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

2019-05-31 10:26:21

In recent years, with the improvement of people's living standards, the demand for automobiles is also growing. The competition among automobile factories is becoming increasingly fierce. New models with cost competitiveness are continuously invested to seize the market. At the same time, the natural resources such as iron ore and coke used to produce automobile steel are becoming increasingly tense. Improving the material utilization ratio 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 layout of blank in uncoiling blanking die can be optimized to reduce waste, as much as possible uncoiling blank and improve material utilization. In order to improve the market competitiveness and enrich the sales product front, every year the automobile factory will have new models input, and new specifications and materials will be produced when new models and parts are put in. At the end of mass production, the corresponding special steel will occupy the stock because of slow consumption. Therefore, every addition of a new specification of steel will lead to an increase in inventory and management costs. Automobile factories must ensure the universality of steel and reduce the number of steel products.

When multiple parts are produced simultaneously on a set of moulds, one or more small parts are produced by using the waste material at the hole of the large part, so as to improve the utilization ratio of materials.

In die design, the left and right symmetrical parts are designed to be stamped together. Through process optimization, two parts are stamped out from two sheets and two parts are stamped out from one sheet, which reduces the supplementary area of process and improves the utilization ratio of material.

By adjusting the position of the blank in the drawing die, the technological supplement of the redundant material outside the drawing rib can be reduced, thus the size of the blank needed for the parts can be reduced and the utilization rate of the material can be improved.

In the production of coils and steel plates, the thickness tolerance of products has a certain range of control. Table 1 is the coil size control standard. If the thickness of the coil is delivered to the automobile factory according to the positive tolerance, the thickness of the uncoiled blank will be thicker in the qualified range, which will cause the actual weight of the blank and stamping parts to be higher than the process quota weight. On the other hand, it will cause the actual number of sheets uncoiled from the coil to be less than the theoretical quantity, resulting in the reduction of the yield.

When some parts are unwinding and blanking, they will produce large unused area of waste. These wastes can be used in the production of other small parts on automobile body. Auto stamping parts can avoid the purchase of materials used for small parts, save costs, and improve the material utilization rate of the whole vehicle.

The stamping process is that the material supplier supplies the coil with packaging. After the coil is unpacked, the coil is sheared into sheets of various shapes required for stamping by uncoiling equipment, and then various parts are stamped out. When uncoiling, it is necessary to cut the outer ring and inner ring of the coil. At the same time, the head and tail of the coil need to pass through the uncoiling equipment. The normal production loss is about 15 meters per coil. Therefore, the larger the volume of uncoiling, the heavier the average weight of the coil, the higher the efficiency of uncoiling, and the less the average loss of the coil.

There are many ways to improve the material utilization rate. More methods need to be verified by practice. For example, when blanking stamping panels, the existing linear or circular knife should be changed into wave knife. By changing the shape of the slab and shortening the length of the slab, the material utilization rate can be improved. This method needs to calculate the relationship between the investment of the die, the cost of maintenance and the profit after improving the material utilization rate. In a word, the purpose of improving material utilization rate is to reduce the total cost of the whole vehicle. When making the plan of improving material utilization rate, we need to consider the relationship between investment cost and income, taking into account the output of the vehicle.