冲模寿命与模具维修

针对我国模具寿命偏低现象,提出了通过规范冷冲模刃磨、修理行为,既可提高冷冲模寿命,又可大幅降低产品成本.     

冲裁模CAD应用研究

介绍了冲裁模计算机辅助设计系统的构成,以及冲裁模CAD/CAM系统,针对冲裁模计算机设计开发的内容,阐述了应用软件五大模块间的相互关系.     

冲模压力中心的快速确定

说明了基于VB6.0的冲模压力中心的开发过程;实现了冲模压力中心的快速、准确定位,即确定冲模压力中心与已知任意两点之间的距离.     

真空导入工艺参数对复合材料孔隙含量的影响

以舰船构件为对象,通过玻璃纤维/乙烯基酯树脂复合材料的真空导入成型实验,研究了真空度、树脂温度参数对制件孔隙含量的影响规律。结果表明:真空度大小对孔隙率含量有显著影响,当真空度为80～90kPa时孔隙含量较低;低于20℃时,温度对孔隙含量有明显的影响,温度高于20℃时孔隙含量变化不大;沿树脂流动方向,试件孔隙含量由低到高变化;沿试件从上到下的厚度方向,孔隙含量也呈由低到高增加的趋势。     

工艺参数对热冲压成型钢组织性能及硼偏聚的影响

通过Gleeble1500热/力模拟实验机对轧后含硼钢板进行了热冲压过程模拟,分析了各种热处理条件对含硼钢组织性能的影响,并采用X射线衍射技术和径迹照相技术分析了硼的偏聚和硼相析出情况。研究结果表明:提高加热温度或延长保温时间,可促进钢的奥氏体化和硼的偏聚。通过偏聚合适含量的硼,能够很好地起到提高淬透性作用,使材料得到全部马氏体组织。热冲压成型过程中的变形破碎了奥氏体组织,促进相变,更易获得细小的马氏体组织。当冷却速度不高时,钢中"硼相"会沿晶界连续析出,从而降低了硼钢的淬透性。     

Fatigue Failure of Extrusion Dies: Effect of Process Parameters and Design Features on Die Life

Analysis of die failure plays an important role in the prediction and prevention of die failure, and subsequently in improving economics of any metal-forming process. Industrial experience has shown that fracture is the most common mode of failure in the case of hot aluminum extrusion dies. The purpose of the present work is to implement fatigue damage models in a Finite Element code for identification of critical process parameters and die design features in the case of fatigue being the dominating failure mode. For the maximum number of billets extruded by the die before fatigue crack initiation (fatigue life cycles in extrusion), Morrow’s stress- and strain-life damage models are implemented for axisymmetric flat extrusion die. With the help of finite element software ABAQUS, extrusion process is simulated and dynamic stress and strain values were obtained by first identifying the potential fatigue location in the die. The evaluation of applicability of the damage models is done for specific hot extrusion die made of H13 steels with Al-6063 as billet material. By considering temperature and strain rate as process parameters and bearing length and fillet radius of the die as geometric features, different simulation runs are performed to investigate the effect of process and design features on the useful die life. Morrow’s stress life model shows a good correspondence between computed and actual failure of dies. By establishing correlations of die life with process and design parameters under different conditions, it was shown that the present investigation is a useful guideline at die design and extrusion process stages.     

高速切削加工的特点及应用

随着 NC 和 CNC 技术的迅速发展和日益普及,HSM 即使用高速切削机械的加工技术已越来越受到人们的重视。HSM 不仅可以提高加工效率,降低成本,而且可以提高加工精度,改善加工质量。同时,HSM 的发展又对主轴系统、进给系统、CNC 控制系统、刀具、刀具夹持系统等各方面提出了新的要求。本文对高速切削的特点及实现高速切削加工的要求做一些具体的分析。     

隔热板冲压成形工艺参数优化

目的确定隔热板合理可行的成形方案。方法简要分析了零件的成形特点,并利用有限元软件对零件的拉延成形进行了数值模拟。设计正交实验时,以压边力、1号和3号拉延筋的完全锁模力、2号和4号拉延筋的完全锁模力及摩擦因数4个参数为自变量,以最大厚度减薄率、破裂情况以及未充分变形区大小为优化目标。结果 2号和4号拉延筋是该隔热板成形的主要影响因素,锁模力都为60 N/mm时,隔热板拉延成形效果较好。结论通过分析各因素对优化目标的影响,得出了优化的工艺参数值,为零件的实际生产提供指导。     

几种奥氏体类耐热钢的切削加工

针对ZG35Cr2 5Ni12、0Cr2 5Ni2 0和ZG40Cr2 5Ni2 0耐热合金以及新开发的ZGCr5 0Ni5 0和0Cr5 6Ni44Ti耐热合金的不同特点 ,通过选择不同的刀具材料、刀具几何参数和切削用量进行切削加工试验 ,摸索出了上述合金的车削、刨削和钻削的切削加工特点 ,并在生产实践中取得了良好的效果     

基于GA–BPNN的圆筒形件多步冲压成形工艺参数优化

目的 研究精密多步冲压成形过程中圆筒形件出现的成形性问题。方法 基于正交试验设计和极差分析方法、BP神经网络建模以及遗传算法得到最优工艺参数,研究制件成形过程中相关工艺参数对减薄率的影响。结果 通过正交试验设计和极差分析,获得各参数对极大减薄率的影响主次顺序为拉延摩擦因数>拉延压边力>反拉延摩擦因数>反拉延压边力,相对最优工艺参数如下:拉延摩擦因数为0.200、反拉延摩擦因数为0.100、拉延压边力为50 kN、反拉延压边力为30 kN。极大减薄率的仿真极值为0.144 4、极小减薄率的仿真极值为?0.127 7;以极大减薄率为成形质量评价指标,经BP神经网络建模并结合遗传算法寻优,获得最优工艺参数如下:拉延摩擦因数为0.200、反拉延摩擦因数为0.159、拉延压边力为55 kN、拉延压边力为40 kN,极大减薄率预测值(0.134 9)与仿真值(0.140 1)的相对误差仅为3.7%,优化后的制件成形质量良好。结论 所提出的方法对量化调整制件的成形工艺具有良好的工程应用价值。     

Microwave Processing of Materials and Applications in Manufacturing Industries: A Review

The main focused aim of developing new processing and manufacturing technologies are to reduce production or manufacturing costs, processing times, and to enhance manufactured product properties. The developed processing techniques should be widely acceptable for all types of materials including metal matrix composites, ceramics, alloys, and fiber reinforced plastics. Microwave materials processing is emerging as a novel processing technology which is applicable to a wide variety of materials system including processing of MMC, FRP, alloys, ceramics, metals, powder metallurgy, material joining, coatings, and claddings. In comparison to the conventional processes, microwave processing of materials offers better mechanical properties with reduced defects and economical advantages in terms of power and time savings. The present review work focuses mainly on global developments taking place in the field of microwave processing of materials and their relevant industrial applications.     

车削力试验设计及数据处理

利用计算机辅助测试车削力试验系统的方案设计及研究，采用二元线性回归法在线分析处理车削力试验数据。实现了车削力试验从数据采集到处理全过程的自动化。     

用切削力的频数差对切削颤振进行早期预报

本文提出一种预报切削颤振的新方法,它利用切削力在幅值域内的频数差作预报参数,可以在颤振孕育过程的初期进行预报,预报的及时性好,它对切削过程中力的随机波动不敏感,且切削条件变化对控制门限值无影响,预报的准确性高。     

Optimization of Tool Geometry and Cutting Parameters for Hard Turning

In the hard-turning process, tool geometry and cutting conditions determine the time and cost of production which ultimately affect the quality of the final product. So reliable models and methods are required for the prediction of the output performance of the process. In the present work, experimental investigation has been conducted to see the effect of the tool geometry (effective rake angle and nose radius) and cutting conditions (cutting speed and feed) on the surface finish during the hard turning of the bearing steel. First- and second-order mathematical models were developed in terms of machining parameters by using the response surface methodology on the basis of the experimental results. The surface roughness prediction model has been optimized to obtain the surface roughness values by using genetic algorithms. The genetic algorithm program gives minimum values of surface roughness and their respective optimal conditions.     

Ultra-Short Pulsed Laser Manufacturing and Surface Processing of Microdevices

Ultra-short laser pulses possess many advantages for materials processing. Ultrafast laser has a significantly low thermal effect on the areas surrounding the focal point; therefore, it is a promising tool for micro- and submicro-sized precision processing. In addition, the nonlinear multiphoton absorption phenomenon of focused ultra-short pulses provides a promising method for the fabrication of various structures on transparent material, such as glass and transparent polymers. A laser direct writing process was applied in the fabrication of high-performance three-dimensional (3D) structured multilayer micro-supercapacitors (MSCs) on polymer substrates exhibiting a peak specific capacitance of 42.6 mF·cm⁻² at a current density of 0.1 mA·cm⁻². Furthermore, a flexible smart sensor array on a polymer substrate was fabricated for multi-flavor detection. Different surface treatments such as gold plating, reduced-graphene oxide (rGO) coating, and polyaniline (PANI) coating were accomplished for different measurement units. By applying principal component analysis (PCA), this sensing system showed a promising result for flavor detection. In addition, two-dimensional (2D) periodic metal nanostructures inside 3D glass microfluidic channels were developed by all-femtosecond-laser processing for real-time surface-enhanced Raman spectroscopy (SERS). The processing mechanisms included laser ablation, laser reduction, and laser-induced surface nano-engineering. These works demonstrate the attractive potential of ultra-short pulsed laser for surface precision manufacturing.     

Design and Manufacturing of Integrated Drilling and Cutting Orthopedic Bone-Specific Surgical Guide

In this paper, the design and fabrication of a bone-specific double function surgical guide are presented. The design of this surgical guide is performed so that it can be used simultaneously for drilling and cutting of cow's tibia bone. The employment of this surgical guide results in higher accuracy, reduction of the number of the holes needed to be pierced through the bone, and lower surgery time. The research is performed in three steps including the digitizing of the bone and production of the bone's 3D model in CATIA (generative shape design environment), design of surgical guide, and fabrication of the guide by FDM process. The guide is used for drilling and cutting of the bone.     

通过噪声的分析评价实现电极切削参数的优化

针对超高速切削铜材料电极产生的噪声问题,通过用INV3018G型噪声仪采用多因素正交试验方法进行数控切削削噪声实验,采用大数据分析的方法,对实验数据进行极差和方差分析,得出各因素对切削噪声的贡献大小依次为装夹高度、主轴转速、进给速度和背吃刀量,显著性大小依次为装夹高度、主轴转速、进给速度和背吃刀量,其中装夹高度对环境噪声的影响最大。通过数控加工电极切削参数的合理选择,可达到降低工作环境噪声的目的。     

Study on Multi-objective Cutting Parameters Optimization of Titanium Alloy

In order to explore the cutting rules,optimize the cutting parameters and improve cutting efficiency of titanium alloy,multiple sets of test parameters were schemed out by using the uniform design method. Test cutting research of cutting forces and surface roughness with these parameters were conducted under the condition of 12 ℃ dry cutting and-50 ℃ cold blast machining,respectively. Through the regression analysis about the results of the test,a multiple linear regression model which was applicable for titanium alloy clean cutting on its surface roughness and cutting force has been established. On this basis,a multi-objective optimization model aimed at surface roughness,cutting force and cutting efficiency had been set up. And by means of the multi-objective data weighted method,successfully converted the multi-objective optimization model into a single-objective one. Verification tests were done under these cutting parameters,and the results are in good agreement with those calculated.