Fabrication and measurement of the performance of a printed EMI shielding mesh filter on PET film

In this paper, Electromagnetic interference (EMI) shielding mesh filter films are fabricated using the screen printing method. An EMI shielding mesh filter requires fine line patterns under 30 μm, therefore, the screen masks with fine-line screen mesh, as well as suitable ink composed of fine metal particles are required. Moreover, because the printed EMI shielding filter has to be fabricated on a PET film, the ink should be sintered at a temperature below 150°C not to deform the film. For the purposes of this study, a screen mesh with a mask of 20 μm line, and ink made nano silver paste with a sintering temperature of 140°oC, which could guarantee fine-line patterning on the PET, were used. The ink had a viscosity of 90,000–12,000 cps and metal content of 85% in weight. The printed EMI shielding mesh had a line width of about 24 μm and a thickness of about 2.5 μm. The measured surface resistance was 0.5∼0.7 ω/□, offering good electrical performance as an EMI mesh. A simple measurement system was used to evaluate the electrical shielding performance of the printed EMI shielding mesh. A comparison of the printed EMI shielding mesh with pure film without mesh and copper sheet revealed that the printed EMI shielding mesh is indeed capable of providing good electrical performance.     

基于IGES的钣金零件特征识别的方法研究

针对钣金设计软件数据模型的外部读取与特征识别问题,对钣金设计软件的数据共享、IGES文件结构以及零件特征分类进行了研究,提出了一种基于IGES曲面模型的后置处理方法,通过遍历IGES文件,获取了钣金零件的所有裁剪参数曲面信息,建立了以折弯面作为结点的双向链表的数据结构,根据IGES文件的数据特征,对钣金零件进行了特征分类,提取了钣金折弯特征并建立了特征间的依赖关系。利用Pro/E软件绘制的钣金零件对特征识别方法进行了测试。研究结果表明,该方法能够准确地获取钣金的特征,为钣金零件折弯仿真与工序规划提供了可靠的特征数据,使得产品开发周期缩短了近30%,最终实现了钣金加工的精确性与高效性。     

二维零件DXF数据的获取与数控加工

通过对新版DXF文件结构及2维零件几何结构特征的分析，研究了从DXF文件的获取2维零件图形数据的方法；采用封闭环及树形线性表，提出了一种存储复杂2维零件几何特征的数据结构，可从复杂的DXF文件中识别分离2维机构特征；依据2维板材切割加工的工艺特点，给出了2维结构件切割下料的数控前后置处理与实现方法。本文方法对于各种类型的切割下料及其辅助工艺有参考价值。     

电子标签与集装箱物流信息化

分析了集装箱物流对电子标签特殊要求,归纳总结了用于集装箱物流的电子标签应具备的动态、远距离、高可靠读写与耐高温、抗盐雾腐蚀、抗冲击、高密封性能与数字安全性能等主要特性。分析对比了有源和无源RFID的应用优势与劣势,探讨了应用于集装箱物流的电子标签标准所应覆盖的相关内容。根据集装箱物流的特征,探讨了由设备层、数据层、应用层组成的集装箱物流信息系统的基本架构。最后讨论了电子标签在集装箱物流应用中的安全性、标准化等技术问题。实际应用表明,基于RFID的高频有源电子标签系统的集装箱信息管理系统,可以实现对货物形态和运输信息的有效监控和实时管理,具有良好的应用前景。     

板料成形模具快速制造技术研究

将快速原型技术与金属电弧喷涂技术相结合，开发一种新的板料成形模具快速制造方法。介绍了该方法的关键工艺和实施步骤，并通过具体实例对该方法进行验证。实践表明，该方法制模周期短、成本低，模具综合性能好，在复杂冲压模具试制、冲压件小批量生产中具有很好的应用前景。     

钣金件焊接性能试验研究

为了提高产品钣金件的抗拉强度和防腐蚀性能,并选择合适的焊接方法,文中分别采用2种胶焊方法(透胶胶焊、毛细作用胶焊)和传统点焊方法对3种材料(St12钢板、5A05铝板、2A12铝板)进行了试验。采用3种方法对试验件做盐雾试验、拉伸试验后再对所得数据进行对比分析。试验结果表明:对于St12钢板,点焊件抗拉强度最高,而毛细作用胶焊的抗腐蚀性能最好;对于5A05和2A12铝板,毛细作用胶焊的抗拉强度和抗腐蚀性能都最好。由此可见,毛细作用胶焊方法是一种较为适合的钣金件连接方式。     

冲压件成形计算机模拟工艺参数优化方法研究

分析了常规有限元金属板料成形模拟的不足，提出了参数化有限元分析的概念，在对人工神经网络、遗传算法进行深入分析研究的基础上，采用参数化有限元分析方法进行分析，得到了训练样本。提出了采用人工神经网络技术建立冲压件成形多参数映射关系模型，采用遗传算法进行多参数组合优化，实现冲压件成形计算机模拟工艺参数优化的方法。实际应用结果表明，优化结果与试验结果基本吻合，该优化方案实用可行。     

基于场景几何特征的ETC识别范围预测方法

超高频(UHF)射频识别(RFID)系统具有标签成本低、识别距离远等优点,在电子不停车收费(ETC)等智能交通领域具有应用潜力。受电波的随机多径传播制约,实际应用中难以准确估计标签识别范围。针对ETC应用场景具有几何共性的特点,基于电波传播的几何光学方法,通过对标签接收多径射线的构成进行分析,融入场景几何特征和天线射频特征参数,提出了一种标签识别范围的预测方法。实际场景测试与仿真表明,能较精确预测标签在三维空间中的接收功率分布和识别范围,且精确性高于对数正态等经验模型,而复杂性低于电磁场的商用仿真软件。     

金属薄板开槽弯曲成形技术与设备

V形弯曲成形前，对金属薄板折弯处进行一定深度的V形开槽，然后在V形开槽处进行弯制成形，此种加工方法称之为V形开槽弯曲成形技术。用V形开槽弯曲成形技术弯制的工件弯曲圆角半径小，色泽变化不明显，弯制成形力小，且减少了窄长工件弯曲棱边直线度误差。并在普通折弯机上用通用模具就能弯制断面形状复杂的工件。V形开槽弯曲成形技术的关键设备是薄板开槽机，有多种结构形式和控制方式供选择。     

SIMULATION OF ROLL-FORMING PROCESSES OF WELDED PIPE

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A study on the effect of rectangular cut out on laser forming of AISI 304 plates

Laser bending of a rectangular AISI 304 plate with a rectangular cut out is investigated in the present work. In particular, effects of process parameters: laser power, scanning speed, and geometric parameters: dimensions of the cut out of sheet metal on temperature distribution and bending angle are explored with the help of numerical simulation. Analyses are carried out through a coupled thermo-mechanical formulation with finite element method using COMSOL MULTIPHYSICS. The temperature distribution and deformation of sheet metal have been obtained from numerical simulations. The bending angle is affected by process parameters, namely, laser power, scanning speed, and width of the cut out of the sheet metal. Position of the cut out vis-à-vis the scanning path and length of the cut out have very little effect on the bending angle.     

Analysis of the tribological behaviour of polymer composite tool materials for sheet metal forming

Today's automotive industry shifts its focus on customised production, facing an increasing demand for medium and small batch production, where cost-effective manufacturability of sheet metal forming dies comes into the foreground. Filled polymers offer possibilities to fulfil such requirements in the ambit of prototype tools manufacturing or in small batch production of sheet metal components. This paper presents investigations dealing with tribological and tool design aspects of using polymeric materials for sheet metal forming purposes. Friction and wear behaviour of two polymer composites on sheet metal counterface materials have been investigated. A new testing method for wear evaluation of polymeric materials for sheet metal forming using a Strip Drawing Test facility is presented and discussed. A method to predict lifetime of polymeric stamping dies using the linear wear–distance relation W_l/s measured with the new testing method is also proposed. Significant improvements in friction and wear performance of polymer composites have been observed using sheet materials with structured surfaces. A theoretical model for abrasive friction and wear of polymer composites on sheet metal counterface material pairs has been developed, based on the results obtained by measurement of friction and wear.     

Electromagnetic blank restrainer in sheet metal forming processes

Electromagnetic blank restrainer (EMBR) is a new technology that was recently developed to control material movement in sheet metal forming processes. Magnetic attraction on the ferrous sheet metal is the intrinsic property of EMBR. Such magnetic force is quantified using Maxwell's stress tensor to assess the feasibility of EMBR in the sheet metal forming process. The 3D finite element analysis (FEA) of an electromagnetic system is conducted to determine the distribution of magnetic flux density on contacting surfaces of the sheet metal. The distribution is then used to estimate the magnetic force. Experiments have been conducted to measure the magnetic force and compare with results from the FEA. Biaxial-loading apparatus has been built to measure restraining forces on the sheet metal with blankholder, drawbead, and EMBR. All the restraining forces are put together in a chart to see where each method stands with respect to one another. In order to evaluate the quality of forming with each method, an experimental die has been built. The die forms a channel in a single stroke and provides a direct indication of how each restraining method controls blank movement in the die. The real advantage of EMBR lies in the effectiveness of force control and its flexible location in a sheet metal forming die. To prove this, a prototype has been built in a tryout die where house appliance panel is formed with blankholder and EMBR. EMBRs are locally installed in the die and actively controlled during the forming process. The part formed with EMBR shows a significant improvement in the forming quality. At the end of this paper, two immediate impacts that EMBR can bring to the sheet metal forming industry are also discussed.     

基于NCP1396的LLC半桥型谐振变换器

为解决开关电源的高效率、低损耗、EMI小等问题,将LLC半桥型谐振技术应用到开关电源中。在整个工作范围内,LLC半桥型谐振变换器实现了零电压转换(ZVS),减小了开关损耗。介绍了LLC半桥型谐振变换器的工作原理,提出了一种以NCP1396为控制芯片的开关电源的设计方法,并进行了实际试验。实验结果表明,提出的设计方法能够实现零电压转换,有效地提高了开关电源的效率。     

ANSYS在小孔冲模间隙优化中的应用

运用软件ANSYS的弹塑性有限元理论,重点研究了冲压模间隙对板材成形性能的影响,观察分析应力、应变分布和变形网格情况并与实践对比,模拟分析结果与生产实践基本吻合.板材成形有限元法为快速有效地确定冲压模间隙,优化模具设计,降低模具设计成本和缩短模具设计周期提供了一种可实施的手段.     

轿车用薄板焊接结构疲劳性能研究

薄板焊接结构的抗疲劳设计是轿车底盘结构件设计开发中的主要难题,充分理解并掌握薄板焊接结构的疲劳性能是进行焊缝抗疲劳设计的基础。通过一系列的薄板焊接结构疲劳性能试验研究,总结出了焊缝疲劳性能受焊接母材材料强度、母材厚度、焊接制造工艺等因素影响的普遍规律,从而为薄板焊接结构的抗疲劳设计打下了基础。     

Quality assessment of electrical drives with strongly deformed supply waveform

In the characterization of electrical drives it is necessary to carry out power measurement on highly distorted signals with low uncertainty and in some cases on-line; this involves the adoption of suitable test station and adequate measurement techniques. In addition, EMI sources not only produce electrical network pollution but also involve a reduction of motor performance and require special instrumentation and appropriate investigation methods. This paper reports three different approaches to variable speed drive characterization: performance testing in static and dynamic working conditions and EMI analysis. It then proposes a measurement station which is VXI-based both for VSD static performance testing and EMI analysis and uses a real-time special purpose instrument for dynamic testing.     

Viscous pressure bulging of aluminium alloy sheet at warm temperatures

Improving the formability of aluminium alloy sheet metal by using warm or elevated temperature has become a valid approach. In this paper, viscous pressure bulging (VPB) at warm temperature is proposed. The coupled thermo-mechanical finite element method and experimental method were used to investigate the VPB of aluminium alloy AA3003 at warm temperature. The temperature distributions of sheet metal and viscous medium were analyzed for non-isothermal VPB. The influence of forming temperature on thickness distribution, forming load and failure location of sheet metal were investigated. Research results show the temperature gradient field in sheet metal forms when the initial temperature of viscous medium is lower than that of sheet metal. The formability and failure location of sheet metal changes with initial temperature of viscous medium.     

Prediction of limiting dome height using neural network and finite element method

Using neural network to predict limiting dome height (LDH) based on the result of finite element analysis is a high efficiency work in spite of little error. Finite element results are presented with different working condition parameters, such as material thickness, punch speed, friction coefficient between punch, die and sheet metal, and blank holder force. Then, a two-layer back propagation network is developed to best fit this discrete engineering problem. Different number of neurons in the hidden layer, three commonly used training algorithms, and two performance functions are adopted and compared to choose the suitable one to minimize the error between the predictive value and the simulation results (one with ideal output). After comparison, the neuron number in the hidden layer is determined to be 12 and the appropriate learning algorithm is Levenberg–Marquardt algorithm. The difference between two performance algorithms is small. The mean square error between the predicted value and targeted one is less than 0.2%. Finally, five sheet metal forming processes under various working conditions are predicted and compared with the finite element method (FEM) result to verify the validity of this neural network model. The small difference indicates that this neural network can predict the LDH in a certain range of working conditions.