Copper Clad Aluminum Busbar Processing Guidelines Manual
| Copper Clad Aluminium Busbar |
Our Copper Clad Aluminum Busbar adopts diecasting continuous rolling and direct casting technique. Copper and aluminum is solid-liquid bonding. There is compound layer and the bond strength is high, so the users could process Copper Clad Aluminum Busbar in the same way as Copper Busbar and do not need to exchange the processing equipments.
Copper Clad Aluminum Busbar is a kind of bimetal product and it is different from monotypic metal. If the processing way is not correct, although the bondstrength is high,
Copper Clad Aluminum Busbar will still delaminate. To avoid destroying the bondstrength of cross-section in the processing, the followings need to be attentioned:
A. Cut
1. Cut with the sawmachine
Use the hydrawlic sawmachine and the sawblade with fine teeth. In order to
prolong the using time of the sawblade, the emulsified liquid and soapsuds must be
used to cool at the same time of sawcutting.
2. Cut with the punching machine
1 The best way is slice cut (drawing No.1) .
 | ||
| drawing no.1 |
2 If Copper Clad Aluminum Busbar is long, the support needs to be used to keep
the workpiece and mould in the same plane.
3. Cut with copper busbar multiple-station processing machine
Straight cut or the mode tape on the mould has some slope (drawing No.2).
 |
| Drawing no.2 |
 |
| Drawing no.3 |
middle part and two sides of the workpiece cross-section and delaminate copper
and aluminum.
B. Pierce
1. Pierce with punching machine.
The die clearance must be adjusted according to the demand on Copper Clad
Aluminum Busbar. Especially, pierce multi holes simultaneously and U-form hole
(drawing No.4), the stripper pad battening device must be used when loading a die
(drawing No.5).
 | ||
| Drawing no.4 |
 |
| Drawing no.5 |
2. Pierce with copper busbar multiple-station processing machine
When pierce with copper busbar multiple-station processing machine, we need not
only adjust die clearance, but also assure that the punch and cavity on the same
concentricity running in close-run (drawing No.6).
 | |
| Drawing no.6 |
1 Drill holes with drilling machine, instantly drill through or back drilling bit
upward after drilling through, we need to press and pull lightly to avoid the
delamination of copper and aluminum in the bottom or top parts.
2 Drilling holes, the board needs to be filled under Copper Clad Aluminum Busbar.
Hanging in the air is forbidden.
3 Cool with the emulsified liquid or soapsuds when drilling.
4 Drilling holes with the electric portable drill, the drilling bit needs to be grinded
as drawing 7. Press downward lightly instantly drilling through.
 | |||
| Drawing no.7 |
1. Copper Clad Aluminum Busbar needs to be bent according to the following bending
radius or bigger than the sizes in the table.
Thickness(mm) Diameter(mm)
3.0 ≤ a ≤ 6.3 2a
6.3 < a ≤12.5 3a
2. Reduce the skin friction force in the bending process.
3. Angel R of bending mould needs to be adjusted according to the thickness.
4. The shape as drawing no. 8 is incorrect and this will influence the electric
conductivity. The correct shape is as drawing No. 9.
 |
| drawing no.8 drawing no.9 |
Item No. Thickness Б (mm) Die clearance
1 3<Б≤6 6 - 9%
2 7 < Б ≤ 10 8 - 12%
3 10 < Б ≤ 14 10 - 14%
Note: The clearance in the above table is the numeric value of two-sided clearance
1. Effect of too small die clearance:
1 Easily cause the burr and dentation rim on the workpieces
2 Reduce the life time
2. Effect of too big die clearance:
There is obvious deformation on the surface of workpiece. The side near the punch
sinks and the other side bulges.
E. Fasten
When fasten Copper Aluminum Compound Busbar with the screw blots, the thickening
plain washer needs to be used.
If there is the bellevill spring, 2-3mm steel plate needs to be filled inside the bellevill
spring in order to disperse the pressure on Copper Aluminum Compound Busbar.
Do not fasten the screw blots too forcibly.
Recommended torques (Nm) are as follow:
M8 : 7.04 - 8.64 M10 : 14.16 - 18.08 M12 : 25.12 - 31.36
M16 : 62.8 - 78.48 M18 : 78.4 - 101.92 M20 : 125.52 - 156.96
0 comments: