We can design and prodce moulds, custom stamping parts from customers’ drawing design.
We can provide manufacturing & machining service and advice based on customers’ requests in various industries as following:
◆ NEV lithium battery stamping mould (Tooling)
◆ Automotive Connector Mold(Tooling and Mold parts)
◆ Semiconductor lead frame Mold(Tooling and Mold parts)
◆ Precision Connector Mold(Tooling and Mold parts)
◆ Machining of high precision Mechanical Parts
◆ CNC Precision Machining & Mold Parts Manufacturing EDM machining mold parts
Stamping die is a special process tool that presses materials (metal or non-metal) into parts ,sections or semi-finished products in cold stamping, called cold stamping die (commonly known as cold stamping die). Stamping is a pressure processing method that uses a die installed on a press machine to apply pressure on materials at room temperature to cut or form it into the specified shape parts.
Classification by product processing method
According to the different processing methods of products, dies can be divided into five categories: punching & shearing dies, bending dies, drawing dies, forming dies and compression dies.
a. Punching &shearing die: The work is done by shearing. The commonly used forms are shearing die, blanking die, punching die, trimming die, edge-forming die, broaching die and punching die.
b. Bending die: It is a shape that bends the flat blank into an angle. Depending on the shape, precision and production volume of the parts, there are many different forms of dies, such as ordinary bending dies, cam bending dies, curling dies Dies, arc bending dies, bending punching dies and twisting dies, etc.
c. Drawing die: Drawing die is to make flat blank into seamless container with bottom.
d. Forming die: It refers to changing the shape of the blank by various local deformation methods.
e. Compression die: It uses strong pressure to make the metal blank flow and deform into the desired shape.
Classification according to the level of process combination
a. Single-process die, a die that only completes one stamping process in one stroke of the press.
b. Compound die, with only one station, in one stroke of the press, a die for completing two or more stamping processes at the same station at the same time.
c. Progressive die (also known as continuous die), which has two or more stations in the feeding direction of the blank. In one stroke of the press, two or two passes are completed at different stations one after another. Dies for the stamping process above.
d. Transfer die, which combines the characteristics of single-process die and progressive die, and uses the manipulator transfer system to realize rapid transfer of products in the die, which can greatly improve the production efficiency of products, reduce product production costs, save material costs, and improve quality. Stable and reliable.
The materials for making stamping dies are plenty such as steel, cemented carbide, steel-bonded cemented carbide, zinc-based alloy, low melting point alloy, aluminum bronze, polymer materials, etc. Most of them for manufacturing stamping dies are mainly steel. The types of commonly used die working parts are: carbon tool steel, low alloy tool steel, high carbon high chromium or medium chromium tool steel, medium carbon alloy steel, high speed steel , base steel and cemented carbide, steel-bonded cemented carbide, etc.
a. Carbon Tool Steel
The most widely used carbon tool steels in dies are T8A, T10A, etc., which have the advantages of good processing performance and low price. However, the hardenability and red hardness are poor, the heat treatment deformation is large, and the bearing capacity is low.
b. Low alloy tool steel
Low alloy tool steel is based on carbon tool steel with an appropriate amount of alloying elements added. Compared with carbon tool steel, it reduces the tendency of quenching deformation and cracking, improves the hardenability of steel, and has better wear resistance. The low alloy steels used to make dies are CrWMn, 9Mn2V, 7CrSiMnMoV (code CH-1), 6CrNiSiMnMoV (code GD), etc.
c. High carbon and high chromium tool steel
Commonly used high-carbon and high-chromium tool steels include Cr12 and Cr12MoV, Cr12Mo1V1 (code D2), and SKD11. They have good hardenability, hardenability and wear resistance, and heat treatment deformation is very small. , the bearing capacity is second only to high-speed steel. However, the segregation of carbides is serious, and repeated upsetting (axial upsetting, radial drawing) must be carried out to change forging to reduce the unevenness of carbides and improve the performance.
d. High carbon medium chromium tool steel
The high-carbon medium-chromium tool steels used for dies include Cr4W2MoV, Cr6WV, Cr5MoV, etc. They have low chromium content, less eutectic carbides, uniform carbide distribution, small heat treatment deformation, and good hardenability and dimensional stability. sex. Compared with high-carbon high-chromium steels with relatively severe carbide segregation, the properties are improved.
e. High speed steel
High-speed steel has the highest hardness, wear resistance and compressive strength among die steels, and has a high bearing capacity. Commonly used in dies are W18Cr4V (code 8-4-1) and W6Mo5 Cr4V2 (code 6-5-4-2, US grade M2) with less tungsten content, as well as carbon-reducing and vanadium-reducing high-speed steel developed to improve toughness. 6W6Mo5 Cr4V (code 6W6 or low carbon M2). High-speed steel also needs to be forged to improve its carbide distribution.
f. Base steel
A small amount of other elements are added to the basic composition of high-speed steel, and the carbon content is appropriately increased or decreased to improve the performance of the steel. Such steel grades are collectively referred to as base steel. They not only have the characteristics of high-speed steel, but also have certain wear resistance and hardness, and their fatigue strength and toughness are better than those of high-speed steel. The matrix steels commonly used in dies are 6Cr4W3Mo2VNb (code 65Nb), 7Cr7Mo2V2Si (code LD), 5Cr4Mo3SiMnVAL (code 012AL), etc.
g. Carbide and Steel Bonded Carbide
The hardness and wear resistance of cemented carbide are higher than that of any other kind of die steel, but the bending strength and toughness are poor. The cemented carbide used for the die is tungsten and cobalt. For dies with low impact and high wear resistance, cemented carbide with lower cobalt content can be selected. For dies with high impact, cemented carbide with higher cobalt content can be selected.
Steel-bonded cemented carbide is made by adding iron powder to a small amount of alloying element powder (such as chromium, molybdenum, tungsten, vanadium, etc.) as a binder, and using titanium carbide or tungsten carbide as a hard phase, sintered by powder metallurgy. The matrix of steel-bonded cemented carbide is steel, which overcomes the disadvantages of poor toughness and difficult processing of cemented carbide, and can be cut, welded, forged and heat treated. Steel-bonded cemented carbide contains a large amount of carbides. Although the hardness and wear resistance are lower than those of cemented carbide, they are still higher than other steel grades. After quenching and tempering, the hardness can reach 68 ~ 73HRC.
h. New materials
The materials used in stamping dies belong to cold work die steels, which are the most widely used, widely used and most types of die steels. The main performance requirements are strength, toughness and wear resistance. The development trend of cold work die steel is based on the performance of high-alloy steel D2 (equivalent to Cr12MoV in my country), which is divided into two branches: one is to reduce the amount of carbon content and alloying elements, and to improve the uniformity of carbide distribution in steel, Prominently improve the toughness of the die. Such as the 8CrMo2V2Si of the American Vanadium Alloy Steel Company, and the DC53 (Cr8Mo2SiV) of the Japan Datong Special Steel Company. The other is a powder high-speed steel developed for high-speed, automated, and mass production with the main purpose of improving wear resistance. Such as Germany's 320CrVMo13, and so on.
For stamping dies, various metal materials and non-metal materials are used, mainly carbon steel, alloy steel, cast iron, cast steel, cemented carbide, low melting point alloy, zinc-based alloy, aluminum bronze, synthetic resin, polyurethane Rubber, plastic, laminated birch boards, etc.
The materials for making dies are required to have properties such as high hardness, high strength, high wear resistance, appropriate toughness, high hardenability, no deformation (or less deformation) during heat treatment, and not easy to crack during quenching.
Reasonable selection of die materials and implementation of the correct heat treatment process are the keys to ensuring the life of the die. For dies with different uses, they should be comprehensively considered according to their working conditions, stress conditions, performance of the material to be processed, production batch and productivity, etc., and focus on the performance of the above requirements, and then make the steel grade and heat treatment. The corresponding selection of the process.
When the production batch of stamping parts is large, the material of punch and die for the working parts of the die should be selected from die steel with high quality and good wear resistance. For other process structural parts and auxiliary structural parts of the die, the material should also be increased accordingly. When the batch is not large, the requirements for material properties should be appropriately relaxed to reduce costs.
When the material to be stamped is hard or has a large deformation resistance, the convex and concave dies of the die should be selected from materials with good wear resistance and high strength. When deep drawing stainless steel, aluminum bronze die can be used because it has better resistance to sticking. The guide post and guide bush require wear resistance and good toughness, so the surface carburizing and quenching of low carbon steel is mostly used. For another example, the main disadvantage of carbon tool steel is its poor hardenability. When the cross-sectional size of the die parts is large, the center hardness is still low after quenching. However, when working on a press with a large number of strokes, due to its resistance. The impact is good but become an advantage. For fixing plate, stripper plate and other parts, not only must have sufficient strength, but also require small deformation during the working process. In addition, cold treatment and cryogenic treatment, vacuum treatment and surface strengthening methods can also be used to improve the performance of die parts. For cold extrusion dies with poor working conditions of convex and concave dies, die steels with sufficient hardness, strength, toughness, wear resistance and other comprehensive mechanical properties should be selected, and should have certain red hardness and thermal fatigue strength, etc. .
The selection of die materials should be determined according to the use conditions of die stamping parts, It's not that the more expensive the material, the better, but the proper and economical.
CNC machining and 3D printing are commonly methods of making prototypes. CNC machining includes metal parts CNC machining and plastic parts CNC machining; 3D printing includes metal 3D printing, plastic 3D printing, nylon 3D printing, etc.; The craft of duplication of modeling can also realize prototypes making, but it needs to cowork with CNC fine machining and manual grinding or polishing. Most of the prototype products need to be manually sanded and then surface treated before delivery so as to achieve the appearance effect and the strength of materials and other physical properties of the parts and components surface.
One-stop delivery service is our domination strength, we can provide product design, design optimization, appearance design, structural design, industrial design, hardware design, software design, electrical development, prototyping, mold design, mold manufacturing, duplication of modeling, Injection molding, die casting, stamping, sheet metal fabrication, 3D printing, surface treatment, assembly and testing, mass production, low-volume production,product packaging, domestic and offshore logistics and transportation, etc.
Product assembly and testing are essential to ensure the normal delivery of products. All prototyped products are required to pass strict quality inspections before they shipping; for mass-produced products, we provide IQC inspection, online inspection, finished product inspection, and OQC inspection
And all test records are required to be archived.
All design drawings will be evaluated and diagnosed by our professional engineers before the molding. We will notify you as soon as there are design defects and hidden processing problems such as shrinkage. With your permission, we will optimize the design drawings until it meet production requirement.
We provide mold design and manufacture, product injection molding and assembly, whether it is plastic injection mold or aluminum alloy die-casting mold, we will provide storage services for all molds or dies.
Usually, we recommend you order an entire of transportation insurance for all logistics and transportation, so as to reduce the risk of loss of goods during transportation.
We provide door-to-door logistics services. According to different trades, you can choose transportation by air or by sea, or a combinated transportation. The most common incoterms are DAP, DDP, CFR, CIF, FOB, EX-WORKS…,
In addition, you can arrange the logistics as your way, and we will assist you in completing the logistics and transportation from the factory to your designated location.
We currently support wire transfer(T/T), letter of credit(L/C), PayPal, Alipay, etc., Usually we will charge a certain percentage of the deposit, and the full payment needs to be paid before delivery.
The surface treatment of products includes surface treatment of metal products, surface treatment of plastic products, and surface treatment of synthetic materials. Our common surface treatments consist of :
Sand blasting, Dry Sand Blasting, Wet Sand Blasting, Atomized Sand Blasting, Shot Blasting,etc.
Spraying,Electrostatic Spraying, Fame Spraying, Powder Spraying, Plastic Spraying, Plasma Spraying, Painting, Oil Painting etc.
Electroless Plating of Various Metals and Alloys,Copper Plating, Chromium Plating, Zinc Plating, Nickel Plating,Anodic Oxidation, Electrochemical Polishing, Electroplating etc.
Bluing and Blackening, Phosphating, Pickling, Grinding, Rolling, Polishing, Brushing, CVD, PVD, Ion implantation, Ion Plating, Laser Surface Treatment ect.
The security of customer information and products is our priority consideration. We will sign the confidentiality agreements(such as NDA) with all customers and establish independent confidential archives. JHmockup has strict confidentiality systems and practice procedures to prevent leakage of customer information and product information from the source.
The cycle of product development depends on what state the products are in when you deliver them.
For instance, you already have a complete design plan including drawings, and now you need to verify the design plan through prototypes making; Or in case of your design has been made with a prototype in other places, but the effect is not satisfactory, then we will optimize your design drawings and then make a prototype to reverify it;Or,
your product already has completed the appearance design, but there is no structural design, or even a complete set of electrical and software solutions, we will provide the corresponding design solutions to offset; Or, your product has been moulded, but the injection-molded or die cast parts cannot meet the function of the overall assembly or finished product, we will re-evaluate your design, mould, dies,materials and other aspects to create an optimized solution. Therefore, the cycle of product development cannot be simply answered, it is a systematic project, some can be completed in one day, some may take a week, and some may even be completed in several months.
Please contact our professional engineers to discuss your project, so as to reduce your cost and shorten development timeline.
Customized service of products design and manufacturing is our key core capability. Different product customizations have different customization standards, such as partial product customization, overall product customization, partial customization of product hardware, partial customization of product software, and customization of product electrical control. The custom manufacturing and fabrication service is based on a comprehensive understanding of the customer’s product function, material strength, material processing technology, surface treatment, finished product assembly, performance testing, mass production, cost control and other factors before comprehensive evaluation and program design. We provide a complete supply chain solution. Probably your product does not use all the services at the current stage, but we will help you consider the scenario that may be needed in the future in advance, which is what differentiates us from other prototype suppliers.