数值模拟快速成形及模具制造集成化的研究
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摘要
本论文是我的导师宋玉泉教授关于“连续局部塑性精成形设备及工艺”研究方向的一个组成部分,与吉林大学超塑性与塑性研究所承担的国家科技攻关计划项目“汽车连杆辊压塑性精成形新设备和新工艺”密切相关,按照导师所提出的“科、教、产”一体化模式进行。
随着科学技术的不断发展,各种先进制造技术不断涌现,如何更好的利用先进制造技术,最大限度的发挥其优势,成为了一个难题。本文从集成化出发,对逆向工程与快速成形集成,CAD/CAE集成,CAD/CAM集成方式做系统研究;并结合吉林大学超塑性与塑性研究所现有设备对集成化方案做具体设计;以连杆成形为例,对集成化制造系统在连杆成形中的应用做具体介绍。
与传统的产品设计制造相比,数值模拟、快速成形及模具制造集成化系统能够缩短产品设计、制造周期,提高产品设计、制造质量,降低成本,最终提高产品市场竞争力。
With the coming of information times and the forming of global market, the world market competition is more and more vehemently, the new product requiry is more and more diversification, the life period of product is more and more short.The manufacturing mode is coming to small batch and more varieties. This pattern forming is related to the development of advanced manufacturing technology. Manufacture corporation is the support industry of country economy, it’s level becomes important symbol of country economy and technology. The near 20 years, the environment of manufacturing market is occurring huge change, at one hand, consumer interest more short time and consumer request more main body, at the another hand is the breaking of distinct and international bank, then the manufacturer have to with an eye to global market fury competition.
The pursuant of traditional product design is the direct experience of designer and the indirect experience come form another way. Designer progress the product design by the finite and lower reliability experience. Then made the actual physical product or the sample bye the first design. After completing of product, maybe coming some pertinence analyzed compute and experience of product reliability (or don’t do analyze and experiment, direct come to market, direct get feedback data from market feedback ) if the first product is not meet capability request, return to design, designer amend the original design. then retry the product trial-manufacture, then redo analyze and experiment. This will cycled until the product capability require is satisfy, the product design is ended. Appearance , this traditional design and manufacturing mode, because the cycle is long, and the mode amend and redesign is difficulty, it hard to fit the require of market competition.
Advanced manufacturing technology is based on the traditional manufacturing technology and absorb mechanism, electron,information, material, energy sources and modern management technology latest fruit, then colligate applied to the product exploitation, design, manufacturing, management, quality guarantee and after service manufacturing process, and it is the manufacturing technology floorboard of realize high quality, high effect, lower cost and acquire the ideal economic effect.
With the extending of many advanced manufacturing technology in modern manufacturing industry, corresponding general an expert, but how to use these advanced manufacturing technology and use the advantage at the most being a problem. At present, except some small scale integration is mature, other software system always lone, these no information share with each other, so it being a information island alone, and the equipment information transmission exist some uniform problem. For example, the model set up used Pro/E, when it is needed to processing finite analyze, yet is always this model can not fold into Ansys exactly, so it must redo the modeling in Ansys. And the CAM communicating with the digital equipment have the some problem. How to integrate these software system and hardware equipment, and hand it together according to it different purpose. It is a key problem that how to translate information used the uniform file kind and guarantee the system information fluently and harmonize the son system function effectively.
The function of integration is to made the independence run multi cell system integrate a corresponding working and a more strong function new system. Integration is not the simple connecting, but through uniform mark out and design, analyzing the original cell system effect and each other relation and optimize to realize. Integration purpose is realizing the manufacturing corporation function integration, it should use modern management technology, computer technology, automatization and information technology to realize technology integration, and the some time it should emphasize man integration., because the system can not no man, system run effect should relate to man and corporation management idea, run mechanism, management mode. So in the some time of technology integration, it should emphasize management and people integration, Integration yield will be the magistral manufacture mode in 21 century.
This paper integrate advanced manufacturing technology(including reverse engineering, rapid prototyping numerical simulation , mould numerical control process)applied it to product design and manufacturing. At first we will introduce advance technology and research status in country and out country.. then we will research reverse engineering and rapid prototyping integration, CAD and CAE integration, CAD and CAM integration, then designing the integration mode to realize it. Combining JiLin university super-plastic and plastic research institute exist equipment, setting up a whole integration manufacturing system. And do a particular introduction about integration manufacturing system apply in connecting-rod process. The main process including: connecting-rod data capture, point cloud data process, CAD model set up, rapid prototyping manufacturing, connecting rod blank and mould design, numerical simulation during connecting forming process, mould NC process. When designing connecting-rod mould, according to professor Yuquan Song’s patent ideal of automotive connecting-rod precise plastic rolling process, design four path rolling mould, through numerical simulation we know, this four path rolling mould can realize automotive connecting-rod precise plastic rolling process. At the end we compare connecting-rod integration manufacturing with other forming method in design manufacturing and connecting-rod forming technics equipment. The conclusion is integration manufacturing system can reduce product design and manufacturing cycle, increase design and manufacture quality, reduce cost, at last improving product market competition.
随着科学技术的不断发展,各种先进制造技术不断涌现,如何更好的利用先进制造技术,最大限度的发挥其优势,成为了一个难题。本文从集成化出发,对逆向工程与快速成形集成,CAD/CAE集成,CAD/CAM集成方式做系统研究;并结合吉林大学超塑性与塑性研究所现有设备对集成化方案做具体设计;以连杆成形为例,对集成化制造系统在连杆成形中的应用做具体介绍。
与传统的产品设计制造相比,数值模拟、快速成形及模具制造集成化系统能够缩短产品设计、制造周期,提高产品设计、制造质量,降低成本,最终提高产品市场竞争力。
With the coming of information times and the forming of global market, the world market competition is more and more vehemently, the new product requiry is more and more diversification, the life period of product is more and more short.The manufacturing mode is coming to small batch and more varieties. This pattern forming is related to the development of advanced manufacturing technology. Manufacture corporation is the support industry of country economy, it’s level becomes important symbol of country economy and technology. The near 20 years, the environment of manufacturing market is occurring huge change, at one hand, consumer interest more short time and consumer request more main body, at the another hand is the breaking of distinct and international bank, then the manufacturer have to with an eye to global market fury competition.
The pursuant of traditional product design is the direct experience of designer and the indirect experience come form another way. Designer progress the product design by the finite and lower reliability experience. Then made the actual physical product or the sample bye the first design. After completing of product, maybe coming some pertinence analyzed compute and experience of product reliability (or don’t do analyze and experiment, direct come to market, direct get feedback data from market feedback ) if the first product is not meet capability request, return to design, designer amend the original design. then retry the product trial-manufacture, then redo analyze and experiment. This will cycled until the product capability require is satisfy, the product design is ended. Appearance , this traditional design and manufacturing mode, because the cycle is long, and the mode amend and redesign is difficulty, it hard to fit the require of market competition.
Advanced manufacturing technology is based on the traditional manufacturing technology and absorb mechanism, electron,information, material, energy sources and modern management technology latest fruit, then colligate applied to the product exploitation, design, manufacturing, management, quality guarantee and after service manufacturing process, and it is the manufacturing technology floorboard of realize high quality, high effect, lower cost and acquire the ideal economic effect.
With the extending of many advanced manufacturing technology in modern manufacturing industry, corresponding general an expert, but how to use these advanced manufacturing technology and use the advantage at the most being a problem. At present, except some small scale integration is mature, other software system always lone, these no information share with each other, so it being a information island alone, and the equipment information transmission exist some uniform problem. For example, the model set up used Pro/E, when it is needed to processing finite analyze, yet is always this model can not fold into Ansys exactly, so it must redo the modeling in Ansys. And the CAM communicating with the digital equipment have the some problem. How to integrate these software system and hardware equipment, and hand it together according to it different purpose. It is a key problem that how to translate information used the uniform file kind and guarantee the system information fluently and harmonize the son system function effectively.
The function of integration is to made the independence run multi cell system integrate a corresponding working and a more strong function new system. Integration is not the simple connecting, but through uniform mark out and design, analyzing the original cell system effect and each other relation and optimize to realize. Integration purpose is realizing the manufacturing corporation function integration, it should use modern management technology, computer technology, automatization and information technology to realize technology integration, and the some time it should emphasize man integration., because the system can not no man, system run effect should relate to man and corporation management idea, run mechanism, management mode. So in the some time of technology integration, it should emphasize management and people integration, Integration yield will be the magistral manufacture mode in 21 century.
This paper integrate advanced manufacturing technology(including reverse engineering, rapid prototyping numerical simulation , mould numerical control process)applied it to product design and manufacturing. At first we will introduce advance technology and research status in country and out country.. then we will research reverse engineering and rapid prototyping integration, CAD and CAE integration, CAD and CAM integration, then designing the integration mode to realize it. Combining JiLin university super-plastic and plastic research institute exist equipment, setting up a whole integration manufacturing system. And do a particular introduction about integration manufacturing system apply in connecting-rod process. The main process including: connecting-rod data capture, point cloud data process, CAD model set up, rapid prototyping manufacturing, connecting rod blank and mould design, numerical simulation during connecting forming process, mould NC process. When designing connecting-rod mould, according to professor Yuquan Song’s patent ideal of automotive connecting-rod precise plastic rolling process, design four path rolling mould, through numerical simulation we know, this four path rolling mould can realize automotive connecting-rod precise plastic rolling process. At the end we compare connecting-rod integration manufacturing with other forming method in design manufacturing and connecting-rod forming technics equipment. The conclusion is integration manufacturing system can reduce product design and manufacturing cycle, increase design and manufacture quality, reduce cost, at last improving product market competition.
引文
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[3] 陈凌, 高秀兰. 我国计算机集成制造系统(CIMS)的现状及前景展望. 现代机械, 2002,(4):16~19
[4] 戴健. 先进制造技术在国防科技工业生产管理中的应用研究:[硕士学位论文]. 西南财经大学,2002. 9～10
[5] 唐伟. 逆向工程及其应用. 山东机械,2004,(1):5~7
[6] Saeid motavalli. Review of Reverse Engineering Approaches. 23rd international conference on computer and industrial engineering,1998,35 (1-2) :25~28
[7] L.Li, N.Schemenauer, X.Peng,Y.Zeng,P. Gu. A reverse engineering system for rapid manufacturing of complex objects. Robotics and Computer Integrated Manufacturing,2002,(18):53~69
[8] Yu Zhang. Research into the engineering application of reverse engineering technology. Journal of materials Processing Technology,2003,(139):473~475
[9] 肖棋. 快速成形技术. 集美大学学报(自然科学版),2001, 6(增刊):153~155
[10] 王运赣. 快速成形技术. 武汉:华中理工大学出版社,1999. 11~12
[11] 张兰. 数值模拟技术在汽车覆盖件拉深成形质量控制中的应用研究:[硕士学位论文]. 四川大学,2006
[12] L.H.You, Y.Y.Tang, J.J.Zhang,etc. Numerical analysis of elastic- plastic rotating disks with arbitrary variable thickness and density. International of solids and structures, 2000,(37):7809~7820
[13] 宗志坚. CAD/CAM 技术. 北京:机械工业出版社,2001. 6~7
[14] 金涛, 陈建良, 童水光. 逆向工程技术研究进展. 中国机械工程,2002, 13 (16): 1430~1436
[15] 黄树槐, 肖跃加, 莫健华, 等. 快速成形技术的展望. 中国机械工程, 2000, 11(1-2):195~200
[16] 汪文虎, 刘晓辉, 张军. 我国模具 C A D / C A M 技术的现状及发展趋势研究. 模具技术, 2007,(1):55~58
[17] 李德群, 肖祥芷. 模具 CAD/CAE/CAM 的发展概况及趋势. 模具工业,2005, (7):9~12
[18] 肖尧先. 基于 RE/RP 系统集成的复杂外形产品快速开发技术研究:[博士学位论文]. 浙江大学, 2002.58~59
[19] 石晓祥, 周雄辉, 卫原平,等. 产品反向工程和快速原型制造的集成技术.上海交通大学学报,2000,34(10):1379~138
[20] 肖尧先, 柯映林. 三角Bezier曲面建模的RE系统与RP系统集成. 机械工程学报,2003,39(2):42~46
[21] 王从军, 张李超, 黄树槐. 一种新的 STL 数据压缩存储格式. 中国机械工程,2001,12(5):558~560
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