十字轴小飞边精密成形工艺

针对十字轴热模锻成形过程中飞边大、成形力大的问题,根据十字轴形状尺寸及锻造成形工艺特点,提出十字轴小飞边精密成形工艺。采用Deform-3D对十字轴小飞边精密成形工艺过程进行数值模拟,对模拟成形的十字轴锻件及其金属速度场、等效应变、模具载荷-时间曲线进行分析。模拟结果显示,十字轴锻件成形完整,金属流动均匀,模具载荷减小。结合模拟结果,设计制造模具进行十字轴成形工艺试验。试验得到的十字轴锻件,填充饱满,无折叠、表面裂纹等缺陷,飞边明显减小,与模拟结果一致。结果表明:改变十字轴热模锻成形工艺,采用十字轴小飞边精密成形工艺,使锻件飞边减小,锻造过程成形载荷降低。     

基于Dynaform的高压舱顶板模拟与制造

介绍了高压舱顶板的成形工艺,通过采用Dynaform软件对高压舱顶板成形过程进行模拟,预测其成形过程中可能出现的缺陷,从而优化成形工艺和模具结构,缩短零件试制周期、降低试制费用。     

基于Dynaform的加油口盒成形工艺分析及优化

依靠经验对外形复杂、需要多次拉延才能成形的汽车覆盖件进行模具及工艺设计困难而效率低.基于板料成形模拟软件Dynaform,对某轿车加油口盒的一次拉延可成形性进行了模拟分析.预测该零件在一次成形过程中存在缺陷,由此提出二次拉延成形的工艺方案.针对零件在成形过程中容易出现拉裂和起皱的部位,进行了工艺优化和模拟验证,获得了满意的工艺方案,对该类零件模具工艺设计具有指导意义.     

汽车覆盖件成形数值模拟与模具型面设计

以某汽车覆盖件为研究对象,利用板料分析软件Autoform对其进行了冲压方向的确定、压料面和工艺补充面设计、拉延筋设计以及拉延成形过程的数值模拟。通过仿真预测了板料成形过程中拉裂、减薄、起皱等缺陷,并根据模拟结果分析了板料与凸凹模的摩擦、工艺补充面、压边力、拉延筋等因素对缺陷产生的影响,进而调整优化了板料成形工艺参数和模具型面结构,消除了零件成形中的质量缺陷,提高了成形工艺的可靠性,为实际生产中覆盖件冲压工艺确定和模具型面设计提供了参考和依据。     

马车螺栓冷镦成形有限元模拟及模具设计

利用有限元软件Deform-3D建立了马车螺栓冷镦成形工艺过程的有限元模型并进行模拟,获得了成形过程中的场量分布,分析了各工步毛坯材料在模具内的流动情况,得到了零件成形的基本规律,预测了零件的成形缺陷,进行了模具结构的优化设计;针对马车螺栓成形过程中坯料出现台阶、 模具填充不满和模具寿命短的问题,分析了各工步毛坯成形缺...     

大型曲轴锻造成形过程数值模拟与工艺试验

曲轴的锻造工艺过程随着曲轴材料、形状和生产条件的不同而不同,利用QForm有限元模拟软件可以有效地对金属的流动规律进行模拟,并且发现其成形过程中的缺陷,为找到合理的成形工艺以及正确地设计模具和选择设备提供依据。     

导电体冷挤压工艺研究

采用DEFORM-3D软件对导电体冷挤压工艺进行数值模拟.通过模拟分析工艺的合理性以及成形过程中可能产生的缺陷,从而改进模具,以成形更为合理的挤压件.模拟结果表明,所提出的冷挤压工艺可以极大地节省铜材料,降低生产成本.     

德系后盖外板成形极限(FLD)缺陷分析与处理

汽车后盖外板尺寸较大、形状复杂、成形困难,模具对外部变化因素敏感,很难进行准确判定缺陷产生原因.随着拉伸模拟技术(CAE)及网格实验分析技术(GGA)的发展和运用,能在冲压成形过程中进行数据模拟与调试实验,这是对冲压工艺、模具设计与制造的技术革新,使得模具在调试期间或者生产过程出现缩颈、开裂、皱等缺陷时能准确分析缺陷处...     

基于Dynaform的一种新型拉延模结构设计与应用

利用Dynaform板料成形有限元模拟分析软件,对某高端重型卡车中地板冲压设计工艺方案进行数值模拟分析,准确地预测出该产品较复杂部位的成形缺陷。为了消除中地板在冲压成形中的开裂、起皱、叠料等缺陷,根据成形CAE分析模拟结果,提出增加不同方向和大小的凸筋的设计建议,并确定采用一种新型的"曰"字型压边圈的冲压工艺和模具结构设计方案,可以有效消除该产品的冲压成形缺陷。试模结果验证了冲压成形有限元分析的可行性,以及采用新型的冲压工艺可以降低模具开发成本,缩短模具调试周期,保证汽车中地板产品的成形质量。     

CAE技术在后纵梁成形工艺及调试中的应用

借助AutoForm软件,利用汽车板成形的有限元模拟分析技术,对某车型后纵梁冲压设计工艺方案进行了模拟分析.为了消除V字形纵梁成形缺陷,制订了特殊工艺方案和相对应的模具结构设计,根据CAE技术在模具设计调试过程中的指导作用,并依据模拟结果对零件拉延工艺方案进行分析、判断和优化,缩短模具设计、制造、调试周期,提高模具质量...     

Process force and technology model for designing and controlling finishing operations with rotating grinding tools

Today the technological design of fine machining processes like finishing of plane surfaces is still a procedure based on experience. In addition, finishing technology is the result of an empirical approach. Innovative methods for designing and controlling finish operations make use of models and the implementation of procedures that allow the derivation of optimal technological parameters and process control strategies as well as the prediction of cutting behaviour of abrasive tools. These process and technology models are based on measuring and evaluating process variables like process forces or cutting torque and parameters of the electric drive like motor current or torque. With these models a finishing process is achieved on the basis of mathematical and technological principles wherein the grinding tool works in a self-sharpening condition providing optimal results.     

Near-net-shape manufacture of engineering components using bulge-forming processes: a review

Bulge forming is a manufacturing process that is becoming increasingly important as a technology that can be used to produce seamless, lightweight and near-net-shape industrial components. The process is being increasingly applied in the automotive and aerospace industries where the demand for increased structural strength and decreased vehicle weight make it a very attractive manufacturing method. This paper discusses the application of bulge forming to the manufacture of near-net-shape components and discusses machine and tool design, and illustrates how finite-element simulation is playing a growing role in the design of bulge-forming processes.     

优化上钢工艺结构,建设短流程炼铁厂

针对上钢化铁炼钢的状况,详述了COREX－MIDREX煤基炼铁工艺和链篦机-回转窑氧化球团的生产工艺、工艺参数、特点、技术经济指标等,认为建设上述工艺为基础的炼铁工序对改造和优化上钢工艺结构具重要意义。     

Monitoring and control of the micro wire-EDM process

A new pulse discriminating and control system has been developed for process monitoring and control in micro wire-EDM. The pulse discriminating and control system identifies four major gap states classified as open circuit, normal spark, arc discharge and short circuit based on the characteristics of gap voltage waveform. The effect of pulse interval, machining feedrate and workpiece thickness on the variations of the proportion of normal spark, arc discharge and short circuit in the total sparks (defined as normal ratio, arc ratio and short ratio, respectively) were investigated. It is found that a long pulse interval results in an increase of the short ratio under a constant feedrate machining condition. A high machining feedrate or an increase of workpiece height results in an increase of the short ratio. To achieve the stability of the machining operation, a control strategy is proposed by regulating the pulse interval of each spark in real-time according to the identified gap states. Experimental results indicate that the developed pulse discriminating and control system can significantly reduce the arc discharge and short sparking frequency as well as achieve stable machining under the condition where the instability of machining operation is prone to occur.     

钢液真空处理法的选用

在介绍VD和RH真空处理的特点、投资和生产成本的前提下，提出电炉和转炉炼钢配置真空处理装置时的选用原则。     

Process control and dynamic process planning

Real time machine tool control and the planning activities which precede manufacture are usually interfaced through a low level language which allows little more than position, feed, and speed information to be passed between the two systems. The higher level systems used to describe geometry and tool paths also lack an adequate capability to describe manufacturing processes. The authors discuss the provision of a much richer interface between the planning and control activities which both facilitates the identification and scheduling of suitable monitoring tasks and allows the updating of process plan data from real time measurements. The result of such integration is an improvement in the efficiency of real time optimisation, and perhaps most importantly the possibility of quasi real time process planning. A system that is able to perform both initial process planning and plan refinement based upon low level feedback must also encompass the path generation activity, such a system is referred to by the authors as a dynamic process planning system. The paper describes the fundamentals of the process models, identification algorithms, control strategies, and low level process plan generation used within such an integrated system.     

复合板油底壳拉延成形研究

介绍了复合减振钢板油底壳拉延成形研究的意义,同时针对复合板材料上下两层板在拉延过程中不允许错动的特点,进行了油底壳结构工艺性分析及结构形状优化.在分析、研究材料的力学性能、相对厚度、凹模圆角半径、压边力、拉延筋、毛坯形状尺寸、润滑等关键技术和工艺参数的基础上,确定了油底壳成形工艺方案.通过在模具上实际生产,验证了复合板油底壳拉延成形工艺参数的正确性.     

诺威力复合锭铸造法的原理和工艺及应用

采用DC法商业化铸造复合铝合金锭是铝业界工程师几十年来追求的目标之一,2005年底美国诺威力公司奥斯威戈轧制厂在瓦格斯塔夫公司专家的协助下,终于成功地实现了复合锭的工业化规模铸造,到2006年3月份已成功地铸出50多种不同合金的复合锭。用此种锭轧制的1200／2124合金薄板及4147／3003合金钎焊带箔已发往用户。奥斯威戈轧制厂已形成70kt／a复合锭的生产能力,诺威力公司将在韩国蔚山轧制厂与瑞士谢尔轧制厂各建一条铸造复合锭的生产线。复合锭的商业化生产将大大扩大复合铝板带箔的应用范围,在DC法发展历程中具有里程碑意义。     

基于因子分析的多元工序能力指数

工序质量最终决定着机械产品的制造质量。通过工序能力指数的分析，可以得到产品在制造过程中工序质量的保证能力，由于很多机械产品需要综合分析多个质量特性评价工序质量，而针对个质量特性的一维工序能力指数无 到这一目的，因此本文提出一种基于因子分析的多元工序能力指数计算方法，通过分析多元工序能力指数这一综合指标，实现工序质量的综合评价，为保证和提高生产制造质量提供依据。最后，给出一个多元工序能力指数的计算实例，该实例表明，提出的方法是非常有效的。     

船用柴油机关键零部件数控加工工艺参数优化及仿真研究

针对我国船用柴油机企业在生产制造过程中工艺参数选择过于保守的问题,在分析国内外工艺参数优化、工艺仿真的基础上,提出一种数控加工工艺参数优化及仿真验证的思路:建立工艺参数优化数学模型,通过求解计算获得优化后的工艺参数,并对优化的工艺参数进行仿真验证,直到获得最优的工艺参数。并以船用柴油机缸盖零件的数控加工工艺参数优化及仿真为例,验证了此思路的可行性。