Aluminum material continuous stamping and shearing mechanism and stamping and shearing process

Abstract

The invention discloses a continuous stamping and shearing mechanism for aluminum materials. The continuous stamping and shearing mechanism for the aluminum materials comprises a punch, a lower die, a top bottom, an ejector pin and an elastic part, wherein the lower die corresponds to the punch and is provided with a knife edge; the top bottom is movably matched with the interior of the knife edge of the lower die; the punch is in zero clearance fit with the inner wall of the knife edge of the lower die; the punching shearing depth of the punch in a die closing state is set to be the thickness of the aluminum material + 0.05 mm, and the top and the bottom synchronously descend by the same height along with the punch. According to the aluminum material continuous stamping and shearing mechanism and the stamping and shearing process, through zero-clearance fit between a punch and a lower die, precise linkage between a top and a bottom and an elastic piece and stable guiding of multiple layers of die plates, a rigid physical platform capable of being precisely regulated and controlled is provided for high-precision shearing; a standardized process of positioning, zero-clearance semi-shearing, reset keeping, continuous feeding and stable discharging is executed, and the structural advantage is converted into stable and repeatable process output.

Description

Technical Field

[0001] This invention relates to the field of continuous stamping and shearing technology for aluminum materials, and in particular to a continuous stamping and shearing mechanism for aluminum materials. Background Technology

[0002] Aluminum and its alloys are widely used in electronics, communication equipment, automotive parts, and precision structural components due to their advantages such as light weight, good electrical and thermal conductivity, and ease of forming. In these applications, many parts need to be separated from aluminum strips or sheets through stamping processes, and the quality of the sheared edge directly affects the assembly accuracy, appearance quality, and fatigue performance of the product. Therefore, how to obtain a smooth, flat, tear-free sheared surface (i.e., "fully bright strip") while maintaining high dimensional accuracy in high-efficiency continuous stamping production has always been a key technical challenge in this field.

[0003] Currently, the industry primarily employs conventional blanking processes for continuous stamping and shearing of aluminum materials. This process involves a blanking gap (typically 5%-10% of the material thickness) between the punch and the die edge. For materials like aluminum, which have relatively low hardness and good ductility, this gap causes significant plastic stretching before separation, ultimately resulting in noticeable tear bands and burrs on the sheared surface. The rough cross-section and poor dimensional consistency make it difficult to meet the stringent requirements of high-end products for a bright and smooth sheared surface. Although subsequent grinding and polishing can improve the appearance, this undoubtedly increases production costs and process complexity, reducing production efficiency.

[0004] To improve cross-sectional quality during stamping, one improvement is to use fine blanking technology or small-clearance blanking. However, when achieving product shape blanking, traditional progressive dies often use multiple stations for segmented blanking to distribute the blanking force and simplify the shape of individual punches. But this design has obvious drawbacks: First, multiple blanking stations increase the complexity of the die, leading to high processing, assembly, and debugging costs, and making maintenance difficult; second, segmented blanking generates a large amount of fine waste, which is easily carried into the cavity during die movement, damaging the product surface and causing irreparable quality defects; finally, the cumulative error between stations affects the final contour accuracy of the product. In addition, in the unloading stage, existing progressive dies often use compressed air to blow the product out of the die cavity. This method easily causes the product to collide and tumble in the collection device, causing deformation or scratches, which is particularly serious for thin aluminum parts. At the same time, the blown-out products accumulate randomly, which is not conducive to operators' online rapid inspection, sorting, and counting, increasing the difficulty of production management and the risk of mixed materials. Summary of the Invention

[0005] Therefore, it is necessary to provide a continuous aluminum stamping and shearing mechanism to address the technical problem that existing continuous aluminum stamping and shearing equipment easily causes rough sheared surfaces of aluminum products.

[0006] A continuous stamping and shearing mechanism for aluminum materials includes: a punch, a lower die corresponding to the punch and having a cutting edge, a top and bottom that are movably fitted inside the cutting edge of the lower die, an ejector pin connected to the bottom of the top and bottom, and an elastic element connected to the bottom of the ejector pin. The punch and the inner wall of the lower die cutting edge are in a zero-clearance fit. The punching and shearing depth of the punch in the closed mold state is set to the thickness of the aluminum material + 0.05 mm, and the top and bottom are lowered synchronously with the punch by the same height. The continuous stamping and shearing mechanism for aluminum materials also includes a lower die base, a lower pad, and a lower template arranged sequentially from bottom to top along the stamping direction. The lower die is embedded in the lower template, and the top and bottom are movably disposed inside the lower die with their bottoms abutting against the top surface of the lower pad. The ejector pin moves through the lower pad and extends into the lower mold base; the elastic element is disposed in the lower mold base and connected to the bottom of the ejector pin. The continuous stamping and shearing mechanism for aluminum materials also includes a stop screw for adjusting the rebound energy of the elastic element. The stop screw is threaded to the bottom of the lower die base and abuts against the elastic element. The continuous stamping and shearing mechanism for aluminum materials also includes an upper cover plate, an upper die base, an upper pad plate, an upper clamping plate, a stop plate, and a stripper plate arranged sequentially from top to bottom along the stamping direction. The top of the punch is installed on the upper pad plate, and its bottom end passes through the upper clamping plate, the stop plate, and the stripper plate in sequence and extends toward the lower die. The continuous aluminum stamping and shearing mechanism also includes a conveyor belt disposed on the bottom side of the lower die base for receiving and conveying the sheared products.

[0007] In one embodiment, the shape of the lower die cutting edge is consistent with the edge shape of the product to be stamped, and the bottom edge shape of the punch matches the shape of the lower die cutting edge.

[0008] In one embodiment, the lower die cutter edge is a square groove, and the punch is a square punch that fits with it with zero clearance.

[0009] In one embodiment, the travel of the top and bottom within the lower die cutter is configured such that, after the punch completes the stamping, the upper surface of the top and bottom is lower than the upper surface of the lower die cutter by a material thickness of -0.05 mm.

[0010] In one embodiment, the elastic element is a spring or a nitrogen spring.

[0011] In one embodiment, the punch is an integral structure.

[0012] In one embodiment, the lower mold base is provided with a vertical channel for mounting the ejector pin and the elastic element, and the fixing screw is screwed into the channel from below and presses against the elastic element.

[0013] In one embodiment, a material guide groove is provided between the conveyor belt and the lower mold base to guide the product to fall smoothly onto the conveyor belt.

[0014] In one embodiment, a guide post and guide sleeve alignment mechanism is provided between the stripper plate and the lower template to ensure zero-gap alignment between the punch and the lower die cutting edge.

[0015] A continuous stamping and shearing process for aluminum materials, employing the aforementioned continuous stamping and shearing mechanism for aluminum materials, includes the following steps: S1: The aluminum strip is fed into the continuous aluminum stamping and shearing mechanism and positioned by the feeding mechanism; S2: Drive the punch to move downwards, and make zero-clearance contact with the lower die blade to shear the aluminum strip. The shearing depth is the material thickness + 0.05mm. At the same time, the top and bottom move down synchronously with the punch. S3: Punch return stroke, top and bottom reset under the action of elastic element, the sheared product remains in a state of slight connection with the material strip; S4: The strip continues to be fed in, and steps S2-S3 are repeated to achieve continuous stamping; S5: At the final station of the product, the product naturally detaches or is slightly pushed onto the conveyor belt and is then conveyed out.

[0016] In one embodiment, in step S2, the punch and the lower die blade are in a zero-clearance fit, achieving a shearing surface without tearing and a fully bright band.

[0017] In one embodiment, in step S3, the product and the conveyor belt are kept rigid by a partially disconnected connection to ensure stable feeding.

[0018] The aforementioned continuous aluminum stamping and shearing mechanism and process provide a rigid and precisely controllable physical platform for high-precision shearing through zero-clearance fit between the punch and lower die, precise linkage between the top and bottom and elastic components, and stable guidance from multi-layer templates. On this structural platform, a standardized process of "positioning → zero-clearance half-shear → reset and hold → continuous feeding → smooth unloading" is executed, transforming structural advantages into stable and repeatable process output. Specifically, for materials like aluminum with low hardness and good plasticity, traditional gaps can create tearing bands. Zero-clearance shearing places the material in a pure shearing state, similar to precision cutting. Step S2 explicitly executes zero-clearance shearing, while the stamping depth is material thickness + 0.05mm, combined with the synchronous action of the top and bottom, applying a small "flattening" force to the shearing zone at the moment of cutting, further compacting the microstructure of the shearing surface. By completing the outer contour shearing of the product in one go, the tooling error and cumulative tolerance caused by multiple punches shearing in stages are avoided. Furthermore, single-stage overall shearing and stable continuous feeding eliminate process fluctuations from step-by-step processing, ensuring high precision in the dimensions of each product. Consistency; In step S3, the product remains in a slightly connected state with the material belt (half-cut), which ensures that the material belt maintains its complete skeleton strength and rigidity during feeding, avoiding the problem of the material belt softening and unstable feeding after the product is completely cut; In addition, the integrated conveyor belt under the mold allows the product to fall naturally at the final station and be smoothly transported away by the conveyor belt, thus replacing the commonly used "compressed air blowing" method, avoiding product collisions, accumulation, deformation, and splashing chaos caused by airflow, thereby achieving neat and orderly output, greatly facilitating online inspection, counting and packaging by operators, improving the efficiency of subsequent processes, and avoiding the risk of mixing good and bad products. Attached Figure Description

[0019] Figure 1 This is a partial structural schematic diagram of the continuous stamping and shearing mechanism for aluminum material in one embodiment; Figure 2 This is a schematic diagram of the continuous stamping and shearing mechanism for aluminum material in one embodiment; Figure 3 This is a partial structural schematic diagram of the continuous stamping and shearing mechanism for aluminum material in one embodiment. Detailed Implementation

[0020] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0021] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0022] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0023] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0024] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0025] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0026] Please see Figures 1 to 3 The present invention discloses a continuous stamping and shearing mechanism for aluminum materials, which includes: a punch 1, a lower die 2 corresponding to the punch 1 and having a cutting edge 21, a top and bottom 3 movably fitted inside the cutting edge 21 of the lower die 2, an ejector pin 4 connected to the bottom of the top and bottom 3, and an elastic member 5 connected to the bottom of the ejector pin 4. The punch 1 and the inner wall of the cutting edge 21 of the lower die 2 have a zero clearance fit; The punching and shearing depth of the punch 1 in the closed mold state is set to the thickness of aluminum material A + 0.05 mm, and the top and bottom 3 descend synchronously with the punch 1 to the same height. The continuous stamping and shearing mechanism for aluminum materials also includes a lower die base 61, a lower pad 62, and a lower template 63 arranged sequentially from bottom to top along the stamping direction. The lower die 2 is embedded in the lower template 63, and the top and bottom 3 are movably disposed inside the lower die 2 and their bottom abuts against the top surface of the lower pad 62. The ejector pin 4 moves through the lower pad 62 and extends into the lower mold base 61. The elastic element 5 is disposed in the lower mold base 61 and connected to the bottom of the ejector pin 4. The continuous stamping and shearing mechanism for aluminum materials also includes a stop screw 7 for adjusting the rebound energy of the elastic element 5. The stop screw 7 is threaded to the bottom of the lower die base 61 and abuts against the elastic element 5. The continuous stamping and shearing mechanism for aluminum materials also includes an upper cover plate 81, an upper die base 82, an upper pad plate 83, an upper clamping plate 84, a stop plate 85, and a stripper plate 86 arranged sequentially from top to bottom along the stamping direction. The top of the punch 1 is installed on the upper pad plate 83, and its bottom end passes through the upper clamping plate 84, the stop plate 85, and the stripper plate 86 in sequence and extends toward the lower die 2. The continuous aluminum stamping and shearing mechanism also includes a conveyor belt 9 disposed on the bottom side of the lower die base 61 for receiving and conveying the sheared products.

[0027] Based on the above settings, this solution constructs a complete zero-gap semi-shear continuous stamping die system, and clarifies the integrated design of punch 1, lower die 2, top and bottom 3, elastic adjustment mechanism, multi-layer template structure and conveyor belt 9, providing a complete hardware foundation for realizing full bright strip shearing.

[0028] Furthermore, the shape of the cutting edge 21 of the lower die 2 is consistent with the edge shape of the product to be stamped, and the bottom edge shape of the punch 1 matches the shape of the cutting edge 21 of the lower die 2. Specifically, in one embodiment, the cutting edge 21 of the lower die 2 is a square groove, and the punch 1 is a square punch 1 that fits with it with zero clearance. In practical applications, by limiting the shearing contour to be consistent with the product shape, a complete product can be stamped in one step, thereby effectively avoiding the joint marks caused by multiple shearings and improving the product's dimensional consistency and appearance quality.

[0029] Furthermore, the moving stroke of the top and bottom 3 inside the cutting edge 21 of the lower die 2 is configured such that after the punch 1 completes the stamping, the upper surface of the top and bottom 3 is lower than the upper surface of the cutting edge 21 of the lower die 2 by a material thickness of -0.05mm. Thus, by precisely controlling the position of the top and bottom 3, the dual function of cutting and flattening the aluminum strip is achieved, further ensuring that the sheared surface is flat and bright.

[0030] Furthermore, the elastic element 5 is a spring or a nitrogen spring to provide a reliable top and bottom 3 reset mechanism, ensuring the stability and lifespan of continuous stamping.

[0031] Furthermore, the punch 1 is an integral structure, used to complete the full circumference shearing of the product shape in one go, thereby simplifying the mold structure, reducing work stations, reducing processing and maintenance costs, and avoiding waste generated by multi-segment shearing.

[0032] Furthermore, the lower mold base 61 is provided with a vertical channel 61a for mounting the ejector pin 4 and the elastic element 5. The fixing screw 7 is screwed into the channel 61a from below and presses against the elastic element 5, thereby allowing the top and bottom 3 to be finely adjusted according to the material thickness and hardness, enhancing process adaptability and stability.

[0033] Furthermore, a material drop guide groove (not shown) is provided between the conveyor belt 9 and the lower mold base 61 to guide the product to fall smoothly onto the conveyor belt 9, so as to realize the smooth dropping and orderly output of the product, avoid product collision, deformation or mixing, and facilitate inspection and collection.

[0034] Furthermore, a guide post and guide sleeve alignment mechanism 64 is provided between the stripper plate 86 and the lower template 63 to ensure zero-gap alignment between the punch 1 and the cutting edge 21 of the lower die 2, ensuring that the punch 1 and the lower die 2 maintain zero-gap fit for a long time and maintain consistent shearing quality.

[0035] A continuous stamping and shearing process for aluminum materials, employing the aforementioned continuous stamping and shearing mechanism for aluminum materials, includes the following steps: S1: The aluminum strip is fed into the continuous aluminum stamping and shearing mechanism and positioned by the feeding mechanism; S2: Drive the punch 1 to move downwards, and make zero-clearance contact with the cutting edge 21 of the lower die 2 to shear the aluminum strip. The shearing depth is the material thickness + 0.05mm. At the same time, the top and bottom 3 move downwards synchronously with the punch 1. S3: Punch 1 returns to its original position, and top and bottom 3 are reset under the action of elastic element 5, so that the sheared product remains in a state of slight connection with the material strip. S4: The strip continues to be fed in, and steps S2-S3 are repeated to achieve continuous stamping; S5: At the final station of the product, the product naturally detaches or is slightly pushed onto the conveyor belt 9 and is then sent out via the conveyor belt 9.

[0036] Furthermore, in step S2, the punch 1 and the cutting edge 21 of the lower die 2 have a zero-clearance fit, achieving a shearing surface without tearing and a fully bright band.

[0037] Furthermore, in step S3, the product and the conveyor belt maintain rigidity through a partially disconnected connection to ensure stable feeding.

[0038] In summary, the continuous stamping and shearing mechanism and stamping and shearing process for aluminum materials disclosed in this invention provide a rigid and precisely controllable physical platform for high-precision shearing through the zero-clearance fit between the punch and the lower die, the precise linkage between the top and bottom and the elastic components, and the stable guidance of the multi-layer template. On this structural platform, a standardized process of "positioning → zero-clearance half-shear → reset and hold → continuous feeding → smooth unloading" is executed, transforming the structural advantages into stable and repeatable process output. Specifically, for materials like aluminum, which have low hardness and good plasticity, traditional gap cutting creates tearing bands. Zero gap cutting puts the material in a pure shearing state, similar to the cutting of a precision tool. Step S2 explicitly executes zero-gap shearing, while the stamping depth is material thickness + 0.05mm, combined with the synchronous action of the top and bottom, applying a small "flattening" force to the shearing zone at the moment of cutting, further compacting the microstructure of the shearing surface. By completing the outer contour shearing of the product in one go, the tooling error and cumulative tolerance caused by multiple punches cutting in stages are avoided. The single overall shearing and stable continuous feeding eliminate the process fluctuations of step-by-step processing, ensuring the high precision of each product dimension. Consistency; In step S3, the product remains in a slightly connected state with the material belt (half-cut), which ensures that the material belt maintains its complete skeleton strength and rigidity during feeding, avoiding the problem of the material belt softening and unstable feeding after the product is completely cut; In addition, the integrated conveyor belt under the mold allows the product to fall naturally at the final station and be smoothly transported away by the conveyor belt, thus replacing the commonly used "compressed air blowing" method, avoiding product collisions, accumulation, deformation, and splashing chaos caused by airflow, thereby achieving neat and orderly output, greatly facilitating online inspection, counting and packaging by operators, improving the efficiency of subsequent processes, and avoiding the risk of mixing good and bad products.

[0039] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0040] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A continuous stamping and shearing mechanism for aluminum materials, characterized in that, include: A punch, a lower die corresponding to the punch and having a cutting edge, a top and bottom that are movably fitted inside the cutting edge of the lower die, an ejector pin connected to the bottom of the top and bottom, and an elastic element connected to the bottom of the ejector pin; The punch and the inner wall of the lower die cutting edge are in a zero-clearance fit. The punching and shearing depth of the punch in the closed mold state is set to the thickness of the aluminum material + 0.05 mm, and the top and bottom are lowered synchronously with the punch by the same height. The continuous stamping and shearing mechanism for aluminum materials also includes a lower die base, a lower pad, and a lower template arranged sequentially from bottom to top along the stamping direction. The lower die is embedded in the lower template, and the top and bottom are movably disposed inside the lower die with their bottoms abutting against the top surface of the lower pad. The ejector pin moves through the lower pad and extends into the lower mold base; the elastic element is disposed in the lower mold base and connected to the bottom of the ejector pin. The continuous stamping and shearing mechanism for aluminum materials also includes a stop screw for adjusting the rebound energy of the elastic element. The stop screw is threaded to the bottom of the lower die base and abuts against the elastic element. The continuous stamping and shearing mechanism for aluminum materials also includes an upper cover plate, an upper die base, an upper pad plate, an upper clamping plate, a stop plate, and a stripper plate arranged sequentially from top to bottom along the stamping direction. The top of the punch is installed on the upper pad plate, and its bottom end passes through the upper clamping plate, the stop plate, and the stripper plate in sequence and extends toward the lower die. The continuous aluminum stamping and shearing mechanism also includes a conveyor belt disposed on the bottom side of the lower die base for receiving and conveying the sheared products.

2. The continuous stamping and shearing mechanism for aluminum materials according to claim 1, characterized in that, The shape of the lower die cutting edge is consistent with the edge shape of the product to be stamped, and the bottom edge shape of the punch matches the shape of the lower die cutting edge.

3. The continuous stamping and shearing mechanism for aluminum materials according to claim 2, characterized in that, The lower die cutting edge is a square groove, and the punch is a square punch that fits with it with zero clearance.

4. The continuous stamping and shearing mechanism for aluminum materials according to claim 3, characterized in that, The travel of the top and bottom within the lower die cutter is configured such that, after the punch completes the stamping, the upper surface of the top and bottom is lower than the upper surface of the lower die cutter by a material thickness of -0.05 mm.

5. The continuous stamping and shearing mechanism for aluminum materials according to claim 4, characterized in that, The elastic element is a spring.

6. The continuous stamping and shearing mechanism for aluminum materials according to claim 5, characterized in that, The punch is a one-piece structure.

7. The continuous stamping and shearing mechanism for aluminum materials according to claim 6, characterized in that, The lower mold base is provided with a vertical channel for mounting the ejector pin and the elastic element.

8. The continuous stamping and shearing mechanism for aluminum materials according to claim 7, characterized in that, The fixing screw is screwed into the channel from below and presses against the elastic element.

9. The continuous stamping and shearing mechanism for aluminum materials according to claim 8, characterized in that, A guide post and guide sleeve centering mechanism is provided between the stripping plate and the lower template.

10. A continuous stamping and shearing process for aluminum materials, employing the continuous stamping and shearing mechanism for aluminum materials as described in any one of claims 1 to 9, comprising the following steps: S1: The aluminum strip is fed into the continuous aluminum stamping and shearing mechanism and positioned by the feeding mechanism; S2: Drive the punch to move downwards, and make zero-clearance contact with the lower die blade to shear the aluminum strip. The shearing depth is the material thickness + 0.05mm. At the same time, the top and bottom move down synchronously with the punch. S3: Punch return stroke, top and bottom reset under the action of elastic element, the sheared product remains in a state of slight connection with the material strip; S4: The strip continues to be fed in, and steps S2-S3 are repeated to achieve continuous stamping; S5: At the final station of the product, the product naturally detaches or is slightly pushed onto the conveyor belt and is then conveyed out.

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