Characteristics and precision of stamping dies
In the process of Copper Stamping Parts, including Relay Copper Stamping Parts, Contactor Copper Stamping Parts, Circuit Breaker Copper Stamping Parts, and Switch Copper Stamping Parts, the design and manufacture of dies directly affect the accuracy and yield of products. We use the following technologies to ensure the performance of dies:
1. Selection of die materials
High hardness and wear-resistant alloy steels such as SKD11 and DC53 are used to extend the life of dies by 30 million times.
Key components (such as punches and dies) are vacuum heat treated with a hardness of HRC 60-62 to reduce wear.
2. Die structure design
(1). Precision guide structure: Use ball guide pins and guide sleeves to ensure that the upper and lower die alignment accuracy is ≤0.01mm.
(2). Gap optimization: Adjust the blanking gap (about 5%-8% of the material thickness) according to the thickness of the copper strip (usually 0.1-2.0mm) to reduce burrs.
(3). Multi-station progressive die: Suitable for complex Copper Stamp parts, improves production efficiency to 500 times/minute (depending on the specific product), and reduces unit cost.
3. Mold processing accuracy
Use slow wire cutting (accuracy ±0.005mm) and mirror EDM to ensure cavity finish Ra≤0.4μm.
3D detection equipment (such as the e-coordinate measuring machine) monitors mold size throughout the process to ensure that it meets the drawing requirements.
Characteristics and key parameters of copper strip
Copper strip stamping has extremely high requirements for material performance. The copper (C1100, T2Y2, etc.) we selected has the following characteristics:
| Parameter | Typical value | Influence on stamping |
| Conductivity | ≥98% IACS | Suitable for terminal parts with high conductivity requirements |
| Hardness (HV) | 60-120 (soft state) | Soft copper has good ductility and is suitable for complex stamping |
| Tensile strength | 200-300 MPa (soft state) | Ensure the strength of stamping parts and avoid cracking |
| Elongation | ≥40% (soft state) | Improve stamping formability and reduce the risk of fracture |
| Thickness tolerance | ±0.01mm (precision strip) | Impact on blanking clearance and dimensional stability |
We strictly control the batches of raw materials to ensure that the mechanical properties, surface finish (no oxidation, scratches), and dimensional tolerances of the copper strips meet the Custom Copper Stamping customization requirements.
surface treatment process after copper stamping
Copper stamping parts are prone to oxidation and discoloration, and surface treatment is required to improve corrosion resistance and welding performance. Common processes include:
1. Electroplating
Tin plating: Improve weldability, thickness is usually 3-5μm, salt spray test ≥72h.
Nickel plating: Enhance wear resistance, suitable for high-frequency contact terminals.
Silver plating: Enhance conductivity, reduce resistance, suitable for high-end relays or switches.
2. Passivation treatment
Use chromate or benzotriazole (BTA) for passivation to form a protective film and delay oxidation.
3. Cleaning and anti-oxidation
Ultrasonic cleaning to remove oil stains, followed by coating with anti-rust oil or vacuum packaging.
Quality control of the copper stamping process
1. Incoming material inspection
A spectrometer is used to detect material composition to ensure compliance with the C1100/T2Y2 copper standard.
Measure the thickness and hardness of the strip and conduct tensile tests on samples.
2. Stamping process control
Press parameters: tonnage (5-200T), and punching speed (200-800 times/minute) are adjusted according to material thickness.
Online inspection: The visual system monitors burrs, material shortages, and other defects in real-time.
3. Finished product inspection
Dimension inspection: Rapid automatic detector and projector measure key dimensions (within tolerance ±0.02mm).
Functional test: On-resistance (≤0.5mΩ), insertion, and extraction force (by customer standards).
Factory Core Advantages
Our factory is located in Xiamen, a coastal city in China. We have more than 20 years of experience in metal stamping processing, focusing on copper strip stamping, brass strip stamping, aluminum alloy strip stamping, and stainless steel strip stamping. Our Customized Electrical Stamping Copper Springs are widely used in the terminal manufacturing of electrical components such as relays, contactors, circuit breakers, switches, and sockets. Our core advantages include:
1. Own mold design and manufacturing capabilities: Equipped with a professional mold design team of 10 people and more than 50 high-precision CNC and machining equipment to ensure the matching and durability of stamping molds.
2. Strict raw material screening: Cooperate with metal strip suppliers of Chinese state-owned listed companies to ensure stable material performance and meet high-precision stamping needs.
3. Mature process and quality control system: From mold design to finished product inspection, standardized operations throughout the process to ensure product consistency.
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