The ram hits the side of the new car at a speed of 50km/h (see Figure 1). Each body of the vehicle has a sensor to obtain a simulation test signal, and in a fraction of a second, the detailed information of the stress is obtained. After that, the full results of the Euro-NCAP crash test were quickly published in a dedicated automotive magazine.
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Euro-NCAP refers to the European New Car Assessment Organization. It was established in 1997 by five European governments and the European Commission. Its results have received close attention and support from the general public, so that almost no car manufacturers will easily ignore its results. Safety performance has become a very important selling point, so people are very concerned about the car body parts related to safety. At the same time, fierce competition has prompted people to continue to study new and more economical manufacturing concepts. The combination of beam and laser welding plays an important role in enabling such body parts to achieve this goal.
Figure 1: Euro-NCAP Side Impact Test
The beam that protects the side impact is a galvanized steel with high tension and ultrafine grain, a thickness of 1.5 mm and a tensile strength of 800 to 980 N/mm2. The high tensile strength of the material requires a high forming force, which brings higher demands on the machine itself, and at the same time, the beam error is more stringent. The inlay of the recessed portion is not easily accessible. The weld quality corresponds to a welding factor of 1. Only lasers with an output of 4 kW of CO2 are considered to be usable in the welding process. Although the laser offers great advantages, it imposes high precision requirements on the molding machine. The precise positioning of the metal strip, especially in the welding area, is necessary (see Figure 2).
Figure 2: Location of the steel strip in the weld zone
In the same way, great care must be taken during the preparation of the weld. The zinc coating in the weld zone must be completely removed because the zinc particles in the weld zone during the melt process may cause unnecessary voids and spillage. Equipment that includes scraping and grooving can solve this problem. Similarly, organic impurities, such as lubricants, can cause welding errors. Despite the large forming forces, it is necessary to avoid the use of excess lubricant. The roller brackets are subjected to greater pressure, so they use felt as a liner. Felt is carefully lubricated by precision electronics to add the correct amount of lubricant. This way the beam itself will not be affected.
In order to minimize the residual stress on the beam, the manufacturer chose a process called "decremental" molding, that is, the surface of the profile slowly decreases as it approaches the exit. Compared to the horizontal forming process, this method results in a significant reduction in stress, resulting in a higher precision of the beam. This is very common in the automotive industry, where frequent processing performance testing is required.
Different openings in the beam (see Figure 3) provide a drain for paint and rain. In order to achieve complete drainage, the opening must be as close as possible to the radius bend. This raises a more difficult requirement because the punching process is performed when the metal is a flat plate and then the entire molding process. The model calculation at the conceptual stage gives a case where the hole deformation may occur due to the presence of the forming force. Therefore, only the transfer of the punching position can ensure that the punching error meets the requirements.
Figure 3: Anti-side collision beam
The assembly process for a four-door car requires four different beam solutions, each with different holes, groove distances and positions. To achieve this, a programmable roller feed is placed at the pre-punch device at the beginning of the line, and the length-programmable slab cross-section machine is placed at the end of the line. There must be no deformation on the edge of the beam.
It is generally believed that the rounded saw blade becomes worn and worn and the sawing time is long. These factors are unlikely to occur during the sawing process of the outer sheet. The required high speed can be achieved by a solution for cutting the punch. The deformation of the sheet section is not due to a special process. A groove is pre-engraved on the flat steel strip, the width of which is equal to the width of the punch blade after the error is added. Therefore, the tip of the cutting blade does not have to protrude directly into the material. In this way, the problem of deformation of the sheet is eliminated. The special shape of the punch blade and the proper coating and lubricant make the tool life more economical.
The entire unit is about 30 meters long and is operated by only one person. Additional personnel are required only when changing coils and moving sheets. Due to the high degree of automation, the coil replacement takes only three minutes. This shows that the line has a long normal working time. In addition, there is no need to have special skills to operate the machine. After the equipment is installed, the operator can get guidance from the manufacturer, so even a company that has never had experience in forming processing can use this extremely economical processing equipment.
Samples for quality testing and reliability testing must be delivered as early as planned delivery. This is only possible if the equipment supplier has its own test equipment available. At the same time, however, important components on the production line also need to be tested. Therefore, most of the necessary optimization work has already been done before starting production. In this way, even if there are frequent occurrences of new machines being put into use due to short-term plans, there will be no accidents.
If the current beam is no longer popular, it is not a problem for the device itself. Very dexterously, the fast tool change system allows the machine to produce many other types of beams. This gives the form factor manufacturer a great deal of flexibility. Due to these outstanding characteristics, it is no wonder that the automotive industry is increasingly considering the use of forming to produce other body parts. The last important point is that security is improved while saving expensive labor.
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