With the continuous development of information technology, aircraft manufacturing enterprises in developed countries have effectively improved the level of process design through the application of three-dimensional digital technology, and solved the problems of standardization and system integration in the design and manufacture of digital products in aviation products. Consistency and standardization of the underlying data of the business application system. After long-term 3D process design and simulation, CAX/CAPP/MES system integration and other technologies, domestic aircraft manufacturers have broken through the definition of model-based definition (MBD), 3D process design visualization, 3D assembly process simulation verification and optimization, 3D work. Key technical bottlenecks such as the creation, distribution and browsing of instructions, multi-system integration and business process optimization, and the construction of a complete system that can support the assembly, machining, sheet metal, metallurgical and other process design business needs. The integrated enterprise-level digital process design platform has realized the successful transformation of the traditional two-dimensional process design and manufacturing system to the three-dimensional digital process design and manufacturing system.

Two-dimensional process design

Process design is a bridge connecting design and production. Under the traditional two-dimensional environment, the process design work is based on the two-dimensional engineering drawings issued by the design, and the process design, matching table, process card preparation and process signing are carried out in the CAPP system. Then, it is sent to the production unit in the form of a paper craft card, plus the paper documents such as the operation instructions and safety regulations on the production site, and finally guides the production process of the production personnel. The core has not yet jumped out of the constraints of two-dimensional planar process design, lacking the function of visualized, three-dimensional space for process design.

In the process of information transmission and design of the entire product design, designers, technicians, and production personnel are constantly performing two-dimensional and three-dimensional reconstruction, resulting in huge time waste and many understanding ambiguities; designers complete the product in three dimensions. Design, convert it into a two-dimensional drawing, and issue it to the manufacturing department as a legal document; after obtaining the 2D drawing, the craftsman must first understand the original design intent, restore the 2D design drawing to the 3D model in thinking, and then compile it. Guide the two-dimensional process instructions for production operations. After the production personnel get the 2D engineering instructions, they need to restore the 2D drawings and process instructions to the 3D model and 3D process again to understand the design intent of the product and process personnel. From the process to the production process, the data transmission volume is large and the cycle is long. It is very easy to appear because the design, process and production personnel have different understandings of the two-dimensional and three-dimensional information, which leads to the unclear intention and even the complete misunderstanding.

Three-dimensional process design

The three-dimensional process design is oriented to the entire process of aircraft process development, including the related business operations in the various stages of process planning and detailed design of the three-dimensional process.

1. Process planning

At the overall design stage of the aircraft, the manufacturing company has begun to design the overall process plan, and through the use of a maturity-based collaborative process review method, based on the design results, simultaneous follow-up process planning, including assembly coordination, part manufacturing technology, process separation surface The definition and preparation of a series of process guidance documents such as component assembly charts.

During the planning stage of the process plan, the craftsman of the manufacturing enterprise divides the process separation surface in the virtual three-dimensional space, reconstructs the EBOM structure of the product, supplements the product process route (flowing water) and engineering components, and builds the product PBOM as a follow-up assembly. The data foundation of detailed process design such as process and part process.

2. Parts (machine plus sheet metal) process design (cold processing design)

The part process is divided into machine adding process and sheet metal process. The machine-added process refers to the use of traditional manual operation of the car, milling, planing, grinding process equipment and numerical control equipment for parts manufacturing; the sheet metal process has a wide variety, and the sheet metal process mainly used in aerospace manufacturing enterprises has gate pressure and rolling. , hydroforming, etc. The 3D part process focuses on the use of lightweight models and MBD data sets, combined with part process simulation analysis functions to improve part process design efficiency and level, 3D part process (instruction) electronic data package editing environment.

(1) The definition of the part process design process and the construction of the process model.

On the one hand, the part process design starts from the blank, and the step-by-step process finally forms the state of the part that meets the design requirements. In the actual process, the process personnel need to refer to the design model, and reversely design the process model that reflects the middle process. On the other hand, Process design and simulation optimization are combined to optimize the process and obtain the optimal process design as a guide for process definition.

(2) 3D part process electronic data package creation, editing and viewing.

The 3D part process instruction is not a traditional spreadsheet or paper document, but an electronic data package that combines structural process information with 3D models, views, animations, etc. to form a 3D part process (instruction). And by providing an intuitive, visual interface, process and manufacturing personnel can directly view the contents of the electronic package of the part process.

3. Metallurgical process design (thermal process design)

Metallurgical majors include a number of specialties, including forging, casting, heat treatment, surface treatment, welding, etc. Metallurgical processes vary in their requirements for three-dimensionality, depending on the type of process. For example, the welding process needs to mark the position of the weld and the welding sequence on the three-dimensional digital model; the surface treatment process needs to use the three-dimensional digital model to perform the coating, painting, milling, surface conversion, and processing range of the pipe insulation in the three-dimensional space. The marking process needs to keep the casting allowance according to the product model and use the three-dimensional model to show the design of the corresponding pouring system.

In general, the demand for three-dimensional metallurgical process design is not as strong as that of parts and assembly processes, but the specific requirements of various metallurgical processes can still be analyzed. Three-dimensional models of products are introduced, modeled on three-dimensional parts and assembly process design, and relevant on three-dimensional models. Information identification, which describes the process status in a three-dimensional view, helping the craftsman to more intuitively display relevant process information.

4. Assembly process design

MBD-based assembly process refers to the use of MBD dataset information and digital and structured methods to define and display the entire process based on lightweight 3D models, achieving efficient and rational assembly process design. The 3D assembly process (instruction) electronic packet editing environment is shown in Figure 3.

(1) Assembly process design process definition and process model construction.

The primary task of assembly process design is to plan the assembly process, assembly sequence, positioning plan, etc. On this basis, the assembly process is defined, and the 3D process model matching the process process is constructed. The process model should also contain the corresponding product. Model, tooling model, and 3D view matching process contents, process operation guidance information (labeling information, auxiliary explanation information, process size information, etc.). And organically correlate the entire process content with the 3D model.

(2) 3D assembly process electronic data package creation, editing and viewing.

Through the definition of the process model, the traditional 2D drawings or schematics are replaced by 3D models. The operation steps in the process instructions are mainly based on 3D view and 3D animation, and the structured text information is used as a supplement to describe the process, 3D conditions. The next process instruction combines structured process information (standard format) with three-dimensional information (lightweight format) such as models, views, and animations to form a three-dimensional assembly process (instruction) electronic data package that guides the assembly staff.

5. Process data management

In the three-dimensional digital process design environment, the storage, sharing and application of process knowledge have undergone tremendous changes. This requires the establishment of relevant knowledge, resource libraries and templates to support the design of 3D digital process, to achieve standardized management and application of process data, and to improve the efficiency and quality of process design.

(1) Process knowledge management.

Process knowledge management is to realize the intelligent online help of the business in the process design process by managing the document resources related to the process knowledge in the enterprise and making full use of the experience and knowledge accumulation of the process experts. It mainly includes management of process terminology database, process parameter database, NC program database, cutting parameter library, sheet metal forming parameter library, etc.; and document knowledge database, including process manual, process standards and procedures, technical summary, learning materials, etc. Classification management.

(2) Process resource management.

According to the requirements of the 3D digital process, build a process resource library, standardize the description and management of various resources in the process design process, including assembly, processing equipment, process equipment, material properties, etc., and implement standard template definition for these resources. Design and manufacture of unified information and standardized and efficient reference to resource information.

(3) Typical process management.

Typical process management is to design one or several optimized processing or assembly process examples based on changes in the structure and size of similar parts, including typical machining processes, typical forging parts, typical casting processes, sheet metal. Typical process, etc., for the process personnel to reuse in design, and then help enterprises to achieve the refinement, storage, management and use of typical processes through the standardization and standardization of process work according to their own needs.

6. Production site visualization

In 3D process mode, 3D data (models, etc.) replaces 2D engineering drawings and paper process instructions. The three-dimensional process electronic data package (instruction) becomes the technical basis for the production site work. Through the integration of the process design platform and the production management system, the process data information such as the three-dimensional process instruction is distributed to the workshop production site, and the three-dimensional, dynamic and interactive The customized interface displays and describes the process, effectively integrates the production process, personnel, equipment, tooling and tools, and displays the product design relationship, process structure relationship and geometric model through an intuitive interface, showing the process simulation process and The tooling uses the positioning method to display the operation instructions corresponding to the simulation process, so that the workers can operate according to the instructions, accurately and quickly refer to the information required in the process, and improve the accuracy and efficiency of the work.

3D process design platform

Jinhang has built a top-level process design, three-dimensional assembly process design, three-dimensional part process design, three-dimensional metallurgical process design, process knowledge base, and process resources through the research of the above three-dimensional process design platform function and the actual needs of related enterprises. The 3D process design platform, such as library and typical process library, realizes the close integration and management of upstream and downstream related business systems, data and processes.

(1) Three-dimensional process design.

Aiming at the hotspot of 3D process design, it is the core function of detailed process design with 3D view and animation as the core.

(2) Management and application of knowledge.

Meet the needs of 3D process design, summarize the process design knowledge of the enterprise, realize the management of relevant process knowledge and resources, and improve the knowledge level of the process design system.

(3) Networked integrated development.

Through the network technology, the process system is integrated with the CAX, PDM system, etc., and the process design is extended to the whole process of production management, thereby exerting the information center and function adjustment function of the process design system in the whole life cycle of the product.

(4) Reconfigurable process design.

The process design system can continue to meet the individualized and changing needs of the enterprise, modular management, and the ability to redevelop, reconfigure and customize related functions according to different needs.

in conclusion

The application of MBD technology makes the 3D model the only basis in the manufacturing process. This paper proposes the working ideas and implementation methods of the 3D process design platform, and builds the prototype system of the platform to realize 3D digital definition, 3D process design and simulation, and weight reduction. The process visualization technology of the model and the application of CAX/PDM/MES multi-system integration technology effectively shorten the product development cycle, improve product quality and production efficiency, and truly realize 3D digital integrated manufacturing without 2D drawings and paperless work instructions. Effectively improve the working environment at the production site, making it easy for field workers to understand, reducing operational errors, and improving product quality and production efficiency. The in-depth application of 3D digital process design technology will certainly promote the rapid development of China's aircraft manufacturing industry.

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