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汽车
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汽车制造工艺及经济性探究,汽车,制造,工艺,经济,探究
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密 级分类号编 号成 绩本科生毕业设计 (论文)外 文 翻 译原 文 标 题Automobile manufacture stamping process Of new development译 文 标 题 汽车制造中冲压工艺的新发展作者所在系别机电工程学院作者所在专业车辆工程作者所在班级B13142作 者 姓 名余豪作 者 学 号201322194指导教师姓名臧继嵩指导教师职称讲师完 成 时 间2017年4月北华航天工业学院教务处制译文标题汽车制造工艺的发展原文标题Automobile manufacture stamping process Of new development作 者Tony译 名托尼国 籍美国原文出处WMEM摘要：汽车制造的整体规模和复杂性，迫使人们要经常地与降低成本、提高产品质量、满足政府对安全和环境日益严格的要求问题打交道，并要能适应款式设计和工具每年的变化。根据这些变化因素，汽车制造商要不断寻找最快素，经济的方法，来设计和制造轿车与卡车。关键词： 制造工艺 要求 发展历史 冲压工艺汽车制造工艺的发展 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调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。減少冲压过程的工序数,意味着減少冲压件数、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。空气阻力減少,又可減少冲压件数量及焊点,能有效地降低成本。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,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也表性。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換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,还同时在工件西面冲压加工,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 。 整个系统的编程可在windows用户界面和菜単下实现,编程涉及模具沿者横向定位納的何服驱动定位,带材的检验矫正及纵向进给定位, 冲模的质量跟踪检验, 冲模的调整及状况监控等多功能 。当冲模重新配置成更換时,这些变化则会被参数并被控制系统所贮存, 以务下次査询和调用 。 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。 l毫米冲压是指汽车车身冲压件的精度控制在 0-1. OMM 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“2MM工程都是90年代后期美国汽车界可-展的大型研究项目 。所谓“2MM工程就是把车身装配尺寸变动量控制在2MM之内, 大大严于原先的8MM工程 。冲压加工成形技术是影口向汽车车身制造水平的关键因素之一 , 美国专家曽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, 冲压本身尺寸造成的不累积误差占 23%, 其主要原因是传统的基于经验和原有工艺基石出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西个目标, 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产准备吋间达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拉、 全系统集成4个子项目 。通过亚毫米冲压项日的研究, 使冲压成形技术有了跳跃性的进展, 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;(4) 实现了过程监测和设备维护被动响应向科学预测式转变。 “2MM 工程和“亚毫米、冲压两项目现已先后完成,正在美国三大汽车制造公司推广应用,取得了许多有益的成果,冲压成本大幅下降, 获得日益増长的经济效益的社会效益, 并逐步向其他国家推广应用 。特种冲压成形技术现代汽车冲压件的技术要求朝着结构复杂、 分块尺寸增大、 相关边的零部件较多、 承载能力变大和内应力限制严格等方向发展 。 这要求并促进特种冲压成形技术如液压成形、 精密成形、 爆炸成形、旋压成形、无模成形、激光成形和电磁成形技术的发展。限于本文常幅,这里主要介绍内压成形和电磁成形两项技术。液压式或注入弹性体式的成形技术, 其高压形成过程一般包括:(1) 有效介质如冰的膨胀或弹性体压入使内部压罚极慢增长的过程;(2) 流体静罚的骨高压形成过程;(3)极端压力如爆炸的动态过程等。介质可以是无定形的固体、液体或气体,在系统中介质可依据要加工的形状作任意变化, 履行凸模功能, 所以介质可等同于一个万能模具 。液压式内高压成形技术与其他冲压成形技术相比, 有几项明显优点:(1)在成形过程中可一次加工出如车桥、 顶盖板、 门框等大型复杂的三维几何形状的工件,(2)因为液体在成形过程中冷却作用,使工件被“冷作强化” ,获得比一般冲压加工更高的工件强度,这使得允许采用更薄的板材,使工件更轻量化;(3)工件外表板面只与压力液体接触,加压过程较平缓,零部件成形变化均匀,可获得匀称的压力分布, 并能获得者好得多的平滑外表面;(4)液压内盛开有的冲模和工具费用可下降40%,特别降低了凸型零件加工的节拍时间较短, 约为0.1-0.5Min,这在特种成形工艺中是较短的,可实现批量生产。利用通电线圈产生的电磁力的电磁成形工艺, 是目前颇有前途的另一种新型加工手段。 该工艺源于六十年代核裂变研究的成果, 但可惜一直没被人们注重 。 电磁成形工艺原理图, 当线圈通入交流电时。数微秒内建立起磁场,使金属工件尤其是导电率强的铜铝材,质感生出电流 ,感生出电流, 感生电流又将受到磁场力作用, 使工件产生张力与凹模吻合迅速成形。 当线圈在工件内时, 电磁力将使工件外张成形, 属当前应用较广泛的一种工艺; 当线圈平面平行于板件放置时, 电磁力将使工件拉伸成形。电磁成形技术系一种非接触成形工艺, 其実出优点一是加工成形迅速工效高, 二是常用于金属与非金属的连接, 可取代粘接或焊接: 其三是不耗脯助材料如润滑油脂等, 有利环境保护 。冲压过程自动监控现代冲压技术的另一个重要特点是对冲压过程进行自动监控以保护冲压件的质量 。 在亚毫米冲压项目的自动检测和监控中,其研究成果就包括有: 1.冲压过程的特征分析在线传诊断和检测系统; 2.高速和非接触的冲压件测量系统; 3.冲模维护的科学预测系统; 4.沖压成形关键参数的在线调节和补偿系统等。冲压过程引起工件质量发生变化的原因主要有凹凸冲模的磨损、 製纹及冲模错位等, 这些微小变化可由高分辩率的位移转感器和冲压力转感器进行跟踪检测 。 其中位移测量是极重要的一种测量, 该装置通常由安装在模具上方的关源和位于下方的接收单元构成, 可监视偏差、 跟踪加工全过程、 及时输出监测信息和进行报警停机 。一种在线冲压的图形处理系统, 是保证冲压工件质量的有效测试方法, 它能进行二维几何图形的标准检测,其项目有长度、直径、平行度、角位、冲压板材结构及识别废品等。图形处理系统是由象仪、光学仪和照明装置等组成,标准的 CCD象仪的珊格分辩率为750X580条珊格,水平方向每珊格为 0.026mm,垂直方向精度为 0.009mm/珊格。监视系统使用的位移及角度传感器有光学式及电学式二种, 前者有激光测试技术和模似光珊技术支持; 后者有电感流式及介质电容式, 它们的测试精度分辩率都可达到 1-10um级的水平 。 最适用冲压技术的转感器安装方案是把多种转感器集中装于一块传感器板上,再把它精确地固定在模具接口处, 即冲头夹紧板上, 利用传感数据监控冲压全过程, 并通过控制器得到及时处理, 保证冲压件的质量。全屏阅读 关闭全屏阅读 你的评分：有道翻译中国最大最稳定的免费在线翻译 添加书签 Automobile manufacture stamping process Of new developmentAutomobile manufilcture has a60_70% of metalparts mustbe approved by the plastic processing forming，stamping process is complete meta1 plastic forming a kind of important ans，it is the most basic， the most traditiona1, the most importantone ofrr1etal processing method, Such as vehicle body a11 kinds ofcovering parts, car support pieces，structure strengthen pieces， theres plenty of auto parts， such as engine exhaust muffler， ho11ow tube bending and camshafi the oilpan， engine stents， fiame structure, horizonta1 1ongeron etc， it is by stamping techno1ogy positively precision，multi-fimction，high efficiency and energy saving，safe cleaning production direction，stamping workpiece manufiicturing technologyleveland quality, ingreat degree ofautornobile manufacturing quality and costhas direct impact.So-called starnping technology refers to the adaptability ofthe stamping to handicraft namely the design of stamping in size，size accuracy and benchmarks， structure shape starnping processing ofcornpliance with technobgica1 requirements. Autornotive stamping parts should be good techno1ogica1 characteristics， and the economy，measure theleve1 of the important symbo1 has starnping process number, body assemblies b1ock nucleer and size， staing structure， and other fictors. Reduce the number of punching process procedure， that means less stampingtooling quantity1， number of packages，save simplified punching process ofconveyors， Narrows the operators and shing 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 manufilcture cost， even?Modern stamping deve1opment and research of the major subjects include:(1) module type and control;stamping (2) new materia1 and composite stamping processing new craft; (3) special stamping techno1ogy;(4) computer simulation stamping mold testing technology; and virtua1(5) die& mold manufacturing technology，(6) stamping process of automatic nxmitoring 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， so1ongas 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. In a nutshe11， module type stamping water-holding points:(1)the stamping process can be rephced rapidly segment mold to improve production efficiency;(2) due to its st0 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 contro1 combination dies action can continua11y stamping processing;(5) dies with program mabte 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 1lieeding device, etc. The stamping system at run-time can undertake stamping transverse displacement, stripteeding positioning, die repeat operation andautomatic a1justment work step punching adjustrr1ent etc multiple functions. Because the stamping process program mable stamping， make this kind of module type stamping system can adapt production requirements， flexible in same strip on March different work piece and batch production, realizing mixed non-stop string&joint processing，also in two sides stamping work piece machining, which has greatly enhanced the work efficiency，have data show that the module type stamping makes processing cost canfil11 to40% - 50%.The current modute type stamping device in teglation is very high， in wid this 300MMsiz1e range can arrange of35 mold, through the rooftop of stamping die for independent We series ofcontro1，is formed namely die of integrated control The whole system programmable in WINDOWS user interface and under implementation programming involves mold abng the late ralpositioning shaft servo drive positioning，inspection correctionand1ongitudinal feeding positioning, stamping quality fo11ow_up inspection, punching machine; the adjustment and Condition monitor in gand versatility.When stamping reconfigure or alteration，these changes would be parameters and contro11ed system to store，next time query and invoke. Declarations Die data include the punch and their combination tags， punch cor1obination in X, Y of die and mold shaft Numbers coordinates and other information. Figure3 shows programmable punchingSystem，figure in A standard mold transverse axis，can undertake servo dynamic to stamping area, fir the sup porting shaft with punching die， C， D for spare axis to orange roll type with material are feeding.And submillimeter stamping projectAnd submi11imeter stamping rers 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 2MMcornpared，is a very big enhancement. This is an roving punching quality and manufiicturing technology as the goal of integrated project. The project with 2MM engineering are all in thelate1990s America QiCheJie conduct large-scale researchproject. So-ca11ed the car is 2MM engineering knowledge，body assembly size changeswithin 2MM quantity control greatly in strict in the origina1 8MM error range.Suing processing forming technology afliect auto body manufilcturing level is one of the key filctors， the American experts work edin a car assembly line to over50 casesfield analysis shows that，cause body size error change many reasons, stamping it self sizecaused by error accumulation23 percent, its main reason is that the traditional based on experience and origina1 technology based on bwleve1 of mold design and manufiicturing.And submi11imeter stamping is the center of precision stamping within creasing agility two goals, precision is to make the stamping size accuracy contro1 in 0 mm or and submil meter leve，the key is to control body stents， pillar on the pieces of the feet, andmake changes in body covering parts, such as partitioned degrees by whole left-right sideplate and the top cover plate， etc. Increasing agility meaning is refers to reduce stamping prajapati was preparation time up to30%, including tooling design, manufiicturing and tooling，sanple preparation time, in order to achieve greatly short en the purpose of gv4 the new models manufacturing cycle， this project diet are die-cutting and assembly integration design，stamping system agile design and manuficturing，stamping process of intelligent detecting and monitoring， who system integration four subsystems project.Through a study of the program and submilli meter stamping, stamping technology has witnessed progress, including:(1) the stamping process and concent 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 traditiona1 attempt method，(3) to implement the mould design manufacture seria1 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 submi1imeter 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 socia1 benefit， andgradua1ly applied to other countries.Specia1 staring technologyModern automotive stamping technology requirements towards structure is complex，1ock size increases, related edge parts more, carrying capacity is large and internal limit strictly etc direction. This requirement and promote specia1 stamping technology such as hydraulic pressure forming, precision forming，exp1osive forming and spinning orming, no die forming，laser 1forming and electromagnetic orming techno1ogy deve1opment. Limited to this paper length, here basically introduces pressure inside the 1forl-nl1ig and electromagnetic forming two techno1ogies.Modern automotive stamping technology requirements towards structure is complexb1ock size increases，related edge parts more，carrying capacity is large and internal limit strictly etc direction This requirement and promote specia1 stamping technology such as hydraulic pressure forming, precision floring， explosive forming and spinning forming，no die forming, laser lioring and electromagnetic forming techno1ogy development. Limited to this paper length, here basically introduces pressure inside the iorming and electromagnetic forming two techno1ogies.The hydraulic or injection of the forming techno1ogy of elastic postures， its high-pressure forming process generally includes:(1) effective media such as ice expansion is cm make the internal pressure pressedinto the penalty extremely s1ow growthprocess，(2)fluid static penalty bone high_pressure forming process，(3) extreme pressure as an exp1osion 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, fulfi1l the punch fimction，so medium can be equated to a universal mold. Figure is phsuper shobachthe example，forming from the graph visible at effective media becomes the punch.The hydraulic interna1 high-pressure forming techno1ogy compared with other sta11nping techno1ogy， there are severa1 obvious advantages:(1) the forming process can one processing out like axle， top cover， door case and other large and cornplex3d geometric shapes of work piece，(2) because of liqudin the forming process cooling effect， make the work piece is acotd strengthening， won than ordinary stamping work piece machining higher strength this makes a11owinga thinner plank， to make the work more light weighting;(3) workpiece surface appearance only with pressureliquid contact, pressure is gentle，parts forming process changes，canobtain the symmetry of uniformpressure distributionand can winner muchbetter smooth outside surfilce，(4)in stamping and bbom some hydraulic tool charge canreduce40%, specia1 reduced convexparts 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 coi1 electromagnetic forming process，is the present quite promising another new processing method. This process fi:om 1960s nuclear fission research achievement，but un1fortunately has not been people attention. Electromagnetic forming technology princple diagram，when the coil access to electricity. Few microseconds inside establish electromagnetic field， so the rreta1 work pieces especially conductivity strong copper aluminum texture produce electriccurrent, a current，induced culent induced by magnetic orce and efliect，make the work piece create tension and dies.the anastomosis and rapid forming. When the coilinthe workp11ecein electromagnetic force will make work piece outside of the current applicatiozhang forming widespread a kind of technology, When the coilplanar para11e1 to the boardpieceis placed, electromagnetic force wi1l make workpiece stretch forming.Electromagnetic forming techno1ogy is a non-contact forming process,and itsoutstanding merits are shaping a rapid high efficiency， 2 it is ofien used inmeta1or nonmeta1 connection，can replace adhesive or welding， A third is not consun1ption lymphocy help materials such aslubri cating grease，etc， the advantageous environmentprotection.Suing process automatic monitoringModern scramjet another important feature is for punching process automaticrmnitoring to protect the stamping quality. In the mmstaing project automatic detection and rronitoring，its research results willinclude: 1. The stampingprocess characteristics of online preach diagnosis and detection system, 2. High speed and non_contact measuring system; the stamping3. Die maintenance scientific prediction system; 4. Stamping key parameters online adjust and compensation system, etc.Stampingprocess changes caused by workpiece quality is mainly caused by the wea
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