φ2500圆盘给料机的设计【连续式容积加料设备】【说明书+CAD】
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Recent achievements in computer aided process planning and numerical modelling of sheet metal forming processes M. Tisza* Manufacturing and processing AbstractPurpose: of this paper: During the recent 10-15 years, Computer Aided Process Planning and Die Design evolved as one of the most important engineering tools in sheet metal forming, particularly in the automotive industry. This emerging role is strongly emphasized by the rapid development of Finite Element Modelling, as well. The purpose of this paper is to give a general overview about the recent achievements in this very important field of sheet metal forming and to introduce some special results in this development activity.Design/methodology/approach: Concerning the CAE activities in sheet metal forming, there are two main approaches: one of them may be regarded as knowledge based process planning, whilst the other as simulation based process planning. The author attempts to integrate these two separate developments in knowledge and simulation based approach by linking commercial CAD and FEM systems.Findings: Applying the above approach a more powerful and efficient process planning and die design solution can be achieved radically reducing the time and cost of product development cycle and improving product quality.Research limitations/implications: Due to the different modelling approaches in CAD and FEM systems, the biggest challenge is to enhance the robustness of data exchange capabilities between various systems to provide an even more streamlined information flow.Practical implications: The proposed integrated solutions have great practical importance to improve the global competitiveness of sheet metal forming in the very important segment of industry.Originality/value: The concept described in this paper may have specific value both for process planning and die design engineers.Keywords: Analysis and modelling; Knowledge and simulation based systems1. Introduction In the recent years, the role and importance of metal forming processes in manufacturing industry have been continuously increasing primarily due to its material- and cost-effective nature. It is further emphasised by the recent advances in tools, materials and design, which in turn provide significant improvements in the mechanical properties and tolerances of the products. It is also characteristic for metal forming processes that the final shape of the component cannot be produced generally by a single operation, but more often several operations should be performed to transform the initial simple geometry into a more complex product. Moreover, in the recent years metal forming develops in the direction of net-shape or near-net-shape manufacturing to reduce the need for subsequent machining operations and to minimise the total manufacturing represent very important and complex tasks. The global competition also requires that manufacturing industry besides the skill and the experience accumulated in the shop practice should increasingly utilise proven techniques of Computer Aided Engineering for rapid and cost effective process design and tool manufacturing. The application of various methods of Computer Aided Engineering has become one of the most important topics in manufacturing industries and particularly in the automotive industry. The application of various CAE techniques practically covers the full product development cycle from the conceptual product design through the process planning and die design up to the manufacturing phase of the production. CAE techniques are widely used in sheet metal forming, for example to predict the formability, to determine the type and sequences of manufacturing processes and their parameters, to design forming tools, etc. The importance of the application of CAE tools becoming more and more important as the manufactured parts are becoming ever increasingly complex. As the need for the widespread application of CAE techniques driven by the demand of global competitiveness accelerates, the need for a robust and streamlined Process and Die Design Engineering (PDDE) becomes more and more crucial. Recently, there are two main approaches to achieve these goals. One of them is the application of knowledge-based expert systems, which are generally based on simplified plasticity theory and empirical technological rules. There are a great number of papers dealing with the exclusive use of knowledge-based systems both in sheet and bulk metal forming 1-3. However, the exclusively knowledge based solutions have certain disadvantages: they usually cannot provide an enough accurate solution to the problem since these systems are generally based on simple technological rules with limited validity. Therefore knowledge-based systems cannot predict for example the material flow, and usually cannot provide the accurate stress and strain distribution inside the component. As another approach, numerical techniques (recently mainly finite element modelling) are applied for the analysis of the plastic deformation 4-6. The main objectives of the application of numerical process simulation in metal forming are to determine appropriate process parameters and to develop adequate die design by process simulation, to improve part quality by predicting process limits and preventing flow induced defects. Besides these, numerical process simulation also leads to reducing process and die try-out, as well as shorter lead times, while significantly reducing manufacturing costs. But the exclusive use of numerical modelling like it is the case in the exclusive use of knowledge-based systems has also some drawbacks, too. In spite of the enormous development of hardware and software facilities, the reliability of results is often dependent on the experiences of the user. It is partly due to the large number of operating parameters whose influence should be investigated, and partly due to the numerical difficulties caused by the complexity of the applied mathematical model to describe the material behaviour. Therefore, in the recent years the integration of these two fields (i.e. the knowledge-based systems and numerical modelling) has gained primary importance 7. 2. Process planning and die-design in sheet metal One of the main drawbacks in industrial practice hindering the even more wide application of simulation techniques that the output results of simulation packages are not usually directly and easily usable for computer aided die design. Obviously, there are tremendous efforts to successfully link CAD and FEM systems, however, still there are a lot to do in this field 8. This solution requires a fully integrated approach of computer aided product design, process planning and die design, as well as the finite element simulation of the forming processes. It means that simulation tools should be efficiently used throughout the whole product development cycle 9. This concept will be illustrated through the examples of automotive part production. In our practice, we use Unigraphics NX 4 as a commercial CAD system for supporting the Computer Aided Process Planning and Die Design tasks and the AutoForm 4.05 and PAM-STAMP 2G are used as the numerical simulation tools, however, the principles applied here can be similarly adopted by using different CAD and simulation packages, too. Before analysing this integrated solution, lets summarize the main features of forming process planning and die design in so-called conventional CAD environment .2.1Process planning and die-design in conventional CAD environmentStamping industry applies CAD techniques both in the process planning and die design already for many years. However, in a traditional” CAD environment, these are practically stand-alone solutions, i.e. for example a knowledge based process planning solution is applied for the determination of the necessary types of forming processes, even in some cases, the forming sequences can be determined in this way together with the appropriate process paramteres, too. After determining the process sequences and process parameters, the forming dies are designed using sophisticated CAD systems, however, still we do not have any evidence whether the designed tools will provide the components with the prescribed properties. Therefore, before it goes to the production line, usually a time- and cost consuming try-out phase follows, as it is shown in Fig.1 If the try-out is successful, i.e. the die produces parts with no stamping defects, it will be sent to the stamping plant for production. On the other hand, if splitting or wrinkling occur during the tryout, the die set needs to be reworked. It means that we have to return first to rework the die construction by changing the critical die parameters (e.g. die radii, drawing gap, etc.). If it does not solve the problem, a new die design, or a new process planning is required. Some cases, we have to go back even to the product design stage to modify the product parameters. The more we go back the higher the development and design costs are. Occasionally, the die set is scraped and a perfectly new product-, process- and die design is needed. As a result, die manufacturing time is increased as well as the cost of die making. 3. Process planning and die-design in sheet metalSimulation and Knowledge Based Systems An Integrated ApproachAs it was mentioned before, this solution will be described through the example of an automotive sheet metal component using the Unigraphics NX (version 4.0) as the CAD system, and the AutoForm 4.05 as the FEM package, however, the principles applied here, can be adopted to other programs as well 10. The selection of these two program packages can be explained by several reasons. On the one hand, both the Unigraphics and the AutoForm are among the most widely applied packages in the automotive industry in the World. On the other hand, these two systems are among the first to offer a special interface module to enhance the information and data exchange between CAD modelling and FEM simulations in both directions making possible the most efficient integration during the whole product development cycle. In the forthcoming sections, this solution will be described in detail following the road map of this simulation-guided process planning and die design procedure. 3.1.Geometric modelling of the sheet metal componentThe CAD model of the component created by the product design engineer is shown in Fig.3. As it often happens in the automotive industry, the component has a symmetric counterpart (so-called left and right handed or double attached parts). The part model is created in Unigrapics NX 4.0 CAD system as a solid model. However, FEM systems dedicated for sheet metal forming usually require surface models. Therefore, before exporting the part model a surface model should be created. This function is well-supported in most CAD systems. Depending on the simulation requirements, even we can decide which surface (top, middle or bottom) will be exported into the surface model. 3.2.Feasibility of the component formabilityIn most cases, process planning engineers would like to know right at the beginning whether the component can be manufactured with the planned formability operations. Therefore, after importing the surface model of the component with the AutoForm input generator, first a fast feasibility study should be performed. The AutoForm has an extremely well suited module for this purpose: in the so-called One-Step simulation module, this formability analysis can be done even if we do not have any or just very few information on the forming tools. Using this One-Step simulation procedure, a quick decision can be made if any modification of the part is required. Besides the part formability validation in this very early stage of product development, further important possibilities are also offered in this module including the analysis of slight part modifications, studying alternative material types and grade, or various thicknesses, material cost estimation and optimization, etc. If this feasibility study is successful as shown for example for this component in Fig.4, the work of process planning engineer can be efficiently supported by determining the optimum blank shape and sizes. 4. ConclusionsComputer aided engineering has a vital and central role in the recent developments in sheet metal forming concerning the whole product development cycle. The application of various methods and techniques of CAE activities resulted in significant developments: the formerly trial-and-error based workshop practice has been continuously transformed into a science-based and technology driven engineering solution. In this paper, an integrated approach for the application of knowledge based systems and finite element simulation is introduced. Applying this knowledge and simulation based concept for the whole product development cycle from the conceptual design through the process planning and die design as an integrated CAE tool provides significant advantages both in the design and in the manufacturing phase. Sheet metal forming simulation results today are already reliable and accurate enough that even tryout tools and the time consuming tryout processes may be eliminated or at least significantly reduced. Thus, the integrated solution described in this paper results in significantly shorter lead times, better product quality and as a consequence more cost-effective design and production.AcknowledgementsThis research work was jointly financed by the Hungarian Academy of Sciences (MTA) and the National Science Foundation (Ref. No.: OTKA NI 61724). This financial support is gratefully acknowledged. References1 S.K. Sitaraman, T. Altan, A Knowledge Based System for Process Sequence Design in Sheet Metal Forming, Journal of Materials Processing and Technology (1991) 247-271. 2 N. Alberti, L. Cannizaro, F. Micari, Knowledge Based Systems and FE Simulations in Metal Forming Processes, Annals of CIRP 40 (1991) 295-298. 3 L. Eshelby, M. Barash, W. Johnson, A Rule Based Modelling for Planning Axisymmetric Deep-drawing, Journal of Mechanics Sciences (1988) 1-113. 4 A. Makinouchi, Sheet Metal Forming Simulation, Journal of Materials Processing and Technology 60 (1996) 19-26. 5 A.E. Tekkaya, State of the art of Simulation in Sheet Metal Forming, Journal of Materials Processing and Technology 103 (2000) 14-22. 6 T. Altan et al., Simulation of Metal Forming Processes, Proceedings of the 6th International Conference ICTP, Nuremberg, 1999, 23. 7 M. Tisza, Numerical Modelling and Knowledge Based Systems in Metal Forming, Advanced Technology of Plasticity 1 (1999) 145-154. 8 A. Andersson, Information Exchange within Tool Design and Sheet Metal Forming, Journal of Engineering Design 12 (2001) 283-291. 9 A. Andersson, Comparison of Sheet Metal Forming Simulation and Try-out Tools in Design of Forming Tools, Journal of Engineering Design15 (2004) 551-561. 10 M. Tisza, Numerical Modelling and Simulation: Academic and Industrial Perspectives, Materials Science Forum 473-474 (2005) 407-414. 近年来计算机辅助工艺规划和板料成形数值模拟过程米蒂萨河*制造和加工摘要目的：本文：在最近的10 - 15年，计算机辅助工艺设计及模具设计的进化成为其中一个最重要的工程工具板料成形过程中，特别是在汽车工业。这一新兴的角色是强烈的迅速发展，强调了有限元模型。本文的目的是给出一个概述，关于近年来所取得的成就在非常重要的板料成形领域，介绍一些在这个发展活动中的特殊结果。设计/方法/途径:对板料成形CAE活动，主要有两种方法：其中一个可能被看作是基于知识的工艺设计，而另一个基础工艺规划为仿真。作者试图通过商业CAD系统和有限元方法整合这两个独立发展的基础知识和仿真方法。结果：应用上述方法一个更强大、更高效的工艺设计及模具设计的解决方案可能达到彻底降低芯片制造时间和费用，降低产品开发周期，提高产品质量的效果。研究局限性/含义：由于有限元方法和CAD系统不同的造型方法,最大的挑战是提高数据交换能力较强的鲁棒性之间的不同系统以提供一个更精简的信息流动。实际应用：该综合解决方案对于提高板料成形过程中很重要的工业环节的全球竞争力有重要的现实意义。创意/价值：本文中介绍的概念对于工艺设计及模具设计工程师都可能有特定价值。关键词：分析和模型；基于知识和仿真系统。1. 介绍近年来成型过程的作用与重要性在制造业中不断增加，主要由于其材料和精打细算的性质。这是进一步强调了近年来的工具、材料和设计，从而提供显著的改善力学性能及公差的产品。它也是对金属板料成形特点中最后形成的组件不能由一般生产的一次手术，但是更常见的几种手术应把初始简单的几何变换成一个更复杂的产品。此外，近年来在金属成形的方向发展分析钣制带轮近净减少或制备生产需要后续加工操作，并尽量避免妨碍总生产成本。因此，金属成形工艺设计和工具设计代表了一个非常重要且复杂的任务。全球竞争也需要制造业，除了在商店实践的技能和经验积累，也应该越来越利用电脑辅助工程实践技术的快速和低成本的工艺设计和工具制造。应用多种多样的计算机辅助工程已成为最重要的课题之一，特别是在制造业的汽车工业。各行各业的CAE技术应用几乎涵盖了从产品概念设计到工艺设计及模具设计到制造阶段的生产的全部产品开发周期。CAE技术广泛应用于板料成形，预测，确定型号序列参数和生产流程，设计成形模具，等。应用CAE技术对于制造日益复杂的工具零件的重要性越来越大。因为需要CAE技术的广泛应用来加速推动全球竞争力，需要一个良好的鲁棒性和流线型的过程和模具设计工程(PDDE)变得越来越重要。最近，有两个主要的方法来实现这些目标。其中一个是基于知识的专家系统的应用，这通常是基于简化塑性理论和实证技术规则。将会有非常大量的文件处理知识系统专用权都和大量的金属成形板材1 - 3。然而，专门为以知识为基础的解决方案有一定的缺点：他们通常无法提供足够精确的解决这个问题的方法，因为这些系统通常基于简单的技术规则和限制的有效性。因此知识系统无法预测例如物流，而且通常不能提供准确的应力和应变分布在组件。作为另一个方法，数值方法(主要是有限元模型)被广泛应用于分析塑性变形4 - 6。应用的主要目的数值模拟在金属成形过程中，确定合适的工艺参数和提供足够的模具设计过程仿真，提高产品的质量，防止被预测的工艺范围流激缺陷。除了这些，也会通过数值过程模拟减少工艺、模具选拔以及交货周期，同时大大降低制造成本。但独家使用数值模拟的研究就象它是这个案子独家使用知识系统，也有一些弊端，也具有一定的参考价值。尽管硬件和软件设施快速发展，其可靠性结果也往往取决于用户的经验。其中一部分是由于大量的操作参数的影响需进行调查,另一部分是由于应用数学模型描述材料的行为造成数值困难的复杂性。因此,在近年来的整合这两个领域（如知识系统和数值模拟）的研究已获得了重要进展7。2. 工艺设计和die-design金属片一个主要的缺点在工业实践阻碍更广泛应用仿真技术，输出结果的模拟软件包通常不直接和容易使用计算机辅助模具设计。显然，还要有巨大的努力去成功连接计算机辅助设计和有限元系统，但是，在这一领域仍然有很多事情需要做 8。这就需要一个完全集成的方法计算机辅助产品设计，工艺设计和模具设计，以及有限元模拟形成过程。这意味着仿真工具应该被有效的利用整个产品开发周期9。这一概念将通过实例的汽车零件生产。在实践中，我们使用Unigraphics NX的4作为商业CAD系统支持计算机辅助工艺设计及模具设计的任务、AutoForm 4.05和PAM-STAMP 2 G作为数值模拟工具，然而，采用的原则在这里同样可以通过使用不同的计算机辅助设计与仿真软件包。在分析这种综合的解决方案,让我们总结形成过程规划的主要特点及模具设计在所谓的传统CAD环境。2.1.传统CAD环境中的工艺设计及模具设计冲压行业应用计算机辅助设计技术在工艺设计和模具设计已经很多年了。然而，在传统的环境，这些几乎是独立的解决方案，即例如基于知识的工艺规划的解决方案是用于确定必要的类型的形成过程中，甚至在某些情况下，形成序列也可以用这种方法连同适当的过程paramteres。在确定过程中的序列和工艺参数，成形模具的设计采用了先进的计算机辅助设计系统，然而，我们仍然没有任何证据是否设计的工具将提供部分规定的特性。因此，在它的生产线，通常是一个时间和成本消耗，试行阶段如下，显示图1。如果试验是成功的，即模具生产零件没有冲压缺陷，它将被发送到冲压厂生产。另一方面，如果分裂或起皱发生在试模，模具需要重做。这意味着我们必须返回第一返工的模具结构改变的关键参数（如模具模具半径，模具间隙，等。）。
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