Blanking Mold Coating Layout to Stop Edge Film Peeling
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Solution Overview
Problem
Mold surface treatment films used in metal blanking processes tend to chip and peel, especially at sharp edges, leading to premature failure and reduced durability due to strong impact loads and inadequate adhesion, which existing techniques like diamond coating with chamfered corners cannot effectively prevent.
Innovation Solution
A mold design with a peripheral end face located lower than or indirectly communicated with the top face, coated with a carbon-based rigid surface treatment film, featuring a groove between the outer edge and inner edge, and a peripheral wall face, where the top and peripheral end faces are coated, and the outer periphery of the peripheral end face is not, to prevent peeling and maintain film adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diamond coating is applied to the cutting edge part, then surface treatment film adhesion is improved, but chipping and scaling occur during polishing or pressing
Solution Approach 1:
The invention applies different surface treatments to different parts of the mold: the cutting edge part receives diamond coating for adhesion, while the peripheral end face is left as base material or receives different treatment to prevent peeling propagation. This local differentiation resolves the contradiction by optimizing each region for its specific functional requirements.
Solution Approach 2:
The mold surface is segmented into distinct functional zones: the cutting edge part with diamond coating for initial adhesion, and the peripheral end face with alternative treatment or geometry to stop peeling. This segmentation allows each zone to address specific problems without compromising the other.
2Reliability
If chamfered corners are used on punch and die, then peeling of diamond film is reduced, but effective prevention is not achieved
Solution Approach 1:
Rather than uniformly chamfering all corners, the invention selectively applies geometry modification only to the peripheral end face where peeling originates, while maintaining the cutting edge geometry for optimal cutting performance. This localized approach achieves peeling prevention without compromising manufacturing precision.
Solution Approach 2:
The peripheral end face geometry is designed in advance to prevent peeling propagation before it can spread to the diamond-coated cutting edge. This preliminary geometric feature acts as a barrier that stops peeling at its origin point.
3Duration of action of stationary object
If surface treatment film is applied to enhance hardness and lubricity, then mold durability is improved, but peeling progresses to other parts causing premature failure
Solution Approach 1:
The invention applies surface treatment selectively: diamond coating on the cutting edge for hardness and lubricity, while the peripheral end face uses base material or alternative treatment to prevent peeling initiation and propagation. This localized treatment strategy maintains durability where needed while preventing failure propagation.
Solution Approach 2:
The invention converts the potential harm of untreated peripheral areas into a benefit by using the base material or differently treated peripheral end face as a barrier that stops peeling propagation, thereby protecting the valuable diamond-coated cutting edge regions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively stops peeling of the surface treatment film at the peripheral end face without spreading to the top face, ensuring high-quality blank shaping and extended mold life by limiting film peeling to the peripheral end face, thus preventing product failures and maintaining mold integrity.
Implementation Method 1
degradation in adhesiveness of the surface treatment film at the cutting edge part
Data Source
AI summary
A mold used for blanking a metal plate to shape a blank to be drawn. The mold has a surface treatment film and a top face to be brought into contact with the metal plate and a peripheral end face communicated indirectly with the top face. At least the top face is coated with the surface treatment film.