Knowledge of Precision Sheet Metal Punching Process

Precision sheet metal punching is a high-precision metal processing method. It is a process that uses the principle of plastic shearing. On a special press, a non-traditional precision punching die is used to make the material to be processed undergo plastic shear deformation under the action of huge pressure, thereby achieving material cutting. This method can produce punching parts with high precision, flat cross-section, less warping deformation, and good interchangeability.

Precision Sheet Metal Punching Processing Method

There are various methods for processing high-precision small holes, including progressive punching, hydraulic punching, laser punching, etching punching, and discharge punching. Each of these techniques has its unique characteristics.

Progressive Punching

Offers high production efficiency and consistent quality.

Hydraulic Punching

It is capable of handling components that traditional methods struggle with.

Laser Punching

This process produces straight, clean openings with exceptional precision.

Etching Punching

Known for its low cost and high accuracy, is ideal for processing filter materials of varying thicknesses.

Discharge punching

It boasts high production efficiency and is particularly suited for the mass production of parts.

Application Fields of Precision Sheet Metal Punching

Punching technology is widely used in many industrial fields, especially in the manufacturing process of parts such as automobiles, air conditioners, furniture, construction and electronic products.

For example, precision parts such as chassis, doors and hoods in the automotive manufacturing industry, key parts such as air inlets, exhaust ports and supports in air conditioning production, and metal parts such as hinges and casters in furniture manufacturing are all inseparable from punching technology.

Future Development Trends

The future development of precision stamping technology will focus on high speed, high efficiency and automation to meet the needs of new material processing, improve precision, and meet the growing high standards of the market. With the continuous upgrading of precision stamping equipment and the improvement of mold technology, precision stamping technology will increasingly replace traditional cutting methods to improve production efficiency and product precision.

Common Problems in Precision Punching Processing

1. Burrs

• Cause: Improper mold gap or edge wear.
• Solution: Reasonably select the mold gap, keep the edge sharp, and ensure the vertical concentricity of the mold.

2. Bulge Around the Orifice

• Cause: The mold gap is too small, or the edge becomes blunt, causing the material to squeeze outward during stamping.
• Solution: Adjust the mold gap, ensure the edge is sharp, and increase the pressing force to overcome the material’s back extrusion force.

3. Copper Foil Flipped at the Hole Mouth

• Cause: Recoil force or poor bonding between copper foil and substrate.
• Solution: Use the positive punching method, replace the punch, and adjust the clearance between the punch and the unloading plate.

4. Delamination and Whitening

• Cause: Improper punching clearance or poor material punching performance.
• Solution: Enlarge the punching clearance, repair the cutting edge, increase the pressing force, and adjust the preheating temperature.

5. Hole Wall Tilt and Offset

• Cause: Insufficient punch rigidity or improper installation.
• Solution: Improve the rigidity and precision of the punch, ensure the concentricity of the punch and the die, and improve the matching accuracy.

6. Rough Section

• Cause: Excessive punching clearance or insufficient punching force.
• Solution: Select appropriate punching clearance, trim the cutting edge in time, and select materials with good punching performance.

7. Cracks Between Holes

• Cause: The hole wall is too thin, or the adjacent holes are not punched out at the same time.
• Solution: Design a reasonable hole spacing, use a pair of molds to punch out adjacent holes at the same time, or adjust the length of the punch.

8. Bulging Appearance

• Cause: Unreasonable mold design or deformation of the die.
• Solution: Use a top-down structure, increase the thickness of the die wall, or reduce deformation caused by heat treatment.

9. Waste Jump

• Cause: Poor adhesion between copper foil and substrate or too large die gap.
• Solution: Strengthen material inspection, reduce mold gap, and trim the die-back taper.

10. Waste Blockage

• -Cause: The die edge is too high, or the leakage hole is too small.
• Solution: Lower the die edge, enlarge the leakage hole, and adjust the concentricity of the leakage hole.

These problems and their solutions are very common in punching processing. Mastering these techniques can significantly improve production efficiency and product quality.

In Conclusion

Precision punching is a high-precision and high-efficiency metal processing method that is widely used in multiple industrial fields. With the continuous innovation and development of technology, precision punching technology will contribute to the transformation, upgrading and sustainable development of the manufacturing industry.