What are the ways to improve the utilization rate of automotive stamping parts?

2023-02-28 09:35:09

In recent years, with the improvement of people's living standards, the demand for automobiles has also increased. The competition among various automobile factories has become increasingly fierce, and new models with cost competitiveness have been continuously invested to seize the market. Natural resources such as iron ore and coke are increasingly scarce. Improving the utilization rate of materials can not only reduce the manufacturing cost of automobiles and improve the competitiveness of automobile brands, but also conform to the environmental protection concept of energy saving and consumption reduction.

For some special-shaped stamping parts, the arrangement of blank sheets in the uncoiling blanking die can be optimized to reduce waste, uncoil as many blank sheets as possible, and improve material utilization. In order to improve market competitiveness and enrich sales product lines, automobile factories will invest in new models every year, and the investment in parts of new models will produce new specifications of materials. When the mass production of models ends, the corresponding special steel will occupy the inventory due to slow consumption. Therefore, every addition of a new specification of steel will increase the inventory and management costs. Automobile factories must ensure the versatility of steel as much as possible to reduce The number of varieties of steel.

When multiple parts are produced on a set of molds at the same time, one or more small parts can be produced by using the waste in the hole of the large part to achieve the effect of improving the utilization rate of materials.

When designing the mold, the left and right symmetrical parts are designed to be stamped together. Through process optimization, two parts are stamped out of two sheets instead of two parts punched out of one sheet, which reduces the process supplementary area and improves material utilization.

By adjusting the positioning of the blank sheet in the drawing die, the process supplement of excess material other than the drawbead is reduced, thereby reducing the size of the blank sheet required by the part and improving the utilization rate of the material.

When steel mills produce steel coils and steel plates, they have a certain control range for the thickness tolerance of the products. Table 1 shows the coil size control standards. If the thickness of the steel coil is delivered to the automobile factory according to the positive tolerance, the thickness of the uncoiled blank sheet will be thicker within the acceptable range, which will cause the actual weight of the blank sheet and stamped parts to be higher than the process rated weight. On the other hand , will cause the actual number of sheets produced by the uncoiling of the steel coil to be less than the theoretical number, resulting in a reduction in the yield.

When some parts are uncoiled and blanked, unused waste with a large area will be generated. These wastes are used for the production of other small parts on the car body. Auto stamping parts can avoid separate procurement of materials for small parts and save costs. At the same time, the material utilization rate of the whole vehicle is also improved.

The stamping process is that material suppliers supply coils with packaging. After the coils are unpacked, they are cut into sheets of various shapes required for stamping by unpacking equipment, and then various parts are punched out. When uncoiling, the outer and inner rings of the coil need to be cut. At the same time, the head and tail of the coil need to pass through the uncoiling equipment. The head and tail of each coil are about 15 meters long, which is normal production loss. Therefore, the larger the uncoiling batch, the heavier the average weight of the coil material, the higher the uncoiling efficiency, and the less the average loss of the coil material.

There are many ways to improve the utilization rate of materials, and more methods need to be verified by practice. For example, when stamping cover parts, change the existing linear knife or arc knife to wave knife, and shorten the slab by changing the shape of the slab. Length, so as to improve the material utilization rate, this method needs to calculate the investment of the mold, the maintenance cost and the income relationship after improving the material utilization rate. In short, the purpose of improving the utilization rate of materials is to reduce the complete cost of the vehicle. When making a plan to improve the utilization rate of materials, it is necessary to consider the relationship between investment cost and income in combination with the output of the model.