Coining of copper - How to deal with tolerances less than 0.025 mm
Coining of small copper parts is extremely challenging due to an unpredictable material flow in combination with extremely small tolerances at the outline.
In this example you can see the typical optimization process required to produce coining parts for the electric industry. The challenge is here to be in tolerance at the border up to 0.025mm. Despite the part that is perfectly feasible, the simulation shows:
✔ Part is not in tolerance at the borderline!
✔ High pressure spot in the guides leading to localized tool wearing!
Both problems could be solved by modifying the outline and slightly changing the connection to the strip.