基于组分快速检测的型砂质量直接优化控制系统

为了有效控制湿型粘土砂的质量，基于快速检测型砂有效粘土含量的新方法，研究了从组分测试到组分控制的型砂质量直接优化控制技术。该技术通过在线测定型砂的有效粘土含量和含水量，采用数字PID控制器控制粘土、水、砂和辅料等的自动添加，使型砂组分保持相对稳定，从而使型砂的紧实率、拉压强度等性能保持稳定。详细论述了该技术的关键部分：有效粘土含量的在线测定方法、人工神经元网络模型结构及直接控制系统的构建方法。     

湿型砂质量参数智能测试车的研制

针对当前适合中小型铸造厂使用的湿型砂质量参数测试装置短缺的实际状况,在双电源二次激励法的基础上,借助于80C196KC单片机和PC机研制了一种湿型砂质量参数智能测试车,该测试装置可移动工作于生产现场,能够快速检测湿型砂的紧实率、温度、有效粘土质量分数、水质量分数、透气性和综合强度等6个基本参数。试验证明,该测试车具有良好的稳定性和较高的测试精度。     

黄壤土砂铸型与铸件界面烧结层的力学行为

黄壤土天然粘土砂湿型铸造工艺应用于铸铁生产,能有效预防粘砂缺陷、提高铸件表面质量,同时具有成本低、污染小、效率高的综合优势。这种工艺与普通的湿型铸造工艺相比,最大的区别在于,它会在铸型与铸件之间形成一层致密的烧结壳。这层烧结壳能抵挡住金属液的冲刷和渗透,在金属凝固后能牢固的粘附在铸件表面,可实现高温打箱,而不至于使铸件冷却过快、表面硬度过高,从而提高生产效率;在室温时,它又能轻易地从铸件表面脱落,减轻清砂工作量。为深入了解这一现象,开展对黄壤土天然粘土砂烧结层的高温和室温力学性能的研究,结果表明,烧结层试样在高温下具有很好的塑性,随着温度的降低,塑性减小、抗压强度提高,在室温下表现出明显的脆性。这说明烧结层力学性能的变化与其在铸造过程中的行为正好吻合。     

快速评价铸造用湿型粘土砂质量的新方法及装置*

介绍快速评价铸造用湿型粘土砂质量的新方法及装置，新方法以型砂有效粘土的质量分数、水的和紧湿率为主要评价指标，采用双电源二次激励法快速测定湿型砂交、直流电导率，通过数学模型求得有效粘土的质量分数及水的质量分数。以上述新方法为基础研制的新装置以８０９８单片机为核心器件，配备制样机构可在线完成自动取样、测试及结果输出。     

基于两级闭环控制的型砂水分在线测控系统

提出了一种基于两级闭环控制的新型型砂水分控制系统,阐述了温度补偿系数的设定方法.该系统以单片机为控制核心,通过检测旧砂温度和含水量控制砂冷却系统的加水量,以实现旧砂含水量的初步控制;通过测量检测冷却后的旧砂含水量,控制混砂机的加水量.系统采用了自行研制的水分传感器实现型砂水分的在线检测,选用了美国Dallas公司最新推出的DS18B20数字式温度传感器检测砂温及环境温度,以实现系统的温度补偿.本系统具有运行可靠,灵敏度高,控制精度高等特点.     

Multi-objective optimization of green sand mould system using evolutionary algorithms

The quality of cast products in green sand moulds is largely influenced by the mould properties, such as green compression strength, permeability, hardness and others, which depend on the input (process) parameters (that is, grain fineness number, percentage of clay, percentage of water and number of strokes). This paper presents multi-objective optimization of green sand mould system using evolutionary algorithms, such as genetic algorithm (GA) and particle swarm optimization (PSO). In this study, non-linear regression equations developed between the control factors (process parameters) and responses like green compression strength, permeability, hardness and bulk density have been considered for optimization utilizing GA and PSO. As the green sand mould system contains four objectives, an attempt is being made to form a single objective, after considering all the four individual objectives, to obtain a compromise solution, which satisfies all the four objectives. The results of this study show a good agreement with the experimental results.     

Optimization of green sand casting process parameters by using Taguchi’s method

This paper analyses various significant process parameters of the green sand casting process. An attempt has been made to obtain optimal settings of the green sand casting process in order to yield the optimum quality characteristics of the spheroidal graphite (SG) cast iron rigid coupling castings. The process parameters considered are: green strength, moisture content, permeability and mould hardness. The effect of selected process parameters and its levels on the casting defects and the subsequent optimal settings of the parameters have been accomplished using Taguchi’s parameter design approach. The result indicates that the selected process parameters significantly affect the casting defects of SG cast iron rigid coupling castings. The estimation of the optimum performance characteristics of green sand casting at the optimum levels of parameters is done in this paper and the results are verified by confirming with practical experiments.     

型砂性能检测的新探索

介绍了一种研制的型砂性能检测系统与测试方法,通过对标准砂样的测试,能迅速、准确地测得砂样受载过程中的应力—应变的动态关系曲线及反映型砂本质特征的几项性能参数,这是型砂性能检测领域中的新探索,其中型砂粘弹性指标及塑性变形临界值乃是型砂性能方面的新概念。     

Optimization of green sand casting process parameters of a foundry by using Taguchi��s method

An optimization technique for process parameters of green sand casting of a cast iron differential housing cover based on the Taguchi parameter design approach is proposed in this paper. The process parameters considered are green strength, moisture content, pouring temperature, and mould hardness vertical and horizontal. An attempt has been made to obtain optimal level of the process parameters in order to yield the optimum quality characteristics of the cast iron differential housing cover castings. An orthogonal array, the signal-to-noise (S/N) ratio, and analysis of variance are used to analyze the effect of selected process parameters and their levels on the casting defects. The results indicate that the selected process parameters significantly affect the casting defects of grey cast iron differential housing cover castings. A confirmation run is used to verify the results, which indicated that this method is more efficient in determining the best casting parameters for differential housing cover.     

A new test method for measuring the galling resistance between metal powders and die tool materials in powder compaction

The friction characteristics and galling resistance between metal powder and die tool material in metal powder compaction is of outmost importance since they will influence the porosity and surface quality of the green body and consequently the porosity, tolerances and surface quality of the final sintered product. In the present study, a new test method for evaluating the tribological performance of die tool materials aimed for powder compaction is presented. The test method is based on controlled scratch testing using a commercial scratch tester but instead of the commonly used Rockwell C diamond stylus a sample holder with a small green body of compacted powder particles is drawn over the surface in a well controlled multi pass linear reciprocating sliding contact. The capability of the test method was evaluated for different types of tool materials including two PVD coatings in contact with different types of metal powders to determine the friction characteristics and the adhesion and material transfer tendency at the sliding interface. Post-test examination of the tool surfaces using FEG-SEM and EDS were performed in order to evaluate the mechanisms controlling the friction behavior and the material transfer tendency. The results show that the proposed test is a simple and fast method to obtain relevant data regarding the friction and galling characteristics of die tool materials in metal powder compaction. The mechanisms prevailing at the green body/die tool material interface, e.g. cold welding, can easily be monitored by the friction and acoustic emission signals. Of the die tool materials investigated the low friction PVD a-C:Cr coating displayed the lowest friction and highest galling resistance.     

深孔的光整加工——砂带磨削

先进的深孔精加工、光整加工技术和高性能价格比的深孔加工装备,是促进我国制造业高速发展和产品质量不断提高的一项重要内容。本文介绍了一种新型磨削工具——深孔砂带磨削的方法与应用参数。     

应用TRIZ的主动再制造绿色创新设计研究

针对主动再制造设计过程中的创新问题,提出一种应用发明问题解决理论(Theory of inventive problem solving,TRIZ)的主动再制造绿色创新设计方法。将TRIZ技术冲突解决原理和环境化质量功能配置方法相结合,建立再制造设计参数与TRIZ工程参数之间的映射关联,在再制造设计需求驱动下进行零部件再制造设计改进。分析存在的主动再制造设计冲突,建立主动再制造绿色创新设计知识关联与提取机制,给出TRIZ物理冲突解决原理与知识集成的主动再制造绿色设计冲突消解方法,并从再制造性能、生命周期能耗及成本三方面进行主动再制造绿色设计评价,同时开发相应的计算机辅助设计系统。通过设计方法与工具研发,以期提高主动再制造结构绿色设计改进的效率和成功率。最后通过变速箱输入轴系零部件的设计案例验证了该方法的可行性。     

A model for predicting the thermal conductivities of bentonite-bonded molding sands at high temperatures

The effective thermal conductivities of bonded molding sands vary with the dry density, binder content, initial moisture content, temperature as well as the types of sand and binder clay. In this study, a theoretical model for predicting the effective thermal conductivities of bentonitebonded molding sands was developed. The results of measurement of the effective thermal conductivities of molding sands at temperatures up to 750°C were used. The binder thermal conductivities of both western bentonite and southern bentonite were suggested as a function of dry density, binder content and initial moisture content and were assumed not to vary with temperature. The radiation model proposed by Vortmeyer was also incorporated. The model developed in this study was proved to predict well the effects of binder content, initial moisture content, dry density and temperature.     

影响烟支端部落丝量的因素研究

通过对可能影响烟支端部落丝量的各因素如烟支质量、烟支密度(分整支烟支密度和烟支端面密度)、烟支水份、烟支含末率、烟丝结构等进行测试和分析,从而确定影响烟支端部落丝量的主要因素,为卷烟生产中控制烟支端部落丝量提供依据和指引。     

绿色发展绿色制造 打造企业的国际核心竞争力——在第七届中国—东盟博览会“装备制造业共享中国—东盟自贸区发展新机遇”高峰论坛上的主题发言（摘要）

＂绿色发展,和谐共赢＂是玉柴的核心理念,是玉柴新时期的历史定位,是玉柴文化建设的思想基础,是玉柴发展进步的行为指南,是玉柴经营活动的战略总纲。在核心理念指引下,玉柴坚持走绿色工业发展之路,积极引领绿色动力发展,以提供高性价比绿色动力和绿色机器为己任,用卓越和领先满足公众的动力需求,做中国绿色动力的引领者,做中国＂最大活动污染源＂的控制者,并着眼未来可持续发展,使玉柴能够在遇到全球金融危机、行业形势严峻、市场竞争惨烈等复杂的环境之时,凭借技术优势、产品优势和服务优势等,披荆斩棘,逆势上扬,打造了企业的核心竞争力,持续深入推进了玉柴的国际化进程。     

粘土砂高压造型型砂控制要点

随着我国铸造产业的国际化，一些国际先进的铸造工艺和铸造不断取代我们传统的手工造型和机械化造型。其中粘土砂高压造型工艺由于其生产效率高，产品适应性强，铸件品质好，非常适合大规模流水线作业。为使型砂很好的适应粘土砂高压造型设备，应有针对性的选择原辅材料，控制型砂性能，选择砂处理工艺。     

Comparative measurement of compaction impact of clay stabilized with cement,peat ash and silica sand

This paper concentrates on measuring the compact ability of Taman Wetland clay stabilized with cement, peat ash and silica sand. The organic content of peat makes it a problematic basement soil for highway construction. Such problem can be solved by removing and incinerating the peat for generating peat ash which is applicable for stabilization of the compacted clay. Compaction tests were conducted on both untreated and stabilized clay specimens. The mix designs from the compaction tests were applied on stabilized clay specimens for testing using direct shear apparatus. A feasible mix design can be developed by partially replacing the cement with 1.5% peat ash in the test specimens. Test specimen with the mix design has the highest cohesion of 133 kPa as compared to those of test specimens with other mix designs under study. Such cohesiveness is attributable to the formation of cementation crystals which effectively clogged the pore spaces of the stabilized clay.     

基于DSP的中药丸料湿度密度在线检测系统

设计与研制一种能在现代化中药制药生产线上在线连续测量中药丸料湿度与密度的微波检测系统。系统包括三个组成模块：微波信号源模块，微波谐振腔，数据处理模块。其中，微波谐振腔是专门设计用于中药丸料湿度与密度检测的中心开通孔的金属谐振腔，当中药丸料通过微波谐振腔的中孔时，丸料密度及湿度均令谐振腔的谐振频率产生偏移和功率衰减，数据处理模块据此计算中药丸料的湿度与密度。为提高检测精度，采用模糊聚类算法对实验数据进行分组，对金属谐振腔的频偏和功率衰减特性进行建模，并利用DSP设计并实现了中药丸料湿度与密度的在线检测。现场调试表明：该检测系统适宜于现代化中药制药生产线上的湿度连续在线测量，其检测精度达到93％以上。     

金-塑微结构注射成型仿真与试验研究*

金属-塑料(聚合物)复合高强件具有强度高、质量小、易成型复杂结构等优点,在航空航天、汽车制造、通信等领域日益得到重视。介绍金-塑复合微结构注射成型原理,建立聚合物熔体在金属表面微结构填充流动的数值模型。采用两相流水平集方法追踪获得了微尺度下聚合物熔体在金属表面的流动前沿,研究金属表面微结构尺寸大小、注射速度和金属表面温度等参数对聚合物熔体填充微结构能力的影响规律,为实际产品的生产成形提供理论基础。根据金-塑复合件的成型理论与技术,构建金-塑复合成型试验装置,采用物理喷砂的方式制备了金属表面的微结构,并注射获得了金属-塑料成型的试验试样。通过对获得的试验试样进行拉伸剪切试验,验证了本文仿真结果的合理性。所取得的研究结果对优化金-塑成型工艺参数和改善产品质量有着重要的启发和指导意义。     

防止铸钢粘砂的黄壤土型砂性能与工艺研究

运用黄壤土型砂的烧结产生可剥离烧结层,可以有效防止铸钢件表面的粘砂类缺陷,提高铸钢件表面质量。调整黄壤土型砂的石英砂质量分数及粒径,进行不同温度下的烧结试验,研究适合不同温度下烧结的型砂配比。通过模拟烧结层试样的高温与室温力学性能测试,研究烧结层力学性能。依据型砂烧结试验和烧结层力学性能试验结果,将黄壤土和粒径为0.15～0.30 mm(50/100目)石英砂以3∶7配制的黄壤土型砂运用在铸钢件浇注试验,发现砂型与铸件界面产生一层致密的烧结层,并且在室温下可以轻易地从铸件表面剥离,获得表面光洁的铸钢件。研究表明,调整黄壤土型砂的成分可以调节型砂耐火度,使其满足在不同浇注温度下,在铸型—铸件界面处生成适度烧结的烧结层。该烧结层在高温下呈现良好塑性,粘附在铸钢件表面,抵挡金属液的冲刷和渗透;当铸钢件冷却至室温时,烧结层呈现出明显的脆性,可以很容易地剥离铸钢件表面,从而极有可能防止铸钢件的粘砂类缺陷,获得表面质量高的铸钢件。