Split-slot terminal cold heading forming process

Abstract

The present application relates to the technical field of split-slot terminal processing, and specifically discloses a split-slot terminal cold heading forming process, which comprises the following steps: first, preparing materials, corresponding coiled material is prepared according to the demand of the product; second, cutting and shaping, the coiled material is sent to a cutting die through a feeding mechanism, cut into a fixed-length blank, and trimmed through a shaping die to remove the excess part to correct the length; third, pre-punching a slot, a shallow slot is pressed through a cold heading machine die; fourth, external shaping, the head and the rod of the blank are extruded through a die with a specific profile to optimize the shape and form the final profile of the terminal exterior; and fifth, processing all the slots, all the grooves are pressed in the head using a special die based on the front-end slot. The present application adopts cold heading to groove, and all the slots are extruded together, so that the inner hole does not need to be processed, the cold heading extrusion surface is smooth and consistent, no sharp angle is generated, and the surface of the pin is ensured not to be abraded, so that the contact performance is stable.

Description

Technical Field

[0001] This invention relates to the field of slotted terminal processing technology, and specifically to a cold heading process for slotted terminals. Background Technology

[0002] A slotted terminal is a metal connector used for electrical or electronic circuit connections. Its core feature is a slotted structure (i.e., a groove for clamping wires, mating plugs, or fixing cables). Its main function is to achieve conductive connections between wires and equipment, and between wires, and to ensure the stability of the connection through a mechanical structure.

[0003] Currently, the most common processing methods for slotted terminals include machining. In machining, when turning the inner hole, the surface finish is difficult to control due to limitations in tools and machining conditions. For example, poor grinding of the inner hole turning tool, improper selection of cutting parameters, insufficient tool rigidity causing vibration, and problems with the machine tool itself can all lead to increased surface roughness of the inner hole, resulting in problems such as ripples and tapers, thus affecting the accuracy of the inner hole.

[0004] However, machining grooving also has drawbacks. Machining methods such as saw blade grooving can easily produce burrs and sharp edges, even without burrs. When these sharp edges come into contact with the pins, they can wear down the pin surface, deteriorating its condition and affecting contact performance, leading to problems such as increased contact resistance and unstable conductivity. Summary of the Invention

[0005] To address the shortcomings of the existing technology, this invention provides a cold forging process for slotted terminals. The process involves cold forging to create all slots at once, eliminating the need for machining the inner hole. The cold forging surface is smooth and uniform, resulting in high precision, reduced processing costs, and the absence of sharp corners. This ensures that the pin surface is not worn and that contact performance is stable.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] A cold heading process for slotted terminals includes the following steps:

[0008] Step 1: Prepare materials. Based on the needs of the products to be produced, prepare the corresponding roll material raw materials.

[0009] The second step is cutting and shaping. The prepared roll material is placed on the cold heading machine and fed to the cutting die through the feeding mechanism. It is cut into blanks of a fixed length and then trimmed through the shaping die to remove excess parts of the blanks to correct the length and straighten the bending of the blanks.

[0010] The third step is to pre-punch the groove. At the pre-set front end position of the cut and shaped blank, a shallow groove is pressed out by the cold heading machine mold, which provides the basis for positioning and material distribution for the subsequent processing of all grooves.

[0011] Step 4: External shaping. The head and rod of the blank are extruded by a mold to form the final outline of the terminal.

[0012] Step 5: Process all the grooves. Based on the front groove, use a special mold to press all the required grooves on the head.

[0013] Preferably, the cold heading machine in the second step is a multi-station automatic cold heading machine.

[0014] Preferably, the depth of the shallow groove in the third step is 10% of the final groove depth, providing a positioning reference for the subsequent processing of all grooves.

[0015] Preferably, the special mold in the fifth step is a forming punch. The outer surface of the forming punch is set with cutting edges corresponding to the number of slots. The remaining slots are pressed by the multi-slot mold, and all slots are deepened to the final size.

[0016] Preferably, the second step includes surface cleaning, cleaning the surface of the roll material, applying a lubricant to the cleaned roll material, and drying it.

[0017] Preferably, after the fifth step, a sixth step is added to process the tail, which is processed into the required special shape by the tail forming mold and is coaxial with the head to meet the assembly requirements of wire insertion and bolt fixing.

[0018] Preferably, after the sixth step, a seventh step of cleaning is also included, in which ultrasonic cleaning is used to clean the terminals after tail processing to remove impurities remaining on the terminal surface, followed by rinsing with clean water and hot air drying to ensure that the terminal surface is clean.

[0019] Preferably, after the seventh step, an eighth step of surface treatment is also included, where the terminals are surface treated as needed to improve their conductivity, corrosion resistance, or weldability.

[0020] Preferably, after step eight, a ninth step of inspection is included, which involves sampling and testing the dimensions, appearance, and performance to ensure that the terminals meet the requirements.

[0021] The beneficial effects of this invention are: the grooving is performed by cold forging, all grooves are forged at the same time, the inner hole does not need to be processed, the cold forging extrusion surface is smooth and consistent, the precision is high, the processing cost is saved, no sharp corners are generated, ensuring that the pin surface will not be worn, and the contact performance is stable. Attached Figure Description

[0022] Figure 1 : This is a flowchart illustrating an embodiment of the present invention;

[0023] Figure 2 : A cross-sectional view showing structural changes according to an embodiment of the present invention;

[0024] Figure 3 : This is a schematic diagram illustrating the structural changes from step four to step seven of an embodiment of the present invention;

[0025] Figure 4 : A schematic diagram of a multi-head punch according to an embodiment of the present invention;

[0026] Figure 5 : This is a schematic diagram illustrating the variation of the welded tail structure according to an embodiment of the present invention;

[0027] Attached image description: 10 - forming punch, 11 - cutting edge. Detailed Implementation

[0028] To more clearly illustrate the structural features, technical means, and specific objectives and functions achieved by the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments:

[0029] This embodiment: as follows Figure 1-4 As shown, a cold heading process for slotted terminals includes the following steps:

[0030] The first step is to prepare materials. Based on the needs of the products to be produced, prepare the corresponding copper alloy coil raw materials.

[0031] The second step is surface cleaning. The surface of the roll material is cleaned, and the cleaned roll material is coated with lubricant and dried.

[0032] The third step is cutting and shaping. The prepared roll material is placed on a multi-station automatic cold heading machine and fed to the cutting die through the feeding mechanism. It is cut into blanks of a fixed length and then trimmed through the shaping die to remove excess parts of the blanks to correct the length and straighten the bending of the blanks.

[0033] The fourth step is to pre-punch the groove. At the pre-set front end position of the cut and shaped blank, a shallow groove is pressed out by the cold heading machine mold. The depth of the shallow groove is 10% of the final groove depth. The blank flows to both sides of the groove under the pressure of the mold, and the edge naturally forms a rounded corner. This provides a positioning reference for the subsequent processing of all grooves and provides a basis for positioning and material distribution.

[0034] Step 5: External shaping. The head and rod of the blank are extruded by a mold to form the final outline of the terminal.

[0035] Step 6: Process all the slots. Based on the front slot, use the forming punch 10 to press all the required grooves on the head. The outer surface of the forming punch 10 is set with cutting edges 11 corresponding to the number of slots. The cutting edges 11 are used to deepen all the slots to the final size, control the slot depth, and make the slot walls smooth and without cracks.

[0036] Step 7: Process the tail end. Use a tail end forming mold to process the required special shape, such as a threaded tail end or a wire-pressed tail end, and make it coaxial with the head end to meet the assembly requirements of wire insertion and bolt fixing.

[0037] Step 8: Cleaning. Ultrasonic cleaning is used to clean the terminals after tail processing to remove any remaining impurities from the terminal surface. After that, the terminals are rinsed with clean water and dried with hot air to ensure that the terminal surface is clean.

[0038] Step 9: Surface treatment. Depending on the requirements, the terminals are subjected to surface treatments such as electroplating or passivation to improve their conductivity, corrosion resistance, or weldability.

[0039] Step 10: Inspection. Use calipers or micrometers to sample and inspect dimensions, including key dimensions such as length, diameter, groove depth, and groove width. Visually inspect or use a magnifying glass to sample and inspect the appearance surface to ensure there are no cracks, shrinkage cavities, deformations, and the integrity of the groove. At the same time, conduct tensile strength and conductivity tests to ensure that the terminals meet the requirements.

[0040] This process uses cold heading for forming, replacing cutting with plastic deformation. During cold heading and grooving, the material is always under the constraint of the mold and undergoes plastic deformation. The edge of the groove is a natural transition surface after the material flows, rather than a fracture surface after saw cutting, so no burrs are generated. Under the pressure of the mold, the material flows to both sides of the groove, and the edge naturally forms rounded corners, thus avoiding sharp corners. When it comes into contact with the pin later, it can avoid wear on the pin surface, ensure stable contact resistance, and the conductivity is more consistent than that of machined products. It can also improve material utilization, reduce processes and labor, and reduce processing costs.

[0041] like Figure 5 It should be noted that the tail section in step seven can also be made into a welded tail section.

[0042] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Therefore, any modifications, equivalent substitutions, improvements, etc., made to the above embodiments based on the technical solutions of the present invention shall still fall within the scope of the technical solutions of the present invention.

Claims

1. A split-slot terminal cold upset forming process characterized by, The method comprises the following steps: The first step is to prepare materials, according to the requirements of the product, prepare the corresponding roll stock; The second step is to cut and shape, place the prepared roll stock on the cold header, send it to the cutting die through the feeding mechanism, cut it into a certain length of blank, and trim it through the shaping die to remove the excess part of the blank to correct the length and straighten the bent blank; The third step is to pre-punch the notch, at the preset front end position of the blank head after cutting and shaping, a shallow groove is pressed by the cold header die, which provides the basis for positioning and material distribution for subsequent processing of all notches; The fourth step is external shaping, the head and stem of the blank are extruded by the die to form the final profile of the terminal exterior; The fifth step is to process all notches, using a special die to press all required grooves in the head based on the front end notch; The special die in the fifth step is a forming punch, the outer surface of the forming punch is provided with a corresponding blade corresponding to the number of notches, the remaining notches are pressed by the forming punch, and all notches are deepened to the final size.

2. The split slot terminal cold upset forming process of claim 1, wherein: The cold header in the second step is a multi-station automatic cold header.

3. The split slot terminal cold upset forming process of claim 1, wherein: The depth of the shallow groove in the third step is 10% of the final groove depth, which provides a positioning reference for subsequent processing of all notches.

4. The split slot terminal cold upset forming process of claim 1, wherein: Before the second step, it also includes surface cleaning, cleaning the surface of the roll, coating the cleaned roll with lubricant and drying.

5. The split slot terminal cold upset forming process of claim 1, wherein: After the fifth step, it also includes the sixth step of processing the tail, which processes the required special shape through the tail forming die and is coaxial with the head to meet the assembly requirements of wire insertion and bolt fixation.

6. The split slot terminal cold upset forming process of claim 5, wherein: After the sixth step, it also includes the seventh step of cleaning, which uses ultrasonic cleaning to clean the terminal after tail processing, removes impurities on the surface of the terminal, and then performs clean water rinsing and hot air drying to ensure the cleanliness of the terminal surface.

7. The split slot terminal cold upset forming process of claim 6, wherein: After the seventh step, it also includes the eighth step of surface treatment, which performs surface treatment on the terminal according to the requirements to improve the conductivity, corrosion resistance or welding performance of the terminal.

8. The split slot terminal cold upset forming process of claim 7, wherein: After the eighth step, it also includes the ninth step of inspection, which performs sampling detection on size, appearance and performance to ensure that the terminal meets the requirements.

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