilling depth for these hinges is 11.5mm, and they are specifically designed for cabinets with a full cover side panel of 18mm. However, the side panel can be adjusted to a range of 15 to 20mm, providing flexibility in installation.
Another type of hinge is the two-stage force 270-degree hinge, which provides a wide range of motion for the door. Made from cold rolled steel plate alloy, these hinges offer enhanced strength and durability. The surface treatment involves copper base plating with nickel, ensuring a strong resistance to rust.
With a cup hole size of 35mm and a distance of 52mm between the two holes, these hinges are suitable for various civil furniture, office furniture, and cabinet applications. They provide a reliable and smooth swinging mechanism for doors, adding convenience and functionality to furniture or cabinetry.
Similarly, the two-stage negative 45-degree hinge, also known as the S45B hinge, is designed to provide a negative angle swing motion for the door. This hinge is also referred to as a two-stage force hinge, highlighting its ability to provide controlled force during operation.
Made from cold rolled steel plate, these hinges offer excellent durability and resistance to rust. The surface treatment involves copper base plating with nickel, ensuring a strong anti-rust capability. With a cup hole size of 35mm and a distance of 45mm between the two holes, these hinges are suitable for use in civilian furniture, office furniture, and cabinets.
Similar to the 90-degree swing door hinge, the drilling depth for these hinges is 11.5mm, and they are specifically designed for cabinets with a full cover side panel of 18mm. However, the side panel can be adjusted to a range of 15 to 20mm, providing flexibility in installation.
Lastly, the 45-degree damping hinge, also known as the S45H hinge, offers a controlled buffering effect during the closing action of the door. This hinge is also referred to as a hydraulic door hinge, highlighting its ability to provide a smooth and controlled closing mechanism.
Made from cold rolled steel plate, these hinges offer excellent durability and resistance to rust. The surface treatment involves copper base plating with nickel, ensuring a strong anti-rust capability. With a cup hole size of 35mm and a distance of 48mm between the two holes, these hinges are suitable for use in various civilian furniture, office furniture, and cabinet applications.
Just like the previous hinges, these are also designed for cabinets with a full cover side panel of 18mm, which can be adjusted to a range of 15 to 20mm. The 45-degree damping hinge provides stability and ease of use, enhancing the overall functionality of the furniture or cabinetry.
In conclusion, the quality of glass hydraulic hinges is highly spoken of. Equipped with new generations of spare parts and processed with the latest technology, these hinges offer enhanced performance and functionality. Their versatility and durability make them suitable for various applications in civil furniture, office furniture, and cabinets. With different hinge styles available and a strong emphasis on anti-rust properties, these hinges provide the perfect solution for smooth and controlled door movements.
Glass hydraulic hinges are also known as mirror door hinges or buffer door hinges, as they provide a smooth and controlled closing action. Made from cold rolled steel plate, these hinges are highly durable and resistant to rust. The surface treatment involves copper base plating with nickel, further enhancing their anti-rust properties.
With a cup hole size of 35mm, these hinges are suitable for various applications in civil furniture, office furniture, and cabinet doors. They offer stability and ease of use, maintaining the integrity of the furniture or cabinetry. Their versatility makes them ideal for use in both residential and commercial settings.
Moving on to aluminum frame door hydraulic buffer hinges, there are three styles to choose from. The full cover door hinge (K509H) provides complete coverage for the door, while the half cover door hinge (K508H) only partially covers the door. The inline door hinge (K507H) is installed within the door frame, similar to the built-in door hinge mentioned earlier.
These hinges are also referred to as damping hinges or buffer door hinges due to their ability to provide a controlled and quiet closing action. Made from cold rolled steel plate, they offer excellent durability and resistance to rust. The surface treatment involves copper base plating with nickel, ensuring a strong anti-rust capability.
With a cup hole size of 14mm and a distance of 28mm between the two holes, these hinges are suitable for use in various civil furniture, office furniture, and cabinet applications. They provide a reliable and smooth closing mechanism for aluminum frame doors, enhancing the overall functionality of the furniture or cabinetry.
Moving on to the 90-degree swing door buffer hinge, also known as the S90H hinge, it provides a 90-degree swing motion for the door. It is also referred to as a 180-degree damping hinge, indicating its ability to control the door's swing movement.
Made from cold rolled steel plate, these hinges are highly durable and resistant to rust. The surface treatment involves copper base plating with nickel, ensuring a strong anti-rust capability. With a cup hole size of 35mm and a distance of 48mm between the two holes, these hinges are suitable for civilian furniture, office furniture, and cabinet doors.
The drilling depth for these hinges is 11.5mm, and they are specifically designed for cabinets with a full cover side panel of 18mm. However, the side panel can be adjusted to a range of 15 to 20mm, providing flexibility in installation.
Another type of hinge is the two-stage force 270-degree hinge, which provides a wide range of motion for the door. Made from cold rolled steel plate alloy, these hinges offer enhanced strength and durability. The surface treatment involves copper base plating with nickel, ensuring a strong resistance to rust.
With a cup hole size of 35mm and a distance of 52mm between the two holes, these hinges are suitable for various civil furniture, office furniture, and cabinet applications. They provide a reliable and smooth swinging mechanism for doors, adding convenience and functionality to furniture or cabinetry.
Similarly, the two-stage negative 45-degree hinge, also known as the S45B hinge, is designed to provide a negative angle swing motion for the door. This hinge is also referred to as a two-stage force hinge, highlighting its ability to provide controlled force during operation.
Made from cold rolled steel plate, these hinges offer excellent durability and resistance to rust. The surface treatment involves copper base plating with nickel, ensuring a strong anti-rust capability. With a cup hole size of 35mm and a distance of 45mm between the two holes, these hinges are suitable for use in civilian furniture, office furniture, and cabinets.
Similar to the 90-degree swing door hinge, the drilling depth for these hinges is 11.5mm, and they are specifically designed for cabinets with a full cover side panel of 18mm. However, the side panel can be adjusted to a range of 15 to 20mm, providing flexibility in installation.
Lastly, the 45-degree damping hinge, also known as the S45H hinge, offers a controlled buffering effect during the closing action of the door. This hinge is also referred to as a hydraulic door hinge, highlighting its ability to provide a smooth and controlled closing mechanism.
Made from cold rolled steel plate, these hinges offer excellent durability and resistance to rust. The surface treatment involves copper base plating with nickel, ensuring a strong anti-rust capability. With a cup hole size of 35mm and a distance of 48mm between the two holes, these hinges are suitable for use in various civilian furniture, office furniture, and cabinet applications.
Just like the previous hinges, these are also designed for cabinets with a full cover side panel of 18mm, which can be adjusted to a range of 15 to 20mm. The 45-degree damping hinge provides stability and ease of use, enhancing the overall functionality of the furniture or cabinetry.
In conclusion, the quality of glass hydraulic hinges is highly spoken of. Equipped with new generations of spare parts and processed with the latest technology, these hinges offer enhanced performance and functionality. Their versatility and durability make them suitable for various applications in civil furniture, office furniture, and cabinets. With different hinge styles available and a strong emphasis on anti-rust properties, these hinges provide the perfect solution for smooth and controlled door movements.
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