汽车制造中冲压工艺发展研讨(中英文翻译)

Automobile manufacture stamping process of new development

Automobile

manufacture

has

a

60-70%

of

metal

parts

must

be

approved

by

the

plastic processing forming, stamping process is complete metal plastic forming a kind

of important means, it is the most basic, the most traditional, the most important one

of

metal

processing

method.

Such

as

vehicle

body

all

kinds

of

covering

parts,

car

support pieces, structure strengthen pieces, there's plenty of auto parts, such as engine

exhaust muffler, hollow tube bending and camshaft, the oil pan, engine stents, frame

structure, horizontal longeron etc, it is by stamping technology positively precision,

multi-function, high efficiency and energy saving, safe cleaning production direction,

stamping

workpiece

manufacturing

technology

level

and

quality,

in

great

degree

of

automobile manufacturing quality and cost has direct impact.

So-called

stamping

technology

refers

to

the

adaptability

of

the

stamping

to

handicraft,

namely

the

design

of

stamping

in

size,

size

accuracy

and

benchmarks,

structure shape stamping processing of compliance with technological requirements.

Automotive

stamping

parts

should

be

good

technological

characteristics,

and

the

economy, measure the level

of the important

symbol has stamping process

number,

body assemblies block number and size, stamping structure, and other factors. Reduce

the number of punching process procedure, that means less stamping tooling quantity,

number

of

packages,

save

simplified

punching

process

of

conveyors,

Narrows

the

operators and stamping 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 manufacture cost, even ?

Modern stamping development and research of the major subjects include:

(1) module type and control

。

stamping

(2) new material and composite stamping processing new craft

。

(3) special stamping technology

。

(4) computer simulation stamping mold testing technology

。

and virtual

(5) die & mould manufacturing technology,

(6) stamping process

of

automatic monitoring and instability mechanism

analysis

and so on .

Module type stamping

Module 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, so long as

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. Oerall, module type stamping water-holding point is:

(1)

the

stamping

process

can

be

replaced

rapidly

combination

to

improve

production efficiency

。

mould

(2) due to its strip 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 control combination dies action

can continually stamping processing

。

(5) dies with programmable 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

feeding

device,

etc.

The

stamping

system

at

run- time

can

undertake

stamping transverse displacement, strip feeding positioning, die repeat operation and

automatic adjustment work step punching adjustment etc multiple functions. Because

the

stamping

process

programmable

stamping,

make

this

kind

of

module

type

stamping system can adapt production requirements, flexible in same strip on March

different

workpiece

and

batch

production,

realizing

mixed

non-stop

string

&joint

processing,

also

in

two

sides

stamping

workpiece

machining,

which

has

greatly

enhanced the work efficiency, have data show that the module type stamping makes

processing cost can fall to 40% - 50%.

The

current

module

type

stamping

device

integration

is

very

high,

in

width

is

300MM size range can arrange of 35 mold, through the roof top of stamping die for

independent

type

series

of

control,

is

formed

namely

die

of

integrated

control.

The

whole

system

programmable

in

WINDOWS

user

interface

and

menu

under

implementation,

programming

involves

mould

along

the

lateral

positioning

shaft

servo

drive

positioning,

strip

inspection

correction

and

longitudinal

feeding

positioning,

stamping

quality

follow-up

inspection,

punching

machine

。

the

adjustment and Condition monitoring and versatility.

When stamping reconfigure or alteration, these changes would be parameters and

controlled system to store, next time query and invoke. Declarations Die data include

the punch and their combination tags, punch combination in X, Y of die and mould

shaft

Numbers

coordinates

and

other

information.

Figure

3

shows

programmable

punching

system,

figure

in

A

standard

mould

transverse

axis,

can

undertake

servo

dynamic

to

stamping

area,

B

for

the

supporting

shaft

with

punching

die,

C,

D

for

spare axis to orange roll type with material are feeding.

And submillimeter stamping project

And submillimeter stamping

0 to

1.0 MM within the scope of the traffic in

the past,

and manufacturing error of

2MM

compared, is

a very big enhancement. This

is

an improving punching quality

and

manufacturing

technology

as

the

goal

of

integrated

project.

The

project

with

2MM

engineering

all

in

the

late

1990s

America

QiCheJie

conduct

large-scale

research project. So-called

size changes within 2MM quantity control, greatly in strict in the original 8MM error

range.

Stamping

processing

forming

technology

affect

auto

body

manufacturing

level

is

one of the key factors, the American experts worked in a car assembly line to over 50

cases field analysis shows that, cause body size error change many reasons, stamping

itself

size

caused

by

error

accumulation

23

percent,

its

main

reason

is

that

the

traditional based on experience and original technology based on low level of mold

design and manufacturing.

And

submillimeter

stamping

is

the

center

of

precision

stamping

with

increasing

agility two goals, precision is to make the stamping size accuracy control in 0 mm or

and submillimeter level, the key is to control body stents, pillar on the pieces of the

feet, and make changes in body covering parts, such as partitioned degrees by whole

left-right side plate and the top cover plate, etc. Increasing agility meaning is refers to

reduce stamping prajapati was preparation time up to 30%, including tooling design,

manufacturing

and

tooling,

sample

preparation

time,

in

order

to

achieve

greatly

shorten

the

purpose

of

the

new

models

manufacturing

cycle,

this

project

diet

are

die-cutting

and

assembly

integration

design,

stamping

system

agile

design

and

manufacturing,

stamping

process

of

intelligent

detecting

and

monitoring,

whole

system integration four subsystems project.

Through a study of the program and submillimeter stamping, stamping technology

has witnessed progress, including:

(1)

the

stamping

process

and

component

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

traditional attempt method,

(3)

to

implement

the

mould

design

manufacture

serial

manner

by

the

past

to

parallel transformation,

(4) realized process monitoring and equipment maintenance from passive response

to

scientific

prediction

type

transformation.

project

and

submillimeter

stamping

manufacturing company popularization and application, and achieved many beneficial

results,

stamping

cost

greatly

decreased,

obtain

the

growing

economic

benefit

of

social benefit, and gradually applied to other countries.

Special stamping technology

Modern

automotive

stamping

technology

requirements

towards

structure

is

complex, block size increases, related edge parts more, carrying capacity is large and

internal

limit

strictly

etc

direction.

This

requirement

and

promote

special

stamping

technology such as hydraulic pressure forming, precision forming, explosive forming

and

spinning

forming,

no

die

forming,

laser

forming

and

electromagnetic

forming

technology

development.

Limited

to

this

paper

length,

here

basically

introduces

pressure inside the forming and electromagnetic forming two technologies.

Modern

automotive

stamping

technology

requirements

towards

structure

is

complex, block size increases, related edge parts more, carrying capacity is large and

internal

limit

strictly

etc

direction.

This

requirement

and

promote

special

stamping

technology such as hydraulic pressure forming, precision forming, explosive forming

and

spinning

forming,

no

die

forming,

laser

forming

and

electromagnetic

forming

technology

development.

Limited

to

this

paper

length,

here

basically

introduces

pressure inside the forming and electromagnetic forming two technologies.

The

hydraulic

or

injection

of

the

forming

technology

of

elastic

postures,

its

high-pressure forming process generally includes:

(1) effective media such as ice expansion iscm make the internal pressure pressed

into the penalty extremely slow growth process,

(2) fluid static penalty bone high- pressure forming process,

(3)

extreme

pressure

as

an

explosion

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, fulfill the punch function, so medium can be equated to

a

universal

mold.

Figure

4

is

plank

super

shobach

the

example,

forming

from

the

graph visible at effective media becomes the punch.

The

hydraulic

internal

high-pressure

forming

technology

compared

with

other

stamping technology, there are several obvious advantages:

(1) the forming process can one processing out like axle, top cover, doorcase and

other large and complex 3d geometric shapes of workpiece,

(2) because of liquid in the forming process cooling effect, make the workpiece is a

strengthening

won

than

ordinary

stamping

workpiece

machining

higher

strength, this makes allowing a thinner plank, to make the work more lightweighting

。

(3)

workpiece

surface

appearance

only

with

pressure

liquid

contact,

pressure

is

gentle, parts forming process changes, can obtain the symmetry of uniform pressure

distribution, and can winner much better smooth outside surface,

(4)

in

stamping

and

bloom

some

hydraulic

tool

charge

can

reduce

40%,

special

reduced

convex

parts

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 coil electromagnetic forming

process, is the present quite promising another new processing method. This process

from

1960s

nuclear

fission

research

achievement,

but

unfortunately

has

not

been

people

attention.

Electromagnetic

forming

technology

principle

diagram,

when

the

coil access to electricity. Few microseconds inside establish electromagnetic field, so

the metal workpieces especially conductivity strong copper aluminum texture produce

electric current, a current, induced current induced by magnetic force and effect, make

the workpiece create tension and anastomosis and rapid forming. When the

coil

in

the

workpiece

in

electromagnetic

force

will

make

workpiece

outside

of

the

current

application,

zhang

forming

widespread

a

kind

of

technology,

When

the

coil

planar

parallel

to

the

board

piece

is

placed,

electromagnetic

force

will

make

workpiece stretch forming.

Electromagnetic

forming

technology

is

a

non-contact

forming

process,

and

its

outstanding merits are shaping a rapid high efficiency, 2 it is often used in metal or

nonmetal

connection,

can

replace

adhesive

or

welding,

A

third

is

not

consumption

lymphocy

help

materials

such

as

lubricating

grease,

etc,

the

advantageous

environment protection.

Stamping process automatic monitoring

Modern

scramjet

another

important

feature

is

for

punching

process

automatic

monitoring

to

protect

the

stamping

quality.

In

the

mm

stamping

project

automatic

detection

and

monitoring,

its

research

results

will

include:

1.

The

stamping

process

characteristics

of

online

preach

diagnosis

and

detection

system,

2.

High

speed

and

non-contact measuring system

。

the stamping 3. Die maintenance scientific prediction

system

。

4. Stamping key parameters online adjust and compensation system, etc.

Stamping

process

changes

caused

by

workpiece

quality

is

mainly

caused

by

the

wear of convex punching die, crack, dislocation, these small changes can be made of

high resolution of a transfer sensor and rushed pressure turn sensor tracking detection.

One extremely important displacement measurement is a kind of measure, this device,

usually by installed in the mould, the GuanYuan and located below the receiving unit

constitution,

can

monitor

deviation,

tracking

processing

process,

timely

output

monitoring information and alarm downtime.

An

online

stamping

graphical

processing

system,

is

the

effective

guarantee

stamping workpiece quality testing method, it can carry out 2-d geometric figure of

standard

testing,

the

project

has

the

length,

diameter,

parallelism,

Angle,

pressing

plank structure and identification of waste, etc. Graphics processing system is by like

meter,

optical

instrument

and

lighting

equipment

etc,

the

standard

of

CCD

like

instrument of bashan 750X580 bar lattice resolution for grid and jokshan horizontal

direction for every sheshan lattice 0.026 mm, vertical accuracy of fungi mm/sheshan

lattice.

Surveillance systems use the displacements and the Angle sensor are optical type

and electrical type two kinds, the former has the laser testing technology and die like

light sheshan technical support, The latter has a inductance and capacitance streaming

media, they test accuracy resolution all may achieve the 1-10um grade level. The most

suitable stamping technology transfer sensor installation plan is to put multiple turn

sensor installed in a centralized sensor board, then put it precisely fixed in the mold

outlet,

namely

the

punch

clamping

board,

using

sensor

data

monitoring

stamping

process, and through the controller get timely treatment, guarantee the quality of the

stamping.

汽车制造中冲压工艺的新发展

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。

所谓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。减少冲压过程的工序数，意味着减少冲压件数、

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，< /p>

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。

空气阻力减少，

又可减少冲压件数量