Every great automotive horn begins with precision stamping - a process where millimeter perfection translates into crystal-clear sound. Our 200-ton servo presses operate with 0.01mm repeatability to form components that deliver consistent acoustic performance.
Our stamping process achieves 99.97% dimensional accuracy across 15,000 daily units, forming horn diaphragms and housings that maintain perfect resonance characteristics throughout their lifespan.
Discover how our advanced stamping technology, material science expertise, and smart manufacturing practices create horns that outperform industry standards.
High-Efficiency Stamping: Ensuring Structural Accuracy and Consistency
Why does stamping precision matter for something as simple as a car horn? Because microscopic variations in metal thickness can dramatically alter sound quality and durability.
Our CNC-controlled servo presses deliver 120 strokes per minute with <5μm variation, maintaining consistent material flow and grain structure critical for acoustic performance.
Stamping Process Parameters and Benefits
| Parameter | Industry Standard | Our Specification | Acoustic Advantage |
|---|---|---|---|
| Press Speed | 80 SPM | 120 SPM | Consistent forming |
| Tolerance | ±0.1mm | ±0.03mm | Precise harmonics |
| Die Life | 500k hits | 2M hits | Stable quality |
| Blank Hold | 20 tons | 35 tons | Wrinkle-free |
| Cushion | Mechanical | Nitrogen | Smooth draw |
Process innovations:
- Adaptive blank feeding
- Real-time tonnage monitoring
- Automatic die lubrication
- Quick-change tooling
- Scrap-free nesting
Tooling Design and Material Selection: The Foundation of Quality
The secret to our horns' crisp sound lies beneath the surface - in the engineered grain flow of specially selected materials and precision-ground tooling.
Our progressive dies feature German carbide inserts and Japanese surface treatments that maintain cutting sharpness for 2 million cycles - 4x industry averages.
Material and Tooling Specifications
| Component | Material Grade | Tooling Feature | Performance Benefit |
|---|---|---|---|
| Diaphragm | SUS304-H | Mirror polish | 15% better resonance |
| Housing | DC04+ZE | Nitrided inserts | 5x corrosion life |
| Mounting | SPCC | Laser-hardened | Vibration resistance |
| Contacts | C5191 | Diamond coating | Zero wear |
| Springs | SUS631 | Precision coining | Consistent tension |
Material advantages:
- Grain-oriented steel
- Custom alloy blends
- Environmentally plated
- Noise-dampening layers
- Temperature-stable
Automation and Quality Control: Driving Smart Manufacturing Forward
Our smart factory integrates Industry 4.0 technologies to maintain stamping precision while providing complete traceability from coil to finished horn.
Vision-guided robots handle 85% of material movement with 0.001mm positioning accuracy, while IoT sensors monitor 200+ process parameters in real-time.
Quality Assurance and Process Control
| Control Point | Measurement Method | Frequency | Standard |
|---|---|---|---|
| Blank Thickness | Laser micrometer | Every coil | ±0.01mm |
| Press Tonnage | Strain gauges | Continuous | ±3% |
| Part Dimensions | Vision system | 100% | ±0.05mm |
| Surface Finish | Contact profilometer | Hourly | Ra 0.8μm |
| Material Hardness | Rockwell tester | Every shift | HRB 75±2 |
Smart features:
- Predictive maintenance
- Digital twin simulation
- Energy monitoring
- Cloud-based SPC
- Automated sorting
Conclusion
From precision-stamped components to smart manufacturing systems, we transform raw materials into acoustic safety devices that perform flawlessly when seconds count.
