薄板冲压件焊装夹具设计方法外文文献翻译、中英文翻译

PAGE29附录附录A英文文献OnWelding-InstallationFixturesDesignofSheetStampingAbstract:Duetoformingerrorandcomplianceofstamp-ing,thefixturedesignofsheetstampingassemblyisdifferentfromthefixturedesignofcommonmachiningcomponent.Inrecentyears,thenewprinciplesandalgorithmsoffixturedesignofsheetstampinghavebeendeveloped.Inthepaper,theconceptofshapeclosureandforceclosure,screwtheorywerefirstlyintroduced.Secondly,thedeterministiclocatingandtotalfixturingconditionswerederived.Thirdly,an“N-2-1”locatingprincipleandoptimaldesignmethodforsheetstampingweredescribed.Finally,thevaria-tionalmethodofrobustfixtureconfigurationdesignfor3-Dworkpieceswasdiscussed.Itcanbepredicatedthatthelocatingerrorcanbereducedbythismethod.KeyWords:Fixture;SheetStamping;OptimalDesign;Ro-BustDesignDuetoitshighproductivityandmaterialutilization,stampingiswidelyusedinautomobiles,aircraft,andvarioushouseholdappliancesmanufacturingindustry.Theweldingassemblyofstampingbecomesthekeyprocessofthoseproductsmanufacturing,becauseweldingfixturenotonlyaffectstheperformanceofproductivity,butalsoisdirectlyrelatedtothequalityoftheproduct.StatisticsfromtheU.S.autoindustryshowthat72%ofthebodymanufacturingerrorsarefromthepositionerrorofweldingfixture,sohowtoeffectivelyreduceandcontrolthepositioningerrorisessentialtoimprovetheweldingquality.Sheetstampingassemblyissignificantlydifferentfromgeneralmachining,whichnotonlymeetsthecommonrequirementsofprecisepositioning,butalsogivesfullconsiderationtotheeasydeformationofsheetmetalpartsandstampingmanufacturingcharacteristicsoflargedeviationstoadapttheproducts’qualityrequirements.Overthelastdecade,manyscholarsworkinginthedesignofsheetstampingassemblyhaveproposeddesigntheoriesandmethodsofsomenewsheetstampingassembly,andachievedremarkableresults.Atfirst,thispaperintroducestheresearchprogressoffixturedesign,andthensystematicallyelaboratestheN-2-1locatingprincipleoffixtureandthemethodsofoptimaldesignandrobustdesign,finallymakestheconclusion.

Manufacturingprocess(suchasmachining,welding,assemblyandtesting,etc.),thefixtureisusedinthree-dimensionalpositioningandclampingdevice.Thecentralproblemoffixturedesignistochoosetheoptimalpositioningpointsanddeterminetheirbestpositiontoachievethedetermineconstraintspositioningofworkpiece.Iftheworkpiececanbefullrestrictiondependingonthegeometryofcontactareawill,wecalledit"shapeclosed";Ifitalsohavetobefullyboundwithfriction,wecalledit"forceclosure."Generally,shapeclosurestressesdynamicanalysis,butforceclosurefocusesontheworkpieceofstaticstability.In1885,Reuleauxfirststudiedthemechanismoftwo-dimensionalobjects’shapeclosure,andprovedthattheformationoftwo-dimensionalobjects’shapeclosureneedfouranchorpoints[2].AfterthatSomoffprovedtheformationofthree-dimensionalobjects’shapeclosureneedsevenanchorpoints.In1978,Lakshminarayana[3]furtherprovedtheformationofthree-dimensionalobjects’shapeclosureneedatleastsevenanchorpointsintheperspectiveofstaticequilibriumusingalgebraictheoryIn1988,Nguyenresearchedthemechanismofthemachinehand’sforceclosure[4],andin1989AsadaandKitagawa[5]researchedthemachinehand’sshapeclosurewhichusedforconvexandconcavepartsGenerallysixpositioningprinciplesrequiresclampingforcetomakeworkpiecefullyconstrained,sousuallyitisforceclosure.Overthelastdecade,the"spiraltheory”widelyusedinfixturedesign,whichdescribesthethree-dimensionalmotionastranslatingalongonedirectionandrotatingaroundthisaxis.OriginallyspiraltheoryproposedbyBall[6],anddevelopedbyliterature[7]and[8].Accordingtospiraltheory,literature[9]studiedsevendifferenttypesoffingercontact,andsuggestedusingfinger-likeshapetocompletelyfixobjects.Literature[10]usingtheextendedspiraltheoryanalyzedthatrigidbody’sfullorpartrestrictionexistfrictionalclamp.Literature[11]proposedmathematicaltheoryoffixture’sautomaticlayoutforprismaticworkpieces.Literature[12]discussedtheabilityofdifferentfixturespositioncontactpreventingworkpiecesfromspiralmovement,andproposedarestrictmethodofworkpiecemovementforthefixturedesign.Usingsmallspiralmodelliterature[13]discussedthepositioningerrorsoffixtureimpactworkpieces’geometryaccuracy.Literature[14]researchedsurfacecontactandfrictionproblemsintheanalysisoffixturerestriction.Consideringdynamicconstraints,completelyclamping,andtoolpatherrors,literature[15]developedfixturedesignandanalysissoftware.Itcanbesaidthatspiraltheoryoffixturedesignhasbeenusedfordeterminingposition,fullclamping,contacttype,andfrictionproblemsandachievedremarkableresults.Lotsofliteraturesfocusonthefixturedesignofrigidpieces,butthefixturedesignofflexiblesheetpiecesisrarelyinvolved,especiallyconsideringthedeformationoftheworkpieceunderprocessingloadsisalmostnone.Infact,asintheaviationindustryandtheautomotiveindustry,thedeformationofsheetmayresultinseriousbias.Foreasilydeformedsheet,positioningfixturenotonlyhasbasicfunctionsthatlimitingrigidbodymotion,butalsomustbeabletolimitexcessivedeformationoftheworkpiece.Theresearchthatearlierconsideringtherigidityofworkpiecesorfixturepositingcellwillbefoundintheliterature[16]basedontheexperimentalresultstheystudiedfixturestiffnessandwear’seffectsonthesizeaccuracy.Literature[17]proposedafiniteelementmodelofthefixturesystemforflexiblepositioningfixture,andthepowerinprocessofprocessingcanbeseenastheforceactingonthenode.Basedonthismodel,youcancalculatethedeformationoftheworkpiece,theclampingforce,stressdistributionandfrictionbetweentheworkpieceandfixturepositioningunit’scontactpointscanbecalculatedbyCoulomb'slaw.Althoughbyconsideringthedeformationoftheworkpieceandthefiniteelementanalysisthisareahavebeenpromoted,butithasneitherproposedanyspecificpositingprinciple,norproposedpositioningschemeforflexiblesheet.Inaddition,thismodeldoesnotcombinethefiniteelementanalysisresultsoftheworkpiecewiththefixturedesign;itismorethantheanalysisoftheworkpieceotherthanfixturedesign.Literature[18]proposedaanalysismethodofsheetfixturepositing,theystudiedthefixturepositioningsystemusingthecaseandflatthree-pointandfour-pointtoposit,sothefixturelayoutmustmakethestressintheworkpiecesbelowtheyieldstress.However,thismethoddoesnotsolvetheessentialproblemofsheetfixture,becausereducingdeformationisthekeytothepositioningofsheet.Basedonliterature[17],literature[19]continuedfurtherstudy,thatusingthefiniteelementmodelingtochoosefixturelayoutmakesthedeformationminimuminthefirstbase-level.Todeterminetheoptimalfixturelayout,usingquasi-Newtonoptimizationalgorithmmakesthedeformationsquaresonthefiniteelementmeshofthekeynodesminimum.Designvariablesarethethreeanchorpointsonthefirstbaserequiredby"3-2-1"principle.Sheetstampingassemblyfixturesarewidelyusedinautomobiles,aircraftandhouseholdappliancesindustries,whosedesignqualitydirectlyaffectstheentireproductmanufacturingdeviations.Duetosheetmetalstamping’scharacteristicofflexibilityandmanufacturingvariations,theprincipleoftraditionalfixturedesigncannotmeetthedesignrequirements,althoughtheresearchoffixturedesignisalreadyquitematureandthepositioningprincipleofrigidpartandthe"spiraltheory"hasbeenin-depthstudy."N-2-1"Locationprinciple,forthecharacteristicofeasydeformationonthehorizontalofSheetMetalStamping,presentsthatwhenthenumberofanchorpointsismorethan3inthefirstbasesurface,positioneffectdependsnotonlyonthenumberofanchorpoints,butalsoonthearrangementoftheanchorpoints.Apartfromthat,itproposesthefiniteelementanalysisandthedesignofnonlinearprogrammingmethodoftheanchor,whichprovidestheoreticalbasisanddesignmethodsforthedesignofsheetweldingfixture.Becauseofthelargermanufacturesizedeviationofsheetmetalpartsandtheremarkableeffectofthechoiceofanchorpositionforpositiondeviation,robustfixturedesigncansignificantlyimprovethepositioningerror.Therefore,duringthedesignofsheetweldingfixture,implementingthe"N-2-1"locationprincipleandrobustdesignmethodisextremelyimportant.Ithasbeenprovedtohaveamultipliereffect.References[1]LiB,TangH,YangX,etal.QualityDesignofFixturePlanningforSheetMetalAssembly[J].InternationalJournalofAdvancedManufacturingTechnology,2007,32(7-8):690-697.[2]CeglarekD,ShiJ.DimensionalVariationReductionforAutomotiveBodyAssembly[J].ManufacturingReview,1995,8(2):139-154.[3]CeglarekD,ShiJ.FixtureFailureDiagnosisforAutobodyAssemblyUsingPatternRecognition[J].ASMEJournalofEngineeringIndustry,1996,118(1):55-66.[4]ApleyD,ShiJ.DiagnosisofMultipleFixtureFaultsinPanelAssembly[J].ASMEJournalofManufacturingScienceandEngineering,1998,120(4):793-801.[5]ChangM,GossardDC.ComputationalMethodforDiagnosisofVariation-relatedAssemblyProblems[J].InternationalJournalofProductionResearch,1998,36(11):2985-2995.[6]LiuY,HuS.AssemblyFixtureFaultDiagnosisUsingDesignatedComponentAnalysis[J].ASMEJournalofManufacturingScienceandEngineering,2005,127(2):358-368.[7]KhanA,CeglarekD,ShiJ,etal.SensorOptimizationforFaultDiagnosisinSingleFixtureSystems:aMethodology[J].ASMEJournalofManufacturingScienceandEngineering,1999,121(1):109-117.[8]DjurdjanovicD,NiJ.StreamofVariationBasedAnalysisandSynthesisofMeasurementSchemesinMulti-stationMachiningSystems[C].ProceedingsoftheASMEInternationalMechamicalEngineeringCongressandExposition,NewYork,2001,12:297-304.[9]DingY,KimP,CeglarekD,etal.OptimalSensorDistributionforVariationDiagnosisforMulti-stationAssemblyProcesses[J].IEEETransactionsofRoboticsandAutomation,2003,19(4):543-556.[10]CamelioJA,HuS.SensorPlacementforEffectiveDiagnosisofMultipleFaultsinFixturingofCompliantParts[J].ASMEJournalofManufacturingScienceandEngineering,2005,127(1):68-74.[11]LiB,YangJ,DingH.ARapidLocationandStateMemoryFixtureSystemforArbitrarilyPart[J].JournalofDonghuaUniversity,2000,17(3):27-31.[12]WangQ,YangJ,LiB.ApplicationandRealizationofRapidSearchingTechnologyintheRL&SMUniversalFixtureSystem[J].JournalofDonghuaUniversity,2002,19(3):19-22.[13]WangY,LiB,YangJ.InvestigationonDimensionalErrorCompensationforSingleSheetMetalAssemblyStation[C].ProceedingsofICMEM,Wuxi,China,2007:699-703.[14]CaiW,HuS,YuanJ.DeformableSheetMetalFixturing:Principles,Algorithms,andSimulations[J].ASMEJournalofManufacturingScienceandEngineering,1996,118(3):318-324.367JournalofDonghuaUniversity(Eng.Ed.)Vol.26,No.4(2009)

附录B文献翻译薄板冲压件焊装夹具设计方法摘要:由于薄板冲压件的易变形性和制造误差特征,薄板焊装夹具设计显著区别于普通机械加工工件定位夹具。本文首先介绍了夹具设计的形闭合与力闭合概念、螺旋理论的发展,给出了确切定位和完全夹紧条件;然后,重点阐述了面向薄板冲压件焊装夹具设计的“N-2-1”定位原理和夹具的优化设计方法;最后分析了夹具的稳健性设计方法。可以预料,采用该方法可有效地减少和控制定位误差的影响。关键词:夹具;薄板冲压件;优化设计;稳健设计冲压加工以其较高的生产率和材料利用率,广泛应用于汽车、飞机和各种家用电器制造工业,冲压件的焊接装配成为上述产品制造的关键工序,焊装夹具的性能不仅影响到生产率,而且直接关系到产品的质量。美国汽车工业的统计表明[1],72%的车身制造误差源于焊装夹具定位误差,因此如何有效地减少和控制定位误差的影响,对提高焊装质量至关重要。薄板焊装夹具与通用的机加工夹具存在显著的差别,它不仅要满足精确定位的共性要求,还要充分考虑薄板冲压件的易变形性和冲压制造偏差较大的特征,以适应于产品的高质量要求。近十几年来,许多学者在薄板焊装夹具的设计上开展了大量工作,提出了一些新型的薄板冲压件焊装夹具的设计理论和方法,取得了显著效果。本文首先介绍夹具设计方法的研究进展,然后系统地阐述夹具的N-2-1定位原理、优化设计及鲁棒性设计方法,最后给出本文的结论。制造过程(如加工、焊接、装配和检测等)中,夹具是用于在三维空间定位和夹紧工件的设备。夹具设计的中心问题就是选择最优定位点数并确定它们的最佳位置,以实现工件的确定约束定位。如果工件依靠接触区域几何形状便可完全约束,称为“形闭合”;如果还必须借助摩擦才能完全约束,则称为“力闭合”。通常形状闭合强调动态分析,而力闭合则研究工件的静态稳定。1885年,Reuleaux首先研究了二维工件的形闭合机制,证明了形成二维物体的形闭合必需四个定位点[2]。之后,Somoff证明三维物体的形闭合需要七个定位点,1978年,Lakshminarayana[3]从静态平衡角度利用代数理论进一步证明了三维工件的形闭合至少需要七个点。1988年,Nguyen研究了机器手力闭合机制[4],而Asada和Kitagawa[5]于1989年研究了用于凸形和凹形工件的机器手的形闭合。通常的六点定位原理一般地需要夹紧力将工件完全约束,因此常常是力闭合。近十几年来,“螺旋理论”广泛流行于夹具设计中,螺旋理论将三维工件的三维空间运动描述为沿某一方向的平移和绕这一