廈門理工學(xué)院材料成型工藝考查論文(翻譯的)

1、材料成型工藝論文 20102011 學(xué)年第1學(xué)期姓 名:林俊飛學(xué) 號(hào):0808022124院 系:機(jī)械工程系班 級(jí):（1）班專 業(yè):材料成型及控制工程指導(dǎo)教師:李輝廈門理工學(xué)院機(jī)械工程系 2010年12月5日原文：（摘自于航空精密制造技術(shù)2009年4月第45卷第二期）材料成形加工技術(shù)發(fā)展趨勢(shì)榮烈潤(rùn)（上海靜安區(qū)職工大學(xué)，上海200040）【摘要】 介紹了新世紀(jì)材料成形加工技術(shù)發(fā)展的精密、優(yōu)質(zhì)、快速、復(fù)合、綠色以及信息化等發(fā)展趨勢(shì)?！娟P(guān)鍵詞】材料成形加工技術(shù)；發(fā)展趨勢(shì)【正文】材料成形加工技術(shù)在制造業(yè)中占有重要的地位，它是汽車、航天航空、電力、石化、造船、機(jī)械等支柱產(chǎn)業(yè)的基礎(chǔ)技術(shù)。現(xiàn)以航空發(fā)動(dòng)機(jī)為例

2、， 現(xiàn)代飛機(jī)要求超聲速巡航、非常規(guī)機(jī)動(dòng)性、低環(huán)境污染、低油耗、低全壽命成本等性能，很大程度上是依靠發(fā)動(dòng)機(jī)性能的改進(jìn)及提高來(lái)實(shí)現(xiàn)的，發(fā)動(dòng)機(jī)提高的目標(biāo)是提高推重比、功率重量比、增壓比和渦輪前溫度。要實(shí)現(xiàn)上述指標(biāo)，就要不斷發(fā)展先進(jìn)渦輪盤材料，與此相應(yīng)發(fā)展這些材料的精密成形與加工技術(shù)，材料的精密成形與加工技術(shù)就成為關(guān)系國(guó)防安全的一種關(guān)鍵技術(shù)。進(jìn)入21世紀(jì)后 ,材料成形加工技術(shù)的發(fā)展面臨環(huán)保、資源、消費(fèi)觀念變革、市場(chǎng)競(jìng)爭(zhēng)、制造全球化和信息技術(shù)等挑戰(zhàn)，同時(shí)也面臨制造業(yè)持續(xù)增長(zhǎng)、我國(guó)加入WTO 等機(jī)遇，這就促使新世紀(jì)材料成形加工技術(shù)在發(fā)展中形成了自己新的特征。1 精密化目前 ,精密和超精密制造技術(shù)已經(jīng)跨越了

3、微米級(jí)技術(shù)，進(jìn)入了亞微米和納米技術(shù)領(lǐng)域。精密化已成為材料成形加工技術(shù)發(fā)展的重要特征，其表現(xiàn)為零件成形的尺寸精度正在從近凈成形(Near NET shape Forming)向凈成形（NET shape Forming）,即近無(wú)余量成形方向發(fā)展?！懊鳌迸c“零件”的接近程度越來(lái)越大。當(dāng)前精密成形技術(shù)已在較大程度上實(shí)現(xiàn)了近凈形。發(fā)展趨勢(shì)是實(shí)現(xiàn)凈成形加工，其工藝要求材料成形向更輕、更薄、更強(qiáng)、更韌及成本低、周期短、質(zhì)量高的方向發(fā)展。精密材料成形技術(shù)有多種形式的精鑄、精鍛、精沖、冷溫?cái)D壓、精密焊接與切割等。2 優(yōu)質(zhì)化凈成形技術(shù)主要反映了成形加工保證尺寸及形狀的精密程度，而反映成形加工優(yōu)質(zhì)程度的則是近無(wú)

4、缺陷、零缺陷成形加工技術(shù)。“缺陷”是指不致造成早期失效的臨界缺陷的概念。目前及今后采取的主要方法有：為了獲得健全的鑄件、鍛件奠定基礎(chǔ)，可以采用先進(jìn)工藝、凈化熔融的金屬、增大合金組織的致密度等。采用模擬技術(shù)、優(yōu)化工藝技術(shù)，實(shí)現(xiàn)一次成形及試模成功，保證工件質(zhì)量。加強(qiáng)工藝過(guò)程監(jiān)控及無(wú)損檢測(cè)，及時(shí)發(fā)現(xiàn)超標(biāo)零件。通過(guò)零件安全可靠性能研究、評(píng)估，確定臨界缺陷量值等。3 快速化隨著全球化市場(chǎng)的激烈競(jìng)爭(zhēng)，加快產(chǎn)品開(kāi)發(fā)速度已成為競(jìng)爭(zhēng)的重要手段之一。制造業(yè)要滿足日益變化的用戶需求，必須有較強(qiáng)的靈活性，以最快的速度提供高質(zhì)量產(chǎn)品。亦即“客戶化、小批量、快速交貨”的要求不斷增加，為此需要材料成形加工技術(shù)的快速化。成形

5、加工技術(shù)的快速化表現(xiàn)在各種新型高效成形的工藝不斷涌現(xiàn)，新型鑄造、鍛壓、焊接方法都從不同角度提高生產(chǎn)效率?？焖僭椭圃旒夹g(shù)(RP) 以離散/堆積原理為基礎(chǔ)和特征，源零件的電子模型（CAD 模型）按一定的方式離散成為可加工的離散面、離散線和離散點(diǎn)，而后采用多種手段，將這些離散的面、線段和點(diǎn)堆積成零件的整體形狀。由于工藝過(guò)程簡(jiǎn)單，故制造速度比傳統(tǒng)方法快得多。到2000年全世界已有6700 多臺(tái)不同類型的RP 裝置在運(yùn)行。快速原型和快速模具相結(jié)合，又提供了一條從CAD模型直接制造模具的新方法，RP正在向著各種制造工藝集成、形成快速制造系統(tǒng)的方向發(fā)展。計(jì)算機(jī)模擬仿真技術(shù)是信息技術(shù)綜合應(yīng)用、發(fā)展的結(jié)果。應(yīng)

6、用數(shù)值模擬于鑄造、鍛壓、焊接等工藝設(shè)計(jì)中，并與物理模擬和專家系統(tǒng)相結(jié)合。來(lái)確定工藝參數(shù)、優(yōu)化工藝方案，預(yù)測(cè)加工過(guò)程中可以產(chǎn)生的缺陷及防止措施，控制和保證加工工件的質(zhì)量。模擬仿真技術(shù)，它可以理論和實(shí)驗(yàn)做得更深刻、更全面、更細(xì)致，可以進(jìn)行一些理論和實(shí)驗(yàn)暫時(shí)還做不到的研究，大大縮短了制造周期。加快了制造進(jìn)程。如鑄造凝固過(guò)程的三維數(shù)值模擬；鑄壓過(guò)程微觀組織的演化及本構(gòu)關(guān)系模擬；焊接凝固裂紋的模擬仿真、開(kāi)裂機(jī)制的研究以及焊接氫致裂紋的模擬；金屬材料熱處理加熱冷卻過(guò)程的模擬仿真及組織-變形 、性能預(yù)測(cè)等。根據(jù)美國(guó)科學(xué)研究院測(cè)算，模擬仿真可提高產(chǎn)品質(zhì)量515 倍 ，降低人工成本5%20%，提高投入設(shè)備的利用

7、率30%60% ，縮短產(chǎn)品設(shè)計(jì)和試制周期30%60%， 增加分析問(wèn)題廣度和深度的能力33.5倍等。目前，模擬仿真技術(shù)已能用于壓力鑄造、熔模鑄造等特種精確成形工藝。很多研究人員開(kāi)展了材料成形加工新工藝，如噴射成形的模擬研究等。多尺度模擬特別是微觀組織模擬（從毫米、微米到納米尺度）是近年來(lái)研究的新熱點(diǎn)課題。多尺度模擬已經(jīng)在汽車及航天工業(yè)中應(yīng)用。4 復(fù)合化激光、電子束、離子束、等離子體等多種新能源的列入，形成多種新型加工與改性技術(shù)，其中以各種形式的激光加工技術(shù)發(fā)展最為迅速。激光加工技術(shù)多種多樣，包括電子元件的精密微焊接、航天航空和汽車制造中的焊接、切割與成形等。有不同種類的激光表面改性處理方法，如熱

8、處理、表面修整、表面熔覆及合金化等。使用的激光器主要為大功率CO2激光器、YAG 激光器。近年來(lái)，激光加工自由成形技術(shù)成為重要的研究動(dòng)向。隨著金屬間化合物材料、金屬基復(fù)合材料、多種新型功能材料、超導(dǎo)材料等高新技術(shù)材料的應(yīng)用，傳統(tǒng)的加工方式或多或少地遇到了困難。與新的材料制備和合成技術(shù)相適應(yīng)，新的加工方法成為材料加工研發(fā)的一個(gè)重要領(lǐng)域。一批新型復(fù)合工藝應(yīng)運(yùn)而生，為超塑成形/擴(kuò)散連接技術(shù) 、材料電磁加工等。此外“復(fù)合化”還表現(xiàn)在冷熱加工之間 、加工過(guò)程 、檢測(cè)過(guò)程、物流過(guò)程、裝配過(guò)程之間的界限趨向。·5 綠色化“綠色化”是指成形加工生產(chǎn)向清潔生產(chǎn)、無(wú)廢棄物加工方向發(fā)展。清潔生產(chǎn)技術(shù)是協(xié)調(diào)

9、工業(yè)發(fā)展與環(huán)境保護(hù)的矛盾、需求日益增加與有限資源的矛盾的一種新的生產(chǎn)方式，是21 世紀(jì)制造業(yè)發(fā)展的重要特征。在成形加工生產(chǎn)過(guò)程中可采取如下措施：采用清潔能源。采用綠色材料。綠色材料是指資源和性能消耗小、生態(tài)環(huán)境影響小、再生循環(huán)利用率高或可降解使用的具有優(yōu)異實(shí)用性能的新型材料。采用和開(kāi)發(fā)新的工藝方法。采用新結(jié)構(gòu)，減少設(shè)備的噪聲和振動(dòng)。美國(guó)在展望未來(lái)的制造業(yè)時(shí)，進(jìn)一步把“材料凈成形工藝”發(fā)展為“無(wú)廢棄物成形加工技術(shù)”。所謂“無(wú)廢棄物加工”的新一代制造技術(shù)是指加工過(guò)程中不產(chǎn)生廢棄物，或產(chǎn)生的廢棄物能被整個(gè)制造過(guò)程中作為原料而利用，并在下一個(gè)流程中不再產(chǎn)生廢棄物。無(wú)廢棄物成形加工技術(shù)將成為今后推廣的重

10、要綠色制造技術(shù)。日本鑄造工廠最近提出了3R的環(huán)境保護(hù)新概念，即減少?gòu)U棄物（Reduce）、重用（Reuse）及回用（Recycle）。6 信息化信息化是21 世紀(jì)社會(huì)發(fā)展的趨勢(shì)。信息技術(shù)也正在向材料成形加工技術(shù)注入和融合，促進(jìn)著材料加工技術(shù)的不斷發(fā)展。信息技術(shù)對(duì)材料加工技術(shù)發(fā)展的作用目前已占第一位。參考文獻(xiàn)：1柳百成,沈厚發(fā).21 世紀(jì)的材料成形加工技術(shù)與科學(xué)M，北京：機(jī)械工業(yè)出版社,20042孫大涌,屈賢明,張松濱.先進(jìn)制造技術(shù)M.北京:機(jī)械工業(yè)出版社,20003李敏賢,閔乃燕,安桂華等.精密成形技術(shù)發(fā)展前沿J.中國(guó)譯文：Introduction to Developing Trend of

11、 Material Forming TechnologyRong Lierun（Shanghai Jingan District Staff University, Shanghai 200040）Abstract Developing trend of precision,high quality,rapidity,comppo- sition,green and information material forming technology was introduced in new century.Keywords material forming technology; develop

12、ing trendTextThe technology of Material forming have an important position in the manufacturing sector, it is the foundation technology of automotive, aerospace, electric power, petrochemical, shipbuilding, machinery and other pillar industries. Now in the aircraft engine as an example, the modern a

13、irplane requires supersonic cruise, poisson mobility, low en- vironmental pollution, low fuel consumption, low cost, such as perfor- mance, largely depend on improvements in engine performance and improve to achieve, the goal to improved engine is to improve the thrust ratio, the thrust loading, the

14、 supercharger ratio and the temperature of turbine inlet. To achieve these objectives, we must continue to develop advanced turbine disk material, and the corresponding development of these ma- terials for precision molding and processing techniques, materials pre- cision forming and machining techn

15、ology becomes the relationship between national security a key technologies.Into the 21st century, the material processing technology for the de- velopment of environmental protection, resources,consumption idea change, market competition, globalization and information technology challenges while al

16、so facing manufacturing industry continues to grow, China's ac- cession to the WTO and other opportunities, this prompted new century materials processing technology in the development of its own new fea- tures.1 PrecisionCurrently, precision and precision manufacturing technology transcends Mic

17、ron Technology, has entered a submicron and nano-technology. Precision has become the material processing technology development of important characteristics, its performance for the parts forming the dimensional accuracy are from Near NET shape Forming to NET shape Forming, which is nearly non-mach

18、ining shaping direction. "Blank" and the "parts" of the growing closeness. Current precision forming technology is already in a large extent achieved Near NET shape. The trend is to achieve net shaping process, its technological requirements materials forming to lighter, thinner,

19、stronger,more ductile and low cost, short cycle time, high qua- lity.Precision materials forming technology comes in many forms of casting, forging, fine blanking, cold temperature extrusion, precision welding and cutting, etc.2 High qualityTechnology of NET shape forming mainly reflects the shaping

20、 process guarantees the accurate dimensions and shape,which reflect the level of processing quality is nearly free of defect,zero defect forming tech- nology. "Defect" refers not to cause premature failure of the concept of critical defects. The current and future take the main method are:

21、In order to obtain a sound basis for castings, forgings, you can use the advanced craft, the purification and melting of metal and alloy in- creased density, etc.Using simulation technology, optimization technology, the realization of a forming and trial run successfully, ensure that the quality of

22、the workpiece.Strengthening the process of monitoring and nondestructive testing, discover excess parts.Safety and reliability through parts can research and evaluation to determine the value of critical defects.3 RapidityAs the global market competition, accelerate product development speed has bec

23、ome one of the important means of competition. Manufacturing in- dustry to meet the changing needs of customer，you must have strong flexibility to quickly deliver high quality products. Or " customers , small volume , rapid delivery ," increasing demands , this requires materials processin

24、g technology of fast.Forming technology for rapid performance in a variety of new efficient forming process of emergence, type casting, forging and welding methods from different angles, improve production efficiency.Rapid prototyping to discrete ( or accumulation ) principle-based and features, the

25、 source part of the e-model (CAD model) in a certain way discrete become discrete surface processing, discrete wire and discrete point, then use a variety of means, will these discrete surfaces, lines and points accumulated into the overall shape of the part. Because the process is simple, it is fas

26、ter than traditional methods of manufacturing much faster. Until 2000 all world have 6700 multiple different types of RP appliance running. Rapid Prototyping and Rapid Tooling integration, and provides a direct line from the CAD model of the new methods of manu- facturing mould, RP is toward various

27、 manufacturing process integration, formation of rapid manufacturing system.The computer simulation technology is a comprehensive application of information technology , the development of results . Application of numerical simulation to casting, forging, welding, process design, and physical modeli

28、ng and the combination of expert systems. To determine the optimal process technological parameters, forecasting process can ge- nerated defects and prevention, control and ensure the quality of the workpieces.Simulation technology that theory and experiment more profound, more comprehensive and det

29、ailed, you can make some theoretical and experi- mental for the time being you do research, dramatically reducing manu- facturing cycle. Accelerates the production process. Such as casting solidification process of three-dimensional numerical simulation; cast- ing pressure process microstructure evo

30、lution and constitutive modelling; weld solidification cracking simulation, cracking mechanism, as well as welding simulation of hydrogen-induced cracking ; metal heat heating cooling process simulation and organization-deformation, per- formance forecasting, etc.According to the American Academy of

31、 estimates, Simulation can improveQuality 5-15 times , reducing labor costs 5% to 20% ,improved inputsEquipment utilization 30% to 60%,shortening product design and evelopment cycle 30% to 60%, increased analytical capacity of the breadth and depth of 3 to 3.5Times, etc.At present, the simulation te

32、chnology has been used for pressure casting, investment casting and other special precision forming technology. Many researchers has launched a new technology for material forming, such as injection molding simulation, etc. Multi-scale simulation especially microstructure simulation (from mm, Micron

33、 to nano-scale) in recent years new hotspots on the subject. Multi-scale modeling has been in the automotive and aerospace industries.4 CompositeLaser, electron beam, ionic-beam or plasma, to include new sources of energy, resulting in a variety of new machining and surface modification technologies

34、, with various forms of laser processing technology is the most rapid development. Laser processing technology are diverse, including electronic components, precision micro-welding, aerospace and automotive manufacturing of welding, cutting and shaping, etc. There are different types of laser surfac

35、e modification method, such as heat treatment, surface finishing, cladding, alloying, etc. Use of lasers for high power CO2 laser, YAG laser. In recent years, laser processing free forming technology become important research trends.With intermetallic materials, metal matrix composites, a variety of

36、 new functional materials, superconducting materials and other high-tech materials, traditional processing methods have difficulties to a greater or lesser degree. And new material preparation and synthesis technology to adapt to new processing methods become material processing an important field o

37、f research and development. A batch of new composite technology came into being, for superplastic forming/diffusion bonding technology, materials, electromagnetic processing and so on. In addition to "composite" also in hot and cold processing, processing, testing procedures, logistic proc

38、esses, the boundaries between the Assembly process tends to 5 Green"Green" means forming production to clean production, no waste processing.Clean production technology is the coordination of industrial development and environmental protection conflicts, increasing demand and limited resou

39、rces of the contradictions of a new mode of production, is the 21st century manufacturing development of important features.In the forming process can take the following measures: adoption of clean energy. Green materials. Green materials refers to the consumption of resources and performance, envir

40、onmental impact is small, the recycling utilization high or biodegradable used has excellent utility properties of new materials. adopt and develop new technologies. adopts new structure, reduce noise and vibration of the device.United States manufacturing industries in the future, further treat "material NET f