1. Using simulation technology to optimize process design Forming, modification and processing are the main processes of the mechanical manufacturing process, and are the process of manufacturing raw materials (mainly metal materials) into blanks or parts. These processes, especially the hot working process, are extremely complex high-temperature, dynamic, and transient processes in which a series of complex physical, chemical, and metallurgical changes occur. These changes are not directly observable, and indirect testing is also very difficult. Processing technology design can only rely on "experience". In recent years, the application of computer technology and modern testing technology to form a hot processing simulation and optimization design technology has become the world's hottest research hotspots and cross-century technology frontiers.
Application simulation technology can virtually display the process of material thermal processing (casting, forging, welding, heat treatment, injection molding, etc.), predict the process results (tissue performance quality), and optimize the process design through different parameter comparisons to ensure large-scale manufacturing. Success; ensure that the batch is successfully tested at one time.
Analog technology has also been applied to machining, special processing and assembly processes, and has evolved into a form of solid manufacturing, which has become the technical basis for decentralized networked manufacturing, digital manufacturing and manufacturing globalization.
2. Forming accuracy is in the near direction. The forming of blanks and parts is the first process of mechanical manufacturing. Metal blanks and parts are generally formed by casting, forging, stamping, welding and rolling. With the development of the precision forming process of the blank, the dimensional accuracy of the shape forming of the part is progressing from Near Net Shape Forming to Net Shape Forming, that is, near-no-form forming. The boundaries between “blank†and “parts†are getting smaller and smaller. After the blank is formed, it has approached or reached the final shape and size of the part and can be assembled after grinding. The main methods are various forms of precision casting, precision forging, fine punching, cold temperature extrusion, precision welding and cutting. For example, in the production of automobiles, “a close-to-zero amount of agile and precision stamping systems†and “smart resistance welding systems†are under development.
3. Forming quality is in the direction of no “defects†Another indicator of the quality of blanks and parts is the number, size and extent of defects. Since the thermal processing process is very complicated and the factors are variable, it is difficult to avoid the occurrence of defects. In recent years, the hot processing industry has proposed the goal of “developing in the direction of “near no defectsâ€. This “defect†refers to the concept of critical defects that does not cause early failure. The main measures adopted are: using advanced technology to purify the molten metal sheet, increasing the density of the alloy structure, laying the foundation for obtaining sound castings and forgings; using simulation technology to optimize the process design to achieve a successful forming and trial-test; Process monitoring and non-destructive testing, timely detection of over-standard parts; determination and critical value of critical defects by means of part safety and reliability research and evaluation.
4. Mechanical processing to ultra-precision, ultra-high-speed development Ultra-precision machining technology has entered the nano-processing era, processing accuracy of 0.025μm, surface roughness of 0.0045μm. The precision cutting technology is approaching from the current red band to the visible light band or the invisible ultraviolet and X-ray bands; the ultra-finishing machine is moving toward multi-functional modularization; the super-finished material is expanded from metal to non-metal.
At present, the cutting of high-speed cutting aluminum alloy has exceeded 1600m/min; the cast iron is 1500m/min; ultra-high-speed cutting has become a way to solve the problem of processing difficult materials.
5. Adopt new energy and composite processing. Solving the problem of processing and surface modification of new materials, the introduction of new energy or energy carriers such as laser, electron beam, ion beam, molecular beam, plasma, microwave, ultrasonic, electro-hydraulic, electromagnetic, high-pressure water jet, etc. Special processing and high-density cutting, welding, melting, forging, heat treatment, surface protection and other processing processes or composite processes. Among them, laser processing in various forms has developed most rapidly. These new processes not only improve processing efficiency and quality, but also solve the processing problems of new materials such as superhard materials, polymer materials, composite materials, and engineering ceramics.
6. Using automation technology to achieve optimal control of process technology Microelectronics, computer, automation technology and process equipment are combined to form a variety of automated forming processes from stand-alone to system, from rigid to flexible, from simple to complex. Technology makes qualitative changes in process control methods. Its development history and trends are:
1) Application of integrated circuit, programmable controller, microcomputer and other new control components and devices to realize automatic control of single machine, production line or system of process equipment.
2) Applying new sensing, non-destructive testing, physical and chemical testing, and computer and microelectronic technology to measure and monitor the temperature, pressure, shape, size, displacement, stress, strain, vibration, sound, image, electricity, magnetism and process of the process in real time. The composition and structure of the alloy and gas, etc., realize the electronic control of the on-line measurement and testing technology, digitization, closed-loop control of computer and process parameters, and then realize adaptive control.
3) Integrate computer-aided process programming (CAPP), numerical control, CAD/CAM, robotics, automated handling and storage, management information system (MIS) and other automated unit technologies into process design, processing and logistics processes to form flexible automation of different grades Systems; CNC machining, machining centers (MC), flexible manufacturing units (FMC), flexible manufacturing islands (FMI), flexible manufacturing systems (FMS) and flexible production lines (FTL), and to form computer integrated manufacturing systems (CIMS) and intelligent manufacturing System (IMS).
7. Adopting clean energy and raw materials to achieve clean production The mechanical processing process produces a large amount of waste water, waste residue, exhaust gas, noise, vibration, heat radiation, etc., and the labor conditions are heavy and dangerous, and it has not adapted to the requirements of contemporary clean production. In recent years, clean production has become a new goal of the processing process. In addition to doing a good job in the three wastes, it is important to start from the source and prevent pollution. One of the ways is as follows: First, the use of clean energy, such as electric heating instead of burning coal to heat the forging billet, using electric melting instead of coke cupola melting molten iron; second, using clean process materials to develop new processes, such as forging Non-graphite type lubricating materials are used in production, non-pulverized type sand is used in sand casting; third is to adopt new structure to reduce noise and vibration of equipment. For example, in the casting production, the shocking type molding machine with great noise has been replaced by the injection molding and static pressure molding machine. In die forging production, the die forging hammer with large noise and high energy consumption has been gradually replaced by the electric hot forging press and high energy screw press driven by electro-hydraulic. On the basis of cleaner production, “green manufacturing†that meets the specific environmental requirements for the entire cycle of design, production, use, and recycling and disposal will become an important feature of manufacturing in the 21st century.
8. The line between processing and design is gradually diminishing and tends to be integrated and integrated. The emergence of advanced manufacturing technologies and philosophies such as CAD/CAM, FMS, CIMS, concurrent engineering, rapid prototyping, etc., has gradually narrowed the boundaries between processing and design and is moving toward integration. At the same time, between the hot and cold processing, the boundary between the processing, the inspection process, the logistics process, and the assembly process tends to be negotiated, disappeared, and integrated into a unified manufacturing system.
9. Process technology is closely integrated with information technology and management technology, and advanced manufacturing production mode is continuously developed. Advanced manufacturing technology system is an integrated system composed of technology, people and organizations. The three can be effectively integrated to achieve satisfactory results. Therefore, advanced manufacturing processes can only improve the use of advanced manufacturing processes by closely integrating with information and management technologies and continuously exploring new production models that meet the needs. The advanced manufacturing production modes mainly include: flexible production, on-time production, lean production, agile manufacturing, concurrent engineering, and distributed networked manufacturing. These advanced manufacturing models are the result of a close integration of manufacturing processes with information and management technologies, which in turn affects and promotes continuous innovation and development of manufacturing processes.
Application simulation technology can virtually display the process of material thermal processing (casting, forging, welding, heat treatment, injection molding, etc.), predict the process results (tissue performance quality), and optimize the process design through different parameter comparisons to ensure large-scale manufacturing. Success; ensure that the batch is successfully tested at one time.
Analog technology has also been applied to machining, special processing and assembly processes, and has evolved into a form of solid manufacturing, which has become the technical basis for decentralized networked manufacturing, digital manufacturing and manufacturing globalization.
2. Forming accuracy is in the near direction. The forming of blanks and parts is the first process of mechanical manufacturing. Metal blanks and parts are generally formed by casting, forging, stamping, welding and rolling. With the development of the precision forming process of the blank, the dimensional accuracy of the shape forming of the part is progressing from Near Net Shape Forming to Net Shape Forming, that is, near-no-form forming. The boundaries between “blank†and “parts†are getting smaller and smaller. After the blank is formed, it has approached or reached the final shape and size of the part and can be assembled after grinding. The main methods are various forms of precision casting, precision forging, fine punching, cold temperature extrusion, precision welding and cutting. For example, in the production of automobiles, “a close-to-zero amount of agile and precision stamping systems†and “smart resistance welding systems†are under development.
3. Forming quality is in the direction of no “defects†Another indicator of the quality of blanks and parts is the number, size and extent of defects. Since the thermal processing process is very complicated and the factors are variable, it is difficult to avoid the occurrence of defects. In recent years, the hot processing industry has proposed the goal of “developing in the direction of “near no defectsâ€. This “defect†refers to the concept of critical defects that does not cause early failure. The main measures adopted are: using advanced technology to purify the molten metal sheet, increasing the density of the alloy structure, laying the foundation for obtaining sound castings and forgings; using simulation technology to optimize the process design to achieve a successful forming and trial-test; Process monitoring and non-destructive testing, timely detection of over-standard parts; determination and critical value of critical defects by means of part safety and reliability research and evaluation.
4. Mechanical processing to ultra-precision, ultra-high-speed development Ultra-precision machining technology has entered the nano-processing era, processing accuracy of 0.025μm, surface roughness of 0.0045μm. The precision cutting technology is approaching from the current red band to the visible light band or the invisible ultraviolet and X-ray bands; the ultra-finishing machine is moving toward multi-functional modularization; the super-finished material is expanded from metal to non-metal.
At present, the cutting of high-speed cutting aluminum alloy has exceeded 1600m/min; the cast iron is 1500m/min; ultra-high-speed cutting has become a way to solve the problem of processing difficult materials.
5. Adopt new energy and composite processing. Solving the problem of processing and surface modification of new materials, the introduction of new energy or energy carriers such as laser, electron beam, ion beam, molecular beam, plasma, microwave, ultrasonic, electro-hydraulic, electromagnetic, high-pressure water jet, etc. Special processing and high-density cutting, welding, melting, forging, heat treatment, surface protection and other processing processes or composite processes. Among them, laser processing in various forms has developed most rapidly. These new processes not only improve processing efficiency and quality, but also solve the processing problems of new materials such as superhard materials, polymer materials, composite materials, and engineering ceramics.
6. Using automation technology to achieve optimal control of process technology Microelectronics, computer, automation technology and process equipment are combined to form a variety of automated forming processes from stand-alone to system, from rigid to flexible, from simple to complex. Technology makes qualitative changes in process control methods. Its development history and trends are:
1) Application of integrated circuit, programmable controller, microcomputer and other new control components and devices to realize automatic control of single machine, production line or system of process equipment.
2) Applying new sensing, non-destructive testing, physical and chemical testing, and computer and microelectronic technology to measure and monitor the temperature, pressure, shape, size, displacement, stress, strain, vibration, sound, image, electricity, magnetism and process of the process in real time. The composition and structure of the alloy and gas, etc., realize the electronic control of the on-line measurement and testing technology, digitization, closed-loop control of computer and process parameters, and then realize adaptive control.
3) Integrate computer-aided process programming (CAPP), numerical control, CAD/CAM, robotics, automated handling and storage, management information system (MIS) and other automated unit technologies into process design, processing and logistics processes to form flexible automation of different grades Systems; CNC machining, machining centers (MC), flexible manufacturing units (FMC), flexible manufacturing islands (FMI), flexible manufacturing systems (FMS) and flexible production lines (FTL), and to form computer integrated manufacturing systems (CIMS) and intelligent manufacturing System (IMS).
7. Adopting clean energy and raw materials to achieve clean production The mechanical processing process produces a large amount of waste water, waste residue, exhaust gas, noise, vibration, heat radiation, etc., and the labor conditions are heavy and dangerous, and it has not adapted to the requirements of contemporary clean production. In recent years, clean production has become a new goal of the processing process. In addition to doing a good job in the three wastes, it is important to start from the source and prevent pollution. One of the ways is as follows: First, the use of clean energy, such as electric heating instead of burning coal to heat the forging billet, using electric melting instead of coke cupola melting molten iron; second, using clean process materials to develop new processes, such as forging Non-graphite type lubricating materials are used in production, non-pulverized type sand is used in sand casting; third is to adopt new structure to reduce noise and vibration of equipment. For example, in the casting production, the shocking type molding machine with great noise has been replaced by the injection molding and static pressure molding machine. In die forging production, the die forging hammer with large noise and high energy consumption has been gradually replaced by the electric hot forging press and high energy screw press driven by electro-hydraulic. On the basis of cleaner production, “green manufacturing†that meets the specific environmental requirements for the entire cycle of design, production, use, and recycling and disposal will become an important feature of manufacturing in the 21st century.
8. The line between processing and design is gradually diminishing and tends to be integrated and integrated. The emergence of advanced manufacturing technologies and philosophies such as CAD/CAM, FMS, CIMS, concurrent engineering, rapid prototyping, etc., has gradually narrowed the boundaries between processing and design and is moving toward integration. At the same time, between the hot and cold processing, the boundary between the processing, the inspection process, the logistics process, and the assembly process tends to be negotiated, disappeared, and integrated into a unified manufacturing system.
9. Process technology is closely integrated with information technology and management technology, and advanced manufacturing production mode is continuously developed. Advanced manufacturing technology system is an integrated system composed of technology, people and organizations. The three can be effectively integrated to achieve satisfactory results. Therefore, advanced manufacturing processes can only improve the use of advanced manufacturing processes by closely integrating with information and management technologies and continuously exploring new production models that meet the needs. The advanced manufacturing production modes mainly include: flexible production, on-time production, lean production, agile manufacturing, concurrent engineering, and distributed networked manufacturing. These advanced manufacturing models are the result of a close integration of manufacturing processes with information and management technologies, which in turn affects and promotes continuous innovation and development of manufacturing processes.
Chameleon Prepainted Steel /Aluminum Coil
Chameleon PREPAINTED STEEL COIL/ALUMINUM COIL
Chameleon prepainted steel has gorgeous metallic decorative coating, which has good adhesive force with the substrate. It has good weather resistance and exterior stability and won`t corrode in 15 years.
Application: Building Material, Decoration, Exterior Wall Panel, Ceiling, Steel Door, Household Appliances, etc.
Chameleon Prepainted Steel Coil,Chameleon Prepainted Aluminum Coil,Chameleon Ppal Coils,Chameleon Coated Wall Panel
Shandong Wofeng New Material Co., Ltd. , https://www.wofengcoil.com