外文翻譯----cadcaecam集成系統(tǒng)在壓鑄模具中的應(yīng)用

1、<p>　　附 錄A 外文文獻(xiàn)及譯文</p><p>　　Application of an integrated CAD/CAE/CAM system for die casting dies</p><p><b>　　Abstract</b></p><p>　　According to the concept of concu

2、rrent engineering (CE), a CAD/CAE/CAM integrated system for die casting dies is established and applied in the primary stage. The platform of the Pro/ENGINEER CAD/CAM software, the MAGMASOFT simulation software and a pri

3、mary expert system for the design of the die casting process are available to establish this integrated system. A primary expert system package including a series of empirical calculation equations and data for the desig

4、n of technological scheme a</p><p>　　Keywords: CAD/CAE/CAM integrated system; Die casting dies; Numerical simulation of metal flow and solidification</p><p>　　1. Introduction</p><p>

5、;　　The application of die castings is expanding continuously. The construction of die castings is becoming more complex and large-sized, and at the same time a shorter development cycle of new die casting products is req

6、uired. How to produce high quality die castings in a shorter period with a lower cost has become an important and urgent task of die casting enterprises. Recently concurrent engineering (CE) has been introduced into die

7、casting production, and the CAD/CAE/CAM integrated system of di</p><p>　　2. Establishment of the CAD/CAE/CAM integrated system for die casting dies</p><p>　　The general scheme of CAD/CAE/CAM int

8、egrated system of die casting dies is shown as Fig. 1. A CAD/CAM software, a CAE simulation software and a die casting expert system are included in it.</p><p>　　Due to the complex shape of die castings, the

9、 large-scale CAD/CAM software is required for the 3D solid modeling and manufacturing. Now the widely used CAD/CAM software are Pro/ENGINEER CAD/CAM software of PTC, Unigraphics II CAD/CAM software of EDS, and IDEAS CAD/

10、CAM software of SDRC, USA.</p><p>　　The principle of CAE simulation of castings is based on the solving of the equations in fluid dynamics and heat transfer (such as the continuity equation, the Navier–Stoke

11、s equation and the Fourier equation, etc.) by means of finite difference method (FDM) or finite element method (FEM). The velocity profile of the metal flow in the die cavity and the temperature distribution of the casti

12、ng and die during the filling and solidification process can be obtained by calculation. Then the metal flow </p><p>　　In this paper the platform of the Pro/ENGINEER CAD/CAM software, the MAGMASOFT simulatio

13、n software, and a primary expert system for the design of die casting process are used to establish the CAD/CAE/CAM integrated system of die casting dies, this system is applied for the die castings of a water pump of al

14、uminum alloy and a housing cover of magnesium alloy [4,5].</p><p>　　3. Application of the CAD/CAE/CAM integrated system for die casting dies</p><p>　　3.1. CAD modeling and design of technologica

15、l scheme and dies</p><p>　　First the 3D solid modeling of a part is created, then the 3D modeling of the die casting including the information of machining allowance, shrinkage and taper is formed by using t

16、he Pro/ENGINEER CAD/CAM software (shown as Fig. 2). The data of machining allowance, shrinkage and taper are chosen from Database II in accordance with the accuracy and surface rating of the parts, the structure of the p

17、arts and the type of alloy.</p><p>　　By means of a primary expert system package for the design of the technological scheme of die casting process, which was developed by the authors, the process parameters

18、of die casting such as the injection pressure, plunger speed, gate velocity and filling time, etc. are selected suitably, and checked by empirical calculation equations in accordance with the type of alloy, and the wall

19、thickness and structure of the casting. The technological scheme of die casting process including the gating s</p><p>　　The shape of the die casting of the water pump is comparatively complex. It includes an

20、 involute outline, a groove with varied height, a distorted transition region connecting different transverse sections with a sphere-like arch, etc. All these are difficult for modeling.</p><p>　　3.2. CAE si

21、mulation and analysis</p><p>　　The die casting of water pump is produced in an IP 550 horizontal die casting machine. There are two types of defects occurring in this casting: air holes and porosity. The met

22、al flow and solidification in the dies is simulated with the use of MAGMASOFT software. The simulation results of several technological scheme are analyzed. The problems occurring in the metal flow and solidification can

23、 be observed directly through the simulation. In the original scheme the gating system of the water pump</p><p>　　3.3. The realization of CAM</p><p>　　On the basis of the data of the 3D solid mo

24、deling of the cavities of die casting dies, with the use of the Pro/MANUFACTURING module of the Pro/ENGINEER CAD/CAM software, the 3D solid modeling of blank figures of the inlays are created first. Then the operation ta

25、ble of the machining including the machining parameters, cutters, cutter path, etc. is listed, and the NC (numerical control) cutting procedures and the CL (cutter locate) data files are also created. Furthermore due to

26、the use of the mo</p><p>　　4. Results of the application of integrated system</p><p>　　As mentioned above, with the help of the Pro/ENGINEER CAD/CAM software and a primary expert system package,

27、 the 3D solid modeling of die casting and the design of technological scheme of die casting process are created. Next the simulation and analysis of metal flow and solidification in dies are performed with the use of the

28、 MAGMASOFT software; the technological scheme and process parameters of die casting are also revised and optimized. Then the 3D solid modeling of whole set of dies is comple</p><p>　　The technological scheme

29、 and process parameters of die casting process are revised and further optimized by using the CAE simulation, and the quality of the die castings improved greatly in a shorter time. For example, due to the use of CAE sim

30、ulation, the percentage of qualified products of die castings of the above-mentioned water pump is raised from 60 to 90% in a shorter time.</p><p>　　Another example is a magnesium die casting of a gearbox ho

31、using of a sedan. The CAE simulation results show the unevenness of the temperature distribution in the die cavity. The thermal balance and temperature distribution of the dies are improved with the regulation of process

32、 parameters such as gate velocity, flow rates of cooling media, etc. And the occurrence of cracks is reduced greatly. Because the percentage of qualified products of die castings can be raised greatly in a shorter time,

33、th</p><p>　　5. Conclusions</p><p>　　The established CAD/CAE/CAM integrated system of die casting dies has been used successfully in the design and manufacture of die casting dies of sedan parts

34、such as a water pump, a gearbox housing, etc. The cycle of design and manufacture of die casting dies are shortened obviously. The process parameters and technological scheme of die castings can be optimized with the hel

35、p of CAE simulation. This results in the production of die castings of consistently high quality in a shorter time, and th</p><p>　　References</p><p>　　[1] K. Chipley, S. Viswanathan, R.H. Coop

36、er, Die Cast. Eng. 40 (2)</p><p>　　(1996) 18–26.</p><p>　　[2] P.M. Bralower, Die Cast. Eng. 42 (5) (1998) 16–20.</p><p>　　[3] S.P. Midson, Die Cast. Eng. 38 (5) (1994) 42–46.</

37、p><p>　　[4] S. Yue, G. Dai, Foundry Eng.-Molding Mater. 22 (1–2) (1998) 8–13.</p><p>　　[5] Shuhua, Yue, J. Yu, H. Sun, et al., Foundry 46 (1) (1997) 14–18.</p><p>　　CAD/CAE/CAM集成系統(tǒng)在壓

38、鑄模具中的應(yīng)用</p><p><b>　　摘 要</b></p><p>　　根據(jù)并行工程（CE認(rèn)證）的概念，CAD/CAE/CAM集成系統(tǒng)目前已在壓鑄模具設(shè)計(jì)中得到建立和初級(jí)階段的應(yīng)用。Pro/ENGINEER中的CAD/CAM軟件， MAGMASOFT仿真軟件，和一個(gè)可以為壓鑄設(shè)計(jì)建立壓鑄模具CAD/CAE/CAM集成系統(tǒng)的專業(yè)系統(tǒng)。軟件公司已開發(fā)出一種重要的

39、壓鑄模具專業(yè)軟件系統(tǒng)包，它提供了模具和方案設(shè)計(jì)中的一系列經(jīng)驗(yàn)計(jì)算公式和數(shù)據(jù)。這種集成系統(tǒng)已成功應(yīng)用于鋁、鎂壓鑄件的模具設(shè)計(jì)和制造，如桑塔納汽車的油泵。使用這個(gè)集成系統(tǒng)，可以縮短模具設(shè)計(jì)和制造周期，并在較短的時(shí)間里，生產(chǎn)出高質(zhì)量的壓鑄件。壓鑄件的交貨時(shí)間也大大縮短。</p><p>　　關(guān)鍵詞：CAD/CAE/CAM集成系統(tǒng)、壓鑄模具、金屬流動(dòng)和凝固的數(shù)值模擬</p><p><b&g

40、t;　　1、介紹</b></p><p>　　壓鑄件的應(yīng)用正在不斷擴(kuò)大。壓鑄件的結(jié)構(gòu)正變得越來(lái)越復(fù)雜化和大型化，同時(shí)，一個(gè)新的壓鑄產(chǎn)品的開發(fā)周期要求更短。如何在較短的時(shí)期里用較低的成本生產(chǎn)出高質(zhì)量的壓鑄件已成為壓鑄企業(yè)一項(xiàng)重要而緊迫的任務(wù)。最近并行工程（ CE ）已引入壓鑄生產(chǎn)工藝，并且已經(jīng)建立了壓鑄模具CAD/CAE/CAM集成系統(tǒng)[1]。在并行工藝過(guò)程中，第一步是創(chuàng)建零件生產(chǎn)過(guò)程中所用到的所有方面

41、3D數(shù)據(jù)庫(kù)。第二步是設(shè)計(jì)壓鑄工藝中的澆注系統(tǒng)，溢出和冷卻通道，以及壓鑄模具的整體框架。為了避免鑄造中的一些缺陷，可以應(yīng)用鑄造模擬軟件里的CAE技術(shù)對(duì)鑄造過(guò)程模具中的金屬的流動(dòng)和凝固進(jìn)行數(shù)值模擬。該數(shù)據(jù)庫(kù)還提供了CAM模具制造過(guò)程中CNC程序?qū)η坏拇旨庸ず途庸に璧臄?shù)據(jù)，還連接了坐標(biāo)測(cè)量機(jī)（CMM）應(yīng)用于測(cè)量[ 1,2]。由于在整個(gè)過(guò)程中使用的是同一三維模型的數(shù)據(jù)庫(kù)，以上這些步驟可以同時(shí)進(jìn)行。交貨的時(shí)間和整體的設(shè)計(jì)與制造周期可以大大縮短

42、[2]。因此，模具設(shè)計(jì)者對(duì)模具的CAD/CAE/CAM集成系統(tǒng)的越來(lái)越多的關(guān)注，體現(xiàn)了現(xiàn)代先進(jìn)制造技術(shù)的CE技術(shù)的重要性越來(lái)越大。</p><p>　　2、CAD/CAE/CAM集成系統(tǒng)在壓鑄模具中的建立</p><p>　　CAD/CAE/CAM集成系統(tǒng)壓鑄模具的總體方案如圖1所示。它包括一個(gè)CAD/CAM軟件,一個(gè)CAE仿真軟件和一個(gè)壓鑄專業(yè)軟件系統(tǒng)包。</p><

43、p>　　由于壓鑄件形狀復(fù)雜，需要大型的CAD/CAM軟件的三維實(shí)體造型和制造?，F(xiàn)在廣泛使用的CAD/CAM軟件是PTC公司的Pro/ENGINEER的CAD/CAM，EDS公司的Unigraphics II的CAD/CAM，和美國(guó)IDEAS的CAD/CAM的軟件。</p><p>　　鑄件CAE模擬技術(shù)原理的解決方法有：有限差分法（FDM）的流體動(dòng)力學(xué)和傳熱方程（如連續(xù)性方程，Navier-Stokes方程

44、和傅立葉方程等）或有限元法（FEM）。金屬液在模具型腔里的流動(dòng)速度和鑄件的溫度分布以及金屬液在模具中的填充和凝固過(guò)程可以通過(guò)計(jì)算得出。然后用CAE模擬軟件模擬壓鑄過(guò)程中金屬液在模具中的流動(dòng)和凝固過(guò)程。鑄造模擬軟件包現(xiàn)在可用的有EKK的CAP，流體科學(xué)的FLOW-3D，美國(guó)UES的PRO/CAST，以及德國(guó)的MAGMASOFT等[3] 。</p><p>　　本論文使用的是Pro/ENGINEER的CAD/CAM軟

45、件，MAGMASOFT仿真軟件，和一個(gè)可以為壓鑄工藝設(shè)計(jì)建立壓鑄模具CAD/CAE/CAM集成系統(tǒng)的專業(yè)系統(tǒng)，這個(gè)系統(tǒng)應(yīng)用于鋁合金油泵壓鑄件和鎂合金的外殼蓋[4,5]。</p><p>　　3、CAD/CAE/CAM集成系統(tǒng)在壓鑄模具中的應(yīng)用</p><p>　　3.1、模具的CAD建模和設(shè)計(jì)的技術(shù)方案</p><p>　　首先新建零件的三維實(shí)體造型，然后通過(guò)使用P

46、ro/ENGINEER的CAD/CAM軟件進(jìn)行壓鑄件的三維建模，建模的內(nèi)容有鑄件的加工余量，收縮率和錐度的形成（如圖2所示）。鑄件的加工余量，收縮率和錐度大小的數(shù)據(jù)是根據(jù)零件的表面精度等級(jí)、零件的結(jié)構(gòu)和合金類型從數(shù)據(jù)庫(kù)II中選擇。</p><p>　　通過(guò)由軟件商開發(fā)的一款重要的專業(yè)軟件系統(tǒng)包進(jìn)行壓鑄工藝技術(shù)方案的設(shè)計(jì)，可以對(duì)壓鑄模的工藝參數(shù)，如注射壓力、柱塞速度、注射速度和充填時(shí)間進(jìn)行適當(dāng)?shù)倪x擇，根據(jù)合金類型的

47、經(jīng)驗(yàn)計(jì)算公式，可以對(duì)壓鑄件的壁厚和結(jié)構(gòu)進(jìn)行校核。該設(shè)計(jì)方案還包括澆注系統(tǒng)，溢出和冷卻通道的工藝設(shè)計(jì)，以及型腔的內(nèi)表面積和模具的熱平衡的計(jì)算和校核。然后選擇壓鑄機(jī)。在數(shù)據(jù)庫(kù)I中存儲(chǔ)了各種標(biāo)準(zhǔn)零部件的數(shù)據(jù)和模具設(shè)計(jì)的經(jīng)驗(yàn)數(shù)據(jù)，如鑲嵌的厚度，型腔內(nèi)表面到模具外表面的距離等一些經(jīng)驗(yàn)數(shù)據(jù)，隨著該專業(yè)軟件系統(tǒng)數(shù)據(jù)庫(kù)I的使用，該壓鑄模完整的三維實(shí)體造型終于全部完成，包括外表面和噴射機(jī)構(gòu)，型芯，澆注系統(tǒng)，溢出和冷卻通道等（如圖3所示） 。然后把所有模擬

48、數(shù)據(jù)轉(zhuǎn)換成數(shù)據(jù)文件。</p><p>　　壓鑄件油泵的形狀是比較復(fù)雜的。它包括一個(gè)漸開線輪廓，具有不同高度的槽，彎曲的過(guò)渡區(qū)域連接著不同橫截面的球體狀拱，所有這些都給建模造成很大麻煩。</p><p>　　3.2、CAE模擬及分析</p><p>　　壓鑄件油泵的生產(chǎn)使用的是IP 550臥式壓鑄機(jī)。在這個(gè)鑄件生產(chǎn)中常出現(xiàn)的缺陷有兩種類型：氣孔和縮孔。該模具中金屬的流

49、動(dòng)和凝固的模擬使用的是MAGMASOFT軟件。然后對(duì)幾種技術(shù)方案的模擬結(jié)果進(jìn)行分析。通過(guò)模擬可以清楚地看出金屬流動(dòng)和凝固過(guò)程中出現(xiàn)的問(wèn)題。在充填金屬液的過(guò)程中使用傳統(tǒng)的澆注系統(tǒng)進(jìn)行澆注將會(huì)導(dǎo)致金屬液的飛濺和空氣不能及時(shí)排出。這將會(huì)出現(xiàn)氣孔和氧化夾雜物等缺陷（如圖4所示）。為了減輕這種缺陷，需要對(duì)澆注系統(tǒng)的設(shè)計(jì)進(jìn)行修改，工藝參數(shù)也要進(jìn)行相應(yīng)調(diào)整，（如圖5所示）。另外，這種傳統(tǒng)的澆注方案往往會(huì)在鑄件的熱節(jié)處出現(xiàn)縮孔缺陷（如圖6所示）。所以，

50、在修改設(shè)計(jì)方案時(shí)，需要控制柱塞的加速度以調(diào)節(jié)合適的注射速度，充填的時(shí)間也要短，因?yàn)槌涮詈蟮脑鰤嚎梢允節(jié)部谔幬磥?lái)得及凝固的金屬液對(duì)熱節(jié)出的縮孔進(jìn)行補(bǔ)縮。這樣，縮孔缺陷就基本消除了。由于油泵復(fù)雜的外形和不均勻的壁厚，導(dǎo)致縮孔和氣孔等缺陷很容易出現(xiàn)。而且油泵壓鑄件的密封要求非常高，所以鑄件需要通過(guò)高水壓測(cè)試，且要求無(wú)任何泄漏。借助于CAE軟件的模擬和分析來(lái)優(yōu)化壓鑄件的設(shè)計(jì)，可以使壓鑄產(chǎn)品的合格率在較短時(shí)間內(nèi)得到大大提高。</p>

51、<p>　　3.3、CAM的應(yīng)用</p><p>　　首先運(yùn)用Pro/ENGINEER的CAD/CAM軟件的Pro/MANUFACTURING模塊，在壓鑄模具型腔三維實(shí)體造型的數(shù)據(jù)基礎(chǔ)上，新建一個(gè)三維實(shí)體造型鑲嵌加工空白頁(yè)。然后，制作一個(gè)加工工藝表，包括加工余量，刀具，刀具路徑等，同時(shí)還要?jiǎng)?chuàng)建一個(gè)NC（數(shù)控）切割程序和CL（銑刀）數(shù)據(jù)文件。此外由于NC 檢查模塊的使用，可以對(duì)加工刀具路徑進(jìn)行檢查和觀察

52、瞬時(shí)加工工藝過(guò)程。數(shù)控切割過(guò)程中的各CL數(shù)據(jù)文件可以進(jìn)行修改，直到達(dá)到一個(gè)滿意的結(jié)果。這時(shí)CAM軟件將及時(shí)對(duì)這些數(shù)據(jù)進(jìn)行處理并傳送到數(shù)控機(jī)床代碼庫(kù)。壓鑄模具外殼蓋的鑲嵌加工刀具路徑如圖7所示。</p><p>　　4、集成系統(tǒng)的應(yīng)用總結(jié)</p><p>　　綜上所述，借助于Pro/ENGINEER的CAD/CAM軟件和主要專業(yè)軟件系統(tǒng)包的幫助，建立壓鑄模的三維實(shí)體造型和設(shè)計(jì)壓鑄工藝的技術(shù)方

53、案。然后使用MAGMASOFT軟件對(duì)模具中金屬液的流動(dòng)和凝固進(jìn)行模擬和分析，對(duì)壓鑄的技術(shù)方案和工藝參數(shù)進(jìn)行修改和優(yōu)化。這樣就完成了模具完整的三維實(shí)體造型。最后創(chuàng)建模具和型芯復(fù)雜表面的CAM加工數(shù)據(jù)，所有CAM加工數(shù)據(jù)都在數(shù)控機(jī)床上完成。由于在整個(gè)過(guò)程中使用的是同一三維模型的數(shù)據(jù)庫(kù)，一些步驟可以同時(shí)進(jìn)行，可以明顯縮短模具的設(shè)計(jì)和制造周期。</p><p>　　通過(guò)CAE模擬軟件對(duì)壓鑄工藝的技術(shù)方案和工藝參數(shù)進(jìn)行修改

54、和進(jìn)一步的優(yōu)化，壓鑄件的質(zhì)量在較短的時(shí)間里得到很大提高。例如，由于使用CAE進(jìn)行模擬，上面提到的壓鑄件油泵的產(chǎn)品合格率在較短的時(shí)間里從60%提高到90%。</p><p>　　另一個(gè)例子是汽車變速箱殼體的鎂合金壓鑄件。CAE模擬結(jié)果表明，模具型腔內(nèi)的溫度分布不均勻。通過(guò)調(diào)節(jié)工藝參數(shù)，如注射速度，冷卻介質(zhì)的流速，可以改善熱平衡和溫度分布，也減小裂縫出現(xiàn)的可能性。由于壓鑄件的產(chǎn)品合格率在較短的時(shí)間里得到很大提高，整個(gè)

55、壓鑄件的交貨時(shí)間也就大大縮短。</p><p><b>　　5、結(jié)論</b></p><p>　　壓鑄模的CAD/CAE/CAM集成系統(tǒng)目前已成功地應(yīng)用在汽車壓鑄件的設(shè)計(jì)和制造中，如油泵，變速箱殼體等壓鑄零件。壓鑄件的壓鑄模具的設(shè)計(jì)和制造周期明顯縮短。借助CAE模擬技術(shù)可以優(yōu)化壓鑄件的工藝參數(shù)和技術(shù)方案。它的作用是可以在較短的時(shí)間里是生產(chǎn)出高質(zhì)量的壓鑄件，交貨時(shí)間也大

56、大縮短。然而，該集成系統(tǒng)還需要進(jìn)一步研究和開發(fā)，特別是專業(yè)軟件系統(tǒng)部分。同時(shí)需要對(duì)更多成功地應(yīng)用在實(shí)際生產(chǎn)中的壓鑄件資料，包括專業(yè)軟件系統(tǒng)中壓鑄件的資料進(jìn)行分析。這些將有助于完善該專業(yè)軟件系統(tǒng)包。</p><p><b>　　參考文獻(xiàn)</b></p><p>　　[1] K. Chipley, S. Viswanathan, R.H. Cooper, Die Cas

57、t. Eng. 40 (2)</p><p>　　(1996) 18–26.</p><p>　　[2] P.M. Bralower, Die Cast. Eng. 42 (5) (1998) 16–20.</p><p>　　[3] S.P. Midson, Die Cast. Eng. 38 (5) (1994) 42–46.</p><