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Introduction of Punching Technology
Time: 2011-10-23

      The precision punching technology we focus on are the precision multi-task step-forward moulds with complicated structure, bigger manufacturing difficulty, long service life and high production efficiency, etc. Looking from the punching parts of the precision multi-task step-forward mould. They include the iron core step-forward motor mould, air-conditioner fin step-forward mould, integrated circuit lead framework step-forward mould, electric connector step-forward mould, colored pipe electron gun parts step-forward mould, automotive parts step-forward mould, home appliance parts step-forward mould, etc. We can say that the punching parts cover the categories of electronics, communication, automotive, mechanics, motor and electric products, and instruments, and home appliance, etc. Our Company is mainly engaged in development and production of high precision home appliance parts punching moulds, and after making efforts for several years, we have made obvious progress in respect of technical contents, manufacturing precision, service life and manufacturing cycles, etc. And some high-quality moulds can compete with those global-level moulds of this kind. Below are listed some technical results we obtained in recent years.
BEARING HOUSING(轴承套)(见图示1 See Fig.1)

        This product is mainly used for precision driving gears, and has a wide application in the optical drive of the laptop and many high precision radiator fans. Due to the inside and outside concentricity (within 0.02) and inside proper circle degree (within 0.005) of the product, the processing precision requirements are higher. The bearing housing is mainly pre-turned brass, causing lower processing efficiency and higher costs, and it is hard to satisfy the production demands. After one-year of efforts, the Company has succeeded in processing such products by precision punching, with the concentricity of 0.01 and proper circle degree of 0.004, which fully satisfies the precision requirements, and therefore, we won production orders from many companies. Compared with the former processing method, the punching method can greatly enhance production efficiency, and the daily output of a single set of moulds may be up to 50,000PCS. And moreover, the price of the SECC material is lower than that of the brass, thus greatly lowering the production costs.
 RING(900),LENS(见图示2 See Fig.2)


       This product is mainly used for the outer framework of the lens of digital cameras. Considering that the lens requires light weight and good strength, iron materials will not be used, but aluminium materials shall be used. To guarantee the strength, the materials must satisfy certain thickness requirements; and therefore, the lens is processed by means of die-casting. The strength of the lens framework lies in the bottom of the product, and the side wall will not need higher strength. As for the product as shown in Fig. 2, the bottom thickness is 3.0mm, and the thickness of the side wall is 1.0mm. Upon production of die-cast moulds, generally the difference between the thickness of the bottom and the side wall shall not be larger; otherwise, it easily causes deformation, and this will need more materials to be filled up upon die-casting, and the actually used parts will be fewer, and redundant materials will be eliminated by turning, causing a great of waste material. The fabrication of the die-casting mould is time-consuming work, with higher fabrication costs and insufficient precision, thus causing lower processing efficiency, so the crystal tightness of the products is lower, and moreover, there are holes on the surface after turning.

       Due to quick updating and re-generation of digital cameras, using die-casting moulds will not better satisfy the production demands. Therefore, the market needs a processing method with high processing efficiency and lower costs. Since 2007, the Company has cooperated with Shanyang Precision Co., Ltd. to research using punching moulds to produce the lens frameworks. After half-a-year of efforts, we succeeded in producing the lens frameworks through the use of the punching method. By means of the continuity moulds, we made the thickness of the side wall of the product 1.3mm by a thinning and extension process, and just left a 0.15mm single side turning space, thus saving some raw materials and lowering the production costs, and in this way, the resources are used more efficiently. The punching mould processing has a higher efficiency, with the daily output is up to 30,000PCS, and this is non-comparable to the use of die-casting moulds. The punching moulds are processed by the use of cold punching, and compared to the heat processing of die-casting, the punching moulds have a longer service life. Until now, we have cooperated with Shanyang Precision Co., Ltd. for five years, and the categories of the products are up to 60 series, and the products are thought highly of by the customers. The lens project has become one of our core projects.

      Our punching moulds adopt Japan’s imported SODICK slow wire cutting process, with profile and stepping accuracy :<3μm; and the materials used for the mould parts adopt the SKH-9 material with high antifriction and high strength and high rigidness, so they have little deformation after heating treatment and sound size stability. This guarantees batch production of the moulds, and the service life of the moulds are up to 10,000,000 times.

                         Fig. 1                                                        Fig. 2

  
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