电子连接器端子冲压考量

9/2/20231橘皮與裂痕輕微裂痕小量模具痕跡9/2/20232小量模具痕跡模具痕跡ToolMark9/2/20233LocatesthebendcenterlineDecreasesformabilityofstripScoresmustextendallthewayfromedgetoedgeScoresthatgotoodeepwillcausecrackingPre-Scoring

預壓痕9/2/20234Pre-ScoringPotentialproblems:CrackingfromdeepscoreandcoiningScorenotextendingtoedge,

stressriserresultedinfatiguefailure9/2/20235CoiningCoining-ThicknessReductiont9/2/20236CoiningCoining-ThicknessReductionUnintendedPunchBottomingPreciseLocationofBendsIncreaseR/tProvide“knife-edge”LocalIncreaseinStrength9/2/20237CoiningEffect9/2/20238CoiningEffect9/2/20239CoiningEffect9/2/202310CoiningIncreasesStrength-SlightlyDecreasesDuctility-GreatlyDecreasesFormability-GreatlyIncreasesStressRelaxation-ModeratelyDecreasesDimensionalStability-Slightly9/2/202311CoiningCoining-ProblemsinAreasWithHighStressLargeDeflectionsModerateFormingRequirementsHighDimensionalAccuracy9/2/202312SpringbackCausedbyresidualcompressivestressontheinsideofthebendandtensilestressontheoutsideofthebendSpringbackincreaseswiththebendradiusandwiththeyieldstrengthThickergagesandhigherelasticmodulidecreasespringbackCompressiveStressTensile

StressResultantTorsional(Straightening)Stress9/2/202313ControllingSpringbackOverbendandallowtospringbackintodesiredshapeAlternatively,Coining(“Hip-up”,or“Hit-forming”)reducesspringback(addscompressivestresstosideintension)Therequired“Hit-formingratioH”tomaterialthickness

isdependentupontheR/tvalueoftheformingpunchtip.Caution:MaymakebendsusceptibletocrackingHRt0.10.20.30.40.55101520H[%]R/t9/2/202314K=Af/A0=-25.54X3+17.91X2–5.85X+1.08X=(YS/E)(R/t)YS=yieldstrength,E=ElasticModulus,R=punchradiust=thicknessR0RfAtAfA09/2/202315試片1成形變薄T1vsT2T1T29/2/202316試片1小量模具痕跡inIDofBend9/2/202317試片2OD試片2橘皮但無裂痕9/2/202318試片2非常輕微的模具痕跡