从数字制造到智能制造的关键技术途径研究

在深入研究智能制造的内涵及关键技术的基础上,提出了我国从数字制造到智能制造的三大发展模式,以及实现从数字制造到智能制造发展的具体技术途径。针对典型行业的生产特点,提出了从数字制造到智能制造发展的技术路线图,为推动我国制造业从数字制造到智能制造的发展提供技术途径的指引。     

推进绿色制造 建设生态文明——中国绿色制造战略研究

我国正处于制造大国迈向制造强国的重要历史阶段,在绿色发展理念的指导下,如何推进制造业与生态环境的协调发展,促进工业文明与生态文明和谐共生,是当前亟待解决的现实问题。绿色制造是制造强国建设的必有之意,是生产方式转变的重要着力点,更是绿色发展的重要组成部分,涵盖了低碳发展和循环发展的全部内容。本文在明晰绿色制造与生态文明建设关系的基础上,深入阐述了绿色制造的科学内涵、目标和评价体系,基于我国绿色制造已取得的成绩和现实发展困境,提出了推进我国绿色制造的战略方向,最后从顶层设计、队伍建设、创新体系、服务平台、体制机制及国际合作等方面给出了政策建议。     

Prototyping and modeling of the centrifugal casting process for paraffin waxes

Centrifugal casting is a technology used for manufacturing hybrid rocket paraffin grains. This technology helps avoiding voids formation inside the solid paraffin as it cools. Voids are formed because of air bubbles being entrapped while pouring and because the liquid wax shrinks by 17–19% upon cooling. In this work, the centrifugal casting process for the manufacturing of paraffin cylinders was prototyped at two different scales considering critical casting issues. The effects of process parameters (rotational speed, melt temperature, and flow rate) on the tensile properties of the manufactured grains were analyzed. The results of the optimization conducted at the lower scale (2.5?kg) were up scaled to manufacture 25?kg grains. The resulting mechanical properties complied with the design specifications, and they were better than those characterized from the gravity cast wax. A numerical model of growth and dissolution of bubbles during the process was then developed to predict the quality of the castings. The numerical results showed how increasing the mold rotational speed up to 1800?rpm reduced the removal time. However, compared to grains solidification time, the predicted removal times were much shorter, proving the advantage of centrifugal casting in counteracting voids formation.     

Spinel-layered integrate structured nanorods with both high capacity and superior high-rate capability as cathode material for lithium-ion batteries

Spinel phase LiMn2O4 was successfully embedded into monoclinic phase layeredstructured Li2MrnO3 nanorods,and these spinel-layered integrate structured nanorods showed both high capacities and superior high-rate capabilities as cathode material for lithium-ion batteries (LIBs).Pristine Li2MnO3 nanorods were synthesized by a simple rheological phase method using α-MnO2 nanowires as precursors.The spinel-layered integrate structured nanorods were fabricated by a facile partial reduction reaction using stearic acid as the reductant.Both structural characterizations and electrochemical properties of the integrate structured nanorods verified that LiMn2O4 nanodomains were embedded inside the pristine Li2MnO3 nanorods.When used as cathode materials for LIBs,the spinel-layered integrate structured Li2MnO3 nanorods (SL-Li2MnO3) showed much better performances than the pristine layered-structured Li2MnO3 nanorods (L-Li2MnO3).When charge-discharged at 20 mA·g-1 in a voltage window of 2.0-4.8 V,the SL-Li2MnO3 showed discharge capadties of 272.3 and 228.4 mAh.g-1 in the first and the 60th cycles,respectively,with capacity retention of 83.8％.The SL-Li2MnO3 also showed superior high-rate performances.When cycled at rates of 1 C,2 C,5 C,and 10 C (1 C =200 mA·g-1) for hundreds of cycles,the discharge capacities of the SL-Li2MnO3 reached 218.9,200.5,147.1,and 123.9 mAh·g-1,respectively.The superior performances of the SL-Li2MnO3 are ascribed to the spineMayered integrated structures.With large capacities and superior high-rate performances,these spinel-layered integrate structured materials are good candidates for cathodes of next-generation high-power LIBs.     

Applications of non-destructive testing techniques for post-process control of additively manufactured parts

This paper presents an overview on the principle of operation for post-process inspection non-destructive testing (NDT) techniques. The techniques include visual inspection, liquid penetrant testing, magnetic particle testing, eddy current testing, ultrasonic testing, and radiography. The applications of these NDT techniques in additive manufacturing (AM) and their suitability for defects detection of additively manufactured parts are reviewed. The sensitivity, and the advantages and disadvantages of each technique are evaluated. The types of defect, and the detectability of these defects by NDT techniques are assessed. The applicability of each NDT technique for different categories of AM process is discussed. The categories of AM are, namely, material extrusion, powder bed fusion, vat photopolymerisation, material jetting, binder jetting, sheet lamination, and directed energy deposition.     

Freestanding hierarchical porous carbon film derived from hybrid nanocellulose for high-power supercapacitors

Nanocellulose is a sustainable and eco-friendly nanomaterial derived from renewable biomass.In this study,we utilized the structural advantages of two types of nanocellulose and fabricated freestanding carbonized hybrid nanocellulose films as electrode materials for supercapacitors.The long cellulose nanofibrils (CNFs) formed a macroporous framework,and the short cellulose nanocrystals were assembled around the CNF framework and generated micro/mesopores.This two-level hierarchical porous structure was successfully preserved during carbonization because of a thin atomic layer deposited (ALD) Al2O3 conformal coating,which effectively prevented the aggregation of nanocellulose.These carbonized,partially graphitized nanocellulose fibers were interconnected,forming an integrated and highly conductive network with a large specific surface area of 1,244 m2·g-1.The two-level hierarchical porous structure facilitated fast ion transport in the film.When tested as an electrode material with a high mass loading of 4 mg·cm-2 for supercapacitors,the hierarchical porous carbon film derived from hybrid nanocellulose exhibited a specific capacitance of 170 F.g-1and extraordinary performance at high current densities.Even at a very high current of 50 A·g-1,it retained 65％ of its original specific capacitance,which makes it a promising electrode material for high-power applications.     

Analytical modelling of residual stress in additive manufacturing

A physics‐based analytical model to assess residual stresses in additive manufacturing made of metallic materials is presented and validated experimentally. The model takes into consideration the typical multi‐pass aspect of additive manufacturing. First, the thermal signature of the process is assessed by predicting the temperature for the problem of a moving heat source, then, the thermally induced stresses in a homogenous semi‐infinite medium are determined. Taking the thermal stresses as input, the residual stresses are calculated analytically to obtain the distribution across the depth. Good agreement is obtained between the analytical prediction and X‐ray measurements made on Selective Laser Melted 316L Stainless Steel. In addition, the analytical approach enables in‐depth interpretations of results with basis in the true mechanisms of the process. Thus, the present model appears as a promising tool for optimization of process parameters in additive manufacturing, which in turn will improve the understanding of process parameters and their effect on properties of the final product.     

Solving cell formation and task scheduling in cellular manufacturing system by discrete bacteria foraging algorithm

We consider a joint decision model of cell formation and task scheduling in cellular manufacturing system under dual-resource constrained (DRC) setting. On one hand, machines and workers are multi-functional and/or multi-skilled, and they are grouped into workstations and cells. On the other hand, there is a processing sequence among operations of the parts which needs to be dispatched to the desirable workstations for processing. Inter-cell movements of parts can reduce the processing times and the makespan but will increase the inter-cell material handling costs. The objective of the problem is to minimise the material handling costs as well as the fixed and operating costs of machines and workers. Due to the NP-hardness of the problem, we propose an efficient discrete bacteria foraging algorithm (DBFA) with elaborately designed solution representation and bacteria evolution operators to solve the proposed problem. We tested our algorithm using randomly generated instances with different sizes and settings by comparing with the original bacteria foraging algorithm and a genetic algorithm. Our results show that the proposed DBFA has better performance than the two compared algorithms with the same running time.     

A spatial variable selection method for monitoring product surface

Two-dimensional (2-D) data maps are generated in certain advanced manufacturing processes. Such maps contain rich information about process variation and product quality status. As a proven effective quality control technique, statistical process control (SPC) has been widely used in different processes for shift detection and assignable cause identification. However, charting algorithms for 2-D data maps are still vacant. This paper proposes a variable selection-based SPC method for monitoring 2-D wafer surface. The fused LASSO algorithm is firstly employed to identify potentially shifted sites on the surface; a charting statistic is then developed to detect statistically significant shifts. As the variable selection algorithm can nicely preserve shift patterns in spatial clusters, the newly proposed chart is proved to be both effective in detecting shifts and capable of providing diagnostic information for process improvement. Extensive Monte Carlo simulations and a real example have been used to demonstrate the effectiveness and usage of the proposed method.