外文翻譯--汽車(chē)制造中沖壓工藝的新發(fā)展【中英文文獻(xiàn)譯文】
外文翻譯--汽車(chē)制造中沖壓工藝的新發(fā)展【中英文文獻(xiàn)譯文】,中英文文獻(xiàn)譯文,外文,翻譯,汽車(chē),制造,沖壓,工藝,新發(fā)展,中英文,文獻(xiàn),譯文
密 級(jí)
分類(lèi)號(hào)
編 號(hào)
成 績(jī)
本科生畢業(yè)設(shè)計(jì) (論文)
外 文 翻 譯
原 文 標(biāo) 題
Automobile manufacture stamping process
Of new development
譯 文 標(biāo) 題
汽車(chē)制造中沖壓工藝的新發(fā)展
作者所在系別
機(jī)電工程學(xué)院
作者所在專(zhuān)業(yè)
車(chē)輛工程
作者所在班級(jí)
B13142
作 者 姓 名
余豪
作 者 學(xué) 號(hào)
201322194
指導(dǎo)教師姓名
臧繼嵩
指導(dǎo)教師職稱(chēng)
講師
完 成 時(shí) 間
2017
年
4
月
北華航天工業(yè)學(xué)院教務(wù)處制
譯文標(biāo)題
汽車(chē)制造工藝的發(fā)展
原文標(biāo)題
Automobile manufacture stamping process Of new development
作 者
Tony
譯 名
托尼
國(guó) 籍
美國(guó)
原文出處
WMEM
摘要:汽車(chē)制造的整體規(guī)模和復(fù)雜性,迫使人們要經(jīng)常地與降低成本、提高產(chǎn)品質(zhì)量、滿(mǎn)足政府對(duì)安全和環(huán)境日益嚴(yán)格的要求問(wèn)題打交道,并要能適應(yīng)款式設(shè)計(jì)和工具每年的變化。根據(jù)這些變化因素,汽車(chē)制造商要不斷尋找最快素,經(jīng)濟(jì)的方法,來(lái)設(shè)計(jì)和制造轎車(chē)與卡車(chē)。
關(guān)鍵詞: 制造工藝 要求 發(fā)展歷史 沖壓工藝
汽車(chē)制造工藝的發(fā)展
汽車(chē)制造中有60%-70%的金屬零部件需經(jīng)塑性加工成形, 沖壓加工是完成金屬塑性成形的一 種重要手段,它是最基本、最傳統(tǒng)、最重要的金屬加工方法之一。如車(chē)身上的各種覆蓋件、車(chē)內(nèi)支撐件、結(jié)構(gòu)加強(qiáng)件,還有大量的汽車(chē)零部件,如發(fā)動(dòng)機(jī)的排氣彎管及消聲器、空心凸輪軸、油底殼、發(fā)動(dòng)機(jī)支架、框架結(jié)構(gòu)件、橫縱梁等等,都是經(jīng)沖壓成形技術(shù)正向精密、多功能、高效節(jié)能、安全清潔的生產(chǎn)方向發(fā)展,沖壓工件的制造工藝水平及質(zhì)量,在較大程度上對(duì)汽車(chē)制造質(zhì)量和成本有直接的影響
所調(diào)沖壓工藝性是指沖壓件對(duì)工藝品的適應(yīng)性, 即所設(shè)計(jì)的沖壓件在尺寸大小、 尺寸精度與基準(zhǔn)、結(jié)構(gòu)形狀等是否符合沖壓加工的工藝要求 。汽車(chē)沖壓件都應(yīng)具有良好的工藝品性和經(jīng)濟(jì)性, 衡量其水平的重要標(biāo)志有沖壓件的工序數(shù)、 車(chē)身總成的分塊數(shù)量和尺寸大小、 沖壓件的結(jié)構(gòu)等因素。減少?zèng)_壓過(guò)程的工序數(shù),意味著減少?zèng)_壓件數(shù)、節(jié)省工裝數(shù)量、簡(jiǎn)化沖壓過(guò)程的傳送裝置, 縮減操作人員和沖壓占地面積, 是節(jié)約投資額和能耗的極好措施, 所以沖壓制造商都能把沖壓工序數(shù)設(shè)計(jì)作為降低汽車(chē)制造成本的重要途徑, 甚至不惜改進(jìn)產(chǎn)品設(shè)計(jì)來(lái)滿(mǎn)足制造工藝方面的要求 。 同時(shí), 還應(yīng)采用盡量大尺寸的合理的車(chē)身總成分塊, 如整塊式車(chē)身左右側(cè)板及車(chē)頂蓋板, 既可使汽車(chē)外形美觀??諝庾枇p少,又可減少?zèng)_壓件數(shù)量及焊點(diǎn),能有效地降低成本。而且現(xiàn)代汽車(chē)制造大量使用卷料、 薄殼式整體車(chē)身結(jié)構(gòu)的高強(qiáng)度鋼板與鍍鋅鋼板, 都要求應(yīng)用沖壓新工藝?,F(xiàn)代沖壓成形發(fā)展和研究的重大課題包括有:
( 1 ) 模塊式?jīng)_壓及其控制;
( 2 ) 新材料及復(fù)合材料沖壓加工新工藝;
( 3 ) 特種沖壓成形技術(shù),
( 4 ) 計(jì)算機(jī)模擬沖壓成形及虛擬試模技術(shù):
( 5 ) 模具制造技術(shù),
模塊式?jīng)_壓的突出優(yōu)點(diǎn)在于能把沖壓加工系統(tǒng)的柔性與高效生產(chǎn)有機(jī)的結(jié)合在一起 。 柔性的含義較廣, 如沖壓件的幾何形狀的多種要求, 只要通過(guò)自由編程就可獲得, 體現(xiàn)了加工形狀的柔性。又如既適用大批量單品種沖壓件的生產(chǎn), 更對(duì)小批量多品種加工發(fā)揮也表性。概括而言,模塊式?jīng)_壓的持點(diǎn)是:
( 1 ) 在沖壓成形過(guò)程中可快速更換組合模具以提高生產(chǎn)效率,
( 2 ) 由于具有帶材的供帶和矯帶裝置, 可省卻另設(shè)上料下料工序,
( 3 ) 實(shí)現(xiàn)了大工件的不停機(jī)加工;
( 4 ) 既能獨(dú)立又能成系列的控制組合沖模動(dòng)作, 能連續(xù)進(jìn)行沖壓加工;
( 5 ) 沖模具有可編和的柔性特點(diǎn) 。
一種模塊式?jīng)_壓加工系統(tǒng)由一臺(tái)帶有控制功能模塊式冷沖壓的壓力機(jī)、 卷材帶材送進(jìn)裝軒、帶材矯正機(jī)及可編程進(jìn)給裝置等構(gòu)成 。 這種沖壓系統(tǒng)在運(yùn)行時(shí)可進(jìn)行沖模橫向位移、 帶材進(jìn)給定位、沖模重復(fù)運(yùn)行及自動(dòng)調(diào)整下工步的沖模調(diào)整等多項(xiàng)功能 。由于在沖壓過(guò)程中進(jìn)行可編程沖壓, 使這種模塊式?jīng)_壓系統(tǒng)能柔性地適應(yīng)生產(chǎn)需求,能在相同帶材上進(jìn)行曲不同工件及批次的混合生產(chǎn),實(shí)現(xiàn)不停機(jī)的串接式加工,還同時(shí)在工件西面沖壓加工,極大地提高了工作效率,有資料表明, 模塊式?jīng)_壓成形使加工費(fèi)用能下降至40%-50%。
當(dāng)前模塊式?jīng)_壓裝置的集成度是很高的, 在寬度為300MM 尺寸范圍內(nèi)可安排達(dá)35個(gè)模具, 通過(guò)沖模上端的頂板可對(duì)沖模進(jìn)行獨(dú)立式系列控制, 即形成沖模的集成控制 。 整個(gè)系統(tǒng)的編程可在windows用戶(hù)界面和菜単下實(shí)現(xiàn),編程涉及模具沿者橫向定位納的何服驅(qū)動(dòng)定位,帶材的檢驗(yàn)矯正及縱向進(jìn)給定位, 沖模的質(zhì)量跟蹤檢驗(yàn), 沖模的調(diào)整及狀況監(jiān)控等多功能 。
當(dāng)沖模重新配置成更換時(shí),這些變化則會(huì)被參數(shù)并被控制系統(tǒng)所貯存, 以務(wù)下次査詢(xún)和調(diào)用 。 沖模數(shù)據(jù)包括有沖頭及其組合標(biāo)記, 沖頭組合在模具中的 X、 Y坐標(biāo)位置及模具軸編號(hào)等信息。 l毫米沖壓是指汽車(chē)車(chē)身沖壓件的精度控制在 0-1. OMM 的范圍內(nèi),與過(guò)去制造業(yè)通行的誤差2MM 相比, 是個(gè)非常大的提高。這是一個(gè)以提高沖壓質(zhì)量和制造技術(shù)為目標(biāo)的綜合項(xiàng)目 。該項(xiàng)目“2MM工程''都是90年代后期美國(guó)汽車(chē)界可-展的大型研究項(xiàng)目 。所謂“2MM工程''就是把車(chē)身裝配尺寸變動(dòng)量控制在2MM之內(nèi), 大大嚴(yán)于原先的8MM工程 。
沖壓加工成形技術(shù)是影口向汽車(chē)車(chē)身制造水平的關(guān)鍵因素之一 , 美國(guó)專(zhuān)家曽在一條汽車(chē)裝配線(xiàn)上對(duì)50多個(gè)個(gè)案進(jìn)行實(shí)地分析表明, 造成車(chē)身尺寸誤差變動(dòng)的諸多原因中, 沖壓本身尺寸造成的不累積誤差占 23%, 其主要原因是傳統(tǒng)的基于經(jīng)驗(yàn)和原有工藝基石出上低水平上的模具設(shè)計(jì)與制造。
亞毫米沖壓的中心是沖壓件的精度與敏捷度西個(gè)目標(biāo), 精度就是使沖壓件尺寸準(zhǔn)確度控制在0毫米或亞毫米的水平,其關(guān)鍵是控制車(chē)身支架、立柱等結(jié)構(gòu)件的尺變動(dòng), 并使車(chē)身覆蓋件分塊度大, 如采用整體左右側(cè)板和頂蓋板等 。 敏捷度含義則是指減少?zèng)_壓件的生產(chǎn)準(zhǔn)備吋間達(dá)30% , 包括模具設(shè)計(jì)、試樣制造和工裝準(zhǔn)備時(shí)間, 以達(dá)到極大縮短新車(chē)型制造周期的目的, 該項(xiàng)目飲食有沖壓和裝配的集成設(shè)計(jì)、 沖壓系統(tǒng)敏捷設(shè)計(jì)和制造、 沖壓過(guò)程的智能檢測(cè)和監(jiān)拉、 全系統(tǒng)集成4個(gè)子項(xiàng)目 。
通過(guò)亞毫米沖壓項(xiàng)日的研究, 使沖壓成形技術(shù)有了跳躍性的進(jìn)展, 其中包含有:
(1) 沖壓過(guò)程和部件裝配工藝的設(shè)計(jì)由基于經(jīng)驗(yàn)和傳統(tǒng)工藝向科學(xué)和數(shù)據(jù)過(guò)程的轉(zhuǎn)化;
(2) 沖壓設(shè)計(jì)向 CAD和模擬試模轉(zhuǎn)化, 摒棄了傳統(tǒng)的嘗試法;
(3) 實(shí)施模具設(shè)計(jì)制造由過(guò)去串行方式向并行方式轉(zhuǎn)化;
(4) 實(shí)現(xiàn)了過(guò)程監(jiān)測(cè)和設(shè)備維護(hù)被動(dòng)響應(yīng)向科學(xué)預(yù)測(cè)式轉(zhuǎn)變。 “2MM 工程''和“亞毫米、沖壓''兩項(xiàng)目現(xiàn)已先后完成,正在美國(guó)三大汽車(chē)制造公司推廣應(yīng)用,取得了許多有益的成果,沖壓成本大幅下降, 獲得日益増長(zhǎng)的經(jīng)濟(jì)效益的社會(huì)效益, 并逐步向其他國(guó)家推廣應(yīng)用 。
特種沖壓成形技術(shù)
現(xiàn)代汽車(chē)沖壓件的技術(shù)要求朝著結(jié)構(gòu)復(fù)雜、 分塊尺寸增大、 相關(guān)邊的零部件較多、 承載能力變大和內(nèi)應(yīng)力限制嚴(yán)格等方向發(fā)展 。 這要求并促進(jìn)特種沖壓成形技術(shù)如液壓成形、 精密成形、 爆炸成形、旋壓成形、無(wú)模成形、激光成形和電磁成形技術(shù)的發(fā)展。限于本文常幅,這里主要介紹內(nèi)壓成形和電磁成形兩項(xiàng)技術(shù)。液壓式或注入彈性體式的成形技術(shù), 其高壓形成過(guò)程一般包括:
(1) 有效介質(zhì)如冰的膨脹或彈性體壓入使內(nèi)部壓罰極慢增長(zhǎng)的過(guò)程;
(2) 流體靜罰的骨高壓形成過(guò)程;
(3)極端壓力如爆炸的動(dòng)態(tài)過(guò)程等。介質(zhì)可以是無(wú)定形的固體、液體或氣體,在系統(tǒng)中介質(zhì)可依據(jù)要加工的形狀作任意變化, 履行凸模功能, 所以介質(zhì)可等同于一個(gè)萬(wàn)能模具 。
液壓式內(nèi)高壓成形技術(shù)與其他沖壓成形技術(shù)相比, 有幾項(xiàng)明顯優(yōu)點(diǎn):
(1)在成形過(guò)程中可一次加工出如車(chē)橋、 頂蓋板、 門(mén)框等大型復(fù)雜的三維幾何形狀的工件,
(2)因?yàn)橐后w在成形過(guò)程中冷卻作用,使工件被“冷作強(qiáng)化” ,獲得比一般沖壓加工更高的工件強(qiáng)度,這使得允許采用更薄的板材,使工件更輕量化;
(3)工件外表板面只與壓力液體接觸,加壓過(guò)程較平緩,零部件成形變化均勻,可獲得勻稱(chēng)的壓力分布, 并能獲得者好得多的平滑外表面;
(4)液壓內(nèi)盛開(kāi)有的沖模和工具費(fèi)用可下降40%,特別降低了凸型零件加工的節(jié)拍時(shí)間較短, 約為0.1-0.5Min,這在特種成形工藝中是較短的,可實(shí)現(xiàn)批量生產(chǎn)。
利用通電線(xiàn)圈產(chǎn)生的電磁力的電磁成形工藝, 是目前頗有前途的另一種新型加工手段。 該工藝源于六十年代核裂變研究的成果, 但可惜一直沒(méi)被人們注重 。 電磁成形工藝原理圖, 當(dāng)線(xiàn)圈通入交流電時(shí)。數(shù)微秒內(nèi)建立起磁場(chǎng),使金屬工件尤其是導(dǎo)電率強(qiáng)的銅鋁材,質(zhì)感生出電流 ,感生出電流, 感生電流又將受到磁場(chǎng)力作用, 使工件產(chǎn)生張力與凹模吻合迅速成形。 當(dāng)線(xiàn)圈在工件內(nèi)時(shí), 電磁力將使工件外張成形, 屬當(dāng)前應(yīng)用較廣泛的一種工藝; 當(dāng)線(xiàn)圈平面平行于板件放置時(shí), 電磁力將使工件拉伸成形。
電磁成形技術(shù)系一種非接觸成形工藝, 其実出優(yōu)點(diǎn)一是加工成形迅速工效高, 二是常用于金屬與非金屬的連接, 可取代粘接或焊接: 其三是不耗脯助材料如潤(rùn)滑油脂等, 有利環(huán)境保護(hù) 。
沖壓過(guò)程自動(dòng)監(jiān)控
現(xiàn)代沖壓技術(shù)的另一個(gè)重要特點(diǎn)是對(duì)沖壓過(guò)程進(jìn)行自動(dòng)監(jiān)控以保護(hù)沖壓件的質(zhì)量 。 在亞毫米沖壓項(xiàng)目的自動(dòng)檢測(cè)和監(jiān)控中,其研究成果就包括有: 1.沖壓過(guò)程的特征分析在線(xiàn)傳診斷和檢測(cè)系統(tǒng); 2.高速和非接觸的沖壓件測(cè)量系統(tǒng); 3.沖模維護(hù)的科學(xué)預(yù)測(cè)系統(tǒng); 4.沖壓成形關(guān)鍵參數(shù)的在線(xiàn)調(diào)節(jié)和補(bǔ)償系統(tǒng)等。
沖壓過(guò)程引起工件質(zhì)量發(fā)生變化的原因主要有凹凸沖模的磨損、 製紋及沖模錯(cuò)位等, 這些微小變化可由高分辯率的位移轉(zhuǎn)感器和沖壓力轉(zhuǎn)感器進(jìn)行跟蹤檢測(cè) 。 其中位移測(cè)量是極重要的一種測(cè)量, 該裝置通常由安裝在模具上方的關(guān)源和位于下方的接收單元構(gòu)成, 可監(jiān)視偏差、 跟蹤加工全過(guò)程、 及時(shí)輸出監(jiān)測(cè)信息和進(jìn)行報(bào)警停機(jī) 。
一種在線(xiàn)沖壓的圖形處理系統(tǒng), 是保證沖壓工件質(zhì)量的有效測(cè)試方法, 它能進(jìn)行二維幾何圖形的標(biāo)準(zhǔn)檢測(cè),其項(xiàng)目有長(zhǎng)度、直徑、平行度、角位、沖壓板材結(jié)構(gòu)及識(shí)別廢品等。圖形處理系統(tǒng)是由象儀、光學(xué)儀和照明裝置等組成,標(biāo)準(zhǔn)的 CCD象儀的珊格分辯率為750X580條珊格,水平方向每珊格為 0.026mm,垂直方向精度為 0.009mm/珊格。監(jiān)視系統(tǒng)使用的位移及角度傳感器有光學(xué)式及電學(xué)式二種, 前者有激光測(cè)試技術(shù)和模似光珊技術(shù)支持; 后者有電感流式及介質(zhì)電容式, 它們的測(cè)試精度分辯率都可達(dá)到 1-10um級(jí)的水平 。 最適用沖壓技術(shù)的轉(zhuǎn)感器安裝方案是把多種轉(zhuǎn)感器集中裝于一塊傳感器板上,再把它精確地固定在模具接口處, 即沖頭夾緊板上, 利用傳感數(shù)據(jù)監(jiān)控沖壓全過(guò)程, 并通過(guò)控制器得到及時(shí)處理, 保證沖壓件的質(zhì)量。
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Automobile manufacture stamping process Of new development
Automobile manufilcture has a60_70% of metalparts mustbe approved by the plastic processing forming,stamping process is complete meta1 plastic forming a kind of important ans,it is the most basic, the most traditiona1, the most importantone ofrr1etal processing method, Such as vehicle body a11 kinds ofcovering parts, car support pieces,structure strengthen pieces, there's plenty of auto parts, such as engine exhaust muffler, ho11ow tube bending and camshafi the oil pan, engine stents, fiame structure, horizonta1 1ongeron etc, it is by stamping techno1ogy positively precision,multi-fimction,high efficiency and energy saving,safe cleaning production direction,stamping workpiece manufiicturing technologyleveland quality, ingreat degree ofautornobile manufacturing quality and costhas direct impact.
So-called starnping technology refers to the adaptability ofthe stamping to handicraft namely the design of stamping in size,size accuracy and benchmarks, structure shape starnping processing ofcornpliance with technobgica1 requirements. Autornotive stamping parts should be good techno1ogica1 characteristics, and the economy,measure theleve1 of the important symbo1 has starnping process number, body assemblies b1ock nucleer and size, staing structure, and other fictors. Reduce the number of punching process procedure, that means less stampingtooling quantity1, number of packages,save simplified punching process ofconveyors, Narrows the operators and shing area, is to save investment and energy consumption extremely good measures,so stamping manufacturers can put punching process reduce vehicle number design as the important way to manufilcture cost, even?
Modern stamping deve1opment and research of the major subjects include:
(1) module type and control;stamping
(2) new materia1 and composite stamping processing new craft;
(3) special stamping techno1ogy;
(4) computer simulation stamping mold testing technology; and virtua1
(5) die& mold manufacturing technology,
(6) stamping process of automatic nxmitoring and instability mechanism analysis and so on.
Module type stamping
Module type of prominent advantages in stamping the stamping processing system of the flexible and efficient production of organic unifies in together Flexible meaning a broader, such as stamping the geometry of the various demands, so1ongas can be obtained through the freedom to programming, which reflects the processing shape of flexible. And as both to be suitable mass single variety stamping production,more for small batch multi-species processing play advantage, and also show flexibility. In a nutshe11, module type stamping water-holding points:
(1)the stamping process can be rephced rapidly segment mold to improve production efficiency;
(2) due to its st0 for belt and masking belt device, can save another set feeding blanking process,
(3) achieved great work pieces the non_stop machining,,
(4) can both independent and can become series of contro1 combination dies action can continua11y stamping processing;
(5) dies with program mabte and the flexible characteristics.
A module type stamping processing system by a with control function module type of cold stamping press,coil strip send into outfit porch, strip correction machines and programmable 1lieeding device, etc. The stamping system at run-time can undertake stamping transverse displacement, stripteeding positioning, die repeat operation and
automatic a1justment work step punching adjustrr1ent etc multiple functions. Because the stamping process program mable stamping, make this kind of module type stamping system can adapt production requirements, flexible in same strip on March different work piece and batch production, realizing mixed non-stop string&joint processing,also in two sides stamping work piece machining, which has greatly enhanced the work efficiency,have data show that the module type stamping makes processing cost canfil11 to40% - 50%.
The current modute type stamping device in teglation is very high, in wid this 300MM
siz1e range can arrange of35 mold, through the rooftop of stamping die for independent We series ofcontro1,is formed namely die of integrated control The whole system programmable in WINDOWS user interface and under implementation programming involves mold abng the late ralpositioning shaft servo drive positioning,inspection correctionand1ongitudinal feeding positioning, stamping quality fo11ow_up inspection, punching machine; the adjustment and Condition monitor in gand versatility.
When stamping reconfigure or alteration,these changes would be parameters and contro11ed system to store,next time query and invoke. Declarations Die data include the punch and their combination tags, punch cor1obination in X, Y of die and mold shaft Numbers coordinates and other information. Figure3 shows programmable punching
System,figure in A standard mold transverse axis,can undertake servo dynamic to stamping area, fir the s·up porting shaft with punching die, C, D for spare axis to orange roll type with material are feeding.
And submillimeter stamping project
And submi11imeter stamping ''rers to the automotive stamping accuracy control at 0 to 1.0 MM within the scope of the traffic in the past,and manufacturing error of 2MMcornpared,is a very big enhancement. This is an roving punching quality and manufiicturing technology as the goal of integrated project. The project with" 2MM engineering ''are all in thelate1990s America QiCheJie conduct large-scale research
project. So-ca11ed" the car is 2MM engineering knowledge,body assembly size changes
within 2MM quantity control greatly in strict in the origina1 8MM error range.
Suing processing forming technology afliect auto body manufilcturing level is one of the key filctors, the American experts work edin a car assembly line to over50 cases
field analysis shows that,cause body size error change many reasons, stamping it self size
caused by error accumulation23 percent, its main reason is that the traditional based on experience and origina1 technology based on bwleve1 of mold design and manufiicturing.
And submi11imeter stamping is the center of precision stamping within creasing agility two goals, precision is to make the stamping size accuracy contro1 in 0 mm or and submil meter leve,the key is to control body stents, pillar on the pieces of the feet, and
make changes in body covering parts, such as partitioned degrees by whole left-right side
plate and the top cover plate, etc. Increasing agility meaning is refers to reduce stamping prajapati was preparation time up to30%, including tooling design, manufiicturing and tooling,sanple preparation time, in order to achieve greatly short en the purpose of gv4 the new models manufacturing cycle, this project diet are die-cutting and assembly integration design,stamping system agile design and manuficturing,stamping process of intelligent detecting and monitoring, who system integration four subsystems project.
Through a study of the program and submilli meter stamping, stamping technology has witnessed progress, including:
(1) the stamping process and concent assembly process design by based on experience and the traditional craft to science and data process of transformation,
(2) stamping design to CAD and simulation test mode transformation,rejected traditiona1 attempt method,
(3) to implement the mould design manufacture seria1 manner by the past to parallel transformation,
(4) realized process monitoring and equipment maintenance from passive response to scientific prediction type transformation 2MM project and and submi1imeter stamping two project has successively is complete, and the three major automobile manufacturing company
popularization and application, and achieved many beneficial results, stamping cost greatly decreased,obtain the growing economic benefit of socia1 benefit, andgradua1ly applied to other countries.
Specia1 staring technology
Modern automotive stamping technology requirements towards structure is complex,1ock size increases, related edge parts more, carrying capacity is large and internal limit strictly etc direction. This requirement and promote specia1 stamping technology such as hydraulic pressure forming, precision forming,exp1osive forming and spinning orming, no die forming,laser 1forming and electromagnetic orming techno1ogy deve1opment. Limited to this paper length, here basically introduces pressure inside the 1forl-nl1ig and electromagnetic forming two techno1ogies.
Modern automotive stamping technology requirements towards structure is complexb1ock size increases,related edge parts more,carrying capacity is large and internal limit strictly etc direction This requirement and promote specia1 stamping technology such as hydraulic pressure forming, precision floring, explosive forming and spinning forming,no die forming, laser lioring and electromagnetic forming techno1ogy development. Limited to this paper length, here basically introduces pressure inside the iorming and electromagnetic forming two techno1ogies.
The hydraulic or injection of the forming techno1ogy of elastic postures, its high-pressure forming process generally includes:
(1) effective media such as ice expansion is cm make the internal pressure pressedinto the penalty extremely s1ow growthprocess,
(2)fluid static penalty bone high_pressure forming process,
(3) extreme pressure as an exp1osion dynamic process, etc. Medium can is amorphous solid liquid or gas,in the system of medium can be basis must processing shape make arbitrary changes, fulfi1l the punch fimction,so medium can be equated to a universal mold. Figure is phsuper shobachthe example,forming from the graph visible at effective media becomes the punch.
The hydraulic interna1 high-pressure forming techno1ogy compared with other sta11nping techno1ogy, there are severa1 obvious advantages:
(1) the forming process can one processing out like axle, top cover, door case and other large and cornplex3d geometric shapes of work piece,
(2) because of liqudin the forming process cooling effect, make the work piece is a
''cotd strengthening'', won than ordinary stamping work piece machining higher strength this makes a11owinga thinner plank, to make the work more light weighting;
(3) workpiece surface appearance only with pressure liquid contact, pressure is gentle,parts forming process changes,can obtain the symmetry of uniformpressure distributionand can winner muchbetter smooth outside surfilce,
(4)in stamping and bbom some hydraulic tool charge canreduce40%, specia1 reduced convexparts processing of takt time is shorter,about 0.1_0.5 MIN this in special forming process is shorter,may realize the batch production.
Using the electromagnetic force generated electricity coi1 electromagnetic forming process,is the present quite promising another new processing method. This process fi:om 1960s nuclear fission research achievement,but un1fortunately has not been people attention. Electromagnetic forming technology princple diagram,when the coil access to electricity. Few microseconds inside establish electromagnetic field, so the rreta1 work pieces especially conductivity strong copper aluminum texture produce electric
current, a current,induced culent induced by magnetic orce and efliect,make the work piece create tension and dies.the anastomosis and rapid forming. When the coilinthe workp11ecein electromagnetic force will make work piece outside of the current applicatio
zhang forming widespread a kind of technology, When the coilplanar para11e1 to the board
pieceis placed, electromagnetic force wi1l make workpiece stretch forming.
Electromagnetic forming techno1ogy is a non-contact forming process,and itsoutstanding merits are shaping a rapid high efficiency, 2 it is ofien used inmeta1or nonmeta1 connection,can replace adhesive or welding, A third is not consun1ption lymphocy help materials such aslubri cating grease,etc, the advantageous environment
protection.
Suing process automatic monitoring
Modern scramjet another important feature is for punching process automaticrmnitoring to protect the stamping quality. In the mmstaing project automatic detection and rronitoring,its research results willinclude:
1. The stampingprocess characteristics of online preach diagnosis and detection system,
2. High speed and non_contact measuring system; the stamping
3. Die maintenance scientific prediction system; 4. Stamping key parameters online adjust and compensation system, etc.
Stampingprocess changes caused by workpiece quality is mainly caused by the wear of convex punching die, crack, dis1ocation, these sma11 changes can be made of high resolution of a transfer sensor and rushed pressure tum sensor tracking detection. 0n!e extremely important displacementmeasurement is a kind oflreasure, this device, usually
byinstalledin the lmuld, the GuanYinn and 1ocated below the receiving unit constitutioncan monitor deviation,trackingprocessing process, timely output monitoringinliormation and alarm downtime.An online stamping graphical processing system is the effective guarantee stamping work piece quality testing method, it can carryout2-dgeorretric figure of standard testing the project has the length, diameter, para11elism, Angle, pressing plank structure and identification of waste, etc. Graphics processing system is by liker reter,opticalinstrum entand lighting equipment etc, the standard of CCD like instrument ofbashan750X580 bar lattice resolution fir grid and jokshanhorizonta1 direction for every she shan lattice 0.026 mm, vertica1 accuracy off ungimm/she shan lattice,,Survei1lance systems use the displacements and the Angle sensorare optica1 type and electrical type two kinds, the filrmer has the laser testing technology and d1e like light she shan technical support, The latter has a inductance and capacitarce streaming media, the test accuracy resolution a11 may achieve the1-10um wdelevel. The most suitablestarnping technek gytransfer sensorinsta1lation plan is to put multiple turn sensorinstalled in a centralized sensor board, then put it precisely fixed in the lmkl outly the punch clamping board, using sensor data monitoring stampingocess, and through the contro11ergettimelytreatment,guarantee the quality of the stamping
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