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Why do car manufacturing need laser processing?

Published:2021-01-12 Browse:5Editor in charge:DNE Laser (Member of Bystronic)

After entering the 21st century, in the automobile industry in Japan, the United States and Europe, people are paying more and more attention to maintaining their competitiveness in the market, especially R&D capabilities. Small batch production and customized production have become a development direction. This production method combines the advantages of manual manufacturing and mass production, while avoiding the disadvantages of excessive manual production costs and lack of flexibility in mass production.

 

Under these conditions, manufacturers of laser processing equipment must continue to innovate their products and maintain their product competitiveness. In the design, they must not only meet the needs of the current automotive panel processing applications, but also To prepare for the future development of users, that is, to provide reasonable solutions in advance for the small batch production mode. In response to the recent years of automotive body industry users have shown a strong demand for equipment performance improvement in the following three aspects-faster processing speed, larger processing range (especially the current very successful MPV, SUV, pickup truck for this The demand is stronger) and with the characteristics of flexibility, compact structure, and simple operation, an industrial company specially made a brand-new design for its flagship 3D laser processing machine. It adopts a gantry frame structure, all moving parts are erected in the air, and the entire processing area is open to users, with very good accessibility. Users can choose a variety of configuration schemes from manual to fully automatic according to their own products. It has reached an unprecedented level in terms of dynamic performance. At the same time, the integrated structure design is adopted, which is not only easy and quick to install, but also has the functions of quick installation and quick repositioning between different production departments, just like the emerging lathes and grinders.

 

As people's requirements for car comfort and safety are getting higher and higher, gradually increasing body size, considering the use of four-wheel drive technology, adding more electronic equipment, etc. have become more and more trends in the automotive industry, and all of these Both will inevitably increase the weight of the entire vehicle and cause a contradiction with the goal of reducing fuel consumption. The only solution is to reduce the weight of the vehicle body without affecting performance. This can be verified from the current extensive use of internal high pressure forming parts (IHU) and high-hardness steel materials (warm forming steel) in the field of automobile bodywork.

 

Internal high pressure molding is to make the outer wall of the hollow part (mainly tubular part) in the mold completely close to the mold through high pressure emulsion (water and additives). The parts produced by this method have high forming accuracy and light weight, and can form multiple pipes that originally need to be welded at one time, reducing the number of welding times and improving the overall strength. Its good strength-to-weight ratio and low production cost enable It has also been widely used in body and chassis structures. Because the shape of the internal high pressure forming part is very complicated, and there are a certain number of holes and grooves to be cut, it cannot be processed with traditional punching dies. Three-dimensional laser cutting is currently one of the best solutions.

 

The high-hard steel material (warm forming steel) has extremely high internal tension (1500MPa/mm2), so the elastic deformation is very small, and it is very suitable for use in the parts of the car body that require high strength, such as bumper brackets, front beams, Positions of side beams, stiffeners, etc. Under the same strength requirements, the weight of high-hard steel is much lighter than normal steel, and many welding processes can be reduced. Therefore, the weight of the car body can be effectively reduced under the premise of ensuring safety. Because of this, parts of this material can hardly be processed by traditional die cutting methods, and the only solution is 3D laser cutting.