In the field of precision manufacturing, a single stamping or machining technology is already powerful enough, but when the two are deeply integrated and work in coordination, the value generated far exceeds the simple addition. The integrated manufacturing model of Dongguan Zhongchuangxing Precision Machinery Manufacturing Co., Ltd. is a perfect interpretation of this "1+1>2" effect.
The physical principles and technical logic of synergy effects
Understand the essence of process collaboration
Limitations of traditional thinking
Most enterprises treat stamping and machining as independent processes, which leads to:
Design compromise: To ensure that both processes can be realized, the design requirements have to be lowered
Cost increase: Additional clamping, positioning and inspection procedures
Quality risk: Damage and contamination caused by the transfer between processes
The collaborative philosophy of Zhongchuangxing
We regard stamping and machining as two organic components of the same manufacturing system. The relationship between them is not sequential but complementary and reinforcing.
The four dimensions of technological collaboration
1. Collaborative optimization of material properties
Traditional question
The material after stamping will undergo work hardening, which brings challenges to subsequent machining:
Aggravated tool wear
The processing accuracy has declined.
The surface quality is difficult to guarantee
Our solution
Technical path
Material selection → Stamping process design → machining strategy → Comprehensive optimization
Specific practice
For stainless steel 304
Stamping stage: Control the deformation within 15-20% to avoid excessive hardening
Machining stage: A high-speed light cutting strategy is adopted, with a linear speed of 120m/min
Result: Tool life increased by 80%, and surface roughness improved by 30%
For aluminum alloy 6061
Artificial aging should be carried out immediately after stamping (180℃×4 hours).
Eliminate internal stress and restore processing performance
The dimensional stability has been improved by 50%
2. Geometric accuracy collaborative control
Challenge
The geometric accuracy of complex parts needs to be guaranteed separately in different processes, and the cumulative error is difficult to control.
Our innovative approach
The principle of unified benchmarks
From the design of the stamping die, the positioning reference for machining should be taken into consideration
Design dedicated process holes throughout the entire manufacturing process
The reference conversion error is less than 0.005mm
Deformation prediction and compensation
Establish a database of material-process-deformation
Predict the possible deformation caused by subsequent processing during the stamping stage
Pre-compensation is carried out in the mold design
Case: Precision sensor housing
Product features: Thin wall, porous, and high flatness requirement
Traditional method: First, it is formed by stamping and then machined, with a flatness of only 0.15mm
Our approach
When stamping, reserve a machining allowance of 0.3mm
Design a special positioning structure
Vacuum adsorption clamping is adopted
Result: The flatness reached 0.05mm, an increase of 300%
3. Synergistic improvement in efficiency
Time-saving analysis
Time comparison table
The traditional process mode and the collaborative mode save costs
-----------------------------------------------
Stamping 5 days 4 days 20%
2 days of transfer, 0 100%
Machining takes 6 to 5 days with a 17% rate
Inspection: 1 day, 0.5 day, 50%
A total of 14 days, 9.5 days, and 32%
Process Reengineering
We have redesigned the manufacturing process:
Concurrent engineering: Synchronous design of stamping and machining processes
Physical integration: Workshop layout optimization to reduce the distance for material movement
Information integration: The MES system transmits process parameters in real time
4. Cost collaborative optimization
Cost composition analysis
Traditional model: Material 25% + Stamping 30% + machining 35% + management 10%
Collaborative model: Materials 25% + Manufacturing 55% + Management 20%
Key findings:
Although the collaborative model seems to increase the manufacturing ratio, in reality:
The material utilization rate has increased from 65% to 85%
The scrap rate has dropped from 5% to 1.5%
The comprehensive cost is reduced by 18-25%
Construction of a collaborative technology platform
1. Process database system
Data structure
Database architecture
├── Materials Library (Over 300 types of materials)
│ ├── Mechanical properties
│ ├── Stamping characteristics
│ └── Processing parameters
├── Craft Library (Over 5,000 Cases)
│ ├── Stamping process parameters
│ ├── Machining strategy
│ └── Collaborative optimization plan
└── Quality library
├── Defect Pattern
├── Solution
└── Preventive measures
Intelligent recommendation function
Input the product requirements, and the system will automatically recommend the best process combination with an accuracy rate of over 90%.
2. Simulation analysis platform
Multi-physics simulation capability
Stamping forming simulation (Dynaform
Processing Deformation Simulation (Deform
Thermodynamic coupling analysis
Residual stress prediction
Application effect
The number of mold trials has decreased by 70%
The process optimization cycle has been shortened by 60%
The initial success rate reached 95%
3. Real-time monitoring and feedback system
Data collection point
Stamping: 12 parameters such as pressure, speed and temperature
Machining: 18 parameters such as power, vibration and temperature
Quality inspection: 24 indicators including dimensions, shape and position tolerances, etc
Closed-loop control
Automatic warning of anomalies
Adaptive adjustment of process parameters
Quality trend prediction
In-depth analysis of typical cases
Case One: Battery connection sheets for new energy vehicles
Technical requirements
Material: Red copper T2, thickness 1.0mm
Resistance: < 0.1mΩ
Flatness: 0.1mm/100mm
Batch size: 500,000 pieces per month
Technical challenges
Copper is soft and prone to deformation after stamping
The resistance requirements are strict and precise coordination is needed
Consistency in mass production
Collaborative solution
Phase One: Process Collaborative Design
1. Optimization of stamping process
It adopts a precision progressive die with 16 workstations
Add shaping procedures and control flatness
Design a dedicated guide material structure to prevent material stretching
2. Machining strategy design
Integrate the marking process in the stamping die
Reserve the positioning reference for subsequent processing
Optimize the processing sequence and reduce the number of clamping operations
Phase Two: Production Collaborative Control
1. Online detection system
Inspect the key dimensions immediately after stamping
The data is transmitted in real time to the machining station
Automatically adjust processing parameters
2. Adaptive compensation
Monitor the batch differences of materials
Automatically compensate for process parameters
Ensure consistency between batches
Phase Three: Continuous optimization
1. Data analysis
Collect one million pieces of production data
Establish a relationship model between process parameters and quality
Identify critical control points
2. Process iteration
Optimize the process parameters once a month
Update the mold structure every quarter
Major technological innovations are carried out every year
Outcome data
Product performance
Resistance: 0.08mΩ (20% better than required)
Flatness: 0.06mm/100mm
Consistency: Cpk=2.3
Production efficiency
Production cycle: 1.2 seconds per piece
Comprehensive equipment efficiency: 94%
Model change time: 15 minutes
Quality level
First-time pass rate: 99.8%
Customer complaint rate: 0
Service life: Over 50% of the design standard
Case Two: Precision Fixtures for Medical Devices
Product features
Material: Titanium alloy TC4
Structure: Thin-walled complex curved surface
Accuracy: ±0.01mm
Aseptic requirements: Production in a 100-level cleanroom
Collaborative innovation points
1. Material processing collaboration
Vacuum annealing before stamping to relieve stress
Immediate solution treatment after stamping
2. Vacuum aging after machining
Collaborative clean production
The stamping workshop and the machining workshop are of the same clean grade
Design a dedicated material transfer channel
Establish a complete traceability system
3. Precision assurance collaboration
The precision of the stamping die is IT4 grade
The machining process adopts five-axis linkage
Online measurement compensation system
Customer value
The development cycle has been shortened by 40%
The manufacturing cost is reduced by 25%
The quality stability has been improved by 300%
The Future outlook of Collaborative Innovation
Technological development trends
Deepening of Digital Twin
1. Establish a digital model for the entire product life cycle
Achieve complete synchronization between the virtual and the real
Predictive maintenance and optimization
Integration of artificial intelligence
2. Intelligent optimization of process parameters
Automatic identification of quality defects
Intelligent decision-making for production scheduling
Expansion of new material applications
3. Co-processing of composite materials
Manufacturing of functionally graded materials
Processing of biocompatible materials
Business model innovation
Collaborative design service
Customers participate in product design
Real-time process feasibility analysis
Suggestions for Cost Optimization
Full value chain collaboration
From raw materials to the final product
Supply chain collaborative optimization
Customer usage data feedback
Platform-based operation
Establish an industry collaborative manufacturing platform
Share process knowledge
Optimize resource allocation
The construction of a collaborative culture
Team collaboration mechanism
Interdepartmental project team
Regular technical exchange meetings
Joint problem-solving mechanism
Knowledge Management System
Process Experience Library
Failed case library
Best Practice Sharing
Incentive mechanism
Collaborative Innovation Award
Cross-departmental performance evaluation
Long-term value orientation
