Where Needs Metal circles ?
For many deep draw metal products, it has to make metal circles firstly and then make the product with deep draw mold, such as motor cover, filter housing, battery housing etc. used in metal auto parts, inner pot of electric cook, bowl etc. metal kitchenware, so it’s the first step to produce the metal circles.
How To Make The Metal Circles?
It’s usually can be produced by stamping dies or laser cutting machines. For mass producing and requirements of high speed producing efficiency in large quantity, it’s suitable produced by punching machines with stamping dies, for multi-products in different size and small scale metal circles, it has great advantages produced by coil fed laser cutting lines.
Advantages of zigzag metal circle blanking line than no-zigzag metal circle blanking line.
a). SCRAP REDUCING
b). At first, this kind of line has been designed TO EXPLOIT THE WHOLE WIDTH OF THE COIL, reducing to the minimum distance between disk to disk and disk to the strip edges，with a consequent REDUCTION OF THE SCRAP QUANTITY. Generally, we use 2mm as the distance. This reduction is realized avoiding the use of expensive and low flexible multiple dies.
a.AVOID ANY FURTHER WORKING PHASE
b.Since it can be blanked the whole width of the strip, with this technology is therefore possible TO REDUCE FURTHER WORKING PHASES, such as the reduction of the coil into coils of smaller width (=slitting), which are usually applied in the disk production and represent both further costs and the possibility of damaging the coil surface (especially with aluminum)
c). FLEXIBILITY
LESS WAIT TIMES: when change the production size (diameter), only change die and change the setting of the HMI.
WIDE PRODUCTION RANGE: the same line can blank different material, without any change or modification. The disk layout setting in the strip is no limit. Any punching path can be set by user.
How To Choose The Suitable Metal Circle Blanking Line ?
It based on the user’s material type, material width, thickness, coil Max. weight, punch machine type (C type or H type punch machine) and requirements on producing efficiency etc.
Metal circle blanking line choice No. 1. (with PIT, high speed producing efficiency) Suitable for both thin and middle thick material.
Comprising of The Metal Circle Blanking Line
Decoiler payoff strips and make strip surface flat and clear inner stress by coil straightener machine, if material is a little thick, it can match one set scrap hydraulic shear at straightener’s exit to cut strip head. It set PIT between straightener and zigzag servo feeder, it can stock enough loops in the pit so as to increase feed speed and increase producing efficiency. Pit size and depth was based on material width, thickness, requirement on producing efficiency etc. Moreover, it sets support bridge both at straightener’s exit and zigzag servo feeder’s entrance, so it can conveniently guide, support and insert strip head into zigzag feeder.
1.Heavy duty decoiler with loading car-Decoiler fixed on ground
2.Precision coil straightener (Optional part of hydraulic scrap shear)-Straightener fixed on ground
3.Zigzag servo feeder
4.Support bridge at straightener’s exit and zigzag feeder’s entrance+ loop support table with sensor at pit’s ground
5.C frame type punch machine or H frame type punch machine
6.Metal circle blanking dies
7.Scrap shear/cutter or scrap strip recoiler
8.Product conveyor belt and scrap pieces conveyor belt (based on actual need)
9.Metal circle auto collector (Optional part)
For zigzag servo feeder, if material is thicker than 1.5mm and material of CR, HR, SS, GI etc. It has to equip with 4pcs feeding rollers so as to it has enough pinch force as there is much pull though force for steel loop storage in the pit. If punch machine chooses C frame type, it has to consider to feed strip from press front direction or side direction. If feed strip from press’s left side or right side, it should be deep throat type punch machine, throat depth was based on material width and circle size etc. metal strip can be cut to pieces by scrap cutter installed at stamping dies end or independent scrap shear, metal scrap strips also can be rolled up into scrap coils by one set recoiler machine.
If feed strip from C type press’s front. It doesn’t need to increase throat depth very much and can save punch machine’s manufacturing cost, scraps should be cut into pieces by the cutter installed at end of stamping dies. It can’t adopt independent scrap shear or rolling up into scrap coils for front feeding type. If punch machine adopts H frame type, it will feed strip from front direction, scrap can be cut to scrap pieces or rolled up into scrap coils. Metal circles can be conveyed out from bottom of metal circle blanking dies and fall to product conveyor belt, then it can be collected by metal circle auto collecting device or product box.
Metal circle blanking line choice No. 2. (WITHOUT PIT, high speed producing efficiency) Suitable for both thin material, usually less than 2.0mm thickness.
Comprising of The Metal Circle Blanking Line
a.ZIGZAG Heavy duty decoiler with loading car-Decoiler is zigzag type
b.Zigzag straightener servo feeder-straightener and servo feeder combined in one machine and zigzag type
c.loop support table with sensor between decoiler and zigzag straightener feeder
d.C frame type punch machine or H frame type punch machine
e.Metal circle blanking dies
f.Scrap shear/cutter or scrap strip recoiler
g.Product conveyor belt and scrap pieces conveyor belt (based on actual need)
h.Metal circle auto collector (Optional part)
It combined in one machine of precision straightener and zigzag servo feeder, saving cost on straightener part and decoiler is ZIGZAG type, swing synchronously with ZIGZAG straightener feeder, moreover, it doesn’t need to set PIT between decoiler and zigzag straightener feeder, so it saves pit cost and occupies less space, it can also ensure high producing efficiency. But it’s mainly for thin material of less than 2.0mm thickness, it’s not very suitable for thick material.
Punch machine can be C type or H type, it can refer to description in item Metal circle blanking line choice No. 1. Metal circle blanking line choice No. 3. (WITHOUT PIT, NORMAL speed producing efficiency) Suitable for thin material.
Comprising of The Metal Circle Blanking Line
a.Heavy duty decoiler with loading car-Decoiler fixed on ground
b.Precision coil straightener-Straightener fixed on ground
c.Zigzag servo feeder
d.loop support table with sensor between decoiler and zigzag straightener feeder
e.C frame type punch machine or H frame type punch machine
f.Metal circle blanking dies
g.Scrap shear/cutter or scrap strip recoiler
h.Product conveyor belt and scrap pieces conveyor belt (based on actual need)
i.Metal circle auto collector (Optional part)
Decoiler payoff strips and make strip surface flat and clear inner stress by coil straightener machine, then strips were pulled though by manual and come to zigzag servo feeder. Punch machine can be C type or H type, it can refer to description in item Metal circle blanking line choice No. 1.
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