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Metal stamping dies play an important role in stamping production, closely related to the quality and efficiency of stamping production. Many hardware stamping factories often do not have complete maintenance and care measures for the metal stamping dies after processing, resulting in various problems when used the next time. Therefore, proper maintenance and usage methods are particularly important.
Daily maintenance of metal stamping dies involves inspecting the state and appearance of the dies under maintenance standards, plans, and requirements to detect and eliminate faults early. The maintenance process of metal stamping dies is divided into three steps: setting the die maintenance standards, formulating annual or monthly maintenance plans, and implementing maintenance as required by the inspection checklist. Each factory can appropriately revise relevant requirements based on the execution of die maintenance to more timely grasp the state of the dies and ensure stable production.
The setting of die maintenance standards needs to comprehensively consider working hours and die structure. The current industry common practice is to define maintenance cycles based on production strokes. Considering that some models have low annual production, metal stamping dies might not be used for a long time. If maintenance is arranged based on production strokes, abnormalities such as die rust, aging, and air leakage in air pipes, and dirty dies might occur during production. Therefore, for models with low production volume, additional maintenance standards can be set, such as arranging die maintenance once every half year.
Based on die maintenance standards and the production plan, annual or monthly maintenance plans can be formulated. Given that the automotive market is affected by chip supply and production demand, if annual maintenance plans are made, the actual production strokes of each die will inevitably differ significantly from the plan. Therefore, it is recommended to formulate the maintenance plan for the next month based on the predicted strokes of the current month to ensure that the actual maintenance cycle of the dies is consistent with the maintenance standards. Die maintenance plans can be made based on the real-time production volume of each model.
Cleaning: Cleaning of the die inside and outside, as well as the cleaning of oil stains on the structural surfaces and exterior. For instance, cleaning the die surfaces, and removing external dust to ensure that the part surface quality meets the requirements during production.
Lubrication: Regular replacement of lubricant on surfaces such as die guide plates and guiding mechanisms. For example, removing oil stains on sliding surfaces during maintenance and adding new lubricant to ensure smooth movement of each mechanism.
Adjustment: Adjusting the clearance of all moving parts and mating parts in the die to ensure stable product quality. For instance, inspecting the penetration depth of the cutting edges, referencing the 2 ～5mm standard requirements, and timely repairing cutting edges that do not meet the penetration depth criteria to ensure stable die production.
Fastening: After a certain number of production strokes, some bolts may become loose due to production vibrations. During maintenance, it is necessary to re-tighten the die insert bolts.
Anti-corrosion: Inspect the internal and external appearance of the die to confirm whether the die surface is damaged, rusty, or cracked, especially in positions subjected to long-term force. Conduct visual inspections during maintenance and arrange die flaw detection if necessary.
The aim of maintaining metal stamping dies is to detect and eliminate die hidden dangers or defects through regular inspections in order to minimize die failures on the production line or reduce offline repair time. This article optimizes the die maintenance approach based on problems encountered during the mass production maintenance process, leverages the role of preventive maintenance for dies, strives to reduce die failures, and improves production availability.
