重载操作机锻压随动过程动力学行为分析与优化
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摘要
大锻件制造业是国家重大技术装备产业的重要基础,关系到国家安全和经济命脉,是国家极端制造能力的集中体现。大锻件产品在电力,冶金,石化、船舶、航天、军工等基础产业中有着广泛的应用。大型锻造液压机是大锻件的制造加工设备,目前我国万吨以上锻造液压机共七台,数量为世界第一,且具备自主设计制造能力。重载锻压操作机是锻造压机重要的协调作业辅助装备,可以大大提高锻件精度、生产效率及材料利用率,降低能耗。但是目前我国还不具备大型操作机的自主设计能力,对于重载锻造操作机的基础理论研究对于提高我国重大技术装备制造水平具有十分重要的意义。
锻压作业过程中,液压机的锻打运动会在操作机的夹钳处产生极大的荷载(力与弯矩),导致操作机机械构件以及锻件自身的破坏。特别是在某些事故工况中,压机失控导致锻锤直接下落冲击锻件,巨大的冲击荷载可能导致夹钳瞬间过载断裂。本文主要研究锻打过程中“压机-锻件-操作机”整体系统的瞬态动力学特性以及力流传递规律,为操作机设计提供理论支持。主要包括以下几个方面的工作：
(1)夹持长棒料操作机缓冲行为分析
长棒料是塑性加工经常遇到的一种工件,在后期整形阶段,压机速度快,冲击振动明显,液压机作业在锻件的不同位置对系统动力学行为影响很大。根据合理假设,建立了操作机系统的单自由度动力学模型,通过与有限元软件LS-DYNA仿真结果比较,证明了模型的有效性。对于简单的线性回复力无阻尼的情况,可以将夹钳所受最大荷载(力与力矩)表达为锻压位置以及系统参数(操作机参数,压机参数,锻件参数)的显式函数,理论上揭示这些参数对操作机所受最大荷载的影响机理。通过对比研究平动式与倾动式操作机的缓冲特性,结果证明二者动力学行为在本质上是相同的。对比分析了两类双线性回复力下操作机的动力学行为,在对比分析的基础上,提出了优化的缓冲力设计方案,以减小操作机锻压随动过程中所受荷载。
(2)操作机大范围缓冲行为分析与多目标优化
锻件拔长初期,锻件短粗,虽然压机在此阶段运行速度相对较慢,但是锻件变形大,操作机缓冲运动的范围随之增大,从而引起缓冲缸自身的刚度非线性以及机构构型变化产生的几何非线性。首先建立操作机系统多体动力学模型,研究了上述两种非线性对操作机动力学行为的影响。推导了缓冲缸压力方程,通过与现场试验结果比对,证明该压力方程的有效性。
在一个锻压周期的不同工作阶段,操作机的设计要求也有所不同。变形期要求操作机受力最小,保证结构安全性；压机回程后,要求夹钳快速回归初始工作位置,以保证操作机的工作效率,两个目标需要同时兼顾。建立了操作机大范围缓冲行为的多目标优化模型,采用NSGA-Ⅱ算法对水平与竖向缓冲缸的相关参数进行优化设计,获得两个目标的Pareto最优解集,为操作机设计提供了更广阔的空间。
(3)落锤冲击工况下操作机动力学行为分析
实际生产中,因为液压系统故障等因素,可能导致压机上砧失控,在重力的作用下,上砧自由落体直接冲撞锻件表面,产生的巨大的高频冲击荷载,其峰值可能到达锻件自重的几十倍,导致夹钳的瞬间过载断裂。在LS-DYNA中建立操作机系统三维有限元模型,模拟落锤冲击引起的系统振动；基于该模型,研究了操作机自身参数、锻件参数以及压机参数这三类系统参数对于最大冲击力的影响。当冲击位置靠近夹钳,冲击力的峰值最大,系统基频对动态响应起主要作用,建立了近端冲击的操作机单自由度系统,对近端冲击的系统动力学行为给予理论解释。
The large forging is the important basis of national heavy machinery industry, which is important for the national safety and economic lifeline, also, it demonstrates the comprehensive national power. Large forging productions are widely used and needed in basic industries, such as electrics, petrochemical, shipbuilding, aeronautics and astronautics, military, et al. Large forging hydraulic press is the manufacturing machine of large forging workpieces. Until now, there are seven hydraulic presses in China whose capacities are more than10000ton, with the largest number all over the world, moreover, and the large forging hydraulic presses could be designed and manufactured independently. Heavy forging manipulator is the important auxiliary tool for the hydraulic press, which greatly improves the workpiece precision, working efficiency, material utilization, and the power consuming for production could be reduced. Unfortunately, the large forging manipulator could not be designed independently in China, so the research in this area is very important for domestic heavy equipment manufacturing industry.
The motion of hydraulic press during metal forging produces large interface load at the clamp of the forging manipulator, which may cause the damages in the mechanical components of the manipulator and the workpiece. Especially in some accident the forging die drops on the workpiece directly without any control, and the huge impact force could possibly damage the clamp because of over loading. This dissertation is focused on the transient response and force flow of the "press-workpiece-manipulator" system, which provides theoretical support for manipulator design. The following works are included:
(1) Dynamic compliance behavior of forging manipulator which clamps a slender bar workpiece
The slender bar workpiece is usually produced in forging industry. During the finishing phase of forging process, the hydraulic press moves fast, the impact vibration effect is significant, and the press position where the press works has a significant influence on the dynamic behavior of the manipulator.. The manipulator system is modeled as a vibration system with single degree of freedom (SDOF) according to some reasonable assumptions. Comparisons between the analytical results and the commercial FEM software LS-DYNA simulations are made to validate the proposed model. In the case of linear compliance without damping, the useful design formula could be derived which explicitly show the dependence of the dynamic load amplitudes on the press positition and system parameters, including the press paremeters, workpiece parameters and manipulator parameters. The compliance behaviors of the translational manipulator and rotational manipulator are compared, and the results show that the two kinds of manipulators are the same in dynamics essentially. The dynamic behaviors of manipulator with two kinds of bilinear compliance force are studied, then the compliance force is optimized to minimize the maximum force exerted to the clamp during the compliance motion.
(2) Dynamic analysis and multi-objective optimization of forging manipulator under large amplitude compliance motion
At the beginning phase of the forging process, the workpiece is podgy, the hydraulic press moves slowly, however, the deformation of the workpiece is large as well as the compliance motion of manipulator which causes the nonlinearities of resilient stiffness and mechanism geometry change. The multibody dynamic model is established, which is used to investigate the influence of the above two kinds of nonlinearities on the dynamic behavior of the manipulator. The actual pressure equation of resilient cylinder is derived, and is validated by the workshop experiment.
The performance requirements of the manipulator are different for different working periods of one forging stroke. During the compression period, the vertical force imposed on the clamp should be minimized to guarantee the safety of the structure; during the rebound period, the clamp needs to rebound to the initial working position as soon as possible to improve the working efficiency. Both criterions need to be satisfied simultaneously in the manipulator design. The multi-objective optimization formulation of the forging manipulator under the large amplitude compliance motion is established, in which the parameters of horizontal and vertical compliance cylinders, including the initial heights of the accumulator and the orifice areas, are optimized by NSGA-II method to obtain Pareto-optimal solutions.
(3) Dynamic behavior of forging manipulator under the impact of dropping die
In practical production, the upper die could possibly lose control due to the malfunction of the hydraulic system. As a result, it drops freely and finally hit the workpiece. producing the huge high frequency impact force instantaneously and exerted to the clamp, with the magnitude tens of times over the self weight of the workpiece, and the clamp could possibly be fractured due to overloading. The3D finite element model of the manipulator system is established in LS-DYNA to simulate the impact due to the dropping die. in which the influence of the system parameters are studied, including the manipulator parameters, workpiece parameters and press parameters.. The impact force is the largest when the impact occurs near the clamp, and the dynamic response of the system is dominated by the fundamental frequency, in such case, the manipulator system could be regarded as a SDOF system, by which the dynamic behavior of the system could be explained theoretically.
锻压作业过程中,液压机的锻打运动会在操作机的夹钳处产生极大的荷载(力与弯矩),导致操作机机械构件以及锻件自身的破坏。特别是在某些事故工况中,压机失控导致锻锤直接下落冲击锻件,巨大的冲击荷载可能导致夹钳瞬间过载断裂。本文主要研究锻打过程中“压机-锻件-操作机”整体系统的瞬态动力学特性以及力流传递规律,为操作机设计提供理论支持。主要包括以下几个方面的工作：
(1)夹持长棒料操作机缓冲行为分析
长棒料是塑性加工经常遇到的一种工件,在后期整形阶段,压机速度快,冲击振动明显,液压机作业在锻件的不同位置对系统动力学行为影响很大。根据合理假设,建立了操作机系统的单自由度动力学模型,通过与有限元软件LS-DYNA仿真结果比较,证明了模型的有效性。对于简单的线性回复力无阻尼的情况,可以将夹钳所受最大荷载(力与力矩)表达为锻压位置以及系统参数(操作机参数,压机参数,锻件参数)的显式函数,理论上揭示这些参数对操作机所受最大荷载的影响机理。通过对比研究平动式与倾动式操作机的缓冲特性,结果证明二者动力学行为在本质上是相同的。对比分析了两类双线性回复力下操作机的动力学行为,在对比分析的基础上,提出了优化的缓冲力设计方案,以减小操作机锻压随动过程中所受荷载。
(2)操作机大范围缓冲行为分析与多目标优化
锻件拔长初期,锻件短粗,虽然压机在此阶段运行速度相对较慢,但是锻件变形大,操作机缓冲运动的范围随之增大,从而引起缓冲缸自身的刚度非线性以及机构构型变化产生的几何非线性。首先建立操作机系统多体动力学模型,研究了上述两种非线性对操作机动力学行为的影响。推导了缓冲缸压力方程,通过与现场试验结果比对,证明该压力方程的有效性。
在一个锻压周期的不同工作阶段,操作机的设计要求也有所不同。变形期要求操作机受力最小,保证结构安全性；压机回程后,要求夹钳快速回归初始工作位置,以保证操作机的工作效率,两个目标需要同时兼顾。建立了操作机大范围缓冲行为的多目标优化模型,采用NSGA-Ⅱ算法对水平与竖向缓冲缸的相关参数进行优化设计,获得两个目标的Pareto最优解集,为操作机设计提供了更广阔的空间。
(3)落锤冲击工况下操作机动力学行为分析
实际生产中,因为液压系统故障等因素,可能导致压机上砧失控,在重力的作用下,上砧自由落体直接冲撞锻件表面,产生的巨大的高频冲击荷载,其峰值可能到达锻件自重的几十倍,导致夹钳的瞬间过载断裂。在LS-DYNA中建立操作机系统三维有限元模型,模拟落锤冲击引起的系统振动；基于该模型,研究了操作机自身参数、锻件参数以及压机参数这三类系统参数对于最大冲击力的影响。当冲击位置靠近夹钳,冲击力的峰值最大,系统基频对动态响应起主要作用,建立了近端冲击的操作机单自由度系统,对近端冲击的系统动力学行为给予理论解释。
The large forging is the important basis of national heavy machinery industry, which is important for the national safety and economic lifeline, also, it demonstrates the comprehensive national power. Large forging productions are widely used and needed in basic industries, such as electrics, petrochemical, shipbuilding, aeronautics and astronautics, military, et al. Large forging hydraulic press is the manufacturing machine of large forging workpieces. Until now, there are seven hydraulic presses in China whose capacities are more than10000ton, with the largest number all over the world, moreover, and the large forging hydraulic presses could be designed and manufactured independently. Heavy forging manipulator is the important auxiliary tool for the hydraulic press, which greatly improves the workpiece precision, working efficiency, material utilization, and the power consuming for production could be reduced. Unfortunately, the large forging manipulator could not be designed independently in China, so the research in this area is very important for domestic heavy equipment manufacturing industry.
The motion of hydraulic press during metal forging produces large interface load at the clamp of the forging manipulator, which may cause the damages in the mechanical components of the manipulator and the workpiece. Especially in some accident the forging die drops on the workpiece directly without any control, and the huge impact force could possibly damage the clamp because of over loading. This dissertation is focused on the transient response and force flow of the "press-workpiece-manipulator" system, which provides theoretical support for manipulator design. The following works are included:
(1) Dynamic compliance behavior of forging manipulator which clamps a slender bar workpiece
The slender bar workpiece is usually produced in forging industry. During the finishing phase of forging process, the hydraulic press moves fast, the impact vibration effect is significant, and the press position where the press works has a significant influence on the dynamic behavior of the manipulator.. The manipulator system is modeled as a vibration system with single degree of freedom (SDOF) according to some reasonable assumptions. Comparisons between the analytical results and the commercial FEM software LS-DYNA simulations are made to validate the proposed model. In the case of linear compliance without damping, the useful design formula could be derived which explicitly show the dependence of the dynamic load amplitudes on the press positition and system parameters, including the press paremeters, workpiece parameters and manipulator parameters. The compliance behaviors of the translational manipulator and rotational manipulator are compared, and the results show that the two kinds of manipulators are the same in dynamics essentially. The dynamic behaviors of manipulator with two kinds of bilinear compliance force are studied, then the compliance force is optimized to minimize the maximum force exerted to the clamp during the compliance motion.
(2) Dynamic analysis and multi-objective optimization of forging manipulator under large amplitude compliance motion
At the beginning phase of the forging process, the workpiece is podgy, the hydraulic press moves slowly, however, the deformation of the workpiece is large as well as the compliance motion of manipulator which causes the nonlinearities of resilient stiffness and mechanism geometry change. The multibody dynamic model is established, which is used to investigate the influence of the above two kinds of nonlinearities on the dynamic behavior of the manipulator. The actual pressure equation of resilient cylinder is derived, and is validated by the workshop experiment.
The performance requirements of the manipulator are different for different working periods of one forging stroke. During the compression period, the vertical force imposed on the clamp should be minimized to guarantee the safety of the structure; during the rebound period, the clamp needs to rebound to the initial working position as soon as possible to improve the working efficiency. Both criterions need to be satisfied simultaneously in the manipulator design. The multi-objective optimization formulation of the forging manipulator under the large amplitude compliance motion is established, in which the parameters of horizontal and vertical compliance cylinders, including the initial heights of the accumulator and the orifice areas, are optimized by NSGA-II method to obtain Pareto-optimal solutions.
(3) Dynamic behavior of forging manipulator under the impact of dropping die
In practical production, the upper die could possibly lose control due to the malfunction of the hydraulic system. As a result, it drops freely and finally hit the workpiece. producing the huge high frequency impact force instantaneously and exerted to the clamp, with the magnitude tens of times over the self weight of the workpiece, and the clamp could possibly be fractured due to overloading. The3D finite element model of the manipulator system is established in LS-DYNA to simulate the impact due to the dropping die. in which the influence of the system parameters are studied, including the manipulator parameters, workpiece parameters and press parameters.. The impact force is the largest when the impact occurs near the clamp, and the dynamic response of the system is dominated by the fundamental frequency, in such case, the manipulator system could be regarded as a SDOF system, by which the dynamic behavior of the system could be explained theoretically.
引文
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