铝单板加工的详细工序

Detailed process of the machining of single aluminum sheet

一、钣金加工/Panel beating

1、 工程设计Project design

2、 分格绘图Cellular drawing

3、 编制程序Work out procedures

4、 板材检查Plate check

5、 板材下料Plate blanking

（1）根据铝单板规格,调整剪板机上、下刀口间隙，保证间隙。

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

（2）根据图纸展开尺寸调整剪切铝板定位装置，试剪后方可进行批量生产。

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：长、宽尺寸偏差和对角线误差控制在YS/T429.2—2000标准要求以内。

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）对所剪的每一块板，由质检员记录板块的尺寸，并在每块板上写明图号。

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

6、 仿型冲剪Contour and punch

（1）根据图纸要求，编制程序。

Program according to the requirements of drawing.

（2）选用合适冲角模并调整好。

Choose and adjust a suitable die.

（3）调整冲床定位装置。

Adjust the positioning set of punching machine.

（4）试冲、检查角部形状是否符合要求。

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

7、 压力折弯Pressure bend

（1）根据图纸要求，选择合适的模具。

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

（2）根据折边高度调整后挡料装置至要求位置。

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

（3）调整折弯机速度和压力。在凹模槽口用专用保护膜贴好，以免挤伤铝板。

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

（4）试折检验：

Trial bending test:

A、折边高度偏差控制在±0.5mm以内，折边无裂纹、压痕。

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

B、折边角度偏差控制在±1度以内。

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

C、板面尺寸控制在YS/T429.2—2000标准要求以内。

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

（5）板面无擦伤、无划伤。

The plate surface should not be grazed or scratched.

8、异型加工Abnormal shape machining

（1）根据图纸要求，调整辊圆机尺寸。

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

（2）试辊检验：Trial roll test

A、半径尺寸偏差控制在±1.0mm以内。

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

B、折边保持完好

The flanging keeps good and perfect.

9、         角封焊Angling & sealing weld

（1）    对所有折弯收角处进行氩弧焊接。

All the bending angles shall be argon arc welded.

（2）    焊缝必须符合图纸要求。

The welding seam must meet the drawing requirements.

10、边角修整和角码安装加工

Rim angle trimming & loader installation and processing

将焊接完毕的边角部分进行修整打磨，将焊缝打磨光滑。

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

有专门的4台数控转塔冲床和专用作冲挂耳的小冲床，以保证挂耳的数量和质量。

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

（1）、一般每间隔500mm安装挂耳一个。

The hangers are installed once every 500 mm.

（2）、相邻两件铝板的挂耳一定要错开。

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

（3）、我公司可以为施工方预留挂耳孔，以方便在现场根据施工实际情况安装。

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）    根据图纸要求规格准备加强筋。

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

（2）    根据图纸要求位置，用螺柱焊机焊接螺柱。

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

（3）    安装紧固加强筋。

Install tightening reinforcing rib.

12、    表面磨光 Surface polish

用磨光机对工件的喷面进行磨光。

Polish the spraying surface of the workpiece by polishing machine.

二、前处理 Pre- treatment

13、    药品化验drug test

14、     清洗铬化cleansing & chromating

采用具有质量稳定可靠的美国PPG认证的八步法：

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

碱洗alkali washing——轻微镂蚀slightly carved and corroded（除油remove oil）

水洗water washing——清水湍流冲洗wash by clean rushing water

水洗water washing——清水湍流冲洗wash by clean rushing water

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

水洗water washing——清水湍流冲洗wash by clean rushing water

转化层conversion layer——无定型铬酸盐chromate（铬化chromating）

水洗water washing——清水湍流冲洗wash by clean rushing water

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

铝材按要求烘干处理Aluminum product should be dried according to the requirements.（80℃）

三、静电喷涂

Electrostatic spray

15、涂料配制 Dosing of coat

16、静电喷涂 Electrostatic spray

喷底漆    烘烤   喷面漆    烘烤   喷罩光漆     烘烤   

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

17、高温固化High temperature solidification

18、品质检验Quality inspection

A.    氟碳涂层外观质量的要求标准

Requirements on the fluorocarbon coating visual appearance

⑴　在自然光下3M远的垂直角度目视涂层表面时，涂层应无流痕、气泡、夹杂物或其它表面缺陷。

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　对于涂层表面上的轻微划伤，可采用室固化体系的氟碳（自干漆）漆来修补。修补（72小时）后，应与原涂层的颜色和光泽一致。

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.     氟碳涂膜的干膜标准

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.    氟碳涂膜的色差检验标准

Inspecting standard for the fluorocarbon film coating

按GB/T9761，在非直射自然光或均匀光源下，目视检查试件或产品的颜色均匀性，目视检查距离为10M；单色涂料用电脑色差仪△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.氟碳涂膜的光泽检验标准

Gloss inspecting standard for fluorocarbon film coating

按GB/T9754，用60°光度计测量试件或产品的光泽度，至少到10个读数，并计算平均值。光泽度的等级由用户选定。同批产品光泽度差别不应超过±5个单位。

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、贴膜包装 Film pasting & packing

（1）                产品在制作转序过程中和成品的搬运过程中应作到轻拿轻放，防止在搬运过程中碰伤、撞伤、擦伤。

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）                包装：喷涂面贴保护膜，保护膜尽量无气泡、无皱纹，与板面紧密

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）                成品包装不可将编号、标识包入包装内。

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

（4）                成品在车间储存时，必须放在指定的待运区，整齐、直立堆放，并立好标签架，注明工程名称、产品规格、批号等。

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、终检装运Final inspection & shipping

（1）    成品装车必须有质检合格证方可装车启运。

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

（2）    由于我们的产品质量较轻，因此只靠人力轻拿轻放就能解决装卸问题。

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

（3）    运输方式通常采用汽车运输，我司有专门独立的车运管理和车队及专门的装运人员，确保产品安全及时的运送到需方所在地。

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.

安装操作规程和维护指南

Installation operating regulations and maintenance guide

（1）、安装工序：测量放线、支座点锚固、受力框架安装、壁板与组件装配、密封胶灌缝、揭掉保护膜并清洁幕墙表面。

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）、操作规程：a、铝幕墙的框架应该使用表面经阳极氧化处理的铝型材，不可使用型钢，因框架与壁板若为2种金属，易产生电极电位差，使铝板受到腐蚀。

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、安装壁板时要使用不锈钢螺丝或镀锌螺丝，不得使用普通螺丝。

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

C、框架系统的每根竖料应与主体结构的预埋铁件牢固连接，横料与竖料间再以不锈钢螺栓固定，保证安装耐久性。

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、幕墙框架应与主体建筑的避雷系统良好连接。

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

（3）、维护：可不定期进行清洗，保持外观持久靓丽。

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