The influence of stamping process selection on automobile manufacturing cost

1. The impact of stamping process selection on manufacturing cost The rationality of stamping process directly affects the manufacturing cost of stamping parts, and the economic performance reflects the advantages and disadvantages of the stamping process plan. In the rational choice of stamping process, domestic mold companies have accumulated a lot of experience, and there are many measures that can be used to achieve cost control. 1. Reasonably design the stamping process. Design the stamping process reasonably to achieve the best structure and the least process. For example, the right side mold of a certain model of our company has 5 processes (not including blanking die), and a total of 10 molds. For the two models developed, the left and right side molds have only 4 processes (not including blanking molds), and a total of 8 molds. After rationally splitting the stamping process, the development cost of the two molds was reduced. In terms of production, after reducing two sets of molds, the production efficiency is greatly improved, and the result is twice the result with half the effort. 2. Using joint installation The operation method of joint installation is to complete two or more process contents in the same mold. For example, the most representative fuel filler box of a certain car model of our company is to use joint installation Way to achieve it. There are a total of 5 molds for the fuel filler box in a certain model. If it is connected to production, it will take up 5 machine tools to meet its requirements. In order to improve production efficiency and reduce the occupation of the machine tool, the last three molds are assembled in a joint installation method, which is assembled on the same mold, as shown in Figure 1. In this way, there are only 3 molds for the fuel filler box in a certain model. After the merged one pair of molds, each completed punch is equivalent to the original three molds, which effectively improves the production efficiency and reduces the pressure on the machine tool. At the same time, three sets of molds are combined on one set of molds, and the use of molds is reduced accordingly, achieving the purpose of reducing quality and reducing costs. The joint installation method is generally used for medium and small stamping parts. It is not recommended to use parts with high surface quality requirements such as large parts and outer plate parts. How to effectively control the cost of mold development and manufacturing in automobile stamping? Figure 2 A drawing die with a scrap cutter on the outer panel of the right front door of a certain car model. 3. The process plan for installing a scrap cutter on the drawing die. Reducing the stamping process is an important way to control stamping costs. There are many ways to reduce the process, and installing a scrap cutter on the drawing die is one of them. Some workpieces have complex shapes, large gaps, and difficult forming. If they are formed directly from a whole sheet, it may be more difficult. If the blanking mold is developed, it will not only increase the investment in the mold, but also increase the process, which is not suitable from an economic point of view. In the process design, you can consider cutting corners on the drawing waste, which can ensure the drawing forming, reduce a pair of molds, and improve economy. This method is often used on the drawing dies for the inner and outer panels of automobile stamping parts. The drawing die with scrap cutter on the outer panel of the right front door of a certain model is shown in Figure 2. 4. Try to realize the common mode production of the left and right parts. The common mode production of the left and right parts is not only more conducive to material forming, but also more important than single-piece production. In the beginning, the left and right fenders of a certain model of our company were only selected from the formability and did not fully consider the cost control factors. The left and right parts were stretched and formed separately, and the material utilization rate was 26.8%. The left and right parts were used together. Die stretching, the material utilization rate reaches 33.5%, which is 6.7% higher than that. Each piece produced (left or right) consumes 2.8kg less material, and 5 sets of molds are less developed, which reduces the number of processes and equipment and personnel. Occupation and resource consumption. From the perspective of cost control, the pros and cons of the two solutions are more obvious. When we developed the CE project, the fenders and door outer panels used the common mode production method of left and right parts. Through the above comparative analysis, it is known that the left and right parts should be produced in common mode as much as possible. In actual production, there are many parts that can be produced by common mode of left and right parts. Previous post: No more