大型液压装载机摇臂结构优化及锻造工艺分析
发布时间：2018-12-12 19:52
【摘要】：摇臂作为大型液压装载机的关键受力构件,对装载机的工作寿命与安全可靠性起着至关重要的作用。目前,铸造成形摇臂重量较大,机械性能不高,严重影响装载机的安全可靠性,已无法满足大吨位装载机的使用要求。锻造成形工艺可在保证制件尺寸特征的同时,大幅度提高强度,采用锻造工艺取代铸造工艺成形摇臂锻件是保证大型液压装载机安全可靠性的有效方法和必然趋势。然而,摇臂体积约为5.8×107 mm3,重量达400 kg,锻造成形工艺复杂,不能简单直接运用现有的锻造工艺进行生产,通过有限元模拟手段开展摇臂锻件结构参数优化设计和成形工艺模拟研究,对后续实际生产具有重要指导意义。本文以大型液压装载机摇臂锻造成形工艺为研究对象,基于铸件与锻件设计原则的不同对摇臂结构进行了相应改进。在不改变摇臂结构安装尺寸、满足使用刚度和强度前提下,以减小摇臂的重量为优化目标对摇臂进行静力分析,采用遗传算法进行了结构参数优化。采用Gleeble-1500D热模拟试验机对摇臂用35Mn B钢进行了高温等温单向热压缩实验,研究其在790~1190℃、0.01~10 s-1下的变形行为,并构建了其本构方程。在摇臂锻件结构参数优化的基础上,对摇臂锻造成形工艺进行了分析,并基于刚塑性有限元法对摇臂锻造成形过程进行了数值模拟。优化后的摇臂在最大载荷工况下,最大应力与最大偏移量分别为211.24MPa、0.95 mm,均小于摇臂的许用应力和许用偏移量,摇臂重量减少了20.12%,实现了优化目的。通过摇臂成形模拟分析,获得了摇臂锻造模拟成形过程中金属坯料的应力、应变、温度场以及锻锤行程载荷曲线等数据。根据摇臂成形模拟分析结果,并结合结构特征及成形工艺设计了摇臂锻造成形模具和切边模具。采用锻锤对摇臂进行了锻造生产试制,摇臂锻造试制件成形饱满,无明显缺陷,验证了摇臂锻造成形工艺的可行性。通过本文研究,为大型液压装载机摇臂铸改锻结构优化和实际锻造成形工艺的完善提供理论依据。
[Abstract]:Rocker arm, as the key component of large hydraulic loader, plays an important role in the working life and safety of loader. At present, the heavy weight and low mechanical properties of the casting rocker arm seriously affect the safety and reliability of the loader, and can not meet the requirements of the large tonnage loader. The forging process can guarantee the dimension characteristics of the parts and increase the strength greatly. It is an effective method and inevitable trend to replace the casting process to form the rocker arm forgings by forging technology to ensure the safety and reliability of large hydraulic loaders. However, the rocker arm's volume is about 5.8 脳 10 ~ 7 mm3, the weight is up to 400 kg, the forging process is complicated, and the existing forging technology can not be used to produce the rocker arm directly. The optimization design of structural parameters of rocker forging and the simulation of forming process by means of finite element simulation are of great significance for subsequent practical production. In this paper, the rocker arm forging technology of large hydraulic loader is studied, and the rocker arm structure is improved based on the difference of design principle between castings and forgings. On the premise of not changing the installation size of rocker arm and satisfying the stiffness and strength of the rocker arm, the static analysis of rocker arm is carried out with the objective of reducing the weight of rocker arm, and the structural parameters are optimized by genetic algorithm. The high temperature isothermal unidirectional thermal compression test of rocker arm 35Mn B steel was carried out by Gleeble-1500D thermal simulator. The deformation behavior of the steel was studied at 790 鈩，
本文编号：2375155
[Abstract]:Rocker arm, as the key component of large hydraulic loader, plays an important role in the working life and safety of loader. At present, the heavy weight and low mechanical properties of the casting rocker arm seriously affect the safety and reliability of the loader, and can not meet the requirements of the large tonnage loader. The forging process can guarantee the dimension characteristics of the parts and increase the strength greatly. It is an effective method and inevitable trend to replace the casting process to form the rocker arm forgings by forging technology to ensure the safety and reliability of large hydraulic loaders. However, the rocker arm's volume is about 5.8 脳 10 ~ 7 mm3, the weight is up to 400 kg, the forging process is complicated, and the existing forging technology can not be used to produce the rocker arm directly. The optimization design of structural parameters of rocker forging and the simulation of forming process by means of finite element simulation are of great significance for subsequent practical production. In this paper, the rocker arm forging technology of large hydraulic loader is studied, and the rocker arm structure is improved based on the difference of design principle between castings and forgings. On the premise of not changing the installation size of rocker arm and satisfying the stiffness and strength of the rocker arm, the static analysis of rocker arm is carried out with the objective of reducing the weight of rocker arm, and the structural parameters are optimized by genetic algorithm. The high temperature isothermal unidirectional thermal compression test of rocker arm 35Mn B steel was carried out by Gleeble-1500D thermal simulator. The deformation behavior of the steel was studied at 790 鈩，
本文编号：2375155
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