Dicas de design de chapa metálica e como otimizá-lo

Sheet Metal Design Tips and How to Optimize It

Preface

Sheet metal parts are commonly used in both exterior surface cladding and interior structural components of automobiles.

As a structural control engineer, cost reduction is always a pressure I must bear in my core business.

After conducting extensive research, I discovered that my colleagues were able to convert the top cover of the controller into a sheet metal stamping part.

To avoid mistakes in the design process, I gathered data and compiled a list of common techniques in designing sheet metal parts. I hope to share and learn from others in the industry through this information.

Sheet metal processing involves four main processes: molding, bending, stretching and forming.

Each process has specific design requirements, and in this section we will provide a brief overview of each process from four different perspectives.

1. Suppression

Suppression is further divided into two categories: common suppression and precision suppression.

As the processing methods differ, the technology used in the blanking process also varies.

The top cover of the motor controller and other structural components normally use only common covers.

In this section, we will focus on the structure and technology of common blanking that we commonly use.

Skill 1.1

It is ideal for the shape and size of blind parts to be simple and symmetrical, as this minimizes waste during the layout process.

Layout of blind parts

Skill 1.2

The shape and internal holes of the blind parts must avoid sharp corners.

Where straight or curved lines meet, an arc connection with radius R ≥ 0.5t must be incorporated, where t is the wall thickness of the material.

Minimum value of fillet radius of the blind part

Skill 1.3

Blind parts with cantilevers and narrow slots should avoid deep and wide convex or concave sections.

As a general rule, these sections should not be less than 1.5t, where t is the thickness of the material.

In addition, narrow and long notches as well as excessively narrow notches should be avoided to increase the strength of the mating parts of the die.

Avoid cantilevers and narrow slots.

Skill 1.4

Circular holes are the preferred choice for punching, especially when considering minimum size requirements.

The minimum size for punching depends on factors such as the shape of the hole, the mechanical properties of the material, and the thickness of the material.

Punch shape example

Material Circular hole diameter (b) Width b of the short side of the rectangular hole
High carbon steel 1.3t 1.0t
Low carbon steel, brass 1.0t 0.7t
Aluminum 0.8t 0.5t

*t is the thickness of the material and the minimum perforation size is generally not less than 0.3mm

Skill 1.5

Hole spacing and hole edge spacing are important considerations.

The minimum distance between the punching edge of a part and its shape is limited based on the shape of the part and the hole, as illustrated in the attached figure.

When the punching edge is not parallel to the contour edge of the part, the minimum distance should not be less than the thickness of the material

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