In the realm of button cell battery manufacturing, precision is paramount. The production of button cell battery steel casings involves a complex, multi-station progressive die that orchestrates a symphony of stamping processes. These processes include blanking, bending, deep drawing, and forming, all meticulously executed within the confines of primary and secondary molds.
Key Players in Materials Manufacturing
When it comes to crafting specialized materials for button cell battery steel casings, a select group of manufacturers stands out. Leading the pack on the global stage are giants like Nippon Steel and Toyo. On the home front, domestic champions like Baosteel and Donghai play a pivotal role in meeting the industry’s demands.
Unraveling Stamping Challenges
The stamping process, though precise, is not without its challenges. One common issue that arises during the creation of button cell battery steel casings is variations in diameter at both ends of the casing and differences in wall thickness between the sealing end and the open end. These inconsistencies can be attributed to several factors, primarily equipment-related and lubrication-based.
1. Die Clearance and Punch Movement
Excessive die clearance and intermittent punch movement are prime culprits behind irregularities in diameter and wall thickness. These issues often stem from poor initial design or improper usage. To ensure uniformity, meticulous attention to die concentricity and regular adjustments are essential.
2. Cutting Edge Precision
Irregular incisions, including non-parallel upper and lower ports, burrs, and distortion, can be linked to equipment problems, particularly flawed or non-parallel cutting edge dies. Addressing these issues requires careful corrections and adjustments to maintain parallelism.
1. Oil Pressure and Penetration
Lubrication plays a pivotal role in the stamping process. Inadequate oil pressure can result in dry friction, while insufficient oil penetration can lead to uneven wall thickness. Achieving the desired uniformity necessitates a critical examination of oil viscosity. Excessive viscosity may cause sidewall rebound, while insufficient viscosity can lead to excessive thinning.
2. High-Temperature Performance
In multi-station continuous processing, the average temperature of the punch before material drop hovers at 300°C or higher. However, this can give rise to issues such as oil coking, smoke generation, and dry friction. Mitigating these challenges involves adopting multi-angle spray oiling techniques and ensuring oil supply within multiple mold cavities.
Finding the Perfect Balance
Maintaining optimal oil properties is crucial. This entails preserving a viscosity range of 80-150 and ensuring lubrication performs impeccably across a broad temperature spectrum, from low to high. Such versatility is essential for year-round use, guaranteeing the seamless production of button cell battery steel casings that meet the highest quality standards.
In conclusion, the production of button cell battery steel casings is a meticulous process where precision is non-negotiable. By addressing equipment-related challenges and perfecting lubrication techniques, manufacturers can ensure the consistent quality of these vital components for various electronic devices.