The Customer tasked us with localizing the stamping of high-precision stators and rotors (tolerance of 10 microns). To implement this project, NordPress Engineering identified four main stages of work:
- Selection of a high-quality crank press.
- Manufacturing of stamping dies.
- Setup (mating) of the new presses with the dies at the press manufacturer's facility.
- Commissioning and launch of the dies/presses into serial production at the Customer's facility.
Now let us look at each stage in more detail. Obtaining quality parts by stamping is a kind of large puzzle that must be assembled from numerous pieces.
The first thing to start with is the press equipment on which the future product will be stamped. It is important to understand here that if the wrong press is selected at the initial stage, the result will not match the task at hand.
If press equipment already in use at the current production facility is to be used, it is necessary to take general measurements of the deviations of the slide, frame, etc., which will show whether this press is suitable for stamping the current part or not. The same applies to new press equipment, because the same press manufactured by different companies can differ significantly in build quality. In our case, we selected press equipment manufactured using German technology with full quality control at every stage of production.
The second stage of work involves the manufacturing of stamping dies. In our case, the part drawing has strict tolerances (10 microns), and the minimum production program for each part is 500,000 parts per year. Therefore, we decided to manufacture the die from Kh12MF steel, which ensures high quality of the stamped part at the output and a high service life or strength margin of the die itself for the current production program.
The third stage involves mating the press and the die at the press equipment manufacturer's facility (in production, this process is often called "marrying"). After setup and stamping of a trial batch of parts, we take measurements in the CMM room, which must conform to the Customer's drawings.
The fourth stage of work is commissioning at the Customer's facility and launching the dies into serial production.
