汽車制造中沖壓工藝的新發(fā)展外文翻譯

1、<p>　　Automobile manufacture stamping process of new development</p><p>　　Automobile manufacture has a 60-70% of metal parts must be approved by the plastic processing forming, stamping process is compl

2、ete metal plastic forming a kind of important means, it is the most basic, the most traditional, the most important one of metal processing method. Such as vehicle body all kinds of covering parts, car support pieces, st

3、ructure strengthen pieces, there's plenty of auto parts, such as engine exhaust muffler, hollow tube bending and camshaft, the oil pan, engine stents, f</p><p>　　So-called stamping technology refers to t

4、he adaptability of the stamping to handicraft, namely the design of stamping in size, size accuracy and benchmarks, structure shape stamping processing of compliance with technological requirements. Automotive stamping p

5、arts should be good technological characteristics, and the economy, measure the level of the important symbol has stamping process number, body assemblies block number and size, stamping structure, and other factors. Red

6、uce the number of p</p><p>　　Modern stamping development and research of the major subjects include:</p><p>　　(1) module type and control; stamping</p><p>　　(2) new material and com

7、posite stamping processing new craft;</p><p>　　(3) special stamping technology;</p><p>　　(4) computer simulation stamping mold testing technology; and virtual</p><p>　　(5) die &

8、 mould manufacturing technology,</p><p>　　(6) stamping process of automatic monitoring and instability mechanism analysis and so on .</p><p>　　Module type stamping</p><p>　　Module t

9、ype 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 dem

10、ands, so long as 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

11、 processing play advantage, and also show flexibilit</p><p>　　the stamping process can be replaced rapidly segment mold to improve production efficiency;</p><p>　　(2) due to its strip for belt a

12、nd masking belt device, can save another set feeding blanking process,</p><p>　　(3) achieved great work pieces the non-stop machining,</p><p>　　(4) can both independent and can become series of

13、control combination dies action can continually stamping processing;</p><p>　　(5) dies with programmable and the flexible characteristics.</p><p>　　A module type stamping processing system by a

14、with control function module type of cold stamping press, coil strip send into outfit porch, strip correction machines and programmable feeding device, etc. The stamping system at run-time can undertake stamping transver

15、se displacement, strip feeding positioning, die repeat operation and automatic adjustment work step punching adjustment etc multiple functions. Because the stamping process programmable stamping, make this kind of module

16、 type stamping</p><p>　　The current module type stamping device integration is very high, in width is 300MM size range can arrange of 35 mold, through the roof top of stamping die for independent type series

17、 of control, is formed namely die of integrated control. The whole system programmable in WINDOWS user interface and menu under implementation, programming involves mould along the lateral positioning shaft servo drive p

18、ositioning, strip inspection correction and longitudinal feeding positioning, stamping quality fo</p><p>　　When stamping reconfigure or alteration, these changes would be parameters and controlled system to

19、store, next time query and invoke. Declarations Die data include the punch and their combination tags, punch combination in X, Y of die and mould shaft Numbers coordinates and other information. Figure 3 shows programmab

20、le punching system, figure in A standard mould transverse axis, can undertake servo dynamic to stamping area, B for the supporting shaft with punching die, C, D for spare axis to o</p><p>　　And submillimeter

21、 stamping project</p><p>　　And submillimeter stamping "refers 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 2MM compa

22、red, is a very big enhancement. This is an improving punching quality and manufacturing technology as the goal of integrated project. The project with" 2MM engineering "are all in the late 1990s America QiCheJi

23、e conduct large-scale research project. So-called" the car is 2MM engineering knowledge, body assembly size changes</p><p>　　Stamping processing forming technology affect auto body manufacturing level i

24、s one of the key factors, the American experts worked in a car assembly line to over 50 cases field analysis shows that, cause body size error change many reasons, stamping itself size caused by error accumulation 23 per

25、cent, its main reason is that the traditional based on experience and original technology based on low level of mold design and manufacturing.</p><p>　　And submillimeter stamping is the center of precision s

26、tamping with increasing agility two goals, precision is to make the stamping size accuracy control in 0 mm or and submillimeter level, the key is to control body stents, pillar on the pieces of the feet, and make changes

27、 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 to 30%, includin

28、g too</p><p>　　Through a study of the program and submillimeter stamping, stamping technology has witnessed progress, including:</p><p>　　(1) the stamping process and component assembly process

29、design by based on experience and the traditional craft to science and data process of transformation,</p><p>　　(2) stamping design to CAD and simulation test mode transformation, rejected traditional attemp

30、t method,</p><p>　　(3) to implement the mould design manufacture serial manner by the past to parallel transformation,</p><p>　　(4) realized process monitoring and equipment maintenance from pas

31、sive response to scientific prediction type transformation. "2MM project" and "and submillimeter stamping" two project has successively is complete, and the three major automobile manufacturing compan

32、y popularization and application, and achieved many beneficial results, stamping cost greatly decreased, obtain the growing economic benefit of social benefit, and gradually applied to other countries.</p><p&g

33、t;　　Special stamping technology</p><p>　　Modern automotive stamping technology requirements towards structure is complex, block size increases, related edge parts more, carrying capacity is large and interna

34、l limit strictly etc direction. This requirement and promote special stamping technology such as hydraulic pressure forming, precision forming, explosive forming and spinning forming, no die forming, laser forming and el

35、ectromagnetic forming technology development. Limited to this paper length, here basically introduces pressure ins</p><p>　　Modern automotive stamping technology requirements towards structure is complex, bl

36、ock size increases, related edge parts more, carrying capacity is large and internal limit strictly etc direction. This requirement and promote special stamping technology such as hydraulic pressure forming, precision fo

37、rming, explosive forming and spinning forming, no die forming, laser forming and electromagnetic forming technology development. Limited to this paper length, here basically introduces pressure ins</p><p>　　

38、The hydraulic or injection of the forming technology of elastic postures, its high-pressure forming process generally includes:</p><p>　　(1) effective media such as ice expansion iscm make the internal press

39、ure pressed into the penalty extremely slow growth process,</p><p>　　(2) fluid static penalty bone high-pressure forming process,</p><p>　　(3) extreme pressure as an explosion dynamic process, e

40、tc. Medium can is amorphous solid, liquid, or gas, in the system of medium can be basis must processing shape make arbitrary changes, fulfill the punch function, so medium can be equated to a universal mold. Figure 4 is

41、plank super shobach the example, forming from the graph visible at effective media becomes the punch.</p><p>　　The hydraulic internal high-pressure forming technology compared with other stamping technology,

42、 there are several obvious advantages:</p><p>　　(1) the forming process can one processing out like axle, top cover, doorcase and other large and complex 3d geometric shapes of workpiece,</p><p>

43、;　　(2) because of liquid in the forming process cooling effect, make the workpiece is a "cold strengthening", won than ordinary stamping workpiece machining higher strength, this makes allowing a thinner plank,

44、 to make the work more lightweighting;</p><p>　　(3) workpiece surface appearance only with pressure liquid contact, pressure is gentle, parts forming process changes, can obtain the symmetry of uniform press

45、ure distribution, and can winner much better smooth outside surface,</p><p>　　(4) in stamping and bloom some hydraulic tool charge can reduce 40%, special reduced convex parts processing of takt time is shor

46、ter, about 0.1-0.5 MIN, this in special forming process is shorter, may realize the batch production.</p><p>　　Using the electromagnetic force generated electricity coil electromagnetic forming process, is t

47、he present quite promising another new processing method. This process from 1960s nuclear fission research achievement, but unfortunately has not been people attention. Electromagnetic forming technology principle diagra

48、m, when the coil access to electricity. Few microseconds inside establish electromagnetic field, so the metal workpieces especially conductivity strong copper aluminum texture produce </p><p>　　Electromagnet

49、ic forming technology is a non-contact forming process, and its outstanding merits are shaping a rapid high efficiency, 2 it is often used in metal or nonmetal connection, can replace adhesive or welding, A third is not

50、consumption lymphocy help materials such as lubricating grease, etc, the advantageous environment protection.</p><p>　　Stamping process automatic monitoring</p><p>　　Modern scramjet another impo

51、rtant feature is for punching process automatic monitoring to protect the stamping quality. In the mm stamping project automatic detection and monitoring, its research results will include: 1. The stamping process charac

52、teristics 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 compen

53、sation system, etc.</p><p>　　Stamping process changes caused by workpiece quality is mainly caused by the wear of convex punching die, crack, dislocation, these small changes can be made of high resolution o

54、f a transfer sensor and rushed pressure turn sensor tracking detection. One extremely important displacement measurement is a kind of measure, this device, usually by installed in the mould, the GuanYuan and located belo

55、w the receiving unit constitution, can monitor deviation, tracking processing process, timely output m</p><p>　　An online stamping graphical processing system, is the effective guarantee stamping workpiece q

56、uality testing method, it can carry out 2-d geometric figure of standard testing, the project has the length, diameter, parallelism, Angle, pressing plank structure and identification of waste, etc. Graphics processing s

57、ystem is by like meter, optical instrument and lighting equipment etc, the standard of CCD like instrument of bashan 750X580 bar lattice resolution for grid and jokshan horizontal direc</p><p>　　Surveillance

58、 systems use the displacements and the Angle sensor are optical type and electrical type two kinds, the former has the laser testing technology and die like light sheshan technical support, The latter has a inductance an

59、d capacitance streaming media, they test accuracy resolution all may achieve the 1-10um grade level. The most suitable stamping technology transfer sensor installation plan is to put multiple turn sensor installed in a c

60、entralized sensor board, then put it precisely f</p><p>　　汽車制造中沖壓工藝的新發(fā)展</p><p>　　汽車制造中有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。如車身上的各種覆蓋件、車內(nèi)支撐件、結構加強件，還有大量的汽車零部件，如發(fā)動機的排氣

61、彎管及消聲器、空心凸輪軸、油底殼、發(fā)動機支架、框架結構件、橫縱梁等等，都是經(jīng)沖壓成形技術正向精密、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量，在較大程度上對汽車制造質量和成本有直接的影響。  </p><p>　　所謂沖壓工藝性是指沖壓件對工藝品的適應性，即所設計的沖壓件在尺寸大小、尺寸精度與基準、結構形狀等是否符合沖壓加工的工藝要求。汽車沖壓件都應具有良好的工藝品性和經(jīng)濟性

62、，衡量其水平的重要標志有沖壓件的工序數(shù)、車身總成的分塊數(shù)量和尺寸大小、沖壓件的結構等因素。減少沖壓過程的工序數(shù)，意味著減少沖壓件數(shù)、節(jié)省工裝數(shù)量、簡化沖壓過程的傳送裝置，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)設計作為降低汽車制造成本的重要途徑，甚至不惜改進產(chǎn)品設計來滿足制造工藝方面的要求。同時，還應采用盡量大尺寸的合理的車身總成分塊，如整塊式車身左右側板及車頂蓋板，既可使汽車外形美觀?？?/p>

63、氣阻力減少，又可減少沖壓件數(shù)量及焊點，能有效地降低成本。而且現(xiàn)代汽車制造大量使用卷料、薄殼式整體車身結構的高強度鋼板與鍍鋅鋼板，都要求應用沖壓新工藝。  </p><p>　　現(xiàn)代沖壓成形發(fā)展和研究的重大課題包括有：</p><p>　　（1）模塊式?jīng)_壓及其控制；  （2）新材料及復合材料沖壓加工新工藝；  （3）特種沖壓成形技術；  （4）計

64、算機模擬沖壓成形及虛擬試模技術；  （5）模具制造技術；  （6）沖壓成形過程自動監(jiān)控及失穩(wěn)機理分析等項。  </p><p><b>　　模塊式?jīng)_壓  </b></p><p>　　模塊式?jīng)_壓的突出優(yōu)點在于能把沖壓加工系統(tǒng)的柔性與高效生產(chǎn)有機的結合在一起。柔性的含義較廣，如沖壓件的幾何形狀的多種要求，只要通過自由編程就可獲

65、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)，更對小批量多品種加工發(fā)揮優(yōu)勢，也表現(xiàn)出柔性。概括而言，模塊式?jīng)_壓的持點是：</p><p>　?。?）在沖壓成形過程中可快速更換組合模具以提高生產(chǎn)效率；</p><p>　?。?）由于具有帶材的供帶和矯帶裝置，可省卻另設上料下料工序；</p><p>　?。?）實現(xiàn)了大工件的不停機加工；</p>

66、;<p>　　（4）既能獨立又能成系列的控制組合沖模動作，能連續(xù)進行沖壓加工；</p><p>　?。?）沖模具有可編和的柔性特點。  </p><p>　　一種模塊式?jīng)_壓加工系統(tǒng)由一臺帶有控制功能模塊式冷沖壓的壓力機、卷材帶材送進裝軒、帶材矯正機及可編程進給裝置等構成。這種沖壓系統(tǒng)在運行時可進行沖模橫向位移、帶材進給定位、沖模重復運行及自動調整下工步的沖模調整等多

67、項功能。由于在沖壓過程中進行可編程沖壓，使這種模塊式?jīng)_壓系統(tǒng)能柔性地適應生產(chǎn)需求，能在相同帶材上進行曲不同工件及批次的混合生產(chǎn)，實現(xiàn)不停機的串接式加工，還同時在工件兩面沖壓加工，極大地提高了工作效率，有資料表明，模塊式?jīng)_壓成形使加工費用能下降至40%-50%。  </p><p>　　當前模塊式?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35個模具，通過沖模上端的頂板可對沖模進行獨立式

68、系列控制，即形成沖模的集成控制。整個系統(tǒng)的可編程在WINDOWS用戶界面和菜單下實現(xiàn)，編程涉及模具沿著橫向定位軸的伺服驅動定位，帶材的檢驗矯正及縱向進給定位，沖壓件的質量跟蹤檢驗，沖模的調整及壓力機；狀況監(jiān)控等多功能。  </p><p>　　當沖模重新配置或更換時，這些變化則會被參數(shù)并被控制系統(tǒng)所貯存，以務下次查詢和調用。沖模數(shù)據(jù)包括有沖頭及其組合標記，沖頭組合在模具中的X、Y坐標位置及模具軸編號等信

69、息。  </p><p><b>　　亞毫米沖壓項目  </b></p><p>　　亞毫米沖壓是指汽車車身沖壓件的精度控制在0-1.0MM的范圍內(nèi)，與過去制造業(yè)通行的誤差2MM相比，是個非常大的提高。這是一個以提高沖壓質量和制造技術為目標的綜合項目。該項目與“2MM工程”都是90年代后期美國汽車界開展的大型研究項目。所謂“2MM工程”就是把車知、

70、身裝配尺寸變動量控制在2MM之內(nèi)，大大嚴于原先的8MM誤差范圍。  </p><p>　　沖壓加工成形技術是影響汽車車身制造水平的關鍵因素之一，美國專家曾在一條汽車裝配線上對50多個個案進行實地分析表明，造成車身尺寸誤差變動的諸多原因中，沖壓件本身尺寸造成的積累誤差占23%，其主要原因是傳統(tǒng)的基于經(jīng)驗和原有工藝基礎上低水平上的模具設計與制造。  </p><p>　　亞

71、毫米沖壓的中心是沖壓件的精度與敏捷度兩個目標，精度就是使沖壓件尺寸準確度控制在0毫米或亞毫米的水平，其關鍵是控制車身支架、立柱等結構件的尺變動，并使車身覆蓋件分塊度大，如采用整體左右側板和頂蓋板等。敏捷度含義則是指減少沖壓件的生主準備時間達30%，包括模具設計、試樣制造和工裝準備時間，以達到極大縮短新車型制造周期的目的，該項目飲食有沖壓和裝配的集成設計、沖壓系統(tǒng)敏捷設計和制造、沖壓過程的智能檢測和監(jiān)控、全系統(tǒng)集成4個子項目。</p

72、><p>　　通過亞毫米沖壓項目的研究，使沖壓成形技術有了飛躍性的進展，其中包含有：</p><p>　?。?）沖壓過程和部件裝配工藝的設計由基于經(jīng)驗和傳統(tǒng)工藝向科學和數(shù)據(jù)過程的轉化；</p><p>　?。?）沖壓設計向CAD和模擬試模轉化，摒棄了傳統(tǒng)的嘗試法；</p><p>　　（3）實施模具設計制造由過去串行方式向并行方式轉化；</

73、p><p>　?。?）實現(xiàn)了過程監(jiān)測和設備維護由被動響應向科學預測式轉變。“2MM工程”和“亞毫米沖壓”兩項目現(xiàn)已先后完成 ，正在美國三大汽車制造公司推廣應用，取得了許多有益的成果，沖壓成本大幅下降，獲得日益增長的經(jīng)濟效益的社會效益，并逐步向其他國家推廣應用。  </p><p>　　特種沖壓成形技術  </p><p>　　現(xiàn)代汽車沖壓件的技術要求

74、朝著結構復雜、分塊尺寸增大、相關邊的零部件較多、承載能力變大和內(nèi)應力限制嚴格等方向發(fā)展。這要求并促進特種沖壓成形技術如液壓成形、精密成形、爆炸成形、旋壓成形、無模成形、激光成形和電磁成形技術的發(fā)展。限于本文篇幅，這里主要介紹內(nèi)壓成形和電磁成形兩項技術。  </p><p>　　現(xiàn)代汽車沖壓件的技術要求朝著結構復雜、分塊尺寸增大、相關邊的零部件較多、承載能力變大和內(nèi)應力限制嚴格等方向發(fā)展。這要求并促進特種

75、沖壓成形技術如液壓成形、精密成形、爆炸成形、旋壓成形、無模成形、激光成形和電磁成形技術的發(fā)展。限于本文篇幅，這里主要介紹內(nèi)壓成形和電磁成形兩項技術。  </p><p>　　液壓式或注入彈性體式的成形技術，其高壓形成過程一般包括：</p><p>　?。?）有效介質如冰的膨脹或彈性體壓入使內(nèi)部壓罰極慢增長的過程；</p><p>　?。?）流體靜罰的骨高壓

76、形成過程；</p><p>　　（3）極端壓力如爆炸的動態(tài)過程等。介質可以是無定形的固體、液體或氣體，在系統(tǒng)中介質可依據(jù)要加工的形狀作任意變化，履行凸模功能，所以介質可等同于一個萬能模具。  </p><p>　　液壓式內(nèi)高壓成形技術與其他沖壓成形技術相比，有幾項明顯優(yōu)點：</p><p>　　（1）在成形過程中可一次加工出如車橋、頂蓋板、門框等大型復雜的

77、三維幾何形狀的工件；</p><p>　　（2）因為液體在成形過程中冷卻作用，使工件被“冷作強化”，獲得比一般沖壓加工更高的工件強度，這使得允許采用更薄的板材，使工件更輕量化；</p><p>　　（3）工件外表板面只與壓力液體接觸，加壓過程較平緩，零部件成形變化均勻，可獲得勻稱的壓力分布，并能獲得者好得多的平滑外表面；</p><p>　　（4）液壓內(nèi)盛開有的沖模

78、和工具費用可下降40%，特別降低了凸型零件加工的節(jié)拍時間較短，約為0.1-0.5MIN，這在特種成形工藝中是較短的，可實現(xiàn)批量生產(chǎn)。  </p><p>　　利用通電線圈產(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，但可惜一直沒被人們注重。電磁成形工藝原理圖，當線圈通入交流電時。數(shù)微秒內(nèi)建立起磁場，使金屬工件尤其是導電率強的銅鋁材質感生出電流 ，感生

79、出電流，感生電流又將受到磁場力作用，使工件產(chǎn)生張力與凹模吻合而迅速成形。當線圈在工件內(nèi)時，電磁力將使工件外張成形，屬當前應用較廣泛的一種工藝；當線圈平面平行于板件放置時，電磁力將使工件拉伸成形。  </p><p>　　電磁成形技術系一種非接觸成形工藝，其突出優(yōu)點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滑油脂等，有利環(huán)境保護。  </

80、p><p>　　沖壓過程自動監(jiān)控  </p><p>　　現(xiàn)代沖壓技術的另一個重要特點是對沖壓過程進行自動監(jiān)控以保護沖壓件的質量。在亞毫米沖壓項目的自動檢測和監(jiān)控中，其研究成果就包括有：1.沖壓過程的特征分析在線傳診斷和檢測系統(tǒng)；2.高速和非接觸的沖壓件測量系統(tǒng)；3.沖模維護的科學預測系統(tǒng)；4.沖壓成形關鍵參數(shù)的在線調節(jié)和補償系統(tǒng)等。  </p><p&

81、gt;　　沖壓過程引起工件質量發(fā)生變化的原因主要有凹凸沖模的磨損、裂紋及沖模錯位等，這些微小變化可由高分辯率的位移轉感器和沖壓力轉感器進行跟蹤檢測。其中位移測量是極重要的一種測量，該裝置通常由安裝在模具上方的關源和位于下方的接收單元構成，可監(jiān)視偏差、跟蹤加工全過程、及時輸出監(jiān)測信息和進行報警停機。  </p><p>　　一種在線沖壓的圖形處理系統(tǒng)，是保證沖壓工件質量的有效測試方法，它能進行二維幾何圖形

82、的標準檢測，其項目有長度、直徑、平行度、角位、沖壓板材結構及識別廢品等。圖形處理系統(tǒng)是由象儀、光學儀和照明裝置等組成，標準的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。  </p><p>　　監(jiān)視系統(tǒng)使用的位移及角度傳感器有光學式及電學式二種，前者有激光測試技術和模似光珊技術支持；后者有電感流式及介質電容式，它們的測試精度分辯率都可