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Sheet metal production: Countermeasures for thin plate welding deformation

Release time:

2024-11-21

The problem of thin plate welding deformation in sheet metal process, combined with many years of practical experience, explains seven countermeasures such as welding parameter control and cooling method selection, emphasizing the importance of deformation hazards and in-depth research to meet customer needs.

In the sheet metal process, thin plate welding technology is an essential process for many product processing, especially for fine and complex polyhedral metal parts. How to solve welding deformation has become a key research point in the sheet metal forming process.

Based on our many years of project research and practice in Ctt machine, we have summarized the following methods to deal with welding deformation:

1. Welding parameter control: Set different process parameters for different materials, plate thicknesses, and different process structures. Including welding current, arc voltage, welding speed, laser welding power, etc. On the premise of meeting the function, use the minimum heat generation method to control the welding effect.

2. Selection of welding method: Commonly used are MIG, MAG, TIG, and laser welding. We must choose the corresponding welding method according to the material, plate thickness, different process structures, and surface requirements.

3. Control of shielding gas method: Shielding gas can effectively prevent the weld from being oxidized at high temperature, control the weld formation, thereby improving the quality of the weld and reducing excessive welding. At the same time, take away part of the heat from the welding position in time to reduce the deformation.

4. Selection of welding sequence: The same weld bead, different welding sequence will lead to different welding deformation of the product. Different welding sequences can be selected according to the product shape, weld direction, and length, forming directional constraints during welding, and reducing the subsequent welding deformation.

5. Selection of cooling method: timely taking away the heat generated by the welding process can most directly and effectively reduce welding deformation. Commonly used methods include copper heat transfer, water heat transfer, and gas heat transfer. Because copper has a relatively high thermal conductivity, it is very common in production. The conventional operation method is to make a heat dissipation fixture, press copper plates on both sides and the back of the weld, and pass cold water or flowing gas through the copper plate to take away heat in time. For larger containers, choosing copper cooling will be more expensive or complicated, and there is also an option to weld in a water environment.

6. Fixture shaping control: Through fixture fixing, positioning constraints are formed on the product, and deformation is restrained during the welding strain process, which can have a good effect.

7. Pre-deformation control: Through CAE analysis or actual welding deformation analysis, a fixed deformation direction and deformation mode are obtained, and the reverse pre-deformation method is adopted in advance. The welding deformation after welding and the pre-deformation amount are offset, so that the size after welding meets the requirements.

Welding deformation is the biggest hazard to the welding process and the biggest hidden quality risk in sheet metal products. Maybe no defects are found after welding, but after a certain period of time, the stress will be gradually released over time, which will lead to quality risks in the product or even scrap. Therefore, welding deformation cannot be judged by appearance. It requires continuous in-depth research, practical demonstration, and early analysis of the product. Only by adopting the most appropriate welding method and deformation control method can we meet the various needs of customers.

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