Common problems and disadvantages of stamping dies
August 29 06:17:30, 2025
**Common Problems and Disadvantages of Stamping Dies and Their Countermeasures**
**1. Problem: Punching Edge Defects**
**Causes:**
- Worn punch or die edge
- Excessive clearance (not easily corrected by blade grinding)
- Collapse of the cutting edge
- Wear on guide pins or bushings
**Solutions:**
- Re-grind the cutting edge
- Adjust the blanking clearance based on the part section
- Recondition the cutting edge
- Adjust the station gap to ensure proper alignment and reduce template hole wear
- Replace or reassemble the guide system
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**2. Problem: Chipping or Crushed Material**
**Causes:**
- Too much clearance between punch and die
- Incorrect feeding position
- Stamping oil drips too fast, causing oil buildup
- Mold demagnetization
- Worn punch leading to scrap sticking
- Punch is too short, not enough blade depth
- Hard material with simple punching shape
**Solutions:**
- Improve punch and die machining accuracy or adjust clearance
- Ensure correct strip positioning and clean the mold regularly
- Control oil viscosity or use a different type of stamping oil
- Demagnetize parts after training
- Recondition the punch edge
- Adjust punch blade length to match the lower die
- Modify the punch blade design—add a bevel or curved edge to reduce contact area and prevent vacuum chipping
- Reduce the sharpness of the lower die edge, minimize grinding, increase surface roughness, and use a vacuum cleaner to remove scraps
- Lower the pressing speed
---
**3. Problem: Chip Blocking**
**Causes:**
- Leakage holes are too small or too large
- Worn cutting edge causing larger burrs
- Fast oil dripping leads to oil adhesion
- Rough lower die edge surface causes material buildup
- Soft material used
**Solutions:**
- Modify leakage hole size
- Recondition the cutting edge
- Control oil amount and consider changing oil type
- Reduce surface roughness during polishing
- Change material or adjust punching clearance
- Modify the punch blade end with a bevel or curve, and use a vacuum cleaner
---
**4. Problem: Variation in Blank Size**
**Causes:**
- Worn punch and die edges leading to burrs
- Poor design or machining accuracy
- Misalignment of punch and die inserts
- Worn guide pins or bushings
- Improper feeder settings or material feeding issues
- Inconsistent clamping depth
- Stripping block wear or excessive pressure
- Material properties vary (e.g., strength, elongation)
- Punching force pulling the material
**Solutions:**
- Recondition the cutting edge
- Improve design and machining accuracy
- Adjust positional alignment
- Replace worn guide components
- Re-adjust the feeder and clamping depth
- Re-grind or replace stripping inserts, increase pressure, and adjust the binder
- Reduce strong pressure depth
- Use consistent quality materials
- Modify the punch tip with a bevel or curved shape to improve stress distribution and provide guidance if possible
---
**5. Problem: Die Jamming**
**Causes:**
- Improper feeding distance or adjustment
- Variations in material feed length
- Feeder malfunction
- Curved material, oversized edges, or poor material quality
- Abnormal stamping causing sickle bend
- Insufficient guide hole size, upper die pulled
- Poor bending/tearing process
- Improperly set material removal function
- Belt misalignment
- Thin material causing warping
**Solutions:**
- Re-adjust feeding and pressing mechanisms
- Calibrate feeding distances
- Repair or maintain the feeder
- Replace material with better quality
- Eliminate belt twisting
- Train and punch the punch punch
- Adjust take-off spring strength
- Modify guide plates and anti-feed belts
- Add pressure plates between feeder and mold, install safety switches
- Re-align the mold
---
**6. Problem: Tape Sickle (Bending)**
**Causes:**
- Stamping flash
- Untrimmed raw edges on material
- Incorrect punching depth
- Internal damage in the die
- Local over-pressure or damage
**Solutions:**
- Recondition the cutting edge
- Replace material and add trimming devices
- Adjust punch depth
- Clean the mold and fix chipping issues
- Check and adjust die height and material removal areas
- Adjust the bending mechanism
- Prevent punch breakage
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*Source: http://news.chinawj.com.cn*
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