基于Hyperworks的精冲压力机机身结构优化-论文

12000KN精冲压力机机身抗偏载性能分析摘要：针对12000KN精冲压力机复杂、瞬时、重载的受力条件和精冲模的高精度对设备刚度提出的高要求，设计精冲机机身结构，建立精冲机机身结构有限元分析模型。采用Hyperworks软件研究侧立板、主立板、下筋板厚度对机身受到偏心载荷时倾斜量的影响，得出机身倾斜量的主要影响因素为主立板厚度，为下一步精冲机机身的设计优化提供了理论依据。关键字：精冲机机身；抗偏载；正交试验Abstract:Forthe12000KNfineblankingmachine’scomplexity,instantaneous,heavystressconditionsandfine-blankingdie’shigh-precision,whichputforwardahighstiffnessrequirementoftheequipment,thestructureoffine-blankingpressframewasdesigned,anditsfiniteelementanalysismodelwasestablished.UsingHyperworkssoftwareresearch(researchwasdonebyhyperworkssoftwareabout)theframe’stiltamounteffectedbythethicknessofsidestandingplate,mainverticalboardandundertheribwhentheeccentricloadisimposed,andthemaininfluencingfactoristhethicknessofmainverticalboard.Itprovidesatheoreticalbasis(canlaythefoundation)forfineblankingpressframedesign(thedesignoffineblankingpressframe).Keywords：fineblankingpressframe;theeccentricloadresistance;orthogonaltest精冲压力机是应用精冲技术的基础，生产得到刚性好、承载能力大、抗偏载能力强、质量轻的精冲压力机至关重要。要保证精冲压力机能生产得到优质的精冲件，就要保证精冲压力机各部件的工作变形小、应力分布均匀、导向精度高。机身结构作为压力机中较为复杂的重要部件，也是人们首先开展结构分析的研究对象[1]。Fineblankingpressisthebasisfortheapplicationoffineblankingtechnology.It’scrucialtogetafineblankingwithgoodrigidity,largebearingcapacity,loaddeflectionresistanceabilityandlightweight.Togethighqualityfineblankingparts,itisnecessarytoensurethatallpartsofthefineblankingpresswithsmallworkdeformation,stressdistributionandhighguidingprecision.Asamorecomplexcriticalcomponent,thestructureoffine-blankingpressframeisalsotheresearchobjectpeoplefirsttocarryoutthestructuralanalysis(去掉)[1].本文以12000KN精冲压力机机身为设计对象,以机身受到偏心载荷时的倾斜量为试验指标，结合正交试验[2-3]研究了各板厚对机身倾斜量的影响规律和影响程度大小，为精冲压力机机身的设计优化提供理论依据。In（去掉）thispaper,（去掉）basedonthe12000KNfineblankingpressframe,using（去掉）theframe’stiltamountundertheeccentricloadas（was）thetestindex,thentheeffectdegreeandruleofthethicknessofsome（去掉）plateonthetiltamountwerestudiedcombinedwithorthogonalexperiment[2-3],Itprovidesatheoreticalbasisforfineblankingpressframedesign.（去掉，第一段有，不用重复，这一段直接接在上一段后面，不用另取一段）Ⅰ、机身结构有限元模型建立Ⅰ、MODELINGANDANALYSISOFTHEFINE-BLANKINGPRESSFRAME1．1结构模型与单元划分1．1Modelingandmeshgeneration12000KN精冲压力机机身由厚钢板焊接而成，闭式整体式。机身材料采用Q235-A,各向同性，弹性模量E=200Gpa，泊松比为υ=0.3，密度为ρ=7.86×103kg·m-3。采用volumetetra方式划分网格单元，单元大小为30mm，单元类型为solid95。机身结构模型见图l。12000KNfineblankingpressframeisweldedbythicksteelplatewithclosedcuboidframe.TheframeuseQ235-Aasthemainmaterialwithelasticity'smodulusof200GPa,poisson'sratioof0.3,anddensityof7850kg/m3.HerethemeshofmachineframewasgeneratedbyHypermeshusingvolumetetra,theelementsizeis30mm,theelementtypeissolid95.ThestructuralmodeloftheframeisshowninFig.1.图1机身三维模型及有限元模型Fig.13Dmodelandfiniteelementmodeloftheframe1．2边界条件与载荷分布1．2constraintsandloads由于考虑12000KN精冲压力机机身的抗偏载情况，按照所给测试简图如图2所示进行加载，其中所施加偏心载荷分别为P=1000、2000、3000、4000、5000、6000KN共六种情况。在受到偏载工作时，机身的上下工作台面均受到大小为P的载荷，载荷均呈矩形区域分布。上工作台面载荷方向垂直向上；下工作台面载荷方向垂直向下。机身通过地脚螺栓固定在地面上，而且机身底面没有竖直向下的位移，在这里将约束等效为机身底面所有节点在各个方向的位移均为零，施加位移约束及载荷后的模型如图3所示。下工作台面矩形区域共74个节点，每个节点上承受(P/74)KN；上工作台面矩形区域共150个节点，每个节点上承受(P/150)KN。Tostudy（considering）theeccentricloadresistanceof12000KNfineblankingpressframe,theeccentricloadwasappliedaccordingtothetestdiagramasshowninFig.2.Respectively,P=1000,2000,3000,4000,5000,6000KNtotalofsixcases.Wheneccentricloadisappliedtothefineblankingpress,theupanddownworkingtablewillbeartothePload.Thedistributionofdownworkingtableloadisarectangleregionalwiththeloaddirectionbeingverticallydownward.Therectangleareaincludes74nodes,so(P/74)KNisappliedtoeachnode.Thedistributionofupworkingtableloadisarectangleregionalwiththeloaddirectionbeingverticallyupward.Thereare150nodesinthesquarearea,so(P/150)KNisappliedtoeachnode.Astheframeisfixedonthegroundusingtheanchorbolt,nodisplacementoftheframebottomproducesintheverticaldirection.Therefore,theconstraintisequivalenttozerodisplacementineachdirectionofallnodesasshowninFig.3.图2测试简图图3机身边界条件Fig.2TestdiagramFig.3Modelafterapplyingconstraintsandloads1．3有限元模拟结果与分析1．3Simulationresults根据实验结果可知，当所施加载荷按比例增加时，机身的倾斜量按比例增加。此处列出P=1000KN时机身的静态分析结果。图4是精冲机机身应变云图,机身倾斜量由所给定点X向的位移之差反映。试验标准值如表1所示，试验结果如表2所示。Accordingtotheexperimentalresults,whentheappliedloadincreasedinproportion,theamountoftiltoftheframeincreasedinproportion，too（accordingly）.HerearethestaticanalysisresultsofthestaticanalysiswhentheP=1000KN.Figure4showsthestraindistributionofthe12000KNfineblankingpressframe,thetiltamountoftheframeisreflectedbythedisplacementdifferencebetweenthegivenpointinXdirection.TeststandardvaluesareshowninTable1.TestresultsareshowninTable2.图4机身应变云图Fig.4Thestraincontoursoftheframe表1机身倾斜量标准对照值Table1Thetiltofthestandardreferencevalue序号No.施加载荷Load（KN）右边百分表数值Dialindicatorvalueontheright（mm）右边百分表数值Dialindicatorvalueontheleft（mm）倾斜量Tilt（mm/600mm）110000.2800.2400.040220000.3780.2920.086330000.4760.3440.132440000.5750.3960.179550000.6740.4480.226660000.7720.5000.272表2机身倾斜量试验结果值Table2Thetiltofthetestresults序号No.施加载荷Load（KN）倾斜量Tilt（mm/600mm）110000.01304220000.02607330000.03907440000.05213550000.06522660000.078232正交试验2Orthogonaltest2.1确定因素、水平和指标2.1Determiningfactors,levelsandindices影响精冲压力机机身抗偏载性能的主要参数有:侧立板厚度A、主立板厚度B、下筋板厚度C。忽略其他因素的影响,本次正交试验是在各个因素经验取值的基础上进行的优化配置。试验的因素及水平见表3。Themainparametersaffectingtheeccentricloadresistanceofthefineblankingpressframeare:sidestandingplatethicknessA,mainverticalboardthicknessBandundertheribthicknessC.Ignoringotherfactors,thisexperimentistheoptimalallocationbasedonexperientialvaluesofvariousfactors.ThelevelofexperimentalfactorsareshowninTable3.表3正交试验的因素水平表Table3Factor-leveltableoforthogonaltest水平Levels因素FactorsABC侧立板厚度Sidestandingplatethickness(mm)主立板厚度Mainverticalboardthickness(mm)下筋板厚度Undertheribthickness(mm)1908050210090553110100604120110655130120702.2试验结果及分析2.2Testresultsandanalysis2.2.1试验结果2.2.1Testresults本试验是一个3因素5水平的正交试验,选用L25(53)型正交表，内容如表5。由正交设计的结构矩阵可得到25种设计变量的组合，每种组合又对应一种机身结构，对这25种结构进行静力分析。分析方法与前面所述相同，应用Hyperworks有限元软件对其进行静力分析。根据初次静态分析结果，当所施加载荷按比例增加时，机身的倾斜量按比例增加，本次正交试验只考虑所受载荷P=1000KN的情况。表4中列出了每次试验的设计变量取值及试验结果。Thisisaorthogonaltestwith3factorsin5levels,usingL25(53)orthogonaltable,contentsasshowninTable5.Byorthogonaldesignstructurematrixobtained25kindsofcombinationsofdesignvariables,eachofwhichcorrespondstoaframestructure,andusingHyperworkstocarryonstaticanalysis（staticanalysiswasmadebyHyperworks）.Accordingtotheinitialresultsofstaticanalysis,thistestonlyconsiderthecaseofloadP=1000KN.ThevaluesofdesignvariablesandtheresultsofeachtestarelistedinTable4.表4正交试验方案及结果Table4Schemeandresultsoforthogonaltest试验号No.ABC实验结果Results123δ(mm/600mm)11110.0162921220.0151931330.0142541440.0132051550.0126162120.0161472230.0150882340.0141792450.01314102510.01265113130.01596123240.01506133350.01406143410.01317153520.01248164140.01531174250.01479184310.01409194420.01307204530.01250215150.01567225210.01487235320.01396245430.01301255540.01246表5正交试验计算结果极差分析Table5Tableofrangeanalysis极差Rangeδ(mm/600mm)ABCⅠ0.014310.015870.01421Ⅱ0.014240.015000.01417Ⅲ0.014150.014110.01416Ⅳ0.013950.013120.01404Ⅴ0.013990.012540.01405R0.000360.003330.00017图5各因素对δ的影响规律Fig.5Lawsofdifferentvariableseffectonδ2.2.2极差分析2.2.2rangeanalysis从表5中的试验数据极差分析结果可见：B>A>C。这说明：机身的主立板厚度水平对机身倾斜量的影响最大，其次是侧立板厚度水平，而下筋板厚度水平对试验结果的影响最小，即因素的主次顺序为：主立板厚度B>侧立板厚度A>下筋板厚度C。因此为了减小机身倾斜量，可以通过增加主立板厚度来实现，通过极差分析为下一步试验提供了方向。TheresultsofrangeanalysisinTable5shows:（，英语中很少用冒号）B>A>C.Thisshowsthat::（，英语中很少用冒号）themainverticalboardthicknessisthegreatestimpactonthetiltamountoftheframe,followedbysidestandingplatethicknessandminimalisundertheribthickness.Theorderoffactorsis:mainverticalboardthicknessB（字母去掉）>sidestandingplatethicknessA>undertheribthicknessC.Soinordertoreducetheamountoftilt,wecanincreasethemainverticalboardthickness.Itprovidesdirectionforthenexttestbyrangeanalysis.3结论3CONCLUSION本文对12000KN精冲压力机机身进行了有限元分析,结合正交试验方法,研究了各板厚对机身受到偏心载荷时的倾斜量的影响规律，结论如下：Inthispaper,staticanalysisofthe12000KNfineblankingpressframewasdoneusingfiniteelement.Lawsofdifferentplatethicknesseffectontheframe’stiltamountarestudiedcombinedwithorthogonaltest,themainconclusionsareasfollows:（1）通过静力学分析，得出机身受到偏心载荷时的倾斜量均在给定范围内，机身的抗偏载性能满足要求。(1)Theframe’stiltamountisobtainedthroughthestaticanalysis,whichisfarlessthantheallowablevalueinTable1,theeccentricloadresistanceoftheframecanmeettherequirementsfully.（2）通过正交试验，得到了侧立板厚度、主立板厚度和下筋板厚度对机身倾斜量的影响规律，同时得出影响因素的主次顺序为：主立板厚度>侧立板厚度>下筋板厚度。(2)Lawsofdifferentplatethickness