基于ANSYS Workbench的精冲模具-压力机一体化结构分析
摘要
精密冲裁是一种先进的板料成形工艺,具有产品成形质量好,材料利用率高等优点。但是精冲行业普遍存在模具开发周期长、寿命低的问题,严重制约了精冲技术的发展。计算机辅助分析技术能够在设计阶段就对模具的工作状况进行预测,是优化精冲工艺、辅助模具结构设计的重要工具。本文以ANSYS Workbench有限元分析软件为平台,对精冲模具和精冲压力机结构的计算机辅助分析方面进行了深入的研究。
本文首先对密封盖零件和TJB9棘轮零件的成形工艺进行了分析,运用ANSYSWorkbench软件对这两种零件的模具分别进行了静力结构分析,预测了模具的等效应力和变形分布,总结和归纳了精冲模具结构分析前处理的一般设置方法,并利用分析结果对密封盖结构进行了优化,在实际生产中有效解决了密封盖零件加工精度低和模具寿命短的问题。
在模具结构静力分析的基础上,本文对模具和压力机整体结构进行了有限元分析,得到了在工作状况下压力机机身和模具的变形情况,更真实的反映模具在工作时的状况;并通过改变压力机机身导轨与滑块之间的间隙值,对多种不同间隙情况下的压力机和模具进行有限元分析,分别得到了不同间隙情况下压力机和模具的变形状况,并通过对比不同结果分析了导轨间隙对模具和压力机整体刚度的影响。
本文最后提出了在ANSYS Workbench软件平台下开发精冲模具CAE系统的方案;以模具实例分析为基础,结合企业的实际需要对系统进行了需求分析,并对系统的总体框架进行了设计。
Fine-blanking is an advanced processing method which has many advantages,suchas high quality of products and high utilization of materials. However,there are manyproblems existed in fine-blanking industry such as a long development cycle and low lifeof die, which are seriously hampering the development of fine-blanking technology.Computer-aided analyzing technology can predict the working states in the design stage.It is an important tool to optimize the fine-blanking techniques and design the diestructure. In this thesis a thorough research on computer-aided analyze of die and press isconducted on the base of ANSYS Workbench software platform.
The forming process of the sealing cover and ratchet part are introduced firstly inthis thesis. ANSYS Workbench is used to carry on the static structure analysis to the dieof the two kinds of part. The stress and deformation distribution of die are predicted andthe method of the pre-processing setting for analyzing the structure of fine-blanking dieis summarized through the simulation. According to the simulation results, the structureof sealing cover is optimized, and great achievements are made in practical production.
On the foundation of the static analysis of die, finite element analysis of dieassembled with press is carried. The simulation results of both die and frame of press areobtained which reflect the working states of die more truly. What’s more, by changingthe value of the gap between the slider and rails, finite element analysis of press and dieunder different states are taken respectively. Through compare the different results, howgap influencing the overall stiffness of press and die is found out.
Finally, the program of developing a CAE system for fine blanking die on the basicof ANSYS Workbench platform is put forward in the thesis. The demands for the systemare summarized and the overall framework of the system is designed.
本文首先对密封盖零件和TJB9棘轮零件的成形工艺进行了分析,运用ANSYSWorkbench软件对这两种零件的模具分别进行了静力结构分析,预测了模具的等效应力和变形分布,总结和归纳了精冲模具结构分析前处理的一般设置方法,并利用分析结果对密封盖结构进行了优化,在实际生产中有效解决了密封盖零件加工精度低和模具寿命短的问题。
在模具结构静力分析的基础上,本文对模具和压力机整体结构进行了有限元分析,得到了在工作状况下压力机机身和模具的变形情况,更真实的反映模具在工作时的状况;并通过改变压力机机身导轨与滑块之间的间隙值,对多种不同间隙情况下的压力机和模具进行有限元分析,分别得到了不同间隙情况下压力机和模具的变形状况,并通过对比不同结果分析了导轨间隙对模具和压力机整体刚度的影响。
本文最后提出了在ANSYS Workbench软件平台下开发精冲模具CAE系统的方案;以模具实例分析为基础,结合企业的实际需要对系统进行了需求分析,并对系统的总体框架进行了设计。
Fine-blanking is an advanced processing method which has many advantages,suchas high quality of products and high utilization of materials. However,there are manyproblems existed in fine-blanking industry such as a long development cycle and low lifeof die, which are seriously hampering the development of fine-blanking technology.Computer-aided analyzing technology can predict the working states in the design stage.It is an important tool to optimize the fine-blanking techniques and design the diestructure. In this thesis a thorough research on computer-aided analyze of die and press isconducted on the base of ANSYS Workbench software platform.
The forming process of the sealing cover and ratchet part are introduced firstly inthis thesis. ANSYS Workbench is used to carry on the static structure analysis to the dieof the two kinds of part. The stress and deformation distribution of die are predicted andthe method of the pre-processing setting for analyzing the structure of fine-blanking dieis summarized through the simulation. According to the simulation results, the structureof sealing cover is optimized, and great achievements are made in practical production.
On the foundation of the static analysis of die, finite element analysis of dieassembled with press is carried. The simulation results of both die and frame of press areobtained which reflect the working states of die more truly. What’s more, by changingthe value of the gap between the slider and rails, finite element analysis of press and dieunder different states are taken respectively. Through compare the different results, howgap influencing the overall stiffness of press and die is found out.
Finally, the program of developing a CAE system for fine blanking die on the basicof ANSYS Workbench platform is put forward in the thesis. The demands for the systemare summarized and the overall framework of the system is designed.
引文
[1]周开华,幺廷先,齐翔宪编.简明精冲手册[M].北京:国防工业出版社,1993
[2]程万军,何忠保,刘化民.齿圈压板精密冲裁的力学分析[J].锻压技术,2001,(4):22~23
[3]黎光启.厚板零件冲裁经验点滴[J].锻压机械,1995,(2):21~22
[4]涂光祺.精冲技术[M].北京:机械工业出版社,2005
[5]张正修,李欠娃.高精度仪表零件的整修与精冲[J].模具制造,2005,(11):17~20
[6]贾建军,彭颖红,阮雪榆.精冲断裂过程的有限元模拟[J].上海交通大学学报,2003,37(7),1064~1067
[7]邓明,彭成允,颜井刚.板状精密轮廓零件的精冲成形[J].机械设计与制造工程,2001,30 (4):68~69
[8]邹济林.精密冲裁及其相关技术[J].模具制造,2001,(5):24~26
[9] Bradley N Maker,Xinhai Zhu.Input Parameter for Metal Forming Simulation usingLS-DYNA [J].Livermore Software Technology Corporation,2000,(4):465
[10] Meada T, Nakagawa T.Experimental investigation on fine-blanking[J].ScientificPapers of the Institute of Physical and Chemical Research,1968,(62):65~80
[11] Johnson R, Fogg B, Chisholm AW.An investigation into the fine-blankingprocess[C].Proceedings of the Ninth International Machine Tool Design andResearch Conference,vol. 9,Birmingham,1968:397~410
[12]黄毅宏.精冲工艺及其机理探讨[J].中国机械工程,1994,(5):57~59
[13] L.C. Chan, Y.C. Leung,T.C. Lee, J.P. Fan, C.Y. Tang.Numerical simulation forfine-blanking-a new approach[J].Materials Science and Engineering,2004,(A364):207~215
[14] Clift L. Hartley P, Sturgess CEN, Rowe GW.Fracture prediction in plasticdeformation process[J].International Journal of Mechanical Sciences,1990:l~17
[15]郑鹏飞,彭群,杨瑞锋.精冲技术的发展[J].机械工人(热加工),2002,(9):36~38
[16]丘宏扬,陈依锦.如何防止精冲模具裂纹的产生和扩展[J].锻压机械, 2002,(5):65~67
[17]杜贵江,彭群,许庆华,贾铭钰.复杂齿形类零件精冲技术的研究[J].机械工人(热加工),2005,(9):85~86
[18]李艳霞,邓明,吕琳.精冲机的现状及发展趋势[J].锻压装备与制造技术,2008,(1):15~17
[19]龙安.精冲工艺的数值模拟与实验研究[D].武汉:武汉理工大学, 2007
[20] Sehiess Feorrer F.Gasehichle desersien Feinschnitt-stanzwerkes Sehiess[M].FritzSehiess U. Co. Liehtenseig,1970
[21]周开华.精冲技术的发展与应用[J].模具制造,2008,(3):1~7
[22]许发樾.模具标准化与现代模具生产技术[J].模具制造,2004,(6):1~2
[23]王新华.精冲技术在我国汽车工业中的应用[J].模具工业,1994,(1):23~24
[24]邓明.国内外精密冲裁技术的现状及发展[J].锻压装备与制造技术,2004,(01):10~13
[25] L. C. Chan, et al.Experimental study on the shearing behavior of fine-blankingversus bar cropping[J].Journal of Materials Processing Technology.1998,(80):126~130
[26] Z.H. Chen,L.C. Chan,T.C. Lee,C.Y. Tang.An investigation on the formation andpropagation of shear band in fine-blanking process[J].Journal of MaterialsProcessing Technology.2003,(138):610~614
[27] T.C. Lee,L.C. Chan, P.F. Zheng.Application of the finite-element deformationmethod in the fine blanking process[J] . Journal of Materials ProcessingTechnology,1997,(63):744~749
[28]孙伦宝,程补元,周曾猛.精密冲裁变形过程的理论分析[J].装备环境工程,1990,(3):15~21
[29] Buderns, Feintool, Hoesch.Cold Forming and Fine blanking [M].France:1997
[30] Sutasn Thipprakmas, Masahiko Jin, Kanaizuka Tomokazu . Prediction ofFineblanked surface characteristics using the finite element method(FEM)[J].Journal of materials processing technology,2008,(198):391~398
[31] Konig W, Rotter F, Krapoth A.Feinschneiden Dicker Bleche-Experiment andTheorie[J].Industrie-Anzeiger,1984,106(14):24~28
[32]赵震,谢晓龙.AISI- 1035钢精冲成形与断裂的数值模拟[J].模具工业,2005(7):13~16
[33] Chen Z H, Tang C Y, Lee T C, et al.Numerical simulation of fine-blanking processusing a mixed finite element method[J].International Journal of MechanicalSciences,2002,44 (7):1309~1333
[34]温莉敏,许树勤.压边圈齿距与精冲质量的关系研究[J].锻压装备与制造技术,2006,(01):54~56
[35]龙安,胡建华,王羽,胡锐.圆盘件精冲工艺的数值模拟与分析[J].热加工工艺,2007,36(01):82~84
[36]谢峰,雷小宝,林巨广,周强.C型压力机机身的有限元分析与优化[J].机械工程师,2007,(07):25~27
[37] Neumann M, Hahn H.Computer simulation and dynamic analysis of a mechanicalpress based on different engineer models[J].Mathematics and Computers inSimulation,1998,(46):559~574
[38]张皓,贾方,王兴松.闭式压力机组合机身的有限元分析[J].锻压装备与制造技术,2006,(04):32~35
[39]秦东晨,祁建中,张明成,武红霞,陈江义.液压机横梁结构的优化设计[J].锻压技术,2004,(02):49~52
[40] Chandrup T.Introduction to Finite Element in Engineering [C].New Jersey:Prentice Hall,1993
[41] ANSYS Training Manual for DesignSpace& Workbench Environment [M].ANSYSInc.,2005
[42]曾锐,平丽浩.基于Workbench的多学科仿真分析平台开发.2007年机械电子学学术会议论文集[C],2008
[43]李兵,何正嘉,陈雪峰.ANSYS Workbench设计、仿真与优化[M].北京:清华大学出版社,2008
[44]陈良.有限元分析在精冲模结构设计中的应用[D].武汉:华中科技大学, 2007
[45]石其年.提高冲裁模具使用寿命的途径与分析[J].锻压装备与制造技术,2006,(5):63~66
[46]贾俐俐.挤压工艺及模具[M].北京:机械工业出版社,2004
[47]杨长顺.冷挤压模具设计[M].北京:国防工业出版社,1994
[2]程万军,何忠保,刘化民.齿圈压板精密冲裁的力学分析[J].锻压技术,2001,(4):22~23
[3]黎光启.厚板零件冲裁经验点滴[J].锻压机械,1995,(2):21~22
[4]涂光祺.精冲技术[M].北京:机械工业出版社,2005
[5]张正修,李欠娃.高精度仪表零件的整修与精冲[J].模具制造,2005,(11):17~20
[6]贾建军,彭颖红,阮雪榆.精冲断裂过程的有限元模拟[J].上海交通大学学报,2003,37(7),1064~1067
[7]邓明,彭成允,颜井刚.板状精密轮廓零件的精冲成形[J].机械设计与制造工程,2001,30 (4):68~69
[8]邹济林.精密冲裁及其相关技术[J].模具制造,2001,(5):24~26
[9] Bradley N Maker,Xinhai Zhu.Input Parameter for Metal Forming Simulation usingLS-DYNA [J].Livermore Software Technology Corporation,2000,(4):465
[10] Meada T, Nakagawa T.Experimental investigation on fine-blanking[J].ScientificPapers of the Institute of Physical and Chemical Research,1968,(62):65~80
[11] Johnson R, Fogg B, Chisholm AW.An investigation into the fine-blankingprocess[C].Proceedings of the Ninth International Machine Tool Design andResearch Conference,vol. 9,Birmingham,1968:397~410
[12]黄毅宏.精冲工艺及其机理探讨[J].中国机械工程,1994,(5):57~59
[13] L.C. Chan, Y.C. Leung,T.C. Lee, J.P. Fan, C.Y. Tang.Numerical simulation forfine-blanking-a new approach[J].Materials Science and Engineering,2004,(A364):207~215
[14] Clift L. Hartley P, Sturgess CEN, Rowe GW.Fracture prediction in plasticdeformation process[J].International Journal of Mechanical Sciences,1990:l~17
[15]郑鹏飞,彭群,杨瑞锋.精冲技术的发展[J].机械工人(热加工),2002,(9):36~38
[16]丘宏扬,陈依锦.如何防止精冲模具裂纹的产生和扩展[J].锻压机械, 2002,(5):65~67
[17]杜贵江,彭群,许庆华,贾铭钰.复杂齿形类零件精冲技术的研究[J].机械工人(热加工),2005,(9):85~86
[18]李艳霞,邓明,吕琳.精冲机的现状及发展趋势[J].锻压装备与制造技术,2008,(1):15~17
[19]龙安.精冲工艺的数值模拟与实验研究[D].武汉:武汉理工大学, 2007
[20] Sehiess Feorrer F.Gasehichle desersien Feinschnitt-stanzwerkes Sehiess[M].FritzSehiess U. Co. Liehtenseig,1970
[21]周开华.精冲技术的发展与应用[J].模具制造,2008,(3):1~7
[22]许发樾.模具标准化与现代模具生产技术[J].模具制造,2004,(6):1~2
[23]王新华.精冲技术在我国汽车工业中的应用[J].模具工业,1994,(1):23~24
[24]邓明.国内外精密冲裁技术的现状及发展[J].锻压装备与制造技术,2004,(01):10~13
[25] L. C. Chan, et al.Experimental study on the shearing behavior of fine-blankingversus bar cropping[J].Journal of Materials Processing Technology.1998,(80):126~130
[26] Z.H. Chen,L.C. Chan,T.C. Lee,C.Y. Tang.An investigation on the formation andpropagation of shear band in fine-blanking process[J].Journal of MaterialsProcessing Technology.2003,(138):610~614
[27] T.C. Lee,L.C. Chan, P.F. Zheng.Application of the finite-element deformationmethod in the fine blanking process[J] . Journal of Materials ProcessingTechnology,1997,(63):744~749
[28]孙伦宝,程补元,周曾猛.精密冲裁变形过程的理论分析[J].装备环境工程,1990,(3):15~21
[29] Buderns, Feintool, Hoesch.Cold Forming and Fine blanking [M].France:1997
[30] Sutasn Thipprakmas, Masahiko Jin, Kanaizuka Tomokazu . Prediction ofFineblanked surface characteristics using the finite element method(FEM)[J].Journal of materials processing technology,2008,(198):391~398
[31] Konig W, Rotter F, Krapoth A.Feinschneiden Dicker Bleche-Experiment andTheorie[J].Industrie-Anzeiger,1984,106(14):24~28
[32]赵震,谢晓龙.AISI- 1035钢精冲成形与断裂的数值模拟[J].模具工业,2005(7):13~16
[33] Chen Z H, Tang C Y, Lee T C, et al.Numerical simulation of fine-blanking processusing a mixed finite element method[J].International Journal of MechanicalSciences,2002,44 (7):1309~1333
[34]温莉敏,许树勤.压边圈齿距与精冲质量的关系研究[J].锻压装备与制造技术,2006,(01):54~56
[35]龙安,胡建华,王羽,胡锐.圆盘件精冲工艺的数值模拟与分析[J].热加工工艺,2007,36(01):82~84
[36]谢峰,雷小宝,林巨广,周强.C型压力机机身的有限元分析与优化[J].机械工程师,2007,(07):25~27
[37] Neumann M, Hahn H.Computer simulation and dynamic analysis of a mechanicalpress based on different engineer models[J].Mathematics and Computers inSimulation,1998,(46):559~574
[38]张皓,贾方,王兴松.闭式压力机组合机身的有限元分析[J].锻压装备与制造技术,2006,(04):32~35
[39]秦东晨,祁建中,张明成,武红霞,陈江义.液压机横梁结构的优化设计[J].锻压技术,2004,(02):49~52
[40] Chandrup T.Introduction to Finite Element in Engineering [C].New Jersey:Prentice Hall,1993
[41] ANSYS Training Manual for DesignSpace& Workbench Environment [M].ANSYSInc.,2005
[42]曾锐,平丽浩.基于Workbench的多学科仿真分析平台开发.2007年机械电子学学术会议论文集[C],2008
[43]李兵,何正嘉,陈雪峰.ANSYS Workbench设计、仿真与优化[M].北京:清华大学出版社,2008
[44]陈良.有限元分析在精冲模结构设计中的应用[D].武汉:华中科技大学, 2007
[45]石其年.提高冲裁模具使用寿命的途径与分析[J].锻压装备与制造技术,2006,(5):63~66
[46]贾俐俐.挤压工艺及模具[M].北京:机械工业出版社,2004
[47]杨长顺.冷挤压模具设计[M].北京:国防工业出版社,1994