整体顶梁组合滑移液压支架有限元分析
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摘要
本文在综述国内外液压支架研究现状和发展趋势的基础上，针对国内外将研究重心放在重型、高强、智能方面而忽略了量大面广的轻型液压支架的研究这一问题，提出了研究滑移液压支架的必要性。针对滑移液压支架易出现的头重脚轻，挤架、倒架问题，提出了研究整体顶梁组合滑移液压支架的必要性。
本文所采用的支架研发流程如下：图纸设计→理论强度校核→建立虚拟样机→有限元分析→设计修改→再次有限元分析→物理样机试验，相较于传统的研发流程：图纸设计→理论强度校核→物理样机试验→设计修改→再次物理样机试验，这种研发流程提高了支架一次性设计成功率，提高了产品质量，缩短了设计周期，节约了设计成本。
以ZH1600/16/24Z(A)型整体顶梁组合滑移液压支架为例，在图纸设计、理论强度校核的基础上，重点利用有限元技术对支架顶梁和立柱强度进行分析。
利用材料力学的方法对顶梁和立柱进行理论强度校核，在校核符合设计要求的基础上，利用有限元技术对支架在不同工况下的强度进行分析。利用CATIA软件建立ZH1600/16/24Z(A)型整体顶梁组合滑移液压支架的虚拟样机模型，并对其进行干涉检查；利用HyperMesh软件对三维模型进行几何清理并划分网格；在ABAQUS中定义材料属性、边界条件并施加载荷，得到不同工况下顶梁的应力云图和位移云图，得到顶梁易受破坏的部位，为支架的设计和分析提供理论参考。对立柱进行有限元强度分析及虚拟强度型式试验，结合理论强度校核结果得知立柱设计过于保守，提出相应改进方案，并对改进后的立柱再次进行有限元分析和虚拟强度型式试验,试验结果表明改进后的设计方案可行。
虚拟样机技术和有限元技术应用于液压支架的研究是一项复杂的、长期的工作，本文在这方面的研究也仅仅是初级的探索性的研究。
The paper is based on the research current situation and development trend of hydraulicsupport ,aiming at the problems that the research focus is heavy,high-strength and intelligenthydraulic support at home and abroad,but ignoreing the light support which has a largecapacity and a wide range ,we put forward the necessity of researching slid ing hydraulicsupport.Aiming at slid ing hydraulic support's top-heavy and easy to crowd and fall ,we putforward the necessity of researching the whole top beam combination slid ing hydraulicsupport.
The research process as following: drawing design→theoretica l strengthchecking→build ing virtual prototyping→finite element analysis→modifying thedesign→finite element analysis again→physica l prototype test.The research process canimprove the success rate of one-time design, improve products quality, shorten the designcycle and save the design cost.
Taking type ZH1600/16/24Z(A) the whole top beam combination slid ing hydraulicsupport designed by PuBai SanTong coMPany in ShanXi province for example.On the basisof drawing design and theoretica l strength checking, to put emphasis on analyzing the strengthof top beam and column making use of finite element technology.
Making use of mechanics of materia ls' knowledge to check the strength of top beam andcolumn,a nd then to analyze the strength of top beam in different conditions using finiteelement technology .Establishing the virtual prototype of type ZH1600/16/24Z(A) the wholetop beam combination slid ing hydraulic support using software CATIA and then to check theinterference of hydraulic support. The software HyperMesh applys to clea n-up the geometricmodel and to divide the finite element mesh.Defining materia l properties,boundary conditionand applying load in software ABAQUS, and then obtain stress cloud map and offset cloud map about top beam in different conditions, from which to find out the positions that aredama ged mostly.Accord ing to these data to provide some references for designer. To analyzethe strength of column and carry out virtual type-tests using finite eleme nt technology,combining the result of theoretica l strength checking to know that the design of column ismuch conservative.To improve the design of column, and then to analyze the strength ofcolumn and carry out virtual type-tests using finite element technology again. The resultindica tes that the improved design program is feasible theoretica lly.
Virtual prototyping and finite element technology applying to hydraulic support is acomplex, long-term work, the research in the paper is only the initia l and exploratory study.
本文所采用的支架研发流程如下：图纸设计→理论强度校核→建立虚拟样机→有限元分析→设计修改→再次有限元分析→物理样机试验，相较于传统的研发流程：图纸设计→理论强度校核→物理样机试验→设计修改→再次物理样机试验，这种研发流程提高了支架一次性设计成功率，提高了产品质量，缩短了设计周期，节约了设计成本。
以ZH1600/16/24Z(A)型整体顶梁组合滑移液压支架为例，在图纸设计、理论强度校核的基础上，重点利用有限元技术对支架顶梁和立柱强度进行分析。
利用材料力学的方法对顶梁和立柱进行理论强度校核，在校核符合设计要求的基础上，利用有限元技术对支架在不同工况下的强度进行分析。利用CATIA软件建立ZH1600/16/24Z(A)型整体顶梁组合滑移液压支架的虚拟样机模型，并对其进行干涉检查；利用HyperMesh软件对三维模型进行几何清理并划分网格；在ABAQUS中定义材料属性、边界条件并施加载荷，得到不同工况下顶梁的应力云图和位移云图，得到顶梁易受破坏的部位，为支架的设计和分析提供理论参考。对立柱进行有限元强度分析及虚拟强度型式试验，结合理论强度校核结果得知立柱设计过于保守，提出相应改进方案，并对改进后的立柱再次进行有限元分析和虚拟强度型式试验,试验结果表明改进后的设计方案可行。
虚拟样机技术和有限元技术应用于液压支架的研究是一项复杂的、长期的工作，本文在这方面的研究也仅仅是初级的探索性的研究。
The paper is based on the research current situation and development trend of hydraulicsupport ,aiming at the problems that the research focus is heavy,high-strength and intelligenthydraulic support at home and abroad,but ignoreing the light support which has a largecapacity and a wide range ,we put forward the necessity of researching slid ing hydraulicsupport.Aiming at slid ing hydraulic support's top-heavy and easy to crowd and fall ,we putforward the necessity of researching the whole top beam combination slid ing hydraulicsupport.
The research process as following: drawing design→theoretica l strengthchecking→build ing virtual prototyping→finite element analysis→modifying thedesign→finite element analysis again→physica l prototype test.The research process canimprove the success rate of one-time design, improve products quality, shorten the designcycle and save the design cost.
Taking type ZH1600/16/24Z(A) the whole top beam combination slid ing hydraulicsupport designed by PuBai SanTong coMPany in ShanXi province for example.On the basisof drawing design and theoretica l strength checking, to put emphasis on analyzing the strengthof top beam and column making use of finite element technology.
Making use of mechanics of materia ls' knowledge to check the strength of top beam andcolumn,a nd then to analyze the strength of top beam in different conditions using finiteelement technology .Establishing the virtual prototype of type ZH1600/16/24Z(A) the wholetop beam combination slid ing hydraulic support using software CATIA and then to check theinterference of hydraulic support. The software HyperMesh applys to clea n-up the geometricmodel and to divide the finite element mesh.Defining materia l properties,boundary conditionand applying load in software ABAQUS, and then obtain stress cloud map and offset cloud map about top beam in different conditions, from which to find out the positions that aredama ged mostly.Accord ing to these data to provide some references for designer. To analyzethe strength of column and carry out virtual type-tests using finite eleme nt technology,combining the result of theoretica l strength checking to know that the design of column ismuch conservative.To improve the design of column, and then to analyze the strength ofcolumn and carry out virtual type-tests using finite element technology again. The resultindica tes that the improved design program is feasible theoretica lly.
Virtual prototyping and finite element technology applying to hydraulic support is acomplex, long-term work, the research in the paper is only the initia l and exploratory study.
引文
[1]罗恩波.国内外液压支架现状及我国的发展趋势[J].煤矿机电,2000.03: 27~29
[2]袁晓光.液压支架技术技术现状及发展趋势[J].2006.07:9~10
[3]鲁忠良,景国勋等.液压支架设计使用安全辨析[M].煤炭工业出版社,2006
[4]刘小峰,姚鸿等.浅谈液压支架的技术现状及发展趋势[J].河北煤炭,2003.03:9~10
[5]王恩鹏.我国综采液压支架现状及发展趋势[J].中国科协2004年学术年会第16场分会论文集,2004
[6]邢福康等.煤炭支护手册[M].北京:煤炭工业出版社,1993
[7]徐亚军.高强度结构钢焊接性与液压支架结构强度的研究[学位论文].北京:.煤炭科学总院,2003
[8]赵协广等.液压支架有限元分析[J].微计算机信息,2007.04
[9]盛选禹.CATIA V5R10机械设计范例教程[M].北京:北京大学出版社,2003.10
[10]李学志,李若松. CATIA实用教程[M].北京:清华大学出版社,2004.02
[11] Gerhard Pahl,Wolga ng Beitz，翻译:冯培恩.工程设计学[M].机械工业出版社,1988
[12]美国MSC公司.MSC.Patran User’s Manual: MSC.Patran 2004用户手册[K].美国MSC公司,2004.
[13]宁贵欣. CATIA V5工业造型设计实例教程[M].北京:清华大学出版社,2004.04
[14]艾德生，刘新河.滑移顶梁液压支架特性及其使用效果分析.河北煤炭.1996
[15]杨振复,罗恩波等.放顶煤开采技术与放顶煤液压支架[M].北京:煤炭工业出版社[M],1994
[16]张胜兰,郑冬黎等.基于HyperWorks的结构优化设计技术[M].机械工业出版社,2007.10 :7~8
[17]杨剑,张璞等.新编MD.Nastra n有限元实例教程[M].北京:机械工业出版社,2008.01
[18]庄茁,张帆等.ABAQUS非线性有限元分析与实例[M].北京:科学出版社,2005
[19]马铁林,刘海桥.CATIA机械设计基础培训教程[M].北京:人们邮电出版社,2004
[20]石亦平,周玉蓉.ABAQUS有限元分析实例详解实例分析[M].北京:机械工业出版社,2006
[21]熊珍兵,罗会信.基于HyperMesh的有限元前处理技术[J].排灌机械,2006.06:36~37
[22]荣军,吴新跃等.有限元建模中的几何清理问题[J].机械设计与制造,2009.09:145~147
[23] J.Tang，V.ogarevic，C.S.Tsai.An integrated CAE environment for simulation-baseddurability and reliability design.Ad vances inEngineering Software. 32(2001)，1~14
[24]周传月,于开平. Hypermesh从入门到精通[M].北京:北京科学出版社,2005.05
[25]何文斌,李菊丽,李立伟.ANSYS在液压支架优化设计中的应用[J].机械设计与制造.2007.06,170~172
[26]魏磊磊,陆萍等.液压支架销轴联接的约束处理[J].矿山机械,2006.06:3~4
[27]成大先.机械设计手册第一卷[K].北京:?化学工业出版社,1993.01
[28]机械工程材料性能数据手册[M].北京:机械工业出版社,1994.
[29]袁海庆.材料力学[M].武汉:武汉理工大学,2004
[30]庄茁,由小川等.基于ABAQUS的有限元分析和应用[M].北京:清华大学出版社,2009.01:220~222
[31]陈雷平.液压支架的整机有限元分析[学位论文].陕西:西安理工大学,2007
[32]中华人民共和国煤炭行业标准. MT458-1995《滑移顶梁液压支架通用技术条件》.北京:中国标准出版社,1996
[33]中华人们共和国煤炭行业标准.MT313-92《液压支架立柱技术条件》.北京:中国标准出版社,1993
[34]郑建荣.ADAMS——虚拟样机技术入门与提高[M].北京:机械工业出版社,2001.11
[35] Miyoshi，G.Yagawa，S.Sasaki.An interface agent that actively supports CAE beginnerusers in Performing analyses. Advances in Engineering Software.30(1999)，575~579
[36]马端志,宋德军.液压支架整机非线性有限元分析[J].同煤科技,2006.12
[37]姜京伟,程阔.有限元网格划分剖析[J].山西交通科技,2007.10,71~73
[38] C.González-Nicieza,A.Menéndez-Díaz. Analysis of support by hydraulic props in alongwall working.Internationa l Journal of Coal Geology, Volume 74, Issue 1, 3 March2008
[39] w.J.Zha ng，K.vanderWerff.Automa tic communieation from a neutral object model ofmeeha nism to meeha nism analysis Programs based on a finite element approach in asoftware environment for CAD/CAM of mecha nisms,Finite Element sin Analysis andDesign28,19 98
[40]刘展.ABAQUS6.6基础教程与实例详解[M].北京:中国水利水电出版社,2008
[41]李军,邢俊文等.ADAMS实例教程[M].北京:北京理工大学出版社,2002
[42]李金国,王慧等.基于HyperMesh的有限元前置优化设计[J].制造业信息化,2005
[43] Shao Guojia n,SU Jingbo;Interval Finite Element and Its Application on Anti-slideStability Analysis;Applied Mathema tics and Mecha nics,2007
[44]王进军,贾新玲等.放顶煤液压支架的整架强度有限元分析[J].煤矿机械,2005.03
[45] Shi Yuanwe. Research on the Interaction Between Roof Strata and Shield Supports.16Conference On Ground Control in Mining,1997
[46]唐玫.液压支架顶梁柱窝有限元分析[J].上海电机学院学报,2007.03
[47] J.Tang,V.ogarevic,C.S.Tsai.An integrated CAE environment for simulation-baseddurability and reliability design.Ad vances inEngineering Software. 32(2001), 1~14
[48]朱冬梅，李炳文.新型单体液压支柱活柱体结构及受力分析[J].河北煤炭，2003.02
[2]袁晓光.液压支架技术技术现状及发展趋势[J].2006.07:9~10
[3]鲁忠良,景国勋等.液压支架设计使用安全辨析[M].煤炭工业出版社,2006
[4]刘小峰,姚鸿等.浅谈液压支架的技术现状及发展趋势[J].河北煤炭,2003.03:9~10
[5]王恩鹏.我国综采液压支架现状及发展趋势[J].中国科协2004年学术年会第16场分会论文集,2004
[6]邢福康等.煤炭支护手册[M].北京:煤炭工业出版社,1993
[7]徐亚军.高强度结构钢焊接性与液压支架结构强度的研究[学位论文].北京:.煤炭科学总院,2003
[8]赵协广等.液压支架有限元分析[J].微计算机信息,2007.04
[9]盛选禹.CATIA V5R10机械设计范例教程[M].北京:北京大学出版社,2003.10
[10]李学志,李若松. CATIA实用教程[M].北京:清华大学出版社,2004.02
[11] Gerhard Pahl,Wolga ng Beitz，翻译:冯培恩.工程设计学[M].机械工业出版社,1988
[12]美国MSC公司.MSC.Patran User’s Manual: MSC.Patran 2004用户手册[K].美国MSC公司,2004.
[13]宁贵欣. CATIA V5工业造型设计实例教程[M].北京:清华大学出版社,2004.04
[14]艾德生，刘新河.滑移顶梁液压支架特性及其使用效果分析.河北煤炭.1996
[15]杨振复,罗恩波等.放顶煤开采技术与放顶煤液压支架[M].北京:煤炭工业出版社[M],1994
[16]张胜兰,郑冬黎等.基于HyperWorks的结构优化设计技术[M].机械工业出版社,2007.10 :7~8
[17]杨剑,张璞等.新编MD.Nastra n有限元实例教程[M].北京:机械工业出版社,2008.01
[18]庄茁,张帆等.ABAQUS非线性有限元分析与实例[M].北京:科学出版社,2005
[19]马铁林,刘海桥.CATIA机械设计基础培训教程[M].北京:人们邮电出版社,2004
[20]石亦平,周玉蓉.ABAQUS有限元分析实例详解实例分析[M].北京:机械工业出版社,2006
[21]熊珍兵,罗会信.基于HyperMesh的有限元前处理技术[J].排灌机械,2006.06:36~37
[22]荣军,吴新跃等.有限元建模中的几何清理问题[J].机械设计与制造,2009.09:145~147
[23] J.Tang，V.ogarevic，C.S.Tsai.An integrated CAE environment for simulation-baseddurability and reliability design.Ad vances inEngineering Software. 32(2001)，1~14
[24]周传月,于开平. Hypermesh从入门到精通[M].北京:北京科学出版社,2005.05
[25]何文斌,李菊丽,李立伟.ANSYS在液压支架优化设计中的应用[J].机械设计与制造.2007.06,170~172
[26]魏磊磊,陆萍等.液压支架销轴联接的约束处理[J].矿山机械,2006.06:3~4
[27]成大先.机械设计手册第一卷[K].北京:?化学工业出版社,1993.01
[28]机械工程材料性能数据手册[M].北京:机械工业出版社,1994.
[29]袁海庆.材料力学[M].武汉:武汉理工大学,2004
[30]庄茁,由小川等.基于ABAQUS的有限元分析和应用[M].北京:清华大学出版社,2009.01:220~222
[31]陈雷平.液压支架的整机有限元分析[学位论文].陕西:西安理工大学,2007
[32]中华人民共和国煤炭行业标准. MT458-1995《滑移顶梁液压支架通用技术条件》.北京:中国标准出版社,1996
[33]中华人们共和国煤炭行业标准.MT313-92《液压支架立柱技术条件》.北京:中国标准出版社,1993
[34]郑建荣.ADAMS——虚拟样机技术入门与提高[M].北京:机械工业出版社,2001.11
[35] Miyoshi，G.Yagawa，S.Sasaki.An interface agent that actively supports CAE beginnerusers in Performing analyses. Advances in Engineering Software.30(1999)，575~579
[36]马端志,宋德军.液压支架整机非线性有限元分析[J].同煤科技,2006.12
[37]姜京伟,程阔.有限元网格划分剖析[J].山西交通科技,2007.10,71~73
[38] C.González-Nicieza,A.Menéndez-Díaz. Analysis of support by hydraulic props in alongwall working.Internationa l Journal of Coal Geology, Volume 74, Issue 1, 3 March2008
[39] w.J.Zha ng，K.vanderWerff.Automa tic communieation from a neutral object model ofmeeha nism to meeha nism analysis Programs based on a finite element approach in asoftware environment for CAD/CAM of mecha nisms,Finite Element sin Analysis andDesign28,19 98
[40]刘展.ABAQUS6.6基础教程与实例详解[M].北京:中国水利水电出版社,2008
[41]李军,邢俊文等.ADAMS实例教程[M].北京:北京理工大学出版社,2002
[42]李金国,王慧等.基于HyperMesh的有限元前置优化设计[J].制造业信息化,2005
[43] Shao Guojia n,SU Jingbo;Interval Finite Element and Its Application on Anti-slideStability Analysis;Applied Mathema tics and Mecha nics,2007
[44]王进军,贾新玲等.放顶煤液压支架的整架强度有限元分析[J].煤矿机械,2005.03
[45] Shi Yuanwe. Research on the Interaction Between Roof Strata and Shield Supports.16Conference On Ground Control in Mining,1997
[46]唐玫.液压支架顶梁柱窝有限元分析[J].上海电机学院学报,2007.03
[47] J.Tang,V.ogarevic,C.S.Tsai.An integrated CAE environment for simulation-baseddurability and reliability design.Ad vances inEngineering Software. 32(2001), 1~14
[48]朱冬梅，李炳文.新型单体液压支柱活柱体结构及受力分析[J].河北煤炭，2003.02