汽车设计与维修人员培训课件汽车工艺流程

Pressshopandcut-to-length2AutomotiveProcessFlowOverview3StorageBlankingPresshopPressingSub-AssemblyPaintingBodyinWhiteBodyAssemblyProcessFlowAutomotive4开卷落料Blanking1.卷料包装层报废Scrapratioforcoil2.仓储Storagehandling3.铝合金落料线的特点BlankinglineforAluminum4.矫平Leveling5.落料线清洁维护Generalcleanlinessofblankingline51.卷料报废率Scrapratioforcoilinnerwinding(eye)卷芯outerwinding卷外圈PartInnerquality内板件25m2windingsSkinquality外板件50m2windings润滑油Lubricant:最内层和最外层卷料润滑油量存在偏差，其与外层包装塑料接触。Lubricantamountwillnotbecorrectonthefirstinnerandouterwindingbecauseitisincontactwithpackaging.卷芯印记Stepmark:卷芯处的卷头由于材料存在厚度，会在卷芯材料处印出印记，并可能影响到最内几层材料Thestepcausedbythethicknessofthestripcancreatemarksthataretransmittedfurtherinsidethecoil.外圈Outerwindings内圈Innerwindings62.仓储Storagehandling■“先进先出”原则FirstinFirstout.0.000.100.200.300.400.500.600.700571015Prestrain[%]Bendingfactor(f=ri/t)Ac170PX;12montholdAc170PX;9montholdAc170PX;6montholdAc170PX;3montholdBendingfactor=r/tThesmaller,thebetter.020406080100120140160050100150200250naturalageingtime[days]Rp0.2%[MPa]Rpmeasuredaverageaverage-3sigmaaverage+3sigmalimitTL0943months4months6months3s=13[MPa]自然时效时间包边系数预应变包边系数f=r/t越小越好。72.仓储Storagehandling■注意避免Trybesttopreventbelowrisks:水汽凝结Watercondensationorotherhumidity表面划伤Scratch灰尘或颗粒Dirtparticle破损Damage■注意点Tips：生产前再打开包装Unpackingjustbeforeproduction卷料温度与室温Coiltemperature=roomtemperaturebeforeopen不挪动没有捆扎的料垛Nohandlingwithoutbanded.Safeandnoscratch工作环境清洁Cleanworkenvironment天吊和叉车操作Craneandforklift,carefulhandling83.铝合金落料线特点BlankinglineforSteel&Aluminum铝合金落料线BlankinglineforAluminum:1.铝合金无磁性。所有的挪动和转运都采用机械手，传送带，空气传送或真空吸盘。Aluminumhavenomagnetism.Foreverytransferringoperationandalsostacking,weuseconveyorandair/vacuumdelivery.2.橡胶辊子避免划伤，油漆是与卷料表面接触强烈的动力辊等。Rubberrollerstoavoidscratchonsurface,especiallyfordrivingroller.3.钢卷矫直机与铝卷矫直机。ForSteel-Alblankingline,itneedseparatelevelersforsteelandAluminum.还有哪些不同Whatelse?94.矫平Levelinga.平度Flatnessb.矫平拉力Tensionc.矫平过程材料硬化Materialhardeningthroughleveling104.矫平Levelinga.Flatness平度a.Flatness:differentcasesofshapeissuesexist平度：典型的不平形状SurfacetosurfacelengthdifferentialEdgetoedgelengthdifferentialOutersurfaceofstriplongerthaninnersurface外外表面比内表面长CoilsetCrossbowEdgewavesCenterbuckleEdgesofstriplongerthancenterline边缘比中心长Centerlinelongerthanedges中心比边缘长11a.Flatness:howtocorrectshapeissues?如何进行形状校正Simplenon-backed-uplevelerorflattener=correctsforcoilset!无支撑辊的简单矫平机，主要用于校正卷料弯曲Coilset4.矫平Levelinga.Flatness平度12a.Howtosetentryandexitrollgaptocorrectcoilset:卷料弯曲矫正时，如何设置进口高度和出口高度StartingsettingsatNovelis:初始设置•Entrygap=“tight”(smallerthanmaterialgauge)进口高度小于板料厚度•Exitgap=closetomaterialgauge出口高度接近材料厚度Ifresidualup-turn:openslightlyexitroll如果板料上翘，微调增大出口高度Ifresidualdown-turn:closeslightlyexitroll如果板料下弯，微调减小出口高度Iflastrolloflevelerisontop,correctionisinverted如果矫平机结构为，最后一道矫平辊在上部，调整过程与之前相反4.矫平Levelinga.Flatness平度13b.Tension矫直拉力矫直拉力不能大于材料屈服强度Tensioninthestripmustn‘texcesstheyieldstrengthofthematerial.如果拉力大于材料屈服强度IftensionRp0.2:■塑性变形会降低材料在冲压焊装过程中的变形性能Plasticdeformationreducesthefurtherformabilityofthematerialatstampingandhemmingoperation■过量拉伸导致卷料中部和边缘发生不均匀的塑性变形，会产生板料波浪Riskofnonhomogeneousplasticdeformationoverthewidth=createswaviness建议矫直拉力为屈服强度的30%左右Commontensionisaround30%ofRp0.2.esRp0.2ToohightensionTotalelongationReducedelongation延伸率减小4.矫平Levelingb.Tension矫直拉力14b.Tension矫直拉力拉力过小有可能导致松卷，产生表面划伤Shouldn’tbetoolowtoavoidloosewindingsthatcancreatescratches:ToolowtensionLoosewindings=scratches!Drawalineoncoilsidetocheckifcoilgetloose在卷料侧面画线以监测是否发生松卷4.矫平Levelingb.Tension矫直拉力154.矫平Levelingc.Materialhardeningthroughleveling矫平过程材料硬化c.矫平过程带有塑性变形，会降低材料延伸率，影响材料冲压和包边时的变形性Levelinginducesplastic(permanent)deformation=canreduceelongation(formability)duringfurtherprocessinglikestampingorhemming.esRp0.2StrengthincreaseTotalelongationReducedelongation•无需过度追求板料平度，满足冲压线设备要求即可Donotaimforperfectflatnessofmaterial,justleveltotheminimumneededbystampinglinetokeepmaximumpotentialofformability•矫平前后对材料进行取样测试，了解矫平过程对材料的影响Measurestrength&elongation(tensiletest)beforeandafterlevelerforeachcoil(atleastduringthefirstmonthsofproduction)tounderstandtheeffectofleveler165.落料线清洁维护Generalcleanlinessofblankingline经常检查辊轴和传送带的清洁程度。润滑油，污渍和灰尘的堆积会在材料表面留下线性印记。脏点留在表面的印记可能在成品后依然可见Regularlycheckcleanlinessofallrollsandtransportbelts.Accumulationoflubricant,smut,dustcancreatedirtylinesonmaterial.Dirtcancreateimpressionsontheblanksthatarevisibleattheendoftheprocess.检查矫直机的清洁度：矫直辊上可能累计润滑油和污渍Regularlycheckcleanlinessoftheleveler:accumulationoflubricantandsmutcanoccurintherolls.落料模的清洁和维护Regularlychecktheconditionandcleanlinessofthecuttingtool.堆垛区域清洁，尤其是传送区域Regularlycheckthecleanlinessofthestackingarea,especiallythevacuumtransportunits.初期需要每卷进行检查，累积经验后，可制定定期检查计划Atthebeginning,checkateverycoil.Aftergainofexperience,setacheckandcleaningschedulethatmakessense.175.落料线清洁Generalcleanlinessofblankingline实例分享Casesharing18冲压Pressing1.De-stacking分张2.TribologyofStamping冲压3.Cuttingquality,similartoblankingcutting切割质量,与落料切割相似4.Generalmaintenanceandcleanliness日常维护和清洁19Ingromat™processThepatentedIngromat™micro-moisteningsystemsal