冲裁工艺噪声发射及其控制的理论与实验研究
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摘要
冲压加工是现代制造业中应用最为广泛的生产技术之一。对于冲压生产技术存在的美中不足—噪声、振动及不安全问题,正在愈来愈多地引起世人的关注。显然,研究冲压加工中的噪声问题,在社会效益、技术经济和学术理论上都具有十分重要的意义。
各种冲压工艺所产生的噪声中,以冲裁工艺噪声为最严重,也最具典型性。因此,本文选择普通冲裁中产生的工艺噪声作为具体研究对象,采取理论分析与实验验证相结合的手段,进行了较为深入、系统的研究,探讨了其噪声发射的理论规律与特点,提出了从积极主动角度降低其噪声峰值的对策。主要研究工作包括;
冲裁工艺噪声测试系统的搭建、噪声测试实验与分析、噪声发射机理的研究;冲裁突然分离阶段冲头自由振动微分方程的建立、突然分离阶段冲裁工艺噪声声压级与冲裁力的数学关系、冲裁工艺噪声发射峰值预报模型的建立与实验验证;板料冲裁加工有限元模拟及变形过程分析、两步法冲裁降噪效果的理论分析、级进模两步法冲裁模设计、级进模两步法冲裁降噪工艺实验研究;反顶力作用下冲裁模具设计与强度校核问题、反顶力作用下冲裁降噪工艺实验研究。并取得了以下主要研究成果;
(1)采用较先进的测试方法,获得了与典型的冲裁力曲线相协调的冲裁噪声发射声压波形图;采用包络线法对冲裁工艺噪声发射声压波形图的整体外轮廓进行描述,得到了冲裁工艺噪声发射树的物理模型,定量地验证了冲裁变形到突然分离阶段噪声最大的结论;较全面地描述了整个冲裁加工过程中噪声发射情况;
(2)系统地推导出冲裁突然分离阶段噪声声压级与冲裁力的数学关系式,即冲裁工艺噪声发射峰值的数学计算模型。该模型表明,冲裁力愈大,则冲裁噪声声压级分贝值愈大;
(3)首次提出了分别用板料的强度极限和用板料的硬度HV值预报冲裁工艺噪声发射峰值的数学模型;并推荐采用板料维氏硬度HV值预报突然分离阶段冲裁工艺噪声发射声压级的数学模型;
(4)通过钢板、黄铜板和铝板这3种金属板料的冲裁变形模拟结果,较为准确地找到了板料突然分离的位置;理论上得出一个重要结论;在冲裁加工中,当冲头切入金属板料深度达到板料厚度的(50%～60%)时,金属板料的变形到达突然分离阶段;
(5)针对提出的一种级进模两步法冲裁新工艺的目的之一—可降低冲裁工艺噪声,通过对板料冲裁变形进行有限元模拟及结果分析,从理论上指导该工艺的实际应用,并作了实验验证,还介绍了4种两步法冲裁级进模的结构形式;
(6)提出了一种带有反顶力作用的冲裁工艺,即在普通冲裁凹模内设置聚氨酯弹性垫块进行冲裁。该工艺与普通冲裁工艺的操作完全相同,可行性好,并可保持原有的生产效率。且通过实验测试验证,也可谓之是又一种新的冲裁降噪工艺。
Pressworking is one of the production technology used widely in modern manufacturing. However, there exist noise, vibration and insecurity problems in pressworking technology, which are more and more attentioned in the world, and pressworking noise has become an acknowledged environmental pollution. Obviously, it is highly significant whether in social benefit or in technical economic value or in academic theory to research pressworking noise.
Blanking process noise is the most serious and the most typical among noise caused in various pressworking processes. Therefore, in this dissertation, process noise caused in the general blanking is selected to be researched, then some systemic and detailed research work have finished with theoretical analysis and experimental methods, where theoretical disciplinarian and characteristic of its noise emission are probed and dicussed, and finally some countermeasures are introduced to reduce its maximum noise actively. The research work includes these aspects:
Establishment of the blanking process noise testing system, analysis of the general blanking noise testing results, and the research of blanking process noise emission mechanism; Deduction of a punch's unrestricted vibration differential equation and a mathematic expression on blanking process noise sound pressure level and blanking force on the break-through stage of blanking deformation, the construction of prediction model on maximum blanking process nose emission; The FEM analysis of sheet metal blanking processing and blanking deformation stage, the theoretic analysis of noise reduction effect in two steps blanking process, the design of progressive dies for two steps blanking process, and the experimental study on noise produced in two steps blanking process with progressive dies compared with that produced in general blanking process; The design and intensity verification of blanking dies while adding counterforce on punch's head, the experimental study on noise produced in the blanking process with adding counterforce on punch's head. The main research results are as follows:
(1) Using an advanced testing method, some typical blanking force curves and noise emission sound pressure wave graphs are obtained; Through the whole profile description for the blanking process noise emission sound pressure wave graph with contour lines, a physical model—blanking process noise emission tree is constructed, which quantificationally proves the conclusion that noise produced on the break-through stage is the maximum among that produced in the whole blanking deformation, and which can describe noise emission status in the whole blanking processing.
(2) A mathematic expression on blanking process noise sound pressure level and blanking force on the break-through stage of blanking deformation is deduced systematically, that is the mathematic calculable model of maximum blanking process noise emission, which shows that blanking force is bigger, blanking noise sound level is higher.
(3) For the first time, this dissertation presents two mathematic model that can predict maximum blanking process noise emission sound level, respectively by sheet metals' tensile strength limit and by sheet metals' HV hardness, and typically suggests the model predicting blanking process noise produced on the break-through stage by sheet metals' HV hardness.
(4) Through the simulation results of blanking deformation of these three kind of sheet metals that are respectively sheet steels, sheet brass and sheet aluminum, accurately locating the sheet metal's break-through; an important conclusion can be drawn theoretically, which shows that sheet metal's deformation is on the break'through stage while proportion of punch's cut-in deep to sheet metals' thickness is almost 0.5 to 0.6.
(5) On basis of theoretical analysis to two steps blanking process, a blanking process with progressive dies for noise reduction is introduced, which can be steered by the simulation results of sheet metal's blanking deformation and has been tested in the experiments. Finally, four sets different progressive dies are introduced for two steps blanking process.
(6) Presenting a new blanking process with adding the counterforce on punch's head to reduce noise level, which equals to general blanking process in operation, practicability, and productivity, and also has been tested in the experiments. So, it is another new blanking process for noise reduction.
各种冲压工艺所产生的噪声中,以冲裁工艺噪声为最严重,也最具典型性。因此,本文选择普通冲裁中产生的工艺噪声作为具体研究对象,采取理论分析与实验验证相结合的手段,进行了较为深入、系统的研究,探讨了其噪声发射的理论规律与特点,提出了从积极主动角度降低其噪声峰值的对策。主要研究工作包括;
冲裁工艺噪声测试系统的搭建、噪声测试实验与分析、噪声发射机理的研究;冲裁突然分离阶段冲头自由振动微分方程的建立、突然分离阶段冲裁工艺噪声声压级与冲裁力的数学关系、冲裁工艺噪声发射峰值预报模型的建立与实验验证;板料冲裁加工有限元模拟及变形过程分析、两步法冲裁降噪效果的理论分析、级进模两步法冲裁模设计、级进模两步法冲裁降噪工艺实验研究;反顶力作用下冲裁模具设计与强度校核问题、反顶力作用下冲裁降噪工艺实验研究。并取得了以下主要研究成果;
(1)采用较先进的测试方法,获得了与典型的冲裁力曲线相协调的冲裁噪声发射声压波形图;采用包络线法对冲裁工艺噪声发射声压波形图的整体外轮廓进行描述,得到了冲裁工艺噪声发射树的物理模型,定量地验证了冲裁变形到突然分离阶段噪声最大的结论;较全面地描述了整个冲裁加工过程中噪声发射情况;
(2)系统地推导出冲裁突然分离阶段噪声声压级与冲裁力的数学关系式,即冲裁工艺噪声发射峰值的数学计算模型。该模型表明,冲裁力愈大,则冲裁噪声声压级分贝值愈大;
(3)首次提出了分别用板料的强度极限和用板料的硬度HV值预报冲裁工艺噪声发射峰值的数学模型;并推荐采用板料维氏硬度HV值预报突然分离阶段冲裁工艺噪声发射声压级的数学模型;
(4)通过钢板、黄铜板和铝板这3种金属板料的冲裁变形模拟结果,较为准确地找到了板料突然分离的位置;理论上得出一个重要结论;在冲裁加工中,当冲头切入金属板料深度达到板料厚度的(50%～60%)时,金属板料的变形到达突然分离阶段;
(5)针对提出的一种级进模两步法冲裁新工艺的目的之一—可降低冲裁工艺噪声,通过对板料冲裁变形进行有限元模拟及结果分析,从理论上指导该工艺的实际应用,并作了实验验证,还介绍了4种两步法冲裁级进模的结构形式;
(6)提出了一种带有反顶力作用的冲裁工艺,即在普通冲裁凹模内设置聚氨酯弹性垫块进行冲裁。该工艺与普通冲裁工艺的操作完全相同,可行性好,并可保持原有的生产效率。且通过实验测试验证,也可谓之是又一种新的冲裁降噪工艺。
Pressworking is one of the production technology used widely in modern manufacturing. However, there exist noise, vibration and insecurity problems in pressworking technology, which are more and more attentioned in the world, and pressworking noise has become an acknowledged environmental pollution. Obviously, it is highly significant whether in social benefit or in technical economic value or in academic theory to research pressworking noise.
Blanking process noise is the most serious and the most typical among noise caused in various pressworking processes. Therefore, in this dissertation, process noise caused in the general blanking is selected to be researched, then some systemic and detailed research work have finished with theoretical analysis and experimental methods, where theoretical disciplinarian and characteristic of its noise emission are probed and dicussed, and finally some countermeasures are introduced to reduce its maximum noise actively. The research work includes these aspects:
Establishment of the blanking process noise testing system, analysis of the general blanking noise testing results, and the research of blanking process noise emission mechanism; Deduction of a punch's unrestricted vibration differential equation and a mathematic expression on blanking process noise sound pressure level and blanking force on the break-through stage of blanking deformation, the construction of prediction model on maximum blanking process nose emission; The FEM analysis of sheet metal blanking processing and blanking deformation stage, the theoretic analysis of noise reduction effect in two steps blanking process, the design of progressive dies for two steps blanking process, and the experimental study on noise produced in two steps blanking process with progressive dies compared with that produced in general blanking process; The design and intensity verification of blanking dies while adding counterforce on punch's head, the experimental study on noise produced in the blanking process with adding counterforce on punch's head. The main research results are as follows:
(1) Using an advanced testing method, some typical blanking force curves and noise emission sound pressure wave graphs are obtained; Through the whole profile description for the blanking process noise emission sound pressure wave graph with contour lines, a physical model—blanking process noise emission tree is constructed, which quantificationally proves the conclusion that noise produced on the break-through stage is the maximum among that produced in the whole blanking deformation, and which can describe noise emission status in the whole blanking processing.
(2) A mathematic expression on blanking process noise sound pressure level and blanking force on the break-through stage of blanking deformation is deduced systematically, that is the mathematic calculable model of maximum blanking process noise emission, which shows that blanking force is bigger, blanking noise sound level is higher.
(3) For the first time, this dissertation presents two mathematic model that can predict maximum blanking process noise emission sound level, respectively by sheet metals' tensile strength limit and by sheet metals' HV hardness, and typically suggests the model predicting blanking process noise produced on the break-through stage by sheet metals' HV hardness.
(4) Through the simulation results of blanking deformation of these three kind of sheet metals that are respectively sheet steels, sheet brass and sheet aluminum, accurately locating the sheet metal's break-through; an important conclusion can be drawn theoretically, which shows that sheet metal's deformation is on the break'through stage while proportion of punch's cut-in deep to sheet metals' thickness is almost 0.5 to 0.6.
(5) On basis of theoretical analysis to two steps blanking process, a blanking process with progressive dies for noise reduction is introduced, which can be steered by the simulation results of sheet metal's blanking deformation and has been tested in the experiments. Finally, four sets different progressive dies are introduced for two steps blanking process.
(6) Presenting a new blanking process with adding the counterforce on punch's head to reduce noise level, which equals to general blanking process in operation, practicability, and productivity, and also has been tested in the experiments. So, it is another new blanking process for noise reduction.
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