Several methods for reducing costs of automotive stamping parts

With the slowdown of economic growth, the annual sales volume of the heavy truck industry in 2015 was 546800 units, a decrease of 27% compared to the same period last year. I want to maintain competition with other heavy truck companies and improve the market competitiveness of our products. This includes improving product quality, enhancing after-sales service quality, and reducing production costs.

The production cost of stamped parts includes fixed costs and variable costs. Fixed costs refer to the equipment and mold costs required for producing stamped parts, while variable costs refer to material and labor costs. The proportion of fixed costs and variable costs is 35% to 65%, respectively. In fixed costs, it mainly consists of fixed investments such as tooling and equipment, which are less broken down into individual unit costs; In variable costs, material costs account for more than half of the total. So, in order to reduce the production cost of stamped parts, material costs should be controlled.

1. Methods to reduce material costs for stamping parts

1.1 Material grade optimization

The material grade has a significant impact on material prices, and the higher the material grade, the higher the material price. Therefore, while meeting the requirements of the molding process and usage of the parts, it is advisable to use low-grade grade materials for processing as much as possible.

To achieve material grade optimization for stamped parts, the shape of the stamped parts should be simplified and the structure of the stamping die should be optimized. The external structure of a product is extremely important, and in the design process, consideration should be given to simplifying the product shape as much as possible while achieving product functionality.

For structures that can be simplified due to their small size, it is generally recommended to enlarge the rounded corners R of the product's stretching ribs, arrange the position, length, and height of the stretching ribs reasonably, control the material flow rate, and avoid quality problems such as wrinkling and cracking of the parts.

1.3 Optimize material quota size

In the stamping process, in order to pursue the reduction of material quota size, it is necessary to achieve the reduction of the pressing surface and process supplement surface in the waste area.

For the sake of product quality, the pressure surface to prevent wrinkling is essential. On the premise of meeting the functional requirements of stamping products, it is necessary to achieve miniaturization while pressing materials.

1.4 Optimize the layout method

The arrangement of punched parts on sheet or strip materials is called the layout of punched parts. When determining a reasonable sampling method, a metal utilization sampling should be established to reduce process waste and improve material utilization.

Several methods for reducing the cost of automotive stamping parts have also been applied in practical production, achieving small errors and worthy of widespread application and promotion. With the fierce competition in the automotive market, it is of great significance for enterprises to reduce production costs while ensuring product quality.

Stamping parts processing is commonplace around us, but sometimes if we encounter bad merchants, the quality of our stamping parts may not be as good. So, what should be the quality of stamping and processing?

In daily life, metal stamping parts; Products are everywhere, and how to improve customer production efficiency is the core direction of Heju Company. It is our responsibility to assist customers in enhancing their competitiveness, and both equipment and technology are indispensable. The following aspects are covered for metal stamping parts.

1. Chemical analysis, metallographic examination

Analyze the content of chemical elements in the material, determine the grain size level and uniformity of the material, evaluate the level of free carbides, banded structures, and non-metallic inclusions in the material, and inspect defects such as shrinkage and porosity.

2. Material inspection

The materials used for stamping parts processing are mainly hot-rolled or cold-rolled (mainly cold-rolled) metal sheet and strip materials. The raw materials for metal stamping parts should have quality certificates and meet the specified technical requirements. When there is no quality certificate or for other reasons, the metal stamping parts production factory can choose raw materials for re inspection as needed.

3. Forming performance test

Perform bending tests and cupping tests on the material to determine its work hardening index n value and plastic strain ratio r. In addition, regarding the testing method for steel plate formability, it can be carried out according to the regulations for thin steel plate formability and testing methods.

4. Hardness testing

The hardness testing of metal stamping parts adopts Rockwell hardness tester. Small and complex shaped stamped parts can be used to test surfaces that are too small to be tested on ordinary desktop Rockwell hardness testers.

5. Determination of other performance requirements

Measurement of the electromagnetic properties of materials and their adhesion to coatings and coatings.