rapid sheet metal prototyping is highly efficient with minimal material loss to zero|www.easoar-s
rapid sheet metal prototyping is highly efficient with minimal material loss to zero|www.easoar-soon.com
Through cutting, pressing, shearing, punching and other conversion operations, the continuous metal sheet is cut into a blank or sheet suitable for the forming of parts.
Modern conversion and cutting technology is a fast, efficient, flexible and cost-effective method.
Figure 1. ruler tangent with single piece punch and stack selection.
Cut and cut.
Fixed size cutting, trimming, blanking, more suitable for cutting metal pieces.
On-line shears are integrated into sheet production lines to convert coils to specific lengths.
Pruning or sizing lines typically consist of coil loading trucks, levelers or straightening rollers, uncoiling machines (used to feed coils), skinning machines, and stacker machines used to arrange cut sheet metal into neat stacks.
Scissors, or shears, have two blades and cut metal with a gate knife or scissors.
Many stores are equipped with shears that manually load and cut sheets for special treatment.
If a narrower width is required, a shear press can be used to cut again.
In the manufacture of some parts, the sheet metal must be converted or cut before forming.
If the coil is made of sheet metal or strip, it does not need to be covered.
A blank of sheet metal and coils of other rolls cut into slices or trimmed to make them easier to carry and place in molding equipment.
Punch presses and stamping systems are commonly used in foil, foil laminates, paper, plastic films, fabrics and foams.
However, replacing additional shears with cutters and cutters is faster and more economical for narrower widths and for high volume production.
A paper cutter is a corner cutter that can easily cut a roll of sheet into a narrow width by wrapping or tangential rotary cutting.
Two rotary slitting rollers with rib slots.
Special roller can be used for perforation, which can not be completely cut off.
The cutter usually has an uncoiling device for a wider feed reel and a rewinding machine for a narrow material reel.
Figure 2. Slitting knife of metal strip slitting machine.
Data source: Metal die casting system.
Stamping, stamping and blanking
Materials can also have programmable combinations of slits and shear lines such as custom product Rollform from customer product Rollform.
ARKU manufactures fixed size or coil processing lines with integral presses, stacker robots, pruning and flattening rollers.
Squares, rectangles, trapezoids, or triangles are pieces that are converted from the coil by the cutting machine and the fixed length cutting line, so that these processes are actually close to the net shape.
In practice, coil processing lines usually have trim or trim shear functions to remove damaged metal plates or deformed outer edges, thereby reducing material loss.
Sheet metal forming begins with the need for a round, more complex two-dimensional blank, resulting in additional material loss, a process that does not conform to true net shape.
Although rectangular blanks are the ideal starting point for many box-like sheet metal processes (such as square shells, grooves, or trays), circular blanks are still needed to make them cylindrical, such as beer or soda cans.
When assembling fasteners, circular openings, square holes, rectangular slots and other openings are required.
When metal discs are blanked or cut, bone and bone waste are produced, so this efficient processing method is not mesh technology.
When cutting or drilling, loss of material will occur in the form of clogging.
A punch is a machine that uses blanking and punching operations to produce complex 2D shapes such as billets, punches, and plates.
Figure 3. Four column blanking and roller press for aluminum sheet production.
Finishing blanking is a special high-precision deformation that causes the metal to shear smoothly across the entire thickness of the material.
This process enables the production of finished parts without the need for secondary edge finishing operations.
The punch uses a matching set of dies and punches to cut shapes or cut plugs to form holes.
This machine drives the punch through the sheet into the matching mold, which falls into the bin, gas cylinder or transport plane.
Drop and punch operations usually require finishing or other auxiliary operations to remove sharp edges, burrs, or other rough features.
Flexible cutting technology.
In addition to cutting or blanking, the punch can also have molding capability.
In mass production, metal plate coil can pull out parts directly from the other side, plug, plug, frame directly into the punch machine.
FIG. 4. Example of sheet metal blank plasma, laser and water knife cutting.
Flexible equipment can be used (such as water jet sharpener, plasma cutting equipment and laser cutting machine) to cut and form the initial blank.
Even CNC milling machines can be used to cut soft metal plate alloys such as aluminum.
Typically, plasma cutters introduce more heat, produce a larger slit (cut width), and more melting at the bottom of the edge.
However, advanced plasma cutting techniques have reduced or eliminated these disadvantages.
Less cutting heat input, small cut, small slag.
Similar to electric spark cutting machine (EDM) cutting, water cutting without heat input, thin incision, smooth edge.
CNC milling machines may have less heat input, but larger clearances, and rotating bits can quickly blunt on hard metals.
In mass production, through improving productivity, can make the die, punch quickly recover higher die costs.
Another advantage of the punch press is that it can cut metal plates and make finished products.
For example, a narrow coil is fed into a progressive molding press and multiple cutting and shaping operations are performed in successive phases or cycles of the part manufacturing process.
Thermotherapy manufacturing plasma, laser and water jet cutting equipment provide accurate comparisons for manufacturing engineers to evaluate production systems.
Such equipment typically includes XY tables, where thermal technology (e.g., laser, plasma) or mechanical technology (e.g., jet, router planer) cuts two-dimensional shapes on paper.
These cutting operations are more flexible than stamping or stamping because expensive hard tools (e.g., punches and dies) are not required.
XY or gantry table cutting process, very suitable for construction, shipbuilding, prototype workshop of small batch production.
These industrial 2D cutting systems will become increasingly popular as billet sizes increase and product customization becomes more prevalent.
Wire cutting machines can also be used to cut small prototype blanks from sheet metal.
Progressive die punching machine can be a series of blanking, stamping die and forming parts processing.
Sheet metal processing is highly efficient with minimal material loss.
The machines used for product conversion can be large and require a large capital investment.
Smaller manual or CNC machines, such as shears, ironworkers and XY cutting tables, may be more cost-effective for stores.
However, large-scale, high-speed production versions can be very expensive.
In most cases, parts made of conversion metal plates or metal blanks are actually pure shape and are fragmentary or zero scrap.
After the metal plate, strip or plate is cut into a blank or sheet, the forming process of the part can begin.
New manufacturing processes, such as additive manufacturing, are attractive because of their high flexibility and minimal waste.
Sheet metal based products are the original additive manufacturing process in which multiple plates are welded or brazed with a skeleton similar to the supporting material.