Automatic wire mold design
Automatic wire mold design is an efficient mold technology for automatic forming of wires (such as iron wire, copper wire, and steel wire). It is suitable for the production of various wire products (such as springs, hooks, and fasteners). It can realize automatic feeding, cutting, bending, and forming of wires. The production efficiency can reach 100-500 pieces per minute, and the part size accuracy is ±0.05mm, which is suitable for mass production. Its core is to reduce manual intervention and improve production consistency through the coordinated work of the automatic feeding mechanism and the multi-station forming mold. In the early stage of design, the number and layout of the mold stations need to be determined according to the wire diameter (usually 0.5-10mm) and the shape of the product. For example, to produce a simple hook, four stations need to be set up: feeding, cutting, primary bending, and secondary bending.
The mold structure consists of an automatic feeding mechanism, a cutting device, a multi-station forming mold, a control system and a discharge device. The automatic feeding mechanism uses a servo motor driven roller feeding, with a feeding accuracy of ±0.01mm. The feeding speed can be adjusted through the PLC control system (50-200mm/s). The appropriate roller pressure (0.5-5MPa) is selected according to the wire diameter to ensure that the wire does not slip or deform. The cutting device uses a cutting knife made of Cr12MoV steel, with a blade hardness of HRC58-62, and a cutting gap of 5%-10% of the wire diameter (0.05-0.1mm for 1mm diameter wire), ensuring that the cut surface is flat and burr-free. The multi-station forming mold is designed with corresponding bending punches and concave dies according to the shape of the product. The punch material is W18Cr4V high-speed steel with a hardness of HRC62-65, and the concave die uses carbide inserts to improve wear resistance.
The control system is the core of the wire automatic mold. It uses PLC (Programmable Logic Controller) as the control core and cooperates with the touch screen to realize parameter setting and production monitoring. The sensor detects the feeding position, forming status and other information of the wire, and feeds back to the PLC in real time to realize closed-loop control. For example, after the feeding in place sensor detects that the wire has reached the specified position, the PLC sends a cut-off signal; after the bending completion sensor confirms that the bending angle meets the requirements, the next process is carried out. The control system can store the process parameters of a variety of products. When changing products, you only need to call the corresponding parameters, and the switching time is less than 5 minutes.
The optimization of the forming process needs to be carried out according to the wire material and the shape of the product. For low-carbon steel wire, the bending angle can be formed to the required angle (such as 90°, 180°) at one time, and the bending radius is 1-2 times the wire diameter; for high-carbon steel or spring steel, progressive bending is required, first bending to a close to the required angle, and then shaping to avoid wire breakage. The forming speed needs to match the feeding speed to ensure smooth connection between each process without jamming. For products that require heat treatment (such as springs), continuous heat treatment equipment can be connected after the automatic mold to achieve integrated production of forming and heat treatment.
Maintenance and debugging require attention to detail management. When testing the mold, first conduct single process debugging to ensure that the forming dimensions of each station meet the requirements, and then conduct continuous production tests to check the consistency of the products. After producing every 10,000 pieces, check the wear of the cutting knife and the forming punch. Replace the cutting knife when the wear is greater than 0.1mm, and polish the punch when scratches appear. Clean the debris in the mold regularly, add grease to the feeding roller and guide mechanism to ensure smooth feeding. The control system needs to regularly back up process parameters to prevent data loss, and the sensor is calibrated once a month to ensure detection accuracy.
