Metal disc blanking stands as a pivotal process in crafting various components like metal cookware, automotive parts, tank heads, lighting fixtures, and motor rotors. The journey to produce these vital components demands labor and resources, with the perpetual quest to streamline costs and bolster efficiency and quality. In recent times, the conventional approach among manufacturers involves diagonal slitting of coil material followed by manual feeding onto a punching press for disc blanking. However, this method grapples with inefficiency, low material utilization rates, and safety risks inherent in manual operations.

Automating Disc Blanking: A Paradigm Shift

To surmount these challenges, we have pioneered an automatic indexing and punching production line for our esteemed clients.

Elevating Efficiency with Advanced Equipment

The arsenal of the disc blanking production line comprises a decoiler for coil material support, a leveling machine for material correction, an NC servo indexing feeder for automatic indexing, and a punching press for disc blanking. The linchpin of this setup lies in the NC servo indexing feeder, boasting a magnetic zero reset switch. This feature ensures that post each blanking operation, parameters revert to the zero position, curbing dimensional deviations stemming from repetitive indexing. Adopting an S-type or M-type disc processing methodology, wherein adjacent blanks align precisely, with a mere 2mm gap between them, maximizes material utilization and minimizes waste, thus slashing production costs.

Innovative Material Support System

Additionally, a material support device bridges the gap between the NC servo indexing feeder and the punching press. This apparatus, comprising rotating interconnected supports and brackets, equipped with hydraulic and pneumatic cylinders, safeguards material from scratching against the punching press table during the blanking process. Furthermore, during die changeovers, the hydraulic cylinder rotates the bracket to elevate the material substantially, facilitating seamless die replacement.

Efficient Dual-Axis Feeding Mechanism

The NC servo indexing feeder employs a dual-axis alternate feeding method, enabling material movement in a two-dimensional plane, thereby expediting disc blanking processing. The swinging platform, orchestrated by a servo drive system, executes lateral swings around a pivot point, optimizing layout and achieving a high material utilization rate. Under the aegis of PLC and servo control systems, the swinging platform’s position coordinates are determined via meticulous programming, ensuring an optimized layout conducive to efficient blanking.

Automated Optimization: Redefining Production

Automatic optimization layout programming harnesses coil material for metal disc blanking production, supplanting the conventional process of cutting sheets from coils, thereby streamlining production, reducing labor intensity, and circumventing material wastage. This approach promises a material utilization enhancement of over 7%, underscoring its efficacy in bolstering efficiency and curbing costs.

Seamless Operations and Economic Viability

Operational prowess defines the disc blanking production line, boasting a production speed exceeding 45 pieces per minute and accommodating rapid die changes for swift product specification alterations. This versatility renders it ideal for medium to small batch production, ensuring significant economic dividends.

Conclusion

The advent of automated disc blanking heralds a new era of efficiency and quality in manufacturing. By leveraging advanced technology and innovative methodologies, manufacturers can navigate the competitive landscape with finesse, maximizing productivity while minimizing costs, thereby charting a path towards sustainable growth and prosperity.

Metal Disc Blanking
Metal Disc Blanking