Solutions for Failing to Achieve an Ideal Flat Surface During the Pressing of Hexagonal Stock into Round Rods

During the process of pressing hexagonal stock into round rods, failure to achieve an ideal flat surface (as indicated by the red circle) may be caused by incorrect pressing methods, issues with the die or grinding head, uneven material stress, or unreasonable operating parameters. Below is a detailed analysis and specific solutions:

I. Common Cause Analysis

1. Incorrect Pressing Method: If the edges of the hexagonal stock lack a adhesive layer, incorrect methods (e.g., oversized grinding head, uncontrolled force, prolonged pressing inside the die) can cause the corners to collapse, affecting flat surface formation.

2. Die or Grinding Head Issues: An uneven die surface, or an unbalanced/worn grinding head, leads to uneven force distribution during pressing, preventing the formation of a flat plane.

3. Uneven Material Stress: Uneven internal stress distribution within the hexagonal stock can easily cause deformation during pressing, resulting in an uneven surface.

4. Unreasonable Operating Parameters: Parameters such as excessive pressing speed, or pressure that is too high or too low, can all adversely affect the flat surface formation.

II. Solutions

1. Adjust the Pressing Method: Use a suitably sized grinding head and control the pressing position to about half inside the die. Control the force precisely, ensuring force is maintained inwardly even as the grinding head exits, to prevent corner collapse.

2. Inspect and Adjust the Die or Grinding Head: Check the die for flatness. If wear or deformation is found, repair or replace it promptly. Check the grinding head for balance; if imbalance is detected, perform balancing adjustment or replace the head.

3. Optimize Material Treatment: Perform pre-treatment on the hexagonal stock, such as annealing, to relieve internal stresses and improve material uniformity. Before pressing, visually inspect the hexagonal stock to ensure it is free from defects like cracks or inclusions.

4. Adjust Operating Parameters: Based on the material properties and die condition, adjust parameters like pressing speed and pressure to ensure a stable and controllable pressing process. During pressing, closely observe the flat surface formation and adjust parameters in real-time to achieve the desired result.