Phase 1: Data and Process Design (approximately 1-3 months)
Product Data Analysis: Based on the digital model of the automotive parts provided by the OEM, we conduct a manufacturability analysis to determine whether the product structure is suitable for stamping and propose modifications.
Process Design: We develop a forming plan for the sheet metal, determining the required steps (such as drawing, trimming, punching, flanging, etc.), essentially creating a "process flow chart."
Mold Structure Design: We conduct a detailed 3D design of the mold structure, including the upper and lower molds, the press plate, inserts, standard parts, and all other components. This serves as the "blueprint" for the mold.
Phase 2: Mold Processing and Manufacturing (approximately 5-10 months)
Rough Machining: Milling, planing, and drilling are performed on the massive mold steel block to remove most of the excess material.
Heat Treatment: Quenching and tempering are performed on key mold components to achieve high hardness and wear resistance.
Finishing Machining:
CNC Milling: High-speed CNC machine tools are used to precisely machine the mold surface, a key step in ensuring mold accuracy.
Fitting and Debugging: Experienced fitters perform manual finishing, polishing, and assembly, demonstrating their skill and experience.
Parts Procurement: Standard parts (such as springs, guide pins, and cylinders) are purchased simultaneously.
Phase 3: Mold Trial and Debugging (approximately 3-6 months)
First Mold Trial: The first stamping is performed on a real press to produce the first batch of samples.
Inspection and Measurement: Samples are thoroughly inspected using equipment such as a coordinate measuring machine and blue-light scanners, and compared with the original data to identify deviations.
Mold Modification and Optimization: Based on the inspection results and analysis, the mold is repeatedly modified, debugged, and re-tested. This "debug-modify-re-debug" cycle can occur as many as a dozen times and aims to address:
Surface Defects: Such as cracks, wrinkles, slip lines, and pits.
Dimensional Accuracy: Ensure that the tolerances of each component are within the designed range.
Fitting Issues: Ensure that the part fits perfectly with adjacent parts.
Trial Production: Before final acceptance, small batches of continuous production are typically conducted to verify mold stability and production efficiency.
Phase 4: Mass Production and Delivery (approximately 1 month)
Final Acceptance: OEM representatives provide final confirmation and approval of the mold and produced parts.
Shipping and On-site Installation: The mold is packaged and shipped to the OEM's stamping shop for installation and commissioning.
Full Mass Production: The mold is put into production, and qualified parts begin to be produced 24/7.
The creation of an automotive mold is a lengthy process that integrates digital design, precision machining, and craftsmanship. While core processing may theoretically take only six months, a significant amount of time is invested in repeated debugging and optimization to meet the automotive industry's stringent quality and precision requirements. Typically, preparing a complete set of stamping molds for a new model takes approximately 18-24 months, in parallel with the overall vehicle development cycle.