In today’s competitive situation, enterprises can achieve the maximization of interests in order to remain invincible.
Improving production efficiency and the utilization of raw materials is a constant theme.
For enterprises that need thousands of tons of plate per year, it is very important to improve the material utilization rate of plate blanking.
In order to improve the material utilization rate of plate blanking, typesetting is undoubtedly the most critical station.
For the same parts, the same plate format and different typesetting, there are different material utilization rates.
Typesetting can be divided into two methods: integration and separation.
Integration in typesetting
Realize nesting processing with high compactness
Assemble the cut product parts as a single vehicle, and integrate the spare space in the typesetting to the greatest extent possible through the movement and rotation of the parts, so as to put more and more parts.
Different plates are arranged for different parts and different plate widths respectively.
After many comparisons of different plates, different parts are optimized and combined to realize nesting cutting with high compactness as far as possible.
For some typesetting with low density, you can integrate parts of other products or parts in the production range of one quarter.
It can also integrate the parts with a thickness difference of 1 ~ 2mm without affecting the use, replace the thin with the thick or find the material with the middle plate thickness, so as to improve the utilization rate of plate materials.
Figure 1 shows the integrated layout.
Figure 1 integrated layout diagram
Common line cutting
According to the thickness of parts, the lap allowance is controlled to be the minimum. If the cutting lines of individual parts are the same, common line cutting can be realized, that is, during typesetting, the parts where the shapes of two parts can coincide can be integrated, that is, collinear.
When cutting, the same part can be cut only once, which can not only improve the utilization rate of materials, but also improve the cutting efficiency, reduce the energy consumption and realize the maximum benefit of plate blanking.
Fig. 2 is the part drawing, and Fig. 3 is the layout drawing.
Order non-standard sheet
For some parts with complex shape, large size and mass production, order non-standard plates of corresponding width according to the layout, integrate the plates of different specifications provided in the market or purchase coil materials, and cut them into corresponding width as required, which not only improves the utilization rate of plates, but also avoids the backlog of a large number of surplus materials.
As shown in Figure 4, the width is 3250mm×1500mm, while the width of standard plate is 4000mm×1500mm。
Fig. 2 parts drawing
Figure 3 Typesetting diagram
Figure 4 Layout of non-standard plates
Split in typesetting
In some cases, due to the limitations of plate width and cutting range of machine tools, it is difficult to improve the material utilization rate.
Only the parts can be reasonably separated to adapt to the plate format and the cutting range of the machine tool.
Three principles should be followed for separation:
(1) the service performance of parts will not be affected. Some parts with high dimensional accuracy shall not be separated to facilitate subsequent splicing;
(2) the split position shall not pass through the hole as far as possible;
(3) try to maximize the size of parts that can be put down in the plate format, and the size of individuals will be divided when splitting;
The size of the parts that the machine tool can cut is divided into the size of the individual.
On the one hand, this is conducive to the improvement of material utilization, on the other hand, it also reduces the number of split parts and facilitates the splicing of parts.
For the individual parts after separation, typesetting shall be carried out according to the principle of integration, so as to finally improve the material utilization rate.
Divide the parts in Fig. 5 along a line in the figure into two parts as shown in Fig. 6, and then typeset according to Fig. 7.
The split position will not affect the use of parts, but also maximize the plate format.
Fig. 5 parts drawing
Figure 6 split diagram
Fig. 7 layout of parts after separation
In the actual production process, the integration and separation methods are not applied separately. In some typesetting, the two methods are used at the same time.
Realizing the common wire cutting of all parts should become the development direction, which not only improves the utilization rate of materials, but also saves a lot of cutting time, improves the production efficiency and reduces the production cost.
Through the application of the above method, the material utilization rate of plate blanking can reach more than 80%.