拉杆预紧结构的力学建模与八万吨压机横梁结构的优化
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摘要
重型模锻液压机是指吨位在100MN以上,对工件进行整体变形压制的液压机。重型模锻压机的设计、制造能力,及其拥有这类压机的数量和等级,是一个国家的国防工业、机械制造工业的综合生产能力及技术水平的重要标志,具有明确的战略意义。无论是发达国家还是发展中国家,都十分重视重型模锻压机的发展。本文综合运用理论分析、数值模拟、优化和实验测试等多种手段对我国自主研制的八万吨重型模锻压机上板梁、活动横梁、固定下梁等组合承载结构的建模方法、整体性和应力分布等关键性问题进行了系统的研究。
本文基于三维有限元弹性接触理论深入研究了拉杆组预紧组合承载结构的建模方法。探讨了仿真环境中拉杆预紧力的施加方法,并对比分析了不同拉杆预紧方法在预紧和承载两种工况下的效果。据此提出了不同工况下合适的拉杆预紧方法以及成组拉杆预紧力优化时的程序。
本文主要对活动横梁的整体性进行了有限元分析,指出活动横梁的整体性主要体现为两片中梁间的开缝问题。系统地研究了拉杆数目、中梁形状、楔键位置等结构参数,以及拉杆预紧力、外载等力能参数对活动横梁整体性的影响。并在上述研究的基础上提出了对八万吨模锻压机活动横梁设计的改进方法,并对动梁最终设计方案进行了分析。结果表明最终方案明显优于原方案:最大开缝由0.36mm降到0.079mm,减幅达78%。
本文考察了八万吨模锻压机横梁结构各部件的应力分布。系统地研究了固定下梁中梁项出孔内应力集中的成因,提出了修改应力集中因素形状法、表面削去法和增加工艺孔法等降低应力集中的方法。经详细分析提出了下梁中梁结构的优化设计方案。分析结果表明中梁新结构优于原结构:其顶出孔最大主应力由161.4MPa降到84.37MPa,应力集中系数由2.405降到1.33。
本文用电测法对预紧状态和承载状态下八万吨模锻压机的1:11.1模型压机关键横梁的应力、变形进行了测试。实验结果表明三横梁各部件的应力、位移与计算结果吻合较好。
Heavy die forging hydraulic press is the one whose tonnage exceeds 100MN and which is used to forge overall workpiece. The design and production capacity of heavy die forging press, and the number and level of this type of press possessing, is one of important symbols of comprehensive productivity and technical level of defense industry and machinery manufacturing industry of a country, having specific strategic significance. Whichever developed countries or developing countries in the world pay attention to the development of heavy die forging press. The dissertation, by means of theoretic analysis, numerical simulation, optimization and tests, studies systemically on many key issues such as modeling approach, integrity and stress distribution, etc. of the composite bearing structure, such as up beam, moving beam and fixed press bed of 800MN heavy die forging press developed by China.
The modeling approach of composite bearing structure preloaded with a group of tie-rods, based on the theory of 3-D FEM elastic contact, is studied. Some methods of prestressing tie-rod, in the simulated environment, are researched into, and the effects of different methods of prestressing tie-rod, under prestressing and loading, are contrastively analyzed. According to result, methods of prestressing tie-rod suitable to corresponding work-state and the program of optimizing preload of groups of tie-rod, are put forward.
The integrity of moving beam is analyzed with FEM, and a viewpoint that its integrity is mainly incarnated by the gaping between two centre beams. Also the effects of the structure parameters of the number of tie-rod, the shape of center beam, the position of taper key, as well as of the force-energy parameters such as pre-tight force of tie-rod, load, on the integrity of moving beam are studied systemically. Based on above studies, some ways of improvement for perfecting the designing of moving beam of the 800MN heavy die forging press are put forward, and then the final designing scheme of moving beam is investigated. As it turned out, the final scheme is markedly superior to original scheme: the maximum of gape falls from 0.36mm to 0.097mm, the drop is 24.9 percent.
Stress distribution of every part of three beams of the press is investigated in this dissertation. The cause of stress concentration in the poke-hole of center beam of fixed press bed is studied, and some methods, such as changing shape of region existing stress concentration, removing material and adding technological hole, to decrease the stress concentration factor, are proposed. Through detailed analysis, the optimized design proposal of centre beam structure of fixed press bed is put forward. Analysis shows that the new structure of centre beam gains ascendancy over the old one: the maximal principal stress of its ejection-hole falls from 161.4MPa to 84.37MPa and the stress concentration factor falls from 2.405 to 1.33.
During the research, a metal model in the proportion of 1:11.1for the 800MN heavy die forging press is used. Measurements and tests about stress and deformation of key beams of this machine under prestressing and loading are conducted. The results indicate that the stress and displacement of parts of three beams obtained from experiments well coincide with that from calculation.
本文基于三维有限元弹性接触理论深入研究了拉杆组预紧组合承载结构的建模方法。探讨了仿真环境中拉杆预紧力的施加方法,并对比分析了不同拉杆预紧方法在预紧和承载两种工况下的效果。据此提出了不同工况下合适的拉杆预紧方法以及成组拉杆预紧力优化时的程序。
本文主要对活动横梁的整体性进行了有限元分析,指出活动横梁的整体性主要体现为两片中梁间的开缝问题。系统地研究了拉杆数目、中梁形状、楔键位置等结构参数,以及拉杆预紧力、外载等力能参数对活动横梁整体性的影响。并在上述研究的基础上提出了对八万吨模锻压机活动横梁设计的改进方法,并对动梁最终设计方案进行了分析。结果表明最终方案明显优于原方案:最大开缝由0.36mm降到0.079mm,减幅达78%。
本文考察了八万吨模锻压机横梁结构各部件的应力分布。系统地研究了固定下梁中梁项出孔内应力集中的成因,提出了修改应力集中因素形状法、表面削去法和增加工艺孔法等降低应力集中的方法。经详细分析提出了下梁中梁结构的优化设计方案。分析结果表明中梁新结构优于原结构:其顶出孔最大主应力由161.4MPa降到84.37MPa,应力集中系数由2.405降到1.33。
本文用电测法对预紧状态和承载状态下八万吨模锻压机的1:11.1模型压机关键横梁的应力、变形进行了测试。实验结果表明三横梁各部件的应力、位移与计算结果吻合较好。
Heavy die forging hydraulic press is the one whose tonnage exceeds 100MN and which is used to forge overall workpiece. The design and production capacity of heavy die forging press, and the number and level of this type of press possessing, is one of important symbols of comprehensive productivity and technical level of defense industry and machinery manufacturing industry of a country, having specific strategic significance. Whichever developed countries or developing countries in the world pay attention to the development of heavy die forging press. The dissertation, by means of theoretic analysis, numerical simulation, optimization and tests, studies systemically on many key issues such as modeling approach, integrity and stress distribution, etc. of the composite bearing structure, such as up beam, moving beam and fixed press bed of 800MN heavy die forging press developed by China.
The modeling approach of composite bearing structure preloaded with a group of tie-rods, based on the theory of 3-D FEM elastic contact, is studied. Some methods of prestressing tie-rod, in the simulated environment, are researched into, and the effects of different methods of prestressing tie-rod, under prestressing and loading, are contrastively analyzed. According to result, methods of prestressing tie-rod suitable to corresponding work-state and the program of optimizing preload of groups of tie-rod, are put forward.
The integrity of moving beam is analyzed with FEM, and a viewpoint that its integrity is mainly incarnated by the gaping between two centre beams. Also the effects of the structure parameters of the number of tie-rod, the shape of center beam, the position of taper key, as well as of the force-energy parameters such as pre-tight force of tie-rod, load, on the integrity of moving beam are studied systemically. Based on above studies, some ways of improvement for perfecting the designing of moving beam of the 800MN heavy die forging press are put forward, and then the final designing scheme of moving beam is investigated. As it turned out, the final scheme is markedly superior to original scheme: the maximum of gape falls from 0.36mm to 0.097mm, the drop is 24.9 percent.
Stress distribution of every part of three beams of the press is investigated in this dissertation. The cause of stress concentration in the poke-hole of center beam of fixed press bed is studied, and some methods, such as changing shape of region existing stress concentration, removing material and adding technological hole, to decrease the stress concentration factor, are proposed. Through detailed analysis, the optimized design proposal of centre beam structure of fixed press bed is put forward. Analysis shows that the new structure of centre beam gains ascendancy over the old one: the maximal principal stress of its ejection-hole falls from 161.4MPa to 84.37MPa and the stress concentration factor falls from 2.405 to 1.33.
During the research, a metal model in the proportion of 1:11.1for the 800MN heavy die forging press is used. Measurements and tests about stress and deformation of key beams of this machine under prestressing and loading are conducted. The results indicate that the stress and displacement of parts of three beams obtained from experiments well coincide with that from calculation.
引文
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