复杂铸件产品生产过程多源异构数据融合技术应用

为了解决汽车行业潮模砂铸造领域质量追溯困难的问题，通过采集铸件生产制造过程影响铸件质量的不同种类、不同格式、不同结构、不同质量的数据，基于MES系统通过程序设计将所采集数据运用多源异构融合技术进行处理，形成铸件制造过程质量相关规范数据，并与铸件实时绑定存入数据库或数据湖中进行共享，供生产计划排程、生产过程管控、全生产过程质量管理、工厂内物流管理系统使用，实现铸件产品单体质量追溯及批次质量追溯。处理后的数据通过对照工艺质量标准进行追溯，在指导铸件生产过程质量参数优化方面起着重要作用。系统运行后，经过大量数据积累，后期运用大数据分析和质量模型算法，实现了质量预测和反馈控制，并探索出一条铸造企业在生产制造领域以数据赋能产品质量提升的数字化系统建设之路。     

基于数字化技术的模具制造工艺优化

探讨基于数字化技术的模具制造工艺优化,旨在改进传统模具制造工艺,提高生产效率,降低成本,增强可持续性。数字化技术在模具制造中的应用,特别是数字化建模与设计、数字化制造工艺以及数字化模拟与仿真,能够有效应对传统工艺的局限性。分析模具制造工艺中的问题与挑战,旨在探讨数字化技术在模具制造工艺优化中的方法。     

机器人激光制造工作站数字化控制系统设计

根据激光加工工艺时序和控制功能要求,提出了一种机器人激光制造工作站数字化控制系统设计方案。基于西门子可编程逻辑控制器,构建了系统通信架构,实现了系统各组件的集成联动控制。建立激光制造工艺数据库并提供数据服务接口,实现与企业信息管理系统的互联互通,方便企业进行生产规划、生产进度管理和产品质量追溯。结果表明,该机器人激光制造工作站数字化控制系统响应速度快,运行稳定且易于维护,能够显著提高焊接效率与质量,改善工人劳动环境,并推动企业向数字化工厂发展。     

三维装配焊接作业指导书生成系统的开发与应用

随着5G时代的到来,传统的制造方式将发生重大变革,二维纸质作业指导书无法应对智能制造提出的数字化、可视化和高效化的需求.针对船舶行业装配焊接工艺过程的特殊性,通过对作业指导书需求的详细分析,设计并开发了一种通用的三维装配焊接作业指导书生成系统.该系统能进行装配焊接过程的三维动态模拟,实现装配焊接工艺信息的三维可视化,自...     

面向智能制造的数字化检测车间构建关键技术

数字化车间是将智能识别技术与柔性制造技术、生产组织系统以及其他管理系统的信息进行高度集成,构成具有自动化性质和综合信息流的集成制造系统。针对国内航空发动机零部件检测车间相关设施不完备、数字化程度不高的问题,研究数字化检测车间的构建需求,提出面向智能制造的数字化检测车间总体架构和构建的关键技术,为相关企业规划和建设数字化检测车间提供可参考的方向和依据。     

基于机器学习的铆接质量数字化检测系统

为实现铆接质量数字化检测和质量追溯,提出基于机器学习的铆接质量数字化检测方法。使用CCD摄像机对铆接部位进行图像采集,然后进行中值滤波、Canny边缘检测、图像形态学处理等,实现铆接部位裂纹检测和特征信息提取。利用改进的粒子群优化最小二乘支持向量机算法建立铆接质量检测模型,并使用检测样本对模型进行检验。对不合格的铆接进行质量追溯,应用专家系统判断产生缺陷的原因。在某型号飞机装配车间对原型系统进行应用验证。结果表明：所设计的系统检测准确率达96%,可提高铆接质量检测效率、统一检测标准、减少工人劳动。     

基于OPC的飞机数字化柔性装配语言系统

为实现飞机数字化柔性装配工装的计算机控制,通过基于OPC通信技术实现了面向数字化柔性工装的编程语言系统,该语言系统通过装配系统监控状态、装配工艺编辑状态以及装配工艺执行状态等三个状态实现工装系统的数字化柔性计算机控制。最后通过本语言系统构建安装于某型飞机的壁板组件装配预定位工装的软件平台,实现了该工装的状态监控、运动控制以及工艺编辑与控制。     

发动机装配线MES信息系统中标准件追溯方法的研究

基于数据库技术,在Microsoft Visual Studio 2010环境下以C#为编程语言开发了针对发动机装配线的MES信息系统,包括系统的结构设计、数据库设计及界面设计等。能够实时与数据库通讯,采集发动机装配的标准件信息,完成发动机装配中标准件的追溯。采用系统的生产线可完成各种标准件的追溯,达到形成发动机装配档案的目的。发动机装配线MES信息系统目前已在某发动机生产中实际应用,运行稳定。     

基于PCM/CAE集成的虚拟装配检测及工艺优化

开发了基于点云模型(PCM)/CAE集成的虚拟装配检测系统,将PCM与CAE模型进行了集成。聚焦虚拟装配检测过程中的误差分析问题,研究了基于仿真的零部件制造与装配误差分析方法。为了使一个存在各种变形与制造误差的零件达到理想或设计目标的装车状态,采用了多目标优化方法,实现了基于CAE仿真的虚拟装配分析与装配工艺优化。     

装配小间隙数字化在线测量系统设计与研究

在部分产品装配过程中，装配间隙大小是否满足需求直接反映了装配质量的高低。传统小间隙测量常采用手工测量，测量准确性和一致性难以保证，数字化在线测量技术的研究与应用迫在眉睫。数字化测量技术受环境、光照等外界因素影响较大。针对装配过程中物体端面间隙的自动化测量问题，提出一种可适应物体结构的间隙视觉测量系统，以实现对装配小间隙的在线测量。对测量系统的原理进行分析，对系统的设计进行说明，随后对该系统在实际不同场景的应用效果开展相关测试与验证。结果表明：该系统测量精度满足要求。     

Effects of Post-weld Heat Treatment on Microstructure,Mechanical Properties and the Role of Weld Reinforcement in 2219 Aluminum Alloy TIG-Welded Joints

In as-welded state, each region of 2219 aluminum alloy TIG-welded joint shows diff erent microstructure and microhardness due to the diff erent welding heat cycles and the resulting evolution of second phases. After the post-weld heat treatment, both the amount and the size of the eutectic structure or θ phases decreased. Correspondingly, both the Cu content in α-Al matrix and the microhardness increased to a similar level in each region of the joint, and the tensile strength of the entire joint was greatly improved. Post-weld heat treatment played the role of solid solution strengthening and aging strengthening. After the post-weld heat treatment, the weld performance became similar to other regions, but weld reinforcements lost their reinforcing eff ect on the weld and their existence was more of an adverse eff ect. The joint without weld reinforcements after the post-weld heat treatment had the optimal tensile properties, and the specimens randomly crack in the weld zone.     

The First Phase of the SRIF Industrialized Base in ＂West Area＂ Has Been Put into Operation

After nearly two years＇ tense construction, the first phase of industrialized base of Shenyang Research Institute of Foundry （SRIF）, located at the Tiexi Casting and Forging Industrial Park in the west of Tiexi District, has now been completed and formally put into operation.     

Thermodynamics Study on the Decomposition of Chromite with KOH

Institute of Process Engineering, Chinese Academy of Sciences, China, has proposed a method for oxidative leaching of chromite with potassium hydroxide. Understanding the mechanism of chromite decomposition, especially in the potassium hydroxide fusion, is important for the optimization of the operating parameters of the oxidative leaching process. A traditional thermodynamic method is proposed and the thermal decomposition and the reaction decomposition during the oxidative leaching of chromite with KOH and oxygen is discussed, which suggests that chromite is mainly destroyed by reactions with KOH and oxygen. Meanwhile, equilibrium of the main reactions of the above process was calculated at different temperatures and oxygen partial pressures. The stable zones of productions, namely, K2CrO4 and Fe2O3, increase with the decrease of temperature, which indicates that higher temperature is not beneficial to thermodynamic reactions. In addition, a comparison of the general alkali methods is carried out, and it is concluded that the KOH leaching process is thermodynamically superior to the conventional chromate production process.     

Influence of Heat Treatment on Damping Behaviour of the Magnesium Wrought Alloy AZ61

The effect of isochronal heat treatments for 1h on variation of damping, hardness and microstructural change of the magnesium wrought alloy AZ61 was investigated. Damping and hardness behaviour could be attributed to the evolution of precipitation process. The influence of precipitation on damping behaviour was explained in the framework of the dislocation string model of Granato and Lücke.     

Effect of Rare Earth Doping on Impedance,Modulus and Conductivity Properties of Multiferroic Composites:0.5(BiLa_xFe_(1-x)O_3)–0.5(PbTiO_3)

The Lanthanum-doped bismuth ferrite–lead titanate compositions of 0.5(Bi LaxFe1-xO3)–0.5(Pb Ti O3)(x = 0.05,0.10,0.15,0.20)(BLxF1-x-PT) were prepared by mixed oxide method.Structural characterization was performed by X-ray diffraction and shows a tetragonal structure at room temperature.The lattice parameter c/a ratio decreases with increasing of La(x = 0.05–0.20) concentration of the composites.The effect of charge carrier/ion hopping mechanism,conductivity,relaxation process and impedance parameters was studied using an impedance analyzer in a wide frequency range(102–106Hz) at different temperatures.The nature of Nyquist plot confirms the presence of bulk effects only,and non-Debye type of relaxation processes occurs in the composites.The electrical modulus exhibits an important role of the hopping mechanism in the electrical transport process of the materials.The ac conductivity and dc conductivity of the materials were studied,and the activation energy found to be 0.81,0.77,0.76 and 0.74 e V for all compositions of x = 0.05–0.20 at different temperatures(200–300 °C).     

Quantitative Analysis of the Crystallographic Orientation Relationship Between the Martensite and Austenite in Quenching–Partitioning–Tempering Steels

The orientation relationships(ORs)between the martensite and the retained austenite in low-and medium-carbon steels after quenching–partitioning–tempering process were studied in this work.The ORs in the studied steels are identified by selected-area electron diffraction(SAED)as either K–S or N–W ORs.Meanwhile,the ORs were also studied based on numerical fitting of electron backscatter diffraction data method suggested by Miyamoto.The simulated K–S and N–W ORs in the low-index directions generally do not well coincide with the experimental pole figure,which may be attributed to both the orientation spread from the ideal variant orientations and high symmetry of the low-index directions.However,the simulated results coincide well with experimental pole figures in the high-index directions{123}_(bcc).A modified method with simplicity based on Miyamoto’s work was proposed.The results indicate that the ORs determined by modified method are similar to those determined by Miyamoto’method,that is,the OR is near K–S OR for the low-carbon Q–P–T steel,and with the increase of carbon content,the OR is closer to N–W OR in medium-carbon Q–P–T steel.     

Using Finite Element and Contour Method to Evaluate Residual Stress in Thick Ti-6Al-4V Alloy Welded by Electron Beam Welding

This work was to reveal the residual stress profile in electron beam welded Ti-6Al-4V alloy plates(50 mm thick) by using finite element and contour measurement methods.A three-dimensional finite element model of 50-mmthick titanium component was proposed,in which a column–cone combined heat source model was used to simulate the temperature field and a thermo-elastic–plastic model to analyze residual stress in a weld joint based on ABAQUS software.Considering the uncertainty of welding simulation,the computation was calibrated by experimental data of contour measurement method.Both test and simulated results show that residual stresses on the surface and inside the weld zone are significantly different and present a narrow and large gradient feature in the weld joint.The peak tensile stress exceeds the yield strength of base materials inside weld,which are distinctly different from residual stress of the thin Ti-6Al-4V alloy plates presented in references before.     

Microstructures and Tensile Properties of Ultrafine-Grained Ni–(1–3.5) wt% SiC_(NP) Composites Prepared by a Powder Metallurgy Route

Silicon carbide nanoparticle-reinforced nickel-based composites(Ni–Si CNP),with a Si CNPcontent ranged from1 to 3.5 wt%,were prepared using mechanical alloying and spark plasma sintering.In addition,unreinforced pure nickel samples were also prepared for comparative purposes.To characterize the microstructural properties of both the unreinforced pure nickel and the Ni–Si CNPcomposites transmission electron microscopy(TEM) was used,while their mechanical behavior was investigated using the Vickers pyramid method for hardness measurements and a universal tensile testing machine for tensile tests.TEM results showed an array of dislocation lines decorated in the sintered pure nickel sample,whereas,for the Ni–Si CNPcomposites,the presence of nano-dispersed Si CNPand twinning crystals was observed.These homogeneously distributed Si CNPwere found located either within the matrix,between twins or on grain boundaries.For the Ni–Si CNPcomposites,coerced coarsening of the Si CNPassembly occurred with increasing Si CNPcontent.Furthermore,the grain sizes of the Ni–Si CNPcomposites were much finer than that of the unreinforced pure nickel,which was considered to be due to the composite ball milling process.In all cases,the Ni–Si CNPcomposites showed higher strengths and hardness values than the unreinforced pure nickel,likely due to a combination of dispersion strengthening(Orowan effects) and particle strengthening(Hall–Petch effects).For the Ni–Si CNPcomposites,the strength increased initially and then decreased as a function of Si CNPcontent,whereas their elongation percentages decreased linearly.Compared to all materials tested,the Ni–Si CNPcomposite containing 1.5% Si C was found more superior considering both their strength and plastic properties.     

Directional Growth of Tin Crystals Controlled by Combined Solute Concentration Gradient Field and Static Magnetic Field

A new method was introduced to achieve directional growth of Sn crystals. Microstructures in liquid(Pb)/liquid(Sn) diffusion couples were investigated under various static magnetic fields. Results show that the β-Sn crystals mainly reveal an irregular dendritic morphology without or with a relatively low static magnetic field(B0.3 T). When the magnetic field is increased to 0.5 T, the β-Sn dendrites close to the final stage of growth begin to show some directional character. With a further increase in the magnetic field to a higher level(0.8–5 T), the β-Sn dendrites have an enhanced directional growth character, but the dendrites show a certain deflection. As the magnetic field is increased to 12 T, the directional growth of the β-Sn dendrites in the center of the couple is severely destroyed. The mechanism of the directional growth of the β-Sn crystals and the deflection of the β-Sn crystals with the application of static magnetic field was tentatively discussed.     

Growth Kinetics of Single Inclusion Particle in Molten Melts

On the basis of the single-particle framework, a new theory on inclusion growth in metallurgical melts is developed to study the kinetics of inclusion growth on account of reaction and collision. The studies show that the early growth of inclusion depends on reaction growth and Brawnian motion collision, and where the former is decisive, the late growth depends on turbulence collision and Stokes＇ collision, and where the former is dominant; collision growth is very quick during the smelting process, lessened in the refining process, but nearly negligible in the continuous casting process.