At present, with the increasing number of orders and customized products for diversified needs in the market, the number of cabs and assemblies of OEMs with multiple varieties and small batches has also increased. For a multi-variety, small-batch order plan, how can the production workshop quickly complete the trial production of the product and deliver it to the OEM? The application of sheet metal technology in the production workshop is particularly important, especially the use of turret punching processing methods, which shortens the product delivery cycle and reduces processing costs, which can meet the needs of OEMs in time.
Parts with regular contours and complex inner cavity contours
In the tractor cab and assembly parts, there are often parts with regular contours and many holes in the inner cavity contour. At first, when planning the sheet metal process, it was considered to use the plane laser cutting process for production and processing. The use of the plane laser cutting process, which is a flexible processing process itself, is no problem. However, as the load of the plane laser cutting machine becomes more and more full, the plane laser cutting It will become a bottleneck process. Considering that our turret punching equipment currently has a surplus in production capacity, we started to optimize whether the parts processed by the flat laser can be transferred to other processes for sorting.
Through the efficiency and cost calculation of the processing procedure, it is found that the parts with regular contours, complex inner cavity contours or porous parts are processed by plane laser. Obviously, the preparation of the sheet metal process is not optimal, and the processing cost is high; instead, the cutting machine is used to cut the material. , And then use the turret to punch the inner cavity contour, this combination processing efficiency is very high, and the cost is also low. At present, the parts with regular appearance and complicated inner cavity contour choose the combination of cutting and turret punching. The efficiency is very high, and the flexibility is also very high, which can meet the needs of the production plan.
To cite a very successful case, a part on the cab has a regular contour and a large size. After cutting the material, the CNC punch is used to punch the inner contour, and the material preparation is used to cut the material. The processing time for each piece is about 10s. Using plane laser cutting, the processing time for each piece is about 72s. The use of plane laser cutting has the consumption of auxiliary materials. At the same time, the daily maintenance cost is much higher than the daily maintenance cost of ordinary shears. Through comparison, it is found that this kind of parts adopts preparation and blanking. The combined processing technology of the turret punch has high production efficiency and low production cost.
Multi-variety parts produced from general-purpose parts blanks
With the diversified market demand orders and more and more customized products, cars with the same horsepower model have many different configurations, resulting in multiple models with the same horsepower. For many models in the cab and assembly, only the inner cavity contour size is different, and the contours are the same. Such small batches and multi-variety parts cannot be produced on the punching machine. At present, most of the stamping processes are mass production, which has very high efficiency and low cost. For such small-batch, multi-variety parts, currently only the production method of flat laser processing can be used. The production efficiency is very low and the processing cost is high. Customers will not pay for this, and only pay for the cost of stamping processing. The excessive cost can only be amortized within the company.
Through process research, sort out similar parts, classify the processing content in the parts, and determine the basic parts, as shown in Figure 4. The production method of stamping technology is adopted, and then the other inner contours required by each model are processed by turret punching. At present, similar parts of many models of this kind of parts are produced by universal parts, which improves production efficiency and reduces production costs.
Dense mesh board parts
In the trial production of dense mesh plate parts, the plane laser cutting process is adopted, which can be delivered quickly, but the output exceeds 20 units, which will seriously affect the production efficiency. For example, for our guard board parts, at first, because we couldn’t purchase suitable mesh panels, we used plane laser cutting to ensure the delivery node. The use of flat laser processing takes 30 minutes for each piece. With the continuous increase in the number of orders for each batch, it has seriously affected the trial production progress of other new products.
Finally, through customizing the turret punching mold, the plane laser cutting shape is used, and the turret punching process is used to process the dense internal holes. After adopting the new combination process, it is estimated that the plane laser cutting the shape and contour takes 1 minute, and the actual processing needs of the turret punching 183 holes 2 minutes, each processing only needs 3 minutes. In the future, this kind of similar parts with complex contours and dense inner cavity holes will use the combination of planar laser + turret punching, which more effectively utilizes the advantages of each machine tool, resulting in higher production efficiency and lower cost.