快锻液压机机架的有限元分析
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摘要
快锻液压机作为压力加工的重要设备，已经成为工业生产中必不可少的装备之一。本文在研究快锻液压机的原理、结构特点及结构分析有限元方法的基础上，以西安重型机械研究所新研究开发的12.5MN双柱下拉式快锻液压机为例，建立了快锻液压机机架的三维有限元模型，分析了在静、动态载荷下，快锻液压机机架的应力和位移分布规律，并对机架进行了模态分析，为双柱下拉式快锻液压机的设计提供了可靠的理论依据，具有一定的理论意义和实际应用价值。
本文的主要研究内容和结论有：
(1)建立了快锻液压机三维几何模型、力学模型、静态和瞬态动力学模型。
(2)通过对快锻液压机正载、沿框架平面偏载和垂直框架平面偏载三种典型工况的有限元分析，得到三个不同工况下机架的应力和位移分布规律。其主要结论为：机架的四个拐角为主要应力集中区，即为机架的危险截面；动载和静载下，机架的应力和位移分布趋势基本一致，但在动载冲击下，危险截面的最大应力增加40％左右；偏载对液压机横梁及立柱的应力分布有较大影响，偏载会使机架危险截面的最大应力增大20％左右。
(3)通过对快锻液压机的机架进行模态分析，得到了机架的前十阶固有频率及相应的固有振型等动态特性参数。结果表明：机架不仅有前后，上下及左右方向的弯曲振动，而且有扭转振动，这些振动将影响机架的强度和刚度，加重机架导向部分的磨损，影响锻件的精度及模具和液压缸的使用寿命，因此，在设计过程中应适当增加局部刚度和阻尼来抑制这些振动的影响；该机架整体的刚度和质量分布较为均衡，无明显的薄弱部位和过剩部位，机架的动态性能良好；机架的最小频率为23.758Hz，远远大于其冲击频率1.33Hz(即80次每分钟)，不会发生共振；且大于20Hz，满足降低噪声污染的设计要求(因为小于20Hz为次声波，处于次声波环境中的人极易疲劳)。
(4)分析结果表明：该12.5MN双柱下拉式快锻液压机机架危险截面静载时的最大应力在60-90MPa之间，动载时的最大应力在90-150MPa之间，远小于机架材料的屈服极限270MPa，且动态性能良好，设计比较合理。
西北丁一业人学硕卜学位论文
本文研究的快锻液压机机架静动态、正偏载的应力分布规律及模态分析结
果，为新式快锻液压机的设计提供了可靠的依据。
The high speed forging hydraulic machine, which is most important equipment in pressure processing field, has become one of the equipments which cannot be shortage in industrial production.This paper has created three-dimensional finite element model of the frame of 12.5MN twin columns pull-down high speed forging hydraulic machine which is designed by Xi'an heavy-duty machinery research institute, analysed the stress and displacement distribution laws of the frame under static and dynamic load, and done the modal analysis of the frame on the base of studying theories and features of the high speed forging hydraulic machine and the structural finite element method, which provides reliable theoretical base and has important theoretical meaning and application value.
The main research contents and results of this paper as follows:
(1) The three-dimensional geometric model, mechanical model, static and transient dynamic model of the frame are created.
(2) Stress and displacement distribution laws of the frame under three different working states are obtained through simulating the three typical working states of the frame, they are no offset load, offsetting load along X axis and offsetting load along Z axis. The main calculation results are:the four corners of the frame are strss concentrate areas, that is they are the dangerous cross-sections of the frame;The stress and displacement distribution trends are almost same under static and dynamic load, but under dynamic load, the largest stresses of the dangerous cross-sections are increased by about 40%;Offsetting load has a great effect on the bridge and upright column of hydraulic machine and makes the largest stress of the dangerous cross-section increased by about 20%.
(3)The dynamic parameters of the frame such as previous ten natural
frequencies and corresponding modes are obtained through modal analyzing the frame of high speed forging hydraulic machine. The simulating results indicate:The frame has not only fore and after, up-down and left-right bending vibration,but also twisting vibration. These vibrations will affect the strength and stiffness of the frame, wear guide sleeves of the frame, affect the precision of forge piece and decrease the service life of die and fluid cylinder, so during the course of designing, the effects of those vibrations should be prevented by increasing partial stiffness and damp;The whole stiffness and quantity of the frame are distributed with equalization,and there is no weak place and surplus location on the frame. The dynamic behaviors of the frame are well;The smallest frequency(23. 758Hz) of frame is larger than impact frequency(1. 33Hz) of frame greatly, so the resonance vibration wont take place on the frame;What' s more, it is larger than the frequency of 20Hz, so the design requirement of decrea
sing noise pollution is satisfied.
(4) Analysis results i.ndicate:under static load, the largest stress of the dangerous cross-section of the 12. 5MN twin columns pull-down high speed forging hydraulic machine is between 60MPa and 90MPa,while under dynamic load, it is between 90MPa and ISOMPa, and they are also smaller than yield limit (270MPa)of the frame.Further, dynamic characteristics are very well, so the design of this machine is satisfying.
The research contents and results of this paper, which contain stress distributon laws of the frame of high speed forging hydraulic machine under static load, dynamic load,no offset load and offset load and modal
analysis, provide reliable theoretical base for the design of new high
speed forging hydraulic machine.
本文的主要研究内容和结论有：
(1)建立了快锻液压机三维几何模型、力学模型、静态和瞬态动力学模型。
(2)通过对快锻液压机正载、沿框架平面偏载和垂直框架平面偏载三种典型工况的有限元分析，得到三个不同工况下机架的应力和位移分布规律。其主要结论为：机架的四个拐角为主要应力集中区，即为机架的危险截面；动载和静载下，机架的应力和位移分布趋势基本一致，但在动载冲击下，危险截面的最大应力增加40％左右；偏载对液压机横梁及立柱的应力分布有较大影响，偏载会使机架危险截面的最大应力增大20％左右。
(3)通过对快锻液压机的机架进行模态分析，得到了机架的前十阶固有频率及相应的固有振型等动态特性参数。结果表明：机架不仅有前后，上下及左右方向的弯曲振动，而且有扭转振动，这些振动将影响机架的强度和刚度，加重机架导向部分的磨损，影响锻件的精度及模具和液压缸的使用寿命，因此，在设计过程中应适当增加局部刚度和阻尼来抑制这些振动的影响；该机架整体的刚度和质量分布较为均衡，无明显的薄弱部位和过剩部位，机架的动态性能良好；机架的最小频率为23.758Hz，远远大于其冲击频率1.33Hz(即80次每分钟)，不会发生共振；且大于20Hz，满足降低噪声污染的设计要求(因为小于20Hz为次声波，处于次声波环境中的人极易疲劳)。
(4)分析结果表明：该12.5MN双柱下拉式快锻液压机机架危险截面静载时的最大应力在60-90MPa之间，动载时的最大应力在90-150MPa之间，远小于机架材料的屈服极限270MPa，且动态性能良好，设计比较合理。
西北丁一业人学硕卜学位论文
本文研究的快锻液压机机架静动态、正偏载的应力分布规律及模态分析结
果，为新式快锻液压机的设计提供了可靠的依据。
The high speed forging hydraulic machine, which is most important equipment in pressure processing field, has become one of the equipments which cannot be shortage in industrial production.This paper has created three-dimensional finite element model of the frame of 12.5MN twin columns pull-down high speed forging hydraulic machine which is designed by Xi'an heavy-duty machinery research institute, analysed the stress and displacement distribution laws of the frame under static and dynamic load, and done the modal analysis of the frame on the base of studying theories and features of the high speed forging hydraulic machine and the structural finite element method, which provides reliable theoretical base and has important theoretical meaning and application value.
The main research contents and results of this paper as follows:
(1) The three-dimensional geometric model, mechanical model, static and transient dynamic model of the frame are created.
(2) Stress and displacement distribution laws of the frame under three different working states are obtained through simulating the three typical working states of the frame, they are no offset load, offsetting load along X axis and offsetting load along Z axis. The main calculation results are:the four corners of the frame are strss concentrate areas, that is they are the dangerous cross-sections of the frame;The stress and displacement distribution trends are almost same under static and dynamic load, but under dynamic load, the largest stresses of the dangerous cross-sections are increased by about 40%;Offsetting load has a great effect on the bridge and upright column of hydraulic machine and makes the largest stress of the dangerous cross-section increased by about 20%.
(3)The dynamic parameters of the frame such as previous ten natural
frequencies and corresponding modes are obtained through modal analyzing the frame of high speed forging hydraulic machine. The simulating results indicate:The frame has not only fore and after, up-down and left-right bending vibration,but also twisting vibration. These vibrations will affect the strength and stiffness of the frame, wear guide sleeves of the frame, affect the precision of forge piece and decrease the service life of die and fluid cylinder, so during the course of designing, the effects of those vibrations should be prevented by increasing partial stiffness and damp;The whole stiffness and quantity of the frame are distributed with equalization,and there is no weak place and surplus location on the frame. The dynamic behaviors of the frame are well;The smallest frequency(23. 758Hz) of frame is larger than impact frequency(1. 33Hz) of frame greatly, so the resonance vibration wont take place on the frame;What' s more, it is larger than the frequency of 20Hz, so the design requirement of decrea
sing noise pollution is satisfied.
(4) Analysis results i.ndicate:under static load, the largest stress of the dangerous cross-section of the 12. 5MN twin columns pull-down high speed forging hydraulic machine is between 60MPa and 90MPa,while under dynamic load, it is between 90MPa and ISOMPa, and they are also smaller than yield limit (270MPa)of the frame.Further, dynamic characteristics are very well, so the design of this machine is satisfying.
The research contents and results of this paper, which contain stress distributon laws of the frame of high speed forging hydraulic machine under static load, dynamic load,no offset load and offset load and modal
analysis, provide reliable theoretical base for the design of new high
speed forging hydraulic machine.
引文
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[2]高文章．30MN双柱下拉式快锻液压机．重型机械．1995，No．1
[3]魏伟．快锻液压机国内外现状及旧水压机改造．锻压机械．1998，No．2
[4]刘刚，陈体恒．浅谈现代设计方法中的优化设计．河南机专学报．1998，Vol．6，No．2
[5]龙慧．论机械产品的现代设计方法．稀有金属与硬质合金．2001，Vol．9，No．146
[6]Koc, Muammer; Altan, Taylan. Application of two dimensional (2D) FEA for the tube hydroforming process, International Journal of Machine Tools and Manufacture v 42 n11 September 2002. p1285-1295
[7]Ghofrani, M. Reza, White, Charles S. Modeling of a precision closed-die forging. American Society of Mechanical Engineers(Paper). 1996, 8p
[8]Chenot, Tronel, Soyris. Finite element calculation ofthermo-coupled large deformation in hot forging. Conduction, Radiation and Phase Change. 1992, p493-511
[9]朱西产，张金换，李一兵，黄世霖．客车车身试验模态分析及其在车身定型中的应用．汽车技术．No．6，1996，p23-26
[10]汪鸣崎，金国栋．有限元法在汽车车身骨架刚度优化中的应用．汽车技术．No．5，1998，5—7
[11]潘紫微．4m斜刃剪切机架有限元分析．重型机械．No．2，1999，p39—41
[12]李德军．22MN液压机整体框架式机身的有限元分析．塑性工程学报．Vol．2，No．3，1995，p55—62
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