More than 90% of parts in automobile production need to be formed by molds, as shown in Figure 1. According to statistics from the International Model and Model Association, approximately 1,500 sets of molds are needed to manufacture an ordinary car, of which more than 1,000 are stamping molds. Adhering to regular maintenance of molds is the most basic way to extend their service life.
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The so-called stamping die is a special process equipment that uses a press to process sheet metal into the required parts (or semi-finished products). At present, the main types of automotive stamping parts molds include: drawing dies, trimming and punching dies (as shown in the picture), inclined wedge trimming and punching dies, flanging dies, and shaping dies. The development of complete vehicles in the automotive industry has led to the development of molds. The rapid development of the industry.
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Mold maintenance work is increasingly important to improve mold performance and extend mold service life. How to carry out the maintenance of stamping molds, thereby controlling production costs, improving product quality and mold production performance, while avoiding mold accidents and reducing operating risks. This is an urgent problem that needs to be solved in the domestic mold industry and is also the development trend of the times.
--- Mold Maintenance Project ---
The mold may have certain defects during use, such as cracks, slight wear, deformation, etc. In this case, although there are hidden dangers, the mold can still continue to work and has not lost its service capability. Comprehensive maintenance of each mechanical part of the mold before production can prevent various possible failure problems of the mold, prevent the expansion of mold problems, and avoid forming defects of stamping parts. Each part of the mold has a relative service life. Due to mold life, personnel operation, structural defects, etc., malfunctions and shutdowns caused by mold problems often occur during the production process. In order to ensure production, we usually perform inspections online (on machine tools). Mold faults are dealt with. After production is completed, the mold is thoroughly maintained offline (mold maintenance area), and the blanking surface of the drawing mold is maintained and maintained (as shown in the picture); the trimming and punching molds are Check and tighten the fastening bolts (as shown in the picture); maintain and maintain the working parts of each flanging and shaping knife block (as shown in the picture).
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How to formulate the content and frequency of mold maintenance? We analyze the abnormal mold maintenance records of previous years and combine it with the production to calculate the items and frequency of mold maintenance for the next year. We call it the annual mold preventive maintenance plan. The main purpose is prevention. Mold problems occur.
Through statistical analysis of the information found by the mold maintenance workers during the online inspection process and the problems fed back by the subsequent automotive processes, the mold is effectively and thoroughly maintained offline. We call it post-mold maintenance. The main purpose is to solve the problem. Effective closed-loop control of the stroke reduces production failures and shutdowns caused by mold problems, improves product quality and improves production efficiency.
Due to production capacity requirements and resource issues, mold maintenance projects (projects that require debugging and verification on the press) cannot be carried out on normal working days. Holidays are used every year to carry out maintenance and upkeep work on the molds to further consolidate and improve the performance of the molds.
--- Preventive Maintenance ---
The annual mold preventive maintenance preparation process is shown in the figure. During the preparation process, the following four points should be paid attention to:
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1. In the last month of each year, the management department organizes each user unit to start the preparation of the mold preventive maintenance plan for the following year.
2. The management department shall review the plans submitted by each user unit according to the "Annual Preventive Maintenance Plan Preparation Standards" (form).
Table Annual Preventive Maintenance Plan Preparation Standards
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3. The user unit shall carry out annual preventive maintenance monthly according to the annual mold preventive maintenance plan. If the plan needs to be adjusted, it shall be adjusted according to the monthly maintenance plan preparation standards.
4. The management department conducts regular spot checks on the implementation of the plan and monitors the completion and quality of the plan.
Each user unit shall carry out effective inspection, maintenance and problem solving of various parts of the mold according to the preventive maintenance plan and the "Mold Maintenance Operation Instructions". After the work is completed, the maintenance information will be entered into the information management system in a timely manner. The management department regularly checks the plan completion status of each user unit, analyzes the completion rate and maintenance effect of preventive maintenance by difficulty, and provides data support for the preparation of preventive maintenance plans for the following year.
---Post-maintenance ---
The mold offline maintenance process is shown in the figure. During the maintenance process, you need to pay attention to the following three points:
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1. The user unit prepares the "Mold Maintenance Day Management Form" every day based on the online "Inspection Record Book", "Mold Status Identification Card", mold inspection form, quality information feedback and other related problem information. The installation and maintenance workers refer to the "Mold Maintenance Implement and maintain the Operation Instructions.
2. After mold maintenance is completed, each user unit needs to confirm the maintenance effect (covering repair quality and debugging accuracy), and fill out the "Inspection and Maintenance Order". The molds that are confirmed to be qualified will be placed in a designated manner, and unqualified (or unfinished) tooling will be placed separately. Schedule maintenance.
3. The management department evaluates and reviews the rationality and implementability of the preparation of the "Mold Maintenance Operation Instructions", and checks the preparation of the "Mold Maintenance Day Management Form" to ensure that problem points are maintained as soon as possible. Appoint people and review the maintenance results regularly to ensure that there are no problems when the mold is put into production after maintenance. The maintained mold "Maintenance Order" is inspected and reviewed to finally solve the problem.
