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Design of Sheet Metal Forming Molds for Proportional Air Servo Valves
Category：answer Publishing time：2025-12-20 01:50:58 Browse： Times
In modern industrial production, with the continuous development of precision control components, the manufacturing accuracy and production efficiency of proportional air servo valves, as key components in the pneumatic system, are particularly important. During the production process of proportional air servo valves, sheet metal forming technology, as one of the basic manufacturing processes, directly affects the performance and service life of the product. Therefore, designing efficient and precise sheet metal forming molds is of great significance for improving the overall manufacturing level of servo valves.
Overview of Sheet Metal Forming Technology
Sheet metal forming is a method of processing parts by applying pressure or tension to metal plates using molds, causing them to undergo plastic deformation and thus obtaining the required shape and size. The sheet metal parts involved in proportional air servo valves usually include valve body shells, connecting flanges, fixed brackets, and other structural components. These parts not only require good structural strength but also high dimensional accuracy and surface quality.
Two, Basic Requirements for Mold Design
1. High precision requirements: The working environment of the servo valve has high requirements for the sealing and response speed of the parts, so the mold must ensure the dimensional accuracy and positional tolerance of the parts.
2. Rational structure: The mold structure should be reasonably designed according to the geometric shape and forming process of the parts to ensure uniform material flow and avoid defects such as wrinkling and cracking.
3. High durability: Due to the large production volume of servo valve parts, the mold should have good wear resistance and fatigue resistance to improve the service life.
4. High processing efficiency: The design of the mold should facilitate installation, debugging, and replacement, improving the utilization rate and production efficiency of the equipment.
Three, Key Mold Structure Design
1. Stamping Mold Design
For flat-type parts in the servo valve, compound blanking dies or progressive dies are used for stamping forming. By reasonably designing the clearance of the punch and die, guide structures, and ejection devices, the flatness and dimensional consistency of the stamped parts can be ensured.
2. Bending Mold Design
For sheet metal components that require bending, an appropriate bending springback compensation angle should be designed, and V-shaped or U-shaped bending dies should be used, combined with elastic ejection structures, to avoid springback or cracking of the parts during the forming process.
3. Deep Drawing Mold Design
For deep cavity structures such as valve body shells, multi-pass deep drawing process should be adopted. When designing the mold, factors such as the blanking force control of the flanging ring, the radius of the die corner, and the lubrication of the punch should be considered to ensure the quality and stability of the deep drawing parts.
Four, Mold Material and Surface Treatment
To improve the wear resistance and anti-adhesion performance of the mold, high-carbon high-chromium cold working mold steel such as Cr12MoV, SKD11 is often used for the working part of the mold, and heat treatment (quenching + tempering) is carried out to obtain high hardness and good toughness. In addition, surface treatment processes such as nitriding, chrome plating, and PVD coating can also be adopted to further extend the mold life and improve the surface quality of the parts.
Five, Simulation and Optimization of Mold Design
Modern mold design widely adopts CAD/CAM/CAE integrated technology. By finite element analysis of the forming process (such as Dynaform, AutoForm, etc. software), it can predict material flow, stress-strain distribution, and possible defects in advance, thus optimizing the mold surface design, improving the success rate of the first trial mold, and reducing development costs.
Six, Conclusion
The design of the blanking mold for proportional air servo valve is a comprehensive engineering task, which requires full consideration of various factors such as part structure, material characteristics, process parameters, and mold life. With the development of intelligent manufacturing and precision processing technology, future mold design will pay more attention to automation, digitization, and intelligence to meet the increasingly high performance and reliability requirements of servo valve products. Only by continuously optimizing mold design and manufacturing processes can a leading position be maintained in the fierce market competition.
In modern industrial production, with the continuous development of precision control components, the manufacturing accuracy and production efficiency of proportional air servo valves, as key components in the pneumatic system, are particularly important. During the production process of proportional air servo valves, sheet metal forming technology, as one of the basic manufacturing processes, directly affects the performance and service life of the product. Therefore, designing efficient and precise sheet metal forming molds is of great significance for improving the overall manufacturing level of servo valves.
Overview of Sheet Metal Forming Technology
Sheet metal forming is a method of processing parts by applying pressure or tension to metal plates using molds, causing them to undergo plastic deformation and thus obtaining the required shape and size. The sheet metal parts involved in proportional air servo valves usually include valve body shells, connecting flanges, fixed brackets, and other structural components. These parts not only require good structural strength but also high dimensional accuracy and surface quality.
Two, Basic Requirements for Mold Design
1. High precision requirements: The working environment of the servo valve has high requirements for the sealing and response speed of the parts, so the mold must ensure the dimensional accuracy and positional tolerance of the parts.
2. Rational structure: The mold structure should be reasonably designed according to the geometric shape and forming process of the parts to ensure uniform material flow and avoid defects such as wrinkling and cracking.
3. High durability: Due to the large production volume of servo valve parts, the mold should have good wear resistance and fatigue resistance to improve the service life.
4. High processing efficiency: The design of the mold should facilitate installation, debugging, and replacement, improving the utilization rate and production efficiency of the equipment.
Three, Key Mold Structure Design
1. Stamping Mold Design
For flat-type parts in the servo valve, compound blanking dies or progressive dies are used for stamping forming. By reasonably designing the clearance of the punch and die, guide structures, and ejection devices, the flatness and dimensional consistency of the stamped parts can be ensured.
2. Bending Mold Design
For sheet metal components that require bending, an appropriate bending springback compensation angle should be designed, and V-shaped or U-shaped bending dies should be used, combined with elastic ejection structures, to avoid springback or cracking of the parts during the forming process.
3. Deep Drawing Mold Design
For deep cavity structures such as valve body shells, multi-pass deep drawing process should be adopted. When designing the mold, factors such as the blanking force control of the flanging ring, the radius of the die corner, and the lubrication of the punch should be considered to ensure the quality and stability of the deep drawing parts.
Four, Mold Material and Surface Treatment
To improve the wear resistance and anti-adhesion performance of the mold, high-carbon high-chromium cold working mold steel such as Cr12MoV, SKD11 is often used for the working part of the mold, and heat treatment (quenching + tempering) is carried out to obtain high hardness and good toughness. In addition, surface treatment processes such as nitriding, chrome plating, and PVD coating can also be adopted to further extend the mold life and improve the surface quality of the parts.
Five, Simulation and Optimization of Mold Design
Modern mold design widely adopts CAD/CAM/CAE integrated technology. By finite element analysis of the forming process (such as Dynaform, AutoForm, etc. software), it can predict material flow, stress-strain distribution, and possible defects in advance, thus optimizing the mold surface design, improving the success rate of the first trial mold, and reducing development costs.
Six, Conclusion
The design of the blanking mold for proportional air servo valve is a comprehensive engineering task, which requires full consideration of various factors such as part structure, material characteristics, process parameters, and mold life. With the development of intelligent manufacturing and precision processing technology, future mold design will pay more attention to automation, digitization, and intelligence to meet the increasingly high performance and reliability requirements of servo valve products. Only by continuously optimizing mold design and manufacturing processes can a leading position be maintained in the fierce market competition.
