侧围外板顶盖搭接处冲压新工艺的应用

侧围外板是白车身制造过程中的关键,探讨合理的工艺方案可以避免产品A面产生二次冲击线,减少焊接边翻边整形时起皱叠料现象,确保产品料边稳定一致,保证产品质量。     

Processing maps for optimizing gas atomization and spray deposition

A validated mathematical model was used to generate processing maps for producing near-net shapes of high-performance products by gas atomization and spray deposition. The processing maps are useful to optimize and control the manufacturing process on the shop floor for producing quality products. The number of trial runs and cost of production can be significantly reduced with the help of processing maps. Using a dispersion-strengthened aluminum alloy as an example, this article examines how processing maps can be used to choose a set of process variables for producing the end product of desired quality.     

真实环境下产品数据仿真及并行质量优化研究

提出了非正态分布和非对称公差条件下产品最优配合的控制方法。该方法利用数据仿真技术,解决了制造过程的最优质量控制问题。该方法考虑了从产品设计、产品制造到用户使用3个过程产品并行工程问题,是产品精益制造较好的分析控制方法,保证了产品的最终质量。     

Incorporating tolerances of customers’ requirements for customized products

Tolerancing conventionally deals with the variation of manufacturing processes to meet the requirements of product quality. With the development in product customization, it has been generally accepted that customers’ requirements also have acceptable tolerance range. This flexibility provides an opportunity to better match customer requirements with richer product offerings through customization. A probabilistic model is presented in this paper to incorporate the tolerance of functional requirements into customized product design. By leveraging on the requirements tolerance, customers are more likely to get their desired products. Customer requirements tolerance can thus open up a new dimension for product customization.     

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.     

压缩机上外罩制作的工艺实施

为了制作合格的上外罩零件,对其结构、成形工艺难点和工序内容进行了分析,确定了落料拉深、冲凸台、车边、冲孔、整形、压印等8道制作工序。结合冲压模具设计的知识和经验,设计了1副复合模和各单工序模,并对每1道制作工序和各模具工作过程进行了详细的阐述。为了保证车边工序的质量,设计了1副车边夹具,并对夹具的工作原理进行了详细说明。经批量生产证明:上外罩零件的制作工艺、成形方法和工序顺序符合零件的结构特点;所生产的产品完全符合图纸要求,且质量稳定,不良品率低;模具的结构紧凑、操作方便、制造成本低、可互换性好;车边夹具操作简便、工件拆装快捷、夹紧力可调,解决了薄壁类零件装夹的难题,为结构类似的零件的生产提供了借鉴与依据。     

考虑EoL产品重用的产品配置优化研究

针对多生命周期产品配置优化问题,将产品组件分为重用组件和新制造组件,对于重用组件,考虑包括再制造在内的一系列EoL产品重用策略;对于新制造组件,则在原始组件的基础上将改进组件考虑在内。通过对需求周期内采用各变体组件比例的研究,以产品配置成本、碳排放量和产品可靠度为优化目标,建立了多目标优化模型,采用gamultiobj函数的遗传算法对该模型进行求解,并基于模糊集理论的Pareto优选机制,得到产品的最优产品配置方案。最后,以某型号汽车发动机为例验证了模型的可行性与合理性。     

Adaptable Design

Increasing competition for better product functionality, quality, features, customization, environmental friendliness, lower cost and shorter delivery time presents unprecedented challenges for product manufacturing enterprises. These challenges cannot be completely addressed by advanced manufacturing technologies alone as some of which are originated from product design. Advanced design technologies and tools for early product design processes are critically needed where most important decisions are made with respect to the product functionality, quality, manufacturability, cost and environmental performance. This paper discusses adaptable design (AD) as a design paradigm for both business success and environmental protection. Adaptable design aims at developing products that are adaptable in their design and/or their production. Adaptability is defined as the extension of the utility (service) of products. Two types of adaptabilities are proposed as product adaptability and design adaptability. Two types of design adaptations are also identified, which include foreseeable specific adaptations and unforeseeable general adaptations. The former can be described by specific adaptability and the latter by general adaptability. Three key elements of AD are presented including functions independence, a measure of adaptability and a function based design process model of the AD. Based on these concepts and design objectives, adaptable design methods and general design guidelines are proposed. Examples are included to illustrate the concepts, design methods and guidelines.     

支持工艺设计的制造质量影响因素关系网多色集合模型

为了保证产品工艺设计方案在制造过程中顺利实现,提出将制造质量影响因素信息反馈到工艺设计过程,分析了制造影响因素信息对工艺设计的支持,建立了支持工艺设计的制造质量影响因素关系网.利用多色集合理论,能清楚表达集合统一颜色与集合元素之间关系的特点,建立了制造质量影响因素关系网的多色集合数学模型;基于此模型,设计了面向给定加工要求的多个可行工艺设计方案选择的流程和算法;并以齿轮中的齿形加工过程为实例,建立齿形加工过程元素的多色集合和多色图,给出了可行齿形加工方案选择过程.     

Analysis–synthesis of dimensional deviation of the machining feature for discrete-part manufacturing processes

Dimensional deviation analysis has been an active and important research topic in mechanical design, manufacturing processes, and manufacturing systems. This paper proposes a comprehensive dimensional deviation evaluation framework for discrete-part manufacturing processes (DMP). A generic, explicit, and transmission model is developed to describe the dimensional deviation accumulation of machining processes by means of kinematic analysis of relationships between fixture error, datum error, machine tool geometric error, fixturing force inducing error and the dimensional quality of the product. The developed modeling technology can deal with general fixture configurations. In addition, the local contact deformations of the workpiece–fixture system are determined by solving a nonlinear programming problem of minimizing the total complementary energy of the frictional workpiece–fixture subsystem in machining system. Moreover, the deviation of an arbitrary point on machining feature can be also evaluated based on a point deviation model with prediction dimension deviation from the transmission model. The dimensional error transmission within the machining process is quantitatively described in this model. A systematic procedure to construct the model is presented and validated. This model can be also applied to process design evaluation for complicated machining processes.     

浅谈企业工装日常管理

工装是工艺装备的简称,即在生产制造过程中所使用的各种工具总称。工装包括模具、焊接夹具及各种工位器具等。工装在各种机械加工行业中被广泛应用,可以说工装是保证产品加工工艺和产品质量不可缺少的辅助设备。近年来,各加工制造业对工装的维护和保养越来越重视起来,所以规范企业的工装使用和管理,采取有效维护保养措施,可降低生产成本及提高产品质量,为顾客提供合格的产品,保证企业获得最好的经济效益。     

Providing product use knowledge for the design of improved product generations

Current design of improved product generations does not exploit use information from previous products systematically. The emerging shift of manufacturing companies from selling products to providing product service systems, the miniaturization of product-embedded sensors, as well as advances in information technology facilitate a product providers access to operation information of current products, which can be used to improve the development and the quality of follower product generations. The paper presents a framework for the acquisition, aggregation and analysis of product use information as well as for the generation and provision of knowledge for the development of improved product generations. The described approach employs knowledge discovery methods like Bayesian Networks and is supported by an IT prototype of a design assistant system. This prototype has been validated in a use case considering the improvement of a rotary spindle for micro machining.     

基于QFD质量工具集成的研究与应用

为消除产品设计制造过程中可能存在的冲突、模糊、潜在失效等因素的影响，将各种质量工具、方法与质量功能展开（QFD）进行集成研究。通过分析QFD与各种质量工具的关系，提出了一个支持产品开发的、集成的QFD系统模型，给出了产品设计与制造各阶段问题解决的方法和工具，并开发了集成的QFD软件系统（1QFDS）。通过IQFDS在起重设备的卷筒设计中的应用，表明采用集成化的QFD系统，不仅可以克服QFD所存在的缺陷，而且可优化产品的设计与制造过程。改进和提高质量水平，进而满足顾客需求。     

协调分析法在机电产品质量评价中的应用

为全面综合评价机电产品质量,提高评价结果准确性,在分析机电产品质量影响因素基础上,构建产品质量评价指标体系。应用模糊-熵权法确定指标权重,基于妥协原理,采用协调分析法建立综合考虑各评价指标优缺点的机电产品质量评价模型;并结合产品质量评价决策流程,输出评价结果,进而为企业制定产品采购方案提供参考;最后以某数控系统生产厂家采购编码器产品为例进行应用说明。结果表明:综合考虑产品质量优缺点的评价模型简单、操作方便,评价结果客观可信。     

面向绿色高表面质量制造的硬态车削工艺多目标参数优化

目的 为了进行硬态车削绿色制造与工艺性能协同优化研究,提出一种同时考虑碳排放量和表面粗糙度的多目标优化方法。方法 首先,通过分析硬态车削过程中切削参数、工件材料、刀具材料等因素对切削功率的影响建立碳排放目标函数,针对工件的表面粗糙度受到切削条件、工件材料、刀具材料等诸多因素的影响,利用正交试验和广义回归神经网络建立轴承硬态车削表面粗糙度目标函数。然后,考虑加工过程中机床特性和硬车实际工况等约束条件,建立以切削参数为优化变量,以碳排放量和表面粗糙度为优化目标的多目标优化模型,引入权重系数将其转化为单目标优化模型。最后,利用遗传算法对优化模型进行优化求解,深入分析切削参数对优化目标的影响。结果 在工厂实际轴承产品硬车试验中验证了优化模型的有效性,结果表明,切削速度为225 m/min、进给量为0.08 mm/r、背吃刀量为0.10 mm时,碳排放量和表面粗糙度的综合优化指标最低。相比优化前,虽然碳排放量上升了13.05%,但表面质量提升了34.44%。结论 研究结果对面向绿色制造的轴承硬车工艺参数优化提供理论方法有重要意义。     

Global manufacturing and the embodied energy of products

Manufacturing energy efficiency has become a key concern due to increasing energy costs and their associated environmental impact. It is important however, that investigations into the embodied energy of a product be in the context of global manufacturing rather than energy efficiency related to a particular product life cycle. This paper presents a model to assess the impact of global manufacturing on the embodied energy of products. Six different products manufactured from various raw materials in a global manufacturing network were used to carry out the assessment. The results show that product, material and key supply chain parameters play a crucial role.     

Optimization of mechanical properties of recycled plastic products via optimal processing parameters using the Taguchi method

The large amount of plastic products presently produced necessitates recycling and reuse of these non-biodegradable materials. However, the degradation in the mechanical properties of products made from recycled plastic is a major drawback that limits their use. This study aims to improve the mechanical properties of products made from recycled plastic by utilizing the Taguchi optimization method, instead of coupling the products with additives. By adopting L₉ Taguchi OA, products made from various compositions of virgin and recycled plastic are produced by injection moulding. Four controllable factors (i.e., melt temperature, packing pressure, injection time, and packing time), each at three levels, are tested to determine the optimal combination of factors and levels in the manufacturing process. By determining the optimal combination of factors and levels, the appropriate blending ratio of virgin and recycled plastic can be evaluated from the mechanical performance exhibited by the compound. The effects of the optimal processing parameters and the addition of recycled plastic in various compositions on the mechanical properties and melt flow index of the produced parts are also investigated. The results reveal that the product made of 25% recycled polypropylene (PP) and 75% virgin PP exhibits a better flexural modulus compared to the virgin form. The same product exhibits a 3.4% decrease in flexural strength. The degradation in mechanical properties of products produced from recycled plastic can be improved by optimizing the influence processing parameters during the manufacturing process.     

试论制造业与模具市场

论述了制造业与模具市场的关系及制造业产品市场对模具性能、质量的需求 ,分析了模具市场的特点 ,提出了应建立或逐步形成各类产品所需的专用模具及相应的模具企业体制 ,提高模具生产企业的竞争力 ,以适应现代制造业发展对模具市场的需求     

铸件产品质量与成本问题思考

从3个方面分析了中国铸件产品质量问题的现状及特点,认为可以基于顾客需要、产品更新周期、产品部件协调等3种平衡造就“最佳质量”,提高工艺出品率;并介绍和分析了传统符合性质量成本模型和现代符合性质量成本模型。最后从5个方面给出了铸件产品正确处理质量与成本之关系、提高中国铸造企业整体竞争力的建议。     

单晶金刚石微型刀具刃磨试验研究

刀具刃磨质量是影响零件加工质量的重要因素之一。为提高单晶金刚石刀具刃磨质量,采用铜盘、铁盘、铜基碳化钨盘和铝基碳化硅盘四种不同的磨盘进行刃磨对比试验。观测分析刃磨后磨盘的表面形貌、材料去除率和刀具的刃口形貌、圆弧半径。结果发现:铜盘和铁盘刃磨过程中不能保证单晶金刚石的完整性,铜基碳化钨盘和铝基碳化硅盘加工可以获得较好的刀具质量。而铜基碳化钨盘通过促进单晶金刚石的氧化反应,在刃磨后获得的刀具刃口圆弧半径稳定在1 μm以内。