In the design phase of non-standard metal stamping parts, optimizing material utilization is crucial for reducing production costs and improving resource efficiency. Due to their complex shapes and diverse dimensions, non-standard parts require layout design that breaks away from the fixed patterns of standard parts. Through innovative layout and process coordination, the generation of waste material at the edges can be minimized. This process involves not only refining the geometric arrangement but also comprehensively considering material properties, mold structure, and production processes to achieve optimization across the entire chain from design to manufacturing.
Innovative layout design is fundamental to improving material utilization in non-standard stamping parts. Traditional layouts often use straight or diagonal lines, but non-standard parts, due to their irregular contours, easily create unusable "islands" at the material edges. By introducing "nested layout" technology, multiple workpieces of different shapes can be interlocked, using concave and convex structures to fill blank areas. For example, small irregularly shaped parts can be embedded into the recessed parts of large parts, or the orientation of workpieces can be adjusted by rotation or mirroring to fully fill the remaining space at the material edges. Furthermore, adopting a "mixed layout" strategy, which groups non-standard parts of different batches or specifications together, can further tap into material potential and avoid localized waste caused by the layout of a single workpiece.
Precise matching of material properties is a key prerequisite for optimizing utilization. Non-standard stamped parts often involve special materials such as high-strength steel and aluminum alloys, whose ductility and springback characteristics directly affect the feasibility of layout. During the design phase, material testing or simulation analysis is necessary to clarify parameters such as material flow stress and forming limits, and adjust the layout gap and overlap value accordingly. For example, for materials prone to springback, the layout gap can be appropriately increased to reduce friction and avoid increased defects due to material deformation; while for materials with good ductility, the gap can be reduced to increase material filling rate. In addition, selecting a material thickness that matches the workpiece shape, avoiding excessive thickness leading to excess material accumulation or excessive thinness causing breakage risk, is also an important means of balancing utilization and quality.
Collaborative design of mold structures can significantly reduce material waste. The complex shapes of non-standard parts often require multi-process forming. If the mold design lacks overall coherence, additional waste can easily be generated between processes. By employing a progressive die or compound die structure, multiple processes such as deep drawing, punching, and trimming can be integrated into a single die. This reduces material transfer and repetitive positioning between processes, thereby decreasing intermediate scrap generation. For example, in a progressive die, a well-designed connection between the carrier and the workpiece ensures material continuity during continuous stamping, preventing waste caused by separation of individual processes. Simultaneously, the die's material guiding system needs optimization to ensure the material does not shift or jam during feeding, preventing scrap caused by positioning errors.
Dynamic adjustment of process parameters is essential for addressing the deformation of non-standard parts. Parameters such as stamping speed, blank holder force, and lubrication conditions directly affect the material flow and forming quality. During the design phase, finite element simulation is needed to model material deformation behavior under different parameters, identifying areas prone to scrap (such as cracking due to overstretching or wrinkling due to insufficient blank holder force). Based on this, process parameters can be adjusted; for example, reducing stamping speed or increasing blank holder force in crack-prone areas, and optimizing lubrication methods in areas with high wrinkling risk, to reduce scrap caused by forming defects. Furthermore, employing a "segmented stamping" process, which breaks down complex shapes into multiple simpler steps for gradual forming, reduces material deformation in a single forming operation, thereby improving overall utilization.
Establishing a scrap recycling and reuse mechanism can further unlock the value of materials. Scrap materials generated during the production of non-standard stamped parts, if their dimensions meet requirements, can be used for small workpieces or auxiliary structures (such as reinforcing ribs and locating pins) through secondary layout. The design phase should reserve interfaces for scrap recycling, for example, by marking the dimensions and locations of usable scrap materials in the layout drawing, or by using modular design to allow scrap materials to be directly embedded into the layout of other workpieces. For scrap materials that cannot be directly reused, they can be recycled into raw materials through crushing, melting, and other processes, forming a closed-loop production system and reducing dependence on new materials.
The integration of design standardization and modularization can improve the versatility of non-standard part layout. Although non-standard parts vary in shape, by extracting common features (such as hole positions, slot types, and surface radii), they can be decomposed into standard modules for combined design. For example, complex non-standard parts can be broken down into multiple standard modules (such as circular bosses and rectangular grooves), and their shapes can be customized through the splicing and adjustment of these modules. This design approach not only simplifies the layout process but also reduces the input of new materials through the reuse of modules. Simultaneously, establishing a modular design library and accumulating layout data for commonly used modules can provide a reference for subsequent non-standard part designs, accelerating the optimization process.
Optimizing material utilization during the design phase of non-standard metal stamping parts is a multi-dimensional collaborative process. From layout innovation to material matching, from mold design to process adjustment, and then to waste material recycling and modular application, each step must aim to "reduce waste and improve efficiency," maximizing resource utilization through technology integration and process optimization. This not only helps reduce production costs but also aligns with the industry trends of green manufacturing and sustainable development, providing solid support for the high-quality production of non-standard stamping parts.
