精密直线导轨矫直机设计与分析
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摘要
21世纪,制造工业的发展更加迅速,通用机械、汽车、电机等行业大量使用如直线导轨这类零件,在由原始胚料经过粗加工、精加工、热处理等工艺手段制成成品的过程中不可避免出现弯曲变形,如果不进行矫直处理会影响工件的后序加工和使用,甚至可能出现相当数量的废品。为了能满足下道工序对工件直线度、切削余量等方面的要求；或者直接满足最终成品对零件直线度、轴颈跳动等方面的要求,需要通过一种精密高效的矫直设备来确保半成品、成品达到较严格的中间工艺要求和最终设计要求。有些直线导轨零件长期或非正常使用后,也会产生直线精度不能达到使用要求得情况,对这类零件采取精密直线校直,往往也会带来巨大的经济效益。
矫直方法一般有加热矫直法、冷压法、冷矫法,其中包括压力矫直法、平行辊矫直法、斜辊矫直法、转毂矫直法、平动矫直法、拉伸矫直法、拉弯矫直法及其他一些特殊矫直法等。本文根据弹塑性理论设计了压力反弯矫直机。首先,操作台向系统输入被矫直工件的材料、几何特性参数。然后,系统自动对工件的弯曲变形进行检测,根据检测信息调整工件压点和两支承的位置.同时通过运行存储在系统中的程序对输入和检测信息进行运算,根据运算结果向控制系统发出指令,从而控制压头的压下量,此时伺服电机带动曲柄滑块运行的行程,完成第一次矫直。接下来进行二次检测、信息处理、并再次矫直,如此循环下去直至工件达到要求的精度。
本文独立设计了基于曲柄滑块机构的压力矫直机的整体结构,进行了矫直机的参数计算与分析,对关键零部件进行了校核,保证其正常工作。采用SolidWorks软件建立了矫直机各部件的三维模型,以此来验证各部分设计的合理性,并制定合理的装配顺序,生成了矫直机的实体模型。运用Abaqus软件对夹头和压头等关键部件进行有限元分析,对矫直机的校直精度进行分析,经过论证完全适合设计要求。
Once getting into the 21st century, manufacturing industry is developing considerably fast. Meanwhile more and more linear rolling guides have been introduced into general machinery, automobiles, electrical and other industries Bending deformation inevitably appears during the process from original billet to the eventual products after roughing, finishing, heat treatment. The deformation will apparently affect the following parts of the order processing and lead to considerable amount of waste without proper straightening treatment. In order to meet the next process on the work piece straightness, cutting margin and other requirements; or directly to meet the final product on the part straightness, journal and jitter requirements, we should make it certain that products meet the middle of more stringent process requirements and final design requirements through a sophisticated and efficient equipment. Some linear rolling guides fail to meet straight-line accuracy standard after long-term or non-normal use. Turning such parts to precision straight alignment often will bring huge economic benefits.
Straightening methods generally include heat, cold, cold straightening methods, the parallel roller straightening method, inclined roller straightening method, transfer hub straightening method, translation straightening method, La stretch straightening method, stretch bending and other special ones. This article manages to design the pressure Op-bending straightening machine according to plastic theory. First, the material and geometry parameters of the work piece are input from the operating platform. Then, the system will automatically detect deformation of the work piece and adjust the location of points and two contractors based on the monitoring result. At the same time, by running the stored procedures in the system to calculate the test and input information. According to the results, the control system will receive the respective commands to control the pressure head, then it will run the servo motor to drive the slider trip, completing the first straightening step. And after secondary detection, information processing, and re-straightening, the cycle will continue until the work piece achieves the required accuracy.
This independent design in this article is based on the overall structure of pressure crank straightening machine. Calculating and analyzing the straightening machine parameters. Besides, the key components are checked to ensure their stable work of whole system. SolidWorks has been used to build the three-dimensional model of each component in order to verify that all parts of the design is reasonable and develop a reasonable assembly sequence, generating the solid model of straightening machine. The use of Abaqus software is to make finite element analysis on top chucks、pressure head and other key components, The precision of straightening machine has also been analyzed, The design requirements have been completely achieved after comprehensive study.
矫直方法一般有加热矫直法、冷压法、冷矫法,其中包括压力矫直法、平行辊矫直法、斜辊矫直法、转毂矫直法、平动矫直法、拉伸矫直法、拉弯矫直法及其他一些特殊矫直法等。本文根据弹塑性理论设计了压力反弯矫直机。首先,操作台向系统输入被矫直工件的材料、几何特性参数。然后,系统自动对工件的弯曲变形进行检测,根据检测信息调整工件压点和两支承的位置.同时通过运行存储在系统中的程序对输入和检测信息进行运算,根据运算结果向控制系统发出指令,从而控制压头的压下量,此时伺服电机带动曲柄滑块运行的行程,完成第一次矫直。接下来进行二次检测、信息处理、并再次矫直,如此循环下去直至工件达到要求的精度。
本文独立设计了基于曲柄滑块机构的压力矫直机的整体结构,进行了矫直机的参数计算与分析,对关键零部件进行了校核,保证其正常工作。采用SolidWorks软件建立了矫直机各部件的三维模型,以此来验证各部分设计的合理性,并制定合理的装配顺序,生成了矫直机的实体模型。运用Abaqus软件对夹头和压头等关键部件进行有限元分析,对矫直机的校直精度进行分析,经过论证完全适合设计要求。
Once getting into the 21st century, manufacturing industry is developing considerably fast. Meanwhile more and more linear rolling guides have been introduced into general machinery, automobiles, electrical and other industries Bending deformation inevitably appears during the process from original billet to the eventual products after roughing, finishing, heat treatment. The deformation will apparently affect the following parts of the order processing and lead to considerable amount of waste without proper straightening treatment. In order to meet the next process on the work piece straightness, cutting margin and other requirements; or directly to meet the final product on the part straightness, journal and jitter requirements, we should make it certain that products meet the middle of more stringent process requirements and final design requirements through a sophisticated and efficient equipment. Some linear rolling guides fail to meet straight-line accuracy standard after long-term or non-normal use. Turning such parts to precision straight alignment often will bring huge economic benefits.
Straightening methods generally include heat, cold, cold straightening methods, the parallel roller straightening method, inclined roller straightening method, transfer hub straightening method, translation straightening method, La stretch straightening method, stretch bending and other special ones. This article manages to design the pressure Op-bending straightening machine according to plastic theory. First, the material and geometry parameters of the work piece are input from the operating platform. Then, the system will automatically detect deformation of the work piece and adjust the location of points and two contractors based on the monitoring result. At the same time, by running the stored procedures in the system to calculate the test and input information. According to the results, the control system will receive the respective commands to control the pressure head, then it will run the servo motor to drive the slider trip, completing the first straightening step. And after secondary detection, information processing, and re-straightening, the cycle will continue until the work piece achieves the required accuracy.
This independent design in this article is based on the overall structure of pressure crank straightening machine. Calculating and analyzing the straightening machine parameters. Besides, the key components are checked to ensure their stable work of whole system. SolidWorks has been used to build the three-dimensional model of each component in order to verify that all parts of the design is reasonable and develop a reasonable assembly sequence, generating the solid model of straightening machine. The use of Abaqus software is to make finite element analysis on top chucks、pressure head and other key components, The precision of straightening machine has also been analyzed, The design requirements have been completely achieved after comprehensive study.
引文
[1]崔甫.矫直原理与矫直机械[M]北京：冶金工业出版社,2002
[2]翟华.轴类零件校直工艺理论研究[D].合肥工业大学,2003.
[3]崔甫,施东成.矫直机压弯量计算法的探讨[J].冶金设备,1999,(01).
[4]曹爱文,熊国良.压力校直技术的发展[J].锻压装备与制造技术,2007,(01).
[5]Yin Yao-bao,Qu Yi-yi,Yan Jin-kun. An Investigation on Hydraulic Servo-systems with asymmetric cylinder[C].Proceedings of the 1st International Symposium on Fluid Power Transmission and Control,Beijing,1991.
[6]轴类自动校直机的开发与研究[D].吉林大学,2005.
[7]井永水,窦忠强,李忠富.矫直理论的新探索[J].北京科技大学学报,2002,(01).
[8]弋景刚,王泽和,孙维连,李猛.轴类零件矫直工艺理论研究[J].河北农业大学学报,2004,(03).
[9]钦明浩,张向军,蒋守仁,徐业宜.轴类零件校直理论分析[J].合肥工业大学学报(自然科学版),1996,(04).
[10]于晓平.轴类全自动校直机[J].金属热处理,2002,(09).
[11]朱奇志.机械制造标准术语大全[M].北京：机械工业出版社,1994
[12]崔甫,朴永洙,刘树桐.对拉弯变形规律的探讨[J].重型机械,1988,(12).
[13]Li Hong-ren,Zhao Yu-zhuo,Han Jun-wei,Pan Gui-bin. Astudy on electro-hydraulic servo system with a symmetrical cylinder using Bond Graph[C]. Proceedings of the 1 st International Symposium on Fluid Power Transmission and Control,Beijing,1991.
[14]单淑梅.液压自动校直机的应用与研究[J].汽车技术,1998,(11).
[15]秦瑞东.浅谈碳钢轴的矫直[J].机械设计与制造,2000,(04).
[16]杨忠林,王海峰,王剑,赵红旗,郝文侠.邯钢冷轧厂辊式矫直机的特点与应用[J].轧钢,2005,(01)
[17]刘安明,刘沈.简易矫直机[J].机械工程师,2006,(04)
[18]Sasaki M,Kawafuku M,Ta kahashiK.An immune feedback mechanism based adaptive learning of neural network controller.ICONIP'99,6th International Conference on Neural Information Processing[C].IEEE Computer Society Press,1999,502-507.
[19]胡高举,王勤,王宇,鄂世伟.拉伸弯曲矫直机组设备关键技术研究[J].钢铁技术, 2004,(01).
[20]S.L.Srimani,A.C.Pankaj,J.Basu.Analysis of end straightness of rail during manufacturing.International Journal of Mechanical Sciences 47(2005)1874-1884
[21]Mehmet Firat,Bilgin Kaftanoglu,Orhan Eser.Sheet metal forming analyses with an emphasis on the springback deformation.journal of materials processing technology 196(2008)135-148
[22]陈学强.拉弯矫直机及其结构的理论研究[J].今日科苑,2009,(06)
[23]戴有涛,拉弯矫直机组的特点与应用[J],轻合金加工技术,2001(29).
[24]刘鸿文.材料力学[M].北京：高等教育出版社,2003.
[25]Kee-cheol PARK and Sang-Moo HWANGDevelopment of a Finite Element Analysis Program for Roller Leveling and Application for Removing Blanking Bow Defects of Thin Steel Sheet.ISIJ International.2002:9:990-999
[26]S.K.Panthi,N.Ramakrishnan,K.K.Pathak,J.S.Chouhan.An analysis of springback in sheet metal bending using finite element method(FEM).Journal of Materials Processing Technology 186(2007)120-124.
[27]魏来生.结构有限元动态模型修正方法综述[J].振动与冲击,1998,(03).
[28]Merklein M, Geiger M. New materials and production technologies for innovative lightweight constructions.Journal of Materials Processing Technology,2002, 125-126:532-536.
[29]Yoshisuke MISAKA Shape Correction of steel Strip by Tension Leveler Journal of Japan Sociery for Technology 1976 Vol 17 P912-934.
[30]边弘晔,李鹤,闻邦椿.HyperMesh有限元前处理关键技术研究[J].机床与液压,2008,(04).
[31]有限元模型静力—模态协同修正技术[D].西北工业大学,2004.
[32]郭永刚.机械振动原因的分析[J].甘肃冶金,2001,,(01).
[33]T Sheppard On the Strip-to-Roll Coforrmity in the Tension-Leveling Process Joural of the Institute of Metals 1972 Vol 100P125-128.
[34]T X YuandW Johnson Influence of Axial Force on the Elasric-plastic Bending and Springhack of a Beam Journal of Mechancal Working Technology 1982 No5.
[35]于亚婷,杜平安,王振伟.有限元法的应用现状研究[J].机械设计,2005,(03)
[36]刘畅.基于ABAQUS冷轧薄板工作辊有限元研究[D].内蒙古科技大学,2009
[37]苏岚,王先进,唐荻,孙吉先,田荣彬.有限元法处理金属塑性成型过程的接触问题[J].塑性工程学报,2000,(04).
[38]雷勇军,李道奎.有限元方法在材料力学试验中的应用[A].2006力学教学与教学改革交流会会议论文集[C],2006.
[39]钦明浩,吴焱明,蒋守仁,徐业宜.轴类零件校直的有限元解法[J].合肥工业大学学报(自然科学版),1996,(02).
[40]罗森.基于弹塑性理论的拉弯矫直过程仿真及工艺参数优化研究[D].重庆大学,2008
[41]周存龙,王国栋,刘相华,秦建平.压弯量对轧件矫直变形影响的有限元分析[J].塑性工程学报,2006,(01).
[2]翟华.轴类零件校直工艺理论研究[D].合肥工业大学,2003.
[3]崔甫,施东成.矫直机压弯量计算法的探讨[J].冶金设备,1999,(01).
[4]曹爱文,熊国良.压力校直技术的发展[J].锻压装备与制造技术,2007,(01).
[5]Yin Yao-bao,Qu Yi-yi,Yan Jin-kun. An Investigation on Hydraulic Servo-systems with asymmetric cylinder[C].Proceedings of the 1st International Symposium on Fluid Power Transmission and Control,Beijing,1991.
[6]轴类自动校直机的开发与研究[D].吉林大学,2005.
[7]井永水,窦忠强,李忠富.矫直理论的新探索[J].北京科技大学学报,2002,(01).
[8]弋景刚,王泽和,孙维连,李猛.轴类零件矫直工艺理论研究[J].河北农业大学学报,2004,(03).
[9]钦明浩,张向军,蒋守仁,徐业宜.轴类零件校直理论分析[J].合肥工业大学学报(自然科学版),1996,(04).
[10]于晓平.轴类全自动校直机[J].金属热处理,2002,(09).
[11]朱奇志.机械制造标准术语大全[M].北京：机械工业出版社,1994
[12]崔甫,朴永洙,刘树桐.对拉弯变形规律的探讨[J].重型机械,1988,(12).
[13]Li Hong-ren,Zhao Yu-zhuo,Han Jun-wei,Pan Gui-bin. Astudy on electro-hydraulic servo system with a symmetrical cylinder using Bond Graph[C]. Proceedings of the 1 st International Symposium on Fluid Power Transmission and Control,Beijing,1991.
[14]单淑梅.液压自动校直机的应用与研究[J].汽车技术,1998,(11).
[15]秦瑞东.浅谈碳钢轴的矫直[J].机械设计与制造,2000,(04).
[16]杨忠林,王海峰,王剑,赵红旗,郝文侠.邯钢冷轧厂辊式矫直机的特点与应用[J].轧钢,2005,(01)
[17]刘安明,刘沈.简易矫直机[J].机械工程师,2006,(04)
[18]Sasaki M,Kawafuku M,Ta kahashiK.An immune feedback mechanism based adaptive learning of neural network controller.ICONIP'99,6th International Conference on Neural Information Processing[C].IEEE Computer Society Press,1999,502-507.
[19]胡高举,王勤,王宇,鄂世伟.拉伸弯曲矫直机组设备关键技术研究[J].钢铁技术, 2004,(01).
[20]S.L.Srimani,A.C.Pankaj,J.Basu.Analysis of end straightness of rail during manufacturing.International Journal of Mechanical Sciences 47(2005)1874-1884
[21]Mehmet Firat,Bilgin Kaftanoglu,Orhan Eser.Sheet metal forming analyses with an emphasis on the springback deformation.journal of materials processing technology 196(2008)135-148
[22]陈学强.拉弯矫直机及其结构的理论研究[J].今日科苑,2009,(06)
[23]戴有涛,拉弯矫直机组的特点与应用[J],轻合金加工技术,2001(29).
[24]刘鸿文.材料力学[M].北京：高等教育出版社,2003.
[25]Kee-cheol PARK and Sang-Moo HWANGDevelopment of a Finite Element Analysis Program for Roller Leveling and Application for Removing Blanking Bow Defects of Thin Steel Sheet.ISIJ International.2002:9:990-999
[26]S.K.Panthi,N.Ramakrishnan,K.K.Pathak,J.S.Chouhan.An analysis of springback in sheet metal bending using finite element method(FEM).Journal of Materials Processing Technology 186(2007)120-124.
[27]魏来生.结构有限元动态模型修正方法综述[J].振动与冲击,1998,(03).
[28]Merklein M, Geiger M. New materials and production technologies for innovative lightweight constructions.Journal of Materials Processing Technology,2002, 125-126:532-536.
[29]Yoshisuke MISAKA Shape Correction of steel Strip by Tension Leveler Journal of Japan Sociery for Technology 1976 Vol 17 P912-934.
[30]边弘晔,李鹤,闻邦椿.HyperMesh有限元前处理关键技术研究[J].机床与液压,2008,(04).
[31]有限元模型静力—模态协同修正技术[D].西北工业大学,2004.
[32]郭永刚.机械振动原因的分析[J].甘肃冶金,2001,,(01).
[33]T Sheppard On the Strip-to-Roll Coforrmity in the Tension-Leveling Process Joural of the Institute of Metals 1972 Vol 100P125-128.
[34]T X YuandW Johnson Influence of Axial Force on the Elasric-plastic Bending and Springhack of a Beam Journal of Mechancal Working Technology 1982 No5.
[35]于亚婷,杜平安,王振伟.有限元法的应用现状研究[J].机械设计,2005,(03)
[36]刘畅.基于ABAQUS冷轧薄板工作辊有限元研究[D].内蒙古科技大学,2009
[37]苏岚,王先进,唐荻,孙吉先,田荣彬.有限元法处理金属塑性成型过程的接触问题[J].塑性工程学报,2000,(04).
[38]雷勇军,李道奎.有限元方法在材料力学试验中的应用[A].2006力学教学与教学改革交流会会议论文集[C],2006.
[39]钦明浩,吴焱明,蒋守仁,徐业宜.轴类零件校直的有限元解法[J].合肥工业大学学报(自然科学版),1996,(02).
[40]罗森.基于弹塑性理论的拉弯矫直过程仿真及工艺参数优化研究[D].重庆大学,2008
[41]周存龙,王国栋,刘相华,秦建平.压弯量对轧件矫直变形影响的有限元分析[J].塑性工程学报,2006,(01).