May 19, 2024

Near net forming technology

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I. Technical Overview

Near-net forming technology refers to the forming technology of mechanical components after the parts are formed, requiring only a small amount of processing or no further processing. It is based on multi-disciplinary high-tech achievements such as new materials, new energy, mechatronics, precision mold technology, computer technology, automation technology, numerical analysis and simulation technology, and transforms the traditional blank forming technology to make it rough. Forming becomes a high-quality, high-efficiency, high-precision, lightweight, and low-cost forming technology. It allows the formed mechanical components to have a precise shape, high dimensional accuracy, shape accuracy and good surface roughness. The technology includes near-net shape casting, precision plastic forming, precision joining, precision heat treatment modification, surface modification, high-precision molds, etc., and is a new process, new equipment, new materials and various new technological achievements. Integrated integration technology.

Second, the status quo and domestic and international development trends

Since the 1970s, governments and industrial circles in various industrialized countries have invested a large amount of capital and manpower in the near-net forming technology, so that this technology has developed rapidly. Due to the outstanding contribution of this technology to market competitiveness, it has been The Japanese government and enterprises were listed as key technologies affecting competitiveness in the 1990s, and their output value growth rate is much higher than the growth rate of manufacturing output. The main development trends are:

1) Continuous development of new net forming technology

Industrial developed countries have been working hard to develop new technologies for near-net forming, and have made great progress in various fields covered by this topic. Therefore, the proportion of near-net shape and the accuracy of forming parts and the complexity of forming parts are very large. improve. For example, automotive cylinder castings have achieved wall thicknesses of 3 to 4 mm. Many of the car gears can be produced by cold extrusion, and the tooth shape is no longer processed. Car constant velocity joint parts are very complex parts that can already be produced using precise plastic forming techniques. The car connecting rod not only has high dimensional accuracy, but also has small weight deviation. The weight accuracy of the car connecting rod can be controlled below 3-4%. These technologies have promoted the reduction of the car's own weight and performance. With the improvement of forming precision, a large number of cars have been developed. Near net forming process technology. The development of new materials has promoted the development of new forming technologies, the development of high-density energy sources (laser, plasma beam, electron beam, etc.) and the use of near-net forming, as well as a number of new near-net forming processes. All of this has made this technology a colorful and competitive development. In China, the proportion of near-net forming technology in the whole forming manufacturing production is still relatively low, and the overall level of forming parts is on average 1 to 2 lower than that in developed countries. Some new technologies are only used by a few enterprises, and many complicated and difficult-to-formed parts are used. China can not produce, some advanced forming equipment, robotic robots, a large part of high-level automated production lines can not be provided in China, so the overall level is 15 to 25 years behind.

2) Applying process simulation technology to optimize net forming process parameters

The traditional forming technology is based on experience and experimental data. The development of a new part forming process often requires extensive modification and debugging during production. The development of computer and computing technology, especially the development of computational technology for nonlinear problems, has made it possible to simulate and optimize the forming process. Foreign companies have formed a number of commercial software such as casting, forging, cover stamping, mold CAD/CAM, etc. through a large number of foreign work. It has promoted the development of near-net forming technology. China has done a lot of work in simulation analysis and research, but its power is scattered, each unit has insufficient input, and there are many single-item researches. Entering the domestic market one after another has also exposed problems such as high cost and unsuitability for national conditions. How to organize domestic power. Starting from the national conditions, organizing the superior units, carrying out process simulation and optimization, and developing advanced and applicable software are the problems that should be solved at present.

3) Continuous development of robots and robots for near net shape production

Near net shape is usually produced in large quantities, and it is necessary to build an automatic production line. It is necessary to have corresponding robots and robots. Due to the diversity of the working environment, it usually works at high temperatures. Therefore, near net forming robots and robots are used for general cold working and assembly. The robot has different characteristics. It has been designed for different forming processes in foreign countries. Through years of work, it has mastered a series of design and manufacturing technologies for forming robots and robots. In addition to the introduction of digestive development and self-development, the production forming robots and robots in China can provide enterprises with needs. Most products also need research and development or through the introduction of digestion and absorption development, and gradually form a series.

4) Develop and use near-net-open automatic production line and flexible production line construction and control technology to continuously improve production efficiency

Most of the near-net forming of mass production in foreign countries adopts automatic line production, which has the advantages of high productivity, stable quality and good working conditions. In the industrialized countries, this production line has been researched and built for decades, and with people Some flexible production lines have emerged for product personalization requirements.

In the early 70s and 80s, some key enterprises in China gradually established some near-net forming production lines by means of imported equipment. (For example, in the 1970s, the second-phase purchase of the 12,000-ton hot forging press produced by the German company Aumco. Automatic line). After the introduction and independent development, China has been able to rely on domestic technology and equipment to build a hot forging production line in the early 1990s. There are still many production line construction technologies that are not yet in the country. In the first ten years of the next century, these technologies must be mastered in order to build production lines and flexible production lines of different automation levels according to the needs of domestic enterprises.

5) Pay attention to the quality control of the near net forming production process and improve the quality consistency

In order to ensure product quality, foreign companies strengthen management and do quality control throughout the production process. On the other hand, through automation and intelligent control in the production process to ensure the stability of near-net forming production quality, and develop various online and non-destructive testing. Technology and instrumentation, and the research and application of statistical process control technology, so that the quality and accuracy of the molded parts are reliable. There are still a lot of gaps in the above-mentioned key technologies in China, and they need to be mastered as soon as possible to ensure the quality of the final formed parts.

6) Development of virtual manufacturing and network manufacturing for near net shaping technology

With the development of computer and network technology, virtual manufacturing and network manufacturing have begun to gain attention and development in foreign countries in recent years. China's near net shape forming enterprises are generally small in scale, lacking in technical strength and ineffective information. Due to the rapid development of China's network information industry in recent years, a number of research institutions and schools in China have accumulated a number of research results and software. If the associations, research institutes, and productivity promotion centers organize enterprises, research institutes, and schools through various channels, Carrying out virtual manufacturing and network manufacturing and conducting paid services may be an effective way to commercialize scientific research results, and it will also be an effective way to improve the overall technical level of the industry.

Third, the "10th Five-Year" goal and main research content

1) Goal

Through scientific research and industrialization, near-net forming technology can catch up with or close to the international advanced level in major aspects, and it has innovation in some technologies; through the maturity, industrialization and complete set of technology, it can provide enterprises with Advanced technology, can also provide a single technology to meet the needs of enterprises, and strive to achieve domestic technology can meet the needs of enterprises 85 to 90%, in most directions can basically block the import of complete sets of technical equipment.

2) Main research content

Near net formation and new technology and its industrialization: including “near net shape casting”, “precision plastic forming”, “high quality and efficient precision connection”, “precise heat treatment modification”, “high quality and efficient surface modification and coating”, Technologies such as “complex high-precision molds” and their comprehensive applications, researching new technologies and common technologies that are urgently needed and covered by enterprises in the above-mentioned directions, providing new processes, new methods, new equipment, and accumulating complete technical data, and Achieve practical use.

Near net forming process simulation analysis and optimization: research and solve the key technology of forming process simulation, make 3D simulation software perfect, mature and commercialized, and provide optimized process parameters for near net forming.

Robots and robots for near-net forming production lines: Researching typical (forging, stamping, die-casting, welding, etc.) robots and robots required for near-net forming lines to achieve serialization, maturity, and meeting the needs of production line construction.

Near-net forming production automatic line and flexible production line construction technology: taking process technology as the core research to master the near-net formation automatic production line construction technology, focusing on research production line control and online detection technology, so that it can be based on the company's production program and possible funding To build different mechanization and automation production lines, we must also build some flexible production lines according to development needs.

Quality control technology in the production process: Through the research and application of online intelligent control technology, non-destructive testing technology and statistical process control technology, the whole process quality control of near net formation is achieved, thus ensuring the final product quality.

Virtual manufacturing and network manufacturing technology of near-net forming technology: For the characteristics of small and medium-sized enterprises in the industry and low level of domestic enterprises, it is closely integrated with associations, associations, and productivity promotion centers to establish virtual manufacturing and network manufacturing systems.

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