Metal Middle Frame Bending and Die-Casting to Cut Machining Waste
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Solution Overview
Problem
Conventional metal middle frame machining processes are inefficient and costly due to material wastage and complex processes like CNC machining, which hinder cost reduction and production efficiency.
Innovation Solution
A process involving sheet material cutting, finish machining, bending to form an R-angle metal border frame, welding, and die-casting to combine with a middle plate, reducing material waste and intermediate processes while improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If CNC machining is performed on integrally formed rough blank, then manufacturing precision can be achieved, but material waste increases and production efficiency decreases
Solution Approach 1:
The manufacturing process is segmented into distinct stages: forming rough blank, CNC machining the rough blank, and assembling the machined parts. This segmentation allows each stage to be optimized independently, with CNC machining focused only on critical precision areas rather than the entire component, thereby reducing overall machining time and improving production efficiency while maintaining necessary manufacturing precision.
2Manufacturing precision
If CNC machining is performed on integrally formed rough blank, then manufacturing precision can be achieved, but material waste increases
Solution Approach 1:
The process segments manufacturing into forming, selective machining, and assembly. CNC machining is applied only to specific regions requiring precision rather than the entire rough blank, significantly reducing material waste while maintaining necessary manufacturing precision for critical features.
Solution Approach 2:
CNC machining is applied locally to specific areas of the rough blank that require high precision, rather than machining the entire component. This localized approach maintains manufacturing precision where needed while minimizing material waste in areas where forming already provides sufficient accuracy.
3Loss of substance
If separately forming metal border frame and middle plate, then material utilization improves, but process complexity increases
Solution Approach 1:
The product is segmented into separately formed metal border frame and middle plate components. This segmentation improves material utilization by allowing each component to be formed from optimized blank shapes. The increased process complexity is managed through standardized forming and assembly procedures, with the border frame and middle plate each having dedicated forming processes that are then integrated through assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes material waste, lowers raw material costs, and significantly reduces machining time, enhancing production efficiency and product quality by using a bending, welding, and die-casting process.
Implementation Method 1
providing a die-casting metal liquid, thereby obtaining a die-cast middle plate
Implementation Method 2
welding the metal border frame
Implementation Method 3
bending the linear profile after finish machining, obtaining a metal border frame with an R angle
Data Source
AI summary
The present disclosure relates to a process of machining a metal middle frame, which includes the following steps of: obtaining a sheet material and cutting the sheet material into a linear profile; performing a finish machining to the linear profile; bending the linear profile after the finish machining, obtaining a metal border frame with an R angle; welding the metal border frame; and placing the metal border frame after the welding in a die-casting mold, providing a die-casting metal liquid, thereby obtaining a die-cast middle plate connected to the metal border frame, so as to form the metal middle frame.