If the sheet metal part is flat and stress free, the subsequent processing will be very smooth. Of course, to achieve this ideal effect, the sheet metal parts must be leveled. In this article, we will list 12 reasons why it is worth adding leveling.
1. The received sheet metal parts are of poor quality
At present, steel is more scarce than ever before. What if the warpage of the received sheet metal parts is far beyond the allowable tolerance? Returning materials can not solve the problem, because there is no material in hand, why processing? At this time, one of the most effective solutions is to flatten the sheet metal. The leveler flattens the bent plate, so the tolerance returns to the correct range.
2. The customer complains about the deformation of sheet metal parts
The stamped parts will be deformed, and the parts processed by thermal cutting processes such as laser cutting, plasma cutting and flame cutting are no exception. The reason is that processing releases the internal stress of the material. The deformation produced in the stamping process or the thermal effect in the cutting process aggravates the deformation of the material. Although the deformation is caused by the process, this does not mean that the customer will accept the deformed parts. There is a remedy: the leveler can level the bent parts in seconds.
3. Angle error often occurs after bending
Angle error after bending? This may be due to materials. Because the plate often has its own internal stress, although it is not visible to the naked eye and difficult to measure. If the springback during bending is different from the expected value, it may be caused by internal stress. Leveling can also help solve this problem. Leveling treatment can not only level the bent plate, but also reduce the internal stress of the plate to the greatest extent. This is conducive to all subsequent processing and allows you to obtain stable processing results.
4. The adjustment time of welding operation area is too long
Are there parts piled up in front of the welding operation area because the adjustment time of the actual operation is longer than planned? This may also be because the internal stress of sheet metal parts slows down the operation speed of employees. If the sheet metal parts cannot be clamped smoothly in the fixture as required, it will take time to make unnecessary adjustments. If the sheet metal parts sent for welding have been leveled, the welding speed will be much faster.
5. The components after welding must be reworked
There seems to be no problem before welding, but the result after welding is unexpected! If the machining result does not meet the tolerance requirements, it must be reworked. Welded components are also affected by built-in internal stresses: invisible, but still present. The heat during welding aggravates the deformation and exceeds the tolerance limit. Therefore, it is best to carry out leveling treatment before welding to eliminate internal stress to the greatest extent.
6. Tolerance accumulation exceeds the limit
In the processing process, each tolerance is qualified, but it is found that the tolerance is obviously unqualified after welding. One reason may be that each machining is too close to the tolerance limits of its process. Finally, the sum exceeds the allowable tolerance range. Therefore, it is best to produce as accurately as possible from the beginning. If it’s not difficult to straighten the sheet metal, do it.
7. Quality problems of finished products
Even if the finished product looks good, the inner sheet metal parts may still have internal stress. Depending on the load on the component, the internal stress will be released at a later stage – which may damage the finished product. However, the quality problems complained by customers can be solved by flattening the parts.
8. The stability of the shape of parts is affected
The setting of laser cutting machine is completely correct; Stamping die is no problem. However, the shape of parts does not have its due stability. The internal stress of sheet metal can also be the reason. Therefore, it is best to carry out leveling treatment first to prevent trouble.
9. The service life of the die is too short
Molds are expensive. They are even more annoying when they are used for a shorter time than expected. However, this can be avoided: compared with the sheet metal parts with large initial internal stress, the sheet metal parts after leveling have less loss to the die. The most important thing is that there are fewer mold failures. Therefore, leveling treatment can improve productivity.
10. The press faces the problem of increasing production capacity
The more strokes of the press, the more parts will be punched out. This can improve its productivity and economic benefits. But just setting a higher number of strokes on the machine is not enough. If the process is not further adjusted, there is a risk of damage to the mold or parts. One way to adjust the process is to use leveled materials. In this way, the number of strokes of the press can be increased – thus increasing the output.
11. Too many rejected products are rejected by the full-automatic welding machine
Automatic welding machines are extremely strict in tolerance requirements. If the actual value of a component is too different from the rated tolerance, it will soon be classified as unqualified and become rejected. This in turn reduces the economy of the fully automatic welding machine. However, if the parts are leveled before being sent to the welding machine, their production capacity can be really fully utilized.
12. The ejected sheet metal will damage the laser head
In the process of laser cutting, sometimes the internal stress of sheet metal parts will be released. At this time, if a cutting piece suddenly jumps up and pops up, it is likely to hit or even damage the laser head, resulting in subsequent unnecessary losses. In order to prevent the accident, the sheet metal parts should be leveled first.