了解不同的制造流程

几乎我们日常使用的每一种产品，从智能手机到汽车，其起源都可以追溯到制造过程。这些流程不仅决定产品的质量和生产效率，还直接影响企业的成本控制和市场竞争力。在本文中，我们将定义制造工艺，深入研究它们的类别和各种方法。现在让我们开始探索它们的广泛含义！

什么是制造工艺？

在讨论制造过程需要什么之前，让我们花点时间看一下制造的大局。制造是通过使用工具、机械和劳动力将原材料或部件转化为成品的过程。

制造业的历史起源于史前时代，当时人类首次使用简单的工具来切割、压碎和塑造材料。随着时间的推移，随着文明的进步，制造技术的复杂性和精密度也在不断提高。工业革命标志着一个重要的转折点，引入了蒸汽动力、机械化和大规模生产方法，彻底改变了商品的制造方式。如今，制造流程已经高度自动化，并与机器人技术、计算机数控 (CNC) 加工和 3D 等先进技术相集成印刷。

制造过程是指在更广泛的制造活动中生产特定产品的具体方法和操作顺序。它包括设计、材料选择、加工、质量控制和最终组装等多个阶段。每个阶段对于塑造成品的整体性能和生命周期都至关重要。

制造工艺的五类

根据生产方式和生产成品的类型，制造工艺可分为多种类型，每种类型都有其自身的特点和应用。一般来说，制造工艺有五类。

车间制造

车间制造是一种高度灵活的生产模式，专为小批量、多品种的要求而设计。它专注于独特的定制产品，这些产品通常需要专门的工具和设置时间。在客户订单的驱动下，加工车间可以迅速适应多样化的生产需求。然而，这种灵活性对预测工作流程模式提出了挑战，因为生产涉及多个、复杂的非线性操作。尽管存在这些复杂性，加工车间制造仍然是小批量或原型生产重型设备、机械或专用产品的行业的理想选择。

离散制造

离散制造涉及生产不同的、可计数的产品，这些产品通常由各种单独的零件或组件组装而成。这种类型的制造侧重于将这些单独的零件组装成成品。每件产品，例如汽车、计算机或电器，都是独一无二的，并且可以在整个生产过程中进行跟踪。离散制造涉及不同的操作，并且通常适应高度的定制。它通常用于汽车、电子和家具等行业。

重复制造

重复制造的特点是长期重复生产相同或非常相似的产品。这种方法强调快速、大批量、相同地生产标准化产品。专用生产线和自动化装配机简化了流程，减少了对体力劳动的需求。质量控制对于确保一致性和最大程度地减少缺陷至关重要，因为材料不断流过一系列自动化步骤。这种方法对于生产汽车零部件、电路板和处理器以及大规模生产统一食品和饮料（如瓶装饮料和罐头食品）非常有效。

批量生产

批处理制造是一种产品批量或批量生产而不是连续生产的生产方法。与离散制造和作业车间制造类似，批量流程制造根据客户订单或市场需求调整其生产计划。每个批次在开始下一个批次之前都会经历整个生产过程，从而允许批次之间的高度定制和灵活性。例如，在制药行业中，不同批次的药物是按照特定的配方和剂量生产的。每一批完成后，设备都会被清洁并为下一批做好准备，下一批可能是不同的药物或前一批的变体。

连续流程制造

与重复制造一样，这种流程制造也提高了生产效率和标准化。在连续制造中，原材料不断流入生产系统，成品从另一端排出。这种不间断的生产通常用于液体、气体或其他可流动物质，例如化学品、石油产品以及食品和饮料。相反，重复制造适合生产高度标准化的产品，其中生产周期或批次之间可能存在暂停。

有哪些不同的制造方法？

在每个类别中，都有各种方法和技术用于实现所需的结果。在下面的文章中，我们将讨论 7 种主要类型的制造方法及其子类型。

1. 减材制造

减材制造是一种多功能工艺，从固体块中去除材料以形成所需的形状。它适用于多种材料，包括金属、塑料、陶瓷和复合材料。现代减材制造工艺通过 CNC 技术实现自动化，确保高速、精确地加工复杂的细节和光滑的表面。车间制造和离散制造企业广泛使用减材工艺来生产定制零件和组件。

以下是常见的减材制造工艺：

• 车削: Using a lathe, the workpiece rotates while a cutting tool removes material to create cylindrical parts.
• 铣削: A rotating multi-point cutting tool moves across the workpiece to remove material, often to create complex shapes or contours.
• 钻孔：A rotating drill bit is used to make a hole of circular cross-section into the solid material.
• 无聊的： Using a boring tool, an existing hole is enlarged and refined to achieve a precise diameter and improved alignment.
• 铰孔：Typically performed after drilling or boring, a reamer with multiple cutting edges is used to slightly enlarge and smooth the existing hole, achieving a final precise diameter and high-quality surface finish.
• 研磨： An abrasive wheel removes small amounts of material to achieve high-precision surfaces and fine finishes.
• 激光切割：Using a high-powered laser beam to cut through materials. It is precise and can cut complex shapes with a fine surface finish.
• 放电加工 (EDM): A non-traditional machining process that uses electrical sparks to erode material from the workpiece, useful for hard or electrically conductive materials.
• 水射流切割： Using a high-pressure jet of water, sometimes mixed with abrasive particles, to cut through materials without generating heat.

2. 加盟

连接是将两块或多块材料永久或半永久连接以创建组件的过程。该技术广泛用于制造通常无法直接生产的复杂产品。通过生产多个更简单的部件然后将它们连接起来，可以降低复杂零件的生产成本。此外，连接过程允许更换有故障的部件，而无需丢弃整个产品。加入过程的一些示例是：

• 焊接： A process that fuses materials by applying heat, pressure, or both, together with the addition of a filler material to form a strong joint upon cooling.
• 钎焊：A joining method where a filler metal with a melting point higher than that of soldering but lower than the base materials is melted and flowed into the joint by capillary action.
• 焊接： Similar to brazing, but performed at lower temperatures. A filler metal (solder) is melted and drawn into the joint between closely fitted parts.
• 粘合剂粘合：A process where an adhesive material is applied between the surfaces to be joined, creating a bond upon curing.
• 机械装配： Connecting components using fasteners such as bolts, nuts, rivets, or screws.
• 过盈配合（压配合）：A method where parts are joined by forcefully pressing them together, creating a tight fit due to the interference between the parts.
• 其他的：Such as clinching and crimping, which are specialized joining techniques.

3. 成型

成型是一种制造过程，其中使用机械力改变材料（通常是金属）的形状，而无需添加或去除材料。该工艺基于材料的塑性变形，从而最大限度地减少材料浪费。成型过程中不同类型的制造工艺有：

• 锻造：A metalworking process where metal is shaped by applying compressive forces. The metal is typically heated to a high temperature to make it more malleable before being hammered, pressed, or rolled into the desired shape. Forging produces strong and durable parts due to the refinement of the grain structure and the elimination of internal voids.
• 冲压：Involving sandwiching a flat sheet of metal(either in coil or blank form) between a punch and a die, then applying force via a press to deform the metal into the die's cavity shape. Stamping can be performed in a single stroke or through a series of operations known as progressive stamping. It is widely used in various industries, particularly for high-volume production of components where precision and consistency are critical.
• 弯曲: Involving deforming a material, typically metal, along a straight axis to create an angular shape or a curve. The process does not remove material but rather changes its geometry by applying force, causing the material to plastically deform and hold the new shape. This can be done using tools and machines like press brakes, roll benders, or hand brakes. In press brakes, for example, the workpiece is clamped between two dies, and a ram applies pressure to the top die, bending the material to the desired angle.
• 滚动：A fundamental and cost-effective manufacturing process that involves passing metal stock through one or more pairs of rolls to reduce thickness, ensure uniformity, or impart desired mechanical properties. It can be conducted at room or elevated temperatures (cold rolling or hot rolling), depending on the material and desired properties of the final product. Rolling is commonly used to produce flat sheets, strips, plates, beams, and other structural components.
• 挤压： A versatile and efficient forming process where material is forced through a die to create objects with a fixed cross-sectional profile. The material, which can be metal, plastic, ceramic, or food, is typically heated and then pushed or drawn through the die, taking the shape of the die opening.

4. 铸造

铸造涉及将液态金属倒入模具型腔中以制造具有特定形状的固体物体。一旦金属冷却并凝固，模具就会被移除，露出铸件。铸造涉及多种工艺，其分类包括以下几种：

• 砂型铸造： Using sand as the mold material to produce castings. It produces castings in sand molds. This is a low-cost method with flexibility in material choices but has lower dimensional accuracy and a coarser surface finish compared to other casting methods, requiring significant finishing work.
• 熔模铸造（脱蜡铸造）：Using a wax pattern coated with ceramic to create precise and intricate parts. It is known for its excellent surface finish and high dimensional accuracy. However, it has size limitations on parts and is a high-cost process due to its labor-intensive nature.
• 离心铸造：Involving pouring molten metal into a rotating mold. The centrifugal force distributes the metal evenly around the mold cavity, resulting in high-quality, dense cylindrical parts with a fine grain structure.
• 压铸： Involving forcing molten metal under high pressure into a precision metal mold cavity, where it cools and solidifies into a casting. Known for fast production cycles, it excels in high-volume manufacturing of intricate parts. However, the initial mold cost is substantial, and it's primarily suited for low-melting-point metals like aluminum, zinc, magnesium, and copper.
• 永久模铸造（重力压铸）： Involving pouring molten metal into a reusable metal mold under gravity, which is then cooled naturally or by using a cooling medium. While it has a slower production speed, this casting method can accommodate a wider range of metals and alloys, including some high-melting-point materials.
• 连续铸造： A process where molten metal is continuously poured into a mold, solidified, and then extracted in an ongoing flow. It is highly efficient and is commonly used to produce long metal sections such as beams, rods, and slabs.
• 外壳成型： An advanced casting method using resin-coated sand to form a mold shell around a heated pattern, creating precise and complex parts. It is known for its good surface finish and high dimensional accuracy, suitable for gears, valves, and small to medium-sized castings in industries such as automotive, aerospace, and machinery manufacturing.

其他铸造方法还有真空压铸、低压铸造、消失模铸造等，也以其独特的优势应用于各个行业，以满足特定的生产要求。

5. 成型

成型与铸造工艺类似，但成型更常见于塑料，而铸造主要涉及金属。在成型过程中，将熔融材料倒入模具中固化成所需的形状。尽管制造模具成本高昂且耗时，但该工艺非常适合批量生产具有精确尺寸和良好表面光洁度的零件。模具的可重复使用性也降低了生产成本。常见的成型方法有：

• 注塑成型：A highly versatile process for producing plastic parts. It involves injecting molten plastic into a closed mold cavity under high pressure. Once the plastic cools and solidifies, the mold is opened, and the part is ejected. This method offers high production rates, excellent repeatability, and the ability to produce complex shapes with fine details, making it a cost-effective solution for many industries.
• 压缩成型： It involves placing a pre-measured amount of molding material into an open mold cavity. The mold is then closed, and pressure is applied to shape and cure the material. This method is suited for materials with low flow characteristics and is ideal for producing high-strength, high-density parts that are large, flat, or moderately curved.
• 吹塑成型：A process used to create hollow plastic parts by inflating a heated plastic tube (parison) until it fills the mold cavity. It is efficient for high-volume production of hollow plastic parts such as bottles, containers, and pipes, and is relatively low-cost.
• 滚塑成型：A process used to create hollow plastic products of various sizes and shapes. It involves filling a heated mold with plastic resin and slowly rotating it around two perpendicular axes. The resin melts and coats the interior of the mold, forming a hollow part. This method has low tooling costs and the ability to produce large, complex parts with smooth interior surfaces, thick walls, and minimal assembly requirements. It is particularly suitable for low-volume production runs and custom designs.
• 热成型（热风成型或真空成型）：A plastic forming process that utilizes heat and pressure to shape a plastic sheet into a desired three-dimensional form. This method offers low tooling costs, quick production cycles, and flexibility in design and material choices. It is commonly used for packaging, disposable cups, trays, lids, and other lightweight plastic products.

6.增材制造

增材制造 (AM)，通常称为 3D 打印，是一种基于数字模型，通过逐层添加材料来构建物体的过程。增材制造适用于可热成型的材料，包括金属和某些塑料，可实现高度定制、复杂的几何形状并减少材料浪费。常见的增材制造工艺类型如下：

• 选择性激光烧结 (SLS)： Using a laser to fuse powdered material into solid parts, ideal for producing functional prototypes and complex end-use parts. SLS is commonly used in aerospace and automotive industries, utilizing materials like nylon and other thermoplastics.
• 数字光处理 (DLP)：Using a digital light projector to cure resin layers in a single flash, speeding up the printing process while maintaining high detail and precision. DLP is ideal for applications requiring fine details and smooth surfaces, such as dental models, jewelry, and detailed miniatures.
• 选择性激光熔化 (SLM)： An advanced additive manufacturing process using a high-powered laser to fully melt and fuse metallic powder particles, creating dense and strong metal components. SLM is widely used in aerospace, automotive, and medical industries for high-performance parts made from materials like titanium, aluminum, and stainless steel.

7. 表面处理工艺

表面处理工艺涉及应用于材料表面以增强其性能的各种技术，例如外观、耐腐蚀性、耐磨性和附着力。这些处理可以是机械的、化学的或电化学的。常见的表面处理类型包括喷砂、抛光、粉末涂层、电镀和阳极氧化。

三种类型的制造策略

根据客户需求和生产流程，制造和供应链管理中常用的制造策略有以下三种：

按库存生产 (MTS)

在按库存生产 (MTS) 方法中，制造商根据过去的销售数据、市场趋势和预测来预测未来的需求来生产商品。在收到任何特定客户订单之前，产品将被制造、组装并储存在仓库中。

这种方法可以快速履行客户订单，因为产品已经可用并准备发货。它通过提供即时可用性来最大限度地缩短交货时间并提高客户满意度。然而，如果需求预测不准确，它也会带来库存过剩的风险。

按订单生产 (MTO)

按订单生产 (MTO) 策略仅在客户下订单后才启动生产流程。制造商维持灵活的生产系统，能够根据不同的订单进行调整，通常生产周期较短。

虽然 MTO 降低了库存成本和过时的风险，但由于每个订单的生产都从头开始，因此通常会导致交货时间延长。此方法非常适合需求量低或定制程度高的产品。

从制造到组装 (MTA)

按组装制造 (MTA) 也称为按订单组装 (ATO)，是一种结合了 MTS 和 MTO 元素的混合方法。在这种模式中，制造商预先生产和库存组件或子组件，这些组件或子组件可以在收到客户订单后快速组装成最终产品。

与完整的 MTO 相比，该策略允许在一定程度上进行定制，同时保持更短的交货时间。 MTA 减少了生产过程中大量定制的需求，使其更加高效且更具成本效益。它还确保只生产必要的组件，最大限度地减少浪费和库存积压。 MTA 特别适合具有标准和可定制功能的产品。

结论

关于制造工艺的类型，显然存在针对特定行业、产品和生产目标定制的多种方法。关于制造方法的讨论强调了可以帮助您实现产品效率、成本效益和质量的关键方面。在 Chiggo，我们为自己在 数控加工 和 钣金加工。此外，我们还提供 3D 打印和注塑服务，根据您的需求提供全面的解决方案。如果您有任何疑问，联系我们！