The body panel press line is the key facility to the production of automobile. Its productivity and quality has a direct effect on the productivity and quality of products. The inter-press automation is the main method to improve the productivity of the traditional line. This paper chooses 6 DOF(Degrees of Freedom) industrial robot as the solution for inter-press automation, and form the robot automation press line with tandem presses. Then takes a car body panel press line for example, designs the layout and builds a control system based on the PROFIBUS-DP Field Bus. This paper also describes a method to build a monitoring system by means of industrial configuration software WinCC through the Industrial Ethernet. The importance of safety guard in robot automation press line and a method to build a safety guard system with SafetyBUS p is discussed.

To research the affects of minishing powder’s size to basic low- hydrogen electrode performance, the medium carbon ferromanganese, ferro-silicon and ferro-titanium of different particles are added to the coating of E5015. The density, surface tension and viscosity of the coating are tested by RTW-10 fusant physical property colligation measuring instrument, and the affect of alloy granularity is researched. Assess the welding technics performance by the test of arc stability and the weldability feeling form welding worker. Assess the size-affects by collecting the molten drops with the d₅₀ collection method and measuring their sizes. The current and voltage waveforms are collected by Labview date collecting system, and the frequency and mode of molten drops transition are compared and analyzed. Use the 60 ton of universal material testing machines, the JB-30B impact testing machine to research the affects of different particles to deposited metal’s mechanical properties respectively. Use microscope to observe the metal microstructure, and analyze the affects of different particles of powder to microstructure of deposited metal.Some conclusions are gained from the research. Adding thin powder can increase interfacial tension of slag, and get thinner molten drop and high transition frequency of molten drops. Adding nano ferro-titanium can make Mn transition preferably, get thinner ferrite grains, the acicular ferrite content and impact ductility of deposited metal are increased. Nano ferro-silicon is available to get stable arc and high hardness. Nano medium carbon ferromanganese can only make the molten drops thiner. It is bad to other performances of electrode. When nano ferro-titanium and nano ferro-silicon exist at the same time, the weldability and molded competence are good, the welding technics performance is excellent, and the deposited metal can get good impact ductility, high hardness at the same time and thin ferrite grain.

In order to resolve the loading issues that high-energy propellant charge used the liquid silicone oil as a highly effective bore-wear reducing additive, the preparation arts and crafts of microcapsules of silicone oil were researched by an in-situ condensation polymerization reaction with a urea-formaldehyde resin wall. Several encapsulating parameters were investigated including different emulsifiers、different dispersed emulsion time, pH, stirring speed, acidification time and curing temperature on microcapsule appearance quality such as particle size, and size distribution. What is more, the microcapsules of silicone oil were prepared with a urea-formaldehyde resin wall material, and the performanceuse of wear reducing is mensurated by the erosion tube test.The result of experiments show that the reaction system of emulsifier is the key factors to determine the success of micro-encapsulation. It plays a vital role in the morphology of micro-capsules; Stirring speed is the other major factors in the microcapsules; The speed of acidification has a direct impact on the microcapsules of formation in particle size in the course of condensation; In addition, the level of pH has effect on the microcapsules wall in the process of condensation; When pH is between 4.0 and 5.5, the forming wall is osteoporosised and it is easy to be destroyed. When pH value is low, the formation of micro-capsule wall is hard and not easy to destroyed. The final reaction conditions of the preparation of silicon oil Microcapsules with a urea-formaldehyde resin wall were as follows: SMA, 2h acidification approximately, the curing temperature under 70℃for 120min. Under these conditions, the mean particle diameter of 50μm, uniform and spherical solid microcapsules of silicone oil were obtained. The wear reducing of microcapsules of silicon oil is obvious, and it is similar to the pure silicone oil.

For more than a hundred years, the method of plastic deformation for measuring pressures has been the main mean to test the chamber pressure of conventional weapons because of its advantages that is reliability, convenience and low price. Aimed at a series of theory problem in the static mechanical characteristic and the dynamic mechanical characteristic, a large amount of work has been done in dissertation. The main work consists of the following parts:a) The frictional coefficient between copper cylinder and the interface is one of the most important factor in the copper cylinder upsetting process. According to the diameter height ratio difference, the interface was divided into three parts : sliding area, restraint area, stagnant area. Bases on the difference of the touch,we get the formula between the pressure and distortion. At last, a comparatively satisfactory result based on the performed static formula of mathmatics and physics was obtained, and it is testified by the tests.b) Regarding Rigid-Viscoplastic FEM(the Finite Element Method) as theoretical foundation, an axial symmetry model of ring upsetting was built up through ANSYS software, the copper cylinder upsetting has been simulated by the FEM. Information about the deformed sample, such as mesh distortion, displacement and pressure has been achieved. The deformation patterns were revealed. In order to verify the FEM simulation results, various experiments about copper cylinder pressure measuring were designed and completed. The experiment results indicated that the simulation results are reliable.c) The mathematical model of copper cylinder pressure-measuring system was established according to the pressure-measuring mechanism of copper cylinders and the numerical solution program was made using the Matlab. The simulation of this model has been done and the simulation results comply with the measuring results quite well. According to the simulating calculation, the regularity of copper cylinder deformation under different pressure is obtained.

Continuous extrusion technology is an advanced manufacturing technology, which is widely applied now. Die plays an important part in the stabilization and high- quantity in the continuous extrusion production, especially in the practical situation of copper lines extrusion production. So that how to improve service life of extrusion die is one of the most significant ways in the realization of high-yield, high-quality, low-consumption, and it also emphasis on the cost reduction and benefit addition.The paper was based on the working principle and technology characteristic of CONFORM continuous extrusion, and the emphasis of factors which effect on service life of extrusion die in the continuous extrusion production. Based on the practical situation of Hefei ABB Transformer Corporation copper lines extrusion production, the paper analyzes the production data used the way of SPSS. Through the regression experimentation, it Analyzed the mostly effect factors, at last arrived at the primary and secondary effect factors and improvement mostly approach about service life of die.Secondly, researched effect technological parameters of continuous extrusion production, at the same time carried out optimal design for the mostly parameters of temperature and velocity, establishes mathematical formulas in order to improvement service life of continuous extrusion die.

Modern precision processing technology needs a higher demand for the measurement of roundness error.This paper designs the circular experimental measurement devices which takes full advantage of computer technology, including their structure design and software design. For the installations using the stepper motor control and the inductors probe using contact measurement, the structure is simple and easy to analysis the source of the error. Adopting the virtual instrument software platform that is to say Labview which is used widely in the industry, we achieve data acquisition, least-squares round, three-point method software and the implementation of displaying the contour of the workpiece using this graphical programming language.This paper gains the software methods of the roundness error of harmonic analysis for the following subsequent error separation experiments which makes full use of computer data powerful computing power and designs a harmonic analyzer using this software platform .In conjunction with the harmonic analysis software, this experiment is completed separately using the least square circle method, the three-point method, multi-step method and other methods.This paper achieves optimization of the round of least-squares and three methods after many experiments, which has obvious improvement comparing with the foregoing methods, proving the validity of the optimization.The experimental device hardware and software owning the basic functions for the measurement of roundness, combining error separation method and data processing software can achieve better performance measurement, which creates foundation for more in-depth analysis of the error sources and the amendment of the system.

Hollow aluminum profiles are widely used in aviation, aerospace, vehicle, civil construction, decoration and electrical industries. The porthole extrusion moulds which are used to produce hollow aluminum profiles are also developed rapidly with newer types, higher precision and longer service life. In traditional pattern, the design and manufacture of porthole extrusion moulds needs to be tested and adjusted many times before it can be used into real production, much time and money are wasted inefficiently. It is quite important and necessary to develop an effective and practical CAD/CAE system for hollow aluminum profiles porthole extrusion moulds. The research in this thesis is a part of Jiangxi Provincial Natural Science Fund “Web based CAD/CAE/CAO research on hollow aluminum profiles porthole extrusion (No.: 2007gzc177)”.Based on grasping and analyzing the design principles and structure characters of the porthole extrusion moulds, the general structure, objects models, objects class models and its operational characteristics of the CAD system for porthole extrusion moulds of hollow aluminum profiles is designed, by adopting the object oriented technology and OMT (Object Modeling Technology) methods. With the help of UG/ OPEN API and UG/OPEN GRIP re-developing interfaces, object classes operational characteristics of the CAD system are developed by using C programming language, and the CAD system for porthole extrusion moulds of hollow aluminum profiles is eventually realized. The sample design proved that it is quite convenient to design parametric porthole extrusion moulds using the CAD system.The extrusion forming process of a typical hollow aluminum profile, rectangular tube, is numerically simulated on the SuperForge software based on FVM (Finite Volume Method), with correctly designing extrusion parameters and re-developing materials library. Exact simulation results, such as metal flow, effective stress, effective plastic strain and temperature are obtained. The distribution of them and effect to the extrusion mould are also analyzed, which could be a good support and reference to the optimization of mould parameters, diminishing of “try and error” and improvement of production efficiency.

Electric Discharge Machining (EDM) is a new type of nontraditional machining and has been developing for a few decades. Now EDM is heading towards high efficiency, high accuracy and intelligence. Wire Cutting Electrical Discharge Machining (WEDM) is an important research field of non-traditional machining, which deals with materials that are difficult to machine and work piece with complicated surface. For WEDM, the discharge gap control technology is a very important technology, which has a direct impact on the performance of the process of stability and processing quality. Under this research background, the present paper has carried on the research design to the WEDM Gap State control system.Based on WEDM principle, this article has studied the detection status in quo of the WEDM gap state, and has presented the control technology development and the tendency, proposed the control system overall project design.The control system consists of hardware and software.The control system hardware has designed the power simulation part, the voltage detection circuit, the comparison circuit of voltage, the circuit of analog-to-digital and digital-to-analog, and the microcontroller AT89C51 system; analyzed in detail various electrical equipment component composition and their corresponding chip;introduced the ISA bus structure characteristics.In the field of the software, the paper has researched the WEDM Gap State control algorithm and carried on the design to the gap state control procedures; to resolve the control card and PC communication problems, make full use of PC resources, have designed the Gap State control system drivers owing to Windows 2000 WDM model.

Sheet metal stampmg is a sheet metal forming process by using molds to get products that fit the requirement of design in shape, dimension and performance. As sheet metal stamping can provide the advantages such as saving materials, high efficiency and low cost, it is one of the important machining processes in manufacturing industries, i.e., machinery, electron, instruments and aerospace, etc. Drawing is one of the most typical sheet metal stamping processes, which is also widely used in practical production of many work pieces. Although existing researches on drawing have already developed to a relatively high level as well as abundant correlative literatures focus on it, there are still some fields need to be studied. Therefore, thorough and further research on drawing process is quite necessary.Based on the development history and status quo of drawing process, this paper is focused on the drawing process which has not been studied well. For example, the influence of material thickness variety and material work hardening were omitted in the calculation to the drawing deformation pressure, etc. The main research contents and results are listed as follows:(1) Technologic experimentsWith utilization of technologic experiments being designed, deformation characteristic and technological parameters are comprehended, as well as drawing force can be measured. The instance of drawing force can provide foundation and validation for theoretical study.(2) Numerical simulationWith utilization of FEM software DEFORM, Simulation and analysis on deformation course of drawing was carried out. Effective stress and effective strain are analyzed, the state and condition of fracture in drawing process are simulated, and drawing force is analyzed, which can provide foundation and validation for theoretical study. (3) Theoretical studyBase on technologic experimental results and numerical simulation results, with utilization of slab method of plastic mechanics and material work-hardening theory, a new calculational formula of cylinder drawing force was deduced, and compared with different calculational formulas of drawing force.The studies of this paper enriched the contents and the theories of drawing process, which brought both academic and practical significance as well as its research method can be validated. It can provide references for the technicians who are engaged in sheet metal stamping field.

LS-WEDM plays an important role in the field of high-precision mould manufacture, shaped tool machining, hard-machined material and the machine of precise complex part. As the central part of the LS-WEDM machine, the performance of the CNC system decides the machine result directly. This paper studies present situation and development tendency of LS-WEDM,combined with practical requirement and analysed a large amount of materials,has done some works as followed:1 .According to total requirement of LS-WEDM has been analysed ,at the same time.plents of hardware and software resource in the PC,the speed of the MCS have been considered,a structure of PC+ MCS was put forward.2.Based on the analysis and required function of LS-WEDM,a total scheme has been put forward ,in this scheme ,there are four modules has been designed.3.Analysed the character of the interface,a new interface has been designed,which based on the coordinate parameters,at the same time ,the methods on how to designe the interface is introduced.4.Aanalysed the character of CNC program and the requirements of words and grammar check,a process of executing the program has been brought forward.and designed the words and grammar check program.5.Because the electrode has radius ,the center position of the electrode must be compensated,in this paper ,it pointed out the methods of calculate the coordinate of electrode thread center,judge the adapter style and coordinate of two linked curve.6.Analysed the interpolation character of Plane XY and UV,gave out the methods of calculalate the interpolation coordinate.and designed the interpolation program.