An in-die composite processing device for use in a progressive die structure

Abstract

The application discloses a device for in-die composite machining in a progressive die, which is installed in a progressive die structure and comprises a base, a drilling assembly and a tapping assembly. The base is fixed to a lower die part of a die and is used for supporting and installing a plurality of machining functional assemblies. An elastic material pressing mechanism matched with the base is installed at an upper die part of the die and is used for applying a vertical material pressing force to a material to be machined during die closing. The material pressing mechanism can keep the material in a stable positioning state during stamping and prevent the material from being warped and displaced due to uneven stress. The structure can realize continuous and high-precision drilling, chamfering and tapping operations in the die closed state and is suitable for the precise machining requirements of high-performance plates in an efficient and automatic stamping production line.

Description

Technical Field

[0001] This application relates to the field of in-mold processing, and in particular to an in-mold composite processing apparatus for progressive mold structures. Background Technology

[0002] In the field of precision metal parts manufacturing, especially in the production of miniaturized, high-strength structural components, it is often necessary to machine tiny holes and complete tapping processes on thin-walled or small workpieces. Currently, the mainstream production processes mainly adopt two modes. The first is die stamping technology, which directly punches out the required holes using precision punches during the product shaping stage. This method has an efficiency advantage when machining materials of ordinary hardness and can achieve continuous in-mold forming. However, as the market demands higher product performance, more and more miniature parts are beginning to use high-hardness materials to meet strength and durability requirements. When punching tiny holes in these high-strength materials, the shear stress on the punch increases dramatically, leading to frequent deformation, chipping, and even breakage of the punch. This not only increases the number of mold downtimes for maintenance, significantly reducing the effective operating time of the production line, but also increases the unit production cost due to the rising cost of punch replacement and maintenance labor.

[0003] To address the issue of punch wear, existing technologies often shift to a second approach: postponing the punching process. This involves first stamping the main body of the product using a die, and then separately drilling and tapping the workpiece using automated equipment or a CNC machining center. While this method avoids wear and tear on the die and punch, it introduces new efficiency bottlenecks due to the additional process. Because the target workpiece is small and compact, challenges arise during multi-process turnover, such as difficulty in ensuring positioning accuracy and poor conveying stability. Automated feeding systems require repeated precise positioning and clamping operations, while CNC machining involves accumulated clamping, positioning, and point-to-point machining time; both significantly extend the processing cycle of a single product. The repetitive positioning actions and equipment changeover time caused by process separation further amplify the loss of production cycle time, making it difficult for overall processing efficiency to meet the demands of modern industry for large-scale, highly economical production.

[0004] Therefore, existing technologies face a dilemma in the manufacturing of high-hardness micro-hole tapped parts: using in-mold punching can easily damage key mold components, while choosing process separation processing sacrifices production efficiency. Utility Model Content

[0005] The purpose of this application is to overcome at least one deficiency of the prior art and provide a multi-process in-mold tapping structure suitable for forming micro-holes in high-strength, thick metal materials. This structure can realize continuous and high-precision drilling, chamfering and tapping operations in the closed state of the mold, and is suitable for the precision processing needs of high-performance sheet metal in efficient automated stamping production lines.

[0006] To achieve the above objectives, this application discloses an in-mold composite processing device for a progressive die structure. The device, installed within the progressive die structure, includes a base, a drilling assembly, and a tapping assembly. The base is fixed to the lower die portion of the die and supports and mounts multiple processing functional components. A cooperating elastic pressure mechanism is installed on the upper die portion of the die and applies a vertical pressure force to the material to be processed during die closure. The pressure mechanism maintains a stable material positioning during stamping, preventing warping, displacement, and other phenomena caused by uneven force distribution.

[0007] Along the material stepping direction of the progressive die, the base is provided with drilling components, chamfering components and tapping components arranged in sequence. Each component is independently constructed and performs its corresponding processing function.

[0008] The drilling and chamfering assemblies are located on one or both sides of the base, with the specific installation position determined according to the structure of the material being processed and the process requirements. When drilling and chamfering are required on both sides of the material, the drilling and chamfering assemblies can be symmetrically installed on both sides of the base; when only one side of the material needs to be processed, the corresponding assemblies can be installed on only one side.

[0009] Furthermore, the drilling assembly includes a horizontally arranged linear slide, a slider capable of linear reciprocating along the slide, and a drilling mechanism mounted on the slider. The drilling mechanism includes a clamping assembly for holding the drilling tool, a motor for providing rotary drive, and a coupling mechanism for transmitting the driving force to the tool. The tool is mounted via the clamping assembly, and the motor provides axial rotational power, which is output to the tool through a coupling structure for drilling the material within the stamping cycle. The slider reciprocates linearly along the slide guide rail to achieve axial feed of the tool, ensuring that the drilling process is carried out within a defined trajectory.

[0010] Furthermore, the base is also equipped with a chamfering assembly located between the drilling assembly and the tapping assembly. The structure of the chamfering assembly is consistent with that of the drilling assembly. The cutting tool used in the chamfering assembly is a special chamfering forming tool, and its installation method is the same as that of the drilling tool. The rotation drive and feed mechanism are also consistent with those of the drilling assembly. This assembly is activated after drilling is completed, causing the tool to rotate around the axis and feed downwards to remove burrs and chamfer the perimeter of the hole.

[0011] Furthermore, the tapping assembly is located at the rear machining station of the base, and the tapping assembly includes a transmission screw, a transmission cup, a tapping mechanism, and a transmission mechanism connecting the transmission cup and the tapping mechanism.

[0012] Furthermore, a waste collection assembly is installed inside the base to handle chips and debris generated during drilling, chamfering, and tapping. This assembly includes a waste guide tray with an inclined surface and a negative pressure extraction device located below it. During processing, the waste is collected by the guide tray and then sucked out of the mold cavity area by the extraction device to avoid debris accumulation interfering with subsequent processing and to reduce the risk of mold wear.

[0013] Through the combination and configuration of the above components, this device realizes in-mold integrated processing of drilling, chamfering and tapping processes within the continuous die structure. It can complete multiple hole processing tasks within the stamping cycle and has technical characteristics such as compact structure, clear transmission path, coordinated process rhythm, high positioning accuracy and strong processing stability. It is suitable for high-density and high-efficiency stamping forming of parts with large plate thickness, small hole diameter and high material strength, and has wide applicability in the automation application of continuous stamping dies.

[0014] The beneficial effects listed above are not exhaustive of all advantages. Other potential beneficial effects and detailed technical implementation methods will be further disclosed in the embodiments or other descriptive sections of this application. Attached Figure Description

[0015] A better understanding of various aspects of this disclosure will be achieved by reading the following detailed description in conjunction with the accompanying drawings. The positions, dimensions, and extents of the structures shown in the drawings, etc., do not always represent actual positions, dimensions, and extents. In the drawings: Figure 1 This is a schematic diagram of the structure of one embodiment disclosed in this application.

[0016] Figure 2 This is a schematic diagram of the internal structure of the tapping component area in one embodiment of this application.

[0017] Figure 3 This is a schematic diagram of the structure of the elastic pressing mechanism area in one embodiment of this application.

[0018] Figure 4 This is a schematic diagram of the structure after the elastic pressing mechanism and the tapping component are engaged in one embodiment of the present application.

[0019] Figure 5 This is a schematic diagram of the tapping component in one embodiment of the present application. Detailed Implementation

[0020] The present disclosure will now be described with reference to the accompanying drawings, which illustrate several embodiments of the present disclosure. However, it should be understood that the present disclosure can be presented in many different ways and is not limited to the embodiments described below; in fact, the embodiments described below are intended to make the disclosure more complete and to fully illustrate the scope of protection of the present disclosure to those skilled in the art. It should also be understood that the embodiments disclosed herein can be combined in various ways to provide further additional embodiments.

[0021] It should be understood that the same reference numerals denote the same elements in all the accompanying drawings. For clarity, the dimensions of certain features may be modified in the drawings.

[0022] It should be understood that the terminology used in this specification is for describing specific embodiments only and is not intended to limit this disclosure. All terms used in this specification (including technical and scientific terms) have the meanings commonly understood by those skilled in the art, unless otherwise defined. For the sake of brevity and / or clarity, techniques, methods, and apparatus known to those skilled in the art may not be discussed in detail; however, where appropriate, such techniques, methods, and apparatus should be considered part of this specification.

[0023] Unless otherwise specified, the singular forms “a,” “the,” and “the” used in this specification include their plural forms. The terms “comprising,” “including,” and “containing” used in this specification indicate the presence of the claimed feature but do not exclude the presence of one or more other features. The term “and / or” used in this specification includes any and all combinations of one or more of the relevant listed items.

[0024] See attached document Figures 1 to 5 This embodiment discloses an in-mold composite machining device for use inside a progressive die. The device is suitable for continuous and high-precision in-mold composite machining operations such as micro-hole drilling, hole chamfering, and thread tapping on high-strength and high-thickness metal workpieces. It can complete multiple complex machining processes within the die closing cycle and is suitable for the process requirements of automated continuous stamping production lines for multi-station, high-efficiency precision machining.

[0025] The device mainly includes a base 1 installed on the lower die of a progressive die, and an elastic pressing mechanism 2 installed on the upper die. The base 1 is preferably made of high-strength alloy steel, which has good structural strength and processing stability. The base 1 serves as the mounting platform for each processing component and is precisely connected to the lower die through positioning pins and bolts to ensure the relative position stability of each component.

[0026] The elastic pressing mechanism 2 is preferably constructed using a nitrogen spring or a mold spring, and is integrated with it via an upper mold pressure head. During the mold closing phase, it applies a vertical clamping force to the workpiece to be processed, thereby stabilizing the workpiece and suppressing warping, lifting, or displacement during the process. Those skilled in the art can implement this pressing structure based on existing mold elastic pressing technology; the relevant structures and installation methods are within the scope of existing technology and are not described in detail in this embodiment.

[0027] To facilitate understanding of the elastic pressure mechanism 2, more specifically, in this embodiment, the elastic pressure mechanism 2 includes a floating pressure plate. The floating pressure plate is made of high-strength tempered steel or high-wear-resistant aluminum alloy, and is disposed on one side of the upper mold and connected to the upper mold fixing frame through a guide structure. The lower surface of the floating pressure plate is configured with a conforming structure adapted to the shape of the target product. This conforming structure can be in the form of a boss, an arc surface, or a stepped structure, etc., to form surface contact with the upper surface of the workpiece during the pressing stage, thereby achieving stable pressing throughout the entire area.

[0028] The floating pressure plate is guided by two sets of parallel guide rods to move vertically relative to each other. A pre-tension spring is connected to the end of each guide rod; one end of the spring is fixed to the pressure plate, and the other end is fixed to the guide seat. During the pressing process, the spring's elastic restoring force provides a constant downward pressing force. This structure not only automatically adapts to pressing differences caused by changes in workpiece shape but also provides flexible buffering during mold closing, effectively preventing local deformation or stress concentration in the workpiece due to sudden pressure changes. Furthermore, the spring stiffness, guide clearance, and specific contour of the contouring structure used in the elastic pressure mechanism 2 can be customized according to different part shapes to ensure wide adaptability and strong positioning stability of the device.

[0029] Based on the above structure, along the feeding direction of the continuous die, a drilling assembly 3, a chamfering assembly 4, and a tapping assembly 5 are sequentially installed on the base 1. These three components are constructed as independent modules, respectively completing drilling, hole machining, and thread forming operations. The drilling assembly 3 and the chamfering assembly 4 can be selectively installed on one or both sides of the base 1 according to the shape requirements of the workpiece. When installed on both sides, a symmetrical arrangement is used to accommodate double-sided machining requirements; when arranged on one side, the structure is more compact and suitable for situations with limited space or single-sided forming requirements.

[0030] Specifically, the drilling assembly 3 includes a horizontal linear slide 301 disposed on the side of the base 1, a slider 302 mounted on the slide 301, and a drilling mechanism 303 disposed on the slider 302. The slide 301 adopts a hardened guide rail and ball-bearing slider pair structure, which has high guiding accuracy and low friction characteristics, ensuring the stability and repeatability of the slider 302's movement. The drilling mechanism 303 includes an electric spindle, a motor base, a coupling, and a tool chuck. The electric spindle is used to drive the tool to rotate, and the tool chuck is used to mount the carbide micro drill. The transmission connection is achieved through the coupling structure. The slider 302 is controlled by the driving device to move linearly along the slide 301, realizing the axial feed of the tool in conjunction with the rotary drilling action.

[0031] It should be understood that the above-mentioned sliding fit, tool clamping and transmission connection methods are within the scope of conventional design of CNC mechanical structures. The specific structural forms and connection details can be implemented by those skilled in the art with reference to existing mature solutions, so they are not disclosed in further detail in this application.

[0032] In this embodiment, the chamfering assembly 4 is identical to the drilling assembly 3 in terms of configuration, installation method, and movement, with only the type of cutting tool being replaced. The chamfering tool uses a tapered multi-blade tip, suitable for precise deburring and chamfering of the hole edge after drilling. Its rotation drive, feed path, and motion control method are consistent with those of the drilling assembly 3. Through program control, it seamlessly switches to the chamfering process after drilling is completed, realizing continuous in-mold processing.

[0033] In this embodiment, the tapping assembly 5 is installed at the end position of the base 1 and is used to perform thread tapping operations on holes that have been drilled and chamfered. The tapping assembly 5 includes a drive screw, a drive cup, a tapping mechanism, and a transmission mechanism connecting the drive cup and the tapping mechanism.

[0034] The connection relationship and transmission method of the above-mentioned tapping mechanism are all mature technologies in the field of in-mold tapping. Those skilled in the art can implement them through conventional methods, so they will not be elaborated further.

[0035] To improve the long-term stability of the device and prevent chip accumulation from affecting the mold life, a waste collection component 6 is installed below the base 1 in this embodiment. This component consists of an inclined chip guide tray and a negative pressure chip suction system located below it. Drill chips, tapping debris, and other materials generated during processing are collected and slid down via the chip guide tray under gravity, and then extracted from the mold cavity area by the negative pressure device, ensuring a clean processing area and preventing jamming and contamination. The suction structure, air path control, and negative pressure generating mechanism of the above-mentioned waste cleaning scheme are common structural forms in existing industrial chip suction technologies. Specific selection and configuration parameters fall within the scope of conventional design by those skilled in the art and are not disclosed in detail in this specification.

[0036] During the automated operation of the mold, the in-mold composite processing device can be synchronously linked with the progressive die feeding device through a PLC control system. Processing steps such as drilling, chamfering, and tapping are executed sequentially according to the station's cycle time by a preset control program. The components work closely together and respond consistently, effectively meeting the demands of high-paced, high-repetition-precision stamping production. The various sensors, actuators, and signal input methods used in the control system are common knowledge in industrial automation control, well-known to those skilled in the art, and will not be detailed here.

[0037] As can be seen from the above configuration and operation process, this embodiment successfully integrates drilling, chamfering, and tapping functional modules within a progressive die structure. It completes a series of complex hole machining tasks without affecting the die's closing cycle, not only improving the processing efficiency and dimensional consistency of stamped products but also reducing subsequent processing steps and manufacturing costs through in-die integration. It is particularly suitable for production scenarios requiring high sheet hardness and stringent hole precision, such as automotive structural parts, electrical assembly plates, and precision connector bases—all requiring mass production and high quality.

[0038] Understandably, compared with existing technologies, this embodiment integrates drilling, chamfering, and tapping actions within a progressive die, completing all processing steps synchronously through the die's opening and closing motion. This completely avoids the repetitive positioning and equipment changeover processes found in traditional processes, significantly reducing single-piece processing time and minimizing yield fluctuations caused by human intervention or clamping errors. Furthermore, this solution allows for strict synchronous control of the die's feeding cycle, improving the consistency of hole positions and overall product assembly accuracy, and greatly enhancing the overall efficiency and reliability of the stamping process.

[0039] While exemplary embodiments of this disclosure have been described, those skilled in the art will understand that various changes and modifications can be made to the exemplary embodiments of this disclosure without departing from the spirit and scope thereof. Therefore, all changes and modifications are included within the scope of protection of this disclosure as defined by the claims. This disclosure is defined by the appended claims, and equivalents of those claims are also included.

Claims

1. An in-mold composite processing device for a progressive die structure, characterized in that, The device is installed in a progressive die structure and includes a base, a drilling assembly, and a tapping assembly. The base is fixed to the lower die portion of the die and is used to support and install multiple processing functional components. An elastic pressure-bearing mechanism that works in conjunction with the base is installed on the upper die portion of the die and is used to apply a vertical pressure-bearing force to the material to be processed during the die closing process. The pressure-bearing mechanism can maintain the stable positioning of the material during the stamping process. Along the material stepping direction of the progressive die, drilling components, chamfering components, and tapping components are arranged in sequence on the base, each component being independently constructed; The drilling assembly and the chamfering assembly are located on one or both sides of the base; The tapping assembly is located at the rear machining station of the base. The tapping assembly includes a transmission screw, a transmission cup, a tapping mechanism, and a transmission mechanism connecting the transmission cup and the tapping mechanism.

2. The in-mold composite processing device for a progressive die structure according to claim 1, characterized in that, The drilling assembly includes a horizontally arranged linear slide, a slider that can reciprocate linearly along the slide, and a drilling mechanism mounted on the slider. The drilling mechanism includes a clamping assembly for holding the drilling tool, a motor for providing rotary drive, and a connecting mechanism for transmitting the driving force to the tool. The tool is mounted through the clamping assembly, and the motor provides axial rotational power, which is output to the tool through the coupling structure for drilling the material within the stamping cycle.

3. The in-mold composite processing apparatus for a progressive die structure according to claim 1, characterized in that, The base is also provided with a chamfering component located between the drilling component and the tapping component, and the structure of the chamfering component is consistent with that of the drilling component.

4. The in-mold composite processing device for a progressive die structure according to claim 1, characterized in that, The base is equipped with a waste collection assembly for handling chips and debris generated during drilling, chamfering and tapping; the assembly includes a waste guide tray with an inclined surface and a negative pressure extraction device located below it.

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