先进材料及其制造技术培养方案

MODEL1What’sthedefinitionofCAD?CADisanadvancedinformationhandlingtechnologytosolvedesignproblemsforengineers.CADcombinespeople’sabilitiesofdeducingandcreationwithcomputer’sfunctionsofprocessingandinformationstorageWhat’sthehistoricaldevelopmentofCAD?(1)2DDrawingand3DWireframemodelingin1960s(2)Surfacemodelingin1970s;(3)Solidmodelingin1980s;(4)Parameterizedandvariablemodelingin1990s.Whatarethethreemethodsofproductdesigninclude?Pleasegivetheircharacterizes.RoutineDesign（常规设计）:onlychangingsomeparametersInnovativeDesign（革新设计）:changingsomepartsCreativeDesign（创新设计）:developinganewproductPleasegivethephasesthatproductdesignprocessisdividedinto.DemandAnalysis→ConceptualDesign→DetailDesign→ProductionPlanningWhatarethethreephasesofconceptualdesign?Generate、Value、SelectWhatarethefunctionsofCAD?(1)Geometrymodeling(2)Designreviewandanalysis(3)Dynamicimitating(4)DesigndocumentationWhatarethethreemethodsofgeometrymodeling?Andgivethedisadvantageofeachmethod.WireframeModeling:(1)Unabletoexpresscurvemodels(2)AmultivocalmodelSurfaceModeling:(1)Onlysuitableforshell;(2)Noinformationaboutsolidorhollow,insideoroutside;(3)Noinformationaboutqualityandvolume;(4)Unsuitableforanalysis.SolidModeling:(1)Lackofengineeringinformation(tolerance,roughness,material);(2)Can’trealizeintegrationofCAD/CAM.Whatarethepopularmethodsofsolidmodeling?①Constructivesolidgeometry(CSG)②SweeprepresentationHowdoesFEAwork?AndwhichparametersdoesFEAdemand?Breakinganobjectupintomanysmallrectangularortriangularelements;Analyzingtheresponseofeachfiniteelementtothestress,heat,orotherforce;Combiningallelementsandpredictingthereactionofthewholeobject.MODEL2Basicconcepts：1、theconcepts,componentsandcharacteristicsofNC,NC,CNC,MCU,DPU,CLUandMC①NumericalControlAsysteminwhichactionsarecontrolledbythedirectinsertionofnumericaldataatsomepoint.Thesystemmustautomaticallyinterpretatleastsomeportionofthisdata.②DirectNumericalControl(DNC)DNCreferstoamanufacturingsystemthatusesacentralcomputertocontrolseveralmachinessimultaneously.SchematicofdirectnumericalcontrolOnekeyadvantageofDNC,istheabilitytoproduceandprintreportsthatprovidevaluableinformationtosystemmanagers.③computernumericalcontrolAnumericalcontrolsystemwhereinadedicated,storedprogramcomputerisusedtoperformsomeorallofthebasicnumericalcontrolfunctionsinaccordancewithcontrolprogramsstoredintheread-writememoryofthecomputer.”ACNCsystemconsistsofthreecomponents Thecontrolcomponent Theinputcomponent TheoutputcomponentAdventofComputerNumericalControlWithCNC,eachmachinetoolhasaPLCoramicrocomputerthatservesthesamepurpose.CNCissometimesreferredtoassoftwiredNC.AdvantageofCNC:allowthedatabasecreatedduringthedesignanddraftingofaparttobeusedinformulatingtheNCprogramtomakethepart.AlibraryofNCprogramscannowbecreatedandeasilystoredforreuse.MastercopiescanbemadeofaspecificNCprogramssothatitcanberevisedtocreateanewNCprogram.④Machine-controlunit(MCU)Readsthepartprogramandcontrolsthemachinetooloperation.⑤Thedataprocessingunit(DPU)aDPUconsistsofadatainputdeviceinclude:– Paper-tapereader– Data-reading– Decodingcircuitstodeterminetherequiredaxismovements⑥Thecontrolloopunit(CLU)ACLUconsistsofaninterpolator,position-controlloopsforallaxesofmotion,velocity-controlloops,decelerationandbacklashtake-upcircuits,andauxiliaryfunctioncontroldevices.⑦MC:definedasmultifunctionCNCmachineswithautomatictool-changingcapabilitiesandrotatingtoolmagazine2、theconcepts,componentsandcharacteristicsofFMSanditsflexibilityFMSDefinition：Aflexiblemanufacturingsystem(FMS)isanindividualmachineorgroupofmachinesservedbyanautomatedmaterialshandlingsystemthatiscomputercontrolledandhasatoolhandlingcapability.AFMShasfourmajorcomponents:Processequipment:Machinetools,assemblystations,inspectionstationandrobots,ControlSystem(Computercontrolledsystem)StorageanddistributionofpartsprogramsWorkflowcontrolandmonitoringProductioncontrolSystem/toolcontrol/monitoringAutomatedmaterialhandlingrobots,conveyors,RGV,AGVandAS/RSHumanoperators(criticalroles)ManufacturingSystemFeatures：①TransferLineMachinesdedicatedtohandleoneortwoproducttypesMaximumutilizationandhighproductionratesDirectlaborinvolvementisminimalLowunitcostofproduction②CNCMachinesHighlevelofflexibility.AnyjobcanbeprocessedwithintherangeofCNCmachineryLowutilizationandlowproductionrateUnitcostismuchhigher③FMSTruemid-volumemid-varietymanufacturingsystemsConsists:SeriesofflexiblemachineriesAutomatedmaterialhandlingsystemsAutomatedtoolchangerCoordinatemeasuringmachinesPartwashersAlltheequipmentsarecontrolledbyacentralcontrollerPermitsbothsequentialandrandomroutingofawidevarietyofpartsTosettletradeoffsbetweenproductionratsandflexibility.Mostmanufacturingsituationsrequiremediumproductionratestoproducemediumvolumeswithenoughflexibilitytoquicklyreconfigureforchangeofproduct.3、thelayoutofFMSanditsfeatures.Progressive(渐进的)Layout:BestforproducingavarietyofpartsClosedLoopLayout:PartscanskipstationsforflexibilityUsedforlargepartsizesBestforlongprocesstimesLadderLayout:PartscanbesenttoanymachineinanysequencePartsnotlimitedtoparticularpartfamiliesOpenFieldLayout:MostcomplexFMSlayoutIncludesseveralsupportstations4.thecomponents,classificationandapplicationofindustrialrobotsComponents：ThemanipulatoristheequivalentofthemachinetoolinCNC.Itconsistsofaseriesofsegments,jointedorslidingrelativetooneanother,thatperformstheworksuchasgraspingand/ormovingobjects.Themanipulatoriscomposedofthemainframe(thearmoftherobot),andthewrist.Thetools,calledtheend-effectors,areattachedtothewrist.Theend-effectorsperformaprescribed（规定的）taskordinarilydonebythehumanworker.Classification：Structurally,therobotcanbeclassifiedaccordingtothecoordinatesystemofthemainframe.Thetypesofcoordinatesystemsare:Cartesian笛卡尔coordinatemanipulator,whichconsistsofthreelinearaxes,Cylindricalcoordinatemanipulator,whichconsistsoftwolinearaxesandonerotaryaxis,Sphericalcoordinatemanipulatorwhichconsistsofonelinearandtworotaryaxes,Articulated（关节）orjointedrobotswhichconsistsofthreerotaryaxes,andGantryrobotSCARArobot.Applications： Loadingandunloading Spraypainting Welding Materialhandling Inspection MachineAssembly5、theconceptsandcharacteristicsofCIMS,MAP,TOP,IGES,STEP,GT,CAPP,MRP,MRPII①ComputerIntegratedManufacturing(CIM):Acomputerizedintegrationofallaspectsofdesign,materialselection,planning,manufacturing,production,qualityassurance,managementandmarketing.②ManufacturingAutomationProtocol(MAP)MAPisacommunicationsstandarddevelopedtopromotecompatibilityamongdifferentautomatedmanufacturingsystems.③TechnicalandOfficeProtocol(TOP)TOPisastandardthatwasdevelopedtopromoteintegrationamongbusinessandofficecomponents.④InitialGraphicsExchangeSpecification(IGES)IGESisdevelopedtopromotecommunicationbetweenCADDsystemsmanufacturedbydifferentvendorsandislimitedtotheproductandprocessdefinitioncomponentoftheCIMWheel.⑤StandardfortheExchangeofProductData(STEP)⑥GroupTechnology（GT）Therelationshipbetweensimilarpartsandpartsfamilies⑦Useofthecomputerinprocessplanningiscalledcomputer-aidedprocessplanning,orCAPP⑧MRP(materialrequirementsplanning)– involvesusingthebillofmaterial,productionschedule,andinventoryrecord,detailedscheduleoftherawmaterialsandcomponentsneededforajob⑨MRPII(Manufacturingresourcesplanning)– notonlydeterminethematerialrequirements,butalsoencompassfinancialtrackingandaccounting.KeyconceptsrelatingtoMRPIIinclude:1. independentanddependentdemand;2. Leadtimes;3. Common-useitemsComprehension1、theadvantagesanddisadvantagesoftheNC,CNC,DNC,FMS,industrialrobots,CIMSandsoon.2、therelationshipbetweentheNC,DNC,CNC,FMSandCIMS3、ThefeaturesandcomparasionoftheFMS,TRANSFERLINE，generalpurposemachines,FMCandsoon.4、TherelationshipbetweentheFM,FMC,FML,FMM,AGV,AS/RS,RGV,Conveyors,5、therelationshipbetweentheMRPandMRPII。MODEL3WhatisthedifferenceamongAJM,WJM,AWJM,AFMintheaspectofmachiningcapabilityandworkpiecematerial？machiningcapabilityandworkpiecematerial：①AJM：可以加工：Hardandbrittlemetals,alloys,andnonmetallic(非金属)materials(e.g.,germanium,silicon,glass,ceramics,andmica(云母))，especiallysuitableforthinsections.不能加工：Soft,resilientmaterials,suchasrubberandsomeplastics,resistthechippingactionandthusarenoteffectivelyprocessedbyAJM.②WJMUsedprimarilytocutandslitporousnonmetalsuchaswoodpaper,leather,foamandfood.ItcanalsostripinganddeburringWaterjetmachiningprovidesomni-directional（万向）cuttingcapabilitiesatveryhighspeedwitharesultingedgequalitythatisusuallysuperiortootherconventionalcuttingprocesses.③AWJMThecoherent,abrasivewaterjet’sthatexitstheAWJMnozzlehastheabilitytocutvariousmaterials,suchasmetal,rock,glass,ceramics,andcomposites,withgreatspeedanddependinguponthematerial,inthicknessofupto20cm.④AFMAbrasiveflowmachining(AFM)isafinishingprocessthatremovessmallquantitiesofmaterialsbyflowasemisolid,abrasive-ladenputtythroughoracrossaworkpiece.Thisabrasivemediacanbethoughtofasadeformablegrindingstonethatisextrudedacrossedgesorsurfacetodeburr,radius,polish,performminorsurfacemachining,orproducecompressiveresidualstresses.WhatkindsofmaterialsshouldbeusedasthetoolmaterialsandtheworkpiecematerialsinUSM?Toolmaterial：Toolmaterialshouldbetoughandductile.Lowcarbonsteelsandstainlesssteelsgivegoodperformance.Toolsareusually25mmlong;itssizeisequaltotheholesizeminustwicethesizeofabrasives.Massoftoolshouldbeminimumpossiblesothatitdoesnotabsorbtheultrasonicenergy.orkpiecematerials：Hardmaterialslikestainlesssteel,glass,ceramics,carbide,quartzandsemi-conductorscanbemachinedbythisprocess.Ithasbeenefficientlyappliedtomachineglass,ceramics,precisionmineralsstones,tungsten.BrittlematerialsBetweenworkpieceandtool,whichoneistheanodeinECM.workpieceisanodeInEDM,whatkindsofmaterialscanbeusedastheelectrode,workpieceandthedielectricsfluid?①electrodeCopper（铜）andbrass（黄铜）、Graphite（石墨）②workpieceelectricallyconductivematerials③dielectricsfluidThemostpopularfluidarehydrocarbonoil，siliconbasedoil,anddeionizedwater.WhatisthedifferencebetweenECMandEDM?ECM：ECMreliesontheprincipleofelectrolysis(电解)formaterialremoval..ECMremovalratewhichisindependentofmaterialhardness,isprimarilycontrolledbycurrentdensity.InECMprocess,ahigh-current,low-voltageDCpowersupplyisconnectedbetweenanelectricallyconductivetoolandworkpiece.Theshapedtoolisconnectedtothenegativepolarityandtheworkpieceisconnectedtothepositive.Aconductiveelectrolyteflowsthroughasmallgapthatismaintainedbetweenthetoolandtheworkpiece,thusprovidingthenecessarypathforelectrolysis。MainlyusedinDiesandglass-makingmolds,turbineandcompressorblades,Holes,Deburring。Currentdensityiscontrollednotonlybyamountofcurrentthatthepowersupplyisdelivering,butalsobythesizeifthegapbetweenthetoolandtheworkpieceEDM：Mechanicsofmaterialremoval-meltingandevaporationaidedbycavitationMedium-dielectricfluidToolmaterials-Cu,Brass,Cu-Walloy,Ag-Walloy,graphiteMODEL41、laserprocessingtechnology(1)Threedistinctcharacteristicsoflaserlight,①Monochromacity②SmallDivergence③Coherence(2)Laserprocessingmechanismsinmanufacturingapplications.VaporizationAblation(intheliquidstateandleavesthesurfaceatarelativelyhighvelocity)Absorptionandheating（Thereflection,absorption,conductionofthelightbytheworkpiecematerialwillaffecttheprocessing）(3)Thelasertypes,andactivemedium,radiationpowerforeachtypeoflaser.Solidstatelasers,lasingmaterialinsolidmatrix,suchasrubyorneodymiumGasstatelasers,lasingmaterialingasstatesuchas:HeNe,CO2.CO2lasersemitenergyinthefar–infrared,andareusedforcuttinghardmaterials.Liquidstatelasers,lasingmaterial:complexorganicdyes,suchasrhodamine6G(若丹明)，thelaseraretunableoverabroadrangeofwavelengths.Semiconductorlasers（Diodelasers）,lasermedia:electornicdevice,verysmallanduselowpower.(4)Examplesofmanufacturingapplicationsoflaserprocessingandthebenefitsbylas