抽水蓄能进水球阀阀体与活门的组装加工

为了避免抽水蓄能进水球阀产生的高压裂纹、漏水及运行过程中频繁出现活门卡死的故障,提高产品的质量和性能,满足使用要求,分析了该故障是由于制造工艺原因引起的,并对原工艺进行了改进,重新设计了工装卡具,以保证焊接、装备、热处理、加工及整体产品质量和性能要求,经现场使用表明,新工艺及改造后的工装卡具能满足生产要求。     

薄壁铝合金镂空零件的高效高精加工工艺研究

针对一种薄壁铝合金镂空零件加工精度难以保证、加工效率低的特点,设计该零件的加工工艺及数控铣削工装,并将该工艺及铣削工装应用于实际加工。结果表明:使用该工艺及工装不仅能够保证零件的尺寸和形位公差,减小零件的变形量,保证零件的加工质量,而且极大地提高了生产效率。     

利用车床加工孔系的工艺装备设计

为了解决中小型企业和非专业厂家既要节省设备投资,又要保证加工精度的实际问题,文章以一典型零件为例,介绍了一种在现有车床上使用专用工艺装备加工孔系的加工方法及工艺装备的设计,通过生产实践及使用证明,此工装设计合理,能保证孔系的加工精度及要求.     

升降器座板冲压工艺的改进

通过对升降器座板进行工艺分析及CAE钣金成形模拟,认为升降器座板的传统冲压工艺存在不合理之处,针对模具加工维修有困难、产品质量不易保证等问题,进行了冲压工艺的改进设计,以弥补传统工艺的不足。通过企业生产证明,改进后的冲压工艺具有可行性,提高了产品的质量和工装的稳定,提高了生产率,降低了成本,为类似冲压件的工艺设计提供了有益的借鉴。     

环眼钩类产品切边冲孔整形复合工装

采用复合工装生产可以节约设备动力,节省劳动成本和劳动力,提高生产效率,同时可以保证加工精度、提高产品质量.本文结合企业生产需要,对公司批量生产的锻造环眼钩类产品切边冲孔工艺设计的基本内容作了探讨,在分析传统工艺和设计原则的基础上,针对产品切边后冲孔精度不高、易变形等影响产品生产效率的工艺因素做了系统改进.从而实现了单工...     

石墨碳块机加工夹具系统的设计

分析核能内构件石墨碳块的加工工艺、工装夹具的结构及设计原则,设计自动加工专用夹紧工装,该工装是能够将工序一与工序二工装组装在一起的套装夹具,解决了碳块加工过程中由于重复定位装夹而产生的误差累积,保证了碳块的加工精度。在加工单位调试使用的效果良好,可满足对碳块加工精度的要求。     

单轴自动车床弹簧夹头工艺改进及验证

单轴自动车床弹簧夹头是我厂多年来自行生产的常规工具。由于形位公差要求高,对工人的技术要求也高,又由于弹簧夹头加工工序长,质量保证程度低。自从采用了改进的新工艺夹具后,只要严格按工艺指定的加工方法并采用工装夹具加工,普通工人同样能生产出合格产品,即靠工艺和工装来保证产品的精度。     

铝合金薄壁散热片零件加工工艺改进

以一种典型的铝合金薄壁散热片零件为试验研究对象,分析该类零件的加工难点,从改进工装结构保证工装实体与零件薄壁部位完全贴合来增强刚度,改进工装结构保证工装平面与零件平面面对面定位以均布螺钉固定的装夹方法消除装夹变形量,改进工装结构保证工装与零件组成方形凸凹配合定位方式提高定位精度等三个方面对生产中原来用的加工工艺进行改进。改进后的加工工艺有效地避免了铝合金薄壁散热片零件加工震颤和加工变形的问题,有效地保证了零件的尺寸精度和表面质量,且装夹方便快捷,重复定位精度高,能高效完成该类零件的批量生产。     

数控铣床气动快速工装的设计

气动装置在现代企业中普遍存在,利用气动装置特性结合具体待加工零件工艺,设计开发出来的工装夹具代替传统工装夹具,能大幅提高企业生产效率,大大降低数控铣床操作工人的劳动强度,这种气动快速工装能起到事半功倍的效果,很值得现代企业推广使用。     

电火花线切割加工带铜膜片圆筒的工装设计

通过优化带铜膜片圆筒产品的加工工序,并针对关键尺寸的加工设计了多套工装,以此提高带铜膜片圆筒在电火花线切割加工中多次装夹的校调效率及精度,从而保证产品精确,提高产品的加工成品率和加工效率。     

基于分层设计结构矩阵的航空产品工装模块划分

工装模块划分是航空产品工装模块化设计的关键环节。为提高航空产品工装模块划分的准确性,提出基于分层设计结构矩阵的航空产品工装模块划分方法。基于航空产品工装结构图建立分层设计结构矩阵,通过遍历构建全局设计结构矩阵,并运用聚类分析法得到工装模块划分的初始解,之后应用联系成本计算方法对划分结果进行评价,获得最优的模块划分方案。以某型号航空散热器焊接总装夹具为例,验证了该设计方法的有效性和可行性。     

复合加工技术的应用

在现代高标准的机械加工生产条件下,选择合适的加工方法,实现低成本、高质量的加工,对提高产品的整体制造质量是非常重要的。复合加工的应用,无论从工艺、进度、成本、质量等方面都是一个最佳选择的方案。特别是在汽车制造、设备制造等行业,复合加工技术的应用意义重大。     

发电机轴支撑架工装设计及加工工艺优化分析

某企业的发电机轴支撑架年产量达4万件/年,该零件空间位置精度要求较高,存在加工效率低、产品质量加工不稳定等问题。为改善这一状况,针对零件的工艺进行优化并自行设计一款夹具,一次装夹完成所有工序,从而提高生产效率和产品质量。实践证明:采用优化后的加工工艺,产品精度均达到图纸要求,且加工效率大大提升,对于同类产品的加工具有一定借鉴意义。     

RAPID MANUFACTURING AND RAPID TOOLING WITH LAYER MANUFACTURING (LM) TECHNOLOGIES, STATE OF THE ART AND FUTURE PERSPECTIVES

Additive processes, which generate parts in a layered way, have more than 15 years of history. These processes are not exclusively used for prototyping any longer. New opportunities and applications in appropriate manufacturing tasks open up, even though the economical impact is still modest.This review starts with the definition of Rapid Manufacturing and Rapid Tooling, dealing only with direct fabrication methods of components. A systematic material dependent classification of layer manufacturing and process oriented metal part manufacturing techniques are proposed. The generic and the major specific process characteristics and materials are described, mainly for metallic parts, polymer parts and tooling. Examples and applications are cited.The paper attempts to understand the state of the art and the prospective, to put questions, to understand limits, to show opportunities and to draw conclusions based on the state of the art.     

基于QFD的产品设计开发技术的研究

将QFD应用于产品开发过程中,以质量屋为工具,通过将用户质量要求逐步转化为系统质量要求、零部件质量要求、工艺质量要求、直至生产质量要求;注重产品从开始的可行性分析研究到产品的生产都是以市场顾客的需求为驱动,从而保证了企业最终能生产出符合市场顾客需求的产品.     

Study on the usability and robustness of polymer and wood materials for tooling in sheet metal forming

The traditional market of sheet metal parts is based in high production volumes normally greater than 10.000 parts by using high-speed presses and highly automated operations, being the tooling usually made from steel or cast iron, which ensures the needed robustness for such production volumes. Current trends in stamping industries can be characterized by the increasing demand for individualization of products which leads to a growing development towards an increasing number of product variants, lower production volumes and shorter innovation cycles. These trends have triggered research in the development of faster and cost-effective tool manufacturing techniques suitable for low production volumes, since high investments in steel tools can only be compensated by huge volume series of one and the same part during long life cycles. A promising approach for production of small series of complex sheet metal parts is the use of non-conventional tooling materials such as polymers, wood and low melting point metals. The usage of these alternative materials in tooling is still looked with some suspicion, due to the lack of know-how on its processing and also on its wear durability, influenced by the required product geometry, blank material and expected production volume.

In this paper a study on the use of non conventional materials for tooling, to be used for producing a complex sheet metal part, is performed. The evolution of tool wear, roughness and geometrical changes in punch and die radius were measured and its influence in the stamped part geometry evaluated, for an imposed production volume target of 500 parts. Also a comparative study of the tooling costs is presented in order to assess the aptitude and economical feasibility of the use of these tooling materials for low production series.     

金属模具快速制造技术

快速成形（RP）技术已成功地实现了面向市场的新产品造型设计敏捷化，并在快速软模制造方面取得长足进步，目前正向快速制造金属模具（RMT）方向迅速发展。本文介绍了有关快速制造金属模具技术的间接制模法和直接制膜法两方面的研究进展，探讨了快速制造金属模具技术大与高速铣削加工（HSM）技术竞争中面临的关键问题。     

A quality-based cost model for new electronic systems and products

This article outlines a method for developing a quality-based cost model for the design of new electronic systems and products. The model incorporates a methodology for determining a cost-effective design margin allocation for electronic products and systems and its impact on manufacturing quality and cost. A spreadsheet-based cost estimating tool was developed to help implement this methodology in order for the system design engineers to quickly estimate the effect of design decisions and tradeoffs on the quality and cost of new products. The tool was developed with automatic spreadsheet connectivity to current process capability and with provisions to consider the impact of capital equipment and tooling purchases to reduce the product cost. Sammy G. Shina earned his M.S. in computer science at WPI in 1972. He is currently an associate professor at the University of Massachusetts at Lowell. Anil Saigal earned his Ph.D. in mechanical engineering at Georgia Institute of Technology in 1983. He is currently a professor at Tufts University. Dr. Saigal is also a member of TMS.     

Closed-loop control of product properties in metal forming: A review and prospectus

Metal forming processes today operate with astounding productivity, repeatably creating precise parts in high volumes out of the stock sheet and bar products of the upstream metals industries. This achievement has come through decades of development of ever stiffer and more precise tooling used in fast-acting tightly controlled equipment, and yet in the wider context of manufacturing, metal forming processes seem to be less effective: tooling costs are high, and can only be justified by large batch production; the parts made by metal forming are usually not as required for assembly, and must be processed in further downstream machining operations; current processes do not respond well to process disturbances such as tool wear or unanticipated variation in material properties; twenty years of laboratory development of new flexible forming processes has led to little industrial take-up, due to a lack of precision. The missing ingredient in forming which gives rise to these problems is the absence of effective closed-loop control of product properties. The normal practice for blacksmiths and craft workers in former times – using their personal senses to adjust processing in response to evolving conditions – has been forgotten in the pursuit of process rigidity. This paper therefore aims to motivate a new wave of interest in applying closed-loop control of product properties to metal forming processes. A novel framework is developed to show metal forming processes at the heart of an outer control loop, and existing applications are reviewed. Surveys of sensors, actuators and modelling techniques reveal a rich seam of opportunities for new developments, and the paper concludes with some suggestions about near term opportunities for applying closed-loop control of properties to metal forming processes.     

W67Y-100/3200型折弯压力机弯管装置的设计

由于对管件产品进行弯曲加工的数量日益增加,如何提高设备利用率成为急待解决的问题.针对在折弯压力机上实现钢管折弯,设计了专用弯管装置.通过半年的生产实践证明:该弯管装置结构较为简单,加工质量好,平均每天生产1000件.该弯管装置已经投入实际生产使用,完全满足产品制造质量要求和企业新产品开发的需要.