Development of an industrial process for producing lead battery terminals

This paper presents an alternative solution for the manufacture of lead battery terminals currently produced by casting. The solution is based on a multi-stage process consisting of two metal forming operations followed by final piercing. The metal forming operations induce the desired shape on the raw material by means of plastic deformation, while the piercing operation opens the inner hole of the component by removing the scrap left by the previous forming stages.The main objective of this work is to present the theoretical and experimental results obtained during the development of the process, which are important for designing an industrial tool.The theoretical analysis is based on the utilization of the finite element method to characterize the material flow, establish the process sequence and related preform geometries, and to design the tools for the metal forming stages of the production cycle. The experimental tests were performed on a laboratory prototype tool. These experiments confirmed previous theoretical analysis, and validated the new proposed technology for producing high-quality lead battery terminals.     

Application of process modelling - an industrial view

Process modelling has become accepted as a normal part of the design and improvement of industrial processes. A rapid increase in the use and application of computer modelling has occurred over the past decade due to the increase in capability of desk-top computers. The Steel industry now has an array of powerful computer-based modelling and simulation tools at its disposal, and these are widely used.

This paper presents an overview of the use of modelling and simulation techniques applied to steel mill processes in an industrial context. Modelling techniques include finite element methods, finite difference applications, and the use of neural networks and expert systems. The application of these methods to flat and long product production processes within a ‘through-mill’ modelling capability are demonstrated to show the potential of computer models to process design and simulation.

While indicating the state of the art in application of this technology, some indications of future requirements and goals from an industrial viewpoint are given.     

齿轮脉冲电化学光整加工控制系统的研究

针对齿轮的脉冲电化学光整加工的实际特点，设计了一套基于上下位机结构的微机控制系统。首先阐述了工艺的控制原理。然后介绍了系统的结构组成和软件模块的设计，最后对步进电机的控制和微机间的通信技术做了重点阐述。     

Planning and realization of an innovative airline catering production plant: industrial case study

ifp, a consultancy for production and logistics, was involved into the planning of a new “greenfield” production plant for one of the world’s leading airline catering companies. The overall project objective was to design a future-proof production plant being prepared for prospective customer requirements in a growing but volatile market environment which is getting more and more complex. The focus was to develop and introduce innovative lean production processes and an organizational structure which amongst others can be reconfigured and adapted quickly to changed boundary conditions. An appropriate flexible new production planning and control system was developed to support the new processes. As a result of the project an impressive catering facility was put into operation—currently one of the largest in Europe.     

Development of an industrial process for minting a new type of bimetallic coin

This paper introduces a technology for minting a new type of bimetallic coin. The coin is manufactured from two metal disks of different materials, one being very thin, joined together by mechanical means during the impartion of the surface details by the minting dies. The proposed technology is based on a multi-stage process consisting of three cold metal forming operations (preforming, rimming and coining) and one intermediate annealing before the coining operation.

The main objective of this work is to present the theoretical and experimental results obtained during the development of the process, which are essential for producing this new type of bimetallic coin. The theoretical analysis was based on the utilization of the finite-element method to characterize metal flow, to establish the process sequence and related intermediate disk geometries, and to design an appropriate geometry for the mechanical joint between the two metal disks.

Experiments consisted on the coinage of several bimetallic prototypes in order to confirm the theoretical predictions and to validate the new proposed technology, which latter can be seen as an alternative to the existing bimetallic coin technology based on the utilization of an outer ring and a central disk.     

Development of an innovative monitoring system for spray fields in hot forging processes

In the field of forging the production processes are subject to extreme influences. This leads to failures in process steps or part qualities. To guarantee a high product quality and process stability it is necessary to measure and evaluate the process parameters during the manufacturing process. Online monitoring systems are especially required to avoid high scrap costs. In this paper an innovative concept for monitoring the spray field of massive forming processes is presented. So far a practical method to monitor the lubrication process for purpose of quality assurance and process fault diagnosis in forging processes does not exist. With the sensor system developed at the Institute of Forming Technology and Machines a qualitative and quantitative assessment of spray fields used for cooling and lubrication of forging die processes is possible. The sensor system operates on the basis of current flow measurements and is able to realize a local determination of the spray field. Furthermore an artificial neuronal network (ANN) was programmed to collect, evaluate and analyze the signal of the sensors automatically. Such networks have already been proven to detect and analyze process failures. Especially in the analyses of systems depending on many parameters and their interactions with each other ANN offer the advantage to deliver the desired statements on the basis of suitable test series.     

微机控制液压系统闭环辨识实验装置

本文分析了液压系统闭环辨识特点，提出了闭环辨识的实验条件，并在微机控制的液压系统闭环辨识实验装置上进行了验证。     

基于状态空间法的板料成形过程闭环控制系统的建模及仿真

冲压过程中,因材料的性能参数、润滑条件的波动和模具参数的改变,导致冲压件质量的不稳定,因此必须提高冲压件质量的控制鲁棒性。压边力是板料冲压过程的重要工艺参数之一,合理控制压边力的大小,可以避免起皱或破裂等缺陷。文章提出了一种基于结合RBF神经网络和经典状态空间理论的板料成形过程控制策略,并建立了其控制模型。引入时序分析法,将压边力的调整与反映工件成形质量的法兰边的吸入量误差联系起来,同时应用非线性最小二乘法识别出增益系数。仿真结果表明,在加入一噪声后,仍能获得满意的冲压件质量,模型具有较高的控制鲁棒性。     

Development of a process signature for electrochemical machining

Electrochemical machining (ECM) principally enables a highly productive and virtually wear-free production of components with simultaneously high surface quality. However, the process generates changes concerning both the geometry as well as the rim zone of manufactured components, so that the entire process design currently runs through several heuristic cycles. As a result, the cost-effectiveness of the process is often only given in large-scale production. The paper therefore mechanistically links the material modifications and the process-induced material loads for electrochemical processes to predict rim zone properties. Inverted components of the resulting process signature can finally be used for virtual process design.     

Development of an operations evaluation system for sinking EDM

This paper describes the development and validation of an operations evaluation system for sinking EDM operations. Based on a given workpiece geometry (e.g. mould), regions to be EDM’ed are automatically indentified. For a given electrode configuration, consisting of one or more regions, EDM machining times are calculated, making a proper process planning possible. The EDM time calculation is based on reference values for machining times which are then corrected for changes in the electrode geometry and generator settings. The developed system has been validated, proving a better and more accurate machining time estimation.     

Punching in industrial wood machining: an alternative production process to drilling

Drilling of wood is besides milling, sawing and grinding one of the most important production processes in industrial furniture manufacturing. For the body assembly and the fixing of fittings, boreholes are essential. They have immediate effect on quality and production costs. The process step drilling limits the output of stationary and throughfeed machines, because the workpieces have to be stopped to create the drillings at a relatively low feed speed. An essentially increased performance cannot be reached by the improvement of conventional drilling devices. The aim of the work presented in this paper is the development of an alternative production process in which blind holes can be punched. Thereby thin-walled, cylinder-shaped tools are pressed into different solid and derived timber workpieces by a simple translative movement. For it special experimental setups have been designed. The new production process opens possibilities for an optimization and acceleration of process cycles in industrial wood machining.     

Technological conditions for purification of hafnium by iodide process

In nuclear industry,the purity of hafnium control rod is usually significant,and the process parameters will affect the impurity contents.In this study,the four key factors(filament temperature,retort materials,feeds,and iodide reaction time) were investigated.It is found that the impurity contents of Fe,Ni in the hafnium crystal bar decrease with the K value rising.Both the retort materials and feed types have obvious influence on the impurity contents of hafnium crystal bar.The iodide reaction...     

簧片冲压成形分析与模具结构创新设计

通过对簧片冲压成形工艺的分析,制订了模具整体结构及排样设计方案.针对簧片结构中的小孔特征,其冲孔凸模在冲压加工中磨损较快,为实现冲孔凸模的快速换修和装配,设计了一种冲压凸模装置——卡槽式快换凸模.采用该结构的凸模既可保证成形产品的表面质量,又显著降低了生产成本,提高了冲压生产效率,尤其适用于凸模形状复杂、局部薄弱、需要经常维修、更换的连续冲压模具,具有很好的应用前景和实际意义.     

基于Windows系统摩擦焊机闭环控制系统研制

根据摩擦焊接质量控制功能、精度和稳定性的更高需要,研制了Windows系统平台下摩擦焊接过程计算机电液比例闭环控制系统.介绍了控制系统硬件的总体结构以及系统软件的设计,对系统研制中的一些关键问题做了分析,如程序运行效率、摩擦时间高精度定时以及硬件抗干扰设计该系统实现了摩擦焊接过程中轴向压力和摩擦缩短量的闭环控制,且功能扩展性好,有较为广阔的应用前景.     

编码器校验程序在工业过程控制中的应用

编码器或直线式位移传感器在工业过程控制中起到重要作用。它是设备正常动作、保证制品质量、避免设备损坏、保障操作人员安全等的重要前提条件。但由于生产现场恶劣,或编码器等硬件本身质量问题,不可避免会出现故障。由于此类事件的不可预知性,出现故障仍然按照错误信号执行动作会造成重大损失。而如果通过安装硬件来检测编码器故障与否又增加了成本。因此有必要寻找一个既相对安全又成本较低的解决办法。本文提出一种在不增加额外成本的情况下,仅通过增加程序量来提高设备安全控制的方法。为使用编码器的设备安全运行提供参考。     

Formation of CuO nanorods and their bundles by an electrochemical dissolution and deposition process

Copper oxide nanorods (NRs) and their bundles were deposited on glass substrates by an electrochemical dissolution and deposition process. Changes in the electrode separation, the deposition time and the voltage could be used to control the morphologies, the thickness and the ratio of bundles/NRs. The formation of the NRs and their bundles was explained by an aggregation mechanism. A transformation of the Cu phase in the as-deposited sample to a single CuO phase was effected by an annealing treatment at 500 °C. The increasing photoluminescence (PL) intensity of the annealed sample resulted from a grain size growth and an improvement in the crystallinity.