ME-制程介绍

1HowaremechanicalpartsproducedHowaremechanicalpartsproduced?FrankFYWuSeniorDirectorMay/20082HowaremechanicalpartsproducedAgenda3HowaremechanicalpartsproducedMechanicalpartsproductionprocess4Howaremechanicalpartsproduced5HowaremechanicalpartsproducedRawmaterials(sheetmetal)SECC(Steel-Electrogalvanized-ColdRolled-Coil)SGCC(Steel-Galvanized-ColdRolled-Coil)SPCC(Steel-Plate-ColdRolled-Coil)(須+電鍍)SUS301(Steel-specialUsage-Stainless)6HowaremechanicalpartsproducedStampingmethodology7Howaremechanicalpartsproduced小噸位沖床介紹聯益(Lien-Yi)使用的沖床有單軸和雙軸兩種型號；沖床的噸位有：45T、60T、80T、110T、160T、200T(有雙軸和單軸)、250T(雙軸)、300T(雙軸)、400T(雙軸)、600T(雙軸)、800T(雙軸)。45T沖床60T沖床80T沖床8Howaremechanicalpartsproduced小噸位沖床介紹110T沖床160T沖床200T沖床9Howaremechanicalpartsproduced大噸位沖床介紹10Howaremechanicalpartsproduced11Howaremechanicalpartsproduced1.Stagedie(工程模)stamping:工程模即是一個產品由多套模具共同加工來完成產品2.Progressivedie(連續模)stamping:連續模即是將多個工程模具合並到一套模具上來完成，根據產品的結構不同，有的連續模所生產的產品直接就是沖壓成品，但有的連續模所生產的是半成品，還需要工程模具的後序加工來完成。3.Robot:Sameprocesslikestagedie,butitusetherobottopickandplacethepartsstagebystageinsteadofmanually,itwillreducethehumanresource.Stampingtypes12Howaremechanicalpartsproduced工程模連續模13Howaremechanicalpartsproduced沖壓用的原材料一般有”捲料”和”片料”兩種包裝:===”捲料”一般用於”連續模”，”片料”一般用於”工程模”五金件常用的材料有：鍍鋅鋼板、熱浸鋼板、不鏽鋼、磷青銅、馬口鐵等。五金件所用的材料在儲存過程中，空氣需幹燥，不可直接將材料放置於地面上，且需要作相關的包裝處理，防止原材料氧化生鏽(不鏽鋼除外)。常用的鋼板厚度規格有：0.15、0.20、0.30、0.50、0.60、0.80、1.00、1.20、1.60、2.00等。進料時須檢驗原材料的厚度、長度、寬度、刮傷、凹痕等項目。捲料片料Rawmaterials(sheetmetal)14HowaremechanicalpartsproducedStamping–Stagedie15HowaremechanicalpartsproducedRobotline16Howaremechanicalpartsproduced下料/沖孔/打凸/壓線17Howaremechanicalpartsproduced沖孔/回壓18Howaremechanicalpartsproduced沖孔/壓毛邊/抽牙/打凸點/打斜/折彎19Howaremechanicalpartsproduced攻牙20Howaremechanicalpartsproduced折彎/打斜/翻孔21Howaremechanicalpartsproduced折彎/壓平22Howaremechanicalpartsproduced折彎23HowaremechanicalpartsproducedStamping–Stagedie24HowaremechanicalpartsproducedStamping–Stagedie25Howaremechanicalpartsproduced外觀檢查26HowaremechanicalpartsproducedAnotherexample27HowaremechanicalpartsproducedAnotherexample(ventingholes)28HowaremechanicalpartsproducedCleaning&protection29HowaremechanicalpartsproducedStamping–Progressivedie30HowaremechanicalpartsproducedStamping–Progressivedie31HowaremechanicalpartsproducedStamping–Progressivedie32HowaremechanicalpartsproducedStamping–Progressivedie33HowaremechanicalpartsproducedStamping–Progressivedie34Howaremechanicalpartsproduced五金產品後置加工介紹35HowaremechanicalpartsproducedSpotwelding(點焊)36HowaremechanicalpartsproducedRiveting(拉釘)37HowaremechanicalpartsproducedRiveting(拉釘)拉釘槍38HowaremechanicalpartsproducedRiveting(拉釘)39HowaremechanicalpartsproducedStaking(鉚合)40HowaremechanicalpartsproducedStaking(鉚合)41HowaremechanicalpartsproducedTapping(攻牙)42HowaremechanicalpartsproducedScrews43HowaremechanicalpartsproducedScrews(Captivescrews/Thumbscrews)44Howaremechanicalpartsproduced五金產品前處理介紹45Howaremechanicalpartsproduced五金產品塗裝流程介紹46HowaremechanicalpartsproducedPainting47HowaremechanicalpartsproducedPrinting48HowaremechanicalpartsproducedPrintingVideo#0849HowaremechanicalpartsproducedPrinting50HowaremechanicalpartsproducedPrinting51HowaremechanicalpartsproducedPrinting52Howaremechanicalpartsproduced塗裝信賴性測試53Howaremechanicalpartsproduced塗裝信賴性測試54Howaremechanicalpartsproduced五金產品塗裝信賴性測試介紹五金產品在噴漆後需要作油漆硬度、耐溶性、附著力、沖擊等信賴性測試，另外還需要根據客戶的要求對噴漆面作色差和膜厚的確認。55Howaremechanicalpartsproduced測試設備色差計採用minota品管級色差計，可測得漂準色與比較色之明暗度及色彩的差別，藉以減少色差值耐候試驗機可模擬塗膜在一般環境的耐候性56Howaremechanicalpartsproduced耐磨測試機針對客戶對塗膜耐的要求，選擇作業性良好且符合所需求的塗料，並維持品品質百格刀利用百格刀及3m膠布，可方便測得塗膜的密著性能測試設備57Howaremechanicalpartsproduced光澤計可測得塗膜的光澤度，藉以維持產品品質膜厚計可檢測塗膜厚度測試設備58Howaremechanicalpartsproduced黏度計可檢測塗料黏度，以維持塗料性能及品質標準光源計可模擬各種光源，進而使色彩比對能在標準的條件下進行，以維持品質測試設備59Howaremechanicalpartsproduced硬度計可檢測塗膜硬度，本公司採用三菱鉛筆硬度計冷熱試驗機可檢測塗膜在高低溫的變化的情形測試設備60Howaremechanicalpartsproduced61HowaremechanicalpartsproducedRawmaterials(plastic)62HowaremechanicalpartsproducedBasicplasticresinintroduction63Howaremechanicalpartsproduced塑膠粒---染色前vs.染色後64HowaremechanicalpartsproducedPlasticmaterial防火等級FR(FlameRetardant)GradeHBV2V1V05V65Howaremechanicalpartsproduced最常用塑膠模具---注塑模(mold)注塑機(InjectionMachine)Injectionmold&machine66Howaremechanicalpartsproduced1、射出系統(injectionsystem)2、鎖模系統(lockingsystem)注塑機基本結構67Howaremechanicalpartsproduced3、動力系統(powersystem)4、電控系統(electricbox)5、頂出系統(ejectionsystem)注塑機基本結構68Howaremechanicalpartsproduced射出成型周邊設備機械手除濕乾燥機粉料機模溫機69HowaremechanicalpartsproducedInjectionmachine小噸位機台大噸位機台70Howaremechanicalpartsproduced注塑成型生產現場No.Q'ty1625374154627381491759450Ton--Toshiba350Ton280Ton--Toshiba250Ton80Ton350Ton--ToshibaDescription160Ton800Ton450Ton每一個射出成型(注塑)廠都會安排大小不一的各種成型機台以生產各種不同尺寸的成型件，機台數量則視各公司的產能需求而定。71Howaremechanicalpartsproduced72HowaremechanicalpartsproducedInjectionprocessintroduction73Howaremechanicalpartsproduced充填、保壓、冷卻完畢合模完畢，准備注塑合模（下一周期）產品與模具分離頂出塑件開模模具動作原理Animation#1Animation#5Animation#674HowaremechanicalpartsproducedCoverrightCoverleftInjectionVideo#21Video#22Video#23–RobotpickingVideo#24–Robotpicking75HowaremechanicalpartsproducedCavityorFemaledie(母模)Nano-scaleTipl