Manufacturing process for punching single stripping block on aluminum substrate die

Abstract

The invention discloses a manufacturing process for punching a single stripping block on an aluminum substrate die, which belongs to the technical field of die manufacturing, and comprises the following steps: S1, grinding machine processing: carrying out one-time finish machining on a plate in the width direction by adopting a grinding machine to enable the plate to reach the required width size, straightness and surface smoothness; s2, jig positioning is carried out, specifically, the ground plate is positioned and fixed in a special jig, the jig adopts an inner pin to carry out main positioning and adopts an outer pin to carry out auxiliary reinforced positioning, and the semi-finished stripping block product and the jig form a whole; and S3, linear cutting is conducted, specifically, the fixed jig and the semi-finished product are clamped to linear cutting equipment together, and linear cutting machining is conducted on the two ends of the stripping block, the inner circular hole and the slotted hole. The stripping block is high in machining efficiency, and the linear cutting workload and the equipment occupation time are reduced.

Description

Technical Field

[0001] This application relates to the technical field of mold making, and more specifically, it relates to a fast manufacturing process for single strip ejection of aluminum substrate molds. Background Technology

[0002] In the field of aluminum substrate mold manufacturing, stripper blocks are key components in stamping dies, especially for the processing of long, single stripper blocks. Related technologies typically employ wire EDM to cut a single sheet of material into shape in one operation. However, wire EDM involves point-by-point cutting, resulting in slow processing speeds. This is particularly problematic for long, strip-shaped parts, where the overall cutting process is time-consuming, impacting the overall mold manufacturing cycle. Furthermore, the entire process relies on wire EDM equipment, leading to long equipment downtime and requiring highly skilled operators with significant labor intensity. Summary of the Invention

[0003] To address the issues of low efficiency and long equipment usage time associated with wire cutting to form a single sheet of material in the production of stripping blocks in related technologies, this application provides a process for manufacturing single stripping blocks using aluminum substrate molds.

[0004] A process for manufacturing a single stripper block for aluminum substrate die punching includes the following steps:

[0005] Step S1: Grinding: The plate is finished in one pass using a grinding machine to achieve the required width, straightness and surface finish.

[0006] Step S2: Fixture positioning. The ground sheet metal is positioned and fixed in a special fixture. The fixture uses an inner pin for main positioning and an outer pin for auxiliary reinforcement positioning, so that the stripping block semi-finished product and the fixture form an integral whole.

[0007] Step S3: Wire cutting. The fixed fixture and the semi-finished product are clamped together in the wire cutting equipment, and the two ends of the stripping block, as well as the inner round hole and the slot, are wire cut.

[0008] Preferably, the fixture includes a base, an inner pin, and an outer pin. The base is provided with positioning holes to position the inner pin and the outer pin. The inner pin is used to cooperate with the pre-machined holes on the stripping block semi-finished product to achieve precise positioning. The outer pin is used to clamp from the outside to enhance the overall rigidity.

[0009] Preferably, in step S1, a high-precision CNC forming grinding machine is used to grind the sheet metal. After grinding, the dimensional tolerance of the sheet metal in the width direction is controlled within ±0.002mm, the parallelism of the two sides is less than 0.005mm, and the surface roughness Ra≤0.4μm.

[0010] Preferably, in step S2, the inner pin and the pre-machined hole on the stripper block semi-finished product are an interference fit with an interference amount of 0.002-0.005mm; the number of outer pins is multiple, and the multiple outer pins surround the stripper block semi-finished product.

[0011] Preferably, before step S1, step S0 is also included: material preparation and rough machining, selecting a plate material with a longer process length according to the design length of the stripper block, machining a pre-machined hole for cooperating with the inner pin of the fixture by a milling machine, and providing at least one finely machined side surface for lateral reference.

[0012] Preferably, the wire cutting process in step S3 is performed using a slow wire EDM machine, with an electrode wire of 0.15-0.25mm used for cutting, the cutting accuracy controlled within ±0.005mm, and the surface roughness Ra≤0.8μm.

[0013] Preferably, the wire cutting process in step S3 specifically includes the following steps: first, cutting all the inner circular holes and slots; then, keeping the workpiece and fixture intact, changing the cutting path program; and finally, cutting the outer contours of both ends of the stripper block.

[0014] Preferably, after step S3, step S4 is further included: post-processing, in which the stripped block after wire cutting is removed from the fixture, the wire-cut surfaces at both ends are ground to remove burrs, all the holes are chamfered, and finally the surface is cleaned and rust-proofed.

[0015] In summary, this application includes at least one of the following beneficial technical effects:

[0016] 1. By employing a high-precision grinding machine to complete the finishing of the long side of the stripper block in a single operation, the original process, which relied entirely on slow wire EDM, is replaced. The grinding machine's processing efficiency is far higher than the point-by-point cutting of wire EDM, especially for the machining of long sides of long strip-shaped parts, significantly reducing processing time. Wire EDM is only used to machine the contours at both ends and complex internal holes, greatly reducing the amount of machining and thus significantly shortening the single-piece machining time of the stripper block and the overall manufacturing cycle of the mold. Shifting the most time-consuming long side finishing task from expensive wire EDM equipment to the grinding machine significantly reduces the equipment occupancy time of the slow wire EDM machine. This allows the wire EDM equipment to be used more efficiently for its strengths in machining complex contours and precision internal holes, improving the utilization rate of key equipment and the overall capacity of the factory, which helps to reduce the manufacturing cost per unit part. The original process required operators to monitor the lengthy wire EDM process throughout and had high requirements for cutting parameters and deformation control. The new process transforms most of the work into standardized operations guaranteed by grinding machines and fixtures. The wire EDM process is more stable due to the increased rigidity of the workpiece, reducing the over-reliance on the personal experience of wire EDM operators, while also reducing manual intervention time and labor intensity.

[0017] 2. Grinding, while ensuring width dimensional accuracy, more easily achieves excellent straightness, parallelism, and surface finish. Precise positioning and rigidity enhancement using specialized fixtures ensure the workpiece's positional stability and overall rigidity during wire EDM, effectively reducing deformation and vibration during processing. This results in higher accuracy and better consistency in the holes, grooves, and end contours produced by subsequent wire EDM. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the fixture in this embodiment.

[0019] Reference numerals: 1. Fixture; 11. Base; 12. Inner pin; 13. Outer pin; Detailed Implementation

[0020] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0021] A process for manufacturing a single stripper block for an aluminum substrate mold includes the following steps: Step S0, material preparation and rough machining: Based on the final design length of the stripper block, a long strip of material with a length slightly larger than the process requirements is selected as the blank. This reserved length is intended to provide clamping and process allowance for subsequent processing. The blank is pre-machined using a milling machine, and two or more round holes are milled on it as pre-machined holes. These holes will later fit precisely with the internal pins of the fixture. At the same time, a high-precision reference side is precision milled on one side along the length of the sheet material, which will provide a reliable positioning and measurement reference for subsequent grinding.

[0022] Step S2: Grinding. A high-precision CNC profile grinding machine is used to grind the sheet metal. Specifically, the rough-machined fine reference side is used as the positioning reference, and the sheet metal is clamped on the grinding machine's worktable. The grinding wheel feeds along the length of the sheet metal, performing precision grinding on the other side in the width direction in one pass. Through this process, the width dimension of the sheet metal is machined to the final requirement in one pass, ensuring that its dimensional tolerance is strictly controlled within ±0.002 mm. The grinding process also ensures that the two sides of the sheet metal have extremely high parallelism, requiring less than 0.005 mm, and obtains excellent surface finish, with a surface roughness Ra value of 0.4 micrometers or better. This step utilizes the efficient and high-precision planar machining characteristics of the grinding machine, replacing the inefficient method of relying entirely on slow wire EDM to form long sides in the original technology, significantly improving the processing efficiency and quality of long sides.

[0023] Step S3: Fixture positioning, refer to... Figure 1 The fixture 1 comprises a rigid base 11, multiple inner pins 12, and multiple outer pins 13. The base 1 has a pre-machined array of high-precision positioning holes for accurate installation of the inner pins 12 and outer pins 13. During positioning, the ground sheet metal is placed on the base 1, aligning its pre-milled holes with the inner pins 12 on the fixture. The inner pins 12 and the pre-machined holes on the semi-finished product are interference-fitted, with the interference amount designed to be between 0.002 and 0.005 mm. Through precise pressing, the inner pins 12 elastically deform and tightly fit with the hole wall of the semi-finished product, thereby achieving precise positioning and constraint of the semi-finished product in multiple degrees of freedom within the fixture plane; this is the primary positioning. To further enhance the rigidity of the entire system during processing and prevent micro-vibration or deformation during wire cutting, multiple outer pins 13 are also used. These outer pins 13 are symmetrically installed on both sides of the sheet metal along its length and width, surrounding the sheet metal and applying clamping force to the stripper block semi-finished product from the outside. Through the interference fit positioning of the inner pin 12 and the lateral clamping of the outer pin 13, the stripper block semi-finished product and the fixture base 1 are firmly combined into a whole, laying the foundation for the stable operation of subsequent wire cutting.

[0024] Step S4: Wire EDM. The entire fixture, already fixed to the semi-finished stripper block, is clamped onto the worktable of a slow wire EDM machine. The coordinates are aligned on the machine using the preset reference surface or reference hole on the fixture base. Wire EDM uses an electrode wire with a diameter of 0.15 to 0.25 mm, following a pre-programmed path. The cutting process is implemented in steps to optimize accuracy and stability: First, all internal holes and various slots on the stripper block are cut. Because the workpiece's rigidity is greatly enhanced by the fixture, deformation and vibration are effectively suppressed when cutting these internal features, thus ensuring the dimensional and positional accuracy of the holes and slots. The cutting accuracy can be controlled within ±0.005 mm, and the surface roughness Ra value can reach 0.8 micrometers. After completing the machining of all internal holes, the overall clamping state of the workpiece and fixture remains unchanged; only the machine's cutting program is changed. Then, the outer contours at both ends of the stripper block are cut. At this time, the cutting wire will enter from outside the sheet metal, ultimately separating the complete stripper block shape from the remaining sheet metal. Since the long side of the workpiece is already finished by the grinding machine during the entire processing, wire EDM is only responsible for the contours at both ends and internal features. This significantly reduces the amount of work compared to the original integral cutting process, thus substantially shortening the downtime of the wire EDM equipment and improving equipment utilization. At the same time, the step-by-step cutting strategy avoids the potential decrease in rigidity caused by the separation of external materials when cutting internally fragile structures, further ensuring the accuracy of the final part.

[0025] Step S4: Post-processing. Remove the fixture from the wire EDM machine, take out the outer pin, and remove the formed stripper block from the inner pin, separating it from the fixture. Then, grind the wire-cut surfaces at both ends of the stripper block to remove burrs and minor cutting marks. Chamfer the edges of all inner holes and slots to eliminate stress concentration and facilitate assembly. Finally, thoroughly clean the surface of the stripper block and apply rust prevention treatment as needed, completing the entire manufacturing process.

[0026] This application assigns the precision machining of long sides to a high-efficiency grinding machine, while leaving the machining of complex contours and holes to high-precision wire cutting. Combined with a dedicated high-rigidity fixture for process stabilization, this achieves a significant improvement in overall manufacturing efficiency, optimized allocation of equipment resources, and reliable assurance of machining accuracy and consistency.

[0027] Although embodiments of this application have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A process for manufacturing a single stripper block for aluminum substrate die punching, characterized in that, Includes the following steps: Step S1: Grinding: The plate is finished in one pass using a grinding machine to achieve the required width, straightness and surface finish. Step S2: Fixture positioning. The ground sheet metal is positioned and fixed in a special fixture. The fixture uses an inner pin for main positioning and an outer pin for auxiliary reinforcement positioning, so that the stripping block semi-finished product and the fixture form an integral whole. Step S3: Wire cutting. The fixed fixture and the semi-finished product are clamped together in the wire cutting equipment, and the two ends of the stripping block, as well as the inner round hole and the slot, are wire cut.

2. The manufacturing process of a single stripper block for aluminum substrate die punching according to claim 1, characterized in that: The fixture includes a base, an inner pin, and an outer pin. The base is provided with positioning holes to position the inner pin and the outer pin. The inner pin is used to cooperate with the pre-machined holes on the stripping block semi-finished product to achieve precise positioning. The outer pin is used to clamp from the outside to enhance the overall rigidity.

3. The manufacturing process of a single stripper block for aluminum substrate die punching according to claim 1, characterized in that: In step S1, a high-precision CNC forming grinding machine is used to grind the sheet metal. After grinding, the dimensional tolerance of the sheet metal in the width direction is controlled within ±0.002mm, the parallelism of the two sides is less than 0.005mm, and the surface roughness Ra≤0.4μm.

4. The manufacturing process of a single stripper block for aluminum substrate die punching according to claim 1, characterized in that: In step S2, the inner pin and the pre-machined hole on the stripper block semi-finished product are an interference fit with an interference amount of 0.002-0.005mm; there are multiple outer pins, which surround the stripper block semi-finished product.

5. The manufacturing process of a single stripper block for aluminum substrate die punching according to claim 1, characterized in that: Before step S1, there is also step S0: material preparation and rough machining. Based on the design length of the stripper block, a plate with a longer process length is selected for material preparation. A pre-machined hole for cooperating with the inner pin of the fixture is machined by a milling machine, and at least one finely machined side is provided to provide a lateral reference.

6. The manufacturing process of a single stripper block for aluminum substrate die punching according to claim 1, characterized in that: In step S3, the wire cutting process is performed using a slow wire EDM machine. During cutting, an electrode wire of 0.15-0.25mm is used, the cutting accuracy is controlled within ±0.005mm, and the surface roughness Ra≤0.8μm.

7. The manufacturing process of a single stripper block for aluminum substrate die punching according to claim 6, characterized in that, The wire cutting process in step S3 specifically includes the following steps: first, cutting all the inner circular holes and slots; then, keeping the workpiece and fixture intact, changing the cutting path program; and finally, cutting the outer contours of both ends of the stripper block.

8. The manufacturing process of a single stripper block for aluminum substrate die punching according to claim 1, characterized in that: After step S3, step S4 is also included: post-processing, in which the stripped block after wire cutting is removed from the fixture, the wire-cut surfaces at both ends are ground and deburred, all the holes are chamfered, and finally the surface is cleaned and rust-proofed.

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