基于广义模块化设计的快锻液压机机架力学特性研究
摘要
快锻液压机是一种广泛应用于金属加工和金属成形领域内的快速锻造液压设备,因其锻造速度是普通液压机的5-6倍,而受到市场的青睐。中小型快锻液压机的市场需求量较大,原有的基于整机的设计方法已经不适合市场的快速需求,广义模块化设计正是响应这一变化产生的一种快速设计技术。本文在研究广义模块化设计的基础上,提出了携带有限元信息的广义有限元模块。给出了广义有限元模块的概念、创建方法、接口关系和广义有限元模块数据库的组装方法,丰富和发展了广义模块化设计,提高了设计效率和设计精度。
全预紧预应力组合框架结构是目前快锻液压机本体结构的首选形式。本文在研究该结构机架广义有限元模块划分、创建的基础上,利用子模型边界插值理论,在广义有限元模块层面上,对机架的核心组件上横梁、立柱和下横梁分别行了拓扑优化和尺寸优化,突破了整机因规模巨大难以优化的瓶颈,也为类似结构的优化设计开辟了一条可行之路。
本文深入研究了全预紧预应力组合框架式快锻液压机多拉杆分步预紧安装时,拉杆内残余预紧力的损失规律。结果表明拉杆内残余预紧力随预紧次序加速衰减,预紧力初始荷载不应等差设计。为使机架预紧安装完毕后拉杆内残余预紧力均值,本文提出了确定多拉杆初始预紧载荷的逆序插值验证法,通过对31.5MN和45MN快锻液压机5组10根拉杆初始预紧力载荷的优化设计,验证了该方法的通用性和正确性。针对全预紧机架上横梁与左右立柱之间装配面的弯曲开缝问题,系统研究了预紧力系数、拉杆面积、上横梁刚度、多拉杆空间布局对弯曲开缝的影响,为此类结构的设计提供了有益的指导。
在广义模块装配基础上,对45MN快锻液压机机架进行了预应力模态分析,获取了前十阶频率和相应振型。分析了预紧力系数对结构模态频率的影响,发现增大预紧力载荷可提高结构的模态频率,但对第一阶频率的影响甚小。
研究了液压机用45°螺纹联接件的轴力在啮合螺纹段的分布规律和牙根峰值等效应力的分布规律。分析了螺栓螺纹牙根圆角半径对轴力和峰值等效应力分布的影响,设计了改善轴力和峰值等效应力分布的螺母螺纹牙型切割方案。最后指出螺母螺纹的塑性区对轴力和牙根峰值等效应力分布有显著影响,将螺母螺纹预紧到塑性区后,轴向载荷的增大对螺栓牙根峰值等效应力几乎不再有影响。
全预紧预应力组合框架结构是目前快锻液压机本体结构的首选形式。本文在研究该结构机架广义有限元模块划分、创建的基础上,利用子模型边界插值理论,在广义有限元模块层面上,对机架的核心组件上横梁、立柱和下横梁分别行了拓扑优化和尺寸优化,突破了整机因规模巨大难以优化的瓶颈,也为类似结构的优化设计开辟了一条可行之路。
本文深入研究了全预紧预应力组合框架式快锻液压机多拉杆分步预紧安装时,拉杆内残余预紧力的损失规律。结果表明拉杆内残余预紧力随预紧次序加速衰减,预紧力初始荷载不应等差设计。为使机架预紧安装完毕后拉杆内残余预紧力均值,本文提出了确定多拉杆初始预紧载荷的逆序插值验证法,通过对31.5MN和45MN快锻液压机5组10根拉杆初始预紧力载荷的优化设计,验证了该方法的通用性和正确性。针对全预紧机架上横梁与左右立柱之间装配面的弯曲开缝问题,系统研究了预紧力系数、拉杆面积、上横梁刚度、多拉杆空间布局对弯曲开缝的影响,为此类结构的设计提供了有益的指导。
在广义模块装配基础上,对45MN快锻液压机机架进行了预应力模态分析,获取了前十阶频率和相应振型。分析了预紧力系数对结构模态频率的影响,发现增大预紧力载荷可提高结构的模态频率,但对第一阶频率的影响甚小。
研究了液压机用45°螺纹联接件的轴力在啮合螺纹段的分布规律和牙根峰值等效应力的分布规律。分析了螺栓螺纹牙根圆角半径对轴力和峰值等效应力分布的影响,设计了改善轴力和峰值等效应力分布的螺母螺纹牙型切割方案。最后指出螺母螺纹的塑性区对轴力和牙根峰值等效应力分布有显著影响,将螺母螺纹预紧到塑性区后,轴向载荷的增大对螺栓牙根峰值等效应力几乎不再有影响。
引文
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