冷摆辗机摆头运动轨迹与成形力的理论分析及试验研究

发布时间：2018-04-18 04:17

本文选题：冷摆辗成形 + 摆头运动轨迹　；参考：《机械科学研究总院》2015年博士论文

【摘要】：本文以具有圆、直线、螺旋线和多叶玫瑰线四种摆头运动轨迹的立式冷摆辗机为研究对象,针对直线、螺旋线和多叶玫瑰线运动轨迹无法实现连续局部成形问题,提出椭圆、不过中心的螺旋线和多叶玫瑰线的摆头新型运动轨迹。在冷摆辗成形力的理论研究及试验的基础上,对摆头摆角对摆辗成形力影响、摆头不同运动轨迹成形过程进行深入研究。这一课题的研究将解决目前冷摆辗机直线轨迹应用少、螺旋线和多叶玫瑰线轨迹没有实际应用的状况,为改进摆头结构、设计新型摆辗机和拓展冷摆辗成形工艺提供理论依据。在分析立式冷摆辗机摆头结构及运动原理基础上,建立摆头运动方程,推导出圆、直线、螺旋线和多叶玫瑰线四种运动轨迹的形成机理及规律,通过对摆头四种运动轨迹特点分析,建立摆头摆角与内、外偏心套夹角函数关系,提出摆头新型运动轨迹,并对其运动方程及规律进行理论分析,对摆头运动机构的改进可行性进行了论证。摆头新型运动轨迹避开了轨迹中心点,可实现成形过程中的连续局部成形,降低摆辗成形力,改善摆头受力状况。通过冷摆辗成形影响因素及受力分析,针对目前摆辗接触面积在摆角较小时计算误差大造成摆辗成形力计算不准确的问题,重新推导摆辗成形接触面积的计算公式并进行校验,建构摆辗成形力与工艺参数关系,完善摆辗成形力理论计算公式,为不同运动轨迹摆辗成形力分析提供了理论基础。在研制的2000kN立式冷摆辗机上,以法兰件为试验对象,摆头采用圆运动轨迹在不同摆角下进行摆辗成形试验,采集摆辗成形力变化数据,结合Deform-3D有限元模拟摆辗成形过程,分析、校验数值模拟结果以及摆辗成形力计算公式,得出摆头摆角与摆辗成形力关系图,为运动轨迹改进的参数选择提供理论依据。建立摆头三维运动轨迹方程,应用MATLAB软件对摆辗成形过程三维曲线进行仿真,对不同运动轨迹摆辗成形过程曲线理论分析,结合圆、螺旋线和多叶玫瑰线运动轨迹摆辗成形试验,对运动轨迹改进前、后成形过程规律及特点进行分析。本文建立了摆头运动方程、摆头摆角与偏心套夹角函数关系、摆辗成形力理论计算公式,分析了摆头改进前、后运动轨迹的形成机理及规律,通过理论分析、模拟研究与成形试验比较、验证,得出摆角与摆辗成形力关系以及不同运动轨迹摆辗成形过程曲线及特点,论证了改进运动轨迹的优势。
[Abstract]:In this paper, the vertical cold rolling machine with circular, straight, helical and multi-leaf rose lines is taken as the research object. Aiming at the problem that the motion trajectory of straight line, spiral line and multi-leaf rose line can not realize continuous local forming, an ellipse is proposed.But the spiral of the center and the new trajectory of the pendulum of the leafy rose line.On the basis of the theoretical study and experiment of the forming force of cold rotary rolling, the effect of pendulum angle on the forming force and the forming process of different moving trajectories of the pendulum head are studied in depth.The research of this subject will solve the problem that the linear track of cold rotary rolling machine is few and the track of spiral line and multi-leaf rose line has no practical application at present. It provides a theoretical basis for improving the structure of the pendulum head, designing a new type of rotary rolling machine and expanding the forming technology of cold rotary rolling.Based on the analysis of the structure and motion principle of the pendulum head of the vertical cold rotary rolling machine, the motion equation of the pendulum head is established, and the forming mechanism and law of four motion trajectories of circle, straight line, spiral line and multi-leaf rose line are deduced.Based on the analysis of the characteristics of the four kinds of motion trajectories of the pendulum head, the relationship between the swing angle of the pendulum head and the angle function of the inner and outer eccentric sleeve is established, and the new motion trajectory of the pendulum head is put forward, and its motion equation and law are analyzed theoretically.The feasibility of improving the movement mechanism of swinging head is demonstrated.The new trajectory of swinging head can avoid the center point of the trajectory and can realize continuous local forming in the forming process, reduce the forming force and improve the force condition of the swinging head.Based on the analysis of the influence factors and forces on the cold rotary rolling forming, aiming at the problem of inaccurate calculation of the forming force caused by the large error in the calculation of the contact area in the rotary rolling at present, the formula for calculating the contact area of the rotary rolling forming is rededuced and verified.The relationship between forming force and technological parameters is constructed, and the theoretical formula of forming force is perfected, which provides a theoretical basis for the analysis of forming force of rotary forging with different motion trajectories.In the 2000kN vertical cold rotary rolling machine, taking flange parts as the test object, the swinging head adopts circular motion track to carry out the forming test under different swing angles, collects the data of the changing force of the rotary rolling, simulates the forming process of the rotary rolling with Deform-3D finite element method, and analyzes the forming process of the pendulum rolling.By checking the numerical simulation results and calculating formula of the forming force of rotary rolling, the diagram of the relationship between the swing angle of the pendulum head and the forming force of the rotary rolling is obtained, which provides a theoretical basis for the parameter selection of the motion trajectory improvement.The three-dimensional motion trajectory equation of the pendulum head is established, and the three-dimensional curve of the forming process is simulated by using MATLAB software. The theoretical analysis of the curve of different motion trajectory is carried out, and the circle is combined with the curve theory.The forming process and characteristics of spiral and multi-leaf rose lines were analyzed before and after the motion trajectory was improved.In this paper, the equation of swinging head motion, the relation between the swing angle and the angle function of eccentric sleeve, the theoretical calculation formula of forming force in rotary rolling are established, and the formation mechanism and law of the trajectory before and after the improvement of the pendulum head are analyzed.By comparing the simulation research with the forming test, the relationship between the swing angle and the forming force, the curves and characteristics of the forming process of different motion tracks are obtained, and the advantages of improving the motion trajectory are demonstrated.
【学位授予单位】：机械科学研究总院
【学位级别】：博士
【学位授予年份】：2015
【分类号】：TG306

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