100MN等温锻造液压机有限元结构分析与优化
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摘要
大型液压机是制品成形加工的重要装备,在国防和航空工业的大型模锻件生产中具有不可替代的作用。液压机的设计对其性能、质量具有决定性作用。传统的液压机设计存在设计周期长、结构笨重、成本高、缺乏对结果的验证等诸多弊端。为此,有必要将有限元结构分析、优化设计等现代设计方法用于液压机产品设计,以提高设计质量,满足成形加工的技术需求。
本文以100MN等温锻造液压机为研究对象,通过对整机结构特点和受力情况的分析,建立了以壳单元为主的整机有限元精细分析模型,并对该液压机的原始设计进行了整机结构刚度和强度的分析校核;利用内嵌于ABAQUS的Python脚本语言,建立了该液压机的参数化有限元模型;基于正交试验设计和一阶响应面建模方法,建立了整机刚度和强度与设计变量之间的关系式,进而建立了以整机重量为目标,以分属五个部件的10个尺寸参数为设计变量,在满足整机静强度、刚度和边界约束条件下的液压机整机结构优化数学模型;采用遗传算法对该数学模型的求解,得到了最优设计参数。基于不同的优化思路,得到了两组优化结果:(1)在维持现有刚度条件不变的前提下,整机质量减轻8.39%;(2)在上横梁刚度提高16.54%的基础上,整机质量减轻4.18%。
本文以大型液压机为对象,总结出一套比较完整的复杂制造装备结构优化设计的方法、体系结构和技术流程,建立优化设计的技术系统,为其它的大型复杂制造装备的结构优化提供了一种思路。
Hydraulic press is one kind of important equipments in forming. It is irreplaceable in the defense and aviation industry for production of large-size forgings. The performance and quality of the press is related directly to its design. There are many problems in traditional design methods such as long design cycle, structure redundancy, high cost and lack of validation. So it is necessary to bring the FEM and optimum design into the design process of the press in order to improve the design quality and fulfill the need of the manufacture industry.
Taking 100MN Numerical control Isothermal Forging Hydraulic Press as the research object, this dissertation established the refined FEM model of the press, which was mainly built with shell element, and a validation check on the primary design of the press was carried out. And then a parametric FE model of the press was created in Python and a series of FE numerical experiments were carried out based on the parametric model and the orthogonal experimental method (OEM). An approximately optimization model for the light weight design of the press was set up based on the FE numerical experiments. The optimization model includes 10 dimensions parameters extracted from 5 parts. The design constraints are composed of the stiffness and strength of the structure of the press and obtained by one-order response face method (RFM). So the optimization mathematic model aimed at the total mass of press is established. Two groups of results are gained and analyzed through the solution to the model by the genetic algorithm (GA):
(1) Reduce the total mass by 8.39% with no improvement in stiffness of the press;
(2) Increase the stiffness of the upper beam by 16.54% and reduce the total mass by 4.18%.
Taking the optimization of the large-sized press as an example, this dissertation tries to generalize the optimization methods and process and build the technology system for structure optimum design, which can be applied to the other large-sized and complex manufacturing equipments.
本文以100MN等温锻造液压机为研究对象,通过对整机结构特点和受力情况的分析,建立了以壳单元为主的整机有限元精细分析模型,并对该液压机的原始设计进行了整机结构刚度和强度的分析校核;利用内嵌于ABAQUS的Python脚本语言,建立了该液压机的参数化有限元模型;基于正交试验设计和一阶响应面建模方法,建立了整机刚度和强度与设计变量之间的关系式,进而建立了以整机重量为目标,以分属五个部件的10个尺寸参数为设计变量,在满足整机静强度、刚度和边界约束条件下的液压机整机结构优化数学模型;采用遗传算法对该数学模型的求解,得到了最优设计参数。基于不同的优化思路,得到了两组优化结果:(1)在维持现有刚度条件不变的前提下,整机质量减轻8.39%;(2)在上横梁刚度提高16.54%的基础上,整机质量减轻4.18%。
本文以大型液压机为对象,总结出一套比较完整的复杂制造装备结构优化设计的方法、体系结构和技术流程,建立优化设计的技术系统,为其它的大型复杂制造装备的结构优化提供了一种思路。
Hydraulic press is one kind of important equipments in forming. It is irreplaceable in the defense and aviation industry for production of large-size forgings. The performance and quality of the press is related directly to its design. There are many problems in traditional design methods such as long design cycle, structure redundancy, high cost and lack of validation. So it is necessary to bring the FEM and optimum design into the design process of the press in order to improve the design quality and fulfill the need of the manufacture industry.
Taking 100MN Numerical control Isothermal Forging Hydraulic Press as the research object, this dissertation established the refined FEM model of the press, which was mainly built with shell element, and a validation check on the primary design of the press was carried out. And then a parametric FE model of the press was created in Python and a series of FE numerical experiments were carried out based on the parametric model and the orthogonal experimental method (OEM). An approximately optimization model for the light weight design of the press was set up based on the FE numerical experiments. The optimization model includes 10 dimensions parameters extracted from 5 parts. The design constraints are composed of the stiffness and strength of the structure of the press and obtained by one-order response face method (RFM). So the optimization mathematic model aimed at the total mass of press is established. Two groups of results are gained and analyzed through the solution to the model by the genetic algorithm (GA):
(1) Reduce the total mass by 8.39% with no improvement in stiffness of the press;
(2) Increase the stiffness of the upper beam by 16.54% and reduce the total mass by 4.18%.
Taking the optimization of the large-sized press as an example, this dissertation tries to generalize the optimization methods and process and build the technology system for structure optimum design, which can be applied to the other large-sized and complex manufacturing equipments.
引文
[1]田会然,800MN多向模锻液压机本体结构设计及分析,硕士学位论文,燕山大学,2005
[2] 8万吨世界最大模锻压机将由二重造满足大飞机需要,www.chinaequip.gov.cn,北京:国资委网站,2007
[3]颜昌亚,焊接结构组合机架液压机本体的CAD/CAE研究,硕士学位论文,燕山大学,2002
[4]潘凤文,金淼,液压机本体CAD的现状及发展,锻压机械,2000(2):39-40
[5]孙靖民,梁迎春,陈时锦,机械结构优化设计,哈尔滨:哈尔滨工业大学出版社,2004,35~40
[6]郭宝峰,赵石岩,管筒形零件机械扩径工艺过程的多目标优化,塑性工程学报,2007,14(4): 35~39
[7]张成成,姚卫星,基于响应面的结构抗疲劳优化设计方法,南京航空航天大学学报,2007,39(1):37~40
[8] N.Krimbacher, M.Garstenauer, R.Scheidl, Optimization of hydraulic systems of numerical simulation, The 2nd International Workshop, 2001
[9] Johan Olvander, Robustness considerations in multi-objective optimal design, Journal of Engineering Design, 2005, 16(6):511~523
[10] Han.C.S., Grandhi.R.V., Srinivasan.R., Optimum design of forging die shapes using nonlinear finite element analysis , AIAA Journal, 1993, 31(4): 774-781
[11]秦东晨,祈建中,液压机横梁结构的优化设计,锻压技术,2004(2):49-52
[12]杨秀萍,曹晓邨,液压缸结构设计的有限元法,机床与液压,2004(1):108~110
[13]王炳乐,刘开,刘龙泉,四柱液压机上横梁静力有限元分析,机械,2002,29(4):23-25
[14]李德军,李培武,22MN液压机整体框架式机身的有限元分析,塑性工程学报,1995,2(3):55-66
[15]侯晓望,基于有限元分析的液压机结构优化,硕士学位论文,浙江大学,2006
[16]张盛华,快锻液压机机架的有限元分析,硕士学位论文,西北工业大学,2004
[17] 100MN数控钛合金等温锻造液压机研制验收材料(上册),天津:天津市天锻压力机有限公司,2003
[18]冯肇华,有限单元体法基础,吉林:吉林人民出版社,1984,24~110
[19]毕继红,王晖,工程弹塑性力学,天津:天津大学出版社,2003,150~163
[20] Hibbitt, Karlsson, Sorensen, Getting Started With ABAQUS Version 6.5, USA:HKS, 2002
[21]成大先主编,机械设计手册,北京:化学工业出版社,1994
[22]天津市锻压机床厂,中小型液压机设计计算,天津:天津人民出版社,1977,116-120
[23]石亦平,周玉蓉,ABAQUS有限元分析实例详解,北京:机械工业出版社,2006,316~317
[24]王明红,面向制件精度的成型模具与装备耦合刚度分析,硕士学位论文,天津大学,2007
[25]庄茁,ABAQUS非线性有限元分析与实例,北京:科学出版社,2005,71~72
[26]杜平安,有限元网格划分的基本原则,机械设计与制造,2000(1):34-36
[27]中国机械工程学会焊接学会,焊接手册,北京:机械工业出版社,2001,62~70
[28]俞新陆,液压机的设计与应用,北京:机械工业出版社,2007,156
[29]王凤岐,张连洪,邵宏宇,现代设计方法,天津:天津大学出版社,2004,65~71
[30]陈立周,机械优化设计方法,北京:冶金工业出版社,2003,21
[31]谢世坤,参数化网格划分及其在板料成形有限元分析中的应用,博士学位论文,南昌大学,2005
[32]孙广磊,征服Python—语言基础与典型应用,北京:人民邮电出版社,2007,3~5
[33] Hibbitt, Karlsson, Sorensen, ABAQUS Scripting User’s Manual, Version 6.5, USA:HKS, 2002
[34]连昌伟,王兆远,杜传军,ABAQUS后处理二次开发在塑料成型模拟中的应用,锻压技术,2006(4):111~114
[35]鲍荣浩,卢文浩,ABAQUS前处理程序二次开发在蜂窝材料中的应用,工程设计学报,2003,10(6):330~333
[36]赵腾伦,ABAQUS6.6在机械工程中的应用,北京:中国水利水电出版社,2007,389~402
[37]卢纹岱,SPSS For Windows统计分析教程,北京:电子工业出版社,2006
[38] Holland J.H., Adapatation in Natural and Artificial Systems, Ann Arbor: University of Michigan Press, 1975
[39] Goldberg D E., Genetic Algorithms in Search, Optimization and Machine Learning, MA: Addison-Wesley, 1989
[40]陈伦军,机械优化设计遗传算法,北京:机械工业出版社,2005,3~5
[41]郭立新,李成植,遗传算法在机械优化设计中的应用,机械设计与制造,1999(1):43~44
[42]程成,须文波,冷文浩,基于iSIGHT平台DOE方法的螺旋桨敞水性能优化设计,计算机工程与设计,2007,28(6):1455~1459
[2] 8万吨世界最大模锻压机将由二重造满足大飞机需要,www.chinaequip.gov.cn,北京:国资委网站,2007
[3]颜昌亚,焊接结构组合机架液压机本体的CAD/CAE研究,硕士学位论文,燕山大学,2002
[4]潘凤文,金淼,液压机本体CAD的现状及发展,锻压机械,2000(2):39-40
[5]孙靖民,梁迎春,陈时锦,机械结构优化设计,哈尔滨:哈尔滨工业大学出版社,2004,35~40
[6]郭宝峰,赵石岩,管筒形零件机械扩径工艺过程的多目标优化,塑性工程学报,2007,14(4): 35~39
[7]张成成,姚卫星,基于响应面的结构抗疲劳优化设计方法,南京航空航天大学学报,2007,39(1):37~40
[8] N.Krimbacher, M.Garstenauer, R.Scheidl, Optimization of hydraulic systems of numerical simulation, The 2nd International Workshop, 2001
[9] Johan Olvander, Robustness considerations in multi-objective optimal design, Journal of Engineering Design, 2005, 16(6):511~523
[10] Han.C.S., Grandhi.R.V., Srinivasan.R., Optimum design of forging die shapes using nonlinear finite element analysis , AIAA Journal, 1993, 31(4): 774-781
[11]秦东晨,祈建中,液压机横梁结构的优化设计,锻压技术,2004(2):49-52
[12]杨秀萍,曹晓邨,液压缸结构设计的有限元法,机床与液压,2004(1):108~110
[13]王炳乐,刘开,刘龙泉,四柱液压机上横梁静力有限元分析,机械,2002,29(4):23-25
[14]李德军,李培武,22MN液压机整体框架式机身的有限元分析,塑性工程学报,1995,2(3):55-66
[15]侯晓望,基于有限元分析的液压机结构优化,硕士学位论文,浙江大学,2006
[16]张盛华,快锻液压机机架的有限元分析,硕士学位论文,西北工业大学,2004
[17] 100MN数控钛合金等温锻造液压机研制验收材料(上册),天津:天津市天锻压力机有限公司,2003
[18]冯肇华,有限单元体法基础,吉林:吉林人民出版社,1984,24~110
[19]毕继红,王晖,工程弹塑性力学,天津:天津大学出版社,2003,150~163
[20] Hibbitt, Karlsson, Sorensen, Getting Started With ABAQUS Version 6.5, USA:HKS, 2002
[21]成大先主编,机械设计手册,北京:化学工业出版社,1994
[22]天津市锻压机床厂,中小型液压机设计计算,天津:天津人民出版社,1977,116-120
[23]石亦平,周玉蓉,ABAQUS有限元分析实例详解,北京:机械工业出版社,2006,316~317
[24]王明红,面向制件精度的成型模具与装备耦合刚度分析,硕士学位论文,天津大学,2007
[25]庄茁,ABAQUS非线性有限元分析与实例,北京:科学出版社,2005,71~72
[26]杜平安,有限元网格划分的基本原则,机械设计与制造,2000(1):34-36
[27]中国机械工程学会焊接学会,焊接手册,北京:机械工业出版社,2001,62~70
[28]俞新陆,液压机的设计与应用,北京:机械工业出版社,2007,156
[29]王凤岐,张连洪,邵宏宇,现代设计方法,天津:天津大学出版社,2004,65~71
[30]陈立周,机械优化设计方法,北京:冶金工业出版社,2003,21
[31]谢世坤,参数化网格划分及其在板料成形有限元分析中的应用,博士学位论文,南昌大学,2005
[32]孙广磊,征服Python—语言基础与典型应用,北京:人民邮电出版社,2007,3~5
[33] Hibbitt, Karlsson, Sorensen, ABAQUS Scripting User’s Manual, Version 6.5, USA:HKS, 2002
[34]连昌伟,王兆远,杜传军,ABAQUS后处理二次开发在塑料成型模拟中的应用,锻压技术,2006(4):111~114
[35]鲍荣浩,卢文浩,ABAQUS前处理程序二次开发在蜂窝材料中的应用,工程设计学报,2003,10(6):330~333
[36]赵腾伦,ABAQUS6.6在机械工程中的应用,北京:中国水利水电出版社,2007,389~402
[37]卢纹岱,SPSS For Windows统计分析教程,北京:电子工业出版社,2006
[38] Holland J.H., Adapatation in Natural and Artificial Systems, Ann Arbor: University of Michigan Press, 1975
[39] Goldberg D E., Genetic Algorithms in Search, Optimization and Machine Learning, MA: Addison-Wesley, 1989
[40]陈伦军,机械优化设计遗传算法,北京:机械工业出版社,2005,3~5
[41]郭立新,李成植,遗传算法在机械优化设计中的应用,机械设计与制造,1999(1):43~44
[42]程成,须文波,冷文浩,基于iSIGHT平台DOE方法的螺旋桨敞水性能优化设计,计算机工程与设计,2007,28(6):1455~1459