液压机系列装备机械耦合刚度标准化研究
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摘要
液压机是制造业的基础，随着我国大轮船、大飞机、核电、化工等大型项目的实施，如何使液压机系列化、高刚度、轻量化变的尤为重要。本文以大型六轴数控回转压头框式液压机THP34Y-1000G、THP34Y-1500D为样机，对液压机系列装备机械耦合刚度进行了标准化研究。
1．船首船尾典型板材成型件工艺分析。提出了通过控制移动液压机压头及工作台位置，对板材进行不同位置的精确压制；通过控制液压机压头及工作台的回转角度，对板材复杂曲面进行精确压制的方法。利用通用模具，通过控制凸模的压下量得到不同曲度板材，并对压下量的控制进行了精确量化，制成了通用表格，为船首船尾典型板材成型件的成型提供了方便。在此基础上，对液压机的成形精度提出了要求。
2．对大型六轴数控回转压头框式液压机进行了刚度有限元分析及样机检测。本文采用制件，模具，装备耦合刚度分析研究方法，建立制件、模具和机身结构耦合刚度分析模型，通过软件接口，将各实体模型的数据进行传送，完成有限元分析。采用激光跟踪仪对大型六轴数控回转压头框式液压机THP34Y-1000G、THP34Y-1500D样机进行荷刚度检测，获得刚度检测数据。两种方法对液压机刚度分析结果高度一致，误差保持在10%以内，验证了液压机产品设计模型进行计算机模拟分析结果的可靠性，使有限元分析可为以后的研究提供更广泛的准确的数据库。
3．根据THP34Y-1000G液压机有限元分析及样机检测的结果，在考虑模具结构刚度和机身预紧-加载条件下，分析上、下横梁承载后的变形规律。用方程对液压机在不同载荷下的变形进行了非线性曲线方程回归，并在THP34Y-1500D液压机上得到了验证。该回归方程可用来预测液压机刚度。
4．提出了根据灵敏度提取大型六轴数控回转压头框式液压机结构部件的优化设计参量的方法。采用制件，模具，装备耦合刚度分析研究方法，建立参数化的主机有限元分析模型，进行主机上横梁和下横梁结构参数的质量灵敏度分析、刚度灵敏度分析。综合质量灵敏度和刚度灵敏度，以整机质量小、刚度大为目标，提取对整机质量及刚度影响显著的关键结构参数，上横梁提取出上横梁肋板厚度、上横梁侧板厚度，下横梁提取出下横梁肋板厚度、下横梁侧板厚度，将这四个结构参数作为该类型液压机的优化设计参量。
5．基于制件-模具-组合框架式机身刚度分析，建立人工神经网络模型，进行优化设计。针对根据灵敏度对大型六轴数控回转压头框式液压机THP34Y-1000G上下横梁提出的四个关键结构参数：上横梁肋板厚度、上横梁侧板厚度、下横梁肋板厚度、下横梁侧板厚度，并添加压机载荷和该类型液压机特有的工艺参数——液压机压头工作台位置，对该液压机进行了优化设计，之后不仅达到了轻量化，同时大大提高了液压机的机械耦合刚度。以上可为其它类似液压机的标准化设计研究提供经验。
Hydraulic press is the foundation of manufacturing industry, along with the large ships,aircraft, nuclear power, chemical and other large projects in our country, how to make thehydraulic machine series, high stiffness, and light weight is particularly important. Based onthe Large-scale Six Axes Numerical Control Locomotive Gyratory Head Frame TypeHydraulic Press THP34Y-1000G, THP34Y-1500D as the prototype, the hydraulic machineseries equipment mechanical coupling stiffness were researched in this thesis.
1. Analysis of typical sheet molding process. The method that the different position ofthe ship sheet is accurate pressed through controlling the mobile hydraulic pressure head andposition is put forward. The typical sheet is processed using the general mold, and through thedifferent capacity of press. All of it is a convenient to the process of ship sheet. On the basis,accurate requirements to hydraulic press are advanced.
2. The stiffness of Frame Type Hydraulic Press with Large-scale Six Axes NumericalControl Locomotive Gyratory Head is tested through element analysis and test. With thecoupled stiffness analysis method, to build parts, mold and the hydraulic press, transfer thedata to the analysis software. Using lacer tracker to test the stiffness of Frame Type HydraulicPress with Large-scale Six Axes Numerical Control Locomotive Gyratory Head. The stiffnesstesting data is obtained. Two kinds of methods for hydraulic machine stiffness analysis resultswere highly consistent, with error less than10%. The reliability of the element analysis tohydraulic press is verified. So more extensive and accurate database could be provided fromfinite element analysis.
3. According to the finite element analysis and the prototype test results ofTHP34Y-1000G hydraulic machine, the deformation of the upper beam and lower beam isanalyzed, regarding to the structural stiffness and pre-tightening. The deformation ofhydraulic machine under different load is regressed by nonlinear curve equation, and theequation is verified in THP34Y-1500D. The regression equation can be used to predict thestiffness of hydraulic press.
4. According to the optimization parameters of sensitivity analysis to Hydraulic Presswith Large-scale Six Axes Numerical Control Locomotive Gyratory Head. Using parts, mold,equipment coupled stiffness analysis method, establishing parameter finite element analysismodel of host, the stiffness sensitivity and the quality sensitivity of upper beam and the lowerbeam are analyzed. Comprehensive quality sensitivity and stiffness sensitivity, with the goalof small quality and large rigidity, the significant key structural parameters on the quality andstiffness are extracted.
5. Based on the parts-mold-frame fuselage stiffness analysis, through establishing themodel of artificial neural network, the structure optimized. Based on the integrated sensitivity on the Hydraulic Press with Large-scale Six Axes Numerical Control Locomotive GyratoryHead THP34Y-1000G, four key parameters of upper and lower beams are presented: the ribof the upper beam, the side plate of the upper beam, the rib of the lower beam, the side plateof the lower beam. And add the load and the press head position to the4elements, five levelsorthogonal experiments. Then the hydraulic press is structural optimized. The hydraulic pressnot only reaches the light heavy, at the same time, greatly improving the stiffness afteroptimized. The hydraulic press reached the stiffness requirement of the product.
1．船首船尾典型板材成型件工艺分析。提出了通过控制移动液压机压头及工作台位置，对板材进行不同位置的精确压制；通过控制液压机压头及工作台的回转角度，对板材复杂曲面进行精确压制的方法。利用通用模具，通过控制凸模的压下量得到不同曲度板材，并对压下量的控制进行了精确量化，制成了通用表格，为船首船尾典型板材成型件的成型提供了方便。在此基础上，对液压机的成形精度提出了要求。
2．对大型六轴数控回转压头框式液压机进行了刚度有限元分析及样机检测。本文采用制件，模具，装备耦合刚度分析研究方法，建立制件、模具和机身结构耦合刚度分析模型，通过软件接口，将各实体模型的数据进行传送，完成有限元分析。采用激光跟踪仪对大型六轴数控回转压头框式液压机THP34Y-1000G、THP34Y-1500D样机进行荷刚度检测，获得刚度检测数据。两种方法对液压机刚度分析结果高度一致，误差保持在10%以内，验证了液压机产品设计模型进行计算机模拟分析结果的可靠性，使有限元分析可为以后的研究提供更广泛的准确的数据库。
3．根据THP34Y-1000G液压机有限元分析及样机检测的结果，在考虑模具结构刚度和机身预紧-加载条件下，分析上、下横梁承载后的变形规律。用方程对液压机在不同载荷下的变形进行了非线性曲线方程回归，并在THP34Y-1500D液压机上得到了验证。该回归方程可用来预测液压机刚度。
4．提出了根据灵敏度提取大型六轴数控回转压头框式液压机结构部件的优化设计参量的方法。采用制件，模具，装备耦合刚度分析研究方法，建立参数化的主机有限元分析模型，进行主机上横梁和下横梁结构参数的质量灵敏度分析、刚度灵敏度分析。综合质量灵敏度和刚度灵敏度，以整机质量小、刚度大为目标，提取对整机质量及刚度影响显著的关键结构参数，上横梁提取出上横梁肋板厚度、上横梁侧板厚度，下横梁提取出下横梁肋板厚度、下横梁侧板厚度，将这四个结构参数作为该类型液压机的优化设计参量。
5．基于制件-模具-组合框架式机身刚度分析，建立人工神经网络模型，进行优化设计。针对根据灵敏度对大型六轴数控回转压头框式液压机THP34Y-1000G上下横梁提出的四个关键结构参数：上横梁肋板厚度、上横梁侧板厚度、下横梁肋板厚度、下横梁侧板厚度，并添加压机载荷和该类型液压机特有的工艺参数——液压机压头工作台位置，对该液压机进行了优化设计，之后不仅达到了轻量化，同时大大提高了液压机的机械耦合刚度。以上可为其它类似液压机的标准化设计研究提供经验。
Hydraulic press is the foundation of manufacturing industry, along with the large ships,aircraft, nuclear power, chemical and other large projects in our country, how to make thehydraulic machine series, high stiffness, and light weight is particularly important. Based onthe Large-scale Six Axes Numerical Control Locomotive Gyratory Head Frame TypeHydraulic Press THP34Y-1000G, THP34Y-1500D as the prototype, the hydraulic machineseries equipment mechanical coupling stiffness were researched in this thesis.
1. Analysis of typical sheet molding process. The method that the different position ofthe ship sheet is accurate pressed through controlling the mobile hydraulic pressure head andposition is put forward. The typical sheet is processed using the general mold, and through thedifferent capacity of press. All of it is a convenient to the process of ship sheet. On the basis,accurate requirements to hydraulic press are advanced.
2. The stiffness of Frame Type Hydraulic Press with Large-scale Six Axes NumericalControl Locomotive Gyratory Head is tested through element analysis and test. With thecoupled stiffness analysis method, to build parts, mold and the hydraulic press, transfer thedata to the analysis software. Using lacer tracker to test the stiffness of Frame Type HydraulicPress with Large-scale Six Axes Numerical Control Locomotive Gyratory Head. The stiffnesstesting data is obtained. Two kinds of methods for hydraulic machine stiffness analysis resultswere highly consistent, with error less than10%. The reliability of the element analysis tohydraulic press is verified. So more extensive and accurate database could be provided fromfinite element analysis.
3. According to the finite element analysis and the prototype test results ofTHP34Y-1000G hydraulic machine, the deformation of the upper beam and lower beam isanalyzed, regarding to the structural stiffness and pre-tightening. The deformation ofhydraulic machine under different load is regressed by nonlinear curve equation, and theequation is verified in THP34Y-1500D. The regression equation can be used to predict thestiffness of hydraulic press.
4. According to the optimization parameters of sensitivity analysis to Hydraulic Presswith Large-scale Six Axes Numerical Control Locomotive Gyratory Head. Using parts, mold,equipment coupled stiffness analysis method, establishing parameter finite element analysismodel of host, the stiffness sensitivity and the quality sensitivity of upper beam and the lowerbeam are analyzed. Comprehensive quality sensitivity and stiffness sensitivity, with the goalof small quality and large rigidity, the significant key structural parameters on the quality andstiffness are extracted.
5. Based on the parts-mold-frame fuselage stiffness analysis, through establishing themodel of artificial neural network, the structure optimized. Based on the integrated sensitivity on the Hydraulic Press with Large-scale Six Axes Numerical Control Locomotive GyratoryHead THP34Y-1000G, four key parameters of upper and lower beams are presented: the ribof the upper beam, the side plate of the upper beam, the rib of the lower beam, the side plateof the lower beam. And add the load and the press head position to the4elements, five levelsorthogonal experiments. Then the hydraulic press is structural optimized. The hydraulic pressnot only reaches the light heavy, at the same time, greatly improving the stiffness afteroptimized. The hydraulic press reached the stiffness requirement of the product.
引文
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