大型曲轴全纤维镦锻成形模拟试验机研制及其应用
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摘要
大型曲轴、船用尾轴、风机增速轴等大型锻件镦锻成形加工工艺难度大、成本高。不合理的成形工艺将导致锻件质量问题,甚至报废,造成巨大的经济损失。因此,大型镦锻件投产前必须进行工艺模拟试验。大型曲轴全纤维镦锻成形模拟试验机可以对各大型锻件镦锻成形加工工艺进行比例模拟,验证其成形工艺及模具设计。
本文以大型曲轴全纤维镦锻成形模拟试验机为研究对象,主要研究工作和成果如下:
1.根据曲轴模拟镦锻试验的要求,提出了镦锻试验机的机械系统构造和具体实施方案。
2.根据试验需求、可靠性和制造成本的要求,提出了基于工控机和NI-7344运动控制器的开放式测控系统配置方案;设计了试验机的测控硬件系统。
3.基于LabVIEW软件平台开发了试验机测控软件系统。该软件系统包括运动控制模块、数据采集模块和控制系统人机界面。
4.对该试验机进行了功能测试。试验结果表明,该试验机可以正常运行,其机械精度,数据采集等各种功能均达到了预期的要求。从而证明了该设备的可行性和可靠性。
5.将该试验机应用于6G32型大型曲轴全纤维镦锻成形工艺模拟,并在试验运行中基本实现了预期的目标,达到了初步的要求。
The upset forging technology, which is used for heavy crankshafts, marine stern shaft, fan shaft and some other large forgings is difficult to achieve and the cost is very high. The quality problem of the forgings is often caused by the unreasonable forming process and sometimes the forgings must be discarded. Hence, simulative engineer test should be done before manufacturing. The upset forging test machine for physical simulation of continuous grain flow forming of large crankshaft is used in providing the analog engineer test equipment in proportion, verifying the forming process and the mold design.
The upset forging test machine for physical simulation of continuous grain flow forming of large crankshaft is studied in this thesis and the following work has been completed:
1. The mechanical system of the device and the scheme are proposed, according to the simulative engineer test.
2. The scheme of open measurement and control system based on the industrial computer and NI-7344 motion controller is proposed, according to the test requirement, machine’s credibility and manufacturing cost demand. The hardware of the measurement and control system is designed.
3. The software of measurement and control system is developed based on the software platform. The system includes the motion control module, data acquire module. Human-computer interface is programmed.
4. The device is tested according to the reasonable means. The result manifests that it can work normally. The mechanical precision and data acquirement are all meet the requirement so that the device has been proved feasibility and reliability.
5. The machine is used in the simulative test of the 6G32 large crankshaft of continuous grain flow. The prospective target has been achieved according to the device test.
本文以大型曲轴全纤维镦锻成形模拟试验机为研究对象,主要研究工作和成果如下:
1.根据曲轴模拟镦锻试验的要求,提出了镦锻试验机的机械系统构造和具体实施方案。
2.根据试验需求、可靠性和制造成本的要求,提出了基于工控机和NI-7344运动控制器的开放式测控系统配置方案;设计了试验机的测控硬件系统。
3.基于LabVIEW软件平台开发了试验机测控软件系统。该软件系统包括运动控制模块、数据采集模块和控制系统人机界面。
4.对该试验机进行了功能测试。试验结果表明,该试验机可以正常运行,其机械精度,数据采集等各种功能均达到了预期的要求。从而证明了该设备的可行性和可靠性。
5.将该试验机应用于6G32型大型曲轴全纤维镦锻成形工艺模拟,并在试验运行中基本实现了预期的目标,达到了初步的要求。
The upset forging technology, which is used for heavy crankshafts, marine stern shaft, fan shaft and some other large forgings is difficult to achieve and the cost is very high. The quality problem of the forgings is often caused by the unreasonable forming process and sometimes the forgings must be discarded. Hence, simulative engineer test should be done before manufacturing. The upset forging test machine for physical simulation of continuous grain flow forming of large crankshaft is used in providing the analog engineer test equipment in proportion, verifying the forming process and the mold design.
The upset forging test machine for physical simulation of continuous grain flow forming of large crankshaft is studied in this thesis and the following work has been completed:
1. The mechanical system of the device and the scheme are proposed, according to the simulative engineer test.
2. The scheme of open measurement and control system based on the industrial computer and NI-7344 motion controller is proposed, according to the test requirement, machine’s credibility and manufacturing cost demand. The hardware of the measurement and control system is designed.
3. The software of measurement and control system is developed based on the software platform. The system includes the motion control module, data acquire module. Human-computer interface is programmed.
4. The device is tested according to the reasonable means. The result manifests that it can work normally. The mechanical precision and data acquirement are all meet the requirement so that the device has been proved feasibility and reliability.
5. The machine is used in the simulative test of the 6G32 large crankshaft of continuous grain flow. The prospective target has been achieved according to the device test.
引文
[1]熊琳.曲轴的设计[M].北京:机械工业出版社,1958
[2]《大型锻件的生产》编写组.大型锻件的生产[M].北京:机械工业出版,1978
[3]龚铭鑫.弯曲镦锻曲轴质量的探讨[J].大型铸锻件,1990,(2):54-56
[4]陈太生.曲轴全纤维弯曲镦锻成形技术RR法、TR法、NTR法对比研究[D](硕士学位论文).天津大学,2005
[5]马金忠,何养民.大型曲轴镦锻生产工艺探讨[J].重型机械,1999,(2):1-3
[6]白雪寒.柴油机曲轴RR锻造工艺[J].机车车辆工艺,1993,(1):23-24
[7]刘正林,杨和庭,李国栋,等.锻造工艺对曲轴安全系数的影响[J].武汉科技大学学报,1995,19(4):375-379
[8]樊志江,孙丹凤.大型全纤维曲轴平衡块成形塌角问题研究[J].大型铸锻件,2009,(4):19-21
[9]樊志江,孙丹凤,孙晓鹏,等.NTR法锻造18V48/60曲轴可行性分析[J].大型铸锻件,2009,(5):14-16
[10]天津重型机械厂锻造处.60000KN水压机弯曲镦锻装置大型全纤维整体曲轴锻造生产介绍[M].1990
[11]牟小维.Gleeble 3500热机模拟试验系统中的数控热扭转单元[J].天津冶金,2007,(3):41-45
[12] FergusonH S, ChenW C.Development of Gleeble System and It's Applications, Journal of Harbin Institute of Technology[J].1996, 28(12): 12-33
[13]骆宗安,苏海龙,张殿华,等.一种新的物理模拟手段MMS100热力模拟实验机的研制[J].塑性工程学报,2003,10(5):57-59
[14]骆宗安,苏海龙,魏谨,等.多功能热力模拟实验机的研制与应用[J].机械工程材料,2006,30(12):60-65
[15]里奇?史密斯,R.基恩?莫布利著,吕川,周栋,马麟译.机械维修使用指南[M].北京:化学工业出版社,2006
[16]王攀峰.基于虚拟仪器技术的五自由度混联机械手TriVariant控制系统设计[D](硕士学位论文).天津大学,2005
[17] Wang S, Shin K G..Reconfigurable software for open architecture controllers [C].IEEE International Conference on Robotics and Automation, 2001, (4): 4090-4095
[18] Ambra Claudio, Oldknow Kevin, Migliorini Giuseppe.The design of a high performance modular CNC system architecture[C].IEEE International Symposiumon Intelligent Control-Proceedings, 2002: 290-296
[19]康存锋,杨建武,费仁元,等.开放式PC型运动控制器的研究[J].中国机械工程,2004,15(9):800-802
[20]文立伟,路华,王永章.基于开放式控制器的六轴数控系统的研究与开发[J].机床与液压,2003(3):32-34
[21]坂本正文著,王自强译.步进电机应用技术[M].北京:科学出版社,2010
[22]强锡富.传感器[M].北京:机械工业出版社,2001
[23]顾宝栋,陈怀海.力传感器动态标定及其精度分析研究[J].振动与冲击,2005,2(24):96-98
[24]廖捷,张琦,李焕良.基于虚拟仪器技术的传感器静态标定仪的设计[J].矿山机械,2005,33(6):79-81
[25]邵东向,李良,王广林.机械工程测试技术基础[M].哈尔滨:哈尔滨工业大学出版社,2003
[26]张晓辉.机器人六维力传感器静态标定研究[J].自动化与仪表,2004,(3):86-88
[27]张洪润,张亚凡.传感技术与实验[M].北京:清华大学出版社,2005
[28]王兰君,张景皓,谭亚林.实用电工控制线路及应用[M].北京:科学出版社,2008
[29]阮礽忠.实用电工控制线路及应用[M].福州:福建科学技术出版社,2009
[30]金涛,付驰,秦树人.虚拟仪器系统中的误差分析与修正,重庆大学学报,2004,27(12):1-4
[31]刘慧军.码垛机器人物流系统研究开发[D](硕士学位论文).天津大学,2008
[32] http://www.ni.com/zhs/
[33] National Instruments Corporation.LabVIEW User Manual[M].2000
[34] Jeffrey Travis, Jim Kring著,乔瑞萍译.LabVIEW大学实用教程[M].北京:电子工业出版社,2008
[35] Nagahiko Shinjo, Larry Buist, Chelakara S.Subramanian.Stepper Motor Control With a PC-Based Data Acquisition Toolkit[C].IEEE Canadian Review -Autumn /Auomne, 1999: 9-14
[36] Wang C, Gao R X.A virtual instrumentation system for integrated bearing condition monitoring Instrumentation and Measurement[C].IEEE Transactions on, 2000, 49(2): 325-332
[37] Hinkson Dezra, Marshall Claude, Robinson.Design and development of a user interface to remotely control a radio telescope using virtual instruments [C].Conference Proceedings - IEEE SOUTHEASTCON, 2002: 279-282
[38]康威,瓦特著,罗霄,周毅译.软件工程方法在LabVIEW中的应用[M].北京:清华大学出版社,2006
[39]阮奇桢.我和LabVIEW——一个NI工程师的十年编程经验[M].北京:北京航空航天大学出版社,2009
[40] Max Thrailkill.Implementing a Test Foundation Framework in LabVIEW [C].IEEE Transactions on Instrumentation and Measurement, 1997.7: 190-193
[41] National Instruments, Measurement and Automation catalog, 2002
[42] National Instruments, LabVIEW Development Guidelines, 2002
[43]杨乐平,李海涛,赵勇,等.LabVIEW高级程序设计[M].北京:清华大学出版社,2003
[44]李方园.人机界面设计与应用[M].北京:化学工业出版社,2008
[45]李乐山.人机界面设计[M].北京:科学出版社,2004
[46]管峻,刘更,贺朝霞,等.基于协同仿真环境的人机界面设计[J].机械设计与制造,2009,(7):246-248
[47]李葆文.简明现代设备管理手册[M].北京:机械工业出版社,2004
[48]曹文钢,陈维.TPM中设备故障处理方法[M].专题论坛及综述,2004,(2):13-15
[49] Wireman Terry.Developing performance indicators for managing maintenance [M].New York, Industrial press inc., Feb.2005
[50]刘希金,刘波,喻红婕,等.数控机床故障检测与维修应答[M].北京:机械工业出版社,2003
[51]王涛.数控系统的可靠性设计理论和方法研究[D](博士学位论文).天津大学,2008
[52]黄锡滋.软件可靠性、安全性与质量保证[M].北京:电子工业出版社,2002
[53]赵振铎,邵明志,张召铎,等.金属塑性成形中的摩擦与润滑[M].北京:化学工业出版社,2004
[54]邹贵生.材料加工系列实验[M].北京:清华大学出版社,2005
[2]《大型锻件的生产》编写组.大型锻件的生产[M].北京:机械工业出版,1978
[3]龚铭鑫.弯曲镦锻曲轴质量的探讨[J].大型铸锻件,1990,(2):54-56
[4]陈太生.曲轴全纤维弯曲镦锻成形技术RR法、TR法、NTR法对比研究[D](硕士学位论文).天津大学,2005
[5]马金忠,何养民.大型曲轴镦锻生产工艺探讨[J].重型机械,1999,(2):1-3
[6]白雪寒.柴油机曲轴RR锻造工艺[J].机车车辆工艺,1993,(1):23-24
[7]刘正林,杨和庭,李国栋,等.锻造工艺对曲轴安全系数的影响[J].武汉科技大学学报,1995,19(4):375-379
[8]樊志江,孙丹凤.大型全纤维曲轴平衡块成形塌角问题研究[J].大型铸锻件,2009,(4):19-21
[9]樊志江,孙丹凤,孙晓鹏,等.NTR法锻造18V48/60曲轴可行性分析[J].大型铸锻件,2009,(5):14-16
[10]天津重型机械厂锻造处.60000KN水压机弯曲镦锻装置大型全纤维整体曲轴锻造生产介绍[M].1990
[11]牟小维.Gleeble 3500热机模拟试验系统中的数控热扭转单元[J].天津冶金,2007,(3):41-45
[12] FergusonH S, ChenW C.Development of Gleeble System and It's Applications, Journal of Harbin Institute of Technology[J].1996, 28(12): 12-33
[13]骆宗安,苏海龙,张殿华,等.一种新的物理模拟手段MMS100热力模拟实验机的研制[J].塑性工程学报,2003,10(5):57-59
[14]骆宗安,苏海龙,魏谨,等.多功能热力模拟实验机的研制与应用[J].机械工程材料,2006,30(12):60-65
[15]里奇?史密斯,R.基恩?莫布利著,吕川,周栋,马麟译.机械维修使用指南[M].北京:化学工业出版社,2006
[16]王攀峰.基于虚拟仪器技术的五自由度混联机械手TriVariant控制系统设计[D](硕士学位论文).天津大学,2005
[17] Wang S, Shin K G..Reconfigurable software for open architecture controllers [C].IEEE International Conference on Robotics and Automation, 2001, (4): 4090-4095
[18] Ambra Claudio, Oldknow Kevin, Migliorini Giuseppe.The design of a high performance modular CNC system architecture[C].IEEE International Symposiumon Intelligent Control-Proceedings, 2002: 290-296
[19]康存锋,杨建武,费仁元,等.开放式PC型运动控制器的研究[J].中国机械工程,2004,15(9):800-802
[20]文立伟,路华,王永章.基于开放式控制器的六轴数控系统的研究与开发[J].机床与液压,2003(3):32-34
[21]坂本正文著,王自强译.步进电机应用技术[M].北京:科学出版社,2010
[22]强锡富.传感器[M].北京:机械工业出版社,2001
[23]顾宝栋,陈怀海.力传感器动态标定及其精度分析研究[J].振动与冲击,2005,2(24):96-98
[24]廖捷,张琦,李焕良.基于虚拟仪器技术的传感器静态标定仪的设计[J].矿山机械,2005,33(6):79-81
[25]邵东向,李良,王广林.机械工程测试技术基础[M].哈尔滨:哈尔滨工业大学出版社,2003
[26]张晓辉.机器人六维力传感器静态标定研究[J].自动化与仪表,2004,(3):86-88
[27]张洪润,张亚凡.传感技术与实验[M].北京:清华大学出版社,2005
[28]王兰君,张景皓,谭亚林.实用电工控制线路及应用[M].北京:科学出版社,2008
[29]阮礽忠.实用电工控制线路及应用[M].福州:福建科学技术出版社,2009
[30]金涛,付驰,秦树人.虚拟仪器系统中的误差分析与修正,重庆大学学报,2004,27(12):1-4
[31]刘慧军.码垛机器人物流系统研究开发[D](硕士学位论文).天津大学,2008
[32] http://www.ni.com/zhs/
[33] National Instruments Corporation.LabVIEW User Manual[M].2000
[34] Jeffrey Travis, Jim Kring著,乔瑞萍译.LabVIEW大学实用教程[M].北京:电子工业出版社,2008
[35] Nagahiko Shinjo, Larry Buist, Chelakara S.Subramanian.Stepper Motor Control With a PC-Based Data Acquisition Toolkit[C].IEEE Canadian Review -Autumn /Auomne, 1999: 9-14
[36] Wang C, Gao R X.A virtual instrumentation system for integrated bearing condition monitoring Instrumentation and Measurement[C].IEEE Transactions on, 2000, 49(2): 325-332
[37] Hinkson Dezra, Marshall Claude, Robinson.Design and development of a user interface to remotely control a radio telescope using virtual instruments [C].Conference Proceedings - IEEE SOUTHEASTCON, 2002: 279-282
[38]康威,瓦特著,罗霄,周毅译.软件工程方法在LabVIEW中的应用[M].北京:清华大学出版社,2006
[39]阮奇桢.我和LabVIEW——一个NI工程师的十年编程经验[M].北京:北京航空航天大学出版社,2009
[40] Max Thrailkill.Implementing a Test Foundation Framework in LabVIEW [C].IEEE Transactions on Instrumentation and Measurement, 1997.7: 190-193
[41] National Instruments, Measurement and Automation catalog, 2002
[42] National Instruments, LabVIEW Development Guidelines, 2002
[43]杨乐平,李海涛,赵勇,等.LabVIEW高级程序设计[M].北京:清华大学出版社,2003
[44]李方园.人机界面设计与应用[M].北京:化学工业出版社,2008
[45]李乐山.人机界面设计[M].北京:科学出版社,2004
[46]管峻,刘更,贺朝霞,等.基于协同仿真环境的人机界面设计[J].机械设计与制造,2009,(7):246-248
[47]李葆文.简明现代设备管理手册[M].北京:机械工业出版社,2004
[48]曹文钢,陈维.TPM中设备故障处理方法[M].专题论坛及综述,2004,(2):13-15
[49] Wireman Terry.Developing performance indicators for managing maintenance [M].New York, Industrial press inc., Feb.2005
[50]刘希金,刘波,喻红婕,等.数控机床故障检测与维修应答[M].北京:机械工业出版社,2003
[51]王涛.数控系统的可靠性设计理论和方法研究[D](博士学位论文).天津大学,2008
[52]黄锡滋.软件可靠性、安全性与质量保证[M].北京:电子工业出版社,2002
[53]赵振铎,邵明志,张召铎,等.金属塑性成形中的摩擦与润滑[M].北京:化学工业出版社,2004
[54]邹贵生.材料加工系列实验[M].北京:清华大学出版社,2005