焊接技术在轨道客车制造行业的推广应用

焊接技术是轨道客车制造行业中最重要的技术加工方法,对轨道客车工艺水平的提升起着重要的推动作用。而中国轨道客车产业的飞速发展,也为焊接行业提供了巨大的潜在应用市场,激光焊接技术、搅拌摩擦焊接技术、激光MIG复合焊接技术等高效焊接新技术的应用也将轨道车辆焊接技术推向了新的时代。文中介绍了轨道车辆行业焊接技术的发展及先进的焊接技术在轨道客车中的应用,以及轨道客车制造行业焊接技术装备在自动化、柔性化、规模化方向上发展的进程。     

激光焊接技术在不锈钢轨道客车制造中的应用与展望

"十二五"期间,不锈钢轨道客车装备制造业发展迅速。传统的电阻点焊存在车体外观质量不高、结构气密性较差以及点焊生产效率较低等难以克服的局限性,采用部分熔透激光搭接焊取代电阻点焊进行不锈钢车体焊接的技术优势明显。结合轨道客车激光焊接的技术特点,围绕不锈钢车体的零件精密成型、部件精细组装、无痕焊接工艺、智能质量监控及无损检测方法等形成了一系列的核心技术、关键装备和标准规程,建立了不锈钢轨道车辆激光焊接生产线和制造工艺体系,分析大规模激光焊接制造不锈钢车辆的主要技术问题,并对激光焊在轨道客车制造行业的应用前景进行预测和展望。     

轨道交通生产制造企业焊接监督人员专项培训及经验交流班在长春成功举办

2007年5月11～13日,哈尔滨焊接技术培训中心与长春轨道客车股份有限公司联合举办了以长春轨道客车股份有限公司及其分包商为主的DIN6700认证轨道交通生产制造企业焊接监督人员专项培训及经验交流班,共有79名DIN6700认证轨道交通生产制造企业的焊接监督人员参加了此次交流班.     

吉林省轨道客车产业发展概况与焊接专业建设的研究

轨道客车产业是吉林省的支柱产业之一。轨道客车产业的焊接技术水平决定了轨道客车产业未来的发展。通过分析我国焊接行业发展现状、轨道客车产业的发展现状以及轨道客车产业焊接人才现状,研究了吉林省轨道客车产业焊接人才需求与吉林省地方高校焊接专业人才培养之间的关系。结果表明:目前轨道客车行业焊接专业人才无法满足产业发展要求;特色性、应用性、复合型焊接技术与工程专业人才是吉林省地方高校培养的目标。     

长春汽车模具产业链促进当地模具产业大发展

据了解，未米3年，长春轨道客车计划形成800辆铁路动车组、800辆城轨客车的产能，实现百亿元产值，向世界级轨道客车制造中心迈进。业内人士称，这将为尔北模具工业及汽车零部件行业的发展创造了良好的机遇。     

空气等离子切割技术在客车制造中的应用

空气等离子切割技术是我国最近几年发展起来的新的热切割技术。它具有设备成本低廉,操作灵活简单,切割速度快,切割变形系数低,切口质量高,适应性强等一系列优点,是一项高效节能技术,在工业领域里有非常大的应用价值。客车制造中应用空气等离子切割技术,可取得良好的经济效益。一、在客车制造中的应用客车的车身大多是由冲压件和钣金件经过组焊,便形成了客车的车身骨架。主要生产工艺有冲压、焊接、铆接等工艺。大客车一般属于中小批量生产,工装系数     

一种基于工艺特征的制造单元划分方法

在现代生产中,单元化生产是提高制造系统生产效率的一个重要手段。对于一个给定的制造系统,其中制造单元的划分并不是唯一的,人们提出了各种制造单元划分方法。这些方法的不足是只采用0和1两值来表示系统中的相似关系。本文提出了相似系数和隶属度的概念,进一步发展了一种完善的制造单元划分方法,最后以一个数值例子进行了验证。     

西南铝生产磁悬浮车辆铝型材

长春轨道客车制造有限公司正在试制磁悬浮列车车辆，需要多种规格的铝合金大型材，而且对表面品质要求高，对尺寸偏差也要求严格，其中有16种规格的长大型材由西南铝业（集团）有限责任公司锻造厂生产。该厂在接到任务后进行了精心组织和严格管理，终于又快又好地完成了生产任务，长春客车公司于2006年9月底收到交货的18t型材。     

柔性化生产在摩托车架批量焊接生产中的应用

为了适应现代工厂级多任务、多品种的生产需求,开发并设计具备先进加工生产能力的柔性化生产设备就变得十分必要.分析了传统作业方式与柔性化生产方式各自的优缺点以及在现代工厂中的应用情况,并结合现代工业控制系统的发展现状,针对多任务、多品种的生产要求,以实际生产需求为设计对象,进行了"专用成套设备制造方案"和"柔性化制造单元集成控制方案"的技术分析和方案论证.以柔性化生产为设计理念,选用三菱PLC为控制核心,在电气控制系统中集成机器人柔性控制单元,开发一套具备CC-Link网络数据交换、人机交互功能的综合电气控制系统,充分满足用户在摩托车车架多品种生产制造中柔性化生产的要求.     

轨道客车轻量化材料及其连接技术的发展与展望

随着轨道客车产业的快速发展,车辆用材料和连接技术取得了长足的进步,耐候钢、不锈钢及铝合金等金属材料大规模使用,推动了电弧焊、电阻焊、搅拌摩擦焊为代表的焊接方法获得广泛应用,焊接作业自动化率不断提升,更好地保证了产品质量。文中对轨道客车产业现状及发展前景、面临的服役环境挑战进行了简要叙述,对车辆应用材料发展历程进行了总结,对面向未来使用的更高强度、更优性能的轻质合金材料、纤维增强复合材料及其优异的综合服役性能对推动轨道客车领域新材料的不断应用情况进行了分析,同时对激光焊、激光-电弧复合焊、自冲摩擦铆接、绿色优质粘接为代表的先进连接技术对解决未来新型材料连接工艺前景做了展望,提出了今后轨道客车轻量化材料和连接技术的发展方向和研究重点。     

冲压件CAPP系统的压机自动选择方法研究

工艺决策是CAPP系统的核心，它包括工艺规划和工序设计两方面的内容。工序设计是零件设计信息与设备加工能力信息相匹配的过程，现有的CAPP应用系统通常是提供一个操作界面由人工选择设备，不仅效率低，而且受到操作者实际经验的制约。本文结合作者开发的冲压件CAPP系统，介绍了加工设备自动选择的实现方法。     

Effect of cold work on the tensile and fatigue performance of aluminum alloy 5754

This article considers the effects of cold work on the tensile and fatigue properties of a non-heat-treatable aluminum alloy, namely, AA5754. Cold work up to 50% was introduced by cold rolling. The critical tensile strain for serration initiation was observed to increase with increasing cold work. The fatigue performance was also improved with increasing cold work. Annealing at 200 °C for 1 h reduced both the critical strain as well as the fatigue performance. Finally, in experiments with drilled holes and punched holes, it was observed that punching improved the fatigue performance compared with drilling, which was attributed to cold work induced at the hole boundary by the punching operation.     

Punching of Ultra Small Size Hole Array

This paper presents a method by which multiple holes of ultra small size can be punched simultaneously. Silicon wafers were used to fabricate punching die. Workpiece used in the present investigation were the rolled pure copper of 3um in thickness and CP titanium of 1.5um in thickness. The metal foils were punched with the dies and arrays of circular and rectangular holes were made. The diameter of holes ranges from 2-10um. The process set-up is similar to that of the flexible rubber pad forming or Guerin process. Arrays of holes were punched successfully in one step forming. The punched holes were examined in terms of their dimensions, surface qualities, and potential defect. The effects of the die hole dimension on ultra small size hole formation of the thin foil were discussed. The optimum process condition such as proper die shape and diameter-thickness ratio (d/t) were also discussed. The results in this paper show that the present method can be successfully applied to the fabrication of ultra small size hole array in a one step operation.     

Punching in industrial wood machining: an alternative production process to drilling

Drilling of wood is besides milling, sawing and grinding one of the most important production processes in industrial furniture manufacturing. For the body assembly and the fixing of fittings, boreholes are essential. They have immediate effect on quality and production costs. The process step drilling limits the output of stationary and throughfeed machines, because the workpieces have to be stopped to create the drillings at a relatively low feed speed. An essentially increased performance cannot be reached by the improvement of conventional drilling devices. The aim of the work presented in this paper is the development of an alternative production process in which blind holes can be punched. Thereby thin-walled, cylinder-shaped tools are pressed into different solid and derived timber workpieces by a simple translative movement. For it special experimental setups have been designed. The new production process opens possibilities for an optimization and acceleration of process cycles in industrial wood machining.     

无毛刺冲裁的模具设计

介绍了金属板材无毛刺冲裁有模具设计,使板料经过冲孔后无需再经过任何附加的加工可直接获得无毛刺冲件     

成形顶盖的废料切刀设计

介绍某车型成形顶盖采用新型切边工艺及上、下模切刀结构,以保证切边模具在自动化生产线上能稳定顺畅地使废料滑落。经生产现场验证,一次合模切断的整块废料能稳定地滑落到废料切刀上,二次合模时完成切断,切断后的废料滑落顺畅,验证了该工艺方案的可行性。     

火车车轮成形新工艺的开发研究

在比较分析技术先进国家的火车车轮成形工艺流程后，采用试验研究和数值模拟相结合方法，研究开发出优化的新工艺。钢坯先在一台水压机上预成形制坯，再在另一台压机上模锻，经轧制扩径后冲孔压弯。这样的生产线效益最好     

An enhanced continuum model for size-dependent strengthening and failure of particle-reinforced composites

We present an enhanced continuum model for the size-dependent strengthening and failure of particle-reinforced composites. The model accounts explicitly for the enhanced strength in a discretely defined “punched zone” around the particle in a metal matrix composite as a result of geometrically necessary dislocations developed through a mismatch in the coefficients of thermal expansion. We incorporate the punched zone explicitly through a unit-cell model within this work, but the approach can be used more generally to account for discrete particle distributions and particle shapes. Smaller particles lead to greater strengthening, and this size effect is larger for larger volume fractions. An equation for the coupling of the size-dependent increase of yield strength of metal matrix composites with the particle volume fraction is obtained. The results indicate that the punched zone effect may amplify the occurrence of a variety of failure modes such as matrix localization, particle fracture and/or particle–matrix interface failure; smaller particles perceive higher stresses. We account for interface failure through a cohesive approach, and show that the interface damage mechanism is also particle-size-dependent. Some implications are presented for microstructural design of metal matrix composites.     

聚氨酯冲裁模设计与应用

用常规钢制冲模冲裁薄板零件 ,冲裁断面常有毛刺。聚氨酯冲裁模能自动调整间隙 ,用1副模具可冲制不同厚度的薄片零件 ,制件平整光洁、无毛刺 ,模具结构简单、制造容易 ,适于薄板冲裁。     

微形电机机壳16工步连续级进弯曲模结构设计

针对微形电机机壳采用板料卷圆生产的工艺要求,设计了一种7工位连续冲裁、6工位连续弯曲冲裁、单工位落料的16工步的360°卷圆成形连续级进模。模具整体工序包括连续冲裁、连续弯曲冲裁和冲裁落料3道工序。针对壳件的成形特征,采用1个工位冲出定位孔,6个工位对壳体上的9个特征进行连续冲裁成形及倒角成形;针对壳件的弯曲成形,采用6个工位对冲裁壳体进行连续弯曲成形,工步中设置了3个弯曲成形机构,分别为仿形凹模机构、楔紧块驱动的双侧滑块挤压弯曲机构及接口压入成形机构,来实现壳件的360°卷圆成形;为保证后续弯曲工步载料及内圆成形,将内圆成形件设计成一种可以跟随弯曲凹模做小距离的向上浮动的成形构件。最终成形的壳件由单冲头落料,并由气缸驱动的接件圆柱进行接料转移。模具结构整体布局设计简单合理,机构设置巧妙,可为同类壳件的生产提供有益借鉴。