Zinc-based Alloy Stamping Die For Small Batch Production Study On Wear Characteristics And Application

Kirksite is one of the most commonly used zinc-based alloys in industrial production,especially in metal molds and injection tools.Zinc-based alloys can improve the hard and brittle properties of zinc metal materials by adding different proportions of Al,Cu and other metals.At present,the wear analysis of zinc-based alloy dies is less.In this paper,we have studied and consulted a large number of domestic and foreign literatures about zinc-based alloy die wear,stamping process parameters and die structure optimization,combined with a variety of wear theory research,and used Deform-3D simulation software to simulate the forming and die wear of stamping die with zinc-based alloy 2 as the matrix material,and compared the experimental analysis of different processors.The main contents are as follows:1.?1?Based on the existing wear theory,an effective and fast method for predicting die wear is proposed in this paper.Based on Archard wear theory,Lagrange increment method is used to simulate sheet metal stamping process,and a dynamic wear process model is established to predict the wear of stamping die.The data of sheet metal stress,die wear,relative slip velocity and contact pressure after forming were calculated and substituted for the dynamic calculation model to calculate the nodes of the die model.The results show that the wear area of the punch mainly concentrates on the corner band and edge,and the punch wear on the side of the punch is less.?2?Using Deform-3D finite element analysis software,a CAE analysis method for wear of zinc alloy stamping dies was established.Taking the automobile fender as the object of analysis and taking No.2 zinc alloy as the base material,the effects of different process parameters on the wear degree and trend of the die were studied comparatively.The orthogonal test method was adopted to change the parameters of blank holder force,stamping speed,sheet metal parameters,friction coefficient and die clearance,respectively,on the premise that other process parameters were set unchanged.The results show that the sheet metal parameters have the greatest impact on the wear of the die;within a certain range,the wear of the die decreases with theincrease of blank holder force and die clearance;and increases with the increase of stamping speed and friction coefficient.?3?A simulation method for predicting die life by staged node control is proposed.Taking the wear rate of 1.0mm as the wear limit,through the comparison of simulation results and experiments,it is found that the service life of the die with Zamak₂material is about 160,000 stamping times.The wear of the die after 155,000 stamping times is larger than that obtained by simulation,with an error of 1.18%.