- 0 -New Trends and Problems in Material Processing Machine Design TheoryWANG Ai-lun ,DUAN Ji-an ,HUANG Ming-hui ,ZHONG Jue(College of Mechanical 超常物理場;制備機械;功能材料1．機械材料加工的時代背景在人類進步的一段長時間范圍內(nèi)，許多工具、機械和方法被提出來；不同的原料用不同的工具來加工。原料及其處理過程已經(jīng)變成了推動人類進步不可缺的一部份。在當前世界中日益激烈的競爭和人們追求幸福生活的今天，物質的功能已經(jīng)遠遠超出了人類現(xiàn)有的并不斷增長的知識及想象。例如：神秘原料功能，半導體材料，原料能量有吸力的材料，在航空領域中占有70%份額的強力鋁合金4~5um的薄金屬片，用各向異性深沖壓金屬板在1%以下；電子鋁箔與強耐熱鋁合金已經(jīng)被應用到航空、宇宙及深海領域中，等等；在原料加工加工領域中不同的時間段里，材料重要發(fā)展趨勢就這樣形成了：（1）在特殊的物理領域里制造原料加工機械，是為了能有特殊的質地結構和輔助性的加工功能。例如：運用熱能和機械能能夠突破科學技術的極限，將一些不常用的能量，例如：微波、化學能、生物能等等，一個接一個的被引入到材料加工中來，因此一些加工特殊能量原材料的加工設備就被制造出來了。（2）突破傳統(tǒng)的物質限制，將溶化、凝固、造型一體化，然后加熱得到具有特殊功能的原料，這樣就可以降低加工費用。例如：材料加工整形技術，比如像快速翻滾，噴霧處理、塑膠成型、噴射造型法、高能量射束等等被應用。（3）原料加工處理正在向高速、重載和高精度在線控制方向上邁進。例如：軋制- 2 -速度達到130m/s，壓力變形已達到300MPa，尺寸精度達到了0.1um ，成型精度已達到0.1i；濃度精度已達到0.1MPa。由于這些原因，原料加工機械設備設計理論將科學與技術相關聯(lián)的領域有機的結合起來設計生產(chǎn)一中新概念材料加工設備是可能的。2．對于新概念材料加工設備的期望功能（1）要有能力生產(chǎn)具有特殊物質的領域；能傳送那些對于新概念材料加工在特定的物質環(huán)境下是非常必要的特殊能流。例如：在高溫環(huán)境下能使那些高溫波或者脈沖以超過104~106K/s的速度冷卻下來；將外表面的凝固、變形合成一體，然后在將超強接觸面應力重新組合成新的分界面；融化的大金屬薄片的湍流；隨機的低頻率磁場用于金屬末加熱的微波、用于大量凝固的超聲波等等都已經(jīng)被應用了。（2）有能力在臨界狀態(tài)下工作，因此高穩(wěn)定性和理想性能的處理設備是在加強技術條件和室外操作的保證。例如：禁止在潤滑狀態(tài)下邊界上的搖晃；在特有的摩擦狀態(tài)下的抗震能力；有韌性的連接管的合力穩(wěn)定性和干擾穩(wěn)定性與軸相比更易驅動系統(tǒng)。（3）有能力精確的控制原料加工而獲得低損耗、高功率、高性能的原料加工。例如：精確的在線監(jiān)測產(chǎn)品成型；在線監(jiān)測和在線調(diào)整產(chǎn)品品質和器具還有在線控制金屬、塑膠成型的程序。產(chǎn)品的精確度指數(shù)可以列舉如下：宏觀上精確度可達到0.1um ，微觀上的晶狀體結構非常均勻，濃度誤差在0.1MPa 。簡而言之，擁有特別功能的新概念原料加工設備應該被設計和生產(chǎn)出來。這樣的話，那些特別性能的原料就能被處理加工了。- 3 -3．在特殊的物理領域和環(huán)境下金屬材料加工設備的問題和需要學習的內(nèi)容由于這些原因和以上提到的背景，如下的一些新的研究主題應該被改進：3.1 連接傳熱裝置和溫度應力場的相界面當融化金屬處于液體和固體的臨界狀態(tài)時通過連續(xù)的變形和快速凝固，一種全新的微觀結構可以被獲得。在這個非常時刻，高濃度的熱流和動態(tài)的熱阻力在材料加工處理中成了主要事項。關于設計這個設備的基本理論問題是要學習核心傳動系統(tǒng)合能量轉化和建立數(shù)學模型。3.2 材料加工設備表面粘流摩擦力的抑制操作裝置和工件的連接是相當復雜的因為粘流阻擋了加工表面界面態(tài)由周轉速度、熱力學處理工作量、操作裝置的彈性、工件的可塑性、滑性界面的動態(tài)行為、局部水力的潤滑油等等來決定。它們影響著材料加工設備抗摩擦裝置的成型。因為它們會會強制其產(chǎn)生很大的非線性，這種強制會在瞬間被損壞或者是失諧，最后會導致動態(tài)不穩(wěn)定性。因此提出了以下的問題：機械裝置的噪聲可能在晃動的界面引起滑動摩擦、不穩(wěn)定狀態(tài)；在高速、重載和邊界潤滑狀態(tài)下在光滑表面和旋轉式噴灌器之間的裝置抑制。潤滑油薄膜吸收裝置和不斷再生的表面的物理化學行為；流變學的特征和操作參數(shù)之間的關系。3.3 在高壓場條件下非線性接觸式機械裝置在大范圍內(nèi)組建一個超強力壓力場是材料加工設備的一個基本功能。當然形成一個大結構的元素也是可能的（例如太空船、大陸洲際間的交通工具、汽車、飛機）。- 4 -組建一個超強壓力場是最重要的特征之一，也是保衛(wèi)國家獨立最基本的裝備。在強壓力場環(huán)境下，接觸式和非線性摩擦將會產(chǎn)生；因此將會導致局部的永久的變形和不好的因素。在強壓力場下設計過程中，將會涉及到設備的設計新理論，例如：非接觸式、非線性摩擦機構。3.4 負荷分配規(guī)律關于超靜定結構，抑制點的負荷分配規(guī)律由相容性條件決定。雖然，關于那些大尺寸的、不定的、靜止的結構在真實空間中是自由變化的，但負荷分配規(guī)律是不能決定相容性條件。因此新的基礎理論由分析接觸行為和變形裝置獲得（例如：摩擦力、變形相容性條件，等等）。3.5 耦合裝置和在材料加工系統(tǒng)中物理領域內(nèi)的穩(wěn)定性隨著系統(tǒng)的功能越來越多元化；許多限制材料加工進度的傳統(tǒng)技術正在不斷的被改善；系統(tǒng)結構也逐漸變得越來越復雜，系統(tǒng)性能變得越來越好。例如：鋼扎廠的快速瞬間反轉受彈性形變、粘流、散熱處理、水動力潤滑處理的，物理化學分子狀態(tài)的影響。另外，機電的耦合在處理系統(tǒng)中已經(jīng)超出了傳統(tǒng)的概念；例如，一些奇特的現(xiàn)象（微小的變化可以引起很大的變化）已經(jīng)出現(xiàn)；因此，滾筒操作的不穩(wěn)定性可能會導致混亂。所以，這個主題將會在機械裝置的物理領域中，在處理系統(tǒng)穩(wěn)定性的影響和加工助劑質量上被提及和充分關注；3.6 技術綜合和合并精準的控制在特定的物理條件下進行操作的材料加工設備是一個相當復雜系統(tǒng)，一些系統(tǒng)的參數(shù)在領域的邊界上也是可以改變的；因此在領域環(huán)境下精確的控制與調(diào)整，調(diào)和尺寸，能量轉換，信息傳遞，界面耦合等等是非常重要的。因為在控制模型中多種交互作用的存在，根據(jù)退耦控制模型而建立綜合框架是必要的；精確的控制基于綜合技術。3.7 優(yōu)化的和創(chuàng)新的設計基于創(chuàng)新的知識材料加工技術能促進產(chǎn)品的設計質量的提高。最優(yōu)化的材料加工技術和材料加工設備意味著實現(xiàn)實質的仿真通過類似的設計和一致的設計是我們學習的主題。3.8 在特殊的領域里機械裝置的特殊功能和應用一些重要的元素和部分在材料加工設備中常常在強力場、溫度場、電磁場和流場- 5 -中工作，有建造特別物理界面的功能；雖然對那些普通單一的物質象金屬、陶瓷等擁有單一的高指數(shù)和卓越的總質量是很困難的。因此我們需要在重要部位采用具有新功能的原料；例如：尺度功能有傾向的材料是想當可貴的。由于這些原因，學習基本法律和以上提到的具有這些功能的機械裝置；例如：強調(diào)分配功能、破壞機理和在特定領域中的設計標準，靜態(tài)（動態(tài)）的硬度和阻尼，模糊設計和明朗設計處理系統(tǒng)構成了有斜度的材料，等等。今天，材料加工科學和技術正在快速的向前發(fā)展；把學習的目標瞄準材料加工設備的技術問題將會為21世紀的制造業(yè)提供技術支持。- 6 -Abstract :Based on reviewing the historical background, prospecting for the development trend ,analyzing the complicacy and mechanism and summing up some achievements and experiences in scientific research , several new problems and the possible direction of development in material processing technology and machine are proposed ,such as ,producing new concept materials possessing some specific and extraovdinary properties by means of integrating and coalescing conelative frontier science and technology ;and thereafter a brief discussion is given.Keywords: interface; extraordinary physical field; procession machine ; function material1 The Time Background of Material Processing MachineIn the long span of history of human progress ,many tools ,machines and methods were created and a variety of materials with different properties were processed. Materials and its processing have become one of pillar and driving force of mankind progress. In pace with multi - polar competition in current world and people’s striving perseveringly for happier life ,material function goes beyond unceasingly men’s knowledge and imagination ,for example ,cryptic function material ,semiconductor material ,energy material ,vibration - absorptive material , super - strength aluminum alloy accounting for 70 percent of application of aeronautics and space ,metal foil of 4～5μm ,deep drawing plate with anisotropy below 1 percent ,electronic aluminum foil with micro - orientation up to 95 percent ,heat resisting aluminum alloy with super strong specific strength used in aeronautics ,space and deep sea ,etc. Thus several important development trends with distinct time features in material processing domain are shaped up as follows :(1) Creating material processing machine with extraordinary physical field for - 7 -processing material with special texture structures and functions. For example ,applications of thermal energy and mechanical energy are breaking through unceasingly technology limit ,and some non - tradition energy ,such as microwave ,chemical energy , bioenergy , etc. , are introduced into material processing procedure one after another ,so that some material processing machines with extraordinary energy circumstance are produced.(2) Breaking through traditional physical limits and integrating melting ,solidifying ,plastic deformation and heat treatment to obtain special function of material and cut down expenses[3 ] . For example ,near - net shaping material processing technology , such as fast rolling , spraying deposition ,over - plastic molding , injection molding , high energy beam ,etc ,is applied.(3) Material processing process is forged ahead in the direction of high speed ,heavy - duty and high accuracy online control ,for instance , the rolling speed goes up to 130 m·s - 1 ,the deformation pressure rises up to 300 MPa ,accuracy of dimension up to 0.1μm ,accuracy of shape up to 0. 1 I ,strength accuracy comes up to 0.1 MPa. For these reasons ,it is necessary for material processing machine design theory to integrate and coalesce ingeniously correlative frontier science and technology to create and produce some new concept material processing machine with following functions.2 Due Functions of New Concept Material Processing Machine(1) To have the ability to produce and bear extraordinary physical field and transmit extraordinary energy flow with the aim of providing extraordinary physical circumstances necessary for new concept material processing. For example ,high gradient temperature field with the speed of cool - down of work interface which exceeds 104～106 K·s - 1 , line wave and pulse complex exerted in solidifying - deforming area , super - strength contact stress field of material forming interface ,turbulent flow field of molten metal with very big flakiness ratio ,low frequency magnetic field with random frequency ,microwave field for powder metal heating ,ultrasonic field for large volume solidifying ,etc. [4 ] ,are applied.(2) To have the ability to work in critical state so that high stability and ideal performance of processing machine is ensured under the circumstance of reinforced technological condition and multi - field coupling operation. For example ,chatter suppressing capability of fast ultra - thin rolling under the condition of boundary lubricating state[5 ] ,the capability of self - excited vibration suppressing under the condition of special friction state ,synergism stability and disturbance stability of flexible connecting parallel shaft with multi - driving system ,etc. [4 ] ,are ensured.(3) To have the ability to accurately control the material processing in order to obtain low loss ,high efficiency and high quality of material processing. For example , super - high accuracy on - line monitor of products form ,on – line monitor and on - line adjustment of products texture and properties ,precision coordination control of multi - procedure , on - line monitor of micro - orientation of metal plastic deformation ,etc. [4 ] ,are ensured. Some - 8 -products accuracy index may be enumerated as follows : dimensional accuracy coming to 0.1μm , microstructure uniformity to crystal lattice ,strength error to 0.1 MPa ,etc. [4 ] In short ,only by new concept material processing machine with extraordinary function being designed and made , can special function material be processed.3 Science Problems and Study Contents of Metal Material Processing MachineUnder the Circumstance of Extraordinary Physical FieldIn view of these facts and background mentioned above ,several new research topics can be advanced as follows.3. 1 Coupling Heat Transfer Mechanism of Multi - Phase Interface Temperature - Stress FieldA brand - new microstructure can be obtained through continuously large deformation and fast solidifying when melting metal is in critical state of liquid solid. At this very moment ,high density heat flow and dynamic heat resistance are present in material processing circumstance . A basic theory problem of designing this kind of machine is to study mechanism of heat transmittance and energy conversion ,and to establish mathematical model .3. 2 Friction Constraint Mechanism of Plastic Flow Interface of Material Processing MachineThe coupling between operation mechanism and workpiece is very complicated because plastic flow is present in processing interface. The interface state , determined by velocity , load thermodynamic process , elasticity of operation mechanism ,plasticity of workpiece ,dynamic behaviour of interface sticking - sliding and partial hydrodynamic lubrication ,etc ,affect and form friction constraints mechanism peculiar to material processing machine ,because these constraints present strong non - linearity ;and under certain circumstances ,the constraints may be destroyed or mismatched instantaneously and thus dynamic instability is resulted in. Thus following problems can be put forward : Mechanism of“spectre chatter”arose from sticking - sliding friction and partial hydrodynamic lubrication in rolling interface , instability condition and mechanism of constraint between smooth surface and rotating body under the circumstance of high speed ,heavy - duty and boundary lubrication , Lubrication film absorption mechanism and physical chemistry behaviour of interface of - 9 -unceasingly regenerative surface ,the relationship between rheological characteristic and machine operation parameters.3. 3 Multi - Body Non - Linear Contact Mechanism Under the Condition of Extra - High Pressure FieldTo build the super strength pressure field on large area is one of basic function of material processing machine , and it is also necessary to form by once large - size structure element (such as spacecraft , intercontinental vehicles ,car and large - scale aeroplane etc) . The ability to build super strong pressure field is one of important feature and the base of independent national defense. Under the circumstance of super strength pressure field ,multi - body strong nonhertz contact and non - linear friction will be produced ,thus local permanent deformation and degrading of element accuracy may be led. New theory foundation of design of machine with super strength pressure field will be furnished through study of multi - body strong non - hertz contact mechanism , multi - body non - linear friction mechanism (such as providing force - displacement mixed solving process of three - dimension multi - body) .3. 4 Load Distribution Law in Multi - Sliding Pair With Structure Bias LoadWith regard to statically indeterminate structure ,load distribution of constraint point is determined by deformation compatibility condition. However ,concerning some plane large - size statically indeterminate structure with sliding degree of freedom in third dimension ,load distribution can not be determined by deformation compatibility condition. Thus new theory basis will be provided by analyzing of contact behaviour and mechanism of sliding pair (such as creep ,force of friction ,integral deformation compatibility condition ,etc) .3. 5 Coupling Mechanism and Stability of Multi - Physical Fields in Material Processing SystemsIn the wake of system function becoming more and more diversified , conventional technology limits in material processing machine is being broke through unceasingly ,system structure also becomes increasingly complicated ,and system performance becomes increasingly multi - causal . For example ,any instantaneous state of roller in fast rolling mills is affected by elastic deformation ,plastic flow ,heat transfer process , hydro - dynamic lubrication process ,interface physical chemistry molecular state and so on . In addition ,electromechanical coupling in processing system have already gone beyond conventional concept ,for instance ,some singular point phenomenon (such as micro - variable can be transformed into macro - variable) ,are present ,thus roller operation instability may be led by perturbation[8 ] . Therefore ,this subject will study the interaction mechanism of multi - physical field and the influence on processing system stability and processing material quality started with analysis of micro - state of executive body.- 10 -3. 6 Multi - Technology Integration and Coalescence of Accurate ControlThe material processing machine ,which operate under the circumstance of extraordinary physical field ,is a complicated large - scale system ,and some parameters of the system vary on feasible field boundary ;thereby ,to keep under accurate control and adjustment of multi field circumstance ,multi - dimension coordination ,multi - energy conversion , multi - level information transfer ,interface multi - process coupling ,etc. is of much significance. Since a variety of multi - interaction exists in control model ,it is necessary to establish integration framework of coordination work according to decoupling of control model ,so as to accurate control based on the multi - technology integration and coalescence is realized.3. 7 Quasi - Reality Design and Concurrent Design Based on Knowledge Innovation SystemsDigitalization and visualization of material processing technology will promote immediately the quality of design, operation and control . Therefore optimization of material processing technology and material processing machine by means of realization of virtual simulation of processing procedure through quasi - reality design and concurrent design is one of our pressing study subjects.3. 8 Mechanical Behavior of Special Function Materials in the Extraordinary Physical FieldMany key elements and parts in material processing machine are often under the circumstance of super strong force field ,temperature field ,electronic magnetic field and flow field ,and must have the functions of constructing special physical interface. However ,it is difficult for common single - substance material such as metal ,ceramic polymer ,etc. to have both high index of single property and excellent overall quality. Therefore we need to use certain material with new functions for key position[9 ] ,for instance ,multi - dimension function gradient material with ultrahigh physical property ,multi - dimension function gradient material with intelligence. For these reasons ,it is necessary to study basic law and mechanism of these kind of function material mentioned above ,for instance ,stress (strain) distribution function ,failure mechanism and design criteria of material under the circumstance of extraordinary physical field ,static (dynamic) stiffness and damping ,digitalization design and visualization design of processing system made of gradient function material ,etc ,so that the general mechanics law of element which is under the circumstance of extraordinary physical field and made of anisotropy multi - dimension gradient function material is obtained. Nowadays ,material processing science and technology is forging rapidly ahead. A forward - looking study aiming at key technology problem of material processing machine will provide theory and technology reserve for manufacturing science and industry of 21st century.