1. Processing equipment and technology selection
CNC punching process
Adopt high-precision CNC punching machine (error ≤ 0.1mm), control the punching position and spacing through programming, which is suitable for mass production of regular hole types (such as round and square).
Use servo motor drive system instead of traditional hydraulic drive to reduce mechanical vibration during punching and improve repeated positioning accuracy.
Laser cutting technology
For complex artistic hole types (such as gradient patterns and irregular geometric shapes), laser cutting technology (error ≤ 0.05mm) is used to avoid aperture deviation caused by mold wear.
Laser cutting supports dynamic focusing function to meet the precise punching requirements of curved or bent plates.
2. Mold and process parameter optimization
Mold design and maintenance
Customize special punching molds to ensure that the blade hardness is ≥ 60HRC, and regularly check the blade wear (it is recommended to grind after every 1000 productions).
For plates with high perforation rate (>50%), multi-station molds are used for step-by-step stamping to reduce the hole position offset caused by stress concentration in a single stamping.
Process parameter control
Adjust the stamping speed to 200-300 times/minute to avoid local deformation of the aluminum plate caused by high-speed stamping;
Set the stamping gap to 8%-12% of the plate thickness (such as 2mm plate thickness corresponds to 0.16-0.24mm gap) to prevent burrs or curling.
3. Material and processing environment management
Substrate quality control
Select grade 3003 or 5052 aluminum alloy with a yield strength of ≥140MPa to ensure that there is no obvious extension and deformation during the punching process;
Strictly control the flatness of the plate (error <1mm/m²), and perform leveling before pre-processing.
Processing environment optimization
The workshop temperature is controlled at 20±2℃, and the humidity is ≤60% to reduce the impact of thermal expansion and contraction on hole spacing;
Large plates (＞1500×3000mm) use vacuum adsorption positioning platform to avoid secondary positioning error.
4. Inspection and calibration process
Online inspection system
CCD visual inspection equipment is installed to monitor the hole diameter and spacing in real time, and automatically stop and adjust when the tolerance is exceeded;
For artistic pattern perforated plates, 3D scanning is used to compare the design drawings, and the tolerance range is ≤±0.3mm.
Sampling quality inspection standard
5% of the samples are taken from each batch, and the hole diameter, hole spacing and roundness are measured using a projector (allowable deviation ±0.1mm);
High-precision projects (such as light and shadow curtain walls) require full inspection, focusing on checking the linearity of the hole density gradient in the gradient area.
5. Installation and reinforcement measures
Back reinforcement and keel design
High perforation rate (＞40%) or large size plate (＞2000×4000mm) need to be equipped with transverse back reinforcement, with a spacing of ≤600mm, to prevent hole deformation during transportation and installation;
Elastic rubber gaskets are used at the keel connection points to compensate for micro-displacement caused by temperature stress.
Installation positioning benchmark
During construction, the center axis is used as the reference, and the laser line projector is used to calibrate the position of the first row of holes, and the error accumulation is controlled within ±2mm/10m.
Comprehensive suggestion: Precision engineering projects should give priority to the composite process of laser cutting + CNC bending, and match it with a full-process digital quality inspection system to achieve dual guarantees of hole accuracy and decorative effect.
