The Ministry of Science and Technology recently released the “National Key R&D Plan New Energy Vehicle Key Special Implementation Plan (Draft for Comment)â€, and plans to establish a complete electric vehicle power system technology system and industrial chain by 2020.
Sheet Metal Fabrication
Definition of sheet metal fabrication
Sheet Metal fabrication is the creation of useful metallic parts and structures by the application of multiple fabrication processes. Sheet metal fabrication is basically a broad term that involves various complex processes like cutting, forming, bending, welding, machining, and assembling. The instructions include below: materials, processes, and tools required for sheet metal fabrication.
Types of Sheet Metal Fabrication Materials
The choice of metal depends on the final use of the fabricated parts.
Common fabrication processes:
· Carbon Steel
· Stainless Steel
· Aluminum
· Bronze
· Copper
· Brass
· Aluminized steel
· Galvanized steel
Types of Metal Fabrication Processes
The journey to the final product from raw sheet metals proceeds through various sheet metal fabrication processes. All the sheet metal fabrication processes can be grouped into the following three categories:
· Cutting
· Deformation
· Assembly
Sheet metal fabrication: Cutting
ii. Water jet cutting
iii. Plasma cutting
Sheet metal fabrication: Forming or Deformation
Bending: Sheet metal bending is one of the most popular deformation processes. A machine known as a Press brake is used to bend sheet metals into V, U, or other complex shapes. With an increase in gauge thicknesses of sheet metals the force required to bend increases.
Stamping: In the stamping process, a hydraulic or mechanical stamping press equipped with a tool and die is used to perform specific tasks like curling, drawing, embossing, flanging, etc
Hemming: Hemming is a process by which the edges of sheet metal are folded over itself or another piece of sheet metal to create a rounded edge. In the sheet metal fabrication process, two types of hemming processes are widely involved. They are roll hemming and conventional die hemming. Conventional hemming is used for mass production. A hemming roller is used for roll hemming.
Spinning: Spinning is a metal fabrication process where a lathe machine is used to rotate the sheet metal against a tool to produce conical or cylindrical shapes.
Sheet metal fabrication: Assembly
Assembly is basically joining sheet metal components produced using above mentioned cutting or bending processes. The common sheet metal assembly process consists of joining by Welding and joining using fasteners.
Welding: In the welding process, sheet metal components are joined together by melting sections with the application of heat to form a solid connection. There are various processes available that are used to weld sheet metals.
Joining using Fasteners: Similar or dissimilar sheet metal parts can easily be joined using fasteners like bolts, screws, rivets, etc.
Brazing: Brazing is a process similar to welding that operates by melting a filler without melting the sheet metals.
Adhesives: Adhesives can be used to hold metal sheets together in conjunction with other joining methods
Advantages and Disadvantages of Sheet Metal Fabrication
As sheet metal fabrication covers a wide area of techniques and methods, the advantages and limitations will vary depending on the process used during fabrication.
Benefits:
i. Sheet metal fabrication is fast and can produce high-quality components.
i. A large number of processes are available with wide range of materials
ii. High strength to weight ratio for sheet metal fabricated parts.
Disadvantage:
i. Each fabrication process has their own limitations.
ii. High initial cost for set up of equipment and tools.
iii. Requirement of skilled labors for each process.
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At present, the major changes in the technology of new energy vehicles, which are based on the three technologies of power electrification, lightweight construction and intelligent vehicles, are underway. In the next 5 to 10 years, the global automotive industry will usher in an important strategic opportunity period for restructuring and transformation and upgrading. The data shows that China's new energy bus technology industrialization scale ranks first in the world. The level of industrialization of new energy car technology ranks second in the world. In January of this year, China's new energy vehicle production increased nearly five times year-on-year. However, in the market that relied on subsidies to heat up, industry insiders expressed concern because no industry can be sustained by subsidies for a long time. Jiang Jinhua’s chairman, An Jin, said: “We need to continuously break through the mileage, renewal mileage and service life of fuel vehicles, increase the construction of charging piles and charging stations, and finally the business model innovation.â€
Some insiders pointed out that China and the United States have become the world's largest new energy vehicle market. Although the market sales of China's new energy vehicles still lag behind the US market by 40,000 in 2014, the policy dependence of the new energy vehicle market itself As well as China's unique policy efficiency system, China's new energy vehicle market will surpass the US market in the last one or two years and become the world's largest new energy vehicle market.
It is understood that the “National Key R&D Plan Key Projects for New Energy Vehicles†is being consulted, and the specific parameters involved in the core technologies of electric vehicles, such as the specific energy of the power battery and the technical level of the drive motor, are proposed. A clear goal will provide technical support for the realization of new energy vehicle ownership of 5 million vehicles by 2020.
Data show that in January of this year, China's new energy vehicles produced 6,599 vehicles, an increase of nearly five times. Among them, pure electric passenger cars produced 2,108 units, an increase of nearly 5 times, and plug-in hybrid passenger cars produced 2,278 units, a year-on-year increase of nearly 7 times; pure electric commercial vehicles produced 1,343 units, a year-on-year increase of nearly 6 times. Electric hybrid commercial vehicles produced 870 units, nearly double the year-on-year growth. 
April 08, 2024