Automated Manufacturing Process Integrated with Intelligent Tooling Systems (AUTOMAN)

自动化制造流程与智能工装系统集成 (AUTOMAN)

• 批准号: EP/L505237/1
• 负责人: Yi Qin
• 金额: $ 20.35万
• 依托单位: University of Strathclyde
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2014
• 资助国家: 英国
• 起止时间: 2014 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FL505237%2F1
• 关键词: Automated; Manufacturing; Process; Integrated; Intelligent

Large 3D panels are used on the bodies of cars, trains, ships and aircraft and for building interiors and facades. TheBeijing Olympic Bird's Nest Stadium provides a high-profile example of a construction employing 3D panels. The worldmarket for large 3D panels is worth billions of pounds and could grow manifold if cost-effective and sustainable methods ofpanel production are available.UK companies invest billions of pounds annually in dedicated tooling to manufacture 3D panels in a variety of materials.The dies and moulds needed to produce such panels are time consuming to fabricate, involving extensive manufacturing trials. Tools are normally associated with specific parts and, when they change, the old tools are discarded or have to bedismounted and then stored. Thus, there are high levels of scrapped material, space and time wastage associated withtraditional tools. This makes current panel production techniques inefficient for small-batch production which is typical inthe manufacture of high-value products (e.g. sports cars, ships and aircraft).Multi-Point Die Forming (MPDF) is a technology pioneered at MIT to enable die surfaces to be modified to generatedifferent component forms without requiring tool changes. MPDF involves using a matrix of pins to represent the diesurfaces. These can be varied before the forming operation by pre-adjusting the lengths of the pins. The setting of the pinlengths in existing MPDF systems is a laborious trial-and-error process and thus these systems are not readilyreconfigurable.This project will develop the world's first fully reconfigurable tooling system with in-process sensing and adaptationcapability. This advanced system will incorporate pins that are actuated so that their lengths can be automatically adjustedduring forming to enable more precise control of the process. It will include sensors and on-line modelling, metrology andreverse engineering to ensure the production of accurate and defect-free panels. This new system will be usable for pressstamping and stretch-drawing operations as well as supporting and locating flexible composite panels during assembly.The proposed system will have the following innovative features not found in prototypes developed to date:- full programmability, in the in-process reconfiguration of the tool to generate tool surfaces digitally and to enable differentforming operations to be carried out;- advanced modelling to support reconfiguration to increase quality and setup efficiency;- on-line metrology to provide in-process information on real part geometry, considering machine and tool deflection andpart spring back;- compensation of spring back and deflection to enable net-shape manufacturing;- measures for ensuring part integrity including accurate geometry, limited residual stresses and high quality surface finish;- localised heating to allow forming of various materials including composites.The reconfigurable tooling system developed in the project will demonstrate the following benefits compared to currenttechnology:- an increase in 3D panel manufacturing efficiency by 50%-100%;- panel manufacturing cost savings of up to 90%;- overall material and energy savings of 30%-50% over the product life-cycle.This project will be carried out in the Schools of Mechanical Engineering and of Metallurgy and Materials at the Universityof Birmingham, the Department of Design, Manufacture & Engineering Management at the University of Strathclyde andthree industrial partners with the support of the High-Value Manufacturing Catapult and a Knowledge Transfer Network.This complete chain linking organisations involved in research, equipment design and manufacture, knowledge transferand end use ensures the relevance of the work and rapid dissemination and exploitation of the results.

大型3D面板用于汽车、火车、船舶和飞机的车身以及建筑内部和立面。北京奥运会鸟巢体育场提供了一个高调的例子，建设采用3D面板。大型3D面板的世界市场价值数十亿英镑，如果有成本效益和可持续的面板生产方法，这个市场可能会增长。英国公司每年投资数十亿英镑用于生产各种材料的3D面板的专用工具。生产这种面板所需的模具和模具制造耗时，涉及大量的制造试验。工具通常与特定的零件相关联，当它们发生变化时，旧工具被丢弃或必须重新安装然后存储。因此，与传统工具相关的材料、空间和时间浪费水平很高。这使得目前的面板生产技术对于小批量生产效率低下，而小批量生产在高价值产品（例如运动汽车，船舶和飞机）的制造中是典型的。多点模具成形（MPDF）是麻省理工学院首创的一种技术，可以修改模具表面以生成不同的部件形式，而不需要更换工具。MPDF涉及使用针矩阵来表示模具表面。这些可以在成形操作之前通过预先调整销的长度来改变。现有的MPDF系统中的针长设置是一个费力的试错过程，因此这些系统不容易重新配置。该项目将开发世界上第一个具有过程中传感和自适应能力的完全可重新配置的工具系统。这一先进的系统将包括被驱动的销，这样它们的长度可以在成型过程中自动调整，从而能够更精确地控制工艺。它将包括传感器和在线建模，计量和逆向工程，以确保生产准确和无缺陷的面板。这套新系统将可用于冲压和拉伸拉伸操作，以及在装配过程中支撑和定位柔性复合材料板。拟议的系统将具有迄今开发的原型所没有的以下创新功能：-完全可编程性，在工具的过程中重新配置，以数字化方式生成工具表面，并使不同的成形操作能够进行;-先进的建模，以支持重新配置，以提高质量和安装效率;- 在线计量，以提供关于真实的零件几何形状的过程中信息，考虑机器和工具的偏转以及零件回弹;-回弹和偏转的补偿，以实现净形状制造;-确保零件完整性的措施，包括精确的几何形状、有限的残余应力和高质量的表面光洁度;- 局部加热，使各种材料（包括复合材料）成型。与现有技术相比，该项目开发的可重构模具系统将展示以下优势：-将3D面板制造效率提高50%-100%;- 面板制造成本节省高达90%;- 在整个产品生命周期内节省30%-50%的材料和能源。该项目将在伯明翰大学机械工程学院和冶金与材料学院设计系进行，斯特拉斯克莱德大学的制造与工程管理和三个工业合作伙伴的支持下，高，价值制造弹射器和知识转移网络这一完整的链条将参与研究、设备设计和制造、知识转移和最终使用的组织联系起来，确保了工作的相关性以及成果的快速传播和利用。

项目成果

Size effects on the springback of CuZn37 brass foils in tension and micro W-bending

• DOI: 10.1177/0954405417690557
• 发表时间: 2018-12
• 期刊: Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
• 作者: Xiaoyu Liu;Shiping Zhao;Y. Qin;Chunju Wang;Wan-Adlan Wan-Nawang-Wan-Adlan-Wan-Nawang-1399641537

A parametric study on the bending accuracy in micro W-bending using Taguchi method

• DOI: 10.1016/j.measurement.2016.12.007
• 发表时间: 2017-03
• 期刊: Measurement
• 影响因子: 5.6
• 作者: Xiaoyu Liu;Shiping Zhao;Y. Qin;Jie-Hua Zhao;Wan-Adlan Wan-Nawang-Wan-Adlan-Wan-Nawang-1399641537

Influences of process and material parameters on quality of small-sized thin sheet-metal parts drawn with multipoint tooling

• DOI: 10.1016/j.promfg.2018.07.395
• 发表时间: 2018-08
• 期刊: Procedia Manufacturing
• 作者: Song Yang;Michael McPhillimy;Taufik Bin Mohamed Supri;Y. Qin

Integrated, multidisciplinary approaches for micro-manufacturing research, and new opportunities and challenges to micro-manufacturing

• DOI: 10.1177/2397791417750350
• 发表时间: 2018-01
• 期刊: Proceedings of the Institution of Mechanical Engineers, Part N: Journal of Nanomaterials, Nanoengineering and Nanosystems
• 作者: Y. Qin

Hybrid Machining: Theory, Methods, and Case Studies

• 发表时间: 2018-06
• 期刊: Journal of Gastroenterology and Hepatology
• 影响因子: 4.1
• 作者: Xichun Luo;Y. Qin