In the fields of product development, прототипирование, и низкое объем производства, precision sheet metal prototype parts forming stands out as a vital process. It can turn complex and customized sheet metal part designs into high-precision, high-quality physical prototypes. But how does this process achieve such excellent results? Let’s explore it in detail.
1. Дизайн и планирование: Заложить основу для точности
Успех precision sheet metal prototype parts forming starts with solid design and planning. This stage is like drawing a detailed map for the entire process, ensuring every subsequent step goes smoothly.
| Шаг | Конкретные операции | Core Objectives |
| 3D Моделирование | Use advanced CAD software (такие как SolidWorks, Autocad) to build a precise 3D model of the product. | Ensure the model accurately reflects the design intent, with every dimension and structure clearly defined. |
| Оптимизация дизайна | Conduct mold flow analysis and structural analysis through professional software. | Verify the производство of the design (avoiding structures that are difficult to process) and enhance the структурная сила of the prototype. |
Например, if a company wants to develop a custom sheet metal shell for a new electronic device, the design team first uses CAD software to create a 3D model of the shell. Затем, through mold flow analysis, they check whether the material can flow smoothly during the forming process. Structural analysis helps them find out if the shell can withstand the impact during daily use, thus optimizing the design in advance.
2. Выбор материала и подготовка: Choose the Right “Raw Materials”
High-quality prototypes cannot be separated from suitable materials and proper pretreatment. This stage directly affects the final quality and performance of the precision sheet metal prototype parts.
2.1 Material Selection Principles
- Match design requirements: Select high-grade metal materials according to the product’s use environment and performance needs. Например, if the prototype needs to have good corrosion resistance, нержавеющая сталь is a good choice; if lightweight is the key requirement, алюминиевый сплав is more suitable.
- Consider processability: The selected materials should be easy to cut, сгибать, weld and other subsequent processing operations to ensure the smooth progress of the forming process.
2.2 Material Pretreatment Steps
- Выслушивание: Remove burrs and sharp edges on the surface of the material to prevent scratches during processing and ensure the safety of operators.
- Уборка: Clean the material surface to remove oil, dust and other impurities, which is conducive to improving the bonding force of subsequent surface treatment.
- Поверхностная обработка (preliminary): Carry out simple surface treatment such as pickling and passivation if necessary to enhance the material’s rust resistance.
3. Обработка с ЧПУ: Achieve High Precision in Forming
CNC machining is the core link of precision sheet metal prototype parts forming, which realizes the accurate forming of materials through two key operations: cutting and bending.
3.1 Precise Cutting
- Equipment used: CNC laser cutting machine or CNC punching machine.
- Преимущества:
- CNC laser cutting can achieve high-precision cutting of complex shapes, with a cutting accuracy of up to ±0.1mm.
- CNC punching machine is suitable for batch cutting of simple shapes, with high efficiency and stable quality.
- Вопрос: Why is CNC cutting more accurate than traditional manual cutting?
- Отвечать: Because CNC cutting is controlled by computer programs, it avoids human operation errors. В то же время, the advanced sensors on the equipment can monitor the cutting process in real time and adjust parameters in time to ensure cutting precision.
3.2 Fine Bending
- Equipment used: CNC press brake.
- Key points: During the bending process, the CNC press brake can accurately control the bending angle and bending force according to the program settings. Operators only need to place the cut material on the machine table, and the machine can complete the bending operation automatically. This not only ensures the consistency of the bending angle (the error is within ±0.5°) but also guarantees the dimensional accuracy of the bent parts.
4. Welding and Assembly: Combine Parts into a Whole
For prototypes composed of multiple components, welding and assembly are essential steps to ensure the integrity and functionality of the precision sheet metal prototype parts.
4.1 Precision Welding
- Techniques adopted: Тиг сварка (tungsten inert gas welding) or MIG welding (metal inert gas welding) are usually used for precision welding. These techniques can effectively control the heat input during welding, reduce welding deformation, and ensure the uniformity and strength of the weld.
- Quality requirements: The weld should be smooth and uniform, without defects such as pores, cracks and slag inclusion. The tensile strength of the weld should be not less than 80% of the base material.
4.2 Careful Assembly
- Assembly basis: Strictly follow the design drawings and assembly process requirements.
- Assembly tools: Use precision measuring tools such as calipers, micrometers and coordinate measuring machines to check the position and fit of each part during the assembly process.
- Core goal: Ensure that each part is accurately matched, and the assembly gap is within the design allowable range (generally not more than 0.2mm).
5. Поверхностная обработка: Enhance Appearance and Performance
After welding and assembly, the prototype needs to go through surface treatment to improve its appearance quality and service life.
| Метод обработки поверхности | Operation Content | Эффект |
| Advanced Polishing | Polish the welding seams, cutting edges and other parts with professional polishing tools (such as polishing machines, наждачная бумага). | Make the surface of the prototype smooth and flat, without blemishes such as scratches and bumps. |
| Special Coatings | Apply corresponding coatings according to needs, such as anti-rust coatings, conductive coatings, and decorative coatings. | – Anti-rust coatings: Improve the corrosion resistance of the prototype, extending its service life in humid or corrosive environments. – Conductive coatings: Make the prototype have good electrical conductivity, suitable for electronic product shells. – Decorative coatings: Enhance the appearance of the prototype, making it more in line with market aesthetics. |
6. Контроль качества: Guard the Final Quality
Quality control runs through the entire precision sheet metal prototype parts forming процесс, and the final inspection is particularly critical to ensure that the prototype meets the design requirements.
6.1 Thorough Inspection
- Проверка размерных: Используйте координатные измерительные машины, laser measuring instruments and other high-precision measuring equipment to inspect all key dimensions of the prototype. Ensure that each dimension is within the design tolerance range.
- Визуальный осмотр: Check the appearance of the prototype, including surface smoothness, weld quality, coating uniformity, и т. д.. Reject prototypes with obvious defects.
6.2 Функциональное тестирование
- Test content: According to the product’s use scenario, conduct corresponding functional tests. Например, for a sheet metal bracket prototype, carry out load-bearing tests to verify its bearing capacity; for a sheet metal shell prototype, conduct waterproof and dustproof tests to check its protective performance.
- Test purpose: Verify whether the prototype’s performance and durability meet the design expectations, and find out potential problems in time for improvement.
Точка зрения Yigu Technology
В Yigu Technology, Мы верим precision sheet metal prototype parts forming is the cornerstone of efficient product development. We integrate advanced CAD design, high-precision CNC machining and strict quality control to provide customers with customized prototype solutions. For each project, we focus on material selection matching design needs and process optimization improving precision. We aim to help customers turn design concepts into high-quality prototypes quickly, shortening product development cycles and enhancing market competitiveness.
Часто задаваемые вопросы
- What industries are suitable for applying precision sheet metal prototype parts forming?
Precision sheet metal prototype parts forming is widely used in industries such as electronics, Автомобиль, аэрокосмическая, medical equipment and industrial equipment. Например, в автомобильной промышленности, it is used to make prototypes of auto parts such as instrument panels and body frames; in the medical equipment industry, it is used to produce prototypes of medical device shells and brackets.
- How long does it usually take to complete a precision sheet metal prototype parts forming process?
The time required varies depending on the complexity of the prototype, the number of parts and the processing technology. В целом, a simple prototype can be completed in 3-5 дни, while a complex prototype with multiple components may take 10-15 дни.
- Can precision sheet metal prototype parts forming be used for mass production?
Precision sheet metal prototype parts forming is mainly suitable for product development, prototyping and low-volume production (usually less than 100 куски). Для массового производства, it is more economical and efficient to use dedicated stamping dies and assembly lines. Однако, the process parameters and experience accumulated in the prototype forming process can provide valuable references for mass production.