Material utilization
Material utilization is a key indicator of the economic viability of the ironing process. It is typically calculated as the ratio of part mass to blank mass. Improving material utilization directly reduces production costs. Material waste in ironing primarily comes from blank excess material, trimming allowance, and scrap loss, so optimization is crucial from the blank design stage. The blank diameter and height should be precisely calculated based on the final part dimensions to avoid excessive excess material due to oversizing. For cylindrical parts, the blank diameter can be derived using the principle of volume conservation, with a 5%-10% trimming allowance reserved to ensure part quality while minimizing material waste.
Properly designing the drawing process is key to improving material utilization. By optimizing the deformation parameters of each pass, material loss during intermediate steps can be reduced. For example, by employing multi-pass progressive thinning, the deformation of each pass can be controlled within a reasonable range to avoid scrap caused by excessive deformation in a single pass and reduce the scrap rate. Within the process schedule, trimming can be performed last to reduce material removal during intermediate steps. Furthermore, by accurately calculating the trimming allowance and controlling it within a range of 1-2mm, material utilization is maximized. Furthermore, for parts with complex shapes, a step-by-step forming approach can be adopted, forming the main body first and then machining the details, to avoid material waste caused by oversizing the overall blank.
The preparation method of the blank has a significant impact on material utilization, and the use of precise blanking technology can reduce the loss of initial material. For example, using laser cutting or plasma cutting can precisely control the blank size, with a cutting accuracy of up to ±0.1mm. Compared with traditional shearing, it can reduce material loss by 1%-3%. For coil processing, continuous stamping is adopted to improve material utilization by optimizing the layout scheme. For example, staggered layout can increase material utilization from 70% to more than 85%. In addition, for precious materials such as copper alloys or titanium alloys, the blank splicing technology can be used to splice small-sized waste materials into qualified blanks to achieve material recycling.
Recycling waste is an effective way to improve material utilization. The trimming waste and waste products generated during the thinning and drawing process can be reused after re-melting or processing. For metal materials, the recycling rate of scrap can reach more than 90%. The performance of the material after re-smelting can basically meet the use requirements and can be used to manufacture low-precision parts, forming a closed-loop circulation of materials. During the production process, waste materials need to be collected and classified to avoid mixing of different materials that affects the recycling quality. At the same time, a waste recycling management system should be established to ensure that waste materials are processed and reused in a timely manner. Through recycling, the overall material utilization rate can be increased by 5%-10%, significantly reducing production costs.
Advanced manufacturing technology provides new possibilities for improving material utilization. The use of computer simulation technology can optimize blank size and forming process and reduce material consumption during the trial mold process. For example, finite element analysis software can be used to simulate the flow pattern of materials during the thinning and drawing process, predict possible defects, adjust process parameters in advance, and reduce scrap rates. 3D printing technology can be used to manufacture complex-shaped blanks, achieve near-net shape, and increase material utilization from 60%-70% in traditional processes to more than 90%. In addition, adaptive control technology can adjust the process parameters during the drawing process in real time to ensure uniform material deformation, reduce scrap caused by parameter fluctuations, and further improve the effective utilization of materials. By comprehensively applying the above methods, the material utilization rate of thinning and deep drawing can reach more than 85%, significantly improving the economy and environmental protection of the process.
