In the microscopic world of manufacturing, precision metal stamping is an integrated discipline that combines science, technology and art. Dongguan Zhongchuangxing Precision Machinery Manufacturing Co., Ltd. has been deeply engaged in this pursuit of excellence for over a decade, elevating stamping accuracy from the millimeter level to the micrometer level, creating irreplaceable value for its customers.
Precision stamping: Not just "punching" and "pressing"
Many people misunderstand that stamping is merely a simple metal forming process. In fact, modern precision stamping is a complex systems engineering project. At Zhongchuangxing, we break it down into four key dimensions:
1. Die: The soul of stamping
The beauty of the high efficiency of continuous molds
Continuous dies are the ultimate embodiment of stamping efficiency. The 32-station continuous die we designed can complete multiple processes such as punching, drawing, forming and blanking in a single stroke. Take the production of lead frames as an example. The mold life can reach over 50 million times, and the dimensional stability is controlled within ±0.005mm.
The precision of the compound mold
For products with extremely high precision requirements, such as precision spring pieces, we adopt compound mold technology. Through the precise coordination of the upper and lower dies, the blanking and forming are completed in one go, avoiding the cumulative error caused by multiple positioning.
The art of drawing dies
Metal stretching is not only a technique but also an art. Our engineering team has mastered complex tensile coefficient calculations and is capable of manufacturing products with a deep drawing ratio of 2.8, such as stainless steel battery casings, where the wall thickness uniformity exceeds 95%.
2. Materials Science: Starting from microstructure
The art of material pretreatment
Different materials require different pretreatment processes:
Stainless steel: Annealing treatment is carried out first to improve plasticity
Aluminum alloy: Surface passivation treatment to prevent oxidation
Copper alloy: Appropriate aging treatment to optimize mechanical properties
We have established a material performance database, which includes detailed parameters of over 200 kinds of metal materials, such as:
Tensile curve
Hardness variation law
Rebound coefficient
Heat treatment response characteristics
Challenges and Breakthroughs in Special Materials
Take titanium alloy stamping as an example. Although this material has high strength and corrosion resistance, its formability is poor. We have achieved breakthroughs through the following technological innovations:
A heating stamping process was developed, heating the die to 300℃
By using progressive forming technology, complex shapes are completed in multiple steps
A dedicated lubrication scheme was designed to reduce frictional resistance
3. Precision control: A leap from ±0.1mm to ±0.01mm
The road to upgrading equipment
In 2008: The first 80-ton precision press was introduced, with an accuracy of ±0.1mm
In 2015: A 200-ton servo press was introduced, with an accuracy of ±0.03mm
In 2020: A 300-ton intelligent stamping line was introduced, with an accuracy of ±0.01mm
Details of environmental control
Many people overlook a fact: when the temperature changes by 0.1℃, the length of steel will change by 0.001mm. Therefore, our stamping workshop:
Maintain a constant temperature of 20±1℃
Humidity control: 50%±5%
Equipped with an independent foundation to isolate ground vibrations
Online detection system
We have introduced a machine vision online inspection system:
Detection frequency: 600 pieces per minute
Inspection items: 32 parameters including size, appearance, burrs, etc
Real-time feedback: Automatically adjust the parameters of the press
4. Innovative technology: Breaking through traditional limitations
Micro-stamping technology
For micro parts (such as micro connectors), we have developed micro-stamping technology:
Minimum punching diameter: 0.05mm
The thinnest material thickness: 0.03mm
Highest precision: ±0.003mm
Hydraulic forming technology
For complex curved surface parts, traditional stamping is difficult to achieve. We have introduced hydroforming:
Pressure range: 100-1000 mpa
Forming accuracy: ±0.05mm
Surface quality: Ra0.4μm
Typical Case: Manufacturing Challenges of 5G Filter Cavities
Technical requirements
Material: Aluminum alloy 6061
Dimensions: 120×80×30mm
Wall thickness: 1.0±0.05mm
Flatness: Within 0.1mm
Surface roughness: Ra0.8μm
Technical difficulties
The thin-walled deep cavity structure is prone to deformation
Strict electromagnetic shielding requirements
The consistency requirements for mass production
Our solution
Innovation in mold design
It adopts an insert structure, which is convenient for maintenance and replacement
Design a multi-level ejection system to prevent product deformation
Increase the guiding accuracy to ensure accurate mold closing
Optimization of process parameters
Stamping speed: Reduced from 200 times per minute to 80 times per minute
Lubrication solution: Use nano-scale lubricants
Pressure curve: Multi-stage pressure control is adopted
Quality assurance measures
A three-coordinate measurement is conducted every 50 pieces
Each batch undergoes RF performance testing
Establish an SPC statistical process control system
"Outcome
The yield rate has increased from 85% to 99.5%
Production efficiency: Increased by 40%
Customer satisfaction: Zero complaint record
Future Outlook: Exploration of Intelligent Stamping
Digital twin technology
We are establishing a digital twin system for the stamping process
Virtual mold design verification
Simulation optimization of process parameters
Real-time monitoring of the production process
Application of Artificial Intelligence
Defect prediction based on machine learning
Intelligent parameter tuning system
Adaptive process control system
Green manufacturing
Develop oil-free stamping technology
The recycling rate of waste materials has reached 95%
Energy consumption is reduced by 30%.
