The processing process of sheet metal automotive parts is a more complex issue. In this paper, we briefly explain the basic principles of process setting for general sheet metal parts in order to find out the basic methods of process setting. In short, as an engineer, we should establish the cost concept, integrate the cost in the process, and look at the process of process setting from the overall global perspective.
Sheet metal parts are thin and easy to form, and can be formed into various shapes of parts. With the application of processes such as welding, assembly, and pull riveting, it gives the possibility to realize multiple structures for the products. At the same time, these characteristics also make the sheet metal parts will be more or less deformed in different degrees during the process, such as bending deformation, twisting deformation, concave and convex deformation, etc.. These deformations make the size or shape of the whole component change, causing quality problems. However, the production process of sheet metal parts has its inherent rules. For the same type of products, according to the existing equipment, manpower, etc., the processing sequence can be flexibly adjusted to give a reasonable processing process. Therefore, choosing the correct process route is an effective preventive and solution measure for this type of problem.
The formulation of the process route must be combined with the shape of the product and the existing processing equipment of the company, with the premise of satisfying the product quality requirements, and the ultimate goal of achieving greater economic benefits. The formulation of the general process route for automobile stamping parts can follow the following principles: (1) meeting product quality requirements, (2) economic product process route, (3) providing optimization for subsequent processes, and (4) convenient processing. The focus of the process personnel's consideration of quality comes from the grasp of the product structure functionality and appearance, as well as the mastery of the equipment processing capability. The three directions to be considered for process preparation are to consider the cumulative error fit relationship of the whole machine, to optimize the processing method of the product to reduce the processing difficulty, and to set a relatively stable process route during mass production.
The optimization of the processing method lies in the adjustment of its processing sequence or process improvement, which is analyzed and illustrated by a simple example. Such as a door plate unfolding diagram, this door plate single piece processing can focus on its quality and time, the general process scheme is: shear under the material → punching machine punching shape and inner hole → bending machine bending → welding four corners. Such a process program to save time and effort, but if the mass production of punching machine tool damage will intensify, greatly increasing the maintenance costs of the machine tool.
In addition, automotive sheet metal parts will cause irreparable damage if there is a slight problem with the programming procedure. Since the role of this type of door plate at the shaped place is to install the door suction, so the mass production of this type of door plate usually uses the following processing scheme: shear bed material (three door suction small piece of separate material) → punching machine punching inside the hole → cutting angle → folding machine folding test → welding four corners and three door suction small piece. The improvement of the program not only saves raw materials, equipment maintenance costs, but also greatly reduces the error rate of programming.
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