Fault Diagnosis and Maintenance for Hardware Stamping Dies

　　Fault Diagnosis and Maintenance for Hardware Stamping Dies——Based on Precision Manufacturing and Intelligent Technology of Szchaopin

　　Hardware stamping dies are the core equipment in modern manufacturing, widely used in automotive, home appliance, industrial control and other key fields. The stability and service life of dies directly determine production efficiency, product precision and manufacturing costs. As a professional enterprise focusing on precision stamping die solutions, Szchaopin has accumulated rich experience in die design, manufacturing, fault diagnosis and maintenance based on its advanced precision processing equipment and intelligent production technology. This article will deeply discuss the common fault types, systematic diagnosis methods and scientific maintenance strategies of hardware stamping dies, combining with Szchaopin's product technology characteristics and practical application cases.

　　Common Fault Types and Cause Analysis of Hardware Stamping Dies. In the actual production process, hardware stamping dies are prone to various faults due to factors such as long-term high-load operation, material characteristics, and improper operation. Based on the analysis of a large number of practical cases of Szchaopin's precision dies (including progressive dies, transfer dies, tandem dies, etc.), the common faults are mainly concentrated in the following aspects:

　　First, burrs on products. This is the most frequent fault in stamping production. For Szchaopin's precision stamping dies used in automotive chassis parts and home appliance components, the main causes of burrs include excessive or offset gap between punch and die, severe wear of cutting edges, blockage of die blanking holes, and deviation of automatic feeding. Taking the automatic stamping line of automotive seat parts as an example, the deviation of feeding parallelism or inaccurate positioning will lead to uneven stress on the die edge, resulting in burrs on the product edge, which affects the assembly precision of automotive parts.

　　Second, punch breakage. The punch is a vulnerable part in stamping dies. For the special-shaped punches and pre-punches in Szchaopin's precision progressive dies, the common causes of breakage include insufficient strength of the punch structure, blockage of die due to insufficient blanking slope, deviation of punch-die gap, failure of stripper spring, and excessive working length of the punch. In the production of precision electronic components, the breakage of small-diameter pre-punches often occurs due to the blockage of metal chips in the die cavity, which leads to sudden increase of punch load.

　　Third, material jumping and unloading failure. Material jumping is mostly caused by excessive die gap, strong magnetism of punch/die, and excessive wear of die edge. Unloading failure is related to factors such as failure of unloading spring, too tight positioning, insufficient relief and stuck slider. In Szchaopin's intelligent stamping production line, the failure of automatic unloading will not only affect the continuity of production, but also cause secondary scratches on products, reducing the qualification rate of precision parts.

　　Fourth, deep drawing cracking and uneven flanging. For the stamping dies of automotive body parts and battery pack components customized by Szchaopin, deep drawing cracking is mainly caused by too small punch-die gap, rough die fillet, poor material plasticity, and excessive deep drawing height. The uneven flanging is mostly due to inaccurate positioning of the workpiece, uneven pressure of the blank holder, and deviation of the die guide mechanism. These faults will directly lead to the scrapping of high-value auto parts and increase manufacturing costs.

　　Systematic Fault Diagnosis Methods Combining Szchaopin's Technical Advantages. The key to efficient solution of die faults lies in systematic and accurate diagnosis. Szchaopin combines its advanced precision detection equipment and digital management system to form a set of scientific diagnosis processes:

　　Precision detection based on high-end equipment. Szchaopin is equipped with more than 50 sets of high-precision CNC machine tools, large gantry CNC and professional die testing equipment. For suspected precision deviation faults, the 100% full inspection of die parts can be realized through high-precision measuring instruments. For example, when there is a burr fault, the gap between punch and die can be accurately measured by three-coordinate measuring instrument to determine whether there is deviation or wear; for the fault of uneven product size, the parallelism and positioning accuracy of the die guide column and guide sleeve can be detected to find out the root cause.

　　Data-driven intelligent diagnosis. Relying on the digital factory construction foundation, Szchaopin's intelligent stamping production line can realize real-time collection and analysis of production data. Through the monitoring of stamping force, stamping speed, feeding position and other data, abnormal changes can be found in time. For example, when the stamping force suddenly increases, the system can automatically alert, and the maintenance personnel can judge whether there is blockage in the die cavity or deviation of the punch-die gap according to the data curve, which greatly shortens the diagnosis time compared with the traditional manual judgment method.

　　Experience-based comprehensive judgment. Szchaopin's maintenance team is composed of professional and technical personnel with 10-30 years of industry experience. They can quickly lock the fault type according to the fault phenomenon and combine with the structural characteristics of different dies. For example, for the punch breakage fault in progressive dies, they can accurately distinguish whether it is caused by structural defects of the punch, material blockage or spring failure according to the breakage position and section characteristics, and put forward targeted solutions.

　　Scientific Maintenance Strategy for Hardware Stamping Dies——Taking Szchaopin's Precision Dies as an Example. Scientific maintenance can effectively reduce fault occurrence, extend die service life and ensure stable production. Combined with the technical characteristics of its precision stamping dies (such as in-mold riveting, in-mold tapping, and automatic self-inspection functions), Szchaopin has formulated a full-life-cycle maintenance system:

　　Daily preventive maintenance. The daily maintenance focuses on cleaning, inspection and lubrication. After the daily production, the die cavity, punch and die edge should be thoroughly cleaned to remove metal chips and debris, so as to avoid blockage and scratch. At the same time, check the wear of key parts such as punch, die and spring, and the connection tightness of fasteners. For Szchaopin's automatic stamping dies, special attention should be paid to the inspection of the automatic feeding system and positioning device to ensure accurate feeding. In addition, regular lubrication of guide parts and moving mechanisms with professional lubricants can reduce friction and wear.

　　Regular professional maintenance. According to the production frequency and service condition of the die, Szchaopin formulates a regular maintenance plan. For high-frequency used precision dies (such as automotive part stamping dies), the punch and die edges are regularly ground to ensure sharpness; the guide columns and guide sleeves are inspected and replaced to ensure the guiding precision. For the progressive dies and transfer dies with complex structures, the stress analysis of the die is carried out regularly by using professional software to check whether there is uneven stress in each part, so as to avoid fatigue damage. All maintenance processes are carried out in strict accordance with Szchaopin's quality management system to ensure maintenance quality.

　　Fault maintenance and technical improvement. When a fault occurs, on the basis of accurate diagnosis, targeted maintenance measures should be taken. For example, for the burr fault caused by excessive punch-die gap, the gap should be adjusted or the parts should be repaired; for the punch breakage caused by insufficient strength, the punch structure should be optimized or the material should be replaced. At the same time, Szchaopin's R&D team will summarize the fault causes, and carry out technical improvement on the die design and manufacturing process. For example, for the problem of easy blockage of blanking holes in automotive chassis part dies, the blanking hole slope is increased in the die design stage, and anti-magnetic treatment is carried out on the die to fundamentally reduce the occurrence of faults.

　　Conclusion. The fault diagnosis and maintenance of hardware stamping dies is a systematic project that combines technology, experience and management. Szchaopin relies on its advanced precision manufacturing equipment, intelligent production technology and professional technical team to form a complete set of fault diagnosis and maintenance system for precision stamping dies. By mastering scientific diagnosis methods and implementing standardized maintenance strategies, it can effectively improve the stability and service life of dies, reduce production costs and ensure product quality.

　　For the hardware stamping die industry, it is particularly important to attach importance to die fault diagnosis and maintenance. With the continuous development of intelligent manufacturing, Szchaopin will continue to integrate digital and intelligent technologies into die maintenance, such as remote fault monitoring and predictive maintenance, to provide more efficient and reliable solutions for global customers, and promote the high-quality development of the hardware stamping industry.

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