Analysis of some metal blanking processes

This provision sets out the operating rules and precautions that must be followed during the company’s blanking process.
This procedure applies to all of our blank manufacturing processes.

  1. Reference standard
    YB / JQ101.10 General technical requirements
    3 Contents of process specifications
    3.1 Preparation before processing (general)
    3.1.1 Staff Preparation: The operator must hold a certificate and the skill level must meet the work requirements.
    3.1.2 Security preparation: Wear protective clothing, protective shoes, safety helmets, protective gloves, protective goggles and other protective equipment as needed, tighten cuffs, ban smokers and maintain good mental condition. Check the braking performance of the carrier to see if the spreader meets the process requirements and their integrity.
    3.1.3 Preparing the installation site: Clean the rangefinder, workbench, and area within 2 meters. Install the necessary equipment and place the parts in the storage area to ensure the flow of goods.
    3.1.4 Equipment preparation Check if the device is healthy according to the device’s TPM checklist. If any abnormality is found, contact the person in charge of equipment maintenance and handle it in a timely manner. Before starting the equipment, the motors, switches, wiring and grounding should be carefully inspected to ensure that the operating parts and buttons of the equipment are in the correct position.
  2. Cutting blanking
    3.2.1 CNC plasma cutting machine blanking PTJ CNC plasma cutting machine The first inspection shall be performed to verify the accuracy of the cutting procedure, cutting template and cutting method, sampling and final inspection. Create inspection records without batching inconsistent products. Prior to cutting, lay the base metal for cutting flat, place it and fix the base metal if necessary. Select the torch according to the thickness of the plate and use a square torch to make sure the torch is perpendicular to the workpiece and get a clean vertical cut. According to the thickness of the cutting plate, the ignition test sets the torch process parameters and ensures that the material is sprayed from the bottom of the workpiece and can be cut after passing the inspection. See Table 1 for Nozzle Selection and Cutting Process Parameters for CNC Plasma Cutting Machines. Prior to formal cutting, water must be drained to ensure that the water level in the water tank is 75-100 mm above the surface of the cutting board. When laser cutting from the edge of a workpiece, place the torch directly above the workpiece joint / cutting line to drill the torch, unless perforation is required. During the cutting operation, it must be installed in an appropriate place, anomalies are found, and inspection must be in time. After confirming that the cutting part has cooled, you can touch the work directly. Unless instructed, it is not permissible to cool the workpiece by water cooling, air cooling and other rapid methods. After cutting the blank, remove slag and burrs from the cutting edge. After blanking, the workpieces should be neatly placed and marked to avoid loss and confusion. After each shift, return the water in the water tank to its original position and clean the slag on the work platform of the water tank to keep the work surface clean.

3.2.2 CNC frame cutting machine blanking The first inspection must be performed to verify the accuracy of the cutting procedure, cutting template and cutting method, sampling and final inspection. Avoid batches of ineligible items and create inspection records. Our CNC frame cutting machine uses oxypropylene cutting. Keep the following in mind when using oxygen-propane cutting: Propane cylinders must be placed in a well-ventilated area. Do not place in basements, quasi-basements, or poorly ventilated areas. It prevents gas from leaking to lowlands and may cause a fire. Immediately before the propane cylinder is used up, there is residual gas in the cylinder, which facilitates checking the gas sample before filling and prevents other gas from entering the bottle. When the cylinder is igniting, the valve should be closed immediately. If inaccessible, inject a large amount of cold water to cool the bottle, then close the valve on the bottle to shut off the gas source and extinguish the flame to prevent the bottle from catching fire. If the cylinder valve leak cannot be stopped, the bottle must be moved to an outdoor safety zone to allow the gas to escape until the bottle is depleted of gas. Before cutting, it is necessary to flatten the base metal for cutting and fix the base metal if necessary. Select the cutting nozzle according to the thickness of the plate. Before using the cutting nozzle, the tapered surface should be inspected for damage to prevent air leaks. If the cutting hole is clogged with debris or debris, use a needle or wire brush to remove the hole. Cutting process parameters are set according to the thickness of the cutting plate. Cutting can only be done after passing the ignition test. See Table 2 for CNC torch selection and cutting process parameters (if the requirements in the propane series nozzle instruction manual differ from the reference data in Table 2, the manual requirements take precedence).

3.2.3 Gas cutting Manual cutting Blanking The first inspection shall be performed to verify the accuracy of the cutting procedure, cutting template and cutting method, sampling and final inspection. Avoid batches of ineligible items and create inspection records. Oxygen-Use acetylene cleavage. Attach the torch to the fixed hose connector before disconnecting. Make sure that the oximeter and acetylene safety tank are working properly and that the torch has a good firing power. When using an oxygen cylinder, keep the oxygen cylinder stable, clean the dust at the interface, and install an oxygen meter. If the pressure inside the bottle is lower than the working pressure, it needs to be replaced. Moving gas cylinders avoid shocks and injecting oil is strictly prohibited. When using an acetylene generator, the acetylene generator must be 10 meters from the source, 3 meters from the oxygen cylinder, 1 meter from the heating equipment and should not be placed under a sidewalk or high voltage line. .. Maintain sufficient clean water in the acetylene generator to maintain a constant water level in the water seal and temper arrester. The amount of calcium carbide added to the acetylene generator is once specified and the degree of calcium carbide should generally meet the requirement of 50-80 mm. Inspect the workpiece according to the drawing. Generally, the thickness of the steel sheet is less than 14 mm, the unevenness of the steel sheet is 2/1000, and the unevenness of the steel sheet of 14 mm or more is 1/1000 (the process card needs to dominate the process card). Manage the work area, flatten the work piece, leave a gap of 100 mm or more under the plate, and remove rust, oil, etc. within 30-50 mm on both sides of the work piece slice. Select the cutting torch according to the thickness of the steel plate and adjust the cutting process parameters according to the regulations

3.2.4 Profile cutting machine cutting blanking PTJ cutting profile cutting machine
3.2.4 Profile cutting machine Cutting blanking Sample preparation The test material is a low carbon steel sheet, the thickness is 4 mm or more in order to obtain sufficient magnetic attraction, and the thickness of the thick plate sample is 6 mm. Sample plates will be created in the workshop depending on the shape and size of the part. Model Manufacturing Dimension Calculation: Since the magnetic roller and the center line of the cutting nozzle are mounted on the same vertical axis, the magnetic roller moves with respect to the template and the torch is driven to form a similar workpiece. do. Therefore, the template size is not the same as the required work size. It has a constant relationship with the radius of the magnetic roller and the radius of the slit of the selected cutting nozzle. The formula is:
Radius of workpiece with 1 sample outer diameter Workpiece size-(Magnetic roller radius-Slit radius)
2 Inner envelope work model size radius = work size radius + (magnetic roller radius-slit radius) magnetic roller diameter = φ10 mm
Cutting torch number 1 2 3
Slot width 2mm 2.6mm 3.2mm
Note: Tip width is for reference only Cutting work: Our factory profile cutting machine is equipped with four valves: acetylene valve, preheated oxygen valve, cutting valve and automatic control valve.
The operation is as follows:

  1. Open the automatic control valve → rotate the acetylene valve 1/4 to 1/2 turn → ignite → open the preheated oxygen valve to adjust the flame, preheat the steel plate → open the cutting oxygen valve → start cutting (flame If you need to readjust the changes) → You need to adjust the movement speed.
  2. Completion of cutting → Close the oxygen valve for cutting → Close the acetylene valve → Close the oxygen valve for preheating → Turn off the power and stop. Remove slag and burrs after cutting the part.

3.3 Sewing blanking
3.3.1 Make sure that the machine oil tank has enough hydraulic oil (oil performance is 30 # normal hydraulic oil or better).
3.3.2 Make sure that the coolant tank is filled with sufficient high performance coolant, but do not exceed the middle position of the coolant tank oil standard and check if the discharged coolant is stable.
3.3.3 Adjust the pressure of the hydraulic system. Under normal circumstances a hydraulic pressure of 1.4Mpa is sufficient (existing GB4040 / 60H band saw oil pressure should not exceed 2.5Mpa).
3.3.4 Select the number of saw blade teeth, feed rate, and linear velocity according to the material of the work material to be sewn.
Under normal conditions, the linear velocity of the band saw blade should not exceed 59 m / min. For harder materials, adjust the speed accordingly. See Table 5 (Our existing GB4040 / 60H band saw, standard band saw size 4800 x 34 x 1.1 mm)
3.3.5 Install the saw blade. Do not install the blade. The saw blade teeth (blade edge) must hit the rear wheel box. Check the tension of the saw blade using a torque wrench. First loosen the tensioned saw blade and use a torque wrench (torque adjustment up to 25 N.m) to tighten the saw blade to the top of the front wheel box (above the screw handle). When you hear the tension, the grid grid grid grid on the wrench indicates that the saw blade is properly tensioned.
3.3.7 Make sure the stop button is sensitive and reliable.
3.3.8 Lower the saw blade to the lowest position and then raise it to the highest position, perform a few empty return strokes and observe if the sound is safe and normal when the machine is idle.
3.3.9 Adjust the position of the left arm according to the width (or diameter) of the work. The distance between the left and right guide arms is only slightly larger than the size of the workpiece to be cut.
3.3.10 Adjust the width of the clamp vise according to the width of the workpiece. Under normal circumstances, as long as the material of the workpiece is slightly larger, it should be cut between 10 and 25 mm.
3.3.11 Feed according to process requirements, adjust and fix fixed length baffles and clamp material with vise. The substrate must rely on a solid baffle during the sewing process. The first inspection should be done carefully to ensure that the length is accurate. Random inspection of process, final inspection inspection record to prevent production batch from starting with defective product
3.3.12 If the machine tool is abnormal between sewing machines, the operator must immediately press the stop button SB1.
3.3.13 Sawdust from the rear wheel box should be removed frequently when sewing. If sawdust rolls between the saw blade and the spool, the saw blade is easily damaged.

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