外文翻译--级进模组件材料选择智能系统的一个简短说明 英文版

Journal of Materials Processing Technology 182 (2007) 456461A short note on an intelligent system for selection ofmaterials for progressiS. Kumara, RColleformAbstractduringanmodules,of ofKnov theuser is demonstratedcomponent. uponK1. IntroductionProgressive die is widely used for mass production of sheetmetal components due to its high productivity, high precisionand relatively economic cost in terms of per piece of prod-uct.tionTheponentstheodstheediebooks,computerwithgressiforhowever, these systems do not take in account the availabil-ity of other suitable materials for the choice of user for betterperformance of die components and hence the long life of pro-gressive die. Further, these systems do not have even knowledgebase consisting of experienced knowledge of domain experts0924-0136/$doi:The design of die components and their material selec-are major activities during progressive die design 1.selection of proper materials for progressive die com-essentially increases the die life and hence reducescost of production of sheet metal parts. Traditional meth-for carrying out this important activity are dependent onvast experience and depth of knowledge of die designxperts. Most of the times, material selection for progressivecomponents is carried out manually using die design hand-material handbooks, thumb-rules and heuristics. Existing-aided die design systems have still not fully dealtthe core die design issue of material selection for pro-ve die components. Some existing CAD/CAM systemsprogressive dies 24 are able to generate bill of materials,Corresponding author. Tel.: +91 130 2210756； fax: +91 130 2210755.E-mail address: skbudhwar2003yahoo.co.in (S. Kumar).in material selection for progressive die components. World-wide researchers 5,6 have stressed to apply research effortsfor capturing and documenting the invaluable practical knowl-edge of experienced die designers and toolmakers through theapplications of artificial intelligence (AI) techniques. The highlyexperience based progressive die design activities such as mate-rial selection of die components can be simplified by usingknowledge-based system (KBS) or intelligent system approachDevelopment of such system can prove a landmark to ease thecomplexities involved in the process of material selection for diecomponents.Although long life of all the components of progressive die isdesirable, however special due attention is required to improvethe life of active components (i.e. punch and die/inserts). Forselecting the suitable material for a progressive die component,the die designer properly investigates the functional require-ments of that component and then a critical study is carried out toidentify the required mechanical properties and possible causes, see front matter 2006 Elsevier B.V. All rights reserved.10.1016/j.jmatprotec.2006.09.004aDepartment of Mechanical Engineering, HindubDepartment of Mechanical EngineeringReceived 10 January 2006； received in revisedSelection of materials for die components is an important activityintelligent system for selection of materials for progressive die ly DIEMAT and SELHRD. The module DIEMAT is designedprogressive die. The module SELHRD is developed for determinationwledge for both the modules of the proposed system is acquired, analyzed,ariety. The system is coded in the AutoLISP language and loaded intothrough the user interface. The usefulness of the proposed systemThe knowledge base of the system can be modified depending2006 Elsevier B.V. All rights reserved.eywords: Progressive die； Material selection； Knowledge base； Intelligent systemve die components. Singhbge of Engineering, Sonepat, Haryana, India, CRSCE, Murthal, Haryana, India15 August 2006； accepted 11 September 2006progressive die design in stamping industries. This paper presentsThe proposed system SMPDC comprises of two knowledge basefor selection of materials for both active and inactive componentshardness range of materials for active components of progressive die.tabulated and incorporated into a set of production rules of IF-THENprompt area of AutoCAD. The system is designed to interact with thethrough a sample run using an example of an industrialthe availability of new materials and advancement in technology.S. Kumar, R. Singh / Journal of Materials Processing Technology 182 (2007) 456461 457which may result the failure of the component. The selection ofmaterial for a given application depends on which failure mech-anisms dominate. The basic idea of a die designer is to select asuitable material such that all other failure mechanisms exceptwear are eliminated. The wear can then be optimized to matchthe required production quantity of sheet metal parts. To obtainlonger die life and hence higher productivity, tool steels are beingwidely used as materials for die components. One of the mostimportant advantages of using steels as cutting tool materialsis that, they are originally soft and machinable, by applyingsuitable heat treatment, they become extremely hard and wearresistant. Selection of suitable hardness range of selected mate-rials of die components depends on the geometry of the part tobe manufactured on progressive die. The specific objective ofthe present work is the development of an intelligent system forselection of materials for progressive die components to assistthe die designers and toolmakers working in small and mediumsize sheet metal industries. A brief description of the procedureTable 1A sample of production rules incorporated in module DIEMATS. no. IF THEN1 Sheet material = Al or Cu or brass or Pb or berylliumcopperSelect an easily available material for punch and die/inserts from the following:EN-31 (5660 HRC) (AISI 52100) ORUHB-ARNE (5462 HRC) (AISI O1, W.-Nr. 1.2510)5 Shear strength of sheet material (kgf/mm2) 20Type of operations = shearingProduction quantity 100,0002 Sheet material = mild steel or stainless steel oraustenitic stainless steel or hardened steel or CRCAor spring steelSelect an easily available material for punch and die/inserts from the following:SEVERKER 3 (6064 HRC) (AISI D6 (D3), W.-Nr. 1.2436, JIS-SKD2) ORUHB-VANADIS 6 (6264 HRC) ORUHB-VANADIS 10 (6064 HRC)30 1,000,0003 Sheet material = Al or Cu or brass or Pb or berylliumcopperSelect an easily available material for punch and die/inserts from the following:EN-31 (5660 HRC) (AISI 52100) ORUHB-ARNE (5462 HRC) (AISI O1, W.-Nr. 1.2510) ORUHB-CALMAX (5659 HRC)5 Shear strength of sheet material (kgf/mm2) 20Type of operations = forming or forming andshearing bothProduction quantity 100,0004 Sheet material = mild steel or stainless steel oraustenitic stainless steel or hardened steel or CRCAor spring steelSelect an easily available material for punch and die/inserts from the following:SEVERKER 21 (5862 HRC) (AISI D2, W.-Nr. 1.2379, JIS-SKD11) ORAISI A2 (5862 HRC) (UHB-RIGOR, W.-Nr. 1.2363)30 Shear strength of sheet material (kgf/mm2) 70Type of operations = forming or forming andshearing both100,000 2mmSheet thickness 5 mmGeometry of blanked part = normalHardness range of selected material in HRC 4Sheet thickness2mmSheet thickness 5mmGeometry of blanked part = complicatedHardness range of selected material in HRC 6Sheet thickness2mmSheet thickness 5 mmGeometry of blanked part = complicatedHardness range of selected material in HRC 6Sheet thickness5mmSheet thickness 8 mmGeometry of blanked part = complicatedHardness range of selected material in HRC 8Sheet thickness8mmGeometry of blanked part = simple or normal or complicatedUse same range of hardness as mentioned with the selected materialUselowerlimit of hardness = upper limit of hardness of selected material-4.0Use upper limit of hardness = upper limit of hardness of selected materialUsesame range of hardness as mentioned with the selected materialUselowerlimit of hardness = upper limit of hardness of selected material-6.0Use upper limit of hardness = upper limit of hardness of selected materialUselowerlimit of hardness = upper limit of hardness of selected material-8.0Use upper limit of hardness = upper limit of hardness of selected materialUsesame range of hardness as mentioned with the selected materialS. Kumar, R. Singh / Journal of Materials Processing Technology 182 (2007) 456461 459intelligentsystemHocaninbetterBothinteractisheetsionbyduringadvicesreleenteringareathroughgramformentscloseof3.2.4systemFig. 1. Execution of proposedSMPDC comprises of more than 60 production rules.wever, the system is flexible enough as its knowledge basebe updated and modified, if necessary, on the advancementtechnology and availability of new materials in future havingperformance than recommended by the proposed system.the modules of the proposed system are designed to beve in nature to enable the user to input the essentialmetal component data； and to displays the optimal deci-choices for the users benefit. The former is accomplishedflashing AutoCAD prompts to the user at appropriate stagesa consultation to feed data items. Messages or items ofare likewise flashed into the computer screen whenevervant production rules are fired. The system can be loaded bythe command (load “A: SMPDC.LSP”) in the promptof AutoCAD. The execution of the system is demonstrateda flow chart as shown in Fig. 1. The output of the pro-includes the intelligent advices for selection of materialsactive elements (i.e. punch and die/inserts) and inactive ele-(i.e. plate elements, guiding and locating elements) andhardness range of the material selected for active elementsprogressive die.Sample run of the proposed systemThe proposed system is implemented on PC (Pentium 4 CPU,GHz, 256 MB of RAM) with Autodesk AutoCAD 2004. Thefornents.obtainedligentgifoundtryIndia)Fig.nesssystem SMPDC.has been tested for different types of sheet metal partsthe problem of material selection for progressive die compo-Typical prompts, user responses and the recommendationsby the user during the execution of the proposed intel-system SMPDC for an example component (Fig. 2) areven in Table 3. The recommended materials by the system wereto be reasonably close to those actually used in indus-(Indo-Asian Fuse Gear Private Limited, Murthal, Haryana,for the example component.2. Example component (all dimensions in mm): Brass, sheet thick-= 0.6 mm.460 S. Kumar, R. Singh / Journal of Materials Processing Technology 182 (2007) 456461Table 3Typical prompts, user responses and expert advice generated during execution of the proposed intelligent system SMPDC for example componentPrompt Example data entry Advice to the user(Load “A: SMPDC.LSP”) Please enter command SMPDCSMPDC Welcome to the module SMPDC. Please enter command DIEMATDIEMATPleasePleasePleasePlease select(5660Please selectplateORplate:PleaseSELHRD4.selectiontionstagetobypreparedsheettotieenter sheet material Brassenter the type of operations Shearingenter shear strength of sheet material 15 kgf/mm2enter required production quantity ofsheet metal parts90,000 PleaseEN-311.2510)enter the category of inactiveelements (i.e. plate elements, locatingand guiding elements)Plate elements Please Top52100) Punch1.2510) Punch back Stripper plate: Die supportenter the category of inactive elements Guiding and locatingelementsPlease selectfollowing: Die gages1148) Die stops6150) Lifter (RaNr.1.2379, JIS-SKD11) Guide pin Ball cage Sleeve (R Shank (Ra Dowel pins(AISI 1055)Please enterPlease enter the selected material of punchand die/insertsEN-31 (5660 HRC) Typical analysisand P each =Please enter sheet thickness (mm) 0.6Please enter the geometry of blanked part(i.e. simple/normal/complicated)NormalPlease enter the difference of upper limitand lower limit of hardness (HRC) ofselected material4.0 Use lower limitUse upper limitConclusionThe proposed system is capable of giving expert advice onof materials for progressive die components and selec-of close hardness range of materials during the designof progressive dies. The user has been provided an optionselect easily available materials from the advice receivedthe proposed system and then a bill of materials can besuitably. The system has been tested for variety ofmetal components and proved to be powerful and easyhandle because of its rich knowledge base and highly interac-ve nature. The sample run of the system using an industrialxample component has demonstrated the usefulness of thesystem.knotheogycanwithinindustries.Refer1an easily available material for punch and die/inserts from the following:HRC) (AISI 52100) OR UHB-ARNE (5462 HRC) (AISI O1, W.-Nr.an easily available material for plate elements from the following:and bottom plate: Mild steel OR UHB-11 (AISI 1148) OR EN-31 (AISIUHB-FORMAX (W. Nr.-10050, SS-2172) OR EN-8 (AISI 1040)Mild steel OR EN-8 (AISI 1040) OR UHB-ARNE (AISI O1, W.-Nr.plate: EN-31 (AISI 52100) OR UHB-ARNE (AISI O1, W.-Nr. 1.2510)EN-31 (AISI 52100) OR UHB-11 (AISI 1148)plate: EN-31 (AISI 52100)an easily available material for guiding and locating elements from the(Ra= 0.10.4H9262m) (4850 HRC): EN-31 (AISI 52100) OR UHB-11 (AISI(Ra= 0.10.4H9262m) (4246 HRC): EN-31 (AISI 52100) OR EN-47 (AISI= 0.10.4H9262m) (5255 HRC): HCHCr OR SEVERKER-21 (AISI D2, W.-OR H.S.S.and guide piller pin (Ra= 0.10.4H9262m) (5052 HRC): EN-353(Ra= 0.0250.05H9262m): Aluminium OR Brass OR plasticsa= 0.10.4H9262m): EN-31 (AISI 52100)= 0.83.2H9262m): Mild steel(Ra= 0.83.2H9262m) (5052 HRC): C-40 OR EN-8 (AISI 1040) OR EN-9OR Silver steelcommand SELHRDof EN-31: C = 0.90/1.2, Si = 0.10/0.35, Mn = 0.30/0.75, Cr = 1.0/1.6, S0.025 (maximum)of hardness = upper limit of hardness of selected material-2.0, andof hardness same as the upper limit of hardness of selected materialThe system supports mainly tool steels, however, itswledge base can be modified and updated