A forming progressive die for an automobile sheet metal part

Abstract

The application discloses a forming continuous die for automobile sheet metal parts and belongs to the field of production and processing of automobile sheet metal parts. The forming continuous die comprises an upper die plate and a lower die plate, a plurality of processing stations are continuously arranged between the upper die plate and the lower die plate, conveying devices for driving workpieces to be conveyed in each processing station are further arranged between the upper die plate and the lower die plate, a material belt sequentially passes through each processing station, a punching and trimming station, a forming and flanging station group, a side processing station group, a second empty step station, a second side punching station and a cutting and discharging station are sequentially arranged between the upper die plate and the lower die plate, a waste port is formed in the surface of the cutting and discharging station, a cutting tool is arranged below the upper die plate and corresponds to the waste port, a discharging port is arranged at the end of the lower die plate, the discharging port penetrates the lower die plate from top to bottom, and the discharging port is arranged close to the cutting and discharging station. Through reasonable station layout, optimized waste treatment and discharging design, efficient and accurate continuous processing is realized.

Description

Technical Field

[0001] This application relates to the field of automotive sheet metal parts manufacturing and processing, and in particular to a progressive die for forming automotive sheet metal parts. Background Technology

[0002] With the rapid development of the automotive industry, the demand for automotive sheet metal parts is constantly increasing. As an important component of the car body, the forming quality of automotive sheet metal parts directly affects the overall performance and appearance of the vehicle. Traditional automotive sheet metal part production mainly uses single-process or multi-process molds for processing. These production methods have many shortcomings and are difficult to meet the high requirements of efficiency and quality in modern automotive manufacturing.

[0003] In existing technologies, single-operation molds have low production efficiency. Each mold needs to be replaced after completing a process, resulting in long production cycles, high labor intensity, and high mold manufacturing costs. For example, when producing the hinge mounting plate for the left rear door of a car, traditional single-operation molds require multiple mold changes to complete processes such as punching, trimming, and bending. This not only increases production time but also easily leads to inaccurate positioning due to mold changes, affecting product quality.

[0004] In recent years, progressive die technology has been increasingly applied to the production of automotive sheet metal parts. Progressive dies, by setting up multiple consecutive processing stations within a single die, allow the workpiece to complete various processes sequentially within the die, thereby significantly improving production efficiency.

[0005] Relevant prior art, such as Chinese patent application "A Continuous Stamping Die for a Hinge Mounting Plate on the Left Rear Door of an Automobile", application number: CN202322078463.7, discloses a die including an upper die structure and a lower die structure. A continuous workstation is set between the upper and lower die structures, and a conveying device for transferring workpieces between each workstation is also provided between the upper and lower die structures. Processing stations are sequentially arranged between the upper and lower die structures, improving production efficiency. Meanwhile, this utility model uses a continuous die, meaning that one die set continuously has multiple processing stations, allowing the product to complete the entire processing process in the same die set without changing the die. Furthermore, the material position is more accurate, improving the surface quality of the parts, increasing the gloss band, reducing fracture bands, ensuring the flatness of the part's surface, resulting in a wide contact surface and excellent conductivity. The industrial effects are significant, demonstrating excellent practicality.

[0006] However, existing progressive dies still present some problems when producing sheet metal parts with certain complex shapes. During stamping, scrap often accumulates inside the die, requiring frequent shutdowns for cleaning. This not only increases production costs but can also damage the die, affecting production efficiency. Furthermore, finished workpieces may not discharge smoothly due to poorly designed ejector ports, causing them to accumulate inside the die and hindering subsequent processing. Utility Model Content

[0007] The technical problem to be solved by this application is to provide a progressive die for forming automotive sheet metal parts, which achieves efficient and precise continuous processing through reasonable station layout, optimized waste handling and discharge design.

[0008] The technical solution adopted in this application is as follows: a continuous forming die for automotive sheet metal parts, including an upper die and a lower die, with multiple processing stations continuously arranged between the upper die and the lower die, and a conveying device for driving the workpiece to be conveyed between the upper die and the lower die. The material strip passes through each processing station in sequence. Between the upper die and the lower die, there are sequentially arranged punching and trimming stations, forming and folding stations, side processing stations, a second idle station, a second side punching station, and a cutting and discharge station. The surface of the cutting and discharge station has a waste outlet, and a cutting tool is arranged below the upper die corresponding to the waste outlet. The end of the lower die has a discharge port that runs through the lower die from top to bottom and is located near the cutting and discharge station.

[0009] Compared with existing technologies, the advantages of this application lie in the fact that by sequentially setting punching and trimming stations, forming and folding stations, side processing stations, a second idle station, a second side punching station, and a cutting and unloading station between the upper and lower molds, continuous processing from raw materials to finished products is achieved. This continuous processing method reduces the time for handling and positioning workpieces between different processes, thereby improving production efficiency. Integrating multiple processing steps into the same mold avoids the hassle of frequent mold changes in traditional processing methods, reduces equipment space requirements, and also lowers equipment investment costs.

[0010] This progressive die encompasses various processing steps, including punching, trimming, forming and folding, side folding, and side punching, meeting the forming requirements of complex sheet metal parts. By rationally arranging the processing sequence of different stations, high-precision and high-efficiency processing of complex sheet metal parts can be achieved. The addition of a second idle station provides buffer and adjustment space for the processing process, allowing for flexible adjustment of the processing rhythm according to actual processing needs, further optimizing the processing technology and improving product quality.

[0011] The lower mold plate has a discharge port at its end, which is located near the cutting and discharge station. This design allows the finished workpiece to be discharged quickly and smoothly from the discharge port, reducing the time the workpiece spends in the mold and preventing subsequent processing from being affected by workpiece accumulation. The discharge port runs through the lower mold plate from top to bottom. This structural design facilitates the smooth discharge of workpieces and also makes it easy to clean and maintain the discharge channel, ensuring a smooth discharge process.

[0012] In some embodiments of this application, the punching and trimming station is provided with multiple blanking ports, and a punching cutter is provided below the upper template corresponding to each blanking port. The punching cutter is located directly above the blanking port, and the structure of the punching cutter matches the structure of the blanking port.

[0013] By setting multiple blanking ports at the punching and trimming station, and placing a matching punching and cutting tool directly above each port, precise punching and trimming operations can be achieved, ensuring processing accuracy and consistency. The design of multiple blanking ports and punching and cutting tools allows for simultaneous punching and trimming operations, reducing processing time and improving production efficiency. The blanking port design allows waste material to be discharged directly from the port, reducing waste accumulation within the mold, lowering cleaning frequency, and improving mold lifespan and production stability.

[0014] In some embodiments of this application, the forming and folding station group includes at least two consecutively arranged boss forming stations, the top surface of the boss forming station is provided with a contour boss, and one side of the boss forming station constitutes a side contour surface.

[0015] By setting up multiple consecutive boss forming stations, complex boss forming operations can be completed step by step, making it suitable for processing sheet metal parts with complex shapes. The design of the contoured boss and side contoured surfaces ensures accuracy and consistency during the forming process, improving product quality. The step-by-step forming method reduces local stress concentration and extends the service life of the mold.

[0016] In some embodiments of this application, the height of multiple consecutively arranged contour bosses located at the boss forming station increases sequentially. This sequential increase in the height of the multiple contour bosses enables progressive forming, gradually adjusting the shape of the workpiece, reducing stress concentration caused by single-stage forming, and improving forming quality. This design can better adapt to sheet metal parts with complex shapes, ensuring the stability and consistency of the forming process.

[0017] In some embodiments of this application, a pressure head is provided below the upper template corresponding to the contoured boss, and the bottom surface of the pressure head is provided with a contoured groove adapted to the contoured boss; the upper template presses down, causing the pressure head to press down, and the contoured boss is embedded in the contoured groove. The contoured groove of the pressure head adapts to the contoured boss, enabling precise positioning and fitting, ensuring the accuracy of the molding process. Through the downward pressure of the pressure head, the contoured boss can be evenly stressed, reducing local stress concentration and improving molding quality.

[0018] In some embodiments of this application, a contouring block is provided on the side contouring surface below the upper template. The contouring block includes a contouring pressing surface and a limiting surface. The contouring pressing surface is adapted to the side contouring surface, and the limiting surface is adapted to the top surface of the boss forming station. When the upper template is pressed down, the contouring block is pressed down, the contouring pressing surface fits against the side contouring surface, and the limiting surface fits against the top surface of the boss forming station.

[0019] The contouring pressure surface and limiting surface of the contouring block enable precise lateral forming control of the side contouring surface, ensuring forming quality. The limiting surface design ensures the stability of the top surface of the boss forming station, reducing deformation during the forming process. The contouring pressure block design enables high-precision lateral forming, improving the overall quality of the product.

[0020] In some embodiments of this application, the side processing station group includes a first side punching station, a first idle station, and a side folding station arranged sequentially. By integrating the first side punching station, the first idle station, and the side folding station together, continuous processing of side punching and side folding is achieved, reducing process changeover time and improving production efficiency. The first idle station provides buffer and adjustment space for the processing, allowing for flexible adjustment of the processing rhythm according to actual processing needs, further optimizing the processing technology. The second idle station operates similarly.

[0021] In some embodiments of this application, a first punching head is provided on one side of the first side punching station, and the first punching head is horizontally arranged; a second punching head is provided on one side of the second side punching station, and the second punching head is horizontally arranged; the first punching head and the second punching head are respectively connected to the upper template through an inclined guide block.

[0022] The horizontally positioned punch head enables precise side punching operations, ensuring punching quality. Connected to the upper template by an inclined guide block, the position and angle of the punch head can be flexibly adjusted to adapt to different processing requirements.

[0023] In some embodiments of this application, a punch is provided on one side of the side-folding station. The punch is horizontally positioned and connected to the upper template via an inclined guide block. The horizontally positioned punch enables precise side-folding operations, ensuring folding quality. The connection to the upper template via the inclined guide block allows for flexible adjustment of the punch's position and angle to adapt to different processing requirements.

[0024] In some embodiments of this application, the punch is provided with a positioning rod, which corresponds to a through hole on the strip. By engaging the positioning rod with the through hole on the strip, precise positioning can be achieved, ensuring the accuracy of the punch's position during processing. Precise positioning reduces processing errors and improves product quality. Through precise positioning, the scrap rate caused by inaccurate positioning is reduced, thus improving production efficiency.

[0025] Based on common knowledge in the field, the above-described embodiments can be combined arbitrarily. Attached Figure Description

[0026] The present application will be described in further detail below with reference to the accompanying drawings and preferred embodiments. However, those skilled in the art will understand that these drawings are drawn only for the purpose of explaining the preferred embodiments and therefore should not be construed as limiting the scope of the present application. Furthermore, unless specifically indicated, the drawings are only schematic representations of the composition or structure of the described objects and may contain exaggerated depictions, and the drawings are not necessarily drawn to scale.

[0027] Figure 1 This is a schematic diagram of the structure of this application; Figure 2 This is a schematic diagram of the internal structure of this application. Figure 1 ; Figure 3 This is a schematic diagram of the internal structure of this application. Figure 2 ; Figure 4 This is a top view of the internal structure of this application.

[0028] The specific annotations in the attached drawings are as follows: 1. Upper template; 2. Lower template; 5. Material strip; 6. Punching and trimming station; 7. Forming and folding station group; 8. Side processing station group; 9. Second idle station; 10. Second side punching station; 11. Cutting and discharge station; 12. Waste outlet; 14. Discharge outlet; 15. Drop outlet; 16. Punching tool; 17. Boss forming station; 18. Contouring boss; 19. Side contouring surface; 22. Contouring pressure block; 24. Side folding station; 25. First side punching station; 26. First idle station; 27. First punching cutter head; 28. Second punching cutter head; 29. ​​Inclined guide block; 30. Punch head; 31. Positioning rod. Detailed Implementation

[0029] The present application will now be described in detail with reference to the accompanying drawings.

[0030] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0031] A progressive die for forming automotive sheet metal parts, as described in Embodiment 1 Figure 1 , Figure 2As shown, the system includes an upper mold 1 and a lower mold 2, with multiple processing stations continuously arranged between them. A conveyor device is also provided between the upper mold 1 and the lower mold 2 to transport the workpiece between each processing station. The material strip 5 passes through each processing station sequentially. Between the upper mold 1 and the lower mold 2, there are sequentially arranged punching and trimming stations 6, forming and folding stations 7, side processing stations 8, a second idle station 9, a second side punching station 10, and a cutting and unloading station 11, realizing continuous processing from raw materials to finished products. This continuous processing method reduces the time spent handling and positioning workpieces between different processes, improving production efficiency. Integrating multiple processing steps into the same mold avoids the hassle of frequent mold changes in traditional processing methods, reduces equipment space requirements, and also lowers equipment investment costs.

[0032] The cutting and unloading station 11 has a waste outlet 12 on its surface, and a cutting tool is installed below the upper template 1 corresponding to the waste outlet 12. The lower template 2 has an outlet 14 at its end, which extends from top to bottom through the lower template 2 and is located adjacent to the cutting and unloading station 11. This design allows the finished workpiece to be discharged quickly and smoothly from the outlet 14, reducing the workpiece's dwell time in the mold and preventing subsequent processing from being affected by workpiece accumulation. The outlet 14 extends from top to bottom through the lower template 2; this structural design facilitates smooth workpiece discharge and also makes it easy to clean and maintain the discharge channel, ensuring a smooth discharge process.

[0033] Example 2, as Figures 1 to 4 As shown, the punching and trimming station 6 has multiple blanking ports 15. A punching cutter 16 is positioned below each blanking port 15, directly above it, and its structure matches that of the blanking port 15. By providing multiple blanking ports 15 on the punching and trimming station 6 and placing matching punching cutters 16 directly above each port 15, precise punching and trimming operations can be achieved, ensuring processing accuracy and consistency. The design of multiple blanking ports 15 and punching cutters 16 allows for simultaneous punching and trimming operations, reducing processing time and improving production efficiency. The blanking port 15 design allows waste material to be discharged directly from it, reducing waste accumulation within the mold, lowering cleaning frequency, and improving mold lifespan and production stability.

[0034] The forming and folding station group 7 includes at least two consecutively arranged boss forming stations 17. The top surface of each boss forming station 17 is provided with a contoured boss 18, and one side of each boss forming station 17 forms a side contoured surface 19. By setting multiple consecutive boss forming stations 17, complex boss forming operations can be completed step by step, making it suitable for processing sheet metal parts with complex shapes. The design of the contoured boss 18 and the side contoured surface 19 ensures accuracy and consistency during the forming process, improving product quality. The step-by-step forming method reduces local stress concentration and extends the service life of the mold.

[0035] Multiple sequentially arranged contour bosses 18 located on the boss forming station 17 have progressively increasing heights. This progressive increase in height allows for gradual forming, adjusting the workpiece shape step by step, reducing stress concentration caused by single-stage forming, and improving forming quality. This design better adapts to sheet metal parts with complex shapes, ensuring the stability and consistency of the forming process.

[0036] A pressure head is provided below the upper template 1 corresponding to the contoured boss 18. The bottom surface of the pressure head has a contoured groove that matches the contoured boss 18. When the upper template 1 is pressed down, the pressure head is pressed down, and the contoured boss 18 is embedded into the contoured groove. The contoured groove of the pressure head matches the contoured boss 18, enabling precise positioning and fitting, ensuring the accuracy of the molding process. Through the downward pressure of the pressure head, the contoured boss 18 can be evenly stressed, reducing local stress concentration and improving molding quality.

[0037] A contouring block 22 is provided below the upper template 1 corresponding to the side contouring surface 19. The contouring block 22 includes a contouring pressing surface and a limiting surface. The contouring pressing surface is adapted to the side contouring surface 19, and the limiting surface is adapted to the top surface of the boss forming station 17. When the upper template 1 presses down, it drives the contouring block 22 to press down, with the contouring pressing surface conforming to the side contouring surface 19 and the limiting surface conforming to the top surface of the boss forming station 17. Through the contouring pressing surface and the limiting surface of the contouring block 22, precise lateral forming control of the side contouring surface 19 can be achieved, ensuring forming quality. The design of the limiting surface ensures the stability of the top surface of the boss forming station 17, reducing deformation during the forming process. The design of the contouring block 22 enables high-precision lateral forming, improving the overall quality of the product.

[0038] The side processing station group 8 includes a first side punching station 25, a first idle station 26, and a side folding station 24 arranged sequentially. By integrating the first side punching station 25, the first idle station 26, and the side folding station 24 together, continuous processing of side punching and side folding is achieved, reducing process changeover time and improving production efficiency. The first idle station 26 provides buffer and adjustment space for the processing, allowing for flexible adjustment of the processing rhythm according to actual processing needs, further optimizing the processing technology. The second idle station 9 operates similarly.

[0039] A first punching head 27 is horizontally positioned on one side of the first side punching station 25; a second punching head 28 is horizontally positioned on one side of the second side punching station 10. The first punching head 27 and the second punching head 28 are each connected to the upper template 1 via an inclined guide block 29. The horizontally positioned punching heads enable precise side punching operations, ensuring punching quality. The position and angle of the punching heads can be flexibly adjusted via the inclined guide block 29 to adapt to different processing requirements.

[0040] A punch 30 is provided on one side of the side-flipping station 24. The punch 30 is horizontally positioned and connected to the upper template 1 via a slanted guide block 29. The horizontally positioned punch 30 enables precise side-flipping operations, ensuring folding quality. Through the connection to the upper template 1 via the slanted guide block 29, the position and angle of the punch 30 can be flexibly adjusted to adapt to different processing requirements.

[0041] The punch 30 is equipped with a positioning rod 31, which corresponds to a through hole on the strip 5. By engaging the positioning rod 31 with the through hole on the strip 5, precise positioning can be achieved, ensuring the accuracy of the punch 30's position during processing. Precise positioning reduces processing errors and improves product quality. Through precise positioning, the scrap rate caused by inaccurate positioning is reduced, thus improving production efficiency.

[0042] The rest of the contents of Example 2 are the same as those of Example 1.

[0043] The present application has been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of the present application. The descriptions of the embodiments above are only for the purpose of helping to understand the present application and its core ideas. It should be noted that those skilled in the art can make several improvements and modifications to the present application without departing from the principles of the present application, and these improvements and modifications also fall within the protection scope of the claims of the present application.

Claims

1. A progressive die for forming automotive sheet metal parts, comprising an upper die (1) and a lower die (2), wherein multiple processing stations are continuously arranged between the upper die (1) and the lower die (2), and a conveying device for conveying workpieces between the upper die (1) and the lower die (2) is also provided, wherein a strip (5) passes through each processing station in sequence, characterized in that: Between the upper template (1) and the lower template (2), there are sequentially arranged punching and trimming station (6), forming and folding station group (7), side processing station group (8), second idle step station (9), second side punching station (10) and cutting and discharge station (11). The surface of the cutting and discharge station (11) is provided with a waste port (12). A cutting tool is provided below the upper template (1) corresponding to the waste port (12). The lower template (2) is provided with a discharge port (14) at its end. The discharge port (14) penetrates the lower template (2) from top to bottom. The discharge port (14) is located near the cutting and discharge station (11).

2. The progressive die for forming automotive sheet metal parts according to claim 1, characterized in that, The punching and trimming station (6) has multiple material outlets (15). A punching cutter (16) is provided below the upper template (1) for each material outlet (15). The punching cutter (16) is located directly above the material outlet (15), and the structure of the punching cutter (16) matches the structure of the material outlet (15).

3. The progressive die for forming automotive sheet metal parts according to claim 1, characterized in that, The forming and folding station group (7) includes at least two consecutively arranged boss forming stations (17). The top surface of the boss forming station (17) is provided with a contour boss (18), and one side of the boss forming station (17) forms a side contour surface (19).

4. The progressive die for forming automotive sheet metal parts according to claim 3, characterized in that, The height of multiple consecutively arranged contour bosses (18) located on the boss forming station (17) increases sequentially.

5. The progressive die for forming automotive sheet metal parts according to claim 3, characterized in that, A pressure head is provided below the upper template (1) corresponding to the contouring boss (18), and the bottom surface of the pressure head is provided with a contouring groove that is compatible with the contouring boss (18); the upper template (1) is pressed down, which drives the pressure head to press down, and the contouring boss (18) is embedded in the contouring groove.

6. The progressive die for forming automotive sheet metal parts according to claim 1, characterized in that, A contouring block (22) is provided on the side contouring surface (19) below the upper template (1). The contouring block (22) includes a contouring pressing surface and a limiting surface. The contouring pressing surface is adapted to the side contouring surface (19), and the limiting surface is adapted to the top surface of the boss forming station (17). When the upper template (1) is pressed down, the contouring block (22) is pressed down. The contouring pressing surface is in contact with the side contouring surface (19), and the limiting surface is in contact with the top surface of the boss forming station (17).

7. The progressive die for forming automotive sheet metal parts according to claim 1, characterized in that, The side processing station group (8) includes a first side punching station (25), a first idle station (26), and a side turning station (24) arranged in sequence.

8. The progressive die for forming automotive sheet metal parts according to claim 7, characterized in that, The first punching station (25) is provided with a first punching head (27) on one side, and the first punching head (27) is horizontally positioned; the second punching station (10) is provided with a second punching head (28) on one side, and the second punching head (28) is horizontally positioned; the first punching head (27) and the second punching head (28) are respectively connected to the upper template (1) through an inclined guide block (29).

9. A progressive die for forming automotive sheet metal parts according to claim 7, characterized in that, A punch (30) is provided on one side of the side-flipping station (24). The punch (30) is horizontally positioned and connected to the upper template (1) through an inclined guide block (29).

10. A progressive die for forming automotive sheet metal parts according to claim 9, characterized in that, The punch (30) is provided with a positioning rod (31), which corresponds to the through hole on the strip (5).

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