K18-泵體加工工藝及夾具設計【鉆12孔+鏜48孔】
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先進制造工藝在機械制造中的應用
北京航空工藝研究所 劉新亞
陸廣 譯
[摘要] 介紹了并行工程、敏捷制造及精良生產等先進制造技術的特點及在組合機床研制中的應用,提出了如何深化和推廣這一應用的具體措施。
關鍵詞：組合機床、并行工程、敏捷制造、精良生產
在機床工業(yè)中,隨著社會對產品要求的不斷提高,隨著市場競爭的不斷加劇,滿足用戶要求,包括提高產品質量、縮短生產周期、降低成本、改進售后服務已成為贏得市場的突破口。為了達到贏得市場這一目的,應當引入現代先進制造技術:并行工程、敏捷制造及精良生產,以促進組合機床的發(fā)展。
1 并行工程
并行工程又稱為同步工程,是集成、并行地優(yōu)化設計產品及其各種相關過程(包括制造及支持)的系統方法,這種方法引導產品開發(fā)人員一開始就考慮到產品從概念設計到消亡的整個生命周期中的所有因素,包括質量、成本、進度計劃和用戶需求等。
并行工程最早是作為縮短產品開發(fā)周期的一種手段而發(fā)展起來的。其特征是將產品的開發(fā)、生產中涉及的各種工程行為分解成一系列子任務,如市場分析、設計、工藝設計、生產計劃和器材外購、加工、質量保證、檢測及售后服務等。這些子任務盡可能并行同步統籌考慮,以達到改進設計、縮短周期、提高質量、降低成本、優(yōu)化設計的目的。它強調集成、協調和并行,即:(1)將管理、設計、生產、服務等所有與項目有關的人員及產品信息集成為一個整體,強調各相關部門總體目標及利益的一致;(2)采取設置一個稱職的項目負責人和有合理人才結構的協同工作小組的管理模式,由工作組負責項目中各部分子任務的協調及推進;(3)并行處理各階段的工作。根據項目中不同任務之間關聯性的不同,各部分子任務的工作過程可以部分重疊或完全重疊。根據這些原則,制定一個合理、優(yōu)化的工作計劃,并在其中必要的位置設置考核點,由項目工作組具體落實,使各子任務并行、有序地向前推進,以保證整個項目的順利實施。
1·1 并行工程與傳統工作方式的比較
按傳統的工作方式,各階段的工作是連續(xù)串行的。在這種產品開發(fā)方式中,各階段相互脫節(jié),互不關聯,導致設計錯誤增多,且難及時發(fā)現,這樣造成設計返工多,使開發(fā)周期拉長,成本增加。
采用并行工作方式后,將各項工作過程集成起來并行考慮,各項工作可重疊進行。有問題時可以及時協調更改,以免因遺留到后續(xù)階段而增加改正的難度及費用。因此,采用并行工程可明顯縮短產品開發(fā)周期,降低成本,很適合組合機床專業(yè)的發(fā)展。
1·2 應用實例
將并行工程的方法應用于產品開發(fā)中,效果非常顯著。1997年3月,北京航空工藝研究所與某摩托車廠簽定了設計制造6臺曲柄加工機床的合同項目,要求年 底交貨,且機床的要求與以往有較大差別。在該項目中采用了并行工程的方法,平行、交叉作業(yè),大大縮短了設計、制造工期,圓滿地完成了任務。
組合機床并行開發(fā)的具體做法是:
(1)設立一個由多專業(yè)人員組成的開發(fā)研制工作組。由工作組具體實施項目的各部分工作，工作組成員分工協作,各負其責,及時協調,從而實現優(yōu)化的設計。如機床的一種夾具要求在夾緊過程中零件能夠浮動,如果單獨從機械結構方面考慮,滿足這一要求比較困難,夾具的結構也復雜。后來通過與電器控制及液壓設計人員協調,提出了修正控制程序、改變夾緊動作次序、調整液壓壓力的解決方案,滿足了夾緊的要求。
(2)在制定工藝方案、簽定合同階段,就初步確定了一些標準部件。
(3)多次多級方案評審。在確定機床總體工藝方案、關鍵部件總體設計過程中,由技術委員會多次對設計方案進行評審,并且在投入生產前還要經過用戶對設計方案會審。這樣,就達到從設計一開始就考慮到工藝設計、工裝設計、加工制造、裝配調試等下游各階段可能出現的問題,從而大大減少了設計額定更改次數,滿足了用戶要求,使設計方案達到最佳。
(4)采用設計預發(fā)布的方法。在正式機床總體圖出圖以前,分階段公布已確定的各部件主要結構及主要數據,使工藝設計、工裝設計能提前進行。在機床總體設計的同時,確定出一些部件如夾具、刀具等的協調尺寸,并同時開始設計夾具和刀具,另外,還同時確定滑臺、移動工作臺等部件,這些部件盡可能選擇已有的標準部件,在總體設計未完成時就將其投產。在設計中總體與各部件如夾具、刀具之間及時協調,有關聯的尺寸改動時互相及時協調,使其他相關圖紙的尺寸得到及時改正。
(5)部件設計中可以將加工周期長的零件如夾具體等鑄件盡早定型,提前進行工藝設計,投入生產。
(6)各部件一完成設計,就隨時進入工藝設計及生產階段。所以各部件中的零件也是在車間并行加工的。
采用這一方式,工作組4人只用了4周的時間就在將部分通用部件如滑臺、移動工作臺和動力頭等投產的同時,完成了機床的機械設計及外購件訂貨。機床的生產過程中,各個部件在北京航空工藝研究所和幾個外協廠家同時進行。在機床的安裝和調試時,也是幾臺機床同時進行,通過這些工作,為機床的按時交付爭取了寶貴的時間。
2 敏捷制造
敏捷制造是美國里海大學在“21世紀制造業(yè)戰(zhàn)略”的報告中提出的一種全新的制造模式。經過發(fā)展,美國lacocca研究所將其定義為:“敏捷是指一個公司在連續(xù)的不可預測市場變化的競爭環(huán)境中發(fā)展和繁榮起來的一種能力,即對迅速變化的全球市場的快速響應能力,是公司用計算機網絡與全球生產系統、市場、競爭者連接起來,在高質量、高性能、低成本、顧客設定產品配置等用戶需求驅動的市場形勢下所表現出的一種能力”。其特征是把柔性生產技術、靈活的組織管理和掌握專業(yè)技能的人員集成為一個協調、互相關聯的系統,同時為了實現統一的戰(zhàn)略目標,把同一行業(yè)的不同企業(yè)通過共同的基礎結構連結起來,將過去你死我活的競爭變?yōu)橛押煤献鞯母偁?從而對瞬息萬變的市場作出快捷的響應。因此,這種技術很適合組合機床專業(yè)的發(fā)展。
(1)敏捷首先是推進產品的模塊化,反映在組合機床中就是推行機床功能部件的標準化和系列化。在曲軸加工機床的開發(fā)與設計中,能大大縮短設計周期,并行工程的應用是一個因素,大量標準部件、通用部件的應用也是一個關鍵因素。
(2)在敏捷制造中,必須體現人和組織都是最寶貴的財富。在大批量的生產中,人們總是把技術當作解決制造和銷售問題的關鍵,而在敏捷制造中,以最佳方式利用人則是解決問題的關鍵,技術僅是方法或手段。因此,需要推行項目工作組的組織模式,提倡愛崗敬業(yè)精神,充分發(fā)揮員工的主觀能動性。
3 精良生產
精良生產是90年代美國在總結日本豐田汽車公司生產管理方式的基礎上總結出來的生產方式。它強調通過改進企業(yè)在生產中的包括管理等各項活動的效率,并對各種活動進行成本核算,以達到以最快的市場響應速度、最低的生產成本、最優(yōu)的產品設計來設計和制造市場所需要的產品。其特征是以用戶為上帝,以人為中心,以精簡為手段,以零缺陷為目標。
4 深化及推廣先進制造技術的應用
從以上分析可看出,先進制造技術在北京航空工藝研究所的組合機床的研制中已得到了一些應用,但仍需進一步深化和推廣這一應用。在以后的工作中,應注意以下幾個方面:
(1)進一步推行項目工作組的模式,實行責任到人,由該小組用并行工程的方式負責完成機床從技術方案到設計、制造、調試和交付的工作;同時加強員工的知識與技能培訓,隨時跟蹤國內外組合機床行業(yè)的最新進展。
(2)研究市場的變化,制定預研計劃;同時保持與用戶的密切聯系,對用戶定期回訪,為用戶提供優(yōu)質的售后服務,并了解設備運行情況及用戶需求,以便改進設計。
(3)以優(yōu)質的產品贏得用戶。在組合機床的開發(fā)中,除了增強質量意識外,新技術、新工藝的應用也是占領市場的一個重要手段?，F在用戶普遍要求機床提高效率、增加柔性,并適應小批量、多品種的加工。要提高組合機床的生產效率,在設計中應從提高切削速度、采用先進刀具、集中加工工序3個方面進行考慮。
(4)重視開發(fā)產品的可重構性,實現機床結構的模塊化。在設計中,可采用成組技術,推進組合機床通用功能模塊的開發(fā)應用,也可采用數控柔性坐標單元的模式。
(5)推行敏捷制造技術的應用,建立有效的虛擬聯盟的動態(tài)合作形式。進一步加強與外購件生產廠及外協廠的合作。充分利用社會上已有的技術、信息及人員設備等資源,實行強—強聯合,優(yōu)勢互補,利用虛擬公司的模式擴大我們的生產能力。
(6)在組合機床的設計與生產中進一步推廣計算機及信息、網絡技術的應用。推進CAD技術的應用,實現無圖設計,進而建立CAD/CAM/CAPP集成工程設計的環(huán)境。
(7)進一步加強技術合作與交流,提高我所組合機床在行業(yè)內的地位及知名度,同時積極發(fā)掘新的市場及用戶。應努力開拓國際市場,如向日本豐田汽車制造公司出口用于汽車發(fā)動機機體的深孔加工的立式數控雙軸深孔鉆床,為我所的組合機床進入國際市場開了一個好頭。
Application of Advanced Manufacturing Technology in Modular Machine Tool
Beijing Institute of Aviation Technology Liu xin Ya
[Abstract] introduced a concurrent engineering, agile manufacturing and sophisticated production, and other advanced manufacturing technology and the characteristics of the development of machine tools in the portfolio of applications, how to deepen and extend the application of specific measures.
Keywords：Modular machine tool、Concurrent Engineering、Agile Manufacturing、Sophisticated production
In the machine tool industry, with the social demands of the continuous improvement of products, along with the growing competition in the market to meet user requirements, including the improvement of product quality, shorten production cycles, reduce costs, improve service and win market has become a breakthrough. In order to achieve this goal and win market, it should be the introduction of modern and advanced manufacturing technology: concurrent engineering, agile manufacturing and sophisticated production, in order to promote the development of combination machine.
1 Concurrent Engineering
Concurrent Engineering is also known as concurrent engineering, integrated, parallel to optimize product design and its related processes (including manufacturing and support) system approach, which guide the product development staff began to consider a product from concept to design to the demise of throughout the life cycle of all the factors, including quality, cost, programming and user needs.
Concurrent Engineering is the first to shorten product development cycles as a means to develop. Products will be characterized by the development, production engineering involved in the acts broken down into a series of tasks, such as market analysis, design, process design, production plans and equipment purchases, processing, quality assurance, testing and after sales service. These sub-tasks as far as possible and consider synchronous parallel to achieve improved design to shorten the cycle and improve quality, reduce costs, optimize the design purpose. It stressed that integrated, coordinated and parallel, namely: (1) management, design, production, and service of all project-related personnel and product information integration as a whole, and stressed that all relevant departments and the interests of the overall goal line (2) to the establishment of a competent and reasonable charge of the project personnel structure of the working group coordinated management model, by the Working Group in the ministries responsible for project elements, and the promotion of the coordination of tasks, (3) parallel processing stages of the work. According to the project in the different tasks of the linkages between the different ministries mandate of the elements of the work process can be completely overlap or duplication. In accordance with these principles, formulate a reasonable, and optimize the work plan, and the location in which the necessary settings assessment, the Working Group by the project implementation so that all sub-tasks in parallel, to move forward in an orderly manner, so as to ensure the smooth implementation of the whole project .
1.1 concurrent engineering work with the traditional way of comparison
According to the traditional methods of work, the work of the various stages in a row serial. In such a product development approach, divorced from each other at various stages, are not related, resulting in increased design error, and difficult to discover such a design rework, to lengthen the development cycle, adding to the costs.
Parallel working methods used, the process will be integrated with parallel consideration, the work can be carried out duplication. Problems can be promptly coordinate the changes so that the follow-up stage left to increase the difficulty of correction
And costs. Thus, the application of concurrent engineering can significantly shorten the product development cycle, reduce costs, it is suitable for the development of professional portfolio machine.
1.2 Applications
Concurrent engineering methods will be applied to product development, the effect was very significant. March 1997, Beijing Institute of Aviation Technology with a motorcycle design and manufacturing plants to sign the 6-crank machine project contract for delivery end of the year, and the requirements of machine tools in the past quite different. In the project using a concurrent engineering approach, in parallel, cross-operation , greatly reducing the design, manufacture period, the successful completion of the tasks.
Parallel development of the combination of machine specific methods are:
(1) the establishment of a multi-composed of professionals to develop working groups. By the Working Group of the specific part of the implementation of the project, members of the Working Group in collaboration division of duties, timely and coordinated in order to achieve optimization of the design. Such as a machine tool demand in the clamping fixture parts to the process of floating, if separate consideration from the mechanical structure to meet this requirement more difficult, complex structure of the fixture. Later, with the hydraulic design of electrical control and coordinate, control procedures proposed amendments to change the order clamping action, adjusting the hydraulic pressure of solutions to meet the requirements of the clamping.
(2) in the formulation of programmes, the signing of the contract stage, on the preliminary identified a number of standard components.
(3) Multiple Multi-accreditation programme. Machine Tool Technology in determining the overall programme, key components in the overall design process, many times by the technical committee to review the design plan, and put into production before the user in the design plan joint trials. Thus, from the design to take into account the beginning of a process design, tooling design, manufacturing, assembly and other downstream various stages of debugging problems that may arise, thus greatly reducing the number of design changes Rated meet user requirements, to achieve design best.
(4) a design pre-release method. Machine overall plans in a formal drawing ago, has been released in stages set by the main structure and the major components of data, process design, tooling design can be carried out ahead of schedule. In the design of the machine tool to determine some components such as fixtures, tools such as the coordination of size, and at the same time began to design and tool fixture, and, also identified slider, mobile workstations and other components, these components have the choice as far as possible Standard components, in the design of its operation will be completed. And the overall design of the various components such as fixtures, and timely coordination between the tool, linked to changes in the size of each other timely coordination so that the size of other relevant drawings are promptly corrected.
(5) components in the design of the processing cycle can be long specific parts such as folders, such as casting stereotypes as soon as possible to advancing the process design, production.
(6) completion of the various components of a design, process design and ready to enter the production stage. Therefore, the various components of the parts is in the workshop, parallel processing.
Adopt this approach, the Working Group 4 were used only four weeks time on the part of generic components such as the slider, mobile platforms and power first went into operation at the same time, the completion of the mechanical design of the machine and outsourcing of orders. Machine tool production process, the various components in the Beijing Institute of Aviation Technology Association, and several manufacturers at the same time. In the machine, installation and debugging, but also several machine at the same time, through these work, and machine tools for the timely delivery of valuable time.
2 Agile Manufacturing
Agile manufacturing in the United States of the Caspian Sea, "the 21st century manufacturing strategy" in the report of a new manufacturing paradigm. After development, the United States lacocca Institute will be defined as: "a company that is agile in the market for the unpredictable changes in the competitive environment in the development and prosperity of a capability, that is rapidly changing global market a rapid response capability, with the company computer network and the global production system, the market, competitors to link up in the high-quality, high-performance, low-cost, customer product configuration settings, such as user demand-driven market situation demonstrated a capability. " Characterized by the flexible production technology, flexible organization management and professional skills of the staff have integrated into a coordinated, interconnected systems, in order to achieve the strategic goal of reunification, the same industry in different enterprises through joint infrastructure links, past life-and-death competition will become friendly and cooperative competition, thereby changing market faster response. Therefore, this technology is suitable for the development of professional portfolio machine.
(1) promote the Agile first modular products, reflected in the composition of the machine is in the machine tool components and the standardization of serialization. Crankshaft Machine Tool in the development and design, can greatly shorten the design cycle, the application of concurrent engineering is a factor, large number of standard components, the application of common components is a key element.
(2) In the Agile Manufacturing, must reflect the people and organizations is the most valuable asset. In the production of large quantities, people are always technical solution as manufacture and sale of the crux of the problem, and in Agile Manufacturing, the best use of people is the key to solve the problem, technology is only a method or means. Therefore, the need for the Project Working Group organizational model advocated hard working, give full play to their initiative.
3 Sophisticated production
Sophisticated production is the United States in the 1990s, Japan's Toyota Motor Corporation summed up production management methods on the basis of summing up by the production. It stressed that by improving the production of enterprises in the management of the activities, including the efficiency of various activities and cost accounting, to achieve the fastest speed of response to the market, the lowest cost of production, the optimal product design to design and Manufacturing of products needed by the market. Its features are user-God, a people-centred, as a means to streamline, to zero defect goal.
4 deepen and promote the application of advanced manufacturing technology
Can be seen from the above analysis, and advanced manufacturing technology in the Beijing Institute of Aviation Technology Portfolio machine has been developed in a number of applications, but still need to further deepen and extend the application. In later work, Should pay attention to the following aspects:
(1) Working Group on the further implementation of the project model, a responsibility to the people, by the use of concurrent engineering group responsible for the completion of the way from the machine tool technology programme to design, manufacture, testing and delivery of the work of the staff at the same time strengthen the knowledge and skills training, keep track machine tool industry at home and abroad combination of the latest developments.
(2) market changes and the development of pre-study plan at the same time maintain close ties with users, users who regularly visit provides its users with quality after-sales service, and equipment operation and understanding of user needs, in order to improve the design.
(3) high-quality products to win customers. Machine Tool in the development portfolio, in addition to enhancing the sense of quality, the new technology, the application of new technology in the market is also an important means. Now users generally require machine efficiency, flexibility, and adapt to small quantities and variety of processing. Portfolio Tool to enhance the efficiency of production and increase in the design should be cutting speed, the use of advanced tools, centralized processing consider three aspects.
(4) attention to the development of products can be reconstructed so as to achieve the structure of modular machine. In the design, the use of group technology, and promote common machine combination of the development and application of functional modules, can be flexible coordinates NC unit model.
(5) the application of agile manufacturing technology, the establishment of an effective Union dynamic virtual forms of cooperation. Further strengthen and outsourcing of production plants and factories, HS cooperation. Make full use of existing community technology, information equipment and personnel resources, strong - strong alliance, complementary advantages, the use of the virtual company model to expand our production capacity.
(6) In combination with the design of machine tools to further promote the production of computer and information network technology applications. Promote the application of CAD technology, the realization of a map designed to establish CAD / CAM / CAPP works Design environment.
(7) to further strengthen technical cooperation and exchanges and enhance my portfolio in the machine tool industry and the status of visibility, at the same time actively explore new markets and customers. Efforts should be made to explore the international market, such as the Toyota Motor Co., Japan's exports to the body of the car's engine of vertical CNC machining deep hole biaxial deep hole drilling machine, I have a combination of machine to enter the international market and made a good start.
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