In the stamping process of car welcome pedal trimming, controlling the scrap rate requires a systematic solution encompassing raw materials, molds, processes, operations, equipment, testing, and the environment. Quality improvement is achieved through refined management and technological optimization.
Raw material quality is the foundation of stamping. car welcome pedal trim often use materials such as stainless steel and aluminum alloys, whose hardness, toughness, and thickness uniformity directly affect the forming effect. If the material has internal defects, surface oxidation, or thickness deviations, cracking, wrinkling, or dimensional deviations are likely to occur during stamping. Therefore, it is necessary to strictly screen suppliers and conduct chemical composition analysis, mechanical property testing, and surface defect detection on each batch of raw materials to ensure they meet design requirements. For example, the corrosion resistance of stainless steel sheets needs to be tested, and the plastic deformation capacity of aluminum alloys needs to be verified, eliminating scrap caused by material problems at the source.
Mold design and maintenance are the core of stamping. The precision, clearance, cutting edge sharpness, and structural rationality of the mold directly determine the product yield. If the die clearance is too large, uneven material flow will lead to burrs on the pedal edges or dimensional errors; if the cutting edge is worn, tearing or corner collapse will occur during punching. Therefore, die parameters need to be optimized according to material characteristics, such as using a gradual clearance design to adapt to the deformation requirements of different parts; at the same time, a regular maintenance system should be established, checking the die wear daily, repairing or replacing worn parts in a timely manner, and calibrating the die accuracy with a laser measuring instrument to ensure that it is in optimal condition for a long time.
Optimization of stamping process parameters is crucial. The pressure, speed, stroke, and lubrication method of the press must be matched with the material characteristics. For example, stainless steel requires higher pressure to ensure full forming, while aluminum alloys require controlled pressure to avoid cracking; insufficient lubrication will lead to increased friction between the material and the die, resulting in scratches or material sticking, while excessive lubrication may contaminate the pedal surface. Therefore, the optimal parameter combination needs to be determined through process experiments, such as using a segmented pressing process, applying lower pressure in the early stage of forming to prevent cracking, and gradually increasing the pressure in the later stage to ensure dimensional accuracy; at the same time, a special lubricant should be selected, and its spraying amount and uniformity should be controlled.
The skills and standard execution of operators are important guarantees. Stamping processes demand high operational skills. Deviations in feeding position, failure to promptly remove scrap, or improper equipment operation can all lead to defective products. For example, feeding misalignment can cause misalignment of pedal holes, and accumulated scrap can scratch the die or pedal surface. Therefore, it is necessary to strengthen operator training, improving their skills through simulated operation and case studies. Simultaneously, standardized operating procedures should be established, such as requiring pre-operation equipment checks, the use of positioning devices during feeding, and post-processing cleaning of the die and worktable. Video monitoring and regular assessments should ensure adherence to these procedures.
Equipment condition monitoring and maintenance are crucial. The precision, stability, and lubrication system of the press directly affect stamping quality. Leaks in the hydraulic system can cause pressure fluctuations, resulting in uneven pedal thickness; wear in transmission components can generate vibration, causing ripples on the pedal surface. Therefore, a preventative maintenance system should be established, including daily checks of equipment operating parameters such as pressure, temperature, and vibration; regular replacement of hydraulic oil, lubricating oil, and wear parts; and testing equipment precision using a laser interferometer to ensure optimal operating conditions.
The detection and feedback mechanism is the last line of defense in quality control. Multiple inspection steps need to be implemented during the stamping process, such as first-piece inspection, in-process sampling, and final product inspection. Tools like calipers and projectors are used to inspect pedal dimensions, hole positions, and surface quality. Defective products are immediately isolated, and the causes are analyzed to adjust process parameters or mold conditions. Simultaneously, a quality traceability system should be established to record the raw material batch, mold usage count, process parameters, and inspection results for each batch of products, enabling rapid identification of the root cause and preventing batch scrap.
Environmental factors are also crucial. Temperature, humidity, and cleanliness affect material properties and equipment operation. For example, high temperatures may cause material softening, making it prone to deformation during stamping; excessive humidity may accelerate mold rusting, affecting its precision. Therefore, the stamping workshop temperature must be controlled within a suitable range, humidity should be regulated using dehumidifiers, and the workshop must be kept clean, regularly removing oil and dust to provide stable environmental conditions for stamping processing.
