面向离散型制造业的MES的研究与设计

针对离散型制造业的行业特点,分析了MES的体系架构,利用J2EE的分布式多层应用开发与部署平台,构建具有多层结构的制造执行系统。提出了适合离散型制造业的功能模块。介绍了该系统的设计与应用。     

增材制造技术在电机中的应用综述

增材制造技术(即3D打印)因具有高设计自由度、高材料利用率、高成形效率和精度等优势,逐渐成为高效轻质高功率密度电机设计与制造的研究热点。该文旨在对3D打印电机的性能及其应用作系统性综述。首先,对3D打印电机的发展脉络进行简要概括。其次,分别对3D打印铁心、磁钢、绕组,以及散热和机械支撑结构的研究现状进行总结,并与传统工艺加工的样件进行性能对比。随后,介绍了适用于增材制造的结构设计方法——拓扑优化。最后,根据目前的研究情况归纳了3D打印电机未来的发展趋势和面临的挑战。     

Wire + Arc Additive Manufacturing

Depositing large components (>10?kg) in titanium, aluminium, steel and other metals is possible using Wire + Arc Additive Manufacturing. This technology adopts arc welding tools and wire as feedstock for additive manufacturing purposes. High deposition rates, low material and equipment costs, and good structural integrity make Wire+Arc Additive Manufacturing a suitable candidate for replacing the current method of manufacturing from solid billets or large forgings, especially with regards to low and medium complexity parts. A variety of components have been successfully manufactured with this process, including Ti–6Al–4V spars and landing gear assemblies, aluminium wing ribs, steel wind tunnel models and cones. Strategies on how to manage residual stress, improve mechanical properties and eliminate defects such as porosity are suggested. Finally, the benefits of non-destructive testing, online monitoring and in situ machining are discussed.     

A linear algorithm for conformal 3D-to-flatness coordinates conversion

Data conversion from a 3D raster to spiral coordinates is the key function in the scanning process for Roll Powder Sintering (RPS) additive manufacturing technology. Conversion process is especially important, as it produces the basis for a processed object. There are many equations for such conformal transformation, but there is still room to improve the computation efficiency. This paper presents an efficient conversion algorithm, which processes 3D objects and linear transforming it into rolling ribbon. The new algorithm has several significant advantages over the old ones due to applying only one main linear equation. The program based on the linear algorithm is simpler, more compact and faster in comparison to other programs which use trigonometric, transcendental or other equations. The proposed algorithm has been developed and extensively tested on several parts of computer-aided design models for RPS processing.     

Data-driven evaluation of fatigue performance of additive manufactured parts using miniature specimens

This overview firstly introduces the state-of-the-art research progress in length scale-related fatigue performance of conventionally-fabricated metals evaluated by miniature specimens. Some key factors for size effects sensitive to microstructures including the specimen thickness, grain size and a ratio between them are highlighted to summarize some general rules for size effects. Then, ongoing research progress and new challenges in evaluating the fatigue performance of additive manufactured parts controlled by location-specific defects, microstructure heterogeneities as well as mechanical anisotropy using miniature specimen testing technique are discussed and addressed. Finally, a potential roadmap to establish a data-driven evaluation platform based on a large number of miniature specimen-based experiment data, theoretical computations and the ‘big data’ analysis with machine learning is proposed. It is expected that this overview would provide a novel strategy for the realistic evaluation and fast qualification of fatigue properties of additive manufactured parts we have been facing to.     

Surface integrity of Inconel 718 by hybrid selective laser melting and milling

ABSTRACT

While selective laser melting (SLM) offers design freedom of metal parts with much less material consumption, there exist several limitations, including high surface roughness, low-dimensional accuracy, and high tensile residual stresses. To make functional parts with high form accuracy and superior surface integrity, an as-SLM part needs finishing to remove the deposited surface material. The integration of machining and SLM creates a hybrid manufacturing route to overcome the inherited limitations of SLM. However, little study has been done to characterise surface integrity of an as-SLM part followed by machining (e.g. hybrid SLM-milling). In this paper, surface, integrity including surface roughness, microstructure, and microhardness, have been characterised for IN718 samples processed by the hybrid process. It has been found that microhardness varies with the scan direction and the use of coolant in the subsequent milling, and surface integrity can be significantly improved by the hybrid SLM-milling route.     

Fabrication of Titanium Aluminides via Powder-Cored Wire Arc Additive Manufacturing: Microstructural and Mechanical Characterization

Herein, an innovative powder-cored wire arc additive manufacturing (PC-WAAM) process is proposed to fabricate γ-TiAl thin-walled intermetallic alloy. The metallography, phase composition, and mechanical properties at different thin-wall locations are characterized. The results show that the alternatively distributed layer-like microstructure composed of α₂ (Ti₃Al) and γ (TiAl) phases is obtained along the building direction. The content of α₂ phase exhibits the tendency of decreasing from the bottom to top region. This unique microstructure characteristic is closely related to the typical thermal cycling history during deposition. Moreover, the tensile strength and microhardness of the top region are lower than the middle and bottom region. In general, the current PC-WAAM technique shows promising capability of fabricating γ-TiAl intermetallic alloy with low cost. This work becomes a valuable reference for understanding the evolution mechanism of microstructure and paves the way for the flexible and customized additive manufacturing of γ-TiAl alloy.     

Assessment of working conditions in two different semiconductor manufacturing lines: Effective ergonomics interventions

This article examines two manufacturing lines producing semiconductors using different technology concepts, namely Conventional Line (CL) and Lean Production Line (LPL). Both lines manufacturing the same products were compared using various factors, including working conditions, task risks and dangers of the job, and physical body stress. Ergonomic approaches were adopted in the investigation of the two lines. Survey questionnaires were administered to 30% of the workers, and multiple statistical tests were used to determine crucial predictors and to investigate the interactions between the factors. This research has shown that improved ergonomics factors will lead to better working conditions and thus increased job satisfaction. The observed ergonomic differences of these two production lines are compared, and appropriate managerial remedial action is recommended. The interventions to both the lines should reduce accident rates, minimize waste of resources, improve work effectiveness, and provide a better working environment that enhances employees' morale and maximizes productivity and profits. © 2010 Wiley Periodicals, Inc.     

Recovery of sensor embedded washing machines using a multi-kanban controlled disassembly line

Product recovery involves the recovery of materials and components from returned or end-of-life products. Disassembly, an element of product recovery, is the systematic separation of an assembly into its components, subassemblies or other groupings. Stricter environmental regulations together with dramatic decrease in natural resources and landfills have increased the importance of disassembly as all product recovery options require some level of disassembly. Due to changes made during the lifetime of a product by customers or service personnel, the number and the version of components prior to disassembly is unknown. Customers may also discriminate between and demand different versions of components. The existence of non-functional components further adds to the uncertainty associated with disassembly yield. Sensors implanted into products during their production can address this uncertainty by providing information on the number, condition and version of components prior to disassembly. In this study, we evaluate the impact of sensor embedded products (SEPs) on the various performance measures of a washing machine (WM) disassembly line controlled by a multi-kanban system, which takes into consideration the highly stochastic behavior of the line while managing material and kanban flows. First, separate design of experiments studies based on orthogonal arrays are performed for conventional products and SEPs. In order to observe the response of each experiment, detailed discrete event simulation (DES) models for both types of products are developed considering the precedence relationships among the components of a WM. Then, pair-wise t-tests are conducted to compare the two cases based on different performance measures. According to the results, SEPs provide significant reductions in all costs (viz., backorder, holding, disassembly, disposal, testing and transportation) while increasing revenue and profit.