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Guide

The process of sheet metal parts has its inherent characteristics. The induction and summary of the process theory will help improve the technology personnel's ability to use sheet metal processing, and help design more optimized process flow and processing schemes. On the premise that the existing equipment processing capacity and the product structure are basically finalized, the structure optimization from the process, based on the production dynamic balance, flexible coordination, and the development of the most optimized process method is our company's service tenet.
Features of sheet metal parts

Sheet metal parts have the characteristics of being thin and easy to form, and can be formed into parts of various shapes. With the application of welding, assembly, riveting and other processes, it has given the product the possibility to realize multiple structures. According to the sheet metal equipment self-produced, our company can flexibly adjust the processing sequence and give a reasonable processing technology.
Basic principles of sheet metal process route setting

In the course of years of development, our company has accumulated a wealth of production process routes for the sheet metal industry. The formulation must be combined with the shape of the product and the company’s existing processing equipment to meet the product quality requirements as the premise, and ultimately achieve the goal of maximizing economic benefits. . The formulation of general process routes can follow the following principles: (1) Meet product quality requirements, (2) Product process routes are economical, (3) Provide optimization for subsequent procedures, (4) Convenient processing. The quality of the craftsman's consideration comes from the grasp of the product structure, functionality and appearance, and the proficiency of the equipment processing capabilities. Considering the cumulative error matching relationship of the whole machine, optimizing the product processing method to reduce the processing difficulty, and setting a relatively stable process route during mass production are three directions that need to be considered in process planning.
Optimization of product processing methods

The optimization of the processing methods lies in the adjustment of its processing method or the improvement of the process, using a simple example to analyze and explain. For example, a certain kind of door panel development drawing, the quality and processing time of this door panel shall be considered firstly when processing a single piece of the door panel. The general process method is: calculating and using the shearing machine to cut the raw material → using the punching machine to shape the edge and cut inner holes →using folding machine to bend the material → using the welding machine to connect the four corners. Such a process plan saves time and effort. But if we start the mass production, the damage to the punching tool and cutting blade will be aggravated, which greatly increases the maintenance cost of the machine tool. In addition, if there is a slight problem with the programming procedure, it will cause irreparable losses in production. Since the function of this type of door panel’s special part is to install the door stopper, the following processing schemes are usually used when producing this type of door panel in large quantities: calculating and using the shearing machine to cut the raw material (cutting the material of the three door stopper separately ) → using punching machine to cut the inner holes → cutting corners → using folding machine to bend the material→using the welding machine to connect the four corners and three small pieces of door stoppers. The improvement of this scheme not only saves the cost of raw materials and equipment maintenance, but also greatly reduces the error rate of programming processing.
The Stability in the selection of process methods

The Stability in the selection of process methods shall match the production quantity. The process methods will face different choices due to changes in the production quantity. The process sequence will be different when the product is in the trial production stage and the small batch production stage. In the trial production stage, the focus is on product overall structure verification and processing timeliness, and it is not sensitive to process costs. In the small-batch production stage, the focus is on process route verification, partial optimization of the single-piece structure and appropriate mold preparation. In mass production, the selected process will take cost as the top priority, optimize the process as much as possible and save costs. Below is a sample of a small corner piece:

Processing method I: calculating and using the shearing machine to cut the raw material → using folding machine to bend the material → marking, drilling and tapping;

Processing method Ⅱ: calculating and using the shearing machine to cut the raw material (several items can be combined) → using the punching machine to punch the bottom holes → using the shearing machine to cut the material into single products → using folding machine to bend the material → tapping;

Processing method III: making mold to process

Through the comparison of the above three process methods, it is found that all of these three methods can effectively meet the requirements of customers, and each method has its own unique characteristics. Process methods I requires a lot of labor and time (marking and punching), resulting in a large percentage of process waste. Generally, it is only suitable for the processing of single product. This solution is not recommended for mass production. Process method II requires many machine tools. The time is slightly faster, and multiple products can be produced at one time, which is suitable for small and medium batch production. But the material pieces needs to be cut after punching, which may cause a small amount of displacement of the holes. Process methods Ⅲ is to make the molds for all the necessary parts. This processing method is suitable for mass production, saving time and effort.

Through the above discussion, it can be seen that the influence from the selection of process methods to the waste in the production procedure is closely related to the production quantity. I think that the selection of the process methods should take various factors into consideration. Therefore, it is particularly important to appropriately select the process methods according to different production conditions.
Conclusion

The process methods of sheet metal and metal parts is a relatively complicated issue. This article briefly describes the basic principles of general sheet metal and metal parts process selection in order to find out the basic method of process setting. In short, as an engineer, you should establish the concept of cost control, integrating the concept cost control into the process methods, and look at the process methods selection from an overall perspective.

Complete solutions for sheet metal process