Progressive Die Engineering Secrets: Ua tiav ± 0.01mm Tolerances hauv Precision Copper Terminals

Precision tooj liab terminals uas tsim los ntawm Progressive Die Stamping yuav tsum tau tswj qhov ntev li ntawm ± 0.01mm hla ntau lab lub voj voog stamping. Qhov kawg ntawm lub davhlau ya nyob twg kev ua tau zoo nyob ntawm cov qauv kev tuag, kev xaiv cov khoom siv punch, cov nyiaj them rov qab, thiab kev saib xyuas lub sijhawm tiag tiag es tsis yog kev kho cov tshuab tom qab tsim khoom.

 

Rau cov tsheb sib txuas, EV roj teeb terminals, relay Cheebtsam, thiab cov khoom siv hluav taws xob hluav taws xob, High Precision Copper Stamping OEM yuav tsum tswj cov khoom deformation, burr qhov siab, flatness, thiab terminal geometry stability nyob rau hauv tas li siab - ntim cov khoom.

 

 

 

Cov Txheej Txheem Tuag Txiav Txim Ntau lab -Cycle Stamping Consistency raws li IATF 16949 Requirements

Lub precision progressive tuag tsis yog ib qho cuab yeej txiav. Nws yog ntau-chaw nres tsheb tsim qhov system tswj kev pub mis kom raug, khoom deformation, dabtsi yog khoov ib ntus, thiab qhov kawg geometry ntawm lub davhlau ya nyob twg.

 

Rau EV thiab hluav taws xob daim ntawv thov, tus tsim tuag ib txwm ua ke:

Sawb layout optimization nyob rau hauv ± 0.01mm pitch kam rau ua tswj
Ntau -theem blanking thiab tsim chaw nres tsheb
Precision qhia ncej thiab bushing tshuab nrog micron -theem clearance
Hauv - tuag riveting lossis clinching chaw nres tsheb
Tsis siv neeg seem cais tshuab
Hauv - tuag sensors rau kev kuaj pom qhov tsis zoo

Raws li IATF 16949-tsim kev tswj hwm kev tsim khoom, cov cuab yeej siv yuav tsum nyob ruaj khov thoob plaws lub voj voog tsim khoom.

 

Hom precision tooj liab davhlau ya nyob twg stamping tsis:

Yam khoom Engineering	Yam Tswj Tus Nqi
Terminal dimensional kam rau ua	± 0.01 hli
strip feeding raug	± 0.005 hli
Tuag clearance tswj	5% -10% ntawm cov khoom thickness
Burr qhov siab	Tsawg dua los yog sib npaug li 10% cov khoom thickness
Flatness tswj	Tsawg dua lossis sib npaug li 0.05mm / 100mm
Tool lub neej phiaj	1,000,000 - 10,000,000 strokes
CMM ntsuas qhov tseeb	Tsawg dua los yog sib npaug li 0.005mm

 

Tus tsim tuag ncaj qha cuam tshuam rau:

Tiv tauj tiv thaiv stability
Kev sib xyaw ua ke
Hluav taws xob conductivity
Terminal insertion quab yuam
Ntev -lub sij hawm vibration resistance

 

Ib qho kev tsim kho tsis zoo tuaj yeem tsim cov qauv siv tau tab sis ua tsis tiav thaum lub sijhawm tsim khoom ntau vim yog xuas nrig ntaus, cov khoom tawv tawv, lossis qhov sib txawv ntawm qhov sib txawv.

 

Copper Material Behavior Requires Dedicated Progressive Die Compensation

Copper alloys muaj cov hluav taws xob hluav taws xob siab tab sis tam sim no tsim cov teeb meem vim lawv lub zog tsis tshua muaj zog thiab siab ductility.

Cov khoom siv dav dav dav suav nrog:

C1100 ntshiab tooj liab
C1020 oxygen-dawb tooj
C2680 tooj dag
CuSn alloy cov ntaub ntawv

 

Khoom sib piv:

Khoom siv	Kev coj ua	Tensile zog	Daim ntawv thov
C1100 ntshiab tooj liab	Ntau dua lossis sib npaug rau 100% IACS	220-260MPa	EV fais fab terminals, busbar terminals
C1020 OFC tooj liab	Ntau dua lossis sib npaug rau 100% IACS	220-250MPa	Siab -kev ntseeg tau hluav taws xob tiv tauj
C2680 tooj dag	25% -30% IAB	300-450MPa	Connector terminals xav tau ntau zog
CuSn alloy	20% -40% IAB	400-600MPa	Caij nplooj ntoos hlav terminals thiab hnav- tiv taus tiv taus

 

Rau C1100 tooj liab stamping, cov tuag tuag yuav tsum tau them rau:

Cov khoom elongation thaum khoov

Ua hauj lwm hardening tom qab rov ua dua

Springback tom qab unloading

Thickness variation ntawm cov khoom coil

 

Engineering tswj muaj xws li:

Finite Element Analysis (FEA) simulation ua ntej tooling ntau lawm

Khoov lub kaum sab xis them nyiaj tsim

Progressive forming es tsis txhob ntawm ib - kauj ruam dabtsi yog khoov

Pilot pin positioning tom qab txhua qhov chaw nres tsheb

 

 

 

Carbide Punch xaiv rau 10 lab Stroke Tool Life

Cov khoom siv punch txiav txim siab txiav ntug kev ruaj ntseg, burr tiam, thiab txij nkawm zaus.

Rau siab -ceev tooj liab davhlau ya nyob twg stamping, cov cuab yeej steel xaiv yuav tsum xav txog:

Hardness tuav
Hnav tsis kam
Kev cuam tshuam lub zog
Ntug chipping kuj

 

Common tooling khoom:

Punch Khoom	Hardness	Hnav Resistance	Daim ntawv thov
Tungsten Carbide (WC{0}}Co)	HRA 88-92	Zoo heev	High -Volume precision blanking
SKD11 Cov cuab yeej Steel	HRC 58-62	Siab	General kev vam meej stamping
ASP23 hmoov hlau	HRC 60-64	Siab heev	Complex forming terminals
SKH51 Siab -Speed ​​Steel	HRC 62-65	Nruab nrab	High - stamping ceev

 

Rau tooj liab terminals xav tau ± 0.01mm raug:

Tungsten carbide punches yog siv rau precision blanking npoo.
SKD11 inserts yog siv los tsim cov seem uas yuav tsum tau muaj kev cuam tshuam.
Cov txheej txheej saum npoo xws li TiN / TiCN tuaj yeem txo kev sib txhuam thiab hnav.

Tuag Clearance Optimization tiv thaiv Burr loj hlob thiab tiv tauj tsis ua haujlwm

Incorrect tuag clearance tsim:

Tshaj burr qhov siab
Ntug tawg
Khoom deformation
Ua kom muaj hluav taws xob tiv thaiv

 

Pom zoo clearance xam:

Khoom Thickness	Pom zoo Clearance
0.1- 0.3 hli tooj	5%-8%
0.3- 1.0 hli tooj	Tooj liab 8% -12%
Hlau alloy	10%-15%

 

Rau EV relay terminals thiab contactor Cheebtsam, burr tswj yog ncaj qha ntsig txog:

Tiv tauj interface kev ntseeg tau

Plating adhesion

Kev sib dhos raug

 

Thov Kev Ntsuam Xyuas DFM Dawb & Tso Cai

 

 

Springback Compensation Design hauv Progressive Forming Process

Copper terminals feem ntau muaj xws li:

90℃dabtsi yog khoov qauv
U-zoo li tus kov caj npab
Vertical txuas tabs
Ntau - dav hlau davhlau ya nyob twg geometry

Tom qab khoov, elastic rov ua rau qhov sib txawv ntawm qhov sib txawv.

 

Springback yam muaj xws li:

Khoom hardness
Khoov vojvoog
Noob nplej
Ua kom ceev
Cov cuab yeej nto kev sib txhuam

 

Engineering daws teeb meem:

Ntau - kauj ruam dabtsi yog khoov es tsis txhob ntawm ib qho - txhaj tshuaj
Tshaj -bending nyiaj
txheej txheem npib
Adjustable forming inserts

 

Piv txwv:

Txheej txheem txheej txheem	Qhov kawg ntawm qhov tseeb	Txaus ntshai
Ib zaug - theem khoov	± 1 degree	High springback
Ob - theem khoov	± 0.3 degree	Nruab nrab
Multi-stage forming + coining	± 0.1 degree	Tsawg

 

Cov txheej txheem npib txhim kho Terminal Flatness thiab hluav taws xob tiv thaiv kev ruaj ntseg

Coining siv tswj compression kev nyuaj siab rau qhov chaw khoov.

 

Cov txiaj ntsig:

Txo elastic rov qab
Txhim kho qhov chaw sib cuag
Tswj qhov siab qhov siab variation
Txhim khu kev sib dhos

 

Tej yam parameter:

Parameter	Tswj ntau yam
Flatness kam rau ua	Tsawg dua los yog sib npaug li 0.05mm
npib siab	300-800MPa
Nto roughness	0.8-1.6 hli
Dimensional repeatability	± 0.01 hli

 

 

 

Tiag -Lub Sijhawm Tuag Saib Xyuas Tiv Thaiv Kev Ua Haujlwm Tsis Zoo

Niaj hnub nimno txheej txheem stamping kab sib txuas cov sensors ncaj qha rau hauv cov cuab yeej siv.

Cov khoom soj ntsuam muaj xws li:

Sawb noj txoj hauj lwm
Punch overload
Cov khoom muaj nyob
Kev tsim siab
Part ejection xwm txheej

 

Kev soj ntsuam tsis zoo:

Saib xyuas System	Kev txheeb xyuas qhov tseeb
Khoom noj khoom haus sensor	± 0.01 hli
Load saib xyuas	1% -3% deviation detection
Punch break detection	Millisecond teb
Kev tshuaj xyuas qhov muag	Micron - qib kev kuaj xyuas qhov tsis raug

 

Qhov no tiv thaiv:

Tsis muaj punches

Muab ob npaug rau noj

Terminal deformation

Cov cuab yeej puas

Loj batch seem

 

CMM Kev Tshuaj Xyuas thiab PPAP Qib 3 Cov Ntaub Ntawv rau Cov Neeg Siv Khoom Siv Tsheb

Rau tsheb-qib tooj liab terminals, kev siv tau zoo suav nrog:

Thawj Tshooj Kev Tshawb Fawb (FAI)
Daim ntawv qhia qhov ntev
Cov ntaub ntawv pov thawj
Kev txheeb xyuas muaj peev xwm (Cp / Cpk)
PPAP Theem 3 xa

 

Cov khoom siv tshuaj ntsuam xyuas:

CMM tswj kev ntsuas tshuab
Optical ntsuas qhov system
Ntsev tshuaj tsuag tester
Microhardness tester
Hluav taws xob tiv thaiv tester

 

Quality parameters:

Cov khoom soj ntsuam	Txuj
Dimensional raug	± 0.01 hli
Cov ntaub ntawv pov thawj	RoHS / REACH
Txoj kev pom zoo	PPAP Qib 3
Qhov system zoo	TIAB SA 16949
Environmental system	ISO 14001 Daim Ntawv Pov Thawj

 

Download Stamping Design Specification

 

 

Xiamen Apollo Stamping Vuam Technology Co., Ltd muab precision hlau stamping thiab cov cuab yeej daws rau:

 

EV roj teeb terminals

HV connector Cheebtsam

Relay tooj liab qhov chaw

Contactor conductive Cheebtsam

Fais fab electronics terminals

 

Manufacturing muaj peev xwm muaj xws li:

Progressive tuag tsim

Precision stamping

CNC tooling processing

Hauv - tuag riveting

Kuj welding

Kev npaj nto plating

Kev tshuaj xyuas tsis siv neeg

 

Kev tswj kev tsim khoom raws li hauv qab no:

IATF 16949 automotive zoo system

ISO 9001 Kev Tswj Xyuas Zoo

RoHS thiab REACH ua raws

 

Yam khoom muaj peev xwm:

Yam khoom muaj peev xwm	Apollo Manufacturing Range
Cov khoom siv tooj liab thickness	0.05- 3.0 hli
Stamping kam rau ua	± 0.01 hli
Xovxwm muaj peev xwm	Ntau-ton precision stamping
Cov cuab yeej txhim kho lub voj voog	20-30 hnub
Prototype xa khoom	7-15 hnub
Kev txhawb nqa ntau lawm	lab- theem strokes

 

 

Yuav ua li cas kam rau ua precision progressive tuag tiav rautooj liab terminal stamping?

Apollo Precision Progressive Die Stamping ua tiav qhov kev tswj xyuas qhov ntev li ntawm ± 0.01mm los ntawm kev txhim kho cov cuab yeej zoo, CMM tshuaj xyuas, thiab hauv - kev soj ntsuam kev tuag.

 

Ntev npaum li cas tuaj yeem ua tau zoo stamping tuag ua haujlwm rau EV tooj liab terminals?

High -qib tungsten carbide thiab SKD11 cov cuab yeej tuaj yeem txhawb nqa 1,000,000 txog 10,000,000 stamping cycles nyob ntawm cov khoom tuab thiab cov khoom siv.

 

Apollo puas tuaj yeem muab OEM cov cuab yeej tsim rau kev cai tooj liab terminals?

Yog lawm. Apollo muab OEM cov cuab yeej tsim, kev txhim kho kev tuag, kev tsim qauv siv tau, thiab PPAP Qib 3 cov ntaub ntawv rau EV thiab cov ntawv thov hluav taws xob hluav taws xob.