Controlling the scrap rate during the processing of stamping parts home appliance parts is the key to ensuring production efficiency and product quality. It requires systematic management from multiple dimensions such as raw material control, mold management, process optimization, and personnel operation.
The quality of raw materials is the basic factor that determines the yield rate of stamping parts. Poor quality raw materials, such as uneven materials and large thickness deviations, are very likely to crack and deform during the stamping process, which directly leads to scrap. Therefore, it is necessary to strictly screen raw material suppliers to ensure that the purchased metal sheets or other materials meet the quality standards. After each batch of raw materials enters the factory, it must be strictly inspected, including material composition testing, surface quality inspection, and mechanical properties testing. Only raw materials that pass the inspection can be put into production, reducing the possibility of scrap from the source.
As the core tool for stamping processing, the quality and state of the mold have a direct impact on the scrap rate. Unreasonable mold design, such as insufficient structural strength of the mold and improper demoulding angle, will lead to poor forming of stamping parts. In the long-term use of the mold, if it is not repaired in time due to wear, deformation or damage, it will also cause defects such as dimensional deviation and burrs in the stamping parts. Therefore, in the mold design stage, the shape, size and processing requirements of the stamping parts should be fully considered to carry out scientific and reasonable design; during the use of the mold, the mold should be regularly inspected, maintained and maintained, the worn parts should be repaired in time, and the damaged parts should be replaced to ensure that the mold is always in good working condition.
Reasonable setting of stamping process parameters is an important link in controlling the scrap rate. Parameters such as pressure, stamping speed, and mold temperature in the stamping parts home appliance parts processing process will affect the forming quality of stamping parts. Excessive pressure may cause excessive deformation or even rupture of stamping parts; too little pressure will cause incomplete forming of stamping parts. Too fast stamping speed will cause uneven material flow, wrinkles, strains and other defects; too slow speed will affect production efficiency. Therefore, it is necessary to accurately adjust the process parameters according to the characteristics of the raw materials, the structure of the mold and the requirements of the stamping parts, and continuously monitor the stability of the parameters during the production process, and make fine adjustments in time according to the actual situation to ensure the smooth progress of the stamping process.
The skill level and work attitude of the operator also have an important impact on the scrap rate. Skilled and standardized operation can effectively avoid the generation of waste products caused by human errors. During the stamping process, operators need to accurately master the operation methods of the equipment and strictly follow the operating procedures to load materials, adjust molds, start equipment and other operations. At the same time, they must have a certain sense of quality and responsibility, carefully observe the forming of stamping parts during the production process, and once an abnormality is found, stop the machine for inspection in time, analyze the cause and take corresponding measures to solve the problem. Enterprises should strengthen the training of operators, organize skill learning and assessment regularly, and improve the professional level and quality awareness of operators.
The management of the production environment is also an important aspect of controlling the scrap rate. Environmental factors such as temperature, humidity, and cleanliness in the stamping workshop will affect the quality of stamping parts. For example, if the ambient humidity is too high, metal sheets are prone to rust, affecting the surface quality of stamping parts; if there is too much dust in the workshop, it may enter the mold gap, causing defects such as indentations and scratches on stamping parts. Therefore, it is necessary to keep the workshop environment clean and dry, reasonably control the temperature and humidity, and regularly clean the production equipment and work area to create good environmental conditions for stamping processing.
Establishing a sound quality inspection system is an effective means to timely discover scrap and control the scrap rate. In the stamping parts production process, multiple inspection links should be set up, including first-piece inspection, patrol inspection and finished product inspection. First-piece inspection is to conduct a comprehensive inspection of the first stamping part at the beginning of production to ensure that the process parameters are set correctly and the mold is in good condition; patrol inspection is to regularly conduct random inspections of stamping parts during the production process to promptly discover and correct problems in the production process; finished product inspection is to conduct a comprehensive quality inspection of the stamping parts that have been processed to ensure that the products flowing into the next process or leaving the factory are qualified. Through strict quality inspection, scrap can be discovered in time and the causes can be analyzed, and targeted measures can be taken to improve, thereby effectively controlling the scrap rate.
Controlling the scrap rate in the process of stamping parts home appliance parts processing requires starting from multiple aspects such as raw materials, molds, processes, personnel, environment and quality inspection, and establishing a comprehensive and systematic management system. Only when all links are closely coordinated and managed in a coordinated manner can the scrap rate be effectively reduced, production efficiency and product quality can be improved, and greater economic benefits can be created for the enterprise.
