Study On Deflection Of Connector Terminal And Its Control In Stamping Forming Of Precise Progressive Die

The connector terminal is metal piece to connect signal or transmit current. Copper and copper alloys are its processing raw materials. Terminal is made by stamping using Precision Progressive Die.This paper takes the connector terminal deflection occurred in precise progressive stamping process as the study object. The causes of terminal deflection, the laws influenced by stamping process parameters and mould wear were detailed studied. The parameters were optimized and new control methods were proposed to control terminal deflection so as to meet the product requirements.Detail research steps are as follows:Firstly, the optimal design of Mould CAD/CAE Integration is proposed by summarizing the structural characteristics of the precise progressive die and the process of progressive stamping was discussed by using the theory of progressive stamping. And at the same time, the connector terminal forming was analyzed by means of the theory of blanking and bending, then the reasons of terminal deflection was discussed and its expression form was indicated.Secondly, the multi-step blanking & bending process was simulated by finite element method for researching the characteristics of material flow in stamping. Based on those characteristics the following conclusions can be drawn that the terminal deflection was the most difficult problem due to the multi-step blanking for strip materials, which would be worse after bending, and then it was much more difficult to predict and control.Thirdly, combining with orthogonal design criterion and practical situation of die, stamping experiments of different process parameters in progressive die were done for researching influence factors of terminal deflection, such as blanking clearance, stamping times, bind force, stamping speed and so on. And then the the effect degree and trend of each factor for terminal deflection were analyzed. Meanwhile, based on factor effect curve, the optimum parameters constitute was provided.Finally, based on the above research, new control methods of terminal deflection was invented by researching applied range, weak and the concrete implementation of current two control methods. The new control methods meet the requirements of quantity production of the connector terminal.The research results of this paper have perfected the progressive stamping forming theory of connector terminal and provided important technique support and theoretic guidance, enhancing the quality of terminal assurances precision stamping forming. Meanwhile, the utility model methods were proposed to control the terminal deflection and instruct die optimization design has some practical values.