How to Produce Precision In-Die Riveted Moving Contact Assembly?

In the metal stamping and assembly process, riveting relies on the plastic deformation of metal to achieve a rigid connection of parts. It is a mainstream forming method that replaces welding and bolt fastening. In-Die Riveted Moving Contact Assembly integrates stamping and riveting into a single mold, significantly reducing dimensional deviations caused by segmented processing. Bending riveting, as a commonly used branch of riveting, relies on specialized bending equipment to achieve locking through unidirectional pulling force. Unlike the torque-locking mode of bolts, it is suitable for the mass production of various precision metal parts with conductive contacts. In the early stages, it is necessary to control basic parameters such as sheet metal ductility and hole diameter allowance to avoid loose contacts and excessive conductive gaps after riveting.

During broaching, the equipment stretches the rivet shank and compresses the outer collar, causing the collar to embed into the screw groove to form a completely fitted, permanent fastening structure. Electrical Contact Assembly, with its integrated in-mold structure, eliminates the need for a separate broaching station, fundamentally reducing the problem of uneven fastening force caused by manual assembly. Traditional offline riveting is prone to inconsistencies in the tightness of fasteners across different contacts. In-die synchronous riveting, however, ensures uniform tightening force at every rivet, resulting in a finished product with stable shear resistance. For contact assemblies requiring frequent switching, this maintains a secure connection structure over the long term, guaranteeing stable electrical contact.

The hole diameter matching during the initial riveting stage is a crucial detail determining the yield rate of the contact assembly. The diameter of the pre-drilled rivet hole on the workpiece must be 0.1mm larger than the rivet's outer diameter. Excessive clearance can lead to rivet misalignment and contact surface tilting, while insufficient clearance can cause rivet jamming and a surge in in-die stamping load. During the machining of Silver Contact Riveted Copper Assemblies, the mold cavity precisely pre-defines standard riveting hole positions, simultaneously completing sheet metal blanking and hole forming. This eliminates the need for secondary drilling corrections, ensuring stable dimensional tolerances and reducing metal burrs from additional machining processes, preventing burrs from scratching the conductive surface of the contacts.

The selection of riveting fixtures must match the rivet mandrel specifications. A mismatch between the gun head bore diameter and the mandrel size can lead to defects such as the mandrel failing to break properly and the riveting surface collapsing, directly affecting the contact conductivity. Within the integrated stamping die, the Electrical Contact Rivet Assemblies integrate a standardized in-die riveting mechanism. This eliminates the need for manual tooling changes; the die automatically matches the corresponding rivet specifications during operation, completing the feeding, punching, riveting, and mandrel breaking processes seamlessly. This fully automated operation avoids human error and effectively controls key dimensional indicators such as contact flatness and riveting height, making it suitable for the mass production of small, precision contacts such as electronic switches and relays.

Compared to traditional segmented processing, in-die riveting offers significant advantages in precision, efficiency, and consistency, especially for compact moving contact products with stringent conductivity requirements. The Electrical Silver Contact Rivets Copper Contacts Assembly integrates stamping and riveting processes, shortening the entire production process, reducing workpiece deformation during transport, and standardizing the fastening parameters of all riveting points. The production process only requires controlling three core elements: sheet material, mold precision, and riveting pressure. This allows for the stable production of contact assemblies with high conductivity and high vibration resistance, representing the mainstream optimized process direction in precision electronic hardware manufacturing.

Most simple in-mold riveting solutions on the market struggle to balance contact conductivity, stability, and long-term fatigue resistance. Our self-developed and mass-produced In-Die Riveted Moving Contact Assembly perfectly solves these pain points. Utilizing mature integrated stamping and riveting mold technology, it strictly controls hole diameter tolerances, riveting pressure, and locking force. It is compatible with various electrical components such as relays and microswitches. The finished product is shear-resistant, prevents loosening, and exhibits no conductivity degradation under long-term switching conditions. Custom sizes and materials can be provided according to customer requirements. Welcome to consult with us regarding product drawings and performance requirements for sample testing and bulk orders.