板材成形新技术及其发展趋势(Ⅱ)

介绍了多点成形技术、激光成形技术、冲压智能化技术、成形过程的计算机仿真技术等几种柔性化程度高的板材成形新技术及其发展趋势     

聚合物材料在快速原型制造技术中的应用

介绍聚合物材料作为成形原料在主要的快速原型制造(RPM)工艺中的应用情况。具体按照立体印刷成形(SLA)、层合实体制造(LOM)、选域激光烧结(SLS)及熔融沉积造型(FDM)这4种工艺的不同,阐述与各工艺对应的聚合物材料的种类、聚合物材料成形过程中可能出现的问题及解决方案。总结了聚合物材料原型的应用情况和聚合物材料在RPM技术应用中存在的问题。     

板材激光弯曲成形数值模拟的研究现状及展望

板材的激光弯曲成形是一种利用高能激光束扫描金属板材表面产生非均匀分布的热应力 ,从而使板材发生塑性变形的金属板材柔性成形新工艺。数值模拟已逐渐成为板材激光弯曲成形研究中的热点内容。综述了近年来国内外对激光弯曲成形过程的温度场及变形场进行数值模拟的研究现状 ,并对其应用范围和发展前景作了展望     

非枝晶半固态金属成形技术的发展概况

此文叙述了非枝晶半固态金属成形技术的发展概况。主要介绍了压铸成形、模锻成形、连续流变铸造成形、注射成形以及半固态金属锭料制造等技术的特点和应用现状。     

2219铝合金TIG焊缝激光冲击强化与腐蚀性能研究

目的 改善2219铝合金钨极氩弧焊焊缝的耐腐蚀性能。方法 采用激光冲击技术对焊缝进行强化处理,比较分析处理前后的表面残余应力、物相组成和元素状态,通过静态浸泡失重法和电化学试验测量腐蚀速率的变化。结果 经过激光冲击强化处理后,2219铝合金焊缝部位的元素状态没有改变,但焊缝区域的残余拉应力变为残余压应力。2219铝合金钨极氩弧焊接区域的自腐蚀电位明显下降,相比未经激光冲击处理的试件,焊核区和焊接过渡区的平均腐蚀电流分别减小了14%和12.7%,腐蚀速率分别减小了16.9%和12.9%。结论 激光冲击强化可以有效提升2219铝合金钨极氩弧焊焊缝区域的耐腐蚀性能,可以为提升特种装备安全性和轻量化提供技术参考。     

连接管件的先进塑性成形技术试验研究

介绍了 3种先进的连接管件成形技术 ,即小弯曲半径管内压推弯成形技术、球形管接头的胀形成形技术和管件的内径滚压成形技术 ,对其基本成形过程进行了描述 ,并通过铝合金、不锈钢和钛合金管件的成形试验获得了主要工艺参数对成形的影响规律 ,结果表明采用这些方法成形所需的连接管件是非常有效的     

精密锻造成形技术在我国的应用

简要介绍了精密锻造成形技术的发展概况及主要应用领域,列举了大量的工程应用实例来阐明冷锻成形、温锻成形、闭塞锻造成形、精密热模锻成形、复合成形、等温锻造成形等精密锻造成形工艺在我国的应用情况。     

基于激光快速成形技术的快速工/模具制造

概括了基于激光快速成形技术的快速工/模具制造的两种方法——间接法和直接法,对两种工/模具制造技术作了较具体的介绍,并分析了其特点.     

铝合金半固态成形工艺及力学性能的研究现状

新型的成形技术半固态成形技术 (SSM )是一种近终成形 (Near net shape)的成形工艺。和传统的成形工艺相比 ,具有一系列突出的优点 :成形温度低 ;成形件力学性能好 ,较好的综合了固态金属模锻与液态压铸成形的优点。阐述了铝合金半固态成形技术的主要工艺方法及工艺参数与传统的液态压铸成形的差异 ,并阐述了半固态成形件在不同状态下的力学性能     

MF-16K型电磁成形机的研制及其在弹箭装配中的应用

论述了电磁成形机研制的技术关键及MF—16K型电磁成形机的设计原则、线路原理与特色,并且概述了放电回路冲击大电流波形的测量结果。此机稳定可靠、实用安全、性价比高,是目前完全国产化的能量等级最大的电磁成形机(16KJ)。还针对某军工厂的两种具体弹箭产品,设计制作了相应的成形线圈和集磁器,进行电磁成形装配。效果良好,优于机械装配。     

External force-assisted laser forming process for gaining high bending angles

Laser forming process is used in forming and bending of metallic and non-metallic sheets. Laser beam irradiation causes a localized temperature increase and a localized mechanical strength decrease. In this article, an external mechanical force is added to a laser beam irradiation, which is called external force-assisted laser forming process, to gain a 90-degree bending angle. Furthermore, Numerical simulation of the process is performed to achieve a good understanding of the process. Simulation results show that more than two-third of the final forming is due to the laser beam irradiation. Equivalent plastic strain values during laser forming and external force-assisted laser forming processes are compared. Results show that equivalent plastic strain in laser forming process increases in a step pattern, with increasing in scan pass numbers. This occurs because when the laser beam irradiates on the sheet surface, it reduces the yield strength of the sheet. Equivalent plastic strain in external force-assisted laser forming process has an oscillatory step nature. This attributes to simultaneous effects of strain hardening and thermal induced reduction of yield strength of the sheet. Simulations were in good accordance with experiments.     

Bending of Titanium Sheet Using Laser Forming

Laser forming, a novel manufacturing method for bending sheet metal first reported in 1985, has been investigated as an alternative to hot brake forming (industry standard) of titanium sheet parts for the aircraft industry. Laser forming involves scanning a focused or partially defocused laser beam over the surface of a titanium workpiece to cause localized heating along the bend line and angular deflection toward the beam. The main advantage that laser forming has over conventional brake forming is increased process flexibility. An experimental investigation of this process (primarily designed experiments) met the following objectives: identified the response variables related to change in geometry (bend angle) and material microstructure; characterized the influence of process variables (scanning speed, beam diameter, laser power) on these response variables; determined the degree of controllability over the process variables; and evaluated the suitability of laser forming for the aircraft industry (most important), all with respect to titanium sheet. It has been determined that laser forming with an Nd:YAG laser is a controllable, flexible manufacturing process for titanium sheet bending. Unfortunately, these advantages over traditional hot brake forming are overshadowed by the fact that, with regard to forming with titanium, laser forming is significantly slower and more labor and energy intensive, and results in unacceptable material properties at the bend line according to aircraft industry standards. These findings cast doubt over the assertions of some researchers that laser forming may be a viable manufacturing process for parts made in small batches. Instead, it appears that it may be best suited for rapid prototyping of sheet metal parts.     

Environmental assessment of laser assisted manufacturing: case studies on laser shock peening and laser assisted turning

Laser assisted manufacturing processes, when compared with traditional manufacturing processes, have the potential to reduce cost, increase surface resistance to wear and fatigue, extend part/tool life, and expand the range of manufacturable materials. These processes have found niche applications in automotive, aerospace, and defense industries. However, very limited research has been conducted to evaluate and compare the environmental performance of laser assisted processes with traditional methods. This paper conducts case studies on two representative laser based processes, i.e. laser shock peening of 7075-T7351 Aluminum and laser assisted turning of compacted graphite iron. Life cycle assessment is used to benchmark the environmental performance of these two processes to conventional processes, i.e. shot peening and turning, respectively. The life cycle inventory of both the laser based processes and conventional processes are developed using SimaPro 7.1 and the Ecoinvent 2.0 database and life cycle impact assessment is performed using US EPA TRACI. The results of this study show that the environmental performance of the two laser based processes is significantly better than conventional processes. For laser shock peening of aluminum, contribution analysis indicates that this is mainly due to the significant extension of fatigue life of the workpiece being treated. For laser assisted turning of compacted graphite iron, the improved performance is mainly due to the extended tool life since cutting tool manufacturing is an energy intensive process. Development of high-power laser with a lower wavelength (e.g. direct diode system) could eliminate the use of paint in laser assisted turning. This, along with improved wall plug efficiency, makes laser assisted turning even more environmentally benign compared to conventional process. A brief cost analysis suggests that both laser shock peening and laser assisted turning can be economically viable with payback period less than three years for niche applications.     

成形工艺对轿车减振器座应变状态影响的研究

通过网格应变分析技术 ,对某轿车采用一次成形、两次成形工艺冲制减振器座的应变状态进行了定量研究 ,结果表明 ,成形工艺对减振器座的应变分布、应变路径、应变大小影响很大 ,一次成形较两次成形对材料的成形性能要求较高 ,两次成形工艺更有利于零件成形     

Optimal and Robust Design of the Laser Forming Process

The laser forming process of sheet metal has been extensively analyzed, but few attempts have been made in the area of process design. The task of the process design in the laser forming of sheet metal is to determine a set of parameters, including laser scanning paths, laser power, and scanning speed, given a prescribed shape. Response surface methodology is used as an optimization tool. The propagation of error technique is built into the design process as an additional response to be optimized via desirability function and hence make the design robust. Focusing on a class of shapes, the design scheme is applied progressively in four cases in which issues such as a large number of design variables are properly addressed.     

基于激光烧结升温特性分析的月壤原位成型技术研究

目的分析利用激光烧结技术实施月壤原位成型的特点及方案,为月壤原位成型工程化设计和分析提供借鉴。方法基于国内外月壤原位成型技术路径,对比分析激光烧结成型技术方案的优势。通过激光照射条件下多层月壤颗粒升温模型,分析加热温度随激光器输出功率、月壤粒径、聚焦光斑直径及激光扫描速度的变化规律。基于“纪念碑”成型任务,提出一种基于封闭烧结腔和补给移动机构的激光烧结方案。结果激光烧结成型技术方案的优势是成型体性能及精度较高,无需添加辅料,非接触式,便于操作和控制,能耗及体积可接受。月壤颗粒能达到的温度取决于能够接受到的辐射能量,无论是提升激光器输出功率,还是缩小光斑直径,都能提升颗粒接受到的辐射能量密度。降低扫描速度,则颗粒接收辐射能量的时间增长,而月壤颗粒粒径变小,由于颗粒质量与粒径是三次方的关系,也能够提高单个颗粒接收到的辐照能量。激光烧结成型系统由控制装置、激光光源、补给装置、移动装置及电源组成,基于初步的分析计算,建议的系统耗能约为300 W,光斑直径为50μm,成型效率约为38 g/h。结论基于激光烧结技术路径的月壤原位成型技术具有一定的优势,建议采用低功率、小光斑、低扫描速度的技术策略,初步估算的技术指标具有工程可实现性。     

板料激光弯曲成形及其数值模拟

介绍了一种利用激光扫描板料时形成的不均匀温度场所诱发的热应力进行弯曲变形的技术。采用非耦合模型,用有限元法对成形过程中的三维瞬态温度场及形变场进行了数值模拟,定量地解释了板料激光弯曲的变形机理。文中还介绍了动态边界热流的引入方法及改进热弹塑有限元计算精度和收敛性的措施。模拟值与实测值吻合。     

利用小角度激光光散射研究阳离子有机高分子絮凝剂的絮体粒径和絮体结构

利用小角度激光光散射在线监测技术研究了不同阳离子有机高分子絮凝剂对带负电荷的高岭土颗粒体系的絮凝动力学和絮体结构.对于高电荷密度的聚二甲基二烯丙基氯化铵(PDADMAC),由于分子量低其初始絮凝反应速度较慢,最终形成的絮体也较小.絮凝过程中,其絮体结构发生重组和排列,分形维数从1.83升高到2.09,所形成的絮体密实.对于低电荷密度的2种阳离子聚丙烯酰胺(CPAM),因其分子量大投药量高,絮凝反应速度较快;但其絮体的分形维数较小且在絮凝反应中基本保持不变,形成的絮体结构开放和松散.基于有机高分子对高岭土体系浊度和zeta电位的影响,结合絮凝动力学和絮体结构分析,结果表明,PDADMAC絮凝机理是电中和作用,而随着分子量的增加和电荷密度的降低,CPAM则主要通过吸附架桥作用产生絮凝.     

Energy-Level Effects on the Deformation Mechanism in Microscale Laser Peen Forming

Laser microscale peen forming has recently received more and more attention as a viable laser processing technology as it not only imparts desirable residual stress for improvement of fatigue life of the material, but can also precisely control part deformation. In the present study, the effect of energy level on the deformation mechanism in laser microscale peen forming was investigated by both numerical and experimental methods. Deformation curvatures and residual stress distributions of both sides of the specimen, characterized by X-ray microdiffraction, were compared with the results obtained from FEM simulation. The forming mechanism for convex and concave bending was explained in terms of the resulting pressure, compressive stress distribution, and plastic strain. Differences in residual stress distribution patterns were also investigated as a function of the forming mechanism.