Some current development trends in metal-forming technology
Some current development trends in metal-forming technology
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DOI：
10.1016/0924-0136(96)02301-1
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发表时间：
1996-06
影响因子：
6.3
通讯作者：
R. Kopp
中科院分区：
文献类型：
--
作者：
R. Kopp
金属成形技术的各种趋势将改变未来的工厂建设和生产技术，这已经变得越来越明显。该报告介绍了若干进程的缩短、灵活化和一体化。此外，中空结构技术对于创新生产变得越来越有趣。此外，有限元模拟和优化，也报告在文件中，越来越重要的工具，为新的或改进的过程和工厂的发展。鉴于需要尽量减少生产成本，提高环境兼容性，并按照规定的质量标准制造产品，应尽可能或必要地缩短漫长而复杂的过程。在带材生产领域，应当提及薄板坯技术和薄带铸造的发展，其中完全消除了某些制造步骤。对于成形零件，缩短工艺的可能方法包括在固-液相线范围内成形（触变成形）。另一种可能性是成形与热处理的组合。更短的工艺链通常意味着产品具有更好的机械性能，因此也意味着新的应用。在成形工艺变得更加灵活以扩大产品范围的背景下，有必要使用具有与前一步骤和后一步骤以及通用模具和智能控制的可适应链接的柔性成形单元。例如，机器人操纵的开式模锻允许以相对较小的余量可重复地制造复杂锻件。轧制过程中的可变轧制间隙意味着可以生产具有与后续部件的载荷情况相匹配的限定纵向厚度轮廓的金属板。不同生产过程的整合也为新方法铺平了道路。通过在成型过程中或成型后直接使用局部加热方法，以及将成型工艺与分型或连接技术相结合，可以扩展现有工艺限制，并优化部件的最终性能。在创新的轻质结构领域，一个有前途的方法是系统地使用中空结构;正在开发用于产生空腔的新工艺和用于加工新中空结构的生产技术。除了适当的测试，物理和数值模拟可以用来优化现有的或开发新的制造方法。物理模拟在解决物质流动问题方面可能特别成功。提出了一种新的物质流模拟器。数值模拟特别用于局部工艺变量的定量分析;最近已经开发了在成形过程中考虑结构修改的方法。
Various trends in metal-forming technology which will change future plant construction and production technology are already becoming apparent. The report describes the shortening, flexibilization and integration of a number of processes. Moreover hollow structure technologies become more and more interesting for innovative production. Furthermore FEM-simulation and optimization, also reported on in the paper, are increasingly important tools for the development of new or improved processes and plants. In view of the need to minimize production costs, to increase environmental compatibility and to manufacture products to a defined quality standard, long, complex processes should be shortened as far as is possible or necessary. In the field of strip production, mention should be made of the development of thin slab technology and thin strip casting, in which certain manufacturing steps are eliminated completely. For formed parts, possible methods for shortening the process include forming in the solidus-liquidus range (thixoforming). Another possibility is a combination of forming with heat treatment. Shorter process chains often mean more favourable mechanical properties for the products and hence new applications. Against a background in which forming processes are becoming more flexible in order to enlarge the spectrum of products, it is necessary to use flexible forming units with adaptable links to preceding and succeeding steps as well as universal dies and intelligent controls. For example, robot-manipulated open die forging allows reproducible manufacture of complex forgings with relatively small allowances. A variable rolling gap in the rolling process means that sheet metals can be produced with a defined longitudinal thickness profile matching the load case for the subsequent component. The integration of different production processes also paves the way for new approaches. Existing process limits can be extended and the final properties of components optimized by using partial heating methods during or directly after forming and by coupling forming processes with parting or joining techniques. A promising approach in the field of innovative lightweight construction is the systematic use of hollow structures; new processes for generating cavities and production techniques for processing the new hollow structures are being developed. Apart from suitable tests, physical and numerical simulation can be used to optimize existing or develop new methods of manufacture. Physical simulation may be especially successful in solving questions of material flow. A new material flow simulator is presented. Numerical simulation is used especially for quantitative analysis of local process variables; methods have recently been developed for taking the modification of structure during the forming process into account.