Longsheng

ケース：新しいエネルギー車両バッテリーパックブラケットブラケット曲げエンジニアリング。

challenge： complex multi-directional bending シリーズのアルミニウム（1.5 mm厚）は、緊張を必要としています。 ≥150mpa。

jsスキーム：

• アニーリングと老化を通じて材料特性を最適化します。
• r = 3mm精度の曲げを達成するためのカスタム非対称ダイ
• セグメント化された曲げプロセスを採用（最終的な曲げ前に90°で予測）。
• 結果：収率は72％から96％に増加し、生産サイクルは40％減少しました。

レーザー切断における金属金属の精度を制御する方法

ダイナミックフォーカスシステムを備えた国際的にリードするレーザー切断機器（IPGファイバーレーザーなど）を採用して、標準型の標準的な標準的な標準的な標準の標準的な標準の標準的な標準的な標準的な標準的な標準的なエドルを確実にするために、動的なフォーカスシステムと自動焦点焦点を備えた機能を採用しています。 複雑な形状を満たすためのリンケージ制御のサポートおよび不規則なプレート処理のニーズ。

2.intelligentソフトウェア支援

• CAD/CAM統合システムは、切断経路を最適化し、熱変形の効果を減らすために使用されます。
• JS Companyは、エンジニアリングチームが専門ソフトウェアを使用してスチールプレートの応力分布を分析し、事前に切断パラメーターを調整して変形を補償することを強調しました。

1.マッチングレーザーパワーと速度

• レーザー出力の動的調整、切断速度、補助ガス圧力（例：酸素、窒素など）、材料（エクセンレススチールなど）に依存する材料に依存します。厚さ。
• JSケーススタディは、の範囲で範囲0.002 mmの範囲で制御できることを示しています。材料。

JS company adopts a vacuum adsorption platform to fix sheet metal, with high precision rolling equipment for pretreatment, eliminating wavy deformation of sheet metal, ensuring that the surface of the cut is less than 0.02mm/m² of the flatness error.

2.Surface cleaning and oxide layer control

Ultrasonic cleaning is used to remove oil stains and impurities before cutting to prevent slag adhesion from affecting accuracy. For materials with high reflectivity, such as aluminum alloys, a special coating is used to reduce reflectivity.

Quality inspection and feedback mechanism

1.Online detection system

Integrated laser displacement sensor and CCD camera, real-time monitoring of cutting edge quality, automatic removal of defective products, proposed process optimization.

JS Company's Quality Control Process

• Samples from 3D contour scanner are provided to compare the deviation values between the design model and the actual cutting parts, and a detailed accuracy analysis is published (for example, an aeronautical aviation component the flatness error of only 0.003mm in the case of a customer).
• Establish a three-level quality inspection system for order repetition, including first inspection, process inspection and finished product inspection to ensure batch consistency.

Environmental and sustainable development control

The influence of ambient temperature and humidity changes on material size stability is reduced through constant temperature and humidity workshops (temperature ±2°C, humidity 40-60% RH).

My company reminds you that its green manufacturing processes, such as waste recycling system, not only reduce energy consumption, but also indirectly improve processing accuracy by reducing material waste (material utilization rate increases to over 92%).

Can carbon steel and aluminum steel metal be directly welded?

In sheet metal fabrication, the direct welding of stainless steel and aluminum plates faces great challenges, mainly due to their different physical and chemical properties:

Difficulties with direct welding

1.Formation intermetallic compounds

When stainless steel (e.g. 304, 316) comes into contact with aluminum (e.g. 1060, 5052) at high temperatures, iron reacts with aluminum to form brittle intermetallic compounds, leading to lower weld strength and even cracking.

2.Differences in thermal expansion coefficients

The thermal expansion coefficient of aluminium (about 23×10-6°C) is 1.4 times that of stainless steel (about 17×10-6°C) and is prone to deformation or cracking during welding due to thermal stress.

3.Differences in melting point and thermal conductivity

The melting point of aluminum (660 °C) is much lower than that of stainless steel (1375-1530 °C), and aluminum has a the thermal conductivity three times that of steel, which results in rapid heat loss during welding and makes it difficult to maintain the stability of the melting pool.

Feasible processes and limitations

1.Traditional arc welding (e.g. TIG/MIG)

• Feasibility: Special welding wire (e.g. ER4043 Al Si) are required and protective gases (argon+helium mixed gas) are added, but the weld strength is relatively low (only 50-70% of the base metal).
• Constraints: Porosity and slag inclusion are easily generated, and intermetallic compounds may expand during long-term use, leading to failure.

2.Brazing or diffusion welding

• Brazing: Low temperature brazing materials (e.g. Al-Si series) are used to fill gaps through capillary action, avoiding direct melting of the substrate, but joint strength is limited (usually<150MPa).
• Diffusion welding: It requires vacuum or inert gas environment to connect atoms horizontally at high temperature and pressure.

3.Recommendations for alternative solutions

If a high intensity connection is required, the following methods are recommended:

• Mechanical connection: use riveting, bolt connection or buckle structure to avoid problems in heated areas, suitable for automobile and electronic equipment housing.
• Adhesive+mechanical composite: Combine epoxy resin adhesive with spot welding to balance sealing and strength.

How to select sheet metal thickness based on the sheet metal gauge chart?

1.Clarify application scenarios and functional requirements

Determine the required sheet metal thickness range according to the load bearing requirements, usage environment and assembly method of the member. For example:

• Lightweight components (electronic case): Preference should be given to thin plates (corresponding gauges 20-24, thickness 0.5-0.8mm).
• Structural support (mechanical brace): Medium thick plates (specifications 10-14, thickness 1.0-1.6mm) are required.

2.Match material type and thickness range

The thickness of different materials varies widely, and the mechanical properties need to be selected:

3.Reference process compatibility verification thickness

To ensure that the thickness matches the process parameters for the limitations of the processing process:

4.Compare tolerance standards with cost balances

Select the optimal optimal specification according to industry standards (ISO 2768) and cost requirements:

Using the sheet metal gauge chart, can quickly locate material specifications, optimize bending radius, laser power and other technological parameters, balance strength, cost and processing feasibility. For example:

• Sheet metal (Gauges 20-24): Low cost but limited strength, suitable for decorative parts.
• Medium Plate (Gauge 12-18): Strong universality, covering 80% of industrial scenes.
• Heavy plate (Gauge ≤10): High cost for heavy equipment but outstanding bearing capacity.

How can JS assist sheet metal fabricators in quickly selecting materials?

Intelligent material database and online material selection system

1.Multi format Compatible Uploading: Supports direct uploading of industrial standard files such as STEP, IGES, STL, etc. The system can automatically match material parameters and shorten material selection cycle.

2.Material Library Real-Time Retrieval: Built on a database of more than 50 metals, composites and special plates, classified and filtered according to application scenarios to improve efficiency.

3.Parameterized recommendation function: Input sheet metal parts design parameters, artificial intelligence algorithm will recommend suitable materials and process combinations.

Senior Engineering Team provides full technical support throughout the process

1.More than 20 years industry experience endorsement: The team is familiar with sheet metal processing difficulties, can provide customized material solutions for complex projects.

2.Comparative analysis of material properties: The the formability, fatigue resistance and cost efficiency of different materials are verified by CAE simulation to reduce trial and error cost.

3.Rapid response mechanism: Consultation on material selection, timely feedback and issuance of technical white papers on complex situations within 48 hours.

Standardized material certification and Rapid Delivery System

1.Pre qualification of materials: All incoming materials have been certified by ISO, ASTM and other international standards, shortening the customer verification cycle.

2.Global Supply Chain Integration: Establish direct supply cooperation with top sheet suppliers for regular ≤24 hour material inventory turnover.

3.Green Channel for emergency orders: Special Material Requirements trigger Global Allocation System, Promise to start emergency procurement process within 72 hours.

Strategies for selecting materials for sustainable development

1.Prioritise green materials: Create a carbon footprint database and prioritise green materials such as recycled aluminium and low-carbon steel in line with EU RoHS and other environmental directives.

2.Material utilization optimization: Through the simulation of the 3D laser cutting path, the waste of angular material is reduced and the comprehensive utilization rate of materials is increased to over 92%.

Summary

In sheet metal fabrication, the choice of materials and processing technology directly affects the performance and service life of the final product. galvanized steel sheet, for example, has become one of the most widely used materials due to its advantages of rust prevention, economy and ease of processing, especially in structural components that require corrosion resistance. However, in bending sheet metal  process, special attention should be paid to the protection of zinc layer, to avoid excessive bending or improper processing resulting in coating damage, thus weakening the durability of the material. With the development of technology, modern sheet metal manufacturing is developing in the direction of high precision, lightweight and sustainable, while taking into account material properties and processing efficiency, while also meeting environmental challenges.

免責事項

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jsチーム

jsは業界をリードする会社ですカスタム製造ソリューションに焦点を当てています。 5,000人以上の顧客にサービスを提供している20年以上の経験により、高精度 cnc machining 、 3d printing 、射出成形、私たちの工場には、100を超える最先端の5軸機械加工センターが装備されており、ISO 9001：2015の認定があります。世界中の150か国以上の顧客に、高速で効率的で高品質の製造ソリューションを提供しています。少ない量の生産であろうと大量のカスタマイズであろうと、24時間以内に最速の配達でお客様のニーズを満たすことができます。 jsテクノロジーを選択してくださいそれは効率、品質、プロフェッショナリズムを選択することを意味します。 href = "https://jsrpm.com/"> jsrpm.com

FAQs

1.Is stainless steel easy to work with?

Stainless steel sheet metal processing due to its obvious hardening work, high rebound rate rate, there are some difficulties. Laser cutting stamping technology can effectively solve hardness issues.

2.How to ensure the bending consistency of irregular parts?

Numerical control programming+high-precision molds+positioning fixtures to optimize parameters and ensure consistent bending of irregular parts.

3.Will zinc fall off when galvanized steel sheet is bent? ​

During bending process, the zinc layer may fall off in part, but the risk of cracking of zinc layer can be significantly reduced by choosing the appropriate type of galvanizing, controlling bending radius and lubrication process.

4.Does sheet metal processing need to consider the malleability of materials?

It is necessary to take into account that the plate with poor ductility is prone to cracking, and appropriate process parameters should be selected according to material characteristics to reduce the risk of cracking.

Resources

Galvannealed

Stainless steel

Metal fabrication