Hardware mold, how to improve material utilization
Competition in the auto market is getting fiercer and more cost-competitive new models are being introduced. Meanwhile, natural resources such as iron ore and coke, which are needed to produce auto steel, are getting tighter.Improving the material utilization rate can not only reduce the manufacturing cost of the automobile, improve the competitiveness of the automobile brand, but also conform to the concept of energy saving and consumption reduction.
Blanking layout optimization, reduce waste
Blanking layout optimization, reduce waste for some special-shaped stamping parts, can be uncoiling blanking die blank layout optimization, in order to reduce waste, as much as possible uncoiling out of blank sheet, improve the utilization rate of materials.Figure 1 shows the layout optimization of the blank plate in the blanking die of the left and right inner longitudinal beam of T6 model. The original one plate is produced step by step, and two plates are produced step by step, which reduces the weight of wastes and improves the material utilization rate of the left and right inner longitudinal beam from 78.2% to 87.6%.
Material specification merge, reduce waste. Hardware mold
In order to improve the market competitiveness and enrich the sales front, the automobile factory will have the input of new models every year, and the input of new model parts will have the production of new materials with new specifications.When the mass production of vehicle models is finished, the corresponding special steel will occupy the inventory due to slow consumption. Therefore, the increase of inventory and management cost will be caused every time the steel of a new specification is added. The automobile factory must ensure the versatility of steel as much as possible and reduce the variety of steel.
Figure 2 shows the layout optimization process of the cover outer plate for T6 model. The coil width of the cover outer plate for T6 model is 1330mm, the uncoiling step distance is 1820mm, and blanking die needs to be used.On the other hand, the coiling width of the outer plate of the cover of X7 model is 1830mm, and the arc pendulum scissors is used to cut blanking without waste.Since the uncoiling step distance of T6 cover is similar to the material width of X7 cover, it can be verified on site that the coil material of X7 cover can be used to produce the sheet material of T6 cover with arc pendulum shear according to the step distance of 1170mm.Through the process optimization, the material utilization rate was increased 3.7%, and the steel specification for the cover plate of the original T6 machine was reduced, which increased the versatility of the material and reduced the inventory and management cost.
Mold design optimization, a mold of more than one
When many parts are produced simultaneously on a set of mould, one or more small parts can be produced by using the wastes in the holes of the large parts to improve the efficiency of material utilization.Mold (figure 3) of cover inner plate and T7 door inner plate of B5 model is used to stamp out cover inner plate parts and door lock reinforcing plate respectively by using the wastes in the holes of cover inner plate and door inner plate parts, so as to avoid using materials to produce cover reinforcing plate and door lock reinforcing plate alone.
Die design optimization, slab combination die design, the left and right symmetry parts design together stamping forming, through process optimization, two sheet metal stamping out two parts into one sheet metal stamping out two parts, reduce the technology supplement area, improve the utilization rate of materials.Figure 4 compares the mold design of the left and right rear door panels of MX3 model with the mold design of the left and right rear door panels of M44 model.The left and right rear door plate of MX3 model presses a part with one sheet of material, and the four directions of the part need the supplementary surface of the process.The rear door plate of the M44 model is stamped with two parts for one sheet, which is equivalent to reducing one supplementary surface of the process.By comparison, the material utilization ratio of M44 rear door panel is 4.16% higher than that of MX3 rear door panel. Hardware mold