1. Optimized blanking layout to reduce waste
For some profiled precision stamping parts, the layout of blank sheet in the uncoiling blanking die can be optimized to reduce waste, uncoiling blank sheet as much as possible and improve the material utilization rate.
Layout optimization of blank sheet in blanking die of left and right inner longitudinal beam of T6 model: one sheet sheet was produced one step away from the original one, and two sheets were produced one step away from the original one, which reduced the weight of waste and improved the material utilization rate of left and right inner longitudinal beam from 78.2% to 87.6%.
2. Combined material specifications to reduce waste
In order to improve the competitiveness of the market and enrich the sales of products, every year the automobile factory will invest in new models, and new models of precision stamping parts will have new specifications and materials.When the mass production of the model ends, the corresponding special steel will occupy the inventory due to slow consumption, so every new specification of steel will lead to an increase in inventory and management costs, the automobile factory must try to ensure the universality of steel, reduce the number of steel varieties.
The layout optimization process of outer plate of machine cover of T6 model: the coil width of outer plate of machine cover of T6 model is 1330mm, and the uncoiling step is 1820mm, so blanking die is needed.The outer plate of the cover of the X7 model has a roll width of 1830mm. It USES arc-shaped pendulum shear to cut blanks without waste.
Since the uncoiling step distance of T6 machine cover is similar to that of X7 machine cover coil material, through on-site verification, the coil material of X7 machine cover can be used to produce the sheet material of T6 machine cover with arc pendulum shears according to the parameter of 1170mm step distance.
Through process optimization, the material utilization rate was increased by 3.7%, and the original T6 housing plate was reduced with the special steel specifications, which increased the material versatility and reduced the inventory and management costs.
3. Mold design optimization, multiple pieces for one mold
When multiple precision stamping parts are produced simultaneously on a set of molds, one or more small precision stamping parts are produced by using the wastes in the holes of large precision stamping parts, so as to improve the material utilization rate.
For the molds of the inner plate of the machine cover of B5 model and the inner plate of the door of T7 model, the wastes in the holes of precision stamping parts of the inner plate of the machine cover and the inner plate of the door are respectively used to punch out the precision stamping parts of the machine cover strengthening plate and the door lock strengthening plate, avoiding the use of materials alone to produce the machine cover strengthening plate and door lock strengthening plate.