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畢業(yè)設計外文資料翻譯 系　　部： 專 業(yè)： 姓 名： 學 號： 外文出處： Process Planning and Concurrent Engineering 附 件： 1.外文資料翻譯譯文；2.外文原文。 指導教師評語： 簽名： 年 月 日 附件1：外文資料翻譯譯文 工序制訂與并行工程 產品設計是用于產品，及它的部件裝配的計劃。為了把產品設計轉化成一個實際存在的物體，這需要一個制造計劃。而制訂一個這樣的計劃的行動就叫做工序制訂。它是產品設計和制造之間的連接。工序制訂包括決定加工順序和制造產品所必須完成的裝配步驟。在這篇文章中，我們將對工序制訂和他的一些相關的主題進行解釋。 首先，我們應該區(qū)別在這篇文章中被反復提到的工序制訂和生產計劃。工序制訂與如何制造產品和它的零件等工程技術問題有關。制造零件和裝配產品需要什么樣的設備和工具？工序制訂與產品制造物流管理有關系。它在工序制訂后面與原料分類及獲得滿足制造充分數(shù)量產品要求的資源有關。 工序制訂 工序制訂包括決定最適當?shù)闹圃旒把b配步驟和順序，可計劃的工序范圍和多樣性通常由于公司車間可用設備和技術能力而受到限制。在公司內部不能夠制造的零件必須到外部市場購買。工序制訂所提及的工序選擇同樣也受到詳細設計資料的限制。我們稍后將會回到這一點。 工序制訂通常是由制造工程師完成的。（工業(yè)工程師擁有其他權利。）工序制訂者必須熟悉工廠中詳細可用的制造流程并且能夠說明工程圖。基于制訂者的知識，技術和經驗，用于制造每個零件的工序步驟以最合乎邏輯的順序被發(fā)展制訂。下列各項是在工序制訂范圍里的許多決定和詳細資料： .設計圖的說明. 在工序制訂的開始，產品設計的這一部分（材料、尺寸、公差、表面處理、等等）必須進行分析。 .工序和順序. 工序制訂者必須選擇哪一個工序是必需的及必需工序的序列。此外還必須準備好一個簡短的工序步驟描述。 .設備選擇. 大體上，工序制訂者必須逐步展開利用工廠現(xiàn)有機器的計劃。另外，組件必須被購買或在新設備上的投資必須被制定。 .工具、沖模、鑄模、夾具、量具. 工序必須決定每個工序需要什么工具。這些工具的實際設計和制造通常通過委派工具設計部門和工具庫或者聯(lián)系專攻那種工具制造的外面廠商來完成。 .方法分析. 車間規(guī)劃、小工具、提升重物的提升間、甚至在一些人工操作情景中的肢體動作也被指定。 .操作步驟. 工作測量技術被用來為每個操作設定時間標準。 .切削工具和切削條件. 這些必須對加工操作通過推薦標準手冊來進行詳細說明。 零件工序制訂 對于單個零件，加工順序通過一種被稱為進路表的表格來進行文件證明備份。 （不是所有的公司使用進路表這個名字；另外的一個名字是“操作說明書?！保┚腿绻こ虉D被用于詳細說明產品設計一樣，進路表被用于詳細說明工序計劃。他們是類似的，一個用于產品設計，另一個用于制造。典型的進路表，如圖21.1 中舉例，包括下列信息：（1）所有工作部分要執(zhí)行的操作都按照他們應當被執(zhí)行的順序列出來；（2）一個指出關于零件圖尺寸公差必須完成加工的每個操作的簡短描述；（3）用于完成這個操作的特定設備；（4）象沖模，鉆模，切削刀具，鉆夾具或夾具，和量具這樣的特定工具。一些公司還包括時間設置，周期標準和其他數(shù)據(jù)。他被稱為進路表是因為工序順序規(guī)定了零件在工廠中必須遵循的路線。如表21-1中，列出了在準備一個進路表時所需要的一些指導方針。 進路表 包含 XYZ在內的機械工廠 零件號 081099 材料 1050 H18 A1 序號 零件名稱 發(fā)電機軸 產品尺寸 60mm diam,206mm length 操作內容 面向末端(0.003mm).粗車直徑至52.00mm.在50.00mm處結束車削面向并車削長15.00mm直徑為42.00mm的軸肩 退刀結束.表面加工至200.00mm長.粗車直徑到52.0mm.至50.mm車削結束. 鉆4個直徑為7.5mm的孔 銑6.5mm深x方向5.00mm寬的槽 在對面銑寬10.00mm的槽 制訂者 MPGroover 校核: N.Needed 日期08/12/xx 頁數(shù) 1/1 注釋 加工方法 設備 裝備 時間設置 操作時間 10 20 30 40 50 lathe L45 Drill Mill Mill L45 G0810 D09 M32 F630 G0810 0.7hr J555 F662 1.5hr 1.0hr 3.0min. 0.5hr 0.7hr 4.8min 5.2min 3.2min 6.2min 圖 21.1 詳細說明工序計劃的典型進路表 表21-1 準備一個進路表的典型指導方針 連續(xù)操作步驟的操作序號應該以10，20，30，等形式列出。如果必要的話這允許插入新的操作。 當一個工件從一個工作站到另一個工作站， 新的操作和序號必須進行詳細說明。 當一個工件從一個夾具到另一個夾具，盡管有可能在同一設備上，新的操作和序號也必須進行詳細說明。 當在一條生產線上如果一個工件從一個工人到另一個工人，新的操作和序號也必須進行詳細說明。 開始 原料 基礎工序 二級工序 特性加強工序 最后工序 完成零件 特性加強工序不一定是必須的 在特性加強之后,有時需要一些二級工序 圖21.2 在零件制造中的典型工序順序 制造單個零件的典型加工順序包括：（1）一個基本工序，（2）二級工序，（3） 提高物質特性工序，和（3）最后工序。在圖21.2中顯示了這種序列。一個基本工序決定了工件的起始造型。金屬鑄件，塑料成型，金屬精煉是基本工序中的實例。 起始造型常常必須通過改變起始造型操作（或者接近于最終造型）的二級工序來精制。二級工序習慣于和基本工序一起提供起始造型。當砂型鑄造是基本工序，車加工通常是二級工序。當軋鋼廠制造金屬片是基本工序，沖壓操作象沖裁和彎曲通常是二級工序。當塑料注入成型是基本工序時，二級工序通常是不必要的，因為他的大多數(shù)幾何特征制造通過別的方式如成型制造來完成。塑料成型和其他操作的二級工序被稱為凈成型工序的并發(fā)二級工序。需要一些但并不多的二級工序的操作就是所提到的近似凈成型工序。許多有印象的摸鍛件就是這一類。這類零件能夠經常在鍛造（初級工序）階段被成型，因此減少了必要的加工（二級工序）。 一旦模型被建立，許多零件的下一步是改良它們的機械物理性能。提高特性工序并不改變零件模型，然而，它卻能改變零件的物理特性。金屬零件的熱處理操作就是最普通的實例。類似的如玻璃通過熱處理來制造鋼化玻璃。對于大多數(shù)零件的制造來說，這些特性加強工序如在圖21.2指出的可選擇路徑那樣在加工工序中并不需要。 最后工序通常對零件（或裝配體）的表面提供一個涂層。例如電鍍，薄膜沉積技術，涂漆。表面處理的目的是改善外觀，改變顏色，或者表面保護防止腐蝕和磨損等等。在很多零件中最后工序是并不需要的；例如，塑料成型就很少需要最后程序。當必須需要最后程序，他通常是加工順序的最后一步。表21-2列出了一些普通原料加工的典型加工順序： 表21-2 一些典型加工順序 基本工序 開始原料 二級工序 最后成型 加強工序 最后工序 砂型鑄造 砂型鑄件 加工 車加工零件 （可選擇） 涂漆 拉摸鑄造 拉摸鑄件 （凈成型） 拉摸鑄造 （可選擇） 涂漆 玻璃鑄造 玻璃錠 擠壓 ，吹塑法 玻璃器皿 熱處理 （無） 注塑成型 模型制品 （凈成型） 成型塑料 （無） （無） 軋扎 金屬片l 切割模 彎曲模 沖壓 （無） 電鍍 噴漆 軋扎 金屬片l 深沖壓 沖壓 （無） 電鍍 噴漆 鍛造 鍛件 （凈成型） 加工 機加工件 （無） 電鍍 噴漆 軋扎和 棒材拉拔 棒料 磨削加工 機加工件 熱處理 電鍍 噴漆 擠壓鋁 壓出型材 切削 擠壓零件 （無） 陽極電鍍 噴漆 霧化 金屬粉末 擠壓 PM 零件 燒結 噴漆 粉碎 陶器粉末 擠壓 陶器 燒結 上釉 錠拉拔 矽塊 鋸和碾磨 硅片 清洗 鋸 和 磨削 矽塊 氧化， CVD，PVD 蝕化 IC芯片 表面處理 裝配工序制訂 一個既定產品的典型裝配方法由以下因素決定的：（1）預期產品數(shù)量；（2）裝配產品的復雜性，例如，不同組件的數(shù)量；和（3）常用裝配工序，例如，機械定位焊接。對于小數(shù)量產品，通常在人工裝配線上進行裝配。對于大量制造的一打或這樣組件的簡單零件，要采用適當?shù)淖詣踊b配線。無論如何，這里有一個工作必須被完成的優(yōu)先順序。這個優(yōu)先需求經常用一個優(yōu)先表來進行圖表描繪。 裝配工序制訂包括裝配指令的發(fā)展，但是更詳細地，對于小批量生產，在一個崗位完成整個裝配。對于一個裝配線上的大批量生產，工序制訂由一種分配工作條件到裝配線個別工位并被叫做人工投入線性平衡法的程序組成。這種裝配線按照裝配線平衡解決方案決定的順序發(fā)送工作單元到個別工位。在個別組成，任意工具或夾具的工序制訂時，一條裝配線的決定，設計，和制造必須被完成,并且工作站的必須被列出來。 制造或購買決定 在工序制定過程中出現(xiàn)的一個重大問題是一個特定零件應該在公司內部的工廠內生產還是從外部銷售商處購買，并且這個問題的答案被認為是制造或購買決定。如果公司沒有技術設備或制造零件所必須的詳細制造工序中的專門技術，那么答案就很明顯了：因為沒有其他選擇零件必須購買。然而，在很多例子中，零件既可以在利用現(xiàn)有設備在內部制造或者可以從外部擁有相似制造能力的生產銷售商處購買。 在我們的關于制造或購買的決定的討論中，他應該認識到在開始幾乎所有的制造者從供應商那里購買原料。一個機械加工廠從一個金屬經銷商購買他的起動柄原料或從一個鑄造廠購買他的砂型鑄件。一個塑料成型廠從一個化工廠購買他的模塑料。一個沖壓廠可以去經銷商或直接從軋鋼廠購買金屬片。很少的公司能夠在操作中從原料一直進行垂直整合，這看來至少購買一些也許在他的工廠可以另外制造的零件是合理的。也有可能為公司使用的每一個組成要求制造或購買決定。 這里有許多影響制造或購買決定的因素。在表21-3中列出一列影響決定的因素和結果。一個人可能認為成本是決定是購買還是制造零件的最重要的因素。如果一個外部經銷商比公司工廠更精通于制造零件的工序，因而公司內部生產成本可能比經銷商賺取成本后的價格還要高?？墒?，如果購買決定導致公司工廠設備和勞動的閑置，可是購買零件的表面優(yōu)勢就會喪失?？紤]以下例子，例21.1制造或購買決定 為一個特定零件被引述的價格是100個單位的每單位$20.00。制造零件的成分如下所示： 單位原料成本=每單位$8.00 直接勞動成本=每單位6.00 勞動加班150%=每單位9.00 設備修理成本=每單位5.00 總計=每單位28.00 表21-3制造或購買決定因素 因素 在制造或購買決定的說明和效果 零件成本是如何比較的？ 這也許被看作是在制造或購買決定的最重要的因素。然而，成本比較并不明顯，如例21.1 這種加工可以在內部使用嗎？ 如果一個給定工序的設備和專門技術在內部不能用，那么購買是顯而易見的決定。經銷商經常適合精通特定工序，這使得他們在內外比較中有較強的成本競爭力。然而，如果公司不發(fā)展在對于制造該類型產品的重要特定工序的專門技術，這將影響公司的長期成本運算。 什么是產品總產量？ 必需的單位總數(shù)在產品的生命上是主要因數(shù)。如果總生產量增大，這用意支持制造決定。較低的生產量支持購買決定。 什么是產品預期壽命？ 較長的產品壽命趨向于支持這種決定 組成是不是一個標準項目？ 標準目錄項目（舉例來說，硬件項目如螺栓，螺釘，螺母，和其他標準件）由那些專門制造這種產品的廠商以低成本制造。在標準件上，成本比較幾乎一直支持一個購買決定 供應商是否值得信賴？ 一個經銷商在關鍵零件的交貨延誤將導致公司總裝配廠的停工。擁有保證交貨期和質量報告的供應商比那些有較少報告的供應商要受到優(yōu)先考慮的。 公司工廠是不是已經全能力操作？ 在最高要求周期中，公司也許被迫從外部經銷商購買一部分必需的產品來增大列出工廠設備能力。 公司需要一個其它可能的供給來源嗎？ 公司有時為他們的生產工廠從外部經銷商購買的零件來維持可選擇的貨源。 附件2：外文原文 Process Planning and Concurrent Engineering The product design is the plan for the product and its components and subassemblies.To convert the product design into a physical entity ,a manufacturing plan is needed .The activity of developing such a plan is called process planning .It is the link between product design and manufacturing .Process planning involves determining the sequence of processing and assembly steps that must be accomplished to make the product .In the present chapter ,we examine processing planning and several related topics. At the outset ,we should distinguish between process planning and production planning ,which is covered in the following chapter. Process planning is concerned with the engineering and technological issues of how to make the products and its parts. What types of equipment and tooling are required to fabricate the parts and assemble the product ? Production planning is concerned with the logistics of making the product .After process planning is concerned with ordering the materials and obtaining the resources required to make the product in sufficient quantities to satisfy demand for it. Process Planning Process planning involves determining the most appropriate manufacturing and assembly processes and the sequence in which they should be accomplished to produce a given part or product according to specifications set forth in the product design documentation.The scope and variety of processes that can be planned are generally limited by the available processing equipment and technological capabilities of the company of plant .Parts that cannot be made internally must be purchased from outside vendors. It should be mentioned that the choice of processes is also limited by the details of the product design.This is a point we will return to later. Process planning is usually accomplished by manufacturing engineers .（Other titles include in industrial engineer.) The process planner must be familiar with the particular manufacturing processes available in the factory and be able to interpret engineering drawings .Based on the planner’s knowledge,skill,and experience ,the processing steps are developed in the most logical sequence to make each part .Following is a list of the many decisions and details usually include within the scope of process planning : .Interpretation of design drawings. The part of product design must be analyzed (materials,dimensions,tolerances ,surface finished,etc.) at the start of the process planning procedure. .Process and sequence. The process planner must select which processes are required and their sequence.A brief description of processing steps must be prepared. .Equipment selection . In general , process planners must develop plans that utilize existing equipment in the plant .Otherwise ,the component must be purchased ,or an investment must be made in new equipment . .Tools ,dies,molds,fixtures,and gages. The process must decide what tooling is required for each processing step.The actual design and fabrication of these tools is usually delegated to a tool design department and tool room ,or an outside vendor specializing in that type of tool is contacted. Methods analysis . Workplace layout ,small tools ,hoists for lifting heavy parts ,even in some cases hand and body motions must be specified for manual operations .The industrial engineering department is usually responsible for this area. .Work standards. Work measurement techniques are used to set time standards for each operation . .Cutting tools and cutting conditions. These must be specified for machining operations ,often with reference to standard handbook recommendations. Process Planning for parts For individual parts,the processing sequence is documented on a form called a route sheet .(Not all companies use the name route sheet ;another name is “operation sheet .”)Just as engineering drawings are used to specify the product design ,route sheets are used to specify the process plan .They are counterparts,one for product design ,the other for manufacturing .A typical route sheet ,illustrated in Fig.21.1,includes the following information: (1) all operations to be performed on the work part ,listed in the order in which they should be performed ; (2) a brief description of each operation indicating the processing to be accomplished,with references to dimensions and tolerances on the part drawing; (3) the specific machines on which the work to be done; and (4) special tooling such as dies molds ,cutting tools,jigs or fixtures ,and gages.Some companies also include setup times ,cycle time standards,and other data.It is called a route sheet because the processing sequence defines the route that the part must follow in the factory .Some of the guidelines in preparing a route sheet are listed in Table 21-1. Decisions on process to be used to fabricate a given part are based largely on the starting material for the part .This starting material is selected by the product designer.Once the material has been specified ,the range of the possible processing operation is reduced considerably .The product designer’s decisions on starting material are based primarily on functional requirements ,although economics and manufacturability a role in the selection. Route Sheet XYZ Machine Shop,Inc. Part no. 081099 Material 1050 H18 A1 No. Part name Shaft ,generator Stock size 60mm diam,206mm length Operation description Face end (approacx.3 mm).Rough turn to 52.00 mm diam Finish turn to 50.00 mm diam.Face and turn shoulder to 42.00 mm diam.and 15.00 mm lenghth Reverse end.Face end to 200.00mm length.Rough turn to 52.00mm diam.Finish turn to 50.00mm diam Drill 4radial holes 7.50mm diam Mill 6.5 mm deep X 5.00 mm wide slot Mill 10.00 mm wide flat ,opposite side. Planner MPGroover Check by: N.Needed Date 08/12/xx Page 1/1 Comments Dept Machine Tooling Setup Sdt 10 20 30 40 50 lathe L45 Drill Mill Mill L45 G0810 D09 M32 F630 G0810 0.7hr J555 F662 1.5hr 1.0hr 3.0min. 0.5hr 0.7hr 4.8min 5.2min 3.2min 6.2min Fig.21.1 Typical routes sheet for specifying the process plan Table 21-1 Typical Guidelines in Preparing a Route Sheet .Operation numbers for consecutive processing steps should be listed as 10,20,30,etc This allows new operations to be inserted if necessary. .A new operation and number shouled be specified when a work part leaves one workstation and is transferred to another station. .A new operation and number should be specified if a part is transferred to another workholder(e.g...,jig or fixture),even if it is on the same machine tool. .A new operation and number should be specified if the work part is transferred from one worker to another ,as on a production line. Starting raw material Basic process Secondary process Property-enhancing processes Finishing operations Finished part Property-enhancing processes not always required Additionary secondary processes sometimes required following property enhancement Fig.21.2 Typical sequence of processes required in part fabrication A typical processing sequence to fabricate an individual part consists of : (1) a basic process,(2)secondary processes ,(3) operations to enhance physical properties,and (4)finishing operations.The sequence is shown in Fig.21.2. A basic process determines the starting geometry of the workpart.Metal casting ,plastic molding ,and roling of sheet metal are examples of basic processes.The starting geometry must often be refined by secondary processes,operations that transform the starting geometry (or close to final geometry ).The secondary geometry processes that might be used are closely correlated to the basic process that provides the starting geometry.When sand casting is the basic processes,machining operations are generally the second processes .When a rolling mill produces sheet metal,stamping operations such as punching and bending are the secondary processes.When plastic injection molding is the basic process ,secondary operations are often unnecessary,because most of the geometric features that would otherwise require machining can be created by the molding operation.Plastic molding and other operation that require no subsequent secondary processing are called net shape processes.Operations that require some but not much secondary processing (usually machining ) are referred to as near net shape processes.Some impression die forgings are in this category .These parts can often be shaped in the forging operation(basic processes)so that minimal machining (secondary processing )is required . Once the geometry has been established ,the next step for some parts is to improve their mechanical and physical properties .Operations to enhance properties do not alter the geometry of the part;instead,they alter physical properties .Heat treating operations on metal parts are the most common examples .Similar heating treatments are performed on glass to produce tempered glass.For most manufactured parts ,these property-enhancing operations are not required in the processing sequence ,as indicated by the alternative arrow path in Fig.21.2. Finally finish operations usually provide a coat on the work parts (or assembly )surface. Examples inclued electroplating ,thin film deposition techniques ,and painting.The purpose of the coating is to enhance appearance ,change color ,or protect the surface from corrosion,abrasion ,and so forth .Finishing operations are not required on many parts ;for example, plastic molding rarely require finishing .When finishing is required ,it is usually the final step in the processing sequence .Table 21-2 presents some typical processing sequences for common materials used in manufacturing . In most cases,parts and materials arriving at the factory have complete their basic process.Thus ,the first operation in the process plan follows the basic process that has provided the starting geometry of the part ..For example ,machined parts begain as bar stock or castings or forgings,which are purchased from outide vendors.The process plan begains with the machining operations in the company’s own plant .Stempings begin as sheet metal coils or strips that are bought from the rolling mill.These raw materials are supplied outside sources so that the secondary processes,property-enhancing operations ,and finishing operatios can be performed in the company’s own factory. In addition to the route sheet ,a more detailed description of eac operation is usually prepared. This is filed in the particular production department office where the operation is performed.It lists specific details of the operation ,such as cutting conditionsand toolings(if the operation is machining )and other instructions that may be useful to the amchine operator.The desciptions often include sketches of the machine setup. Table 21-2 Some Typical Process Sequence Basic Process Starting Material Secondary processes Final shape Enhancing Processes Finishing Processes Sand casting Sand casting Machining Machined part (optional) Painting Die casting Die casting (Net shape) Die casting (optional) Painting Casting of glass Glass ingot Pressing ,blow molding Glass ware Heat treatment (None) Injection modeling Molded part (Net shape) Plastic Molding (None) (None) Rolling Sheet metal Blanking punching bending forming Stamping (None) Plating painting Rolling Sheet metal Deep drawing Drawing (None) Plating painting Forging Forging (near net shape) Machining Machined part (None) Plating painting Rolling and bar drawing Bar stock Machining grinding Machined part Heat treatment Plating painting Extrusion of aluminum Extrudate Cutoff Extruded part (None) Painting anodizing Atomize Metal powders Press PM part Sinter Paint Comminution Ceramic powders press Ceramic ware Sinter Glaze Ingot pulling Silicon boule Sawing and grinding Silicon wafer Cleaning Sawing and grinding Silicon boule Oxidation,CVD,PVD etching IC chip Coating Processing Planning for Assemblies The type of assembly method used for a given product depends on factors such as : (1) the anticipated production quantities ;(2) complexity of the assembled product ,for example ,the number of distinct components ;and (3)assembly processes used ,for example ,mechanical assembly versus welding .For a product that is to be made in relatively small quantities ,assembly is usually performed on manual assembly lines .For simple products of a dozen or so components,to be made in large quantities ,automated assembly systems are appropriate .In any case ,there is a precedence order in which the work must be accomplished .The precedence requirements are sometimes portrayed graphically on a precedence diagram. Process planning for assembly involves development of assembly instructions,but in more detail .For low production quantities,the entire assembly is completed at a single station .For high production on an assembly line ,process planning consists of allocating work elements to the individual stations of the line, a procedure called line balancing.The assembly line routes the work unit to individual stations in the proper order as determined by the line balance solution.As in process planning for individual components ,any tools and fixtures required to accomplish an assembly task must be determined ,designed,and built;and the workstation arrangement must be laid out. Make or Buy Decision An important question that arises in process planning is whether a given part should be produced in the company’s own factory or purchased from an outside vendor ,and the answer to this question is known as the make or buy decision .If the company does not possess the technological equipment or expertise in the particular manufacturing processes required to make the part ,then the answer is obvious: The part must be purchased because there is no internal alternative .However ,in many cases ,the part could either be made internally using existing equipment ,or it could be purchased externally from a vendor that process similar manufacturing capability. In our discussion of the make or buy decision ,it should be recognized at the outset that nearly all manufactures buy their raw materials from supplies .A machine shop purchases its starting bar stock from a metal