The quality of busbar processing directly affects the conductivity and installation efficiency of complete electrical equipment. Achieving high smoothness, high precision, and low scrap rate depends primarily on the following core dimensions:

Item Influence indicators Solution
Mold Cross-sectional smoothness, burrs Optimize punching and shearing clearance and regularly grind the dies.
Equipment Machining accuracy, perpendicularity To improve frame rigidity, a high-precision servo system was selected.
Process Cross-sectional appearance, waste amount Choose between a double-shear process (for quality) or a single-shear process (for efficiency).
Software scrap rate, production cost Use intelligent overlay and layout software

Key physical factors: mold quality and clearance

The mold is a direct factor that determines the quality of the busbar cross-section.

  • Punching/Shearing Clearance: The clearance between the upper and lower cutting edges of a punching or shearing die must be precise. Excessive clearance will result in severe burrs and corner collapse on the cross-section; insufficient clearance will lead to secondary shearing, resulting in a rough cross-section and shortening the die life.
  • Mold Material: Using high-hardness, high-wear-resistant mold steel (such as Cr12MoV or SKD11 or DC 53) and finely grinding significantly improves the flatness and smoothness of the cross-section.

Tips:Requirements for die clearance when punching copper and aluminum busbars

Mechanical rigidity and positioning accuracy of machine tools

  • Structural Stability: Insufficient rigidity of the equipment frame can cause minute deformations during shearing or punching, leading to cross-sectional tilting or dimensional deviations.
  • Servo Control System: For precision, the repeatability of the feeding system is crucial. Using a high-performance servo motor paired with a precision ball screw can control machining errors within 0.1 mm. Recommended product: MX602K-8C CNC busbar punching and shearing machine.
  • Closed-Loop Feedback: Systems with real-time feedback from linear scales or encoders effectively compensate for deviations caused by mechanical wear.

Process parameters and lubrication

  • Shearing Method: While cross-cut shearing (no scrap) saves material, the cross-section often has a slight slope. Double shearing (with scrap at the cut) yields a more vertical and flatter cross-section.

  • Lubrication: Using appropriate stamping oil during stamping and shearing reduces friction between the die and the copper/aluminum busbar, preventing built-up edge formation and improving cross-sectional surface finish.

Software optimization and nesting algorithms (to reduce scrap rate)

  • Automatic Nesting: Advanced CNC busbar machine software optimizes the nesting of parts along the entire busbar based on their dimensions, maximizing utilization.

  • Scrapping Management: Excellent algorithms effectively reduce “head and tail scrap” and adjust dimensions across multiple orders, minimizing the scrap rate.