What are the core processes included in sheet metal fabrication?
The core processes of sheet metal fabrication typically incude. blanking (laser cutting, punching, shearing; forming (bending, punching, riveting; joining (welding, bolting); and surface treatment (spray painting, electroplating, oxidation, pickling).
How to ensure the consistency of quality in mass production?
1. Standardized operations (Develop standard operating procedures and clarify process parameters).
2. Process monitoring (First-article inspection + regular sampling inspections, using statistical process control to analyze data fluctuations).
3. Automation upgrade (Introduce robotic welding and intelligent processing equipment to reduce human error).
How to control the dimensional accuracy of sheet metal parts?
The key control points include:
1. Equipment calibration (Regularly maintain equipment such as laser cutting machines and bending machines to ensure positioning accuracy).
2. Process optimization (Consider thermal deformation compensation during cutting, and calculate the spring back and adjust the die parameters during bending).
3. Inspection tools (Strictly verify the first article and random samples using tools such as calipers and coordinate measuring instruments).
What are the common welding defects and how to prevent them?
Common defects include porosity, cracks, distortion, and incomplete penetration. Preventive measures:
1. Clean the base material surface (remove oil, grease, and oxide layers).
2. Control the current/voltage to match the material thickness.
3. Use fixtures to reduce distortion, or employ a segmented welding process.
How to choose the surface treatment process?
The following factors need to be considered comprehensively:
1.Material type (Anodizing is commonly used for aluminum parts, while steel can be treated with electro-galvanizing or powder coating).
2.Product application environment (For outdoor products, weather-resistant processes should be selected; for food and medical devices, environmentally friendly and non-toxic coatings are required).
Where are the common sources of cost waste in sheet metal processing?
Main waste points and improvement directions:
1. Material waste (Optimize cutting paths through intelligent nesting software).
2. Rework waste (Strengthen design reviews to avoid conflicts between drawings and processes).
3. Energy waste (Select high-efficiency equipment to reduce power consumption).
How to avoid delays in delivery due to quality issues?
Preventive control: Conduct manufacturability analysis during the design phase to reduce modifications in later stages; perform full inspection of the first article to confirm process feasibility.
Process control: Set up quality inspection points for critical processes; use mistake-proofing tooling to reduce error rates.
How to respond when customers change their requirements at the last minute?
1. Rapid assessment mechanism: The engineering team provides feedback on the impact of the change on delivery time and cost within one hour.
2. Flexible response: Maintain design redundancy or negotiate phased delivery.
