Punching machines, as one of the core equipment in modern manufacturing, play an indispensable role in many fields such as automobiles, home appliances, electronics, aerospace, etc. due to their high efficiency and precision. The punching machine, on the other hand, is the "soul" of the punching machine, directly determining the shape, size, and quality of the final product. However, punch operation is essentially a process of concentrating enormous energy into an instant release, and its operation comes with extremely high risks. Therefore, mastering the use of punching machines and strictly implementing meticulous safety measures is the fundamental prerequisite for ensuring smooth production and protecting the safety of personnel.

Part One: Precise Use and Maintenance of Punching Dies

The use of punching machines is a systematic project, not just a simple clamping and starting process. It covers every delicate step from preparation to completion.

1. Careful preparation before homework

Technical document confirmation: The operator must carefully read the "Operation Manual" or "Process Card" of this production task, fully understand the specifications, materials, size requirements of the processed products, as well as the key parameters such as mold number, stamping frequency, and tonnage used. Any unclear information must be clarified with the supervisor or technical personnel.
Mold inspection and preparation:
Appearance inspection: Check whether there are cracks, damages, or severe rust on the upper and lower mold seats, guide columns, and guide sleeves of the mold.
Blade inspection: Carefully check whether the cutting edges of the punch and die are sharp, and whether there are any broken edges, curled edges, or wear. Minor wear and tear can still be repaired, while severe damage must be immediately reported for repair or replacement.
Internal organization inspection: For molds with unloading plates, top feeders, springs, and other mechanisms, it is necessary to ensure that their movement is flexible and there is no jamming phenomenon. Check for fatigue failure of the spring.
Cleaning and lubrication: Use cotton cloth, soft brush and other tools to thoroughly remove oil stains, iron filings and dust from the mold cavity, cutting edge and positioning device. Subsequently, according to the lubrication standard, apply an appropriate amount of specialized lubricating oil to the guide column, guide sleeve, and sliding parts.
Inspection of punching equipment:
Tonnage confirmation: Ensure that the nominal pressure (tonnage) of the punching machine is much greater than the theoretical punching pressure required for this stamping process, and overloading is absolutely prohibited.
Operation status inspection: Check whether the machine tool clutch, brake, emergency stop button, photoelectric protection device, etc. are sensitive and reliable. Run the empty car several times and listen for any abnormal sounds.

Workbench cleaning: Clean up the oil stains and waste on the workbench and slide bottom to ensure that the mold installation base is flat and clean.

2. Mold installation and commissioning

Safe power-off: Before installing the mold, the power supply of the punching machine must be completely disconnected, and if necessary, a safety warning sign reading "under maintenance, no switching on" should be hung. This is the lifeline to prevent malicious accidents caused by accidental activation.
Standardized installation:
Adjust the closing height: manually or jog the slider to make its height slightly higher than the closing height of the mold.
Lifting and positioning: When using lifting equipment such as overhead cranes to lift molds, it is necessary to ensure smooth lifting and slowly move the molds to the center position of the workbench. After initial positioning, gently lower the slider to allow the mold handle to enter the mold handle hole of the slider, or to ensure that the upper mold seat is in contact with the bottom surface of the slider.
Tightening: First, use suitable pressure plates, bolts, and shims to firmly fix the lower mold onto the workbench. Then, tighten the upper mold. When tightening, diagonal alternating tightening must be used to ensure even force distribution and prevent the mold from shifting or overturning under impact.
Fine tuning:
Travel adjustment: jog the punching machine, gradually lower the slider, and observe the fit between the upper and lower molds. By adjusting the closing height, ensure that the mold is closed in place without overpressure (which can cause damage to the mold) or gaps (which can affect product quality).
Debugging of feeding mechanism: Install and debug automatic feeding machines, guide plates, positioning pins, etc. to ensure that sheet or coil materials can be smoothly and accurately fed into the mold with precise step spacing.

Trial punching and inspection: Use the same materials or material heads as in formal production for trial punching. Take out the test piece and use measuring tools such as calipers and projectors to comprehensively inspect whether its dimensions, burrs, etc. meet the requirements of the drawing. Fine tune according to the results until qualified products are produced.

3. Standardized operation and monitoring in production

Strictly follow the regulations: Mass production can only begin after the equipment is operating normally and all safety protection devices are in place. The operator should maintain focus and use standardized actions for feeding and retrieving materials.
Continuous monitoring: During the production process, it is important to constantly monitor whether the stamping sound is normal. Abnormal impact sound may indicate foreign objects or loose parts inside the mold. Regularly (such as every 50-100 stamping cycles) inspect product quality and promptly detect trends in mold wear or deviation.

Process discipline: It is strictly prohibited to change a single stamping process to continuous stamping (continuous rolling), and it is forbidden to insert hands or any tools into the dangerous area of the mold. For small workpieces, manual tools such as tweezers and magnetic suction cups must be used for operation.

4. Mold maintenance and storage after homework

Thoroughly clean: After production is completed, the iron filings and oil stains inside the mold must be thoroughly cleaned, and rust proof oil must be applied to the cutting edge and key surfaces to prevent rusting.
Integrity check: Briefly check whether each component of the mold is intact, record the production quantity and mold status on duty.

Standardized storage: Lift the mold to a dedicated mold storage area and place it on a wooden or rubber pad. Small molds should be stored on shelves, while large molds should be placed steadily and labeled for easy use next time.

Part 2: Safety Measures for Building a Life Line of Defense

Safety is the cornerstone of stamping operations and must be jointly built through three layers of defense: technology, management, and personal protection.

1. Technical protection - intrinsic safety

Safety protection device:
Fixed protective cover: completely enclose the hazardous area of the mold, preventing any part from entering.
Interlocking protective device: Once the protective cover is opened, the control system of the punching machine will be immediately cut off, and the slider cannot move. The machine tool can only be started when the protective cover is completely closed. This is one of the most effective ways of protection.
Optoelectronic safety protection device: A light curtain is installed in front of the hazardous area of the mold. When the operator's hand or other object blocks the light beam, the punching machine will stop urgently.
Two handed operation button: The operator is required to simultaneously press two start buttons that are far apart with both hands before the slider can move, ensuring that both hands are outside the danger zone.

Equipment safety function: Ensure that the emergency stop button of the punching machine is prominent, easily accessible, and reliable in function. Regularly check the clutch and brake to ensure they respond quickly and have no slipping phenomenon.

2.  Management Protection - Systems and Processes

Strict safety training and certification: All operators must receive comprehensive and systematic safety education and operational skills training, and can only operate independently after passing the assessment.
Clear safety operating procedures: Develop detailed and clear operating procedures and place them in prominent locations on the operating site. The content should include safety requirements for the entire process from preparation, mold installation, debugging, operation to mold placement.
Regular equipment and mold inspections: Establish and implement daily, weekly, and monthly inspection systems, with professional maintenance personnel inspecting, maintaining, and recording key safety components of punching machinees and molds.

Standardized labor discipline: It is strictly prohibited to play and frolic, play with mobile phones, or do anything unrelated to work during working hours. The operator must remain awake and not work when fatigued.

3. Personal Protection - The Last Line of Defense

Labor protection equipment: It is necessary to wear anti smashing safety shoes that meet the requirements to prevent workpieces or tools from falling and injuring feet; Wear anti cutting gloves for handling boards and workpieces, but it is strictly prohibited to operate the slider area with gloves while the equipment is running; Wear goggles if necessary to prevent debris from splashing into the eyes.

The correct safety attitude: Technical and management measures ultimately need to be executed by people. Cultivating the awareness of "safety first" among every operator, abandoning the mentality of taking chances, and cultivating the habit of operating according to regulations are the fundamental guarantees for preventing accidents.

The use of punching machines is an art that combines technology, experience, and responsibility. It requires operators to strive for excellence like craftsmen, accurately controlling every detail to ensure the excellent quality of products; They are required to be vigilant at all times like guardians, internalizing safety regulations in their hearts and externalizing them in their actions to resist potential risks. Only by deeply integrating scientifically rigorous usage processes with ironclad safety measures can we truly achieve a harmonious unity of efficiency, quality, and safety in this production that dances with tremendous power, allowing this powerful industrial machine to create maximum value on a safe track.