In the prototype processing of stamped sheet metal parts, the core goal is to verify the feasibility of the design through rapid prototyping, ensuring quality and accuracy before mass production. Prototype processing is different from mass production, emphasizing flexibility, low cost, and short-term delivery (usually 1-3 days). The key points can be summarized into the following four core aspects, combined with design, materials, processes, and quality control, to ensure efficiency and reliability.
Design and Planning Preparation
During the design phase, CAD software such as SolidWorks or AutoCAD should be used to optimize sheet metal structures and avoid stamping defects such as cracking or deformation. The key points include: selecting appropriate design tolerances (generally within ± 0.1mm), conducting finite element analysis to simulate the stamping process, and predicting stress distribution; Ensure that the drawings are clearly labeled for manual error compensation. For example, for curved parts, a rebound allowance needs to be reserved. The initial planning should clearly define the processing objectives and schedule to reduce the risk of rework.
Material selection and pretreatment
Select suitable sheet metal materials according to application requirements, commonly available options include aluminum alloy (lightweight, easy to process), low-carbon steel (high strength), or stainless steel (corrosion-resistant). The material thickness is usually 0.5-3mm and requires pre-treatment such as cleaning the surface oil stains and cutting to shape. Pay attention to the impact of material hardness on processing difficulty – soft materials are more suitable for prototyping. Pretreatment also includes heat treatment (such as annealing) to reduce internal stress and ensure stable subsequent molding.
Processing and Forming Technology
Processing is mainly carried out by manual or semi-automatic equipment, with priority given to laser cutting or CNC punching machines to ensure contour accuracy; During the molding stage, bending and stretching are achieved through manual bending machines or small hydraulic presses. The key points are to control the stamping parameters: moderate punch speed (to avoid material tearing), accurate mold clearance (matching with material thickness). For complex parts, they can be formed in steps (such as cutting first and then bending), and deformation can be monitored in real time, fixed in position using fixtures. At the same time, emphasis is placed on operational safety (such as wearing protective equipment) to reduce human errors.
Post processing and quality control
After processing, surface treatment (such as grinding to remove burrs, spraying anti rust layer) and assembly testing are required. Quality control includes dimensional inspection (using calipers or coordinate measuring machines to compare design drawings), functional testing (such as assembly compatibility and load verification). Record defect data and iteratively optimize the design. The entire process requires cost control (minimizing material waste) and time to ensure that the prototype quickly serves the product development loop.
Summary: Prototype processing is a key link in the development of stamping parts. Through the above points, efficient prototype verification can be achieved, laying the foundation for mass production. Focusing on precision, material adaptability, and rapid response can effectively reduce post production risks.
