制造翼子板模具关键技术的基础研究

华中科技大学硕士学位论文直接制造翼子板模具关键技术的基础研究姓名：陶龙申请学位级别：硕士专业：材料加工工程指导教师：张海鸥20090531IMIGSTL1.2.MIG3.4.STLSTL5.MIGIIAbstractArcDepositionManufacturingisonetypeofshape-creativeandmass-creativeparallelrapidmanufacturingtechnologyusingarcasthermalresourcewhichincludesPlasmaDepositionManufacturingandPulsedMIGwelding.Thistechnologyprovidesalow-costrapidmanufacturingofhigh-qualityway.Theconvexandconcavemolddesigningisveryessentialintherapidmanufacturingtechnologyforfendermold.Thetechnicalanalysisofthenumericalsimulationcanbeusedtodeterminetherationalityofdiedesign,optimizetheprocessparametersofthecorrection,therebyformingabetterdesignofthemold.Inordertomeettherapidprototypingmanufacturingsystem,themodelofconvexandconcavemoldmustbesimplifiesandtheSTLshouldbedetectedandrepaired.Onlyinthiswaythesystemcanformdepositiontrajectory,preparingforthefollow-upprocessing.Therefore,thispaperhasresearchedonrapidfendermoldmanufacturingtechnology,toachievingvolumeandsurfacefinishformingintegratedmanufacturing.Keyelementsinclude:1.Basedontherapidtoolingmanufacturingtechnology,thispaperhasanalyzedtherapidtoolingmanufacturingtechnologyatthisstage,studiedthekeytorapidtoolingstudiedthekeytorapidtoolingtechnologyandthecharacteristics,providedtheoreticalguidanceforarcdepositionmanufacturingsystem.2.Thispaperhasintroducedthebasicknowledgeoftherapidtoolingmanufacturingtechnology,analyzedtheformingprincipleofPlasmaDepositionManufacturingandPulsedMIGwelding,andstudiedthestructure,equipment,principles,andcharacteristicsoftheformingprocessoftherapidtoolingmanufacturingsystem.3.Themajorissuesandfactorsoftheformingsimulationresultswereanalyzedin-depth,theformingprocesssimulationofthefendermetalsheetwassimulated,andthesimulationprocessesandthefenderformingsimulationresultswerestudies.4.Thebasicknowledgeabouttherapidfendermoldmanufacturingtechnologywasstudiedindetail,themolderoffendermoldwasreconstructedandtheSTLfileswererepaired.5.Tovalidatetheutilityofaboveresearch,adouble-twistleavehasbeenmadebyIIIHybridPlasmaDeposition&Milling.Theresultsshowthatthefenderformingtoolpathisinfullcompliancewiththeanalogprocessingpathandmanufacturingprocesstechnology,andprovidethefoundationforfollow-upfendermoldmanufacturing.Keyword:ArcDepositionManufacturing,fendermold,PlasmaDepositionManufacturing,NumericalSimulationPulsedMIGwelding□_____□“√”11MIG1.1“”,,,[1-2]GEIBMRPMRPM[3]RP(RapidTooling2RT)()CAD1-1[26-28]1-1CADCAD(DRMTDirectRapidMetalTooling)DRMTSLSLENSLOM[4-5]MIG3[6-7][8-9]1.2[13]10DirectMetalDeposition,DMDLENSSelectiveLaserSintering,SLSDirectedLightFabrication,DLF1.2.1141979()MRMMitsubishiRapidMolding)[13][14][15]2RPMExtludeHone3DP1000WRPEsachaFDMRPRPEDM[15]3LMF(LaserMetalForming)OptomecLNES1.2.215[11]2G(ET500A)[11-12]3RP[13]RP[14]4[13-14]9061.3StanfordCarnegieMellonShapeDepositionManufacturingSDMSDMCNC[17-18]Yong-AkSongSolidFreeformFabricationSolidFreeformFabrication[19]FraunhoferFraunhoferInstituteforProductionTechnologyLENSCMBCMB2.5[20]71-1a1-1b1-1c1-1dMIG1-1[21-25]1.4STL81234STL5692(Rapidprototyping:RP)80,/CAD/CAM,,,[16-20]RPRP[16-20]2.1+CADCAD/CMA10()CAD1/3[27]RP()()();()[26]2.22.2.1DRMTDRMT(LENS)(SLS)11(PDMplasmadepositionmethod)(3DP)LOM(1)LENSLENSCAD,,2-1AerometLENS[32].2-1AerometLENSSLS5SLS[28]2SLSSLSC.R.Dechand1989CAD[28]12SLS(3)SLASLACharlesHul1984,2-2[33]2-2SLA(SLA)CAD43DP133DP2-360(MIT)EsackSRP3DP2-33DP(5)LOM,,,,CAD±0.1mm,0.050.5mm2-4[35]142-4,,,LOM[34]6PDM,(),,,[36]15KroppThyssen[28]2.2.2RMP[38]KeltoolEDM1.RP1025TEK430500HAS557512.460.1MPa200500300[39-40]162,,RP,(),,[26]3.RP&M,,,,,()17[27][35][39]4.KeltoolKeltool3DKeltoolRPA6()30%()48~50HRCCNC25%40%[13][35]5.EDM(EDM)EDMRPRPRPEDMG(TE500A)RPM[26][40]2.3,181.RPM[27]2.[27][37]3.,RTHSMRTHSM[37][38]4.[39]2.4/211.RT19RT[37]2.[37][38]3.,[37]4.RT(HSM)RTHSM5.RTVRVRRTRP[37][38]2.5203STL,[42]MIG[42-43]3.1MIG213.1.1[27][28]3-13-2[29]3-13-23.1.2MIGMAG(MetalActiveGaswelding)MIG(MetalInertGasWelding)MAGCO2MIGArHe(22)OCO2H2(0.61.6mm)[45]MIGMIG;3-3IpIaIbTpTb[44-45]3-3MIG233.1.3MIGCNCCAMSTLSTLSTLCAMNCMIGCNCCNC3-4CADSTLNCCAD[30]CADSTLNCSTLYN3-4243.2CNCMIGCAM3.2.1CNC[46-49]1[46][49]2[46]253-5[46-49]3-53-63-6326[48][49]12343.2.2MIGSAF-FRODIGI@WAVE280/400/5003-7DIGI@WAVEA1A2A3UDIGI@WAVE3-8273-7DIGI@WAVE3-83.2.3CNCCNCCADCNC[46]3-93-93.2.4CAMCAMAutoCADProENGINEERUGCADSTLSTLSTL,,MIGNCMIGNC283-10CAMCAM5:NC[47][49]NCSTL3-10CAM3.33.3.1FGM[46]1[46]22910000-50000[46]3“”[50]12[51]3[52]4303.3.2MIGMIGMIG();[54-55]1()()[54-56]2MIGMIGMIG[57]3MIGMIG31[58]3.41MIGMIG2MIGCNCCAM3MIG324,,,0.71.5mm,[61][62][64],,.Autoform4.14-1CAD33CADIGES4-14.2CAD[61]1()[61][65]2CADCADCADUGCADIGS34[60][63]a[65]b[65]c3[60]4.34.3.1(),,,35,,,[62][66][67]4.3.2[62][66][67]364-24-2,,,4-34-34.44.4.1,CAD,CAD,[70]UG,IGESAutoformIGES,,,37,[69-70]4-4CAE,4-44.4.24-2SGCD30.8mm4-14-1SGCD3SGCD3%CSiALMnPS0.0060.10.080.450.030.034-2:4-2MPaMPa%SGCD3160210280340420.3210000MPa0.24r0=1.82r45=1.34384-54-50.151200KN300mm1200KN4.4.3,,1m/s,,Autoform4-6(FLD)4-7,4-8394-64-7404-84-6,FLC5-8,0.635mm4-94-103D4-9414-104.512425STLSTLSTLCADCADSTLCADUGSTLSTL5.15.1.15-1,,,5-1A0.5mmB0.5mmCD[68]1.2.3.4.56