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What kinds of galvanized sheet can be divided into?
According to the production and processing methods, galvanized plates can be divided into the following categories: hot-dip galvanized steel plate (commonly known as galvanized iron sheet), electro galvanized steel plate, single-sided or double-sided differential thickness galvanized steel plate, alloy composite galvanized steel plate, etc. in addition to the above, there are color galvanized steel plate (commonly known as color plate), printing coated galvanized steel plate, PVC laminated galvanized steel plate, etc. In addition, according to the purpose, it can be divided into galvanized steel plates for general use, roof, building outer side plate, structure, tile ridge plate, stretching and deep stretching. The quality requirements of high-quality galvanized sheet include specification and size, appearance, galvanized quantity, chemical composition, sheet shape, mechanical properties and packaging.
Lpbk50 width measuring instrument product introduction: galvanized sheet width measuring instrument is a non-contact on-line detection system for width measurement by using double barrel photoelectric probe. The double barrel photoelectric probe is composed of two groups of transmitting lenses and two groups of receiving lenses. It uses LED clean light source and CCD imaging method to measure the geometric dimension.Measuring principle of lpbk50 width gauge:
In the figure, the two transmitting lenses are provided with LED point light sources, and the light emitted by the point light sources is transformed into parallel beams through the lens and directed to the two receiving lenses respectively. The parallel beam is imaged on the photoelectric conversion element CCD chip through the lens in the receiving lens (Note: a transmitting lens and a receiving lens form a group of photoelectric probes). When the measured object passes through the field of view composed of two parallel lights, a virtual shadow will appear on the image of the photoelectric conversion element, and its widths are set as L1 and L2 respectively. After processing and calculating the electrical signal sent by the photoelectric conversion element, the dimensions B1 and B2 corresponding to L1 and L2 can be obtained. The width dimension a of the measured object can be obtained by adding B1 and B2 and the net spacing C between the two lenses.
In practical application, the net spacing C of the probe is the size calibrated with a standard ruler of fixed length. When the spacing of the probe is changed, the width of different specifications can be measured by taking into account the spacing change.Lpbk50 width gauge system composition and connection mode:The width gauge system is a complete set of equipment integrating optical, mechanical, electronic circuit, communication and computer software technology. The whole system is mainly composed of width gauge body, main control cabinet, industrial computer, display, audible and visual alarm device, large LED display screen and so on.
In the whole system, the width gauge body and large LED display are installed on the measurement site, and the main control cabinet is placed in the control room. The width measuring instrument is connected with the main control cabinet by a three core power line and an optical cable. The power supply and power off of the width measuring instrument are realized by the main control cabinet through the power line, and the data signal of the width measuring instrument is transmitted to the main control cabinet through the optical cable. The power supply of the large LED display screen is also led out from the main control cabinet. The power supply and power failure of the display screen are synchronized with the start and stop of the main control cabinet. The display data of the display screen is sent to the display screen by the main control cabinet through optical cable.
Lpbk50 width measuring instrument software system:
(1) Interface display contents: width standard value, positive and negative tolerance, real-time width value, width deviation value, etc. (2) Curve fitting function: it can fit the width change fluctuation curve and temperature change fluctuation curve. (3) Product parameter setting: you can set product specifications, positive and negative tolerances and other parameters. (4) Out of tolerance alarm function: when the width exceeds the set tolerance, it is an audible and visual alarm. (5) Calibration function: when the measurement error is too large, put it into the standard ruler and calibrate it. (6) Automatic adjustment function of probe spacing: automatically adjust probe spacing when switching width specifications. (7) manual adjustment function of measuring head distance: adjusting the distance between probe heads after opening and closing distance. (8) System parameter setting: serial port, probe head, refresh frequency and other parameters can be set. (9) Data storage function: automatic storage of measurement data. The storage records can be opened by measurement software or converted into excel format.
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National standard for galvanized steel sheet?BSEN 10214-1995 continuously hot dip galvanized aluminum sheet and strip - Technical delivery conditions. BS EN 10215-1995 continuously hot dip aluminized galvanized steel sheet and strip - Technical delivery conditions. BS EN 10147-2000 continuously hot dip galvanized structural steel sheet and strip - Technical delivery conditions. BS 2858-1957 specification for steel plates for the manufacture of galvanized cans. BS 3083-1988 specification for ordinary hot dip galvanized and hot dip aluminum zinc corrugated steel plates.Recommended instruments for measuring the width of galvanized sheet
Lpbk50 width measuring instrument product introduction: galvanized sheet width measuring instrument is a non-contact on-line detection system for width measurement by using double barrel photoelectric probe. The double barrel photoelectric probe is composed of two groups of transmitting lenses and two groups of receiving lenses. It uses LED clean light source and CCD imaging method to measure the geometric dimension.Measuring principle of lpbk50 width gauge:Measuring principle of lpbk50 width meter
In the figure, the two transmitting lenses are provided with LED point light sources, and the light emitted by the point light sources is transformed into parallel beams through the lens and directed to the two receiving lenses respectively. The parallel beam is imaged on the photoelectric conversion element CCD chip through the lens in the receiving lens (Note: a transmitting lens and a receiving lens form a group of photoelectric probes). When the measured object passes through the field of view composed of two parallel lights, a virtual shadow will appear on the image of the photoelectric conversion element, and its widths are set as L1 and L2 respectively. After processing and calculating the electrical signal sent by the photoelectric conversion element, the dimensions B1 and B2 corresponding to L1 and L2 can be obtained. The width dimension a of the measured object can be obtained by adding B1 and B2 and the net spacing C between the two lenses.
In practical application, the net spacing C of the probe is the size calibrated with a standard ruler of fixed length. When the spacing of the probe is changed, the width of different specifications can be measured by taking into account the spacing change.Composition and connection mode of lpbk50 width gauge system: the width gauge system is a complete set of equipment integrating optical, mechanical, electronic circuit, communication and computer software technology. The whole system is mainly composed of width gauge body, main control cabinet, industrial computer, display, audible and visual alarm device, large LED display screen and so on.
In the whole system, the width gauge body and large LED display are installed on the measurement site, and the main control cabinet is placed in the control room. The width measuring instrument is connected with the main control cabinet by a three core power line and an optical cable. The power supply and power off of the width measuring instrument are realized by the main control cabinet through the power line, and the data signal of the width measuring instrument is transmitted to the main control cabinet through the optical cable. The power supply of the large LED display screen is also led out from the main control cabinet. The power supply and power failure of the display screen are synchronized with the start and stop of the main control cabinet. The display data of the display screen is sent to the display screen by the main control cabinet through optical cable.
Lpbk50 width measuring instrument software system:
(1) Interface display contents: width standard value, positive and negative tolerance, real-time width value, width deviation value, etc. (2) Curve fitting function: it can fit the width change fluctuation curve and temperature change fluctuation curve. (3) Product parameter setting: you can set product specifications, positive and negative tolerances and other parameters. (4) Out of tolerance alarm function: when the width exceeds the set tolerance, it is an audible and visual alarm. (5) Calibration function: when the measurement error is too large, put it into the standard ruler and calibrate it. (6) Automatic adjustment function of probe spacing: automatically adjust probe spacing when switching width specifications. (7) manual adjustment function of measuring head distance: adjusting the distance between probe heads after opening and closing distance. (8) System parameter setting: serial port, probe head, refresh frequency and other parameters can be set. (9) Data storage function: automatic storage of measurement data. The storage records can be opened by measurement software or converted into excel format.
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Stamping and sheet metal production involve many fields of manufacturing industry. In recent years, as China has become the world's manufacturing center and consumer power, stamping and sheet metal industry, as one of the basic industries of manufacturing industry, has also achieved unprecedented development. At present, China's equipment manufacturing industry is large but not strong, and the distribution is uneven. The backward heavy equipment manufacturing industry is distributed in the three northeastern provinces, while the new sheet metal equipment manufacturing industry is distributed in the coastal Yangtze River Delta and Pearl River Delta, and has just started, which is difficult to meet the domestic market demand. In the next 5-10 years, the equipment manufacturing industry will still be one of the main industries in China, especially the sheet metal industry in the manufacturing industry.
The improvement of the sheet metal processing industry is the main evaluation aspect that can best reflect the comprehensive capacity of a country's manufacturing industry. The development of the industry will reflect the improvement of the overall quality of the national development economy. China has joined the World Trade Organization for many years, but the current sheet metal processing industry is still scattered. The emerging national industry has just started, and the scale is very small. Industry integration can cope with the impact of foreign enterprises and ensure that national industries have a place in the competition. In the next 5-10 years, in addition to expanding the scale to meet domestic demand, China's sheet metal processing industry also needs to integrate production and supply and demand on the advanced Internet, so as to gain an invincible foothold and prepare for foreign development faster and better.
Analysis on the overall scale of the industry
With the rise of China's manufacturing industry, China's sheet metal and manufacturing industry has developed rapidly. According to the analysis report on market demand forecast, transformation and upgrading of sheet metal processing industry released by forward looking Industry Research Institute, as early as 2012, the whole industry had more than 30000 enterprises (workshops) and 2 million employees, with an annual production of about 42 million tons of sheet metal parts. In 2016, the sales of sheet metal processing industry was about 688.5 billion yuan. However, generally speaking, the sheet metal processing industry started late, the industry scale is generally small, and there is a lack of production and technical personnel. It is difficult to form the core competitiveness of enterprises. The market competition is becoming increasingly fierce, and it does not have the strength to compete with international multinational corporations.
Sales scale of China's sheet metal processing industry from 2009 to 2016 (unit: 100 million yuan)Source: compiled by prospective industry research instituteIndustry economic benefit analysis
At present, on the whole, the economic benefits of sheet metal processing in China are good, and the operating profits of many industrial enterprises are more than 20%. The sheet metal processing industry is mainly engaged in distribution processing for automobile, shipbuilding, precision machine tools, precision instruments, communication electronics, elevators and other industries, and most of the partners are large foreign companies (GE, Bosch, Otis). With the further deepening and lasting cooperation, they learn advanced technology, process, strict and standardized production environment Management experience in production process and other aspects, so as to gradually localize key components and key technologies, which correspondingly reduces the procurement of key components by foreign-funded enterprises from abroad and reduces the production cost of manufacturing enterprises.
At the same time, this method can also do supporting processing for domestic manufacturing enterprises, and enable them to obtain key production technologies, so as to improve the product performance of domestic manufacturing enterprises. At present, there are not many domestic high-precision sheet metal processing enterprises. Developing the sheet metal processing industry in a certain area and providing perfect supporting processing services to domestic and foreign manufacturing enterprises can not only promote the overall development of machinery manufacturing enterprises, but also drive the regional economy to achieve a new leap, and the economic benefits of enterprises are also guaranteed.
With China becoming an international processing and manufacturing center and the increasing foreign investment, the demand for metal processing capacity is increasing. Generally speaking, the electrical control box and machine shell in the metal processing industry are sheet metal parts, so the demand for sheet metal processing capacity is also increasing. In addition, as far as sheet metal processing is concerned, sheet metal processing enterprises usually need a variety of mechanical equipment to meet different process requirements. The punching accuracy of sheet metal is generally about 0.1mm, and the bending accuracy can generally reach 0.5mm. Therefore, compared with sheet metal processing, the accuracy is much lower. Therefore, the progress of industry technology has also brought high profits. For example, the stamping profit margin in sheet metal processing can generally reach about 30%, while the profit of laser cutting is more than 50%.
Industry profit level and change trendOverall, the profit level of sheet metal processing industry mainly depends on product quality and processing precision, products and value-added services, downstream user enterprises and upstream raw material prices. Therefore, in the future, with the increasing technical content of products in the industry, the impact of raw material price fluctuations on products will be gradually reduced, and the change trend of industry profit level will be better.At the same time, the future trend of profit level mainly depends on factors such as product quality and precision, product value-added services and downstream customer industries. Enterprises with strong technical strength, high-end customer resource advantages and management advantages in the industry will obtain a higher profit level in the future fierce competition.
In this new context, Asymmetric Incremental Sheet Metal Forming (AISF) is consolidating as one of the most promising plastic forming processes to manufacture in a fast way small batches of sheet products from a variety of metallic alloys (e.g. aluminium, titanium or steels) . The term fast is not referred to a short total manufacturing time for each part but, instead, to the short elapsed time between the CAD/CAM design and the beginning of the manufacturing step ,. Thus, in contrast to press forging, AISF allows manufacturing the metal part prototype just immediately after defining the required tool trajectories. Moreover, overcoming the need to prepare, with high accuracy, the pressing dies allows also decreasing the production costs and performing rapid prototyping. Therefore, AISF appears as a very suitable manufacturing approach for innovation and development of new products. Two variants of the ISF process are used: negative forming or SPIF, in which it is not necessary using a die; and positive forming or TPIF, where other dies are usually used ,5,.
Currently, a very limited number of machines specifically designed to apply AISF are commercially available . The investment related to the acquisition of this particular type of equipment, which strongly counterbalances the savings that result from avoiding the use of dyes, is slowing down the establishment of this innovative manufacturing method ,. Implementing AISF in an already available CNC machine centre appears as an interesting approach to overcome this limitation.
This does not only allows diversifying the machining strategies available on this type of more widely spread instruments but also opening novel machining techniques which combine material removal and deformation steps. This finally provides an extra flexibility to the original CNC machine ,9,.
Previous works have already reported the application of AISF on CNCs. As an illustration, J. Kopac and Z. Kampus have reported the use of a CNC milling machine-tool Mori Seiki . On its hand, Malwad et al.
have analysed the details of the deformation mechanisms during Single point AISF on AA8011 aluminium alloy sheets using a 3 axis HAAS CNC Milling Machine . Likewise, R. Ben Hmida et al. have investigated the influence of the initial grain size of FPG copper foils on the material behaviour during SP AISF using a 3-axis CNC vertical milling machine The design of the metal sheet clamping tools is one of the necessary steps to implement AISF on CNCs. The specific characteristics of these tools will result key for the final performance of the adapted machine. This contribution focuses specifically on this aspect. In particular, two alternative designs for this clamping tool is presented which allow fast customization of the working area and which is easily adaptable to different metal sheets formats. Additionally, the manufacture of a prototype of this clamping tool using 3D printing is also presented.
The proposed design refers to a teaching-oriented CNC milling centre. Therefore, the dimensional and operational parameters employed here may differ from others corresponding to CNC equipment used for industrial purposes.
2. Methodology The CNC machine adapted in this work was an ODISEA from Alecop SC, Figure 1(a). Table 1 includes its most relevant technical features. CAD design of the proposed tools was performed using the Dassault System Software "CATIA V5R20". The corresponding PLA prototypes were further prepared on a Cubex 3D printer, Figure 1(b). For the manufacture of the prototypes, the 3D printer parameters previously optimized in ,12, were employed. Finally, let us mention that the corresponding ISF tool to be used with the CNC machine here adapted was manufactured by grinding on a WC-Co bar.
3. Results The major constrains considered for the design of the clamping tool were the maximum dimensions available as working area, the maximum length of the path along the X and Y axis which limit the characteristics of the tool trajectories and the maximum distance between the ISF tool tip and the working table. We have also considered that all the necessary metallic parts involved in the design can be manufactured in fact using the CNC milling machine adapted.
Figure 2 shows isometric views of the proposed CAD design solutions, considering 100 x 100 mm and 100 x 200 mm formats for the metal blanks. The first part of the clamping tool consists of a rectangular-shaped support plate (1), which is fixed to the working table by screws at each of its corners. An array of regularly distributed holes, 3 x 5 in Figure 2, are drilled into this basement plate. Screws inserted from the bottom face of the plate will allow further anchoring of columns (2) onto the top face. Decreasing the pitch between neighbouring holes allows a more flexible customization of the blank dimensions.
Each of the four thick columns is threaded on its two bases so as to allow being tightly fixed to both the support plate and the lower pressing plate (3). The metal blank to be formed by AISF is kept locked by pressing it between two, upper (4) and lower (3), pressing plates. Up to eight screws uniformly distributed along the rim of the pressing plates allow a tight fixation of the metal blank, which will be kept fix at any time during the AISF procedure.
Nevertheless, to ensure a better clamping, lateral shifts of the metal blank are avoided. In order to facilitate its centring, the lower pressing plate was flanged reducing its thickness, by 0.5 mm, up to 1 mm from the inner edge. This clamping tool can be manufactured in an aluminium alloy to make it lighter.
Additionally, a partial or complete die can be fixed by screwing onto the upper part of the support plate in case that two point incremental forming is to be carried out.
Let us finally mention PLA prototypes of all the parts involved in this design were manufactured by 3D printing. Figure 3 shows a general view of all these parts both as separated items (a), after assembling them into the final clamping tool design (b), and mounting it on the ODISEA CNC milling centre (c). Numbers in Figure 3 correspond with the same parts on Figure 2. An ISF tool designed to operate in the adapted CNC centre was manufactured, and is shown as item 5 in Figure 3 (a).
4. Conclusions A design is proposed for a clamping tool that allows implementing AISF on an ODISEA CNC milling centre in a flexible way. With this design SPIF can be combined with other machining operations, like drilling or milling, at the end of the deformation step, thus improving the flexibility of the CNC machine. The proposed design can be manufactured in an aluminium alloy.
In case this design should be transferred to a CNC centre with industrial production purposes aimed at the production of metal parts of larger dimensions, the number of columns supporting the upper and lower pressing plates should be increased, in order to provide a higher stiffness to the clamping tool. By doing so, a higher stability during the AISF process would be guaranteed.
As a further improvement to the design described in this paper, we intend to implement a translation system along the Z-axis of the supporting columns, to synchronize the path followed by the tool with the movement of the clamping tool. This would allow achieving more complex shapes during the ISF process.
DOI: 10.2507/26th.daaam.proceedings.129 5. Acknowledgements The UE (Project COSSTA), the Andalusian Government (PAIDI) and from Fundacion Tecnalia R&I (through the CATEDRA TECNALIA of the UCA) have provided financial support to this work.
6. References W.C. Emmens, G. Sebastiani A.H. van den Boogaard, The technology of Incremental Sheet Forming--A brief review of the history.
J. Mat. Proc. Tech. 210 (2010) 981-997.
J. Kopac, Z. Kampus, Incremental sheet metal forming on CNC milling machine -tool, J. Mat. Proc. Tech. 162-163 (2005) 622-628 Rozmarina Dubovska, Jaroslav Jambor, Jozef Majerik, Implementation of CAD/CAM system CATIA V5 in Simulation of CNC Machining Process, Proc. Eng. 69 (2014) 638-645, 24th DAAAM, 2013.
Jozef Majerik, Jaroslav Jambor, Computer Aided Design and Manufacturing Evaluation of Milling Cutter when High Speed Machining of Hardened Steels, Proc. Eng. TO0 (2015) 450-459, 25th DAAAM, 2014.
D. S. Malwad, Dr. V. M. Nandedkar, Deformation Mechanism Analysis of Single Point Incremental Sheet Metal Forming. Proc. Mat.
Sci. 6 (2014) 1505-1510.
R. Ben Hmida, S., Influence of the initial grain size in single point incremental forming process for thin sheets metal and microparts:
Experimental investigations, Mat. and Design 45 (2013) 155-165.
Masaaki Amino, Masashi Mizoguchi, Yuji Terauchi, Trent Maki, Current status of "Dieless" Amino's incremental forming, Proc. Eng. 81 (2014) 54-62.
T.Madeira, C.M.A.Silva, M.B.Silva, P.A.F.Martins, Failure in single point incremental forming, Int. J. Adv. Manuf. Techol. (2015) 80:1471-1479.
Yanle Li, Haibo Lu, William J. T. Daniel, Paul A. Meehan, Investigation and optimization of deformation energy and geometric accuracy in the incremental sheet forming process using response surface methodology, Int. J. Adv. Manuf. Technol. (2015) 79:2041-2055.
Holger Voswinckel, Markus Bambach, Gerhard Hirt, Improving geometrical accuracy for flanging by incremental sheet metal forming, Int. J. Mat. Form. (2015) 8:391-399.
Matej Paulic, Tomaz Irgolic, Joze Balic, Franc Cus, Andrej Cupar, Tomaz Brajlih, Igor Drstvensek, Reverse Engineering of Parts with Optical Scanning and Additive Manufacturing, Proc. Eng. 69 (2014) 795-803, 24th A.P. Valerga, M. Batista, R. Bienvenido, S.R.
Fernandez-VidalC. Wendt, M. Marcos, Application of Reverse Engineering and Additive Manufacturing Techniques to Cutting Tools Redesign, Proc.
of the 6th Man. Eng. Soc. Int. Conf., Barcelona, Spain, 2015.
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Fernandez-Vidal, M. Marcos, Preliminary design and analysis of tensile test samples developed by Additive"Manufacturing, Proc. of the 6th Man. Eng. Soc. Int. Conf., Barcelona, Spain, 2015.
Antonio Calvino (a), Asuncion Rivero (b), Miguel Alvarez (a), Francisco Puerta (a), Jorge Salguero (a), Mariano Marcos (a) (a) University of Cadiz, Faculty of Engineering. Mechanical Engineering and Industrial Design Dept. Av. Universidad de Cadiz 10, E-11519 - Puerto Real, Cadiz, Spain (b) Fundacion Tecnalia Research & Innovation. Scientific and Technological Park of Guipuzkoa. Paseo Mikeletegui 7, E 20009, Donostia-San Sebastian (Guipuzkoa), Spain Caption: Fig. 1. A general view of: (a) ODISEA CNC Milling Center; (b) CubeX Duo 3D Printer.
Caption: Fig. 2. Isometric views of the CAD designs of two possible configurations of the designed clamping tool for two different metal blank formats: (a) 100 x 100 mm; (b) 200 x 100 mm.
Caption: Fig. 3. PLA prototypes of all the parts involved: (a) separated items; (b) Assembly of the ISF clamping tool; (c) Mount of the ISF clamping tool on ODISEA CNC milling center.
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