先進(jìn)制造技術(shù)施平三單元

AdvancedManufacturingTechnology先進(jìn)制造技術(shù)施平Part31Contents1.IntroductiontoAMT2.Computerandcommunication3.Computer-aidedengineering4.Automation5.Modernmanufacturingtechnologies23.Computer-AidedEngineering3.4Computer-AidedManufacturingThefieldscomputerbeingusedinmanufacturingindustryFinancialcomputationandtransactionsInventorymanagementLaborreportingProductionschedulingProductionroutingNumericalcontroltechnologyApplicationofcomputertechnologyinmanufacturingfieldisregardedasakeyweaponinthesocalledsecondindustrialrevolution.33.Computer-AidedEngineeringManoperatedmachinetoolsLatheMillingmachineDrillingmachineGrindingmachine

ThequalityofmachinedpartsbyManualmachinetool

arerelatedandlimitedtotheskilloftheoperator3.4.1Computer-AidedManufacturing-manualmachinetoolAmanuallathe43.Computer-AidedEngineering3.4.2Computer-AidedManufacturing-NCNC(NumericalControl)amethodofcontrollingthemovementsofmachinecomponentsbydirectlyinsertingcodedinstructionsintothesystem,thesysteminterpretsandconvertsthesedataintooutputsignals,whichcontrolvariousmachinecomponentsToolpointpositioncontrolSecondlyfunctionscontrolToolspeedFeedrateCoolantflowToolselectionandchanginggaugingMillingcenter

EXAMPLEMulti-axismachine

EXAMPLEHousingbox

EXAMPLE53.Computer-AidedEngineering3.4.2Computer-AidedManufacturing-NCFirstNCMIT1950,a3axesservo-controlledmillingmachinetool63.Computer-AidedEngineering3.4.2Computer-AidedManufacturing-NCSometypesofCNCmachinetoolCNCmillingmachineVMC:verticalmachiningcenter,3,4,5axesofmotionHMC:horizontalmachiningcenter,3,4,5axesofmotion(normally,CNCmachinetoolhasanATC,orautomatictoolchanger)CNClatheVMCHMC73.Computer-AidedEngineeringTheadvantageofNC,CNCmachineMoreaccurateFasterLowercostHigheruniformalityandconsistencyAutomatic3.4.2Computer-AidedManufacturing-NC83.Computer-AidedEngineering3.4.2Computer-AidedManufacturing-NCComponentsofNCsystem1.PartProgrampreprogrammedinstructions,tellingthemachinetoolwhattodo,stepbystep.CertainprogramminglanguageisusedCodedonsomemedia:punchedtape;computerdisketc.(programstoredincomputer,thecomputerdirectlylinkedtothemachinetool,thisiscalleddirectnumericalcontrol,orDNC.)DNC:directnumericalcontrol.93.Computer-AidedEngineering3.4.2Computer-AidedManufacturing-NCComponentsofNCsystem2.CNCControlSystemTheelectromechanicaldevice,readingandinterpretingpartprogramandconvertingitintomechanicalactionsofthemachinetool(mostmodernsystemsuseamicroprocessorasthecontrolunit,thistypeofnumericalcontroliscalledcomputernumericalcontrol,orCNC)103.Computer-AidedEngineeringNC2.CNCControlSystemThreesubsystemsofCNCcontrolsystemcontrolunit:centerpieceofCNCsystem,(alsocalledcontrolsystem,MCU(machinecontrolunit),controller).Usually,itisacomputerandinterfaceoftheCNCsystem.Drive:ScrewandmotorBallscrew:eliminatingbacklashforhigh-precisionpositioningSteppingmotor:rotatesafixedangleforaelectricalpulseinput;easytobecontrolled;discretemovement,usedinlowpricedCNCtrainerandassemblysystemServomotor:morecommonused,smoothandcontinuousmotion;feedbackisneeded(closedloopsystem).AlternatingcurrentservomotoristhestandardchoiceforindustrialCNCsystemFeedbackProvidesthecontrolunitwithinformationaboutthestatusofmotioncontrolsystem113.Computer-AidedEngineeringComponentsofNCcessingequipmentItisactuallythemachinetool,whichperformtheworkComponentsofprocessingequipmentSpindleCuttingtoolWorktableChunkorotherFixtureMotorsanddrivers123.Computer-AidedEngineeringNC133.Computer-AidedEngineeringNC143.Computer-AidedEngineeringNC153.Computer-AidedEngineeringNCStepmotor&driverservomotor&driver163.Computer-AidedEngineeringProgrammingofCADGcodealsocalledpreparatorycodes,andareanywordinaCNCprogramthatbeginswiththeletterG.Generallyitisacodetellingthemachinetoolwhattypeofactiontoperform,suchas:rapidmovecontrolledfeedmoveinastraightlineorarcseriesofcontrolledfeedmovesthatwouldresultinaholebeingbored,aworkpiececut(routed)toaspecificdimension,oradecorativeprofileshapeaddedtotheedgeofaworkpiece.changeapalletsettoolinformationsuchasoffset.CommonFANUCGCodesforMill173.Computer-AidedEngineeringProgrammingofCADGcodeThereareaISOstandard,butalotofNCprovidersdonotadheretoit,andtherearemanyversionseveninthesameindustryProgrammingistediousandpronetomakingmistakesFuturedevelopmentisautomaticprogrammingwithprogramlanguagebasedoninteractivegraphicsdirectlyfromCADdatabase183.Computer-AidedEngineeringGcodeexampleToolPathforprogramLineCodeDescriptionN01M216TurnonloadmonitorN02G00X20Z20Rapidmoveawayfromthepart,toensurethestartingpositionofthetoolN03G50S2000SetMaximumspindlespeedN04M01OptionalstopN05T0303M6Selecttool#3fromthecarousel,usetooloffsetvalueslocatedinline3oftheprogramtable,indextheturrettoselectnewtoolN06G96S854M42M03M08Variablespeedcutting,854ft/min,Highspindlegear,StartspindleCWrotation,TurnthefloodcoolantonN07G00X1.1Z1.1Rapidfeedtoapoint0.1"fromtheendofthebarand0.05"fromthesideN08G01Z1.0F.05Feedinhorizontallyuntilthetoolisstanding1"fromthedatumN09X0.0Feeddownuntilthetoolisoncenter-FacetheendofthebarN10G00Z1.1Rapidfeed0.1"awayfromtheendofthebarN11X1.0RapidfeedupuntilthetoolisstandingatthefinishedODN12G01Z0.0Feedinhorizontallycuttingthebarto1"diameterallthewaytothedatumN13M05M09Stopthespindle,TurnoffthecoolantN14G28G91X0HomeXaxisinthemachinecoordinatesystem,thenhomeallotheraxesN15M215TurntheloadmonitoroffN16M30Programstop,palletchangeifapplicable,rewindtobeginningoftheprogram193.Computer-AidedEngineeringComponentsofNCsystemPartProgramMachineControlUnitProcessingequipment203.Computer-AidedEngineeringNCsystemtype:open-loopsystem;close-loopsystem213.Computer-AidedEngineeringNCsystemtypeopen-loopsystemThesignalsaresenttotheservomotorsbythecontroller,butthemovementsandfinalpositionsoftheworktablearenotcheckedforaccuracy(withoutfeedback)close-loopsystemEquippedwithvarioustransducers,sensors,andcountersthatmeasureaccuratelythepositionoftheworktable(output),thistransducedsignalsarecalledfeedbacksignalsThroughfeedbackcontrol,thefeedbacksignaliscomparedagainsttheinputsignal,whenproperpositionisreached,themovementstops.Thedifferentiationoftheinputandoutputfeedbacksignalisthedrivingsignal.223.Computer-AidedEngineeringMeasurementoffeedbacksignals23Multi-axisNCMachineCenter24Examples:http://6.cn/watch/437895.htmlhttp://6.cn/watch/443326.htmlMulti-axisNCMachineCenterForcomplicatedpartmachiningExample:5axismachiningExample:3DwordsculpturingExample:GermanMakaCar-modelmaking253.Computer-AidedEngineeringBenefitofmulti-axismachinetoolIncreasepartmakingdiversityandtheabilitytomachinecomplexpartsmoreefficientlyIncreasethroughputbyeliminatingpartsetupsandhandlingsReducein-processinventorycostswhileraisingjust-in-timepartschedulingOptimizepartqualityandaccuracyFewermachinesinmanufacturingchain,lowcostLowerfixturecost,fewerdedicatedfixturesandtools263.Computer-AidedEngineeringDisadvantagesExpensiveComplexprogrammingHightrainingfeesUsage:aerospaceindustry:propellerShipmanufacturing:submarinepropellerDefenseindustry:missilepartsmanufacturing273.Computer-AidedEngineeringMachiningCellAgroupofmachinetoolslinkedbybothcontrolandparthandlingfacilitiesMachiningcentermultifunctionalCNCmachinewithautomatictool-changingcapabilityandrotatingtoolmagazineVerticalHorizontalUniversalTendsIndividualmachinecanperformmorefunctions,sofewermachinesinonecellandlessfloorspaceneeded.HighspeedandprecisionRoboticsandtransfersystemEasytoprogramandoperate283.Computer-AidedEngineeringInspectionAnorganizedexaminationorformalevaluationexercise.Itinvolvesthemeasurements,tests,andgaugesappliedtocertaincharacteristicsinregardstoanobjectoractivity.TestingIngeneral,testingisfindingouthowwellsomethingworks.AssessingthefunctionalityofthemanufacturedproductWhat’’sthedifference?293.Computer-AidedEngineeringWhatcharacteristicswewanttoinspect?DimensionalmeasuresofanobjectlengthWidthDepthdiameterGeometricshapeRoughnessConcentricitysquareness303.Computer-AidedEngineering3.4.2Computer-AidedManufacturing-computer-aidedtestingandinspectionHowweinspect?Off-lineinspectionOn-lineinspectionSpecificvariableinspectionduringoperation,withoutunloadingandreloadingworkpieces.ExampleofOn-lineinspectionContinuouslymeasuringdiameterofaturnedpartbyusingthecuttingtooltipasthemeasuringinstrument313.Computer-AidedEngineering3.4.2Computer-AidedManufacturing-computer-aidedtestingandinspectionComputer-aidedinspection:UsingsensorsformeasuringcharacteristicsofpartsContactinspection:thesensor(probe)contactswithworkpieces.Example:theprobeofaCMM(coordinatemeasuringmachine)contactswiththeworkpiece323.Computer-AidedEngineering3.4.2Computer-AidedManufacturing-computer-aidedtestingandinspectionNoncontactinspectionMachinevisionsystemusingvideocamerainrivetaligningonfuselageLaserbeamlaserpositioningUltrasonictechniquedimensionalfeaturesflawsdetectingX-rayradiationtechniqueThicknessflawsdetectingElectricalfieldtechniqueVoidscracksdetectingbyusingeddycurrents333.Computer-AidedEngineering3.4.3Computer-AidedManufacturing-CAD/CAMsystemWhatisCAD/CAMsystem?AcombinationofComputer-AidedDesignandComputer-AidedManufactureasawholesystemHowdoesitwork?SharinginformationautomaticallyfromdesignstagetomanufacturingstageCADdatabaseisstored,andusedbyCAMtoforminstructionsforoperatingandcontrollingproductionmachinery,materialhandlingequipment,andforoperating,testing,inspectionetc343.Computer-AidedEngineering3.4.3Computer-AidedManufacturing-CAD/CAMsystemTypicalapplicationsofCAD/CAMProgrammingforNC,CNC,industrialrobotDesignoftools,fixtures,EDMelectrodesQualitycontrol,inspection,Processplanning,schedulingPlantlayoutApaperlessCAD/CAMofBoeing777isafantasticexampleofthisartofindustrialproduction353.Computer-AidedEngineering3.4.3Computer-AidedManufacturing-CAD/CAMsoftwareSelectionofCAD/CAMSoftwareUGPro/ECimatronMasterCAMCATIA363.Computer-AidedEngineering3.4.4Computer-AidedManufacturing-CAPPWhatisprocessplanning?SystematicdeterminationofmethodsbywhichaproductistobemanufacturedeconomicallyandcompetitivelyConcerningwithselectingmethodsofproductionToolingMachinerySequenceofoperationsAssemblyAnintermediatestagebetweendesigningandmanufacturingProcessplanforthesamepartcanbevariedduetoDifferentplannerDifferentavailableequipmentsofdifferentfacilitiesDifferentlotsizeApplicationofnewtechnologies373.Computer-AidedEngineering3.4.4Computer-AidedManufacturing-CAPPWhatisaRouteSheet?Acardonwhichthesequenceofprocessandoperations,machinestobeused,standardtimeforeachoperation,andsimilarinformationaredocumented383.Computer-AidedEngineering3.4.4Computer-AidedManufacturing-CAPPWhatisCAPP?CAPPstandsforComputer-AidedProcessPlanningTwotypesofCAPPsystemsVariantProcessPlanningSystemAlsoknownasretrievalprocessplanning.Basedonconceptsofgrouptechnologyandpartsclassification.RetrievalofexistingplanformodificationGenerativeprocessPlanningSystemProcessplanisautomaticallygeneratedinatraditionallogicalprocedure(it’sthetrendofCAPP)FurtherinformationofCAPP393.Computer-AidedEngineering3.4.4Computer-AidedManufacturing-CAPPAdvantagesofCAPPSystemProductivityofprocessplannerenhancedLeadtimes,planningcostsreducedConsistencyofproductqualityandreliabilityimprovedRetrievalofsimilarplan–modification,newplaneasilyestablishedRoutesheetmorequicklyprepared,neaterandclearer.Otherfunctions,suchascostestimating,workstandards,canbeincorporatedintoCAPP403.Computer-AidedEngineering3.4.5Computer-AidedManufacturing-CEConcurrentEngineeringasystematicapproachtointegratedproductdevelopmentthatemphasizestheresponsetocustomerexpectationsembodiesteamvaluesofco-operation,trustandsharinginsuchamannerthatdecision-makingisbyconsensus,involvingallperspectives(function,manufacturing,assembly,scheduling,quality,cost,maintenance,etc)inparallel,fromthebeginningoftheproductlife-cycleCEprovidesacollaborative,co-operative,collectiveandsimultaneousengineeringworkingenvironmentCEdealwithConcurrentengineeringmanagementandprocesscontrolConcurrentdesignRapidmanufacturing413.Computer-AidedEngineering3.4.5Computer-AidedManufacturing-CEFivekeyelementsonwhichCEapproachisbasedaprocessProductdevelopmentisaprocess,effectiveandefficientprocesscanbeobtainedbyconcurrentengineeringmanagementandprocesscontrollingamultidisciplinaryteamEngineeringdesign,Manufacturingengineering,finance,marketing,R&D,logistic,purchasing,QCanintegrateddesignmodelIntegrationofdecision-makingconsensusfromdifferentaspectsafacilityasoftwareinfrastructureElectronictool/CADtoolsShareddatabasePDES:productdataexchangespecification/communicationlanguage423.Computer-AidedEngineering3.4.5Computer-AidedManufacturing-CEFeaturesofCEmultidisciplinaryteamToolsCADtoolsenableteammembersharingthedesign-relatedinformation/databaseElectronictool/CADtoolsPDES:productdataexchangespecification/communicationlanguageDesignmethodDFM:ruleforavoidingdifficultandcostmanufacturingDFA:ruleforavoidingdifficultandcostassemblingDFI:ruleforavoidingdifficultandcostinspectionDFx:QualityMethodQualityisaddressedfromthestartoftheproductdesign,itisbetterguaranteedMaintainability:simpleandeffectiveisthegoal.e-documentations,suchasVirtualReality,AugmentedRealityareapplied.CostanalysisAllfunctionsmustconsiderthecostimpactandeffectoftheirdecisiontothetotalproductcost.Themathematicalmodelpredictingfuturecostisapplied43TheFeaturesofCEVirtualRealitydocumentationVirtualRealitydocumentation443.Computer-AidedEngineeringGroupTechnologyaconceptseekstotakeadvantagesofthedesignandprocessingsimilaritiesamongthepartstobeproduced.TheconceptwasfirstdevelopedinEuropein1900,thetermGTfirstusedin1959amanufacturingphilosophymakingsmall&mediumsizebatchproductionpossiblebyusingdesignandmanufacturingsimilaritiesamongparts453.Computer-AidedEngineeringGTsimilarpartscanbecodedtoaselectioncode,manufacturedinthesomededicatedmachiningcellExampleThesefourpartscanbeinthesamegroup,becauseTheyaresimilarinsizeandshapeTherawmaterialisacastingtheinternalholewillbeboredinonedirectionFacemillingisrequired463.Computer-AidedEngineeringSomepackagesofpartsclassificationandcodingsystemarenowavailableinthemarketdesignstandardizationdesignretrievalcapabilities(retrieval-modification-newdesign)forCAPP,tooldesignandchoice,materialrequirementplanning.etcAparticularpartisclassifiedandcodedaccordingtoDesignattributeGeometricshapeSize(length,diameter)MaterialTolerancesurfacefinish,etc.Manufacturingattributesequenceofoperationstreatmentsimilaritiesmachinetimesimilarityofcuttingtoolsandfixtures,etc.473.Computer-AidedEngineeringGTimpacttoarrangementofequipmentsTraditionalproductflowinbatchmanufacturingArrangementaccordingtoequipmentstypesGTlayoutattributeoperationsequenceandmachineroutingarrangementaccordingtopartfamily.Forcertainpart,choosealayoutaccordingtoGTcode.483.Computer-AidedEngineeringAdvantagesofGTStandardizationofdesign&minimizationofdesignduplicationDesignandprocessplanning(forcertainpartfamily)experiencescanbestoredindatabasefornovice’’sretrievalProcessplansarestandardizedandschedulingmoreefficientManufacturingcostsaremoreeasilyestimatedProductivityandcostreducingenhancedinsmall-batchproduction493.Computer-AidedEngineeringRapidPrototyping&ManufacturingApictureisworthathousandwords;onerealprototypeisworthathousandpicturesTwoimportantchallengingtasksSubstantialreductionofproductdevelopmenttimeImprovementonflexibilityformanufacturingsmallbatchsizeproductsandavarietyoftypesofproductsRP/Misasolution503.Computer-AidedEngineeringRapidPrototyping&ManufacturingCADmodel.STLformat(sectionalpicture)makingprototypepartslayerbylayeraccordingto.STLfiles.SomeRP/MavailableSLA:stereolithographySLS:selectivelasersinteringLOM:laminatedobjectmanufacturingFDM:fuseddepositionmodeling3DP:threedimensionalprinting513.Computer-AidedEngineeringSLAStereolithographyCADdesign—digitalpartmodelSectionpicturebyslicingfileformat:***.STLMakingeachslicedlayerpicturerealbyapplyingPhotocurablepolymerLaserbeamIntegratingalllayerstogetthedesigned““object”523.Computer-AidedEngineeringLayerthickness50~200micronsPolymertankSupportneededSupportingcolumnsPostcuringHandsandingandpolishing(stair-steppingeffectmitigation)533.Computer-AidedEngineeringSLSselectivelasersinteringSupportingcolumnnotneededPowdertemperatureafewdegreesbelowmeltingpointheatedbyinfraredpanelsGrainyappearance,surfacesmoothingneeded543.Computer-AidedEngineeringLOMlaminatedobjectmanufacturingStackofpaperCrosshatchfortheunwantedareaforeasyremovalTrimming,handfinishing553.Computer-AidedEngineeringFDMfuseddepositionmodeling563.Computer-AidedEngineering3DPthree-dimensionalprinting573DprinterEDEN250Example1Example1Example1