CC BY
0УДК 621.9
IMPROVING THE PRODUCTIVITY OF METHODS FOR PROCESSING
SHAPED SURFACES.
Fayzimatov SH.N., Gafurov A.M.
ABSTRACT: With the expansion of the product range, the dynamic development of such production involves a constant increase in the need for technological equipment of CAD/CAM/CAE systems. It is characterized by high-quality and resource-intensive production conditions, the development of new products, the development of technological systems and complex production technologies.
KEY WORDS: system, G-code, RDB machine, software, production, design, details, cutting tool, cutting process
I. METHODOLOGY
Metalwork modeling
When modeling metal molding, sheet metal molding is modeled on a computer using special software. Simulation can detect errors and problems, such as wrinkles or cracks in parts, on a computer at an early stage of formation. Thus, there is no need to create real tools to run practical tests. Molding imitation has become popular in the automotive industry as it is used to design and optimize every sheet metal part.
To illustrate the metal forming process, there must be a model of the real process. This is calculated in software using the finite element method based on implicit or explicit increments. Model parameters should describe the real process as accurately as possible so that the simulation results are realistic.
Metal forming simulation-modeling the entire sheet metal processing chain
Simulation of metal molding allows you to quickly and accurately simulate the entire molding process, including drawing and secondary operations, as well as elastic recovery. In this way, the part can be developed fully and efficiently.
Typical parameters for molding modeling are, for example, part and tool geometry, material properties, pressing forces, and friction. Simulation calculates stresses and strains during the molding process. In addition, modeling allows you to recognize errors and problems (for example, wrinkles or splitting), as well as results (for example, strength and thinning of the material). Even the elastic recoil, the elastic behavior of the material after molding, can be predicted in advance. Molding modeling also provides valuable information about the effect of process changes on stamping reliability.
Molding modeling is used throughout the entire sheet metal forming process chain. Modeling allows the part designer to evaluate the formability of a sheet metal part already at the design stage, which leads to the creation of a part that is easy to manufacture. The process engineer can already evaluate the process at the planning stage and optimize various alternatives using simulation, which subsequently can reduce the fine tuning of the forming tool. Finally, with regard to fine tuning the forming tool, modeling can provide useful information on how to tune an existing, not yet fully functioning tool. You can also see how the process parameters should be adjusted to guarantee optimal drawing results.
Strength
Reliability is an important topic in the sheet metal forming industry. Traditionally, companies have focused on the reliability of stamping at the production stage through their
manufacturing and quality departments. Today, modern modeling software allows companies to also solve the problems of stamping stability in the early stages of product design and tooling. In other words, companies can now design better product designs and better tool designs for a reliable stamping process.
With reliable analysis, the stability of the deep drawing process is analyzed under predetermined process conditions. In everyday production, parts can be produced smoothly in one day, and problems arise the next day, even if the production conditions do not seem to have changed at all. This is due to noise and changes in the molding process
In real production conditions, there are important, but inevitable and uncontrolled changes to the drawing parameters. These variations can be divided into two classes:
Noise in the parameters of the molding process, such as, for example, the force limiting the pulling of the roller, bevel radii due to tool wear, pressure changes in the workpiece holder due to the pressing state, lubrication fluctuations, etc.
Noise in material properties, such as, for example, yield strength, tensile strength and r values, which vary from coil to coil and from supplier to supplier
Reliable analysis is performed to analyze the effect of noise variables on the formation process. The user defines the change for each noise variable in the form of an average value and the corresponding standard deviation. Based on this change, multiple simulations are carried out. All simulations available are then analyzed using an analysis identical to the sensitivity analysis. However, the analysis is currently based on a change in noise variables, and not on project parameters. Thus, a quality function is calculated, which depends on the noise variables. With a reliable analysis, you can check whether the molding process provides stable results under the influence of total noise of various parameters. Noise variables for reliable analysis. Input diagram of noise variables for reliable analysis. Reliable process window in robust analysis.
Reliable analysis allows you to determine a stable and capable process. If the influence and sensitivity of the noise variables is known, the molding process can be designed accordingly to:
Fig. 1 Stamped metal products.
Noise does not affect the desired quality of the result.
Nominal marriages are minimized while production efficiency is improved.
Tolerance limits for material quality control can be determined.
The result is used to predict the stability and ability of molding processes depending on the selected noise variables. Reliable analysis allows the user to determine a reliable process window that takes into account the best formation conditions taking into account noise variables.
Solving the stamping stability problem is important because potential stamping problems can be solved at an earlier stage in the vehicle development cycle, which saves more time and resources. This means faster entry into the market for new car models with obvious benefits.
II. RECOMMENDATIONS
The created geometric bodies in NX are divided into surfaces and solids. One of the subspecies of a solid is a sheet metal part model, for the creation of which several specialized NX applications are proposed. Solid modeling is the creation of a closed geometric volume that describes the geometry of the part. For this, primitives obtained by stretching and rotating flat contours, structural elements and logical operations of combining bodies are used. There is no explicitly expressed solid-state modeling module in NX, since tools from different applications are used for this. In particular, solids can be obtained by giving the thickness of the surface to the shape created in the Studio application, or by filling a closed loop from the surfaces.
The main goal of modeling solids is to create an accurate geometric representation of the designed part, which will be the basis for the production of documentation, calculations and writing CNC programs. From the point of view of the system, the geometric representation is the result of a connected sequence of operations that make up the model building tree. The user's job is to add operations to the construction tree that create certain structural elements or modify the geometry. This is true for a classic modeling case with a build history. NX also supports modeling without a build history, which will be discussed in a separate chapter. This chapter will
provide an overview of the basic tools for creating solid models in modeling with a history of construction.
To create models, you can use typical structural elements or create bodies based on two-dimensional contours, as well as combine these two methods. Sketches are the basis for all bodies obtained by rotation or pulling along a path.
Progressive stamping
Progressive stamping is a metal forming process widely used to produce parts for various industries, such as automotive, electronics and household appliances. Progressive stamping consists of several separate workstations, each of which performs one or more different operations on the part. A part is transferred from station to station along the reserve strip and in the last operation is cut down from the strip.
Progressive stamping-from steel strips to finished parts
With progressive stamping, a steel strip is formed into a finished part in a few operations.
The decision to make a part in a progressive or transfer head depends on the size, complexity and volume of production. Progressive stamping is used to manufacture a large number of parts and maintain costs at the lowest possible level. The highest requirements for precision and durability must be met.
Due to the complexity of progressive dies, it is important to consider all factors that contribute to achieving the desired level of part quality, including the position of the workpiece, pilots, workpiece boundaries and the deformation of the stretch tape.
Pilots play an important role in progressive stamping-they fix the strip in the proper position and retain control over it. In addition, they are necessary for precise positioning of the sheet during tool closing and drawing operations in the transfer matrices. Other factors to consider are the time and interaction of the holders, pillows, and upper and lower tools. The advantages of progressive stamping are increased productivity and a significant reduction in costs in large-scale production.
III. EXPERIMENTAL RESULTS
A joint venture established in the Republic of Uzbekistan, since 2012, uses progressive molds using CAD/CAM/CAE systems managed by UZ-HANWOO ENGINEERING LLC. Advanced technological presses with advanced technology The use of advanced technologies in production technology requires the production of molds, improved molds, improved quality of parts, extended shelf life and extended working surface life. UZ-HANWOO ENGINEERING LLC uses mold processing technology. The quality of the printing plates determines the accuracy of the parts. Mold preparation is a complex process. Therefore, the working part of the mold is in great demand. Mold preparation is carried out in several stages. First of all, mold paper is made. After stamping, the required mold part is removed and heat treatment is applied to the work surface. Heat treatment also requires a lot of attention.
Progressive molds require the formation of consistent surfaces. This process also requires a lot of hard work. The geometric dimensions of the parts are taken into account. SAM systems help us with the project. SAM systems create a virtual environment that helps us create molds and create complex notebook surfaces. SAM systems were developed by NX to extend the life of progressive molds manufactured by the UZ-HANWOO ENGINEERING JV to predict errors in production processes. Defects in progressive printing forms are resolved and resolved in a virtual environment.
We can understand the appearance of the mold as an example. UZ-HANWOO ENGINEERING has led to significant labor savings. The development stages of CAM systems
in the region are rapidly developing.
Fig. 2. Development of mold parts for control programs in NX CAM.
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Progressive press forms programming:
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N0020 G91 G28 Z0.0 N0710 X.7104
N0030 T01 M06 N0720 X.7183
N0040 T00 N0730 Z2.0327
N0050 G00 G90 Y0.0 Z4.277 S678 M03 N0740 G01 X.671 F24.8
N0060 G43 X1.1787 H00 N0750 X.6656 Z1.9291 F17.7
N0070 Z3.8421 N0760 X.671 F29.8
N0080 X1.0512 N0770 G00 Z1.9625
N0090 G01 X1.0039 F7.8 M08 N0780 X.7044
N0100 X-.0472 F5.4 N0790 Z4.277
N0110 G00 X-.0945 N0800 X1.1787
N0120 Z3.9602 N0810 G91 G28 Z0.0
N0130 X1.0512 N0820 T00 M06
N0140 Z3.7472 N0830 T01
N0150 G01 X1.0039 F7.8 N0840 G00 G90 Y0.0 Z4.277 S648 M03
N0160 X-.0472 F9. N0850 G43 X1.1787 H00
N0170 G00 X-.0945 N0860 Z2.7704
N0180 Z3.8653 N0870 X.5508
N0190 X1.0512 N0880 G01 X.5429 F40.5
N0200 Z3.6523 N0890 X.3483 F27.4
N0210 G01 X1.0039 F7.8 N0900 G04 P.026
N0220 X-.0472 F9. N0910 G00 X.3562
N0230 G00 X-.0945 N0920 X.5743
N0240 Z4.277 N0250 X1.1787 N0930 Z2.7822
N0260 G00 Y0.0 Z4.277 S519 M03 N0940 X.4326
N0270 X1.1787 N0950 G01 X.4248 F51.5
N0280 Z3.8177 N0960 G18 G03 X.413 Z2.7704 I-.0118 K0.0
N0290 X.7784 F58.3
N0300 G01 Z3.7704 F22.9 N0970 G00 X.4878
N0310 Z1.9291 F15.3 N0980 X.5508
N0320 X.8858 F25.4 N0990 Z2.7686
N0330 G00 Z1.9625 N1000 G01 X.5429 F40.5
N0340 X.9192 N1010 X.3483 F45.6
N0350 Z3.8177 N1020 G00 Z2.7703
N0360 X.671 N1030 X.35
N0370 G01 Z3.7704 F26.6 N1040 X.5819
N0380 Z1.9291 F29.5 N1050 Z2.7568
N0390 X.7784 N1060 X.4326
N0400 G00 Z1.9625 N1070 G01 X.4248 F51.5
N0410 Х.8118 N1080 002 Х.413 Z2.7686 1-.0118 К0.0 F58.3
N0420 Z3.8177 N1090 000 Х.4208
N0430 X.5479 N1100 Z4.277
N0440 001 Z3.7704 F32.5 N1110 Х1.1787
N0450 Z2.3444 F36.2 N1120 000 У0.0 Z4.277 Б648 М03
N0460 Х.671 N1130 Х1.1787
N0470 000 Z2.3779 N1140 Z2.38
N0480 Х.7044 N1150 Х.5508
N0490 Z3.8177 N1160 001 Х.5429 F40.5
N0500 Х.4248 N1170 Х.3059 F27.4
N0510 001 Z3.7704 F42. N1180 000 Х.3138
N0520 Z2.3444 F46.6 N1190 Х.4326
N0530 Х.5479 N1200 Z2.3918
N0540 000 Z2.3779 N1210 001 Х.4248 F51.5
N0550 Х.5813 N1220 003 Х.413 Z2.38 1-.0118 К0.0 F58.3
N0560 Z2.8558 N1230 000 Х.4208
N0570 Х.472 N1240 Х.5894
N0580 001 Х.4248 F37.8 N1250 Z2.35
N0590 Х.4189 Z2.7441 F28. N1260 001 Х.5838 Z2.3444 F37.8
N0600 Х.4248 Z2.7335 F47.3 N1270 Х.3059 F42.4
N0610 000 Z2.7669 N1280 Р.028
N0620 Х.4582 N1290 000 Z2.3578
N0630 Х.4641 N1300 Х.3193
N0640 Х.472 N1310 Z4.277
N0650 Z2.4654 N1320 Х1.1787
N0660 001 Х.4248 F37.8 N1330 М02
N0670 Х.4184 Z2.3444 F28. %
N0680 Х.4248 F47.3
N0690 000 Z2.3779
