Different metal materials have different process differences in sheet metal manufacturers.
Taking aluminum as an example, the process standards for aluminum sheet metal fabrication involve multiple aspects. Here, Mulan Group introduces them in detail as follows, including process standards, process operation deviation rate and deviation rate control methods:
1. Material standards
Material selection: Aluminum sheet metal fabrication
The material is usually based on 3003 aluminum alloy, and the material hardness is preferably T5.
Material thickness: The material thickness error should be strictly controlled to ensure processing accuracy and product quality.
Material surface: The material surface must not have scratches, oil stains and other quality problems, and keep it clean and flat.
2. Dimension tolerance standards
Length and width:
When the length and width are ≤2000mm, the allowable deviation is ±1.0mm.
When the length and width are >2000mm, the allowable deviation is ±1.5mm.
Diagonal difference:
When the length of the aluminum veneer is ≤2000mm, the allowable deviation of the diagonal difference is ±2.0mm.
When the length of the aluminum veneer is >2000mm, the allowable deviation of the diagonal difference is ±3.0mm.
Folding angle: The allowable deviation of the folding angle should be ≤1°.
3. Flatness standard
Original plate flatness: The allowable value of unevenness varies according to the width and brand of the plate. For example, for aluminum plates of brands such as 1100 and 3003, when the plate width is ≤1800mm, the allowable value of unevenness is ≤3mm; when the plate width is >1800mm, the allowable value of unevenness is ≤5mm.
Product flatness: The allowable deviation of the plate surface straightness is ≤1.5mm/m.
4. Surface quality standard
Appearance: The surface of aluminum sheet metal fabrication should be flat and smooth, with uniform color, and should not have quality problems such as dents, bubbles, and cracks.
Scratches and abrasions: The depth of scratches and abrasions shall not be greater than the thickness of the surface treatment layer, the total length of scratches shall be ≤80mm, the total area of abrasions shall be ≤240mm², and the total number of scratches and abrasions shall be ≤3.
Cleanliness: The surface of aluminum sheet metal fabrication should be kept clean and free of impurities such as oil, dust, etc.
V. Welding quality standards
Appearance of welds: The welds should be free of burrs, pits, and stickiness, and the welds should be smooth and flat without edges and corners after grinding.
Welding quality: The non-destructive coating at the welding point should be intact to ensure that the welding quality of the sheet meets the regulations. At the same time, the welding temperature group should meet the temperature requirements of the welding material, and the current should be appropriate.
VI. Performance standards
Strength: Aluminum veneer sheet metal parts should have reliable strength, including tensile strength and bending strength, to meet the use requirements.
Anti-corrosion performance: After the aluminum veneer sheet metal is completed, anti-corrosion treatment should be carried out, such as spraying or anodizing, to enhance its corrosion resistance.
VII. Other requirements
Identification: Aluminum sheet metal fabrication should have clear identification, including product number, production date, manufacturer information, etc., for easy traceability and management.
Packaging: Aluminum veneer sheet metal should take appropriate protective measures when packaging to avoid damage during transportation and storage.
In summary, the quality standards for aluminum veneer sheet metal processing cover requirements for materials, dimensional tolerances, flatness, surface quality, welding quality, performance and other aspects. These standards ensure the quality and reliability of aluminum veneer sheet metal products and meet the needs of customers.
What is the deviation rate of aluminum veneer bending?
The deviation rate of aluminum veneer bending does not have a fixed value. It is affected by many factors, including the thickness of the aluminum plate, material, bending angle, mold accuracy, process parameters, etc. The following is some analysis of the deviation rate of aluminum veneer bending:
1. Influencing factors
Aluminum plate thickness:
The thinner aluminum plate has a relatively small positive and negative difference during bending due to the limitations of its production process and material characteristics.
Thicker aluminum plates, such as 6mm, 8mm and other specifications, are more likely to deviate during bending due to their own weight and thickness.
Material:
Aluminum plates of different materials have different rebound performance and plastic deformation ability during bending, which affects the bending accuracy.
Bending angle:
The larger the bending angle, the larger the deformation zone and the larger the rebound value, which affects the bending accuracy.
Mold accuracy:
The higher the precision of mold manufacturing, the more accurate the assembly, and the higher the dimensional accuracy of the workpiece obtained.
Process parameters:
Including bending pressure, bending speed, gap between upper and lower molds, etc., the setting of these parameters needs to be tested and adjusted many times to achieve the best bending effect.
2. Deviation rate range
Although it is impossible to give a specific deviation rate value, in general, the deviation rate of aluminum veneer bending can be controlled within a certain range. This range usually depends on the combined effect of the above-mentioned influencing factors. In actual production, the deviation rate can be reduced by optimizing process parameters, improving mold accuracy, and strengthening quality inspection.
3. Control measures
Optimize process parameters:
According to the material and thickness of the aluminum plate, reasonably set the process parameters of the bending machine, such as pressure, speed, etc.
Improve mold accuracy:
Select high-precision molds and perform regular maintenance and maintenance to ensure the accuracy and stability of the molds.
Strengthen quality inspection:
During and after the bending process, strictly inspect the quality of the aluminum veneer to promptly discover and deal with deviation problems.
Adopt advanced equipment and technology:
Introduce advanced bending equipment and detection technology to improve production efficiency and product quality.
In summary, the deviation rate of aluminum veneer bending (bending) is a complex problem affected by many factors. In actual production, it is necessary to reduce the deviation rate by optimizing process parameters, improving mold accuracy, strengthening quality inspection and other measures to ensure that product quality and accuracy meet design requirements.
How to control the deviation rate of aluminum veneer bending
Controlling the deviation rate of aluminum veneer bending (bending) needs to start from multiple aspects. The following are some key measures:
1. Control in the design stage
Accuracy of design drawings:
Before bending aluminum veneers, you must have an accurate design drawing. The drawing should clearly mark the bending angle, position, size, material, thickness and other key information of the plate.
Designers need to work closely with engineers to ensure that the design meets both aesthetic requirements and structural mechanics principles.
Consider the rebound factor:
During the design process, special attention should be paid to the strength and stability of the aluminum veneer after bending to avoid increased bending difficulty or angle error caused by improper design.
Taking into account the impact of rebound, a certain amount of rebound compensation should be reserved during design to ensure that the angle after bending meets the design requirements.
2. Material selection and preparation
High-quality materials:
High-quality aluminum alloy materials that meet national standards should be selected, and their hardness, toughness, corrosion resistance and other indicators must meet the standards.
Commonly used aluminum sheet series include 1 series, 3 series, and 5 series. These series of aluminum sheets have moderate hardness and are easy to bend.
Material thickness uniformity:
The thickness uniformity of the material has a great influence on the bending accuracy. Uneven thickness will lead to inconsistent springback, which will affect the accuracy of the bending angle.
Therefore, when purchasing materials, the material thickness should be ensured to be uniform, and the thickness should be tested before processing.
3. Equipment and process control
High-precision bending equipment:
CNC bending machines or hydraulic bending machines with high precision and good stability should be selected. These equipment can automatically complete the bending process according to preset parameters, effectively reducing human errors.
When choosing a bending machine, the matching of its mold should also be considered. The appropriate mold can control the bending radius of the aluminum plate bending, so as to meet the design requirements.
Accurately set the process parameters:
Before bending, the technical parameters of the bending machine, including the gap between the upper and lower molds, bending pressure, bending speed, etc., need to be accurately set according to the material, thickness and bending angle of the aluminum veneer.
The setting of parameters requires multiple tests and adjustments to achieve the best bending effect.
Positioning and adjustment:
Precise positioning of aluminum veneers on the bending machine is an important step to ensure accurate angles. Tools such as laser locators or rulers can be used to ensure that the bending line of the sheet is accurately aligned with the mold.
During the bending process, the operator needs to closely observe the bending of the sheet and adjust the parameters of the bending machine or the position of the sheet in time.
IV. Inspection and post-processing
First piece inspection:
Before bending each batch of aluminum veneers, the first piece inspection should be carried out. By measuring the bending angle and checking the surface quality of the sheet, verify whether the bending process meets the design requirements.
If problems are found, the process parameters or molds should be adjusted in time to avoid the same problems in subsequent batches.
Comprehensive inspection:
After the bending is completed, the finished product needs to be fully inspected. In addition to checking the bending angle, attention should also be paid to the flatness, surface quality, dimensional accuracy and other aspects of the sheet.
For unqualified products, rework or scrapping should be carried out in time.
Post-processing:
After bending, aluminum veneer needs to be post-processed, such as trimming and grinding, to further improve product quality and precision.
Trimming can remove burrs and sharp angles generated during the bending process, making the surface smoother; grinding can remove scratches and flaws on the surface of the plate, improving the appearance and corrosion resistance.
Therefore, controlling the deviation rate of aluminum veneer bending requires starting from multiple aspects such as design, material selection, equipment and process control, inspection and post-processing. By taking a series of effective measures, the accuracy and product quality of aluminum veneer bending can be significantly improved.
Here is our custom aluminum metal parts Display：
