Common problems and disadvantages of stamping dies
August 29 06:23:14, 2025
**Common Problems and Disadvantages of Stamping Dies and Their Countermeasures**
**1. Problem: Punching Edge Defects**
**Causes:**
1. Worn punch or blade.
2. Excessive clearance (no significant improvement after blade sharpening).
3. Blade collapse.
4. Wear on guide pillars or sleeves.
**Solutions:**
1. Sharpen the blade edge.
2. Adjust the blanking clearance based on the product section.
3. Recondition the blade edge.
4. Adjust the station gap to ensure template hole wear or forming accuracy.
5. Replace or reassemble the guide components.
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**2. Problem: Chipping or Crush**
**Causes:**
1. Too large a gap between punch and die.
2. Incorrect feeding position.
3. Stamping oil drips too fast, causing oil buildup.
4. Mold demagnetization.
5. Worn punch with scrap sticking to it.
6. Punch is too short, not enough blade length.
7. Hard material and simple punching shape.
**Solutions:**
1. Improve punch and die machining accuracy or adjust the clearance.
2. Trim the strip to the correct position and clean the mold regularly.
3. Control the oil amount or use a lower-viscosity oil.
4. Demagnetize parts after training.
5. Recondition the punch edge.
6. Adjust the punch blade length to enter the lower die properly.
7. Modify the punch blade end face to be curved or chamfered to reduce the contact area with chips, preventing vacuum chipping.
8. Reduce the sharpness of the lower die edge, decrease grinding, increase surface roughness, and use a vacuum cleaner to remove scraps. Also, reduce the speed.
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**3. Problem: Chip Blocking**
**Causes:**
1. Small leakage hole.
2. Large leakage hole causing material tumbling.
3. Worn blade edge leading to larger burrs.
4. Fast oil dripping causing oil buildup.
5. Rough surface on the lower straight blade, with powder sintering.
6. Soft material.
**Solutions:**
1. Modify the leakage hole size.
2. Adjust the leakage hole if necessary.
3. Recondition the blade edge.
4. Control oil drip amount and consider changing oil type.
5. During polishing, reduce surface roughness.
6. Change the material or adjust the punching clearance.
7. Chamfer or curve the punch blade end and use a vacuum cleaner for chip removal.
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**4. Problem: Dimensional Variation in Blanks**
**Causes:**
1. Worn punch and die causing burrs (larger outer dimensions, smaller inner holes).
2. Inappropriate design size or clearance, poor machining accuracy.
3. Misalignment of punch and die inserts, uneven gap.
4. Worn guide pins, insufficient alignment.
5. Guide wear.
6. Improper feeder feed distance, press material, or incorrect adjustment.
7. Incorrect mold clamping depth.
8. Stripping block material worn, not pressing properly.
9. Stripping block too strong, causing excessive punching force.
10. Material properties vary (e.g., strength, elongation instability).
11. Punching force pulling the material, causing dimensional changes.
**Solutions:**
1. Recondition the blade edge.
2. Modify the design and control machining accuracy.
3. Adjust positional accuracy.
4. Replace guide pins.
5. Replace guide pillars and sleeves.
6. Readjust the feeder.
7. Adjust the clamping depth.
8. Re-grind or replace the stripping insert, increase pressure, and adjust the binder.
9. Reduce the depth of strong pressure.
10. Replace materials and control feed quality.
11. Chamfer or curve the punch blade end to improve stress conditions during punching. If allowed, place the blanking portion on the stripping insert to provide guidance.
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**5. Problem: Die Jamming**
**Causes:**
1. Improper adjustment of feeding distance, pressing, or relaxing.
2. Variations in production spacing.
3. Feeder malfunction.
4. Material curvature, width out of tolerance, or large raw edges.
5. Abnormal stamping causing sickle bend.
6. Insufficient guide hole, upper die pulled.
7. Bending or tearing process not smooth.
8. Improper setting of the guide plate’s material removal function.
9. Belt misalignment.
10. Thin material causing warping.
**Solutions:**
1. Readjust the system.
2. Fine-tune the production spacing.
3. Maintain and adjust the feeder.
4. Replace materials and control feed quality.
5. Eliminate belt twisting.
6. Train and punch the punch blade.
7. Adjust the take-off spring strength.
8. Modify the guide plate and install anti-feed belts.
9. Add upper and lower pressing plates between the feeder and the mold, and include safety switches.
10. Re-lay the mold if necessary.
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**6. Problem: Tape Sickle Bend**
**Causes:**
1. Stamping flash.
2. Untrimmed raw edges on the material.
3. Incorrect punching depth.
4. Internal damage in the stamping die.
5. Local over-pressure causing damage.
**Solutions:**
1. Recondition the cutting edge.
2. Replace the material and add a trimming device to the mold.
3. Adjust the punch depth.
4. Clean the mold and resolve chipping issues.
5. Check and adjust the damage in material removal and lower die height.
6. Adjust the bending mechanism.
7. Prevent punch breakage by ensuring proper maintenance and alignment.
*Source: http://news.chinawj.com.cn*
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