汽车制造中冲压工艺发展研讨（中英文翻译）

Automobile manufacture stamping process of new developmentAutomobile manufacture has a 60-70% of metal parts must be approved by the plastic processing forming, stamping process is complete 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, structure strengthen pieces, theres plenty of auto parts, such as engine exhaust muffler, hollow tube bending and camshaft, the oil pan, engine stents, frame structure, horizontal longeron etc, it is by stamping technology positively precision, multi-function, high efficiency and energy saving, safe cleaning production direction, stamping workpiece manufacturing technology level and quality, in great degree of automobile manufacturing quality and cost has direct impact.So-called stamping technology refers to the 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 parts 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. Reduce the number of punching process procedure, that means less stamping tooling quantity, number of packages, save simplified punching process of conveyors, Narrows the operators and stamping area, is to save investment and energy consumption extremely good measures, so stamping manufacturers can put punching process reduce vehicle number design as the important way to manufacture cost, even ? Modern stamping development and research of the major subjects include:(1) module type and control; stamping(2) new material and composite stamping processing new craft;(3) special stamping technology;(4) computer simulation stamping mold testing technology; and virtual(5) die & mould manufacturing technology,(6) stamping process of automatic monitoring and instability mechanism analysis and so on . Module type stampingModule type 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 demands, 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 processing play advantage, and also show flexibility. Oerall, module type stamping water-holding point is:(1) the stamping process can be replaced rapidly combination to improve production efficiency; mould(2) due to its strip for belt and masking belt device, can save another set feeding blanking process,(3) achieved great work pieces the non-stop machining,(4) can both independent and can become series of control combination dies action can continually stamping processing;(5) dies with programmable and the flexible characteristics. A module type stamping processing system by a 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 transverse 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 type stamping system can adapt production requirements, flexible in same strip on March different workpiece and batch production, realizing mixed non-stop string &joint processing, also in two sides stamping workpiece machining, which has greatly enhanced the work efficiency, have data show that the module type stamping makes processing cost can fall to 40% - 50%.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 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 positioning, strip inspection correction and longitudinal feeding positioning, stamping quality follow-up inspection, punching machine; the adjustment and Condition monitoring and versatility.When stamping reconfigure or alteration, these changes would be parameters and controlled system to 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 programmable 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 orange roll type with material are feeding. And submillimeter stamping projectAnd 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 compared, 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 QiCheJie conduct large-scale research project. So-called the car is 2MM engineering knowledge, body assembly size changes within 2MM quantity control, greatly in strict in the original 8MM error range. Stamping processing forming technology affect auto body manufacturing level is 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 percent, its main reason is that the traditional based on experience and original technology based on low level of mold design and manufacturing. And submillimeter stamping is the center of precision stamping 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 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%, including tooling design, manufacturing and tooling, sample preparation time, in order to achieve greatly shorten the purpose of the new models manufacturing cycle, this project diet are die-cutting and assembly integration design, stamping system agile design and manufacturing, stamping process of intelligent detecting and monitoring, whole system integration four subsystems project. Through a study of the program and submillimeter stamping, stamping technology has witnessed progress, including:(1) the stamping process and component assembly process design by based on experience and the traditional craft to science and data process of transformation,(2) stamping design to CAD and simulation test mode transformation, rejected traditional attempt method,(3) to implement the mould design manufacture serial manner by the past to parallel transformation,(4) realized process monitoring and equipment maintenance from passive response to scientific prediction type transformation. 2MM project and and submillimeter stamping two project has successively is complete, and the three major automobile manufacturing company 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. Special stamping technologyModern automotive stamping technology requirements towards structure is complex, block 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 forming, explosive forming and spinning forming, no die forming, laser forming and electromagnetic forming technology development. Limited to this paper length, here basically introduces pressure inside the forming and electromagnetic forming two technologies. Modern automotive stamping technology requirements towards structure is complex, block 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 forming, explosive forming and spinning forming, no die forming, laser forming and electromagnetic forming technology development. Limited to this paper length, here basically introduces pressure inside the forming and electromagnetic forming two technologies. The hydraulic or injection of the forming technology of elastic postures, its high-pressure forming process generally includes:(1) effective media such as ice expansion iscm make the internal pressure pressed into the penalty extremely slow growth process,(2) fluid static penalty bone high-pressure forming process,(3) extreme pressure as an explosion dynamic process, etc. 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 plank super shobach the example, forming from the graph visible at effective media becomes the punch. The hydraulic internal high-pressure forming technology compared with other stamping technology, there are several obvious advantages:(1) the forming process can one processing out like axle, top cover, doorcase and other large and complex 3d geometric shapes of workpiece,(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, to make the work more lightweighting;(3) workpiece surface appearance only with pressure liquid contact, pressure is gentle, parts forming process changes, can obtain the symmetry of uniform pressure distribution, and can winner much better smooth outside surface,(4) in stamping and bloom some hydraulic tool charge can reduce 40%, special reduced convex parts processing of takt time is shorter, about 0.1-0.5 MIN, this in special forming process is shorter, may realize the batch production.Using the electromagnetic force generated electricity coil electromagnetic forming process, is the 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 diagram, when the coil access to electricity. Few microseconds inside establish electromagnetic field, so the metal workpieces especially conductivity strong copper aluminum texture produce electric current, a current, induced current induced by magnetic force and effect, make the workpiece create tension and dies.the anastomosis and rapid forming. When the coil in the workpiece in electromagnetic force will make workpiece outside of the current application, zhang forming widespread a kind of technology, When the coil planar parallel to the board piece is placed, electromagnetic force will make workpiece stretch forming. Electromagnetic 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 consumption lymphocy help materials such as lubricating grease, etc, the advantageous environment protection.Stamping process automatic monitoringModern scramjet another important 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 characteristics 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 compensation system, etc. 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 of 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 below the receiving unit constitution, can monitor deviation, tracking processing process, timely output monitoring information and alarm downtime.An online stamping graphical processing system, is the effective guarantee stamping workpiece quality 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 system 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 direction for every sheshan lattice 0.026 mm, vertical accuracy of fungi mm/sheshan lattice. Surveillance 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 and 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 centralized sensor board, then put it precisely fixed in the mold outlet, namely the punch clamping board, using sensor data monitoring stamping process, and through the controller get timely treatment, guarantee the quality of the stamping.汽车制造中冲压工艺的新发展汽车制造中有60%-70%的金属零部件需经塑性加工成形，冲压加工是完成金属塑性成形的一种重要手段，它是最基本、最传统、最重要的金属加工方法之一。如车身上的各种覆盖件、车内支撑件、结构加强件，还有大量的汽车零部件，如发动机的排气弯管及消声器、空心凸轮轴、油底壳、发动机支架、框架结构件、横纵梁等等，都是经冲压成形技术正向精密、多功能、高效节能、安全清洁的生产方向发展，冲压工件的制造工艺水平及质量，在较大程度上对汽车制造质量和成本有直接的影响。 所谓冲压工艺性是指冲压件对工艺品的适应性，即所设计的冲压件在尺寸大小、尺寸精度与基准、结构形状等是否符合冲压加工的工艺要求。汽车冲压件都应具有良好的工艺品性和经济性，衡量其水平的重要标志有冲压件的工序数、车身总成的分块数量和尺寸大小、冲压件的结构等因素。减少冲压过程的工序数，意味着减少冲压件数、节省工装数量、简化冲压过程的传送装置，缩减操作人员和冲压占地面积，是节约投资额和能耗的极好措施，所以冲压制造商都能把冲压工序数设计作为降低汽车制造成本的重要途径，甚至不惜改进产品设计来满足制造工艺方面的要求。同时，还应采用尽量大尺寸的合理的车身总成分块，如整块式车身左右侧板及车顶盖板，既可使汽车外形美观。空气阻力减少，又可减少冲压件数量及焊点，能有效地降低成本（图一）。而且现代汽车制造大量使用卷料、薄壳式整体车身结构的高强度钢板与镀锌钢板，都要求应用冲压新工艺。 现代冲压成形发展和研究的重大课题包括有： （1）模块式冲压及其控制； （2）新材料及复合材料冲压加工新工艺； （3）特种冲压成形技术； （4）计算机模拟冲压成形及虚拟试模技术； （5）模具制造技术； （6）冲压成形过程自动监控及失稳机理分析等项。 模块式冲压 模块式冲压的突出优点在于能把冲压加工系统的柔性与高效生产有机的结合在一起。柔性的含义较广，如冲压件的几何形状的多种要求，只要通过自由编程就可获得，体现了加工形状的柔性。又如既适用大批量单品种冲压件的生产，更对小批量多品种加工发挥优势，也表现出柔性。概括而言，模块式冲压的持点是： （1）在冲压成形过程中可快速更换组合模具以提高生产效率； （2）由于具有带材的供带和矫带装置，可省却另设上料下料工序； （3）实现了大工件的不停机加工； （4）既能独立又能成系列的控制组合冲模动作，能连续进行冲压加工； （5）冲模具有可编和的柔性特点。 一种模块式冲压加工系统由一台带有控制功能模块式冷冲压的压力机、卷材带材送进装轩、带材矫正机及可编程进给装置等构成。这种冲压系统在运行时可进行冲模横向位移、带材进给定位、冲模重复运行及自动调整下工步的冲模调整等多项功能。由于在冲压过程中进行可编程冲压，使这种模块式冲压系统能柔性地适应生产需求，能在相同带材上进行曲不同工件及批次的混合生产，实现不停机的串接式加工，还同时在工件两面冲压加工，极大地提高了工作效率，有资料表明，模块式冲压成形使加工费用能下降至40%-50%。 当前模块式冲压装置的集成度是很高的，在宽度为300MM尺寸范围内可安排达35个模具，通过冲模上端的顶板可对冲模进行独立式系列控制，即形成冲模的集成控制。整个系统的可编程在WINDOWS用户界面和菜单下实现，编程涉及模具沿着横向定位轴的伺服驱动定位，带材的检验矫正及纵向进给定位，冲压件的质量跟踪检验，冲模的调整及压力机；状况监控等多功能。 当冲模重新配置或更换时，这些变化则会被参数并被控制系统所贮存，以务下次查询和调用。冲模数据包括有冲头及其组合标记，冲头组合在模具中的X、Y坐标位置及模具轴编号等信息。图三表明可编程的冲模系统，图中A为标准模具的横向支承轴，可进行伺服动至冲压区，B为备有冲模的支承轴，C为备用轴，D为橙色卷式带料正在进给。 亚毫米冲压项目 亚毫米冲压是指汽车车身冲压件的精度控制在0-1.0MM的范围内，与过去制造业通行的误差2MM相比，是个非常大的提高。这是一个以提高冲压质量和制造技术为目标的综合项目。该项目与2MM工程都是90年代后期美国汽车界开展的大型研究项目。所谓2MM工程就是把车知、身装配尺寸变动量控制在2MM之内，大大严于原先的8MM误差范围。 冲压加工成形技术是影响汽车车身制造水平的关键因素之一，美国专家曾在一条汽车装配线上对50多个个案进行实地分析表明，造成车身尺寸误差变动的诸多原因中，冲压件本身尺寸造成的积累误差占23%，其主要原因是传统的基于经验和原有工艺基础上低水平上的模具设计与制造。 亚毫米冲压的中心是冲压件的精度与敏捷度两个目标，精度就是使冲压件尺寸准确度控制在0毫米或亚毫米的水平，其关键是控制车身支架、立柱等结构件的尺变动，并使车身覆盖件分块度大，如采用整体左右侧板和顶盖板等。敏捷度含义则是指减少冲压件的生主准备时间达30%，包括模具设计、试样制造和工装准备时间，以达到极大缩短新车型制造周期的目的，该项目饮食有冲压和装配的集成设计、冲压系统敏捷设计和制造、冲压过程的智能检测和监控、全系统集成4个子项目。通过亚毫米冲压项目的研究，使冲压成形技术有了飞跃性的进展，其中包含有： （1）冲压过程和部件装配工艺的设计由基于经验和传统工艺向科学和数据过程的转化； （2）冲压设计向CAD和模拟试模转化，摒弃了传统的尝试法； （3）实施模具设计制造由过去串行方式向并行方式转化；