Stamping Parts and Stamping Mold Design

　　Stamping mold design is a critical engineering process that directly determines the quality, precision, and production efficiency of stamping parts, serving as the core of stamping manufacturing for industries like automotive, electronics, and aerospace. A well-designed stamping mold ensures stamping parts meet dimensional tolerances (often ±0.02mm for precision parts), surface finish requirements, and structural integrity, while minimizing material waste and production costs. The design process involves multiple stages, starting with product analysis—engineers review the stamping part’s 3D model (e.g., a car door hinge bracket) to identify key features like holes, bends, and notches, then determine the mold type (progressive die, transfer die, or compound die) based on production volume and part complexity.

　　Progressive die design is widely used for high-volume parts (100,000+ units/year). It integrates multiple stamping operations (blanking, punching, bending, forming) into a single mold, allowing the metal strip to move sequentially through each station during production. For example, a progressive die for a smartphone SIM card tray performs blanking (cutting the strip into a basic shape), punching (creating the SIM slot hole), and bending (forming the tray’s edges) in one pass, reducing production time by 40% compared to using separate molds. Compound die design, by contrast, combines blanking and forming in a single stroke, ideal for simple parts like washers or gaskets, ensuring high precision by eliminating positional errors from multiple mold setups.

　　Key design considerations include material compatibility, die clearance, and cooling systems. Die clearance (the gap between the punch and die cavity) must match the stamping material’s thickness and ductility—too small a clearance causes burrs on parts, while too large leads to dimensional inaccuracies. For example, when stamping 1mm-thick aluminum alloy parts, a die clearance of 0.1mm (10% of material thickness) is optimal. Cooling systems are essential for high-speed stamping (500+ strokes/minute) to prevent mold overheating, which can warp the mold and degrade part quality. Water-cooled channels embedded in the mold base circulate coolant, maintaining the mold temperature at 40-60°C. Additionally, mold materials (typically H13 hot-work steel or SKD11 cold-work steel) are selected based on stamping force and material—H13 steel is preferred for high-temperature forming of stainless steel parts, as it offers excellent wear and impact resistance. A case study of an automotive stamping plant showed that optimizing die clearance and cooling design reduced part rejection rates from 5% to 1.2%, while increasing mold lifespan by 20%. For stamping parts, mold design is not just a technical task but a strategic factor influencing manufacturing competitiveness.

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