Abstract The main long-term goal of machine tool manufacturing technology has always been to improve productivity and processing quality. However, in recent years, with the increasing awareness of environmental protection and the increasing shortage of natural resources, the effective use of energy and resources in the production process and the design concept of reducing pollution in machine tools...
The main long-term goal of machine tool manufacturing technology has always been to improve productivity and processing quality. However, in recent years, with the increasing awareness of environmental protection and the increasing shortage of natural resources, the effective use of energy and resources in the production process and the reduction of pollution play an increasingly important role in the design concept of machine tools.
Lightweight is the technical direction
In order to achieve economic and environmental protection goals, machine tool light structure technology came into being. Light technology is particularly suitable for the corresponding processing requirements in accordance with the stiffness requirements, light structure technology plays a vital role.
Perhaps it is for this reason that the University of Stuttgart Machine Tool Research Institute and the Fraunhofer Institute for Production Technology and Automation, the new department of Light Structure Technology, collaborate on basic research and production application research and teaching activities. I want to combine and better promote the innovation and teaching content of industrial production.
At the 3rd Sino-German Advanced Manufacturing Technology Forum, experts at the conference believed that the implementation of the new sustainable production method combined with the application of the new factory structure and organizational management structure determined the success or failure of industrial manufacturing enterprises in the global large-scale market. .
Part of the new sustainable production method is the development of so-called lightweight materials, which are extended to new fields and the development of the necessary production and processing processes that are compatible with the production of the products.
Taking the structural chain as a clue, the light structure must first deal with the raw material problem, followed by the challenges that the new material will face in the subsequent processing, such as the evaluation method of processing quality caused by the different cutting processing, colleagues, processing technology and The tool is also a new perspective and direction.
The specific load characteristics and wear characteristics of the light structure during processing and the resulting tool design concept have also received much attention.
Finally, the joining process necessary for lightweight materials to construct structural materials is also difficult, because in addition to the use of matching fasteners, there is the possibility of using binders and particle beams.
According to industry insiders, from the energy point of view, the quality-strength ratio of lightweight materials has obvious advantages, which makes its application field continue to expand.
For a long time, fiber composite materials have been fully used in aerospace technology and wind power equipment, and it is foreseeable that fiber composite materials will surely shine in the automobile manufacturing industry.
This means that the current single-piece or small-scale production model (mostly manual production) on the market will be changed through automated material production and processing to achieve mass production.
Automotive lightweighting has been applied in batches
“There is no energy saving, and the product will not be sold.†This situation is more prominent in 2012. Especially in Japan, after the 2011 Japan earthquake, topics related to energy shortages continued to heat up, and consumers' awareness of energy conservation continued to increase. In this context, processing technologies that enable lightweighting have gained more attention than ever before. Among them, the promotion of related development is the automotive industry.
At present, the main contents of automotive lightweighting include a combination of lightweight materials, lightweight design, and lightweight construction.
The weight of the material is lightened by the replacement material of the steel plate or the light metal material. The substitute material replaces the ordinary low-carbon cold-rolled steel plate with high-strength steel plate, improves the strength and rigidity of the component, and reduces the thickness or section size of the steel plate to reduce the weight. .
In recent years, domestic automakers have gradually adopted high-strength steel. For example, the application ratio of DP340 high-strength steel used by Chery in its newly developed models has reached 45%, and some models have reached 50%. Dongfeng Motor Co. adopted a 700MPa grade high-strength steel instead of a tensile strength of 510MPa on the commercial vehicle frame. Through structural optimization, the main beam loses 38kg, the beam reduces the weight by 170kg, and the total weight loss is 208kg. In terms of lightweight, 700MPa grade high-strength steel plate is used instead of Q235 to produce standard car box, achieving weight loss of 20%~37%.
As lightweighting contributes more to improving fuel efficiency, more and more automakers have set numerical targets for component manufacturers, such as reducing weight by 10%. In this case, there have been instances of significant weight reduction. For example, KOIWAI Corporation of Japan has continuously obtained orders with the “KOIWAI Methodâ€, a laminated mold casting technology. The company has produced a car aluminum alloy sub-frame that is 45% lighter than steel-based products, and 40% of the motorcycle fuel tank frame, which has received great attention from car manufacturers.
It is reported that by manufacturing a core with rapid prototyping (RP) technology and combining with a low temperature mold, a sub-frame with a thin wall and a hollow integrated structure is cast.
In fact, material technology, the low level of design also affects the development of lightweight products.
Members of the China Engineering Society's Lightweight Technology Innovation Strategic Alliance Committee believe that automotive lightweight technology is not just relying on materials. Automotive lightweighting is the engineering of design, manufacturing, and material technology integration. For example, Dongfeng tractors lose 1400 kilograms, of which 19% are structurally optimized and 40% are functionally optimized. The two together account for 59%, and true new materials and new technologies account for only 41%.
If we only consider lightweighting as a material supply problem, it will hinder one of the main technical bottlenecks in China's lightening level.
It is reported that the domestic vehicle lightweight target is that the fuel car in the target model in 2013 will lose 5% to 8%, and the hybrid bus will lose 10%. At the same time, it is necessary to overcome 7 technologies and establish design and evaluation methods, including high-strength steel. Advanced molding technology for parts, module design and application technology of fiber reinforced plastics, development and manufacturing of deformed aluminum alloys, integrated application of multi-target lightweight technology, and construction of common technology platforms.
Domestic academic circles are also discussing in many ways. For example, Harbin Institute of Technology in China has replaced the traditional stamped butt-welded parts with the theory of internal high-pressure forming. This method has the advantages of light weight, rigidity and mild fatigue, so it is lightweight in automobile manufacturing. The field has played an important role.
According to reports, the internal high pressure forming plastic deformation of the pipe through the action of high pressure liquid, the required pressure is often as high as 200 ~ 400 MPa, hence the name.
However, the higher the pressure, the larger the tonnage of the required equipment, and the higher the requirements for the pressure bearing capacity of the mold, the structural reliability of the seal, and the pressure of the high pressure source, resulting in an increase in product cost. For example, a pipe with a diameter of 100 mm is formed at 200 MPa. If the total length reaches 2000 mm, a clamping force of 4000 t is required. Therefore, reducing the pressure of internal high pressure forming by improving the process is an important way to reduce the threshold of internal high pressure forming technology, reduce equipment investment and improve product competitiveness.
Going back to continue to talk about machine tools, it is precisely because of the emergence of new materials and new structural parts such as automobiles and aerospace. It is necessary to make adjustments to the machine tool as soon as possible. For example, in addition to plastic materials, the US auto industry is trying. The application of titanium-magnesium alloy is a new challenge and attempt for machine tools.
However, it is worth noting that the needs of the user industry are not only to meet their processing requirements, but also to increase productivity and economic efficiency while further reducing costs while ensuring processing quality.
These require machine tool companies to make innovative changes to meet the new requirements of the user industry. After all, it is the survival of the machine tool manufacturing industry.
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