常州亿创钣金加工厂专业从事精密钣金加工、激光切割加工为主的钣金加工型厂家

常州亿创钣金加工厂

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常规钣金加工工艺的变化新工艺的特点

2018-05-05 14:47:31 常州亿创钣金加工厂 阅读

常规的钣金加工工艺是采用:剪切-冲-折弯-焊接流程或者火焰等离子切割-折弯-焊接工艺。在多品种,小批量,定制化,高质量,短交货期的订单面前,它显现出明显的不适应。激光切割工艺作为“剪切-冲”的替代工艺出现,具有灵活、柔性高的特点。同时多数人也认为其成本高。故常应用在异形(或形状复杂的)工件和样品(单件或极小批量)制造上。但当小批量制造越来越普及时,激光切割的需求也日益上升。

当重新审视新的钣金加工工艺:激光切割-折弯-焊接/铆焊时,由于激光切割的高柔性、高精度,三维设计技术的成熟与普及,用户可从新的设计、新的流程中获益,从而达到降低成本、缩短工期的要求。因此新的钣金工艺是从设计开始的:设计 激光切割 折弯 焊接/铆焊。下面通过几个事例来说明新工艺的特点。

1)传统的工艺下,该工件由几部分组成。现在,一次切割 折弯就完成了。达到了减少工序,缩短工期,降低成本的目的

2)传统的工艺下,为焊接配置专用夹具。现在部件间使用类似木工榫的工艺,定位准,省时,焊接夹具简单,产品变形小。达到了缩短工期,降低成本,提高质量的目的。

3)多重折弯工艺在国内的箱体制造业已经比较普及。好处是省掉了传统的加强筋。它有其设计与工艺上独特的地方。从而达到产品质量高,制造成本低的目的。在实际工艺下,还需配合点焊。

4)利用激光的切缝细,精度高的特点,一次切割(带微连接),配合四次折弯,完成四个工件。突破了传统工艺下的设计思想,达到了缩短工期,降低成本的目的。

5)由于使用了榫结构,工件折弯后配合点焊工艺,就可完成整个流程。工件变形小,喷涂前无需整形,打磨。

由于新工艺流程的特点,先进的钣金设备软件支持与设计,激光切割工艺,折弯工艺。其支持二维零件设计,管材类零件设计,折弯工件设计(仅支持百超的折弯机),三维图形展开。并通过标准计算机网络将数控程序传输到指定的机器上。

Conventional sheet metal fabrication processes include shear punching bending welding process or flame plasma cutting bending welding process. In the face of many varieties, small batch, customized, high quality, short delivery time orders, it shows obvious lack of adjustment. Laser cutting technology, as an alternative technology of shear and impact, has the characteristics of flexibility and flexibility. At the same time, most people also think its cost is high.  It is often used in the manufacture of special-shaped (or complex) workpieces and samples (single or small batch). But when small batch manufacturing is becoming more and more popular, the demand for laser cutting is also increasing.

When the new sheet metal processing technology is re examined: laser cutting, bending, welding / riveting welding, because of the high flexibility and precision of laser cutting and the maturity and popularization of the 3D design technology, users can benefit from the new design and new process, thus reducing the cost and shortening the requirements of the time limit. Therefore, the new sheet metal process starts with design: laser cutting, bending, welding, and riveting.  The following examples illustrate the characteristics of the new process.

1) under traditional technology, the workpiece consists of several parts. Now, a cutting and bending is done. The purpose of reducing process, shortening construction period and reducing cost is achieved.

2) under traditional technology, special fixture is set up for welding. Now, similar to woodworking tenon technology is used in parts, positioning accuracy, time saving, welding fixture is simple, product deformation is small. The purpose of shortening the construction period, reducing the cost and improving the quality is achieved.

3) multiple bending technology has been popularized in the domestic box manufacturing industry. The advantage is to save the traditional reinforcement. It has its unique design and process. The aim is to achieve high product quality and low manufacturing cost. In the actual process, it is necessary to cooperate with spot welding.

4) make use of the characteristics of laser slit and high accuracy, one cut (with micro connection) and four bending to finish four workpiece. It breaks through the design thought under the traditional technology, and achieves the purpose of shortening the construction period and reducing the cost.

5) since the tenon structure is used, the whole process can be completed after the workpiece is bent and matched with the spot welding process. The workpiece has small deformation and no need for shaping and polishing before spraying.

Due to the characteristics of the new process, advanced sheet metal equipment software support and design, laser cutting technology, bending technology. It supports two dimensional parts design, pipe parts design, bending workpiece design (only supporting 100 hundred bending machine), three-dimensional graphics development. The NC program is transmitted to the designated machine through the standard computer network.



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