Influence Of WEDM-LS On The Wear And Life Of Precise Progressive Die

With the background of a fast development of our country telecommunications industry, mobile phone business make a better use of domestic and foreign markets to maintain good momentum of development. Greater and greater demand is created for connector terminals, which is the important component of mobile phone. Connector terminals of mobile battery is stamped by precise progressive die based on blanking and bending forming. Manufacturing process is one of the difficulties in such mould. Incorrect manufacturing process will add procedure, have the machining further complicated, and also result in the premature wear failure of blanking punches and dies.In this paper, a typical progressive die for connector terminals of mobile battery is taken for example, and a manufacturing process which relies mainly on WEDM-LS is studied. Besides, the wear behavior and serve life of blanking punches and dies is investigated from WEDM-LS. The orthogonal experiment is used to analyze the influence of electrical parameters on density of cracks, thickness of recast layer and surface hardness, and then a typical blanking punch is taken for example to analyze the influence of density of cracks, thickness of recast layer and surface hardness on its wear behavior and serve life. The specific research steps are as follows.Firstly, a whole manufacturing process based on WEDM-LS is studied and the details are given. For the P24B straight blanking punch, specific WEDM-LS process is studied, including the determination of machining criteria and clearance, programming and the treatment of connecting section. Meanwhile, the viewpoint is proposed that WEDM-LS with different type of pulse current keeping the same discharge energy can also obtain the same machining precision and surface roughness.Secondly, after the analysis of WEDM-LS surface integrity to determine experiment factors and indexes, the orthogonal experiment is used to analyze the influence of electrical parameters on density of cracks, thickness of recast layer and surface hardness.Finally, through the analysis of fraction between blanking punches and dies and sheet metal, it is confirmed that wear occurs predominately on punch and its flank. The samples of wear experiment are prepared according to the results of surface integrity test. The wear experiment is performed to compare the serve of blanking punches machined by different types of pulse current and analyze the influence of density of cracks, thickness of recast layer and surface hardness on its wear behavior and serve life in order to optimize the processing condition and guide production.