鋁單板加工的詳細(xì)工序

Detailed process of the machining of single aluminum sheet

一、鈑金加工/Panel beating

1、 工程設(shè)計(jì)Project design

2、 分格繪圖Cellular drawing

3、 編制程序Work out procedures

4、 板材檢查Plate check

5、 板材下料Plate blanking

（1）根據(jù)鋁單板規(guī)格,調(diào)整剪板機(jī)上、下刀口間隙，保證間隙。

Adjust the clearance between the upper and lower cutter point of plate shears according to the specifications of single aluminum sheet.

（2）根據(jù)圖紙展開(kāi)尺寸調(diào)整剪切鋁板定位裝置，試剪后方可進(jìn)行批量生產(chǎn)。

Adjust the positioning set of the aluminum sheet to be sheared on the basis of the spreading size of drawing. Batch production may be started after the try shearing.

（3）剪板尺寸：長(zhǎng)、寬尺寸偏差和對(duì)角線(xiàn)誤差控制在YS/T429.2—2000標(biāo)準(zhǔn)要求以?xún)?nèi)。

The size of the plate shearing: The size errors of length, width and diagonal should be controlled within the requirements of YS/T429.2—2000 Standard.

（4）對(duì)所剪的每一塊板，由質(zhì)檢員記錄板塊的尺寸，并在每塊板上寫(xiě)明圖號(hào)。

The inspector of quality should record the size of each sheared plate and mark the diagram number on each plate.

6、 仿型沖剪Contour and punch

（1）根據(jù)圖紙要求，編制程序。

Program according to the requirements of drawing.

（2）選用合適沖角模并調(diào)整好。

Choose and adjust a suitable die.

（3）調(diào)整沖床定位裝置。

Adjust the positioning set of punching machine.

（4）試沖、檢查角部形狀是否符合要求。

Trial punching and check whether the angle shape conforms to requirements.

7、 壓力折彎Pressure bend

（1）根據(jù)圖紙要求，選擇合適的模具。

Choose a suitable die in line with the requirements of drawing.

（2）根據(jù)折邊高度調(diào)整后擋料裝置至要求位置。

Adjust the back material blocking equipment to the required location according to the flanging height.

（3）調(diào)整折彎?rùn)C(jī)速度和壓力。在凹模槽口用專(zhuān)用保護(hù)膜貼好，以免擠傷鋁板。

Adjust the speed and pressure of bending machine. Paste the notch of die with special protective film to avoid damaging aluminum sheet.

（4）試折檢驗(yàn)：

Trial bending test:

A、折邊高度偏差控制在±0.5mm以?xún)?nèi)，折邊無(wú)裂紋、壓痕。

The deviation of flanging height should be controlled within ±0.5mm without crack and indentation.

B、折邊角度偏差控制在±1度以?xún)?nèi)。

The deviation of the flanging angle should be restricted within ±1 degree.

C、板面尺寸控制在YS/T429.2—2000標(biāo)準(zhǔn)要求以?xún)?nèi)。

The size of plate surface should be controlled within the requirements of YS/T429.2—2000 Standard.

（5）板面無(wú)擦傷、無(wú)劃傷。

The plate surface should not be grazed or scratched.

8、異型加工Abnormal shape machining

（1）根據(jù)圖紙要求，調(diào)整輥圓機(jī)尺寸。

Adjust the size of venner reeling machine according to the drawing requirements.

（2）試輥檢驗(yàn)：Trial roll test

A、半徑尺寸偏差控制在±1.0mm以?xún)?nèi)。

The error of the size of radius should be within ±1.0mm.

B、折邊保持完好

The flanging keeps good and perfect.

9、         角封焊Angling & sealing weld

（1）    對(duì)所有折彎收角處進(jìn)行氬弧焊接。

All the bending angles shall be argon arc welded.

（2）    焊縫必須符合圖紙要求。

The welding seam must meet the drawing requirements.

10、邊角修整和角碼安裝加工

Rim angle trimming & loader installation and processing

將焊接完畢的邊角部分進(jìn)行修整打磨，將焊縫打磨光滑。

Trim and polish the welded rim angle part, and polish the welding seam shiny and smooth.

有專(zhuān)門(mén)的4臺(tái)數(shù)控轉(zhuǎn)塔沖床和專(zhuān)用作沖掛耳的小沖床，以保證掛耳的數(shù)量和質(zhì)量。

Four NC turret punch presses and the small punch press special for punching the hangers guarantee the quality and quantity of the hangers.

（1）、一般每間隔500mm安裝掛耳一個(gè)。

The hangers are installed once every 500 mm.

（2）、相鄰兩件鋁板的掛耳一定要錯(cuò)開(kāi)。

The hangers for the neighboring two aluminum sheets should be staggered.

（3）、我公司可以為施工方預(yù)留掛耳孔，以方便在現(xiàn)場(chǎng)根據(jù)施工實(shí)際情況安裝。

We can preset the hanger holes for the constructor for later installation by the actual conditions.

11、    柱焊加筋Stud welding reinforcement

（1）    根據(jù)圖紙要求規(guī)格準(zhǔn)備加強(qiáng)筋。

Prepare the reinforcing rib according to the specifications noted in the drawing.

（2）    根據(jù)圖紙要求位置，用螺柱焊機(jī)焊接螺柱。

Weld the stud with stud welding unit according to the locations specified in the drawing.

（3）    安裝緊固加強(qiáng)筋。

Install tightening reinforcing rib.

12、    表面磨光 Surface polish

用磨光機(jī)對(duì)工件的噴面進(jìn)行磨光。

Polish the spraying surface of the workpiece by polishing machine.

二、前處理 Pre- treatment

13、    藥品化驗(yàn)drug test

14、     清洗鉻化cleansing & chromating

采用具有質(zhì)量穩(wěn)定可靠的美國(guó)PPG認(rèn)證的八步法：

Adopt the eight steps of the reliable and stable USA PPG Certification.

堿洗alkali washing——輕微鏤蝕slightly carved and corroded（除油remove oil）

水洗water washing——清水湍流沖洗wash by clean rushing water

水洗water washing——清水湍流沖洗wash by clean rushing water

酸洗 acid washing——去除氧化物remove oxide（中和neutralize）

水洗water washing——清水湍流沖洗wash by clean rushing water

轉(zhuǎn)化層conversion layer——無(wú)定型鉻酸鹽chromate（鉻化chromating）

水洗water washing——清水湍流沖洗wash by clean rushing water

最后清洗final washing——清水湍流沖洗 wash by clean rushing water（去除表面微粒remove the surface particle）

鋁材按要求烘干處理Aluminum product should be dried according to the requirements.（80℃）

三、靜電噴涂

Electrostatic spray

15、涂料配制 Dosing of coat

16、靜電噴涂 Electrostatic spray

噴底漆    烘烤   噴面漆    烘烤   噴罩光漆     烘烤   

Spray prime coat, bake, spray top coat, bake, spray finishing varnish, bake

17、高溫固化High temperature solidification

18、品質(zhì)檢驗(yàn)Quality inspection

A.    氟碳涂層外觀(guān)質(zhì)量的要求標(biāo)準(zhǔn)

Requirements on the fluorocarbon coating visual appearance

⑴　在自然光下3M遠(yuǎn)的垂直角度目視涂層表面時(shí)，涂層應(yīng)無(wú)流痕、氣泡、夾雜物或其它表面缺陷。

The coating should be free of flow mark, bubble, inclusion or other surface flaws if being observed at a distance of 3 meters vertically under daylight.

⑵　對(duì)于涂層表面上的輕微劃傷，可采用室固化體系的氟碳（自干漆）漆來(lái)修補(bǔ)。修補(bǔ)（72小時(shí)）后，應(yīng)與原涂層的顏色和光澤一致。

The light scratch on the coating surface can be repaired by the PVDF coating (air-drying varnish) of the room curing system. It should be in line with original coating in color and gloss after repairing.

B.     氟碳涂膜的干膜標(biāo)準(zhǔn)

Specifications for the dry film of the fluorocarbon coating film

⑴ 底漆5um—10um；面漆25um—35um；清漆10um—20um。

 Prime coat5um—10um；top coat 25um—35um；varnish10um—20um。

⑵ 平均漆膜厚度：二涂≥30um；三涂≥40um；四涂≥50um

Average film thickness：two coatings≥30um；three coatings≥40um；four coatings≥50um

C.    氟碳涂膜的色差檢驗(yàn)標(biāo)準(zhǔn)

Inspecting standard for the fluorocarbon film coating

按GB/T9761，在非直射自然光或均勻光源下，目視檢查試件或產(chǎn)品的顏色均勻性，目視檢查距離為10M；單色涂料用電腦色差儀△E≤2.0NBS。

According to GB/T9761，under non-direct day light or under uniform source of light， visually check the specimen or product for the color evenness. the visually inspecting distance is 10 meters. For mono-color coating, check with computer color difference meter, △E≤2.0NBS.

D.氟碳涂膜的光澤檢驗(yàn)標(biāo)準(zhǔn)

Gloss inspecting standard for fluorocarbon film coating

按GB/T9754，用60°光度計(jì)測(cè)量試件或產(chǎn)品的光澤度，至少到10個(gè)讀數(shù)，并計(jì)算平均值。光澤度的等級(jí)由用戶(hù)選定。同批產(chǎn)品光澤度差別不應(yīng)超過(guò)±5個(gè)單位。

According to GB/T9754，measure the gloss of the specimen or product with 60°photomerer. Take at least 10 readings and calculate the average value. The gloss rate is chosen by the customer. The gloss difference of the same batch of products should not exceed ±5 units.

19、貼膜包裝 Film pasting & packing

（1）                產(chǎn)品在制作轉(zhuǎn)序過(guò)程中和成品的搬運(yùn)過(guò)程中應(yīng)作到輕拿輕放，防止在搬運(yùn)過(guò)程中碰傷、撞傷、擦傷。

The product should be carefully handled  against any bump or scratch during the transit of the semi-finished product and the transport of the final product.

（2）                包裝：噴涂面貼保護(hù)膜，保護(hù)膜盡量無(wú)氣泡、無(wú)皺紋，與板面緊密

Packing：The spray-coated surface is pasted with protective film. The protective film should possibly free of bubbles or winkles and tightly attached to the plate surface.

（3）                成品包裝不可將編號(hào)、標(biāo)識(shí)包入包裝內(nèi)。

For the finished product packing, the no. and identification should not put inside the package.

（4）                成品在車(chē)間儲(chǔ)存時(shí)，必須放在指定的待運(yùn)區(qū)，整齊、直立堆放，并立好標(biāo)簽架，注明工程名稱(chēng)、產(chǎn)品規(guī)格、批號(hào)等。

In case of storage in the workshop, the finished goods must stand in order in the designated transit area with label support indicating the name of works, product specifications, batch number, etc.

20、終檢裝運(yùn)Final inspection & shipping

（1）    成品裝車(chē)必須有質(zhì)檢合格證方可裝車(chē)啟運(yùn)。

Only the finished goods with the Quality Certificate can be loaded onto the truck and shipped out.

（2）    由于我們的產(chǎn)品質(zhì)量較輕，因此只靠人力輕拿輕放就能解決裝卸問(wèn)題。

Because of light weight, the product can be manually loaded and unloaded.

（3）    運(yùn)輸方式通常采用汽車(chē)運(yùn)輸，我司有專(zhuān)門(mén)獨(dú)立的車(chē)運(yùn)管理和車(chē)隊(duì)及專(zhuān)門(mén)的裝運(yùn)人員，確保產(chǎn)品安全及時(shí)的運(yùn)送到需方所在地。

Usually the products are transported by vehicle. We have the special shipping team responsible for the product’s transportation, which ensures the safe and timely delivery of the products to our customers.

安裝操作規(guī)程和維護(hù)指南

Installation operating regulations and maintenance guide

（1）、安裝工序：測(cè)量放線(xiàn)、支座點(diǎn)錨固、受力框架安裝、壁板與組件裝配、密封膠灌縫、揭掉保護(hù)膜并清潔幕墻表面。

Install process: paying off, supporting seat anchors, frame is fixed, wallboard and components are assembled, fluid sealant is poured into crack, lift up away protection film and clean the surface of curtain wall.

（2）、操作規(guī)程：a、鋁幕墻的框架應(yīng)該使用表面經(jīng)陽(yáng)極氧化處理的鋁型材，不可使用型鋼，因框架與壁板若為2種金屬，易產(chǎn)生電極電位差，使鋁板受到腐蝕。

Operating regulations: a. The frame of aluminum curtain wall should adopt aluminum section bar with a surface being oxidized by positive electrode, and section steel is forbidden.  If the frame and wallboard are made of two kinds of metals, electrode potential difference will easily occur and the aluminum will be corroded.

B、安裝壁板時(shí)要使用不銹鋼螺絲或鍍鋅螺絲，不得使用普通螺絲。

Use stainless screw or galvanized screw when install wallboard, and ordinary screw is forbidden.

C、框架系統(tǒng)的每根豎料應(yīng)與主體結(jié)構(gòu)的預(yù)埋鐵件牢固連接，橫料與豎料間再以不銹鋼螺栓固定，保證安裝耐久性。

Each upright material of frame system should be firmly linked with buried iron piece of the principal structure. Fasten the horizontal material and the upright material with stainless bolt to ensure the durability.

D、幕墻框架應(yīng)與主體建筑的避雷系統(tǒng)良好連接。

The curtain wall frame should be well linked with the lighting protection system of the principal building.

（3）、維護(hù)：可不定期進(jìn)行清洗，保持外觀(guān)持久靚麗。

Maintenance: cleanse it irregularly to keep it clean and pretty.