结晶器搅拌桨快速设计与制造关键技术研究
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摘要
工业结晶技术是一种高效低能耗、低污染的制造与分离技术,是化工、医药等行业的关键技术之一。搅拌桨是搅拌釜式结晶器的关键部件,桨的结构和叶形决定了釜内溶液的整体流动形式。搅拌桨传统设计/制造方法为仿船用螺旋桨的图谱设计法,需查表计算、手工制造,其过程信息共享度低、周期长,难以保证桨的质量,且无法预测桨的流体动力性能。本文以实现结晶器搅拌桨优质高效的设计/制造为目标,针对搅拌桨CAD/CAE/CAM集成、搅拌桨结构优化和数控加工工艺等关键问题进行了系统的研究,取得如下创新性研究成果:
1.提出搅拌桨集成制造的创新思想,构建了搅拌桨CAD/CAE/CAM集成制造系统的总体框架。采用基于特征的面向对象技术建立了集成化的搅拌桨数据模型,为搅拌桨设计、制造各环节提供了统一的产品数据模型。该系统克服了搅拌桨传统设计与制造各环节相互脱节、信息共享度低的缺陷。实现了搅拌桨CAD、CAE与CAM各环节的有效集成和信息共享,大大缩短了搅拌桨的设计/制造周期。
2.提出了一种新的大型螺旋式搅拌桨的结构设计方法,即分体设计/制造桨叶和桨毂,整体焊接组装的方法,解决了大尺寸搅拌桨的加工受机床加工范围限制的难题。应用CFD(Calculating Fluid Dynamics)分析软件FLUENT对分体式组装桨进行了结构参数的优化设计,优化了叶根几何形状。基于固体力学分析,应用ANSYS软件对桨叶进行强度和刚度校核,优化了桨叶的厚度。优化后的搅拌桨即保证了搅拌效果,又减轻了桨的重量,并减少了后续组装时的焊接工作量。
3.研究了搅拌桨数控加工工艺,提出五轴数控铣削搅拌桨木模的新方法。该方法利用自行开发的搅拌桨建模平台,建立了搅拌桨铸造毛坯木模的三维数据模型,生成木模的五轴加工程序,完成了木模的加工,从而提高了搅拌桨毛坯的铸造精度。并通过实验研究,得出球头铣刀铣削不锈钢时铣削力经验公式,为数控铣削不锈钢搅拌桨推荐了合理的切削参数。
4.基于UG平台,应用其二次开发工具OPEN GRIP开发了搅拌桨快速设计与制造集成系统,基于螺旋桨结构开发了适用于常用桨型的搅拌桨型值点计算模块,建立了搅拌桨三维实体模型。以880型螺旋桨式搅拌桨为例,完成其设计和加工。实际验证,搅拌桨的设计/制造周期比传统方法提高了近3-5倍,加工精度得到显著提高。经动平衡检验后使用,搅拌效果良好。
上述创新成果丰富了工业结晶装备的设计/制造技术,并增加了我国结晶器成套装置的技术含量。
Industrial Crystal Process is one of the key technologies on chemical and pharmacy industry. It is a kind of manufacturing and separating technologies, which is of high efficiency and low energy-consuming and environment friendly. Stirrer is a crucial component of stirring type crystallizer; the geometry shape and dimension of Stirrer determine the flow field in the crystallizer. The traditional design & manufacturing process of stirrers is calculating the surface of marine propeller from table of offsets, which is low information-sharing and time-consuming. The quality of propeller cannot be ensured and the dynamic flow performance couldn’t also be forecasted by this method. In order to realize rapid design & manufacturing for crystallizer propeller, this paper systemically studies the key problems, such as the CAD/CAE/CAM integration technology, the optimizing technology for propeller structure parameters and NC milling process of propeller, and etc, which are critical factors in the rapid design & manufacturing of crystallizer propeller. The main contents and innovation are as following:
1. The innovation idea of integrated manufacturing is presented for crystallizer propeller. The whole frame of CAD/CAE/CAM integrated system of propeller is constructed. OO (Object Oriented) technology based on the feature is applied to set up the integrated propeller data model, which provides a united propeller data model for the whole design and manufacturing process of propeller. The system gets rid of the defect of traditional method, in which every stage such as design、analysis and manufacturing is separated independently and messages cannot be shared in different stages. Using our method, all stages such as CAD, CAE and CAM for propeller are integrated effectively and the messages are shared widely. The cycle of propeller design & manufacturing is shortened greatly.
2. A new structure design method is proposed for large propeller. The blades and hub of the propeller are designed and manufactured separately and assembled by welding. This method solves the machining problem for large propeller. The main structure parameters of propeller and shape of root of blade are optimized for propeller assembling by using Calculating Fluid Dynamics software. And on the basis of Solid Dynamics Analyzing, the intensity and rigidity of propeller are checked by using ANSYS software, in order to optimize the thickness of blade. The weight of propeller be optimized is more light and needs less jointing work for assembly.
3. The NC machining process of propeller is studied and a new 5-axis based NC milling process of propeller casting wood-model was also proposed. The 3D math data of propeller was built based on the propeller design platform and 5-axis NC milling code for machining propeller casting wood-model was also generated. The casting wood-model made by this method has higher casting precision and quality. The fixing method of propeller is determined, and the special clamp and assistant support is designed for machining propeller in 3-axis NC machine tool. We also studied NC machining tool path plan for stainless steel propeller. At last, the tool path is checked. According to the principle of Taguchi design of experiments method, predictive cutting force models are developed, and the recommendation values of the ball-end milling parameter are presented for casting stainless steel propeller-blade. Reasonable high speed milling parameters of the flat-end milling are obtained in machining smooth blade area exactly by high speed milling experiments.
4. Basing on the UG software platform, the propeller rapid design & manufacturing integrated system is developed by using OPEN GRIP redevelopment tool. An algorithm is introduced to calculate feature points of propeller and the 3D math data of propeller is constructed. As an example, the 880 propeller was designed and machined, in which the above method is used. Because of high productivity and good machining quality in the process, the result of this research task is satisfied.
The above research results enriches the design and manufacturing technology of industry crystal facility and raises hi-tech value in the crystallizer whole set in our country.
1.提出搅拌桨集成制造的创新思想,构建了搅拌桨CAD/CAE/CAM集成制造系统的总体框架。采用基于特征的面向对象技术建立了集成化的搅拌桨数据模型,为搅拌桨设计、制造各环节提供了统一的产品数据模型。该系统克服了搅拌桨传统设计与制造各环节相互脱节、信息共享度低的缺陷。实现了搅拌桨CAD、CAE与CAM各环节的有效集成和信息共享,大大缩短了搅拌桨的设计/制造周期。
2.提出了一种新的大型螺旋式搅拌桨的结构设计方法,即分体设计/制造桨叶和桨毂,整体焊接组装的方法,解决了大尺寸搅拌桨的加工受机床加工范围限制的难题。应用CFD(Calculating Fluid Dynamics)分析软件FLUENT对分体式组装桨进行了结构参数的优化设计,优化了叶根几何形状。基于固体力学分析,应用ANSYS软件对桨叶进行强度和刚度校核,优化了桨叶的厚度。优化后的搅拌桨即保证了搅拌效果,又减轻了桨的重量,并减少了后续组装时的焊接工作量。
3.研究了搅拌桨数控加工工艺,提出五轴数控铣削搅拌桨木模的新方法。该方法利用自行开发的搅拌桨建模平台,建立了搅拌桨铸造毛坯木模的三维数据模型,生成木模的五轴加工程序,完成了木模的加工,从而提高了搅拌桨毛坯的铸造精度。并通过实验研究,得出球头铣刀铣削不锈钢时铣削力经验公式,为数控铣削不锈钢搅拌桨推荐了合理的切削参数。
4.基于UG平台,应用其二次开发工具OPEN GRIP开发了搅拌桨快速设计与制造集成系统,基于螺旋桨结构开发了适用于常用桨型的搅拌桨型值点计算模块,建立了搅拌桨三维实体模型。以880型螺旋桨式搅拌桨为例,完成其设计和加工。实际验证,搅拌桨的设计/制造周期比传统方法提高了近3-5倍,加工精度得到显著提高。经动平衡检验后使用,搅拌效果良好。
上述创新成果丰富了工业结晶装备的设计/制造技术,并增加了我国结晶器成套装置的技术含量。
Industrial Crystal Process is one of the key technologies on chemical and pharmacy industry. It is a kind of manufacturing and separating technologies, which is of high efficiency and low energy-consuming and environment friendly. Stirrer is a crucial component of stirring type crystallizer; the geometry shape and dimension of Stirrer determine the flow field in the crystallizer. The traditional design & manufacturing process of stirrers is calculating the surface of marine propeller from table of offsets, which is low information-sharing and time-consuming. The quality of propeller cannot be ensured and the dynamic flow performance couldn’t also be forecasted by this method. In order to realize rapid design & manufacturing for crystallizer propeller, this paper systemically studies the key problems, such as the CAD/CAE/CAM integration technology, the optimizing technology for propeller structure parameters and NC milling process of propeller, and etc, which are critical factors in the rapid design & manufacturing of crystallizer propeller. The main contents and innovation are as following:
1. The innovation idea of integrated manufacturing is presented for crystallizer propeller. The whole frame of CAD/CAE/CAM integrated system of propeller is constructed. OO (Object Oriented) technology based on the feature is applied to set up the integrated propeller data model, which provides a united propeller data model for the whole design and manufacturing process of propeller. The system gets rid of the defect of traditional method, in which every stage such as design、analysis and manufacturing is separated independently and messages cannot be shared in different stages. Using our method, all stages such as CAD, CAE and CAM for propeller are integrated effectively and the messages are shared widely. The cycle of propeller design & manufacturing is shortened greatly.
2. A new structure design method is proposed for large propeller. The blades and hub of the propeller are designed and manufactured separately and assembled by welding. This method solves the machining problem for large propeller. The main structure parameters of propeller and shape of root of blade are optimized for propeller assembling by using Calculating Fluid Dynamics software. And on the basis of Solid Dynamics Analyzing, the intensity and rigidity of propeller are checked by using ANSYS software, in order to optimize the thickness of blade. The weight of propeller be optimized is more light and needs less jointing work for assembly.
3. The NC machining process of propeller is studied and a new 5-axis based NC milling process of propeller casting wood-model was also proposed. The 3D math data of propeller was built based on the propeller design platform and 5-axis NC milling code for machining propeller casting wood-model was also generated. The casting wood-model made by this method has higher casting precision and quality. The fixing method of propeller is determined, and the special clamp and assistant support is designed for machining propeller in 3-axis NC machine tool. We also studied NC machining tool path plan for stainless steel propeller. At last, the tool path is checked. According to the principle of Taguchi design of experiments method, predictive cutting force models are developed, and the recommendation values of the ball-end milling parameter are presented for casting stainless steel propeller-blade. Reasonable high speed milling parameters of the flat-end milling are obtained in machining smooth blade area exactly by high speed milling experiments.
4. Basing on the UG software platform, the propeller rapid design & manufacturing integrated system is developed by using OPEN GRIP redevelopment tool. An algorithm is introduced to calculate feature points of propeller and the 3D math data of propeller is constructed. As an example, the 880 propeller was designed and machined, in which the above method is used. Because of high productivity and good machining quality in the process, the result of this research task is satisfied.
The above research results enriches the design and manufacturing technology of industry crystal facility and raises hi-tech value in the crystallizer whole set in our country.
引文
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